Manual 6250 - Titan Industrial
P.O.Box 791, Travelers Rest, S.C. 29690
Phone 864-834-7212
Service/Replacement Parts 800-845-4141
OWNER’S MANUAL
MODEL TG 5500D Industrial Generator
The Emission Control System for this generator is warranted for standards set by the Environment Protection Agency.
IMPOR
TANT!
IMPORT
It is extremely important to read and understand the entire contents of this
Owner’s Manual for the Titan Industrial Model TG 5500D before attempting to operate the generator. This is a diesel engine powered, industrial strength generating unit of electrical power. The diesel engine
and the generator are both potentially extremely hazardous and could
cause physical injury or even death if improperly used.
WARNING!
Do Not Operate Equipment until reading & understanding Owner’s Manual!
Disconnect all loads before starting or stopping generator.
Allow to run for a few minutes with no load before stopping.
TG5500D Manual
Revision # 030321A
IMPORTANT !
READ FIRST
OWNER’S
MANUAL
MODEL TG 5500D
Industrial Generator
It is extremely important to read and understand the entire contents of this Owner’s
Manual for the Titan Industrial- Model TG 5500D before attempting to operate the generator. This is a diesel engine powered, industrial strength generating unit of electrical power. The diesel engine and the generator are both potentially extremely hazardous and could cause physical injury or even death if improperly used.
TITAN INDUSTRIAL shall not be responsible for any consequences resulting from improper use of
this equipment. The operator is required to read the entire contents of this manual before attempting to operate the unit. If the operator does not completely understand the instructions and all of the
hazards of operating this unit after reading this manual, he/she must call the factory at 1-800-845-4141
to answer these questions to his/her complete satisfaction before proceeding.
READ AND COMPLETELY UNDERSTAND entire contents of this Owner’s Manual and become familiar with
the unit before attempting to start using this equipment! It is your responsibility to know its applications,
limitations, and hazards! Call the factory at 1-800-845-4141 with any questions.
FOR OUTDOOR USE ONLY! Never use this unit inside any enclosure including the generator compartment of
a recreation vehicle (RV) or inside any building. No modifications will eliminate the danger of possible carbon
monoxide poisoning, fire, or explosion.
TWO (2) FEET OF CLEARANCE on all sides is required even while using outdoors.
This unit is sold solely for the purpose of portable power. Other applications could void warranty.
User accepts responsibility for injuries and/or damage resulting from other applications.
This Manual contains information to ensure your safety and to prevent any equipment problems. Various terms such as ‘WARNING’, ‘CAUTION’, ‘DANGER’, ‘IMPORTANT’, and the SYMBOLz are all used to signify information that is essential for the
operator of this equipment to understand and to practice!
2
CONNECTING LOADS
Add up the Watts of all devices you connect to the TITAN INDUSTRIAL GENERATOR at one time. Do not exceed 4800 Watts on (see wattage reference guide page
6), These are approximate wattages.
The rated Watts of most electrical devices can be found
on its nameplate. The rated Watts of lights can be taken
from the light bulbs. In cases where only Volts and Amps
are shown on the nameplate, simply multiply Volts by
the Amps to get Watts (Volts X Amps = Watts).
MODEL TG 5500D
DIESEL POWERED
ELECTRIC GENERATOR
Some electric motors require about three times the rated
Watts of power for start-up. This surge of power is required for only a few seconds. Be sure to allow for this
high starting wattage when selecting electrical devices
to connect to the generator.
First, figure the watts needed to start the largest motor.
Add to that figure the running watts of all other connected loads.
Please see the Wattage Reference Guide.
It provides an estimated approximation of running watts,
to help determine which devices to select to connect to
the generator.
CAUTION! Do not tamper with engine governed speed.
The TITAN INDUSTRIAL GENERATOR supplies correct rated frequency and voltage when running at the
proper governed speed. Incorrect frequency and/or voltage could damage connected electrical devices.
DESCRIPTION
GROUNDING THE GENERATOR
THE TITAN INDUSTRIAL INC. MODEL TG 5500D is a
diesel engine driven, revolving field, alternating current (AC)
generator designed to supply electrical power for compatible electrical tools, motors, appliances, and lighting
(see wattage reference guide on page 6).
It is required by The National Electrical Code to have
the frame and all external conductive parts of the generator connected to an earth ground. Proper grounding
also satisfies most local electrical codes.
Connect a No. 12 AWG standard copper wire to the
Grounding Lug Block (See Figure 1). The grounding lug
is located on the control panel. Connect the other end of
the wire to an earth driven copper or brass grounding rod
(electrode).
CAUTION! Do not connect ground to a preexisting ground
rod, water pipe, or building frame.
The Model TG 5500D operates at 120 volt and/or 240 volt,
single phase, and will operate devices that require up to
4200 watts, continuous and 4800 watts surge.
Figure #1 - Grounding Lug Block
Consult with a licensed electrician in your area because
local codes vary. Properly grounding the generator helps
prevent electrical shock if a ground fault condition exists
in the generator or in connected electrical devices. This
will also help to dissipate static electricity resulting from
ungrounded devices.
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SAFETY z
This generator was designed for specific applications. DO NOT attempt to modify the unit in any way or use
it for any application that it was not designed to do. Ask the dealer or contact the factory if you have any
questions concerning the generator’s application.
Warnings and cautions in this manual and on decals and tags on the unit are not all inclusive. It would be
impossible to anticipate every circumstance that might involve a hazard. Handling, operating, or servicing this unit by any procedure not recommended by the manufacturer may render this equipment unsafe
and may pose a threat to you or to others.
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The generator produces a very powerful voltage that can cause extremely dangerous electrical shock. Avoid contact with bare wires, terminals, etc. never permit an unqualified person to operate or service the generator.
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Never handle any kind of electrical cord or device while standing in water, while barefoot or
with wet hands or when feet are wet. Dangerous electrical shock could result.
Never store a generator with fuel in the tank where
diesel fuel vapors could be ignited by a flame,
spark, or pilot light from an appliance such as a
furnace, water heater, or clothes dryer.
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The National Electric Code requires that the
frame and external conductive parts be properly connected to an approved earth ground.
Local electrical codes may vary. Check with an
electrician for local grounding requirements.
Always allow a minimum of 2 feet of clearance on
all sides for ventilation while unit is operating. Allow 2 feet of clearance from all combustibles.
z Generator must always be stopped or started with
all loads unconnected. Start the engine and let it
stabilize before connecting any loads. Disconnect
all loads before shutting down the generator.
Use a ground fault circuit interrupter in any
damp or highly conductive area such as metal
decking or steel work.
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Do not use worn, bare, frayed or otherwise damaged electrical cords or wiring with the generator. A defective cord may result in electrical
shock or may cause damage to equipment.
Never insert any object through the cooling slots
of the engine. You could damage the unit or cause
injury.
z NEVER OPERATE THE GENERATOR:
In rain
In an enclosed compartment
If connected devices overheat
If electrical output is lost
If engine or generator sparks
If flame or smoke is observed
If unit vibrates excessively
Do not expose unit to excessive moisture, dirt
or corrosive vapors. Unit must be operated on
a level surface.
Comply with all laws regulating the storage and
handling of diesel fuel. Diesel fuel is highly flammable and explosive. Avoid spilling diesel fuel
on a hot engine. Do not allow smoking, open
flames, sparks or heat in the vicinity while handling diesel fuel.
Do not overfill the fuel tank. Always allow room
for diesel fuel expansion. Diesel fuel could overflow and cause fire or explosion if tank is overfilled. Allow for a 20 minute cool down before
refueling. Never refuel tank while engine is
running.
Only operate this unit outside with adequate ventilation. This generator’s diesel engine exhaust produces carbon monoxide gas that can cause unconsciousness or even death.
CAUTION! The engine exhaust contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.
CAUTION! If it is your first time starting the generator, allow it to run for 30 minutes before connecting electrical loads. This is for wet seating
purposes
Caution: Customer takes full responsibility for use
of this unit as a home generation system.
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IMPORTANT ! IMPORTANT ! IMPORTANT ! IMPORTANT ! IMPORTANT
BEFORE STARTING THE ENGINE
CHECK AND/OR FILL OIL
WARNING!
DO NOT ATTEMPT TO START THE
ENGINE BEFORE FILLING WITH OIL!
Titan Industrial
Recommends
ONLY
Using Rotella T
Multigrade
15W - 40
engine oil.
Fill with oil
CHECK AND/OR FILL DIESEL
CHECK AND/OR REPLACE FILTER
WARNING!
WARNING!
Do not overfill! Leave room for
fuel expansion. Never fill fuel
indoors. Never fill fuel when
engine is hot or running. Do
not smoke or fill fuel near
an open flame or sparks.
Fill with diesel fuel only
z Use #1 diesel fuel only.
z Clean area around fuel cap.
z Remove fuel cap.
z Add diesel fuel to fuel tank.
z Place generator on a level surface.
z DO NOT overfill. Do not fill above
the red plug inside the fuel tank filter
(this allows for fuel expansion).
z Clean area around oil fill opening.
z Replace fuel cap.
z Remove the dipstick.
z Wipe up any spilled diesel fuel.
Do not clean filter with any type of
detergent.
Check air filter
z Remove cover panel.
Loosen wingnut and remove air
filter cover.
z Never wash air cleaner with any
kind of detergent or cleaning
solvent.
z Air filter should be changed if
engine performance decreases or
color of exhaust changes.
z Never run engine without air filter.
This can cause rapid engine wear.
.
Figure #2 - Air Filter Housing
z Wipe the dipstick clean.
z Pour oil in until it reaches the FULL
mark on dipstick.
z DO NOT OVERFILL!
Note:
Because this is a diesel engine, frequent oil and filter changes are required.
z CLOSE OIL CAP!
Oil Filter\Screen
Oil Capacity:
6-7 hp------ 28-30oz.
8hp----------35oz
Oil Drain Plug
Clean/Change filter after the first 5 hours of operations.
Change oil every 30 hours, or sooner in adverse conditions. Replace/Clean oil filter
each and every time oil is changed. Failure to do so, will cause engine damage and
void the warranty.
IMPORTANT
! IMPORTANT ! IMPORTANT ! IMPORTANT ! IMPORTANT
5
Watta
ge R
ef
er
ence Guide
ttag
Ref
efer
erence
Device
Running Watts
*Air Conditioner (12,000 BTU)
Battery Charger (20 Amp)
Belt Sander (3”)
Chain Saw
Circular Saw (6-1/2”)
Coffee Maker
Compressor (1 HP)
Compressor (3/4 HP)
Compressor (1/2 HP)
Curling Iron
*Freezer
Disc Sander (9”)
Edge Trimmer
Electric Nail Gun
Electric Range (one element)
Electric Skillet
*Furnace Fan (1/3 HP)
Hair Dryer
Hand Drill (1”)
Hand Drill (1/2”)
Hand Drill (3/8”)
Hand Drill (1/4”)
1700
500
1000
1200
800 to 1000
1000
2000
1800
1400
700
500
1200
500
1200
1500
1250
1200
1200
1100
750 to 1000
500
250
Device
Running Watts
Impact Wrench
*Jet Pump
Lawn Mower
Light Bulb
Microwave Oven
*Milk Cooler
Oil Burner on Furnace
Oil Fired Space Heater (140,000 BTU)
Oil Fired Space Heater (85,000 BTU)
Oil Fired Space Heater (30,000 BTU)
*Airless Paint Sprayer (1/3 HP)
Handheld Airless Paint Sprayer
Radio
Refrigerator
Slow Cooker
*Submersible Pump (1-1/2 HP)
*Submersible Pump (1 HP)
*Submersible Pump (1/2 HP)
Sump Pump
*Table Saw (10”)
Television
Weed Trimmer
500
800
1200
100
700
1100
300
400
225
150
600
150
50 to 200
600
200
2800
2000
1500
600
1750 to 2000
200 to 500
500
*Allow 3 times the listed Watts for starting these devices
These wattages shown are approximate and may vary with each specific device
WARNING:
Factory warranty is voided if fuel, other than specified diesel fuel, is
used in this engine. Refer to owners manual for fuel.
Maintenance Guide
DAILY EVERY MONTH/ 30 HRS EVERY 3 MONTHS/ 100 HRS EVERY 6 MONTHS/ 500 HRS
Check/Refill Fuel
Drain fuel from tank
Check/Refill Oil
Check for oil leakage
Change oil
Clean/Replace oil filter
Replace air filter
Clean/Replace fuel filter
X
X
X
X
X*
X
X*
X*
*First oil change should be after 5 hours. After initial break-in period change oil every (30) hours.
X*Air filter may need to be replaced frequently, due to adverse conditions. Check filter frequently.
6
X
OPERATION OF THE GENERATOR
Starting the Engine - Electric starting
CAUTION!
DO NOT start or stop the engine with electrical
loads connected to the receptacles. Be certain
connected devices are OFF before connecting
or disconnecting.
1. Be sure unit is at a level, well ventalated position
2. Check fluids for proper levels.
3. Turn on fuel valve. (figure #3)
DANGER!
DO NOT run generator indoors or in poorly ventilated areas. Engine exhaust contains carbon
monoxide which is an odorless, deadly gas.
WARNING!
To avoid burns, avoid muffler and nearby areas.
Starting the Engine - Recoil starting
4. Put Throttle lever in the run position
(figure #5)
5. Turn the ignition key to the “Start” position
6. Once engine has started return the key to
the “ON”
1. Be sure unit is at a level, well ventalated
7. Let engine settle before attaching any appliances
position.
2. Check fluid for proper levels
3. Turn on fuel valve. (figure #3)
Figure #5
4. Put Throttle lever to the run position
(figure #5)
5. Turn ignition key on control panel to the
run positon.
6. Push and hold down the decompression
lever (figure #4)
Pull the recoil starter briskly until the engine is
rotating, then,
release lever.
7. Let engine settle before attaching any appliances
Figure
#3
off
-
Fuel
Valve
Positions
Figure #4 - Compression Release Switch
on
7
OPERATION OF THE GENERATOR
Bleeding Instructions
Figure #6
Rubber Fuel Line
Fuel Pump Port
Steel Fuel Line
Fuel Pump
Throttle Lever
Figure #7
1. With the fuel valve in the off position take off the
rubber fuel line off the fuel pump port.
2. Open fuel valve and let rubber fuel line fill up with
diesel fuel. Quickly replace rubber fuel line on the fuel
pump port
3. Follow starting procedure(page7)
If the unit still won’t start.
1. Loosen\remove the steel fuel line compression nut.
so you can see the top of the fuel pump.(figure #6)
2. With the throttle lever in the run position turn over the
engine. Diesel fuel should squirt out ot the top of fuel
pump.
* If no fuel is coming out of pump retry bleeding
procedures, if still no fuel, possible bad fuel pump.
3. Reconnect fuel line and follow starting procedures.
Figure #8
Fuel pumping but unit will not start.
1. Follow the steel fuel line up to the injector
2. Disconnect the fuel line from the injector with a
17mm wrench (figure #7)
3. Remove the fuel injector from head assembly and
inspect it. Make sure injector tip is clean and free from
debris. Invert it. Reconnect metal fuel line. (figure #8)
4. With the throttle lever in the run position turn over the
engine. You should have four ports of fuel spraying from
the injector tip.
5. Re-install injector in to the head assembly
6. Follow starting procedures.
If the fuel injector does not spray (possible bad injector)
If the fuel injector is working , look under the valve
cover to see if the valves are function properly.
TDC see Page 20
8
Valve Cover
Valve Settings
.012-intake
.013-exhaust
Control Panel
Starting Switch
Shows operating
voltage
240 volt receptacle
Hourmeter
Twist Lock
120-Volt
Receptacle
120-Volt Receptacle
DC Output
Some Control Panels May Vary
9
Ground Lug
AC Voltage
Selection Switch
Main Breaker
(opens and closes
receptacle circuits)
TROUBLESHOOTING
Problem
Cause
Solution
Engine is running but no
power output is available.
1. Circuit breaker is open.
2. Poor connection or defective
cord set.
3. Connected device is bad.
4. Fault in generator.
1. Reset the circuit breaker.
2. Check & repair.
3. Connect another device
that is in good condition.
4. Contact service center.
Engine runs good until loads
are connected, then bogs
down.
1. Short circuit in a connected
load.
2. Overloaded generator.
3. Engine speed is too slow.
4. Short in generator circuit.
1. Disconnect shorted load.
2. See ‘Connecting Electrical
Loads’ section of manual.
3. Contact service center.
4. Contact service center.
Engine will not start or engine
starts but runs rough.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
1. Turn On/Off Switch to ‘ON’.
On/Off Switch is turned ‘OFF’.
2. Charge or replace it.
Battery is dead
3. Clean air filter
Dirty air cleaner.
4. Fill fuel tank.
Out of diesel fuel.
5. Drain fuel tank and refill.
Stale diesel fuel.
6. Read and follow directions.
Not enough speed or force is
7. Drain and refill tank.
used for recoil start.
8. Move speed control to “RUN”
Water in diesel fuel.
position.
Speed control is not set to
9. Add oil to proper level.
“RUN”.
10. Clean oil nozzle.
Low oil level.
11. Contact service center.
Oil nozzle is dirty.
Engine has lost compression.
Engine shuts down during
operation.
1. Out of diesel fuel.
2. Fault in engine.
1. Fill fuel tank.
2. Contact service center
Engine lacks power
1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
1. See ‘Connecting Electrical
Loads’ section of manual.
2. Replace the air filter.
3. Contact service center.
Add 2-5 oz. of 15W-40
motor oil to the orange cap
located on top of engine,
next to the Decompression lever.
If engine has a difficult time
starting around freezing
temperatures
Service
1-800-845-4141
Replacement Parts
1-800-845-4141
Fax
864-834-5127
Toll Free 1-800-845-4141
www.titanindustrial.com
10
Parts Catalog
P.O.Box 791, Travelers Rest, S.C. 29690
Phone 864-834-7212
Service/Replacement Parts 800-845-4141
11
1. Cylinder Block Assembly
Part Name
Titan Part #
1. PTO Seal
LCT-5552
3. Oil Sensor
LCT-016
4. Oil Pipe
LCT-5528
5. Dowel Pins
LCT-5528
6. Cam Shaft Bearing
LCT-5528
7. Crank Case Cover Gasket LCT-5529
8. Main Bearing
LCT-5557
9. Cylinder Head Gasket
LCT-5520
10. Push Rod O-ring
LCT-5513
11. Starter Cover Plate
N\A
Part Name
12. Crank Shaft Bearing
13. CamShaft Bearing
14. Bearing Retainer Plate
15. Fuel Pump cover
16. Fuel Pump Gasket
17. Fuel Pump Shims
18. CrankShaft Oil Seal
19. Cylinder Block
20. Crank Case Cover
Titan Part #
LCT-5515
LCT-5514
LCT-5553
LCT-5537
LCT-5537
LCT-5536
LCT-5552
LCT-5553
LCT-5528
Some Parts Sold As Assemblies
12
2. Crank Shaft Assembly
Part Name
Titan Part #
1. Crank Case Cover
2. Balancer Shaft Bearing
3. Balancer Shaft
4. Key
5. Balancer Shaft Gear
6. Camshaft Drive Gear
7. CrankShaft
8. Balancer Shaft Drive Gear
9. Flywheel
10. Camshaft
11. Cam Shaft Drive Gear
LCT-5528
LCT-5522
LCT-5522
LCT-5522
LCT-5522
LCT-5515
LCT-5515
LCT-5515
LCT-5551
LCT-5514
LCT-5514
Some Parts Sold As Assemblies
13
3. Governor Gear Assembly
Part Name
Titan Part #
1. Oil Pump
2. Oil Pump O-ring
3. Oil Pump Rotor
4. Oil Pump Drive Pin
5. Oil Filter\Sreen
6. O-Ring
7. Governor Assembly
8. Governor Arm
9. Dowel Pin
Part Name
LCT-5527
LCT-5527
LCT-5523
LCT-5523
LCT-015
LCT-015
LCT-5523
LCT-5525
LCT-5525
Titan Part #
10. Governor Arm Shaft
11. Flat Washer
12. Governor Shaft Bearing
13. Lock Nut
14. Dowel Pin
15. Governor Arm
16. Thrust Bearing
17. Seal Wire
19. Governor Stop
LCT-5525
N\A
N\A
LCT-5526
LCT-5525
LCT-5525
LCT-5525
N\A
LCT-5526
Some Parts Sold As Assemblies
14
4. Head Asssembly
Part Name
1. Decompression Lever
2. Return Spring
3. Retaining Pin
4. Valve Cover
5. Valve Cover Gasket
6. Rocker Pedestal Bolt
7. Push Rod
8. Exhaust Rocker Arm
9. Adjusting Screw
10. Rocker Arm Pedestal
11. Intake Rocker Arm
12. Split Valve Locks
Titan Part #
Part Name
LCT-5530
LCT-5530
LCT-5530
LCT-5530
LCT-5531
LCT-5541
LCT-5512
LCT-5541
LCT-5541
LCT-5541
LCT-5541
LCT-5511
15
Titan Part #
13. Valve Keepers
LCT-5511
14. Valve Spring
LCT-5511
15. Valve Guide Seal
LCT-5511
16. Spring Seat Washer
N\A
17. Padestal Dowel Pin
LCT-5501
18. Cylinder Head
LCT-5501
19. Exhaust Valve
LCT-5511
20. Intake Valve
LCT-5511
21. Injector Clamp Nuts
LCT-5504
22. Injector Clamp Plate
LCT-5504
23. Injector Spacer
N\A
24. Injector Gasket
LCT-5503
Some Parts Sold As Assemblies
5. Piston Assembly
*(3) Pistion Rings Not Shown
Part # LCT-5513A
Part Name
1. Snap Rings
2. Piston
3. Piston Pin
4. Pin Bushin
5. Connecting Rod
Part Name
Titan Part #
LCT-5516
LCT-5516
LCT-5516
LCT-5517
LCT-5517
6. Rod Cap Bolt
7. Rod Sleeve Bearing
8. Rod Cap
9. Washer
10. Nut
Titan Part #
LCT-5517
LCT-5517
LCT-5517
N\A
N\A
Some Parts Sold As Assemblies
16
6. Fuel Injection System
Fuel Injector
LCT-5502
Fuel Pump
LCT-5535
These Parts Sold As Assemblies
17
7. Fuel System
Fuel Tanks Vary
Part Name
1. Fuel Cap
2. Fuel Cap Seal
3. Fuel Cap Gasket
4. Filter Screen
5. Mounting Clamp
6. Fuel Injector
7. Fuel Return line
8. Vibration Dampers
9. Fuel Tank
10. Fuel Gauge
Part Name
Titan Part #
LCT-009
LCT-009
LCT-009
LCT-009A
N\A
LCT-5502
LCT-057
N\A
LCT-008
LCT-008A
11. Drain Plug
12. Gasket
13. Fuel Injector Line
14. Fuel Filter
15. Fuel Injector Pump
16. Fuel Filter Plate
17. Rubber Fuel Line
18. O-ring
19. Fuel Shut Off Valve
20. Mounting Clamp
Titan Part #
N/A
N\A
LCT-5550
LCT-010
LCT-5535
LCT-10A
LCT-056
LCT-011
LCT-012
N\A
Some Parts Sold As Assemblies
18
8. Starter Assembly
1
2
3
4
5
Part Name
Titan Part #
1. Fly Wheel
2. Recoil Cup
3. Blower Housing Gaskets
4. Blower Housing
5. Recoil Assembly
LCT-5551
LCT-5544
LCT-5546
LCT-5546
LCT-5542
Some Parts Sold As Assemblies
19
20
P.O.Box 791, Travelers Rest, S.C. 29690
Phone 864-834-7212
Service/Replacement Parts 800-845-4141
21
22
TITAN INDUSTRIAL
P.O. Box 791
Travelers Rest, S.C. 29690
(800) 845-4141
www.titanindustrial.net
Model 5500
Specifications:
________________
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Output 4200watts Continuous5000watts Surge
2- L5-20 Receptacles
1- L14-20 Receptacle
Circuit Breaker Protection
84 Decibel’s @ 10’
Electric Start\recoil
7hp Titan Diesel Engine
(steel sleeve) Cylinder
3.5 Gallon Fuel Tank
Approx. Run Time 10hrs
@50% Load
___
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___________________
RPM 3720
Brushless Generator Head
Copper Windings
Single Phase 60Hz.
Low Oil Shut Down
Oil Capacity 26-28oz. 15w-40
Size: L-26” W-19” H-24”
Net. Weight 230LBS.
One Year Warranty (Residential)
90day (commercial)
P.O.Box
791, Travelers Rest, S.C. 29690
Phone 864-834-7212
Service/Replacement
Parts
800-845-4141
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