Hi Ranger 5tc 55 Service Manual
. Operator/Service & Parts Manual First Edition Rev A1 Part No. 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 T50 Super Quiet Generator Part No. 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.
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.
Hi Ranger 5tc 55
Owners, Users, and Operators: TEREX appreciates your choice of our product for A dry-element air cleaner is standard equipment to your application. Our number one priority is user ensure a clean air supply, and a remote fuel/water safety which is best achieved by our joint efforts. Yellow with safety alert be energized. Lockout and tagout all symbol - Indicates a energy sources prior to performing potentially hazardous situation which, if not maintenance adjustments. Avoided, may result in minor or moderate injury. T50 Super Quiet Generator Part No.
Operator's Manual GENERAL SAFETY (Cont.) SAFETY SIGN LOCATIONS Part No. 833009 T50 Super Quiet Generator. Check exhaust system regularly for leaks and ensure that the exhaust manifolds are secure and not warped. Make sure the unit is well ventilated. Any unauthorized welding or repair procedure will void the warranty. T50 Super Quiet Generator Part No.
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. 833009 T50 Super Quiet Generator. Use the lifting eye for lifting the trailer (with cabi- The generator will be serviced, tested and ready net). Make sure any tie-downs at the bottom of the for operation upon delivery. Terex recommends trailer are released prior to lifting. The following checks.
Check the tires for proper inflation and verify TRANSPORT & TOWING that the lug nuts are tight. All trailer-mounted Terex Super Quiet generators are designed for highway and off road towing. If equiped with towing lights, connect the capability. 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. T50 Super Quiet Generator Part No.
“MANUAL” position. If the STARTING THE ENGINE/ engine fails to start again refer to the DynaGen GENERATOR SET manual or call Terex service. The “AUTO” position is to be used only with the remote start NEVER ATTEMPT TO START THE GENERA- feature. OPERATION PRESSING THE 'OFF' BUTTON ON THE CAS- CADE CONTROL PANEL. SWITCH THE TOG- The TEREX Super Quiet generator sets rated GLE TO THE “OFF” POSITION BEFORE MAK- from T25I to the T280J are equipped with a ING ANY ELECTRICAL CONNECTIONS. THE VOLTAGE SELECTOR SWITCH. Line - to - Neutral (“L1”, “L2” or “L3” to “N”) 277 VAC/1P.
ONCE THE PROPER VOLTAGE SELECTOR SWITCH POSITION IS SELECTED, TEREX NOTICE: This three-phase wiring configuration HIGHLY RECOMMENDS THAT THE SWITCH is referred to as “Hi Wye”. For generators with the Woodward Speed Control- ler installed refer to the 'Woodward Manual LCS Series Integrated Speed Control p/n 37101S1' POTENTIOMETER (VOLTAGE (Terex part number 833013) supplied with the unit ADJUSTMENT) for configuration and operation. The potentiometer is set at the factory. Turn all generator breakers to the “OFF” should correct the problem.
Allow the engine to run for 5 minutes under no NOTICE: Call TEREX Service for wiring and load until the coolant temperature gauge reads troubleshooting information. Approximately 175°F as a cool down cycle. 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). 25.6 25.1 34.1 48.6 64.9 69.7 94.5 92.2 30.1 40.8 54.3 77.4 46.9 63.6 62.5 84.8 64.5 87.5 86.2 1055 1233. An anti-seize lubricant MUST be used on all stainless steel hardware. 833009 T50 Super Quiet Generator.
Operator's Manual GENERATOR TORQUE SPECIFICATIONS Generator FT.LB Flex Plate to Flywheel 32-44 Generator Case to Bellhousing 1/2' Socket Head Cap Screws for Lifting Channel 1/2' Hex Head Screws for Lifting Channel Genset Isolators T50 Super Quiet Generator Part No. October 2006 REV A Service & Parts Catalog Part No. 833009 T50 Super Quiet Generator. TEREX policy.
Therefore, product specifications are subject to change without 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. October 2006 How to Read Your Serial Number REV A 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.
833009 T50 Super Quiet Generator. October 2006 REV A This page intentionally left blank. T50 Super Quiet Generator Part No.
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. 833009 T50 Super Quiet Generator. These components or maintenance information. 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.
T50J Lubrication and Maintenance Service Intervals.3 - 4 T50J and T50P Newage Generators Maintenance Schedule. 3 - 5 Section 4 Troubleshooting Introduction.4 - 1 Troubleshooting Guide.
4 - 3 Part No. 833009 T50 Super Quiet Generator. Figure 9-B Control Panel - Lower.9 - 4 Section 10 Rev Control Box Components Figure 10-A Distribution Panel. 10 - 2 Figure 10-B Voltage Selector Switch. 10 - 4 viii T50 Super Quiet Generator Part No. Engine Muffler Assembly - John Deere & Perkins.
11 - 6 Section 12 Rev Trailer Components Figure 12-A Trailer Components.12 - 2 Section 13 Rev Options Figure 13-A Options LIst. 13 - 2 Part No. 833009 T50 Super Quiet Generator. Parts Stocking List REV A Required Parts The following parts are required to perform maintenance procedures as outlined in the TEREX T50 Parts and Service Manual. Description Part No. Perkins 1104C.44G2 Models Oil Filter.
741921 Air Filter.866049 & 866048 Fuel Filter. October 2006 How To Order Parts REV A Please be prepared with the following information TEREX North America when ordering replacement parts for your TEREX Telephone (803) 324-3011 product: Toll Free (800) 433-3026 in U.S.A. And Canada Fax (803) 366-1101. Ship all available parts and contact customer on disposition of backordered parts Other (please specify) TEREX U Order Number Origin Code Comments T50 Super Quiet Generator Part No. 833009 Date Scheduled Ship Condition Order Total. Run Time (75% load) Fuel Consumption, Prime Power (gal per hr) 100% load 75% load 50% load 25% load Controller Type Digital/Analog Analog Start/Stop Controller Cascade Dynagen 12V Battery (CCA) Part No. 833009 T50 Super Quiet Generator 2 - 1.
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 2 - 2 T50 Super Quiet Generator Part No. 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 64.9 69.7 94.5 92.2 30.1 40.8 54.3 77.4 46.9 63.6 62.5 84.8 64.5 87.5 86.2 1055 1233 Part No. 833009 T50 Super Quiet Generator 2 - 3. Section 2. Specifications October 2006 This page intentionally left blank. 2 - 4 T50 Super Quiet Generator Part No.
Wheels chocked 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. 833009 T50 Super Quiet Generator 3 - 1. Inspector signature Inspector title Inspector company TEREX North America P.O. BOX 3147 Rock Hill, SC 29732 USA Toll Free (800) 433-3026 in U.S.A. And Canada Copyright © 2006 by TEREX Corporation.
TEREX® is a registered trademark of TEREX Corporation. Change cooling system coolant. Test/change fuel injector Change cooling system coolant. (commercial 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. 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 3 - 4 T50 Super Quiet Generator Part No.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. 833009 T50 Super Quiet Generator 3 - 5.
Section 3. Scheduled Maintenance Procedures October 2006 REV A This page intentionally left blank.
3 - 6 T50 Super Quiet Generator Part No. Use extreme caution when working with high voltage electrical components. Contact with hot engine components may cause severe burns. Use caution when working around a hot engine. 833009 T50 Super Quiet Generator 4 - 1.
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. 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. 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. 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.
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. October 2006 Section 4. Troubleshooting TROUBLESHOOTING Electrical Troubleshooting Generator Test resistance of field, stator and exciter wind- ings.
Contact TEREX for procedures or repair 5 Components that cause voltage facility recommended by generator manufacturer. Related problems Potentiometer Procedure for testing generator with no output Connects to voltage regulator.
In this case, pan marked MPU + and MPU. You should contact the TEREX service department. Both wires are isolated in their own shielded cable. If any further adjustment is needed to the voltage all other wiring on the back of the control panel of the generator please call Terex at 1-800-433- and on the inside of the control box.
3026 for assistance. Section 4.
Troubleshooting October 2006 This page intentionally left blank. 4 - 10 T50 Super Quiet Generator Part No. Return to Inspect Perform Be sure that all necessary tools and test service and test repair problem equipment are available and ready for use. Solved Part No. 833009 T50 Super Quiet Generator 5 - 1.
Section 5. Schematics October 2006 Control Panel Wiring for Murphy Cascade Controller REV A Drawing #ES1000001 (Standard) 5 - 2 T50 Super Quiet Generator Part No. October 2006 Section 5. Schematics Control Panel Wiring for Dynagen Controller REV A Drawing #EU0007 Part No.
833009 T50 Super Quiet Generator 5 - 3. Section 5.
Schematics October 2006 Distribution Panel Wiring for 'D' Series Single Phase Control REV A Drawing #ES1000003 5 - 4 T50 Super Quiet Generator Part No. October 2006 Section 5. Schematics Three Position Stack Switch Wiring Drawing #ES1000005 REV A Part No. 833009 T50 Super Quiet Generator 5 - 5. Section 5. Schematics October 2006 Overcurrent Relay Wiring Drawing #ES1000006 REV A 5 - 6 T50 Super Quiet Generator Part No. October 2006 Section 5.
Schematics Generator Wiring Breakdown Drawing #ES1000007 REV A Part No. 833009 T50 Super Quiet Generator 5 - 7. Section 5. Schematics October 2006 Standard Generator Wiring for 'D' Series REV A Drawing #ES1000008 5 - 8 T50 Super Quiet Generator Part No.
Section 6. Decals October 2006 Section Six Decals Part No. 833009 T50 Super Quiet Generator 6 - 1. Section 6. Decals October 2006 Figure 6-A REV A Decals 6 - 2 T50 Super Quiet Generator Part No.
Section 6. Decals October 2006 REV A FIGURE 6-A Part No. 833009 T50 Super Quiet Generator 6 - 3. Section 6. Decals October 2006 This page intentionally left blank.
6 - 4 T50 Super Quiet Generator Part No. October 2006 Section 7.
Base Components Section Seven Base Components Part No. 833009 T50 Super Quiet Generator 7 - 1. Section 7. Base Components October 2006 Figure 7-A REV A Base Components 7 - 2 T50 Super Quiet Generator Part No.
C74967 HEX NUT 1/2-13 SBZ C74972 FLAT WASHER 1/2 SBZ C74954 SCREW,HEX,1/2'-13 X 2.5' 993440 SCREW 1/4-20NCX3/4 - NOT SHOWN 684070 CORD GRIP - NOT SHOWN CD22F000 BASE, ALL MODELS Part No. 833009 T50 Super Quiet Generator 7 - 3.
Section 7. Base Components October 2006 Figure 7-B REV A Base Components 7 - 4 T50 Super Quiet Generator Part No. BULKHEAD,AIR, T50J CD34P020 BULKHEAD,AIR, T50P CD31F010 FOOT,ENGINE, RIGHT, T50J CD31F020 FOOT,ENGINE, RIGHT, T50P 261252 BATTERY WET 12V GRP34/78 AMERISTART 750 CCA C33700800 HOOK, BATTERY HOLD DOWN, PAIR CU22A252 ANGLE, BATTERY, HOLD-DOWN Part No. 833009 T50 Super Quiet Generator 7 - 5. Section 7. Base Components October 2006 This page intentionally left blank. 7 - 6 T50 Super Quiet Generator Part No.
Hi Ranger 5tc 55 Service Manual
October 2006 Section 8. Cabinet Components Section Eight Cabinet Components Part No. 833009 T50 Super Quiet Generator 8 - 1.
Section 8. Cabinet Components October 2006 Figure 8-A REV A Cabinet Components - Panels 8 - 2 T50 Super Quiet Generator Part No. HOUSING, LEFT FRONT CORNER CD58F010 HOUSING, FRONT PANEL CD52F010 HOUSING, RIGHT FRONT CORNER GUU401100 TRIMLOCK SEAL, PER FT 680465 EDGE STRIP, PER FT C72100400 WEATHERSTRIP, PER FT GUU401000 INSULATION, FOIL, PER SQ FT Part No. 833009 T50 Super Quiet Generator 8 - 3. Section 8. Cabinet Components October 2006 Figure 8-B REV A Cabinet Components - Doors 8 - 4 T50 Super Quiet Generator Part No. FOAM BLK URETHANE 1', PER SQ FT C74100100 GASKET,WINDOW,CTRL DR, PER FT CU54T021 WINDOW,CTRL DOOR C73000100 TRIM LOCK,1/4', PER FT C51400200 STOP,DOOR,RUBBER C41037 RIVET C74419 SCREW, CARRIAGE,1/4-20 C71014 FLAT WASHER 990150 NUT LOCK NYLON INSERT, 1/4-20 Part No.
833009 T50 Super Quiet Generator 8 - 5. Section 8. Cabinet Components October 2006 This page intentionally left blank. 8 - 6 T50 Super Quiet Generator Part No. Section 9. Control Box Components October 2006 Section Nine Control Box Components Part No.
833009 T50 Super Quiet Generator 9 - 1. Section 9. Control Box Components October 2006 Figure 9-A REV A Control Panel - Upper 9 - 2 T50 Super Quiet Generator Part No. DECAL: CONTROL PANEL 853813 DECAL: KIT-RECEPTACLES 853838 DECAL: CONTROL PANEL CDWV40150 RELAY,50A,BOSCH CDWV40151 RELAY BASE,50A,BOSCH CDWV40152 RELAY PIN R660115 JUMPER TERMINAL STRIP R660715 DIODE,6AMP-50PIV CU42T070 BRACKET,LATCH C51601550 SCREW,SELF-TAPPING,#10 CU51A122 DECAL: HIGH VOLTAGE Part No. 833009 T50 Super Quiet Generator 9 - 3. Section 9. Control Box Components October 2006 Figure 9-B REV A Control Panel - Lower 9 - 4 T50 Super Quiet Generator Part No.
C73716 SCREW,#6-32X1/2' C27514 SCREW,#10-24X3' Z KEG C37810 NUT,COUPLER,#10-24X3/4 R980900 NUT,LOCK NYLON INSERT #8-32NF C54400100 SCREW, SET, 8-32X1/2' C51600800 NUT,CLIP,1/4'-20X3/4' CD41P020 PANEL,1PH,D-SERIES 683875 BREAKER, 200A, 2 POLE CU51A122 DECAL: HIGH VOLTAGE Part No. 833009 T50 Super Quiet Generator 9 - 5. Section 9. Control Box Components October 2006 This page intentionally left blank. 9 - 6 T50 Super Quiet Generator Part No.
Section 10. Distribution Panel October 2006 Section Ten Distribution Panel Part No. 833009 T50 Super Quiet Generator 10 - 1. Section 10. Distribution Panel October 2006 Figure 10-A REV A Distribution Panel 10 - 2 T50 Super Quiet Generator Part No.
995970 WASHER LOCK STAR 1/2 C74972 FLAT WASHER 1/2 SBZ C75240 LOCK WASHER 1/2 SBZ C74967 HEX NUT 1/2-13 SBZ 852255 3PH DIST PNL 994830 WASHER,LOCK,M10 990340 WASHER FLAT 1/4 Part No. 833009 T50 Super Quiet Generator 10 - 3. Section 10. Distribution Panel October 2006 Figure 10-B REV A Voltage Selector Switch 10 - 4 T50 Super Quiet Generator Part No.
ITEM # PART # DESCRIPTION QTY. C42202402 VOLTAGE SELECTOR SWITCH CD42I031 BCI, FRAME EXTENSION, BACK CD42I030 BCI, FRAME EXTENSION, FRONT CD42I040 BCI. FRAME EXTENSION, SIDE CL-008 DECAL, DO NOT CHANGE POSITION Part No. 833009 T50 Super Quiet Generator 10 - 5. Section 10. Distribution Panel October 2006 This page intentionally left blank. 10 - 6 T50 Super Quiet Generator Part No.
Section 11. Engine & Genset Components October 2006 Section Eleven Engine & Genset Components Part No. 833009 T50 Super Quiet Generator 11 - 1. Section 11.
Engine & Genset Components October 2006 Figure 11-A REV A Engine Genset Assembly - Perkins 1104C-44G1 11 - 2 T50 Super Quiet Generator Part No. FAN GUARD 866058 FAN GUARD 866059 FAN GUARD, SMALL 866065 TEMP SWTICH/COLD START ADVANCE C90700500 ADAPTER, MAG PICKUP C33200500 FILTER, FUEL, 245R30 W/WATER SEPERATOR ASSEMBLY CR25-P WATER SEPARATOR, ELEMENT ONLY Part No. 833009 T50 Super Quiet Generator 11 - 3.
Section 11. Engine & Genset Components October 2006 Figure 11-B REV A Engine Genset Assembly - John Deere 4045 DF270 11 - 4 T50 Super Quiet Generator Part No. SWITCH, TEMP, W/SENDER, 1/2' THREAD, VDO C33200500 FILTER, FUEL, 245R30, W/WATER SEPARATOR ASSEMBLY 791580 CLAMP 1-9/16' TO 2-1/2' WITH LINER C91101201 ELBOW, RUBBER, 2' 90 DEGREE CD35F030 PIPE, AIR BREATHER 40KW Part No. 833009 T50 Super Quiet Generator 11 - 5.
Section 11. Engine & Genset Components October 2006 Figure 11-C REV A Engine Muffler Assembly - John Deere & Perkins 11 - 6 T50 Super Quiet Generator Part No. INCLUDED IN ITEM 12 INCLUDED IN ITEM 12 INCLUDED IN ITEM 12 CD33P020 EXHAUST ASSY., T50-P C91100601 TUBING,FLEX,EXHAUST CD33F050 MUFFLER,ASSY., T50-J CD33F060 EXHAUST PIPE ASSY., T50-J 760453 CLAMP V-BAND EXHAUST Part No. 833009 T50 Super Quiet Generator 11 - 7.
Section 11. Engine & Genset Components October 2006 This page intentionally left blank. 11 - 8 T50 Super Quiet Generator Part No.
Section 12. Trailer Components October 2006 Section Twelve Trailer Components Part No. 833009 T50 Super Quiet Generator 12 - 1. Section 12. Trailer Components October 2006 Figure 12-A REV A Trailer Components 12 - 2 T50 Super Quiet Generator Part No.
CLEARANCE LIGHT MOUNTING KIT 834234 STOP, TAIL LIGHT W/GROMMET AND PLUG 834236 TAG LIGHT KIT 834247 ELECTRIC BOX 834248 WIRE HARNESS FOR ELECTRIC BOX 834243 HYDRAULIC LINE, METAL 834245 HYDRAULIC HOSE KIT Part No. 833009 T50 Super Quiet Generator 12 - 3. Section 12. Trailer Components October 2006 This page intentionally left blank. 12 - 4 T50 Super Quiet Generator Part No.
Hi Ranger 5tc 55 Service Manual
Section 13. Options October 2006 Section Thirteen Options Part No. 833009 T50 Super Quiet Generator 13 - 1. BLOCK HEATER, PK 682776 RECEPTACLE, 15A, 125V, 682777 RECEPTACLE, 15A, 125V, 0GSX0150 124880 TRAILER, W /HYDRAULIC SURGE BRAKES (STD) 0GSX0151 124885 TRAILER, W /ELECTRIC BRAKES 0GSX0164 841083 LED TRAILER LIGHTS 13 - 2 T50 Super Quiet Generator Part No.