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Summary of Contents for Boss DY8500 Series
- Page 1 OWNER’S MANUAL DY8500 GENERATOR AIR-COOLED DIESEL ENGINE GENERATOR 1 - 8 8 8 - 5 5 7 - 5 2 4 4 s a l e s @ b o s s f o r k l i f t s . c o m w w w .
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Page 2: Table Of Contents
TABLE OF CONTENTS: Chapter 1: Overview Chapter 3: Maintenance ........15 Technical Specifications & Data ......3 3-1 Maintenance Schedules ....... 15 3-1.1 Changing the Engine Oil ......16 Chapter 2: Operating The Diesel Generator 3-1.2 Replacing the Oil Filter ......16 2-1 General Main Points of Safety During 3-1.3 Air Filter Maintenance Schedule .. -
Page 3: Chapter 1: Overview
CHAPTER 1: OVERVIEW TECHNICAL SPECIFICATIONS & DATA (in SI Units) ITEM/MODEL DG8500LN Excitation Self-excitation voltage Condenser Compensation Voltage System System Frequency (Hz) Rated power (kW) AC Rated Voltage (V) 110, 220, 230, 240, 110/220, 120/240, 220/380, 230/400 DC Rated Output (V-A) 12-8.3 Speed (rpm) 3000/3600... -
Page 4: Chapter 2: Operating The Diesel Generator
CHAPTER 2: OPERATING THE DIESEL GENERATOR 2-1 General main points of safety during operation of the generator set. 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. 2-1.1 Fire Preventions The proper fuel for the diesel generator set is light diesel fuel. -
Page 5: 2-1.5 Other Safety Points
NOTE: When connecting devices to the generator, make sure all other devices are rated lower than the generators output. Any generator socket should not be overloaded over its regulated limit. 2-1.5 Other Safety Points Before operating this generator, all operators should have a good knowledge of how to break the circuit if any accidents occur. -
Page 6: 2-2 Preparation Before Operation
2-2 Preparation Before Operation 2-2.1 Fuel Choices and Fuel Treatment Air Filter Element Fuel Tank Do not wash the air filter. The element Use only light diesel fuel. The fuel should be is made of dry material, which does not clean. -
Page 7: 2-2.2 Fill Engine Oil
2-2.2 Fill Engine Oil Fabrication Oil Filling Inlet Put the generator set in a level state. Fill the oil into the oil-filling 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. -
Page 8: 2-2.3 Check Air Filter
2-2.3 Check Air Filter 2-2.4 Checking the Generator (1) Loosen the butterfly nut, take the cover of Before starting the generator, make sure the the air filter off and take the air filter out. air switch is in the “off” position. Starting the generator with the switch in the “on”... -
Page 9: Checking The Operation
Checking the Operation (3) Check the outer cover of the oil nozzle. Loosen the butterfly nut and of the Diesel Engine 2-3.1 Low-pressure alarm system. open the outer cover. The diesel engines have a low- pressure sensor system where if the oil pressure drops too low, the sensor RUBBER will shut the engine off. -
Page 10: Starting The Generator
Starting the Generator 2-4.2 Electric Starting 2-4.1 Manual Starting The procedure for preparing to start Start the engine in accordance with the engine are the same as the procedure below: manual starting engine. (1) Put the fuel switch in the “ON” position. - Page 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, fill it with distilled water until it reaches the high mark.
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Page 12: Proper Operation Of The Generator
Proper Operation Loading of the Generator Set 2-6.1 Load Conditions 2-5.1 Operating the Diesel Engine Exert loads in accordance with the Pre-heat the diesel engine for 3 specified parameters. minutes under no load conditions. First check the height of the 2-6.2 Output of Electricity lubricating oil level, if it is low, refill it. -
Page 13: 2-6.3 Charging The Battery
various devices are too high. In this 5. When charging the battery, the event, decrease the number of small battery produces flammable gases. devices until everything is functional. Do not smoke, flames, and sparks The total drawn power should not get near the battery while it is exceed the maximum output power charging as this may cause a fire. - Page 14 4. Press down on the brake handle. 7. Finally, pull slowly on the recoil 5. If equipped with an electric starter, handle until you feel resistance turn the key to the “OFF” position. (this is when the piston is on the 6.
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Page 15: Chapter 3: Maintenance
CHAPTER 3: MAINTENANCE 3-1 Maintenance Schedules 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. -
Page 16: 3-1.1 Changing The Engine Oil
3-1.1 Changing the Engine Oil 3-1.4 Fuel Filter Maintenance (every 100 hours) 1. The fuel filter should be cleaned Take the oil cover out. Take off the oil often to keep the engine running at drain plug when the diesel engine is maximum performance. -
Page 17: 3-2 Storing For Long Periods Of Time
3-2 Storing for Long Periods of Time 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. -
Page 18: Troubleshooting
CHAPTER 4: OVERHAULING AND TROUBLESHOOTING 4-1 Overhauling & Troubleshooting Procedures Causes of Malfunction Remedy 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 Disassemble the nozzle and adjust it at test inject fuel or the injected amount is less. -
Page 19: Chapter 5: Part Listings
CHAPTER 5: PART LISTINGS Overall view of engine generator assembly Number Part Description Quantity Part Number Series Diesel Engine 4LN1/6LN1 Starter Motor 4LN2/6LN2 Flywheel Generator 4LN3/6LN3 Bolt 4LN4/6LN4 Voltage Regulator 4LN5/6LN5 Battery Cable (red, black) 4LN6/6LN6 Battery 4LN8/6LN7 Oil Level Sensor 4Ln9/6LN8 Generator 4LN9/6LN9... -
Page 20: Exploded View Of Frame Assembly
Exploded view of frame assembly Number Part Description Quantity Part Number Muffler Cover Plate 4LN17/6LN17 Muffler Elbow 4LN18/6LN18 Left Outer Cover 4LN19/6LN19 Fuel Gauge 4LN21/6LN21 Fuel Tank Sleeve 4LN22/6LN22 Main Cover 4LN23/6LN23 Door Knob 4LN24/6LN24 Right Outer Cover 4LN27/6LN27 Output Panel Assembly 4LN28/6LN28 Air Cleaner Cover 4LN29/6LN29... -
Page 21: Electric Panel Parts Drawing
Electric panel parts drawing Number Part Description Quantity Part Number Positive DC Port 4LN37/6LN37 Negative DC Port 4LN38/6LN38 Grounded Bolt 4LN39/6LN39 Bolt 4LN40/6LN40 Large Nut 4LN41/6LN41 Bolt 4LN42/6LN42 Bolt 4LN43/6LN43 Large Nut 4LN44/6LN44 Current Adjusting Switch 4LN45/6LN45 3 Prong Socket 4LN46/6LN46 Bolt 4LN47/6LN47... -
Page 22: Generator Head Assembly
Generator Head Assembly Number Part Description Quantity Part Number Front End Cover 4LN64/6LN64 Diode 4LN65/6LN65 M4 x 8 Bolt 4LN66/6LN66 Fan Blade 4LN67/6LN67 Bearing 4LN68/6LN68 Rotor Unit 4LN69/6LN69 Center Bolt 4LN70/6LN70 Motor Cover 4LN71/6LN71 Stator 4LN72/6LN72 Long Bolt 4LN73/6LN73 Capacitor 4LN74/6LN74 Wiring Seat 4LN75/6LN75... -
Page 23: Fuel System Components
Fuel System Components Number Part Description Quantity Part Number Fuel Cap 4LN79/6LN79 Seal 4LN80/6LN80 Filtering Cup 4LN81/6LN81 M5 x 10 Screw 4LN82/6LN82 Fuel Lever Indicator 4LN83/6LN83 M6 x 25 Bolt 4LN84/6LN84 Large Flat Washer 6 4LN85/6LN85 Fuel Tank Lining 4LN86/6LN86 Shock Absorbing Gasket 4LN87/6LN87 Fuel Tank...
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Questions and answers
where would I go for service for this generator? Can it be connected for automatic startup as a standby generator when there is a power outage? What is the sound level during household use? (near max output)
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Hulp nodig? Heeft u een vraag over de DY8500-serie en staat het antwoord niet in de handleiding? naar 12 uur slaat die uit het lijkt dat die geen brandstof krijgt en daar naar niet meer willen aangaan start wel slaat niet aan