Clarke Power FG3000 Operation & Maintenance Instructions Manual

GENERATOR

MODEL NO: FG3000

PART NO: 8857700

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

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 plugs ..................................................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

PARTS AND SERVICING ........................................................24

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

NOTES ....................................................................................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 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

ounding building or structures.

surr

2. Always en
a solid, flat surface.

3. Always ensure th
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.

sure the generator is on

e surrounding

FIRE PREVENTION

1. Always switch the engine OFF
when refuelling.

2. Always refuel aw
source of heat.

3. Always refuel in a well ventilated
area.

4. Never overfill the tank, fill to
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.

ay from any

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.

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
in the tank.

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

disconnect the generator when

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

2 Fuel tank cap 11 Dipstick

3 Engine 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

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

• 12 Volt DC Battery Charging Lead

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

“Specif

• We recommend the use of

SAE30 oil in this generator.

4. Replace the oil filler cap.

ications” on page 21.)

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

en you have fuel in the tank

wh
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
periodically and remove
contaminants which may have
accumulated.

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

.

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 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.
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 ‘RUN’
position.

12

CONNECTING ELECTRICAL DEVICES

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

AC POWER

Start the engine. See page 11.

1.

2. Make sure the appliance is turned
off before
generator.

Set the breaker to ‘ON’

3.

4. Connect the appliance to the
gen
that draws the most current.

connecting it to the

erator starting with the device

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.

13

DC POWER

For charging car batteries only.

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

1. Start the engine. See page 11.

2.

Connect the battery charging
leads to the battery.

• Clamp the red wire to the

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

3. Connect the battery charging

to the generator.

leads

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.

minal and the

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.

14

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: To stop the generator in an

e

mergency simply Set the

engine switch to ‘O’

15

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
crankcas

NOTE: Drain the engine oil when the engine is warm, this will ensure the

4. Replace the drain plug and

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

e into the oil collection tray.

oil flows out quicker.

its seal ring.

on the dipstick. See

16

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
accu

mulated 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
spark plug
necessary.

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

and replace if

17

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 damaged.

•

If the air filter is damaged
cont

act Clarke spare parts
department for a replacement
See page 24.

• 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.

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

d rep

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

18

lace the air filter

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.

Wash these parts in a non-

3.
inflammable solvent. Make sure
that the valve filter
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
possible.

is not

the cup as far as

19

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

The generator fails

start

to

The generator fails

g

enerate

to
electricity

The generator is
di

fficult to start

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

Not enough oil in the

rator

gene

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 is switched off Switch the AC breaker on

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

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

Add more oil, See page 9

Change the spark plugs, See
page 17

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 24

20

SPECIFICATIONS

FG3000

Engine Engine Model UP168

Type Petrol air cooled 4-Stroke OHV single

cylin

der

3

Displacement (cm

Max. power output (hp/rpm) 6.5 / 3000

Ignition type Mag

Start system Recoil

Fuel tank capacity (L) 15

Fuel consumption (L/hr.) 1.4

Duration of run (h) 11

Engine oil capacity (L) 0.6

Guaranteed sound power (L

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

)

WA dB) 96

196

21

EXPLODED PARTS DIAGRAM

22

PARTS LIST

NO DESCRIPTION QTY PA R T N O NO DESCRIPTION QTY PART NO

1 Petrol Engine 1 RKFG300001 24 Muffler hood 1 RKFG300024

2 Muffler washer 1 RKFG300002 25 Nut M6 7 RKFG300025

3 Muffler 1 RKFG300003 26 Flange bolt

M8*1

2

4 Washer Ø8 2 RKFG300004 27 Gasket M8 2 RKFG300027

5 Spring washer Ø82 RKFG300005 28 Nut M8 2 RKFG300028

6 Nut M8 2 RKFG300006 29 Fuel stator 2 RKFG300029

7 Flange bolt

2

0

M8*

9 Alternator

assembl

10 Shock Absorber 4 RKFG300010 32 Fuel tank 15L 1 RKFG300032

11 Nut M8 8 RKFG300011 33 Fuel tank

12 Spring washer Ø82 RKFG300012 34 Clamp 2 RKFG300034

13 Wash er Ø8 2 RKFG300013 35 Fuel pipe 1 RKFG300035

y

2 RKFG300007 30 Plain washer

M6*8

1 RKFG300009 31 Flange bolt

M6*12

ck assem

co

2 RKFG300026

4 RKFG300030

2 RKFG300031

1 RKFG300

033

15 Screw M6*12 4 RKFG300015 36 Fuel tank

17 Flange bolt

18 Gasket 2 RKFG300018 38 Fuel marker 1 RKFG300038

19 Nut M6 1 RKFG300019 39 Screw M5*12

20 Grounding wire 1 RKFG300020 40 Flange bolt

21 Muffler hood 1 RKFG300021 42 Bush Ø6 4 RKFG300042

22 Flange bolt

23 Flange bolt M6 Ø87 RKFG300023 44 Nut M6 4 RKFG300044

M6*1

M8*2

2

5

1 RKFG300017 37 Strainer 1 RKFG300037

4 RKFG300022 43 Shock

mbly

asse

5

M6*2

absorber Ø8

1 RKFG300

2 RKFG300039

4 RKFG300040

4 RKFG300043

036

23

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]

24

DECLARATION OF CONFORMITY

25

DECLARATION OF CONFORMITY

26

NOTES

27