Clarke Power G1200 Operation & Maintenance Instructions Manual

1100W PORTABLE GENERATOR

MODEL NO: G1200

PART NO: 8010110

OPERATION & MAINTENANCE

INSTRUCTIONS

LS1111

INTRODUCTION

For Parts & Servicing, please contact your nearest dealer, or

CLARKE International, on one of the following numbers.

PARTS & SERVICE TEL: [phone]

PARTS & SERVICE FAX: [phone]

or e-mail as follows:

PARTS: [e-mail]

SERVICE: [e-mail]

Thank you for purchasing this CLARKE 1100W Portable 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.

PARTS AND SERVICING

Parts & Service: 020 8988 7400 / E-mail: [e-mail] or [e-mail]

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TABLE OF CONTENTS

INTRODUCTION ............................................................... 2

GUARANTEE .................................................................... 2

PARTS AND SERVICING .................................................. 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

BEFORE USING THE GENERATOR .................................... 8

Earth Connector ............................................................................. 8

Checking the engine oil level ....................................................... 9

Checking the fuel level ................................................................... 10

USING YOUR GENERATOR .............................................. 11

Starting the engine ......................................................................... 11

Shutting down the generator ........................................................ 12

Connecting electrical devices ..................................................... 13

MAINTENANCE ............................................................... 15

Changing the engine oil ................................................................ 15

the spark plugs (every 50 hours of use) ........................................ 16

the air filter (every 150 hours of use) ............................................. 16

the fuel filter (every 150 hours of use) ........................................... 17

TROUBLESHOOTING ........................................................ 18

SPECIFICATIONS ............................................................. 19

EXPLODED DIAGRAM & PARTS LIST ............................... 20

DECLARATION OF CONFORMITY ................................... 22

DECLARATION OF CONFORMITY ................................... 23

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GENERAL SAFETY RULES

1M (3ft)

1M (3ft)

WARNING: EXHAUST FUMES CAN BE EXTREMELY DANGEROUS IF INHALED

WORK AREA

• Always use in a well ventilated area. Never use indoors or in a
confined space.

• Always position the exhaust outlet away from people.

• Read these safety instructions before using the equipment.

• Keep children and animals away from the generator.

POSITIONING THE GENERATOR

1. Always keep the generator at
least 1 m (3 ft.) from walls or other
equipment, or the engine may
overheat.

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 in a well ventilated
area.

3. Never refuel while smoking or in
the vicinity of an open flame.

4. Never overfill the tank, fill to the
level specified (See “Checking
the fuel level” on page 10).

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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 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.

3. Never use water or any other liquids to
clean the generator.

4. Make sure you ground (earth) 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

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.

7. Never allow the generator air vents to
become blocked.

disconnect the generator when

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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

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UNPACKING AND ASSEMBLY

Unpack your generator and make sure the following items are present.

1 x Generator 1 x 12V Battery Charging Lead

1 x Spark Plug Box Spanner 1 x Petrol Tank Cap

1 x Phillips No.1 Screwdriver 1 x Handle + Fixings Pack

Should there be anything missing or damaged in transit contact your Clarke
dealer immediately.

BEFORE USING THE GENERATOR

IMPORTANT: Generators should ALWAYS be earthed. Make sure you ground
(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 positioned for use (See page 4).

• The fuel system and connectors are intact and there is no leakage.

WARNING: DO NOT CONNECT TO A BUILDINGS ELECTRICAL SYSTEM
UNLESS AN ISOLATION SWITCH HAS BEEN INSTALLED BY A QUALIFIED
ELECTRICIAN.

WARNING: CONNECTIONS FOR STANDBY POWER TO A BUILDINGS
ELECTRICAL SYSTEM MUST BE MADE BY A QUALIFIED ELECTRICIAN AND
MUST COMPLY WITH ALL APPLICABLE LAWS AND ELECTRICAL CODES.
IMPROPER CONNECTIONS CAN ALLOW ELECTRICAL CURRENT FROM THE
GENERATOR TO BACK FEED INTO THE UTILITY LINES. SUCH BACK FEED
MAY ELECTROCUTE UTILITY COMPANY WORKERS OR OTHERS WHO
CONTACT THE LINES DURING A POWER OUTAGE, AND WHEN POWER IS
RESTORED, THE GENERATOR MAY EXPLODE, BURN, OR CAUSE FIRES IN THE
BUILDINGS ELECTRICAL SYSTEMS.

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EARTH CONNECTOR

Always connect the generator to an
earth point. The earth terminal is
shown on the right.

CHECKING THE ENGINE OIL LEVEL

NOTE: Place the generator on a level surface and check the oil level as

follows.

1. Turn the oil filler cap anti-clockwise and remove from the oil reservoir, 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. If the oil is below the Min. level on
the dipstick, add oil to the oil
reservoir. (Maximum 0.35L)

• Oil Capacity (See

“Specifications” on page 19)

• We recommend the use of

SAE30 oil in this generator.

• Do not tilt the generator when adding engine oil. This could result in

overfilling and damage to the engine.

4. Replace the oil filler cap.

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CHECKING THE FUEL LEVEL

WARNING: FUEL IS HIGHLY FLAMMABLE AND POISONOUS.

WARNING: SEE “GENERAL SAFETY RULES” ON PAGE 4 AND READ THEM
CAREFULLY BEFORE REFUELING.

WARNING: WIPE UP ANY SPILLED FUEL IMMEDIATELY.

WARNING: AFTER REFUELING, MAKE SURE THE FUEL CAP IS TIGHTENED
SECURELY.

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.

1. Use the Fuel gauge to check the
fuel level, if it is low

2. Open the fuel cap.

3. Slowly add fuel to the fuel tank
(maximum 5.5 L).

• 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

• Do not overfill the fuel tank.

4. Replace the fuel cap securely.

RECOMMENDED FUEL

Your generator has been designed to use regular unleaded petrol with an
octane number of 90 or higher.

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USING YOUR GENERATOR

Make sure there is sufficient fuel in the tank before using the generator.

STARTING THE ENGINE

1. Remove all connections from the
AC socket on the generator.

2. Turn fuel valve to the ON position.

3. Set the choke lever to the
“Choke” position (all the way to
the right).

4. Set the engine switch to the “I”
(ON) position.

5. Hold the generator handle firmly
and pull the starting handle 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 WHIPS BACK.

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6. Once the engine has warmed up,
return the choke lever to the run
position (all the way to the left).

SHUTTING DOWN THE GENERATOR

To stop the generator in an emergency simply set the engine switch to ‘0’ (OFF)
position.

1. Turn off and disconnect any electric devices.

2. Set the engine switch to the “0”
(OFF) position.

3. Turn the fuel valve to the “OFF”
position.

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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 11.

2. Make sure the appliance is turned
off before connecting it to the
generator.

3. Connect the appliance 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.

CAUTION: CARE SHOULD BE TAKEN WHEN CONNECTING SENSITIVE
DEVICES SUCH AS LAPTOP COMPUTER AND TELEVISIONS TO THE
GENERATOR. A SURGE PROTECTION DEVICE IS RECOMMENDED WHEN
CONNECTING THESE TYPES OF APPLIANCE.

AC OVERLOAD PROTECTOR

If the AC overload protector
activates, the AC circuit breaker/
reset switch will flip to the OFF
position.

1. Disconnect the appliance.

• Wait for 2-3 minutes.

2. Switch the AC circuit breaker/
reset switch shown on the right to
the ON position.

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DC POWER (FOR CHARGING CAR BATTERIES ONLY)

WARNING: FOR YOUR SAFETY, PERFORM THE FOLLOWING INSTRUCTIONS
IN THE ORDER SHOWN.

1. Start the engine, See page 11.

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.

CAUTION: WHEN DISCONNECTING THE BATTERY, ALWAYS DISCONNECT
THE NEGATIVE LEAD FIRST.

DC OVERLOAD PROTECTOR

If the DC overload protector
activates:

1. Disconnect the appliance

• Wait for 2-3 minutes.

2. Press the DC circuit breaker/reset
button shown in this picture.

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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. Remove the left side maintenance panel.

2. Turn the oil filler cap anti­clockwise and remove from the oil
tank, wipe the dipstick with a
clean cloth.

3. Lift the generator and pour the oil
out of the oil reservoir into a
suitable container.

4. Fill the oil reservoir to the Max level
on the dipstick with fresh oil.

• Oil Capacity (See “Specifications” on page 19.)

• We recommend the use of SAE30 oil in this generator.

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 trash or down drains and sinks. Place it in a
leak proof container and take it to your local waste disposal site.

Replace the filter back into its original position and replace the air filter cover.

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THE SPARK PLUG (EVERY 50 HOURS OF USE)

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

1. Remove the spark plug cap from
the spark plug.

2. Use a spark plug spanner
(supplied) to remove the spark
plug.

3. Check for discoloration and use a
wire brush to remove any carbon
build up.

4. Check the spark plug gap (a) with
a feeler gauge, it should be
between 0.6 and 0.7 mm.

• Adjust if necessary.

5. 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.

6. Reinstall the spark plug and replace the spark plug cap.

THE AIR FILTER (EVERY 150 HOURS OF USE)

1. Remove the air filter cover screws.

2. Remove the air filter cover.

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3. Remove the air filter element.

4. Wash it in a solution of warm
water and mild detergent.

5. Rinse thoroughly and leave it to
dry. Once it is completely dry
immerse the filter in clean engine
oil and squeeze the filter to
remove excess oil.

• If the air filter is damaged

contact Clarke spare parts
department for a replacement.

WARNING: DO NOT USE FLAMMABLE SOLVENTS OR PETROL TO CLEAN THE
AIR FILTER.

6. Replace the filter into its original position and replace and secure the
maintenance panel.

THE FUEL FILTER (EVERY 150 HOURS 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 cap from the
generator.

2. Lift out the fuel filter.

3. Clean the filter with solvent.

• If the filter is damaged contact

Clarke spare parts department
for a replacement.

4. Replace the filter and fuel cap.

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TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

The generator fails
to start

The generator fails
to generate
electricity

If this does not solve your problem, please contact the Clarke service
department.

Engine switch is off. Set the engine switch to ‘on’.

No fuel. Add more fuel, see page 10.

Spark plug is defective. Change the spark plug. see

page 16.

The device you are trying to
power is faulty.

(AC supply only) The AC
Circuit Breaker has activated.

Make sure the device you want to
power is working properly.

Remove the appliance
immediately, wait for a 2-3 minutes
and press the AC Circuit Breaker/
reset button.
Do not connect any appliance that
requires more than 1100W.

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SPECIFICATIONS

G1200

Engine Type Petrol - Over head Valve/

Displacement (cm

3

)

Ignition type Recoil

Fuel tank capacity (L) 5.5

Oil tank capacity (L) 0.35

Maximum run time (h) 8 hours @ 75% Load

Guaranteed sound power level (L

Sound pressure level (Lp

A dB) 71.8

WA dB) 92

Generator Rated Frequency (Hz) 50

Rated AC Voltage (V) 230

Rated Power (W) 1000

Max. Power (W) 1100

Rated DC Voltage (V) 12

Rated DC Current (A) 8.3

Dimensions Length (mm) 443

Width (mm) 338

Height (mm) 332

Weight (k g) 25

Forced-Air Cooling/single

Cylinder/4 stroke

87

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EXPLODED DIAGRAM & PARTS LIST

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EXPLODED DIAGRAM & PARTS LIST

NO DESCRIPTION PART NO:

1 Screw M4×16 SUG120001

2 AC socket SUG120002

3 Screw M3×16 SUG120003

4Screw

M4.2×13

5 Control panel SUG120005

6 Flat washer SUG120006

7 Spring washer SUG120007

8 Nut M4 SUG120008

9 Flat washer SUG120009

10 Spring washer SUG120010

11 Nut M3 SUG120011

12 AC circuit

breaker

13 Wire bind SUG120013

14 Screw M6×25 SUG120014

15 Control box SUG120015

16 Screw M6×12 SUG120016

17 Screw M8×25 SUG120017

18 Flat washer SUG120018

19 Screw M8×16 SUG120019

20 Vibration

absorber

21 Flat washer 8 SUG120021

22 Vibration

absorber seat

23 Screw M6×12 SUG120023

24 Control box

rack

25 Back cover

rack

26 Back cover SUG120026

27 Clip SUG120027

28 Fuel hose SUG120028

29 Fuel tank SUG120029

SUG120004

SUG120012

SUG120020

SUG120022

SUG120024

SUG120025

NO DESCRIPTION PART NO:

30 Fuel seal SUG120030

31 Handle SUG120031

32 Flat washer 6 SUG120032

33 Screw M6×25 SUG120033

34 Fuel tank cap SUG120034

35 Fuel hose SUG120035

36 Fuel meter SUG120036

37 Screw M6×16 SUG120037

38 Nylon washer SUG120038

39 Nut M6 SUG120039

40 Fuel cock

filter

41 Fuel cock SUG120041

42 Screw M6×25 SUG120042

43 Rubber

washer

44 Fuel tank rack SUG120044

45 Washer SUG120045

46 Exhaust bolt SUG120046

47 Exhaust

gasket

48 Spring washer SUG120048

49 Nut M8 SUG120049

50 Muffler SUG120050

51 Engine SUG120051

52 Alternator

front frame

53 Screw M8×20 SUG120053

54 Rotor

assembly

55 Stator

assembly

56 Wire clip SUG120056

57 Ball bearing

6203

SUG120040

SUG120043

SUG120047

SUG120052

SUG120054

SUG120055

SUG120057

NO DESCRIPTION PART NO:

58 Wire bind

seat

59 Screw

M3.5×13

60 Condenser SUG120060

61 Engine switch SUG120061

62 DC circuit

breaker

63 DC socket SUG120063

64 Rack SUG120064

65 Side cover SUG120065

66 Alternator

rear cover

67 Screw M5×12 SUG120067

68 Heat insulator SUG120068

69 Flat washer 5 SUG120069

70 Screw M5×10 SUG120070

71 Stator

protector

72 Rear frame SUG120072

73 Flat washer 5 SUG120073

74 Spring washer SUG120074

75 Spring washer SUG120075

76 Screw

M6×105

77 Alternator

center screw

78 Control box

rack

79 Screw M8×40 SUG120079

80 Nut M8 SUG120080

SUG120058

SUG120059

SUG120062

SUG120066

SUG120071

SUG120076

SUG120077

SUG120078

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DECLARATION OF CONFORMITY

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DECLARATION OF CONFORMITY

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