Clarke IG1200D Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0521
1100W INVERTER GENERATOR
MODEL NO: IG1200D
PART NO: 8877112

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INTRODUCTION
Thank you for purchasing this CLARKE 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.
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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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. 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 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.
WARNING: EXHAUST FUMES CAN BE EXTREMELY DANGEROUS IF INHALED

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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 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.
SAFETY SYMBOLS
Read instruction
manual before use.
Hot surface - Do not
touch
Dangerous Voltage Poisonous fumes - Do
not use the generator in
an enclosed space.
Flammable Caution - The user
should be aware of a
general hazard.

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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 (230V)
4 Starting Handle 13 DC Socket (12V)
5 Side Maintenance Cover 14 DC Circuit Breaker
6 Top Maintenance Cover 15 Output Indicator
7 Muffler 16 Overload Indicator
8 Choke 17 Oil Alarm Indicator
9 Engine ON/OFF Switch 18 Primer Bulb

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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.
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, 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
An earth spike and cable can be purchased at your local camping supplier,
or alternatively an earth spike can be made and it is suggested you get
advice from a qualified electrician.
To make a spike use a copper tube or copper rod 12mm diameter, a minimum
length of 200 mm and with an M6 machine screw one end.
The cable used should be a maximum length of 1 metre and a minimum of
1.0mm2to carry a 10 amp load.
Attach the cable to the generator at the earth point (shown on the right).
1 x 1100 Watt Inverter Generator 1 x 12 Volt Connecting Lead Assembly
1 x Spark Plug Box Spanner 1 x CLARKE instruction manual
1 x Cross-head Screwdriver
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 THE UNIT.

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Connect the other end to the spike
between a flat washer and the
copper rod with a lock washer under
the head of the M6 machine screw in
a similar fashion to the earth point
screw on the generator.
When pushing the spike into the
ground the generator must not be
running and it is suggested that the
spike is pushed into the ground by at
least 100 mm.
If you have doubt about earthing of generators in accordance with BS -
EN7430, consult a qualified electrician.
CHECKING THE AIR FILTER
1. Remove the side maintenance
panel.
2. Remove the air filter cover screw
shown on the right.
3. Slide out the air filter panel.

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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 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 then replace the side maintenance panel.
CHECK THE ENGINE OIL LEVEL
1. Place the generator on a level
surface and check the oil level as
follows.
2. Remove the side maintenance
panel.
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.
WARNING: DO NOT USE FLAMMABLE SOLVENTS OR PETROL TO CLEAN THE
AIR FILTER.
WARNING: YOUR GENERATOR MAY NOT BE SUPPLIED WITH OIL - ALWAYS
ENSURE THERE IS SUFFICIENT OIL BEFORE USE.
CAUTION: ONLY CARRY OUT THIS CHECK WITH THE ENGINE OFF.

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5. If the oil is below the Min. level on
the dipstick, top up the oil
reservoir with fresh oil.
• Do not fill above the max level
mark (0.27 litres)
• We recommend the use of 1L
SAE10W/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. Replace the oil filler cap and the left side maintenance panel.
CHECK THE FUEL LEVEL
1. To check the fuel level, open the
fuel filler cap.
2. Slowly add fuel to the fuel tank
(maximum 2.1 litres)
• Do not overfill the fuel tank.
3. Replace the fuel filler cap
securely.
RECOMMENDED FUEL
Your generator has been designed to use regular unleaded petrol with a
octane number of 86 or higher.
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 3 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.
Max Level
Min. Level
Fuel filler cap

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USING YOUR GENERATOR
STARTING THE ENGINE
1. Remove all connections from the
AC sockets.
2. Hold the fuel tank cap so that it
will not move, and turn the air
vent knob to the ‘open’ position.
3. Turn fuel valve to the ON position
(pointing right).
4. Set the engine switch to ‘ON’.
5. Move the choke lever to the right,
to the ‘Choke’ position.

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6. If this is the first time you are using
the generator or if the generator
had run out of fuel the last time
you used it, pump the primer bulb
a minimum of 6 times to introduce
fuel into the carburetter.
7. 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.
8. Once the engine has warmed up,
move the choke lever to the left,
to the “run” position.
WARNING: ONCE THE GENERATOR HAS STARTED, RELEASE THE STARTING
HANDLE SLOWLY TO AVOID INJURY/DAMAGE AS IT WHIPS BACK.

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ECONOMY SWITCH
ON:
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:
The smart throttle system does not
operate.
CONNECTING ELECTRICAL DEVICES
The generator can supply both 230V AC and 12V DC
AC POWER
1. Start the engine.
2. Make sure the appliance is turned
off before connecting it to the
generator.
3. Connect the appliance (max
load 1100W) to the generator.
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.
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 page 10.
3. Make sure the appliance is turned
off before connecting it to the
generator.
4. Connect the 12V appliance (max
4A) to the generator.
DC POWER (TOPPING UP CAR BATTERIES)
1. Set the economy control switch to
'OFF'.
2. Start the generator. See page 10.
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.
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.
CAUTION: WHEN DISCONNECTING THE BATTERY, ALWAYS DISCONNECT
THE NEGATIVE LEAD FIRST.

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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.
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 engine.
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 engine.
LOW OIL ALERT
The oil alert indicator (Red) will light up when the oil level is low.
• To add oil, follow the instructions on pages 8 & 9.

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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”
(pointing left).
3. Turn the air vent knob to the
‘Close’ position.
4. Set the engine switch to the “0”
(OFF) position.

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MAINTENANCE
ENGINE OIL (EVERY 20 HOURS OF USE)
1. Remove the maintenance panel
shown on the right.
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.
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 (0.27 litres)
• We recommend the use of
SAE10W/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.
CAUTION: PROLONGED EXPOSURE TO USED ENGINE OIL IS DANGEROUS,
ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED
ENGINE OIL.
Max Level
Min. Level

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AIR FILTER (EVERY 50 HOURS OF USE)
1. Remove the maintenance panel
shown on the right.
2. Remove the air filter cover screw.
3. Remove the air filter panel.
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.
WARNING: DO NOT USE FLAMMABLE SOLVENTS OR PETROL TO CLEAN THE
AIR FILTER.

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SPARK PLUG (EVERY 50 HOURS OF USE)
1. Remove the top maintenance
panel.
2. Remove the spark plug cap from
the spark plug.
3. Fit the spark plug box spanner
over the spark plug as shown.
4. Remove the side panel and use
the screwdriver supplied to turn
the spark plug box spanner as
shown.
5. When the spark plug has been
removed, check for discoloration
and use a wire brush to remove
any carbon build up.
CAUTION: ALLOW THE ENGINE TO COOL BEFORE REMOVING THE SPARK
PLUG.

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6. Check the spark plug gap (a) with a feeler gauge, it should be between
0.6 and 0.7 mm.
• Adjust if necessary.
7. 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.
8. Reinstall the spark plug and replace the spark plug cap and top panel.
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.

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TROUBLESHOOTING
If this does not solve your problem, please contact the CLARKE service
department.
PROBLEM CAUSE SOLUTION
The generator
fails to start
Engine switch is off Set the engine switch to ‘on’
Not enough oil in the
generator
Add more oil, See pages 8-9.
No fuel Add more fuel, See page 9.
Spark plug not working
correctly
Change the spark plug, See
page 18-19.
The generator
fails to generate
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 1100W.
(DC supply only) The DC
Overload protector has
activated.
Press the reset button. See page
14.
The generator is
difficult to start
The air filter is dirty Clean the air filter. See page 17.