Etq TG4000 User Manual
Owner’s Manual Model TG4000
NW
PREFACE
Thank you for purchasing products from EASTERN TOOLS & EQUIPMENT, INC. We
appreciate your business. The following manual is only a guide to assist you and is not a
complete or comprehensive manual of all aspects of maintaining and repairing your
generator. The equipment you have purchased is a complex piece of machinery. We
recommend that that you consult with a dealer if you have doubts or concerns as to your
experience or ability to properly maintain or repair your equipment. You will save time and
the inconvenience of having to go back to the store if you choose to write or call us
concerning missing parts, service questions, operating advice, and/or assembly questions.
Our gasoline generators have some of the following features:
．Lightweight construction
．Air cooled
．Four-stroke gasoline internal combustion engine
．Recoil starter
．Large fuel tank
．Automatic voltage stabilizer
．NFB circuit protector
．AC outputs
．Low oil level sensor
The ETQ air-cooled gasoline generators are widely used when electrical power is scarce.
Our generators provide a portable mobile solution in supplying power for field operations
during project construction.
This manual will explain how to operate and service your generator set.
If you have any questions or suggestions about this manual, please contact your local
dealer or us directly. Consumers should notice that this manual might differ slightly
from the actual product as more improvements are made to our products. Some of
the pictures in this manual may differ slightly from the actual product as well.
Eastern Tools and Equipment, Inc. reserves the right to make changes at any time
without notice and without incurring any obligation.
TABLE OF CONTENTS
Page
TECHNICAL SPECIFICATIONS AND DATA 1
EQUIPMENT DESCRIPTION & KNOWING YOUR GENERATOR 2
PACKAGE CONTENTS 3
ASSEMBLY 4
SAFETY PRECAUTIONS 7
Electric shock and short circuit 7
Prevention from accidental burns 7
Refueling precautions 7
Engine safety precautions 8
Generator safety 8
PREPARATION BEFORE OPERATION 8
Engine oil 8
Air cleaner 9
GROUNDING THE GENERATOR 10
OPERATING THE GENERATOR 10
Starting the engine 10
Connecting electrical loads and electrical capacity 11
Stopping the engine 12
RECEPTACLES 13
MAINTENANCE 14
Cleaning the generator 15
Spark Plug 15
Storage 16
TROUBLESHOOTING 17
WIRING DIAGRAM 18
PART LISTINGS 19
Exploded Generator View 19
Crankcase 21
Push rod & Valve Rocker 22
Cylinder Head & Cylinder Head Cover Assembly 23
Crankcase Cover Assembly 24
Crankshaft, Piston & Tie-Rod 25
Carburetor Assembly & Air Cleaner Assembly 26
Flywheel & Recoil Starter 27
Ignition Coil 28
Regulating Control System 28
LIMITED WARRANTY 29
PRODUCT REGISTRATION CARD 32
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EASTERN TOOLS & EQUIPMENT INC Tel: (888)908-6200 Web Site: easterntools.com
TECHNICAL SPECIFICATIONS AND DATA
TG4000
Engine Type 4-stroke, Air-cooled, OHV
Displacement
Bore × Stroke
Engine Rated Power
4.78 KVA @ 3600 r/min
6.5Hp @ 3600 r/min
196 cc
11.95 cu in
68×54 mm
2.68×2.29 in
Fuel Unleaded
Fuel Tank Capacity
15.14 L
4 Gal
Operation Hours 13Hrs @ 50% load
Engine Oil SAE 10W-30 or equivalent motor oil
0.6L (20.3 Ounces)
Engine Oil Capacity
1.Need to add oil to engine when “oil warning light “ is on
2.Engine may stop and will damage if the oil is too low.
Engine Start Pattern Manual start
Generator Type Synchronous generator
Phase Single
Power Factor Cos θ = 1.0
AC Output Voltage 120V/240V
AC Output Frequency 60Hz
AC Output Max Power 4000 ± 10% Watts
AC Output Rated Power 3250 ± 3% Watts
Noise Level 75 dB @ 7m
Product Weight
Product Dimensions
60.0 x 54.0 x 49.0 cm
23.62 x 21.26 x 19.29 in
46.3 kg
102 lbs
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EQUIPMENT DESCRIPTION & KNOWING YOUR GENERATOR
Please read this manual and follow the procedures covered in this manual. Become familiar with the
generators functions, applications, and limitations.
Below is a diagram of the locations of the various controls and functions of the generator
ILLUSTRATION OF CONTROLS
5-20R GFCI Receptacle(2pcs)
Circuit Breaker 15AMP
Cap Comp, Fuel Fille
Handle
Fuel Tank
Starter
Ground Terminal
Stop Switch
Generator Foot
Ground Lug
Rubber Wheel 7’
L14-20 Receptacle
Frame
lternato
Spark Arrest Pulse
Muffler
Cover Comp, Head
Carburetor
Air Cleane
WARNING: DO NOT exceed the generator’s wattage/amperage capacity. Our products are
continuously being changed and improved. Every effort has been made to ensure that information in
the manual is accurate and up to date. However, we reserve the right to change, alter or otherwise
improve the product and this manual at any time without prior notice.
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PACKAGE CONTENTS
Your generator comes with the items listed below. Please check to see that all of the following items
are included with your generator.
If you are missing components DO NOT RETURN TO STORE, please call (888)908-6200 for
customer service.
Order No. Name Qty
1 Air-cooled generator set 1
2 Tool Kit:
3 Assembly Kit:
Flat Head Screwdriver
Spark Plug Wrench
Wrench, 8×10
1
Wheel (2 pcs)
Handle
1
Wheel Kit Hardware (2 set)
Generator Foot (2 pcs)
4 Owner’s manual 1
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ASSEMBLY
In order to best protect the generator while in the package, this product comes with some components
disassembled. Please complete the following assembly steps before proceeding to use the generator.
For ease of assembly, we recommend attaching the components in the order listed in this manual.
If after reading this section, you are unsure about how to perform any of the steps,
please call (888)908-6200 for customer service.
WARNING: This generator is heavy. Some assembly procedures may require
two people.
Attach Feet
To attach the feet to the generator, perform the following steps:
1. Stack the two generator wheels on top of each other. Lift the end of the generator that has the
recoil starter onto the stack of wheels (see figure 1). Be careful not to obstruct any holes on the
generator.
2. Place one foot onto the frame as shown in figure 2. Line up the holes on the generator frame with
the holes on the bracket portion of the foot. Tighten the M6x40 bolts and M6 nuts, using the
included wrench.
3. Repeat step 2 for the other generator foot.
A
Figure 1 - Stacking the wheels
Figure 2- Foot assembly
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Attach Wheels
To attach the wheels to the generator, perform the following steps:
1. Take one wheel shaft and one M12 nut as shown. Slide the wheel shaft, with the threaded part
facing inward, through the frame holes. Secure using an M12 nut and the included wrench as
shown in figure 4.
2. Lift up slightly the generator frame and put shaft into the holes of wheel and tighten it on the frame
and Slide the wheel onto the axle and secure in place using a large cotter pin as shown in figure 5.
3. Place one washer on the shaft and do not obstruct the hole of the shaft. Spread the pin legs apart
slightly to help secure the pin in place.
4. Repeat steps 2 and 3 for the other wheel.
Figure 3 - Placing the shaft
Figure 5 - Wheel installation
Figure 4 - Shaft assembly
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Attach Handles
The handles attach to the same end of the generator as the feet. To attach the handles to the
generator, perform the following steps:
1. The handle assembly consists of the handle, two bolts, and two nuts as shown in figure 6.
2. Line up the holes on the handle bracket, with bolts attached, the holes on the generator frame.
Fasten it tightly with wrench.
3. Secure the handle to the frame using the bolt and nut. Make this attachment so that the nut is on
the inside of the frame.
4. Fasten the bolt of the movable part.
5. Repeat steps 1-4 for the other handle.
Figure 6 - Handle assembly
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SAFETY PRECAUTIONS
In order to ensure safety for the consumer,
please carefully follow instructions on being
careful with the generators.
Operate the generator ONLY outdoors. Never
run the generator indoors as the engine gives
off poisonous carbon monoxide, an odorless
and colorless gas. Inhaling carbon monoxide
will cause nausea, fainting or death. Also, keep
the generator at least 3 feet away from
flammable matter for adequate ventilation.
ELECTRIC SHOCK AND SHORT CIRCUIT
Be sure to notify the utility company when using
the generator for backup power. Use approved
transfer equipment to isolate the generator from
electric utility. In highly conductive area such as
metal decking or steel work, use a ground
circuit fault interrupter. Never touch the
generator if the generator is wet. Also, never
touch the generator if your hand is wet. Never
operate your generator if the weather
conditions call for any type of precipitation such
as rain, snow, or fog.
DANGER
Always properly ground the generator. Failing
to do so can result in electrocution, particularly
if the generator is equipped with a wheel kit.
PREVENTION FROM ACCIDENTAL BURNS
Never touch the muffler and its cover when the
engine is running. Never touch the muffler and
cover after the engine has been used, as the
muffler remains hot for a good period of time.
REFUELING PRECAUTIONS
Gasoline and its vapors are extremely
flammable. Do not smoke near gasoline and
keep gasoline away from generator while the
generator is running. When adding fuel, turn the
generator off and let it cool at least 2 minutes
before removing the gas cap. Loosen gas cap
slowly to relieve the pressure in the tank.
Fill fuel tank outdoors and never overfill the
tank.
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them. Keep the same concept when
disconnecting electrical devices; make sure all
devices are in the "OFF" position before
disconnecting.
Operate the generator on level surfaces only.
Inclined surfaces reduce the effective
lubrication of the engine.
When storing gasoline or equipment with fuel in
tank.
Store away from appliances or equipment that
have a pilot light or other ignition sources
because it can ignite gasoline vapors.
ENGINE SAFETY PRECAUTIONS
Do not touch hot surfaces. Allow equipment to
fully cool down before touching.
Do not expose the generator to excessive
moisture, dust, dirt, or corrosive vapors.
PREPARATION BEFORE
OPERATION
Before starting the generator, verify the
following conditions.
ENGINE OIL
• Fill the engine with SAE 10W-30 engine oil
for generator use or follow the table below.
After the generator has been run, the engine
produces heat. The temperature of the muffler
and nearby areas can reach or exceed 1600 F.
Severe burns will occur on contact with skin. Do
not modify the generator in any way. The
generator supplies the rated voltage and rated
frequency at its governed speed.
GENERATOR SAFETY
Never overload your generator as this can
damage your generator or the electrical devices
connected to it
Do not start generator with electrical devices
connected to it. Start the generator first and
after the speed of the generator stabilizes,
electrical loads can be applied to it.
When connecting electrical loads, make sure
the devices are "OFF" first before connecting
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• Make sure the generator is on a level
surface and make sure the oil dipstick is on
tight.
GASOLINE
• Add unleaded gasoline and never fill the
fuel tank indoors. Also, be sure to install the
fuel tank cap on tight after filling.
• DO NOT overfill the fuel tank. Always allow
room for fuel expansion. Never fill the fuel
tank when the engine is running or hot.
Allow the unit to cool for two minutes before
refueling. DO NOT use light a cigarette or
smoke when filling the fuel tank.
AIR CLEANER
• Unsnap the air cleaner cover springs, and
remove the air cleaner cover.
• Check the air cleaner element to be sure
they are clean and in good condition.
• If the air filter is dirty, remove and clean the
element.
o Wash in solvent
o Squeeze
o Soak oil
o Squeeze dry
• Reinstall the air cleaner element and
secure the cover by setting the cover
spring.
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GROUNDING THE GENERATOR
The National Electric Code requires that the
frame of generator and the external electrically
conductive parts of the generator be connected
to an approved earth ground. Local codes may
differ and require other grounding specifications.
For this purpose, please use the ground wire
that attaches from the frame to the generator
unit.
OPERATING THE GENERATOR
STARTING THE ENGINE
Before starting the engine, verify that the
engine oil is full, gasoline is full, and air Filter is
in place. Also, disconnect any load from the AC
receptacle, and turn the AC circuit breaker OFF
(Figure 1)
Figure 1. Disconnecting electrical devices
Using a No. 12 AWG (American Wire Gauge)
stranded copper wire to the frame and to an
earth-driven copper or brass grounding rod
provides sufficient safety against shock.
However, local codes may differ. Contact a
local electrician to find out specifications for
grounding your generator.
Note: Grounding your generator is highly
recommended. It helps prevent electrical shock
if a ground fault condition exists in the
generator or in faulty connected electrical
devices. Also, because the generator is rotating
at high speeds, static electricity tends to buildup
within the unit. Grounding helps dissipate the
static electricity buildup often buildup in
underground devices.
• Turn the fuel valve to the "On" position
(Figure 2).
Figure 2. Fuel Valve
Figure 3. Engine switch on position
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• Pull the recoil starter grip lightly until
resistance is felt, then pull hard. Warning:
Do not allow the starter grip to snap back
against the engine. Return it gently.
Figure 4. Recoil starting rope
load. Never exceed the capacity of the
generator.
Estimate how many surge (starting) watts you
will need. Surge wattage is the short burst of
power needed to start electric motor-driven
tools or appliances such as a circular saw or
refrigerator.
Table 1. Wattage reference chart
Additional
Surge
(Starting)
Watts
• Push the choke rod to the "OPEN" position
a short distance at a time over several
seconds as the engine warms up.
CONNECTING ELECTRICAL LOADS AND
ELECTRICAL CAPACITY
After starting the generator, let the engine warm
up after connecting electrical loads to it. Do not
have any electrical loads connected before
starting the generator.
Make sure all electrical devices are 60 Hz
devices.
Do not connect 50 Hz devices to the generator.
Do not connect 3-phase loads to the generator.
Do not overload the generator.
Before beginning your work, you must verify
that the rated (running) and surge (starting)
watts for the items you will power at the same
time are within the generators operating
capacity. Please refer to the following Table 1
for wattage / amperage ratings. Also, to prolong
the life of your generator, prolong the life of your
generator, sequentially add loads and permit
the generator to stabilize before adding another
Rated
Tool or Appliance
Essentials
Light Bulb – 75 watt 75 Freezer 500 500
Sump Pump 800 1200
Refrigerator / Freezer – 18
Cu. Ft.
1/3 HP Water Well Pump 1000 2000
Heating/Cooling
Air condition – 10000 BTU 1200 1800
Window Fan 300 600
½ HP Furnace Fan Blower 800 1300
Kitchen
1000 Watt Microwave Oven 1000 -
Coffee Maker 1500 Single element electric stove 1500 Hot plate 2500 -
Family Room
DVD / CD Player 100 VCR 100 -
Stereo Receiver 450 27 “ Color Television 500 Personal Computer w/17”
monitor
Other
Security system 180 AM / FM clock radio 300 -
½ HP Garage door opener 480 520
40 Gallon electric water
heater
(Running)
Watts
800 1600
800 -
4000 -
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DIY / Job Site
Halogen work light 1000 1/3 HP Airless sprayer 600 1200
Reciprocating Saw 960 960
½ HP Electric Drill 1000 1000
7 ¼ “ Circular saw 1500 1500
10” Miter saw 1800 1800
6” Table Planer 1800 1800
10” Table saw / Radial arm
saw
1 ½ HP air compressor 2500 2500
Note: wattages listed are only approximates. Check
your electrical device for actual wattage.
2000 2000
• Let the engine run at no-load for several
minutes to stabilize the internal
temperatures of engine and generator.
• Turn the engine switch to the "OFF"
position (Figure 3).
Figure 3.
STOPPING THE ENGINE
• Turn the AC circuit breaker to the "OFF"
position (Figure 1).
Figure 1.
• Turn the fuel valve to the "OFF" position
(Figure 4).
Figure 4.
• Unplug all the electrical loads from the
generator panel (Figure 2).
Figure 2.
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RECEPTACLES
This generator is equipped with the following
Receptacles
Figure 1. NEMA 5-20R: 125 Volt, 20 Amp
GFCI Duplex Receptacle
Figure 2. NEMA L14-20R: 240/120Volt,
20Amp Twist Lock Receptacle
Note: Please be sure to use electrical cords that
support the amount of wattage being used.
The electrical cords should be able to handle
13.5 Amps of current at 125/250 Volts.
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MAINTENANCE
Below is a routine maintenance schedule.
(1): These items should be serviced by a dealer.
(2): Every 3 years.
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CLEANING THE GENERATOR
Generator maintenance consists of keeping the
unit clean and dry. Be sure to store the unit in a
clean and dry environment, where it will not be
exposed to excessive dust, dirt, moisture or any
corrosive vapors. Cooling slots should always
be clean and free from clogs.
Note: Do not use a garden hose to clean the
generator. Water can enter the fuel and intake
system and cause problems. In addition, if
water and dirt buildup on the generators
internal windings, the resistance of these
windings will decrease.
Gap measurements
0.7~0.8 mm (.028~.031 inches)
NOTE: If spark plug needs to be replaced, use
NGK(or STAR) Brand: BPR6ES or F6(R)TC
• To clean the generator, use a damp cloth to
wipe the exterior surfaces.
• Use a soft bristle brush to loosen caked on
dirt of oil.
• Use a vacuum cleaner to pick up loose dirt
and debris.
• Compressed air (not to exceed 25 psi) may
be used to blow away dirt.
SPARK PLUG
• Remove the spark plug
• Remove the carbon deposits
• Check for discoloration. Standard is tan in
color.
• Check spark plug gap
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STORAGE
Figure 3.
The generator should be started at least once
every week. If this cannot be done and you
must store the unit more than 30 days, please
follow the following guidelines.
Close the fuel valve: drain the fuel from the fuel
tank (Figure 1).
Figure 1.
• Tighten the oil drain plug and fill the engine
with new oil to the filter neck (Figure 4).
Figure 4.
• Drain the fuel from the carburetor (Figure
2).
Figure 2.
• Remove the oil filter cap and drain plug to
drain the oil (Figure 3).
• Pull the starter grip carefully until resistance
is felt (Figure 5).
Figure 5.
• Store the generator in a clean area.
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TROUBLESHOOTING
PROBLEM
Engine will not
start or runs
rough when
started
Engine running
but no AC
output
CAUSE SOLUTION
1.Engine switch set to "OFF".
2.Fuel valve is in the "OFF" position.
3.Dirty air cleaner.
4.Out of gasoline.
5.Bad gasoline.
6.Loose or disconnected spark plug
wire.
7.Bad spark plug.
8.Water in gasoline.
9.Overchoking.
10.Low oil level.
11.Excessive rich fuel mixture.
12.Intake valve stuck open or closed.
13.No compression.
1.Circuit breaker open.
2.Defective cord or poor connection.
3.Connected device is faulty.
4.Fault in generator.
See How to Spray Wand paragraph
in the Operation Section.
Clean filter.
Ensure end of chemical hose is fully
submerged into chemical. Dilute
chemical.
Chemical should be the same
consistency as water.
Lengthen water supply hose instead
of high pressure hose.
Have parts cleaned or replaced by
AWSC.
1.Reset circuit breaker.
2.Check and repair.
3.Connect a good condition device.
4.Contact your local service dealer.
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WIRING DIAGRAM
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PART LISTINGS
EXPLODED GENERATOR VIEW
-
NUMBER PART NUMBER DESCRIPTION QTY
1 GASOLINE ENGINE 1
2 50310-170-00 FRAME COMP 1
3 17612-168-00 STRIPE,FUEL TANK 1
4 94050-08000-00 NUT FLANGE M8 8
5 77320-168-00 BOTTOM RUBBER A 2
6 90203-06000-00 NUT M8 4
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EXPLODED GENERATOR VIEW CONTINUE
NUMBER PART NUMBER DESCRIPTION QTY
8 77330-168-00 BOTTOM RUBBER B 2
9 18383-168-00 SUPPORTING PLSTE 1
10 18382-168-00 MUFFLER STAY 1
11 90013-08016-00 BOLT,FLANGE 8X16 3
12 95701-06012-00 BOLT,FLANGE,6X12 6
13 18310-170-00 MUFFLER COMP 1
13-1 18311-168-00 SCREEN SPARK ARREST PULSE 1
14 94111-08000-00 WASHER,SPRING 8.5MM 2
15 94050-168-00 NUT 8MM 2
16 18381-168-00 GASKET,MUFFLER 1
17 18320-168-00 PROTR,OUT MUFFLER 1
18 17510-168-00 TANK COMP,FUEL(BLUE) 1
19 1762A-168-00 CAP COMP,FUEL FILLER 1
20 17640-168-00 FUEL SENSOR ASSY 1
21 16950-168-00 COCK ASSY.FUEL 1
22 95001-168-00-CARB TUBE,FUEL (CARB) 4.5×115 1
23 95002-168-00 CLIP,TUBE (B8) 2
24 31200-D32-00 MOTOR ASSY.,STARTING(3.25KW) 1
25 31130-D32-00 ROTOR,COMP 1
26 31150-170-00 STATOR COVER 1
27 31120-D32-00 STATOR COMP 1
28 31170-168-00 GENERATOR STAY 1
29 31160-168-00 BRUSH ASSY 1
30 30300-168-00 VOLTAGE REGULATOR 1
31 92101-08220-00 BOLT(ROTOR)8×220 1
32 95701-06165-00 BOLT FLANGE(STATOR) 6×165 4
33 94102-08000-00 WASHER,PLAIN(ROTOR) 8MM 1
33 94111-08000-00 WASHER,SPRING(ROTOR) 8MM 1
34 95701-05012-00 BOLT,FLANGE 5×12 8
35 31203-168-00 BRACKET,RR.,MOTOR(BLACK) 1
36 33100-168-00 CONTROL PANEL ASSY(BLACK) 1
37 95701-06012-00 BOLT,FLANGE,6X12 4
38 33120-168-00 CONTROL PANEL CASE 1
41 33150-L20-00 FOUR SOCKET ASSY (20A) 1
42 33140-G20-00 SHREE SOCKET ASSY (20A) 2
43 35150-168-00 SWITCH ASSY,STARTER KILL 1
44 90200-168-00 EARTH TERMINAL SET ASSY 1
45 34915-168-00 LOW OIL INDICATOR LEVEL 1
46 33110-168-00 CONTROL PANEL (BLACK) 1
47 28402-170-00 PANEL APPLIQUE 1
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