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Clarke
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IG1100
User guide
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Clarke IG1100 User guide

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Page 1
WARNING: Do not use the generator without reading this manual
1050W INVERTER GENERATOR
MODEL NO: IG1100
PART NO: 8877113
OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS DL0225 Rev 1
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INTRODUCTION
Before you use this product, read this manual and follow the instructions carefully. In doing so you will ensure the safety of yourself and others around you, and you can also expect your purchase to give you a 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 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 PROTECTION
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted and taken to a recycling centre for disposed in a manner compatible with the environment.
By purchasing this product, the customer is taking on the obligation to deal with its safe disposal in accordance with the Waste Electrical and Electronic Equipment (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. If disposing of this product or any damaged components, do not dispose of with general waste. This product contains valuable raw materials. Metal products should be taken to your local civic amenity site for recycling of metal products.
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SPECIFICATIONS
Engine Engine Model LY144F
Type Petrol
Displacement (cc) 53.5
RPM 5000
Ignition type Mag
Fuel tank capacity: Safe Fuel Level (L) 2
Fuel Consumption at 3/4 Load (L/h) 0.7
Maximum run time at 3/4 load (h) Approx. 2h 50m
Engine oil capacity (L) 0.15
Emissions (g/kWh) CO, HC, NOx 240.12, 34.84, 1.93
Guaranteed sound power (LWA dB) 93
Generator Rated Frequency (Hz) 50
Rated AC Voltage per 13A socket x 1 (V) 230
Rated DC Voltage per socket x 3 (V) 2 x 5V USB
1 x 12V Connector
Max. Rated Output Current @1050W/230V(A) 4.56
Rated Output Current (A) 4.3
Rated Output Power: (Continuous) (W) 1000
Maximum Rated Output Power (W) 1050
Output Type Sine Wave
Starter Type Recoil
Operating Temperatures
o
-5
C to 40oC
IP Rating IP23M
Dimensions Depth x Width x Height (mm) 405 x 250 x 425
Unpacked & Unfueled Weight (kg) 13.4
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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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.
• Read these safety instructions before using the equipment.
• Keep children away from the generator.
POSITIONING THE GENERATOR
1. Keep the generator at least 1 m (3 ft.) from buildings or other equipment, or the engine may overheat.
2. Place the generator on a solid, flat surface.
3. Make sure 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 STOP when refuelling.
2. ALWAYS refuel in a well ventilated area.
3. NEVER overfill the fuel tank only fill to the level specified.
4. NEVER smoke whilst refuelling and avoid smoking or using a naked flame near the generator.
5. 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 the rain or 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.
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4. Make sure you ground (earth) the generator.
ADDITIONAL SAFETY RULES FOR GENERATORS
1. ALWAYS make sure the applied load does not exceed the generator rating. Overloading the generator is dangerous and could cause serious damage.
2. ALWAYS turn off and
out any maintenance.
3. ALWAYS allow the generator to reach 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. NEVER connect the generator to a commercial or residential power supply; e.g. ring main.
7. NEVER allow the generator air vents to become blocked.
8. NEVER directly cover the generator while in use.
disconnect any appliance from the generator when carrying
SAFETY SYMBOLS
The following safety symbols are shown on the product or it’s packaging. Please read all of the safety and operating instructions carefully before using this product.
Read instruction manual before use.
Dangerous Voltage Poisonous fumes - DO
Flammable Caution - The user
DO NOT cover while in operation
Hot surface - DO NOT touch
NOT use the generator in an enclosed space.
should be aware of a general hazard.
Earth Connection Point
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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OVERVIEW - CONTROL PANEL
NO DESCRIPTION NO DESCRIPTION
1 Oil Alarm, Overload & Output
Indicator Lights
2 Economy Control Switch 6 2 x 5V/2.1A USB DC Outlets
3 DC Breaker Reset Switch 7 Earthing Point
4 3 Pin 13A 230V AC Outlet
5 2 Pin 12V/5A DC Outlet
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OVERVIEW - GENERAL COMPONENTS
NO DESCRIPTION NO DESCRIPTION
1 Recoil Starter 3 Fuel Cap/Fuel Tank Vacuum Relief
Valve
2 Stop/Run/Start Engine Switch 4 Spark Plug Cover
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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UNPACKING AND ASSEMBLY
Unpack your generator and check the following items are present. Should there be any missing or damaged during transit contact your CLARKE dealer.
1 x 1050 Watt Inverter Generator 1 x 12 Volt Crocodile Clip Lead Assembly
1 x Spark Plug Box Spanner with Arm 1 x Oil Bottle & Spout
BEFORE USING THE GENERATOR
IMPORTANT: Generators should ALWAYS be earthed. Make sure you earth the generator.
Before using your generator check that the generator is:
• In good condition and free from any damage.
• Clean and free from fuel or oil spillage.
• Correctly located for use (see page 4).
• Free from leakage.
NOTE: To avoid accidental spillage of fuel, always use a funnel to fill the fuel
tank. If fuel is spilled it must be removed from the unit before attempting to start the engine.
EARTHING
WARNING: IT IS ADVISABLE TO PROPERLY EARTH YOUR GENERATOR BEFORE STARTING, USING A WIRE AND A SMALL METAL EARTH SPIKE. THE WIRE AND EARTH SPIKE ARE NOT SUPPLIED WITH THIS UNIT.
An earth rod and cable can be purchased at your local camping or electrical supplier, or alternatively an earth rod can be made, and it is suggested you get advice from a qualified electrician.
The cable used should be insulated and a maximum length of 1 metre and a minimum of 1.0mm2 to carry a 10amp load.
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Attach the cable to the generator at the earthing point (shown on the right).
Connect the other end of the cable to a steel or copper earth rod. If you have purchased a rod, make sure you connect it in accordance with the installation instructions supplied with the rod.
When pushing the rod into the ground the generator must not be running and it is suggested that the rod is pushed into the ground by at least 100 mm.
Earthing of generators is covered in BS7430:2011. If you have any doubts about this subject consult a qualified electrician.
CHECKING & ADDING ENGINE OIL
NOTE: For a more reliable reading, check the oil level when the engine is cold.
1. Place the generator on a level surface and check the oil level as follows.
2. Remove the access panel located on the side of the generator by unscrewing the two screws at the top.
3. Turn the oil filler cap anti-clockwise and remove from the oil reservoir, wipe the dipstick with a clean cloth.
4. Insert the dipstick back into the oil filler tube and then remove it again.
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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5. If the oil is below the Min. level on the dipstick, top up the oil reservoir with fresh oil using the oil bottle and spout.
• DO NOT fill above the max
level mark (0.15 litres)
• We recommend the use of
SAE 10W-30 oil in this generator. (CLARKE part number 3050845)
• DO NOT tilt the generator when adding engine oil. This could result in
overfilling and damage to the engine.
6. Clear up any spillages
7. Replace the oil filler cap.
8. Replace the access panel.
CHECKING & ADDING FUEL
WARNING: MAKE SURE THERE IS 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.
WARNING: FUEL IS HIGHLY FLAMMABLE AND POISONOUS.
WARNING: SEE GENERAL SAFETY RULES ON PAGES 4-5 AND READ THEM CAREFULLY BEFORE REFUELING.
WARNING: DO NOT FILL ABOVE THE TOP OF THE FUEL FILTER OR IT MAY OVERFLOW WHEN THE FUEL HEATS UP AND EXPANDS.
WARNING: WIPE UP ANY SPILLED FUEL IMMEDIATELY.
WARNING: AFTER REFUELING, MAKE SURE THE FUEL FILLER CAP IS TIGHTENED SECURELY.
RECOMMENDED FUEL
Your generator has been designed to use regular unleaded petrol with a octane number of 86 or higher.
NOTE: The fuel tank capacity is 2 Litres (Safe Fuel Level).
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1. Open the fuel cap located on top of the generator.
2. Slowly add fuel to the fuel tank, until the fuel level float is at the top of the fuel filter.
• DO NOT overfill the fuel tank.
Maximum safe level is 2 litres.
3. Replace the fuel filler cap securely.
4. Clear up any spillages
USING YOUR GENERATOR
WARNING: BE SURE TO GROUND THE GENERATOR BEFORE STARTING.
STARTING THE ENGINE
1. Remove all connections from the AC & DC sockets.
2. Hold the fuel tank cap so that it will not move and turn the fuel tank vacuum relief valve knob to the ‘ON’ position.
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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3. Turn the engine switch to the ‘START’ position.
4. Hold the recoil starter handle firmly and pull lightly until you start to feel resistance and then pull up sharply to start the engine.
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 CAN WHIP BACK. DO NOT LET THE HANDLE SNAP BACK.
5. Once the temperature of the engine has increased, turn the engine switch to the ‘RUN’ position.
NOTE: Allow the generator to run for
several minutes and the Output light is ‘Green’ before attempting to connect any electrical devices. This allows the generator to stabilize its speed and temperature.
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ECONOMY (ECO) CONTROL SWITCH
When the Economy Control Switch is turned to ‘ON (I)’, the engine keeps running at idle state automatically when an electrical appliance is disconnected. It will return to the correct speed with the
requirements of an electrical load.
Switching the ECO switch to ‘ON (I)’ is recommended to minimise the fuel consumption with a load equal or less than 0.5Kw.
NOTE: When a high load electrical appliance (equal or above 0.5Kw) is connected, in
order to reduce voltage change, turn the ECO switch to the ‘OFF (O)’ position.
NOTE: In DC operation, turn the ECO switch to the ‘OFF (O)’ position.
NOTE: When in both AC and DC operation, turn the ECO switch to the ‘OFF (O)’
position.
CONNECTING ELECTRICAL DEVICES
The generator can supply both 230V AC and 12V DC.
AC POWER
1. Start the engine, see pages 11-12. Make sure the Output Indicator light is green.
2. Make sure the appliance is turned off before connecting it to the generator.
3. Connect the appliance (max load 1050W) to the generator.
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 WHICH CONTAINS AN INDUCTIVE LOAD E.G. DEVICES THAT CONTAIN A MOTOR MAY REQUIRE MORE CURRENT ON STARTUP.
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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DC POWER
1. Set the economy switch to ‘OFF (O)’.
2. Start the generator, see pages 11-12.
3. Make sure the appliance is turned off before connecting it to the generator.
4. Connect the USB appliance (max 5A) to the generator.
12V DC POWER (TOPPING UP CAR BATTERIES)
WARNING: FOR YOUR SAFETY PERFORM THE FOLLOWING INSTRUCTIONS IN THE ORDER SHOWN.
WARNING: YOU SHOULD ONLY USE THIS GENERATOR TO ‘TOP UP’ THE BATTERY, ALSO TRYING TO CHARGE A COMPLETELY FLAT BATTERY MAY CAUSE THE FUSE TO BLOW.
1. Set the economy switch to 'OFF'.
2. Start the generator, see pages 11-12.
3. 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.
4. Connect the battery charging leads to the generator.
• The battery will begin to charge
5. Monitor the voltage across the battery regularly during charging and disconnect the battery when the voltage reaches 14.4 volts.
CAUTION: WHEN DISCONNECTING THE BATTERY, ALWAYS DISCONNECT THE NEGATIVE LEAD FIRST.
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INDICATOR LIGHTS
OUTPUT
The Output Indicator Light (Green) will remain on during normal operation.
OVERLOAD
If the generator becomes overloaded or the connected appliance short circuits, the Overload Light will turn red, the Output Indicator Light will turn from Green to Red. The power will switch OFF, but the engine will continue running.
If this happens, proceed as follows:
1. Turn off and disconnect any connected electrical devices.
2. Press and Hold the DC Breaker button for at least 5 seconds.
3. If the Output Indicator Light turns from Red to Green, reconnect the electrical appliances.
4. If the Outlet Indicator Light stays Red, stop the engine and check the generator, earthing connection and/or electrical appliance for any problems before attempting to restart.
OIL ALERT
The oil alert system is designed to prevent engine damage caused by an insufficient amount of oil in the crankcase. Before the oil level in the crankcase falls below a safe limit, the oil alert system will automatically shut down the engine, note the engine switch will remain in the ‘RUN’ position.
If the oil alert system shuts down the engine, the Oil Alert Indicator Light will turn Yellow/Amber and the engine will not start. To clear the light, check and add oil by following the instructions on pages 9-10
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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SHUTTING DOWN THE GENERATOR
To stop the generator in an emergency simply turn the Stop/Run/Start Engine Switch to the ‘STOP’ position.
NOTE: Turn off any electric devices.
NOTE: Set the economy control switch to the ‘OFF (O)’ position.
1. Disconnect any electric devices.
2. Turn the Stop/Run/Start Engine Switch to the ‘STOP’ position.
3. Hold the Fuel Tank Cap and turn the fuel tank vacuum relief valve knob to the ‘OFF’ position.
NOTE: Be sure the Stop/Run/Start Engine Switch and the Fuel Tank Vacuum Relief
Valve are in the STOP’ and ‘OFF’ positions when stopping, transporting and storing the generator.
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MAINTENANCE
ENGINE OIL (EVERY 100 HOURS OR 6 MONTHS OF USE)
CAUTION: PROLONGED EXPOSURE TO USED ENGINE OIL IS DANGEROUS, ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED ENGINE OIL.
1. Remove the access panel located on the side of the generator by unscrewing the two screws at the top.
2. Turn the oil filler cap anti-clockwise and remove from the oil tank.
3. Tilt the generator to allow the oil to drain out of the oil reservoir into a suitable container via the drain channel.
NOTE: You may need assistance with
this step as the generator is heavy.
4. Once empty of old oil, fill the oil reservoir with fresh oil.
• DO NOT fill above the max level
mark (0.15 litres)
• We recommend the use of SAE
10W-30 oil in this generator. (CLARKE part number 3050845)
5. Replace the oil filler cap and maintenance panel.
ENVIRONMENTAL PROTECTION
One of the most damaging sources of pollution is oil. DO NOT throw away used engine oil in with your domestic waste or down drains and sinks. Place it in a leak proof container and dispose of it according to local regulations.
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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AIR FILTER (EVERY 50 HOURS OR 3 MONTHS OF USE)
WARNING: DO NOT USE FLAMMABLE SOLVENTS OR PETROL TO CLEAN THE AIR FILTER.
1. Remove the access panel located on the side of the generator by unscrewing the two screws at the top.
2. Remove the air filter cover screw.
3. Remove the air filter cover.
4. Remove the air filter element.
5. If the air filter is damaged contact the CLARKE spare parts department for a replacement.
• If the filter is dirty, wash it in a
solution of warm water and mild detergent and then rinse thoroughly.
• Leave the filter to dry completely,
once it is dry immerse the filter in clean engine oil and squeeze the filter to remove excess oil.
6. Replace the filter into its original position and replace and secure the air filter cover.
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SPARK PLUG (EVERY 300 HOURS OR 2 YEARS OF USE)
CAUTION: ALLOW THE ENGINE TO COOL BEFORE REMOVING THE SPARK PLUG.
1. Slide out the spark plug cover panel located on top of the generator.
2. Remove the spark plug cap from the spark plug.
3. Fit the spark plug box spanner over the spark plug as shown.
4. When the spark plug has been removed, check for discoloration and use a wire brush to remove any carbon build up.
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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5. Check the spark plug gap (a) with a feeler gauge, it should be between
0.6 and 0.7 mm.
• Adjust if necessary.
6. Check the overall condition of the spark plug and replace if damaged.
NOTE: Spark plugs are available from
CLARKE Spare Parts department 020 8988 7400.
7. Reinstall the spark plug and replace the spark plug cap and cover.
CLEAN FUEL TANK FILTER (EVERY 2 YEARS OF USE)
Just inside the fuel tank is a fuel filter, check this filter periodically and remove any contaminants which may have accumulated.
1. Remove the fuel tank cap.
2. Lift out the filter inside.
3. Clean the filter with solvent. If the filter is damaged, contact CLARKE Spare Parts department 020 8988 7400 for a replacement.
4. Replace the filter and fuel tank cap.
CAUTION: ALLOWING PETROL TO SIT IN A FUEL TANK FOR LONG PERIODS OF TIME CAN MAKE IF DIFFICULT TO START THE GENERATOR IN THE FUTURE. NEVER STORE THE GENERATOR FOR EXTENDED PERIODS OF TIME WITH FUEL IN THE TANK.
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TROUBLESHOOTING
WHEN THE ENGINE CAN NOT BE STARTED
APPLIANCE DOES NOT OPERATE
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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DC RECEPTACLE WITHOUT ANY ELECTRICITY
If these do not solve your problem, please contact the CLARKE service department. see below.
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EXPLODED DIAGRAM - ENGINE
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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PARTS LIST - ENGINE
No Description No Description
1 Flange Bolt M5 x 12 24 Oil Scale Gasket
2 Gasket 25 Lower Crankcase
3 Recoil Starter 26 Oil Sensor O Sealing Ring
4 Flange Bolt M5 x 20 27 Oil Sensor
5 High Voltage Transformer 28 Flange Bolt M5 x 12
6 Fan Cover 29 Flange Bolt M5 x 12
7 Line Cord Bolt 30 Gasket 5 x 14 x 1
8 Line Cord Flange 31 Air Filter
9 Flange Bolt 32 Air Filter Gasket
10 Gasket 6.5 x 17.6 x 1.5 33 Crankcase Gasket
11 Starting Cup 34 Circlip 12.5
12 Flange Bolt M5 x 12 35 Fuel Pipe
13 Starting Cup Base 36 Circlip 10
14 Fan 37 Carburetor
15 Tie 38 Carburetor Gasket
16 Trigger 39 Heat Shield
17 Rotor 40 Air Intake Tower
18 Flange Bolt M5 x 25 41 Intake Gasket
19 Stator 42 Carburetor Double End Studs
20 Flange Nut M5 43 Double End Studs
21 Double End Studs 44 Pin 6 x 15
22 Oil Seal 45 Breathing Plate
23 Oil Scale 46 Breathing Plate Pressure Plate
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47 Bolt M3 x 6 70 Circlip 3
48 Flange Bolt M5 x 12 71 Jilt Oil Gear
49 Cylinder Head Cover 72 Jilt Oil Gear Shaft
50 Cylinder Head Gasket 73 Gasket
51 Spring Upper Retainer 74 Crankcase Cover
52 Exhaust Valve 75 Exhaust Pipe Gasket
53 Valve Oil Seal 76 Exhaust Pipe
54 Exhaust Valve 77 Muffler Gasket
55 Intake Valve 78 Muffler
56 Spark Plug 79 Muffler Bolt 1
57 Upper Crankcase 80 Muffler Bolt 2
58 Adjusting Nut 81 Muffler Plate
59 Rocker Arm Shaft 82 Piston Circlip
60 Upper Rocker Arm Shaft 83 Piston
61 Adjusting Bolt 84 Piston Pin
62 Push Rod 85 Crankshaft
63 Lower Rocker Arm 86 Woodruff Key
64 Lower Rocker Arm Shaft 87 Bearing
65 Shaft Sleeve 88 Flywheel Nut M10 x 1.25
66 Cam 89 Piston Ring
67 Gasket 90 Connecting Rod
68 Pin 91 Jilt Oil Plate
69 Crankcase Cover Gasket
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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EXPLODED DIAGRAM - GENERAL
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PARTS LIST - GENERAL
No Description No Description
1 Right Side Cover 23 Rubber Feet
2 Trim Bolt 24 Rubber Foot Fixing Bolt
3 Skeleton Step Fixing Bolt 25 Inverter
4 Right Frame 26 Panel Cover
5 Skeleton Bolt 27 Panel
6 Muffler Housing Fixing Bolts 28 M5 Screw
7 Muffler Housing 29 M5 Screw Card
8 Fuel tank 30 3 in 1 Igniter
9 Fuel Filter 31 3 in 1 Igniter Wiring Harness
10 Fuel tank Opening Pad 32 Bridge Pile Fixing Bolt
11 Fuel Tank Cap 33 Bridge Pile
12 Left Frame 34 DC Breaker Cable
13 Spark Plug Maintenance Cover 35 DC Breaker + Waterproof Cap
14 Left Side Cover 36 T Model Socket
15 Fuel Pipe Clip 37 Grounding Bolt
16 Fuel pipe 38 Gear Gasket
17 3 in 1 Oil Switch 39 Spring Washers 6
18 Recoil Starter Cover 40 Nut M6
19 Engine Floor 41 AC Socket Line
20 M5 Screw Card 42 AC Socket
21 Square Nut M6 43 Socket Fixing Bolt
22 Floor 44 DC Line
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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WIRING DIAGRAM - ENGINE
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WIRING DIAGRAM - GENERAL
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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DECLARATION OF CONFORMITY -UKCA
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DECLARATION OF CONFORMITY -CE
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Parts & Service: 020 8988 7400 / E-mail: [email protected] or [email protected]
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