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T25
Operator, Service & Parts Manual
74 pgs5.32 Mb0
Service Manual
38 pgs2.04 Mb0

Terex T25, T45 Service Manual

Service Manual
T25/T45
First Edition
Rev A
Part No. 134878
August 2008
Introduction
August 2008
Important
Read, understand and obey the safety rules and operating instructions in the appropriate Operator's Manual on your machine before attempting any maintenance procedure.
Basic mechanical, hydraulic and electrical skills are required to perform most procedures. However, several procedures require specialized skills, tools, lifting equipment and a suitable workshop. In these instances, we strongly recommend that maintenance and repair be performed at an authorized TEREX dealer service center.
Technical Publications
TEREX Corporation has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a TEREX policy. Therefore, product specifications are subject to change without notice.
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
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.
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.
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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.
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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.
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SAFETY RULES
Section 1 • Safety Rules
August 2008
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.
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.
Be sure to wear protective eye wear and other protective clothing if the situation warrants it.
Be aware of potential crushing hazards such as moving parts, free swinging or
unsecured components when lifting or placing loads. Always wear approved steel-toed shoes.
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Introduction
Table of Contents
Important Information - Introduction ....................................................................
How to Read Your Serial Number ......................................................................
Parts Stocking List ............................................................................................
How to Order Parts ............................................................................................
Service Parts Fax Order Form .........................................................................
Section 1 Safety Rules
General Safety Rules ........................................................................................
Section 2 Rev Specifications
A Specifications .............................................................................................. 2 - 1
A Specifications (Continued) ............................................................................ 2 - 2
A Torque Specifications ................................................................................... 2 - 3
A Generator Torque Specifications .................................................................. 2 - 4
Section 3 Rev Scheduled Maintenance Procedures
Introduction .................................................................................................. 3 - 1
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ix
xi
xii
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Pre-delivery Preparation Report .................................................................... 3 - 2
A Maintenance Schedules
Isuzu Lubrication and Maintenance Service Intervals ................................... 3 - 3
Newage Generators Maintenance Schedule ................................................. 3 - 4
Section 4 Rev Troubleshooting
Introduction .................................................................................................. 4 - 1
A Troubleshooting Guide ..... .......... ......... .......................................................... 4 - 2
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TABLE OF CONTENTS
Section 5 Rev Schematics
A Introduction .................................................................................................. 5 - 1
A Electrical Schematic - Control Panel Wiring for
Murphy Cascade Controller .......................................................................... 5 - 2
A Electrical Schematic - Control Panel Wiring for
Murphy Cascade Controller w/Electronic Governor ....................................... 5 - 3
A Electrical Schematic - Distribution Panel Wiring ........................................... 5 - 4
A Electrical Schematic - Three Position Stack Switch Wiring .......................... 5 - 5
A Electrical Schematic- Overcurrent Relay ...................................................... 5 - 6
A Electrical Schematic - Generator Wiring Breakdown ..................................... 5 - 7
A Electrical Schematic - Standard Generator Wiring ........................................ 5 - 8
August 2008
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Required Parts
The following parts are required to perform maintenance procedures as outlined in the
TEREX T25I & T45I Parts and Service Manual.
Description Part No.
Isuzu Models
Oil Filter .............................................................. 868075
Air Filter .............................................................. 834460
Fuel Filter ........................................................... 868137
Belt ..................................................................... 868067
Parts Stocking List
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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
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Service Parts fax Order Form
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) _________________
FAX TO: (800) 633-5534 OR TOLL FREE: 800-433-3026
Optional Equipment __________________________________________________________________________
Part Number Description Quantity Price
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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)
FOR TEREX USE ONLY
Order Number ______________ Origin Code ________________ Comments _________________________
Date Scheduled ____________ Ship Condition ______________ __________________________________
Order Total ________________ Terms Code ________________ __________________________________
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