Clarke CP6550NESLR User guide

GENERATOR

MODEL NO: CP6550NESLR

PART NO: 8857685

OPERATION & MAINTENANCE

INSTRUCTIONS

ORIGINAL INSTRUCTIONS GC01/25-REV 1

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 PROTECTION

Recycle unwanted materials instead of disposing of them as waste. All
tools, accessories and packaging should be sorted and taken to a
recycling centre for disposed in a manner compatible with the
environment.

By purchasing this product, the customer is taking on the obligation to deal with its
safe disposal in accordance with the Waste Electrical and Electronic Equipment
(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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GENERAL SAFETY RULES

WARNING: EXHAUST FUMES CAN BE EXTREMELY DANGEROUS IF
INHALED

WORK AREA

1. ALWAYS use in a well ventilated area.

2. ALWAYS position the exhaust outlet away from people.

3. Read these safety instructions before using the equipment.

4. Keep children and animals away from the generator.

FIRE PREVENTION

1. ALWAYS switch the engine OFF when re-fuelling.

2. ALWAYS refuel in a well ventilated area.

3. NEVER overfill the tank, only fill to the level specified.

4. NEVER smoke whilst re-fuelling and avoid smoking or using a naked flame near
the generator.

5. 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.

3. NEVER use water or any other liquids to clean the generator.

4. Make sure you ground (earth) the generator.

POSITIONING THE GENERATOR FOR USE

1. ALWAYS leave at least a 1 metre gap between the generator and any
surrounding building or structure or the engine may overheat.

2. ALWAYS ensure the generator is on a solid, flat surface.

3. ALWAYS ensure the surrounding area is free from any material that could burn or
be damaged by heat.

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4. NEVER move or tilt the generator whilst it is switched on.

5. NEVER cover or enclose the generator whilst it is in use.

6. Be aware of the weight of the generator, do not attempt to lift or move the
generator without the assistance of another person.

EXHAUST GAS PRECAUTIONS

WARNING!: EXHAUST FUMES CAN BE FATAL

1. ALWAYS ensure that there is adequate ventilation when using the generator.

2. ALWAYS position the generator so that the exhaust is pointing away from people
or animals.

3. NEVER use the generator indoors or in a enclosed area. (i.e. in warehouse,
tunnel, well or a hold).

ADDITIONAL SAFETY RULES FOR GENERATORS

1. ALWAYS make sure the applied load does not exceed the generator rating.
Overloading the generator is dangerous and could cause serious damage.

2. ALWAYS

3. ALWAYS allow the generator to reach 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. NEVER connect the generator to a commercial or residential power supply; e.g.
ring main.

7. NEVER allow the generator air vents to become blocked.

8. NEVER alter or tamper with the internal wiring of the generator.

9. NEVER touch any part of the engine, alternator or exhaust when the generator is
in use as these get hot and could cause burns.

10. NEVER allow anyone, not fully familiar with generator sets to use this equipment.

11. This generator set is NOT suitable for use with electronic equipment such as
televisions, hi-fi’s or computers etc.

12. Connect only those appliances that are in good working order.

disconnect the generator when carrying out any maintenance.

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.

13. 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.

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14. Connect only those appliances whose voltage (according to their data plate)
corresponds to that produced by the generator.

IMPORTANT!: This generator uses a floating chassis (refer to technical
information sheet).

Floating earth generators DO NOT require earthing.

SAFETY SYMBOLS

The following safety symbols are shown on the product or it’s packaging. Please read
all of the safety and operating instructions carefully before using this product.

Read instruction manual
before use.

Dangerous voltage Poisonous fumes - Do not

Flammable Caution - The user should

This product produces
high noise levels during
operation. Ear protection
is advised.

Hot surface - Do not touch

use the generator in an
enclosed space.

be aware of a general
hazard.

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UNPACKING AND ASSEMBLY

Unpack your generator and check all are present. Should there be any missing or
damaged during transit contact your CLARKE dealer.

BEFORE USING THE GENERATOR

Before using your generator check that the generator is:

• In good condition and free from any damage.

• Is clean and free from fuel or oil spillage or leaks.

• Is correctly located for use.

NOTE: To avoid accidental spillage of fuel, always use a funnel to fill the fuel

tank. If fuel is spilled it must be wiped up from the unit before
attempting to start the engine.

CHECK THE ENGINE OIL LEVEL

WARNING: YOUR GENERATOR MAY NOT BE SUPPLIED WITH OIL ­ALWAYS ENSURE THERE IS SUFFICIENT OIL BEFORE USE.

CAUTION: ONLY CARRY OUT THIS CHECK WITH THE ENGINE OFF.

1. Stand the generator on a level
surface and check the oil level as
follows.

2. Turn the oil filler cap/dipstick anti­clockwise to remove from the oil
reservoir and wipe with a clean cloth.

3. Insert the dipstick back into the oil
filler tube and then remove it again.

4. If the oil is below the Min. level on
the dipstick, top up the oil reservoir
with fresh oil.

• DO NOT fill above the max level

mark.

• We recommend the use of

SAE10W/30 oil in this generator.
(CLARKE part number 3050845)

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• DO NOT tilt the generator when adding engine oil. This could result in

overfilling and damage to the engine.

5. Replace and tighten the oil filler cap.

ADDING/CHECKING THE FUEL LEVEL

WARNING: MAKE SURE THERE IS 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.

1. To check the fuel level, open the fuel
filler cap.

2. Slowly add fuel to the fuel tank
(maximum 15 litres)

• DO NOT overfill the fuel tank.

3. Replace the fuel filler cap securely.

RECOMMENDED FUEL

Your generator has been designed to use
regular unleaded petrol with a octane
number of 86 or higher. The user should confirm that current E10 fuels are suitable.

.

WARNING: FUEL IS HIGHLY FLAMMABLE AND POISONOUS.

WARNING: SEE “GENERAL SAFETY RULES” ON PAGE 3 AND READ
THEM CAREFULLY BEFORE REFUELING.

WARNING: DO NOT FILL ABOVE THE TOP OF THE FUEL FILTER OR IT
MAY OVERFLOW WHEN THE FUEL HEATS UP AND EXPANDS.

WARNING: WIPE UP ANY SPILLED FUEL IMMEDIATELY.

WARNING: AFTER REFUELING, MAKE SURE THE FUEL FILLER CAP IS
TIGHTENED SECURELY.

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4. Replace the fuel filler cap securely.

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.

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PREPARATION FOR USE

This electric start machine is supplied with a 19AH 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 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 2.5 Amps 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.

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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.

Conductor (mm²) Max Length (m) Current (Amps) Single Phase (kW)

1.5 25 10 2.3

2.5 40 16 3.7

4.0 60 28 6.5

Ensure the cable is fully unwound when in use to avoid overheating, and the placing
of extra load on the generator.

OPERATION

IMPORTANT: Ensure all precautions are taken, referring to this and the
Honda engine manual before proceeding.

Start the engine as follows (referring to
engine manual) and allow to run for a
few minutes at full speed in order for it
to warm up.

1. Move the fuel valve lever to the ON
position

2. To start a cold engine, move the
choke lever to the On position.

3. Pull the recoil starter grip lightly until
you feel resistance, then pull briskly.
Return the starter grip gently.

NOTE: DO NOT allow the starter grip to snap back against the engine at high

speed causing damage.

4. To re-start a warm engine, leave the choke lever in the Off position.

5. To use the electric starter, turn the key to the start position until the engine starts.

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6. If the engine fails to start within 5 seconds, release the key and wait at least 10
seconds before operating the starter again. When the engine starts, release the
key.

NOTE: Using the starter for more than 5 seconds can overheat and damage

the starter motor.

7. Set the engine speed by moving the
throttle lever away from the MIN
position

IMPORTANT: Ensure no appliances
are connected to the generator
when starting the engine.

8. 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.

9. For generators with dual output, ensure the voltage selector switch is set to

deliver the appropriate output - 115V or 230V, see fig’sbelow..

10. 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 reset button on the
panel.

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.

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Additionally, please refer to the specifications sheet attached, to ensure the machine
is used under the correct operating conditions.

SHUTTING DOWN THE GENERATOR

IMPORTANT: Never switch off the engine whilst an electrical appliance
is connected.

To stop the generator in an emergency simply set the engine switch to ‘OFF’.

Move the throttle lever to the MIN position.

1. Set the engine switch to the “0” (OFF) position.

2. Turn the fuel valve knob to “OFF” (pointing left).

3. Disconnect any electric devices.

MAINTENANCE

ENGINE OIL (AFTER FIRST 20 HOURS OF USE)

CAUTION: PROLONGED EXPOSURE TO USED ENGINE OIL IS DANGEROUS,
ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED
ENGINE OIL.

1. Turn the oil filler cap anti-clockwise
and remove from the oil reservoir.

2. Remove the drain plug and tilt the
generator to allow the oil to drain out
of the oil reservoir into a suitable
container.

NOTE: You may need assistance with

this step as the generator is
heavy.

3. Fill the oil reservoir with fresh oil.

• DO NOT fill above the max level mark.

• We recommend the use of SAE10W/30 oil in this generator. (CLARKE part

number 3050845)

4. Replace the oil filler cap.

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ENVIRONMENTAL PROTECTION

One of the most damaging sources of pollution is oil. DO NOT throw away used
engine oil in with your domestic waste or down drains and sinks. Place it in a leak
proof container and dispose of it according to local regulations.

AIR FILTER (EVERY 50 HOURS OF USE)

WARNING: DO NOT USE FLAMMABLE SOLVENTS OR PETROL TO
CLEAN THE AIR FILTER.

1. Remove the air filter cover,
unscrewing the securing nut.

2. Remove the air filter panel and the
air filter element.

3. If the air filter is damaged contact
the CLARKE spare parts department
for a replacement.

• If the filter is dirty, wash it in a

solution of warm water and mild
detergent and then rinse
thoroughly.

• Leave the filter to dry completely, once it is dry immerse the filter in clean

engine oil and squeeze the filter to remove excess oil.

4. Replace the filter into its original position and replace and secure the air filter
cover.

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SPARK PLUG (EVERY 50 HOURS OF USE)

CAUTION: ALLOW THE ENGINE TO COOL BEFORE REMOVING THE SPARK
PLUG.

1. Remove the spark plug cap from the
spark plug.

2. Fit the spark plug box spanner over
the spark plug as shown and use the
lever to turn it.

3. When the spark plug has been
removed, check for discoloration and
use a wire brush to remove any
carbon build up.

4. Check the spark plug gap with a
feeler gauge which should be
between 0.6 and 0.7 mm.

• Adjust if necessary.

5. Check the overall condition of the
spark plug and replace if damaged.

NOTE: Spark plugs are available from

CLARKE Spare Parts department
020 8988 7400.

6. Reinstall the spark plug and replace the spark plug cap.

FUEL TANK FILTER (EVERY 100 HOURS OF USE)

Just inside the fuel tank is a fuel filter, check this filter periodically and remove any
contaminants which may have accumulated.

1. Remove the fuel tank cap.

2. Lift out the filter inside.

3. Clean the filter with solvent. If the filter is damaged, contact CLARKE Spare Parts
department for a replacement.

4. Replace the filter and fuel tank cap.

STORAGE

1. Always store in a damp free environment away from children.

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TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

The generator
fails to start

The generator
fails to generate
electricity (no AC
output)

Engine switch is off Set the engine switch to ON

Fuel valve OFF Move the lever to ON position.

Choke open (Off) Move the lever to CLOSED position

unless engine is warm.

Lack of engine oil. (with Oil
Alert feature fitted)

No fuel Add more fuel.

Bad fuel due to long term
storage with fuel in tank

Spark plug defective, foul or
wrongly gapped.

The device you are trying to
power is faulty

Selector switch in wrong
position

Add more oil.

Drain the fuel tank and carburetor.
Refuel with fresh fuel.

Clean, re-gap or replace the spark
plug.

Make sure the device you want to
power is working properly.

Set the selector switch

Tripped circuit breaker Reset the AC safety trip

Poor connection or defective
lead

The generator is
difficult to start

Erratic supply Incorrect engine rpm Adjust the engine speed

If this does not solve your problem, please contact the CLARKE service department.

The air filter is dirty Clean the air filter.

Internal alternator problem Contact CLARKE servicing

Check the connection and/or
replace lead

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SCHEMATIC WIRING DIAGRAM

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SPARE PARTS

Frame SH0211009

Alternator mount SH0270004

Engine mount SH0270027

Alternator NAC5500 BC-A0/T SH0130090

IP23 Alternator cover SH0280040

Control box D/V wired cw covers SH0491001

Control box 5 SKT CON5 SH0090193

Mounting set C/BOX SH0130106

Collar SH0130063

Grommet SH0130070

MCB GTEC 25AMP 1 pole SH0360011

MCB GTEC 50AMP 1 pole SH0360020

MCB Cover 2 SH0360038

Switch Merz Z101 20/25A SH0430005

Socket 115v 16a SH0440001

Socket 230v 16a SH0440002

Battery Box SH0210093

Battery Box Lid SH0210094

Battery YB16CL-B19A/H SH0540001

Alternator end cover SH0130067

Diode PCB assy SH0130073

Capacitor 22uf SH0370015

Diode PCB assy SH0130073

Fuel tank (steel) 15.5 L SH0210092

Fuel tap inline SH0480002

Fuel filter small in-line SH0480003

Filler neck SH0480005

Filler cap SH0480006

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SPECIFICATION

Item Specification

Model No CP6550NESLR

Dimensions (L x W x H) 710 x 510 x 600 mm

Weight 87 kg

Engine type Honda GX390

Displacement 389cc

Engine power 13HP

Fuel capacity 15.5 L

Fuel consumption 2.16 L/h

Running time (full tank) 7.2 H

Fuel type Unleaded

Lubrication Oil Capacity/grade 1.1 L (SAE 10W30)

Spark plug type BPR 6ES

Rated power 6.5 kVA

Voltage AC 230/115 V

AC Rated frequency 50 Hz 1ph

Earthing Floating

Sound output 71 dB(A) @7m

Measured sound power 96.512 dB

Guaranteed sound power 97 dB

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DECLARATIONS OF CONFORMITY

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