Clarke Power FG2500 Operation & Maintenance Instructions Manual

OPERATION & MAINTENANCE

INSTRUCTIONS

LS0114

GENERATOR

MODEL NO: FG2500

PART NO: 8857727

2

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.

3

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

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

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

4

GENERAL SAFETY RULES

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.

1M (3ft)

1M (3ft)

Always leave a least a 1M gap

between the generator and any
surr

ounding building or structures.

2. Always en

sure the generator is on

a solid, flat surface.

3. Always ensure th

e 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 aw

ay from any

source of heat.

3. Always refuel in a well ventilated
area.

4. Never overfill the tank, fill to

the
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.

WARNING: EXHAUST FUMES CAN BE EXTREMELY DANGEROUS IF INHALED

5

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

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.

6

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.

7

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

8

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 and split pins

• 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

9

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 .

4. Slide both wheels on to the axles.

NOTE: Make sure that

the valve on
each wheel is on the
outside.

5. Secure the wheel to the axle using
the

split pin provided

6. Carefully place the generator
onto its wheels/feet.

10

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.

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.

11

CHECKING THE ENGINE OIL LEVEL

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

pe 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.

‘H’ Level

‘L’ Level

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.

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.

12

CHECKING THE FUEL LEVEL

1. To add fuel, open the fuel filler
cap.

2.

Fuel filter

Just inside the fuel tank is a fuel
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).

RECOM

MENDED FUEL

We recommend the use of standa

rd unleaded petrol.

NOTE: Do not overfill the fuel tank.

4. 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.

13

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.

4.

Set the engine switch to ‘I’.

14

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.






.

6.

Once the engine has warmed up,
set the choke lever to the ‘OFF’
position.

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

15

CONNECTING ELECTRICAL DEVICES

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

AC POWER

1.

Start the engine. See page 13.

2. Make sure the appliance is turned
off before

connecting it to the

generator.

3.

If the AC overload protector
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.

16

DC POWER (FOR CHARGING CAR BATTERIES ONLY)

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

ve (+

) 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
b

a

ttery regularly during charging
and disconnect the battery when
the voltage reaches 14.4 volts.

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.

WARNING: FOR YOUR SAFETY PERFORM THE FOLLOWING INSTRUCTIONS
IN THE ORDER SHOWN.

CAUTION: WHEN DISCONNECTING THE BATTERY, ALWAYS DISCONNECT
THE NEGATIVE LEAD FIRST.

17

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

em

ergency simply set the

engine switch to ‘OFF’

18

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 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. See

page 11.

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.

19

CHANGING THE SPARK PLUGS

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

accu

mulated around the spark

plug.

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.

20

CHECKING THE AIR FILTER

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 filter is damaged
contact

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.

5. Replace the filter back into its original position an

d rep

lace 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.

21

CLEANING THE FUEL VALVE FILTER / DRAINING THE FUEL TANK

1. Set the fuel supply valve to OFF.

2. U

Add pic

VALVE FILTER

‘O’ RING

CUP

nscrew and remove the cup,
then remove the valve filter and
‘O’ ring.

3.

Wash these parts in a non­flammable 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.

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

the cup as far as

possible.

22

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

The generator fails
to

start

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

Not enough oil in the
gene

rator

Add more oil, See page 11

No fuel Add more fuel, See page 12

Spark plugs not working
correctly

Change the spark plugs, See
page 19

The generator fails
to

g

enerate

electricity

The device you are trying to
power is faulty

Make sure the device you want to
power is working properly

The AC breaker has activated Press the AC overload reset button

The generator is
di

fficult to start

The air filter is dirty Clean the air filter, See page 20

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

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

23

SPECIFICATIONS

FG2500

Engine Engine Model UP168

Displacement (cm

3

)

196

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

WA dB) 98

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

Height (mm) 420

Unpacked Weight (kg) 38

24

EXPLODED PARTS DIAGRAM

25

PARTS LIST

NO DESCRIPTION PAR T N O NO DESCRIPTION PAR T N O

1 Frame RKFG250001 16 Housing RKFG250016

2 Rubber Right Bottom RKFG250002 17 Pan Screw 5x12 RKFG250017

3 Nut Flange 8mm RKFG250003 18 Bolt Flange 6x100 RKFG250018

4 Rubber Left Bottom RKFG250004 19 Regulator Assembly RKFG250019

5 Cushion RKFG250005 20 Cable Tie RKFG250020

6 Fuel Tank RKFG250006 21 Rotor RKFG250021

7 Air Cleaner RKFG250007 22 Bearing Assembly RKFG250022

8 Muffler RKFG250008 23 Plain Washer RKFG250023

9 Cylinder Head RKFG250009 24 Bolt Flange 8x180 RKFG250024

10 Crankshaft Case Assembly RKFG250010 25 Panel RKFG250025

11 Stator Cover RKFG250011 26 AC Socket RKFG250026

12 Stator Assembly RKFG250012 27 AC Circuit Breaker RKFG250027

13 Cooling Fan RKFG250013 28 DC Circuit Breaker RKFG250028

14 Brush Assembly RKFG250014 29 DC Output RKFG250029

15 Tapping Screw 5x14 RKFG250015 30 Earth Point RKFG250030

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]

26

DECLARATION OF CONFORMITY

27

DECLARATION OF CONFORMITY