Terex SX125D-101 Operator's Manual
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Terex SX125D-101 Operator's Manual

Terex SX125D-101 Operator's Manual

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Operator's Manual
ZX-135/70
With Jib Extend
with Jib-Extend™
Serial Number Range
from ZX13513-2001
AUS
Australia
with
Maintenance
Information
First Edition
Fifth Printing
Part No. 160569

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Summary of Contents for Terex SX125D-101

  • Page 1 Operator's Manual Serial Number Range ZX-135/70 from ZX13513-2001 Australia With Jib Extend with Jib-Extend™ with Maintenance Information First Edition Fifth Printing Part No. 160569...

  • Page 2: Table Of Contents

    Maintenance ............60 Specifications ............63 Copyright © 2011 by Terex Corporation First Edition: Fifth Printing, September 2015 Genie and "ZX" are registered trademarks of Terex South Dakota, Inc. in the U.S.A. and many other countries. These machines comply with AS1418.10 ZX-135/70...

  • Page 3: About This Manual

    First Edition • Fifth 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: Contacting The Manufacturer

    Operator's Manual First Edition • Fifth 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: Hazard Classification

    First Edition • Fifth 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 • Fifth Printing Symbol and Hazard Pictorials Definitions Symbol and Hazard Pictorials Definitions Crush 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 • Fifth Printing Operator's Manual Symbol and Hazard Pictorials Definitions Platform tie-down Lifting & tie down instructions Tie-down point Lifting point instructions Wind speed Maximum capacity Weight of welder Wheel load Tire specifications reduces capacity Recovery procedure if tilt alarm sounds while elevated Do not use ether or Voltage rating for...

  • Page 8: General Safety

    Operator's Manual First Edition • Fifth Printing General Safety General Safety 1263543 97865 114390 1263543 82237 97602 114258 229356 or 230977 or 1261816 or 1261817 229356 or 230977 or 1261816 or 1261817 229356 or 230977 114258 1261816 or 1261817 82237 DANGER DANGER DANGER...
  • Page 9 First Edition • Fifth Printing Operator's Manual General Safety Part No. 160569 ZX-135/70...
  • Page 10 Operator's Manual First Edition • Fifth Printing General Safety 114390 1263543 DANGER 31788 31060 82237 97865 DANGER DANGER WARNING DANGER Explosion / Burn Hazard Ignition of explosive gases or contact with corrosive acid will cause death, burns or blindness Tip-over Hazard Electrocution/Burn Hazard Altering or disabling limit Failure to disconnect all...

  • Page 11: Personal Safety

    First Edition • Fifth 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 • Fifth 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 • Fifth Printing Operator's Manual Work Area Safety Do not raise or extend the If the tilt alarm sounds with boom unless the machine the platform uphill: is on a firm, level surface. Lower the primary boom. Lower the secondary boom.
  • Page 14 Operator's Manual First Edition • Fifth Printing Work Area Safety Do not alter or disable machine components that in Use extreme care and 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 15 First Edition • Fifth 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 of machine.

  • Page 16: Fall Hazards

    Operator's Manual First Edition • Fifth 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 governmental regulations. operating. Attach the lanyard to the Be aware of the boom position and tailswing when anchor provided in the...
  • Page 17 First Edition • Fifth 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 18: Explosion And Fire Hazards

    Operator's Manual First Edition • Fifth Printing Work Area Safety Explosion and Fire Hazards Damaged Machine Hazards Do not start the engine if you smell or detect liquid Do not use a damaged or malfunctioning machine. petroleum gas (LPG), gasoline, diesel fuel or other Conduct a thorough pre-operation inspection of the explosive substances.

  • Page 19: Battery Safety

    First Edition • Fifth Printing Operator's Manual 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 20 Operator's Manual First Edition • Fifth 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 21 First Edition • Fifth Printing Operator's Manual Work Area Safety Weld Line to Platform 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

    Operator's Manual First Edition • Fifth Printing Legend Legend Platform controls Square-end tire Sliding mid-rail Ground controls Manual storage container Secondary boom 10 Lanyard anchorage points Primary boom 11 Foot switch Jib boom Platform ZX-135/70 Part No. 160569...

  • Page 23: Controls

    First Edition • Fifth Printing Operator's Manual Controls Controls Ground Control Panel Glow plug button 16 Alarm Turntable rotate right button 10 Key switch for 17 Bypass/recovery key switch Turntable rotate left button off/ground/platform selection 18 Platform rotate right button Secondary boom up/extend 11 Engine start button and down/retract buttons...

  • Page 24: Ground Control Panel

    Operator's Manual First Edition • Fifth Printing Controls LCD screen control buttons Ground Control Panel Engine speed select button Turntable rotate right button Press the engine speed select button to select Press the turntable rotate right button and the the engine speed. When the arrow above the turntable will rotate right.
  • Page 25 First Edition • Fifth Printing Operator's Manual Controls 10 Key switch for off/ground/platform selection 18 Platform rotate right button Turn the key switch to the off position and the Press the platform rotate right button and the machine will be off. Turn the key switch to the platform will rotate right.
  • Page 26 Operator's Manual First Edition • Fifth Printing Controls Platform Control Panel Generator switch with 11 Engine idle select switch with Horn button indicator light (if equipped) indicator light: Platform not level indicator  Rabbit: high idle Emergency power switch light ...
  • Page 27 First Edition • Fifth Printing Operator's Manual Controls 15 16 STOP 21 Drive select switch with 24 Axle extend/retract switch 18 Dual axis proportional control indicator lights with indicator lights handle for drive and steer functions Machine on incline symbol: 25 Drive enable switch with OR Proportional control Low range operation for...

  • Page 28: Platform Control Panel

    Operator's Manual First Edition • Fifth Printing Controls Emergency power switch with indicator light Platform Control Panel Use emergency power if the primary power Horn button source (engine) fails. Press this button and the horn will sound. Simultaneously move the emergency power Release the button and the horn will stop.
  • Page 29 First Edition • Fifth Printing Operator's Manual Controls 12 Platform overload indicator light 18 Dual axis proportional control handle for drive and steer functions Light flashing indicates the platform is OR Proportional control handle for drive overloaded. The engine will stop and no function and thumb rocker for steer function.
  • Page 30 Operator's Manual First Edition • Fifth Printing Controls 19 Steer mode select switch with indicator lights 22 Thumb rocker for jib boom extend/retract function Move the steer mode select switch Push the top of the rocker to choose steer switch and the jib boom will mode.
  • Page 31 First Edition • Fifth Printing Operator's Manual Controls 24 Axle extend/retract switch with indicator lights 27 Dual axis proportional control handle for primary boom up/down and turntable rotate Move the axle select left/right functions switch to choose an axle setting. The indicator Move the control handle up light will flash while the and the primary boom will...

  • Page 32: Inspections

    Operator's Manual First Edition • Fifth Printing 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 33: Pre-Operation Inspection

    First Edition • Fifth Printing Operator's Manual 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 34 Operator's Manual First Edition • Fifth 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 35 First Edition • Fifth 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 obstruction. At the ground controls, push and hold a function enable/speed select button and push Turn the key switch to ground control.
  • Page 36 Operator's Manual First Edition • Fifth Printing Inspections 10 Push and hold a function enable/speed select 14 Push and hold a function enable/speed select button and push the turntable rotate left button. button and push the primary boom up button and then the primary boom down button.
  • Page 37 First Edition • Fifth Printing Operator's Manual Inspections Test Machine Functions Test the Tilt Sensor 18 Do not press and hold a function enable/speed 24 Press one of the LCD select button. Attempt to activate each boom screen control buttons until and platform function button.
  • Page 38 Operator's Manual First Edition • Fifth Printing Inspections 32 Press and hold the secondary boom up/extend Test the Operating Envelope button. 27 Press the LCD screen Result: The secondary boom should raise and control buttons shown until the LCD screen should display the secondary PRI BOOM ANGLE TO boom angle in degrees.
  • Page 39 First Edition • Fifth Printing Operator's Manual Inspections Test the Foot Switch At the Platform Controls 39 Push in the platform red Emergency Stop Test Emergency Stop button to the off position. 34 Turn the key switch to platform control. 40 Pull out the red Emergency Stop button to the on position and do not start the engine.
  • Page 40 Operator's Manual First Edition • Fifth Printing Inspections 51 Press down the foot switch. Test the Steering 52 Slowly move the control handle in the direction 46 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 41 First Edition • Fifth Printing Operator's Manual Inspections 57 Slowly move the control handle in the direction Test Drive and Braking indicated by the yellow triangle on the control 62 Press down the foot switch. panel OR press the thumb rocker switch in the direction indicated by the yellow triangle.
  • Page 42 Operator's Manual First Edition • Fifth Printing Inspections Test the Drive Enable System Test Limited Drive Speed 65 Press down the foot switch and lower the 69 Press down the foot switch. boom to the stowed position. 70 Raise the primary boom to 5° above 66 Rotate the turntable until the primary boom horizontal.
  • Page 43 First Edition • Fifth Printing Operator's Manual Inspections 77 Slowly move the drive control handle to the full 81 Extend the primary boom 1.2 m. drive position. 82 Slowly move the drive control handle to the full Result: The maximum achievable drive speed drive position.
  • Page 44 Operator's Manual First Edition • Fifth Printing Inspections Test Emergency Controls 84 Push in the red Emergency Stop button to the off position to shut off the engine. 85 Pull out the red Emergency Stop button to the on position. 86 Press down the foot switch.
  • Page 45 First Edition • Fifth 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 46 Operator's Manual First Edition • Fifth Printing Inspections Inspection for Decals with Words Part No. Decal Description 97865 Warning – Electrocution Hazard Use the pictures on the next page to verify that all 97875 Warning – Weld Line to Platform (option) decals are legible and in place.
  • Page 47 First Edition • Fifth Printing Operator's Manual Inspections 160424 1263543 97602 1000083 160654 114390 82237 128953 97865 or 219960 72086 28159 114258 160682 40434 160682 229356 or 230977 229356 or 230977 or 1261816 or 1261817 or 1261816 or 1261817 133163 1263543 160683 219974...

  • Page 48: Operating Instructions

    Operator's Manual First Edition • Fifth 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 49: Starting The Engine

    First Edition • Fifth Printing Operator's Manual Operating Instructions Perkins models Starting the Engine Move the glow plug switch to either side and At the ground controls, turn the key switch to hold. the desired position. Move the engine start toggle switch to either Be sure both ground and platform control red side.

  • Page 50: Emergency Stop

    Operator's Manual First Edition • Fifth Printing Operating Instructions Emergency Stop To Extend and Retract Axles Push in the red Emergency Stop button to the off Turn the key switch to platform control. position at the ground controls or the platform At the platform controls, controls to stop all machine functions and turn the press down the foot switch...
  • Page 51 First Edition • Fifth Printing Operator's Manual Operating Instructions Operation from Ground Operation from Platform Turn the key switch to ground control. Turn the key switch to platform control. Pull out the red Emergency Stop button to the Pull out both ground and platform red on position.
  • Page 52 Operator's Manual First Edition • Fifth Printing Operating Instructions To Drive Driving on a slope Press down the foot switch. Determine the uphill, downhill and side slope ratings for the machine and determine the slope Increase speed: Slowly move the drive grade.
  • Page 53 First Edition • Fifth Printing Operator's Manual Operating Instructions To determine the slope grade: Drive Enable Measure the slope with a digital inclinometer OR Light on indicates that the primary use the following procedure. boom has moved past either circle-end wheel and the drive You will need: function is turned off.
  • Page 54 Operator's Manual First Edition • Fifth Printing Operating Instructions Check Engine Light Machine Not Level indicator light flashing: The Light on and engine stopped: Tag the tilt alarm will be sounding machine and remove from service. when this light is flashing. Light on and engine still running: If the tilt alarm sounds with Contact service personnel within...
  • Page 55 First Edition • Fifth Printing Operator's Manual Operating Instructions Platform Out of Level (P22 code) Generator (if equipped) Bypass key position to be used to level the To operate the generator, move the generator platform if ground control display shows platform switch.
  • Page 56 Operator's Manual First Edition • Fifth 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 57 First Edition • Fifth Printing Operator's Manual Operating Instructions Pipe Cradle Operation Panel Cradle Assembly Be sure the pipe cradle assembly and Apply the warning decal to the front of each installation instructions have been followed panel cradle (if needed). properly and that the pipe cradles are secured Install rubber bumper 1 in the panel cradle to the platform railings.
  • Page 58 Operator's Manual First Edition • Fifth Printing Operating Instructions Installation of Padding Install the 2 pieces of padding on the platform rubber rails. Position the padding to protect the panels bumper 2 from contact with the platform rails. Installation of Strap rubber Open the clamp and install it around a vertical bumper 1...

  • Page 59: Observe And Obey

    First Edition • Fifth 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 60 Operator's Manual First Edition • Fifth Printing Transport and Lifting Instructions Securing the Chassis Securing to Truck or Trailer for Transit Use chains of ample load capacity. Use a minimum of 6 chains. Always use the turntable rotation lock pin each time the machine is transported.
  • Page 61 First Edition • Fifth Printing Operator's Manual Transport and Lifting Instructions Lifting Instructions Fully lower and retract the boom. Fully lower the jib (if equipped). Remove all loose items on the machine. Determine the center of gravity of your machine using the table and the picture on this page.

  • Page 62: Maintenance

    Operator's Manual First Edition • Fifth Printing 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 63: Check The Hydraulic Oil Level

    First Edition • Fifth Printing Operator's Manual Maintenance Check the Hydraulic Oil Level Check the Engine Coolant Level – Liquid Cooled Models Maintaining the hydraulic oil at the proper level is essential to machine operation. Improper hydraulic Maintaining the engine coolant at the proper level oil levels can damage hydraulic components.

  • Page 64: Check The Batteries

    Operator's Manual First Edition • Fifth Printing Maintenance Check the Batteries Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on Proper battery condition is essential to good this machine according to the procedures found in machine performance and operational safety.

  • Page 65: Specifications

    First Edition • Fifth Printing Operator's Manual Specifications Specifications Model Platform rotation 160° ZX-135/70 AC outlet in platform standard Height, working maximum 42.9 m Fuel tank capacity 151 liters Height, platform maximum 41.4 m Hydraulic pressure, maximum 203 bar Height, stowed maximum 3.1 m (boom functions) Horizontal reach, maximum...
  • Page 66 Operator's Manual First Edition • Fifth Printing Specifications ZX-135/70 Range of Motion Chart ZX-135/70 Part No. 160569 Operator's Manual First Edition • Fifth Printing ZX-135/70 Part No. 160569...
  • Page 67 www.genielift.com...

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Genie zx-135/70

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