PORTABLE GENERATORS
OPERATION, SERVICE, AND
REPAIR MANUAL
FOR TSURUMI TPG-SERIES
Tsurumi Manufacturing Co., Ltd
LIMITED WARRANTY
TABLE OF CONTENTS
1. INTRODUCTION
Tsurumi’s Operation, Service, and Repair Manual
Tsurumi’s Operation, Service, and Repair Manual
A. PRECAUTIONS AND PLACARDS
HOT MUFFLER & EXHAUST PLACARD
AIR CLEANER MAINTENANCE
DATA PLATE
FUEL WARNING PLACARD
Tsurumi’s Operation, Service, and Repair Manual
B. SAFETY PRECAUTIONS
C. SPECIFICATIONS/KEY FEATURES
Tsurumi’s Operation, Service, and Repair Manual
•100% Copper Windings…for long life
2. DESCRIPTION AND OPERATION
A.PHYSICAL DESCRIPTION
Tsurumi’s Operation, Service, and Repair Manual
2Description of Generator
Tsurumi’s Operation, Service, and Repair Manual
5Description of the Front Panel
Tsurumi’s Operation, Service, and Repair Manual
3Description of the Engine
4Description of the Fuel Tank
2Voltage Fluctuations Under Load refer to Figure
B.FUNCTIONAL DESCRIPTION
Tsurumi’s Operation, Service, and Repair Manual
1Generation of No-LoadVoltage refer to Figure
Figure 4: Full Power Switch Circuit Diagram
Tsurumi’s Operation, Service, and Repair Manual
Switch
Tsurumi’s Operation, Service, and Repair Manual
Tsurumi’s Operation, Service, and Repair Manual
3. OPERATING INSTRUCTIONS
A.OPERATING CONTROLS
B.DC CIRCUIT CONTROLS
Figure 8: Model TPG-4300H-DX
Tsurumi’s Operation, Service, and Repair Manual
Figure 7: Model TPG-2900H-DX
LEGEND
LEGEND
Tsurumi’s Operation, Service, and Repair Manual
LEGEND
Figure 9: Model TPG-6000H-DX
Tsurumi’s Operation, Service, and Repair Manual
C. CHECK THE ENGINE OIL LEVEL
Tsurumi’s Operation, Service, and Repair Manual
D. CHECK ENGINE FUEL
E. PRE-STARTCHECKS
F.STARTING & OPERATING THE ENGINE
Tsurumi’s Operation, Service, and Repair Manual
G. USING THE GENERATOR
H.AC APPLICATION
Tsurumi’s Operation, Service, and Repair Manual
BDual Voltage Type
Tsurumi’s Operation, Service, and Repair Manual
Table
I.STOPPING THE GENERATOR
Tsurumi’s Operation, Service, and Repair Manual
Available Receptacles With Full Power Switch On
Tsurumi’s Operation, Service, and Repair Manual
J.OIL ALERT
L.STOPPING THE ENGINE
M. WATTAGE INFORMATION
Applicable Wattage W
Tsurumi’s Operation, Service, and Repair Manual
Table Wattage Chart
Applicable Wattage w
Tsurumi’s Operation, Service, and Repair Manual
4. MAINTENANCE
Figure 16: Draining Engine Oil
B. AIR CLEANER SERVICE
A.CHANGING ENGINE OIL
Tsurumi’s Operation, Service, and Repair Manual
C. SEDIMENT CUP CLEANING
D. CLEANING AND ADJUSTING SPARK PLUG
Tsurumi’s Operation, Service, and Repair Manual
Figure 19: Spark Plug Gap
Tsurumi’s Operation, Service, and Repair Manual
Tsurumi’s Operation, Service, and Repair Manual
5. TROUBLESHOOTING
Tsurumi’s Operation, Service, and Repair Manual
C. ELECTRICAL LIMITS REFERENCE CHART
FAULT
D. TROUBLESHOOTING CHARTS
Tsurumi’s Operation, Service, and Repair Manual
Table 7: Fault Isolation Procedures
PROBABLE CAUSE
Tsurumi’s Operation, Service, and Repair Manual
FAULT
refer to COMPONENT REPLACEMENT for
Tsurumi’s Operation, Service, and Repair Manual
Troubleshooting
Page
No DC output
Tsurumi’s Operation, Service, and Repair Manual
Engine speed does
Tsurumi’s Operation, Service, and Repair Manual
Tsurumi’s Operation, Service, and Repair Manual
Troubleshooting
Page
E. WIRING DIAGRAMS
Tsurumi’s Operation, Service, and Repair Manual
CONTROL BOX
CONTROL BOX
CONTROL BOX
Wiring Diagram - Model TPG-6000H-DX
CONTROL BOX
Tsurumi’s Operation, Service, and Repair Manual
Tsurumi’s Operation, Service, and Repair Manual
6. REMOVAL/INSTALLATION
Tsurumi’s Operation, Service, and Repair Manual
A. REPLACEMENT OF BATTERY
Tsurumi’s Operation, Service, and Repair Manual
B. REMOVAL/INSTALLATION OF BATTERY ENCLOSURE
C.REPLACEMENT OF ENGINE MUFFLER
Tsurumi’s Operation, Service, and Repair Manual
Figure 22: Battery Enclosure Exploded View
Figure 23: Replacement of Muffler
Tsurumi’s Operation, Service, and Repair Manual
Tsurumi’s Operation, Service, and Repair Manual
Figure 24: Replacement of Muffler
Model TPG-2900H-DX
Tsurumi’s Operation, Service, and Repair Manual
E. REPLACEMENT OF FUEL TANK
H-13 H-2
Tsurumi’s Operation, Service, and Repair Manual
Figure 26: Draining Fuel from Fuel Tank
Tsurumi’s Operation, Service, and Repair Manual
9Remove four frame bolts 31 from front panel
Tsurumi’s Operation, Service, and Repair Manual
•Model TPG-2900H-DXuses four vibration mounts of two different part numbers. Two vibration
Tsurumi’s Operation, Service, and Repair Manual
H-9 H-10 H-5
Tsurumi’s Operation, Service, and Repair Manual
G. REPLACEMENT OF GENERATOR STATOR
Tsurumi’s Operation, Service, and Repair Manual
Figure 28: Replacement of Stator
Tsurumi’s Operation, Service, and Repair Manual
H. REPLACEMENT OF ROTOR BEARING
I.REPLACEMENT OF ROTOR
Tsurumi’s Operation, Service, and Repair Manual
Figure 29: Bearing Puller in Use
Tsurumi’s Operation, Service, and Repair Manual
Figure 30: Removal of Through Bolt
Figure 31: Pouring Oil in Rotor Shaft
Wind tape on bolt
Tsurumi’s Operation, Service, and Repair Manual
Removal/Installation
Figure 32: Wrapping Bolt with Tape
Tsurumi’s Operation, Service, and Repair Manual
Replacement of Rotor Bearing
Figure 34: Front Cover Bolts
Tsurumi’s Operation, Service, and Repair Manual
J.REPLACEMENT OF FRONT PANEL COMPONENTS
Figure 35: Front Panel and Control Box Components
Tsurumi’s Operation, Service, and Repair Manual
5Engine Start Key Switch TPG-7000H-DXE
Tsurumi’s Operation, Service, and Repair Manual
Figure 36: Front Panel and Control Box Components
Tsurumi’s Operation, Service, and Repair Manual
11Full-powerSwitch
Tsurumi’s Operation, Service, and Repair Manual
Tsurumi’s Operation, Service, and Repair Manual
7. STORAGE INSTRUCTIONS
Tsurumi’s Operation, Service, and Repair Manual
8. REPLACEMENT PARTS
A. INTRODUCTION
B. ORDERING PARTS
Exploded View - Generator - Model TPG-2900H-DX
Tsurumi’s Operation, Service, and Repair Manual
Number
Tsurumi’s Operation, Service, and Repair Manual
Parts List – Generator – Model TPG-2900H-DX
Part
Exploded View - Front Panel - Model TPG-2900H-DX
Tsurumi’s Operation, Service, and Repair Manual
Number
Tsurumi’s Operation, Service, and Repair Manual
Parts List – Front Panel – Model TPG-2900H-DX
Part
Exploded View - Generator - Model TPG-4300H-DX
Tsurumi’s Operation, Service, and Repair Manual
Number
Tsurumi’s Operation, Service, and Repair Manual
Parts List – Generator – Model TPG-4300H-DX
Part
Exploded View - Front Panel - Model TPG-4300H-DX
Tsurumi’s Operation, Service, and Repair Manual
Number
Tsurumi’s Operation, Service, and Repair Manual
Parts List – Front Panel – Model TPG-4300H-DX
Part
Exploded View - Generator - Model TPG-6000H-DX
Tsurumi’s Operation, Service, and Repair Manual
Number
Tsurumi’s Operation, Service, and Repair Manual
Parts List – Generator – Model TPG-6000H-DX
Part
Exploded View - Front Panel - Model TPG-6000H-DX
Tsurumi’s Operation, Service, and Repair Manual
Number
Tsurumi’s Operation, Service, and Repair Manual
Parts List – Front Panel – Model TPG-6000H-DX
Part
Exploded View - Generator - Model TPG-7000H-DXE
Tsurumi’s Operation, Service, and Repair Manual
Number
Tsurumi’s Operation, Service, and Repair Manual
Parts List – Generator – Model TPG-7000H-DXE
Part
Exploded View - Front Panel - Model TPG-7000H-DXE
Tsurumi’s Operation, Service, and Repair Manual
Number
Tsurumi’s Operation, Service, and Repair Manual
Parts List – Front Panel – Model TPG-7000H-DXE
Part
Part
Description
Number
Tsurumi’s Operation, Service, and Repair Manual
APPENDIX A BATTERY ENCLOSURE KIT
ASSEMBLY AND INSTALLATION INSTRUCTIONS FOR
TSURUMI MODEL TPG-7000H-DXE PORTABLE GENERATOR
CHECK KIT CONTENTS
ASSEMBLY AND INSTALLATION INSTRUCTIONS
FOR TSURUMI PORTABLE GENERATOR BATTERY ENCLOSURE
Tsurumi’s Operation, Service, and Repair Manual
Tsurumi’s Operation, Service, and Repair Manual
INSTALLATION OF BATTERY ENCLOSURE
INSTALLATION OF BATTERY
Appendix B
INSTALLATION INSTRUCTIONS
APPENDIX B PGWK-100WHEEL KIT
Tsurumi’s Operation, Service, and Repair Manual
WHEEL KIT INSTALLATION INSTRUCTIONS
FOR TSURUMI GENERATORS AND PUMPS
Tsurumi’s Operation, Service, and Repair Manual
INSTALL WHEELS
Tsurumi’s Operation, Service, and Repair Manual
INSTALL AXLE ON GENERATOR
INSTALL AXLE ON TRASH PUMP
Page C-1
APPENDIX C PGWK-200WHEEL KIT
INSTALLATION INSTRUCTIONS
Tsurumi’s Operation, Service, and Repair Manual
Tsurumi’s Operation, Service, and Repair Manual
Before Installation
Completed Chart
Installation Instructions
Fig.
Step 1 - Install Axle Assembly and Wheels
Step 2 - Install Handles
Tsurumi’s Operation, Service, and Repair Manual