Terex GenPac T15 Guide

Operator/Service & Parts Manual
First Edition
Rev A1
Part No. 833006
T15/T25 GenPac
after serial number GGG-19214

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OPERATOR’S MANUAL
To the Operator ................................................................................................. 4
Safety Alert Symbols ......................................................................................... 5
General Safety ............................................................................................... 6-9
Receipt of Delivery Checklist........................................................................... 10
Transport & Towing ..........................................................................................11
Set-Up ........................................................................................................ 12-13
Operating Instructions ................................................................................ 14-16
Maintenance............................................................................................... 17-18
Troubleshooting.......................................................................................... 19-21
Wiring Diagram - Kubota Gen-Pac Control Panel........................................... 22
Wiring Diagram - Isuzu Gen-Pac Control Panel.............................................. 23
Wiring Diagram - T25G Single Phase Distribution .......................................... 24
Wiring Diagram - T15G Single Phase Distribution .......................................... 25
Wiring Diagram - T15G & T25G Generator..................................................... 26
Dimensions ..................................................................................................... 27
Torque Specifications ...................................................................................... 28
PARTS MANUAL
Parts Ordering Information.............................................................................. 29
General Information ........................................................................................ 31
Cabinet Assembly ........................................................................................... 34
Trailer Frame/ Tongue/ Fuel Tank.................................................................... 36
Axle Assembly................................................................................................ 38
Electrical Enclosure......................................................................................... 40
Control Panel Assembly .................................................................................. 42
Distribution Panel Assembly........................................................................... 44
Engine T25G ................................................................................................... 46
Engine T15G ................................................................................................... 48
Generator T15G & T25G................................................................................. 50
Hitches ............................................................................................................ 51
Tail Lights ........................................................................................................ 52

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Operator’s
Manual

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To The Operator
An operator should never use drugs, alcohol or any other substance which can change his alertness or
coordination.
Do not work on this equipment when mentally or physically fatigued.
This manual is compiled from information available and current at time of approval for printing. Terex reserves
the right to improve its products without giving prior notice or incurring any obligation.
If this manual becomes lost, order a new one from Terex so future operation and maintenance personnel may
read these instructions.
DO NOT ATTEMPT TO SETUP, OPERATE, OR WORK ON THE TEREX GEN-PAC GENERATORS UNLESS
YOU HAVE READ AND UNDERSTAND THIS MANUAL AND THE ENGINE AND GENERATOR MANUALS
CAREFULLY. READING THESE MANUALS WILL TEACH YOU HOW TO SAFELY SETUP, OPERATE,
AND PROPERLY MAINTAIN THE GENERATOR SET AND ITS COMPONENTS.
REMEMBER THAT YOU ARE THE KEY TO SAFETY. GOOD SAFETY PRACTICES NOT ONLY PROTECT
YOU, BUT ALSO THOSE WORKING AROUND YOU. MAKE THIS MANUAL A WORKING PART OF YOUR
SAFETY PROGRAM.
THIS EQUIPMENT USES HIGH VOLTAGE CIRCUITS CAPABLE OF CAUSING
SERIOUS INJURY OR DEATH.

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Safety Alert Symbols
MEANS:
ATTENTION! BE ALERT!
YOUR SAFETY IS INVOLVED
THIS SAFETY SYMBOL IS USED FOR IMPORTANT SAFETY MESSAGES. WHEN YOU
SEE THIS SYMBOL, FOLLOW THE SAFETY MESSAGE TO AVOID PERSONAL INJURY
OR PROPERTY DAMAGE.
Understanding Signal Words
Asignal word - DANGER, WARNING or CAUTION is used with the safety alert symbol.
DANGER Identifies the hazard or unsafe practice that will
result in severe injury or death.
WARNING Identifies the hazard or unsafe practice that
could result in severe injury or death.
CAUTION Identifies the hazard or unsafe practice that
could result in minor injury or property damage.
NOTICE Identifies important installation, operation or
maintenance information.

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General Safety
DO NOT SETUP OR OPERATE THE TEREX GEN-PAC GENERATORS WITH-
OUT READING THIS OPERATOR’S MANUAL.
SAFETY ALERT SYMBOL
Stop and take time to readALL Safety alert messages.
Follow the safety messages to avoid personal injury or
propertydamage.
ACCIDENT PREVENTION
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
DO NOT weld on any structural member.
Any unauthorized welding or repair procedure will void
thewarranty.
DO NOT WORK ON OR OPERATE THE TEREX GEN-PAC GENERATORS WHILE UNDER THE INFLU-
ENCE OF PERFORMANCE IMPAIRING DRUGS OR ALCOHOL.
UNAUTHORIZED WELDING
CAN CAUSE STRUCTURAL
FAILURE OR PERSONAL
INJURY.

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General Safety
FUELING
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.
Prevent fires by keeping the generator and its sur-
rounding 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.
Have a fire extinguisher nearby. Be sure the extin-
guisher is properly maintained and be familiar with its
use. Extinguishers ratedABC by the NFPA are appro-
priate for all applications.
FIRES CAN CAUSE
SEVERE PERSONAL
INJURY OR MACHINE
DAMAGE.

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BATTERY HAZARDS
Lead acid batteries can be dangerous. 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.
ELECTRICAL SAFETY
This equipment uses high voltage circuits capable of causing serious injury or death. Exercise ex-
treme caution around any electrical component while operating this unit.
Always ground the unit when possible.
A grounding lug has been added to the trailer frame for your convenience.
Beware of cut or damaged power cords. Have a qualified electrician replace any damaged cords
immediately.
General Safety
EXHAUST GASES ARE TOXIC. DO NOT USE IN-
DOORS 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.
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.

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General Safety
KEEP ALL BODY PARTS AND CLOTHING AWAY
FROM MOVING PARTS
Loose jackets, shirts, sleeves, and especially 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 servicing. Never remove guards while unit is operating.
Keep your hands away from moving parts, particularly 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 periodically to insure all are tight and nothing is in danger of
falling off during transit.
Be careful when lifting. Never suspend any other
equipment from the shipping tie downs.
Use the lifting eye for lifting the trailer (with cabinet).
Make sure any tie-downs at the bottom of the trailer are released prior to lifting.
NEVER CLIMB ON TOP OF THE CABINET.

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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.
Insure manuals are in the pocket provided inside the unit.