Clarke FG3005 Operation & Maintenance Instructions Manual

OPERATION & MAINTENANCE

INSTRUCTIONS

LS0413

GENERATOR

MODEL NO: FG3005

PART NO: 8857707

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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

BEFORE USING THE GENERATOR ......................................... 8

Earth point ............................................................................ 8

Checking the engine oil level ............................................ 9

Checking the fuel level ...................................................... 10

USING YOUR GENERATOR ................................................... 11

Starting the engine ..............................................................11

Connecting electrical devices .......................................... 13

DC power ............................................................................. 14

Shutting down the generator ............................................ 15

MAINTENANCE ..................................................................... 16

Changing the engine oil ....................................................16

Changing the spark plug ................................................... 17

Checking the air filter ......................................................... 18

Cleaning the fuel valve filter / Draining the fuel tank ..... 19

TROUBLESHOOTING ............................................................. 20

SPECIFICATIONS .................................................................. 21

EXPLODED PARTS DIAGRAM .............................................. 22

PARTS LIST ............................................................................. 23

DECLARATION OF CONFORMITY ........................................ 24

DECLARATION OF CONFORMITY ........................................ 25

NOTES ................................................................................... 26

NOTES ................................................................................... 27

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GENERAL SAFETY RULES

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
sur

rounding building or structures.

2. Always e

nsure the generator is on

a solid, flat surface.

3. Always en

sure 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. Never over

fill the tank, fill to the
level specified (See “Checking
the fuel level” on page 10.).

WARNING: EXHAUST FUMES CAN BE EXTREMELY DANGEROUS IF INHALED

1M (3ft)

1M (3ft)

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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.

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 gene

rator air vents to

become 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

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.

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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 Fuel level gauge 10 AC plug sockets (2 x 230V)

2 Fuel tank cap 11 Dipstick

3 Engine on/off switch 12 Drain plug

4 Power Indicator 13 Starting handle

5 Voltmeter 14 Air filter

6 AC breaker 15 Fuel supply valve

7 DC reset Button 16 Muffler

8 DC 12V outlet 17 Spark plug

9 Earth Terminal

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UNPACKING AND ASSEMBLY

Inside the box there should be. The Generator, Spark Plug Box Spanner, Tommy
Bar and 12 Volt DC Battery Charging Lead

If any are missing or have been damaged in transit, speak to your Clarke
dealer immediately.

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 make sure that the generator is:

• in good condition and not damaged.

• clean and free from fuel or oil spillage.

• 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. If fuel is spilt it must be

cleaned up before you start the engine

.

EARTH POINT

Always connect the generator to an
earth point. The earth terminal is
shown on the right.

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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CHECKING THE ENGINE OIL LEVEL

1. Turn the oil filler cap
counterclockwise and remove
from the oil tank,

2. Clean the dipstick with a cloth.

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

• Do not screw it in when doing

this.

4. 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 21.)

• We recommend the use of

SAE30 oil in this generator.

5. Replace the oil filler cap.

WARNING: TO CARRY OUT THIS CHECK, PLACE THE GENERATOR ON LEVEL
GROUND WITH THE ENGINE SWITCHED OFF (O).

WARNING: TAKE CARE NOT TO TOUCH ANY HOT PARTS OF THE
GENERATOR WHEN CHECKING THE OIL LEVEL.

‘H’ Level

‘L’ Level

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CHECKING THE FUEL LEVEL

1. Check the fuel level on the fuel
gauge (located on the top of the
generator).
The fuel gauge will show as red
w

hen you have fuel in the tank
turning white as the fuel level
decreases.

2. To add fuel, remove the fuel filler
cap.

3. Just inside the fuel tank is a fuel
tank filter, check this filter
periodic

ally and remove any
contaminants which may have
accumulated.

4. Slowly add fuel to the fuel tank
(maximum 15L) watching the fuel
level gauge as you do so.

RECOMMENDED FUEL

We recommend the use of standard unleaded petrol.

NOTE: Do not overfill the fuel tank.

5. Replace the fuel filler cap securely.

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.

Empty

Full

Fuel filler cap

Fuel filter

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USING YOUR GENERATOR

STARTING THE ENGINE

1. Remove all connections from the AC sockets.

2. Set the breaker to the off position.

3. Turn the fuel supply valve to the
‘on’ position.

4. If you are starting the generator
‘cold’, set the choke lever to the
ON position.

If the generator is

warm skip this step.

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5. Set the engine switch to ‘I’

6. 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.






.

7. Once the engine has warmed up,
set the choke lever to the ‘RUN’
po

sition.

WARNING: ONCE THE GENERATOR HAS STARTED, RELEASE THE STARTING
HANDLE SLOWLY TO AVOID INJURY/DAMAGE AS IT WHIPS BACK.

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CONNECTING ELECTRICAL DEVICES

The generator can supply both 230V AC and 12V DC.

AC POWER

1. Start the engine. See page 11.

2. Make sure the appliance is turned
off before connecting it to the
generator.

3. Set the breaker to ‘ON’.

4. Connect the appliance to the
generator starting with the device
that draws the most current.

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.)

1. Start the engine. See page 11.

2. Connect the battery charging
leads to the battery.

• Clamp the red wire to the

posit

ive (+) terminal and the
black wire to the negative (-)
terminal of the battery. Do not
reverse these positions.

3. Connect the battery charging
le

ads to the generator.

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.

CAUTION: MAKE CONNECTIONS TO THE BATTERY AFTER STARTING THE
ENGINE.

WARNING: TO PREVENT THE POSSIBILITY OF CREATING A SPARK NEAR THE
BATTERY, DISCONNECT THE CABLE TO THE GENERATOR FIRST AND THEN
DISCONNECT THE BATTERY

WARNING: AFTER YOU HAVE CHARGED THE BATTERY, ALWAYS
DISCONNECT THE NEGATIVE LEAD FIRST.

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SHUTTING DOWN THE GENERATOR

1. Disconnect all appliances connected to the generator.

2. Set the breaker to ‘OFF’.

3. Set the engine switch to ‘O’.

4. Set the fuel supply valve to ‘OFF’.

NOTE: T

o stop the generator in an
emergency simply set the
engine switch to ‘O’.

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Maintenance

CHANGING THE 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
crankcas

e into the oil collection tray.

NOTE: Drain the eng

ine oil when the engine is warm, this will ensure the

oil flows out quicker.

4. Replace the drain plug and

its seal ring.

5. Fill the crankcase with engine oil to the ‘H’ mark

on the dipstick. See

page 9.

6. Replace the oil filler cap/dipstick.

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.

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

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CHANGING 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
ac

cumulated around the

sparkplug.

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 and replace if
necessary.

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

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

Add pic

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CHECKING THE AIR FILTER

1. Unlock 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

co

ntact Clarke spare parts

department for a replacement.

• 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 squeeze the filter to remove excess oil.

4. Replace the filter back into its original position an

d replace the air filter

cover.

CAUTION: DO NOT USE THE GENERATOR WITHOUT THE AIR FILTER FITTED,
THIS CAN DAMAGE THE GENERATOR.

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

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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’ rin

g.

3. Wash these parts in a non­flammable solvent. Mak

e 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.

5. Replace the ‘O’ ring and valve
filter and

tighten the cup as far as

possible.

Add pic

VALVE FILTER

‘O’ RING

CUP

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TROUBLESHOOTING

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

PROBLEM CAUSE SOLUTION

The generator
fails to

start

Engine switch is off Set the engine switch to ‘I’

Not enough oil in the
gene

rator

Add more oil, See page 9

No fuel Add more fuel, See page 10

Spark plugs not working
correctly

Change the spark plugs, See
page 17

The generator
fails t

o generate

electricity

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 generator is
difficult to start

The air filter is dirty Clean the air filter, See page 18

The fuel filter is dirty Clean the fuel filter, See page 19

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SPECIFICATIONS

Engine Engine Model UP170

Type Petrol air cooled 4-Stroke OHV single

cyl

inder

Displacement (cm

3

)

208

Max. power output (HP/rpm) 7.0 / 3600

Ignition type Magneto

Start system Recoil

Fuel tank capacity (L) 15

Fuel consumption (L/h) 1.4

Duration of run (h) 11

Engine oil capacity (L) 0.6

Guaranteed sound power (L

WA dB) 96

Generator Rated Frequency (Hz) 50

Rated Voltage (V) 230

Rated Power (kVA) 2.6

Max. Power (kVA) 2.8

Dimensions Length (mm) 592

Width (mm) 498

Height (mm) 432

Unpacked Weight (kg) 45

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EXPLODED PARTS DIAGRAM

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PARTS LIST

NO DESCRIPTION PAR T NO

1 UP170-41 Engine RKFG300501

2 Frame RKFG300502

3 Fuel Tank RKFG300503

4 Φ4.5

mm Fuel Pipe RKFG300504

5 Φ8 C

lamp RKFG300505

6 Φ7 C

lamp RKFG300506

7 Fuel Tank Filter RKFG300507

8 Fuel Switch RKFG300508

9 Fuel Tank Cap RKFG300509

10 Shock Absorption RKFG300510

11 Fuel Marker Assembly RKFG300511

12 Control Pannel RKFG300512

13 Alternator Guard Board RKFG300513

14 190 Front End Cover RKFG300514

15 190 Rear End Cover

Guar

d

RKFG300515

16 190 Rear End Cover RKFG300516

17 Wire Fasten Connection RKFG300517

18 AVR RKFG300518

19 Muffler RKFG300519

20 Mufler Gasket RKFG300520

21 Shock Absorption RKFG300521

22 Grounding Wire RKFG300522

23 Muffler Side Guard RKFG300523

24 Muffler Outside Guard RKFG300524

25 Rotor RKFG300525

26 Stator RKFG300526

27 Carbon Brush RKFG300527

28 Flange Bolt M5x12 RKFG300528

29 Flange Bolt M5x16 RKFG300529

30 Flange Bolt M6x12 RKFG300530

31 Flange Bolt M6x14 RKFG300531

32 Bolt M6x130 RKFG300532

33 Flange Bolt M8x20 RKFG300533

34 Bolt M8x25 RKFG300534

35 Bolt 5/16-210 RKFG300535

36 Full-thread Bolt M5x20 RKFG300536

37 Nut M5 RKFG300537

38 Flange Nut M6 RKFG300538

39 Flange Nut M8 RKFG300539

40 Flat Washer Φ5 RKFG300540

41 Flat Washer Φ6 RKFG300541

42 Flat Washer Φ8 RKFG300542

43 Spring Washer Φ5 RKFG300543

44 Spring Washer Φ6 RKFG300544

45 Spring Washer Φ8 RKFG300545

46 External Tooth Lock

Wa

sher Φ5

RKFG300546

47 External Tooth Lock

Wa

sher Φ6

RKFG300547

48 Flat Washer Φ8 RKFG300548

49 Large Flat Washer

Φ8(

H=3)

RKFG300549

50 Screw M6x12 RKFG300550

NO DESCRIPTION PART NO

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DECLARATION OF CONFORMITY

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DECLARATION OF CONFORMITY

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NOTES

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NOTES