GENERATOR
MODEL NO: PG2500
PART NO: 8857805
OPERATION & MAINTENANCE
INSTRUCTIONS
LS0716
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 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.
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GENERAL SAFETY RULES
WARNING: EXHAUST FUMES CAN BE EXTREMELY DANGEROUS IF INHALED
WORK AREA
• 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.
POSITIONING THE GENERATOR
1. Always leave a least a 1m gap between the generator and any
surrounding building or structures.
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.
4. Never move or tilt the generator whilst it is switched on.
FIRE PREVENTION
1. Always switch the engine OFF when refuelling.
2. Always refuel away from any source of heat.
3. Always refuel in a well ventilated area.
4. Only use standard unleaded petrol.
5. Never smoke whilst refuelling and avoid smoking or using a naked flame
near the generator.
6. 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.
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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.
ADDITIONAL SAFETY RULES FOR GENERATORS
1. Always ensure the applied load does not exceed the generator rating.
Overloading the generator is dangerous and could cause serious
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. Never allow the generator air vents to become blocked.
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SAFETY SYMBOLS
Read Instruction
manual before use
Flammable
Caution - The user
should be aware of a
general hazard
Hot Surface - Do not
touch
Dangerous voltage
Poisonous fumes - Do
not use the generator
in an enclosed space.
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GENERATOR OVERVIEW
NO
DESCRIPTION
NO DESCRIPTION
1
Fuel Supply Valve
7
Engine Switch
2
Fuel Tank Cap
8
Anti-vibration Feet
3
Fuel Level Gauge
9
Oil Dipstick
4
Frame
10
Control Panel
5
Air Filter
11
Choke Lever
6
Starting Handle (recoil/pull start)
12
Earth Point
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UNPACKING AND ASSEMBLY
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.
• The generator
• Spark plug box spanner
• Tommy bar
• 12 Volt D.C. output lead assembly
BEFORE USING THE GENERATOR
Attach a suitable earth lead to a good earthing point - 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.
• The generator is clean and free from fuel or oil spillage.
• The generator is correctly located for use (See page 3).
• The fuel system is intact and there is no leakage.
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.
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.
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EARTH POINT
WARNING: FAILURE TO PROPERLY GROUND THE GENERATOR CAN RESULT
IN ELECTROCUTION
1. Ground the generator by
connecting a suitable grounding
wire to the earth point.
NOTE: Connect the other end of the
grounding wire to a copper or
brass grounding rod that is driven
into the earth.
CHECKING THE ENGINE OIL LEVEL
WARNING: TO CARRY OUT THIS CHECK, PLACE THE GENERATOR ON LEVEL
GROUND WITH THE ENGINE SWITCHED OFF.
WARNING: TAKE CARE NOT TO TOUCH ANY HOT PARTS OF THE
GENERATOR WHEN CHECKING THE OIL LEVEL.
1. Turn the dipstick anti-clockwise
and remove from the oil fill tube.
2. Wipe the dipstick with a clean
cloth.
3. Insert the dipstick back into the oil
fill tube and then remove it again.
Do not screw in the oil filler cap/
dipstick when doing this.
4. If the oil level is at or below the ‘L’
mark on the dipstick, add oil to
the crankcase.
• Fill until the oil reaches the
threads in the oil fill tube.
• Oil capacity (See page 20).
• We recommend the use of
SAE15W/40 oil in this generator.
available from your Clarke
dealer.
5. Replace the oil filler cap.
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CHECKING THE FUEL LEVEL
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.
Empty
Full
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.
Fuel filter
4. Slowly add fuel to the fuel tank
(maximum 15L) watching the fuel
level gauge as you do so.
RECOMMENDED FUEL
Only use standard unleaded petrol.
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.
NOTE: Do not overfill the fuel tank.
5. Replace the fuel filler cap securely.
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USING YOUR GENERATOR
STARTING THE ENGINE
1. Remove all connections from the
AC sockets.
2. Set the fuel valve to the ON
position as shown.
3. Make sure that the AC breaker is
set to the off (down) position.
4. Move the choke lever to the
‘Choke’ position.
5. Set the engine switch to ‘ON’.
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6. Hold the generator steady and
pull the starting handle lightly until
you start to feel resistance.
Then pull sharply to start the
engine.
NOTE: You may have to do this
more than once.
WARNING: ONCE THE GENERATOR HAS STARTED, RELEASE THE STARTING
HANDLE SLOWLY TO AVOID INJURY/DAMAGE AS IT RECOILS.
NOTE: When you first start the generator, the overload indicator may light
up for a few seconds, this is normal. If the overload indicator is still
lit after 5 seconds, stop the engine and contact your Clarke
dealer.
7. Once the engine has warmed up,
move the choke lever to the “run”
position.
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CONNECTING ELECTRICAL APPLIANCES
The generator can supply both 230V AC and 12V DC
AC POWER
1. Start the engine. See page 10.
2. Make sure that the AC Breaker is
set to the ON (up) position.
3. Connect the appliance to the
generator.
• Make sure the appliance is
turned off before connecting it
to the generator.
• The voltage being supplied is
shown on the voltmeter.
AC BREAKER
The AC Breaker will activate if the
generator is overloaded, If the AC
Breaker activates,
1. Remove any connected devices
from the generator
2. Wait for a few minutes
3. Set the AC breaker to the ON (up)
position.
4. Reconnect the devices to the generator, making sure your do not exceed
the maximum capacity of the generator.
CAUTION: MAKE SURE THAT THE APPLIANCE BEING CONNECTED IS IN
GOOD WORKING ORDER, IF IT BEGINS TO ACT ABNORMALLY OR STOPS
SUDDENLY, DISCONNECT IT FROM THE GENERATOR
CAUTION: MAKE SURE THE APPLIANCE DOES NOT EXCEED THE MAXIMUM
RATED LOAD FOR THE GENERATOR.
CAUTION: ANY DEVICE WHICH CONTAINS AN INDUCTIVE LOAD E.G.
DEVICES THAT CONTAIN A MOTOR MAY REQUIRE MORE CURRENT ON
STARTUP.
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DC POWER
1. Start the generator. See page 10.
2. Make sure the appliance is turned
off before connecting it to the
generator.
3. Connect the 12V DC appliance
(max 8.3A) to the generator.
DC POWER (CHARGING CAR BATTERIES)
WARNING: FOR YOUR SAFETY PERFORM THE FOLLOWING INSTRUCTIONS
IN THE ORDER SHOWN.
WARNING: YOU SHOULD ONLY USE THIS GENERATOR TO ‘TOP UP’ THE
BATTERY, ALSO TRYING TO CHARGE A COMPLETELY FLAT BATTERY MAY
CAUSE THE FUSE TO BLOW.
1. Start the generator. See page 10.
2. Connect the battery charging leads to the battery.
• Make sure you clamp the red wire to the positive (+) terminal and
the black wire to the negative (-) terminal of the battery.
3. Connect the battery charging leads to the generator.
• The battery will begin to charge
4. Monitor the voltage across the battery regularly during charging and
disconnect the battery when the voltage reaches 14.4 volts.
• Do not allow the clamps to touch each other whilst connected to
the generator.
CAUTION: WHEN DISCONNECTING THE BATTERY, ALWAYS DISCONNECT
THE NEGATIVE (BLACK) LEAD FIRST.
DC OVERLOAD PROTECTOR
If the DC overload protector
activates, wait for a few minutes and
then press the reset button shown on
the right.
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SHUTTING DOWN THE GENERATOR
To stop the generator in an emergency simply set the engine switch to ‘OFF’.
1. Turn off and disconnect any
electric devices.
2. Make sure that the AC breaker is
set to the off (down) position.
3. Set the engine switch to the “0”
(OFF) position.
4. Set the fuel valve to the OFF
position as shown.
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MAINTENANCE
CHANGING THE ENGINE OIL
CAUTION: PROLONGED EXPOSURE TO USED ENGINE OIL IS DANGEROUS,
ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED
ENGINE OIL.
1. Turn the dipstick anti-clockwise
and remove from the oil fill tube.
2. Place an oil collection tray under
the drain plug.
3. Unscrew the drain plug and allow
the used engine oil to drain from
the crankcase into the oil
collection tray.
NOTE: Drain the engine oil when the
engine is warm, this will ensure
the oil flows out faster.
4. Replace the drain plug.
5. Fill the crankcase with engine oil.
• Fill until the oil reaches the threads in the oil fill tube.
• Oil capacity (See page 20.).
• We recommend the use of SAE15W/40 oil in this generator. available
from your Clarke dealer .
6. Replace the dipstick.
ENVIRONMENTAL PROTECTION
One of the most damaging sources of pollution is oil, Do not throw away used
engine oil in with your domestic rubbish or pour it down drains and sinks. Place
it in a leak proof container and take it to your local waste disposal site.
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CHANGING THE SPARK PLUG
CAUTION: ALLOW THE ENGINE TO COOL BEFORE REMOVING THE SPARK
PLUG.
1. Remove the spark plug cap from
the spark plug.
2. Use the spark plug spanner
supplied to remove the spark
plug.
3. Remove any carbon that has
accumulated around the
electrode.
Add pic
4. Check the spark plug gap (a), it
should be between 0.7 and 0.8
mm, adjust if necessary.
5. Check the overall condition of the
spark plug for erosion or pitting
and replace if necessary.
6. Reinstall the spark plug and
replace the spark plug cap.
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CHECKING THE AIR FILTER
CAUTION: DO NOT USE THE GENERATOR WITHOUT THE AIR FILTER FITTED,
THIS CAN DAMAGE THE GENERATOR.
1. Unclip and remove the air filter
cover.
2. Remove the air filter element.
3. Make sure that the air filter is
clean and not damaged.
• If the air filter is damaged
contact Clarke spare parts
department for a replacement.
• If the filter is dirty, wash in a
solution of warm water and
mild detergent and rinse
thoroughly. Leave the filter to
dry completely, once it is dry immerse in clean engine oil and
squeeze to remove excess oil.
WARNING: DO NOT USE INFLAMMABLE SOLVENTS OR PETROL TO CLEAN
THE AIR FILTER.
4. Replace the filter to its original position and replace the air filter cover.
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CLEANING THE FUEL VALVE FILTER / DRAINING THE FUEL TANK
1. Set the fuel supply valve to OFF.
2. Unscrew and remove the cup,
then remove the valve filter and
‘O’ ring.
3. Wash these parts in a noninflammable solvent. Make sure
that the valve filter is not
damaged.
4. Place an approved petrol storage
container under the fuel valve
and set the fuel supply valve to
‘ON’.
• The fuel in the tank will drain
into the container.
VALVE FILTER
5. Replace the ‘O’ ring and valve
filter and tighten the cup as far as
possible.
‘O’ RING
CUP
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TROUBLESHOOTING
PROBLEM
CAUSE
SOLUTION
The generator fails
to start
Ignition switch is off
Set the ignition switch to ‘on’
Not enough oil in the generator
Add more oil, See page 8
No fuel
Add more fuel, See page 9
Spark plug not working correctly
Change the spark plug, See
page 16
The device you are trying to
power is faulty
Make sure the device you want
to power is working properly
The AC breaker is switched off
Switch the AC breaker on
The air filter is dirty
Clean the air filter, See page 17
The fuel filter is blocked
Clean the fuel filter, See page 18
The generator fails
to generate electricity
The generator is
difficult to start
If this does not solve your problem, please contact the Clarke service
department.
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SPECIFICATIONS
PG2500
Engine
Engine Model
PT168F-1
Fuel Type
Petrol
196
Displacement (cm3)
Max. power output (hp/rpm)
Start system
Hand recoil
Fuel tank capacity (L)
15
Fuel consumption (L/hr.)
1.6
Maximum run time (h) @75% Load
10.6
Engine oil type
Generator
Dimensions
6.5-4.84/3000
SAE15W/40
Engine oil capacity (L)
0.6
Guaranteed sound power (LWA dB)
94
Rated Frequency (Hz)
50
AC Output Voltage (V)
230
DC Output Voltage (V)
12V (Max 8.3A)
Maximum Rated Power (W)
2200
Length (mm)
600
Width (mm)
435
Height (mm)
445
Unpacked Weight (kg)
40.7
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EXPLODED DIAGRAM
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PARTS LIST
No
Description
No
Description
1
Switch
19
Bolt M6x25
2
Panel
20
Fuel Filler Cap
3
Voltmeter
21
Fuel Filter
4
AC Socket
22
Screw M5x12
5
AC Breaker
23
Fuel Gauge
6
Screw M3x8
24
Fuel Valve
7
Earth Bolt
25
Frame
8
DC Socket
26
Cross Beam
9
DC Breaker
27
Anti Vibration Foot (LH)
10
Panel Back Cover
28
Flange Nut M8
11
Wiring Loom
29
Rubber Feet
12
Bolt M6x12
30
Anti Vibration Foot (RH)
13
Bridge Pile
31
Back Guard Plate
14
Engine
32
Flange Bolt M6x12
15
Generator
33
Side Guard Plate
16
Fuel Tank
34
Flange Bolt M6x12
17
Rubber Gasket
35
Flange Bolt M6x35
18
Washer
36
Upper Guard Plate
Please quote the reference THPG250001 onwards. e.g. Fuel Filter will be
THPG250021.
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DECLARATION OF CONFORMITY
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