Clarke FG 3050, 8857705 User guide

GENERATOR

MODEL NO: FG3050

PART NO: 8857705

OPERATION & MAINTENANCE

INSTRUCTIONS

LS0214

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.

2

TABLE OF CONTENTS

INTRODUCTION ............................................................... 2

GUARANTEE .................................................................... 2

ENVIRONMENTAL RECYCLING POLICY ......................... 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

Shutting down the generator .............................................14

MAINTENANCE ............................................................... 15

Changing the engine oil .....................................................15

Changing the spark plugs ..................................................16

Checking the air filter ..........................................................17

Cleaning the fuel valve filter / draining the fuel tank .....18

TROUBLESHOOTING ........................................................ 19

SPECIFICATIONS ............................................................. 20

EXPLODED DIAGRAM & PARTS LIST .............................. 21

PARTS AND SERVICING .................................................. 25

DECLARATION OF CONFORMITY ................................... 26

3

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 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

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 10.).

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

4

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.




ADDITIONAL SAFETY RULES FOR GENERATORS

1. Always ensure the applied load does
not exceed the generator rating.
Overloading t
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
residential power supply; e.g. ring main.

7. Never allow the generator air vents to
become blocked.

he generator is

disconnect the generator when

sport the generator with fuel

connect to a commercial or

5

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.

6

GENERATOR OVERVIEW

NO DESCRIPTION NO DESCRIPTION

1 Fuel level gauge 9 Starting handle

2 Fuel tank cap 10 Fuel supply valve

3 AC plug sockets (2x115V, 1 x 230V) 11 Air filter

4 AC circuit breaker 12 Choke Lever

5 Voltmeter 13 Earth terminal

6 Dipstick 14 Muffler

7 Engine switch 15 Spark plug

8Drain plug

7

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

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 removed from the unit
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.

8

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 (O).

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, wipe the dipstick with a
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.

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

“Speci

fications” on page 20.)

• We recommend the use of

SAE30 oil in this generator.

4. Replace the oil filler cap.

9

CHECKING THE FUEL LEVEL

Empty

Full

Fuel filler cap

Fuel filter

1. Check the fuel level on the fuel
gauge.
The fuel gauge will show as red

hen you have fuel in the tank

w
turning white as the fuel level
decreases

To add fuel, open the fuel filler

2.
cap.

3.

Just inside the fuel tank is a fuel
tank filter, check this filter
periodic
contaminants which may have
accumulated.

4. Slowly add fuel to the fuel tank
(maximum 25L) watching the fuel
level gauge as you do so.

.

ally and remove any

RECOMMENDED FUEL

We recommend the use of 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.

10

USING YOUR GENERATOR

STARTING THE ENGINE

1. Remove all connections from the AC sockets.

2.

Set the AC breaker to the off
position.

3. Turn on the fuel supply valve.

4.

If you are starting the generator
‘cold’ set the choke lever to the
ON position.
warm skip this step.

If the generator is

11

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.






.

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,

7.
set the choke lever to the OFF
position (pushed in).

12

CONNECTING ELECTRICAL DEVICES

The generator can supply both 230V AC and 115V AC.

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

2. Select the voltage that you
require using the voltage selector
switch.

3. Set the circuit breaker to ‘ON’.

13

SHUTTING DOWN THE GENERATOR

1. Disconnect all appliances connected to the generator.

2.

Set the circuit 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’

14

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 it ring seal.

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.

15

CHANGING THE SPARK PLUGS

Add pic

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

sparkplug.

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.

16

CHECKING THE AIR FILTER

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

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

• If the air filter is damaged

co

ntact 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.

Replace the filter back into its

4.
original position and replace the
air filter

cover.

17

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 non­inflammable
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.

.

solvent. Make sure

into the container.

tighten the cup as far as

18

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

The generator fails

o start

t

The generator fails

generate

to
electricity

The generator is
d

ifficult to start

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

Not enough oil in the

nerator

ge

No fuel Add more fuel, See page 10

Spark plugs not working
correctly

The device you are trying to
power is faulty

The AC breaker has activated Switch the AC breaker to “on”

The air filter is dirty Clean the air filter, See page 17

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

Add more oil, See page 9

Change the spark plugs, See
page 16

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

19

SPECIFICATIONS

FG3050

Engine Engine Model 173F

Type Petrol air cooled 4-Stroke OHV single

cy

linder

3

Displacement (cm

Max. power output (hp/rpm) 8/3600

Ignition type TCI

Start system Recoil

Fuel tank capacity (L) 25

Fuel consumption (L/hr.) 1.9

Duration of run (h) 13

Engine oil capacity (L) 1.1

Guaranteed sound power (L

Generator Rated Frequency (Hz) 50

Rated Voltage (V) 230

Rated Power (kVA) 3.0

Max. Power (kVA) 3.0

Dimensions Length (mm) 683

Width (mm) 539

Height (mm) 548

Unpacked Weight (kg) 65

)

WA dB) 97

242

20

EXPLODED DIAGRAM & PARTS LIST

21

EXPLODED DIAGRAM & PARTS LIST

NO DESCRIPTION QTY PAR T NO

1 Crankcase 1 RKFG3050001

2 Oil seal,

crankshaft

3 Washer 2 RKFG3050003

4 Drain plug 2 RKFG3050004

5 Oil seal,

regulating sway
bar

6 Split pin 1 RKFG3050006

7 Washer 1 RKFG3050007

8 Regulating

sway bar

9 Oil sensor 1 RKFG3050009

10 Diode 1 RKFG3050010

11 Camshaft Assy 1 RKFG3050011

12 Exhaust valve 1 RKFG3050012

13 Intake valve 1 RKFG3050013

14 Spring retainer,

exhaust valve

15 Valv e sp ring 2 RKFG3050015

16 Spring seat,

exhaust valve

17 Spring seat,

intake valve

18 Cap, exhaust

valve

19 Pusher 2 RKFG3050019

20 Pusher guide 1 RKFG3050020

21 Valv e r ocker

Assy

22 Set pin 2 RKFG3050022

23 Gasket,

cylinder head

24 Stud

M6×M8×106

25 Bolt M6×12 1 RKFG3050025

26 Spark plug

F6RTCU

27 Stud M8×35 2 RKFG3050027

28 Flange bolt 4 RKFG3050028

1 RKFG3050002

1 RKFG3050005

1 RKFG3050008

1 RKFG3050014

1 RKFG3050016

1 RKFG3050017

1 RKFG3050018

2 RKFG3050021

1 RKFG3050023

2 RKFG3050024

1 RKFG3050026

NO DESCRIPTION QTY PART NO

29 Lead wind

cover

30 Gasket,

cylinder head
cover

31 Cylinder head

cover Assy

32 Bolt 1 RKFG3050032

33 Cylinder head

Assy

34 Outlet pipe 1 RKFG3050034

35 Connecting rod

Assy

36 Piston pin circlip 2 RKFG3050036

37 Piston pin 1 RKFG3050037

38 Piston 1 RKFG3050038

39 Piston ring assy 1 RKFG3050039

40 Crankshaft sets 1 RKFG3050040

41 Driven gear set,

regulator

42 Gasket,

crankcase

43 Set pin 2 RKFG3050043

44 Bearing 6207 1 RKFG3050044

45 Oil seal,

crankshaft

46 Crankcase

cover

47 Dipstick 1 RKFG3050047

48 Seal 1 RKFG3050048

49 Guard

crankcase
cover

50 Bolt M5×12 3 RKFG3050050

51 Air cleaner Assy 1 RKFG3050051

52 Nut M5 6 RKFG3050052

53 Air cleaner stay 1 RKFG3050053

54 Nut M6 1 RKFG3050054

55 Boot, vent pipe 1 RKFG3050055

56 Air duck 1 RKFG3050056

1 RKFG3050029

1 RKFG3050030

1 RKFG3050031

1 RKFG3050033

1 RKFG3050035

1 RKFG3050041

1 RKFG3050042

1 RKFG3050045

1 RKFG3050046

1 RKFG3050049

22

EXPLODED DIAGRAM & PARTS LIST

NO DESCRIPTION QTY PART NO

57 Gasket, air

cleaner

58 Manual choke

Assy

59 Gasket, air

cleaner

60 Carburetor Assy 1 RKFG3050060

61 Gasket, inlet 1 RKFG3050061

62 Connecting

block,
carburetor

63 Gasket,

carburetor

64 Check valve

Assy

65 Clamp, check

valve

66 Bolt M6×12 2 RKFG3050066

67 Supporting

plate set

68 Back spring 1 RKFG3050068

69 Fine regulating

spring

70 Pulling rod 1 RKFG3050070

71 Nut M6 1 RKFG3050071

72 Lock bolt 1 RKFG3050072

73 Regulating arm 1 RKFG3050073

74 Ignition coil unit 1 RKFG3050074

75 Bolt M6×30 2 RKFG3050075

76 Flywheel 1 RKFG3050076

77 Flywheel fan 1 RKFG3050077

78 Starting flange 1 RKFG3050078

79 Nut M16×1.25 1 RKFG3050079

80 Fan hood assy 1 RKFG3050080

81 Bolt M6×12 5 RKFG3050081

82 Grommet 1 RKFG3050082

83 Recoil starter 1 RKFG3050083

84 Bolt M6×8 3 RKFG3050084

85 Gasket, outlet 1 RKFG3050085

86 Exhaust pipe 1 RKFG3050086

1 RKFG3050057

1 RKFG3050058

1 RKFG3050059

1 RKFG3050062

1 RKFG3050063

1 RKFG3050064

1 RKFG3050065

1 RKFG3050067

1 RKFG3050069

NO DESCRIPTION QTY PART NO

87 Gasket, exhaust

pipe

88 Outer hood 1 RKFG3050088

89 Muffler 1 RKFG3050089

90 Inner hood 1 RKFG3050090

91 Side hood 1 RKFG3050091

92 Gasket, inner

hood

93 Muffler stay 1 RKFG3050093

94 Flange bolt

M6×12

95 Flange bolt

M8×25

96 Nut M8 2 RKFG3050096

97 Flange bolt

M8×16

98 Tube cl ip 2 RKFG3050098

99 Fuel cock 1 RKFG3050099

100 Cushion 4 RKFG3050100

101 Fitting brush,

fuel tank

102 Washer 4 RKFG3050102

103 Flange bolt

M6×22

104 Gasket, fuel

sensor

105 Fuel sensor 1 RKFG3050105

106 Screw M5×10 2 RKFG3050106

107 Fuel filler cap

comp.

108 Fuel tank 1 RKFG3050108

109 Stripe, fuel tank 1 RKFG3050109

110 Plug, sump 1 RKFG3050110

111 Screw M5×14 9 RKFG3050111

112 Generator fan 1 RKFG3050112

113 Stator cover 1 RKFG3050113

114 Nut M5 2 RKFG3050114

115 Stator Assy 1 RKFG3050115

116 Spring washer

5mm

1 RKFG3050087

1 RKFG3050092

7 RKFG3050094

2 RKFG3050095

4 RKFG3050097

4 RKFG3050101

4 RKFG3050103

1 RKFG3050104

1 RKFG3050107

6 RKFG3050116

23

EXPLODED DIAGRAM & PARTS LIST

NO DESCRIPTION QTY PART NO

117 Bolt M5×213 2 RKFG3050117

118 Bearing 6204-

2ZN

119 Rotor Assy 1 RKFG3050119

120 Plain washer 1 RKFG3050120

121 Bolt M10×265 1 RKFG3050121

122 Generator stay 1 RKFG3050122

123 Screw M5×12 3 RKFG3050123

124 Brush Assy 1 RKFG3050124

125 Bolt M6×175 4 RKFG3050125

126 Screw M5×18 1 RKFG3050126

127 Clip A 2 RKFG3050127

128 Vo lt ag e

regulator

129 Bolt M5×20 2 RKFG3050129

130 Generator end

cover

131 Frame comp. 1 RKFG3050131

132 Rubber pad,

frame

133 Bolt M6×12 4 RKFG3050133

134 Nut M6 4 RKFG3050134

135 Bottom rubber A2 RKFG3050135

136 Nut M6 4 RKFG3050136

137 Bottom rubber B2 RKFG3050137

1 RKFG3050118

1 RKFG3050128

1 RKFG3050130

2 RKFG3050132

NO DESCRIPTION QTY PART NO

146 Earth terminal

set

147 Vo lt me te r 1 RKFG3050147

148 DC terminal 2 RKFG3050148

149 Ignition switch 1 RKFG3050149

150 Control panel 1 RKFG3050150

151 Bearing 6202 2 RKFG3050151

152 Balancing shaft 1 RKFG3050152

153 Split pin 2 RKFG3050153

154 Wheel kit 2 RKFG3050154

155 Bolt M8×60 2 RKFG3050155

156 Flat washer 6 RKFG3050156

157 Screw M8 6 RKFG3050157

158 Wheel axel 1 RKFG3050158

159 Wheel kit Assy 1 RKFG3050159

160 Underpart 2 RKFG3050160

161 Bolt M8×24 2 RKFG3050161

162 Handle bar 2 RKFG3050162

163 Bolt M8×40 2 RKFG3050163

164 Cable, starting

motor

165 Relay, start-up 1 RKFG3050165

166 Starting motor

Assy

167 Bolt M8×35 2 RKFG3050167

1 RKFG3050146

1 RKFG3050164

1 RKFG3050166

138 Rubber pad,

frame

139 Nut M8 4 RKFG3050139

140 Cushion, frame 4 RKFG3050140

141 Control panel

case

142 Circuit

protector

143 Consent 2 RKFG3050143

144 Main wire

harness Assy

145 Bolt M6×12 5 RKFG3050145

2 RKFG3050138

1 RKFG3050141

1 RKFG3050142

1 RKFG3050144

24

PARTS AND SERVICING

For Parts & Servicing, please contact your nearest dealer, or

CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: [phone]

PARTS & SERVICE FAX: [phone]

or e-mail as follows:

PARTS: [e-mail]

SERVICE: [e-mail]

25

DECLARATION OF CONFORMITY

26

DECLARATION OF CONFORMITY

27