Clarke IG3500AF Instruction Manual

OPERATION & MAINTENANCE
INSTRUCTIONS
ORIGINAL INSTRUCTIONS GC0420 - ISS 3
3.4KW INVERTER GENERATOR
MODEL NO: IG3500AF
PART NO: 8877125

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INTRODUCTION
Thank you for purchasing this CLARKE Generator.
Before attempting to operate the machine, it is essential that you read this
manual thoroughly and carefully follow all instructions given. In doing so you
will ensure the safety of yourself and that of others around you, and you can
also look forward to the product giving you long and satisfactory service.
Ensure the welder and its components suffered no damage during transit and
that all components are present. Should any loss or damage be apparent,
please contact your CLARKE dealer immediately.
GUARANTEE
This CLARKE product is guaranteed against faulty manufacture for a period of
12 months from the date of purchase. Please keep your receipt 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 RECYCLING POLICY
Through purchase of this product, the customer is taking on the
obligation to deal with the WEEE in accordance with the WEEE
regulations in relation to the treatment, recycling & recovery and
environmentally sound disposal of the 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
1. Always use in a well ventilated area.
2. Always position the exhaust outlet away from people.
3. Never use indoors or in a confined space.
4. Read these safety instructions before using the equipment.
5. Keep children away from the generator.
POSITIONING THE GENERATOR
1. Always leave a least a 1m gap between the generator and any
surrounding building or structures.
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 away from any source of heat.
3. Always refuel in a well ventilated area.
4. Only use standard unleaded petrol.
5. Never smoke whilst refuelling and avoid smoking or using a naked flame
near the generator.
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.
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.
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 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 with fuel in the tank.
6. Do Not connect to a commercial or residential power supply; e.g. ring
main.
SAFETY SYMBOLS
The above symbols are to be found on the product.
Read Instruction
manual before use
Danger - highly
flammable liquid.
Caution - The user
should be aware of
a general hazard
Engine and exhaust
become hot during
use - Do not touch
Dangerous voltage.
Risk of electric
shock
Poisonous fumes - Do
not use the generator
in an enclosed space.
Wear ear defenders For outdoor use only.
Do not expose to rain.
Do not use in the
wet

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GENERATOR OVERVIEW
NO DESCRIPTION NO DESCRIPTION
1 Fuel Supply Valve 7 Control Panel
2 Fuel Cap 8 Anti-vibration Feet
3 Fuel Level Gauge 9 Dipstick
4 Frame 10 Choke Lever
5 Air Filter (at the rear) 11 Earth Point
6 Starting Handle

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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.
• Spark plug box spanner
• Oil Funnel
• 12 Volt D.C. output lead assembly
BEFORE USING THE GENERATOR
Attach a suitable earth lead to a good earthing point - water pipe, ground
spike etc., whenever you use this 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).
• The fuel system is intact and there is no leakage.
NOTE: Always use a funnel to fill the fuel tank to avoid accidental
spillage of fuel. If fuel is spilled it must be cleaned up before use.
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.

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EARTH POINT
1. Ground the generator by
connecting a suitable grounding
wire to the earth point.
NOTE: Connect the other end of the
grounding wire to a copper or
brass grounding rod that is driven
into the earth.
CHECKING THE ENGINE OIL LEVEL
1. Turn the dipstick anti-clockwise
and remove from the oil filler tube.
2. 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. If the oil level is at or below the ‘L’
mark on the dipstick, add oil to
the crankcase.
• Fill until the oil reaches the
threads in the oil fill tube.
• Oil capacity (See page 19).
• We recommend the use of
SAE15W40 oil in this generator.
available from your CLARKE
dealer.
5. Replace the oil filler cap.
WARNING: FAILURE TO PROPERLY GROUND THE GENERATOR CAN RESULT
IN ELECTROCUTION
WARNING: TO CARRY OUT THIS CHECK, PLACE THE GENERATOR ON LEVEL
GROUND WITH THE ENGINE SWITCHED OFF.
WARNING: TAKE CARE NOT TO TOUCH ANY HOT PARTS OF THE
GENERATOR WHEN CHECKING THE OIL LEVEL.

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CHECKING THE FUEL LEVEL
1. Check the fuel level on the fuel
gauge.
2. To add fuel, open the fuel filler
cap.
3. Slowly add fuel to the fuel tank
(maximum 13L) watching the fuel
level gauge as you do so.
RECOMMENDED FUEL
We recommend the use of standard
unleaded petrol.
IMPORTANT: Do not overfill the fuel tank.
4. Replace the fuel filler cap securely.
WARNING: ALWAYS REFUEL IN A WELL VENTILATED AREA AWAY FROM
ANY HEAT SOURCES.
WARNING: ALLOW THE UNIT TO COOL DOWN BEFORE REFUELLING.
WARNING: DO NOT LEAVE FUEL WITHIN THE REACH OF CHILDREN.

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INDICATOR LIGHTS
OUTPUT
The output indicator (Green) will
remain whenever the generator is
producing power.
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 obstructions are
found, remove them.
4. After checking, restart the engine.
OIL ALERT
The oil alert indicator (Yellow) will light up when the oil level is low.
• To add oil, follow the instructions on page 7.

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USING YOUR GENERATOR
STARTING THE ENGINE
1. Remove all connections from the AC sockets.
2. Set the ECON switch to ‘OFF’.
3. Set the fuel valve to the ON
position as shown.
4. Set the engine switch to ‘ON’.

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5. Move the choke to the ‘Choke’
position.
NOTE: Not required if the engine is
warm.
6. Hold the generator steady and
pull the starting handle lightly until you start to feel resistance.
Then pull 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,
move the choke to the “run”
position.
WARNING: ONCE THE GENERATOR HAS STARTED, RELEASE THE STARTING
HANDLE SLOWLY TO AVOID INJURY/DAMAGE AS IT RECOILS.

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ECONOMY SWITCH
ON:
Minimizes fuel consumption and reduces 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 APPLIANCES
The generator can supply both 230V AC and 12V DC
AC POWER
1. Start the engine. See page 10
2. Connect the appliance to the
generator.
• Make sure the appliance is
turned off before connecting it
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 (CHARGING CAR BATTERIES ONLY)
1. Start the generator. See page 10.
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.
• Do not allow the clamps to
touch each other whilst
connected to the generator.
DC OVERLOAD PROTECTOR
If the DC overload protector
activates, wait for a few minutes and
then press the DC overload protector
button shown on the right.
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 (BLACK) LEAD FIRST.

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SHUTTING DOWN THE GENERATOR
1. Turn off and disconnect any electric devices.
2. Set the engine switch to the “0”
(OFF) position.
To stop the generator in an
emergency simply set the engine
switch to ‘OFF’.
3. Set the fuel valve to the OFF
position as shown.

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MAINTENANCE
CHANGING THE ENGINE OIL
1. Unscrew and remove the oil filler
cap/dipstick.
2. Place an oil collection tray under
the drain plug.
3. Unscrew the drain plug and allow
the used engine oil to drain from
the crankcase into the oil
collection tray.
NOTE: Drain the engine oil when the
engine is warm, this will ensure
the oil flows out faster.
4. Replace the drain plug.
5. Fill the crankcase with engine oil.
• Fill until the oil reaches the threads in the oil fill tube.
• Oil capacity (See page 19).
• We recommend the use of SAE15W40 oil in this generator. available
from your CLARKE dealer.
6. Replace the dipstick.
ENVIRONMENTAL PROTECTION
One of the most damaging sources of pollution is oil. Do not throw away used
engine oil in with your domestic rubbish or pour it down drains and sinks. Place
it in a leak proof container and take it to your local waste disposal site.
CAUTION: PROLONGED EXPOSURE TO USED ENGINE OIL IS HARMFUL,
ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED
ENGINE OIL.

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CHANGING THE SPARK PLUG
1. Remove the spark plug cap from
the spark plug.
2. Use the spark plug spanner
supplied to remove the spark
plug.
3. Remove any carbon that has
accumulated around the
electrode.
4. Check the spark plug gap (a), it
should be between 0.7 and 0.8
mm, adjust if necessary.
5. Check the overall condition of the
spark plug for erosion or pitting
and replace if necessary.
6. Reinstall the spark plug and
replace the spark plug cap.
CAUTION: ALLOW THE ENGINE TO COOL BEFORE REMOVING THE SPARK
PLUG.
Add pic

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CHECKING THE AIR FILTER
1. Unclip and remove the air filter
cover.
2. Remove the air filter element.
3. Make sure that the air filter is
clean and not damaged.
• If the air filter is damaged
contact CLARKE spare parts
department for a replacement.
• If the filter is dirty, wash in a
solution of warm water and
mild detergent and rinse
thoroughly. Leave the filter to
dry completely, once it is dry immerse in clean engine oil and
squeeze to remove excess oil.
4. Replace the filter to its original position and replace the air filter cover.
CAUTION: DO NOT USE THE GENERATOR WITHOUT THE AIR FILTER FITTED,
THIS CAN DAMAGE THE GENERATOR.
WARNING: DO NOT USE INFLAMMABLE SOLVENTS OR PETROL TO CLEAN
THE AIR FILTER.

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TROUBLESHOOTING
If this does not solve your problem contact the CLARKE service department.
PROBLEM CAUSE SOLUTION
The generator
fails to start
Ignition switch is off. Set the ignition switch to ‘on’.
Choke in the wrong position Adjust choke accordingly
Not enough oil in the
generator.
Add more oil, See page 7.
No fuel, Fuel valve not fully
open.
Check valve is fully open or
add more fuel, See page 8.
Spark plug defective or has
loose cable.
Change the spark plug and
check cable, See page 16.
Equipment already con-
nected to the generator
Disconnect device from the
generator.
The generator
fails to generate
electrical output
The device you are trying to
power is faulty.
Ensure the device you want
to power is working properly.
The AC breaker is switched
off.
Switch the AC breaker on.
Worn generator brushes. Have your CLARKE dealer
replace the brushes.
Damaged cables. Replace cables.
The generator is
difficult to start
The air filter is dirty. Clean the air filter,.
The fuel line is blocked. Clean the fuel line between
the tank and carburetor,
including any filter used.
Circuit breaker
repeatedly trips
Unit is overloaded. Reduce load on generator
Faulty cable or equipment Check for damaged, bare or
frayed wires on equipment.
Generator over-
heating
Generator is overloaded. Reduce load.
Insufficient ventilation. Move unit to an adequate
supply of fresh air.

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SPECIFICATIONS
CLARKE part no 8877125 IG3500AF
Engine Engine Model QL170F
Fuel Type Unleaded Petrol (RON95)
Displacement (cm3)212
Start system Hand recoil
Fuel tank capacity (L) 13
Fuel consumption 420 g/kwh
Maximum run time @75% Load 8 hours
Engine oil type SAE15W40
Engine oil capacity (L) 0.6
Guaranteed sound power
(LWA dB)
96
Generator Rated Frequency (Hz) 50
AC Output Voltage (V) 230
DC Output Voltage (V) 12V (Max 8A)
Rated Power (W) 3200
Max. Rated Power (W) 3400
Dimensions Length (mm) 520
Width (mm) 440
Height (mm) 470
Unpacked Weight (kg) 35
Environmental Sound pressure level 73.6 dB
Sound power level 93.06 dB
Guaranteed sound power level 96 dB
Uncertainty factor 2 dB

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PARTS LISTS AND DIAGRAMS
ENGINE ACCESSORIES
ITEM PART NUMBER DESCRIPTION QTY
1 QLKJ151001 Hex Flange Bolt M5 5
2 QLKJ151002 Recoil Starter Assembly 1
3 QLKJ151003 Engine 1
4 QLKJ151004 Exhaust Gasket 1
5 QLKJ151005 Hex Nut M6 2
6 QLKJ151006 Insulation Board 1
7 QLKJ151007 Hex Socket Head Cap Screw M8 4
8 QLKJ151008 Muffler Support Plate 1 1
9 QLKJ151009 Muffler Support Plate 2 1
10 QLKJ151010 Hex Flange Bolt M6 2
11 QLKJ151011 Muffler 1