Clarke PG9500ADVES Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
DL0623
8.5KVA PETROL GENERATOR
MODEL NO: PG9500ADVES
PART NO: 8857860

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IINTRODUCTION
Thank you for purchasing this CLARKE Generator.
Before attempting to operate the machine, it is essential that you read this
manual thoroughly and carefully follow all instructions given. In doing so you
will ensure the safety of yourself and that of others around you, and you can
also look forward to the product giving you long and satisfactory service.
Ensure the generator and its components suffered no damage during transit
and that all components are present. Should any loss or damage be
apparent, please contact your CLARKE dealer immediately.
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 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.
If disposing of this product or any damaged components, do not dispose of
with general waste. This product contains valuable raw materials. Metal
products should be taken to your local civic amenity site for recycling of metal
products.

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SPECIFICATIONS
CLARKE part no 8857860 PG9500ADVES
Engine Engine Model SC460
Engine Power 16HP - 10.5kW
Fuel Type E10 Unleaded Petrol
(87 Octane Rate)
Displacement (cc) 459
Starting system Electric & Hand Recoil
Fuel tank capacity (Litre) 20 L (Safe Capacity)
Fuel consumption 3.3 L/Hr
Maximum run time @75% Load 6 hours 30 mins
Engine oil type SAE30-10W30 or 5W30
Engine oil capacity (L) 1.1L
Battery Type 12V,18Ah, SLA
Generator Rated Frequency (Hz) 50
AC Output Voltage (V) 230 & 110
Rated Power (W) 8000
Max. Rated Power (W) 8500
Dimensions L x W x H (mm) 730 x 660 x 630
Unpacked Weight (kg) 100
Environmental IP Rating (Generator/Sockets) IP23M/IP44
Sound pressure level 74 dB
Sound power level 94 dB
Guaranteed sound power level 97 dB
Uncertainty factor 2.8 dB

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GENERAL SAFETY RULES & SYMBOLS
SAFETY SYMBOLS
Read Instruction manual
before use
DANGER - highly
flammable liquid.
Caution - The user should
be aware of a general
hazard
Engine and exhaust
become hot during use
- DO NOT touch
Dangerous voltage. Risk
of electric shock
Poisonous fumes - DO
NOT use in an enclosed
space.
Wear ear defenders For outdoor use only. DO
NOT expose to rain.
DO NOT use in the wet. These symbols are to be found on
the product.

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WORK AREA
1. ALWAYS use in a well ventilated area.
2. ALWAYS position the exhaust outlet away from people.
3. NEVER use indoors or in a confined space.
4. ALWAYS keep children away from the generator.
POSITIONING THE GENERATOR
1. ONLY use the folding handles to wheel the generator into position. NEVER
use them to lift the generator off the ground.
2. ALWAYS leave a least a 1m gap between the generator and any
surrounding building or structure.
3. ALWAYS ensure the generator is on a dry, solid, flat surface.
4. ALWAYS ensure the surrounding area is free from any material that could
burn or be damaged by heat.
5. NEVER move or tilt the generator whilst it is switched on.
FIRE PREVENTION
1. ALWAYS switch the engine OFF when refuelling. Allow generator to cool for
at least 2 minutes before removing the fuel cap. Loosen cap slowly to
relieve pressure in the tank.
2. ALWAYS refuel away from any source of heat.
3. ALWAYS refuel in a well ventilated area.
4. ONLY use standard unleaded petrol.
5. DO NOT overfill the fuel tank. DO NOT fill to the very top of the tank and
leave room for petrol expansion.
6. NEVER smoke whilst refuelling and avoid smoking or using a naked flame
near the generator.
7. DO NOT operate near an open flame, heat or flammable materials. This
generator may emit highly flammable and explosive petrol vapours.
8. 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
1. NEVER use the generator in wet conditions unless it is well protected/
covered. Under these conditions, adequate ventilation MUST be provided.
2. NEVER operate the generator with wet hands.

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3. NEVER use water or any other liquid to clean the generator.
4. ALWAYS ground the generator before using it to maximise safety, see
‘Ground The Generator’ section on page 14.
5. ALWAYS use a ground fault circuit interrupter (GFCI) (not included) in highly
conductive areas such as metal decking or steel work. Extension cords with
an in-line GFCI are recommended for these operations.
GENERAL SAFETY RULES FOR GENERATORS
1. ALWAYS ensure the applied load does not exceed the generator rating.
Overloading the generator is dangerous and could cause damage.
2. ALWAYS disconnect the generator when carrying out any maintenance.
3. ALWAYS ensure the generator reaches operating speed before connecting
a load.
4. NEVER allow the generator to run out of fuel when a load is connected.
5. NEVER transport the generator with fuel in the tank.
6. DO NOT connect to a commercial or residential power supply; e.g. ring
main.
7. DO NOT touch hot parts. This generator produces heat when running.
Temperatures near the exhaust can exceed 150°F/65°C. Allow the
generator to cool down after use before touching the engine or areas of
the generator that become hot during use.
8. If any part of the generator, electrical device or power cable is broken,
damaged or defective, make sure it is repaired or replaced before using.
Service or repair of the generator should only be performed by a qualified
technician.
9. NEVER modify the generator in any way. Modifying or using the generator
for any other purpose for which it is not designed may result in serious injury,
machine damage and voiding of the warranty.
10. ALWAYS turn off all connected electrical devices before stopping the
generator.
11. ALWAYS turn the engine switch to the ‘OFF’ position when the engine is not
running.

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GENERATOR OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Control Panel 7 Folding Handles
2 Battery 8 Fuel Cap
3 Oil Fill Cap/Dipstick 9 Fuel Gauge
4 Oil Drain Plug 10 Choke
5 Recoil Starter 11 Spark Plug
6 Air Filter 12 Muffler/Exhaust

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CONTROL PANEL OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Electric Start Ignition 8 32A, 240V Plug Socket
2 Oil Level Alert Lamp 9 16A Breaker Switch
3 Data Centre (Volts & Hertz per
hour)
10 16A, 110V Plug Socket
4 Main Breaker Switch 11 Earth Grounding Terminal
5 13A Breaker Switch 12 32A Breaker Switch
6 AC 230V Plug Socket 13 32A, 110V Plug Socket
7 32A Breaker Switch

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UNPACKING
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.
BEFORE USING THE GENERATOR
Attach a suitable earth lead to a good earthing point (see page 14) - e.g.
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.
• Clean and free from fuel or oil spillage and the fuel system is intact.
• Correctly located for use (see page 5).
NOTE: ALWAYS use a funnel to fill the fuel tank to avoid accidental
spillage of fuel. If fuel is spilled it must be cleaned up before use.
1 x 8.5kW Petrol Generator 2 x Folding Handle c/w fixings
2 x Axle, Washer & R Clip 1 x Spark Plug Box Spanner & Pouch
2 x Wheel & Axle Cover 1 x Tommy Bar
2 x Foot Assembly c/w fixings 1 x Pair of Ignition keys
1 x Lead Acid Battery
(Not Connected, see page 11)
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: ALWAYS CHECK THE OIL LEVEL BEFORE STARTING SEE PAGE
12, FAILURE TO MAINTAIN THE CORRECT OIL LEVEL MAY SERIOUSLY
DAMAGE THE ENGINE.

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ASSEMBLY
CAUTION: DUE TO THE WEIGHT OF THE GENERATOR, IT IS RECOMMENDED THAT THE
ASSEMBLY IS UNDERTAKEN BY 2 PERSONS.
FITTING THE WHEELS
1. Slide the axle through the
wheel and place the washer
on the axle on the frame side
of the wheel.
2. Slide the axle assembly
through the frame bracket
and insert the R clip through
the axle hole to secure in
place.
3. Attach the wheel centre cap
to the outside of the wheel.
FITTING THE FEET
1. Insert an M6 bolt through the
rubber pad and secure to the
bottom of the foot support
bracket with M6 nut.
2. Place the foot support
bracket to the underside of
the frame and insert two
flange nuts and bolts and
tighten.

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FITTING THE FOLDING HANDLES
1. Insert the rubber block in the end
of the handle with the hinge
bracket.
2. Fit the hinge bracket to the
generator frame and secure with
M8 washers, nut and bolt.
3. Slide the handle grip onto the
end of the handle.
CONNECTING THE BATTERY
1. Connect the negative wire to the
negative (‘-’ / Black) terminal on
the battery as shown on the right.
2. Connect the positive wire to the
positive (‘+’ / Red) terminal on
the battery.
• Ensure both terminals are
covered by the plastic covers
as shown.

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PREPARATION BEFORE OPERATION
ADDING ENGINE OIL
WARNING: THIS GENERATOR IS SOLD WITHOUT OIL INCLUDED.
DO NOT ATTEMPT START THE GENERATOR WITHOUT
INSTALLING THE CORRECT OIL FIRST.
Always check and add the
correct engine oil before
starting the generator. DO NOT
use any special additives.
Select the oil viscosity grade
according to the expected
operating temperature (see
chart).
• Above 40oF (4oC), use SAE 30 oil.
• Between 10oF (-18oC) & 40oF (4oC), use 10W-30 oil.
•Below10
oF (-18oC), use 5W-30 oil.
1. Place the generator on a flat,
level surface.
2. Clean the area around the oil
fill cap and remove the cap/
dipstick.
3. Slowly fill the engine with the
appropriate oil until it reaches
the full mark on the dipstick.
• Stop filling occasionally to
check the oil level & be
careful to not over fill.
4. Replace the oil fill cap/dipstick and finger tighten securely.
NOTE: Check engine oil level before starting each time thereafter.
NOTE: The engine is equipped with a low oil level sensor and the Oil Level
Alert Lamp will light up (see Control Panel on Page 8). This will shut
down the engine automatically when the oil level drops below a
specified level.If the engine shuts down by itself and the fuel tank
has enough petrol, check the engine oil level.

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ADDING FUEL
RECOMMENDED FUEL: Only use standard unleaded petrol. DO NOT mix with oil.
1. Check the fuel level on the fuel
gauge.
The fuel gauge will show as red
when you have fuel in the tank
turning white as the fuel level
decreases.
2. To add fuel, open the fuel filler cap.
3. Just inside the fuel tank is a fuel filter
which catches any contaminants as
you refuel.
4. Slowly add fuel to the fuel tank
(maximum 20L) watching the fuel
level gauge as you do so.
5. Replace the fuel filler cap securely.
NOTE: DO NOT overfill the fuel tank.
WARNING: ALWAYS REFUEL IN A WELL VENTILATED AREA AWAY FROM
ANY HEAT SOURCES.
WARNING: ALLOW THE UNIT TO COOL DOWN BEFORE REFUELLING.
WARNING: DO NOT LEAVE FUEL WITHIN THE REACH OF CHILDREN.

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GROUND THE GENERATOR
WARNING: TO REDUCE THE RISK OF ELECTRIC SHOCK AND TO MAXIMISE SAFETY,
THE GENERATOR SHOULD BE PROPERLY GROUNDED BEFORE USE.
Ground the generator by tightening the earth grounding terminal on the front
control panel against a grounding wire. A generally acceptable grounding wire
is a No. 14 SWG (Standard Wire Gauge)(2.108mm) stranded copper wire.
This grounding wire should be connected at the other end to a copper, brass or
steel grounding rod that is driven into the earth. Wire and grounding rods are not
included with the generator
USING YOUR GENERATOR
STARTING THE ENGINE
1. Turn the Engine Switch to the ‘ON’
position.
2. Turn the Fuel Switch to the ‘ON’
position.
WARNING: NEVER START OR STOP THE ENGINE WITH ELECTRICAL DEVICES
PLUGGED IN AND TURNED ON. UNPLUG ALL ELECTRICAL LOADS FROM THE
GENERATOR BEFORE STARTING THE ENGINE.

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3. Move the Engine Choke Lever to the
‘CHOKE’ position.
FOR ELECTRIC START
1. Insert the key into the ignition.
2. Turn and hold key in the start
switch to the ‘Start’ position until
the generator starts.
NOTE: To prolong the life of the
starter components, DO NOT
hold the key in the ‘Start’
position for more than 15
seconds, and pause for at least
1 minute between starting
attempts.
3. Once the engine has started, move the choke lever to 1/2 CHOKE position
until the engine runs smoothly and then fully to the ‘RUN’ position. If the
engine falters, move the choke lever back to the 1/2 CHOKE position until
the engine runs smoothly, then back to the ‘RUN’ position.
NOTE: If the battery is discharged, use the manual recoil start instructions
on page 14-16.
NOTE: If the engine fires, but does not continue to run, move the choke
lever to the ‘OFF’ position and repeat starting instructions.

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FOR MANUAL RECOIL START
1. Firmly grasp the recoil starter
handle and pull slowly until
increased resistant is felt.
2. Then pull rapidly up.
3. Once the engine has started,
move the choke lever to 1/2
CHOKE position until engine runs
smoothly and then fully to the
‘RUN’ position. If the engine
falters, move the choke lever
back to the 1/2 CHOKE position
until engine runs smoothly, then
back to the ‘RUN’ position.
CONNECTING ELECTRICAL DEVICES
Follow the steps below to properly connect your device(s) to the generator.
1. Before connecting electrical devices, allow the generator to run for a few
minutes to stabilise the speed and voltage output.
2. Select the device with the highest wattage and make sure it is turned off.
Plug the device into the generator and then turn the device on. Allow the
engine to stabilise.
3. Repeat step 2 to plug in each additional device. DO NOT attempt to plug
in and start multiple devices at the same time.
GENERATOR CAPACITY
Make sure the generator can supply enough running (rated) and starting
(max.) watts for the items you will power at the same time. Follow these simple
steps.
1. Select the items you will want to power at the same time.
2. Add together the running (rated) watts of these items. This is the amount of
power the generator must produce to keep the items running.
3. Estimate how many starting (max.) watts you will need. Starting wattage is
the short burst of power needed to start electric motor driven tools such as
a circular saw or refrigerator. Because not all motors start at the same time,
WARNING: STARTER CORD KICKBACK (RAPID RETRACTION) WILL PULL
YOUR HAND AND ARM TOWARD THE ENGINE FASTER THAN YOU CAN LET
GO, WHICH COULD CAUSE SERIOUS INJURY. WHEN STARTING THE
ENGINE, PULL THE CORD SLOWLY UNTIL RESISTANCE IS FELT AND THEN PULL
RAPIDLY TO AVOID KICKBACK.

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total starting (max.) watts can be estimated by adding only the items with
the highest additional starting (max.) to the total rated watts.
Example only:
Total Running Watts: 1255
Highest Starting Watts: +1350
Total Starting Watts Needed = 2605
To prolong the life of the generator and attached devices, it is important to
take care when adding electrical loads to the generator. There should be
nothing connected to the generator outlets before starting its engine. The
correct and safe way to manage the generator power is to sequentially add
loads as follows:
1. With nothing connected to the generator, start the engine as described on
pages 14-16 of this manual.
2. Plug in and turn on the first load, preferably the largest load you have.
3. Allow the generator output to stabilise (engine runs smoothly and any
attached device operates properly).
4. Plug in and turn on the next load.
5. Again, allow the generator to stabilise.
6. Repeat steps 4 & 5 for each additional load.
NEVER add more loads than the generator capacity. Take special care to
consider surge loads in generator capacity as previously described.
Tool/Appliance Running Watts Additional Starting Watts
Refrigerator 700 1350
Portable Fan 40 120
Laptop 250 250
46 in. Flat Screen TV 190 190
Light (75 Watts) 75 75
1255 Total Running Watts 1350 Highest Starting Watts

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The chart below serves as a reference only for the estimated wattage
requirements of common electrical devices. However, DO NOT solely reply on
this chart as all appliances are built differently, ALWAYS check the wattage listed
on the electrical device before consulting this chart:
SHUTTING DOWN THE GENERATOR
Shut off all loads then unplug the devices from the generator panel. NEVER start
or stop the engine with electrical devices plugged in and turned on.
1. Let the engine run at no-load for several minutes to stabilise the internal
temperature of the engine and generator.
2. Move the ON/OFF switch to the
‘OFF ‘position.
Tool/Appliance Rated (Running) Watts Surge (Starting) Watts
Hot Plate 2500 0
Saw - Circular 1500 1500
Saw - Mitre 1200 1200
Microwave 1000 0
Well Water Pump 1000 1000
Sump Pump 800 1200
Refrigerator/Freezer 800 1200
Computer 800 0
Television 500 0
Box Fan 300 600
Light Bulb 75 0

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3. Turn the fuel switch to the ‘OFF’
position.
MAINTENANCE & TROUBLESHOOTING
MAINTENANCE SCHEDULE
Proper routine maintenance of the generator will help prolong the life of the
machine. Please perform maintenance checks and operations according to
the Maintenance Schedule below. If there are any questions about the
maintenance procedures listed in this manual, please contact the CLARKE
service centre.
WARNING: NEVER PERFORM MAINTENANCE OPERATIONS WHILE THE
GENERATOR IS RUNNING. BEFORE MAINTENANCE OR SERVICING THE
GENERATOR, TURN OFF THE GENERATOR, DISCONNECT ALL DEVICES AND
ALLOW THE GENERATOR TO COOL DOWN
First 5 Hours of use
• Change engine oil (see page 21)
Every 8 Hours of use or Daily
• Clean debris (see page 20)
• Check engine oil level (see page 12)
• Check fuel level (see page 13)
Every 25 Hours or use or Yearly
• Clean engine air filter (see page 23)
Every 50 Hours or use or Yearly
• Clean engine oil filter

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GENERATOR MAINTENANCE
Generator maintenance consists of keeping the unit clean and dry. Operate
and store the unit in a clean dry environment where it will not be exposed to
excessive dust, dirt, moisture or any corrosive vapours. Cooling air slots in the
generator must not become clogged with snow, leaves, or any other foreign
material. Check the cleanliness of the generator frequently and clean when
dust, dirt, oil, moisture or other foreign substances are visible on its exterior
surface.
TO CLEAN THE GENERATOR
1. Use a damp cloth to wipe exterior surfaces clean.
2. A soft bristle brush may be used to loosen caked on dirt, oil etc.
3. A vacuum cleaner may be used to pick up loose dirt and debris.
4. Low pressure air (DO NOT exceed 25psi and ALWAYS wear eye protection)
may be used to blow away dirt. Inspect the cooling air slots and openings
on the generator. These openings must be kept clean and unobstructed.
• Change engine oil (see page 21)
Yearly
• Replace engine air filter (see page 23)
• Service fuel valve
• Clean and service spark plug and replace if necessary (see page
22)
• Inspect muffler (exhaust) and spark arrester (see page 23)
• Clean cooling system
WARNING: NEVER INSERT ANY OBJECT OR TOOL THROUGH THE AIR
COOLING SLOTS, EVEN IF THE ENGINE IS NOT RUNNING.
WARNING: DO NOT USE A GARDEN HOSE TO CLEAN THE GENERATOR.
WATER CAN ENTER THE ENGINE FUEL SYSTEM AND CAUSE PROBLEMS. IN
ADDITION, IF WATER ENTERS THE GENERATOR THOUGH THE COOLING AIR
SLOTS, SOME WATER WILL BE RETAINED IN VOIDS AND CREVICES OF THE
ROTOR AND STATOR WINDING INSULATION. WATER AND DIRT BUILD UP
ON THE GENERATOR INTERNAL WINDINGS WILL EVENTUALLY DECREASE
THE INSULATION RESISTANCE OF THE WINDINGS.