Terex T180, T240 Operator's Manual
Operator's Manual First Edition • First Printing
Important
Read, understand and obey these safety rules and
operating instructions before operating this
machine.
Only trained and authorized personnel shall be
permitted to operate this machine. This manual
should be considered a permanent part of your
machine and should remain with the machine at all
times. If you have any questions, call Terex.
Contents
Page
Introduction ...........................................................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:
Copyright © 2009 by Terex
Internet: www.terex.com
Terex Light Construction Division
590 Huey Road
Rock Hill, SC 29730
First Edition: First Printing, June 2009
Printed on recycled paper
Printed in U.S.A.
T180 • T240 Part No. 140435
First Edition • First Printing
Operator's Manual
Introduction
Description of equipment
The engine/generator assembly consists of a diesel
engine combined with an electrical generator. This
assembly is firmly bolted together to form an
integral unit and does not require anything other
than routine maintenance.
The engine is equipped with a 12-volt starter and
can be wired for remote starting capability at the
control panel.
A dry-element air cleaner is standard equipment to
ensure a clean air supply, and a fuel/water
separator is included for additional fuel system
protection.
A governor on the engine provides a stable
operating speed under varying load conditions.
The generator is equipped with a solid-state
voltage regulator to stabilize the output voltage
under these same conditions. Figures and
schematics of both the governor and regulator are
provided in the service manual.
An automatic shut down system is incorporated in
the generator set to sense low oil pressure and/or
high coolant temperature. In either case, the
engine/generator assembly will automatically shut
down to protect the engine.
The enclosure for the generator set is constructed
from 12 or 14-gauge sheet metal to ensure rigidity,
and is bolted together to allow easy access to
major components if necessary. Four lockable
hinged access doors are provided for routine
operation and maintenance.
The enclosure on the Super Quiet Generator is
specifically designed for a high degree of sound
attenuation. This allows the generator set to be
operated in noise-sensitive environments. The
interior of the enclosure is coated with sounddampening polymer foam that is highly effective in
noise suppression.
A high ambient temperature radiator and an integral
exhaust and muffler system are contained within
the enclosure as standard equipment.
A center-point lifting attachment is located on top
of the enclosure to allow crane lifting of the entire
unit.
The generator set can be mounted on a trailer
equipped for highway operation which is available
as an option. Standard trailers do not come
equipped with brakes but hydraulic surge brakes or
electric brakes are available as an option.
A diesel fuel tank is incorporated within the base of
the unit to ensure an uninterrupted operating cycle
under a full load. The engine/generator assembly is
mounted to the base using high durometer
vibration isolators.
Part No. 140435 T180 • T240 1
Operator's Manual First Edition • First Printing
Introduction
Owners, Users and Operators:
Terex appreciates your choice of our generator for
your application. Our number one priority is user
safety, which is best achieved by our joint efforts.
We feel that you make a major contribution to
safety if you, as the generator users and operators:
1 Comply with employer, job site and
governmental rules.
Danger
Failure to obey the instructions and
2 Read, understand and follow the instructions
in this and other manuals supplied with this
generator.
3 Use good safe work practices in a
commonsense way.
safety rules in this manual will result
in death or serious injury.
Do Not Operate Unless:
4 Only have trained/certified operators,
directed by informed and knowledgeable
supervision, operating the generator.
You learn and practice the principles of safe
generator operation contained in this operator's
manual.
If there is anything in this manual that is not clear
or which you believe should be added, please send
your comments to the Terex Service Department.
www.terex.com
1 Avoid hazardous situations.
Know and understand the general safety
rules 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 the
manufacturer's instructions and safety rules —
safety and operator's manuals, and decals.
You read, understand and obey employer's
safety rules and all applicable governmental
regulations.
You are properly trained to safely operate the
generator.
2 T180 • T240 Part No. 140435
First Edition • First Printing
Operator's Manual
Introduction
Hazard Classification
Terex uses symbols, color coding and signal words
to identify the following:
Safety alert symbol—used to alert
you to potential personal injury
hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Indicates a hazardous situation
which, if not avoided, will result in
Red
Orange
Yellow
Blue
death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in death or serious injury.
Indicates a hazardous situation
which, if not avoided, could result
in minor or moderate injury.
Indicates a property damage
message.
Intended Use
This generator set is intended to be used only to
supply 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 mild
soap and water to clean safety signs. Do not use
solvent-based cleaners because they may damage
the safety sign material.
Part No. 140435 T180 • T240 3
Operator's Manual First Edition • First Printing
Symbol and Hazard Pictorials Definitions
Read the
operator’s
manual
Burn Hazard
Do not touch. Allow
surface to cool
Carbon Monoxide
Poisoning Hazard
Wear protective
clothing and eye wear
Electrocution Hazard
Hazardous voltage
Crushing Hazard
Lock out/tag out Earth ground
No smokingNo open flames
Keep clear of
leveling jack
Stop the engine
Fire extinguisher
Stay clear
Check for damaged
cords
Coolant in radiator
should not be more
than 50% antifreeze
4 T180 • T240 Part No. 140435
Engine explosion
Do not use ether or any
high energy engine
starting aids
Unauthorized welding
First Edition • First Printing
Burn Hazard. Fuel
and fumes can
explode and burn.
Symbol and Hazard Pictorials Definitions
Explosion Hazard
Burn Hazard
Operator's Manual
Flames and Sparks
Hazard
Part No. 140435 T180 • T240 5
Operator's Manual First Edition • First Printing
General Safety
Safety Signs and Locations (Word Decals)
DANGER
DANGER
Burn Hazard
No smoking. No
Fuel and fumes
flame. Stop
can explode
engine.
and burn.
WARNING
Crushing hazard.
Lowering the leveling jack onto
a person's foot can result in
serious injury.
Keep clear of the leveling jack
before lowering.
133007 proto
DANGER
Explosion / Burn Hazard
Ignition of explosive gases or contact with corrosive
acid will cause death, burns or blindness
Keep all open flames and sparks away. Wear
personal protective equipment, including face
shield, gloves and long sleeve shirt.
READ MANUALS
Read all manuals prior to operation.
DO NOT OPERATE equipment if you do not
understand the information in the manuals.
Consult your supervisor, the owner or the
manufacturer.
WARNING
Electrocution hazard.
Contact with live
electrical components/
conductors will result
in death or serious
injury.
Stay clear.
114258 A
WARNING
Read and understand
Improper operation or
operator's manual and all
maintenance can result in
safety signs before using
serious injury or death.
or maintaining machine.
If you do not understand
the information in the
manuals, consult your
supervisor, the owner or
the manufacturer.
97666 B
133006 B
DANGER
Electrocution
hazard.
Hazardous voltage
will result in death
or serious injury.
Lockout/tagout
before servicing
the machine.
133009 proto
WARNING
Electrocution
hazard.
Improper grounding
may result in death
or serious injury
Ground unit properly.
Always comply with
local electrical codes.
Read the manual.
133010 proto
DANGER
31788 C
Burn Hazard
Fuel and fumes
can explode
and burn.
No smoking. No
flame. Stop
engine.
114258 A
Read and understand
Improper operation or
operator's manual and all
maintenance can result in
safety signs before using
serious injury or death.
or maintaining machine.
If you do not understand
the information in the
manuals, consult your
supervisor, the owner or
the manufacturer.
97666 B
DANGER
Electrocution
hazard.
Hazardous voltage
will result in death
or serious injury.
Lockout/tagout
before servicing
the machine.
133009 proto
EMERGENCY
STOP
6 T180 • T240 Part No. 140435
WARNING
Explosion Hazard
Death or serious injury can
result from the use of ether or
other high energy starting
aids.
Do not use ether or
other high energy
starting aids on
machines equipped
with glow plugs or
grid heater.
133059 A
DANGER
Burn / Carbon
monoxide hazard.
Hot exhaust can contain
carbon monoxide that
will result in death or
serious injury.
Do not touch hot surfaces
or breathe exhaust.
W ear protective gloves
when handling hot parts.
Read the operator's m anual.
133012 A
First Edition • First Printing
Safety Signs and Locations (Symbol Decals)
133052 A
114251 A
Operator's Manual
General Safety
82487 C
133054 A
82481 B
EMERGENCY
STOP
82475 D
133053 A
114251 A
82487 C
130059 A
Part No. 140435 T180 • T240 7
133055 A
Operator's Manual First Edition • First Printing
Operation Safety
Personal Safety
Operators must comply with employer, job site and
governmental rules regarding the use of personal
protective equipment.
Use protective clothing and safety equipment such
as gloves, safety boots, safety hard hat, goggles,
ear protection, and dust mask when necessary.
Wear protective clothing that is snug and belted
where required.
Electrocution Hazards
This equipment contains high voltage circuits.
Contact with high voltage will result in death or
serious injury. Exercise extreme caution around
any electrical component while operating this unit.
Always ground the unit
according to local codes. A
grounding lug is provided for
your convenience. Improper
grounding can result in death or
serious injury.
Beware of cut or damaged power
cords and cables. Have a
qualified electrician replace any
damaged cords or cables
immediately.
Do not apply voltage to a terminal that is outside
the range specified for that terminal.
Do not operate with covers or panel removed.
Extreme caution must be taken when operating the
unit in wet or damp conditions.
Explosion and Fire Hazards
Explosion or fire can cause severe personal injury
or machine damage.
Prevent fires by keeping the generator and its
surrounding area clean.
Do not place flammable objects near the generator.
Always have a fire extinguisher
nearby. Be sure that the
extinguisher is properly
maintained and be familiar with
its use. Extinguishers rated ABC
by the NFPA are appropriate for
all applications.
Do not refuel while smoking or
when near open flames or
sparks.
Fuel is highly flammable and
should always be handled with
care.
Always stop the engine before
fueling. Fill the fuel tank
outdoors in a well ventilated
area.
Do not use ether or other high
energy starting aids on
machines equipped with a glow
plug or grid heater. Starting
fluids, which contain ether, can
cause an explosion that can
result in death or serious injury.
Refer to the engine
manufacturer’s operating
instructions.
8 T180 • T240 Part No. 140435
First Edition • First Printing
Operator's Manual
Operation Safety
Do not refuel while the engine is still hot. Allow the
engine to cool down for several minutes before
refueling.
Do not spill fuel inside the engine compartment. If
fuel has leaked, wipe it up and have the leak
repaired before the next use.
Toxic Gas and Burn Hazard
The exhaust manifold, tail pipe
and other parts of the engine get
hot. Do not touch hot parts.
Hot exhaust can contain toxic
gases like carbon monoxide
that, if inhaled, will result in
death or serious injury. Do not
breath exhaust gas.
Use protective gloves when
handling hot parts.
Never remove the radiator cap
while the engine is running or
while the engine is hot.
Do not use indoors unless the
area is properly ventilated or an
exhaust scrubber is used.
Bodily Injury and Component
Damage Hazards
Loose jackets, shirts, sleeves, jewelry and neck
ties should not be worn while working on or
operating the generator.
Never remove the fan guards while the unit is
operating. Turn the generator off before removing
the fan guards or other protective devices from
the generator to gain temporary access for
maintenance. Replace the fan guards and other
protective devices immediately after servicing.
Keep your hands away from moving parts,
particularly clear of the radiator fan and alternator
belts when the engine is running.
Do not shut the unit down with the main generator
circuit breaker in the on position. Shutting the unit
down with the breaker in the on position can cause
damage to the generator and/or connected
apparatus.
Do not change the position of the voltage selector
switch while the generator is running. This will
result in immediate damage to the switch, the
generator or the conected equipment. It may result
in serious injury to the operator.
Check the exhaust system
regularly for leaks and ensure
that the exhaust manifolds are
secure and not warped. Make
sure that the machine is well
ventilated.
Welding Hazard
Do not weld on any structural
member. Unauthorized welding
or repair procedure can result in
structural failure or personal
injury and will void the warranty.
Part No. 140435 T180 • T240 9
Improper Use Hazard
When leaving the generator set unattended,
secure the machine from unauthorized use.
Unauthorized personnel may attempt to operate
the machine without proper instructions, creating
an unsafe condition.
Operator's Manual First Edition • First Printing
Operation Safety
Transport and Lifting Hazard
Be careful when lifting. Never suspend any other
equipment 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 the
trailer are released prior to lifting. Refer to Transport
and Towing section for recommended tie-down
procedures.
Never climb on top of the cabinet.
Always use the proper trailer hitch and safety
chains. Obey all local or state D.O.T. laws when
transporting the generator set.
Failure to properly secure the generator set to the
transport vehicle may result in death or serious
injury.
Towing Hazards
Driving a vehicle/trailer combination is different
from driving a vehicle alone. Read, understand and
obey all of your tow vehicle manufacturer’s
recommendations, warning and instructions before
towing the trailer.
Increase the distance between your vehicle and
the vehicle in front of you to twice the normal
following distance when towing a trailer. Allow
more following distance in adverse weather
condition.
Always slow down for curves, wet roads and
down grades.
Heavy winds, excessive speed, load shifting or
passing vehicles can cause the trailer to sway
while driving. If this occurs, do not step on the
brake, speed up or turn the steering wheel.
Applying the brakes or turning the steering wheel
can cause the vehicle to jackknife. Release the
gas pedal and keep the steering wheel straight.
When passing other vehicles, be sure to leave
enough room for the extra length of the trailer.
Check for tire inflation. Do not over or under inflate
the tires. Tire pressure goes up while driving. Allow
the tires to cool down to get the accurate tire
pressure. Refer to the trailer VIN decal for proper
tire inflation.
Stay clear of traffic when starting or checking the
unit along the road.
Check the fuel tank, oil pan, fuel lines, oil lines and
drain plugs for leaks that would spill fuel or oil on
the road.
Check fasteners and mounting brackets
periodically to insure that all are tight and nothing is
in danger of falling off during transit.
Always use the proper trailer hitch and safety
chains. Obey all local or state D.O.T. laws when
towing the generator set.
Failure to properly secure the trailer to the towing
vehicle may result in death or serious injury.
Observe the posted speed limits for trailers.
10 T180 • T240 Part No. 140435
First Edition • First Printing
Operator's Manual
Operation Safety
Battery Safety
Lead acid batteries can be dangerous. The 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.
Burn Hazards
Do not remove the vent caps
when charging the batteries.
Always wear protective clothing
and eye wear when working with
batteries. If acid gets on your
skin or eyes, immediately flush
under running water and obtain
medical attention.
Do not expose the batteries or the charger to water
or rain during charging.
Explosion and Fire Hazards
Keep sparks, flames and lighted tobacco away
from batteries. Batteries emit an explosive gas.
Do not contact the battery terminals or the cable
clamps with tools that may cause sparks.
Disconnect the negative terminal of the battery
when working on the engine or other parts to
prevent accidental arcing.
Component Damage
Hazards
Electrocution/Burn Hazards
If using a charger, connect the
battery charger to a grounded,
AC 3-wire electrical outlet only.
Avoid electrical shock from
contact with battery terminals.
Remove all rings, watches and
other jewelry.
Lifting Hazard
Use the appropriate number of people and proper
lifting techniques when lifting batteries.
Lockout After Each Use
1 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 no
load until the coolant temperature gauge reads
approximately 175°F (79.4°C) as a cool down
cycle.
4 Push the Cascade controller off button to stop
the engine.
5 Move the on/off toggle switch to the off position.
5 Chock the wheels.
6 Lock the doors.
Do not use any battery charger greater than 24V to
charge the batteries.
Part No. 140435 T180 • T240 11
Operator's Manual First Edition • First Printing
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)
12 T180 • T240 Part No. 140435
10 Document holder (back of door)
11 Red Emergency Stop button
12 Tongue jack
13 Battery compartment
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