workbook t15g-t25g 03-27-06 - …manuals.gogenielift.com/operators/english/833006 rev a1_0801...

Operator/Service & Parts Manual

First Edition

Rev A1

Part No. 833006

T15/T25 GenPacafter serial number GGG-19214

2 Terex T15G and T25G Gen-Pac Generator

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March 2006

OPERATORS MANUAL

To the Operator ................................................................................................. 4Safety Alert Symbols ......................................................................................... 5General Safety ............................................................................................... 6-9Receipt of Delivery Checklist ........................................................................... 10Transport & Towing .......................................................................................... 11Set-Up ........................................................................................................ 12-13Operating Instructions ................................................................................ 14-16Maintenance ............................................................................................... 17-18Troubleshooting.......................................................................................... 19-21Wiring Diagram - Kubota Gen-Pac Control Panel ........................................... 22Wiring Diagram - Isuzu Gen-Pac Control Panel .............................................. 23Wiring Diagram - T25G Single Phase Distribution .......................................... 24Wiring Diagram - T15G Single Phase Distribution .......................................... 25Wiring Diagram - T15G & T25G Generator ..................................................... 26Dimensions ..................................................................................................... 27Torque Specifications ...................................................................................... 28

PARTS MANUAL

Parts Ordering Information .............................................................................. 29General Information ........................................................................................ 31Cabinet Assembly ........................................................................................... 34Trailer Frame/ Tongue/ Fuel Tank.................................................................... 36Axle Assembly ................................................................................................ 38Electrical Enclosure ......................................................................................... 40Control Panel Assembly .................................................................................. 42Distribution Panel Assembly ........................................................................... 44Engine T25G ................................................................................................... 46Engine T15G ................................................................................................... 48Generator T15G & T25G ................................................................................. 50Hitches ............................................................................................................ 51Tail Lights ........................................................................................................ 52

Terex T15G and T25G Gen-Pac Generator 3

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OperatorsManual


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To The Operator

An operator should never use drugs, alcohol or any other substance which can change his alertness orcoordination.

Do not work on this equipment when mentally or physically fatigued.

This manual is compiled from information available and current at time of approval for printing. Terex reservesthe right to improve its products without giving prior notice or incurring any obligation.

If this manual becomes lost, order a new one from Terex so future operation and maintenance personnel mayread these instructions.

DO NOT ATTEMPT TO SETUP, OPERATE, OR WORK ON THE TEREX GEN-PAC GENERATORS UNLESSYOU HAVE READ AND UNDERSTAND THIS MANUAL AND THE ENGINE AND GENERATOR MANUALSCAREFULLY. READING THESE MANUALS WILL TEACH YOU HOW TO SAFELY SETUP, OPERATE,AND PROPERLY MAINTAIN THE GENERATOR SET AND ITS COMPONENTS.

REMEMBER THAT YOU ARE THE KEY TO SAFETY. GOOD SAFETY PRACTICES NOT ONLY PROTECTYOU, BUT ALSO THOSE WORKING AROUND YOU. MAKE THIS MANUAL A WORKING PART OF YOURSAFETY PROGRAM.

THIS EQUIPMENT USES HIGH VOLTAGE CIRCUITS CAPABLE OF CAUSINGSERIOUS INJURY OR DEATH.


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Safety Alert Symbols

MEANS:ATTENTION! BE ALERT!YOUR SAFETY IS INVOLVED

THIS SAFETY SYMBOL IS USED FOR IMPORTANT SAFETY MESSAGES. WHEN YOUSEE THIS SYMBOL, FOLLOW THE SAFETY MESSAGE TO AVOID PERSONAL INJURYOR PROPERTY DAMAGE.

Understanding Signal WordsA signal word - DANGER, WARNING or CAUTION is used with the safety alert symbol.

DANGER Identifies the hazard or unsafe practice that willresult in severe injury or death.

WARNING Identifies the hazard or unsafe practice thatcould result in severe injury or death.

CAUTION Identifies the hazard or unsafe practice thatcould result in minor injury or property damage.

NOTICE Identifies important installation, operation ormaintenance information.


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General Safety

DO NOT SETUP OR OPERATE THE TEREX GEN-PAC GENERATORS WITH-OUT READING THIS OPERATORS MANUAL.

SAFETY ALERT SYMBOL

Stop and take time to read ALL Safety alert messages.Follow the safety messages to avoid personal injury orproperty damage.

ACCIDENT PREVENTION

Use protective clothing and safety equipment. Alwayswear approved safety equipment such as gloves,safety boots, safety hard hat, goggles, ear protection,and dust masks when necessary. Wear protectiveclothing that is snug and belted where required.

UNAUTHORIZED WELDING

DO NOT weld on any structural member.

Any unauthorized welding or repair procedure will voidthe warranty.

DO NOT WORK ON OR OPERATE THE TEREX GEN-PAC GENERATORS WHILE UNDER THE INFLU-ENCE OF PERFORMANCE IMPAIRING DRUGS OR ALCOHOL.

UNAUTHORIZED WELDINGCAN CAUSE STRUCTURALFAILURE OR PERSONALINJURY.


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General Safety

FUELING

ALWAYS handle fuel with care. It is highly flammable.

ALWAYS stop engine before refueling. Fill fuel tankoutdoors.

DO NOT replace fuel lines with materials different fromthose supplied as original equipment.

Prevent fires by keeping the generator and its sur-rounding area clean.

DO NOT refuel while smoking or when near openflame or sparks.

DO NOT refuel the engine when it is hot. Allow to coolfor several minutes before refueling.

DO NOT spill fuel inside the engine compartment.

If fuel has leaked, wipe it up and have leak repairedbefore next use.

Have a fire extinguisher nearby. Be sure the extin-guisher is properly maintained and be familiar with itsuse. Extinguishers rated ABC by the NFPA are appro-priate for all applications.

FIRES CAN CAUSESEVERE PERSONALINJURY OR MACHINEDAMAGE.


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BATTERY HAZARDS

Lead acid batteries can be dangerous. The sulfuric acid in the battery can cause severe skin and eye burns.The hydrogen gas emitted during charging can explode if an arc or flame is present.

DO NOT smoke while servicing the battery.

DO NOT allow tools to touch battery terminals and create an arc.

Disconnect the negative terminal of the battery when working on the engine or other parts to prevent accidentalarcing. Disconnect the negative cable at the end away from the battery.

DO NOT remove the vent caps when charging the battery.

Always wear eye protection when servicing the battery.

If acid gets on skin or eyes, immediately flush under running water and obtain medical attention.

ELECTRICAL SAFETY

This equipment uses high voltage circuits capable of causing serious injury or death. Exercise ex-treme caution around any electrical component while operating this unit.

Always ground the unit when possible.A grounding lug has been added to the trailer frame for your convenience.

Beware of cut or damaged power cords. Have a qualified electrician replace any damaged cordsimmediately.

General Safety

EXHAUST GASES ARE TOXIC. DO NOT USE IN-DOORS UNLESS PROPERLY VENTILATED OR ANEXHAUST SCRUBBER IS USED.

Check exhaust system regularly for leaks and ensure that the exhaust manifolds are secure and notwarped.

Make sure the unit is well ventilated.

DO NOT TOUCH HOT PARTS

The exhaust manifold and tail pipe are very hot. Parts of the engine are also hot. Use protectivegloves when handling hot parts.


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General Safety

KEEP ALL BODY PARTS AND CLOTHING AWAYFROM MOVING PARTS

Loose jackets, shirts, sleeves, and especially neckties should not be worn while working on or runningthe unit.

Only remove guards or protective devices from unit temporarily to gain access for maintenance.Always replace guards immediately after servicing. Never remove guards while unit is operating.

Keep your hands away from moving parts, particularly clear of the radiator fan and alternator beltswhen the engine is running.

BEWARE OF TRAFFIC HAZARDSStand clear of traffic when starting or checking the unit along the road.

Check the fuel tank, oil pan, and fuel and oil lines for leaks that would spill fuel or oil on the road.

Check fasteners and mounting brackets periodically to insure all are tight and nothing is in danger offalling off during transit.

Be careful when lifting. Never suspend any otherequipment from the shipping tie downs.

Use the lifting eye for lifting the trailer (with cabinet).

Make sure any tie-downs at the bottom of the trailer are released prior to lifting.

NEVER CLIMB ON TOP OF THE CABINET.


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Receipt of Delivery Checklist

The generator will be serviced, tested and ready for operation upon delivery. Terex recommends the followingchecks:

Insure there is no freight handling damage which should be charged against the carrier.

Check the front jack for security and proper operation.

Check that the tires are not damaged, under inflated or that any lugs are loose.

Check the engine/generator for obvious damage, loose connections, or leaks.

Check the control panel for damage or loose connections.

Check the exhaust system for damage.

Check all fluid levels; battery, radiator, and engine oils.

Insure manuals are in the pocket provided inside the unit.


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ALWAYS USE THE PROPER TRAILER HITCH AND SAFETYCHAINS. OBEY ALL LOCAL OR STATE D.O.T. LAWS WHEN TOW-ING A GENERATOR.

Transport and Towing

All trailer-mounted Terex Gen-Pac generators are designed for highway and off-road towing capability. Pleaseconsult state and local transportation codes before transporting the generator set. Additionally, all state andlocal traffic laws take precedence over the following instructions whenever differences arise between them.

1. Make sure the towing vehicle is of adequate size to both tow and stop the unit.

2. Disconnect all wiring and cabling (including the ground wire) from the generator set.

3. Close and latch or lock all access doors.

4. 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.

5. Insure that the coupler is properly secured to the towing vehicle and attach the safety chains. Attach thebreakaway chain on the surge brake and the electrical coupler if these options are included on the unit.

6. Retract and rotate the front leveling jack into its stowed position.

7. Check the tires for proper inflation and verify the lug nuts are tight.

8. Remove tire chocks.

9. Observe posted speed limits for trailers. Generally, do not exceed 45 mph on paved roads and 10 mph onunpaved roads.

FAILURE TO PROPERLY SECURE THE TRAILER TO THE TOW-ING VEHICLE MAY RESULT IN SERIOUS INJURY OR DEATH.

Exceeding these recommended speeds can cause severedamage to the unit. Damage caused by these unsafe practiceswill void the manufacturers warranty.


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Setup

Move the generator set to the desired location keeping the following in mind:

1. The spot where the generator set is positioned should be relatively level.

2. The location selected should be centrally located to equipment requiring the loadsto minimize voltage drop in the power cord.

3. Locate so power cords can be routed without crossing roads and access routes.

4. Locate where the engine will get good ventilation. Do not locate where fumes willenter a building.

5. Do not place beside a building wall that would reflect and intensify noise.

Unhitch from the towing vehicle as follows:

1. Locate the generator set in the desired location.

2. If the axle is sloped downhill, turn the generator set so that the axle is level.

3. Chock wheels if generator set is not on level ground.

4. Unhook hitch, safety chains and running lights.

5. Rotate the tongue jack into position (90 degrees), release the hitch pin and raisethe tongue off the towing vehicle.

THE WHEELS MUST BE PROPERLY CHOCKED IF THEGENERATOR IS ON UNLEVEL GROUND.DO NOT OPERATETHE GENERATOR SET UNTIL IT HAS BEEN PROPERLYSECURED.


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Never remove the radiator cap while the engine is runningor while the engine is hot.

2. Check the oil level in the engine crankcase, and add as required.

Check engine manufacturers recommendations for motoroil types and weights.

3. If the battery is not a maintenance free battery, check the electrolyte level in the battery and add distilledwater if necessary.

4. Check fuel/water separator for water in the fuel system. Drain water from separator if necessary.

5. Check fuel level in the fuel tank and add as required. Check to insure the fuel tank vent is open and notclogged.

Use #2 diesel fuel only.

6. Verify that the generator main circuit breaker is in the OFF position.

7. Make sure the generator set is properly grounded. This is accomplished by connecting the grounding lugprovided at the rear of the generator set enclosure to a mechanical earth-ground with a minimum 2/0 sizeelectrical cable. If this differs from your local code, always follow the local code for grounding.

8. Check all electrical connections to insure they are in the proper configuration and all connections are tight.

When preparing to start the generator set, follow the sequence listed below:

1. Check the coolant level in the radiator, and add as necessary. If adding coolant, use only a 50/50 mixtureof antifreeze and water.

Setup

THIS GENERATOR SET PRODUCES VOLTAGES THAT CANCAUSE SEVERE SHOCK OR DEATH! ONLY QUALIFIEDELECTRICIANS SHOULD PERFORM ELECTRICAL WORK.


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STARTING THE ENGINE/GENERATOR SET

Operating Instructions

Once setup procedures are completed, the generator set is ready to be started. Start the unit according to thefollowing steps:

1. Turn the ENGINE ON/OFF SWITCH clockwise to the run position until the glow plug indicator LED illumi-nates. The unit will preheat for 15-20 seconds.

Never attempt to start the generator set with the main circuitbreaker ON. This breaker is located on the distributionpanel. Starting with the breaker ON can cause damage to thegenerator.

Never preheat for more than 30 seconds, damage may bedone to the heating elements.

2. Turn the ENGINE ON/OFF SWITCH to the extreme clockwise or start position until the engine fires,then release it.

To avoid starter damage, never operate the starter formore than 30 seconds at a time.

3. Now that the generator set is running, allow five minutes for warm-up time.

4. Listen for any unusual sounds or excess vibrations that could signal problems and require immediateshutdown of the unit. Should unusual sounds be detected, shut the unit down, and contact the TerexService Department at 1-800-433-3026.

5. Once the engine has been started and running smoothly, the following gauges should be monitored:

-AC Voltmeter- This gauge should read 240 VAC in the standard factory setconfiguration.

-AC Frequency Meter- This gauge should read 60-62 Hz. This indicates a properengine speed of about 1800 rpm.

-AC Ammeter- The reading on this gauge should be zero since the main breaker isin the OFF position. Once a load is applied to the generator, theammeter will produce an appropriate reading.


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LOADING INSTRUCTIONS:If all readings are correct, an electrical hookup can be made to the generator set. To make the electricalhookup to the generator set, observe the following set of procedures:

SHUT DOWN THE GENERATOR SET BY TURNING THEENGINE ON/OFF SWITCH TO THE OFF POSITION BE-FORE MAKING ANY ELECTRICAL CONNECTIONS.

1. Shut down the generator set, verify the main breaker is in the OFF position.2. Connect the desired electrical equipment/apparatus to the generator set, while making sure no other

power source is connected to the same equipment/apparatus.3. After the connections have been completed, close the cover over the 3 phase distribution lugs.

Failure to close the cover over the 3 phase lugs will cause themain breaker to shunt trip when the unit is started.

4. Restart the engine and monitor the critical functions as outlined in the Operating Instructions section.5. Switch the main generator circuit breaker to the ON position.6. Monitor the AC Ammeter- If the needle deflects severely to the right and stays there, immediately turn the

main generator circuit breaker to the OFF position.

Severe deflection of the ammeter indicates a wiringproblem or an overload problem. Continued operationunder this condition will cause damage to the generatorand/or connected apparatus.

The needle on the ammeter will deflect to the right temporarily and then return to a normal reading if the unit isoperating properly.


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SHUTDOWN PROCEDURES:

1. Switch the main generator breaker to the off position.

2. Allow the engine to run for 5 minutes under no load as a cool down cycle.

3. Stop the engine by turning the Engine On/Off Switch to the OFF position.

NEVER SHUT THE UNIT DOWN WHILE UNDER LOAD. THISCOULD CAUSE SERIOUS INJURIES TO THE PERSON OPER-ATING THE MACHINE OR DAMAGE TO THE GENERATOR.

Never shut the unit down with the main generator circuitbreaker in the ON position. This can cause damage to thegenerator and/or the connected apparatus.


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Maintenance

MINIMUM MAINTENANCE PROCEDURES:

The following maintenance intervals are only suggested by Terex. You should always check your engineowners manual for specific information. Should you find any discrepancies between the Terex Manual and theEngine Manufacturers Manual always follow the Engine Manufacturers Manual.

Every 8 Hours of Operation:-Check the crankcase oil and fill as required.-Check the fuel tank level and fill as required.

NEVER ADD FUEL TO THE UNIT WHILE IT IS RUNNING.THIS CONSTITUTES A SEVERE FIRE HAZARD THAT CANCAUSE DAMAGE TO THE UNIT AND INJURY TO THEOPERATOR.

Daily:-Check the engine and generator for any loose bolts, connections, and fittings.-Check the coolant levels and fill as required.-Check the fuel/water separator for the presence of water contamination. Drain as required.

Water contaminated fuel will cause severe damage to theinjection and fuel pumps.

-Check battery electrolyte level and replenish if necessary.

NEVER REMOVE THE RADIATOR CAP OR CHECKELECTOLYTE LEVELS ON A HOT UNIT. THIS COULDRESULT IN SEVERE BURN TO THE OPERATOR.

Note: Use a 50% solution of water and antifreeze for the engine coolant.

Weekly:-Check the air cleaner and clean as required.-Inspect the radiator fins for damage or clogging and clean as required.

Bi-weekly:-Check the engine oil quality and change as required.

Bi-Monthly or every 250 hours:-Change the engine crankcase oil.-Check cooling fan belt tension and adjust if necessary.


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Maintenance

Six months or every 500 hours:-Replace the oil filter.-Check valve clearances (consult Manufacturers Manual)-Check electrical components and clean as required.-Check electrical wiring for chafing, wear and replace as needed.

Yearly or every 1,000 hours:-Clean or replace the fuel filter.-Clean or replace the fuel pump strainer, if equipped.-Check the head and manifold bolts for tightness.-Replace air cleaner element.

CLEANING:

The Terex GenPac generators employ various electronic controls that may be damaged by liquid spray wash-ing 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:1. The exterior housing may be washed by most conventional cleaners and methods.

2. The exterior housing may be waxed using any conventional automotive wax.

Interior Cleaning:1. Using a damp cloth covered with a mild soap, carefully clean around any electric controls, generator, and

thermostats.

2. The base and housing foam may be cleaned with a damp cloth covered with mild soap.


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Trouble Shooting GuideThe engine/generator set is factory installed. These units are tested and set at the factory for proper operationin the field. These units should never require additional adjustments in the field. Adjustments should only bemade by a qualified service technician, otherwise the manufacturers warranty may become void.

TROUBLE POSSIBLE CAUSE REMEDY1. No generator output voltage. a. Circuit breaker is tripped a. Reset circuit breaker

b. Voltage regulator power lead loose b. Check voltage regulator wiringc. Defective voltage regulator c. Replace voltage regulatord. Defective generator d. Refer to generator manual

2. Low generator output voltage a. Voltage adjustment potentiometer a. Reset voltage adjustmentset too lowb. Low engine speed b. Reset engine speed to 61.5 Hz

(1845 rpm) under no loadc. Loose wire on voltage selector c. Check wiringswitchd. Fluctuating or surging engine d. Check engine fuel, oil, and oilspeed filterse. Loose wire on voltage selector e. Check wiringsensing circuitf. Defective voltage regulator f. Replace voltage regulator

3.High generator output voltage a. Voltage adjustment potentiometer a. Reset voltage adjustmentset too highb. High engine speed b. Reset engine speed to 61.5 Hz

(1845 rpm) under no loadc. Loose wire on voltage adjustment c. Check wiringpotentiometerd. Defective automatic voltage d. Replace voltage regulatorregulator

4.Fluctuating generator output a. An "ON/OFF" type load may be a. Redistribute load if possiblevoltage the cause

b. Fluctuating or surging engine b. Check: Engine fuel system, airspeed leaks, plugged filters, clogged pick-up

tube in fuel tankc. Automatic voltage regulator setting c. Check stability adjustment andmay be wrong check engine governor for stabilityd. Loose wire on automatic voltage d. Check wiringregulator sensing lead


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Trouble Shooting Guide5.Low engine speed a. Engine speed adjustment has a. Reset engine speed to 61.5 Hz

slipped (1845 rpm) under no loadb. Clogged fuel system b. Check for air leaks, clogged fuel

line, or clogged fuel pick-up tubec. Blocked air intake c. Check air filterd. Blocked exhaust system d. Check engine exhaust system,

remove obstructionse. Contaminated fuel e. Check fuel/water separator and

fuel tank for contamination. Replacefuel if needed

f. Defective governor on engine f. Have governor checked by aqualified technician

g. Defective injectors on engine g. Have injectors checked by aqualified technician

h. "Surging" engine speed h. Reset engine speed to 61.5 Hz(1845 rpm) under no load

6. Engine turns over (cranks), but a. Unit out of fuel a. Check fuel level in tank, fill aswill not run needed

b. Loose or bad DC FUSE in engine b. Check and replace with 25 ampcontrol circuit SLOBLO type fuse if neededc. Loose or broken wire in control c. Check wiring to verify 12v DC iscircuit to fuel injection pump solenoid being supplied to the pumpd. Clogged fuel system d. Check fuel systeme. Air in fuel system e. "Bleed" fuel systemf. Defective fuel pump f. Check and replace if neededg. Clogged air intake g. Check air cleanerh. Clogged exhaust h. Check exhaust systemI. Contaminated fuel I. Check fuel/water separator and


j. Defective injectors on engine j. Have injectors checked by aqualified technician

k. Loss of engine compression k. Have compression checked by aqualified technician

7. Engine will not crank a. Loose battery cable or discharged a. Check cables and batterybattery electrolyte level and recharge if

neededb. Engine "ON/OFF" switch set in b. Check switch position"ON"c. Blown fuse in DC control circuit c. Replace fused. Defective starter solenoid d. Replace solenoide. Defective starter e. Replace starterf. Seized engine f. Have engined checked by a

qualified technician


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IF YOU FEEL AN ELECTRIC SHOCK AT ANY TIME WHILEOPERATING THIS UNIT, SHUT IT DOWN IMMEDIATELY!HAVE THE UNIT INSPECTED BY A TRAINED ELECTRI-CIAN.

Trouble Shooting Guide

This engine/generator set is factory installed, tested, and setfor field operation. Any damage to the engine or generator unitsoccurring after adjustments are made in the field by unautho-rized personnel will not be covered by your manufacturerswarranty and will also void the manufacturers warranty on thisparticular unit. If you can not reach your local dealer, contactthe factory Service Manager TOLL FREE at 1-800-433-3026.

8. Engine runs but losses power a. Unit is overloaded a. Reduce loadunder load b. Clogged fuel system or air in b. Check fuel system

fuel linesc. Blocked air intake c. Check air filterd. Blocked exhaust system d. Check engine exhaust system,

remove obstructionse. Contaminated fuel e. Check fuel/water separator and


f. Defective governor on engine f. Have governor checked by aqualified technician

g. Defective injectors on engine g. Have injectors checked by aqualified technician

h. Defective fuel pump g. Have the fuel pump checked by aqualified technician

9. Engine shuts down automatically a. Low coolant level a. Check radiatorand TROUBLE light on the control b. Improper coolant or water mixture b. Use a 50/50 mix of water and anti-panel lights up freeze only

c. Overloaded engine c. Reduce loadd. Broken fan belt d. Inspect fan belt and replace if

needede. Defective thermostat or thermo- e. Inspect thermostatcouple switchf. Defective water pump f. Inspect water pump and replace

if neededg. Blocked cooling air inlet or g. Inspect and remove anyexhaust obstructionsh. Defective or grounded h. Inspect switch and repair ortemperature switch replaceI. Defective injectors or injector I. Have the engine inspected by apumps qualified technicianj. Low crankcase oil level j. Check oil level and fill as neededk. Defective oil pump k. Have the engine inspected by a

qualified technicianl. Defective or grounded oil pressure l. Inspect switch and repair orswitch replace


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Kubota Gen-Pac - Control Panel Wiring


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Isuzu Gen-Pac - Control Panel Wiring


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T25G Single Phase Distribution Wiring


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T15G Single Phase Distribution Wiring


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T15G and T25G Generator Wiring


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Overall length 119 (3023mm)Trailer frame length 70 (1778 mm)Overall height 54 3/4 (1391mm)Overall width with fenders 61 (1549 mm)Trailer frame width 41.5 (1054mm)Tongue length 44 (1118 mm)Wheel size 15 (381mm)Axle Rating 3500 lb. (1588 kg)Tongue weight travel position 150 lb. (68kg)Total weight no fuel 1468 lb. (666kg)Fuel Capacity 30 gal. (114 l)Unit weight with full fuel tank 1685 (764kg)

T15G Dimensions

Overall length 119 (3023mm)Trailer frame length 70 (1778 mm)Overall height 54 3/4 (1391mm)Overall width with fenders 61 (1549 mm)Trailer frame width 41.5 (1054mm)Tongue length 44 (1118 mm)Wheel size 15 (381mm)Axle Rating 3500 lb. (1588 kg)Tongue weight travel position 168 lb. (76kg)Total weight no fuel 1654 lb. (750kg)Fuel Capacity 30 gal. (114 l)Unit weight with full fuel tank 1871 (849kg)

T25G Dimensions


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FASTENER STAINLESS STAINLESS SAE GRADE SAE GRADE SAE GRADE SAE GRADESIZE STEEL* STEEL* 5 PLATED 5 PLATED 8 PLATED 8 PLATEDUNF NYLOK (METRIC NYLOK (METRIC NYLOK

& NUT 8.8) NUT 10.9) NUTUNC#6 (10-12) (8.5-10) (14-16)#8 (20-22) (17-19) (25-28)#10 (26-32) (22-27) (40-45)1/4" (75-94) (64-80) 7-9 12-145/16" 12-Nov 14-Dec 15-17 23-263/8" 20-22 22-24 28-34 45-507/16" 31-33 32-35 40-45 70-751/2" 43-45 45-50 75-85 70-80 100-110 95-1059/16" 57-63 60-65 80-100 75-95 145-160 135-1505/8" 92-104 100-105 130-170 125-165 175-205 165-1953/4" 128-135 140-150 220-240 205-225 380-420 365-4054mm (22-26) (19-22) (23-27)6mm (45-50) (38-43) (72-78)8mm 12-Nov 9-10 14-1610mm 18-20 15-17 45-50 40-45 70-7512mm 42-44 36-38 56-60 50-55 95-10516mm 140-14818mm 185-20020mm 280-290

Torque Specifications

Generator FT*LB

Flex Plate to Flywheel 12-15

Generator Case to Bellhousing 60

1/2" Socket Head Cap Screws for Lifting Channel 126

1/2" Hex Head Screws for Lifting Channel 120

Genset Isolators 33

Generator Torque Specifications


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Parts Ordering Information

Machine Information

Model

Serial Number

Date of Purchase

Authorized TEREX Distributor

Phone Number

Please be prepared with the following informationwhen ordering replacement parts for your TEREXproduct:

Machine model numberMachine serial numberTerex part numberPart description and quantityPurchase order number"Ship to" addressDesired method of shipmentName and telephone number of theauthorized TEREX Distributor in your area

Use the Service Parts Fax Order Form on thenext page and fax your order to our PartsDepartment.

If you don't know the name of your authorizeddistributor, or if your area is not currently servicedby an authorized distributor, please call TEREXCorporation.

Genie Industries18340 NE 76th StreetP.O. Box 97030Redmond, WA 98073-9730Telephone (877) 367-5606Fax (888) 274-6102genieindustries.com

Part Number Description Quantity Price

All backordered parts will be shipped when available via the same ship method as the original orderunless 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)

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 __________________________________________________________________________

FOR TEREX USE ONLY

Order Number ______________ Origin Code ________________ Comments _________________________

Date Scheduled ____________ Ship Condition ______________ __________________________________

Order Total ________________ Terms Code ________________ __________________________________

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Service Parts fax Order FormFAX TO: (800) 633-5534 OR TOLL FREE: 800-433-3026


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General Information - Parts Manual

INTRODUCTION

This manual contains parts ordering information for the Terex T15G and T25G Gen-Pac generators.

IDENTIFICATION of PARTS

All parts are identified with a part number and brief description. If there are multiple quantities of the partrequired, the quantity required will be shown along with part number and description. If no quantity is given it isassumed that there is only one part required.

NOTES and DESIGNATIONS

This manual is compiled from information available and current at time of approval for printing. Terex reservesthe right to improve its product without notice to follow its policy of constantly striving to manufacture a betterproduct.

ILLUSTRATIONS

The illustrations in this manual are intended to show typical construction of the various parts. In some in-stances the shapes or details of the parts illustrated may not exactly represent their actual appearance.However, they will serve to show the servicing methods explained or help to identify parts performing the samefunction.


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Parts Catalog

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March 2006

Parts CatalogSection


Parts Catalog

REV A

March 2006

T15G and T25G Cabinet Assembly


Parts Catalog

REV A

March 2006

T15G and T25G Cabinet Assembly

ITEM # PART # DESCRIPTION QTY.1 124430 USE 124436 & 796390 1

124436 CABINET, REAR PANEL 1796390 PLUG, PLASTIC, 3/8 1

2 188550 CABINET, TOP PANEL 13 188560 CABINET, DOOR PANEL 24 188570 CABINET, SIDE PANEL, ROADSIDE 15 188580 CABINET, SIDE PANEL, CURBSIDE 16 796610 HINGE PIANO 1.5X51.75 27 791840 BUMPER, RUBBER 48 790940 HANDLE, 5.75", CHROME PLATED 29 189796 HASP, CABINET DOOR 210 176380 COVER PLATE, CABINET TAILLIGHT HOLES 211 794990 PLUG, PLASTIC, 5/16, NOT SHOWN 212 796385 PLUG, PLASTIC, 3 /16, NOT SHOWN 213 796390 PLUG, PLASTIC, 3/8, NOT SHOWN 114 841710 REFLECTOR RED, NOT SHOWN 215 794940 PLUG PLASTIC 4 116 124420 GROUND ROD STORAGE TUBE 117 113399 GROUND ROD 118 790540 PIN QUICK 1/4 X 1.75 ZP 1

109472 KIT: DECALS FOR MODEL T25G, NOT SHOWN 1109473 KIT: DECALS FOR MODEL T15G, NOT SHOWN 1

19 853792 DECAL: TEREX 4.5" X 43" BLACK CUT VINYL 220 C52100100 DECAL: CALIF.PROP 65 121 CR51A101 DECAL: WARNING-IMPROPER GROUNDING 122 CU51A102 DECAL: NOTICE-NO ETHER 123 CU51A112 DECAL: DANGER HOT EXHAUST 124 CU51A113 DECAL: NOTICE: RADIATOR FILL 125 CU51A213 DECAL: GEN-PAC 226 CU51A304 DECAL: GROUND U.P.C.L. CODE 127 123256 LIFTING EYE, REAR 128 123255 LIFTING EYE, FRONT 129 123490 FENDER W/SKIRT 230 CGPU450000 CABINET, FRONT PANEL 131 176370 LITERATURE RACK FOR CABINET 132 CU51A121 DECAL: LIFT HERE 133 850150 DECAL: DIESEL FUELONLY 134 853802 DECAL: T25G 235 853800 DECAL: T15G 236 796436 GAS SPRING,16, 60 LB. 437 796432 GAS SPRING, SHORT BRACKET W/BALL 838 992040 RIVET, POP, 3/16 X .602, 63-66, MULTI BLIND 1639 990670 RIVET, POP, 3/16 X 1/2, S/S, BLIND RIVET AR


Parts Catalog

REV A

March 2006

T15G and T25G Trailer Assembly


Parts Catalog

REV A

March 2006

T15G and T25G Trailer Assembly

T15G and T25G Optional - Two Fuel Tanks

ITEM # PART # DESCRIPTION QTY.1 124415 TRAILER FRAME, 41 X 70, 2-FUEL TANKS 12 GPU121001 BATTERY TRAY 13 721051 CAPLUG, TUBE PLUG, 2 1/2 X 2 1/2-16GA TUBE 64 851820 DECAL: SYMBOL FORGROUND 15 124470 TONGUE, B-O-H W/JACK BRACKET 16 851310 DECAL: WARNING ALL JACKS MUST BE SWIVELED 17 840120 COUPLER, 2", #980P-2, ZP, BOLT-ON 18 841430 JACK, SIDEWIND, LONG, 3KLB 19 840222 JACK SNAP RING 110 Z52475 DECAL, LABEL TRANSPORT, TIEDOWN 411 188631 FUEL TANK PAN FOR 20GAL TANK 112 189805 FUEL TANK, 20 GALLON 113 742240-1 TANK CAP, NO-GAUGE 1

ITEM # PART # DESCRIPTION QTY.1 124410 TRAILER FRAME 41X70 W/O AXLE 12 GPU121001 BATTERY TRAY 13 721051 CAPLUG, TUBE PLUG, 2 1/2 X 2 1/2-16GA TUBE 64 851820 DECAL: SYMBOL FORGROUND 15 124470 TONGUE, B-O-H W/JACK BRACKET 16 851310 DECAL: WARNING ALL JACKS MUST BE SWIVELED 17 840120 COUPLER, 2", #980P-2, ZP, BOLT-ON 18 841430 JACK, SIDEWIND, LONG, 3KLB 19 840222 JACK SNAP RING 110 Z52475 DECAL, LABEL TRANSPORT, TIEDOWN 411 188630 FUEL TANK PAN FOR 30 GALLON TANK 112 742220 TANK, FUEL, 30GAL, RMPE, 26.5W X 33L X 9H 113 742240-1 TANK CAP, NO-GAUGE 114 111936 CHAIN, SAFETY, 3000LB, 3/8 X 30 W/ S HOOK 215 C33700800 HOOK, BATTERY, HOLD DOWN, (PAIR) 116 CU22A252 ANGLE, BATTERY HOLD-DOWN 117 261252 BATTERY, WET, 12V, GRP34/78, AMERISTART, 750 CCA 118 160276 BATTERY CABLE SET, 24" 1


Parts Catalog

REV A

March 2006

T15G and T25G Axle Assembly


Parts Catalog

REV A

March 2006

T15G and T25G Axle Assembly

ITEM # PART # DESCRIPTION QTY.1 841050 AXLE, 3500LB, 38.5 SC 12 834267 U-BOLT KIT - 3500# 23 834225 SEAL, GREASE 24 834226 INNER BEARING 25 834220 HUB ASSEMBLY, HT1000, 3500LB 26 834227 OUTER BEARING 27 834255 COTTER PIN 28 834250 SPINDLE NUT 29 834228 GREASE CAP 210 841060 TIRE & WHEEL MOUNTED P205/75-15 LOAD B2 211 840376 AXLE, WHEEL NUT 1012 840395 AXLE, SPRING NUT 613 840392 AXLE, REAR HANGER 214 840394 AXLE, SPRING BOLT 615 841473 AXLE, SHACKLE 216 834246 SPRING EYE BUSHING 417 834211 SPRING FOR AXLE, 4-LEAF 218 841051 AXLE, FRONT HANGER 2


Parts Catalog

REV A

March 2006

T15G and T25G Electrical Enclosure


Parts Catalog

REV A

March 2006

T15G and T25G Electrical Enclosure

ITEM # PART # DESCRIPTION QTY.1 GPU300000 ELECTRICAL ENCLOSURE, GENPAC 12 GPU430001 DOOR, ELECTRICAL ENCLOSURE 13 113734 DISTRIBUTION PANEL, 3PH, GENPAC, T25 1

133735 DISTRIBUTION PANEL, 1PH, GENPAC, T15 14 CB42G000 CONTROL PANEL 15 170250 SPLASH GUARD, RUBBER 16 170255 STRIP, SPLASH GUARD, HOLD DOWN 17 CU51A221 DECAL: DANGER HIGH VOLTAGE (RED-WHITE) 18 CU51A122 DECAL: HIGH VOLTAGE 19 853070 DECAL: CAUTION READ MANUAL 110 794890 HINGE, LIFT-OFF, STEEL 111 794890 HINGE, LIFT-OFF, STEEL 112 C51200000 LATCH, BLACK, KEY LOCK, ADJ T-HANDLE, T25 1

C51101000 LATCH, BLACK, T15 113 66812 E-STOP, PUSH BUTTON, MUSHROOM HEAD ASSEMBLY 114 66817 EMERGENCY STOP, BASE WITH 1 N.C. CONTACT 115 686662 EMERGENCY STOP, FACE PLATE 1


Parts Catalog

REV A

March 2006

T15G and T25G Control Panel Assembly


Parts Catalog

REV A

March 2006

T15G and T25G Control Panel Assembly

ITEM # PART # DESCRIPTION QTY.1 GPU302001 CONTROL PANEL, GENPAC 12 NPN ENGINE DECAL, PART OF KIT 853813 13 NPN GENERATOR DECAL, PART OF KIT 853813 14 Z80562 CONTROLLER, ENGINE SHUTDOWN 15 CU51A122 DECAL: HIGH VOLTAGE 16 853839 DECAL: CONTROL PANEL, GENPAC, TML CONTROLLER 17 C43100800 GAUGE, DC VOLT 18 260360 HOURMETER, 12V, DC 19 CDWV40151 RELAY BASE, 50A 310 CDWV40150 RELAY, 50A 311 C43100400 METER, FREQUENCY, 55-65HZ 112 C43100600 METER, VOLT, DUAL, 0-300/600 113 C43100500 METER, AMP, 0-100 114 C42200500 POTENTIOMETER, VOLTAGE ADJUST, 1K, 10 TURN 115 684380 SWITCH, IGNITION, LEVER OPERATED 116 C42401700 RELAY, OVER CURRENT, CROMPTON 1


Parts Catalog

REV A

March 2006

T15G and T25G Distribution Panel Assembly


Parts Catalog

REV A

March 2006

T15G and T25G Distribution Panel Assembly

ITEM # PART # DESCRIPTION QTY.1 GPU301001 DISTRIBUTION PANEL 12 C51200201 HINGE, PIANO, 9" 33 CU43A030 BOARD, DISTRIBUTION 14 170265 BRACKET, LUG COVERMOUNT 15 170260 BRACKET, CUTOFF SWITCH 16 170270 LUG COVER, POLY CLEAR 17 CU41S030 TEMP POWER SLOPE 18 685885 CLIPS, MOUNTING, FACE, QC BREAKER 49 685880 BREAKER, 2POLE, 1PH 110 C42103400 BREAKER, 20A, 120/240V 211 C42103600 BREAKER, 50A, 120/240V, 2POLE 212 684640 RECEPTACLE, 20A, 120V, DUPLEX W/GFI 213 C47100300 RECEPTACLE, TWISTLOCK, 50A 214 C42104500 BREAKER, 70A, SHUNTTRIP, 240VAC, 12VDC 1

685275 BREAKER, 2P, 70A, SHUNTTRIP, T15G 415 C74954 SCREW, HEX, 1/2"-13 X 2.5" 116 NPN DECAL INCLUDED IN DECAL KIT 853813 117 853751 DECAL: SINGLE PHASE MAIN BREAKER 118 683480 BUSHING, 9/16 OD X 3/8 ID 119 C42205401 PLUNGER, MICROSWITCH 120 C42205400 SWITCH, SNAP ACTION 121 796671 LATCH, MAGNETIC 122 C74972 FLAT WASHER, 1/2" 423 C75240 LOCK WASHER, 1/2" 824 C74967 HEX NUT, 1/2-13 825 796671 LATCH, MAGNETIC 126 853840 DECAL: DISTRUBUTION, GPLAYOUT, 3P, 240 127 CU51A310 DECAL: DO NOT OPEN 3PHASE DOOR 128 NPN ITEMS 28 - 37 INCLUDED IN DECAL KIT 853813 129 NPN ITEMS 28 - 37 INCLUDED IN DECAL KIT 853813 130 NPN ITEMS 28 - 37 INCLUDED IN DECAL KIT 853813 231 NPN ITEMS 28 - 37 INCLUDED IN DECAL KIT 853813 232 NPN ITEMS 28 - 37 INCLUDED IN DECAL KIT 853813 133 NPN ITEMS 28 - 37 INCLUDED IN DECAL KIT 853813 134 CU51A400 INCLUDES ITEMS 34-37 135 NPN INCLUDED IN ITEM 34 136 NPN INCLUDED IN ITEM 34 137 NPN INCLUDED IN ITEM 34 1


Parts Catalog

REV A

March 2006

T25G Isuzu Engine


Parts Catalog

REV A

March 2006

T25G Isuzu Engine

ITEM # PART # DESCRIPTION QTY.1 116394 GENSET, ISUZU 4LE, NEWAGE GENERATOR, 20KW, 3PH 12 732111PP ENGINE, ISUZU, 20KW, 4LE1PV02-502, POWER PAK 13 CB45A116 HARNESS, ENGINE, T25G 14 742060 RADIATOR 15 868113 UPPER RADIATOR HOSE 16 868112 LOWER RADIATOR HOSE 17 868089 RADIATOR BRACKET 18 868012 FAN 19 868067 FAN BELT 110 868013 GUARD 111 868099 CONTROL MODULE (FAN) 112 741976 OIL DRAIN VALVE 113 868075 OIL FILTER 114 834458 AIR FILTER ASSEMBLY 115 834460 AIR ELEMENT ONLY 116 742372 MUFFLER 117 190180 BRACKET, MUFFLER SUPPORT 118 190181 STRAP, MUFFLER SUPPORT 119 188396 MUFFLER SPACER 120 791610 CLAMP MUFFLER 121 868137 FUEL FILTER 122 890790 HOSE, FUEL, 1/4 X 1/2, 200#, PUSH-LOK 123 C90200600 BARB, 3/8" X 1/4" NPT 124 C90203100 HOSE FITTING, PIPE/BARB,1/4M X 1/4HB 125 C91100700 HOSE, FUEL, 3/8" 126 868069 NOZZLE ASSEMBLY 127 868070 FUEL PUMP ASSEMBLY 128 868068 FUEL INJECTION PUMP 129 C42300100 SWITCH, OIL PRESSURE SENDER 130 868086 STOP SOLENOID 131 868077 ALTERNATOR 132 868076 STARTER ASSEMBLY 1


Parts Catalog

REV A

March 2006

T15G Kubota Engine


Parts Catalog

REV A

March 2006

T15G Kubota Engine

ITEM # PART # DESCRIPTION QTY.1 116388 GENSET, KUBOTA 1505 WITH NEWAGE GENERATOR, T15G 12 732175 ENGINE,KUBOTA V1505EBG2E, 18.2HP 13 116775 WIRE HARNESS, KUBOTA TO CONTROL BOX 14 866120 RADIATOR CAP 15 741140 TEMPERATURE SENDER 16 866015 ELEMENT ONLY, AIR CLEANER 17 839170 VALVE, AIR CLEANER 18 866044 2 WIRE STOP SOLENOID 19 866070 FUEL PUMP, MECHANICAL 110 866050 OIL FILTER 111 839209 V-BELT 112 839107 FUEL FILTER ASSEMBLY 113 866110 RADIATOR KIT 114 740620 FUEL FILTER, IN-LINE 115 839109 UPPER RADIATOR HOSE 116 866090 ALTERNATOR 117 839190 LOW OIL PRESSURE SWITCH 118 865276 MUFFLER 119 832128 MUFFLER GASKET 120 839110 LOWER RADIATOR HOSE 121 866394 WATER PIPE 122 865054 WATER HOSE 123 866101 STARTER 1


Parts Catalog

REV A

March 2006

T15G and 25G Generators

ITEM # PART # DESCRIPTION QTY.1 630940 GENERATOR, NEWAGE, 12KW, 1P, BCI164D1J195A, T15G 1

630975 GENERATOR, NEWAGE, 20KW, C107, BCI184E1L203A, T25G 12 836420 SX-460, AUTOMATIC VOLTAGE REGULATOR 13 836427 RECTIFIER SERVICE KIT 14 CL-008 DECAL: DO NOT CHANGE POSITION OF SELECTOR SWITCH 15 C42201102 SWITCH, 3POSITION, ZZ, 20-30 KW 16 990210 WASHER FLAT 1/2 87 189335 GENERATOR MOUNT BAR 18 740920 VIBRATION MOUNT, 390LB 49 830001 OPERATION MANUAL, BCI MODELS 1


Parts Catalog

REV A

March 2006

T15G and T25G Trailer Hitches

ITEM # PART # DESCRIPTION QTY.1 940000 KIT: COMBO HITCH, includes items 2-6 12 840120 COUPLER, 2", BOLT ON 13 176336 COMBO HITCH SIDE SPACER 24 176335 COMBO HITCH SIDE PLATE 25 840470 BALL, 2" 16 121572 COMBO HITCH RING, 16" LONG 17 213770 RING HITCH BOLT-ON, 2-1/2 ID 18 124450 ADJUSTABLE HEIGHT HITCH, 24" 19 221580 ADJUSTABLE HEIGHT HITCH, 18" TO 36" 110 211410 RING HITCH FOR ADJ. HEIGHT HITCH, 2 1/2" ID 111 841200 RING HITCH FOR ADJ. HEIGHT HITCH, 3" ID 1


Parts Catalog

REV A

March 2006

T15G and T25G Stop, Tail, and Tag LIght

ITEM # PART # DESCRIPTION QTY.1 663525 LIGHT, SIDE MARKER, AMBER 22 663520 LIGHT, LICENSE TAG W/BRACKET 13 663840 LIGHT, TRAILER, RECESSED ,STOP, TURN, TAIL 2

workbook t15g-t25g 03-27-06 - …manuals.gogenielift.com/operators/english/833006 rev a1_0801...

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