Terex SX135D-101 Operator's Manual
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Terex SX135D-101 Operator's Manual

Terex SX135D-101 Operator's Manual

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Operator's Manual
SX
-135 XC
™
Front Matter
Serial Number Range
™
from SX135H-515
from SX135D-101
CE
with
Maintenance
Information
Original Instructions
Second Edition
Third Printing
Part No. 1301106GT

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  • Page 1 Operator's Manual Serial Number Range -135 XC ™ ™ from SX135H-515 from SX135D-101 with Maintenance Information Original Instructions Second Edition Third Printing Part No. 1301106GT Front Matter...

  • Page 2: Table Of Contents

    NG31 6BH Copyright © 2016 by Terex Corporation Second Edition: Third Printing, September 2022 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 • 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 Operator's Manual Second Edition • Third Printing Introduction Steer right/left Platform controls symbology and related 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 • Third Printing Operator's Manual Introduction Limitations of use: Ground controls symbology and related 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 • Third 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 • 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 8: Symbol And Hazard Pictorials Definitions

    Operator's Manual Second Edition • Third Printing 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 Electrocution hazard...
  • Page 9 Second Edition • Third Printing Operator's Manual 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 Platform tie-down Lifting, tie down instructions Tie-down point Lifting point instructions...
  • Page 10 Operator's Manual Second Edition • Third Printing 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 11: General Safety

    Second Edition • Third Printing Operator's Manual General Safety Gener al Safety Part No. 1301106GT -135 XC ™ ™...
  • Page 12 Operator's Manual Second Edition • Third Printing General Safety -135 XC Part No. 1301106GT ™ ™...
  • Page 13 Second Edition • Third Printing Operator's Manual General Safety Part No. 1301106GT -135 XC ™ ™...

  • Page 14: Personal Safety

    Operator's Manual Second Edition • Third Printing 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 15: Work Area Safety

    Second Edition • Third Printing Operator's Manual Work Area Safety Work Ar ea Safety Tip-over Hazards Electrocution Hazards Occupants, equipment and materials shall not This machine is not electrically insulated and will exceed the maximum platform capacity for the not provide protection from contact with or restricted or unrestricted range of motion.
  • Page 16 Operator's Manual Second Edition • Third Printing Work Area Safety Do not attach a platform rated at 660 lbs/300 kg If the tilt alarm sounds when the platform is raised, (unrestricted range of motion) or 1000 lbs/454 kg use extreme caution. Identify the condition of the (restricted range of motion) to machines with any boom on the slope as shown below.
  • Page 17 Second Edition • Third Printing Operator's Manual Work Area Safety Do not alter or disable machine components that Use extreme care and in any way affect safety and stability. slow speeds while driving the machine in the stowed Do not replace items critical to machine stability position across uneven with items of different weight or specification.
  • Page 18 Operator's Manual Second Edition • Third Printing Work Area Safety Do not modify or alter a mobile elevating work Operation on Slopes Hazards platform without prior written permission from the Do not drive the machine on a slope that exceeds manufacturer.
  • Page 19 Second 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 20 Operator's Manual Second Edition • Third Printing 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 21 Second 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 22 Operator's Manual Second Edition • Third Printing 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 23 Second Edition • Third Printing Operator's Manual 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 24 Operator's Manual Second Edition • Third Printing 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 25: Legend

    Second Edition • Third Printing Operator's Manual 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 Part No. 1301106GT -135 XC ™ ™...

  • Page 26: Controls

    Operator's Manual Second Edition • Third Printing 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 27 Second Edition • Third Printing Operator's Manual 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 28 Operator's Manual Second Edition • Third Printing 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 29 Second Edition • Third Printing Operator's Manual Controls Platform Control Panel Part No. 1301106GT -135 XC ™ ™...
  • Page 30 Operator's Manual Second Edition • Third Printing Controls -135 XC Part No. 1301106GT ™ ™...
  • Page 31 Second Edition • Third Printing Operator's Manual 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 32 Operator's Manual Second Edition • Third Printing 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 33 Second Edition • Third Printing Operator's Manual 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 34: Inspections

    Operator's Manual Second Edition • Third Printing 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 35 Second Edition • Third Printing Operator's Manual Inspections Pre-operation Inspection  Steer and axle sensors  Alarms and beacons (if equipped)  Be sure that the operator’s manual is  Nuts, bolts and other fasteners complete, legible and in the storage container located in the platform.
  • Page 36 Operator's Manual Second Edition • Third Printing Inspections Function Test Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. A malfunctioning machine must never be used. If malfunctions are discovered, the machine must be Do Not Operate Unless: tagged and removed from service.
  • Page 37 Second Edition • Third Printing Operator's Manual 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 38 Operator's Manual Second Edition • Third Printing Inspections 11 With the jib fully retracted, push and hold the Test Machine Functions function enable button and push the jib extend 18 Do not push and hold the function enable button. button. Attempt to activate each boom and Result: The jib should not extend unless the platform function button.
  • Page 39 Second Edition • Third Printing Operator's Manual 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 40 Operator's Manual Second Edition • Third Printing Inspections At the Platform Controls Test the Foot Switch 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 41 Second Edition • Third Printing Operator's Manual 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 42 Operator's Manual Second Edition • Third Printing 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 43 Second Edition • Third Printing Operator's Manual 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 44 Operator's Manual Second Edition • Third Printing 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 45 Second Edition • Third Printing Operator's Manual 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 the contact alarm cable to release the actuator off position to shut off the engine.
  • Page 46 Operator's Manual Second Edition • Third Printing 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 47 Second Edition • Third Printing Operator's Manual Inspections Inspection for Decals with Part No. Decal Description Symbols 1262446 Platform Control Panel, SX-135 XC 1263540 Label – Tip-over Hazard Use the pictures on the next page to verify that all 1263542 Label – Compartment Access decals are legible and in place.
  • Page 48 Operator's Manual Second Edition • Third Printing Inspections 1276685 82481 133067 1272242 44981 1286362 1281175 97757 1263545 1263542 38149 *28174 82487 *28235 1263542 1262446 122343 1276684 230984 1296907 1278542 1263544 1275451 1278982 1254807 1276008 114252 1263542 1275417 1273027 114249 114249 1273027 133205 161691...

  • Page 49: Operating Instructions

    Second 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 manual.
  • Page 50 Operator's Manual Second Edition • Third Printing 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 51 Second 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 52 Operator's Manual Second Edition • Third Printing 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 53 Second Edition • Third Printing Operator's Manual Operating Instructions Driving on a slope To determine the slope grade: Measure the slope with a digital inclinometer OR Determine the uphill, downhill and side slope use the following procedure. ratings for the machine and determine the slope grade.
  • Page 54 Operator's Manual Second Edition • Third Printing 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 55 Second Edition • Third Printing Operator's Manual 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 56 Operator's Manual Second Edition • Third Printing Operating Instructions During the DPF standstill generation process, all boom functions are disabled. Keep clear of the engine exhaust and muffler. Don't leave the machine unattended. The DPF standstill regeneration cannot be activated if not requested by the engine, or in the presence of some engine faults.
  • Page 57 Second Edition • Third Printing Operator's Manual Operating Instructions Operating Envelope Indicator Lights Platform Overload Indicator Light The operating envelope indicator lights will come Light flashing indicates the platform on to notify the operator that a function has been is overloaded. The engine will stop interrupted and/or an action is required by the and no functions will operate.
  • Page 58 Operator's Manual Second Edition • Third Printing Operating Instructions Platform Out of Level (P22 code) Platform Out of Level (Platform Level > 15 Degrees Fault) Bypass key position to be used to level the platform if ground control display shows platform If ground control display shows PLATFORM out of level (P22) and platform level controls do LEVEL >...
  • Page 59 Second Edition • Third Printing Operator's Manual Operating Instructions Contact Alarm (if equipped) Generator The contact alarm is designed to alert ground To operate the generator, move the generator personnel when an operator makes contact with toggle switch. the platform control panel, interrupting boom Note: If the foot switch is activated during movement, sounding an alarm and flashing generator start-up, the generator will not operate.
  • Page 60 Operator's Manual Second Edition • Third Printing Operating Instructions Platform Capacity Range LCD Screen (if equipped) Range of motion is controlled automatically based The LCD screen displays hour meter, voltage, oil pressure and coolant temperature. The screen on platform load. also displays fault codes and other service Unrestricted Range of Motion information.
  • Page 61 Second 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 Load: 660 lbs/300 kg alarm sounds, the following Chassis Chassis functions are affected; drive Angle (front Angle functions are disabled.
  • Page 62 Operator's Manual Second Edition • Third Printing Operating Instructions Pipe Cradle Instructions Observe and Obey: The pipe cradle assembly consists of 2 pipe  Pipe cradles must be installed on the inside of cradles positioned at either side of the platform the platform.
  • Page 63 Second Edition • Third Printing Operator's Manual Operating Instructions Pipe Cradle Operation Be sure the pipe cradle assembly and installation instructions have been followed properly and that the pipe cradles are secured to the platform railings. Place the load so that it rests in both pipe cradles.
  • Page 64 Operator's Manual Second Edition • Third Printing 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 65: Transport And Lifting Instructions

    Second 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 66 Operator's Manual Second Edition • Third Printing 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 67 Second Edition • Third Printing Operator's Manual Transport and Lifting Instructions Push in the yellow lever located near the To return the machine to operation swing drives to set the boom transport chock. Pull out the red Emergency Stop button to the on position.
  • Page 68 Operator's Manual Second Edition • Third Printing Transport and Lifting Instructions Raise the jib boom until the platform is no longer tucked under the boom, the bellcrank has stopped moving and the jib lift cylinder has started to extend. If the platform is not level, level the platform. Lower the boom until the boom angle is less than 10 degrees.
  • Page 69 Second Edition • Third Printing Operator's Manual Transport and Lifting Instructions Adjust the rigging to prevent damage to the Securing the Chassis 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 70 Operator's Manual Second Edition • Third Printing 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 71: Maintenance

    Second 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 72 Operator's Manual Second Edition • Third Printing 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 73 Second 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 74 Operator's Manual Second Edition • Third Printing 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 75: Specifications

    Second Edition • Third Printing Operator's Manual Specifications Specific ati ons Hydraulic pressure, maximum 2,900 psi 200 bar Model 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)
  • Page 76 Operator's Manual Second Edition • Third Printing Specifications SX-135 XC Range of motion chart Maximum platform capacity 1 660 lbs / 300 kg 2 1000 lbs / 454 kg Max Height Max Reach 150 ft 45.72 m -10 ft -3.05 m 140 ft 42.67 m 0 ft...
  • Page 77 Second Edition • Third Printing Operator's Manual Specifications Contents of EC Declaration of Conformity - 1 <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>...
  • Page 78 Operator's Manual Second Edition • Third Printing Specifications Contents of EC Declaration of Conformity - 2 <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, Conformity assessment procedure: art.12 (3) (a), with the application of European Harmonized Standard EN 280:2013+A1:2015.
  • Page 79 Second Edition • Third Printing Operator's Manual Specifications Contents of UK Declaration of Conformity - 1 <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Legislation: 1. Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597) as amended (SI 2011/1043, SI 2011/2157, SI 2019/696) under consideration of designated standard EN280 as described in type- examination certificate <variable field>...
  • Page 80 Operator's Manual Second Edition • Third Printing Specifications Contents of UK Declaration of Conformity - 2 <Manufacturer’s name> hereby declares that the machinery described below complies with the provisions of the following Legislation: 1. Supply of Machinery (Safety) Regulations 2008 (SI 2008/1597) as amended (SI 2011/1043, SI 2011/2157, SI 2019/696) conformity assessment procedure according to Part 3, 11.

This manual is also suitable for:

Genie sx-135 xcSx135h-515

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