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T70/T80 - Genie Industries

1. 16 Perkins 7 16 Cummins View Flex Hose amp Header T70J amp T80J Muffler Pipe Assembly T70P Shown Mounting Location 11 10 T70 amp T80 Super Quiet Generator PartNo 833015 December2006 REV Section 11 Engine amp Genset Components TEREX FIGURE 11 E DESCRIPTION CD33F040 CD33F030 C51601570 981120 C51601462 C21819 990210 C51601462 CP33A010 CF33C035 C33503300 C90104000 CP33K020 C90103600 C90102900 C91103300 CF33C036 C3503301 C91101500 MUFFLER EXTENSION RIGHT MUFFLER EXTENSION LEFT SCREW FLANGE 3 8 X 3 4 WASHER 3 8 NUT FLANGE 3 8 16 SCREW CARRIAGE 3 8 16 WASHER FLAT 1 2 NUT FLANGE 3 8 16 MUFFLER ASSEMBLY 70 AND 70 EXHAUST PIPE MUFFLER OUT T 70P T 70C CAP RAIN 3 CLAMP U BOLT 3 INCLUDED IN ITEM 12 INCLUDED IN ITEM 12 INCLUDED IN ITEM 12 EXHAUST COWL PERKINS EXHAUST COWL CUMMINS TUBING FLEX EXHAUST 3 MUFFLER ASSY T70 J AND T80 J 4 OD EXHAUST CLAMP V BAND EXHAUST 4 CLAMP U BOLT 4 TUBE FLEX EXHAUST 4 EXHAUST PIPE MUFFLER OUT CAP RAIN 4 FLANGE 4 EXHAUST 1 1 4 8 4 4 4 4 1 1 1 3 3 3 3 1 1 1 1 1 1 4 3 1 1 1 Part No 833015 T70 amp T80 Super Quiet Generator 11 11 Section 11 Engine amp Genset Components December 2006 TEREX This page intentionally left blank 11 12 T70 amp T80 Super Quiet
2. PartNo 833015 T70 amp T80 Super Quiet Generator Section 10 Distribution Panel December2006 TEREX This page intentionally left blank 10 6 70 amp T80 Super Quiet Generator PartNo 833015 December2006 Section 11 Engine amp Genset Components Section Eleven Engine amp Genset Components Part No 833015 T70 amp T80 Super Quiet Generator 11 1 December2006 Section 11 Engine amp Genset Components TEREX Figure 11 A REV Engine Genset Assembly Perkins 1104C 44TG1 T70P PartNo 833015 T70 amp T80 Super Quiet Generator 11 December2006 REV Section 11 Engine amp Genset Components TEREX FIGURE 11 A DESCRIPTION 116835 732267PP 630942 800001 C42300100 C42300400 C42300500 ENGINE amp GENERATOR ASSEMBLY T70P ENGINE 1104C 44TG1 GENERATOR NEWAGE W PMG UCI224E1L73D HARNESS PERKINS ENGINE SWITCH LOW OIL PRESSURE SENDER LOW OIL PRESSURE SWITCH W SENDER WATER TEMP DOUBLE PRONG MAG PICKUP WITH 6 CABLE ADAPTER MAG PICKUP FUEL HOSE 3 8 AIR CLEANER ASSEMBLY FILTER PRIMARY FILTER SECONDARY OIL FILTER FUEL FILTER BELT WATER SEPARATOR RADIATOR HOSE UPPER RADIATOR HOSE LOWER PartNo 833015 T70 amp T80 Super Quiet Generator 11 3 REV December2006 li gt DI AN S A SARS CA S A SA 27 W E
3. 3 5 Troubleshooting E 4 1 Troubleshooting Guide 4 2 833015 70 amp 80 Super Quiet Generator vii TEREX December 2006 TABLE OF CONTENTS REV Section 5 Rev Schematics A INMOGUCTION Ss l 5 1 A Electrical Schematic Control Panel Wiring for Murphy Cascade Controller lU 5 2 A Electrical Schematic Control Panel for Dynagen Controller 5 3 A Electrical Schematic Control Panel for Murphy iGuard Controller 5 4 A Electrical Schematic Distribution Panel Wiring 5 5 A Electrical Schematic Three Position Stack Switch Wiring 5 6 A Electrical Schematic Overcurrent Relay Wiring 5 7 A Electrical Schematic Generator Wiring Breakdown 5 8 A Electrical Schematic Standard Generator Wiring 5 9 Section 6 Rev Decals A Figure 6 A DOCAIS ge 6 2 Section 7 Rev Base Components A Figure 7 A Base 7 2 A Figure 7 B Base Components Liit sind 7 4 Section 8 Rev Cabinet Components A Figure 8 A Cabinet Components Panels
4. 12 2 Rev Options A Figure 13 A Options Llst UU uu aaah luas asta 13 2 Part No 833015 T70 amp T80 Super Quiet Generator ix December 2006 Parts Stocking List Required Parts The following parts are required to perform maintenance procedures as outlined in the TEREX T70 amp T80 Parts and Service Manual Description Part No Perkins 1104C 44TG1 Models Qil Filtet 2 u 741921 Air Filter 741925 amp 741924 Fuel 0 741923 er 866054 John Deere 4045 270 Models elici 741915 Air Filter C33100502 amp C33100503 Fuel Filte T 741916 Veten 741943 Cummins 4BT3 9 G5 Models c er 839062 Air Filt r aaa s C33100502 amp C33100503 Fuel Filled esi core krass spa qisassssssqkas 839061 151 839063 John Deere 4045 275 Models 741915 Air Filter C33100502 amp C33100503 Fuel Fite rss IE 741944 V DEIT esas 741943 x T70 amp T80 Super Quiet Generator Part No 833015 December 2006 Please be prepared with the following information when ordering replacement parts for your TEREX product Machine model number Machine serial number Tere
5. 350 NO bbu OL TIUM TIA mE THON T T 7 Gu D m 9 gt ata z E z dis 100820 9 335 NO OL ston Od 184311404 3NISN3 3HnSS3Hd dii 8 1 SION IV PRATET Drawing ES1000019 Part No 833015 T70 amp T80 Super Quiet Generator ij TEREX Control Panel Wiring Section 5 Schematics December 2006 Drawing EU0007 for Dynagen Controller REV A Snid oma sm YILIN Z183H NO DIN OL ovig GION31OS ON Id MOTO 40 1504 3ALLISOd SHL 440 SNOLLO3NNOO 170A 21 TIY 318VO HOLIMS 3SVHd SV IWYS JHL SI 31890 LYYLS 31038 gain zia NOILNSIYLSIA 3SVHd NO SI 390 18 1 3LON NO S d OL NONNOD YOLIINNOD jo HOLMS did n pis 69029Sr8Z1 Nr desa HHHHHHBBB 1534 4 XINVHOSAO osia Nvuo 2
6. m S10d LNSNLSNFAV posl mE els asna voz ANAL HOIH mn E N3349 m ASVIXNV re LOWLNOD 1391 3LOW3H 2 PE 318vo 222885882 BY JN OcZ 8 vhi 6 d I NMOSE E NEM 9 ania Voor osu WAS 4 635 1Snrav SLIOA HOLIMS 319901 NOLLNSHSN 1 9 1531 pg ks AONIDHINI SL 3LIHM MOVTE Q3aunovia 00400vZ SI LUV Nvd 1051409 40 OVE IHL OL GIONSTOS LNNOW yovig Movia Movia 2 SYNOH 3NION3 J9AI1 Tan 35055339 10 WAL SLIOA OV 100390 335 AV 138 HOO NO L OL MOV Ig aas T70 amp T80 Super Quiet Generator Part No 833015 Section 5 Schematics December 2006 TEREX Control Panel Wiring for Murphy iGuard Controller REV A Drawing EU0004 ENGINE GENERATOR AC FREQUENCY A B WHITE FROM SHUNT PLUGGED WHITE 14GA TO SOLENOID BUTT SPLICE PIN1TO VOLTS SOLANOID AMPS AU DOOR 3 PIN2 SWITCH GABLE POTENTIOMETER YELLOW E STOP 5 4 T70 amp T80
7. Please environmentally safe vi T70 amp T80 Super Quiet Generator Part No 833015 December 2006 REV A Introduction Section 1 Section 2 Rev A A A A Section 3 Rev A Section 4 Rev A TEREX Table of Contents Important Information Introduction ii How to Read Your Serial Number iii Parts Stocking 22424 x Howto Order umu ERR xi Service Parts Fax Order Form Safety Rules General Safety RUES u aa Quan uu Sasak Specifications SDpecCificatfioniSr u uu nu nq eden a 2 1 Specifications Contiued a 2 2 Torque Specifications 2 3 Generator Torque Specifications 2 4 Scheduled Maintenance Procedures 3 1 Pre delivery Preparation 3 2 Maintenance Schedules T70P amp T70C Lubrication and Maintenance Service Intervals 3 3 T70J Lubrication and Maintenance Service Intervals 3 4 T80J Lubrication and Maintenance Service Intervals 3 4 T70J T70P amp T70C Newage Generators Maintenance Schedule 3 5 T80J Newage Generators Maintenance Schedule
8. 8 2 A Figure 8 B Cabinet Components Doors 8 4 Section 9 Rev Control Box Components A Figure 9 A Control Panel Upper T70C T70J amp T70 P 9 2 A Figure 9 B Control Panel Upper 9 4 A Figure 9 C Control Panel Lower T70C T70J amp T70 P 9 6 A Figure 9 B Control Panel Lower T80J 9 8 viii T70 amp T80 Super Quiet Generator Part No 833015 December 2006 REV A Section 10 Section 11 Section 12 Section 13 TEREX TABLE OF CONTENTS Rev Distribution Panel A Figure 10 A Distribution Panel 10 2 A Figure 10 B Generator amp Generator Parts 10 4 Rev Engine amp Genset Components A Figure 11 A Engine Genset Assembly Perkins 11 2 A Figure 11 8 Engine Genset Assembly John Deere 11 4 A Figure 11 C Engine Genset Assembly Cummins 11 6 A Figure 11 D Engine Genset Assembly John Deere 11 8 A Figure 11 E Engine Muffler Assembly Cummins John Deere amp 11 10 Rev Trailer Components A Figure 12 A Trailer Components
9. TEREX Figure 7 B REV amp Cummins Radiator Drain Components Engine Shown Note Perkins Base Components gt o lt S Detail Battery Mounting E o c 5 og Part No 833015 T70 amp T80 Super Quiet Generator December 2006 REV Section 7 Base Components TEREX DESCRIPTION FITTING BULK HEAD 1 2 ADAPTER 1 2 X1 4 NIPPLE PIPE 1 4 X1 5 VALVE NEEDLE BARB 3 8 X1 4 NPT CLAMP 7 16 TO 25 32 HOSE FUEL 3 8 ADAPTER 1 4BSPP X 1 ANPT BARB 3 8 X1 4 NPT 90 DEGREE NIPPLE PIPE 1 4 X1 5 VALVE NEEDLE BARB 3 8 X1 4 NPT 90 DEGREE CLAMP 7 16 25 32 HOSE FUEL 3 8 SCREW HEX 1 2 X1 5 S S GENERATOR HAT CHANNEL T 70P GENERATOR HAT CHANNEL T 70C WASHER FLAT 1 2 NUT LOCK NYLON INSERT 1 2 13NC GR 2 ZPIN HOSE OIL DRAIN 3 4 CLAMP 9 16 X 1 1 16 BARB 3 4 X1 2 NPT VALVE BALL 1 2 FITTING SWIVEL FITTING STR TRD ELBOW FITTING ELBOW BULKHEAD AIR 60KW PERKINS BULKHEAD AIR 60KW JOHN DEERE BULKHEAD AIR 60KW CUMMINS FOOT ENGINE RIGHT 60KW JOHN DEERE FOOT ENGINE RIGHT 60KW CUMMINS FOOT ENGINE LEFT 60KW JOHN DEERE FOOT ENGINE LEFT 60KW CUMMINS BATTERY WET 12V GR31 1000 CCA DEEP CYCLE LA BATTERY CABLE SET 54 4GA MBT TERM P amp N R amp B HOOK BATTERY HOLD DN PAIR ANGLE BATTERY HOLD DOWN Part No 833015 T70 amp
10. December 2006 Section 5 Schematics X 14 ing IN Control Panel W for Murphy Cascade Controller REV 318VO GaH1V3HS OMV 3GIS AH LN3 3HIM WO H4 M3IA HOLO3NNOO SLOVINOO 14 15 ozovsrnn TT Jovi SS3NHVH olovsenn SSINYYH 3SVHd NO SLOVLNOO 18V1S SLOWSY 311 TYNINYIL 440 SNOLLO3NNOO 110A 21 TIY 318V9 HOLIMS 4000 3SVHd IHL SV SI 318 0 1591 SLOWSY 31 ON HOLVNLOV OL Gina EE HOLVNLOV OL mS aay alelsia lt x elo 5 z o az UL 2 B 8 gt yayvan 2 5 5 Im m a lt 919 dnvsi 8 2 B 3 ui 8 EET LIVE A 5 118 A SIHNWNMOSS e 1N0 I xnv T 1 xnv 9 auoxa rv 5 r3 9944 1001 mnm g 3NION3 IH 208 NIL xn 5 z 2 9 MNVHD OL TIVO n o 1no xnv 29 0 380 LON Mava z 3avosvo 85 MOTE MOTER EMEKEEI 3ng o3s 3N18 038 8 BEEN REET E zu 1snrav sLion ams ams HOLIMS zu 319901 ZONVEO w Movie 2 LYVLS 9105 OL 10020 338
11. Go Go NI AJ o GN Co AJ col mn eJ OIN O OJ Ive OO PO e em CIN NI ON amp Co NIN OW zs EN o clo rol RI ESAN Ni e PRES e a D NI I EN a ES zu DI 5 Em o e AR I ail zi a NI KR AY O AY N Gaai kasa N 9v An anti seize lubricant MUST be used stainless steel hardware Part No 833015 T70 amp T80 Super Quiet Generator 19 TEREX GENERATOR TORQUE SPECIFICATIONS Generator Flex Plate to Flywheel Operator s Manual REV B Generator Case to Bellhousing 1 2 Hex Head Screws for Lifting Channel Genset Isolators 20 T70 amp T80 Super Quiet Generator Part No 833015 December 2006 TEREX Service amp Parts Catalog TEREX Introduction December 2006 Important Read understand and obey the safety rules and operating instructions in the appropriate Operator s Manual on your machine before attempting any maintenance procedure Basic mechanical hydraulic and electrical skills are required to perform most procedures However several procedures require specialized skills tools lifting eq
12. 6 gt GENERATOR STACK SWITCH WIRE SIZE 70 ALL C42204002 6 GA EPDM SUE S GA E DM NOTE FOR REFERENCE SEE DRAWINGS ES100007 amp ES100008 5 6 T70 amp T80 Super Quiet Generator Part No 833015 December 2006 REV BRN INPUT 1 ORG INPUT 2 GROUND zx Section 5 Schematics TEREX Overcurrent Relay Wiring Drawing ES1000006 OVER CURRENT PROTECTOR 3 DOOR SWITCH N O WHITE RED 14 YELLOW 14 GREEN 14 WHITE 14 BLAGK SHIELDED CABLE TO ENGINE RUNNING 12 VDC SOURCE TO SHUNT TRIP ON BREAKER RED BLACK 14 TO SHUNT TRIP ON BREAKER TO ON VOLT METER O Z YN WARNING LIGHT SECONDS 18 15 16 00000000 OVER CURRENT RELAY FACE PLATE THE CT S FOR EACH UNIT WITH THE OVERCURRENT RELAY ARE AS FOLLOWS 251 T25G 4 100 5 451 T50 J P amp T70 J C P 3 100 5 8 1 200 5 T90P amp T120 C P 3 200 5 amp 1 400 5 T180C 3 400 5 amp 1 600 5 T270C 3 600 5 1 1000 5 Part No 833015 T70 amp T80 Super Quiet Generator TEREX Section 5 Schematics Generator Wiring Breakdown Drawing ES1000007 T9 FROM GENERATOR 9 FROM STACK SWITCH T8 FROM GENERATOR 8 FROM STACK SWITCH T7 FROM GENERATOR 7 FROM STACK SWITCH T6 FROM GENERATOR 6 FROM STACK SWITCH 8 SENSING LEAD FROM AVR BLUE TAPED WIRE FROM CONT
13. INCLUDED IN ITEM 13 INCLUDED IN ITEM 13 DECAL SYMBOL FOR GROUND SCREW HEX 1 2 13 X 2 5 WASHER LOCK STAR 1 2 FLAT WASHER 1 2 SBZ LOCK WASHER 1 2 SBZ PAR RRA RA HEX NUT 1 2 13 SBZ DECAL 3PH DISTRIBUTION PANEL WASHER LOCK 3 8 NUT CLIP 1 4 20 X 3 4 WASHER LOCK 1 4 WASHER FLAT 1 4 TRIM LOCK 1 4 Part No 833015 70 amp T80 Super Quiet Generator 10 3 Section 10 Distribution Panel December2006 TEREX Figure 10 B Generator amp Generator Parts REV mr Items 5 9 are located inside the generator 0 The items shown this view located inside of the Stack Switch Housing 10 4 T70 amp T80 Super Quiet Generator PartNo 833015 December2006 REV Section 10 Distribution Panel TEREX FIGURE 10 B DESCRIPTION C43304002 CL 008 630100 124105 836427 836424 836425 836426 CMX341 830005 O 0 NS VOLTAGE SELECTOR SWITCH DECAL DO NOT CHANGE POSITION GENERATOR POST TERM ISOLATOR STUD BRACKET GENERATOR ISOLATOR POST RECTIFIER SERVICE KIT RSK1001 FORWARD DIODE PLATE 130 1413 REVERSE DIODE PLATE 130 1414 VARISTOR 073 08063 AUTOMATIC VOLTAGE REGULATOR NEWAGE UCH 027 OPERATION MANUAL UCI
14. RAIN DEFLECTOR RADIATOR HOSE UPPER RADIATOR HOSE LOWER FAN SHROUD PartNo 833015 T70 amp T80 Super Quiet Generator REV December2006 EGON CAO 4 VNR NPE am Ni SE EN 82 gt am ESA J Uf x Va s Part No 833015 Section 11 Engine amp Genset Components TEREX Figure 11 D Engine Genset Assembly John Deere 4045 TF275 T80J T70 T80 Super Quiet Generator December2006 REV Section 11 Engine amp Genset Components TEREX FIGURE11 D DESCRIPTION G IN ENGINE amp GENERATOR ASSEMBLY T80J ENGINE 4045TF275 GENERATOR NEWAGE W PMG UCI224F1L73D FAN BREEZA 21 FAN GUARD FAN SHROUD AIR CLEANER ASSEMBLY FILTER PRIMARY FILTER SECONDARY RADIATOR RADIATOR HOSE UPPER RADIATOR HOSE LOWER ELBOW RUBBER 3 ID 90 DEGREE HOSE SPIRALITE 110 3 ID 3 5 0D GREEN PIPE AIR INTAKE 90 DEGREE FUEL LINE STEEL 1 4 FUEL HOSE 1 4 FUEL HOSE 3 8 ADAPTER LOP SENDER BELT WATER SEPARATOR OIL FILTER FUEL FILTER mk ae k k PartNo 833015 T70 amp T80 Super Quiet Generator Section 11 Engine amp Genset Components December 2006 l TEREX Figure 11 E Engine Muffler Assembly Cummins John Deere amp Perkins REVA ar E 2 Front
15. T80 Super Quiet Generator Section 7 Base Components December 2006 TEREX This page intentionally left blank 7 6 T70 amp T80 Super Quiet Generator Part No 833015 December 2006 Section 8 Cabinet Components Section Eight Cabinet Components Part No 833015 T70 amp T80 Super Quiet Generator 8 1 Section 8 Cabinet Components December 2006 TEREX Figure 8 A Cabinet Components Panels REV A Perkins Exhaust amp Radiator Hatch Arrangement Cummins Exhaust amp Radiator John Deere Exhaust amp Radiator Hatch Arrangement Hatch Arrangement 8 2 T70 amp T80 Super Quiet Generator Part No 833015 December 2006 993422 C71014 CF59T019 990670 CU59T019 720440 C51601462 CF58T043 CF58T036 CF57T010 CF52T030 CF58T010 CF52T010 720440 72100400 GUU401000 71100200 Section 8 Cabinet Components TEREX FIGURE 8 A DESCRIPTION SCREW FLNGE 1 4 20 75 FLAT WASHER 11 16 OD EXHAUST HOLE COVER RIVET POP 3 16 1 2 S S BLIND RIVET COVER DECKPLATE WEATHERSTRIP ADHESIVE 1 8 X 1 2 WIDE PLATE DECK SCREW OUT NUT LOCK NYLON INSERT 1 4 20NC GR 2 ZP FOAM BLK URETHANE 1 INCH HOUSING TOP PANEL SCREW FLANGE 3 8 X 3 4 PATCH WASHER FLAT 3 8 Z NUT FLANGE 3 8 16 Z EXPANDED LOUVER MESH LOUVER ASSEMBLY F SERIES EXPANDED SCREW 3 8 16NCX3 HHCS GR 5 ZP WASHER LOCK 3 8 WASHER FLAT 3 8 NUT CLIP 3 8 16X3 4 HOUSING REAR CNR L
16. 12 4 70 amp T80 Super Quiet Generator PartNo 833015 December2006 Section 13 Options Section Thirteen Options Part No 833015 70 amp T80 Super Quiet Generator 13 1 Section 13 Options December 2006 TEREX Figure 13 A REVA Options List PART DESCRIPTION 0GSX0030 0GSX0031 0GSX0036 0GSX0037 0GSX0040 0GSX0042 0GSX0066 0GSX0071 OGSX0075 0GSX0086 0GSX0115 0GSX0116 0GSX0137 0GSX0140 0GSX0142 0GSX0110 0GSX0111 0GSX0164 0GSX0138 0GSX0024 C41101000 C33204000 C42300800 C33301002 682776 682777 C33301003 CORNER JACKS JACK MOUNT TUBE CENTER MOUNT JACK TRICKLE CHARGER WITH MALE RECEPTACLE RECEPTACLE 15A 125V RECEPTACLE 15A 125V 3 5A BATTERY CHARGER WITH MONITORING RECEPTACLE 15A 125V RECEPTACLE 15A 125V TRAILER HITCH 2 BALL LIGHTED CONTROL PANEL EXTERNAL FUEL CONNECTION LOW COOLANT SHUTDOWN SELECTOR SWITCH IN PANEL BATTERY DISCONNECT SWITCH TRAILER HITCH 2 16 BALL 12 000 LB RATED TRAILER LIGHT CONNECTOR 4 POLE FLAT SPARE TIRE AND WHEEL MOUNTS ON A FRAME SPARE TIRE MOUNTING BRACKET UNIVERSAL BLOCK HEATER JOHN DEERE RECEPTACLE 15A 125V RECEPTACLE 15A 125V BLOCK HEATER PERKINS RECEPTACLE 15A 125V RECEPTACLE 15A 125V TRAILER W HYDRAULIG SURGE BRAKES TRAILER W ELECTRIC BRAKES LED TRAILER LIGHTS SPARE TIRE AND WHEEL MOUNTS ON A FRAME SPARE TIRE MOUNTING BRACKET SPARE TIRE MOUNTING BRACKET UNIVERSAL OPTION GS C
17. 176 17 23 i 24 25 339 2 284 2 352 571773 1016 80 110 149 93 126 20 64 90 90 122 10 200 271 380 515 146 474 670 908 560 8 12 800 7290 1749 1090 12 1260 2010 2725 1700 METRIC FASTENER TORQUE CHART DI 3 3 0 1 Ep wo 1 m ER EP c H ER 0 1 1 za T D I ro D En k mk m D JO to oe a c PO Q NI co e Dv e Dv Po N Po Ber D odo NAM 0 o gt A ola m alo gt O CO o e N 9 lt p W 8 Fr c W 8 oO B lt co Al Ol ON 00 A N do an olo ojo olm ol oj S BIAS ol N o o co PINI OF po AN D 83 eim Go P gt RIAN NIA Sj 29 o 2 ol oo no NI OW 5 N AIO alo gt PRN A Ol NI ro a OF Co NI mmo lt o on
18. AlN ele ele bs gje AT N pc OJ EA Part 833015 70 amp 80 Super Quiet Generator 2 3 TEREX Section 2 Specifications GENERATOR TORQUE SPECIFICATIONS Generator Flex Plate to Flywheel December 2006 REV Generator Case to Bellhousing 1 2 Hex Head Screws for Lifting Channel Genset Isolators T70 amp T80 Super Quiet Generator Part No 833015 December2006 Section Scheduled Maintenance Procedures TEREX Scheduled Maintenance Procedures REVA Observe and Obey Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine Scheduled maintenance inspections shall be completed as specified using the supplied Lubrication and Maintenance Service Interval Charts provided in this section AWARNING Failure to perform each procedure as presented and scheduled could result in death serious injury or substantial damage M Immediately tag and remove from service a damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Keep records on all inspections for three years M Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection Unless otherwis
19. CONNECTIONS UN LESS YOU HAVE CREATED A SAFE WORKING AREA AROUND YOU MAKE SURE YOU HAVE MADE ALL OTHER PERSONS IN THE IMMEDI ATE AREA FULLY AWARE OF WHAT YOU ARE DOING When new generator is not producing voltage the testing or wiring personnel should first verify that the unit is wired correctly The stack switch and generator leads should all be checked as well as the breaker and sensing leads If the unit was not wired correctly and you flashed the generator you could burn up the unit Do not forget to check the sensing leads Part No 833015 T70 amp T80 Super Quiet Generator TEREX TROUBLESHOOTING Procedure for testing generator with no output cont After performing the initial checks above remove the field wires from the voltage regulator F1 or X is positive and F2 or XX is negative Connect the battery to the F1 or X wire and battery to the F2 or XX wire Start the engine and check for the rated voltage Hooking this up incorrectly will reverse polarity and could damage the voltage regulator and or generator end This check should correct any voltage problems If your voltage does not come up to the rated voltage this indicates an internal problem with the generator end The output should be close to proper voltage Also if the unit comes up to voltage check for even reading across the lines if they are not this would mean you probably have a problem with the wiring of the switch o
20. December 2006 TEREX SPECIFICATIONS REV MODEL 7 1 776 TOP 789 GENERATOR Brushless 4 pole Synchronous Single bearing Standard Standard Standard Standard 1 800 rpm Class Insulation Generator Standard Standard Standard Standard High wye Low wye Zig zag Voltage Selector Standard Standard Standard Standard 3 Phase Voltage 208 220 240 416 440 480 Standard Standard Standard Standard 600 Volt Optional Optional Optional Optional 1Phase Voltage 120 127 139 240 254 277 Standard Standard Standard Standard Convenience Receptacles Standard Standard Standard Standard 2 20A 120V GFCI Duplex Receptacles Standard Standard Standard Standard 3 50A Tempowers Standard Standard Standard Standard AVR Voltage Regulation 1 596 Standard Standard Standard Standard Electronic 1 296 Speed Control Governor Standard Standard Standard Standard Murphy Cascade Start Stop Controller Standard Standard Dynagen ES52 Start Stop Controller Standard Murphy iGuard Start Stop Controller Standard TRAILER HydraulicBrakes Standard Standard Standard Standard Electric Brakes Optional Optional Optional Optional Pintle Rng 3 inch Standard Standard Standard Standard Coupler Hitch 2 inch Optional Optional Optional Optional Coupler Hitch 2 5 16 inch Optional Optional Optional Optional SKID MOUNT Standard Standard Standard Standard DIM LxWxH in 110x44x60 110x44x60 110x44x60 110x44x63 Weight Dry Ibs 4157 4157 4157 4157
21. Generator Part No 833015 December2006 Section 12 Trailer Components Section Twelve Trailer Components Part No 833015 70 amp T80 Super Quiet Generator 12 1 Section 12 Trailer Components December2006 TEREX Figure 12 A Trailer Components REV Electric Brake Controller amp Hitch 12 2 T70 T80 Super Quiet Generator Part No 833015 December2006 REV Section 12 Trailer Components TEREX FIGURE 12 A DESCRIPTION G TRAILER GENSET F1 SERIES HYDRAULIC BRAKES TRAILER GENSET F1 SERIES ELECTRIC BRAKES AXLE HYDRAULIC TRAILER BRAKES AXLE ELECTRIC TRAILER BRAKES TIRE AND WHEEL MOUNTED ST205 75R15 LOAD C LUG NUT SAFETY CHAIN HITCH MOUNT INCLUDES HYDRAULIC ACTUATOR CONNECTOR 6 PIN NUT RING HITCH STANDARD FENDER PLASTIC LEFT REAR OR RIGHT FRONT AMBER CLEARANCE LIGHT RED CLEARANCE LIGHT C HOOK SAFETY CHAIN CLEARANCE LIGHT MOUNTING KIT STOP TAIL LIGHT W GROMMET AND PLUG TAG LIGHT KIT ELECTRIC BOX WIRE HARNESS FOR ELECTRIC BOX HYDRAULIC LINE METAL HYDRAULIC HOSE KIT HITCH MOUNT FOR TRAILER WITH ELECTRIC BRAKES FENDER PLASTIC LEFT FRONT OR RIGHT REAR N N R 2 1 6 6 6 2 1 2 1 1 1 2 2 2 2 4 2 1 1 1 1 1 1 2 PartNo 833015 T70 amp T80 Super Quiet Generator Section 12 Trailer Components December2006 TEREX This page intentionally left blank
22. INJURIES TO THE PERSON OPERATING THE MACHINE OR DAMAGE THE GENERATOR NEVER SHUT THE UNIT DOWN WITH THE MAIN GENERATOR CIRCUIT BREAKER IN THE ON POSITION THIS CAN CAUSE DAMAGE TO THE GENERATOR AND OR THE CONNECT ED APPARATUS Turn all generator breakers to the OFF position Allow the engine to run for 5 minutes under no load until the coolant temperature gauge reads approximately 175 F as a cool down cycle For Cascade Equipped Generators Stopthe engine by pushing the Cascade Controller OFF button For DynaGen Equipped Generators Stopthe engine by switching the DynaGen toggle switch to the OFF position For iGuard Equipped Generators Stopthe engine by pushing the iGuard Controller OFF button Part No 833015 T70 amp T80 Super Quiet Generator 17 TEREX WET STACKING Wet Stacking is a common problem with diesel engines which are operated for extended periods with light or no loads applied When a diesel engine operates without sufficient load it will not operate at its optimum temperature This will allow unburned fuel to accumulate in the exhaust system which can foul the fuel injectors engine valves and exhaust system including turbocharg ers causing the engine to run rough and reduce the operating performance Wet Stacking does not usually cause any perma nent damage and can be alleviated if additional load is applied to relieve the condition Applying an increa
23. OR DEATH EXCERCISE EXTREME CAUTION AROUND ANY ELECTRICAL COMPONENT WHEN OPERATING THIS UNIT Procedure for changing the voltage potentiometer INSTALLATION AND ANY WORK PERFORMED ON THIS UNIT SHOULD BE DONE ONLY BY A QUALIFIED ELECTRICIAN Make sure generator is turned off and e stop is engaged before opening control panel Locate the two wires going to the back of the potentiometer Both wires will be white with a red stripe Both wires have been spliced into harness wires and should be cut so that the splice is taken out It is better to have as few splices as possible and you will be replacing the splice you cut out Section 4 Troubleshooting TEREX TROUBLESHOOTING Oncethe wires are loose go to the front of the control panel and loosen the lock nut holding the potentiometer Putthe new potentiometer in its place and retighten lock nut HReattach new wires to the same wires and the same configuration as the ones that were cut loose in step 3 e After completing the installation of the new potentiometer go back and check all connections to make sure everything is tight and that no connections are loose this includes all other wiring on the back of the control panel and on the inside of the control box You should now be able to restart the generator and check for proper operation If any further adjustment is needed to the voltage of the generator please call TEREX at 1 800 433 3
24. Sqv311 Bim J ar HOLVHINEO 0 HOLVHINSON NO 5 9 o OLIN OLIN OL d 5 VINEN VW3N 2 5 a ja a 5 5 Lal 1 p fe EE 2 wa te ded Vard Ve VINSN VINSN E 2 6H Nr Si L He 796 VIN3N VIN3N x E p Jar Jaje Ee g u VWAN 87 55 gz eg INNHS L 3NNOO cc H313W OL 3LIHWMOV IS r vvenoooL ama wada ou ZBL 42001 A U Wada ois LLI December 2006 70 amp T80 Super Quiet Generator Part No 833015 Section 5 Schematics October 2006 TEREX This page intentionally left blank 5 10 T50 Super Quiet Generator Part No SSQMT50J P December 2006 Section 6 Decals Section Six Decals Part No 833015 T70 amp T80 Super Quiet Generator 6 1 TEREX Section 6 Decals December 2006 Figure 6 A REV Decals 853070 T70J amp T80J C52100100 T70P amp T70C CU51A102 720 E T70 NO 2 DIESEL FUEL O CU51A126 CU51A305 CU51A112 51 110 CU51A113 T70P amp T70C 853070 T70P amp T70C C52100100 T70J am
25. amp R HOUSING DOOR STOP HOUSING LT FRNT CNR HOUSING FRONT PANEL HOUSING RT FRNT CNR WEATHERSTRIP ADHESIVE 1 8 THICK X 1 2 WIDE WEATHER STRIP 3 8X3 4 1 5 INSULATIO MELAMINE FOIL BAKED FOAM BLK URETHANE 1 2 Part No 833015 T70 amp T80 Super Quiet Generator TEREX Figure 8 B Cabinet Components Doors Section 8 Cabinet Components A December 2006 REV A 8 4 T70 amp T80 Super Quiet Generator Part No 833015 November2007 Section 8 Cabinet Components TEREX REV B FIGURE 8 B SCREW FHSC 1 4 20 X 1 BLACK WASHER FLAT 3 8 NUT NYLOCK 10 24 Z HINGE LIFT OFF STEEL BLACK C53200100 LITERATURE BOX BLACK PLASTIC C51200000 LATCH BLACK KEY LOCK ADJ T HANDLE 993360 RIVET POP 3 16 X 3 4 ALUM 3 8 1 2 GR CF54T011 HOUSING DOOR DISTRIBUTION C74419 SCREW CARRIAGE 1 4 20 X 75 STAINLESS STEEL C71014 FLAT WASHER 11 16 OD 990150 NUT LOCK NYLON INSERT 1 4 20 NO GR 2 ZP 71100500 BLACK URETHANE 1 51400200 RUBBER DOOR STOP W WASHER C41135000 RIVET POP 1 4 X 1 2 HOUSING DOOR ACCESS LEFT HOUSING DOOR ACCESS RIGHT WINDOW CONTROL DOOR HOUSING DOOR CONTROL GASKET WINDOW CONTROL DOOR TRIMLOCK SEAL 7 16 BLACK FINE PEBBLE KEY N G N EN gt gt N 5 Part No 833015 T70 amp T80 Super Quiet Generator 8 5 Section 8 Cab
26. of steps PartNo 833015 T70 amp T80 Super Quiet Generator 3 1 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual TEREX TEREX North America P O BOX 3147 Rock Hill SC 29732 USA Toll Free 800 433 3026 in U S A and Canada Copyright 2006 by TEREX Corporation TEREX is a registered trademark of TEREX Corporation Rev B Instructions Use the operator s manual on your machine The Pre delivery Preparation consists of completing the Pre operation Inspection the Maintenance items and the Function Tests Use this form to record the results Place a check in the appropriate box after each part is completed Follow the instructions in the operator s manual If any inspec
27. press the MANUAL MAN BUTTON on the Cascade Controller Make sure all debris and obstructions have been cleared from moving parts and electrical terminals The generator will only make 3 attempts at starting before it must be reset with the switch If unit starts proceed to step 4 For DynaGen Equipped Generators 2 If the unit is equipped with a DynaGen controller TEREX place the toggle switch in the MANUAL position to start the engine Make sure all debris and obstructions have been cleared from moving parts and electrical terminals If the engine fails to start the NO SPEED SIGNAL led will light Return the toggle switch to the OFF position then back to the MANUAL position If the engine fails to start again refer to the DynaGen manual or call Terex service The AUTO position is to be used only with the remote start feature If unit starts proceed to step 4 For iGuard Equipped Generators 3 Place the toggle switch in ON position then press the START BUTTON on the iGuard Controller Make sure all debris and obstructions have been cleared from moving parts and electrical terminals The generator will only make 3 attempts at starting before it must be reset with the switch If unit starts proceed to step 4 4 Now that the generator set is running allow five minutes for warm up time 5 Listen for any unusual sounds or excess vibrations that could signal problems and require immediate shutdown of the unit
28. 0 4826 4067 METRIC FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual Class4 6 44 Class 8 8 Class 10 9 Class 12 9 DRY DRY DR 110 130 200 271 N e e t A FT gt N gt i B iz Bl ile Bli ile Bl 1 gt eo zr Pol Po e CO 4 o amp P C1 CO On E N O1 a a o D l CO N co no N D one oO ao oS l I m a r 00 B 9 lt r c 0 B g lt 00 B DRY DR 9 365 236 2 722 0 13 830 1055 682 925 909 1233 8E B 1 E N o OY En A o toj lt OY 2 AIR SIN SEIN co Ao NO NIE I AI ge oF M o p oN olo SA S SJ oy CO ER 00 o gt ny S o co N gt o ol Dv gt ol 4 A O al ob OY nob
29. 026 for assistance Part No 833015 T70 amp T80 Super Quiet Generator Section 4 Troubleshooting December 2006 TEREX This page intentionally left blank 4 10 T70 amp T80 Super Quiet Generator Part No 833015 December 2006 REV A Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Section 5 Schematics TEREX Schematics About This Section There are two groups of schematics in this section An illustration legend precedes each group of drawings Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry General Repair Process Malfunction Identify discovered symptoms gt Troubleshoot problem still exists Return to Perform service i repair solved Part No 833015 T70 amp T80 Super Quiet Generator 5 1
30. AM LOCK DISTRIBUTION PANEL N ed 13 2 T70 amp T80 Super Quiet Generator PartNo 833015
31. AUSE SEVERE SHOCK OR DEATH ONLY QUALIFIED ELECTRICIANS SHOULD PERFORM ELECTRICAL WORK NEVER OPERATE THE VOLTAGE SELECTOR SWITCH WHILE THE GENERATOR IS RUN NING THIS WILL RESULT IN IMMEDIATE DAMAGE TO THE SWITCH THE GENERATOR OR THE CONNECTED EQUIPMENT WHICH WILL ALSO VOID THE WARRANTY IT MAY RESULT IN SERIOUS INJURY TO THE OPER ATING PERSONNEL 14 T70 amp T80 Super Quiet Generator Part No 833015 Operator s Manual REV VOLTAGE SELECTOR SWITCH OPERATION voltage selector switch can control the single phase receptacles provided on the unit Their indicated voltages should be checked after selecting the setting of the switch The Y voltage configurations of 480 and 240 will have a voltage of 139 on the GFI receptacles The voltage selector switch will have three posi tions and each position gives a different output to the three phase distribution lugs designated as L1 L2 13 and N located on the distri bution panel In the three phase 480 277 position the follow ing will be the normal output voltages Line to Line L1 to L2 L2 to L3 L1 to L3 480 VAC 3P Line to Neutral L1 12 or L3 to N 277 VAC 1P NOTICE This three phase wiring configuration is referred to as Hi Wye In the three phase 240 139 position the follow ing will be the normal output voltages Line to Line L1 to L2 an
32. GE OIL PRESSURE GAUGE COOLANT TEMP SCREW 1 4 20NCX3 4 BUTTON HEAD 18 8 S S WASHER LOCK 1 4 WASHER FLAT 1 4 RIVET POP 3 16X 602 C51600800 NUT CLIP 1 4 20X3 4 261305 CONTROLLER IGUARD 600A C51200201 HINGE PIANO 9 SS CU43A050 PLASTIC ABS 1 8 10 5 X33 51601550 SCREW SELF TAPPING 10 X 3 4 CU42T070 BRACKET LATCH 220370 WIRE HARNESS 853813 DECAL KIT RECEPTACLES BREAKERS 853815 DECAL CONTROL PANEL C42400700 SOLENOID STARTER amp GLOWPLUGS R661493 120V RELAY R661494 120V RELAY BASE N N 2 1 1 1 2 1 1 1 1 1 1 1 PartNo 833015 T70 amp T80 Super Quiet Generator 9 5 Section 9 Control Box Components December 2006 TEREX Figure 9 C Control Panel Lower T70P T70C amp T70 J REV A ENGINE GENERATOR 9 6 T70 amp T80 Super Quiet Generator PartNo 833015 December2006 REV Section 9 Control Box Components TEREX FIGURE 9 C DESCRIPTION CF42T010 CF41F020 C42104900 C42103400 C42103600 CF41F040 684640 C42500100 C42500200 CF41T031 47100300 CU45A010 C51600800 853813 CU51A122 CONTROL PAN ASSY PANEL 1PH 60 70KW BREAKER 225A SHUNTTRIP 240VAG 12VDC BREAKER 20A 120 240V BREAKER 50A 120 240V BREAKER MNT PLATE RECEPTACLE 20A 120V DUPLEX W GFI TRANSFORMER 100 5 TRANSFORMER 200 5 TEMP POWER SLOPE RECEPTACLE TWISTLOCK SCREW 1 4 20NCX3 4 WASHER LOCK 1 4 WA
33. LY BY A QUALIFIED ELECTRICIAN Make sure generator is turned off and e stop is engaged before opening control panel Locate the two wires going to the speed controller mounted on the inside of the control pan marked MPU and MPU Both wires are isolated in their own shielded cable Once the wires are loose pull them through the back of the control box until they are completely free from all ty wraps and wire harnesses Unscrew and remove the old sensor Align the flywheel tooth to the center of the sensor hole e Install new sensor until it bottoms out on flywheel tooth and then back it off 1 4 turn Toinsure proper installation the sensor must T70 amp T80 Super Quiet Generator Part No 833015 December 2006 REV A Procedure for changing the magnetic pick up sensor cont be checked with a voltage meter With the engine in a starting sequence check for 2 5 to 3 VAC between the red and black wire Adjust the sensor in or out to obtain the correct voltage the voltage is correct reinstall the shielded cable through the control box opening and reattach the wire leads to the speed controller Also secure the new cable through the housing with ty wraps where needed If any further adjustment is needed to the voltage of the generator please call Terex at 1 800 433 3026 for assistance THIS EQUIPMENT USES HIGH VOLTAGE CIRCUITS CAPABLE OF CAUSING SERIOUS INJURY
34. NERAL SAFETY Cont Checkthe tires for proper inflation and verify that the lug nuts are tight If equiped with towing lights connect the electrical coupler to the towing vehicle Observe posted speed limits for trailers Generally do not exceed 45 mph on paved roads and 10 mph on unpaved roads EXCEEDING THESE RECOMMENDED SPEEDS CAN CAUSE SEVERE DAMAGE TO THE UNIT DAMAGE CAUSED BY THESE UNSAFE PRACTICES WILL VOID THE MANU FACTURER S WARRANTY A SETUP Move the generator set to the desired location keeping the following in mind The spot where the generator set is positioned should be relatively level The location selected should be centrally located to equipment requiring the loads to minimize voltage drop in the power cord Locate so power cords can be routed without crossing roads and access routes Locate where the engine will get good ventilation Do not locate where fumes will enter a building Donot place beside a building wall that would reflect and intensify noise Unhitch from the towing vehicle as follows Locate the generator set in the desired location Part No 833015 T70 amp T80 Super Quiet Generator 11 TEREX AX SETUP Cont Ifthe axle is sloped downhill turn the generator set so that the axle is level ALWAYS chock the wheels of the generator set Unhook safety chains and running lights e Rotate the tongue jack into position 90 degrees a
35. ROL BOX BLK WHT 14ga FROM CONTROL BOX O 7 SENSING LEAD FROM AVR RED TAPED WIRE FROM CONTROL BOX BLK RED 14ga FROM CONTROL BOX F1 AND 2 FROM GENERATOR AVR 4 FROM GENERATOR TO 4 FROM STACK SWITCH 12 FROM GENERATOR TO 12 FROM STACK SWITCH BROWN TAPED WIRE FROM CONTROL BOX TO 21 POSITION ON STACK SWITCH ORANGE TAPED WIRE FROM CONTROL BOX TO 23 POSITION ON STACK SWITCH YELLOW TAPED WIRE FROM CONTROL BOX TO 1 POSITION ON STACK SWITCH T5 FROM GENERATOR 5 FROM STACK SWITCH T3 FROM GENERATOR 3 FROM CONTROL BOX T2 FROM GENERATOR 2 FROM STACK SWITCH T1 FROM GENERATOR 311 FROM CONTROL BOX 2 ORANGE TAPED WIRE FROM CONTROL BOX TO 26 POSITION ON STACK SWITCH S1SOd 401 YOLVYINID December 2006 REVA FLEX PLATE FLYWHEEL T70 amp T80 Super Quiet Generator Part No 833015 Section 5 Schematics c 28 o Wess 272 MOT Ove L OVZOIZ Ove ely Van ZN 1 61 bs ha E D DE Z as amp SIN LEN 91 2 es N SN NHL m 5 S u o 90000163 OL 343 S3ZIS LO 90000153 OL 9 YASWNN LYYd HOLIMS MOVLS gt Sonn NOLLNAIHLSIG
36. RT CN SCREW 46 32 X 1 2 SCREW 1 4 20NC X 5 HHC GRADE 5 ZP NUT LOCK NYLON INSERT 1 4 20NC GR 2 ZP NUT LOCK NYLON INSERT 8 32NF NUT LOCK NYLON INSERT 1 4 20 WIRE HARNESS NUT CLIP 1 4 20 X 3 4 DECAL KIT RECEPTACLES DECAL HIGH VOLTAGE G N GQ N N no Part No 833015 70 amp T80 Super Quiet Generator 9 9 Section 9 Control Box Components December 2006 TEREX This page intentionally left blank 9 10 T70 amp T80 Super Quiet Generator Part No 833015 December2006 Section 10 Distribution Panel Section Distribution Panel Part No 833015 70 amp T80 Super Quiet Generator 10 1 Section 10 Distribution Panel December2006 TEREX Figure 10 A Distribution Panel REV 10 2 T70 amp T80 Super Quiet Generator PartNo 833015 November2007 REV B Section 10 Distribution Panel TEREX FIGURE 10 A DESCRIPTION CU43T020 CU43A041 C37819 CF44T045 C94903 R980195 990580 990080 C42200702 42200701 G N CU51A400 C73000100 PANEL 3PH DISTRIBUTION DISTRIBUTION LUG PANEL NUT COUPLER 3 8 16 DISTRIBUTION LUG COVER SCREW 3 8 16 X 1 1 42 SCREW 1 4 20NC X 3 4 BUTTON HEAD 18 8 S S SCREW 3 8 16NC X 3 1 2 HHC GRADE 5 ZP WASHER FLAT 3 8 PLUNGER ACTUATOR SWITCH SNAP ACTION INCLUDED IN ITEM 9 INCLUDED IN ITEM 9 DECAL L1 L2 L3 N INCLUDED IN ITEM 13
37. S 22 27 NS ch 1 By GIRS 2 4 D PartNo 833015 Section 11 Engine amp Genset Components TEREX Figure 11 B Engine Genset Assembly John Deere 4045 TF270 T70J T70 amp T80 Super Quiet Generator December2006 REV Section 11 Engine amp Genset Components TEREX FIGURE11 B DESCRIPTION C33202900 C42300100 C42300400 C90700200 C33100501 C33100502 C33100503 C91109800 CF33T020 791580 C33301800 C33301201 CF34T030 C3330160 C91111100 C91109600 C91100700 890790 ENGINE amp GENERATOR ASSEMBLY T70J ENGINE 4045TF270 GENERATOR NEWAGE W PMG UCI224E1L73D ACTUATOR ELECTRONIC GOVERNOR SWITCH LOW OIL PRESSURE SENDER LOW OIL PRESSURE ADAPTER LOP SENDER SWITCH W SENDER WATER TEMP 1 2 THREAD VDO MAG PICKUP WITH 6 CABLE ADAPTER MAG PICKUP HARNESS DC ENGINE HOSE SPIRALITE 110 3 ID 3 5 OD GREEN AIR ASSEMBLY FILTER PRIMARY FILTER SECONDARY ELBOW RUBBER 3 ID 90 DEGREE PIPE AIR INTAKE 90 DEGREE CLAMP RADIATOR FAN BREEZA 21 FAN SHROUD FAN GUARD RADIATOR HOSE UPPER RADIATOR HOSE LOWER BELT FUEL FILTER WATER SEPARATOR OIL FILTER FUEL HOSE 3 8 FUEL HOSE 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 A A DD Part No 833015 70 amp T80 Super Quiet Generator REV December2006 Sectio
38. SHER FLAT 1 4 SCREW SET 8 32X1 2 SCREW FLANGE 1 4 20 E STOP PUSH BUTTON EMERGENCY STOP BASE EMERGENCY STOP FACE PLATE BINDING POST FOR REMOTE START DECAL REMOTE START CN SCREW 6 32X1 2 SCREW 10 24X3 Z KEG NUT COUPLER 10 24X3 4 NUT LOCK NYLON INSERT 8 32NF NUT LOCK NYLON INSERT 1 4 20 HARNESS AC GEN NUT CLIP 1 4 20X3 4 DECAL KIT RECEPTACLES DECAL HIGH VOLTAGE G N GQ N am PartNo 833015 T70 amp T80 Super Quiet Generator 9 7 Section 9 Control Box Components December 2006 TEREX Figure 9 D Control Panel Lower T80J REV A 9 8 T70 amp T80 Super Quiet Generator Part No 833015 December2006 REV Section 9 Control Box Components TEREX FIGURE 9 D DESCRIPTION CF42T010 CF41F020 C42105000 C42103400 C42103600 CU41T041 684640 C42501200 981745 CF41T031 C47100300 C51600800 853813 CU51A122 CONTROL PAN ASSEMBLY PANEL 1PH 60 70KW BREAKER 250 SHUNTTRIP 240VAC 12VDC BREAKER 20A 120 240V BREAKER 50A 120 240V BREAKER MOUNT PLATE RECEPTACLE 20A 120V DUPLEX W GFI TRANSFORMER 400 5 WASHER FLAT 1 4 TEMP POWER SLOPE RECEPTACLE TWISTLOCK SCREW 1 4 20NC X 3 4 WASHER LOCK 1 4 WASHER FLAT 1 4 SCREW SET 8 32 X 1 2 SCREW FLANGE 1 4 20 E STOP PUSH BUTTON EMERGENCY STOP BASE EMERGENCY STOP FACE PLATE BINDING POST FOR REMOTE START DECAL REMOTE STA
39. Should unusual sounds be detected shut the unit down and contact TEREX Service 6 Once the engine has been started and running smoothly the following gauges should be monitored All gauges are located on the control panel Oil Pressure Gauge This gauge should read 30 psi or higher Coolant Temperature Gauge This gauge should read between 170 200 degrees F Part No 833015 T70 amp T80 Super Quiet Generator 13 TEREX OPERATING INSTRUCTIONS Cont Voltmeter This gauge should read at least 13 15 volts DC to indicate the diesel engine s alternator is charging properly AC Voltmeter This gauge should reflect the proper voltage selected for this operation Refer to Potentiometer Voltage Adjustment on page 16 AC Ammeter The reading on this gauge should be zero since the main breaker is in the OFF position Once a load is applied to the generator the ammeter will produce an appropriate reading AX LOADING INSTRUCTIONS To make the electrical hookup to the generator set observe the following set of procedures SHUT DOWN THE GENERATOR SET BY PRESSING THE OFF BUTTON ON THE CAS CADE CONTROL PANEL SWITCH THE TOG GLE TO THE OFF POSITION BEFORE MAK ING ANY ELECTRICAL CONNECTIONS THE MAIN GENERATOR BREAKER SHOULD BE IN THE OFF POSITION Shut down the generator set Connect the desired electrical apparatus to the generator set while making sure no other power sour
40. Super Quiet Generator Part No 833015 TEREX Distribution Panel Wiring for F Series Single Phase Control Section 5 Schematics December 2006 REV A SLIHM 8 Drawing ES1000010 OOO 3339 ILIHM 21 3ZIS YIM ALON 33 3339 21 8 MLW 99V 18 8 911 LNNHS E HOLIMS MIVLS OL Wada 3ZIS O4 31ON 338 MOT13A WGd3 SONVHO wads HO1VH3N39 JHL OL NMO38 Nada MLIADIOV TIS MLW MLW 32V78 8 MALIN MOV 8 8 MLW MOVE 8 MLW MOVE 8 MLN MOVTA 8 LL 61 T70 amp T80 Super Quiet Generator Part No 833015 Section 5 Schematics December 2006 TEREX Three Position Stack Switch Wiring Drawing ES1000005 REV FROM CONTROL BOX FROM CONTROL BOX FROM CONTROL BOX 6 GENERATOR POST TO 5 GENERATOR POST TO 42 GENERATOR POST TO GEN 12 LEAD GEN 4 LEAD YELLOW BROWN ORANGE dub lls T Va 90600006 NE e 2 lt c o LI Li LN LN e a 2 5 2 3 2 a m x x E x 5 ia lt x x y dad 44 e 5 o ps
41. TER FREQUENCY METER AMP 0 200 SCREW 1 4 20NC X 3 4 WASHER LOCK 1 4 WASHER FLAT 1 4 RIVET POP 3 16 X 602 HARNESS AC CONTROL PANEL HARNESS CONTROL UNIVERSAL NUT CLIP 1 4 20 X 3 4 HINGE PIANO 9 SS PLASTIC 1 8 X 10 5 X 33 SOLENOID CONTROLLER ELECTRONIC GOVERNOR DPG2104 CONTROLLER BC 10784 RELAY OVER CURRENT SHUTDOWN DYNAGEN ECU ES52 SWITCH SPST MOMENTARY SWITCH TOGGLE SPDT ON OFF ON CONTROL PANEL DYNAGEN TERMINAL STRIP 6 POS JUMPER TERMINAL STRIP RELAY 50A BOSCH RELAY BASE 50A BOSCH RELAY PIN DECAL CONTROL PANEL DYNA TIER DECAL CONTROL PANEL CASCADE DECAL KIT RECEPTACLES DECAL HIGH VOLTAGE BRACKET LATCH SCREW SELF TAPPING 10 wow N N PartNo 833015 T70 amp T80 Super Quiet Generator Section 9 Control Box Components December 2006 TEREX Figure 9 B Control Panel Upper T80J REVA View A T80J 9 4 T70 amp T80 Super Quiet Generator PartNo 833015 December2006 Section 9 Control Box Components TEREX REV FIGURE 9 B DESCRIPTION CF42T010 CONTROL PAN ASSY CU42S031 CONTROL PANEL IGUARD C42200500 POTENTIOMETER VOLTAGE C42208400 SWITCH TOGGLE SINGLE THROW GAUGE AC FREQ 40 80 HZ GAUGE 600VAC VOLT METER GAU
42. TEREX Operator Service amp Parts Manual 170 180 First Edition Rev A1 Part No 833045 Operator s Manual TEREX REV Table Of Contents AWARNING The operator must read and understand all the instructions in this manual before operating the machine Serial Number Registration Serial Number Registration 4 Introduction 5 Description of Equipment iced 5 General Safety Hazard ClassitiCatlon ERR 6 Safety Sign LOCaliOllS 7 Accident Prevention 8 Unauthorized 42 EN 8 FUEMO 8 Electrical Safety uuu uu 9 B ttery Hazard EE 9 Beware of Traffic 9 Receipt of Delivery Checklist 10 Transport OWING kasa 11 rop EM 11 Operating Instructions Starting the Engine Generator Set sss 13 Loading Instructions mener 14 Voltage Selector Switch Operation sss 14 Potentiometer Voltage Adjustment 16 Murphy Cascade Controller 16 Dynagen Auto Start Engine Controller 2 16 Murphy iGua
43. Weight Full Ibs 4995 4995 4995 4995 TRAILER MOUNT Optional Optional Optional Optional Dim Lx W x H 177x72x77 177x72x77 177x72x77 177x72x77 Weight Dry Ibs 4980 4980 4980 5357 Weight Full Ibs 5806 5806 5806 6195 1 Maximum motor size is based on 35 voltage dip at 480V AC 3 phase 60Hz with a code G motor 2 2 T70 amp T80 Super Quiet Generator Part No 833015 December 2006 Section 2 Specifications TEREX REV SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 High Strength Grade 8 Black Oxide Bolts RY LUBED CUBED in Ibs in Ibs Nm 15 8 130 135 13 5 140 DRY LUBED DRY Nm is Wm elbs 339 LUB 14 7 15 8 LUBED Nm _ 700 120 LUB m B o g 13 14 23 17 6 19 31 2 26 35 2 37 50 1 41 55 5 57 77 3 64 86 7 108 4 122 149 176 60 81 108 30 Fo 17 19 31 35 49 55 75 85 813 80 1084 68 91 110 120 120 150 170 270 220 298 300 o 320 433 430 344 350 474 470 s 48 50 640 1233 32 530 718 710 962 750 06 990 132 1749 1477 570 908 890 1205 1080 1464 1440 1952 1654 2467 2074 930 1260 1240 1681 1510 2047 2010 2725 2304 6 1460 1979 1950 2643 2370 3213 3160 4284 3620 12 1640 2223 2190 2969 2670 3620 356
44. Y TIME WHILE OPERATING THIS UNIT SHUT IT DOWN IMMEDIATELY HAVE THE UNIT INSPECTED BY A TRAINED ELECTRICIAN THIS ENGINE GENERATOR SET IS FACTORY INSTALLED TESTED AND SET FOR FIELD OPERATION ANY DAMAGE TO THE ENGINE OR GENERATOR UNITS OCCURRING AFTER ADJUSTMENTS ARE MADE IN THE FIELD BY UNAUTHORIZED PERSONNEL WILL NOT BE COVERED BY YOUR MANUFACTURER S WARRANTY AND WILL ALSO VOID THE MANUFACTURER S WARRANTY ON THIS PARTICULAR UNIT IF YOU CAN NOT REACH YOUR LOCAL DEALER CONTACT THE FACTORY SERVICE MANAGER TOLL FREE AT 1 800 433 3026 4 6 T70 amp T80 Super Quiet Generator Part No 833015 December 2006 REV A Electrical Troubleshooting 5 Components that cause voltage related problems Potentiometer Connects to voltage regulator Bypass potentiom eter by unplugging from voltage regulator and installing jumper on 2 male spades on regulator Voltage Regulator Located inside the upper control panel behind the gauges Measure DC voltage at F1 amp F2 Normal voltage is 10 12 V DC Remove 2 wires marked F1 X F2 X X from voltage regulator Connect wire marked F1 to positive and F2 to negative of a 12 volt battery Start unit and measure voltage If unit produces close to maximum output replace Automatic Voltage Regulator Voltage Selector Switch The correct way to test is to disconnect from generator and hard wire the generator into one configuration This will eliminate the switch from the circuit and
45. ator 7 1 Section 7 Base Components December 2006 TEREX Figure 7 A Base Components REV 7 2 T70 amp T80 Super Quiet Generator Part No 833015 December 2006 REV Section 7 Base Components TEREX FIGURE 7 A DESCRIPTION HOSE FUEL 3 8 HOSE FUEL 1 4 X 1 2 200 CLAMP 7 16 TO 25 32 BARB 3 8 X 1 4 BARB 1 4 FITTING PICKUP amp RETURN PIPE NIPPLE 2X3 COUPLING PIPE 2 NPT FUEL CAP FOR GENERATORS NYLON TUBING HOSE FUEL 3 8 CLAMP 7 16 TO 25 32 BARB 3 8 X 1 4 NPT VALVE CHECK COUPLING PIPE 1 4 HEX BRASS NPTF NUT CLIP 1 4 20 X 3 4 FUEL SENDER RING CAP CORD GRIPS SCREW 1 4 20NCX3 4 HHC GRADE 2 ZP SENDER FUEL LEVEL VDO VALVE VACCUUM RELIEF CLAMP 7 16 TO 25 32 HOSE FUEL 1 4 X 1 2 200 FITTING BARB 3 8 NPT 1 4 HB ROD LIFTING 1 25 X 45 NUT 1 25 WASHER LOCK 1 25 WASHER FLAT 1 25 ZP SCREW 1 2 13 X 1 Z G5 WASHER LOCK 1 2 MOUNT VIBRATION GREEN 40 DURO SCREW HEX 1 2 13 X 2 5 WASHER LOCK STAR 1 2 EXT TOOTH S S LOCK WASHER 1 2 582 HEX NUT 1 2 13 SBZ FLAT WASHER 1 2 SBZ BASE GENERATOR T70 T80 JOHN DEERE OR PERKINS BASE GENERATOR 70 CUMMINS aR AR 6 1 1 2 1 1 1 1 1 6 1 1 1 3 1 1 3 1 1 1 2 4 1 1 2 6 6 6 8 8 4 1 1 2 2 2 1 1 Part No 833015 T70 amp T80 Super Quiet Generator December 2006 Section 7 Base Components
46. ce is connected to the same apparatus Restart the engine and monitor the gauges as outlined in the Operating Instructions section under Starting the Engine Generator Set Turn the required generator circuit breakers to the ON position Monitor the AC Ammeter If the needle deflects severely to the right and stays there immediately turn the required generator circuit breakers to the OFF position Operator s Manual REVA SEVERE DEFLECTION OF THE AMMETER INDICATES A WIRING PROBLEM OR AN OVERLOAD PROBLEM CONTINUED OPERA TION UNDER THIS CONDITION WILL CAUSE DAMAGE TO THE GENERATOR AND OR CONNECTED APPARATUS The needle on the ammeter will deflect to the right temporarily and then return to a normal reading if the unit is operating properly VOLTAGE SELECTOR SWITCH OPERATION The TEREX Super Quiet generator sets rated from T25l to the T280J are equipped with a VOLTAGE SELECTOR SWITCH This switch can have three positions marked 480 277 3 Phase and 240 139 3 Phase or 240 120 1 Phase Each position delivers a different output voltage to the DISTRIBUTION LUGS The SELECTOR SWITCH and DISTRIBUTION LUGS are located on the DISTRIBUTION PANEL The following instructions should be considered when operating the VOLTAGE SELECTOR SWITCH Always make sure the voltage selector switch has been set to the desired range before starting the generator set THIS GENERATOR SET PRODUCES VOLTAG ES THAT CAN C
47. ction plus running audible check Measure stator winding insulation resistance record Monitor Monitor bearing s condition condition Remove terminal box lid and check us Re grase Re grease bearings NN Replace beaingls 1 Replace NDE oring r Inepectbeaing housings winding Inspect rotating diode assembly Refer to the manufacturers manuals for detailed maintence intervals and instructions If the information in the manufacturer s manual differs from that in this manual the manufacturer s manual should take precedence Part No 833015 70 amp T80 Super Quiet Generator 3 5 Section Scheduled Maintenance Procedures December 2006 TEREX This page intentionally left blank 3 6 T70 amp T80 Super Quiet Generator PartNo 833015 December 2006 REV A Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine M Unless otherwise specified perform each repair procedure with the machine in the following configuration Machine parked firm level surface Wheels chocked Toggle switch in OFF position Secti
48. cut or damaged power cords Have a qualified electrician replace any damaged cords immediately DO NOT TOUCH HOT PARTS The exhaust manifold and tail pipe are very hot Parts of the engine are also hot Use protective gloves when handling hot parts A BATTERY HAZARDS LEAD ACID BATTERIES CAN BE DANGER OUS THE SULFURIC ACID IN THE BATTERY CAN CAUSE SEVERE SKIN AND EYE BURNS THE HYDROGEN GAS EMITTED DURING CHARGING CAN EXPLODE IF AN ARC OR FLAME IS PRESENT DO NOT smoke while servicing the battery DO NOT allow tools to touch battery terminals and create an arc Disconnect the negative terminal of the battery when working on the engine or other parts to prevent accidental arcing Disconnect the negative cable at the end away from the battery TEREX GENERAL SAFETY Cont DO NOT remove the vent caps when charging the battery Always wear eye protection when servicing the battery If acid gets on skin or eyes immediately flush under running water and obtain medical attention KEEP ALL BODY PARTS AND CLOTHING AWAY FROM MOVING PARTS Loose jackets shirts sleeves jewely and espe cially neckties should not be worn while working on or running the unit Only remove guards or protective devices from unit temporarily to gain access for maintenance Always replace guards immediately after servic ing Never remove guards while unit is operating Keep your hands away from moving parts particu larly clear of th
49. d L2 to L3 L1 to L3 240 VAC 3P Line to Neutral L1 L2 or L3 to 139 NOTICE This three phase wiring configuration is referred to as Lo Wye NOTICE The above voltages can be dialed down or adjusted lower by using the voltage adjustment potientiometer located on the gen erator main control panel TEREX OPERATING INSTRUCTIONS Cont THIS EQUIPMENT USES HIGH VOLT AGE CIRCUITS CAPABLE OF CAUSING SERIOUS INJURY OR DEATH EXCERCISE EX TREME CAUTION AROUND ANY ELECTRICAL COMPONENT WHEN OPERATING THIS UNIT The three position selector switch has HI WYE 480 V 3ph LOW WYE 240 V 3ph and 240V single phase that is Zig Zag The following is the output voltages on the zigzag position Line to Line L1 to L3 240 VAC 1P Line to Neutral L1 or L3 to N 120 VAC 1P L2 is not used in this position Once the required voltages are known then the combination of the proper switch position and voltage adjustment potentiometer allows for fine tuning the voltage to the exact needs of the application ONCE THE PROPER VOLTAGE SELECTOR SWITCH POSITION IS SELECTED TEREX HIGHLY RECOMMENDS THAT THE SWITCH BE PADLOCKED IN THAT POSITION THIS PREVENTS THE SWITCH FROM BEING MOVED WHILE THE UNIT IS OPERATING OR BY UNAUTHORIZED PERSONNEL DAMAGE TO THE UNIT AND CONNECTED EQUIP MENT WILL BE AVOIDED Part No 833015 T70 amp T80 Super Quiet Gen
50. e radiator fan and alternator belts when the engine is running A BEWARE OF TRAFFIC HAZARDS Stand clear of traffic when starting or checking the unit along the road Check the fuel tank oil pan fuel oil lines and drain plugs for leaks that would spill fuel or oil on the road Check fasteners and mounting brackets periodi cally to insure all are tight and nothing is in danger of falling off during transit Part No 833015 T70 amp T80 Super Quiet Generator 9 TEREX GENERAL SAFETY Cont BE CAREFUL WHEN LIFTING NEVER SUS PEND ANY OTHER EQUIPMENT FROM THE SHIPPING TIE DOWNS Use the lifting eye for lifting the trailer with cabi net Make sure any tie downs at the bottom of the trailer are released prior to lifting Lifting Channel Tie Down NEVER CLIMB ON TOP OF THE CABINET Operator s Manual REV RECEIPT OF DELIVERY CHECKLIST The generator will be serviced tested and ready for operation upon delivery Terex recommends the following checks O Insure there is no freight handling damage which should be charged against the carrier L Check the front jack for security and proper operation Check that the tires are not damaged under inflated or that any lugs are loose Check the engine generator for obvious damage loose connections or leaks Check the control panel for damage or loose connections Check the exhaust system for damage Check all fluid le
51. e specified perform each maintenance procedure with the machine in the following configuration Machine parked on a firm level surface Toggle switch in the OFF position Wheels chocked About This Section This section contains detailed procedures for each scheduled maintenance inspection Each procedure includes a description safety warnings and step by step instructions Symbols Legend Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER Orange used to indicate the AWARNING presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazardous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Indicates that a specific result is expected after performing a series of steps Indicates that an incorrect result has occurred after performing a series
52. eproductive harm CU51A305 52100100 GROUND NO 2 DIESEL FUEL CU51A126 ATTENTION TO AVOID DAMAGE TO GENERATOR AND OR CONNECTED EQUIPMENT PLACE BREAKER IN OFF POSITION BEFORE STARTING OR STOPPING GENERATOR 3 PHASE DOOR MUST BE CLOSED TO RESET O O VOLTAGE CONTROL ADJUST BREAKER O 853838 CU51A110 CAUTION 853070 SINGLE PHASE MAIN BREAKER 853751 y ADANGER Hazardous voltage Can cause serious injury or death Shut down generator before servicing 850130 240 30A DO NOT START OR STOP UNIT UNDER LOAD 240 3 PHASE MAIN BREAKER 1 PHASE BREAKERS 5 50 50 20 GFCI GFCI 120V 120V 20A 20A GFCI 120 20 ENGINE GENERATOR VOLTAGE ADJUST 20A 30A 240 Neutral Bonded to Frame 240 853813 AUTO OFF MANUAL LED TEST 853810 CONTROL BREAKER THIS SHEET CONTAINS DECALS FOR THE ENTIRE CONTROL PANEL ASSEMBLY INDIVIDUAL DECALS ARE NOT AVAILABLE FOR PURCHASE Part No 833015 T70 amp T80 Super Quiet Generator Section 6 Decals December 2006 TEREX This page intentionally left blank 6 4 T70 amp T80 Super Quiet Generator Part No 833015 December 2006 Section 7 Base Components TEREX Section Seven Base Components Part No 833015 T70 amp T80 Super Quiet Gener
53. erator 15 TEREX OPERATING INSTRUCTIONS Cont DO NOT OPERATE THE UNIT UNLESS VOLTAGE HAS BEEN CHECKED AT THE RECEPTACLES CALL TEREX SERVICE IF YOU HAVE ANY QUESTIONS INSTALLATION AND ANY WORK PERFORMED ON THIS UNIT SHOULD BE DONE ONLY BY A QUALIFIED ELECTRICIAN DO NOT REMOVE OR COVER ORIGINAL SAFETY AND OPERATION DECALS REPLACE ANY DAMAGED DECALS BEFORE USING THIS EQUIPMENT POTENTIOMETER VOLTAGE ADJUSTMENT The potentiometer is set at the factory However if the voltage reading on the voltmeter is not as desired use the following procedure to make the necessary adjustments With the unit running under no load observe the AC voltmeter Locate the voltage adjustment knob on the control panel The decal above the knob indicates the direction to turn the knob to increase or decrease the voltage Turning the knob to the right increases the voltage while turning the knob to the left decreases the voltage Slowly turn the adjustment knob in the desired direction while observing the AC voltage meter stop when the desired voltage is obtained The unit is now ready to load If the desired voltage cannot be reached contact the TEREX Service Department at 1 800 433 3026 MURPHY CASCADE CONTROLLER For generators with the Murphy Cascade Control ler installed refer to the Cascade Controller Installation and Operations Manual p n 00 02 0594 Terex part number 83301 1 supplied with the unit for configuration and operatio
54. f backordered parts o Other please specify For TEREX Use Order Number Origin Code Comments Date Scheduled Ship Condition Order Total Terms Code remove this page and make copies remove this page and make copies December 2006 Section 2 Specifications TEREX Specifications REV MODEL TJ TP POWER CAPABILITY PRIME kVA kilovolt amps 72 72 70 81 kW 58 58 54 65 3 Phase Amp Ratings 200 200 189 225 173 173 164 195 87 87 82 97 POWER CAPABILITY STANDBY kVA kilovolt amps 79 79 75 90 kW kilowatts 63 63 60 72 3 Phase Amp Ratings 219 219 208 250 190 190 180 217 95 95 90 108 VOLTAGE 3 Phase 208 220 240 416 440 480 Standard Standard Standard Standard 600 Volt Optional Optional Optional Optional 1 Phase 120 127 139 240 254 277 Standard Standard Standard Standard Max Motor Starting1 39 39 39 49 29 29 29 37 SKVA 235 235 235 290 DIESEL ENGINE CUMMINS JOHN DEERE PERKINS JOHN DEERE 4BT3 9 G5 4045TF270 1104C 44TG 4045TF275 4 4 4 4 Air Intake aspiration Natural Turbo Turbo Turbo Cooling System Fuel Capacity gal Run Time 75 load Fuel Consumption Prime Power gal per hr 100 load 75 load 50 load 25 load dBA Controller Type Digital Analog Analog Digital Analog Digital Start Stop Controller Cascade Dynagen Cascade iGuard 12V Battery CCA 750 750 750 750 Part No 833015 T70 amp T80 Super Quiet Generator 2 1 Section 2 Specifications
55. h care It is highly flammable ALWAYS stop engine before refueling Fill fuel tank outdoors DO NOT replace fuel lines with materials different from those supplied as original equipment FIRES CAN CAUSE SEVERE PERSONAL INJURY OR MACHINE DAMAGE Prevent fires by keeping the generator and its surrounding area clean DO NOT refuel while smoking or when near open flame or sparks DO NOT refuel the engine when it is hot Allow to cool for several minutes before refueling DO NOT spill fuel inside the engine compartment If fuel has leaked wipe it up and have leak repaired before next use ALWAYS have a fire extinguisher nearby Be sure the extinguisher is properly maintained and be familiar with its use Extinguishers rated ABC by the NFPA are appropriate for all applications EXHAUST GASES ARE TOXIG DO NOT USE INDOORS UNLESS PROPERLY VENTILATED OR AN EXHAUST SCRUBBER IS USED Check exhaust system regularly for leaks and ensure that the exhaust manifolds are secure and not warped Make sure the unit is well ventilated 8 T70 amp T80 Super Quiet Generator Part No 833015 Operator s Manual REV A ELECTRICAL SAFETY THIS EQUIPMENT USES HIGH VOLTAGE CIR CUITS CAPABLE OF CAUSING SERIOUS INJU RY OR DEATH EXERCISE EXTREME CAUTION AROUND ANY ELECTRICAL COMPONENT WHILE OPERATING THIS UNIT Always ground the unit according to local codes A grounding lug is provided for your convenience Beware of
56. inet Components December 2006 TEREX This page intentionally left blank 8 6 T70 amp T80 Super Quiet Generator Part No 833015 December2006 Section 9 Control Box Components TEREX Section Nine Control Box Components Part No 833015 T70 amp T80 Super Quiet Generator 9 1 Section 9 Control Box Components November 2007 TEREX Figure 9 Control Panel Upper T70P T70C amp T70J REV B T70P amp C Control Panel Layout View A T70J 9 2 T70 amp T80 Super Quiet Generator PartNo 833015 November2007 REV B Section 9 Control Box Components TEREX FIGURE9 A DESCRIPTION CF42T010 CU42Q032 42200500 682070 42208400 43100800 43200400 260360 43200300 43200600 261341 43100600 43100400 43101000 CB45A112 CU45A100 C51600800 51200201 42401700 42400810 686747 42202900 CU42Q031 C42404000 R660115 CDWV40150 CDWV40151 CDWV40152 853810 853838 853813 CU51A122 CU42T070 C51601550 CONTROL PAN ASSEMBLY CONTROL PANEL CASCADE POTENTIOMETER VOLTAGE ADJUSTMENT BREAKER MINI 1P 15A SWITCH TOGGLE SINGLE THROW GAUGE DC VOLT GAUGE OIL PRESSURE HOURMETER 12V DC GAUGE WATER TEMP 12V GAUGE FUEL CASCADE CONTROLLER INCLUDED IN ITEM 11 METER VOLT ME
57. is allows the generator set to be operated in noise sensitive environments The interior of the enclosure is coated with sound dampening polymer foam that is highly effective in noise suppression A high ambient temperature radiator and a critical grade exhaust silencer are contained within the enclosure as standard equipment Part No 833015 T70 amp T80 Super Quiet Generator 5 TEREX DESCRIPTION OF EQUIPMENT Cont A center point lifting attachment is located in the top of the enclosure to allow crane lifting of the entire unit The generator set is mounted on a trailer equipped for highway operation Hydraulic surge brakes are standard on larger generator sets for maximum stopping efficiency Electric brakes are also available as an option GENERAL SAFETY HAZARD CLASSIFICATION A multi tier hazard classification system is used to communicate potential personal injury hazards The following signal words used with the safety alert symbol indicate a specific level of severity of the potential hazard Signal words used without the safety alert symbol relate to property damage and protection only All are used as attention getting devices throughout this manual as well as on decals and labels fixed to the machinery to assist in potential hazard recognition and preven tion Red Indicates an DANGER imminently hazardous situation which if not avoided will result in death or serious injury Orange Indicate
58. ler or call or write to TEREX P O Box 3147 29732 590 Huey Road Rock Hill SC 29730 Telephone 800 433 3026 FAX 803 366 1101 4 70 amp T80 Super Quiet Generator Part No 833015 Operator s Manual REV INTRODUCTION Owners Users and Operators TEREX appreciates your choice of our product for your application Our number one priority is user safety which is best achieved by our joint efforts We feel that you can make a major contribution to safety if you as the equipment users and opera tors Comply with OSHA Federal State and Local Regulations Read Understand and Follow the instructions in this and other manuals supplied with this product Use Good Safe Work Practices in a common sense way Only have trained operators directed by informed and knowledgeable supervision operating this product If there is anything in this manual that is not clear or which you believe should be added please send your comments to TEREX Service Depart ment in Rock Hill SC THE SAFETY ALERT SYMBOL IS USED TO ALERT YOU TO POTENTIAL PERSONAL INJURY HAZARDS OBEY ALL SAFETY MESSAGES THAT FOLLOW THIS SYMBOL TO AVOID POSSIBLE INJURY OR DEATH DESCRIPTION OF EQUIPMENT The engine generator assembly consists of a diesel engine combined with an electrical genera tor This assembly is firmly bolted together to form an integral unit and does not require anything other than routine
59. maintenance TEREX The engine is equipped with a 12 volt starter and can be wired for remote starting capability at the control panel A dry element air cleaner is standard equipment to ensure a clean air supply and a remote fuel water separator is included for additional fuel system protection A governor on the engine provides a stable operating speed under varying load conditions and the generator is equipped with a solid state voltage regulator to stabilize the output voltage under these same conditions Figures and schematics of both the governor and regulator are provided in the ENGINE and GENERATOR OPERATOR S MANUALS An automatic shutdown system is incorporated in the generator set to sense low oil pressure and or high coolant temperature and in either case the engine generator assembly will automatically cease operation A diesel fuel tank is incorporated within the base of the unit to ensure an uninterrupted operating cycle under full load The engine generator assembly is mounted to the base using high durometer vibration isolators The enclosure for the generator set is constructed from 12 or 14 gauge sheet metal to ensure maximum rigidity and is bolted together to allow easy access to major components if necessary Four lockable hinged access doors are provided for routine operation and maintenance The enclosure on the Super Quiet Generator is specifically designed for a high degree of sound attenuation Th
60. n Operator s Manual REVA DYNAGEN AUTO START ENGINE CONTROLLER For generators with the DynaGen Controller installed refer to the DynaGen Installation and User Manual for the ES51 52 Auto Start Engine Controller Terex part number 833012 supplied with the unit for configuration and operation MURPHY iGUARD CONTROLLER For generators with the Murphy iGUARD Control ler installed refer to the Installation and Opera tions Manual for iGuard Digital Generator Set Controller p n IG 021 1 7N Terex part number 839058 supplied with the unit for configuration and operation WOODWARD SPEED CONTROLLER For generators with the Woodward Speed Control ler installed refer to the Woodward Manual LCS Series Integrated Speed Control p n 3710151 part number 833013 supplied with the unit for configuration and operation 16 T70 amp T80 Super Quiet Generator Part No 833015 Operator s Manual REV A OVERCURRENT PROTECTION This relay is mounted behind the control panel and monitors the current draw and uneven current draw to protect the generator set This trip setting is set at the factory with the proper kW using a loadbank THIS SETTING SHOULD NEVER BE CHANGED OR GENERATOR FAILURE CAN OCCUR NOTICE Call TEREX Service for wiring and troubleshooting information TEREX OPERATING INSTRUCTIONS Cont A SHUTDOWN PROCEDURES NEVER SHUT THE UNIT DOWN WHILE UNDER LOAD THIS COULD CAUSE SERIOUS
61. n Check fuel level in tank fill as needed Check wiring to verify 12V DC is being supplied to the pump solenoid Replace solenoid Adjust for 2 5 3 0 VAC Check fuel system Bleed fuel system Check and replace if defective Check air cleaner Check exhaust system Check fuel water separator and tank for contamination Have injection system checked by a trained technician Have compression checked by a trained technician Engine won t crank Loose battery cable or discharged battery Check cables and battery electrolyte level Recharge as necessary T70 amp T80 Super Quiet Generator Part No 833015 December 2006 Section 4 Troubleshooting TEREX REV A TROUBLESHOOTING POSSIBLE CAUSE set in OFF position Blown fuse in DC control circuit E Stop Defective starter solenoid Defective starter Oil Pressure or Hi temp switch defective Seized engine SOLUTION eck switch position Replace with 25 Amp SLO BLO TYPE fuse if needed Check to see if engaged Replace solenoid Replace starter Check or call TEREX Service Have engine checked by a qualified technician Engine runs but loses speed Unit is overloaded Improper connection Reduce load Check or Call TEREX Service Engine runs but loses power under load Clogged fuel system Blocked air intake Blocked exhaust Contaminated fuel Faulty governor defective injectors or defective fuel p
62. n 11 Engine amp Genset Components Engine Genset Assembly Cummins 4BT3 9 G5 70 Figure 11 SERS Q To SR 2 lt S HEEN 7 Cl syl NN lt Ge Z LLL ETS GA NE IN lt Part No 833015 T70 T80 Super Quiet Generator December2006 REV Section 11 Engine amp Genset Components TEREX FIGURE11 C DESCRIPTION 116825 732109 630958 184995 CE31A090 C33100501 C33100502 C42300100 C42300400 42300500 42300600 91100700 773630 897920 91109800 010 CU33T020 184996 C91111100 C91107700 C33301600 C33301800 CF34T035 ENGINE amp GENERATOR ASSEMBLY T70G ENGINE 4BT3 9 G5 GENERATOR UCI224E1L32D CHANNEL GENERATOR MOUNT SPACER FAN CUMMINS AIR CLEANER ASSEMBLY FILTER PRIMARY FILTER SECONDARY FUEL FILTER OIL FILTER FILTER FUEL 245R30 WWATER SEP ASSEMBLY FAN BREEZA 21 SWITCH LOW OIL PRESSURE SENDER LOW OIL PRESSURE SWITCH W SENDER WATER TEMP DOUBLE PRONG MAG PICKUP WITH 6 CABLE RESISTOR 820HM 12W ADAPTER MAG PICKUP HARNESS ENGINE DC TANK 4 QUART COOLANT OVERFLOW M10 X 1 0 1 8 27 ADAPTER CONVERSION FUEL HOSE 1 4 FUEL HOSE 3 8 PIPE 3 BLACK HOSE SPIRALITE 110 3 ID 3 5 0D GREEN ELBOW RUBBER 3 ID X 3 ID 90 DEGREE INTAKE TO TURBO BRACKET 4 QUART COOLANT OVERFLOW
63. nd raise the tongue off the towing vehicle Levelthe generator set with the tongue jack Coupler Hitch Level Ground Safety Chains Jack THE WHEELS MUST BE PROPERLY CHOCKED IF THE GENERATOR IS ON UNLEVEL GROUND DO NOT OPERATE THE GENERA TOR SET UNTIL IT HAS BEEN PROPERLY SE CURED When preparing to start the generator set follow the sequence listed below Checkthe coolant level in the radiator and add as necessary If adding coolant use only a 50 50 mixture of antifreeze and water Refer to your engine manufacturer s maintenance manual for specific antifreeze information Operator s Manual REVA NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS RUNNING OR WHILE THE ENGINE IS HOT Checkthe oil level in the engine crankcase and add as required USE CLASS API CC OR CD GRADE ENGINE OIL REFER TO THE ENGINE MANUFACTUR ER S MANUAL FOR VISCOSITY AND QUANTITY Ifthe battery is not a maintenance free battery check the electrolyte level in the battery and add distilled water if necessary Check fuel water separator for water in the fuel System Drain water from separator if necessary e Check fuel level in the fuel tank and add as required Check to insure the fuel tank vent is open and not clogged USE 2 DIESEL FUEL ONLY Verify that the generator main circuit breaker is in the OFF position Make sure the generator set is properly grounded This is accomplished by connec
64. o not open gt 3 Phase door while generator Hazardous voltage Will is under load cause serious injury or death Disconnect power before servicing Lockout Tagout Breaker will trip EET U51A310 machine 3 1 GROUND NOTICE VAN DANGER Radiator fill UNIT Engine damage could PROPE RLY occur if coolant mixture is over 50 anti freeze EAR CONSULT LOCAL 5 CODE 4 6 H G H READ OWNER S MANUAL BEFORE OPERATING Je and void manufacturer s ATTENTION OR SERVICING U51A102 N DANGER Hazardous voltage CALIFORNIA Can cause serious injury or death Shut down generator before servicing 12 GROUND 10 11 13 Part 833015 T70 amp T80 Super Quiet Generator 7 TEREX GENERAL SAFETY Cont A ACCIDENT PREVENTION Use protective clothing and safety equipment Always wear approved safety equipment such as gloves safety boots safety hard hat goggles ear protection and dust masks when necessary Wear protective clothing that is snug and belted where required A UNAUTHORIZED WELDING UNAUTHORIZED WELDING CAN CAUSE STRUCTURAL FAILURE OR PERSONAL INJURY DO NOT weld on any structural member Any unauthorized welding or repair procedure will void the warranty Operator s Manual REVA FUELING ALWAYS handle fuel wit
65. on 4 Troubleshooting TEREX Troubleshooting Before Troubleshooting Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine Be sure that all necessary tools and test equipment are available and ready for use Be aware of the following hazards and follow generally accepted safe workshop practices ADANGER Electrocution hazard Exposure to electrically charged circuits could result in death or serious injury Remove all rings watches and other jewelry ADANGER Electrocution hazard Attempting to sevice the machine before the capacitors are fully discharged will result in death or serious injury 74711711 High voltage Exposure to electrical wires or electrical current will result in death or serious injury Remove all rings watches and other jewelry Turn off all power when not needed for testing Use extreme caution when working with high voltage electrical components ACAUTION Burn hazard Contact with hot engine components may cause severe burns Use caution when working around a hot engine Part No 833015 T70 amp T80 Super Quiet Generator 4 1 Section 4 Troubleshooting December 2006 TEREX REV A Troubleshooting Guide The engine generator set is tested and set at the factory for proper operation in the field These units should never require additional adjustments in the field If needed adjustments should
66. only be made by a qualified service technician otherwise the manufacturer s warranty may become void No generator output voltage POSSIBLE CAUSE Circuit breaker tripped Voltage regulator Defective voltage regulator Defective Selector Switch Defective generator SOLUTION Reset circuit breaker Check voltage regulator wiring Replace voltage regulator By pass by hardwiring generator Refer to generator manual Low generator output voltage Voltage adjustment set too low Defective potentiometer Low engine speed Loose wire on voltage selector switch Fluctuating or surging engine speed Loose wire on voltage regulator sensing circuit Defective voltage regulator Adjust voltage potentiometer By pass or replace Call TEREX Service Check wiring Check engine fuel oil and air filters Check wiring Replace voltage regulator High generator output voltage Voltage adjustment potentiometer High engine speed Adjust potentiometer Call TEREX Service T70 amp T80 Super Quiet Generator Part No 833015 December 2006 REV A High generator output voltage Section 4 Troubleshooting POSSIBLE CAUSE Defective automatic voltage regulator Loose wire on voltage adjustment potentiometer TEREX TROUBLESHOOTING SOLUTION Replace voltage regulator Check wiring Fluctuating generator output voltage An ON OFF type load may be the cause Fluctuating
67. or surging engine speed Loose wiring in generator Automatic voltage regulator stability setting may be wrong Loose wire on the automatic voltage regulator sensing lead Redistribute load if possible Check engine fuel oil and air filters Check connections Call TEREX Service Check wiring Low engine speed Engine speed adjustment has slipped Clogged fuel system Blocked air intake Blocked exhaust system Contaminated fuel Defective governor on engine Call TEREX Service Check for air leaks clogged fuel filter kinked fuel line or clogged fuel pick up tube Check air filter Check engine exhaust system remove obstructions Check fuel water separator and fuel tank for contamination Replace fuel if needed Call TEREX Service Part No 833015 T70 amp T80 Super Quiet Generator TEREX TROUBLESHOOTING Section 4 Troubleshooting POSSIBLE CAUSE Detective injectors on engine Surging engine speed December 2006 SOLUTION ave injectors checked by a qualified technician Check engine fuel oil and air filters REVA Engine turns over cranks but won t run Unit out of fuel Loose or broken wire in control circuit fuel injection pump solenoid Defective solenoid Magnetic Pick up Clogged fuel system Air in fuel system Defective fuel pump Clogged air intake Clogged exhaust Contaminated fuel Defective injectors Lost engine compressio
68. ous situation which if not avoided may result in property damage CAUTION Green used to indicate operation or maintenance information Section 1 Safety Rules December 2006 Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards Bl such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases and engine fuels Always have an approved fire extinguisher within easy reach Be sure that all tools and working areas N are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage am Be sure that your workshop or work area 5 f I is properly ventilated and well lit other lifting or supporting device is fully capable of supporting and stabilizing the weight to be lifted Use only chains or straps that are in good condition and of ample capacity Be sure any forklift overhead crane or Be sure that fasteners intended for one N time use i e cotter pins and self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old or other fluids Use approved container
69. p T80J 853070 CU51A205 TEREX CUS1A310 SUPER QUIET A CU51A122 CR51A101 CU51A304 CU51A112 CU51A221 850130 T70J amp T80J 853761 17 18 0 853807 853313 853792 MS 853792 853313 m maaa CU51A205 SUPER QUIET T70 amp T80 Super Quiet Generator Part No 833015 December 2006 REV A y j Hazardous voltage Will cause serious injury or death Disconnect power before servicing Lockout Tagout machine CU51A122 CU51A122 Section 6 Decals CAUTION Do not open 3 Phase door while generator is under load Breaker will trip 0514310 51 310 NOTICE Radiator fill Engine damage could occur if coolant mixture is over 50 anti freeze US1A102 CU51A112 CU51A113 NOTICE No ether Use of engine starting fluids will cause engine damage and void manufacturer s warranty U51A102 DANGER HIGH VOLTAGE TEREX FIGURE 6 A AWARNING gt R51A101 CR51A101 GROUND UNIT PROPERLY CONSULT LOCAL CODE CU51A304 ATTENTION 4 READ OWNER S MANUAL BEFORE OPERATING OR SERVICING 853070 CU51A102 CU51A221 CALIFORNIA Proposition 65 Warning Diesel engine exhaust and some of its OF California to cause cancer birth defects and other r
70. r generator If the generator voltage reads correctly you know there is not a problem with the generator end Your problem is more than likely with the voltage regulator In this case you should contact the TEREX service department If the voltage is uneven between the legs when you 12 volts to the field wires you need to recheck your wiring connections If you can not find the problem hard wire the generator After you have the field wire connected start the unit again and check your output voltage It may still be necessary to flash the fields to restore residual voltage This needs to be done with the unit off and the field wires removed Do not flash the regulator flash the field wires e As with any electrical device use extreme caution when working around a running generator it could cost you your life Observe proper polarity when working with the regulator So you don t break something that is not broken to begin with and if you are ever in doubt ask Section 4 Troubleshooting December 2006 REV A INSTALLATION AND ANY WORK PERFORMED ON THIS UNIT SHOULD BE DONE ONLY BY A QUALIFIED ELECTRICIAN THIS EQUIPMENT USES HIGH VOLTAGE CIR CUITS CAPABLE OF CAUSING SERIOUS IN JURY OR DEATH EXCERCISE EXTREME CAU TION AROUND ANY ELECTRICAL COMPO NENT WHEN OPERATING THIS UNIT Procedure for changing the magnetic pick up sensor INSTALLATION AND ANY WORK PERFORMED ON THIS UNIT SHOULD BE DONE ON
71. rator 3 3 Section Scheduled Maintenance Procedures December 2006 TEREX MAINTENANCE SCHEDULES CONTINUED REV A T70J amp T80J LUBRICATION AND MAINTENANCE SERVICE INTERVALS Every 2 500 Hrs or 2000 Hrs or ih Operate engine at rated speed and 50 70 load a minium of 30 minutes Check ETT oil and coolant level Check fuel filter water Check fuel filter water separator bowl bowl Check air cleaner dust unloader valve and ors a a a Check engine mounts J fJ sentr Clean crankcase vent tube crankcase vent tube Check air intake hoses connections and system Replace single or dual fuel filter elements f Check engine speeds no a Check Check cooling system system Coolant solution analysis add SCAs as s TT C Pressure test Pressure test cooling system 21 G EE Fush cooling system pp Testthermostats Check and adjust engine valve clearance Addcodan Replace aircleanerelements Replace polyveebett Checkfuses pp PP Check air compressor if equipped J Bleed pp pp 3 4 T70 amp T80 Super Quiet Generator Part No 833015 December2006 Section Scheduled Maintenance Procedures TEREX MAINTENANCE SCHEDULES CONTINUED REVA NEWAGE GENERATORS MAINTENANCE SCHEDULE 4500 Hours r 12 oga 3 Years Months Months n Visual inspe
72. rd 16 2 T70 amp T80 Super Quiet Generator Part No 833015 Operator s Manual TEREX REV Operating Instructions Continued Woodward Speed Controller ua iita kaqa bedres 16 Overcurrent Protectio seemed ne estimatet 17 Shutdown Procedures 17 herede 18 Torque Specifications SAE Fastener Torque Chart 2 222 4 0 eene 19 Metric Fastener Torque Chalrt nnnm 19 Generator Torque Specifications L Sus 20 Part No 833015 T70 amp T80 Super Quiet Generator 3 Operator s Manual TEREX REV SERIAL NUMBER REGISTRATION TEREX Model Number Serial Number Engine Model Number Serial Number Generator Model Number Serial Number Owner Ship to Options This Operation and Service Manual contains information specifically pertaining to the operation and maintenance of the TEREX Super Quiet Generators We suggest that you read this manual carefully prior to operating the generator This manual should be retained and refered to for operation maintenance and ordering parts When ordering parts PLEASE INCLUDE THE MODEL AND SERIAL NUMBER located on the nameplate of the generator For major repair and service or other information contact your TEREX dea
73. re trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate tools lifting equipment and a suitable workshop Part No 833015 T70 amp T80 Super Quiet Generator TEREX SAFETY RULES Personal Safety Any person working on or around a machine must be aware of all known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Read each procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnel to potential personal injury hazards Obey all safety messages that follow this symbol to avoid possible injury or death 777 1 Red used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Orange used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert symbol ACAUTION used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Yellow without safety alert symbol used to indicate the presence of a potentially hazard
74. s a A WARNING potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert A CAUTION symbol Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Operator s Manual REVA Yellow without safety CAUTION alert symbol Indicates a situation which if not avoided may result in property or equipment damage Green Indicates impor NOTICE tant installation operation or maintenance information Hazardous voltage Will cause serious injury or death Hot exhaust Can contain carbon monoxide Will cause serious injury or death Read all manuals that shipped with your equipment Maintenance is done more easily and safely when you know what you re doing Keep all guards in place e Wear hearing protection when you are near this equipment Lockout and Tagout Equipment may be energized Lockout and tagout all energy sources prior to performing maintenance adjustments 70 amp 80 Super Quiet Generator Part No 833015 Operator s Manual TEREX REV A GENERAL SAFETY Cont SAFETY SIGN LOCATIONS 9 11 12 9 2 1 91 7 FJTEREX FJTEREX 22 4 8 1 6 3 13 10 4 5 Items shaded are hidden from view CAUTION WARNING D
75. sing load until the excess fuel build up is burned off and the system capacity is reached usually can repair the condition review of the appropriate equipment manuals is important to understand fully the connection and use of the load bank you choose for your mainte nance and testing requirements TEREX suggests a minimum load of 30 percent of nameplate to prevent wet stacking inversely related to temperature the lower the ambient temperature the higher the minimum load TEREX recommends testing at least monthly for a minimum of 30 minutes at not less than 80 percent of nameplate rating The proper installation and use of a load bank can prevent loss of capacity and increased maintenance caused by unburned fuel due to wetstacking In the event you have a generator set that is already wet stacked it is recommended that the load bank be used in progressive steps Assure the generator set is properly grounded and connected to the load bank as instructed by the manufacture It is also recommended that the generator be set at 240 VAC 3 phase when doing this test Operator s Manual REVA Starting out using less than 2596 of the nameplate rating until the engine has warmed up Progres sively increase the load as the generator will allow with out shutting down and continue to run for 20 minutes per step When you reach 80 of the nameplate rating run the generator for a minimum of 45 minutes or until the exhaust on the
76. ting the grounding lug provided at the rear of the generator set enclosure to a mechanical earthground with a minimum 2 0 size 4 bare electrical cable If this differs from your local code always follow the local code for grounding THIS GENERATOR SET PRODUCES VOLTAG ES THAT CAN CAUSE SEVERE SHOCK OR DEATH ONLY QUALIFIED ELECTRICIANS SHOULD PERFORM ELECTRICAL WORK 12 T70 amp T80 Super Quiet Generator Part No 833015 Operator s Manual REV A OPERATING INSTRUCTIONS STARTING THE ENGINE GENERATOR SET NEVER ATTEMPT TO START THE GENERA TOR SET WITH ANY OF THE CIRCUIT BREAK ERS ON THESE BREAKERS ARE LOCATED ON THE CONTROL PANEL STARTING WITH THE BREAKERS ON CAN CAUSE DAMAGE TO THE GENERATOR Once setup procedures are completed the generator set is ready to be started Start the unit according to the following steps Make sure the GENERATOR VOLTAGE SELECTOR SWITCH has been set to the proper range This switch should be located above the 3 phase distribution panel DISREGARD IF THE UNIT DOESN T HAVE A SELECTOR SWITCH THIS UNIT IS PRESET FOR ONE VOLTAGE SEE NAME TAG NEVER CHANGE THE POSITION OF THE VOLTAGE SELECTOR SWITCH WHILE THE GENERATOR IS RUNNING THIS WILL RESULT IN IMMEDIATE DAMAGE TO THE SWITCH THE GENERATOR OR THE CONNECTED EQUIPMENT IT MAY RESULT IN SERIOUS INJURY TO THE OPERATING PERSONNEL For Cascade Equipped Generators 1 Place the toggle switch in ON position then
77. tion receives an N remove the machine from service repair and re inspect it After repair place a check in the R box Legend Y yes completed N no unable to complete R repaired Comments Pre Delivery Preparation Y N R Pre operation inspection completed Maintenance items completed Function tests completed Model Serial number Date Machine owner Inspected by print Inspector signature Inspector title Inspector company December2006 Section Scheduled Maintenance Procedures TEREX Maintenance Schedules REVA T70P amp T70C LUBRICATION AND MAINTENANCE SERVICE INTERVALS 50 Hrs or 500 Hrs or spect adjust or replace alternator or fan belt PJ In Check driven equipment L o o Inspect engine air cleaner service indicator mao em ot o j po p separator Inspecvelean engine ground 1 Inspect adjust engine valve lash Inspect aftercooler core Inspect alternator Inspect engine mounts Inspect starting motor Inspect turbocharger Inspect water pump 3000 Hrs or 6000 Hrs or 12000 Hrs Change cooling system coolant Low dE d y Testichange fuel injector 2 gy sem j j Change cooling system coolant _ j j commercial heavy duty 1 pf Cleanhestaftercoolercore Add cooling system coolant extender ELC Change cooling system coolant ELC Part No 833015 T70 amp T80 Super Quiet Gene
78. uipment and a suitable workshop In these instances we strongly recommend that maintenance and repair be performed at an authorized TEREX dealer service center Technical Publications TEREX Corporation has endeavored to deliver the highest degree of accuracy possible However continuous improvement of our products is a TEREX policy Therefore product specifications are subject to change without notice Readers are encouraged to notify TEREX of errors and send in suggestions for improvement All communications will be carefully considered for future printings of this and all other manuals Contact Us www TEREX com Serial Number Information TEREX Corporation offers the following manuals for these models Title Part No TEREX T70 amp T80 Operator s Parts Manual 833015 First Edition Newage Generator Manual 830005 John Deere Engine Manual 839018 Perkins Engine Manual 839019 Cummins Engine Manual 839059 Cummins Engine Manual 839060 Woodward Controls 833013 DynaGen Controller Manual 833012 Cascade Controller Manual 833011 Murphy iGuard Controller Manual 839058 Dexter A
79. ump Check fuel system air in fuel lines Check air cleaner Check exhaust system Check fuel water separator and fuel tank for contamination Have unit checked by a trained service technician for all of these items Engine shuts down automatically and TROUBLE LIGHT on CONTROL PANEL is illuminated Oil Pressure Switch Improper coolant level Not opening Use a 50 50 on mix of water and anti freeze only Part No 833015 T70 amp T80 Super Quiet Generator TEREX TROUBLESHOOTING Engine shuts down automatically and TROUBLE LIGHT on CONTROL PANEL is illuminated Section 4 Troubleshooting POSSIBLE CAUSE Overloaded engine Broken fan belt Defective thermostat or thermocouple switch Defective water pump Blocked cooling air inlet or exhaust Defective or grounded temperature switch Defective injectors or injector pump Low crankcase oil level Defective oil pump Defective or grounded oil pressure switch December 2006 SOLUTION Reduce load Inspect fan belt and replace as needed Inspect thermostat switch Inspect water pump and replace if needed Inspect and remove any obstructions Inspect switch and repair or replace Have the engine inspected by a trained service technician Check oil level and refill as required Have the engine inspected by a trained service technician Inspect switch and repair or replace REV A IF YOU FEEL AN ELECTRIC SHOCK AT AN
80. unit runs clean Allow the machine to fully cool down Start the unit again and load 80 for and additional 30 minutes A full engine service is recommended after this type wetstack burn off 18 T70 amp T80 Super Quiet Generator Part No 833015 Operator s Manual TEREX REV _ gt 1044 1139 1477 1654 2074 2304 ES pr Due N This chart is to be used as a guide only unless noted elsewhere in this manual LUBED in lbs Nm Nm up P LUBED LUBED ft lbs Nm ft lbs Nm ft lbs Nm 16 24 50 1 86 7 916 12 18 149 210 298 420 569 550 910 1233 770 908 1206 1080 1464 1440 1952 1220 12 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 12 4067 This chart is to be used as a guide only unless noted elsewhere in this manual A574 High h THREAD Grade 5 lt gt Grade 8 65 574 High Strengt in Ibs I in Ibs 130 14 7 ibs Nm ft lbs Nm 31 2 7461 14 49 66 20 555 55 745 60 813 80 1084 68 921 108 4 11 18 130 176 240 9 320 433 610 827 510 691 144 718 1016 1342 840 7 1138 1120 1518 1360 1844 1820 2467 1530 1640 2223 2190 2969 26 0 3620 3560 4826 3000 i Class 4 6 Class 8 8 Class 10 9 Class 12 9 DRY N TORQUE SPECIFICATIONS Black Oxide Bolts DRY Nm 28 90 101 120 135 10 135 160 18 140 158 38 13
81. vels battery radiator and engine oils Ensure manuals are in the pocket provided inside the unit 10 T70 amp T80 Super Quiet Generator Part No 833015 Operator s Manual REV A TRANSPORT amp TOWING All trailer mounted Terex Super Quiet generators are designed for highway and off road towing capability Please consult state and local transpor tation codes before transporting the generator set Additionally all state and local traffic laws take precedence over the following instructions when ever differences arise between them Make sure the towing vehicle is of adequate size to both tow and stop the unit Disconnect all wiring and cabling including the ground wire from the generator set Close and latch or lock all access doors Using the front leveling jack raise the trailer hitch to an adequate height so that the generator can be securely attached to the transporting vehicle Ensure that the coupler is properly secured to the towing vehicle and attach the safety chains Attach the breakaway chain on the surge brake and the electrical coupler if these options are included on the unit ALWAYS USE THE PROPER TRAILER HITCH AND SAFETY CHAINS OBEY ALL LOCAL OR STATE D O T LAWS WHEN TOW ING A GENERATOR FAILURE TO PROPERLY SECURE THE TRAIL ER TO THE TOWING VEHICLE MAY RESULT IN SERIOUS INJURY OR DEATH Retract the front leveling jack into its stowed position TEREX GE
82. verify that the generator is function ing properly All contacts should be checked following the proper schematic with the switch disconnected from the generator set Actual loads can cause failures in contacts that cannot be duplicated using a meter Overcurrent Relay This device causes the 3 phase breaker to trip that supplies AC power to the distribution lugs if uneven or excessive current is measured at the distribution lugs It is also connected to the 3 phase door switch and will automatically trip the 3 phase breaker when the door is open and pre vents the breaker from being reset while it is open Section 4 Troubleshooting TEREX TROUBLESHOOTING Generator Test resistance of field stator and exciter wind ings Contact TEREX for procedures or repair facility recommended by generator manufacturer A Procedure for testing generator with no output THIS EQUIPMENT USES HIGH VOLTAGE CIRCUITS CAPABLE OF CAUSING SERIOUS INJURY OR DEATH EXCERCISE EXTREME CAUTION AROUND ANY ELECTRICAL COMPONENT WHEN OPERATING THIS UNIT IT IS ESSENTIAL THAT ALL TEST INSTRU MENTS ARE REGULARLY CHECKED FOR SAFETY AND ANY CONNECTION LEADS PROBES OR CLIPS ARE CHECKED TO ENSURE THAT THEY ARE SUITABLE FOR THE VOLTAGE LEVELS BEING TESTED NEVER ATTEMPT TO TEST A LIVE GENERA TOR UNLESS THERE IS ANOTHER COMPE TENT PERSON PRESENT WHO CAN SWITCH OFF THE POWER SUPPLY OR SHUT DOWN THE ENGINE IN AN EMERGENCY NEVER EXPOSE LIVE
83. x part number Part description and quantity Purchase order number Ship to address Desired method of shipment Name and telephone number of the authorized TEREX Distributor in your area FI FI I I l I El ER Use the Service Parts Fax Order Form on the next page and fax your order to our Parts Department If you don t know the name of your authorized distributor or if your area is not currently serviced by an authorized distributor please call TEREX Corporation Machine Information Model Serial Number Date of Purchase Authorized TEREX Distributor Phone Number TEREX How To Order Parts Genie Industries 18340 NE 76th Street P O Box 97030 Redmond WA 98073 9730 Telephone 877 367 5606 Fax 888 274 6102 genieindustries com Part No 833015 T70 amp T80 Super Quiet Generator xi December 2006 TEREX Service Parts fax Order Form FAX TO 800 633 5534 OR TOLL FREE 800 433 3026 Please fill out completely Date Account Number Your Name Your Fax Number Your Phone Number Bill To Ship To Purchase Order Number Ship Via Model s Serial No s Optional Equipment Part Number Description Quantity Price All backordered parts will be shipped when available via the same ship method as the original order unless noted below Ship complete order only backorders o Ship all available parts and contact customer on disposition o
84. xle Manual 833014 Copyright 2006 by TEREX Corporation 833015 Rev A December 2006 First Edition First Printing TEREX is a registered trademark of TEREX Corporation in the USA and many other countries Super Quiet is a trademark of TEREX Corporation 6 Printed paper Printed U S A ii T70 amp T80 Super Quiet Generator Part No 833015 November2007 TEREX How to Read Your Serial Number Serial Number Legend The serial number plate on your T70 amp T80 Super Quiet Generator is located on the twist lock area of the lower control panel P TEREX LIGHT CONSTRUCTION P O BOX 3147 ROCK HILL S C 29732 803 324 3011 KW KVA HZ CL LISTED 3044021 CERTIFIED TO CSA STD C22 2 NO 100 Part No 833015 T70 amp T80 Super Quiet Generator ili December 2006 TEREX This page intentionally left blank iv T70 amp T80 Super Quiet Generator Part No 833015 December 2006 Section 1 Safety Rules TEREX Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M You a

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