Clarke FG2500 Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0114
GENERATOR
MODEL NO: FG2500
PART NO: 8857727

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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.

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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

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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
surrounding building or structures.
2. Always ensure the generator is on
a solid, flat surface.
3. Always ensure the 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 away 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

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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.
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.

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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.

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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

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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

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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.

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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 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.

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CHECKING THE ENGINE OIL LEVEL
1. Turn the oil filler cap anti-
clockwise 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.
‘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.

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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).
RECOMMENDED FUEL
We recommend the use of standard 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.

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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’.

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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.

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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.

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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 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. Monitor the voltage across the
battery 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.

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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
emergency simply set the
engine switch to ‘OFF’

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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.

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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
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.
CAUTION: ALLOW THE ENGINE TO COOL BEFORE REMOVING THE SPARK
PLUG.

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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 and replace 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.