Terex T25 Guide

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

Operating Instructions and Parts Manual
2 Terex T25I and T45I Super Quiet Generator
June 2006
REV A
Table Of Contents
INTRODUCTION......................................................................................... 5
DESCRIPTION OF EQUIPMENT................................................................ 5
GENERAL SAFETY.................................................................................... 6
SAFETY SIGN LOCATIONS ...................................................................... 7
RECEIPT OF DELIVERY CHECKLIST..................................................... 10
TRANSPORT & TOWING......................................................................... 11
SETUP ...................................................................................................... 11
OPERATING INSTRUCTIONS ................................................................. 13
MAINTENANCE........................................................................................ 19
TROUBLESHOOTING GUIDE.................................................................. 22
ELECTRICAL TROUBLESHOOTING ...................................................... 27
T25I / T45I SPECIFICATIONS AND DIMENSIONS.................................. 37
TORQUE SPECIFICATIONS .................................................................... 39
GENERATOR TORQUE SPECIFICATIONS ............................................ 39
SERVICE PARTS FAX ORDER FORM .................................................... 41
PARTS CATALOG ................................................................................... 43
CABINET DECALS................................................................................... 44
SAFETY DECALS .................................................................................... 45
FIGURE 1 - BASE W/FUEL TANK ........................................................... 46
FIGURE 2 - BASE W/LIFTING EYE & BATTERY.................................... 48
FIGURE 3 - GENSET................................................................................ 50
FIGURE 4 - CABINET ASSEMBLY.......................................................... 52
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

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Table Of Contents
FIGURE 10 - AIR CLEANER ASSEMBLY ............................................... 64
FIGURE 11A - ENGINES - T25I................................................................ 66
FIGURE 11B - ENGINES - T45I................................................................ 68
FIGURE 12 - VOLTAGE SELECTOR SWITCH........................................ 70
FIGURE 13 - TRAILER ............................................................................. 72
FIGURE 14 - OPTIONS............................................................................. 74

Operating Instructions and Parts Manual
4 Terex T25I and T45I Super Quiet Generator
June 2006
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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 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. 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:

Terex T25I and T45I Super Quiet Generator 5
Operating Instructions and Parts Manual
June 2006
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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 (24-
volt starter optional) 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.
A governor 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 governor and regulator are
provided in the ENGINE and GENERATOR
OPERATOR’S MANUALS.
An automatic shutdown system is incorporated in
the generator set to sense low oil pressure and/or
high coolant temperature, and in either 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 and is impervious to water, fuel,
and oil.
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.

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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.)

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GENERAL SAFETY (Cont.)
SAFETY SIGN LOCATIONS

Operating Instructions and Parts Manual
8 Terex T25I and T45I Super Quiet Generator
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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

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ELECTRICAL SAFETY
THIS EQUIPMENT USES HIGH VOLTAGE CIR-
CUITS CAPABLE OF CAUSING SERIOUS IN-
JURY OR DEATH. EXERCISE EXTREME CAU-
TION AROUND ANY ELECTRICAL COMPO-
NENT WHILE OPERATING THIS UNIT.
Always ground the unit according to local
codes. A grounding lug has been added to the
base frame 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.)

Operating Instructions and Parts Manual
10 Terex T25I and T45I Super Quiet Generator
June 2006
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BE CAREFUL WHEN LIFTING. NEVER SUS-
PEND ANY OTHER EQUIPMENT FROM THE
SHIPPING TIE DOWNS.
Use the lifting eye 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.)