Clarke Power FG2000 Operation & Maintenance Instructions Manual

GENERATOR

MODEL NO: FG2000

PART NO: 8857725

OPERATION & MAINTENANCE

INSTRUCTIONS

LS0609

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.

2

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 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

DC Power ..............................................................................16

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

DECLARATION OF CONFORMITY .........................................27

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 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

2. Always ensure the ge
a solid, flat surface.

3. Always ensure the surroun
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.

structures.

nerator is on

ding

FIRE PREVENTION

1. Always switch the engine OFF
when refuelling.

2. Always refuel away from an
source of heat.

3. Always refuel in a well ventilated
area.

4. Never overfill the tank, fill to the
level specified (Se
the fuel level” on page 12.).

5. Never smoke whilst refuelling and avoid smoking or using a naked flame
near the generator.

y

e “Checking

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.

4. NEVER allow the generator 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

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 ge
in the tank.

6. Do Not connect to a commercial or
residential power supply; e.g. ring main.

disconnect the generator when

nerator with fuel

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 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

7

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

8

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.

Slide both wheels on to the axles.

4.

NOTE: Make sure that the valve on

each wheel is on the
outside.

5. Secure the wheel to the axle using
a flat washer and 19mm nut
provided

6. Ca

refully place the generator

onto its wheels/feet.

9

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.

10

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, wipe the dipstick 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.

ith 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.

11

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

recommend the use of standard unleaded pe

We

WARNING: ALWAYS REFUEL IN A WELL VENTILATED AREA AWAY FROM
ANY HEAT SOURCES.

WARNING: ALLOW THE UNIT TO COOL DOWN BEFORE REFUELLING.

trol.

WARNING: DO NOT LEAVE FUEL WITHIN THE REACH OF CHILDREN.

NOTE: Do not overfill the fuel tank.

4. Replace the fuel filler cap securely.

12

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.

13

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.

14

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 before connecti
generator.

If the AC overload protector

3.
activates, wait for a few minutes
and then press the reset button
shown on the right.

ng it to the

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.

15

DC POWER

For charging car batteries only

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

1. Start the generator.

2.

Connect the battery charging
leads to the generator.

3. Connect the battery charging
leads to the battery.

• C

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

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.

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.

16

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: To stop the generator in an

emergenc
engine switch to ‘OFF’

y simply set the

17

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 on the dipstick. Se
page 11.

6. Replace the oil filler cap/dipstick.

e

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.

18

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
accumulated
plug.

around the spark

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
spark plug and re
necessary.

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

place if

19

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 damaged.

• If the air filt

contact clarke spare parts
depa
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.

er is damaged

rtment for a replacement

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

5. Replace the filter back into its original position an
cover.

20

d replace the air filte

r

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

4. Place an approved petr

5. Replace the ‘O’ ring and valve

these parts in a non­flammable solvent. Make sure
that the valve filter is not
damaged.

ol storage
container under the fuel valve
and set the fuel supply valve to
‘ON’.

• The fuel in the tank will drain

into the container.

filter and tighten the cup as far as
possible.

21

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

The generator fails
to start

The generator fails

gene

to
electricity

The generator is
difficult to start

rate

tion switch is off Set the ignition switch to ‘on’

Igni

Not enough oil in the
generator

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 fil

The fuel filter is dirty Clean the fuel filter, See page 21

ter is dirty Clean the air filter, See page 20

Add mo

Change the spark plugs, See
page 19

Make sure the device you want to
power is working properly

re oil, See page 11

If this does not solve your problem, please contact the Clarke service
department. See page 25

22

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

23

EXPLODED PARTS DIAGRAM

24

PARTS LIST

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]

NO DESCRIPTION PAR T N O NO DESCRIPTION PART NO

1 Frame RK200001 16 Housing RK200016

2 Rubber Right Bottom RK200002 17 Pan Screw 5x12 RK200017

3 Nut Flange 8mm RK200003 18 Bolt Flange 6x100 RK200018

4 Rubber Left Bottom RK200004 19 Regulator Assembly RK200019

5 Cushion RK200005 20 Cable Tie RK200020

6 Fuel Tank RK200006 21 Rotor RK200021

7 Air Cleaner RK200007 22 Bearing Assembly 6202

DU239

8 Muffler RK200008 23 Plain Washer RK200023

9 Cylinder Head RK200009 24 Bolt Flange 8x180 RK200024

10 Crankshaft Case Assembly RK200010 25 Panel RK200025

11 Stator Cover RK200011 26 AC Socket RK200026

12 Stator Assembly RK200012 27 AC Circuit Breaker RK200027

13 Cooling Fan RK200013 28 DC Circuit Breaker RK200028

14 Brush Assembly RK200014 29 DC Output RK200029

15 Tapping Screw 5x14 RK200015 30 Earth Point RK200030

RK200022

PARTS AND SERVICING

25

DECLARATION OF CONFORMITY

26

DECLARATION OF CONFORMITY

27