Terex T50 Operator, Service & Parts Manual

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Page 1

Operator/Service & Parts Manual

T50

First Edition

Rev A1

Part No. 833009

Page 2

Serial Number Registration

Serial Number Registration............................................................................... 4

Introduction

Introduction....................................................................................................... 5

Description of Equipment.................................................................................. 5

Operator's Manual

Table Of Contents

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

Dynagen Auto Start Engine Controller ............................................................ 16

Woodward Speed Controller ........................................................................... 16

2 T50 Super Quiet Generator Part No. 833009

Page 3

Operator's Manual

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

Part No. 833009 T50 Super Quiet Generator 3

Page 4

Operator's Manual

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 T50 Super Quiet Generator Part No. 833009

Page 5

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.

A governor 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 governor and regulator are provided in the ENGINE and GENERATOR OPERATOR’S MANUALS.

An automatic shutdown system is incorporated in the generator set to sense low oil pressure and/or high coolant temperature, and in either 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. 833009 T50 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 enclosure as standard equipment.

Page 6

DESCRIPTION OF EQUIPMENT (Cont.)

A center-point lifting attachment is located in the top of the enclosure to allow crane lifting of the entire unit.

Operator's Manual

Yellow without safety

alert symbol - Indicates a situation which, if not avoided, may result in property or equipment damage.

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.

Green - Indicates important 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 T50 Super Quiet Generator Part No. 833009

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.

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Operator's Manual

SAFETY SIGN LOCATIONS

GENERAL SAFETY (Cont.)

Part No. 833009 T50 Super Quiet Generator 7

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GENERAL SAFETY (Cont.)

Operator's Manual

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 T50 Super Quiet Generator Part No. 833009

ALWAYS Have a fire extinguisher nearby. Be sure the extinguisher is properly maintained and be amiliar 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.

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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. 833009 T50 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

BE CAREFUL WHEN LIFTING. NEVER SUSPEND ANY OTHER EQUIPMENT FROM THE SHIPPING TIE DOWNS.

Use the lifting eye 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 T50 Super Quiet Generator Part No. 833009

Check all fluid levels; battery, radiator, and engine oils.

Ensure manuals are in the pocket provided inside the unit.

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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. 833009 T50 Super Quiet Generator 11

Page 12

SETUP (Cont.)

• If the axle is sloped downhill, turn the generator set so that the axle is level.

Operator's Manual

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.

• Rotate the tongue jack into position (90 degrees), 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 T50 Super Quiet Generator Part No. 833009

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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 DISTRIBUTION 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 DynaGen Equipped Generators:

• If the unit is equipped with a DynaGen controller place the toggle switch in the “MANUAL”

position to start the engine. If the engine fails to start, the “NO SPEED SIGNAL” led will light. Return the toggle switch to the “OFF” position then back to the “MANUAL” position. If the engine fails to start again refer to the DynaGen manual or call Terex service. The “AUTO” position is to be used only with the remote start feature.

• 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 12 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.

• 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.

Part No. 833009 T50 Super Quiet Generator 13

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OPERATING INSTRUCTIONS (Cont.)

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.

Operator's Manual

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 from T25I to the T280J are equipped with a VOLTAGE SELECTOR SWITCH. This switch can have three positions marked “480/277” and “208/ 120”, or “240/120”. 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.

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.

14 T50 Super Quiet Generator Part No. 833009

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 WHICH WILL ALSO VOID THE WARRANTY. IT MAY RESULT IN SERIOUS INJURY TO THE OPERATING PERSONNEL.

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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 have 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 “208/120” 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 1-to-L3 240 VAC/1P.

• Line-to-Neutral 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. 833009 T50 Super Quiet Generator 15

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OPERATING INSTRUCTIONS (Cont.)

Operator's Manual

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.

DYNAGEN AUTO START ENGINE CONTROLLER

For generators with the DynaGen Controller installed refer to the "DynaGen Installation and

User Manual for the ES51/52 Auto Start Engine Controller" (Terex part number 833012) supplied

with the unit for configuration and operation.

WOODWARD SPEED CONTROLLER

For generators with the Woodward Speed Controller installed refer to the "Woodward Manual LCS

Series Integrated Speed Control p/n 37101S1"

(Terex part number 833013) 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.

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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 DynaGen Equipped Generators:

• Stop the engine by switching the DynaGen

toggle switch to the “OFF” position.

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Operator's Manual

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.

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Operator's Manual

SIZE THREAD

1/4

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1.125

1.25

1.5

20 28

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

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

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

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

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

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

10.814.714.419.627.937.837.250.539.954.153.272.246.763.362.384.4

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

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

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

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

91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 71 3

124 169 16 6 225 331 450 442 600 458 622 612 830 536 727 715 970

157 214 21 0 285 420 570 562 762 583 791 778 1055 682 925 909 1233

* An anti-seize lubricant MUST be used on all stainless steel hardware.

Part No. 833009 T50 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

GENERATOR TORQUE SPECIFICATIONS

Generator FT*LB

Flex Plate to Flywheel 32-44 Generator Case to Bellhousing 60 1/2" Socket Head Cap Screws for Lifting Channel 126 1/2" Hex Head Screws for Lifting Channel 120 Genset Isolators 78

Operator's Manual

20 T50 Super Quiet Generator Part No. 833009

Page 21

October 2006

REV A

Service &

Parts Catalog

Part No. 833009 T50 Super Quiet Generator

Page 22

October 2006

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 T50 Operator's/Parts Manual, ................ 833009

First Edition

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

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

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

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

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

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

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

Readers are encouraged to notify TEREX of errors and send in suggestions for improvement. All communications will be carefully considered for future printings of this and all other manuals.

www.TEREX.com e-mail: [email protected]

833009 Rev A October 2006 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.

T50 Super Quiet Generator Part No. 833009

Page 23

October 2006

REV A

How to Read Your Serial Number

Serial Number Legend

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

Part No. 833009 T50 Super Quiet Generator

iii

Page 24

October 2006

REV A

This page intentionally left blank.

T50 Super Quiet Generator Part No. 833009

Page 25

October 2006

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. 833009 T50 Super Quiet Generator

Page 26

Section 1 • Safety Rules

October 2006

REV ASAFETY RULES

Personal Safety

Any person working on or around a machine must be aware of all known safety hazards. Personal safety and the continued safe operation of the machine should be your top priority.

Read each procedure thoroughly. This manual and the decals on the machine, use signal words to identify the following:

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

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

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

Yellow with safety alert symbol— used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Yellow without safety alert symbol—used to indicate the presence of a potentially hazardous situation which, if not avoided, may result in property damage.

Green—used to indicate operation or maintenance information.

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

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

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

Workplace Safety

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

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

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of debris that could get into machine components and cause damage.

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

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

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

Be sure that fasteners intended for one

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

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

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be environmentally safe .

T50 Super Quiet Generator Part No. 833009

Page 27

October 2006

REV A

Introduction

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

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

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

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

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

Section 1 Safety Rules

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

Section 2 Rev Specifications

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

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

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

Table of Contents

iii

xii

Section 3 Rev Scheduled Maintenance Procedures

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

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

A Maintenance Schedules

T50P Lubrication and Maintenance Service Intervals .................................. 3 - 3

T50J Lubrication and Maintenance Service Intervals .................................. 3 - 4

T50J and T50P Newage Generators Maintenance Schedule ...................... 3 - 5

Section 4 Rev Troubleshooting

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

A Troubleshooting Guide ................................................................................. 4 - 3

Part No. 833009 T50 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 Dynagen Controller ....................... 5 - 3

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

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

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

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

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

Section 6 Rev Decals

October 2006

REV ATABLE OF CONTENTS

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 .......................................................... 9 - 2

A Figure 9-B Control Panel - Lower .......................................................... 9 - 4

Section 10 Rev Control Box Components

A Figure 10-A Distribution Panel .............................................................. 10 - 2

A Figure 10-B Voltage Selector Switch ..................................................... 10 - 4

viii

T50 Super Quiet Generator Part No. 833009

Page 29

October 2006

REV A TABLE OF CONTENTS

Section 11 Rev Engine & Genset Components

A Figure 11-A Engine Genset Assembly - Perkins ................................... 11 - 2

A Figure 11-B Engine Genset Assembly - John Deere ............................. 11 - 4

A Figure 11-C Engine Muffler Assembly - John Deere & Perkins ............. 11 - 6

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. 833009 T50 Super Quiet Generator

Page 30

October 2006

Parts Stocking List

Required Parts

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

TEREX T50 Parts and Service Manual.

Description Part No.

Perkins 1104C.44G2 Models

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

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

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

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

John Deere 4045DF270 Models

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

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

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

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

REV A

T50 Super Quiet Generator Part No. 833009

Page 31

October 2006

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

TEREX North America

Telephone (803) 324-3011 Toll Free (800) 433-3026 in U.S.A. and Canada Fax (803) 366-1101

Machine Information

Model

Serial Number

Date of Purchase

Authorized TEREX Distributor

Phone Number

Part No. 833009 T50 Super Quiet Generator

Page 32

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

T50 Super Quiet Generator Part No. 833009

Page 33

November 2007

Section 2 • Specifications

REV B

Specifications

MODEL T50P T50J

POWER CAPABILITY-PRIME

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

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

POWER CAPABILITY-STANDBY

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

240V 130 130 480V 65 65

OLTAGE

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

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

Max Motor Starting1 Hp 20 20

kW 15 15

SKVA 126 126

DIESEL ENGINE

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

75% load 2.5 2.6 50% load 1.8 1.9

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

Part No. 833009 T50 Super Quiet Generator 2 - 1

Page 34

Section 2 • Specifications

October 2006

SPECIFICATIONS

MODEL T50P T50J

GENERATOR

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

TRAILER

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

REV A

SKID MOUNT

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

TRAILER MOUNT

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

Standard Standard

Optional Optional

2 - 2 T50 Super Quiet Generator Part No. 833009

Page 35

October 2006

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

1.125

1.25

1.5

20 28

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

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

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

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

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

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

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

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

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

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

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

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

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

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

Part No. 833009 T50 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

October 2006

This page intentionally left blank.

2 - 4 T50 Super Quiet Generator Part No. SSQMT50J-P

Page 37

October 2006

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. 833009 T50 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

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

October 2006

Section 3 • Scheduled Maintenance Procedures

REV A

T50P 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 (commer cial heavy duty) Clean/test aftercooler core Add cooling system coolant extender (ELC) Change cooling system coolant (ELC)

Part No. 833009 T50 Super Quiet Generator 3 - 3

2 Yrs 3000 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

T50J LUBRICATION AND MAINTENANCE SERVICE INTERVALS

October 2006

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 T50 Super Quiet Generator Part No. 833009

Page 41

October 2006

Section 3 • Scheduled Maintenance Procedures

MAINTENANCE SCHEDULES CONTINUED

T50J AND T50P NEWAGE GENERATORS MAINTENANCE SCHEDULE

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. 833009 T50 Super Quiet Generator 3 - 5

Page 42

Section 3 • Scheduled Maintenance Procedures

October 2006

REV A

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3 - 6 T50 Super Quiet Generator Part No. 833009

Page 43

Section 4 • TroubleshootingOctober 2006

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

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. 833009 T50 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 October 2006

Troubleshooting Guide

The engine/generator set is tested and set at the factory for proper operation in the field. These units should never require additional adjustments in the field. If needed, adjustments should only be made by a qualified service technician, otherwise the manufacturer’s warranty may become void.

FAULT POSSIBLE CAUSE SOLUTION

No generator output voltage Circuit breaker tripped Reset circuit breaker

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

Low generator output voltage Voltage adjustment Adjust voltage potentiometer

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

selector switch Fluctuating or surging Check engine fuel, oil,

engine speed and air filters Loose wire on voltage Check wiring

regulator sensing circuit Defective voltage regulator Replace voltage regulator

High generator Voltage adjustment Adjust potentiometer output voltage potentiometer

High engine speed Call TEREX Service

4 - 2 T50 Super Quiet Generator Part No. 833009

Page 45

Section 4 • TroubleshootingOctober 2006

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. 833009 T50 Super Quiet Generator 4 - 3

Page 46

Section 4 • Troubleshooting October 2006

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 T50 Super Quiet Generator Part No. 833009

Page 47

Section 4 • TroubleshootingOctober 2006

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. 833009 T50 Super Quiet Generator 4 - 5

Page 48

Section 4 • Troubleshooting October 2006

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 T50 Super Quiet Generator Part No. 833009

Page 49

Section 4 • TroubleshootingOctober 2006

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 upper control panel behind the gauges.)

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. 833009 T50 Super Quiet Generator 4 - 7

• When a new generator is not producing voltage, the testing or wiring personnel should first verify that the unit is wired correctly! The stack switch and generator leads should all be checked as well as the breaker and sensing leads. If the unit was not wired correctly and you flashed the generator, you could burn up the unit. (Do not forget to check the sensing leads!).

Page 50

TROUBLESHOOTING

Section 4 • Troubleshooting October 2006

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 T50 Super Quiet Generator Part No. 833009

• 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 • TroubleshootingOctober 2006

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. 833009 T50 Super Quiet Generator 4 - 9

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Section 4 • Troubleshooting October 2006

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4 - 10 T50 Super Quiet Generator Part No. 833009

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October 2006

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. 833009 T50 Super Quiet Generator 5 - 1

Page 54

Control Panel Wiring

for Murphy Cascade Controller Drawing #ES1000001 (Standard)

Section 5 • Schematics

October 2006

REV A

5 - 2 T50 Super Quiet Generator Part No. 833009

Page 55

October 2006

REV A

Section 5 • Schematics

Control Panel Wiring

for Dynagen Controller

Drawing #EU0007

Part No. 833009 T50 Super Quiet Generator 5 - 3

Page 56

Distribution Panel Wiring

for "D" Series Single Phase Control Drawing #ES1000003

Section 5 • Schematics

October 2006

REV A

5 - 4 T50 Super Quiet Generator Part No. 833009

Page 57

October 2006

REV A

Section 5 • Schematics

Three Position Stack Switch Wiring

Drawing #ES1000005

Part No. 833009 T50 Super Quiet Generator 5 - 5

Page 58

Overcurrent Relay Wiring

Drawing #ES1000006

Section 5 • Schematics

October 2006

REV A

5 - 6 T50 Super Quiet Generator Part No. 833009

Page 59

October 2006

REV A

Section 5 • Schematics

Generator Wiring Breakdown

Drawing #ES1000007

Part No. 833009 T50 Super Quiet Generator 5 - 7

Page 60

Standard Generator Wiring

for "D" Series Drawing #ES1000008

Section 5 • Schematics

October 2006

REV A

5 - 8 T50 Super Quiet Generator Part No. 833009

Page 61

October 2006

Section 6 • Decals

Section Six

Decals

Part No. 833009 T50 Super Quiet Generator 6 - 1

Page 62

Section 6 • Decals

October 2006

Figure 6-A

Decals

REV A

6 - 2 T50 Super Quiet Generator Part No. 833009

Page 63

October 2006

Section 6 • Decals

REV A

FIGURE 6-A

Part No. 833009 T50 Super Quiet Generator 6 - 3

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Section 6 • Decals

October 2006

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6 - 4 T50 Super Quiet Generator Part No. 833009

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October 2006

Section 7 • Base Components

Section Seven

Base

Components

Part No. 833009 T50 Super Quiet Generator 7 - 1

Page 66

Section 7 • Base Components

October 2006

Figure 7-A

Base Components

REV A

7 - 2 T50 Super Quiet Generator Part No. 833009

Page 67

November 2007

Section 7 • Base Components

REV B

FIGURE 7-A

ITEM# PART# DESCRIPTON QTY.

1 890787 HOSE,FUEL,1/2" ID AR 2 796090 CLAMP,HOSE,9/16 TO 1-1/16", S/S, SIZE 10X5/8 1 3 C90200250 BARB,1/4" MNPT 1/2" ID HOSE 1 4 C90200400 FITTING,PICKUP&RETURN 1 5 895775 PIPE NIPPLE 2X3 1 6 C90500850 COUPLING,PIPE,2" NPT 1 7 796151 FUEL CAP 1 8 C91100300 NYLON TUBING 1

9 890787 HOSE,FUEL,1/2" ID AR 10 796090 CLAMP,HOSE,9/16 TO 1-1/16", S/S, SIZE 10X5/8 1 11 C90200300 BARB,3/8"X1/4"NPT,90 1 12 C90500800 COUPLING,PIPE,1/4" 1 13 896781 VALVE,CHECK 1 14 C90200400 FITTING,PICKUP&RETURN 1 15 C51600800 NUT,CLIP,1/4"-20X3/4" 3 16 186695 FUEL SENDER RING CAP 1 17 INCLUDED IN ITEM 18 18 C43200601 SENDER,FUEL LEVEL, VDO 1 19 INCLUDED IN ITEM 18 20 895371 VALVE,VACCUUM RELIEF 1 21 792750 CLAMP 7/16 TO 25/32 1 22 890790 HOSE FUEL 1/4X1/2 200# AR 23 C91001300 FITTING,BARB,3/8"NPT 1 24 NPN PURCHASE LOCALLY 1 25 CD21F050 ROD,LIFTING 2 26 C36560 NUT,1.125"-7 6 27 C33638 WASHER,LOCK,1.125" 6 28 C33024 WASHER,FLAT,1.125" 6 29 C54200700 SCREW,1/2"-13X 1" Z G5 8 30 991650 WASHER LOCK 1/2 8 31 C33600200 MOUNT,VIBRATION 40DURO 4 32 995790 CLEVIS PIN 1 33 C75240 LOCK WASHER 1/2 SBZ 2 34 C74967 HEX NUT 1/2-13 SBZ 2 35 C74972 FLAT WASHER 1/2 SBZ 2 36 C74954 SCREW,HEX,1/2"-13 X 2.5" 1 37 993440 SCREW 1/4-20NCX3/4 - NOT SHOWN 3 38 684070 CORD GRIP - NOT SHOWN 1 39 CD22F000 BASE, ALL MODELS 1

Part No. 833009 T50 Super Quiet Generator 7 - 3

Page 68

Section 7 • Base Components

October 2006

Figure 7-B

Base Components

REV A

7 - 4 T50 Super Quiet Generator Part No. 833009

Page 69

October 2006

Section 7 • Base Components

REV A

ITEM # PART # DESCRIPTION QTY.

1 C90202200 FITTING,BULK HEAD,1/2 NPT 1

2 C90700800 ADAPTER,1/2"X1/4" REDUCER 1

3 C90400900 NIPPLE,PIPE,1/4"X1.5" 1

4 C90800200 VALVE,NEEDLE,1/4"FPTX1/4" FPT 1

5 C90200600 BARB,3/8"X1/4"NPT 1

6 792750 CLAMP 7/16 TO 25/32 WITH LINER 2

7 C91100700 HOSE,FUEL,3/8" 3

8 C90200300 BARB,3/8"X1/4"NPT, 90DEGREE, T50J ONLY, NOT SHOWN 1

9 981660 SCREW,1/2-13NCX1-1/2 HHC,GRADE 5,ZP 4 10 CD32F010 HAT CHANNEL,T50J 1 11 CD32P010 HAT CHANNEL,T50P 1 12 990210 WASHER FLAT 1/2 4 13 990200 NUT LOCK NYLON INSERT 1/2-13NC GR 2 ZPIN 4 14 C91104400 HOSE,OIL DRAIN,3/4" 1 15 C90101500 CLAMP,9/16" X 1-1/16" WITH LINER 1 16 C90200900 BARB,3/4"X1/2"NPT 1 17 C90800100 VALVE,BALL,1/2" 1 18 C90701000 FITTING,SWIVEL,7/8-14 NUT,1/2-14 1 19 898521 FITTING,ELBOW,7/8-14 M FLARE X 18M, T50J 1 20 898421 FITTING,STR TRD,ELBOW, 45 7/8-14X3/4-16, T50P 1 21 CD34F020 BULKHEAD,AIR, T50J 1 22 CD34P020 BULKHEAD,AIR, T50P 1 23 CD31F010 FOOT,ENGINE, RIGHT, T50J 1 24 CD31F020 FOOT,ENGINE, RIGHT, T50P 1 25 261252 BATTERY WET 12V GRP34/78 AMERISTART 750 CCA 1 26 C33700800 HOOK, BATTERY HOLD DOWN, PAIR 1 27 CU22A252 ANGLE, BATTERY, HOLD-DOWN 1

Part No. 833009 T50 Super Quiet Generator 7 - 5

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Section 7 • Base Components

October 2006

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7 - 6 T50 Super Quiet Generator Part No. 833009

Page 71

October 2006

Section 8 • Cabinet Components

Section Eight

Cabinet

Components

Part No. 833009 T50 Super Quiet Generator 8 - 1

Page 72

Section 8 • Cabinet Components

October 2006

Figure 8-A

Cabinet Components - Panels

REV A

8 - 2 T50 Super Quiet Generator Part No. 833009

Page 73

October 2006

Section 8 • Cabinet Components

REV A

FIGURE 8-A

ITEM # PART# DESCRIPTION QTY.

1 993422 SCREW, FLANGE 1/4-20 X 3/4" 4

2 C71014 FLAT WASHER 11/16" O.D. 8

3 CU59F005 EXHAUST HOLE COVER 1

4 990150 NUT 1/4-20, LOCK NYLON INSERT 4

5 990670 RIVET, POP, 3/16 X 1/2, SS 12

6 669174 PLATE DECK 1

7 CD59F015 RADIATOR ACCESS CAP 1

8 720440 WEATHERSTRIP, PER FT AR

9 C71100500 INSULATION, FOAM 1" THICK, PER SQ FT AR 10 CD59F000 HOUSING, TOP PANEL 1 11 C51601570 SCREW, FLANGE 3/8 X 3/4", PATCH AR 12 C54300600 WASHER, FLAT, 3/8" AR 13 C51601462 NUT, FLANGE, 3/8" AR 14 CF58T035 GUARD, LOUVER MESH 1 15 CD58F020 HOUSING, REAR PANEL 1 16 981605 SCREW, 3/8"-16 X 3" 8 17 990470 WASHER, LOCK, 3/8" 8 18 981120 WASHER, FLAT, 3/8" 8 19 C51600600 NUT, CLIP 8 20 CD52F020 HOUSING, REAR CORNER 2 21 CD57F010 HOUSING, DOOR STOP 2 22 CD52F030 HOUSING, LEFT FRONT CORNER 1 23 CD58F010 HOUSING, FRONT PANEL 1 24 CD52F010 HOUSING, RIGHT FRONT CORNER 1 25 GUU401100 TRIMLOCK SEAL, PER FT AR 26 680465 EDGE STRIP, PER FT AR 27 C72100400 WEATHERSTRIP, PER FT AR 28 GUU401000 INSULATION, FOIL, PER SQ FT AR

Part No. 833009 T50 Super Quiet Generator 8 - 3

Page 74

Section 8 • Cabinet Components

October 2006

Figure 8-B

Cabinet Components - Doors

REV A

8 - 4 T50 Super Quiet Generator Part No. 833009

Page 75

October 2006

Section 8 • Cabinet Components

REV A

FIGURE 8-B

ITEM # PART # DESCRIPTION QTY.

1 995701 SCREW, 1/4-20 X 1 32

2 990080 WASHER, FLAT, 3/8" 32

3 C37014 NUT,NYLOCK,10-24,Z 32

4 794891 HINGE,LIFT-OFF,STEEL 8

5 C53200100 LITERATURE BOX 1

6 C51200000 LATCH,BLACK,ALLEGIS 4

7 CD54F035 HOUSING DOOR 3PH 1

8 CD54F055 HOUSING DOOR ACCESS, LEFT 1

9 CD54F045 HOUSING DOOR ACCESS, RIGHT 1 10 CD54F025 HOUSING DOOR CTRL 1 11 C71100500 FOAM BLK URETHANE 1", PER SQ FT AR 12 C74100100 GASKET,WINDOW,CTRL DR, PER FT AR 13 CU54T021 WINDOW,CTRL DOOR 1 14 C73000100 TRIM LOCK,1/4", PER FT AR 15 C51400200 STOP,DOOR,RUBBER 2 16 C41037 RIVET 2 17 C74419 SCREW, CARRIAGE,1/4-20 4 18 C71014 FLAT WASHER 4 19 990150 NUT LOCK NYLON INSERT, 1/4-20 4

Part No. 833009 T50 Super Quiet Generator 8 - 5

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Section 8 • Cabinet Components

October 2006

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8 - 6 T50 Super Quiet Generator Part No. 833009

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October 2006

Section 9 • Control Box Components

Section Nine

Control Box

Components

Part No. 833009 T50 Super Quiet Generator 9 - 1

Page 78

Section 9 • Control Box Components

October 2006

Figure 9-A

Control Panel - Upper

REV A

9 - 2 T50 Super Quiet Generator Part No. 833009

Page 79

October 2006

Section 9 • Control Box Components

REV A

FIGURE 9-A

ITEM # PART # DESCRIPTION QTY.

1 CD42F010 CONTROL PAN ASSY 1 2 CU42Q031 CONTROL PANEL, DYNAGEN 1 2 CU42Q032 CONTROL PANEL, CASCADE 1 3 C42200500 POTENTIOMETER, VOLTAGE 1 4 682070 BREAKER MINI 1P 15A 1 5 C42202900 SWITCH,TOGGLE 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 C43101000 METER,AMP,0-200 1 16 R980195 SCREW,1/4-20NCX3/4 6

16A 990400 WASHER LOCK 1/4 6

17 981745 WASHER,FLAT,1/4" 6 18 992040 RIVET POP 3/16X.602 10 19 CB45A112 HARNESS,AC CTRL/PNL 1 20 CU45A100 HARNESS,CTRL,UNIVERSAL 1 21 C51600800 NUT,CLIP,1/4"-20X3/4" 6 22 CU43A050 PLASTIC 1/8"X10.5"X33 1 23 C51200201 HINGE,PIANO,9",SS 1 24 C42400700 SOLENOID 1 25 C33203000 CONTROLLER ELEC.GOV DPG2104 1 26 C42404000 TERMINAL STRIP,6 POS 1 27

28 C42401700 RELAY,OVER CURRENT 1 29 C42400810 SHUTDOWN,DYNAGEN,ECU-ES52 1 30 686747 SWITCH,SPST MOMENTARY 1 31 853810 DECAL: CONTROL PANEL 1 32 853813 DECAL: KIT-RECEPTACLES 1 33 853838 DECAL: CONTROL PANEL 1 34 CDWV40150 RELAY,50A,BOSCH 3 35 CDWV40151 RELAY BASE,50A,BOSCH 3 36 CDWV40152 RELAY PIN 12 37 R660115 JUMPER TERMINAL STRIP 1 38 R660715 DIODE,6AMP-50PIV 1 39 CU42T070 BRACKET,LATCH 1 40 C51601550 SCREW,SELF-TAPPING,#10 2 41 CU51A122 DECAL: HIGH VOLTAGE 1

SX460 OR SX465

AVR - CHECK UNIT BEFORE ORDERING 1

Part No. 833009 T50 Super Quiet Generator 9 - 3

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Section 9 • Control Box Components

October 2006

Figure 9-B

Control Panel - Lower

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Section 9 • Control Box Components

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FIGURE 9-B

ITEM # PART # DESCRIPTION QTY.

1 CD42F010 CONTROL PAN ASSY 1 2 CD41F020 PANEL,1PH,D-SERIES 1 3 C42104800 BREAKER,150A,SHUNTTRIP 1 4 C42103400 BREAKER,20A,120/240V 1 5 C42103600 BREAKER,50A,120/240V 1 6 C42103600 BREAKER,50A,120/240V 1 7 684640 RECEPTACLE 20A 120V DUPLEX W/GFI 2 8 C42500100 TRANSFORMER,100:5 3 9 C42500200 TRANSFORMER,200:5 1

9 C42500200 TRANSFORMER,200:5 ( 1 PHASE ONLY) 3 10 CU41S030 TEMP POWER SLOPE 1 11 C47100300 RECEPTACLE,TWISTLOCK 2 12 R980195 SCREW,1/4-20NCX3/4 6 13 981745 WASHER,FLAT,1/4" 6 14 CU45A010 HARNESS,AC/GEN 1 15 C51601442 SCREW,FLANGE,1/4"-20 4 16 990150 NUT LOCK NYLON INSERT, 1/4-20 6 17 990400 WASHER LOCK 1/4 6 18 853752 DECAL: REMOTE START CN 1 19 853813 DECAL: KIT-RECEPTACLES 1 20 66812 E-STOP, PUSH BUTTON 1 21 686662 EMERGENCY STOP, FACE PLATE 1 22 66817 EMERGENCY STOP, BASE 1 23 671278 BINDING POST FOR REMOTE START 1 24 C73716 SCREW,#6-32X1/2" 12 25 C27514 SCREW,#10-24X3" Z KEG 4 26 C37810 NUT,COUPLER,#10-24X3/4 4 27 R980900 NUT,LOCK NYLON INSERT #8-32NF 8 28 C54400100 SCREW, SET, 8-32X1/2" 8 29 C51600800 NUT,CLIP,1/4"-20X3/4" 6 30 CD41P020 PANEL,1PH,D-SERIES 1 31 683875 BREAKER, 200A, 2 POLE 1 32 CU51A122 DECAL: HIGH VOLTAGE 1

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October 2006

Section 10 • Distribution Panel

Section Ten

Distribution

Panel

Part No. 833009 T50 Super Quiet Generator 10 - 1

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Section 10 • Distribution Panel

October 2006

Figure 10-A

Distribution Panel

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Section 10 • Distribution Panel

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FIGURE 10-A

ITEM # PART # DESCRIPTION QTY.

1 CU43T020 PAN 3PH DIST 1

2 CU43A041 DIST LUG PANEL 1

3 C37819 NUT,COUPLER,3/8"-16 4

4 CF44T045 DIST. LUG COVER 1

5 C94903 SCREW, 3/8-16X1 1/4Z 4

6 994340 SCREW,#6-32X5/8" 4

7 990160 SCREW 3/8-16NCX3-3/4 4

8 994830 WASHER,LOCK,M10 4

9 C42200702 PLUNGER (ACTUATOR) 1 10 C42200701 SWITCH,SNAP-ACTION 1 11 INCLUDED IN ITEM 9 12 INCLUDED IN ITEM 9 13 CU51A400 DECAL: L1,L2,L3,N 1 14 INCLUDED IN ITEM 13 15 INCLUDED IN ITEM 13 16 INCLUDED IN ITEM 13 17 851820 DECAL: SYMBOL FOR GROUND 1 18 C74954 SCREW,HEX,1/2"-13 X 2.5" 5 19 995970 WASHER LOCK STAR 1/2 5 20 C74972 FLAT WASHER 1/2 SBZ 5 21 C75240 LOCK WASHER 1/2 SBZ 10 22 C74967 HEX NUT 1/2-13 SBZ 10 23 852255 3PH DIST PNL 1 24 994830 WASHER,LOCK,M10 8 25 990340 WASHER FLAT 1/4 4

Part No. 833009 T50 Super Quiet Generator 10 - 3

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Section 10 • Distribution Panel

October 2006

Figure 10-B

Voltage Selector Switch

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Section 10 • Distribution Panel

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FIGURE 10-B

ITEM # PART # DESCRIPTION QTY.

1 C42202402 VOLTAGE SELECTOR SWITCH 1

2 CD42I031 BCI, FRAME EXTENSION, BACK 1

3 CD42I030 BCI, FRAME EXTENSION, FRONT 1

4 CD42I040 BCI. FRAME EXTENSION, SIDE 2

5 CL-008 DECAL, DO NOT CHANGE POSITION 1

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October 2006

Section 11 • Engine & Genset Components

Section Eleven

Engine &

Genset

Components

Part No. 833009 T50 Super Quiet Generator 11 - 1

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Section 11 • Engine & Genset Components

October 2006

Figure 11-A

Engine Genset Assembly - Perkins 1104C-44G1

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Section 11 • Engine & Genset Components

REV B

FIGURE 11-A

ITEM # PART # DESCRIPTION QTY.

1 116843 GENSET,40KW PERKINS/NEWAGE 1

2 630947 GENERATOR,NEWAGE,40KW, BCI184J1A1232A, PERKINS 1

3 630992 GENERATOR,NEWAGE,40KW, SINGLE PHASE, PERKINS 1

4 830001 MANUAL, BCI GENERATOR 1

5 836427 RECTIFIER SERVICE KIT 1

6 732266PP ENGINE,PERKINS,40KW, T2, RE51215, 1104C.44G2 1

7 866047 AIR FILTER ASSY. 1

8 866049 ELEMENT, INNER 1

9 866048 ELEMENT, OUTER 1 10 741921 OIL FILTER 1 11 741923 FUEL FILTER 1 12 C42300100 LOW OIL PRESSURE SWITCH 1 13 C42300400 LOW OIL SENDER 1 14 C90700200 LOP SENDER ADAPTER 1 15 866064 SWITCH, COLD START ADVANCE 1 16 C42300500 HIGH TEMP SWITCH 1 17 C42300600 MAGNETIC PICK UP 1 18 866054 BELT 1 19 866064 WATER SEPARATOR 1 20 866055 RADIATOR 1 21 866056 FAN 1 22 866062 HOSE, UPPER 1 23 866063 HOSE, LOWER 1 24 C91100700 FUEL HOSE, 3/8" 1 25 890790 FUEL HOSE, 1/4" 1 26 866057 FAN GUARD 1 27 866058 FAN GUARD 1 28 866059 FAN GUARD, SMALL 1 29 866065 TEMP SWTICH/COLD START ADVANCE 1 30 C90700500 ADAPTER, MAG PICKUP 1 31 C33200500 FILTER, FUEL, 245R30 W/WATER SEPERATOR ASSEMBLY 1 32 CR25-P WATER SEPARATOR, ELEMENT ONLY 1

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Section 11 • Engine & Genset Components

October 2006

Figure 11-B

Engine Genset Assembly - John Deere 4045 DF270

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Section 11 • Engine & Genset Components

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FIGURE 11-B

ITEM # PART # DESCRIPTION QTY.

1 116853 GENSET, T50J, JD/NEWAGE, TIER 2 1

2 630944 GENERATOR,NEWAGE,40KWJD/I,4,BCI184J1L202A 1

3 732121 ENGINE,JD,4045DF270,T2, 50KVA/40KW,164P 1

4 830001 MANUAL, BCI GENERATOR 1

5 836427 RECTIFIER SERVICE KIT 1

6 33100702 AIR FILTER ASSY. 1

7 NA ELEMENT, INNER 1

8 33100703 ELEMENT, OUTER 1

9 741915 OIL FILTER 1 10 741916 FUEL FILTER 1 11 C42300100 LOW OIL PRESSURE SWITCH 1 12 C90700200 LOP SENDER ADAPTER 1 13 C42300400 LOW OIL SENDER 1 14 C42300500 HIGH TEMP SWITCH 1 15 C42300600 MAGNETIC PICK UP 1 16 741942 BELT 1 17 CR25P WATER SEPARATOR 1 18 C33300300 RADIATOR 1 19 C33301401 FAN 1 20 C91102100 HOSE, UPPER 1 21 C91109600 HOSE, LOWER 1 22 C91100700 FUEL HOSE, 3/8" 1 23 890790 FUEL HOSE, 1/4" 1 24 C33300900 FAN GUARD 1 25 CD34F030 FAN SHROUD 1 26 C33202900 ACTUATOR 1 27 C42301700 SWITCH, TEMP, W/SENDER, 1/2" THREAD, VDO 1 28 C33200500 FILTER, FUEL, 245R30, W/WATER SEPARATOR ASSEMBLY 1 29 791580 CLAMP 1-9/16" TO 2-1/2" WITH LINER 4 30 C91101201 ELBOW, RUBBER, 2" 90 DEGREE 2 31 CD35F030 PIPE, AIR BREATHER 40KW 1

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Section 11 • Engine & Genset Components

October 2006

Figure 11-C

Engine Muffler Assembly - John Deere & Perkins

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Section 11 • Engine & Genset Components

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FIGURE 11-C

ITEM # P ART # DESCRIPTION QTY.

1 CD33P045 MUFFLER EXTENSION, RIGHT 1 2 CD33P035 MUFFLER EXTENSION, LEFT 1 3 C51601570 SCREW,FLANGE,3/8" X 3/4" 4 4 990080 WASHER FLAT 3/8 8 5 C51601462 NUT, FLANGE, 3/8"-16 4 6 C21819 SCREW,CARRIAGE,3/8"-16 4 7 990210 WASHER FLAT 1/2 4 8 C51601462 NUT, FLANGE, 3/8"-16 4

9 CD33P010 MUFFLER, ASSEMBLY, T50-P 1 10 CD33F052 PIPE, EXHAUST 1 11 C33503401 CAP,RAIN,2.5" 1 12 C90101000 CLAMP,U-BOLT,2.5" 3 13 INCLUDED IN ITEM 12 3 14 INCLUDED IN ITEM 12 3 15 INCLUDED IN ITEM 12 3 16 CD33P020 EXHAUST ASSY., T50-P 1 17 C91100601 TUBING,FLEX,EXHAUST 1 18 CD33F050 MUFFLER,ASSY., T50-J 1 19 CD33F060 EXHAUST PIPE ASSY., T50-J 1 20 760453 CLAMP V-BAND EXHAUST 1

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October 2006

Section 12 • Trailer Components

Section Twelve

Trailer

Components

Part No. 833009 T50 Super Quiet Generator 12 - 1

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Section 12 • Trailer Components

October 2006

Figure 12-A

Trailer Components

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Section 12 • Trailer Components

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FIGURE 12-A

ITEM # PART # DESCRIPTION QTY.

1 124880 TRAILER, GENSET, D-SERIES, HYDRAULIC BRAKES 1 1 124885 TRAILER, GENSET, D-SERIES, ELECTRIC BRAKES 1 2 834238 AXLE, HYDRAULIC TRAILER BRAKES 1 2 834239 AXLE, ELECTRIC TRAILER BRAKES 1 3 841063 TIRE AND WHEEL MOUNTED, ST225/75R15D 2 4 840396 LUG NUT 12 5 834208 SAFETY CHAIN 2 6 834212 HITCH MOUNT, FOR TRAILER WITH ELECTRIC BRAKES 1 6 834241 HITCH MOUNT, INCLUDES HYDRAULIC ACTUATOR 1 7 C15309 BOLT 6 8 990210 WASHER 6

9 993170 NUT 6 10 834213 BOLT 2 11 834214 CONNECTOR, 6 PIN 1 12 834215 NUT 2 13 834216 RING HITCH, STANDARD 1 14 834237 JACK 1 15 834218 PIN 1 16 840082 FENDER, PLASTIC 2 17 834221 AMBER CLEARANCE LIGHT 2 18 834223 RED CLEARANCE LIGHT 2 19 834209 C-HOOK, SAFETY CHAIN 2 20 834232 CLEARANCE LIGHT MOUNTING KIT 4 21 834234 STOP, TAIL LIGHT W/GROMMET AND PLUG 2 22 834236 TAG LIGHT KIT 1 23 834247 ELECTRIC BOX 1 24 834248 WIRE HARNESS FOR ELECTRIC BOX 1 25 834243 HYDRAULIC LINE, METAL 1 26 834245 HYDRAULIC HOSE KIT 1

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Section 12 • Trailer Components

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12 - 4 T50 Super Quiet Generator Part No. 833009