T70 from SN 09-101 (PN 134277)
Contents
1. mx TONGS LL fet ouj Hi 1 3223 A a La du 28 118658 n n 120001534 OL X343Y 53215 LO X04 RR 8g 92000153 OL 33433 YSEWNN LYVd HOLIMS MOVLS 304 84 T 84 Som NOUREIISId FE 5 1 nom BOER aNnoso 170 OL D AT s N 8 01 2 O1 Z vi S 5 5 19181035 91 21 E 2 Bog a 8 55 5 als aly 92 x 88 X a lo I gt ZL i m el rh ee E zl o s 81 19 aes 81 ESTEE di a iet Zh ifs t 88 gt 85 51 61 NM OL Ae E HOO OL Wada P X90 OL EM 193NNOO y a Nada oif T70 T90 amp T120 Super Quiet Generator September 2008 Section 5 Schematics TEREX Idle Run Wiring Cummins REVA Drawing ES100039 50 CONNECTOR GENERATOR SPEED LOAD GOVERNING BIAS RETURN SENSOR RETURN 3 A 1 G2. 33 3218 520008 853 AHdanW 0 0 SS3N IVH 29 N3349 ATA 91610 51091 0 14415 4 5 g GIDN3DS 31491 OL ls 35938 8 aw de e 8 h 161712 5 m z e 91919 m z 2 5 E gt gt 51818 IDIA A as a 8 a 2 div ST 3 1 B SRE 4 63 5 LEA 202020 8 8 3 x UVA 18 92 54 ye 3mE ND E 8 S 1001 100490 amp 9 inne xw BEB SNIAVNO 335 NOD 5 m 3HL ND 6 NINI IH NDILISDd OL S or 820 Tu y SzG s si 21 DL TWO 31034 We 2 E CONI 106 xnv viele 8 xn 2 100 1 1 Sja 7 AVIS 4 AV 133 2 42 2 Ly 7 15 5 0 Wn xi JR JE HOLIMS 1 3 15901 2978 OG 17187434 AVES 134 9 0 OF 3LIHA V8 a s VO yr m a a 4 1 w B 100420 8 ONIAVa 335 NOD ND 7 OL 3NISN3 3a TAIT n3 Sanss3sd
3. 70 7 90 T90P T120C E Maintenance T12 OP Information Part No 134277 Rev November 2008 TEREX Introduction November 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 communications will be carefully considered for future printings of this and all other manuals Contact Us www TEREX com Serial Number Information TEREX Corporation offers the following manuals for these models Title Part No TEREX T70 T90 amp T120 Operator s Manual 134207 First Edition TEREX T70 T90 amp T120 Service Manual 1
4. e 1 01 Dj o 4 O 0 5 lt r c 0 lt 0 DRY DR 9 365 235 2 722 0 13 3 830 1055 682 925 909 1233 2 Co c 00 8 1 21 D e N Co o 4 E OY za ex o poy ES D co NX ge o o oF o D AY o OLR 5 OFS o CO w 9 v 1 w M On ala af o ol 05 0 N gt o o 1 eo oo A O ob DN nob elo NIN ao 4 o olol A 2 1 nv e el EN olo Part No 134277 T70 T90 amp T120 Super Quiet Generator 2 13 Section 2 Specifications November 2008 TEREX SPECIFICATIONS REVA GENERATOR TORQUE SPECIFICATIONS Generator Flex Plate to Flywheel 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 2 14 T70 T90 amp
5. 3 3 Perkins Lubrication and Maintenance Service Intervals 3 4 Newage Generators Maintenance Schedule 3 5 Section 4 Rev Troubleshooting 4 1 Troubleshooting 0896 4 2 Section 5 Rev Schematics A WACO CI CT OM HE 5 1 A Electrical Schematic Control Panel Wiring for Murphy Cascade 5 2 A Electrical Schematic Distribution Panel Wiring 5 3 A Electrical Schematic Stack Switch 2 5 4 A Electrical Schematic Overcurrent Relay 5 5 A Electrical Schematic Standard Generator Wiring 5 6 A Electrical Schematic Idle Run Wiring CUMMINS 5 7 viii T70 T90 amp T120 Super Quiet Generator Part No 134277 November 2008 Required Parts The following parts are required to perform maintenance procedures as outlined in the TEREX T70 T90 and T120 Parts and Service Manuals Description Part No Cummins 5 11 4 Models PEERS 125550 Air Filter Primary 125561 Air Filter Secondary 125562 izle 125551 sre 125552 TEREX Parts Stocking Li
6. 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 134277 T70 T90 amp T120 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 Defective oil pump Defective or grounded oil pressure switch September 2008 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 FIEL
7. 90 d o r ozL 0 6 00 v 9921 507103 Sv AVT38 LN3BBDON3AO HLIM LINN HOV3 304 5 10 3HL 30V AV 3M LN3SSDOO W3AO N 1 91 GL 81 1 50 0235 N Ava 13S n o E 08 Sanv 9 313W LIOA NO OL NO dial 1 5 OL xov38 N3349 M33V3M8 NO dlML LNNHS OL MOTI3A 308005 JA ONINNNY ANION OL anayo 5 31M c vl 1 9 GI 81 e 8 O N HOLMS 3000 sanv NA 940 3 010310 T70 90 amp T120 Super Quiet Generator Part No 134277 REVA September 2008 Section 5 Schematics Standard Generator Wiring for T70 T90 amp T120 Series Drawing ES100030 TEREX 21 08 ObZ OVZOIZ OFZ aN mU s 6 1 61 7 25 45 iv 1 7 91 ien SIN LEN 9L ziL UN N L N Part No 134277
8. Compression ratio 17 851 Monitoring gauges oil pressure water temperature fuel level battery voltage hours Coolant capacity engine only 9 6 qts 9 0 L Cooling system liquid cooled rated to 105 F 41 C ambient Continuous improvement of our products is a Terex policy Product specifications are subject to change without notice or obligation TEREX Specifications Fuel system Specification 2 diesel Filter fuel water separator Capacity 160 gal 606 L internal fuel tank with 110 fluid spill containment Tank and containment Fuel consumption run time Full load 5 6 gal per hr 21 0 L per hr 28 hr 34 load 4 5 per hr 17 0 L per hr 35 hr Half load 3 0 gal per hr 11 0 L per hr 53 hr System Controls and Distribution Engine governor electronic 0 596 Protection safety shutdowns low oil pressure high water temp overcrank overspeed amp underspeed voltmeter ammeter Hz meter 2 Each 20 Amp GFCI Duplex Generator gauges Receptacles 120 V Receptacles 240 V 3 Each 50 Amp Tempower T L Primary Distribution 5 lug terminals with mainline circuit breaker Generator specifications Manuafacturer Stamford Model UCI224FIL73D Rating 60 kW Phase 480 240 V 0 8 power factor Description brushless 4 pole synchronous single bearing Insulation Class H Temperature rating 125 C rise o
9. 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 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
10. voltmeter ammeter Hz meter Generator gauges Receptacles 120 V 2 Each 20 Amp GFCI Duplex Receptacles 240 V 3 Each 50 Amp Tempower T L Primary Distribution 5 lug terminals with mainline circuit breaker Generator specifications Manufacturer Stamford Model UCI224EIL73D Rating 60 kW Phase 480 240 V 0 8 power factor Description brushless 4 pole synchronous single bearing Insulation Class H Temperature rating 125 C rise over 40 C ambient external solid state adjustable Automatic voltage regulator 1 60 Hz 1 800 RPM Voltage regulation Frequency speed Part No 134277 T70 T90 amp T120 Super Quiet Generator 2 3 TEREX SPECIFICATIONS T70P SPECIFICATIONS CONTINUED Section 2 Specifications Packaging Enclosure sound attenuated weatherproof with lockable doors Sound levels 66 dBA at 23 ft 7 meters Lifting system roof mounted single point Weight no trailer empty 5 390 Ibs 2 445 kg full 6 782 Ibs 3 076 Dimensions L x W x 110 x 47 x 64 in no trailer 279 x 119 x 162 cm Weight with trailer empty 6 887 Ibs 3 124 kg full 8 279 Ibs 3 755 kg Dimensions L x W x H 171 x 75 x 82 in with trailer 434 x 190 x 208 cm T70 Trailer Tire 225 75R15 Tongue weight electric brakes 884 Ibs 401 kg hydraulic brakes 631 Ibs 286 2 kg Trailer weight electric brakes 1023 Ibs 464 kg h
11. 480 Associated 3 phase amps 0 8 power factor 330 312 286 156 143 Prime 1 phase power 72 kW Prime 1 phase kVA 72 kVA Available 1 phase voltage 120 240 Associated 1 phase amps 600 300 1 0 power factor Max amp rating main breaker size 350A Engine specifications Manufacturer Cummins Model QSB5 G5NR3 Horsepower prime 1 800 rpm 139 hp 104 kWm Description 4 cylinder 4 cycle water cooled OHV in line direct injection turbocharged and charge air cooled Bore amp stroke 4 21 x 4 88 in 107 x 124mm Piston displacement 275 4 5L Compression ratio 17 3 1 Monitoring gauges oil pressure water temperature fuel level battery voltage hours Coolant capacity engine only 10 qts 8 5L Cooling system liquid cooled rated to 105 F 41 C ambient Continuous improvement of our products is a Terex policy Product specifications are subject to change without notice or obligation TEREX SPECIFICATIONS Fuel system Specification 12 diesel Filter fuel water separator Capacity 160 gal 606 L internal fuel tank with 11096 fluid spill containment Tank and containment Fuel consumption run time Full load 7 9 gal per hr 30 L per hr 20 hr 34 load 6 6 gal per hr 25 L per hr 24 hr Half load 4 4 gal per hr 17 L per hr 36 hr System Controls and Distribution Engine govern
12. T120P SPECIFICATIONS CONTINUED Packaging Enclosure sound attenuated weatherproof with lockable doors Sound levels 68 dBA at 23 ft 7 meters Lifting system roof mounted single point Weight no trailer empty 5 390 Ibs 2 445 kg full 6 782 Ibs 3 076 kg Dimensions L x W x H 110 x 47 x 64 in no trailer 279 x 119 x 162 cm Weight with trailer empty 6 887 Ibs 3 124 kg full 8 279 Ibs 3 755 kg Dimensions L x W x H 171x75x82 in with trailer 434 x 190 x 208 cm T120 Trailer Tire 225 75 15 Tongue weight electric brakes 912 Ibs 414 kg hydraulic brakes 652 Ibs 296 kg Trailer weight electric brakes 1023 Ibs 464 kg hydraulic brakes 1110 Ibs 506 kg 2 12 T70 T90 amp T120 Super Quiet Generator Part No 134277 November 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 High Strength Grade 5 lt Grade 8 Black Oxide Bolts LUBED DRY LUBED DRY LUBED Nm 100 140 158 130 120 120 135 140 LUBED LUBED DRY LUBED 24 339 271 447 50 1 678 813 80 1084 68 921 108 4 122 162 176 217 244 10 271 270 366 280 379 16 220 298 300 406 310 420 8 9 3520 483 430 450 610 610 827 210 891 14 350 474 470 637 500 678 670 908 560
13. 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 November 2008 REVA T70C Specifications System power output Section 2 Specifications Prime 3 phase power 69 55 kW Standby 3 phase power 75 kVA 60 kW Available phase voltage 208 220 240 440 480 Associated 3 phase amps 191 181 166 90 83 0 8 power factor Prime 1 phase power 42 kW Prime 1 phase kVA 42 Available 1 phase voltage 120 240 Associated 1 phase amps 350 175 1 0 power factor Max amp rating main breaker size 225A Engine specifications Manufacturer Cummins Model QSB5 G1 NR3 Horsepower prime 1 800 rpm 91 hp 68 Description 4 cylinder 4 cycle water cooled OHV in line direct injection turbocharged and charge air cooled Bore amp stroke 4 21 x 4 88 in 107 x 124 mm Piston displacement 275in 4 5L
14. 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 p emm Se tgs J1939 SHIELD 91939 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 134277 T70 T90 amp T120 Super Quiet Generator 5 7 Section 5 Schematics September 2008 TEREX REVA This page intentionally left blank 5 8 T70 T90 amp T120 Super Quiet Generator Part No 134277 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 Battery post terminals and related accessories contain lead compounds chemicals known to the State of California to cause cancer and other reproductive harm 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
15. Wal 8 5 ZINJ Part No 134277 T70 T90 amp T120 Super Quiet Generator TEREX Distribution Panel Wiring for T70 T90 amp T120 Single Phase Control Section 5 Schematics September 2008 REVA Drawing 5100027 El OW O T1 21 El 5 1708 annoa5 2718 JAMA 31UN 335 s 3715 31UN 335 N3335 88 N3389 2H 80915 OL AUTI3A W d3 FONVSD Wadd OL NAUBG Woda AIW 2H 1 88 7 N33385 218 i O7 KO it it at at Eg k e gt gt gt gt gt gt X 3 9 x ALW 2V38 2H 1 oe dWV 02 06 06 06 21 i i i 61 T70 T90 8 T120 Super Quiet Generator Part No 134277 September 2008 Section 5 Schematics TEREX Three Position Stack Switch Wiring Dra
16. doors Sound levels 66 dBA at 23 ft 7 meters Lifting system roof mounted single point Weight no trailer empty 5 390 Ibs 2 445 kg full 6 782 Ibs 3 076 kg Dimensions L x W x 110 x 47 x 64 in no trailer 279 x 119 x 162 cm Weight with trailer empty 6 887 Ibs 3 124 kg full 8 279 Ibs 3 755 kg Dimensions L x W x 171x75x82 in with trailer 434 x 190 x 208 cm T90 Trailer Tire 225 75 15 Tongue weight electric brakes 903 Ibs 410 kg hydraulic brakes 645 Ibs 293 kg Trailer weight electric brakes 1023 Ibs 464 kg hydraulic brakes 1110 Ibs 503 5 kg November 2008 REVA 2 6 T70 T90 amp T120 Super Quiet Generator Part No 134277 November 2008 REVA Section 2 Specifications T90P Specifications System power output Prime 3 phase power 90 kVA 72 kW Standby 3 phase power 100 kVA 80 kW Available 3 phase voltage 208 220 240 440 480 Associated 3 phase amps 0 8 power factor 250 236 217 118 108 Prime 1 phase power 59 kW Prime 1 phase kVA 59 kVA Available 1 phase voltage 120 240 Associated 1 phase amps 492 246 1 0 power factor Max amp rating main breaker size 300A Engine specifications Manufacturer Perkins Model 1104D E44TAG1 Horsepower prime 1 800 rpm 110 hp 82 Description 4 cylinder 4 cycle water cooled OHV in line direct injection turbocharged and charge air
17. 34277 First Edition TEREX T70 T90 amp T120 Parts Manual 134234 First Edition Newage Generator Manual 836430 Cummins Engine Manual 839059 Cummins Engine Manual 839060 Perkins Engine Manual 839019 Cascade Controller Manual 833011 Cummins Controller Manual 900 0661 Dexter Axle 833014 Copyright O 2008 by TEREX Corporation 134277 Rev A November 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 T70 90 8 T120 Super Quiet Generator Part No 134277 November 2008 TEREX How to Read Your Serial Number Serial Number Legend The serial number plate on your T70 T90 amp T120 Super Quiet Generator is located area of the lower control panel on the twist lock MANUFACTURED BY FABRIQUE PAR TEREX ROCK HILL 590 Huey Road Rock Hill SC 29732 DATE FEBRUARY 2008 PRESS DE GONFL A FROID SINGLE MOTOR VEHICLE SAFETY STANDARDS IN OF MANUFACTURE SHOWN ABOVE VIGUEUR A LA DATE DE SA FABRICATION MODEL T40K SERIAL NUMBER XXXX MO
18. 759 14 7 15 8 I 2 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 86 108 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 co N o 7 480 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 Class 12 9 DRY DRY DR gt iz Bl ilz ile 1 oO D ag N oy NO D age al 00 CO Go rp N ox oi iol ojo n N EN E A a a eo na D 3
19. D BY UNAUTHORIZED PERSONNEL WILL NOT BE COVERED BY YOUR MANUFACTURER S WARRANTY AND WILL ALSO VOID THE MANUFACTURER S WARRANTY ON THIS PARTICULAR UNIT IF YOU CAN NOT REACH YOUR LOCAL DEALER CONTACT THE FACTORY SERVICE MANAGER TOLL FREE AT 1 800 433 3026 4 6 T70 T90 amp T120 Super Quiet Generator Part No 134277 September 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 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 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 phas
20. DEL YEAR 2008 GVWR PNBV 1 244 KG 2 743 LBS GAWR PNBE 1 244 KG 2 743 LBS TIRES PNEU ST205 75D15 LOAD RANGE C RIMS JANTE 15 0 X 4 5 5H COLD TIRES INFL 35 PSI 250 KPA THIS VEHICLE CONFORMS TO ALL APPLICABLE U S FEDERAL THIS VEHICLE CONFORMS TO ALL APPLICABLE STANDARDS PRESCRIBED UNDER THE CANADIAN MOTOR VEHICLE SAFETY REGULATIONS IN EFFECT ON THE DATE MANUFACTURE CE VEHICULE EST CONFORME A TOUTES LES NORMES QUI LUI SONT APPLICABLES EN VERTU DU REGLEMENT SUR LA SECURITE DES VEHICULES AUTOMOBILES DU CANADA EN TYPE OF VEHICLE TYPE DE VEHICULE TRAILER REMORQUE gt TEREX EFFECT ON THE DATE Part No 134277 T70 T90 amp T120 Super Quiet Generator lii November 2008 TEREX This page intentionally left blank iv T70 T90 amp T120 Super Quiet Generator Part No 134277 November 2008 Section 1 Safety Rules TEREX Safety Rules Danger Failure to obey the instructions and safety rules in this manual and the appropriate Operator s Manual on your machine will result in death or serious injury Many of the hazards identified in the operator s manual are also safety hazards when maintenance and repair procedures are performed Do Not Perform Maintenance Unless 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 reg
21. OVERNING BIAS SIGNAL LOAD SHARE Y GENERATOR SPEED LOAD GOVERNING BIAS SHIELD Do EQUIPMENT GENERATOR SPEED LOAD GOVERNING BIAS 5 VOLT SUPPLY OPTIONAL SENSOR SUPPLY 3 GAIN ADJUST ROTENTIOMETEP DROOP ADJUST POTENTIOMETER f FREQUENCY ADJUST POTENTIOMETER B 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 FREQUENCY ADJUST POTENTIOMETER 5 VOLT SUPPLY FREQUENCY ADJUST POTENTIOMETER SIGNAL FREQUENCY ADJUST POTENTIOMETER RETURN ENGINE COOLANT LEVEL 5 VOLT SUPPLY Peg Biggs 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 DIAGNOSTIC TEST MODE Swe Gp DAGNOSTIC TEST MODE SWITCH SIGNAL ALTERNATE Gp ALTERNATE FREQUENCY SWITCH SIGNAL IDLE DIAGNOSTIC INCREMENT MOMENTARY INCREMENT SWITCH DIAGNOSTIC DECREMENT SWITCH O77 PULE DAGNOSTIC DECREMENT SWITCH ENGINE PROTECTION DVERRIDE SWITEH 2 ENGINE PROTECTION OVERRIDE SWITCH SIGNAL FAUCI ACKNOWLEDGE SWITCH FAULT ACKNOWLEDGE SWITCH SIGNAL TACHOMETER PRESSURE TEMPERATURE COOLANT TEMPERATURE METER SIGNAL
22. T120 Super Quiet Generator Part No 134277 September 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 21 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 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 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 sa
23. cooled Bore amp stroke 4 13 x 5 00 in 105 x 127 mm Piston displacement 269 in 4 41 L Compression ratio 16 251 Monitoring gauges oil pressure water temperature fuel level battery voltage hours Coolant capacity engine only 7 4 qts 7 0L Cooling system liquid cooled rated to 105 F 41 C ambient Continuous improvement of our products is a Terex policy Product specifications are subject to change without notice or obligation TEREX SPECIFICATIONS Fuel system Specification 2 diesel Filter fuel water separator Capacity 160 gal 606 L internal fuel tank with 11096 fluid spill containment Tank and containment Fuel consumption run time Full load 6 3 gal per hr 23 7 L per hr 25 hr 34 load 4 9 gal per hr 18 7 L per hr 32 hr Half load 3 5 gal per hr 13 5 L per hr 45 hr System Controls and Distribution Engine governor electronic 0 596 Protection safety shutdowns low oil pressure high water temp overcrank overspeed underspeed voltmeter ammeter Hz meter Generator gauges Receptacles 120 V 2 Each 20 Amp GFCI Duplex Receptacles 240 V 3 Each 50 Amp Tempower T L Primary Distribution 5 lug terminals with mainline circuit breaker Generator specifications Manufacturer Stamford Model UCI274CIL32D Rating 83 kW Phase 480 240 V 0 8 power factor Des
24. cription brushless 4 pole synchronous single bearing Insulation Class H Temperature rating 125 C rise over 40 C ambient external solid state adjustable Automatic voltage regulator Voltage regulation 1 Frequency speed 60 Hz 1 800 RPM Part No 134277 T70 T90 amp T120 Super Quiet Generator TEREX SPECIFICATIONS T90P SPECIFICATIONS CONTINUED Section 2 Specifications Packaging Enclosure sound attenuated weatherproof with lockable doors Sound levels 66 dBA at 23 ft 7 meters Lifting system roof mounted single point Weight no trailer empty 5 390 Ibs 2 445 kg full 6 782 Ibs 3 076 kg Dimensions L x W x H 110 x 47 x 64 in no trailer 279 x 119 x 162 cm Weight with trailer empty 6 887 Ibs 3 124 kg full 8 279 Ibs 3 755 kg Dimensions L x W x 171x75x82 in with trailer 434 x 190 x 208 cm T90 Trailer Tire 225 75 15 Tongue weight electric brakes 903 Ibs 410 kg hydraulic brakes 645 Ibs 293 kg Trailer weight electric brakes 1023 Ibs 464 kg hydraulic brakes 1110 Ibs 503 5 kg November 2008 REVA 2 8 T70 T90 amp T120 Super Quiet Generator Part No 134277 November 2008 REVA Section 2 Specifications T120C Specifications System power output Prime 3 phase power 120 kVA 95 kW Standby 3 phase power 125 kVA 100 kW Available 3 phase voltage 208 220 240 440
25. ction plus running audible check Measure stator winding insulation resistance i Monitor Monitor bearing s condition condition Remove terminal box lid and check Re 018880 Re grease bearings Replace bearings Replace NDE oring o inspect bearinghousings Inspect winding conditons J S Inspect rotating diode assembly J 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 T70 T90 amp T120 Super Quiet Generator Part No 134277 September 2008 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 the following hazards and follow Troubleshooting and repair procedures shall be generally accepted safe workshop practices completed by a person trained and qualified on 4 1 DANGER Electrocution hazard Exposure to the repair of this machine ADA d electrically charged circuits could Immediately tag and remove from service a result in death or se
26. cy Product specifications are subject to change without notice or obligation TEREX SPECIFICATIONS Fuel system Specification 12 diesel Filter fuel water separator Capacity 160 gal 606 L internal fuel tank with 11096 fluid spill containment Tank and containment Fuel consumption run time Full load 7 3 gal per hr 27 8 L per hr 21 hr 34 load 5 8 gal per hr 22 L per hr 27 hr Half load 4 3 gal per hr 16 1 L per hr 37 hr System Controls and Distribution Engine governor electronic 0 596 Protection safety shutdowns low oil pressure high water temp overcrank overspeed underspeed voltmeter ammeter Hz meter 2 Each 20 Amp GFCI Duplex Generator gauges Receptacles 120 V Receptacles 240 V 3 Each 50 Amp Tempower T L Primary Distribution 5 lug terminals with mainline circuit breaker Generator specifications Manufacturer Stamford Model UCI274DIL32D Rating 117 kW Phase 480 240 V 0 8 power factor Description brushless 4 pole synchronous single bearing Insulation Class H Temperature rating 125 C rise over 40 C ambient external solid state adjustable Automatic voltage regulator 1 60 Hz 1 800 RPM Voltage regulation Frequency speed Part No 134277 T70 T90 amp T120 Super Quiet Generator Section 2 Specifications November 2008 TEREX SPECIFICATIONS REVA
27. d bo 4 Drain fuel system primary filter water Walk around Walk around inspection check battery eectroytelevel gt Oeanrepaceengnearceaersemm T Inspectclean engine ground change engine oit ana finer Replace water separator element 11 11 T Replace tuel system secondary ter _ hoses and clamps inspectadjust engine valve lash aftercooler core Inspect alternator Inspect engine mounts Inspect starting motor Inspect turbocharger Inspect water pump s 12 or B or 12000 Hrs Change cooling system coolant cooling system coolant Test change fuel injector Change cooling system coolant L L L commercia heavy duty j Clemfestatrcodercoe Add cooling system coolant extender ELC Change cooling system coolant ELC 134277 T70 90 amp T120 Super Quiet Generator 3 3 Section Scheduled Maintenance Procedures September 2008 TEREX MAINTENANCE SCHEDULES CONTINUED REVA Newage Generators Maintenance Schedule 4500 Hours onte or 3 Years Months Months Visual inspection Visual inspe
28. d Replace solenoid 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 85 necessary T70 T90 amp T120 Super Quiet Generator Part No 134277 September 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 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 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
29. e 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 Part No 134277 T70 T90 amp T120 Super Quiet Generator 5 1 September 2008 Section 5 Schematics X 14 Control Panel Wiring REVA for Murphy Cascade Controller Drawing ES100029 Standard 131041415101 3 341434 dOLS 3 3Hl SI N3 Ud LIDA TW 314 2 21148 X00 3SVHd SV 3AVS 3Hl SI 31890 1491 31D433 j N TaNVd NOILN IALSIG 359 Q31NnUW 38V SLOVLNOD 1491 31DW3B 3015 ABLN3 ASIA 103 0
30. e breaker to trip that supplies AC power to the distribution lugs if uneven or excessive current is measured at the distribution lugs It is also connected to the 3 phase door switch and will automatically trip the 3 phase breaker when the door is open and pre vents the breaker from being reset while it is open Section 4 Troubleshooting TEREX TROUBLESHOOTING Generator Test resistance of field stator and exciter wind ings Contact TEREX for procedures or repair facility recommended by generator manufacturer A Procedure for testing generator with no output THIS EQUIPMENT USES HIGH VOLTAGE CIRCUITS CAPABLE OF CAUSING SERIOUS INJURY OR DEATH EXCERCISE EXTREME CAUTION AROUND ANY ELECTRICAL COMPONENT WHEN OPERATING THIS UNIT IT IS ESSENTIAL THAT ALL TEST INSTRU MENTS ARE REGULARLY CHECKED FOR SAFETY AND ANY CONNECTION LEADS PROBES OR CLIPS ARE CHECKED TO ENSURE THAT THEY ARE SUITABLE FOR THE VOLTAGE LEVELS BEING TESTED NEVER ATTEMPT TO TEST A LIVE GENERA TOR UNLESS THERE IS ANOTHER COMPE TENT PERSON PRESENT WHO CAN SWITCH OFF THE POWER SUPPLY OR SHUT DOWN THE ENGINE IN AN EMERGENCY NEVER EXPOSE LIVE 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 WARNING DO NOT PERFORM THIS PROCEDURE WHILE GENERATOR IS UNDER LOAD e When new generator is not producing voltage the tes
31. epartment 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 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 September 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 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 Disconnec
32. er tripped Voltage regulator Defective voltage regulator Defective Selector Switch Defective generator SOLUTION Reset circuit breaker Check voltage regulator wiring Replace voltage regulator By pass by hardwiring generator Refer to generator manual Low generator output voltage Voltage adjustment set too low Defective potentiometer Low engine speed Loose wire on voltage selector switch Fluctuating or surging engine speed Loose wire on voltage regulator sensing circuit Defective voltage regulator Adjust voltage potentiometer By pass or replace Call TEREX Service Check wiring Check engine fuel oil and air filters Check wiring Replace voltage regulator High generator output voltage Voltage adjustment potentiometer High engine speed Adjust potentiometer Call TEREX Service T70 T90 amp T120 Super Quiet Generator Part No 134277 September 2008 High generator output voltage Section 4 Troubleshooting POSSIBLE CAUSE Defective automatic voltage regulator Loose wire on voltage adjustment potentiometer Neutral binding strap not in 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 setti
33. fety 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 Part No 134277 T70 T90 amp T120 Super Quiet Generator 3 1 Pre Delivery Preparation Fundamentals It is the responsibility of the dealer to perform the Pre delivery Preparation The Pre delivery Preparation is performed prior to each delivery The inspection is designed to discover if anything is apparently wrong with a machine before it is put into Service A damaged or modified machine must never be used If damage or any variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified Service technician according to the manufacturer s specifications Scheduled maintenance inspections shall be perfor
34. ification 2 diesel Filter fuel water separator Capacity 160 gal 606 L internal fuel tank with 11096 fluid spill containment Tank and containment Fuel consumption run time Full load 6 0 gal per hr 23 0 L per hr 26 hr 34 load 5 0 gal per hr 19 0 L per hr 32 hr Half load 3 4 gal per hr 13 0 L per hr 47 hr System Controls and Distribution Engine governor electronic 0 596 Protection safety shutdowns low oil pressure high water temp overcrank overspeed amp underspeed voltmeter ammeter Hz meter 2 Each 20 Amp GFCI Duplex Generator gauges Receptacles 120 V Receptacles 240 V 3 Each 50 Amp Tempower T L Primary Distribution 5 lug terminals with mainline circuit breaker Generator specifications Manuafacturer Stamford Model UCI274CIL32D Rating 60 kW Phase 480 240 V 0 8 power factor Description brushless 4 pole synchronous single bearing Insulation Class H Temperature rating 125 C rise over 40 C ambient external solid state adjustable Automatic voltage regulator 1 60 Hz 1 800 RPM Voltage regulation Frequency speed Part No 134277 T70 T90 amp T120 Super Quiet Generator 2 5 TEREX SPECIFICATIONS T90C SPECIFICATIONS CONTINUED Section 2 Specifications Packaging Enclosure sound attenuated weatherproof with lockable
35. med 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 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 no unable to complete 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 September 2008 Section Scheduled Maintenance Procedures TEREX Maintenance Schedules REVA Perkins amp Cummins Lubrication and Maintenance Service Intervals 50 Hrs or 500 Hrs or a DR S t S L 8 engine oil level 411
36. ng may be wrong Loose wire on the automatic voltage regulator sensing lead Redistribute load if possible Check engine fuel oil and air filters Check connections Call TEREX Service Check wiring Low engine speed Engine speed adjustment has slipped Clogged fuel system Blocked air intake Blocked exhaust system Contaminated fuel Defective governor on engine Call TEREX Service Check for air leaks clogged fuel filter kinked fuel line or clogged fuel pick up tube Check air filter Check engine exhaust system remove obstructions Check fuel water separator and fuel tank for contamination Replace fuel if needed Call TEREX Service Part No 134277 T70 T90 amp T120 Super Quiet Generator TEREX TROUBLESHOOTING Section 4 Troubleshooting POSSIBLE CAUSE Detective Injectors on engine Surging engine speed September 2008 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 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 solenoi
37. o 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 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 that all tools and working areas 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 2 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 other fluids Use an approved container Please be environmentally safe sure that your workshop or work area is properly ventilated and well lit T c M 2 vi T70 T90 amp T120 Super Quiet Generator Part No 134277 November 2008 Introduction Section 1 Section 2 Rev gt gt gt gt gt gt gt gt gt gt gt gt gt gt Table of Contents Important Information How to Read Your Serial Number iii Parts Stocking List X Howto Order cpm m Ser
38. or electronic 0 596 Protection safety shutdowns low oil pressure high water temp overcrank overspeed underspeed voltmeter ammeter Hz meter 2 Each 20 Amp GFCI Duplex Generator gauges Receptacles 120 V Receptacles 240 V 3 Each 50 Amp Tempower T L Primary Distribution 5 lug terminals with mainline circuit breaker Generator specifications Manufacturer Newage Model UCI274DIL32D Rating 117 kW Phase 480 240 V 0 8 power factor Description brushless 4 pole synchronous single bearing Insulation Class H Temperature rating 125 C rise over 40 C ambient external solid state adjustable Automatic voltage regulator 1 60 Hz 1 800 RPM Voltage regulation Frequency speed Part No 134277 T70 T90 amp T120 Super Quiet Generator TEREX SPECIFICATIONS T120C SPECIFICATIONS CONTINUED Section 2 Specifications Packaging Enclosure sound attenuated weatherproof with lockable doors Sound levels 68 dBA at 23 ft 7 meters Lifting system roof mounted single point Weight no trailer empty 5 390 Ibs 2 445 kg full 6 782 Ibs 3 076 kg Dimensions L x W x 110 x 47 x 64 in no trailer 279 x 119 x 162 cm Weight with trailer empty 6 887 Ibs 3 124 kg full 8 279 Ibs 3 755 kg Dimensions L x W x 171x75x82 in with trailer 434 x 190 x 208 cm T120 Trailer Tire 225 75 15 Tongue
39. phase power 42 kW Prime 1 phase kVA 42 Available 1 phase voltage 120 240 Associated 1 phase amps 350 175 1 0 power factor Max amp rating main breaker size 225A Engine specifications Manufacturer Perkins Model 1104DE 44TG1 Horsepower prime 1 800 rpm 78 hp 58 Description 4 cylinder 4 cycle water cooled OHV in line direct injection turbocharged Bore amp stroke 4 13 x 5 00 in 105 x 127 mm Piston displacement 269 4 41L Compression ratio 18 2 1 Monitoring gauges oil pressure water temperature fuel level battery voltage hours Coolant capacity engine only 7 4 qts 7 0 L Cooling system liquid cooled rated to 105 F 41 C ambient Continuous improvement of our products is a Terex policy Product specifications are subject to change without notice or obligation TEREX SPECIFICATIONS Fuel system Specification 2 diesel Filter fuel water separator Capacity 160 gal 606 L internal fuel tank with 11096 fluid spill containment Tank and containment Fuel consumption run time Full load 4 4 gal per hr 16 6 L per hr 36 hr 34 load 3 4 gal per hr 12 8 L per hr 47 hr Half load 2 4 gal per hr 9 0 L per hr 67 hr System Controls and Distribution Engine governor electronic 0 596 Protection safety shutdowns low oil pressure high water temp overcrank overspeed amp underspeed
40. rious injury damaged or malfunctioning machine Remove all rings watches and 1 other jewelry Repair any machine damage or malfunction Y before operating the machine ADANGER Electrocution hazard Attempting 25 to sevice the machine before the Unless otherwise specified perform each 4 MAN capacitors are fully discharged will repair procedure with the machine in the 2 in death 2 2 following configuration Machine parked on a firm level surface High voltage Exposure to 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 ACAUTION Burn hazard Contact with hot engine components may cause severe burns Use caution when working around a hot engine Part No 134277 T70 T90 amp T120 Super Quiet Generator 4 1 TEREX Section 4 Troubleshooting Troubleshooting Guide September 2008 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 break
41. st Part No 134277 T70 T90 amp T120 Super Quiet Generator November 2008 TEREX This page intentionally left blank x T70 T90 amp T120 Super Quiet Generator Part No 134277 November 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 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 803 324 301 1 Toll Free 800 433 3026 in U S A and Canada Fax 803 366 1101 Part No 134277 T70 T90 amp T120 Super Quiet Generator Xi November 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
42. t both wires e Once the wires are loose go to the front of the control panel and loosen the lock nut holding the potentiometer e 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 T70 T90 amp T120 Super Quiet Generator Part No 134277 September 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 Ther
43. ting 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 134277 T70 T90 amp T120 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 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 d
44. ulations applicable governmental regulations You have the appropriate tools lifting equipment and a suitable workshop Part No 134277 T70 T90 amp T120 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 property damage message Be sure to wear protective eye wear and other protective clothing if the situation warrants it Be aware of potential crushing hazards 3l such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes Section 1 Safety Rules November 2008 Workplace Safety Be sure t
45. ver 40 C ambient external solid state adjustable Automatic voltage regulator 1 60 Hz 1 800 RPM Voltage regulation Frequency speed Part No 134277 T70 T90 amp T120 Super Quiet Generator 2 1 TEREX SPECIFICATIONS T70C SPECIFICATIONS CONTINUED Section 2 Specifications Packaging Enclosure sound attenuated weatherproof with lockable doors Sound levels 66 dBA at 23 ft 7 meters Lifting system roof mounted single point Weight no trailer empty 5 390 Ibs 2 445 kg full 6 782 Ibs 3 076 kg Dimensions L x W x 110 x 47 x 64 in no trailer 279 x 119 x 162 cm Weight with trailer empty 6 887 Ibs 3 124 kg full 8 279 Ibs 3 755 kg Dimensions L x W x H 171x75x82 in with trailer 434 x 190 x 208 cm T70 Trailer Tire 225 75 15 Tongue weight electric brakes 884 Ibs 401 kg hydraulic brakes 631 Ibs 286 2 kg Trailer weight electric brakes 1023 Ibs 464 kg hydraulic brakes 1110 Ibs 503 5 kg November 2008 REVA 2 2 T70 T90 amp T120 Super Quiet Generator Part No 134277 November 2008 REVA T70P Specifications System power output Section 2 Specifications Prime 3 phase power 70 54 kw Standby 3 phase power 74 kVA 59 Available phase voltage 208 220 240 440 480 Associated 3 phase amps 188 177 163 89 81 0 8 power factor Prime 1
46. vice Parts Fax Order Form Xii Safety Rules General Safety Rules Specifications Specifications 2 1 T70C Specifications 2 2 T7OP Specifications p 2 3 T70P Specifications Continued cree ne ea 2 4 2 5 T90C Specifications Continued 0 2 6 2 trn 2 2 7 T90P Specifications 2 8 T120 Specifications nri mo seti tbe te t ub 2 9 T120C Specifications Continued 2 10 T120P Specifications 2 11 T120P Specifications Continued 2 12 Torque ctum eres 2 13 Generator Torque Specifications 2 14 Part No 134277 T70 T90 amp T120 Super Quiet Generator vii November 2008 TEREX TABLE OF CONTENTS Section 3 Rev Scheduled Maintenance Procedures I 3 1 Pre delivery Preparation 3 2 A Maintenance Schedules Cummins Lubrication and Maintenance Service Intervals
47. weight electric brakes 912 Ibs 414 kg hydraulic brakes 652 Ibs 296 kg Trailer weight electric brakes 1023 Ibs 464 kg hydraulic brakes 1110 Ibs 503 5 kg November 2008 REVA 2 10 T70 T90 amp T120 Super Quiet Generator Part No 134277 November 2008 REVA Section 2 Specifications T120P Specifications System power output Prime 3 phase power 113 kVA 90 kW Standby 3 phase power 122 kVA 98 kW Available 3 phase voltage 208 220 240 440 480 Associated 3 phase amps 0 8 power factor 316 296 271 148 135 Prime 1 phase power 72 kW Prime 1 phase kVA 72 kVA Available 1 phase voltage 120 240 Associated 1 phase amps 600 300 1 0 power factor Max amp rating main breaker size 350A Engine specifications Manufacturer Perkins Model 1104D 44TAG2 Horsepower prime 1 800 rpm 134 hp 100 kWm Description 4 cylinder 4 cycle water cooled in line direct injection turbocharged and charge air cooled Bore amp stroke 4 13 x 5 00 in 105 x 127mm Piston displacement 269 in 4 41 L Compression ratio 16 21 Monitoring gauges oil pressure water temperature fuel level battery voltage hours Coolant capacity engine only 7 4 qts 7 0L Cooling system liquid cooled rated to 105 F 41 C ambient Continuous improvement of our products is a Terex poli
48. wing ES100026 REVA 1504 SOLI V33N39 1504 YOLVYANAD 1081 80000153 29 00001537 SONIMVMO 33S 3ON3H343M M04 310N 99 989 YSEWAN LYVd HOLIMS 0821 20 21 ZZ HOLIMS 0 15 lOHLNOO WO4 1504 MOLVS3N39 xog 10841 O8 1081 WO 9 0 N39 0 aval N39 Q I1SOd MOLVM3N39 S OL 09 OL ge T SSS Sc 8c 26 GG ov 6 o 4068 5 5 c 9 1 c 48 40 92 6 7 MOTI3A mee 9f O 4260 N vc 151 Ol 5 4 8 0 90 JONVYO 7 opte 9 4 LJVHS 410 HOLIMS O N39 OL e 1504 MOL1V33N39 Ol aval v N39 OL Part No 134277 T70 T90 amp T120 Super Quiet Generator Section 5 Schematics September 2008 TEREX co 2 28 S cs 5 o 2 O lt gt 2 5 009 8 20961 9 000 1 9 009 20 21 51009 1 9 9 009 2081 S 00v 1 8 002 420021 9 4061 5 006 1
49. ydraulic brakes 1110 Ibs 503 5 kg November 2008 REV A 2 4 T70 T90 amp T120 Super Quiet Generator Part No 134277 November 2008 REVA Section 2 Specifications T90C Specifications System power output Prime 3 phase power 90 kVA 72 kW Standby 3 phase power 100 kVA 80 kW Available 3 phase voltage 208 220 240 440 480 Associated 3 phase amps 0 8 power factor 250 236 217 118 108 Prime 1 phase power 59 kW Prime 1 phase kVA 59 kVA Available 1 phase voltage 120 240 Associated 1 phase amps 492 246 1 0 power factor Max amp rating main breaker size 300A Engine specifications Manufacturer Cummins Model QSB5 G2 NR3 Horsepower prime 1 800 rpm 103 hp 77 kWm Description 4 cylinder 4 cycle water cooled OHV in line direct injection turbocharged and charge air cooled Bore amp stroke 4 21 x 4 88 in 107 x 124 mm Piston displacement 275 4 5 1 Compression ratio 17 2 1 Monitoring gauges oil pressure water temperature fuel level battery voltage hours Coolant capacity engine only 10 0 qts 9 5 L Cooling system liquid cooled rated to 105 F 41 C ambient Continuous improvement of our products is a Terex policy Product specifications are subject to change without notice or obligation TEREX SPECIFICATIONS Fuel system Spec
Download Pdf Manuals
Related Search