Page 1
Operator/Service & Parts Manual
T270/T280
First Edition
Rev A1
Part No. 833018
Page 2
Serial Number Registration
Serial Number Registration............................................................................... 4
Introduction
Introduction....................................................................................................... 5
Description of Equipment.................................................................................. 5
Operator's Manual
Table Of Contents
May 2007
REV A
General Safety
Operating Instructions
Hazard Classification ........................................................................................ 6
Safety Sign Locations ....................................................................................... 7
Accident Prevention.......................................................................................... 8
Unauthorized Welding....................................................................................... 8
Fueling.............................................................................................................. 8
Electrical Safety ................................................................................................ 9
Battery Hazards................................................................................................ 9
Beware of Traffic Hazards ................................................................................ 9
Receipt of Delivery Checklist .......................................................................... 10
Transport & Towing ........................................................................................ 11
Setup .............................................................................................................. 11
Starting the Engine/Generator Set .................................................................. 13
Loading Instructions........................................................................................ 14
Voltage Selector Switch Operation ................................................................. 14
Potentiometer (Voltage Adjustment) ............................................................... 16
Murphy Cascade Controller ............................................................................ 16
Murphy iGuard Controller................................................................................ 16
2 T270 & T280 Super Quiet Generator Part No. 833018
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May 2007
REV A
Operating Instructions (Continued)
Overcurrent Protection.................................................................................... 17
Shutdown Procedures .................................................................................... 17
Wet Stacking .................................................................................................. 18
Torque Specifications
SAE Fastener Torque Chart ........................................................................... 19
Metric Fastener Torque Chart......................................................................... 19
Generator Torque Specifications .................................................................... 20
Operator's Manual
Part No. 833018 T270 & T280 Super Quiet Generator 3
Page 4
Operator's Manual
May 2007
REV A
SERIAL NUMBER REGISTRATION
TEREX Model Number _____________________ Serial Number ____________________________
Engine Model Number______________________ Serial Number ____________________________
Generator Model Number ___________________ Serial Number ____________________________
Owner:__________________________________ Ship to: _________________________________
Options:_________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
This Operation and Service Manual contains information specifically pertaining to the operation and
maintenance of the TEREX Super Quiet Generators. We suggest that you read this manual carefully prior
to operating the generator. This manual should be retained and refered to for operation, maintenance and
ordering parts. When ordering parts, PLEASE INCLUDE THE MODEL AND SERIAL NUMBER located
on the nameplate of the generator . For major repair and service or other information, contact your
TEREX dealer, or call or write to:
P.O. Box 3147 (29732)
590 Huey Road
Rock Hill, SC 29730
Telephone: (800) 433-3026
FAX: (803) 366-1101
4 T270 & T280 Super Quiet Generator Part No. 833018
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May 2007
REV A
Operator's Manual
INTRODUCTION
Owners, Users, and Operators:
TEREX appreciates your choice of our product for
your application. Our number one priority is user
safety which is best achieved by our joint efforts.
We feel that you can make a major contribution to
safety if you as the equipment users and operators:
• Comply with OSHA, Federal, State, and Local
Regulations.
• Read, Understand, and Follow the
instructions in this and other manuals supplied
with this product.
• Use Good, Safe Work Practices in a common
sense way.
• Only have trained operators — directed by
informed and knowledgeable supervision —
operating this product.
If there is anything in this manual that is not clear
or which you believe should be added, please
send your comments to TEREX Service Department in Rock Hill, SC.
The engine is equipped with a 12-volt starter and
can be wired for remote starting capability at the
control panel.
A dry-element air cleaner is standard equipment to
ensure a clean air supply, and a remote fuel/water
separator is included for additional fuel system
protection.
The ECM (Engine Control Module) on the engine
provides a stable operating speed under varying
load conditions, and the generator is equipped
with a solid-state voltage regulator to stabilize the
output voltage under these same conditions.
Figures and schematics of both the ECM and
regulator are provided in the ENGINE and GEN-
ERATOR OPERATOR’S MANUALS.
An automatic shutdown system is incorporated in
the generator set to sense low oil pressure, high
coolant temperature, as well as overspeed and
underspeed conditions. In each case the engine/
generator assembly will automatically cease
operation.
A diesel fuel tank is incorporated within the base
of the unit to ensure an uninterrupted operating
cycle under full load. The engine/generator
assembly is mounted to the base using high
durometer vibration isolators.
THE SAFETY ALERT SYMBOL IS USED TO
ALERT YOU TO POTENTIAL PERSONAL
INJURY HAZARDS. OBEY ALL SAFETY
MESSAGES THAT FOLLOW THIS SYMBOL
TO AVOID POSSIBLE INJURY OR DEATH.
DESCRIPTION OF EQUIPMENT
The engine/generator assembly consists of a
diesel engine combined with an electrical generator. This assembly is firmly bolted together to form
an integral unit and does not require anything
other than routine maintenance.
Part No. 833018 T270 & T280 Super Quiet Generator 5
The enclosure for the generator set is constructed
from 12 or 14-gauge sheet metal to ensure
maximum rigidity, and is bolted together to allow
easy access to major components if necessary.
Four lockable, hinged access doors are provided
for routine operation and maintenance.
The enclosure on the Super Quiet Generator is
specifically designed for a high degree of sound
attenuation. This allows the generator set to be
operated in noise-sensitive environments. The
interior of the enclosure is coated with sounddampening polymer foam that is highly effective in
noise suppression.
A high ambient temperature radiator and a critical
grade exhaust silencer are contained within the
Page 6
Operator's Manual
DESCRIPTION OF EQUIPMENT (Cont.)
enclosure as standard equipment.
A center-point lifting attachment is located in the
top of the enclosure to allow crane lifting of the
entire unit.
The generator set is mounted on a trailer equipped
for highway operation. Hydraulic surge brakes are
standard on larger generator sets for maximum
stopping efficiency. Electric brakes are also
available as an option.
GENERAL SAFETY
HAZARD CLASSIFICATION
A multi-tier hazard classification system is used to
communicate potential personal injury hazards.
The following signal words used with the safety
alert symbol indicate a specific level of severity of
the potential hazard. Signal words used without
the safety alert symbol relate to property damage
and protection only. All are used as attentiongetting devices throughout this manual as well as
on decals and labels fixed to the machinery to
assist in potential hazard recognition and prevention.
Red - Indicates an
imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
May 2007
REV A
Yellow without safety
alert symbol - Indicates a
situation which, if not avoided, may result in
property or equipment damage.
Green - Indicates impor-
tant installation, operation
or maintenance information.
Hazardous voltage. Will cause
serious injury or death.
Hot exhaust. Can contain carbon
monoxide. Will cause serious injury
or death.
Read all manuals that shipped with
your equipment. Maintenance is
done more easily and safely when
you know what you're doing.
Keep all guards in place.
Orange - Indicates a
potentially hazardous
situation which, if not avoided, could result in
death or serious injury.
Yellow with safety alert
symbol - Indicates a
potentially hazardous situation which, if not
avoided, may result in minor or moderate injury.
6 T270 & T280 Super Quiet Generator Part No. 833018
Wear hearing protection when you
are near this equipment.
Lockout and Tagout. Equipment may
be energized. Lockout and tagout all
energy sources prior to performing
maintenance adjustments.
Page 7
May 2007
REV A
SAFETY SIGN LOCATIONS
Operator's Manual
GENERAL SAFETY (Cont.)
Part No. 833018 T270 & T280 Super Quiet Generator 7
Page 8
GENERAL SAFETY (Cont.)
Operator's Manual
May 2007
REV A
ACCIDENT PREVENTION
Use protective clothing and safety equipment.
Always wear approved safety equipment such as
gloves, safety boots, safety hard hat, goggles, ear
protection, and dust masks when necessary.
Wear protective clothing that is snug and belted
where required.
UNAUTHORIZED WELDING
UNAUTHORIZED WELDING CAN CAUSE
STRUCTURAL FAILURE OR PERSONAL
INJURY.
DO NOT weld on any structural member.
FUELING
ALWAYS handle fuel with care. It is highly
flammable.
ALWAYS stop engine before refueling. Fill
fuel tank outdoors.
DO NOT replace fuel lines with materials
different from those supplied as original
equipment.
FIRES CAN CAUSE SEVERE PERSONAL
INJURY OR MACHINE DAMAGE.
Prevent fires by keeping the generator and its
surrounding area clean.
DO NOT refuel while smoking or when near
open flame or sparks.
DO NOT refuel the engine when it is hot.
Allow to cool for several minutes before
refueling.
DO NOT spill fuel inside the engine compartment.
If fuel has leaked, wipe it up and have leak
repaired before next use.
Any unauthorized welding or repair procedure
will void the warranty.
8 T270 & T280 Super Quiet Generator Part No. 833018
ALWAYS have a fire extinguisher nearby. Be sure
the extinguisher is properly maintained and be
familiar with its use. Extinguishers rated ABC
by the NFPA are appropriate for all applications.
EXHAUST GASES ARE TOXIC. DO NOT USE
INDOORS UNLESS PROPERLY VENTILATED
OR AN EXHAUST SCRUBBER IS USED.
Check exhaust system regularly for leaks and
ensure that the exhaust manifolds are secure and
not warped. Make sure the unit is well ventilated.
Page 9
May 2007
REV A
Operator's Manual
GENERAL SAFETY (Cont.)
ELECTRICAL SAFETY
THIS EQUIPMENT USES HIGH VOLTAGE CIRCUITS CAPABLE OF CAUSING SERIOUS INJURY OR DEATH. EXERCISE EXTREME CAUTION
AROUND ANY ELECTRICAL COMPONENT
WHILE OPERATING THIS UNIT.
Always ground the unit according to local
codes. A grounding lug is provided for your
convenience.
Beware of cut or damaged power cords. Have a
qualified electrician replace any damaged cords
immediately.
DO NOT TOUCH HOT PARTS.
The exhaust manifold and tail pipe are very hot.
Parts of the engine are also hot. Use protective
gloves when handling hot parts.
BATTERY HAZARDS
DO NOT remove the vent caps when charging the
battery.
Always wear eye protection when servicing the
battery.
If acid gets on skin or eyes, immediately flush
under running water and obtain medical
attention.
KEEP ALL BODY PARTS AND CLOTHING
AWAY FROM MOVING PARTS.
Loose jackets, shirts, sleeves, jewely and especially neckties should not be worn while working
on or running the unit.
Only remove guards or protective devices from
unit temporarily to gain access for maintenance.
Always replace guards immediately after servicing. Never remove guards while unit is operating.
Keep your hands away from moving parts, particularly clear of the radiator fan and alternator belts
when the engine is running.
LEAD ACID BATTERIES CAN BE DANGEROUS. THE SULFURIC ACID IN THE BATTERY
CAN CAUSE SEVERE SKIN AND EYE BURNS.
THE HYDROGEN GAS EMITTED DURING
CHARGING CAN EXPLODE IF AN ARC OR
FLAME IS PRESENT.
DO NOT smoke while servicing the battery.
DO NOT allow tools to touch battery terminals and
create an arc.
Disconnect the negative terminal of the battery
when working on the engine or other parts to
prevent accidental arcing. Disconnect the negative
cable at the end away from the battery.
Part No. 833018 T270 & T280 Super Quiet Generator 9
Stand clear of traffic when starting or checking the
unit along the road.
Check the fuel tank, oil pan, and fuel and oil lines
for leaks that would spill fuel or oil on the road.
Check fasteners and mounting brackets periodically to insure all are tight and nothing is in danger
of falling off during transit.
BEWARE OF TRAFFIC HAZARDS
Page 10
GENERAL SAFETY (Cont.)
Operator's Manual
May 2007
REV A
BE CAREFUL WHEN LIFTING. NEVER SUSPEND ANY OTHER EQUIPMENT FROM THE
SHIPPING TIE DOWNS.
Use the lifting lug for lifting the trailer (with cabinet). Make sure any tie-downs at the bottom of the
trailer are released prior to lifting.
RECEIPT OF DELIVERY
CHECKLIST
The generator will be serviced, tested and ready
for operation upon delivery. Terex recommends
the following checks:
Insure there is no freight handling damage
which should be charged against the
carrier.
Check the front jack for security and proper
operation.
Check that the tires are not damaged, under
inflated or that any lugs are loose.
Check the engine/generator for obvious
damage, loose connections, or leaks.
Check the control panel for damage or loose
connections.
Check the exhaust system for damage.
NEVER CLIMB ON TOP OF THE CABINET.
10 T270 & T280 Super Quiet Generator Part No. 833018
Check all fluid levels; battery, radiator, and
engine oils.
Ensure manuals are in the pocket provided
inside the unit.
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May 2007
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Operator's Manual
TRANSPORT & TOWING
All trailer-mounted Terex Super Quiet generators
are designed for highway and off road towing
capability. Please consult state and local transportation codes before transporting the generator set.
Additionally, all state and local traffic laws take
precedence over the following instructions whenever differences arise between them.
• Make sure the towing vehicle is of adequate
size to both tow and stop the unit.
• Disconnect all wiring and cabling (including the
ground wire) from the generator set.
GENERAL SAFETY (Cont.)
• Check the tires for proper inflation and verify
that the lug nuts are tight.
• If equiped with towing lights, connect the
electrical coupler to the towing vehicle.
• Observe posted speed limits for trailers.
Generally, do not exceed 45 mph on paved
roads and 10 mph on unpaved roads.
EXCEEDING THESE RECOMMENDED SPEEDS
CAN CAUSE SEVERE DAMAGE TO THE UNIT.
DAMAGE CAUSED BY THESE
UNSAFE PRACTICES WILL VOID THE MANUFACTURER’S WARRANTY.
• Close and latch or lock all access doors.
• Using the front leveling jack, raise the trailer
hitch to an adequate height so that the
generator can be securely attached to the
transporting vehicle.
• Ensure that the coupler is properly secured to
the towing vehicle and attach the safety chains.
Attach the “breakaway” chain on the surge
brake and the electrical coupler if these options
are included on the unit.
ALWAYS USE THE PROPER TRAILER HITCH
AND SAFETY CHAINS. OBEY ALL
LOCAL OR STATE D.O.T. LAWS WHEN TOWING A GENERATOR.
FAILURE TO PROPERLY SECURE THE TRAILER TO THE TOWING VEHICLE MAY
RESULT IN SERIOUS INJURY OR DEATH.
• Retract the front leveling jack into its stowed
position.
SETUP
Move the generator set to the desired location
keeping the following in mind:
• The spot where the generator set is positioned
should be relatively level.
• The location selected should be centrally
located to equipment requiring the loads to
minimize voltage drop in the power cord.
• Locate so power cords can be routed without
crossing roads and access routes.
• Locate where the engine will get good
ventilation. Do not locate where fumes will enter
a building.
• Do not place beside a building wall that would
reflect and intensify noise.
Unhitch from the towing vehicle as follows:
• Locate the generator set in the desired location.
Part No. 833018 T270 & T280 Super Quiet Generator 11
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Operator's Manual
SETUP (Cont.)
• If the axle is sloped downhill, turn the generator
set so that the axle is level.
May 2007
REV A
NEVER REMOVE THE RADIATOR CAP WHILE
THE ENGINE IS RUNNING OR WHILE THE
ENGINE IS HOT.
• ALWAYS chock the wheels of the generator
set.
• Unhook hitch, safety chains and running lights.
• Release the hitch pin and raise the tongue off
the towing vehicle.
• Level the generator set with the tongue jack.
THE WHEELS MUST BE PROPERLY CHOCKED
IF THE GENERATOR IS ON UNLEVEL
GROUND. DO NOT OPERATE THE GENERATOR SET UNTIL IT HAS BEEN PROPERLY SECURED.
When preparing to start the generator set, follow
the sequence listed below:
• Check the oil level in the engine crankcase, and
add as required.
USE CLASS API, CC OR CD GRADE ENGINE
OIL. REFER TO THE ENGINE MANUFACTURER'S MANUAL FOR VISCOSITY AND QUANTITY.
• If the battery is not a maintenance free battery,
check the electrolyte level in the battery and
add distilled water if necessary.
• Check fuel/water separator for water in the fuel
system. Drain water from separator if
necessary.
• Check fuel level in the fuel tank and add as
required. Check to insure the fuel tank vent is
“open” and not clogged.
USE #2 DIESEL FUEL ONLY.
• Verify that the generator main circuit breaker is
in the “OFF” position.
• Make sure the generator set is properly
grounded. This is accomplished by connecting
the grounding lug provided at the rear of the
generator set enclosure to a mechanical
earthground with a minimum 2/0 size #4 bare
electrical cable. If this differs from your local
code, always follow the local code for
grounding.
THIS GENERATOR SET PRODUCES VOLTAGES THAT CAN CAUSE SEVERE SHOCK OR
DEATH! ONLY QUALIFIED ELECTRICIANS
SHOULD PERFORM ELECTRICAL WORK.
• Check the coolant level in the radiator, and add
as necessary. If adding coolant, use only a
50/50 mixture of antifreeze and water. Refer to
your engine manufacturer's maintenance
manual for specific antifreeze information.
12 T270 & T280 Super Quiet Generator Part No. 833018
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May 2007
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Operator's Manual
OPERATING INSTRUCTIONS
STARTING THE ENGINE/
GENERATOR SET
NEVER ATTEMPT TO START THE GENERATOR SET WITH ANY OF THE CIRCUIT BREAKERS "ON". THESE BREAKERS ARE LOCATED
ON THE CONTROL PANEL. STARTING WITH
THE BREAKERS "ON" CAN CAUSE DAMAGE
TO THE GENERATOR.
Once setup procedures are completed, the
generator set is ready to be started. Start the
unit according to the following steps:
• Make sure the GENERATOR VOLTAGE
SELECTOR SWITCH has been set to the
proper range.This switch should be located
above the 3-phase distribution panel.
(DISREGARD IF THE UNIT DOESN’T HAVE
A SELECTOR SWITCH. THIS UNIT IS
PRESET FOR ONE VOLTAGE. SEE NAME
TAG.)
NEVER CHANGE THE POSITION OF THE
VOLTAGE SELECTOR SWITCH WHILE THE
GENERATOR IS RUNNING! THIS WILL
RESULT IN IMMEDIATE DAMAGE TO THE
SWITCH, THE GENERATOR, OR THE
CONNECTED EQUIPMENT. IT MAY RESULT
IN SERIOUS INJURY TO THE OPERATING
PERSONNEL.
For Cascade Equipped Generators:
• Place the toggle switch in "ON" position then
press the MANUAL ("MAN") BUTTON on the
Cascade Controller. Make sure all debris and
obstructions have been cleared from moving
parts and electrical terminals. The generator will
only make 3 attempts at starting before it must
be reset with the switch.
For iGuard Equipped Generators:
• Place the toggle switch in "ON" position then
press the START BUTTON on the iGuard
Controller. Make sure all debris and
obstructions have been cleared from moving
parts and electrical terminals. The generator will
only make 3 attempts at starting before it must
be reset with the switch.
• Now that the generator set is running, allow five
minutes for warm-up time.
• Listen for any unusual sounds or excess
vibrations that could signal problems and
require immediate shutdown of the unit. Should
unusual sounds be detected, shut the unit
down, and contact TEREX Service.
• Once the engine has been started and running
smoothly, the following gauges should be
monitored. All gauges are located on the control
panel.
• Oil Pressure Gauge - This gauge should read
30 psi or higher.
• Coolant Temperature Gauge -This gauge
should read between 170-200 degrees F.
• Voltmeter - This gauge should read at least
13 -15 volts DC to indicate the diesel engine’s
alternator is charging properly.
• AC Voltmeter - This gauge should reflect the
proper voltage selected for this operation.
Part No. 833018 T270 & T280 Super Quiet Generator 13
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Operator's Manual
OPERATING INSTRUCTIONS (Cont.)
• AC Ammeter - The reading on this gauge
should be zero since the main breaker is in the
“OFF” position. Once a load is applied to the
generator, the ammeter will produce an
appropriate reading.
May 2007
REV A
SEVERE DEFLECTION OF THE AMMETER
INDICATES A WIRING PROBLEM OR AN
OVERLOAD PROBLEM. CONTINUED OPERATION UNDER THIS CONDITION WILL CAUSE
DAMAGE TO THE GENERATOR AND/OR
CONNECTED APPARATUS.
LOADING INSTRUCTIONS
To make the electrical hookup to the generator
set, observe the following set of procedures:
SHUT DOWN THE GENERATOR SET BY
PRESSING THE "OFF" BUTTON ON THE CASCADE CONTROL PANEL. SWITCH THE TOGGLE TO THE “OFF” POSITION BEFORE MAKING ANY ELECTRICAL CONNECTIONS. THE
MAIN GENERATOR BREAKER SHOULD BE IN
THE “OFF” POSITION.
• Shut down the generator set.
• Connect the desired electrical apparatus to the
generator set, while making sure no other
power source is connected to the same
apparatus.
• Restart the engine and monitor the gauges as
outlined in the "Operating Instructions" section
under "Starting the Engine/Generator Set".
• Turn the required generator circuit breakers to
the “ON” position.
The needle on the ammeter will deflect to the right
temporarily and then return to a normal
reading if the unit is operating properly.
VOLTAGE SELECTOR SWITCH
OPERATION
The TEREX Super Quiet generator sets rated are
equipped with a VOLTAGE SELECTOR SWITCH.
This switch can have three positions marked “480/
277 - 3 Phase” and “240/139 - 3 Phase”, or “240/
120 - 1 Phase”. Each position delivers a different
output voltage to the DISTRIBUTION LUGS. The
SELECTOR SWITCH and DISTRIBUTION LUGS
are located on the DISTRIBUTION PANEL. The
following instructions should be considered when
operating the VOLTAGE SELECTOR SWITCH.
• Always make sure the voltage selector switch
has been set to the desired range before
starting the generator set.
THIS GENERATOR SET PRODUCES VOLTAGES THAT CAN CAUSE SEVERE SHOCK OR
DEATH! ONLY QUALIFIED ELECTRICIANS
SHOULD PERFORM ELECTRICAL WORK.
• Monitor the AC Ammeter - If the needle deflects
severely to the right and stays there,
immediately turn the required generator circuit
breakers to the “OFF” position.
14 T270 & T280 Super Quiet Generator Part No. 833018
NEVER OPERATE THE VOLTAGE SELECTOR
SWITCH WHILE THE GENERATOR IS RUNNING! THIS WILL RESULT IN IMMEDIATE
DAMAGE TO THE SWITCH, THE GENERATOR,
OR THE CONNECTED EQUIPMENT AND MAY
RESULT IN SERIOUS INJURY TO THE OPERATING PERSONNEL.
IMPROPER OPERATION OF THE GENERATOR
SET WILL VOID THE WARRANTY.
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May 2007
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Operator's Manual
OPERATING INSTRUCTIONS (Cont.)
VOLTAGE SELECTOR SWITCH
OPERATION
• The voltage selector switch can control the
single-phase receptacles provided on the unit.
Their indicated voltages should be checked
after selecting the setting of the switch. The Y
voltage configurations of 480 and 240 will
produce a voltage of 139 on the GFI
receptacles.
The voltage selector switch will have three positions, and each position gives a different output to
the three-phase distribution lugs (designated as
“L1”, “L2”, “L3”, and “N”) located on the distribution panel.
In the three-phase “480/277” position, the following will be the normal output voltages:
• Line - to - Line (“L1” to “L2”, “L2” to “L3”,
“L1” to “L3”) 480 VAC/3P.
• Line - to - Neutral (“L1”, “L2” or “L3” to “N”)
277 VAC/1P.
NOTICE: This three-phase wiring configuration
is referred to as “Hi Wye”.
In the three-phase “240/139” position, the following will be the normal output voltages:
• Line - to - Line (“L1” to “L2” and “L2” to
“L3”; “L1” to “L3”) 240 VAC/3P.
THIS EQUIPMENT USES HIGH VOLT-
AGE CIRCUITS CAPABLE OF CAUSING
SERIOUS INJURY OR DEATH! EXCERCISE EXTREME CAUTION AROUND ANY ELECTRICAL
COMPONENT WHEN OPERATING THIS UNIT.
The three position selector switch has HI WYE
480 V 3ph., LOW WYE 240 V 3ph. and 240V
single phase that is Zig Zag. The following is the
output voltages on the zigzag position.
• Line - to - Line ("L1" to "L3") 240 VAC/1P.
• Line - to - Neutral ("L1" or "L3" to "N") 120
VAC/1P. "L2" is not used in this position.
Once the required voltages are known, then the
combination of the proper switch position and
voltage adjustment potentiometer allows for fine
tuning the voltage to the exact needs of the
application.
ONCE THE PROPER VOLTAGE SELECTOR
SWITCH POSITION IS SELECTED, TEREX
HIGHLY RECOMMENDS THAT THE SWITCH
BE PADLOCKED IN THAT POSITION. THIS
PREVENTS THE SWITCH FROM BEING
MOVED WHILE THE UNIT IS OPERATING OR
BY UNAUTHORIZED PERSONNEL. DAMAGE
TO THE UNIT AND ANY CONNECTED EQUIPMENT WILL BE AVOIDED.
• Line - to - Neutral (“L1”, “L2”, or “L3” to
“N”) 139 VAC/1P.
NOTICE: This three-phase wiring configuration
is referred to as “Lo Wye”.
NOTICE: The above voltages can be “dialed
down”, or adjusted lower, by using the voltage
adjustment potientiometer located on the generator main control panel.
Part No. 833018 T270 & T280 Super Quiet Generator 15
Page 16
Operator's Manual
OPERATING INSTRUCTIONS (Cont.)
May 2007
REV A
DO NOT OPERATE THE UNIT UNLESS
VOLTAGE HAS BEEN CHECKED AT
THE RECEPTACLES. CALL TEREX SERVICE IF
YOU HAVE ANY QUESTIONS.
INSTALLATION AND ANY WORK PERFORMED
ON THIS UNIT SHOULD BE DONE ONLY BY A
QUALIFIED ELECTRICIAN.
DO NOT REMOVE OR COVER ORIGINAL
SAFETY AND OPERATION DECALS. REPLACE
ANY DAMAGED DECALS BEFORE USING THIS
EQUIPMENT!
POTENTIOMETER (VOLTAGE
ADJUSTMENT)
The potentiometer is set at the factory. However, if
the voltage reading on the voltmeter is not as
desired use the following procedure to make the
necessary adjustments. With the unit running,
under no load, observe the AC voltmeter. Locate
the voltage adjustment knob on the control panel.
The decal above the knob indicates the direction
to turn the knob to increase or decrease the
voltage. Turning the knob to the right increases
the voltage while turning the knob to the left
decreases the voltage. Slowly turn the adjustment
knob in the desired direction, while observing the
AC voltage meter, stop when the desired voltage
is obtained. The unit is now ready to load. If the
desired voltage cannot be reached contact the
TEREX Service Department at 1-800-433-3026.
MURPHY iGUARD CONTROLLER
For generators with the Murphy iGUARD Controller installed refer to the "Installation and Opera-
tions Manual for iGuard Digital Generator Set
Controller p/n IG-02117N" (Terex part number
839058) supplied with the unit for configuration
and operation.
MURPHY CASCADE CONTROLLER
For generators with the Murphy Cascade Controller installed refer to the "Cascade Controller
Installation and Operations Manual p/n 00-020594" (Terex part number 833011) supplied with
the unit for configuration and operation.
16 T270 & T280 Super Quiet Generator Part No. 833018
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May 2007
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Operator's Manual
OPERATING INSTRUCTIONS (Cont.)
OVERCURRENT PROTECTION
This relay is mounted behind the control panel and
monitors the current draw and uneven current
draw to protect the generator set. This trip setting
is set at the factory with the proper kW using a
loadbank.
THIS SETTING SHOULD NEVER BE CHANGED
OR GENERATOR FAILURE WILL OCCUR.
The time delay setting is on the right side of the
relay and this setting may need to be adjusted. If
the overcurrent is tripping the time delay setting
needs to be turned clockwise a 1/4 turn. This
should correct the problem.
NOTICE: Call TEREX Service for wiring and
troubleshooting information.
SHUTDOWN PROCEDURES
NEVER SHUT THE UNIT DOWN WHILE
UNDER LOAD. THIS COULD CAUSE SERIOUS
INJURIES TO THE PERSON OPERATING THE
MACHINE OR DAMAGE THE GENERATOR.
NEVER SHUT THE UNIT DOWN WITH THE
MAIN GENERATOR CIRCUIT BREAKER IN THE
“ON” POSITION. THIS CAN CAUSE DAMAGE
TO THE GENERATOR AND/OR THE CONNECTED APPARATUS.
• Turn all generator breakers to the “OFF”
position.
• Allow the engine to run for 5 minutes under no
load until the coolant temperature gauge reads
approximately 175°F as a cool down cycle.
For Cascade Equipped Generators:
• Stop the engine by pushing the Cascade
Controller “OFF” button.
For iGuard Equipped Generators:
• Stop the engine by pushing the iGuard
Controller "OFF" button and switching the
iGuard toggle switch to the “OFF” position.
Part No. 833018 T270 & T280 Super Quiet Generator 17
Page 18
Operator's Manual
May 2007
REV A
WET STACKING
Wet-Stacking is a common problem with diesel
engines which are operated for extended periods
with light or no loads applied. When a diesel
engine operates without sufficient load, it will not
operate at its’ optimum temperature. This will allow
unburned fuel to accumulate in the exhaust
system, which can foul the fuel injectors, engine
valves and exhaust system, including turbochargers, causing the engine to run rough and reduce
the operating performance.
Wet Stacking does not usually cause any permanent damage and can be alleviated if additional
load is applied to relieve the condition. Applying an
increasing load until the excess fuel build up is
burned off and the system capacity is reached
usually can repair the condition.
A review of the appropriate equipment manuals is
important to understand fully the connection and
use of the load bank you choose for your maintenance and testing requirements.
Starting out using less than 25% of the nameplate
rating until the engine has warmed up. Progressively increase the load as the generator will allow
with out shutting down, and continue to run for 20
minutes per step. When you reach 80% of the
nameplate rating, run the generator for a minimum
of 45 minutes, or until the exhaust on the unit runs
clean. Allow the machine to fully cool down. Start
the unit again and load @ 80% for and additional
30 minutes. A full engine service is recommended
after this type wetstack burn off.
TEREX suggests a minimum load of 30 percent of
nameplate to prevent wet stacking, inversely
related to temperature (the lower the ambient
temperature the higher the minimum load).
TEREX recommends testing at least monthly for a
minimum of 30 minutes at not less than 80 percent
of nameplate rating. The proper installation and
use of a load bank can prevent loss of capacity
and increased maintenance caused by unburned
fuel due to wetstacking.
In the event you have a generator set that is
already wet stacked, it is recommended that the
load bank be used in progressive steps.
Assure the generator set is properly grounded and
connected to the load bank as instructed by the
manufacture. It is also recommended that the
generator be set at 240 VAC, 3 phase when doing
this test.
18 T270 & T280 Super Quiet Generator Part No. 833018
Page 19
May 2007
REV A
SIZE THREAD
1.125
1.25
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
1.5
Operator's Manual
TORQUE SPECIFICATIONS
SA E FASTENER TORQUE CH ART
• T his chart is to be used as a gui d e on ly unless noted elsewh ere in t his man ual •
Grad e 5
in-lbs Nm in-lbs Nm in-lbs N m in-lbs N m in-lbs Nm
20
28
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
7
12
7
12
6
12
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 Nm ft-lbs Nm 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 11 0 149 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
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 1 46 4 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
DRYLUBED
Grad e 8
A574 High Strength
Black Oxide Bolts
LUBEDDRYLUBED
LUBED
METRIC FASTENER TORQUE CHART
• T his chart is to b e u se d as a guide o nly unless n oted elsewh er e in this manual •
Size
(mm)
in-lbs Nm in- lbs N m in-lbs N m in-lbs N m in-lbs N m in-lbs N m in-lb s Nm in- lbs Nm
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 Nm ft-lbs N m ft-lbs N m ft-lbs Nm 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
10.814.714.419.627.937.837.250.539.954.153.272.246.763.362.384.4
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 71 3
20
124 169 16 6 225 331 450 442 600 458 622 612 830 536 727 715 970
22
157 214 21 0 285 420 570 562 762 583 791 778 1055 682 925 909 1233
24
* An anti-seize lubricant MUST be used on all stainless steel hardware.
Part No. 833018 T270 & T280 Super Quiet Generator 19
DRYLUBED
Class 10.9Class 8.8
LUBEDDRYLUBED
LUBED DRY LUBED DRYLUBED DRY LUBED DRY
10.9 12.98.84.6
DRY
Class 12.9Class 4 .6
LUBED DRY
Page 20
Operator's Manual
GENERATOR TORQUE SPECIFICATIONS
Generator FT*LB
Flex Plate to Flywheel 55
Generator Case to Bellhousing 33
1/2" Hex Head Screws for Lifting Channel 70
3/4" Hex Head Screws for Lifting Channel 240
Genset Isolators 70
May 2007
REV A
20 T270 & T280 Super Quiet Generator Part No. 833018
Page 21
May 2007
Service &
Parts Catalog
Part No. 833018 T270 & T280 Super Quiet Generator
Page 22
May 2007
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 T270 & T280 Operator's/Parts Manual, . 833018
First Edition
Newage Generator Manual ................................. 836430
John Deere Engine Manual ................................ 833020
Cummins Engine Manual .................................... 839069
Cummins Engine Manual .................................... 839070
Cascade Controller Manual ................................ 833011
Murphy iGuard Controller Manual ....................... 839058
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
Copyright © 2007 by TEREX Corporation
833018 Rev A March 2007
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
T270 & T280 Super Quiet Generator Part No. 833018
Page 23
November 2007
REV B
How to Read Your Serial Number
Serial Number Legend
The serial number plate on your T270C & T280J
Super Quiet Generator is located on the twist lock
area of the lower control panel.
Part No. 833018 T270 & T280 Super Quiet Generator
iii
Page 24
May 2007
REV A
This page intentionally left blank.
iv
T270 & T280 Super Quiet Generator Part No. 833018
Page 25
May 2007
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. 833018 T270 & T280 Super Quiet Generator
v
Page 26
Section 1 • Safety Rules
May 2007
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.
vi
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be environmentally safe .
T270 & T280 Super Quiet Generator Part No. 833018
Page 27
May 2007
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 Specifications (Continued) ........................................................................... 2 - 2
A Torque Specifications .................................................................................. 2 - 3
Table of Contents
ii
iii
x
xi
xii
v
A Generator Torque Specifications ................................................................. 2 - 4
Section 3 Rev Scheduled Maintenance Procedures
Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report................................................................... 3 - 2
A Maintenance Schedules
Cummins Lubrication and Maintenance Service Intervals ............................ 3 - 3
John Deere Lubrication 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. 833018 T270 & T280 Super Quiet Generator
vii
Page 28
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 Murphy iGuard 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
A Electrical Schematic - Idle-Run Wiring (Cummins) ....................................... 5 - 9
May 2007
REV ATABLE OF CONTENTS
Section 6 Rev Decals
A Figure 6-A Decals ................................................................................. 6 - 2
Section 7 Rev Base Components
A Figure 7-A Base Components ............................................................... 7 - 2
A Figure 7-B Base Components ............................................................... 7 - 4
Section 8 Rev Cabinet Components
A Figure 8-A Cabinet Components - Panels ............................................. 8 - 2
A Figure 8-B Cabinet Components - Doors .............................................. 8 - 4
Section 9 Rev Control Box Components
A Figure 9-A Control Panel - Upper - T270C ............................................ 9 - 2
A Figure 9-B Control Panel - Upper T280J ............................................... 9 - 4
A Figure 9-C Control Panel - Lower - T270C & T280J .............................. 9 - 6
Section 10 Rev Distribution Panel
A Figure 10-A Distribution Panel .............................................................. 10 - 2
viii
T270 & T280 Super Quiet Generator Part No. 833018
Page 29
May 2007
REV A TABLE OF CONTENTS
A Figure 10-B Voltage Selector Switch ..................................................... 10 - 4
Section 11 Rev Engine & Genset Components
A Figure 11-A Engine Genset Assembly - Cummins ................................ 11 - 2
A Figure 11-B Engine Genset Assembly - John Deere ............................. 11 - 4
Section 12 Rev Trailer Components
A Figure 12-A Trailer Components ........................................................... 12 - 2
Section 13 Rev Options
A Figure 13-A Options LIst ....................................................................... 13 - 2
Part No. 833018 T270 & T280 Super Quiet Generator
ix
Page 30
November 2007
Parts Stocking List
Required Parts
The following parts are required to perform
maintenance procedures as outlined in the
TEREX T270C & T280J Parts and Service Manual.
Description Part No.
Cummins QSL9-G2 Models - T270C
Oil Filter .............................................................. 839066
Air Filter ....................................................... C33101101
Fuel Filter ...........................................839067 & 839068
V-belt .................................................................. 839065
John Deere 6081HF070 Models - T280J
Oil Filter .............................................................. 741907
Air Filter ....................................................... C33101101
Fuel Filter .......................................... 741946 & 741947
V-belt .................................................................741948
REV B
x
T270 & T280 Super Quiet Generator Part No. 833018
Page 31
May 2007
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 (877) 367-5606
Fax (888) 274-6102
genieindustries.com
Machine Information
Model
Serial Number
Date of Purchase
Authorized TEREX Distributor
Phone Number
Part No. 833018 T270 & T280 Super Quiet Generator
xi
Page 32
May 2007
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: (800) 633-5534 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 ________________ __________________________________
remove this page and make copies
T270 & T280 Super Quiet Generator Part No. 833018
Page 33
May 2007
V
Section 2 • Specifications
REV A
Specifications
MODEL T270C T280J
POWER CAPABILITY-PRIME
kVA (kilovolt-amps) 267 279
kW 214 223
3 Phase Amp Ratings
208V 741 774
240V 435 671
480V 218 336
POWER CAPABILITY-STANDBY
kVA (kilovolt-amps) 200 329
kW (kilowatts) 160 263
3 Phase Amp Ratings 208V 555 913
240V 481 791
480V 241 396
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 113 130
kW 84 98
SKVA 680 790
DIESEL ENGINE
Manufacturer
Model QSL9-G2 6081HF070
Cylinder 6 6
Air Intake (aspiration) Turbo Turbo
Cooling System
Fuel Capacity (gal) 238 300
Run Time (75% load) 25 24
Fuel Consumption, Prime Power (gal per hr) 100% load 16.9 16.9
75% load 12.6 12.6
50% load 8.7 8.7
25% load 4.7 4.7
dBA 68 68
Controller Type Digital/Analog Digital
Start/Stop Controller Cascade iGuard
12V Battery (CCA) 1,000 1,000
CUMMINS
Charge Air
Cooling
Radiator
JOHN DEERE
Charge Air
Cooling
Radiator
Part No. 833018 T270 & T280 Super Quiet Generator 2 - 1
Page 34
Section 2 • Specifications
r
May 2007
SPECIFICATIONS
REV A
MODEL T270C T280J
GENERATOR
Brushless, 4 pole, Synchronous, Single-bearing Standard Standard
1,800 rpm, Class H Insulation Generator Standard Standard
High wye, Low wye, Zig-zag Voltage Selector Standard Standard
3 Phase Voltage: 208, 220, 240,416, 440, 480 Standard Standard
600 Volt Optional Optional
1Phase Voltage: 120, 127, 139, 240, 254, 277 Standard Standard
Convenience Receptacles: Standard Standard
2 - 20A, 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 Standard
Murphy iGuard Start/Stop Controller
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
SKID MOUNT
DIM (L x W x H - in) 144x50x87 144x50x87
Weight Dry (lbs) 11000 11000
Weight Full (lbs) 13130 13130
TRAILER MOUNT
Dim (L x W x H) 171x68x102 171x68x102
Weight Dry (lbs) 14000 14000
Weight Full (lbs) 16130 16130
1 Maximum motor size is based on 35% voltage dip at
480V AC 3 phase 60Hz with a code G moto
Standard Standard
Optional Optional
2 - 2 T270 & T280 Super Quiet Generator Part No. 833018
Page 35
May 2007
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 TORQUE CHART
• T his chart i s t o be used as a g u ide on ly u n less noted elsewhere in t his manual •
Grade 5
DRYLUBED
in-lbs Nm in-lbs Nm 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 Nm ft-lbs N m ft-lbs Nm ft-lbs N m 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 i s t o be used as a g uide o nly unless n o t ed elsewhere in t his manu al •
Size
(mm)
in-lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm in- lbs Nm
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 Nm ft-lbs Nm ft-lbs N m ft-lbs Nm ft-lbs N m ft-lbs N m ft-lbs Nm
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
Part No. 833018 T270 & T280 Super Quiet Generator 2 - 3
DRYLUBED
Class 10.9Class 8.8
LUBEDDRYLUBED
LUBED DRY LUBED DRYLUBED DRY LUBED DRY
10.9 12.98.84.6
DRY
Class 12.9Class 4.6
LUBED DRY
Page 36
Section 2 • Specifications
GENERATOR TORQUE SPECIFICATIONS
Generator FT*LB
Flex Plate to Flywheel 55
Generator Case to Bellhousing 33
1/2" Hex Head Screws for Lifting Channel 70
3/4" Hex Head Screws for Lifting Channel 240
Genset Isolators 70
May 2007
REV A
2 - 4 T270 & T280 Super Quiet Generator Part No. 833018
Page 37
May 2007
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.
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.
Part No. 833018 T270 & T280 Super Quiet Generator 3 - 1
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.
Page 38
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 (800) 433-3026 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
Page 39
May 2007
Section 3 • Scheduled Maintenance Procedures
REV A
CUMMINS 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
Maintenance Schedules
DAILY
•
•
•
•
•
•
•
50 Hrs or
Wkly
•
500 Hrs or
12 Mths
•
•
•
•
•
•
•
1000 Hrs 2000 Hrs
•
•
•
•
•
•
•
ITEM
Change cooling system coolant •
Test/change fuel injector •
Change cooling system coolant
(comm ercial heavy duty)
Clean/test aftercooler core •
Add cooling system coolant extender (ELC) •
Change cooling system coolant (ELC)
Part No. 833018 T270 & T280 Super Quiet Generator 3 - 3
2 Yrs 30 00 Hr s
3000 Hrs or
2 Yrs
•
4000 Hrs
6000 Hrs or
3 Yrs
12000 Hrs
or 6 Yrs
•
Page 40
Section 3 • Scheduled Maintenance Procedures
MAINTENANCE SCHEDULES CONTINUED
JOHN DEERE LUBRICATION AND MAINTENANCE SERVICE INTERVALS
May 2007
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.
•
•
•
•
•
•
3 - 4 T270 & T280 Super Quiet Generator Part No. 833018
Page 41
May 2007
Section 3 • Scheduled Maintenance Procedures
REV A
NEWAGE GENERATORS MAINTENANCE SCHEDULE
MAINTENANCE SCHEDULES CONTINUED
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
DAILY
•
250 Hours
or 3
Months
•
1500 Hours
or 12
Months
•
•
•
4500 Hours
or 3 Years
•
15000
Hours or 19
Years
•
•
•
•
•
•
*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. 833018 T270 & T280 Super Quiet Generator 3 - 5
Page 42
Section 3 • Scheduled Maintenance Procedures
May 2007
REV A
This page intentionally left blank.
3 - 6 T270 & T280 Super Quiet Generator Part No. 833018
Page 43
Section 4 • TroubleshootingMay 2007
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.
Part No. 833018 T270 & T280 Super Quiet Generator 4 - 1
Burn hazard. Contact with hot
engine components may cause
severe burns. Use caution when
working around a hot engine.
Page 44
Section 4 • Troubleshooting May 2007
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 T270 & T280 Super Quiet Generator Part No. 833018
Page 45
Section 4 • TroubleshootingMay 2007
FAULT POSSIBLE CAUSE SOLUTION
High generator Defective automatic Replace voltage
output voltage voltage regulator regulator
Loose wire on voltage Check wiring
adjustment potentiometer
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
Automatic voltage regulator Call TEREX Service
stability setting may be
wrong
TROUBLESHOOTING
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. 833018 T270 & T280 Super Quiet Generator 4 - 3
Page 46
Section 4 • Troubleshooting May 2007
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
Magnetic Pick-up Adjust for 2.5-3.0 VAC
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 T270 & T280 Super Quiet Generator Part No. 833018
Page 47
Section 4 • TroubleshootingMay 2007
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
Oil Pressure or Hi temp Check or call TEREX Service
switch defective
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. 833018 T270 & T280 Super Quiet Generator 4 - 5
Page 48
Section 4 • Troubleshooting May 2007
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
Low crankcase oil level Check oil level and refill as
required
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 T270 & T280 Super Quiet Generator Part No. 833018
Page 49
Section 4 • TroubleshootingMay 2007
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 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. 833018 T270 & T280 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!).
Page 50
TROUBLESHOOTING
Section 4 • Troubleshooting May 2007
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 12 volts to the field wires you need to
recheck your wiring connections. (If you can
not find the problem hard wire the
generator!) After you have the field wire
connected start the unit again and check your
output voltage. It may still be necessary to flash
the fields to restore residual voltage. This needs
to be done with the unit off and the field wires
removed. (Do not flash the regulator, flash
the field wires)
INSTALLATION AND ANY WORK PERFORMED
ON THIS UNIT SHOULD BE DONE ONLY BY A
QUALIFIED ELECTRICIAN.
Procedure for changing the
magnetic pick-up sensor
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 speed
controller mounted on the inside of the control
pan marked MPU + and MPU -.
• Both wires are isolated in their own shielded
cable.
• Once the wires are loose, pull them through the
back of the control box until they are completely
free from all ty-wraps and wire harnesses.
• Unscrew and remove the old sensor.
• Align the flywheel tooth to the center of the
sensor hole.
• 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.
4 - 8 T270 & T280 Super Quiet Generator Part No. 833018
• Install new sensor until it bottoms out on
flywheel tooth and then back it off ¼ turn.
• To insure proper installation, the sensor must
Page 51
Section 4 • TroubleshootingMay 2007
TROUBLESHOOTING
Procedure for changing the
magnetic pick-up sensor
(cont.)
be checked with a voltage meter. With the
engine in a starting sequence check for 2.5 to 3
VAC between the red and black wire. Adjust the
sensor in or out to obtain the correct voltage.
• Once the voltage is correct, reinstall the
shielded cable through the control box opening
and reattach the wire leads to the speed
controller. Also, secure the new cable through
the housing with ty-wraps where needed.
If any further adjustment is needed to the voltage
of the generator please call Terex at 1-800-4333026 for assistance.
Procedure for changing the
voltage potentiometer
• Once the wires are loose, go to the front of the
control panel and loosen the lock nut holding
the potentiometer.
• Put the new potentiometer in its place and
retighten lock nut.
• Reattach new wires to the same wires and in
the same configuration as the ones that were
cut loose 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.
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.
• Both wires have been spliced into harness
wires and should be cut so that the splice is
taken out. It is better to have as few splices as
possible and you will be replacing the splice
you cut out.
If any further adjustment is needed to the voltage
of the generator please call TEREX at 1-800-4333026 for assistance.
Part No. 833018 T270 & T280 Super Quiet Generator 4 - 9
Page 52
Section 4 • Troubleshooting May 2007
This page intentionally left blank.
4 - 10 T270 & T280 Super Quiet Generator Part No. 833018
Page 53
May 2007
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. 833018 T270 & T280 Super Quiet Generator 5 - 1
Page 54
Control Panel Wiring
for Murphy Cascade Controller
Drawing #ES100029 (Standard)
Section 5 • Schematics
May 2007
REV A
5 - 2 T270 & T280 Super Quiet Generator Part No. 833018
Page 55
May 2007
REV A
Section 5 • Schematics
Control Panel Wiring
for Murphy iGuard Controller
Drawing #EU0004
Part No. 833018 T270 & T280 Super Quiet Generator 5 - 3
Page 56
Distribution Panel Wiring
for "H" Series Single Phase Control
Drawing #ES100010
Section 5 • Schematics
May 2007
REV A
5 - 4 T270 & T280 Super Quiet Generator Part No. 833018
Page 57
May 2007
REV A
Section 5 • Schematics
Three Position Stack Switch Wiring
Drawing #ES100026
Part No. 833018 T270 & T280 Super Quiet Generator 5 - 5
Page 58
Overcurrent Relay Wiring
Drawing #ES100006
Section 5 • Schematics
May 2007
REV A
5 - 6 T270 & T280 Super Quiet Generator Part No. 833018
Page 59
May 2007
REV A
Section 5 • Schematics
Generator Wiring Breakdown
Drawing #ES100007
Part No. 833018 T270 & T280 Super Quiet Generator 5 - 7
Page 60
Standard Generator Wiring
for "H" Series
Drawing #ES100030
Section 5 • Schematics
May 2007
REV A
5 - 8 T270 & T280 Super Quiet Generator Part No. 833018
Page 61
May 2007
REV A
Section 5 • Schematics
Idle-Run Wiring (Cummins)
Drawing #ES100039
Part No. 833018 T270 & T280 Super Quiet Generator 5 - 9
Page 62
Section 5 • Schematics
May 2007
REV A
This page intentionally left blank.
5 - 10 T270 & T280 Super Quiet Generator Part No. 833018
Page 63
May 2007
Section 6 • Decals
Section Six
Decals
Part No. 833018 T270 & T280 Super Quiet Generator 6 - 1
Page 64
Section 6 • Decals
May 2007
Figure 6-A
Decals
REV A
6 - 2 T270 & T280 Super Quiet Generator Part No. 833018
Page 65
May 2007
Section 6 • Decals
REV A
FIGURE 6-A
Part No. 833018 T270 & T280 Super Quiet Generator 6 - 3
Page 66
Section 6 • Decals
May 2007
This page intentionally left blank.
6 - 4 T270 & T280 Super Quiet Generator Part No. 833018
Page 67
May 2007
Section 7 • Base Components
Section Seven
Base
Components
Part No. 833018 T270 & T280 Super Quiet Generator 7 - 1
Page 68
Section 7 • Base Components
May 2007
Figure 7-A
Base Components
REV A
7 - 2 T270 & T280 Super Quiet Generator Part No. 833018
Page 69
November 2007
Y
Section 7 • Base Components
REV B
FIGURE 7-A
ITEM # PART # DESCRIPTION QTY.
1 NO PART NO. SEE ITEMS 45 - 54 1
2 C15309 SCREW, HEX CAP, 5/8-11"X 1.5", ZINC , GR8 8
3 993890 WASHER, LOCK, 5/8 8
4 C54200700 SCREW, 1/2"-13X 1", G5 12
5 991650 WASHER 12
6 C33600300 MOUNT, VIBRATION 6
7 890787 HOSE, FUEL, 1/2" ID 6
8 C90101500 CLAMP, 11/16" X 1-1/4" WITH LINER 3
9 C90200250 BARB, 1/4" MNPT, 1/2" ID HOSE 1
10 C90500800 COUPLING, PIPE, 1/4" HEX, BRASS, NPTF 1
11 896781 VALVE, CHECK, 0.3 CRACK , 1/4"NPT, MALE-MALE 1
12 C90200400 FITTING, PICKUP & RETURN 2
13 C91100300 NYLON TUBING, MUST CUT TO LENGTH 2
14 C91100700 HOSE, FUEL, 3/8" 6
15 C90200600 BARB, 3/8" X 1/4" NPT 1
16 C43200601 SENDER, FUEL LEVEL, VDO 1
17 796151 CAP, FUEL 1
18 993560 SCREW, 5/8-11 NC X 2-1/2 HHC, GRADE 8, Y-ZINC 8
19 993890 WASHER, LOCK, 5/8 8
20 GHJ230110 RAIDATOR FOOT T280J 2
21 CGHJ220100 MUFFLER BRACKET ASSEMBLY 1
22 CGHJ230000 HAT, RADIATOR MOUNT ASSEMBLY, T280J 1
GHC230000 HAT, RADIATOR MOUNT ASSEMBLY, T270C 1
23 CGHJ200000 HAT, ENGINE MOUNT ASSEMBLY 1
24 CGHJ120000 BATTTERY BRACKET ASSEMBLY 1
25 CGHJ210100 HAT, FRONT GENERATOR MOUNT ASSEMBLY 1
26 CGHJ210000 HAT, REAR GENERATOR MOUNT ASSEMBLY 1
27 981660 SCREW, 1/2-13 NC X 1-1/2 HHC, GRADE 5, ZP 20
28 990210 WASHER, FLAT, 1/2 20
29 895371 VALVE, VACCUUM RELIEF 1
30 792750 CLAMP, 7/16 TO 25/32 2
31 890790 HOSE, FUEL, 1/4 X 1/2, 200# 4
32 C91001300 FITTING, BARB, 3/8"NPT, 1/4" 1
33 C51601460 SCREW, FLANGE, 3/8"-16X 1", PATCH 8
34 990210 WASHER, FLAT, 1/2 8
35 892915 PIPE ELBOW, STREET 90*, 1/2 M X F BRASS 1
36 C90700800 ADAPTER, 1/2" X 1/4" REDUCER 1
37 C90200300 BARB, 3/8" X 1/4"NPT, 90 DEGREE 1
38 792750 CLAMP, 7/16 TO 25/32 2
39 C91100700 HOSE, FUEL, 3/8" 3
40 C90200600 BARB, 3/8" X 1/4"NPT 1
41 C90800200 VALVE, NEEDLE, 1/4" FPTX 1/4"FPT 1
42 CGHJ100000 FUEL TANK ASSEMBLY 1
43 NO PART NO. NO PART NUMBER, PURCHASE LOCALL
1
Part No. 833018 T270 & T280 Super Quiet Generator 7 - 3
Page 70
Section 7 • Base Components
May 2007
Figure 7-A
Base Components
REV A
7 - 4 T270 & T280 Super Quiet Generator Part No. 833018
Page 71
May 2007
Section 7 • Base Components
REV A
FIGURE 7-A
ITEM # PART # DESCRIPTION QTY.
44 CGHJ110000 BASE ASSEMBLY 1
45 993640 SCREW, 3/4-10 NC X 5 HHC, GRADE 8, Y-ZINC 4
46 993870 WASHER, FLAT, 3/4" 8
47 CGHJ500400 LIFTING LUG 1
48 993180 NUT, LOCK NYLON INSERT 3/4-10 NC.GR 2, ZP 12
49 CGHJ500300 TUBE, TOP LIFTING ASSEMBLY 1
50 CGHJ500200 UPRIGHT, LEFT LIFTING FRAME 1
51 990210 WASHER, FLAT, 1/2 16
52 993520 SCREW, 1/2-13 NC X 5, HHC, GRADE 8,Y-ZINC 8
53 990200 NUT, LOCK NYLON INSERT, 1/2-13 NC,GR 2 8
54 CGHJ500100 UPRIGHT, RIGHT LIFTING FRAME 1
Part No. 833018 T270 & T280 Super Quiet Generator 7 - 5
Page 72
Section 7 • Base Components
May 2007
Figure 7-B
Base Components
REV A
7 - 6 T270 & T280 Super Quiet Generator Part No. 833018
Page 73
May 2007
Section 7 • Base Components
REV A
FIGURE 7-B
ITEM # PART # DESCRIPTION QTY.
1 CGHJ240010 BRACKET, AIR CLEANER 1
2 994710 SCREW, 7/16-14NC X 3/4 HHC, GRADE 2, ZP 4
3 995800 NUT, LOCK NYLON INSERT, 7/16-14NC, GR2, ZPN 4
4 C90106800 CLAMP, T-BOLT, 6.50" 1
5 C33101100 AIR CLEANER, ASSEMBLY 1
6 C33101101 AIR FILTER ELEMENT 1
7 720540 HOSE, HUMP, 4" X 4" 1
8 C91104000 REDUCER, RUBBER, 6"ID- 5"OD, 90DEGREE 1
9 C90106750 CLAMP, CONSTANT TORQUE, 6 2
10 C33502602 PIPE, 4" OD, EXHAUST 2
11 C91106600 PIPE, 5" OD, EXHAUST 1
12 C90106700 CLAMP, CONSTANT TORQUE, 5 3
13 C33107600 REDUCER, RUBBER, 5"ID X 4"ID, 90DEGREE 1
14 GHC240100 CHARGE AIR COOLER PIPE, RIGHT SIDE 1
15 GHC240300 CHARGE AIR COOLER PIPE, RIGHT SIDEPIPE, LEFT SIDE 1
16 839072 CLAMP, CUMMINS PART 8
17 839071 HOSE, CUMMINS PART 4
18 990200 NUT, LOCK, NYLON INSERT, 1/2-13NC, GR 2, ZP 6
19 990210 WASHER, FLAT, 1/2" 6
20 742062 RADIATOR 1
21 90200400 FITTING, 90 DEGREE 1
22 C90400900 NIPPLE, PIPE, 1/4" X 1.5" 1
23 C90800200 VALVE, NEEDLE, 1/4"FPT X 1/4"FPT 1
24 90200600 BARB, 3/8" X 1/4"NPT 1
25 792750 CLAMP, 7/16 TO 25/32 WITH LINER 1
26 C91100700 HOSE, FUEL, 3/8" 3
27 GHC200101 ENGINE MOUNT LEFT, T270C 1
28 GHC200201 ENGINE MOUNT RIGHT, T270C 1
29 C51601570 SCREW, FLANGE, 3/8" X 3/4", PATCH 4
30 GHC490000 HOUSING, BULKHEAD, T270C 1
31 C33503801 CAP, RAIN, 6" 1
32 GHC220201 TAILPIPE, T270C 1
33 C77209 SCREW, HEX, 1/2" X 1.5, S/S 6
34 898583 CLAMP, WIDE BAND, ALUM 6", 1
35 GHC220100 MUFFLER ASSEMBLY, T270C 1
36 C51601462 NUT, FLANGE, 3/8"-16 Z 4
37 C51601570 SCREW, FLANGE, 3/8" X 3/4", PATCH 4
38 C91103300 TUBE, FLEX EXHAUST, 4" 4
39 898581 CLAMP, WIDE BAND, ALUM 4" 4
40 GHC220010 EXHAUST PIPE, T270C, MIDDLE SECTION 1
41 C91103300 TUBE, FLEX EXHAUST, 4" 2
42 GHC220005 EXHAUSE PIPE, T270C, TURBO OUTLET 1
43 261251 BATTERY, WET, 12V, GR31, 1000 CCA, DEEP-CYCLE, LA 2
44 C33700800 HOOK, BATTERY HOLD DOWN, (PAIR) 2
Part No. 833018 T270 & T280 Super Quiet Generator 7 - 7
Page 74
Section 7 • Base Components
May 2007
Figure 7-B
Base Components
REV A
7 - 8 T270 & T280 Super Quiet Generator Part No. 833018
Page 75
May 2007
Section 7 • Base Components
REV A
FIGURE 7-B
ITEM # P ART # DESCRIPTION QTY.
45 210100 BATTERY HOLDDOWN 2
46 C91100700 HOSE, FUEL, 3/8" 3
47 792750 CLAMP, 7/16 TO 25/32 1
48 C90200600 BARB, 3/8" X 1/4" NPT 1
49 112345 TANK: 4 QUART COOLANT OVERFLOW 1
50 994490 WASHER, FLAT, SNUBBING, 1 OD X 3/16 ID X 1/32 4
51 C54400200 SCREW, TEK, #10 X 3/4" 4
52 897923 HOSE, 2.5" ID X 3' LONG, CHARGE AIR COOLER 1
53 GHC230101 PIPE, UPPER RADIATOR CONNECT, T270C 1
54 702538 HOSE, RADIATOR, 2.25X 2.5 18" LONG, 1
55 897922 HOSE, HEATER, SILICONE, 1" 7
56 C42208705 SWITCH/SENSOR, COOLANT LEVEL, CASCO, 1/4 NPT 1
57 C90101500 CLAMP, 11/16" X 1-1/4" 1
58 C90107100 CLAMP, T-BOLT, 3.25" 1
59 C91102700 REDUCER RUBBER, 3 X 2.5 ID, STRAIGHT, 5" LONG 1
60 770606 PIPE, EXHAUST, 2.5" OD 1
61 C90107050 CLAMP,T-BOLT, 2.5 7
62 C90101500 CLAMP, 11/16" X 1-1/4" 1
63 702538 HOSE, RADIATOR, 2.25 X 2.5, 18" LONG, 1
64 897922 HOSE, HEATER, SILICONE, 1" 7
65 C33503801 CAP, RAIN, 6" 2
66 770608 PIPE, EXHAUST, ALUMINIZE, 6"OD 1
67 CGHJ220000 MUFFLER 1
68 GHJ220201 MUFFLER BRACKET, T280J 2
Part No. 833018 T270 & T280 Super Quiet Generator 7 - 9
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7 - 10 T270 & T280 Super Quiet Generator Part No. 833018
Page 77
May 2007
Section 8 • Cabinet Components
Section Eight
Cabinet
Components
Part No. 833018 T270 & T280 Super Quiet Generator 8 - 1
Page 78
Section 8 • Cabinet Components
May 2007
Figure 8-A
Cabinet Components - Panels
REV A
8 - 2 T270 & T280 Super Quiet Generator Part No. 833018
Page 79
May 2007
Section 8 • Cabinet Components
REV A
FIGURE 8-A
ITEM # PART # DESCRIPTION QTY.
1 CGHJ460200 TOP PANEL ASSEMBLY, REAR 1
2 CGHJ460000 CAP, TOP HOUSING 1
3 CGHJ440000 UPPER DOOR JAM ASSEMBLY 2
4 CGHJ460100 TOP PANEL ASSEMBLY, FRONT 1
5 669174 PLATE, DECK, SCREW-OUT 1
6 990670 RIVET, POP, 3/16 X 1/2 S/S, BLIND RIVET 6
7 993422 SCREW, FLANGE, 1/4-20 X .75, SS 12
8 990400 WASHER, LOCK, 1/4" 12
9 C71014 FLAT WASHER, 11/16" OD AR
10 990150 NUT, LOCK, NYLON INSERT ,1/4-20NC, GR 2, ZP 12
11 GHU460901 GRILL, CABINET 1
12 CGHJ410300 HOUSING, CORNER, RIGHT FRONT 1
13 CGHJ440201 DOOR STOP, RIGHT 1
14 CGHJ470300 HOUSING, PANEL, TOP CONTROL 1
15 CGHJ450300 HOUSING, LOUVER, SUPPORT 1
16 CGHJ450200 LOUVER, ASSEMBLY 1
17 CGHJ450250 GUARD, LOUVER MESH 1
18 C73000100 TRIM LOCK, 1/4" AR
19 994490 WASHER, FLAT SNUBBING, 1" OD X 3/16 ID X 1/32 16
20 C54400200 SCREW, TEK, #10 X 3/4" 16
21 C71100200 FOAM, BLACK URETHANE, 1/2" AR
22 CGHJ470200 HOUSING, PANEL, BOTTOM CONTROL 1
23 CGHJ470000 HOUSING, PANEL, DISTRIBUTION TOP 1
24 CGHJ440100 LEFT DOOR SUPPORT ASSEMBLY 1
25 CGHJ470100 HOUSING, PANEL, DISTRIBUTION BOTTOM 1
26 CGHJ410200 HOUSING, CORNER, LEFT FRONT 1
27 CGHJ450100 HOUSING, PANEL, FRONT 1
28 C54200601 SCREW, FLANGE, 5/16"-18 X 3/4", PATCH AR
Part No. 833018 T270 & T280 Super Quiet Generator 8 - 3
Page 80
Section 8 • Cabinet Components
May 2007
Figure 8-B
Cabinet Components - Doors
REV A
8 - 4 T270 & T280 Super Quiet Generator Part No. 833018
Page 81
May 2007
Section 8 • Cabinet Components
REV A
FIGURE 8-B
ITEM # PART # DESCRIPTION QTY.
1 CGHJ430003 HOUSING, DOOR, CONTROL 1
2 C74100100 GASKET, WINDOW, CONTROL DOOR 5
3 CU54T021 WINDOW, CONTROL DOOR 1
4 C71100500 FOAM, BLACK URETHANE 1" AR
5 CGHJ350000 HOUSING, DOOR, ACCESS, RIGHT 1
6 GUU401100 TRIMLOCK SEAL, 7/16", BLACK FINE PEBBLE 18
7 C51400200 STOP, DOOR, RUBBER W/WASHER 2
8 C41135000 RIVET, POP,1 /4 X 1/2" 2
9 990170 NUT, NYLOCK, 10-24, Z 40
10 794890 HINGE, STAINLESS STEEL, BLACK COATED 10
11 C21353 1/4-20 X 1, SS, FLAT HEAD, SOCKET SCREW 40
12 CGHJ340000 HOUSING, DOOR, ACCESS, LEFT 1
13 C71014 FLAT WASHER 11/16" OD 4
14 990150 NUT, LOCK NYLON INSERT, 1/4-20NC, GR 2, ZP 4
15 C74419 SCREW, CARRIAGE, 1/4-20 X .75 STAINLESS STEEL 4
16 C53200100 LITERATURE BOX, BLACK PLASTIC 1
17 CGHJ430000 HOUSING, DOOR, DISTRIBUTION 1
18 C51200000 LATCH, BLACK, KEY LOCK ADJUSTABLE T-HANDLE 4
19 993360 RIVET, POP, 3/16 X 3/4, ALUM, 3/8-1/2 GR 16
20 981120 WASHER 40
Part No. 833018 T270 & T280 Super Quiet Generator 8 - 5
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8 - 6 T270 & T280 Super Quiet Generator Part No. 833018
Page 83
May 2007
Section 9 • Control Box Components
Section Nine
Control Box
Components
Part No. 833018 T270 & T280 Super Quiet Generator 9 - 1
Page 84
Section 9 • Control Box Components
May 2007
Figure 9-A
Control Panel - Upper T270C
REV A
9 - 2 T270 & T280 Super Quiet Generator Part No. 833018
Page 85
May 2007
Section 9 • Control Box Components
REV A
FIGURE 9-A
ITEM # PART # DESCRIPTION QTY.
1 CGHJ320000 CONTROL PAN ASSEMBLY 1
2 GHU321001 CONTROL PANEL, CASCADE 1
3 C42200500 POTENTIOMETER, VOLTAGE ADJUSTMENT 1
4 682070 BREAKER, MINI, 1P, 15A 1
5 C42208400 SWITCH, TOGGLE, SINGLE THROW 1
6 C43100800 GAUGE, DC VOLT 1
7 C43200400 GAUGE, OIL PRESSURE 1
8 260360 HOURMETER, 12V DC 1
9 C43200300 GAUGE, WATER TEMP, 12V 1
10 C43200600 GAUGE, FUEL 1
11 261341 CASCADE CONTROLLER 1
12 INCLUDED IN ITEM 11
13 C43100600 METER, VOLT 1
14 C43100400 METER, FREQUENCY 1
15 C43105500 METER, AMP, 0-1000 1
16 R980195 SCREW, 1/4-20NC X 3/4" 6
17 990400 WASHER, LOCK, 1/4" 6
18 981745 WASHER, FLAT, 1/4" 6
19 992040 RIVET, POP, 3/16 X .602 10
20 C51800100 LANYARD, NYLON 1
21 800025 HARNESS, CUMMINS, ECU 1
22 C51600800 NUT, CLIP, 1/4"-20 X 3/4" 6
23 C51200201 HINGE, PIANO, 9", SS 2
24 CU43A050 PLASTIC 1/8" X 10.5" X 33" 1
25 C90103800 CLAMP, RUBBER COATED 1
26 C51601550 SCREW, SELF-TAPPING, #10 1
27 686735 RAIL, RELAY MOUNTING 1
28 C42401700 RELAY, OVER CURRENT 1
29 C42404000 TERMINAL STRIP, 6 POS 1
30 R660115 JUMPER TERMINAL STRIP 1
31 CDWV40150 RELAY, 50A, BOSCH 2
32 CDWV40151 RELAY BASE, 50A, BOSCH 2
33 CDWV40152 RELAY PIN 6
34 853838 DECAL: CONTROL PANEL, CASCADE 1
35 853813 DECAL: KIT-RECEPTACLES 1
36 R980900 NUT, LOCK NYLON INSERT #8-32NF 18-8 S/S 1
37 C54400100 SCREW, SET, 8-32X1/2" 1
38 990110 SCREW, 1/4-20NCX1, HHC GRADE 2 ZP 1
39 990150 NUT, LOCK NYLON INSERT, 1/4-20NC, GR 2, ZP 1
40 992120 NUT, HEX, 1/4-20NC, GRADE 2, ZP 1
41 996390 WASHER, LOCK STAR, 1/4" INT-EXT, ZP 1
Part No. 833018 T270 & T280 Super Quiet Generator 9 - 3
Page 86
Section 9 • Control Box Components
May 2007
Figure 9-B
Control Panel - Upper T280J
REV A
9 - 4 T270 & T280 Super Quiet Generator Part No. 833018
Page 87
May 2007
Section 9 • Control Box Components
REV A
FIGURE 9-B
ITEM # PART # DESCRIPTION QTY.
1 CGHJ320000 CONTROL PANEL ASSY 1
2 CU42S031 CONTROL PANEL, IGUARD 1
3 C42200500 POTENTIOMETER, VOLTAGE 1
4 C42208400 SWITCH, TOGGLE, SINGLE THROW 1
5 261308 GAUGE, AC FREQ., 40-80 HZ 1
6 261328 GAUGE, 600VAC, VOLT METER 1
7 261314 AC AMP METER, 0-600 1
8 261307 GAUGE, 24VDC, 0-24VDC 1
9 261313 GAUGE, FUEL, 0-100% 1
10 261309 GAUGE, OIL PRESSURE 1
11 261312 GAUGE, COOLANT TEMP 1
12 R980195 SCREW, 1/4-20, NC X 3/4 BUTTON HEAD, 18-8 S/S 2
13 990400 WASHER, LOCK, 1/4" 2
14 981745 WASHER, FLAT, 1/4" 2
15 992040 RIVET, POP, 3/16 X .602 10
16 C51600800 NUT, CLIP, 1/4"-20 X 3/4" 2
17 261305 CONTROLLER, IGUARD, 600A 1
18 C51200201 HINGE, PIANO, 9", SS 2
19 CU43A050 PLASTIC, ABS, 1/8" X 10.5" X 33" 1
20 C51800100 LANYARD, NYLON 2
21 C90103800 CLAMP, RUBBER COATED 1
22 220370 WIRE HARNESS 1
23 853813 DECAL: KIT-RECEPTACLES, BREAKERS 1
24 853815 DECAL: CONTROL PANEL 1
25 C42400700 SOLENOID - STARTER & GLOWPLUGS 1
26 R661493 120V RELAY 1
27 R661494 120V RELAY BASE 1
28 R980900 NUT, LOCK NYLON INSERT, #8-32NF, 18-8 S/S 1
29 C54400100 SCREW, SET, 8-32X1/2" 1
30 C51601550 SCREW, SELF-TAPPING, #10 X 3/4" 1
Part No. 833018 T270 & T280 Super Quiet Generator 9 - 5
Page 88
Section 9 • Control Box Components
May 2007
Figure 9-C
Control Panel - Lower T270C & T280J
REV A
9 - 6 T270 & T280 Super Quiet Generator Part No. 833018
Page 89
May 2007
Section 9 • Control Box Components
REV A
FIGURE 9-C
ITEM # PART # DESCRIPTION QTY.
1 CGHJ320000 CONTROL PAN ASSEMBLY 1
2 CGHJ322000 PANEL, DISTRIBUTION 1
3 C42105400 BREAKER, 900A, SHUNTTRIP, 12VDC 1
4 C42103400 BREAKER, 20A, 120/240V 2
5 C42103600 BREAKER, 50A, 120/240V 3
6 684640 RECEPTACLE, 20A, 120V, DUPLEX W/GFI 2
7 C42501200 TRANSFORMER, 400:5, T270C ONLY 3
8 993830 WASHER, FLAT, 5/8 ZP, USS 1-3/4 O.D. 20
9 CF41T031 TEMP POWER SLOPE 1
10 C47100300 RECEPTACLE, TWISTLOCK 50A, 240V 3
11 R980195 SCREW, 1/4-20NC X 3/4" 8
12 990400 WASHER, LOCK, 1/4" 8
13 981745 WASHER, FLAT, 1/4" 8
14 C54400100 SCREW, SET, 8-32 X 1/2" 4
15 C51601442 SCREW, FLANGE, 1/4"-20 6
16 66812 E-STOP, PUSH BUTTON 1
17 66817 EMERGENCY STOP, BASE 1
18 686662 EMERGENCY STOP, FACE PLATE 1
19 671278 BINDING POST FOR REMOTE START 1
20 853752 DECAL: REMOTE START CN 1
21 C73716 SCREW, #6-32 X 1/2" 16
22 981205 SCREW, 5/16-18NC X 6-1/2 HHC, GR 5, ZP 4
23 991940 NUT, LOCK NYLON INSERT, 5/16-18NC, GR 2, ZP 4
24 R980900 NUT, LOCK NYLON INSERT, #8-32NF 10
25 C51600800 NUT, CLIP, 1/4"-20 X 3/4" 6
26 CB45A112 HARNESS, AC CONTROL PANEL 1
27 C51600800 NUT, CLIP, 1/4"-20 X 3/4" 16
28 853813 DECAL: KIT-RECEPTACLES 1
29 CU51A122 DECAL: HIGH VOLTAGE 1
30 C42501000 TRANSFORMER, 1000:5, T270C ONLY 1
C42501000 TRANSFORMER, 1000:5, T280J ONLY 3
31 C73000100 TRIM LOCK, 1/4" AR
32 CU45A010 HARNESS, AC/GEN 1
Part No. 833018 T270 & T280 Super Quiet Generator 9 - 7
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9 - 8 T270 & T280 Super Quiet Generator Part No. 833018
Page 91
May 2007
Section 10 • Distribution Panel
Section Ten
Distribution
Panel
Part No. 833018 T270 & T280 Super Quiet Generator 10 - 1
Page 92
Section 10 • Distribution Panel
May 2007
Figure 10-A
Distribution Panel
REV A
10 - 2 T270 & T280 Super Quiet Generator Part No. 833018
Page 93
November 2007
Section 10 • Distribution Panel
REV B
FIGURE 10-A
ITEM # PART # DESCRIPTION QTY.
1 CGHJ330300 PANEL, 3PH DISTRIBUTION 1
2 CGHJ330001 DISTRIBUTION LUG PANEL 1
3 686756 SWITCH, 3POSITION 1
4 CJ34F030 BUS BOARD, 5-LUG 1
5 CGHJ330014 COVER, PANEL, MODULAR 1
6 850130 DECAL: DANGER HIGH VOLTAGE 1
7 C42200702 PLUNGER (ACTUATOR) 1
8 C42200701 SWITCH, SNAP-ACTION 1
9 852255 DECAL: 3PH DISTRIBUTION PANEL 1
10 981630 SCREW, 1/2-13NC X 3/4 HHC, GR5, ZP 10
11 991650 WASHER, LOCK, 1/2" 10
12 851820 DECAL: SYMBOL FOR GROUND 1
13 981660 SCREW, 1/2-13NC X 1-1/2 HHC, GRADE 5, ZP 5
14 991650 WASHER, LOCK, 1/2" 5
15 C74967 HEX NUT, 1/2-13, SBZ 5
16 981620 SCREW, 1/4-20NC X 1-1/2 HHS, GRADE 5, ZP 4
17 CU51A400 DECAL: L1, L2, L3, N 1
18 CL-008 DECAL: DO NOT CHANGE POSITION OF SELECTOR 1
19 R980195 SCREW, 1/4-20NC X 3/4 BUTTON HEAD, 18-8 S/S 18
20 990400 WASHER, LOCK , 1/4" 18
21 981745 WASHER, FLAT, 1/4" 18
22 C51600800 NUT, CLIP, 1/4"-20 X 3/4" 18
23 C94903 SCREW, 3/8-16 X 1 1/4, Z 4
24 990470 WASHER, LOCK, 3/8" 4
25 R980015 WASHER, FLAT, 3/8" 4
26 990170 NUT, LOCK ,NYLON INSERT, 3/8-16NC, GR 2, ZPN 4
27 990150 NUT, LOCK, NYLON INSERT, 1/4-20NC, GR 2, ZP 4
28 CGHJ330400 COVER,STACK SWITCH 1
29 CGHJ330003 ACCESS PLATE, STACK SWITCH 3
30 R980195 SCREW, 1/4-20NC X 3/4, BUTTON HEAD, 18-8 S/S 20
31 990400 WASHER, LOCK, 1/4 20
32 981745 WASHER, FLAT, 1/4" 20
NOTE: ITEMS 28 ~ 32 NOT SHOWN IN DRAWING.
Part No. 833018 T270 & T280 Super Quiet Generator 10 - 3
Page 94
Section 10 • Distribution Panel
May 2007
Figure 10-B
Generator
REV A
10 - 4 T270 & T280 Super Quiet Generator Part No. 833018
Page 95
November 2007
Section 10 • Distribution Panel
REV B
FIGURE 10-B
ITEM # PART # DESCRIPTION QTY.
1 CGHJ330400 COVER, STACK SWITCH 1
2 R980195 SCREW, 1/4-20 NC X 3/4 BUTTON HEAD, 18-8 S/S 4
3 990400 WASHER, LOCK 1/4 4
4 981745 WASHER, FLAT 1/4 4
5 CGHJ330003 ACCESS PLATE, STACK SWITCH 3
6 630964 GENERATOR, NEWAGE 250KW JD, SAE2 HCI434C1L556A 1
7 CMX341 NEWAGE MX341 AVR VOLTAGE REGULATOR 1
8 836428 NEWAGE 45-0263 PMG KIT 1
9 836429 NEWAGE 45-0320 NON-DRIVE END BEARING 1
10 836430 NEWAGE 2H-056E OPERATION MANUAL HCI 1
Part No. 833018 T270 & T280 Super Quiet Generator 10 - 5
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Section 10 • Distribution Panel
May 2007
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10 - 6 T270 & T280 Super Quiet Generator Part No. 833018
Page 97
May 2007
Section 11 • Engine & Genset Components
Section Eleven
Engine &
Genset
Components
Part No. 833018 T270 & T280 Super Quiet Generator 11 - 1
Page 98
Section 11 • Engine & Genset Components
May 2007
Figure 11-A
Engine Genset Assembly - Cummins QSL9-G2 - T270C
REV A
11 - 2 T270 & T280 Super Quiet Generator Part No. 833018
Page 99
November 2007
Section 11 • Engine & Genset Components
REV B
FIGURE 11-A
ITEM # PART # DESCRIPTION QTY.
1 732128 ENGINE, CUMMINS, QSL9-G2 1
2 C33303605 FAN, HASCON WING, 28", T270C, QSL9, WHITE BLADE 1
3 C42301700 SWITCH, TEMP, W/SENDER 1
4 C42300100 SWITCH, OIL PRESSURE SENDER 1
5 C90700200 ADAPTER, 1/8" X 1/8" 1
6 C42300400 SENDER,OIL PRESSURE 1
7 898575 FITTING, MALE BRANCH, TEE, 1/8, 1/8MM, S-S 1
8 839065 BELT 1
9 839066 OIL FILTER 1
10 839067 FUEL FILTER - FF5580 1
11 839068 FUEL FILTER - FS18732 - FUEL/WATER SEPARATOR 1
12 C33101100 AIR CLEANER, ASSEMBLY 1
13 C33101101 AIR FILTER ELEMENT 1
14 839073 BELT TENSIONER 1
15 839074 ALTERNATOR 1
16 839076 STARTER 1
17 839077 WATER PUMP 1
18 839078 THERMOSTAT 1
19 839097 OIL PRESSURE SENSOR 1
20 839079 DIPSTICK 1
21 839069 OPERATION MANUAL 1
Part No. 833018 T270 & T280 Super Quiet Generator 11 - 3
Page 100
Section 11 • Engine & Genset Components
May 2007
Figure 11-B
Engine Genset Assembly - John Deere 6081HF070 - T280J
REV A
11 - 4 T270 & T280 Super Quiet Generator Part No. 833018
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