Casals GEN2500 User manual

2500W Petrol Generator
PLEASE READ ALL INSTRUCTIONS BEFORE USE
Model:
GEN2500
2500W

1.6. Do not refuel whilst smoking or near naked
flames. Do not overfill or spill fuel. If this happens
clean the fuel on and around the generator properly
before operating.
1.7. Be careful around the generator as some parts of
the internal combustion engine are hot and may cause
burns, Pay attention to all warning signs displayed on
the generator set.
1.8. Engine exhaust gases are toxic. Do not operate the
generator in an unventilated room
1.9. Regularly check that the bolts and nuts are
properly tightened as they may become lose due to
vibration of the generator whilst in use.
1.10. Before using the generator ensure that you have
checked the periodic maintenance schedule in the
operator’s manual.
1.11. Pay attention to the wiring or extension cords
from the generator to the connected device. If the wire
is under the generator or in contact with a vibrating
part, it may break and possibly cause a fire, generator
burnout, or electric shock hazard. Replace damaged or
worn cords immediately.
1.12. Ensure that the specifications of the extenstion
cord you are using is compatible with the generator.
1.13. Do not operate in rain, wet or damp conditions,
or with wet hands. The operator may suffer severe
electric shock if the generator is wet.
1.14. If wet, wipe and dry it well before starting. Do
not pour water directly over the generator, nor wash hit
with water.
1.15. Do not connect the generator to the mains power
grid.
1.16. Keep children and all bystanders at a safe
distance from the generator whilst in use.
1.17. It is absolutely essential that you know and
understand the safe and proper use of the power tool
or appliance that you intend to connect to the genera-
tor. All operators must read, understand and follow the
tool/ appliance operators’ manual. The tool and appli-
ance applications and limitations must be understood.
Keep all instruction manuals and in a safe place for
future reference.
1.18. Always switch off the circuit breaker on the
generator when not in use.
2. ELECTRICAL SAFETY INFORMATION:
2.1. Electrical equipment including cable, cords and
plug connection must not be defective. Please check
before using.
2.2. Do not plug the generator directly into a wall
socket-outlet.
2.3. The generator should not be connected to other
sources such as the power company supply mains. In
IMPORTANT:
Thank you for purchasing a Casals Petrol Generating
Set (hereinafter referred to as the “generator”).
This manual will assist you in operating and maintain-
ing your generator. This manual is the latest version.
With the continuous improvement and upgrading of
this product, the manufacturer reserves the right to
modify this manual without notice. The manufacturer
shall assume no liability for incorrect information
contained in this manual.
This manual is an integral part of the generator. When
the generator is transferred to others, this manual
should be handed over to the new owner.
Some important information in this manual will be
indicated in the following way (please see below). The
users should pay special attention to these instruc-
tions.
The range of CASALS GENERATORS is safe and reli-
able, but incorrect use of these products may cause
personal injury and or damage to your machine.
Please read this manual thoroughly before operation
as this product is required to operate strictly in ac-
cordance with this manual.
IMPORTANT NOTICES:
PLEASE PAY SPECIAL ATTENTION TO STATEMENTS
PRECEDED BY THE FOLLOWING WORDS:
Safety advice and warnings!
Read these instructions carefully before switching on
the portable generator and keep them for future refer-
ence. Failure to follow and observe these instructions
could lead to an accident. The use of this machine
will only be safe and long lasting if you follow these
instructions. The use of this portable generator is NOT
recommended for commercial and industrial purposes.
1. GENERAL SAFETY PRECAUTIONS:
1.1. This generator is not intended for use by persons
(including children) with reduced physical, sensory
or mental capabilities, or lack of experience and
knowledge, unless they have been given supervision
or instruction concerning use of the generator by a
person responsible for their safety.
1.2. The generator may only be operated observing the
regulations of the operation documentation and under
permanent supervision.
1.3. The generator must not be used indoors!
1.4. Fuel (Petrol) is combustible and easily ignited. Do
not perform refuelling while in operation.
1.5. Only use the specified fuel when operating the
generator. (95 Unleaded)

special cases where stand-by connection to existing
electrical systems or integration therewith is intended,
note that it is a legal requirement that such connections
or integration may only be performed by a qualified
technician.
2.4. Protection against electrical shock depends on
circuit-breakers that are specially matched to the
generator. If a circuit breaker requires replacement, it
shall be replaced by a circuit breaker that has identical
ratings and performance characteristics.
2.5. Due to high mechanical stresses only tough, flex-
ible cable should be used.
2.6. If the generator is of CLASS II construction then
the generator does not have to be eathed.
2.7. Cord Extension Sets:
2.7.1. A 1mm2flexible cable can draw a maximum of
10A provided that the cable is no longer than 25m.
2.7.2. A 1.5mm2flexible cable can draw a maximum of
10a provided that the cable is no longer than 35m
2.7.3. A 1.5mm2flexible cable can draw a maximum of
16a provided that the cable is no longer than 20m
2.7.4. A 2.5mm2flexible cable can draw a maximum of
10a provided the cable is no longer than 65m
2.7.5. A 2.5mm2flexible cable can draw a maximum of
16a provided that the cable is no longer than 45m
2.7.6. A 4mm2flexible cable can draw a maximum of
10a provided that the cable is no longer than 100m
2.7.7. A 4mm2flexible cable can draw a maximum of
16a provided that the cable is no longer than 65m
2.8. DROP IN ELECTRIC EXTENSION CORDS:
When a long electric extension cord is used to connect
an appliance or tool to the generator, a certain amount
of voltage drop or loss occurs in the extension cord
which reduces the effective voltage available for the
appliance or tool.
3. SAFETY STICKERS AND EXPLANATIONS:
6.5 HP
CAUTION
Never operate this product inside a room or
other situation without good ventilating.
Never operate this product when fueling.
Clean oil and petrol spillage if occured during
refueling
Ensure the unit has sufficient oil
before starting
WARNING: HOT!
AIR FILTER MAINTENANCE
CLEAN FILTER EVERY 50
HOURS (EVERY 10 HOURS
UNDER DUSTY CONDI-
TIONS), WASH IN HIGH
FLASH-POINT SOLVENT.
SQUEEZE DRY.
Do not allow open
flames near the
generator
Horsepower Indicator
Air filter maintenance
information label
Choke Indication LabelOil refilling and dipstick
indication
Heat warning label
Operation warning label
Oil level warning label

1- 3 phase outlet
2- Circuit breaker
3- Voltmeter
4- Mains power outlets
5- Power Switch
6- Oil dipstick
7- Choke
8- Fuel Valve
9- Pull starter handle
10- Sponge filter cover
11- Exhaust Outlet
12- Fuel filler cap
13- Fuel level indicator
Please note that no grounding rod is supplied with
this generator.
6. PRE-OPERATION CHECKS:
6.1. CHECKING THE ENGINE OIL:
6.1.1. Unscrew the dipstick to check the oil level.
NB The generator is not supplied with oil
6.2. CHECKING THE ENGINE FUEL:
WARNING: Do not refuel while smoking or near an
open flame or other potential fire hazards.
6.2.1. Check the fuel level by the fuel level guage.
6.2.2. If petrol is too low, only add 95 unleaded petrol.
6.2.3. Ensure that you use the fuel filter screen on the
fuel filter.
6.3. FUEL CAPACITY FOR THE GEN2500:
6.3.1. GEN2500 – 12L
WARNING:
Make sure you review each warning in order to prevent
fire hazards. Do not refill the fuel tank whilst the engine
is running or hot. Please ensure that the fuel valve is
closed before refuelling. Be careful not to contaminate
the fuel with any dust, dirt, water or other foreign
liquids/objects. Please clean all spilt fuel thoroughly
before starting the generator.
Ensure that the generator is clear from any open
4. SPECIFICATIONS:
Petrol fueled genera-
tor
GEN2500
Generated power
(AC)
220V/380V -
50Hz
Maximal nominal
performance
W 2500
Permanent perfor-
mance
W 2000
Rotation/idle (+/-5%) RPM 3000/minute
Nominal Performance
of the engine
HP 6,5
Type of engine 4-stroke
Cubic capacity cm3196
Cooling System Air cooled
Protection degree IP23
Ignition system TCI
Fuel tank l 12
Fuel type 95 Unleaded
Weight kg 38
Dimensions cm 605x430x425
Noise level dB(A) 96
Protection class II
Specifications are subject to change without notice.
5. COMPONENTS:
1
2
3
4
5
6
8
7
9
11
12
13
10

flames. Do not smoke whist refuelling the generator.
6.4. CHECKING COMPONENT PARTS:
Before starting the generator please check the
following:
6.4.1. Check for any fuel leaking from any part of the
generator.
6.4.2. Check that all the nuts and bolts are securely
tightened on the generator.
6.4.3. Check for any visible damaged components on
the generator.
6.4.4. Check that the generator is not resting on or
adjacent to any electrical wiring.
6.5. CHECK THE GENERATOR SURROUNDINGS:
WARNING:
Make sure you review each warning in order to
prevent fire hazards. Keep the surrounding area clear
of flammables or other hazardous materials. Keep
the generator at least 3 feet (1 meter) away from
all buildings and or other structures. Only operate
the generator in a dry, well-ventilated area. Keep the
exhaust pipe clear of all foreign objects. Keep the
generator away from open flames. Do not smoke in
close proximity to the generator. Keep the generator on
a flat and level surface.
Do not attempt to block the generator air vents with
any paper or other material/objects.
7. OPERATING PROCEDURES:
7.1. STARTING THE GENERATOR ENGINE:
7.1.1. Switch to the “ON” position. FIG.1
7.1.2. Open the fuel valve. FIG.2
7.1.3. Turn the choke lever to “CLOSED” position if the
generator engine is cold. Fig.3
7.1.4. Pull the recoil starter until resistance is felt.
FIG.5
7.1.5. This is the “compression” point. Return the
handle to its original position, and then pull swiftly.
7.1.6. Once the engine has started, please return the
choke lever to the open position.
7.1.6. If the generator engine fails to start after several
attempts, repeat above the procedures with the choke
knob returned to the “OPEN” position. FIG.4
7.1.7. Do not pull the rope of the recoil starter out
completely.
7.1.8. After starting the generator allow the starter
handle to return to its original position whilst still
holding on to the handle.
7.2. USING ELECTRIC POWER:
WARNING:
Make sure that the appliance is switched OFF before
connecting it to the generator.
Do not move the generator while it is running.
7.3. STOPPING THE GENERATOR:
7.3.1. Turn off the power switch of the electric
equipment and unplug the cord from the receptacle of
the generator.
7.3.2. Switch to the “OFF” position. Fig 6
7.3.3. Close the fuel valve. Fig 7
Fig 1
Fig 2
Fig 3 Fig 4
Fig 5
Fig 6
Fig 7

IT IS ALSO NECESSARY FOR THE USER OF THIS
GENERATOR TO CONDUCT THE MAINTENANCE AND
ADJUSTMENTS ON THE EMISSION-RELATED PARTS
LISTED BELOW TO KEEP THE EMISSION CONTROL
SYSTEM EFFECTIVE.
The emission control system consists of the following
parts:
(1) Carburettor and internal parts
(2) Cold start enrichment system, (if applicable)
(3) Intake manifold, (if applicable)
(4) Air cleaner elements
(5) Spark plug
(6) Magneto or electronic ignition system (if
applicable)
(7) Spark advance/retard system, (if applicable)
(8) Exhaust manifold, (if applicable)
(9) Hoses, belts, connectors and assemblies
The maintenance schedule indicated in the table is
based on normal generator operation. Should the
generator be operated in extremely dusty conditions
or in heavier loading conditions, the maintenance
intervals must be shortened. This will dependent on
the contamination of oil, clogging of filter elements and
the wear and tear of parts.
10. “HOW – TO” MAINTENANCE
10.1. CLEANING AIR FILTER:
CAUTION
Do not wash the elements with kerosene, petrol or oil.
A dirty air filter element will make the starting of the
generator difficult. It will also cause the generator to
under- perform and may cause permanent damage.
Always keep the air filter element clean.
10.1.1. The urethane foam element must be washed
with a cleaning detergent. After cleaning it ensure that
it is dried properly before reinstalling. Please clean
every 100 hours.
10.1.2. Clean the paper element by tapping and
blowing it gently to remove dirt and dust. Never use
oil to clean the paper element. Please clean every 50
hours and replace every 200 hours. (If applicable)
Please clean the air filter elements more often when
operating in dusty environments.
8. WATTAGE INFORMATION:
8.1. Some appliances need a “surge” of energy when
starting. This is commonly known as a “LAGGING”
Load.
8.2. This means that the amount of electrical power
needed to start the appliance may exceed the amount
needed to maintain its use.
8.3. Electrical appliances and tools normally come with
a label indicating voltage, cycles/Hz, amperage (amps)
and electrical power needed to run the appliance or
tool.
8.4. Check with your nearest branch with questions
regarding power surges of certain appliances or power
tools.
8.5. Electrical loads such as incandescent lamps
and hot plates require the same wattage to start as is
needed to maintain their use. This is commonly known
as a “LEADING” Load
8.6. Loads such as fluorescent lamps with starters
require1.5 to 2 times the indicated wattage during
start-up.
8.7. Electrical motors require a large starting current.
Power requirements depend on the type of motor and
its use. Once enough “power” is attained to start the
motor, the appliance will require only +-50% of the
wattage in order to continue running.
8.8. Most electrical tools require 1.5 to 3 times their
wattage for running under load during use. Loads such
as submersible pumps and air compressors require
a very large force to start. They need 3 to 5 times the
normal running wattage in order to start.
9. MAINTENANCE SCHEDULE:
FOR ALL YOUR SERVICE, MAINTENANCE AND
WARRANTY QUERIES PLEASE CONTACT CREATIVE
HOUSEWARES. PLEASE REFER TO THE BACK PAGE
FOR CONTACT DETAILS.
9.1. DAILY INSPECTION:
Before staring the generator please check the following
service items:
9.9.1. Check if there is enough fuel
9.9.2. Excessive vibration, noise
9.9.3. Loose or broken bolts
9.9.4. Fuel leakage
9.9.5. Safe surroundings
9.2. PERIODIC MAINTENANCE:
Periodic maintenance is vital for the safe and efficient
operation of the generator. Check the table below for
periodic maintenance intervals.

Maintanace Items Every 8
hours
(Daily)
Every 20
hours
Every 100
hours
(Weekly)
Every 200
hours
(Monthly)
Every 500
hours
Every
1000
hours
Clean Generator and check
bolts and nuts
Clean spark plug
Clean air filter
Replace air filter element
Clean fuel strainer
Clean and adjust spark plug
and electrodes
Replace spark plug
Remove carbon from cylinder
head (note 1)
Clean and adjust valve clear-
ance (note 2)
Clean and adjust carburetor
(note 2)
Clean and replace carbon
brushes
Replace fuel lines
Overhaul engine (note 2) If and when needed
10.2. CLEANING AND ADJUSTING SPARK PLUG:
10.2.1. If the spark plug is clogged with carbon please
clean it using a plug cleaner or wire brush.
10.2.2. Always check electrode gap after cleaning.
Adjust gap to 0.03 inches (0.7mm to 0.8mm).

10.3. CLEANING FUEL STRAINER:
Please note that dirt and water in the fuel are
removed by the fuel strainer.
10.3.1. Remove the strainer cup and clean it properly
by removing the water and dirt collected.
10.3.2. Clean the screen and strainer cup with petrol.
10.3.3. Fasten the cup tightly to the main body and
ensure that there are no fuel leaks.
10.4. FUEL HOSE REPLACEMENT:
WARNING
Please take extreme caution when replacing the fuel
hose as petrol is extremely flammable and dangerous.
DO NOT SMOKE OR EXPOSE TO OPEN FLAMES
whilst doing this.
10.4.1. Please ensure that the fuel hose is replaced
every 500 hours. Do not attempt to do this whilst there
fuel valve is open.
10.4.2. Please replace the fuel hose immediately
should a leak develop or if the fuel hose is perished.
11. TRANSPORTING AND STORAGE:
11.1. Before transporting the generator please ensure
that the fuel valve is in the “OFF” position.
Contact with a hot engine or exhaust system can cause
severe burns and or fires, always allow for the engine
to cool down prior to transporting and or storing.
Always ensure that the generator is transported and
or stored in a flat horizontal position. Tilting of the unit
may cause fuel spillage which may result in a fire.
11.2. Before storing the generator for an extended
period of time please ensure that the area of storage is
free from excessive water, dust and humidity. Please
follow the table below:
Storage Time Recommended Mainten-
cance
0-1 Month •No preparation required
1-2 Months •Drain out original fuel in
the fuel tank and replace
with clean fuel
2-12 Months •Drain out original fuel in
the fuel tank and replace
with clean fuel
•Empty fuel from the
carburetor
•Empty fuel from the fuel
sediment cup
>12 Months •Drain out original fuel in
the fuel tank and replace
with clean fuel
•Empty fuel from the
carburetor
•Empty fuel from the fuel
sediment cup
•Remove the spark plug
and pour a teaspoon of 2
stroke engine oil into the
cylinder. Turn the engine
slowly by pulling on the
recoil starter. Reinstall the
spark plug
•After removal from stor-
age, drain the stored fuel
into a suitable container
and replace with fresh fuel
before starting.
•Drain the carburetor by loosening the drain screw.
Drain the fuel into a suitable container. Reinstall the
drain plug.
•Having switched the fuel valve off, remove the
sediment cup, empty the fuel, then reinstall the cup
and secure it properly.
NEVER STORE THE GENERATOR INSIDE A HOUSE OR
OFFICE. DO NOT STORE THE GENERATOR WHERE IT
IS SUSEPTABLE TO RAIN OR WATER.
12. TROUBLESHOOTING:
If the generator engine fails to start after several
attempts and if there is no electricity available at the
output socket then please check the chart below. If the
generator still fails to start or generate electricity the
please contact CREATIVE HOUSEWARES (see the back
page of this manual for the contact details)

When the engine fails to start:
Check if the choke lever
is in it’s proper position
Set the choke lever to
the “CLOSED” position
Check if the fuel valve
is open
If it is closed, open it
Check the fuel level If the fuel tank is empty,
refill it. CAUTION: Do not
overfill
Check if the engine
switch is in the “OFF”
position
Turn the engine switch
to the “ON” position.
Ensure that the genera-
tor is not connected to
an appliance
If it is connected to an
appliance, turn off the
power switch on the ap-
pliance and unplug it.
Test to see if the spark
plug cap is loose.
If it is loose, push the
spark plug cap back
tight
Check the spark plug for
carbon build up

Casals guarantees that this product has been thoroughly inspected and tested before being dispatched and is
free from mechanical and electrical defects and complies with the applicable safety standards. However, should
defects due to faulty material or workmanship develop, under normal domestic use, within 6 months from the
date of purchase please return the product to the store from where it was purchased for a full refund or replace-
ment.
The following conditions apply:
1. Please ensure you retain your receipt as this must be presented when making a claim under the terms of the
warranty. It is impossible to determine the warranty period without proof of purchase, so please keep this in
a safe place.
2. If a refund or exchange is required the product must be complete with all accessories, parts and packaging.
3. Missing parts will render the warranty void.
4. Upon receipt of your appliance check it for any transport damage to ensure it is safe for use. Return it to the
store as soon as possible for exchange if damaged. The warranty is void if products are damaged after use,
so please do not use the damaged product.
5. Your product is designed for normal domestic household use. Failure to read and comply with the instruc-
tions for use, cleaning and maintenance will render your warranty void, so please read these instructions
carefully to ensure your safety, and get the most effective use from the product.
6. Any abuse, negligent, improper use will render the warranty void and Creative Housewares (Pty) Ltd
will not be liable for any loss or damage.
7. This Guarantee will not apply if this tool is damaged by accident or from normal wear and tear.
8. Any attempted repair, or replacement of unauthorised parts will render the warranty void, so please contact
an authorised service centre or agent for any service or repair requirements.
9. Accessories such as bits, blades, sanding disc, cutting lines, etc are excluded from this guarantee.
10. Normal consumables parts, such as carbon brushes, bearings, chucks, cord assembly’s, spark plugs,
recoil pulleys and bump head assembly’s are specically excluded from this guarantee.
Extended 24 Month Limited Warranty
Casals takes pride in their product quality and therefore offer an extended 24 month limited warranty from the
original date of purchase to offer the consumer peace of mind on their purchase.
• Should defects due to faulty material or workmanship develop, under normal domestic use, within 24 months
from the original date of purchase, please return the product to the store from where it was purchased for
repair free of charge.
• Casals will however replace a product, if the cost of the repair is not commercially viable or if their ability to
conduct repair effectively cannot be guaranteed.
• NB: The warranty on replaced products will be from the original date of purchase.
• All repairs carry a 3 month warranty even if this falls outside of the 2 year warranty period. Casals will attempt
to conduct repairs within reasonable industry standards but cannot be held responsible or liable for any cir-
cumstances not under their control.
Before returning your product, check for the following:
1. Your household mains supply socket is working and switched on.
2. The mains supply circuit is not overloaded (White trip switch on your DB board is off).
3. You have read the trouble shooting guide in your Instructions for Use.
4. All accessories and parts are present.
If service or repair becomes necessary outside the guarantee period, this service is still available however all
transport/postage, spares and labour costs will be paid by the consumer. All chargeable repairs will require the
consumers’ approval in writing once the quote is accepted. Once the go-ahead has been received Casals will
undertake to conduct the repair within a reasonable time and maintain the condition of the product as received.
For any assistance, service, queries and complaints please contact our Customer Care on 086 111 5006 or e-mail help@
creativehousewares.co.za.
2 YEAR WARRANTY
Cape Town
20 Tekstiel Street, Parow, Cape Town,
7493, South Africa •P.O. Box 6156 Parow
East, 7501, South Africa Tel: [phone]
8117
Fax: [phone]
Durban
35 Adrain Road, Windermere, Durban,
South Africa, 4001
Tel: [phone]
Fax: [phone]
Johannesburg
Unit 25 & 26 San Croy Ofce park
Die Agora Road, Croydon, 1619
Tel: [phone]
Fax: [phone]

HELPLINE
086 111 5006