Terex Genie SX-135 XC Operator's Manual
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Terex Genie SX-135 XC Operator's Manual

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Operator's Manual
SX
-135 XC
™
Serial Number Range
™
from SX135H-515
CE
with
Maintenance
Information
Original Instructions
Second Edition
Second Printing
Part No. 1301106GT

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Summary of Contents for Terex Genie SX-135 XC

  • Page 1 Operator's Manual Serial Number Range -135 XC ™ ™ from SX135H-515 with Maintenance Information Original Instructions Second Edition Second Printing Part No. 1301106GT...

  • Page 2: Table Of Contents

      Copyright © 2016 by Terex Corporation Second Edition: Second Printing, October 2021 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

    Second Edition • Second Printing Operator's Manual Introduction Introduction 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 Operator's Manual Second Edition • Second Printing Introduction Platform controls symbology and related Steer right/left machine movement: Platform level Jib boom extend/retract Platform rotate Axle extend Jib boom up/down Axle retract Boom up/down Square end steer Boom extend/retract Circle end steer Turntable rotate Crab steer Drive forward/reverse...
  • Page 5 Second Edition • Second Printing Operator's Manual Introduction Ground controls symbology and related Limitations of use: machine movement: The intended use of this machine is to lift  personnel, including tools, and materials to an Platform level, jib boom aerial work site. up/down, boom extend/retract,and boom Do not elevate the platform unless the machine...
  • Page 6 Operator's Manual Second Edition • Second Printing 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 7 Second Edition • Second 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 8 Operator's Manual Second Edition • Second Printing Introduction Hazard Classification Decals on this machine use symbols, color coding, and signal words to identify the following: Safety alert symbol—used to alert you to potential personal injury hazards. Obey all safety messages that follow this symbol to avoid possible injury or death.

  • Page 9: Symbol And Hazard Pictorials Definitions

    Second Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Crushing hazard Keep away from Crush hazard Overhead obstruction Collision hazard moving parts Electrocution hazard Maintain required Tip-over hazard Tip-over hazard Tip-over hazard clearance Electrocution hazard Avoid contact...
  • Page 10 Operator's Manual Second Edition • Second Printing Symbol and Hazard Pictorials Definitions Explosion hazard No smoking. Explosion hazard Burn hazard Fire extinguisher No flame. Stop engine. Fire hazard No smoking Explosion hazard No step Lanyard anchorage point / fall arrest Platform tie-down Lifting and tie down instructions Tie-down point...
  • Page 11 Second Edition • Second Printing Operator's Manual Symbol and Hazard Pictorials Definitions 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 power to platform air line to platform 1 Lower boom.

  • Page 12: General Safety

    Operator's Manual Second Edition • Second Printing General Safety General Safety ™ ™ -135 XC Part No. 1301106GT...
  • Page 13 Second Edition • Second Printing Operator's Manual General Safety ™ ™ Part No. 1301106GT -135 XC...
  • Page 14 Operator's Manual Second Edition • Second Printing General Safety ™ ™ -135 XC Part No. 1301106GT...

  • Page 15: Personal Safety

    Second Edition • Second Printing Operator's Manual Personal Safety Personal Safety Personal Fall Protection Personal fall protection equipment (PFPE) is required when operating this machine. Occupants must wear a safety belt or harness in accordance with governmental regulations. Attach the lanyard to the anchor provided in the platform. Operators must comply with employer, job site and governmental rules regarding the use of personal protective equipment.

  • Page 16: Work Area Safety

    Operator's Manual Second Edition • Second Printing Work Area Safety Work Area Safety Electrocution Hazards Keep away from the machine if it contacts This machine is not electrically insulated and will energized power lines. not provide protection from contact with or Personnel on the ground proximity to electrical current.
  • Page 17 Second Edition • Second Printing Operator's Manual Work Area Safety If the tilt alarm sounds when the platform is raised, Do not attach a platform rated at 660 lbs/300 kg use extreme caution. Identify the condition of the (unrestricted range of motion) or 1000 lbs/454 kg boom on the slope as shown below.
  • Page 18 Operator's Manual Second Edition • Second Printing Work Area Safety Use extreme care and Do not push off or pull slow speeds while driving toward any object outside the machine in the stowed of the platform. position across uneven Maximum allowable terrain, debris, unstable or manual force: slippery surfaces and near...
  • Page 19 Second Edition • Second 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 20 Operator's Manual Second Edition • Second Printing Work Area Safety Fall Hazards Collision Hazards Occupants must wear a Be aware of limited sight safety belt or harness in distance and blind spots accordance with when driving or operating. governmental regulations. Attach the lanyard to the anchor provided in the platform.
  • Page 21 Second Edition • Second Printing Operator's Manual Work Area Safety Bodily Injury Hazard Observe and use the color-coded direction arrows on the platform controls and drive chassis for drive Always operate the machine in a well-ventilated and steer functions. area to avoid carbon monoxide poisoning. Do not lower the boom Do not operate the machine with a hydraulic oil or unless the area below is...
  • Page 22 Operator's Manual Second Edition • Second Printing Work Area Safety Damaged Machine Hazards Battery Safety Do not use a damaged or malfunctioning machine. Burn Hazards Conduct a thorough pre-operation inspection of Batteries contain acid. the machine and test all functions before each Always wear protective work shift.
  • Page 23 Second Edition • Second 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 24 Operator's Manual Second Edition • Second Printing Work Area Safety Panel Cradle Safety Welder Safety Read, understand and obey all warnings and Read, understand and obey all warnings and instructions provided with the panel cradles. instructions provided with the welding power unit. Do not exceed the rated platform capacity.
  • Page 25 Second Edition • Second Printing Operator's Manual Work Area Safety Lockout After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable until the boom is positioned between the circle end wheels.

  • Page 26: Legend

    Operator's Manual Second Edition • Second Printing Legend Legend Circle-end tire Sliding mid-rail Square-end tire Manual storage container Ground controls 10 Lanyard anchorage points Boom 11 Foot switch Jib boom Platform Platform controls ™ ™ -135 XC Part No. 1301106GT...

  • Page 27: Controls

    Second Edition • Second 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 28 Operator's Manual Second Edition • Second Printing Controls Ground Control Panel 10 LCD readout screen Turntable rotate right button Press the turntable rotate right button and the turntable will rotate right. a low fuel indicator Turntable rotate left button b engine oil pressure indicator Press the turntable rotate left button and the c water temperature indicator turntable will rotate left.
  • Page 29 Second Edition • Second Printing Operator's Manual Controls 15 Jib boom retract button 24 Platform rotate left button Press the jib boom retract button and the jib Press the platform rotate left button and the boom will retract. platform will rotate to the left. 16 Jib boom up button 25 Auxiliary power button Press the jib boom up button and the jib boom...
  • Page 30 Operator's Manual Second Edition • Second Printing Controls Platform Control Panel ™ ™ -135 XC Part No. 1301106GT...
  • Page 31 Second Edition • Second Printing Operator's Manual Controls ™ ™ Part No. 1301106GT -135 XC...
  • Page 32 Operator's Manual Second Edition • Second Printing Controls Platform Control Panel 10 Engine start switch with indicator light Move the engine start switch and the engine Horn button will start. The engine start indicator light will Press this button and the horn will sound. flash during engine start up and will turn solid Release the button and the horn will stop.
  • Page 33 Second Edition • Second Printing Operator's Manual Controls 19 Red Emergency Stop button 21 Steer mode select switch with indicator lights Push in the red Emergency Stop button to the Move the steer off position to stop all functions and turn the mode select switch engine off.
  • Page 34 Operator's Manual Second Edition • Second Printing Controls 24 Drive select switch with indicator lights 27 Drive enable switch with indicator light Move the drive select Light on indicates that the switch to choose drive boom has moved past a setting.

  • Page 35: Inspections

    Second Edition • Second Printing Operator's Manual Inspections Inspections Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. The pre-operation inspection is a visual inspection performed by the operator prior to each work shift. Do Not Operate Unless: The inspection is designed to discover if anything is apparently wrong with a machine before the...
  • Page 36 Operator's Manual Second Edition • Second Printing Inspections Pre-operation Inspection  Steer and axle sensors  Alarms and beacons (if equipped)  Be sure that the operator’s, safety, and  Nuts, bolts and other fasteners responsibilities manuals are complete, legible and in the storage container located in the ...
  • Page 37 Second Edition • Second 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 38 Operator's Manual Second Edition • Second Printing Inspections At the Ground Controls Test the Extendable Axles 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 39 Second Edition • Second Printing Operator's Manual Inspections 11 With the jib fully retracted, push and hold the Test Machine Functions the function enable button and push the jib 18 Do not push and hold the function enable extend button. button.
  • Page 40 Operator's Manual Second Edition • Second Printing Inspections Test the Tilt Sensor Test the Operating Envelope 24 Press one of the LCD 27 Simultaneously press the 2 screen control buttons until LCD screen control buttons TURNTABLE LEVEL shown to activate status SENSOR X-DIRECTION mode.
  • Page 41 Second Edition • Second Printing Operator's Manual Inspections Test the Foot Switch At the Platform Controls 38 Push in the platform red Emergency Stop Test Emergency Stop button to the off position. 33 Turn the key switch to platform control. 39 Pull out the red Emergency Stop button to the on position and do not start the engine.
  • Page 42 Operator's Manual Second Edition • Second Printing Inspections Test the Steering 50 Press down the foot switch. 51 Slowly move the control handle in the direction 45 Move the steer indicated by the yellow triangle on the control mode select switch panel OR press the thumb rocker switch in the and choose direction indicated by the yellow triangle.
  • Page 43 Second Edition • Second Printing Operator's Manual Inspections Test Drive and Braking 56 Slowly move the control handle in the direction indicated by the yellow triangle on the control 61 Press down the foot switch. panel OR press the thumb rocker switch in the 62 Slowly move the drive control handle in the direction indicated by the yellow triangle.
  • Page 44 Operator's Manual Second Edition • Second Printing Inspections Test the Drive Enable System Test Limited Drive Speed 64 Press down the foot switch and lower the 68 Press down the foot switch. boom to the stowed position. 69 Raise the boom to 10° above horizontal. 65 Rotate the turntable until the boom moves past 70 Slowly move the drive control handle to the full a circle-end wheel and is outside of the range...
  • Page 45 Second Edition • Second Printing Operator's Manual Inspections 85 Return to level ground and stow the boom. Test Drive Tilt Cutout 86 Press down the foot switch. 77 Press down the foot switch. 87 With the boom fully stowed, drive the machine 78 With the boom fully stowed, drive the machine onto a slope where the chassis angle is onto a slope where the chassis angle is...
  • Page 46 Operator's Manual Second Edition • Second Printing Inspections Test Auxiliary Controls Test the Contact Alarm (if equipped) 95 Push in the red Emergency Stop button to the 100 Do not activate the foot switch and press on off position to shut off the engine. the contact alarm cable to release the actuator from the switch socket.
  • Page 47 Second Edition • Second Printing Operator's Manual Inspections Workplace Inspection Checklist Be aware of and avoid the following hazardous situations:  drop-offs or holes  bumps, floor obstructions, or debris  sloped surfaces Do Not Operate Unless:  unstable or slippery surfaces ...
  • Page 48 Operator's Manual Second Edition • Second Printing Inspections Inspection for Decals with Part No. Decal Description Symbols 1263544 Bypass Key Switch 1263545 Instructions – Bypass Key Switch Use the pictures on the next page to verify that all 1272242 Label – Machine Registration/Owner decals are legible and in place.
  • Page 49 Second Edition • Second Printing Operator's Manual Inspections ™ ™ Part No. 1301106GT -135 XC...

  • Page 50: Operating Instructions

    Operator's Manual Second Edition • Second Printing Operating Instructions Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator’s responsibility to follow all the safety rules and instructions in the operator’s, safety, and responsibilities manuals.
  • Page 51 Second Edition • Second 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 52 Operator's Manual Second Edition • Second Printing 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 53 Second Edition • Second Printing Operator's Manual Operating Instructions Operation from Platform To Steer 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 54 Operator's Manual Second Edition • Second Printing 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 55 Second Edition • Second 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 56 Operator's Manual Second Edition • Second Printing Operating Instructions Standstill Regeneration The LCD screen displays the message NOTICE: ALL FUNCTIONS WILL BE When the LCD screen displays the message LOCKED. REGEN WILL TAKE APPROX. 1 "Regen Required" and the Regeneration lamp is HOUR.
  • Page 57 Second Edition • Second Printing Operator's Manual Operating Instructions Operating Envelope Indicator Lights During the DPF standstill generation process, all boom functions are disabled. The operating envelope indicator lights will come on to notify the operator that a function has been Keep clear of the engine exhaust and muffler.
  • Page 58 Operator's Manual Second Edition • Second Printing Operating Instructions Platform Out of Level (P22 code) Platform Not Level indicator light flashing: The tilt alarm will Bypass key position to be used to level the be sounding when this light is platform if ground control display shows platform flashing.
  • Page 59 Second Edition • Second Printing Operator's Manual Operating Instructions Platform Out of Level (Platform Level > 15 Contact Alarm (if equipped) Degrees Fault) The contact alarm is designed to alert ground personnel when an operator makes contact with If ground control display shows PLATFORM the platform control panel, interrupting boom LEVEL >...
  • Page 60 Operator's Manual Second Edition • Second Printing Operating Instructions Generator Platform Capacity Selection To operate the generator, move the generator Range of motion is controlled automatically based toggle switch. on platform load. Note: If the foot switch is activated during Unrestricted Range of Motion: generator start-up, the generator will not operate.
  • Page 61 Second Edition • Second Printing Operator's Manual Operating Instructions Tilt Sensor Activation Settings When the Machine On Incline indicator light is on and the tilt Platform Load: 660 lbs/300 kg alarm sounds, the following Chassis Chassis functions are affected; drive Angle (front Angle (side to functions are disabled.
  • Page 62 Operator's Manual Second Edition • Second Printing 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 63 Second Edition • Second Printing Operator's Manual Operating Instructions Observe and Obey:  Pipe cradles must be installed on the inside of the platform.  Pipe cradles must not obstruct the platform controls or the platform entrance.  The bottom of the pipe cradle tube must rest on the platform floor.
  • Page 64 Operator's Manual Second Edition • Second Printing Operating Instructions Pipe Cradle Operation Be sure the pipe cradle assembly and installation instructions have been followed properly and that the pipe cradles are secured to the platform railings. Place the load so that it rests in both pipe cradles.
  • Page 65 Second Edition • Second Printing Operator's Manual Operating Instructions After Each Use Select a safe parking location—firm level surface, clear of obstruction and traffic. Retract and lower the boom to the stowed position. Rotate the turntable until the boom is positioned between the circle end wheels.

  • Page 66: Transport And Lifting Instructions

    Operator's Manual Second Edition • Second Printing Transport and Lifting Instructions Transport and Lifting Instructions  Be sure the turntable is secured with the turntable rotation lock before transporting. Be sure to unlock the turntable for operation.  Do not drive the machine on a slope that exceeds the uphill, downhill or side slope rating.
  • Page 67 Second Edition • Second Printing Operator's Manual Transport and Lifting Instructions Securing to Truck or Trailer for Stowing for Transport Transit Note: Before stowing the machine for transport, be sure the jib is fully retracted, the boom is fully Always use the turntable rotation lock pin each retracted, the turntable is between the circle-end time the machine is transported.
  • Page 68 Operator's Manual Second Edition • Second Printing Transport and Lifting Instructions Raise the boom until the boom angle is Lower the boom until the boom is below between 20 and 30 degrees. The boom should horizontal. Check the primary boom stowed be raised enough to clear the truck bed and indicator light located at the side of the ground control panel.
  • Page 69 Second Edition • Second Printing Operator's Manual Transport and Lifting Instructions To return the machine to operation Raise the jib boom until the platform is no longer tucked under the boom, the bellcrank Pull out the red Emergency Stop button to the has stopped moving and the jib lift cylinder has on position.
  • Page 70 Operator's Manual Second Edition • Second Printing Transport and Lifting Instructions Securing the Chassis Adjust the rigging to prevent damage to the chains. Use chains of ample load capacity. Use a minimum of 6 chains. SX-135 XC 6 ft 4 in 13 ft 6 in 1.93 m 4.11 m...
  • Page 71 Second Edition • Second Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully extend the axles. Fully lower and retract the boom. Fully lower the jib. Remove all loose items on the machine. Determine the center of gravity of your machine Observe and Obey: using the table and the picture on this page.

  • Page 72: Maintenance

    Operator's Manual Second Edition • Second Printing Maintenance Maintenance Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life. Observe and Obey: Operating the machine with an improper oil level can damage engine components.
  • Page 73 Second Edition • Second Printing Operator's Manual Maintenance Diesel Fuel Requirements Check the Hydraulic Oil Level Satisfactory engine performance is dependent on Maintaining the hydraulic oil at the proper level is the use of a good quality fuel. The use of a good essential to machine operation.
  • Page 74 Operator's Manual Second Edition • Second Printing Maintenance Check the Engine Coolant Level – Check the Batteries Liquid Cooled Models Proper battery condition is essential to good machine performance and operational safety. Maintaining the engine coolant at the proper level Improper fluid levels or damaged cables and is essential to engine service life.
  • Page 75 Second Edition • Second Printing Operator's Manual Maintenance Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine. Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service.

  • Page 76: Specifications

    Operator's Manual Second Edition • Second Printing Specifications Specifications Model Hydraulic pressure, maximum 2,900 psi 200 bar SX-135 XC (boom functions) Height, working maximum 141 ft 43.15 m Hydraulic pressure, maximum 3,200 psi 220 bar Height, platform maximum 135 ft 41.15 m (auxiliary power unit) Height, stowed maximum...
  • Page 77 Second Edition • Second Printing Operator's Manual Specifications SX-135 XC Range of motion chart Maximum platform capacity 1 660 lbs / 300 kg 2 1000 lbs / 454 kb Max Height Max Reach 150 ft 45.72 m -10 ft -3.05 m 140 ft 42.67 m 0 ft...
  • Page 78 Operator's Manual Second Edition • Second Printing 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>...

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