Genie DPL-30S, DPL-25S, DPL-35S User Manual

Operator’s Manual

with Maintenance Information

Second Edition

First Printing

Part No. 82799

Operator’s Manual Second Edition • First Printing

Important

Read, understand and obey these safety rules and
operating instructions before operating this machine.
Only trained and authorized personnel shall be
permitted to operate this machine. This manual should
be considered a permanent part of your machine and
should remain with the machine at all times. If you have
any questions, call Genie Industries.

Contents

Page

Safety Rules .............................................................. 1

Controls ..................................................................... 7

Legend ....................................................................... 8

Pre-operation Inspection ............................................ 9

Maintenance ............................................................. 11

Function Tests.......................................................... 14

Workplace Inspection................................................ 17

Operating Instructions............................................... 18

Battery and Charger Instructions............................... 21

Transport and Lifting Instructions .............................. 22

Decals ...................................................................... 24

Specifications ........................................................... 28

Contact us:

Internet: http://www.genieindustries.com
e-mail: [e-mail]

Copyright © 1996 by Genie Industries
First Edition: Fifth Printing, April 2002
Second Edition: First Printing, November 2003
"Genie" and "DPL" are registered trademarks

of Genie Industries in the USA and many other
countries. "Super Series" is a trademark of
Genie Industries.

This machine complies with
ANSI/SIA 92.3-1990.

Printed on recycled paper
Printed in U.S.A.

Genie DPL Super Series Part No. 82799

Operator’s ManualSecond Edition • First Printing

Safety Rules

Danger

Failure to obey the instructions and
safety rules in this manual will
cause death or serious injury.

Do Not Operate Unless:

You learn and practice the principles of safe

machine operation contained in this operator's
manual.

1 Avoid hazardous situations.
Know and understand the safety rules before

going on to the next section.

2 Always perform a pre-operation inspection.
3 Always perform the function tests prior to use.
4 Inspect the workplace.
5 Only use the machine as it was intended.

You read, understand and obey the

manufacturer's instructions and safety rules—
safety and operator's manuals and machine
decals.

You read, understand and obey employer's

safety rules and worksite regulations.

You read, understand and obey all applicable

governmental regulations.

You are properly trained to safely operate the

machine.

The first time this machine is set up for use, a

breather cap is installed. See Pre-operation
Inspection section for breather cap instructions.

Part No. 82799 Genie DPL Super Series 1

Operator’s Manual Second Edition • First Printing

SAFETY RULES

Tip-over Hazards

Do not raise the platform
unless the base is level,
all four outriggers are
properly set up and the
leveling jacks firmly
contact the ground.

Do not move the machine
while the platform is
raised.

Do not adjust or remove the outriggers while the
platform is occupied or raised.

Do not place or attach overhanging loads to any
part of this machine.

Do not transport tools and materials unless they are
evenly distributed and can be safely handled by
person(s) in the platform.

Do not raise the platform
unless the machine is
level. Do not set the
machine up on a surface
where it cannot be leveled
using only the outriggers.

Do not place ladders or
scaffolds in the platform or
against any part of this
machine.

Do not push off or pull toward any object outside
the platform.

Do not use the machine on a moving or mobile
surface or vehicle.

Do not operate the machine in strong or gusty
winds. Do not increase the surface area of the
platform or the load. Increasing the area exposed to
the wind will decrease machine stability.

Occupants, equipment and materials shall not
exceed the maximum platform capacity.

Maximum capacity - DPL-25S

ANSI and CE 750 lbs 340 kg
CSA 600 lbs 272 kg
Maximum occupants 2

Maximum capacity - DPL-30S

ANSI and CE 750 lbs 340 kg
CSA 600 lbs 272 kg
Maximum occupants 2

Maximum allowable
manual force 90 lbs 400 N

2 Genie DPL Super Series Part No. 82799

Operator’s ManualSecond Edition • First Printing

SAFETY RULES

Maximum capacity - DPL-35S

ANSI and CE 600 lbs 272 kg
CSA 500 lbs 227 kg
Maximum occupants 2

Do not operate the machine near drop-offs, holes,
bumps, debris, unstable or slippery surfaces or
other possible hazardous conditions.

Do not alter or disable machine components that in
any way affect safety and stability.

Do not replace items critical to stability with items
of different weight or specification. Use only Genie
authorized replacement parts.

When moving the machine with a forklift or other
transport vehicle, the platform should be fully
lowered, the guard rails should be down, the
machine should be turned off and no personnel
shall remain in the platform.

Do not modify or alter an aerial work platform
without prior written permission from the
manufacturer. Mounting attachments for holding
tools or other materials onto the platform, toeboards
or guard rail system can increase the weight in the
platform and the surface area of the platform or the
load.

Fall Hazards

The guard rail system provides fall protection. If
occupants of the platform are required to wear
personal fall protection equipment (PFPE) due to
job site or employer rules, PFPE equipment and its
use shall be in accordance with the PFPE
manufacturer’s instructions and applicable
governmental requirements.

Do not sit, stand or climb
on the platform guard rails.
Maintain a firm footing on
the platform floor at all
times.

Do not enter or raise the
platform unless the
platform side guard rails
are locked upright and the
platform end guard rail and
the platform entry gate are
closed and latched.

Do not exit the platform while raised. If a power
failure occurs, have ground personnel activate the
manual lowering valve.

Keep the platform floor clear of debris.

Part No. 82799 Genie DPL Super Series 3

Operator’s Manual Second Edition • First Printing

SAFETY RULES

Electrocution
Hazards

This machine is not
electrically insulated
and will not provide
protection from contact
with or proximity to
electrical current.

Keep away from the machine if it contacts
energized power lines or becomes electrically
charged. Personnel on the ground or in the platform
must not touch or operate the machine until the
energized power lines are shut off.

Maintain safe distances from electrical power lines
and apparatus in accordance with applicable
governmental regulations and the following chart.

Voltage Minimum Safe

Approach Distance

Phase to Phase Feet Meters

0 to 300V Avoid Contact

Allow for platform movement, electrical line sway
or sag and movement due to strong or gusty winds.

Do not use the machine as a ground for welding.
Do not operate the machine during lightning or

storms.
Do not operate an AC powered machine or a DC

battery charger unless using a 3-wire grounded
extension cord connected to a grounded AC circuit.
Do not alter or disable the 3-wire grounded plugs.

Collision Hazards

Operators must comply with employer, job site and
governmental rules regarding the use of personal
protective equipment.

Check the work area for overhead obstructions or
other possible hazards.

Be aware of crushing hazards when grasping the
platform side guard rails.

Do not lower the platform unless the area below is
clear of personnel and obstructions.

300V to 50KV 10 3.05
50KV to 200KV 15 4.60
200KV to 350KV 20 6.10
350KV to 500KV 25 7.62
500KV to 750KV 35 10.67
750KV to 1000KV 45 13.72

4 Genie DPL Super Series Part No. 82799

Be careful when transporting on an incline.
Stay clear of descending platform.

Component Damage Hazards

Do not operate the machine unless a breather cap
has been installed in the hydraulic reservoir. See
the Pre-operation Inspection section for breather
cap instructions.

Do not use the machine as an electrical ground for
welding.

DC models: Do not operate the machine with a
weak or overly discharged battery.

Operator’s ManualSecond Edition • First Printing

SAFETY RULES

Improper Use Hazard

Do not leave the machine unattended unless the
key is removed to secure from unauthorized use.

Damaged Machine Hazards

Do not use a damaged or malfunctioning machine.
Conduct a thorough pre-operation inspection of the

machine and test all functions before each
work shift. Immediately tag and remove from
service a damaged or malfunctioning machine.

Be sure all maintenance has been performed
as specified in this manual and the

Service Manual

Be sure all decals are in place and legible.
Be sure the operator’s, safety and responsibilities

manuals are complete, legible and in the storage
container located in the platform.

.

Genie DPL

Bodily Injury Hazard

Do not operate the machine with a hydraulic oil or
air leak. An air leak or hydraulic leak can penetrate
and/or burn skin.

Improper contact with components under any cover
will cause serious injury. Only trained maintenance
personnel should access compartments. Access
by the operator is only advised when performing a
pre-operation inspection. All compartments must
remain closed and secured during operation.

Decal Legend

Genie product decals use symbols, color coding
and signal words to identify the following:

Safety alert symbol—used to alert
personnel to potential personal
injury hazards. Obey all safety
messages that follow this symbol
to avoid possible injury or death.

Red—used to indicate the
presence of an imminently
hazardous situation which, if not
avoided, will result in death or
serious injury.

Orange—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, could result in death or
serious injury.

Yellow with safety alert symbol—
used to indicate the presence of a
potentially hazardous situation
which, if not avoided, may cause
minor or moderate injury.

Yellow without safety alert
symbol—used to indicate the
presence of a potentially
hazardous situation which, if not
avoided, may result in property
damage.

Green—used to indicate operation
or maintenance information.

Part No. 82799 Genie DPL Super Series 5

Operator’s Manual Second Edition • First Printing

SAFETY RULES

Battery and Charger Safety

- DC Models
Burn Hazards

Batteries contain acid. Always wear protective
clothing and eye wear when working with batteries.

Avoid spilling or contacting battery acid. Neutralize
battery acid spills with baking soda and water.

Explosion Hazards

Batteries emit explosive gas.
Keep sparks, flames and
lighted tobacco away from
the battery.

Electrocution Hazards

Connect the charger to a
grounded AC circuit only.

Do not expose the battery or
the charger to water or rain.

Before each use, inspect for
damage. Replace damaged
items before operating.

Lifting Hazard

The battery weighs 105 lbs / 48 kg. Use the
appropriate number of people and proper lifting
techniques when lifting the battery.

Charge the battery in a
well-ventilated area.

Do not disconnect the charger DC output wires from
the battery when the charger is on.

The sliding door on the base cover must remain
open during the entire charging cycle.

6 Genie DPL Super Series Part No. 82799

Ground Controls Platform Controls

Operator’s ManualSecond Edition • First Printing

Controls

1 2

3 4

1

8

9

7 6 5

1 Red Emergency Stop button
2 Key switch
3 Outrigger interlock display lights (four)
4 Low battery indicator light for auxiliary

lowering

Part No. 82799 Genie DPL Super Series 7

5 DC models: Low battery indicator light
6 Power light
7 Auxiliary platform lowering button
8 Control activate button
9 Up/Down switch

Operator’s Manual Second Edition • First Printing

Legend

1 Platform end guard rail
2 Platform side guard rail
3 Manual storage container
4 Platform controls
5 AC outlet
6 Guard rail lifting arm
7 Platform entry gate
8 Platform end gate latch
9 Platform
1 0 Interlock display

8 Genie DPL Super Series Part No. 82799

1 1 AC models: Circuit breaker
1 2 Platform entry ladder
1 3 AC models: Power supply for

machine
DC models: AC power to

platform
1 4 Platform entry ladder lock pin
1 5 Outrigger with leveling jack
16 Forklift pocket
1 7 Bubble level
18 Sequencing cable

19 Transport tie-down
20 Manual lowering lever
21 Battery charger plug-in
22 Base
2 3 Caster with swivel lock
2 4 Base cover
25 Mast
26 Steer handle
2 7 Platform guard rail locking

handle