Terex T270 Guide

Operator/Service & Parts Manual
First Edition
Rev A1
Part No. 833018
T270/T280

2 T270 & T280 Super Quiet Generator Part No. 833018
REV A
Operator's Manual May 2007
Table Of Contents
Serial Number Registration
Serial Number Registration ............................................................................... 4
Introduction
Introduction....................................................................................................... 5
Description of Equipment.................................................................................. 5
General Safety
Hazard Classification ........................................................................................ 6
Safety Sign Locations ....................................................................................... 7
Accident Prevention.......................................................................................... 8
UnauthorizedWelding....................................................................................... 8
Fueling.............................................................................................................. 8
Electrical Safety ................................................................................................ 9
Battery Hazards................................................................................................ 9
Beware of Traffic Hazards ................................................................................ 9
Receipt of Delivery Checklist .......................................................................... 10
Transport & Towing ........................................................................................ 11
Setup .............................................................................................................. 11
Operating Instructions
Starting the Engine/Generator Set .................................................................. 13
Loading Instructions........................................................................................ 14
Voltage Selector Switch Operation ................................................................. 14
Potentiometer(VoltageAdjustment) ............................................................... 16
Murphy Cascade Controller ............................................................................ 16
Murphy iGuard Controller................................................................................ 16

Part No. 833018 T270 & T280 Super Quiet Generator 3
REV A
Operator's Manual
May 2007
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

4 T270 & T280 Super Quiet Generator Part No. 833018
REV A
Operator's Manual May 2007
TEREX Model Number _____________________ Serial Number ____________________________
Engine Model Number______________________ Serial Number ____________________________
Generator Model Number ___________________ Serial Number ____________________________
Owner:__________________________________ Ship to: _________________________________
Options:_________________________________
_______________________________________
_______________________________________
_______________________________________
_______________________________________
P.O. Box 3147 (29732)
590 Huey Road
Rock Hill, SC 29730
Telephone: [phone]
FAX: [phone]
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:
SERIAL NUMBER REGISTRATION

Part No. 833018 T270 & T280 Super Quiet Generator 5
REV A
Operator's Manual
May 2007
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 opera-
tors:
• 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 Depart-
ment in Rock Hill, SC.
DESCRIPTION OF EQUIPMENT
The engine/generator assembly consists of a
diesel engine combined with an electrical genera-
tor. This assembly is firmly bolted together to form
an integral unit and does not require anything
other than routine maintenance.
The engine is equipped with a 12-volt starter and
can be wired for remote starting capability at the
control panel.
A dry-element air cleaner is standard equipment to
ensure a clean air supply, and a remote fuel/water
separator is included for additional fuel system
protection.
The ECM (Engine Control Module) on the engine
provides a stable operating speed under varying
load conditions, and the generator is equipped
with a solid-state voltage regulator to stabilize the
output voltage under these same conditions.
Figures and schematics of both the ECM and
regulator are provided in the ENGINE and GEN-
ERATOR OPERATOR’S MANUALS.
An automatic shutdown system is incorporated in
the generator set to sense low oil pressure, high
coolant temperature, as well as overspeed and
underspeed conditions. In each case the engine/
generator assembly will automatically cease
operation.
A diesel fuel tank is incorporated within the base
of the unit to ensure an uninterrupted operating
cycle under full load. The engine/generator
assembly is mounted to the base using high
durometer vibration isolators.
The 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 sound-
dampening polymer foam that is highly effective in
noise suppression.
A high ambient temperature radiator and a critical
grade exhaust silencer are contained within the
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.

6 T270 & T280 Super Quiet Generator Part No. 833018
REV A
Operator's Manual May 2007
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 attention-
getting devices throughout this manual as well as
on decals and labels fixed to the machinery to
assist in potential hazard recognition and preven-
tion.
Red - Indicates an
imminently hazardous
situation which, if not avoided, will result in death
or serious injury.
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.
Yellow without safety
alert symbol - Indicates a
situation which, if not avoided, may result in
property or equipment damage.
Green - Indicates impor-
tant installation, operation
or maintenance information.
Hazardous voltage. Will cause
serious injury or death.
Hot exhaust. Can contain carbon
monoxide. Will cause serious injury
or death.
Read all manuals that shipped with
your equipment. Maintenance is
done more easily and safely when
you know what you're doing.
Keep all guards in place.
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
maintenanceadjustments.
enclosure as standard equipment.
A center-point lifting attachment is located in the
top of the enclosure to allow crane lifting of the
entire unit.
The generator set is mounted on a trailer equipped
for highway operation. Hydraulic surge brakes are
standard on larger generator sets for maximum
stopping efficiency. Electric brakes are also
available as an option.
DESCRIPTION OF EQUIPMENT (Cont.)

Part No. 833018 T270 & T280 Super Quiet Generator 7
REV A
Operator's Manual
May 2007
GENERAL SAFETY (Cont.)
SAFETY SIGN LOCATIONS

8 T270 & T280 Super Quiet Generator Part No. 833018
REV A
Operator's Manual May 2007
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.
GENERAL SAFETY (Cont.)
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.
Any unauthorized welding or repair procedure
will void the warranty.
ACCIDENT PREVENTION
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.
ALWAYS have a fire extinguisher nearby. Be sure
the extinguisher is properly maintained and be
familiar with its use. Extinguishers rated ABC
by the NFPA are appropriate for all applications.
FUELING

Part No. 833018 T270 & T280 Super Quiet Generator 9
REV A
Operator's Manual
May 2007
ELECTRICAL SAFETY
THIS EQUIPMENT USES HIGH VOLTAGE CIR-
CUITS CAPABLE OF CAUSING SERIOUS INJU-
RY 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
LEAD ACID BATTERIES CAN BE DANGER-
OUS. 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.
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 espe-
cially 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 servic-
ing. Never remove guards while unit is operating.
Keep your hands away from moving parts, particu-
larly clear of the radiator fan and alternator belts
when the engine is running.
BEWARE OF TRAFFIC HAZARDS
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 periodi-
cally to insure all are tight and nothing is in danger
of falling off during transit.
GENERAL SAFETY (Cont.)

10 T270 & T280 Super Quiet Generator Part No. 833018
REV A
Operator's Manual May 2007
BE CAREFUL WHEN LIFTING. NEVER SUS-
PEND ANY OTHER EQUIPMENT FROM THE
SHIPPING TIE DOWNS.
Use the lifting lug for lifting the trailer (with cabi-
net). Make sure any tie-downs at the bottom of the
trailer are released prior to lifting.
NEVER CLIMB ON TOP OF THE CABINET.
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.
Check all fluid levels; battery, radiator, and
engine oils.
Ensure manuals are in the pocket provided
inside the unit.
GENERAL SAFETY (Cont.)

Part No. 833018 T270 & T280 Super Quiet Generator 11
REV A
Operator's Manual
May 2007
TRANSPORT & TOWING
All trailer-mounted Terex Super Quiet generators
are designed for highway and off road towing
capability. Please consult state and local transpor-
tation codes before transporting the generator set.
Additionally, all state and local traffic laws take
precedence over the following instructions when-
ever 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.
• 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 TOW-
ING A GENERATOR.
FAILURE TO PROPERLY SECURE THE TRAIL-
ER TO THE TOWING VEHICLE MAY
RESULT IN SERIOUS INJURY OR DEATH.
• Retract the front leveling jack into its stowed
position.
EXCEEDING THESE RECOMMENDED SPEEDS
CAN CAUSE SEVERE DAMAGE TO THE UNIT.
DAMAGE CAUSED BY THESE
UNSAFE PRACTICES WILL VOID THE MANU-
FACTURER’S WARRANTY.
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.
• 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.
GENERAL SAFETY (Cont.)

12 T270 & T280 Super Quiet Generator Part No. 833018
REV A
Operator's Manual May 2007
THE WHEELS MUST BE PROPERLY CHOCKED
IF THE GENERATOR IS ON UNLEVEL
GROUND. DO NOT OPERATE THE GENERA-
TOR SET UNTIL IT HAS BEEN PROPERLY SE-
CURED.
When preparing to start the generator set, follow
the sequence listed below:
• 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.
NEVER REMOVE THE RADIATOR CAP WHILE
THE ENGINE IS RUNNING OR WHILE THE
ENGINE IS HOT.
• 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 MANUFACTUR-
ER'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.
• If the axle is sloped downhill, turn the generator
set so that the axle is level.
•ALWAYS chock the wheels of the generator
set.
• Unhook hitch, safety chains and running lights.
• Release the hitch pin and raise the tongue off
the towing vehicle.
• Level the generator set with the tongue jack.
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 VOLTAG-
ES THAT CAN CAUSE SEVERE SHOCK OR
DEATH! ONLY QUALIFIED ELECTRICIANS
SHOULD PERFORM ELECTRICAL WORK.
SETUP (Cont.)

Part No. 833018 T270 & T280 Super Quiet Generator 13
REV A
Operator's Manual
May 2007
OPERATING INSTRUCTIONS
STARTING THE ENGINE/
GENERATOR SET
Once setup procedures are completed, the
generator set is ready to be started. Start the
unit according to the following steps:
• Make sure the GENERATOR VOLTAGE
SELECTOR SWITCH has been set to the
proper range.This switch should be located
above the 3-phase distribution panel.
(DISREGARD IF THE UNIT DOESN’T HAVE
A SELECTOR SWITCH. THIS UNIT IS
PRESET FOR ONE VOLTAGE. SEE NAME
TAG.)
NEVER CHANGE THE POSITION OF THE
VOLTAGE SELECTOR SWITCH WHILE THE
GENERATOR IS RUNNING! THIS WILL
RESULT IN IMMEDIATE DAMAGE TO THE
SWITCH, THE GENERATOR, OR THE
CONNECTED EQUIPMENT. IT MAY RESULT
IN SERIOUS INJURY TO THE OPERATING
PERSONNEL.
For Cascade Equipped Generators:
• Place the toggle switch in "ON" position then
press the MANUAL ("MAN") BUTTON on the
Cascade Controller. Make sure all debris and
obstructions have been cleared from moving
parts and electrical terminals. The generator will
only make 3 attempts at starting before it must
be reset with the switch.
For iGuard Equipped Generators:
• Place the toggle switch in "ON" position then
press the START BUTTON on the iGuard
NEVER ATTEMPT TO START THE GENERA-
TOR SET WITH ANY OF THE CIRCUIT BREAK-
ERS "ON". THESE BREAKERS ARE LOCATED
ON THE CONTROL PANEL. STARTING WITH
THE BREAKERS "ON" CAN CAUSE DAMAGE
TO THE GENERATOR.
• Now that the generator set is running, allow five
minutes for warm-up time.
• Listen for any unusual sounds or excess
vibrations that could signal problems and
require immediate shutdown of the unit. Should
unusual sounds be detected, shut the unit
down, and contact TEREX Service.
• Once the engine has been started and running
smoothly, the following gauges should be
monitored. All gauges are located on the control
panel.
• Oil Pressure Gauge - This gauge should read
30 psi or higher.
• Coolant Temperature Gauge -This gauge
should read between 170-200 degrees F.
• Voltmeter - This gauge should read at least
13 -15 volts DC to indicate the diesel engine’s
alternator is charging properly.
• AC Voltmeter - This gauge should reflect the
proper voltage selected for this operation.
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.

14 T270 & T280 Super Quiet Generator Part No. 833018
REV A
Operator's Manual May 2007
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 CAS-
CADE CONTROL PANEL. SWITCH THE TOG-
GLE TO THE “OFF” POSITION BEFORE MAK-
ING 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.
• 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 OPERA-
TION UNDER THIS CONDITION WILL CAUSE
DAMAGE TO THE GENERATOR AND/OR
CONNECTED APPARATUS.
The needle on the ammeter will deflect to the right
temporarily and then return to a normal
reading if the unit is operating properly.
OPERATING INSTRUCTIONS (Cont.)
• AC Ammeter - The reading on this gauge
should be zero since the main breaker is in the
“OFF” position. Once a load is applied to the
generator, the ammeter will produce an
appropriatereading.
VOLTAGE SELECTOR SWITCH
OPERATION
The TEREX Super Quiet generator sets rated are
equipped with a VOLTAGE SELECTOR SWITCH.
This switch can have three positions marked “480/
277 - 3 Phase” and “240/139 - 3 Phase”, or “240/
120 - 1 Phase”. Each position delivers a different
output voltage to the DISTRIBUTION LUGS. The
SELECTOR SWITCH and DISTRIBUTION LUGS
are located on the DISTRIBUTION PANEL. The
following instructions should be considered when
operating the VOLTAGE SELECTOR SWITCH.
• Always make sure the voltage selector switch
has been set to the desired range before
starting the generator set.
NEVER OPERATE THE VOLTAGE SELECTOR
SWITCH WHILE THE GENERATOR IS RUN-
NING! THIS WILL RESULT IN IMMEDIATE
DAMAGE TO THE SWITCH, THE GENERATOR,
OR THE CONNECTED EQUIPMENT AND MAY
RESULT IN SERIOUS INJURY TO THE OPER-
ATING PERSONNEL.
IMPROPER OPERATION OF THE GENERATOR
SET WILL VOID THE WARRANTY.
THIS GENERATOR SET PRODUCES VOLTAG-
ES THAT CAN CAUSE SEVERE SHOCK OR
DEATH! ONLY QUALIFIED ELECTRICIANS
SHOULD PERFORM ELECTRICAL WORK.

Part No. 833018 T270 & T280 Super Quiet Generator 15
REV A
Operator's Manual
May 2007
OPERATING INSTRUCTIONS (Cont.)
• The voltage selector switch can control the
single-phase receptacles provided on the unit.
Their indicated voltages should be checked
after selecting the setting of the switch. The Y
voltage configurations of 480 and 240 will
produce a voltage of 139 on the GFI
receptacles.
VOLTAGE SELECTOR SWITCH
OPERATION
The voltage selector switch will have three posi-
tions, and each position gives a different output to
the three-phase distribution lugs (designated as
“L1”, “L2”, “L3”, and “N”) located on the distri-
bution panel.
In the three-phase “480/277” position, the follow-
ing will be the normal output voltages:
•Line - to - Line (“L1” to “L2”, “L2” to “L3”,
“L1” to “L3”) 480 VAC/3P.
•Line - to - Neutral (“L1”, “L2” or “L3” to “N”)
277 VAC/1P.
NOTICE: This three-phase wiring configuration
is referred to as “Hi Wye”.
In the three-phase “240/139” position, the follow-
ing will be the normal output voltages:
•Line - to - Line (“L1” to “L2” and “L2” to
“L3”; “L1” to “L3”) 240 VAC/3P.
•Line - to - Neutral (“L1”, “L2”, or “L3” to
“N”) 139 VAC/1P.
NOTICE: The above voltages can be “dialed
down”, or adjusted lower, by using the voltage
adjustment potientiometer located on the gen-
erator main control panel.
NOTICE: This three-phase wiring configuration
is referred to as “Lo Wye”.
The three position selector switch has HI WYE
480 V 3ph., LOW WYE 240 V 3ph. and 240V
single phase that is Zig Zag. The following is the
output voltages on the zigzag position.
•Line - to - Line ("L1" to "L3") 240 VAC/1P.
•Line - to - Neutral ("L1" or "L3" to "N") 120
VAC/1P. "L2" is not used in this position.
THIS EQUIPMENT USES HIGH VOLT-
AGE CIRCUITS CAPABLE OF CAUSING
SERIOUS INJURY OR DEATH! EXCERCISE EX-
TREME CAUTION AROUND ANY ELECTRICAL
COMPONENT WHEN OPERATING THIS UNIT.
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 EQUIP-
MENT WILL BE AVOIDED.

16 T270 & T280 Super Quiet Generator Part No. 833018
REV A
Operator's Manual May 2007
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!
MURPHY CASCADE CONTROLLER
For generators with the Murphy Cascade Control-
ler installed refer to the "Cascade Controller
Installation and Operations Manual p/n 00-02-
0594" (Terex part number 833011) supplied with
the unit for configuration and operation.
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.
POTENTIOMETER (VOLTAGE
ADJUSTMENT)
OPERATING INSTRUCTIONS (Cont.)
MURPHY iGUARD CONTROLLER
For generators with the Murphy iGUARD Control-
ler installed refer to the "Installation and Opera-
tions Manual for iGuard Digital Generator Set
Controller p/n IG-02117N" (Terex part number
839058) supplied with the unit for configuration
and operation.

Part No. 833018 T270 & T280 Super Quiet Generator 17
REV A
Operator's Manual
May 2007
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 CONNECT-
ED APPARATUS.
• Turn all generator breakers to the “OFF”
position.
• Allow the engine to run for 5 minutes under no
load until the coolant temperature gauge reads
approximately 175°F as a cool down cycle.
For Cascade Equipped Generators:
• Stop the engine by pushing the Cascade
Controller “OFF” button.
For iGuard Equipped Generators:
• Stop the engine by pushing the iGuard
Controller "OFF" button and switching the
iGuard toggle switch to the “OFF” position.
OPERATING INSTRUCTIONS (Cont.)
OVERCURRENT PROTECTION

18 T270 & T280 Super Quiet Generator Part No. 833018
REV A
Operator's Manual May 2007
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 turbocharg-
ers, causing the engine to run rough and reduce
the operating performance.
Wet Stacking does not usually cause any perma-
nent 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 mainte-
nance and testing requirements.
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.
Starting out using less than 25% of the nameplate
rating until the engine has warmed up. Progres-
sively 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.

Part No. 833018 T270 & T280 Super Quiet Generator 19
REV A
Operator's Manual
May 2007
SIZE THREAD
in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm in-lbs Nm
20 100 11.3 80 9 140 15.8 110 12.4 130 14.7
28 90 10.1 120 13.5 120 13.5 160 18 140 15.8
ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
18 13 17.6 17 23 18 24 25 33.9 21 28.4
24 14 19 19 25.7 20 27.1 27 36.6 24 32.5
16 23 31.2 31 42 33 44.7 44 59.6 38 51.5
24 26 35.2 35 47.4 37 50.1 49 66.4 43 58.3
14 37 50.1 49 66.4 50 67.8 70 94.7 61 82.7
20 41 55.5 55 74.5 60 81.3 80 108.4 68 92.1
13 57 77.3 75 101.6 80 108.4 110 149 93 126
20 64 86.7 85 115 90 122 120 162 105 142
12 80 108.4 110 149 120 162 150 203 130 176
18 90 122 120 162 130 176 170 230 140 189
11 110 149 150 203 160 217 210 284 180 244
18 130 176 170 230 180 244 240 325 200 271
10 200 271 270 366 280 379 380 515 320 433
16 220 298 300 406 310 420 420 569 350 474
9320 433 430 583 450 610 610 827 510 691
14 350 474 470 637 500 678 670 908 560 759
8480 650 640 867 680 922 910 1233 770 1044
12 530 718 710 962 750 1016 990 1342 840 1139
7590 800 790 1071 970 1315 1290 1749 1090 1477
12 670 908 890 1206 1080 1464 1440 1952 1220 1654
7840 1138 1120 1518 1360 1844 1820 2467 1530 2074
12 930 1260 1240 1681 1510 2047 2010 2725 1700 2304
61460 1979 1950 2643 2370 3213 3160 4284 2670 3620
12 1640 2223 2190 2969 2670 3620 3560 4826 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
LUBEDDRYLUBED
SAE FASTENER TORQUE CHART
Grade 5
DRYLUBED
• This chart is tobe usedas a guide onlyunless notedelsewhere in this manual •
A574 High Strength
Black Oxide Bolts
Grade 8
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
516 1.8 21 2.4 41 4.63 54 6.18 58 6.63 78 8.84 68 7.75 91 10.3
619 3.05 36 4.07 69 7.87 93 10.5 100 11.3 132 15 116 13.2 155 17.6
745 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 Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm ft-lbs Nm
85.4 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 10.814.714.419.627.937.837.250.539.954.153.272.246.763.362.384.4
12 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
14 30.1 40.8 40 54.3 77.4 105 103 140 110 150 147 200 129 175 172 234
16 46.9 63.6 62.5 84.8 125 170 166 226 173 235 230 313 202 274 269 365
18 64.5 87.5 86.2 117 171 233 229 311 238 323 317 430 278 377 371 503
20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713
22 124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970
24 157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233
LUBED DRY LUBED DRYLUBED DRY LUBED DRY
LUBEDDRYLUBED
Class 12.9Class 4.6
DRYLUBED
METRIC FASTENER TORQUE CHART
• This chart is tobe usedas a guide onlyunless notedelsewhere in this manual •
LUBED DRY
Class 10.9Class 8.8
DRY
10.9 12.98.84.6
* An anti-seize lubricant MUST be used on all stainless steel hardware.
TORQUE SPECIFICATIONS

20 T270 & T280 Super Quiet Generator Part No. 833018
REV A
Operator's Manual May 2007
Generator FT*LB
Flex Plate to Flywheel 55
Generator Case to Bellhousing 33
1/2" Hex Head Screws for Lifting Channel 70
3/4" Hex Head Screws for Lifting Channel 240
Genset Isolators 70
GENERATOR TORQUE SPECIFICATIONS