BOLIY BOLIY POWER GENERATOR SHOP MANUAL DIGITAL GENERATOR Pro3600Si Pro3600SiE (electric start) BOLIY POWER ©2010-2011 www.boliypower.
Preface This manual covers the construction, function and servicing procedure of the BOLIY Pro3600Si/E model generators. This manual is principally concerned with the generator specifications, function, troubleshooting and repair. There is a separate manual to cover engine overhaul which includes the starting systems. Careful observance of the instructions contained in this manual will result in safe and quality service work.
Table of Contents 1. Specifications ..................................................................................................................3 1.1 Specifications.................................................................................................................3 2. Service information ..........................................................................................................6 2.1 The importance of proper service ...........................................................
1.1 SPECIFICATIONS DIMENSIONS & WEIGHT OVERALL LENGTH ( mm / in ) 585 / 23 OVERALL WIDTH ( mm / in ) 420 / 16.5 OVERALL HEIGHT ( mm / in ) 470 /18.5 DRY WEIGHT ( kg / lb. ) 31/ 68 GROSS WEIGHT ( kg / lb. ) 35.5 / 78 FUEL TANK CAPACITY ( L / US gal. ) 7.4 / 1.9 FUEL CONSUMPTION AT RATED OUTPUT 0.55 L/kwh NOISE LEVEL ( at 7m ) 53-58 dB ENGINE TYPE 166F, OHV, AIR-COOLED, 4 * STROKE STARTING SYSTEM RECOIL START CYLINDER ARRANGEMENT INCLINED,SINGLE CYLINDER BORE * STROKE ( mm/in) 66(2.
GENERATOR TYPE AC OUTPUT, Multistage permanent-magnet generator RATED OUTPUT ( WATTS ) 3,000 MAX 3,300 OUTPUT ( WATTS ) FULL TANK OUTPUT ( WATTS ) 13,500 RUN TIME AT 1/2 RATED LOAD 8.3 hours RUN TIME AT RATED LOAD 4.
BOLIY Pro 3600Si & 3600Si/E DSP INVERTER GENERATOR WIRING DIAGRAM Color code B - Black G - Green L - Blue O - Orange R - Red W - White Y - Yellow P - Pink B/W - Black/White G/Y - Green/Yellow W/L - White/Blue 1 - Main coil 2 - Sub coil 3 - Control unit 4 - AC indicator light/ Overload indicator light 5 - AC receptacle 6 - Ground (Earth) terminal 7 - Economy Control Switch 8 - Step Motor controller 9 - Engine switch 10 - Oil warning light 11 - Oil warning unit 12 - Oil level gauge 5 13 - Ignition coil 14
2. Service information 2.1 The importance of proper servicing Proper servicing is essential to the safety of the operator and the reliability of the generator. Any error or oversight made by the technician while servicing can easily result in faulty operation and/or damage to the equipment or injury to the operator. WARNING * Improper servicing can cause an unsafe condition that can lead to serious injury or death. * Follow the procedures and precautions in this shop manual carefully.
2.3 Service rules *Use genuine BOLIY or BOLIY-recommended parts and lubricants or their equivalents. Parts that do not meet BOLIY design specifications may damage the engine. *Use the special tools designed for the product. *Always install new gaskets, O-rings, etc. when reassembling components. *Clean parts in cleaning solvent upon disassembly. Lubricate any sliding surfaces before reassembly. After reassembly, check all parts for proper installation and operation.
*Clamp the wire harnesses securely so that they do not interfere with the rotating parts, moving parts and hot parts. *Route and connect the wire harnesses properly. Be sure that the harnesses are not slack, twisted or pulled overly taut. *Route the wire harnesses properly so that they do not contact sharp edges and corners and the end of the bolts and screws on the body.
2.6 Maintenance standards Engine Part Item Standard(mm) Service limit Cylinder Sleeve I.D. 66.02~66.04 66.15 Piston Skirt O.D 67.97~67.99 66.67 0.040~0.060 0.12 O.D 15.990~16.000 .15.95 Pin-to-piston clearance 0.002~0.018 0.080 Ring width Top 1.420~1.440 1.32 1.420~1.440 1.32 0.02~0.06 0.15 6.006~18.017 16.07 Big end I.D 28.015~28.025 28.07 Big end oil clearance 0.046~0.060 0.12 Crankshaft Crank pin O.D. 27.960~27.975 27.90 Valve Valve clearance Intake 0.1?.
Generator Part Ignition coil Item Ty p e Standard Service 120V Limit R e s i s t a n c e Ye l l o w / G r e e n - R e d 0 . 7 ~ 0 . 8 5 O u t e r c h a r g i n g w i n d i n g c o i l R e s i s t a n c e Ye l l o w - Y e l l o w 0.35~0.45 E C O N feedback w i n d i n g c o i l Resistance White-White 0.2~0.3 Control feedback R e s i s t a n c e Ye l l o w - Y e l l o w 0.4~0.45 Main winding coil Resistance Blue-Blue 10 ~ 0.8~1.
3 MAINTENANCE 3.1 Maintenance schedule Item Attention Spark plug Clean-Adjust Valve clearance Check-Adjust Crankshaft System Each use First month or 20 Hrs. Every 3 months or 50Hrs. Every 6 months or 100 Hrs. Every year or 300 Hrs.
3.2 Engine Oil Check Engine Oil leak Check the engine whether or not have leak oil. If leak replace gasket, or oil seal or O ring. A. Checking Oil Level Engine should be shut off and generator be on level ground when checking the oil level. ON OFF 1. Check engine oil level and oil warning light When start whether or not the light ray. 1 Light ray- add oil No light ray- ok AC a 1 2. Remove the oil dipstick,Add the proper viscosity engine oil to the upper limit if oil level is low.
3.3 Fuel leak 1 Check Check fuel tank, fuel switch,fuel pipe and carburetor. Caution: Every 2 years replace the fuel pipe and fuel filter. 1 Caution: No fire when you clean it. 2 1. Take off hat. 2. get the strainer Check strainer Damage-replace If ok-Clean it. Remark: You'd better use impregnant clean it then for dry.
3 .4 Ai r Fi l te r Ma i n te n a n ce ( 1 ) Op e n th e s e rv i c e d o o r. ( 2 ) Op e n th e c o v e r o f ai r fi l te r a n d ta ke o u t th e fi l te r e l e m e n t. (3) Blow the inner side of filter element using compressed a i r o r li g h tl y kn o ck it to r e mo ve d i rt. If an y d i rt re ma i n s, change the element. Be sure to use a genuine Kipor element to m a i n ta i n a p ro p e r se a l a n d a vo i d e n g i n e d a ma g e .
3 .5 Exh a u st 1. Take off Wire netting, collar clamp,and bolt etc. 2. remove carbon dust. The exhaust as picture method to knock. 3. Clean the wire netting. Waring: Don't use metal silk for clean. That will damage the material.
3.6 Adjusting valve clearance Attention Valve adjustment should only be performed on a cool engine. (1) Remove back case, then take off valve cover. (2) Pull the starter rope gently and set the piston in top dead center (Use a stick in the spark plug hole measure the depth). (3) Insert a feeler gauge into the gap between rocker and valve to measure the valve clearance. Valve Clearance Intake: 0.1mm(0.004 in) Exhaust:. 0.1mm (0.004in) (4) If adjustment is necessary, proceed as follows: a.
3.7 compress pressure Remark: 1 When finish adjust Valve Clearance, then measure the compress pressure. 1. For running few mins. 2. Remove spark plug. 3. Use manometer and adapter for measure. Manometer Adapter Measure: Measure pressure you need pull the starter when the pressure finger stop, read the NO.. The standard:400-600kpa(4-6kg/cm3,57-85 psi ) Waring: When start engine, spark plug need connect for ground, that no spark.
3.8 Rating speed Frist connect the speed meter Accord with standard speed = right If not right please check chapter3. for repair. Check step: 1) Start engine (0% load) ON A 2) Turn to off ECON switch. 3)Measure the speed. OFF B 3800-3950r/min 3.9 Hose 1.Check: Hose Crack/- Replace.
4.0 Spark plug Attention Check the cylinder position should only be performed on a cool engine. When you take off the spark plug must keep no durity into engine. a 1. Take off the spark plug and spark cap. take off the spark plug. 2. Check electrode Bad-replace dielectric- color a b 3. Measure Spark plug clearance Ues thickness tool. No standard- Adjust Spark plug clearance 0.7-0.8mm If need for clean, please use cleaner for clean Standard spark plug BPR4ES(NSK or F7RTC) ON STOP 4.
4.2 ECON switch ON A Check step: When switch "ON" Start engine B When turn to "OFF" Check the engine speed. STOP 4.3 Check electric components ON Start the engine pilot lamp(1) for illume. STOP ON OFF OIL AC 1 ON STOP AC plug.
4.4 Troubleshooting Section 1- Fuel related problems 1. Fuel leak 2. Fuel flow 3. Stepping motor Section 2- Generator won*t start 1. No Start, Cranks, has spark & fuel. 2. Choke pin Section 3- No Start, no spark. 1. No Start, Cranks, has no spark. 2. Low oil switch 3. Ignition winding 4. Ignition coil Section4- No AC Output (Inverter series) 1. No AC 2. No DC Section5- ECON Switch failurel. 1.High Speed, Ingition be disconnected,ECON switch failurel. Section6-The controler box failurel. 1.
Section 11- Fuel Leak For the Pro3600Si/Pro3600SiE, it could be the valve or it could be the tank leaking between the plastic tank. Both are replaceable. Determine which is leaking and either part is replaceable. For all generators, check all fuellines, valve, and carburetor. 2- Fuel Flow. Open the drain screw on the bottom of the carburetor, do you get a steady flow of fuel? If so, there is no blockage. If no fuel flow, blockage may be the case.
Section 21-No Start, Cranks, has spark & fuel. 2- Choke pin. It's possible that the choke pin that fell out. Look under the choke plate for a pin operating the choke mechanism. If not, change the choke plate and thechoke cable. Section 31- No Start, Cranks, has no spark. Do you hear a click when you turn the engine switch to on? If no, the micro switch is not operating properly. It could be a wire stopping it from moving or could be dirty.
Section 41- No AC Output (Inverter series) This could be a loose wire from the inverter to the receptacles. Check to see if the red and black wires are securely plugged in and the wires are securely attached to the receptacles. Check 3pin blue connector. the reading should be 0.8~1ohm. The voltage should be 160~220V. 2- No DC out put Check the Protector switch, Keep the "ON", If ok, please check the DC wire connector. Section51.High Speed, Ignition be disconnected, ECON switch failure.
Section6-The controller box failure. 1.The engine can not change speed. The step motor no control. Method: Adjust controller (120V / 60Hz) W 103 134 T A W 203 128 T A is ECON=OFF adjust knob, when ECON=OFF, the three -phase voltage reading is AC 210V± 5V, in clockwise to increase the voltage, in counter-clockwise to reduce the voltage.
