Terex T25 User manual
Service Manual
First Edition
Rev A
Part No. 134878
August 2008
T25/T45
August 2008
T25I & T45I Super Quiet Generator Part No.134878
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
134878 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 T25I & T45I Operator's Manual, .............133255
First Edition
TEREX T25I & T45I Parts Manual, .....................134877
First Edition
Newage Generator Manual ................................ 836430
Isuzu Engine Manual .......................................... 116133
Cascade Controller Manual ...............................833011
Dexter Axle Manual ............................................833014
Introduction
August 2008
Part No.134878 T25I & T45I Super Quiet Generator
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.
iii
How to Read Your Serial Number
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T25I & T45I Super Quiet Generator Part No.134878
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August 2008
Part No.134878 T25I & T45I 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
T25I & T45I Super Quiet Generator Part No.134878
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.134878 T25I & T45I 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
Isuzu Lubrication and Maintenance Service Intervals ................................... 3 - 3
Newage Generators Maintenance Schedule ................................................. 3 - 4
Section 4 Rev Troubleshooting
Introduction .................................................................................................. 4 - 1
A Troubleshooting Guide .................................................................................. 4 - 2
vii
August 2008
T25I & T45I Super Quiet Generator Part No.134878
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 - Control Panel Wiring for
Murphy Cascade Controller w/Electronic Governor ....................................... 5 - 3
A Electrical Schematic - Distribution Panel Wiring ........................................... 5 - 4
A Electrical Schematic - Three Position Stack Switch Wiring .......................... 5 - 5
A Electrical Schematic- Overcurrent Relay ...................................................... 5 - 6
A Electrical Schematic - Generator Wiring Breakdown ..................................... 5 - 7
A Electrical Schematic - Standard Generator Wiring ........................................ 5 - 8
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August 2008
Part No.134878 T25I & T45I Super Quiet Generator
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 ........................................................... 868137
Belt ..................................................................... 868067
Parts Stocking List
ix
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