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T25

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3. 3 NOTICE GROUND Radiator fill UNIT pore PROPERLY CONSULT LOCAL CODE DANGER 6 NOTICE HIGH ATTENTION READ OWNER S MANUAL VO LT AG E BEFORE OPERATING Use of engine staring lds wil cause OR SERVICING 853070 engine damage and void manufacturer s warranty 8 9 7 A DANGER Hazardous voltage Can cause serious injury or death Shut down generator CALIFORNIA before servicing Terex T25l and 7451 Super Quiet Generator 7 Operating Instructions and Parts Manual TEREX June 2006 REVA GENERAL SAFETY Cont AX ACCIDENT PREVENTION AY 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 FIRES CAN CAUSE SEVERE PERSONAL INJURY OR MACHINE DAMAGE 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 Prevent fires by keeping the generator and its surrounding area clean DO NOT refuel while smoking or when near open flame or sparks A UNAUTHORIZED WELDING DO NOT refuel the engine when it is hot Allow to cool f
4. 70 FIGURE 13 TRAILER Q 72 FIGURE 14 OP TIONS 74 Terex T25l and 7451 Super Quiet Generator 3 Operating Instructions and Parts Manual TEREX June 2006 REVA TEREX Model Number Serial Number Engine Model Number Serial Number Generator Model Number Serial Number Owner Ship to Options This Operation and Service Manual contains information specifically pertaining to the operation and maintenance of the TEREX T25l 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 P O Box 3147 29732 590 Huey Road Rock Hill SC 29730 Telephone 800 433 3026 FAX 803 366 1101 4 Terex T25l 7451 Super Quiet Generator Operating Instructions and Parts Manual June 2006 REVA 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 ac
5. x55 ue 5539810 01 EE 5 AV 139 SEI NL ANIONS H 0g A 227 1 ie 5 5 4 6 OLTIVO 1 5 amp E Lt woud qassnioN Mava 05 2 MOTTA Sms EMREN EMERE CER DEELS ams jen Lm M079 OL ama ama 3 O Mi HOLIMS 319904 INVIO gt xs o m Ts o 2015 AoNSOti3Ia o 100000 33S HOO N oL misa o t sus eh z 1 EB 1 o M 100820 33S c AVIS 300 NO OL 517107759 BAST aNd SUNOH 3unsssHd JWL OW ZIHSH SPOA OV SETS a 90g O S550 O Q gt Terex 251 T45I Super Quiet Generator 30 X 14 Operating Instructions and Parts Manual Control Panel Wiring for Murphy Cascade Controller June 2006 Drawing ES1000001 REV Standard Q3H1V3HS v HE
6. 66 Terex 251 and T45I Super Quiet Generator Operating Instructions and Parts Manual TEREX November 2007 REV DESCRIPTION INJECTOR NOZZLE ASSEMBLY FUEL INJECTOR PUMP OIL FILTER DIPSTICK ENGINE STOP SOLENOID FUEL FEED PUMP ASSEMBLY GLOW PLUG THERMOSTAT FUEL FILTER GENERATOR ALTERNATOR OIL FILLER CAP OIL DRAIN PLUG VALVE COVER GASKET TIMER TEMPERATURE SENDER FAN 868013 FAN GUARD 868014 RADIATOR C33200500 FILTER WATER SEPARATOR 116075 TEMPERATURE SWITCH 116076 OIL PRESSURE SWITCH 116077 OIL PRESSURE SENDER Terex T25l 7451 Super Quiet Generator 67 Operating Instructions and Parts Manual TEREX November 2007 REV B FIGURE 11B ENGINES T45l T45l Engine 68 Terex 251 and T45I Super Quiet Generator Operating Instructions and Parts Manual November 2007 REV TEREX DESCRIPTION INJECTOR NOZZLE ASSEMBLY OIL FILTER DIPSTICK ENGINE STOP SOLENOID FUEL FEED PUMP ASSEMBLY GLOW PLUG THERMOSTAT FUEL FILTER FAN BELT WATER PUMP GENERATOR ALTERNATOR OIL FILLER CAP OIL DRAIN PLUG VALVE COVER GASKET TEMPERATURE SENDER FILTER WATER SEPARATOR TEMPERATURE SWITCH FAN GUARD FAN OIL PRESSURE SENDER OIL PRESSURE SWITCH c l l c l c l l c l c l l l l l la 24 Terex T25l and 7451 Super Quiet Generator 69 Operating Instructions and Parts Manual
7. 41 PARTS CATALOG uu aaa ias asss ss iseina REGRES dariis 43 CABINET DECALS E Bd nun a a2 naina ved D dud V FEE aura RU 44 SAFETY DECALS a Ra uq E riesaa SHa 45 FIGURE 1 BASE W FUEL TANK 46 FIGURE 2 BASE W LIFTING EYE amp 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 2 Terex T25l 7451 Super Quiet Generator Operating Instructions and Parts Manual TEREX June 2006 REVA Table Of Contents FIGURE 10 AIR CLEANER ASSEMBLY 64 FIGURE 11 ENGINES T25lI 66 FIGURE 11B ENGINES T45l 68 FIGURE 12 VOLTAGE SELECTOR SWITCH
8. N V b i 2 4 v Oo T 4 KL e s s Terex T25l T45I Super Quiet Generator 52 Operating Instructions and Parts Manual June 2006 REVA TEREX DESCRIPTION GCU460000 GCU470001 GCU420021 GCU42001 1 GCU470001 GCI490001 GUUA01100 GCU110060 C54200601 54400200 994490 993422 HOUSING PANEL HOUSING JAMB DOOR HOUSING FRONT STREET HOUSING FRONT CURB HOUSING JAMB DOOR HOUSING DISTRIBUTION PANEL HOUSING CONTROL PANEL HOUSING REAR LOUVER GUARD LOUVER MESH BAFFLE LOUVER BULKHEAD 251 BULKHEAD 4 SEAL TRIMLOCK 7 16 MUFFLER FRONT MOUNT SCREW FLANGE 5 16 18 WEATHERSTRIP ADHESIVE PLATE DECK SCREW OUT THREADED RING PLATE DECK SCREW OUT RIVET POP 3 16 X 1 2 SCREW TEK 10 X 3 4 WASHER FLAT SNUBBING SCREW FLANGE 1 4 20 X 75 SS NUT LOCK NYLON 1 4 20 GR2 WASHER FLAT 11 16 O D FILTER FUEL WATER SEPARATOR COMPLETE WATER SEPARATOR ELEMENT ONLY Terex T25l 7451 Super Quiet Generator 53 Operating Instructions and Parts Manual TEREX June 2006 REVA FIGURE 5 CABINET ASSEMBLY W DOORS 54 Terex T25l and T45I Super Quiet Generator Operating Instructions and Part
9. O did LNNHS HOLIMS MOVLS OL 1715 SHIM ALON 33S MONIA Wada 3ONVHO Wada YOLVYANAS JHL OL NMOS Wada NIVIA 3SVHd 319NIS 41 61 Terex T25l 451 Super Quiet Generator 32 Operating Instructions and Parts Manual TEREX June 2006 REV A Three Position Stack Switch Wiring Drawing ES1000005 X m b a o 2 6 9 Ps 5 x a 5 zz 5 250 99 g 2 gt 0 5 9 99 GENERATOR STACK SWITCH WIRE SIZE T25 C42201102 10 GA EPDM 1451 C42202402 8 GA EPDM NOTE FOR REFERENCE SEE DRAWINGS ES100007 amp ES100008 6 6 m 2 o 5 B 9 a a E 28 lt a t x 9 m Y _ W 2 5 2 Ze 9 Z oz 2 W x Ww Terex T25l 7451 Super Quiet Generator 33 June 2006 REVA Operating Instructions and Parts Manual Overcurrent Relay Wiring Drawing ES1000006 TEREX YALAW OL vl MOV Ig q33 NO LNNHS OL PL 3LIHA H33V38 NO LNNHS OL PL MOTI3A 015 3 OL vl aay a18v yovia 3LIHM JlvV Id
10. x si 2022 2224 2834 4550 7n amp 3133 3235 4045 7075 4mm 2220 1922 ean i 6mm 4550 6843 278 J 8mm 12No 910 1416 iomm 1820 1547 4550 4045 7075 4244 3638 5660 5055 395105 emm as 18mm 2mm 28029 j GENERATOR TORQUE SPECIFICATIONS Generator Flex Plate to Flywheel Generator Case to Bellhousing 1 2 Socket Head Cap Screws for Lifting Channel 1 2 Hex Head Screws for Lifting Channel Genset Isolators Terex T25I and 7451 Super Quiet Generator 39 TEREX Operating Instructions and Parts Manual June 2006 REVA This page intentionally left blank 40 Terex T25l and T45I Super Quiet Generator remove this page and make copies remove this page and make copies Operating Instructions and Parts Manual TEREX 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 All backordered parts will be shipped when available via the same ship method as the original order unless noted below Ship complete order only
11. backorders o Ship all available parts and contact customer on disposition of backordered parts Other please specify For TEREX Use ONLY Order Number Origin Code Comments Date Scheduled Ship Condition Order Total Terms Code TEREX Operating Instructions and Parts Manual June 2006 REVA This page intentionally left blank 42 Terex T25l T45I Super Quiet Generator Operating Instructions and Parts Manual TEREX June 2006 REVA PARTS CATALOG SECTION Terex T25l 7451 Super Quiet Generator 43 Operating Instructions and Parts Manual TEREX June 2006 REV CABINET DECALS GCU401020 GCU401100 T25 ONLY GCU401040 T45 ONLY GCU401010 GUU402000 TEREX Power Products GCU401100 T25 ONLY GCU401040 T45 ONLY GCU401100 GCU401040 GU401020 GU401010 77 49 TEREX Power Products 44 Terex T25l and T45I Super Quiet Generator Operating Instructions and Parts Manual June 2006 REVA TEREX SAFETY DECALS death machine b Hazardous voltage Will cause serious injury or Disconnect power before servicing Lockout Tagout U51A122 U51A122 ADANG ER US1A102 U 51A112 NOTIC No ether Use of engine
12. To reset the controller press the OFF button Then correct the cause of the shutdown This will clear all faults except when the aux inputs are programmed for either shutdown immediate or warning immediate or if the engine ECU is broadcasting a shutdown fault In the event of a fault that causes the engine to shutdown the cause of the event will be indicated on one of the 11 status lights on the right hand side of the controller See Fig 1 When the cause of shutdown is corrected the controller can resume normal operation AUTO Mode LED Figure 2 Terex T25l and 7451 Super Quiet Generator 17 TEREX OPERATING INSTRUCTIONS Cont A OVERCURRENT PROTECTION This relay is mounted behind the control panel and monitors the current draw and uneven current draw to protect the generator set This trip setting is set at the factory with the proper kW using a loadbank THIS SETTING SHOULD NEVER BE CHANGED OR GENERATOR FAILURE WILL OCCUR The time delay setting is on the right side of the relay and this setting may need to be adjusted If the overcurrent is tripping on small load condi tions the time delay setting needs to be turned clockwise a 1 4 turn This should correct the problem NOTICE Call TEREX Service for wiring and troubleshooting information Operating Instructions and Parts Manual June 2006 REVA A SHUTDOWN PROCEDURES NEVER SHUT THE UNIT DOWN WHILE UNDER LOAD THIS COULD CAUSE SERIOUS INJURIE
13. 1 3AO O ON HOLIMS cL V N 1 9 SL 8b 1H9r19NINHYM SaNoo3s N Awad H3AO Z Terex 251 and 451 Super Quiet Generator 34 TEREX Drawing ES1000007 Generator Wiring Breakdown Operating Instructions and Parts Manual June 2006 REVA T3J33HMA 1d GENERATOR TOPPOSTS 1031405 WOW 1 YOLVYESNAD WO33 LL HOLIMS MOVLS Wow 2 YOLVYANSD cL lOHLNOO WOW YOLVYANAD L HOLIMS MOVLS WOw4 S YOLVYANAD WO SL HOLIMS HOVLS NO NOILISOd 92 OL SHIM Q3dV L 2 HOLIMS MOVLS NO NOILISOd 1 1OHINOO 3HIM Q3dV L HOLIMS MOVLS NO NOILISOd EZ OL XO8 lOHLNOO SHIM Q3dV L 39NVHO HOLIMS MOVLS NO NOILISOd LZ OL Q3dV L NMWOSNg8 HOLIMS MOVLS HOIVH3N39 HOLIMS MOVLS YOLVYANAS WOMW4 v WAV OL HOIVH3N39 WO 4 Z4 QNVL HOLIMS MOWLS 9 HOlVH3N39 WO 91 xog HOLIMS MOVIS HOJVH3N3O WOW 21 WA QVv31 ONISNAS Z HOLIMS MOWLS WOH 8 YOLVYANSD 81 HOLIMS MOVIS WO 6 YOLVYANAD WO 4 61 431 ONISNAS 8 35 Terex T25l 7451 Super Quiet Generator June 2006 REVA L OVZ
14. 1 4 20NCX3 4 WASHER FLAT 1 4 RIVET POP 3 16X 602 HARNESS AC CTRL PNL HARNESS CTRL UNIVERSAL NUT CLIP 1 4 20X3 4 PLASTIC ABS 1 8 X 10 5 X 22 5 HINGE PIANO 9 SS RELAY OVER CURRENT RAIL RELAY MOUNTING AVR CHECK UNIT BEFORE ORDERING PART TERMINAL STRIP 6 POS JUMPER TERMINAL STRIP RELAY 50A BOSCH RELAY BASE 50A BOSCH RELAY PIN DECAL KIT RECEPTACLES AND BREAKERS DECAL KIT CONTROL PANEL CASCADE O N PF Ss k 1 1 4 1 2 1 2 mk Terex T25l 7451 Super Quiet Generator 57 Operating Instructions and Parts Manual TEREX June 2006 FIGURE 7 CONTROL PANEL ASSEMBLY LOWER eave 58 Terex T25l T45I Super Quiet Generator Operating Instructions and Parts Manual June 2006 REVA TEREX DESCRIPTION ODODANODOOAR RWW GCU320000 GCU300000 42104500 42104800 685880 685930 42103400 42103600 684640 42500100 42500100 42500200 CU41S030 47100300 R980195 990340 CU45A010 C51601442 C51601441 990340 990340 CONTROL PANEL ASSEMBLY PANEL 1PHASE BREAKER 70A SHUNTTRIP T251 BREAKER 150A SHUNTTRIP 451 BREAKER 2POLE 1PH 45 25 BREAKER 2POLE 1PH 90 T451 BREAKER 20A 120 240V BREAKER 50A 120 240V RECEPTACLE 20A 120V TRANSFORMER 100 5 TRANSFORMER 100 5 25 TRANSFORMER 200 5 451 TEMP POWER SLOPE RECEPTACLE TWISTLOCK 50A SCR
15. 841067 SPARE TIRE AND WHEEL MOUNTS ON A FRAME 124317 SPARE TIRE MOUNTING BRACKET 841070 SPARE TIRE MOUNTING BRACKET UNIVERSAL 0GSX0113 124877 TRAILER STANDARD NO BRAKES 0GSX0118 124879 TRAILER HYDRAULIC BRAKES 0GSX0114 124878 TRAILER ELECTRIC BRAKES Terex T25l 7451 Super Quiet Generator 73 Operating Instructions and Parts Manual TEREX November 2007 FIGURE 14 OPTIONS REV B OPTION 2 PART DESCRIPTION 0GSX0086 0GSX0036 0GSX0037 0GSX0141 0GSX0143 0GSX0057 0GSX0066 0GSX0145 0GSX0149 0GSX0042 0GSX0071 C33204000 C33203000 C42300600 742376 C33203000 C41101000 C42300800 BATTERY DISCONNECT SWITCH TRICKLE CHARGER WITH MALE RECEPTACLE RECEPTACLE 15A 125V RECEPTACLE 15A 125V 3 5A BATTERY CHARGER WITH MONITORING RECEPTACLE 15A 125V RECEPTACLE 15A 125V BLOCK HEATER ISUZU T45 RECEPTACLE 15A 125V RECEPTACLE 15A 125V BLOCK HEATER ISUZU T25 RECEPTACLE 15A 125V RECEPTACLE 15A 125V C SERIES CAM LOCK DISTRIBUTION PANEL WITH STANDARD LUG PANEL EXTERNAL FUEL CONNECTION ELECTRONIC GOVERNOR T45 MAG PICK UP ACTUATOR ELECTRONIC WOODWARD ELECTRONIC GOVERNOR T25 MAG PICKUP ACTUATOR APECS LIGHTED CONTROL PANEL LOW COOLANT SHUTDOWN 74 Terex T25l and T45I Super Quiet Generator
16. 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 TEREX 251 45 SPECIFICATIONS AND 100 load 75 load 50 load 25 load Standard Optional Standard 12 9 70 Isuzu 4LE1PV02 4 Natural Std Rad 64 53 1 5 1 1 0 8 0 4 64 Analog Digital Cascade 750 DIMENSIONS 60 Standard Optional Standard 27 20 Isuzu 4JG1TPV 4 Turbo Std Rad 64 29 2 8 2 2 1 7 1 2 64 Analog Digital Cascade 750 Terex T25l and 7451 Super Quiet Generator 37 TEREX Operating Instructions and Parts Manual 251 45 SPECIFICATIONS AND DIMENSIONS Cont 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 20 Duplex Receptacles 2 50A Tempowers AVR Voltage Regulation Mechanical Standard 5 Speed Con
17. LOCK NYLON INSERT 1 2 13NC CY59A111 PLASTIC 1 8 X 3 X 4 SCREW 1 2 13NC X 1 1 2 WASHER FLAT 1 2 LIFTING CHAN SPACER BATTERY WET 12V GRP34 750CCA NUT WING CU22A252 ANGLE BATTERY C33700800 HOOK BATTERY HOLD DN GCU121010 BATTERY TIE DOWN SCREW 1 4 20NC X 5 8 HWH TRAY BATTERY SCREW 1 2 13NC X 1 1 2 WASHER LOCK 1 2 AMA ANA G 9 S Terex T25l 7451 Super Quiet Generator 49 Operating Instructions and Parts Manual TEREX June 2006 REVA FIGURE 3 GENSET 7451 Genset Terex T25l 7451 Super Quiet Generator 50 Operating Instructions and Parts Manual TEREX November 2007 REV 630975 GENERATOR NEWAGE 20KW T25l 630944 GENERATOR NEWAGE 40KW T45l C33602400 MOUNT VIBRATION FAIL 981635 SCREW 1 2 13NCX1 CC32T010 HAT CHANNEL NEWAGE 120051 CHANNEL NEWAGE 451 SCREW 1 2 13NCX1 1 2 WASHER FLAT 1 2 NUT LOCK NYLON INSERT SCREW FLANGE 3 8 16 X 1 732112PP ENGINE ISUZU 20KW 4LE1PV02 POWER 508 732114PP ENGINE ISUZU 30 40KW 4JG1TPV POWER PACK 503 T45l 836427 RECTIFIER SERVICE KIT 830001 BCI GENERATOR OPERATION MANUAL m O 0 NS Terex T25l 7451 Super Quiet Generator 51 Operating Instructions and Parts Manual TEREX June 2006 REVA CABINET ASSEMBLY FIGURE 4
18. 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 Engine shuts down automatically and TROUBLE LIGHT on CONTROL PANEL is illuminated Cil Pressure Switch Improper coolant or water mixture Not opening Use a 50 50 on mix of water and anti freeze only Terex T25l and 7451 Super Quiet Generator 25 Operating Instructions and Parts Manual TEREX June 2006 REVA TROUBLESHOOTING Cont POSSIBLE CAUSE Engine shuts down automatically and TROUBLE LIGHT on CONTROL PANEL is illuminated 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 Low crankcase oil level 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 Check oil level and refill as required Have the engine inspected by a trained service technician Inspect switch and repair or replace IF YOU FEEL AN ELECTRIC SHOCK AT ANY TIME WHIL
19. the follow ing will be the normal output voltages Line to Line L1 to L2 L2 to L3 L1 to L3 480 VAC 3P Line to Neutral L1 12 or L3 to N 277 VAC 1P NOTICE This three phase wiring configuration is referred to as Hi Wye In the three phase 208 120 position the follow ing will be the normal output voltages Line to Line L1 to L2 and L2 to L3 L1 to L3 240 VAC 3P Line to Neutral L1 L2 L3 to 139 VAC 1P NOTICE This three phase wiring configuration is referred to as Lo Wye NOTICE The above voltages can be dialed down or adjusted lower by using the voltage adjustment potientiometer located on the gen erator main control panel TEREX OPERATING INSTRUCTIONS Cont THIS EQUIPMENT USES HIGH VOLT AGE CIRCUITS CAPABLE OF CAUSING SERIOUS INJURY OR DEATH EXCERCISE EX TREME CAUTION AROUND ANY ELECTRICAL COMPONENT WHEN OPERATING THIS UNIT The three position selector switch has HI WYE 480 V 3ph LOW WYE 240 V 3ph and 240V single phase that is Zig Zag The following is the output voltages on the zigzag position Line 1 to L3 240 VAC 1P Line to Neutral 120 VAC 1P L2 is not used this position Once the required voltages are known then the combination of the proper switch position and voltage adjustment potentiometer allows for fine tuning the voltage to th
20. 1 Super Quiet Generator 19 Operating Instructions and Parts Manual TEREX June 2006 REVA MAINTENANCE Cont 200 HOURS Change Oil and Fuel Filter Replace Fuel Filter Injection Nozzle Check Clean Radiator Surface 750 HOURS Replace Engine Oil 1000 HOURS Change Oil and Filter Replace Fuel Filter Injection Nozzle Check e Coolant System Circuit Cleaning Starter and Alternator Check and Cleaning Cylinder Compression Pressure Valve Clearance Check Feed Pump Strainer Cleaning Clean Radiator Surface 1250 HOURS Replace Engine Oil Water Pump Grease Change e Coolant System Circuit Cleaning Starter and Alternator Check and Cleaning 1900 HOURS Change Oil and Filter Replace Fuel Filter Injection Nozzle Check Clean Radiator Surface Positive Crankcase Ventilation Valve Cleaning AY CLEANING The TEREX Super Quiet Generators employ various electronic controls that may be damaged by liquid spray washing or high pressure washing Follow these procedures to prevent any damage to these components DO NOT SPRAY WATER INTO THE UNIT WHILE IT IS RUNNING THIS MAY RESULT IN INJURY OR DEATH BY ELECTRIC SHOCK Exterior Cleaning The exterior housing be washed by most conventional cleaners and methods The exterior housing may be waxed using any conventional automotive wax Interior Cleaning Using a damp cloth covered with a mild soap carefully clean a
21. 1 Super Quiet Generator 29 5 5 pun P 318v23 IdNvd NOLLNSIMLSIC 3SVHd NO SLOVINOO 14915 31038 o 4151 440 SNOLLO3NNOO LOA 21 TIY c OMY 318v HOLIMS 3009 3SVHd SY IWYS SI 318 2 1491 SLOWSY J LON SLOVLNOO 341 SHIM 14915 MIIA HOLO3NNOO o oma 9 ond 5 000 ov 5 OOO o HOOOH 250 Cog 0 690 D woLvnLoVOL WOLWNLOV OL a gt wove oL m alea g gt 2 5 5258 ia g dy St zz 2 18 8 2 5 Live A noanana gt gt 2828834 ame gt SIHWUNMOWG m b Ze M pre N E I 1002 xnv m Z
22. BE PROPERLY CHOCKED IF THE GENERATOR IS ON UNLEVEL GROUND DO NOT OPERATE THE GENERA TOR SET UNTIL IT HAS BEEN PROPERLY SE CURED When preparing to start the generator set follow the sequence listed below Checkthe coolant level in the radiator and add as necessary If adding coolant use only a 50 50 mixture of antifreeze and water Refer to your engine manufacturer s maintenance manual for specific antifreeze information Operating Instructions and Parts Manual June 2006 REVA NEVER REMOVE THE RADIATOR CAP WHILE THE ENGINE IS RUNNING OR WHILE THE ENGINE IS HOT Checkthe oil level in the engine crankcase and add as required USE CLASS API CC OR CD GRADE ENGINE OIL REFER TO ISUZU ENGINE MANUAL FOR VISCOSITY AND QUANTITY Ifthe battery is not a maintenance free battery check the electrolyte level in the battery and add distilled water if necessary Check fuel water separator for water in the fuel System Drain water from separator if necessary e Check fuel level in the fuel tank and add as required Check to insure the fuel tank vent is open and not clogged USE 2 DIESEL FUEL ONLY Verify that the generator main circuit breaker is in the OFF position Make sure the generator set is properly grounded This is accomplished by connecting the grounding lug provided at the rear of the generator set enclosure to a mechanical earthground with a minimum 2 0 size 4 bare electrical cable If t
23. E 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 26 Terex T25l T45I Super Quiet Generator Operating Instructions and Parts Manual June 2006 REVA ELECTRICAL TROUBLESHOOTING 5 COMPONENTS THAT CAUSE VOLTAGE RELATED PROBLEMS POTENTIOMETER Connects to voltage regulator Bypass potentiom eter by unplugging from voltage regulator and installing jumper on 2 male spades on regulator VOLTAGE REGULATOR Located inside the upper control panel behind the gauges Measure DC voltage at F1 amp 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 fr
24. EW 1 4 20NCX3 4 WASHER FLAT 1 4 HARNESS AC GEN SCREW FLANGE 1 4 20 X 3 4 PATCH NUT FLANGE 1 4 20 Z WASHER FLAT 1 4 WASHER FLAT 1 4 DECAL REMOTE START DECAL KIT RECEPTACLES AND BREAKERS E STOP PUSHBUTTON E STOP LABEL PLATE E STOP CONTACT N C REMOTE START CONTACT 1 1 1 1 1 1 2 2 2 3 1 1 1 2 4 8 1 4 4 8 8 1 1 1 1 1 1 Terex T25l 7451 Super Quiet Generator 59 Operating Instructions and Parts Manual TEREX June 2006 REVA FIGURE 8 DISTRIBUTION PANEL 60 Terex 251 and T45I Super Quiet Generator Operating Instructions and Parts Manual TEREX June 2006 REVA DESCRIPTION GCU310000 PANEL DISTRIBUTION CC43A043 DISTRIBUTION LUG PANEL C37816 TURNBUCKLE 1 4 20 X 1 3 4 GCU310009 5 LUG REAR COVER C51601443 SCREW FLANGE 1 4 20 990340 WASHER FLAT 1 4 C51601442 SCREW FLANGE 1 4 20 990340 WASHER FLAT 1 4 42200702 PLUNGER ACTUATOR 42200701 SWITCH SNAP ACTION USE WITH 42200702 SCREWS INCLUDED WITH ITEM 9 SCREWS INCLUDED WITH ITEM 9 U51A400 DECAL L1 L2 L3 N INCLUDED WITH ITEM 13 INCLUDED WITH ITEM 13 INCLUDED WITH ITEM 13 DECAL SYMBOL FOR GROUND SCREW HEX 1 2 13 X 2 5 SBZ WASHER LOCK STAR 1 2 WASHER FLAT 1 2 SBZ LOCK WASHER 1 2 SBZ NUT HEX 1 2 13 SBZ DECAL 3PH DISTRIBUTION PANEL ALL 5 LUG 3PH UNITS WASHER LOCK 1 4 WASHER FLAT 1 4 10 10 Terex T25l 7451 Super Quiet Gener
25. LE 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 Both wires have been spliced into harness wires and should be cut so that the splice is taken out It is better to have as few splices as possible and you will be replacing the splice you cut out TEREX ELECTRICAL TROUBLESHOOTING Cont Once the wires are loose go to the front of the control panel and loosen the lock nut holding the potentiometer Putthe new potentiometer in its place and retighten lock nut Reattach new wires to the same wires and in the same configuration as the ones that were cut loose 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 Terex T25l and 745
26. LY INDIVIDUAL DECALS ARE NOT AVAILABLE FOR PURCHASE Terex T25l 7451 Super Quiet Generator 45 Operating Instructions and Parts Manual TEREX June 2006 REVA FIGURE 1 BASE W FUEL TANK Fuel Tank Rotated 90 For Clarity 46 Terex T25l T45I Super Quiet Generator Operating Instructions and Parts Manual TEREX June 2006 REVA DESCRIPTION GCU1 10000 C90900601 91100300 90200900 792750 897910 90800100 CHANNEL REAR HAT CHANNEL ENGINE TANK FUEL 64 GAL RUBBER SHEET 1 8 BLK 12 SQ FT BASE CONTAINMENT PLUG PIPE 3 SQUARE HEAD WASHER FLAT 1 2 WASHER LOCK 1 2 SCREW 1 2 13NCX1 1 2 SENDER FUEL LEVEL GASKET INCLUDED WITH ITEM 10 SCREW INCLUDED WITH ITEM 10 FUEL CAP VALVE VACCUUM RELIEF CLAMP 7 16 TO 25 32 HOSE FUEL 1 4X1 2 200 1 FT FITTING BARB 3 8 NPT BARB 3 8 X1 4 NPT FITTING PICKUP amp RETURN NYLON TUBING 1 FT BARB 3 4 X1 2 NPT CLAMP 7 16 TO 25 32 HOSE OIL 3 4 VALVE BALL 1 2 Terex T25l and 7451 Super Quiet Generator 47 Operating Instructions and Parts Manual TEREX June 2006 REVA FIGURE 2 BASE W LIFTING EYE amp BATTERY 48 Terex T25l T45I Super Quiet Generator Operating Instructions and Parts Manual TEREX June 2006 REVA GCU500000 LIFTING ASSEMBLY C82301010 LIFTING EYE 5000 LBS C82300850 BOLT 1 2 20 X 6 SOCKETHEAD CAP 990210 WASHER FLAT 1 2 990200 NUT
27. REATED 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 Terex T25l and 7451 Super Quiet Generator 27 TEREX ELECTRICAL TROUBLESHOOTING Cont 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
28. S TO THE PERSON OPERATING THE MACHINE OR DAMAGE THE GENERATOR NEVER SHUT THE UNIT DOWN WITH THE MAIN GENERATOR CIRCUIT BREAKER IN THE ON POSITION THIS CAN CAUSE DAMAGE TO THE GENERATOR AND OR THE CON NECTED APPARATUS Turn all generator breakers to the OFF position Allow the engine to run for 5 minutes under no load until the coolant temperature gauge reads approximately 175 F as a cool down cycle Stopthe engine by pushing the Cascade Controller OFF button Cascade DC Volt Controller Gauge O O GENERATOR ENGINE Volt Meter eter Frequency ater temp Met 5 Gauge eler MURPHY CAUTION Fuel Ammeter 1 Or pes Gauge Oil Pressure Gauge 18 Terex T25l and 7451 Super Quiet Generator Operating Instructions and Parts Manual June 2006 REVA A MAINTENANCE MINIMUM MAINTENANCE PROCEDURES The following maintenance intervals are only suggested by TEREX You should always check your engine owner s manual for specific informa tion Should you find any discrepancies between the TEREX Super Quiet Generator Manual and the Engine Manufacturer s Manual always follow the Engine Manufacturer s Manual Every 8 Hours of Operation Checkthe crankcase oil and fill as required Checkthe fuel t
29. SIZ Ove 1 a 1 L 61 ZL 81 L 61 91 el vl VL EE ES YAY 597 ISN 081 ISPL 88 88 6 ral 087 HN uL 10d 3OVIIOA 10d 39vL0 e z aL vL n 10d 39VLI0 104 39VL10 20st ONIMVYC OL 53215 19 HOLIMS MOVLS OL 3433 H3SIARN LYVd HOLIMS 16 YAY 097 SASN 921 semnNounsnisian Operating Instructions and Parts Manual X 14 Standard Generator Wiring Drawing ES1000008 for Series OVERCURRENT RELAY TO OVERCURRENT RELAY POSITION 14 dil INNHSN OL yavan f G o r DEO VWAN VIN3N YLIN VWAN YLIN 925490 OL 1011 ONY 1O3NNOO 171 9500 OL wada z ZBL YOO OL Wada 0 OL quia HOlVH3N39 OL G3N SIIHM XX F2 SALON 33s HAV YILIN LIOA OL H313W LIOA OL 3LIHW3OV1S Q3S 3LIHM Terex T25l and T45I Super Quiet Generator 36 Operating Instructions and Parts Manual June 2006 REVA POWER
30. TEREX November 2007 FIGURE 12 VOLTAGE SELECTOR SWITCH 5 1 2 DO NOT CHANGE POSITION OF SELECTOR SWITCH WHILE UNIT IS RUNNING 3 4 70 Terex T25l and T45I Super Quiet Generator Operating Instructions and Parts Manual TEREX November 2007 REVB C42201102 VOLTAGE SWITCH T25l C42202402 VOLTAGE SWITCH T45l CD421031 BCI FRAME EXTENSION BACK CD421030 BCI FRAME EXTENSION FRONT CD421040 BCI FRAME EXTENSION SIDE CL 008 DECAL DO NOT CHANGE POSITION Terex T25l and 7451 Super Quiet Generator 71 nd Parts Man Operating Instructions a TEREX November 2007 REV B FIGURE 13 TRAILER tor Terex 251 T45I Super Quiet Genera Operating Instructions and Parts Manual TEREX November 2007 REV DESCRIPTION TRAILER STANDARD NO BRAKES AXLE COMPLETE TIRE AND WHEEL MOUNTED ST205 CONNECTOR 6 PIN NUT 834216 RING HITCH STANDARD 834237 JACK PIN FENDER PLASTIC AMBER CLEARANCE LIGHT RED CLEARANCE LIGHT C HOOK SAFETY CHAIN CLEARANCE LIGHT MOUNTING KIT STOP TAIL LIGHT W GROMMET AND PLUG TAG LIGHT KIT N N N N 0GSX0031 841082 CENTER MOUNT JACK 0GSX0164 841083 LED TRAILER LIGHTS 0GSX0030 840223 CORNER JACKS 840223 JACK MOUNT TUBE 0GSX0040 840641 TRAILER HITCH 2 BALL 0GSX0115 C11261 TRAILER HITCH 2 16 BALL 12 000 LB RATED 0GSX0116 261190 TRAILER LIGHT CONNECTOR 4 POLE FLAT 0GSX0137
31. TEREX Operator Service amp Parts Manual 125 T45 First Edition Operating Instructions and Parts Manual TEREX June 2006 REVA Table Of Contents The operator must read and understand all the instructions in this manual before operating the machine INTRODUCTION Tc eienn 5 DESCRIPTION OF EQUIPMENT 5 GENERAL SAFETY REN BA UA dd i iun 6 SAFETY SIGN LOCATIONS 7 RECEIPT OF DELIVERY CHECKLIST A 10 TRANSPORT amp TOWING 11 SETUP 11 OPERATING INSTRUCTIONS 13 MAINTENANCE M a 19 TROUBLESHOOTING GUIBDBE 22 ELECTRICAL TROUBLESHOOTING 27 T251 45 SPECIFICATIONS AND DIMENSIONS 37 TORQUE SPECIFICATIONS 39 GENERATOR TORQUE SPECIFICATIONS 39 SERVICE PARTS FAX ORDER FORM
32. VA A TRANSPORT amp TOWING All trailer mounted Terex Super Quiet Pac genera tors are designed for highway and off road towing capability Please consult state and local transportation codes before transporting the generator set Additionally all state and local traffic laws take precedence over the following instructions whenever differences arise between them Make sure the towing vehicle is of adequate size to both tow and stop the unit Disconnect all wiring and cabling including the ground wire from the generator set Close and latch or lock all access doors Using the front leveling jack raise the trailer hitch to an adequate height so that the generator can be securely attached to the transporting vehicle Ensure that the coupler is properly secured to the towing vehicle and attach the safety chains Attach the breakaway chain on the surge brake and the electrical coupler if these options are included on the unit ALWAYS USE THE PROPER TRAILER HITCH AND SAFETY CHAINS OBEY ALL LOCAL OR STATE D O T LAWS WHEN TOW ING A GENERATOR FAILURE TO PROPERLY SECURE THE TRAILER TO THE TOWING VEHICLE MAY RESULT IN SERIOUS INJURY OR DEATH Retract and rotate the front leveling jack into its stowed position TEREX GENERAL SAFETY Cont Checkthe tires for proper inflation and verify that the lug nuts are tight If equiped with towing lights connect the electrical coupler to the towing v
33. ake sure all debris and obstructions have been cleared from moving parts and electrical terminals The generator will only make 3 attempts at starting before it must be reset with the switch TEREX Now that the generator set is running allow five minutes for warm up time Listen for any unusual sounds or excess vibrations that could signal problems and require immediate shutdown of the unit Should unusual sounds be detected shut the unit down and contact TEREX Service Once the engine has been started and running smoothly the following gauges should be monitored All gauges are located on the control panel Oil Pressure Gauge This gauge should read 30 psi or higher Coolant Temperature Gauge This gauge should read between 170 200 degrees F Voltmeter This gauge should read at least 12 volts DC to indicate the diesel engine s alternator is charging properly AC Voltmeter This gauge should reflect the proper voltage selected for this operation AC Ammeter The reading on this gauge should be zero since the main breaker is in the OFF position Once a load is applied to the generator the ammeter will produce an appropriate reading Terex T25l and 7451 Super Quiet Generator 13 Operating Instructions and Parts Manual TEREX June 2006 REVA OPERATING INSTRUCTIONS LOADING INSTRUCTIONS If all readings are correct an electrical hookup can be made to the generator set To make the
34. alled as this will protect against loose debris entering the engine General cleaning of cartridges should be accom plished by either a light brushing or mild air pressure application NEVER DIRECT A HIGH PRESSURE AIR STREAM DIRECTLY INTO A FILTER PACK AS IT MAY RESULT IN MEDIA BREAKDOWN NEVER TAP A FILTER TO REMOVE DIRT AS THIS COULD DAMAGE THE SEALING SUR FACES Carefully remove any loose dust from the canister using a vacuum and then wipe with a damp cloth NEVER BLOW AIR INTO THE CANISTER AS IT MAY FORCE DIRT INTO THE ENGINE Make sure the sealing areas of the canister and the element are clean and free of defect before installing the element The safety element should be changed sparingly every three or four filter changes and extreme care should be taken to not allow dirt to enter the engine when the safety TEREX MAINTENANCE Cont element is removed NEVER WASH THE CANISTER WITH HIGH PRESSURE WATER AS IT COULD DAMAGE OR BREAK THE PRECLEANER ROTOR Terex T25l 7451 Super Quiet Generator 21 Operating Instructions and Parts Manual TEREX June 2006 REVA 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 No generato
35. ank level and fill as required EXPLOSION HAZARD NEVER ADD FUEL TO THE UNIT WHILE IT IS RUNNING THIS CON STITUTES A SEVERE FIRE HAZARD THAT CAN CAUSE DAMAGE TO THE UNIT AND IN JURY TO THE OPERATOR Daily Checkthe engine and generator for any loose bolts connections and fittings Checkthe coolant levels and fill as required e Check the fuel water separator for the presence of water contamination Drain as required WATER CONTAMINATED FUEL WILL CAUSE SEVERE DAMAGE TO THE INJECTION AND FUEL PUMPS TEREX BURN HAZARD NEVER REMOVE THE RADIA TOR CAP OR CHECK ELECTOLYTE LEVELS ON A HOT UNIT THIS COULD RESULT IN SEVERE BURNS TO THE OPERATOR Note Use a 50 solution of water and antifreeze for the engine coolant Refer to your engine manufacturer s maintenance manual for specific antifreeze information DAILY Oil Level and Condition Oil Leakage Check Oil Pressure Gauge Reading Oil Pressure Warning Lamp Fuel Leakage Check Drain Water From Fuel Filter Coolant Level and Condition Coolant Leakage Check Radiator Filler Cap Fan Belt Tension Check e Coolant Temperature Reading e Electrolyte Level Check Battery Cleaning Battery Charge Condition Ammeter Reading Charge Warning Lamp Preheating Condition Check Engine Vibration and Noise Levels Exhaust Smoke Condition 50 HOURS Change Oil and Filter 250 HOURS Change Oil and Filters Terex T25l and 745
36. arying 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 Terex T25l and 7451 Super Qu
37. ator 61 Operating Instructions and Parts Manual TEREX June 2006 lt lt _ 2 d CO lui irm 10 62 Terex T25l and T45I Super Quiet Generator Operating Instructions and Parts Manual TEREX November 2007 REV DESCRIPTION MUFFLER NELSON 2 5 IN MUFFLER PIPE OUT AS ENGINE TO MUFFLER EXHAUST PIPE 251 GCI210010 ENGINE TO MUFFLER EXHAUST PIPE T45l C33503401 CAP RAIN 2 5 791625 CLAMP MUFFLER BAND C90101000 CLAMP U BOLT 2 5 INCLUDED IN ITEM 6 INCLUDED IN ITEM 6 INCLUDED IN ITEM 6 C100550 BUMPER RUBBER GCU110060 MUFFLER FRONT C100552 RUBBER EXST ISOLATOR GCU460005 TOP EXHST STABILZER WW Terex T25l 7451 Super Quiet Generator 63 Operating Instructions and Parts Manua TEREX June 2006 FIGURE 10 AIR CLEANER ASSEMBLY EVA 64 Terex T25l and T45I Super Quiet Generator Operating Instructions and Parts Manual TEREX June 2006 REVA AIR CLEANER ASSEMBLY T45 AIR CLEANER ELEMENT AIR CLEANER ASSEMBLY T25 AIR CLEANER ELEMENT Terex T25l 7451 Super Quiet Generator 65 Operating Instructions and Parts Manual TEREX November 2007 FIGURE 11A ENGINES T251 1251 Engine
38. d 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 Terex T25l 7451 Super Quiet Generator 9 TEREX GENERAL SAFETY Cont 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 Lifting Eye NEVER CLIMB ON TOP OF THE CABINET Operating Instructions and Parts Manual June 2006 REVA RECEIPT OF DELIVERY CHECKLIST The generator will be serviced tested and ready for operation upon delivery Terex recommends the following checks O Insure there is no freight handling damage which should be charged against the carrier L Check the front jack for security and proper operation L 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 L Check the control panel for damage or loose connections L Check the exhaust system for damage L Check all fluid levels battery radiator and engine oils Ensure manuals are in the pocket provided inside the unit 10 Terex 251 and T45I Super Quiet Generator Operating Instructions and Parts Manual June 2006 RE
39. e exact needs of the application ONCE THE PROPER VOLTAGE SELECTOR SWITCH POSITION IS SELECTED TEREX HIGHLY RECOMMENDS THAT THE SWITCH BE PADLOCKED IN THAT POSITION THIS PREVENTS THE SWITCH FROM BEING MOVED WHILE THE UNIT IS OPERATING OR BY UNAUTHORIZED PERSONNEL DAMAGE TO THE UNIT AND ANY CONNECTED EQUIP MENT WILL BE AVOIDED Terex T25l and 7451 Super Quiet Generator 15 TEREX OPERATING INSTRUCTIONS Cont DO NOT OPERATE THE UNIT UNLESS VOLTAGE HAS BEEN CHECKED AT DISTRIBUTION LUGS AND RECEPTACLES CALL TEREX SERVICE IF YOU HAVE ANY QUESTIONS INSTALLATION AND ANY WORK PERFORMED ON THIS UNIT SHOULD BE DONE ONLY BY A QUALIFIED ELECTRICIAN DO NOT REMOVE OR COVER ORIGINAL SAFETY AND OPERATION DECALS REPLACE ANY DAMAGED DECALS BEFORE USING THIS EQUIPMENT POTENTIOMETER VOLTAGE ADJUSTMENT The potentiometer is set at the factory However if the voltage reading on the voltmeter is not as desired use the following procedure to make the necessary adjustments With the unit running under no load observe the AC voltmeter Locate the voltage adjustment knob on the control panel The decal above the knob indicates the direction to turn the knob to increase or decrease the voltage Turning the knob to the right increases the voltage while turning the knob to the left decreases the voltage Slowly turn the adjustment knob in the desired direction while observing the AC voltage meter stop when the desired voltage is
40. e sure generator is turned off and e stop is engaged before opening control panel Locate the two wires going to the speed controller mounted on the inside of the control pan marked MPU and MPU Both wires are isolated in their own shielded cable the wires are loose pull them through the back of the control box until they are completely free from all ty wraps and wire harnesses Unscrew and remove the old sensor Align the flywheel tooth to the center of the sensor hole Install new sensor until it bottoms out on flywheel tooth and then back it off turn Toinsure proper installation the sensor must 28 Terex T25l and T45I Super Quiet Generator Operating Instructions and Parts Manual June 2006 REVA PROCEDURE FOR CHANGING THE MAGNETIC PICK UP SENSOR Cont be checked with a voltage meter With the engine in a starting sequence check for 2 5 to 3 VAC between the red and black wire Adjust the sensor in or out to obtain the correct voltage the voltage is correct reinstall the shielded cable through the control box opening and reattach the wire leads to the speed controller Also secure the new cable through the housing with ty wraps where needed If any further adjustment is needed to the voltage of the generator please call Terex at 1 800 433 3026 for assistance PROCEDURE FOR CHANGING THE VOLTAGE POTENTIOMETER THIS EQUIPMENT USES HIGH VOLTAGE CIRCUITS CAPAB
41. ehicle Observe posted speed limits for trailers Generally do not exceed 45 mph on paved roads and 10 mph on unpaved roads EXCEEDING THESE RECOMMENDED SPEEDS CAN CAUSE SEVERE DAMAGE TO THE UNIT DAMAGE CAUSED BY THESE UNSAFE PRACTICES WILL VOID THE MANUFACTURER S WARRANTY A SETUP Move the generator set to the desired location keeping the following in mind The spot where the generator set is positioned should be relatively level The location selected should be centrally located to equipment requiring the loads to minimize voltage drop in the power cord Locate so power cords can be routed without crossing roads and access routes Locate where the engine will get good ventilation Do not locate where fumes will enter a building Donot place beside a building wall that would reflect and intensify noise Unhitch from the towing vehicle as follows Locate the generator set in the desired location Terex T25l and 7451 Super Quiet Generator 11 TEREX AX SETUP Cont Ifthe axle is sloped downhill turn the generator set so that the axle is level Chock wheels if generator set is not on level ground Unhook hitch safety chains and running lights Rotate the tongue jack into position 90 degrees release the hitch pin and raise the tongue off the towing vehicle Level the generator set with the tongue jack Hitch Level Ground Safety Chains THE WHEELS MUST
42. electrical hookup to the generator set observe the following set of procedures SHUT DOWN THE GENERATOR SET BY PRESSING THE OFF BUTTON ON THE CAS CADE CONTROL PANEL SWITCH THE TOGGLE TO THE OFF POSITION BEFORE MAKING ANY ELECTRICAL CONNECTIONS THE MAIN GENERATOR BREAKER SHOULD BE IN THE OFF POSITION Shutdown the generator set Connect the desired electrical apparatus to the generator set while making sure no other power source is connected to the same apparatus Restart the engine and monitor the gauges as outlined in the Operating Instructions section under Starting the Engine Generator Set Turn the required generator circuit breakers to the ON position Monitor the AC Ammeter If the needle deflects severely to the right and stays there immediately turn the required generator circuit breakers to the OFF position SEVERE DEFLECTION OF THE AMMETER INDICATES A WIRING PROBLEM OR AN OVERLOAD PROBLEM CONTINUED OPERA TION UNDER THIS CONDITION WILL CAUSE DAMAGE TO THE GENERATOR AND OR CONNECTED APPARATUS The needle on the ammeter will deflect to the right temporarily and then return to a normal reading if the unit is operating properly VOLTAGE SELECTOR SWITCH OPERATION The TEREX Super Quiet generator sets rated from 25 and are equipped with VOLT AGE SELECTOR SWITCH This switch can have three positions marked 480 277 and 208 120 or 240 120 Each posi
43. g Loose wire on the automatic voltage regulator sensing lead Redistribute load if possible Check engine fuel oil and air filters Check connections Call TEREX Service Check wiring Low engine speed 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 Terex T25l 7451 Super Quiet Generator 23 Operating Instructions and Parts Manual TEREX June 2006 REVA TROUBLESHOOTING Cont Low Speed POSSIBLE CAUSE Defective injectors on engine Surging engine speed SOLUTION Have injectors checked by a qualified technician Check engine fuel oil and air filters Engine turns over cranks but won t run Unit out of fuel Loose or broken wire in control circuit fuel injection pump solenoid Defective solenoid Magnetic Pick up Clogged fuel system Air in fuel system Defective fuel pump Clogged air intake Clogged exhaust Contaminated fuel Defective injectors Lost engine compression Check fuel level in tank fill as needed Check wiring to verify 12V DC is being
44. hieved 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 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 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 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 TEREX 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 v
45. his LED is blinking slowly it indicates that one or more engine parameters are near exceeding engine manufacturer s setpoints If the LED is blinking fast it indicates that one or more engine param eters have exceeded setpoints the ECU has issued a fault and most likely the engine has shut down Aux 2 If the red LED is on it indicates that this custom configured input is active Overspeed amp Underspeed If these two LED s are both blinking the controller has lost its speed signal LEDs ENGINE RUNNING Ecustatus REMOTE REST LOW OIL PRESSURE HIGH ENGINE TEMPERATURE OVERSPEED UNDERSPEED D OVERCRANK START FAIL CHARGE FAIL _ LEDs 5 T AUXILIARY1 AUXILIARY2 Figure 1 TEREX OPERATING INSTRUCTIONS Cont OPERATING THE CASCADE When power is first applied all LEDs will flash indicating a Lamp Test function Refer to Fig 2 below for the following procedures To manually start the engine press the MAN Manual button The controller will initiate a normal start sequence To manually stop the engine or turn off the controller press the OFF button To place the controller in automatic mode press the button labeled AUTO The LED next to the AUTO button should come on to indicate that the controller is waiting for the remote start input to become active to initiate a start sequence
46. his differs from your local code always follow the local code for grounding THIS GENERATOR SET PRODUCES VOLT AGES THAT CAN CAUSE SEVERE SHOCK OR DEATH ONLY QUALIFIED ELECTRICIANS SHOULD PERFORM ELECTRICAL WORK 12 Terex T25l and T45I Super Quiet Generator Operating Instructions and Parts Manual June 2006 REVA A OPERATING INSTRUCTIONS STARTING THE ENGINE GENERATOR SET NEVER ATTEMPT TO START THE GENERA TOR SET WITH ANY OF THE CIRCUIT BREAK ERS ON THESE BREAKERS ARE LOCATED ON THE DISTRIBUTION PANEL STARTING WITH THE BREAKERS ON CAN CAUSE DAMAGE TO THE GENERATOR Once setup procedures are completed the generator set is ready to be started Start the unit according to the following steps Make sure the GENERATOR VOLTAGE SELECTOR SWITCH has been set to the proper range This switch should be located above the 3 phase distribution panel DISREGARD IF THE UNIT DOESN T HAVE A SELECTOR SWITCH THIS UNIT IS PRESET FOR ONE VOLTAGE SEE NAME TAG NEVER CHANGE THE POSITION OF THE VOLTAGE SELECTOR SWITCH WHILE THE GENERATOR IS RUNNING THIS WILL RESULT IN IMMEDIATE DAMAGE TO THE SWITCH THE GENERATOR OR THE CONNECTED EQUIPMENT IT MAY RESULT IN SERIOUS INJURY TO THE OPERATING PERSONNEL Place the toggle switch in ON position then press the MANUAL MAN BUTTON on the Cascade Controller The unit will start an automatic timing sequence After the timing sequence the engine will attempt to start M
47. iet Generator 5 TEREX DESCRIPTION OF EQUIPMENT Cont enclosure as standard equipment 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 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 DANGER imminently hazardous situation which if not avoided will result in death or serious injury Orange Indicates a AWARNING potentially hazardous situation which if not avoided could result in death or serious injury Yellow with safety alert ACAUTION symbol Indicates a potentially hazardous situation which if not avoided may result in minor or moderate injury Operating Instructions and Parts Manual June 2006 REVA Ye
48. king the crank cycle has ended and is now in crank rest cycle Low oil pressure If the red LED is on the controller has caused the engine to shutdown and lockout If the LED is blinking the engine ECU has transmitted a SPN for an oil pressure related condition High Engine Temperature If the red LED is on the controller has caused the engine to shutdown and lockout If the LED is blinking the engine ECU has transmitted a SPN for an engine temperature related condition Overspeed If the red LED is on the controller has caused the engine to shutdown and lock out due to engine speed exceeding the setpoint Underspeed If the red LED is on the controller has caused the engine to shutdown and lock out due to engine speed falling below the minimum needed for proper operation Overcrank If the red LED is on the controller has exceeded the set number of start attempts 16 Terex 251 and T45I Super Quiet Generator Operating Instructions and Parts Manual June 2006 REVA without receiving a valid speed signal indicating that engine speed is above crank disconnect This causes the engine to shutdown and lockout Charge Fail If the red LED is on it indicates that the battery charging alternator is not charging the cranking batteries or that the battery charger fail output is on Aux 1 If the red LED is on it indicates that this custom configured input is active On an ECU ECM equipped engine if t
49. llow without safety CAUTION alert symbol Indicates a situation which if not avoided may result in property or equipment damage Green Indicates impor NOTICE 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 e 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 maintenance adjustments Terex T25l 7451 Super Quiet Generator Operating Instructions and Parts Manual TEREX June 2006 REVA GENERAL SAFETY Cont SAFETY SIGN LOCATIONS T25 9 T45 11 Items shaded are hidden from view CAUTION ANWARNING Do not open 3 Phase door while generator Ed is under load Hazardous voltage Will cause serious injury or death Breaker will trip Disconnect power before servicing Lockout Tagout machine 51 101 0514310
50. obtained The unit is now ready to load If the desired voltage cannot be reached contact the TEREX Service Department at 1 800 433 3026 LED STATUS LIGHTS Eleven LEDs separated into two banks see Fig 1 are provided on the faceplate The LEDs Bank 1 includes 6 LEDs and Bank 2 includes 5 In Setup mode these banks form a binary code to indicate either the controller setup configuration or error status which is indicated by the last 8 red LEDs Refer to Tables 1 2 3 and 4 See Cas cade Controller Installation and Operations Operating Instructions and Parts Manual June 2006 REVA Manual supplied with unit for configuration and status listings One LED is located next to the AUTO button to indicate that the controller is waiting for the remote start input to become active The LED status lights are from top to bottom see Fig 1 Engine running If the green LED is on then the unit is receiving a speed signal indicating that the engine is above the crank cut speed ECU status If the green LED is on solid it indicates that in a J1939 application the ECU and the unit are communicating properly If the LED is blinking slowly the ECU is broadcasting mes sage If the LED is blinking fast the ECU is NOT communicating properly Remote Start Crank Rest If the green LED is on then the remote start input is active and if the system is in AUTO mode it will try to start If the LED is blin
51. om the circuit and verify that the generator is function ing 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 3 phase door switch and will automatically trip the 3 phase breaker when the door is open and pre vents the breaker from being reset while it is open TEREX GENERATOR Test resistance of field stator and exciter wind ings Contact TEREX for procedures or repair facility recommended by generator manufacturer 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 C
52. or several minutes before UNAUTHORIZED WELDING CAN CAUSE refueling STRUCTURAL FAILURE OR PERSONAL INJURY DO NOT spill fuel inside the engine compartment If fuel has leaked wipe it up and have leak DO NOT weld on any structural member 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 EXHAUST GASES ARE TOXIC DO NOT USE INDOORS UNLESS PROPERLY VENTILATED OR AN EXHAUST SCRUBBER 1 USED Check exhaust system regularly for leaks and ensure that the exhaust manifolds are secure Any unauthorized welding or repair procedure not warped Make sure the unit is well ventilated will void the warranty 8 Terex 251 7451 Super Quiet Generator Operating Instructions and Parts Manual June 2006 REVA A 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 pr
53. otective gloves when handling hot parts A 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 TEREX GENERAL SAFETY Cont 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 A 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 an
54. r output voltage POSSIBLE CAUSE Circuit breaker tripped Voltage regulator Defective voltage regulator Defective Selector Switch Defective generator SOLUTION Reset circuit breaker Check voltage regulator wiring Replace voltage regulator By pass by hardwiring generator Refer to generator manual Low generator output voltage 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 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 22 Terex T25l and T45I Super Quiet Generator Operating Instructions and Parts Manual June 2006 REVA High generator output voltage POSSIBLE CAUSE Defective automatic voltage regulator Loose wire on voltage adjustment potentiometer TEREX TROUBLESHOOTING Cont SOLUTION Replace voltage regulator Check wiring Fluctuating generator output voltage 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 wron
55. round any electric controls generator and thermostats The base and housing foam may be cleaned with a damp cloth covered with mild soap CARE AND SERVICING AIR FILTERS A common belief in air filtration is that new clean filters are the best In reality a filter is the least efficient it will ever be when it is first installed Filter paper is specially designed paper that is woven with a series of small openings that allows air to pass through it and dust to be stopped As small particles of dust are trapped in the paper the holes become smaller and the efficiency increases 20 Terex 251 and T45I Super Quiet Generator Operating Instructions and Parts Manual June 2006 REVA Enginaire filtration systems using staged precleaners keep large particles of dust from the air stream which would bridge across the element and cause premature filter failure The most common cause of engine failure due to dust ingestion is over servicing DO NOT USE VISUAL INSPECTION TO DETER MINE FILTER FAILURE Use a dust load indicator vacuum gauge to determine when the filter should be changed These are available in many configurations but should trigger when 10 15 inches of water column over the clean element is reached When you remove a filter from the canister the seal is broken and loose particles of dust can fall into the outlet and be drawn into the engine the next time it starts Leave the inner safety element inst
56. s Manual June 2006 REVA TEREX DESCRIPTION GCU430000 GCU430020 71100500 794891 21353 73000100 51101000 992040 CU54T021 HOUSING DISTRIBUTION DOOR HOUSING ACCESS DOOR FOAM BLACK URETHANE HINGE LIFT OFF STEEL BOLT CARRIAGE 3 8 16X3 4 Z KEG TRIM LOCK 1 4 HOUSING FRONT PANEL SCREW FLANGE 1 4 20X 75 WEATHER STRIP 3 8X3 4 HOUSING ACCESS DOOR LITERATURE BOX LATCH RIVET POP 3 16X 602 WINDOW CONTROL DOOR GASKET WINDOW CONTROL DR HOUSING REAR LOUVER FOAM BLACK URETHANE 1 2 EDGE STRIP SBM RUBBER TRIMLOCK SEAL 7 16 SCREW FLANGE 1 4 20X 75 NUT LOCK NYLON INSERT 3 8 16NC GR 2 ZPN BIN WASHER FLAT 5 16 WASHER FLAT 11 16 OD HOUSING CONTROL DOOR POP RIVET BUMPER Terex T25l 7451 Super Quiet Generator 55 Operating Instructions and Parts Manual TEREX June 2006 REVA FIGURE 6 CONTROL PANEL ASSEMBLY UPPER 56 Terex T25l T45I Super Quiet Generator Operating Instructions and Parts Manual TEREX June 2006 REVA CONTROL PAN ASSY CONTROL PANEL POTENTIOMETER VOLTAGE BREAKER MINI 15A SWITCH TOGGLE SINGLE GAUGE DC VOLT GAUGE OIL PRESSURE HOURMETER 12V DC GAUGE WATER TEMP 12V GAUGE FUEL W BLACK CASCADE CONTROLLER INCLUDED WITH ITEM 11 METER VOLT DUAL METER FREQUENCY METER AMP 0 100 W SCREW
57. starting fluids wil warranty engine damage and void manufacturer s E cause USTA102 CAUTION Do not open 3 Phase door while generator is under load Breaker will trip M U51A310 U51A310 R51A101 R51A101 GROUND Radiator fill U N IT Engine damage could PROP ERLY occur if coolant mixture is over 50 anti freeze TNs CONSULT LOCAL U51A113 CODE U51A304 DANGER HIGH READ OWNER S MANUAL BEFORE OPERATING VO LTAG E 127770 853070 051 102 U51A221 CALIFORNIA NO 2 DIESEL FUEL U51A110 ee EE US1A305 mw Z injury or death GROUND SINGLE PHASE before MAIN BREAKER 850130 U51A126 853751 TO AVOID DAMAGE TO GENERATOR AND OR EQUIPMENT PLACE BREAKER IN OFF POSITION BEFORE STOPPING GENERATOR 3 PHASE DOOR MUST BE CLOSED TO RESET ATTENTION CONNECTED STARTING OR MAIN BREAKER CAUTION DO NOT START OR STOP UNIT UNDER LOAD 3 PHASE MAIN BREAKER 1 PHASE BREAKERS 50 SOA 50 20 20A 20A 30A GFCI GFCI Neutral Bonded 240 120V 120V 120V 50 to Frame 20 20 20 240 V ENGINE GENERATOR A 853813 VOLTAGE CONTROL ADJUST BREAKER 853838 THIS SHEET CONTAINS DECALS FOR THE ENTIRE CONTROL PANEL ASSEMB
58. supplied to the pump solenoid Replace solenoid Adjust for 2 5 3 0 VAC 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 Engine won t crank Loose battery cable or discharged battery Check cables and battery electrolyte level Recharge as necessary 24 Terex T25l and T45I Super Quiet Generator Operating Instructions and Parts Manual June 2006 REVA Engine won t crank POSSIBLE CAUSE Engine ON OFF switch set in OFF position Blown fuse in DC control circuit E Stop Defective starter solenoid Defective starter Oil Pressure or Hi temp switch defective Seized engine TEREX TROUBLESHOOTING Cont SOLUTION Check switch position Replace with 25 Amp SLO BLO TYPE fuse if needed Check to see if engaged Replace solenoid Replace starter Check or call TEREX Service Have engine checked by a qualified technician Engine runs but loses speed Unit is overloaded Improper connection Reduce load Check or Call TEREX Service Engine runs but loses power under load Clogged fuel system Blocked air intake Blocked exhaust Contaminated fuel Faulty governor defective injectors or defective fuel pump Check fuel system
59. tion delivers a different output voltage to the DISTRIBUTION LUGS The SELECTOR SWITCH and DISTRIBUTION LUGS are located on the DISTRIBUTION PANEL The following instructions should be considered when operating the VOLTAGE SELECTOR SWITCH Always make sure the voltage selector switch has been set to the desired range before starting the generator set THIS GENERATOR SET PRODUCES VOLT AGES THAT CAN CAUSE SEVERE SHOCK OR DEATH ONLY QUALIFIED ELECTRICIANS SHOULD PERFORM ELECTRICAL WORK NEVER OPERATE THE VOLTAGE SELECTOR SWITCH WHILE THE GENERATOR IS RUN NING THIS WILL RESULT IN IMMEDIATE DAMAGE TO THE SWITCH THE GENERATOR OR THE CONNECTED EQUIPMENT WHICH WILL ALSO VOID THE WARRANTY IT MAY RESULT IN SERIOUS INJURY TO THE OPER ATING PERSONNEL 14 Terex T25l and 7451 Super Quiet Generator Operating Instructions and Parts Manual June 2006 REVA VOLTAGE SELECTOR SWITCH OPERATION The voltage selector switch can control the single phase receptacles provided on the unit Their indicated voltages should be checked after selecting the setting of the switch The Y voltage configurations of 480 and 240 will have a voltage of 139 on the GFI receptacles The voltage selector switch will have three posi tions and each position gives a different output to the three phase distribution lugs designated as L1 L2 13 and N located on the distri bution panel In the three phase 480 277 position
60. trol 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 phase 6 2 with a code motor SKID MOUNT DIM Lx W x H in Weight Dry Ibs Weight Full 105 TRAILER MOUNT Dim L x W x H Weight Dry Ibs Weight Full 105 Standard Standard Standard Standard Optional Standard Standard Standard Standard Standard Standard Standard Standard Optional Optional Standard Optional Optional 84x39x51 1 900 2 354 137x66x68 2 375 2 829 June 2006 REVA Standard Standard Standard Standard Optional Standard Standard Standard Standard Standard Standard Standard Standard Optional Optional Standard Optional Optional 84x39x51 2 725 3 173 137x66x68 3 200 3 648 38 Terex 251 and T45I Super Quiet Generator Operating Instructions and Parts Manual TEREX November 2007 REV TORQUE SPECIFICATIONS FASTENER STAINLESS STAINLESS SAE GRADE SAE GRADE SAE GRADE 5 GRADE STEEL STEEL 5 PLATED 5 PLATED 8 PLATED 8 PLATED NYLOK METRIC NYLOK METRIC NYLOK NUT 8 8 36 912 539 aa 48 2022 719 528 410 632 227 40 45 14 5949 6480 79 Ta j 56 12Nov 140 1517 2326
61. 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 fthe voltage is uneven between the legs when you apply 12 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 Aswith 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 Operating Instructions and Parts Manual June 2006 REVA INSTALLATION AND ANY WORK PERFORMED ON THIS UNIT SHOULD BE DONE ONLY BY A QUALIFIED ELECTRICIAN PROCEDURE FOR CHANGING THE MAGNETIC PICK UP SENSOR THIS EQUIPMENT USES HIGH VOLTAGE CIR CUITS CAPABLE OF CAUSING SERIOUS IN JURY OR DEATH EXCERCISE EXTREME CAU TION AROUND ANY ELECTRICAL COMPO NENT WHEN OPERATING THIS UNIT INSTALLATION AND ANY WORK PERFORMED ON THIS UNIT SHOULD BE DONE ONLY BY A QUALIFIED ELECTRICIAN Mak

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