T25-45 Service Manual-134878-08-05-08
Contents
1. 116133 Cascade Controller Manual 833011 Dexter Axle 833014 Copyright 2008 by TEREX Corporation 134878 Rev A August 2008 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 on recycled paper Printed in U S A ii 251 amp Super Quiet Generator PartNo 134878 August2008 TEREX How to Read Your Serial Number Serial Number Legend The serial number plate on your 251 amp T45l Super Quiet Generator is located on the twist lock area of the lower control panel TEREX LIGHT CONTSTRUCTION P O BOX 3147 ROCK HILL S C 29732 803 324 3011 Modei MEN lt KW KVA HZ LISTED 3044021 CERTIFIED TO CSA STD C22 2 NO 100 PartNo 134878 251 amp 451 Super Quiet Generator ili August2008 TEREX This page intentionally left blank iv 251 amp T45l Super Quiet Generator Part No 134878 August2008 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 a2. N33H9 21 0 E o 9 ae div 06 m a G m div 06 dV SP Mo te 521 1709 3l vid X X E 40 3018 0901 cao Sas aun aN ue NO 3215 34M NO 3215 Mn NINE V1 1 N e sem 1 l 21 NADE SIIHM Zi oz Oc 09 MAL Ov 8 MAL ova 8 MAL XOV1E 8 MAL 8 3ZIS 38IM 31ON 33S MAL 39V18 c Ht MAL MOVIE dil LNDHS HOLIMS MOVLS OL eL ai Wada 3216 310335 3SVHd 319NIS JONvuO Wada YOLVYANAS 3H1 OL Wada wows 61 PartNo 134878 251 amp Super Quiet Generator August2008 Section 5 Schematics TEREX Three Position Stack Switch Wiring REV A Drawing ES100005 x x x O O a 0 8 zd d 8 E z amp o 5 gt z 5 9 lt 6 lt 5 o u 2 2 6 Y a 9 gt 5 W o N 9 o e P 2 9 96 L STACK SWITCH WIRE SIZE 2 C42201102 10 GA EPDM T45l C42202402 8 GA EPDM NOTE FOR REFERENCE SEE DRAWINGS ES100007 amp ES100008
3. JOkl sivinsw 1 Vl VIN3N OLIN VIN3N JILIN ONY 193NNOO OL HOO OL 29100001 g Wada 0 XX F2 S310N 336 HAV Po W313W LION OL aaay YILIN LIOAOL 3LIHW3OV18 OL Part No 134878 251 amp Super Quiet Generator Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm Towing Checklist Use at each stop Before Towing Towing hitch is properly secured to tow vehicle Safety chains if required are properly attached and secure chains are crossed below hitch All lights are connected and working Tires are properly inflated Before Driving Fasten safety restraints Properly adjust mirrors On The Road Do not exceed 60 mph 97 km h Obey all local and national towing speed laws Check connections and tire pressure at each stop Slow down for hazardous conditions Allow extra distance for following and passing other vehicles Genie China Phone 86 21 538
4. une 45 v b19 210 20999090 481 12 pe 18 TO 9 GENERATOR POST OS TO GENERATOR GROUND O3 7 GENERATOR POST G gt TO 8 GENERATOR POST FROM CONTROL BOX PartNo 134878 T25l amp 451 Super Quiet Generator 5 5 August2008 REV Section 5 Schematics Overcurrent Relay Wiring Drawing ES100006 TEREX YILIN NO OL A Part No 134878 vl Mov Ig aas H3 V38 NO LNNHS OL L 3LIHA vl N33HD H3 v3a NO LNNHS OL YL MOTISA dO1S 3 OL vl Gay 318v0 yva LHM J1V 1d 303 AV Tad LN3HHCYO H3AO O0 Oo O O O O O ON HOLIMS X000 k VW 9 SL 8L 1H91M NINYYM sSaNooas N VA YyOLOALOYd 5 AO 251 amp Super Quiet Generator TEREX Generator Wiring Breakdown Drawing ES100007 Section 5 Schematics August2008 REV A T33HMACTH 3lVd X314 GENERATOR TOPPOSTS lOHLNOO WO 1 HOLlVH3N39 Wows LL HOLIMS MOVLS WO 2 HOIVHJN39 NONI 21 lO41NOO WOUS HOLlVHJN3O WOW L HOLIMS MOVLS WOUS S HOLIVH3N39 WO SL HOLIMS MOVLS NO NOILISOd 92 OL 1OHINOO WO 3HIM Q3dV L 3ONVHO Z HOLIMS 15 NO NOILISOd l OL IOHINOO WO 3HIM Q3dV L MOTISA HOLIMS MOVLS NO NOILISOd c OL lOHINOO 3HIM G3dV1 3SNV3HO HOLIMS MOVLS NO NOILI
5. 5 2 Electrical Schematic Control Panel Wiring for Murphy Cascade Controller w Electronic Governor 5 3 A Electrical Schematic Distribution Panel Wiring 5 4 A Electrical Schematic Three Position Stack Switch Wiring 5 5 A Electrical Schematic Overcurrent Relay 5 6 A Electrical Schematic Generator Wiring Breakdown 5 7 A Electrical Schematic Standard Generator Wiring 5 8 viii 251 amp T45l Super Quiet Generator Part No 134878 August2008 lij TEREX Parts Stocking List Required Parts The following parts are required to perform maintenance procedures as outlined in the TEREX 7251 amp T45l Parts and Service Manual Description Part No Isuzu Models 868075 AIF URGE css tists ctr deor cipis rrt E riri 834460 Fuel Filter 868137 E 868067 Part No 134878 T25l amp Super Quiet Generator ix August2008 TEREX This page intentionally left blank x 251 amp T45l Super Quiet Generator PartNo 134878 August2008 Please be prepared with the following information when ordering replacement parts for your TEREX product Machine model nu
6. Table of Contents Introduction ii How to Read Your Serial Number nnns iii Parts Stocking iSt sssaaa e a ar nennen ix How to Order Pans asas asena Gears eae axes Xi Service Parts Fax Order Form xii Section 1 Safety Rules GeneraliSafety Rules i os cans resta ds isda ares Section 2 Rev Specifications A Specifications cs uu LEE 2 1 A Specifications Continued sss 2 2 A Torque Specifications 2 93 A Generator Torque Specifications 2 42 44040 0 0 2 4 Section 3 Rev Scheduled Maintenance Procedures miseret yun Su luma 3 1 Pre delivery Preparation Report 11 3 2 A Maintenance Schedules Isuzu Lubrication and Maintenance Service Intervals 3 3 Newage Generators Maintenance Schedule 3 4 Section 4 Rev Troubleshooting nireeitfei pe NSE 4 1 A Troubleshooting GUAE ss eene eene nnne 4 2 PartNo 134878 251 amp Super Quiet Generator vii TEREX August2008 TABLE OF CONTENTS Section 5 Rev Schematics A INTOGUCUION 5 1 Electrical Schematic Control Panel Wiring for Murphy Cascade
7. 0 140 158 130 120 120 135 140 LUBED LUBED DRY LUBED 24 339 271 447 50 1 678 813 80 108448 68 921 108 4 122 162 176 217 244 10 200 271 270 366 280 379 16 220 298 300 406 310 420 9 3520 483 430 563 450 610 610 827 50 69i 114 350 474 470 637 500 678 670 908 560 759 14 7 15 8 m gt 13 5 E lt 13 14 23 17 6 19 31 2 26 35 2 37 50 1 41 55 5 57 77 3 64 86 7 108 4 122 110 149 130 176 170 230 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 3 50 120 130 160 180 e EN co N o 7 1 s 480 50 840 867 680 922 910 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 42 930 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 03 Class 12 9 DRY DRY DR ile Bl ilz 2 ile
8. 52570 Fax 86 21 53852569 Genie Scandinavia Phone 46 31 575100 Fax 46 31 579020 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie Korea Phone 82 25 587 267 Fax 82 25 583 910 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie Gerfnany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Holland Phone 31 183 581 102 Fax 31 183 581 566 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241
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10. ALIFIED 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 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 If any further adjustment is needed to the voltage of the generator please call TEREX at 1 800 433 3026 for assistance 251 amp Super Quiet Generator Part No 134878 August2008 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 M Read understand and obey the safety rules and operating
11. 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 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 Part No 134878 251 amp Super Quiet Generator 4 7 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
12. SERE a R 2 dy St Eg z zz 5 a z 8 Live A 2 8 ay mus Live AN ze S W noanans gt gt 5543122 ame gt gt 6 i 3IIHWNWOS8 Ne 6 z M pre NZ I 1noz xnv m x Zl PEN civ x55 s 5539810 01 E AV IH 2 3NI N3 IH DB soit640 le lvaH3ud NZ XN Av 133 4 OLTIVO 1 Tana anoe xnv 100 xnv G3sn LON Mava 3avosvo MOTTA MOTEA Sms EMREN EMERE CER DEELS TOYE Asnray SION M079 OL er ama 1 O0 Mi HOLIMS TOR 319901 EEE 2 xovia ovis ELEK m Ixus 2015 AON3S33W3 100000 33S m WAWiswsooNO L 01 G3MIMOTI3A ms THOR r m La 5 DS ea Ba 8 5 9 89 z S E 3 t Do 10020 ONIMWHG 33S AVI HOO NO OL STON 50 BAST n3 SUNOH 3unsssHd JWL OW ZIHSH ENON OV SERIES August 2008 REVA T25l amp 451 Super Quiet Generator Part No 134878 August2008 REV Section 5 Schematics for 25 amp Series Single Phase Control Distribution Panel Wiring Drawing ES100003 TEREX YAMOd dW3L d3MOd dWa L 09 09 3LIHM 8
13. SOd Le OL 1 3HIM Q3dV L NMOHS HOLIMS OL HOIVH3N39 HOLIMS 3OV1S O 1 HOIVH3N3O WOW v WAV OL HOIVH3N39 WO Z4 ONVLA HOLIMS MOVLS N O4 9 MOIVH3NdO WO 91 xog HOLIMS MOVLS WOU 2 YOLVYSNAD wows 21 WOHJ QV31 ONISNAS HOLIMS MOVLS N 8 HOIVH3N39 81 HOLIMS MOVLS Wows 6 HOIVH3N3O WO 61 WAV Wot Qv31 ONISNAS 8 T25l amp 451 Super Quiet Generator Part No 134878 August2008 Section 5 Schematics X Y Standard Generator Wiring REV Drawing ES1000008 4OO ONIMVHG OL 4343Y 52215 LO HOLIMS MOVLS ONIMVYC OL 33433 YASWNN LYVd HOLIMS MOVIS 404 semnNounsnisian WAV S9vVS ASN 091 9 ISHL 10d 39 0 10d 39V L10 10d 39VLI0 10d 39VLION WAV 09vXS SASN 1821 E Ove e 1 GIN LLD 91 2 N OLL vl SN Z N TIL LL ul i l 9vZ9IZ Ove 1 91 SN NIL N OL tl sovai HOIVHIN9 0000 dNV OL OLAN OLAN C M dz wa Vs 4 sk Na of Ne 26 lt Sp peng pe LA ys p YLIN VWAN OLIN C TO OVERCURRENT RELAY TO OVERCURRENT RELAY POSITION 14 Maxvauan 925490 OL L 1NnHsn
14. TEREX 125 45 First Edition TEREX Introduction August2008 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 251 4 T45l Operator s Manual 133255 First Edition TEREX T25l amp T451 Parts Manual 134877 First Edition Newage Generator Manual 836430 Isuzu Engine
15. U 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 6 251 amp Super Quiet Generator Part No 134878 August2008 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 generator rear housing Measure DC voltage at F1 amp F2 Normal voltage is 10 to 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 circu
16. a SdWV OV aaspiovia SION OV 100820 33S NO OL Xovigia3s Part No 134878 251 amp Super Quiet Generator Section 5 Schematics x 5 c ams ooo _ gt 14 5 c 318v23 IdNvd NOLLNSIMLSIC 3SVHd NO G31NnON SLOVINOO LYY1S 31038 dIHLS TVNIWNH3 3H1 440 SNOLLO3NNOO LOA 21 TIY 318v HOLIMS 3SVHd 3H1 SY IWYS IHL SI 318 2 18915 SLOWSY 3 LON or SLOVLNOO SHIM m 14915 WOU HOLO3NNOO L sma n ond pur 0 6 ov cop O00 HOOOH 250 909 OOO o0 wove nan 2 0 4 EIE O38 lt PI s lg nan OL l 8 59 eg uayv usn 88
17. cifications GENERATOR TORQUE SPECIFICATIONS Generator Flex Plate to Flywheel August 2008 Generator Case to Bellhousing 1 2 Socket Head Cap Screws for Lifting Channel 1 2 13 Hex Head Screws for Lifting Channel Genset Isolators 251 amp 451 Super Quiet Generator Part No 134878 August2008 Section Scheduled Maintenance Procedures TEREX Scheduled Maintenance Procedures 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 Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Keep records on all inspections for three years Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection 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 secti
18. d 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 Part No 134878 251 amp 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 Defective 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 YO
19. dard High wye Low wye Zig zag Voltage Selector Standard Standard 3 Phase Voltage 208 220 240 416 440 480 Standard Standard 600 Volt Optional Optional 1Phase Voltage 120 127 139 240 254 277 Standard Standard Convenience Receptacles Standard Standard 2 20A GFCI Duplex Receptacles Standard Standard 2 50 Tempowers Standard Standard AVR Voltage Regulation Standard Standard Mechanical Standard 596 Speed Control governor Standard Standard Murphy Cascade Start Stop Controller on All Engines Standard Standard TRAILER No Brakes Standard Standard HydraulicBrakes Optional Optional Electric Brakes Optional Optional Pintle Rng 3 inch Standard Standard Coupler Hitch 2 inch Optional Optional Coupler Hitch 2 5 16 inch Optional Optional 1 Maximum motor size is based on 35 voltage dip at 480V AC 3 phase 60Hz with a code G motor SKID MOUNT DIM Lx W x H in 84x39x51 84x39x51 Weight Dry Ibs 1 900 2 725 Weight Full Ibs 2 354 3 173 TRAILER MOUNT Dim Lx W x H 137x66x68 137x66x68 Weight Dry Ibs 2 375 3 200 Weight Full Ibs 2 829 3 648 2 2 251 amp Super Quiet Generator Part No 134878 August 2008 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 5 lt Grade 8 Black Oxide Bolts LUBED DRY LUBED DRY LUBED Nm 0
20. er s manual differs from that in this manual the manufacturer s manual should take precedence Part No 134878 251 amp T45l Super Quiet Generator 3 3 Section Scheduled Maintenance Procedures August 2008 TEREX MAINTENANCE SCHEDULES CONTINUED REV Newage Maintenance Service Intervals 4500 Hours Months Months Visual inspection Visual inspection plus running audible check Measure stator winding insulation resistance ao Rm record Monitor Monitor bearing s condition condition Remove terminal box lid and check Re 18888 Re grease bearings 1 7 Replace bearings Replace NDE oring Inspect bearing housings ST ST S gt e Inspect winding conditions S Inspect rotating diode assembly L 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 4 251 amp Super Quiet Generator Part No 134878 August2008 Section 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 Observe and Obey Be aware of
21. gine 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 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 251 amp Super Quiet Generator Part No 134878 August2008 High generator output voltage Section 4 Troubleshooting POSSIBLE CAUSE Defective automatic voltage regulator Loose wire on voltage adjustmentpotentiometer Neut
22. ile 1 gt o Co eo ze Po 2 D Po N P e M O O NJ oO D or za age al O CO Go rp N ox zil a iol ojo n N N A e oi oO l NI m c AJ c 00 5 lt r c 0 B g lt r c 0 B DRY DR S 365 235 2 722 0 13 3 830 1055 682 925 909 1233 Co Co r c 8 1 zi D A zl A N e N N Co o 4 E OY za ex o col Nj o ES D a e co o NX o ge m o o oF NI vj o o OLR S o OFS o CO o rN 2 SC w 9 S DO o AAT co N af o ol 6 ex Nj N gt ol eo oo N O ob e nob R celo elo coro NIN ao o olol A A 2 nv e EE el EN olo Part No 134878 251 amp Super Quiet Generator 2 3 TEREX Section 2 Spe
23. 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 Perform repair Return to service problem solved PartNo 134878 T25l amp 451 Super Quiet Generator 5 1 August2008 Section 5 Schematics X Y m Control Panel Wiring for Murphy Cascade Controller REV Drawing ES100001 Standard 3189 Q3H1V3HS OMV vL 3418 AH LN3 Wows MIIA HO LO3NNOO aay G3H MOTIBA MOTHA oma ov 6 5 ri en 19994 OF m E a lt 8 2n 2
24. it 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 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
25. lso safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless You are trained and qualified to perform maintenance on this machine 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 134878 251 amp Super Quiet Generator TEREX SAFETY RULES Personal Safety Any person working on or around a machine must be aware ofall known safety hazards Personal safety and the continued safe operation of the machine should be your top priority Readeach procedure thoroughly This manual and the decals on the machine use signal words to identify the following Safety alert symbol used to alert personnelto 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 resu
26. lt in property damage Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Section 1 Safety Rules August 2008 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 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 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 oil or cS other fluids Use an approved container Please environmentally safe Be sure that your workshop or work area is H3 properly ventilated and well lit vi 251 amp Super Quiet Generator PartNo 134878 August2008 TEREX
27. mber 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 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 TEREX North America Telephone 803 324 3011 Toll Free 800 433 3026 in U S A and Canada Fax 803 366 1101 PartNo 134878 251 amp Super Quiet Generator Xi August2008 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 disposi
28. mpany August2008 Section Scheduled Maintenance Procedures TEREX Maintenance Schedules REV A Isuzu Lubrication and Maintenance Service Intervals ITEM Daily 250 500 750 1000 1250 1500 Hours Hours Hours Hours Hours Hours Oil level and oilfouing f ef Oil leakage check oe Oil pressure warninglamp Fuel leakage check i 114 TH Coolant leakage check O O 2 JAHE Q lt D o 2 o 9 5 a gt la 2 o 5 c S 2 2 e 2 Fan belt tension check Replace if necessary Coolant replacement lectrolyte level check attery cleaning attery charge condition reheating condition check conditions xhaust smoke condition ngine oil replacement uel filter element replacement njection nozzle check cleaning alve clearance check lt O O s Tmn ITI mi m 9 n o s 1 e 5 lt IN 2 a n A 3 3 S o 5 2 0 giz D 5 lt 5 o D JS gt 5 O Go 3 o gt n o o o gt 5 5 5 a lt gt Q A O lt o cleaning Refer to the manufacturers manuals for detailed maintence intervals and instructions If the information in the manufactur
29. njection pump solenoid Defective solenoid Clogged fuelsystem 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 Check fuel system 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 251 amp Super Quiet Generator Part No 134878 August2008 Section 4 Troubleshooting TEREX TROUBLESHOOTING POSSIBLE CAUSE set in OFF position Blown fuse in DC control circuit E Stop Defective starter solenoid Defective starter 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 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 Blocke
30. 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 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 August 2008 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 QU
31. on 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 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 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 134878 251 amp T45l 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 f
32. ralbinding strap notin place TEREX TROUBLESHOOTING SOLUTION Replace voltage regulator Check wiring Installneutralbinding 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 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 PartNo 134878 251 amp Super Quiet Generator TEREX TROUBLESHOOTING Section 4 Troubleshooting POSSIBLE CAUSE Delective 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 i
33. rom 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 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 co
34. the following hazards and follow 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 ad electrically charged circuits could Immediately tag and remove from service result in death or serious injury damaged or malfunctioning machine Remove all rings watches and other jewelry Repair any machine damage or malfunction J y before operating the machine ADANGER Electrocution hazard Attempting to sevice the machine before the Unless otherwise specified perform each MAN capacitors are fully discharged will repair procedure with the machine in the aa in death or 2 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 134878 251 amp Super Quiet Generator 4 1 TEREX Section 4 Troubleshooting Troubleshooting Guide The en
35. tion of 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 August 2008 Section 2 Specifications TEREX Specifications REV MODEL 5 45 POWER CAPABILITY PRIME kVA kilovolt amps 45 kW 36 3 Phase Amp Ratings 125 108 54 POWER CAPABILITY STANDBY kVA kilovolt amps 50 kW kilowatts 40 3 Phase Amp Ratings 139 120 60 VOLTAGE 3 Phase 208 220 240 416 440 480 Standard Standard 600 Volt Optional Optional 1 Phase 120 127 139 240 254 277 Standard Standard Max Motor Starting1 12 27 9 20 SKVA 70 165 DIESEL ENGINE Manufacturer Isuzu Isuzu Model 4LE1PV02 4JG1TPV Cylinder 4 4 Air Intake aspiration Natural Turbo Cooling System Std Rad Std Rad Fuel Capacity gal 64 64 Run Time 75 load 53 29 Fuel Consumption Prime Power gal per hr 100 load 1 5 2 8 75 load 1 1 2 2 50 load 1 7 25 load 1 2 64 Analog Digital Analog Digital Start Stop Controller Cascade Cascade 12V Battery CCA 750 750 Part No 134878 T25l amp Super Quiet Generator 2 1 Section 2 Specifications August 2008 TEREX SPECIFICATIONS REV MODEL T 5 45 Brushless 4 pole Synchronous Single bearing Standard Standard 1 800 rpm Class H Insulation Generator Standard Stan
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