Terex Genie SX-105 XC, Operator'S Manual

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

Page 2: ...e Netherlands Contents Introduction 1 Symbol and Hazard Pictorials Definitions 5 General Safety 8 Personal Safety 10 Work Area Safety 11 Legend 20 Controls 21 Inspections 30 Operating Instructions 45 Transport and Lifting Instructions 60 Maintenance 66 Specifications 70 Copyright 2016 by Terex Corporation First Edition Third Printing July 2020 Genie is a registered trademark of Terex South Dakota ...

Page 3: ... label Serial number stamped on chassis Serial label located under cover Intended Use and Familiarization Guide The intended use of this machine is to lift personnel including tools and materials to an aerial work site Before operating the machine it s the operator s responsibility to read and understand this familiarization guide Each person must be trained to operate a Mobile Elevating Work Plat...

Page 4: ...and boom up down Turntable rotate and platform rotate Sequential functions and movement Drive and steer Interlocked functions Elevated drive speed Elevated drive in an off level condition Drive enable when the boom is rotated past the non steer wheels All platform and ground controls Limitations of use The intended use of this machine is to lift personnel including tools and materials to an aerial...

Page 5: ... the action indicated in a respective bulletin To view any open bulletins for your machine visit us on the web at www genielift com 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 Accident reporting Questio...

Page 6: ...nd worksite regulations You read understand and obey all applicable governmental regulations You are properly trained to safely operate the machine 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 Hazard Classi...

Page 7: ...azard Keep away from moving parts Crush hazard Overhead obstruction Collision hazard Electrocution hazard Maintain required clearance Tip over hazard Tip over hazard Tip over hazard Electrocution hazard Avoid contact Disconnect battery Read the operator s manual Read the service manual Explosion hazard No smoking No flame Stop engine Explosion hazard Burn hazard Fire extinguisher ...

Page 8: ... 125 XC Part No 1270327GT Fire hazard No smoking Explosion hazard No step Lanyard anchorage points Platform tie down instructions Lifting tie down instructions Maximum capacity Fall arrest Tie down point Lifting point Platform overloaded Support the platform or boom during maintenance Auxiliary lowering ...

Page 9: ...fications Recovery procedure if tilt alarm sounds while elevated Platform uphill 1 Lower boom 2 Retract boom Platform downhill 1 Retract boom 2 Lower boom Do not use ether or other high energy starting aids on machines equipped with glow plugs Voltage rating for power to platform Pressure rating for air line to platform Color coded direction arrows Access by trained and authorized personnel only M...

Page 10: ...Operator s Manual First Edition Third Printing General Safety 8 SX 105 XC SX 125 XC Part No 1270327GT Gener al Safety ...

Page 11: ...First Edition Third Printing Operator s Manual General Safety Part No 1270327GT SX 105 XC SX 125 XC 9 ...

Page 12: ...chine 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 All PFPE must comply with applicable governmental regulations and must be inspected and used in accordance with the PFPE manufac...

Page 13: ...rgized power lines Personnel on the ground or in the platform must not touch or operate the machine until energized power lines are shut off Do not operate the machine during lightning or storms Do not use the machine as a ground for welding Tip over Hazards Occupants equipment and materials shall not exceed the maximum platform capacity for the restricted or unrestricted range of motion Maximum p...

Page 14: ... alarm sounds when the platform is raised use extreme caution Identify the condition of the boom on the slope as shown below Follow the steps to lower the boom before moving to a firm level surface Do not rotate the boom while lowering The recovery mode should be used only by trained and authorized personnel If the tilt alarm sounds with the platform uphill 1 Lower the boom 2 Retract the boom If t...

Page 15: ... Do not alter or disable machine components that in any way affect safety and stability Do not replace items critical to machine stability with items of different weight or specification Do not replace factory installed tires with tires of different specification or ply rating Do not use air filled tires These machines are equipped with foam filled tires Wheel weight is critical to stability Do no...

Page 16: ...a moving or mobile surface or vehicle Be sure the tires are in good condition and the lug nuts tightened Operation on Slopes Hazards Do not drive the machine on a slope that exceeds the maximum uphill downhill or side slope rating of the machine Slope rating applies only to machines in the stowed position Maximum slope rating stowed position Platform downhill 40 22 Platform uphill 40 22 Side slope...

Page 17: ...g Do not enter or exit the platform unless the machine is in the stowed position and the platform is at ground level Hazards related with the specific product application of exiting at height have been considered in the design of the machine for further information contact Genie see section Contacting the Manufacturer Collision Hazards Be aware of limited sight distance and blind spots when drivin...

Page 18: ...id carbon monoxide poisoning Do not operate the machine with a hydraulic oil or air leak An air leak or hydraulic leak can penetrate and or burn skin Improper contact with components under any cover will cause serious injury Only trained maintenance personnel should access compartments Access by the operator is only advised when performing a pre operation inspection All compartments must remain cl...

Page 19: ...afety and responsibilities manuals are complete legible and in the storage container located on the machine Component Damage Hazards Do not use any battery or charger greater than 12V to jump start the engine Do not use the machine as a ground for welding Do not operate the machine in locations where extremely high magnetic fields may be present Battery Safety Burn Hazards Batteries contain acid A...

Page 20: ...radles will reduce rated platform capacity and must be factored into total platform load The pipe cradle assembly weighs 9 5 kg The maximum capacity of the pipe cradle assembly is 91 kg The weight of the pipe cradle assembly and the load in the pipe cradles may limit the maximum number of occupants in platform Center the load within the perimeter of the platform Secure the load to the platform Do ...

Page 21: ...d The weight of the welder will reduce the rated platform capacity and must be factored into the total platform load The welder power supply weighs 34 kg Do not operate the welder unless a fire extinguisher is immediately available for instant use per OSHA regulation 1926 352 d Lockout After Each Use 1 Select a safe parking location firm level surface clear of obstruction and traffic 2 Retract and...

Page 22: ... Legend 20 SX 105 XC SX 125 XC Part No 1270327GT Leg end 1 Square end tire 2 Ground controls 3 Boom 4 Jib boom 5 Platform 6 Circle end tire 7 Platform controls 8 Sliding mid rail 9 Manual storage container 10 Lanyard anchorage points 11 Foot switch ...

Page 23: ... 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 When the ground control station is selected the platform controls are inoperable including the E stop switch Ground Control Panel ...

Page 24: ...om up button and the jib boom will raise 6 Platform level up button Press the platform level up button and the level of the platform will raise 7 Platform level down button Press the platform level down button and the level of the platform will lower 8 Jib boom down button Press the jib boom down button and the jib boom will lower 9 20A circuit breaker for system circuit 10 Alarm 11 Bypass recover...

Page 25: ... Press the boom extend button and the boom will extend 22 Unrestricted range of motion indicator light Light on indicates that the range of motion is unrestricted 23 LCD screen control buttons 24 Restricted range of motion indicator light Light on indicates that the range of motion is restricted 25 LCD readout screen a low fuel indicator b engine oil pressure indicator c water temperature indicato...

Page 26: ...Operator s Manual First Edition Third Printing Controls 24 SX 105 XC SX 125 XC Part No 1270327GT Platform Control Panel ...

Page 27: ...First Edition Third Printing Operator s Manual Controls Part No 1270327GT SX 105 XC SX 125 XC 25 ...

Page 28: ...switch to turn the generator on Move the switch again to turn the generator off 8 Emergency power switch with indicator light Use emergency power if the primary power source engine fails Push down the foot switch and simultaneously move the emergency power switch and activate the desired function The indicator light will be on when emergency power is being used 9 Diesel models Glow plug indicator ...

Page 29: ... the on position to operate the machine 20 Dual axis proportional control handle for drive and steer functions OR Proportional control handle for drive function and thumb rocker for steer function Move the control handle in the direction indicated by the blue arrow on the control panel and the machine will drive forward Move the control handle in the direction indicated by the yellow arrow and the...

Page 30: ... the jib boom will lower Move the control handle to the left and the platform will rotate to the left Move the control handle to the right and the platform will rotate to the right 23 Drive select switch with indicator lights Move the drive select switch to choose drive setting The indicator light next to the current setting will be on Machine on incline symbol Low range operation for inclines Mac...

Page 31: ... function has been interrupted To drive move the drive enable switch and slowly move the drive control handle off center Use the color coded direction arrows on the platform box and drive chassis to identify the direction the machine will travel 27 Dual axis proportional control handle for boom up down and turntable rotate left right functions Move the control handle up and the boom will raise Mov...

Page 32: ...pection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any una...

Page 33: ... section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications Electrical components wiring and electrical cables Hydraulic hoses fittings cylinders and manifolds Fuel and hydraulic tanks Drive and turntable motors and drive hubs Wear pads Tires and wheels Engine and related components Limit switches and horn Rotation sensors Steer ...

Page 34: ...nly use the machine as it was intended 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 tagged and removed from service Repairs to the machine...

Page 35: ... enable button and press the boom up button Result The boom should raise approximately 10 and then stop On the LCD screen the arrow next to the extend axle symbol will flash The boom should not raise unless the axles are extended 8 Push and hold the function enable button and press the boom extend button Result The boom should extend 30 cm then stop On the LCD screen the arrow next to the extend a...

Page 36: ...oom should extend and retract normally 15 Push and hold a function enable button and push the turntable rotate left button and then the turntable rotate right button Result The turntable should rotate normally Test Machine Functions 16 Do not push and hold the function enable button Attempt to activate each boom and platform function button Result No boom and platform functions should operate 17 P...

Page 37: ...until PLATFORM LEVEL SENSOR DEGREES appears Result The LCD screen should display the angle in degrees Test the Operating Envelope 25 Simultaneously press the 2 LCD screen control buttons shown to activate status mode 26 Press one of the LCD screen control buttons shown until PRIMARY ANGLE DEGREES is displayed 27 Raise the boom and observe the LCD screen Result The LCD screen will display the boom ...

Page 38: ...select switch Result The alarm should sound at the platform controls Test the Foot Switch 36 Push in the platform red Emergency Stop button to the off position 37 Pull out the red Emergency Stop button to the on position and do not start the engine 38 Press down the foot switch and attempt to start the engine Result The engine should not start 39 Do not press down the foot switch and restart the e...

Page 39: ... switch and choose circle end yellow arrow steer 48 Press down the foot switch 49 Slowly move the control handle in the direction indicated by the yellow triangle on the control panel OR press the thumb rocker switch in the direction indicated by the yellow triangle Result The circle end wheels should turn in the direction that the blue triangles point on the drive chassis 50 Slowly move the drive...

Page 40: ...le in the direction indicated by the yellow triangle on the control panel OR press the thumb rocker switch in the direction indicated by the yellow triangle Result The square end wheels should turn in the direction that the yellow triangles point on the drive chassis The circle end wheels should turn in the direction that the blue triangles point on the drive chassis Test Drive and Braking 59 Pres...

Page 41: ...chassis to identify the direction of travel If the drive control handle is not moved within two seconds of moving the drive enable toggle switch the drive function will not operate Test Limited Drive Speed 66 Press down the foot switch 67 Raise the boom to 10 above horizontal 68 Slowly move the drive control handle to the full drive position Result The maximum achievable drive speed with the prima...

Page 42: ...latform controls 81 Lower the boom to the stowed position or drive in the opposite direction Result The machine should drive 82 Return to level ground and stow the boom 83 Press down the foot switch 84 With the boom fully stowed drive the machine onto a slope where the chassis angle is greater than 3 along the X Axis side to side Result The machine should continue to drive 85 Return the machine to...

Page 43: ...usly move and hold the auxiliary power switch and activate each function control handle toggle switch or thumb rocker switch Note To conserve battery power test each function through a partial cycle Result All boom and steer functions should operate Test the Lift Drive Select Function 96 Press down the foot switch 97 Move the drive control handle off center and activate a boom function control han...

Page 44: ...e operator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine Workplace Inspection Checklist Be aware of and avoid the following hazardous sit...

Page 45: ...cution Hazard 3 133205 Label Electrocution Burn Hazard 2 219958 Label Tip over Crush Hazard 1 Part No Decal Description Qty 230984 Ground Control Panel 1 1254807 Label 112 dB 1 1256420 Label Power to Platform 208 115V 1 1256421 Label Power to Platform 110V 1 1256422 Label Power to Platform 415V 240V 1 1256424 Label Tip over Hazard anemometer 1 1256425 Label Danger Electrocution Hazard 1 1258677 La...

Page 46: ...Operator s Manual First Edition Third Printing Inspections 44 SX 105 XC SX 125 XC Part No 1270327GT ...

Page 47: ...It is the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected t...

Page 48: ...g to prevent hydraulic system damage In extreme cold conditions 18 C and below machines should be equipped with optional cold start kits Attempting to start the engine when temperatures are below 18 C may require the use of a booster battery Emergency Stop Push in the red Emergency Stop button to the off position at the ground controls or the platform controls to stop all machine functions and tur...

Page 49: ...when the axles are fully retracted The axles can only be retracted if the boom is fully lowered and retracted and the platform is between the circle end wheels Operation from Ground 1 Turn the key switch to ground control 2 Pull out the red Emergency Stop button to the on position 3 Start the engine To Position Platform 1 Push and hold the function enable button 2 Push the appropriate function but...

Page 50: ...ght next to the current steer mode will be on 3 Slowly move the drive control handle in the direction indicated by blue or yellow triangles OR press the thumb rocker switch located on top of the drive control handle Use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the wheels will turn To Drive 1 Press down the foot switch 2 Increase spee...

Page 51: ...Move the drive speed select switch to machine on incline symbol To determine the slope grade Measure the slope with a digital inclinometer OR use the following procedure You will need carpenter s level straight piece of wood at least 1 m long tape measure Lay the piece of wood on the slope At the downhill end lay the level on the top edge of the piece of wood and lift the end until the piece of wo...

Page 52: ...rive enable switch again Be aware that the machine may move in the opposite direction that the drive and steer controls are moved Always use the color coded direction arrows on the platform controls and the drive chassis to identify the direction the machine will travel When the drive enable light is on the axles cannot retract Engine Idle Select rpm Select the engine idle rpm by pressing the engi...

Page 53: ...ight flashing Lower the boom until the indicator light is off Machine Not Level indicator light flashing The tilt alarm will be sounding when this light is flashing Move the machine to a firm level surface If the tilt alarm sounds with the platform uphill 1 Lower the boom 2 Retract the boom If the tilt alarm sounds with the platform downhill 1 Retract the boom 2 Lower the boom Platform Not Level i...

Page 54: ... key from the main key switch and insert the key into the bypass recovery key switch 3 Turn the bypass recovery key switch to the bypass position 4 Using auxiliary power operate the platform level button to level the platform 5 Turn the bypass recovery key switch to the run position 6 Remove the key from the bypass recovery key switch and insert the key into the main key switch 7 Push in and then ...

Page 55: ...latform was overloaded For information on how to reset this message please consult the appropriate Genie Service Manual Generator To operate the generator move the generator toggle switch Note If the foot switch is activated during generator start up the generator will not operate The generator indicator light will flash during generator start up After generator start up is complete the generator ...

Page 56: ... by a qualified service technician Under emergencies the DPF standstill regeneration can be interrupted in two ways The engine is turned off by the key switch The ESTOP stop button is pushed If this occurs the standstill regeneration may need to be restarted The DPF standstill regeneration cannot begin until the engine has been run for at least two minutes and the coolant temperature has reached 3...

Page 57: ...rt the engine if not already done and press the LCD screen control button shown 12 The LCD screen displays the message REGEN REQUESTED At this time the system will warm the engine if necessary and proceed with the process 13 If the Regeneration process has begun successfully the LCD screen displays the message REGEN TIME REMAINING 14 Once the regeneration is completed the LCD screen displays the m...

Page 58: ...election Range of motion is controlled automatically based on platform load Unrestricted Range of Motion When the platform load is less than 300 kg the unrestricted range of motion light is on Restricted Range of Motion When the platform load is 301 454 kg the restricted range of motion light is on and the jib function is limited ...

Page 59: ...s 454 kg 0 123 ft 37 49 m 78 ft 23 77 m 2 5 124 ft 37 8 m 75 ft 22 86 m 5 0 118 ft 35 97 m 75 ft 22 86 m 2 5 125 ft 38 1 m 74 ft 22 56 m 5 0 121 ft 36 38 74 ft 22 56 When the Machine On Incline indicator light is on and the tilt alarm sounds the following functions are affected drive functions are disabled Follow the Boom lowering procedure see Operating Instructions to restore drive function When...

Page 60: ...kins 854F 34T Diesel engines have a regeneration mode that should run automatically when needed LCD will display REGEN FORCED and WARNING HIGH EXHAUST SYSTEM TEMP when the regeneration mode is running No service required Pipe Cradle Instructions The pipe cradle assembly consists of 2 pipe cradles positioned at either side of the platform and mounted to the guardrails with U bolts 1 strap 2 U bolts...

Page 61: ...and installation instructions have been followed properly and that the pipe cradles are secured to the platform railings 2 Place the load so that it rests in both pipe cradles The length of the load should be parallel with the length of the platform 3 Center the load in the pipe cradles 4 Secure the load to each pipe cradle Pass the nylon strap over the load Depress the buckle and slide the strap ...

Page 62: ... while the machine is being loaded Be sure the vehicle capacity loading surfaces and chains or straps are sufficient to withstand the machine weight Genie lifts are very heavy relative to their size See the serial label for the machine weight 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 ...

Page 63: ...Turn the key switch to the off position and remove the key before transporting Inspect the entire machine for loose or unsecured items Securing the Platform Lower the jib boom to the stowed position Lower the platform as far as it will go so that the jib and platform are tucked underneath the boom Run a strap through the platform support between the plates next to the rotator Anchor the strap to e...

Page 64: ...t and Lifting Instructions 62 SX 105 XC SX 125 XC Part No 1270327GT Securing the Chassis SX 105 XC Center of Gravity Measurements 1 3 ft 0 92 m 5 13 5 ft 4 12 m 2 9 6 ft 2 94 m 6 1 8 ft 0 55 m 3 9 3 ft 2 83 m 7 4 8 ft 1 48 m 4 39 ft 11 93 m 8 9 9 ft 3 01 m ...

Page 65: ...t and Lifting Instructions Part No 1270327GT SX 105 XC SX 125 XC 63 Securing the Chassis SX 125 XC Center of Gravity Measurements 1 3 ft 0 92 m 5 13 5 ft 4 12 m 2 6 5 ft 1 98 m 6 1 9 ft 0 58 m 3 8 8 ft 2 68 m 7 5 1 ft 1 56 m 4 39 ft 11 88 m 8 9 9 ft 3 03 m ...

Page 66: ...ine weight Lifting Instructions option 1 Fully extend the axles Fully lower and retract the boom Fully lower the jib Remove all loose items on the machine Determine the center of gravity of your machine using the table and the picture on this page Attach the rigging only to the designated lifting points on the machine There are four lifting points on the drive chassis one lifting point on each axl...

Page 67: ... center of gravity of your machine using the table and the picture on this page Attach the rigging only to the designated lifting points on the machine There are four lifting points on the drive chassis one lifting point on each axle and two lifting points on the riser plate of the swing chassis Adjust the rigging to prevent damage to the machine and to keep the machine level Center of gravity X A...

Page 68: ... maintenance procedure it conveys the meaning below Indicates that tools will be required to perform this procedure Indicates that new parts will be required to perform this procedure Indicates that a cold engine is required before performing this procedure Check the Engine Oil Level Maintaining the proper engine oil level is essential to good engine performance and service life Operating the mach...

Page 69: ...el LSD Deutz TD2 9L Engine Fuel Type Ultra Low Sulfur Diesel ULSD Deutz TCD 2 2L Stage V Engine Fuel Type Ultra Low Sulfur Diesel ULSD Check the Hydraulic Oil Level Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the...

Page 70: ...in the degas tank are under pressure and extremely hot Use caution when removing cap and adding fluids Check the Batteries Proper battery condition is essential to good machine performance and operational safety Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions Electrocution hazard Contact with hot or live circuits may result in death o...

Page 71: ... quarterly annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service ...

Page 72: ...wer unit 221 bar System voltage 12V Tire size IN385 65D 22 5 Weight 18 605 kg Machine weights vary with option configurations See serial label for specific machine weight Airborne noise emissions Sound pressure level at ground workstation 91 dBA Sound pressure level at platform workstation 75 dBA Guaranteed sound power level 112 dBA Total vibration value to which the hand arm system is subjected d...

Page 73: ...ar System voltage 12V Tire size 445D50 710 18 ply HD FF Weight 20 700 kg Machine weights vary with option configurations See serial label for specific machine weight Airborne noise emissions Sound pressure level at ground workstation 91 dBA Sound pressure level at platform workstation 75 dBA Guaranteed sound power level 112 dBA Total vibration value to which the hand arm system is subjected does n...

Page 74: ...Operator s Manual First Edition Third Printing Specifications 72 SX 105 XC SX 125 XC Part No 1270327GT SX 105 XC Range of motion chart SX 125 XC Range of motion chart ...

Page 75: ...ngine only Test Report This machine has been tested and passed the following categories per EN 280 2013 A1 2015 clause 6 3 prior to entering the market 1 BRAKES Brakes working properly in forward and reverse 2 OVERLOAD Overload tested at XXX rated load 3 FUNCTIONAL Smooth operation at XXX rated load 4 FUNCTIONAL All safety devices working correctly 5 FUNCTIONAL Speeds set within permitted specific...

Page 76: ......