Terex Genie Super Series User manual

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
ii
Copyright © 2011 Terex Corporation
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.
Contact Us:
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
6
5
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
5
4
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
iv
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
v
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
vi

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
ix
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

2 - 2 DPL-25S • DPL-30S • DPL35S Super Series Part No.40462
Section 2 - Specifications September 2016
Torque - Dry
inch-pounds
Torque - Dry
foot-pounds
Torque - Dry
Newton meters
Torque - Dry
inch-pounds
Torque - Dry
foot-pounds
Torque - Dry
Newton meters
43
49
96
120
17
19
30
35
50
55
75
90
110
120
150
170
260
300
430
470
640
700
5
6
11
14
23
28
41
48
68
75
102
122
149
163
204
231
353
407
583
637
868
949
60
68
144
168
25
25
45
50
70
80
110
120
150
170
220
240
380
420
600
660
900
1000
7
8
16
19
34
34
61
68
95
109
149
163
204
231
298
326
515
570
814
895
1221
1356
Torque specifications for lubricated bolts are 25% less than the dry torque specifications for each bolt size.
These bolt torque specifications are for general use only. Specification may vary depending on application of bolt.
Size Threads SAE Grade 5 Bolts SAE Grade 8 Bolts
per inch
Bolt Torque Specifications
24
32
20
28
18
24
16
24
14
20
13
20
12
18
11
18
10
16
9
14
8
12
10
1/4
5/16
3/8
7/16
1/2
9/16
5/8
3/4
7/8
1
SPECIFICATIONS

Part No.40462 DPL-25S • DPL-30S • DPL-35S Super Series 3 - 1
Section 3 - Scheduled Maintenance InspectionsSeptember 2016
Dealer
service
suggested
Tools are
required
New parts
required
Scheduled Maintenance Inspections
Observe and Obey:
Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance inspections shall be
completed daily, quarterly and annually as
specified on the Maintenance Inspection
Report.
Failure to properly complete each
inspection when required may
result in death, serious injury or
substantial machine damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating machine.
Machines that have been out of service for a
period longer than 3 months must have a
quarterly inspection.
About This Section
Schedule
There are three types of maintenance inspections
that must be performed according to a schedule—
daily, quarterly and annual. To account for
repeated procedures, the Maintenance Tables and
the Maintenance Inspection Report have been
divided into three subsections—A, B and C. Use
the following chart to determine which group(s) of
procedures are required to perform a scheduled
inspection.
Inspection Table or Checklist
Daily A
Quarterly (every 150 hours or three months) A + B
Annual A + B + C
Maintenance Tables
The maintenance tables contained in this section
provide summary information on the specific
physical requirements for each inspection.
Complete step-by-step instructions for each
scheduled maintenance procedure are provided in
section 4, Scheduled Maintenance Procedures .
Maintenance Inspection Report
The Maintenance Inspection Report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
regulations and requirements.

3 - 2 DPL-25S 30S • DPL-35S Super Series Part No.40462
Section 3 - Scheduled Maintenance Inspections September 2016
Dealer
service
suggested
Tools are
required
New parts
required
Table A
A-1 Inspect the Operator's and Responsibility Manuals
A-2 Inspect the Decals and Placards
A-3 Inspect for Damage and Loose or Missing Parts
A-4 Check for Hydraulic Leaks
A-5 Check the Auxiliary Platform Lowering Operation
A-6 Check the Manual Platform Lowering Operation
A-7 Inspect the Battery and Battery Charger
- DC Models
A-8 Inspect the Columns for Damage
A-9 Check the Sequencing Cables
A-10 Check the Interlock System for Proper Operation
A-11 Test the Power and Function Controls
A-12 Inspect the Lifting Chains and Idler Wheels
A-13 Inspect the Breather Cap
Maintenance Tables

Part No.40462 DPL-25S • DPL-30S • DPL-35S Super Series 3 - 3
Section 3 - Scheduled Maintenance InspectionsSeptember 2016
Dealer
service
suggested
Tools are
required
New parts
required
MAINTENANCE TABLES
Table B
—Complete all procedures in Table A
B-1 Inspect the Electrical Wiring
B-2 Inspect All Welds
B-3 Check the Lifting Chain Adjustments
B-4 Check the Battery - DC Models
B-5 Clean and Lubricate the Columns
B-6 Test the Lifting Capacity
B-7 Test the Power To Platform Operation
B-8 Adjust the Sequencing Cables
B-9 Inspect for Proper Outrigger Length

3 - 4 DPL-25S 30S • DPL-35S Super Series Part No.40462
Section 3 - Scheduled Maintenance Inspections September 2016
Dealer
service
suggested
Tools are
required
New parts
required
Table C
—Complete all procedures in Table A and Table B
C-1 Inspect and Lubricate the Casters and Wheels
C-2 Inspect the Mast Assembly for Wear
C-3 Lubricate the Lifting Chains
C-4 Replace the Hydraulic Oil
C-5 Replace the Auxiliary Platform Lowering Batteries
MAINTENANCE TABLES

Part No.40462 DPL-25S • DPL-30S • DPL-35S Super Series 3 - 5
Section 3 - Scheduled Maintenance InspectionsSeptember 2016
Dealer
service
suggested
Tools are
required
New parts
required
Checklist B Y N R
Refer to Table B
B-1 Electrical wiring
B-2 Welds
B-3 Lifting chain
adjustments
B-4 Battery
B-5 Clean and lubricate
columns
B-6 Lifting capacity
B-7 Power to platform
operation
B-8 Sequencing cables
B-9 Proper outrigger
length
Checklist C Y N R
Refer to Table C
C-1 Casters and wheels
C-2 Mast assembly
C-3 Lifting chains
C-4 Hydraulic oil
C-5 Auxiliary platform
lowering batteries
Checklist A Y N R
Refer to Table A
A-1 Operator's
and Responsibility
manuals
A-2 Decals and placards
A-3 Damage, loose or
missing parts
A-4 Hydraulic leaks
A-5 Auxiliary lowering
operation
A-6 Manual lowering
operation
A-7 Battery and charger
- DC models
A-8 Columns
A-9 Sequencing cables
A-10 Interlock system
operation
A-11 Power and
function controls
A-12 Lifting chains
and idler wheels
A-13 Breather cap
Maintenance Inspection Report
Model
Serial number
Date
Machine owner
Inspected by (print)
Inspector signature
Inspector title
Inspector company
Instructions
• Make copies of this page to use for
each inspection.
• Select the appropriate checklist(s) for
the type of inspection to be
performed.
Daily Inspection: A
Quarterly Inspection: A+B
Annual Inspection: A+B+C
• Place a check in the appropriate box
after each inspection procedure is
completed.
• Use the maintenance tables in this
section and the step-by-step
procedures in section 4 to learn how to
perform these inspections.
• If any inspection receives an “N”,
remove the machine from use, repair
and re-inspect it. After repair, place a
check in the “R” box.
Legend
Y = yes, acceptable
N = no, unacceptable
R = repaired
Comments

3 - 6 DPL-25S 30S • DPL-35S Super Series Part No.40462
Section 3 - Scheduled Maintenance Inspections September 2016
Dealer
service
suggested
Tools are
required
New parts
required
This page intentionally left blank.

Part No.40462 DPL-25S • DPL-30S • DPL-35S Super Series 4 - 1
September 2016 Section 4 - Scheduled Maintenance Procedures
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Symbols Legend
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.
Indicates that a specific result is expected after
performing a series of steps.
Observe and Obey:
Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of these machines.
Scheduled maintenance inspections shall be
completed daily, frequently (every 3 months),
and annually as specified on the maintenance
report.
Failure to properly complete each
inspection when required may
result in death, serious injury or
substantial machine damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating machine.
Keep records on all inspections for three years.
Scheduled Maintenance Procedures

4 - 2 DPL-25S • DPL-30S • DPL-35S Super Series Part No.40462
September 2016
Section 4 - Scheduled Maintenance Procedures
A-1
Inspect the Operator’s and
Responsibility Manuals
Maintaining the operator’s and responsibility
manuals in good condition is essential to safe
machine operation. Manuals are included with
each machine and should be stored in the
container provided at the platform. An illegible or
missing manual will not provide safety and
operational information necessary for a safe
operating condition.
1 Check to be sure the storage container and lid
are present and in good condition.
2 Check to make sure that the operator’s and
responsibility manuals are present and
complete in the storage container at the
platform.
3 Examine the pages of each manual to be sure
that they are legible and in good condition.
4 Always return the manuals to the storage
container after use.
Note: Contact your authorized Genie distributor or
Genie if replacement manuals are needed.
A-2
Inspect the Decals and Placards
Maintaining all of the safety and instructional
decals and placards in good condition is essential
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using a machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
Table A Procedures
1 Refer to the Decals section in the Genie DPL
Super Series Operator's Manual and use the
decal list and illustrations to determine that all
decals and placards are in place.
2 Inspect all decals for legibility and damage.
Replace any damaged or illegible decal
immediately.
Note: Contact your authorized Genie distributor or
Genie if replacement decals are needed.
A-3
Inspect for Damage and Loose or
Missing Parts
Daily machine condition inspections are essential
to safe machine operation and good machine
performance. Failure to locate and repair damage,
and discover loose or missing parts may result in
an unsafe operating condition.
1 Inspect the entire machine for damage and
improperly installed or missing parts including:
• Electrical components and wiring
• Coil cord (if equipped)
• Hydraulic power unit, hoses, fittings and
cylinders
• Manual lowering lever and components
• Platform end guard rail, platform side guard
rails and platform entry gate
• Guard rail lock handles
• Sequencing cables and pulleys
• Lifting chains and idler wheels
• Nuts, bolts and other fasteners
• Mast and mast braces
• Breather cap
• Outriggers, leveling jacks and footpads
• Guard rail lift arm
• Platform entry ladder
• Dents or damage to machine
• Corrosion or oxidation
• Cracks in welds or structural components

Part No.40462 DPL-25S • DPL-30S • DPL-35S Super Series 4 - 3
September 2016 Section 4 - Scheduled Maintenance Procedures
TABLE A PROCEDURES
A-4
Check for Hydraulic Leaks
Detecting hydraulic fluid leaks is essential to
operational safety and good machine performance.
Undiscovered leaks can develop into hazardous
conditions, impair machine functions and damage
machine components.
1 Inspect for hydraulic oil puddles, dripping or
residue on or around the following areas:
• Hydraulic power unit—reservoir, valves,
fittings
• Hydraulic cylinders
• Ground area under the machine
• All hydraulic hoses and fittings
A-5
Check the Auxiliary Platform
Lowering Operation
The auxiliary platform lowering is powered by a
secondary battery pack that is located in the
ground control box. The auxiliary platform lowering
can be activated from the ground or platform
controls. Detection of an auxiliary lowering
malfunction is essential for safe machine
operation. An unsafe working condition exists if the
auxiliary platform lowering function does not
operate in the event of a main power failure.
1 Raise the platform slightly.
2 Disconnect the power source from the machine.
3 Activate the auxiliary platform lowering button at
the ground controls.
Result: Platform should lower.
4 Reconnect the power and raise the platform
slightly.
5 Disconnect the power source from the machine.
6 Push in the control activate button and rotate
the up/down switch in the down direction.
Result: Platform should lower.
A-6
Check the Platform Manual
Lowering Operation
Detection of a platform manual lowering
malfunction is essential for safe machine
operation. An unsafe working condition exists if the
manual lowering function does not operate in the
event of a main and auxiliary power failure.
1 Raise the platform slightly.
2 Activate the manual lowering lever.
Result: Platform should lower.