Clarke G700 Manual

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: [phone]
Parts and Service Fax: [phone]
or email as follows:
Parts: [email protected]
Service: [email protected]
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.
- 2 -

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
- 3 -
]
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.
- 4 -
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
- 5 -
Fig (1) Overview
1
2
3
4
5
6
9 10 11 12
87
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.
- 6 -
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
I MPORTANT: 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)

- 7 -
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.
- 8 -
Maintenance
1.
2.
3.
4.
5.
Fig (7)
Fig (8)
Socket for a
standard 13 Amp
BS 1363 type plug

4.
- 9 -
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
- 10 -
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
- 11 -
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
- 12 -

Spare Parts Diagram (fig 7)
- 13 -

Spare Parts List
- 14 -
No. Description Part No.
1Fuel Tank .............................................................................................. HT70001
2Fuel Valve ............................................................................................ HT70002
3Fuel Hose ............................................................................................. HT70003
4Exhaust ................................................................................................ HT70004
5Starter Cover ...................................................................................... HT70005
6Engine .................................................................................................. HT70006
7Governor Arm Spring ......................................................................... HT70007
8Gasket ................................................................................................. HT70008
9Carburettor ......................................................................................... 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 ...................................................................................... HT70040
410 Screw M5x8 ......................................................................................... HT70041