Clarke DG6000DVES Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS1216
GENERATOR
MODEL NO: DG6000DVES
PART NO: 8675000

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INTRODUCTION
Thank you for purchasing this CLARKE Generator.
Before attempting to use this product, please read this manual thoroughly and
follow the instructions carefully. In doing so you will ensure the safety of yourself
and that of others around you, and you can look forward to your purchase
giving you long and satisfactory service.
GUARANTEE
This product is guaranteed against faulty manufacture for a period of 12
months from the date of purchase. Please keep your receipt which will be
required as proof of purchase.
This guarantee is invalid if the product is found to have been abused or
tampered with in any way, or not used for the purpose for which it was
intended.
Faulty goods should be returned to their place of purchase, no product can
be returned to us without prior permission.
This guarantee does not effect your statutory rights.
ENVIRONMENTAL RECYCLING POLICY
Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the WEEE.
In effect, this means that this product must not be disposed of with general
household waste. It must be disposed of according to the laws governing
Waste Electrical and Electronic Equipment (WEEE) at a recognised disposal
facility.

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TABLE OF CONTENTS
INTRODUCTION ...............................................................2
GUARANTEE .....................................................................2
ENVIRONMENTAL RECYCLING POLICY ..........................2
TABLE OF CONTENTS .......................................................3
GENERAL SAFETY .............................................................4
Positioning the Generator .................................................. 6
Fire Prevention ..................................................................... 6
Additional safety rules for Generators .............................. 6
SAFETY SYMBOLS .............................................................7
UNPACKING AND ASSEMBLY .........................................8
Fitting the Handles ............................................................... 8
Fitting the Exhaust outlet .................................................... 8
BEFORE USING THE GENERATOR .....................................9
USING THE GENERATOR FOR THE FIRST TIME ..................9
Subsequent Use of the Generator .................................... 14
STARTING THE GENERATOR .............................................15
USING THE GENERATOR ..................................................17
Maximum Wattage ............................................................. 17
SOME NOTES ABOUT POWER Cables ................................ 18
AC Usage ............................................................................. 18
DC Usage ............................................................................. 20
STOPPING THE GENERATOR ............................................20
MANUAL STARTING .........................................................21
MANUAL STOPPING ........................................................22
MAINTENANCE ................................................................23
Cleaning the Generator ..................................................... 23
MAINTENANCE SCHEDULE ..............................................24
Checking the Oil ................................................................. 25
Changing/ Adding Oil ........................................................ 26
Replacing the Air filter ........................................................ 27
Clean the Fuel Filter ............................................................ 28
Changing the Battery ......................................................... 29
STORAGE / TRANSPORT PROCEDURES ...........................29
TROUBLESHOOTING .........................................................30
SPECIFICATIONS ..............................................................32
DECLARATION OF CONFORMITY ..................................33
DECLARATION OF CONFORMITY ..................................34
SPARE PARTS LIST .............................................................35

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GENERAL SAFETY
Read these safety instructions before using the generator.
WARNING: POISONOUS GAS. GENERATORS GIVE OFF CARBON
MONOXIDE, A POISONOUS GAS THAT CAN KILL YOU QUICKLY. YOU
CANNOT SMELL IT, SEE IT, OR TASTE IT.
• ONLY run the generator outdoors and away from air
intakes, open windows and garages.
• Never use inside homes, garages, or sheds, EVEN IF you run
a fan or open doors and windows.
If you start to feel sick, dizzy, or weak while using the generator, shut it
off and get to fresh air RIGHT AWAY. See a doctor. You may have
carbon monoxide poisoning.
WARNING: THE EXHAUST FROM THIS PRODUCT CONTAINS CHEMICALS
KNOWN TO BE CARCINOGENIC
WARNING: THIS GENERATOR MAY EMIT HIGHLY FLAMMABLE FUEL
VAPOURS, WHICH CAN CAUSE SEVERE BURNS OR EVEN DEATH. A
NEARBY OPEN FLAME CAN LEAD TO EXPLOSION EVEN IF NOT DIRECTLY IN
CONTACT WITH FUEL.
• Do not operate near open flame. Do not smoke near the
generator.
• Always operate on a firm, level surface.
• Always turn the generator off before refueling and allow
the generator to cool for at least 2 minutes before
removing the fuel cap. Loosen cap slowly to relieve
pressure in the tank.
• Do not overfill the fuel tank. Diesel fuel may expand during
operation. Do not fill to the top of the tank.
• Always check for spilled fuel before operating.
• Empty the fuel tank before storing or transporting the
generator.
• Before transporting, turn fuel valve to the off position.

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WARNING: THIS GENERATOR PRODUCES HIGH VOLTAGES, WHICH CAN
RESULT IN ELECTROCUTION.
• ALWAYS ground the generator before using it. (See “Step 5-
Ground the Generator” on page 14.)
• Do not use in rainy or wet conditions.
• Do not touch bare wires or sockets (outlets).
• Do not allow children or non-qualified persons to operate.
WARNING: NEVER CONNECT A GENERATOR DIRECTLY TO ANY EXISTING
ELECTRICAL BUILDING CIRCUIT. THE GENERATOR CAN BACKFEED INTO
POWER LINES AND ELECTROCUTE NEARBY ELECTRICAL REPAIR WORKERS.
WARNING: THIS GENERATOR PRODUCES HEAT WHEN RUNNING.
TEMPERATURES NEAR THE EXHAUST CAN EXCEED 150OF (65OC).
• Do not touch hot surfaces. Pay attention to warning labels
on the generator denoting hot parts of the machine.
• Allow the generator to cool for several minutes after use
before touching the engine or areas which get hot during
use.
CAUTION: MISUSE OF THIS GENERATOR CAN DAMAGE IT OR SHORTEN ITS
LIFE.
• Use the generator only for its intended purpose.
• Allow the generator to run for several minutes before
connecting electrical devices.
• Shut off and disconnect any malfunctioning devices from
the generator.
• Do not exceed the wattage capacity of the generator by
plugging in more electrical devices than the unit can
handle.
• Do not turn on electrical devices until after they are
connected to the generator.
• Disconnect all electrical devices from the generator before
stopping the generator.

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POSITIONING THE GENERATOR
1. Always leave a least a 1M gap between the generator and any
surrounding structures.
2. Always ensure the generator is on dry level surface.
3. Always ensure the surrounding area is free from any material that could
burn or be damaged by heat.
4. Never move or tilt the generator whilst it is running.
5. Always make sure that the wheel brakes are engaged during use.
FIRE PREVENTION
1. Always switch the engine OFF when refuelling.
2. Always refuel away from any source of heat.
3. Always refuel in a well ventilated area.
4. Never overfill the tank, fill to the level specified.
5. Never smoke whilst refuelling, and avoid smoking or using a naked flame
near the generator.
6. 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.
ADDITIONAL SAFETY RULES FOR GENERATORS
1. Always ensure the applied load does not exceed the generator rating.
Overloading the generator is dangerous and could cause serious
damage.
2. Always disconnect any plugs from the generator when carrying out any
maintenance.
3. Never allow the generator to run out of fuel when a load is connected.
4. Never allow the generator air vents to become blocked.

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SAFETY SYMBOLS
Caution - The user
should be aware of a
general hazard
Read Instruction
manual before use
Dangerous voltage Corrosive material
Flammable Explosive risk
Hot Surface - Do not
touch
Always wear suit-
able ear protection
Poisonous fumes - Do
not use the generator in
an enclosed space.

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UNPACKING AND ASSEMBLY
Unpack your generator and check to ensure the following items are present.
Should there be any deficiency or damage caused during transit contact
your Clarke dealer immediately.
FITTING THE HANDLES
1. Secure each handle using four
bolts and washers supplied.
NOTE: These handles are for moving
the generator on it’s wheels,
not for lifting the generator.
FITTING THE EXHAUST OUTLET
1. Slide the exhaust deflector into
position as shown.
2. Tighten the screw and nut to secure
in place.
• Do not overtighten.
1 x 5 kW Dual Voltage Diesel Generator 2 x Handles c/w fixings
1 x 32 Amp IEC 60309-2 Plug, Blue (230 V) 1 x Lead/Acid Battery (installed)
1 x 16 Amp IEC 60309-2 Plug, Yellow (115 V) 1 x 12 Volt Battery Charging Cable
1 x 32 Amp IEC 60309-2 Plug, Yellow (115 V) 1 x Filler Tube (for engine oil)
1 x 5 mm Hexagon key 2 x Ignition Key
1 x Double open-ended Spanner; 10/12 mm 1 x Cabinet Lid lock Key

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BEFORE USING THE GENERATOR
IMPORTANT: Generators should ALWAYS be earthed.
Attach a suitable earth lead to a good earth point - water pipe, ground spike
etc., whenever you use this generator.
Before using your generator check that:
• The generator is in good condition and free from any damage.
• The generator is clean and free from fuel or oil spillage.
• The fuel system and connectors are intact and there is no leakage.
• 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.
USING THE GENERATOR FOR THE FIRST TIME
If you are using the generator for the first time, there are a few steps you must
take to prepare it for operation. Failure to perform these steps can damage
the generator.
STEP 1- CONNECT THE BATTERY
The generator comes with the battery disconnected for safety, which must be
reconnected before use as follows.
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: DO NOT CONNECT OR DISCONNECT THE BATTERY WHILE THE
GENERATOR IS RUNNING.
WARNING: ONLY SERVICE THE BATTERY IN WELL VENTILATED AREAS.
WARNING: WEAR PROTECTIVE CLOTHING AND SAFETY GLASSES WHEN
SERVICING THE BATTERY.
WARNING: KEEP OUT OF REACH OF CHILDREN.
WARNING: DO NOT TILT THE GENERATOR WITH THE BATTERY INSTALLED.

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1. Open the front panel.
2. Remove the protective covering
from the free end of the negative
battery cable.
3. Attach the free end of the
negative cable to the point
indicated on the right and secure
the connection.
4. If you do not plan to use the
generator for some time, you
should disconnect the negative
battery cable before storage.
• After disconnecting the cable,
cover the free end with an
insulator such as electrical tape.
STEP 2- ADD OIL
The crankcase of the new generator engine contains no oil. The correct
amount of oil must be added before operating the generator for the first time.
To add oil, follow these steps:
1. Make sure the generator is on a
level surface and open the front
panel.
2. Unscrew the oil filler/dipstick cap
from the engine.
3. Using a funnel, add the
appropriate amount of oil into the
crankcase.
• The oil capacity of the engine
crankcase is approximately 1.65
litres.

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• For general use, we recommend SAE 5W-40 oil.
4. The crankcase is full when the oil
level reaches the lower lip of the
opening of the oil filler hole.
5. Replace and tighten the oil filler
cap.
STEP 3- ADD DIESEL FUEL
This generator runs on regular diesel fuel. To add fuel:
1. Make sure the generator is on a level surface.
2. Lift open the top cover.
WARNING: DIESEL FUEL AND DIESEL FUMES ARE HIGHLY FLAMMABLE. A
NEARBY OPEN FLAME CAN LEAD TO AN EXPLOSION EVEN IF NOT
DIRECTLY IN CONTACT WITH THE FUEL.
• Do not operate near an open flame. Do not smoke near the
generator.
• Always operate on a firm, level surface.
• Always turn the generator off before refueling. Allow the
generator to cool for at least 2 minutes before removing the
fuel cap. Loosen cap slowly to relieve any pressure in tank.
• Do not overfill the fuel tank. Fuel may expand during operation.
Do not fill to the top of the tank.
• Always check for spilled fuel before operating.
• Before transporting, turn fuel valve to the off position.

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3. Unscrew fuel cap.
• Check that the strainer located
in the mouth of the fuel tank, is
free from contaminants.
4. Slowly add diesel fuel to the fuel
tank through the built-in strainer.
• Do not let dirt or water get in the
fuel tank.
• Be careful not to overfill.
• The capacity of the fuel tank is 16 L.
• The fuel gauge on top of the
tank indicates the fuel level.
• NOTE: Fuel can expand. Do not
fill the fuel tank to the very top.
5. Refit the fuel cap and wipe up any
spilled fuel with a dry cloth.
IMPORTANT: Use diesel fuel only. Never
use petrol.
IMPORTANT: Avoid getting dirt or water
in the fuel tank.

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STEP 4- BLEED THE FUEL LINE
When adding diesel fuel for the first time or after the fuel tank has been
emptied or drained, air can get trapped in the fuel line between the fuel tank
and the engine. After adding fuel, you must bleed the fuel line of this trapped
air. To bleed the fuel line:
1. Open the front panel.
2. Turn the fuel valve to the “closed”
position.
3. Loosen the clamp that holds the
fuel line to the engine.
4. Detach the fuel line from the
engine and place the end of the
detached fuel line over a bucket to
catch fuel as it runs out.
5. Turn the fuel valve to the “open”
position.
6. When fuel starts running out of the
fuel line in a steady stream,
reattach the fuel line to the engine.
NOTE: Do not close the fuel valve
until you have reattached
the fuel line.

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7. After reattaching the fuel line to the engine, turn the fuel valve to the
“closed” position until you are ready to start the generator.
CAUTION: IF YOU ARE IN ANY REGARDING THIS PROCEDURE CONSULT A
QUALIFIED DIESEL FITTER/MECHANIC.
STEP 5- GROUND THE GENERATOR
1. Ground the generator by
connecting a suitable grounding
wire to the earth point.
• A generally acceptable
grounding wire is a No. 12 AWG
(American Wire Gauge)
stranded copper wire.
2. Connect the other end of the
grounding wire to a copper or brass
grounding rod that is driven into the
earth.
SUBSEQUENT USE OF THE GENERATOR
If this generator has been used before,
Carry out the following steps.
1. “Step 2- Add Oil” on page 10
2. “Step 3- Add Diesel Fuel” on page 11
3. “Step 4- Bleed the Fuel Line” on page 13 (if the fuel tank has been emptied
or allowed to run dry)
4. “Step 5- Ground the Generator” on page 14
IMPORTANT: At this point you should be familiar with the procedures
described in “Using the Generator for the First Time” on page 9. If you have
not yet read this section, go back and read it now.
WARNING: FAILURE TO PROPERLY GROUND THE GENERATOR CAN RESULT
IN ELECTROCUTION

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STARTING THE GENERATOR
Before starting the generator, make sure you have read and performed the
steps in the”Preparing the Generator for Use” section of this manual.
WARNING: GENERATORS GIVE OFF CARBON MONOXIDE, A POISONOUS
GAS THAT CAN KILL YOU QUICKLY. YOU CANNOT SMELL IT, SEE IT, OR
TASTE IT.
• ONLY run the generator outdoors and away from air
intakes, open windows, and garages.
• Never use inside homes, garages, or sheds, EVEN IF you run
a fan or open doors and windows.
If you start to feel sick, dizzy, or weak while using the generator, shut it
off and get to fresh air RIGHT AWAY. See a doctor. You may have
carbon monoxide poisoning.
WARNING: THIS GENERATOR PRODUCES HIGH VOLTAGES, WHICH CAN
RESULT IN ELECTROCUTION.
• ALWAYS ground the generator before using it (See “Step 5-
Ground the Generator” on page 14.)
• This generator should only be used to connect electrical
devices, either directly or with an extension cable. NEVER
connect the generator directly to a building’s electrical
system without a transfer switch. Such a connection must
comply with local electrical laws, and should be done by a
qualified electrician. Failure to comply can create a
backfeed, which may result in serious injury or death to
utility workers.
• Do not use in rainy or wet conditions.
• Do not allow children or non-qualified persons to operate.
CAUTION: DISCONNECT ALL ELECTRICAL LOADS FROM THE GENERATOR
BEFORE ATTEMPTING TO START.
CAUTION: ALWAYS MAKE SURE THE WHEEL BRAKES ARE ENGAGED
DURING USE.

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TO START THE GENERATOR PERFORM THE FOLLOWING STEPS:
1. Make sure no electrical devices are connected to the generator.
• Such devices can make it difficult for the engine to start.
2. Check that the generator is properly grounded (See “Step 5- Ground the
Generator” on page 14.)
3. Check the oil and fuel levels See page 10 & page 11.
4. If the generator has run out of fuel or been emptied of fuel since the last
use, or if this is the first time using the generator, be sure to bleed the fuel
line (See “Step 4- Bleed the Fuel Line” on page 13.).
5. Open the front panel and locate
the fuel valve.
6. Turn the fuel valve to the “open”
position.
7. Make sure that the start/run lever
is in the RUN position.

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8. Set the engine switch key to the
“on” position.
9. Turn the engine key to the “start”
position for about 10 seconds or
until the engine starts.
NOTE: If the engine does not start
within 10 seconds, release
the key and wait 15
seconds, then try again.
NOTE: After repeated unsuccessful
attempts to start the engine, please consult the troubleshooting
guide on page 30 before trying again.
10. Allow the generator to run for several minutes before attempting to
connect any electrical devices.
USING THE GENERATOR
Allow the generator to run several minutes before connecting electrical
devices.
MAXIMUM WATTAGE
The total running wattage required by all of the electrical devices connected
to a generator should not exceed the rated wattage of the generator.
To calculate the total wattage requirement of the electrical devices you wish
to connect, find the rated (or running) wattage of each device and add
them together.
If this number exceeds the rated wattage of the generator (5kW), DO NOT
connect all these devices. Select a combination of electrical devices, which
has a total rated wattage lower than or equal to the rated wattage of the
generator.
Once the decision has been made on what electrical devices will be
powered by the generator, connect these devices from highest power to
lowest.
WARNING: NEVER CONNECT A GENERATOR DIRECTLY TO ANY EXISTING
ELECTRICAL BUILDING CIRCUIT. THE GENERATOR CAN BACKFEED INTO
POWER LINES AND ELECTROCUTE NEARBY UTILITY WORKERS.

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SOME NOTES ABOUT POWER CABLES
When using extension cables, allow for a slightly higher rated wattage
requirement by the electrical device. See the table below for recommended
cables based on the power requirement of the electrical device.
*NR = not recommended.
AC USAGE
1. Move the voltage selector switch
to the desired position.
• Move the switch to the left to
use the 115 Volt sockets.
• Move the switch to the right to
use the 230 Volt socket.
Device Requirements Max. Cable Length (ft.) by Wire Gauge
Amps Watts
(115V)
Watts
(230 V)
#8 wire
(3.26 mm)
#10 wire
(2.5 mm)
#12 wire
(2 mm)
#14 wire
(1.6 mm)
#16 wire
(1.3 mm)
5 600 1200 NR 500 300 200 125
7.5 900 1800 NR 350 200 125 100
10 1200 2400 NR 250 150 100 50
15 1800 3600 NR 150 100 65 NR
20 2400 4800 175 125 75 50 NR
25 3000 6000 150 100 60 NR NR
30 3600 7200 125 65 NR NR NR
CAUTION: IF YOU ARE IN ANY DOUBT, PLEASE CONSULT A QUALIFIED
ELECTRICIAN.
CAUTION: PLEASE FAMILIARISE YOURSELF WITH THE CONTROL PANEL
BEFORE CONNECTING ELECTRICAL DEVICES.
CAUTION: DO NOT CONNECT 60HZ OR 3-PHASE LOADS TO THE
GENERATOR.

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2. Turn off each device before
plugging in.
• Connect 115 Volt, single phase,
50 Hz loads to the 115 Volt
sockets.
• Connect 230 Volt, single phase,
50Hz loads to the 230 Volt
socket.
• Make sure that you attach
appliances to the correct
socket.
AC BREAKER
If the AC Breaker activates;
1. Remove the load from the
generator.
2. Reset the breaker.
3. Make sure that the generator is
not being overloaded.

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DC USAGE
The generator is equipped with a DC
terminal. This terminal is not intended
to charge automotive batteries.
1. Start the generator. See page 16
2. Make sure any appliance is
turned off before connecting it to
the generator.
3. Connect the 12V appliance (max
8.3A) to the generator.
DC OVERLOAD PROTECTOR
If the DC overload protector activates, wait for a few minutes and then press
the reset button shown on the right of the DC12V Output.
STOPPING THE GENERATOR
1. Turn off, then unplug all
connected electrical devices.
2. Allow the generator to run for
several more minutes with no
electrical devices connected.
This helps stabilize the
temperature of the generator.
3. Turn the engine switch key to the
“off” position. Remove the key.
4. Turn the fuel valve to the “closed”
position.
WARNING: ALLOW THE
GENERATOR TO COOL FOR
SEVERAL MINUTES BEFORE
TOUCHING AREAS THAT
BECOME HOT DURING USE.
CAUTION: LEAVING THE BATTERY CONNECTED FOR LONG PERIODS OF
TIME WITHOUT USING THE GENERATOR CAN CAUSE THE BATTERY TO
DRAIN. DISCONNECT THE NEGATIVE BATTERY CABLE FROM THE BATTERY
FOR STORAGE. AFTER DISCONNECTING THE CABLE, COVER THE FREE
END WITH AN INSULATOR SUCH AS ELECTRICAL TAPE.