Terex SX18014-101 Operator's Manual
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Terex SX18014-101 Operator's Manual

Terex SX18014-101 Operator's Manual

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Operator's Manual
SX-180
Serial Number Range
from SX18014-101 to SX18015-292
ANSI/CSA
North America
South America
Asia
with
Maintenance
Information
First Edition
Second Printing
Part No. 217927

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Summary of Contents for Terex SX18014-101

  • Page 1 Operator's Manual Serial Number Range SX-180 from SX18014-101 to SX18015-292 ANSI/CSA North America South America Asia with Maintenance Information First Edition Second Printing Part No. 217927...

  • Page 2: Table Of Contents

    Maintenance ............66 Specifications ............70 Copyright © 2014 by Terex Corporation First Edition: Second Printing, September 2014 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

    First 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 First 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 First 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 First 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 Electrocution hazard Maintain required Tip-over hazard Tip-over hazard Tip-over hazard clearance Electrocution hazard Avoid contact...
  • Page 7 First 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 First Edition • Second Printing General Safety General Safety SX-180 Part No. 217927...
  • Page 9 First Edition • Second Printing Operator's Manual General Safety 218559 161692 28236 72875 WARNING WARNING DANGER WARNING WARNING Bodily Injury Hazard Failure to use pipe cradle assembly according to instructions and safety rules below and in operator's and responsibilities manual could result in death or serious injury.
  • Page 10 Operator's Manual First Edition • Second Printing General Safety SX-180 Part No. 217927...
  • Page 11 First Edition • Second Printing Operator's Manual General Safety Part No. 217927 SX-180...
  • Page 12 Operator's Manual First Edition • Second Printing General Safety 219958 219958 161687 161691 161687 114473 133067 133067 82487 114473 82487 161691 82487 82487 B SX-180 Part No. 217927...
  • Page 13 First Edition • Second Printing Operator's Manual General Safety Part No. 217927 SX-180...

  • Page 14: Personal Safety

    Operator's Manual First Edition • Second 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

    First Edition • Second 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 First Edition • Second 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 First Edition • Second Printing Operator's Manual 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 18 Operator's Manual First Edition • Second Printing 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 19 First Edition • Second 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 First Edition • Second 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 First Edition • Second Printing Operator's Manual Work Area Safety Explosion and Fire Hazards Damaged Machine Hazards Do not start the engine if you smell or detect liquid Do not use a damaged or malfunctioning machine. petroleum gas (LPG), gasoline, diesel fuel or other Conduct a thorough pre-operation inspection of the explosive substances.
  • Page 22 Operator's Manual First Edition • Second Printing Work Area Safety Battery Safety Pipe Cradle Safety Read, understand and obey all warnings and Burn Hazards instructions provided with the pipe cradles. Batteries contain acid. Do not exceed the rated platform capacity. The Always wear protective pipe cradle assembly and the weight in the pipe clothing and eye wear when...
  • Page 23 First Edition • Second Printing Operator's Manual Work Area Safety Welder Safety Read, understand and obey all warnings and instructions provided with the welding power unit. Do not connect weld leads or cables unless the welding power unit is turned off at the platform controls.

  • Page 24: Legend

    Operator's Manual First Edition • Second 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 SX-180 Part No. 217927...

  • Page 25: Controls

    First Edition • Second Printing Operator's Manual Controls Controls STOP 230984 A Ground Control Panel Jib boom up/down buttons 16 High speed function enable LCD readout screen button Boom extend/retract buttons Engine speed select button 17 Low speed function enable 10 20A circuit breaker for system Red Emergency Stop button button...
  • Page 26 Operator's Manual First 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 27 First Edition • Second Printing Operator's Manual Controls 13 Platform rotate left button 19 Turntable rotate right button Press the platform rotate left button and the Press the turntable rotate right button and the platform will rotate left. turntable will rotate right. 14 Jib boom rotate right button 20 Emergency power button Press the jib boom rotate right button and the...
  • Page 28 Operator's Manual First Edition • Second Printing Controls Platform Control Panel SX-180 Part No. 217927...
  • Page 29 First Edition • Second Printing Operator's Manual Controls Part No. 217927 SX-180...
  • Page 30 Operator's Manual First 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 31 First 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 32 Operator's Manual First 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 33 First Edition • Second Printing Operator's Manual Controls 25 Drive enable switch with indicator light 27 Platform rotate switch Light on indicates that the Move the platform rotate primary boom has moved switch to the left and the past 50° in either platform will rotate left.

  • Page 34: Inspections

    Operator's Manual First 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 35 First Edition • Second Printing Operator's Manual Inspections Pre-operation Inspection  Steer and axle sensors  Alarms and beacons (if equipped)  Be sure that the operator’s, safety and  Nuts, bolts and other fasteners responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 36 Operator's Manual First 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 37 First 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 38 Operator's Manual First 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 39 First 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 40 Operator's Manual First 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 41 First 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 42 Operator's Manual First Edition • Second Printing Inspections 55 Press down the foot switch. est the Steering 56 Slowly move the control handle in the direction 50 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 43 First Edition • Second Printing Operator's Manual Inspections 61 Slowly move the control handle in the direction Test Drive and Braking indicated by the yellow triangle on the control 66 Press down the foot switch. panel OR press the thumb rocker switch in the direction indicated by the yellow triangle.
  • Page 44 Operator's Manual First Edition • Second Printing Inspections Test the Drive Enable System Test Limited Drive Speed 69 Press down the foot switch and lower the 73 Press down the foot switch. boom to the stowed position. 74 Raise the boom to 10° above horizontal. 70 Rotate the turntable until the boom moves past 75 Slowly move the drive control handle to the full 50°.
  • Page 45 First Edition • Second Printing Operator's Manual Inspections 90 Press down the foot switch. Test Drive Tilt Cutout 91 With the boom fully stowed, drive the machine 81 Press down the foot switch. onto a slope where the chassis angle is 82 With the boom fully stowed, drive the machine greater than 3°...
  • Page 46 Operator's Manual First Edition • Second Printing Inspections Test the Platform Level Recovery Test Emergency Controls 99 Press down the foot switch. 103 Push in the red Emergency Stop button to the off position to shut off the engine. 100 Push and hold the platform level recovery switch up.
  • Page 47 First 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 48 Operator's Manual First Edition • Second Printing Inspections Inspection for Decals with Words Part No. Decal Description 114258 Danger – Explosion Hazard Use the pictures on the next page to verify that all 114390 Danger – Electrocution Hazard decals are legible and in place. 114416 Danger –...
  • Page 49 First Edition • Second Printing Operator's Manual Inspections 1256420 or 1256421 or 1256422 219660 or 1255402 or 824615 or 1257237 1256420 or 1256421 or 1256422 Part No. 217927 SX-180...
  • Page 50 Operator's Manual First Edition • Second Printing Inspections Inspection for Decals with Part No. Decal Description Symbols 114249 Label – Tip-over Hazard, Tires 114251 Label – Explosion Hazard Use the pictures on the next page to verify that all 114252 Label –...
  • Page 51 First Edition • Second Printing Operator's Manual Inspections 1256420 or 1256421 or 1256422 1256420 or 1256421 or 1256422 Part No. 217927 SX-180...

  • Page 52: Operating Instructions

    Operator's Manual First 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 53 First Edition • Second Printing Operator's Manual Operating Instructions Perkins models Starting the Engine 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 First Edition • Second 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 First Edition • Second Printing Operator's Manual Operating Instructions To Rotate the Jib Operation from Ground 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 First Edition • Second Printing 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 57 First Edition • Second 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 First Edition • Second Printing Operating Instructions Drive Enable Engine Idle Select (rpm) Light on indicates that the primary Select the engine idle (rpm) by boom has moved past 50° in pressing the engine idle select either direction, at the square end switch.
  • Page 59 First Edition • Second Printing Operator's Manual Operating Instructions Operating Envelope Indicator Lights Platform Level Recovery The operating envelope indicator lights will come Press down the foot switch. on to notify the operator that a function has been Push and hold the platform level recovery interrupted and/or an action is required by the switch up.
  • Page 60 Operator's Manual First Edition • Second Printing 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 61 First Edition • Second Printing Operator's Manual 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 62 Operator's Manual First Edition • Second Printing 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 63: Transport And Lifting Instructions

    First Edition • Second 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 64 Operator's Manual First Edition • Second Printing Transport and Lifting Instructions Securing the Platform Securing to Truck or Trailer for Transit Note: Be aware of the boom position during the platform stowing sequence to avoid contact with Always use the turntable rotation lock pin each the boom.
  • Page 65 First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Fully lower the boom onto the turntable boom As the jib and platform approach the boom, rest pad. Raise the jib if necessary so the rotate the platform toward the boom until it platform does not contact the trailer deck.
  • Page 66 Operator's Manual First Edition • Second Printing Transport and Lifting Instructions SX-180 Part No. 217927...
  • Page 67 First 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 68: Maintenance

    Operator's Manual First 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 69 First 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 70 Operator's Manual First 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 71 First 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 72: Specifications

    Operator's Manual First Edition • Second Printing Specifications Specifications Model Tire size 445D50/710, 18 ply HD FF SX-180 Weight 55,000 lbs 24,948 kg Height, working maximum 186 ft 56.7 m (Machine weights vary with option configurations. See Height, platform maximum 180 ft 54.8 m serial label for specific machine weight.)
  • Page 73 First Edition • Second Printing Operator's Manual Specifications SX-180 Range of Motion Chart SX-180 Part No. 217927 Operator's Manual First Edition • Second Printing Part No. 217927 SX-180...

This manual is also suitable for:

Genie sx-180Sx18015-292

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