Service Manual

T25/T45

First Edition

Rev A

Part No. 134878

August 2008

August 2008

Introduction

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.

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

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.

ii

Contact Us:

www.TEREX.com

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.

T25I & T45I Super Quiet Generator Part No. 134878

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 iii

August 2008

This page intentionally left blank.

iv T25I & T45I Super Quiet Generator Part No. 134878

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.

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.

Part No. 134878 T25I & T45I Super Quiet Generator v

Section 1 • Safety Rules August 2008

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.

unsecured components when lifting or placing loads. Always wear approved steel-toed shoes.

Be aware of potential crushing hazards such as moving parts, free swinging or

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.

vi T25I & T45I Super Quiet Generator Part No. 134878

August 2008

Table of Contents

Introduction

Section 1

Section 2

Section 3

Section 4

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

Safety Rules

General Safety Rules ........................................................................................

v

Rev Specifications

A Specifications .............................................................................................. 2 - 1

A

A

A

Specifications (Continued) ............................................................................ 2 - 2

Torque Specifications ................................................................................... 2 - 3

Generator Torque Specifications .................................................................. 2 - 4

Rev Scheduled Maintenance Procedures

Introduction .................................................................................................. 3 - 1

A

Pre-delivery Preparation Report .................................................................... 3 - 2

Maintenance Schedules

Isuzu Lubrication and Maintenance Service Intervals ................................... 3 - 3

Newage Generators Maintenance Schedule ................................................. 3 - 4

Rev Troubleshooting

Introduction .................................................................................................. 4 - 1

A Troubleshooting Guide .................................................................................. 4 - 2

Part No. 134878 T25I & T45I Super Quiet Generator vii

August 2008

TABLE OF CONTENTS

Section 5

A

A

A

A

A

Rev Schematics

A Introduction .................................................................................................. 5 - 1

A

A

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 ........................................... 5 - 4

Electrical Schematic - Three Position Stack Switch Wiring .......................... 5 - 5

Electrical Schematic- Overcurrent Relay ...................................................... 5 - 6

Electrical Schematic - Generator Wiring Breakdown ..................................... 5 - 7

Electrical Schematic - Standard Generator Wiring ........................................ 5 - 8 viii T25I & T45I Super Quiet Generator Part No. 134878

August 2008

Required Parts

The following parts are required to perform maintenance procedures as outlined in the

TEREX T25I & T45I Parts and Service Manual.

Description

Isuzu Models

Part No.

Oil Filter .............................................................. 868075

Air Filter .............................................................. 834460

Fuel Filter ........................................................... 868137

Belt ..................................................................... 868067

Parts Stocking List

Part No. 134878 T25I & T45I Super Quiet Generator ix

August 2008

This page intentionally left blank.

x T25I & T45I Super Quiet Generator Part No. 134878

August 2008

How To Order Parts

Please be prepared with the following information when ordering replacement parts for your TEREX product:

Machine model number

Machine serial number

Terex part number

Part description and quantity

Purchase order number

"Ship to" address

Desired method of shipment

Name and telephone number of the authorized TEREX Distributor in your area

Use the Service Parts Fax Order Form on the next page and fax your order to our Parts

Department.

If you don't know the name of your authorized distributor, or if your area is not currently serviced by an authorized distributor, please call TEREX

Corporation.

Machine Information

TEREX North America

Telephone (803) 324-3011

Toll Free (800) 433-3026 in U.S.A. and Canada

Fax (803) 366-1101

Model

Serial Number

Date of Purchase

Authorized TEREX Distributor

Phone Number

Part No. 134878 T25I & T45I Super Quiet Generator xi

August 2008

Service Parts fax Order Form

FAX TO: (800) 633-5534 OR TOLL FREE: 800-433-3026

Please fill out completely

Date _________________________________ Account Number _______________________________

Your Name ______________________________ Your Fax Number _____________________________

_________________________________ Your Phone Number ____________________________

Bill To _________________________________ Ship To ___________________________________

_________________________________ ___________________________________

_________________________________ ___________________________________

_________________________________ ___________________________________

Purchase Order Number ____________________ Ship Via ___________________________________

Model(s) ______________________________________________________ Serial No.(s) _________________

Optional Equipment __________________________________________________________________________

Part Number Description Quantity Price

All backordered parts will be shipped when available via the same ship method as the original order unless noted below: o Ship complete order only - no backorders o Ship all available parts and contact customer on disposition of backordered parts o Other (please specify)

F

OR

TEREX U

SE

O

NLY

Order Number ______________

T25I & T45I Super Quiet Generator Part No. 134878

Date Scheduled ____________ Ship Condition ______________ __________________________________

Order Total ________________ Terms Code ________________ __________________________________

August 2008

REV A

MODEL

POWER CAPABILITY-PRIME kVA (kilovolt-amps) kW

3 Phase Amp Ratings

POWER CAPABILITY-STANDBY kVA (kilovolt-amps) kW (kilowatts)

3 Phase Amp Ratings

VOLTAGE

3 Phase 208, 220, 240, 416, 440, 480

600 Volt

1 Phase 120, 127, 139, 240, 254, 277

Max Motor Starting1

SKVA

DIESEL ENGINE

Manufacturer

Model

Cylinder

Air Intake (aspiration)

Cooling System

Fuel Capacity (gal)

Run Time (75% load)

Fuel Consumption, Prime Power (gal per hr) dBA

Controller Type

Start/Stop Controller

12V Battery (CCA)

Section 2 • Specifications

Specifications

T25I T45I

208V

240V

480V

208V

240V

480V

Hp kW

25

20

69

60

30

30

24

83

72

36

Standard

Optional

Standard

12

9

70

100% load

75% load

50% load

25% load

Isuzu

4LE1PV02

4

Natural

Std Rad

64

53

1.5

1.1

0.8

Isuzu

4JG1TPV

4

Turbo

Std Rad

64

29

2.8

2.2

1.7

0.4

64

1.2

64

Analog/Digital Analog/Digital

Cascade

750

Cascade

750

45

36

125

108

54

50

40

139

120

60

Standard

Optional

Standard

27

20

165

Part No. 134878 T25I & T45I Super Quiet Generator 2 - 1

Section 2 • Specifications

SPECIFICATIONS

MODEL

GENERATOR

Brushless, 4 pole, Synchronous, Single-bearing

1,800 rpm, Class H Insulation Generator

High wye, Low wye, Zig-zag Voltage Selector

3 Phase Voltage: 208, 220, 240,416, 440, 480

600 Volt

1Phase Voltage: 120, 127, 139, 240, 254, 277

Convenience Receptacles:

2 - 20A GFCI Duplex Receptacles

2 - 50A Tempowers

AVR Voltage Regulation

Mechanical Standard (5%) Speed Control (governor)

Murphy Cascade Start/Stop Controller on All Engines

TRAILER

No Brakes

HydraulicBrakes

Electric Brakes

Pintle Rng, 3 inch

Coupler Hitch, 2 inch

Coupler Hitch, 2 5/16 inch

1 Maximum motor size is based on 35% voltage dip at

480V AC 3 phase 60Hz with a code G motor

SKID MOUNT

DIM (L x W x H - in)

Weight Dry (lbs)

Weight Full (lbs)

TRAILER MOUNT

Dim (L x W x H)

Weight Dry (lbs)

Weight Full (lbs)

August 2008

T25I

Standard

Standard

Standard

Standard

Optional

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Optional

Optional

Standard

Optional

Optional

REV A

T45I

Standard

Standard

Standard

Standard

Optional

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Standard

Optional

Optional

Standard

Optional

Optional

84x39x51

1,900

2,354

84x39x51

2,725

3,173

137x66x68

2,375

2,829

137x66x68

3,200

3,648

2 - 2 T25I & T45I Super Quiet Generator Part No. 134878

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 •

SIZE THREAD

LUBED

Grade 5

DRY LUBED

Grade 8

DRY

A574 High Strength

Black Oxide Bolts

LUBED

1/4

20

28 in- lbs

100

90

N m

11.3

10.1

in- lbs

80

120

N m

9

13.5

in- lbs

140

120

N m

15.8

13.5

in- lbs

110

160

N m

12.4

18 in- lbs

130

140

N m

14.7

15.8

5/16

3/8

7/16

1/2

9/16

5/8

3/4

7/8

1

1.125

1.25

1.5

13

20

12

18

11

18

10

18

24

16

24

14

20

7

12

7

12

16

9

14

8

12

6

12

LUBED f t - lbs

200

220

320

350

480

64

80

90

110

130

13

14

23

26

37

41

57

530

590

670

840

930

1460

1640

N m

86.7

108.4

122

149

176

271

298

433

474

650

17.6

19

31.2

35.2

50.1

55.5

77.3

718

800

908

1138

1260

1979

2223

DRY

N m

366

406

583

637

867

115

149

162

203

230

23

25.7

42

47.4

66.4

74.5

101.6

962

1071

1206

1518

1681

2643

2969 f t - lbs

270

300

430

470

640

85

110

120

150

170

17

19

31

35

49

55

75

710

790

890

1120

1240

1950

2190

LUBED f t - lbs

280

310

450

500

680

90

120

130

160

180

18

20

33

37

50

60

80

750

970

1080

1360

1510

2370

2670

N m

379

420

610

678

922

122

162

176

217

244

24

27.1

44.7

50.1

67.8

81.3

108.4

1016

1315

1464

1844

2047

3213

3620

DRY

N m

162

203

230

284

325

515

569

827

908

1233

33.9

36.6

59.6

66.4

94.7

108.4

149

1342

1749

1952

2467

2725

4284

4826 f t - lbs

380

420

610

670

910

120

150

170

210

240

25

27

44

49

70

80

110

990

1290

1440

1820

2010

3160

3560 f t - lbs

320

350

510

560

770

105

130

140

180

200

21

24

38

43

61

68

93

840

1090

1220

1530

1700

2670

3000

LUBED

N m

142

176

189

244

271

433

474

691

759

1044

28.4

32.5

51.5

58.3

82.7

92.1

126

1139

1477

1654

2074

2304

3620

4067

METRIC FASTENER TORQUE CHART

• This chart is to be used as a guide only unless noted elsewhere in this manual •

Size Class 4.6

4.6

Class 8.8

8.8

Class 10.9

10.9

Class 12.9

12.9

(m m )

5

6

7

LUBED DRY LUBED DRY LUBED DRY LUBED DRY in- lbs N m in- lbs

16 1.8

19 3.05

45 5.12

21

N m in- lbs

2.4

41

N m in- lbs

4.63

54

N m in- lbs N m in- lbs

6.18

58 6.63

N m in- lbs

78 8.84

N m in- lbs

68 7.75

91

N m

10.3

36 4.07

69 7.87

93 10.5

100 11.3

132 15 116 13.2

155 17.6

60 6.83

116 13.2

155 17.6

167 18.9

223 25.2

1.95

22.1

260 29.4

LUBED DRY LUBED DRY LUBED DRY LUBED DRY f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m f t - lbs N m

8 5.4

7.41

7.2

9.88

14 19.1

18.8

25.5

20.1

27.3

26.9

36.5

23.6

32 31.4

42.6

10 10.8

14.7

14.4

19.6

27.9

37.8

37.2

50.5

39.9

54.1

53.2

72.2

46.7

63.3

62.3

84.4

12 18.9

25.6

25.1

34.1

48.6

66

14 30.1

40.8

40 54.3

77.4

105

64.9

103

88

140

69.7

110

94.5

150

92.2

147

125

200

81

129

110

175

108

172

147

234

16 46.9

63.6

62.5

84.8

125 170 166 226 173 235 230 313 202 274 269 365

18 64.5

87.5

86.2

117 171 233 229 311 238 323 317 430 278 377 371 503

20 91 124 121 165 243 330 325 441 337 458 450 610 394 535 525 713

22

24

124 169 166 225 331 450 442 600 458 622 612 830 536 727 715 970

157 214 210 285 420 570 562 762 583 791 778 1055 682 925 909 1233

Part No. 134878 T25I & T45I Super Quiet Generator 2 - 3

Section 2 • Specifications

GENERATOR TORQUE SPECIFICATIONS

Generator

Flex Plate to Flywheel

Generator Case to Bellhousing

1/2" Socket Head Cap Screws for Lifting Channel

1/2-13" Hex Head Screws for Lifting Channel

Genset Isolators

FT*LB

12-15

60

126

120

33

August 2008

2 - 4 T25I & 45I Super Quiet Generator Part No. 134878

August 2008 Section 3 • Scheduled Maintenance Procedures

Scheduled Maintenance Procedures

Observe and Obey:

Maintenance inspections shall be completed by a person trained and qualified on the maintenance of this machine.

Scheduled maintenance inspections shall be completed as specified using the supplied

Lubrication and Maintenance Service Interval

Charts provided in this section.

Failure to perform each procedure as presented and scheduled could result in death, serious injury or substantial damage.

Immediately tag and remove from service a damaged or malfunctioning machine.

Repair any machine damage or malfunction before operating the machine.

Keep records on all inspections for three years.

Machines that have been out of service for a period longer than 3 months must complete the quarterly inspection.

Unless otherwise specified, perform each maintenance procedure with the machine in the following configuration:

· Machine parked on a firm, level surface

· Toggle switch in the "OFF" position

· Wheels chocked

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.

Symbols Legend

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.

Used to indicate the presence of an imminently hazardous situation which, if not avoided, will result in death or serious injury.

Used to indicate the presence of a potentially hazardous situation which, if not avoided, could result in death or serious injury.

Used to indicate the presence of a potentially hazardous situation which, if not avoided, may cause minor or moderate injury.

Used to indicate operation or maintenance information.

Indicates that a specific result is expected after performing a series of steps.

Indicates that an incorrect result has occurred after performing a series of steps.

Part No. 134878 T25I & T45I Super Quiet Generator 3 - 1

Pre-Deliver y Preparation

Fundamentals

It is the responsibility of the dealer to perform the

Pre-delivery Preparation.

The Pre-delivery Preparation is performed prior to each delivery. The inspection is designed to discover if anything is apparently wrong with a machine before it is put into service.

A damaged or modified machine must never be used. If damage or any variation from factory delivered condition is discovered, the machine must be tagged and removed from service.

Repairs to the machine may only be made by a qualified service technician, according to the manufacturer's specifications.

Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer's specifications and the requirements listed in the responsibilities manual.

Instructions

Use the operator’s manual on your machine.

The Pre-delivery Preparation consists of completing the

Pre-operation Inspection, the Maintenance items and the

Function Tests.

Use this form to record the results. Place a check in the appropriate box after each part is completed. Follow the instructions in the operator’s manual.

If any inspection receives an N, remove the machine from service, repair and re-inspect it. After repair, place a check in the R box.

Legend

Y = yes, completed

N = no, unable to complete

R = repaired

Comments

Pre-Delivery Preparation

Pre-operation inspection completed

Maintenance items completed

Function tests completed

Y N R

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

Model

Serial number

Date

Machine owner

Inspected by (print)

Inspector signature

Inspector title

Inspector company

August 2008 Section 3 • Scheduled Maintenance Procedures

Maintenance Schedules

REV A

Isuzu Lubrication and Maintenance Service Intervals

ITEM

Oil level and oil fouling

Oil leakage check

Oil pressure warning lamp

Fuel leakage check

Draining water in fuel filter

Coolant level and fouling check

Coolant leakage check

Radiator filler cap fitting condition

Fan belt tension check (Replace if necessary)

Coolant replacement

Electrolyte level check

Battery cleaning

Battery charge condition

Preheating condition check

Engine starting conditions and noise conditions

Exhaust smoke condition

Engine oil replacement

Oil filter element replacement

Fuel filter element replacement

Injection nozzle check

Cooling system circuit cleaning

Starter and alternator check and cleaning

Cylinder compression pressure

Valve clearance check

Positive crankcase ventilation valve cleaning

Daily

First 50

Hours

Every

250

Hours

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

•

• •

Every

500

Hours

Every

750

Hours

Every

1000

Hours

Every

1250

Hours

Every

1500

Hours

•

•

•

• •

•

•

•

•

• •

•

•

•

•

•

•

•

•

*Refer to the manufacturers manuals for detailed maintence intervals and instructions. If the information in the manufacturer's manual differs from that in this manual the manufacturer's manual should take precedence.

Part No. 134878 T25I & T45I Super Quiet Generator 3 - 3

Section 3 • Scheduled Maintenance Procedures August 2008

MAINTENANCE SCHEDULES CONTINUED

REV A

Newage Maintenance Service Intervals

ITEM

Visual inspection

Visual inspection plus running audible check

Measure stator winding insulation resistance and record

Monitor bearing/s condition

Remove terminal box lid and check connections

Re-grease bearings

Measure vibration levels

Replace bearing/s

Replace NDE o-ring

Inspect bearing housings

Inspect winding conditions

Inspect rotating diode assembly

DAILY

250 Hours or 3

Months

1500 Hours or 12

Months

4500 Hours

Hours or 19 or 3 Years

15000

Years

•

•

•

•

•

•

•

•

•

•

•

•

*Refer to the manufacturers manuals for detailed maintence intervals and instructions. If the information in the manufacturer's manual differs from that in this manual the manufacturer's manual should take precedence.

3 - 4 T25I & T45I Super Quiet Generator Part No. 134878

August 2008 Section 4 • Troubleshooting

Troubleshooting

Observe and Obey:

Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine.

Immediately tag and remove from service a damaged or malfunctioning machine.

Repair any machine damage or malfunction before operating the machine.

Unless otherwise specified, perform each repair procedure with the machine in the following configuration:

· Machine parked on a firm, level surface.

· Wheels chocked.

· Toggle switch in "OFF" position.

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.

Be aware of the following hazards and follow generally accepted safe workshop practices.

Electrocution hazard. Exposure to electrically charged circuits could result in death or serious injury.

Remove all rings, watches and other jewelry.

Electrocution hazard. Attempting to sevice the machine before the capacitors are fully discharged will result in death or serious injury.

High voltage. Exposure to electrical wires or electrical current will result in death or serious injury. Remove all rings, watches and other jewelry. Turn off all power when not needed for testing. Use extreme caution when working with high voltage electrical components.

Burn hazard. Contact with hot engine components may cause severe burns. Use caution when working around a hot engine.

Part No. 134878 T25I & T45I Super Quiet Generator 4 - 1

Section 4 • Troubleshooting August 2008

Troubleshooting Guide

The engine/generator set is tested and set at the factory for proper operation in the field. These units should never require additional adjustments in the field. If needed, adjustments should only be made by a qualified service technician, otherwise the manufacturer’s warranty may become void.

FAULT

No generator output voltage

Low generator output voltage

POSSIBLE CAUSE

Circuit breaker tripped

Voltage regulator

Defective voltage regulator

Defective Selector Switch

Defective generator

Voltage adjustment set too low

Defective potentiometer

Low engine speed

Loose wire on voltage selector switch

Fluctuating or surging engine speed

Loose wire on voltage regulator sensing circuit

Defective voltage regulator

SOLUTION

Reset circuit breaker

Check voltage regulator wiring

Replace voltage regulator

By pass by hardwiring generator

Refer to generator manual

Adjust voltage potentiometer

By pass or replace

Call TEREX Service

Check wiring

Check engine fuel, oil, and air filters

Check wiring

Replace voltage regulator

High generator output voltage

Voltage adjustment potentiometer

High engine speed

Adjust potentiometer

Call TEREX Service

4 - 2 T25I & T45I Super Quiet Generator Part No. 134878

August 2008

FAULT

High generator output voltage

Fluctuating generator output voltage

Low engine speed

Section 4 • Troubleshooting

POSSIBLE CAUSE

Defective automatic voltage regulator

Loose wire on voltage adjustment potentiometer

Neutral binding strap not in place.

An “ON/OFF” type load may be the cause

Fluctuating or surging engine speed

Loose wiring in generator

Automatic voltage regulator stability setting may be wrong

Loose wire on the automatic voltage regulator sensing lead

TROUBLESHOOTING

SOLUTION

Replace voltage regulator

Check wiring

Install neutral binding strap

Redistribute load if possible

Check engine fuel, oil, and air filters

Check connections

Call TEREX Service

Check wiring

Engine speed adjustment has slipped

Clogged fuel system

Blocked air intake

Blocked exhaust system

Contaminated fuel

Defective governor on engine

Call TEREX Service

Check for air leaks, clogged fuel filter, kinked fuel line, or clogged fuel pick-up tube

Check air filter

Check engine exhaust system, remove obstructions

Check fuel/water separator and fuel tank for contamination.

Replace fuel if needed

Call TEREX Service

Part No. 134878 T25I & T45I Super Quiet Generator 4 - 3

Section 4 • Troubleshooting

TROUBLESHOOTING

FAULT

Low Speed

Engine turns over (cranks), but won’t run

POSSIBLE CAUSE

Defective injectors on engine

“Surging” engine speed

Unit out of fuel

Loose or broken wire in control circuit fuel injection pump solenoid

Defective solenoid

Clogged fuel system

Air in fuel system

Defective fuel pump

Clogged air intake

Clogged exhaust

Contaminated fuel

Defective injectors

Lost engine compression

SOLUTION

Have injectors checked by a qualified technician

Check engine fuel, oil, and air filters

Check fuel level in tank, fill as needed

Check wiring to verify 12V DC is being supplied to the pump solenoid

Replace solenoid

Check fuel system

“Bleed” fuel system

Check and replace if defective

Check air cleaner

Check exhaust system

Check fuel/water separator and tank for contamination

Have injection system checked by a trained technician

Have compression checked by a trained technician

August 2008

Engine won’t crank Loose battery cable or discharged battery

Check cables and battery electrolyte level. Recharge as necessary

4 - 4 T25I & T45I Super Quiet Generator Part No. 134878

August 2008 Section 4 • Troubleshooting

TROUBLESHOOTING

FAULT

Engine won’t crank

POSSIBLE CAUSE SOLUTION

Engine “ON/OFF” switch Check switch position set in “OFF” position

Blown fuse in DC

control circuit

E-Stop

Defective starter solenoid

Replace with 25 Amp.

SLO-BLO TYPE

fuse if needed.

Check to see if engaged

Replace solenoid

Defective starter

Seized engine

Replace starter

Have engine checked by a qualified technician

Engine runs, but loses speed

Engine runs, but loses power under load

Engine shuts down automatically and

TROUBLE LIGHT on

CONTROL PANEL is illuminated

Unit is overloaded

Improper connection

Clogged fuel system

Blocked air intake

Blocked exhaust

Contaminated fuel

Faulty governor, defective injectors, or defective fuel pump

Oil Pressure Switch

Improper coolant or water mixture

Reduce load

Check or Call TEREX Service

Check fuel system air in fuel lines

Check air cleaner

Check exhaust system

Check fuel/water separator and fuel tank for contamination

Have unit checked by a trained service technician for all of these items

Not opening

Use a 50/50 on mix of water and anti-freeze only

Part No. 134878 T25I & T45I Super Quiet Generator 4 - 5

Section 4 • Troubleshooting August 2008

TROUBLESHOOTING

FAULT

Engine shuts down automatically and

TROUBLE LIGHT on

CONTROL PANEL is illuminated

POSSIBLE CAUSE

Overloaded engine

Broken fan belt

Defective thermostat or thermocouple switch

Defective water pump

Blocked cooling air inlet or exhaust

Defective or grounded temperature switch

Defective injectors or injector pump

Defective oil pump

Defective or grounded oil pressure switch

SOLUTION

Reduce load

Inspect fan belt and replace as needed

Inspect thermostat switch

Inspect water pump and replace if needed

Inspect and remove any obstructions

Inspect switch and repair or

replace

Have the engine inspected by a trained service technician

Have the engine inspected by a trained service technician

Inspect switch and repair or replace

IF YOU FEEL AN ELECTRIC SHOCK AT ANY TIME WHILE OPERATING THIS UNIT, SHUT IT DOWN

IMMEDIATELY! HAVE THE UNIT INSPECTED BY A TRAINED ELECTRICIAN.

THIS ENGINE/GENERATOR SET IS FACTORY INSTALLED, TESTED, AND SET FOR FIELD

OPERATION. ANY DAMAGE TO THE ENGINE OR GENERATOR UNITS OCCURRING AFTER

ADJUSTMENTS ARE MADE IN THE FIELD BY UNAUTHORIZED PERSONNEL WILL NOT BE

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.

4 - 6 T25I & T45I Super Quiet Generator Part No. 134878

August 2008 Section 4 • Troubleshooting

TROUBLESHOOTING

Electrical Troubleshooting

5 Components that cause voltage related problems

Generator

Test resistance of field, stator and exciter windings.

Contact TEREX for procedures or repair facility recommended by generator manufacturer.

Potentiometer

Connects to voltage regulator. Bypass potentiometer by unplugging from voltage regulator and installing jumper on 2 male spades on regulator.

Voltage Regulator

(Located inside the generator rear housing.)

Measure DC voltage at F1 & F2. Normal voltage is

10 to 12 V DC. Remove 2 wires marked (F1,

X)(F2, X X) from voltage regulator. Connect wire marked F1 to positive and F2 to negative of a 12 volt battery. Start unit and measure voltage. If unit produces close to maximum output, replace

Automatic Voltage Regulator.

Voltage Selector Switch

The correct way to test is to disconnect from generator and hard wire the generator into one configuration. This will eliminate the switch from the circuit and verify that the generator is functioning properly. All contacts should be checked following the proper schematic with the switch disconnected from the generator set. Actual loads can cause failures in contacts that cannot be duplicated using a meter.

Overcurrent Relay

This device causes the 3-phase breaker to trip that supplies AC power to the distribution lugs if uneven or excessive current is measured at the distribution lugs. It is also connected to the 3phase door switch and will automatically trip the 3phase breaker when the door is open and prevents the breaker from being reset while it is open.

Procedure for testing generator with no output

THIS EQUIPMENT USES HIGH VOLTAGE

CIRCUITS CAPABLE OF CAUSING SERIOUS

INJURY OR DEATH! EXCERCISE EXTREME

CAUTION AROUND ANY ELECTRICAL

COMPONENT WHEN OPERATING THIS UNIT.

IT IS ESSENTIAL THAT ALL TEST INSTRU-

MENTS ARE REGULARLY CHECKED FOR

SAFETY, AND ANY CONNECTION LEADS,

PROBES, OR CLIPS, ARE CHECKED TO

ENSURE THAT THEY ARE SUITABLE FOR

THE VOLTAGE LEVELS BEING TESTED.

NEVER ATTEMPT TO TEST A "LIVE" GENERA-

TOR UNLESS THERE IS ANOTHER COMPE-

TENT PERSON PRESENT WHO CAN SWITCH

OFF THE POWER SUPPLY OR SHUT DOWN

THE ENGINE IN AN EMERGENCY.

NEVER EXPOSE "LIVE" CONNECTIONS UN-

LESS YOU HAVE CREATED A SAFE WORKING

AREA AROUND YOU. MAKE SURE YOU HAVE

MADE ALL OTHER PERSONS IN THE IMMEDI-

ATE AREA FULLY AWARE OF WHAT YOU ARE

DOING.

• When a new generator is not producing voltage, the testing or wiring personnel should first verify that the unit is wired correctly! The stack switch and generator leads should all be checked as well as the breaker and sensing leads. If the unit was not wired correctly and you flashed the generator, you could burn up the unit. (Do not

forget to check the sensing leads!).

Part No. 134878 T25I & T45I Super Quiet Generator 4 - 7

Section 4 • Troubleshooting August 2008

TROUBLESHOOTING

Procedure for testing generator with no output

(cont.)

• After performing the initial checks above, remove the field wires from the voltage regulator (F1 or X is positive and F2 or XX is negative). Connect the battery + to the F1 or X wire and battery - to the F2 or XX wire. Start the engine and check for the rated voltage.

Hooking this up incorrectly will reverse polarity and could damage the voltage

regulator and /or generator end. This check should correct any voltage problems. If your voltage does not come up to the rated voltage, this indicates an internal problem with the generator end. The output should be close to proper voltage. Also, if the unit comes up to voltage, check for even reading across the lines if they are not this would mean you probably have a problem with the wiring of the switch or generator. If the generator voltage reads correctly you know there is not a problem with the generator end. Your problem is more than likely with the voltage regulator. In this case, you should contact the TEREX service department.

• If the voltage is uneven between the legs when you apply 24 volts to the field wires you need to recheck your wiring connections. (If you can not find the problem hard wire the

generator!) After you have the field wire connected start the unit again and check your output voltage. It may still be necessary to flash the fields to restore residual voltage. This needs to be done with the unit off and the field wires removed. (Do not flash the regulator, flash the field wires)

• As with any electrical device use extreme caution when working around a running generator it could cost you your life. Observe proper polarity when working with the regulator so you don’t break something that is not broken to begin with, and if you are ever in doubt, ask.

INSTALLATION AND ANY WORK PERFORMED

ON THIS UNIT SHOULD BE DONE ONLY BY A

QUALIFIED ELECTRICIAN.

Procedure for changing the voltage potentiometer

THIS EQUIPMENT USES HIGH VOLTAGE

CIRCUITS CAPABLE OF CAUSING SERIOUS

INJURY OR DEATH! EXCERCISE EXTREME

CAUTION AROUND ANY ELECTRICAL

COMPONENT WHEN OPERATING THIS UNIT.

INSTALLATION AND ANY WORK PERFORMED

ON THIS UNIT SHOULD BE DONE ONLY BY A

QUALIFIED ELECTRICIAN.

• Make sure generator is turned off and e-stop is engaged before opening control panel.

• Locate the two wires going to the back of the potentiometer. Both wires will be white with a red stripe.

• Disconnect both wires.

• Once the wires are loose, go to the front of the control panel and loosen the lock nut holding the potentiometer.

• Put the new potentiometer in its place and retighten lock nut.

• Reattach the disconnected wires that were disconnected in step 3.

• After completing the installation of the new potentiometer go back and check all connections to make sure everything is tight and that no connections are loose, this includes all other wiring on the back of the control panel and on the inside of the control box.

• You should now be able to restart the generator and check for proper operation.

If any further adjustment is needed to the voltage of the generator please call TEREX at 1-800-433-3026 for assistance.

4 - 8 T25I & T45I Super Quiet Generator Part No. 134878

August 2008 Section 5 • Schematics

Schematics

REV A

Observe and Obey:

Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine.

Immediately tag and remove from service a damaged or malfunctioning machine.

Repair any machine damage or malfunction before operating the machine.

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.

About This Section

There are two groups of schematics in this section.

An illustration legend precedes each group of drawings.

Electrical Schematics

Electrocution hazard. Contact with electrically charged circuits could result in death or serious injury.

Remove all rings, watches and other jewelry.

General Repair Process

Malfunction discovered

Identify symptoms problem still exists

Return to service problem solved

Inspect and test

Troubleshoot

Perform repair

Part No. 134878 T25I & 45I Super Quiet Generator 5 - 1

Control Panel Wiring for Murphy Cascade Controller

Drawing #ES100001 (Standard)

Section 5 • Schematics August 2008

REV A

5 - 2 T25I & T45I Super Quiet Generator Part No. 134878

August 2008

REV A

Section 5 • Schematics

Control Panel Wiring for Cascade w/Electronic Governor

Drawing #ES100000 (Optional)

Part No. 134878 T25I & 45I Super Quiet Generator 5 - 3

Section 5 • Schematics

Distribution Panel Wiring for T25I & T45I Series Single Phase Control

Drawing #ES100003

August 2008

REV A

5 - 4 T25I & T45I Super Quiet Generator Part No. 134878

August 2008

REV A

Section 5 • Schematics

Three Position Stack Switch Wiring

Drawing #ES100005

Part No. 134878 T25I & 45I Super Quiet Generator 5 - 5

Overcurrent Relay Wiring

Drawing #ES100006

Section 5 • Schematics August 2008

REV A

5 - 6 T25I & T45I Super Quiet Generator Part No. 134878

August 2008

REV A

Section 5 • Schematics

Generator Wiring Breakdown

Drawing #ES100007

Part No. 134878 T25I & 45I Super Quiet Generator 5 - 7

Standard Generator Wiring

Drawing #ES1000008

Section 5 • Schematics August 2008

REV A

5 - 8 T25I & T45I Super Quiet Generator Part No. 134878

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.

Genie North America

Phone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Genie Australia Pty Ltd.

Phone + 61 7 3375 1660

Fax + 61 7 3375 1002

Genie China

Phone + 86 21 53852570

Fax + 86 21 53852569

Genie Malaysia

Phone + 65 98 480 775

Fax + 65 67 533 544

Genie Japan

Phone + 81 3 3453 6082

Fax + 81 3 3453 6083

Genie Korea

Phone + 82 25 587 267

Fax + 82 25 583 910

Genie Brasil

Phone + 55 11 41 665 755

Fax + 55 11 41 665 754

Genie Holland

Phone + 31 183 581 102

Fax + 31 183 581 566

Genie Scandinavia

Phone + 46 31 575100

Fax + 46 31 579020

Genie France

Phone + 33 (0)2 37 26 09 99

Fax + 33 (0)2 37 26 09 98

Genie Iberica

Phone + 34 93 579 5042

Fax + 34 93 579 5059

Genie Germany

Phone + 49 (0)4202 88520

Fax + 49 (0)4202 8852-20

Genie U.K.

Phone + 44 (0)1476 584333

Fax + 44 (0)1476 584334

Genie Mexico City

Phone + 52 55 5666 5242

Fax + 52 55 5666 3241

Before Towing

Towing Checklist

(Use at each stop)

· Towing hitch is properly secured to tow vehicle

· Safety chains (if required) are properly attached and secure (chains are crossed below hitch)

· All lights are connected and working

· Tires are properly inflated

Before Driving

On The Road

· Fasten safety restraints

· Properly adjust mirrors

· Do not exceed 60 mph / 97 km/h. Obey all local and national towing speed laws

· Check connections and tire pressure at each stop

· Slow down for hazardous conditions

· Allow extra distance for following and passing other vehicles