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Service Manual - Genie Industries

1. UE an T env a 1 WE Wi EX PLATFORM NC 7 PLATFORM DOWN x KS1 MODE RDN J BOX z DOWN gt 8 KTO 4 I EN2 DATT TRSN YL SWITCH ft PK X Ao r i ra FOR 240 V OPERATION N BK x Bk JUMPER BROWN TO WHITE N 1 fs m GROUND CONTROL BOX U11 THROUGH TERMINALSTRIP GN YL J BOX EX P2 SU T TRANSFORMER yL AND LEAVE BLACK UNCONNECTEDJ YL GN YL GN YL ANHI Hi YL EMERGENCY 3 tiun ELATI RD BK cn e SM eter of YL Y EN1 STOP Bic 11218 W3 poddaj T 3 BN Y a WH WH A MODE ia L CENTER TAP INPUT 2 RDL WH RD gt e 12V DC POWER INPUT RD 3 PLATFORM NC omm L NEGATIVE 12V DC AUX INPUT _ 16 0V AC INPUT 3 Rb __ BL 2 1 L POSITIVE 12V DC AUX INPUT FRONTRIGHT 4 WH OR RD SW13 OR 2 EMERGENCY 2 LEVELING LEVELING LED 15 REAR RIGHT 5 BL ao SW15 421 RD OX SIOR CREEMOS i 6416 INPUTS LED 14 REAR LEFT 6 e m BK y 14 RD RD T RD RD LED 12 FR
2. POWER UNIT ASSEMBLY J G F E D C B A 1 CYLINDER ASSEMBLY CYLINDER ASSEMBLY CYL CYL 2 NCV NCV IO 4 e M X 3 y FC FC T EXT T EXT 4 EON p cre S Deel snus ARV ADJUSTABLE RELIEF VALVE 6 T p CV CHECK VALVE r CYL CYLINDER DOUBLE ACTING LO FC FLOW CONTROL PRESSURE COMPENSATING NOV M MOTOR NCV NORMALLY CLOSED VALVE H i os W MANUAL OVERRIDE 10 VOLT DC NOV NORMALLY OPEN VALVE W 10 VOLT DC COIL 7 P PUMP 8 40462 Genie DPLSuper Series 6 13 Section 6 Schematics Service Manual First Edition Z Hydraulic Schematic DPL Super Series ANSI Models Service Manual First Edition Section 6 Schematics E LE Hydraulic Schematic DPL Super Series CE Models J G F E D C B A 1 CYLINDER ASSEMBLY CYLINDER ASSEMBLY CYL CYL 2 NCV NCV Ob 19 IO lt OQ CV 3 X FC FC a EXT T EXT 4 212 stryj 2 FC 7 la PRESSURE SWITCH CE LOAD SENSE ONLY ARV ADJUSTABLE RELIEF VALVE 6 CV CHECK VALVE CYL CYLINDER DOUBLE ACTING LO FC FLOW CONTROL PRESSURE
3. Electrical Schematic DPL Super Series AC CE Models C after serial number DPLO7 1562 A B l Y7 Y7 FOR 240 V OPERATION N B C FORM 1 7 JUMPER BROWN TO WHITE N EX ne 2 THROUGH TERMINAL STRIP AND LEAVE X J BOX TOWN PLATFORM KSI PLATFORM WH I BLACK UNCONNECTED AS SHOWN gt DOWN 7 ano EN2 i CB4 8A CB9 3A YL SAGE F FOR 120V OPERATION JUMPER BROWN TO J BOX SS SS SS SS SFE I U11 BLACK AND BLUE TO WHITEAS cox Bi SHOWN WITH DASHED LINES CNNI P2 IA ex GROUND CONTROL BOX TRANSFORMER y Na GBA 15A CB 6A 4 YL GN YL ur rc
4. DPL 30S DPL 35S EZ L IND Mast Components number 4 column idler wheel assembly number 3 column idler wheel assembly number 2 column idler wheel assembly number 1 column number 2 column number 3 column number 4 column carriage number 5 column number 5 column idler wheel assembly number 6 column idler wheel assembly number 6 column TK TT Ta 7 14 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 7 Repair Procedures 4 1 Lift Cylinder How to Remove a Lift Cylinder This procedure requires specific repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may resu
5. 3 3 o MEUM CERE MEME 3 4 Maintenance Inspection Report 3 5 Scheduled Maintenance Procedures LEE 4 1 A 1 Inspect the Operator s and Responsibility Manuals including storage contalner AE ya 4 2 2 Inspect the Decals and 4 2 Inspect for Damage Loose or Missing 4 2 A 4 Check for Hydraulic Eeaks eene cer rk eue ccce ne deas 4 3 A 5 Check the Auxiliary Platform Lowering Operation 4 3 6 Check the Platform Manual Lowering Operation 4 3 7 Inspect the Battery and Battery Charger DC Models 4 4 8 Inspect the Columns for 4 4 A 9 Check the Sequencing 4 4 A 10 Check the Interlock System for Proper Operation 4 5 A 11 Test the Power and Function 4 5 Part No 40462 Genie DPL Super Series v Service Manual First Edition TABLE OF CONTENTS Section Four Section Five Scheduled Maintenance Procedures continued A 12 Inspect the Lifting Chains and Idler 2 4 6 43 Inspect the Breather ie tede
6. 7 8 3 3 How to Remove the Hydraulic Power Unit AC 7 10 3 4 How to Remove the Hydraulic Power Unit DC Models 7 10 3 5 Howto Remove the Hydraulic 7 11 3 6 How to Adjust the Pressure 2 7 12 3 7 How to Check the Resistance of a Valve 7 13 3 8 How to Test the Motor Start Solenoid gt 7 13 Mast Assembly Mast Illustrations eee en nmm nnne 7 14 4 1 Howto Remove a Lift 7 15 4 2 Howto Remove a Mast Assembly 7 16 4 3 How to Adjust the Lifting 2 7 19 4 4 How to Adjust the Glide 7 19 4 5 How to Inspect the Lifting 7 20 Platform 5 1 How to Remove the Platform esse eee aaa aaa aaa zeza aaa aaa 7 22 5 2 How to Test the 7 22 viii Genie DPL Super Series Part No 40462 Service Manual First Edition Section 2 Specifications Specifications Model DPL 25S DPL 30S DPL 35S Height 31 ft 4 in 36 ft 40 ft 9 in maximum working 9 5m 11m 12 4 m Height 25 ft 4 in 30ft 34 ft 9 in maximum platform 7 7m 9 2m 10 6 m Height 78 in 78 in 78 in guard rails stowed 197 8
7. 5 13 6 Machine Will Not Lift DC 5 15 7 Machine Will Not Lift But Power Unit Will Operate DC Models 5 18 8 Machine Will Not Lower Up Function 5 20 9 Platform Will Not Hold In Up 5 22 10 Power Unit Will Not Lift Rated 5 23 11 A Auxiliary Platform Lowering Will Not 5 24 vi Genie DPL Super Series Part No 40462 Service Manual First Edition S TABLE OF CONTENTS Section Six Schematics NOOO 6 1 Electrical LGGENA zeus ASA eae deena EEE 6 2 Hydraulic Legend Pm 6 3 Electrical Schematic DPL Super Series DC All Models before serial number DPLO7 1499 aaa aaa aaa aaa 6 5 Electrical Schematic DPL Super Series DC ANSI Models after serial number 07 1498 0 00 0 6 6 Electrical Schematic DPL Super Series DC CE Models after serial number 07 1498 6 7 Electrical Schematic DPL Super Series AC All Models before serial number 07 1499 2 6 8 Electrical Schematic DPL Super Series AC ANSI Models from s
8. Malfunction discovered Identify L gt Troubleshoot symptoms Perform repair problem still exists Return to service problem solved Part No 404632 Genie DPL Super Series 6 1 Section 6 Schematics Electrical Legend RD Wire with description Circuits crossing no connection Diode Connection with no terminal Connector A Flashing Beacon 4 LED Limit Switch Switch or Button Toggle Switch CN Red Emergency Stop Button f N CB2 Circuit Breaker 2 30 86 87A Te 85 Relay M U F11 Fuse d Horn or Alarm Service Manual First Edition EZ ZIE RD BK BN RD YL WH RD it BL Transformer N MOTOR Motor E U9 Battery Charger 8 AA Batteries a AER elle PR4 Power Relay function pump Sai F ecsenson 1 CIRCUIT BOARD I 187 Level Sensor EX Solenoid Valve with Diode Pressure Switch M e 12V Battery s WH PLATFORM KS1 MODE KEY 45 RD SWITCH 3 x BK Y 4 B1 5 B ee 2 wh 1
9. I i YL YL EMERGENCY RD BK lh fi 2 EN1 STOP BK 11215 W3 16 0V AC INPUT 1 EE WH WH WH WH RD x BASE 6 RZE 12 POWER INPUT CENTER TAP INPUT 2 _ em mati RD RD RD 2 NC M 2 gms L NEGATIVE 12V DC AUX INPUT 16 0V AC INPUT WH t SE POSITIVE 12V DC AUX INPUT WH i OR RD SW13 P1 LED 13 FRONTLEFT 4 m 5 EMERGENCY BEEN ah 1 LEDTS REAR RIGHT 52 oR BL RD lt RD Ee BL I EN mr OX STOP 646 INPUTS LED 14 REAR LEFT 6 SW14 BD T RD RD 4 td LED 12 FRONT LEFT 7 Bic i INDICATOR FOR 12V DC OUTPUT 8 a SW8 BAA 113 L1 S AUXILIARY LOWERING RD BLK I I CONTROL BK YL BATTERIES 12V DC OUTPUT 9 ACTIVATE NC oS G7 12V DC OUTPUT gAe L i le gt BK WH 1112 14 GROUND 10 i 7 gt 7 Bk 3 i ILOW BATTERY WH L 6 gt 6 ERD INDICATOR UP SIGNAL OUTPUT 11 WH trans UP SIGNAL OUTPUT DELAYED 12e SW11 LS UP SIGNAL INPUT 13 zi BSE o iria PLATFORM UPS SW12 POWER INDICATOR U 1 0 1 orh s 2 a I on AUXILIARY BLH 2 2 2 J BL UP DOWN W4 i DOWN DOWN RD RD qus jeu eos OWE GZ sil NS PC BOARD wH 127 14 WH i CMS en i
10. Result Normally open contactors should have 7 Remove the platform from the machine no continuity Normally closed contactors AWARNING Crushing Hazard The platform will should have full continuity fall if it is not properly supported 5 Push the small triangular button on the top of with the overhead crane the contactor and check the continuity AWARNING If a platform is being replaced be Result Normally open contactors should have sure that all appropriate safety and full continuity Normally closed contactors instructional decals are applied to should have no continuity the new platform 7 22 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 7 Repair Procedures MMM PLATFORM How to Test Power to Platform GFCI outlet 1 Fully lower the platform turn the key switch off 2 AC and DC models Be sure the AC power supply is properly connected 3 Connect an AC voltage tester or a small hand tool to the platform GFCI receptacle 4 Test the voltage or test the hand tool operation Result The voltage should be 115V AC nominal or the hand tool should operate normally 5 Push the black TEST button on the GFCI receptacle Result The voltage should be OV or the hand tool should not operate 6 Push the red RESET button on the GFCI receptacle Result The voltage should be 115V AC nominal or the hand tool should operate normally Part No 40462 Genie DPL Super Serie
11. 07 4 tet tater 5 __ CONTROL UNITS WITHOUT PLUG c Q ES l WH AND BK WIRES N 9p 55 BOX A REPLACE BL 1 AND BN 7 WIRES 88 z 15 NS 6 dT UT 5 a M da66 268 __ _ STRAIN RELIEF STRAIN RELIEF Uu F E TO PLUG TO MOTOR TT 002811234567 Lan ch TT DS 112345671 7 POWER i ETETA SUPPLY GNYL za5z B AG H4 7 5 a DESCENT R RE MM FE R ZE R ALARM m SS ues rmv uar d eremi BI POWER UNIT esu m m BK 2 MOTOR WARNING ic RD CONTACTOR LIGHT B2 BATTERY zx 8 OPTIONAL 12V DC WARNING LIGHT m U9 MS QD1 WH DESCENT ALARM RD RD H F11 Ses BATTERY Y30 4 CHARGER a 175 FUSE BK DUMP VALVE GEO z ES0074_J Part No 40462 Genie DPL Super Series 6 6 Section 6 Schematics Service Manual First Edition Electrical Schematic DPL Super Series DC Models after serial number DPLO7 1498 WIRE COLOR LEGEND Description Blue Black Brown Green Y ellow Orange Red Red Black White Yellow ABBREVIATION LEGEND Description Batte B2 12V Battery B4 8 AA Batteries R Control Relay CR27 Load Sense CR95 Guardrail latch D5 Power supply AC EN Enclosure Platform control box EN2 Ground control box EN4 Power to platform GFCI receptacle Fuse 175 AMP Warning light D Ground Horn or alarm H4 Descent alarm H6 Platform overload alarm Key switc
12. ABBREVIATION LEGEND WIRE COLOR LEGEND tem Description Description Batte Blue B2 12V Battery Black B4 8 AA Batteries Brown Power supply AC Green Y ellow EN Enclosure 1 Platform control box range EN2 Ground control box Red EN4 Power to platform GFCI receptacle Red Black Fuse 175 AMP White FB2 Warming light YL Yellow H4 Descent alarm KS1 Key switch ground platform L Led or light L5 Power indicator ground L6 Lowbattery indicator for auxiliary ground L7 Lowbattery indicator main ground L12 Outrigger front left ground L13 Outrigger front right ground L14 Outrigger rear left ground L15 Outrigger rear right g C Normally closed Normally open Note with description N17 Narrow platform units WH and BK wires replace BL and OR wires N27 Units with out plug WH and BK wires replace BL and BN wires Power switch P1 Emergency Stop button at ground controls 8s 2 x P2 Emergency Stop button at platform controls QD Quick disconnect QD1 Battery quick disconnect QD3 Control cable to platform control box QD4 Control cable to base SW SW 8 Control activate SW11 Platform up down SW12 Auxiliary down SW13 Outrigger interlock front left SW14 Outrigger interlock front right SW15 Outrigger interlock rear left SW16 Outrigger interlock rear right Electronic compone
13. ren pes Z AA A Poe c Ru Du 4 6 B 1 Inspect the Electrical 0 4 7 2 lInspectAll Welds 22sec ute O cca bentes 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 sesssssssseseeeeeeenneeen nn 4 9 B 6 Test the Lifting Capacity nennen nnns 4 9 B 7 Testthe Power To Platform Operation 2 4 40 4 4 10 B 8 Adjust the Sequencing Cables sesssssssseseeeeenennneeennnnnn 4 10 B 9 Inspect for Proper Outrigger Length 4 11 C 1 Inspect and Lubricate the 4 12 C 2 Inspect the Mast Assemblies for 4 12 C 3 Lubricate the Lifting 004100000 enne 4 13 C 4 Replace the Hydraulic 4 13 C 5 Replacing the Auxiliary Platform Lowering Batteries 4 14 Troubleshooting Flow Charts gt EMEND 5 1 1 Power Light Will Not Turn On AC Models 5 3 2 Power Light Will Not Turn On DC 200 5 5 3 Interlock Lights Will Not Turn rece ce tto Z LSP edain 5 7 4 Machine Will Not Lift AC 5 10 5 Machine Will Not Lift But Power Unit Will Operate AC Models
14. If measurement does not meet specification adjust the chains See Repair procedure 5 3 How to Adjust the Lifting Chains Specifications Model Height DPL 25S 78 inches 197 8 cm DPL 30S 78 inches 197 8 cm DPL 35S 78 inches 197 8 cm B 4 Check the Battery DC Models 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 Batteries contain acid Avoid AWARNING spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Put on protective clothing and eye wear Slide open the battery cover to access the charger and the battery The cover must remain open for the entire charging cycle Remove the battery vent caps and check the specific gravity with a hydrometer Check the battery acid level If needed replenish with distilled water to cover the battery plates Do not overfill Install the battery vent caps 6 Set timer based on the amount of use Light Use less than 15 lifting cycles Set to 7 hours Heavy Use greater than 15 lifting cycles Set to the on position The charger will automatically shut off at the end of the set period Note If ammeter drops to 3A or less within the first 15 minutes the battery is fully charged 8 Observe charger ammeter after one hour to confirm charging amperage has
15. 5 0 XM Part No 40462 Genie DPL Super Series 7 7 Section 7 Repair Procedures a zz o ml HYDRAULIC POWER UNITS Service Manual First Edition 3 2 Hydraulic Power Unit Components DC Models Index No Description Function 1 12V DC electric 12V DC standard duty 1 terminal 180 amp at 2650 psi 183 bar 2 Electric motor starter solenoid Relay connecting power supply to electric motor 3 Pressure relief valve Hydraulic relief valve adjustment 4 Solenoid operated N O dump valve Diverts pump output back to reservoir during motor start up 5 10V DG Coil 1 reos en tree PA Activates N O dump valve 6 Breather Cap ease treten tene Reservoir vent 7 Sight Hydraulic fluid level 8 m 1 3 gallons 4 9 liters 9 Pipe plug RIDERE Drains reservoir 10 Pick up Rai er di eid Filters hydraulic fluid 11 Ode Seals reservoir 12 Check One way valve for pump output 13 PUMP A iei 0 7 to 1 gallons per minute at 2000 psi 2 6 to 3 76 liters per minute at 138 bar 14 Motor Seal scsi RR Seals motor from contaminants 15 Motor bearing rennen rennen Aligns motor shaft into pump 7 8 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 7 Repair Procedu
16. B 9 Inspect for Proper Outrigger Length Proper outrigger length is essential to safe machine operation Operating a machine with outriggers different from those originally designed for the model will result in death or serious injury 1 Measure each outrigger and verify for proper length Length DPLS Models models that meet ANSI and CE indoor DPL 25S 20 inches 51 cm DPL 30S 26 inches 66 cm DPL 35S 26 inches 66 cm DPLS Models models that meet CSA DPL 25S 301 2 inches 77cm DPL 30S 36 inches 91 cm DPL 35S 36 inches 91 cm Part No 40462 Genie DPL Super Series 4 11 Section 4 Scheduled Maintenance Procedures Service Manual First Edition Table C Procedures C 1 Inspect and Lubricate the Casters Extremely dirty conditions may require that the casters be inspected and lubricated more often 1 Visually inspect each caster for cuts cracks or unusual wear 2 Move the machine on a flat smooth surface and check that the casters roll smoothly 3 Pump grease into the caster until it can be seen coming out of the bearing seal gap Grease Type Lithium based C 2 Inspect the Mast Assemblies for Wear Detection of excessive or unusual wear in the mast assembly is essential for safe machine operation An unsafe working condition exists if the mast assembly has excessive wear and or does not operate smoothly free of hesitation and binding 1 Raise the platf
17. Continued from the previous page power at terminal 4 of the up switch contact While pushing in the control activate switch and activating the up function hold both switches and check for power at terminal 3 of up switch contact 12V DC While pushing in the control activate switch and activating the up function hold both switches and check for power at terminal 13 orange wire of 13 pole terminal strip J1 in base control box ov DC 12V DC While pushing in the control activate switch and activating the up function hold both switches and check for power at terminal 11 white wire of 13 pole terminal strip J1 in the ground control box ov DC 12V DC While pushing in the control activate switch and activating the up function hold both switches and check for power at the motor contactor coil terminal 1 red wire Put Neg lead of the voltage meter on terminal 0 green yellow wire ov DC 12V DC Continued on the next page CHART 4 Replace the red wire because of open circuit between the control activate switch contact block and the up switch contact block OV DC Replace up switch contact block Replace 16 6 cable because of open in orange wire OR repair open in quick disconnect under ground control box Replace P C board OR consult Genie Industries Service Department Relocate Neg lead of the voltage meter at terminal 0V DC
18. How to Inspect the Lifting Chains Inspection Wear Rust and Corrosion Tight Joints Procedure Count out 16 chain links and measure pin to pin centerline dimension with a steel tape Note Be sure to measure a section of chain that moves over the idler wheels Visually inspect the chains for rust and corrosion Service Manual First Edition Inspection Failure When the length of the 16 links pin to pin measure more than 8 25 inches for 1 2 inch chain or 10 31 inches for 5 8 inch chain Evidence of rust or corrosion Inspection Remedy Replace both chains on that column section Replace entire chain Do not repair just the affected portion of the chain Remove chain and inspect for cracked plates see inspection of cracked plates If no cracks are found lubricate chain with motor oil SAE 40 and re install chain Visually inspect the chains for lubrication Inspect chain link joints for easy movement When external surfaces are not protected with a layer of oil Joints that do not flex freely or are bound up Lubricate chain with motor oil SAE 40 If rust and corrosion is found refer to Failure Remedy for rust and corrosion If link plates or pins are bent or deformed replace entire chain Replace both chains on that column Do not repair just the affected portion of the chain Genie DPL Super Series Part No 40462 Service Manual First Edition
19. Section 7 Repair Procedures Inspection Raised or Turned Pins Chain Side Chain Terminals chain terminals Idler Wheels idler wheel Cracked Link Plates Procedure Visually inspect for raised pins Inspection Failure Raised pins MAST ASSEMBLY Inspection Remedy Replace both chains on that column section Do not repair just the affected portion of the chain Visually inspect for turned pins by insuring all the flats on the V heads are aligned Visually inspect for wear patterns on heads of link pins and outside link plates where they contact the idler wheel Visually inspect chain terminals threaded rod Visually inspect chain idler wheels Visually inspect chain link plates for cracks Misalignment of flats on all V heads Wear on pin heads or noticeable wear in the profile of the outside link plate O bd link plate wear Broken chain terminals fingers Replace both chains on that column section Do not repair just the affected portion of the chain Replace both chains on that column section Do not repair just the affected portion of the chain Check alignment of chain anchors and idler wheels Replace chain terminal Bent or damaged terminal Replace chain terminal Twisted or misaligned chain terminal Re align chain terminal to ensure even loading of chain Threaded rod not visible in
20. WH AND BK WIRES REPLACE NN 2 AND OR 3 WIRES EN4 POWER TO PLATFORM GFCI RECEPTACLE Dg Hi GN YL GROUND STUD Service Manual First Edition Section 6 Schematics MM Electrical Schematic DPL Super Series AC Models after serial number DPLO7 1562 F E D C B A SW8 BK RD MOTOR DETAIL MOTOR DETAIL 4 _ FOR240VOPERATION N 1 JUMPER BROWN TO WHITE N THROUGH TERMINAL STRIP AND LEAVE PLATFORM WH BLACK UNCONNECTED AS SHOWN MSDE LN EN 2 i CB9 777777771 FOR 120V OPERATION JUMPER BROWN TO BLACK AND BLUE TO WHITE AS Bea
21. 8 BK NS 2 AND OR 3 WIRES an MEN SW16 E lt Mi OR 1 8528 GND m pra GROUND BK elle I STUD I I 1 15A CIRCUIT BREAKER 8A CIRCUIT BREAKER EN4 CB4 7 110V AC MODELS 220V AC MODELS ZERA waco eee eee QD4 POWER TO NG as ieee ans RN EV OPE DENISE 5 Mun BK 7 2 7 BK RECEPTACLE RD LL e 2 6 R Em N30 110V AC 220V AC BN H 5 5 LYL je a p 4 m ITA Z X x Z a zz z TERMINAL STRIP wH H 4 gt 4HanwL Xr Y N27 4 L ongs 3 0R z 1 Jed 8 7 UNITS WITHOUT PLUG N s s EE fI E BE Hi WH AND BK WIRES WH TE 2 177WH REPLACE BL 1 AND BN 7 WIRES 8a 2 e a 2 al amp gl WB TERMINAL 6 a 2 STRIP 2c 5 a 2 Z m Mir 4 Do ee GROUND T T T T TO PLUG QD3 1 234587 STUD IAA A 4 A Ay AI D5 I MODENA 1224567 POWER GND Poe tte SUPPLY S GROUND age AC I z a 6 STUD 7 5 STRAIN RELIEF Vy r DESCENT ALARM TO MOTOR n S ZLA RD O GROUND GROUND l BK SCREW Y30 SCREW Y30 ains 2227122 no NO z x gt DUMP z xz DUMP LIGHT IE gt ja 2 J
22. BASE Z MODE Key Switch Genie DPL Super Series Part No 40462 Service Manual First Edition Section 6 Schematics Cylinder Check Valve Q Pump NCV Or Solenoid operated dump valve Hydraulic Legend NOV Ht lo 2 position 2 way directional valve Filter Se a E Pressure compensated Adjustable relief valve flow control Part No 404632 Genie DPL Super Series 6 3 Section 6 Schematics Service Manual First Edition SS AU WIRE COLOR LEGEND Color Description BL Blue BK Black GNYL Green Yellow Note Use this legend BE Orange for the schematic on RD Red Wn WI the opposing page YL Yellow 6 4 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 6 Schematics Electrical Schematic DPL Super Series DC Models before serial number DPLO7 1499 M K J F E D C B A LEGEND 1 CAS CONTROL ACTIVATE SWITCH lik w PEWNO ES EMERGENCY STOP
23. Be sure the keyswitch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the ground control box PC board fuse is not blown Check the power supply 0V AC with a voltage meter 110V AC Check the voltage at terminal 3 on the key switch N O contact Put Ov AC Pos lead of voltage meter on terminal 3 and Neg lead on the white wire from the AC power cord 110V AC Check the voltage at terminal 4 on the key Ov switch N O contact 110V AC Check the voltage at terminal 1 on the 0V AC Emergency Stop button N C contact 110V AC Check the voltage at terminal 2 on the 0V AC Emergency Stop button N C contact 110V AC Check the voltage at the black transformer wire 0V AC where it connects to the brown transformer wire 110V AC Continued on the next page Plug into a different power supply and recheck the voltage Repair or replace the AC power cord and or the 12 3 cable WE the key switch N O contact Trace the black wire fro terminal 1 on the Emergency Stop N C contact back to the key switch N O contact and repair open in wire Replace the Emergency Stop button N C contact Repair open in the yello transformer wire betwee the Emergency Stop button and the transformer OR replace the transformer because of a faulty thermal fuse Chart 1 Part No 40462 Genie DPL Super Se
24. WH AND BK WIRES REPLACE BL 1 AND BN 7 WIRES lt GN YL GN YL RN z F W CR95 2 z z z TERMINAL GUARDRAIL 8 168 J 9 4 3 gt WS strip 2 86 LATCH GN 6 5 S zj 85 86 TM T PLATFORM E 2i 5 0 a a PIN OVERLOAD a665 ea GROUND BK lt zu c L GN YL Bk 87 1 T T TO PLUG 1 30 WH RD 00211234567 ITI ha AAR A J Ds IC l423456 7 S power GND CR27 SUPPLY r5 7 WH LOAD SENSE r T 171 x Z GROUND zACZ CA I STUD BK BK 7 BK LI TRAIN RELIEF AGR 9 DESCENT Ed ZE Z ZLEW 2 PE Z ERN NC No cj ALARM TO MOTOR 1 S Ee R meer eem m I PS2 H6 EB i PLATFORM OVERLOAD PLATFORM gt PRESSURE SWITCH GROUND GROUND OVERLOAD I BK ALARM FB2 SCREW i Y30 SCREW Y30 f wine E lens az kn Pee 2 BOX z VALVE 2 1 80 z VALVE 8 gt a O DOWN OPTIONAL cd M5 LIMIT SWITCH WARNING LIGHT CE ONLY E E 3 N8 l N10 Le 8 IDESCENT ALARM 5 110V AC 220 V FEN l a MOTOR DETAIL l MOTOR DETAIL GND l S ES0075_H Part No 40462
25. a o 8 eS Sw z Service Manual First Edition Section 6 Schematics nam H ueg Electrical Schematic DPL Super Series DC CE Models after serial number DPLO7 1498 N M L K J H G F E D C B A RD BLK RD 1 PLATFORM Se WH x KS1 MODE B S KEY ra 4 3BD N Y T SWITCH 4BK EN2 poe stg Po E GROUND EMERGENCY fem Z IS EN1 STOP f RD W3 16 0V DC INPUT
26. 3A For 120V operation Jumper brown wire to black wire and blue wire to white wire as shown with dashed lines CB4 15A CB9 6A N29 N Denotes a neutral wire to be tagged with an N sleeve N30 110V AC 220V AC terminal strip detail Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls Power relay PR4 Function pump M5 Pressure switch Quick disconnect QD3 Control cable to platform control box QD4 Control cable to base SW 8 Control activate SW11 Platform up down SW12 Auxiliary down SW13 Outrigger interlock front left SW14 Outrigger interlock front right SW15 Outrigger interlock rear left SW16 Outrigger interlock rear right Electronic component U11 Transformer Wiring component legends for the W3 Terminal strip 3 pole 3 pin U10 W4 Terminal strip 14 pole 14 010 schematic on the WS Terminal strip 13 pole 26 pin 30 Valve coil Oppos i ng page Y7 Platform down Y30 Normally open dump valve U FB2 ksi Ps2 z Service Manual First Edition Section 6 Schematics
27. COMPENSATING NOV M MOTOR NCV NORMALLY CLOSED VALVE H W MANUAL OVERRIDE 10 VOLT DC NOV NORMALLY OPEN VALVE m W 10 VOLT DC COIL 7 mi ARV P M P 8 POWER UNIT ASSEMBLY Part No 40462 Genie DPLSuper Series 6 14 Service Manual First Edition Section 7 Repair Procedures Observe and Obey Repair procedures shall be completed by a person trained and qualified on the repair of this machine Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Repairs Start M Read understand and obey the safety rules and operating instructions in the Genie DPL Super Series Operator s Manual Be sure that all necessary tools and parts are available and ready for use Read each procedure completely and adhere to the instructions Attempting shortcuts may produce hazardous conditions Repair Procedures About This Section Most of the procedures in this section should only be performed by a trained service professional in a suitably equipped workshop Select the appropriate repair procedure after troubleshooting the problem Perform disassembly procedures to the point where repairs can be completed Then to re assemble perform the disassembly steps in reverse order General Repair Process Identify symptoms Malfunction L gt Trou
28. EMERGENOYS d T 1 BK ESE W3 16 0V AC INPUT 1 c RD EK xe 1 STOP BASE 11213 nT gt EN1 WH RD 4 mE DC POWERINPUT CENTER TAP INPUT 2 WH 212271 m e e ee PLATFORM NC pm L NEGATIVE 12V DC AUX INPUT 16 0V AC INPUT RO _ X _ BL 2 1 POSITIVE 12V AUX INPUT ep 13 FRONTRIGHT 4 WH ew Y7 a OR i 2 EMERGENCY fons INDICATORS INDICATORS TEDIS HEAR BIGHT Se NC STOP PIR BL PLATFORM OX 6 INPUTS LED 14 REAR LEFT 6 PLATE A i RD 1 i RD AT RD RD EE owu NM LED 12 FRONT LEFT 7 gt z Y7 SW8 B 1713 L15 NPICATOR FOR 12V DC OUTPUT 1 4 AUXILIARY LOWERING RD BLK NC I CONTROL BK 12 YL AR I 12V DC OUTPUT 9 J BOX PLATFORM ACTIVATE N C BATTERIES ci a Gn 7 12V DC OUTPUT 9A T DOWN WHT YL pm L2 m 3 I 7 R 3 OBALI UP SIGNAL OUTPUT 11 GN J BOX aX swit 15 UP SIGNAL OUTPUT DELAYED 12 s Tenn GNE UP SIGNAL INPUT 13 I YL YL PLATFORM P4 SW12 FOWERINDISATOR U1 0 I WH WH WH UP DOWN DOWN 7 AUXILIARY RD RD W4 wi eel PE DOWN PC BOARD RD RD RD Ho kz ire ROS SW13 NE 4 BN E SW BK RD I 15 BK E 7O n7 DN ZE m OR SS NARROW PLATFORM UNITS z I BK Be gt SW14 WH AND BK WIRES REPLACE
29. SWITCH KS KEY SWITCH L LIGHT LED T EEEE ide CNRC ERR MC MOTOR CONTACTOR NOV NORMALLY OPEN VALVE J1 i PB POWER TO BASKET J 1h53 GROUND FAULT CIRCUIT INTERRUPT af BK TBK KS BK S SWITCH OUTRIGGER L 12 VDC POWER INPUT GNYL SOL SOLENOID 2 NEGATIVE 12 VDC INPUT 2 WA L POSITIVE 12 VDC INPUT 4 CHARGE LED1 12 VDC INPUT BATTERY I LEDI 1 2 Yo LED2 12 VDC INPUT 5 BLK M 3 GN YL DOWN SOL YL 8 AA BATTERIES wH SOL 51 RD 4 LED4 7 _ J BOX 2 LLL LED3 12 VDC INPUT MO GN YL 4 4 Me ars 4 277 INDICATOR j mr 5 J BOX GN YL 4 GN YL gt GN YL LED4 12 VDC INPUT ee WH 1 VWH WH LOW BATTERY INDICATOR OR _3 RD FOR AUXILIARY LOWERING BL 2 BL 5 RD _6 RD RD m 12 VDC OUTPUT BK 7 BK BK 12 VDC OUTPUT 9 RD s YL YL an DC MODEL LOW 12 OUTPUT 3 AL RD AUX DOWN s2 BATTERY INDICATOR T DOWN SOL GROUND 19 GN YL YL 4 12 VDC MOTOR SOLENOID OUTPUT gt 1 SEC TIME DELAY 12 VDC OUTPUT 12 BL 2 BL ES PLATFORM DOWN 12 VDC UP SIGNAL INPUT 1 OR _6 T 549 3 OR UP 7 BK 7 4 GN YL T1 1 WH X 8 Part No 40462 Genie DPL Super Series 6 5 Section 6 Schematics Service Manual First Edition n nqJ M ye Electrical Schematic DPL Super Series DC Models before serial number DPLO7 1499
30. bot switches and check the pressure less tnan 1800 psi On the power unit remove the return to tank hose off of the T port fitting and plug the hose fitting leaving the 3000 180010 psi gauge teed in at the 2000 psi port fitting Push in the control activate switch activate the up function hold both switches and check the pressure less than 1800 psi Continued on the next page Replace or repair the white wire between the motor contactor coil and the N O valve coil because of an open circuit AR the N O valve coil Inspect the mast assemblies for a mechanical bind such as foreign objects that could have fallen in between the columns Activate the up function and check for voltage at the N C down valve coils 0V DC yellow wire at the barrel end of each lift cylinder 12V DC Replace defective N O contact block for down function in the platform control box Remove the N C down valves and inspect for contamination or damage OR consult Genie Industries Service Department Genie DPL Super Series Part No 40462 Service Manual First Edition Section 5 Troubleshooting Flow Charts jw zz w wz c Gc o CHART 7 On the power unit remove and inspect the N O valve for contamination or damagg Clean repair or replace valve and then perform pressure test again Continued from the previous page less tha
31. cm 197 8 cm 197 8 cm Length 813 4 815 4 in 815 4 in outriggers stowed 207 6 cm 207 6 cm 207 6 cm Width 311 2 in 311 2 in 311 2 in outriggers stowed 80 cm 80 cm 80 cm Outrigger footprint 82 x 561 2 in 861 4 672 4 in 861 4 672 4 I x w 208 3 x 143 5 cm 218 7 x 172 1 cm 218 7 x 172 1 cm Platform dimensions 72 x 27 2 in 72 x 27 2 in 72 x 27 2 in I x w 182 9 x 69 9 cm 182 9 x 69 9 cm 182 9 x 69 9 cm Lift capacity 750 Ibs 750 Ibs 600 Ibs 340 kg 340 kg 272 kg Power source 12V DC or 12V DC or 12V DC or Shipping weight AC DC Maximum capacity 220V or 115V AC 1375 1450 Ibs 624 658 kg 220V or 115V AC 1475 1550 Ibs 669 703 kg 220V or 115V AC 1575 1650 Ibs 714 748 kg ANSI CE CSA 750 1 5 340 kg 750 1 5 340 kg 600 Ibs 272 kg 750 Ibs 340 kg 750 Ibs 340 kg 600 Ibs 272 kg 600 Ibs 272 kg 600 Ibs 272 kg 500 Ibs 227 kg 20 F to 135 F 29 C to 57 C Ambient operating temperature 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 15A fuse circuit breaker 5A fuse printed circuit board 175A fuse power unit 5A fuse printed circuit board 110V AC models DC models Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligatio
32. component damage Electrocution hazard Contact with AWARNING hot or live circuits may cause death or serious injury Remove all rings watches and other jewelry 1 Inspect the following areas for burnt chafed corroded and loose wires All base wiring Inside of the ground control box Inside of the base junction boxes Hydraulic power unit All external machine electrical cables Inside of the platform control box DC models battery and charger AC power supply cord Table B Procedures B 2 Inspect All Welds Weld inspections are essential to safe machine operation and good machine performance Failure to locate and repair damage may result in an unsafe operating condition 1 Visually inspect the welds in the following locations Platform and platform components Base Mast brace mounting brackets Ladder mounting bracket Part No 40462 Genie DPL Super Series 4 7 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 3 Check the Lifting Chain Adjustments Maintaining proper adjustment of the lifting chains is essential to safe machine operation Failure to maintain proper chain adjustment could result in unsafe operating conditions and may cause component damage 1 Lower the platform 2 Lowerthe platform side guard rails to the stowed position 3 Measure the maximum height of the machine Result The machine should be no taller than specification
33. dropped If amperage does not drop the battery is bad and needs to be replaced 4 8 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 4 Scheduled Maintenance Procedures 9 Remove the battery vent caps Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 10 Install the battery vent caps B 5 Clean and Lubricate the Columns Clean and properly lubricated columns are essential to good machine performance and safe operation Extremely dirty conditions may require that the columns be cleaned and lubricated more often 1 Raise the platform to the maximum height 2 Visually inspect the inner and outer channels of the columns for debris or foreign material If necessary use a mild cleaning solvent to clean the columns This procedure will require the use AWARNING of additional access equipment Do not place ladders or scaffold on or against any part of the machine Performing this procedure without the proper skills and tools may result in death or serious injury Dealer service is strongly recommended 3 If needed lubricate the inner and outer channels of the columns with a dry silicone spray or silicone wax Genie part no 90337 TABLE B PROCEDURES B 6 Test the Lifting Capacity Proper lifting capacity is essential to safe machine operation Improper lifting capacity adjustment could allow machine to
34. n 2 Se _ L NEGATIVE 12V DC AUX INPUT _ 16 0V DC INPUT Y7 2 1 7 POSITIVE 12V DC AUX INPUT 13 FRONTRIGHT 4 NC CONTROL EMERGENCY LEVELING LEVELING LED 15 REARRIGHT 5 OR PLATFORM STOP i INDICATORS INDICATOR BL w BOX r 6 NPUTS LED 14REARLEFT 6 Y7 T RD ILOW BATTERY HED 12 FRONT LEFT 7 EX ORM BK PLATFORM INDICATOR FOR 12V DC OUTPUT J BOX SW8 BK 113 L15 5 xitIARY LOWERING GN YL DOWN CONTROL BK is BK I 12V DC OUTPUT 9 YL ACINATE NC e GH L7 12V DC OUTPUT Kwi am 1112 L14 oc moner GROUND 10 WHT GN YL J BOX 7X 3 BATTERIES CA UP SIGNAL OUTPUT 11 RD YL IGNI 5 UP SIGNAL OUTPUT DELAYED 12 m A Swit up POWER INDICATOR U 1 0 UP SIGNAL INDI 19 s PLATFORM BK RD RD RD UP DOWN WA DOWN SW12 PC BOARD SW13 AUXILIARY L BK RD DOWN SS ES ES SS SS BK RD m NO BK 17 N BN 4 BN SW14 NARROW PLATFORM UNITS WH AND BK WIRES REPLACE E 5 2 BK 5 BL 2 AND OR 3 WIRES d MEET zd o T m O c wa GND GROUND 1 m RD STUD EN4 GND GN YL POWER TO GROUND PLATFORM STUD E 5 E 2 X MT 2 RECEPTACLE gp p e WS GROUND D 2 lt LQ Lad
35. pin 30 Valve coil Y7 Platform down Y30 Normally open dump valve Note Use these 2 legends for the schematic on the opposing page Service Manual First Edition Section 6 Schematics Electrical Schematic DPL Super Series AC Models from serial number DPLO7 1499 to DPLO7 1562 N M L K J H G F E D C B A 7 EUM It ttd LATFORM WH 7 PLATFORM X KS1 Sf MODE ata BEN EN2 ec a e T SWITCH ft xj 4 BK X SSS See FOR 240 V OPERATION 5 BK Y JUMPER BROWN TO WHITE v 1 fs a x GROUND CONTROL BOX U11 THROUGH TERMINAL STRIP P2 BHH m TRANSFORMER AND LEAVE BLACK UNCONNECTED uL LLLI AS SHOWN
36. platform control box Chart 5 ov DC Replace P C board ov DC Part No 40462 Genie DPL Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition ea CHART 5 On the power unit remove and inspect the N O valve for contamination or damagg Clean repair or replace valve and then perform pressure test again Continued from the previous page less than 1800 psi Adjust the pressure relief valve See Repair procedure How to Adjus the Pressure Relief Valve and then perform pressure test again less than 1800 psi Consult Genie Industries Service Department 5 14 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 5 Troubleshooting Flow Charts Machine Will Not Lift DC Models Be sure the keyswitch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the power light and all interlock display lights are on Check for power at terminal 9 red wire of 13 Chart 6 ole terminal strip J1 Put Neg lead of voltage ODC Replace the P C board meter on terminal 10 ground terminal 12V DC Check for power at terminal 1 of Emergency Stop switch contact in platform control box Put oy pc Neg lead of voltage meter on terminal 10 green yellow wire of 13 pole terminal strip J1 in ground control box 12V
37. type spray lubricant This procedure will require the use AWARNING of additional access equipment Do not place ladders or scaffold on or against any part of the machine Performing this procedure without the proper skills and tools may result in death or serious injury Dealer service is strongly recommended TABLE C PROCEDURES C 4 Replace the Hydraulic Oil Replacement of the hydraulic oil is essential for good machine performance and service life Dirty oil and a dirty suction strainer may cause the machine to perform poorly and continued use may cause component damage Extremely dirty conditions may require oil changes to be performed more often 1 Fully lower the platform 2 Remove the base cover from the power unit 3 Remove the drain plug from the hydraulic reservoir and completely drain the reservoir into a container Properly discard the oil 4 Remove the power unit See 3 3 How to Remove the Power Unit AC Models or 3 4 How to Remove the Power Unit DC Models 5 Remove the reservoir from the hydraulic power unit 6 Remove the magnet from the reservoir and clean the magnet and reservoir using a mild solvent 7 Install the magnet then the reservoir 8 Apply pipe thread sealant to the drain plug and re install it in the reservoir 9 Fill the reservoir with hydraulic oil until the level is visible in the sight gauge on the end of the reservoir Do not overfill 10 Replace the breather cap with a n
38. work and not from the red wire from terminal 9a ground control box of 13 pole terminal strip J1 5 24 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 6 Schematics Observe and Obey Troubleshooting and repair procedures shall be completed by a person trained and qualified on the repair of this machine M Immediately tag and remove from service a damaged or malfunctioning machine Repair any machine damage or malfunction before operating the machine Before Troubleshooting M Read understand and obey the safety rules and operating instructions printed in the Genie AWP Super Series Operator s Manual and the Genie IWP Super Series Operator s Manual M Be sure that all necessary tools and test equipment are available and ready for use Schematics About This Section There are two groups of schematics in this section An alpha numeric legend and wire color legend for each schematic is located on the fold of the opposing page Electrical Schematics AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry Hydraulic Schematics AWARNING injury hazard Spraying ydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray General Repair Process
39. 10 green yellow wire of Uns pole terminal strip Repair open circuit in red wire 12V DC Repair open circuit in green yellow wire Part No 40462 Genie DPL Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 4 Perform a continuity test no across the motor continuit contactor coil terminals and 0 Continued from the previous page Replace the motor contactor continuity Check for 110 volts AC at the common terminals white and black wires BEE ee faulty circuit the motor contactor 110V AC While pushing in the control activate switch and activating the up function hold both Replace the motor switches and check for contactor because of power at the N O damaged contacts terminals white and black wires on the moto contactor 110V AC Check the motor wiring OR consult Genie Industries Service Department 5 12 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 5 Troubleshooting Flow Charts Machine Will Not Lift But Power Unit Will Operate AC Models Be sure the power unit reservoir is full and the breather cap has been installed Be sure the manual lowering cable is properly adjusted While pushing in the control activate switch and activating the up function hold both switches and check for input voltage at the N O valve coil on the power unit Wai
40. 2 Genie DPL Super Series 5 23 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 11 Auxi liary Check the low auxillary battery indicator red Platform LED light fon itis Replace the 8 1 5V AA j showing a low voltage size batteries Loweri ng condition Will Not ff Operate j Check the auxillary lowering battery holder tq make sure that the batteries have been Install the 8 1 5V AA installed size batteries yes Disconnect the main power source Check forl power at terminal 9 and Check for power at Check the auxillary 9A of the 13 pole terminal terminal 1 of the 3 pole lowering battery holder strip J1 located in the 0V DC terminal strip J2 in the wires red wire connects ground control box ground control box Put OV DC to terminal 1 and black the positive lead of wire connects to terminal voltage meter on termina 2 for loose connections 1 and the negative lead at the J2 terminal strip on terminal 2 the OR check for defects in grounding terminal the battery holder and its wires 12V DC Replace the P C board Correct the loose 12V DC OR contact Genie connections at the J2 Industries Service terminal strip OR Department Replace the battery holder If power is seen then the wont Replace the auxillary symptom would be that lower down N O contact block the auxillary lowering from located in the ground from the platform would base control box OR repair the
41. 5 5 YL ly D lt TERMINAL waft 4 2 4 d GNYL al 2 N27 4 STRIP OR L 3 gt 3 Lor 2 UNITS WITHOUT PLUG N act 23 248 WH AND BK WIRES 1 1 L WH REPLACE BL 1 AND BN 7 WIRES eie I gaj go L68 Mal 2 WH WH 6 gt N BKN GNIYL TTT PLATFORM lur Sami 2 PEJE MH OR GN YL BK OVERLOAD ano cc T STRAIN RELIEF V STRAIN RELIEF gt 1 TETUR en M LL 1 85 86 85 86 a 112345671 MOTOR QD3 AAAA AA D5 CR95 7 LK 87A 87A CR95 C l423456 7 O POWER GUARDRAIL go 30 GUARDRAIL sza ETETETT SUPPLY s z PIER i ter 87 me D wi BK I 2 4 i 7 2 TU DESCENT Ir uc c CR27 mm 1 LS6 Z a fk M LOAD SENSE f EF DOWN POWER UNIT l RD 6 2 LIMIT SWITCH NC NO G PLATFORM CE ONLY OVERLOAD BK ALARM FB2 MOTOR PS2 WARNING CONTACTOR PLATFORM OVERLOAD LIGHT PRESSURE SWITCH 8 a a zE dbz BUE OPTIONAL B2 voc 5 WARNING LIGHT RD AND W a DESCENT ALARMI ue H MGS CHARGER m EE 175 AMP FUSE Y30 fox 4 non 0 5 PLUGS N O DUMP VALVE AC ar ES0074_J Part No 40462 Genie DPL Super Series 6 7 Section 6 Schema
42. AC EN EN Brown EN1 Platform control box GN Green EN2 Ground control box EN4 Power to platform GFCI receptacle GN YL Green Yellow ENS Power unit 110V AC EN6 Power unit 220V AC OR Orange FB2 Warning light RD Red Grund ef ONE Ground RD BK Red Black H Horn or alarm H4 Descent alarm RD YL Red Yellow H6 Platform overload alarm WH White KS1 Key switch ground platform WH BK White Black L5 Power indicator ground L6 Low battery indicator for auxiliary ground YL Yellow L7 Low battery indicator main ground L12 Outrigger front left ground L13 Outrigger front right ground L14 Outrigger rear left ground L15 Outrigger rear right ground L68 Platform overload LS6 Note with description N8 110V AC motor detail N10 220V AC motor detail N17 Narrow platform units WH and BK wires replace BL and OR wires N27 Units with out plug WH and BK wires replace BL and BN wires N30 110V AC 220V AC terminal strip detail Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls B4 a FB2 BB LKSt 166 5 z O M5 N O 0 2 1 Power relay PRA Function pump M5 PS2 Pressure switch QD Quick disconnect QD3 Control cable to platform control box QD4 Control cable to base Sw Switch SW 8 Control activat
43. AC outlet Result The tool should operate normally GFCI outlet may require that the outlet be reset with the reset button B 8 Adjust the Sequencing Cables Maintaining proper adjustment of the sequencing cables is essential for safe machine operation An unsafe working condition exists if the sequencing cables are improperly adjusted A frequent check of the sequencing cables allows the inspector to identify changes in the operating condition that might indicate damage 1 Fully lower the platform 2 Check the tension on each sequencing cable by grasping the cable halfway down the column and pulling the cable from one side then to the other Measure the total distance between the two points this is the maximum deflection Specification 11 2 to 21 2 inches 3 8 to 6 4 cm Maximum Deflection 3 Hold the end of the cable from turning and adjust the tension nut to obtain correct tension deflection Turn the adjustment nut clockwise to increase the tension or counterclockwise to decrease the tension Component damage hazard Do ACAUTION not exceed the recommended tension 4 Re check the tension on each sequencing cable 5 Repeat adjustment for each cable as required 6 Raise and lower the platform through three complete cycles and re check the deflection Genie DPL Super Series Part No 40462 Service Manual First Edition Section 4 Scheduled Maintenance Procedures a Z w Se O TABLE B PROCEDURES
44. B 5 Clean and lubricate Inspector title columns A 5 Auxiliary lowering B Lift Inspector company operation 5 iting capacity 6 Manual lowering B 7 Power to platform Instructions operation operation this to use for 7 Battery and charger B 8 Sequencing cables each inspection DC models B 9 Proper outrigger Select the appropriate checklist s for length the type of inspection to be 8 Columns rmed A 9 Sequencing cables Daily Inspection A A 10 Interlock system Checklist C NR Quarterly Inspection A B operation Refer to Table C A 11 Powerand C 1 Casters and wheels Annual Inspection A B C function controls i i C 2 Mast assembly Place a check in the appropriate box A 12 Lifting chains after each inspection procedure is and idler wheels C 3 Lifting chains completed Use the maintenance tables in this A 13 Breather cap C 4 Hydraulic oil 2 andthe 422 howi C 5 Auxiliary platform procedures in section 4 to learn how to lowering batteries 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 Part No 40462 Genie DPL Super Series 3 5 Section 3 Scheduled Maintenance Inspections Service Manual First Edition a x This page intentionally left blank 3 6 Genie DPL Super Series Part No 40462 Service Manual
45. BOX z VALVE 2 J BOX I VALVE 8 5 I 5 I OPTIONAL T I M5 I BL 1 M5 WARNING LIGHT 1 OR_3 oor N8 OR 3 orn 0 IDESCENTALARM 2 77 110V AC 220 VAC EST 4 MOTOR DETAIL Yi 4 MOTOR DETAIL We ap ee ES0075_H Part No 40462 Genie DPL Super Series 6 9 Section 6 Schematics Service Manual First Edition SS SS A ee ee Electrical Schematic DPL Super Series AC Models from serial number DPLO7 1499 to DPLO7 1562 ABBREVIATION LEGEND WIRE COLOR LEGEND Description gt tion SES 8AA ie Color Description BL Blue 15A 110V 8A 220V CB9 6A 110V AC 3A 220V AC B Black Power supply AC BN Brown GN YL Green Yellow Platform control box EN2 Ground control box OR Orange EN4 Power to platform GFCI receptacle ENS Power unit 110V RD Red 6 Power unit 220V RD BK Red Black Red Yellow WH White Key switch ground platform Led or light YL Yellow L5 Power indicator ground L6 Low battery indicator for auxiliary ground L7 Low battery indicator main ground L12 Outrigger front left ground L13 Outrigger front right ground L14 Outrigger rear left ground L15 Outrigger rear right ground Note with description N8 110V AC
46. BREAKER i 220V AC MODELS z a 5 5 5 TERMINAL STRIP BL WH LE DETAIL z E BL BK N29 N 6 Ld 6 W5 DENOTES A NEUTRAL E a S gt z TERMINAL WIRE TO BE TAGGED Z x 2 2 2 STRIP NWITH AN N SLEEVE moo cm 5 6 L STRAIN RELIEF aede T T rer TO PLUG E OR 1234567 Miis up D POWER GN YL SUPPLY x ax AC GN YL E 5122 RE Ha STRAIN RELIEF U 7 DESCENT ALARM TO MOTOR lt N27 UNITS WITHOUT PLUG ap gt NQUH AND BK WIRES REPLACE ej BL AND EN WIRES CES GROUND ke BK FB2 SOREW amp WARNING N O DUMP LIGHT I I z VALVE 8 g E OPTIONAL WARNING LIGHT I AND DESCENT ALARMI N8 N10 pet 110V AC 1 220 ES0075_M Part No 40462 Genie DPL Super Series 6 10 Section 6 Schematics Service Manual First Edition cr ncrngnygng E Electrical Schematic DPL Super Series AC Models after serial number DPLO7 1562 ABBREVIATION LEGEND WIRE COLOR LEGEND Description B4 8 AA Batteries Color Description CB4 15A 110V AC 8AMP 220V AC BL Blue CR Control Relay CR27 Load Sense BK Black CR95 Guardrail latch BK WH Black White Power supply
47. C Emergency Stop button N C contact 12V DC Check the voltage at terminal 2 on the 0V DC Emergency Stop button N C contact 12V DC Check the voltage at terminal 3 black wire of 0V DC 3 pole terminal strip J2 12V DC Continued on the next page Charge the battery OR check the battery condition and replace a bad battery Trace the black input wire back to the motor start solenoid and repair open in the wire the key switch N O contact Trace the black wire fro terminal 1 on the Emergency Stop N C contact back to the key switch N O contact and repair open in wire Replace the Emergency Stop button N C contact Trace the black wire fro terminal 3 of the 3 pole terminal strip J2 back to the Emergency Stop button N C contact and repair open in the wire Chart 2 Part No 40462 Genie DPL Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 2 Check the voltage on m the both sides of the 5amp page P C board fuse Put Neg lead of voltage meter on grounding terminal 10 of the 13 pole terminal strip J1 Replace the 5amp fuse If there is voltage on bot sides of the fuse and the power light is not turned on replace P C board OR consult Genie Industries Service Department 5 6 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 5 Tro
48. CATOR OR 3 OR 7 FOR AUXILIARY LOWERING BL 2 BL RD RD _6 RD RD Bu 12 VDC OUTPUT BK ae 12 VDC OUTPUT RD ps YE a 53 5 DC MODEL LOW 12 VDC OUTPUT JA RD AUX DOWN NGK S2 BATTERY INDICATOR TYL YL DOWN SOL GROUND 10 GN YL Sir 12 VDC MOTOR RELAY OUTPUT 11 RD L3 OH UP 6 RD CAS 1 SEC TIME DELAY 12 VDC OUTPUT 12 BK L2 BL ESPLATFORM__f pown 7 BK 6 12 VDC UP SIGNAL INPUT 13 OR 11 WH 4 GNYL V rT 7 LEGEND CAS CONTROL ACTIVATE SWITCH BK NOV SOL ES EMERGENCY STOP SWITCH NOTES GNE KS LIGHT LED 722 FOR 120V OPERATION MC MOTOR CONTACTOR JUMPER BROWN TO BLACK LIT NOV NORMALLY OPEN VALVE AND BLUE TO WHITE PB POWER TO BASKET AS SHOWN GROUND FAULT CIRCUIT INTERRUPT FOR 240V OPERATION 8 SB SLOW BLOW FUSE JUMPER BROWN TO WHITE SOL SOLENOID AND BLACK UNCONNECTED Part No 40462 Genie DPL Super Series 6 8 Section 6 Schematics Service Manual First Edition Electrical Schematic DPL Super Series AC Models before serial number DPLO7 1499 Item CB4 D5 FB2 GND KS1 ABBREVIATION LEGEND Description 8 AA Batteries 15A 110V AC 8AMP 220V AC Power supply AC Enclosure EN1 Platform control box EN2 Ground control box EN4 Power to platform GFCI receptacle ENS Power unit 110V AC EN6 Power unit 220V AC Warning light Ground Descent alarm Key switch ground platform Led or light L5 Power indicator ground L6 Low battery indicator f
49. DC Emergency Stop switch should be pulled up for the contact to close 0V DC Check for power at terminal 2 of Emergency Stop switch contact 12V DC Check for power at terminal 4 of control activate switch While pushing in and holding the control activate switch check for power at terminal 3 of the control activate switch contact 12V DC Continued on the next page Replace 16 6 cable because of open in red wire OR repair open in quick disconnect under ground control box Replace Emergency Sto switch N C contact block Replace the red wire because of open circuit between the Emergency Stop switch contact block and the control activate switch contact block Replace the control activate switch N O contact block Part No 40462 Genie DPL Super Series 5 15 Section 5 Troubleshooting Flow Charts CHART 6 While pushing in and holding the control Continued from the previous page up switch contact While pushing in the control activate switch and activating the up function hold both switches and check for power at terminal 3 of the up switch contact While pushing in the control activate switch and activating the up function hold both switches and check for power at terminal 13 orange wire of the 13 pole terminal strip J1 in the ground control box While pushing in the control activate switch and activating the up function hold both
50. First Edition Section 4 Scheduled Maintenance Procedures Scheduled Maintenance Procedures 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 AWARNING inspection when required may result in death serious injury or substantial machine damage Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years 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 A DANGER that will cause death or serious injury Indicates the presence of a hazard AWARNING that may cause death or serious injury Indicates the presence of a hazard ACAUTION 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 Part No 40462 Genie DPL Super Series 4 1 Section 4 Scheduled Mainte
51. GROUND CONTROL BOX RE 04 SRONNWNHDASHEDUNES _ AE at eg TRANSFORMER yli CB4 15A CB9 6A _ 1 BRI 7 lt x RDBLK Fett BK W3 16 0V AC INPUT BD EN R RD YL o BASE amp L12v POWER INPUT CENTER TAP INPUT EB 3 BL S L NEGATIVE 12V DC AUX INPUT 16 0 AC INPUT t WH 2 s L POSITIVE 12V DC AUX INPUT FRONTLEFT 4 LED 13 FRONT LEFT 1 ew Y7 LEVELING LED 15 REAR RIGHT I NC 6416 INPUTS LED 14 REAR LEFT i EX R WNE IM RD BA ILOW BATTERY LED 12 FRONT LEFT z Y7 SAA INDICATOR FOR 12V DC OUTPUT AUXILIARY LOWERING YL BATTERIES I 12V DC OUTPUT J BOX PLATFORM e 6617 12V DC OUTPUT PA DOWN L12 114 m m 3 Dn NN LOW BALE UP SIGNAL OUTPUT J BOX LEX L5 UP SIGNAL OUTPUT DELAYED w TARE _GNYE 1 YL e POWER INDICATOR U 1 0 UP SIGNALINPUT wo WH WH WH RD RD PC BOARD RD RD RD gt gt gt I BK BK lt Um GND w 4 GROUND trup paris ABK 6A CIRCUIT BREAKER 110V AC MODELS A i p 9 3A CIRCUIT BREAKER 220 MODELS 1 222 PE RAA PAR I EA 5 t BK RD BN 15A CIRCUIT BREAKER WH CB4 110V AC MODELS 1 W CIRCUIT
52. Genie DPLSuper Series 6 11 Section 6 Schematics Service Manual First Edition Eee EEE Electrical Schematic DPL Super Series AC CE Models from serial number DPLO7 1499 to DPLO7 1562 ABBREVIATION LEGEND WIRE COLOR LEGEND Color Description Circuit breaker BL Blue CB4 15A 110V AC 8A 220V AC CB9 110V AC 220V BK Black Power supply AC BK WH Black White EN1 Platform control box BN Brown EN2 Ground control box GN Green EN4 Power to platform GFCI receptacle EN5 Power unit 110V AC GN YL Green Yellow EN6 Power unit 220V AC Warning light 2R Orange RD Red Key switch ground platform RODE Led or light RD YL Red Yellow L5 Power indicator ground L6 Low battery indicator for auxiliary ground WH White L7 Low battery indicator main ground WH BK White Black L12 Outrigger front left ground L13 Outrigger front right ground YL Yellow L14 Outrigger rear left ground L15 Outrigger rear right ground Note with description N8 110V AC motor detail N10 220V AC motor detail N17 Narrow platform units WH and BK wires replace BL and OR wires N27 Units without plug WH and BK wires replace BL and BN wires N28 For 240V operation Jumper brown wire to white wire through terminal strip and leave black wire unconnected as shown CB4 8A CB9
53. Genie Industries Technical Publications RIE Genie 5S9 Service 4 5 Part No 40462 First Edition First Printin Introduction Service Manual First Edition Genie SHE Important Read understand and obey the safety rules and operating instructions inthe 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 Industries 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 encourag
54. L WH go ee he SUPPLY RZCLJOYX AC GNL Ex gt gt H4 EJ BK BK 7 pee EERE 2 STRAIN RELIEF V en UU DESCENT LUI IL 1 2 pon ZE Ef TO MOTOR H6 C N27 CR27 1 11 PLATFORM UNITS WITHOUT PLUG tent Z E LOAD SENSE NO OVERLOAD WH AND BK WIRES REPLACE CSN mm ALARM R AND BN WIRES a GROUND GROUND PS2 EK SCREW SCREW Y30 FB2 ct NO NO PLATFORM OVERLOAD WARNING PRESSURE SWITCH LIGHT Z 42X DUMP z DUMP LS6 gt J BOX z VALVE 2 J BOX VALVE 8 20g 58g 5 5 DOWN OPTIONAL M5 I M5 LIMIT SWITCH WARNING LIGHT BL 1 BL 1 1 CE ONLY AND fon a N8 3 Nio 1 a z DESCENT ALARM MOTOR amm _ Wi 110V AC 220 VAC Ty 47 MOTOR DETAIL I 4 MOTOR DETAIL GND I GND ES0075_M Part No 40462 Genie DPLSuper Series 6 12 Section 6 Schematics Service Manual First Edition eee E Electrical Schematic DPL Super Series AC CE Models after serial number DPLO7 1562 Service Manual First Edition Section 6 Schematics pA c W ZZ EZ TZT Hydraulic Schematic DPL Super Series ANSI Models
55. ONT LEFT 7 gt ae INDICATOR FOR 12V DC OUTPUT ee SW8 I iL13 L1 S AUXILIARY LOWERING RD BLK SW16 CONTROL BK Qu YL 12V DC OUTPUT 9 QD4 ACTIVATE NC BATTERIES a 12V DC OUTPUT 9A WH 1112 L14 osaa GROUND 10 mE BK 7 2 7 BK 3 a LOW BATTERY UP SIGNAL OUTPUT 11 WH to 0 6 gt s r INDICATOR M 159 54 SW11 L UP SIGNAL OUTPUT DELAYED 12 i Aki Lam OR AO AE UP SIGNAL INPUT 13 PLATFORM BK UP POWER INDICATOR U1 0 5 Ll ie B EM mj wmm w ROSE AUXILIARY L PC BOARD ENS AA DOWN ze SS CE N O N17 N BN BN L NARROW PLATFORM UNITS z s 4 WH AND BK WIRES REPLACE amp 4 BL 2 AND OR 3 WIRES Ll z d A e sa l ols on CR95 a e wil OR 1 GUARDRAIL a 52 I GN YL LATCH BK 45 PR4 a i I SS 1 Tar Jea 6 85 EN4 CB 15A CIRCUIT BREAKER CIRCUIT BREAKER f I RD 110V AC MODELS 220V AC MODELS POWER TO GND 4 e ecce 9 PLATFORM GROUND Bk on BK WH 5 GFC STUD 7 1 WH BK LI K I 110V AC 220V GNE m z dializ TERMINAL STRIP l o7 7 7 N27 al EJ DETAIL WH z S N Vid GN YL GNYL UNITS WITHOUT PLUG N 7 P 8 WH
56. 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 Contact your authorized Genie distributor or Genie Industries 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 ails 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 4 2 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 4 Scheduled Maintenance Procedures A 4 Check for Hydraulic Leaks Detecting hydraulic fluid leaks is
57. _ a N17 N GND WH OR CR95 4 NARROW PLATFORM UNITS x I T WH AND BK WIRES REPLACE amp z a GROUND wet Lo GUARDRAIL BL 2 AND OR 3 WIRES STUD j 1 LATCH N BK IN PRA PR eie eee cca 85 _ _ mau ARR 87 Se E CIRCUIT RD m oc 110V AC MODELS WH 30 Az t 4 2 CB9 I BKWH x POWER TO 3A CIRCUIT BREAKER z TUM 220V AC MODELS 1 ew 122 PRS ee NEA ene ee meee E NT REN 1 GN YL RECEPTACLE I WH BK 1 lig Q J z 15A LT BH SACS T N B 5 110V I 30 5 N gl CB4 8A CIRCUIT BREAKER o 2 5 110V AC 220V AC WH P 220V AG MODELS amp S al EJ 5 B 6 TERMINAL STRIP a a e e a DETAIL N29 an c z L68 z DENOTES A NEUTRAL WH T4 T PLATFORM z 2 BL BK fg 4 e e 4 0 44 WIRE TO BE TAGGED amp CR95 BK BK 6 OVERLOAD x mW WS NVITHAN N SLEEVE 4 GN YL GN YL LED a m5 E x d E 8 z z E z zz TERMINAL a GUARDRAIL Mc 2 gt 6 2 2 2 2 STRIP 86 LATCH 1 znoosmcmm 5 RT RD STRAIN RELIEF z JE ae ee 5 P2 V I T rry TO PLUG NS OR e 2452 0031124587 x lt A 4 D5 GNE RDO WO 4 K BK 87A I 11234567 DA POWER GN Y
58. ace the motor contactor continuity While pushing in the control activate switch oV DC Replace the motor and activating the up contactor because of function hold both switches and check for power at the N O side of the motor contactor number 4 weld cable to 12 volt motor damaged contacts 12V DC no continuity Replace the motor brushes OR the 12 volt Perform a continuity test across the 12 volt motor DC motor continuity Check the condition of the battery OR consult Genie Industries Service Department Part No 40462 Genie DPL Super Series 5 17 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 7 Machine Will Not Lift But Power Unit Will Operate DC Models Be sure the power unit reservoir is full and the breather cap has been installed Be sure the manual lowering cable is properly adjusted While pushing in the control activate switch and activating the up function hold both switches and check for input voltage at the N O OV DC valve coil on the power unit Put Pos lead of the voltage meter on the white wire and Neg lead on the green yellow grounding wire 12V DC Check the resistance of ae the N O valve coil 7 ohms Tee in a 3000 psi pressure gauge at the pressure port fitting 1800 to stamped P of the powe 2000 psi unit Push in the control activate switch activate the up function hold
59. ant component damage Dealer service is strongly recommended 1 Remove the platform See 5 1 How to Remove the Platform 2 Remove the cross braces X pattern from the mast assemblies 3 Remove the sequencing cable adjustment nut from each cable 4 Loosen the sequencing cable pulley mounting bolts Do not remove them Mast assembly steer handle end 5 Remove the junction box from the mast Mast assembly ladder end 5 Remove the electrical cable mounting clamps from the side of the mast Remove the junction box and electrical cable from the side of the mast Remove the ladder upper mounting bolts Mast assembly both 6 Attach an overhead crane to the mast 7 Remove the base end cover to access the hydraulic hoses 8 Tag disconnect and cap the lift cylinder hydraulic hoses Remove the flow control valve from the cylinder Plug the cylinder ports Bodily injury hazard Spraying ACAUTION hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 9 Remove the strut mounting fasteners 10 Remove the four mast mounting fasteners Push the fasteners toward the mast for clearance during mast removal 11 Carefully lift and remove the mast Do not damage the lift cylinder hydraulic fittings when removing the mast Crushing hazard The mast will fall ACAUTION unless it is properly supported 12 P
60. anual First Edition Section 4 Scheduled Maintenance Procedures 1 Visually inspect the cables and components for the following Frayed or broken wire strands Kinks in the cables Corrosion Paint or foreign materials Broken or damaged pulleys Unusual or excessive pulley wear Split or cracked swage ends Split or cracked chain adjustment bolts Bent or damaged pulley guards 2 Check to be sure of the following Cables are on the pulleys Cable ends are properly secured Mounting brackets are properly secured A 10 Check the Interlock System for Proper Operation 1 Turn the key switch to the on position 2 Pull out the red Emergency Stop button to the ON position Result The power light should come on 3 Select an outrigger and slide it into a base socket until the outrigger lock pin snaps into the locked position Bring the outrigger leveling jack into firm contact with the ground 4 Check the interlock display lights at the ground controls Confirm that the corresponding light is on 5 Repeat steps 3 and 4 for each of the remaining outriggers TABLE A PROCEDURES A 11 Test the Power and Function Controls Testing the machine functions and the Emergency Stop buttons for malfunctions is essential for safe machine operation An unsafe working condition exists if any function fails to operate properly or either Emergency Stop button fails to stop all the machine functions Each function should operate s
61. be overloaded and may cause death or serious injury This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Place the maximum load capacity in the platform Refer to the operators manual or the load capacity decal on the machine to determine the maximum load capacity Be sure the load is secure 2 Raise the platform slightly O Result The hydraulic power unit should raise the platform Fully lower the platform 4 Add an additional 30 pounds 14 kg to the platform Secure the additional weight Raise the platform slightly Result The hydraulic power unit should not be able to raise the platform If the hydraulic power unit is unable to lift rated load or lifts more than rated load see Repair procedure 3 6 How to Adjust the Pressure Relief Valve Part No 40462 Genie DPL Super Series 4 9 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE B PROCEDURES B 7 Test the Power To Platform Operation AC power to the platform is intended to be an extension cord to the platform for using hand tools 1 Connect an appropriate extension cord to the AC power supply cord at the base of the machine 2 Inthe platform plug a power drill or similar tool into the
62. ber 3 column toward the top of the mast 15 Install the idler wheel assembly into the top of the number 2 column Tighten the mounting fasteners Be sure all idler wheels rotate with no excessive side to side movement and be sure that they do not rub on the inside of the column Replace worn shims if necessary 16 Follow steps 14 and 15 for each remaining idler wheel assembly 17 Be sure that all of the idler wheel axle mounting fasteners are flush with the column Component damage hazard The ACAUTION roller wheels will become damaged if the idler wheel axle mounting fasteners are not flush with the column 18 Reassemble the machine Then adjust the lifting chains See 4 8 How to Adjust the Lifting Chains Genie DPL Super Series Part No 40462 Service Manual First Edition Section 7 Repair Procedures 4 3 How to Adjust the Lifting Chains When adjusting the lifting chains it is very important to maintain equal adjustment for both mast assemblies 1 Fully lower the machine and check to see if all the columns except the carriage are even at the top The chains are adjusted correctly if all the columns are even at the top To adjust column chains 2 Markthe column to be adjusted 3 Raise the platform 6 feet 2 m 4 Turn the adjustment lock nuts evenly on both chain terminals clockwise to raise the column or counterclockwise to lower the column 5 Fully lower the machine and recheck the alignme
63. bleshoot discovered problem still exists Return to Perform service problem repair solved Symbols Legend wyry Indicates the presence of a hazard ADANGER that will cause death or serious injury Indicates the presence of a hazard AWARNING that may cause death or serious injury Indicates the presence of a hazard ACAUTION 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 Part No 40462 Genie DPL Super Series 7 1 Section 7 Repair Procedures Service Manual First Edition Base Assembly 1 1 1 2 Interlocks Base Components The interlock contact brackets indicate proper How to Adjust the Platform installation of the outriggers and only allow the machine to operate when the outriggers Manual Lowering Cable properly installed and adjusted 1 Remove the base end covers to access the How to Remove an Interlock platform manual lowering cable Contact Bracket 2 Check to be sure Steer handle end 1 Fully lower the platform turn the machine off and remove the key Actuator bracket is connected to the base 1 and the manual lowering valve 2 Store the outriggers in the storage sockets Manual lowering cable is connected to the 3 Trace the interlock contact bracket wires into base with iwa
64. bs 340kg 340 kg 272 kg DPL 35S 600 Ibs 600 Ibs 500 Ibs 272kg 272kg 227 kg Be sure to add the weight of the operator as part of the maximum load 7 Hold the relief valve screw and loosen the lock nut 8 While activating the platform up function turn the relief valve screw clockwise just until the platform begins to raise 9 Fully lower the platform 10 Add an additional 30 pounds 14 kg to the platform Secure the additional weight 11 Raise the platform slightly 12 The power unit should not be able to lift the platform If the power unit lifts the platform turn the relief valve clockwise or counterclockwise until the adjustment is correct 13 Hold the relief valve screw and tighten the lock nut Be sure the relief valve screw does not turn 14 Bleed the hydraulic system by raising the platform to full height If the pump cavitates or platform fails to reach full height add hydraulic oil until the pump is functioning correctly Do not overfill the hydraulic reservoir Component damage hazard Do ACAUTION not continue to operate the machine if the hydraulic pump is cavitating 15 Install the breather cap and the base cover Genie DPL Super Series Part No 40462 Service Manual First Edition Section 7 Repair Procedures Sas HYDRAULIC POWER UNITS 3 7 3 8 How to Check the Resistance How to Test the Motor Start of a Valve Coil Solenoid DC Models 1 Fully lower the platform turn the mach
65. e SW11 Platform up down SW12 Auxiliary down SW13 Outrigger interlock front left SW14 Outrigger interlock front right SW15 Outrigger interlock rear left SW16 Outrigger interlock rear right U Electronic component U10 PC board U11 Transformer Wiring component W3 Terminal strip 3 pole 3 pin U10 W4 Terminal strip 14 pole 14 pin U10 Note Use these 2 W5 Terminal strip 7 pole 14 pin 30 Valve legends for the i Y30 Normally open dump valve schematic on the opposing page Service Manual First Edition Section 6 Schematics Electrical Schematic DPL Super Series AC CE Models from serial number DPLO7 1499 to DPLO7 1562 N M L K J H G F E D C B A
66. e nut where the red wire from switch 4 connects to the red wire If LED 1 is not on check for power at the wire nut where the white wires connect in the ladder enq junction box If LED 4 is not on check for power at the wire nut where the red wires connect If LED 1 is not on check for power at terminal 4 white wire If LED 4 is not on check for power at terminal 7 red wire These terminals are on the 13 pole terminal strip J1 in the ground control box Replace P C board OR consult Genie Industries Service Department ov DC CHART 3 Repair or replace damaged interlock contacts Inspect the outrigger bad interlock contacts and the 22 base interlock contacts for damage Repair open circuit in the black wire or the red wire from base interlock contacts Replace the 18 7 cable from the steer handle end junction box because of open circuit in the white wire or in the red wire Replace the 18 7 cable from the ladder end junction box because of open circuit in white wire or in the red wire Part No 40462 Genie DPL Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 4 Machine Will Not Lift AC Models Be sure the keyswitch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the power light and all interlock display lights are on Be sure the ground con
67. e of the DPL 30S 6 quarts 5 6 liters battery pack DPL 35S 6 quarts 5 6 liters 3 8 Install the battery pack into the ground control box and tighten the fasteners 9 Close the ground control box cover and tighten the fasteners 4 14 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 5 Troubleshooting Flow Charts Troubleshooting Flow Charts Before Troubleshooting Read understand and obey the safety rules and operating instructions printed in the Genie DPL Super Series Operator s Manual Be sure that all necessary tools and test equipment are available and ready for use Observe and Obey Read each appropiate flow chart thoroughly Troubleshooting and repair procedures shall be Attempting shortcuts may produce hazardous completed by a person trained and qualified on conditions the repair of this machine Be aware of the following hazards and follow Immediately tag and remove from service a generally accepted safe workshop practices damaged or malfunctioning machine ADANGER Electrocution hazard Contact with Repair any machine damage or malfunction electrically charged circuits may before operating the machine result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Spraying AWARNING hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do no
68. ed 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 genieindustries com e mail awp techpub terex com Genie North America Telephone 206 881 1800 Toll Free 800 536 1800 in U S A Toll Free 800 426 8089 in Canada Sales Fax 206 883 3475 Service Fax 206 556 8649 Genie Europe Telephone 44 01636 605030 Fax 44 01636 611090 Genie Industries Copyright 1996 by Genie Industries First Edition First Printing August 1996 Genie is a registered trademark of Genie Industries Registered 2009987 69 Printed on recycled paper Printed in U S A ii Genie DPL Super Series Part No 40462 Service Manual First Edition 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 M You are trained and qualified to perform maintenance on this machine M You read understand and obey manufacturer s instructions and safety rules employer s safety rules and worksite regulations applicable governmental regulations M You have the appropriate to
69. erial number DPLO7 1499 to 07 1562 6 9 Electrical Schematic DPL Super Series AC ANSI Models after serial number DPLO7 1562 sisirin 6 10 Electrical Schematic DPL Super Series AC CE Models from serial number DPLO7 1499 to 07 1562 6 11 Electrical Schematic DPL Super Series AC CE Models after serial number DPLO7 1562 6 12 Hydraulic Sehematic ttn enu utn 6 13 Hydraulic Schematic CE siti ses A tes RE taa 6 14 vii Part No 40462 Genie DPL Super Series Service Manual First Edition S ZE Z Z Section Seven Repair Procedures 7 1 Base Assembly 121 INIETIOCKSN ce HH EET 7 2 1 2 Platform Manual Lowering 7 2 1 3 How to Check the Resistance of a Valve 7 3 Ground Control Box 2 1 Howto Test the Transformer AC 7 4 2 2 Howto Test the AC Contactor AC 7 4 Hydraulic Power Units 3 1 Hydraulic Power Unit Components AC 7 6 3 2 Hydraulic Power Unit Components DC
70. 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 TABLE A PROCEDURES 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 fo
71. evious page for power at the wire nut where the red wire from 0V DC outrigger switch 2 connects to the orange wire If LED 3 is not on check for power at the wire nut where the red wire from outrigger switch Repair open circuit in the 3 connects to the blue black wire or the red wire wire from base interlock contacts contacts good 12V DC If LED 2 is not on check for power at terminal 5 orange wire If LED 3 is not on check for power at terminal 6 blue 0V DC wire These terminals are on the 13 pole terminal strip J1 in the Replace 18 7 cable from the ladder end junction box because of open circuit in orange wire or blue wire ground control box 12 V DC Replace P C board OR consult Genie Industries Service Department If LED 1 or 4 are not on continue from here Replace 18 7 cable from black wires that are ladder end junction box connected together with OV DC because of open circuit i wire nut located in the black wire steer handle end junctio Check for power at the box 12 V DC Continued on the next page 5 8 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 5 Troubleshooting Flow Charts Continued from the previous page If LED 1 is not on check for power at the wire nut where the red wire from switch 1 connects to the white wire If LED 4 is not on check for power at the wir
72. ew one Part No 40462 Genie DPL Super Series Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE C PROCEDURES 11 Raise and lower the platform through three complete cycles Add hydraulic oil if needed to allow platform to reach full height Component Damage Hazard Do ACAUTION not allow the hydraulic reservoir to completely empty when raising the platform Pressurized air in the hydraulic system can damage hydraulic components Hydraulic System Hydraulic fluid Dexron equivalent Hydraulic reservoir capacity AC models DC models 4 7 liters 4 7 liters 5 quarts 5 quarts Hydraulic System Capacity includes reservoir C 5 Replacing the Auxiliary Platform Lowering Batteries 1 Turn the machine off and remove the key 2 Remove the two ground control box cover fasteners 3 Open the base control box and locate the battery pack inside the base control box 4 Remove the fasteners that hold the battery pack in place 5 Carefully slide the battery pack out of the holder The wires connected to the battery pack are very small Be careful not AC models to damage the wires DPL 25S 6 quarts 5 6 liters Remove the old batteries from the pack DPL 30S 6 quarts 5 6 liters DPL 35S 6 quarts 5 6 liters Insert new batteries into the pack DC models Make sure the batteries are installed correctly by following the DPL 25S 6 quarts 5 6 liters diagram on the insid
73. fi CONTROL WH RD 42V DC POWERINPUT CENTER TAP INPUT 2 BOX PLATFORM N NE L NEGATIVE 12V DC AUX INPUT 16 0V DC INPUT 2 1 L POSITIVE 12V DC AUX INPUT ep 13 FRONTRIGHT 4 WH Y7 Qa OR w E EMERGENCY E DICAT Oe LEVELING LED 15 REAR RIGHT 5 N C sto IL fs INDICATOR BL PLATFORM OX oe Ge INPUTS LED14REARLEFT 6 DOWN y Y7 m 2 RD Low BATTERY LED 12 FRONT LEFT 7 N C SW8 I L13 L15 N0ICATOR FOR 12V DC OUTPUT 8 J BOX 2 PLATFORM BK AUXILIARY LOWERING mek fe EE DOWN CONTROL BK l BK 12V DC OUTPUT 9 GN YL YL ACTIVATE NC B4 e GH L7 12V DC OUTPUT sA m BATTERIES 112 114 GROUND 108 O J BOX EX 3 E BATTERY UP SIGNAL OUTPUT 11 RD YL GN YL INDICATOR YL X Yi SW11 UP SIGNAL OUTPUT DELAYED 12 OR PLATFORM BK UP POWER owe U 1 0 UP SIGNAL INPUT 13 UP DOWN m RD RD RD DOWN WA L LH SW12 PC BOARD SW13 AUXILIARY o e bic BK R nz Es T TM 17 N BN 1L BN SW14 NARROW PLATFORM UNITS r 4 WH AND BK WIRES REPLACE 3 6 BK N 2 AND OR 3 WIRES NOZ a ORAN EI c Q z o amp Z Wi GND GROUND mE 7 RD STUD EN4 GN YL POWER TO QD4 V PLATFORM GND 5 GFCI IL R WNO 28 0 ek 7 71 8k RECEPTACLE i 6 2 6 RD STUD K W5 BN
74. h ground platform Led or light L5 Power indicator ground L6 Low battery indicator for auxiliary ground L7 Low battery indicator main ground L12 Outrigger front left ground L13 Outrigger front right ground L14 Outrigger rear left ground L15 Outrigger rear right ground L68 Platform overload LS6 Down limit switch Hydraulic power unit Normally closed Normally open Note with description N17 Narrow platform units WH and BK wires replace BL and OR wires N27 Units with out plug WH and BK wires replace BL and BN wires Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls Pressure switch Quick disconnect QD1 Battery quick disconnect QD3 Control cable to platform control box QD4 Control cable to base Switch SW 8 Control activate SWh1 Platform up down SW12 Auxiliary down SW13 Outrigger interlock front left SW14 Outrigger interlock front right SW15 Outrigger interlock rear left SW16 Outrigger interlock rear right U Electronic component U9 Battery Charger U10 PC board Wiring component W3 Terminal strip 3 pole 3 pin U10 W4 Terminal strip 14 pole 14 pin U10 W5 Terminal strip 5 pole 10 pin Y Valve coil Y7 Platform down Note Use these 2 Y30 Normally open dump valve open ame legends for the schematic on the opposing page e Z oja x
75. he Battery DC Models B 5 Clean and Lubricate the Columns B 6 Test the Lifting Capacity E ZE B 7 Test the Power To Platform Operation B 8 Adjust the Sequencing Cables B 9 Inspect for Proper Outrigger Length ra ra za ra ra ra Ua Part No 40462 Genie DPL Super Series 3 3 Section 3 Scheduled Maintenance Inspections Service Manual First Edition z i EE Z Z MAINTENANCE TABLES Table C Dealer Tools are New parts service required required suggested 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 o C 3 Lubricate the Lifting Chains 4 Replace the Hydraulic Oil C 5 Replace the Auxiliary Platform Lowering Batteries ra ra ra ra ra ZZZE gt 3 4 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 3 Scheduled Maintenance Inspections Maintenance Inspection Report Model Checklist A YNR Checklist B NR Serial number Refer to Table A Refer to Table B A 1 Operator s B 1 Electrical wiring Date m and Responsibility manuals B 2 Welds Machine owner A 2 Decals and placards B 3 Lifting chain Inspected by print adjustments A 3 Damage loose or B 4 Batt am atter Inspector signature missing parts A 4 Hydraulic leaks
76. hese skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Thoroughly clean all columns 2 Secure the number 1 column to the saw horses and lay the chains out on the floor at the top 3 Apply a generous amount of Boe lube wax Genie part number 90337 to the inside and outside channels of each column 4 Slide the number 2 column into the number 1 column 5 Lay the number 2 column chains onto the floor Do not allow the chains to become twisted or dirty 6 Pick up the number 1 column chains and lay them inside the number 2 column 7 Slide the number 3 column into the number 2 column 8 When the column is almost all the way in guide the number 1 column chains into the chain tension rocker on the number 3 column 9 Install the adjustment nuts onto the number 1 column chains Adjust the adjustment nuts so the lifting chains have equal tension and the chain tension rocker is centered in the inspection hole in the column 10 Lay the number 3 column chains on the floor Do not allow the chains to become twisted or dirty 11 Pick up the number 2 column chains and lay them inside the number 3 column 12 Follow steps 4 through 11 for each remaining column and the carriage 13 After all the columns are together the idler wheel assemblies need to be installed 14 Remove the tension from the lifting chains on the number 2 column by pushing the num
77. ine off Electrocution hazard Contact with and remove the key AWARNING electrically charged circuits may 2 Connect the leads from an onmmeter to the result in death or serious injury valve coil terminals Remove all rings watches and other jewelry Electrocution hazard Disconnect AWARNING the ground cable from the battery before performing this procedure 1 Label and disconnect all the wiring from the motor start solenoid 2 Connect the leads from an ohmmeter to each terminal combination and check for continuity Test Desired result Small post to ground 13 to 17 Q 2 large posts no continuity infinite Q Valve coil specifications Small post to no continuity any large post infinite Q Solenoid operated N O valve 10V 5 9 to 7 2 Q Lowering valve 10V 7 8 to 9 5 Q located at base of cylinder a high amp power contact terminal large post b solenoid activate coil terminal small post 3 Connect 12V DC to the small post and a ground wire to the case of the solenoid then test the following terminal combinations Test Desired result 2 large posts continuity zero Q Part No 40462 Genie DPL Super Series 7 13 Section 7 Repair Procedures Service Manual First Edition Mast Assembly DPL 25S
78. inspection hole Idler wheels have badly worn flanges Replace chain terminal and threaded rod Replace idler wheel and check chain alignment Idler wheels have grooves worn into chain contact surface Cracks in any chain link plate Replace idler wheel Replace both chains on that column section Replace entire chain Do not repair just the affected portion of the chain Part No 40462 Genie DPL Super Series Section 7 Repair Procedures Service Manual First Edition Platform 5 1 How to Remove the Platform 1 Remove the cover from the platform control box and the AC outlet to access the mounting screws Remove the control box and AC outlet 5 2 Platform Control Box How to Test the Contactors 1 Fully lower the platform turn the key switch off and disconnect the power supply 3 Remove the platform control cable clamps from 2 Loosen the platform control box lid fasteners the platform and open the control box 4 Rotate the platform guard rails to the upright Observe the markings on the contactor to be position Close and latch the platform entry gate checked The N O marking designates the and the platform end guard rail switch as normally open and N C designates ee the switch as normally closed 5 Attach an overhead crane or similar lifting device to the platform 4 Connect a continuity tester to the exposed screw terminals 6 Remove the platform mounting fasteners
79. ion or contamination Broken or missing chain leafs and pins Tight or kinked joints in the chain Missing or damaged idler wheels and related components 3 Inspect the chain terminations near the bottom of each column to confirm that each termination has a lock nut 4 Inspect the chain terminations near the bottom of each column to confirm that the chain tensioner bracket is centered in the inspection hole D D GD GD chain tensioner bracket adjustment nut hidden from view termination rod hidden from view column A 13 Inspect the Breather Cap The hydraulic reservoir is a breathing type reservoir The breather cap has an internal air filter that can clog and may cause the power unit to operate improperly If the breather cap is not properly installed and checked daily impurities can enter the hydraulic system and cause component damage 1 Be sure the breather cap is installed on the hydraulic power unit reservoir and is not damaged Do not remove it Genie DPL Super Series Part No 40462 Service Manual First Edition Section 4 Scheduled Maintenance Procedures B 1 Inspect the Electrical Wiring Maintaining electrical wiring in good condition is essential to safe operation and good machine performance Failure to find and replace burnt chafed corroded or pinched wires could result in unsafe operating conditions and may cause
80. lace two saw horses under the mast 13 Lower the bottom of the mast onto one saw horse and continue to lower the mast until the top is resting on the second saw horse The mast should be resting on the carriage side How to Disassemble the Mast This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and significant component damage Dealer service is strongly recommended 1 Remove the mast See How to Remove a Mast Assembly 2 Remove the mounting fasteners from the cylinder mounting plates Genie DPL Super Series Part No 40462 Service Manual First Edition Section 7 Repair Procedures 3 Remove the socket head retaining bolt from the clevis block on the lift cylinder rod end a topofno 1 column b retaining bolt c clevis block 4 Support the cylinder and carefully slide it out of the bottom of the mast 5 Carefully rotate the mast until it is resting on the back of the number 1 column 6 Slide the carriage toward the top enough to remove the tension on the lifting chain 7 Slide the column that is under the carriage toward the top about 6 inches 15 2 cm to access the idler wheel mounting fasteners 8 Hold the idler wheel axle from turning by placing a screwdriver in the hole of the axle Remove the axle mounting fasteners the
81. lock nuts the junction box Manual lowering cable is attached to the actuator bracket Remove the interlock contact bracket mounting Ladder end fasteners from the outrigger base socket 4 Label and disconnect the contact bracket wires Actuator bracket is connected to the base 6 Grasp the interlock contact bracket inside the and the manual lowering valve base outrigger socket and pull it out with the wires Manual lowering threaded rod is attached to the actuator bracket 3 Adjust the manual lowering lever Adjust the cable and the threaded rod at the lever Be sure to maintain equal tension on the cable and threaded rod Do not over tighten the platform manual lowering cable The platform may not raise if there is to much tension on the cable 7 2 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 7 Repair Procedures M BASE ASSEMBLY 1 3 How to Check the Resistance of a Valve Coil The valve coil is located at the bottom of the hydraulic lift cylinder 1 Lowerthe platform turn the machine off and remove the key 2 Connect the leads from an onmmeter to the valve coil terminals Valve coil specifications Solenoid operated N C valve 10V 7 8 to 9 5 Q Part No 40462 Genie DPL Super Series 7 8 Section 7 Repair Procedures Service Manual First Edition Ground Control Box 2 1 2 2 How to Test the Transformer How to Test the AC Contactor AC Mode
82. ls AC Models 1 Fully lower the platform turn the key switch off 1 Fully lower the platform turn the key switch off and disconnect the power supply and disconnect the power supply 2 Open the ground control box and locate the 2 Open the ground control box and locate the AC transformer contactor 3 Label and then disconnect all wiring from the 3 Label and then disconnect all wiring from the transformer contactor 4 Connect the leads from an ohmmeter to the 4 Connect the leads from an ohmmeter to the following terminal combinations and check the following terminal combinations and check the resistance continuity resistance a yellow wire b black wire c white wire d brownwire e bluewire f red wire no 1 0 Tedyelowwire Test Desired result h red wire no 2 terminal 0 to 1 80 to 85 Q Test Desired result all other terminal combinations no continuity brown wire to blue wire 20 to 22 Q infinite Q black wire to white wire 16 to 19 Q yellow wire to white wire 16 to 19 Q red yellow wire to red wire no 1 0 5 to 1 50 red yellow wire to red wire no 2 0 5 to 1 50 red wire no 1 to red wire no 2 0 5 to 1 50 yellow wire to black wire 0 5 to 1 50 all other wire combinations no continuity infinite 7 4 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 7 Repair Procedures M This page intentionally left blank Part No 40462 Genie DPL Super Se
83. lt in death or serious injury and significant component damage Dealer service is strongly recommended AWARNING 1 Remove the mast See 4 2 How to Remove the Mast Assembly 2 Remove the socket head retaining bolt from the clevis block on the lift cylinder rod end a of no 1 column b retaining bolt c clevis block Bodily injury hazard Spraying ACAUTION hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray MAST ASSEMBLY 3 Remove the cylinder mounting fasteners from the cylinder barrel end 4 Loosen the cylinder bracket mounting fasteners fff bracket mounting fasteners cylinder mounting fasteners hydraulic cylinder cylinder mounting plate ao 00 5 Support the cylinder and carefully slide it out of the bottom of the mast Crushing hazard The lift cylinder ACAUTION will fall unless it is properly supported Part No 40462 Genie DPL Super Series Section 7 Repair Procedures Service Manual First Edition MAST ASSEMBLY 4 2 How to Remove a Mast Assembly This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without these skills and tools may result in death or serious injury and signific
84. moothly and be free of hesitation jerking and unusual noise 1 Turn the key switch to the on position and pull out the red Emergency Stop button to the on position O Result The power light should be on 2 Twistto release the red Emergency Stop button at the platform controls 3 Pushin the control activate button and rotate to the up position then the pown position Result Platform up and down functions should operate smoothly 4 Push in the Emergency Stop button at the platform controls to the orr position and test up and down functions Result Up down function should not operate 5 Twist to release the red Emergency Stop button at the platform controls 6 Push in the Emergency Stop button at the ground controls to the orr position Then test up and down functions Result Up down function should not operate Part No 40462 Genie DPL Super Series Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 12 Inspect the Lifting Chains and Idler Wheels Maintaining the lifting chains and idler wheels in good condition is essential to safe machine operation Failure to find and replace damaged chains or idler wheels could result in unsafe operating conditions and may cause component damage 1 Raise the platform approximately 3 feet 1 m 2 Visually inspect the chains and idler wheels near the top of each column for the following Excessive corros
85. motor detail N10 220V AC motor detail N17 Narrow platform units WH and BK wires replace BL and OR wires N27 Units without plug WH and BK wires replace BL and BN wires N28 For 240V operation Jumper brown wire to white wire through terminal strip and leave black wire unconnected as shown CB4 8A CB9 3A For 120V operation Jumper brown wire to black wire and blue wire to white wire as shown with dashed lines CB4 15A CB9 6A N29 N Denotes a neutral wire to be tagged with an N sleeve N30 110V AC 220V AC terminal strip detail P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls PSZ QD3 Control cable to platform control box QD4 Control cable to base Switch o SW 8 Control activate SW11 Platform up down SW12 Auxiliary down SW13 Outrigger interlock front left SW14 Outrigger interlock front right SW15 Outrigger interlock rear left Note Use these 2 ite abdita legends for the Se rafie schematic on the W3 Terminal strip 3 pole 3 pin U10 W4 Terminal strip 14 pole 14 pin U10 W5 Terminal strip 13 pole 26 pin 30 opposi ng page Y Y7 Platform down Y30 Normally open dump valve FB ow KGHM Ps EMERGENCY EN1 PLATFORM 0 OX CONTROL ACTIVATE BK WH SW11 PLATFORM Bk UP UP DOWN DOAN LL m i ee A pa N17 NARROW PLATFORM UNITS
86. n Part No 40462 Genie DPL Super Series Section 2 Specifications Service Manual First Edition SPECIFICATIONS Bolt Torque Specifications Size Threads SAE Grade 5 Bolts lt gt SAE Grade 8 Bolts per inch Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry Torque Dry inch pounds foot pounds Newton meters inch pounds foot pounds Newton meters 10 24 43 5 60 7 32 49 6 68 8 1 4 20 96 11 144 16 28 120 14 168 19 5 16 18 17 23 25 34 24 19 28 25 34 3 8 16 30 41 45 61 24 35 48 50 68 7 16 14 50 68 70 95 20 55 75 80 109 1 2 13 75 102 110 149 20 90 122 120 163 9 16 12 110 149 150 204 18 120 163 170 231 5 8 11 150 204 220 298 18 170 231 240 326 3 4 10 260 353 380 515 16 300 407 420 570 7 8 9 430 583 600 814 14 470 637 660 895 1 8 640 868 900 1221 12 700 949 1000 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 2 2 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 3 Scheduled Maintenance Inspections 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 in
87. n 1800 psi Adjust the pressure relief valve See Repair procedure How to Adjus the Pressure Relief Valve and then perform pressure test again less than 1800 psi Consult Genie Industries Service Department Part No 40462 Genie DPL Super Series 5 19 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 8 Machine Will While pushing in the Check the resistance of infinite Replace the coil because Not Lower Ra E 12V DC down valve ohms__ of an open circuit and activating the down coils j function hold both Up Function switches and check for 7ohm Operates power at the N C down 5 valve coils at the barrel end of the lifting Pull the manual lowering rd One or both of the N C cylinders Put Pos lead lever red handle located lowers down valves are the a no a on the base damaged or e yellow wire and Neg contaminated Consult lead on the green yellow Genie Industries Service grounding wire platform will not lower Department One or both flow control valves at the barrel end of the lifting cylinders are oV DC possibly contaminated Consult Genie Industries Service Department Repeat the test but Check for a loose relocate the Neg lead of connection at the the voltage meter at the grounding stud in the ground terminal 10 12V ground control box OR green yellow wire of the check for a bad pin 13 pole terminal strip J1 connection a
88. n remove the idler wheel assembly When the idler wheel assemblies are removed be sure to label the location of each idler wheel assembly Be sure the shims and related components remain in the correct location 9 Remove the adjustment nuts from the chain tension rocker on the carriage MAST ASSEMBLY 10 Slide the carriage out the bottom of the mast assembly 11 Lay the chains out on the floor at the top of the mast Do not allow the chains to become twisted or dirty 12 Remove the adjustment nuts from the chain tension rocker on the column 13 Slide the column out the bottom of the mast 14 Push the next column toward the top of the mast to access the idler wheel assembly mounting fasteners 15 Hold the idler wheel axle from turning by placing a screwdriver in the hole of the axle Remove the axle mounting fasteners then remove the idler wheel assembly 16 Remove the adjustment nuts from the chain tension rocker on the column 17 Slide the column out the bottom of the mast 18 Follow steps 14 through 17 for each remaining column If the chains are removed be sure to mark the location and label each chain before removal Part No 40462 Genie DPL Super Series Section 7 Repair Procedures Service Manual First Edition MAST ASSEMBLY How to Assemble the Mast This procedure requires specific AWARNING repair skills lifting equipment and a suitable workshop Attempting this procedure without t
89. nance Procedures Service Manual First Edition Table A Procedures A 1 Inspect the Operators and Responsibility Manuals Maintaining the operators 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 operators 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 Contact your authorized Genie distributor or Genie Industries 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 1 Refer to the Decals section in the Genie DPL Super
90. nspection Report contains checklists for each type of scheduled inspection Make copies of the Maintenance Inspection Report to use for each inspection Store completed forms for three years Part No 40462 Genie DPL Super Series 3 1 Section 3 Scheduled Maintenance Inspections Service Manual First Edition Maintenance Tables Table A Dealer Tools are New parts service required required suggested 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 ra 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 3 2 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 3 Scheduled Maintenance Inspections I Se MAINTENANCE TABLES Table B Dealer Tools are New parts service required required suggested Complete all procedures in Table A B 1 Inspect the Electrical Wiring E B 2 Inspect All Welds B 3 Check the Lifting Chain Adjustments E B 4 Check t
91. nt U10 PC board W3 Terminal strip pole 3 pin 010 W4 Terminal strip 14 pole 14 pin 010 WS Terminal strip 5 pole 10 pin Valve coil Y7 Platform down Y30 Normally open dump valve u w Y Note Use these 2 legends for the schematic on the opposing page Service Manual e First Edition Section 6 Schematics ZEG O OO LOS Electrical Schematic DPL Super Series DC Models after serial number DPLO7 1498 N M L K J H G F E D C B A RD BLK RD 1 p 4 KS1 7 Nc m x KEY 71 3RD_A Y amp SWITCH I m aek ARRA c strz BK P2 LE Ll P EMERGENCY tits p 1 E i EN 1 STOP N BASE Z 11213 W3 16 0V DC INPUT 1 WH RD Sy MODE 2 Li2V DC POWERINPUT CENTER TAP INPUT 2 RD_
92. nt of the columns Re adjust if necessary 6 Check to make sure the chain terminals on each column have equal tension and the lock nuts are tight MAST ASSEMBLY 4 4 How to Adjust the Glide Pads When adjusting the glide pads it is very important to maintain equal adjustment for both mast assemblies 1 Fully lower the platform turn off the machine and remove the key 2 Locate the upper and lower glide pad bolts below each top roller wheel bolt on both sides of the columns 3 Hold each glide pad bolt and loosen the lock nut on all the glide pads 4 Turn all the glide pad bolts clockwise until the glide pads make contact with the column Adjust both sides of the mast Be sure the sides of the columns are within 1 8 inch 3 175 mm to even with each other 5 Starting at the number 1 column torque the upper and lower glide pad bolts to 12 in Ibs 1 356 Nm Hold the glide pad bolt and tighten the lock nut Be sure the glide pad bolt does not turn 6 Repeat step 5 for each remaining upper and lower glide pad bolt on one side of the mast Start at the number 1 column and adjust each column working toward the carriage 7 Repeat step 5 for all of the upper and lower glide pad bolts on the other side of the mast Make sure glide pad bolts are adjusted evenly on each side to maintain squareness of the columns Part No 40462 Genie DPL Super Series Section 7 Repair Procedures sms EE MAST ASSEMBLY 4 5
93. o Remove the Hydraulic Pump 1 Fully lower the platform turn the machine off and remove the key 2 Remove the base cover from the power unit 3 Remove the drain plug from the hydraulic reservoir and completely drain the reservoir into a container Properly discard of oil 5 Remove the power unit See 3 3 How to Remove the Power Unit AC Models or 3 4 How to Remove the Power Unit DC Models 6 Support the hydraulic reservoir with a lifting device 7 Remove the mounting fasteners from the reservoir Then remove the reservoir from the power unit It may be necessary to tap the side of the reservoir with a soft rubber mallet to loosen it 8 Remove the mounting fasteners from the pump Then remove the pump from the power unit When installing the reservoir be sure not to damage the o ring Part No 40462 Genie DPL Super Series 7 11 Section 7 Repair Procedures Service Manual First Edition HYDRAULIC POWER UNITS 3 6 How to Adjust the Pressure Relief Valve 1 Remove the base cover Remove the breather cap from the reservoir Fill the reservoir up to the sight gauge with Dexron ATF hydraulic oil equivalent Install the breather cap 5 Follow the appropriate operator s manual to set up the machine 6 Place maximum rated load into the platform Secure the load to the platform Maximum capacity ANSI CE CSA DPL 25S 750 Ibs 750 Ibs 600 Ibs 340kg 340 kg 272 kg DPL 30S 750 Ibs 750 Ibs 600 I
94. ols lifting equipment and a suitable workshop Part No 40462 Genie DPL Super Series iii Introduction Service Manual First Edition SAFETY RULES 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 ADANGER a hazard that will cause death or serious injury Indicates the presence of AWARNING a hazard that may cause death or serious injury Indicates the presence of ACAUTION 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 such as moving parts free swinging or unsecured components when lifting or placing loads Always wear approved steel toed shoes zj Be aware of potential crushing hazards EJ Workplace Safety Be sure to keep sparks flames and W lighted tobacco away from flammable and combustible materials like battery gases Always have an approved fire extinguisher within easy reach are properly maintained and ready for use Keep work surfaces clean and free of debris that could get into machine components and ca
95. or auxiliary ground L7 Low battery indicator main ground L12 Outrigger front left ground L13 Outrigger front right ground L14 Outrigger rear left ground L15 Outrigger rear right ground Hydraulic power unit Normally closed Normally open WIRE COLOR LEGEND Color Description BL Blue BK Black BN Brown GN YL Green Yellow OR Orange RD Red RD BK Red Black RD YL Red Yellow WH White YL Yellow PR QD Sw Note with description N8 110V AC motor detail N10 220V AC motor detail N17 Narrow platform units WH and BK wires replace BL and OR wires N27 Units with out plug WH and BK wires replace BL and BN wires N30 110V AC 220V AC terminal strip detail Power switch P1 Emergency Stop button at ground controls P2 Emergency Stop button at platform controls Power relay PR4 Function pump M5 Quick disconnect QD3 Control cable to platform control box QD4 Control cable to base Switch SW 8 Control activate SW11 Platform up down SW12 Auxiliary down SW13 Outrigger interlock front left SW14 Outrigger interlock front right SW15 Outrigger interlock rear left SW16 Outrigger interlock rear right Electronic component U10 PC board U11 Transformer Wiring component W3 Terminal strip 3 pole 3 pin U10 W4 Terminal strip 14 pole 14 pin U10 WS Terminal strip 7 pole 14
96. orm until 3 to 5 inches 7 6 to 12 7 cm of the top of each column is visible 2 Visually inspect the top of each column for clearance between the roller wheels and the adjacent column surface Result There should be a equal amount of distance between the roller wheel and the column on each side If mast inspection results in a measurement that is not within specification refer to Repair procedure 5 4 How to Adjust the Glide Pads 3 Loosen but do not remove the adjustment nut on the sequencing cable 4 Raise the platform approximately 3 feet 1 m 5 Inspect each idler wheel for the following Excessive wear on the side flanges Unusual wear Movement side to side in excess of 0 040 inches 1 mm Any movement of wheel front to back OCE a idler wheel b spacer c lifting chain If idler wheel inspection results in a measurement that is not within specification refer to Repair procedure 5 2 How to Assemble the Mast 6 Adjust the sequencing cables See B 8 Adjust the Sequencing Cables 4 12 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 4 Scheduled Maintenance Procedures C 3 Lubricate the Lifting Chains Lubricated chains are essential to good machine performance and safe operation Extremely dirty conditions may require that the chains be cleaned and lubricated more often 1 Raise the platform to the maximum height 2 Lubricate each chain with a dry
97. r 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 Part No 40462 Genie DPL Super Series 4 3 Section 4 Scheduled Maintenance Procedures Service Manual First Edition TABLE A PROCEDURES A 7 Inspect the Battery and Battery Charger DC Models Proper battery and charger 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 Batteries contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water AWARNING 1 Put on protective clothing and eye wear 2 Slide open the battery cover to access the charger and the battery The cover must remain open for the entire charging cycle 3 Be sure that the battery cable connections are tight and free of corrosion 4 Check the battery acid level If needed replenish with distilled water to the bottom of the battery fill tube Do not overfill 5 Install the vent caps 6 Connect the battery charger to a grounded outlet of proper voltage and amperage as indicated on battery charger 7 Settimer based on the amount of use Light Use less than 15 lifting cycles Set to 7 ho
98. res HYDRAULIC POWER UNITS OE EN O Part No 40462 Genie DPL Super Series 7 9 Section 7 Repair Procedures Service Manual First Edition HYDRAULIC POWER UNITS 3 3 How to Remove the Hydraulic Power Unit AC Models 1 Fully lower the platform turn the machine off remove the key and disconnect the power Source 2 Remove the base cover from the power unit 3 Tag disconnect and plug the hydraulic hoses Cap the fittings on the power unit Bodily injury hazard Spraying ACAUTION hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Tagand disconnect the electrical wiring from the valve coil AWARNING Electrocution hazard Contact with electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 5 Support the hydraulic power unit with a lifting device Remove the power unit mounting fasteners 7 Remove the cover from the junction box on the motor Then tag and disconnect the electrical wiring in the junction box Loosen the squeeze connector on the junction box and pull the wiring out through the squeeze connector 8 Remove the power unit from the machine Crushing hazard The power unit AWARNING will fall unless it is properly supported If anew power uni
99. ries Section 5 Troubleshooting Flow Charts Service Manual First Edition M NJ CHART 1 Continued from the previous page Check the voltage at Repair the transformer terminals 1 and 3 of 13 wires OR replace the terminal strip J1 transformer ut Pos lead of voltage meter on terminal 1 and Neg lead on terminal 3 14 to 16V AC Check the voltage on both sides of the 5 amp 12V DC i 6 Put eg lead of voltage i RA on rounding Replace the 5amp fuse terminal 10 of the 13 pole terminal strip J1 If there is voltage on bot sides of the fuse and the power light is not turned on replace P C board OR consult Genie Industries Service Department Genie DPL Super Series Part No 40462 Service Manual First Edition Section 5 Troubleshooting Flow Charts Power Light Will Not Turn On DC Models Be sure the keyswitch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the battery cables are connected Be sure the ground control box PC board fuse is not blown Check the battery pack gv DC voltage 12V DC Check i cj terminal 3 on the key switch N O contact Put ov DC Neg lead of voltage meter on grounding terminal 10 of the 13 pole terminal strip J1 12V DC Check the voltage at terminal 4 on the key ov DC switch N O contact 12V DC Check the voltage at terminal 1 on the 0V D
100. ries 7 5 Section 7 Repair Procedures Service Manual First Edition Hydraulic Power Units 3 1 Hydraulic Power Unit Components AC Models Index No Description Function 1 115 230V AC electric motor Single phase 2850 3450 rpm 50 60 Hz 2 ia deii OD Motor start circuit 3 Pressure relief valve Hydraulic relief valve adjustment 4 Solenoid operated N O dump valve Diverts pump output back to reservoir during motor start up 5 10V DGC Coil 5 rio catia teet Activates N O dump valve 6 Breather Gapa i titre wy KA dE Reservoir vent 7 Sight gauge siii Hydraulic fluid level 8 cil Ze 1 3 gallons 4 9 liters 9 Pipe plug iEn ERES Drains reservoir 10 Pick p filler oreet Filters hydraulic fluid 11 Ne tas eese Seals reservoir 12 Check Vale acy One way valve for pump output 13 PUMP esi AE Pad 0 5 to 0 6 gallons per minute at 2000 psi 1 89 to 2 27 liters per minute at 138 bar 14 Motor seal erede rire Seals motor from contaminants 15 Motor Dearlligi acne reete tetti Aligns motor shaft into pump 7 6 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 7 Repair Procedures HYDRAULIC POWER UNITS
101. s 7 23 Section 7 Repair Procedures Service Manual First Edition nO Dl This page intentionally left blank 7 24 Genie DPL Super Series Part No 40462 Distributed By 4 Genie North America 18340 NE 76th Street P O Box 97030 Redmond Washington 98073 9730 4 Genie Europe Brunel Drive Newark Nottinghamshire NG24 2EG England Genie DPL Super Series Service Manual First Edition Part No 40462
102. s up system for valve Test the unit contamination Be sure manual lowering cable is adilisted platform wont hold up On the power unit remove the return to tank hose off the T port fitting and put it into a bucket leaking Replace or repair both and activate the platfom N C down valves up function Check for leaking from the hose not leaking While platform is drifting Replace or repair all 3 is the motor spinning check valves The first backwards and second are located i each lifting cylinder and the third is located in the power unit Remove the lifting cylinders and replace damaged piston seal OR contact Genie Industries Service Department 5 22 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 5 Troubleshooting Flow Charts Chart 10 Power Unit Will Not Lift Rated Load Check the power source Charge the battery OR Note on DC models the check battery condition low battery indicator red voltage and replace bad battery LED light would be on OR use the appropriate indicting a low voltage power cord OR consult condition Genie Industries Service Department Check the pressure relief Adjust the pressure relief valve setting See incorrect Valve See Repair Maintenance procedure procedure How to Adjus Test the Lifting Capacity n Pressure Relief alve correct Consult Genie Industries Service Department Part No 4046
103. spections shall be completed daily quarterly and annually as specified on the Maintenance Inspection Report AWARNING Failure to properly complete each inspection when required may result in death serious injury or substantial machine damage Immediately tag and remove from service damaged or malfunctioning machine Repair any machine damage or malfunction before operating machine Keep records on all inspections for three years 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 I
104. switches and check for power at terminal 11 white wire of the 13 pole terminal strip J1 in the ground control box Continued on the next page activate switch check for power at terminal 4 of the Replace the up switch N O contact block Service Manual First Edition Im XML il Replace the red wire because of open circuit between the control activate switch contact block and the up switch contact block Replace the 16 6 cable because of open in the orange wire OR repair open in the quick disconnect under ground control box Replace P C board OR consult Genie Industries service Department 5 16 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 5 Troubleshooting Flow Charts CHART 6 Continued from the previous page While pushing in the Relocate the Neg lead of OV DC Repair open circuit in the control activate switch the voltage meter at red wire and activating the up terminal 10 green yello function hold both switches and check for power at the motor wire of the 13 pole terminal strip J1 in the ground control box contactor coil positive terminal white wire Put Neg lead of the voltage meter on the negative 12V DC terminal green yellow wire Repair open circuit in the green yellow wire 12V DC no Perform a continuity test continuit across the motor contactor coil Repl
105. t 1 second before checking voltage Put Pos lead of the voltage meter on the black wire and Neg lead on the green yellow grounding wire 12V DC Check the resistance of the N O valve coil 7 ohms Tee in pressure gauge at port stamped of power unit Push in the control activate switch activate the up function hold both switches and check the pressure While pushing in the control activate switch and activating the up function hold both switches and check for oV DC power at terminal 12 black wire of the 13 pole terminal strip J1 This is a 1 second ON time delayed terminal 12V DC Replace or repair black wire because of an open circuit infinite ohms Replace N O valve coil Inspect the mast 1800 to assemblies for a 2000 psi mechanical bind such as foriegn objects that could have fallen in between columns less than 1800 psi On the power unit remove the return to tank hose off of the T port fitting and plug the hose fitting leaving 3000 psi gauge teed in at the P port fitting Push in the control activate switch activate the up function hold and check the pressure less than 1800 psi Continued on the next page Activate the up function 1800 to and check for voltage at 2000 psi the N C down valve coils yellow wire at the barrel end of each lifting cylinder 12V DC Replace defective N O contact block for down function in
106. t allow oil to squirt or spray Perform all troubleshooting on a firm level surface Two persons will be required to safely perform some troubleshooting procedures Part No 40462 Genie DPL Super Series 5 1 Section 5 Troubleshooting Flow Charts Service Manual First Edition TROUBLESHOOTING FLOW CHARTS About This Section When a malfunction is discovered the flow charts in this section will help a service professional pinpoint the cause of the problem To use this section basic hand tools and certain pieces of test equipment are required voltmeter ohmmeter pressure gauges The location of terminals mentioned in this section can be found on the appropriate electrical or hydraulic schematics provided in Section 6 Schematics Since various degrees of a particular function loss may occur selecting the appropriate flow chart may be troublesome When a function will not operate with the same speed or power as a machine in good working condition refer to the flow chart which most closely describes the problem General Repair Process Malfunction _ Identify discovered gt Troubleshoot symptoms problem Still exists Perform repair Return to service problem solved 5 2 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 5 Troubleshooting Flow Charts Power Light Will Not Turn On AC Models
107. t is installed the pressure relief valve must be properly adjusted See 3 6 How to Adjust the Pressure Relief Valve 3 4 How to Remove the Hydraulic Power Unit DC Models 1 Fully lower the platform turn the machine off remove the key and disconnect the power source 2 Remove the base cover from the power unit 3 Tag disconnect and plug the hydraulic hoses Cap the fittings on the power unit Bodily injury hazard Spraying ACAUTION hydraulic oil can penetrate and burn skin Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually Do not allow oil to squirt or spray 4 Tag and disconnect the electrical wiring from the valve coil Electrocution hazard Contact with AWARNING electrically charged circuits may result in death or serious injury Remove all rings watches and other jewelry 5 Tag and disconnect the electrical wiring from the motor start solenoid 6 Support the hydraulic power unit with a lifting device 7 Remove the power unit mounting fasteners then remove the power unit from the machine Crushing hazard The power unit AWARNING will fall unless it is properly supported If a new power unit is installed the pressure relief valve must be properly adjusted See 3 6 How to Adjust the Pressure Relief Valve Genie DPL Super Series Part No 40462 Service Manual First Edition Section 7 Repair Procedures Im MM HYDRAULIC POWER UNITS 3 5 How t
108. t the quick in the ground control box disconnect under the base control box OR replace 18 7 cable because of an open circuit in the green yello 0V DC grounding wire Check the voltage at terminal 3 on the down Replace the red jumper N O contact block OV DC wire because of an open located in the platform circuit control box 12V DC Continued on the next page 5 20 Genie DPL Super Series Part No 40462 Service Manual First Edition Section 5 Troubleshooting Flow Charts wz A CHART 8 Activate the down function and check the Replace the N O down voltage at terminal 4 blu contact block because of wire of the N O down an open circuit contact block Continued from the previous page Check the voltage at Inspect pin 2 for a defect terminal 2 on the N O in the quick disconnect auxilary down contact located under the ground block in the base control control box OR replace box the 16 6 cable because o an open circuit in the blue wire pin 5 for a defect in the quick disconnect located under the ground control box OR replace the 18 7 cable because 0 open circuit in the yellow wire Part No 40462 Genie DPL Super Series 5 21 Section 5 Troubleshooting Flow Charts Service Manual First Edition Chart 9 Platform Will Activate the platform up function while Not Hold In simultaneously activating Inspect the hydraulic Up Position the manual lowering old
109. tics Service Manual First Edition EA ZZG GF Electrical Schematic DPL Super Series DC CE Models after serial number DPLO7 1498 WIRE COLOR LEGEND Description Blue Black Green Y ellow Orange Red White Yellow Note Use this legend for the schematic on the opposing page gt Service Manual First Edition na J 4 Section 6 Schematics Electrical Schematic DPL Super Series AC Models before serial number DPLO7 1499 L K J H G F E D C B A CONTROL BOX nD PC BOARD di THERMAL DEVICE ES BASE Jeji 23 YL 1 RD BK x NEGATIVE 12 VDC INPUT MAG INPUT 2 POSITIVE 12 VDC INPUT RD YL WH pN 15 AMP SB 2 E BK GN YL 2 m 16 0 VAC INPUT 3 BL WH WH LED1 12 VDC INPUT 2 z 0 LED1 LED2 LED2 12 VDC INPUT gt MC BK GN YL__ A DOWN SOL YL 3 8 AA BATTERIES BK GN YL LED4 LED 3 j AT MOTOR kr LED3 12 VDC INPUT GNYL X POWER INDICATOR J BOX GN YL 4 GNYL Se 4 LED4 12 VDC INPUT Wa G Wa E RD LOW BATTERY INDI
110. trol box circuit breaker has been reset In ground control box check for power at terminal 9 red wire of 13 pole terminal strip J1 Put Neg lead of voltage meter on terminal 10 grounding terminal 12V DC Check for power at terminal 1 of Emergency Stop switch contact in platform control box Put Neg lead of voltage meter on terminal 10 green yellow wire of 13 pole terminal strip J1 in base control box 12V DC Emergency Stop switch should be pulled up for the contact to close Check for power at terminal 2 of Emergency Stop switch contact 12V DC Check for power at terminal 4 of control activate switch 12V DC While pushing in and holding control activate switch check for power at terminal 3 of control activate switch contact 12V DC Continued on the next page eye Replace the P C board Replace 16 6 cable because of open in red OV wire OR repair open in quick disconnect under ground control box Replace Emergency Stog ov DC eich N C contact block Replace red wire because of open circuit between Emergency Stop switch SAL contact block and control activate switch contact block OV DC Replace control activate switch N O contact block Genie DPL Super Series Part No 40462 Service Manual First Edition Section 5 Troubleshooting Flow Charts While pushing in and holding the control activate switch check for
111. ubleshooting Flow Charts Interlock Lights Will Not Turn On Be sure the keyswitch is in the appropriate position Be sure the Emergency Stop buttons are pulled up to the on position Be sure the power light is on Be sure the unit is set up according to the operator s manual Be sure the outriggers are the correct length Check the power light light on Check for power at terminal 8 black wire the 13 pole terminal strip J1 located in the ground control box Put Neg lead of voltage meter on grounding terminal 10 green yellow wire Disconnect the power supply Unplug the 18 7 cable quick disconnect from the ladder end junction box under the ground control box and inspect the male and female connectors for damage Check for power at the black wires that are connected together with 4 wire nut in the ladder end junction box Continued on the next page Refer to either Chart 1 or Chart 2 Replace the P C board Repair or replace damaged connectors Replace 18 7 cable from the ground control box because of open circuit i black wire Chart 3 Part No 40462 Genie DPL Super Series Section 5 Troubleshooting Flow Charts Service Manual First Edition CHART 3 If LED 2 is not on check Inspect the outrigger Repair or replace interlock contacts and the bad damaged interlock base interlock contacts for damage Continued from the pr
112. urs Heavy Use greater than 15 lifting cycles Set to the on position 8 The charger will automatically shut off at the end of the set period Note If ammeter drops to 3A or less within the first 15 minutes the battery is fully charged 9 Check the battery acid level when the charge cycle is complete Replenish with distilled water to the bottom of the fill tube A 8 Inspect the Columns for Damage Detection of damage to columns is essential for safe machine operation An unsafe working condition exists if the columns are damaged and do not operate smoothly free of hesitation and binding A daily check of the columns allows the inspector to identify changes in the operating condition of the column assemblies that might indicate damage 1 Visually inspect each column on each mast for the following Dents gouges or abrasions Bends or warping Excessive wear 2 Raise and lower the platform through a complete cycle Result Platform should raise and lower smoothly free of hesitation and binding A 9 Check the Sequencing Cables Detection of damage to sequencing cables or components is essential for safe machine operation An unsafe working condition exists if the sequencing components are damaged and do not operate smoothly A daily check of the sequencing system allows the inspector to identify changes in the operating condition that might indicate damage Genie DPL Super Series Part No 40462 Service M
113. use damage NN Be sure that all tools and working areas sure that your workshop or work area 4 is well ventilated and safely and TS adequately illuminated 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 any forklift overhead crane 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 that fasteners intended for 4o oy Be sure to properly dispose of old oil or 2 other fluids Use an approved container Please be mindful of the environment iv Genie DPL Super Series Part No 40462 Service Manual First Edition Introduction Section One Section Two Section Three Section Four Table of Contents Important Information A ii Safety Rules General Safety 24 20 22 0 aaa aaa aaa nennen ener nennen iii Specifications Dj ada 2 1 2 1 DPLE 305 sve 2 1 Bolt Torque Specification ae susa ad 2 2 Scheduled Maintenance Inspections EE 3 1 TABIEA 3 2

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