Terex Genie SX-105 XC Operator's Manual
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Terex Genie SX-105 XC Operator's Manual

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Operator's Manual
SX
-105 XC
™
SX
-125 XC
™
Serial Number Range
™
from SX105D-174
™
from SX125D-101
CE
with
Maintenance
Information
Original Instructions
First Edition
Third Printing
Part No. 1270327GT

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  • Page 1 Operator's Manual Serial Number Range -105 XC ™ ™ from SX105D-174 -125 XC ™ ™ from SX125D-101 with Maintenance Information Original Instructions First Edition Third Printing Part No. 1270327GT...

  • Page 2: Table Of Contents

    The Netherlands Copyright © 2016 by Terex Corporation First Edition: Third Printing, July 2020 Genie is a registered trademark of Terex South Dakota, Inc. in the U.S.A. and many other countries. "SX" and "XC" are trademarks of Terex South Dakota, Inc.

  • Page 3: Introduction

    First Edition • Third Printing Operator's Manual Introduction Intr oducti on About this manual Intended Use and Familiarization Guide Genie appreciates your choice of our machine for your application. Our number one priority is user The intended use of this machine is to lift safety, which is best achieved by our joint efforts.
  • Page 4 First Edition • Third Printing Operator's Manual Introduction Ground controls symbology and related Platform controls symbology and related machine movement: machine movement: Platform level, jib boom Platform level up/down, boom extend/retract,and boom up/down Platform rotate Turntable rotate and platform rotate Jib boom up/down Sequential functions and movement: ...
  • Page 5 First Edition • Third Printing Operator's Manual Introduction Bulletin Distribution and Contacting the Manufacturer Compliance At times it may be necessary to contact Genie. When you do, be ready to supply the model Safety of product users is of paramount number and serial number of your machine, along importance to Genie.
  • Page 6 First Edition • Third Printing Operator's Manual Introduction Safety Sign Maintenance Replace any missing or damaged safety signs. Keep operator safety in mind at all times. Use mild soap and water to clean safety signs. Do not use solvent-based cleaners because they may damage the safety sign material.

  • Page 7: Symbol And Hazard Pictorials Definitions

    First Edition • Third Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and H az ard Pictorials Definiti ons Crushing hazard Keep away from Crush hazard Overhead obstruction Collision hazard moving parts Electrocution hazard Maintain required Tip-over hazard Tip-over hazard Tip-over hazard clearance Read the operator’s...
  • Page 8 First Edition • Third Printing Operator's Manual Symbol and Hazard Pictorials Definitions Fire hazard No smoking Explosion hazard No step Lanyard anchorage points Platform tie-down Lifting & tie down instructions Maximum capacity Fall arrest instructions Support the platform Tie-down point Lifting point Platform overloaded or boom during...
  • Page 9 First Edition • Third Printing Operator's Manual Symbol and Hazard Pictorials Definitions Wind speed Runaway hazard Weight of welder Wheel load Tire specifications reduces capacity Recovery procedure if tilt alarm sounds while elevated. Platform uphill: Platform downhill: Do not use ether or Voltage rating for Pressure rating for other high energy...

  • Page 10: General Safety

    First Edition • Third Printing Operator's Manual General Safety Gener al Safety ™ ™ • SX ™ ™ -105 XC -125 XC Part No. 1270327GT...
  • Page 11 First Edition • Third Printing Operator's Manual General Safety ™ ™ • SX ™ ™ Part No. 1270327GT -105 XC -125 XC...

  • Page 12: Personal Safety

    First Edition • Third Printing Operator's Manual Personal Safety Pers onal 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.

  • Page 13: Work Area Safety

    First Edition • Third Printing Operator's Manual Work Area Safety Wor k Ar ea Safety Electrocution Hazards Keep away from the machine if it contacts This machine is not electrically insulated and will energized power lines. not provide protection from contact with or Personnel on the ground proximity to electrical current.
  • Page 14 First Edition • Third Printing Operator's Manual Work Area Safety The recovery mode should be used only by trained The weight of options and accessories such as and authorized personnel. pipe cradles and welders will reduce the rated platform capacity, and must be subtracted from the If the tilt alarm sounds with the platform capacity.
  • Page 15 First Edition • Third Printing Operator's Manual Work Area Safety Use extreme care and Do not alter or disable machine components that slow speeds while driving in any way affect safety and stability. the machine in the stowed Do not replace items critical to machine stability position across uneven with items of different weight or specification.
  • Page 16 First Edition • Third Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Do not place or attach fixed or overhanging loads Do not drive the machine on a slope that exceeds to any part of this the maximum uphill, downhill or side slope rating machine.
  • Page 17 First Edition • Third Printing Operator's Manual Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the platform.
  • Page 18 First Edition • Third Printing Operator's Manual Work Area Safety Bodily Injury Hazard Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Always operate the machine in a well-ventilated and steer functions. area to avoid carbon monoxide poisoning. Do not lower the boom Do not operate the machine with a hydraulic oil or unless the area below is...
  • Page 19 First Edition • Third Printing Operator's Manual Work Area Safety Damaged Machine Hazards Battery Safety Do not use a damaged or malfunctioning machine. Burn Hazards Conduct a thorough pre-operation inspection of Batteries contain acid. the machine and test all functions before each Always wear protective work shift.
  • Page 20 First Edition • Third Printing Operator's Manual Work Area Safety Contact Alarm Safety Pipe Cradle Safety Read, understand and obey all warnings and Read, understand, and obey all warnings and instructions provided with the contact alarm. instructions provided with the pipe cradles. Do not exceed the rated platform capacity.
  • Page 21 First Edition • Third Printing Operator's Manual Work Area Safety Welder Safety Lockout After Each Use Read, understand and obey all warnings and Select a safe parking location—firm level instructions provided with the welding power unit. surface, clear of obstruction and traffic. Retract and lower the boom to the stowed Do not connect weld leads or cables unless the position.

  • Page 22: Legend

    First Edition • Third Printing Operator's Manual Legend Leg end Square-end tire Platform controls Ground controls Sliding mid-rail Boom Manual storage container Jib boom 10 Lanyard anchorage points Platform 11 Foot switch Circle-end tire ™ ™ • SX ™ ™ -105 XC -125 XC Part No.

  • Page 23: Controls

    First Edition • Third Printing Operator's Manual Controls Controls The ground control station is to be used as a means to raise the platform for storage purposes and for function tests. The ground control station can be used in the event of an emergency to rescue an incapacitated person in the platform.
  • Page 24 First Edition • Third Printing Operator's Manual Controls Ground Control Panel Jib boom down button Red Emergency Stop button Press the jib boom down button and the jib boom will lower. Push in the red Emergency Stop button to the 20A circuit breaker for system circuit off position to stop all functions and turn the engine off.
  • Page 25 First Edition • Third Printing Operator's Manual Controls 16 Turntable rotate right button 22 Unrestricted range of motion indicator light Press the turntable rotate right button and the Light on indicates that the range of motion is turntable will rotate to the right. unrestricted.
  • Page 26 First Edition • Third Printing Operator's Manual Controls Platform Control Panel ™ ™ • SX ™ ™ -105 XC -125 XC Part No. 1270327GT...
  • Page 27 First Edition • Third Printing Operator's Manual Controls ™ ™ • SX ™ ™ Part No. 1270327GT -105 XC -125 XC...
  • Page 28 First Edition • Third Printing Operator's Manual Controls Platform Control Panel Emergency power switch with indicator light Horn button Use emergency power if the primary power source (engine) fails. Press this button and the horn will sound. Push down the foot switch and simultaneously Release the button and the horn will stop.
  • Page 29 First Edition • Third Printing Operator's Manual Controls 13 Unrestricted range of motion indicator light 20 Dual axis proportional control handle for drive and steer functions. Light on indicates that the range of motion is unrestricted. Proportional control handle for drive function 14 Platform overload indicator light and thumb rocker for steer function.
  • Page 30 First Edition • Third Printing Operator's Manual Controls 23 Drive select switch with indicator lights 21 Steer mode select switch with indicator lights Move the drive select Move the steer switch to choose drive mode select switch setting. The indicator to choose steer light next to the current mode.
  • Page 31 First Edition • Third Printing Operator's Manual Controls 25 Axle extend/retract switch with indicator lights 27 Dual axis proportional control handle for boom up/down and turntable rotate left/right Move the axle select functions switch to choose an axle setting. The axle extend Move the control handle up and retract indicator lights and the boom will raise.

  • Page 32: Inspections

    First Edition • Third Printing Operator's Manual Inspections Ins pections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 33 First Edition • Third Printing Operator's Manual Inspections Pre-operation Inspection  Wear pads  Tires and wheels  Be sure that the operator’s, safety, and  Engine and related components responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 34 First Edition • Third Printing Operator's Manual Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 35 First Edition • Third Printing Operator's Manual Inspections Test the Extendable Axles At the Ground Controls Note: Start this test with the axles retracted. Select a test area that is firm, level and free of hazards. At the ground controls, push and hold the function enable button and press the boom up Turn the key switch to ground control.
  • Page 36 First Edition • Third Printing Operator's Manual Inspections 11 Turn the key switch to platform control. At the Test Machine Functions platform controls, move the drive control 16 Do not push and hold the function enable handle in the forward direction and move the button.
  • Page 37 First Edition • Third Printing Operator's Manual Inspections Test the Tilt Sensor Test the Operating Envelope 22 Press one of the LCD 25 Simultaneously press the 2 screen control buttons until LCD screen control buttons TURNTABLE LEVEL shown to activate status SENSOR X-DIRECTION mode.
  • Page 38 First Edition • Third Printing Operator's Manual Inspections Test the Foot Switch At the Platform Controls 36 Push in the platform red Emergency Stop Test Emergency Stop button to the off position. 31 Turn the key switch to platform control. 37 Pull out the red Emergency Stop button to the on position and do not start the engine.
  • Page 39 First Edition • Third Printing Operator's Manual Inspections Test the Steering 48 Press down the foot switch. 43 Move the steer 49 Slowly move the control handle in the direction mode select switch indicated by the yellow triangle on the control and choose panel OR press the thumb rocker switch in the square-end (blue...
  • Page 40 First Edition • Third Printing Operator's Manual Inspections Test Drive and Braking 54 Slowly move the control handle in the direction indicated by the yellow triangle on the control 59 Press down the foot switch. panel OR press the thumb rocker switch in the 60 Slowly move the drive control handle in the direction indicated by the yellow triangle.
  • Page 41 First Edition • Third Printing Operator's Manual Inspections Test the Drive Enable System Test Limited Drive Speed 62 Press down the foot switch and lower the 66 Press down the foot switch. boom to the stowed position. 67 Raise the boom to 10° above horizontal. 63 Rotate the turntable until the boom moves past 68 Slowly move the drive control handle to the full a circle-end wheel and is outside of the range...
  • Page 42 First Edition • Third Printing Operator's Manual Inspections Test Drive Tilt Cutout 83 Press down the foot switch. 84 With the boom fully stowed, drive the machine 74 Press down the foot switch. onto a slope where the chassis angle is 75 With the boom fully stowed, drive the machine greater than 3°...
  • Page 43 First Edition • Third Printing Operator's Manual Inspections Test Auxiliary Controls 92 Push in the red Emergency Stop button to the off position to shut off the engine. 93 Pull out the red Emergency Stop button to the on position. 94 Press down the foot switch.
  • Page 44 First Edition • Third Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 45 First Edition • Third Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols 230984 Ground Control Panel 1254807 Label – 112 dB Use the pictures on the next page to verify that all 1256420 Label – Power to Platform, 208/115V* decals are legible and in place.
  • Page 46 First Edition • Third Printing Operator's Manual Inspections ™ ™ • SX ™ ™ -105 XC -125 XC Part No. 1270327GT...

  • Page 47: Operating Instructions

    First Edition • Third Printing Operator's Manual Operating Instructions Operati ng Instr ucti ons Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety, and responsibilities manuals.
  • Page 48 First Edition • Third Printing Operator's Manual Operating Instructions Starting the Engine Emergency Stop At the ground controls, turn the key switch to Push in the red Emergency Stop button to the off the desired position. position at the ground controls or the platform controls to stop all machine functions and turn the Be sure both ground and platform control red engine off.
  • Page 49 First Edition • Third Printing Operator's Manual Operating Instructions To Extend and Retract Axles Operation from Ground Turn the key switch to platform control. Turn the key switch to ground control. Pull out the red Emergency Stop button to the At the platform controls, on position.
  • Page 50 First Edition • Third Printing Operator's Manual Operating Instructions To Steer Operation from Platform Press down the foot switch. Turn the key switch to platform control. Select the steer mode by moving the steer Pull out both ground and platform red mode switch.
  • Page 51 First Edition • Third Printing Operator's Manual Operating Instructions Driving on a slope To determine the slope grade: Determine the uphill, downhill and side slope Measure the slope with a digital inclinometer OR ratings for the machine and determine the slope use the following procedure.
  • Page 52 First Edition • Third Printing Operator's Manual Operating Instructions Drive Enable Engine Idle Select (rpm) Light on indicates that the boom Select the engine idle (rpm) by has moved past a circle-end tire pressing the engine idle select and the drive function has been switch.
  • Page 53 First Edition • Third Printing Operator's Manual Operating Instructions Operating Envelope Indicator Lights If the tilt alarm sounds with the The operating envelope indicator lights will come platform uphill: on to notify the operator that a function has been interrupted and/or an action is required by the Lower the boom.
  • Page 54 First Edition • Third Printing Operator's Manual Operating Instructions Platform Out of Level (P22 code) Turn the bypass/recovery key switch to the run position. Bypass key position to be used to level the Remove the key from the bypass/recovery key platform if ground control display shows platform switch and insert the key into the main key out of level (P22) and platform level controls do...
  • Page 55 First Edition • Third Printing Operator's Manual Operating Instructions Platform Out of Level (Platform Level > 15 Generator Degrees Fault) To operate the generator, move the generator toggle switch. If ground control display shows PLATFORM LEVEL > 15 DEGREES FAULT and the platform Note: If the foot switch is activated during level controls do not work, the machine will need generator start-up, the generator will not operate.
  • Page 56 First Edition • Third Printing Operator's Manual Operating Instructions Standstill Regeneration The DPF standstill regeneration cannot begin until the engine has been run for at least two When the LCD screen displays the message minutes and the coolant temperature has "Regen Required"...
  • Page 57 First Edition • Third Printing Operator's Manual Operating Instructions 13 If the Regeneration process has begun The LCD screen displays the message successfully, the LCD screen displays the NOTICE: ALL FUNCTIONS WILL BE message REGEN TIME REMAINING. LOCKED. REGEN WILL TAKE APPROX. 1 HOUR.
  • Page 58 First Edition • Third Printing Operator's Manual Operating Instructions Platform Capacity Selection Range of motion is controlled automatically based on platform load. Unrestricted Range of Motion: When the platform load is less than 300 kg, the unrestricted range of motion light is on. Restricted Range of Motion: When the platform load is 301-454 kg, the restricted range of motion light is...
  • Page 59 First Edition • Third Printing Operator's Manual Operating Instructions Tilt Sensor Activation Settings When the Machine On Incline indicator light is on and the tilt Platform Chassis Angle alarm sounds, the following Load (front to back) Max Height Max Reach functions are affected;...
  • Page 60 First Edition • Third Printing Operator's Manual Operating Instructions LCD Screen (if equipped) Pipe Cradle Instructions The LCD screen displays hour meter, voltage, oil The pipe cradle assembly consists of 2 pipe pressure and coolant temperature. The screen cradles positioned at either side of the platform also displays fault codes and other service and mounted to the guardrails with U-bolts.
  • Page 61 First Edition • Third Printing Operator's Manual Operating Instructions Observe and Obey: Pipe Cradle Operation  Be sure the pipe cradle assembly and Pipe cradles must be installed on the inside of installation instructions have been followed the platform. properly and that the pipe cradles are secured ...

  • Page 62: Transport And Lifting Instructions

    First Edition • Third Printing Operator's Manual Transport and Lifting Instructions Trans port and Lifti ng Instr ucti ons  Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation. ...
  • Page 63 First Edition • Third Printing Operator's Manual Transport and Lifting Instructions Securing the Platform Securing to Truck or Trailer for Transit Lower the jib boom to the stowed position. Always use the turntable rotation lock pin each Lower the platform as far as it will go, so that the time the machine is transported.
  • Page 64 First Edition • Third Printing Operator's Manual Transport and Lifting Instructions Securing the Chassis SX-105 XC Center of Gravity Measurements 3 ft/0.92 m 13.5 ft /4.12 m 9.6 ft/2.94 m 1.8 ft/0.55 m 9.3 ft/2.83 m 4.8 ft/1.48 m 39 ft/11.93 m 9.9 ft/3.01 m ™...
  • Page 65 First Edition • Third Printing Operator's Manual Transport and Lifting Instructions Securing the Chassis SX-125 XC Center of Gravity Measurements 3 ft/0.92 m 13.5 ft /4.12 m 6.5 ft/1.98 m 1.9 ft/0.58 m 8.8 ft/2.68 m 5.1 ft/1.56 m 39 ft/11.88 m 9.9 ft/3.03 m ™...
  • Page 66 First Edition • Third Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions (option 1) Fully extend the axles. Fully lower and retract the boom. Fully lower the jib. Remove all loose items on the machine. Determine the center of gravity of your machine Observe and Obey: using the table and the picture on this page.
  • Page 67 First Edition • Third Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions (option 2) There are four lifting points on the drive chassis, one lifting point on each axle, and two lifting points Fully extend the axles. Fully lower and retract the on the riser plate of the swing chassis.

  • Page 68: Maintenance

    First Edition • Third Printing Operator's Manual Maintenance Maintenanc e Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Operating the machine with an improper oil level Observe and Obey: can damage engine components.
  • Page 69 First Edition • Third Printing Operator's Manual Maintenance Diesel Fuel Requirements Check the Hydraulic Oil Level Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is the use of a good quality fuel. The use of a good essential to machine operation.
  • Page 70 First Edition • Third Printing Operator's Manual Maintenance Check the Engine Coolant Level – Check the Batteries Liquid Cooled Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.
  • Page 71 First Edition • Third Printing Operator's Manual Maintenance Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine. Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service.

  • Page 72: Specifications

    First Edition • Third Printing Operator's Manual Specifications Specific ati ons Model System voltage SX-105 XC Tire size IN385/65D 22.5 Height, working maximum 34.00 m Weight 18,605 kg Height, platform maximum 32.00 m (Machine weights vary with option configurations. See Height, stowed maximum 3.00 m serial label for specific machine weight.)
  • Page 73 First Edition • Third Printing Operator's Manual Specifications System voltage Model SX-125 XC Tire size 445D50/710, 18 ply HD FF Height, working maximum 40.10 m Weight 20,700 kg Height, platform maximum 38.10 m (Machine weights vary with option configurations. See Height, stowed maximum 3.05 m serial label for specific machine weight.)
  • Page 74 First Edition • Third Printing Operator's Manual Specifications SX-105 XC Range of motion chart SX-125 XC Range of motion chart ™ ™ • SX ™ ™ -105 XC -125 XC Part No. 1270327GT...
  • Page 75 First Edition • Third Printing Operator's Manual Specifications Contents of EC Declaration of Conformity <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Directives: 1. EC Directive 2006/42/EC, Machinery Directive, under consideration of harmonized European standard EN280 as described in EC type-examination certificate <variable field>...

This manual is also suitable for:

Genie sx-125 xcGenie sx105d-174Genie sx125d-101

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