Titan TG 5500D User manual

IMPORIMPOR
IMPORIMPOR
IMPORTT
TT
TANT!ANT!
ANT!ANT!
ANT!
The Emission Control System for this generator is warranted for standards set by the Environment Protection Agency.
It is extremely important to read and nderstand the entire contents of this
Owners Man al for the Titan Ind strial Model TG 5500D before at-
tempting to operate the generator. This is a diesel engine powered, in-
d strial strength generating nit of electrical power. The diesel engine
and the generator are both potentially extremely hazardo s and co ld
ca se physical inj ry or even death if improperly sed.
WARNING!
Do Not Operate Eq ipment ntil reading & nderstanding Owners Man al!
Disconnect all loads before starting or stopping generator.
Allow to r n for a few min tes with no load before stopping.
OWNERS MANUAL
MODEL TG 5500D Industrial Generator
P O Box 791, Travelers Rest, S C 29690
Phone [phone]
Service/Replacement Parts 800-845-4141
Revision # 030321ATG5500D Manual

TITAN INDUSTRIAL shall not be responsible for any conseq ences res lting from improper se of
this eq ipment. The operator is req ired to read the entire contents of this man al before attempt-
ing to operate the nit. If the operator does not completely nderstand the instr ctions and all of the
hazards of operating this nit after reading this man al, he/she m st call the factory at 1-800-845-4141
to answer these q estions to his/her complete satisfaction before proceeding.
READ AND COMPLETELY UNDERSTAND entire contents of this Owners Manual an become familiar with
the unit before attempting to start using this equipment! It is your responsibility to know its applications,
limitations, an hazar s! Call the factory at 1-800-845-4141 with any questions.
FOR OUTDOOR USE ONLY! Never use this unit insi e any enclosure inclu ing the generator compartment of
a recreation vehicle (RV) or insi e any buil ing. No mo ifications will eliminate the anger of possible carbon
monoxi e poisoning, fire, or explosion.
TWO (2) FEET OF CLEARANCE on all si es is require even while using out oors.
This nit is sold solely for the p rpose of portable power. Other applications co ld void warranty.
User accepts responsibility for inj ries and/or damage res lting from other applications.
IMPORTANT !
READ FIRST
It is extremely important to read and nderstand the entire contents of this Owners
Man al for the Titan Ind strial- Model TG 5500D before attempting to operate the gen-
erator. This is a diesel engine powered, ind strial strength generating nit of electri-
cal power. The diesel engine and the generator are both potentially extremely haz-
ardo s and co ld ca se physical inj ry or even death if improperly sed.
This Man al contains information to ens re yo r safety and to prevent any eq ip-
ment problems. Vario s terms s ch as WARNING, CAUTION, DANGER, IMPOR-
TANT, and the SYMBOL are all sed to signify information that is essential for the
operator of this eq ipment to nderstand and to practice!
z
OWNERS MANUAL
MODEL TG 5500D
Industrial Generator
2

CONNECTING LOADS
THE TITAN INDUSTRIAL INC. MODEL TG 5500D is a
iesel engine riven, revolving fiel , alternating current (AC)
generator esigne to supply electrical power for com-
patible electrical tools, motors, appliances, an lighting
(see wattage reference gui e on page 6).
The Mo el TG 5500D operates at 120 volt an /or 240 volt,
single phase, an will operate evices that require up to
4200 watts, continuous an 4800 watts surge.
GROUNDING THE GENERATOR
It is require by The National Electrical Co e to have
the frame an all external con uctive parts of the gen-
erator connecte to an earth groun . Proper groun ing
also satisfies most local electrical co es.
Connect a No. 12 AWG stan ar copper wire to the
Groun ing Lug Block (See Figure 1). The groun ing lug
is locate on the control panel. Connect the other en of
the wire to an earth riven copper or brass groun ing ro
(electro e).
CAUTION! Do not connect groun to a preexisting groun
ro , water pipe, or buil ing frame.
Consult with a license electrician in your area because
local co es vary. Properly groun ing the generator helps
prevent electrical shock if a groun fault con ition exists
in the generator or in connecte electrical evices. This
will also help to issipate static electricity resulting from
ungroun e evices.
MODEL TG 5500D
DIESEL POWERED
ELECTRIC GENERATOR
A up the Watts of all evices you connect to the TI-
TAN INDUSTRIAL GENERATOR at one time. Do not ex-
cee 4800 Watts on (see wattage reference gui e page
6), These are approximate wattages.
The rate Watts of most electrical evices can be foun
on its nameplate. The rate Watts of lights can be taken
from the light bulbs. In cases where only Volts an Amps
are shown on the nameplate, simply multiply Volts by
the Amps to get Watts (Volts X Amps = Watts).
Some electric motors require about three times the rate
Watts of power for start-up. This surge of power is re-
quire for only a few secon s. Be sure to allow for this
high starting wattage when selecting electrical evices
to connect to the generator.
First, figure the watts nee e to start the largest motor.
A to that figure the running watts of all other con-
necte loa s.
Please see the Wattage Reference Gui e.
It provi es an estimate approximation of running watts,
to help etermine which evices to select to connect to
the generator.
CAUTION! Do not tamper with engine governe spee .
The TITAN INDUSTRIAL GENERATOR supplies cor-
rect rate frequency an voltage when running at the
proper governe spee . Incorrect frequency an /or volt-
age coul amage connecte electrical evices.
Figure #1 - Grounding Lug Block
DESCRIPTION
3

SAFETY
This generator was esigne for specific applications. DO NOT attempt to mo ify the unit in any way or use
it for any application that it was not esigne to o. Ask the ealer or contact the factory if you have any
questions concerning the generators application.
Warnings an cautions in this manual an on ecals an tags on the unit are not all inclusive. It woul be
impossible to anticipate every circumstance that might involve a hazar . Han ling, operating, or servic-
ing this unit by any proce ure not recommen e by the manufacturer may ren er this equipment unsafe
an may pose a threat to you or to others.
CAUTION! The engine exha st contains chemi-
cals known to the State of California to ca se can-
cer, birth defects, or other reprod ctive harm.
The generator pro uces a very powerful volt-
age that can cause extremely angerous elec-
trical shock. Avoi contact with bare wires, ter-
minals, etc. never permit an unqualifie per-
son to operate or service the generator.
Never han le any kin of electrical cor or e-
vice while stan ing in water, while barefoot or
with wet han s or when feet are wet. Danger-
ous electrical shock coul result.
The National Electric Co e requires that the
frame an external con uctive parts be prop-
erly connecte to an approve earth groun .
Local electrical co es may vary. Check with an
electrician for local groun ing requirements.
Use a groun fault circuit interrupter in any
amp or highly con uctive area such as metal
ecking or steel work.
Do not use worn, bare, fraye or otherwise am-
age electrical cor s or wiring with the genera-
tor. A efective cor may result in electrical
shock or may cause amage to equipment.
Do not expose unit to excessive moisture, irt
or corrosive vapors. Unit must be operate on
a level surface.
Comply with all laws regulating the storage an
han ling of iesel fuel. Diesel fuel is highly flam-
mable an explosive. Avoi spilling iesel fuel
on a hot engine. Do not allow smoking, open
flames, sparks or heat in the vicinity while han-
ling iesel fuel.
Do not overfill the fuel tank. Always allow room
for iesel fuel expansion. Diesel fuel coul over-
flow an cause fire or explosion if tank is over-
fille . Allow for a 20 minute cool own before
refueling. Never refuel tank while engine is
running.
Only operate this unit outsi e with a equate venti-
lation. This generators iesel engine exhaust pro-
uces carbon monoxi e gas that can cause un-
consciousness or even eath.
Never store a generator with fuel in the tank where
iesel fuel vapors coul be ignite by a flame,
spark, or pilot light from an appliance such as a
furnace, water heater, or clothes ryer.
Always allow a minimum of 2 feet of clearance on
all si es for ventilation while unit is operating. Al-
low 2 feet of clearance from all combustibles.
Generator must always be stoppe or starte with
all loa s unconnecte . Start the engine an let it
stabilize before connecting any loa s. Disconnect
all loa s before shutting own the generator.
Never insert any object through the cooling slots
of the engine. You coul amage the unit or cause
injury.
NEVER OPERATE THE GENERATOR:
In rain
In an enclose compartment
If connecte evices overheat
If electrical output is lost
If engine or generator sparks
If flame or smoke is observe
If unit vibrates excessively
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CAUTION! If it is yo r first time starting the gen-
erator, allow it to r n for 30 min tes before con-
necting electrical loads. This is for wet seating
p rposes
Caution: Customer takes full responsibility for use
of this unit as a home generation system.
4

IMPORTANT ! IMPORTANT ! IMPORTANT ! IMPORTANT ! IMPORTANT
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!
Fill with oil
zPlace generator on a level surface.
zClean area aroun oil fill opening.
zRemove the ipstick.
zWipe the ipstick clean.
zPour oil in until it reaches the FULL
mark on ipstick.
zDO NOT OVERFILL!
zCLOSE OIL CAP!
CHECK AND/OR FILL DIESEL
WARNING!
Do not overfill! Leave room for
f el expansion. Never fill f el
indoors. Never fill f el when
engine is hot or r nning. Do
not smoke or fill f el near
an open flame or sparks.
Fill with diesel f el only
zUse #1 iesel fuel only.
zClean area aroun fuel cap.
zRemove fuel cap.
zA iesel fuel to fuel tank.
zDO NOT overfill. Do not fill above
the re plug insi e the fuel tank filter
(this allows for fuel expansion).
zReplace fuel cap.
zWipe up any spille iesel fuel.
WARNING!
Do not clean filter with any type of
detergent.
Check air filter
zRemove cover panel.
Loosen wingnut an remove air
filter cover.
zNever wash air cleaner with any
kin of etergent or cleaning
solvent.
zAir filter shoul be change if
engine performance ecreases or
color of exhaust changes.
zNever run engine without air filter.
This can cause rapi engine wear.
.
CHECK AND/OR REPLACE FILTER
Figure #2 - Air Filter Housing
Titan Industrial
Recommends
ONL
Using Rotella T
Multigrade
15W - 40
engine oil.
Note:
Because this is a iesel engine, fre-
quent oil an filter changes are re-
quire .
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.
Oil Drain Plug
Oil Filter\Screen Oil Capacity:
5
6-7 hp------ 28-30oz.
8hp----------35oz

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ge Re R
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e Refef
efef
eferer
erer
erence Guideence Guide
ence Guideence Guide
ence Guide
*Air Con itioner (12,000 BTU) 1700
Battery Charger (20 Amp) 500
Belt San er (3) 1000
Chain Saw 1200
Circular Saw (6-1/2) 800 to 1000
Coffee Maker 1000
Compressor (1 HP) 2000
Compressor (3/4 HP) 1800
Compressor (1/2 HP) 1400
Curling Iron 700
*Freezer 500
Disc San er (9) 1200
E ge Trimmer 500
Electric Nail Gun 1200
Electric Range (one element) 1500
Electric Skillet 1250
*Furnace Fan (1/3 HP) 1200
Hair Dryer 1200
Han Drill (1) 1100
Han Drill (1/2) 750 to 1000
Han Drill (3/8) 500
Han Drill (1/4) 250
Device R nning Watts Device R nning Watts
Impact Wrench 500
*Jet Pump 800
Lawn Mower 1200
Light Bulb 100
Microwave Oven 700
*Milk Cooler 1100
Oil Burner on Furnace 300
Oil Fire Space Heater (140,000 BTU) 400
Oil Fire Space Heater (85,000 BTU) 225
Oil Fire Space Heater (30,000 BTU) 150
*Airless Paint Sprayer (1/3 HP) 600
Han hel Airless Paint Sprayer 150
Ra io 50 to 200
Refrigerator 600
Slow Cooker 200
*Submersible Pump (1-1/2 HP) 2800
*Submersible Pump (1 HP) 2000
*Submersible Pump (1/2 HP) 1500
Sump Pump 600
*Table Saw (10) 1750 to 2000
Television 200 to 500
Wee Trimmer 500
*Allow 3 times the listed Watts for starting these devices
These wattages shown are approximate and may vary with each specific device
Check/Refill Fuel X
Drain fuel from tank X
Check/Refill Oil X
Check for oil leakage X
Change oil X*
Clean/Replace oil filter X
Replace air filter X* X*
Clean/Replace fuel filter X
Maintenance GuideMaintenance Guide
Maintenance GuideMaintenance Guide
Maintenance Guide
DAIL EVER MONTH/ 30 HRS EVER 3 MONTHS/ 100 HRS EVER 6 MONTHS/ 500 HRS
*First oil change should e after 5 hours. After initial reak-in period change oil every (30) hours.
X*Air filter may need to e replaced frequently, due to adverse conditions. Check filter frequently.
WARNING:
Factory warranty is voided if fuel, other than specified diesel fuel, is
used in this engine. Refer to owners manual for fuel.
6

OPERATION OF THE GENERATOR
Starting the Engine - Recoil starting
CAUTION!
DO NOT start or stop the engine with electrical
loa s connecte to the receptacles. Be certain
connecte evices are OFF before connecting
or isconnecting.
DANGER!
DO NOT run generator in oors or in poorly venti-
late areas. Engine exhaust contains carbon
monoxi e which is an o orless, ea ly gas.
WARNING!
To avoi burns, avoi muffler an nearby areas.
Figure #3 - Fuel Valve Positions
Starting the Engine - Electric starting
off on
Figure #4 - Compression Release Switch
Figure #5
1. Be sure unit is at a level, well ventalated
position.
2. Check fluid for proper levels
3. Turn on fuel valve. (figure #3)
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 riskly until the engine is
rotating, then,
release lever.
7. Let engine settle efore attaching any appli-
ances
1. Be sure unit is at a level, well ventalated position
2. Check fluids for proper levels.
3. Turn on fuel valve. (figure #3)
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
7. Let engine settle efore attaching any appliances
7

OPERATION OF THE GENERATOR
8
1. With the fuel valve in the off position take off the
ru er fuel line off the fuel pump port.
2. Open fuel valve and let ru er fuel line fill up with
diesel fuel. Quickly replace ru er fuel line on the fuel
pump port
3. Follow starting procedure(page7)
If the unit still wont start.
Ru er Fuel Line
Steel Fuel Line
Fuel Pump
Throttle Lever
Fuel Pump Port
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.
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 assem ly and
inspect it. Make sure injector tip is clean and free from
de ris. 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 assem ly
6. Follow starting procedures.
If the fuel injector does not spray (possi le ad injector)
If the fuel injector is working , look under the valve
cover to see if the valves are function properly.
Figure #7
Figure #8
Valve Cover
Valve Settings
.012-intake
.013-exhaust
Figure #6
Bleeding Instructions
TDC see Page 20

Control Panel
Main Breaker
(opens and closes
receptacle circuits)
Shows operating
voltage
DC Output
240 volt receptacle
Starting Switch
AC Voltage
Selection Switch
120-Volt Receptacle
Hourmeter
Twist Lock
120-Volt
Receptacle
9
Ground Lug
Some Control Panels May Vary

Engine is running but no
power output is available.
Engine runs goo until loa s
are connecte , then bogs
own.
Engine will not start or engine
starts but runs rough.
Engine shuts own uring
operation.
Engine lacks power
1. Circuit breaker is open.
2. Poor connection or efective
cor set.
3. Connecte evice is ba .
4. Fault in generator.
1. Short circuit in a connecte
loa .
2. Overloa e generator.
3. Engine spee is too slow.
4. Short in generator circuit.
1. On/Off Switch is turne OFF.
2. Battery is ea
3. Dirty air cleaner.
4. Out of iesel fuel.
5. Stale iesel fuel.
6. Not enough spee or force is
use for recoil start.
7. Water in iesel fuel.
8. Spee control is not set to
RUN.
9. Low oil level.
10. Oil nozzle is irty.
11. Engine has lost compression.
1. Out of iesel fuel.
2. Fault in engine.
1. Loa is too high.
2. Dirty air filter.
3. Engine nee s to be service .
TROUBLESHOOTING
Problem Ca se Sol tion
1. Reset the circuit breaker.
2. Check & repair.
3. Connect another evice
that is in goo con ition.
4. Contact service center.
1. Disconnect shorte loa .
2. See Connecting Electrical
Loa s section of manual.
3. Contact service center.
4. Contact service center.
1. Turn On/Off Switch to ON.
2. Charge or replace it.
3. Clean air filter
4. Fill fuel tank.
5. Drain fuel tank an refill.
6. Rea an follow irections.
7. Drain an refill tank.
8. Move spee control to RUN
position.
9. A oil to proper level.
10. Clean oil nozzle.
11. Contact service center.
1. Fill fuel tank.
2. Contact service center
1. See Connecting Electrical
Loa s section of manual.
2. Replace the air filter.
3. Contact service center.
Service
1-800-845-4141
Replacement Parts
1-800-845-4141
Fax
864-834-5127
Toll Free 1-800-845-4141
www.titanind strial.com
If engine has a ifficult time
starting aroun freezing
temperatures
A 2-5 oz. of 15W-40
motor oil to the orange cap
locate on top of engine,
next to the Decompression lever.
10

Parts Catalog
P O Box 791, Travelers Rest, S C 29690
Phone [phone]
Service/Replacement Parts 800-845-4141
11

1. PTO Seal
3. Oil Sensor
4. Oil Pipe
5. Dowel Pins
6. Cam Shaft Bearing
7. Crank Case Cover Gasket
8. Main Bearing
9. Cylinder Head Gasket
10. Push Rod O-ring
11. Starter Cover Plate
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
LCT-5552
LCT-016
LCT-5528
LCT-5528
LCT-5528
LCT-5529
LCT-5557
LCT-5520
LCT-5513
N\A
LCT-5515
LCT-5514
LCT-5553
LCT-5537
LCT-5537
LCT-5536
LCT-5552
LCT-5553
LCT-5528
Part Name Part Name Titan Part #
Titan Part #
Some Parts Sold As Assem lies
1. Cylinder Block Assembly
12

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
Part Name Titan Part #
2. Crank Shaft Assembly
13
Some Parts Sold As Assem lies

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 Assem ly
8. Governor Arm
9. Dowel Pin
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-5527
LCT-5527
LCT-5523
LCT-5523
LCT-015
LCT-015
LCT-5523
LCT-5525
LCT-5525
LCT-5525
N\A
N\A
LCT-5526
LCT-5525
LCT-5525
LCT-5525
N\A
LCT-5526
Part Name Part NameTitan Part # Titan Part #
3. Governor Gear Assembly
14
Some Parts Sold As Assem lies

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
13. Valve Keepers
14. Valve Spring
15. Valve Guide Seal
16. Spring Seat Washer
17. Padestal Dowel Pin
18. Cylinder Head
19. Exhaust Valve
20. Intake Valve
21. Injector Clamp Nuts
22. Injector Clamp Plate
23. Injector Spacer
24. Injector Gasket
LCT-5530
LCT-5530
LCT-5530
LCT-5530
LCT-5531
LCT-5541
LCT-5512
LCT-5541
LCT-5541
LCT-5541
LCT-5541
LCT-5511
LCT-5511
LCT-5511
LCT-5511
N\A
LCT-5501
LCT-5501
LCT-5511
LCT-5511
LCT-5504
LCT-5504
N\A
LCT-5503
Part Name Part NameTitan Part # Titan Part #
4. Head Asssembly
Some Parts Sold As Assem lies
15

5. Piston Assembly
1. Snap Rings
2. Piston
3. Piston Pin
4. Pin Bushin
5. Connecting Rod
6. Rod Cap Bolt
7. Rod Sleeve Bearing
8. Rod Cap
9. Washer
10. Nut
LCT-5516
LCT-5516
LCT-5516
LCT-5517
LCT-5517
LCT-5517
LCT-5517
LCT-5517
N\A
N\A
Part Name Part Name
Titan Part # Titan Part #
Some Parts Sold As Assem lies
*(3) Pistion Rings Not Shown
Part # LCT-5513A
16

Fuel Injector LCT-5502 Fuel Pump LCT-5535
6. Fuel Injection System
These Parts Sold As Assem lies
17

7. Fuel System
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. Vi ration Dampers
9. Fuel Tank
10. Fuel Gauge
11. Drain Plug
12. Gasket
13. Fuel Injector Line
14. Fuel Filter
15. Fuel Injector Pump
16. Fuel Filter Plate
17. Ru er Fuel Line
18. O-ring
19. Fuel Shut Off Valve
20. Mounting Clamp
LCT-009
LCT-009
LCT-009
LCT-009A
N\A
LCT-5502
LCT-057
N\A
LCT-008
LCT-008A
N/A
N\A
LCT-5550
LCT-010
LCT-5535
LCT-10A
LCT-056
LCT-011
LCT-012
N\A
Part Name Part Name
Titan Part # Titan Part #
Some Parts Sold As Assem lies
Fuel Tanks Vary
18

8. Starter Assembly
1
2
34
5
1. Fly Wheel
2. Recoil Cup
3. Blower Housing Gaskets
4. Blower Housing
5. Recoil Assem ly
LCT-5551
LCT-5544
LCT-5546
LCT-5546
LCT-5542
Part Name Titan Part #
Some Parts Sold As Assem lies
19

20