BOSSCO DY8500 Series User manual
1
Chapter 1: Overview
Technical Specications & Data ......................... 3
Chapter 2: Operating The Diesel Generator
2-1 General Main Points of Safety During
Operation.......................................................................... 4
2-1.1 Fire Prevention............................................... 4
2-1.2 Exhaust Gases ............................................... 4
2-1.3 Accidental Burns.......................................... 4
2-1.4 Electric Shock and Short Circuits...... 4
2-1.5 Other Safety Points..................................... 5
2-1.6 Battery................................................................ 5
2-2 Preparation Before Operation..................... 6
2-2.1 Fuel Choices and Fuel Treatment ..... 6
2-2.2 Fill Engine Oil................................................. 7
2-2.3 Check Air Filter............................................. 8
2-2.4 Checking the Generator ......................... 8
2-2.5 The Fuel and Oil........................................... 8
2 -3 Checking the Operation
of Diesel Engine ........................................................... 9
2-3.1 Low Pressure Alarm System................. 9
2-3.2 Open Case Door and Cover.................. 9
2-3.3 Engine Break In ............................................ 9
2-4 Starting the Generator...................................10
2-4.1 Manual Starting ..........................................10
2-4.2 Electric Starting .........................................10
2-4.3 Battery .............................................................10
2-5 Proper Operation of the Generator........ 12
2-5.1 Operating The Diesel Engine............. 12
2-5.2 Checks During Engine Operation ... 12
2-6 Loading................................................................... 12
2-6.2 Output of Electricity................................ 12
2-6.3 Charging the Battery.............................. 13
2-7 Stopping the Generator ................................ 13
Chapter 3: Maintenance ........................................ 15
3-1 Maintenance Schedules ............................... 15
3-1.1 Changing the Engine Oil........................16
3-1.2 Replacing the Oil Filter ..........................16
3-1.3 Air Filter Maintenance Schedule .....16
3-1.4 Fuel Filter Maintenance.........................16
3-1.5 Cylinder Head Bolt Tensions..............16
3-1.6 Battery Check..............................................16
3-2 Storing for Long Periods of Time........ 17
Chapter 4: Overhauling
& Troubleshooting.....................................................18
4-1 Overhauling & Troubleshooting
Procedures ....................................................................18
4-2 Questions & Answers...................................... 18
Chapter 5: Part Listings..........................................19
Overall view of engine
generator assembly.................................................19
Exploded view of frame assembly.................20
Electric panel parts drawing .............................. 21
Generator head assembly....................................22
Fuel system components.....................................23
3
Self-excitation voltage
Condenser Compensation
System
60
6.3
110, 220, 230, 240,
110/220, 120/240,
220/380, 230/400
12-8.3
3000/3600
190F
Single-cylinder, vertical,
4-stroke, air-cooled,
direct-injection
7.6/8.3
8.3/8.8
90 x 75
474
1.65
15
164
920 x 530 x 705
In order to operate the generator set safely, please follow all the instructions provided in this
manual carefully. Failing to do so may lead to accidents and or equipment damage.
The proper fuel for the diesel generator set is light diesel fuel. Do no use gasoline, kerosene
and or other fuels other than light diesel fuel. Keep all ammable fuels away from the generator
as the generator may spark and ignite these gases. In order to prevent res from occurring and
to provide enough ventilation for people and the machine, keep the diesel generator at least
1.5 meters or 5 feet away from buildings and or other equipment. Always operate your diesel
generator on a level site. If the generator is operated on an incline, the lubrication system within
the engine will not perform well and may lead to failure of the engine.
Never inhale exhaust gases emitted by the engine. The exhaust gases contain toxic carbon
monoxide. Never operate your generator in places with poor ventilation. In order to operate
this machinery indoors, a suitable ventilation system for the building is required to draw the
poisonous exhaust gases out.
Never touch the muer and its cover when the diesel engine is running. Never touch the muer
and cover after the diesel engine has been used, as the muer remains hot for a good period of
time.
Never touch the generator if the generator is wet. Also never touch the generator if your hand is
wet. Never operate your generator if the weather conditions call for any type of precipitation such
as rain, snow or fog. To prevent electrical shocks, the generator should be grounded. Use a lead
to connect the grounding end of the generator to the grounding surface of choice.
Before operating this generator, all operators should have a good knowledge of how to break
the circuit if any accidents occur. Also, all operators should be familiar with all the switches and
functions of the generator before using this machine. While operating the generator, wear safe
shoes and suitable clothes during operation. Always keep children and animals away from the
generator.
The electrolytic liquid of the battery contains sulfuric acid. In order to protect your eyes, skin and
clothing, wear protective gear when working with the battery. If you come in contact with the
electrolytic liquid, wash it immediately with clean water. Also, if they electrolytic liquid comes in
contact with your eyes, see a doctor immediately.
Use only light diesel fuel. The fuel should be
clean. Never let dust and water mix with fuel
in the fuel tank. Otherwise it will clog the fuel
lines and oil nozzles. It may also damage your
pressure pump.
Do not wash the air lter. The element
is made of dry material, which does not
permit washing. When the output of the
diesel engine is bad or the color of the
exhaust gas is abnormal, replace the
air lter element. Never start the diesel
engine without the air lter.
Put the generator set in a level state. Fill the oil into the
oil-lling inlet. At the time of checking the oil level, it is
necessary only to lightly insert the oil ruler. Please pay
attention that you should not rotate the oil ruler.
Engine oil is the most important factor in determining the life of your generator engine. If you use
poor engine oil or if you don’t change the oil regularly, the piston and cylinder will wear easily or
seize up. Also, the life of the other parts in your engine such as bearings, and other rotating parks
will shorten considerably.
Although there is an alarm system for low oil
pressure, it is always a good idea to check the
amount of oil inside the engine. If the oil level
is low, ll it before starting the engine. A good
time to drain the oil from the engine is when
the diesel engine is still hot. If the engine is fully
cooled, it is more dicult to drain all the oil out
and some impurities will remain in the engine.
A.P.I. Diesel engine maintenance classication.
The lubricating oil should be CC or CD Grade.
Volume
Type 186FG
1.65 (0.36)
Volume (L)
English Gallon
Top Limit (H)
Low Limit (H)
About 1 month or 20 hours
DIPSTICK
BOLT TO DRAIN LUBRICATING OIL
WARNING: Don’t fill engine oil when diesel generator is operating
Every 3 months or 1000 hours
8
(1) Loosen the buttery nut, take the cover of
the air lter o and take the air lter out.
Before starting the generator, make sure the
air switch is in the “o” 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 xture 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 rm. 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 o. Otherwise,
it will burn the capacitor. (For silent set, the
inspection may not be carried out).
The fuel and oil in a new engine is drained
before sold. Before you start the engine,
please ll the fuel tank and oil rst. Then,
check to see if there are air bubbles in the
engine. If there are, follow the procedure:
Loosen the connecting nut between the oil
injection pump and oil pipe. Bleed the air from
the system until there are no more bubbles.
Then replace the connecting nut and tighten
it.
Do not use detergent to wash the air lter.
When the performance of the engine
decreases or when the color of the exhaust
gases is bad, exchange the lter. Never start
the engine without air lter as foreign objects
may enter the intake and damage the engine.
(2) After replacing the air lter, replace the
cover and tighten the buttery nut rmly.
BUTTERFLY NUT
AIR FILTER COVER
FILTER CORE
COVER AT THE CHECK
MOUTH FOR AIR FILTER
9
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 o. 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-L
model cannot automatically stop
itself.)
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 lter and outer cover of the oil
nozzle, and then check the air lter.
(3) Check the outer cover of the oil
nozzle. Loosen the buttery nut and
open the outer cover.
2-3.3 Engine Break In
When you purchase a brand new
engine, the engine must be properly
broken in. The break in period is about
20 hours.
(1) Avoid overloading the engine when
brand new.
(2) Change the engine oil according
to specications. An oil change for a
brand new engine is about 20 hours
or every month, an older engine, the
oil change is about 100 hours or three
months.
KNOB HANDLE
RUBBER
COCK
2-4.1 Manual Starting
Start the engine in accordance with
procedure below:
(1) Put the fuel switch in the “ON”
position.
(2) Turn the handle of the engine to
the “RUN” position.
(3) Pull the recoil starter handle out.
(4) until you feel resistance. It will reset
to its original position automatically.
The handle should be reset into its
recoil device slowing to prolong the
life of the engine starter.
In cold climate, it is dicult to start
the engine. To remedy this, pull the
rubber plug from the rocker of the
diesel engine and ll 2ml of engine oil.
Before starting, put the rubber plug
back in place, If you don’t replace it,
rain, dust and other dirt can enter into
the diesel engine. It will cause parts
inside to wear quickly and lead to
engine failure.
2-4.2 Electric Starting
The procedure for preparing to start
the engine are the same as the
manual starting engine.
2-4.3 Battery
1. Insert key into ignition and place in
the “o” position.
2. Put the speed handle in the “Run”
position.
3. Turn the start switch clockwise
to the “START” position; To set the
silent type, rst turn it clockwise to
the “RUN” (ON) position for the 1-2
seconds. The electromagnetic iron
will be triggered, now turn it clock-
wise to the “START” position.
4. After the diesel engine is started,
remove your hand from the switch
handle; the switch will automatically
reset itself to the “ON” position.
5. If the engine is not starting after
10 seconds of cranking, wait about
15 seconds before trying again. If
you crank too long, the voltage of
the battery will drop. This can lead to
improper ignition. When the diesel
engine is operating, let the ignition
remain in the “ON” position.
FUEL
SWITCH
SPEED
HANDLE
SPEED
HANDLE
RUBBER
COCK
11
NOTE: If you crank the starter too long, the battery may be drained too much to
provide enough energy for proper engine ignition. Also, when the diesel engine
is operating, let the key remain in the “ON” position.
Check the level of the water in the battery once a month. If the level of the liquid
drops too low, ll it with distilled water until it reaches the high mark. If there is not
enough distilled water, then the diesel engine cannot be started. It is important to
keep the liquid level between the high and low limits.
If the level in the batter is too high, the liquid may ow out and end up on the
surrounding parts resulting in corrosion of these parts.
NOTE: Avoid too much or too little distilled water. Check and ll it once a month.
2-5.1 Operating the Diesel Engine
Pre-heat the diesel engine for 3
minutes under no load conditions.
First check the height of the
lubricating oil level, if it is low, rell it.
Our diesel engines are equipped with
an alarm system that will notify you if
the oil pressure is too low. The alarm
system will shut down the engine if
the oil pressure is too low. Do not
adjust the speed limit regulation nut
or the fuel adjustment bolt. These
bolts have been set by the factory
already, changing them will aect the
properties of the engine performance.
2-5.2 Checks during engine operation
1. Check to see if there are abnormal
noises.
2. Check to see if the performance is
good or bad.
3. Check the color of the exhaust
gases (whether it is too black or too
white). If any of these conditions exist,
stop the engine and nd the cause of
the problem. if no problems are found,
please contact your local dealer or
our nearest company branch.
2-6.1 Load Conditions
Exert loads in accordance with the
specied parameters.
2-6.2 Output of Electricity
1. Raise the revolutions per minute
(turn the speed handle to the max
setting) of the generator to get the
maximum power out of the generator.
If not, the automatic voltage regulator
device will excite and doing this for
long periods of time will cause the
capacitor to burn.
2. For the rated speed of the
generator, please refer to Chapter 1,
item 1-1 technical specication and
data.
3. Observe the pointer of the
voltmeter, it should point to 220+
-
5%(50Hz). (For 60 Hz set, it will be
240V+
-
5%). This is the reading of the
voltage at the ac socket.
4. When connecting devices to the
generator, make sure to connect
these devices in order. Connect the
large loads onto the generator rst. If
everything else is functional, smaller
loads can then be added. If the
generator shuts o, it may be because
the load being drawn by all the
HIGH-PRESSURE
FUEL PIPE NUT
FUEL
ADJUSTMENT
BOLT
CAUTION: Do not start more than
two machines at the same time. The
machines should be started one
by one. Do not use the oodlight
at the same time when using other
devices.
13
various devices are too high. In this
event, decrease the number of small
devices until everything is functional.
The total drawn power should not
exceed the maximum output power
of the generator. Please see table 1-1
for technical specications of what
the generator can output. In order to
reset the generator after overdrawn
power, let it sit for several minutes.
If the indication of the voltmeter is
too high or too low, adjust the speed
accordingly. If there are problems,
stop the generator immediately and
x the issue.
5. Make sure you are operating your
generator in a well-ventilated area.
The generator should never be
covered with anything to prevent
overheating the generator.
2-6.3 Charging the Battery
1. For the electric starter generator,
the 12V battery is automatically
charged through the regulator on the
generator when it is running.
2. If the generator is not used for long
periods of time, the battery should
be disconnected to avoid energy loss
from the battery.
3. Do not connect the negative and
positive terminals of the battery
together at any time. Doing so will
damage the battery.
4. Do not reverse the polarities when
attaching the battery cables to the
battery. Doing so will damage both
the battery and the electric starter.
5. When charging the battery, the
battery produces ammable gases.
Do not smoke, ames, and sparks
get near the battery while it is
charging as this may cause a re. To
avoid sparking while connecting the
cables to the battery rst, connect
the cables to the battery then to the
motor. To disconnect battery cables,
rst disconnect the motor end of the
cable.
1. Take the electrical load o the
generator.
2. Turn generator run switch o.
3. Put the speed handle in the “RUN”
position and let the engine run for 3
minutes after unloading. Do not stop
the diesel engine immediately let it
cool o. Stopping the diesel engine
suddenly may raise the temperature
of the engine abnormally and lock the
nozzle and damage the diesel engine.
NOTE:
1. If the speed handle is in the
“STOP” position and the engine is
still running, turn the fuel switch to
the “OFF” position or lossen the high
pressure oil pipe nut. The engine
could be stopped more than one
way other than using the speed
handle.
2. If you cannot stop the engine with
a load on it, then remove the load
rst then stop the engine.
4. Press down on the brake handle.
5. If equipped with an electric starter,
turn the key to the “OFF” position.
6. Put the fuel handle to the “S”
position.
7. Finally, pull slowly on the recoil
handle until you feel resistance
(this is when the piston is on the
compression stroke, where the intake
and exhaust valves are closed). What
this does is prevent the engine from
rusting when not in use.
FUEL
SWITCH
LOOSE THE HIGH PRESSURE
OIL PIPE NUT
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 o.
Please refer to the table 3-1 for the proper maintenance schedule.
Table 3-1: Maintenance schedule for diesel generator set.
Note: “X” indicates that it needs a special wrench, please contact dealer.
O
O
O
O
O X
O
O
O
O
O X
X
X
X
X
X
X
X
X
3-1.1 Changing the Engine Oil
(every 100 hours)
Take the oil cover out. Take o the oil
drain plug when the diesel engine is
still hot. Be careful of hot oil and hot
engine as you may bet burned. The
bolt is located at the bottom of the
cylinder. After draining the oil, put the
bolt back and tighten it. Then ll with
the proper engine oil to the proper
level.
3-1.2 Replacing the oil lter
1. Replacing the oil lter every 6
months or 500 hours of operation.
3-1.3 Air Filter Maintenance Schedule
1. Clean air lter every 6 months or
500 hours of operation.
2. If necessary, replace it.
3. Do not use detergent to clean air
lter. AIR
FILTER
NOTE:
Never start the engine without the air
lter. This can cause serious damage
to the engine if foreign objects enter
the intake system. Always change
the air lter on time.
3-1.4 Fuel Filter Maintenance
1. The fuel lter should be cleaned
often to keep the engine running at
maximum performance.
2. The recommended time period for
cleaning the fuel lter is 6 months or
500 hours of operation.
a. To do this rst drain the fuel
from the fuel tank.
b. Loosen the small screws on
the fuel switch and remove the
fuel lter from the port. Use
diesel fuel to clean the fuel lter.
Also, remove the fuel injector and
clean the carbon deposit around
it. The recommended time period
for this is 3 months or 100 hours.
3-1.5 Cylinder Head Bolt Tensions
The cylinder head bolts should be
tightened to specications. Please
refer to the diesel engine manual for
specications and the special tools
required to do this.
3-1.6 Battery Check
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 lling, verify
that the battery is not damaged in any
way. Add distilled water to the batter
when lling. Perform checks on the
batter once a month.
DIPSTICK
OIL DRAIN BOLT
HIGH-PRESSURE
FUEL PIPE BOLT
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)
6. Finally, pull the recoil starter until you feel resistance; this is when the piston is on
the compression stroke where the intake and exhaust valves are closed. Having the
intake and exhaust valves closed will prevent rust, as moisture cannot get inside the
combustion chamber.
7. Clean the engine and store it in a dry place.
18
If cannot generate electricity still, please contact with dealer of our company or with our company
directly.
If you do not understand anything or have any questions, please feel free to contact your local
dealer or with our company directly. Below is a list of some information you should have ready
before contacting your local dealer or us.
1. Model of diesel engine generator and engine model number.
2. State of residency
3. Number of hours of operating equipment along with the problem that occurred.
4. A detailed condition and time when the problem occurred.
In other words, climate and atmosphere.
Not enough fuel. Add fuel.
The switch of fuel is not at “OPEN” position. Turn the switch of fuel to “OPEN” position.
High pressure pump and nozzle do not
inject fuel or the injected amount is less.
Disassemble the nozzle and adjust it at test
table.
Speed control lever is not at “RUN” position. Turn speed control lever to “RUN” position.
Check level of lubrication oil. The standard amount of lubricating oil should
be between high and graduation “H” and low
graduation “L”
It is not quick and powerful to pull reactive
starter.
Start diesel engine in accordance with the
requirements of “start operation procedures”.
Nozzle is dirty. Clean the nozzle.
Accumulator has no electricity. Charge the accumulator or change it.
Master switch (NFB) is not switched on. Turn master witch handle to “ON” position.
Carbon brush of generator was worn. The
contact is bad.
Change the carbon brush.
The socket contact is bad. Adjust the contact feet of socket.
The rated revolution of engine cannot be
reached.
Make it reach the rated revolution in
accordance with the requirements.
AVR automatic governor is damaged. Change it.
The potentiometer of current regulations
for electric welding is damaged.
Change it.
19
Overall view of engine generator assembly
1 Series Diesel Engine 1 4LN1/6LN1
2 Starter Motor 1 4LN2/6LN2
3 Flywheel Generator 1 4LN3/6LN3
4 Bolt 2 4LN4/6LN4
5 Voltage Regulator 1 4LN5/6LN5
6 Battery Cable (red, black) 2 4LN6/6LN6
7 Battery 1 4LN8/6LN7
8 Oil Level Sensor 1 4Ln9/6LN8
9 Generator 1 4LN9/6LN9
10 Output Panel Assembly 1 4LN10/6LN10
11 Throttle Cable 2 4LN11/6LN11
12 Connector Assembly 1 4LN12/6LN12
13 Capacitor 1 4LN13/6LN13
14 Bolt 2 4LN14/6LN14
15 Voltage Regulator Bracket 1 4LN15/6LN15
16 Bolt 2 4LN16/6LN16
Exploded view of frame assembly
1 Muer Cover Plate 1 4LN17/6LN17
2 Muer Elbow 1 4LN18/6LN18
3 Left Outer Cover 1 4LN19/6LN19
4 Fuel Gauge 1 4LN21/6LN21
5 Fuel Tank Sleeve 1 4LN22/6LN22
6 Main Cover 1 4LN23/6LN23
7 Door Knob 1 4LN24/6LN24
8 Right Outer Cover 1 4LN27/6LN27
9 Output Panel Assembly 1 4LN28/6LN28
10 Air Cleaner Cover 1 4LN29/6LN29
11 Lower Chassis 1 4LN30/6LN30
12 Engine Tray Mounts 4 4LN31/6LN31
13 Engine/Generator Tray 1 4LN32/6LN32
14 Wheels 4 4LN33/6LN33
15 Battery 1 4LN34/6LN34
16 Battery Tie Down 1 4LN35/6LN35
17 Long Cover Plate 1 4LN36/6LN36
This manual suits for next models
1
Table of contents
Other BOSSCO Portable Generator manuals
Popular Portable Generator manuals by other brands
Sincro
Sincro EP Series Use and maintenance manual
Durapac
Durapac 30 PEM3024 Series instruction manual
Anritsu
Anritsu MG369 C Series Programming manual
Generac Portable Products
Generac Portable Products Handyman-Plus PowerBOSS 3250 owner's manual
Tektronix
Tektronix PPG3000 Series instructions
Westerbeke
Westerbeke WMD 4.4 specification