Sealey GG1100 User manual

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.
1. SAFETY INSTRUCTIONS
IMPORTANT: PLEASE READ THESE INSTRUCTIONS CAREFULLY. NOTE THE SAFE OPERATIONAL REQUIREMENTS, WARNINGS AND CAUTIONS.
USE THIS 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. PLEASE KEEP INSTRUCTIONS SAFE FOR FUTURE USE.
INSTRUCTIONS FOR:
PORTABLE GENERATORS
WARNING! Ensure any Health & Safety, Government, or local authority regulations are adhered to when using this equipment.
Familiarise yourself with the application and limitations, as well as the potential hazards, of the generator.
 Maintain 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.
This 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 dealer.
 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! NEVER refuel when the engine is running or when the engine is hot. Allow cool down time.
 Operate 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).
 Remove ill fitting clothing, ties, watches, rings and other loose jewellery and contain long hair. Wear appropriate protective clothing.
 Keep non-essential persons 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.
 DO NOT use the generator for any purpose other than that for which it is designed.
 DO NOT operate the generator if any parts are missing or damaged, as this may cause failure and/or personal injury.
 DO NOT over-fill fuel tank. Always leave room for fuel to expand.
 DO 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.
 DO NOT operate the generator when you are tired, or under the influence of alcohol, drugs or intoxicating medication.
 DO NOT store generator with fuel in tank where petrol vapours might reach an open flame or spark.
MODELS: GG1100 GG2800 GG3800 GG7500
Original Language Version GG1100, GG2800, GG3800, GG7500 Issue: 2 - 12/10/09

3. OPERATING INSTRUCTIONS
 WARNING! Before use, ensure you read, understand and comply with the safety instructions in this document. Ensure
you fully understand the application and limitations, as well as the potential hazards, of the generator.
 WARNING! Never connect the generating set earth lead to pipes. Pipes may carry inflammable substances such as gas or
domestic fuel and there is a risk of fire or explosion in the event of a short circuit.
 WARNING! Never run the engine without an air filter fitted.
3.1. EARTHING
3.1.1 The generating set must be earthed every time it is used, to reduce the chance of electric shock. To do this, use a 12mm² copper
wire and bolt it to the generator chassis using the earthing point seen in Figs.3, 4 & 5. At the other end, bolt it to an earthing rod of
copper or brass which has been driven into the ground. This earthing connection will also dissipate static electricity generated by the
electrical equipment.
PRE START-UP OF THE GENERATOR
 WARNING! Check the engine oil level before each start-up. Only use an approved oil and NEVER operate the engine with insufficient
oil.
 Check the air filter element to ensure it is clean and in good condition, clean or replace as necessary.
3.2. FILLING WITH ENGINE OIL
3.2.1 Ensure the generator set is on a flat horizontal surface.
3.2.2 Unscrew the oil filler cap and wipe the dipstick clean (See Fig.6).
3.2.3 Insert the dipstick into the filler neck but DO NOT screw in.
3.2.4 Remove the dipstick and check the level indicated. If the level is too low, top up to the top of
the filler neck with the recommended oil.
3.2.5 Replace the dipstick and screw in the oil filler cap.
3.3 FILLING WITH FUEL
 WARNING! NEVER refuel when the engine is running or when the engine is hot.
 WARNING! Petrol is highly flammable and petrol vapour is explosive.
 WARNING! Never use an oil/fuel mixture or any polluted fuel.
3.3.1 Ensure all electrical loads are DISCONNECTED and the circuit breaker where fitted is in the "OFF" position.
3.3.2 Ensure the area around the fuel tank filler hole is clean.
3.3.3 Remove the fuel tank filler cap, check the level of the fuel and refill with the recommended fuel if necessary.
3.3.4 Do not over-fill the fuel tank, always leave room for the fuel to expand.
3.4. STARTING THE GENERATOR
 WARNING! The output sockets will be live once the engine has started.
 WARNING! DO NOT run this generator unless there is adequate ventilation, the
exhaust gases contain deadly carbon monoxide.
3.4.1 Ensure you have performed all actions in paragraphs 3.2. and 3.3. above.
3.4.2 Turn the fuel valve to the "ON" position, Fig.1.
3.4.3 Move the choke lever to the CHOKE position, Fig.2.
Note: If starting a warm engine or when the ambient temperature is high, move the choke control
to the "RUN" position.
3.4.4 Set the Engine Switch to the "ON" position, Fig.3.
Note: Ensure there is sufficient free area around the generator to prevent personal injury when
pulling the rope.
3.4.5 Grasp the recoil handle and pull rope slowly until some resistance is felt (Fig.2A). Let rope
rewind slowly, then pull with a rapid full arm stroke. Let rope slowly return.
3.4.6 When engine starts, move choke lever to half choke position until engine runs smoothly and
then to the "RUN" position. If engine fails to start, repeat the procedure from section 3.4.5.
If it still will not start, refer to ’Trouble-Shooting’ section. If necessary contact your authorised
Sealey service agent.
3.4.7 On models fitted with a circuit breaker, set the switch to "ON".
 WARNING! Never pull out the starting handle when the engine is running, as this will damage the engine.
2. INTRODUCTION & SPECIFICATIONS
2.1 Heavy-duty industrial frame design provides full protection and aids portability. Suitable for running power tools and lighting units etc.
Models GG2800, GG3800 & GG7500 are fitted with automatic voltage control which protects the units and provides higher efficiency. Long
running time from 6 hours up to 12 hours on a full tank. Fitted with 12V battery charging outlet, 230V and 110V sockets (110V not available on
GG1100). Powerful and reliable generator fitted with maintenance-free brushless alternator. Smooth running unit fitted with anti-vibration
mountings. Low oil cut-out feature and fuel gauge (not available on GG1100).
Model No: GG1100 GG2800 GG3800 GG7500
Motor Power: 2.4hp 6.5hp 9hp 13hp
Motor Type: 4-Stroke
Fuel: Unleaded 95 RON
Output: 230V - 50Hz/12VDC 230V/110V - 50Hz/12VDC
Current Rating: 4A/8.3A 10.4A/21.8A/8.3A 14A/29A/8.3A 22A/45A/8.3A
Cont Power Rating: 900W 2400W 3200W 5000W
Max Power Rating: 1100W 2800W 3800W 6000W
Fuel Tank Capacity: 6ltr 15ltr 25ltr 25ltr
Max Running Time: 6hrs 10hrs 12hrs 10hrs
Noise Rating LwA: 90dB 90dB 94dB 96dB
Dry Weight: 25kg 46.5kg 82kg 85kg
Dimensions (L x W x H): 479 x 377 x 434mm 623 x 480 x 538mm 713 x 541 x 569mm 713 x 541 x 569mm
Fig.1
Fig.2
Choke Lever
Fig.2A
Original Language Version GG1100, GG2800, GG3800, GG7500 Issue: 2 - 12/10/09

3.5. USING THE GENERATOR
 WARNING! Do not exceed the wattage capacity of the generator.
3.5.1 Allow the engine to warm up (approximately 3 minutes).
3.5.2 Connect the equipment to the appropriate generator socket.
 WARNING! If connecting to a home power circuit, the unit must be
wired in by a qualified electrician. The incorrect installation of this unit may
cause damage to the generator, the appliance and may lead to the risk of
fire and/or personal injury.
3.6. TO STOP THE GENERATOR
3.6.1 Disconnect the electrical load.
3.6.2 Allow the engine to run unloaded for 1 - 2 mins.
3.6.3 Stop engine by moving the engine switch to the "OFF" position, Figs 3 to 5.
3.6.4 Set the circuit breaker to the "OFF" position.
3.6.5 Turn off the fuel valve, Fig.1.
Fig.3
Earth Connection
Fig.6
Fig.5
GG1100
GG3800 & GG7500
4. STORAGE & TRANSPORTATION
4.1 Storing the Generator
4.1.1 Always drain off the fuel from the carburettor and fuel tank when storing
the generator for long periods of time.
4.1.2 Drainandrelltheengineoil,seeSection5.1.
4.1.3 Store in a dry and childproof area.
4.2 Transporting the Generator
4.2.1 Turn the engine switch and the fuel tap to the "OFF" position.
4.2.2 Keep the generator level to avoid fuel spillage and away from sources of
ignition.
4.2.3 Allow the generator to cool before transportation, the engine and exhaust
system can cause serious burns.
Dipstick
Drain Plug
GG2800
Fig.4
Maintenance should be carried out as stated in the maintenance
schedule.
5.1 Changing the Oil
5.1.1 Unscrew the dipstick (Fig.6).
5.1.2 Place a suitable container underneath the drain plug and then
remove the drain plug.
5.1.3 Once the oil has drained replace the drain plug.
5.1.4 Refill with SAE 10W/30 oil.
5.1.5 Replace dipstick.
5.2 Air Filter
5.2.1 Remove screws (GG1100) (Fig.7) or clips on other models and
remove the air filter cover.
5.2.2 Remove the foam element from the air filter assembly (Fig.8).
5.2.3 Wash out the element using paraffin and dry thoroughly.
5.2.4 Dip the element into clean machine oil and remove excess oil.
5.2.5 Ensure air filter housing is clean and replace element and
cover.
Note: Wear suitable protective gloves when handling element during
cleaning and reproofing.
5.3 Spark Plug
5.3.1 Remove the high tension lead from the spark plug.
5.3.2 Using the supplied spark plug wrench remove the spark plug.
5.3.3 Clean spark plug with a wire brush.
5.3.4 Check the electrode gap with a set of feeler gauges, the gap
should be 0.7mm to 0.8mm (Fig.10).
5.3.5 Check the spark plug washer is in good condition and screw
the plug in by hand to avoid cross threading.
5.3.6 Once the spark plug is installed, tighten it using the spark plug
wrench to compress the washer.
Note: In the case of a new spark plug being fitted, screw it in by hand
and tighten it by 1/2 turn with a spark plug wrench to compress
the washer. If the spark plug has already been used, screw it in
by hand and only tighten it by 1/8 to 1/4 turn to compress the
washer.
5.4 Carburettor Float Chamber
5.4.1 Turn off the fuel supply switch.
5.4.2 Using a 10mm spanner remove the bolt underneath the float
chamber (Fig.9) and lower the chamber taking care not to spill
any fuel in the process. Dispose of old fuel in line with local
authority regulations and thoroughly clean the chamber.
5.4.3 Replace the O-ring and refit the float chamber.
5.4.4 Turn on fuel supply and check for leaks.
5. MAINTENANCE
Original Language Version GG1100, GG2800, GG3800, GG7500 Issue: 2 - 12/10/09

6. TROUBLESHOOTING
7. DECLARATION OF CONFORMITY
WARNING! The warnings, cautions and instructions discussed in this manual cannot cover all possible conditions and situations that may
occur. It must be understood that common sense and caution are factors which cannot be built into this product, but must be applied by the
operator.
Maintenance Schedule
Item Daily Check 20hrsorrstmonth 50hrs or every 3 months 100hrs or every 6 months 300hrs or yearly
Check Engine Oil  Check
Replace Engine Oil  Replace  Replace
Check Air Filter  Check
Clean Air Filter  Clean
Spark Plug  Clean  Replace
Carburettor Float Chamber  Clean
0.7 to 0.8mm
Problem Cause Remedy
Engine will not start Insufcientfuel Checkandrellfueltank
Engine switch in "OFF" position Switch to "ON"
Engine oil is low Check and top up oil
Spark plug fouled Clean or replace spark plug
Incorrect starting technique Read section 3.4.5 for correct technique
No power generated Circuit breaker in OFF position Reset to ON
Incorrect voltage selected Set switch to correct voltage (excluding GG1100)
Fig.9
Float
Chamber
Foam
Element
Cover
Screws
Fig.8Fig.7
Fig.10
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 will be required for any claim.
INFORMATION: For a copy of our latest catalogue and promotions call us on 01284 757525 and leave your full name and address, including postcode.
01284 757500
01284 703534
[e-mail]
Sole UK Distributor, Sealey Group,
Kempson Way, Suffolk Business Park,
Bury St. Edmunds, Suffolk,
IP32 7AR
www.sealey.co.uk
Web
email
Original Language Version GG1100, GG2800, GG3800, GG7500 Issue: 2 - 12/10/09