Titan TG 7500D 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 understand the entire contents of this
Owner’s Manual for the Titan Industrial Model TG 7500D before at-
tempting to operate the generator. This is a diesel engine powered, in-
dustrial 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.
OWNER’S MANUAL
MODEL TG 7500D Industrial Generator
P.O.Box 791, Travelers Rest, S.C. 29690
Phone [phone]
Service/Replacement Parts 800-845-4141
Revision # 030321ATG7500D Manual

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 attempt-
ing 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 must call the factory at 1-800-845-4141 to
answer these questions to his/her complete satisfaction before proceeding.
READ AND COMPLETELYUNDERSTAND 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 SOLELYFOR THE PURPOSE OF PORTABLE POWER.OTHER APPLICATIONS COULD
VOID WARRANTY. USER ACCEPTS RESPONSIBILITY FOR INJURIES AND/OR DAMAGE RESULTING FROM
OTHER APPLICATIONS.
IMPORTANT !
READ FIRST
It is extremely important to read and understand the entire contents of this Owner’s
Manual for the Titan Industrial- Model TG 7500D before attempting to operate the gen-
erator. This is a diesel engine powered, industrial strength generating unit of electri-
cal power. The diesel engine and the generator are both potentially extremely haz-
ardous and could cause physical injury or even death if improperly used.
This Manual contains information to ensure your safety and to prevent any equip-
ment problems. Various terms such as ‘WARNING’, ‘CAUTION’, ‘DANGER’, ‘IMPOR-
TANT’, and the SYMBOL are all used to signify information that is essential for the
operator of this equipment to understand and to practice!
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OWNER’S MANUAL
MODEL TG 7500D
Industrial Generator
2

CONNECTING LOADS
THE TITAN INDUSTRIAL INC. MODEL TG 7500D is a
diesel engine driven, revolving field, alternating current (AC)
generator designed to supply electrical power for com-
patible electrical tools, motors, appliances, and lighting
(see wattage reference guide on page 6 ).
The Model TG 7500D operates at 120 volt and/or 240 volt,
single phase, 60 Hz and will operate devices that require
up to 6000 watts. continuouos and 6800 surge watts at
240 Volts.
GROUNDING THE GENERATOR
It is required by The National Electrical Code to have
the frame and all external conductive parts of the gen-
erator 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 ground-
ing rod (electrode).
CAUTION! Do not connect ground to a preexisting ground
rod, water pipe, or building frame.
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.
P.O. Box 791
Travelers Rest, S.C. 29690
864-834-8550
Toll Free 1-888-828-8126
Replacement Parts 1-800-845-4141
MODEL TG 7500D
DIESEL POWERED
ELECTRIC GENERATOR
Add up the Watts of all devices you connect to the
TITAN INDUSTRIAL GENERATOR at one time. Do not
exceed 6800 Watts on TITAN INDUSTRIAL Generator
Model TG 7500D (see wattage reference guide).
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).
Some electric motors require about three times the rated
Watts of power for start-up. This surge of power is re-
quired 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 con-
nected 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 cor-
rect rated frequency and voltage when running at the
proper governed speed. Incorrect frequency and/or volt-
age could damage connected electrical devices. Chang-
ing settings voids the warranty.
Figure #1 - Grounding Lug Block
DESCRIPTION
Model TG 7500
Voltage 120/240
Frequecny 60Hz
Continuous Watts. 6000
Surge Watts. 6800
3

SAFETY
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 servic-
ing 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.
CAUTION! The engine exhaust contains chemi-
cals known to the State of California to cause can-
cer, birth defects, or other reproductive harm.
The generator produces a very powerful volt-
age that can cause extremely dangerous elec-
trical shock. Avoid contact with bare wires, ter-
minals, etc. never permit an unqualified per-
son to operate or service the generator.
Never handle any kind of electrical cord or de-
vice while standing in water, while barefoot or
with wet hands or when feet are wet. Danger-
ous electrical shock could result.
The National Electric Code requires that the
frame and external conductive parts be prop-
erly connected to an approved earth ground.
Local electrical codes may vary. Check with an
electrician for local grounding requirements.
Use a ground fault circuit interrupter in any
damp or highly conductive area such as metal
decking or steel work.
Do not use worn, bare, frayed or otherwise dam-
aged electrical cords or wiring with the genera-
tor. Adefective cord may result in electrical
shock or may cause damage to equipment.
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 flam-
mable and explosive. Avoid spilling diesel fuel
on a hot engine. Do not allow smoking, open
flames, sparks or heat in the vicinity while han-
dling diesel fuel.
Do not overfill the fuel tank. Leave one inch be-
low fill neck. 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 venti-
lation. This generator’s diesel engine exhaust pro-
duces carbon monoxide gas that can cause un-
consciousness or even death.
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 or other
sources of heat.
Always allow a minimum of 2 feet of clearance on
all sides for ventilation while unit is operating. Al-
low 2 feet of clearance from all combustibles.
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.Change
oil per published schedule
Never insert any object through the cooling slots
of the engine. You could damage the unit or cause
injury.
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
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CAUTION! If it is your first time starting the gen-
erator, allow it to run for 30 minutes before con-
necting electrical loads. This is for wet seating
purposes
CAUTION: Customer takes full responsibility
for use of this unit as a home generation system.
4

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 around oil fill opening.
zRemove the dipstick.
zWipe the dipstick clean.
zPour oil in until it reaches the FULL
mark on dipstick.
zDO NOT OVERFILL!
zCLOSE OIL CAP!
Change oil as published
CHECK AND/OR FILL DIESEL
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
zUse diesel fuel only.
zClean area around fuel cap.
zRemove fuel cap.
zAdd diesel fuel to fuel tank.
zDO NOT overfill. Do not fill above
the red plug inside the fuel tank filter
(this allows for fuel expansion).
zReplace fuel cap.
zWipe up any spilled diesel fuel.
WARNING!
Do not clean filter with any type of
detergent.
Check air filter
zRemove cover panel.
Loosen wingnut and remove air
filter cover.
zNever wash air cleaner with any
kind of detergent or cleaning
solvent.
zAir filter should be changed if
engine performance decreases or
color of exhaust changes.
zNever run engine without air filter.
This can cause rapid engine wear.
.
CHECK AND/OR REPLACE FILTER
Figure #2 - Air Filter Housing
WARNING!
Do not try to start engine with a “dry”
battery! This cause irreversible dam-
age to the battery!
Titan Industrial
Recommends
ONLY
Using Rotella T
Multigrade
15W - 40 Type
engine oil.
Note:
Because this is a diesel engine, fre-
quent oil and filter changes are re-
quired.
Oil Filter\Screen
Oil Capacity 1.2 U.S. Qts.
Oil Drian 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.
5

Wattage Reference GuideWattage Reference Guide
Wattage Reference GuideWattage Reference Guide
Wattage Reference Guide
*Air Conditioner (12,000 BTU) 1700
Battery Charger (20 Amp) 500
Belt Sander (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 Sander (9”) 1200
Edge Trimmer 500 Electric
Nail Gun 1200
Electric Range (one element) 1500
Electric Skillet 1250
*Furnace Fan (1/3 HP) 1200
Hair Dryer 1200
Hand Drill (1”) 1100
Hand Drill (1/2”) 750 to 1000
Hand Drill (3/8”) 500
Hand Drill (1/4”) 250
Device Running
Watts
Device Running
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 Fired Space Heater (140,000 BTU) 400
Oil Fired Space Heater (85,000 BTU) 225
Oil Fired Space Heater (30,000 BTU) 150
*Airless Paint Sprayer (1/3 HP) 600
Handheld Airless Paint Sprayer 150
Radio 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
Weed 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
DAILYEVERYMONTH/ 30 HRS EVERY3 MONTHS/ 100 HRS EVERY6 MONTHS/ 500 HRS
*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.
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
loads connected to the receptacles. Be certain
connected devices are OFF before connecting or
disconnecting.
DANGER!
DO NOT run generator indoors or in poorly venti-
lated areas. Engine exhaust contains carbon mon-
oxide which is an odorless, deadly gas.
WARNING!
To avoid burns, avoid muffler and 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 briskly until the engine is
rotating, then,
release lever.
7. Let engine settle before 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 before attaching any appliances
7

OPERATION OF THE GENERATOR
8
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.
Rubber 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 to 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 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 functioning , 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

RECEPTACLES
Main Breaker
(opens and closes
receptacle circuits)
Shows operating
voltage
DC Output
240 volt receptacle
Starting Switch
Twist Lock
120- Volt
Receptacle
AC Voltage
Selection Switch
120-Volt Receptacle
Hourmeter
20A
9

Engine is running but no
power output is available.
Engine runs good until loads
are connected, then bogs
down.
Engine will not start or engine
starts but runs rough.
Engine shuts down during
operation.
Engine lacks power
1. Circuit breaker is open.
2. Poor connection or defective
cord set.
3. Connected device is bad.
4. Fault in generator.
1. Short circuit in a connected
load.
2. Overloaded generator.
3. Engine speed is too slow.
4. Short in generator circuit.
1. On/Off Switch is turned ‘OFF’.
2. Battery is dead
3. Dirty air cleaner.
4. Out of diesel fuel.
5. Stale diesel fuel.
6. Not enough speed or force is
used for recoil start.
7. Water in diesel fuel.
8. Speed control is not set to
“RUN”.
9. Low oil level.
10. Oil nozzle is dirty.
11. Engine has lost compression.
1. Out of diesel fuel.
2. Fault in engine.
1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
TROUBLESHOOTING
Problem Cause Solution
1. Reset the circuit breaker.
2. Check & repair.
3. Connect another device
that is in good condition.
4. Contact service center.
1. Disconnect shorted load.
2. See ‘Connecting Electrical
Loads’ 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 and refill.
6. Read and follow directions.
7. Drain and refill tank.
8. Move speed control to “RUN”
position.
9. Add oil to proper level.
10. Clean oil nozzle.
11. Contact service center.
1. Fill fuel tank.
2. Contact service center
1. See ‘Connecting Electrical
Loads’ 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.titanindustrial.com
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-7552
LCT-016
LCT-7528
LCT-7528
LCT-7528
LCT-7529
LCT-7557
LCT-7520
LCT-7513
N\A
LCT-7515
LCT-7514
LCT-7543
LCT-7537
LCT-7537
LCT-7536
LCT-7552
LCT-7553
LCT-7528
Part Name Part Name Titan Part #
Titan Part #
Some Parts Sold As Assemblies
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-7520
LCT-7522
LCT-7522
LCT-7522
LCT-7522
LCT-7515
LCT-7515
LCT-7515
LCT-7551
LCT-7514
LCT-7514
Part Name Titan Part #
2. Crank Shaft Assembly
13
Some Parts Sold As Assemblies

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
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-7522
LCT-7527
LCT-7523
LCT-7523
LCT-015
LCT-015
LCT-7523
LCT-7525
LCT-7525
LCT-7525
N\A
N\A
LCT-7526
LCT-7525
LCT-7525
LCT-7525
N\A
LCT-7526
Part Name Part NameTitan Part # Titan Part #
3. Governor Gear Assembly
14
Some Parts Sold As Assemblies

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
N\A
N\A
N\A
LCT-7530
LCT-7531
LCT-7541
LCT-7512
LCT-7541
LCT-7541
LCT-7541
LCT-7541
LCT-7511
LCT-7511
LCT-7511
LCT-7511
N\A
LCT-7501
LCT-7501
LCT-7511
LCT-7511
LCT-7504
LCT-7504
N\A
LCT-7503
Part Name Part NameTitan Part # Titan Part #
4. Head Asssembly
Some Parts Sold As Assemblies
15

5. Piston Assembly
1. Snap Rings
2. Piston
3. Piston Pin
4. Pin Bushing
5. Connecting Rod
6. Rod Cap Bolt
7. Rod Sleeve Bearing
8. Rod Cap
9. Washer
10. Nut
LCT-7516
LCT-7516
LCT-7516
LCT-7517
LCT-7517
LCT-7517
LCT-7517
LCT-7517
N\A
N\A
Part Name Part Name
Titan Part # Titan Part #
Some Parts Sold As Assemblies
*(3) Pistion Rings Not Shown
Part # LCT-5519
16

Fuel Injector LCT-7502 Fuel Pump LCT-7535
6. Fuel Injection System
These Parts Sold As Assemblies
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. Vibration 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. Rubber Fuel Line
18. O-ring
19. Fuel Shut Off Valve
20. Mounting Clamp
LCT-009
LCT-009
LCT-009
LCT-009A
N\A
LCT-7502
LCT-057
N\A
LCT-008
LCT-008A
N/A
N\A
LCT-7550
LCT-010
LCT-7535
LCT-10A
LCT-056
LCT-011
LCT-012
N\A
Part Name Part Name
Titan Part # Titan Part #
Some Parts Sold As Assemblies
Fuel Tanks Vary
18

8. Starter Assembly
1
2
3
4
5
1. Fly Wheel
2. Recoil Cup
3. Blower Housing Gaskets
4. Blower Housing
5. Recoil Assembly
LCT-7551
LCT-7544
LCT-7546
LCT-7545
LCT-7542
Part Name Titan Part #
Some Parts Sold As Assemblies
19

20