Terex T270, T280 Operator, Service & Parts Manual
Operator/Service & Parts Manual
T270/T280
First Edition
Rev A1
Part No. 833018
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
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
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
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
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.
May 2007
REV A
SAFETY SIGN LOCATIONS
Operator's Manual
GENERAL SAFETY (Cont.)
Part No. 833018 T270 & T280 Super Quiet Generator 7
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.
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
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.
May 2007
REV A
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
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
May 2007
REV A
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
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.
May 2007
REV A
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
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
May 2007
REV A
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
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
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
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
May 2007
Service &
Parts Catalog
Part No. 833018 T270 & T280 Super Quiet Generator
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
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
May 2007
REV A
This page intentionally left blank.
iv
T270 & T280 Super Quiet Generator Part No. 833018
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
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
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
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
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
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
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