Sealey G2000I.V2 User manual

INSTRUCTIONS FOR
INVERTER GENERATOR 2000W 230V
4-STROKE ENGINE
MODEL NO: G2000I.V2
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! 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 dealer.
▲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. To do so may result in electric
shock.
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 Ifsupplyingelectronicequipment,orinanareawhereelectronicequipmentisbeingused,keepthegeneratorasufcientdistance
away to prevent electrical noise from the engine.
G2000I.V2 | Issue 1 05/09/16
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
Digital inverter technology provides pure sine wave electric power suitable for use with sensitive electrical equipment. Lightweight, easily
liftedandfullyportable.Ecomodesetupallowingthegeneratortorunquieter(60dB@7mtr.),increasefuelefciency(4ltr.fueltankwilllast
6hrs.) and reduce emissions. Features light recoil start, fuel gauge, auto voltage adjuster, low oil alarm and electric circuit protector. Fitted
with two 230 V AC sockets and 12V DC 8.3A port.
3. SPECIFICATION
Model No.................................................................... G2000I
Motor Power..................................................................... 3hp
Motor Type .................................................... 4_StrokePetrol
Fuel........................................................... Unleaded 95 RON
Output ..................................................... 230V-50Hz/12V DC
Current Rating.................................................................8.3A
Continuous Power Rating............................................1600W
Maximum Power Rating ..............................................2000W
Fuel Tank Capacity............................................................ 4ltr
Maximum Running Time....................................................6hr
Noise Rating ..................................................................95dB
Dry Weight .................................................................. 21.5kg
Dimensions (WxDxH)..................................480x285x390mm
4. CONTROL PANEL
1. Oil Warning Light
2. AC Pilot light
3. Overload Indicator Light
4.EconomyControlSwitch
5. Engine Switch
6. Fuel Switch
7. Ground Earth Terminal
8. Choke
9. AC Socket
10. DC Socket
11. DC Protector
5. CONTROLS
5.1. Engine Switch
“STOP” Ignition circuit is switched off. The engine will not run.
“ON” Ignition circuit is switched on. The engine can run.
5.2. Oil Warning Light (Yellow)
If the oil level falls below the lower level, the oil warning light will come on and the engine will stop automatically. The engine will not
 startagainuntiltheoilislledup.
 Iftheenginestallsordoesnotstart,presstheengineswitchto“ON”andthenpulltherecoilstarter,ittheoilwarninglightickers
 forafewseconds,thereisinsufcientoil,addoiltorestart.
5.3. Overload Indicator Light (Red)
The overload indicator light comes on when an overload of a connected electrical device is detected, the inverter control unit
overheats, or the AC output voltage rises. Then, the AC protector will trip, stopping power generation in order to protect the
generator and any connected electrical devices. The AC pilot light (Green) will go off and the overload indicator light (Red) will stay
on, the engine will continue to run. If the overload indicator light comes on and power generation stops, proceed as follows:
5.3.1. Turn off any connected electrical devices and stop the engine.
5.3.2. Reduce the total wattage of connected appliances to the rated output.
5.3.3. Check for blockages in the cooling air inlets and around the control unit and remove.
5.3.4. Restart the engine
Note:-Theoverloadindicatorlightmaycomeonforafewsecondsatrstwhenusingelectricaldevicesthatrequirealargestarting
current, such as a compressor or a submersible pump. This is not a malfunction.
5.4. AC Pilot Light (Green)
The AC Pilot light comes on when the engine starts and power is produced.
5.5. DC Protector
The DC protector turns to “OFF” automatically when an electrical device connected to the generator is operating above the rated
G2000I.V2 | Issue 1 05/09/16
Original Language Version
© Jack Sealey Limited
g.1

G2000I.V2 | Issue 1 05/09/16
Original Language Version
© Jack Sealey Limited
capacity. To switch the generator back on , press the DC protector button to “ON”, Direct current will resume.
 ReducetheloadoftheconnecteddevicebelowthespeciedratingoutputofthegeneratoriftheDCprotectorturnsoffagain,Stop
using the device and contact authorized stockist.
5.6. Economy Control Switch (ECS)
When the ECS switch is “ON” the economy control unit controls the engine speed according to the connected load. The results are
better fuel consumption and less noise.
 WhentheECSswitchis“OFF”theenginerunsattheratedspeed(4500rev/min)regardlessofwhetheraloadisconnectedornot.
Note:- The ECS must be “OFF” when using electrical devices that require a large starting current, such as a compressor or
submersible pump.
5.7. Fuel Tank Cap
Turn the fuel tank cap counter clockwise to remove
 Thefueltankcapisprovidedwithanairventknobtoallowfuelow.Theairventknobmustbeturnedto“ON”Thiswillallowfuelto
 owtothecarburettorandtheenginetorun.Whentheengineisnotinuseturntheairventknobto“OFF”tostopfuelow.
5.8. Ground (Earth) terminal
When the electrical device is earthed, the generator must always be earthed.
6. OPERATION
6.1. Engine Oil
WARNING! The generator has been shipped without engine oil. DO NOTstarttheengineuntilithasbeenlledwithsufcientengine
oil.
 Recommendedengineoil................................................SAESJ15W-40
Recommended engine oil grade................ API Service SE type or higher
Quantity...........................................................................................0.35ltr
6.1.1. Place the generator on a level surface.
6.1.2. Removethescrewsg.2.1andthenremovecoverg.2.2.
6.1.3. Removeoilllercap.
6.1.4. Fillwiththespeciedamountoftherecommendedengineoilreplaceandtightentheoilllercap.
6.1.5. Replace the cover and tighten the screws.
6.2. Fuel
▲Danger: TheFuelishighlyammable.
8DO NOToverllthefueltank,asitmightoverow
when the fuel warms up and expands.
9Use only unleaded petrol. The use of leaded petrol will
cause severe damage to internal engine parts.
WARNING! The generator should be kept in an upright position
when fuel is in the tank.
Recommended Fuel....................................Unleaded Petrol
 FuelTankCapacity.....................................................4.0ltr.
6.2.1. Tolltankremovefueltankcapandpourfuelintothetank
 uptotheredlineinsidethellertubeg.3.
 Maximumfuellevelisshowning.4.
6.3. Starting the Engine
6.3.1. TurntheECSswitch(Bkack)to“OFF”g.5.
6.3.2. Turntheairventknobto“ON”g.6.
g.2
g.3
g.5
g.4
g.6

G2000I.V2 | Issue 1 05/09/16
Original Language Version
© Jack Sealey Limited
6.3.3. TurnthefuelKnobto“ON”g.7.
6.3.4. Turntheengineswitch(Red)to“ON”g.8.
6.3.5. Turnthechokeknobfullyoutg.9.
Note:- The choke is not required to start a warm engine.
Push the choke knob in to the original position.
6.3.6. Graspthecarryinghandlermlytopreventthegeneratorfrom
falling over. Pull slowly on the recoil starter until it is engaged,
 thenpullitbrisklyg.10.
6.3.7. After the engine starts, let the engine warm up until the engine does
not stop when the choke knob is retuned to the original position.
Note:- When starting the engine , with the ECS “ON” and
there is no load on the generator:
In ambient temperature below 0°C the engine will
 runat4500rev/min.for5min.towarmuptheengine.
In ambient temperature below 5°C the engine will
 runat4500rev/min.for3min.towarmuptheengine.
The ECS unit operates normally after the above
time period, while the ECS is “ON”.
6.4. Stopping The Engine
6.4.1. Turn off any electric devices.
6.4.2. TurntheECSto“OFF”g.11.
6.4.3. Disconnectanyelectricaldevicesg.12.
6.4.4. Turn the engine switch (Red) to “Stop”.
6.4.5. Turnthefuelknobto“OFF”g.13.
6.4.6. Turnthefueltankcapairventknobto“OFF”g.14
after the engine has completely cooled down.
6.5. Alternating Current (AC) connection
WARNING! Be sure any electric devices are turned off before
plugging them in.
9Ensure all electrical devices including the cables and plug
connections are in good condition before connecting to the generator.
9Ensure the total load is within the generator rated output.
9Ensure the receptacle load current is within receptacle rated current.
9Ensure the generator is earthed, if the electrical device is earthed.
6.5.1. Start the engine.
6.5.2. Turn the ECS to “ON”.
6.5.3. Plug electrical device into the AC connection socket.
6.5.4. Make sure the AC pilot light is on.
6.5.5. Turn on the electrical device.
6.5.6. If the generator is to be used to supply medical equipment , obtain advice from manufacture / medical professional.
6.5.7. Some electrical appliances have high starting currents and therefore can not be used, even if they lie within the supply ranges of the
generator.
6.6. Battery Charging
6.6.1. General Safety
The generator DC rated voltage is 12V.
Before starting to charge the battery, make sure that the DC protector is turned on.
6.6.2. Start the engine.
6.6.3. Connect the red battery charger lead to the positive (+) battery terminal.
6.6.4. Connect the black battery charger lead to the negative (-) battery terminal.
6.6.5. Turn the ECS to “OFF” to start battery charging.
6.6.6. Charge the battery using the correct procedure laid down by the battery manufacturer’s instructions. Follow the instructions to
 determinetheendofbatterycharging,thismayincludemeasurementsofspecicgravityatregularintervals.DO NOT over charge
battery.
WARNING! “Modern vehicles contain extensive electronic systems. You are required to check with the vehicle Manufacturer, for any
 specicinstructionsregardingtheuseofthistypeofequipmentoneachvehicle.Noliabilitywillbeacceptedfordamage/injury,where
this product is not used in accordance with all instructions.”
6.6.7. 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.7
g.9
g.11
g.8
g.10
g.12
g.14
g.13
Electrical
shock
hazard
Wear eye
protection
Wear protective
gloves
Warning
corrosive
substance
Warning:
explosive
material
Keep away
from sources of
ignition
Use in well
ventilated areas
Keep in dry area
protect from rain

G2000I.V2 | Issue 1 05/09/16
Original Language Version
© Jack Sealey Limited
7. MAINTENANCE
WARNING! Stop the engine before servicing. Put the engine on a level surface and remove spark plug cap.
In order to keep the engine in good working condition, it must be serviced.
Items Frequency Each Time Firstmonthorrst
20hrs of operation
Every 3 months
or every 50hrs of
operation
Every Year or every
100hrs of operation
Engine Oil Check-Rell 9
Replace 9 9
Reduction gear Oil
(if equipped)
Oil Level Check 9
Replace 9 9
Air Filter Element 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/lter Clean 9
Fuel Line Check Every 2 Years (change if necessary)
Cylinder head piston Clean Carbon ** < 225cc Every 125hrs, ≥225cc Every 250hrs.
* These items should be replaced if required.
**The repair work should be carried out by authorized stockists.
If the engine frequently works under high temperature or heavy load, change the oil every 25hrs.
Iftheengineworksinadustyatmospherecleantheairlterelementevery10hrs.Ifnecessarychangetheairlterelementevery25hrs.
7.1. Spark Plug Inspection
7.1.1. Remove cap in outer case and the spark plug cap. Insert spark plug socket through external case
turn counter clockwise to remove spark plug.
7.1.2. 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.
7.1.3. Checkthesparkpluggapg.15.thisshouldbemeasuredwithathicknessgauge.
7.1.4. Install the spark plug.
7.1.5. Install the spark plug cap and the spark plug cover.
Standard Spark Plug................ E6TC/E6RTC
Spark Plug Gap.............................0.6-0.7mm.
Spark Plug Torque...........................20.0 Nm
7.2. Carburettor Adjustment
Adjusting the carburettor should be left to an authorised stockist with the professional knowledge,
specialised data and equipment to adjust to the correct settings.
7.3. Engine Oil Replacement
7.3.1. Place the generator on a level surface and warm up the engine for several minutes.
7.3.2. Switch off engine, switch fuel knob to “OFF” and switch fuel tank cap air vent to “OFF”. Remove
spark plug cap.
7.3.3. Removethetwoscrewsg.16.1inthesidepanelandremovepanelg.16.2.
7.3.4. Removetheoilllercap.
7.3.5. Place an oil pan under the engine. Tilt the generator to drain the oil completely.
7.3.6. Place the generator back on a level surface. DO NOT tilt the generator when adding engine oil. This
 couldresultinoverllinganddamagetotheengine.
7.3.7. Add engine oil to the upper level. (see section 6.1)
7.3.8. Wipe the cover clean and ensure no foreign material enters the crankcase.
7.3.9. Install the cover and tighten the screws.
7.4. Air Filter
7.4.1. Removethetwoscrewsg.16.1andthenremovethecoverg.16.2.
7.4.2. Removethescrewg.16.3andthenremovetheairltercasecoverg.16.4.
7.4.3. Removethefoamelementg.17.5
7.4.4. Wash the foam element in detergent and dry it.
7.4.5. Oil the foam element and squeeze out the excess oil. The foam element should be wet but not dripping.
8DO NOT wring out the foam element when squeezing it, as this could cause it to tear.
7.4.6. Insertthefoamelementintotheairltercase.Installtheairltercasecoverinitsoriginalposition
and tighten the screw. Install the side cover and tighten the screws.
g.16
g.17
g.15

G2000I.V2 | Issue 1 05/09/16
Original Language Version
© Jack Sealey Limited
7.5. Mufer Screen and Spark Arrester
WARNING!Theengineandmuferwillbeveryhotafterthe
engine has been running.
7.5.1. Removethescrewsg.18.1,thenpulloffcoverg.18.2.
7.5.2. Loosentheboltg.19.3andthenremovethemufercapg.19.4,
 themuferscreeng.19.5,andsparkarresterg.20.6.
7.5.3. Cleanthecarbondepositsonthemuferscreenandsparkarrester
 usingawirebrushg.21.Whencleaningusethewirebrushgently
 toavoiddamagingorscratchingofthemuferscreenandspark
arrester.
7.5.4. Checkthemuferscreenandsparkarrester.Replacethemifdamaged.
7.5.5. Installthesparkarrester.Alignthesparkarresterprojectiong.22.7
 withtheholeg.22.8inthemuferpipe.
7.5.6. Installthemuferscreenandthemufercap.
7.5.7. Install the cover and tighten the screws.
7.6. Fuel Tank Filter
WARNING! Neverusepetrolwhilesmokingorinthevicinityofanopename.
7.6.1. Removethefueltankcapandlter.g.23
7.6.2. Cleanthelterwithpetrolinawashtank.
7.6.3. Wipethelterandinstallit.
7.6.4. Install the fuel tank cap. Be sure the fuel tank cap is tightened securely.
7.7. Fuel Filter
7.7.1. Removethescrewsg.24.1andthenremovecoverg.24.2and
 drainthefuelg.25.3.
7.7.2. Holdandmoveuptheclampg.25.4andthetakeoffthehoseg.25.5
from the tank
7.7.3. Takeoutthefuellterg.26.6.
7.7.4. Cleanthelterwithpetrol.
7.7.5. Drythelterandputitbackintotank.
7.7.6. Install the hose and clamp, then open the fuel valve to check
if it is leaking.
7.7.7. Install the cover and tighten the screws.
8. STORAGE
8.1. Drain the Fuel
8.1.1. Turn the engine switch to “STOP”
8.1.2. Removethefueltankcapandlter.Extractthefuelfromthefueltankintoanapprovedfuelcontainer.Replacefueltankcap.
8.1.3. Start the engine and leave it to run out of fuel. Approx 20min.
8.1.4. Removethescrewsandcoverg.24.
8.1.5. Drainthefuelfromthecarburettorbylooseningthedrainscrewonthecarburettoroatchamber.
g.19
g.18
g.21
g.22
g.23
g.20
g.25
g.24
g.26

8.1.6. Turn the engine switch to “STOP”
8.1.7. Tighten the drain screw.
8.1.8. Install the cover and tighten the screws.
8.1.9. Turn the fuel tank cap air vent knob to “OFF” after the engine has completely cooled down.
8.2. Engine
Perform the following steps to protect the cylinder, piston ring, etc. from corrosion.
8.2.1. Remove the spark plug and pour about one table spoon of clean engine oil into the spark plug hole and replace spark plug. Pull start
cord to turn over the engine several times to coat the cylinder walls with oil.
8.2.2. Pull the recoil starter until you feel compression. Then stop pulling (this stops the cylinder and valves from rusting.
8.2.3. Clean exterior of the generator. Store the generator in a dry, well ventilated place , with a cover paced over it.
9. TROUBLESHOOTING
9.1. Engine will not Start
9.1.1. No fuel supplied to combustion chamber.
No fuel in tank................Supply fuel.
Fuel in tank.....................Turn fuel air vent and fuel knob to “ON”.
 Cloggedfuellter............Cleanfuellter.
Clogged carburettor.........Clean Carburettor.
9.1.2. Engineoilsysteminsufcient.
Oil level is low..................Add engine oil.
9.1.3. Electrical Systems
Poor spark. Spark plug dirty or wet.........Remove spark plug and clean/dry
Faulty Ignition system..........Consult authorised stockist.
9.1.4. Generator will not produce power
Press the DC protector to “ON”
The AC pilot light (Green) goes off.......Stop the engine and restart.
Parts support is available for this product. To obtain a parts listing and/or diagram,
please log on to www.sealey.co.uk, email [e-mail] or telephone [phone].
NOTE: It is our policy to continually improve products and as such we reserve the right to alter data, specications 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 will be required for any claim.
Sole UK Distributor, Sealey Group.
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk.
IP32 7AR
www.sealey.co.uk
[e-mail]
01284757500
01284703534
G2000I.V2 | Issue 1 05/09/16
Original Language Version
© Jack Sealey Limited
Environmental 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 off any fluids (if applicable)
into approved containers and dispose of the product and the 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.