Tsurumi Pump TPG4-3000HDX Operation, Service And Repair Manual
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Tsurumi Pump TPG4-3000HDX Operation, Service And Repair Manual

Tpg4-series portable generators
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OPERATION, SERVICE, AND
NOTE: Model TPG3-11000 is covered by a separate manual.
Contact your dealer or visit our web site for details:
REPAIR MANUAL
FOR TSURUMI TPG4-SERIES
PORTABLE GENERATORS
TPG MODELS
TPG4-3000HDX
TPG4-4500HDX
TPG4-6000HDX
TPG4-7000HDX
TPG4-7000HDXE
http://www.tsurumipump.com/

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Questions and answers

Mohammed
March 30, 2025

How to convert 110v to 220v to enable power the 220v facility.

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1 comments:
Mr. Anderson
March 31, 2025

To convert from 110V to 220V on the Tsurumi Pump TPG4-3000HDX, set the generator's switch to the "120V / 240V" position. This enables the higher voltage receptacle (NEMA L14-30R, 120/240V, 30A Twist Lock) to output 220V (nominal 240V). The 120V receptacles will then provide only half of the rated output. Ensure proper grounding and use the twist-lock plug to draw power safely.

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Summary of Contents for Tsurumi Pump TPG4-3000HDX

  • Page 1 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.com/...

  • Page 2: Limited Warranty

    This warranty does not apply to any TSURUMI product that has been disassembled without prior approval of TSURUMI nor does it apply to any product that has been subjected to misuse, neglect, alteration, misapplication, accident or act of God.

  • Page 3: Table Of Contents

    Tsurumi’s Operation, Service, and Repair Manual TABLE OF CONTENTS Section Title Page INTRODUCTION ........................... General ............................Precautions and Placards ......................Placards ............................Safety Precautions ........................Key Features ..........................Portable Generator Specifications ....................2-0 ..DESCRIPTION AND OPERATION ....................Description and Operation ......................
  • Page 4 Tsurumi’s Operation, Service, and Repair Manual TROUBLESHOOTING ........................General ............................Isolating Fault to the Generator or to the Control Panel ..............5-3. Measuring Insulation Resistance ....................Electrical Limits Reference Chart ....................Troubleshooting Charts ......................... Wiring Diagrams ..........................Diagram for TPG4-3000HDX ......................

  • Page 5: Introduction

    1-0 INTRODUCTION 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.

  • Page 6: Placards

    Tsurumi’s Operation, Service, and Repair Manual 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. WARNING: DO NOT OPERATE THE GENERATOR BEFORE YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND THE ENGINE MANUFACTURER’S MANUAL.

  • Page 7: Air Cleaner Maintenance

    Tsurumi’s Operation, Service, and Repair Manual Figure 1-2: Electrical Warning TSURUMI PORTABLE GENERATOR Figure 1-4: Fuel Handling Warning MODEL TPG4-3000HDX MAX. OUTPUT 2.6kVA RATED OUTPUT 2.2kVA VOLTAGE 120V TPG4 Fig. 1-2 FREQUENCY 60Hz ＊＊＊＊＊＊ SERIAL NO. MADE IN JAPAN TPG4 Fig. 1-1 ■CHECK FOR SPILLED FUEL OR FUEL LEAKS.

  • Page 8: Key Features

    Voltage Selector (Full Power) Switch - - allows voltage selection; either full-rated output from 120V receptacle or half-rated output from 120V receptacle and full-rated output from 240V receptacles (this feature is not available on Model TPG4-3000HDX). Circuit Breaker - - protects generator from overload damage -- can be reset with the flip of a switch (no fuse to replace).

  • Page 9: Portable Generator Specifications

    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 21.7/18.3 37.5/30,18.8/15 50/40,25/20 58.3/50,29.2/25 58.3/50,29.2/25 (120V.240V) Voltage 120(60Hz) 120/240(60Hz) 120/240(60Hz) 120/240(60Hz) 120/240(60Hz) 2-NEMA 5-20R Duplex (20A , 120V)
  • Page 10 Tsurumi’s Operation, Service, and Repair Manual THIS PAGE INTENTIIONAALLY LEFT BLANK Introduction...

  • Page 11: Description And Operation

    Tsurumi’s Operation, Service, and Repair Manual 2-0 DESCRIPTION AND OPERATION 2-1 PHYSICAL DESCRIPTION Description of the TPG4 Portable Generator 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.

  • Page 12: Description Of The Generator

    The muffler for Models TPG4-4500HDX, TPG4-6000HDX, TPG4-7000HDX and TPG4-7000HDXE expels exhaust gases through a port in the side of the muffler. The muffler for Model TPG4-3000HDX has a smaller muffler that expels gases through a curved tube on the bottom of the muffler.
  • Page 13 (Models TPG4-4500HDX, TPG4-6000HDX, TPG4-7000HDX and TPG4-7000HDXE have a ring-type choke control; Model TPG4-3000HDX has a choke lever.) NOTE: Refer to the Honda Owner’s Manual for Models GX160, GX240, GX340, and GX390 for additional coverage of the engine.

  • Page 14: Description Of The Fuel Tank

    Tsurumi’s Operation, Service, and Repair Manual Description of the Fuel Tank 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.

  • Page 15: Voltage Fluctuations Under Load

    Tsurumi’s Operation, Service, and Repair Manual 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.
  • Page 16 Tsurumi’s Operation, Service, and Repair Manual TPG4 Fig. 2-4 Figure 2-4: Full Power Switch Circuit Diagram 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.
  • Page 17 Tsurumi’s Operation, Service, and Repair Manual TPG4 Fig. 2-5 Figure 2-5: Full Power Switch Set for Single-Voltage Output TPG4 Fig. 2-6 Figure 2-6: Full Power Switch Set for Dual-Voltage Output Table 2-1: Full Power Switch – Switch Setting Versus Output Available...
  • Page 18 Tsurumi’s Operation, Service, and Repair Manual THIS PAGE INTENTIONALLY LEFT BLANK Description and Operation...

  • Page 19: Operating Instructions

    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. NOTE: The auto throttle feature is not available on Model TPG4-3000HDX, which uses a hand operated throttle lever. The Model TPG4-7000H-DXE generator is equipped with a electric starter motor.
  • Page 20 Tsurumi’s Operation, Service, and Repair Manual Engine switch Receptacle Pilot 120V lamp Circuit breaker Ground terminal Figure 3-1: Model TPG4 4 4 4 -3000HDX Receptacle 120/240V Engine switch Pilot lamp Circuit breaker Voltage selector GFCI switch VOLTAGE SELECTOR CIRCUIT BREAKER TEST ENGINE S W.
  • Page 21 Tsurumi’s Operation, Service, and Repair Manual Pilot Circuit breaker Receptacle 120/240V lamp GFCI switch Voltage selector Idle control switch Circuit breaker VOLTAGE SELECTOR CIRCUIT BREAKER TEST START PILOT ＯＦＦ ＯＮ ＯＮ GFCI 120V/240V 120V ON LY AT 120/240V CIRCUIT BREAKER IDLE CONTROL S W .

  • Page 22: Grounding Provisions

    Tsurumi’s Operation, Service, and Repair Manual 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.
  • Page 23 Tsurumi’s Operation, Service, and Repair Manual (67) GROUNDING POST (68) STAR WASHER (69) NUT (70) CUP WASHER (73) WINGNUT (71) FLATWASHER (72) LOCKWASHER PARTS BREAKDOWN GROUND ROD TO GROUND ROD GROUND CLAMPING WIRE SCREW GROUND WIRE SOIL CONTROL PANEL (46)

  • Page 24: Check Engine Oil Grade

    Tsurumi’s Operation, Service, and Repair Manual 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.
  • Page 25 Reinstall the oil filler cap / dipstick. TPG3 FIG 3-6 Figure 3-6: Checking Oil Level...

  • Page 26: Check Engine Fuel

    FUEL LEVEL INDICATOR RESPONDS TO FLOAT LEVEL TANK EMPTY TANK FULL (FLOAT LOW) (FLOAT HIGH) TPG4 FIG 3-7 Figure 3-7: Fuel Gauge Indications Fuel tank capacity TPG4-3000HDX (4.2 gal.) TPG4-4500HDX (6.6 gal.) TPG4-6000HDX (6.6 gal.) TPG4-7000HDX (6.6 gal.) TPG4-7000HDXE (6.6 gal.)

  • Page 27: Pre-Start Checks

    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. Check the following items before starting the engine. Fuel leakage from fuel hoses, shutoff valve, auto-throttle unit, engine, and fitttingd Loose bolts and nuts.

  • Page 28: Starting & Stopping Engine

    Starting & Stopping the Engine MANUAL START: (Models TPG4-3000HDX, TPG4-4500HDX, TPG4-6000HDX, and TPG7-7000HDX. Before starting the engine, set AC circuit breakers to OFF (the generator may be hard to start if a load is connected. Refer to the Honda engine owner’s manual for location of fuel valve. Turn the fuel valve to the ON position.
  • Page 29 NOTE: If the speed of the starter motor drops after a period of time, it is an indication that the battery should be recharged. Release key (the key is spring-loaded to the RUN position).

  • Page 30: Using The Generator

    As the engine warms up, gradually open the choke ring. 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:.
  • Page 31 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 Set switches on the electrical appliances to OFF before connecting to the generator.
  • Page 32 Dual Voltage Type 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. Table 3-2: Available Receptacles With Full Power Switch On Switch Setting Lower Voltage Receptacle Higher Voltage Receptacle...

  • Page 33: Stopping The Generator

    3-12 Stopping the Generator Set the ENGINE SWITCH to OFF or unplug from the cord receptacle of the generator. Set the engine switch to the OFF position. Turn fuel valve on fuel tank to CLOSE. Figure 3-8: Fuel Valve 3-13 Oil Alert 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.

  • Page 34: Idle Control

    3-14 Idle Control (Models TPG4-4500HDX, TPG4-6000HDX, TPG4- 7000HDX and TPG4-7000HDXE) 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.

  • Page 35: Ground Fault Circuit Interrupter(Gfci)

    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.
  • Page 36 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.
  • Page 37 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.

  • Page 38: Wattage Information

    3-18 Wattage Information 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.

  • Page 40: Maintenance

    Tsurumi’s Operation, Service, and Repair Manual MAINTENANCE General 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. An initial oil change should be performed after the first twenty (20) hours of use. Thereafter, change oil every 100 hours.

  • Page 41: Changing Engine Oil

    Tsurumi’s Operation, Service, and Repair Manual Changing Engine Oil Drain the oil while the engine is still warm to assure rapid and complete draining. Remove the oil filler dipstick/cap and drain plug. Allow oil to drain from the engine (Figure 4-1).

  • Page 42: Sediment Cup Cleaning

    Tsurumi’s Operation, Service, and Repair Manual 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.

  • Page 43: Cleaning And Adjusting Spark Plug

    Tsurumi’s Operation, Service, and Repair Manual Cleaning and Adjusting Spark Plug Recommended spark plugs: BPR6ES(NGK) W20EPR-U (NIPPONDENSO) To ensure proper engine operation, the spark plug must be properly gapped and free of deposits. Remove the spark plug cap. Clean any dirt from around the spark plug base.

  • Page 44: Troubleshooting

    Before testing generator components, determine if the failure is located in the generator head or in the control panel. If after following these procedures, your generator fails to start or generate electricity, contact the nearest Tsurumi generator dealer. Isolating Fault to the Generator or to the Control Panel This unit uses permanent magnets built into the rotor for initial excitation.

  • Page 45: Electrical Limits Reference Chart

    Tsurumi’s Operation, Service and Repair Manual Electrical Limits Reference Chart 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 Insulation AC Winding AC Winding...
  • Page 46 Tsurumi’s Operation, Service and Repair Manual Table 5-2: Fault Isolation Procedures FAULT PROBABLE CAUSE REMEDY No AC output. Condenser failed. 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.
  • Page 47 Tsurumi’s Operation, Service and Repair Manual FAULT PROBABLE CAUSE REMEDY No AC output. 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.
  • Page 48 Tsurumi’s Operation, Service and Repair Manual FAULT PROBABLE CAUSE REMEDY AC voltage is Engine speed too low 4. Check engine speed. normal at no-load, (continued). 5. Operate the generator at no load. but load cannot be 6. If the speed is too low, adjust to the normal applied (continued).
  • Page 49 Tsurumi’s Operation, Service and Repair Manual FAULT PROBABLE CAUSE REMEDY Engine speed does Wattage of connected TPG4-3000HDX 3550 to 3650 RPM not increase when appliance or electric tool TPG4-4500HDX 3550 to 3650 RPM load applied exceeds rating. TPG4-6000HDX 3550 to 3650 RPM (continued) (continued).
  • Page 50 Tsurumi’s Operation, Service and Repair Manual Table 8: Idle Control Unit – Circuit Parameters Circuit Tester Power Source Apply Black (Negative) Probe of the Circuit Tester Apply Red - - - ∞ 250 kΩ 250 kΩ 250 kΩ (Positive) Probe of - - - ∞...

  • Page 51: Wiring Diagrams

    Tsurumi’s Operation, Service and Repair Manual Wiring Diagrams TPG4-3000HDX Wiring Diagram – Model TPG4-3000HDX Troubleshooting...
  • Page 52 Tsurumi’s Operation, Service and Repair Manual TPG4-4500HDX Wiring Diagram – Model TPG4-4500HDX Troubleshooting...
  • Page 53 Tsurumi’s Operation, Service and Repair Manual TPG4-6000HDX,TPG4-7000HDX Wiring Diagram – Models TPG4-6000HDX and TPG4-7000HDX Troubleshooting...
  • Page 54 Tsurumi’s Operation, Service and Repair Manual TPG4-7000HDXE Wiring Diagram – Model TPG4-7000HDXE Troubleshooting...
  • Page 55 Tsurumi’s Operation, Service and Repair Manual THIS PAGE INTENTIONALLY LEFT BLANK Troubleshooting...

  • Page 56: Removal/Installation

    Tsurumi’s Operation, Service, and Repair Manual 6-0 REMOVAL / INSTALLATION General 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. Exploded views and other Illustrations are provided to supplement the replacement procedures.

  • Page 57: Replacement Of Battery

    Tsurumi’s Operation, Service, and Repair Manual Table 6-1B: Fastener Torque Values for kgf.cm Structure Stainless Material Cast Iron Steel Steel Bolt Size Nominal Max. Min. Nominal Max. Min. Nominal Max. Min. 1016 1079 1294 1322 1586 1058 1076 1291 1485...
  • Page 58 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. Refer to Figure 6-1. Remove two nuts (88) from bolts (88). Remove plate...

  • Page 59: Removal/Installation Of Battery Enclosure

    Tsurumi’s Operation, Service, and Repair Manual Put threaded ends of bolts (89) in holes in plate (93). Install nuts (88) on bolts to secure battery. Connect cables (85 and 86) to terminals on the battery. Start and operate generator to verify that the battery is properly connected.

  • Page 60: Replacement Of Engine Muffler

    Tsurumi’s Operation, Service, and Repair Manual Figure 6-2: Battery Enclosure Components 44 (Ref) TPG4 FIG 6-2 Replacement of Muffler (Models TPG4-4500HDX, TPG4-6000HDX, TPG4-7000HDX, and TPG4- 7000HDXE) Refer to Figure 6-3. Remove screws (H-9) and remove outer shield (H-8). Do not remove spark arrestor (H-11) unless damaged.
  • Page 61 Tsurumi’s Operation, Service, and Repair Manual H-13 H-11 H-12 H-10 H-14 (2x) TPG4 FIG 6-3 Figure 6-3: Replacement of Muffler (Models TPG4-4500HDX, TPG4-6000HDX, TPG4-7000HDX, and TPG4-7000HDXE) Removal/Installation...
  • Page 62 Tsurumi’s Operation, Service, and Repair Manual 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).
  • Page 63 Tsurumi’s Operation, Service, and Repair Manual H-13 H-10 44.1 44.2 36 (2x) 35 (2x) 37 (2x) TPG FIG 6-4 Figure 6-4: Replacement of Muffler (Model TPG4-3000HDX Only) Removal/Installation...

  • Page 64: Replacement Of Fuel Tank

    Tsurumi’s Operation, Service, and Repair Manual 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.
  • Page 65 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).
  • Page 66 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.

  • Page 67: Removal Of Fuel Tank

    Tsurumi’s Operation, Service, and Repair Manual 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.

  • Page 68: Installation Of Fuel Tank

    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. NOTE: Tsurumi recommends that the heavy generator/engine unit be removed from the frame before removing generator components.

  • Page 69: Removal Of Generator/Engine Unit

    Tsurumi’s Operation, Service, and Repair Manual 6-11 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.

  • Page 70: Installation Of Generator/Engine Unit

    Tsurumi’s Operation, Service, and Repair Manual 6-12 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.
  • Page 71 Tsurumi’s Operation, Service, and Repair Manual H-13 36 REF H-10 15 (4x) 10 (4x) 4 (3x) 23 (4x) 24 (4x) 25 (4x) 26 (4x) 2 (2x) 44.1 44.2 36 (2x) 36 (2x) 37 (2x) 35 (2x) 37 (2x) 35 (2x)

  • Page 72: Replacement Of Generator Stator

    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.
  • Page 73 Tsurumi’s Operation, Service, and Repair Manual 15 (4x) 10 (4x) 4 (3x) 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.

  • Page 74: Replacement Of Rotor Bearing

    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.
  • Page 75 Tsurumi’s Operation, Service, and Repair Manual Puller Threaded Rod Bearing TPG4 FIG 6-9 TPG3 FIG 6-9 Fi1gure 6-9: Bearing Puller in Use Through Bolt TPG4 FIG 6-10 TPG3 FIG 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.
  • Page 76 Tsurumi’s Operation, Service, and Repair Manual Oil Container Rotor TPG4 FIG 6-11 TPG3 FIG 6-11 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.
  • Page 77 TPG3 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.

  • Page 78: Replacement Of Rotor

    Tsurumi’s Operation, Service, and Repair Manual 6-16 Replacement of Rotor 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).
  • Page 79 Tsurumi’s Operation, Service, and Repair Manual Remove screws (84) and pushbutton (82). Install replacement pushbutton (82) and secure with screws (84). Connect wiring. Install front panel (45) and control box (46) (refer to Removal/Installation of Front Panel and Control Box).
  • Page 80 Tsurumi’s Operation, Service, and Repair Manual 60 (2X) 61 (2X) 61 (2X) 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).
  • Page 81 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).
  • Page 82 Tsurumi’s Operation, Service, and Repair Manual 74 (2x) 61 (2x) 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).
  • Page 83 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).
  • Page 84 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).

  • Page 85: Storage Instructions

    Tsurumi’s Operation, Service and Repair Manual STORAGE INSTRUCTIONS General 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.
  • Page 86 Tsurumi’s Operation, Service and Repair Manual THIS PAGE INTENTIONALLY LEFT BLANK Storage Instructions...

  • Page 87: Replacement Parts

    Honda Parts Honda Motor Company supplies parts that generally provide the interface between the Honda engine and the Tsurumi generator. When required, replacement Honda parts may be ordered from the Honda Motor Company parts catalog. Reference numbers used to identify Honda parts are prefixed with the letter H (such as H-20)
  • Page 88 Tsurumi’s Operation, Service and Repair Manual Figure 8-1: Generator (Exploded View) - Model TPG3-3000HDX H-13 36 REF H-10 15 (4x) 10 (4x) 4 (3x) 23 (4x) 24 (4x) 25 (4x) 26 (4x) 2 (2x) 44.1 44.2 36 (2x) 36 (2x)
  • Page 89 Tsurumi’s Operation, Service and Repair Manual Figure 8-1: Generator (Parts List) - Model TPG4-3000HDX Ref. Part Ref. Part Number Description Number Description 15111471000 Cover, Bracket 15601797000 Case, Control (Blue) 15550210000 Bolt, Hex (with Flange) 15550438000 Screw, Cross Head, (M5 x 0.8-12)
  • Page 90 Tsurumi’s Operation, Service and Repair Manual Figure 8-2: Control Box (Exploded View) – Model TPG4-3000HDX 74 (2x) 61 (2x) TPG4-3000 PANEL TPG3-3000 PANEL Replacement Parts...
  • Page 91 Tsurumi’s Operation, Service and Repair Manual Figure 8-2 - Control Box (Parts List) - Model TPG4-3000HDX Ref. Part Ref. Part Number Description Number Description 15350690000 Box, Control 15550329000 Nut, Hex (with Flange) (M5) 15601696000 Panel, Control 15301979000 Washer, Cap 15400104000...
  • Page 92 Tsurumi’s Operation, Service and Repair Manual Figure 8-3: Generator (Exploded View) - Model TPG3-4500HDX H-13 H-11 H-12 36 Ref H-10 H-14 (2x) 15 (4x) 10 (4x) 4 (2x) 23 (4x) 24 (4x) 25 (4x) 2 (2x) 26 (4x) 34 (2x) 45 (See Fig.
  • Page 93 Tsurumi’s Operation, Service and Repair Manual Figure 8-3 – Generator (Parts List)– Model TPG3-4500HDX Ref. Part Ref. Part Number Description Number Description 15311471000 Cover, Bracket 19SS6906016 Bolt (M6-16) 15550210000 Bolt, Hex (with Flange) 200900520 Rubber, Anti-Vibration (M5 x 0.8-12) 203200020...
  • Page 94 Tsurumi’s Operation, Service and Repair Manual Figure 8-4 - Control Box (Exploded View) - Model TPG4-4500HDX 62(x 2) 79(x 2) 61(x 2) 61(x 2) 74(x 2) (x 2) (x 2) 77(x 2) (x 2) (x 2) (x 2) TPG4-4500HDX PANEL...
  • Page 95 Tsurumi’s Operation, Service and Repair Manual Figure 8-4 - Control Box (Parts List) - Model TPG4-4500HDX Ref. Part Ref. Part Number Description Number Description 15350680000 Box, Control 19N10906000 Nut, Hex (with Flange) (M6) 15601697000 Panel, Control 15400559000 UNIT , GFCI...
  • Page 96 Tsurumi’s Operation, Service and Repair Manual Figure 8-5: Generator (Exploded View) - Model TPG4-6000HDX H-13 H-11 H-12 36 Ref H-10 H-14 (2x) 15 (4x) 10 (4x) 4 (2x) 23 (4x) 24 (4x) 25 (4x) 2 (2x) 26 (4x) 34 (2x) See Fig.
  • Page 97 Tsurumi’s Operation, Service and Repair Manual Figure 8-5 – Generator (Parts List)– Model TPG4-6000HDX Ref. Part Ref. Part Number Description Number Description 15311471000 Cover, Bracket 19SS6906016 Bolt (M6-16) 15550210000 Bolt, Hex (with Flange) 200900520 Rubber, Anti-Vibration (M5 x 0.8-12) 203200020...
  • Page 98 Tsurumi’s Operation, Service and Repair Manual Figure 8-6 - Control Box (Exploded View) – Model TPG4-6000HDX 62(x 2) 79(x 2) 61(x 2) 61(x 2) 74(x 2) (x 2) (x 2) 77(x 2) (x 2) (x 2) (x 2) TPG4-6000HDX PANEL...
  • Page 99 Tsurumi’s Operation, Service and Repair Manual Figure 8-6- Control Box (Parts List) - Model TPG4-6000HDX Ref. Part Ref. Part Number Description Number Description 15350680000 Box, Control 19SF4906015 Screw, Cross Head Recessed (M6x15) 15601698000 Panel, Control 15400105000 Receptacle (30A, 19N10906000 Nut, Hex (with Flange)
  • Page 100 Tsurumi’s Operation, Service and Repair Manual Figure 8-7: Generator (Exploded View) - Model TPG4-7000HDX H-13 H-11 H-12 36 Ref H-10 H-14 (2x) 15 (4x) 10 (4x) 4 (2x) 23 (4x) 24 (4x) 25 (4x) 2 (2x) 26 (4x) 34 (2x) See Fig.
  • Page 101 Tsurumi’s Operation, Service and Repair Manual Figure 8-7 – Generator (Parts List)– Model TPG4-7000HDX Ref. Part Ref. Part Number Description Number Description 15311471000 Cover, Bracket 19SS6906016 Bolt (M6-16) 15550210000 Bolt, Hex (with Flange) 200900520 Rubber, Anti-Vibration (M5 x 0.8-12) 203200020...
  • Page 102 Tsurumi’s Operation, Service and Repair Manual Figure 8-8 - Control Box (Exploded) – Model TPG4-7000HDX 62(x 2) 79(x 2) 61(x 2) 61(x 2) 74(x 2) (x 2) (x 2) 77(x 2) (x 2) (x 2) (x 2) TPG4-7000HDX PANEL Replacement Parts...
  • Page 103 Tsurumi’s Operation, Service and Repair Manual Figure 8-8- Control Box (Parts List) - Model TPG4-7000HDX Ref. Part Ref. Part Number Description Number Description 15350680000 Box, Control 19SF4906015 Screw, Cross Head Recessed (M6x15) 15601699000 Panel, Control 15400105000 Receptacle (30A, 19N10906000 Nut, Hex (with Flange)
  • Page 104 Tsurumi’s Operation, Service and Repair Manual Figure 8-9: Generator (Exploded View) - Model TPG4-7000HDXE H-13 H-11 H-12 36 Ref H-10 H-14 (2x) 15 (4x) 10 (4x) 4 (2x) 23 (4x) 24 (4x) 25 (4x) 2 (2x) 26 (4x) 34 (2x) See Fig.
  • Page 105 Tsurumi’s Operation, Service and Repair Manual Figure 8-9 – Generator (Parts List)– Model TPG4-7000HDXE Ref. Part Ref. Part Number Description Number Description 15311471000 Cover, Bracket 19SS6906016 Bolt (M6-16) 15550210000 Bolt, Hex (with Flange) 200900520 Rubber, Anti-Vibration (M5 x 0.8-12) 203200020...
  • Page 106 Tsurumi’s Operation, Service and Repair Manual Figure 8-10–Control Box (Exploded View)-Model TPG4-7000HDXE 79(x 2) TPG4-7000HDXE PANEL...
  • Page 107 Tsurumi’s Operation, Service and Repair Manual Figure 8-10- Control Box (Parts List) - Model TPG4-7000HDXE Ref. Part Ref. Part Number Description Number Description 15350680000 Box, Control 15550330000 Screw, Cross Head, Recessed 15601699000 Panel, Control (M5 x 25) 15400105000 Receptacle (30A,...
  • Page 108 Tsurumi’s Operation, Service and Repair Manual Figure 8-11 - Battery Enclosure (Exploded View/Parts List) Model TPG4-7000HDXE 44 (Ref) Ref. Part Number Description 15361575000 Cable, Ground 15361574000 Cable, Starter 15361370300 Plate, Setting 19N10906000 Nut, Hex (with Flange) (M6) 15361570310 Bolt, Setting...
  • Page 109 Tsurumi’s Operation, Service and Repair Manual THIS PAGE INTENTIONALLY LEFT BLANK...

This manual is also suitable for:

Tpg4-4500hdxTpg4-6000hdxTpg4-7000hdxTpg4-7000hdxe

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