Genie SX-180 Operator's Manual

Boom lift

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Service and repair manual (292 pages)

Maintenance manual (178 pages)

Maintenance manual (182 pages)

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Page 1 Operator's Manual Serial Number Range SX-150 From SX15015-101 ANSI/CSA North America SX-180 From SX18015-293 South America Asia with Maintenance Information Second Edition Third Printing Part No. 1262335...
Page 2: Table Of Contents
Maintenance ............68 Specifications ............72 Copyright © 2015 by Terex Corporation Second Edition: Third Printing, April 2017 Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. These machines comply with ANSI/SIA A92.5 CAN B.354.4...
Page 3: Introduction
This book is an operation and daily maintenance manual for the user or operator of a Genie Bulletin Distribution and machine. Compliance...
Page 4 Second Edition • Third Printing Introduction Contacting the Manufacturer At times it may be necessary to contact Genie. When you do, be ready to supply the model number and serial number of your machine, along with your name and contact information. At...
Page 5 Indicates a hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a hazardous situation which, if not avoided, could result in minor or moderate injury. NOTICE Indicates a property damage message. Part No. 1262335 SX-150 • SX-180...
Page 6: Symbol And Hazard Pictorials Definitions
Disconnect battery Read the operator’s Read the service manual manual Explosion hazard No smoking. Explosion hazard Burn hazard Fire extinguisher No flame. Stop engine. Fire hazard No smoking Explosion hazard No step Lanyard anchorage points SX-150 • SX-180 Part No. 1262335...
Page 7 1 Lower boom. 1 Retract boom. starting aids on 2 Retract boom. 2 Lower boom. machines equipped with glow plugs. Color Coded Access by trained and Runaway Hazard Direction Arrows authorized personnel only Part No. 1262335 SX-150 • SX-180...
Page 8: General Safety
Operator's Manual Second Edition • Third Printing General Safety General Safety SX-150 • SX-180 Part No. 1262335...
Page 9 Second Edition • Third Printing Operator's Manual General Safety Part No. 1262335 SX-150 • SX-180...
Page 10 Operator's Manual Second Edition • Third Printing General Safety SX-150 • SX-180 Part No. 1262335...
Page 11 Second Edition • Third Printing Operator's Manual General Safety Part No. 1262335 SX-150 • SX-180...
Page 12 Operator's Manual Second Edition • Third Printing General Safety SX-150 • SX-180 Part No. 1262335...
Page 13 Second Edition • Third Printing Operator's Manual General Safety Part No. 1262335 SX-150 • SX-180...
Page 14: Personal Safety
Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment. All PFPE must comply with applicable governmental regulations, and must be inspected and used in accordance with the PFPE manufacturer’s instructions. SX-150 • SX-180 Part No. 1262335...
Page 15: Work Area Safety
See the decals with the options and accessories. If using accessories, read, understand and obey the decals, instructions and manuals with the accessory. Part No. 1262335 SX-150 • SX-180...
Page 16 Increasing the area exposed level surface. Do not rotate the boom while to the wind will decrease machine stability. lowering. The recovery mode should be used only by trained and authorized personnel. SX-150 • SX-180 Part No. 1262335...
Page 17 Do not push off or pull platform or the load. toward any object outside of the platform. Maximum allowable side force – ANSI & CSA 150 lbs / 667 N Part No. 1262335 SX-150 • SX-180...
Page 18 Do not use the machine on a moving or mobile surface or vehicle. Be sure the tires are in good condition and the lug nuts tightened. SX-150 • SX-180 Part No. 1262335...
Page 19 Lower the platform entry mid-rail or close the entry governmental rules regarding use of personal gate before operating. protective equipment. Do not enter or exit the platform unless the machine is in the stowed position and the platform is at ground level. Part No. 1262335 SX-150 • SX-180...
Page 20 Do not operate a boom in the path of any crane unless the controls of the crane have been locked out and/or precautions have been taken to prevent any potential collision. No stunt driving or horseplay while operating a machine. SX-150 • SX-180 Part No. 1262335...
Page 21 Be sure all maintenance has been performed as flames and lighted tobacco. specified in this manual and the appropriate Genie service manual. Do not operate the machine or charge the battery in hazardous locations or locations where Be sure all decals are in place and legible.
Page 22 Do not cause a horizontal force or side load to machine by raising or lowering a fixed or overhanging load. Electrocution Hazard: Keep pipes away from all Electrocution Hazard energized electrical conductors. Avoid contact with electrical terminals. SX-150 • SX-180 Part No. 1262335...
Page 23 The welder power supply weighs 75 lbs / 34 kg. Do not operate the welder unless a fire extinguisher is immediately available for instant use, per OSHA regulation 1926.352(d). Part No. 1262335 SX-150 • SX-180...
Page 24: Legend
Operator's Manual Second Edition • Third Printing Legend Legend Platform controls Square-end tire Sliding mid-rail Ground controls Manual storage container Boom 10 Lanyard anchorage points Jib boom 11 Foot switch Platform Circle-end tire SX-150 • SX-180 Part No. 1262335...
Page 25: Controls
22 Boom up/down buttons 14 Platform rotate left button Platform level up/down 23 LCD screen control buttons buttons 15 Jib boom rotate right button 24 Jib rotate indicator 16 Jib boom rotate left button (operating envelope) Part No. 1262335 SX-150 • SX-180...
Page 26 (P22) and platform level controls do not work. Refer to the operating instructions. Recovery key position should be used only by trained and authorized personnel. SX-150 • SX-180 Part No. 1262335...
Page 27 Press the low speed function enable button to enable the functions on the ground control panel to operate at low speed. 19 Turntable rotate left button Press the turntable rotate left button and the turntable will rotate left. Part No. 1262335 SX-150 • SX-180...
Page 28 Operator's Manual Second Edition • Third Printing Controls Platform Control Panel SX-150 • SX-180 Part No. 1262335...
Page 29 Second Edition • Third Printing Operator's Manual Controls Part No. 1262335 SX-150 • SX-180...
Page 30 11 Engine idle select switch with indicator light: Move this switch to select engine idle setting. Rabbit symbol light on indicates high idle is selected. Turtle symbol light on indicates low idle is selected. SX-150 • SX-180 Part No. 1262335...
Page 31 Pull out the red Emergency Stop button to the on position to operate the machine. Part No. 1262335 SX-150 • SX-180...
Page 32 The axle extend indicator light will stay on when the axles are fully extended. The axle retract indicator light will stay on when the axles are fully retracted. SX-150 • SX-180 Part No. 1262335...
Page 33 Move the control handle to the left and the turntable will rotate left. Move the control handle to the right and the turntable will rotate right. Part No. 1262335 SX-150 • SX-180...
Page 34: Inspections
Scheduled maintenance inspections shall be performed by qualified service technicians, according to the manufacturer’s specifications and the requirements listed in the responsibilities manual. SX-150 • SX-180 Part No. 1262335...
Page 35  Fuel and hydraulic tanks  Drive and turntable motors and drive hubs  Wear pads  Tires and wheels  Engine and related components  Limit switches and horn  Rotation sensors Part No. 1262335 SX-150 • SX-180...
Page 36 3 Always perform function tests prior to use. Know and understand the function tests before going on to the next section. 4 Inspect the workplace. 5 Only use the machine as it was intended. SX-150 • SX-180 Part No. 1262335...
Page 37 Result: The turntable should return to center, rotate 40° to the right and then stop. The turntable should not rotate more than 40° unless the axles are extended. Part No. 1262335 SX-150 • SX-180...
Page 38 Note: To conserve battery power, test each Result: The turntable should rotate normally. function through a partial cycle. Result: All boom functions should operate. 21 Start the engine. SX-150 • SX-180 Part No. 1262335...
Page 39 Result: The LCD screen should display the SENSOR EXTENSION angle in degrees. INCHES is displayed. 29 Extend the boom and observe the LCD screen. Result: The LCD screen will display the string pot extension length. 30 Retract the boom. Part No. 1262335 SX-150 • SX-180...
Page 40 30° from the centerline of the boom Test the Tilt Sensor Alarm assembly. 39 Move a toggle switch, such as the engine idle select switch. Result: The alarm should sound at the platform controls. Jib rotate left Jib rotate right SX-150 • SX-180 Part No. 1262335...
Page 41 Result: No functions should operate. 50 Move the dual axis proportional control handle to the left. Result: The jib rotation should come to a stop at 30° from the centerline of the boom assembly. Part No. 1262335 SX-150 • SX-180...
Page 42 OR press the thumb rocker and choose switch in the direction indicated by the blue circle-end (yellow triangle. arrow) steer. Result: All wheels should turn in the direction that the blue triangles point on the drive chassis. SX-150 • SX-180 Part No. 1262335...
Page 43 Result: The square-end wheels should turn in the direction that the yellow triangles point on the drive chassis. The circle-end wheels should turn in the direction that the blue triangles point on the drive chassis. Part No. 1262335 SX-150 • SX-180...
Page 44 If the drive control handle is not moved within two seconds of moving the drive enable toggle switch, Note: The machine will travel 40 ft / 12 m in the drive function will not operate. 270 seconds. SX-150 • SX-180 Part No. 1262335...
Page 45 Result: The machine should drive. 89 Lower the boom to the stowed position. 99 Return to level ground and stow the boom. Result: The machine should drive. 90 Return to level ground and stow the boom. Part No. 1262335 SX-150 • SX-180...
Page 46 Result: All boom and steer functions should Note: The platform level switch will only work in the operate. direction that will return the platform to a level position. SX-150 • SX-180 Part No. 1262335...
Page 47 It is the operator’s responsibility to read and remember the workplace hazards, then watch for and avoid them while moving, setting up and operating the machine. Part No. 1262335 SX-150 • SX-180...
Page 48 82314 Danger – Tip-over Hazard 1256422 Label – Power to Platform, 415V / 240V 82366 Label – Chevron Rando 1262266 Cosmetic – Genie, 16 inch 82862 Danger – Fire Extinguisher, Welder 1262267 Cosmetic – SX-150, 16 inch (option) 1262268 Cosmetic – SX-150, 12 inch 97579 Danger –...
Page 49 Second Edition • Third Printing Operator's Manual Inspections Part No. 1262335 SX-150 • SX-180...
Page 50 1255581 Cosmetic – Genie 28159 Label – Diesel 1255582 Cosmetic – Genie 38149 Label – Patent 1262266 Cosmetic – Genie, 16 inch 40434 Label – Lanyard Anchorage Point 1262267 Cosmetic – SX-150, 16 inch 44981 Label – Air Line to Platform (option) 1262268 Cosmetic –...
Page 51 Second Edition • Third Printing Operator's Manual Inspections Part No. 1262335 SX-150 • SX-180...
Page 52: Operating Instructions
That means 4 Inspect the workplace. every new operator should perform a pre-operation inspection, function tests, and a workplace 5 Only use the machine as it was inspection before using the machine. intended. SX-150 • SX-180 Part No. 1262335...
Page 53 Attempting to start the engine when engine fails to start or dies, the temperatures are below 0°F / -18°C may require restart delay will disable the start the use of a booster battery. switch for 3 seconds. Part No. 1262335 SX-150 • SX-180...
Page 54 Press down the foot switch when using the controls from the platform. Simultaneously hold the emergency power switch on and activate the desired function. The drive functions will not operate with emergency power. SX-150 • SX-180 Part No. 1262335...
Page 55 There is no flashing arrow for the jib rotate left Push the appropriate function. Rotate jib right to continue. function button according to the markings on the control panel. Drive and steer functions are not available from the ground controls. Part No. 1262335 SX-150 • SX-180...
Page 56 Use the color-coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel. Machine travel speed is restricted when the boom is raised or extended. SX-150 • SX-180 Part No. 1262335...
Page 57 0.3 m ÷ 3.6 m = 0.083 x 100 = 8.3% grade If the slope exceeds the maximum slope or side slope rating, then the machine must be winched or transported up or down the slope. See Transport and Lifting section. Part No. 1262335 SX-150 • SX-180...
Page 58 Always use the color-coded direction arrows on the 24 hours. platform controls and the drive chassis to identify the direction the machine will travel. When the drive enable light is on, the axles cannot retract. SX-150 • SX-180 Part No. 1262335...
Page 59 +/-15 degrees the only way to recover is to use the Service/Recovery key switch on the side of the ground controls to activate Recovery Mode. If the tilt alarm sounds with the platform downhill: Retract the boom. Lower the boom. Part No. 1262335 SX-150 • SX-180...
Page 60 The generator indicator light will technician. flash during generator shut-down sequence. After the generator shut-down sequence is complete the generator indicator light will turn off and the engine rpm will move into low rpm, turtle symbol mode. SX-150 • SX-180 Part No. 1262335...
Page 61 Turn the key switch to the off position and automatically when needed. remove the key to secure from unauthorized use. LCD will display REGEN FORCED and WARNING HIGH EXHAUST SYSTEM TEMP when the regeneration mode is running. No service required. Part No. 1262335 SX-150 • SX-180...
Page 62 Secure each U-bolt with 2 washers and 2 nuts. strap U-bolts pipe cradle mount upper platform railing pipe cradle weldment middle platform railing flat washers nylock nuts SX-150 • SX-180 Part No. 1262335...
Page 63 Maximum Pipe Cradle Capacity 200 lbs All models 90.7 kg Pipe Cradle Assembly Weight 21 lbs 9.5 kg Part No. 1262335 SX-150 • SX-180...
Page 64: Transport And Lifting Instructions
Winching  Genie customers needing to containerize any lift or Genie product should source a qualified Chock the wheels to prevent the machine from freight forwarder with expertise in preparing, rolling. loading and securing construction and lifting equipment for international shipment.
Page 65 Inspect the entire machine for loose or unsecured items. Note: Only the operator may be in the platform during this process. Note: Keep hands on the controls at all times during the stowing operation. Part No. 1262335 SX-150 • SX-180...
Page 66 As the jib and platform approach the boom, rotate the platform toward the boom until it stops. SX-150 • SX-180 Part No. 1262335...
Page 67 Second Edition • Third Printing Operator's Manual Transport and Lifting Instructions Use a minimum of 6 chains. Securing the Chassis Use chains of ample load capacity. Adjust the rigging to prevent damage to the chains. SX-150 Part No. 1262335 SX-150 • SX-180...
Page 68 Operator's Manual Second Edition • Third Printing Transport and Lifting Instructions SX-180 SX-150 • SX-180 Part No. 1262335...
Page 69 Center of gravity X Axis Y Axis the machine weight. See the serial label for the SX-180 131 in 62 in machine weight. 3.3 m 1.6 m SX-150 98 in 61 in 2.49 m 1.55 m Part No. 1262335 SX-150 • SX-180...
Page 70: Maintenance
10W-30 and the requirements specified in the responsibilities manual. Deutz TD2011 L04i Engine  Oil type 15W-40 Use only Genie approved replacement parts. Oil type - cold conditions 5W-30 Maintenance Symbols Legend Perkins 854F-34T Engine Oil type 15W-40 The following symbols have been used in this...
Page 71 Low Sulfur Diesel (LSD) Add oil as needed. Do not overfill. Deutz TD2.9L Engine Fuel Type Ultra Low Sulfur Diesel (ULSD) Maximum oil level Minimum oil level Hydraulic oil specifications Hydraulic oil type Chevron Rando HD equivalent Part No. 1262335 SX-150 • SX-180...
Page 72 Use caution when removing cap are in place and secure. and adding fluids. Note: Adding terminal protectors and a corrosion preventative sealant will help eliminate the corrosion on the battery terminals and cables. SX-150 • SX-180 Part No. 1262335...
Page 73 Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service. Part No. 1262335 SX-150 • SX-180...
Page 74: Specifications
It should Horizontal jib rotation 60° be used only with adequate safety factors. Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. SX-150 • SX-180...
Page 75 It should be used only with adequate safety factors. Horizontal jib rotation 60° Continuous improvement of our products is a Genie policy. Product specifications are subject to change without notice or obligation. Part No. 1262335...
Page 76 Operator's Manual Second Edition • Third Printing Specifications SX-150 Range of Motion Chart SX-180 Range of Motion Chart 160 ft / 48.8 m 180 ft / 54.9 m 150 ft / 45.7 m 170 ft / 51.8 m 140 ft / 42.7 m 160 ft / 48.8 m...

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Genie SX-180 Operator's Manual

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