Page 1
GENERATOR
MODEL NO: FG4050ES / FG5100ES
PART NO: 8857715, 8857720
OPERATION & MAINTENANCE
INSTRUCTIONS
LS0310
Page 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.
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TABLE OF CONTENTS
INTRODUCTION ............................................................... 2
GUARANTEE .................................................................... 2
TABLE OF CONTENTS ....................................................... 3
GENERAL SAFETY RULES ................................................. 4
SAFETY SYMBOLS ............................................................ 6
GENERATOR OVERVIEW ................................................. 7
UNPACKING AND ASSEMBLY ........................................ 8
BEFORE USING THE GENERATOR .................................... 11
USING YOUR GENERATOR .............................................. 14
MAINTENANCE ............................................................... 18
TROUBLESHOOTING ........................................................ 22
SPECIFICATIONS ............................................................. 23
EXPLODED DIAGRAM & PARTS LIST ............................... 24
PARTS AND SERVICING .................................................. 27
DECLARATION OF CONFORMITY .................................. 28
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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
unding building or structures.
surro
2. Always ensur
a solid, flat surface.
3. Always ensure the s
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.
e the generator is on
urrounding
FIRE PREVENTION
1. Always switch the engine OFF
when refuelling.
2. Always refuel away from
source of heat.
3. Always refuel in a well ventilated
area.
4. Never overfill the tank, fill to the
level s
the fuel level” on page 13.).
5. Never smoke whilst refuelling and avoid smoking or using a naked flame
near the generator.
any
pecified (See “Checking
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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 the g
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 th
in the tank.
6. Do Not connect to a commer
residential power supply; eg ring main.
7. Never allow the generator air vents to
become blocked.
disconnect the generator when
enerator is
e generator with fuel
cial or
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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.
Corrosive material
Explosive risk
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GENERATOR OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Fuel level gauge 9 Starting handle
2 Fuel tank cap 10 Fuel supply valve
3 Ignition panel 11 Handle
4Control panel 12Air Filter
5 Wheel 13 Choke lever
6 Battery 14 Muffler
7 Dipstick 15 Spark plug
8Drain plug 16
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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
• Wheel kit
FITTING THE WHEEL KIT
1. Lay the generator on it’s front and
attach the 2 feet to the frame
using 4 x Short bolts, 4 x Washers,
4 x Spring washers and 4 x Nuts.
Slide both wheels on to the axle.
2.
NOTE: Make sure that the valve on
e
ach wheel is on the outside.
Secure the wheel to the axle using
3.
a split pin.
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4. Place the axle against the frame
on the generator as shown.
Fix the axle to the frame using
5.
2 x Long bolts, 2 x Washers, 2 x
Spring washer
6. Carefully place the generator
onto its wheels/feet.
s and 2 x Nuts.
FITTING THE HANDLES
1. Place thehandle into position as
shown.
secure the handle using the nNut
2. S
and bolt supplied
• Making sure that the 2 plastic
wash
ers are inserted between
the handle and frame as
shown.
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CONNECTING THE BATTERY
• Connect the negative wire to
the negative terminal on the
battery as shown on the right.
• Connect the positive wire to
the positive terminal on the
battery.
• Ensure both terminals are
covered by the plastic covers
as shown.
EARTH POINT
Always connect the generator to an
earth point. The earth terminal is
shown on the right.
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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.
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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
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.
the dipstick with 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.
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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
n you have fuel in the tank
whe
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 any
cont
accumulated.
4. Slowly add fuel to the fuel tank
(maximum 25L) watching the fuel
level gauge as you do so.
.
aminants which may have
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.
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USING YOUR GENERATOR
STARTING THE ENGINE
1. Remove all connections from the AC sockets.
2.
Set the AC circuit 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. If the gene
warm skip this step.
rator is
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5. Insert the key into the ignition.
6. Turn and hold the key in the START
position
7. Once the engine starts to run turn
the key back to the ON position.
Once the engine has warmed up,
8.
set the choke lever to the OFF
position pushed in).
.
BACKUP STARTING PROCEDURE
If for any reason the engine will not start using the above procedure, you can
start your generator manually
1.
Set the ignition key to the ON
position.
2. Pull the starting handle lightly until
you start to feel resistance and
then pull up sharply to start the
generator.
3. 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.
by carrying out the following.
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CONNECTING ELECTRICAL DEVICES
The generator can supply both 230V AC and 115V AC.
The ports are laid out in the following order: (from left to right):
1 x 32amp 230v (Blue),1 x 32amp 115v (Large Yellow) and 1 x 16amp 115v
(Small Yellow).
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’.
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SHUTTING DOWN THE GENERATOR
1. Disconnect all appliances connected to the generator.
2.
Set the circuit breaker to ‘OFF’.
3. Turn the ignition key to the OFF
position.
4. Set the fuel supply valve to OFF.
NOTE: To stop the generator in an
em
ergency simply turn the
ignition key to the off position.
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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 an 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 it ring seal.
5. Fill the crankcase with engine oil to the ‘H’ mark
page 12.
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
oil flows out quicker.
collection tray.
the dipstick. See
on
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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
accum
sparkplug.
ulated around the
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 an
necessary.
6. Reinstall the spark plug and
replace the spark plug cap.
d replace if
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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.
• I
f the air filter is damaged
contact
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 sqeeze the filter to remove excess oil.
Clarke spare parts
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.
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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.
ash these parts in a non-
3. W
inflammable 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
possible.
as far as
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TROUBLESHOOTING
PROBLEM CAUSE SOLUTION
The generator fails
tart
to s
The generator fails
ge
nerate
to
electricity
The generator is
if
ficult to start
d
Ignition switch is off Set the ignition switch to ‘on’
Not enough oil in the generator Add more oil, See page 12
No fuel Add more fuel, See page 13
Spark plugs not working correctly Change the spark plugs, See
page 19
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 20
The fuel filter is dirty Clean the fuel filter, See page 21
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 27
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SPECIFICATIONS
FG4050ES FG5100ES
Engine Engine Model 182FD 188FD
Type Petrol
3
Displacement (cm
Max. power output (hp/rpm) 11/3600 13/3600
Ignition type Non contact transisterised ignition
Start system Electric with recoil backup
Fuel tank capacity (L) 25 25
Fuel consumption (L/hr.) 2.45 2.7
Maximum run time (h) 10 9
Engine oil capacity (L) 1.1 1.1
Guaranteed sound power (L
dB)
Generator Rated Frequency (Hz) 50 50
Output Voltage (V) 115v / 230v 115v / 230v
Rated Power (kVA) 4 5
Max. Power (kVA) 4.5 5.5
Dimensions Length (mm) 680 680
Width (mm) 540 540
Height (mm) 510 510
)
WA
337 389
97 97
Unpacked Weight (kg) 70 82
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EXPLODED DIAGRAM & PARTS LIST
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EXPLODED DIAGRAM & PARTS LIST
NO DESCRIPTION QTY PART NO
1 Crankcase 1 RKFGES001
2 Oil seal, crankshaft 1 RKFGES002
3 Washer 2 RKFGES003
4 Drain plug 2 RKFGES004
5 Oil seal, regulating
6 Split pin 1 RKFGES006
7 Washer 1 RKFGES007
8 Regulating sway
9 Oil sensor 1 RKFGES009
10 Diode 1 RKFGES010
11 Camshaft Assy 1 RKFGES011
12 Exhaust valve 1 RKFGES012
13 Intake valve 1 RKFGES013
14 Spring retainer,
15 Valv e spring 2 RKFGES015
16 Spring seat,
17 Spring seat, intake
18 Cap, exhaust valve 1 RKFGES018
19 Pusher 2 RKFGES019
20 Pusher guide 1 RKFGES020
21 Valve rocker Assy 2 RKFGES021
22 Set pin 2 RKFGES022
23 Gasket, cylinder
24 Stud M6×M8×106 2 RKFGES024
25 Bolt M6×12 1 RKFGES025
26 Spark plug F6RTCU 1 RKFGES026
27 Stud M8×35 2 RKFGES027
28 Flange bolt 4 RKFGES028
29 Lead wind cover 1 RKFGES029
30 Gasket, cylinder
31 Cylinder head
y bar
a
sw
bar
exha
exhaus
valv
e
head
head c
cove
us
t valve
t valve
o
r Assy
ver
1 RKFGES005
1 RKFGES008
1 RKFGES014
1 RKFGES016
1 RKFGES017
1 RKFGES023
1 RKFGES030
1 RKFGES031
NO DESCRIPTION QTY PART NO
32 Bolt 1 RKFGES032
33 Cylinder head Assy 1 RKFGES033
34 Outlet pipe
35 Connecting rod
36 Piston pin circlip 2 RKFGES036
37 Piston pin 1 RKFGES037
38 Piston 1 RKFGES038
39 Piston ring assy 1 RKFGES039
40 Crankshaft sets 1 RKFGES040
41 Driven gear set,
42 Gasket, crankcase 1 RKFGES042
43 Set pin 2 RKFGES043
44 Bearing 6207 1 RKFGES044
45 Oil seal, crankshaft 1 RKFGES045
46 Crankcase cover 1 RKFGES046
47 Dipstick 1 RKFGES047
48 Seal 1 RKFGES048
49 Guard, crankcase
50 Bolt M5×12 3 RKFGES050
51 Air cleaner Assy 1 RKFGES051
52 Nut M5 6 RKFGES052
53 Air cleaner stay 1 RKFGES053
54 Nut M6 1 RKFGES054
55 Boot, vent pipe 1 RKFGES055
56 Air duck 1 RKFGES056
57 Gasket, air cleaner 1 RKFGES057
58 Manual choke Assy 1 RKFGES058
59 Gasket, air cleaner 1 RKFGES059
60 Carburetor Assy 1 RKFGES060
61 Gasket, inlet 1 RKFGES061
62 Connecting block,
63 Gasket, carburetor 1 RKFGES063
64 Check valve Assy 1 RKFGES064
4.
9×
Assy
regula
er
v
co
r
buretor
ca
5×160
tor
1 RKFGES034
1 RKF
1 RKF
1 RKFGES049
1 RKFGES062
GES035
GES041
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EXPLODED DIAGRAM & PARTS LIST
NO DESCRIPTION QTY PART NO
65 Clamp, check
valve
66 Bolt M6×12 2 RKFGES066
67 Supporting plate
set
68 Back spring 1 RKFGES068
69 Fine regulating
spring
70 Pulling rod 1 RKFGES070
71 Nut M6 1 RKFGES071
72 Lock bolt 1 RKFGES072
73 Regulating arm 1 RKFGES073
74 Ignition coil unit 1 RKFGES074
75 Bolt M6×30 2 RKFGES075
76 Flywheel 1 RKFGES076
77 Flywheel fan 1 RKFGES077
78 Starting flange 1 RKFGES078
79 Nut M16×1.25 1 RKFGES079
80 Fan hood assy 1 RKFGES080
81 Bolt M6×12 5 RKFGES081
82 Grommet 1 RKFGES082
83 Recoil starter 1 RKFGES083
84 Bolt M6×8 3 RKFGES084
85 Gasket, outlet 1 RKFGES085
86 Exhaust pipe 1 RKFGES086
87 Gasket, exhaust
88 Outer hood 1 RKFGES088
89 Muffler 1 RKFGES089
90 Inner hood 1 RKFGES090
91 Side hood 1 RKFGES091
92 Gasket, inner hood 1 RKFGES092
93 Muffler stay 1 RKFGES093
94 Flange bolt M6×12 7 RKFGES094
95 Flange bolt M8×25 2 RKFGES095
96 Nut M8 2 RKFGES096
97 Flange bolt M8×16 4 RKFGES097
98 Tube clip
pe
pi
1 RKFGES065
FGES067
1 RK
1 RK
FGES069
FGES087
1 RK
2 RKFGES098
NO DESCRIPTION QTY PART NO
99 Fuel cock 1 RKFGES099
100 Cushion 4 RKFGES100
101 Fitting brush, fuel
102 Washe r 4 RKFGES102
103 Flange bolt M6×22 4 RKFGES103
104 Gasket, fuel sensor 1 RKFGES104
105 Fuel sensor 1 RKFGES105
106 Screw M5×10 2 RKFGES106
107 Fuel filler cap 1 RKFGES107
108 Fuel tank 1 RKFGES108
109 Stripe, fuel tank 1 RKFGES109
110 Plug, sump 1 RKFGES110
111 Screw M5×14 9 RKFGES111
112 Generator fan 1 RKFGES112
113 Stator cover 1 RKFGES113
114 Nut M5 2 RKFGES114
115 Stator Assy 1 RKFGES115
116 Spring washer 5mm 6 RKFGES116
117 Bolt M5×213 2 RKFGES117
118 Bearing 6204-2ZN 1 RKFGES118
119 Rotor Assy 1 RKFGES119
120 Plain washer 1 RKFGES120
121 Bolt M10×265 1 RKFGES121
122 Generator stay 1 RKFGES122
123 Screw M5×12 3 RKFGES123
124 Brush Assy 1 RKFGES124
125 Bolt M6×175 4 RKFGES125
126 Screw M5×18 1 RKFGES126
127 Clip A 2 RKFGES127
128 Voltage regulator 1 RKFGES128
129 Bolt M5×20 2 RKFGES129
130 Generator end
131 Frame comp. 1 RKFGES131
132 Rubber pad, frame
133 Bolt M6×12 4 RKFGES133
ta
co
nk
v
er
4 RKF
1 RKFGES130
2 RKFGES132
GES101
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Page 27
PARTS AND SERVICING
For Parts & Servicing, please
contact your nearest dealer, o
CLARKE International, on one of
the following numbers.
PARTS & SERVICE TEL: 020 8988 7400
PARTS & SERVICE FAX: 020 8558 3622
or e-mail as follows:
PARTS: Parts@clarkeinternational.com
SERVICE: Service@clarkeinternational.com
NO DESCRIPTION QTY PART NO
134 Nut M6 4 RKFGES134
135 Bottom rubber A 2 RKFGES135
136 Nut M6 4 RKFGES136
137 Bottom rubber B 2 RKFGES137
138 Rubber pad, frame 2 RKFGES138
139 Nut M8 4 RKFGES139
140 Cushion, frame 4 RKFGES140
141 Control panel case 1 RKFGES141
142 Circuit protector 1 RKFGES142
143 Consent 2 RKFGES143
144 Main wire harness
145 Bolt M6×12 5 RKFGES145
146 Earth terminal set 1 RKFGES146
147 Vol tm et e r 1 RKFGES147
148 DC terminal 2 RKFGES148
149 Ignition switch 1 RKFGES149
150 Control panel 1 RKFGES150
151 Bearing 6202 2 RKFGES151
152 Balancing shaft 1 RKFGES152
153 Split pin 2 RKFGES153
154 Wheel kit 2 RKFGES154
155 Bolt M8×60 2 RKFGES155
156 Flat washer 6 RKFGES156
157 Screw M8 6 RKFGES157
158 Wheel axel 1 RKFGES158
159 Wheel kit Assy 1 RKFGES159
160 Underprop 2 RKFGES160
161 Bolt M8×24 2 RKFGES161
162 Handle bar 2 RKFGES162
163 Bolt M8×40 2 RKFGES163
164 Cable, starting
165 Relay, start-up 1 RKFGES165
166 Starting motor Assy 1 RKFGES166
167 Bolt M8×35 2 RKFGES167
168 Battery 1 RKFGES168
Ass
mo
y
tor
1 RKFG
1 RKFG
NO DESCRIPTION QTY PART NO
169 Battery Bracket 1 RKFGES169
170 Dam Board 1 RKFGES170
171 Nut 2 RKFGES171
172 Bolt M6x12 2 RKFGES172
PARTS AND SERVICING
ES144
ES164
27
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DECLARATION OF CONFORMITY (FG4050ES)
28
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DECLARATION OF CONFORMITY (FG4050ES)
29
Page 30
DECLARATION OF CONFORMITY (FG5100ES)
30
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DECLARATION OF CONFORMITY (FG5100ES)
31
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