operator's manual first edition • first...

Operator's Manual First Edition • First Printing

T180 • T240 Part No. 140435

Important

Read, understand and obey these safety rules andoperating instructions before operating thismachine.

Only trained and authorized personnel shall bepermitted to operate this machine. This manualshould be considered a permanent part of yourmachine and should remain with the machine at alltimes. If you have any questions, call Terex.

Contents

PageIntroduction ........................................................... 1

Symbol and Hazard Pictorials Definitions ............. 4

General Safety ...................................................... 6

Operation Safety ................................................... 8

Legend ................................................................ 12

Inspections ......................................................... 16

Setup .................................................................. 22

Operating Instructions ......................................... 24

Transport Instructions ......................................... 28

Lifting Instructions ............................................... 30

Towing Instructions ............................................. 31

Maintenance ....................................................... 33

Specifications ..................................................... 36

Serial Number Registration ................................. 40

Receipt of Delivery Checklist .............................. 40

Contact us:

Internet: www.terex.com

Copyright © 2009 by Terex

Terex Light Construction Division590 Huey RoadRock Hill, SC 29730First Edition: First Printing, June 2009

Printed on recycled paper

Printed in U.S.A.

Operator's ManualFirst Edition • First Printing

Part No. 140435 T180 • T240 1

Introduction

Description of equipment

The engine/generator assembly consists of a dieselengine combined with an electrical generator. Thisassembly is firmly bolted together to form anintegral unit and does not require anything otherthan routine maintenance.

The engine is equipped with a 12-volt starter andcan be wired for remote starting capability at thecontrol panel.

A dry-element air cleaner is standard equipment toensure a clean air supply, and a fuel/waterseparator is included for additional fuel systemprotection.

A governor on the engine provides a stableoperating speed under varying load conditions.The generator is equipped with a solid-statevoltage regulator to stabilize the output voltageunder these same conditions. Figures andschematics of both the governor and regulator areprovided in the service manual.

An automatic shut down system is incorporated inthe generator set to sense low oil pressure and/orhigh coolant temperature. In either case, theengine/generator assembly will automatically shutdown to protect the engine.

A diesel fuel tank is incorporated within the base ofthe unit to ensure an uninterrupted operating cycleunder a full load. The engine/generator assembly ismounted to the base using high durometervibration isolators.

The enclosure for the generator set is constructedfrom 12 or 14-gauge sheet metal to ensure rigidity,and is bolted together to allow easy access tomajor components if necessary. Four lockablehinged access doors are provided for routineoperation and maintenance.

The enclosure on the Super Quiet Generator isspecifically designed for a high degree of soundattenuation. This allows the generator set to beoperated in noise-sensitive environments. Theinterior of the enclosure is coated with sound-dampening polymer foam that is highly effective innoise suppression.

A high ambient temperature radiator and an integralexhaust and muffler system are contained withinthe enclosure as standard equipment.

A center-point lifting attachment is located on topof the enclosure to allow crane lifting of the entireunit.

The generator set can be mounted on a trailerequipped for highway operation which is availableas an option. Standard trailers do not comeequipped with brakes but hydraulic surge brakes orelectric brakes are available as an option.


2 T180 • T240 Part No. 140435

Danger

Failure to obey the instructions andsafety rules in this manual will resultin death or serious injury.

Do Not Operate Unless:

You learn and practice the principles of safegenerator operation contained in this operator'smanual.

1 Avoid hazardous situations.

Know and understand the general safetyrules before going on to the next section.

2 Always perform a pre-operation inspection.

3 Follow the setup instructions.

4 Follow the operating, transport and towing instructions.

5 Only use the generator as it was intended.

You read, understand and obey themanufacturer's instructions and safety rules —safety and operator's manuals, and decals.

You read, understand and obey employer'ssafety rules and all applicable governmentalregulations.

You are properly trained to safely operate thegenerator.

Introduction

Owners, Users and Operators:

Terex appreciates your choice of our generator foryour application. Our number one priority is usersafety, which is best achieved by our joint efforts.We feel that you make a major contribution tosafety if you, as the generator users and operators:

1 Comply with employer, job site andgovernmental rules.

2 Read, understand and follow the instructionsin this and other manuals supplied with thisgenerator.

3 Use good safe work practices in acommonsense way.

4 Only have trained/certified operators,directed by informed and knowledgeablesupervision, operating the generator.

If there is anything in this manual that is not clearor which you believe should be added, please sendyour comments to the Terex Service Department.

www.terex.com


Part No. 140435 T180 • T240 3

Introduction

Intended Use

This generator set is intended to be used only tosupply electrical power to a work site.

Safety Sign Maintenance

Replace any missing or damaged safety signs.Keep operator safety in mind at all times. Use mildsoap and water to clean safety signs. Do not usesolvent-based cleaners because they may damagethe safety sign material.

Hazard Classification

Terex uses symbols, color coding and signal wordsto identify the following:

Safety alert symbol—used to alertyou to potential personal injuryhazards. Obey all safetymessages that follow this symbolto avoid possible injury or death.

Indicates a hazardous situationwhich, if not avoided, will result indeath or serious injury.

Indicates a hazardous situationwhich, if not avoided, could resultin death or serious injury.

Indicates a hazardous situationwhich, if not avoided, could resultin minor or moderate injury.

Indicates a property damagemessage.

Red

Orange

Yellow

Blue


4 T180 • T240 Part No. 140435

Symbol and Hazard Pictorials Definitions

Read theoperator’smanual

Crushing Hazard Keep clear ofleveling jack

Burn HazardDo not touch. Allowsurface to cool

Carbon MonoxidePoisoning Hazard

Wear protectiveclothing and eye wear

Electrocution HazardHazardous voltage Lock out/tag out Earth ground Stay clear

Engine explosion

Do not use ether or anyhigh energy enginestarting aids

Fire extinguisher

Coolant in radiatorshould not be morethan 50% antifreeze

Stop the engineNo smokingNo open flames

Unauthorized welding

Check for damagedcords


Part No. 140435 T180 • T240 5

Symbol and Hazard Pictorials Definitions

Burn Hazard. Fueland fumes canexplode and burn.

Explosion Hazard Burn Hazard Flames and SparksHazard


6 T180 • T240 Part No. 140435

General Safety

Safety Signs and Locations (Word Decals)

Burn / Carbonmonoxide hazard.

Hot exhaust can containcarbon monoxide thatwill result in death orserious injury.

133012 A

DANGER

Do not touch hot surfacesor breathe exhaust.W ear protective gloveswhen handling hot parts.Read the operator's m anual.

EMERGENCYSTOP

Explosion HazardDeath or serious injury canresult from the use of ether orother high energy startingaids. 133059 A

Do not use ether orother high energystarting aids onm achines equippedwith glow plugs orgrid heater.

WARNING

Explosion / Burn HazardIgnition of explosive gases or contact with corrosiveacid will cause death, burns or blindness

31788 C

Keep all open flames and sparks away. Wearpersonal protective equipment, including faceshield, gloves and long sleeve shirt.

READ MANUALSRead all manuals prior to operation.

DO NOT OPERATE equipment if you do notunderstand the information in the manuals.

Consult your supervisor, the owner or themanufacturer.

DANGER

WARNINGElectrocutionhazard.

Improper groundingmay result in deathor serious injury

Ground unit properly.Always comply withlocal electrical codes.Read the manual.

133010 proto

DANGERElectrocutionhazard.Hazardous voltagewill result in deathor serious injury.

133009 proto

Lockout/tagoutbefore servicingthe machine.

DANGERElectrocutionhazard.Hazardous voltagewill result in deathor serious injury.

133009 proto

Lockout/tagoutbefore servicingthe machine.

DANGERElectrocution hazard.Contact with liveelectrical components/conductors will resultin death or seriousinjury.

Stay clear.

133006 B

Crushing hazard.

Lowering the leveling jack ontoa person's foot can result inserious injury.

133007 proto

WARNING

Keep clear of the leveling jackbefore lowering.

WARNING

97666 B

Improper operation ormaintenance can result inserious injury or death.

Read and understandoperator's manual and allsafety signs before usingor maintaining machine.

If you do not understandthe information in themanuals, consult yoursupervisor, the owner orthe manufacturer.

Burn HazardFuel and fumescan explodeand burn.

No smoking. Noflame. Stopengine.

114258 A

DANGER

WARNING

97666 B

Improper operation ormaintenance can result inserious injury or death.

Read and understandoperator's manual and allsafety signs before usingor maintaining machine.

If you do not understandthe information in themanuals, consult yoursupervisor, the owner orthe manufacturer.

Burn HazardFuel and fumescan explodeand burn.

No smoking. Noflame. Stopengine.

114258 A

DANGER


Part No. 140435 T180 • T240 7

General Safety

Safety Signs and Locations (Symbol Decals)

133053 A

133054 A

82487 C

133052 A

114251 A

82481 B

82475 D

133055 A

130059 A

114251 A

82487 C

EMERGENCYSTOP


8 T180 • T240 Part No. 140435

Operation Safety

Personal SafetyOperators must comply with employer, job site andgovernmental rules regarding the use of personalprotective equipment.

Use protective clothing and safety equipment suchas gloves, safety boots, safety hard hat, goggles,ear protection, and dust mask when necessary.Wear protective clothing that is snug and beltedwhere required.

Electrocution HazardsThis equipment contains high voltage circuits.Contact with high voltage will result in death orserious injury. Exercise extreme caution aroundany electrical component while operating this unit.

Always ground the unitaccording to local codes. Agrounding lug is provided foryour convenience. Impropergrounding can result in death orserious injury.

Beware of cut or damaged powercords and cables. Have aqualified electrician replace anydamaged cords or cablesimmediately.

Do not apply voltage to a terminal that is outsidethe range specified for that terminal.

Do not operate with covers or panel removed.

Extreme caution must be taken when operating theunit in wet or damp conditions.

Explosion and Fire HazardsExplosion or fire can cause severe personal injuryor machine damage.

Prevent fires by keeping the generator and itssurrounding area clean.

Do not place flammable objects near the generator.

Always have a fire extinguishernearby. Be sure that theextinguisher is properlymaintained and be familiar withits use. Extinguishers rated ABCby the NFPA are appropriate forall applications.

Do not refuel while smoking orwhen near open flames orsparks.

Fuel is highly flammable andshould always be handled withcare.

Always stop the engine beforefueling. Fill the fuel tankoutdoors in a well ventilatedarea.

Do not use ether or other highenergy starting aids onmachines equipped with a glowplug or grid heater. Startingfluids, which contain ether, cancause an explosion that canresult in death or serious injury.Refer to the enginemanufacturer’s operatinginstructions.


Part No. 140435 T180 • T240 9

Operation Safety

Do not refuel while the engine is still hot. Allow theengine to cool down for several minutes beforerefueling.

Do not spill fuel inside the engine compartment. Iffuel has leaked, wipe it up and have the leakrepaired before the next use.

Toxic Gas and Burn HazardThe exhaust manifold, tail pipeand other parts of the engine gethot. Do not touch hot parts.

Hot exhaust can contain toxicgases like carbon monoxidethat, if inhaled, will result indeath or serious injury. Do notbreath exhaust gas.

Use protective gloves whenhandling hot parts.

Never remove the radiator capwhile the engine is running orwhile the engine is hot.

Do not use indoors unless thearea is properly ventilated or anexhaust scrubber is used.

Check the exhaust systemregularly for leaks and ensurethat the exhaust manifolds aresecure and not warped. Makesure that the machine is wellventilated.

Welding HazardDo not weld on any structuralmember. Unauthorized weldingor repair procedure can result instructural failure or personalinjury and will void the warranty.

Bodily Injury and ComponentDamage Hazards

Loose jackets, shirts, sleeves, jewelry and neckties should not be worn while working on oroperating the generator.

Never remove the fan guards while the unit isoperating. Turn the generator off before removingthe fan guards or other protective devices fromthe generator to gain temporary access formaintenance. Replace the fan guards and otherprotective devices immediately after servicing.

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

Do not shut the unit down with the main generatorcircuit breaker in the on position. Shutting the unitdown with the breaker in the on position can causedamage to the generator and/or connectedapparatus.

Do not change the position of the voltage selectorswitch while the generator is running. This willresult in immediate damage to the switch, thegenerator or the conected equipment. It may resultin serious injury to the operator.

Improper Use HazardWhen leaving the generator set unattended,secure the machine from unauthorized use.Unauthorized personnel may attempt to operatethe machine without proper instructions, creatingan unsafe condition.


10 T180 • T240 Part No. 140435

Transport and Lifting HazardBe careful when lifting. Never suspend any otherequipment from the shipping tie-downs.

Use the lifting eye for lifting the trailer (with cabinet).Make sure that the tie-downs at the bottom of thetrailer are released prior to lifting. Refer to Transportand Towing section for recommended tie-downprocedures.

Never climb on top of the cabinet.

Always use the proper trailer hitch and safetychains. Obey all local or state D.O.T. laws whentransporting the generator set.

Failure to properly secure the generator set to thetransport vehicle may result in death or seriousinjury.

Towing HazardsDriving a vehicle/trailer combination is differentfrom driving a vehicle alone. Read, understand andobey all of your tow vehicle manufacturer’srecommendations, warning and instructions beforetowing the trailer.

Increase the distance between your vehicle andthe vehicle in front of you to twice the normalfollowing distance when towing a trailer. Allowmore following distance in adverse weathercondition.

Always slow down for curves, wet roads anddown grades.

Operation Safety

Heavy winds, excessive speed, load shifting orpassing vehicles can cause the trailer to swaywhile driving. If this occurs, do not step on thebrake, speed up or turn the steering wheel.Applying the brakes or turning the steering wheelcan cause the vehicle to jackknife. Release thegas pedal and keep the steering wheel straight.

When passing other vehicles, be sure to leaveenough room for the extra length of the trailer.

Check for tire inflation. Do not over or under inflatethe tires. Tire pressure goes up while driving. Allowthe tires to cool down to get the accurate tirepressure. Refer to the trailer VIN decal for propertire inflation.

Stay clear of traffic when starting or checking theunit along the road.

Check the fuel tank, oil pan, fuel lines, oil lines anddrain plugs for leaks that would spill fuel or oil onthe road.

Check fasteners and mounting bracketsperiodically to insure that all are tight and nothing isin danger of falling off during transit.

Always use the proper trailer hitch and safetychains. Obey all local or state D.O.T. laws whentowing the generator set.

Failure to properly secure the trailer to the towingvehicle may result in death or serious injury.

Observe the posted speed limits for trailers.


Part No. 140435 T180 • T240 11

Operation Safety

Battery SafetyLead acid batteries can be dangerous. The acid inthe battery can cause severe skin and eye burns.The hydrogen gas emitted during charging canexplode if an arc or flame is present.

Burn HazardsDo not remove the vent capswhen charging the batteries.

Always wear protective clothingand eye wear when working withbatteries. If acid gets on yourskin or eyes, immediately flushunder running water and obtainmedical attention.

Do not expose the batteries or the charger to wateror rain during charging.

Explosion and Fire HazardsKeep sparks, flames and lighted tobacco awayfrom batteries. Batteries emit an explosive gas.

Do not contact the battery terminals or the cableclamps with tools that may cause sparks.

Disconnect the negative terminal of the batterywhen working on the engine or other parts toprevent accidental arcing.

Component DamageHazards

Do not use any battery charger greater than 24V tocharge the batteries.

Electrocution/Burn HazardsIf using a charger, connect thebattery charger to a grounded,AC 3-wire electrical outlet only.

Avoid electrical shock fromcontact with battery terminals.Remove all rings, watches andother jewelry.

Lifting HazardUse the appropriate number of people and properlifting techniques when lifting batteries.

Lockout After Each Use1 Select a safe parking location-firm level surface,

clear of obstruction and traffic.

2 Turn all generator breakers to the off position.

3 Allow the engine to run for 5 minutes under noload until the coolant temperature gauge readsapproximately 175°F (79.4°C) as a cool downcycle.

4 Push the Cascade controller off button to stopthe engine.

5 Move the on/off toggle switch to the off position.

5 Chock the wheels.

6 Lock the doors.


12 T180 • T240 Part No. 140435

Legend

1 Radiator fill

2 Lifting eye

3 Generator compartment

4 Three-phase door

5 Distribution panel (behind door)

6 Main control panel

7 Engine (behind door)

8 Tie-down points (generator set)

9 Tie-down points (trailer)

10 Document holder (back of door)

11 Red Emergency Stop button

12 Tongue jack

13 Battery compartment


Part No. 140435 T180 • T240 13

Legend

Main Control Panel - Cascade Controller

1 Cascade controller

2 On/off toggle switch

3 Engine voltmeter

4 Engine oil pressure gauge

5 Engine hour meter

6 Engine coolant gauge

7 Engine fuel gauge

8 Single phase breakers

9 Receptacle - 120V, 20 Amp GFI

10 Receptacle - 50 Amp, twist lock

11 Receptacle - Battery charger (optional)

12 Receptacle - Block heater (optional)

13 Emergency Stop button

14 Remote start switch

15 Shunt trip breaker

16 Control breaker

17 Voltage adjustment switch

18 Generator ammeter

19 Generator frequency meter

20 Generator voltmeter

21 Idle/run switch

22 Single phase main breaker

23 ECU fault code reader


14 T180 • T240 Part No. 140435

Legend

Main Control Panel - Cummins Controller

1 Cummins controller

2 Engine voltmeter

3 Engine oil pressure gauge

4 Engine hour meter

5 Engine coolant gauge

6 Engine fuel gauge

7 Single phase breakers

8 Receptacle - 120V, 20 Amp GFI

9 Shunt trip breaker

10 Receptacle - Battery charger (optional)

11 Receptacle - Block heater (optional)

12 Receptacle - 50 Amp, twist lock

13 Emergency Stop button

14 Remote start switch

15 Single phase main breaker

16 Control breaker

17 Voltage adjustment switch


Part No. 140435 T180 • T240 15

Distribution Panel

1 Cam-lock panel (optional)

2 Distribution panel

3 Distribution lug

4 3-Phase distribution panel diagram

5 Voltage selector switch

6 Neutral bonding bar

Legend


16 T180 • T240 Part No. 140435

Inspections




2 Always perform a pre-operationinspection.

Know and understand the pre-operationinspection before going on to the nextsection.

3 Follow setup instructions.

4 Follow operating, and transport and towinginstructions.

5 Only use the generator as it was intended.

Pre-operation InspectionFundamentals

It is the responsibility of the operator to perform apre-operation inspection and routine maintenance.

The pre-operation inspection is a visual inspectionperformed by the operator prior to each work shift.The inspection is designed to discover if anythingis apparently wrong with the generator set beforeputting it in service.

The pre-operation inspection also serves todetermine if routine maintenance procedures arerequired. Only routine maintenance items specifiedin this manual may be performed by the operator.

Refer to the list on the next page and check eachof the items.

If damage or any unauthorized variation fromfactory delivered condition is discovered, thegenerator set must be tagged and removed fromservice.

Repairs to the generator set may only be made bya qualified service technician, according to themanufacturer's specifications. After repairs arecompleted, the operator must perform apre-operation inspection again before putting thegenerator into service.

Scheduled maintenance inspections shall beperformed by qualified service technicians,according to the manufacturer's specifications.


Part No. 140435 T180 • T240 17

Inspections

Pre-operation Inspection

o Be sure that the operator’s manuals arecomplete, legible and in the storage containerlocated at the back of the control panel accessdoor.

o Be sure that all decals are legible and in place.See Inspection section.

o Check the engine fuel level.

o Check for fuel leaks.

o Check for engine oil leaks and proper oil level.Add oil if needed. See Maintenance section.

o Check for engine coolant leaks and proper levelof coolant. Add coolant if needed. SeeMaintenance section.

o Check the fuel/water separator for water in thefuel system.

Check the following components or areas fordamage, improperly installed or missing parts andunauthorized modifications:

o Electrical components, wiring andelectrical cables

o Nuts, bolts and other fasteners

Check entire generator for:

o Cracks in welds or structural components

o Excessive rust, corrosion or oxidation

o Be sure that all structural and other criticalcomponents are present and all associatedfasteners are in place and properly tightened.


18 T180 • T240 Part No. 140435

Inspection for decals with words

Determine whether the decals on your machinehave words or symbols. Use the appropriateinspection to verify that all decals are legible and inplace.

Below is a numerical list with quantities anddescription.

Inspections

Part No. Description Quantity

31788 Warning - Battery Safety 1

97666 Warning - Read the Manual 2

114258 Danger - No Smoking 2

114494 Red Stripe - 45 inches / 1.1 m 1

114498 Black Stripe - 140 inches / 3.5 m 2

133003 Cosmetic - Terex, left panel 1

133006 Danger - Electrocution Hazard 1

133007 Warning - Foot Crushing Hazard 1

133008 Instructions - Do not open3-Phase Door 1

133009 Danger - Electrocution Hazard,Lockout/Tagout 1

133010 Warning - Electrocution Hazard,Ground Unit 1

133011 Notice - Radiator Fill 1

133012 Danger - Burn/CarbonMonoxide Hazard 1


133047 Label - Number 2 Diesel Fuel 1

133058 Cosmetic - Terex, right panel 1

133059 Warning - Engine Explosion 1

133074 Cosmetic - T180 2

133105 Cosmetic - Super Quiet 2

134721 Label - Operating Instruction 1

134721 Instructions - Cascade Controller 1

134829 Instructions - Cummins Controller 1

140519 Cosmetic - T240 2

852255 Label - 3-Phase Distribution Panel 1

C52100100 Label - California Proposition 65 1

CU51A305 Label - Emegency Stop 1


Part No. 140435 T180 • T240 19

Inspections

Distribution Panel Side

Control Panel Side


20 T180 • T240 Part No. 140435


82475 Label - Foot Crushing Hazard 1

82481 Label - Battery/Charger Safety 1

82487 Label - Read the Manual 2

114251 Label - Explosion Hazard 2

114494 Red Stripe - 45 inches / 1.1 m 1

114498 Black Stripe - 140 inches / 3.5 m 2

133003 Cosmetic - Terex, left Panel 1

133047 Label - Number 2 Diesel 1

133052 Label - Electrocution Hazard,High Voltage 1

133053 Label - Electrocution Hazard,Lockout/Tagout 1

133054 Label - Electrocution Hazard,Ground Unit Properly 1

Inspections

Inspection for decals withsymbols

Determine whether the decals on your machinehave words or symbols. Use the appropriateinspection to verify that all decals are legible and inplace.

Below is a numerical list with quantities anddescription.


133055 Label - Burn / CarbonMonoxide Hazard 1

133056 Label - Engine ExplosionHazard Do Not UseEngine Starting Aid 1

133058 Cosmetic - Terex, right Panel 1

133074 Cosmetic - T180 2

133105 Cosmetic - Super Quiet 2

134721 Instruction- Cascade Controller 1

134829 Instruction- Cummins Controller 1

140519 Cosmetic - T240 2

852255 Label - 3-Phase Distribution Panel 1

CU51A305 Label - Emegency Stop 1


Part No. 140435 T180 • T240 21

Inspections

Distribution Panel Side

Control Panel Side


22 T180 • T240 Part No. 140435






Know and understand the setupinstructions before going on to the nextsection.

4 Follow the operating, transport and towinginstructions.

5 Only use the generator set as it was intended.

Setup

Fundamentals

The setup section provides instructions for settingup the generator set in the work place so it can beused safely.

It is the operator's responsibility to follow all thesafety rules and instructions in the operator'smanual.

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

• The spot where the generator set is positionedshould be relatively level.

• The location selected should be centrallylocated to the equipment requiring the loads tominimize voltage drop in the power cord.

• Locate the machine so the power cords can berouted without crossing roads and accessroutes.

• Locate the machine where the engine will getproper ventillation. Avoid locations where fumescan enter a building.

• Do not place the machine beside a building wallthat would reflect and intensify noise.


Part No. 140435 T180 • T240 23

4 Check the fuel/water separator for water in thefuel system. Drain water from the separator ifnecessary.

5 Check the fuel level in the fuel tank. Add asrequired. Make sure that the fuel tank vent isopen and not clogged.

Use number 2 diesel fuel only.

6 Verify that the generator main circuit breaker isin the off position.

7 Connect the grounding lug in the distributionpanel to a mechanical earth ground as per yourlocal electrical code.

Note: Always follow the local code for grounding.

Make sure that the generator set is properlygrounded.

The generator set produces voltages that maycause severe shock or death. Only qualifiedelectricians should perform electrical work.

Unhitching from the towing vehicle:

1 Position the generator set in the desiredlocation.

Note: If the axle is sloped downhill, turn thegenerator set so that the axle is level.

2 Chock the wheels.

3 Unhook the safety chains and running lights.

4 Pull the spring pin on the leveling jack and slidethe jack down.

5 Release the hitch pin and raise the tongue offthe towing vehicle.

6 Level the generator set with the tongue jack.

Note: The wheels must be properly chocked if thegenerator is on unlevel ground. Do not operate thegenerator set until it has been properly secured.

Preparing to start the generator set:

1 Check the coolant level in the radiator. Addcoolant if necessary. See maintenance section.

Note: If adding coolant, only use a 50/50 mixture ofantifreeze and water. Refer to your enginemanufacturer’s maintenance manual for specificantifreeze information.

2 Check the oil level in the engine crankcase. Addoil if necessary. See Maintenance section.

Note: Use class API, CC, or CD grade engine oil.Refer to the engine manufacturer’s manual forviscosity and quantity.

3 If the battery is not a maintenance free battery,check the electrolyte level. Add distilled water ifnecessary.

Setup


24 T180 • T240 Part No. 140435

Operating Instructions






4 Follow the operating, transport and towinginstructions.

Know and understand the operating,transport and towing instructionsbefore going on to the next section.

5 Only use the generator set as it was intended.

Fundamentals

The Operating Instructions section providesinstructions for the general operation of the unit.For more in-depth information on operating the unit,refer to the generator and engine manufacturer’soperating instructions.

It is the operator's responsibility to follow all thesafety rules and instructions in the operator'smanual.


Part No. 140435 T180 • T240 25


Starting the engine / generator set

1 Follow the setup procedure.

2 Make sure that the circuit breakers, located onthe control panel, are in the off position.

3 At the distribution panel side of the generatorset, locate the voltage selector switch and set itto the desired range.

4 At the control panel side, locate thetoggle switch. Switch it to the onposition.

5 Press the manual button(MAN) on the Cascadecontroller to start thegenerator.

The generator will make three attempts at startingbefore it must be reset with the switch.

Note: The installation and operations manual for theCascade CD101 auto-start controller is available atwww.fwmurphy.com.

6 Allow the generator to warm up for 5 minutesafter starting.

Listen for unusual sounds or excess vibrations thatcould signal problems and require immediateshutdown of the unit. If unusual sounds aredetected, shut the unit down and contact TerexSevice at 1-800-433-3026.

7 Once the engine is running smoothly, monitorthe gauges as stated in the table below.

Oil Pressure equal to or greater than 30 psi

Coolant Temperature 170-225 °F / 77-93 °C

DC Voltmeter 13-15 volts(indicates that the diesel engine’s alternator is charging)

AC Voltmeter reflects the proper voltageselected

Refer to potentiometer (Voltage Adjustment ) on page 27.

AC Ammeter 0 (main breaker in off position)Note: The ammeter will register the appropriate readingonce a load is applied to the generator.

Never change the position of the voltageselector switch while the generator is running. Thiswill result in immediate damage to the switch, thegenerator, or the connected equipment. It mayresult in serious injury to the operator.

Loading instructions

1 Shut down the generator set.

2 Press the off button on the Cascade controlpanel. Move the on/off toggle switch to the offposition.

3 Connect the desired electrical apparatus to thegenerator set.

4 Restart the engine and monitor the gauges astabulated in step 7 in starting the generator seton this page.

5 Turn the required circuit breakers to the onposition.

6 Monitor the AC ammeter. If the needle deflectsseverely to the right and stays there,immediately turn the required generator circuitbreakers to the off position.

Note: Severe deflection of the ammeter indicates awiring problem or an overload problem. Continuedoperation under this condition will cause damageto the generator and/or connected apparatus.

The needle on the ammeter will deflect to the righttemporarily and then return to a normal reading ifthe unit is operating properly.


26 T180 • T240 Part No. 140435

Voltage Selector Switch Operation

The voltage selector switch can affect the single-phase receptacles provided on the unit. Theindicated voltages should be checked afterselecting the setting of the switch. The Y voltageconfiguration of 480 and 240 will produce a voltageof 139 on the GFI receptacles.

This generator set produces voltages that cancause severe shock or death. Only qualifiedelectricians should perform electrical work.Exercise extreme caution around any electricalcomponent when operating this unit.

Never operate the voltage selector switch whilethe generator is running. This will result inimmediate damage to the switch, the generator orthe connected equipment and may result in seriousinjury to the operator.

Note: Always make sure that the voltage selectorswitch has been set to the desired range beforestarting the generator set.

The voltage selector switch for all the generatorshas three positions marked 480 / 277 - 3 phase,240 / 139 - 3 phase, and 240 / 120 - 1 phase. Eachposition gives a different output to the three-phasedistribution lugs (designated as L1, L2, L3 and N)located on the distribution panel.

480 / 277, 3 - phase position Output(Hi Wye configuration)

Line - to - Line 480 VAC / 3P(L1 to L2,/ L2 to L3 / L1 to L3)

Line - to - Neutral 277 VAC / 1P(L1, L2 or L3 to N)

240 / 139, 3 - phase position(Lo Wye configuration) Output

Line - to - Line 240 VAC / 3P(L1 to L2,/ L2 to L3 / L1 to L3)

Line - to - Neutral 139 VAC / 1P(L1, L2 or L3 to N)

240 single phase(Zig Zag configuration - L2 not used) Output

Line - to - Line (L1 to L3) 240 VAC / 1P

Line - to - Neutral (L1 or L3 to N) 120 VAC 1P

Note: The Hi Wye and the Lo Wye configurationscan be adjusted by using the voltage adjustment.

Once the required voltages are known, thecombination of the proper switch position andvoltage adjustment potentiometer allows for finetuning the voltage to the exact needs of theapplication.

When the proper voltage selector switch position isselected, lock the switch in that position. Thisprevents the switch from being moved while theunit is operating or by unauthorized personnel.Damage to the unit and any connected equipmentwill be avoided.



Part No. 140435 T180 • T240 27

Overcurrent Protection

The overcurrent protection relay is mounted behindthe control panel. It monitors the current draw toprotect the generator set. The trip setting is set atthe factory with the proper kW using a loadbank.

Note: Do not change the setting. Generator failurecan occur. Call Terex Service for wiring andtrouble shooting information.

Shut down Procedures

Never shut the unit down while under load. Thismay cause serious injuries to the operator ordamage the generator.

Never shut the unit down with the maingenerator circuit breaker in the on position. Thiscan cause damage to the generator and/or theconnected apparatus.

1 Turn all generator breakers to the off position.

2 Allow the engine to run for 5 minutes under noload until the coolant temperature gauge readsapproximately 175°F (79.4°C) as a cool downcycle.

3 Push the Cascade controller off button to stopthe engine.

4 Move the on/off toggle switch to the off position.

5 Lock the doors.


Do not operate the unit unless the voltage hasbeen checked at the receptacles. If you have anyquestions, call Terex Service at 1-800-433-3026.

Installation and any work performed on this unitshould be done only by a qualified electrician.

Potentiometer (Voltage adjustment)

The potentiometer is set at the factory. However, ifthe voltage reading on the voltmeter is not asdesired, follow the procedure below to make thenecessary adjustments.

1 With the unit running under no load, observe theAC voltmeter.

2 Locate the voltage adjustment knob on thecontrol panel. To increase the voltage, turn theknob to the right. To decrease the voltage, turnthe knob to the left.

3 Slowly turn the adjustment knob in the desireddirection while observing the AC voltage meter.

4 Stop when the desired voltage is reached.

The unit is now ready to load. If the desired voltagecannot be reached, contact the Terex ServiceDepartment at 1-800-433-3026.

For more information, refer to the Murphy CascadeController Installation and Operations Manual p/n00-02-0594 (Terex part number 833011) suppliedwith the unit for configuration and operation.


28 T180 • T240 Part No. 140435

Transport Instructions

Observe and Obey:Terex Corporation provides this securementinformation as a recommendation. Drivers aresolely responsible for making sure that thegenerator set is properly secured and thecorrect trailer is selected pursuant to USDepartment of Transportation regulations, otherlocalized regulations and company policy.

Terex customers needing to containerize anyTerex product should source a qualified freightforwarder with expertise in preparing, loadingand securing Terex equipment for internationalshipment.

The transport vehicle must be parked on a levelsurface.

The transport vehicle must be secured toprevent rolling while the equipment is beingloaded.

Be sure the vehicle capacity, loading surfacesand chains or straps are sufficient to withstandthe unit weight. See Specifications section forunit weight.

Securing to truck or trailer fortransit

1 Close, latch and lock all doors.

2 Level the unit.

3 Inspect the entire machine for loose andunsecured items.

4 Place a chock on both sides of each axlebehind the wheels. Use the four tie-down pointson the machine for anchoring down to thetransport surface.

5 Use chain or straps of ample load capacity.

6 Adjust the rigging to prevent damage to thechains.


Part No. 140435 T180 • T240 29

Transport Instructions

Tie-down configuration, with trailer Tie-down configuration, no trailer

Tie-down configuration for all models


30 T180 • T240 Part No. 140435

Observe and Obey:Only qualified riggers should rig and lift themachine

Be sure the crane capacity, loading surfacesand straps or lines are sufficient to withstandthe machine weight. See Specifications sectionfor unit weight.

Lifting

1 Close, latch and lock all doors.

2 Inspect the entire machine for loose orunsecured items.

3 Use the lifting eye mounted on the top to lift themachine.

Note: Make sure that tie-downs at the bottom ofthe trailer or cabinet are released prior to lifting.

Lifting Instructions

Lifting configuration


Part No. 140435 T180 • T240 31

Towing Instructions

All trailer-mounted Terex generator sets aredesigned for highway and off the road towingcapabilites. Consult state and local transportationcodes before transporting the generator set.Additionally, all state and local traffic laws takeprecedence over the following instructionswhenever differences arise between them.

Note: Make sure the towing vehicle is of adequatesize to both tow and stop the unit.

1 Disconnect all wiring and cabling (including theground wire) from the generator set.

2 Close, latch and lock all access doors.

3 With the leveling jack, raise the trailer hitch to anadequate height so that the generator can besecurely attached to the towing vehicle.

4 Secure the coupler to the vehicle and attach thesafety chains. Attach the “breakaway” chain onthe surge brake and the electrical coupler(if equipped).

Always use the proper trailer hitch and safetychains. Obey all local or state D.O.T. laws whentowing a generator.

Failure to properly secure the trailer to thetowing vehicle may result in death or serious injury.

5 Retract the front leveling jack into its stowedposition.

6 Check the tires for proper inflation and verify lugnuts are tight. See Maintenance section.

7 If equipped with towing light, connect theelectrical coupler to the towing vehicle.

8 Inspect all connections at each stop.

Observe the posted speed limits for trailer.Generally, do not exceed 60 mph on paved roadsand 10 mph on unpaved roads.

Note: Exceeding these recommended speeds cancause severe damage to the unit. Damage causedby these unsafe practices will void themanufacturer’s warranty.

Observe and Obey:

Hitching

Make sure that the hitch is sufficient to tow thegenerator set.

Make sure that the hitch is properly attached tothe tow vehicle.

Make sure that the safety chains are properlyattached.

Inspect the tires and make sure that all tires areproperly inflated. Refer to the trailer VIN decalfor proper cold tire inflation.

Make sure that all lights are connected andworking.

Towing

Do not exceed 60 mph / 97 km/h.

Check connections and tire pressure at eachstop.

Slow down for hazardous conditions.

Allow extra distance for following and passingother vehicles.


32 T180 • T240 Part No. 140435

Towing Information

Use the checklist provided on the back cover ofthis manual before towing and while on the road.

Inspect all connections at each stop.

Driving a vehicle/trailer combination isdifferent from driving a vehicle alone.

All tires must be properly inflated. Find therecommended cold tire pressure on the tiresidewall or trailer VIN decal. Do not overinflate thetires. Tire pressures go up during driving. Checkingthe tire pressure when the tires are warm will giveyou an inaccurate pressure and reading.

Increase the distance between your vehicle and thevehicle in front of you to twice the normal followingdistance when towing a trailer. Allow more followingdistance in adverse weather.

Slow down for downgrades and shift yourtransmission into a lower gear.

Slow down for curves, hazardous road conditions,freeway exits, and when driving in adverseweather.

Heavy winds, excessive speed, load shifting orpassing vehicles can cause the trailer to swaywhile driving. If this occurs, do not brake, speed upor turn the steering wheel. Turning the steeringwheel or applying the brakes can cause the vehicleand trailer to jackknife. Let up on the gas pedal andkeep the steering wheel straight.

If the vehicle and/or trailer travels off the pavedroad, hold the steering wheel firmly and let up onthe gas pedal. Do not apply the brakes. Do not turnsharply. Slow down to under 25 mph /40 km/h. Gradually turn the steering wheel to getback on the road. Proceed with caution whenentering traffic.

Towing Instructions

When passing other vehicles, be sure to leaveenough room for the extra length of the trailer. Youwill need to go much farther beyond the passedvehicle before you can return to your lane.

Avoid sudden movements when turning.


Part No. 140435 T180 • T240 33

Maintenance

Observe and Obey:Only routine maintenance items specified in thismanual shall be performed by the operator.

Scheduled maintenance inspections shall becompleted by qualified service technicians,according to the manufacturer's specifications.

Use only Terex approved replacement parts.

Maintenance Symbols Legend

The following symbols have been used in thismanual to help communicate the intent of theinstructions. When one or more of the symbolsappear at the beginning of a maintenanceprocedure, it conveys the meaning below.

Indicates that new parts will be required toperform this procedure.

Indicates that a cold engine is requiredbefore performing this procedure.


34 T180 • T240 Part No. 140435

Check the Batteries

Proper battery condition is essential to good engineperformance and operational safety. Improper fluidlevels or damaged cables and connections canresult in engine component damage and hazardousconditions.

Electrocution/burn hazard. Contact with hot orlive circuits may result in death or serious injury.Remove all rings, watches and other jewelry.

Bodily injury hazard. Batteries contain acid.Avoid spilling or contacting battery acid. Neutralizebattery acid spills with baking soda and water.

1 Put on protective clothing and eye wear.

2 Be sure that the battery cable connections aretight and free of corrosion.

3 Be sure that the battery hold-down bracket is inplace and secure.

4 Remove the battery vent caps.

5 Check the battery acid level. If needed, replenishwith distilled water to the bottom of the batteryfill tube. Do not overfill.

6 Install the vent caps.

Note: Adding terminal protectors and a corrosionpreventative sealant will help eliminate corrosionon the battery terminals and cables.

Check the Engine Oil Level

Maintaining the proper engine oil level is essentialto good engine performance and service life.Operating the machine with an improper oil levelcan damage engine components.

Note: Check the oil level with the engine off.

1 Check the oil dipstick. Add oil as needed.

Refer to the engine manufacturer’s operatinginstructions manual for more information regardingengine oil recommendations.

Check the Engine Coolant Level

Maintaining the engine coolant at the proper level isessential to engine service life. Improper coolantlevel will affect the engine's cooling capability anddamage engine components. Daily checks willallow the inspector to identify changes in coolantlevel that might indicate cooling system problems.

Burn hazard. Beware of hot engine parts andcoolant. Contact with hot engine parts and/orcoolant may cause severe burns.

Adding coolant to a hot engine can damagethe casting. Allow the engine to cool down to below120°F (50°C) before adding the coolant.

1 Allow the engine to cool down to below 120°F(50°C).

2 Open the radiator cap.

3 Visually check the coolant level. Add fluid asneeded.

Result:The fluid level should be at the bottom ofthe fill neck.

The engine manufacturer recommends using a 50/50 mixture of good quality water and fullyformulated antifreeze.

Antifreeze type must meet TMC 329 orTMC RP 330

Refer to the engine manufacturer’s operatinginstructions manual for more information.

Maintenance


Part No. 140435 T180 • T240 35

Maintenance

Scheduled MaintenanceScheduled maintenance must be completed by aperson trained and qualified to performmaintenance on this generator set according to theschedule and procedures found in the servicemanual for this unit.

The proper installation and use of a loadbank canprevent loss of capacity and increasedmaintenance caused by unburned fuel due to wetstacking.

If you have a generator set that is already wetstacked, it is recommended that the load bank beused in progressive steps outlined below.

1 Assure that the generator set is properlygrounded and connected to the load bank asinstructed by the manufacturer.

2 Set the generator at 240 VAC, 3-Phase.

3 Start using less than 25% of the nameplaterating until the engine has warmed up.

4 Progressively increase the load as the generatorwill allow without shutting down.

5 Continue to run for 20 minutes per step.

6 When you reach 80% of the nameplate rating,run the generator for a minimum of 45 minutesor until the exhaust on the unit runs clean.

7 Allow the machine to fully cool down.

8 Start the unit again.

9 Load at 80% for an additional 30 minutes.

A full engine service is recommended after thistype of wetstack burns off.

Check the Tires and Wheels

Bodily injury hazard. An over-inflated tire canexplode and may cause death or serious injury.

Collision hazard. An excessively worn tire cancause poor handling and continued use could resultin tire failure.

Tip-over hazard. Do not use temporary flat tirerepair products.

Maintaining the tires and wheels in good conditionis essential to safe operation and goodperformance. Tire and/or wheel failure could resultin a machine tip-over. Component damage mayalso result if problems are not discovered andrepaired in a timely fashion.

1 Check the tire surface and sidewalls for cuts,cracks, punctures and uneven or excessivetread wear. Replace the tire if uneven orexcessive tread wear is found.

2 Check each wheel for damage, bends andcracks. Replace the wheel if any damage isfound.

Note: Tires and wheels must be replaced with tiresand wheels of the specifications listed.

3 Check each tire with an air pressure gauge andadd air as needed.

4 Check the torque of each lug nut.

Tire Specifications, U.S.

Tire sizeT180 & T240 ST235/85R16 Load E

Lug nut torque 80 ft/lbs 108 Nm

Tire pressure (cold) 50 psi 3.4 bar


36 T180 • T240 Part No. 140435

Continuous improvement of our products is a Terexpolicy. Product specifications are subject to changewithout notice or obligation.

Specifications

T180 Specifications

System power output

Prime 3 phase power 145 kW

Prime 3 phase kVA 181 kVA

Available 3 phase voltage 208 / 220 / 240 / 440 / 480

Associated 3 phase amps 502 / 475 / 435 / 238 / 218(0.8 power factor)



Available 1 phase voltage 120 / 240

Associated 1 phase amps 816 / 408(1.0 power factor)

Max amp rating (main breaker size) 600 A

Engine specifications

Manufacturer Cummins

Model QSB7-G3

Horsepower - prime (1,800 rpm) 217 hp / 162 kWm

Description 6 cylinder, 4 cycle, water cooled,OHV, in-line, direct injection

Bore & stroke 4.21 x 4.88 in. / 107 x 124 mm

Piston displacement 409 in3 / 6.7 L

Compression ratio 17.3 : 1

Exhaust system Critical grade silencer

Monitoring gauges oil pressure, water temperature,fuel level, battery voltage, hours

Coolant capacity - engine only 10.6 qts / 10 L

Cooling system liquid cooled -air to air charge air cooler rated

to 120° F (49° C) ambient

Fuel system

Specification #2 diesel

Filter fuel / water separator

Capacity 255 gal / 901 L

Tank and containment internal fuel tank with 110%fluid spill containment

Fuel consumption (run time)

Full load 11.2 gal per hr / 42 L per hr 22.7 hr

¾ load 8.6 gal per hr / 32 L per hr 30 hr

Half load 6.2 gal per hr / 23 L per hr 41 hr

System Controls and Distribution

Engine governor ECM controlled

Protection low oil pressure, high water temp.,(safety shutdowns) overcrank, overspeed, underspeed

voltmeter, ammeter & hertz meter

Generator gauges voltmeter, ammeter,dial type Hz meter

Receptacles, 120V 2 each 20 Amp GFCI Duplex

Receptacles, 240V 3 each 50 Amp Tempower T/L

Primary distribution 5 lug terminals with mainline circuit breaker

Generator specifications

Manufacturer Newage

Model UCI274F

Rating 165 kW 3 Phase @ 480 / 240 V(0.8 power factor)

Description brushless, 4 pole, synchronous, single bearing

Insulation Class H

Temperature rating 125° C rise over 40° C ambient257° F rise over 104° F ambient

Automatic voltage regulator external, solid state,adjustable

Voltage regulation +/- 1%

Frequency (speed) 60 Hz / 1,800 RPM


Part No. 140435 T180 • T240 37

Specifications

Packaging

Enclosure sound attenuated, weatherproof with lockable doors

Sound level 68 dBA at 23 ft / 7 metersprime load

Lifting system roof mounted, single point

Weight (no trailer) empty 5,904 lbs / 2,678 kg full 7,587 lbs / 3,441 kg

Dimensions - L x W x H 146 x 57 x 67 in(no trailer) 370 x 145 x 170 cm

Weight (with trailer) empty 7,615 lbs / 3,454 kg full 9,298 lbs / 4,217 kg

Dimensions - L x W x H 226 x 84.2 x 88.4 in(with trailer) 576 x 214 x 224 cm


38 T180 • T240 Part No. 140435

Continuous improvement of our products is a Terexpolicy. Product specifications are subject to changewithout notice or obligation.

Specifications

T240 Specifications

System power output



Available 3 phase voltage 208 / 220 / 240 / 440 / 480

Associated 3 phase amps 658 / 622 / 570 / 311 / 285(0.8 power factor)



Available 1 phase voltage 120 / 240

Associated 1 phase amps 1008 / 504(1.0 power factor)

Max amp rating (main breaker size) 800 A

Engine specifications

Manufacturer Cummins

Model QSB7-G5

Horsepower - prime (1,800 rpm) 286 hp / 215 kWm

Description 6 cylinder, 4 cycle, water cooled,OHV, in-line, direct injection

Bore & stroke 4.21 x 4.88 in. / 107 x 124 mm

Piston displacement 409 in3 / 6.7 L

Compression ratio 17.3 : 1

Exhaust system Critical grade silencer

Monitoring gauges oil pressure, water temperature,fuel level, battery voltage, hours

Coolant capacity - engine only 10.6 qts / 10 L

Cooling system liquid cooled -air to air charge air cooler rated

to 120° F (49° C) ambient

Fuel system

Specification #2 diesel

Filter fuel / water separator

Capacity 255 gal / 901 L

Tank and containment internal fuel tank with 110%fluid spill containment

Fuel consumption (run time)

Full load 13.3 gal per hr / 50.3 L per hr 19.1 hr

¾ load 10.6 gal per hr / 40.1 L per hr 24 hr

Half load 7.8 gal per hr / 29.5 L per hr 32 hr

System Controls and Distribution

Engine governor ECM controlled

Protection low oil pressure, high water temp.,(safety shutdowns) overcrank, overspeed, underspeed

voltmeter, ammeter & hertz meter

Generator gauges voltmeter, ammeter,dial type Hz meter

Receptacles, 120V 2 each 20 Amp GFCI Duplex

Receptacles, 240V 3 each 50 Amp Tempower T/L

Primary distribution 5 lug terminals with mainline circuit breaker

Generator specifications

Manufacturer Newage

Model UCDI274J

Rating 240 kW 3 Phase @ 480 / 240 V(0.8 power factor)

Description brushless, 4 pole, synchronous, single bearing

Insulation Class H

Temperature rating 125° C rise over 40° C ambient257° F rise over 104° F ambient

Automatic voltage regulator external, solid state,adjustable

Voltage regulation +/- 1%

Frequency (speed) 60 Hz / 1,800 RPM


Part No. 140435 T180 • T240 39

Packaging

Enclosure sound attenuated, weatherproof with lockable doors

Sound level 68 dBA at 23 ft / 7 metersprime load

Lifting system roof mounted, single point

Weight (no trailer) empty 6,345 lbs / 2,878 kg full 8,028 lbs / 3,641 kg

Dimensions - L x W x H 146 x 57 x 67 in(no trailer) 370 x 145 x 170 cm

Weight (with trailer) empty 8,056 lbs / 3,654 kg full 9,739 lbs / 4,418 kg

Dimensions - L x W x H 226 x 84.2 x 88.4 in(with trailer) 576 x 214 x 224 cm


40 T180 • T240 Part No. 140435

Serial Number Registration

Terex Model Number : ______________________Serial Number : ____________________________

Engine Model Number: ______________________Engine Serial Number: ______________________

Generator Model Number: ___________________Generator Serial Number: ___________________

Owner : __________________________________

Options: __________________________________

_________________________________________

_________________________________________

_________________________________________

Receipt of Delivery Checklist

The generator will be serviced, tested and ready foroperation upon delivery. Terex recommends thefollowing checks upon delivery.

o Insure there is no freight handling damage. Anyfreight damaged should be charged against thecarrier.

o Check the front jack for security and properoperation.

o Check the tires for damage, proper inflation orloosened lug nuts.

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

o Check the control panel for damage or looseconnections.

o Check the exhaust system for damage.

o Check all fluid levels; battery, radiator, andengine oils.

o Ensure the manuals are in the pocket providedinside the unit.

Dis

trib

ute

d B

y:

Genie North AmericaPhone 425.881.1800

Toll Free USA and Canada

800.536.1800

Fax 425.883.3475

Genie Australia Pty Ltd.Phone +61 7 3375 1660

Fax +61 7 3375 1002

Genie ChinaPhone +86 21 53852570

Fax +86 21 53852569

Genie MalaysiaPhone +65 98 480 775

Fax +65 67 533 544

Genie JapanPhone +81 3 3453 6082

Fax +81 3 3453 6083

Genie KoreaPhone +82 25 587 267

Fax +82 25 583 910

Genie BrasilPhone +55 11 41 665 755

Fax +55 11 41 665 754

Genie HollandPhone +31 183 581 102

Fax +31 183 581 566

Genie ScandinaviaPhone +46 31 575100

Fax +46 31 579020

Genie FrancePhone +33 (0)2 37 26 09 99

Fax +33 (0)2 37 26 09 98

Genie IbericaPhone +34 93 579 5042

Fax +34 93 579 5059

Genie GermanyPhone +49 (0)4202 88520

Fax +49 (0)4202 8852-20

Genie U.K.Phone +44 (0)1476 584333

Fax +44 (0)1476 584334

Genie Mexico CityPhone +52 55 5666 5242

Fax +52 55 5666 3241

Before Driving

On The Road

Before Towing ·

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

· All lights are connected and working

· Tires are properly inflated

· Fasten safety restraints

· Properly adjust mirrors

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

· Check connections and tire pressure at each stop

· Slow down for hazardous conditions

· Allow extra distance for following and passing other vehicles

Towing hitch is properly secured to tow vehicle

Towing Checklist(Use at each stop)

California Proposition 65

WarningThe exhaust from this product

contains chemicals known to

the State of California to

cause cancer, birth defects

or other reproductive harm.

California Proposition 65

WarningBattery post terminals and related

accessories contain lead compounds,

chemicals known to the State of

California to cause cancer

and other reproductive harm.

operator's manual first edition • first...

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