Service Manual - Parts, Service and Operations …

1 Service ManualSerial numbersT7009-000101T9009-000101T12009-00 0101and aboveT70CT70PT90CT90PT120CT120 PPart No. 134277 Rev ANovember 2008withMaintenanceInformationNovember 2008T70, T90 & T120 Super Quiet GeneratorPart No. 134277iiImportantRead, understand and obey the safety rules andoperating instructions in the appropriate Operator'sManual on your machine before attempting anymaintenance mechanical, hydraulic and electricalskills are required to perform most , several procedures require specializedskills, tools, lifting equipment and a suitableworkshop. In these instances, we stronglyrecommend that maintenance and repair beperformed at an authorized TEREX dealerservice PublicationsTEREX Corporation has endeavored to deliver thehighest degree of accuracy possible.

2 However,continuous improvement of our products is aTEREX policy. Therefore, product specificationsare subject to change without are encouraged to notify TEREX of errorsand send in suggestions for improvement. Allcommunications will be carefully considered forfuture printings of this and all other 2008 by TEREX Corporation134277 Rev A November 2008 First Edition, First Printing"TEREX" is a registered trademark of TEREXC orporation in the USA and many other countries."Super Quiet" is a trademark of TEREXC orporation. Printed on recycled paperPrinted in Number InformationTEREX Corporation offers the following manualsfor these models:TitlePart T70, T90 & T120 Operator's Manual , .. 134207 First EditionTEREX T70, T90 & T120 Service Manual .

3 134277 First EditionTEREX T70, T90 & T120 Parts Manual ,..134234 First EditionNewage Generator Engine Engine Engine Controller Controller Manual ..900-0661 Dexter Axle 2008 part No. 134277T70, T90 & T120 Super Quiet GeneratorSerial Number LegendThe serial number plate on your T70, T90 & T120 Super Quiet Generator is located on the twist lockarea of the lower control to Read Your Serial NumberNovember 2008T70, T90 & T120 Super Quiet GeneratorPart No. 134277 This page intentionally left 2008 part No. 134277T70, T90 & T120 Super Quiet GeneratorvDangerFailure to obey the instructions and safety rulesin this Manual and the appropriate Operator'sManual on your machine will result in death orserious of the hazards identified in theoperator s Manual are also safety hazardswhen maintenance and repair proceduresare Not Perform MaintenanceUnless:You are trained and qualified to performmaintenance on this read, understand and obey:- manufacturer s instructions and safety rules- employer s safety rules and worksiteregulations- applicable governmental regulationsYou have the appropriate tools, liftingequipment and a suitable RulesSection 1 Safety RulesNovember 2008T70, T90 & T120 Super Quiet GeneratorPart No.

4 134277 SAFETY RULESviSection 1 Safety RulesPersonal SafetyAny person working on or around a machine mustbe aware of all known safety hazards. Personalsafety and the continued safe operation of themachine should be your top each procedure thoroughly. Thismanual and the decals on the machine,use signal words to identify the following:Safety alert symbol used to alertpersonnel to potential personalinjury hazards. Obey all safetymessages that follow this symbolto avoid possible injury or an imminently hazardoussituation which, if not avoided, willresult in death or serious a potentially hazardoussituation which, if not avoided,could result in death or a potentially hazardoussituation which, if not avoided,may cause minor or a property sure to wear protective eye wear andother protective clothing if the situationwarrants aware of potential crushing hazardssuch as moving parts, free swinging orunsecured components when lifting orplacing loads.

5 Always wear approved SafetyBe sure to keep sparks, flames andlighted tobacco away from flammable andcombustible materials like battery gasesand engine fuels. Always have an approved fireextinguisher within easy sure that all tools and working areasare properly maintained and ready foruse. Keep work surfaces clean and free ofdebris that could get into machine components andcause sure any forklift, overhead crane orother lifting or supporting device is fullycapable of supporting and stabilizing theweight to be lifted. Use only chains or straps thatare in good condition and of ample sure that fasteners intended for onetime use ( , cotter pins and self-lockingnuts) are not reused. These componentsmay fail if they are used a second sure to properly dispose of old oil orother fluids.

6 Use an approved be environmentally sure that your workshop or work areais properly ventilated and well 2008 part No. 134277T70, T90 & T120 Super Quiet GeneratorTable of ContentsIntroductionImportant Information - Introduction ..iiHow to Read Your Serial Stocking List ..xHow to Order Parts ..xiService Parts Fax Order Form ..xiiSection 1 Safety RulesGeneral Safety Rules ..vSection 2 RevSpecificationsAT70C Specifications .. 2 - 1AT70C Specifications (Continued).. 2 - 2AT70P Specifications .. 2 - 3AT70P Specifications (Continued).. 2 - 4AT90C Specifications .. 2 - 5AT90C Specifications (Continued).. 2 - 6AT90P Specifications .. 2 - 7AT90P Specifications (Continued).. 2 - 8AT120C 2 - 9AT120C Specifications (Continued).

7 2 - 10AT120P 2 - 11AT120P Specifications (Continued).. 2 - 12 ATorque 2 - 13 AGenerator Torque 2 - 14viiNovember 2008T70, T90 & T120 Super Quiet GeneratorPart No. 134277 TABLE OF CONTENTSS ection 3 RevScheduled Maintenance 3 - 1 Pre-delivery Preparation 3 - 2 AMaintenance SchedulesCummins Lubrication and Maintenance Service Intervals .. 3 - 3 Perkins Lubrication and Maintenance Service Intervals .. 3 - 4 Newage Generators Maintenance 3 - 5 Section 4 - 1 ATroubleshooting 4 - 2 Section 5 - 1 AElectrical Schematic - Control Panel Wiring forMurphy Cascade 5 - 2 AElectrical Schematic - Distribution Panel Wiring .. 5 - 3 AElectrical Schematic - Stack Switch .. 5 - 4 AElectrical Schematic- Overcurrent 5 - 5 AElectrical Schematic - Standard Generator Wiring.

8 5 - 6 AElectrical Schematic - Idle-Run Wiring (Cummins) .. 5 - 7viiiNovember 2008 part No. 134277T70, T90 & T120 Super Quiet GeneratorRequired PartsThe following parts are required to performmaintenance procedures as outlined in theTEREX T70, T90 and T120 Parts and QSM11G4 ModelsOil Filter - Primary ..125561 Air Filter - Secondary ..125562 Fuel Stocking ListixNovember 2008T70, T90 & T120 Super Quiet GeneratorPart No. 134277xThis page intentionally left 2008 part No. 134277T70, T90 & T120 Super Quiet GeneratorMachine InformationModelSerial NumberDate of PurchaseAuthorized TEREX DistributorPhone NumberPlease be prepared with the following informationwhen ordering replacement parts for your TEREX product.

9 Machine model numberMachine serial numberTerex part numberPart description and quantityPurchase order number"Ship to" addressDesired method of shipmentName and telephone number of theauthorized TEREX Distributor in your areaUse the Service Parts Fax Order Form on thenext page and fax your order to our you don't know the name of your authorizeddistributor, or if your area is not currently servicedby an authorized distributor, please call To Order PartsTEREX North AmericaTelephone (803) 324-3011 Toll Free (800) 433-3026 in and CanadaFax (803) 366-1101xiNovember 2008T70, T90 & T120 Super Quiet GeneratorPart No. 134277 part NumberDescriptionQuantityPriceAll backordered parts will be shipped when available via the same ship method as the original orderunless noted below:oShip complete order only - no backordersoShip all available parts and contact customer on disposition of backordered partsoOther (please specify)Please fill out completelyDate_____Account Number _____Your Name _____Your Fax Number _____Your Phone Number _____Bill To_____Ship To_____Purchase Order Number _____Ship Via_____Model(s) _____ Serial No.

10 (s) _____Optional Equipment _____FOR TEREX USE ONLYO rder Number _____Origin Code _____Comments _____Date Scheduled _____Ship Condition _____Order Total _____Terms Code _____remove this page and make copiesremove this page and make copiesService Parts fax Order FormFAX TO: (800) 633-5534 OR TOLL FREE: 800-433-3026 REV APart No. 134277T70, T90 & T120 Super Quiet Generator2 - 1 Section 2 SpecificationsNovember 2008 SpecificationsT70C SpecificationsSystem power outputPrime 3 phase power69 kVA / 55 kWStandby 3 phase power75 kVA / 60 kWAvailable 3 phase voltage208 / 220 / 240 / 440 / 480 Associated 3 phase amps191 / 181 / 166 / 90 / 83( power factor)Prime 1 phase power42 kWPrime 1 phase kVA42 kVAAvailable 1 phase voltage120 / 240 Associated 1 phase amps350 / 175( power factor)Max amp rating (main breaker size)225 AEngine specificationsManufacturerCumminsModelQS B5-G1 NR3 Horsepower - prime (1,800 rpm)91 hp (68 kWm)