Honda Power Equipment TPG-2900H-DX, TPG-7000H-DXE User Manual

0 (0)

OPERATION, SERVICE, AND

REPAIR MANUAL

FOR TSURUMI TPG-SERIES PORTABLE GENERATORS

MODELS

TPG-2900H-DX

TPG-4300H-DX

TPG-6000H-DX

TPG-7000H-DXE

LIMITED WARRANTY

TSURUMI MANUFACTURING CO., LTD. (“TSURUMI”) warrants to the original end purchaser during the warranty period, every new TSURUMI generator or product to be free from defects in material and workmanship under normal use and service, when properly installed, used, and maintained (in accordance with Tsurumi’s Operation, Service, and Repair Manual) for a period of two years from the date the unit was first installed or twenty six months from the date of shipment by TSURUMI to wholesaler, whichever comes first.

TSURUMI’S sole obligation under this warranty is to repair or replace at TSURUMI’S option, with new or remanufactured parts, any part(s) that fail or that are found to be defective during the warranty period. No allowance will be made for shipping charges, damages, labor, or other charges due to failure, repair or replacement.

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.

TSURUMI assumes no responsibility for compliance with any regulations, codes, standards, or ordinances applicable to the installation, location, operation or maintenance of its products.

No other warranty, expressed or implied, is authorized by, or applicable to, the seller. No person, agent or dealer is authorized to enlarge upon this warranty.

TSURUMI expressly disclaims liability for consequential or incidental damages or breach of expressed or implied warranty; and any implied warrant of fitness for a particular purpose and merchantability shall be limited to the duration of the expressed warranty.

Some states do not allow limitations on the duration of an implied warranty, so the above limitation or exclusion may not apply to you. Some states do not allow the exclusion or limitation of incidental or consequential damages, so the above limitation of exclusion may not apply to you.

This warranty gives you specific legal rights and you may also have other rights, which vary from state to state.

Tsurumi Manufacturing Co., Ltd.

TABLE OF CONTENTS

 

Section/Title

 

Page

1.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1

 

A.

Precautions and Placards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2

 

B.

Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4

 

C.

Specifications/Key Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5

2.

Description and Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

 

A.

Physical Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6

 

B.

Functional Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

9

3.

Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

 

A.

Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

 

B.

DC Circuit Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

12

 

C.

Check the Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

15

 

D.

Check Engine Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

16

 

E.

Pre-Start Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

 

F.

Starting and Operating the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

17

 

G.

Using the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

 

H.

AC Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

18

 

I.

Stopping the Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

20

 

J.

Oil Alert . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

 

K.

Idle Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

 

L.

Stopping the Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

 

M.

Wattage Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

21

4.

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

23

 

A.

Changing Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

 

B.

Air Cleaner Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

24

 

C.

Sediment Cup Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

 

D.

Cleaning and Adjusting Spark Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

25

 

 

(Models TPG-4300H-DX, TPG-6000H-DX, TPG-7000H-DXE)

 

5.

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

 

A.

Isolating Fault to the Generator or to the Control Panel . . . . . . . . . . . . . . . . . .

27

 

B.

Measuring Insulation Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

27

 

C.

Electrical Limits Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

28

 

D.

Troubleshooting Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

29

 

E.

Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

35

6.

Removal/Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

39

 

A.

Replacement of Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

40

 

B.

Removal/Installation of Battery Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . .

41

 

C.

Replacement of Engine Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

42

 

 

(Models TPG-4300H-DX, TPG-6000H-DX, TPG-7000H-DXE)

 

 

D.

Replacement of Engine Muffler . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

43

 

 

(Model TPG-2900H-DX)

 

 

E.

Replacement of Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

45

 

F.

Removal/Installation of Engine and Generator as a Unit . . . . . . . . . . . . . . . . . .

47

 

G.

Replacement of Generator Stator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

51

 

H.

Replacement of Rotor Bearing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

52

 

I.

Replacement of Rotor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

53

 

J.

Replacement of Front Panel Components . . . . . . . . . . . . . . . . . . . . . . . . . . . .

57

7.

Storage Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

62

8.

Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63

 

A.

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63

 

B.

Ordering Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

63

Appendix A – Battery Enclosure Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

A-1

Appendix B – Wheel Kit Model PGWK-100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

B-1

Appendix C – Wheel Kit Model PGWK-200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

C-1

Tsurumi’s Operation, Service, and Repair Manual

1. INTRODUCTION

We thank you for purchasing a Tsurumi 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. Key features of the generator are shown in the DESCRIPTION

section.

TPG-2900H-DX

TPG-4300H-DX

TPG-6000H-DX

TPG-7000H-DXE

This manual provides instructions for operation, service, and repair of your generator. We strongly recommend that those who operate the generator become familiar with the generator’s features and controls, and read the operating instructions before using the generator.

The Operation, Repair, and Service Manual also provides instructions to service, checkout, and repair the generator. This manual also provides replacement parts information.

Repair and service information for the Honda engine is provided in the Owner’s Manual for Models GX160, GX240, GX340, and GX390. A copy of the Owner’s Manual has been provided in the generator’s literature package. Parts information for the Honda Engine is available in Honda’s Parts Catalogs.

When there are differences between generator models, separate instructions are provided. The separate instructions are provided to make sure the correct procedures are used on the affected generators.

All information in the Tsurumi manuals is based upon the latest production configuration of the generator at the time of approval for printing.

If you have a problem with your generator that cannot be resolved using the Operation, Repair, and Service Manual, or if you have questions about the operation, service, repair, or maintenance of your generator, contact your local Tsurumi generator dealer.

Page 1

Introduction

Tsurumi’s Operation, Service, and Repair Manual

A. PRECAUTIONS AND PLACARDS

Pay special attention to precautionary notes preceded by the words WARNING, CAUTION, and

NOTE.

WARNINGS indicate that there is a strong possibility of personal injury or loss of life if the procedure is not followed, or if cleaning, lubricating, adhesives, and other materials are not used properly.

CAUTIONS indicate that there is a possibility of equipment damage if instructions are not followed.

NOTES are used in procedures to provide additional or supplemental information to make the procedure easier or more efficient.

WARNING:

ïTHE GENERATOR IS DESIGNED TO GIVE SAFE AND DEPENDABLE SERVICE WHEN OPERATED ACCORDING TO THE INSTRUCTIONS IN THE TECHNICAL MANUAL PROVIDED WITH THE GENERATOR.

ïDO NOT OPERATE THE GENERATOR BEFORE YOU HAVE READ AND UNDERSTAND THE INSTRUCTIONS AND THE ENGINE MANUFACTURERíS MANUAL. FAILURE TO DO SO COULD RESULT IN PERSONAL INJURY OR EQUIPMENT DAMAGE.

Introduction

Page 2

Tsurumi’s Operation, Service, and Repair Manual

Placards, shown below, are provided on the portable generator to warn operating and maintenance personnel of potential hazards, to provide maintenance information, and to provide generator rating and capabilities. The large label below is located on the front panel of the portable generator. The label presents operational Warnings and Cautions for generator users.

 

TSURUMI A.C. GENERATOR

MODEL

DATA PLATE

OUTPUT

MAX

2900W

SER.NO.

 

RATED

2400W

 

 

VOLTAGE

 

 

 

120V

TSURUMI MANUFACTURING CO., LTD.

 

FREQUENCY

 

60Hz

OSAKA, JAPAN

 

 

 

 

FUEL WARNING PLACARD

CHECK FOR SPILLED FUEL OR FUEL LEAKS . STOP ENGINE BEFORE REFUELING .

CONTROLER QU ’ IL N ’ Y A NI FUITE NI ESSENCE REPANSUE SUR L ’ APPAREIL .

ARRETER LE MOTEUR AVANT DE REFAIRE LE PLEIN .

INSPECCIONAR PARA COMBUSTIBLE DERRAMADO O ESCAPE .

PARAR MOTOR ANTES DE ECHAR .

AIR CLEANER MAINTENANCE

HOT MUFFLER & EXHAUST PLACARD

HOT EXHAUST

ECHAPPEMENTCHAUD

 

WARNING

 

ATENCION

 

DO NOT USE INDOORS. EXHAUST

 

NO LO USE EN LUGARES CERRADOS

 

GAS CONTAINS POISONOUS

 

PORQUE EL MONOXIDE DE CARBONO

 

CARBON MONOXIDE.

 

ES VENENOSO

 

 

 

 

WARNING

USING THE GENERATOR IN RAIN, SNOW OR NEAR WATER CAN LEAD TO DEATH FROM ELECTRIC SHOCK. KEEP GENERATOR DRY.

WARNING

ELECTROCUTION OR PROPERTY DAMAGE CAN OCCUR. DO NOT CONNECT THIS GENERATOR TO ANY BUILDINGíS ELECTRICAL SYSTEM UNLESS AN ISOLATION SWITCH HAS BEEN INSTALLED BY A LICENSED ELECTRICIAN. READ OWNERíS MANUAL CAREFULLY.

CAUTION

NOT RESPONSIBLE WHEN EXCEEDING GENERATORS WATTAGE/AMPERAGE CAPACITY CAN DAMAGE GENERATOR AND/OR ELECTRICAL DEVICES CONNECTED TO IT.

ïSTART GENERATOR AND LET ENGINE STABILIZE BEFORE CONNECTING ELECTRICAL LOADS.

ïNO SENSITIVE EQUIPMENT LIKE COMPUTERS, STEREOS, TVS, OR ANY PRODUCTS THAT CONSUME CLEAN POWER. (CHECK MANUFACTURERíS PRODUCT MANUAL.)

Page 3

Introduction

Tsurumi’s Operation, Service, and Repair Manual

B. SAFETY PRECAUTIONS

WARNING:

IN ORDER TO ASSURE SAFE AND EFFICIENT OPERATION OF THE GENERATOR, OPERATORíS SHOULD READ AND COMPLY WITH THE FOLLOWING SAFETY PRECAUTIONS.

Do not operate the generator near gasoline or gaseous fuels because of the potential danger from explosion or fire. Do not fill the fuel tank with fuel while the engine is running. Do not smoke or use open flame near the fuel tank. Be careful not to spill fuel during refueling. If fuel is spilled, wipe it off and let it dry before starting the engine.

Do not place flammable materials near the generator. Be careful not to place fuel, matches, gunpowder, oily cloths, straw, trash, or any other combustibles near the generator.

Do not operate the generator inside a room, cave, tunnel, or other insufficiently ventilated area. Always operate the generator in a well-ventilated area. The engine may become overheated, and the poisonous carbon monoxide gas contained in the exhaust gases will endanger human lives.

Keep the generator at least 1 meter (3 feet) away from any structure or building during use.

When a generator is located close to a building or nearby equipment, heat and exhaust from the engine will cause the surrounding temperature to rise. This will degrade the engines cooling efficiency, causing overheating.

Do not enclose the generator nor cover it with a box. The generator has a built-in, forced-air cooling system, and may become overheated if it is enclosed.

Operate the generator on a level surface. It is not necessary to prepare a special foundation for the generator. However, the generator will vibrate on an irregular surface. Therefore, choose a level place without surface irregularities.

Shutoff the generator when moving the generator to another work site. It the generator is tilted or moved during operation, fuel may spill and/or the generator may tip over, causing a hazardous situation. Proper lubrication cannot be expected if the generator is operated on a steep incline or slope. In such a case, the piston may seize; it may seize even if the oil is above the upper level.

Do not operate in rain or with wet hands. The operator may suffer severe electric shock, if the generator is wet due to rain or snow. If wet, wipe dry well before starting. Do not pour water directly over the generator, nor wash it with water.

Do not connect the generator to a commercial power line. Connection to a commercial power line may result in short circuit and damage the generator. When connecting to domestic circuits, install only approved transfer switches and make sure power and control circuitry meet local electrical code requirements.

Do not smoke or use other smoking materials (pipes, cigars, etc.) while handling the battery. The battery emits flammable hydrogen gas, which can explode if exposed to electric arcing or open flame. Keep the work area well ventilated and keep the battery away from open flames/sparks.

Introduction

Page 4

Tsurumi’s Operation, Service, and Repair Manual

C. SPECIFICATIONS/KEY FEATURES

Honda Powered…proven reliability…quiet operation…efficient fuel consumption

Automatic Idle Control…reduces fuel consumption, noise, and engine wear (this feature is not available on Model TPG-2900H-DX).

Large, Silent Muffler (with USDA qualified spark arrestor) to significantly reduce noise. The spark arrestor is designed to screen out hot sparks.

Large Air Filter…for superior emission control.

Large Capacity Fuel Tank with Fuel Gauge…for extended run time.

Rubber Vibration Pads…isolates generator/engine vibration from the frame for maximum protection and noise reduction.

Ground Fault Circuit Interrupter (GFCI)…on 120V duplex receptacle protects operator from shock.

Full Power Switch…allows voltage selection; either full-rated output from 120V receptacle or halfrated output from 120V receptacle and full-rated output from 240V receptacles (this feature is not available on Model TPG-2900H-DX).

Circuit Breaker…protects generator from overload damage; can be reset with the flip of a switch (no fuse to replace).

100% Copper Windings…for long life.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Page 5

 

 

 

 

 

 

Introduction

Honda Power Equipment TPG-2900H-DX, TPG-7000H-DXE User Manual

Tsurumi’s Operation, Service, and Repair Manual

2. DESCRIPTION AND OPERATION

A.PHYSICAL DESCRIPTION

(1)Description of the Portable Generator

(a)The key features of the portable generator are shown in Figure 1. A cutaway view of the generator is provided in Figure 2.

Filler Cap

Fuel Gauge

Fuel Tank

Controls

Air Filter

Front Panel

Oil

Engine Filler

Plug

Vibration Mounts

Tubular Frame

Control Box

Generator

Muffler

Spark Arrestor

Figure 1: Key Features of Generator (Model TPG-7000H-DXE Shown)

Description and Operation

Page 6

Tsurumi’s Operation, Service, and Repair Manual

(b)The generator consists of a tubular frame onto which is installed the generator, engine, front panel, control box and fuel tank.

(c)The generator and engine are installed on crossover plates that form the base of the tubular frame. Vibration isolators support the generator and engine unit. The isolators are fitted with threaded studs that secure the generator and engine unit to the frame.

(2)Description of Generator

(a)The generator consists of a rear cover, stator cover, stator, rotor, and front cover.

(b)The front cover of the generator attaches to the engine and forms the generator-to- engine interface.

(c)The front cover has a series of slots that allow entry of cooling air into the generator. A fan on the rotor circulates air through the generator.

(d)The rear cover has mounting lugs that are the generator-to-frame attachment points. The rear cover supports a ball bearing at the back end of the generator rotor.

(e)The rear cover has a removable access plate to provide access to the stator wiring (an access plate is not used on Model TPG-2900H-DX.)

(f)The rotor consists of a shaft, a stack of steel laminations, and copper wire windings. Components mounted on the rotor include a diode, a surge absorber, two permanent magnets, and a cooling air fan.

(g)The windings and the laminated steel core form the field coil. The permanent magnets are used to induce voltage in the main coil of the stator. The diode and the surge absorber are located under the rotor windings at the bearing end of the rotor shaft.

(h)The rotor is attached to the engine crankshaft with a through bolt (tie-bolt). The engine crankshaft is tapered and mates with a tapered bore in the rotor shaft. The clamping force applied to the through bolt ties the rotor shaft to the engine crankshaft.

 

 

Cooling Fan

Tie-Bolts (3)

Rotor

Stator

 

Generator-To-Engine-Bolts

Tapered Shaft

Vibration Mounts Ball Bearing

Through-Bolt

Figure 2: Cutaway of Generator (Model TPG-2900H-DX Shown)

Page 7

Description and Operation

Tsurumi’s Operation, Service, and Repair Manual

(3)Description of the Engine

NOTE:

Refer to the Honda engine Owner’s Manual for Models GX160, GX240, GX340, and GX390 for additional coverage of the engine.

(a)The TPG-7000H-DXE generator has an electric starter and a recoil starter. All other generators are equipped with a recoil starter.

(b)The engine is equipped with an air filter to remove airborne contaminants from the engine inlet air.

(c)The engine is fitted with a muffler that provides quiet operation and controls the flow of engine exhaust gases. The muffler is attached to the rear generator cover using a mounting bracket.

(d)The muffler for Models TPG-4300H-DX, TPG-6000H-DX, and TPG-7000-DX expels exhaust gases through a port in the side of the muffler. The muffler for Model TPG- 2900H-DX has a smaller muffler that expels gases through a curved tube on the bottom of the muffler.

(e)The muffler is fitted with a spark arrestor to screen-out sparks ejected in the exhaust gases. The spark arrestor for Models TPG-4300H-DX, TPG-6000H-DX, and TPG- 7000-DX is installed in the exhaust port of the muffler. The spark arrestor for Model TPG-2900H-DX is installed in the inlet side of the muffler.

(f)The engine has an oil filler plug that is used to check engine oil level. Engine oil is added through the same filler plug port. The engine oil drain plug is installed in the engine casing adjacent to the oil filler plug.

(g)The engine has a carburetor choke control for starting the engine during cold weather operation. (Models TPG-4300H-DX, TPG-6000H-DX, and TPG-7000H-DXE have a ring-type choke control; Model TPG-2900H-DX has a choke lever.)

(4)Description of the Fuel Tank

(a)The fuel tank is attached to one side of the frame by two cushioned mounts. The tank is supported on the opposite side by cushioned pads that fit into a channel on the backside of the front panel.

(b)A screen is provided under the filler cap to prevent entry of large contaminants.

(c)The tank has a fuel shutoff valve that is used to prevent fuel spillage when the generator is not in use. The fuel shutoff valve is used to drain fuel from the tank if needed for replacement of generator components. The fuel shutoff valve should be closed during transport to prevent fuel spillage.

(d)The fuel shutoff valve has a sediment bowl to capture heavier contaminants that may have passed through the fuel tank filler screen.

(5)Description of the Front Panel

NOTE:

Refer to Figure 7 through Figure 10 for illustrations of the generator front panels. Familiarize yourself with the layout of the front panel for your generator before operating the generator.

(a)The operating controls, switches, lights, electrical receptacles, and circuit breakers for the generator are mounted on the front panel.

(b)A control box is mounted on the back of the front panel. The control box contains the idle control unit, diode, condensers, and dc reset pushbutton switch (refer to Figure 11).

Description and Operation

Page 8

Tsurumi’s Operation, Service, and Repair Manual

(c)The engine, starter, and control wiring exits through a hole in the side of the control box. The diode and fuse that are part of the DC circuit are located inside the control box.

(d)The generator leads and control wiring are connected inside the control box. A flexible rubber sleeve provides protection for the generator wiring.

B.FUNCTIONAL DESCRIPTION

(1)Generation of No-Load Voltage (refer to Figure 3)

(a)When the generator rotor begins to rotate, the permanent magnet in the rotor generates 3 to 6 volts alternating current in the main coil and in the condenser coil windings.

(b)The low voltage generated in the condenser coil also generates minute current flow (a) through the condenser coil. At the same time, low-level magnetic flux intensifies at the rotor’s magnetic pole. As the magnetic force intensifies, voltage increases in the main coil and in the condenser coil. As current (a) increases, magnetic flux also increases at the rotor’s magnetic pole, and continues to increase as generator speed increases.

(c)As AC current flows through the condenser coil, the density of the magnetic flux in the rotor changes. The change in magnetic flux density induces AC voltage in the field coil, and the diode rectifier in the field coil circuit rectifies the AC voltage into DC voltage. The resultant DC current flows (b) through the field coil and magnetizes the rotor core to generate output voltage in the main coil.

(d)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.

(2)Voltage Fluctuations Under Load (refer to Figure 3)

(a)When output current (c) flows through the main coil to the appliance being used, a magnetic flux is produced and serves to increase current (a) in the condenser coil. As a result, the current flowing in the field coil increases and the generator output voltage is prevented from decreasing.

Stator

Main coil

Permanent magnet for initial excitation

Appliance

Surge absorber

Receptacle

Field coil

Diode

Main coil

Condenser coil

Condenser

Figure 3: Generation of No-Load Voltage

Page 9

Description and Operation

Tsurumi’s Operation, Service, and Repair Manual

(3)Full Power Switch (Dual Voltage Type) (refer to Figure 4)

(a)The full power switch provides both 120V and 240V dual voltages at full rated power. The full rated power will be available from one 120V receptacle and one 240V receptacle.

(b)Two main coils are wound over core of the stator. Each main coil outputs half the rated power at the lower voltage (110V or 120V). These main coils are wound so they are in the same phase. The full power switch reconnects these main coils in parallel or in series.

(c)Refer to the circuit diagram in Figure 4. When the full power switch is set for single lower voltage indication (110V or 120V), the switch position will be as indicated by the lower coils line in the diagram.

 

120V/240V (or 110V/220V)

 

Rec. 1

 

MC1

120V

 

(or 110V)

240V (or 220V)

 

120V

 

 

(or 110V)

 

 

 

Rec. 3

 

Rec. 2

 

MC2

 

 

 

120V (or 110V)

Figure 4: Full Power Switch Circuit Diagram

(d)Refer to Figure 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. Rec. 2 for the lower voltage is available up to the rated power (up to 30A if the rated current is over 30A), and Rec. 1 is available up to 15A. When the full power switch is set for double voltage indication (110V/220V or 120V/240V), the switch position is indicated by the upper dotted line in Figure 8.

(e)Refer to Figure 6 for a simplified diagram of the circuit. The two main coils are shown connected in series. In this example, power is simultaneously available from the receptacles for both voltages. Higher voltage receptacle, Rec. 3, has power available up to rated power, however, Rec. 1 and Rec. 2 for the lower voltage can output only up to the rated power of each receptacle.

(f)Table 1 summarizes in tabular form the power available, or not available, depending upon the position of the full power switch.

Description and Operation

Page 10

Tsurumi’s Operation, Service, and Repair Manual

MC1

 

Rec. 2

120V

120V (or 110V)

(or 110V)

MC2

Figure 5: Full Power Switch Set for Single-Voltage Output

 

Rec. 1

MC1

120V

(110V)

 

Rec. 3

240V

(220V)

Rec. 2

MC2

Figure 6: Full Power Switch Set for Dual-Voltage Output

Table 1: Full Power Switch ñ Switch Setting Versus Output Available

Switch

Lower Voltage

Higher Voltage

Position

Receptacle

Receptacles

 

 

 

110V

Rated

No Output

or 120V

Output

Can Be Taken

 

 

 

110V /120V

Half of Rated

Rated

or 120V / 240V

Output

Output

 

 

 

Page 11

Description and Operation

Tsurumi’s Operation, Service, and Repair Manual

3. OPERATING INSTRUCTIONS

A.OPERATING CONTROLS

(1)The main operating controls for the generator are, with a few exceptions, mounted on the front panel of the generator.

(2)The controls consist of an ENGINE switch, an IDLE switch, a FULL POWER switch, a PILOT light, circuit BREAKER(s), a ground (or earth) post, and electrical receptacles. The specific controls used in each model are shown in Figures 7 through 10.

(3)The Model TPG-7000H-DXE generator is equipped with a electric starter motor. The ENGINE switch in this model is a key-operated, STOP/RUN/START switch. The springloaded switch is turned to the right to start the engine, and to the left to shut off the engine.

(4)The IDLE switch allows the generator speed to drop to idle speed if there is no electrical load demand on the generator. When an electrical load is sensed, the idle control increases the speed of the generator up to operating speed level. When there is no load, the engine speed returns to idle.

(5)The FULL POWER switch allows the generator to provide full rated power for the loading appliances and/or tools. When the FULL POWER switch is set to on, power will be provided to only one 120 Vac receptacle and one 240 Vac receptacle.

(6)The PILOT light provides an indication to the operator that the generator is generating electricity.

(7)Circuit breakers are provided to protect the generator in the event of a short circuit. The breakers will trip when the circuit load exceeds the breaker’s rated value.

(8)The ground post is used to provide a positive ground for the generator. The post has a wing-nut to quickly connect a ground wire to the generator.

(9)There are three types of receptacles: one 120 Vac, GFI-protected receptacles (two on most models), one twist-type, 120 Vac receptacle, and one 120 Vac / 240 Vac, combination receptacle.

B.DC CIRCUIT CONTROLS

(1)The circuitry for DC circuit consists of a 10 Amp fuse, an overload protector, and a re-set switch.

(2)In the event of an overload, the overload protector will trip the reset switch (refer to Figure 11).

Operating Instructions

Page 12

Tsurumi’s Operation, Service, and Repair Manual

TSURUMI MANUFACTURING CO., LTD. MADE IN JAPAN

1

2

3

4

 

ENGINE

PILOT

BREAKER

TSURUMI

RUN

 

 

MANUFACTURING CO.,LTD.

 

 

9

 

 

ON

STOP

 

 

 

 

OFF

5

AC 120V

LEGEND

1

120 Vac Receptacle

4

18 Amp Circuit Breaker

2

Engine Switch

5

Ground Post

3

Pilot Light

 

 

Figure 7: Model TPG-2900H-DX

TSURUMI MANUFACTURING CO., LTD. MADE IN JAPAN

1

2

3

 

4

5

ENGINE

IDLE

PILOT

FULL

 

BREAKER

RUN

ON

 

120

 

 

 

 

 

 

TSURUMI

 

 

 

 

 

MANUFACTURING CO., LTD.

 

 

 

 

 

 

 

 

 

 

ON

STOP

OFF

 

 

 

OFF

4 3

 

 

 

 

 

 

120

 

 

 

 

 

240

 

 

MAX20

MAX20

 

 

 

 

AC 120V

 

AC120V/240V

 

 

9

8

7

6

LEGEND

1

Engine Switch

6

Ground Post

2

Idle Switch

7

Receptacle 120Vac / 240Vac

3

Pilot Light

8

Receptacle 120Vac

4

Full Power Switch

9

Receptacle 120Vac, GFI (2)

5

14 Amp Circuit Breaker

 

 

Figure 8: Model TPG-4300H-DX

Page 13

Operating Instructions

TSURUMI MANUFACTURING CO., LTD. MADE IN JAPAN

Tsurumi’s Operation, Service, and Repair Manual

1

2

3

4

5

6

ENGINE

IDLE

PILOT

FULL

 

BREAKER

RU

O

 

120

 

 

 

 

 

 

TSURUMI

 

 

 

 

 

MANUFACTURING CO., LTD.

 

 

 

 

 

 

 

 

 

O

O

STO

OF

 

 

OF

OF

6

 

 

 

 

 

120

 

 

 

 

 

240

 

 

MAX20

MAX20

 

 

AC 120V

AC120V/240V

10 9 8 7

LEGEND

1

Engine Switch

6

20 Amp Circuit Breaker

2

Idle Switch

7

Ground Post

3

Pilot Light

8

Receptacle 120Vac / 240Vac

4

Full Power Switch

9

Receptacle 120Vac

5

30 Amp Circuit Breaker

10

Receptacle 120Vac, GFI (2)

Figure 9: Model TPG-6000H-DX

1

2

3

4

5

6

TSURUMI MANUFACTURING CO., LTD. MADE IN JAPAN

 

ENGINE

IDLE

PILOT

FULL

BREAKER

 

 

ON

 

120

 

 

 

 

 

 

TSURUMI

 

 

 

 

 

MANUFACTURING CO., LTD.

 

 

 

 

 

 

 

 

 

ON

ON

 

 

OFF

 

OFF

OFF

7

E

 

 

 

 

120

 

 

 

 

 

240

 

MAX20

MAX20

 

 

 

 

AC 120V

 

AC120V/240V

 

 

10

9

8

7

LEGEND

1

Engine Switch

6

22 Amp Circuit Breaker

2

Idle Switch

7

Ground Post

3

Pilot Light

8

Receptacle 120Vac / 240Vac

4

Full Power Switch

9

Receptacle 120Vac

5.

30 Amp Circuit Breaker

10

Receptacle 120Vac, GFI (2)

Figure 10: Model TPG-7000H-DX

Operating Instructions

Page 14

Tsurumi’s Operation, Service, and Repair Manual

Fuel Tank

Reset Button

TO FRAME

Control Box

Figure 11: DC Circuit Reset Pushbutton

C. CHECK THE ENGINE OIL LEVEL

CAUTION:

ïEngine oil is a major factor affecting performance and service life. Non-detergent oils and 2-stroke oils are not recommended because they have inadequate lubricating characteristics

ïCheck the oil level with the engine on a level surface and the engine stopped.

(1)Use Honda 4-stroke oil, or use an equivalent high detergent, premium quality motor oil certified to meet or exceed U.S. automobile manufacturer’s requirements for Service Classification SG, SF. Motor oils classified SG, SF will show this designation on the container.

(2)SAE 10W/30 is recommended for general, all-temperature use.

(3)Other viscosity grades shown in Figure 12 may be used when the average temperature in your area is within the indicated range.

Figure 12: Oil Viscosity Grade-to-Temperature Recommendations

Page 15

Operating Instructions

Tsurumi’s Operation, Service, and Repair Manual

When checking oil, observe the following (refer to Figure 13):

(1)Make sure the engine is in a level position.

(2)Remove the oil filler cap/dipstick and wipe it clean.

(3)Insert the filler cap/dipstick into the oil filler neck, but do not screw it in.

(4)Remove the filler cap/dipstick and check the oil level.

(5)If the level is low, fill to the top of the oil filler neck with the recommended oil.

(6)Reinstall the oil filler cap/dipstick.

Figure 13: Checking Oil Level

D. CHECK ENGINE FUEL

WARNING:

ïMAKE SURE YOU REVIEW EACH WARNING IN ORDER TO PREVENT FIRE HAZARD.

ïDO NOT REFILL TANK WHILE ENGINE IS RUNNING OR HOT.

ïCLOSE FUEL SHUT OFF VALVE BEFORE REFUELING WITH FUEL.

ïBE CAREFUL NOT TO GET DUST, DIRT, WATER OR OTHER FOREIGN OBJECTS INTO FUEL.

ïWIPE OFF SPILLED FUEL THOROUGHLY BEFORE STARTING ENGINE.

ïKEEP AWAY FROM OPEN FLAMES.

ïDO NOT USE SMOKING MATERIALS WHEN FILLING THE FUEL TANK.

ïDO NOT REFUEL WHILE SMOKING OR NEAR OPEN FLAME OR OTHER SUCH POTENTIAL FIRE HAZARDS. OTHERWISE FIRE ACCIDENT MAY OCCUR.

ïAVOID REPEATED OR PROLONGED CONTACT WITH SKIN OR BREATHING OF VAPOR.

ïKEEP OUT OF REACH OF CHILDREN.

(1)Check fuel level at fuel level gauge (refer to Figure 14).

(2)If fuel level is low, refill with unleaded automotive gasoline.

(3) Fuel tank capacity TPG-2900H-DX

(2.9 gal.)

TPG-4300H-DX

(4.5 gal.)

TPG-6000H-DX

(4.5 gal.)

TPG-7000H-DXE

(4.5 gal.)

Operating Instructions

Page 16

Tsurumi’s Operation, Service, and Repair Manual

Figure 14: Fuel Gauge Indications

E. PRE-START CHECKS

WARNING:

ïMAKE SURE YOU REVIEW EACH WARNING IN ORDER TO PREVENT FIRE HAZARD.

ïKEEP AREA CLEAR OF FLAMMABLES OR OTHER HAZARDOUS MATERIALS.

(1)Check the following items before starting the engine.

(a)Fuel leakage from fuel hose, etc.

(b)Bolts and nuts for looseness.

(c)Components for damage or breakage.

(2)Check generator surroundings.

(a)Keep generator at least 3 feet (1 meter) away from buildings or other structures.

(b)Only operate generator in a dry, well-ventilated area.

(c)Keep exhaust pipe clear of foreign objects.

(d)Keep generator away from open flame.

(e)Keep generator on a stable and level surface.

(f)Do not block generator air vents with paper or other material.

F.STARTING & OPERATING THE ENGINE

(1)Before starting the engine, set AC circuit breakers to OFF.

(2)Refer to the Honda engine owner’s manual.

(a)Turn the fuel valve to the ON position.

(b)Move the choke lever to the CLOSE position.

Page 17

Operating Instructions

Tsurumi’s Operation, Service, and Repair Manual

NOTE:

The choke may not be needed if the engine is warm or the air temperature is high.

(3)Move the throttle lever slightly to the left.

(4)(MODEL TPG-7000H-DXE ONLY): To start the engine using the electric starter, proceed as follows:

(a)Turn key in engine START/STOP switch.

(b)Turn key fully right to START position. Hold in START position until engine starts.

(c)Release key; the key is spring-loaded to the RUN position.

(d)As the engine warms up, gradually move the choke lever to the OPEN position.

(e)Position the throttle lever at the desired engine speed.

(5)(ALL MODELS): When starting the engine using recoil starter, proceed as follows:

(a)Turn the engine switch to the ON position.

(b)Pull the starter grip lightly until resistance is felt, then pull briskly.

NOTE:

When using the recoil starter, do not allow the starter grip to snap back against the engine. Return it gently to prevent damage to the starter.

(c)As the engine warms up, gradually move the choke lever to the OPEN position.

(d)Position the throttle lever at the desired engine speed.

G. USING THE GENERATOR

WARNING:

ïTO PREVENT ELECTRICAL SHOCK FROM FAULTY APPLIANCES, THE GENERATOR SHOULD BE GROUNDED. CONNECT A LENGTH OF HEAVY WIRE BETWEEN THE GENERATORíS GROUND TERMINAL AND EXTERNAL GROUND SOURCE.

ïCONNECTIONS FOR STANDBY POWER TO A BUILDINGíS ELECTRICAL SYSTEM MUST BE MADE BY A QUALIFIED ELECTRICIAN AND MUST COMPLY WITH ALL APPLICABLE LAWS AND ELECTRICAL CODES. IMPROPER CONNECTIONS CAN ALLOW ELECTRICAL CURRENT FROM THE GENERATOR TO BACK-FEED INTO THE UTILITY LINES. SUCH BACKFEED MAY ELECTROCUTE UTILITY COMPANY WORKERS OR OTHERS WHO CONTACT THE LINES DURING A POWER OUTAGE, AND WHEN UTILITY POWER IS RESTORED, THE GENERATOR MAY EXPLODE, BURN, OR CAUSE FIRES IN THE BUILDINGíS ELECTRICAL SYSTEM.

H.AC APPLICATION

ASingle Voltage Type

(1)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.

(2)Set switches on the electrical appliances to OFF before connecting to the generator.

(3)Insert the plug of the electrical appliance into the appropriate receptacle.

Operating Instructions

Page 18

Tsurumi’s Operation, Service, and Repair Manual

NOTE:

Check the amperage of the receptacles used referring to Table 2, and be sure not to take a current exceeding the specified amperage.

Be sure that the total wattage of all appliances does not exceed the rated output of the generator.

WARNING:

ïTO CONNECT AND LOCK A PLUG IN A TWIST LOCK RECEPTACLE, INSERT THE PLUG INTO RECEPTACLE AND TURN CLOCKWISE.

ïBE SURE TO GROUND THE GENERATOR IF THE CONNECTED ELECTRICAL EQUIPMENT IS GROUNDED.

NOTE:

When the circuit breaker trips off during operation, the generator is overloaded or the appliance is defective.

When the circuit breaker trips, stop the generator immediately. Check the appliance and/or generator for an overload or defect and repair as necessary.

CAUTION:

ïThe 120V duplex receptacle is protected by a GFCI (Ground Fault Circuit Interrupter). The GFCI shuts off the output current from the 120V duplex receptacle when a ground fault occurs in the generator or the appliance.

ïPlease note that other receptacles are not protected by a GFCI.

BDual Voltage Type

(1)Select the voltage using the FULL POWER switch in accordance with the electrical appliance. Refer to Table 3.

(2)Operate the generator in the same way as step (a) through step (c) of single voltage type.

Page 19

Operating Instructions

Tsurumi’s Operation, Service, and Repair Manual

Table 3

Available Receptacles With Full Power Switch On

Switch Setting

Lower Voltage Receptacle

Higher Voltage Receptacle

 

 

 

 

 

120V

Rated Output is Available

Unavailable

 

 

 

 

 

120V/240V

Half of Rate Output is Available

Rated Output is Available

 

 

 

 

 

WARNING:

ïTO TAKE OUT POWER FROM TWIST LOCK RECEPTACLE, INSERT THE PLUG INTO RECEPTACLE AND TURN CLOCKWISE TO LOCK IT.

ïBE SURE TO GROUND THE GENERATOR IF THE CONNECTED ELECTRICAL EQUIPMENT IS GROUNDED.

NOTE:

When the circuit breaker turns off during operation, the generator is overloaded or the appliance is defective.

Stop the generator immediately, check the appliance and/or generator for overloading or defect and repair as necessary.

I.STOPPING THE GENERATOR

(1)Set the power switch to OFF or unplug the cord from the receptacle.

(2)Move the throttle lever fully to the right.

(3)Turn the engine switch to the OFF position.

(4)Turn the fuel valve to the OFF position.

Figure 15: Fuel Valve

Operating Instructions

Page 20

Tsurumi’s Operation, Service, and Repair Manual

J.OIL ALERT

(1)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.

(2)When the engine has stopped automatically, check the oil level. Refill engine oil to the upper level and restart the engine.

(3)If the engine does not start by usual starting procedures, check the oil level.

K.IDLE CONTROL (TPG-4300H-DX, TPG-6000H-DX, AND TPG-7000H-DXE)

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.

The idle control feature provides fuel economy and low noise operation at no-load running.

(1)How To Use Idle Control

(a)Start the engine with IDLE switch set to OFF.

NOTE:

Warm up the engine without a load for a few minutes.

(b)Set IDLE switch to the ON position.

(2)Checking Idle Function

(a)When the idle function does not operate normally, please check the following:

NOTE:

Most induction loads, such as an electric motor, require wattage three to five times larger than their rating at starting. This starting wattage should not exceed the rated output of the generator.

(b)Is the generator overloaded? Make sure that the generator is not overloaded.

(c)Turn the IDLE switch off when the idle control does not work normally under the rated output.

L. STOPPING THE ENGINE

(1) Turn off the switch of load or disconnect the load.

(2) Turn the IDLE switch off.

(3) Push ENGINE to stop.

NOTE:

• Allow the engine about 3 minutes to cool down at no-load before stopping.

M. 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 4 for appliances you may use with this generator.

Electrical appliances and tools normally come with a label indicating voltage, cycles/Hz, amperage (amps) and electrical power needed to run the appliance or tool. Check with your nearest dealer with questions regarding power surge of certain appliances or power tools.

Page 21

Operating Instructions

Tsurumi’s Operation, Service, and Repair Manual

Electrical loads such as incandescent lamps and hot plates require the same wattage to start as needed to maintain use.

Loads such as fluorescent and mercury lamps require 1.2 to 2 times the indicated wattage to start. Electric motors require a large starting current. Power requirements depend on the type of motor and its use. Once enough “surge” is attained to start the motor, the appliance will require only 50% to 30% of the wattage to continue running.

CAUTION:

ï Check motor starting current and power factor carefully.

Most electrical tools require 1.2 to 3 times their wattage for running. For example, the 5,000 watts generated could power an 1800-watt to a 4000-watt electric drill.

Loads such as submersible pumps and air compressors require a very large force to start. They need 3 to 5 times the wattage needed to maintain the tool in order to start. For example, a 5,000 watt generator would only be able to drive a 1,000 watt to 1,700 watt pump.

NOTE:

The wattage chart (Table 4) is a guide only. Refer to your specific appliance for correct wattage.

To determine the total wattage required for operating a particular electrical appliance or tool, multiply the wattage figure of the appliance/tool by the tool’s amperage (amps). The voltage and amperage (amps) information can usually be found on a data plate or label, which is normally attached to electric appliances and tools.

Table 4

Wattage Chart

 

 

Applicable Wattage (w)

 

 

 

 

 

 

Applicable Wattage (W)

TPG-2900H-DX

TPG-4300H-DX

TPG-6000H-DX

TPG-7000H-DXE

 

 

 

 

 

60 Hz

60 Hz

60 Hz

60 Hz

 

 

 

 

 

Incandescent Lamp, Heater

2000

3300

4500

5300

 

 

 

 

 

Fluorescent Lamp, Mercury Lamp

1200

1900

2800

3100

 

 

 

 

 

Electric Tool

1200

1900

2800

3100

 

 

 

 

 

Pump, Compressor

500

700

1000

1500

 

 

 

 

 

Operating Instructions

Page 22

Tsurumi’s Operation, Service, and Repair Manual

4. MAINTENANCE

To maintain the generator in peak operating condition, observe and implement the maintenance and adjustment schedule in Table 5. Inspect and/or service the generator as scheduled in Table 5.

WARNING:

SHUT OFF THE ENGINE BEFORE PERFORMING ANY MAINTENANCE. IF OPERATION OF THE ENGINE IS REQUIRED, MAKE SURE THE AREA IS WELL VENTILATED; THE ENGINE EXHAUST CONTAINS POISONOUS CARBON MONOXIDE GAS.

CAUTION:

ï Refer to the Honda engine ownerís manual for other maintenance requirements.

An initial oil change should be performed after the first twenty (20) hours of use. Thereafter, change oil every 100 hours.

Before changing the oil, check for a suitable way to dispose of the used oil. Do not pour it down sewer drains, onto garden soil or into open streams. Refer to your local zoning and environmental regulations for disposal and handling requirements.

 

 

Table 5: Maintenance Schedule

 

 

 

Daily

Check oil level.

 

Check all components according to the PRE-OPERATIONAL CHECKS section.

 

 

 

50 Hours

Wash cleaner element.

 

Check spark plug and clean if necessary.

 

 

 

100 Hours

Change engine oil.

 

 

 

200 Hours

Adjust spark plug gap.

 

Clean fuel strainer.

 

 

 

500 Hours

Replace spark plug and cleaner element.

(12 Months)

Clean and adjust carburetor, valve clearance, and valve seat along with

 

 

 

cylinder head.

 

 

 

1,000 Hours

Inspect control panel parts.

(24 Months)

Check rotor and stator.

 

 

Replace engine mount rubber.

 

Overhaul engine.

 

Change fuel lines.

Page 23

Maintenance

Tsurumi’s Operation, Service, and Repair Manual

A.CHANGING ENGINE OIL

(1)Drain the oil while the engine is still warm to assure rapid and complete draining.

(2)Remove the oil filler dipstick/cap and drain plug.

(3)Allow oil to drain from the engine (Figure 16).

Figure 16: Draining Engine Oil

(4)Install the drain plug, and tighten it securely.

(5)Refill with the recommended oil (Figure 12). Check the oil level. Install the oil filler dipstick/cap (Figure 17).

NOTE:

• Engine oil capacity: 1.1 liters (1.16 U.S. Quart)

Figure 17: Checking Oil Level

B. AIR CLEANER SERVICE

WARNING:

ïNEVER USE GASOLINE OR LOW FLASH POINT SOLVENTS FOR CLEANING THE AIR CLEANER ELEMENT. A FIRE OR EXPLOSION COULD RESULT.

(1)A dirty air cleaner will restrict airflow to the carburetor. To prevent carburetor malfunction, service the air cleaner regularly. Service more frequently when operating the engine in extremely dusty areas.

NOTE:

Never run the engine without the air cleaner. Rapid engine wear will result from contaminants, such as dust and dirt, being drawn through the carburetor, into the engine.

Maintenance

Page 24

Tsurumi’s Operation, Service, and Repair Manual

C. SEDIMENT CUP CLEANING

WARNING:

ïGASOLINE IS EXTREMELY FLAMMABLE AND IS EXPLOSIVE UNDER CERTAIN CONDITIONS. DO NOT SMOKE OR ALLOW FLAMES OR SPARKS IN THE AREA.

ïAFTER INSTALLING THE SEDIMENT CUP, CHECK FOR LEAKS, AND MAKE SURE THE AREA IS FREE OF RESIDUAL FUEL SPILLS OR SEEPAGE BEFORE STARTING THE ENGINE.

(1)Turn the fuel valve to OFF.

(2)Remove (turn clockwise) the sediment cup and O-ring. Wash both parts in nonflammable or high flash point solvent.

(3)Wipe the sediment cup and O-ring dry, then reinstall.

(4)Set the fuel shutoff valve (Figure 18) to ON. Check for leaks.

H-13

H-2

Figure 18: Fuel Shutoff Valve

D. 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.

(1)Remove the spark plug cap.

(2)Clean any dirt from around the spark plug base.

(3)Use the proper size spark plug wrench to remove the spark plug.

WARNING:

THE MUFFLER BECOMES VERY HOT DURING OPERATION AND REMAINS HOT FOR A WHILE AFTER STOPPING THE ENGINE. BE CAREFUL NOT TO TOUCH THE MUFFLER WHILE IT IS HOT.

Page 25

Maintenance

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