Genie T15, T25, T45, T50 Service Manual

Service Manual

T50

First Edition
Rev A
Part No. 134880
August 2008

August 2008

Introduction

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.

REV A

Serial Number Information

TEREX Corporation offers the following manuals for
these models:

Title Part No.

TEREX T25 thru T80 Operator's Manual, ...........133255

First Edition

TEREX T50 Part's Manual, .................................134879

First Edition

Newage Generator Manual ................................830001

John Deere Engine Manual ...............................839018

Perkins Engine Manual ......................................839019

Woodward Controls Manual ..............................833013

DynaGen Controller Manual .............................. 833012

Cascade Controller Manual ...............................833011

Dexter Axle Manual ............................................833014

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
e-mail: [e-mail]

Copyright © 2008 by TEREX Corporation

134880 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.

Printed on recycled paper

Printed in U.S.A.

ii

T50 Super Quiet Generator Part No. 134880

August 2008

REV A

How to Read Your Serial Number

Serial Number Legend

The serial number plate on your T50 Super Quiet
Generator is located on the twist lock area of the
lower control panel.

Part No. 134880 T50 Super Quiet Generator

iii

August 2008

REV A

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iv

T50 Super Quiet Generator Part No. 134880

August 2008

Section 1 • Safety Rules

REV A

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.

Part No. 134880 T50 Super Quiet Generator

v

Section 1 • Safety Rules

August 2008

REV ASAFETY 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.

Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.

Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.

Yellow with safety alert symbol—
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.

Green—used to indicate operation
or maintenance information.

Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.

Be aware of potential crushing hazards
such as moving parts, free swinging or

unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.

Workplace Safety

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases
and engine fuels. Always have an approved fire
extinguisher within easy reach.

Be sure that all tools and working areas

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 your workshop or work area
is properly ventilated and well lit.

Be sure any forklift, overhead crane or
other lifting or supporting device is fully

capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample capacity.

Be sure that fasteners intended for one

time use (i.e., cotter pins and self-locking

nuts) are not reused. These components
may fail if they are used a second time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe .

vi

T50 Super Quiet Generator Part No. 134880

August 2008

REV A

Introduction

Important Information - Introduction ....................................................................

How to Read Your Serial Number ......................................................................

Parts Stocking List ............................................................................................

How to Order Parts ............................................................................................

Service Parts Fax Order Form .........................................................................

Section 1 Safety Rules

General Safety Rules ........................................................................................

Section 2 Rev Specifications

A Specifications .............................................................................................. 2 - 1

A Newage Generator ........................................................................................ 2 - 2

A Torque Specifications ................................................................................... 2 - 3

Table of Contents

ii

iii

ix

xi

xii

v

Section 3 Rev Scheduled Maintenance Procedures

Introduction .................................................................................................. 3 - 1

Pre-delivery Preparation Report .................................................................... 3 - 2

A Maintenance Schedules

Perkins Lubrication and Maintenance Service Intervals ................................ 3 - 3

John DeereLubrication and Maintenance Service Intervals ........................... 3 - 4

Newage Generators Maintenance Schedule ................................................. 3 - 5

Section 4 Rev Troubleshooting

Introduction .................................................................................................. 4 - 1

A Troubleshooting Guide ..... .......... ......... .......................................................... 4 - 2

Part No. 134880 T50 Super Quiet Generator

vii

Section 5 Rev Schematics

A Introduction .................................................................................................. 5 - 1

A Electrical Schematic - Control Panel Wiring for

Murphy Cascade Controller ......................................................................... 5 - 2

A Electrical Schematic - Control Panel for Dynagen Controller ....................... 5 - 3

A Electrical Schematic - Distribution Panel Wiring........................................... 5 - 4

A Electrical Schematic - Three Position Stack Switch Wiring .......................... 5 - 5

A Electrical Schematic - Overcurrent Relay Wiring ......................................... 5 - 6

A Electrical Schematic - Generator Wiring Breakdown.................................... 5 - 7

A Electrical Schematic - Standard Generator Wiring ....................................... 5 - 8

August 2008

REV ATABLE OF CONTENTS

viii

T50 Super Quiet Generator Part No. 134880

August 2008

REV A

Required Parts

The following parts are required to perform
maintenance procedures as outlined in the

TEREX T50 Parts and Service Manual.

Description Part No.

Perkins 1104C.44G2 Models

Oil Filter .............................................................. 741921

Air Filter .............................................. 866049 & 866048

Fuel Filter ........................................................... 741923

V-belt .................................................................. 866054

John Deere 4045DF270 Models

Oil Filter .............................................................. 741915

Air Filter .......................................................... 33100703

Fuel Filter ........................................................... 741916

V-belt .................................................................. 741942

Parts Stocking List

Part No. 134880 T50 Super Quiet Generator

ix

August 2008

REV A

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x

T50 Super Quiet Generator Part No. 134880

August 2008

REV A

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.

How To Order Parts

Genie Industries

18340 NE 76th Street
P.O. Box 97030
Redmond, WA 98073-9730
Telephone [phone]
Fax [phone]

genieindustries.com

Machine Information

Model

Serial Number

Date of Purchase

Authorized TEREX Distributor

Phone Number

Part No. 134880 T50 Super Quiet Generator

xi

Service Parts fax Order Form

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) _________________

FAX TO: [phone] OR TOLL FREE: 800-433-3026

Optional Equipment __________________________________________________________________________

Part Number Description Quantity Price

remove this page and make copies

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 ONLY

Order Number ______________ Origin Code ________________ Comments _________________________

Date Scheduled ____________ Ship Condition ______________ __________________________________

Order Total ________________ Terms Code ________________ __________________________________

T50 Super Quiet Generator Part No. 134880

remove this page and make copies

August 2008

V

Section 2 • Specifications

REV A

Specifications

MODEL T50P T50J

POWER CAPABILITY-PRIME

kVA (kilovolt-amps) 50 50
kW 40 40
3 Phase Amp Ratings

208V 139 139
240V 120 120
480V 60 60

POWER CAPABILITY-STANDBY

kVA (kilovolt-amps) 54 54
kW (kilowatts) 43 43
3 Phase Amp Ratings 208V 150 150

240V 130 130
480V 65 65

OLTAGE

3 Phase 208, 220, 240, 416, 440, 480 Standard Standard
600 Volt Optional Optional

1 Phase 120, 127, 139, 240, 254, 277 Standard Standard

Max Motor Starting1 Hp 20 20

kW 15 15

SKVA 126 126

DIESEL ENGINE

Manufacturer PERKINS JOHN DEERE
Model 1104C-44G2 4045 DF270
Cylinder 4 4
Air Intake (aspiration) Natural Natural
Cooling System Std Rad Std Rad
Fuel Capacity (gal) 80 80
Run Time (75% load) 32 31
Fuel Consumption, Prime Power (gal per hr) 100% load 3.5 3.3

75% load 2.5 2.6
50% load 1.8 1.9

25% load 1.3 1.2
dBA 64 64
Controller Type Digital/Analog Analog
Start/Stop Controller Cascade Dynagen
12V Battery (CCA) 750 750

Part No. 134880 T50 Super Quiet Generator 2 - 1

Section 2 • Specifications

August 2008

SPECIFICATIONS

MODEL T50P T50J

GENERATOR

Brushless, 4 pole, Synchronous, Single-bearing Standard Standard
1,800 rpm, Class H Insulation Generator Standard Standard
High wye, Low wy e, Zig-zag Voltage Selector Standard Standard
3 Phase Voltage: 208, 220, 240,416, 440, 480 Standard Standard
600 Volt Optional Optional
1Phase Voltage: 120, 127, 139, 240, 254, 277 Standard Standard
Convenience Receptacles: Standard Standard
2 - 20A, 120V GFCI Duplex Receptacles Standard Standard
2 - 50A Tempowers Standard Standard
AVR Voltage Regulation (+/- 1.5%) Standard Standard
Electronic (+/- 1/2%) Speed Control Governor Standard Standard
Murphy Cascade Start/Stop Controller Standard
Dynagen ES52 Start/Stop Controller Standard

TRAILER

HydraulicBrakes Standard Standard
Electric Brakes Optional Optional
Pintle Rng, 3 inch Standard Standard
Coupler Hitch, 2 inch Optional Optional
Coupler Hitch, 2 5/16 inch Optional Optional

REV A

SKID MOUNT

DIM (L x W x H - in) 88x40x53 88x40x53
Weight Dry (lbs) 3,069 3,069
Weight Full (lbs) 3,637 3,637

TRAILER MOUNT

Dim (L x W x H) 151x73x73 151x73x73
Weight Dry (lbs) 4,185 4,185
Weight Full (lbs) 4,745 4,745
1 Maximum motor size is based on 35% voltage dip at
480V AC 3 phase 60Hz with a code G motor

Standard Standard

Optional Optional

2 - 2 T50 Super Quiet Generator Part No. 134880

August 2008

Section 2 • Specifications

REV A

SIZE THREAD

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1

1.125

1.25

1.5

20
28

18
24
16
24
14
20
13
20
12
18
11
18
10
16

14

12

12

12

12

SA E FASTENER TOR Q UE CHAR T

• T his chart is t o be u sed as a gu ide only unless noted el sewh ere i n th i s manual •

Grade 5

DRYLUBED

in-lbs N m in-lbs N m in- lbs Nm in- lbs Nm in-lbs Nm

100 11.3 80 9 140 15.8 110 12.4 130 14.7

90 10.1 120 13.5 120 13.5 160 18 140 15.8

LUBED DRY LUBED DRY

ft-lbs N m ft-lbs N m ft-lbs Nm ft-lbs Nm ft-lbs Nm

13 17.6 17 23 18 24 25 33.9 21 28.4
14 19 19 25.7 20 27.1 27 36.6 24 32.5
23 31.2 31 42 33 44.7 44 59.6 38 51.5
26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
57 77.3 75 101.6 80 108.4 110 149 93 126
64 86.7 85 115 90 122 120 162 105 142
80 108.4 110 149 120 162 150 203 130 176

90 122 120 162 130 176 170 230 140 189
110 149 150 203 160 217 210 284 180 244
130 176 170 230 180 244 240 325 200 271
200 271 270 366 280 379 380 515 320 433
220 298 300 406 310 420 420 569 350 474

9

8

7

7

6

320 433 430 583 450 610 610 827 510 691
350 474 470 637 500 678 670 908 560 759
480 650 640 867 680 922 910 1233 770 1044
530 718 710 962 750 1016 990 1342 840 1139
590 800 790 1071 970 1315 1290 1749 1090 1477
670 908 890 1206 1080 1464 1440 1952 1220 1654
840 1138 1120 1518 1360 1844 1820 2467 1530 2074
930 1260 1240 1681 1510 2047 2010 2725 1700 2304

1460 1979 1950 2643 2370 3213 3160 4284 2670 3620
1640 2223 2190 2969 2670 3620 3560 4826 3000 4067

Grade 8

A574 High Strength

SPECIFICATIONS

Black Oxide Bolts

LUBEDDRYLUBED

LUBED

METRIC FASTENER TORQUE CHART

• T his chart is t o be u sed as a guid e only unless noted el sewh ere i n th is manu al •

Size

(mm)

in-lbs N m in-lbs Nm in-lbs N m in-lbs N m in-l bs N m in-lbs N m in-lbs Nm in-lbs N m

16 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3

5

19 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6

6

45 5.12 60 6.83 116 13.2 155 17.6 167 18.9 223 25.2 1.95 22.1 260 29.4

7

ft-lbs N m ft-lbs N m ft-lbs N m ft-lbs N m ft-lbs N m ft-lbs N m ft-lbs N m ft-lbs N m

5.4 7.41 7.2 9.88 14 19.1 18.8 25.5 20.1 27.3 26.9 36.5 23.6 32 31.4 42.6

8

10.8 14.7 14.4 19.6 27.9 37.8 37.2 50.5 39.9 54.1 53.2 72.2 46.7 63.3 62.3 84.4

10

18.9 25.6 25.1 34.1 48.6 66 64.9 88 69.7 94.5 92.2 125 81 110 108 147

12

30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234

14

46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365

16

64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503

18

91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713

20

124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970

22

157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

24

DRYLUBED

Class 10.9Class 8.8

LUBEDDRYLUBED

LUBED DRY LUBED DRYLUBED DRY LUBED DRY

10.9 12.98.84.6

DRY

Part No. 134880 T50 Super Quiet Generator 2 - 3

Class 12.9Class 4.6

LUBED DRY

Section 2 • Specifications

GENERATOR TORQUE SPECIFICATIONS

Generator FT*LB

Flex Plate to Flywheel 32-44
Generator Case to Bellhousing 60
1/2" Socket Head Cap Screws for Lifting Channel 1 26
1/2-13" Hex Head Screws for Lifting Channel 120
Genset Isolators 78

August 2008

2 - 4 T50 Super Quiet Generator Part No. 134880

August 2008

Section 3 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

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.

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

Failure to perform each procedure
as presented and scheduled could
result in death, serious injury or
substantial damage.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating the machine.

Keep records on all inspections for three years.

Machines that have been out of service for a

period longer than 3 months must complete the
quarterly inspection.

Unless otherwise specified, perform each

maintenance procedure with the machine in the
following configuration:

· Machine parked on a firm, level surface

· Toggle switch in the "OFF" position

· Wheels chocked

.

Symbols Legend

Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.

Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.

Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.

Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.

Used to indicate operation or
maintenance information.

Indicates that a specific result is expected after

performing a series of steps.

Indicates that an incorrect result has occurred

after performing a series of steps.

Part No. 134880 T50 Super Quiet Generator 3 - 1

Pre-DeliverPre-Deliver

Pre-Deliver

Pre-DeliverPre-Deliver

y Preparationy Preparation

y Preparation

y Preparationy 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 performed by
qualified service technicians, according to the
manufacturer's specifications and the requirements listed
in the responsibilities manual.

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completing the
Pre-operation Inspection, the Maintenance items and the
Function Tests.

Use this form to record the results. Place a check in the
appropriate box after each part is completed. Follow the
instructions in the operator’s manual.

If any inspection receives an N, remove the machine from
service, repair and re-inspect it. After repair, place a check
in the R box.

Legend

Y = yes, completed
N = no, unable to complete
R = repaired

Comments

TEREX North America

P.O. BOX 3147
Rock Hill, SC 29732 USA

Toll Free [phone] in U.S.A. and Canada

Copyright © 2006 by TEREX Corporation. TEREX® is a registered trademark of TEREX
Corporation.
Rev B

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 3 • Scheduled Maintenance Procedures

REV A

Maintenance Schedules

Perkins Lubrication and Maintenance Service Intervals

ITEM

Inspect, adjust or replace alternator or fan belt
Check cooling system coolant level
Check driven equipment
Inspect engine air cleaner service indicator
Check engine oil level

Drain fuel system primary filter/water
separator

Walk around inspection
Drain tank water and sediment
Check battery electrolyte level
Clean/replace engine air cleaner element
Inspect/clean engine ground
Change engine oil and filter
Replace water separator element
Replace fuel system secondary filter
Inspect/replace hoses and clamps
Inspect/adjust engine valve lash
Inspect aftercooler core
Inspect alternator
Inspect engine mounts
Inspect starting motor
Inspect turbocharger
Inspect water pump

DAILY

•

•

•

•

•

•

•

50 Hrs or

Wkly

•

500 Hrs or

12 Mths

•

•

•

•

•

•

•

1000 Hrs 2000 Hrs

•

•

•

•

•

•

•

•

3000 Hrs or

2 Yrs

•

4000 Hrs

ITEM

Change cooling system coolant
Test/change fuel injector

Change cooling system coolant
(commer cial heavy duty)
Clean/test aftercooler core
Add cooling system coolant extender (ELC)
Change cooling system coolant (ELC)

*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. 134880 T50 Super Quiet Generator 3 - 3

2 Yrs 3000 Hrs

•

•

6000 Hrs or

3 Yrs

•

12000 Hrs

or 6 Yrs

•

Section 3 • Scheduled Maintenance Procedures

John Deere Lubrication and Maintenance Service Intervals

August 2008

REV A

ITEM

Operate engine at rated speed and 50%-70%
load a minium of 30 minutes

Check engine oil and coolant level
Check fuel filter/water separator bowl

Check air cleaner dust unloader valve and
indicator

Perform visual walk around inspection
Change engine oil and replace filter
Check engine mounts
Service battery
Clean crankcase vent tube

Check air intake hoses, connections and
system

Replace single or dual fuel filter elements
Check belt tensioner and belt wear
Check engine speeds
Check engine electrical ground connection
Check cooling system

Coolant solution analysis-add SCAs as
required

Pressure test cooling system
Check variable speed (droop) (gensets)
Flush cooling system
Test thermostats
Check and adjust engine valve clearance
Add coolant
Replace air cleaner elements
Replace poly-vee belt
Checkfuses
Check air compressor (if equipped)
Bleed fuel system

Every 2

Weeks

•

•

•

•

•

250 Hrs or

12 Mths

•

•

•

500 Hrs or

12 Mths

•

•

•

•

•

•

•

•

•

2000 Hrs or

12 Mths

•

•

•

•

As Req.

•

•

•

•

•

•

*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 T50 Super Quiet Generator Part No. 134880

August 2008

REV A

Section 3 • Scheduled Maintenance Procedures

Newage Maintenance Service Intervals

MAINTENANCE SCHEDULES CONTINUED

250 Hours

ITEM

Visual inspection
Visual inspection plus running audible check

Measure stator winding insulation resistance
and record

Monitor bearing/s condition
Remove terminal box lid and check
connections

Re-grease bearings
Measure vibration levels
Replace bearing/s
Replace NDE o-ring
Inspect bearing housings
Inspect winding conditions
Inspect rotating diode assembly

*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.

DAILY

•

or 3

Months

•

1500 Hours

or 12

Months

•

•

•

4500 Hours

or 3 Years

•

15000

Hours or 19

Years

•

•

•

•

•

•

Part No. 134880 T50 Super Quiet Generator 3 - 5

Section 3 • Scheduled Maintenance Procedures

August 2008

REV A

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3 - 6 T50 Super Quiet Generator Part No. 134880

Section 4 • TroubleshootingAugust 2008

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.

Unless otherwise specified, perform each

repair procedure with the machine in the
following configuration:

· Machine parked on a firm, level surface.

· Wheels chocked.

· Toggle switch in "OFF" position.

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.

Be aware of the following hazards and follow

generally accepted safe workshop practices.

Electrocution hazard. Exposure to
electrically charged circuits could
result in death or serious injury.
Remove all rings, watches and
other jewelry.

Electrocution hazard. Attempting
to sevice the machine before the
capacitors are fully discharged will
result in death or serious injury.

High voltage. Exposure to
electrical wires or electrical current
will result in death or serious
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.

Burn hazard. Contact with hot
engine components may cause
severe burns. Use caution when
working around a hot engine.

Part No. 134880 T50 Super Quiet Generator 4 - 1

Section 4 • Troubleshooting August 2008

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.

FAULT POSSIBLE CAUSE SOLUTION

No generator output voltage Circuit breaker tripped Reset circuit breaker

Voltage regulator Check voltage regulator wiring
Defective voltage regulator Replace voltage regulator
Defective Selector Switch By pass by hardwiring generator
Defective generator Refer to generator manual

Low generator output voltage Voltage adjustment Adjust voltage potentiometer

set too low
Defective potentiometer By pass or replace
Low engine speed Call TEREX Service
Loose wire on voltage Check wiring

selector switch
Fluctuating or surging Check engine fuel, oil,

engine speed and air filters
Loose wire on voltage Check wiring

regulator sensing circuit
Defective voltage regulator Replace voltage regulator

High generator Voltage adjustment Adjust potentiometer
output voltage potentiometer

High engine speed Call TEREX Service

4 - 2 T50 Super Quiet Generator Part No. 134880

Section 4 • TroubleshootingAugust 2008

FAULT POSSIBLE CAUSE SOLUTION

High generator Defective automatic Replace voltage
output voltage voltage regulator regulator

Loose wire on voltage Check wiring
adjustment potentiometer

Neutral binding strap Install neutral binding strap
not in place.

Fluctuating generator An “ON/OFF” type Redistribute load if
output voltage load may be the cause possible

Fluctuating or surging Check engine fuel, oil,
engine speed and air filters

Loose wiring in generator Check connections

TROUBLESHOOTING

Automatic voltage regulator Call TEREX Service
stability setting may be
wrong

Loose wire on the automatic Check wiring
voltage regulator sensing lead

Low engine speed Engine speed adjustment Call TEREX Service

has slipped
Clogged fuel system Check for air leaks, clogged fuel

filter, kinked fuel line, or

clogged fuel pick-up tube
Blocked air intake Check air filter
Blocked exhaust system Check engine exhaust

system, remove

obstructions
Contaminated fuel Check fuel/water separator and

fuel tank for contamination.

Replace fuel if needed
Defective governor on engine Call TEREX Service

Part No. 134880 T50 Super Quiet Generator 4 - 3

Section 4 • Troubleshooting August 2008

TROUBLESHOOTING

FAULT POSSIBLE CAUSE SOLUTION

Low Speed Defective injectors on engine Have injectors checked by a

qualified technician

“Surging” engine speed Check engine fuel, oil,

and air filters

Engine turns over (cranks), Unit out of fuel Check fuel level in tank, fill as
but won’t run needed

Loose or broken wire in Check wiring to verify 12V DC
control circuit fuel injection is being supplied to the pump
pump solenoid solenoid

Defective solenoid Replace solenoid
Clogged fuel system Check fuel system
Air in fuel system “Bleed” fuel system
Defective fuel pump Check and replace if defective
Clogged air intake Check air cleaner
Clogged exhaust Check exhaust system
Contaminated fuel Check fuel/water separator and

tank for contamination

Defective injectors Have injection system checked

by a trained technician

Lost engine compression Have compression checked by

a trained technician

Engine won’t crank Loose battery cable Check cables and battery

or discharged battery electrolyte level. Recharge

as necessary

4 - 4 T50 Super Quiet Generator Part No. 134880

Section 4 • TroubleshootingAugust 2008

TROUBLESHOOTING

FAULT POSSIBLE CAUSE SOLUTION

Engine won’t crank Engine “ON/OFF” switch Check switch position

set in “OFF” position
Blown fuse in DC Replace with 25 Amp.

control circuit SLO-BLO TYPE

fuse if needed.
E-Stop Check to see if engaged
Defective starter Replace solenoid

solenoid
Defective starter Replace starter
Seized engine Have engine checked by a

qualified technician

Engine runs, but loses Unit is overloaded Reduce load
speed

Improper connection Check or Call TEREX Service

Engine runs, but loses Clogged fuel system Check fuel system
power under load air in fuel lines

Blocked air intake Check air cleaner
Blocked exhaust Check exhaust system
Contaminated fuel Check fuel/water separator and

fuel tank for contamination
Faulty governor, defective Have unit checked by a

injectors, or defective fuel trained service technician
pump for all of these items

Engine shuts down Oil Pressure Switch Not opening
automatically and
TROUBLE LIGHT on Improper coolant Use a 50/50 on
CONTROL PANEL or water mixture mix of water and
is illuminated anti-freeze only

Part No. 134880 T50 Super Quiet Generator 4 - 5

Section 4 • Troubleshooting August 2008

TROUBLESHOOTING

FAULT POSSIBLE CAUSE SOLUTION

Engine shuts down Overloaded engine Reduce load
automatically and
TROUBLE LIGHT on Broken fan belt Inspect fan belt and replace as
CONTROL PANEL needed
is illuminated

Defective thermostat or Inspect thermostat
thermocouple switch switch

Defective water pump Inspect water pump and replace

if needed

Blocked cooling air inlet Inspect and remove any
or exhaust obstructions

Defective or grounded Inspect switch and repair or
temperature switch replace

Defective injectors or Have the engine inspected by a
injector pump trained service technician

Defective oil pump Have the engine inspected by

a trained service technician

Defective or grounded oil Inspect switch and repair or
pressure switch 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 T50 Super Quiet Generator Part No. 134880

Section 4 • TroubleshootingAugust 2008

TROUBLESHOOTING

Electrical Troubleshooting

5 Components that cause voltage
related problems

Potentiometer

Connects to voltage regulator. Bypass potentiom­eter 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 & 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 function­ing 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.

Generator

Test resistance of field, stator and exciter windings.
Contact TEREX for procedures or repair facility
recommended by generator manufacturer.

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 INSTRU­MENTS 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" GENERA­TOR UNLESS THERE IS ANOTHER COMPE­TENT PERSON PRESENT WHO CAN SWITCH
OFF THE POWER SUPPLY OR SHUT DOWN
THE ENGINE IN AN EMERGENCY.

NEVER EXPOSE "LIVE" CONNECTIONS UN­LESS YOU HAVE CREATED A SAFE WORKING
AREA AROUND YOU. MAKE SURE YOU HAVE
MADE ALL OTHER PERSONS IN THE IMMEDI­ATE AREA FULLY AWARE OF WHAT YOU ARE
DOING.

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 3­phase door switch and will automatically trip the 3­phase breaker when the door is open and pre­vents the breaker from being reset while it is open.

Part No. 134880 T50 Super Quiet Generator 4 - 7

• 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!).

TROUBLESHOOTING

Section 4 • Troubleshooting August 2008

Procedure for testing
generator with no output
(cont.)

• After performing the initial checks above,
remove the field wires from the voltage
regulator (F1 or X is positive and F2 or XX is
negative). Connect the battery + to the F1 or X
wire and battery - to the F2 or XX wire. Start the
engine and check for the rated voltage.

Hooking this up incorrectly will reverse
polarity and could damage the voltage
regulator and /or generator end. This check

should correct any voltage problems. If your
voltage does not come up to the rated voltage,
this indicates an internal problem with the
generator end. The output should be close to
proper voltage. Also, if the unit comes up to
voltage, check for even reading across the lines
if they are not this would mean you probably
have a problem with the wiring of the switch or
generator. If the generator voltage reads
correctly you know there is not a problem with
the generator end. Your problem is more than
likely with the voltage regulator. In this case,
you should contact the TEREX service
department.

• If the voltage is uneven between the legs when
you apply 24 volts to the field wires you need to
recheck your wiring connections. (If you can

not find the problem hard wire the
generator!) After you have the field wire

connected start the unit again and check your
output voltage. It may still be necessary to flash
the fields to restore residual voltage. This needs
to be done with the unit off and the field wires
removed. (Do not flash the regulator, flash

the field wires)

• 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.

INSTALLATION AND ANY WORK PERFORMED
ON THIS UNIT SHOULD BE DONE ONLY BY A
QUALIFIED ELECTRICIAN.

Procedure for changing the
voltage potentiometer

THIS EQUIPMENT USES HIGH VOLTAGE
CIRCUITS CAPABLE OF CAUSING SERIOUS
INJURY OR DEATH! EXCERCISE EXTREME
CAUTION AROUND ANY ELECTRICAL
COMPONENT WHEN OPERATING THIS UNIT.

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.

• Disconnect both wires.

• 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 the disconnected wires that were
disconnected in step 3.

• 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.

4 - 8 T50 Super Quiet Generator Part No. 134880

August 2008

Section 5 • Schematics

REV A

Observe and Obey:

Troubleshooting and repair procedures shall be

completed by a person trained and qualified on
the repair of this machine.

Immediately tag and remove from service a

damaged or malfunctioning machine.

Repair any machine damage or malfunction

before operating the machine.

Before Troubleshooting:

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.

Schematics

About This Section

There are two groups of schematics in this section.
An illustration legend precedes each group of
drawings.

Electrical Schematics

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
discovered

Return to

service

still exists

problem

solved

Identify

symptoms

problem

Inspect

and test

Troubleshoot

Perform

repair

Part No. 134880 T50 Super Quiet Generator 5 - 1

Control Panel Wiring

for Murphy Cascade Controller
Drawing #ES1000001 (Standard)

Section 5 • Schematics

August 2008

REV A

5 - 2 T50 Super Quiet Generator Part No. 134880

August 2008

REV A

Section 5 • Schematics

Control Panel Wiring

for Dynagen Controller

Drawing #EU0007

Part No. 134880 T50 Super Quiet Generator 5 - 3

Distribution Panel Wiring

for "D" Series Single Phase Control
Drawing #ES1000003

Section 5 • Schematics

August 2008

REV A

5 - 4 T50 Super Quiet Generator Part No. 134880

August 2008

REV A

Section 5 • Schematics

Three Position Stack Switch Wiring

Drawing #ES1000005

Part No. 134880 T50 Super Quiet Generator 5 - 5

Overcurrent Relay Wiring

Drawing #ES1000006

Section 5 • Schematics

August 2008

REV A

5 - 6 T50 Super Quiet Generator Part No. 134880

August 2008

REV A

Section 5 • Schematics

Generator Wiring Breakdown

Drawing #ES1000007

Part No. 134880 T50 Super Quiet Generator 5 - 7

Standard Generator Wiring

for "D" Series
Drawing #ES1000008

Section 5 • Schematics

August 2008

REV A

5 - 8 T50 Super Quiet Generator Part No. 134880

Before Towing

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 Checkli st

(Use at each stop)

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

Genie North America

Phone [phone]

Toll Free USA and Canada

800.536.1800

Fax [phone]

Genie Australia Pty Ltd.

Phone [phone]

Fax [phone]

Genie China

Phone [phone]

Fax [phone]

Genie Malaysia

Phone [phone]

Fax [phone]

Genie Scandinavia

Phone [phone]

Fax [phone]

Genie France

Phone [phone]

Fax [phone]

Before Driving

On The Road

· Fasten safety restraints

· Properly adjust mirrors

· 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 Japan

Phone [phone]

Fax [phone]

Genie Korea

Phone [phone]

Fax [phone]

Genie Brasil

Phone [phone]

Fax [phone]

Genie Holland

Phone [phone]

Fax [phone]

Genie Iberica

Phone [phone]

Fax [phone]

Genie Germany

Phone [phone]

Fax [phone]

Genie U.K.

Phone [phone]

Fax [phone]

Genie Mexico City

Phone [phone]

Fax [phone]

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