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GENERATOR
MODEL NO: FG2000
PART NO: 8857725
OPERATION & MAINTENANCE
INSTRUCTIONS
LS0313
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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.
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TABLE OF CONTENTS
INTRODUCTION......................................................................2
GUARANTEE ...........................................................................2
TABLE OF CONTENTS .............................................................3
GENERAL SAFETY RULES .......................................................4
Work area .............................................................................4
Positioning the generator ...................................................4
Fire prevention .....................................................................4
Prevention of electric shock ...............................................5
Additional safety rules for generators ...............................5
SAFETY SYMBOLS ...................................................................6
GENERATOR OVERVIEW........................................................7
UNPACKING AND ASSEMBLY ...............................................8
Fitting the Handles ...............................................................9
Fitting the feet/wheel kit .....................................................9
BEFORE USING THE GENERATOR...........................................10
Earth point ............................................................................10
Checking the fuel level .......................................................12
USING YOUR GENERATOR ....................................................13
Starting the engine ..............................................................13
Connecting electrical devices ..........................................15
Shutting down the generator .............................................17
MAINTENANCE ......................................................................18
Changing the engine oil .....................................................18
Changing the spark plugs ..................................................19
Checking the air filter ..........................................................20
cleaning the fuel valve filter / Draining the fuel tank ......21
TROUBLESHOOTING...............................................................22
SPECIFICATIONS....................................................................23
EXPLODED PARTS DIAGRAM ................................................24
PARTS LIST ..............................................................................25
PARTS AND SERVICING .........................................................25
DECLARATION OF CONFORMITY .........................................26
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GENERAL SAFETY RULES
1M (3ft)
1M (3ft)
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 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
rounding building or structures.
sur
2. Always e
a solid, flat surface.
3. Always en
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.
nsure the generator is on
sure the surrounding
FIRE PREVENTION
1. Always switch the engine OFF
when refuelling.
2. Always
source of heat.
3. Always refuel in a well ventilated
area.
4. Never over
level specified (See “Checking
the fuel level” on page 12.).
5. Never smoke whilst refuelling and avoid smoking or using a naked flame
near the generator.
refuel away from any
fill the tank, fill to the
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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.
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. NEVER allow the generator air vents to
be
come blocked.
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
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 tran
in the tank.
6. Do Not connect to a commercial or
residential power supply; e.g. ring main.
disconnect the generator when
sport the generator with fuel
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SAFETY SYMBOLS
Caution - The user should be aware of a general hazard
Dangerous Voltage
Flammable
Hot Surface - Do not touch
Poisonous fumes - Do not use the generator in an
enclosed space.
Read Instruction manual before use.
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GENERATOR OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Handle 10 Spark Plug
2 AC Plug Socket (230V) 11 Air Filter
3 AC Overload Reset Button 12 Choke
4 DC Overload Reset Button 13 Fuel Valve
5 DC 12V Outlet 14 Starting Handle
6 Earth Terminal 15 Wheel
7 Oil Filler Cap/Dipstick 16 Engine Switch
8 Drain Plug 17 Fuel Tank Cap
9 Muffler
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UNPACKING AND ASSEMBLY
Unpack your generator and check to ensure the following items are present.
Should there be any missing or damaged caused during transit contact your
Clarke dealer immediately.
• 1 x Generator
• 2 x Wheels
• 2 x Axles
• 2 x Foot Assemblies
• 1 x Fixings Pack
• 1 x Double-ended Screwdriver
• 1 x Long-reach Spark Plug Box Spanner
• 1 x Tommy Bar
• 1 x 12 Volt Charging Lead c/w Battery Clips
• 2 x Handles c/w pins and split pins
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FITTING THE HANDLES
1. With the handle in position insert
the pin as shown.
2. Secure the pin using the split pin
provided as shown.
FITTING THE FEET/WHEEL KIT
1. Lay the generator on its front end
and attach the 2 feet as shown.
2. Fix each foot to the frame using
4 x Short Bolts & 4 x 12mm nuts.
3.
Fix the axles to the frame as
shown and secure the inside end
using a flat washer and 19mm nut
provided.
4. Slide both wheels on to the axles.
NOTE: Make
5. Secure the wheel to the axle using
a
flat washer and 19mm nut
provided
6. Carefully place the generator
onto its wheels/feet.
sure that the valve on
each wheel is on the
outside.
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BEFORE USING THE GENERATOR
IMPORTANT: Generators should ALWAYS be earthed.
Attach a suitable earth lead to a good earth - 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 4).
• The fuel system and connectors are intact and there is no leakage.
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 cleaned up before
attempting to start the engine.
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.
EARTH POINT
Always connect the generator to an
earth point. The earth terminal is
shown on the right.
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CHECKING THE ENGINE OIL LEVEL
‘H’ Level
‘L’ 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 oil filler cap anticlockwise and remove from the oil
tank, w
clean cloth.
2.
Insert the dipstick back into the oil
filler tube and then remove it
again. Do not screw in the oil filler
cap/dipstick when doing this.
ipe the dipstick with a
3.
If the oil is below the ‘L’ level on
the dipstick, fill the oil reservoir to
the ‘H’ level on the dipstick.
• Oil Capacity (See
“Specifications” on page 23.)
• We recommend the use of
SAE30 oil in this generator.
4. Replace the oil filler cap.
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CHECKING THE FUEL LEVEL
Fuel filter
1. To add fuel, open the fuel filler
cap.
Just inside the fuel tank is a fuel
2.
tank filter, check this filter
periodically and remove any
contaminants which may have
accumulated.
3. Slowly add fuel to the fuel tank
(maximum 4.5L
RECOMMENDED FUEL
We recommend the use of stan
WARNING: ALWAYS REFUEL IN A WELL VENTILATED AREA AWAY FROM
ANY HEAT SOURCES.
WARNING: ALLOW THE UNIT TO COOL DOWN BEFORE REFUELLING.
).
dard unleaded petrol.
WARNING: DO NOT LEAVE FUEL WITHIN THE REACH OF CHILDREN.
NOTE: Do not overfill the fuel tank.
4. Replace the fuel filler cap securely.
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USING YOUR GENERATOR
STARTING THE ENGINE
1. Remove all connections from the sockets.
2.
Set the fuel supply lever to the
‘on’ position.
3. If you are starting the generator
‘cold’ set the choke lever to the
ON position. If the generator is
warm skip this step.
Set the engine switch to ‘I’.
4.
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5. Pull the starting handle lightly until
you start to feel resistance and
then pull up sharply to start the
generator.
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 WHIPS BACK.
Once the engine has warmed up,
6.
set the choke lever to the ‘OFF’
position.
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CONNECTING ELECTRICAL DEVICES
The generator can supply both 230V AC and 12V DC.
AC POWER
Start the engine. See page 13.
1.
2. Make sure the appliance is turned
off be
fore connecting it to the
generator.
If the AC overload protector
3.
activates, wait for a few minutes
and then press the reset button
shown on the right.
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 WITH CONTAINS AN INDUCTIVE LOAD E.G.
DEVICES THAT CONTAIN A MOTOR MAY REQUIRED MORE CURRENT ON
STARTUP.
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DC POWER (FOR CHARGING CAR BATTERIES ONLY)
WARNING: FOR YOUR SAFETY PERFORM THE FOLLOWING INSTRUCTIONS
IN THE ORDER SHOWN.
1. Start the generator. See page 13.
2. Connect the battery charging leads to the battery.
• Make sure you clamp the red wire to the positi
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
b
attery regularly during charging
and disconnect the battery when
the voltage reaches 14.4 volts.
CAUTION: WHEN DISCONNECTING THE BATTERY, ALWAYS DISCONNECT
THE NEGATIVE LEAD FIRST.
ve (+) terminal and
DC OVER LOAD 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
1. Disconnect all appliances connected to the generator.
2.
Set the engine switch to ‘0’.
3. Set the fuel supply lever to ‘OFF’.
NOTE: T
o stop the generator in an
emergency simply set the
engine switch to ‘OFF’
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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. Unscrew and remove the oil filler
cap/dipstick.
2. Place a 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
quicker.
4. Replace the drain plug and its ring
seal.
5. Fill the crankcase with engine oil to the ‘H’ mark
page 11.
6. Replace the oil filler cap/dipstick.
on the dipstick. See
ENVIRONMENTAL PROTECTION
One of the most damaging sources of pollution is oil, Do not throw away used
engine oil in with your domestic trash or 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 PLUGS
CAUTION: ALLOW THE ENGINE TO COOL BEFORE REMOVING THE SPARK
PLUG.
1. Remove the spark plug cap from
the spark plug.
2. Use the supplied spark plug
spanner to remove the spark plug.
3. Remove any carbon that has
acc
umulated around the spark
plug.
Check the spark plug gap (a), it
4.
should be between 0.7 and 0.8
mm, adjust if necessary.
5. Check the overall condition of the
sp
ark plug 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. Remove the wingnut and remove
the air filter cover.
2.
Remove the wingnut shown.
3.
Remove the air filter element.
4. Make sure that the air filter is
clean and not
• If the air filter is damaged
cont
act clarke spare parts
department for a replacement
See page 25.
• If the filter is dirty, wash the filter
in a solution of warm water and
mild detergent and rinse
thoroughly. Leave the filter to dry completely, once it is dry immerse
the filter in clean engine oil and sqeeze the filter to remove excess
oil.
damaged.
WARNING: DO NOT USE INFLAMMABLE SOLVENTS OR PETROL TO CLEAN
THE AIR FILTER.
5. Replace the filter back into its original position an
cover.
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d replace the air filter
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CLEANING THE FUEL VALVE FILTER / DRAINING THE FUEL TANK
Add pic
VALVE FILTER
‘O’ RING
CUP
1. Set the fuel supply valve to OFF.
2. U
nscrew and remove the cup,
then remove the valve filter and
‘O’ ring
3. Wash these parts in a nonflammable solvent. Make sur
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
5. Replace the ‘O’ ring and valve
filter and
possible.
.
e
into the container.
tighten the cup as far as
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TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
The generator fails
o start
t
The generator fails
generate
to
electricity
The generator is
d
ifficult to start
Ignition switch is off Set the ignition switch to ‘on’
Not enough oil in the
nerator
ge
No fuel Add more fuel, See page 12
Spark plugs not working
correctly
The device you are trying to
power is faulty
The AC breaker has activated Press the AC overload reset button
The air filter is dirty Clean the air filter, See page 20
The fuel filter is dirty Clean the fuel filter, See page 21
Add more oil, See page 11
Change the spark plugs, See
page 19
Make sure the device you want to
power is working properly
If this does not solve your problem, please contact the Clarke service
department. See page 25
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SPECIFICATIONS
FG2000
Engine Engine Model UP168
Displacement (cm
Max. power output (hp/rpm) 6.5 / 3000
Start system Recoil
Fuel tank capacity (L) 4.5
Fuel consumption (L/hr.) 0.8
Duration of run (h) 5.6
Guaranteed sound power (L
Generator Rated Frequency (Hz) 50
Rated Voltage (V) 230
Rated Power (kVA) 2.2
Max. Power (kVA) 2.4
Dimensions Length (mm) 575
Width (mm) 435
3
)
WA dB) 98
196
Height (mm) 420
Unpacked Weight (kg) 38
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EXPLODED PARTS DIAGRAM
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PARTS LIST
For Parts & Servicing, 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
NO DESCRIPTION PAR T N O NO DESCRIPTION PAR T N O
1 Frame RKFG200001 16 Housing RKFG200016
2 Rubber Right Bottom RKFG200002 17 Pan Screw 5x12 RKFG200017
3 Nut Flange 8mm RKFG200003 18 Bolt Flange 6x100 RKFG200018
4 Rubber Left Bottom RKFG200004 19 Regulator Assembly RKFG200019
5 Cushion RKFG200005 20 Cable Tie RKFG200020
6 Fuel Tank RKFG200006 21 Rotor RKFG200021
7 Air Cleaner RKFG200007 22 Bearing Assembly RKFG200022
8 Muffler RKFG200008 23 Plain Washer RKFG200023
9 Cylinder Head RKFG200009 24 Bolt Flange 8x180 RKFG200024
10 Crankshaft Case Assembly RKFG200010 25 Panel RKFG200025
11 Stator Cover RKFG200011 26 AC Socket RKFG200026
12 Stator Assembly RKFG200012 27 AC Circuit Breaker RKFG200027
13 Cooling Fan RKFG200013 28 DC Circuit Breaker RKFG200028
14 Brush Assembly RKFG200014 29 DC Output RKFG200029
15 Tapping Screw 5x14 RKFG200015 30 Earth Point RKFG200030
PARTS AND SERVICING
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DECLARATION OF CONFORMITY
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DECLARATION OF CONFORMITY
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