BOLIY PRO3600SIE User Manual Download

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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.

All information, illustrations, directions and specifications included in this publication

are based on the latest product information available at the time of approval for

printing.

BOLIY POWER, reserves the right to make changes without incurring any obligation

whatever. No part of this publication may be reproduced without written permission.

Summary of Contents for PRO3600SIE

Page 1: ...DIGITAL GENERATOR BOLIY BOLIY POWER Pro3600Si GENERATOR SHOP MANUAL BOLIY POWER 2010 2011 www boliypower com Pro3600SiE electric start ...

Page 2: ...ch includes the starting systems Careful observance of the instructions contained in this manual will result in safe and quality service work All information illustrations directions and specifications included in this publication are based on the latest product information available at the time of approval for printing BOLIY POWER reserves the right to make changes without incurring any obligatio...

Page 3: ...gular inspection schedule 11 3 2 Engine oil 12 3 3 Fule leak 13 3 4 Air filter maintenance 14 3 5 Exhuast 15 3 6 Adjusting of valve clearance 16 3 7 Compress pressure 17 3 8 Rating speed 18 4 0 Spark plug 19 4 1 Check engine switch 19 4 2 ECON switch 20 4 3 Check electric components 20 4 4 Troubleshooting 21 Section 1 Fuel related problems 22 Section 2 Generator won t start 23 Section 3 No Start n...

Page 4: ...NSUMPTION 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 6 50 1 97 IGNITION SYSTEM CDI SPARK PLUG TYPE BPR4ES NGK F7RTC GAP mm in 0 7 0 8 0 028 0 031 DISPLACEMENT cc 171CC RATED OUTPUT KW HP r min 3 6 4 9 3 600 FUEL UNLEADED GASOLINE ENGINE OIL QUANTITY ...

Page 5: ...N RATE 85 92 RATED VOLTAGE V 120 230 RATED CURRENT A 25 13 DC OUTPUT 12V 8 A YES CHARACTERISTIC AUTOMATIC RELEASE PRESSURE YES ELECTRO BREAKER YES FUEL LEVEL GAUGE YES ENGINE Oil WARNING LIGHT YES OVERLOAD INDICATOR LIGHT NO AC INDICATOR LIGHT YES ENERGY CONSERVATION CURRENT IDLING YES INSULATION CLASS E THE FLUCTUATION OF VOLTAGE FREQUENCY INSTANTANEOUS 25 STABLE STATE 2 STABLE TIME second 3 sec ...

Page 6: ...ght 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 13 Ignition coil 14 Spark plug 15 AC CDI unit 16 Pulsar coil 17 Stepping motor 18 Charge coil 19 DC receptacle 20 Ballast BOLIY Pro 3600Si 3600Si E DSP INVERTER GENERATOR WIRING DIAGRAM ...

Page 7: ...actices and that you are wearing appropriate clothing and safety equipment When performing maintenance or repairs be especially careful of the following Read the instructions before you begin and be sure you have the tools and skills required to perform the tasks safely Be sure that the engine is off before you begin any maintenance or repairs This will reduce the possibility of several hazards Ca...

Page 8: ...teners The use of incorrect tools and fasteners will damage the engine 2 4 Electrical precautions Hold the connector body to disconnect the connector Do not disconnect by pulling the wire harness To disconnect the locking connector be sure to unlock first and then disconnect Check the connector terminals for bend excessive extrusion missing terminals or other abnormalities before connecting the co...

Page 9: ...ss has a grommet set the grommet securely Take care not to pinch the wire harnesses during installation of a part If a wire harness has damaged insulation repair by winding with electrical insulating tape When using an electrical tester like a volt ohm meter or clamp on meter read the manufacturer抯 operating instructions carefully before operating the tester Be sure that the tester battery is full...

Page 10: ...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 2 Exhaust 0 15 2 Stem OD Intake 5 46 5 48 5 35 Exhaust 5 45 5 47 5 35 Vessel I D Intake Exhaust 5 500 5 518 5 56 Clearance of valve and vessel Intake 0 020 0 058 0 1 Valve spring Free Length Intake Exhaust 26 8 25 5 Camshaft O D 14 966 14 984 14 92 Crankcase cover Camshaft Bea...

Page 11: ... 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 3 5 0 4 5 E C O N feedback w i n d i n g c o i l R e s i s t a n c e W h i t e W h i t e 0 2 0 3 C o n t r o l f e e d b a c k R e s i s t a n c e Ye l l o w Y e l l o w 0 4 0 4 5 M a i n w i n d i n g c o i l R e s i s t a n c e B l u e B l u e 0 8 1 0 10 ...

Page 12: ...0 Hrs Spark Clean Adjust plug Valve Check Adjust clearance Crankshaft Check System Idile Check Ajust Speed Exhaust Check Replace System Engine oil Check Replace Air cleaner Check Replace Fuel clearner Check Fuel pipe Check Replace Chock Check Cooling Check System Start Check system Clean Clean engine carbon Generator Check light Assembly Check Part 11 ...

Page 13: ...move the oil dipstick Add the proper viscosity engine oil to the upper limit if oil level is low Be careful to over fill B Changing engine oil 1 Remove the bottom oil screw and unscrew oil drain plug to drain used oil 2 Replace the drain plug and secure tightly 3 Add the proper viscosity oil to the upper oil limit level 4 Reinstall the dipstick and screw it tightly 17Nm 1 7 m kg 12 ft ib Enginine ...

Page 14: ...pipe and carburetor Caution Every 2 years replace the fuel pipe and fuel filter Caution No fire when you clean it 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 13 1 2 ...

Page 15: ...lter element 3 Blow the inner side of filter element using compressed air or lightly knock it to remove dirt If any dirt remains change the element Be sure to use a genuine Kipor element to maintain a proper seal and avoid engine damage 4 Reinstall the filter element and close the service door 14 O il ...

Page 16: ...ust 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 15 ...

Page 17: ...h 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 Hold rocker axis using the wrench and loosen the lock nut b Loosen the lock nut of rocker axis to gain the specified intake and exhaust valve clearance c Hold rocker axis using a wrench and tight...

Page 18: ...4 6kg cm3 57 85 psi Waring When start engine spark plug need connect for ground that no spark Measure step At lowest level dripping little engine oil for cylinder then mesure the compress pressure Reading Estimate Low than no oil Cylinder piston or piston rings are wear and tear The same with no oil Piston piston rings valve Cylinder gasket fail Or need adjust valve clearance Measure step At high ...

Page 19: ...r Accord with standard speed right If not right please check chapter3 for repair Check step 1 Start engine 0 load 2 Turn to off ECON switch 3 Measure the speed 3800 3950r min 3 9 Hose 1 Check Hose Crack Replace No good connect Adjust 18 A B ON OFF ...

Page 20: ...lug and spark cap take off the spark plug 2 Check electrode Bad replace dielectric color 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 4 1 Check engine switch Turn to witch for ON If start that s ok Turn off the engine stop ok 19 a a b ON STOP ...

Page 21: ...ep When switch ON Start engine When turn to OFF Check the engine speed Start the engine pilot lamp 1 for illume AC plug If bad replace 4 3 Check electric components 20 A B ON STOP STOP ON OFF ON AC OIL STOP ON OFF ON AC OIL 1 ...

Page 22: ...oke 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 The engine can not chang speed The the step motor no control 21 ...

Page 23: ... flow freely thru the carb This is a very simple process However it may be easier to remove the carburetor first Be careful to not damage the gasket Clean the parts and replace them and try again to see if the unit will run properly It could also be a plugged fuel filter For the generator you have to take the fuel valve off and it should come out attached to the valve 3 Stepping Motor Electric Thr...

Page 24: ...ming on and the unit will not start The oil switch might be stuck 1 Check the oil level 2 Unplug the oil switch and run the engine for 2 minutes 3 Reconnect the oil switch with the engine running 4 Check for a damaged wire shorting to ground 3 Ignition Windings It could be the ignition system Remove the control panel you will see 4 pin connector Yellow Green Red 0 7 0 85Ω 5 Ignition Coil To check ...

Page 25: ...please check the DC wire connector Section5 1 High Speed Ignition be disconnected ECON switch failure Open the control panel Check ECON switch connector whether or not ok 1 White wire 2 Green wire 3 Yellow wire In the control panel Check 2 pin connector Red wire The reading should be 0 8 1 0 ohm the rated voltage 170V 230V Check feedback signal 4 pin connector From generator fan out 1 2 White wire...

Page 26: ...g method When the generator is with 100 load please take the ECON ON as the base normal three phase voltage 150V 155V and then swift to ECON OFF if the three phase voltage is not in the range of 150V 155V please turn the knob in clockwise to increase the voltage or turn the A knob in counter clockwise to reduce the voltage In one word in the normal condition do not need adjust the knob A A A A 2 H...

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