Terex SX15015-101 Operator's Manual
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Terex SX15015-101 Operator's Manual

Terex SX15015-101 Operator's Manual

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Operator's Manual
SX-150
SX-180
Serial Number Range
From SX15015-101
From SX18015-293
CE
with
Maintenance
Information
Original Instructions
Third Edition
Second Printing
Part No. 1262336

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Summary of Contents for Terex SX15015-101

  • Page 1 Operator's Manual Serial Number Range SX-150 From SX15015-101 SX-180 From SX18015-293 with Maintenance Information Original Instructions Third Edition Second Printing Part No. 1262336...

  • Page 2: Table Of Contents

    Specifications ............66 Copyright © 2015 by Terex Corporation Third Edition: Second Printing, October 2015 Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. Complies with EC Directive 2006/42/EC See EC Declaration of Conformity SX-150 •...

  • Page 3: Introduction

    Third Edition • Second Printing Operator's Manual Introduction Introduction About this manual Intended Use Genie appreciates your choice of our machine for This machine is intended to be used only to lift your application. Our number one priority is user personnel, along with their tools and materials to safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Third Edition • Second 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 minimum, Genie should be contacted for: Danger Accident reporting...
  • Page 5 Third Edition • Second Printing Operator's Manual Introduction Safety Sign Maintenance Hazard Classification Replace any missing or damaged safety signs. Decals on this machine use symbols, color coding Keep operator safety in mind at all times. Use mild and signal words to identify the following: soap and water to clean safety signs.

  • Page 6: Symbol And Hazard Pictorials Definitions

    Operator's Manual Third Edition • Second Printing Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Crushing hazard Keep away from Crush hazard Overhead obstruction Collision hazard moving parts Maintain required Electrocution hazard Tip-over hazard Tip-over hazard Tip-over hazard clearance Electrocution hazard Avoid contact...
  • Page 7 Third Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Platform tie-down Lifting & tie down instructions Tie-down point Lifting point instructions Wind speed Maximum capacity Weight of welder Wheel load Tire specifications reduces capacity Recovery procedure if tilt alarm sounds while elevated.

  • Page 8: General Safety

    Operator's Manual Third Edition • Second Printing General Safety General Safety SX-150 • SX-180 Part No. 1262336...
  • Page 9 Third Edition • Second Printing Operator's Manual General Safety 219958 219958 161688 161691 161688 114473 133067 133067 82487 114473 82487 161691 82487 82487 B Part No. 1262336 SX-150 • SX-180...
  • Page 10 Operator's Manual Third Edition • Second Printing General Safety SX-150 • SX-180 Part No. 1262336...

  • Page 11: Personal Safety

    Third Edition • Second Printing Operator's Manual Personal Safety Personal Safety Personal Fall Protection Personal fall protection equipment (PFPE) is required when operating this machine. Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform. Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment.

  • Page 12: Work Area Safety

    Operator's Manual Third Edition • Second Printing Work Area Safety Work Area Safety Electrocution Hazards Keep away from the machine if it contacts This machine is not electrically insulated and will energized power lines. not provide protection from contact with or Personnel on the ground proximity to electrical current.
  • Page 13 Third Edition • Second Printing Operator's Manual Work Area Safety Do not raise or extend the If the tilt alarm sounds with the boom unless the machine platform uphill: is on a firm, level surface. Lower the boom. Retract the boom. If the tilt alarm sounds with the platform downhill: Retract the boom.
  • Page 14 Operator's Manual Third Edition • Second Printing Work Area Safety Do not alter or disable machine components that in Use extreme care and any way affect safety and stability. slow speeds while driving the machine in the stowed Do not replace items critical to machine stability position across uneven with items of different weight or specification.
  • Page 15 Third Edition • Second Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Do not place or attach fixed or overhanging loads Do not drive the machine on a slope that exceeds to any part of this the maximum uphill, downhill or side slope rating of machine.
  • Page 16 Operator's Manual Third Edition • Second Printing Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the platform.
  • Page 17 Third Edition • Second Printing Operator's Manual Work Area Safety Bodily Injury Hazard Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Always operate the machine in a well-ventilated and steer functions. area to avoid carbon monoxide poisoning. Do not lower the boom Do not operate the machine with a hydraulic oil or unless the area below is...
  • Page 18 Operator's Manual Third Edition • Second Printing Work Area Safety Damaged Machine Hazards Battery Safety Do not use a damaged or malfunctioning machine. Burn Hazards Conduct a thorough pre-operation inspection of the Batteries contain acid. machine and test all functions before each work Always wear protective shift.
  • Page 19 Third Edition • Second Printing Operator's Manual Work Area Safety Pipe Cradle Safety Welder Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the pipe cradles. instructions provided with the welding power unit. Do not exceed the rated platform capacity.

  • Page 20: Legend

    Operator's Manual Third Edition • Second 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. 1262336...

  • Page 21: Controls

    Third Edition • Second Printing Operator's Manual Controls Controls Ground Control Panel Jib boom up/down buttons 17 High speed function enable LCD readout screen button Boom extend/retract buttons Engine speed select button 18 Low speed function enable 10 20A circuit breaker for system Red Emergency Stop button button circuit...
  • Page 22 Operator's Manual Third Edition • Second Printing Controls Key switch for off/ground/platform selection Ground Control Panel Turn the key switch to the off position and the LCD readout screen machine will be off. Turn the key switch to the ground position and the ground controls will operate.
  • Page 23 Third Edition • Second Printing Operator's Manual Controls 13 Platform rotate right button 20 Turntable rotate right button Press the platform rotate right button and the Press the turntable rotate right button and the platform will rotate right. turntable will rotate right. 14 Platform rotate left button 21 Emergency power button Press the platform rotate left button and the...
  • Page 24 Operator's Manual Third Edition • Second Printing Controls Platform Control Panel Emergency power switch 12 Jib rotate indicator light Horn button (operating envelope) Glow plug switch with Platform not level indicator indicator light 13 Platform overload indicator light light 10 Engine start switch with Machine on incline indicator indicator light 14 Power indicator light...
  • Page 25 Third Edition • Second Printing Operator's Manual Controls 22 Drive speed select switch with 24 Axle extend/retract switch 19 Dual axis proportional control indicator lights with indicator lights handle for drive and steer functions Machine on incline symbol: 25 Drive enable switch with OR Proportional control Low range operation for indicator light...
  • Page 26 Operator's Manual Third Edition • Second Printing Controls Emergency power switch with indicator light Platform Control Panel Use emergency power if the primary power Horn button source (engine) fails. Press this button and the horn will sound. Push down the foot switch and simultaneously Release the button and the horn will stop.
  • Page 27 Third Edition • Second Printing Operator's Manual Controls 12 Jib rotate indicator light (operating envelope) 19 Dual axis proportional control handle for drive and steer functions Continued use of the rotate jib right function OR Proportional control handle for drive will cause the jib rotate indicator light to flash.
  • Page 28 Operator's Manual Third Edition • Second Printing Controls 20 Steer mode select switch with indicator lights 22 Drive select switch with indicator lights Move the steer Move the drive select mode select switch switch to choose drive to choose steer setting.
  • Page 29 Third Edition • Second Printing Operator's Manual Controls 24 Axle extend/retract switch with indicator lights 26 Dual axis proportional control handle for boom up/down and turntable rotate left/right Move the axle select functions switch to choose an axle setting. The axle extend Move the control handle and retract indicator up and the boom will...

  • Page 30: Inspections

    Operator's Manual Third Edition • Second Printing Inspections Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 31 Third Edition • Second Printing Operator's Manual Inspections  Wear pads Pre-operation Inspection  Tires and wheels  Be sure that the operator’s, safety and  Engine and related components responsibilities manuals are complete, legible  Limit switches and horn and in the storage container located in the platform.
  • Page 32 Operator's Manual Third Edition • Second Printing Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 33 Third Edition • Second Printing Operator's Manual Inspections Test the Extendable Axles At the Ground Controls Note: Start this test with the axles retracted. Select a test area that is firm, level and free of obstruction. At the ground controls, press and hold a function enable/speed select button and press Turn the key switch to ground control.
  • Page 34 Operator's Manual Third Edition • Second Printing Inspections 11 Turn the key switch to platform control. At the Test Machine Functions platform controls, move the drive control 16 Do not press and hold a function enable/speed handle in the forward direction and move the select button.
  • Page 35 Third Edition • Second Printing Operator's Manual Inspections Test the Tilt Sensor Test the Operating Envelope 22 Press one of the LCD 25 Simultaneously press the 2 screen control buttons until LCD screen control buttons TURNTABLE LEVEL shown to activate status SENSOR X-DIRECTION mode.
  • Page 36 Operator's Manual Third Edition • Second Printing Inspections Test the Jib Rotate Limit At the Platform Controls 31 At the ground controls, press and hold a Test Emergency Stop function enable button and press either the jib boom rotate right button or the jib boom rotate 35 Turn the key switch to platform control.
  • Page 37 Third Edition • Second Printing Operator's Manual Inspections Test the Foot Switch Test Machine Functions 40 Push in the platform red Emergency Stop 45 Press down the foot switch. button to the off position. 46 Activate each function control handle, toggle 41 Pull out the red Emergency Stop button to the switch or thumb rocker switch.
  • Page 38 Operator's Manual Third Edition • Second Printing Inspections 56 Press down the foot switch. Test the Steering 57 Slowly move the control handle in the direction 51 Move the steer indicated by the yellow triangle on the control mode select switch panel OR press the thumb rocker switch in the and choose direction indicated by the yellow triangle.
  • Page 39 Third Edition • Second Printing Operator's Manual Inspections 62 Slowly move the control handle in the direction Test Drive and Braking indicated by the yellow triangle on the control 67 Press down the foot switch. panel OR press the thumb rocker switch in the direction indicated by the yellow triangle.
  • Page 40 Operator's Manual Third Edition • Second Printing Inspections Test the Drive Enable System Test Limited Drive Speed 70 Press down the foot switch and lower the 74 Press down the foot switch. boom to the stowed position. 75 Raise the boom to 10° above horizontal. 71 Rotate the turntable until the boom moves past 76 Slowly move the drive control handle to the full a circle-end wheel and is outside of the range...
  • Page 41 Third Edition • Second Printing Operator's Manual Inspections 91 Press down the foot switch. Test Drive Tilt Cutout 92 With the boom fully stowed, drive the machine 82 Press down the foot switch. onto a slope where the chassis angle is 83 With the boom fully stowed, drive the machine greater than 3°...
  • Page 42 Operator's Manual Third Edition • Second Printing Inspections Test Emergency Controls 100 Push in the red Emergency Stop button to the off position to shut off the engine. 101 Pull out the red Emergency Stop button to the on position. 102 Press down the foot switch.
  • Page 43 Third Edition • Second Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 44 Operator's Manual Third Edition • Second Printing Inspections Inspection for Decals with Part No. Decal Description Symbols 161688 Label – Maximum Capacity, Wind & Manual Force Use the pictures on the next page to verify that all 161691 Label – Slope Rating decals are legible and in place.
  • Page 45 Third Edition • Second Printing Operator's Manual Inspections 822718 218747 (SX-180) 133205 28159 1255581 or 1262268 (SX-150) Boom T ube #3 114251 1256420 822719 (SX-180) 218746 (SX-180) or 1256421 or 1262266 (SX-150) or 1262267 (SX-150) 40434 or 1256422 or 1258677 or 1258678 1256425 114252...

  • Page 46: Operating Instructions

    Operator's Manual Third Edition • Second Printing Operating Instructions Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety and responsibilities manuals.
  • Page 47 Third Edition • Second Printing Operator's Manual Operating Instructions Starting the Engine Emergency Stop At the ground controls, turn the key switch to Push in the red Emergency Stop button to the off the desired position. position at the ground controls or the platform controls to stop all machine functions and turn the Be sure both ground and platform control red engine off.
  • Page 48 Operator's Manual Third Edition • Second Printing Operating Instructions To Extend and Retract Axles Operation from Ground Turn the key switch to platform control. Turn the key switch to ground control. Pull out the red Emergency Stop button to the At the platform controls, on position.
  • Page 49 Third Edition • Second Printing Operator's Manual Operating Instructions To Steer Operation from Platform Press down the foot switch. Turn the key switch to platform control. Select the steer mode by moving the steer Pull out both ground and platform red mode switch.
  • Page 50 Operator's Manual Third Edition • Second Printing Operating Instructions Driving on a slope To determine the slope grade: Determine the uphill, downhill and side slope Measure the slope with a digital inclinometer OR ratings for the machine and determine the slope use the following procedure.
  • Page 51 Third Edition • Second Printing Operator's Manual Operating Instructions Drive Enable Engine Idle Select (rpm) Light on indicates that the boom Select the engine idle (rpm) by has moved past a circle-end tire pressing the engine idle select and the drive function has been switch.
  • Page 52 Operator's Manual Third Edition • Second Printing Operating Instructions Operating Envelope Indicator Lights If the tilt alarm sounds The operating envelope indicator lights will come with the platform uphill: on to notify the operator that a function has been interrupted and/or an action is required by the Lower the boom.
  • Page 53 Third Edition • Second Printing Operator's Manual Operating Instructions Platform Out of Level (P22 code) Platform Out of Level (Platform Level > 15 Degrees Fault) Bypass key position to be used to level the platform if ground control display shows platform If ground control display shows PLATFORM out of level (P22) and platform level controls do not LEVEL >...
  • Page 54 Operator's Manual Third Edition • Second Printing Operating Instructions Perkins Engine Generator To operate the generator, move the generator Machines equipped with Perkins 854F-34T Diesel toggle switch. engines have a regeneration mode that should run automatically when needed. Note: If the foot switch is activated during generator start-up, the generator will not operate.
  • Page 55 Third Edition • Second Printing Operator's Manual Operating Instructions After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable until the boom is positioned between the circle end wheels.
  • Page 56 Operator's Manual Third Edition • Second Printing Operating Instructions Pipe Cradle Instructions Observe and Obey:  The pipe cradle assembly consists of 2 pipe Pipe cradles must be installed on the inside of cradles positioned at either side of the platform the platform.
  • Page 57 Third Edition • Second Printing Operator's Manual Operating Instructions Pipe Cradle Operation Be sure the pipe cradle assembly and installation instructions have been followed properly and that the pipe cradles are secured to the platform railings. Place the load so that it rests in both pipe cradles.

  • Page 58: Transport And Lifting Instructions

    Operator's Manual Third Edition • Second Printing Transport and Lifting Instructions Transport and Lifting Instructions  Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation.  Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating.
  • Page 59 Third Edition • Second Printing Operator's Manual Transport and Lifting Instructions Securing the Platform Securing to Truck or Trailer for Transit Note: Be aware of the jib and platform position during the platform stowing sequence to avoid Always use the turntable rotation lock pin each contact with the boom.
  • Page 60 Operator's Manual Third Edition • Second Printing Transport and Lifting Instructions Continue rotating the jib until it stops and the Fully lower the boom onto the turntable boom platform is stowed under the boom. rest pad. Raise the jib if necessary so the platform does not contact the trailer deck.
  • Page 61 Third Edition • Second Printing Operator's Manual Transport and Lifting Instructions SX-150 Part No. 1262336 SX-150 • SX-180...
  • Page 62 Operator's Manual Third Edition • Second Printing Transport and Lifting Instructions SX-180 SX-150 • SX-180 Part No. 1262336...
  • Page 63 Third Edition • Second Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully extend the axles. Fully lower and retract the boom. Fully lower the jib. Remove all loose items on the machine. Determine the center of gravity of your machine Observe and Obey: using the table and the picture on this page.

  • Page 64: Maintenance

    Operator's Manual Third Edition • Second Printing Maintenance Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level Observe and Obey: can damage engine components.
  • Page 65 Third Edition • Second Printing Operator's Manual Maintenance Diesel Fuel Requirements Check the Hydraulic Oil Level Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is the use of a good quality fuel. The use of a good essential to machine operation.
  • Page 66 Operator's Manual Third Edition • Second Printing Maintenance Check the Engine Coolant Level – Check the Batteries Liquid Cooled Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.
  • Page 67 Third Edition • Second Printing Operator's Manual Maintenance Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine. Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service.

  • Page 68: Specifications

    Operator's Manual Third Edition • Second Printing Specifications Specifications System voltage Model SX-150 Tire size 445D50/710, 18 ply HD FF Height, working maximum 48.16 m Weight 22,657 kg Height, platform maximum 46.33 m (Machine weights vary with option configurations. See Height, stowed maximum 3.05 m serial label for specific machine weight.)
  • Page 69 Third Edition • Second Printing Operator's Manual Specifications System voltage Model SX-180 Tire size 445D50/710, 18 ply HD FF Height, working maximum 56.7 m Weight 24,948 kg Height, platform maximum 54.8 m (Machine weights vary with option configurations. See Height, stowed maximum 3.05 m serial label for specific machine weight.) Horizontal reach, maximum...
  • Page 70 Operator's Manual Third Edition • Second Printing Specifications SX-150 Range of Motion Chart SX-180 Range of Motion Chart SX-150 • SX-180 Part No. 1262336 Operator's Manual Third Edition • Second Printing SX-150 • SX-180 Part No. 1262336...
  • Page 71 www.genielift.com...

This manual is also suitable for:

Genie sx-180Genie sx-150Sx18015-293

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