Terex T25 Operator, Service & Parts Manual
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Terex T25 Operator, Service & Parts Manual

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See also: Service Manual
Operator/Service & Parts Manual
T25/T45
First Edition
Rev A1
Part No. 833008

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Summary of Contents for Terex T25

  • Page 1 Operator/Service & Parts Manual T25/T45 First Edition Rev A1 Part No. 833008...

  • Page 2: Table Of Contents

    FIGURE 5 - CABINET ASSEMBLY W/DOORS ........54 FIGURE 6 - CONTROL PANEL ASSEMBLY- UPPER......56 FIGURE 7 - CONTROL PANEL ASSEMBLY - LOWER......58 FIGURE 8 - DISTRIBUTION PANEL ............60 FIGURE 9 - MUFFLER ASSEMBLY ............62 Terex T25I and T45I Super Quiet Generator...
  • Page 3 FIGURE 11A - ENGINES - T25I..............66 FIGURE 11B - ENGINES - T45I..............68 FIGURE 12 - VOLTAGE SELECTOR SWITCH ........70 FIGURE 13 - TRAILER ................72 FIGURE 14 - OPTIONS................74 Terex T25I and T45I Super Quiet Generator...

  • Page 4: June

    This Operation and Service Manual contains information specifically pertaining to the operation and maintenance of the TEREX T25I and T45I 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.

  • Page 5: Introduction

    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.

  • Page 6: General Safety

    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. Terex T25I and T45I Super Quiet Generator...

  • Page 7: Safety Sign Locations

    Operating Instructions and Parts Manual June 2006 REV A GENERAL SAFETY (Cont.) SAFETY SIGN LOCATIONS Terex T25I and T45I Super Quiet Generator...
  • Page 8 Check exhaust system regularly for leaks and ensure that the exhaust manifolds are secure and Any unauthorized welding or repair procedure not warped. Make sure the unit is well ventilated. will void the warranty. Terex T25I and T45I Super Quiet Generator...
  • Page 9 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. Terex T25I and T45I Super Quiet Generator...

  • Page 10: Receipt Of Delivery Checklist

    Check the exhaust system for damage. NEVER CLIMB ON TOP OF THE CABINET. Check all fluid levels; battery, radiator, and engine oils. Ensure manuals are in the pocket provided inside the unit. Terex T25I and T45I Super Quiet Generator...

  • Page 11: Transport & Towing

    • Check the tires for proper inflation and verify TRANSPORT & TOWING that the lug nuts are tight. All trailer-mounted Terex Super Quiet Pac genera- tors are designed for highway and off road • If equiped with towing lights, connect the towing capability.
  • Page 12 • 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. Terex T25I and T45I Super Quiet Generator...

  • Page 13: Operating Instructions

    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. Terex T25I and T45I Super Quiet Generator...
  • Page 14 OPERATION SHUT DOWN THE GENERATOR SET BY PRESSING THE "OFF" BUTTON ON THE CAS- The TEREX Super Quiet generator sets rated CADE CONTROL PANEL. SWITCH THE from T25I and T45I are equipped with a VOLT- TOGGLE TO THE “OFF” POSITION BEFORE AGE SELECTOR SWITCH.
  • Page 15 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 gen- erator main control panel. Terex T25I and T45I Super Quiet Generator...
  • Page 16 Manual" supplied with unit) for configuration and VOLTAGE HAS BEEN CHECKED AT status listings. DISTRIBUTION LUGS AND RECEPTACLES. CALL TEREX SERVICE IF YOU HAVE ANY One LED is located next to the “AUTO” button to QUESTIONS. indicate that the controller is waiting for the remote start input to become active.
  • Page 17 11 status lights on the right hand side of the controller (See Fig. 1). When the cause of shutdown is corrected, the controller can resume normal operation. Terex T25I and T45I Super Quiet Generator...
  • Page 18 • Allow the engine to run for 5 minutes under no load until the coolant temperature gauge reads NOTICE: Call TEREX Service for wiring and approximately 175°F as a cool down cycle. troubleshooting information. • Stop the engine by pushing the Cascade Controller “OFF”...

  • Page 19: Maintenance

    Note: Use a 50% solution of water and antifreeze The following maintenance intervals are only for the engine coolant. Refer to your engine suggested by TEREX. You should always check manufacturer's maintenance manual for specific your engine owner’s manual for specific informa- antifreeze information.
  • Page 20 As small particles of dust are trapped in the paper, • Clean Radiator Surface the holes become smaller and the efficiency • Positive Crankcase Ventilation Valve Cleaning increases. Terex T25I and T45I Super Quiet Generator...
  • Page 21 The safety element should be changed sparingly (every three or four filter changes) and extreme care should be taken to not allow dirt to enter the engine when the safety Terex T25I and T45I Super Quiet Generator...

  • Page 22: Troubleshooting Guide

    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 Terex T25I and T45I Super Quiet Generator...
  • Page 23 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 Terex T25I and T45I Super Quiet Generator...
  • Page 24 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 Terex T25I and T45I Super Quiet Generator...
  • Page 25 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 Terex T25I and T45I Super Quiet Generator...
  • Page 26 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. Terex T25I and T45I Super Quiet Generator...

  • Page 27: Electrical Troubleshooting

    June 2006 REV A GENERATOR ELECTRICAL TROUBLESHOOTING Test resistance of field, stator and exciter wind- ings. Contact TEREX for procedures or repair 5 COMPONENTS THAT CAUSE facility recommended by generator manufacturer. VOLTAGE RELATED PROBLEMS PROCEDURE FOR TESTING POTENTIOMETER GENERATOR WITH NO OUTPUT Connects to voltage regulator.
  • Page 28 • To insure proper installation, the sensor must Terex T25I and T45I Super Quiet Generator...
  • Page 29 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.
  • Page 30 Operating Instructions and Parts Manual Control Panel Wiring June 2006 for Cascade w/Electronic Governor REV A Drawing #ES1000000 (Optional) Terex T25I and T45I Super Quiet Generator...
  • Page 31 Operating Instructions and Parts Manual Control Panel Wiring June 2006 for Murphy Cascade Controller REV A Drawing #ES1000001 (Standard) Terex T25I and T45I Super Quiet Generator...
  • Page 32 Operating Instructions and Parts Manual Distribution Panel Wiring June 2006 for "C" Series Single PhaseControl REV A Drawing #ES1000003 Terex T25I and T45I Super Quiet Generator...
  • Page 33 Operating Instructions and Parts Manual June 2006 REV A Three Position Stack Switch Wiring Drawing #ES1000005 Terex T25I and T45I Super Quiet Generator...
  • Page 34 Operating Instructions and Parts Manual June 2006 REV A Overcurrent Relay Wiring Drawing #ES1000006 Terex T25I and T45I Super Quiet Generator...
  • Page 35 Operating Instructions and Parts Manual June 2006 REV A Generator Wiring Breakdown Drawing #ES1000007 Terex T25I and T45I Super Quiet Generator...
  • Page 36 Operating Instructions and Parts Manual June 2006 Standard Generator Wiring REV A for "C" Series Drawing #ES1000008 Terex T25I and T45I Super Quiet Generator...

  • Page 37: T25I / T45I Specifications And Dimensions

    Fuel Capacity (gal) Run Time (75% load) Fuel Consumption, Prime Power (gal per hr) 100% load 75% load 50% load 25% load Controller Type Analog/Digital Analog/Digital Start/Stop Controller Cascade Cascade 12V Battery (CCA) Terex T25I and T45I Super Quiet Generator...
  • Page 38 DIM (L x W x H - in) 84x39x51 84x39x51 Weight Dry (lbs) 1,900 2,725 Weight Full (lbs) 2,354 3,173 TRAILER MOUNT Dim (L x W x H) 137x66x68 137x66x68 Weight Dry (lbs) 2,375 3,200 Weight Full (lbs) 2,829 3,648 Terex T25I and T45I Super Quiet Generator...

  • Page 39: Torque Specifications

    20mm 280-290 GENERATOR TORQUE SPECIFICATIONS Generator FT*LB Flex Plate to Flywheel 12-15 Generator Case to Bellhousing 1/2" Socket Head Cap Screws for Lifting Channel 1/2" Hex Head Screws for Lifting Channel Genset Isolators Terex T25I and T45I Super Quiet Generator...
  • Page 40 Operating Instructions and Parts Manual June 2006 REV A This page intentionally left blank. Terex T25I and T45I Super Quiet Generator...

  • Page 41: Service Parts Fax Order Form

    Ship all available parts and contact customer on disposition of backordered parts Other (please specify) TEREX U Order Number ______________ Origin Code ________________ Comments _________________________ Terex T25I and T45I Super Quiet Generator Date Scheduled ____________ Ship Condition ______________ __________________________________ Order Total ________________ Terms Code ________________...
  • Page 42 Operating Instructions and Parts Manual June 2006 REV A This page intentionally left blank. Terex T25I and T45I Super Quiet Generator...

  • Page 43: Parts Catalog

    Operating Instructions and Parts Manual June 2006 REV A PARTS CATALOG PARTS CATALOG SECTION Terex T25I and T45I Super Quiet Generator...

  • Page 44: Cabinet Decals

    Operating Instructions and Parts Manual June 2006 REV A CABINET DECALS Terex T25I and T45I Super Quiet Generator...

  • Page 45: Safety Decals

    Operating Instructions and Parts Manual June 2006 REV A SAFETY DECALS Terex T25I and T45I Super Quiet Generator...

  • Page 46: Figure 1 - Base W/Fuel Tank

    Operating Instructions and Parts Manual June 2006 REV A FIGURE 1 - BASE W/FUEL TANK Terex T25I and T45I Super Quiet Generator...
  • Page 47 FITTING BARB, 3/8 NPT C90200600 BARB 3/8 X1/4 NPT C90200400 FITTING, PICKUP&RETURN C91100300 NYLON TUBING (1 FT.) C90200900 BARB, 3/4 X1/2 NPT 792750 CLAMP, 7/16 TO 25/32 897910 HOSE,OIL, 3/4" C90800100 VALVE, BALL 1/2 Terex T25I and T45I Super Quiet Generator...

  • Page 48: Figure 2 - Base W/Lifting Eye & Battery

    Operating Instructions and Parts Manual June 2006 REV A FIGURE 2 - BASE W/LIFTING EYE & BATTERY Terex T25I and T45I Super Quiet Generator...
  • Page 49 BATTERY, WET 12V GRP34/750CCA NUT, WING CU22A252 ANGLE BATTERY C33700800 HOOK BATTERY HOLD DN GCU121010 BATTERY TIE DOWN 995810 SCREW 1/4-20NC X 5/8 HWH GCU121000 TRAY BATTERY 994600 SCREW 1/2-13NC X 1-1/2 991650 WASHER LOCK 1/2 Terex T25I and T45I Super Quiet Generator...

  • Page 50: Figure 3 - Genset

    Operating Instructions and Parts Manual June 2006 REV A FIGURE 3 - GENSET Terex T25I and T45I Super Quiet Generator...
  • Page 51 WASHER, FLAT 1/2 990200 NUT, LOCK-NYLON INSERT 51601460 SCREW, FLANGE 3/8-16 X 1 732112PP ENGINE, ISUZU, 20KW, 4LE1PV02,POWER PAK-508-T25I 732114PP ENGINE, ISUZU,30-40KW 4JG1TPV,POWER PACK-503-T45I 836427 RECTIFIER SERVICE KIT 830001 BCI GENERATOR OPERATION MANUAL Terex T25I and T45I Super Quiet Generator...

  • Page 52: Figure 4 - Cabinet Assembly

    Operating Instructions and Parts Manual June 2006 REV A FIGURE 4 - CABINET ASSEMBLY Terex T25I and T45I Super Quiet Generator...
  • Page 53 994490 WASHER, FLAT SNUBBING 993422 SCREW, FLANGE 1/4-20 X .75, SS 990150 NUT, LOCK NYLON, 1/4-20, GR2 C71014 WASHER, FLAT. 11/16" O.D. C33200500 FILTER, FUEL, WATER SEPARATOR, COMPLETE CR25-P WATER SEPARATOR ELEMENT ONLY Terex T25I and T45I Super Quiet Generator...

  • Page 54: Figure 5 - Cabinet Assembly W/Doors

    Operating Instructions and Parts Manual June 2006 REV A FIGURE 5 - CABINET ASSEMBLY W/DOORS Terex T25I and T45I Super Quiet Generator...
  • Page 55 TRIMLOCK SEAL 7/16 993422 SCREW, FLANGE 1/4-20X.75 990170 NUT, LOCK NYLON INSERT,3/8-16NC GR 2 ZPN BIN 981070 WASHER, FLAT 5/16 C71014 WASHER, FLAT,11/16" OD GCU430010 HOUSING, CONTROL DOOR 41135000 POP RIVET 51400200 BUMPER Terex T25I and T45I Super Quiet Generator...

  • Page 56: Figure 6 - Control Panel Assembly- Upper

    Operating Instructions and Parts Manual June 2006 REV A FIGURE 6 - CONTROL PANEL ASSEMBLY- UPPER Terex T25I and T45I Super Quiet Generator...
  • Page 57 C42404000 TERMINAL STRIP, 6 POS R660115 JUMPER, TERMINAL STRIP CDWV40150 RELAY, 50A BOSCH CDWV40151 RELAY, BASE 50A BOSCH CDWV40152 RELAY, PIN 853813 DECAL, KIT RECEPTACLES AND BREAKERS 853838 DECAL, KIT CONTROL PANEL CASCADE Terex T25I and T45I Super Quiet Generator...

  • Page 58: Figure 7 - Control Panel Assembly - Lower

    Operating Instructions and Parts Manual June 2006 REV A FIGURE 7 - CONTROL PANEL ASSEMBLY - LOWER Terex T25I and T45I Super Quiet Generator...
  • Page 59 990340 WASHER, FLAT 1/4 990340 WASHER, FLAT 1/4 853752 DECAL, REMOTE START 853813 DECAL, KIT RECEPTACLES AND BREAKERS 66812 E-STOP PUSHBUTTON 686662 E-STOP LABEL PLATE 66817 E-STOP CONTACT (N.C.) 671278 REMOTE START CONTACT Terex T25I and T45I Super Quiet Generator...

  • Page 60: Figure 8 - Distribution Panel

    Operating Instructions and Parts Manual June 2006 REV A FIGURE 8 - DISTRIBUTION PANEL Terex T25I and T45I Super Quiet Generator...
  • Page 61 C74972 WASHER, FLAT 1/2 SBZ C75240 LOCK, WASHER 1/2 SBZ C74967 NUT, HEX 1/2-13 SBZ 852255 DECAL, 3PH DISTRIBUTION PANEL, ALL 5 LUG 3PH UNITS 990400 WASHER, LOCK 1/4 990340 WASHER, FLAT 1/4 Terex T25I and T45I Super Quiet Generator...

  • Page 62: Figure 9 - Muffler Assembly

    Operating Instructions and Parts Manual June 2006 REV A FIGURE 9 - MUFFLER ASSEMBLY Terex T25I and T45I Super Quiet Generator...
  • Page 63 CLAMP MUFFLER BAND C90101000 CLAMP U-BOLT 2.5 INCLUDED IN ITEM 6 INCLUDED IN ITEM 6 INCLUDED IN ITEM 6 C100550 BUMPER, RUBBER GCU110060 MUFFLER FRONT MNT C100552 RUBBER EXST ISOLATOR GCU460005 TOP EXHST STABILZER Terex T25I and T45I Super Quiet Generator...

  • Page 64: Figure 10 - Air Cleaner Assembly

    Operating Instructions and Parts Manual June 2006 REV A FIGURE 10 - AIR CLEANER ASSEMBLY Terex T25I and T45I Super Quiet Generator...
  • Page 65 Operating Instructions and Parts Manual June 2006 REV A ITEM # PART # DESCRIPTION QTY. 834461 AIR CLEANER ASSEMBLY - T45 868139 AIR CLEANER ELEMENT 834458 AIR CLEANER ASSEMBLY - T25 834460 AIR CLEANER ELEMENT Terex T25I and T45I Super Quiet Generator...

  • Page 66: Figure 11A - Engines - T25I

    Operating Instructions and Parts Manual November 2007 REV B FIGURE 11A - ENGINES - T25I Terex T25I and T45I Super Quiet Generator...
  • Page 67 OIL DRAIN PLUG 868121 VALVE COVER GASKET 868078 TIMER 868011 TEMPERATURE SENDER 868012 868013 FAN GUARD 868014 RADIATOR C33200500 FILTER, WATER SEPARATOR 116075 TEMPERATURE SWITCH 116076 OIL PRESSURE SWITCH 116077 OIL PRESSURE SENDER Terex T25I and T45I Super Quiet Generator...

  • Page 68: Figure 11B - Engines - T45I

    Operating Instructions and Parts Manual November 2007 REV B FIGURE 11B - ENGINES - T45I Terex T25I and T45I Super Quiet Generator...
  • Page 69 OIL FILLER CAP 868024 OIL DRAIN PLUG 868046 VALVE COVER GASKET 440346 TEMPERATURE SENDER C33200500 FILTER, WATER SEPARATOR 116084 TEMPERATURE SWITCH 116086 FAN GUARD 116087 116077 OIL PRESSURE SENDER 116076 OIL PRESSURE SWITCH Terex T25I and T45I Super Quiet Generator...

  • Page 70: Figure 12 - Voltage Selector Switch

    Operating Instructions and Parts Manual November 2007 REV B FIGURE 12 - VOLTAGE SELECTOR SWITCH Terex T25I and T45I Super Quiet Generator...
  • Page 71 PART # DESCRIPTION QTY. C42201102 VOLTAGE SWITCH, T25I C42202402 VOLTAGE SWITCH, T45I CD42I031 BCI, FRAME EXTENSION, BACK CD42I030 BCI, FRAME EXTENSION, FRONT CD42I040 BCI. FRAME EXTENSION, SIDE CL-008 DECAL, DO NOT CHANGE POSITION Terex T25I and T45I Super Quiet Generator...

  • Page 72: Figure 13 - Trailer

    Operating Instructions and Parts Manual November 2007 REV B FIGURE 13 - TRAILER Terex T25I and T45I Super Quiet Generator...
  • Page 73 SPARE TIRE AND WHEEL, MOUNTS ON A FRAME 124317 SPARE TIRE MOUNTING BRACKET 841070 SPARE TIRE MOUNTING BRACKET,UNIVERSAL 0GSX0113 124877 TRAILER, STANDARD, NO BRAKES 0GSX0118 124879 TRAILER, HYDRAULIC BRAKES 0GSX0114 124878 TRAILER, ELECTRIC BRAKES Terex T25I and T45I Super Quiet Generator...

  • Page 74: Figure 14 - Options

    0GSX0145 C33203000 ELECTRONIC GOVERNOR, T45 C42300600 MAG PICK UP 742376 ACTUATOR, ELECTRONIC, WOODWARD 0GSX0149 C33203000 ELECTRONIC GOVERNOR, T25 C42300600 MAG PICKUP 741193 ACTUATOR, APECS 0GSX0042 C41101000 LIGHTED CONTROL PANEL 0GSX0071 C42300800 LOW COOLANT SHUTDOWN Terex T25I and T45I Super Quiet Generator...

This manual is also suitable for:

T45

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