Titan TG 5500D Owner's Manual

Page 1
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.
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.
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.
IMPORIMPOR
IMPOR
IMPORIMPOR
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ANT!ANT!
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ANT!ANT!
WARNING!
Revision # 030321ATG5500D Manual
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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 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 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.
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 generators 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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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 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.
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
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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
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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
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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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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
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Titan Part #
LCT-5525 N\A N\A LCT-5526 LCT-5525 LCT-5525 LCT-5525 N\A LCT-5526
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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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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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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
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P.O.Box 791, Travelers Rest, S.C. 29690
Phone 864-834-7212
Service/Replacement Parts 800-845-4141
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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 Decibels @ 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
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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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