Genie DPL-25S Manuale utente

Service Manual

Part No. 40462

Rev A6

September 2016

DPL-25S

DPL-30S

DPL-35S

Super Series

Serial Number Range

from 1596-101

to 1501-915

from DPL02-916

to DPL16-2311

from DPL16G-2312

to DPL16G-2599

from DPLG-2600

DPL-25S • DPL-30S • DPL-35S Super Series Part No.40462

September 2016

First Edition, First Printing, August 1996

Genie is a registered trademark of Terex South

Dakota, Inc in the USA and many other

countries.

Printed on recycled paper

Printed in U.S.A.

Important

Read, understand and obey the safety rules and

operating instructions in the appropriate operator's

manual on your machine before attempting any

maintenance or repair procedure.

This manual provides detailed scheduled

maintenance information for the machine owner and

user. It also provides troubleshooting and repair

procedures for qualified service professionals.

Basic mechanical, hydraulic and electrical skills are

required to perform most procedures. However,

several procedures require specialized skills, tools,

lifting equipment and a suitable workshop. In these

instances, we strongly recommend that

maintenance and repair be performed at an

authorized Genie dealer service center.

Compliance

Machine Classification

Group A/Type 1 as defined by ISO 16368

Machine Design Life

Unrestricted with proper opeation, inspection and

scheduled maintenance.

Technical Publications

Genie has endeavored to deliver the highest degree

of accuracy possible. However, continuous

improvement of our products is a Genie policy.

Therefore, product specifications are subject to

change without notice.

Readers are encouraged to notify Genie of errors

and send in suggestions for improvement. All

communications will be carefully considered for

future printings of this and all other manuals.

http://www.genlift.com

e-mail: [email protected]

Introduction

Part No.40462 DPL-25S • DPL-30S • DPL-35S Super Series

September 2016

Serial Number Legend

Model: Serial number:

Model year:

Elec/Hydr Schematic:

Manufacture date:

Power supply voltage/Pneumatic Pressure:

Maximum Wind Speed:

Maximum allowable inclination of the chassis:

Gradeability:

Maximum platform height:

Maximum allowable side force:

Machine unladen weight:

Max Load:

Occupants and Equipment must not exceed:

Indoor:

Outdoor:

Nominal Power:

DPL16G-1234

2016

01/02/2010

DPL 16 G - 1234

21 43

Model:

Elec/Hydr Schematic:

Year of Manufacture :

Power supply voltage/Pneumatic Pressure:

Maximum Wind Speed:

Maximum allowable inclination of the chassis:

Gradeability:

Maximum platform height:

Maximum allowable side force:

Machine unladen weight:

Max Load:

Occupants and Equipment must not exceed:

Indoor:

Outdoor:

Nominal Power:

2016

DPL G - 1234

21 3

Serial number: DPLG-1234

1 Model

2 Facility code

3 Sequence number

4 Serial number (stamped on chassis)

5 Serial label

From September 1, 2016

1 Model

2 Model year

3 Facility code

4 Sequence number

5 Serial number (stamped on chassis)

6 Serial label

To August 31, 2016

iii

DPL-25S • DPL-30S • DPL-35S Super Series Part No.40462

September 2016

Section 1 - Safety Rules

Safety Rules

Danger

Failure to obey the instructions and safety rules

in this manual and the

Genie DPL Super Series

Operator's Manual

will cause death or serious

injury.

Many of the hazards identified in the

operator’s manuals are also safety hazards

when maintenance and repair procedures

are performed.

Do Not Perform Maintenance

Unless:

You are trained and qualified to perform

maintenance on this machine.

You read, understand and obey:

- manufacturer’s instructions and safety rules

- employer’s safety rules and worksite

regulations

- applicable governmental regulations

You have the appropriate tools, lifting

equipment and a suitable workshop.

Part No.40462 DPL-25S • DPL-30S • DPL-35S Super Series

September 2016 Section 1 - Safety Rules

Workplace Safety

Be sure to keep sparks, flames and

lighted tobacco away from flammable and

combustible materials like battery gases.

Always have an approved fire extinguisher within

easy reach.

Be sure that all tools and working areas

are properly maintained and ready for

use. Keep work surfaces clean and free of

debris that could get into machine components and

cause damage.

Be sure that your workshop or work area

is well ventilated and safely and

adequately illuminated.

Be sure any forklift, overhead crane or

other lifting or supporting device is fully

capable of supporting and stabilizing the

weight to be lifted. Use only chains or straps that

are in good condition and of ample load capacity.

Be sure that fasteners intended for

one-time use (i.e., cotter pins and

self-locking nuts) are not reused. These

components may fail if they are used a second

time.

Be sure to properly dispose of old oil or

other fluids. Use an approved container.

Please be mindful of the environment.

Personal Safety

Any person working on or around a machine must

be aware of all known safety hazards. Personal

safety and the continued safe operation of the

machine should be your number one priority.

Read each procedure thoroughly. This

manual and the decals on the machine

use signal words to identify the following:

Indicates the presence of

a hazard that will cause

death or serious injury.

Indicates the presence of

a hazard that may cause

death or serious injury.

Indicates the presence of

a hazard that will or may

cause serious injury or

damage to the machine.

Indicates special

operation or maintenance

information.

Be sure to wear protective eye wear and

other protective clothing if the situation

warrants it.

Be aware of potential crushing hazards

such as moving parts, free-swinging or

unsecured components when lifting or

placing loads. Always wear approved steel-toed

shoes.

SAFETY RULES

DPL-25S • DPL-30S • DPL-35S Super Series Part No.40462

September 2016

Table of Contents

Introduction

Important Information ...................................................................................................... ii

Section One Safety Rules

General Safety Rules ..................................................................................................... iv

Section Two Specifications

DPL-25S ................................................................................................................... 2 - 1

DPL-30S ................................................................................................................... 2 - 1

DPL-35S ................................................................................................................... 2 - 1

Bolt Torque Specification .......................................................................................... 2 - 2

Section Three Scheduled Maintenance Inspections

Introduction ............................................................................................................... 3 - 1

Table A ..................................................................................................................... 3 - 2

Table B ..................................................................................................................... 3 - 3

Table C ..................................................................................................................... 3 - 4

Maintenance Inspection Report ................................................................................. 3 - 5

Section Four Scheduled Maintenance Procedures

Introduction ............................................................................................................... 4 - 1

A-1 Inspect the Operator's and Responsibility Manuals -

including storage container ............................................................................. 4 - 2

A-2 Inspect the Decals and Placards ..................................................................... 4 - 2

A-3 Inspect for Damage, Loose or Missing Parts................................................... 4 - 2

A-4 Check for Hydraulic Leaks .............................................................................. 4 - 3

A-5 Check the Auxiliary Platform Lowering Operation ........................................... 4 - 3

A-6 Check the Platform Manual Lowering Operation ............................................. 4 - 3

A-7 Inspect the Battery and Battery Charger - DC Models .................................... 4 - 4

A-8 Inspect the Columns for Damage .................................................................... 4 - 4

A-9 Check the Sequencing Cables ........................................................................ 4 - 4

A-10 Check the Interlock System for Proper Operation ........................................... 4 - 5

A-11 Test the Power and Function Controls ............................................................ 4 - 5

Part No.40462 DPL-25S • DPL-30S • DPL-35S Super Series

September 2016

Section Four Scheduled Maintenance Procedures, continued

A-12 Inspect the Lifting Chains and Idler Wheels .................................................... 4 - 6

A-13 Inspect the Breather Cap ................................................................................ 4 - 6

B-1 Inspect the Electrical Wiring ............................................................................ 4 - 7

B-2 Inspect All Welds ............................................................................................ 4 - 7

B-3 Check the Lifting Chain Adjustments .............................................................. 4 - 8

B-4 Check the Battery - DC Models ....................................................................... 4 - 8

B-5 Clean and Lubricate the Columns ................................................................... 4 - 9

B-6 Test the Lifting Capacity .................................................................................. 4 - 9

B-7 Test the Power-To-Platform Operation ......................................................... 4 - 10

B-8 Adjust the Sequencing Cables ...................................................................... 4 - 10

B-9 Inspect for Proper Outrigger Length .............................................................. 4 - 11

C-1 Inspect and Lubricate the Casters................................................................. 4 - 12

C-2 Inspect the Mast Assemblies for Wear .......................................................... 4 - 12

C-3 Lubricate the Lifting Chains ........................................................................... 4 - 13

C-4 Replace the Hydraulic Oil.............................................................................. 4 - 13

C-5 Replacing the Auxiliary Platform Lowering Batteries ..................................... 4 - 14

Section Five Troubleshooting Flow Charts

Introduction ............................................................................................................... 5 - 1

1 Power Light Will Not Turn On - AC Models ..................................................... 5 - 3

2 Power Light Will Not Turn On - DC Models ..................................................... 5 - 5

3 Interlock Lights Will Not Turn On..................................................................... 5 - 7

4 Machine Will Not Lift - AC Models ................................................................. 5 - 10

5 Machine Will Not Lift, But Power Unit Will Operate - AC Models ................... 5 - 13

6 Machine Will Not Lift - DC Models ................................................................. 5 - 15

7 Machine Will Not Lift, But Power Unit Will Operate - DC Models ................... 5 - 18

8 Machine Will Not Lower - Up Function Operates ........................................... 5 - 20

9 Platform Will Not Hold In Up Position ............................................................ 5 - 22

10 Power Unit Will Not Lift Rated Load .............................................................. 5 - 23

11 Auxiliary Platform Lowering Will Not Operate ................................................ 5 - 24

TABLE OF CONTENTS

vii

DPL-25S • DPL-30S • DPL-35S Super Series Part No.40462

September 2016

TABLE OF CONTENTS

viii

Section Six Schematics

Introduction ............................................................................................................... 6 - 1

Electrical Legend ...................................................................................................... 6 - 2

Hydraulic Legend ...................................................................................................... 6 - 3

Electrical Schematic - DPL Super Series DC - All Models

(before serial number DPL07-1499) ......................................................................... 6 - 5

Electrical Schematic - DPL Super Series DC - ANSI Models

(after serial number DPL07-1498) ............................................................................ 6 - 6

Electrical Schematic - DPL Super Series DC - CE Models

(after serial number DPL07-1498) ............................................................................ 6 - 7

Electrical Schematic - DPL Super Series AC - All Models

(before serial number DPL07-1499) ......................................................................... 6 - 8

Electrical Schematic - DPL Super Series AC - ANSI Models

(from serial number DPL07-1499 to DPL07-1562).................................................... 6 - 9

Electrical Schematic - DPL Super Series AC - ANSI Models

(after serial number DPL07-1562) .......................................................................... 6 - 10

Electrical Schematic - DPL Super Series AC - CE Models

(from serial number DPL07-1499 to DPL07-1562).................................................. 6 - 11

Electrical Schematic - DPL Super Series AC - CE Models

(after serial number DPL07-1562) .......................................................................... 6 - 12

Hydraulic Schematic - ANSI ................................................................................... 6 - 13

Hydraulic Schematic - CE ....................................................................................... 6 - 14

Part No.40462 DPL-25S • DPL-30S • DPL-35S Super Series

September 2016

Section Seven Repair Procedures

Introduction ............................................................................................................... 7 - 1

Base Assembly

1-1 Interlocks ........................................................................................................ 7 - 2

1-2 Platform Manual Lowering Cable ..................................................................... 7 - 2

1-3 How to Check the Resistance of a Valve Coil .................................................. 7 - 3

Ground Control Box

2-1 How to Test the Transformer - AC Models ....................................................... 7 - 4

2-2 How to Test the AC Contactor - AC Models ..................................................... 7 - 4

Hydraulic Power Units

3-1 Hydraulic Power Unit Components - AC Models .............................................. 7 - 6

3-2 Hydraulic Power Unit Components - DC Models .............................................. 7 - 8

3-3 How to Remove the Hydraulic Power Unit - AC Models ................................. 7 - 10

3-4 How to Remove the Hydraulic Power Unit - DC Models ................................. 7 - 10

3-5 How to Remove the Hydraulic Pump ............................................................. 7 - 11

3-6 How to Adjust the Pressure Relief Valve ....................................................... 7 - 12

3-7 How to Check the Resistance of a Valve Coil ................................................ 7 - 13

3-8 How to Test the Motor Start Solenoid ............................................................ 7 - 13

Mast Assembly

Mast Illustrations .................................................................................................... 7 - 14

4-1 How to Remove a Lift Cylinder ...................................................................... 7 - 15

4-2 How to Remove a Mast Assembly ................................................................. 7 - 16

4-3 How to Adjust the Lifting Chains .................................................................... 7 - 19

4-4 How to Adjust the Glide Pads ........................................................................ 7 - 19

4-5 How to Inspect the Lifting Chains .................................................................. 7 - 20

Platform

5-1 How to Remove the Platform ......................................................................... 7 - 22

5-2 How to Test the Contactors ........................................................................... 7 - 22

TABLE OF CONTENTS

Part No.40462 DPL25S • DPL-30S • DPL-35S Super Series 2 - 1

Section 2 - SpecificationsSeptember 2016

Specifications

Model DPL-25S DPL-30S DPL-35S

Height, 31 ft 4 in 36 ft 40 ft 9 in

maximum working 9.5 m 11 m 12.4 m

Height, 25 ft 4 in 30 ft 34 ft 9 in

maximum platform 7.7 m 9.2 m 10.6 m

Height, 78 in 78 in 78 in

guard rails stowed 197.8 cm 197.8 cm 197.8 cm

Length, 813/4in 813/4in 813/4in

outriggers stowed 207.6 cm 207.6 cm 207.6 cm

Width, 311/2in 311/2in 311/2in

outriggers stowed 80 cm 80 cm 80 cm

Outrigger footprint 82 x 561/2in 861/4x 673/4in 861/4x 673/4in

(l x w) 208.3 x 143.5 cm 218.7 x 172.1 cm 218.7 x 172.1 cm

Platform dimensions 72 x 271/2in 72 x 271/2in 72 x 271/2in

(l x w) 182.9 x 69.9 cm 182.9 x 69.9 cm 182.9 x 69.9 cm

Lift capacity 750 lbs 750 lbs 600 lbs

340 kg 340 kg 272 kg

Power source 12V DC or 12V DC or 12V DC or

220V or 115V AC 220V or 115V AC 220V or 115V AC

Shipping weight 1375 / 1450 lbs 1475 / 1550 lbs 1575 / 1650 lbs

(AC / DC) 624 / 658 kg 669 / 703 kg 714 / 748 kg

Maximum capacity

ANSI 750 lbs / 340 kg 750 lbs / 340 kg 600 lbs / 272 kg

CE 750 lbs / 340 kg 750 lbs / 340 kg 600 lbs / 272 kg

CSA 600 lbs / 272 kg 600 lbs / 272 kg 500 lbs / 227 kg

Ambient operating -20°F to 135°F

temperature -29°C to 57°C

Airborne noise emissions 80 dB

Maximum sound level at normal operating workstations

(A-weighted)

Current Protection Rating

220V AC models 8A fuse, circuit breaker

5A fuse, printed circuit board

110V AC models 15A fuse, circuit breaker

5A fuse, printed circuit board

DC models 175A fuse, power unit

5A fuse, printed circuit board

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