Sealey GI2300 User manual
INSTRUCTIONS FOR
INVERTER GENERATOR 2300/3500W 230V
4-STROKE ENGINE
MODEL NO: GI2300, GI3500
Thank you for purchasing a Sealey product. Manufactured to a high standard, this product will, if used according to these
instructions, and properly maintained, give you years of trouble free performance.
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS & CAUTIONS. USE
THE PRODUCT CORRECTLY AND WITH CARE FOR THE PURPOSE FOR WHICH IT IS INTENDED. FAILURE TO DO SO MAY CAUSE DAMAGE AND/OR
PERSONAL INJURY AND WILL INVALIDATE THE WARRANTY. KEEP THESE INSTRUCTIONS SAFE FOR FUTURE USE.
1. SAFETY
WARNING! The Generator is shipped without oil. Check oil level and ll as required before use.
WARNING! Ensure any Health & Safety, Government, or local authority regulations are adhered to when using this equipment.
9Familiarise yourself with the application and limitations, as well as the potential hazards, of the generator.
9Maintain the generator in good condition (use an authorised service agent). Replace or repair damaged parts. Use genuine parts only.
Unauthorised parts may be dangerous and will invalidate the warranty.
9This generator is designed and manufactured for specific applications. DO NOT attempt to modify the unit or use it for any application
for which it is not designed. If you have any questions regarding the application of the unit please contact your local Sealey stockist.
WARNING! DO NOT exceed the Wattage/Amperage capacity of the generator.Add rated wattage of all devices intended for
connection at any one time, the total must not exceed rated wattage of generator (see specifications).
WARNING! Generator exhaust gases contain deadly carbon monoxide which must not be inhaled. Always allow sufficient ventilation.
WARNING! If you decide to use an Earth Leakage Circuit Breaker (also referred to as an RCD or Ground Fault Circuit Interrupter),
it is imperative that the neutral end of the power winding is connected to the frame of the generator set and that the earth lug on the
frame is connected with a low impedance connector to the local earth via an earth spike or local protective earth conductor. This
connection should only be attempted by a qualified electrician, after first having consulted your local stockist.
▲DANGER! This generator is designed for outdoor use only. To use the generator inside any building or enclosure, including the
generator compartment of a caravan, may result in fire or an explosion. No user performed modifications, including venting of the
exhaust and/or cooling ventilation, will eliminate the danger.
▲DANGER! If this unit is used for back-up power in the event of a commercial power failure, the following steps must be taken.
Before connecting the generator to the electrical system, open the main circuit breaker to isolate the generator and system from the
commercial electric supply. Failure to do this may result in damage to the generator and may result in serious injury or fatality, due to a
back-feed of electrical energy.
▲DANGER! The generator produces a very powerful voltage that can cause a severe electrical shock. Avoid contact with bare wires,
terminals etc. Never allow any unqualified person to operate or service the generator.
WARNING! Petrol is highly flammable and petrol vapour is explosive. Do not permit smoking, naked flames, sparks or heat in the
vicinity while handling petrol. Avoid spilling petrol onto a hot engine. Comply with all laws regulating storage and handling of fuels.
WARNING! Risk of burns. DO NOT touch the exhaust system or the drive unit.
WARNING! NEVER refuel when the engine is running or when the engine is hot. Allow cool down time.
9Operate the generator only on level surfaces (maximum allowable tilt is 10º) and where it will not be exposed to excessive moisture, dirt
or corrosive vapours or be in the proximity of combustible material (flammable liquids, solids or gases).
8DO NOT tip or change the generator’s position whilst it is operating.
9Remove ill fitting clothing, ties, watches, rings and other loose jewellery and contain long hair. Wear appropriate protective clothing.
9Keep non-essential persons and children away from the working area.
WARNING! Never start or stop the generator while electrical loads are connected. Start the engine, let it stabilise, then connect the
electrical load. To stop engine, disconnect the electrical load and let engine stabilise before switching off.
WARNING! DO NOT use worn, bare, frayed or otherwise damaged electrical cables with the generator. Electric shock may occur.
8DO NOT use the generator for any purpose other than that for which it is designed.
8DO NOT operate the generator if any parts are missing or damaged, as this may cause failure and/or personal injury.
8DO NOT over-fill fuel tank. Always leave room for fuel to expand.
8DO NOT operate in the rain.
▲DANGER! DO NOT tamper with the engine governed speed setting. Higher operating speeds are dangerous and increase the risk
of personal injury and/or equipment damage. The generator supplies the correct rated frequencies and voltage only when running at the
correct governed speed. Incorrect frequency and/or voltage can damage some connected electrical loads.
Operating at excessively low speeds may result in shortened engine life. Over-speeding will invalidate the warranty.
8DO NOT operate the generator when you are tired, or under the influence of alcohol, drugs or intoxicating medication.
8DO NOT store generator with fuel in tank where petrol vapours might reach an open flame or spark.
9The generator must be grounded with a good quality insulated conductor.
9Keep vents free from dirt etc.
9 Ifsupplyingelectronicequipment,orinanareawhereelectronicequipmentisbeingused,keepthegeneratorasufcientdistance
away to prevent electrical noise from the engine.
GI2300,GI3500Issue2(g1)19/04/18
Original Language Version
© Jack Sealey Limited
Refer to
instructions
Electrical
shock
hazard
Hot surfaces Do not cover Do not use in
non ventilated
area
Switch off the engine
Before refuelling
2. INTRODUCTION
Heavy-duty frame provides full protection and incorporates carry handles for portability. Inverter generator suitable for running sensitive
electricalequipment.ProducesacleanACcurrenttomatchtheload.Longrunningtimeofupto8hoursonafulltankoffuel.Fittedwithtwo
230V13Ampsockets.Increasedfuelefciencycomparedtostandardgenerators.Featuresoilwarninglight,overloadindicatorandsight
glass to monitor fuel level.
3. SPECIFICATION
Model No................................GI2300.........................GI3500
Motor Power........................... 2.3KW...........................3.5KW
Motor Type ................4-StrokePetrol..............4-StrokePetrol
Output .............................230V-50Hz....................230V-50Hz
Current Rating...........................8.3A.............................15.2A
Continuous Power Rating......2000W...........................3200W
Max. Power Rating................2300W...........................3500W
Fuel Tank Capacity................... 13ltr................................13ltr
Max. Running Time ................. 13Hr..................................8hr
Noise Rating ...................... 95dB(A)..........................95dB(A)
Noise pressure level............... 74db................................74db
Dry Weight .......................... 35.1Kg............................35.5Kg
Dimension (WxDxH)...440x520x470mm......440x520x470mm
Fuel....................... Unleaded Petrol..............Unleaded Petrol
4. OPERATION
4.1. Descriptiong.1.
1. Control panel
2. Choke Knob
3.Inverter cover
4.Fuelcockknob
5. Recoil starter
6.Mufer
7.Mufercover
8.Fueltank
9.Fueltankcap
10. Fuel gauge
11.Airlter
4.2. Control Panel g.2.
1. Oil warning light
2. AC pilot light
3. Overload indicator light
4.Economycontrolswitch
5. Engine switch
6. DC socket
7. Earth terminal
8.DCprotector
9.ACsocket
4.3. Control Functions
4.3.1. Engine Switch
Ignition circuit is switched off
Ignition circuit is switched on
4.3.2. Oil warning light (yellow)
Whentheoillevelfallsbelowthelowerlevel,theoilwarninglightg.3.1.comeson
theenginethenstopsautomatically.Untiltheoilisrelledtheenginewillnotstart.
If the engine stalls or does not start, turn the engine switch to “ON” and then pull
recoilstartercord.Iftheoilwarninglightickersforafewseconds,thereis
insufcientoil.topupoilandrestart.
4.3.3. Overload indicator light (red)
The overload indicator light (3) comes on when an overload is detected, the inverter control unit overheats, or the AC output
voltages rise. The AC protector will trip and stop power generation in order to protect the generator. The AC pilot light (Green) will
go off and the overload indicator light (red) will stay on, The power generation will stop. When this happens proceed as follows.
Turn off any connected electric devices and stop the engine.
Reduce the total wattage of connected appliance into the rated output.
Check for blockages in the cooling air inlet and around the control unit. If any blockages are found, remove.
Afterchecking,restarttheengine.Note:Theoverloadindicatorlightmaycomeonforafewsecondsatrstwhenusingelectrical
g.1
g.2
g.3
GI2300,GI3500Issue2(g1)19/04/18
Original Language Version
© Jack Sealey Limited
devices that require a large starting current. This is not a malfunction.
4.3.4. AC pilot light (green)
TheACpilotlightg.3.(2)comesonwhentheenginestartsandproducespower.
4.4. DC Protector
4.4.1. TheDCprotectorturnsto“OFF”g.4.(2)automaticallywhenelectricdevicebeing
connected to the generator is operating at a higher current than the max stated in
specications.
4.4.2. To turn the power on press the button to the “ON” (1) position.
N.B. Reduce the load before restarting.
4.5. Economy control switch (ECS) g.5
4.5.1. “ON” (1)
When the ECS switch is turned to “ON” the economy control unit controls the engine speed according to the connected load. The
results are better fuel consumption and less noise.
4.5.2. “OFF” (2)
When the ECS switch is turned to “OFF” the engine runs at the rated speed (3600r/min) regardless of whether a load is connected or
not.
4.5.3. The ECS must be turned to “OFF” when using electric devices that require a larger starting current.
4.6. Earth terminal g.4
4.6.1. Earthterminalg.5.(1)connectstheearthlinetopreventelectricshock.
N.B If the device is earthed the generator must be earthed.
4.7. FUEL
4.7.1. Do Notoverllthefueltank,otherwiseitmay
overowwhenthefuelwarmsupandexpands.
4.7.2. Afterllingensuretankcapistightenedsecurely.
4.7.3. Wipe off any fuel that has been spilled.
4.7.4. Use only unleaded petrol.
4.7.5. Removethefueltankcapg.6.
4.7.6. Pourinfueluptotheredlineg.7.(1)
4.7.7. Fuellevelg.8.(2)
4.8. Engine oil
N.B. The generator has been transported without engine oil. Do not start the
engineuntillledwithsufcientengineoil.
4.8.1. Place the generator on a level surface.
4.8.2. Remove the oil gauge.
4.8.3. Fillthegeneratorwiththeamountofengineoilspecied.
4.8.4. Replaceoilgaugeg.9.
4.8.5. RecommendedengineoilSAESJ15W-40.
4.8.6. Engineoilcapacity0.45L.
4.9. Standard atmospheric conditions
Ambient temperature 25oC
Barometric pressure 100kPa
Relative humidity 30%
The output of the generator will vary dependant on the deviation from the standard conditions.
g.4
g.5
g.6 g.7
g.8
g.9
GI2300,GI3500Issue2(g1)19/04/18
Original Language Version
© Jack Sealey Limited
4.10. Starting the engine
4.10.1. TurntheECSswitchto“OFF”g.10.
4.10.2. Turnthefuelcockknobto“ON”g.11.
4.10.3. Turntheengineswitchto“ON”g.12.
4.10.4. Pullthechokeknobfullyoutg.13.(Thechokeisnot
required to start a warm engine.)
4.10.5. Grasp the carrying handle to prevent the generator
from falling over. Pull slowly on the recoil starter until
itisengaged,thenpullitbrisklyg.14.
4.10.6. After the engine starts, let the engine warm up until
the engine does not stop when the choke knob is
returnedtotheoriginalpositiong.15.
4.11. Stopping the engine
4.11.1. Turn off any electric devices.
4.11.2. Turn the ECS to “OFF”
4.11.3. Disconnect any electric devices.
4.11.4. Turn the engine switch to “STOP”
4.12. Alternating Current (AC) connection
4.12.1. Turn off all electrical devices before plugging them in.
4.12.2. Ensure total load is within generator rated output.
4.12.3. Ensure generator is earthed if any of the electrical devices are earthed.
4.12.4. Start the engine.
4.12.5. Turn the ECS to “ON”.
4.12.6. Plug device into socket and make sure AC pilot light is on.
4.12.7. Turn on electrical device.
4.13. Battery Charging
4.13.1. General Safety
The generator DC rated voltage is 12V.
Before starting to charge the battery, make sure that the DC protector is turned on.
4.13.2. Start the engine.
4.13.3. Connect the red battery charger lead to the positive (+) battery terminal.
4.13.4. Connect the black battery charger lead to the negative (-) battery terminal.
4.13.5. Turn the ECS to “OFF” to start battery charging.
4.13.6. Charge the battery using the correct procedure laid down by the battery manufacturer’s instructions. Follow the instructions to
determinetheendofbatterycharging,thismayincludemeasurementsofspecicgravityatregularintervals.DO NOT over charge
battery.
WARNING! “Modern vehicles contain extensive electronic systems. You are required to check with the vehicle Manufacturer, for any
specicinstructionsregardingtheuseofthistypeofequipmentoneachvehicle.Noliabilitywillbeacceptedfordamage/injury,where
this product is not used in accordance with all instructions.”
4.13.7. The DC protector turns off automatically if current is above the generator rating. To restart charging the battery, turn the DC protector
on. If the protector turns off again, stop charging the battery immediately.
g.10 g.11
g.12 g.13
g.14 g.15
Electrical
shock
hazard
Wear eye
protection
Wear protective
gloves
Warning
corrosive
substance
Keep away
from sources of
ignition
Use in well
ventilated areas
Keep in dry area
protect from rain
GI2300,GI3500Issue2(g1)19/04/18
Original Language Version
© Jack Sealey Limited
5. MAINTENANCE
N.B. Stop the engine before servicing. Put the engine on a level surface and remove the spark plug cap to prevent engine from
starting.
5.1. The engine must be properly maintained to ensure its operation be safe and economical.
In order to keep the engine in good working condition, it must be periodically serviced. the following maintenance schedule and routine
inspection procedures must be carefully followed:
Items
Each Time Firstmonthorrst
20hrs of operation.
Thereafter every
3 months or every
50hrs of operation
Every year or every
100hrs of operation.
Engine Oil Check-Rell 9
Replace 9 9
Reduction gear
Oil (if equipped)
Oil Level Check 9
Replace 9 9
Airlterelements Check 9
Clean 9
Replace 9
Deposit Cup (if
equipped)
Clean 9
Spark Plug Check-adjust 9*
Spark arrester Clean 9
Idling (if
equipped)**
Check-adjust 9
Valve clearance** Check-adjust 9
Fuel tank & fuel
lter**
Clean 9
Fuel Line Check Every 2 years (change if necessary)
Cylinder head
,piston
Clean up carbon <225cc, Every 125hrs
≤225cc,Every250hrs
* These items should be replaced if replacement is need.
**Theinstallationandmajorrepairworkshallbecarriedoutbyspecicallytrainedpersonnel.
5.2. If the engine frequently works under high temperature or heavy load, change the oil every 25 hours.
5.3. Iftheengineworksinadustyorotherenvironmentcleantheairlterelementevery10hrs,ifnecessary,changetheairlter.
5.4. Spark plug inspection g.16.
5.4.1. Remove the cap and spark plug cap, insert the tool through the hole from the outside of the cover.
5.4.2. Insert the bar into the tool and turn it anti-clockwise to remove the spark plug.
5.4.3. Check for discolouration and remove the carbon. The porcelain insulator around the centre electrode of
the spark plug should be a medium-to-light tan colour.
5.4.4. Check the spark plug type and gap. adjust as required.
Standard Spark Plug: E6TC/E6RTC.
Spark Plug Gap:0.6-0.7mm
Spark Plug Torque: 20Nm
5.5. Carburettor adjustment
Adjustment should be left to authorized stockist with knowledge, data and equipment.
5.6. Engine oil replacement
Do Not drain the engine oil immediately after stopping the engine, the oil will be hot and should be handled with care.
5.6.1. Place the generator on a level surface and warm up the engine for several minutes. Stop the engine and turn off fuel switch knob.
5.6.2.Removetheoilllercap.
5.6.3. Place an oil pan under the engine. Tilt the generator to drain the oil.
5.6.4. Putthegeneratoronaatsurface.
5.6.5. Add engine oil to the top limit level.
Recommendedengineoil:SAESJ15W-40
Recommended engine oil grade: API Service SE type or higher
Engine oil quantity: 0.35L
5.6.6. Wipe away any spilled oil, be sure no foreign material enters the crankcase
5.6.7. Installtheoilllercap/cover
5.7. Air Filter
5.7.1. Removetheairltercover.
5.7.2. Remove the foam element.
5.7.3. Wash the foam element in solvent and dry it.
5.7.4. Oil the foam element and squeeze out excess oil.
5.7.5. The foam element should be wet but not dripping.
5.7.6. Insertthefoamelementintotheairltercase.
5.7.7. Installtheairltercasecoverinpositionandtightenscrews.
g.16
g.17
GI2300,GI3500|Issue1g119/04/18
Original Language Version
© Jack Sealey Limited
Sealey Group, Kempson Way, Suffolk Business Park, Bury St Edmunds, Suffolk. IP32 7AR
01284 757500 01284 703534 sales@sealey.co.uk www.sealey.co.uk
ENVIRONMENT PROTECTION
Recycle unwanted materials instead of disposing of them as waste. All tools, accessories and packaging should be sorted, taken to
a recycling centre and disposed of in a manner which is compatible with the environment. When the product becomes completely
unserviceable and requires disposal, drain any fluids (if applicable) into approved containers and dispose of the product and fluids
according to local regulations.
WEEE REGULATIONS
Dispose of this product at the end of its working life in compliance with the EU Directive on Waste Electrical and Electronic Equipment
(WEEE). When the product is no longer required, it must be disposed of in an environmentally protective way. Contact your local solid
waste authority for recycling information.
Note: It is our policy to continually improve products and as such we reserve the right to alter data, specifications and component parts without prior
notice.
Important: No Liability is accepted for incorrect use of this product.
Warranty: Guarantee is 12 months from purchase date, proof of which is required for any claim.
5.8. Mufer screen and spark arrester.
WARNING!Theengineandmuferwillbeveryhotaftertheenginehasbeenrun.Avoidtouchingtheengineandmuferwhilethey
are still hot.
5.8.1. Loosen the cover and remove.
5.8.2. Loosentheboltsthenremovethemufercap,themuferscreenandsparkarrester.
5.8.3. Cleanthecarbondepositsonthemuferscreenandsparkarresterusingawirebrush.
Brush gently to avoid damage to the component.
5.8.4. Checkthemuferscreenandsparkarrester.Replaceifdamaged.
5.8.5. Install the spark arrester.
5.8.6. Installthemuferscreenandthemufercap.
5.8.7. Install the cover and tighten the screws.
5.9. Fuel tank lter
5.9.1. Removethetankcapandlter.
5.9.2. Cleanthelterwithpetrol.
5.9.3. Wipethelterandinstallit.
5.9.4. Replace the fuel tank cap. Be sure the fuel tank cap is tightened securely.
5.10. Fuel Filter
5.10.1. Thefuellterislocatedinthefuelpipeleadingfromthefueltanktothecarburettor.
5.10.2. Drain fuel from fuel tank.
5.10.3. Squeezethepipeclampsandremovethelter.
5.10.4. Replacethelter.
5.10.5. Attach the fuel pipes and re-clamp.
5.10.6. Check for any fuel leaks.
6. STORAGE
Long term storage of the generator will require preventive procedures to guard against deterioration.
6.1. Turn the engine switch to “STOP”.
6.2. Removefueltankcapandlter.
6.3. Extractthefuelfromthetankintoanapprovedfuelcontainer.Replacethefuellterandcap.
6.4. Wipe off any spilt fuel.
6.5. Start the engine and leave it to stop. (approx 20 min)
6.6. Drainthefuelfromthecarburettor,byremovingscrewontheoatchamber.Replacescrew.
6.7. Turn the engine switch to “STOP”.
6.8. Remove the spark plug, pour about one table-spoon of SAE 10W-30 into spark plug hole. Using the recoil starter turn over the engine
to coat the cylinder walls with oil.
6.9. Replace spark plug, pull the recoil starter until you feel compression. Then stop pulling. (This prevents the cylinder and valves from
rusting)
6.10. Clean exterior of the generator with a dry cloth. Store the generator in a dry, well-ventilated child proof area.
7. TROUBLESHOOTING
7.1. Fuel System:- Check fuel in tank, vent knob and fuel tap to “ON”
Checkfuellter,carburettor,cleanasrequired.
7.2. OilSystem:-Checkoillevel,llasrequired.
7.3. Electrical system:- Check/Clean spark plug
Faulty ignition system, Consult our authorized stockist.
7.4. No power produced:- Press the DC protector to “ON”
The AC pilot light (green) goes off, Stop the engine and then restart.
GI2300,GI3500Issue2(g1)19/04/18
Original Language Version
© Jack Sealey Limited
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