Clarke IG3500AF 3.4KW Inverter Generator Instruction Manual

Clarke IG3500AF 3.4KW Inverter Generator Instruction

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.

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. 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.

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

GENERATOR OVERVIEW

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

EARTH POINT

WARNING: FAILURE TO PROPERLY GROUND THE GENERATOR CAN RESULT IN ELECTROCUTION

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

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.

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.
5. Replace the oil filler cap.

• 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.

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.

USING YOUR GENERATOR

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.

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’.
5. Move the choke to the ‘Choke’ 6. Hold the generator steady and pull the starting handle lightly until you start to feel resistance. Then pull sharply to start the engine.position.
6. NOTE: You may have to do this more than once
7. Once the engine has warmed up, move the choke to the “run” position.

ECONOMY SWITCH

ON

Minimizes fuel consumption and reduces noise levels when no load is applied to the generator. Engine speed varies with the load

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

AC POWER

1. Start the engine. See page 9
2. Connect the appliance to the generator.

Make sure the appliance is turned off before connecting it 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.

DC POWER (CHARGING CAR BATTERIES ONLY)

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.

1. Start the generator. See page 9.

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.

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.

SHUTTING DOWN THE GENERATOR

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

MAINTENANCE

CHANGING THE ENGINE OIL

CAUTION: PROLONGED EXPOSURE TO USED ENGINE OIL IS HARMFUL, ALWAYS WASH YOUR HANDS THOROUGHLY AFTER HANDLING USED 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.
4. Replace the drain plug.
5. Fill the crankcase with engine oil.
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.

CHANGING THE SPARK PLUG

CAUTION: ALLOW THE ENGINE TO COOL BEFORE REMOVING 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.

CHECKING THE AIR FILTER

CAUTION: DO NOT USE THE GENERATOR WITHOUT THE AIR FILTER FITTED, THIS CAN DAMAGE THE GENERATOR.

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.
4. Replace the filter to its original position and replace the air filter cover.

• 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.

TROUBLESHOOTING

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.

SPECIFICATIONS

CLARKE part no 8877125

Engine| Engine Model
Fuel Type
Displacement (cm3)
Start system
Fuel tank capacity (L)
Fuel consumption
Maximum run time @75% Load
Engine oil type
Engine oil capacity (L)
Guaranteed sound power (LWA dB)
Generator| Rated Frequency (Hz)
AC Output Voltage (V)
DC Output Voltage (V)
Rated Power (W)
Max. Rated Power (W)
Dimensions| Length (mm)
Width (mm)
Height (mm)
Unpacked Weight (kg)
Environmental| Sound pressure level
Sound power level
Guaranteed sound power level
Uncertainty factor

PARTS LISTS AND DIAGRAMS

ENGINE ACCESSORIES

FUEL TANK ASSEMBLY

INVERTER ASSEMBLY

OPEN FRAME ASSEMBLY

PROTECTIVE COVER

CONTROL PANEL

GENERATOR ASSEMBLY

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