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HOW TO RESOURCE: BOLIY GENERATOR MAINTENANCE



In this section, you will find information on the following:

DAILY-OPERATION CHECKS
MONTHLY-OPERATION CHECKS(every 20 hours)
CHECKS AFTER THREE MONTHS(or 50 hours)
CHECKS AFTER SIX MONTHS(or 100 hours)
CHECKS AFTER TWELVE MONTHS(or 300 hours)
SPARK-PLUG CARE
REPLACING ENGINE OIL
CARING FOR FUEL-TANK FILTER
CARING FOR SPARK ARRESTOR

In order to keep your Boliy generator operating properly, regular maintenance is essential.

Following are some standard generator maintenance needs, and how often to perform them:

WARNING: Never attempt to perform maintenance work with the generator engine running!


DAILY-OPERATION CHECKS:

A)Engine-oil levels.

B)Examine fuel line for cuts or breaks; replace if necessary.

C)Look for exhaust leaks around muffler; inspect wire mesh in muffler tip.

D)See that choke cable has correct amount of play(roughly 1/2 inches).

E)See that recoil start is operating smoothly.

F)Make sure that AC pilot light(which doubles as overload indicator with load attached) flickers on when generator is started.


MONTHLY-OPERATION CHECKS(every 20 hours):

This ONLY applies to a new generator being used from box for the first time! Oil should be changed after first 20 hours of operation to remove any shavings, particles, or debris which manufacturing process may have left in engine!

REMEMBER: that regular oil-change interval after first 20 hours of operation is 6 months or 100 hours.

A)Replace engine oil(using 10W-30 weight).


CHECKS AFTER THREE MONTHS(or 50 hours):

A)Examine spark plug; adjust gap, and clean if necessary.

B)Clean foam air-filter element, replacing if necessary.


CHECKS AFTER SIX MONTHS(or 100 hours):

A)Replace engine oil(with 10W-30).

B)Clean fuel-tank filter, replacing if necessary; insure that fuel cock operates smoothly.

C)Check and clean spark arrestor, replacing if necessary.

D)Check bolts, fittings, and fasteners for continued tightness.


CHECKS AFTER TWELVE MONTHS(or 300 hours):

A)Check and adjust valve clearance – should always be done when engine is cold(we recommend that valve adjustments be performed by authorized Boliy dealer).

B)Check for damage to cooling fan(should be performed by authorized Boliy dealer).

C)Carburetor maintenance.


SPARK-PLUG CARE:

Follow these pointers for basic spark-plug care:

A)With plug removed, look for discoloration on the electrode. If generator engine is operating properly, electrode color will be tan or light grey.

TIP: Boliy generators are sold from the factory to be operated at sea level. If you find spark-plug electrodes covered in soot, it means that generator engine is running rich or burning too much fuel.

For help changing carburetor jets for altitude operation, and adjusting carburetor's air/fuel mixture, see how-to section BOLIY TROUBLESHOOTING - CARBURETOR.

To obtain high-altitude fuel jets, contact your authorized Boliy dealer.

B)After spark plug has been cleaned, check gap(should be between 0.7 – 0.8 mm or 0.028 – 0.031 inches). Adjust if necessary.

TIP: because spark plugs are not precisely pre-gapped at factory, or checked before being installed, it is good practice to insure proper gap before starting generator from the box.


REPLACING ENGINE OIL:

TIP: if possible, engine oil should be replaced when engine is warm. Warming engine will thin oil, helping it to drain more completely. Running generator 2 – 5 minutes should thin oil without making motor components too hot to touch.

Follow these procedures to change engine oil in your Boliy generator:

A)With the engine warm(see above), place generator on level surface.

B)Remove oblong rubber cap from right-end(facing generator from outlet-panel side) of underneath pan. This will expose oil-drain plug.

C)After placing oil pan beneath engine, carefully unscrew drain bolt.

D)Open compartment underneath generator outlet panel. Unscrew and remove cap from oil-filler tube. This will help engine drain more thoroughly.

CAUTION: While drain plug is removed, take precautions to keep dirt or foreign matter from entering engine block.

E)Before replacing drain bolt in bottom of generator, inspect accompanying gasket to see that it remains in good condition. If cracked or broken, replace.

F)Re-install oil drain plug, tightening to 12 lb-ft(or 1.7 kg-m) of torque. Replace oblong rubber cover to protect engine bay from dirt and debris.

G)Before refilling generator with oil, check the O-ring on the filler plug for damage or cracks.

H)Add 10W-30 weight motor oil(capacity is 0.6 liters or 0.63 U.S. quarts). Oil should extend halfway up filler-tube threads when full. Replace filler cap. You're ready to go!

REMEMBER: not to overfill. This can cause overheating and sluggish engine operation.

NEVER: add oil with generator tilted, a sure way to overfill!


CARING FOR FUEL-TANK FILTER:

For fuel-tank filter maintenance, do the following:

A)Remove fuel-tank cap so that filter can be withdrawn.

B)Examine filter for tears or other damage; replace if necessary.

C)If filter remains in good condition, clean with solvent and dry with a clean cloth before re-inserting.


CARING FOR SPARK ARRESTOR:

WARNING: For safety reasons, it is advisable to allow engine to cool prior to toying with spark arrestor or other exhaust-system components. Handling a hot exhaust can result in severe burns.

A)Remove spark arrestor(will be attached to the metal tip on your generator muffler).

B)The part of the spark arrestor which needs inspection and cleaning is the cone of mesh screening that extends into muffler. Best way to slide mesh screen from metal tip is to press gently from the outside. Careful not to apply too much pressure.

C)Check muffler screen for damage, and then use wire brush to remove accumulated particles.

CAUTION: if you discover tears, rips, or holes in mesh screen of spark arrestor, it should be replaced. The spark arrestor is a safety device, designed to capture sparks that can escape in generator exhaust.

It is particularly crucial to maintain condition of spark arrestor if your generator will be used in an outdoor recreational setting! Even one unwanted spark from a generator tailpipe can produce a wildfire.

D)After mesh screening has been cleaned, gently press into metal tip and reinstall onto exhaust.

TIP: Don’t forget to securely tighten down muffler-tip clamp. Generator exhaust can produce enough force to knock off a loose tip.



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T-Rex Generators distributes products from many different standby and portable generator manufacturers at substantially discounted prices. These represented companies include: Asco automatic transfer switches, Briggs & Stratton generators, Winco generators, Generac Generators, GenTran transfer switches, Reliance Controls Transfer Switches, and Zenith automatic transfer switches. T-Rex also carries Honda powered generators which have the same time-tested Honda engines as the substantially more expensive Honda generator brand units.