Clarke CGH 3500, 8852005 User guide

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GAS POWERED GENERATOR

Model CGH3500

Operating & Maintenance

Instructions

Product Serial/Batch No:........................

0201

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: 0208 988 7400

PARTS AND SERVICE Fax: 0208 558 3622

or email as follows:

Parts: Parts@clarkeinternational.com

Service: Service@clarkeinternational.com

If you have any problems using or setting up your Generator

call the Clarke Helpline on,

0208 988 7400

Clarke

Press 1 for Parts : 2 for Technical Assistance

WARNING!

IF THIS GENERATOR SET IS TO BE CONNECTED TO THE MAINS NETWORK OF

A BUILDING TO PROVIDE A BACK-UP ELECTRICAL SUPPLY, THIS SHOULD

ALWAYS BE CARRIED OUT BY A QUALIFIED ELECTRICIAN AND IN

ACCORDANCE WITH CURRENT IEE REGULATIONS FOR ELECTRICAL

INSTALLATIONS.

FAILURE TO HEED THIS WARNING COULD RESULT IN SEVERE ELECTRIC

SHOCK, FIRE AND EVEN DEATH

Helpline

CONTENTS Page

Parts and Service Contacts ............................................................................................ 2

Guarantee .......................................................................................................................... 3

Features and Use .............................................................................................................. 3

For your Own Safety .......................................................................................................... 4

Overview and Description of Components ....................................................................6

Unpacking your Generator .............................................................................................. 7

Before Use (Important Notes) ...........................................................................................7

Using your Generator ....................................................................................................... 7

Starting the Engine ......................................................................................... 7

Shutting Down ................................................................................................ 8

Connecting Electrical Devices .....................................................................8

Extension Cables ............................................................................................ 9

Maintenance Schedule ............................................................................................... 11

Oil Change .................................................................................................... 12

Air Filter .......................................................................................................... 13

Spark Plug ......................................................................................................13

Storage .......................................................................................................... 14

Troubleshooting ................................................................................................................14

Specifications ................................................................................................................... 15

Spare Parts Diagrams .............................................................................................. 16 - 17

Spare Parts List .................................................................................................................. 17

Electrical Diagram ........................................................................................................... 18

Declaration of Conformity ........................................................................................... 19

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, gas powered generator is designed to provide an output of 3.0kVA (2.4kW),

and using a 19kg gas container, will run continuously for 24 hours. The relative low cost of liquid gas results in the unit being highly economical and ideal for emergency or stand-by uses or use in remote areas. It is also ideal where a continuous supply is required for long uninterrupted periods as gas bottles may be linked together for extended running.

The unit is provided with 110V and 230V outlet sockets.

FOR YOUR OWN SAFETY

WARN IN G:

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 and animals away from the generator

Fire Prevention

NEVER

smoke when changing a gas cylinder.

NEVER

change the gas cylinder in the vicinity of

naked flames.

WARNING!

PROPANE VAPOUR IS HIGHLY FLAMMABLE

Prevention of Electric Shock

NEVER use the generator in wet conditions unless it

is well protected/covered. Under these conditions, adequate ventilation MUST be provided

NEVER operate the generator with wet hands

NEVER use water or any other liquids to clean the

generator.

NEVER allow the generator air vents to become blocked.

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

Always

ensure there is adequate ventilation when

using the generator.

Always

position the generator so that the exhaust

is aimed away from people or animals.

Never

use the generator indoors or in an enclosed

area. (i.e. in a warehouse, tunnel, etc), unless adequate precautions are taken to remove exhaust gases completely.

General Safety Precautions

1M (3ft)

Always

generator rating. Overloading the generator is dangerous and could cause serious damage.

Always

before connecting a load.

Ensure you know how to stop the generator quickly...in an emergency situation...READ THIS MANUAL THOROUGHLY

ALWAYS

away from damp or wet conditions.

Never

is connected.

Do Not

supply.

Do Not

ensure the applied load does not exceed the

ensure the generator reaches operating speed

store the generator undercover when not in use

allow the generator to run out of gas when a load

connect to a commercial or residential power

connect to any other electrical source.

OVERVIEW

Fig.1

A - Gas Controller

B - Alternator

C - 110/230V Selector Switch

D - 230V Outlet (BLUE)

E - 110V Outlet (YELLOW)

Fig.2

F - 110V and 230V Reset Buttons

G - Gas Regulator

H - Starter Cord

J - Ignition ON/OFF Switch

K - Air Filter Box Securing Nut

UNPACKING AND ASSEMBLY

Unpack your Generator and check to ensure that no damage was suffered in transit. If any

damage is apparent.... contact your Clarke dealer immediately.

Your generator is fully assembled with all necessary adjustments having been made at the factory.

BEFORE USING THE GENERATOR

• Locate the generator set on a solid, flat, level surface, and as close as possible to the site where power is required. This is in order to keep the length of extension cables down to a minimum.

• If used outdoors, the generator should either be covered, or provision should be made to ensure that cover can be erected quickly in order prevent the generator getting wet.

• If used indoors, there must be sufficient ventilation so that exhaust fumes can escape

satisfactorily.....locate the set adjacent to an open door, and place a notice so that

people in the area are aware of the importance of leaving the door open.

• If the generator set is easily accessible, it must be screened off to prevent the dangers

involved should people or animals get too close....burns, shocks etc. Remember that

the generator may need to be run for many hours and it is almost impossible to provide supervision for the whole period, nor may it be desirable.

• Procure a cylinder or cylinders of propane gas, sufficient to provide fuel for the duration. Ensure the gas bottle is stable and close enough to the generator set so as not to stretch the gas hose. Keep the bottle away from the generators engine exhaust.

• In particularly cold weather, there is a risk of the gas bottle freezing, resulting in a loss of power. If necessary, cover the cylinder to avoid this.

• Connect the Gas Regulator to the gas bottle, taking all precautions and ensuring there are no foreign bodies within the gas bottle outlet. Ensure the connection is tight, remembering that the gas bottle connection has a LEFT HAND THREAD.

• Before starting the engine, you should always check the engine oil level. Remove the dipstick, shown arrowed in Fig.3. If the level is lower than the bottom of the

dipstick hole, it must be topped up so that it is level with the top of the hole.

Fig.3

Use CLARKE High Performance Oil - SAE10W30, available from your Clarke dealer.

1 Litre..............Part No. 3050852 5 litre..............Part No. 3050855

USING YOUR GENERATOR

A. Starting the Engine

IMPORTANT ! Ensure the generator is not connected to any electrical equipment when starting the engine. (See ‘Connecting Electrical Devices’, page 9).

Ensure you perform all maintenance tasks before attempting to start the engine.

Turn the gas ON at the gas bottle.

Depress the ‘Prime Button’, arrowed

in Fig. 4, which is located on the rear

of the Gas Controller (A, Fig.1)....for

2 - 3 seconds ONLY

Fig.4

Fig.5

Switch the Ignition ON by turning the

rotary switch, arrowed in fig. 5, to the “I” (ON) position.

Pull the Recoil Starter Cord (H, Fig.2), to

start the engine.

Notes:

1. Pull the Recoil Starter Cord 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) DO NOT let go of the Starter Cord. Bring it back gently to avoid damaging the starter.

2. DO NOT use the choke at any time.

3. The engine is preset to run at a constant speed (300RPM). DO NOT attempt to alter this in

any way

4. The engine is provided with a safety device which prevents it from starting should the oil

level fall below a certain level. The oil level should be checked prior to starting.

B. Connecting Electrical devices

Before connecting any appliance to the generator, it is IMPORTANT to strictly follow all safety precautions previously given, and also to take the following limitations and considerations into account when planning your installation.

1.1 General

(i) Ensure that the power rating of the connected appliance does not exceed

the rating for the generator (See Specifications), and the appliance is switched OFF.

Note that The sum of power requirements of the connected appliances must not exceed the rating for the generator.

(ii) Some appliances may require more power when they start up than their

nominal power rating (eg. electric motors, compressors etc.). This should be taken into account when calculating the load.

(iii) This generator set is set to provide optimal performance under the following

conditions:

- Atmospheric pressure: 1bar

- Ambient air temperature: 25OC

- Air humidity: 30%

If this generator is used in extreme conditions, i.e. at high altitude, or unusually hot conditions, the performance may be compromised. Under these conditions the load on the generator should be reduced.

(iv) It is NOT recommended that sensitive electrical or electronic appliances be

connected to this machine, such as, computers, Hi-Fi’s etc unless an antisurge device is fitted.

1.2 Extension cables

(i) Extension Cables must be in good condition and the insulation must provide

maximum protection against electric shock.

(ii) If the extension cable runs through a public area, it must be further protected

against accidental damage. i.e. inside a protective tube/pipe etc.

(iii) Choose the length and cross section of the conductors according to the

work to be done.

a) An extension cable with conductors of 1.5mm2 cross section, must not

be greater than 60M in length.

b) An extension cable with conductors of 2.5mm2 cross section, must not

be greater than 100M in length.

(iv) IMPORTANT: Most portable hand tools are Class II (Double Insulated), and are ideally suited for this machine as the generator windings are not connected to earth. This is known as a ‘floating winding’ arrangement.

Tools which are Class I, require a 3- conductor cable, (with an earth conductor) to ensure correct earthing in the event of an electric fault. Should Class I insulated appliances be connected to this machine, ensure a competent electrician and installs the appliance so that correct earthing can be carried out.

With all the above taken into account, and only when completely satisfied that the

proposed installation is perfectly safe, proceed to connect and operate the appliances as follows:

(i) Ensure the 110/230V selector switch, on top of the generator

MIDDLE (OFF) position, and the electrical appliance is switched OFF

(ii) Insert the plug, from the appliance, into the respective socket outlet,

(BLUE - 230V.......YELLOW - 110V).

(iii) Switch the 110/230V selector switch to the appropriate voltage.

(iv) Switch ON the appliance.

(C. Fig.1)

, is in the

C. Shutting down the Generator

ALWAYS use the following procedure.

Switch OFF....

a. ALL appliances

b. The 110/230V selector switch. (Select the MIDDLE position)

Disconnect the appliances from the outlet socket.

Turn OFF the gas, at the gas bottle, and allow the engine to stop through lack of fuel,

THEN turn the ignition switch to the ‘OFF’ position.

This ensures that no gas is left in the hoses etc., which could be hazardous.

NOTE: If you are simply changing gas bottles, it is not necessary to disconnect the electrical appliances. Switch OFF the appliances, then switch OFF the 110/230V selector switch on top of the generator (C. Fig.1). i.e. set to the MIDDLE (OFF) position. The gas bottle may then be changed.

IMPORTANT ! Never switch off the engine whilst an electrical device is connected.

D. Thermal Overload

If the circuit is overloaded the thermal circuit breaker will trip, to protect the alternator, and output will cease.

Should this occur, disconnect the appliance from the generator and switch OFF the engine. Wait until the alternator has cooled down, before pressing the reset button, shown at F, Fig.1.

Before starting the engine and reconnecting the appliance, determine, and eliminate the cause of the overload.

MAINTENANCE

To ensure that the generator performs correctly and has a long working life, it is essential that the Maintenance Schedule be observed

CAUTION: The engine and silencer reach temperatures likely to cause severe burns if touched. ALWAYS allow the engine to cool for at least 15 minutes before carrying out any maintenance tasks.

Use only those parts provided by CLARKE International. The use of unapproved parts could cause damage to your generator set.

Maintenance Schedule

Interval

Maintenance to be carried out at the intervals shown, either in months or hours, whichever comes first.

Maintenance Item Action

Engine Oil

Air Cleaner Element

Spark Plug

Combustion

Chamber & Valves

Valve Clearance

2345

Check Level

Change

Check

Clean

Clean & Adjust

Clean

Check & Adjust

Clean more often if used in dusty conditions

EACH

USE

234567890

MONTH

20 HOURS

23456789

1st

EVERY 3

Months

50 HOURS

2345

EVERY

6MONTHS

100

HOURS

234567890

EVERY

YEAR

300

HOURS

These operations should be referred to Clarke International Service department unless the user has the special tools required and is qualified to carry out the work.

Change the air filter at any time, if it becomes damaged or contaminated in any way.

Change the spark plug at any timre, should it be damaged or heavily encrusted with carbon deposit.

Changing the Oil

NOTE: Prolonged and frequent contact with used engine oil can cause skin irritation and is thought

to contribute to skin cancer. It is a wise precaution therefore to wear a pair of industrial quality gloves when handling engine oil, otherwise always wash your hands thoroughly after handling engine oil.

Drain the engine oil whilst the engine is still warm.

Remove the oil filler plug/dipstick (see Fig. 6)

Remove the oil drain plug (Fig. 7), and place a

suitable receptacle beneath the drain hole. Allow the oil to drain.

Carefully wipe the drain hole with a clean, lint free cloth and then replace the drain

plug..ensuring the washer is in place and the plug is tight.

Fill the sump with new Clarke SAE30 Engine Oil. (see your Clarke dealer and Specifications

for details).

Fig.6

Fig.7

IMPORTANT:

Waste oil is a serious source of pollution to our environment. We strongly recommend

that you take it, in a leakproof container, to a service station or a waste disposal sight

for recycling. NEVER throw it away with household waste, and NEVER pour it away on

to the ground, or down a drain.

Servicing the Air Cleaner

WARNING!

NEVER USE PETROL OR INFLAMMABLE LIQUIDS TO CLEAN THE AIR CLEANER

ELEMENTS: THIS PRACTICE COULD CAUSE FIRE WITH THE RESULTING

CONSEQUENCES.

1. Remove the wing nut, securing the air filter

cover, and pull off the cover.

Remove the wing nut securing the filter

element assembly and pull off the element.

Remove the foam filter from the element.

Proceed to clean the foam filter using warm

soapy water. Rinse well and allow to dry before reassembling.

DO NOT brush any dust from the element as this causes impurities to penetrate the fibres. Tap it lightly several times to remove any loose dirt and blow through from the inside to the outside with compressed air.

CAUTION: ALWAYS wear a face mask to perform this operation

Replace either or both if damaged or contaminated

NEVER attempt to start the engine without the air filter fitted

Paper Element

Foam Filter

Fig.8

Servicing the Spark Plug

CAUTION:

• Use only the plug type recommended for this engine. The use of any other type of plug

could damage the engine.

• If the engine has been running, do not touch the exhaust or spark plug as serious burns

could result.

Remove the spark plug cap and using a proper spark plug socket spanner, remove the

spark plug.

Examine the plug carefully and replace if there is a thick deposit on the electrodes or

if the insulation is cracked or broken. Clean off any minor deposits carefully using a fine emery cloth.

Check the plug gap and adjust if necessary to 0.7 - 0.8mm (0.28 - 0.31in)

Replace the spark plug ensuring the copper washer is in place. If a new plug is used,

screw in an extra 1/2 turn in order to compress the washer. If an old plug is used, screwing in an extra 1/8 - 1/4 turn is sufficient.

The spark plug must be tightened otherwise overheating could occur which could cause considerable engine damage.

Transporting the Generator Set

DO NOT transport the generator set with a gas bottle connected.

Ensure the ignition switch is OFF.

Transport in a horizontal position and if transported in the back of a truck or van, ensure it is adequately secured to prevent it from being damaged by sliding around.

Storing for Extended Period.

Always store in a dry, clean environment, under cover, protected from the elements.

• Remove the Spark Plug and pour a spoonful of engine oil into the cylinder. Gently pull

the starter cord to distribute the oil around the cylinder, stopping the piston at its highest point on the compression stroke.

• Replace the spark plug.

• Change the engine oil (see page 13)

TROUBLESHOOTING

Problem

Engine will not Start

Difficult to start or Low output

No Current Output.

Probable Cause

1. Ignition switch is OFF

2. Gas turned OFF

3. Gas bottle empty

4. Faulty gas regulator/ controller

5. Insufficient starting pull

6. Electrical appliances are connected to the generator outlets

7. Engine oil level is low

8. Loose/faulty spark plug

9. Insufficient Gas

1. Air Cleaner dirty

2. Extreme operating conditions

1. The Thermal circuit breaker has intervened.

2. The equipment connected to the generator is faulty

3. 110/230V selector in wrong position.

Remedy

1. Switch to ON

2. Turn ON gas

3. Renew gas bottle

Contact your Clarke Dealer or Clarke Service.

5. Pull more sharply

6. Disconnect all appliances

7. Top up engine oil

8. Tighten/clean spark plug

9. Re-Prime system

1. Clean/replace air cleaner element

2. See page 9, para (ii)

1. Wait until the generator has cooled sufficiently then press the Reset button

2. Investigate and rectify

3. Select correct position.

Should you experience difficulties other than those outlined here, you should consult your Clarke dealer.

SPECIFICATIONS

Model No ............................................................................. CGH3500

Part .No ................................................................................ 8852005

Dimensions (L, W, H) ........................................................... 585x435x440mm

Gross Weight ....................................................................... 35KG

Engine (HONDA)

Type ...................................................................................... 4 Stroke Single Cylinder

Displacement ...................................................................... 196cc

Max. Power ......................................................................... 4.8kW @3,600RPM

Ignition Type ........................................................................ Flywheel Magneto

Oil Capacity ........................................................................ 0.8ltr

Weight .................................................................................. 16kg (dry)

Spark Plug Type .................................................................. BPR-6ES (NGK) - W20EPR-U

Running Time on Full Gas Bottle (19kg) ........................... 24hrs (approx.)

Cooling System ................................................................... Forced Air Cooling

Stroke/Bore .......................................................................... 45x68mm

Air Cleaner .......................................................................... Paper Element

Compression Ratio ............................................................. 8.5 : 1

Sound Pressure Level .......................................................... 86.5db(A)

Sound Power Level ............................................................. 97LW(A)

Engine Oli ............................................................................. SAE10W30

1 Litre Part No. ..................................... 3050852

5 Litre Part No. ..................................... 3050855

(DENSO) or equivalent

Generator (MECA ALTE SPA)

Type ...................................................................................... Brushless Single Phase

Floating Windings

Model ................................................................................... AP102/2/B919

Max. Rated Output ............................................................ 3.0kVA

Rated Output ...................................................................... 2.4kVA

Rated Rotation Speed ....................................................... 3000 RPM

AC Rated Voltage .............................................................. 110/230 Volts @ 3000RPM

AC Rated Frequency ......................................................... 50 Hz

Outlet Sockets ..................................................................... 2 x 3 pin 16A (IP44)

Water Protection ................................................................ IP21

Please note that the details and specifications contained herein, are correct at the time of going to

print. However, CLARKE International reserve the right to change specifications at any time without

prior notice. Always consult the machine’s data plate

SPARE PARTS DIAGRAM

Gas System

Engine

Generator

Spare Parts List

No. Description Part No.

Gas Controller CGH350001

Gas Regulator CGH350002

Hose CGH350003

Adapter CGH350004

Hose Connector CGH350005

Hose Connector CGH350006

Elbow CGH350007

Worm Drive Clip CGH350008

Wing Nut CGH350010

Filter Cover CGH350011

Filter Element CGH350012

Foam Filter CGH350013

Rubber Seal CGH350014

Dipstick CGH350015

Spark Plug Holder CGH350016

Spark Plug CGH350017

Pull Cord CGH350018

ON/OFF Switch CGH350019

No. Description Part No.

Alt. End Cover CGH350020

Alt. End Housing CGH350021

Alt. Centre Cover CGH350022

Alt. Stator CGH350023

Alt. End Housing CGH350024

Alt. Screw set CGH350025

Alt. End Cover CGH350026

Thermal Overload/Reset CGH350027

110/230V Switch CGH350028

230V Receptacle Skt CGH350029

110V Receptacle Skt CGH350030

Rubber End Cap CGH350031

Capacitor CGH350032

Alt. Shaft CGH350033

Alt. Bearing CGH350034

Alt. Rotor CGH350035

Alt. Fan CGH350036

ALTERNATOR WIRING DIAGRAM

PARTS & SERVICE CONTACTS

For Spare Parts and Service,please contact your nearest dealer, or

CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: 020 8988 7400

PARTS & SERVICE FAX: 020 8558 3622

or e-mail as follows:

PARTS: Parts@clarkeinternational.com

SERVICE: Service@clarkeinternational.com

Clarke CGH 3500, 8852005 User guide

Specifications and Main Features

Frequently Asked Questions

User Manual