Page 1
P.O.Box 791, Travelers Rest, S.C. 29690
Phone 864-834-7212
Service/Replacement Parts 800-845-4141
OWNERS MANUAL
MODEL TG 5500D Industrial Generator
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
Owners 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.
Do Not Operate Equipment until reading & understanding Owners Manual!
Disconnect all loads before starting or stopping generator.
Allow to run for a few minutes with no load before stopping.
IMPORIMPOR
IMPOR
IMPORIMPOR
TT
ANT!ANT!
T
ANT!
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ANT!ANT!
WARNING!
Revision # 030321ATG5500D Manual
Page 2
IMPORTANT !
READ FIRST
OWNERS MANUAL
MODEL TG 5500D
Industrial Generator
It is extremely important to read and understand the entire contents of this Owners
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 Owners 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 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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MODEL TG 5500D
DIESEL POWERED
ELECTRIC GENERATOR
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).
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.
DESCRIPTION
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).
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
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.
GROUNDING THE GENERATOR
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.
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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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 generators 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.
SAFETY
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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.
Never handle any kind of electrical cord or de-
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vice while standing in water, while barefoot or
with wet hands or when feet are wet. Dangerous electrical shock could result.
The National Electric Code requires that the
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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.
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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.
Do not expose unit to excessive moisture, dirt
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or corrosive vapors. Unit must be operated on
a level surface.
Comply with all laws regulating the storage and
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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
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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.
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Only operate this unit outside with adequate ventilation. This generators diesel engine exhaust produces carbon monoxide gas that can cause unconsciousness or even death.
Never store a generator with fuel in the tank where
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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.
Always allow a minimum of 2 feet of clearance on
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all sides for ventilation while unit is operating. Allow 2 feet of clearance from all combustibles.
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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.
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Never insert any object through the cooling slots
of the engine. You could damage the unit or cause
injury.
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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
CAUTION! The engine exhaust contains chemicals known to the State of California to cause can-
cer, 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
CHECK AND/OR FILL DIESEL
CHECK AND/OR REPLACE FILTER
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
z Place generator on a level surface.
z Clean area around oil fill opening.
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 DO NOT overfill. Do not fill above
the red plug inside the fuel tank filter
(this allows for fuel expansion).
z Replace fuel cap.
WARNING!
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 Remove the dipstick.
z Wipe the dipstick clean.
z Pour oil in until it reaches the FULL
mark on dipstick.
z DO NOT OVERFILL!
z CLOSE OIL CAP!
z Wipe up any spilled diesel fuel.
Note:
Because this is a diesel engine, frequent oil and filter changes are required.
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
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ence Guideence Guide
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ence Guideence Guide
Device Running Watts
*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
*Allow 3 times the listed Watts for starting these devices
These wattages shown are approximate and may vary with each specific device
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
WARNING:
Factory warranty is voided if fuel, other than specified diesel fuel, is
used in this engine. Refer to owners manual for fuel.
Maintenance GuideMaintenance Guide
Maintenance Guide
Maintenance GuideMaintenance Guide
DAILY EVERY MONTH/ 30 HRS EVERY 3 MONTHS/ 100 HRS EVERY 6 MONTHS/ 500 HRS
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
*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.
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OPERATION OF THE GENERATOR
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.
Starting the Engine - Electric starting
1. Be sure unit is at a level, well ventalated position
2. Check fluids for proper levels.
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
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 appliances
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
Figure #5
Figure #3 - Fuel Valve Positions
off
Figure #4 - Compression Release Switch
on
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Page 8
OPERATION OF THE GENERATOR
Bleeding Instructions
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)
Figure #6
Rubber Fuel Line
Fuel Pump Port
Steel Fuel Line
Fuel Pump
Throttle Lever
Figure #7
If the unit still wont 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.
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.
Figure #8
Valve Cover
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.
Valve Settings
TDC see Page 20
.012-intake
.013-exhaust
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Control Panel
Starting Switch
Shows operating
voltage
240 volt receptacle
AC Voltage
Selection Switch
Hourmeter
Twist Lock
120-Volt Receptacle
120-Volt
Receptacle
Some Control Panels May Vary
DC Output
Ground Lug
Main Breaker
(opens and closes
receptacle circuits)
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TROUBLESHOOTING
Problem Cause Solution
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.
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. 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.
Engine shuts down during
operation.
Engine lacks power
If engine has a difficult time
starting around freezing
temperatures
Service
1-800-845-4141
Replacement Parts
1-800-845-4141
1. Out of diesel fuel.
2. Fault in engine.
1. Load is too high.
2. Dirty air filter.
3. Engine needs to be serviced.
Toll Free 1-800-845-4141
www.titanindustrial.com
10
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.
Add 2-5 oz. of 15W-40
motor oil to the orange cap
located on top of engine,
next to the Decompression lever.
Fax
864-834-5127
Page 11
Parts Catalog
P.O.Box 791, Travelers Rest, S.C. 29690
Phone 864-834-7212
Service/Replacement Parts 800-845-4141
11
Page 12
1. Cylinder Block Assembly
Part Name
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
Titan Part #
LCT-5552
LCT-016
LCT-5528
LCT-5528
LCT-5528
LCT-5529
LCT-5557
LCT-5520
LCT-5513
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
Some Parts Sold As Assemblies
12
Titan Part #
LCT-5515
LCT-5514
LCT-5553
LCT-5537
LCT-5537
LCT-5536
LCT-5552
LCT-5553
LCT-5528
Page 13
2. Crank Shaft Assembly
Part Name
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
Titan Part #
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
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Page 14
3. Governor Gear Assembly
Part Name
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
LCT-5527
LCT-5527
LCT-5523
LCT-5523
LCT-015
LCT-015
LCT-5523
LCT-5525
LCT-5525
Part NameTitan 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
Some Parts Sold As Assemblies
14
Titan Part #
LCT-5525
N\A
N\A
LCT-5526
LCT-5525
LCT-5525
LCT-5525
N\A
LCT-5526
Page 15
4. Head Asssembly
Part Name Part NameTitan Part #
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
LCT-5530
LCT-5530
LCT-5530
LCT-5530
LCT-5531
LCT-5541
LCT-5512
LCT-5541
LCT-5541
LCT-5541
LCT-5541
LCT-5511
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
Some Parts Sold As Assemblies
15
Titan Part #
LCT-5511
LCT-5511
LCT-5511
N\A
LCT-5501
LCT-5501
LCT-5511
LCT-5511
LCT-5504
LCT-5504
N\A
LCT-5503
Page 16
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
Titan Part #
LCT-5516
LCT-5516
LCT-5516
LCT-5517
LCT-5517
16
Part Name
6. Rod Cap Bolt
7. Rod Sleeve Bearing
8. Rod Cap
9. Washer
10. Nut
Some Parts Sold As Assemblies
Titan Part #
LCT-5517
LCT-5517
LCT-5517
N\A
N\A
Page 17
6. Fuel Injection System
Fuel Injector LCT-5502 Fuel Pump LCT-5535
These Parts Sold As Assemblies
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Page 18
7. Fuel System
Part Name 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
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
Fuel Tanks Vary
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
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Page 19
8. Starter Assembly
1
2
3
4
Part Name
1. Fly Wheel
2. Recoil Cup
3. Blower Housing Gaskets
4. Blower Housing
5. Recoil Assembly
5
Titan Part #
LCT-5551
LCT-5544
LCT-5546
LCT-5546
LCT-5542
Some Parts Sold As Assemblies
19
Page 20
20
Page 21
P.O.Box 791, Travelers Rest, S.C. 29690
Phone 864-834-7212
Service/Replacement Parts 800-845-4141
21
Page 22
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Page 23
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 Continuous-
5000watts Surge
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2- L5-20 Receptacles
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1- L14-20 Receptacle
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Circuit Breaker Protection
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84 Decibels @ 10
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Electric Start\recoil
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7hp Titan Diesel Engine
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(steel sleeve) Cylinder
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3.5 Gallon Fuel Tank
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Approx. Run Time 10hrs
@50% Load
RPM 3720
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Brushless Generator Head
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Copper Windings
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Single Phase 60Hz.
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Low Oil Shut Down
Oil Capacity 26-28oz. 15w-40
z
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Size: L-26 W-19 H-24
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Net. Weight 230LBS.
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One Year Warranty (Residential)
90day (commercial)
Page 24
P.O.Box 791, Travelers Rest, S.C. 29690
Service/Replacement Parts 800-845-4141
Phone 864-834-7212
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