Clarke FG5100ES Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
LS0310
GENERATOR
MODEL NO: FG4050ES / FG5100ES
PART NO: 8857715, 8857720

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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.

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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
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.
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 13.).
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.
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; eg ring main.
7. Never allow the generator air vents to
become blocked.

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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
4Controlpanel 12AirFilter
5 Wheel 13 Choke lever
6 Battery 14 Muffler
7 Dipstick 15 Spark plug
8Drainplug 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
•Tommybar
• 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.
2. Slide both wheels on to the axle.
NOTE: Make sure that the valve on
each wheel is on the outside.
3. Secure the wheel to the axle using
a split pin.

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4. Place the axle against the frame
on the generator as shown.
5. Fix the axle to the frame using
2 x Long bolts, 2 x Washers, 2 x
Spring washers and 2 x Nuts.
6. Carefully place the generator
onto its wheels/feet.
FITTING THE HANDLES
1. Place thehandle into position as
shown.
2. Ssecure the handle using the nNut
and bolt supplied
• Making sure that the 2 plastic
washers 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
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. Check the fuel level on the fuel
gauge.
The fuel gauge will show as red
when you have fuel in the tank
turning white as the fuel level
decreases
Empty Full
.
2.
Fuel filler cap
To add fuel, open the fuel filler
cap.
3.
Fuel filter
Just inside the fuel tank is a fuel
tank filter, check this filter
periodically and remove any
contaminants which may have
accumulated.
4. Slowly add fuel to the fuel tank
(maximum 25L) watching the fuel
level gauge as you do so.
RECOMMENDED FUEL
We recommend the use of standard unleaded petrol.
NOTE: Do not overfill the fuel tank.
5. 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 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 generator is
warm skip this step.

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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.
8. Once the engine has warmed up,
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 by carrying out the following.
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.

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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
emergency simply turn the
ignition key to the off position.

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MAINTENANCE
CHANGING THE 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
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 it ring seal.
5. Fill the crankcase with engine oil to the ‘H’ mark on the dipstick. See
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.
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.
Add pic
Use the supplied spark plug
spanner to remove the spark plug.
3. Remove any carbon that has
accumulated around the
sparkplug.
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. 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
contact Clarke spare parts
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.
4. 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.