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Operational Manual - The Official Tsurumi Pump Store

1. Muffler 1 29 95002 02080 Rubber Fuel Tube 1 IOs i See eee Bolt 2 Honda Part Number NOTE Items prefixed with letter H are Honda Engine parts 30 15301192000 Clamp Tube 1 Refer to Honda Parts Catalog for part numbers 31 15550293001 Screw M5 x 12 2 Replacement Parts Tsurumi s Operation Service and Repair Manual Figure 8 2 Control Box Exploded View Model TPG4 3000HDX 58 TPG4 3000 PANEL 73 Replacement Parts Figure 8 2 Control Box Parts List Model TPG4 3000HDX Tsurumi s Operation Service and Repair Manual Ref Part Ref Part No Number Description Qty No Number Description Qty 45 15350690000 Box Control 1 69 15550329000 Nut Hex with Flange 1 46 15601696000 Panel Control 1 MS 48 15400104000 Receptacle 2 70 15301979000 Washer Cap 1 20A 125V 5 52 15400137000 Circuit Breaker 20 1 71 15550333000 Washer Flat 1 53 85111573300 Bracket Neon 1 5 58 15400175000 Condenser Assembly 2 72 15550331000 Washer Look 4 5 59 15400253000 Switch Engine 1 73 15550335000 Nut Wing 1 61 19N10904000 Nut Hex with Flange 2 5 4 74 19521904012 Screw Self Tapping 2 66 15301080001 Spacer 1 M4x12 67 19S00905025 Screw Cross Head 1 75 15321880130 Grommet Panel 1 Recessed Lead 2 68 15550331000 Washer Tooth Lock 1 MS 74 Replacement
2. QN GENERATOR n 67 iov D8 70 E 72 73 TPG3 FIG 3 4 Figure 3 4 Grounding Provisions Operating Instructions 17 Tsurumi s Operation Service and Repair Manual 3 4 Check Engine Oil Grade CAUTION ENGINE OIL IS MAJOR FACTOR AFFECTING PERFORMANCE AND SERVICE LIFE NON DETERGENT OILS AND TWO STROKE OILS ARE NOT RECOMMENDED BECAUSE THEY HAVE INADEQUATE LUBRICATING CHARACTERISTICS CAUTION CHECK THE OIL LEVEL WITH THE ENGINE ON ALEVEL SURFACE AND THE ENGINE STOPPED 1 Use Honda 4 stroke oil or use an equivalent high detergent premium quality motor oil certified to meet or exceed U S automobile manufacturer s requirements for Service Classification SG SF Motor oils classified SG SF will show this designation on the container SAE 10W30 is recommended for general all temperature use Other viscosity grades shown in Figure 3 5 may be used when the average temperature in your area is within the indicated range a w N graue temperature 32 B3 B8 IFF TPG3 Fig 3 5 Figure 3 5 Oil Viscosity Grade to Temperature Recommendations 3 5 Check Engine Oil Level 1 When checking oil observe the following see Figure 3 6 e Make sure the engine is in a level position f Remove the oil filler cap dipstick and wipe it clean g Insert the filler cap dipstick into the oil filler neck but do not screw it in h Remove the filler cap dipstick and check the oil l
3. 22 TsuRUMI PUMP OPERATION SERVICE AND REPAIR MANUAL FOR TSURUMI TPG4 SERIES PORTABLE GENERATORS TPG MODELS TPG4 3000HDX TPG4 4500HDX TPG4 6000HDX TPG4 7000HDX TPG4 7000HDXE NOTE Model TPG3 11000 is covered by a separate manual Contact your dealer or visit our web site for details http www tsurumipump com Tsurumi s Operation Service and Repair Manual LIMITED WARRANTY TSURUMI MANUFACTURING CO LTD TSURUMI warrants to the original end purchaser during the warranty period every new TSURUMI generator or product to be free from defects in material and workmanship under normal use and service when properly installed used and maintained in accordance with Tsurumi s Operation Service and Repair Manual for a period of two years from the date the unit was first installed or twenty six months from the date of shipment by TSURUMI to wholesaler whichever comes first TSURUMI s sole obligation under this warranty is to repair or replace at TSURUMI s option with new or remanufactured parts any part s that fail or are found to be defective during the warranty period No allowance will be made for shipping charges damages labor or other charges due to failure repair or replacement This warranty does not apply to any TSURUMI product that has been disassembled without prior approval of TSURUMI nor does it apply to any product that has been subjected to misuse neglect alteration misapplication acc
4. 8 diei lt eee BN eee ee J Wiring Diagram Model TPG4 3000HDX Troubleshooting 42 Tsurumi s Operation Service and Repair Manual TPG4 4500HDX Wiring Diagram Model TPG4 4500HDX 4 Troubleshooting Tsurumi s Operation Service and Repair Manual TPG4 7000HDX 3 TPG4 6000HDX Wiring Diagram Models TPG4 6000HDX and TPG4 7000HDX 44 Troubleshooting Tsurumi s Operation Service and Repair Manual TPG4 7000HDXE uw 5 gn a Lal Wiring Diagram Model TPG4 7000HDXE 45 Troubleshooting Tsurumi s Operation Service and Repair Manual THIS PAGE INTENTIONALLY LEFT BLANK Troubleshooting 46 Tsurumi s Operation Service and Repair Manual 6 0 REMOVAL INSTALLATION 6 0 General Repair of the generator is limited to the replacement of failed components This section provides the procedures for removal of failed components and installation of replacement components Exploded views and other Illustrations are provided to supplement the replacement procedures The item numbers used in the component replacement procedures are identical to item numbers in the Replacement Parts section Refer to the Replacement Parts section for part numbers of replacement parts Table 6 1 provides torque values for the fasteners used on the generator Torque values are expressed in Ibf in a
5. Bolt 1 32 19901798099 Gase Control NOTE Items prefixed with letter are Honda Engine parts 33 15550438000 Screw Cross Head 4 Recessed M6 15 77 Refer to Honda Parts Catalog for part numbers Replacement Parts Tsurumi s Operation Service and Repair Manual Figure 8 4 Control Box Exploded View Model TPG4 4500HDX TPG4 4500HDX PANEL 79 Replacement Parts Tsurumi s Operation Service and Repair Manual Figure 8 4 Control Box Parts List Model TPG4 4500HDX Ref Part Ref Part No Number Description Qty No Number Description Qty 45 15350680000 Box Control 1 64 19N10906000 Nut Hex with Flange 1 46 15601697000 Panel Control 1 M6 65 15400559000 UNIT GFCI 1 47 15400105000 Receptacle 30A 1 125V 66 15301082001 Spacer Switch 1 48 15400003000 Receptacle 20A 2 67 15550330000 Screw Cross Head 1 125V Recessed 49 15400106000 Receptacle 1 5 x 25 30A 125V 250V 68 15550331000 Washer Tooth Lock 1 50 15400539000 Circuit Breaker 15A 1 M5 51 15350337000 Grommet 2 69 15550329000 Nut Hex with 1 52 15400171000 Circuit Breaker 20A 2 Flange M5 53 85111573300 Bracket Neon 1 70 15301979000 Washer Cap 5 1 54 15400143000 Switch Voltage 1 71 15550333000 Washer Flat M5 1 Selector 72 15550334000 Washer Lock M5 1 55 15400108000 Switch Auto Throttle 1 73 15550335000 Nut Wing M5 1 56 19500700660 Control Unit Auto 1 Throttle
6. Connection to a building s electrical system must be made by a qualified electrician Refer to the Removal Installation section for grounding post installation procedures and connection of generator ground wire 3 9 Starting amp Stopping the Engine 1 MANUAL START Models TPG4 3000HDX TPG4 4500HDX TPG4 6000HDX and TPG7 7000HDX a Before starting the engine set AC circuit breakers to OFF the generator may be hard to start if a load is connected b Refer to the Honda engine owner s manual for location of fuel valve Turn the fuel valve to the ON position c The automatic choke will be closed if the engine is cold If you want to operate the choke manually move the choke lever to the CLOSED position NOTE The choke may not be needed if the engine is warm or the air temperature is high d Move the throttle lever slightly to the left e Set the switch to the ON position f Pull the starter grip lightly until resistance is felt then pull briskly NOTE Do not allow the starter grip to snap back against the engine Return it gently to prevent damage to the engine 2 ELECTRIC START Model TPG4 7000HDXE NOTE The engine on the Model TPG4 7000HDXE generator is primarily started using the electric starter but may be started using the recoil starter NOTE The model TPG4 7000HDXE generator has a 12 volt DC starting system Use a 12 volt garden tractor type battery as a replacement battery a Connect bat
7. TPG4 3000HDX TPG4 6000HDX TPG4 7000HDXE TPG4 4500HDX TPG4 7000HDX This manual provides instructions for operation service and repair of your Tsurumi generator We strongly recommend that those who operate the portable generator become familiar with the generator s features and controls and read the operating instructions before using the generator The manual also provides instructions to service checkout and repair the generator This manual also provides replacement parts information Repair and service information for the Honda engine is provided in the Honda Owner s Manual for Models GX160 GX240 GX340 and GX390 A copy of the Owner s Manual has been provided in the generator s literature package shipped with the generator Parts information for the Honda Engine is available in Honda s Parts Catalogs When there are differences between generator models separate instructions are provided The separate instructions are provided to make sure the correct procedures are used on the affected generators All information in the Tsurumi manual is based upon the latest production configuration of the generator at the time of approval for printing If you have a problem with your generator that cannot be resolved using the Operation Repair and Service Manual or if you have questions about the operation service repair or maintenance of your generator contact your local Tsurumi generator dealer 1 2 PRECAUTIONS AND PLACARD
8. 1 Check rating of connected appliance or electric tool exceeds rating Use appliance or tool having compatible rating 2 Check the slow set RPM Normal idling speeds are as follows Troubleshooting 39 Tsurumi s Operation Service and Repair Manual FAULT PROBABLE CAUSE REMEDY Engine speed does not increase when load applied continued Wattage of connected appliance or electric tool exceeds rating continued TPG4 3000HDX 3550 to 3650 RPM TPG4 4500HDX 3550 to 3650 RPM TPG4 6000HDX 3550 to 3650 RPM TPG4 7000HDX 3550 to 3650 RPM TPG4 7000HDXE 3550 to 3650 RPM NOTE The engine speeds are for a cold engine If the engine speed adjustment screw is out of its adjustment range move the solenoid backward 3 Check the wiring through the coil on the idle control unit SINGLE VOLTAGE TYPE Make sure that an output wire form the main coil is passing through the coil on the idle control unit DUAL VOLTAGE TYPE Check to make sure that the two output wires from the main coils pass through the coil on the idle control unit in the same direction 4 Check the idle control unit Check resistance between the five leads 5 Observe the terminal identification diagram below 6 Refer to Table 5 1 for resistance values NOTE The resistance readings in Table 5 1 will vary depending upon the type of circuit tester being used Table 5 1 is an example of the resistance readings measured by an or
9. Qs PORTABLE GENERATOR MODEL TPG4 3000HDX MAX OUTPUT 2 6kVA RATED OUTPUT 2 2kVA VOLTAGE 120V FREQUENCY 60Hz SERIAL NO kkk kkk MADE IN JAPAN TPG4 Fig 1 1 Figure 1 1 Typical Data Plate Figure 1 3 Carbon Monoxide Warning A DANGER Using a generator indoors CAN KILL YOU IN MINUTES Generator exhaust contains carbon monoxide This is a poison you cannot see or smell NEVER use inside a home Only use OUTSIDE and or garage EVEN IF doors far away from windows and windows are open doors and vents Avoid other generator hazards READ MANUAL BEFORE USE Fig 1 3 Tsurumi s Operation Service and Repair Manual Figure 1 2 Electrical Warning Figure 1 4 Fuel Handling Warning A WARNING ELECTROCUTION OR PROPERTY DAMAGE CAN OCCUR DO NOT CONNECT THIS GENERATOR TO ANY BUILDING S ELECTRICAL SYSTEM UNLESS AN ISOLATION SWITCH HAS BEEN INSTALLED BY A UCENSED ELECTRICIAN TPGA Fig 1 2 STOP ENGINE BEFORE REFUELING INCONTR LER QU IL N Y A NI FUITE NI ESSENCE REPANDUE SUR L APPAREIL ARRETER LE MOTEUR AVANT DE REFAIRE LE PLEIN WINSPECCIONAR PARA COMBUSTIBLE DERRAMADO 0 ESCAPE PARAR MOTOR ANTES DE ECHAR Fig 1 4 Figure 1 5 Air Cleaner Maintenance Warning AIR CLEANER MAINTENANCE MCLEAN ELEMENT EVERY 50 HOURS EVERY 10 HOURS UNDER DUSTY CONDITIONS WASH IN HIGH FLASH POINT SOLVENT SQUEEZE DRY THEN DIP IN CLEAN ENGINE OIL_AND SQUEEZ
10. Refer to Replacement of Rotor for rotor installation procedures 2 If bearing 13 was removed install according to the bearing installation procedure in Replacement of Rotor Bearing 3 Install the stator 8 stator cover 8 1 and rear cover 1 Refer to Replacement of Generator Stator for installation procedures Removal Installation 68 Tsurumi s Operation Service and Repair Manual 6 16 Replacement of Rotor A The generator stator 6 Figure 6 0 must be removed before the rotor 12 can be removed Refer to Replacement of Stator for stator removal instructions NOTE The rotor 12 Figure 6 9 at this point is free to rotate and must be kept from rotating to enable removal of the through bolt 11 1 Restrain the rotor to keep it from rotating 2 Puta box end wrench on the hex of the through bolt 11 3 Using a plastic rubber or other soft faced hammer strike the side of the wrench using sharp blows to loosen the th1rough bolt 11 6 17 Front Panel and Control Box A Gain Access to Components 1 To ease the replacement of components drain and remove the fuel tank 18 remove the front panel 46 and control box 45 from the frame 44 2 Refer to Figure 35 Remove four screws 33 and two screws 74 to separate control box 45 from front panel 46 3 Disconnect generator tube 7 from rear cover 1 4 Tag and disconnect generator wires Pull generator wires free from the control
11. WARNING KEEP AREA CLEAR OF FLAMMABLES OR OTHER HAZARDOUS MATERIALS 1 3 8 WARNING C1 O Check the following items before starting the engine a Fuel leakage from fuel hoses shutoff valve auto throttle unit engine and fitttingd b Loose bolts and nuts c Components for damage or breakage Check generator surroundings a Keep generator at least 3 feet 1 meter away from buildings or other structures b Operate generator in a dry well ventilated area c Keep exhaust pipe clear of foreign objects d Keep generator away from open flame e Keep generator on a stable and level surface f Do not block generator air vents with paper or other material Grounding the Generator WARNING IMPROPER CONNECTIONS CAN ALLOW ELECTRICAL CURRENT FROM THE GENERATOR TO BACKFEED INTO THE UTILITY LINES WHICH MAY ELECTROCUTE UTILITY COMPANY WORKERS OR OTHERS WHO CONTACT THE LINES DURING A POWER OUTAGE WHEN UTILITY POWER IS RESTORED THE GENERATOR MAY EXPLODE BURN OR CAUSE FIRES IN THE BUILDING S ELECTRICAL SYSTEM A POTENTIAL ELECTROCUTION HAZARD EXISTS IF THE GENERATOR IS NOT GROUNDED A GENERATOR GROUNDING POST IS PROVIDED ON THE CONTROL PANEL OF THE GENERATOR REFER TO 3 4 FOR GROUNDING PROVISIONS If you plan to use the portable generator as a backup for the facilitys power supply during power outages make sure the connections are made in compliance with applicable laws and electrical codes
12. 2 65 15400559000 UNIT GFCI 1 125V 66 15301082001 Spacer Switch 1 49 15400106000 Receptacle 1 67 15550330000 Screw Cross Head 1 30A 125V 250V 50 15400540000 Circuit Breaker 20 1 M5 x 25 68 15550331000 Washer Tooth Lock 1 51 15400173000 Circuit Breaker 30A 2 M5 52 15400171000 Circuit Breaker 20A 2 69 15550329000 Nut Hex with 1 Flange M5 53 85111573300 Bracket Neon 1 54 15400143000 Switch Voltage 1 70 15301979000 Washer Cap M5 1 Selector 71 15550333000 Washer Flat M5 1 55 15400108000 Switch Auto Throttle 1 72 15550334000 Washer Lock M5 1 56 19500700660 Control Unit Auto 1 73 15550335000 Nut Wing M5 1 Throttle 57 15400240000 Diode Bridge 1 74 19821904012 pus 2 Tapping 2 58 15400177000 Condenser Assembly 2 18 pF 75 15321880130 Grommet Panel Lead 1 59 15400253000 Switch Engine 1 2 60 19SS4903005 Screw Cross Head 4 76 15350472000 Grommet 2 Recessed M3x5 77 19SF4903012 Screw Cross Head 2 61 19N10904000 Nut Hex with Flange 13 Recessed M4 M3 x 12 62 19SF49040014 Screw Cross Head 13 78 15400161000 Connector 2P 1 R d M4x14 pessroe 79 15400157000 Connector 6P 2 79 Replacement Parts Tsurumi s Operation Service and Repair Manual TPG4 7000HDX EXPL WIEW 76 36 Ref Figure 8 7 Generator Exploded View Model TPG4 7000HDX See Fig 8 8 Tsurumi s Operation Service and Repair Manual Figure 8 7 Generator Parts List
13. Bracket 1 M6 x 25 1 0 Thick H 6 Shield Inner 1 25 15321880100 Cushion Tank Rubber 4 BH mem Seal 1 26 15321670270 Collar Tank Cushion 4 H 8 Shield Outer 1 27 15350694000 Tube Fuel 1 9 o seis Selenite ets Bolt Flanged 13 28 90854 ZB2 0000 Rubber Fuel Tube 1 Muffler Shield 29 95002 02080 Honda Part Number 1 H 40 ade e sur Muffler 1 lamp TUDE Bo H 11 Spark Arrestor 1 Honda Part Number H 12 Screw Spark Arrestor 1 30 15301192000 Clamp Tube 1 H43 22222 Bolt 1 31 15550293001 Screw M5 x 12 2 14 Bolt 1 32 19901798099 Gase Control NOTE Items prefixed with letter are Honda Engine parts 33 15550438000 Screw Cross Head 4 Recessed M6 15 77 Refer to Honda Parts Catalog for part numbers Replacement Parts Tsurumi s Operation Service and Repair Manual Figure 8 6 Control Box Exploded View Model TPG4 6000HDX TPG4 6000HDX PANEL Replacement Parts 74 Tsurumi s Operation Service and Repair Manual Figure 8 6 Control Box Parts List Model TPG4 6000HDX Ref Part Ref Part No Number Description Qty No Number Description Qty 45 15350680000 Box Control 1 63 19SF4906015 Screw Cross Head 1 46 15601698000 Panel Control 1 Recessed M6x15 47 15400105000 Receptacle 30A 1 64 19N10906000 Nut Hex with Flange 1 125V M6 48 15400003000 Receptacle 20A
14. Model TPG4 7000HDX Ref Part Ref Part No Number Description Qty No Number Description Qty 1 15311471000 Cover Bracket 1 34 19SS6906016 Bolt M6 16 4 2 15550210000 Bolt Hex with Flange 2 35 200900520 Rubber Anti Vibration 4 M5 x 0 8 12 36 203200020 Nut Hex With Flange 4 3 15311461000 Bracket 1 M10 x 1 25 4 15550152000 Bolt Hex with Flange 4 37 203000720 Bolt Hex M10 x 45 4 M6 x 1 0 1500 38 203200010 Nut Hex With Flange 4 5 15350550000 Bushing Rubber 1 M8 x 1 25 6 19500905007 Screw Cross Head 1 39 19556906012 Bolt M6 x 12 2 Recessed 5 7 40 15501130000 Wire Bonding 1 7 15350107000 Tube Lead Wire 1 8 15250384000 Stator Assembly 1 41 19B30906012 Bolt Hex With Flange 1 M6 x 12 8 No Number Cover Stator provided 1 with Stator Assembly 42 19W50906000 Lockwasher Tooth 1 9 15311462000 N Bracket 1 43 19N10906000 Nut Hex With Flange 1 10 19830908020 Bolt Hex with Flange 4 44 15302009000 Frame 1 M8 x 1 0 20 45 15950138000 Carbon Canister 1 11 15550154000 Bolt Hex with Flange 1 46 15950141000 Stay Carbon Canister 1 125 239 47 15302060000 Clamp 10 0 2 12 15200432000 Rotor Assembly 1 48 15302061000 Clamp 12 0 1 13 15311780100 Bearing Ball 1 Ho 15302063000 14 15311460000 Bracket 1 di od 15 19850908020 Bolt Flat Head with 4 9D 153506 6000 Tube Canister Socket M8x1 0 20 51 15350678000 Tube Canister 1 16 15
15. When the generator speed reaches its rated speed the generator output will be at its rated value 2 Voltage Fluctuations Under Load refer to Figure 2 6 a When output current c flows through the main coil to the appliance being used a magnetic flux is produced and serves to increase current a in the condenser coil As a result the current flowing in the field coil increases and the generator output voltage is prevented from decreasing Stator Man coil Permanent magnet for mitial excitation 4 3 m Appliance FPA 7 1 Surge 3 t 11 d P absorber a J 3 T te ae pe Receptacie eld cod c 4 Diode LM a Condenser coil 7 Condenser TPG4 Fig 2 3 Figure 2 3 Generation of No Load Voltage 3 Full Power Switch Dual Voltage Type refer to Figure 2 4 a The full power switch provides both 120V and 240V dual voltages at full rated power The full rated power will be available from one 120V receptacle and one 240V receptacle b Two main coils are wound over core of the stator Each main coil outputs half the rated power at the lower voltage 110V or 120V These main coils are wound so they are in the same phase The full power switch reconnects these main coils in parallel or in series Refer to the circuit diagram in Figure 4 When the full power switch is set for single lower voltage indication 110V or 120V the switch position will be as
16. measure field coil resistance Measure resistance at the soldered terminals of the rotor and the core NOTE Because a diode is soldered to the coil ends at the terminals resistance may be measured only when the multimeter probes touch the terminals in one combination of polarity Therefore if no resistance reading appears try checking in reverse polarity 4 Using a megger tester check insulation resistance between the soldered terminal and the stator core 5 Replace rotor if it does not meet the resistance values in Table 5 1 AC voltage too high Engine speed too high or 1 Check engine speed SUIS0 9Ms 00100 2 Operate the generator with no load applied on the generator 3 If the speed is too high or too low adjust throttle adjustment screw to set engine speed as specified in Table 5 1 Total wattage applied by appliances lights power tools etc exceeds generator s rated load Calculate generator load 2 Calculate total wattage being applied to the generator rated load of each connected power consuming device times the power factor of the device 3 Disconnect power consuming device s as required to reduce total wattage to the level shown on the generator data placard Troubleshooting 38 Tsurumi s Operation Service and Repair Manual FAULT PROBABLE CAUSE REMEDY AC voltage is Engine speed too low normal at no load continued but load canno
17. the generator may explode burn or cause fires in the building s electrical system B Grounding Post Components 1 The portable generator is fitted with a grounding post on the right side of the control panel The parts that make up the grounding post are shown in the Replacement Parts section The grounding post components and their installation sequence are shown in more detail in Figure 3 4 2 Ifthe grounding post has been disassembled reassemble as follows a Install star washer 68 on screw 69 Insert screw 69 in backside of panel 46 b Install nut 69 on screw 69 and tighten c Install cup washer 70 with sides facing out d Install flat washer 71 lock washer 72 and wing nut 73 C Typical Connection of Ground Wire 3 Form a loop in ground wire and slip wire between flat washer 71 and cup washer 70 Tighten wing nut 73 4 Drive ground rod in ground or attach to known facility ground Insert free end of ground wire in clamping screw on rod or other clamping device and tighten Operating Instructions 16 Tsurumi s Operation Service and Repair Manual ow Vm GROUNDING POST 68 STAR WASHER AS 69 NUT 70 CUP WASHER ene 71 FLATWASHER 72 LOCKWASHER PARTS BREAKDOWN GROUND ROD A N GROUND EE CLAMPING TO GROUND ROD WIRE cg T SCREW x GROUND WIRE SOIL CONTROL PANEL 46 es
18. 61 19410904000 Nut Hex with Flange 13 Le i Screw Cross Head 2 M4 Recessed M3 x 12 62 19SF49040014 Screw Cross Head 13 Recessed M4x14 78 15400161000 Connector 2P 1 79 15400157000 Connector 6P 2 79 Replacement Parts Tsurumi s Operation Service and Repair Manual Figure 8 9 Generator Exploded View Model TPG4 7000HDXE a 36 Ref 2798 15 4 23 4 cee 24 4x __ 25 4x 26 4x SY See Fig 8 10 TPG4 7000HDXE EXPL WIEW 76 Tsurumi s Operation Service and Repair Manual Figure 8 9 Generator Parts List Model TPG4 7000HDXE Ref Part Ref Part No Number Description Qty No Number Description Qty 1 15311471000 Cover Bracket 1 34 19SS6906016 Bolt M6 16 4 2 15550210000 Bolt Hex with Flange 2 35 200900520 Rubber Anti Vibration 4 M5 x 0 8 12 36 203200020 Nut Hex With Flange 4 3 15311461000 Bracket 1 M10 x 1 25 4 15550152000 Bolt Hex with Flange 4 37 203000720 Bolt Hex M10 x 45 4 M6 x 1 0 1500 38 203200010 Nut Hex With Flange 4 5 15350550000 Bushing Rubber 1 M8 x 1 25 6 19500905007 Screw Cross Head 1 39 19SS6906012 Bolt M6 x 12 2 Recessed 5 7 40 15501130000 Wire Bonding 1 7 15350107000 Tube Lead Wire 1 8 15250384000 Stator Assembly 1 41 19B30906012 Bolt Hex With Flange 1 M6 x 12 8 No Number Cover Stator provided 1 with Stat
19. 74 19521904012 Screw Self Tapping 2 4 12 57 15400240000 Diode Bridge 1 75 15321880130 Grommet Panel Lead 1 58 15400177000 Condenser Assembly 2 2 18 yF 76 15350472000 Grommet 2 59 15400253000 Switch Engine 1 77 19SF4903012 Screw Cross Head 2 60 19SS4903005 Screw Cross Head 4 Recessed Recessed M3x5 M3 x 12 61 19N10904000 Nut Hex with Flange 13 M4 78 15400161000 Connector 2P 1 62 19SF49040014 Screw Cross Head 13 79 15400157000 Connector 6P 2 Recessed M4x14 63 19SF4906015 Screw Cross Head 1 Recessed M6x15 80 Replacement Parts Tsurumi s Operation Service and Repair Manual Figure 8 5 Generator Exploded View Model TPG4 6000HDX e 36 Ref See Fig 8 6 TPG4 6000HDX EXPL WIEW Replacement Parts 76 Tsurumi s Operation Service and Repair Manual Figure 8 5 Generator Parts List Model TPG4 6000HDX Ref Part Ref Part No Number Description Qty No Number Description Qty 1 15311471000 Cover Bracket 1 34 19556906016 Bolt M6 16 4 2 15550210000 Bolt Hex with Flange 2 35 200900520 Rubber Anti Vibration 4 M5 x 0 8 12 36 203200020 Nut Hex With Flange 4 3 15311461000 Bracket 1 M10 x 1 25 4 15550152000 Bolt Hex with Flange 4 37 203000720 Bolt Hex M10 x 45 4 M6 x 1 0 1500 38 203200010 Nut Hex With Flange 4 5 15350550000 Bushing Rubber 1 M8 x 1 25 6 19500905007 Screw Cross Head 1 39 19SS69060
20. Bonding 1 with Stator Assembly 41 19830906012 Bolt Hex With Flange 1 9 15111462000 N Bracket 1 M6 x 12 10 19B30906020 Bolt Hex with Flange 4 42 19W50906000 Lock Washer Tooth 1 M6 x 1 25 20 43 19N10906000 Nut Hex With Flange 1 11 15550160000 Bolt Hex with Flange 1 urit a Eo 12 15200426000 Rotor Assembly 1 M M Rn ae 13 15250328000 Bearing Ball 1 udi s 14 15111460000 Bracket 1 Ge 15 19850908020 Bolt Flat Head with 4 Mu dd Socket M8x1 0 20 84 15350679000 Tube Canister 1 16 15400160000 Connector 2 P 1 85 15350701000 Tube Corrugate 1 17 15400156000 Connector 6 P 2 86 15350700000 Tube Corrugate 1 18 15301131010 Tank Fuel Blue 1 19 15150514000 Valve Fuel Shutoff 1 Ref Fart INE RE HEN No Number Description Qty 20 15350504000 Gauge RESET Fuel 1 H 1 GX160RT2 VES6 Engine Honda 1 21 15301046000 Fuel Filler 1 oes I 5 22 15350343000 Filter Fuel 1 LT Gasket Exhaust Fangs 23 19830906025 Bolt Hex with Flange 4 6 6 1 0 25 H 4 Bracket 1 24 19W00906025 Washer Tank Cushion 4 5 Screw Bracket M6 x 25 1 0 Thick H 6 Shield Inner 1 25 15321880100 Cushion Tank Rubber 4 Hef eem Seal 1 26 15321670270 Collar Tank Cushion 4 H8 Shield Outer 1 27 15350693000 Tube Fuel 1 HO Bolt Flanged Muffler 1 Shield 28 90854 ZB2 0000 Rubber Fuel Tube 1 Honda Part Number
21. Circuit Interrupter The GFCI shuts off the output current from the 120V duplex receptacle when a ground fault occurs in the generator or the appliance B Dual Voltage Type 1 Select the voltage using the FULL POWER switch in accordance with the electrical appliance Refer to Table 3 2 12 Operate the generator in the same way as step 1 through step 3 of single voltage type Table 3 2 Available Receptacles With Full Power Switch On Switch Setting Lower Voltage Receptacle Higher Voltage Receptacle 120V Rated Output is Available Unavailable 120V 240V Half of Rated Output is Available Rated Output is Available WARNING TO TAKE OUT POWER FROM TWIST LOCK RECEPTACLE INSERT THE PLUG INTO RECEPTACLE AND TURN CLOCKWISE WARNING BE SURE TO GROUND THE GENERATOR IF THE CONNECTED ELECTRICAL NOTE NOTE EQUIPMENT IS GROUNDED When the circuit breaker turns off during operation the generator is overloaded or the appliance is defective Stop the generator immediately check the appliance and or generator for overloading or defect and repair as necessary 3 12 Stopping the Generator 1 Set the ENGINE SWITCH to OFF or unplug from the cord receptacle of the generator 2 _ Set the engine switch to the OFF position 3 Turn fuel valve on fuel tank to CLOSE Figure 3 8 Fuel Valve 3 13 Oil Alert 1 The oil alert detects the fall in oil level in the crankcase and automatically
22. DEATH FROM ELECTRIC SHOCK KEEP THE GENERATOR DRY All receptacles on the generator are protected by a ground fault circuit interrupter GFCI for protection against the shock hazard of ground fault current The GFCI has TEST and RESET buttons and is connected to the circuit breaker An example of ground fault current is the current which would flow through a person who is using an appliance with faulty insulation and at the same time is in contact with an electrical ground such as a plumbing fixture wet floor or earth The ground fault circuit interrupter will not protect against short circuits or overloads The circuit breaker in the control panel which supplies power to the circuit provides that protection refer to circuit breaker Observe the following precautions to ensure proper GFCI operation and to reduce shock hazards Use grounded 3 conductor extension cords tools and appliances or double insulated tools and appliances Inspect cords and plugs and replace if damaged Do not use cord lengths greater than 164 feet 50 meters and do not use multiple tools and appliances with built in noise filters Such use may activate the GFCI and trip the circuit breaker Inspection Models TPG4 4500HDX TPG4 6000HDX TPG4 7000HDX TPG4 7000HDXE NOTE ALWAYS CHECK GFCI OPERATION BEFORE USING THE GENERATOR WARNING YOU RISK ELECTRIC SHOCK IF YOU OPERATE THIS GENERATOR WITH A FAULTY GFCI GROUND FAULT CIRCUIT INTER
23. EQUIPMENT LIKE COMPUTERS STEREOS TVS ETC TPG4 Tig 1 8 EMISSION CONTROL INFORMATION DAISHIN INDUSTRIES LTD FAMILY EDHNPNHEQTPG THIS EQUIPMENT MEETS U S EPA EVAP STANDARD DATE OF MANUFACTURE 1 1 5 KEY FEATURES Honda Powered proven reliability quiet operation efficient fuel consumption Automatic Idle Control reduces fuel consumption noise and engine wear this feature is not available on Model TPG4 3000HDX Large Silent Muffler with USDA qualified spark arrestor to significantly reduce noise The spark arrestor is designed to screen out hot sparks Large Air Filter for superior emission control Large Capacity Fuel Tank with Fuel Gauge for extended run time Rubber Vibration Pads isolates generator engine vibration from the frame for maximum protection and noise reduction Ground Fault Circuit Interrupter leakage prevention mechanism outlets protects operator from shock Voltage Selector Full Power Switch allows voltage selection either full rated output from 120V receptacle or half rated output from 120V receptacle and full rated output from 240V receptacles this feature is not available on Model TPG4 3000HDX Circuit Breaker protects generator from overload damage can be reset with the flip of a switch no fuse to replace 100 Copper Windings for long life U S EPA non load emission regulation This equipment
24. THE HYDROGEN GAS TO IGNITE CAUSING INJURY AND BURNS TO NEARBY PERSONNEL NOTE Do not remove the battery enclosure unless required to gain access to other components If removal of the battery support is required remove according to the following procedures NOTE Refer to exploded view in Replacement Parts section for parts information The item numbers in the following procedure are identical to those in the Replacement Parts exploded views A Remove battery refer to Replacement of Battery section B Refer to Figure 6 2 Replacement Parts section Remove bolts 97 and nuts 98 from frame 44 C Remove nuts 100 and U bolts 99 from frames 96 Remove entire battery enclosure unit and set aside for installation later NOTE Do not disassemble the battery enclosure unit any further unless disassembly is required to replace damaged battery enclosure components If necessary follow procedures beginning with step D D Remove bolts 91 nuts 92 and plate 90 E Remove bolts 94 nuts 95 and plate 93 Perform required repair and or maintenance then proceed as follows 1 Align screw holes in plate 93 with holes in frames 96 Install and tighten four bolts 86 and four nuts 87 2 Align screw holes in plate 90 with holes in frames 96 Install and tighten four bolts 91 and nuts 92 3 Align screw holes in frames 96 with holes in generator frame 44 Install and tighten two screws 97 and nut
25. attachment points The rear bracket provides support for a ball bearing at the back end of the generator rotor The rotor consists of a shaft a stack of steel laminations and copper wire windings Components mounted on the rotor include a surge absorbing diode a bridge diode two permanent magnets and a cooling air fan The windings and the laminated steel core form the field coil The permanent magnets are used to induce voltage in the main coil of the stator The diode and the surge absorber are located under the rotor windings at the bearing end of the rotor shaft The rotor is attached to the engine crankshaft with a through bolt tie bolt The engine crankshaft is tapered and mates with a tapered bore in the rotor shaft The clamping force applied to the through bolt ties the rotor shaft to the engine crankshaft 3 Description of the Engine NOTE Refer to the Honda Owner s Manual for Models GX160 GX240 GX340 and GX390 for additional coverage of the engine a b c d The TPG4 7000HDXE portable generator has an electric starter and a recoil starter All other models of portable generators are equipped with a recoil starter The engine is equipped with an air filter to remove airborne contaminants from the engine inlet air The engine is fitted with a muffler that provides quiet operation and controls the flow of engine exhaust gases The muffler is attached to the rear generator cover using a muffler moun
26. circuit breaker test correctly then you will know that the fault is in the power tool appliance or cord Repair or replace the faulty power tool appliance or cord before further use 3 18 Wattage Information 1 When starting some appliances a surge of energy occurs Depending upon the nature of the electrical load the amount of electrical power needed to start the appliance may exceed the amount needed to maintain its use See Table 3 3 for appliances you may use with this generator 18 21 22 Electrical appliances and tools normally come with a label indicating voltage cycles Hz amperage amps and electrical power needed to run the appliance or tool Check with your nearest dealer with questions regarding power surge of certain appliances or power tools Electrical loads such as incandescent lamps and hot plates require the same wattage to start as needed to maintain use Loads such as fluorescent and mercury lamps require 1 2 to 2 0 times the indicated wattage to start Electric motors require a large starting current Power requirements depend on the type of motor and its use Once enough surge is attained to start the motor the appliance will require only 5096 to 3096 of the wattage to continue running Most electrical tools require 1 2 to 3 0 times their wattage for running For example the 5 000 watts generated could power an 1800 watt to a 4000 watt electric drill Loads such as submersible pumps an
27. indicated by the lower coils line in the diagram Description and Operation 17 Tsurumi s Operation Service and Repair Manual 120V 240V or 110V 220V v d b o Rec 1 ana p 2 2 egy 3 gt FE J Wort110V 240V or 220V 110V Lap XX H E Rec 28 Rec 2 1 i j 120V or 110V TPG4 Fig 2 4 Figure 2 4 Full Power Switch Circuit Diagram d Refer to Figure 2 5 for a simplified diagram of the circuit The two main coils are shown in parallel In this case the higher voltage 220V or 240V at Receptacle Rec 3 is not available Rec 2 for the lower voltage is available up to the rated power up to 30A if the rated current is over 30A and Rec 1 is available up to 15A When the full power switch is set for double voltage indication 110V 220 V or 120V 240V the switch position is indicated by the upper dotted line in Figure 2 4 e Refer to Figure 2 6 for a simplified diagram of the circuit The two main coils are shown connected in series In this example power is simultaneously available from the receptacles for both voltages Higher voltage receptacle Rec 3 has power available up to rated power however Rec 1 and Rec 2 for the lower voltage can output only up to the rated power of each receptacle f 2 1 summarizes in tabular form the power available or not available depending upon the position of the full power switch Des
28. meets U S EPA EVAP STANDARD 4 Introduction Tsurumi s Operation Service and Repair Manual Table 1 1 Portable Generator Specifications RET TPG4 3000HDX TPG4 4500HDX TPG4 6000HDX TPG4 7000HDX TPG4 7000HDXE Max Rated Output 2600 2200 4500 3600 6000 4800 7000 6000 7000 6000 Max Rated Current 21 7 18 3 37 5 30 18 8 15 50 40 25 20 58 3 50 29 2 25 58 3 50 29 2 25 120V 240V Voltage 120 60Hz 120 240 60Hz 120 240 60Hz 120 240 60Hz 120 240 60Hz 2 NEMA 5 20R Duplex 20A 120V AC Outlet 1 NEMA 5 20 1 NEMA L5 30R 30A 120V Twist Lock Duplex 1 NEMA L14 30R 30A 120 240V Twist Lock Receptacles 20A 120V W GFCI GFCI UNIT LEAKAGE PREVENTION MECHANISM ALL OUTLETS GX240RT2EDT6 GX340RT2EDT6 Gx390RT2EDT6 GX390RT2EDS6 8 0 3600rpm 11 0 3600rpm 13 0 3600rpm 13 0 3600rpm 0 0 7 0 Engine Models GX160RT2VES6 Displacement 163cc Fuel Tank 16 Capacity Liter Running Time 12 1 hrs Full Load Running Time 16 8 hrs 1 2 Load Starting System Recoil L x W x inches 23 6 x 18 5 x 19 7 L x W x H mm 600 x 470 x 500 Weight pounds 103 6 Weight kg 47 0 25 11 4 16 4 Recoil Recoil Recoil Electric 27 2 x 22 8 21 1 27 2 x 22 8 x 21 1 27 2 x 22 8 x 21 1 27 2 x 22 8 x 21 1 690 x 580 x 535 690 x 580 x 535 690 x 580 x 535 690 x 580 x 535 158 8 176 4 186 3 191 8 N N Introduction 5 Tsurumi s Operation Service and Repair Manual THIS PAGE INTENTIIONAALLY LEFT BL
29. which uses a hand operated throttle lever 3 The Model TPG4 7000H DXE generator is equipped with a electric starter motor The ENGINE switch in this model is a key operated STOP RUN START switch The spring loaded switch is turned to the right to start the engine and to the left to shut off the engine 4 The IDLE Control switch allows the generator speed to drop to idle speed if there is no electrical load demand on the generator When an electrical load is sensed the idle function increases the speed of the generator up to operating speed level When there is no load the engine speed returns to idle 5 The FULL POWER switch allows the generator to provide full rated power for the loading appliances and or tools When the FULL POWER switch is set to on power will be provided to only one 120 Vac receptacle and one 240 Vac receptacle 6 PILOT light provides an indication to the operator that the generator is generating electricity 7 Circuit breakers are provided to protect the generator the event of a short circuit The breakers will trip when the circuit load exceeds the breaker s rated value 8 ground post is used to provide a positive ground for the generator The post has a wing nut to quickly connect a ground wire to the generator 9 There are three types of receptacles one 120 Vac GFl protected receptacles two on most models one twist type 120 Vac receptacle and one 120 Vac 240 Vac c
30. 0 031 in Figure 4 4 Spark Plug Gap The gap should be 0 7 to 0 8 mm 0 028 to 0 031 inch as shown Maintenance 34 Tsurumi s Operation Service and Repair Manual 5 0 TROUBLESHOOTING 5 1 General 1 The procedures that follow together with the troubleshooting tables can be used as a guide to isolate generator faults Refer to these procedures when the engine fails to start after several attempts or when electricity is not available at the receptacles 2 Before testing generator components determine if the failure is located in the generator head or in the control panel If after following these procedures your generator fails to start or generate electricity contact the nearest Tsurumi generator dealer 5 2 Isolating Fault to the Generator or to the Control Panel 1 This unit uses permanent magnets built into the rotor for initial excitation Do not flash the fields to try to re excite the field 2 Isolate the defect by disconnecting the red gray orange and blue wires from the stator do not disconnect the two yellow wires Then measure the AC voltage of each AC coil 3 Check for 120 vac 5 from the red gray wires and then check for 120 vac 5 from the orange blue wires 4 If the voltage is correct the failure is in the control panel If the voltage is too low from either coil the defect lies in the rotor stator or condensers 5 3 Measuring Insulation Resistance 1 No AC
31. 0 74 gt 1 36uF TPG4 6000HDX 1 58 gt 1 MQ 0 22 0 22 0 57 gt 1 36uF TPG4 7000HDX 1 14 gt 1 0 21 0 21 0 57 gt 1 36uF TPG4 7000HDXE 1 76 gt 1 MQ 0 18 0 18 0 46 gt 1 36uF 1 Measure insulation across one of the solder terminals and the core of the rotor 2 Measure between stator leads as follows BLUE lead and core WHITE lead and core YELLOW lead and core and BROWN lead and core WARNING DO NOT USE ANY PART WITH INSULATION RESISTANCE OF LESS THAN 1 MO LOW INSULATION RESISTANCE IS AN INDICATION THAT THE PART IS FAULTY INSULATION AND MAY CAUSE ELECTRICAL LEAKAGE AND POTENTIALLY FATAL ELECTRICAL SHOCK REPLACE ALL FAULTY PARTS 5 5 Troubleshooting Charts 1 This section provides the instructions for generator checkout and fault isolation The troubleshooting procedures are presented in Table 5 2 The table lists typical faults presents probable cause and provides the remedy for the majority of generator operational faults Troubleshooting 36 Tsurumi s Operation Service and Repair Manual Table 5 2 Fault Isolation Procedures FAULT PROBABLE CAUSE REMEDY No AC output Condenser failed 1 Check condenser NOTE If you do not have measuring equipment install a known good condenser Start the generator and check ac output If the generator ac output is normal the fault was in the original condenser 2 Short the condenser leads across each othe
32. 0 Nut Wing M5 1 53 85111573300 Bracket Neon 1 74 19S21904012 Screw Self Tapping 2 54 15400143000 Switch Voltage 1 4 12 Selector 75 15321880130 Grommet Panel Lead 1 55 15400108000 Switch Auto Throttle 1 2 56 19500700660 Control Unit Auto 1 76 15350472000 Grommet 1 Throttle 77 19SF4903012 Screw Cross Head 2 Recessed 57 15400240000 Diode Bridge 1 M3 x 12 58 15400177000 eS Assembly 2 78 45400161000 Connector 2P 1 18 HS 79 15400157000 Connector 6 2 59 Switch Assembly 1 Combination 80 Case Comp Fuse Honda Part Honda Part 60 19554903005 Screw Cross Head 4 81 Caupler Comp Silicon 1 Recessed M3x5 Rectifire 61 19N10904000 Nut Hex with Flange 13 Honda Part rotector Circuit M4 82 P Circui 1 62 19SF49040014 Screw Cross Head 13 1A 125V Recessed M4x14 Honda Part 63 19SF4906015 Screw Cross Head 1 83 A paia 1 Recessed UE 84 19800903012 S ee 3b 12 64 19N10906000 Nut Hex with Flange 1 OSS M6 Head Recessed M3 x 12 65 15400559000 UNIT GFCI 1 66 15301082001 Spacer Switch 1 96 Tsurumi s Operation Service and Repair Manual Figure 8 11 Battery Enclosure Exploded View Parts List Model TPG4 7000HDXE Ref Part No Number Description Qty 85 15361575000 Cable Ground 1 86 15361574000 Cable Starter 1 87 15361370300 Plate Setting 1 88 19N10906000 Nut Hex with Flange 2 M6 89 15361570310 Bolt Setting 2 90 15301688000
33. 11 12 13 14 Install generator engine unit on anti vibration mounts 35 and secure to frame 44 with flanged nuts 38 Install assembled generator engine unit over bolts 37 in anti vibration mounts 35 Install terminal ring of bonding wire 40 on threaded end of bolt 38 Install flanged nuts 36 on the anti vibration mounts 35 Install fuel tank refer to Installation of Fuel Tank Install control box refer to Installation of Control Box Connect engine wiring in panel 46 according to the tags attached to the wires during disassembly NOTE Replace tube 7 if it was damaged or discarded during repair or replacement of stator 8 After replacement tube 7 is installed install grommet 75 over tube 7 Install grommet 75 in the hole in control box 45 Removal Installation 61 Tsurumi s Operation Service and Repair Manual 26 4x _ See Fig 8 2 Figure 6 7 Removal of Engine and Generator as a Unit 62 Removal Installation 15 16 6 13 Tsurumi s Operation Service and Repair Manual Insert engine wiring through small hole in back of control box 45 Connect wiring as required Refer to the wiring diagrams in Troubleshooting Install front panel and control box see Removal Installation of Front Panel and Control Box Install fuel tank see Replacement of Fuel Tank and engine muffler see Replacement of Engine Muffler Replacement of Generator Stator N
34. 12 Bolt M6 x 12 2 Recessed 5 7 40 15501130000 Wire Bonding 1 7 15350107000 Tube Lead Wire 1 8 45250382000 Stator Assembly 1 41 19B30906012 Bolt Hex With Flange 1 M6 x 12 8 No Number Cover Stator provided 1 with Stator Assembly 42 19W50906000 Lockwasher Tooth 1 9 15311462000 N Bracket 1 43 19N10906000 Nut Hex With Flange 1 10 19830908020 Bolt Hex with Flange 4 44 15302009000 Frame 1 M8 x 1 0 20 45 15950138000 Carbon Canister 1 11 15550154000 Bolt Hex with Flange 1 46 15950141000 Stay Carbon Canister 1 10 1 25 235 47 15302060000 Clamp 10 0 2 12 15200430000 Rotor Assembly 1 48 15302061000 Clamp 12 0 1 13 15311780100 Bearing Ball 1 jo i 14 15311460000 Bracket 1 camps en 15 19850908020 Bolt Flat Head with 4 Bee 19950876000 Tube yCanister Socket M8x1 0 20 51 15350678000 Tube Canister 1 16 15400160000 Connector 2 P 1 52 15350701000 Tube Corrugate 1 17 15400156000 Connector 6 P 2 53 15350700000 Tube Corrugate 1 18 15301982000 Tank Fuel Blue 1 19 15150135001 Valve Fuel Shutoff 1 Ref Part No Number Description Qty 20 15301674001 Gauge Assembly Fuel 1 Em SAID EDTE Enare Hond 21 15302001000 Cap Fuel Filler 1 pu ipd k 22 15350343000 Filter Fuel 1 ds c PA 23 19830906025 Bolt Hex with Flange 4 ae iil eee 6 1 0 25 H 4 Bracket 1 24 19 00906025 Washer Tank Cushion 4 Heo fe eerste Screw
35. 20V Circuit breaker 30A Receptacle 120V Figure 3 3 Model TPG4 7000HDXE Operating Instructions 15 3 3 WARNING WARNING Tsurumi s Operation Service and Repair Manual Grounding Provisions TO PREVENT ELECTRICAL SHOCK FROM FAULTY APPLIANCES THE PORTABLE GENERATOR SHOULD BE GROUNDED CONNECT A LENGTH OF HEAVY WIRE BETWEEN THE GENERATOR S GROUND TERMINAL AND EXTERNAL GROUND SOURCE CONNECTIONS FOR STANDBY POWER TO A BUILDING S ELECTRICAL SYSTEM MUST BE MADE BY A QUALIFIED ELECTRICIAN AND MUST COMPLY WITH ALL APPLICABLE LAWS AND ELECTRICAL CODES IMPROPER CONNECTIONS CAN ALLOW ELECTRICAL CURRENT FROM THE GENERATOR TO BACKFEED INTO THE UTILITY LINES SUCH BACKFEED MAY ELECTROCUTE UTILITY COMPANY WORKERS OR OTHERS WHO CONTACT THE LINES DURING A POWER OUTAGE AND WHEN UTILITY POWER IS RESTORED THE GENERATOR MAY EXPLODE BURN OR CAUSE FIRES IN THE BUILDING S ELECTRICAL SYSTEM A Electrical Connection Hazards 1 If you plan to use the portable generator as a backup for the facility s power supply make sure the connections are made in compliance with applicable laws and electrical codes 1 Connection to a building s electrical system must be made by a qualified electrician 2 Improper connections can allow electrical current from the generator to backfeed into the utility lines which may electrocute utility company workers or others who contact the lines during a power outage When utility power is restored
36. 400160000 Connector 2 P 1 52 15350701000 Tube Corrugate 1 17 15400156000 Connector 6 P 2 53 15350700000 Tube Corrugate 1 18 15301982000 Tank Fuel Blue 1 19 15150135001 Valve Fuel Shutoff 1 Ref Part x No Number Description Qty 20 15301674001 Gauge Assembly Fuel 1 Tm GXORISEBTS ERG fiend i 21 15302001000 Cap Fuel Filler 1 id d 22 15350343000 Filter Fuel 1 i oa ji ini x 23 19830906025 Bolt Hex with Flange 4 6 1 0 25 4 1 24 19W00906025 Washer Tank Cushion 4 Screw Bracket 1 M6 x 25 1 0 Thick H6 Shield Inner 1 25 15321880100 Cushion Tank Rubber 4 Ee Seal 1 26 15321670270 Collar Tank Cushion 4 Hug Shield Outer 1 27 15350694000 Tube Fuel 1 H 9 Bolt Flanged 13 28 90854 ZB2 0000 Rubber Fuel Tube 1 Muffler Shield 29 95002 02080 Honda Part Number 1 EET Muffler 1 Clamp Tube B8 H 11 Spark Arrestor 1 Honda Fart Number H 12 Screw Spark Arrestor 1 30 15301192000 Clamp Tube 1 TNI Sl i 31 15550293001 Screw M5 x 12 2 T ERE Boh i 32 19601798000 CaSe 108 NOTE Items prefixed with letter are Honda Engine parts 33 15550438000 Screw Cross Head 4 Recessed M6 15 77 Refer to Honda Parts Catalog for part numbers Tsurumi s Operation Service and Repair Manual f bd aS Figure 8 8 C
37. 44 30 M6 37 44 30 51 61 41 63 75 51 M8 91 109 73 125 150 100 154 184 124 M10 180 216 144 249 298 200 305 366 244 M12 315 378 252 434 520 348 532 638 426 M14 501 601 401 691 829 553 847 1016 678 M16 782 938 626 1079 1294 864 1322 1586 1058 M18 1076 1291 861 1485 1782 1188 1818 2181 1455 M20 1526 1831 1221 2105 2526 1684 2578 3093 2063 M22 2076 2491 1661 2364 3436 2292 3508 4209 2807 M24 2638 3165 2111 3640 4368 2912 4458 5349 3567 M27 3859 4630 3088 5326 6391 4261 6522 7826 5218 M30 5241 6289 4193 7232 8678 5786 8857 10628 7086 NOTES 1 The figures above must be applied to fitting of components made of metal 2 The tightening coefficient shall be 1 5 6 1 Replacement of Battery Model TPG3 7000HDXE Only WARNING DISCONNECT THE SPARK PLUG WIRE FROM THE SPARK PLUG BEFORE WORKING ON THE GENERATOR TO PREVENT INADVERTENT ENGINE START WARNING MAKE SURE THAT YOU DISCONNECT OR REMOVE THE BATTERY WHEN YOU DO MAINTENANCE EXPLOSIVE HYDROGEN GAS MAY BE PRESENT AROUND THE BATTERY WARNING SPARKS FROM STATIC ELECTRICITY OR FROM HAND TOOLS CONTACTING BATTERY TERMINALS CAN CAUSE HYROGEN GAS TO IGNITE CAUSING INJURY AND BURNS TO NEARBY PERSONNEL NOTE Do not disassemble the battery enclosure unit unless disassembly is required to gain access to other affected components NOTE Refer to exploded view in Replacement Parts section for parts information The item numbers in the following procedure are identical to those in the Replaceme
38. 8 Install front panel 29 and control box 46 refer to Removal Installation of Front Panel and Control Box 11 GFCI Receptacles 1 Refer to Figure 6 15 Remove front panel 45 and control box 46 refer to Removal Installation of Front Panel and Control Box 2 Remove two screw and lock washer assemblies 45 and receptacle 42 3 Disconnect wiring and remove receptacle Remowval Installation 74 Tsurumi s Operation Service and Repair Manual 4 Connect wiring to replacement receptacle 5 Install two screws 45 through screw holes in front panel 45 6 Install receptacle 42 Secure with the two screw and washer assemblies 45 and two nuts 43 7 Install front panel 45 and control box 46 refer to Removal Installation of Front Panel and Control Box Removal Installation 75 Tsurumi s Operation Service and Repair Manual 70 STORAGE INSTRUCTIONS 71 General WARNING TO AVOID SEVERE BURNS OR FIRE HAZARDS LET THE ENGINE COOL BEFORE TRANSPORTING OR BEFORE STORING THE PORTABLE GENERATOR INDOORS WARNING WHEN TRANSPORTING THE PORTABLE GENERATOR TURN THE FUEL SHUTOFF VALVE TO THE OFF POSITION AND KEEP THE ENGINE LEVEL DURING TRANSPORT TO PREVENT FUEL SPILLAGE IF PRESENT FUEL VAPOR OR SPILLED FUEL MAY IGNITE A The following procedures should be followed before storing your portable generator for periods of 6 months or longer 1 Carefully drain fuel from the fuel tank gasoline le
39. ANK 6 Introduction Tsurumi s Operation Service and Repair Manual 2 0 DESCRIPTION AND OPERATION 2 1 PHYSICAL DESCRIPTION 1 Description of the TPG4 Portable Generator a The key features of the portable generator are shown in Figure 2 1 An exploded view of a typical generator is provided in Figure 2 2 b The generator consists of a tubular frame onto which is installed the generator engine front panel control box and fuel tank GENERATOR PLATE HOLD DOWN ROD AIR CLEANER MUFFLER VIBRATION ISOLATERS SPAR ARRESTOR TPG3 Fig 2 1B Description and Operation 13 Tsurumi s Operation Service and Repair Manual The generator and engine are installed on crossover plates that form the base of the tubular frame Vibration isolators support the generator and engine unit The isolators are fitted with threaded studs that secure the generator and engine unit to the frame 2 Description of Generator 9 The generator consists of a front bracket intermediate N bracket stator assembly and cover rotor rear bracket and bracket cover The rear bracket of the generator attaches to the engine and this unit forms the generator to engine interface The front bracket has a series of slots that allow entry of cooling air into the generator A fan on the rotor circulates air through the generator The rear bracket has mounting lugs that are the generator to frame
40. Circuit 13 3 3 Grounding Provisions fece e ete Does 14 3 4 Check Erigine Oil Grade 2 1 Bice bed 15 3 5 Check Engine Oll Level i E EE re Or E e ortae 16 3 6 Check Engine Fuel 2 5 sis An eine ei aa ee 17 3 7 Pre Start eloie c 18 3 8 Grounding the Generator i tbe den i d etai 19 3 9 Starting amp Stopping Engine sss ee ee ne enne nennen 20 3710 Usg the Gerierator usi ier ee o d nores cbe cebat Ee ante Pel b Rt e ter Dri rede ead 21 3 11 AC Application iic i e ee en dte ead Le EE UR EE Eee EE ERU E Hore o deb laa 22 3 12 Stopping the Generator inneren 24 SVS OM ANS 25 3214 Idle Control iiie Meere cer PE E car Eee Ue eda alee 25 3 15 Howto Use Idle Controlan ieod eenei a eeii 25 J 16 Checking Idle FUNCOM hand rete cecus PUES Meo EIN RO DRE ea lie tacked 26 3 17 Ground Fault Circuit Interrupter GFCl ireset deta nennen nnn nnn nennen 27 3 18 Wattage Information gt SER TR CURRERE 28 4 0 gt em f put ur e epo te e eased eros uidet te etd 29 4 1 ie cle E E EEE 29 4 2 Changing Engine det c re ie aetna te PRO TE
41. E OUT EXCESS OIL TPG4 Tig 1 5 Figure 1 6 Gasoline Carbon Monoxide Warning Gacaline rx highly lamrrianie and explosive Turn engine and iet esol before retuelirig Tha ragine emits Bn mot run ia an enclosed area Read Owners Manga bufore operation Ce LTib Mane my ra rA irie le siner el ia pon releyde de gps a He d HR We pai Ear qu ecp ribs Un LhA S sn TPG4 Fig 1 6 Introduction Tsurumi s Operation Service and Repair Manual Figure 1 7 Hot Exhaust Placard HOT EXHAUST ECHAPPEMENT CHAUD TPG4 Fig 1 7 Figure 1 8 Multiple Warning Caution Placard A WARNING WARNING EXHAUST GAS CAN LEAD TO DEATH FROM ELECTRIC SHOCK KEEP CONTAINS POISONOUS GENERATOR DRY CARBON MONOXIDE A WARNING A ATTENTION CONNECT THIS GENER ATOR TO ANY BUILDIN G S ELECTRICA L UN ENDROIT FERME A SYSTEM UNLESS AN ISOLATION SWITCH HAS BEEN INSTALLE D CAUSE DU RISQUE BY A LICENSED ELECTRICIAN READ OWNE R S MANUA L D EMPOISONNEMENT T Pn WORT VT UU T DU GAZ A CAUTION TET ETE EN ATENCION CAN DAMAGE GENER ATOR AND OR ELECTRICAL DEVICES LUGARES CERRADOS CONNECTED TO IT M ON eae oe START GENERATOR AND LET ENGINE STABILIZE BEFORE VENENOSO CONNECTING ELECTRICAL LOADS NO SENSITIVE
42. MERE ER PERS 30 4 3 Air CICANCH 5 PME Lr 30 4 4 Sediment Cup Cleanifhg e scr ocior 31 4 5 Cleaning and Adjusting Spark Plug ssssssse ee emen menn 32 Introduction 4 Tsurumi s Operation Service and Repair Manual 5 0 TIROUBEESEIOQOTING da ERR BER ERE ERR Ue UR RR eR en duet 5 1 General c 5 2 Isolating Fault to the Generator or to the Control Panel sss 5 3 Measuring Insulation Resistance 5 4 Electrical Limits Reference 5 5 Troubleshooting Charts seats cou e Eee te EU ALIE go Edd Du 5 6 MEE Diagram for TPG4 3000HDX 1 re creen eid Diagram for TPO4 4500 P1 X uia detenti Si Ot PI s dace tr er Ao oup eL aee eet Diagram for TPG4 6000HDX and TPG4 7000HDX Diagramifor TPGAs7000 EID XE coe De 6 0 REMOVAL INSTALLAT ION sensns snis nnns 6 1 C u c T 6 2 Gro nding PrOVISIOFls e ce intr hand ie rto Song iui nderit oue e Ente Lond bebes 6 3 Replacementof Ba
43. MMABLE AND IS EXPLOSIVE UNDER CERTAIN CONDITIONS DO NOT SMOKE OR ALLOW FLAMES OR SPARKS IN THE AREA WARNING AFTER INSTALLING THE SEDIMENT CUP CHECK FOR LEAKS AND MAKE SURE THE AREA IS FREE OF RESIDUAL FUEL SPILLS OR SEEPAGE BEFORE STARTING THE ENGINE 1 Turn the fuel valve to OFF 2 Remove turn clockwise the sediment cup and O ring Wash both parts in nonflammable or high flash point solvent 3 Wipe the sediment cup and O ring dry then reinstall 4 Set the fuel shutoff valve Figure 4 3 to ON Check for leaks Figure 4 3 Fuel Shutoff Valve Maintenance 33 Tsurumi s Operation Service and Repair Manual Cleaning and Adjusting Spark Plug Recommended spark plugs BPR6ES NGk W20EPR U NIPPONDENSO To ensure proper engine operation the spark plug must be properly gapped and free of deposits Remove the spark plug cap Clean any dirt from around the spark plug base Use the proper size spark plug wrench to remove the spark plug WARNING THE MUFFLER BECOMES VERY HOT DURING OPERATION AND REMAINS HOT FOR 8 A WHILE AFTER STOPPING THE ENGINE BE CAREFUL NOT TO TOUCH THE MUFFLER WHILE IT IS HOT Visually inspect the spark plug Discard spark plug if the insulator is cracked or chipped Clean the spark plug with a wire brush if it is to be reused Measure the plug gap with a feeler gauge Adjust the gap as necessary by bending the side electrode Figure 4 4 y 4 0 7 0 8 mm 0 028
44. NS WARNING IN ORDER TO ASSURE SAFE AND EFFICIENT OPERATION OF THE GENERATOR OPERATOR S SHOULD READ AND COMPLY WITH THE FOLLOWING SAFETY PRECAUTIONS Do not operate the generator near gasoline or gaseous fuels because of the potential danger from explosion or fire Do not fill the fuel tank with fuel while the engine is running Do not smoke or use open flame near the fuel tank Be careful not to spill fuel during refueling If fuel is spilled wipe it off and let it dry before starting the engine Do not place flammable materials near the generator Be careful not to place fuel matches gunpowder oily cloths straw trash or any other combustibles near the generator Do not operate the generator inside a room cave tunnel or other insufficiently ventilated area Always operate the generator in a well ventilated area The engine may become overheated and the poisonous carbon monoxide gas contained in the exhaust gases will endanger human lives Keep the generator at least 1 meter 3 feet away from any structure or building during use When a generator is located close to a building or nearby equipment heat and exhaust from the engine will cause the surrounding temperature to rise This will degrade the engines cooling efficiency causing overheating Do not enclose the generator nor cover it with a box The generator has a built in forced air cooling system and may become overheated if it is enclosed Operate the generator on a level
45. O SUPPORT THE GENERATOR ENGINE UNIT DURING REMOVAL AND INSTALLATION OF GENERATOR COMPONENTS Set generator engine unit on the workbench Position the unit with the generator end facing up use support blocks to steady the assembly Removal Installation 60 6 12 Tsurumi s Operation Service and Repair Manual Installation of Generator Engine Unit If you are replacing the stator 8 refer to Replacement of Generator Stator If you are replacing the rotor 12 refer to Replacement of Rotor If you are replacing the rotor bearing 13 refer to Replacement of Rotor Bearing If you are replacing the engine H 1 refer to Replacement of Engine Tighten fasteners to the torque values shown in Table 6 1 If anti vibration mounts 35 are being replaced proceed as follows Insert one screw 37 in each of four anti vibration mounts 35 Install screws 37 so threaded end of screws 37 face upward If bonding wire 40 was removed install screw 43 through hole in the underside of frame 44 Secure wire with toothed washer 42 and nut 43 Install anti vibration mounts with bolts on frame 44 Install mounts with threaded stud in large hole and keying tab in the smaller hole in the frame The anti vibration mounts on Model TPG4 3000HDX are installed at approximately 45 degees The anti vibration mounts on all other models are installed parallel with the frame member to which it is attached 9 10
46. OTE Refer to exploded view in Replacement Parts section for parts information The item numbers in the following procedure are identical to those in the Replacement Parts exploded views A 7 Drain and remove fuel tank 18 refer to Replacement of Fuel Tank for removal instructions Remove the muffler H 10 and shields H 6 and H 8 to gain access to generator refer to Replacement of Muffler for removal instructions Remove screws 2 and cover 1 Pull bushing 5 from slot in rear bracket 3 Disconnect ground wire by removing screw 6 Remove tube 7 from the rear cover 7 Pull the wires out of the access opening in the rear cover Tag and disconnect the wires Remove bolts 4 Use a plastic rubber or other soft faced hammer to loosen the rear cover 3 Alternately tap upward on the generator mounting lugs until the rear cover can be removed by hand With the rear cover loosened carefully position the rear cover so you have access to ground screw 6 Remove the stator cover 8 1 WARNING TO AVOID BEING INJURED BE PREPARED TO LIFT THE HEAVY STATOR APPROXIMATELY 37 POUNDS NOTE Itis suggested that you have second person assist with stator removal While you tap upward with the hammer the other person should lift the stator from the front cover 10 11 Use a plastic rubber or other soft faced hammer to loosen the stator Tap upward on the side of the laminations Tap upward and alternate tappin
47. Parts Tsurumi s Operation Service and Repair Manual Figure 8 3 Generator Exploded View Model TPG3 4500HDX e 36 Ref Ce 15 4 See Fig 8 4 TPG4 4500 EXPL WIEW Replacement Parts 76 Tsurumi s Operation Service and Repair Manual Figure 8 3 Generator Parts List Model TPG3 4500HDX Ref Part Ref Part No Number Description Qty No Number Description Qty 1 15311471000 Cover Bracket 1 34 19556906016 Bolt M6 16 4 2 15550210000 Bolt Hex with Flange 2 35 200900520 Rubber Anti Vibration 4 M5 x 0 8 12 36 203200020 Nut Hex With Flange 4 3 15311461000 Bracket 1 M10 x 1 25 4 15550152000 Bolt Hex with Flange 4 37 203000720 Bolt Hex M10 x 45 4 M6 x 1 0 1500 38 203200010 Nut Hex With Flange 4 5 15350550000 Bushing Rubber 1 M8 x 1 25 6 19500905007 Screw Cross Head 1 39 19SS6906012 Bolt M6 x 12 2 Recessed 5 7 40 15501130000 Wire Bonding 1 7 15350107000 Tube Lead Wire 1 8 45250380000 Stator Assembly 1 41 19B30906012 Bolt Hex With Flange 1 M6 x 12 8 No Number Cover Stator provided 1 with Stator Assembly 42 19W50906000 Lockwasher Tooth 1 9 15311462000 N Bracket 1 43 19N10906000 Nut Hex With Flange 1 10 19830908020 Bolt Hex with Flange 4 44 15302009000 Frame 1 M8 x 1 0 20 45 15950138000 Carbon Canister 1 11 15550154000 Bolt Hex with Flange 1 46 15950141000 Stay Carbon Canister 1 10 1 25 235 47 15302060000 C
48. Plate Protection 1 91 19B30908035 Bolt Hex with Flange 4 M8 x 35 92 203200010 Nut Hex with Flange M8 4 93 15301687000 Plate Battery 1 94 19B30908035 Bolt Hex with Flange 4 M8 x 35 95 203200010 Nut Hex with Flange M8 4 96 15302068000 Frame Battery 2 97 19B30908016 Bolt Hex with Flange 2 M8 x 16 98 203200010 Nut Hex with Flange M8 21 99 15550184000 U Bolt 2 100 203200010 Nut Hex with Flange M8 4 99 Tsurumi s Operation Service and Repair Manual THIS PAGE INTENTIONALLY LEFT BLANK j 100
49. RUPTER TEST GFCI BEFORE USE If the FAILS TESTING DO NOT USE YOUR GENERATOR CONTACT YOUR TSURUMI DEALER Inspection 1 Unplug all tools and appliances from the generator 2 Start the engine 3 Turn the circuit breaker to the ON position The GFCI green LED lamp lights up 4 Turn the Idle Control switch to the OFF position 5 Press the GFCI TEST button Circuit breaker to be automatically OFF position The GFCI red LED lamp lights up 3 The GFCI green LED lamp light up 3 Turn the ON position 5 Turn off the OFF 5 The GFCI red LED lamp position lights up 6 Press the GFCI RESET button The GFCI green LED lamp lights up 7 Turn the circuit breaker ON position With the RESET button in and engine running turn the circuit breaker to the ON position The circuit breaker should remain in the ON position The circuit breaker will not remain in the ON position if the RESET button is extended If the GFCI and circuit breaker do not function as described take the generator to an authorized TSURUMI generator dealer for repair 6 The GFCI green LED lamp lights up 6 Press the RESET button During generator use if the GFCI RESET button extends and the circuit breaker trips this usually indicates a faulty power tool appliance or cord If that occurs perform test steps 1 through 6 to verify that the GFCI and circuit breaker are in proper working order If the GFCI and
50. S Pay special attention to precautionary notes preceded by the words WARNING CAUTION or NOTE WARNINGS indicate that there is a strong possibility of personal injury or loss of life if the procedures in the manual are not followed and or if materials are not applied properly These materials include cleaning agents lubricants and adhesives CAUTIONS indicate that there is a possibility of equipment damage if instructions are not followed NOTES are used in procedures to provide additional or supplemental information to make the procedure easier to perform and to do so efficiently Introduction 3 Tsurumi s Operation Service and Repair Manual WARNING THIS GENERATOR IS DESIGNED TO GIVE SAFE AND DEPENDABLE SERVICE WHEN OPERATED ACCORDING TO THE INSTRUCTIONS IN THE TECHNICAL MANUALS PROVIDED WITH THE GENERATOR WARNING DO NOT OPERATE THE GENERATOR BEFORE YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND THE ENGINE MANUFACTURER S MANUAL FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE 1 3 Placards Placards shown in Figure 1 1 through Figure 1 8 are attached to the portable generator to warn operating and maintenance personnel of potential hazards to provide maintenance information and to provide generator ratings and capabilities The large label below is located on the front panel of the portable generator The label presents operational Warnings and Cautions for generator users 1 4 SAFETY PRECAUTIO
51. TALLY IGNITED CAN CAUSE SEVERE BURNS AND DEATH MAKE SURE THAT YOU DISCONNECT OR REMOVE THE BATTERY BEFORE DRAINING FUEL OR WHENEVER MAINTENANCE WILL INVOLVE HANDLING ENGINE FUEL ENGINE FUEL IS EXTREMELY FLAMMABLE AND CAN CAUSE SEVERE OR FATAL BURNS IF IGNITED MAKE SURE THAT YOU DISCONNECT OR REMOVE THE BATTERY WHEN YOU DO MAINTENANCE EXPLOSIVE HYDROGEN GAS MAY BE PRESENT AROUND THE BATTERY SPARKS FROM STATIC ELECTRICITY OR FROM HAND TOOLS CONTACTING BATTERY TERMINALS CAN CAUSE THE HYROGEN GAS TO EXPLODE CAUSING INJURY AND BURNS TO NEARBY PERSONNEL NOTE Refer to exploded view in Replacement Parts section for parts information The item numbers in the following procedure are identical to those in the Replacement Parts exploded views Removal Installation 57 6 7 Tsurumi s Operation Service and Repair Manual Removal of Fuel Tank Models TPG3 4500HDX TPG3 6000HDX TPG3 7000HDX TPG3 7000HDXE A 1 2 Drain fuel from fuel tank refer to Draining of the Fuel Tank Remove four screws 32 and two screws 74 Carefully open panel 46 taking care not to damage wiring Disconnect two large connectors 17 and one small connector 16 Disconnect remaining electrical wires Take note of wire terminations color striping pin socket etc and tag wires NOTE Generator wiring is gathered and covered by tube 7 The wiring is further contained by 6 7 grommet 75 Do not dismantle the wiring unless r
52. a Owner s Manual for Models GX160 GX240 GX340 and GX390 for additional coverage of the engine Description and Operation 15 Tsurumi s Operation Service and Repair Manual 4 Description of the Fuel Tank The fuel tank is located at the top of the portable generator Fuel flows by gravity from the tank through a tank mounted fuel shutoff valve and to the carburetor inlet A fuel gauge and tank filler cap are provided on the top of the tank A screen is provided under the filler cap to prevent entry of contaminants The tank is attached to the frame by four cushioned mounts A fuel shutoff valve is mounted on the underside of the tank The valve is opened to provide fuel to the carburetor The valve is closed when the generator is not in use or when transporting the generator The fuel shutoff valve has a sediment bowl to capture contaminants that may have passed through the fuel tank filler screen 5 Description of the Front Panel NOTE Refer to Figures 3 3 through 3 5 for illustrations of the generator front panels Familiarize yourself with the layout of the front panel for your generator before operating the generator a b The operating controls switches lights electrical receptacles and circuit breakers for the generator are mounted on the front panel The engine starter and control wiring exit through holes in the back of the control box The generator leads and control wiring are connected inside
53. ace between the Honda engine and the Tsurumi generator When required replacement Honda parts may be ordered from the Honda Motor Company parts catalog Reference numbers used to identify Honda parts are prefixed with the letter H such as H 20 75 Replacement Parts Tsurumi s Operation Service and Repair Manual Generator Exploded View Model TPG3 3000HDX Figure 8 1 26 4 5 x x N 23 4x See Fig 8 2 TPG4 3000 EXPL WIEW Replacement Parts 76 Tsurumi s Operation Service and Repair Manual Figure 8 1 Generator Parts List Model TPG4 3000HDX Ref Part Ref Part No Number Description Qty No Number Description Qty 1 15111471000 Cover Bracket 1 32 15601797000 Case Control Blue 1 2 15550210000 Bolt Hex with Flange 2 33 15550438000 Screw Cross Head 4 M5 x 0 8 12 Recessed M6 15 3 15311461000 Bracket 1 34 19556906016 Bolt M6 16 4 4 15550158000 Bolt Hex with Flange 3 35 203200010 Rubber Anti Vibration 4 M6 x 140 36 203200010 Nut Hex With Flange 4 5 15350549000 Bushing Rubber 1 8 x 1 25 6 19500905007 Screw Cross Head 1 37 19B30908045 Bolt Hex M8 x 45 4 Recessed 5 7 38 203200010 Nut Hex With Flange 4 7 15350107000 Tube Lead Wire 1 8 x 1 25 8 15250378000 Stator Assembly 1 39 15550446000 Bolt M6 x 14 2 8 No Number Cover Stator provided 1 40 15501121000 Wire
54. ained within tube 7 and are sealed by a rubber bushing 5 The wiring is then routed through tube 75 A groove at the control box end of the tube 75 holds the tube in place in the control box wall The engine and generator connectors 16 and 17 are housed within control box 45 To access and separate the connectors collapse tube 75 enough to disengage the groove from the hole in the control box back wall Remove two screws 39 and remove control box 45 Remove flanged nuts 37 from the vibration anti vibration mounts 35 The generator engine unit may now be lifted off bolts 37 Remove air cleaner support H 4 See discussion below for description of the physical differences between the support used on Model TPG3 3000HDX and the support used on all other models 1 The support used on Model TPG3 3000HDX is basically a flat strap with a bend at the air cleaner attachment point This support is secured at one end by screw H 5 and by flanged nut 36 at the other end 2 The support used on all other models is an S shaped strap with bends at the air cleaner attachment point and at the opposite end This support is secured at one end by a screw H 5 and by flanged nut 36 at the other end 6 Lift the generator engine unit from the frame 44 using an overhead lifting device CAUTION BE SURE TO PROTECT THE ENGINE FROM DAMAGE PUT CUSHIONING B MATERIAL BETWEEN THE ENGINE AND THE WORKBENCH USE WOODEN BLOCKS T
55. autions o cepto ee tte there etre bob etse 2 1 5 CVM K P Een 4 1 6 Portable Generator 5 2 0 DESCRIPTION 7 2 1 Description and Operation 7 2 2 Physical Description e epe te e ere He 7 1 Description of the TPG4 Generator 8 2 Description of the Generator cesses eene einen netten 8 3 Description of the Erigihe iet tree 8 4 Description of the Fuel nennen nnnm 10 5 Description of the Front theme nennen nnne 10 2 3 Functional Description EE A 10 1 Generation of No Low Voltage 000 0 eee me eene menn 11 2 Voltage Fluctuations Under Lad emen 11 3 RUIN Power Switch cen ed ices efe Ettore D idi adap tied Leet hited 11 3 0 OPERATING INSTRUCTIONS II eI enn en nennen nennen 13 3 1 Operating Controls o duc ine ED aa 13 3 2 DG
56. bber Fuel Tube 1 Muffler Shield 29 95002 02080 Honda Part Number 1 EET Muffler 1 Clamp Tube B8 H 11 Spark Arrestor 1 Honda Fart Number H 12 Screw Spark Arrestor 1 30 15301192000 Clamp Tube 1 TNI Sl i 31 15550293001 Screw M5 x 12 2 T ERE Boh i 32 19601798000 CaSe 108 NOTE Items prefixed with letter are Honda Engine parts 33 15550438000 Screw Cross Head 4 Refer to Honda Parts Catalog for part numbers Recessed M6 15 77 Tsurumi s Operation Service and Repair Manual Figure 8 10 Control Box Exploded View Model TPG4 7000HDXE 79 x 2 78 m 0 76 TPG4 7000HDXE PANEL 95 Tsurumi s Operation Service and Repair Manual Figure 8 10 Control Box Parts List Model TPG4 7000HDXE Ref Part Ref Part No Number Description Qty No Number Description Qty 45 15350680000 Box Control 1 67 15550330000 Screw Cross Head 1 46 15601699000 Panel Control 1 Recessed M5 x 25 13400195000 Receptacle 30A 68 15550331000 Washer Tooth Lock 1 125V M5 48 15400003000 Receptacle 20A 2 125V 69 15550329000 Nut Hex with 1 49 15400106000 Receptacle 1 Flange M5 30A 125V 250V 70 15301979000 Washer Cap M5 1 50 15400541000 Circuit Breaker 25A 1 T1 15550333000 Washer Flat M5 1 51 15400173000 Circuit Breaker 30A 2 72 15550334000 Washer Lock M5 1 52 15400171000 Circuit Breaker 20A 2 73 1555033500
57. box 45 CAUTION CAREFULLY REMOVE THE FRONT PANEL FROM THE FRAME TO AVOID DAMAGE TO WIRING AND OR ELECTRICAL OR ELECTRONIC COMPONENTS CAUTION USE CARE TO AVOID DAMAGE BY THE WIRE LOOP THAT PASSES THROUGH THE COIL ON THE IDLE CONTROL UNIT 5 Remove four frame bolts 33 at the corners of the front panel 46 Separate the front panel 46 from the frame 44 6 Replace panel mounted or control box mounted components as applicable 7 After replacing the panel mounted component connect generator and engine wires using the tags as a guide Install control box 45 on front panel 46 and secure with screws 34 1 Reset Pushbutton TPG4 7000HDXE Only 1 Refer to Figure 6 14 Remove front panel 45 and control box 46 refer to Removal Installation of Front Panel and Control Box 2 Disconnect wiring Removal Installation 69 Tsurumi s Operation Service and Repair Manual 3 Remove screws 84 and pushbutton 82 4 Install replacement pushbutton 82 and secure with screws 84 5 Connect wiring 6 Install front panel 45 and control box 46 refer to Removal Installation of Front Panel and Control Box Removal Installation 70 Tsurumi s Operation Service and Repair Manual TPG3 FIG 6 14 Figure 6 14 Front Panel and Control Box Components Model TPG3 7000HDXE Shown 2 DC Fuse TPG3 7000HDXE 1 Refer to Figure 6 14 Remove front panel 46 a
58. cription and Operation 18 Tsurumi s Operation Service and Repair Manual L MC gt A 2 X epee th MS vr Tov 120V or 110V MCo d TPG4 Fig 2 5 Figure 2 5 Full Power Switch Set for Single Voltage Output T3 120 b gt 110 J p 220 2 jJ A MCa QUE TPG4 Fig 2 6 Figure 2 6 Full Power Switch Set for Dual Voltage Output J Table 2 1 Full Power Switch Switch Setting Versus Output Available Description and Operation Switch Lower Voltage Higher Voltage Position Receptacle Receptacles 110V Rated No Output or 120V Output Can Be Taken 110V 120V Half of Rated Rated or 120V 240V Output Output 19 Tsurumi s Operation Service and Repair Manual THIS PAGE INTENTIONALLY LEFT BLANK Description and Operation 20 Tsurumi s Operation Service and Repair Manual 3 0 OPERATING INSTRUCTIONS 3 1 Operating Controls 1 The main operating controls for the generator are with a few exceptions mounted on the front panel of the generator 2 The controls consist of an ENGINE switch an AUTOTHROTTLE switch a FULL POWER Switch a PILOT light circuit BREAKER s a ground or earth post and electrical receptacles The specific controls used in each model are shown in Figures 3 1 through 3 4 NOTE The auto throttle feature is not available on Model TPG4 3000HDX
59. d air compressors require a very large force to start They need 3 to 5 times the wattage needed to maintain the tool in order to start For example a 5 000 watt generator would only be able to drive a 1 000 watt to 1 700 watt pump NOTE The wattage chart Table 3 3 is a guide only Refer to your specific appliance for correct wattage 23 To determine the total wattage required for operating a particular electrical appliance or tool multiply the voltage figure of the appliance tool by the tool s amperage amps The voltage and amperage amps information can usually be found on a data plate or label which is normally attached to electric appliances and tools Table 3 3 Wattage Chart Applicable Wattage w Applicable Wattage W TPG4 3000HDX TPG4 4500HDX TPG4 6000HDX TPG4 7000HDX TPG4 7000HDXE 60 Hz 60 Hz 60 Hz 60 Hz 60 Hz Incandescent Lamp 2000 3300 4500 5300 5300 Heater Fluorescent Lamp 1200 1900 2800 3100 3100 Mercury Lamp Electric Tool 1200 1900 2800 3100 3100 Pump Compressor 500 700 1000 1500 1500 Tsurumi s Operation Service and Repair Manual 4 0 MAINTENANCE 4 1 General 1 To maintain the generator in peak operating condition observe and implement the maintenance and adjustment schedule in Table 4 1 Inspect and or service the generator as scheduled in Table 4 1 2 An initial oil change should be performed after the first twenty 20 hours of use Th
60. damage to the starter c t e 3 10 WARNING WARNING 3 11 As the engine warms up two to three minutes gradually move the choke lever or choke ring o the OPEN position Position the throttle lever to the desired engine speed or set the auto throttle switch to ON 8 Emergency Stopping of the Engine a To stop the engine in an emergency set the ENGINE SWITCH to the OFF position For normal use turn the AC circuit breaker to the OFF position Disconnect battery cables Turn the engine switch to the OFF position Turn the fuel valve lever to the OFF POSITION Using The Generator TO PREVENT ELECTRICAL SHOCK FROM FAULTY APPLIANCES THE GENERATOR SHOULD BE GROUNDED CONNECT A LENGTH OF HEAVY WIRE BETWEEN THE GENERATOR S GROUND TERMINAL AND EXTERNAL GROUND SOURCE CONNECTIONS FOR STANDBY POWER TO A BUILDING S ELECTRICAL SYSTEM MUST BE MADE BY A QUALIFIED ELECTRICIAN AND MUST COMPLY WITH ALL APPLICABLE LAWS AND ELECTRICAL CODES IMPROPER CONNECTIONS CAN ALLOW ELECTRICAL CURRENT FROM THE GENERATOR TO BACK FEED INTO THE UTILITY LINES SUCH BACK FEED MAY ELECTROCUTE UTILITY COMPANY WORKERS OR OTHERS WHO CONTACT THE LINES DURING A POWER OUTAGE AND WHEN UTILITY POWER IS RESTORED THE GENERATOR MAY EXPLODE BURN OR CAUSE FIRES IN THE BUILDING S ELECTRICAL SYSTEM REFER TO 3 4 AC Application Single Voltage 1 Check the pilot lamp for proper voltage NOTE The generator is tho
61. dinary analog circuit tester with a 1 5 volt battery power source It is advisable to check the resistance readings using your standard circuit tester and adjust the values accordingly Engine speed does not decrease when load removed Solenoid bracket damaged or distorted Check bend angle of solenoid bracket Correct as required Wire leads damaged Check to make sure two solenoid leads are securely connected Check wiring to idle control unit Check to make sure wire leads to idle control unit are securely connected Solenoid failed Check resistance between two solenoid leads refer to Table 5 1 for resistance limits If resistance is higher or lower than limits replace solenoid Troubleshooting 40 Tsurumi s Operation Service and Repair Manual Table 8 Idle Control Unit Circuit Parameters Circuit Tester Power Source Apply Black Negative Probe of the Circuit Tester 1 2 3 4 5 Apply Red 1 oo 250 kQ 250 250 kQ Positive Probe of Circuit Tester 2 W DU 9 90 3 250 kQ 2559 250 75 4 250 250 75 5 8 5 oo 7 8 KQ 7 8 KQ XE Table 9 Diode Rectifier Checking Apply Black Negative Probe of the Circuit Tester Using Analog Circuit Tester Brown Brown Orange Brown White Brown No Continuity No Continuity Continuity Brown No Continuity No Conti
62. e Unit WARNING THE COMBINED WEIGHT OF THE ASSEMBLED ENGINE AND GENERATOR IS IN EXCESS OF 125 POUNDS USE OF AN OVERHEAD LIFTING DEVICE IS RECOMMENDED WARNING INJURY TO MAINTENANCE PERSONNEL MAY RESULT FROM ATTEMPTING TO LIFT THE HEAVY ENGINE AND GENERATOR ASSEMBLY FROM THE FRAME WITHOUT THE AID OF A LIFTING DEVICE NOTE Refer to exploded view in Replacement Parts section for parts information The item numbers in the following procedure are identical to those in the Replacement Parts exploded views NOTE Tsurumi recommends that the heavy generator engine unit be removed from the frame before removing generator components NOTE The engine and generator wires have in line plug and socket connectors that can be disconnected to take electrical measurements or to allow component replacement Tag both ends of the wires as they are disconnected Write the wire color and or other characteristics such as color of stripe on the tag to assure the wires are properly reconnected Removal Installation 59 6 11 Tsurumi s Operation Service and Repair Manual Removal of Generator Engine Unit In order to prepare for the removal of the generator and engine as a unit the fuel tank will first need to be drained Then the front panel 45 and control box 46 must be removed before tank 18 itself can be removed Refer to the procedures in Draining of the Fuel Tank and Replacement of the Fuel Tank The generator leads are cont
63. ent muffler H 10 Install new exhaust flange gasket H 3 and connect exhaust flange to the muffler Align upper screw hole in top of the muffler support with the screw hole in tab of generator bracket 9 Install screw H 13 Tighten fasteners to the torque values shown in Table 6 1 Removal Installation 53 Tsurumi s Operation Service and Repair Manual TPG FIG 6 4 Figure 6 4 Replacement of Muffler Model TPG4 3000HDX Only 54 Removal Installation 6 5 Tsurumi s Operation Service and Repair Manual Replacement of Fuel Tank WARNING DO NOT DRAIN FUEL WHILE SMOKING OR WHILE IN CLOSE PROXIMITY TO OPEN WARNING WARNING WARNING 6 6 FLAME ENGINE FUEL GASOLINE IS HIGHLY FLAMMABLE AND IF ACCIDENTALLY IGNITED CAN CAUSE SEVERE BURNS AND DEATH MAKE SURE THAT YOU DISCONNECT OR REMOVE THE BATTERY BEFORE DRAINING FUEL OR ANYTIME MAINTENANCE WILL INVOLVE HANDLING ENGINE FUEL ENGINE FUEL IS EXTREMELY FLAMMABLE AND CAN CAUSE SEVERE OR FATAL BURNS IF IGNITED MAKE SURE THAT YOU DISCONNECT OR REMOVE THE BATTERY WHEN YOU DO MAINTENANCE EXPLOSIVE HYDROGEN GAS MAY BE PRESENT AROUND THE BATTERY AND CAN BE IGNITED BY STATIC ELECTRICITY OR BY CONTACT WITH THE BATTERY TERMINALS BE SURE TO FOLLOW LOCAL GASOLINE HANDLING TRANSPORT AND FUEL DISPOSAL REGULATIONS Draining the Fuel Tank A It is not necessary to drain the engine fuel tank for the majority of routine maintenance tasks Howe
64. eplacing stator 8 or repairing wiring Push connectors and wiring through holes in back of control box 45 Remove four screws 33 and control case 31 Do not remove rubber strip 34 unless damaged Remove two screws 39 securing control box 45 Remove control box 45 Disconnect fuel tube 27 from fuel shutoff valve 19 by releasing clamp 29 or 30 Remove four bolts 23 and four washers 24 Remove fuel tank from frame 44 NOTE If the tank is being replaced remove bushings 25 and cushions 24 and install on replacement tank If tank is not being replaced leave the bushings and cushions installed Replacement of the Fuel Gauge Drain fuel from fuel tank refer to Draining of the Fuel Tank Remove fuel tank refer to Removal of Fuel Tank Remove filler cap 21 and screen 22 from tank 18 Using TBD TOOL remove fuel gauge 20 Install replacement fuel gauge Install screen 22 and cap 21 Install fuel tank 18 in frame 44 refer to Installation of Fuel Tank Removal Installation 58 Tsurumi s Operation Service and Repair Manual 6 9 Installation of Fuel Tank A If removed install fuel shutoff valve 19 in tank 18 1 If removed install bushings 26 and cushions 25 2 Install tank 18 in frame 44 and secure with four bolts 23 and four washers 24 3 Connect fuel tube 27 to shutoff valve outlet Secure with clamps 29 and 30 6 10 Removal Installation of Generator Engin
65. ereafter change oil every 100 hours 3 Before changing the oil check for a suitable way to dispose of the used oil Do not pour it down sewer drains onto garden soil or into open streams Refer to your local zoning and environmental regulations for disposal and handling requirements WARNING SHUT OFF THE ENGINE BEFORE PERFORMING ANY MAINTENANCE IF OPERATION OF THE ENGINE IS REQUIRED MAKE SURE THE AREA IS WELL VENTILATED THE ENGINE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS CAUTION REFER TO THE HONDA ENGINE OWNER S MANUAL FOR OTHER MAINTENANCE REQUIREMENTS Table 4 1 Maintenance Schedule FREQUENCY RECOMMEDED MAINTENANCE ACTION Daily e Check oil level e Check all components according to the pre operational checks in the OPERATING INSTRUCTIONS 50 Hours e Wash cleaner element e Check spark plug and clean if necessary 100 Hours e Change engine oil 200 Hours e Adjust spark plug gap e Clean fuel strainer 500 Hours e Replace spark plug and cleaner element 12 Months e Clean and adjust carburetor valve clearance and valve seat along with cylinder head 1 000 Hours e Inspect control panel parts 24 Month Vet Months e Check rotor and stator see 5 1 TROUBLESHOOTING e Replace engine vibration isolators see 8 1 REPLACEMENT PARTS for part number of the isolator used on your generator e Overhaul engine e Change fuel lines Maintenance 31 Tsurumi s Operat
66. eseeee nennen nennen nennen nnns 7 0 STORAGE INSTRU GTIONS ere eet ee anil ea TORQUE 8 0 REPLACEMENT PARTS rite Rte biet E kite deti ante ed nei ke ae ai iiaae 8 1 Exploded View Generator Model 4 0 8 2 Exploded View Generator Model 4 4500 0 nennen nnn 8 3 Exploded View Generator Model 4 6000 0 8 4 Exploded View Generator Model 4 7000 0 8 5 Exploded View Generator Model TPG4 7000HDXE esses nennen 8 6 Exploded View Battery Unit Model 4 7000 Appendices Appendix A OPTIONAL Wheel Kit Model 200 43 44 59 61 62 62 62 62 64 66 67 68 72 73 Introduction Tsurumi s Operation Service and Repair Manual 1 0 INTRODUCTION 1 1 GENERAL We thank you for purchasing a Tsurumi Portable Generator We are sure that the generator you have selected will meet all your portable electric power needs This manual applies to the Tsurumi Generators listed below Specifications for the generators are provided in the SPECIFICATIONS section Key features of the generator are shown in the DESCRIPTION section
67. evel i If the level is low fill to the top of the oil filler neck with the recommended oil Operating Instructions 18 j Reinstall the oil filler cap dipstick OIL FILLER CAP DIPSTICK DN UPPER LIMIT TPG3 FIG 3 6 Figure 3 6 Checking Oil Level 3 6 Check Engine Fuel WARNING MAKE SURE YOU REVIEW EACH WARNING IN ORDER TO PREVENT FIRE HAZARD DO NOT REFILL TANK WHILE ENGINE IS RUNNING OR HOT CLOSE FUEL SHUT OFF VALVE BEFORE REFUELING WITH FUEL BE CAREFUL NOT TO GET DUST DIRT WATER OR OTHER FOREIGN OBJECTS INTO FUEL WIPE OFF SPILLED FUEL THOROUGHLY BEFORE STARTING ENGINE KEEP AWAY FROM OPEN FLAMES DO NOT USE SMOKING MATERIALS WHEN FILLING THE FUEL TANK DO NOT REFUEL WHILE SMOKING OR NEAR OPEN FLAMES OR OTHER SUCH POTENTIAL FIRE HAZARDS OTHERWISE FIRE ACCIDENT MAY OCCUR AVOID REPEATED OR PROLONGED CONTACT WITH SKIN OR BREATHING OF VAPOR KEEP OUT OF REACH OF CHILDREN 1 Check fuel level at fuel level gauge see Figure 3 7 2 Iffuel level is low refill with unleaded automotive gasoline FUEL LEVEL INDICATOR RESPONDS TO FLOAT LEVEL TANK EMPTY TANK FULL FLOAT LOW FLOAT HIGH TPG4 FIG 3 7 Figure 3 7 Fuel Gauge Indications Fuel tank capacity TPG4 3000HDX 4 2 gal TPG4 4500HDX 6 6 gal TPG4 6000HDX 6 6 gal TPG4 7000HDX 6 6 gal TPG4 7000HDXE 6 6 gal 3 7 Pre Start Checks WARNING MAKE SURE YOU REVIEW EACH WARNING IN ORDER TO PREVENT FIRE HAZARD
68. ft in the fuel tank will eventually deteriorate making engine starting difficult 2 Remove the carburetor float chamber and also drain the carburetor 3 Change engine oil 4 Check for loose bolts and screws tighten if necessary 5 Clean generator thoroughly with oiled cloth Spray with preservative if available NEVER USE WATER TO CLEAN GENERATOR 6 Pull starter handle until resistance is felt leaving handle in that position 7 Store generator in a well ventilated low humidity area Storage Instructions 67 Tsurumi s Operation Service and Repair Manual THIS PAGE INTENTIONALLY LEFT BLANK Storage Instructions 68 Tsurumi s Operation Service and Repair Manual REPLACEMENT PARTS Introduction This section provides exploded view illustrations that show the replacement parts for Tsurumi Portable Generators Models TPG4 3000HDX TPG4 4500HDX TPG4 6000HDX TPG4 7000HDX and TPG4 7000HDXE Also provided are parts listings that provide part number description and quantity The item numbers shown on the illustrations correspond with the item numbers in the facing parts listing Ordering Parts Order replacement parts from Tsurumi America Inc 1625 Fullerton Court Glendale Heights IL 60139 Tel 1 888 878 7864 FAX 1 630 793 0146 E mail info tsurumiamerica com Web site http www tsurumipump com Honda Parts Honda Motor Company supplies parts that generally provide the interf
69. g the near side and far side of the stator until loosened enough to remove by hand Move the removed stator away from the work area Position the replacement stator 8 with the wires as shown in Figure 6 6 Put stator 8 over rotor 12 and against the front cover 14 Install stator cover 8 1 evenly over the stator Removal Installation 63 Tsurumi s Operation Service and Repair Manual 4 3x TPG4 Fig 6 8 Figure 6 8 Replacement of Stator 12 Align the bore in rear cover 14 with the rotor bearing 13 Position the rear cover 1 with the hole for grommet 75 aligned with the stator wires 13 Route the stator wires through grommet 75 and into access hole in the control box 45 14 Slip tube 7 over the wires Put tube 7 in the wire access hole making sure the groove in the tube is seated in the lip of the wire access hole 15 Install bolts 4 Tighten bolts 4 in small increments and in an alternating pattern Tighten the bolts so the stator cover is pulled down evenly against the relief at the edge of the front cover 14 and rear cover 1 Make sure the thin stator cover is seated all 360 degrees in the relief on both covers 16 Tighten fasteners to the torque values shown in Table 6 1 Removal Installation 64 Tsurumi s Operation Service and Repair Manual 6 14 Replacement of Rotor Bearing NOTE Refer to exploded view in Replacement Parts section for parts information The item nu
70. h bolt 11 9 Restrain the rotor to keep it from rotating 10 Put a box end wrench on the hex of the through bolt 11 11 Using a plastic rubber or other soft faced hammer strike the side of the wrench using sharp blows to loosen the through bolt 11 12 When the through bolt 11 is loosened it can easily be removed Removal Installation 65 Tsurumi s Operation Service and Repair Manual Puller Threaded Rod TPG4 FIG 6 9 Fi1gure 6 9 Bearing Puller in Use Through Bolt TPG4 FIG 6 10 Figure 6 10 Removal of Through Bolt NOTE Inthe steps that follow motor oil is used to generate hydraulic pressure Hydraulic pressure is used to separate the tight fitting engine and generator shafts 13 Refer to Figure 6 10 With the generator in the vertical position pour a small amount of motor oil in the bore in the center of the rotor shaft The oil level should be flush with the end of the rotor shaft Removal Installation 66 Tsurumi s Operation Service and Repair Manual Oil Container Sie gt gt TPG4 FIG 6 11 Figure 6 11 Pouring Oil in Rotor Shaft 14 Refer to Figure 6 12 Wrap electrical tape around the threads of a bolt to form a seal do not put tape on the first two threads of the bolt NOTE Use an M8 x 215 bolt for all models Wrap tape on bolt TPG4 FIG 6 12 Figure 6 12 Wrapping Bolt with Tape NOTE Have
71. ident or act of God TSURUMI assumes no responsibility for compliance with any regulations codes standards or ordinances applicable to the installation location operation or maintenance of its products No other warranty expressed or implied is authorized by or applicable to the seller No person agent or dealer is authorized to enlarge upon this warranty TSURUMI expressly disclaims liability for consequential or incidental damages or breach of expressed or implied warranty Any applied warranty of fitness for a particular purpose and merchantability shall be limited to the duration of the expressed warranty Some states do not allow limitations on the duration of an implied warranty so the above limitation or exclusion may not apply to you Some states do not allow the exclusion or limitation of incidental or consequential damages so the above limitation of exclusion may not apply to you This warranty gives you specific legal rights and you may also have other rights which vary from state to state Tsurumi Manufacturing Co Ltd Tsurumi s Operation Service and Repair Manual TABLE OF CONTENTS Section Title Page 1 0 INTRODUCTION oed t ite ate Lee REY n OO eR Soak nena pa ni ges 1 1 1 LE 1 1 2 Preca tons and Placards aeo nnn ret 1 1 3 lam 2 1 4 Safety Prec
72. ion Service and Repair Manual 4 2 Changing Engine Oil 1 2 Drain the oil while the engine is still warm to assure rapid and complete draining Remove the oil filler dipstick cap and drain plug 4 5 1 2 3 Allow oil to drain from the engine Figure 4 1 4 Refill with the recommended oil Figure 3 6 Check the oil level Install the oil filler dipstick 5 Install the drain plug and tighten securely NOTE Engine oil capacity 1 1 liters 1 16 U S Quart 6 Refill with the recommended oil Figure 3 4 Check the oil level Install the oil filler dipstick cap Figure 4 2 OIL FILLER CAF DIPFSTICK esu V 27 um UPPER LIMIT RAIN PLUG TPGA FIG 4 1 TPGA FIG 4 2 Figure 4 1 Draining Engine Oil Figure 4 2 Checking Oil Level 4 3 Air Cleaner Service WARNING NEVER USE GASOLINE OR LOW FLASH POINT SOLVENTS FOR CLEANING THE AIR CLEANER ELEMENT A FIRE OR EXPLOSION COULD RESULT 1 A dirty air cleaner will restrict airflow to the carburetor To prevent carburetor malfunction service the air cleaner regularly Service more frequently when operating the engine in extremely dusty areas NOTE Never run the engine without the air cleaner Rapid engine wear will result from contaminants such as dust and dirt being drawn through the carburetor into the engine Maintenance 32 Tsurumi s Operation Service and Repair Manual 4 4 Sediment Cup Cleaning WARNING GASOLINE IS EXTREMELY FLA
73. lamp 10 0 2 12 15200428000 Rotor Assembly 1 48 15302061000 Clamp 12 0 1 13 15311780100 Bearing Ball 1 jo i 14 15311460000 Bracket 1 camps en 15 19850908020 Bolt Flat Head with 4 Bee 19950876000 Tube yCanister Socket M8x1 0 20 51 15350678000 Tube Canister 1 16 15400160000 Connector 2 P 1 52 15350701000 Tube Corrugate 1 17 15400156000 Connector 6 P 2 53 15350700000 Tube Corrugate 1 18 15301982000 Tank Fuel Blue 1 19 15150135001 Valve Fuel Shutoff 1 Ref Part No Number Description Qty 20 15301674001 Gauge Assembly Fuel 1 Em Enare Hond 21 15302001000 Cap Fuel Filler 1 pu ipd k 22 15350343000 Filter Fuel 1 ds pe c PA 23 19830906025 Bolt Hex with Flange 4 ae eee 6 1 0 25 H 4 Bracket 1 24 19 00906025 Washer Tank Cushion 4 Heo fe eerste Screw Bracket 1 M6 x 25 1 0 Thick H 6 Shield Inner 1 25 15321880100 Cushion Tank Rubber 4 BH mem Seal 1 26 15321670270 Collar Tank Cushion 4 H 8 Shield Outer 1 27 15350694000 Tube Fuel 1 9 o seis Selenite ets Bolt Flanged 13 28 90854 ZB2 0000 Rubber Fuel Tube 1 Muffler Shield 29 95002 02080 Honda Part Number 1 H 40 ade e sur Muffler 1 lamp H 11 Spark Arrestor 1 Honda Part Number H 12 Screw Spark Arrestor 1 30 15301192000 Clamp Tube 1 H43 22222 Bolt 1 31 15550293001 Screw M5 x 12 2 14
74. mbers in the following procedure are identical to those in the Replacement Parts exploded views A Remove the generator rear cover 7 Refer to Replacement of Stator for removal instructions NOTE Make sure the diameter of the bearing puller threaded rod is larger than the threaded bore in the center of the rotor shaft 1 Install a three jaw gear or bearing puller on the rotor shaft Make sure all three jaws are under the outer race of the bearing refer to Figure 6 9 2 Rotate the threaded rod of the bearing puller and remove the bearing 13 from the rotor shaft 12 3 Pre heat an oven to 350 25 Fahrenheit Place the replacement bearing 13 in the oven for 30 minutes WARNING TO AVOID BEING BURNED BY THE HEATED BEARING WEAR THERMAL INSULATED GLOVES 4 Wear insulated gloves and remove bearing from the oven Immediately place the bearing on the rotor shaft Make sure the bearing is seated against the shoulder of the shaft 5 Let the bearing cool to room temperature 6 Check the bearing for free rotation 7 Install the rear cover 1 Refer to Replacement of Stator for rotor installation instructions 6 15 Replacement of Rotor 8 The generator stator 6 Figure 6 0 must be removed before the rotor 12 can be removed Refer to Replacement of Stator for stator removal instructions NOTE The rotor 12 Figure 6 9 at this point is free to rotate and must be kept from rotating to enable removal of the throug
75. moval Installation of Front Panel and Control Box 5 Engine Start Key Switch TPG3 7000HDXE 1 2 Refer to Figure 6 14 Pull switch 59 from backside of front panel 46 Separate switch from its connector box 45 refer to Removal Installation of Front Panel and Control Box 6 Circuit Breaker 50 Refer to Figure 36 Remove front panel 45 and control box 46 refer to Removal Installation of Front Panel and Control Box Remove two screws and washers Disconnect wiring Connect wiring and install replacement breaker 50 in back of front panel 45 Secure with two screws 7T Circuit Breaker 51 52 or 53 1 2 3 For breaker 51 52 or 53 remove four screws and washers Disconnect wiring Connect wiring and install replacement breaker 51 52 or 53 in back of front panel 45 Secure with four screws and washers Removal Installation 72 Tsurumi s Operation Service and Repair Manual re TPG3 FIG 6 15 Figure 6 15 Front Panel and Control Box Components Model TPG3 3000HDX Shown 4 Install front panel 45 and control box 45 refer to Removal Installation of Front Panel and Control Box 8 Idle Control Switch ModelsTPG3 4500HDX TPG3 6000HDX and TPG3 7000HDXE 1 Refer to Figure 6 15 Remove front panel 45 and control box 46 refer to Removal Installation of Front Panel and Control Box 2 Remove two screws 45 from switch 55 3 Disconnect wiri
76. nd control box 45 refer to Removal Installation of Front Panel and Control Box 2 Remove fuse from its fuse holder 3 Align notch in panel with the key on the switch Install replacement switch 59 in back side of front panel 46 4 Install fiber washer and ring nut Tighten ring nut 5 Connect switch with mating connector 3 Engine Switch Models TPG3 3000HDX TPG3 4500HDX and TPG3 6000HDX 1 Refer to Figure 6 14 Remove front panel 46 and control box 45 refer to Removal Installation of Front Panel and Control Box 2 Disconnect wiring 3 Connect wiring and install replacement switch 59 in back of front panel 46 Removal Installation 71 4 Tsurumi s Operation Service and Repair Manual Install front panel 46 and control box 45 refer to Removal Installation of Front Panel and Control Box 4 Pilot Lamp ALL MODELS 1 2 Refer to Figure 6 14 Remove front panel 45 and control box 45 refer to Removal Installation of Front Panel and Control Box Disconnect wire from pilot light 53 Squeeze inward on tab to release the pilot light 53 from the panel 45 Install replacement pilot light 53 from front of panel Install pilot light 53 until the tab snaps into place Connect the wire to the pilot light 53 Install front panel 46 and control older Install replacement fuse H TBD in its fuse holder Install front panel 45 and control box 46 refer to Re
77. nd in kgf in Tighten the fasteners to torque value shown to provide the required clamping force Table 6 1A Fastener Torque Values for Ibf in Cast Structure Stainless Structure Stainless Structure Stainless Material Iron Steel Steel Cast Iron Steel Steel Cast Iron Steel Steel Bolt Size Nominal Max Min Nominal Max Min Nominal Max Min M5 19 23 16 26 31 21 32 38 26 M6 32 38 26 44 53 36 55 65 44 M8 79 95 63 109 130 87 134 160 108 M10 156 187 125 216 259 174 265 318 212 M12 273 328 219 377 451 302 462 554 370 M14 435 522 348 600 720 480 735 882 589 M16 679 814 543 937 1123 750 1147 1377 918 M18 934 1121 747 1289 1547 1031 1578 1893 1263 M20 13251 1589 1080 1827 2193 1462 2238 2685 1791 M22 1802 2162 1442 2052 2982 1989 3045 3653 2436 M24 2290 2747 1832 3160 3791 2528 3870 4643 3096 M27 3350 4019 2680 4623 5547 3699 5661 6793 4529 M30 4549 5459 3640 6277 7533 5022 7688 9225 6151 NOTES 1 The figures above must be applied to fitting of components made of metal 2 The tightening coefficient shall be 1 5 Remowval Installation 47 Tsurumi s Operation Service and Repair Manual Table 6 1B Fastener Torque Values for kgf cm Structure Stainless Material Cast Iron Steel Steel Bolt Size Nominal Max Min Nominal Max Min Nominal Max Min M5 22 26 18 30 36 24 37
78. ng Removal Installation 73 Tsurumi s Operation Service and Repair Manual 4 Connect wiring and install replacement switch 55 in back of front panel 56 Secure with two screws 1 5 Install front panel 45 and control box 46 refer to Removal Installation of Front Panel and Control Box 9 Full power Switch ModelsTPG3 4500HDX TPG3 6000HDX and TPG3 7000HDXE 1 Refer to Figure 6 15 Remove front panel 45 and control box 46 refer to Removal Installation of Front Panel and Control Box 2 Remove two screws 41 from switch 40 3 Disconnect wiring 4 Connect wiring and install replacement switch 40 in back of front panel 45 and secure with two screw and lock washer assemblies 41 5 Install front panel 45 and control box 46 refer to Removal Installation of Front Panel and Control Box 10 Twist Lock Receptacles 1 Refer to Figure 6 15 Install front panel 45 and control box 46 refer to Removal Installation of Front Panel and Control Box 2 For receptacle 47 remove two screws 48 3 Disconnect wiring 4 Connect wiring and install replacement receptacle 47 in back of front panel 45 and secure with two screw and lock washer assemblies 48 5 For receptacle 49 remove two screw and lock washer assemblies 50 6 Disconnect wiring 7 Connect wiring and install replacement receptacle 49 in back of front panel 45 and secure with two screws 50
79. nt Parts exploded views Removal Installation 48 Tsurumi s Operation Service and Repair Manual NOTE The model TPG4 7000HDXE generator has a 12 volt DC starting system Use a 12 volt garden tractor type battery as a replacement battery A Refer to Figure 6 1 Remove two nuts 88 from bolts 88 Remove plate 88 and two bolts 86 from battery plate 93 B Remove cables 85 and 86 from battery terminals C Remove battery from battery enclosure A Put replacement battery in battery enclosure with battery terminal side of the battery facing the generator B Place plate 88 on battery being careful not to contact the battery terminals Insert L shaped ends of bolts 89 in holes in plate 93 in base of battery enclosure 12 VOLT BATTERY Figure 6 1 Replacing Battery Removal Installation 49 Tsurumi s Operation Service and Repair Manual Put threaded ends of bolts 89 in holes in plate 93 Install nuts 88 on bolts to secure battery E Connect cables 85 and 86 to terminals on the battery Start and operate generator to verify that the battery is properly connected 6 2 Removal Installation of Battery Enclosure Model TPG4 7000HDXE Only WARNING MAKE SURE THAT YOU DISCONNECT OR REMOVE THE BATTERY WHEN YOU DO MAINTENANCE EXPLOSIVE HYDROGEN GAS MAY BE PRESENT AROUND THE BATTERY WARNING SPARKS FROM STATIC ELECTRICITY OR FROM HAND TOOLS CONTACTING BATTERY TERMINALS CAN CAUSE
80. nuity Continuity Apply Red Positive Probe of Orange Continuity Continuity Continuity Circuit Tester Brown White No Continuity No Continuity No Continuity Apply Red Positive Probe of the Circuit Tester Using Digital Circuit Tester Brown Brown Orange Brown White Brown No Continuity No Continuity Continuity Apply Black Negative Probe Brown No Continuity No Continuity Continuity of Circuit Tester Orange Continuity Continuity Continuity Brown White No Continuity No Continuity No Continuity Note 1 Because of the difference of measuring methods between the analog circuit tester and the digital circuit tester polarity of the tester needles should be reversed Note 2 Continuity means forward direction characteristics of the diode and is different from short circuit condition in which a pointer of the tester goes out or its normal scale it shows resistance to some extent When results of the checking indicates failure even in one section replace with a new diode Note 3 Simpson brand analog testers have the same characteristics as a digital tester Troubleshooting 41 Tsurumi s Operation Service and Repair Manual 5 6 Wiring Diagrams TPG4 3000HDX 25 zl 5 Reese 3 sea _ 3 4 qi M ec F E WO ld um
81. ombination receptacle 3 2 DC Circuit Controls 1 The circuitry for DC circuit consists of a 10 Amp fuse an overload protector and a reset switch Model TPG4 7000HDXE only 2 In the event of an overload the overload protector will trip the reset switch located immediately below the engine key starter switch Operating Instructions 13 Tsurumi s Operation Service and Repair Manual Engine switch Receptacle Pilot 120V BIGINESW Circuit breaker Ground terminal Figure 3 1 Model TPG4 3000HDX Receptacle 120 240V Engine switch Pilot lamp Volt isc Circuit breaker oltage selector GFCI switch AT 120 240V 120V ONLY AC 120 240V CIRCUIT BREAKER PRESS TO RESET Circuit breaker 30A Circuit breaker 20A Idle control switch Ground terminal Receptacle 120V Receptacle 120V Circuit breaker 30A Figure 3 2 Models TPG4 4500HDX TPG4 6000HDX and TPG4 7000HDX Operating Instructions 14 Tsurumi s Operation Service and Repair Manual Pilot ite lamp Receptacle 120 240V GFCI switch Idle control switch Voltage selector Circuit breaker C WOLTAGE SELECTOR GIRCUIT BREAKER EXE on CIRCUIT BREAKER 1 AT 120 240 120V 240V 120V_ONY PRESS RESET 4 AT 120V ONLY AC 1200 2400 Circuit breaker 20A Engine switch St rter res t Ground terminal switch Receptacle 1
82. ontrol Box Exploded Model TPG4 7000HDX TPG4 7000HDX PANEL Replacement Parts 78 Tsurumi s Operation Service and Repair Manual Figure 8 8 Control Box Parts List Model TPG4 7000HDX Ref Part Ref Part No Number Description Qty No Number Description Qty 45 15350680000 Box Control 1 63 19SF4906015 Screw Cross Head 1 46 15601699000 Panel Control 1 Recessed M6x15 47 15400105000 Receptacle 30A 1 64 19N10906000 Nut Hex with Flange 1 125V M6 48 15400003000 Receptacle 20A 2 65 15400559000 UNIT GFCI 1 125V 66 15301082001 Spacer Switch 1 49 15400106000 Receptacle 1 67 15550330000 Screw Cross Head 1 30A 125V 250V Recessed 50 15400541000 Circuit Breaker 25 1 5 25 51 15400173000 Circuit Breaker 30 2 68 15550331000 Washer Tooth Lock 1 52 15400171000 Circuit Breaker 20A 2 5 53 85111573300 Bracket Neon 1 69 15550329000 Nut Hex with 1 54 15400143000 Switch Voltage 1 Flange Me Selector 70 15301979000 Washer Cap M5 1 55 15400108000 Switch Auto Throttle 1 71 15550333000 Washer Flat M5 1 56 19500700660 Control Unit Auto 1 72 15550334000 Washer Lock M5 1 Throttle 73 15550335000 Nut Wing M5 1 ao id Brage 74 19821904012 Screw Self Tapping 2 58 15400177000 Condenser Assembly 2 M4x12 18 75 15321880130 Grommet Panel Lead 1 59 15400253000 Switch Engine 1 2 60 19SS4903005 Screw Cross Head 4 Recessed M3x5 76 15350472000 Grommet 2
83. or Assembly 42 19W50906000 Lockwasher Tooth 1 9 15311462000 N Bracket 1 43 19N10906000 Nut Hex With Flange 1 10 19830908020 Bolt Hex with Flange 4 44 15302009000 Frame 1 M8 x 1 0 20 45 15950138000 Carbon Canister 1 11 15550154000 Bolt Hex with Flange 1 46 15950141000 Stay Carbon Canister 1 10 1 25 235 47 15302060000 Clamp 10 0 2 12 15200432000 Rotor Assembly 1 48 15302061000 Clamp 12 0 1 13 15311780100 Bearing Ball 1 Ho 15302063000 14 15311460000 Bracket 1 Clamp 15 19850908020 Bolt Flat Head with 4 90N Canister 1 Socket M8x1 0 20 51 15350678000 Tube Canister 1 16 15400160000 Connector 2 P 1 52 15350701000 Tube Corrugate 1 17 15400156000 Connector 6 2 53 15350700000 Tube Corrugate 1 18 15301982000 Tank Fuel Blue 1 19 15150135001 Valve Fuel Shutoff 1 Ref Part x No Number Description Qty 20 15301674001 Gauge Assembly Fuel 1 Tm CREDE aane isra 7 21 15302001000 Cap Fuel Filler 1 idi d 22 15350343000 Filter Fuel 1 i Sta ji ini x 23 19830906025 Bolt Hex with Flange 4 6 1 0 25 H 4 Bracket 1 24 19W00906025 Washer Tank Cushion 4 be egressus Screw Bracket 1 M6 x 25 1 0 Thick H 6 Shield Inner 1 25 15321880100 Cushion Tank Rubber 4 H7 0 GIAI Seal 1 26 15321670270 Collar Tank Cushion 4 HEB omes Shield Outer 1 27 15350694000 Tube Fuel 1 H 9 Bolt Flanged 13 28 90854 ZB2 0000 Ru
84. output Measuring Insulation Resistance 2 Use a megger tester to test each component for proper insulation An insulation resistance of 1 MQ or greater is normal The insulation resistance from the factory is at least 10 MQ 3 Insulation Resistance Stator a Measure the insulation resistance between BLUE lead and the core AC coil b Measure the insulation resistance between RED lead and the core AC coil c Measure the insulation resistance between YELLOW lead and the core d Measure the insulation resistance between BROWN lead and the core DC coil 4 Insulation Resistance Rotor a Measure the insulation across one of the soldered terminals of the rotor and the core b Parts with insulation resistance of less than 1MQ have faulty insulation and may cause electric leakage and electric shock Replace the faulty part Figure 5 1 Measuring Resistance Troubleshooting 35 Tsurumi s Operation Service and Repair Manual 5 4 Electrical Limits Reference Chart 1 The Electrical Limits Reference Chart Table 5 1 provides a ready reference to electrical component limits Table 5 1 Electrical Limits Reference Chart Model Rotor Stator Condenser Field Insulation AC Winding AC Winding Condenser Insulation Capacitance Coil 1 2 Red White Red White Winding 2 3 Yellow Yellow TPG4 3000HDX 1 70 gt 1 MQ 0 58 0 58 1 56 21MO 14uF TPG4 4500HDX 1 75 gt 1 0 29 0 29
85. r to discharge the condenser NOTE To make sure you get a good reading discharge the condenser before checking capacitance 3 Check capacitance of condensers refer to Table 5 1 for capacitance values for each generator model Replace condensers that do not meet normal capacitance Stator fault 1 Check Stator 2 Remove bolts 34 from front panel 32 Pull the front panel 32 away from frame 44 to provide clearance for removal of control box 3 Remove four screws 33 from front panel 32 to separate the control box 45 from the front panel 4 Locate the stator leads Separate the leads at the in line connector 5 Use adhesive label or tag to identify the leads use the label or tag to make sure you have the proper connection 6 Measure resistance between the in line connector on the stator leads refer to Table 5 1 for resistance values for each generator model 7 Replace stator if it does not meet resistance values in Table 5 1 Troubleshooting 37 Tsurumi s Operation Service and Repair Manual FAULT PROBABLE CAUSE REMEDY No AC output Stator fault continued 8 Check insulation resistance between the stator core and each stator leads Check using a megger tester Replace the stator if it fails the megger test Rotor fault 1 Check rotor 2 Remove generator rear cover and stator refer to COMPONENT REPLACEMENT for procedures 3 Using a multimeter
86. roughly tested and adjusted in the factory If the generator does not produce the specific voltage consult your nearest Tsurumi Generator dealer 9 _ Set switches on the electrical appliances to OFF before connecting to the generator 10 Insert the plug of the electrical appliance into the appropriate receptacle NOTE Check the amperage of the receptacles used referring to Table 3 1 and be sure not to take a current exceeding the specified amperage 11 Be sure that the total wattage of all appliances does not exceed the rated output of the generator WARNING TO CONNECT AND LOCK A PLUG IN A TWIST LOCK RECEPTACLE INSERT THE PLUG INTO RECEPTACLE AND TURN CLOCKWISE WARNING BE SURE TO GROUND THE GENERATOR IF THE CONNECTED ELECTRICAL EQUIPMENT IS GROUNDED NOTE Whenever a circuit breaker trips off during operation the generator is overloaded or the appliance is defective NOTE When a circuit breaker trips stop the generator immediately Check the appliance and or generator for an overload or defect and repair as necessary Table 3 1 Receptacle Types and Amperage Style Ampere Receptacle AC Plug Description iF Receptacle Duplex Up to NEMA NEMA Ground Fault Circuit 20A 5 20R 5 20P Interrupter Up to NEMA NEMA e 20A L14 20R L14 20P Rocking Receptacle Up to NEMA NEMA 30A L5 30R L5 30P Locking Receptacle CAUTION The 120V duplex receptacle is protected by a Ground Fault
87. s 98 4 Position frames 96 on generator frame 44 Install two U bolts 99 and secure using nuts 100 Removal Installation 50 Tsurumi s Operation Service and Repair Manual Figure 6 2 Battery Enclosure Components 89 TPG4 FIG 6 2 6 3 Replacement of Muffler Models TPG4 4500HDX TPG4 6000HDX TPG4 7000HDX and TPG4 7000HDXE A Refer to Figure 6 3 Remove screws H 9 and remove outer shield H 8 Do not remove spark arrestor H 11 unless damaged If damaged remove screw H 12 and spark arrestor H 11 B Remove two screws H 2 and exhaust gasket H 3 from engine exhaust connection C Remove screws H 13 and H 14 Remove muffler H 10 together with inner shield H 6 D Separate inner shield H 6 from muffler H 10 TPG4 E Insert support brackets of replacement muffler H 10 through seals H 7 on inner shield H 6 F Install bolt H 13 through hole in lower muffler support bracket and into threaded hole in generator bracket 9 Do not tighten bolt at this time G Install bolt H 14 in lower lug of generator bracket 3 on muffler H 10 Do not tighten bolt at this time H Install new exhaust flange gasket H 3 Align gasket H 3 with holes for exhaust flange screw H 2 Make sure gasket H 3 remains aligned Install two screws H 3 to connect exhaust flange to the muffler Tighten all fasteners in an alternating pattern Apply torque to the values shown in Table 6 1 Remo
88. shop towels available to wipe up spilled oil 15 Install the bolt in the center of the rotor shaft refer to Figure 6 13 Turn the bolt into the shaft the force required to turn the bolt will increase as the pressure increases Removal Installation 67 Tsurumi s Operation Service and Repair Manual Taped Bolt HI HI IL DII EI ud II II TPG4 FIG 6 13 Figure 6 13 Tightening of Through Bolt for Separation of Engine and Generator CAUTION TSURUMI RECOMMENDS THAT YOU REMOVE FLATHEAD SCREWS 15 USING AN ALLEN TYPE HEX WRENCH MOUNTED IN A SOCKET WRENCH ADAPTER BEFORE REMOVING SCREWS 15 TAP THE HEX ADAPTER WITH A HAMMER TO MAKE SURE THE HEX IS FULLY SEATED FAILURE TO DO SO MAY RESULT IN ROUNDING OF THE SOCKET FLATS IN SCREWS 15 AND THE NEED TO REMOVE USING DESTRUCTIVE REMOVAL METHODS 16 When the shafts separate place the rotor on a shop towel and let the oil drain from the shaft Wipe up oil that drained into the front cover 17 The front cover may remain installed unless it is damaged or the engine is being replaced To remove the front cover remove four bolt and washer assemblies 13 18 If the front cover 14 was removed position front cover with cooling air slots on the bottom of the generator Secure with four bolts 15 Tighten to the torque values shown in Table 6 1 19 Complete assembly of the generator as follows 1 Install rotor 12
89. stops the engine when the oil level falls down below the predetermined level 13 When the engine has stopped automatically check the oil level Refill engine oil to the upper level and restart the engine 14 Ifthe engine does not start by usual starting procedures check the oil level 3 14 Idle Control Models TPG4 4500HDX TPG4 6000HDX TPG4 7000HDX and TPG4 7000HDXE 1 idle control feature automatically reduces engine speed when there is no load on the generator and automatically increases engine speed up to rated speed when load is applied 15 The idle control feature provides fuel economy and lower noise leevels at no load operation 3 15 to use Idle Control 1 Start the engine with AUTO THROTTLE switch set to OFF 16 Warm up the engine without a load for a few minutes 17 Set AUTO THROTTLE switch to the ON position 3 16 Checking Idle Function 1 When the idle function does not operate normally check the following NOTE Most induction loads such as an electric motor require wattage three to five times larger than their rating at starting This starting wattage should not exceed the rated output of the generator a Make sure that the generator is not overloaded b Set the IDLE Control switch to off when the idle control does not work normally under the rated output 3 17 Ground Fault Circuit Interrupter WARNING USING THE GENERATOR IN RAIN SNOW OR NEAR WATER CAN LEAD TO
90. surface It is not necessary to prepare a special foundation for the generator However the generator will vibrate on an irregular surface Therefore choose a level place without surface irregularities Shutoff the generator when moving the generator to another work site It the generator is tilted or moved during operation fuel may spill and or the generator may tip over causing a hazardous situation Proper lubrication cannot be expected if the generator is operated on a steep incline or slope In such a case the piston may seize it may seize even if the oil is above the upper level Do not operate in rain or with wet hands The operator may suffer severe electric shock if the generator is wet due to rain or snow If wet dry before starting Do not pour water directly over the generator nor wash it with water Do not connect the generator to a commercial power line Connection to a commercial power line may result in short circuit and damage the generator When connecting to domestic circuits install only approved transfer Switches and make sure power and control circuitry meet local electrical code requirements Do not smoke or use other smoking materials pipes cigars etc while handling the battery The battery emits flammable hydrogen gas which can explode if exposed to electrical arcing or open flame Keep the work area well ventilated and keep the battery away from open flames sparks Introduction 3
91. t be applied continued Check engine speed Operate the generator at no load If the speed is too low adjust to the normal engine speed specified in Table 5 1 7 Restart the generator and apply load If load still can not be applied check stator rotor and condensers refer to No AC Output troubleshooting steps above Faulty power consuming device Check for faulty appliance power tool or other power consuming devices Engine overheated Check for and clear away debris covering engine and generator cooling air inlets and outlets Failed generator insulation 1 Check Insulation 2 Stop engine Measure the insulation resistance between the live terminal of a receptacle and the ground post on the front panel 3 If the insulation resistance is less than 1 disassemble the generator to obtain the stator and rotor 4 Disassemble to gain access to the components in the control box 5 Check the insulation resistance of the stator the rotor and the live electrical components in the control box Any component whose insulation resistance is less than 1MQ is faulty and may cause electrical leakage 6 Replace any component having insulation resistance of less than 1MQ Engine speed does Solenoid damaged not increase when load applied Check bend angle of solenoid bracket Correct as required Wattage of connected appliance or electric tool exceeds rating
92. tery cables to battery b Turn ENGINE SWITCH to the START position and hold for 5 seconds or until the engine starts c Verify that the starter reset pushbutton switch is not extended If extended push in to reset If reset switch resets stays in proceed to next step If not correct the reason for the trip before attempting to start the engine d To start the engine using the starter turn key switch to START e Turn key fully right to START position Hold in START position until engine starts NOTE Operating the starter motor for more than 5 seconds can damage the motor If the engine fails to start release the switch and wait 10 seconds before operating the starter again NOTE If the speed of the starter motor drops after a period of time it is an indication that the battery should be recharged f Release key the key is spring loaded to the RUN position b g As the engine warms up gradually open the choke ring h Set auto throttle switch to ON The engine idle function is enabled and will remain at idle until a load is sensed and increases speed in response to the load 7 MODELS When starting the engine using recoil starter proceed as follows a Turn the engine switch to the ON position Pull the starter grip lightly until resistance is felt then pull briskly NOTE When using the recoil starter do not allow the starter grip to snap back against the engine Return it gently to prevent
93. the control box A flexible rubber sleeve provides protection for the generator wiring 2 2 FUNCTIONAL DESCRIPTION 1 Generation of No Load Voltage refer to Figure 2 3 a b When the generator rotor begins to rotate the permanent magnet in the rotor generates 3 to 6 volts alternating current in the main coil and in the condenser coil windings The low voltage generated in the condenser coil also generates minute current flow a through the condenser coil At the same time low level magnetic flux intensifies at the rotor s magnetic pole As the magnetic force intensifies voltage increases in the main coil and in the condenser coil As current a increases magnetic flux also increases at the rotor s magnetic pole and continues to increase as generator speed increases As AC current flows through the condenser coil the density of the magnetic flux in the rotor changes The change in magnetic flux density induces AC voltage in the field coil and the diode rectifier in the field coil circuit rectifies the AC voltage into DC voltage The resultant DC current flows b through the field coil and magnetizes the rotor core to generate output voltage in the main coil Description and Operation 16 Tsurumi s Operation Service and Repair Manual d When the generator speed reaches 3000 to 3300 rpm 60 Hz generators the current in the condenser coil increases rapidly This acts to stabilize the output voltage of each coil
94. ting bracket The muffler for Models TPG4 4500HDX TPG4 6000HDX TPG4 7000HDX and TPG4 7000HDXE expels exhaust gases through a port in the side of the muffler The muffler for Model TPG4 3000HDX has a smaller muffler that expels gases through a curved tube on the bottom of the muffler Description and Operation 14 Tsurumi s Operation Service and Repair Manual FRONT BRACKET ROTOR BALL BEARING 2 PIN CONNECTOR 6 PIN CONNECTOR LEAD WIRE TUBE ca CONNECTOR GENERATOR LEAD WIRES REAR BRACKET TIE BOLT STATOR COVER REAR COVER TPG4 FIG2 2 Figure 2 2 Exploded View of TPG4 Generator Components h muffler is fitted with a spark arrestor to screen out sparks ejected in the exhaust gases The spark arrestor for Models TPG4 4500HDX TPG4 6000HDX TPG4 7000HDX and TPG4 7000HDXE is installed the exhaust port of the muffler The spark arrestor for Model TPG4 3000HDX is installed in the inlet side of the muffler i The engine is fitted with oil filler plugs that are used to check engine oil level Engine oil is added through the same filler plug ports The engine oil drain plug is installed in the engine casing adjacent to the oil filler plug j The engine has a carburetor choke control for starting the engine during cold weather operation Models TPG4 4500HDX TPG4 6000HDX TPG4 7000HDX and TPG4 7000HDXE have a ring type choke control Model TPG4 3000HDX has a choke lever NOTE Refer to the Hond
95. ttery ce Etat E E en AED er IRE 6 4 Removal Installation of Battery Enclosure esee 6 5 Replacement of Engine Muffler caes n nemen nenens Models TPG4 4500HDX TPG4 6000HDX TPG4 7000HDXE 6 6 Replacement of Engine Muffler eee nnn nnne Model TPG4 3000HDX 6 7 Replacement of Fuel 6 8 Draining of the Fuel nnns 6 9 Removal of F el Earik uiii oie rre pe ERA Fire seite A 6 10 Replacement of the Fuel Gauge 6 11 Installation of Fuel Tanks a eiie e Fra ea ate ore ER Mx Se HER CE seca eu EGRE PERCHE 6 12 Replacement of the Generator Engine Unit 6 13 Removal of Generator Engine Ie Irem rennen 6 14 Installation of Generator Engine Unit eee cere teeter ener em m nnne 6 15 Replacement of Generator Stator 6 8 Replacement of Rotor nennen ennt ntn 6 9 Replacement of 6 10 Replacement of Front Panel and Control Box ssssssssssesssss
96. val Installation 51 Tsurumi s Operation Service and Repair Manual TPG4 FIG 6 3 Figure 6 3 Replacement of Muffler Models TPG4 4500HDX TPG4 6000HDX TPG4 7000HDX and TPG4 7000HDXE 52 Removal Installation 6 4 Tsurumi s Operation Service and Repair Manual Replacement of Muffler Model TPG4 3000HDX Only Refer to Figure 6 4 Remove screws H 9 and outer muffler shield H 8 to expose the muffler Disconnect muffler H 10 from engine exhaust connection Remove screw H 13 Remove muffler H 10 together with inner shield H 6 from slot in bracket 44 1 Do not remove bracket 44 1 unless damaged If damaged remove screws 44 2 and bracket 44 1 There are two attachment points on the muffler The lower support has a lip that fits into a slot in bracket 44 1 on the side of the generator The upper support has a screw hole for securing the muffler to the generator bracket 9 10 11 Separate inner shield H 6 from muffler H 10 Insert support brackets of replacement muffler H 10 through seals H 7 on inner shield H 6 If removed install bolt H 13 through hole in lower muffler support bracket and into threaded hole in generator bracket 9 Do not tighten bolt at this time After removing screw H 13 lift the muffler so the lip clears the slot in generator bracket Then move the muffler away from the generator bracket Install inner shield H 6 and replacem
97. ver the tank should be drained anytime the generator will be stored or when the fuel tank must be removed for maintenance 1 If the engine can be started start the engine and close the fuel tank shutoff valve 19 refer to Figure 6 5 Let the engine operate until it is starved of fuel and stops By doing so residual fuel in the fuel lines and carburetor will be reduced to a minimum Disconnect the fuel hose from the fuel tank shutoff valve 19 refer to Figure 6 6 Removal Installation 55 Tsurumi s Operation Service and Repair Manual 4 7 as a a gt C n N Fuel o Container M S TPG3 FIG 6 5 Figure 6 5 Draining Fuel into Container 2 Connect a drain hose to the fuel tank shutoff valve and place the free end of the tube in an approved gasoline container The container should have a capacity of 6 6 gallons minimum see Figure 6 6 3 Open the fuel shutoff valve 19 and allow the fuel to drain from the tank 4 Tighten the cap on the fuel container TPG3 FIG 6 6 Figure 6 6 Fuel Shutoff Valve Shown in CLOSED Position Removal Installation 56 WARNING WARNING WARNING WARNING Tsurumi s Operation Service and Repair Manual DO NOT DRAIN FUEL WHILE SMOKING OR WHILE IN CLOSE PROXIMITY TO OPEN FLAME ENGINE FUEL GASOLINE IS HIGHLY FLAMMABLE AND IF ACCIDEN

Operational Manual - The Official Tsurumi Pump Store

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