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T360

1. D or age CO Go 2 a 4 iol ojo n N CD A e S oO CAL x NI m c ol c 5 lt r c 0 Jg lt c 0 DRY DR 9 365 23 6 2 722 0 13 3 830 1055 682 925 909 1233 2 Co Co r c 8 1 21 D e e M N E OY za ex o S bal COL So NX RIS ge o o SE oF o D OLR 1 o CO op gt rN 2 SC w 9 v o AAT w N OVA ala af o ol 6 0 N gt eo oo A O ob DN nob elo NIN ao 4 o olol X nv e EE el EN olo Part No 833019 T360 Super Quiet Generator 2 3 TEREX Section 2 Specifications GENERATOR TORQUE SPECIFICATIONS Generator Flex Plate to Flywheel July 2007
2. 5 2 Electrical Schematic Distribution Panel Wiring 5 3 Electrical Schematic Stack Switch 5 4 Electrical Schematic Overcurrent Relay 5 5 A Electrical Schematic Standard Generator Wiring 5 6 A Electrical Schematic Idle Run Wiring Cummins 5 7 Section 6 Rev Decals A Figure 6 A Decals ned uec 6 2 Section 7 Rev Base Components A Figure 7 A Components tette 7 2 A Figure 7 B Base 7 4 Section 8 Rev Cabinet Components A Figure 8 A Cabinet Components Panels 8 2 A Figure 8 B Cabinet Components Doors 8 4 Section 9 Rev Control Box Components A Figure 9 A Control Panel Upper T360C 9 2 A Figure 9 B Control Panel Lower T360C 9 4 viii T360 Super Quiet Generator Part No 833019 July 2007 TABLE OF CONTENTS Section 10 Rev Distribution Panel A Figure10 A X Distribution Panel 10 2 Section 11 Rev Engine amp Genset Components A Figure 11 Engine Genset Assembly Cummins
3. bearing housings winding conditions Inspect rotating 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 3 4 T360 Super Quiet Generator PartNo 833019 July 2007 Section 4 Troubleshooting TEREX Troubleshooting Before Troubleshooting M Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine M Be sure that all necessary tools and test equipment are available and ready for use Observe and Obey M Be aware of the following hazards and follow M Troubleshooting and repair procedures shall be generally accepted safe workshop practices completed by a person trained and qualified on DANGER Electrocution hazard Exposure to the repair of this machine ADA electrically charged circuits could M Immediately tag and remove from service a result in death or serious injury damaged or malfunctioning machine Remove all rings watches and other jewelry M Repair any machine damage or malfunction before operating the machine ADANGER Electrocution hazard Attempting to sevice the machine before the Unless otherwise specified perform each capacitors are fully discharged
4. 836430 Cummins Engine Manual 125558 Cascade Controller Manual 833011 Dexter Axle Manual 833014 Copyright 2007 by TEREX Corporation 833019 Rev A July 2007 First Edition First Printing is a registered trademark of TEREX Corporation in the USA and many other countries Super Quiet is a trademark of TEREX Corporation 6 Printed on recycled paper Printed in U S A T360 Super Quiet Generator Part No 833019 July 2007 TEREX How to Read Your Serial Number Serial Number Legend The serial number plate on your T360 Super Quiet Generator is located on the twist lock area of the lower control panel e TEREX LIGHT CONTSTRUCTION P O BOX 3147 ROCK HILL S C 29732 803 324 3011 Mode s KW KVA HZ QI LISTED 3044021 CERTIFIED TO CSA STD 22 2 NO 100 Part 833019 60 Super Quiet Generator iii July 2007 TEREX This page intentionally left blank iv T360 Super Quiet Generator Part No 833019 July 2007 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
5. 11 2 A Figure 11 B Engine Muffler Assembly CUMMINS 11 4 Section 12 Rev Trailer Components A Figure 12 A Trailer Components pp 12 2 Part No 833019 T360 Super Quiet Generator ix July 2007 TEREX Parts Stocking List Required Parts The following parts are required to perform maintenance procedures as outlined in the TEREX T360 Parts and Service Manual Description Part No Cummins QSM11G4 Models OIL FUSE cS 125550 Air Filter Primary sees 125561 Air Filter Secondary 125562 C 125551 125552 x T360 Super Quiet Generator Part No 833019 July 2007 Please be prepared with the following information when ordering replacement parts for your TEREX product Machine model number Machine serial number Terex 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 N N Use the Service Parts Fax Order Form 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
6. NOD 5594 WOM Z NO 6 NINI IH Boe NDILISDd OL S NIXw 820 Tu y SzG s si S 21 DL TWO 31099 We 2 E Vo S ing e xny viele 8 el ino y xn 2 ss n SI msn 10N Aaaa ve 85 AVIH AVIS 2 42 2 Ly 7 1 15 S170A xi JR ZTE HOLIMS 3 15901 VE 90718 OG 79797 ESE 134 9 0 YD OF a S gt a s VO H m a a 4 s w k 100420 8 ONIAVa 335 E 890 ND 7 OL 3NISN3 3a TAIT Tand Sanss3sd Wal 8 5 ZINJ SHA 2 Part No 833019 T360 Super Quiet Generator TEREX Distribution Panel Wiring for T360 Series Single Phase Control Section 5 Schematics July 2007 REV A Drawing ES100027 OW El IL 2399399 E 1 2L EL 1 gt N 88 1708 annoa5 359 2H 371 JMA 404 31UN 335 2 N3349 216 f C gc HOLIAS 72918 OL 3715 04 335
7. W d3 AIW 2H FONVSD Wadd 01 NAUBG Woda L o o o xou 6 o w w w gt gt gt gt gt gt IR lt x x a 3 I3 9 ALW 4 9 9 dWV dNY dAV 02 0c 05 05 0S 21 W i i 61 wows T360 Super Quiet Generator PartNo 833019 July 2007 Section 5 Schematics TEREX Three Position Stack Switch Wiring Drawing ES100026 REVA 1504 SOLI V33N39 1504 YOLVYANAD 1081 80000153 00001537 SONIMVMO 33S 3ON343434 404 310N 99 989 YSEWAN LYVd HOLIMS 0821 20 21 ZZ HOLIMS MOVIS lOHLNOO WO4 1504 MOLVS3N39 xog 10841 O8 10HLNOD WO SOK 1 0 N39 0 aval N39 09 OL ge T SSS Sc 5 8c 26 GG ov 6 o 5 5 9 1 c PTET F 92 6 7 MOTI3A s N en vc FINVYO 1515 x Ti Ol 5 4 8 0 90
8. 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 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 e When a 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 PartNo 833019 T360 Super Quiet Generator 4 7 TEREX TROUBLESHOOTING Procedure testing generator with no output cont e After performing the initial checks above remove the field wires from the voltage regulator F1 or X is positive and F2 or XX is nega
9. JONVYO C 7 opte 9 4 LJVHS 410 HOLIMS Q I1SOd MOLVM3N39 Sf OL O N39 OL 0 1SOd MNOL1V33N39 8 aval v N39 OL PartNo 833019 T360 Super Quiet Generator Section 5 Schematics July 2007 TEREX co Es 2 S5 cs 5 o gt 2 2 5 009 8 20961 9 000 1 9 009 20221 51009 1 9 9 009 2081 00 1 8 002 9 0 04 1 9 061 5 006 1 90 5 0 1 41 081 5991 00L v 9921 507103 Sv 34V AVT38 LN3BBDON3AO LINN HOV3 X04 SLO 3HL 30V AV 139 LN3SSDOO 9250 CL 1 9 GL 31 50 0235 N Y130 135 E 08 Sanv 9 9 amp 313A LIOA OL 929399 NO dial INNHS OL xov38 029 vl N3349 NO dlML INNHS OL TL MOTI3A 308005 JA ONINNNY ANION OL vL 029 anayo 5 31M c vl 1 9 GI 81 e 7 8 O N HOLIMS 3000 sawv NA K Ts INdN 13 980 Nua YOLOALOYd INI4HYNI
10. Packaging Enclosure Sound Levels Lifting System Weight Empty No Trailer Weight Full No Trailer Dimensions L x W x No Trailer Weight Empty with Trailer Weight Full with Trailer Dimensions L x W x H with Trailer Section 2 Specifications July 2007 REVA 352 kW 3 Phase 480 240V Brushless 4 Pole Synchronous Single Bearing Class H 125 C Rise Over 40 C Ambient External Solid State Adjustable 196 60 Hertz 1800 RPM ECM Controlled Low Oil Pressure High Water Temperature Overcrank Overspeed Underspeed Voltmeter Ammeter Hertz Meter 2 Each 20 Amp GFCI Duplex 3 Each 50 Amp Tempower T L 5 Lug Terminals with Mainline Circuit Breaker Sound Attenuated Weatherproof with Lockable Doors 72 dBA at 23 ft 7 meters Roof Mounted Single Point 10450 Ib 4740 kg 13227 Ib 6000 kg 165 x 62 x 94 in 419 x 157 x 2394 cm 13120 Ib 5964 kg 15890 Ib 7223 kg 230 x 88 x 114 in 584 x 224 x 290 cm 2 0 ol T360 Super Quiet Generator Part No 833019 July 2007 Section 2 Specifications TEREX REV A 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 5 Grade 8 Black Oxide Bolts LUBED DRY LUBED DRY LUBED Nm 100 140 158 730 120 120 135 140 LUBED LUBED DRY LUBED 24 33 9 271 447 50 1 678 813 80 1084 68 921
11. July 2007 Section 8 Cabinet Components TEREX Section Eight Cabinet Components Part No 833019 T360 Super Quiet Generator 8 1 Section 8 Cabinet Components July 2007 TEREX Figure 8 A Cabinet Components Panels REVA 8 2 T360 Super Quiet Generator Part No 833019 July 2007 REV A Section 8 Cabinet Components TEREX FIGURE 8 A DESCRIPTION GM 125179 51601570 71100200 00401000 FORMING WASHER FLAT 1 4 5 8 5 SCREW FLANGE 1 4 20 X 75 STAIN STEEL RIVET POP 3 16 X 1 2 S S BLIND RIVET PLATE DECK SCREW OUT WEATHERSTRIP ADHESIVE 1 8 THICK X 1 2 WIDE FOAM BLACK URETHANE 1 WELDMENT REAR CORNER CONTROL SIDE WELDMENT BACK LOUVER PANEL REAR LOUVER PANEL MESH WELDMENT REAR CORNER DISTRIBUTION SIDE WELDMENT BOX TOP SCREW FLANGE 3 8 X 3 4 PATCH FOAM BLACK URETHANE 1 2 1 5 INSULATION MELAMINE FOIL BAKED FORMING PLENUM DISTRIBUTION SIDE FORMING PLENUM CONTROL SIDE FORMING PLENUM FRONT TOP FORMING PLENUM FRONT BOTTOM WELDMENT PLENUM TOP GRILL WELDMENT TOP DOOR FRAME WELDMENT LIFTING ATTACHMENT WASHER FLAT 1 4 5 8 S SCREW FLANGE 1 4 20 X 75 STAIN STEEL PLATE LIFT ATTACHMENT CLAMP WASHER FLAT 5 8 SCREW SHC 5 8 11 X 7 WELDMENT DOOR POST DISTRIBUTION SIDE WELDMENT DOOR POST CONTROL SIDE WELDMENT PLENUM TOP GRILL PLENUM FRONT INSIDE SQUARE PLENUM RADIATOR DOOR SQUARE PLENUM DIST
12. PLUG PIPE 3 SQUARE HEAD BASE WELDMENT 500 GAL CONTAIN WASHER LOCK 5 8 SCREW HEX CAP 5 8 11 X 1 5 KEG Y ZINC GR8 NYLON TUBING CUT TO PROPER LENGTH FITTING PICKUP BARB 1 4 MNPT 1 2 ID HOSE CLAMP 11 16 X 1 1 4 HOSE FUEL 1 2 ID CAP FUEL SENDER FUEL LEVEL VDO NUT LOCK NYLON INSERT 1 2 13NC GR 2 ZPIN WELDMENT GENERATOR MOUNT FRONT WELDMENT GENERATOR MOUNT REAR WELDMENT ENGINE MOUNT BEAM FRONT MOTOR MOUNT CUMMINS QSM BATTERY SUPPORT FORMING HOSE END BARBED 90 DEGREE k k k MM k k k Part No 833019 T360 Super Quiet Generator Section 7 Components July 2007 TEREX Figure 7 B Base Components REV A Battery Mounting 7 4 T360 Super Quiet Generator Part No 833019 July 2007 Section 7 Components TEREX REV A FIGURE 7 B DESCRIPTION AIR CLEANER ASSEMBLY DUAL ELEMENT INCLUDES 2 4 MOUNTING BAND AIR CLEANER ELEMENT PRIMARY ELEMENT SECONDARY ELBOW RUBBER 90DEG 7 X 6 CLAMP PIPE AIR INTAKE CLAMP HUMP HOSE RUBBER REDUCING 6 X 4 AIR FILTER MOUNT CUMMINS 5 11 C90107200 CLAMP 897925 HOSE CAC 4 ID X 8 LONG 125038 PIPE TURBO OUTLET 125040 PIPE CHARGE COOLER OUTLET ELBOW 90D 8 MALE SAEX 8 FEMPIPE HOSE END BARBED RIGID 8 8 CLAMP 11 16 X 1 1 4 W LINER WELDMENT FRONT CORNER CONTROL SIDE 125172 WELDMENT RADIATOR TOP 125167 WELDMENT FRONT CORNER DISTRIBUTION SIDE C42208705 SWITCH SENSOR COO
13. REV A for Murphy Cascade Controller Drawing ES100029 Standard TaNVd NOILNGIALSIC 359 NO GALNNOW 38V SLOVLNOD 1491 340 34 131041415101 SNI3 340438 dOLS 3 3Hl SI 4340d 17DA 21 TW 314 2 HOLIMS 52009 3SYHd E SV 3AVS 3Hl SI 31892 1491 310W38 3 LON 3015 ASIA 30193NN09 OVE 33 3218 520008 853 r AHdanW 0T0vGyn SS3N IVH 29 N3349 2 85 q O0 xx SLOWLNOI 184915 C g CION310S A3LAVLS OL ls lela la 35938 laa 8 aw de e 81313 8 SJ SIWIS E 5 8 E div ST 5 gis s 8 5 2909299 RR 8 5 LIVE A 18 98 ve 3mE ND S nsi 308 vo Sr HOVE VO H 8c 8 859 100420 amp 919 SNIAVNO 335 1 TY
14. 61 eg OL E HOO OL Wada P aguz MOO OL EM 193NNOO y a Nada oif T360 Super Quiet Generator July 2007 Section 5 Schematics TEREX Idle Run Wiring Cummins REVA Drawing ES 100039 50 OEM CONNECTOR GENERATOR SPEED LOAD GOVERNING BIAS RETURN SENSOR RETURN 3 atten GOVERNING BIAS SIGNAL LOAD SHARE Y GENERATOR SPEED LOAD GOVERNING BIAS SHIELD D EQUIPMENT GENERATOR SPEED LOAD GOVERNING BIAS 5 VOLT SUPPLY OPTIONAL SENSOR SUPPLY 3 GAIN ADJUST ROTENTIOMETEP DROOP ADJUST POTENTIOMETER f FREQUENCY ADJUST POTENTIOMETER 6 4 SERI GAIN ADJUST POTENTIOMETER 5 VOLT SUPPLY SENSOR SUPPLY 2 GAIN ADJUST POTENTIOMETER SIGNAL fd SENSOR RETURN 2 GAIN ADJUST POTENTIOMETER RETURN DROOP ADJUST POTENTIOMETER 5 VOLT SUPPLY DROOP ADJUST POTENTIOMETER SIGNAL DROOP ADJUST POTENTIOMETER RETURN cp FREQUENCY ADJUST POTENTIOMETER 5 VOLT SUPPLY FREQUENCY ADJUST POTENTIOMETER SIGNAL FREQUENCY ADJUST POTENTIOMETER RETURN ENGINE COOLANT LEVEL 5 VOLT SUPPLY L gt gt ENGINE COOLANT LEVEL RETURN ENGINE COOLANT LEVEL SENSOR INTAKE AIR HEATER SIGNAL INTAKE AIR HEATER INTAKE AIR HEATER RETURN IDLE RATED SWITCH SIGNAL IDLE RATED SWITCH oo DIAGNOSTIC TEST MODE SWIEH Gp DIAGNOSTIC TE
15. Generator Case to Bellhousing 5 8 11 Socket Head Cap Screws for Lifting Channel 1 2 13 Hex Head Screws for Lifting Channel Genset Isolators T360 Super Quiet Generator Part No 833019 July 2007 Section 3 Scheduled Maintenance Procedures TEREX Scheduled Maintenance Procedures Observe and Obey M Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine M 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 Immediately tag and remove from service damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine M 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 M Unless otherwise 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
16. If any further adjustment is needed to the voltage of the generator please call TEREX at 1 800 433 3026 for assistance T360 Super Quiet Generator PartNo 833019 July 2007 REV A Observe and Obey M 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 damaged or malfunctioning machine M Repair any machine damage or malfunction before operating the machine Before Troubleshooting M Read understand and obey the safety rules and operating instructions in the appropriate operator s manual on your machine M 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 Perform repair Return to service problem solved PartNo 833019 T360 Super Quiet Generator 5 1 July 2007 Section 5 Schematics ij TEREX Control Panel Wiring
17. 108 4 122 162 176 217 244 10 200 271 270 366 280 379 16 220 298 300 406 310 420 8 19 32014311 430 583 450 610 610 827 50 69i 14 350 474 470 637 500 678 670 908 560 759 14 7 15 8 I 20 gt 13 5 E lt 73 14 23 17 6 19 31 2 26 35 2 37 50 1 41 55 5 57 77 3 64 86 7 108 4 122 110 149 130 176 170 230 17 19 31 35 49 55 75 85 110 120 150 23 25 7 42 47 4 66 4 74 5 101 6 115 149 162 203 18 20 33 37 50 120 130 160 180 e e e EN co N 7 e 20 650 840 867 680 92 910 1233 1044 i12 530 718 710 962 750 1016 990 1342 1139 1071 1315 1290 1749 1090 1477 12 670 908 890 1206 1080 1464 1440 1952 1220 1654 1138 1120 1518 1360 1844 1820 2467 1530 2074 12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304 6 1460 1979 1950 2643 2370 3213 3160 4284 2670 3620 12 1640 2223 2190 2969 2670 3620 3560 4826 3000 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 iz il ile ile 1 gt o CD oo Q Po Po e OF
18. 114499 Side REV 114492 97666 133008 133009 133007 133010 852255 133006 CR 114258 31788 Control Panel Side 114485 114499 114492 a C52100100 97666 E 4 133047 97602 GS 2 OJ 133012 Serial Label 6 2 T360 Super Quiet Generator Part No 833019 July 2007 Section 7 Components TEREX Section Seven Base Components Part No 833019 T360 Super Quiet Generator 7 1 Section 7 Components July 2007 TEREX Figure 7 Base Components REV A 7 2 T360 Super Quiet Generator Part No 833019 July 2007 REV A Section 7 Components TEREX FIGURE 7 A DESCRIPTION GM 90700800 90200300 91100700 90200600 90800200 125064 90900601 125062 993890 15309 91100300 WELDMENT LIFTING SCREW 1 2 13 NC X 1 GR5 ZP WASHER LOCK 1 2 MOUNT VIBRATION YELLOW SCREW 1 2 13 NC X 2 HHC GR 8 Y ZINC SCREW 1 2 13 NC X 1 1 2 HHC GRADE 5 ZP WASHER FLAT 1 2 VALVE VACCUUM RELIEF 1 4 CLAMP 7 16 TO 25 32 W LINER HOSE FUEL 5 8 BLACK FITTING BARB 3 8 NPT 1 4 HB PIPE ELBOW STREET 90 1 2 M X F BRASS ADAPTER 1 2 X1 4 REDUCER BARB 3 8 X 1 4 NPT 90 DEGREE HOSE FUEL 3 8 BARB 3 8 X 1 4 NPT VALVE NEEDLE 1 4 FPT X 1 4 FPT TANK FUEL 428 GAL
19. AND MAINTENANCE SERVICE INTERVALS 50 Hrs or 500 Hrs or spect adjust or replace alternator or fan belt Ps 0 L4 In Check driven equipment Inspect engine air cleaner service indicator Checkengineoillevel o ea Lot LL separator linspect clean engine ground 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 poe Test change fuel injector Ol eo I wp oj Change cooling system coolant _ I I commercial heavy duty j Cleanhestaftercoolercore cooling system coolant extender ELC Change cooling system coolant ELC Part No 833019 T360 Super Quiet Generator 3 3 Section Scheduled Maintenance Procedures July 2007 TEREX MAINTENANCE SCHEDULES CONTINUED REVA NEWAGE GENERATORS MAINTENANCE SCHEDULE ITEM DAILY or3 or 12 ER salle Months Months 1 Visual inspection plus running audible check Measure stator winding insulation resistance Monitor Monitor bearing s condition condition Remove terminal box lid and check i 20077 Re Re grease bearings Replace beaingls H 1 2 Replace NDE oring
20. H3A0 T360 Super Quiet Generator PartNo 833019 July 2007 REV Section 5 Schematics Standard Generator Wiring for T360 Series Drawing ES100030 TEREX PartNo 833019 0 r MOT OFZ 41 5757 092 aN Van a mU s 1 61 L bed 1 7 as 5 5 1 DN TIL SIN LEN 91 2 oi N N wit mx TONGS LL ouj 58 530333 ul EN 58 1 556 120001534 OL 43434 53715 LO 404 88 88 92000153 OL 43434 yd38NnN LYVd HOLIMS MOVLS 304 33 s E 84 99 Som FE 1 BOER 6 X 170 OL d V A R 2 2181 52 EE EIE IL 91 pom 3 7 3 S als aly 92 x 88 X a lo I L 1 2 ZL ZL c ls i m SHON 335 Y 03 lt el zl o s 81 19 5 81 ESTEE S 3 1 116 fea 02 TP B B RT t 99 82 55
21. damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards P such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Section 1 Safety Rules July 2007 Workplace Safety Be sure to keep sparks flames and 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 W are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage Be sure any forklift overhead crane or d 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 that fasteners intended for one time use i e cotter pins self locking nuts are not reused These components may fail if they are used a second time Be sure to properly dispose of old oil or 23 other fluids Use approved container Please environmentally safe Be sure that your workshop or work area is H3 properly ventilated and well lit N vi T360 Super Quiet Generator Part No 833019 July 2007 TEREX Table of Contents I
22. 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 Used to indicate the presence of an imminently hazardous situation which if not avoided will result in death or serious injury ADANGER AWARNING Used to indicate the presence of a potentially hazardous situation which if not avoided could result in death or serious injury ACAUTION Used to indicate the presence of a potentially hazardous situation which if not avoided may cause minor or moderate injury Used to indicate operation or maintenance information O Indicates that a specific result is expected after performing a series of steps W Indicates that an incorrect result has occurred after performing a series of steps PartNo 833019 T360 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
23. will repair procedure with the machine in the 2 in death or 2 me following configuration Machine parked on a firm level surface ADANGER High voltage Exposure 10 electrical wires electrical current Wheels chocked will result in death or serious Toggle switch in OFF position 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 PartNo 833019 T360 Super Quiet Generator 4 1 TEREX Section 4 Troubleshooting 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 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
24. 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 T360 Super Quiet Generator PartNo 833019 July 2007 High generator output voltage Section 4 Troubleshooting POSSIBLE CAUSE Defective automatic voltage regulator Loose wire on voltage adjustment potentiometer Neutral binding strap notin place TEREX TROUBLESHOOTING SOLUTION Replace voltage regulator Check wiring Install neutral binding strap Fluctuating generator output voltage An ON OFF type load may be the cause Fluctuating 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
25. AL KIT RECEPTACLES C42500600 TRANSFORMER CURRENT 1200 5 73000100 TRIM LOCK 1 4 682776 RECEPTACLE 15A OPTIONAL NOT STANDARD 0300 000 0 LG MGM HH H Part No 833019 T360 Super Quiet Generator 9 5 Section 9 Control Box Components July 2007 TEREX This page intentionally left blank 9 6 T360 Super Quiet Generator Part No 833019 July 2007 Section 10 Distribution Panel TEREX Section Ten Distribution Panel Part No 833019 T360 Super Quiet Generator 10 1 Section 10 Distribution Panel July 2007 TEREX Figure 10 A Distribution Panel REV A Cam Lock option shown for reference only Detail of Buss Board item 18 10 2 T360 Super Quiet Generator PartNo 833019 July 2007 Section 10 Distribution Panel REVA TEREX FIGURE 10 A DESCRIPTION 5 GM 51601441 125198 125265 125263 125058 42200701 42200702 125075 125180 125442 C42501500 C42501600 CU51A400 851820 SCREW FLANGE 1 4 20 X 75 WASHER FLAT 1 4 NUT FLANGE 1 4 20 FORMING COVER STACK SWITCH FORMING STACK SWITCH STRUT FORMING STACK SWITCH REAR MOUNT SWITCH STACK 3POSITION SWITCH SNAP ACTION PLUNGER ACTUATOR WELDMENT DISTRIBUTION BOX WELDMENT CAM LOCK PANEL PANEL DISTRIBUTION J SERIES CONNECTOR CAM LOCK WHITE CONNECTOR CAM LOCK RED CONNECTOR CAM LOCK BLUE CONNECTOR CAM LOCK BLACK CONNECTOR CAM LOCK G
26. Authorized TEREX Distributor Phone Number TEREX How To Order Parts TEREX North America Telephone 803 324 301 1 Toll Free 800 433 3026 in U S A and Canada Fax 803 366 1101 Part No 833019 T360 Super Quiet Generator Xi July 2007 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 o Ship complete order only backorders o Ship all available parts and contact customer on disposition of backordered parts o Other please specify For TEREX Use ONLY 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 July 2007 Section 2 Specifications REV A System Power Output Prime 3 Phase Power Prime 3 Phase Available 3 Phase Voltage Associated 3 Phase Amps 0 8 power factor Prime 1 Phase Power Prime 1 Phase Available 1 Phase Voltage Associated 1 Phase Amps 1 0 power factor Max Amp Rating Main Breaker Size Engi
27. LANT LEVEL 125169 FORMING RADIATOR BOTTOM 125377 FORMING PLENUM DRAIN C33700800 HOOK BATTERY HOLD DOWN PAIR 125283 FORMING BATTERY HOLDDOWN 2 X 4D 125336 BATTERY 12V GROUP 4D 1080 CCA WET 125268 BATTERY SUPPORT FORMING 125563 FAN GUARD PIPE COOLANT PRESSURE PIPE COOLANT SUCTION HOSE CAC 2 5 ID X 3 LONG CLAMP CLAMP T BOLT 4 25 CLAMP SCREW 8MM X 20MM NUT FIN HEX M8 1 25 P NUT LOCK NYLON INSERT 1 2 13NC GR 2 ZPIN WASHER FLAT 1 2 REAR MOTOR MOUNT CUMMINS QSM 1 WASHER LOCK 5 8 SCREW HEX CAP 5 8 11 X 1 5 KEG Y ZINC GR8 SCREW 3 4 10NC X 2HHC GRADE 2 ZP WASHER LOCK 3 4 NUT HEX 3 4 10NC GRADE 2 ZP Part No 833019 T360 Super Quiet Generator 7 5 July 2007 Section 7 Components TEREX REV A 7 Base Components cont igure 5 5 a Radiator Plumbing Part No 833019 T360 Super Quiet Generator July 2007 REV A Section 7 Components TEREX FIGURE 7 B BARB 3 8 X 1 4 NPT HOSE FUEL 3 8 HOSE HEATER SILICONE 1 NIPPLE PIPE 1 4 X 1 5 VALVE NEEDLE 1 4 FPT X 1 4 FPT CLAMP 7 16 TO 25 32 C90200600 C91100700 897922 C90400900 C90800200 792750 Part No 833019 T360 Super Quiet Generator 7 7 Section 7 Components July 2007 TEREX This page intentionally left blank 7 8 T360 Super Quiet Generator Part No 833019
28. NAL STRIP 6 POS JUMPER TERMINAL STRIP RELAY 50A BOSCH RELAY BASE 50A BOSCH RELAY PIN DECAL CONTROL PANEL CASCADE DECAL KIT RECEPTACLES NUT LOCK NYLON INSERT 8 32 18 8 S S SCREW SET 8 32X1 2 SCREW 1 4 20NCX1 HHC GRADE 2 ZP NUT LOCK NYLON INSERT 1 4 20NC GR 2 ZP NUT HEX 1 4 20NC GRADE 2 ZP WASHER LOCK STAR 1 4 INT EXT ZP HARNESS DC ENGINE T360 TRIM LOCK 1 4 Part No 833019 T360 Super Quiet Generator 9 3 Section 9 Control Box Components July 2007 TEREX Figure 9 B Control Panel Lower T360 REVA 9 4 T360 Super Quiet Generator PartNo 833019 July 2007 Section 9 Control Box Components TEREX REV A FIGURE 9 B DESCRIPTION 125065 WELDMENT CONTROL BOX 125273 PLATE LOWER CONTROL PANEL C42105500 BREAKER 1200A 3POLE C42103400 BREAKER 20A 120 240V C42103600 BREAKER 50A 120 240V 684640 RECEPTACLE 20A 120V DUPLEX W GFI TRANSFORMER 600 5 WASHER FLAT 5 16 TEMP POWER SLOPE RECEPTACLE TWISTLOCK 50A 240V 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 START CN SCREW 46 32 X 1 2 SCREW 5 16 18NC X 6 1 2 HHC GR 5 ZP NUT LOCK NYLON INSERT 5 16 18NC GR 2 ZP NUT LOCK NYLON INSERT 8 32NF NUT CLIP 1 4 20 X 3 4 NUT CLIP 1 4 20 X 3 4 DEC
29. REEN DISTRIBUTION BOARD COMPLETE ASSEMBLY DECAL 3PHASE DISTRIBUTION PANEL SCREW 1 4 20NC X 3 4 BUTTON HEAD 1 8 8 S S WASHER LOCK 1 4 WASHER FLAT 1 4 WASHER FLAT 3 8 NUT COUPLING 3 8 16NC X 1 3 4 HEX ZP DECAL L1 L2 L3 N DECAL SYMBOL FOR GROUND SCREW 1 2 13NC X 1 1 2 HHC GRADE 5 ZP WASHER LOCK 1 2 HEX NUT 1 2 13 SBZ SCREW 10 32NF X 7 8 LG NUT LOCK NYLON INSERT 10 32NF 18 8 S S SCREW 1 2 13NC X 1HHC GR5 ZP GROUND STRAP BUSS BAR STANDOFF ISOLATOR DISTRIBUTION BOARD ONLY WASHER LOCK STAR 1 2 EXT TOOTH S S OH HWWWWW HH HHH KH ORO PartNo 833019 T360 Super Quiet Generator Section 10 Distribution Panel July 2007 TEREX This page intentionally left blank 10 4 T360 Super Quiet Generator Part No 833019 July 2007 Section 11 Engine amp Genset Components TEREX Section Eleven Engine amp Genset Components Part No 833019 T360 Super Quiet Generator 11 1 Section 11 Engine amp Genset Components July 2007 TEREX Figure 11 A Engine Genset Assembly Cummins REVA 11 2 T360 Super Quiet Generator PartNo 833019 July 2007 REV A Section 11 Engine amp Genset Components TEREX FIGURE 11 A DESCRIPTION 125081 125526 49217 C42300400 839097 C42300500 GENERATOR NEWAGE HCI434E1L80D MX341 AUTOMATIC VOLTAGE REGULATOR RECTIFIER SERVICE KIT W FWD amp REV DIODES VARIS
30. RIBUTION SIDE SQUARE PLENUM PAN SQUARE PLENUM LATCH POST SQUARE PLENUM DOOR SQUARE PLENUM DOOR POST FORMING SQUARE PLENUM FRONT SQUARE PLENUM CONTROL SIDE M 94 6 1 AR AR 1 1 1 1 2 25 AR AR 1 1 1 1 1 2 1 4 4 1 4 4 1 1 1 1 1 1 1 1 1 1 1 1 Part No 833019 T360 Super Quiet Generator Section 8 Cabinet Components July 2007 TEREX Figure 8 B Cabinet Components Doors REV A 8 4 T360 Super Quiet Generator Part No 833019 July 2007 REV A Section 8 Cabinet Components TEREX FIGURE 8 B DESCRIPTION GUU401100 CU54T021 74100100 125084 71100500 GM C51200000 125185 125541 125483 C41135000 C21353 981120 990170 794890 TRIMLOCK SEAL 7 16 WINDOW CONTROL DOOR GASKET WINDOW CONTROL DOOR FORMING CONTROL PANEL DOOR FOAM BLACK URETHANE 1 LITERATURE BOX FLAT WASHER 11 16 OD NUT LOCK NYLON INSERT 1 4 20NC GR 2 ZP SCREW CARRIAGE 1 4 20 X 75 STAINLESS STEEL WELDMENT ACCESS DOOR RIGHT RIVET POP 3 16 X 1 2 S S BLIND RIVET LATCH BLACK KEY LOCK ADJ T HANDLE FORMING DISTRIBUTION PANEL DOOR WELDMENT ACCESS DOOR LEFT STOP DOOR RUBBER W WASHER RIVET POP 1 4 X 1 2 CARRIAGE BOLT 3 8 16 X 3 4 WASHER FLAT 3 8 NUT LOCK NYLON INSERT 3 8 16NC GR 2 ZPN HINGE STAINLESS STEEL BLACK COATED MM KK K KK m Part No 833019 T360 Super Quiet Generator 8 5 Sec
31. ST MODE SWITCH SIGNAL ALTERNATE Go ALTERNATE FREQUENCY SWITCH SIGNAL IDLE DIAGNOSTIC INCREMENT MOMENTARY INCREMENT SWITCH DIAGNOSTIC DECREMENT SWITCH lt o PULE DAGNOSTIC DECREMENT SWITCH ENGINE PROTECTION VERRIDE SWITEH 2 ENGINE PROTECTION OVERRIDE SWITCH SIGNAL FAUCI ACKNOWLEDGE SWITCH FAULT ACKNOWLEDGE SWITCH SIGNAL TACHOMETER OIL PRESSURE pna R TEMPERATURE COOLANT TEMPERATURE METER SIGNAL SWITCH METER RETURN SENSOR RETURN 6 OVERSPEED SHUTDOWN LAMP Q OVERSPEED SHUTDOWN LAMP RED COMMON WARNING LAMP 0 COMMON WARNING LAMP AMBER COMMON SHUTDOWN LAMP 0 COMMON SHUTDOWN LAMP RED LOW OIL PRESSURE LOP SHUTDOWN LAMP LOW OIL PRESSURE LOP SHUTDOWN LAMP NOT CONNECTED emm C J1939 SHIELD 11939 SHIELD 9 DEUTSCH CONNECTOR IGNITION BATTERY EMERGENCY STOP RUN STOP SWITCH EMERGENCY STOP OEM le O POWER CONNECTOR ECM BATTERY RETURN 01 02 GROUND lt 03 OPTIONAL ECM BATTERY SUPPLY 04 PartNo 833019 T360 Super Quiet Generator 5 7 Section 5 Schematics July 2007 TEREX REV A This page intentionally left blank 5 8 T360 Super Quiet Generator PartNo 833019 July 2007 Section 6 Decals TEREX Section Six Decals Part No 833019 T360 Super Quiet Generator 6 1 Section 6 Decals July 2007 TEREX Figure 6 A Decals Distribution Panel 114496 114484
32. Super Quiet Generator Part No 833019 July 2007 Section 4 Troubleshooting TEREX TROUBLESHOOTING POSSIBLE CAUSE set in OFF position Blown fuse in DC control circuit E Stop Defective starter solenoid Defective starter Seizedengine SOLUTION eck switch position Replace with 25 Amp SLO BLO TYPE fuse if needed Check to see if engaged Replace solenoid Replace starter 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 pump 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 or water mixture Not opening Use a 50 50 on mix of water and anti freeze only PartNo 833019 T360 Super Quiet Generator TEREX TROUBLESHOOTING Engine shuts down automatically and TROUBLE LIGHT on CONTROL PANEL isilluminated Section 4 Troubleshooting POSSIBLE CAUSE Overloaded engine Broken fan belt Defe
33. TEREX E 9 25 qj 9 p 9 1360 TEREX Introduction July 2007 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 equipment 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 T360 Operator s Manual 133005 First Edition TEREX T360 Service amp Parts Manual 833019 First Edition Newage Generator Manual
34. 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 833019 T360 Super Quiet Generator TEREX TROUBLESHOOTING Section 4 Troubleshooting POSSIBLE CAUSE Detective injectors on engine Surging engine speed SOLUTION ave injectors checked by a qualified technician Check engine fuel oil and air filters 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 Cloggedfuelsystem Airinfuelsystem Defective fuel pump Clogged air intake Clogged exhaust Contaminated fuel Defective injectors Lost engine compression Check fuel level in tank fill as needed Check wiring to verify 12V DC is being supplied to the pump solenoid Replace solenoid Checkfuelsystem Bleed fuel system Check and replace if defective Check air cleaner Check exhaust system Checkfuel water separator and tankforcontamination 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 T360
35. TOR PMG KIT INCLUDES STATOR ROTOR HARDWARE COVER OPERATION MANUAL HCI MODEL ENGINE CUMMINS QSM 1 1 OIL FILTER FUEL FILTER WATER SEPARATOR BELT BELT TENSIONER STARTER WATER PUMP THERMOSTAT ALTERNATOR OPERATION MANUAL DIPSTICK QUICK COUPLING OIL DRAIN MALE 1 18 UNS FAN HOSE END BARBED STRAIGHT FUEL P U WATER SEP HOSE END BARBED 90 DEG FUEL RETURN SENDER OIL PRESSURE VDO OIL PRESSURE SENSOR SWITCH WATER TEMP SD DOUBLE PRONG PartNo 833019 T360 Super Quiet Generator 11 3 Section 11 Engine amp Genset Components July 2007 TEREX Figure 11 B Engine Muffler Assembly Cummins REVA 11 4 T360 Super Quiet Generator PartNo 833019 July 2007 Section 11 Engine amp Genset Components REVA TEREX FIGURE 11 B DESCRIPTION GM WELDMENT FRONT CORNER CONTROL SIDE CLAMP U BOLT 5 PIPE EXHAUST WELDMENT RADIATOR TOP FORMING MUFFLER MOUNT WIDE CLAMP TORCTITE MUFFLER CLAMP RAIN CAP MUFFLER T360 CLAMP ACCUSEAL 5 FLEX CONNECTOR 5 ID ID 18 LG ELBOW EXHAUST 90DEG 5 EXHAUST CONNECTOR FLARED 4 TO 5 OD SCREW FLANGE 1 4 20 X 75 WASHER FLAT 1 4 SCREW 3 8 16NC X 1 1 4 WASHER FLAT 3 8 NUT LOCK NYLON INSERT 3 8 16NC GR 2 ZPN CLAMP V BAND Part No 833019 T360 Super Quiet Generator Section 11 Engine amp Genset Components July 2007 TEREX This page intention
36. ally left blank 11 6 T360 Super Quiet Generator Part No 833019 July 2007 Section 12 Trailer Components TEREX Section Twelve Trailer Components Part No 833019 T360 Super Quiet Generator 12 1 July 2007 Section 12 Trailer Components TEREX Figure 12 REV A Trailer Components gt 2 gt a I bed 2 gt 2 Trailer Hitch Mounting PartNo 833019 T360 Super Quiet Generator 12 July 2007 REV A Section 12 Trailer Components TEREX FIGURE 12 A DESCRIPTION TRAILER TANDEM TEARDROP FENDER TRAILER FENDER BACK CLEARANCE LIGHT MOUNT KIT AMBER CLEARANCE LIGHT TRAILER ELECTRIC BREAKAWAY BOX WITH SWITCH JACK 10K LBS CONNECTOR 6 PIN TRAILER ELECTRIC AXLE COMPLETE TIRE amp WHEEL MOUNTED 235 85R16 8 BOLT LOAD E LUG NUT BOLT FOR PINTLE EYE NUT FOR PINTLE EYE TOW RING 3 PINTLE EYE STOP TAIL LIGHT W GROMMETT amp PLUG TAG LIGHT KIT 2 5 RED CLEARANCE LIGHT CLEARANCE LIGHT MOUNT KIT TRAILER 2 RED CLEARANCE LIGHT TRAILER 2 CLEARANCE LIGHT MOUNT KIT MMM 5 K K MM M M Part No 833019 T360 Super Quiet Generator Section 12 Trailer Components July 2007 TEREX This page intentionally left blank 12 4 T360 Super Quiet Generator Part No 833019
37. also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless M You are 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 You have the appropriate tools lifting equipment and a suitable workshop Part No 833019 T360 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 ADANGER Indicates an imminently hazardous situation which if not avoided will result in death or serious injury AWARNING Indicates a potentially hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous ACAUTION situation which if not avoided may cause minor or moderate injury Indicates a potentially hazardous situation which if not avoided may result in property
38. ctive thermostat or thermocouple switch Defective water pump Blocked cooling air inlet or exhaust Defective or grounded temperature switch Defective injectors or injector pump Defective oil pump Defective or grounded oil pressure switch 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 Have the engine inspected by a trained service technician Inspect switch and repair or replace IF YOU FEEL AN ELECTRIC SHOCK AT ANY 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 T360 Super Quiet Generator PartNo 833019 July 2007 Electrical Troubleshooting 5 Components that cause voltage related problems Potentiometer Connects to voltage regulator Bypass potentiom eter by unplugging from voltage regula
39. 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 is a registered trademark of TEREX Corporation Rev 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 inspection 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 July 2007 Section Scheduled Maintenance Procedures TEREX Maintenance Schedules REVA CUMMINS LUBRICATION
40. ne Specs Manufacturer Model Horsepower Prime 1800 rpm Description Bore amp Stroke Piston Displacement Compression Ratio Exhaust System Monitoring Gauges Engine Cooling System Coolant Capacity engine only Cooling System Fuel System Fuel Specification Fuel Filter Fuel Capacity Fuel Tank and Containment Fuel Consumption Run Time Full Load 3 4 Load Half Load TEREX Specifications 288 kW 360 208 220 240 440 480 999 945 866 472 433 160kW 160 kVA 120 240 1333 667 1200 Cummins QSM11 G4 426 hp 318 6 Oyl 4 Cycle Water Cooled OHV In Line Direct Inj 4 92 x 5 79 in 125mm x 170mm 661 cu In 10 8 L 16 3 1 Critical Grade Silencer Oil Press Water Temp Fuel Level Battery Voltage Hours 2 5 gal 9 5 L Liquid Cooled Air to Air CAC Rated to 105 F Ambient 2 Diesel Fuel Water Separator 400 gal 1514 L Internal Fuel Tank with Fluid Spills Containment 20 7 gal hr 78 L hr 19 hr 15 5 gal hr 59 L hr 25 8 hr 10 6 gal hr 40 L hr 37 7 hr Part No 833019 T360 Super Quiet Generator 2 1 TEREX SPECIFICATIONS Generator Specs Rating 0 8 power factor Description Insulation Temperature Rating Automatic Voltage Regulator Voltage Regulation Frequency Speed System Controls Governor Protection Safety Shutdowns Generator Gauges Distribution Receptacles 120 V Receptacles 240 V Primary Distribution
41. ntroduction Important Information Introduction 222 kr aanas ii How to Read Your Serial Number iii Parts Stocking 14 x How to Order Pants xi Service Parts Fax Order FOTM xii Section 1 Safety Rules GenicraliSatety RUGS Section 2 Rev Specifications A Specifications LEE 2 1 Specifications Continued sss 2 2 A Torque Specifications 2 93 A Generator Torque Specifications 2 4 Section 3 Rev Scheduled Maintenance Procedures miseret re he hr 3 1 Pre delivery Preparation 0002 3 2 A Maintenance Schedules Cummins Lubrication and Maintenance Service Intervals 3 3 Newage Generators Maintenance Schedule 3 5 Section 4 Rev Troubleshooting 4 1 Troubleshooting ee eene eene 4 2 833019 T360 Super Quiet Generator vii July 2007 TEREX TABLE OF CONTENTS Section 5 Rev Schematics A TOS ee 5 1 Electrical Schematic Control Panel Wiring for Murphy Cascade
42. serve 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 July 2007 INSTALLATION AND ANY WORK PERFORMED ON THIS UNIT SHOULD BE DONE ONLY BY A QUALIFIED ELECTRICIAN THIS EQUIPMENT USES HIGH VOLTAGE CIRCUITS CAPABLE OF CAUSING SERIOUS INJURY 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 red stripe Disconnect both wires 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 Reattach the disconnected wires that were disconnected 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
43. tion 8 Cabinet Components July 2007 TEREX This page intentionally left blank 8 6 T360 Super Quiet Generator Part No 833019 July 2007 Section 9 Control Box Components TEREX Section Nine Control Box Components Part No 833019 T360 Super Quiet Generator 9 1 Section 9 Control Box Components July 2007 TEREX Figure 9 A Control Panel Upper T360 REVA T ENGINE GENERATOR 77 View A T360 Control Panel 9 2 T360 Super Quiet Generator Part No 833019 682070 C42208400 C43101600 C43200400 260360 C43200300 C43200600 261341 C43100600 C43100400 C51800100 800008 C51600800 C51200201 C42401700 C42404000 C54400100 990110 Section 9 Control Box Components TEREX FIGURE 9 A DESCRIPTION WELDMENT CONTROL BOX CONTROL PANEL CASCADE POTENTIOMETER VOLTAGE ADJUSTMENT BREAKER MINI 1P 15A SWITCH TOGGLE SINGLE THROW GAUGE DC 24VOLT GAUGE OIL PRESSURE HOURMETER 12V DC GAUGE WATER TEMP 12V GAUGE FUEL CASCADE CONTROLLER INCLUDED IN ITEM 11 METER VOLT METER FREQUENCY METER AMP 0 1200 SCREW 1 4 20NC X 3 4 WASHER LOCK 1 4 WASHER FLAT 1 4 RIVET POP 3 16 X 602 LANYARD NYLON HARNESS AC GAUGES TO GENERATOR NUT CLIP 1 4 20 X 3 4 HINGE PIANO 9 SS PLASTIC 1 8 X 10 5 X 33 CLAMP RUBBER COATED SCREW SELF TAPPING 10 RAIL RELAY MOUNTING RELAY OVER CURRENT TERMI
44. tive 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 or 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 apply 24 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 Ob
45. tor and installing jumper on 2 male spades on regulator Voltage Regulator Located inside the generator rear housing Measure DC voltage at F1 amp F2 Normal voltage is 10 to 12 VDC 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 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 windings Contact TEREX for procedures or repair facility recommended by generator manufacturer

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