Terex T12009-000101 Service Manual Download

Page: 1 / 48

Service Manual

Serial numbers
T7009-000101
T9009-000101
T12009-000101
and above

T70C
T70P
T90C
T90P
T120C
T120P

Part No. 134277
Rev A
November 2008

with
Maintenance
Information

Summary of Contents for T12009-000101

Page 1: ...Service Manual Serial numbers T7009 000101 T9009 000101 T12009 000101 and above T70C T70P T90C T90P T120C T120P Part No 134277 Rev A November 2008 with Maintenance Information...

Page 2: ...hout notice 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...

Page 3: ...4277 T70 T90 T120 Super Quiet Generator Serial Number Legend The serial number plate on your T70 T90 T120 Super Quiet Generator is located on the twist lock area of the lower control panel iii How to...

Page 4: ...November 2008 T70 T90 T120 Super Quiet Generator Part No 134277 This page intentionally left blank iv...

Page 5: ...e 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...

Page 6: ...ective 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...

Page 7: ...les v Section 2 Rev Specifications A T70C Specifications 2 1 A T70C Specifications Continued 2 2 A T70P Specifications 2 3 A T70P Specifications Continued 2 4 A T90C Specifications 2 5 A T90C Specific...

Page 8: ...ice Intervals 3 4 Newage Generators Maintenance Schedule 3 5 Section 4 Rev Troubleshooting Introduction 4 1 A Troubleshooting Guide 4 2 Section 5 Rev Schematics A Introduction 5 1 A Electrical Schemat...

Page 9: ...g parts are required to perform maintenance procedures as outlined in the TEREX T70 T90 and T120 Parts and Service Manuals Description Part No Cummins QSM11G4 Models Oil Filter 125550 Air Filter Prima...

Page 10: ...November 2008 T70 T90 T120 Super Quiet Generator Part No 134277 x This page intentionally left blank...

Page 11: ...ption 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 t...

Page 12: ..._______ _________________________________ ___________________________________ _________________________________ ___________________________________ _________________________________ __________________...

Page 13: ...105 F 41 C ambient Continuous improvement of our products is a Terex policy Product specifications are subject to change without notice or obligation Fuel system Specification 2 diesel Filter fuel wat...

Page 14: ...ler empty 5 390 lbs 2 445 kg full 6 782 lbs 3 076 kg Dimensions L x W x H 110 x 47 x 64 in no trailer 279 x 119 x 162 cm Weight with trailer empty 6 887 lbs 3 124 kg full 8 279 lbs 3 755 kg Dimensions...

Page 15: ...C ambient Fuel system Specification 2 diesel Filter fuel water separator Capacity 160 gal 606 L Tank and containment internal fuel tank with 110 fluid spill containment Fuel consumption run time Full...

Page 16: ...ler empty 5 390 lbs 2 445 kg full 6 782 lbs 3 076 kg Dimensions L x W x H 110 x 47 x 64 in no trailer 279 x 119 x 162 cm Weight with trailer empty 6 887 lbs 3 124 kg full 8 279 lbs 3 755 kg Dimensions...

Page 17: ...o 105 F 41 C ambient Fuel system Specification 2 diesel Filter fuel water separator Capacity 160 gal 606 L Tank and containment internal fuel tank with 110 fluid spill containment Fuel consumption run...

Page 18: ...iler empty 5 390 lbs 2 445 kg full 6 782 lbs 3 076 kg Dimensions L x W x H 110 x 47 x 64 in no trailer 279 x 119 x 162 cm Weight with trailer empty 6 887 lbs 3 124 kg full 8 279 lbs 3 755 kg Dimension...

Page 19: ...to 105 F 41 C ambient Fuel system Specification 2 diesel Filter fuel water separator Capacity 160 gal 606 L Tank and containment internal fuel tank with 110 fluid spill containment Fuel consumption r...

Page 20: ...iler empty 5 390 lbs 2 445 kg full 6 782 lbs 3 076 kg Dimensions L x W x H 110 x 47 x 64 in no trailer 279 x 119 x 162 cm Weight with trailer empty 6 887 lbs 3 124 kg full 8 279 lbs 3 755 kg Dimension...

Page 21: ...ed to 105 F 41 C ambient Fuel system Specification 2 diesel Filter fuel water separator Capacity 160 gal 606 L Tank and containment internal fuel tank with 110 fluid spill containment Fuel consumption...

Page 22: ...ler empty 5 390 lbs 2 445 kg full 6 782 lbs 3 076 kg Dimensions L x W x H 110 x 47 x 64 in no trailer 279 x 119 x 162 cm Weight with trailer empty 6 887 lbs 3 124 kg full 8 279 lbs 3 755 kg Dimensions...

Page 23: ...d to 105 F 41 C ambient Fuel system Specification 2 diesel Filter fuel water separator Capacity 160 gal 606 L Tank and containment internal fuel tank with 110 fluid spill containment Fuel consumption...

Page 24: ...nt Weight no trailer empty 5 390 lbs 2 445 kg full 6 782 lbs 3 076 kg Dimensions L x W x H 110 x 47 x 64 in no trailer 279 x 119 x 162 cm Weight with trailer empty 6 887 lbs 3 124 kg full 8 279 lbs 3...

Page 25: ...6 3000 4067 5 16 3 8 7 16 1 2 1 5 9 16 5 8 3 4 7 8 1 1 125 1 25 LUBED 1 4 LUBED DRY LUBED DRY LUBED DRY LUBED SAE FASTENER TORQUE CHART Grade 5 DRY LUBED This chart is to be used as a guide only unles...

Page 26: ...Specifications November 2008 Generator FT LB Flex Plate to Flywheel 70 Generator Case to Bellhousing 45 5 8 11 Socket Head Cap Screws for Lifting Channel 190 1 2 13 Hex Head Screws for Lifting Channel...

Page 27: ...nce procedure with the machine in the following configuration Machine parked on a firm level surface Toggle switch in the OFF position Wheels chocked About This Section This section contains detailed...

Page 28: ...move 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 Fundamentals It is the responsibility...

Page 29: ...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 sepa...

Page 30: ...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 Rep...

Page 31: ...ious 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 tes...

Page 32: ...lator 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 g...

Page 33: ...ging 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 Loose wire on the auto...

Page 34: ...it fuel injection is being supplied to the pump pump solenoid solenoid Defective solenoid Replace solenoid Clogged fuel system Check fuel system Air in fuel system Bleed fuel system Defective fuel pum...

Page 35: ...ne 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 Bl...

Page 36: ...CT THE FACTORY SERVICE MANAGER TOLL FREE AT 1 800 433 3026 TROUBLESHOOTING FAULT POSSIBLE CAUSE SOLUTION Engine shuts down Overloaded engine Reduce load automatically and TROUBLE LIGHT on Broken fan b...

Page 37: ...to the 3 phase door switch and will automatically trip the 3 phase breaker when the door is open and pre vents the breaker from being reset while it is open Generator Test resistance of field stator a...

Page 38: ...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 che...

Page 39: ...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 About This Section...

Page 40: ...REV A Section 5 Schematics 5 2 T70 T90 T120 Super Quiet Generator Part No 134277 September 2008 Control Panel Wiring for Murphy Cascade Controller Drawing ES100029 Standard...

Page 41: ...REV A Section 5 Schematics Part No 134277 T70 T90 T120 Super Quiet Generator 5 3 September 2008 Distribution Panel Wiring for T70 T90 T120 Single Phase Control Drawing ES100027...

Page 42: ...REV A Section 5 Schematics 5 4 T70 T90 T120 Super Quiet Generator Part No 134277 September 2008 Three Position Stack Switch Wiring Drawing ES100026...

Page 43: ...REV A Section 5 Schematics Part No 134277 T70 T90 T120 Super Quiet Generator 5 5 September 2008 Overcurrent Relay Wiring Drawing ES100006...

Page 44: ...REV A Section 5 Schematics 5 6 T70 T90 T120 Super Quiet Generator Part No 134277 September 2008 Standard Generator Wiring for T70 T90 T120 Series Drawing ES100030...

Page 45: ...REV A Section 5 Schematics Part No 134277 T70 T90 T120 Super Quiet Generator 5 7 September 2008 Idle Run Wiring Cummins Drawing ES100039...

Page 46: ...REV A Section 5 Schematics 5 8 T70 T90 T120 Super Quiet Generator Part No 134277 September 2008 This page intentionally left blank...

Page 47: ......

Page 48: ...Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Before Driving On The Road Before Towing Safety chains if required are properly attached and secure chains are crossed below hitch All light...

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Terex T12009-000101, Service Manual

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