Terex SX180H-745 Operator's Manual
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Terex SX180H-745 Operator's Manual

Terex SX180H-745 Operator's Manual

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Operator's Manual
SX
-150
™
SX
-180
™
Serial Number Range
from SX150H-612
from SX180H-745
CE
with
Maintenance
Information
Original Instructions
Fourth Edition
Third Printing
Part No. 1292555GT

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  • Page 1 Operator's Manual Serial Number Range -150 ™ from SX150H-612 -180 ™ from SX180H-745 with Maintenance Information Original Instructions Fourth Edition Third Printing Part No. 1292555GT...

  • Page 2: Table Of Contents

    Copyright © 2015 by Terex Corporation Fourth Edition: Third Printing, June 2022 "Genie" is a registered trademark and "SX" is a 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 Supply of Machinery (Safety) Regulations 2008 ™...

  • Page 3: Introduction

    Fourth Edition • Third Printing Operator's Manual Introduction Introduction About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual Fourth Edition • Third Printing Introduction Platform controls symbology and Ground controls symbology and related machine movement: related machine movement: Platform level Platform level, jib boom up/down, boom extend/retract,and boom up/down Platform rotate Turntable rotate and platform rotate Jib boom up/down Sequential functions and movement: Drive and steer.
  • Page 5 Fourth Edition • Third Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 6 Operator's Manual Fourth Edition • Third Printing Introduction 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.
  • Page 7 Fourth Edition • Third Printing Operator's Manual Introduction Hazard Classification Decals on this machine use 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.

  • Page 8: Symbol And Hazard Pictorials Definitions

    Operator's Manual Fourth Edition • Third Printing Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Crushing hazard Keep away from Crush hazard Overhead obstruction Collision hazard moving parts Electrocution hazard Maintain required Tip-over hazard Tip-over hazard Tip-over hazard clearance Electrocution hazard Avoid contact...
  • Page 9 Fourth Edition • Third Printing Operator's Manual Symbol and Hazard Pictorials Definitions Platform tie-down Lifting and 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 10 Operator's Manual Fourth Edition • Third Printing Symbol and Hazard Pictorials Definitions Color coded direction Runaway hazard Access by trained and Crush hazard Support the platform arrows authorized personnel or boom during only maintenance Auxiliary lowering Platform overloaded ™ -150 • SX ™...

  • Page 11: General Safety

    Fourth Edition • Third Printing Operator's Manual General Safety General Safety Part No. 1292555GT ™ -150 • SX ™ -180...
  • Page 12 Operator's Manual Fourth Edition • Third Printing General Safety ™ -150 • SX ™ -180 Part No. 1292555GT...
  • Page 13 Fourth Edition • Third Printing Operator's Manual General Safety Part No. 1292555GT ™ -150 • SX ™ -180...

  • Page 14: Personal Safety

    Operator's Manual Fourth Edition • Third Printing 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 15: Work Area Safety

    Fourth Edition • Third Printing Operator's Manual 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 16 Operator's Manual Fourth Edition • Third Printing 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 17 Fourth Edition • Third Printing Operator's Manual Work Area Safety Do not operate the machine in strong or gusty Do not push off or pull winds. Do not increase the surface area of the toward any object outside platform or the load. Increasing the area exposed of the platform.
  • Page 18 Operator's Manual Fourth Edition • Third Printing Work Area Safety Operation on Slopes Hazards Do not alter or modify a mobile elevating work platform without prior written permission from the Do not drive the machine on a slope that exceeds manufacturer.
  • Page 19 Fourth Edition • Third Printing Operator's Manual 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 20 Operator's Manual Fourth Edition • Third Printing 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 21 Fourth Edition • Third Printing Operator's Manual 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 Batteries contain acid. the machine and test all functions before each Always wear protective work shift.
  • Page 22 Operator's Manual Fourth Edition • Third Printing Work Area Safety Contact Alarm Safety Welder Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the contact alarm. instructions provided with the welding power unit. Do not exceed the rated platform capacity.
  • Page 23 Fourth Edition • Third Printing Operator's Manual Work Area Safety Pipe Cradle Safety Lockout After Each Use Read, understand, and obey all warnings and Select a safe parking location—firm level instructions provided with the pipe cradles. surface, clear of obstruction and traffic. Retract and lower the boom to the stowed Do not exceed the rated platform capacity.

  • Page 24: Legend

    Operator's Manual Fourth Edition • Third Printing Legend Legend Square-end tire Platform controls Ground controls Sliding mid-rail Boom Manual storage container Jib boom 10 Lanyard anchorage points Platform 11 Foot switch Circle-end tire ™ -150 • SX ™ -180 Part No. 1292555GT...

  • Page 25: Controls

    Fourth Edition • Third Printing Operator's Manual Controls Controls The ground control station is to be used as a means to raise the platform for storage purposes and for function tests. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.
  • Page 26 Operator's Manual Fourth Edition • Third Printing Controls Ground Control Panel Key switch for off/ground/platform selection 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 27 Fourth Edition • Third 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 Auxiliary power button Press the platform rotate left button and the...
  • Page 28 Operator's Manual Fourth Edition • Third Printing Controls Platform Control Panel ™ -150 • SX ™ -180 Part No. 1292555GT...
  • Page 29 Fourth Edition • Third Printing Operator's Manual Controls Part No. 1292555GT ™ -150 • SX ™ -180...
  • Page 30 Operator's Manual Fourth Edition • Third Printing Controls Platform Control Panel Auxiliary power switch with indicator light Use auxiliary power if the primary power Horn button source (engine) fails. Push down the foot Press this button and the horn will sound. switch and simultaneously move the auxiliary Release the button and the horn will stop.
  • Page 31 Fourth Edition • Third Printing Operator's Manual Controls 11 Engine idle select switch with indicator light: 14 Power indicator light Light on indicates the machine is on. Move this switch to select engine idle setting. Rabbit 15 Check engine indicator light symbol light on indicates high Light on indicates an engine fault.
  • Page 32 Operator's Manual Fourth Edition • Third Printing Controls 20 Steer mode select switch with indicator lights 19 Dual axis proportional control handle for drive and steer functions. Move the steer mode select switch Proportional control handle for drive function to choose steer and thumb rocker for steer function.
  • Page 33 Fourth Edition • Third Printing Operator's Manual Controls 22 Drive select switch with indicator lights 24 Axle extend/retract switch with indicator lights Move the drive select Move the axle select switch to choose drive switch to choose an axle setting. The indicator setting.
  • Page 34 Operator's Manual Fourth Edition • Third Printing Controls 26 Dual axis proportional control handle for boom up/down and turntable rotate left/right functions Move the control handle up and the boom will raise. Move the control handle down and the boom will lower.

  • Page 35: Inspections

    Fourth Edition • Third Printing Operator's Manual 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 36 Operator's Manual Fourth Edition • Third Printing Inspections Pre-operation Inspection  Steer and axle sensors  Alarms and beacons (if equipped)  Be sure that the operator’s manual is  Nuts, bolts and other fasteners complete, legible and in the storage container located in the platform.
  • Page 37 Fourth Edition • Third Printing Operator's Manual 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 38 Operator's Manual Fourth Edition • Third Printing Inspections At the Ground Controls Test the Extendable Axles Note: Start this test with the axles retracted. Select a test area that is firm, level and free of hazards. At the ground controls, press and hold a function enable/speed select button and press Turn the key switch to ground control.
  • Page 39 Fourth Edition • Third Printing Operator's Manual Inspections Test Machine Functions 11 Turn the key switch to platform control. At the 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 40 Operator's Manual Fourth Edition • Third Printing 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 41 Fourth Edition • Third Printing Operator's Manual Inspections At the Platform Controls Test the Jib Rotate Limit 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 42 Operator's Manual Fourth Edition • Third Printing 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 43 Fourth Edition • Third Printing Operator's Manual Inspections Test the Steering 56 Press down the foot switch. 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 44 Operator's Manual Fourth Edition • Third Printing Inspections Test Drive and Braking 62 Slowly move the control handle in the direction indicated by the yellow triangle on the control 67 Press down the foot switch. panel OR press the thumb rocker switch in the 68 Slowly move the drive control handle in the direction indicated by the yellow triangle.
  • Page 45 Fourth Edition • Third Printing Operator's Manual 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 46 Operator's Manual Fourth Edition • Third Printing Inspections Test Drive Tilt Cutout 91 Press down the foot switch. 82 Press down the foot switch. 92 With the boom fully stowed, drive the machine onto a slope where the chassis angle is 83 With the boom fully stowed, drive the machine greater than 3°...
  • Page 47 Fourth Edition • Third Printing Operator's Manual Inspections Test the Platform Level Recovery Test Auxiliary Power 100 Press down the foot switch. 104 Push in the red Emergency Stop button to the off position to shut off the engine. 101 Push and hold the platform level recovery switch up.
  • Page 48 Operator's Manual Fourth Edition • Third Printing Inspections 113 Insert the actuator into the switch socket. Test the Contact Alarm (if equipped) Result: The lights and horn will turn off. 108 Do not activate the foot switch and press on the contact alarm cable to release the actuator 114 Operate each machine function.
  • Page 49 Fourth Edition • Third 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 50 Operator's Manual Fourth Edition • Third Printing Inspections Inspection for Decals with Part No. Decal Description Symbols 219958 Label – Tip-over, Crush Hazard 230984 Ground Control Panel Use the pictures on the next page to verify that all 232978 Platform Control Panel decals are legible and in place.
  • Page 51 Fourth Edition • Third Printing Operator's Manual Inspections Part No. 1292555GT ™ -150 • SX ™ -180...

  • Page 52: Operating Instructions

    Operator's Manual Fourth Edition • Third 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 manual.
  • Page 53 Fourth Edition • Third Printing Operator's Manual Operating Instructions Starting the Engine Perkins models Move the glow plug switch to either side and At the ground controls, turn the key switch to hold. the desired position. Move the engine start toggle switch to either Be sure both ground and platform control red side.
  • Page 54 Operator's Manual Fourth Edition • Third Printing Operating Instructions Emergency Stop To Extend and Retract Axles Push in the red Emergency Stop button to the off Turn the key switch to platform control. position at the ground controls or the platform At the platform controls, controls to stop all machine functions and turn the press down the foot switch...
  • Page 55 Fourth Edition • Third Printing Operator's Manual Operating Instructions Operation from Ground To Rotate the Jib Push and hold a function enable/speed select Turn the key switch to ground control. button. Pull out the red Emergency Stop button to the Push the jib boom rotate right button on position.
  • Page 56 Operator's Manual Fourth Edition • Third Printing Operating Instructions Operation from Platform To Steer 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 57 Fourth Edition • Third Printing Operator's Manual 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 58 Operator's Manual Fourth Edition • Third Printing Operating Instructions Tilt Sensor Activation Settings When the Machine On Incline indicator light is on and the tilt alarm sounds, the following Chassis Angle functions are affected; drive Model (front to back) Max Height Max Reach functions are disabled.
  • Page 59 Fourth Edition • Third Printing Operator's Manual Operating Instructions Drive Enable Check Engine Light Light on indicates that the boom Light on and engine stopped: Tag the has moved past a circle-end tire machine and remove from service. and the drive function has been Light on and engine still running: interrupted.
  • Page 60 Operator's Manual Fourth Edition • Third Printing Operating Instructions During the DPF standstill generation process, The LCD screen displays the message all boom functions are disabled. NOTICE: ALL FUNCTIONS WILL BE LOCKED. REGEN WILL TAKE APPROX. 1 Keep clear of the engine exhaust and muffler. HOUR.
  • Page 61 Fourth Edition • Third Printing Operator's Manual Operating Instructions Operating Envelope Indicator Lights Platform Not Level indicator light flashing: The tilt alarm will The operating envelope indicator lights will come be sounding when this light is on to notify the operator that a function has been flashing.
  • Page 62 Operator's Manual Fourth Edition • Third Printing 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 LEVEL >...
  • Page 63 Fourth Edition • Third Printing Operator's Manual Operating Instructions Generator LCD Screen (if equipped) To operate the generator, move the generator The LCD screen displays hour meter, voltage, oil toggle switch. pressure and coolant temperature. The screen also displays fault codes and other service Note: If the foot switch is activated during information.
  • Page 64 Operator's Manual Fourth Edition • Third Printing Operating Instructions Contact Alarm (if equipped) Pipe Cradle Instructions The contact alarm is designed to alert ground The pipe cradle assembly consists of 2 pipe personnel when an operator makes contact with cradles positioned at either side of the platform the platform control panel, interrupting boom and mounted to the guardrails with U-bolts.
  • Page 65 Fourth Edition • Third Printing Operator's Manual Operating Instructions Observe and Obey: Pipe Cradle Operation Be sure the pipe cradle assembly and Pipe cradles must be installed on the inside of  installation instructions have been followed the platform. properly and that the pipe cradles are secured ...
  • Page 66 Operator's Manual Fourth Edition • Third Printing 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 67: Transport And Lifting Instructions

    Fourth Edition • Third Printing Operator's Manual 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 68 Operator's Manual Fourth Edition • Third Printing Transport and Lifting Instructions Securing to Truck or Trailer for Securing the Chassis Transit Use chains of ample load capacity. Always use the turntable rotation lock pin each Use a minimum of 6 chains. time the machine is transported.
  • Page 69 Fourth Edition • Third Printing Operator's Manual Transport and Lifting Instructions Fully lower the boom onto the turntable boom Continue rotating the jib until it stops and the rest pad. Raise the jib if necessary so the platform is stowed under the boom. platform does not contact the trailer deck.
  • Page 70 Operator's Manual Fourth Edition • Third Printing Transport and Lifting Instructions SX-150 ™ -150 • SX ™ -180 Part No. 1292555GT...
  • Page 71 Fourth Edition • Third Printing Operator's Manual Transport and Lifting Instructions SX-180 Part No. 1292555GT ™ -150 • SX ™ -180...
  • Page 72 Operator's Manual Fourth Edition • Third Printing Transport and Lifting Instructions Adjust the rigging to prevent damage to the machine and to keep the machine level. Center of gravity X Axis Y Axis SX-180 131 in 62 in 3.3 m 1.6 m SX-150 98 in...

  • Page 73: Maintenance

    Fourth Edition • Third Printing Operator's Manual Maintenance Check the Engine Oil Level Maintenance Maintaining the proper engine oil level is essential to good engine performance and service life. Observe and Obey: Operating the machine with an improper oil level can damage engine components.
  • Page 74 Operator's Manual Fourth Edition • Third Printing 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 75 Fourth Edition • Third Printing Operator's Manual 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 76 Operator's Manual Fourth Edition • Third Printing 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 77: Specifications

    Fourth Edition • Third Printing Operator's Manual Specifications Specifications Model Tire size 445D50/710, 18 ply HD FF SX-150 Weight 49,950 lbs 22,657 kg Height, working maximum 158 ft 48.16 m (Machine weights vary with option configurations. See Height, platform maximum 152 ft 46.33 m serial label for specific machine weight.)
  • Page 78 Operator's Manual Fourth Edition • Third Printing Specifications Tire size 445D50/710, 18 ply HD FF Model SX-180 Weight 55,000 lbs 24,948 kg Height, working maximum 186 ft 56.69 m (Machine weights vary with option configurations. See Height, platform maximum 180 ft 54.86 m serial label for specific machine weight.) Height, stowed maximum...
  • Page 79 Fourth Edition • Third Printing Operator's Manual Specifications SX-150 Range of Motion Chart Maximum Platform Capacity - 750 lbs / 340 kg Max Height Max Reach 160 ft 48.8 m -20 ft -6.1 m 150 ft 45.7 m -10 ft -3 m 140 ft 42.7 m...
  • Page 80 Operator's Manual Fourth Edition • Third Printing Specifications SX-180 Range of Motion Chart Maximum Platform Capacity - 750 lbs / 340 kg Max Height Max Reach 180 ft 54.9 m -20 ft -6.1 m 170 ft 51.8 m -10 ft -3 m 160 ft 48.8 m...
  • Page 81 Fourth Edition • Third Printing Operator's Manual Specifications Part No. 1292555GT ™ -150 • SX ™ -180...
  • Page 82 Operator's Manual Fourth Edition • Third Printing Specifications ™ -150 • SX ™ -180 Part No. 1292555GT...
  • Page 83 Fourth Edition • Third Printing Operator's Manual Specifications Part No. 1292555GT ™ -150 • SX ™ -180...
  • Page 84 Operator's Manual Fourth Edition • Third Printing Specifications SX™-150 • SX™-180 Part No. 1292555GT Operator's Manual Fourth Edition • Third Printing ™ -150 • SX ™ -180 Part No. 1292555GT...

This manual is also suitable for:

Genie sx-180Sx150h-612Genie sx-150

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