Terex T25 Service Manual
  1. Manuals
  2. Brands
  3. Terex Manuals
  4. Inverter
  5. T25
  6. Service manual

Terex T25 Service Manual

Hide thumbs Also See for T25:
Table of Contents

Advertisement

Quick Links

Service Manual
T25/T45
First Edition
Rev A
Part No. 134878
August 2008

Advertisement

Table of Contents
loading

Related Manuals for Terex T25

Summary of Contents for Terex T25

  • Page 1 Service Manual T25/T45 First Edition Rev A Part No. 134878 August 2008...

  • Page 2: Introduction

    Manual on your machine before attempting any Title Part No. maintenance procedure. TEREX T25I & T45I Operator's Manual, ..... 133255 Basic mechanical, hydraulic and electrical First Edition skills are required to perform most procedures. However, several procedures require specialized TEREX T25I &...

  • Page 3: How To Read Your Serial Number

    August 2008 How to Read Your Serial Number Serial Number Legend The serial number plate on your T25I & T45I Super Quiet Generator is located on the twist lock area of the lower control panel. Part No. 134878 T25I & T45I Super Quiet Generator...
  • Page 4 August 2008 This page intentionally left blank. T25I & T45I Super Quiet Generator Part No. 134878...

  • Page 5: Safety Rules

    August 2008 Section 1 • Safety Rules Safety Rules 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.

  • Page 6: Personal Safety

    Section 1 • Safety Rules August 2008 SAFETY RULES Personal Safety Workplace Safety Any person working on or around a machine must Be sure to keep sparks, flames and be aware of all known safety hazards. Personal lighted tobacco away from flammable and safety and the continued safe operation of the combustible materials like battery gases machine should be your top priority.

  • Page 7: Table Of Contents

    August 2008 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 ..................
  • Page 8 August 2008 TABLE OF CONTENTS Section 5 Schematics Introduction ....................5 - 1 Electrical Schematic - Control Panel Wiring for Murphy Cascade Controller ................5 - 2 Electrical Schematic - Control Panel Wiring for Murphy Cascade Controller w/Electronic Governor ........5 - 3 Electrical Schematic - Distribution Panel Wiring ...........

  • Page 9: Parts Stocking List

    August 2008 Parts Stocking List Required Parts The following parts are required to perform maintenance procedures as outlined in the TEREX T25I & T45I Parts and Service Manual. Description Part No. Isuzu Models Oil Filter .............. 868075 Air Filter .............. 834460 Fuel Filter ............
  • Page 10 August 2008 This page intentionally left blank. T25I & T45I Super Quiet Generator Part No. 134878...

  • Page 11: How To Order Parts

    August 2008 How To Order Parts 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 Machine model number...

  • Page 12: Service Parts Fax Order Form

    Ship complete order only - no backorders Ship all available parts and contact customer on disposition of backordered parts Other (please specify) TEREX U Order Number ______________ Origin Code ________________ Comments _________________________ T25I & T45I Super Quiet Generator Part No.

  • Page 13: Specifications

    August 2008 Section 2 • Specifications Specifications REV A MODEL T25I T45I POWER CAPABILITY-PRIME kVA (kilovolt-amps) 3 Phase Amp Ratings 208V 240V 480V POWER CAPABILITY-STANDBY kVA (kilovolt-amps) kW (kilowatts) 3 Phase Amp Ratings 208V 240V 480V VOLTAGE 3 Phase 208, 220, 240, 416, 440, 480 Standard Standard 600 Volt...
  • Page 14 Section 2 • Specifications August 2008 SPECIFICATIONS REV A MODEL T25I T45I GENERATOR Brushless, 4 pole, Synchronous, Single-bearing Standard Standard 1,800 rpm, Class H Insulation Generator Standard Standard High wye, Low wye, Zig-zag Voltage Selector Standard Standard 3 Phase Voltage: 208, 220, 240,416, 440, 480 Standard Standard 600 Volt...

  • Page 15: Sae Fastener Torque Chart

    August 2008 Section 2 • Specifications REV A SPECIFICATIONS SAE FASTENER TORQUE CHART • This chart is to be used as a guide only unless noted elsewhere in this manual • A574 High Strength Grade 5 Grade 8 SIZE THREAD Black Oxide Bolts LUBED LUBED...

  • Page 16: Generator Torque Specifications

    Section 2 • Specifications August 2008 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 1/2-13" Hex Head Screws for Lifting Channel Genset Isolators 2 - 4 T25I &...

  • Page 17: Observe And Obey

    August 2008 Section 3 • Scheduled Maintenance Procedures Scheduled Maintenance Procedures 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. Observe and Obey: Symbols Legend Safety alert symbol—used to alert Maintenance inspections shall be completed by personnel to potential personal a person trained and qualified on the...
  • Page 18 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. Rev B...

  • Page 19: Maintenance Schedules

    August 2008 Section 3 • Scheduled Maintenance Procedures Maintenance Schedules REV A Isuzu Lubrication and Maintenance Service Intervals Every Every Every Every Every Every First 50 ITEM Daily 1000 1250 1500 Hours Hours Hours Hours Hours Hours Hours • Oil level and oil fouling •...
  • Page 20 Section 3 • Scheduled Maintenance Procedures August 2008 MAINTENANCE SCHEDULES CONTINUED REV A Newage Maintenance Service Intervals 250 Hours 1500 Hours 15000 4500 Hours ITEM DAILY or 3 or 12 Hours or 19 or 3 Years Months Months Years • Visual inspection •...

  • Page 21: Troubleshooting And Repair Procedures Shall Be Completed By A Person Trained And Qualified On The Repair Of This Machine

    August 2008 Section 4 • Troubleshooting Troubleshooting Before Troubleshooting: Read, understand and obey the safety rules and operating instructions in the appropriate operator's manual on your machine. Be sure that all necessary tools and test equipment are available and ready for use. Observe and Obey: Be aware of the following hazards and follow generally accepted safe workshop practices.

  • Page 22: Troubleshooting Guide

    Low generator output voltage Voltage adjustment Adjust voltage potentiometer set too low Defective potentiometer By pass or replace Low engine speed Call TEREX Service Loose wire on voltage Check wiring selector switch Fluctuating or surging Check engine fuel, oil, engine speed...
  • Page 23 Check engine fuel, oil, engine speed and air filters Loose wiring in generator Check connections Automatic voltage regulator Call TEREX Service stability setting may be wrong Loose wire on the automatic Check wiring voltage regulator sensing lead Low engine speed...
  • Page 24 Section 4 • Troubleshooting August 2008 TROUBLESHOOTING FAULT POSSIBLE CAUSE SOLUTION Low Speed Defective injectors on engine Have injectors checked by a qualified technician “Surging” engine speed Check engine fuel, oil, and air filters Engine turns over (cranks), Unit out of fuel Check fuel level in tank, fill as but won’t run needed...
  • Page 25 Have engine checked by a qualified technician Engine runs, but loses Unit is overloaded Reduce load speed Improper connection Check or Call TEREX Service Engine runs, but loses Clogged fuel system Check fuel system power under load air in fuel lines Blocked air intake...
  • Page 26 Section 4 • Troubleshooting August 2008 TROUBLESHOOTING FAULT POSSIBLE CAUSE SOLUTION Engine shuts down Overloaded engine Reduce load automatically and TROUBLE LIGHT on Broken fan belt Inspect fan belt and replace as CONTROL PANEL needed is illuminated Defective thermostat or Inspect thermostat thermocouple switch switch...

  • Page 27: Voltage Regulator

    August 2008 Section 4 • Troubleshooting TROUBLESHOOTING Electrical Troubleshooting Generator Test resistance of field, stator and exciter windings. Contact TEREX for procedures or repair facility 5 Components that cause voltage recommended by generator manufacturer. related problems Potentiometer Procedure for testing generator with no output Connects to voltage regulator.
  • Page 28 If any further adjustment is needed to the voltage of generator it could cost you your life. Observe the generator please call TEREX at 1-800-433-3026 proper polarity when working with the regulator for assistance.
  • Page 29 August 2008 Section 5 • Schematics Schematics REV A About This Section There are two groups of schematics in this section. An illustration legend precedes each group of drawings. Electrical Schematics Observe and Obey: Electrocution hazard. Contact with electrically charged circuits could Troubleshooting and repair procedures shall be result in death or serious injury.
  • Page 30 Section 5 • Schematics August 2008 Control Panel Wiring for Murphy Cascade Controller REV A Drawing #ES100001 (Standard) 5 - 2 T25I & T45I Super Quiet Generator Part No. 134878...
  • Page 31 August 2008 Section 5 • Schematics Control Panel Wiring for Cascade w/Electronic Governor REV A Drawing #ES100000 (Optional) Part No. 134878 T25I & 45I Super Quiet Generator 5 - 3...
  • Page 32 Section 5 • Schematics August 2008 Distribution Panel Wiring for T25I & T45I Series Single Phase Control REV A Drawing #ES100003 5 - 4 T25I & T45I Super Quiet Generator Part No. 134878...
  • Page 33 August 2008 Section 5 • Schematics Three Position Stack Switch Wiring Drawing #ES100005 REV A Part No. 134878 T25I & 45I Super Quiet Generator 5 - 5...
  • Page 34 Section 5 • Schematics August 2008 Overcurrent Relay Wiring Drawing #ES100006 REV A 5 - 6 T25I & T45I Super Quiet Generator Part No. 134878...
  • Page 35 August 2008 Section 5 • Schematics Generator Wiring Breakdown Drawing #ES100007 REV A Part No. 134878 T25I & 45I Super Quiet Generator 5 - 7...
  • Page 36 Section 5 • Schematics August 2008 Standard Generator Wiring Drawing #ES1000008 REV A 5 - 8 T25I & T45I Super Quiet Generator Part No. 134878...
  • Page 38 California Proposition 65 Warning The exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm. Towing Checklist (Use at each stop) · Towing hitch is properly secured to tow vehicle Before Towing ·...

This manual is also suitable for:

T45

Table of Contents