Terex T360 User manual

Service Manual
First Edition
Rev A
Part No. 134890
August 2008
T360

August 2008
T360 Super Quiet Generator Part No.134890
ii
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.
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.
Copyright © 2008 by TEREX Corporation
134890 Rev A August 2008
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.
Contact Us:
www.TEREX.com
Serial Number Information
TEREX Corporation offers the following manuals for
these models:
Title Part No.
TEREX T360 Operator's Manual, .......................133005
First Edition
TEREX T360 Service Manual, ...........................134890
First Edition
TEREX T360 Parts Manual, ...............................134889
First Edition
Newage Generator Manual ................................836430
Cummins Engine Manual ...................................125558
Cascade Controller Manual ............................... 833011
Cummins Controller Manual .......................... 900-0661
(available through Cummins Manuafacturing only)
Dexter Axle Manual ............................................833014
Introduction

August 2008
Part No.134890 T360 Super Quiet Generator
Serial Number Legend
The serial number plate on your T360 Super Quiet
Generator is located on the twist lock area of the
lower control panel.
iii
How to Read Your Serial Number

August 2008
T360 Super Quiet Generator Part No.134890
This page intentionally left blank.
iv

August 2008
Part No.134890 T360 Super Quiet Generator
v
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.
Safety Rules
Section 1 • Safety Rules

August 2008
T360 Super Quiet Generator Part No.134890
SAFETY RULES
vi
Section 1 • Safety 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.
Indicates an imminently hazardous
situation which, if not avoided, will
result in death or serious injury.
Indicates a potentially hazardous
situation which, if not avoided,
could result in death or serious
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may cause minor or moderate
injury.
Indicates a potentially hazardous
situation which, if not avoided,
may result in property damage.
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 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.
Be sure that your workshop or work area is
properly ventilated and well lit.

August 2008
Part No.134890 T360 Super Quiet Generator
Table of Contents
Introduction
Important Information - Introduction .................................................................... ii
How to Read Your Serial Number ...................................................................... iii
Parts Stocking List ............................................................................................ ix
How to Order Parts ............................................................................................ xi
Service Parts Fax Order Form ......................................................................... xii
Section 1 Safety Rules
General Safety Rules ........................................................................................
v
Section 2 Rev Specifications
A Specifications .............................................................................................. 2 - 1
A Specifications (Continued) ............................................................................ 2 - 2
A Torque Specifications ................................................................................... 2 - 3
A Generator Torque Specifications .................................................................. 2 - 4
Section 3 Rev Scheduled Maintenance Procedures
Introduction .................................................................................................. 3 - 1
Pre-delivery Preparation Report .................................................................... 3 - 2
AMaintenance Schedules
Cummins Lubrication and Maintenance Service Intervals ............................. 3 - 3
Newage Generators Maintenance Schedule ................................................. 3 - 5
Section 4 Rev Troubleshooting
Introduction .................................................................................................. 4 - 1
A Troubleshooting Guide .................................................................................. 4 - 2
vii

August 2008
T360 Super Quiet Generator Part No.134890
TABLE OF CONTENTS
Section 5 Rev Schematics
A Introduction .................................................................................................. 5 - 1
A Electrical Schematic - Control Panel Wiring for
Murphy Cascade Controller .......................................................................... 5 - 2
A Electrical Schematic - Distribution Panel Wiring ........................................... 5 - 3
A Electrical Schematic - Stack Switch ............................................................ 5 - 4
A Electrical Schematic - Overcurrent Relay ..................................................... 5 - 5
A Electrical Schematic - Standard Generator Wiring ........................................ 5 - 6
A Electrical Schematic - Idle-Run Wiring (Cummins) ....................................... 5 - 7
A Electrical Schematic - Control Panel Wiring for
Cummins Controller ...................................................................................... 5 - 8
viii

August 2008
Part No.134890 T360 Super Quiet Generator
Required Parts
The following parts are required to perform
maintenance procedures as outlined in the
TEREX T360 Parts and Service Manual.
Description Part No.
Cummins QSM11G4 Models
Oil Filter .............................................................. 125550
Air Filter - Primary .............................................. 125561
Air Filter - Secondary ......................................... 125562
Fuel Filter ........................................................... 125551
Belt ..................................................................... 125552
Parts Stocking List
ix

August 2008
T360 Super Quiet Generator Part No.134890
x
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August 2008
Part No.134890 T360 Super Quiet Generator
Machine Information
Model
Serial Number
Date of Purchase
Authorized TEREX Distributor
Phone Number
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 [phone]
Toll Free [phone] in U.S.A. and Canada
Fax [phone]
xi

August 2008
T360 Super Quiet Generator Part No.134890
Part Number Description Quantity Price
All backordered parts will be shipped when available via the same ship method as the original order
unless noted below:
oShip complete order only - no backorders
oShip all available parts and contact customer on disposition of backordered parts
oOther (please specify)
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) _________________
Optional Equipment __________________________________________________________________________
FOR TEREX USE ONLY
Order Number ______________ Origin Code ________________ Comments _________________________
Date Scheduled ____________ Ship Condition ______________ __________________________________
Order Total ________________ Terms Code ________________ __________________________________
remove this page and make copies remove this page and make copies
Service Parts fax Order Form
FAX TO: [phone] OR TOLL FREE: 800-433-3026

REV A
Part No. 134890 T360 Super Quiet Generator 2 - 1
Section 2 • Specifications
August 2008
Specifications
System Power Output
Prime 3 Phase Power 288 kW
Prime 3 Phase kVA 360 kVA
Available 3 Phase Voltage 208 / 220 / 240 / 440 / 480
Associated 3 Phase Amps (0.8 power factor) 999 / 945 / 866 / 472 / 433
Prime 1 Phase Power 160kW
Prime 1 Phase kVA 160 kVA
Available 1 Phase Voltage 120 / 240
Associated 1 Phase Amps (1.0 power factor) 1333 / 667
Max Amp Rating (Main Breaker Size) 1200 A
Engine Specs
Manufacturer Cummins
Model QSM11-G4
Horsepower - Prime (1800 rpm) 426 hp (318 kWm)
Description 6-Cyl., 4 Cycle, Water Cooled, OHV, In-Line, Direct Inj.
Bore & Stroke 4.92 x 5.79 in. (125mm x 170mm)
Piston Displacement 661 cu. In (10.8 L)
Compression Ratio 16.3 : 1
Exhaust System Critical Grade Silencer
Monitoring Gauges Oil Press., Water Temp., Fuel Level, Battery Voltage, Hours
Engine Cooling System
Coolant Capacity - engine only 2.5 gal (9.5 L)
Cooling System Liquid Cooled - Air to Air CAC - Rated to 105° F Ambient
Fuel System
Fuel Specification #2 Diesel
Fuel Filter Fuel/Water Separator
Fuel Capacity 400 gal (1514 L)
Fuel Tank and Containment Internal Fuel Tank with Fluid Spills Containment
Fuel Consumption (Run Time) Full Load 20.7 gal/hr (78 L/hr) 19 hr
3/4 Load 15.5 gal/hr (59 L/hr) 25.8 hr
Half Load 10.6 gal/hr (40 L/hr) 37.7 hr

REV A
2 - 2 T360 Super Quiet Generator Part No. 134890
Section 2 • Specifications August 2008
SPECIFICATIONS
Generator Specs
Rating (0.8 power factor) 352 kW 3 Phase @ 480/240V
Description Brushless, 4 Pole, Synchronous, Single Bearing
Insulation Class H
Temperature Rating 125° C Rise Over 40° C Ambient
Automatic Voltage Regulator External, Solid State, Adjustable
Voltage Regulation +/- 1%
Frequency (Speed) 60 Hertz (1800 RPM)
System Controls
Governor ECM Controlled
Protection (Safety Shutdowns) Low Oil Pressure, High Water Temperature
Overcrank, Overspeed, Underspeed
Generator Gauges Voltmeter, Ammeter, Hertz Meter
Distribution
Receptacles, 120 V 2 Each 20 Amp GFCI Duplex
Receptacles, 240 V 3 Each 50 Amp Tempower T/L
Primary Distribution 5 Lug Terminals with Mainline Circuit Breaker
Packaging
Enclosure Sound Attenuated, Weatherproof with Lockable Doors
Sound Levels 72 dBA at 23 ft. (7 meters)
Lifting System Roof Mounted, Single Point
Weight Empty (No Trailer) 10450 lb. (4740 kg)
Weight Full (No Trailer) 13227 lb. (6000 kg)
Dimensions - L x W x H (No Trailer) 165 x 62 x 94 in. (419 x 157 x 2394 cm)
Weight Empty with Trailer 13120 lb. (5964 kg)
Weight Full with Trailer 15890 lb. (7223 kg)
Dimensions - L x W x H with Trailer 230 x 88 x 114 in. (584 x 224 x 290 cm)

REV A
Part No. 134890 T360 Super Quiet Generator 2 - 3
Section 2 • Specifications
August 2008
SPECIFICATIONS
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 10.8 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
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 to be usedas a guide onlyunless notedelsewhere in this manual•
LUBED DRY
Class 10.9Class 8.8
DRY
10.9 12.98.84.6

Section 2 • Specifications
2 - 4 T360 Super Quiet Generator Part No. 134890
August 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 70
Genset Isolators 70
GENERATOR TORQUE SPECIFICATIONS

Section 3 • Scheduled Maintenance Procedures
Part No.134890 T360 Super Quiet Generator 3 - 1
August 2008
Scheduled Maintenance Procedures
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
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.
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.
Used to indicate the presence of
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, could result
in death or serious injury.
Used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.
Used to indicate operation or
maintenance information.
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.

Copyright © 2006 by TEREX Corporation. TEREX® is a registered trademark of TEREX
Corporation.
Rev B
Pre-DeliverPre-Deliver
Pre-DeliverPre-Deliver
Pre-Delivery Preparationy Preparation
y Preparationy Preparation
y Preparation
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
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
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.
TEREX North America
P.O. BOX 3147
Rock Hill, SC 29732 USA
Toll Free [phone] in U.S.A. and Canada

REV A
Section 3 • Scheduled Maintenance Procedures
Part No.134890 T360 Super Quiet Generator 3 - 3
August 2008
Maintenance Schedules
CUMMINS LUBRICATION AND MAINTENANCE SERVICE INTERVALS
ITEM DAILY 50 Hrs or
Wkly 500 Hrs or 12 Mths 1000 Hrs 2000 Hrs
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 •
ITEM 2 Yrs 3000 Hrs 3000 Hrs or
2 Yrs 4000 Hrs 6000 Hrs or 3 Yrs 12000 Hrs or 6 Yrs
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) •

REV A
Section 3 • Scheduled Maintenance Procedures
3 - 4 T360 Super Quiet Generator Part No.134890
August 2008
MAINTENANCE SCHEDULES CONTINUED
NEWAGE GENERATORS MAINTENANCE SCHEDULE
ITEM DAILY 250 Hours
or 3
Months
1500 Hours
or 12
Months
4500 Hours
or 3 Years
15000
Hours or 19
Years
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 •
*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.