Tsurumi Pump TPG-3000HM User manual

Service manual
Portable generator
TPG-3000HM TPG-6000HM
TPG-6000HEL TPG-7000HM TPG-7000HEL
SANDE S.A. - PRODUCTOS INDUSTRIALES

Table of contents
1. The control method of a generator 1
2. Table of specifications 2
3. Outline view 3
4. Generator winding resistance 7
5. Troubleshooting 9
6. Disassembly and an assembly 15
7. Maintenance 20
8. Wiring diagram 25
SANDE S.A. - PRODUCTOS INDUSTRIALES

- 1 -
Magnetism with the magnet of a rotor 
(For voltage establishment)
It is work of AVR connected to supplement winding, and is a brush.
Direct-current electricity controlled by
the field winding through the collector ring is sent
AVR controls an AVR output to .
detect output winding voltage
and to become stipulated voltage
Output winding voltage establishment
A rotor iron core is magnetized
powerfully
Voltage occurs in auxiliary
winding.
The voltage of output winding
rises.
(Rated voltage)
Load current flows into output winding.
The magnetism of a rotor increases
The power surge of output winding
As for output voltage, change of load hardly changes, either. 
AVR makes the current of a field winding
increase through a brush and a collector
ring, when output voltage falls.
Sag of output
1. The control method of a generator
ａ）Self-excitation action
If a dynamo is driven and it becomes with an engine more than specified speed, as shown in the following
figure, a self-excitation action will work, and it will generate.
b）Voltage compensation action
Although the voltage of regulation to output winding occurred by the self-excitation action of the preceding
clause, if external load is connected to this, as shown in the following figure, a voltage compensation action
will work, and it will prevent the fall of output voltage.
SANDE S.A. - PRODUCTOS INDUSTRIALES

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2. Table of specifications
MODEL
TPG-3000HM
TPG-6000HM
(HEL)
TPG-7000HM
(HEL)
ALTERNATOR
AC Voltage
50Hz
220V
60Hz
110/220V
Max.Output
50Hz
2.2kVA
4.8kVA
5.5kVA
60Hz
2.8kVA
5.5kVA
7.2kVA
Rated Output
50Hz
2.0kVA
4.0kVA
5.0kVA
60Hz
2.4kVA
4.5kVA
6.1kVA
DC Output
12V - 8.3A
Voltage Regulator
AVR Type
Rated Power Factor
1.0cosφ
ENGINE
Model
GX160
GX340
GX390
Type
Air-Cooled , 4-Cycle , OHV Gasoline Engine
Displacement
163cm2(9.95cu.in.)
337cm2(20.58cu.in.)
389cm2(23.75cu.in.)
Rated Output
3000rpm
2.6kW(3.5HP)
5.3kW(7.2HP)
6.1kW(8.3HP)
3600rpm
2.9kW(4.0HP)
5.9kW(8.0HP)
6.7kW(9.0HP)
Ignition System
Transister (C.D.I.)
Fuel Tank Capacity
16ℓ (4.22USG)
25ℓ (6.60USG)
Continuous
Operating
Hours (Rated)
3000rpm
14.1Hr
10.1Hr
9.0Hr
3600rpm
12.1Hr
8.5Hr
7.6Hr
Starting System
Recoil Starter
Recoil Starter(Option;Electric Starter)
Dimensions (L × W × H)
600.8 × 420.0 × 500.8 mm
691.2 × 540.4 × 515.0 mm
(23.7 × 16.6 × 19.8 in)
(27.3 × 21.3 × 20.3 in)
Dry Weight
45.8kgs (99.5lbs)
78.2kgs (170.7lbs)
82.0kgs (178.1lbs)
(81.2kgs (176.3lbs))
(85.0kgs (184.6lbs))
SANDE S.A. - PRODUCTOS INDUSTRIALES

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3. Outline view
OIL DRAIN PLUG
AIR CLEANER
FUEL TANK CAP
RECOIL STARTER GRIP
FUEL VALVE
FUEL METER
MUFFLER
SPARK PLUG CAP
CHOKE ROD
SANDE S.A. - PRODUCTOS INDUSTRIALES

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Control panel
TPG-3000HM 220V 50Hz
TPG-6000～7000HM , TPG-6000～7000HEL 220V 50Hz
CIRCUIT BREAKER
GROUND TERMINAL
PILOT LAMP
AC RECEPTACLE
ENGINE SWITCH
DC RECEPTACLE
VOLTMETER
CIRCUIT BREAKER
GROUND TERMINAL
PILOT LAMP
AC RECEPTACLE
ENGINE SWITCH
DC RECEPTACLE
VOLTMETER
STERTER
RESET SWITCH
ENGINE SWITCH
SANDE S.A. - PRODUCTOS INDUSTRIALES

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TPG-3000HM (110/220V , 60Hz)
TPG-6000~7000HM , TPG-6000~7000HEL(110/220V , 60Hz)
CIRCUIT BREAKER
GROUND TERMINAL
PILOT LAMP
AC RECEPTACLE
ENGINE SWITCH
DC RECEPTACLE
VOLTMETER
VOLTAGE
SELECTOR
CIRCUIT BREAKER
STERTER
RESET SWITCH
ENGINE SWITCH
CIRCUIT BREAKER
GROUND TERMINAL
PILOT LAMP
AC RECEPTACLE
DC RECEPTACLE
VOLTMETER
ENGINE SWITCH
VOLTAGE SELECTOR
CIRCUIT BREAKER
SANDE S.A. - PRODUCTOS INDUSTRIALES

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TPG-7000HM , TPG-7000HEL(220V 50Hz) Twist Lock Receptacle
CIRCUIT BREAKER
GROUND TERMINAL
PILOT LAMP
AC RECEPTACLE
ENGINE SWITCH
DC RECEPTACLE
VOLTMETER
STERTER
RESET SWITCH
ENGINE SWITCH
SANDE S.A. - PRODUCTOS INDUSTRIALES

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4. Generator winding resistance
220V 50Hz (Measurement unit；Ω)
Item
TPG-3000HM
TPG-6000HM
(HEL)
TPG-7000HM
(HEL)
Standard
value range
Main coil
Resistance
（Lead: Red-blue）
2.045
0.503
0.551
±１０％
battery charge
Coil resistance
（Lead: brown-brown）
0.221
0.151
0.126
±１０％
Sub coil
Resistance
（Lead: Yellow-yellow）
3.567
±１０％
Sub coil
Resistance
（Lead: blue-blue）
1.972
1.788
±１０％
Rotor coil
Resistance
（Collector ring）
41.7
46.5
52.6
±１０％
110/220V 60Hz (Measurement unit；Ω)
Item
TPG-3000HM
TPG-6000HM
(HEL)
TPG-7000HM
(HEL)
基準値範囲
Main coil
Resistance
（Lead: Red-blue）
1.365
0.377
0.585
±１０％
battery charge
Coil resistance
（Lead: brown-brown）
0.173
0.067
0.085
±１０％
Sub coil
Resistance
（Lead: Yellow-yellow）
1.619
±１０％
Sub coil
Resistance
（Lead: blue-blue）
1.808
2.342
±１０％
Rotor coil
Resistance
（Collector ring）
41.7
46.5
52.6
±１０％
SANDE S.A. - PRODUCTOS INDUSTRIALES

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※This resistance is a value at the time of the ambient air temperature of 20 ℃.
When you compare the standard value of an upper table with actual measured value, please compare by
performing 20 ℃temperature conversion of resistance from the ambient air temperature at the time of
measurement.
The temperature conversion of resistance is as follows.
R1 = R2 ×
234.5+20
234.5+T
Ｒ１ ：20 ℃equivalent（Ω）
Ｒ２ ：Measured value（Ω）
Ｔ：Ambient air temperature at the time of measurement（℃）
SANDE S.A. - PRODUCTOS INDUSTRIALES

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5. Troubleshooting
▼The main failures and a cause
・Engine
The clog of an air cleaner element
A jam of a fuel filter and a hose
１
Starting
difficulty
A poor carburetor（A jam of a port and jets）
Operation bad
condition
A poor spark plug
●Generator
Breaker OFF
１
Alternating current
voltage is OV
AVR failure
２
Alternating current
voltage is low.
Rotor failure
３
Direct voltage is
OV.
Stator failure
４
Direct voltage is
low.
Bridge diode failure
SANDE S.A. - PRODUCTOS INDUSTRIALES

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Starting difficulty and an operation bad condition
N.G. O.K.
Step 1 Oil supply Re-starting O.K.
O.K. N.G.
Go Step 2
N.G. 1. Is Fuel Valve Open?  O.K.
Step 2
Fuel tank check
2. Fuel Hose, Filter 
O.K.
3. Nozzle of Carburetor, 
a port, a jet 
if it checks respectively and 
O.K. is abnormal -- cleaning -- or component N.G.
replacement is carried out  Spark plug check 
When how to leak is remarkable
1. Check whether the carburetor
is overflowing. O.K.
(If it is overflowing, cleaning or Re-starting O.K.
a carburetor will be exchanged) Notes. Exaggerated chalk is used. 
2. Dry an electrode.
N.G.
Go Step 3
Weak or does not fly.
Step 3 Sparks check of a  1. Is the stop switch "ON"? 
spark plug 2. Isn't disconnection or covering torn as O.K.
for the ignition system lead O.K.
(primary order [ 2nd ])?
3. Total of 1, even when it is Normal 2nd 
Clause, when Not Carrying Out Jump Fire.
It checks a new article, exchange, and N.G.
carrying out jump fire for an Engine exchange 
ignition coil.
Amount check of oil
Re-starting
Re-starting
SANDE S.A. - PRODUCTOS INDUSTRIALES

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Alternating current voltage is OV.
N.G. OK
Step 1 Brush contact check Recheck 完了
O.K. NG
Go Step 2
N.G. OK
Step 2 AVR unit check Recheck 完了
O.K. NG
Go Step 3
N.G. O.K.
Step 3 Lead check ・Aren't there disconnection of a O.K.
lead and loose connection?
・Isn't there any blank of a terminal? 
O.K. NG
Go Step 4
N.G. OK
Step 4 Stator check O.K.
lead?
It will be stator exchange if there is a defect.
O.K. NG
Go Step 5
N.G.
Step 5 Rotor check ・Resistance of rotor winding is 
measured.
It will be rotor exchange if there
is a defect.
O.K.
Recheck
・Isn't there any disconnection of a
Brush
exchange
AVR unit
exchange
O.K.
Recheck
Recheck
・Resistance of each winding is measured.
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Alternating current voltage is low (50～80V).
DC voltage does not come out.
N.G OK
Step1 AVR unit check Recheck O.K.
O.K NG
Go Step2
N.G.
Step2 ・Resistance of each winding is measured. 
It will be stator exchange if there is a defect.
O.K.
Recheck
ＤＣ OFF OK
Step1 Circuit breaker Breaker Recheck O.K.
Check Reset
ON NG
Go Step2
不良 OK
Step2 AVR unit check Recheck O.K.
良品 NG
Go Step3
Stator check
AVR unit
exchange
AVR unit
exchange
SANDE S.A. - PRODUCTOS INDUSTRIALES

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N.G. ・Aren't there disconnection of a lead and OK
Step3 Lead check  loose connection? O.K.
・Isn't there any blank of a terminal?
O.K. N.G.
Go Step4
OFF O.K.
Step4 Bridge diode  Bridge diode Recheck O.K.
Check
Exchange
ON N.G.
Go Step5
N.G. O.K.
Step5 Stator check ・Resistance of each winding is measured. Recheck O.K.
・Isn't there any disconnection of a lead? 
It will be stator exchange if there is a defect.
O.K. N.G.
Go Step6
N.G.
Step6 Rotor check ・Resistance of rotor winding is measured.
It will be rotor exchange if there is a defect.
O.K.
Recheck
Recheck
SANDE S.A. - PRODUCTOS INDUSTRIALES

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Direct voltage is low (6～9V).
N.G. O.K.
Step1 AVR unit AVR unit Recheck O.K.
Check Exchange
O.K. N.G.
Go Step2
N.G. OK
Step2 Bridge diode Bridge diode Recheck O.K.
Check Exchange
O.K. NG
Go Step3
N.G.
Step3 Stator check ・Resistance of each winding is measured. 
It will be stator exchange if there is a defect.
O.K.
Recheck
SANDE S.A. - PRODUCTOS INDUSTRIALES

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6. Disassembly and an assembly
Each torque with a bolt bundle
Item
The diameter of a screw
Torque with a bundle（Ｎ・ｍ）
Rotor bolt
Ｍ８
２４
Stator bolt
Ｍ６
８
Tapping screw
Ｍ５
４
Bolt
Ｍ４
２
Ｍ５
４
Ｍ６
６
Ｍ８
１２
Disassembly and an assembly
1）Panel remove..
2）Fuel tank remove.
Four bolt remove. Bolt M6-12
Torque with a bundle ：5～6.5 N・m
Connector remove.
Inserts to the back at the time of
connector attachment.
Cautious of a lead color at
thetime of with a group.
Four bolt remove. Bolt M6-25
Torque with a bundle ：5～6.5 N・m
Fuel hose remove.
It removes carefully and attaches so
that a fuel hose may not be torn.
SANDE S.A. - PRODUCTOS INDUSTRIALES

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3）Muffler cover remove.
4）Muffler remove.
Remove: Make it slide to the engine side from the side of a frame.
Attachment: Make it slide from the side of a frame to the engine
side.
It hits against a frame and makes it not damage a fuel tank at this
time.
Detaching
direction
The attachment direction
Six bolt remove. Bolt M6-12
Two bolt remove. Bolt M8-20
Torque with a bundle ：12.0 ～15.0 N・m
It is this bundle after carrying out 12 temporary stop
at the time of attachment.
Torque with a bundle ：5.0 ～6.5 N・m
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5) Frame remove.
6) Alternator remove.
Two bolt remove. Bolt M8-20
Torque with a bundle ：22.0 ～24.0 N・m
This bundle of this bolt is carried out to the very first at
the time of with a group.
A generator is stood and four nuts remove.
Nut M8 4個
Torque with a bundle ：20.0 ～24.0 N・m
A frame is extracted from a top.
Two bolt remove. Bolt M5-20
Torque with a bundle ：3.0 ～4.0 N・m
Brush remove. Bolt M5-16 2本
Carry out by removing so that a brush
may not be folded.
It is that engine oil extracts
before standing a generator.
SANDE S.A. - PRODUCTOS INDUSTRIALES

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Torque with a rotor bolt bundle
Model
Bolt
Torque with a bundle
TPG-3000MH
5/16-24UNF 185L
20.0～24.0N・m
TPG-6000HM（HEL)
M10×265 P1.25
43.0～47.0N・m
TPG-7000HM（HEL)
M10×295 P1.25
43.0～47.0N・m
Model
Bolt
Torque with a
bundle
TPG-3000MH
M6×20
6.0～8.0N・m
TPG-6000HM（HEL)
M8×20
12.0～15.0N・m
TPG-7000HM（HEL)
At the time of brush attachment
It is with a group about a bolt, pressing a brush at
right angles to a collector ring, and pushing towards
the figure Nakaya mark
Torque with a bundle ：1.5 ～2.0 N・m
Carry out in the state where the rotor bolt is
bound tight, in the case of attachment of a
brush and removal.
A brush may be damaged.
Rotor bolt remove.
An attachment bolt and the torque with a
bundle are depended for every model.
Bolt remove. Four bolt
An attachment bolt and the torque with a bundle
are depended for every model.
Take care about the polarity of wiring.
They are those with marking to a lead
and a brush.
Lead blue (+)
Stator remove.
While a hammer strikes lightly from under a red
O portion, it raises perpendicularly and removes.
When raising, it takes care that a stator does not
rub against a rotor.
SANDE S.A. - PRODUCTOS INDUSTRIALES