Clarke Power IG1000 Operation & Maintenance Instructions Manual

OPERATION & MAINTENANCE

INSTRUCTIONS

LS0709

1KW INVERTER GENERATOR

MODEL NO: IG1000

PART NO: 8877050

2

INTRODUCTION

Thank you for purchasing this CLARKE 1kw Inverter 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

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]

3

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 point ....................................................................................... 8

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

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

Checking the air filter ..................................................................... 11

USING YOUR GENERATOR .............................................. 12

Starting the engine ......................................................................... 12

Connecting electrical devices ..................................................... 14

Economy switch ............................................................................. 16

Indicator lights ................................................................................. 16

Shutting down the generator ........................................................ 17

MAINTENANCE ............................................................... 18

The engine oil (every 20 hours of use) .......................................... 18

The air filter (every 50 hours of use) ............................................... 19

The spark plugs (every 50 hours of use) ........................................ 20

Fuel tank filter .................................................................................. 21

TROUBLESHOOTING ........................................................ 22

PARTS AND SERVICING .................................................. 22

SPECIFICATIONS ............................................................. 23

EXPLODED DIAGRAM & PARTS LIST ............................... 24

DECLARATION OF CONFORMITY ................................... 27

4

GENERAL SAFETY RULES

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.

1M (3ft)

1M (3ft)

Keep the generator at least 1 m (3
ft) from buildings or other
equipment, or the engine

may

overheat.

2. Always ensure the genera

tor 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.).

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

5

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. 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
danger

ous 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 w

ith 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.

6

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.

7

GENERATOR OVERVIEW

NO DESCRIPTION NO DESCRIPTION

1 Air Vent Knob 10 Earthing Point

2 Fuel Cap 11 Economy Control Switch

3 Fuel Valve Knob 12 AC Socket

4 Starting Handle 13 DC Socket

5 Left Side Maintenance Cover 14 DC Circuit Breaker

6 Top Maintenance Cover 15 Overload Indicator

7 Muffler 16 Output Indicator

8 Choke 17 Oil Alarm Indicator

9 Engine ON/OFF Switch

8

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.

• 1 x Inverter Generator

• 1 x Spark Plug Box Spanner

• 1 x Screwdriver/Tommy Bar

• 1 x Container with Spout for Oil Filling

• 1 x Operating & Instruction Manual

• 1 x 12V Battery Connector Lead

BEFORE USING THE GENERATOR

IMPORTANT: Generators should ALWAYS be earthed. Make sure you ground
(earth) the generator.

Bef

ore 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.

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.

9

CHECKING THE ENGINE OIL LEVEL

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

follows.

1. Remove the left side maintenance panel.

2.

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

3. 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.

4.

Max Level

Min. Level

If the oil is below the Min. level on
the dipstick, add oil to the oil
reservoir.

• Oil Capacity (See

“Specifications

” on page 23)

• 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.

5. Replace the oil filler cap.

WARNING: TO CARRY OUT THIS CHECK, SWITCH THE ENGINE OFF.

WARNING: TAKE CARE NOT TO TOUCH ANY HOT PARTS OF THE
GENERATOR WHEN CHECKING THE OIL LEVEL.

10

CHECKING THE FUEL LEVEL

Make sure there is sufficient fuel in the tank.

1.

Fuel filler cap

To check the fuel level, open the
fuel filler cap.

2. Slowly add fuel to the fuel tank
(maximum 2.7L)

• Do not overfill the fuel tank.

3. Replace the fuel filler cap
secure

ly.

RECOMMENDED FUEL

Your generator has been designed to use regular unleaded gasoline with a
octane number of 86 or higher.

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 TANK CAP IS TIGHTENED
SECURELY.

11

CHECKING THE AIR FILTER

1. Remove the left side maintenance panel.

2.

Remove the air filter cover screw
shown on the right.

3.

Remove the air filter cover

4.

Remove the air filter element.

5. Make sure that the air filter is
clean and not damaged.

• If the air filter is damag

ed

contact Clark

e spare parts
department for a replacement
See page 2

• 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.

6. Replace the filter back into its original position an

d replace the air filter

cover

.

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

12

USING YOUR GENERATOR

STARTING THE ENGINE

1. Remove all connections from the AC sockets.

2.

air vent knob

Hold the fuel tank cap so that it
will not move, and turn the air
vent knob to the ON position.

3. Turn fuel valve to the ON position.

4.

Set the engine switch to ‘ON’.

13

5. Set the choke to the required
position.

• If the engine is cold, pull the

choke all the way out.

•

If the generator is warm, push
the choke all the way in.

6.

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.

.

NOTE: When you first start the generator, the overload indicator 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.

7.

Once the engine has warmed up,
push the choke knob all the way
in.

WARNING: ONCE THE GENERATOR HAS STARTED, RELEASE THE STARTING
HANDLE SLOWLY TO AVOID INJURY/DAMAGE AS IT WHIPS BACK.

14

CONNECTING ELECTRICAL DEVICES

The generator can supply both 230V AC and 12V DC

AC POWER

1.

Start the engine. See page 12.

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 WITCH CONTAINS AN INDUCTIVE LOAD E.G.
DEVICES THAT CONTAIN A MOTOR MAY REQUIRED MORE CURRENT ON
STARTUP.

15

DC POWER

For charging car batteries only

1. Set the economy control switch to
‘OFF’.

2. Start the generator.

3. Connect the battery charging
leads to the generator.

4. Connect the battery charging
leads to the battery.

• Cla

mp the red wire to the
positive (+) terminal and the
black wire to the negative (-)
terminal of the battery. Do not
reverse these positions.

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.

CAUTION: MAKE CONNECTIONS TO THE BATTERY AFTER STARTING THE
ENGINE.

WARNING: TO PREVENT THE POSSIBILITY OF CREATING A SPARK NEAR THE
BATTERY, CONNECT THE CABLE TO THE GENERATOR FIRST AND THEN TO
THE BATTERY. DISCONNECT FROM THE BATTERY FIRST.

WARNING: AFTER YOU HAVE CHARGED THE BATTERY, ALWAYS
DISCONNECT THE NEGATIVE LEAD FIRST.

16

ECONOMY SWITCH

When the economy control switch is
turned on, the engine speed varies
according to the load connected.
This results in decreased fuel
consumption and less noise.

When the economy control switch is
turned off, the engine runs at the
5,500 r/min. regardless of whether
there is a load connected or not.

INDICATOR LIGHTS

PILOT LIGHT

The pilot light (Green) will remain on
during normal operat

ion.

OVERLOAD INDICATOR

The overload indicator (Red) will light
up if there is an overload (in excess of
1kva) or a short circuit in the
connected appliance.

If this happens, proceed as follows:

1. Turn off any connected electrical devices and stop the engine.

2. Reduce the total wattage of connect

ed electric devices w

ithin the

application range.

3. Check air inlet and around the control unit. If any blockages are found,
remove them.

4. After checking, r

estart the engine.

LOW OIL INDICATOR

The oil indicator will light up when the oil level is low. See page 9.

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.

17

SHUTTING DOWN THE GENERATOR

To stop the generator in an emergency 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 valve knob to “OFF”.

3.

air vent knob

Turn the air vent knob to the off
position.

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

18

MAINTENANCE

THE ENGINE OIL (EVERY 20 HOURS OF USE)

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 clot

h.

3. Lift the generator and pour the oil
out of the oil reservoir

into a

suitable container

4.

Max Level

Min. Level

Fill the oil reservoir to the Max level
with fresh oil.

• Oil Capacity (See

“Specifications” on page 23.)

• We recommend the use of

SAE30 oil in this generator.

5. Replace the oil filler cap and
m

aintenance pa

nel.

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 dispose of it according to local regulations.

CAUTION: PROLONGED EXPOSURE TO USED ENGINE OIL IS DANGEROUS,
ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED
ENGINE OIL.

19

THE AIR FILTER (EVERY 50 HOURS OF USE)

1. Remove the left side maintenance panel.

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
Clarke spare parts department for
a repla

cement See page 2.

• 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.

6. Replace the filter back into its original position an

d replace the air filter

cover

.

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

20

THE SPARK PLUGS (EVERY 50 HOURS OF USE)

1. Remove the top maintenance panel.

2.

Remove the spark plug cap from
the spark plug.

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

4. Check for discoloration and
remove any carbon build up.

5. Check the spark plug gap (a), 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.

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

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

21

FUEL TANK FILTER

Just inside the fuel tank is a fuel filter, check this filter periodically and remove
any contaminants which may have accumulated.

1.

Fuel filler cap

Remove the fuel tank cap and
filter.

2.

Fuel filter

Clean the filter with solvent. If
damaged, replace.

3. Wipe the filter and insert it.

4. Make sure the tank cap is
tightened securely.

22

TROUBLESHOOTING

PROBLEM CAUSE SOLUTION

The generator fails
to start

Engine s

witch is off Set the engine switch to ‘on’

Not enough oil in the
generator

Add more

oil, See page 9

No fuel Add more fuel, See page 10

Spark plugs not working
correctly

Change the spark plugs, See
page 20

The generator fails
to

genera

te

electricity

The device you are trying to
power is faulty

Make sure the device you want to
power is working properly

The overload indicator is on Remove

the appliance
immediately, do not connect any
appliance that requires more than
1 KVA.

(dc supply only) The DC
Ov

erload protector has

activated.

Press the reset button. See

page 15

The generator is
d

ifficult to start

The air filter is

dirty Clean the air filter. See page 19

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

PARTS AND SERVICING

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]

23

SPECIFICATIONS

IG1000

Engine Engine Model 144F

Type

Forced air cooled 4­stroke gasoline OHV

Displacement (cm3)

53

Ignition type

TDI

Fuel tank capacity (L) 2.7

Maximum run time (h) 6

Engine oil capacity (L) 0.25

Guaranteed sound power (L

WA dB) 92

Generator Rated Frequency (Hz) 50

Rated AC Voltage (V) 230

Rated Power (kVA) 0.9

Max. Power (kVA) 1

Rated DC Voltage (V) 12

Rated DC Current (A) 5

Dimensions Length (mm) 460

Width (mm) 250

Height (mm) 420

Unpacked Weight (kg) 15

24

EXPLODED DIAGRAM & PARTS LIST

25

EXPLODED DIAGRAM & PARTS LIST

NO DESCRIPTION PAR T N O

1 Engine RKIG100001

2 Ignition coil sleeve RKIG100002

3 Ignition coil RKIG100003

4 M6 Hex bolt RKIG100004

5 Stud(short) RKIG100005

6 Sensor Assembly RKIG100006

7 Stud(long) RKIG100007

8 Stator assembly RKIG100008

9 M6 Hex bolt RKIG100009

10 Rotor assembly RKIG100010

11 M10 nut RKIG100011

12 Fan blade RKIG100012

13 Clutch RKIG100013

14 M6 nut RKIG100014

15 Clutch pedal RKIG100015

16 M6 Hex bolt RKIG100016

17 Fan blade cover RKIG100017

18 M5 nut RKIG100018

19 Recoil Starter RKIG100019

20 M6 Hex bolt RKIG100020

21 Fuel outlet hose RKIG100021

22 Fuel tank RKIG100022

23 Fuel tank cover RKIG100023

24 Fuel cap RKIG100024

25 Front clapboard RKIG100025

26 M5 hex bolt RKIG100026

27 Fan RKIG100027

28 Fan blade shaft RKIG100028

29 Left fan cover RKIG100029

30 Muffler assy RKIG100030

31 Right fan cover RKIG100031

32 Fan cover RKIG100032

33 M4 tapping screw RKIG100033

34 Handle holder RKIG100034

35 Rear cover RKIG100035

36 M6 Hex bolt RKIG100036

37 Bakelite pad RKIG100037

38 Carburetor RKIG100038

39 M4 nut RKIG100039

40 Washer RKIG100040

41 Step motor holder RKIG100041

42 M4 hex bolt RKIG100042

43 Choke holder (1) RKIG100043

44 Choke holder (2) RKIG100044

45 M4 hex bolt RKIG100045

46 Step motor RKIG100046

47 M3 hex bolt RKIG100047

48 Step motor top cover RKIG100048

49 Double-headed stud RKIG100049

50 Air filter RKIG100050

51 Breath pipe RKIG100051

52 M5 nut RKIG100052

53 Air filter sponge RKIG100053

54 Air filter cover RKIG100054

55 Fuel cock RKIG100055

56 Left case RKIG100056

57 Left maintenance cover RKIG100057

58 M6 screw RKIG100058

59 Starter grip RKIG100059

60 Starter cover RKIG100060

61 Fuel cock, plastic knob RKIG100061

62 Vent-pipe washer RKIG100062

63 Ven t- pip e RKIG100063

64 M5 nut RKIG100064

65 Right case RKIG100065

66 Top maintenance cover RKIG100066

67 Controller box RKIG100067

68 Controller panel RKIG100068

69 Choke soft axis RKIG100069

70 Engine holder RKIG100070

71 Absorber RKIG100071

72 Bottom bracket RKIG100072

NO DESCRIPTION PART NO

26

EXPLODED DIAGRAM & PARTS LIST

73 Pads RKIG100073

74 M5 nut RKIG100074

75 M5 screw cap RKIG100075

76 M5 Hex bolt RKIG100076

77 CDI box holder RKIG100077

78 Vac u um p um p RKIG100078

79 Fuel inlet hose RKIG100079

80 Vac u um p ip e RKIG100080

81 Pump inlet hose RKIG100081

82 M5 Hex bolt RKIG100082

83 CDI box assembly RKIG100083

84 M5 nut RKIG100084

85 Inverter assembly RKIG100085

86 M4 hex bolt RKIG100086

87 Inverter holder RKIG100087

88 M5 Hex bolt RKIG100088

NO DESCRIPTION PART NO

27

DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

This is an important document and should be retained.

IG1000- RV1.doc Page 1 of 1

We declare that this product complies with the following directives:

89/336/EE Electromagnetic Compatibility directive, as amended.
73/23/EEC Low Voltage Equipment directive, amended by 93/68/EEC.
98/37/ EC Machinery Directive.
2000/14/EC Noise emissions (amended by 2005/88/EC)

The Following Standards have been applied to the product:

BS EN 55012:2002 BS EN 61000-6-1:2001
EN 61000-6-3:2001+A11 BS EN 12601:2001

The technical documentation required to demonstrate that the products meet the
requirements of the Low Voltage Equipment directive has been compiled and is available
for inspection by the relevant enforcement authorities.

The CE mark was first applied in: 2006

Product Description: 1kW Inverter Generator
Model number(s): IG1000
Serial / batch Number: Current Manufacture.
Date of Issue: 01/05/2008

Signed

A.C. AIKEN

Senior Manager Clarke International.