BOSS Generator DY8500

(1) Loosen the butterfly nut, take the cover of the air filter off and take the air filter out.

Do not use detergent to wash the air filter. When the performance of the engine decreases or when the color of the exhaust gases is bad, exchange the filter. Never start the engine without air filter as foreign objects may enter the intake and damage the engine.

(2) After replacing the air filter, replace the cover and tighten the butterfly nut firmly.

Before starting the generator, make sure the air switch is in the “off” position. Starting the generator with the switch in the “on” position is very dangerous. The generator should be grounded in order to prevent electric shock.

Use dry compressed air (with pressure about 1.96 x 105 Pa) to blow the dust out in the electric control cabinet and at the surface of the generator. Check to see how clean the surface of the sliding ring is. Check the pressure of the carbon brush. Also, check whether the position of the carbon brush at the slide rig is correct and the fixture is reliable with a good contact.

According to the electric wiring diagram, check to see whether the connecting wire is correct and the connection is firm. Use a 500MΩ meter to measure the insulation resistance of the electrical part.; The resistance should be less than 2MΩ. When measuring devices, make sure the capacitor is turned off. Otherwise, it will burn the capacitor. (For silent set, the inspection may not be carried out).

2-3.1 Low-pressure alarm system. The diesel engines have a low-pressure sensor system where if the oil pressure drops too low, the sensor will shut the engine off. The purpose of having this system is to ensure that the engine does not seize up. If there is not enough oil in the engine, the temperature of the oil will be raised too high. On the contrary, if there is too much oil in the engine, the engine oil can slow the engine down considerably. (NOTE: The 2 GF-Lmodel cannot automatically stop itself.)

When you purchase a brand new engine, the engine must be properly broken in. The break in period is about 20 hours.

Make sure the electrolytic solution of the battery is full. The engine uses a 12V battery. Due to numerous starting cycles, the electrolytic solution may be used up. Also, before filling, verify that the battery is not damaged in any way. Add distilled water to the batter when filling. Perform checks on the batter once a month.;

Keeping your generator well maintained will prolong the life of your generator. Everything needs to be checked including the diesel engine, welder, generator, control cabinet and frame. For overhauling procedures, please refer to the instruction manual of the relative subassembly. If you need these manuals, please call our company and we will send you one.

Before starting the maintenance, make sure the diesel engine is off.

Please refer to the table 3-1 for the proper maintenance schedule.

If your generator needs to be stored for long periods of time, the following preparations should be made:

1. Start the diesel engine for 3 minutes then stop it.

2. When the engine is still hot, change the engine oil with the new engine oil of the proper grade.

3. Pull the rubber plug out of the cylinder head cover and put 2CC of lubricating oil in it, then cover the plughole up again.

4. For manual starting generators, press the decompression handle down and pull the recoil handle 2 or 3 times. This pushes the intake out. (Do not start the engine)

5. For electric start generators, press the decompression handle down and crank the engine for 2-3 seconds. To do this, put the starter switch in the “START” position. (Do not start the diesel engine)

2-3.2 How to open the case door/cover

(1) Open the case door: turn the handle counterclockwise and open the door. Do these checks daily.

(2) Loosen the outer cover bolt of the air filter and outer cover of the oil nozzle, and then check the air filter.

(3) Check the outer cover of the oil nozzle. Loosen the butterfly nut and open the outer cover

Check and fill enough engine oil

Check and screw each fastened part

Adjust the gaps of air intake and air exhaust gate