GENERATOR MODEL NO: FG2500 PART NO: 8857727 OPERATION & MAINTENANCE INSTRUCTIONS LS0114
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.
TABLE OF CONTENTS INTRODUCTION......................................................................2 GUARANTEE ...........................................................................2 ENVIRONMENTAL RECYCLING POLICY ................................2 TABLE OF CONTENTS .............................................................3 GENERAL SAFETY RULES .......................................................4 Work area .............................................................................
GENERAL SAFETY RULES 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 structures. 2. Always ensure the generator is on a solid, flat surface.
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.
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.
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.
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.
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.
CHECKING THE ENGINE OIL 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 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.
CHECKING THE FUEL LEVEL 1. To add fuel, open the fuel filler cap. 2. Just inside the fuel tank is a fuel tank filter, check this filter periodically and remove any contaminants which may have accumulated. Fuel filter 3. Slowly add fuel to the fuel tank (maximum 4.5L). 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.
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’.
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. 6. Once the engine has warmed up, set the choke lever to the ‘OFF’ position.
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.
DC POWER (FOR CHARGING CAR BATTERIES ONLY) WARNING: FOR YOUR SAFETY PERFORM THE FOLLOWING INSTRUCTIONS IN THE ORDER SHOWN. 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 positive (+) 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.
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’.
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.
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 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.
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 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.
CLEANING THE FUEL VALVE FILTER / DRAINING THE FUEL TANK 1. Set the fuel supply valve to OFF. 2. Unscrew 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. VALVE FILTER Add pic 4. Place an approved petrol storage container under the fuel valve and set the fuel supply valve to ‘ON’. ‘O’ RING • The fuel in the tank will drain into the container. CUP 5.
TROUBLESHOOTING PROBLEM CAUSE SOLUTION The generator fails to start Ignition switch is off Set the ignition switch to ‘on’ Not enough oil in the generator 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 device you are trying to power is faulty Make sure the device you want to power is working properly The generator fails to generate electricity The AC breaker has activated Press the AC overload reset button
SPECIFICATIONS FG2500 Engine Generator Dimensions Engine Model UP168 3 Displacement (cm ) 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 (LWA dB) 98 Rated Frequency (Hz) 50 Rated Voltage (V) 230 Rated Power (kVA) 2.2 Max. Power (kVA) 2.
EXPLODED PARTS DIAGRAM 24
PARTS LIST NO DESCRIPTION PART NO NO DESCRIPTION PART NO 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 Wa
DECLARATION OF CONFORMITY 26
DECLARATION OF CONFORMITY 27
