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Operator`s Manual

1. 1 Square end tire 7 Platform controls 2 Ground controls 8 Sliding mid rail 3 Boom 9 Manual storage container 4 Jib boom 10 Lanyard anchorage point 5 Platform 11 Foot switch 6 Circle end tire Genie 18 SX 180 Part No 217929 First Edition First Printing Operator s Manual Controls wo H BRO E LLG INZL NZ NA INTEL NZ IAN ZNI ANSIZIN IZNI L H oi Ground Control Panel Qn GM Oo LCD readout screen Engine speed select button Red Emergency Stop button Glow plug button Key switch for off ground platform selection Engine start button Platform level up down buttons 11 12 13 14 15 Jib boom up down buttons Boom extend retract buttons 20A circuit breaker for system circuit Alarm Platform rotate right button Platform rotate left button Jib boom rotate right button Jib boom rotate left button Genie Part No 217929 18 19 20 21 22 23 eG T n High speed function enable button Low speed function enable button Turntable rotate left button Turntable rotate right button Emergency power button Boom up down buttons LCD screen control buttons Jib rotate indicator operating envelope SX 180 19 Operator s Manual First Edition First Printing
2. gt Jib rotate indicator light operating envelope Continued use of the rotate jib right function will cause the jib rotate indicator light to flash Rotate jib left to continue There is no flashing indicator light for the jib rotate left function Rotate jib right to continue Platform overload indicator light Light flashing indicates the platform is overloaded The engine will stop and no functions will operate Remove weight until the light goes off and then restart the engine Power indicator light Light on indicates the machine is on Check engine indicator light Light on indicates an engine fault Low fuel indicator light Light on indicates the machine is low on fuel Fault indicator light Light on indicates a system fault Red Emergency Stop button Push in the red Emergency Stop button to the off position to stop all functions and turn the engine off Pull out the red Emergency Stop button to the on position to operate the machine Part No 217929 Genie Operator s Manual Controls 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
3. Controls Ground Control Panel 5 1 LCD readout screen B ook Eq U a b C e a low fuel indicator 6 b engine oil pressure indicator c water temperature indicator d emergency power indicator 7 e engine rpm indicator f hour meter 2 Engine speed select button Press the engine speed select button to select the engine speed When the arrow above the rabbit is lit the engine is in high idle speed When the arrow above the turtle is lit the engine is in low idle speed 3 Red Emergency Stop button 9 Push in the red Emergency Stop button to the off position to stop all functions and turn the engine off Pull out the red Emergency Stop button to the on position to operate the machine 10 4 Glow plug button 11 Push the glow plug button and hold for 3 to 12 5 seconds Genie 20 SX 180 Key switch for off ground platform selection Turn the key switch to the off 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 Engine start button Press the engine start button to start the engine Platform level up down buttons Press the platform level up button and the level of the platform will raise Press the platform level down button and the level of the platform will lower Jib boom up down buttons Press the jib boom up button and the jib boom will raise Press the jib boom down button
4. Inspections Test the Drive Enable System 69 Press down the foot switch and lower the boom to the stowed position 70 Rotate the turntable until the boom moves past 50 Result The drive enable indicator light should come on E and remain on while the boom is anywhere in the range shown O 71 Move the drive control handle off center Result The drive function should not operate 72 Move the drive enable toggle switch and slowly move the drive control handle off center Result The drive function should operate Note When the drive enable system is in use the machine may drive in the opposite direction that the drive and steer control handle is moved arrows on the platform controls and the drive chassis lt to identify the direction of travel Use the color coded direction Blue T Yellow If the drive control handle is not moved within two seconds of moving the drive enable toggle switch the drive function will not operate Genie 38 SX 180 Test Limited Drive Speed 73 Press down the foot switch 74 Raise the boom to 10 above horizontal 75 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the primary boom raised should not exceed 18 cm per second Note The machine will travel 12 m in 68 seconds 76 Lower the boom to the stowed position 77 Extend the boom 1 2 m 78 Slowly move the drive control handl
5. Explosion and Fire Hazards Do not start the engine if you smell or detect liquid petroleum gas LPG gasoline diesel fuel or other explosive substances Do not refuel the machine with the engine running Refuel the machine and charge the battery only in an open well ventilated area away from sparks flames and lighted tobacco Do not operate the machine or charge the battery in hazardous locations or locations where potentially flammable or explosive gases or particles may be present Do not spray ether into engines equipped with glow plugs Operator s Manual First Edition e First Printing Work Area Safety A 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 sure all decals are in place and legible Be sure the operator s safety and responsibilities manuals are complete legible and in the storage container located on the machine A Component Damage Hazards Do not use any battery or charger greater than 12V to jump start the engine Do not use the machine as a ground for welding Do not operate the machine in locations where extremely high magnetic fields may be present G
6. Press down the foot switch Move the dual axis proportional control handle to the left There is no flashing indicator light for the jib rotate left function Rotate jib right to continue Genie 48 SX 180 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 Xo Xo Ye Y 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 the drive control handle Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the wheels will turn To Drive 1 Press down the foot switch 2 Increase speed Slowly move the drive control handle in the direction indicated by the blue or yellow arrows Decrease speed Slowly move the drive control handle toward center Stop Return the drive control handle to center or release the foot switch Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel Machine travel speed is restricted when the boom is raised or extended Part No 217929 First Edition First Printing Operator s Manual A Driving on a slope Determine the uphill downhill and side slope ratings for the machine and determine the slope grade Maximum slope rating platform
7. Liquid Cooled Models Maintaining the engine coolant at the proper level is essential to engine service life Improper coolant level will affect the engine s cooling capability and damage engine components Daily checks will allow the inspector to identify changes in coolant level that might indicate cooling system problems A Burn hazard Beware of hot engine parts and coolant Contact with hot engine parts and or coolant may cause severe burns 1 Check the fluid level in the coolant recovery tank Add fluid as needed Result The fluid level should be at the FULL mark Note Do not remove the radiator cap Part No 217929 First Edition s First Printing Operator s Manual 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 serious injury Remove all rings watches and other jewelry A Bodily injury hazard Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water 1 Puton protective clothing and eye wear 2 Be sure that the battery cable connections are tight and free of corrosion 3 Be sure that the battery hold down brackets are in place and secure Note Adding terminal protectors
8. First Printing Operating Instructions Drive Enable Light on indicates that the primary boom has moved past 50 in 1 either direction at the square end ey of the machine and the drive function has been interrupted O 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 Genie 50 SX 180 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 Om Of Oe e Turtle symbol low idle e Rabbit symbol high idle Check Engine Light cy Light on and engine stopped Tag the machine and remove from service Light on and engine still running Contact service personnel within 24 hours Part No 217929 First Edition First Printing Operator s Manual Operating Envelope Indicator Lights The operating envelope indicator lights will come on to notify the operator
9. Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use Know and understand the function tests before going on to the next section 4 Inspect the workplace 5 Only use the machine as it was intended Genie 30 SX 180 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 only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection and function tests again before putting the machine into service Part No 217929 First Edition s First Printing L At the Ground Controls 1 Select a test area that is firm level and free of Operator s Manual Inspections Test the Extendable Axles Note Start this test with the axles retracted obstruction 7 Turn the key switch to ground control Pull out the red Emergency Stop button to the on position Result The beacons if equipped sho
10. and a corrosion preventative sealant will help eliminate the corrosion on the battery terminals and cables Part No 217929 Genie SX 180 61 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 Operator s Manual First Edition s First Printing Specifications Model SX 180 AC outlet in platform standard Height working maximum 56 7 m Fuel tank capacity 189 3 liters Height platform maximum 54 8m Hydraulic pressure maximum 203 bar Height stowed maximum 3 05 m boom Lenore Horizontal reach maximum 24 4m Hydraulic pean een 221 bar auxiliary power unit Width axles retracted 2 5m G ee 5 System voltage 12V ios lala M Tire size 445D50 710 18 ply HD FF DUE M Weight 24 948 kg new d Tor Mi un m Machine weights vary with option configurations jib stowed for transport See serial label for specific machine weight Maximum load capacity 340 kg S Maxi ind d 1 5 mi Airborne noise emissions aximum wind spee 5 m s E Sound press
11. and the machine will drive backwards Move the control handle in the direction indicated by the blue triangle and the machine will steer to the left Move the control handle in the direction indicated by the yellow triangle and the machine will steer to the right OR 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 drive backwards Press the left side of the thumb rocker and the machine will steer to the left Press the right side of the thumb rocker and the machine will steer to the right SX 180 25 Operator s Manual First Edition First Printing Controls 20 Steer mode select switch with indicator lights Move the steer mode o Wo Ao Xo select switch to v n choose steer mode The indicator light next to the current steer mode will be on 21 Dual axis proportional control handle for jib boom up down and rotate left right functions Move the control handle up and the jib boom will t raise Move the control handle down and the jib i boom will lower Move the control handle to the left and the jib boom will rotate left Move the control handle to the right and the jib boom will rotate right Re 26 22 23 24 Genie SX 180 Drive select switch with indicator lights Move the drive select da L l O switch to ch
12. function enable speed Q Q select button X PN 2 Push the appropriate function button according to the markings on the control panel Drive and steer functions are not available from the ground controls Genie Part No 217929 SX 180 Push and hold a function enable speed select button 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 Push and hold a function enable speed select button Push the jib boom rotate left button There is no flashing arrow for the jib rotate left function Rotate jib right to continue 47 Operator s Manual First Edition First Printing Operating Instructions Operation from Platform 1 Turn the key switch to platform control 2 Pull out both ground and platform red Emergency Stop buttons to the on position 3 Start the engine Do not press down the foot switch when starting the engine To Position Platform 1 Press down the foot switch 2 Slowly move the appropriate function control handle or thumb rocker switch or toggle switch according to the markings on the control panel To Rotate the Jib 1 Press down the foot switch 2 Move the dual axis proportional control handle to the right Continued use of the jib rotate right function will cause O J Lo the jib rotate indicator lightto W Nd flash Rotate jib left to continue
13. handle in the direction indicated by the blue triangle on the control panel OR press the thumb rocker switch in the direction indicated by the blue triangle Result The circle end wheels should turn in the direction that the yellow triangles point on the drive chassis ko ii O H H fo vs O bs O Move the steer mode select switch and choose crab steer Press down the foot switch Slowly move the drive control handle in the direction indicated by the blue triangle on the control panel OR press the thumb rocker switch in the direction indicated by the blue triangle Result All wheels should turn in the direction that the blue triangles point on the drive chassis Part No 217929 First Edition First Printing L 61 62 63 64 65 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 All wheels should turn in the direction that the yellow triangles point on the drive chassis ko u O H O Ie vse O O pU Move the steer mode select switch and choose coordinated steer Press down the foot switch Slowly move the drive control handle in the direction indicated by the blue triangle on the control panel OR press the thumb rocker switch in the direction indicated by the blue triangle Result The square end wheels should turn in the direction that the blue tri
14. lower the boom and do not continue to operate the machine If the tilt alarm sounds when the platform is raised use extreme caution Identify the condition of the boom on the slope as shown below Follow the steps to lower the boom before moving to a firm level surface Do not rotate the boom while lowering Part No 217929 Do not operate the machine in strong or gusty winds Do not increase the surface area of the platform or the load Increasing the area exposed to the wind will decrease machine stability Genie SX 180 11 Operator s Manual First Edition First Printing Work Area Safety Use extreme care and slow speeds while driving the machine in the stowed position across uneven terrain debris unstable or slippery surfaces and near holes y and drop offs Do not drive the machine on or near uneven terrain unstable surfaces or other hazardous conditions with the boom raised or extended Do not use the machine as a crane Do not push the machine or other objects with the boom Do not contact adjacent structures with the boom Do not tie the boom or platform to adjacent structures Do not place loads outside the platform perimeter Do not push off or pull toward any object outside of the platform Maximum allowable manual force Australia 400 N Genie 12 SX 180 Do not alter or disable machine components that in any way affect safety and stability Do not repla
15. shin READ MANUALS Read all manuals prior to operation 31060 A DANGER 82237 W Y Electrocution e Tip over Hazard Altering or disabling limit switches can result in machine tip over Machine tip over will Hazard Contact with energized components can result in death or serious injury Avoid contact with energized components 82237 B result in death or serious injury Do not alter or disable limit switch s Onlytrained maintenance personnel should access compartments Access by operator is only advised when performing Pre operation Inspection All compartments must remain closed and n secured during operation is restricted Contact with components under any cover may result in serious injury s DO NOT OPERATE equipment if you do not 31060 C understand the information in the manuals Consult your supervisor the owner or the manufacturer Electrocution Burn Hazard Failure to disconnect all the batteries before performing service on this machine may result in cay d Do not use ether or other high energy starting aids on machines equipped with glow plugs 97602 B Explosion Hazard Death or serious injury can result from the use of ether or other high energy starting aids death or serious injury Disconnect all the batteries before performing service on this machine 97005 B enie ATEREX BRAND 8 SX 180 Part No 217929 First Ed
16. tie points and the path is clear of all obstructions Reverse the procedures described to re engage the brakes Note The pump free wheel valve should always remain closed Operator s Manual First Edition First Printing Transport and Lifting Instructions Securing to Truck or Trailer for Transit Always use the turntable rotation lock pin each time the machine is transported 1 Turntable rotation lock pin Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items Securing the Platform Note Be aware of the boom position during the platform stowing sequence to avoid contact with the boom Note To start the platform stowing sequence the axles must be retracted Note The boom must be fully retracted and at or below horizontal Note Platform stowing for transport can only be done from the platform controls Note Only the operator may be in the platform during this process Note Keep hands on the controls at all times during the stowing operation 56 SX 180 Genie Fully lower the jib before passing 30 to the right side of the boom Rotate the jib to the right Once the jib passes 35 to the right of the boom boom up will be restricted to 2 above horizontal and automatic jib level will be disabled As the platform approaches the boom adjust platform level and jib height as necessary so the pl
17. 5402 Instructions Deutz Engine Specs 1 97579 Danger Tip over Welder option 1 L Shading indicates decal is hidden from view i e 97602 Warning Explosion Hazard 1 under covers Genie 42 SX 180 Part No 217929 First Edition First Printing Operator s Manual Inspections 822718 218747 Boom Tube 3 p rey 1254375 822722 CE 1 28159 114258 218746 822719 31060 1000083 219660 or J1 255402 S 97602 A 31788 eN 114390 NS 161693 1254849 PORTU d I ALA gr 40434 161693 28175 822723 1254849 822724 Li 232987 218559 114416 K 97815 p ge 71 pene 52475 ORDEI 97579 65278 b ee P 28236 82862 52865 82314 1254375 97757 X 219485 S gt AS 230984 Z 230987 31788 114390 161693 161693 1254849 1254849 40434 Genie Part No 217929 SX 180 43 Operator s Manual First Edition First Printing Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operati
18. Edition First Printing Inspections 11 Turn the key switch to platform control At the platform controls move the drive control handle in the forward direction and move the extend axle toggle switch Result The machine should drive and the axles should extend The axle extend and retract indicator lights will flash while the axles are moving and the axle extend light will stay on when the axles are fully extended 12 Return to the ground controls Turn the key switch to ground control 13 Press and hold a function enable speed select button and press the boom up button and then the boom down button Result The boom should raise and lower normally 14 Push and hold a function enable speed select button and push the boom extend button and the boom retract Result The boom should extend 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 Genie 32 SX 180 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 operate 17 Press and hold a function enable speed select button and activate each boom and platform function button Result All boom and platform functions should operate through a full cycle T
19. 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 up is complete the generator indicator light will stay lit and the engine rpm will move into high rpm rabbit symbol mode Note Only jib and platform functions are operable during generator operation The foot switch must be pressed to enable the jib and platform functions The generator will continue to function during jib and platform operation To operate the drive turntable and boom functions the generator must be turned off Plug a power tool into the power to platform GFCI outlet There is GFCI protection built into the generator electrical box located on the turntable chassis To turn off the generator move the generator toggle switch The generator indicator light will flash during generator shut down sequence After the generator shut down sequence is complete the generator indicator light will turn off and the engine rpm will move into low rpm turtle symbol mode Genie 52 SX 180 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 positioned between the circle end wheels 4 Turn the key switch to
20. Genie A TEREX BRAND Operator s Manual Serial Number Range SX 1 8 0 from SX18014 100 AUS Australia with Maintenance Information First Edition First Printing Part No 217929 Operator s Manual First Edition First Printing es Contents IrtroO duction eiie ett Let S 1 Symbol and Hazard Pictorials Definitions 4 General Safety 6 Personal Safety cccccccececeseeeseeeeeeneeeseneeeteaeeees 9 Work Area Safety 10 Legend u epi etai teta kids 18 Controls iiiter ite Oed 19 IMSPOCHONS eic hen nei Ea cs 28 Operating Instructions 44 Transport and Lifting Instructions 55 Maintenance eessseeeeeesseeeeeenenennnnnns 59 Teilen 62 Copyright 2014 by Terex Corporation First Edition First Printing February 2014 Genie ia a registered trademark of Terex South Dakota Inc in the U S A and many other countries These machines comply with AS1418 10 Genie SX 180 Part No 217929 First Edition First Printing Operator s Manual About this manual Genie appreciates your choice of our machine for your application Our number one priority is user safety which is best achieved by our joint efforts This book is an operation and daily maintenance manual for the user or operator of a Genie machine This manual should be considered a perman
21. Result The horn should sound Test the Tilt Sensor Alarm 39 Move a toggle switch such as the engine idle select switch Result The alarm should sound at the platform controls 4 4 c YS N Jib rotate left Jib rotate right Genie 34 SX 180 Part No 217929 First Edition First Printing L Test the Foot Switch Operator s Manual Inspections Test Machine Functions Press down the foot switch 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 40 Push in the platform red Emergency Stop 45 button to the off position 46 41 Pull out the red Emergency Stop button to the on position and do not start the engine 42 Press down the foot switch and attempt to start the engine by moving the start toggle switch to either side Result The engine should not start 47 43 Do not press down the foot switch and restart 48 the engine Result The engine should start 44 Do not press down the foot switch and test each machine function Result No functions should operate 49 Genie Part No 217929 SX 180 Press down the foot switch Move the dual axis proportional control handle to the right Result The jib rotation should come to a stop at 30 from the centerline of the boom assembly Move the dual axis proportional control handle to the left Resul
22. 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 35 19 35 19 25 14 Platform downhill Platform uphill Side slope Note Slope rating is subject to ground conditions and adequate traction See Driving on a Slope in the Operating Instructions section Operator s Manual First Edition First Printing Work Area Safety A Fall Hazards Occupants must wear a safety belt or harness in accordance with governmental regulations Attach the lanyard to the anchor provided in the platform Do not sit stand or climb on the platform guard rails Maintain a firm footing on the platform floor at all times Do not climb down from the platform when raised X Ta Keep the platform 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 Genie 14 SX 180 A 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 area for overhead obstructions or S other possible hazards N b Be aware of crush
23. and the jib boom will lower Boom extend retract buttons Press the boom extend button and the boom will extend Press the boom retract button and the boom will retract 20A circuit breaker for system circuit Alarm Platform rotate right button Press the platform rotate right button and the platform will rotate right Part No 217929 First Edition First Printing s OE Ksxsscasmwxsss Platform rotate left button Press the platform rotate left button and the platform will rotate left Jib boom rotate right button Press the jib boom rotate right button and the jib boom will rotate right Jib boom rotate left button Press the jib boom rotate left button and the jib boom will rotate left High speed function enable button Press the high speed function enable button to enable the functions on the ground control panel to operate at high speed Low speed function enable button Press the low speed function enable button to enable the functions on the ground control panel to operate at low speed Turntable rotate left button Press the turntable rotate left button and the turntable will rotate left Part No 217929 19 20 21 22 23 Genie SX 180 Operator s Manual Controls Turntable rotate right button Press the turntable rotate right button and the turntable will rotate right Emergency power button Use emergency power if the primary power source engine fails Si
24. anging load Do not cause a horizontal force or side load to machine by raising or lowering a fixed or overhanging load Electrocution Hazard Keep pipes away from all energized electrical conductors Part No 217929 Genie SX 180 17 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 Do not operate unless the weld cables are properly connected and the welder is properly grounded The weight of the welder will reduce the rated platform capacity and must be factored into the total platform load The welder power supply weighs 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 Selecta 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 positioned between the circle end wheels 4 Turn the key switch to the off position and remove the key to secure from unauthorized use Operator s Manual First Edition First Printing Legend
25. angles point on the drive chassis The circle end wheels should turn in the direction that the yellow triangles point on the drive chassis 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 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 Part No 217929 Operator s Manual Inspections Test Drive and Braking 66 67 Press down the foot switch Slowly move the drive control handle in the direction indicated by the blue arrow on the control panel until the machine begins to move then return the handle to the center position Result The machine should move in the direction that the blue arrow points on the drive chassis then come to an abrupt stop Slowly move the control handle in the direction indicated by the yellow arrow on the control panel until the machine begins to move then return the handle to the center position Result The machine should move in the direction that the yellow arrow points on the drive chassis then come to an abrupt stop Note The brakes must be able to hold the machine on any slope it is able to climb Genie SX 180 37 Operator s Manual First Edition First Printing
26. arance Occupants equipment and materials shall not 0 to 50KV 305m exceed the maximum platform capacity for the restrict r unrestricted ran f motion 50 to 200KV 4 60 m estricted or unrestricted range of motio 200 to 350KV 6 10 m Maximum platform capacity 340 kg 350 to 500KV 7 62 m Maximum occupants 2 200 10 TOUR V 10 67M Tie weight of options and accessories such as 750 to 1000KV 13 72m pipe cradles and welders will reduce the rated Allow for platform movement electrical line sway or sag and beware of strong or gusty winds Genie 10 SX 180 platform capacity and must be subtracted from the platform capacity See the decals with the options and accessories If using accessories read understand and obey the decals instructions and manuals with the accessory Part No 217929 First Edition First Printing Operator s Manual Work Area Safety Do not raise or extend the Oi If the tilt alarm sounds with the boom unless the machine is on a firm level surface 7 Do not depend on the tilt alarm as a level indicator The tilt alarm sounds in the platform only when the machine is on a severe slope Ty platform uphill 42 1 Lower the boom 2 Retract the boom x j If the tilt alarm sounds with the Z 1 platform downhill y 1 Retractthe boom 2 2 Lower mne boom Do not raise the boom j when wind speeds may exceed 12 5 m s If wind speeds exceed 12 5 m s when the boom is raised
27. atform does not contact the boom or the trailer deck As the platform approaches the boom rotate the platform towards the boom until it stops Continue rotating the jib until it stops and the platform is stowed under the boom Depending on the trailer configuration boom raise or lower may be required to allow for blocking and tying off for transport Place a foam block between the platform and the trailer deck Secure the platform with a nylon strap placed through the lower platform support Do not use excessive downward force when securing the boom section Place foam block SL between platform and trailer deck Part No 217929 First Edition First Printing Operator s Manual p a 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 1 37 m Genie Part No 217929 SX 180 57 Operator s Manual First Edition First Printing Transport and Lifting Instructions Observe and Obey MI Only qualified riggers should rig the machine V Only certified crane operators should lift the machine and only in accordance with the applicable crane regulations M Be sure the crane capacity loading surfaces and straps or lines are sufficient to withstand the machine weight See the serial lab
28. ce Tip over Hazard Tip over Hazard Tip over Hazard Electrocution Hazard Avoid contact NM LEN Disconnect battery Read operator s manual LEN Read service manual mof Explosion Hazard R No smoking No flame Stop engine Explosion hazard C Burn Hazard Fire extinguisher a 9 X1 qd LT ON i Fire Hazard No smoking Explosion hazard No step Lanyard attachment point Genie 4 SX 180 Part No 217929 First Edition First Printing Operator s Manual Symbol and Hazard Pictorials Definitions Platform tie down instructions Lifting amp tie down instructions Tie down point Lifting point Wind speed 1 _ Maximum capacity HL Weight of welder reduces capacity Ww Wheel load Tire specifications elevated Platform uphill 1 Lower boom 2 Retract boom Recovery procedure if tilt alarm sounds while Platform downhill 1 Retract boom 2 Lower boom A Voltage rating for power to platform Do not use ether or other high energy starting aids on machines equipped with glow plugs Pressure rating for air line to platform Color coded directions arrows Runaway Hazard BS Only trained maintenance personnel should access compartments Manual force Genie Part No 217929 SX 180 Operator s Manual Firs
29. ce 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 stability Do not use the platform controls to free a platform that is caught snagged or otherwise prevented from normal motion by an adjacent structure All personnel must be removed from the platform before attempting to free the platform using the ground controls Do not modify or alter an aerial work platform without prior written permission from the manufacturer Mounting attachments for holding tools or other materials onto the platform toeboards or guard rail system can increase the weight in the platform and the surface area of the platform or the load Part No 217929 First Edition First Printing Operator s Manual Do not place or attach fixed or overhanging loads to any part of this machine Do not place ladders or scaffolds in the platform or against any part of this machine Do not transport tools and materials unless they are evenly distributed and can be safely handled by person s in the platform Do not use the machine on a moving or mobile surface or vehicle Be sure the tires are in good condition and the lug nuts tightened Part No 217929 Genie SX 180 13 Work Area Safety A Operation on
30. ctions have been followed properly and that the pipe cradles are secured to the platform railings 2 Place the load so that it rests in both pipe cradles The length of the load should be parallel with the length of the platform Center the load in the pipe cradles Secure the load to each pipe 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 factored into the total platform load Tip over hazard The weight of the pipe cradle assembly and the load in the pipe cradles may limit the maximum number of occupants in the platform Maximum Pipe Cradle Capacity All models 90 7 kg Pipe Cradle Assembly Weight 9 5 kg Genie 54 SX 180 Part No 217929 First Edition First Printing Operator s Manual Transport and Lifting Instructions Observe and Obey V Genie provides this securement information as a recommendation Drivers are solely responsible for making sure machines are properly secured and the correct trailer is selected pursuant to US Department of Transportation regulations other localized regulations and their company policy M Gen
31. d observe the LCD screen Result The LCD screen will display the boom angle to gravity in degrees Press one of the LCD screen control buttons shown until LENGTH SENSOR EXTENSION CM is displayed J Extend the boom and observe the LCD screen Result The LCD screen will display the string pot extension length Retract the boom 33 Operator s Manual eeo al Inspections Test the Jib Rotate Limit 31 32 33 34 At the ground controls press and hold a function enable button and press either the jib boom rotate right button or the jib boom rotate left button Rotate the jib boom in line with the boom assembly Press and hold a function enable speed select button and press the boom extend button Extend the boom approximately 91 4 cm Rotate the jib to the right Result The jib rotation should come to a stop at 30 from the centerline of the boom assembly Rotate the jib to the left Result The jib rotation should come to a stop at 30 from the centerline of the boom assembly First Edition e First Printing At the Platform Controls Test Emergency Stop 35 36 37 Turn the key switch to platform control Push in the platform red Emergency Stop button to the off position Result The engine should shut off and no functions should operate Pull out the red Emergency Stop button and restart the engine Test the Horn 38 Press the horn button
32. downhill gradeability 3596 19 Maximum slope rating platform 3596 19 Maximum side slope rating Bab so Note Slope rating is subject to ground conditions and adequate traction The term gradeability applies to the counterweight uphill configuration only Be sure the boom is below horizontal and the platform is between the circle end wheels Move the drive speed select switch to machine on incline symbol Part No 217929 Genie SX 180 49 Operating Instructions To determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need e carpenter s level e Straight piece of wood at least 1 m long e 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 piece of wood level measure the vertical distance from the bottom of the piece of wood to the ground Divide the tape measure distance rise by the length of the piece of wood run and multiply by 100 Example run rise v Piece of wood 2 3 6 m Run 3 6 m Rise 0 3m 0 3 m 3 6 m 0 083 x 100 8 3 grade If the slope exceeds the maximum uphill downhill or side slope rating then the machine must be winched or transported up or down the slope See Transport and Lifting section Operator s Manual First Edition
33. e to the full drive position Result The maximum achievable drive speed with the primary boom raised should not exceed 18 cm per second Note The machine will travel 12 m in 68 seconds 79 Raise the boom to 50 above horizontal and then extend the boom to maximum length 80 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the boom fully extended should not exceed 4 5 cm per second Note The machine will travel 12 m in 270 seconds Part No 217929 First Edition First Printing H n ug Test Drive Tilt Cutout 90 81 Press down the foot switch 91 82 With the boom fully stowed drive the machine onto a slope where the chassis angle is greater than 4 5 along the Y Axis front to back 92 Result The machine should continue to drive 83 Return the machine to level ground and extend 93 the boom approximately 91 4 cm 84 Drive the machine onto a slope where the chassis angle is greater than 4 5 along the Y Axis front to back Result The machine should stop once the 94 machine reaches 4 5 of chassis tilt 85 Retract the boom to the stowed position 95 Result The machine should drive 86 Return to level ground and raise the boom to 96 approximately 15 above horizontal 87 Drive the machine onto a slope where the c
34. el 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 one on each axle Adjust the rigging to prevent damage to the machine and to keep the machine level X Axis 3 3m Y Axis 1 6m Center of gravity SX 180 Genie 58 SX 180 Part No 217929 First Edition First Printing Operator s Manual Observe and Obey M Only routine maintenance items specified in this manual shall be performed by the operator V Scheduled maintenance inspections shall be completed by qualified service technicians according to the manufacturer s specifications and the requirements specified in the responsibilities manual MI Use only Genie approved replacement parts Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one or more of the symbols appear at the beginning of 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 o perform this procedure Indicates that a cold engine i
35. enie 16 SX 180 A Battery Safety Burn Hazards Batteries contain acid Always wear protective clothing and eye wear when working with batteries t Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Explosion Hazards Keep sparks flames and lighted tobacco away from batteries Batteries emit explosive gas bot A Electrocution Hazard Avoid contact with electrical terminals Part No 217929 First Edition First Printing Operator s Manual A Pipe Cradle Safety Read understand and obey all warnings and instructions provided with the pipe cradles Do not exceed the rated platform capacity The pipe cradle assembly and the weight in the pipe cradles will reduce rated platform capacity and must be factored into total platform load The pipe cradle assembly weighs 9 5 kg The maximum capacity of the pipe cradle assembly is 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 platform Do not obstruct the entrance or the exit of the platform Do not obstruct the ability to operate the platform controls or the red Emergency Stop button Do not operate unless you are adequately instructed and are aware of all of the hazards associated with movement of the platform with an overh
36. ent part of your machine and should remain with the machine at all times If you have any questions contact Genie Product Identification The machine serial number is located on the serial label Serial label Serial number located under cover stamped on chassis Part No 217929 Genie SX 180 1 Introduction 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 contained in the bulletins is tied to specific machines using the machine model and serial number Distribution of bulletins is based on the most current owner on record along with their associated dealer so it is important to register your machine and keep your contact information up to date To ensure safety of personnel and the reliable continued operation of your machine be sure to comply with the action indicated in a respective bulletin Operator s Manual First Edition First 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 y
37. h and hold the platform level recovery switch up 101 Move the platform level switch up and the level of the platform will raise The platform should return to a level position 102 Move the platform level switch down and the level of the platform will lower 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 Genie 40 SX 180 Test Emergency Controls 103 Push in the red Emergency Stop button to the off position to shut off the engine 104 Pull out the red Emergency Stop button to the on position 105 Press down the foot switch 106 Simultaneously move and hold the emergency power switch and activate each function control handle toggle switch or thumb rocker switch Note To conserve battery power test each function through a partial cycle Result All boom and steer functions should operate Part No 217929 First Edition First Printing Operator s Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations L drop offs or holes L bumps floor obstructions or debris Do Not Operate Unless LI sloped suitaues unstable or slippery surfaces M You learn and practice the principles of safe J ppery machine operation contained in this operator s L overhead obstructions and high voltage manual conductors 1 Avoid hazardo
38. hassis angle is greater than 4 5 along the Y Axis front to back Result The machine should stop once the 97 machine reaches 4 5 of chassis tilt 88 Lower the boom to the stowed position 98 Result The machine should drive 89 Return to level ground and stow the boom Genie Part No 217929 SX 180 Operator s Manual Inspections Press down the foot switch 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 Return the machine to level ground and extend the boom approximately 91 4 cm 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 stop once the machine reaches 3 of chassis tilt Retract the boom to the stowed position Result The machine should drive Return to level ground and raise the boom to approximately 15 above horizontal 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 stop once the machine reaches 3 of chassis tilt Lower the boom to the stowed position Result The machine should drive Return to level ground and stow the boom 39 Operator s Manual First Edition e First Printing Inspections Test the Platform Level Recovery 99 Press down the foot switch 100 Pus
39. he descent alarm should sound while the boom is lowering Test Emergency Controls 18 Push in the red Emergency Stop button to the off position to shut off the engine 19 Pull out the red Emergency Stop button to the on position Note To conserve battery power test each function through a partial cycle 20 Simultaneously push and hold the emergency power button and push each boom function button Result All boom functions should operate 21 Start the engine Part No 217929 First Edition First Printing Operator s Manual Test the Tilt Sensor 22 Press one of the LCD screen control buttons until lt TURNTABLE LEVEL SENSOR X DIRECTION Inspections Test the Operating Envelope 25 appears Be Result The LCD screen should display the angle in degrees 23 Press the LCD screen control buttons until TURNTABLE LEVEL SENSOR Y DIRECTION appears 27 Result The LCD screen should display the angle in degrees 24 Press the LCD screen control buttons until 28 PLATFORM LEVEL SENSOR DEGREES appears Result The LCD screen should display the angle in degrees 29 30 Genie Part No 217929 SX 180 Simultaneously press the 2 LCD screen control buttons shown to activate status mode f Press one of the LCD screen control buttons shown until PRIMARY ANGLE DEGREES is displayed lt Raise the boom an
40. ie customers needing to containerize any lift or Genie product should source a qualified freight forwarder with expertise in preparing loading and securing construction and lifting equipment for international shipment M Only qualified aerial lift operators should move the machine on or off the truck V The transport vehicle must be parked on a level surface V The transport vehicle must be secured to prevent rolling while the machine is being loaded Part No 217929 Genie SX 180 55 M 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 M Be sure the turntable is secured with the turntable rotation lock before transporting Be sure to unlock the turntable for operation Yl Do not drive the machine on a slope that exceeds the uphill downhill or side slope rating See Driving on a Slope in the Operating Instructions section V If the slope of the transport vehicle bed exceeds the maximum slope rating the machine must be loaded and unloaded using a winch as described in the brake release operation Free wheel Configuration for Winching Chock the wheels to prevent the machine from rolling Release the wheel brakes by turning over all four drive hub disconnect caps Disengage Be sure the winch line is properly secured to the drive chassis
41. ill turn on for 30 seconds 2 Move the engine start toggle switch to either side The engine start switch can be moved at any time while the glow plugs are on If the engine fails to start or dies the restart delay will disable the start switch for 3 seconds Part No 217929 Genie SX 180 45 Operating Instructions 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 repair any malfunction Wait 60 seconds before trying to start again In cold conditions 6 C and below warm the engine for 5 minutes before operating to prevent hydraulic system damage In extreme cold conditions 18 C and below machines should be equipped with optional cold start kits Attempting to start the engine when temperatures are below 18 C may require the use of a booster battery Operator s Manual First Edition First Printing Operating Instructions Emergency Stop Push in the red Emergency Stop button to the off position at the ground controls or the platform controls to stop all machine functions and turn the engine off Repair any function that operates when either red Emergency Stop button is pushed in Selecting and operating the ground controls will
42. in the direction that will level the platform Machine on incline indicator light Light on indicates all functions have stopped See the instructions in the Operating Instructions section Lower boom indicator light Lower the boom until the light is off Raise retract boom indicator light Raise retract the boom until the light is off Used for optional equipment Generator switch with indicator light Move the generator switch to turn the generator on Move the switch again to turn the generator off 24 10 11 Genie SX 180 Emergency power switch with indicator light Use emergency 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 Glow plug switch with indicator light Move this switch and hold 3 to 5 seconds to activate the glow plugs Engine start switch with indicator light Move the engine start switch and the engine will start The engine start indicator light will flash during engine start up and will turn solid once the engine is running Engine idle select switch with indicator light Om off O6 Move this switch to select engine idle setting Rabbit symbol light on indicates high idle is selected Turtle symbol light on indicates low idle is selected Part No 217929 First Edition First Printing H
43. ing hazards when grasping the platform guard rail k Operators must comply with employer job site and governmental rules regarding use of personal protective equipment Part No 217929 First Edition First Printing Operator s Manual Observe and use the color coded direction arrows on the platform controls and drive chassis for drive and steer functions Do not lower the boom unless the area below is clear of personnel and obstructions Limit travel speed according to the condition of the ground surface congestion slope location of personnel and any other factors which may cause collision Do not operate a boom in the path of any 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 Part No 217929 Genie SX 180 15 Work Area Safety A 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 and or burn skin Improper contact with components under any cover will cause serious injury Only trained maintenance personnel should access compartments Access by the operator is only advised when performing a pre operation inspection All compartments must remain closed and secured during operation
44. ition First Printing Operator s Manual n lt TrsuC 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 All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufacturer s instructions Genie Part No 217929 SX 180 9 Operator s Manual First Edition First Printing Work Area Safety A Electrocution Hazards This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current Obey all local and governmental regulations regarding required clearance from electrical power lines At a minimum the required clearance contained in the chart below must be followed Keep away from the machine if it contacts energized power lines Personnel on the ground M or in the platform must BN not touch or operate the Ke machine until energized K power lines are shut off Do not operate the machine during lightning or storms Do not use the machine as a ground for welding A Tip over Hazards Line Voltage Required Cle
45. ly with adequate safety factors Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation Genie 62 SX 180 Part No 217929 First Edition First Printing Operator s Manual a Specifications SX 180 Range of Motion Chart 54 9 m 51 8 m 48 8 m 45 7 m 42 7 m 39 6 m 36 6 m 33 5 m 30 5 m 27 4 m 24 4 m 21 3 m 18 3 m 15 2 m 12 2 m 3 1 1 12 2 m 15 2m 18 3m 213m 244m Genie Part No 217929 SX 180 63 www genielift com
46. multaneously hold the emergency power button and activate the desired function Boom up down buttons Press the boom up button and the boom will raise Press the boom down button and the boom will lower LCD screen control buttons Jib rotate indicator operating envelope Continued use of the jib rotate right function will show a flashing arrow above the jib rotate indicator Rotate jib left to continue There is no flashing arrow for the jib rotate left function Rotate jib right to continue 21 Operator s Manual First Edition First Printing Controls Im oO ED O D Platform Control Panel 1 Horn button 2 Platform not level indicator light 3 Machine on incline indicator light 4 Lower boom indicator light 5 Raise retract boom indicator light 6 Used for optional equipment 7 Generator switch with indicator light o Emergency power switch Glow plug switch with indicator light Engine start switch with indicator light Engine idle select switch with indicator light e Rabbit high idle e Turtle low idle Genie 22 14 15 16 17 18 Jib rotate indicator light operating envelope Platform overload indicator light Power indicator light Check engine indicator light Low fuel indicator light Fault indicator light Red Emergency Stop button SX 180 Part No 217929 First Edition Fi
47. nspection performed by the operator prior to each work shift The inspection 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 unauthorized variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection again before going on to the function tests Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual Part No 217929 First Edition First Printing Operator s Manual Pre operation Inspection LJ Be sure that the operators safety and responsibilities manuals are complete legible and in the storage container located in the platform Q Be sure that all decals are legible and in place See Inspections section LQ Check for hydraulic oil leaks and proper oil level Add oil if needed See Mai
48. ntenance section Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section Che Q Check for engine oil leaks and proper oil level Add oil if needed See Maintenance section L Check for engine coolant leaks and proper level of coolant Add coolant if needed See E Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications a L Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds a L Fuel and hydraulic tanks a Drive and turntable motors and drive hubs Genie Inspections Wear pads Tires and wheels Engine and related components Limit switches and horn Rotation sensors Steer and axle sensors Alarms and beacons if equipped Nuts bolts and other fasteners U U U U U C U C U Platform entry mid rail or gate ck entire machine for L Cracks in welds or structural components L Dents or damage to machine L Excessive rust corrosion or oxidation Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened After you complete your inspection be sure that all compartment covers are in place and latched Part No 217929 SX 180 29 Operator s Manual First Edition First Printing Inspections Do
49. on It is the operator s responsibility to follow all the safety rules and instructions in the operators safety and responsibilities manuals Do Not Operate Unless Using the machine for anything other than lifting personnel along with their tools and materials to M You learn and practice the principles of safe an aerial work site is unsafe and dangerous machine operation contained in this operator s Only trained and authorized personnel should be permitted to operate a machine If more than one 1 Avoid hazardous situations operator is expected to use a machine at different times in the same work shift they must all be manual lad paHormer prereperallominspecton qualified operators and are all expected to follow 3 Always perform function tests prior to use all safety rules and instructions in the operator s 4 Inspect the workplace safety and responsibilities manuals That means every new operator should perform a pre operation 5 Only use the machine as it was inspection function tests and a workplace intended inspection before using the machine Genie 44 SX 180 Part No 217929 First Edition s First Printing Operator s Manual Starting the Engine 1 Atthe ground controls turn the key switch to the desired position 2 Be sure both ground and platform control red Emergency Stop buttons are pulled out to the on position Deutz models 1 Move the glow plug switch to either side The glow plugs w
50. on Hazard 3 Part No Decal Description Qty 114416 Danger Tip over Hazard Tilt Alarm 1 27204 Arrow Blue 2 161690 Danger Maximum Capacity Wind amp 1 27205 Arrow Yellow 2 Manual pr s 27206 Triangle Blue 4 161692 Warning Slope Rating 1 27207 Triangle Yellow 4 161693 Label Wheel Load 4 28159 Label Diesel 2 218559 SN Warning Tip over Crush 1 28175 Warning Compartment Access 2 218746 ore Genie 1 28176 i Missing Manuals 1 218747 Cosmetic SX 180 1 5299 Warning E SE 1 219485 Notice Operating Instructions 1 31060 angers U Hazard Pimi Switch 3 219960 Instructions Perkins Engine Specs 1 31788 Danger Explosion Burn Hazard 2 230984 Ground Control Panel 1 20494 Bol banvardonenorage Point 9 230987 Ground Control Panel Key Switch 1 44981 Label Air Line to Platform option 2 232978 Platform Control Panel 1 52475 Label Transport Tie Down 6 822718 Cosmetic Genie 1 52865 Warning Annual Inspection Record 1 822719 Cosmetic SX 180 1 652 8 Caution No Step 8 822722 Label Fuse and Relay Panel Layout 1 12086 Label Lifting Point E 822723 Label Transport Diagram 2 72875 Warning Pipe Cradle option 2 822724 Clear Plastic Cover 1 i osa Besoin Haze 1000083 Notice Start and Controls Battery 1 Bed Dn TID ver HR 1 1254375 Label Power to Platform 415V 240V 2 Sheen Bande i 1254849 Danger Tire Specifications Low Profile 4 BERGE pw Fire Extinguisher Welder i 125
51. oose 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 Single axis proportional control handle for boom extend retract function Move the control handle down and the boom will extend Move the control handle up and the boom will retract e Axle extend retract switch with indicator lights Move the axle select MA At switch to choose an axle O a C O setting The axle extend and retract indicator lights will flash while the axles are moving The axle extend indicator light will stay on when the axles are fully extended The axle retract indicator light will stay on when the axles are fully retracted Part No 217929 First Edition s First Printing Operator s Manual 25 26 Drive enable switch with indicator light Light on indicates that the primary boom has moved past 50 in either direction at the square end of the machine and the drive function has been interrupted To drive move the drive enable switch and slowly move the drive control handle off center Dual axis proportional control handle for boom up down and turntable rotate left right A nct 9 S 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 t
52. ou read understand and obey all applicable governmental regulations V You are properly trained to safely operate the machine Part No 217929 First Edition s First Printing Operator s Manual 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 the safety sign material Introduction Hazard Classification Decals on this machine use symbols color coding solvent based cleaners because they may damage Part No 217929 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 AWARNING which if not avoided could result in death or serious injury A CAUTION Indicates a hazardous situation CAUTIO which if not avoided could result in minor or moderate injury Indicates a property damage message Genie SX 180 3 Operator s Manual First Edition First Printing Symbol and Hazard Pictorials Definitions Crush Hazard Lo xf Keep away from moving parts le E Crush Hazard Z Bi Overhead obstruction e Electrocution Hazard Maintain required distan
53. our machine along with your name and contact information At minimum Genie should be contacted for Accident reporting Questions regarding product applications and safety Standards and regulatory compliance information Current owner updates such as changes in machine ownership or changes in your contact information See Transfer of Ownership below Transfer of Machine Ownership Taking a few minutes to update owner information will ensure that you receive important safety maintenance and operating information that applies 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 Genie 2 SX 180 Do Not Operate Unless V You learn and practice the principles of safe machine operation contained in this operators manual 1 Avoid hazardous situations Know and understand the safety rules before going on to the next section 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended M You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals V You read understand and obey employer s safety rules and worksite regulations MI Y
54. override the platform red Emergency Stop button Emergency Controls Use emergency power if the primary power source engine fails 1 Turn the key switch to ground or platform control 2 Pull out the red Emergency Stop button to the on position 3 Press down the foot switch when using the controls from the platform The drive function will not operate with emergency power 4 Simultaneously hold the emergency power switch on and activate the desired function Genie 46 SX 180 To Extend and Retract Axles 1 Turn the key switch to platform control 2 Atthe platform controls O G AX Oo press down the foot switch eee eee and move the drive control handle in either direction and move the axle switch in the appropriate direction The axle extend and retract indicator lights will flash while the axles are moving The axle extend indicator light will stay on when the axles are fully extended The axle retract indicator light will stay on when the axles are fully retracted The axles can only be retracted if the boom is fully lowered and retracted and the platform is between the circle end wheels Part No 217929 First Edition s First Printing Operator s Manual Operating Instructions Operation from Ground To Rotate the Jib 1 Turn the key switch to ground control 1 2 Pull out the red Emergency Stop button to the on position 3 Startthe engine To Position Platform 1 Push and hold a I
55. rating Tire Size 445D50 710 18 ply HD Foam filled Genie P N 1255639 left side Genie P N 1255640 right side 28175 Compartment access 4 axle extension cylinder 31060 114258 82237 97865 114258 114390 31788 EP 1254849 31060 114390 Lug NutTorque Dry bolts 420 ft lbs 569 5 Nm Lubricated bolts 320 ft Ibs 433 9 Nm Foam filled Tire Minimum New Weight 850 Ibs 386 kg Electrocution Hazard Death or injury can result from contacting electric power lines Always contact the electric power line owner The electric power shall be disconnected or the power lines moved or insulated before machine operations 4254849 A begin 28175 1254849 97602 114258 ADANGER Maintain required clearance Line Voltage Required Clearance Burn Hazard No smoking No 0 to SOKV 10ft 30m Fuel and fumes flame Stop 50 to 200KV 15ft 46m can explode engine 200 to 350KV 20f eim and burn 144258 A 350 to 500KV 25ft 7 6m 500 to 750KV 35 tt 106m 750 to 1000KV 45 tt 137m 114390 A 31788 A DANGER Explosion Bum Hazard Ignition of explosive gases or contact with corrosive gg 106 wit nase death bums orbindness Keep all open lames and sparks away Wear personal protective equipment including face shield loves and long sleeve
56. rst Printing Operator s Manual 19 20 21 J a G9 I Controls f Dual axis proportional control handle for drive and steer functions OR Proportional control handle for drive function and thumb rocker for steer function Steer mode select switch with indicator lights Dual axis proportional control handle for jib boom up down and rotate left right functions 22 Drive speed select switch with 23 indicator lights Machine on incline symbol Low range operation for inclines Machine on level surface symbol High range operation for maximum drive speed Single axis proportional control handle for boom extend retract function Genie 24 25 26 27 28 29 Axle extend retract switch with indicator lights Drive enable switch with indicator light Dual axis proportional control handle for boom up down and turntable rotate left right functions Platform rotate switch Platform level switch Platform level recovery switch located on the side of the platform controls Part No 217929 SX 180 23 Operator s Manual First Edition First Printing Controls Platform Control Panel 1 Horn button Press this button and the horn will sound Release the button and the horn will stop Platform not level indicator light Level the platform until the light is off The platform level toggle switch will only work
57. s required before performing this procedure Part No 217929 Genie SX 180 59 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 can damage engine components Note Check the oil level with the engine off 1 Check the oil level dipstick Add oil as needed Perkins 1104D 44T Engine Oil type 15W 40 10W 30 Oil type cold conditions Deutz TD2011 L04i Engine Oil type 15W 40 5W 30 Oil type cold conditions Operator s Manual First Edition First Printing Maintenance 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 stowed position and the engine is off 2 Visually inspect the sight gauge located on the side of the hydraulic oil tank Result The hydraulic oil level should be between the two marks on the decal next to the sight gauge 3 Add oil as needed Do not overfill Maximum oil level Minimum oil level Hydraulic oil specifications Hydraulic oil type Chevron Rando HD equivalent Genie 60 SX 180 Check the Engine Coolant Level
58. t The jib rotation should come to a stop at 30 from the centerline of the boom assembly 35 Operator s Manual First Edition First Printing Inspections Test the Steering 50 51 52 53 54 Move the steer mode select switch and choose square end blue arrow steer i J x Ao Ao Press down the foot switch Slowly move the drive control handle in the direction indicated by the blue triangle on the control panel OR press the thumb rocker switch in the direction indicated by the blue triangle Result The square end wheels should turn in the direction that the blue triangles point on the drive chassis 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 square end wheels should turn in the direction that the yellow triangles point on the drive chassis Move the steer ty mode select switch 94 and choose circle end yellow arrow steer 36 55 56 58 59 60 Genie SX 180 Press down the foot switch 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 Slowly move the drive control
59. t Edition First Printing General Safety A Compartment access is restricted Contact with components under any cover may result in serious injury fs Only trained maintenance personnel should access compartments Access by operator is only advised when performing Pre operation Inspection All compartments must remain closed and secured during operation 114390 97865 AWARNING 52865 Electrocution Burn Hazard Annual Insp Failure to disconnect all d the batteries before ould naut Failure to complete required inspections ection Record in death or serious injury performing service on this machine may result in inspec death or serious injury L BS GES Disconnect all the batteries before performing service on this machine Scheduled manvenance competed a s he bppreprate senice ania machine owner cli n ren 31788 A DANGER Explosion Burn Hazard acid will cause death bums or blindness Ignition of explosive gases or contact with corrosive A DANGER y IY 2 Line Voltage Required Clearance Keep all open flames and sparks away Wear personal protective equipment including face aiiai agad PR dm 30m D shield gloves and long sleeve shir lectrocution Hazart 50 to 200KV isk 46m Death or injury can result from contacting electric READ MANUALS power in
60. that a function has been interrupted and or an action is required by the operator Raise Retract Boom indicator light flashing Raise retract the boom until the indicator light is off et en O O O Lower Boom indicator light flashing Lower the boom until the indicator light is off Machine Not Level indicator light flashing The tilt alarm will be sounding when this light is flashing Move the machine to a firm level surface 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 Je Part No 217929 Genie SX 180 51 Operating Instructions Platform Level Recovery 1 Press down the foot switch 2 Push and hold the platform level recovery switch up 3 Move the platform level switch in the desired direction Note The platform level switch will only work in the direction that will return the platform to a level position Out of Operational Envelope Recovery If all functions stop operating you may have exceeded the operational envelope A trained operator on the ground will need to lower the platform from the ground controls Please see the Service Bypass Recovery Key Switch section in the service manual Operator s Manual First Edition First Printing Operating Instructions
61. the off position and remove the key to secure from unauthorized use Part No 217929 First Edition First Printing Operator s Manual Pipe Cradle Instructions The pipe cradle assembly consists of 2 pipe cradles positioned at either side of the platform and mounted to the guardrails with U bolts Operating Instructions Observe and Obey v H 7 AOR HR oe e m N WN A 1 lt 9 strap U bolts pipe cradle mount upper platform railing pipe cradle weldment middle platform railing flat washers nylock nuts Ja FO O O O 99 CC Genie Part No 217929 SX 180 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 Install a pipe cradle on each side of the platform Refer to the illustration on the left Make sure the bottom of the pipe cradle tube rests on the platform floor Install two U bolts from the outside of the platform rails through each pipe cradle mount Secure each U bolt with 2 washers and 2 nuts 53 Operator s Manual First Edition First Printing Operating Instructions Pipe Cradle Operation 1 Besure the pipe cradle assembly and installation instru
62. uld flash 4 Startthe engine See Operating Instructions section 8 Test Emergency Stop 5 Push in the red Emergency Stop button to the off position Result The engine should shut off and no functions should operate 6 Pull out the red Emergency Stop button to the 9 on position and restart the engine 10 Genie Part No 217929 SX 180 At the ground controls press and hold a function enable speed select button 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 Press and hold a function enable speed select button and press the boom extend button Result The boom should extend 30 cm then stop On the LCD screen the arrow next to the extend axle symbol will flash The boom should not extend unless the axles are extended Push and hold a function enable speed select button and push the turntable rotate left button Result The turntable should rotate 40 and then stop The turntable should not rotate more than 40 unless the axles are extended Push and hold a function enable speed select button and push the turntable rotate right button Result The turntable should return to center rotate 40 to the right and then stop The turntable should not rotate more than 40 unless the axles are extended 31 Operator s Manual First
63. ure level at ground 91 dBA Wheelbase axles extended 4 7m workstation Wheelbase axles retracted 5M Sound pressure level at platform 75 dBA Ground clearance 38 cm workstation Turning radius axles extended Guaranteed sound power level 112 dBA Inside 3m Vibration value does not exceed 2 5 m s Outside 7 3 m Maximum slope rating stowed position 4WD Turning radius axles retracted Counterweight uphill 35 19 Inside 6 3M Counterweight downhill 35 19 Outside 8 6M Side slope 25 14 Turntable rotation degrees 360 continuous Note Slope rating is subject to ground conditions Turntable tailswing axles extended 1 06 m and adequate traction Turntable tailswing axles retracted 1 14 m Drive speeds Controls 12V DC proportional prive speed stowed 3 7 km h Platform dimensions 1 8 m 182 x 76 cm 12 m 11 8 sec length x width Drive speed raised or extended 0 6 km h Platform dimensions 2 4 m 244 x 91 cm 12 m 68 sec length x width Drive speed boom above 38 1 m 0 16 km h Platform leveling self leveling 12 m 270 sec Platform rotation 160 Floor loading information Vertical jib rotation 135 Tire load maximum 13 381 kg Horizontal jib rotation 60 Tire contact pressure 9 13 kg cm 896 kPa Occupied floor pressure 844 kg m axles extended 8 27 kPa Occupied floor pressure 1 620 kg m axles retracted 15 89 kPa Note Floor loading information is approximate and does not incorporate different option configurations It should be used on
64. urntable will rotate left Move the control handle to the right and the turntable will rotate right Part No 217929 27 28 29 Genie SX 180 Controls o7 I Platform level recovery switch located on the side of the platform controls 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 will rotate right Platform level switch Move the platform level switch up and the level of the platform will raise Move the platform level switch down and the level of the platform will lower Push and hold the platform level recovery switch up Use the platform level switch to level the platform 27 Operator s Manual First Edition First Printing Inspections Do Not Operate Unless MI You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection Know and understand the pre operation inspection before going on to the next section 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended Genie 28 SX 180 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 i
65. ury 4 Do not move alter or disable angle sensor 1254849 114390 82314 1254849 28175 enie axle extension cylinder 9 31060 ATEREX BRAND SX 180 Part No 217929 First Edition First Printing Operator s Manual General Safety 218559 161692 um AWARNING 72875 218559 s 114416 IH pem 161690 i 114390 Al 161692 _ 97579 114416 82862 97579 28236 pu t 82862 E cu d 72875 Genie Part No 217929 SX 180 7 Operator s Manual First Edition First Printing General Safety C g 1254849 A DANGER Tip over Hazard Failure to replace tires with tires of the same specification will result in death or serious injury Do not use air filled tires Foam filled tires are critical to machine stability Do not replace factory installed tires with tires of a different specification or ply
66. us situations L hazardous locations 2 Always perform a pre operation inspection L inadequate surface support to withstand all load forces imposed by the machine 3 Always perform function tests prior to use L wind and weather conditions 4 Inspect the workplace _ the presence of unauthorized personnel Know and understand the workplace B inspection before going on to the next L other possible unsafe conditions section 5 Only use the machine as it was intended Workplace Inspection Fundamentals The workplace inspection helps the operator 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 Genie Part No 217929 SX 180 41 Operator s Manual First Edition First Printing L Inspections Inspection for Decals with Words PartNo Decal Description Qty Use the pictures on the next page to verify that all s label Li cals Qil Level 1 decals are legible and in place 97815 Label Lower Mid rail 1 I u 97865 Warning Electrocution Hazard 2 SRM dE list with quantities and 114258 Danger Explosion Hazard 2 114390 Danger Electrocuti
67. ves 200 to 350KV on aim CN Read all manuals prior to operation 350 to S00KV 258 7 6m Always contact the electric power line owner The lj po NOT OPERATE equipment t you do not aiia power shall be disconnected or the power 500 to 780KV 35h 106m understand the information in the manuals lines moved or insulated before machine operations 750 to 1000KV asn 137m Consult your supervisor the owner or the begin nom a manufacturer 1254849 A DANGER Lug NutTorque Dry bolts Tip over Hazard 420 ft lbs Failure to replace tires with tires 569 5 Nm of the same specification will Lubricated bolts result in death or serious injury 320 ft Ibs 433 9 Nm Do not use air filled tires Foam filled tires are critical to machine stability Do not replace factory installed tires with tires of a different specification or ply rating Foam filled Tire Minimum New Weight 850 Ibs 386 kg Tire Size 445D50 710 18 ply HD Foam filled Genie P N 1255639 left side Genie P N 1255640 right side 1254849 A 31060 A DANGER Tip over Hazard Altering or disabling limit switches can result in machine tip over Machine tip over will result in death or serious injury Do not alter or disable limit switch s 31060 C 82314 A DANGER Tip over Hazard Altering or disabling angle sensor can result in machine tip over Machine tip over will result in death or serious Inj

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