TOYAMA TDG4000BX OWNER'S MANUAL Pdf Download

Preface

Safety Symbols

READ MANUAL

Instructions to read the manual for safety precautions.

WEAR EAR PROTECTORS

Requirement to wear hearing protection.

WEAR RESPIRATORY PROTECTION

Requirement to wear respiratory protection.

SAFETY GLOVES MUST BE WORN

Requirement to wear safety gloves.

WEAR PROTECTIVE FOOTWEAR

Requirement to wear protective footwear.

WEAR EAR, EYE AND HEAD PROTECTION

Requirement to wear eye, ear, and head protection.

GENERAL WARNING

General warning symbol indicating caution or alert.

ELECTRICAL HAZARD WARNING

Symbol indicating electrical hazard or risk of shock.

TUMBLE HAZARD

Symbol indicating a tip-over or falling hazard.

BURN HAZARD WARNING

Symbol indicating a burn hazard from hot surfaces or components.

HOT SURFACE WARNING

Symbol indicating a hot surface or high temperature.

HIGH TEMPERATURE WARNING

Symbol indicating high temperature.

ROTATING PARTS HAZARD

Symbol indicating rotating parts that pose a hazard.

FLAMMABLE MATERIAL WARNING

Symbol indicating flammable material.

SLIPPING HAZARD WARNING

Symbol indicating a risk of slipping.

TOXIC AIR WARNING

Symbol indicating toxic air or harmful fumes.

KICKBACK HAZARD

Symbol indicating a kickback hazard.

GENERAL INJURY RISK

Symbol indicating a general risk of injury.

Generator Parts Position

STARTING HANDLE

The handle used to start the engine manually.

FUEL COCK

Valve to control fuel flow to the engine.

FUEL TANK

Container for storing fuel.

FUEL TANK CAP

Cap for the fuel tank.

FUEL LEVEL INDICATOR

Indicator for the fuel level in the tank.

OIL LEVEL DIPSTICK

Tool for checking the engine oil level.

CRANKCASE OIL DRAIN POINT

Point for draining oil from the engine crankcase.

AIR FILTER COMPONENT

Component that filters air entering the engine.

DECOMPRESSION LEVER

Lever to reduce compression for easier starting.

DIGITAL CONTROL PANEL

Display panel showing generator status and controls.

POWER OUTLET PLUG

Output sockets for connecting electrical loads.

ENGINE OIL FILTER

Filter for the engine oil.

GROUNDING TERMINAL

Terminal for connecting the generator to ground.

CIRCUIT BREAKER LEVER

Lever for the circuit breaker.

ELECTRIC START SWITCH

Switch for electric start function.

OVERLOAD PROTECTOR DEVICE

Device to protect against electrical overload.

VOLTAGE SELECTOR KEY

Key to select generator output voltage.

MUFFLER COMPONENT

Component to reduce engine noise.

Specifications

Cares When Operating Your Generator - I

EXHAUST GAS HAZARD

Warning about operating in poorly ventilated areas or indoors due to toxic exhaust.

VENTILATION REQUIREMENTS

Instruction to maintain at least 1m of free space for ventilation.

OPERATION IN WET AREAS

Warning against operating the generator in wet or moist areas.

ENGINE BREAK-IN PROCEDURE

Guideline for breaking in new or serviced engines: no load, low speed for 2 hours.

FUEL QUALITY RECOMMENDATION

Recommendation to use high-quality fuel for optimal performance.

FLUID LEVEL MANAGEMENT

Instruction to maintain correct oil and fuel levels.

Cares When Operating Your Generator - II

ELECTRIC SHOCK HAZARD

Warning about the risk of electric shock from the generator.

GRID CONNECTION PROHIBITION

Prohibition of connecting to internal grids without an approved project.

MANUAL ACCESSIBILITY ADVICE

Advice to keep the manual accessible for future reference.

MANUAL TRANSFER GUIDELINE

Instruction to include the manual when transferring ownership.

UNAUTHORIZED USER RESTRICTION

Prohibition of use by untrained children or users.

DECAL INTEGRITY WARNING

Warning against removing safety decals from the product.

Cares When Operating Your Generator - III

PRODUCT MODIFICATION VOIDS WARRANTY

Warning that product modification voids the warranty.

CABLE MANAGEMENT SAFETY

Caution against leaving cables on the generator to prevent short circuits.

LOAD LIMIT ADHERENCE MANDATE

Instruction not to exceed the generator's load capacity.

OPERATIONAL FAMILIARIZATION REQUIREMENT

Recommendation to familiarize with controls and output before operation.

Inspection Before Operating

CHECK FUEL LEVEL

Procedure to check the fuel level before operation.

CHECK ENGINE OIL LEVEL

Procedure to check the engine oil level before operation.

CHECK FOR FLUID LEAKS

Inspection for oil or fuel leaks around the equipment.

CHECK FOR DEBRIS

Check for dirt or debris around the muffler and starting handle.

CHECK AIR FILTER CLEANLINESS

Check the cleanliness of the air filter.

Grounding Procedure

USE ADEQUATE POWER CORD

Instruction to use a power cord with adequate capacity.

CONNECT WIRE TO GENERATOR GROUND TERMINAL

Procedure to connect the grounding wire to the generator.

CONNECT WIRE TO METAL PART ON GROUND

Procedure to connect the other end of the grounding wire to a metal part on the ground.

Installing the Wheels

SUPPORT WHEEL AND ALIGN DRILLINGS

Procedure to support the wheel and align drillings.

FIT THE SHAFT

Step to fit the shaft into the wheel assembly.

INSERT WASHER AND PIN LOCK

Procedure to insert washer and nuts or pin lock.

Installing the Handle Support

CENTERING LEVER BORE

Procedure to center the lever bore with the generator base drilling.

INSTALL AND TIGHTEN SCREWS OR PIN LOCK

Procedure to install and tighten screws or pin lock.

Installing the Base Bracket

CENTER RUBBER CUSHION

Procedure to center the rubber cushion in the generator base.

INSERT AND TIGHTEN BOLT AND NUT

Procedure to insert and tighten the bolt and nut.

Checking the Oil Engine Level - I

PLACE EQUIPMENT ON LEVEL SURFACE

Instruction to place the equipment on a flat and level surface.

REMOVE AND CLEAN DIPSTICK

Procedure to remove and clean the oil dipstick.

INSERT DIPSTICK TO CHECK LEVEL

Procedure to insert and remove dipstick to check oil level.

Checking the Oil Engine Level - II

COMPLETE WITH OIL IF BELOW LIMIT

Procedure to add oil if level is below the lower limit.

REINSTALL OIL DIPSTICK

Procedure to reinstall the oil dipstick.

Fueling the Generator

REMOVE TANK CAP

Step to remove the fuel tank cap.

FILL WITH FUEL TO MAXIMUM LEVEL

Procedure to fill the fuel tank without exceeding the maximum level.

ATTACH TANK CAP SECURELY

Step to securely attach the fuel tank cap.

Starting the Engine with Manual Starter - I

PLACE FUEL REGISTER IN OPEN POSITION

Step to place the fuel register in the open position.

SET THROTTLE LEVER TO RUN POSITION

Step to set the throttle lever to the run position.

HOLD HANDLE AND USE DECOMPRESSOR

Procedure for engaging decompressor and pulling starter handle.

Starting the Engine with Manual Starter - II

PULL HANDLE UNTIL ENGINE STARTS

Procedure to pull the starter handle until the engine starts.

REPEAT STARTING STEPS IF ENGINE FAILS

Instruction to repeat starting steps if the engine fails to start.

Battery Connection for Engines with Electric Starter

CONNECT POSITIVE BATTERY TERMINAL

Procedure to connect the positive battery terminal.

CONNECT NEGATIVE BATTERY TERMINAL

Procedure to connect the negative battery terminal.

Starting the Engine with Electric Starter

PLACE FUEL REGISTER IN OPEN POSITION

Step to place the fuel register in the open position.

SET THROTTLE LEVER TO RUN POSITION

Step to set the throttle lever to the run position.

HOLD DECOMPRESSOR AND TURN IGNITION KEY

Procedure for engaging decompressor and turning the ignition key.

REPEAT STARTING IF ENGINE FAILS

Instruction to repeat starting if the engine fails within 5 seconds.

Connecting Loads

SET LOAD CIRCUIT BREAKER TO OFF

Step to turn off the load circuit breaker before connecting.

SWITCH OFF APPLIANCE TO BE CONNECTED

Instruction to switch off the appliance before connecting.

CONNECT DEVICE TO POWER OUTLET

Procedure to connect the appliance to the generator's power outlet.

SET LOAD CIRCUIT BREAKER TO ON

Step to turn on the load circuit breaker after connecting.

CONNECT HIGHER POWER APPLIANCES FIRST

Guideline to connect appliances with higher power first.

Disconnecting Loads

DISCONNECT ALL APPLIANCES

Step to disconnect all connected appliances.

SET GENERATOR LOAD SWITCH TO OFF

Step to turn off the generator's load switch.

REMOVE POWER SOCKETS

Procedure to remove the power outlets.

ENGINE RUN WITHOUT LOAD BEFORE SHUTDOWN

Instruction to let the engine run without load before shutting down.

Stopping the Engine with Manual Starter

MOVE THROTTLE LEVER TO STOP POSITION

Step to move the throttle lever to the stop position.

PLACE FUEL REGISTER IN CLOSED POSITION

Step to place the fuel register in the closed position.

Stopping the Engine with Electric Starter

MOVE THROTTLE LEVER TO STOP POSITION

Step to move the throttle lever to the stop position.

PLACE FUEL REGISTER IN CLOSED POSITION

Step to place the fuel register in the closed position.

TURN IGNITION KEY COUNTER-CLOCKWISE

Procedure to turn the ignition key counter-clockwise to stop the engine.

Maintenance Schedule

INITIAL MAINTENANCE (20 HRS / 1 MO)

Initial maintenance tasks within the first 20 hours or 1 month.

100 HRS / 3 MONTHS MAINTENANCE

Maintenance tasks every 100 hours or 3 months.

500 HRS / 6 MONTHS MAINTENANCE

Maintenance tasks every 500 hours or 6 months.

1000 HRS / 12 MONTHS MAINTENANCE

Maintenance tasks every 1000 hours or 12 months.

Replacing the Engine Oil - I

PLACE ENGINE ON FLAT SURFACE

Instruction to place the engine on a flat and level surface.

REMOVE DIPSTICK AND DRAIN OIL

Procedure to remove dipstick and drain all engine oil.

REINSTALL AND TIGHTEN DRAIN BOLT

Procedure to reinstall and tighten the oil drain bolt.

Replacing the Engine Oil - II

FILL OIL RESERVOIR TO MAXIMUM LEVEL

Procedure to fill the oil reservoir to the recommended maximum level.

REINSTALL OIL DIPSTICK AND TIGHTEN

Procedure to reinstall and tighten the oil dipstick.

Removing Air from the Pipe - I

SET THROTTLE LEVER TO RUN POSITION

Step to set the throttle lever to the run position.

REMOVE CLAMP FROM FUEL PIPE

Procedure to remove the clamp from the fuel pipe.

DISCONNECT TUBE AND DRAIN FUEL

Procedure to disconnect the tube and drain fuel until no bubbles exist.

RECONNECT FUEL LINE

Step to reconnect the fuel line.

Removing Air from the Pipe - II

LOOSEN HIGH PRESSURE PIPE NUT

Procedure to loosen the nut of the high pressure pipe.

MANUAL START AIR REMOVAL

Procedure for manual start engines to remove air.

ELECTRIC START AIR REMOVAL

Procedure for electric start engines to remove air.

TIGHTEN PIPE NUT AND START ENGINE

Procedure to tighten the pipe nut and start the engine.

Air Filter Maintenance

REMOVE BUTTERFLY NUT

Step to remove the butterfly nut securing the air filter cover.

REMOVE AIR FILTER COVER

Step to remove the air filter cover.

REMOVE FILTER ELEMENT

Step to remove the filter element.

CLEAN ELEMENT WITH COMPRESSED AIR

Procedure to clean the filter element using compressed air.

REPLACE FILTER ELEMENT

Step to reinstall the filter element.

REPLACE COVER AND RETIGHTEN NUT

Step to replace the cover and retighten the butterfly nut.

Cleaning the Oil Filter of the Engine - I

ENSURE CRANKCASE IS EMPTY

Condition check: crankcase must be empty of oil.

REMOVE FIXATION SCREW AND CAP

Procedure to remove the fixation screw and cap of the oil filter.

REMOVE OIL FILTER

Step to remove the oil filter.

CLEAN FILTER WITH NON-FLAMMABLE SOLVENT

Procedure to clean the filter using a non-flammable solvent.

Cleaning the Oil Filter of the Engine - II

DRY THE FILTER COMPLETELY

Step to ensure the filter is completely dry.

CHECK CONDITION OF O-RING

Procedure to check the condition of the O-ring.

RETIGHTEN OIL CAP

Step to retighten the oil cap.

REPLACE AND RETIGHTEN SET SCREW

Procedure to replace and retighten the set screw.

Fuel Filter Maintenance - I

DRAIN FUEL FROM TANK

Procedure to drain all fuel from the tank into a container.

REMOVE FUEL TAPPET LOCKING NUTS

Step to remove the fuel tappet locking nuts.

REMOVE FUEL LOG AND GASKETS

Procedure to remove the fuel log and gaskets.

PULL FILTER USING FINE-NEEDLE PLIERS

Procedure to pull the filter using fine-needle nose pliers.

Fuel Filter Maintenance - II

REPLACE USED FILTER WITH NEW ONE

Procedure to replace the used fuel filter with a new one.

REPLACE FILTER THROUGH NOZZLE

Procedure to replace the filter through the fuel tank nozzle.

REPLACE GASKETS AND FUEL COCK

Procedure to replace gaskets and the fuel cock.

Removing Fuel From the Tank

PLACE FUEL REGISTER IN CLOSED POSITION

Step to place the fuel register in the closed position.

REMOVE FUEL DRAIN BOLT

Procedure to remove the fuel drain bolt.

REMOVE TANK FUEL CAP

Step to remove the fuel tank cap.

DRAIN ALL FUEL INTO CONTAINER

Procedure to drain all fuel into a suitable container.

REINSTALL DRAIN BOLT AND CAP

Procedure to reinstall the oil drain bolt and fuel tank cap.

Storage - I

REMOVE FUEL FROM TANK

Procedure to remove fuel from the tank before storage.

CLEAN AIR FILTER

Step to clean the air filter before storage.

ADD OIL TO CYLINDER FOR STORAGE

Procedure to add oil to the cylinder for storage.

DISTRIBUTE OIL AND POSITION HANDLE

Procedure to distribute oil and position handle for storage.

Storage - II

CLEAN METAL PARTS WITH NON-FLAMMABLE PRODUCT

Procedure to clean metal parts with a non-flammable product.

COVER ENGINE AND STORE IN DRY, VENTILATED PLACE

Instruction to cover the engine and store it in a dry, ventilated place.

RECHARGE ELECTRIC BATTERY MONTHLY

Guideline to recharge the electric starter battery monthly if stored.

Transport Procedures

WAIT FOR ENGINE COOLING

Instruction to wait for the engine to cool before transport.

PLACE FUEL REGISTER IN CLOSED POSITION

Step to place the fuel register in the closed position.

PLACE ENGINE ON FLAT SURFACES TO PREVENT SPILLS

Instruction to place the engine on flat surfaces to prevent spills.

Warranty Term

WARRANTY PERIOD AND COVERAGE

Details on the warranty period and what it covers.

WARRANTY EXCLUSIONS

List of conditions and uses that void the warranty.

IMPORTANT WARRANTY NOTES

Key information regarding warranty claims and documentation.

Toyama TDG4000BX Owner's Manual

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