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HOW TO RESOURCE: Boliy Pro3600Si Basic Troubleshooting



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

WHAT IF YOUR GENERATOR DOES NOT START?
FUEL VALVE & ENGINE ON SWITCH
ENGINE OIL LEVELS
LOW OIL SHUT DOWN
FUEL SUPPLY
FOULED SPARK PLUG
CHECKING FOR SPARK
MORE COMPLEX PROBLEMS
GENERATOR POWER OUTTAGE

WHAT IF YOUR GENERATOR DOES NOT START?

If your Boliy generator engine will not start, here are a few things to check as you try to isolate problem:


FUEL VALVE & ENGINE ON SWITCH:

A)Sometimes the simplest possibilities are cause of problem. If generator will not start, check to see that fuel valve(located beneath recoil start) has been turned ON, and that engine switch(located above and to left of outlets) is also ON.

ENGINE OIL LEVELS:

B)If engine oil is low, your Boliy generator will not start. Open oil filler tube(located inside compartment beneath generator outlet panel), and check to see that oil extends halfway up filler tube threads(considered full capacity). If not, add oil and try starting generator.

LOW OIL SHUT DOWN:

If oil levels are adequate and generator still will not start, low oil shut down feature may be malfunctioning. To test, do the following:

C)Turn generator engine switch ON, and pull recoil start. Watch low oil warning lamp in control panel. If lamp flickers, sensor believes oil levels are insufficient.

D)Low oil sensor must therefore be deactivated. Look for BLACK wire entering engine block above oil fill tube. Do not disconnect wire at block!

Instead trace black wire to connection point(where it mates with secondary wire) in opposite direction, and separate. This will allow generator to run.

REMEMBER: to be especially vigilant monitoring oil levels by eye anytime you use generator with low oil feature deactivated.

TIP: there is no easy fix for a malfunctioning low oil sensor. Replacing sensor involves opening up engine block. If sensor is malfunctioning, the simplest remedy is to operate generator with it disengaged!

If oil levels are fine and low oil shut down is functioning properly, yet generator refuses to start, you will need to seek another cause.


FUEL SUPPLY:

A)Be sure that vent in fuel cell cap is switched ON.

B)Be sure there is sufficient fuel in tank. If you are starting generator for first time from its shipping box, or if it has been in long term storage(so that fuel lines and tank were drained), tank should be filled to at least ONE HALF capacity.

REMEMBER: Boliy generators employ gravity based fuel distribution instead of a standard fuel pump. The additional weight of fuel in tank will help prime lines!

TIP: for best results, always use fresh gasoline. Without additives, gasoline will go bad in roughly six months. If you fill tank with bad fuel, generator will either run poorly, or not at all.

If you determine there is bad fuel in system, drain it by removing tank(see BOLIY TROUBLESHOOTING: CARBURETOR for instructions).

C)Check to see if fuel is reaching carburetor bowl.

To do this, loosen drainage screw attached to the clear plastic drainage tube which exits back panel of generator. Drainage screw can be reached with flathead screwdriver through upper left hole of ventilation grid in back panel.

CAREFUL: not to remove screw completely. To replace it, back panel of generator would need to be pulled.

TIP: try shining flashlight beam through sparkplug door in back panel to help you see drainage screw!

IF NO FUEL IS REACHING CARBURETOR BOWL:

If fuel is failing to reach carburetor, there are three possible causes: 1)fuel line is crimped or clogged; 2)fuel filter is clogged; 3)fuel cock or carburetor is malfunctioning.

D)There are three segments of fuel line to examine. The first runs from fuel tank to bell shaped fuel filter; the second runs from fuel filter to fuel cock; the third runs from fuel cock to carburetor.

Look for crimps in line first. If found, repair, and test to determine if gas is now reaching carburetor bowl.

If no crimps are discovered, then you may be dealing with a clog. Do the following: E)The likeliest positions for clogs are: 1)in the line between fuel tank and fuel filter. Check it first; 2)if no obstruction is found, check segment of line between FUEL COCK and carburetor; 3)last line segment to check runs between fuel filter and fuel cock.

If a clog is discovered, remove and test to determine if gas can now reach carburetor bowl.

F)If fuel line is clear, then your problem is probably with fuel filter(white plastic and bell shaped, located inside front panel of generator near fuel cock). If fuel filter is cause of blockage, it will need to be replaced.

TIP: replacement of fuel filter is not complicated, but it will require removal of side and back generator panels(for disassembly instructions, see section BOLIY TROUBLESHOOTING: CASING).

G)If fuel lines are fine and fuel filter has been replaced, and still no gas is reaching carburetor bowl, FUEL COCK may be bad, or there may be a CARBURETOR problem; consult your authorized Boliy dealer.


FOULED SPARK PLUG:

A)If engine will not start, and fuel supply does not appear to be the reason, remove spark plug and check to see that electrodes are not contaminated with dirt or carbon.

Also check plug gap for accuracy(gap should be in range of 0.7 to 0.8 mm or 0.028 to 0.031 inches).


CHECKING FOR SPARK:

If generator will not start, and the above things have been checked and no abnormalities discovered, then one of following problems may exist:

TIP: these are harder fixes which may require exchanging parts or the use of special tools. They are best left to your authorized Boliy dealer.

A)The computer controlled ignition system may not be functioning.

B)There may be a problem with windings in ignition coil.

C)There may be a bad wire or connection in ignition circuit.

Problems A through C can be diagnosed by checking for ignition spark. Here is how to do it:

TIP: it is easier to check for spark if a friend helps. Spark on generator models(like inverters) that sport polyurethane cases often cannot be done without a helper unless there has been substantial disassembly to case!

D)Unscrew spark plug from block; attach plug wire to tip of plug.

E)Using insulated pliers for safety, hold plug electrode to engine block or alternative ground.

F)Have friend briskly pull recoil start. You should see spark flash across electrodes as recoil start is pulled.

WHAT TO WATCH FOR: keep your eye open for two things:

First, that spark is bluewhite in color. A spark that is orange or yellow indicates worn parts.

Second, that spark is consistent(not sporadic). Spark should appear each time recoil start is pulled. If it appears haphazardly, there are worn parts in ignition system.

G)If no spark appears, the plug itself may be bad. There are two ways to check: one is to test for spark again using new plug; another is to remove plug from plug wire, hold naked end of plug wire to ground, and have friend pull recoil start. You should see spark jump between plug wire and ground.


MORE COMPLEX PROBLEMS:

If you determine that gas flow to carburetor is sufficient, and if spark appears adequate, yet generator refuses to run, it may indicate one of following internal engine problems:

A)Cylinder head or piston or both may be worn or damaged.

B)Cylinder head gasket may be damaged, causing low engine compression.

C)Cylinder head nuts may be loose, affecting compression.

D)A combination of the above problems may exist. Consult authorized Boliy dealer for repair options and other recommendations.


GENERATOR POWER OUTAGE:

If your Boliy generator has stopped producing power, before assuming that a major problem exists, turn machine off and try restarting. It could be that electronic circuit breaker has been tripped; if so, restarting motor will reset.

If power outage continues, consult your authorized Boliy generator dealer for instructions.



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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.