Clarke G700 Operating And Maintenance Instructions Manual

©

Generator

Model G700

Part Number 8010010

Operating & Maintenance

Instructions

0600

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: [e-mail]

Service: [e-mail]

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 -

For Your Own Safety

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

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

in use away from damp or wet conditions.

Never

or in wet or damp conditions.

Never

Never

generator.

store the generator undercover when not

use the generator when it is raining or snowing

operate the generator with wet hands.

use water or any other liquids to clean the

- 3 -

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

1M (3ft) 1M (3ft)

Always

using the generator.

Always

pointed away from people or animals .

Never

area. (i.e. in a warehouse, tunnel, well, hold.)

Always

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

Always

maintenance.

Always

before connecting a load.

Never

is connected.

Never

Do Not

supply.

Do Not

ensure there is adequate ventilation when

position the generator so that the exhaust is

use the generator indoors or in an enclosed

General Safety Precautions for Generators

ensure the applied load does not exceed the

disconnect the generator when carrying out any

ensure the generator reaches operating speed

allow the generator to run out of fuel when a load

transport the generator with fuel in the tank.

connect to a commercial or residential power

connect to any other electrical source.

- 4 -

Fig (1) Overview

1

9 10 11 12

2

3

4

5

6

5

DC Reset Switch

AC Trip Indicator

AC Reset Switch

DC Connector

AC Connector

8 7

7

Engine ON / OFF

Choke

Throttle

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

- 5 -

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.

1.

The Generator Unit

2.

Plastic Handle (with two fastening screws)

3.

12 Volt DC Battery Attachment Leads

4.

Spark Plug Wrench

Fit the plastic carrying handle to the fuel tank with the
two screw provided as shown in fig (2).

Before Using the Generator

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.

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.
should be filled to just below the fuel filter
shoulder as shown in fig (3).

The Tank

Fig (2)

Fig (2A)

(3)

Fig (3)

Fuel Filter

Fill Level

Mix Ratio

50 : 1

Unleaded Petrol : Two Stroke Oil

Use Clarke 2 stroke oil....Part No.5060260

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 -

Using your Generator

(a)

Starting the Engine

IMPORTANT ! Ensure the generator is not connected to any electrical equipment
when starting the engine.

1.

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).

ON OFF RES

2.

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 (4)

Fig (5)

3.

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.

4.

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)

5.

Return Throttle lever to “ 0 “

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.

as shown in fig (5).

- 7 -

Choke

Fig (6)

“ 0 “

Throttle

(b)

Connecting Electrical devices

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 to 230 Volts AC.

Insert the three pin plug into the AC connector

Fig (7)

5

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.

(c)

Shutting down the Generator

DC Reset Switch

AC Trip Indicator

AC Reset Switch

DC Connector

AC Connector.
Socket for a
standard 13 Amp
BS 1363 type plug

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

Switch off the electrical device.

1.

2.

Unplug the device from the generator.

Switch the Engine OFF (see page 7).

3.

Fig (8)

4.

Turn the Fuel OFF (see page 7).

Maintenance

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 :

1.

Turn the Fuel OFF (see page 7)

Unclip the fuel hose (see fig (8)).

2.

Unbolt the tank from the unit (see fig (8)).

3.

Empty contents of the tank into a suitable

4.

container.

5.

Refit the tank, start up engine and let it

run until all the fuel has been used.

- 8 -

Maintenance Ref: Fig. 1

(a)

Air Inlet Filter

Check after 50 Hours Normal use

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.

1.

Remove the air inlet cover

Remove the foam filter and wash thoroughly

2.

with soapy water.

Rinse the Filter and allow it to dry thoroughly

3.

so that no unwanted liquids enter the carburettor.

4.

Replace the filter and the air inlet cover

(b)

Fuel Tank Filter

Check after 50 Hours Normal use

If the filter has become soiled, clean as
stated below. If the filter is damaged or has
become clogged, replace.

1.

Turn the Fuel Tap (9) OFF.

2.

Undo the fuel cap (2) and remove the filter.

3.

Wash thoroughly with soapy water.

4.

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).

(6)

.

(6)

.

(c)

Fuel Tap Filter

Check after 100 Hours Normal use

If the filter has become soiled, clean as
stated below. If the filter is damaged or has
become clogged, replace

Empty the fuel

1.

Unbolt the fuel tap

2.

(3)

tank described on page 8.

(9)

.

from the tank and
unscrew the shouldered bolt from the tap to
remove the filter.

Wash thoroughly with soapy water, rinse

3.

thoroughly and allow to dry completely before
reassembling.

4.

Replace fuel tap

(9)

and refit tank

- 9 -

(3)

.

(b)

Spark Plug

Check after 50 Hours Normal use

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

1.

the plug using the supplied wrench.

Clean the electrode with a wire brush until it is

2.

restored to its original metal colour.

Check the gap between electrodes is

3.

0.7- 0.8mm (0,028-0.031”) with a suitable gauge

Return the spark plug

4.

refit lead.

(10)

(10)

to the engine and

Troubleshooting : The Engine

Problem

Will not Start

Will not start or Low output

Probable Cause

Loose spark plug

Loose cylinder head bolt

Damaged head gasket

Insufficient starting pull

Dirt in fuel tank

Clogged fuel line

No fuel

and remove

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

Erratic performance

Fuel tap closed

Tarnished spark plug

Damaged spark plug

Faulty magneto or
carburettor settings

Improper fuel

Overheating

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

- 10 -

Troubleshooting : Electrical Fault finding

Problem

AC Indicator Light on :

No AC Output

No DC Output

Erratic Supply

Figure (9) Electrical Diagram

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

* Engine RPM (No Load): 50 Hz = 3150 RPM

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

- 11 -

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

No. Description Part No.

1 Fuel Tank.............................................................................................. HT70001

2 Fuel Valve ............................................................................................ HT70002

3 Fuel Hose ............................................................................................. HT70003

4 Exhaust ................................................................................................ HT70004

5 Starter Cover ...................................................................................... HT70005

6 Engine ..................................................................................................HT70006

7 Governor Arm Spring .........................................................................HT70007

8 Gasket ................................................................................................. HT70008

9 Carburettor ......................................................................................... 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

- 14 -