Clarke 8010010 G700 Generator Instructions PDF

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Summary of Content for Clarke 8010010 G700 Generator Instructions PDF

Generator Model G700

0600

Part Number 8010010

Operating & Maintenance Instructions

Parts and Service For Spare Parts and Servicing, please contact your local dealer, or

Clarke International on one of the following Numbers:

Parts and Service Tel: 0208 988 7400

Parts and Service Fax: 0208 558 3622 or email as follows:

Parts: Parts@clarkeinternational.com

Service: Service@clarkeinternational.com

If you have any problems using or setting up your Generator call the Clarke Helpline on,

0208 988 7400 Press 1 for Parts : 2 for Technical Assistance

Copyright: Clarke International, All rights reserved. June,2000

Contents Page

Guarantee ......................................................................................................................... 2 Features and Use ............................................................................................................. 2 For your Own Safety ......................................................................................................... 3 Overview of your Generator ........................................................................................... 5 Unpacking your Generator ............................................................................................. 6 Before Use ......................................................................................................................... 6 Using your Generator ...................................................................................................... 7

Starting the Engine ........................................................................................ 7 Connecting to the Generator .................................................................... 8 Stopping the Engine ..................................................................................... 8

Periodic Maintenance ..................................................................................................... 9 Air Filter ........................................................................................................... 9 Fuel Tank Inlet Filter ....................................................................................... 9 Fuel Line Filter ................................................................................................. 9 Spark Plug ...................................................................................................... 10

Troubleshooting ................................................................................................................. 10 The Engine ...................................................................................................... 10 Electrical Fault Finding .................................................................................. 11

Electrical Diagram ............................................................................................................ 11 Specifications .................................................................................................................... 12 Spare Parts Diagram ......................................................................................................... 13

Spare Parts List ................................................................................................................... 14

Thank you for purchasing this Clarke Power Generator. Before use please read these instructions. This is for your own safety and that of others around you, and also to ensure the Generator provides you with long and trouble free service.

Guarantee This product is guaranteed against faults in manufacture for 12 months from

purchase date. Keep your receipt as proof of purchase. This guarantee is invalid if the product has been abused or tampered with in any way, or not used for the purpose for which it is intended. The reason for return must be clearly stated. This guarantee does not affect your statutory rights.

Features and Use This portable generator is designed to provide an output of 3.2 Amps at 230

Volts and 10 Amps at 12 Volts. A battery charging lead is supplied for connection to the 12 Volt output which is designed for BATTERY CHARGING ONLY.

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WARNING:

Exhaust fumes can be extremely dangerous if inhaled

Always use in a well ventilated area.

Always position the exhaust outlet away from people.

Never use indoors or in a confined space.

Read these safety instructions before using the equipment.

Keep Children away from the generator

For Your Own Safety

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Fire Prevention

Always switch the engine OFF when refuelling.

Always refuel away from any source of heat.

Always refuel in a well ventilated area.

Never overfill the tank, fill to the level specified (see page 6).

Never smoke whilst refuelling and avoid smoking or using a naked flame near the generator.

Never start the engine if there is spilled fuel. Any spillage must be wiped clean and the generator allowed to dry before attempting to start the engine.

Prevention of Electric Shock

Always store the generator undercover when not in use away from damp or wet conditions.

Never use the generator when it is raining or snowing or in wet or damp conditions.

Never operate the generator with wet hands.

Never use water or any other liquids to clean the generator.

1M (3ft) 1M (3ft)

Always ensure the applied load does not exceed the generator rating. Overloading the generator is dangerous and could cause serious damage.

Always disconnect the generator when carrying out any maintenance.

Always ensure the generator reaches operating speed before connecting a load.

General Safety Precautions for Generators

Never allow the generator to run out of fuel when a load is connected.

Never transport the generator with fuel in the tank.

Do Not connect to a commercial or residential power supply.

Do Not connect to any other electrical source.

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Positioning the Generator for use

Always leave a least a 1M gap between the generator and any surrounding building or structures.

Always ensure the generator is on a solid, flat surface.

Always ensure the surrounding area is free from any material that could burn or be damaged by heat.

Never move or tilt the generator whilst it is switched on.

Never cover the generator or enclose it while it is in use.

Exhaust Gas Precautions Regarding Generators

Always ensure there is adequate ventilation when using the generator.

Always position the generator so that the exhaust is pointed away from people or animals .

Never use the generator indoors or in an enclosed area. (i.e. in a warehouse, tunnel, well, hold.)

7

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Fig (1) Overview

1

2

3

4

5

6

9 10 11 12

8 7

Choke

Throttle

Engine ON / OFF

5

DC Reset Switch

AC Trip Indicator

AC Reset Switch

DC Connector

AC Connector

1 Carrying Handle

2 Fuel Cap

3 Fuel Tank

4 Alternator

5 Control Panel

6 Air Inlet Cover

7 Engine Control

8 Recoil Starter

9 Fuel Tap

10 Spark Plug

11 Exhaust

12 Exhaust Outlet

Unpacking and Assembly

Unpack your Generator and check to ensure the following items are present. Should there be any defficiency or damage caused during transit contact your Clarke dealer immediately.

The Generator Unit

Plastic Handle (with two fastening screws)

12 Volt DC Battery Attachment Leads

Spark Plug Wrench

Fit the plastic carrying handle to the fuel tank with the two screw provided as shown in fig (2).

(3)

Before Using the Generator

Note : Always use a funnel to fill the fuel tank so as to avoid accidental spillage of fuel. If fuel is spilled it must be removed from the unit before attempting to start the engine.

WARNING ! observe all safety precautions when handling fuel. Always refuel in a well ventilated area away from any heat sources.

WARNING ! ensure there is adequate fuel in the tank when using the generator. Running out of fuel or stopping the engine suddenly with a load connected could cause serious damage.

WARNING ! allow the unit to cool down before refuelling.

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Fill Level

1.

2.

3.

4.

Fig (2)

Use Clarke 2 stroke oil....Part No.5060260

Before using your generator check that :

1. The Generator unit is in good condition and free from any damage.

2. The Generator Unit is clean and free from fuel or oil spillage.

3. The Generator Unit is correctly located for use (see page 4).

4. The fuel hose and connectors are intact and there is no leakage.

5. The Fuel Tank is properly filled with a fuel mix of unleaded petrol and two stroke oil at a ratio of 50 Parts Petrol to 1 Part oil. The Tank should be filled to just below the fuel filter shoulder as shown in fig (3).

Mix Ratio

50 : 1 Unleaded Petrol : Two Stroke Oil

Fig (3) Fuel Filter

IMPORTANT: Generators should ALWAYS be earthed. The Earthing Point for the G700 is to be found to the left of the control panel, as shown, arrowed in Fig. 2A. Attach a suitable earth lead to a good earth - water pipe, ground spike etc., whenever you use this machine.

Fig (2A)

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Using your Generator (a)

IMPORTANT ! Ensure the generator is not connected to any electrical equipment when starting the engine.

ON OFF RES

Turn the Fuel ON as shown in fig (4).

Note : The Fuel Tap has three positions : ON, OFF, and RES (reserve). If the fuel runs low the tap can be switched to Reserve to allow a short period of further operation. When the fuel gets this low it is recommended that you refuel (see page 6).

1.

Set the choke by moving the throttle lever in the direction of the arrow shown in fig (5).

Note : The choke position is indicated by the symbol .

Fig (5)2.

Pull the Recoil Starter as shown in fig (6).

Note : To start the engine, pull the recoil Starter slowly until you feel full resistance, then pull briskly to turn the engine over. (The engine should start after no more than three or four pulls. If the engine does not start see Troubleshooting)

4.

Switch the Ignition ON by pushing the rocker switch, shown in fig. 5, so that the I is depressed. To turn the engine OFF, push the switch so that the O is depressed.

3.

Return Throttle lever to 0 as shown in fig (5).

Note : When the engine has started the throttle should be returned to position 0 to allow the engine to run at its set operating level.

5.

Choke Throttle

0

Starting the Engine

Fig (4)

Fig (6)

(b)

IMPORTANT ! Ensure that the power rating of the connected load does not exceed the rating for the generator (650 Watts [3.2 Amps AC] / 15 Amps at 12VDC)

Connecting Electrical devices

Connecting to 230 Volts AC.

Insert the three pin plug into the AC connector ensuring that the power rating of the device is below 650 Watts.

Note : If the AC circuit is overloaded the circuit protection switch will trip and the indicator will illuminate. To reset the circuit press the AC reset switch.

Connecting to a 12 Volt Battery.

Insert the supplied two pin battery lead into the DC connector. The red conductor must connect to the Positive or + terminal and the black wire to the Negative or - terminal.

Note : If the DC circuit is overloaded the circuit protection switch will be tripped . To reset the circuit press the DC reset switch.

5

DC Reset Switch

AC Trip Indicator

AC Reset Switch

DC Connector

AC Connector.

IMPORTANT ! Never switch off the engine whilst an electrical device is connected.

Shutting down the Generator

Switch off the electrical device.

Unplug the device from the generator.

Switch the Engine OFF (see page 7).

Turn the Fuel OFF (see page 7).

If the generator is not going to be used for some time then the fuel tank must be drained and any remaining fuel run through as follows :

Turn the Fuel OFF (see page 7)

Unclip the fuel hose (see fig (8)).

Unbolt the tank from the unit (see fig (8)).

Empty contents of the tank into a suitable container.

Refit the tank, start up engine and let it run until all the fuel has been used.

(c)

1.

2.

3.

4.

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Maintenance

1.

2.

3.

4.

5.

Fig (7)

Fig (8)

Socket for a standard 13 Amp BS 1363 type plug

4.

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Maintenance Ref: Fig. 1

Check after 50 Hours Normal use

(a) Air Inlet Filter

1.

2.

3.

Check after 100 Hours Normal use

(c) Fuel Tap Filter

Check after 50 Hours Normal use

(b) Fuel Tank Filter

If the air filter has become soiled, clean as stated below. If the filter is damaged or still appears to be soiled after cleaning, replace.

Remove the air inlet cover (6).

Remove the foam filter and wash thoroughly with soapy water.

Rinse the Filter and allow it to dry thoroughly so that no unwanted liquids enter the carburettor.

Replace the filter and the air inlet cover (6).

If the filter has become soiled, clean as stated below. If the filter is damaged or has become clogged, replace.

Empty the fuel (3) tank described on page 8.

Unbolt the fuel tap (9) from the tank and unscrew the shouldered bolt from the tap to remove the filter.

Wash thoroughly with soapy water, rinse thoroughly and allow to dry completely before reassembling.

Replace fuel tap (9) and refit tank (3).

If the filter has become soiled, clean as stated below. If the filter is damaged or has become clogged, replace.

Turn the Fuel Tap (9) OFF.

Undo the fuel cap (2) and remove the filter.

Wash thoroughly with soapy water.

Rinse the Filter and allow it to dry thoroughly so that no unwanted liquids enter the tank.

Replace the Filter and the fuel cap(2).

1.

2.

3.

4.

1.

2.

3.

4.

Check the spark plug(10) for build up of carbon and the gap between electrodes. Take the corrective action below if needed.

Unplug the spark plug lead (10) and remove the plug using the supplied wrench.

Clean the electrode with a wire brush until it is restored to its original metal colour.

Check the gap between electrodes is 0.7- 0.8mm (0,028-0.031) with a suitable gauge

Return the spark plug (10) to the engine and refit lead.

1.

2.

3.

4.

Check after 50 Hours Normal use

(b) Spark Plug

Troubleshooting : The Engine

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PLUG GAP - 0.7 - 0.8mm - 0.028 - 0.031

Remedy

1. Tighten spark plug

2. Tighten cyl. head bolt

3. Replace gasket

4. Pull recoil starter harply

5. Clean fuel tank

6. Clean fuel line

7. Fill fuel tank

8. Open fuel tap

9. Clean spark plug

10. Replace spark plug

11. Contact Clarke Service Department

12. Check fuel

13. Contact Clarke Service Department

Problem

Will not Start

Will not start or Low output

Erratic performance

Probable Cause

Loose spark plug

Loose cylinder head bolt

Damaged head gasket

Insufficient starting pull

Dirt in fuel tank

Clogged fuel line

No fuel

Fuel tap closed

Tarnished spark plug

Damaged spark plug

Faulty magneto or carburettor settings

Improper fuel

Overheating

Troubleshooting : Electrical Fault finding

* Engine RPM (No Load): 50 Hz = 3150 RPM

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Figure (9) Electrical Diagram

Remedy

1. Reset AC safety trip

2. Check connection and (or) replace lead

3. Contact Clarke Servicing

4. Contact Clarke Servicing

1. Reset DC safety trip

2. Check connection and (or) replace lead

3. Contact Clarke Servicing

4. Contact Clarke Servicing

1. Set Engine RPM *

2. Contact Clarke Servicing

Problem

AC Indicator Light on :

No AC Output

No DC Output

Erratic Supply

Possible Cause

Tripped Circuit Breaker

Poor connection or faulty lead

Broken AC connector

Faulty Circuit Breaker

Tripped Circuit Breaker

Poor connection or faulty lead

Broken DC connector

Faulty Circuit Breaker

Incorrect engine RPM

Internal Generator problem

Specifications

Model No ................................................................. G700

Part No ..................................................................... 8010010

Dimensions ............................................................... 375(H) x 380(L) x 300(W) MM

Gross Weight ............................................................ 21KG

Engine Type .......................................................................... 2 Stroke Single Cylinder

Displacement .......................................................... 64cc

Fuel Capacity .......................................................... 4 Litres

Running Time on Full Tank ...................................... 4hrs 30min (approx.)

Cooling System ........................................................ Forced Air Cooling

Stroke/Bore .............................................................. 45x40mm

Carburettor Type ..................................................... HG63

Air Cleaner ............................................................... Sponge Element

Fuel / Oil Mix Ratio .................................................. 50 : 1

Compression Ratio .................................................. 6 : 1

Generator Type .......................................................................... Brushless Single Phase

Peak Power .............................................................. 800Watt

Rated Power ............................................................ 650 Watt

Rated Rotation Speed ............................................ 3000 RPM

AC Rated Voltage .................................................. 230 Volts

AC Rated Frequency ............................................. 50 Hz

Maximum Output ................................................... 3.2 Amps

DC Rated Voltage .................................................. 12Volts (For Battery Charging ONLY)

DC Rated Current ................................................... 10 Amps

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Spare Parts Diagram (fig 7)

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Spare Parts List

- 14 -

No. Description Part No.

1 Fuel Tank.............................................................................................. HT70001 2 Fuel Valve ............................................................................................ HT70002 3 Fuel Hose ............................................................................................. HT70003 4 Exhaust ................................................................................................ HT70004 5 Starter Cover ...................................................................................... HT70005 6 Engine .................................................................................................. HT70006 7 Governor Arm Spring ......................................................................... HT70007 8 Gasket ................................................................................................. HT70008 9 Carburettor ......................................................................................... HT70009

10 Gasket ................................................................................................. HT70010 11 CDI ....................................................................................................... HT70011 12 Ignition Coil ......................................................................................... HT70012 13 Spark Plug ........................................................................................... HT70013 14 ON / OFF Switch ................................................................................. HT70014 15 Front Panel .......................................................................................... HT70015 16 Air Filter ................................................................................................ HT70016 17 Gasket ................................................................................................. HT70017 18 Seal Ring .............................................................................................. HT70018 19 Air Filter Cover .................................................................................... HT70019 20 Conrol Panel ....................................................................................... HT70020 21 AC Socket ........................................................................................... HT70021 22 DC Socket ........................................................................................... HT70022 23 AC Trip Switch ..................................................................................... HT70023 24 Indicator Lamp ................................................................................... HT70024 25 DC Trip Switch ..................................................................................... HT70025 26 Cover Plate ......................................................................................... HT70026 27 Capacitor ........................................................................................... HT70027 28 Alternator Cover ................................................................................ HT70028 29 Stator ................................................................................................... HT70029 30 Rotor .................................................................................................... HT70030 31 Front Cap ............................................................................................ HT70031 32 Rectifier ............................................................................................... HT70032 33 Screw M6x12 ....................................................................................... HT70033 34 Screw M6x12 ....................................................................................... HT70034 35 Screw M6x12 ....................................................................................... HT70035 36 Screw M6x65 ....................................................................................... HT70036 37 Screw M5x20 ....................................................................................... HT70037 38 Screw M5x8 ......................................................................................... HT70038 39 Screw M8x150 ..................................................................................... HT70039 40 Screw M5X18 .................

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