Genie DPL-25S User manual

Operator’s Manual Second Edition
First Printing
Part No. 82799
with Maintenance Information

GenieDPLSuperSeries PartNo.82799
Operator’s Manual Second Edition • First Printing
Important
Read,understandandobeythesesafetyrulesand
operatinginstructionsbeforeoperatingthismachine.
Onlytrainedandauthorizedpersonnelshallbe
permitted to operate this machine. This manual should
beconsidered apermanentpart ofyourmachine and
should remain with the machine at all times. If you have
any questions, call Genie Industries.
Contents
Page
Safety Rules .............................................................. 1
Controls ..................................................................... 7
Legend ....................................................................... 8
Pre-operationInspection ............................................ 9
Maintenance ............................................................. 11
Function Tests.......................................................... 14
WorkplaceInspection................................................ 17
OperatingInstructions............................................... 18
BatteryandChargerInstructions............................... 21
Transportand LiftingInstructions .............................. 22
Decals ...................................................................... 24
Specifications ........................................................... 28
Contact us:
Internet:http://www.genieindustries.com
e-mail:[email protected]
Copyright © 1996 by Genie Industries
First Edition: Fifth Printing, April 2002
Second Edition: First Printing, November 2003
"Genie" and "DPL" are registered trademarks
of Genie Industries in the USA and many other
countries. "Super Series" is a trademark of
Genie Industries.
This machine complies with
ANSI/SIA 92.3-1990.
Printed on recycled paper
Printed in U.S.A.

PartNo.82799 GenieDPLSuperSeries 1
Operator’s ManualSecond Edition • First Printing
Safety Rules
Danger
Failure to obey the instructions and
safety rules in this manual will
cause death or serious injury.
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator's
manual.
1 Avoidhazardoussituations.
Knowandunderstandthesafetyrulesbefore
going on to the next section.
2 Alwaysperformapre-operationinspection.
3 Always perform the function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Youread,understandandobeythe
manufacturer'sinstructions and safetyrules—
safetyandoperator'smanualsandmachine
decals.
Youread,understandandobeyemployer's
safety rules and worksite regulations.
Youread,understandandobeyallapplicable
governmentalregulations.
Youareproperlytrainedtosafelyoperate the
machine.
The first time this machine is set up for use, a
breathercapisinstalled.SeePre-operation
Inspection section for breather cap instructions.

2 GenieDPLSuperSeries PartNo.82799
Operator’s Manual Second Edition • First Printing
Tip-over Hazards
Do not raise the platform
unless the base is level,
allfouroutriggersare
properly set up and the
leveling jacks firmly
contacttheground.
Do not move the machine
while the platform is
raised.
Do not adjust or remove the outriggers while the
platform is occupied or raised.
Do not place or attach overhanging loads to any
part of this machine.
Do not transport tools and materials unless they are
evenly distributed and can be safely handled by
person(s)intheplatform.
Do not raise the platform
unless the machine is
level. Do not set the
machine up on a surface
whereitcannotbeleveled
usingonly the outriggers.
Donotplaceladdersor
scaffolds in the platform or
against any part of this
machine.
Do not push off or pull toward any object outside
theplatform.
Maximum allowable
manual force 90 lbs 400 N
Do not use the machine on a moving or mobile
surface or vehicle.
Do not operate the machine in strong or gusty
winds. Do not increase the surface area of the
platform or the load. Increasing the area exposed to
the wind will decrease machine stability.
Occupants,equipment and materials shall not
exceed the maximum platform capacity.
Maximum capacity - DPL-25S
ANSI and CE 750 lbs 340 kg
CSA 600 lbs 272 kg
Maximum occupants 2
Maximum capacity - DPL-30S
ANSI and CE 750 lbs 340 kg
CSA 600 lbs 272 kg
Maximum occupants 2
SAFETY RULES

PartNo.82799 GenieDPLSuperSeries 3
Operator’s ManualSecond Edition • First Printing
Maximum capacity - DPL-35S
ANSI and CE 600 lbs 272 kg
CSA 500 lbs 227 kg
Maximum occupants 2
Donot operate themachine near drop-offs,holes,
bumps, debris, unstable or slippery surfaces or
otherpossiblehazardousconditions.
Do not alter or disable machine components that in
any way affect safety and stability.
Do not replace items critical to stability with items
of different weight or specification. Use only Genie
authorizedreplacementparts.
When moving the machine with a forklift or other
transport vehicle, the platform should be fully
lowered,the guardrails shouldbedown, the
machineshould beturned offandno personnel
shall remain in the platform.
Do not modify or alter an aerial work platform
withoutprior writtenpermission fromthe
manufacturer.Mountingattachmentsforholding
toolsor other materials onto the platform,toeboards
or guard rail system can increase the weight in the
platform and the surface area of the platform or the
load.
SAFETY RULES
Fall Hazards
The guard rail system provides fall protection. If
occupantsof the platform are required to wear
personalfall protection equipment(PFPE)due to
job site or employer rules, PFPE equipment and its
use shall be in accordance with the PFPE
manufacturer’sinstructionsandapplicable
governmentalrequirements.
Do not sit, stand or climb
onthe platform guard rails.
Maintain a firm footing on
the platform floor at all
times.
Do not enter or raise the
platform unless the
platformside guardrails
arelocked upright andthe
platformendguardrailand
the platform entry gate are
closedand latched.
Do not exit the platform while raised. If a power
failureoccurs, have ground personnel activate the
manualloweringvalve.
Keep the platform floor clear of debris.

4 GenieDPLSuperSeries PartNo.82799
Operator’s Manual Second Edition • First Printing
SAFETY RULES
Electrocution
Hazards
This machine is not
electricallyinsulated
andwill not provide
protection from contact
with or proximity to
electricalcurrent.
Keep away from the machine if it contacts
energizedpowerlinesorbecomeselectrically
charged.Personnel ontheground or intheplatform
must not touch or operate the machine until the
energizedpowerlinesare shut off.
Maintain safe distances from electrical power lines
andapparatusinaccordancewithapplicable
governmentalregulationsandthefollowingchart.
Voltage Minimum Safe
Approach Distance
Phase to Phase Feet Meters
0 to 300V Avoid Contact
300V to 50KV 10 3.05
50KV to 200KV 15 4.60
200KV to 350KV 20 6.10
350KV to 500KV 25 7.62
500KV to 750KV 35 10.67
750KV to 1000KV 45 13.72
Allow for platform movement, electrical line sway
or sag and movement due to strong or gusty winds.
Do not use the machine as a ground for welding.
Donotoperatethemachineduring lightningor
storms.
Donot operateanAC powered machineor a DC
batterychargerunlessusinga3-wiregrounded
extension cord connected to a grounded AC circuit.
Donotalterordisablethe3-wiregroundedplugs.
Collision Hazards
Operators must comply with employer, job site and
governmentalrulesregardingtheuseofpersonal
protectiveequipment.
Checkthe work area foroverheadobstructionsor
otherpossiblehazards.
Beawareof crushinghazards whengrasping the
platformside guard rails.
Do not lower the platform unless the area below is
clearof personnelandobstructions.
Becareful when transporting on an incline.
Stay clear of descending platform.
Component Damage Hazards
Donotoperatethe machine unless a breather cap
has been installed in the hydraulic reservoir. See
the Pre-operationInspectionsection forbreather
cap instructions.
Do not use the machine as an electrical ground for
welding.
DC models: Do not operate the machine with a
weakor overly discharged battery.

PartNo.82799 GenieDPLSuperSeries 5
Operator’s ManualSecond Edition • First Printing
SAFETY RULES
Improper Use Hazard
Do not leave the machine unattended unless the
key is removed to secure from unauthorized use.
Damaged Machine Hazards
Donot use a damaged or malfunctioning machine.
Conductathoroughpre-operationinspectionofthe
machine and test all functions before each
work shift. Immediately tag and remove from
serviceadamagedormalfunctioningmachine.
Besureallmaintenancehasbeen performed
as specified in this manual and the Genie DPL
ServiceManual .
Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities
manualsarecomplete, legible and in the storage
container located in the platform.
Bodily Injury Hazard
Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/orburnskin.
Impropercontact with componentsunderany cover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access
by the operator is only advised when performing a
pre-operationinspection.Allcompartmentsmust
remainclosedandsecuredduringoperation.
Decal Legend
Genie product decals use symbols, color coding
and signal words to identify the following:
Safety alert symbol—used to alert
personneltopotentialpersonal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.
Red—usedtoindicatethe
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
seriousinjury.
Orange—usedtoindicatethe
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
seriousinjury.
Yellow with safety alert symbol—
used to indicate the presence of a
potentiallyhazardoussituation
which, if not avoided, may cause
minorormoderateinjury.
Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.
Green—usedtoindicateoperation
ormaintenanceinformation.

6 GenieDPLSuperSeries PartNo.82799
Operator’s Manual Second Edition • First Printing
Battery and Charger Safety
- DC Models
Burn Hazards
Batteries contain acid. Always wear protective
clothingandeyewearwhenworking withbatteries.
Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.
Explosion Hazards
Batteries emit explosive gas.
Keep sparks, flames and
lightedtobaccoawayfrom
the battery.
Chargethe battery in a
well-ventilatedarea.
Do not disconnect the charger DC output wires from
the battery when the charger is on.
The sliding door on the base cover must remain
openduring theentirecharging cycle.
Electrocution Hazards
Connectthechargertoa
groundedACcircuit only.
Do not expose the battery or
thecharger to water or rain.
Before each use, inspect for
damage.Replacedamaged
itemsbeforeoperating.
Lifting Hazard
The battery weighs 105 lbs / 48 kg. Use the
appropriatenumberofpeopleandproperlifting
techniques when lifting the battery.
SAFETY RULES

PartNo.82799 GenieDPLSuperSeries 7
Operator’s ManualSecond Edition • First Printing
Controls
Ground Controls Platform Controls
1
8
9
3 4
7 6 5
1 2
1 RedEmergencyStop button
2 Key switch
3 Outriggerinterlockdisplay lights(four)
4 Low battery indicator light for auxiliary
lowering
5 DCmodels: Low battery indicator light
6 Powerlight
7 Auxiliaryplatformloweringbutton
8 Controlactivatebutton
9 Up/Downswitch

8 GenieDPLSuperSeries PartNo.82799
Operator’s Manual Second Edition • First Printing
1 Platformendguardrail
2 Platformside guard rail
3 Manualstoragecontainer
4 Platformcontrols
5 AC outlet
6 Guardrail lifting arm
7 Platform entry gate
8 Platform end gate latch
9 Platform
10 Interlock display
11 ACmodels: Circuitbreaker
12 Platformentryladder
13 AC models: Power supply for
machine
DCmodels:AC power to
platform
14 Platform entry ladder lock pin
15 Outriggerwith levelingjack
16 Forklift pocket
17 Bubblelevel
18 Sequencingcable
19 Transporttie-down
20 Manualloweringlever
21 Batterychargerplug-in
22 Base
23 Caster with swivel lock
24 Base cover
25 Mast
26 Steerhandle
27 Platformguard rail locking
handle
Legend

PartNo.82799 GenieDPLSuperSeries 9
Operator’s ManualSecond Edition • First Printing
Pre-operation Inspection
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator’s
manual.
1 Avoidhazardous situations.
2 Always perform a pre-operation
inspection.
Know and understand the pre-operation
inspection before going on to the next
section.
3 Always perform the function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Breather Cap - AC & DC
Models
Componentdamage will occur if the machine
isoperated withoutabreather cap.
The first time this machine is
set up for use, the pipe plug in
thehydraulicreservoir,underthe
battery cover, must be removed
andpermanentlyreplacedwitha
breathercap.
A breather cap is supplied and
canbe found in an envelope
taped to the mast.
Fundamentals
It is the responsibility of the operator to perform a
pre-operationinspectionandroutinemaintenance.
Thepre-operationinspection is a visual inspection
performed by the operator prior to each work shift.
The inspection is designed to discover if anything
isapparently wrong with a machine before the
operator performs the function tests.
Thepre-operationinspectionalsoservesto
determineifroutinemaintenanceproceduresare
required.Onlyroutinemaintenanceitemsspecified
in this manual may be performed by the operator.
Refer to the list on the next page and check each
of the items.
Ifdamage oranyunauthorized variationfrom
factory delivered condition is discovered, the
machinemust be tagged and removed from
service.
Repairs to the machine may only be made by a
qualified service technician, according to the
manufacturer'sspecifications.After repairsare
completed,the operatormust perform a
pre-operationinspectionagainbeforegoingonto
the function tests.
Scheduledmaintenanceinspectionsshallbe
performedby qualified service technicians,
accordingto the manufacturer's specifications and
the requirements listed in the responsibilities
manual.

10 GenieDPLSuperSeries PartNo.82799
Operator’s Manual Second Edition • First Printing
Pre-operation Inspection
oBe sure that the operator’s, safety and
responsibilitiesmanualsarecomplete,legible
and in the storage container located in the
platform.
oBe sure that all decals are legible and in place.
See Decals section.
oCheck for battery fluid leaks and proper fluid
level. Add distilled water if needed. See
Maintenancesection.
oCheck for hydraulic oil leaks and proper oil level.
Add oil if needed. See Maintenance section.
Checkthe following components or areas for
damage,improperly installed ormissingpartsand
unauthorizedmodifications:
oElectricalcomponentsandwiring
oCoilcord(ifequipped)
oHydraulic power unit, hoses, fittings and
cylinders
oManualloweringlever
oPlatformend guardrail, platformsideguard
rails and platform entry gate
oGuardraillockhandles
oSequencingcablesandpulleys
oLiftingchainsand idler wheels
oNuts, bolts and other fasteners
oMast and mast braces
PRE-OPERATIONINSPECTION
oBreathercap
oOutriggers,levelingjacks and footpads
oGuard rail lift arm
oPlatformentryladder
Checkentire machine for:
oDentsordamage
oCorrosionoroxidation
oCrack in welds or structural components
oInspect and clean battery terminals and all
batterycableconnections.
oBe sure that all structural and other critical
componentsare present andallassociated
fastenersand pins are in place and properly
tightened.

PartNo.82799 GenieDPLSuperSeries 11
Operator’s ManualSecond Edition • First Printing
Maintenance
Observe and Obey:
Only routine maintenance items specified in this
manualshallbeperformedbythe operator.
Scheduledmaintenanceinspectionsshallbe
completed by qualified service technicians,
accordingto the manufacturer's specifications
andtherequirements specified in the
responsibilitiesmanual.
MaintenanceSymbolsLegend
Thefollowing symbols have been
used in this manual to help
communicate the intent of the
instructions. When one or more of
the symbols appear at the
beginningofamaintenance
procedure,itconveysthemeaning
below.
Indicates that tools will be required to
performthisprocedure.
Indicates that new parts will be required to
performthisprocedure.

12 GenieDPLSuperSeries PartNo.82799
Operator’s Manual Second Edition • First Printing
MAINTENANCE
Check the Hydraulic Oil Level -
AC and DC Models
Maintaining the hydraulic oil at the proper level is
essentialtomachineoperation.Improperhydraulic
oil levels can damage hydraulic components. Daily
checks allow the inspector to identify changes in oil
level that might indicate the presence of hydraulic
system problems.
1 Be sure the platform is fully lowered.
2 Check the sight gauge on the side of the
hydraulicreservoir.
Result: The hydraulic oil level should be visible
in the middle of the sight gauge. Do not overfill.
Hydraulic oil specifications
Hydraulic oil type Chevron Rykon
Premium MV equivalent
Check the Battery - DC Models
Proper battery condition is essential to good
machineperformanceandsafeoperation.Improper
fluid levels or damaged cables and connections can
resultincomponentdamageandhazardous
conditions.
Electrocutionhazard. Contactwith
hot or live circuits could result in
death or serious injury. Remove all
rings,watches and otherjewelry.
Bodily injury hazard. Batteries
contain acid. Avoid spilling or
contactingbatteryacid.Neutralize
battery acid spills with baking soda
andwater.
Perform this test after fully
chargingthebatteries.
1 Put on protective clothing and eye wear.
2 Remove the battery vent caps.
3 Check the battery acid level. If needed,
replenish with distilled water to the bottom of the
battery fill tube. Do not overfill.
4 Install the vent caps.

PartNo.82799 GenieDPLSuperSeries 13
Operator’s ManualSecond Edition • First Printing
MAINTENANCE
Scheduled Maintenance
Maintenanceperformedquarterly,annuallyand
every two years must be completed by a person
trainedand qualifiedto performmaintenanceon this
machineaccordingto 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.

14 GenieDPLSuperSeries PartNo.82799
Operator’s Manual Second Edition • First Printing
Fundamentals
The function tests are designed to discover any
malfunctions before the machine is put into service.
Theoperator must followthestep-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 may only be made by a qualified service
technician,accordingtothemanufacturer's
specifications.
Afterrepairs are completed, the operator must
performapre-operationinspectionandfunction
tests before putting the machine into service.
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator’s
manual.
1 Avoidhazardous situations.
2 Alwaysperformapre-operationinspection.
3 Always perform the function tests prior
to use.
Know and understand the function tests
before going on to the next section.
4 Inspect the workplace.
5 Only use the machine as it was intended.
Function Tests
1 Position the machine directly below the desired
workarea.
2 Connecttotheappropriatepowersource:
DC models: Connect the battery pack.
AC models: Connect to a grounded 15A AC
power supply. Use a 12 gauge / 3.3 mm2
3-wiregroundedextensioncordnolongerthan
50 feet / 13 m.
3 Insert the key and turn to platform control.
4 Pull out the red Emergency Stop button at the
ground controls to the on position.
Result: The power light should come on.
5 Install each outrigger and adjust the leveling
jacks to level the machine. Level the machine
usingonly the outriggers.
FunctionTests

PartNo.82799 GenieDPLSuperSeries 15
Operator’s ManualSecond Edition • First Printing
FUNCTIONTESTS
6 Be sure that all four interlock display lights at
thegroundcontrolsare on.
7 Use the bubble level and adjust
the leveling jacks until the
machine base is level.
8 Rotatetheplatformguard
raillockinghandleand
rotate the platform side
guardrail to theupright
position. Be sure the side
guard rail locks in place.
Repeat for the other side.
9 Pull the ladder lock pins and rotate the ladder
down. Be sure the ladder locks in place.
10 Climb the ladder to enter the platform. Close and
latch the platform entry gate and the platform
endguardrail.
TestEmergencyStop
11 Twist to release the red Emergency Stop button
at the platform controls.
12 Push in the red Emergency Stop button at the
ground controls to the off position.
13 Push and hold the control activate button and
rotate the up/down switch in the direction of
intendedtravel.
Result:Theup/down function should not
operate.
14 Push in the red Emergency Stop button at the
platform controls to the off position.
15 Pull out the red Emergency Stop button at the
ground controls to the on position.
16 Push and hold the
control activate button
androtatetheup/down
switch in the direction
ofintended travel.
Result:Theup/down
functionshouldnot
operate.

16 GenieDPLSuperSeries PartNo.82799
Operator’s Manual Second Edition • First Printing
FUNCTIONTESTS
TestOutriggerInterlock
17 Twist to release the red Emergency Stop button
at the platform controls.
18 Push and hold the control activate button and
rotate the up/down switch in the direction of
intendedtravel.
Result:Theup/downfunctionshouldoperate.
19 Unscrew one leveling jack until the
corresponding interlock display light turns off.
20 Push and hold the control activate button and
rotate the up/down switch in the direction of
intendedtravel.
Result:Theup/down function should not
operate.
21 Return the leveling jack to the previous setting
and check the bubble level.
22 Repeattheprocedureforeachoutrigger.
TestAuxiliaryPlatformLowering
- AC & DC Models
23 Raise the platform slightly.
24 Disconnect the power source from the machine.
25 Turn the key switch to ground control.
26 Push in the auxiliary platform lowering button at
thegroundcontrols.
Result:The platformshouldlower.
27 Connectthe power source to the machine.
28 Turn the key switch to platform control.
29 Raise the platform approximately 6 in / 15 cm.
30 Disconnect the power source from the machine.
31 Push and hold the control activate button and
rotate the up/down switch in the down direction.
Result:The platformshouldlower.
32 Connectthe power source to the machine.
TestManualLowering
33 Raise the platform slightly.
34 Activatethe manual lowering lever.
Result:The platformshouldlower.

PartNo.82799 GenieDPLSuperSeries 17
Operator’s ManualSecond Edition • First Printing
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator’s
manual.
1 Avoidhazardous situations.
2 Alwaysperformapre-operation
inspection.
3 Always perform function tests prior to use.
4 Inspecttheworkplace.
Knowandunderstandtheworkplace
inspection before going on to the next
section.
5 Only use the machine as it was intended.
Fundamentals
Theworkplaceinspectionhelpstheoperator
determine if the workplace is suitable for safe
machineoperation.Itshouldbeperformedby the
operator prior to moving the machine to the
workplace.
It is the operator’s responsibility to read and
remembertheworkplacehazards, thenwatchfor
and avoid them while moving, setting up and
operatingthemachine.
Workplace Inspection
Workplace Inspection
Beaware of andavoid the followinghazardous
situations:
· drop-offsorholes
· bumps,floor obstructions or debris
· slopes that exceed the machine’s leveling
capability
· unstableor slippery surfaces
· overheadobstructionsandhighvoltage
conductors
· hazardouslocations
· inadequatesurface supporttowithstand all load
forces imposed by the machine
· windandweatherconditions
· thepresenceofunauthorizedpersonnel
· otherpossibleunsafeconditions

18 GenieDPLSuperSeries PartNo.82799
Operator’s Manual Second Edition • First Printing
OperatingInstructions
Do Not Operate Unless:
You learn and practice the principles of safe
machineoperationcontainedinthisoperator’s
manual.
1 Avoidhazardous situations.
2 Alwaysperformapre-operation
inspection.
3 Always perform function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was
intended.
Fundamentals
TheOperating Instructions sectionprovides
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.
Using the machine for anything other than lifting
personnel, along with their tools and materials, to
an aerial work site is unsafe and dangerous.
Onlytrainedandauthorizedpersonnelshouldbe
permitted to operate a machine. If more than one
operator is expected to use a machine at different
times in the same work shift, they must all be
qualified operators and are all expected to follow all
safety rules and instructions in the operator's,
safety and responsibilities manuals. That means
everynewoperatorshouldperformapre-operation
inspection, function tests, and a workplace
inspectionbefore using the machine.