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Honda Power Equipment TPG-7000H-DXE Control Box, Tsurumi’s Operation, Service, and Repair Manual

Models: TPG-4300H-DX TPG-6000H-DX TPG-7000H-DXE TPG-2900H-DX

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Tsurumi’s Operation, Service, and Repair Manual

ENGINE

CONTROL BOX

		GREEN/W
F/C
SOL			GREEN					BLUE
							GREEN/WHITE
							WHITE/BLACK
								WHITE	K SW
	OS-UN							GREEN
	OS-UN							BLACK
	IG
+	-					F	CB	DI
BAT	ST							DI
BAT	ST
	MT	M SW
		M SW
			BLACK
CH-CO					SW	IDLE
	LC				SW	IDLE
			WHITE	1	3	CONTROL
						UNIT
			WHITE
		I/D SOL
ENGINE			NFB 1
		BLACK	NFB 1
		BLACK
					H	SW	1
					H		3
	D	MC1				2	3		G
	D	MC1				2			G
		BLUE			G		4
		BLUE			G			Y	X
	FC					5		Y	X
	FC					5	6		H
		RED					6
		RED					7
							7
		MC2	L1		H	8	9
		MC2	L1				9
	SC	WHITE
	SC				G	NFB
		WHITE			G	NFB
		WHITE				2
						2
		Yellow
		Yellow		C					ET
		Yellow		C

Wiring Diagram - Model TPG-7000H-DXE

Troubleshooting

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Honda Power Equipment TPG-7000H-DXE, TPG-2900H-DX manual Control Box, Tsurumi’s Operation, Service, and Repair Manual

Contents

REPAIR MANUAL OPERATION, SERVICE, ANDFOR TSURUMI TPG-SERIES PORTABLE GENERATORSTsurumi Manufacturing Co., Ltd LIMITED WARRANTYTABLE OF CONTENTS 1. INTRODUCTION Tsurumi’s Operation, Service, and Repair ManualTsurumi’s Operation, Service, and Repair Manual A. PRECAUTIONS AND PLACARDSDATA PLATE AIR CLEANER MAINTENANCEFUEL WARNING PLACARD HOT MUFFLER & EXHAUST PLACARDTsurumi’s Operation, Service, and Repair Manual B. SAFETY PRECAUTIONS•100% Copper Windings…for long life C. SPECIFICATIONS/KEY FEATURESTsurumi’s Operation, Service, and Repair Manual Tsurumi’s Operation, Service, and Repair Manual 2. DESCRIPTION AND OPERATIONA.PHYSICAL DESCRIPTION 2Description of Generator Tsurumi’s Operation, Service, and Repair Manual3Description of the Engine Tsurumi’s Operation, Service, and Repair Manual4Description of the Fuel Tank 5Description of the Front PanelTsurumi’s Operation, Service, and Repair Manual B.FUNCTIONAL DESCRIPTION1Generation of No-LoadVoltage refer to Figure 2Voltage Fluctuations Under Load refer to FigureFigure 4: Full Power Switch Circuit Diagram Tsurumi’s Operation, Service, and Repair ManualSwitch Tsurumi’s Operation, Service, and Repair ManualA.OPERATING CONTROLS 3. OPERATING INSTRUCTIONSB.DC CIRCUIT CONTROLS Tsurumi’s Operation, Service, and Repair ManualFigure 7: Model TPG-2900H-DX Tsurumi’s Operation, Service, and Repair ManualLEGEND Figure 8: Model TPG-4300H-DXLEGEND Tsurumi’s Operation, Service, and Repair ManualFigure 9: Model TPG-6000H-DX LEGENDTsurumi’s Operation, Service, and Repair Manual C. CHECK THE ENGINE OIL LEVELTsurumi’s Operation, Service, and Repair Manual D. CHECK ENGINE FUELTsurumi’s Operation, Service, and Repair Manual E. PRE-STARTCHECKSF.STARTING & OPERATING THE ENGINE Tsurumi’s Operation, Service, and Repair Manual G. USING THE GENERATORH.AC APPLICATION BDual Voltage Type Tsurumi’s Operation, Service, and Repair ManualTsurumi’s Operation, Service, and Repair Manual I.STOPPING THE GENERATORAvailable Receptacles With Full Power Switch On TableL.STOPPING THE ENGINE J.OIL ALERTM. WATTAGE INFORMATION Tsurumi’s Operation, Service, and Repair ManualTable Wattage Chart Tsurumi’s Operation, Service, and Repair ManualApplicable Wattage w Applicable Wattage WTsurumi’s Operation, Service, and Repair Manual 4. MAINTENANCEA.CHANGING ENGINE OIL B. AIR CLEANER SERVICETsurumi’s Operation, Service, and Repair Manual Figure 16: Draining Engine OilTsurumi’s Operation, Service, and Repair Manual C. SEDIMENT CUP CLEANINGD. CLEANING AND ADJUSTING SPARK PLUG Figure 19: Spark Plug Gap Tsurumi’s Operation, Service, and Repair ManualTsurumi’s Operation, Service, and Repair Manual 5. TROUBLESHOOTINGTsurumi’s Operation, Service, and Repair Manual C. ELECTRICAL LIMITS REFERENCE CHARTTsurumi’s Operation, Service, and Repair Manual D. TROUBLESHOOTING CHARTSTable 7: Fault Isolation Procedures FAULTFAULT Tsurumi’s Operation, Service, and Repair Manualrefer to COMPONENT REPLACEMENT for PROBABLE CAUSEPage Tsurumi’s Operation, Service, and Repair ManualTroubleshooting No DC output Tsurumi’s Operation, Service, and Repair ManualEngine speed does Tsurumi’s Operation, Service, and Repair ManualPage Tsurumi’s Operation, Service, and Repair ManualTroubleshooting CONTROL BOX E. WIRING DIAGRAMSTsurumi’s Operation, Service, and Repair Manual CONTROL BOX CONTROL BOX Wiring Diagram - Model TPG-6000H-DXCONTROL BOX Tsurumi’s Operation, Service, and Repair ManualTsurumi’s Operation, Service, and Repair Manual 6. REMOVAL/INSTALLATIONTsurumi’s Operation, Service, and Repair Manual A. REPLACEMENT OF BATTERYTsurumi’s Operation, Service, and Repair Manual B. REMOVAL/INSTALLATION OF BATTERY ENCLOSUREFigure 22: Battery Enclosure Exploded View C.REPLACEMENT OF ENGINE MUFFLERTsurumi’s Operation, Service, and Repair Manual Figure 23: Replacement of Muffler Tsurumi’s Operation, Service, and Repair ManualModel TPG-2900H-DX Tsurumi’s Operation, Service, and Repair ManualFigure 24: Replacement of Muffler Tsurumi’s Operation, Service, and Repair Manual E. REPLACEMENT OF FUEL TANKH-13 H-2 Tsurumi’s Operation, Service, and Repair ManualFigure 26: Draining Fuel from Fuel Tank Tsurumi’s Operation, Service, and Repair Manual9Remove 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 ManualH-9 H-10 H-5 Tsurumi’s Operation, Service, and Repair ManualFigure 28: Replacement of Stator G. REPLACEMENT OF GENERATOR STATORTsurumi’s Operation, Service, and Repair Manual Tsurumi’s Operation, Service, and Repair Manual H. REPLACEMENT OF ROTOR BEARINGFigure 29: Bearing Puller in Use I.REPLACEMENT OF ROTORTsurumi’s Operation, Service, and Repair Manual Figure 31: Pouring Oil in Rotor Shaft Tsurumi’s Operation, Service, and Repair ManualFigure 30: Removal of Through Bolt Removal/Installation Tsurumi’s Operation, Service, and Repair ManualFigure 32: Wrapping Bolt with Tape Wind tape on boltFigure 34: Front Cover Bolts Tsurumi’s Operation, Service, and Repair ManualReplacement of Rotor Bearing Tsurumi’s Operation, Service, and Repair Manual J.REPLACEMENT OF FRONT PANEL COMPONENTSFigure 35: Front Panel and Control Box Components Tsurumi’s Operation, Service, and Repair Manual5Engine Start Key Switch TPG-7000H-DXE Tsurumi’s Operation, Service, and Repair ManualFigure 36: Front Panel and Control Box Components Tsurumi’s Operation, Service, and Repair Manual11Full-powerSwitch Tsurumi’s Operation, Service, and Repair ManualTsurumi’s Operation, Service, and Repair Manual 7. STORAGE INSTRUCTIONSA. INTRODUCTION 8. REPLACEMENT PARTSB. ORDERING PARTS Tsurumi’s Operation, Service, and Repair ManualExploded View - Generator - Model TPG-2900H-DX Tsurumi’s Operation, Service, and Repair ManualParts List – Generator – Model TPG-2900H-DX Tsurumi’s Operation, Service, and Repair ManualPart NumberExploded View - Front Panel - Model TPG-2900H-DX Tsurumi’s Operation, Service, and Repair ManualParts List – Front Panel – Model TPG-2900H-DX Tsurumi’s Operation, Service, and Repair ManualPart NumberExploded View - Generator - Model TPG-4300H-DX Tsurumi’s Operation, Service, and Repair ManualParts List – Generator – Model TPG-4300H-DX Tsurumi’s Operation, Service, and Repair ManualPart NumberExploded View - Front Panel - Model TPG-4300H-DX Tsurumi’s Operation, Service, and Repair ManualParts List – Front Panel – Model TPG-4300H-DX Tsurumi’s Operation, Service, and Repair ManualPart NumberExploded View - Generator - Model TPG-6000H-DX Tsurumi’s Operation, Service, and Repair ManualParts List – Generator – Model TPG-6000H-DX Tsurumi’s Operation, Service, and Repair ManualPart NumberExploded View - Front Panel - Model TPG-6000H-DX Tsurumi’s Operation, Service, and Repair ManualParts List – Front Panel – Model TPG-6000H-DX Tsurumi’s Operation, Service, and Repair ManualPart NumberExploded View - Generator - Model TPG-7000H-DXE Tsurumi’s Operation, Service, and Repair ManualParts List – Generator – Model TPG-7000H-DXE Tsurumi’s Operation, Service, and Repair ManualPart NumberExploded View - Front Panel - Model TPG-7000H-DXE Tsurumi’s Operation, Service, and Repair ManualParts List – Front Panel – Model TPG-7000H-DXE Tsurumi’s Operation, Service, and Repair ManualPart NumberNumber PartDescription ASSEMBLY AND INSTALLATION INSTRUCTIONS FOR APPENDIX A BATTERY ENCLOSURE KITTSURUMI MODEL TPG-7000H-DXE PORTABLE GENERATOR Tsurumi’s Operation, Service, and Repair ManualFOR TSURUMI PORTABLE GENERATOR BATTERY ENCLOSURE ASSEMBLY AND INSTALLATION INSTRUCTIONSTsurumi’s Operation, Service, and Repair Manual CHECK KIT CONTENTSINSTALLATION OF BATTERY Tsurumi’s Operation, Service, and Repair ManualINSTALLATION OF BATTERY ENCLOSURE APPENDIX B PGWK-100WHEEL KIT INSTALLATION INSTRUCTIONSTsurumi’s Operation, Service, and Repair Manual Appendix BTsurumi’s Operation, Service, and Repair Manual WHEEL KIT INSTALLATION INSTRUCTIONSFOR TSURUMI GENERATORS AND PUMPS INSTALL AXLE ON GENERATOR Tsurumi’s Operation, Service, and Repair ManualINSTALL AXLE ON TRASH PUMP INSTALL WHEELSINSTALLATION INSTRUCTIONS APPENDIX C PGWK-200WHEEL KITTsurumi’s Operation, Service, and Repair Manual Page C-1Completed Chart Before InstallationInstallation Instructions Tsurumi’s Operation, Service, and Repair ManualStep 2 - Install Handles Step 1 - Install Axle Assembly and WheelsTsurumi’s Operation, Service, and Repair Manual Fig.