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-101
AUS
Australia
with
Maintenance
Information
First Edition
Third Printing
Part No. 1273022GT

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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-101 Australia with Maintenance Information First Edition Third Printing Part No. 1273022GT...

  • Page 2: Table Of Contents

    Specifications ............62 Copyright © 2016 by Terex Corporation First Edition: Third Printing, December 2017 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 Introduction About this manual Intended Use Genie appreciates your choice of our machine for This machine is intended to be used only to lift your application. Our number one priority is user personnel, along with their tools, and materials to safety, which is best achieved by our joint efforts.
  • Page 4 Operator's Manual First Edition • Third 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 your machine, along with your name and contact information. At minimum, Genie should be contacted for: Danger Accident reporting...
  • Page 5 First Edition • Third Printing Operator's Manual Introduction Safety Sign Maintenance Hazard Classification Replace any missing or damaged safety signs. Decals on this machine use symbols, color coding, Keep operator safety in mind at all times. Use mild and signal words to identify the following: soap and water to clean safety signs.

  • Page 6: Symbol And Hazard Pictorials Definitions

    Operator's Manual First Edition • Third Printing 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 7 First Edition • Third Printing Operator's Manual Symbol and Hazard Pictorials Definitions Platform tie-down Lifting & tie down instructions Tie-down point Lifting point instructions Wind speed Runaway Hazard Weight of welder Wheel load Tire specifications reduces capacity Recovery procedure if tilt alarm sounds while elevated.

  • Page 8: General Safety

    Operator's Manual First Edition • Third Printing General Safety General Safety ™ ™ -135 XC Part No. 1273022GT...
  • Page 9 First Edition • Third Printing Operator's Manual General Safety ™ ™ Part No. 1273022GT -135 XC...
  • Page 10 Operator's Manual First Edition • Third Printing General Safety ™ ™ -135 XC Part No. 1273022GT...

  • Page 11: Personal Safety

    First Edition • Third 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 12: Work Area Safety

    Operator's Manual First Edition • Third 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 13 First Edition • Third Printing Operator's Manual Work Area Safety The weight of options and accessories such as If the tilt alarm sounds with the pipe cradles and welders will reduce the rated platform uphill: platform capacity, and must be subtracted from the Lower the boom.
  • Page 14 Operator's Manual First Edition • Third Printing Work Area Safety Do not use the platform controls to free a platform Use extreme care and that is caught, snagged, or otherwise prevented slow speeds while driving from normal motion by an adjacent structure. All the machine in the stowed personnel must be removed from the platform position across uneven...
  • Page 15 First Edition • Third Printing Operator's Manual Work Area Safety Operation on Slopes Hazards Fall Hazards Do not drive the machine on a slope that exceeds Occupants must wear a the maximum uphill, downhill or side slope rating of safety belt or harness in the machine.
  • Page 16 Operator's Manual First Edition • Third Printing Work Area Safety Observe and use the color-coded direction arrows Collision Hazards on the platform controls and drive chassis for drive and steer functions. Be aware of limited sight distance and blind spots Do not lower the boom when driving or operating.
  • Page 17 First Edition • Third Printing Operator's Manual Work Area Safety Bodily Injury Hazard Damaged Machine Hazards Always operate the machine in a well-ventilated Do not use a damaged or malfunctioning machine. area to avoid carbon monoxide poisoning. Conduct a thorough pre-operation inspection of the Do not operate the machine with a hydraulic oil or machine and test all functions before each work air leak.
  • Page 18 Operator's Manual First Edition • Third Printing Work Area Safety Battery Safety Pipe Cradle Safety Read, understand, and obey all warnings and Burn Hazards instructions provided with the pipe cradles. Batteries contain acid. Do not exceed the rated platform capacity. The Always wear protective pipe cradle assembly and the weight in the pipe clothing and eye wear when...
  • Page 19 First Edition • Third Printing Operator's Manual 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.

  • Page 20: Legend

    Operator's Manual First Edition • Third Printing Legend Legend Sliding mid-rail Circle-end tire Manual storage container Square-end tire 10 Lanyard anchorage points Ground controls 11 Foot switch Boom Jib boom Platform Platform controls ™ ™ -135 XC Part No. 1273022GT...

  • Page 21: Controls

    First Edition • Third Printing Operator's Manual Controls Controls Ground Control Panel ™ ™ Part No. 1273022GT -135 XC...
  • Page 22 Operator's Manual First Edition • Third Printing Controls 10 LCD readout screen Ground Control Panel 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 23 First Edition • Third 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 Emergency power button Press the jib boom up button and the jib boom...
  • Page 24 Operator's Manual First Edition • Third Printing Controls Platform Control Panel ™ ™ -135 XC Part No. 1273022GT...
  • Page 25 First Edition • Third Printing Operator's Manual Controls ™ ™ Part No. 1273022GT -135 XC...
  • Page 26 Operator's Manual First Edition • Third Printing Controls 10 Engine start switch with indicator light Platform Control Panel 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 27 First Edition • Third Printing Operator's Manual Controls 19 Red Emergency Stop button 22 Thumb rocker for jib boom extend/retract function Push in the red Emergency Stop button to the off position to stop all functions and turn the Push the top of the rocker switch engine off.
  • Page 28 Operator's Manual First Edition • Third Printing Controls 25 Single axis proportional control handle for 28 Dual axis proportional control handle for boom boom extend/retract function up/down and turntable rotate left/right functions Move the control handle down and the boom will Move the control handle up extend.

  • Page 29: Inspections

    First Edition • Third 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 30 Operator's Manual First Edition • Third Printing Inspections  Steer and axle sensors Pre-operation Inspection  Alarms and beacons (if equipped)  Be sure that the operator’s, safety, and  Nuts, bolts and other fasteners responsibilities manuals are complete, legible ...
  • Page 31 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 32 Operator's Manual First Edition • Third Printing 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 obstruction. At the ground controls, push and hold the function enable button and press the boom up Turn the key switch to ground control.
  • Page 33 First Edition • Third Printing Operator's Manual Inspections 12 Turn the key switch to platform control. At the Test Machine Functions platform controls, move the drive control 18 Do not push and hold the function enable handle in the forward direction and move the button.
  • Page 34 Operator's Manual First Edition • Third 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 35 First Edition • Third 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 36 Operator's Manual First Edition • Third Printing Inspections 51 Slowly move the control handle in the direction Test the Steering indicated by the yellow triangle on the control 45 Move the steer panel OR press the thumb rocker switch in the mode select switch direction indicated by the yellow triangle.
  • Page 37 First Edition • Third Printing Operator's Manual Inspections 56 Slowly move the control handle in the direction Test Drive and Braking indicated by the yellow triangle on the control 61 Press down the foot switch. panel OR press the thumb rocker switch in the direction indicated by the yellow triangle.
  • Page 38 Operator's Manual First Edition • Third 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 39 First Edition • Third 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 40 Operator's Manual First Edition • Third Printing Inspections Test the Platform Level Recovery Test the Lift/Drive Select Function 95 Press down the foot switch. 103 Press down the foot switch. 96 Push and hold the platform level recovery 104 Move the drive control handle off center and switch up.
  • Page 41 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 42 Operator's Manual First Edition • Third Printing Inspections Inspection for Decals with Words Part No. Decal Description 218559 Danger, Warning – Tip-over, Crush Use the pictures on the next page to verify that all Hazard decals are legible and in place. 230984 Ground Control Panel Below is a numerical list with quantities and...
  • Page 43 First Edition • Third Printing Operator's Manual Inspections ™ ™ Part No. 1273022GT -135 XC...

  • Page 44: Operating Instructions

    Operator's Manual First Edition • Third 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 45 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 46 Operator's Manual First Edition • Third 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 47 First Edition • Third Printing Operator's Manual Operating Instructions To Drive Operation from Platform Press down the foot switch. Turn the key switch to platform control. Increase speed: Slowly move the drive Pull out both ground and platform red control handle in the direction Emergency Stop buttons to the on position.
  • Page 48 Operator's Manual First Edition • Third 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 49 First Edition • Third Printing Operator's Manual Operating Instructions Drive Enable Operating Envelope Indicator Lights The operating envelope indicator lights will come Light on indicates that the boom on to notify the operator that a function has been has moved past a circle-end tire interrupted and/or an action is required by the and the drive function has been operator.
  • Page 50 Operator's Manual First Edition • Third Printing Operating Instructions Platform Out of Level (P22 code) Platform Not Level indicator light flashing: The tilt alarm Bypass key position to be used to level the will be sounding when this platform if ground control display shows platform light is flashing.
  • Page 51 First Edition • Third Printing Operator's Manual Operating Instructions Platform Overload Indicator Light Platform Capacity Selection Rang of motion is controlled automatically based Light flashing indicates the on platform load. platform is overloaded. The engine will stop and no Unrestricted Range of Motion: functions will operate.
  • Page 52 Operator's Manual First 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 53 First Edition • Third Printing Operator's Manual 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 54 Operator's Manual First Edition • Third 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 55: Transport And Lifting Instructions

    First Edition • Third Printing Operator's Manual 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 56 Operator's Manual First Edition • Third Printing Transport and Lifting Instructions Insert a key into the Bypass/Recovery key Securing to Truck or Trailer for switch, located on the side of the ground Transit control box. Turn the key to the Bypass position, P22.
  • Page 57 First Edition • Third Printing Operator's Manual Transport and Lifting Instructions Press and and hold the enable button and the To return the machine to operation jib down button to lower the jib boom. The jib Pull out the red Emergency Stop button to the boom will begin to tuck under the boom.
  • Page 58 Operator's Manual First 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 59 First Edition • Third Printing Operator's Manual Transport and Lifting Instructions Use a minimum of 6 chains. Securing the Chassis Use chains of ample load capacity. Adjust the rigging to prevent damage to the chains. SX-135 XC ™ ™ Part No. 1273022GT -135 XC...
  • Page 60 Operator's Manual First 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 61: Maintenance

    First Edition • Third Printing Operator's Manual Maintenance 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 Observe and Obey: can damage engine components.
  • Page 62 Operator's Manual First 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 63 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 64: Specifications

    Operator's Manual First Edition • Third Printing Specifications Specifications Model System voltage SX-135 XC Tire size 445D50/710, 18 ply HD FF Height, working maximum 43.15 m Weight 21,727 kg Height, platform maximum 41.15 m (Machine weights vary with option configurations. See Height, stowed maximum 3.05 m serial label for specific machine weight.)
  • Page 65 First Edition • Third Printing Operator's Manual Specifications SX-135 XC Range of Motion Chart SX™-135 XC™ Part No. 1273022GT Operator's Manual First Edition • Third Printing ™ ™ Part No. 1273022GT -135 XC...

This manual is also suitable for:

Sx135h-101

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