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Operator's Manual

Second Edition • Third Printing

Operating Instructions

SX-150 • SX-180

Part No. 1262335

Drive Enable

Light on indicates that the boom
has moved past a circle-end tire
and the drive function has been
interrupted.

To drive, move the drive enable switch and slowly
move the drive/steer control handle off center.

If the drive/steer control handle is not moved within
two seconds of moving the drive enable switch, the
drive function will not operate. Release and move
the drive enable switch again.

Be aware that the machine may move in the
opposite direction that the drive and steer controls
are moved.

Always use the color-coded direction arrows on the
platform controls and the drive chassis to identify
the direction the machine will travel.

When the drive enable light is on, the axles cannot
retract.

Engine Idle Select (rpm)

Select the engine idle (rpm) by
pressing the engine idle select
switch. The indicator light next to
the current setting will be on.



Turtle symbol: low idle



Rabbit symbol: high idle

Check Engine Light

Light on and engine stopped: Tag the
machine and remove from service.

Light on and engine still running:
Contact service personnel within
24 hours.

Summary of Contents for SX-150

Page 1: ...Operator s Manual Serial Number Range SX 150 From SX15015 101 ANSI CSA North America South America Asia SX 180 From SX18015 293 with Maintenance Information Second Edition Third Printing Part No 1262335 ...

Page 2: ...fety 12 Work Area Safety 13 Legend 22 Controls 23 Inspections 32 Operating Instructions 50 Transport and Lifting Instructions 62 Maintenance 68 Specifications 72 Copyright 2015 by Terex Corporation Second Edition Third Printing April 2017 Genie is a registered trademark of Terex South Dakota Inc in the U S A and many other countries These machines comply with ANSI SIA A92 5 CAN B 354 4 ...

Page 3: ...rial label located under cover Intended Use This machine is intended to be used only to lift personnel along with their tools and materials to an aerial work site Bulletin Distribution and Compliance Safety of product users is of paramount importance to Genie Various bulletins are used by Genie to communicate important safety and product information to dealers and machine owners The information co...

Page 4: ...es to your machine Please register your machine by visiting us on the web at www genielift com or by calling us toll free at 1 800 536 1800 Danger Failure to obey the instructions and safety rules in this manual will result in death or serious injury Do Not Operate Unless You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situation...

Page 5: ...ine 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 Indicates a hazardous situation which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or ...

Page 6: ...azard Overhead obstruction Collision hazard Electrocution hazard Maintain required clearance Tip over hazard Tip over hazard Tip over hazard Electrocution hazard Avoid contact Disconnect battery Read the operator s manual Read the service manual Explosion hazard No smoking No flame Stop engine Explosion hazard Burn hazard Fire extinguisher Fire hazard No smoking Explosion hazard No step Lanyard an...

Page 7: ...er reduces capacity Wheel load Tire specifications Recovery procedure if tilt alarm sounds while elevated Platform uphill 1 Lower boom 2 Retract boom Platform downhill 1 Retract boom 2 Lower boom Do not use ether or other high energy starting aids on machines equipped with glow plugs Voltage rating for power to platform Pressure rating for air line to platform Color Coded Direction Arrows Runaway ...

Page 8: ...Operator s Manual Second Edition Third Printing General Safety 6 SX 150 SX 180 Part No 1262335 General Safety ...

Page 9: ...Second Edition Third Printing Operator s Manual General Safety Part No 1262335 SX 150 SX 180 7 ...

Page 10: ...Operator s Manual Second Edition Third Printing General Safety 8 SX 150 SX 180 Part No 1262335 ...

Page 11: ...Second Edition Third Printing Operator s Manual General Safety Part No 1262335 SX 150 SX 180 9 ...

Page 12: ...Operator s Manual Second Edition Third Printing General Safety 10 SX 150 SX 180 Part No 1262335 ...

Page 13: ...Second Edition Third Printing Operator s Manual General Safety Part No 1262335 SX 150 SX 180 11 ...

Page 14: ...ne 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 All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufactur...

Page 15: ...ctrical line sway or sag and beware of strong or gusty winds Keep away from the machine if it contacts energized power lines Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off Do not operate the machine during lightning or storms Do not use the machine as a ground for welding Tip over Hazards Occupants equipment and materials s...

Page 16: ... moving to a firm level surface Do not rotate the boom while lowering The recovery mode should be used only by trained and authorized personnel If the tilt alarm sounds with the platform uphill 1 Lower the boom 2 Retract the boom If the tilt alarm sounds with the platform downhill 1 Retract the boom 2 Lower the boom Do not raise the boom when wind speeds may exceed 28 mph 12 5 m s If wind speeds e...

Page 17: ...s 667 N Do not alter or disable machine components that in any way affect safety and stability Do not replace items critical to machine stability with items of different weight or specification Do not replace factory installed tires with tires of different specification or ply rating Do not use air filled tires These machines are equipped with foam filled tires Wheel weight is critical to stabilit...

Page 18: ...oving or mobile surface or vehicle Be sure the tires are in good condition and the lug nuts tightened Operation on Slopes Hazards Do not drive the machine on a slope that exceeds the maximum uphill downhill or side slope rating of the machine Slope rating applies only to machines in the stowed position Maximum slope rating stowed position Platform downhill 35 19 Platform uphill 35 19 Side slope 25...

Page 19: ...rm floor clear of debris Lower the platform entry mid rail or close the entry gate before operating Do not enter or exit the platform unless the machine is in the stowed position and the platform is at ground level Collision Hazards Be aware of limited sight distance and blind spots when driving or operating Be aware of the boom position and tailswing when rotating the turntable Check the work are...

Page 20: ... crane unless the controls of the crane have been locked out and or precautions have been taken to prevent any potential collision No stunt driving or horseplay while operating a machine Bodily Injury Hazard Always operate the machine in a well ventilated area to avoid carbon monoxide poisoning Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate ...

Page 21: ...ines equipped with glow plugs Damaged Machine Hazards Do not use a damaged or malfunctioning machine Conduct a thorough pre operation inspection of the machine and test all functions before each work shift Immediately tag and remove from service a damaged or malfunctioning machine Be sure all maintenance has been performed as specified in this manual and the appropriate Genie service manual Be sur...

Page 22: ...s will reduce rated platform capacity and must be factored into total platform load The pipe cradle assembly weighs 21 lbs 9 5 kg The maximum capacity of the pipe cradle assembly is 200 lbs 91 kg The weight of the pipe cradle assembly and the load in the pipe cradles may limit the maximum number of occupants in platform Center the load within the perimeter of the platform Secure the load to the pl...

Page 23: ...eight of the welder will reduce the rated platform capacity and must be factored into the total platform load The welder power supply weighs 75 lbs 34 kg Do not operate the welder unless a fire extinguisher is immediately available for instant use per OSHA regulation 1926 352 d Lockout After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Retract and...

Page 24: ...nting Legend 22 SX 150 SX 180 Part No 1262335 Legend 1 Square end tire 2 Ground controls 3 Boom 4 Jib boom 5 Platform 6 Circle end tire 7 Platform controls 8 Sliding mid rail 9 Manual storage container 10 Lanyard anchorage points 11 Foot switch ...

Page 25: ...Jib boom up down buttons 9 Boom extend retract buttons 10 20A circuit breaker for system circuit 11 Alarm 12 Bypass recovery key switch 13 Platform rotate right button 14 Platform rotate left button 15 Jib boom rotate right button 16 Jib boom rotate left button 17 High speed function enable button 18 Low speed function enable button 19 Turntable rotate left button 20 Turntable rotate right button ...

Page 26: ...ff position and the machine will be off Turn the key switch to the ground position and the ground controls will operate Turn the key switch to the platform position and the platform controls will operate 6 Engine start button Press the engine start button to start the engine 7 Platform level up down buttons Press the platform level up button and the level of the platform will raise Press the platf...

Page 27: ...e low speed function enable button to enable the functions on the ground control panel to operate at low speed 19 Turntable rotate left button Press the turntable rotate left button and the turntable will rotate left 20 Turntable rotate right button Press the turntable rotate right button and the turntable will rotate right 21 Emergency power button Use emergency power if the primary power source ...

Page 28: ...Operator s Manual Second Edition Third Printing Controls 26 SX 150 SX 180 Part No 1262335 Platform Control Panel ...

Page 29: ...Second Edition Third Printing Operator s Manual Controls Part No 1262335 SX 150 SX 180 27 ...

Page 30: ...mergency power if the primary power source engine fails Push down the foot switch and simultaneously move the emergency power switch and activate the desired function The indicator light will be on when emergency power is being used 9 Diesel models Glow plug button with indicator light Press the glow plug button and hold for 3 to 5 seconds The glow plug indicator light will be on when the glow plu...

Page 31: ...o operate the machine 19 Dual axis proportional control handle for drive and steer functions OR Proportional control handle for drive function and thumb rocker for steer function Move the control handle in the direction indicated by the blue arrow on the control panel and the machine will drive forward Move the control handle in the direction indicated by the yellow arrow and the machine will driv...

Page 32: ...select switch with indicator lights Move the drive select switch to choose drive setting The indicator light next to the current setting will be on Machine on incline symbol Low range operation for inclines Machine on level surface symbol High range operation for maximum drive speed 23 Single axis proportional control handle for boom extend retract function Move the control handle down and the boo...

Page 33: ...l 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 Move the control handle to the right and the turntable will rotate right 27 Platform rotate switch Move the platform rotate switch to the left and the platform will rotate left Move the platform rotate switch to the right and the platform w...

Page 34: ...ion is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unautho...

Page 35: ...nance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Wear pads Tires and wheels Engine and related components Limit switches and horn Rotation sensors S...

Page 36: ...use the machine as it was intended 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 tagged and removed from service Repairs to the machine may...

Page 37: ...and press the boom up button Result The boom should raise approximately 10 and then stop On the LCD screen the arrow next to the extend axle symbol will flash The boom should not raise unless the axles are extended 8 Press and hold a function enable speed select button and press the boom extend button Result The boom should extend 1 ft 30 cm then stop On the LCD screen the arrow next to the extend...

Page 38: ...end and retract normally 15 Push and hold a function enable speed select button and push the turntable rotate left button and the turntable rotate right button Result The turntable should rotate normally Test Machine Functions 16 Do not press and hold a function enable speed select button Attempt to activate each boom and platform function button Result No boom and platform functions should operat...

Page 39: ...il PLATFORM LEVEL SENSOR DEGREES appears Result The LCD screen should display the angle in degrees Test the Operating Envelope 25 Simultaneously press the 2 LCD screen control buttons shown to activate status mode 26 Press one of the LCD screen control buttons shown until PRIMARY ANGLE DEGREES is displayed 27 Raise the boom and observe the LCD screen Result The LCD screen will display the boom ang...

Page 40: ...ome to a stop at 30 from the centerline of the boom assembly 34 Rotate the jib to the left Result The jib rotation should come to a stop at 30 from the centerline of the boom assembly Jib rotate left Jib rotate right At the Platform Controls Test Emergency Stop 35 Turn the key switch to platform control 36 Push in the platform red Emergency Stop button to the off position Result The engine should ...

Page 41: ...art 44 Do not press down the foot switch and test each machine function Result No functions should operate Test Machine Functions 45 Press down the foot switch 46 Activate each function control handle toggle switch or thumb rocker switch Result All functions should operate through a full cycle Test the Jib Rotate Limit 47 Press down the foot switch 48 Extend the boom approximately 3 ft 91 4 cm 49 ...

Page 42: ...tch and choose circle end yellow arrow steer 56 Press down the foot switch 57 Slowly move the control handle in the direction indicated by the yellow triangle on the control panel OR press the thumb rocker switch in the direction indicated by the yellow triangle Result The circle end wheels should turn in the direction that the blue triangles point on the drive chassis 58 Slowly move the drive con...

Page 43: ...n the direction indicated by the yellow triangle on the control panel OR press the thumb rocker switch in the direction indicated by the yellow triangle Result The square end wheels should turn in the direction that the yellow triangles point on the drive chassis The circle end wheels should turn in the direction that the blue triangles point on the drive chassis Test Drive and Braking 67 Press do...

Page 44: ...irection of travel If the drive control handle is not moved within two seconds of moving the drive enable toggle switch the drive function will not operate Test Limited Drive Speed 74 Press down the foot switch 75 Raise the boom to 10 above horizontal 76 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the primary boom raised should not...

Page 45: ... the alarm should sound at the platform controls 89 Lower the boom to the stowed position Result The machine should drive 90 Return to level ground and stow the boom 91 Press down the foot switch 92 With the boom fully stowed drive the machine onto a slope where the chassis angle is greater than 3 along the X Axis side to side Result The machine should continue to drive 93 Return the machine to le...

Page 46: ...sult The platform should return to a level position Note The platform level switch will only work in the direction that will return the platform to a level position Test Emergency Controls 104Push in the red Emergency Stop button to the off position to shut off the engine 105Pull out the red Emergency Stop button to the on position 106Press down the foot switch 107Simultaneously move and hold the ...

Page 47: ...erator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace Inspection Checklist Be aware of and avoid the following hazardous situati...

Page 48: ...over Hazard Tilt Alarm 1 133278 Label Low Sulfur Fuel 2 161689 Danger Maximum Capacity Wind Side Force 1 161692 Warning Slope Rating 1 Part No Decal Description Qty 161693 Label Wheel Load 4 218559 Danger Warning Tip over Crush Hazard 1 218746 Cosmetic Genie 1 218747 Cosmetic SX 180 1 219960 Instructions Perkins Engine Specs 1 230984 Ground Control Panel 1 232978 Platform Control Panel 1 822718 Co...

Page 49: ...Second Edition Third Printing Operator s Manual Inspections Part No 1262335 SX 150 SX 180 47 ...

Page 50: ...el Electrocution Hazard 3 133205 Label Electrocution Burn Hazard 2 161687 Label Maximum Capacity Wind Manual Force 1 Part No Decal Description Qty 161691 Label Slope Rating 1 161693 Label Wheel Load 4 218746 Cosmetic Genie 1 218747 Cosmetic SX 180 1 219958 Label Tip over Crush Hazard 1 230984 Ground Control Panel 1 232978 Platform Control Panel 1 822718 Cosmetic Genie 1 822719 Cosmetic SX 180 1 82...

Page 51: ...Second Edition Third Printing Operator s Manual Inspections Part No 1262335 SX 150 SX 180 49 ...

Page 52: ... the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to use...

Page 53: ...he engine fails to start or dies the restart delay will disable the start switch for 3 seconds Perkins models 1 Move the glow plug switch to either side and hold 2 Move the engine start toggle switch to either side If the engine fails to start or dies the restart delay will disable the start switch for 3 seconds If the engine fails to start after 15 seconds of cranking determine the cause and repa...

Page 54: ...to the on position 3 Press down the foot switch when using the controls from the platform 4 Simultaneously hold the emergency power switch on and activate the desired function The drive functions will not operate with emergency power To Extend and Retract Axles 1 Turn the key switch to platform control 2 At the platform controls press down the foot switch and move the drive control handle in eithe...

Page 55: ...n button according to the markings on the control panel Drive and steer functions are not available from the ground controls To Rotate the Jib 1 Push and hold a function enable speed select button 2 Push the jib boom rotate right button Continued use of the rotate jib right function will show a flashing arrow above the jib rotate indicator Rotate jib left to continue 3 Push and hold a function ena...

Page 56: ...There is no flashing indicator light for the jib rotate left function Rotate jib right to continue To Steer 1 Press down the foot switch 2 Select the steer mode by moving the steer mode switch The indicator light next to the current steer mode will be on 3 Slowly move the drive control handle in the direction indicated by blue or yellow triangles OR press the thumb rocker switch located on top of ...

Page 57: ...o machine on incline symbol To determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 3 feet 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wood is level While holding the...

Page 58: ... enable switch again Be aware that the machine may move in the opposite direction that the drive and steer controls are moved Always use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel When the drive enable light is on the axles cannot retract Engine Idle Select rpm Select the engine idle rpm by pressing the engine i...

Page 59: ...platform downhill 1 Retract the boom 2 Lower the boom Platform Not Level indicator light flashing The tilt alarm will be sounding when this light is flashing The Platform Level toggle switch will only work in the direction that will level the platform Level the platform until the indicator light is off Platform Level Recovery 1 Press down the foot switch 2 Push and hold the platform level recovery...

Page 60: ...the platform level controls do not work the machine will need to be recovered by trained and authorized personnel or a qualified service technician Generator To operate the generator move the generator toggle switch Note If the foot switch is activated during generator start up the generator will not operate The generator indicator light will flash during generator start up After generator start u...

Page 61: ...iesel engines have a regeneration mode that should run automatically when needed LCD will display REGEN FORCED and WARNING HIGH EXHAUST SYSTEM TEMP when the regeneration mode is running No service required After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Retract and lower the boom to the stowed position 3 Rotate the turntable until the boom is p...

Page 62: ...serve and Obey Pipe cradles must be installed on the inside of the platform Pipe cradles must not obstruct the platform controls or the platform entrance The bottom of the pipe cradle tube must rest on the platform floor Be sure the platform is level before installing a pipe cradle Pipe Cradle Installation 1 Install a pipe cradle on each side of the platform Refer to the illustration on the left M...

Page 63: ... cradle Pass the nylon strap over the load Depress the buckle and slide the strap through Tighten the strap 5 Gently push and pull on the load to make sure the pipe cradles and load are secure 6 Keep the load secured when the machine is moving Tip over hazard The weight of the pipe cradle assembly and the load in the pipe cradles will reduce the rated platform capacity of the machine and must be f...

Page 64: ...ine is being loaded Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial label for the machine weight 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...

Page 65: ...he Platform Note Be aware of the jib and platform position during the platform stowing sequence to avoid contact with the boom Note To start the platform stowing sequence the axles must be retracted the boom must be retracted and jib must be approximately in line with the boom Note The boom must be fully lowered and resting on the turntable boom rest pad before beginning the stowing sequence Note ...

Page 66: ...the platform toward the boom until it stops 5 Continue rotating the jib until it stops and the platform is stowed under the boom Depending on the trailer configuration boom raise and lower may be required to allow for blocking and tying off for transport 6 Place optional foam blocks between the platform and the trailer deck Secure the foam blocks to the platform 7 Adjust the platform to be centere...

Page 67: ...ing Operator s Manual Transport and Lifting Instructions Part No 1262335 SX 150 SX 180 65 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 150 ...

Page 68: ...Operator s Manual Second Edition Third Printing Transport and Lifting Instructions 66 SX 150 SX 180 Part No 1262335 SX 180 ...

Page 69: ...hine weight See the serial label for the machine weight 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 using the table and the picture on this page Attach the rigging only to the designated lifting points on the machine There are four lifting points on the machine...

Page 70: ...f a maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine is required before performing this procedure Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life Operating the m...

Page 71: ...eutz TD2 9L Engine Fuel Type Ultra Low Sulfur Diesel ULSD Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure that the boom is in the stow...

Page 72: ...he degas tank are under pressure and extremely hot Use caution when removing cap and adding fluids Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Electrocution hazard Contact with hot or live circuits may result in death or se...

Page 73: ...rterly 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 74: ...on 60 AC outlet in platform standard Fuel tank capacity 50 gallons 189 liters Hydraulic pressure maximum boom functions 2900 psi 203 bar Hydraulic pressure maximum auxiliary power unit 3200 psi 221 bar System voltage 12V Tire size 445D50 710 18 ply HD FF Weight 49 950 lbs 22 657 kg Machine weights vary with option configurations See serial label for specific machine weight Maximum slope rating sto...

Page 75: ...outlet in platform standard Fuel tank capacity 50 gallons 189 liters Hydraulic pressure maximum boom functions 2900 psi 203 bar Hydraulic pressure maximum auxiliary power unit 3200 psi 221 bar System voltage 12V Tire size 445D50 710 18 ply HD FF Weight 55 000 lbs 24 948 kg Machine weights vary with option configurations See serial label for specific machine weight Maximum slope rating stowed posit...

Page 76: ... 70 ft 21 3 m 90 ft 27 4 m 110 ft 33 5 m 130 ft 39 6 m 150 ft 45 7 m 0 ft 0 m 20 ft 6 1 m 10 ft 3 m 30 ft 9 1 m 40 ft 12 2 m 50 ft 15 2 m 60 ft 18 3 m 70 ft 21 3 m 80 ft 24 4 m 10 ft 3 m 20 ft 6 1 m 0 m 0 m 10 ft 3 m 20 ft 6 1 m 40 ft 12 2 m 60 ft 18 3 m 80 ft 24 4 m 100 ft 30 5 m 120 ft 36 6 m 140 ft 42 7 m 160 ft 48 8 m 180 ft 54 9 m 0 ft 0 m 20 ft 6 1 m 10 ft 3 m 30 ft 9 1 m 40 ft 12 2 m 50 ft ...

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