BOLIY POWER

OWNERS MANUAL

DIGITAL GENERATOR

DSP TECHNOLOGY

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MODEL

Pro3600Si

Pro3600Si/E

Electric Start

TABLE OF CONTENTS

PLEASE READ ENTIRE MANUAL BEFORE OPERATING

Introduction ....................................................................................1

Warranty ........................................................................................2-3

Safety Information ............................................................................4-5

Exhaust Fumes Are Poisonous

Never Run Generator Indoors

Fuel is Highly Flammable and Poisonous

Engine and Muffler May be Hot

Electric Shock Prevention

Connection Notes

Extension Cord Notes

Battery

Control Function

................................................................................6-7

Description and Control Panel Key

Oil Warning System

Engine Switch

DC Protector

Pre-Operation Check...........................................................................8

Fuel System

Refueling and Fuel Level Gauge

Engine Oil

Ground (Earth)

Operation............................................................................................9-12

Starting the Engine

Economy Control Switch

Application Range

Connection

Stopping the Engine

Periodic Maintenance.........................................................................13

Maintenance Chart

Spark Plug Inspection.........................................................................14

Engine Oil Replacement

Fuel Filter

Fuel Tank Filter

Troubleshooting.................................................................................15

Engine won’t Start

Generator won’t produce power

Storage

Drain the fuel

Engine

Specifications...................................................................................16

Wiring Diagram...................................................................................17

Grounding Information .......................................................................18

Portable Generator Hazards ...............................................................19

Appendix............................................................................................20

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INTRODUCTION

Congratulations on purchasing your new BOLIY Generator. This manual covers operation and maintenance of the Pro3600Si/E generator. This manual will provide you with an excellent basic understanding of the operation, and maintenance of this machine. If you have any questions regarding the operation or maintenance of your machine, please consult your BOLIY dealer.

xxx-xxxxx

MACHINE IDENTIFICATION

SERIAL NO.

MODEL

Record your generator model and serial number in the spaces provided, to assist you in ordering spare parts from a BOLIY dealer. Also record and keep these I.D. numbers in a separate place in case your machine is lost or stolen.

Pro3600 SI & SiE

OWNER’S MANUAL

7th Edition, June, 2010

All rights reserved.

www.boliypower.com

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2 YEAR FULL RUNABILITY & EMISSIONS COVERAGE

BOLIY POWER WARRANTY POLICY

T his warranty is limited to Boliy products when distributed by Boliy Power. The following warranty applies to products purchased at retail or for recreational use after January 1, 2010.

Warranty Procedure:

Congratulations on your purchase of a Boliy Generator. There are 2 ways to register your machine.

1.

Register your machine online:

Website: www.boliypower.com.

or

2. Complete your warranty registration cards and mail to:

Boliy Power America,

PO BOX 007 Iselin,

NJ 08830-0007 or

Suzhou Zhonggu Mould Co., Ltd.

Huangqiao Industrial Park,

Suzhou Jiangsu,

215132,China

Tel: +86-512-65466507

Please note that your warranty coverage is valid only if we have received a copy of your card.

BOLIY hereby warrants that new BOLIY consumer

generator purchased from an authorized BOLIY consumer generator dealer will be free from defects

in material and workmanship for the period of time

stated herein subject to certain stated limitations.

SPECIFIC EXCLUSIONS from this warranty shall include parts replaced due to normal wear or routine maintenance.

THE PERIOD OF WARRANTY Any new SI -

Series or SIE - Series BOLIY Generator purchased for private, non- commercial use from an authorized

BOLIY consumer generator dealer will be warranted against defects in material or workmanship for a period of two years from date of purchase, subject to exclusions noted herein. Any BOLIY non-commercial generator purchased and utilized for commercial or rental applications will be warranted for a period of one year from the date of purchase, subject to exclusions noted herein.

THE CUSTOMER’S RESPONSIBILITY under this warranty shall be to:

1. Operate and maintain the generator as specified

in the appropriate Owner’s Manual

2. Give notice to an authorized BOLIY consumer

generator dealer of any and all apparent defects

within ten days after discovery, and make the

unit available at that time for inspection and

repairs at such dealer’s place of business.

BOLIY MAKE NO OTHER WARRANTY OF ANY

KIND, EXPRESSED OR IMPLIED. ALL IMPLIED

WARRANTIES OF MERCHANTABILITY AND FIT-

NESS FOR A PARTICULAR PURPOSE WHICH

EXCEED THE OBLIGATIONS AND TIME LIMITS

STATED IN THIS WARRANTY ARE HEREBY DIS-

CLAIMED BY BOLIY EXCLUDED FROM THIS

WARRANTY.

DURING THE PERIOD OF WARRANTY any authorized BOLIY consumer generator dealer will, free of charge, repair or replace, at BOLIY’s option, any part judged defective by BOLIY due to faulty workmanship or material from the factory.

Parts used in warranty repairs will be warranted for the balance of the product’s warranty period. All parts replaced under warranty become property of

BOLIY.

GENERAL EXCLUSIONS from this warranty shall include any failures caused by:

SOME STATES DO NOT ALLOW LIMITATIONS ON

HOW LONG AN IMPLIED WARRANTY LASTS, SO

THE ABOVE LIMITATION MAY NOT APPLY TO YOU.

ALSO EXCLUDED FROM THIS WARRANTY ARE

ANY INCIDENTAL OR CONSEQUENTIAL DAMAGES

INCLUDING LOSS OF USE. SOME STATES DO NOT

ALLOW THE EXCLUSION OR LIMITATION OF INCI-

DENTAL OR CONSEQUENTIAL DAMAGES, SO THE

ABOVE EXCLUSION MAY NOT APPLY TO YOU.

a. Installation of parts or accessories that are

not qualitatively equivalent to genuine

BOLIY parts.

b. Abnormal strain, neglect, or abuse.

c. Lack of proper maintenance.

d. Accident or collision damage.

THIS WARRANTY GIVES YOU SPECIFIC LEGAL

RIGHTS, AND YOU MAY ALSO HAVE OTHER

RIGHTS WHICH VARY FROM STATE TO STATE.

- BOLIY POWER

- In a case the generator needs to be sent to a service center it is important to keep all of the original packaging materials.

2

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WARRANTY QUESTIONS AND ANSWERS

Q. What costs are my responsibilities during the warranty period?

of normal maintenance service, non-warranty repairs, accident damages, as well as oil and spark plugs.

Q. What responsibility does my dealer have under this warranty?

A. Each BOLIY generator dealer is expected to:

1. Check the operation of the generator before sale.

2. Explain the operation, maintenance, and warranty requirements to your satisfaction at the time of sale, and upon your request at any later date.

Q. What are some examples of “abnormal” strain, neglect, or abuse?

A. These terms are general and overlap each other in areas. Specific examples include: Running the machine out of oil; lack of proper maintenance; operating the machine with a broken or damaged part which causes another part to fail; and so on. If you have any specific questions on operation or maintenance, please contact your dealer for advice.

Q. Does the warranty cover incidental costs such as transportation due to a failure?

A. Y es. If it is determined that it is an emmissions related problem.

A. No. If it is a warranty claim that is not

emmissions related.

CUSTOMER SERVICE

In the event that something goes wrong with your

Boliy Generator, our authorized team of technicians are available to help you get your Boliy Generator back up and running as quickly as possible. To take full advantage of our service center please chose one of the following options for your repair:

1) For the fastest service, you may exchange your unit for a ready to go unit of equal age and condition. A $500 deposit will be required and will be refunded when the defective unit is returned. All replacement units will be shipped within 24 hours.

2) Return your defective unit and it will be repaired within 10 days and returned to you at no charge.

Q. May I perform any or all of the recommended maintenance shown in the Owner’s Manual instead of having the dealer do them?

CHANGE OF ADDRESS

The federal government requires each manufacturer to maintain a complete, up-to-date list of all first purchasers against the possibility of a safety-related

A. Yes, if you are a qualifi ed mechanic and follow the procedures specified ed in the Owner’s and

Service Manual. We do recommend, however, that items requiring special tools or equipment be done by a BOLIY generator dealer.

defect and recall. This list is compiled from the purchase registrations sent to BOLIY. If you should move after you have purchased your new generator, please advise us of your new address by sending a

Q. Will the warranty be void or cancelled if I do not operate or maintain my new BOLIY exactly as specifi ed in the Owner’s Manual?

A. Y es. The warranty on a new BOLIY can be

“voided” or “cancelled”.

If a particular failure is caused by operation or maintenance other than as shown in the Owners

Manual, that failure will not be covered under warranty.

post-card listing your BOLIY model name, engine number, and dealer name as it is shown on your warranty identi cation, your name and new mailing address. Mail to:

Boliy Power America,

PO BOX 007 Iselin,

NJ 08830-0007 or

Suzhou Zhonggu Mould Co., Ltd.

Huangqiao Industrial Park,

Suzhou Jiangsu,

215132,China

Tel: +86-512-65466507

This will ensure that BOLIY has an up-to-date registration record in accordance with federal law.

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SAFETY INFORMATION

WARNING

EXHAUST FUMES ARE POISONOUS. Never operate the engine in a close area or it may cause

unconsciousness and death within a short time. Operate the engine in a well ventilated area.

NEVER RUN GENERATORS INDOORS OR IN CONFINED SPACES.

•Never sleep a running generator due to the emission of carbon monoxide.

•When working with a generator, keep at least 20 feet away from where it is running.

•Keep generators clear of all fresh air inlets (houses, buildings, campers, or tents) to avoid possible

carbon monoxide poisoning.

•Failure to adhere to these precautions could result in POISONING or possibly even DEATH

FUEL IS HIGHLY FLAMMABLE AND POISONOUS

•Always turn off the engine when refueling.

•Never refuel while smoking or in the vicinity of an open flame.

•Take care not to spill any fuel on the engine or muffler when refueling.

• If you swallow any fuel, inhale fuel vapor, or allow any to get in your eyes, see your doctor immediately.

If any fuel spills on your skin or clothing, immediately wash soap and water and change your clothes.

• When operating or transporting the machine, be sure it is kept upright. If it tilts, fuel may leak from the

carburetor or fuel tank.

ENGINE AND MUFFLER MAY BE HOT

•Place the machine in a place where pedestrians or children are not likely to touch the machine.

•Avoid placing any flammable materials near the exhaust outlet during operation.

•Keep the machine at least 1 meter/3 feet from buildings or other equipment, or the engine may overheat.

•Avoid operating the engine with a dust cover.

ELECTRIC SHOCK PREVENTION

•Never operate the engine in rain or snow.

•Never touch the machine with wet hands or electrical shock will occur.

•Be sure to ground (Earth) the generator.

CONNECTION NOTES

Avoid connecting the generator to commercial power outlet. Avoid connecting the generator in parallel with any other generator.

WARNING

Before the generator can be connected to a building’s electrical system, a licensed electrician must install an isolation (transfer) switch in the building’s main fuse box. The switch is the connection point for generator power and allows selection of generator or main line power to the building. This will prevent the generator from charging the main power line (backfeeding) when the main power supply has failed or has been turned off for line repair. Backfeeding can electrocute or injure line maintenance personnel. Also, generator and building electrical system damage can occur when normal operating power returns if unit is used without an isolation switch.

EXTENSION CORD NOTES

•When using an extension cord, is total length should not exceed 50 feet with 12 gauge wire or up to 100

feet with 10 gauge wire.

•This extension cord should be protected by a tough flexible rubber sheath (IEC 245) or the equivalent to

withstand mechanical stresses.

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BATTERY

Battery

This generator is equipped with a sealed type (MF) battery, which does not require any maintenance.

There is no need to check the electrolyte or to add distilled water.

Battery preparation

1. Open the front door.

2. Check the positive lead (red) connection to the positive (+) terminal.

3. Connect the negative lead (black) to the negative (-) terminal.

4. Close the front door.

To charge the battery

Have a Boliy dealer charge the battery as soon as possible if it seems to have discharged.

Recommended battery

Recommended battery:

Capacity: 12V/4.5Ah or 12V 5Ah

Size: L90*W70*H102mm

+ -

CAUTION

Do not connect negative battery cable until you start to use the machine!

WARNING

Electrolyte is poisonous and dangerous since it contains sulfuric acid, which causes severe burns.

Avoid any contact with skin, eyes or clothing and always shield your eyes when working near batteries.

In case of contact, administer the following FIRST AID.

EXTERNAL: Flush with plenty of water.

INTERNAL: Drink large quantities of water or milk and immediately call a physician.

EYES: Flush with water for 15 minutes and seek prompt medical attention.

Batteries produce explosive hydrogen gas. Therefore, keep sparks, flames, cigarettes, etc., away from the battery and provide sufficient ventilation when charging it in an enclosed space.

KEEP THIS AND ALL BATTERIES OUT OF THE REACH OF CHILDREN.

Battery Storage

1. Remove the battery.

2. Store the battery in a cool, dark and dry place. Do not store the battery in an excessively warm or cold place [i.e., less than 0°C (30°F) or more than 30°C (90°F)].

WARNING

Disconnect the negative lead (black) first, then the positive lead (red) from the battery.

Connect the positive lead (red) first, then the negative lead (black) to the battery when installing the battery.

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1

CONTROL FUNCTION

1

2

3

10

12

11

13

ON

OFF

ON

STOP

ECON

ON

OF F

AC

TO RESE T A

C

RESTART E

NGINE

ENGINE

START

DIGITAL

TECH

O N O FF

(P US H)

PR O TEC

T OR

5

6

7

8

9

4

Description and Control Panel Key

1. Carrying Handles

2. Fuel Level Gauge

3. Fuel Cap and Vent

4. Fuel On/Off Switch

5. AC Ready Pilot Light

6. Oil Warning Light

7. Ground (Earth) Terminal

8. 30 Amp Receptacle

9. 30 Amp RV Receptacle

10. Engine On/Off Switch

11. Choke Knob

12. Economy Control Switch

(SMART throttle switch)

13. Recoil Starter

14. DC Outlet and Reset Button

15. Oil Fill Access Door Panel

16. Engine Start button

15

14

16

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CONTROL FUNCTION CONTINUED

OIL WARNING SYSTEM

If the oil level falls below the safe operating level, the engine will stop automatically. Unless you refill with oil, the engine will not start again.

NOTE:

If the engine stalls or does not start, turn the engine switch to “ON” position and then pull the recoil starter. If the oil warning light flickers for a few seconds, the engine oil is low. Add oil and restart.

ON

A

ENGINE SWITCH

The engine switch controls the ignition system.

A. Ignition circuit is switched on.

The engine can be started.

B. Ignition circuit is switched off.

The engine will not run.

STOP

B

DC PROTECTOR

The DC Protector turns of automatically when the loads exceeds the generator rated output.

ON OFF

(PUSH)

PROTECTOR

NOTE:

If the DC Protector trips to the OFF position, press to reset. Reduce the load to the specified generator output if the DC protector turns off. If it turns off again, consult the authorized dealer.

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PRE OPERATION CHECKLIST

NOTE:

Pre-operation checks should be made each time the generator is used.

FUEL SYSTEM

Make sure there is sufficient fuel in the tank.

Recommended fuel: Unleaded gasoline

Fuel tank capacity: Total 2.1 US Gallons

The engine must use regular unleaded gasoline with a pump octane number (R+M)/2) of 86 or higher, or research octane number of 91or higher. E-85 is NOT recommended.

REFUELING AND FUEL LEVEL GAUGE

E

F

Fuel Level Gauge

“F”

“E”

Full

Empty

E

F

To refuel, remove cap and fuel slowly until fuel gauge indicates full.

WARNING

• Fuel

is high flammable and poisonous. Check “SAFETY INFORMATION” carefully before refueling.

• DO not fill above the top of fuel filler or it may overflow when the fuel the fuel heats up later and

expands.

• Wipe up any spilled fuel immediately.

• After refueling, make sure the tank cap is tightened.

ENGINE OIL

Make sure the engine oil is at the upper level of the oil filler hole. Add oil as necessary.

Recommended oil for most climates: 10W 30

For extremely cold conditions the oil viscosity may be lowered to ease starting: 5W 30

Engine Oil Quantity: 0.63 US qt

NOTE:

Recommended engine oil classification: API Service “SE” or “SF”; if not available, “SD”

CAUTION

The generator has been shipped without engine oil. Fill with oil or it will not start.

GROUND (EARTH)

Make sure to ground (Earth) the generator. SEE PAGE 17.

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OPERATION

STARTING THE ENGINE

NOTE:

Before starting the engine, do not connect any electric devices.

1. Turn the fuel switch lever to the “ON” position.

2. Turn the engine switch to the “ON” position.

3. Please make sure fix cathcode cable to the crank case(Electric start model).

1.

ON

2.

ON

A

3.

STOP

OFF

B

+ -

CAUTION

Do not connect negative battery cable until you start to use the machine!

Note: Sometimes the choke is required to start a warm engine.

3. Hold the choke knob fully out.

4. Pull slowly on the recoil starter until it is engaged, then pull it briskly.

(Electric start model can press engine

start button to start.)

5. After the engine starts, warm up the engine until the engine does not stop when the choke knob is returned

to the original position.

6. Push the choke knob back to the original position.

D I G I T A L

ENGINE

START

T E C H

CHOKE

NO

CHOKE

OFF

OFF

ON OFF

(PUSH)

PROTECTOR

NO

NO

ECONOMY CONTROL SWITCH (120V/60Hz type have this switch)

Engine speed is kept at idle automatically when the electrical device is disconnected and is returned to the proper speed by the electrical load when the electrical device is reconnected. The economy control switch in

“ON” position is recommended to minimize the fuel consumption while in normal operation.

NOTE:

When high electrical load devices are connected simultaneously, turn the economy control switch to the “OFF” position, the engine speed will increase to reduce voltage changes. Otherwise the generator will not operate sufficiently to run high demand electrical devices.

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OPERATION CONTINUED

AC CONNECTION

ALTERNATING CURRENT (AC)

CAUTION

• Be sure electric devices including the lines and plug connections are in good condition

before connection to the generator.

• Be sure any electric devices are turned off before plugging it in.

• Be sure the total load is within generator rated output.

• Be sure the receptacle load current is within receptacle rated current.

1. Wind the power lead 2 or 3 turns around the carrying handle.

2. Start the engine.

3. Plug in to the AC receptacle.

4. Make sure the AC indicator light is on.

5. Turn on any electric devices.

OVERLOAD INDICATOR LIGHT

The overload indicator light (the AC pilot light) will flash when an overload of connected electrical device is

detected or the inverter control unit overheats. The electronic breaker will then activate, stopping power

generation in order to protect the generator and any connected electric devices, but the engine will not stop

running.

When the overload indicator light comes on and power generation stops, proceed as directed:

1. Turn off any connected electric devices and stop the engine.

2. Reduce the total wattage of connected electric devices within the application range.

3. Check for blockages in the cooling air inlet and around the control unit. If any blockages are found, remove.

4. After checking, restart the engine.

Note: The highest peak load on this model is 3600 watts, the short term peak load is 3300 watts and the max operating load is 3,000 watts. High temperatures or high elevations will reduce the expected performance of this generator.

NOTE:

The generator AC output automatically resets when the engine is stopped and restarted.

USING THE GENERATOR FOR BATTERY CHARGING

CAUTION

Do not use AC and DC power at the same time or the generator may be damaged.

NOTE:

The generator DC rated voltage is 12 V.

1. Start Engine

2. Plug in battery charge wires to D.C. receptacle-#14 on CONTROL FUNCTION DIAGRAM

NOTE:

•

Make connections to the battery after starting the engine

•

Clamp the red wire to the positive(+)terminal and the black wire to the negative(-)terminal of the battery.

Do not reverse these positions.

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OPERATION CONTINUED

CAUTION

• Be sure the battery leads are properly connected and is not damaged or obstructed.

• Be sure breather hose is properly connected and is not damaged or obstructed.

• Reduce the load to the specified generator rated output if the DC protector turns off.

If it turns off again, consult the authorized dealer.

NOTE:

• If short or overdraw should occur in the system, it will cause the DC Protector to trip. Press to reset

the DC protector.

NOTE:

• At full charge, electrolyte specific gravity is between 1.26 and 1.28

• Check specific gravity hourly.

WARNING

Never smoke near the battery while charging. Do not make or break connections while the battery is charging. This may cause sparks to ignite the battery gas. Battery acid is poisonous and dangerous; it contains sulfuric acid. Avoid contact with skin, eyes, and clothing as it will cause severe burns.

If contact occurs:

EXTERNAL - Flush with water.

INTERNAL - Drink large quantities of water or milk, then drink milk of magnesia beaten egg or

vegetable oil. Call physician immediately.

EYES - Flush with water for 15 minutes and get prompt medical attention.

Batteries produce explosive gases. Keep sparks, flame, cigarettes, etc., away from the generator.

Ventilate when charging or using in closed space. Always cover eyes when working near batteries.

KEEP OUT OF REACH OF CHILDREN.

STOPPING THE ENGINE

1. Disconnect any electric devices.

2. Turn the engine switch to the “STOP” position.

3. Turn the fuel lever to “OFF”

1.

ON

3.

2.

STOP

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OPERATION CONTINUED

APPLICATION RANGE: APPROXIMATE WATTAGE REQUIRED FOR STARTING

Household RV Household RV

Coffee Maker 1750 1750 Electric Chain Saw 1100 1000

Dishwasher - 14 inces,2HP

-Cool Dry 700 1400 Table Saw

Electric Fry Pan 1300 1300 - 10 inches 1800 4500

Electric Range Drills

-8- inch element 2100 2100 -3/8 inch,4 amps 440 600

Microwave Oven 1000 2100 -1/2 incn,5.4 amps 600 900

20”Box Fan or Table Fan 120 180 Capacitor Start induction Run

Electric Blanket 150 150 -1/3 Horsepower 720 1300

Refrigerator 192 1200 -1 Horsepower 1600 4500

Automatic Washer 1150 2300 Capacitor Start Capacitor Run

Clothes Dryer -1 1/2 Horsepower 2000 6100

-Electric 5750 1800 Fan Duty

Furnace Fan, gas or fuel oil -1/6 Horsepower 550 850

1/8 Horsepower 300 500 Farm Equipment

1/4 Horsepower 600 1000 Electric Fence,25 miles 250 230

½ Horsepower 875 2350 Milk Cooler 1100 1800

Lights (as indicated on bulb) Milkier (vacuum pump)

Radio 50-200 50 -2 Horsepower 1000 2300

Sump Pump Portable Heater(kerosene, diesel fuel)

1/3 Horsepower 800 1300 -50,000BTU 400 600

½ Horsepower 1050 2150 -90,000BTU 500 725

Television -150,000 BTU 625 1000

-color 300 300 Battery Charger

RV Air Conditioner -15 amp 380 380

13,500 BTU 1800 2800 -60 amp/250-amp boost 1500/5750 1500

Room Air Conditioner -100 amp/300-amp boost 2400/7800 2400

10,000 BTU 1500 2200 Electric Welder

Contractor -200 amp AC 9000 9000

Air Compressor -230 amp AC, at 100 amp 7800 7800

-1 Horsepower 1500 4500 Air Compressors

Bench Grinder -1/2 Horsepower 975 1600

-8 inches 1400 2500 -1 Horsepower 1600 4500

Hand Drill Computers

-1/2 inch 600 600 -Desktop 600to800 600

High-Pressure Washer -Laptop 600to250 200

-1 Horsepower 1200 3600 -Monitor 200to250 200

Circular Saw, Heavy Duty Fax 600to800 600

-7 1/4 inches 1400 2300 Printer 400to600 400

NOTE:

• Application wattage indicates when each device is used by itself

CAUTION

• Be sure the total load is within generator rated output otherwise generator damage may occur.

• Do not use AC and DC power at the same time or the generator may be damaged

NOTE:

Some precision equipment is voltage sensitive and may require a uniform voltage supply than portable genera-torso provide Examples include some medical equipment, personal computers, and some inverters that sense peak and RMS voltage values. Consult the precision-equipment vendor before relying on any portable generator to provide power to such equipment.

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12

PERIODIC MAINTENANCE

MAINTENANCE CHART

Regular maintenance is most important for the best performance and safe operation.

WARNING

Stop the engine before starting maintenance work.

Item Remark

Spark Plug

Engin Oil

Air Filter

Fuel Filter

Check condition. Adjust gap and clean. Replace if necessary.

Check oil level/Replace

Clean/Replace if necessary

Clean fuel cock and fuel tank filter. Replace if necessary.

Value Clearance

Check and adjust when engine is cold.

Fuel Line

Exhaust System

Check fuel hose for crack or damage. Replace if necessary.

Check for leakage.

Re-tighten or replace gasket if necessary.

Check muffler screen.

Clean/replace if necessary.

Choke Handle

Check choke’s operation.

Cooling System Check fan damage.

Starting System

Check recoil starter operation.

Decarburization

More frequently if necessary.

Generation

Check the pilot light comes on.

Fittings

/Fasteners

Check all fittings and fasteners. Correct if necessary.

Pre-Operation

Check (Daily)

Initial 1 month

/20 Hours

Every 3 Month

/50 Hours

Every 6Month

/100 Hours

Every 12Month

/300 Hours

CAUTION

Use only genuine BOLIY replacement parts. If you have questions, contact your dealer or Boliy USA (651-407-1457)

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SPARK PLUG INSPECTION

You should periodically remove and inspect the spark plug.

1. Check for discoloration and remove the carbon.

2. Check the spark plug type and gap.

Standard electrode color: Tan Color

Standard Spark Plug:BPR4ES(NGK)(F7RTC)

Gap:(0.028-0.031 inches)

3. Install the spark plug.

Spark Plug Torque:14 lbs. -Ft.

(0.028-0.031 inch)

ENGINE OIL REPLACEMENT

1. Place the machine on a level surface and warm up the engine. Then stop the engine.

2. Remove the rubber cap on the bottom..

3. Place an oil pan under the engine. Remove the drain bolt

4. Open the oil filler cover as shown and remove the oil filler

cap so that the oil can be completely drained.

5. Check the drain bolt, gasket, oil filler gap and O-ring.

6. Reinstall the oil drain bolt.-Drain Bolt Torque:12 Ft. lbs.

7. Add engine oil to the upper level.

• Recommended oil for most climastes:10 W30

• For extremely cold conditions the oil viscosity may be lowered to ease starting: 5W 30

• Engine Oil Quantity:0.63US qt

NOTE:

Recommended engine oil classification: API Service “SE” or “SF”

CAUTION

Be sure no foreign material enters the crankcase.

8. Install the oil filler cap.

9. Install the rubber cap on the bottom.

CAUTION

Be sure to install securely to prevent from falling off during operation.

10. Close the oil filler cover.

FUEL FILTER

WARNING

Do not smoke or have an open flame in the vicinity of the fuel and solvent.

1.Stop the engine:

2.Clamp the fuel line with the clip.

3.Replace the fuel filter.

FUEL TANK FILTER

1. Remove the fuel tank cap and filter.

2. Clean the filter with solvent, if damaged, replace.

3. Wipe the filter and insert it.

WARNING

Be sure the tank cap is securely tightened.

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14

TROUBLESHOOTING

ENGINE WON’T START

1. Fuel system, engine is not getting fuel.

• No fuel in tank... Supply fuel.

• Clogged fuel line... Clean fuel line.

• Foreign matter in fuel filter... Replace fuel filter.

• Clogged carburetor... Clean carburetor.

2. Engine oil light flashes

• Oil level is low... Add engine oil.

3. Electrical system

• Engine switch to “ON”. Poor or no spark.

• Spark plug is dirty... Replace sparkplug.

• Faulty ignition system... Consult dealer.

4. Compression Insufficient

•Worn out piston and cylinder... Consult dealer.

GENERATOR WON’T PRODUCE POWER

Stop the engine, then restart. If A/C lights continue to flash consult your dealer.

STORAGE

Long term storage of your machine will require some preventive procedures to guard against deterioration.

DRAIN THE FUEL

1. Remove the fuel tank cap. Drain the fuel tank into an approved gasoline container using a commercially available hand siphon. Then, install the fuel tank cap.

WARNING

• Fuel is highly flammable and poisonous.

• Wipe up any spilled fuel immediately.

2.Drain fuel from the carburetor by loosening the drain screw on the carburetor float chamber.

3.Turn the fuel cock lever to “OFF”. Start the engine and leave it run until it stops.

This will burn any remaining fuel in the carburetor.

ENGINE

1. Remove the spark plug, pour about one tablespoon of SAE 10W30 or 20W40 motor oil into the spark plug hole and reinstall the spark plug. Turn over engine several times (with ignition off) to coat the cylinder walls with oil.

2. Pull the recoil starter until you feel compression. The stop pulling. (This prevents the cylinder and valves from rusting).

3. Clean exterior of the generator and apply a rust inhibitor.

4. Store the generator in a dry, well-ventilated place, with the cover placed over it.

5. The generator must remain in a vertical position when stored, carried or operated.

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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

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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

13 - Ignition coil

14 - Spark plug

15 - AC-CDI unit

16 - Pulsar coil

17 - Stepping motor

18 - Charge coil

19 - DC receptacle

20 - Ballast

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BOLIY Pro 3600Si/ Pro3600SiE DSP INVERTER GENERATOR

SPECIFICATIONS & DIMENSIONS

OVERALL LENGTH (in)

OVERALL WIDTH (in)

OVERALL HEIGHT (in)

DRY WEIGHT (lb..)

SHIPPING WEIGHT (lb.)

FUEL TANK CAPACITY (US gal.)

NOISE LEVEL (1/4 load at 7m)

23

16.5

18.5

3600 SI - 68 lbs, 3600 SI/E - 74 lbs

SI - 72lbs, SI/E -78lbs

2.1

53-58 dB

GENERATOR

RATED OUTPUT (WATTS)

MAX OUTPUT (WATTS)

FULL TANK OUTPUT (WATTS)

RUN TIME AT 1/2 RATED LOAD

RUN TIME AT RATED LOAD

POWER CONVERSION RATE

RATED FREQUENCY (Hz)

RATED CURRENT (A)

DC OUTPUT (12V/8A)

3000

3300

13500

7.5 hours

4 hours

85-92%

60 50

25 13

YES

ENGINE

CYLINDER ARRANGEMENT

BORE X STROKE (mm)

IGNITION SYSTEM

SPARK PLUG TYPE

GAP (in)

DISPLACEMENT

RATED OUTPUT (HP) r/min

TC

/ELECTRIC START

INCLINED, SINGLE CYLINDER

66 X 50

CDI

BPR4ES (NGK) / F7R

0.8 (0.028 - 0.031)

171CC

(4.9) / 3600

FUEL

ENGINE OIL QUANTITY (US qt)

UNLEADED GASOLINE

THE FLUCTUATION OF VOLTAGE & FREQUENCY

-0.63

INSTANTANEOUS

STABLE STATE

STABLE TIME (second)

FREQUENCY

AUTOMATIC RELEASE PRESSURE

CHARACTERISTIC

ELECTRO-BREAKER

FUEL LEVEL GAUGE

ENGINE OIL WARNING LIGHT

OVERLOAD INDICATOR LIGHT

AC INDICATOR LIGHT

ENERGY CONSERVATION CURRENT IDLING

INSULATION CLASS

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25%

0%

3

0.2%

YES

YES

YES

YES

NO

YES

YES

F

ADDITIONAL GROUNDING INFORMATION & SAFETY TIPS

MAJOR CAUSES OF INJURIES AND FATALITIES

• Shocks & electrocution to users from improper use-improper connection to structures, such as

residences, offices, shops and trailers.

SAFE WORK PRACTICES

• Maintain and operate generators in accordance with the manufacturer’s use and safety instructions.

• Do not attach a portable generator directly to the electrical system of a structure(home,office or

trailer) unless the generator has a properly installed open-transition transfer switch.

• Always plug electrical appliances and tools directly into the generator using manufacturers supplied

cords. Use heavy duty extension cords that contain a grounding conductor(3-wire flexible cord and

3-pronged cord connectors).

• Proper grounding and bonding prevent shocks and electrocutions.

• Use ground-fault circuit interrupters(GFCIs)as per the manufacturer’s instructions.

• Visually inspect the equipment before use; remove defective equipment from service; mark or tag it

as unsafe for use.

GROUNDING REQUIREMENTS(Portable and Vehicle-mounted Generators)

Under the following conditions, OSHA directs that the frame of a portable generator need be grounded

(connected to earth)and that the frame may serve as the ground(in place of the earth):

·The generator supplies only equipment mounted on the generator and/or cord-and plug-connected

equipment through receptacles mounted on the generator.

·The noncurrent-carrying metal parts of equipment(such as the fuel tank, the internal combustion

engine, and the generator’s housing)are bonded to the generator frame, and the equipment grounding

conductor terminals are bonded to the generator frame.

Thus, rather than connect to a grounding electrode system, such as a driven ground rod, the generator’s frame replaces the grounding electrode.

If these conditions do not exist, then a grounding electrode, such as a ground rod, is required.

If these conditions do not exist, then a grounding electrode system, such as a driven ground rod, the generator’s frame rep; aces the grounding electrode.

If the portable generator is providing electric to a structure by connection via a transfer switch to a structure(home,office,shop,trailer,or similar)it must be connected to a grounding electrode system, such as a driven ground rod. The transfer switch must be approved for the use and installed in accordance with the manufacturer’s installation instructions by a qualified electrician.

SAFE WORK PRACTICES FOR PORTABLE TOOLS

• Do not use underrated cord--replace them with appropriately rated cords that use heavier gauge wires.

• Never use electrical tools or appliances with frayed cords, missing grounding prongs, or damaged or

cracked housings.

• Use double-insulated tools and equipment distinctively marks as such, where possible.

• Use batter-operated tools, where possible.

BONDING VERSUS GROUNDING

Bonding and grounding are separate requirements for generators and other electrical distribution systems. Grounding means the connection, or the establishment of a connection, of an electric circuit or equipment to reference ground, which includes the generator’s frame. Bonding is the intentional connection between the grounded circuit conductor(neutral)and the grounding means for the generator, which includes the generator’s frame. Thus, effective bonding of the neutral conductor to the generator’s frame is also a concern for the safe use of the equipment. As with grounding terminal connections, proper bonding of the neutral terminal of a power receptacle may be confirmed via testing by a competent electrician with the correct equipment, and the ohmic resistance should measure near zero and must not be intermittent, which indicates a loose connection.

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PORTABLE GENERATOR HAZARDS

A Fact sheet on Portable Generator Safety

Portable generators are useful when temporary or remote electric power is needed, but they can be hazardous. The primary hazards to avoid during use are carbon monoxide poisoning, electric shock or electrocution, and fire.

TO AVOID CARBON MONOXIDE HAZARDS:

• Always use generators outdoors, away from doors, windows, and vents.

• NEVER use generators in homes, garages, basements, crawl spaces, or other enclosed or partially

enclosed areas, even with ventilation.

• Follow manufacturer’s instructions.

• Install battery-operated or plug-in(with battery backup)carbon monoxide(CO)alarms in your home,

following manufacturer’s instructions.

• Test CO alarms often and replace batteries when needed.

TO AVOID ELECTRICAL HAZARDS:

• Keep the generator dry. Operate on a dry surface under an open, canopy-like structure.

• Dry your hands before into generator or use a heavy-duty outdoor-rated extension cord that is free of

cuts or tears and the plug has all 3 prongs, especially a grounding pin.

• NEVER plug the generator into a wall outlet. This practice, known as backfeeding, can cause an

electrocution risk to utility workers and others and served by the same utility transformer.

• If necessary to connect generator to house wiring to power appliances, have a qualified electrician

install appropriate equipment. Or, your utility company may be able to install an appropriate transfer

switch.

TO AVOID FIRE HAZARDS:

• Before refueling the generator, turn it off and let it cool. Fuel spilled on hot engine parts could ignite.

• Always store fuel outside of living areas in properly labeled, non-glass containers.

• Store fuel away from any fuel-burning appliance.

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For more information contact:

The U.S. Fire Administration

16825 South Seton Avenue

Emmitsburg, MD 21727

Or

Visit the USFA Web Site: www.usfa.fema.gov

Appendix

High Altitude Jetting 4,000 Feet and Over

Change nozzle jet for high altitude application

Modifications are as follows:

On the bottom of the carburetor bowl there is a large hex nut. Unscrew the nut and pull off the bowl.

Right up the center of where the nut just unscrewed from is the nozzle jet.

Take the proper flathead screwdriver and carefully insert up the hole and unscrew the jet. Be very careful as the jet is brass. Remove jet only as there are other parts above the jet that might fall out. Insert new jet and screw back into bottom of hole doing exactly opposite of what you did to get jet out. do not over tighten jet, only get it seated snugly.

Part number:

BOLYE17

Replace fuel bowl and the nut in the bottom center and also tighten snugly. Note, you can take a small mirror and place under the carburetor and see the jet and also you will need this as well to make sure that the fuel bowl is aligned properly. It is very easy for the fuel bowl to hang up on a flange of the aluminum carburetor casting and not seat on the gasket that sits between the fuel bowl and carburetor casting causing a leak. After this is done turn on the gas and check for leaks. After this is done turn on the gas and check for leaks. If there are leaks it will most likely be that the fuel bowl is not sitting on the gasket properly as it is very easy to hang up on the carburetor casting. If it leaks, just loosen the center nut and move fuel bowl around to seat properly on the gasket only and re-tighten nut.

The best screwdriver to get jet out with is just the multi type screwdriver and camps it with a small pair of vise grips. Be very careful not bo over tighten and also watch proper counter-clockwise to remove and clockwise to re-install.

Note; there is also a small gasket between the fuel bowl and the nut. Don't loose it and make sure its there when you replace nut or it will leak.

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Suzhou Zhonggu Mould Co., Ltd.

Huangqiao Industrial Park,

Suzhou Jiangsu,

215132,China

Tel: +86-512-65466507

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BOLIY WARRANTY

REGISTRATION

You can also register ONLINE at www.boliypower.com

Important ! Please complete and return within the next 15 days!

Digital inverter generator

1.

First Name Initial Last Name

Street Apt. No.

City State ZIP code

E-mail Address:

2.

Date of birth

4.

Telephone Number

6.

Serial Number

MM YY YY

3.

Marital status

5.

Date of the purchase

Month Day ear Y

7.

Name of the store where purchased

8.

Price you paid (excluding sales tax): $

9.

If you feel there is need for improvement, what should it be?

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Fold, staple or tape as indicated, and mail.

Fold Here

Boliy Power America,

PO BOX 007 Iselin,

NJ 08830-0007

Fold Here

PLACE STAMP

HERE

The Post Office will not deliver mail without postage.

Fold Here

Fold Here

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22

www.boliypower.com

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Suzhou Zhonggu Mould Co., Ltd.

Huangqiao Industrial Park,

Suzhou Jiangsu,

215132,China

Tel: +86-512-65466507

Version 7, 2010