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