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Clarke
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IG1900
User guide
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Clarke IG1900 User guide

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WARNING: Do not use the generator without reading this manual
2000W INVERTER GENERATOR
MODEL NO: IG1900
PART NO: 8877117
OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS DL0524
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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 KM148F
Type Petrol
Displacement (cc) 79.8
RPM 4800
Ignition type C.D.I
Fuel tank capacity (L) 5.6
Fuel Consumption at 3/4 Load (L/h) 1.13
Maximum run time at 3/4 load (h) Approx. 5
Engine oil capacity (L) 0.35
Emissions (g/kWh) CO, HC, NOx 379.68, 40.12, 1.93
Guaranteed sound power (LWA dB) 95
Generator Rated Frequency (Hz) 50
Rated AC Voltage per socket x 2 (V) 230
Rated DC Voltage per socket x 1 (V) 12
Rated Output Current (A) 7.8
Maximum Rated Output Current (A) 8.7
Rated Output Power: (Continuous) (W) 1800
Maximum Rated Output Power (W) 2000
Output Type Sine Wave
Starter Type Recoil
Operating Temperatures
o
-5
C to 40oC
IP Rating IP23M
Dimensions Depth x Width x Height (mm) 465 x 307 x 500
Unpacked & Unfueled Weight (kg) 20
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GENERAL SAFETY RULES
WARNING: EXHAUST FUMES CAN BE EXTREMELY DANGEROUS IF INHALED
WORK AREA
1. ALWAYS use in a well ventilated area.
2. ALWAYS position the exhaust outlet away from people.
3. Read these safety instructions before using the equipment.
4. 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 OFF 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/under cover. Under these conditions, adequate ventilation MUST be provided.
2. NEVER operate the generator with wet hands.
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3. NEVER use water or any other liquids to clean the generator.
4. Make sure you ground (earth) the generator (See pages 9-10).
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
disconnect the generator when carrying 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.
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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 ­Risk of Electrocution.
Flammable Caution - The user
DO NOT directly cover the generator while in use
Hot surface - DO NOT TOUCH
Poisonous fumes - DO NOT use the generator in an enclosed space.
should be aware of a general hazard.
Earth Connection Point
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GENERATOR OVERVIEW - CONTROLS & OUTLETS
NO DESCRIPTION NO DESCRIPTION
1 ON/OFF/CHOKE Fuel Switch 5 ON/OFF Switch
2 Economy Control Switch 6 2 Pin 12V/8.3A DC Outlet
3 Reset Button 7 2 x 3 Pin 13A 230V AC Outlets
4 Oil Alarm, Overload & Output
Indicator Lights
8 Earth Connection Point
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GENERATOR OVERVIEW - GENERAL COMPONENTS
NO DESCRIPTION NO DESCRIPTION
1 Recoil Starter 4 Spark Plug Cover
2 Fuel Cap/Fuel Tank Vacuum
Relief Valve
3 Fuel Gauge
5 Oil Filler Cap Cover
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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 2000 Watt Inverter Generator 1 x 12 Volt Crocodile Clip Lead Assembly
1 x Spark Plug Box Spanner with Lever
1 x Oil Funnel
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.
• The generator is clean and free from fuel or oil spillage.
• The generator is correctly located for use (see page 3).
• There is no leakage.
NOTE: To avoid accidental spillage of fuel, 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, making 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
1. Place the generator on a level surface and check the oil level as follows.
NOTE: The oil reservoir capacity is
350mm
2. Remove the oil cap cover located on the side of the generator.
3. Turn the oil filler cap anti­clockwise 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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5. If the oil is below the Min. level on the dipstick, top up the oil reservoir with fresh oil using the oil funnel.
• DO NOT fill above the max
level mark.
• We recommend the use
of SAE10W-30 oil in this generator. (CLARKE part number 3050852)
• DO NOT tilt the generator when adding engine oil. This could result in
overfilling and damage to the engine.
6. Replace the oil filler cap.
7. Replace the oil cap 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 PAGE 4 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.
1. Check the fuel level via the fuel gauge window located on top of the generator.
NOTE: The fuel tank capacity is
5.6 Litres (Safe Fuel Level).
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2. Open the fuel filler cap located on top of the generator.
3. Slowly add fuel to the fuel tank.
• DO NOT overfill the fuel tank.
4. Replace the fuel filler cap securely.
USING YOUR GENERATOR
STARTING THE ENGINE
1. Remove all connections from the AC & DC sockets.
2. Check that the generator is correctly earthed, see pages 8-9
3. Hold the fuel tank cap so that it will not move and turn the fuel tank vacuum relief valve knob to the ‘ON’ position.
4. Set the Economy Control Switch to the ‘OFF-HIGH SPEED MODE’ position.
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5. Move the fuel switch to the right, to the ‘CHOKE’ position.
6. 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.
NOTE: NEVER let the handle snap
back.
7. Once the engine has started, slowly turn the fuel switch to the ‘ON’ position.
NOTE: Allow the generator to run for
several minutes before attempting to connect any electrical devices. This allows the generator to stabilize its speed and temperature.
NOTE: When you first start the
generator, the overload indicator (see item 4, page 6) may light up for a few seconds, this is normal. If the overload indicator is still lit after 5 seconds, stop the engine and contact your CLARKE dealer or the CLARKE Service Department.
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ECONOMY CONTROL SWITCH
ON (ECO MODE):
Recommended to minimize fuel consumption and further reduce noise levels when no load is applied to the generator. Engine speed varies with the load.
OFF (HIGH-SPEED MODE):
The engine will run at the rated speed regardless of whether a load is connected or not. The switch should be in the ‘OFF’ position if you are using electrical devices that require a large starting current, such as compressors or water pumps.
CAUTION: THE ECONOMY CONTROL DOES NOT WORK EFFECTIVELY IF THE ELECTRICAL APPLIANCE REQUIRES ‘BURSTS’ OF POWER.
CAUTION: TURN THE ECONOMY CONTROL FEATURE OFF WHEN CONNECTING HIGH LOAD APPLIANCES OR WHEN CONNECTING TO THE DC OUTPUT.
CONNECTING ELECTRICAL DEVICES
The generator can supply both 230V AC and 12V DC.
AC POWER
1. Start the engine. See pages 12-13.
2. Make sure the appliance is turned off before connecting it to the generator.
3. Connect the appliance to the generator using one of the two 3 Pin 13A 230V AC outlets.
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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DC POWER
1. Set the economy control switch to ‘OFF’.
2. Start the generator. See pages 12-13.
3. Make sure the appliance is turned off before connecting it to the generator.
4. Lift the cover and connect the 12V appliance (max 8.3A) to the generator.
DC POWER (TOPPING UP CAR BATTER-
IES)
WARNING: FOR YOUR SAFETY PERFORM THE FOLLOWING INSTRUCTIONS IN THE ORDER SHOWN.
WARNING: YOU SHOULD ONLY USE THIS GENERATOR TO ‘TOP UP’ THE BATTERY AS TRYING TO CHARGE A COMPLETELY FLAT BATTERY MAY CAUSE THE FUSE TO BLOW.
1. Set the Economy Control Switch to the ‘OFF-HIGH SPEED MODE’ position.
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.
CAUTION: DO NOT ALLOW THE RED AND BLACK CLAMPS TO TOUCH WHILE STILL CONNECTED TO THE GENERATOR.
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DC OVER LOAD PROTECTOR
If the overload protector activates, wait for a few minutes and then press the reset switch shown on the right.
INDICATOR LIGHTS
OUTPUT
The output indicator (Green) will remain on during normal operation.
OVERLOAD
The overload indicator (Red) will light up if there is an overload or a short circuit in the connected appliance.
If this happens, proceed as follows:
1. Turn off any connected electrical devices and stop the generator.
2. Reduce the total wattage of connected electric devices to within the rated output of the generator.
3. Check air inlet and around the control unit. If any blockages are found, remove them.
4. After checking, restart the generator.
OIL ALERT
The oil alert indicator (Red) will light up when the oil level is low.
• To add oil, follow the instructions on page 10.
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SHUTTING DOWN THE GENERATOR
To stop the generator simply set the engine switch to ‘OFF’.
NOTE: Turn off any electric devices.
NOTE: Set the economy control switch
to the ‘0’ (OFF) position.
1. Disconnect any electric devices.
2. Turn the fuel switch to the “OFF”.
3. Hold the fuel tank cap so that it will not move and turn the fuel tank vacuum relief valve knob to the ‘OFF’ position.
CAUTION: ALLOW THE GENERATOR TO COOL FOR SEVERAL MINUTES BEFORE TOUCHING AREAS THAT BECOME HOT USING USE.
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MAINTENANCE
CHANGING ENGINE OIL (EVERY 20 HOURS OF USE)
CAUTION: PROLONGED EXPOSURE TO USED ENGINE OIL IS DANGEROUS, ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED ENGINE OIL.
1. Unscrew the 3 fixing screws on each corner and remove the maintenance panel shown on the right.
2. Turn the oil filler cap anti­clockwise 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. Fill the oil reservoir with fresh oil.
• DO NOT fill above the max level
mark (0.35 litres)
• We recommend the use of
SAE10W-30 oil in this generator. (CLARKE part number 3050852)
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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CHANGING AIR FILTER (EVERY 50 HOURS OF USE)
WARNING: DO NOT USE FLAMMABLE SOLVENTS OR PETROL TO CLEAN THE AIR FILTER.
1. Unscrew the 3 fixing screws on each corner and remove the maintenance panel shown on the right.
2. Remove the air filter cover screw, shown on the right.
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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CHANGING SPARK PLUG (EVERY 50 HOURS OF USE)
CAUTION: ALLOW THE ENGINE TO COOL BEFORE REMOVING THE SPARK PLUG.
1. Remove 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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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 top panel.
CLEAN FUEL TANK FILTER (EVERY 100 HOURS OF USE OR EVERY 6
MONTHS)
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 THE FUEL TANK FOR LONG PERIODS OF TIME CAN MAKE IT 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
PROBLEM CAUSE SOLUTION
Engine does not start
Engine switch in OFF position
Fuel tank is filled with contaminated or old fuel
Not enough oil in crankcase
Air filter is dirty Clean or replace air filter
Spark plug is dirty Clean spark plug
Spark plug is broken Replace spark plug
Generator is not on level surface
Engine needs maintenance
Set engine switch to CHOKE position
Change the fuel in the tank
Add or replace oil
Move generator to a level surface to prevent low oil shutdown from triggering
Contact the CLARKE service department for more information
Generator was tilted when adding oil or shipped side down
Engine Stops Fuel tank vacuum relief
valve on OFF position
Not enough oil in crankcase
Engine is out of fuel Check fuel gauge and add fuel
Remove spark plug, turn engine switch to the OFF position then pull recoil starter four (4) times to remove oil from the combustion chamber. Replace spark plug and restart engine
Turn fuel tank vacuum relief valve to the ON position
Add or change oil
if needed
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PROBLEM CAUSE SOLUTION
Blue smoke in exhaust
Generator runs but does not support all electrical devices connected
Generator inclined, oil has entered combustion chamber
To much oil has been added to the crankcase
Bad connecting wires/ cables
Bad electrical device connected to generator
Generator is overloaded, (overload light is on).
Move generator to a level position
Drain excess oil
If using an extension cable, try a different one
Try connecting a different device
Perform these steps: 1: Turn off all electrical devices 2: Unplug all electrical devices 3: Shut down the engine 4: Wait several minutes and then restart the engine 5: Try connecting fewer electrical loads to the generator
Short circuit in one of the connected devices
Try disconnecting any faulty or short circuited electrical loads
If this does not solve your problem, please contact the CLARKE Service Department.
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DECLARATION OF CONFORMITY -UKCA
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DECLARATION OF CONFORMITY -CE
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EXPLODED DIAGRAM - ENGINE
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PARTS LIST - ENGINE
No Description No Description
1 Recoil Starting Assembly 24 Valve Lifter
2 Nut (M12 x 1.25) 25 Push Rod
3 Starting Pulley 26 Piston
4 Flywheel 27 Circlip (Piston Pin)
5 Rotor 28 Piston Pin
6 Stator 29 Connecting Rod
7 35mm Flip-Flop 30 Big End
8 Air Filter 31 Bolt
9 Damping Base 32 Crankshaft
10 Bolt (M6 x 30) 33 Oil Seal
11 Recoil Starter Housing 34 Spark Plug Coil
12 Screw (5.5 x 12) 35 Spark Plug
13 Bolt (M6 x 88) 36 Cylinder Head
14 Crank Case 37 Exhaust Valve Gasket
15 Wire Clamp 38 Bolt (M6 x 88)
16 Bolt (M6 x 16) 39 Bolt (M6 x 88)
17 Location Pin 40 Spark Plug
18 Bearing 41 Nut (M6 x 8)
19 Camshaft Assembly 42 Bolt (M6 x 78)
20 Governor Gear Set 43 Intake Valve
21 Governor Arm Shaft Gasket 44 Exhaust Valve
22 Governor Arm 45 Valve Spring
23 Oil Alert Switch 46 Valve Collet
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47 Bolt 63 Nut (M6 x 8)
48 Nut 64 Exhaust Pipe Connector
49 Valve Rocker Arm 65 Waste Pipe
50 Valve Rocker Arm Shaft 66 Crankcase Cover Set
51 Cylinder Head Cover 67 Oil Level Gauge Cover Plate
52 Exhaust Pipe Connector 68 Oil Gauge Set
53 Bolt 69 Muffler
54 Limit Plate 70 Bolt (M6 x 12)
55 Intake Gasket 71 Air Duct
56 Carburetor Insulation Board 72 Bolt (M6 x 20)
57 Carburetor Gasket 73 Lower Duct
58 Carburetor 74 Bolt (M6 x 12)
59 Air Filter Gasket 75 Air Duct
60 Fuel Pipe 76 Bolt (M5.5 x 12)
61 Tube Clip 77 Gasket
62 Air Filter Inlet Pipe 78 Muffler Heat Shield
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EXPLODED DIAGRAM - GENERATOR
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PARTS LIST - GENERATOR
No Description No Description
1 Rear Cover 24 Left Cover Plate
2 Screw (M5 x 16) 25 Screw (ST3 x10)
3 Bushing 26 Handle Trim Cover
4 Nut (M5) 27 Corner Piece Cover (Right)
5 Fuel Tank 28 Starting Handle
6 Rubber Gasket 29 Corner Piece Cover (Left)
7 Nozzle 30 Soundproofing Cotton
8 Fuel Pipe 31 Baseplate
9 Fuel Pipe 32 Nut (M6)
10 Throttle Cable 33 Nut (M6)
11 Soundproof Cotton 34 Rubber Feet
12 Gum Cover 35 Bolt
13 Fuel Tank Seal 36 Bushing
14 Fuel Tank Cap 37 Nut (M5)
15 Bolt (M6 x 12) 38 Screw (M5 x 16)
16 Pressing Plate (Oil Level) 39 Shockproof Foot
17 Fuel Meter 40 Engine Assembly
18 Fuel Meter 41 Inverter
19 Damping Ring 42 3 in 1 Switch
20 Sight-glass (Oil Level) 43 Locating Pin
21 Left Handle 44 Locating Pin
22 Screw (M5 x16) 45 Locating Pin
23 Bolt (M6 x 18) 46 Locating Pin
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47 Panel Cover 56 Voltmeter
48 Locating Pin Cover 57 EU Socket
49 Screw (M5 x 16) 58 3 in 1 Indicator
50 Valve Cable Pressing Plate 59 Switching
51 Panel 60 Earth Bolt
52 Screw (M5 x 16) 61 Right Handle
53 Idling Switch 62 Screw
54 T Type Socket 63 Gasket
55 Socket (Connected to Grid) 64 Right Cover Plate
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