Clarke G900 Operation & Maintenance Instructions Manual

PORTABLE GENERATOR

PORTABLE GENERATOR

MODEL NO: G900

PART No: 8010100

OPERATION & MAINTENANCE

INSTRUCTIONS

0704

7. Schematic

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.

-1-

-14-

5. Storage



If the generator is to be stored for long periods, proceed as follows.
Drain fuel tank, (fuel left in the tank for long periods will deteriorate causing difficulty

when trying to start the engine).



Drain fuel from the carburettor.



Change the engine oil.



Wash the air cleaner.



Check for loose bolts etc, tighten any found.



Check for other defects, any defects should be rectified before continuing.



Clean generator thoroughly and apply a preservative spray if available.



Ensure the engine switch is in the STOP position.



Pull the starter handle until resistance is felt, leave in that position.



Store indoors in a well ventilated area, preferably with a low humidity level.

Observe extreme caution when draining the fuel tank, DO NOT pour fuel down drains etc,
always dispose of fuel, oils and chemicals etc, according to local authority regulations.

W ARNING

6. Specifications

Thank you for purchasing this CLARKE Portable Generator.
Before attempting to use the equipment, 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 the Generator giving you long and
satisfactory service.

CLARKE 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.

Contents

Page No

Engine.

Generator.

Dimensions.

Dry Weight.

Type. Petrol / Forced air cooled / 4 stroke / Side valve.
Displacement. 92cc (5.61cv.in).
Fuel Tank capacity. 1.5 Litres.
Ignition System. Solid state ignition.
Starting System. Recoil.
Continuous Rating. Approx 3-4 Hours (50Hz).

Type. Type.2 pole revolving field.
Exciting System.
Voltage Regulating

System.
AC Frequency. 50Hz.
AC Voltage. 230 vac.
AC Max Output. 700W 50Hz.
AC Rated Output. 600W 50 Hz.
DC Output. 12V 100W.
Over Current

Protection. Circuit breaker.

L x W x H 365 x 265 x 345mm (14½ x 10½ x 13½)

-13- -2-

Self-exciting.

Condenser type.

22.5kg (49½lbs).

Guarantee .................................................................................... 2

Safety Precautions .......................................................................3

Component Identification......................................................... 4

Operation ........................................................................ 5,6,7 & 8

Maintenance ............................................................. 8,9,10 & 11

Trouble Shooting ....................................................................... 12

Storage ....................................................................................... 13

Specifications ............................................................................. 13

Wiring Schematic .......................................................................14

1. Safety Precautions

5. Trouble Shooting

WARNING:

As with all machinery, there are certain hazards involved with their operation

and use. Exercising respect and caution will considerably lessen the risk of

personal injury. However, if normal safety precautions are overlooked or

ignored, personal injury to the operator or damage to property, may result.

1.

ALWAYS

hazards peculiar to it. Read and become familiar with the entire
operating manual.

2.

AL WAYS

any damaged part, should be checked to ensure that
it will operate properly, and perform its intended
function. Check for alignment of moving parts, breakage
of parts, mountings, and any other condition that may
affect the machines operation. Any damage should be
properly repaired or the part replaced. If in doubt,
Consult your local dealer.

3.

ALWA YS

while the generator is operating.

4.

ALWAYS

etc.

5.

ALWAYS

best and safest performance. Follow maintenance instructions.

6.

AL WAYS

the generator. Surrounding areas should be free of
inflammables and hazardous materials (lubricants,
celluloid items, explosives etc).

7.

NEVER

when refuelling.

8.

NEVER

up and allowed to dry thoroughly before starting the generator.

9.

NEVER

10.

NEVER

11.

NEVER

12.

NEVER

insufficient ventilation, such as a tunnel etc, ensure the
exhaust pipe is directed towards a well ventilated open
area.

13.

NEVER

if connected, could lead to a malfunction, even worse, a
fire could result.

Exhaust fumes contain toxic gases. Extreme care must be
observed to ensure people an animals in the surrounding areas are not affected.

Learn the machines applications, limitations and the specific potential

check for damage. Before using the machine,

3ft

3ft

DO NOT

use the generator on a flat level surface. A void tilting or moving

switch the machine off before servicing and when refuelling

maintain machine in top condition. Keep clean for the

allow at least 1 metre (3ft) clearance around

smoke, use a naked flame or allow others to do so

overfill the tank, fill to the specified level only. Any spillages must be cleaned

cover or enclose in box etc.
operate the generator indoors.
operate the generator when raining or snowing.
operate in enclosed area where there is

connect the generator to a residual power source,

W ARNING

-3- -12-

use the machine.

3ft

3ft

Engine Fails To Start

Engine switch and or
choke lever are
incorrectly set.

Fuel tank empty. Check fuel level and top up as required.

Appliance connected
to the generator.

Spark plug !

Oil warning lamp
flashing.

No power supplied to the appliance

Circuit breaker tripped. Check the wattage of connected appliance is

Faulty connection at
the appliance.

If problems persist, contact Clarke service department for advice.

Set engine switch to RUN, move the choke
lever to its uppermost position (CHOKE).
Return choke lever to its normal position (RUN)
when engine warms up.

If connected, turn off the power switch at the
appliance or disconnect completely.

Check spark plug is connected correctly.
Remove spark plug and clean.
Fit new spark plug

Check oil level and top up as required.

within the permissible tolerance level of the
generator , if OK, reset the tripped circuit breaker
and resume as normal.

Check connections and make good if faulty
one found.

PARTS & SERVICE TEL: [phone]

or e-mail as follows:

PARTS: [e-mail]

SERVICE: [e-mail]



Using the box spanner/plug spanner Fig. 11,
loosen and remove the plug by turning in an

anticlockwise position.



Using a plug cleaner or wire brush, clean plug
electrode of burnt or deposited carbon.

2. Component Identification

Fig. 11

Check for correct gap between
the electrodes. Adjust gap to 0.6
to 0.7mm (0.02 to 0.03) by
reforming the electrode (Fig. 12).
Recommended replacement
plug type:

NGK - BMR4A

Refit spark plug in reverse order,
DO NOT overtighten and take
extra care not to break or
damage the porcelain.

Carburettor Adjustment

NOTE: It shouldnt be necessary to adjust the carburettor air screw as this has been preset
at the factory. before attempting to make further adjustments, we recommend that you
contact your nearest Clarke dealer for advice.

If it is necessary to make adjustments, remove the rubber grommet to gain access to the
adjusting screw Fig. 13b (cut away view), to view the screw when making this adjustment
is possible by looking through the open spark plug cover.
Replace rubber grommet when finished.

Champion - RCJ8

or

Porcelain

Fig. 12

Electrode

Spark Plug Gap

0.6~0.7mm
(0.02~0.03)

A. Carry Handle.
B. Fuel Filler Cap.
C. Recoil Starter Handle.
D. Earth Terminal (Ground).
E. Dual AC Sockets.
F. Indicator Lamp.
G. AC Circuit Breaker.
H. Low Oil Warning Lamp.
I. Engine Control Switch.
J. Negative DC Terminal.
K. DC Circuit Breaker.
L. Positive DC Terminal.
M. Spark Plug Cover.
N. Air Adjusting Screw (Internal).
O. Choke Lever.
P. Exhaust Outlet.
Q. Tool Box.
R. Air Cleaner Cover.
S. Frequency Adjusting Screw

(Internal).

T. Oil Filler.

Fig. 13

ab

-11- -4-

3. Operation

Before operation, the following must be carried out,

Engine Oil Level



Ensure the generator is standing on a flat level surface and not running.



Unscrew anticlockwise, the oil filler plug/dipstick and remove.



Using a clean soft cloth or tissue, wipe the dipstick, insert the dipstick into the filler neck
as shown, remove and check the level on the minimum and maximum marks, top up

as necessary with suitable oil.

SAE 10W-30 or 10W-40

oil is used, select the appropriate viscosity for
the average temperature in your area.

Oil Filler Plug/Dipstick

is recommended for general all temperature use. If single viscosity

Max
Level

Min
Level

Max

Min

Fig. 1

Oil Filler Neck

Fig. 2

Fig. 9

Use as a plug spanner , insert the tommy bar into the holes in the top of the box spanner
Fig.9.
To access the plug, open the spark plug cover by pushing in at the bottom, Fig. 10a and
lifting upwards, Fig. 10b.

Fuel Level

Check fuel level before starting the generator,
by viewing the fuel gauge on top of the
generator.
If the tank requires filling, observe all the safety
aspects before doing so.

WARNING

Always connect a ground lead to the generator
body when refuelling. One end of the lead
should be connected to the ground terminal
below the recoil handle, the other to a good
known ground.

NOTE: the generator should also be grounded
when the appliance is grounded.

-5- -10-

Tank Empty

Tank Full

Fig. 3

a

Pull the spark plug cap off to expose the spark
plug Fig. 11.

Fig. 10

b

Fig. 11

Plug Cap

Air Filter

Siting The Generator

The air cleaner consists of three
parts, (Fig. 7).
To Clean/replace the air filter
proceed as follows.
All parts removed must be
carefully put to one side prior to
cleaning and reassembling.



Using No 2 phillips screwdriver
loosen (anticlockwise) and

remove the cover securing
screw, Fig. 7a.



Remove the air filter cover.



Withdraw filter element 1,
Fig. 7b.



Withdraw the filter cage 2,
Fig. 7c.



Withdraw filter element 3,
Fig. 7d



Wipe out the air filter housing
using a clean soft cloth and a mild household detergent solution, DO NOT use chemicals

or harsh abrasives. Ensure the housing is dried thoroughly before reassembling. Carefully
wash the filter elements in a clean detergent solution, remove excess solution and allow
to dry thoroughly. Once dry soak the elements in a mixture of 3 parts petrol to 1 part
engine oil, squeeze out the excess oil and reinstall into generator.

NOTE:
DO NOT twist the elements to remove the excess oil, just grasp and squeeze them tightly.

Spark Plug

Remove the spark plug using the plug spanner supplied, the spanner is stored in the
toolbox, underneath the generator (Fig. 8). To access the spanner, remove the securing
screw, allow the box to hinge down on the R/H side and withdraw in direction of arrow.
To remove and clean the plug, proceed as follows.

a

Fig.7

2

c

1

b

3

d



The area should be free of inflammables and hazardous materials.



The generator is placed at least 1 metre away from buildings and other facilities.



The area must be well ventilated,



The generator must be positioned with the exhaust directed towards a well ventilated
open space.



The generator must be positioned away from any type of open flame or sparks etc.



The generator must be positioned in a stable condition on a flat level surface.



The generator is not enclosed or blocked by obstructions such as pieces of wood and
cardboard etc.

Engine Control Switch

The engine control switch has a built in fuel shut OFF
valve, this enables easy starting and stopping of the
generator.
The control switch has two positions, STOP and RUN.
When finished using the generator, turn the switch to
the stop position, this not only switches the engine OFF,
but also shuts the fuel OFF.

Fig. 4

Choke Lever

Starting the generator requires the choke lever to be
moved to the upper position (CHOKE).
When the engine has warmed up, slowly move the
lever down to the lower position (RUN).

Fig. 8

Tools included are universal, consisting of, 1 box spanner (plug spanner) and 1 tommy
bar/phillips screwdriver. To use as a screwdriver , simply withdraw the tommy bar from the
box spanner and insert the keyed end into the box spanner , see Fig. 9.

-9- -6-

Indicator Lamp

Fig. 5

When the generator is running, the indicator lamp is ON (green). when the engine is
switched OFF, the indicator lamp is extinguished.

Oil Low Warning Lamp

When the oil level drops below the minimum level, the warning lamp flashes, if this should
happen, switch the generator OFF, allow five minutes to cool down and for the oil to
settle, check the oil level and top up as necessary, see maintenance, section 4.

Battery Charging

Frequency Adjusting Screw

The DC output is used for charging 12volt batteries ONLY.
To charge a 12volt battery, proceed as follows.
ENSURE the generator is switched off by turning the engine control switch to the STOP
position
Using suitable cables (not supplied), connect one end of the negative lead to the
negative terminal (BLACK) on the generator, and the other to the negative terminal on
the battery.
Connect one end of the positive lead to the positive terminal (RED) on the generator,
and the other end to the positive on the battery.
Remove the battery caps and check the water level, top up with distilled water if required,
Refit the caps, leaving slightly loose if battery not the sealed type, this will prevent the
build up of dangerous gasses.
Turn the engine control switch to the run position, pull the recoil starter handle to start the
engine.

NOTE:
the charging time depends very much on the state of discharge! e.g. a fully discharged
12v-40Ah auto battery will take approx 5 to 6 hours to fully charge, the charge level can
be checked using a hydrometer to measure the specific gravity in each cell.
Take care when handling auto batteries as they contain acid, always wear protective
gloves and goggles when doing so.
Always refer to specific battery manufacturers instructions before commencing any
maintenance.

Circuit Breakers

Both circuit breakers AC and DC are designed to cut the electric current when the
current exceeds its limit or a malfunction occurs in the connected appliance.
The circuit breaker buttons are transparent with an internal coloured button which will
pop out in the event of an overload etc.
Before attempting to reset the relevant circuit breaker, switch the generator OFF , locate
and rectify the reason for the tripped breaker.
Once the fault is rectified, restart the generator, wait for a couple of seconds, depress the
breaker button, the internal coloured button should remain IN when the breaker button
is released.
If the circuit breaker continually trips out, and the cause cannot be traced, contact your
nearest Clarke dealer for advice, alternatively, have the connected appliance checked
by a qualified electrician.
To determine if the fault lies with the appliance or the generator itself, try connecting
another appliance, if the breaker still trips out, the fault is clearly within the generator, if it
doesnt trip, then the appliance must be at fault.

NOTE:
When charging a large capacity battery, DC output will exceed the limit and the DC
circuit breaker will trip out and cut the current, this is normal, if this does happen, wait a
few minutes, then reset the circuit breaker to resume charging, this applies only when
charging large capacity batteries.

The frequency is factory set and should not require further
adjustment, however the frequency can be adjusted,
simply by removing the rubber grommet in the front panel
to gain access to the adjusting screw.
Using a small phillips screwdriver adjust as required, replace
the grommet when finished.

NOTE:
This adjustment should only be carried out by a competent
person.

Frequency Adjusting Screw

Fig. 6

4. Maintenance

Daily



Check engine oil level and top up as required.



Check generator for worn or broken parts, any found should be rectified before

continuing.



Wipe generator with a clean soft cloth, lightly moistened with water. DO NOT use
harsh abrasive cleaning agents or chemicals which could damage certain parts.

Periodic

Item 20hrs 50hrs 100hrs 200hrs 500hrs 1000hrs

Clean air filter.
Check & clean spark plug. .
Change engine oil. . .

Check & adjust plug gap. . . .

Clean fuel filter . . . .

Replace spark plug. ....

Replace air filter. ....

Clean carburettor. ....

Remove carbon from cyl head. ....

Check & adjust valve clearance. ....

Check oil sensor system. ....

Overhaul (CLARKE Service). .....

Check engine switch. ....

Check rotor. .....

Check stator. .....

Check engine mounts. .....

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HighLow

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WARNING

Always ensure any appliances are switched OFF/disconnected

before starting the generator.

-7- -8-

NOTE:
If operating in extremely dusty conditions, the air and fuel filters should be inspected and
cleaned more frequently.