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.
Tsurumi’s Operation, Service, and Repair Manual LIMITED WARRANTY TSURUMI MANUFACTURING CO., LTD.
Tsurumi’s Operation, Service, and Repair Manual TABLE OF CONTENTS Section Title 1-0 INTRODUCTION ........................................................................................................................... 1-1 General ......................................................................................................................................... 1-2 Precautions and Placards ..............................................................................................................
Tsurumi’s Operation, Service, and Repair Manual 5-0 5-1 5-2 5-3. 5-4 5-5 5-6 TROUBLESHOOTING................................................................................................................... General ......................................................................................................................................... Isolating Fault to the Generator or to the Control Panel ..................................................................
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.
Tsurumi’s Operation, Service, and Repair Manual WARNING: 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. 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.
Tsurumi’s Operation, Service, and Repair Manual Figure 1-2: Electrical Warning TSURUMI PORTABLE GENERATOR MODEL MAX. OUTPUT RATED OUTPUT VOLTAGE FREQUENCY SERIAL NO. Figure 1-4: Fuel Handling Warning TPG4-3000HDX 2.6kVA 2.2kVA 120V 60Hz ＊＊＊＊＊＊ MADE IN JAPAN TPG4 Fig. 1-2 TPG4 Fig. 1-1 ■CHECK FOR SPILLED FUEL OR FUEL LEAKS. STOP ENGINE BEFORE REFUELING. ^ ■CONTROLER QU’IL N’Y A NI FUITE NI ESSENCE ´ REPANDUE SUR L’ APPAREIL ^ ARRETER LE MOTEUR AVANT DE REFAIRE LE PLEIN.
Tsurumi’s Operation, Service, and Repair Manual Figure 1-7: Hot Exhaust Placard ECHAPPEMENT TPG4 Fig. 1-7 Figure 1-8: Multiple Warning/Caution Placard WARNING DO NOT USE INDOORS. EXHAUST GAS CON TAINS POISONOUS CARBON MONOXIDE. ATTENTION NE PAS UTILISER DANS UN ENDROIT FERME A CAUSE DU RISQUE D’EMPOISONNEMENT DU GAZ. ATENCION NO LO USE EN LUGARES CERRADOS PORQUE EL MONOXIDE DE CARBONO ES VENENOSO. WARNING USING THE GENER ATOR IN RAIN, SNOW OR NEAR WATER CAN LEAD TO DE ATH FROM ELECTRIC SHOCK.
Tsurumi’s Operation, Service, and Repair Manual Table 1-1 Portable Generator Specifications 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 (120V.240V) 21.7/18.3 37.5/30,18.8/15 50/40,25/20 58.3/50,29.2/25 58.3/50,29.
Tsurumi’s Operation, Service, and Repair Manual THIS PAGE INTENTIIONAALLY LEFT BLANK 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.
Tsurumi’s Operation, Service, and Repair Manual (c) (2) 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. Description of Generator (a) (b) (c) (d) (e) (f) The generator consists of a front bracket, intermediate N-bracket, stator assembly and cover, rotor, rear bracket and bracket cover.
Tsurumi’s Operation, Service, and Repair Manual ENGINE FRONT BRACKET TAPERED SHAFT ROTOR BALL BEARING 2-PIN CONNECTOR N-BRACKET 6-PIN CONNECTOR LEAD WIRE TUBE AIR COOLING FAN 6-PIN CONNECTOR ROTOR GENERATOR LEAD WIRES REAR BRACKET TIE BOLT RUBBER BUSHING STATOR COVER STATOR REAR COVER TPG4-FIG2-2 Figure 2-2: Exploded View of TPG4 Generator Components (h) The muffler is fitted with a spark arrestor to screen-out sparks ejected in the exhaust gases.
Tsurumi’s Operation, Service, and Repair Manual (4) Description of the Fuel Tank (a) (b) (c) (d) (e) (5) 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.
Tsurumi’s Operation, Service, and Repair Manual (d) (2) 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. When the generator speed reaches its rated speed, the generator output will be at its rated value.
Tsurumi’s Operation, Service, and Repair Manual TPG4 Fig. 2-4 Figure 2-4: Full Power Switch Circuit Diagram (d) (e) (f) Description and Operation 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.
Tsurumi’s Operation, Service, and Repair Manual TPG4 Fig. 2-5 Figure 2-5: Full Power Switch Set for Single-Voltage Output TPG4 Fig.
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 3-1 OPERATING INSTRUCTIONS 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.
Tsurumi’s Operation, Service, and Repair Manual Engine switch Receptacle 120V Pilot lamp Circuit breaker Ground terminal Figure 3-1: Model TPG4 4-3000HDX Receptacle 120/240V Pilot lamp Voltage selector Circuit breaker GFCI switch VOLTAGE SELECTOR ENGINE SW. TEST TEST ＯＮ CIRCUIT BREAKER PILOT ＯＮ ＯＦＦ IDLE CONTROL W S. CIRCUIT BREAKER PRESS TO RESET 120V/240V AT 120/240V AT 120V ONLY ＯＮ 120V ONLY AC 120V/240V ＯＦＦ ＯＦＦ GFCI SW.
Tsurumi’s Operation, Service, and Repair Manual Pilot lamp Idle control switch Circuit breaker Receptacle 120/240V GFCI switch Voltage selector Circuit breaker 30A VOLTAGE SELECTOR START CIRCUIT BREAKER TEST PILOT ＯＮ ＯＦＦ ENGINE SW. IDLE CONTROL W S. CIRCUIT BREAKER PRESS TO RESET 120V/240V AT 120/240V AT 120V ONLY 120V ONLY AC 120V/240V ＯＮ ＯＦＦ GFCI SW. RESET RESET ON TEST OFF ON／PUSH OFF STARTER RESET SW.
Tsurumi’s Operation, Service, and Repair Manual 3-3 Grounding Provisions WARNING: 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. WARNING: 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.
Tsurumi’s Operation, Service, and Repair Manual (67) GROUNDING POST (68) STAR WASHER (69) NUT (70) CUP WASHER (71) FLATWASHER (72) LOCKWASHER (73) WINGNUT PARTS BREAKDOWN GROUND ROD GROUND WIRE TO GROUND ROD CLAMPING SCREW GROUND WIRE SOIL CONTROL PANEL (46) ON GENERATOR 67 69 68 70 71 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 A 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 A LEVEL 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.
(j) Reinstall the oil filler cap / dipstick.
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.
3-7 Pre-Start Checks WARNING: MAKE SURE YOU REVIEW EACH WARNING IN ORDER TO PREVENT FIRE HAZARD. WARNING: KEEP AREA CLEAR OF FLAMMABLES OR OTHER HAZARDOUS MATERIALS. (1) (2) 3-8 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.
3-9 Starting & Stopping the Engine (1) NOTE: NOTE: 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.
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).
(7) (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. (ALL MODELS): When starting the engine using recoil starter, proceed as follows:. (a) (b) Turn the engine switch to the ON position. Pull the starter grip lightly until resistance is felt, then pull briskly.
A (1) Single Voltage Type Check the pilot lamp for proper voltage. NOTE: The generator is thoroughly 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.
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.
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 stops the engine when the oil level falls down below the predetermined level. (13) When the engine has stopped automatically, check the oil level.
3-14 Idle Control (Models TPG4-4500HDX, TPG4-6000HDX, TPG47000HDX and TPG4-7000HDXE) 3-15 3-16 (1) The 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. How to use Idle Control (1) Start the engine with AUTO THROTTLE switch set to OFF.
3-17 Ground Fault Circuit Interrupter (GFCI) WARNING: USING THE GENERATOR IN RAIN, SNOW OR NEAR WATER CAN LEAD TO 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.
Inspection: (Models TPG4-4500HDX, TPG4-6000HDX, TPG4-7000HDX and 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 INTERRUPTER). TEST GFCI BEFORE USE. If the GFCI 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.
(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.
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) 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.
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. Thereafter, change oil every 100 hours. (3) Before changing the oil, check for a suitable way to dispose of the used oil.
Tsurumi’s Operation, Service, and Repair Manual 4-2 Changing Engine Oil (1) Drain the oil while the engine is still warm to assure rapid and complete draining. (2) Remove the oil filler dipstick/cap and drain plug. (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.
Tsurumi’s Operation, Service, and Repair Manual 4-4 Sediment Cup Cleaning WARNING GASOLINE IS EXTREMELY FLAMMABLE 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.
Tsurumi’s Operation, Service, and Repair Manual 4-5 Cleaning and Adjusting Spark Plug (1) Recommended spark plugs: BPR6ES(NGK) W20EPR-U (NIPPONDENSO) (2) To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. (3) Remove the spark plug cap. (4) Clean any dirt from around the spark plug base. (5) Use the proper size spark plug wrench to remove the spark plug.
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.
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 Coil Insulation (1)(2) AC Winding Red/White AC Winding Red/White Condenser Winding Yellow/Yellow Insulation (2)(3) Capacitance TPG4-3000HDX 1.70 > 1 MΩ 0.58 0.58 1.56 > 1 MΩ 14µF TPG4-4500HDX 1.75 > 1 MΩ 0.
Tsurumi’s Operation, Service and Repair Manual Table 5-2: Fault Isolation Procedures FAULT No AC output. PROBABLE CAUSE Condenser failed. REMEDY 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 other to discharge the condenser.
Tsurumi’s Operation, Service and Repair Manual FAULT No AC output. PROBABLE CAUSE REMEDY 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, measure field coil resistance.
Tsurumi’s Operation, Service and Repair Manual FAULT AC voltage is normal at no-load, but load cannot be applied (continued). PROBABLE CAUSE Engine speed too low (continued). REMEDY 4. Check engine speed. 5. Operate the generator at no load. 6. 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).
Tsurumi’s Operation, Service and Repair Manual FAULT PROBABLE CAUSE Engine speed does not increase when load applied (continued) Wattage of connected appliance or electric tool exceeds rating. (continued). REMEDY TPG4-3000HDX TPG4-4500HDX TPG4-6000HDX TPG4-7000HDX TPG4-7000HDXE 3550 to 3650 RPM 3550 to 3650 RPM 3550 to 3650 RPM 3550 to 3650 RPM 3550 to 3650 RPM NOTE: The engine speeds are for a cold engine.
Tsurumi’s Operation, Service and Repair Manual Table 8: Idle Control Unit – Circuit Parameters Circuit Tester Power Source Apply Red (Positive) Probe of Circuit Tester Apply Black (Negative) Probe of the Circuit Tester 1 2 3 4 5 1 --- ∞ 250 kΩ 250 kΩ 250 kΩ 2 ∞ --- ∞ ∞ ∞ 3 250 kΩ ∞ --- 250 kΩ 75 kΩ 4 250 kΩ ∞ 250 kΩ --- 75 kΩ 5 8.5 kΩ ∞ 7.8 kΩ 7.
Tsurumi’s Operation, Service and Repair Manual 5-6 Wiring Diagrams TPG4-3000HDX Wiring Diagram – Model TPG4-3000HDX Troubleshooting 42
Tsurumi’s Operation, Service and Repair Manual TPG4-4500HDX Wiring Diagram – Model TPG4-4500HDX Troubleshooting 43
Tsurumi’s Operation, Service and Repair Manual TPG4-6000HDX,TPG4-7000HDX Wiring Diagram – Models TPG4-6000HDX and TPG4-7000HDX Troubleshooting 44
Tsurumi’s Operation, Service and Repair Manual TPG4-7000HDXE Wiring Diagram – Model TPG4-7000HDXE Troubleshooting 45
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 A. 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. B. 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.
Tsurumi’s Operation, Service, and Repair Manual Table 6-1B: Fastener Torque Values for kgf.cm Material Structure Steel Cast Iron Stainless Steel Bolt Size Nominal Max. Min. Nominal Max. Min. Nominal Max. Min.
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.
Tsurumi’s Operation, Service, and Repair Manual D. 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. F. 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.
Tsurumi’s Operation, Service, and Repair Manual Figure 6-2: Battery Enclosure Components 85 86 44 (Ref) 99 88 96 87 90 100 92 98 91 94 89 97 93 95 6-3 TPG4 FIG 6-2 Replacement of Muffler (Models TPG4-4500HDX, TPG4-6000HDX, TPG4-7000HDX, and TPG47000HDXE) 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.
Tsurumi’s Operation, Service, and Repair Manual H-9 H-13 H-11 H-3 H-12 H-2 H-8 H-10 9 H-14 (2x) H-1 H-7 3 36 H-6 44 TPG4 FIG 6-3 Figure 6-3: Replacement of Muffler (Models TPG4-4500HDX, TPG4-6000HDX, TPG4-7000HDX, and TPG4-7000HDXE) Removal/Installation 52
Tsurumi’s Operation, Service, and Repair Manual 6-4 A. 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. 1. Disconnect muffler (H-10) from engine exhaust connection. 2. Remove screw (H-13). Remove muffler (H-10) together with inner shield (H-6) from slot in bracket (44.1). . 3. Do not remove bracket (44.1) unless damaged. If damaged, remove screws (44.2) and bracket (44.1).
Tsurumi’s Operation, Service, and Repair Manual H-9 H-8 H-13 H-3 H-7 H-10 H-6 44.1 44.
Tsurumi’s Operation, Service, and Repair Manual 6-5 Replacement of Fuel Tank WARNING: DO NOT DRAIN FUEL WHILE SMOKING OR WHILE IN CLOSE PROXIMITY TO OPEN FLAME. ENGINE FUEL (GASOLINE) IS HIGHLY FLAMMABLE AND IF ACCIDENTALLY IGNITED CAN CAUSE SEVERE BURNS AND DEATH. WARNING: 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.
Tsurumi’s Operation, Service, and Repair Manual 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.
Tsurumi’s Operation, Service, and Repair Manual WARNING: DO NOT DRAIN FUEL WHILE SMOKING OR WHILE IN CLOSE PROXIMITY TO OPEN FLAME. ENGINE FUEL (GASOLINE) IS HIGHLY FLAMMABLE AND IF ACCIDENTALLY IGNITED CAN CAUSE SEVERE BURNS AND DEATH. WARNING: 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.
Tsurumi’s Operation, Service, and Repair Manual 6-7 A. Removal of Fuel Tank (Models TPG3-4500HDX, TPG3-6000HDX, TPG3-7000HDX, TPG3-7000HDXE) Drain fuel from fuel tank (refer to Draining of the Fuel Tank). 1. Remove four screws (32) and two screws (74). Carefully open panel (46) taking care not to damage wiring. 2. 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.
Tsurumi’s Operation, Service, and Repair Manual 6-9 A. Installation of Fuel Tank 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).
Tsurumi’s Operation, Service, and Repair Manual 6-11 A. 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.) 1. The generator leads are contained within tube (7) and are sealed by a rubber bushing (5).
Tsurumi’s Operation, Service, and Repair Manual 6-12 A. Installation of Generator/Engine Unit If you are replacing the stator (8), refer to Replacement of Generator Stator. 1. If you are replacing the rotor (12), refer to Replacement of Rotor. 2. If you are replacing the rotor bearing (13), refer to Replacement of Rotor Bearing. 3. If you are replacing the engine (H-1), refer to Replacement of Engine. 4. Tighten fasteners to the torque values shown in Table 6-1. 5.
Tsurumi’s Operation, Service, and Repair Manual H-9 H-5 H-2 H-4 H-8 H-13 H-3 36 REF H-7 14 H-10 H-1 15 (4x) H-6 13 36 10 (4x) 9 16 17 12 7 11 3 5 4 (3x) 23 (4x) 21 31 24 (4x) 20 8.1 22 25 (4x) 8 6 26 (4x) 1 18 2 (2x) 29 86 82 19 27 82 83 84 30 85 44 81 81 28 44.1 80 44.2 39 36 (2x) 40 36 (2x) 41 37 (2x) 35 (2x) 37 (2x) 34 (2x) 42 38 (2x) 38 (2x) (See Fig.
Tsurumi’s Operation, Service, and Repair Manual 15. Insert engine wiring through small hole in back of control box (45). Connect wiring as required. (Refer to the wiring diagrams in Troubleshooting.) 16. 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).
Tsurumi’s Operation, Service, and Repair Manual 14 15 (4x) 13 10 (4x) 9 16 17 12 7 11 3 5 4 (3x) 8.1 8 6 1 2 (2x) 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.
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 numbers 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.
Tsurumi’s Operation, Service, and Repair Manual Puller Threaded Rod Bearing TPG4 TPG3FIG FIG6-9 6-9 Fi1gure 6-9: Bearing Puller in Use Through Bolt TPG4 TPG3 FIG FIG 6-10 6-10 Figure 6-10: Removal of Through Bolt NOTE: In the 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.
Tsurumi’s Operation, Service, and Repair Manual Oil Container Rotor TPG4 FIGFIG 6-116-11 TPG3 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 TPG3FIG FIG6-12 6-12 Figure 6-12: Wrapping Bolt with Tape NOTE: Have shop towels available to wipe up spilled oil. 15.
Tsurumi’s Operation, Service, and Repair Manual Taped Bolt TPG4 6-13 TPG3 FIG 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.
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. Put a box-end wrench on the hex of the through bolt (11). 3.
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).
Tsurumi’s Operation, Service, and Repair Manual 76 58 45 60 (2X) 59 75 61 (2X) 61 61 57 46 49 56 66 77 64 51 61 (2X) 54 61 48 52 65 53 55 51 62 79 47 63 78 80 62 61 81 74 68 62 67 50 69 71 73 70 72 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) and control box (45) (refer to Removal/Installation of Front Panel and Control Box).
Tsurumi’s Operation, Service, and Repair Manual (4) Install front panel (46) and control box (45) (refer to Removal/Installation of Front Panel and Control Box). 4. Pilot Lamp (ALL MODELS) (1) Refer to Figure 6-14. Remove front panel (45) and control box (45) (refer to Removal/Installation of Front Panel and Control Box). (2) Disconnect wire from pilot light (53). Squeeze inward on tab to release the pilot light (53) from the panel (45). (3) Install replacement pilot light (53) from front of panel.
Tsurumi’s Operation, Service, and Repair Manual 58 45 74 46 66 59 75 53 48 74 (2x) 61 (2x) 52 69 62 73 72 71 68 67 70 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.
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).
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).
Tsurumi’s Operation, Service and Repair Manual STORAGE INSTRUCTIONS General 7-0 7-1 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.
Tsurumi’s Operation, Service and Repair Manual THIS PAGE INTENTIONALLY LEFT BLANK Storage Instructions 68
Tsurumi’s Operation, Service and Repair Manual 8-0 REPLACEMENT PARTS 8-1 Introduction (1) 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. (2) The item numbers shown on the illustrations correspond with the item numbers in the facing parts listing.
Tsurumi’s Operation, Service and Repair Manual Figure 8-1: Generator (Exploded View) - Model TPG3-3000HDX H-9 H-5 H-2 H-4 H-8 H-13 H-3 36 REF H-7 14 H-10 H-1 15 (4x) H-6 13 36 10 (4x) 9 16 17 12 7 11 3 5 4 (3x) 23 (4x) 21 31 24 (4x) 20 8 8.1 22 25 (4x) 6 26 (4x) 1 18 2 (2x) 29 86 82 19 27 82 83 84 30 85 44 81 81 28 44.1 80 44.2 39 36 (2x) 40 36 (2x) 41 37 (2x) 35 (2x) 37 (2x) 35 (2x) 34 (2x) 42 38 (2x) 38 (2x) See Fig. 8-2 45 (See Fig.
Tsurumi’s Operation, Service and Repair Manual Figure 8-1: Generator (Parts List) - Model TPG4-3000HDX Ref. No. Part Number Description 1 15111471000 Cover, Bracket 1 2 15550210000 Bolt, Hex (with Flange) (M5 x 0.8-12) 3 15311461000 4 15550158000 5 6 Ref. No.
Tsurumi’s Operation, Service and Repair Manual Figure 8-2: Control Box (Exploded View) – Model TPG4-3000HDX 58 45 74 46 66 59 75 53 48 74 (2x) 61 (2x) 52 69 62 73 72 71 68 67 70 TPG4-3000 PANEL TPG3-3000 PANEL 73 Replacement Parts
Tsurumi’s Operation, Service and Repair Manual Figure 8-2 - Control Box (Parts List) - Model TPG4-3000HDX Ref. No. Part Number Description Box, Control Panel, Control Receptacle (20A, 125V) Circuit Breaker (20A) Bracket, Neon Condenser Assembly (4 µF) Switch, Engine Ref. No.
Tsurumi’s Operation, Service and Repair Manual Figure 8-3: Generator (Exploded View) - Model TPG3-4500HDX H-9 H-13 H-11 H-5 H-3 H-4 H-12 36 Ref H-2 H-8 H-10 H-1 14 H-7 H-14 (2x) 15 (4x) 36 13 H-6 10 (4x) 9 16 17 17 12 7 11 3 5 4 (2x) 23 (4x) 21 31 24 (4x) 8.1 8 6 20 22 25 (4x) 1 2 (2x) 26 (4x) 18 29 19 27 30 28 34 (2x) 45 (See SeeFig. Fig.
Tsurumi’s Operation, Service and Repair Manual Figure 8-3 – Generator (Parts List)– Model TPG3-4500HDX Ref. No. Part Number Description 1 15311471000 Cover, Bracket 1 2 15550210000 Bolt, Hex (with Flange) (M5 x 0.8-12) 2 Ref. No. Qty 3 15311461000 Bracket 1 4 15550152000 Bolt, Hex (with Flange) (M6 x 1.0-1500 4 5 15350550000 Bushing, Rubber 1 6 19S00905007 Screw, Cross Head, Recessed (M5-7) 1 7 15350107000 Tube, Lead Wire 1 8 15250380000 Stator Assembly 1 8 .
Tsurumi’s Operation, Service and Repair Manual Figure 8-4 - Control Box (Exploded View) - Model TPG4-4500HDX 58 79(x 2) 76 45 21 78 57 66 61 49 46 59 62(x 2) 56 61(x 2) 52 75 61(x 2) 54 64 67 50 68 53 20 55 73 51 62 (x 2) 63 65 74(x 2) 48 61 (x 2) 62 69 71 70 72 47 51 60 77(x 2) 62 (x 2) 61 (x 2) 62 (x 2) TPG4-4500HDX PANEL 79 Replacement Parts
Tsurumi’s Operation, Service and Repair Manual Figure 8-4 - Control Box (Parts List) - Model TPG4-4500HDX Ref. No. Part Number Description Qty Ref. No.
Tsurumi’s Operation, Service and Repair Manual Figure 8-5: Generator (Exploded View) - Model TPG4-6000HDX H-9 H-13 H-11 H-5 H-3 H-4 H-12 36 Ref H-2 H-8 H-10 H-1 14 H-7 H-14 (2x) 15 (4x) 36 13 9 H-6 10 (4x) 16 17 17 12 7 11 3 5 4 (2x) 23 (4x) 21 8.1 31 24 (4x) 8 6 20 22 25 (4x) 1 2 (2x) 26 (4x) 18 29 19 27 30 28 34 (2x) 45 (See SeeFig. Fig.
Tsurumi’s Operation, Service and Repair Manual Figure 8-5 – Generator (Parts List)– Model TPG4-6000HDX Ref. No. Part Number Description 1 15311471000 Cover, Bracket 1 2 15550210000 Bolt, Hex (with Flange) (M5 x 0.8-12) 2 Ref. No. Qty 3 15311461000 Bracket 1 4 15550152000 Bolt, Hex (with Flange) (M6 x 1.0-1500 4 5 15350550000 Bushing, Rubber 1 6 19S00905007 Screw, Cross Head, Recessed (M5-7) 1 7 15350107000 Tube, Lead Wire 1 8 15250382000 Stator Assembly 1 8 .
Tsurumi’s Operation, Service and Repair Manual Figure 8-6 - Control Box (Exploded View) – Model TPG4-6000HDX 58 79(x 2) 76 45 21 78 57 66 61 49 46 59 62(x 2) 51 56 61(x 2) 52 75 61(x 2) 54 64 67 50 68 65 74(x 2) 53 20 55 73 48 62 (x 2) 63 61 (x 2) 62 69 71 47 60 70 72 77(x 2) 62 (x 2) 51 62 (x 2) 61 (x 2) TPG4-6000HDX PANEL 74 Replacement Parts
Tsurumi’s Operation, Service and Repair Manual Figure 8-6- Control Box (Parts List) - Model TPG4-6000HDX Ref. No. Part Number Description Qty Ref. No.
Tsurumi’s Operation, Service and Repair Manual Figure 8-7: Generator (Exploded View) - Model TPG4-7000HDX H-9 H-13 H-5 H-11 H-3 H-4 H-12 36 Ref H-2 H-8 H-10 H-1 14 H-7 H-14 (2x) 15 (4x) 36 13 9 10 (4x) H-6 16 17 17 12 7 11 3 5 4 (2x) 23 (4x) 21 8.1 31 24 (4x) 8 6 20 22 25 (4x) 1 2 (2x) 26 (4x) 18 29 19 27 30 28 34 (2x) See Fig. 8-8 45 (See Fig.
Tsurumi’s Operation, Service and Repair Manual Figure 8-7 – Generator (Parts List)– Model TPG4-7000HDX Ref. No. Part Number Description Ref. No. Qty Part Number Description Qty 1 15311471000 Cover, Bracket 1 34 19SS6906016 Bolt (M6-16) 4 2 15550210000 Bolt, Hex (with Flange) (M5 x 0.8-12) 2 35 200900520 Rubber, Anti-Vibration 4 36 203200020 15311461000 Bracket 1 Nut, Hex (With Flange) (M10 x 1.25) 4 3 4 15550152000 Bolt, Hex (with Flange) (M6 x 1.
Tsurumi’s Operation, Service and Repair Manual Figure 8-8 - Control Box (Exploded) – Model TPG4-7000HDX 58 79(x 2) 76 45 21 78 57 66 61 49 46 59 62(x 2) 51 56 61(x 2) 52 75 61(x 2) 54 64 67 50 68 65 74(x 2) 53 20 55 73 48 62 (x 2) 63 61 (x 2) 62 69 71 47 60 70 72 77(x 2) 62 (x 2) 51 62 (x 2) 61 (x 2) TPG4-7000HDX PANEL 78 Replacement Parts
Tsurumi’s Operation, Service and Repair Manual Figure 8-8- Control Box (Parts List) - Model TPG4-7000HDX Ref. No. Part Number Description Qty Ref. No.
Tsurumi’s Operation, Service and Repair Manual Figure 8-9: Generator (Exploded View) - Model TPG4-7000HDXE H-9 H-13 H-11 H-5 H-3 H-4 H-12 36 Ref H-2 H-8 H-10 H-1 14 H-7 H-14 (2x) 15 (4x) 36 13 9 H-6 10 (4x) 16 17 17 12 7 11 3 5 4 (2x) 23 (4x) 21 8.1 31 24 (4x) 8 6 20 22 25 (4x) 1 2 (2x) 26 (4x) 18 29 19 27 30 28 34 (2x) See Fig. 45 (See Fig.
Tsurumi’s Operation, Service and Repair Manual Figure 8-9 – Generator (Parts List)– Model TPG4-7000HDXE Ref. No. Part Number Description Ref. No. Qty Part Number Description Qty 1 15311471000 Cover, Bracket 1 34 19SS6906016 Bolt (M6-16) 4 2 15550210000 Bolt, Hex (with Flange) (M5 x 0.8-12) 2 35 200900520 Rubber, Anti-Vibration 4 36 203200020 15311461000 Bracket 1 Nut, Hex (With Flange) (M10 x 1.25) 4 3 4 15550152000 Bolt, Hex (with Flange) (M6 x 1.
Tsurumi’s Operation, Service and Repair Manual Figure 8-10–Control Box (Exploded View)-Model TPG4-7000HDXE 79(x 2) 78 76 62 45 58 51 59 61 52 66 80 57 61 49 56 75 61 64 54 81 82 46 61 83 67 50 84 68 65 48 20 53 55 61 51 32 62 20 74 73 47 69 71 60 72 70 35 77 62 61 36 62 TPG4-7000HDXE PANEL 95
Tsurumi’s Operation, Service and Repair Manual Figure 8-10- Control Box (Parts List) - Model TPG4-7000HDXE Ref. No. Part Number Description Qty Ref. No.
Tsurumi’s Operation, Service and Repair Manual Figure 8-11 - Battery Enclosure (Exploded View/Parts List) Model TPG4-7000HDXE 85 86 44 (Ref) 99 88 96 87 90 100 92 98 91 94 89 97 93 95 Ref. No.
Tsurumi’s Operation, Service and Repair Manual THIS PAGE INTENTIONALLY LEFT BLANK j 100
