Sealey HG50.25.V2 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 GENERATOR
Models:
HG50.25.V2, HG55.28.V2, HG65.30, HG90.44, HG130.74.V2. - 3 - 030502
SPECIFICATIONS
Model No. HG50.25.V2 HG55.28.V2 HG65.30 HG90.44 HG130.74.V2
Power Unit: 5.0hp 5.5hp 6.5 9.0hp 13hp
Motor Type Honda GC160 Honda GX160 Honda GX200 Honda GX270 Honda GX390
Output: 230V/110V 50hz 230V/110V 50hz 230V/110V 50hz 230V/110V 50hz 230V/110V 50hz
Current Rating: 9.1A/19.0A 9.6A/20.0A 13.0A/27.3A 17.4A/36.4A 26.0A/54.5A
Continuous Power Rating: 2100W 2200W 3000W 4000W 6000W
Fuel Tank Capacity: 2.0l 3.6l 4.3l 6.0l 6.5l
Running time: 2.2h 3.1h 3.2h 3.2h 2.7h
Noise Rating: 98LWA 95LWA 98LWA 96LWA 99LWA
Dry Weight: 30kg 38kg 41kg 56kg 75kg
2. INTRODUCTION & SPECIFICATIONS
2.1 These generators are powered by Honda OHC GC and OHV GX engines. The units offer a quiet and refined power delivery. In models
HG50.25 and HG55.28 the power units are coupled to dual voltage brushless alternators. Models HG65.30, HG90.44 and HG130.74 power
industrial quality alternators and are for industrial or arduous applications.
pWARNING! Ensure any Health & Safety, Government, or local authority regulations are adhered to when using this equipment.
3Familiarise yourself with the application and limitations, as well as the potential hazards, of the generator.
3Maintain 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.
3This 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.
pWARNING! 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). In most cases the rated wattage of an electrical
device can be found on the nameplate. If the nameplate only gives voltage and amperage, multiply the two to give rated wattage (Volts x
Amps = Watts)
p p
WARNING! Generator exhaust gases contain deadly carbon monoxide which must not be inhaled. Always allow sufficient ventilation.
p p
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.
s
s
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.
s s
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.
s s
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.
p p
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.
p p
WARNING! NEVER refuel when the engine is running or when the engine is hot. Allow cool down time.
3Operate 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).
3Remove ill fitting clothing, ties, watches, rings and other loose jewellery and contain long hair. Wear appropriate protective clothing.
3Keep non-essential persons away from the working area.
p p
WARNING! Never start or stop the generator while electrical loads are connected and switched on. 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.
p p
WARNING! Do not use worn, bare, frayed or otherwise damaged electrical cables with the generator. To do so may result in electric shock.
7DO NOT use the generator for any purpose other than that for which it is designed.
7DO NOT operate the generator if any parts are missing or damaged, as this may cause failure and/or personal injury.
7DO NOT over-fill fuel tank. Always leave room for fuel to expand.
7DO NOT operate in the rain.
s s
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.
7DO NOT operate the generator when you are tired, under the influence of alcohol, drugs or intoxicating medication.
7DO NOT store generator with fuel in tank where petrol vapours might reach an open flame or spark.
HG50.25.V2, HG55.28.V2,HG65.30,HG90.44 & HG130.74.V2

3. OPERATING INSTRUCTIONS
p p
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.
p p
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.
p p
WARNING! Never run the engine without an air filter fitted.
p p
WARNING! If the generator is being used after storage of more than 30 days, remove the desicant bags from the alternator
and the plastic tape from the air inlet and outlet ports - see paragraph 5.7.
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. 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
p p
WARNING! Check the engine oil level before each start-up. Only use an approved oil and NEVER operate the engine with insufficient oil.
3 Check the air filter elements to ensure they are clean and in good condition, clean or replace as necessary.
3.2. FILING WITH ENGINE OIL
3.2.1. Ensure the generator set is on a flat horizontal surface strong enough to prevent it from sinking.
3.2.2. Unscrew the oil filler cap and wipe the dipstick clean.
3.2.3. Insert the dipstick into the filler neck but DO NOT screw it 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.
Note: OIL WARNING SYSTEM The oil warning system is designed to prevent any damage to the engine as a result of insufficient oil in the
lower sump. Before the oil level in the lower sump can fall below the safety limit, the oil warning system will automatically stop the
engine (the engine ON/OFF switch will remain in the ON position).
3.3. FILING WITH FUEL
p
p
WARNING! NEVER refuel when the engine is running or when the engine is hot. Allow cool down time.
p p
WARNING! Petrol is highly flammable and petrol vapour is explosive.
p p
WARNING! Never use an oil/fuel mixture or any polluted fuel. Fuel substitutes are not recommended.
3.3.1. Ensure all electrical loads are disconnected.
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
p p
WARNING! The output sockets will be live once the engine has started.
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.2. Not fitted to HG50.25.V2.
Note: If starting a warm engine or when the ambient temperature is high, move the choke control to the OPEN position.
3.4.3. Close the choke, figs.1 & 2.
3.4.4. Set the Engine Switch to the 1 position, figs.1 & 3.
Note: Ensure there is sufficient free area behind to prevent peronal injury when pulling the rope.
3.4.5. Grasp the recoil handle and pull rope slowly until some resistance is felt. 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 OPEN position.
3.4.7. If engine fails to start, repeat the procedure from paragraph 3.4.5. If it still will not start, refer to Trouble-Shooting section. If necessary
contact your authorised Sealey service agent.
3.5. USING THE GENERATOR
p p
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. Select the required voltage output by positioning the voltage selector switch accordingly.
3.5.3. Connect the equipment to the generator socket.
3.5.4. Always observe the safety instructions of the equipment being used.
3.5.5. Carry out the following checks whilst the generator is in use:
Is there any vibration or abnormal noise?
Is there any backfiring or is the engine not running smoothly?
What colour is the exhaust gas? (Is it black or too white.)
3.5.6. If you notice any of the above points stop the generator (paragraph 3.6) and contact your local servicing agent.
HG50.25.V2, HG55.28.V2, HG65.30, HG90.44, HG130.74.V2. - 3 - 030502
Fig.1. Fig.2.
HG50.25.V2, HG55.28.V2, HG65.30, HG90.44, & HG130.74.V2.
Fig.3.
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 0 position, figs 1 & 3.
3.6.4. Turn off the fuel valve, fig .2. Not fitted to HG50.25.V2.
CLOSED
ENGINE
SWITCH
CHOKE
ROD
ON
FUEL VALVE
CHOKE LEVER
OPEN
ON
CLOSE
OFF ON
0 1
ENGINE
SWITCH
STARTER
GRIP
OFF

4.2. CHANGING THE ENGINE OIL - Fig.4.
p p
WARNING! Exposing the skin for long periods and repeatedly to used engine oil can
cause cancer. It is obvious that the risk is relatively low unless oil is handled every day
and for a long period of time. However, it is recommended to carefully wash hands
immediately after handling dirty oil.
4.2.1. Drain the engine oil when the engine is warm to ensure a quick and complete drainage.
4.2.2. Place a suitable container below the tranmission, remove the oil filler cap, the oil drain plug
and let the oil drain completely.
4.2.3. Refit the oil drain plug and tighten fully.
4.2.4. Fill the sump with new approved oil, through the filler hole, up to the dipstick upper level.
4.2.5. Refit the oil filler cap.
Note: 1 Service more often if used in dusty environments.
2 These services must be carried out by an authorised Servicing Agent.
Model Nos: HG55.28.V2, HG65.30, HG90.44 & HG130.74.V2 - Fig.6.
p p
WARNING! Never use fuel or solvent to clean the foam element. This can cause a fire or
an explosion.
4.3.5. Unscrew the wing nut and remove the air filter cover.
4.3.6. Unscrew the second wing nut, lift off the two elements and separate them.
4.3.7. Carefully check both elements for tears or holes and replace if damaged.
4.3.8. Lightly tap the paper element several times on a hard surface to remove the dirt, or clean it
using compressed air blowing from the inside to the outside of the paper filter. Replace the
paper element if it is very dirty.
Note: Never attempt to remove dirt with a brush as brushing could imbed the dirt into the fibres.
4.3.9. Wash the foam element in household detergent diluted in warm water, rinse with plenty of
water and dry thoroughly.
4.3.10. Dip the foam element into some clean engine oil and press out to remove any excess oil.
Note: The engine will start smoking during the first start up if too much oil is left on the foam.
4.3.11. The refitting procedure is the reverse of the above.
4.3. MAINTAINING THE AIR FILTER
Note: If the air filter is dirty, air passing towards the carburettor will be restricted. To avoid the
carburettor from malfunctioning, clean the air filter regularly. Clean more often when the
engine is used in extremely dusty places.
Model No: HG50.25.V2 - Fig.5.
4.3.1. Press the latch tabs on the fuel tank side of the air cleaner cover and remove the air cleaner cover.
4.3.2 Remove the air filter element, carefully check for holes or tears and replace if damaged.
4.3.3. Lightly tap the paper element several times on a hard surface to remove the dirt, or clean it using
compressed air blowing from the inside to the outside of the paper filter. Replace the paper
element if it is very dirty.
Note: Never attempt to remove dirt with a brush as brushing could imbed the dirt into the fibres.
4.3.4. The refitting procedure is the reverse of the above.
4.4. CLEANING THE SEDIMENT CUP - Fig.7. (Not fitted on Model No. HG50.25.V2.)
4.4.1. Close the fuel valve, fig.2.
4.4.2. Remove the sediment cup and the O ring by unscrewing the bolt at the bottom of the cup.
4.4.3. Wash the sediment cup and O ring with a non flammable high flash point solvent.
4.4.4. Dry thoroughly and refit ensuring the bolt is fully tightened.
4.4.5. Open the fuel valve and check for leaks.
HG50.25.V2, HG55.28.V2, HG65.30, HG90.44, HG130.74.V2. - 3 - 030502
4. MAINTENANCE
4.1.GENERAL MAINTENANCE SCHEDULE
p p
WARNING! All maintenance work is carried out when the engine is stopped. If the engine must run, ensure that the working area is
well ventilated. Exhaust gases contain carbon monoxide; exposure to this toxic gas can cause loss of consciousness and can be fatal.
p p
WARNING! If the engine has just been running, the muffler will be very hot, take care not to touch it.
3Ensure the spark plug HT lead has been disconnected prior to commencing maintenance.
3The oil, air filter and spark plug must be changed regularly. All other maintenance must be carried out by qualified staff, contact your
local Sealey service agent.
Maintenance period First month Every 3 months Every 6 months Every year
or every 20 hours or 50 hours or 100 hours or 300 hours
Operations to be performed
at whichever comes first (months or hours)
Drain and renew the engine oil 
Clean the air filter (1)
Clean the carburettor sediment cup 
Clean and check the spark plug 
Check and adjust the valve clearance (2)
Clean the fuel tank (2)
Check or replace the fuel line Every 2 years
Clean the generating set 
Fig.4.
Fig.5.
Fig.6.
Fig.7.
OIL FILLER CAP
DRAIN PLUG
AIR CLEANER COVER
ELEMENT
AIR FILTER
COVER
WING NUT
PAPER ELEMENT
FOAM ELEMENT
SEDIMENT CUP
O-RING

4.6. CLEANING THE GENERATING SET
4.6.1 Clean the generating set using a brush and cloth (water jet cleaning is not recommended). Remove dust and debris around the
exhaust muffler and the cooling fins.
4.6.2. Clean the engine and alternator air inlets and outlets. Make the most of this cleaning by checking the general condition of the
generating set and change any defective or worn parts.
4.5. MAINTAINING THE SPARK PLUG
p p
WARNING! If the engine has just been running, the muffler will be very hot, take care not to touch it.
p p
WARNING! The spark plug must be correctly tightened. If the plug is not well tightened, it can overheat and damage the engine.
Note: To ensure that the engine performs correctly, the spark plug must not have any deposits on it and its gap must be correct.
4.5.1. Remove the spark plug cap and the spark plug using a spark plug wrench.
4.5.2. Inspect the spark plug and discard it if the electrodes are worn or if the porcelain is cracked or scaled. If the spark plug is to be re-
used, clean with a wire brush.
4.5.3. Measure the electrodes gap using a feeler gauge. The gap must be between 0.7mm and 0.8mm. Adjustment of the gap can be
achieved by bending the side electrode.
4.5.4. Check the spark plug washer is in good condition and screw the plug in by hand to avoid cross threading the threads.
4.5.5. Once the spark plug is installed, tighten it using a 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.
HG50.25.V2, HG55.28.V2, HG65.30, HG90.44, HG130.74.V2. - 3 - 030502
5. STORAGE OF MORE THAN 30 DAYS
Note: If you store the generator for more than 30 days it is essential to protect the fuel system. This can be done by either draining all the
fuel or using a fuel additive such as STA-BIL¨, Fuel Fresh¨, or equivalent to prevent fuel gum deposits from forming.
Note: Store the generator in a safe, dry, childproof area, free of excessive humidity and dust.
p p
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.
5.1. CLEAN
5.1.1. Remove debris and dust accumulations from the generating set surfaces.
5.2. DRAINING ALL THE FUEL - HG50.25.V2.
5.2.1. Siphon the fuel from the fuel tank into an approved container.
5.2.2. Loosen the carburetor drain screw and drain the carburetor, fig.8.
5.2.3 Re-tighten the carburetor drain screw.
5.3. DRAINING ALL THE FUEL -HG55.28.V2, HG65.30, HG90.44, HG130.74.V2.
5.3.1. Turn the fuel valve OFF, fig.2, remove and empty the sediment cup, fig.9 (for removal instructions see paragraph 4.4).
5.3.2. Turn the fuel valve ON and drain the fuel into an approved container, fig. 9.
5.3.3. Refit the sediment cup (see paragraph 4.4. for fitting instructions).
5.3.4. Remove the carburetor drain screw, fig.9. and drain the fuel into an approved container.
5.3.5. Refit the carburetor drain screw.
5.4. USING A FUEL ADDITIVE
5.4.1. Fill the fuel tank with fresh fuel.
Note: If only partially filled, air in the tank will promote fuel deterioration during storage.
5.4.2. Add the fuel stabilizer following the manufacturers instructions.
5.4.3. Run the engine outdoors for ten minutes to ensure that all untreated fuel has been used.
5.4.4. Stop the engine and move the fuel valve to the OFF position (not fitted to HG.50.V2).
5.5. CHANGE THE ENGINE OIL
5.5.1 To change the engine oil, refer to the instructions in paragraph 4.2.
5.6. BORE LUBRICATION
5.6.1 Remove the spark plug and pour approximately one tablespoon of clean engine oil into the cylinder.
5.6.2. Crank the engine several times in order to circulate the the oil into the cylinder, then refit the spark plug.
5.6.3. Slowly pull the recoil starter cord until some resistance is felt, then keep pulling until the arrow on the starter pulley aligns with the hole
on the recoil starter.
5.7. ALTERNATOR PROTECTION
5.7.1. Remove the alternator end cover and put descicant bags inside the alternator.
5.7.2. Refit the alternator end cover.
5.7.3. Cover the alternator air inlets and oulets with plastic adhesive tape.
Fig. 8 Fig. 9
CARBURETOR DRAIN SCREW SEDIMENT CUP
DRAIN SCREW

Declaration of Conformity We, the sole importer into the UK, declare that the products listed here
are in conformity with the following standards and directives.
The construction files for these products are held by the Manufacturer and may be inspected, by a national authority,
upon request to Jack Sealey Ltd.
For Jack Sealey Ltd. Sole importer into the UK of Sealey Power Products.
3rd May 2002
PORTABLE GENERATORS
Models: HG50.25.V2, HG55.28.V2, HG65.30,
HG90.44, HG130.74.V2
98/37/EC Machinery Directive
73/23/EEC Low Voltage Directive
89/336/EEC EMC Directive
BS EN60335 - 1:1995 + Amendments.
Signed by Mark Sweetman
Sole UK Distributor,
Sealey Group,
Bury St. Edmunds, Suffolk. 01284 757500 E-mail: [e-mail]
01284 703534
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 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.
6. TROUBLESHOOTING
PROBLEM CAUSE ACTION
Engine will not start. Fuel tap not turned on. Turn fuel on.
No fuel in tank. Fill fuel tank.
Oil not filled to correct level. Fill oil to correct to level.
Engine run switch not turned on. Set engine control correctly.
Choke not set correctly. Set engine control correctly.
Spark plug fouled. Clean/replace spark plug.
Air cleaner blocked. Clean/replace air filter.
Engine runs rough. Air cleaner blocked. Clean/replace air filter.
Spark plug fouled. Clean/replace spark plug.
Choke set incorrectly. Set engine control correctly.
Dirty/stale fuel. Drain and replace fuel.
No electrical output. Voltage selector switch
incorrectly positioned. Select the correct voltage.
Circuit breaker tripped. Re-set circuit breaker.
Rated CABLE LENGTH
Current (A) 0 - 50 metres 51 - 100 metres 101 - 150 metres
6 1.50mm² 1.50mm² 2.50mm²
8 1.50mm² 2.50mm² 4.00mm²
10 2.50mm² 4.00mm² 6.00mm²
12 2.50mm² 6.00mm² 10.00mm²
16 2.50mm² 10.00mm² 10.00mm²
18 4.00mm² 10.00mm² 10.00mm²
24 4.00mm² 10.00mm² 16.00mm²
26 6.00mm² 16.00mm² 16.00mm²
28 6.00mm² 16.00mm² 16.00mm²
7. CABLE SIZES TO BE USED
8. PARTS LIST
Model No Engine Oil Spark Plug Air Filter Recoil Wheel Kit
(Paper Element) (Optional Extra)
HG50.25.V2 10W-30 9807956846 17211ZL8505 28400ZL8003ZB
HG55.28.V2 15W-40 9807956846 17210ZE1505 28400ZH8013ZA Gen Kit 1
HG65.30 15W-40 9807956846 17210ZE1505 28400ZH8013ZA Gen Kit 1
HG90.44 15W-40 9807956846 17210ZE2505 28400ZE2W01ZA Gen Kit 2
HG130.74.V2 15W-40 9807956846 17210ZE3505 28400ZE3W01ZA Gen Kit 2
HG50.25.V2, HG55.28.V2, HG65.30, HG90.44, HG130.74.V2. - 3 - 030502