Terex SX18015-219 Manual
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Terex SX18015-219 Manual

Terex SX18015-219 Manual

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Operator's Manual
SX-180
Serial Number Range
from SX18014-101 to SX18015-219
(includes SX18013-005)
CE
with
Maintenance
Information
Original Instructions
First Edition
Second Printing
Part No. 217928

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Summary of Contents for Terex SX18015-219

  • Page 1 Operator's Manual Serial Number Range SX-180 from SX18014-101 to SX18015-219 (includes SX18013-005) with Maintenance Information Original Instructions First Edition Second Printing Part No. 217928...

  • Page 2: Table Of Contents

    Specifications ............61 Copyright © 2014 by Terex Corporation First Edition: Second Printing, April 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-180 Part No.

  • 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. 217928...
  • Page 9 First Edition • Second Printing Operator's Manual General Safety 219958 219958 161688 161691 114473 161688 133067 133067 82487 114473 82487 161691 82487 82487 B Part No. 217928 SX-180...
  • Page 10 Operator's Manual First Edition • Second Printing General Safety SX-180 Part No. 217928...

  • Page 11: Personal Safety

    First 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 First 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 First 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 First 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 Do not replace items critical to machine stability stowed position across with items of different weight or specification.
  • Page 15 First Edition • Second Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Do not place or attach fixed or overhanging Do not drive the machine on a slope that exceeds loads to any part of this the maximum uphill, downhill or side slope rating of machine.
  • Page 16 Operator's Manual First 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 First 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 First 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 First 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 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. 217928...

  • Page 21: Controls

    First Edition • Second Printing Operator's Manual Controls Controls STOP 230984 A Ground Control Panel LCD readout screen Jib boom up/down buttons 16 High speed function enable button Engine speed select button Boom extend/retract buttons 17 Low speed function enable Red Emergency Stop button 10 20A circuit breaker for system button...
  • Page 22 Operator's Manual First Edition • Second 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 23 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 24 Operator's Manual First Edition • Second Printing Controls Platform Control Panel Horn button Emergency power switch 12 Jib rotate indicator light Platform not level indicator Glow plug switch with (operating envelope) light indicator light 13 Platform overload indicator Machine not level indicator 10 Engine start switch with light light...
  • Page 25 First Edition • Second Printing Operator's Manual Controls 19 Dual axis proportional control 22 Drive speed select switch with 24 Axle extend/retract switch handle for drive and steer indicator lights with indicator lights functions Machine on incline symbol: 25 Drive enable switch with OR Proportional control Low range operation for indicator light...
  • Page 26 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 27 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 28 Operator's Manual First Edition • Second Printing Controls 21 Dual axis proportional control handle for jib 23 Single axis proportional control handle for boom up/down and rotate left/right functions boom extend/retract function Move the control handle Move the control handle up and the jib boom will down and the boom will raise.
  • Page 29 First Edition • Second Printing Operator's Manual 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. Move the control handle to the left and the turntable will rotate left.

  • Page 30: 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 31 First 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 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 33 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 34 Operator's Manual First Edition • Second Printing Inspections 12 Turn the key switch to platform control. At the Test Machine Functions platform controls, move the drive control 17 Do not press and hold a function enable/speed handle in the forward direction and move the select button.
  • Page 35 First Edition • Second Printing Operator's Manual Inspections Test the Tilt Sensor Test the Operating Envelope 23 Press one of the LCD 26 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 First Edition • Second Printing Inspections Test the Jib Rotate Limit At the Platform Controls 32 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 36 Turn the key switch to platform control.
  • Page 37 First Edition • Second Printing Operator's Manual Inspections Test the Foot Switch Test the Steering 41 Push in the platform red Emergency Stop 51 Move the steer button to the off position. mode select switch and choose 42 Pull out the red Emergency Stop button to the square-end (blue on position and do not start the engine.
  • Page 38 Operator's Manual First Edition • Second Printing Inspections 57 Slowly move the control handle in the direction 62 Slowly move the control handle in the direction indicated by the yellow triangle on the control indicated by the yellow triangle on the control panel OR press the thumb rocker switch in the panel OR press the thumb rocker switch in the direction indicated by the yellow triangle.
  • Page 39 First Edition • Second Printing Operator's Manual Inspections Test Drive and Braking Test the Drive Enable System 67 Press down the foot switch. 70 Press down the foot switch and lower the boom to the stowed position. 68 Slowly move the drive control handle in the direction indicated by the blue arrow on the 71 Rotate the turntable until the boom moves past control panel until the machine begins to move,...
  • Page 40 Operator's Manual First Edition • Second Printing Inspections Use the software version noted in step 3 to Test Limited Drive Speed determine which Drive Tilt Cutout test to perform. 74 Press down the foot switch. Use this function test for software versions 75 Raise the boom to 10°...
  • Page 41 First Edition • Second Printing Operator's Manual Inspections 89 Lower the boom to the stowed position. Use this function test for software versions 2.01 and higher Result: The machine should drive. 90 Return to level ground and stow the boom. Test Drive Tilt Cutout 91 Press down the foot switch.
  • Page 42 Operator's Manual First Edition • Second Printing Inspections 108 Return to level ground and stow the boom. Test Emergency Controls 109 Press down the foot switch. 117 Push in the red Emergency Stop button to the off position to shut off the engine. 110 With the boom fully stowed, drive the machine onto a slope where the chassis angle is 118 Pull out the red Emergency Stop button to the...
  • Page 43 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 44 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 45 First Edition • Second Printing Operator's Manual Inspections Part No. 217928 SX-180...

  • Page 46: 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 47 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 48 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 49 First Edition • Second Printing Operator's Manual Operating Instructions Operation from Ground Operation from Platform Turn the key switch to ground control. Turn the key switch to platform control. Pull out the red Emergency Stop button to the Pull out both ground and platform red on position.
  • Page 50 Operator's Manual First Edition • Second Printing Operating Instructions To Steer Driving on a slope Press down the foot switch. Determine the uphill, downhill and side slope ratings for the machine and determine the slope Select the steer mode by moving the steer grade.
  • Page 51 First Edition • Second Printing Operator's Manual Operating Instructions To determine the slope grade: Drive Enable Measure the slope with a digital inclinometer OR Light on indicates that the primary use the following procedure. boom has moved past 50° in either direction, at the square end You will need: of the machine and the drive...
  • Page 52 Operator's Manual First Edition • Second Printing Operating Instructions Engine Idle Select (rpm) Machine Not Level indicator light flashing: The Select the engine idle (rpm) by tilt alarm will be sounding pressing the engine idle select when this light is flashing. switch.
  • Page 53 First Edition • Second Printing Operator's Manual Operating Instructions Platform Overload Indicator Light Generator To operate the generator, move the generator Light flashing indicates the toggle switch. platform is overloaded and no functions will operate. Note: If the foot switch is activated during generator start-up, the generator will not operate.
  • Page 54 Operator's Manual First 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 55 First 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 56: Transport And Lifting Instructions

    Operator's Manual First 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 57 First Edition • Second Printing Operator's Manual Transport and Lifting Instructions Securing to Truck or Trailer for Fully lower the jib before passing 30° to the right side of the boom. Transit Rotate the jib to the right. Always use the turntable rotation lock pin each Once the jib passes 35°...
  • Page 58 Operator's Manual First Edition • Second Printing Transport and Lifting Instructions Securing the Chassis Use chains of ample load capacity. Use a minimum of 6 chains. Adjust the rigging to prevent damage to the chains. SX-180 Part No. 217928...
  • Page 59 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 60: 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 61 First Edition • Second Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Check the Engine Coolant Level – Liquid Cooled Models Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic Maintaining the engine coolant at the proper level oil levels can damage hydraulic components.
  • Page 62 Operator's Manual First Edition • Second Printing Maintenance Check the Batteries Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Proper battery condition is essential to good this machine according to the procedures found in machine performance and operational safety.

  • Page 63: Specifications

    First Edition • Second Printing Operator's Manual Specifications Specifications Model AC outlet in platform standard SX-180 Fuel tank capacity 189.3 liters Height, working maximum 56.7 m Hydraulic pressure, maximum 203 bar Height, platform maximum 54.8 m (boom functions) Height, stowed maximum 3.05 m Hydraulic pressure, maximum 221 bar...
  • Page 64 Operator's Manual First Edition • Second Printing Specifications SX-180 Range of Motion Chart SX-180 Part No. 217928 Operator's Manual First Edition • Second Printing SX-180 Part No. 217928...
  • Page 65 www.genielift.com...

This manual is also suitable for:

Genie sx-180Sx18013-005Sx18014-101

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