Sealey DG5000 - User Manual

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5000W 110/230V GENERATOR - 4-STROKE ENGINE

MODEL NO:DG5000

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.

Refer to

instruction

manual

DG5000 Issue:1 28/02/23

Original Language Version

Wear ear

protection

Hot surfaces

No open ame

Warning Warning

Electricity

Inhalation

Risk

Never operate

in non-ventilated

rooms

Keep away

from rain

1. SAFETY

 WARNING! Ensure any Health & Safety, Government, or local authority regulations are adhered to when using this equipment.

9 Familiarise yourself with the application and limitations, as well as the potential hazards, of the generator.

9 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.

9 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! Diesel is flammable. Do not permit smoking, naked flames, sparks or heat in the vicinity while handling Diesel. Avoid spilling

Diesel 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.

9 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).

8 DO NOT tip or change the generator’s position whilst it is operating.

9 Remove ill fitting clothing, ties, watches, rings and other loose jewellery and contain long hair. Wear appropriate protective

clothing.

9 Keep 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.

8 DO NOT use the generator for any purpose other than that for which it is designed.

8 DO NOT operate the generator if any parts are missing or damaged, as this may cause failure and/or personal injury.

8 DO NOT over-fill fuel tank. Always leave room for fuel to expand.

8 DO NOT operate in the rain.

Switch o󰀨 the engine before

refuelling

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This document describes the DG5000, a 5000W 110/230V generator designed for 4-stroke engine operation. It is manufactured by Jack Sealey Limited.

Function Description

The DG5000 is a portable generator designed to provide electrical power for various applications, including home and business use, as well as for powering tools and lighting. It features a 4-stroke engine and is capable of producing both 110V and 230V output. The generator includes a control panel with multiple sockets for connecting devices, an engine stop/run lever, and an emergency stop button for safety. It is equipped with a low oil warning system and an overload protection system to prevent damage to the unit and connected appliances. The generator is designed for ease of use with features like an electric start and a fuel gauge.

Important Technical Specifications

Model No.: DG5000
Continuous Power Rating: 4600W
Maximum Power Rating: 5000W
Dimensions (L x W x H): 940 x 540 x 705mm
Displacement (cc): 418
Fuel Tank: 14.5L
Fuel: Diesel
IP Rating: IP23
Maximum Power Rating: 5000W
Maximum Running Time: 7.5 Hrs
Motor Power: 4.9kW/3000rpm
Motor Type: 4 Stroke Diesel
Noise Rating: 97dB
Output: 110/230V

The generator includes a 12V DC output for charging batteries, with a maximum charging current of 8.3A. It is equipped with circuit breakers for overload protection on both 110V and 230V outputs. The engine is a 4-stroke diesel engine, ensuring efficient fuel consumption.

Usage Features

The DG5000 is designed for straightforward operation. To start the generator, the main AC switch must be in the 'OFF' position, and the engine switch must be in the 'ON' position. The decompression lever should be pulled, and the key turned to the 'START' position. Once the engine starts, the key should be released. For stopping, the engine stop/run lever is used, or the emergency stop button can be pressed.

The control panel features multiple sockets: two 110V 16A sockets, one 110V 32A socket, and one 230V 32A socket. It also includes a voltmeter, frequency meter, and event timer to monitor the generator's performance. The generator is equipped with a fuel gauge to indicate the fuel level. For safety, it has a low oil warning light that illuminates when the oil level is low, and an automatic shutdown feature if the oil level drops too low.

The generator is suitable for powering a range of appliances. For lighting, it can handle incandescent lamps up to 1000 watts or fluorescent lamps up to 80VA. For motor-driven equipment, it can power motors up to 3.5 horsepower or refrigerators up to 150 watts.

Maintenance Features

Regular maintenance is crucial for the longevity and efficient operation of the DG5000. Key maintenance tasks include:

Fuel and Oil Checks: Before each use, check the fuel level and engine oil level. Refill with diesel fuel and engine oil (SAE 15W/40 or SAE 10W/30) as needed. The oil level should be checked using the dipstick, and the fuel level using the fuel gauge.
Air Filter Maintenance: The air filter should be checked regularly and cleaned or replaced if necessary. A dirty air filter can reduce engine performance.
Spark Plug Check: Although this is a diesel engine, the manual refers to spark plug checks for general engine maintenance, which might be a generic instruction. For diesel engines, injector checks are more relevant.
Battery Maintenance: For models with electric start, the battery should be checked regularly for charge and connections. Keep the battery clean and charged to prevent starting issues.
Cooling System: Ensure the cooling fins are clean and free from obstructions to prevent overheating.
General Cleaning: Keep the generator clean, especially the engine and control panel, to prevent dirt and debris from affecting performance.
Scheduled Maintenance: The manual provides a maintenance schedule including daily, first month or 20 hours, every 100 hours, every 250 hours, every 500 hours, and every year or 1000 hours. This schedule covers tasks such as checking and refilling diesel, checking and refilling engine oil, checking for oil leakage, checking and tightening fastening parts, replacing engine oil, cleaning engine oil filter, replacing air filter, replacing fuel filter, checking fuel injection pump, checking injector nozzle, checking fuel pipes, adjusting clearance of intake and exhaust valves, grinding intake/exhaust valves, replacing piston rings, checking battery condition, and checking carbon brushes and slip rings.

The manual also includes a troubleshooting guide to help diagnose and resolve common issues such as the engine not starting, the generator not producing power, and other operational problems. For instance, if the engine does not start, possible causes include insufficient fuel, a faulty fuel injection pump, or a flat battery. If the generator is not producing power, it could be due to the main breaker switch being off, worn brushes, or a faulty AVR.

The DG5000 is designed with access panels for easy maintenance, such as the access to the air filter behind the panel and the access to the oil filler cap and dipstick. The manual emphasizes the importance of using only specified spare parts and fluids for maintenance.