Clarke CP range User manual

USER INSTRUCTIONS
0706
CP/CYB/CD Range
GENERATOR SET
GENERATOR SET

Thank you for purchasing this CLARKE portable generator set.
Please read through this instruction leaflet, and the instruction manuals for the
engine and alternator thoroughly before operating the generator, in doing so you
will ensure the safety of yourself and that of others around you, this will also ensure
that the portable generator set will give you long and satisfactory service.
Please keep these instructions in a safe place for future reference.
CLARKE GUARANTEE
This CLARKE product is guaranteed against faulty manufacture for a period
of 12 months from the date of purchase. Please keep your receipt 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 is 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.
Please Note that details and specifications herein, are correct of time of going to print.
However CLARKE International reserve the right to change specifications at any time without prior notice.
Copyright CLARKE International All rights Reserved 2006.
Waste electrical products should not be disposed of with household waste. Please dispose of at your local
recycling facility.
CONTENTS
Guarantee ...................................................................................................... 1
Important Safety Precautions ....................................................................... 2
General Safety Precautions .......................................................................... 2
Preparation For Use ....................................................................................... 4
Extension Cables ............................................................................................ 5
Operation ....................................................................................................... 6
Shutting Down The Generator ...................................................................... 7
Maintenance ................................................................................................. 7
Trouble Shooting ............................................................................................ 7
Parts List, Specifications & Schematic Wiring Diagrams can be found on
the technical information sheet.
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IMPORTANT SAFETY PRECAUTIONS
•NEVER allow anyone, not fully familiar with generator sets to use this equipment.
• This generator set is NOT suitable for use with electronic equipment such as
televisions, hi-fi’s or computers etc.
•IMPORTANT!: This generator uses either a floating chassis or neutral reference to
chassis earthing system. (refer to technical information sheet).
Neutral reference to chassis generators MUST be connected to an earthing
spike to ensure they are properly grounded.
Floating earth generators DO NOT require earthing.
• Connect only those appliances that are in good working order.
NOTE: Most portable electric tools are Class II (double insulated) appliances.
Always check BEFORE connecting. Equipment that does not meet this
standard (i.e. tools with metal casing) require a three conductor cable with
an earth conductor.
• DO NOT Alter the engine settings, the voltage and frequency of the generator
output is directly linked to the engine speed. These settings are factory set.
Should they need re-calibration - consult your CLARKE dealer.
• Connect only those appliances whose voltage (according to their data plate)
corresponds to that produced by the generator.
GENERAL SAFETY PRECAUTIONS
•ALWAYSuse in a well ventilated area.
•ALWAYSensure the applied load does not exceed the generators rating.
Overloading the generator is dangerous and could cause serious damage.
•ALWAYSdisconnect the generator when carrying out any maintenance.
•ALWAYSensure the generator reaches operating speed before connecting
a load.
•ALWAYSstart the engine BEFORE connecting any appliances to the output
receptacles.
•ALWAYS check the generator for damage before use.
•ALWAYS keep well clear of all moving parts on the generator at all times.
• NEVER allow children or animals near the generator.
• NEVER connect to a commercial or mains power supply, or any other
electrical source.
• NEVER allow the generator to run out of fuel when a load is connected.
• NEVER alter or tamper with the internal wiring of the generator.
•NEVER climb or stand on the generator as dents may cause overheating of
the acoustic lining.
•
NEVER touch any part of the engine, alternator or exhaust when the generator
is in use as these get hot and could burn.
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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 fill the tank, fill to the level specified.
•NEVER smoke whilst refuelling and avoid smoking or using a naked flame
near the generator.
•NEVER start the engine if there is a fuel spill. 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 and 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 unit.
POSITIONING THE GENERATOR FOR USE
•ALWAYSleave at least a 1 metre gap between the generator and any
surrounding building or structure.
•ALWAYSensure the generator is on a solid, flat surface.
•ALWAYSensure 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 or enclose the generator whilst it is in use.
• Be aware of the weight of the generator, do not attempt to lift or move the
generator without the assistance of other personnel or suitable lifting equipment.
EXHAUST GAS PRECAUTIONS
WARNING!: EXHAUST FUMES CAN BE FATAL.
•ALWAYS ensure that there is adequate ventilation when using the generator.
•ALWAYS position the generator so that the exhaust is pointing away from
people or animals.
•NEVER use the generator indoors or in a enclosed area. (i.e. in ware house,
tunnel, well or a hold).
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PREPARATION FOR USE
Electric Start Models:
Electric start models are supplied with a 24AH dry charged battery, and a
battery acid pack. The battery must be prepared as follows:
Check to ensure the battery is in good condition, with no damage caused
during transit. Should there be any apparent damage, please consult your
CLARKE dealer immediately.
1. Disconnect the and remove the battery from the frame.
2. Remove the vent plugs and fill to 12mm above the top of the separators.
3. Allow the battery pack to soak for 30 mins, then check the levels and top
up as necessary.
4. Replace the vent plugs.
Your battery is now ready for use, however we recommend that you put it on
charge, at a rate of 2.5Amps ONLY, for 4 hours. Should you do this, remember to
re-check the battery levels when completed, and top up if necessary with
distilled water (to BS4974).
NOTE: You may charge at a lower rate than that specified, but a longer charge
time will be necessary to achieve the same ampere hour input.
NOTE: Before connecting to the generator, ensure the outside of the battery is
completely dry.
Connect the battery as follows:
1. Ensure the battery is firmly secured in its compartment within the frame.
2. Connect the battery terminals to the battery posts, ensuring you connect
the POSITIVE connection FIRST. (When disconnecting ALWAYS disconnect the
positive terminal last).
NOTE: Smear the connections and terminals with petroleum jelly.
Fuelling:
Fill with fuel, according to the instructions within the engine manual.
NOTE: Long range ‘LR’ models are fitted with a three position fuel tap as illustrated
in fig.1. These positions are ON/OFF/RESERVE.
•Ensure the tap is set in the required position.
•The fuel hose connectors are intact and there is no leakage.
NOTE: Always use a fuel funnel to fill the tank so as to avoid accidental spillage
of fuel. If fuel is spilled it must be removed from the unit and the surrounding
area, BEFORE attempting to start the engine.
IMPORTANT: ALWAYS check the engine oil level before use. Top up if
necessary according to the engine manufacturers hand book.
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Fig.1
WARNING:
• Observe all safety precautions when handling fuel. Always refuel in a
well ventilated area away from any heat sources.
• 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.
• Allow the unit to cool down before refuelling.
• Be aware that fuel and lubricants are potentially carcinogenic, direct
skin contact should be avoided, wear suitable rubber gloves.
EXTENSION CABLES
All extension cables, from the generator set to the appliance, must be carefully
selected, fitted and maintained. Cables in accordance with IEC 245-4 should
be used.
Cables should be inspected regularly, and should be replaced, not repaired in
the event of a defect.
The length and cross section of conductors should be selected according to the
job to be done. The table below is an indication of the sizes that should be used.
)²mm(rotcudnoC )m(htgneLxaM )spmA(tnerruC )Wk(esahPelgniS
5.152013.2
5.204617.3
0.406825.6
IMPORTANT! Ensure the cable is fully unwound when in use to avoid
overheating, and the placing of extra load on the generator.
- 5 -

OPERATION
IMPORTANT! Ensure all precautions are taken, referring to this and the
engine manual, before proceeding.
1. Start the engine. (refer to engine manual) and allow to run for a few minutes
at full speed in order for it to warm up.
IMPORTANT! Ensure no appliances are connected to the generator
when starting the engine.
2. Check the condition of the appliance, including the supply cable and the
extension cable if used, and ensure it is switched OFF. Ensure also that the
operating voltage is the same as the output from the generator.
3. For generators with dual output, ensure the voltage selector switch is set to
the deliver the appropriate output - 115V or 230V, see fig’s 2 & 3.
Depending on the model the switch is mounted as shown or similar, to that in
fig’s 2, 3 & 4.
4. With the engine running smoothly connect the appliance to the appropriate
receptacle: BLUE - 230V, YELLOW - 115V.
NOTE: If the AC circuit is overloaded the circuit protection switch will trip. To
reset the circuit, first disconnect the appliance, and rectify the cause of the
overload. Wait a short period and then press the appropriate reset button.
BE AWARE!
Some appliances draw more current on start-up than their normal running
current, i.e. electric motors, and compressors. If in any doubt as to whether
an appliance is compatible or not, please consult your CLARKE dealer.
Additionally, please refer to the specifications sheet attached, to ensure the
machine is used under the correct operating conditions.
Fig.2 Fig.3 Fig.4
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SHUTTING DOWN THE GENERATOR
IMPORTANT! Never switch OFF the engine whilst an electrical appliance is connected.
1. Switch OFF the electrical appliance.
2. Unplug the appliance from the generator.
3. Switch the engine OFF (refer to engine manual).
4. Turn the fuel OFF (refer to engine manual, long run models refer to page 4).
MAINTENANCE
Always ensure the generators air vents are completely clear. Brush away any
dust which may have accumulated.
The engine requires periodic servicing. Please refer to the engine manual for
details.
If the generator is not going to be used for some time, the engine must be
adequately prepared. Please refer to the engine manual for details.
ELECTRICAL TROUBLE SHOOTING
PROBLEM: No AC Output.
CAUSE: TROUBLE SHOOTING:
Selector switch in wrong position.
Tripped circuit breaker.
Poor connection or faulty lead.
Broken AC connector.
Faulty circuit breaker.
Set selector switch.
Reset AC safety trip.
Check connection and/or replace
lead.
Contact CLARKE servicing.
Contact CLARKE servicing.
PROBLEM: Erratic Supply.
CAUSE: TROUBLE SHOOTING:
Incorrect engine RPM.
Internal alternator problem.
Set engine RPM - Consult your CLARKE
dealer.
Contact CLARKE servicing.
ENGINE TROUBLE SHOOTING
Consult the engine manual.
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