Toyama XP LINE User manual

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DIESEL GENERATOR XP LINE
Owner’s Manual

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Contents
1. FOREWARD..........................................................................................................3
2. GENERAL SAFETY INFORMATION.....................................................................5
3. PARAMETERS......................................................................................................7
4. DESCRIPTION OF SPARE PARTS.....................................................................8
5. OPERATION METHOD.........................................................................................9
6. STARTING THE GENERATOR SET...................................................................10
7. SHUT DOWN THE ENGINE...................................................................................14
8. STORAGE...........................................................................................................15
9. TRANSPORTING................................................................................................16
10. ACCESSORIES INSTALLATION.....................................................................17
11. POWERS OF COMMON APPLIANCES...........................................................18
12. MAINTENANCE...............................................................................................20
Replace the engine oil.............................................................................................21
Air filter inspection...................................................................................................21
Clean engine oil filter...............................................................................................22
Valve clearance (should be conducted by a professional person) ...........................22
13. COMMON FAULT ANALYSIS..........................................................................23

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Save this operating manual properly and carry it with the generator for the convenience of
emergency query in the future. This manual constitutes one permanent element of the
generator. This manual shall be provided along with the generator set when you lend or resell it.
Relevant information and technical specifications defined in this manual take effect when
printing is approved, with the contents based on the equipment in production at time of
publication. TOYAMA reserves the rights to modify and improve any parts described in the text
without prior notice.
1. FOREWARD
Thank you for purchasing TOYAMA diesel generator. This air cooling device, powered by diesel
engine, is a household generator of compact structure and high performance. It is applicable to
the situation of no electricity supply or sudden electricity cut. We recommend that the operator
read this manual carefully before use this generator, and fully comprehend all requirements and
operating procedure concerning the generator. In case of any questions about this manual,
contact the recent authorized dealer for startup, operation, maintenance program and so on.
The technician will teach you how to use the generator in a correct and safe manner. We also
recommend that the operator consult startup and operating procedure of this generator when
buying it.
SAFETY PRECAUTIONS
This generator will work in a safe, effective and reliable way only when it is kept, operated and
maintained properly. Before operation or maintenance of the generator, the operator should:
Know well and strictly observe local laws and regulations.
Read and observe all safety warnings in this manual and on the device.
Let your family get familiar with all safety warnings in this manual.
It is impossible for manufacturers to predict all hazardous circumstances that may occur, for this
reason, warnings in this manual and caution signs on the generator set may not cover all
hazardous circumstances. If we do not give extra cautions for operating procedures, methods or
techniques, operate the generator in such ways that helps guarantee personal safety, make
sure no damage to generator set arises there from.
To make sure safe operation, Please read carefully three vital safety warnings in this manual
and on the generator, preceded by a safety alert symbol including:
DANGER - You WILL be KILLED or SERIOUSLY HURT if you don't follow instructions.
You CAN be HURT if you don't follow instructions.
NOTICE - Your generator or other property could be damaged if you don't follow instructions.

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1. SAFETY REGLATIONS
DANGER - Do not use it indoors.
DANGER - The generator surface has high
temperature, avoid scalding. Pay attention to
the warnings on the generating set.
DANGER - Keep the machine clean and avoid
spilt combustibles including diesel fuel on it.
DANGER - Do not connect to a home power
system

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WARNING - It must realize safe grounding.
2. GENERAL SAFETY INFORMATION
Operator should put on personal protective equipment
During operation and maintenance.
The installation and major repair work shall be carried
Out only by specifically trained personnel.
Do not use the generator underground.
Do not use the generator under an explosive condition.
The generator produces enough electric power to cause a serious shock or
electrocution if misused.
It is prohibited to use bare wire to connect power supply to the electric equipment
directly, use the plug that fits local regulations.
In equipment operation, do not touch wire or live parts of the equipment. Never touch
the machine with wet hands or electrical shock will occur.
In equipment operation, keep children certain safe distance from the generator.
In equipment operation, strictly prohibit assembling and disassembling any parts.
It is suggested to realize tandem connection of a ground fault circuit interrupter (GFCI)
when the power supply is out to guarantee safety.
External electric accessory (including cable and plug interconnecting piece) shall have
no fault. Electric shock defend depends on the breaker, especially the matching
between breaker and generator. During replacement of the breaker, only that with the
same rating and performance features can be adopted. Contact local dealers or the
after-sales service center for support.
In case of using lengthening wire or mobile power distribution cabinet, overall length of
the wire with cross section of 1.5mm shall be no longer than 60m, and that
of 2.5mm shall be no longer than 100m.
Avoid connecting the generator in parallel with any other generator.
DANGER
FUEL OF THE MACHINE IS FLAMMABLE,
WHICH WILLGENERATE HIGH TEMPERATURE AND EASILY CAUSE FIRE
DURING OPERATION.
It is strictly prohibited to add fuel during equipment operation.
In case of adding fuel, keep far away from fire brand, no smoking.
In case of adding fuel, do not spill fuel on the equipment.
As to accidental spilling, use cotton cloth to clean it.
In operation, make sure that there is no flammable substance within 2 meter range, and
no flammable substance will approach the equipment.
In case of long-term nonuse, take out the fuel from fuel tank and store it safely.

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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 with
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 fuel tank.
Do not throw the residue fuel and used motor oil into the trash or pour it onto the
ground. We suggest you take used oil in a sealed container to your local recycling
center or service station for reclamation.
CAUTION
THIS EQUIPMENT CONTAINS HIGH SPEED REVOLVING PARTS, WHICH
WILL HARM HUMAN BODY
In equipment operation, do not approach it and strictly prohibit touching revolving parts.
In equipment operation, do not lift or move it. Move it only after equipment completely
stopped.
In equipment operation, observe surroundings. Make sure no articles are involved into
the equipment.
NOTICE - OPERATING REQUIREMENTS
Do not place heavy weight on the equipment.
The wheel is for easy moving of the equipment. Do not use it for long distance moving,
otherwise it will be damaged.
Prevent duct from entering into the equipment during peration or storage.
THERE IS THE WARNING LABEL ON THE MACHINE TO REMIND YOU OF
THE SAFETY REGULATIONS. PLEASE READ THEM.

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3. PARAMETERS
Modelo / Model
TDG8000EXP
TDG8000EXP3D TDG8000EXP3
Código / Part Number:
252-002 252-003 252-004
Motorização / Engine
Motor / Engine type : quatro tempos diesel / 4 cycle diesel
Cilindrada / Displacement [cm³] : 462 462 462
Sistema de Refrigeração / Cooling system : ar / air ar / air ar / air
Potência máxima/Maximum power [kW(HP)] : 12,1 12,1 12,1
Potência nominal / Net power [kW(HP)] : 10,1 10,1 10,1
Rotação Nominal / Rated speed [rpm]: 3600 3600 3600
Nº de cilindros / Number of Cylinders: monocilindrico / monocylinder
Tanque de combustível/Fuel tank capacity [L]: 14,5 14,5 14,5
Capacidade Oleo / Oil capacity [L]: 1,6 1,6 1,6
Sistema de partida / Starting system: partida elétrica / electric start
Alternador / Alternator
Tipo / Type :
Monofásico duas
tensões/ Dual
Phase two
voltage
Trifásico / Three
Phase Trifásico/ Three Phase
Regulador de Tensão / Voltage regulator AVR AVR AVR
Saída CA / Output AC: Monofásico / Single
Phase : 120 / 240 127 V 220 V
Saída CA/Output AC:Trifásico/Three Phase : X 220 V 380 V
Frequência / Frequency : 60 Hz 60 Hz 60 Hz
Corrente Nominal / Nominal Current [A] :
46A/120
23A/240 18A 10.4A
Fator de Potência / Power Factor [cos Ø ] : 1,0 0,8 0,8
Potência Máxima / Máx POWER [kW]: 6,0 6,0 6,0
Potência nominal / RATED POWER [kW] : 5,5 5,5 5,5
Horas de Trabalho Contínuo /CONTINUING
TIME [horas / hours]* : 7~10 7~10 7~10
Base / Base : Sobre rodas/On
wheels Sobre rodas/On wheels Sobre rodas/On wheels
Dimensões (CxLxA)/Dimensions (lxwxh) [mm] : 720 X 545 X 630
720 X 545 X 630 720 X 545 X 630
Peso líquido/Net weight [kg] : 112 112 112
Peso bruto/Gross weight[kg] : 117 117 117
AVR: SIM / YES SIM / YES SIM / YES
Bateria / Battery : NÃO / NO NÃO / NO NÃO / NO
Rodas / Wheels : SIM / YES
(duas/two) SIM / YES (duas/two) SIM / YES (duas/two)
Alerta de Óleo / Oil alert : SIM / YES SIM / YES SIM / YES

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4. DESCRIPTION OF SPARE PARTS

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Sockets can be following patterns according to relevant regulations in various areas:
WARNING
When the rated current from one socket output more than the socket 's nominal
rated current , you shoud to use simultaneously two or more sockets for power
output.
5. OPERATION METHOD
Unit grounding
Shift the machine outdoors, use wire of no less than
2,5mm2 to make the machine and grounding terminal
connected to the ground. One end of the wire is
pressed below the butterfly nut of the unit, screwed up
tightly, and the other end is connected with the metal

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rod shape article (such as the iron nail and the opener), and inserted into soil.
6. STARTING THE GENERATOR SET
Filling oil
Remove the oil filler cap,fill oil of proper model.As to dosage.Use the funnel for fil
ling,incase of careless spilling,clean the ground to avoid slipping.
Oil specification
Oil Viscosity Select the appropriate engine oil viscosity based on the ambient
temperature and use the SAE Service Grade Viscosity in the chart.
Upper level

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Filling fuel
Open the fuel tank cap and fill diesel fuel, the fuel leveler's position will display diesel
fuel mass in the fuel tank and take care the maximum fuel position shall not excceed
the inner strainer of the tank when filling.
WARNING
Keep away from the fire source and heat source hen filling;do not fill
when be operating.
Connect electric battery (BATTERY IS NOT INCLUDED)
Connect the storage battery wire to the storage battery, red for positive electrode and
green for the negative electrode, and make sure screwing the nut tightly. Not contact
between positive electrode to negative electrode to avoid short circuit. After connection,
metal parts of two pieces of wire shall keep at least 15mm safety distance, and be
protected by rubber cover.
No exceeding
this level

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Turn on the fuel valve lever
Turn the fuel valve lever to ON and let the fuel
flow into the fuel pump.
Set engine speed control to start
Move the lever (1) to the right, it click into the
RUN position.
Start the generator
Insert the key into the key switch, Turn the
start switch to the START position release
the key as soon as the engine starts, it will
return to the ON position.

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Start the generator in cold weather
When the engine is difficult to start in cold
weather, press the heater button for about 10-
-20 seconds and then release, you can easily
start the engine with the start switch.
Warm up the engine
After starting, Warm up the engine without
load for about 3 minutes.
Connect to load
Access electric equipment and turn the circuit
breaker to ON. Please note that when several
loads are used at the same time, do not
access the next one unless the former one is
running normally. The total power of the
loads should not exceed the rated power of
the unit.

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7. SHUT DOWN THE ENGINE
Disconnect load
Disconnect the electric equipment from the
control panel of the generator.
Set engine speed control to stop
After 3 minutes of no-load running, press
down the stop button (2) ,the speed control
lever (1) will automatically return to the STOP
position.
Turn off the engine switch
Turn off the engine switch and the
Generator unit will be shut down immediately.

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Close the fuel valve lever
Turn off the fuel valve lever after the
shutdown of the unit.
The surface temperature of the generator unit
is still high after shutdown, and it can not be
moved or operated before cooling down in
order to avoid scalding
8. STORAGE
Protective treatment
The unit should be stored in a clean and dry
place and should be protected from rain and
high temperature. Shield the unit with paper
box or plastic bag to prevent dust from
entering the unit.

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9. TRANSPORTING
To prevent fuel spillage when transporting or during temporary storage, the generator should be
secured upright in its normal operating position, with the engine switch OFF. The fuel valve
lever should be turned OFF.
WARNING
When transporting the generator:
Do not overfill the tank.
Do not operate the generator while it is on a vehicle.Take the generator off the vehicle
and use it in a well ventilated place.
Do not drive on a rough road for an extended period with the generator on board.If you
must transport the generator on a rough road,drain the fuel from the generator
beforehand.
NOTE:
To transport the generator, hold the holding part(shaded areas in the figure 1).
Take care not to drop or strike the generator when transporting.
Do not place heavy objects on the generator.
When transporting the generator by loading it on to a vehicle, secure to the generator frame as
shown (See figure 2).

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10. ACCESSORIES INSTALLATION
You can install the wheel assemblies for the convenience of moving the unit.
You may need to prepare the following equipment before the installation.
Please install the handrail, vibration reduction bracket and wheel on the base plate and tighten
the bolt as shown in the following picture.
Two-wheel short axle

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11. POWERS OF COMMON APPLIANCES

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The starting powers of the appliances are far more higher than the operation powers. Please
read the labels of the electric equipment for reference. The total power of the loads should not
exceed the rated power of the generator.

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12. MAINTENANCE
Operation
Item hours
Daily 20 hours 100 hours 200 hours 500 hours 1000hours
Check
and
tighten
bolt and nuts ○
Before
operation
Check
and
resupplyengine oil ○
Before
operation
Replace engine oil ○
1st time ○
2nd &
after
Clean
oil
filter
replace if damaged
○
1st time ○
2nd
&
after
Check oil leakage ○
Before
&after
operation
Clean
or
replace
air
cleaner element
Service
more
frequently
when
used
in
dustyareas ○
Drain
and
clean
the
fuel tank
○
Check
and
replace
fuel filter ○
Check
fuel
injection
nozzle
▲
Check
fuel
injection
pump ▲
Check
fuel
piping
replace if damaged
○
Adjust
intake/exhaust
valves head clearance
▲
1st time ▲
Check
and
lap
intake/exhaust
valves
seat
▲
Replace
piston
rings
▲
Check battery ○
Before
operation