Manuals / Honda Power Equipment / Lawn and Garden / Portable Generator

Honda Power Equipment TPG-2900H-DX, TPG-7000H-DXE I.Replacement Of Rotor, Bearing Puller in Use

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

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Tsurumi’s Operation, Service, and Repair Manual

(4)Pre-heat an oven to 350° ± 25° Fahrenheit. Place the replacement bearing (3) in the oven for 30 minutes.

WARNING:

•TO AVOID BEING BURNED BY THE HEATED BEARING, WEAR THERMAL-INSULATED GLOVES.

(5)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.

(6)Let the bearing cool to room temperature.

(7)Check the bearing for free rotation.

(8)Install the rear cover (1). (Refer to Replacement of Stator for rotor installation instructions.)

Puller Threaded Rod

Bearing

Figure 29: Bearing Puller in Use

I.REPLACEMENT OF ROTOR

(1)The generator stator (6), (Figure 28) must be removed before the rotor (2) can be removed. Refer to Replacement of Stator for stator removal instructions.

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Removal/Installation

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Honda Power Equipment TPG-2900H-DX, TPG-7000H-DXE I.Replacement Of Rotor, Tsurumi’s Operation, Service, and Repair Manual

Contents

OPERATION, SERVICE, AND REPAIR MANUALFOR TSURUMI TPG-SERIES PORTABLE GENERATORSLIMITED WARRANTY Tsurumi Manufacturing Co., LtdTABLE OF CONTENTS Tsurumi’s Operation, Service, and Repair Manual 1. INTRODUCTIONA. PRECAUTIONS AND PLACARDS Tsurumi’s Operation, Service, and Repair ManualAIR CLEANER MAINTENANCE DATA PLATEFUEL WARNING PLACARD HOT MUFFLER & EXHAUST PLACARDB. SAFETY PRECAUTIONS Tsurumi’s Operation, Service, and Repair Manual•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 Tsurumi’s Operation, Service, and Repair Manual 2Description of GeneratorTsurumi’s Operation, Service, and Repair Manual 3Description of the Engine4Description of the Fuel Tank 5Description of the Front PanelB.FUNCTIONAL DESCRIPTION Tsurumi’s Operation, Service, and Repair Manual1Generation of No-LoadVoltage refer to Figure 2Voltage Fluctuations Under Load refer to FigureTsurumi’s Operation, Service, and Repair Manual Figure 4: Full Power Switch Circuit DiagramTsurumi’s Operation, Service, and Repair Manual Switch3. OPERATING INSTRUCTIONS A.OPERATING CONTROLSB.DC CIRCUIT CONTROLS Tsurumi’s Operation, Service, and Repair ManualTsurumi’s Operation, Service, and Repair Manual Figure 7: Model TPG-2900H-DXLEGEND Figure 8: Model TPG-4300H-DXTsurumi’s Operation, Service, and Repair Manual LEGENDFigure 9: Model TPG-6000H-DX LEGENDC. CHECK THE ENGINE OIL LEVEL Tsurumi’s Operation, Service, and Repair ManualD. CHECK ENGINE FUEL Tsurumi’s Operation, Service, and Repair ManualTsurumi’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 Tsurumi’s Operation, Service, and Repair Manual BDual Voltage TypeI.STOPPING THE GENERATOR Tsurumi’s Operation, Service, and Repair ManualAvailable Receptacles With Full Power Switch On TableJ.OIL ALERT L.STOPPING THE ENGINEM. WATTAGE INFORMATION Tsurumi’s Operation, Service, and Repair ManualTsurumi’s Operation, Service, and Repair Manual Table Wattage ChartApplicable Wattage w Applicable Wattage W4. MAINTENANCE Tsurumi’s Operation, Service, and Repair ManualB. AIR CLEANER SERVICE A.CHANGING ENGINE OILTsurumi’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 Tsurumi’s Operation, Service, and Repair Manual Figure 19: Spark Plug Gap5. TROUBLESHOOTING Tsurumi’s Operation, Service, and Repair ManualC. ELECTRICAL LIMITS REFERENCE CHART Tsurumi’s Operation, Service, and Repair ManualD. TROUBLESHOOTING CHARTS Tsurumi’s Operation, Service, and Repair ManualTable 7: Fault Isolation Procedures FAULTTsurumi’s Operation, Service, and Repair Manual FAULTrefer to COMPONENT REPLACEMENT for PROBABLE CAUSEPage Tsurumi’s Operation, Service, and Repair ManualTroubleshooting Tsurumi’s Operation, Service, and Repair Manual No DC outputTsurumi’s Operation, Service, and Repair Manual Engine speed doesPage Tsurumi’s Operation, Service, and Repair ManualTroubleshooting CONTROL BOX E. WIRING DIAGRAMSTsurumi’s Operation, Service, and Repair Manual CONTROL BOX Wiring Diagram - Model TPG-6000H-DX CONTROL BOXTsurumi’s Operation, Service, and Repair Manual CONTROL BOX6. REMOVAL/INSTALLATION Tsurumi’s Operation, Service, and Repair ManualA. REPLACEMENT OF BATTERY Tsurumi’s Operation, Service, and Repair ManualB. REMOVAL/INSTALLATION OF BATTERY ENCLOSURE Tsurumi’s Operation, Service, and Repair ManualFigure 22: Battery Enclosure Exploded View C.REPLACEMENT OF ENGINE MUFFLERTsurumi’s Operation, Service, and Repair Manual Tsurumi’s Operation, Service, and Repair Manual Figure 23: Replacement of MufflerModel TPG-2900H-DX Tsurumi’s Operation, Service, and Repair ManualFigure 24: Replacement of Muffler E. REPLACEMENT OF FUEL TANK Tsurumi’s Operation, Service, and Repair ManualTsurumi’s Operation, Service, and Repair Manual H-13 H-2Tsurumi’s Operation, Service, and Repair Manual Figure 26: Draining Fuel from Fuel TankTsurumi’s Operation, Service, and Repair Manual 9Remove four frame bolts 31 from front panelTsurumi’s Operation, Service, and Repair Manual •Model TPG-2900H-DXuses four vibration mounts of two different part numbers. Two vibrationTsurumi’s Operation, Service, and Repair Manual H-9 H-10 H-5Figure 28: Replacement of Stator G. REPLACEMENT OF GENERATOR STATORTsurumi’s Operation, Service, and Repair Manual H. REPLACEMENT OF ROTOR BEARING Tsurumi’s Operation, Service, and Repair ManualFigure 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 Tsurumi’s Operation, Service, and Repair Manual Removal/InstallationFigure 32: Wrapping Bolt with Tape Wind tape on boltFigure 34: Front Cover Bolts Tsurumi’s Operation, Service, and Repair ManualReplacement of Rotor Bearing J.REPLACEMENT OF FRONT PANEL COMPONENTS Tsurumi’s Operation, Service, and Repair ManualTsurumi’s Operation, Service, and Repair Manual Figure 35: Front Panel and Control Box ComponentsTsurumi’s Operation, Service, and Repair Manual 5Engine Start Key Switch TPG-7000H-DXETsurumi’s Operation, Service, and Repair Manual Figure 36: Front Panel and Control Box ComponentsTsurumi’s Operation, Service, and Repair Manual 11Full-powerSwitch7. STORAGE INSTRUCTIONS Tsurumi’s Operation, Service, and Repair Manual8. REPLACEMENT PARTS A. INTRODUCTIONB. ORDERING PARTS Tsurumi’s Operation, Service, and Repair ManualTsurumi’s Operation, Service, and Repair Manual Exploded View - Generator - Model TPG-2900H-DXTsurumi’s Operation, Service, and Repair Manual Parts List – Generator – Model TPG-2900H-DXPart NumberTsurumi’s Operation, Service, and Repair Manual Exploded View - Front Panel - Model TPG-2900H-DXTsurumi’s Operation, Service, and Repair Manual Parts List – Front Panel – Model TPG-2900H-DXPart NumberTsurumi’s Operation, Service, and Repair Manual Exploded View - Generator - Model TPG-4300H-DXTsurumi’s Operation, Service, and Repair Manual Parts List – Generator – Model TPG-4300H-DXPart NumberTsurumi’s Operation, Service, and Repair Manual Exploded View - Front Panel - Model TPG-4300H-DXTsurumi’s Operation, Service, and Repair Manual Parts List – Front Panel – Model TPG-4300H-DXPart NumberTsurumi’s Operation, Service, and Repair Manual Exploded View - Generator - Model TPG-6000H-DXTsurumi’s Operation, Service, and Repair Manual Parts List – Generator – Model TPG-6000H-DXPart NumberTsurumi’s Operation, Service, and Repair Manual Exploded View - Front Panel - Model TPG-6000H-DXTsurumi’s Operation, Service, and Repair Manual Parts List – Front Panel – Model TPG-6000H-DXPart NumberTsurumi’s Operation, Service, and Repair Manual Exploded View - Generator - Model TPG-7000H-DXETsurumi’s Operation, Service, and Repair Manual Parts List – Generator – Model TPG-7000H-DXEPart NumberTsurumi’s Operation, Service, and Repair Manual Exploded View - Front Panel - Model TPG-7000H-DXETsurumi’s Operation, Service, and Repair Manual Parts List – Front Panel – Model TPG-7000H-DXEPart NumberNumber PartDescription APPENDIX A BATTERY ENCLOSURE KIT ASSEMBLY AND INSTALLATION INSTRUCTIONS FORTSURUMI MODEL TPG-7000H-DXE PORTABLE GENERATOR Tsurumi’s Operation, Service, and Repair ManualASSEMBLY AND INSTALLATION INSTRUCTIONS FOR TSURUMI PORTABLE GENERATOR BATTERY ENCLOSURETsurumi’s Operation, Service, and Repair Manual CHECK KIT CONTENTSINSTALLATION OF BATTERY Tsurumi’s Operation, Service, and Repair ManualINSTALLATION OF BATTERY ENCLOSURE INSTALLATION INSTRUCTIONS APPENDIX B PGWK-100WHEEL KITTsurumi’s Operation, Service, and Repair Manual Appendix BTsurumi’s Operation, Service, and Repair Manual WHEEL KIT INSTALLATION INSTRUCTIONSFOR TSURUMI GENERATORS AND PUMPS Tsurumi’s Operation, Service, and Repair Manual INSTALL AXLE ON GENERATORINSTALL AXLE ON TRASH PUMP INSTALL WHEELSAPPENDIX C PGWK-200WHEEL KIT INSTALLATION INSTRUCTIONSTsurumi’s Operation, Service, and Repair Manual Page C-1Before Installation Completed ChartInstallation Instructions Tsurumi’s Operation, Service, and Repair ManualStep 1 - Install Axle Assembly and Wheels Step 2 - Install HandlesTsurumi’s Operation, Service, and Repair Manual Fig.