T180 &T230 Service Manual-134886-08-05-08
Contents
1. 830001 John Deere Engine Manual 839018 Cummins Engine Manual 839059 Cummins Engine 839060 Cascade Controller Manual 833011 Murphy iGuard Controller Manual 839058 Dexter Axle Manual 833014 Copyright 2008 by TEREX Corporation 134886 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 T180 amp T230 Super Quiet Generator Part No 134886 August 2008 TEREX How to Read Your Serial Number Serial Number Legend The serial number plate on your T180 amp T230 Super Quiet Generator is located on the twist lock area of the lower control panel LIGHT CONSTRUCTION e P O BOX 3147 ROCK HILL S C 29732 803 324 3011 Model i s 8 KW KVA HZ 1 LISTED 3044021 CERTIFIED TO CSA STD C22 2 NO 100 amp Part No 134886 T180 amp T230 Super Quiet Generator iii August 2008 TEREX This page intentionally left blank iv T180 amp T230 Super Quiet Generator Part No 134886 August 2008 Section 1 Safety Rules TEREX2. el fo EN olo Part No 134886 T180 amp T230 Super Quiet Generator 2 3 TEREX Section 2 Specifications 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 Hex Head Screws for Lifting Channel Genset Isolators T180 amp T230 Super Quiet Generator Part No 134886 August 2008 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 Ma
3. 3 3 John Deere Lubrication and Maintenance Service Intervals 3 4 Newage Generators Maintenance Schedule 3 5 Section 4 Rev Troubleshooting uere LEE 4 1 A Troubleshooting Guide sisii iieiea ainainen aiaa aia iaaiiai gaiena 4 2 Part No 134886 T180 amp T230 Super Quiet Generator vii TEREX TABLE OF CONTENTS Section 5 Rev A A gt gt gt gt gt gt gt August 2008 Schematics o a 5 1 Electrical Schematic Control Panel Wiring for Murphy Cascade 5 2 Electrical Schematic Control Panel for Murphy iGuard Controller 5 3 Electrical Schematic Distribution Panel Wiring 5 4 Electrical Schematic Three Position Stack Switch Wiring 5 5 Electrical Schematic Overcurrent Relay Wiring 5 6 Electrical Schematic Generator Wiring Breakdown 5 7 Electrical Schematic Standard Generator Wiring 5 8 Electrical Schematic Idle un Wiring Cummins 5 9 viii T180 amp T230 Super Quiet Generator Part No 134886 August 2008 Required Parts The following parts are required to perform maintenance proc
4. 52 Ms or ies B 12000 Hrs Change cooling system coolant cooling system coolant Test change fuel injector Change cooling system coolant _ L j commercial heavy duty j Clemfestatrcodercoe cooling system coolant extender ELC Change cooling system coolant ELC Part No 134886 180 amp T230 Super Quiet Generator 3 3 Section Scheduled Maintenance Procedures August 2008 TEREX MAINTENANCE SCHEDULES CONTINUED REVA John Deere Lubrication and Maintenance Service Intervals Every 2 500 Hrs or 2000 Hrs or us Operate engine at rated speed and 50 70 load a minium of 30 minutes Check oil and coolant level Check fuel filter water Check fuel filler water separator bowl bowl Check air cleaner dust unloader valve and Perform visual walk around Perform visual walk around inspection Check engine mounts TT Clean crankcase venttube crankcase vent tube Check air intake hoses connections and system Replace single or dual fuel filter elements _ Checkengmespeeds E Check Check cooling system system Coolant solution analysis add SCAs as e Flush cooling system Test thermostats Check and adjust engine valve clearance J Add coolant Replace airclea
5. ACAUTION Burn hazard Contact with hot engine components may cause severe burns Use caution when working around a hot engine PartNo 134886 180 amp T230 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 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 Servic
6. 240 416 440 480 Standard Standard Standard 600 Volt Optional Optional Optional 1Phase Voltage 120 127 139 240 254 277 Standard Standard Standard Convenience Receptacles Standard Standard Standard 2 20A 120V GFCI Duplex Receptacles Standard Standard Standard 2 50A Tempowers Standard Standard Standard AVR Voltage Regulation 1 5 Standard Standard Standard Electronic 1 2 Speed Control Governor Standard Standard Standard Murphy Cascade Start Stop Controller Standard Standard Standard Murphy iGuard Start Stop Controller TRAILER HydraulicBrakes Standard Standard Standard Electric Brakes Optional Optional Optional Pintle Rng 3 inch Standard Standard Standard Coupler Hitch 2 inch Optional Optional Optional Coupler Hitch 2 5 16 inch Optional Optional Optional SKID MOUNT Standard Standard Standard DIM Lx W x H in 131x50x67 131x50x67 131x50x67 Weight Dry Ibs 7850 7850 7850 Weight Full lbs 9540 9540 9540 TRAILER MOUNT Optional Optional Optional Dim L x W x H 184x68x82 184x68x82 184x68x82 Weight Dry Ibs 8800 8800 8800 Weight Full Ibs 10446 10446 10446 1 Maximum motor size is based on 35 voltage dip at 480V AC 3 phase 60Hz with a code motor 2 2 T180 amp T230 Super Quiet Generator Part No 134886 August 2008 Section 2 Specifications TEREX REVA SPECIFICATIONS SAE FASTENER TORQUE CHART This chart is to be used as a guide only unless noted elsewhere in this manual A574 Hig
7. 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 inspection receives an N remove the machine from service repair and re inspect it After repair place a
8. amp T230 Super Quiet Generator TEREX Section 5 Schematics August 2008 gt o 2 De XD LL im mes Og 6 im im o c o o gt TaSHMA14 4 1V1d X374 GENERATOR TOP POSTS H LIMS 16 NO NOILISOd 92 OL 1OHINOO SHIM G3dV1 39NV3O HOLIMS 32 VIS NO NOILISOd WO 38IM Q3dVL MOTISA HOLIMS MOVLS NO NOILISOd OL TONLNOD WO 33HIM G3dV1 39NV3HO HOLIMS MOVLS NO NOILISOd LZf OL 1OHINOO 33IM Q3d VL NMO38 HOLIMS 15 WO ZL OL HOJIV33N39 ZL HOLIMS MOVLS t OL HOJVSH3N39 WO vf 1OH LNOO WO L YOLVYANAS WO LL 1OH LNOO HOLIMS M2 VLS WO 2 aasna YOLVYANAS NONI ZL HAV WO QV31 9NISN3S OL YOLVYANAS IWO l3 L3 WO YOLVYANAS WO 1 1OH1NOO HOLIMS MOVLS WO S ebp LHWM18 WO3 9 WO SL 1 ania WOJ QV31 9NISN3S 8 HOLIMS MOVLS 9 WHOLIVH3N39 WO 91 HOLIMS MOVLS Z3 YOLVYANAS WO ZL HOLIMS MOVLS 8 YOLVYANAS 81 HOLIMS MOVLS 6 YOLVYANAS WO3 61 180 amp T230 Super Quiet Generator PartNo 134886 August 2008 Section 5 Schematics X 14 Standard Generator Wiring for G Series RE
9. 134886 T180 amp T230 Super Quiet Generator August 2008 Section 5 Schematics TEREX Three Position Stack Switch Wiring REVA Drawing ES100005 9 9 99 9 irre In girm 1e 97 of wn 13 dis 17 vig 210 23 ze V 2R A NC A12 7 TA 20 229 26e Pas GENERATOR STACK SWITCH WIRE SIZE T180 C42204103 1 0 EPDM T230 C42204103 2 0 EPDM NOTE FOR REFERENCE SEE DRAWINGS ES100007 amp 5100008 PartNo 134886 T180 amp T230 Super Quiet Generator 5 5 August 2008 REV A Section 5 Schematics Overcurrent Relay Wiring Drawing ES 100006 TEREX S3l3W L1OANO OL ES H3XV3H8 NO LNNHS OL vL N33HO H3 V3H8 NO diti LNNHS OL vl MOTISA 9 009 1 8 00v 90A ZY ONINNNY 3NION3 OL vL 9 009 1 8 9 00 20811 5 SV LNAYYNOYSAO JHL HLIM LINN HOV3 519 3HL 318vo wove 31IHM a AW Id 99 AV 1321 LNSYYND ooo ooo ON HOLIMS YL N 9 SL 8L 9 2 c z NINYYM saNooas BN Sawy 0L 2189 0 O 021 198 Ov D HOLO31O0Md T IN3HMHOO HJAO lio 8 TSA OUO Part No 134886 T180
10. ACKNOWLEDGE SWITCH FAULT ACKNOWLEDGE SWITCH SIGNAL TACHOMETER PRESSURE TEMPERATURE COOLANT TEMPERATURE METER SIGNAL SWITCH METER RETURN SENSOR RETURN 6 OVERSPEED SHUTDOWN LAMP Q OVERSPEED SHUTDOWN LAMP RED COMMON WARNING LAMP Q COMMON WARNING LAMP AMBER COMMON SHUTDOWN LAMP Q COMMON SHUTDOWN LAMP RED LOW OIL PRESSURE LOP SHUTDOWN LAMP LOW OIL PRESSURE LOP SHUTDOWN LAMP RED NOT CONNECTED p emm C Se o J1939 SHIELD J1939 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 BATTERY SUPPLY 04 Part No 134886 T180 amp T230 Super Quiet Generator 5 9 Section 5 Schematics August 2008 TEREX REV A This page intentionally left blank 5 10 T180 amp T230 Super Quiet Generator Part No 134886 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
11. E 5 nn 8 aaa z e gg 91919 Ee n lt 5 E gt gt 388 u WX A as a oie RR 438 As 3 l gt dH 5 FO um 8 E o 2 x 2 12 92 ye 2 3N ND nu E 3m vo yi t Rum m x VE Vo yi olls annex 5 10042 amp qud 5 2 DNIAVHO 335 2 amauw NOD 9 8 sss E lt NO rll 6 dL 3NDN3 NDILISDd OL S Or 525 Sab Si E 21 DL 7792 Mir 38 V9 N inne xw vne GrP 1107 xnv 2 eis 8 ee B s 1N E 52 AVI 4 AV 1321 ANYAI 5 Ly 2g 1snrav SLA Wn xi VD JR JE HOLIMS TADIA BN e 9 9 319901 XN YD T 0 a 134 9 07 ET Ta OF e B E t TROVE o s V9 yr O x O 8 M 1 6 O ett gess 2 t t nO 55 E ERN 4 af ale 3NISN3 STTA TT TAIT Tan 384155344 10 Nal JILVA ZIN3H SITA 29 gt C aD 5 _ g 9 Control Panel Wiring PartNo 134886 180 amp 230 Super Quiet Generator August 2008 Section 5 Schematics TEREX Control Panel Wiring REVA for Murphy iGuard Controller Drawing EU0004 ENGINE GENERATOR WH
12. PERFORMED ON THIS UNIT SHOULD BE DONE ONLY BY A QUALIFIED ELECTRICIAN A 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 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 speed controller mounted on the inside of the control pan marked MPU and MPU Both wires are isolated in their own shielded cable e 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 Install new sensor until it bottoms out on flywheel tooth and then back it off turn Toinsure proper installation the sensor must T180 amp T230 Super Quiet Generator Part No 134886 August 2008 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 Once the voltage is correct reinstall the shielded cable throug
13. 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 134886 180 amp T230 Super Quiet Generator 5 1 33 3218 co lt gt N o ao 5 D 5 lt TaNWd 5 3SvHd I NH C3LNNOW 38V S13V1ND3 14915 3LOWIA DNI38 380438 dOLS 3 C3LNOY SI N3ADd LTDA 2I TW 1015 AXINI ANIM 31892 HOLIAS 3SVHd SV IWYS SI 31892 14715 310W33 31 N AMAIA NULO3NNUO 520008 SSINAYH m AHdANW 0T0vGyn SS3NNVH 29 N3349 AVES eo Tx HOOOH n OOD 512 1 2 184915 H GIDN3DS 31491 OL CIIM 35938 21015 8 ES
14. ERATOR SPEED LOAD SOVERNING_BIAS RETURN SENSOR RETURN 3 _ GOVERNING BIAS SIGNAL LOAD SHARE Y GENERATOR SPEED LOAD GOVERNING BIAS SHIELD EQUIPMENT GENERATOR SPEED LOAD GOVERNING BIAS 5 VOLT SUPPLY OPTIONAL SENSOR SUPPLY 3 GAIN ADJUST ROTENTIOMETEP DROOP ADJUST POTENTIOMETER I FREQUENCY ADJUST POTENTIOMETER NE GAIN ADJUST POTENTIOMETER 5 VOLT SUPPLY SENSOR SUPPLY 2 GAIN ADJUST POTENTIOMETER SIGNAL 41 i SENSOR RETURN 2 GAIN ADJUST POTENTIOMETER RETURN DROOP ADJUST POTENTIOMETER 5 VOLT SUPPLY DROOP ADJUST POTENTIOMETER SIGNAL DROOP ADJUST POTENTIOMETER RETURN FREQUENCY ADJUST POTENTIOMETER 5 VOLT SUPPLY FREQUENCY ADJUST POTENTIOMETER SIGNAL FREQUENCY ADJUST POTENTIOMETER RETURN lt gt ENGINE COOLANT LEVEL 5 VOLT SUPPLY gt gt 9 ENGINE COOLANT LEVEL RETURN ENGINE COOLANT LEVEL SENSOR mi INTAKE AIR HEATER SIGNAL INTAKE AIR HEATER INTAKE AIR HEATER RETURN IDLE RATED SWITCH SIGNAL IDLE RATED SWITCH oo DIAGNOSTIC TEST MODE SWIEH Gp DAGNOSTIC TEST MODE SWITCH SIGNAL ALTERNATE EREQUENGY STER S p ALTERNATE FREQUENCY SWITCH SIGNAL IDLE DIAGNOSTIC INCREMENT MOMENTARY SOE INCREMENT SWITCH DIAGNOSTIC DECREMENT SWITCH O77 DECREMENT SWITCH ENGINE PROTECTION DVERRIDE SWITEH 2 ENGINE PROTECTION OVERRIDE SWITCH SIGNAL FAUCI
15. ITE FROM SHUNT PLUGGED WHITE 14GA TO SOLENOID BUTT SPLICE PIN 1 TO SOLENOID 12 RED 14 GAUGE 8 RED 14 GAUGE YELLOW gi AU FROM i SHUNT DOOR SWITCH OFF POTENTIOMETER CABLE BUTT SPLICE al BUTT SPLICE B E STOP Part No 134886 T180 amp T230 Super Quiet Generator 5 3 Section 5 Schematics August 2008 TEREX iring Panel W Distribution REVA for G Series Single Phase Control Drawing ES100010 8 092 MAZ 09 Jo JED VSUS lt annouo 103015 0 01 SNITNO 25 SHIM dniLINDHS BON V1 21 N D CD CD e NSSUO t 3ZIS SHIM SLON 33S did LNNHS 2 a Wada gt 3ZIS HIM ALON 336 MOT 13A WGd3 WqQd3 YOLVYSANAS JHL OL NMO38 Wada HOLIMS MOVLS OL N33H9 CH 3LIHM 8 MLW 8 MLW CHE MLW 21 02 MLW 8 dAV oz 05 MLW 8 MLW 8 MLW 8 MLW 8 41 Wola 61 Wola Part No
16. NTIAL 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 Part No 134886 T180 amp T230 Super Quiet Generator 4 7 TEREX TROUBLESHOOTING Procedure for 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 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 o
17. 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 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 PartNo 134886 T180 amp T230 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 TOTTI 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 prese
18. 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 53852570 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
19. TEREX 1180 230 First Edition Introduction August 2008 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 T90 thru T360 Operator s Manual 133005 First Edition TEREX T180 amp T230 Service Manual 134886 First Edition TEREX T180 amp T230 Parts Manual 134885 Newage Generator Manual
20. V A Drawing ES 100009 9 0 son 5 90000LS3 OL J333 S3ZIS 19 S0000LS3f ONIMVYC OL 213433 H3EIATN LYYd HOLIMS MOVLS aN z vL aj HOlVH3N3O E Ove 1 ps 2 SLN LED 91 211 L OVZOIZ Ove 1 81 ENN Sr Hl N OLL vL M313W dA OL OVER CURRENT RELAY TO OVER CURRENT RELAY POSITION 14 SLAM dled LNNHS L lal L L L dol sa D OOOODOO00 dtm jsp si AYLIN VWAN 110 OL 01913 OL XX F2 VWAN S310N 33s HAV 3 929490 OL L CM awns c r Po ualaW EEL YLIN L10A OL E HOO OL 193NNOO wada ots Wada 01 18 Part No 134886 T180 amp T230 Super Quiet Generator August 2008 Section 5 Schematics TEREX Idle Run Wiring Cummins REV A Drawing amp ESES 100039 50 OEM CONNECTOR GEN
21. W 145 145 181 3 Phase Amp Ratings 502 502 627 435 435 544 218 218 272 POWER CAPABILITY STANDBY kVA kilovolt amps 200 200 251 kW kilowatts 160 160 201 3 Phase Amp Ratings 555 555 697 481 481 604 241 241 302 VOLTAGE 3 Phase 208 220 240 416 440 480 Standard Standard Standard 600 Volt Optional Optional Optional 1 Phase 120 127 139 240 254 277 Standard Standard Standard Max Motor Starting1 113 112 120 84 84 90 SKVA 680 620 730 DIESEL ENGINE Manufacturer CUMMINS JOHN DEERE JOHN DEERE Model QSB7 G3 6068HF275 6068HF475 Cylinder 6 6 6 Air Intake aspiration Turbo Turbo Turbo Charge Air Charge Air Charge Air Cooling Cooling Cooling Cooling System Radiator Radiator Radiator Fuel Capacity gal 238 238 238 Run Time 75 load 25 28 24 Fuel Consumption Prime Power gal per hr 100 load 5 8 11 0 13 3 75 load 4 5 8 4 9 8 50 load 3 1 5 7 6 8 25 load 2 4 3 1 3 7 dBA 65 68 68 Controller Type Digital Analog Digital Digital Start Stop Controller Cascade iGuard iGuard 12V Battery CCA 1 000 1 000 1 000 Part No 134886 T180 amp T230 Super Quiet Generator 2 1 Section 2 Specifications August 2008 TEREX SPECIFICATIONS REVA MODEL 22 T180C T180J T230J GENERATOR Brushless 4 pole Synchronous Single bearing Standard Standard Standard 1 800 rpm Class H Insulation Generator Standard Standard Standard High wye Low wye Zig zag Voltage Selector Standard Standard Standard 3 Phase Voltage 208 220
22. age 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 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 ESSE
23. ced 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 PartNo 134886 T180 amp T230 Super Quiet Generator August 2008 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 no backorders o Ship all available parts and contact customer on disposition 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 REVA MODEL T180C T180J T230J POWER CAPABILITY PRIME kVA kilovolt amps 181 181 226 k
24. check in the R box Legend Y yes completed N 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 August 2008 Section Scheduled Maintenance Procedures TEREX Maintenance Schedules REVA Cummins Lubrication and Maintenance Service Intervals 50 Hrs or 500 Hrs or aspect adjust or replace alternator orfan belt adjust or replace alternator or fan belt EN Check cooling system coolant level system coolant level Check driven equipment 1 3 ss engine air cleaner service indicator Check engine oil level engine oil level Drain fuel system primary filter water a C Walk around Walk around inspection Eg Le L T Oeanrepaceengnearcemereeme _ Inspeciclean engine ground L Le T change engine oll anat _ L T Replace water separator element T _ Replace fuel system secondary er C T hoses and clamps T L T Inspect adjust engine valve lash Inspect aftercooler core Inspect alternator Inspect engine mounts Inspect starting motor Inspect turbocharger Inspect water pump
25. chine 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 of steps PartNo 134886 T180 amp T230 Super Quiet Generator 3 1 Pre Delivery Preparation
26. e T180 amp T230 Super Quiet Generator Part No 134886 August 2008 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 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 134886 T180 amp T230 Super Quiet Generator TEREX TROUBLESHOOTING Section 4 Troubleshooting POSSIBLE CAUSE Detective injectors on engine Surging engine speed August 2008 SOLUTION ave injec
27. eded 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 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 T180 amp T230 Super Quiet Generator Part No 134886 August 2008 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 to 12 V DC Remove 2 wires marked F1 X F2 X X from volt
28. edures as outlined in the TEREX T180C T180J amp T230J Parts and Service Manual Description Part No Cummins QSB7 G3 Models T180C elle D ERE 134023 Air Filter 134022 amp 134025 Fuel Fite renesse 134024 839068 amp 134026 EI E SES 134031 John Deere 6068HF275 Models T180J elder 741915 Air Filter C33101101 amp C33101103 Fuel Fiter 741934 lA p 134041 John Deere 6068HF475 Models T230J 22 741915 Air Filter C33101101 amp C33101103 IEEE 134040 WEDGE cR 134042 lij TEREX Parts Stocking List PartNo 134886 T180 amp T230 Super Quiet Generator August 2008 TEREX This page intentionally left blank x T180 amp T230 Super Quiet Generator PartNo 134886 August 2008 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 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 servi
29. h Strength Grade 5 lt Grade 8 Black Oxide Bolts LUBED DRY LUBED DRY LUBED Nm 00 140 158 130 120 120 135 140 LUBED LUBED DRY LUBED 24 339 271 447 50 1 678 813 80 1084 68 921 108 4 122 162 176 217 244 10 20 271 270 366 280 379 16 20 298 300 406 310 420 9 3520 483 430 563 450 610 610 827 510 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 s EN co N 7 1 s 20 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
30. h 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 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 e 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 Once the wires are loose go to the front of the control panel and loosen the lock nut holding the potentiometer Put the new potentiometer in its place and retighten lock nut Reattach 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 connectio
31. ly 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 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 other fluids Use an approved container Please be environmentally safe vi T180 amp T230 Super Quiet Generator Part No 134886 August 2008 TEREX Table of Contents Introduction ii How to Read Your Serial Number iii Parts Stocking nennen ix HOW to Order Parts cese cierta exo eren xi Service Parts Fax Order FORM Xii Section 1 Safety Rules General Safety Rules esis ama eene Section 2 Rev Specifications A Specifications LEE 2 1 A Specifications Continued sss 2 2 A Torque Specifications 2 93 A Generator Torque Specifications 2 4 Section 3 Rev Scheduled Maintenance Procedures miseret 3 1 Pre delivery Preparation 0002 3 2 A Maintenance Schedules Cummins Lubrication and Maintenance Service Intervals
32. nce 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 Section 1 Safety Rules August 2008 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 are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and cause damage sure that your workshop or work area 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 on
33. nerelements Replace poly vee bet Checkfuses Check air compressor if equipped J Bleed fuel system L L L 3 4 180 amp 230 Super Quiet Generator Part No 134886 August 2008 Section Scheduled Maintenance Procedures TEREX MAINTENANCE SCHEDULES CONTINUED Newage Generators Maintenance Schedule 4500 Hours ons orte or 3 Years Months Months Visual inspection Visual inspection plus running audible check Measure stator winding insulation resistance Ka s record Monitor Monitor bearing s condition condition Remove terminal box lid and check Re Re grease bearings a 5 Replace bearings Replace NDE o ring Inspect bearing housings Inspect winding conditions Soe 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 Part No 134886 T180 amp T230 Super Quiet Generator 3 5 Section Scheduled Maintenance Procedures August 2008 TEREX REV A This page intentionally left blank 3 6 T180 amp T230 Super Quiet Generator Part No 134886 August 2008 Section 4 Troubleshooting TEREX Troubleshooting Before Troublesh
34. ns 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 Part No 134886 T180 amp T230 Super Quiet Generator 4 9 Section 4 Troubleshooting August 2008 TEREX This page intentionally left blank 4 10 T180 amp T230 Super Quiet Generator Part No 134886 August 2008 REVA 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
35. ooting 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 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 electrically charged circuits could Immediately tag and remove from service a result in death or serious injury damaged or malfunctioning machine Remove all rings watches and other jewelry Repair any machine damage or malfunction J 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 or 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
36. r 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 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 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
37. 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 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 134886 T180 amp T230 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 SOLUTION Reduce load Inspect fan belt and replace as ne
38. this manual Class4 6 44 Class 8 8 Class 10 9 12 9 DRY DRY DR iz Bl ilz 2 ile ile 1 gt Co eo ze Po o1 Po 2 Po N P e M OF O NJ oO D or age al O CO Go rp N ox zil a iol ojo n N N A oi oO A x NI m c 00 5 lt r c 0 B g lt r 112 B DRY DR S 365 236 2 722 0 13 3 830 1055 682 925 909 1233 s Co Co r c 8 1 D e N e N N Co o 4 E OY za ex o col gt Nj co NX E ge o o oF o NI o AY OLR S ofc o CO op rN 2 SC w 9 v DO Kea AAT w M O af o ol Nj N gt ol eo oo A O ob nob R elo NIN ao o olol A n3 nv e EE
39. tors 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 Magnetic Pick up Clogged fuel system Air in fuel system 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 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 T180 amp T230 Super Quiet Generator Part No 134886 August 2008 Section 4 Troubleshooting TEREX 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
Download Pdf Manuals
Related Search