Genie DPL-25S Utility Vehicle User Manual
Contents
1. Operator s Manual DECALS 82803 or 82487 28175 82802 82879 82804 or 28235 82805 62939 62940 82783 Serial Plate 82806 or 82807 82806 or 82807 82993 82993 62050 82992 or 62051 82806 82992 82487 82481 or 62052 82801 or 82807 82993 Part No 82799 Genie DPL Super Series 27 Operator s Manual Specifications Model DPL 25S Height 31 ft 4 in maximum working 9 5m Height 25 ft 4 in maximum platform 7 7 m Height 78 in guard rails stowed 1 98 m Length 813 4 in outriggers stowed 2 07 m Width 311 2 in outriggers stowed 80 cm Outrigger footprint 84 x 60 in I x w 2 1x1 5m Platform dimensions 72 x 27 2 in I x w 1 83 m x 69 9 cm Power source AC 220V or 115V DC 12V Air power 100 psi 6 9 bar 80 cfm 2 26 m min Weight See Serial Plate Machine weights vary with option configurations Maximum capacity DPL 30S 36 ft 11m 30ft 9 1m 78 in 1 98 m 813 4 in 2 07 m 311 2 in 80 cm 89 x 73 in 2 3x1 9m 72 x 27 2 in 1 83 m x 69 9 cm 220V or 115V 12V 100 psi 6 9 bar 80 cfm 2 26 m min See Serial Plate Second Edition First Printing DPL 35S 40 ft 9 in 12 4m 34 ft 9 in2. Genie DPL Super Series 15 Operator s Manual Second Edition First Printing FUNCTION TESTS Test Outrigger Interlock 17 Twist to release the red Emergency Stop button at the platform controls 18 Push and hold the control activate button and rotate the up down switch in the direction of intended travel Result The up down function should operate 19 Unscrew one leveling jack until the corresponding interlock display light turns off 20 Push and hold the control activate button and rotate the up down switch in the direction of intendedtravel Result The up down function should not operate 21 Return the leveling jack to the previous setting and check the bubble level 22 Repeat the procedure for each outrigger Test Auxiliary Platform Lowering AC amp DC Models 23 Raise the platform slightly 24 Disconnect the power source from the machine 25 Turn the key switch to ground control 26 Push in the auxiliary platform lowering button at the ground controls Result The platform should lower 27 Connect the power source to the machine 28 Turn the key switch to platform control 29 Raise the platform approximately 6 in 15 cm 30 Disconnect the power source from the machine 31 Push and hold the control activate button and rotate the up down switch in the down direction Result The platform should lower 32 Connect the power source to the machine Test Manual Lowering 33 Rais
3. The pre operation inspection is a visual inspection performed by the operator prior to each work shift The inspection is designed to discover if anything is apparently wrong with a machine before the operator performs the function tests The pre operation inspection also serves to determine if routine maintenance procedures are required Only routine maintenance items specified in this manual may be performed by the operator Refer to the list on the next page and check each of the items If damage or any unauthorized variation from factory delivered condition is discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection again before going on to the function tests Scheduled maintenance inspections shall be performed by qualified service technicians according to the manufacturer s specifications and the requirements listed in the responsibilities manual PartNo 82799 Genie DPL Super Series Operator s Manual Second Edition First Printing PRE OPERATIONINSPECTION Pre operation Inspection Ii Be sure that the operator s safety and responsibilities manuals are complete legible and in the storage container located in the platform LU Be sure that all decals are legible and in place See Decals sect
4. Genie Operators Manual with Maintenance Information Second Edition First Printing Part No 82799 DPL 25S DPL 30S DPL 35S Operators Manual Second Edition First Printing oI 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 0 ccccccccceeeeeeeeeeeeeeeeeecaeeeeeeeeeeseaaeeeseas 1 CONOIS aona EW Aaaa 7 E a n o P A E TA 8 Pre operation Inspection eeseesseseseirrsererrrersrrenns 9 Maintenance cccecee cece cee eeeeeeeeeeeenaaeeaeeaeceeeeeeeees 11 Function Tests ceeeeeeecececeeceeeeeeeeeeeeeeeeeeeeeeees 14 Workplace Inspection e sseeaa aaa aaaaaaaznnacai 17 Operating Instructions eeeaaaaaaaaaaasanaaccea 18 Battery and Charger Instructions 12122222111112 21 Transport and Lifting Instructions 1 22 DeGalS EEE A az Aaaa Eta 24 Specifications eooeeea aaa aaa aaa aaa cca 28 Contact us Copyright 1996 by Genie Industries First Edition Fifth Printing April 2002 Internet http www geniein ries com ig Je Hp
5. battery fill tube Do not overfill 4 Install the vent caps Check the Hydraulic Oil Level AC and DC Models Maintaining the hydraulic oil at the proper level is essential to machine operation Improper hydraulic oil levels can damage hydraulic components Daily checks allow the inspector to identify changes in oil level that might indicate the presence of hydraulic system problems 1 Be sure the platform is fully lowered 2 Check the sight gauge on the side of the hydraulic reservoir Result The hydraulic oil level should be visible in the middle of the sight gauge Do not overfill Hydraulic oil specifications Hydraulic oil type Chevron Rykon Premium MV equivalent 12 Genie DPL Super Series PartNo 82799 Second Edition First Printing Operators Manual E MAINTENANCE Scheduled Maintenance Maintenance performed quarterly annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service Part No 82799 Genie DPL Super Series 13 Operator s Manual Second Edition First Printing Function Tests Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this oper
6. 40466 28174 or 41216 28235 97530 37118 62939 40514 62940 40469 28174 82783 or 28235 38142 Serial Plate 27868 82366 82993 27857 82993 ee 40516 40465 40467 62050 or 62051 82993 82992 40466 or 62052 82992 27865 Part No 82799 Genie DPL Super Series 25 Operators Manual Second Edition First Printing E DECALS Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place Part No Description Quantity 28174 Label Power to Platform 230V 2 28235 Label Power to Platform 115V 2 62050 Cosmetic DPL 25S 2 62051 Cosmetic DPL 30S 2 62052 Cosmetic DPL 35S 2 62939 Cosmetic Genie Logo 2 62940 Cosmetic DPL Super Series Logo 2 82481 Danger Battery Safety 1 82487 Label Read the Manual 2 82783 Interlock Display AC and DC Models 1 82801 Label Manual Lowering Lever 1 82802 Label Control Activate 1 82803 Danger Max Capacity 272 kg 1 82804 Danger Max Capacity 340 kg 1 82805 Danger Maximum Manual Force 82806 Label 51 cm Outriggers CE 4 82807 Label 66 cm Outriggers CE 4 82879 Label Platform Overload 1 82992 Label Wheel Load 4 82993 Label Outrigger Load 4 26 Genie DPL Super Series Part No 82799 Second Edition First Printing eee
7. each use inspect for damage Replace damaged items before operating w Lifting Hazard The battery weighs 105 Ibs 48 kg Use the appropriate number of people and proper lifting techniques when lifting the battery 6 Genie DPL Super Series PartNo 82799 Second Edition First Printing Operators Manual Controls Ground Controls Platform Controls O 2 AN O O da z Red Emergency Stop button DC models Low battery indicator light Key switch Power light Outrigger interlock display lights four Auxiliary platform lowering button R N Low battery indicator light for auxiliary lowering Control activate button ON O Up Down switch PartNo 82799 Genie DPL Super Series 7 Operators Manual Second Edition First Printing Legend OOO OO 9 3 48 CD 8 GD GD 18 D 1 Platform end guard rail 2 Platform side guard rail 3 Manual storage container 4 Platform controls 5 AC outlet 6 Guardrail lifting arm 7 Platform entry gate 8 Platform end gate latch 9 Platform 10 Interlock display 11 AC models Circuit breaker 12 Platform entry ladder 13 AC models Power supply for machine DC models AC power to
8. gt ge eingustigs ce Second Edition First Printing November 2003 e mail techpub genieind com 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 PartNo 82799 Second Edition First Printing Operators Manual Safety Rules Danger Failure to obey the instructions and safety rules in this manual will cause death or serious injury Do Not Operate Unless M 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 M You read understand and obey the manufacturer s instructions and safety rules safety and operator s manuals and machine decals MT You read understand and obey employer s safety rules and worksite regulations M You read understand and obey all applicable governmental regulations M You are properly trained to safely operate the machine MI The first time this machine is set up for use a breather cap is installed See Pre operation Inspection sect
9. or more of the symbols appear at the beginning of amaintenance procedure it conveys the meaning Observe and Obey M Only routine maintenance items specified in this below manual shall be performed by the operator M Scheduled maintenance inspections shall be U Indicates that tools will be required to completed by qualified service technicians M performthis procedure according to the manufacturer s specifications and the requirements specified in the responsibilities manual Indicates that new parts will be required to A perform this procedure PartNo 82799 Genie DPL Super Series 11 Operator s Manual Second Edition First Printing MAINTENANCE Check the Battery DC Models Proper battery condition is essential to good machine performance and safe operation Improper fluid levels or damaged cables and connections can resultin component damage and hazardous conditions Electrocution hazard Contact with AWARNING hot or live circuits could result in death or serious injury Remove all rings watches and other jewelry Bodily injury hazard Batteries AWARNING contain acid Avoid spilling or contacting battery acid Neutralize battery acid spills with baking soda and water Perform this test after fully charging the batteries 1 Puton protective clothing and eye wear 2 Remove the battery vent caps 3 Check the battery acid level If needed replenish with distilled water to the bottom of the
10. 10 6 m 78 in 1 98 m 813 4 in 2 07 m 31 2 in 80 cm 89 x 73 in 2 3x1 9m 72 x 27 2 in 1 83 m x 69 9 cm 220V or 115V 12V 100 psi 6 9 bar 80 cfm 2 26 m min See Serial Plate ANSI 750 Ibs 340 kg CE 750 Ibs 340 kg CSA 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 Wheel load maximum 419 Ibs 190 kg Outrigger load maximum 581 Ibs 264 kg Continuous improvement of our products is a Genie policy Product specifications are subject to change without notice or obligation 28 Genie DPL Super Series Part No 82799 Genie North America Phone 425 881 1800 Toll Free USA and Canada 800 536 1800 Fax 425 883 3475 Genie Australia Pty Ltd Phone 61 7 3375 1660 Fax 61 7 3375 1002 Genie Scandinavia Phone 46 31 3409612 Fax 46 31 3409613 Genie China Phone 86 21 53852570 Fax 86 21 53852569 Genie France Phone 33 0 2 37 26 09 99 Fax 33 0 2 37 26 09 98 Genie Malaysia Phone 65 98 480 775 Fax 65 67 533 544 Genie Iberica Phone 34 93 579 5042 Fax 34 93 579 5059 Genie G rmany Phone 49 0 4202 88520 Fax 49 0 4202 8852 20 Genie Japan Phone 81 3 3453 6082 Fax 81 3 3453 6083 Genie K
11. 84 1cm MI Only qualified riggers should rig and lift the machine MI Be sure the crane capacity loading surfaces and straps or lines are sufficient to withstand the machine weight See the serial plate for the machine weight Lifting Instructions Fully lower the platform Be sure the controls and covers are secure Remove all loose items on the machine a 7 Y Axis 1 Determine the center of gravity of your machine ae using the table and the picture on this page X Axis Attach the rigging only to the designated lifting points on the machine There are two lifting points on each side of the machine Adjust the rigging to prevent damage to the machine and to keep the machine level p p ZAxis PartNo 82799 Genie DPL Super Series 23 Operator s Manual Second Edition First Printing Decals Inspection for Decals with Words Determine whether the decals on your machine have words or symbols Use the appropriate inspection to verify that all decals are legible and in place Part No Description Quantity Part No Description Quantity 27857 Caution Component Damage 1 41216 Notice Max Capacity 750 Ibs 340 kg 27865 Label Bubble Level 2 A NA i 27868 Danger Tip over Relief 1 1128 A e POSH 1 28174 Label
12. ING Orange used to indicate the presence of a potentially A hazardous situation which if not avoided could result in death or serious injury gt Yellow with safety alert symbol ACAUTION used to indicate the presence of a 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 CAUTION Green used to indicate operation or maintenance information PartNo 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 e 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 24 lighted tobacco away from AM the battery Charge the battery ina 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 Electrocution Hazards Connect the charger to a grounded AC circuit only Do not expose the battery or the charger to water or rain Before
13. Power to Platform 230V 2 62050 Cosmetic DPL 25S 2 28176 Notice Missing Manuals 1 62051 Cosmetic DPL 30S 2 28235 Label Power to Platform 115V 2 62052 Cosmetic DPL 35S 2 28236 Warning Failure To Read 1 62939 Cosmetic Genie Logo 2 97118 Warning Bodily Injury Mazara 1 62940 Cosmetic DPL Super Series Logo 2 38142 Label Circuit Breaker AC models 1 82366 Label Chevron Rykon 1 40469 Notice Manua TE OW SIG aver 1 82783 Interlock Display AC and DC Models 1 40466 Danger General Safety 2 82802 Label Control Activate 1 40467 Notice Operating Instructions Ground 1 82992 Label Wheel Load 4 40468 Notice Operating Instructions Platform 1 82993 Label Outrigger Load 4 40469 Danger Tipover Fal mazara 1 97530 Notice Maximum Manual Force 1 40514 Warning Guard Rail Lock Handle 2 40515 Notice Max Capacity 600 Ibs 272 kg ANSI CSA 1 40516 Danger Notice Battery Safety amp Charger Instructions 1 24 Genie DPL Super Series Part No 82799 Second Edition First Printing Operators Manual eee DECALS 28236 41263 or 40468 82802 28176 40515 or
14. V to 750KV 35 10 67 750KV to 1000KV 45 13 72 Allow for platform movement electrical line sway or sag and movement due to strong or gusty winds Do not use the machine as a ground for welding Do not operate the machine during lightning or storms Do not operate an AC powered machine ora 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 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 4 Genie DPL Super Series PartNo 82799 Second Edition First Printing Operator s Manual Improper Use Hazard Do not leave the machine unattended unless the key is removed to secure from u
15. achine using only the outriggers 14 Genie DPL Super Series PartNo 82799 Second Edition First Printing Operator s Manual 6 Be sure that all four interlock display lights at the ground controls are on 7 Use the bubble level and adjust the leveling jacks until the machine base is level SS 8 Rotate the platform guard rail locking handle and rotate the platform side guard rail to the upright position Be sure the side guard rail locks in place Repeat for the other side 9 Pull the ladder lock pins and rotate the ladder down Be sure the ladder locks in place 10 Climb the ladder to enter the platform Close and latch the platform entry gate and the platform end guard rail FUNCTION TESTS Test Emergency Stop 11 Twist to release the red Emergency Stop button at the platform controls 12 Push in the red Emergency Stop button at the ground controls to the off position 13 Push and hold the control activate button and rotate the up down switch in the direction of intended travel Result The up down function should not operate 14 Push in the red Emergency Stop button at the platform controls to the off position 15 Pull out the red Emergency Stop button at the ground controls to the on position 16 Push and hold the control activate button and rotate the up down switch in the direction of intended travel Result The up down function should not operate Part No 82799
16. 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 PartNo 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 Minimum Safe Approach Distance Voltage Phase to Phase Feet Meters 0 to 300V Avoid Contact 300V to 50KV 10 3 05 50KV to 200KV 15 4 60 200KV to 350KV 20 6 10 350KV to 500KV 25 7 62 500K
17. ator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform the function tests prior to use Know and understand the function tests before going on to the next section 4 Inspect the workplace 5 Only use the machine as it was intended Fundamentals The function tests are designed to discover any malfunciions before the machine is put into service The operator must follow the step by step instructions to test all machine functions A malfunctioning machine must never be used If malfunctions are discovered the machine must be tagged and removed from service Repairs to the machine may only be made by a qualified service technician according to the manufacturer s specifications After repairs are completed the operator must perform a pre operation inspection and function tests before putting the machine into service Function Tests 1 Position the machine directly below the desired workarea 2 Connecttothe appropriate power source DC models Connect the battery pack AC models Connect to a grounded 15A AC power supply Use a 12 gauge 3 3 mm 3 wire grounded extension cord no longerthan 50 feet 13 m Insert the key and turn to platform control Pull out the red Emergency Stop button at the ground controls to the on position Result The power light should come on 5 Install each outrigger and adjust the leveling jacks to level the machine Level the m
18. e battery 20 Genie DPL Super Series PartNo 82799 Second Edition First Printing Operator s Manual Battery and Charger Instructions Observe and Obey M Do not use an external charger or booster battery MI Charge the battery in a well ventilated area MI Use the proper AC input voltage for charging as indicated on the charger MI Use only Genie authorized battery and charger To Charge Battery 1 Slide open the battery cover to access the charger and the battery The cover must remain open for the entire charging cycle 2 Remove the battery vent caps and check the battery acid level If necessary add only enough distilled water to cover the plates Do not overfill prior to the charge cycle Install the battery vent caps 4 Connectthe battery charger to a grounded outlet ofproper voltage and amperage as indicated on the battery charger BRE OPERATINGINSTRUCTIONS 5 Set the 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 6 The charger will automatically shut off at the end of the set period Note If the ammeter drops to 3A or less within the first 15 minutes the battery is fully charged 7 Check the battery acid level when the charge cycle is complete Replenish with distilled water to the bottom of the fill tube Dry Battery Filling And Charging Instruct
19. e the platform slightly 34 Activate the manual lowering lever Result The platform should lower 16 Genie DPL Super Series PartNo 82799 Second Edition First Printing Operators Manual Workplace Inspection Workplace Inspection Be aware of and avoid the following hazardous situations Do Not Operate Unless MI You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection 3 Always perform function tests prior to use 4 Inspectthe workplace Know and understand the workplace inspection before going on to the next section 5 Only use the machine as it was intended Fundamentals The workplace inspection helps the operator determine if the workplace is suitable for safe machine operation It should be performed by the operator prior to moving the machine to the workplace It is the operator s responsibility to read and remember the workplace hazards then watch for and avoid them while moving setting up and operating the machine drop offs or holes bumps floor obstructions or debris slopes that exceed the machine s leveling capability unstable or slippery surfaces overhead obstructions and high voltage conductors hazardous locations inadequate surface support to withstand all load forces imposed by the machine wind and weather conditions the presence of una
20. he platform 2 Lower the platform side guard rails the platform end guard rail and the platform entry gate Secure the side guard rails with the tie down strap 3 Push in the red Emergency Stop buttons at the ground and platform controls turn the key switch to the off position and remove the key 4 Inspect the entire machine for loose or unsecured items 5 Use the forklift pockets located on the sides of the machine Winching the Machine onto a Flatbed Truck 1 Lower the platform 2 Lower the platform side guard rails the platform end guard rail and the platform entry gate Secure the side guard rails with the tie down strap 3 Push in the red Emergency Stop buttons at the ground and platform controls turn the key switch to the off position and remove the key 4 Inspect the entire machine for loose or unsecured items 5 Connect the cable to the winching point tie down points located on the base 6 Carefully winch the machine onto the truck 7 Secure the machine base and masts to the transport vehicle Use chains or straps of ample load capacity 22 Genie DPL Super Series PartNo 82799 Second Edition First Printing Operators Manual TRANSPORT AND LIFTING INSTRUCTIONS Center of gravity X Axis Y Axis Z Axis DPL 25 40 5 in 13 15 in 32 9 in 1 03 m 34 3cm 83 6cm DPL 30 40 5 in 13 15 in 33 in 1 03 m 34 3cm 83 8 cm DPL 35 40 5 in 13 15 in 33 11 in Observe and Obey 1 03m 34 3cm
21. ion U Check for battery fluid leaks and proper fluid level Add distilled water if needed See Maintenance section i Check for hydraulic oil leaks and proper oil level Add oil if needed See Maintenance section Check the following components or areas for damage improperly installed or missing parts and unauthorized modifications U Electrical components and wiring U Coil cord if equipped U Hydraulic power unit hoses fittings and cylinders L Manual lowering lever L Platform end guard rail platform side guard rails and platform entry gate Guard rail lock handles Sequencing cables and pulleys Lifting chains and idler wheels Nuts bolts and other fasteners LLL O Mast and mast braces LI Breather cap Li Outriggers leveling jacks and footpads U Guard rail lift arm i Platform entry ladder Check entire machine for Li Dents ordamage 0 Corrosion or oxidation Li Crack in welds or structural components U Inspect and clean battery terminals and all battery cable connections U Be sure that all structural and other critical components are present and all associated fasteners and pins are in place and properly tightened 10 Genie DPL Super Series Part No 82799 Second Edition First Printing Operators Manual Maintenance Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions When one
22. ion for breather cap instructions Part No 82799 Genie DPL Super Series 1 Operator s Manual Second Edition First Printing SAFETY RULES Tip over Hazards if ri Do not adjust or remove the outriggers while the platform is occupied or raised 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 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 l Do not push off or pull toward any object outside the platform Maximum allowable manual force 90 Ibs 400 N Do not use the machine on a moving or mobile surface or vehicle Do not operate the machine in strong or gusty winds Do not increase the surface area of the platform or the load Increasing the area exposed to the wind will decrease machine stability Occupants equipment and materials shall not exceed the maximum platform capacity Maximum capacity DPL 25S ANSI and CE 750 Ibs 340
23. ions 1 Remove the battery vent caps and permanently remove the plastic seal from the battery vent openings 2 Fill each cell with battery acid electrolyte until the level is sufficient to cover the plates Do not fill to the maximum level until the battery charge cycle is complete Overfilling can cause battery acid to overflow during charging Neutralize battery acid spills with baking soda and water 3 Install the battery vent caps 4 Charge the battery for seven hours or until the charger ammeter reads 3A or less 5 Check the battery acid level when the charge cycle is complete Fill with distilled water to the bottom of the fill tube PartNo 82799 Genie DPL Super Series 21 Operator s Manual Second Edition First Printing Transport and Lifting Instructions Observe and Obey M Common sense and planning must be applied to control the movement ofthe machine when lifting it with a crane or forklift MI The transport vehicle must be parked on a level surface MI The transport vehicle must be secured to prevent rolling while the machine is being loaded M Vehicle capacity loading equipment and surfaces must be capable of supporting the machine weight See the serial plate for the machine weight M The machine must be secured to the transport vehicle with chains or straps of ample load capacity O PE Mr TE A I ra SE Loading the Machine With a Forklift 1 Lowert
24. kg CSA 600 Ibs 272 kg Maximum occupants 2 Maximum capacity DPL 30S ANSI and CE 750 Ibs 340 kg CSA 600 Ibs 272 kg Maximum occupants 2 2 Genie DPL Super Series Part No 82799 Second Edition First Printing Operator s Manual Maximum capacity DPL 35S ANSI and CE 600 Ibs 272 kg CSA 500 Ibs 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 SAFETY RULES 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
25. n First Printing E Setup 1 Position the machine directly below the desired work area Connectto an appropriate power source DC models Connect the battery pack AC models Connect to a grounded 15A AC power supply Use a 12 gauge 3 3 mm 3 wire grounded extension cord no longer than 50 feet 13 m 3 Insert the key and turn to platform control Pull out the red Emergency Stop button at the ground controls to the on position Be sure the power light is on Install the outriggers and adjust the leveling jacks to level the machine Use the bubble level to be sure the machine is level Be sure that all four interlock display lights at the ground controls are on Pull down on the platform guard rail locking handle and rotate the platform side guard rail to the upright position Be sure the side guard rail locks in place Repeat for the other side Pull the ladder lock pins and rotate the ladder down Be sure the ladder locks in place Climb the ladder to enter the platform Close and latch the platform entry gate and the platform end guard rail Operator s Manual OPERATING INSTRUCTIONS Emergency Stop 1 Push in the red Emergency Stop button at the platform controls or at the ground controls to stop the up function Platform Raise and Lower 1 Twist to release the red Emergency Stop button 2 Push and hold the control activate button and rotate the up down switch in the desired direction of t
26. nauthorized 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 Genie DPL 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 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 SAFETY RULES 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 ADANGER Red used to indicate the presence of an imminently A hazardous situation which if not avoided will result in death or serious injury AWARN
27. orea Phone 82 25 587 267 Fax 82 25 583 910 Genie U K Phone 44 0 1476 584333 Fax 44 0 1476 584334 Genie Brasil Phone 55 11 41 665 755 Fax 55 11 41 665 754 Genie Mexico City Phone 52 55 5666 5242 Fax 52 55 5666 3241 Genie Holland Phone 31 10 220 7911 Fax 31 10 220 6642
28. platform 14 Platform entry ladder lock pin 15 Outrigger with leveling jack 16 Forklift pocket 17 Bubble level 18 Sequencing cable S O OO O 19 Transporttie down 20 Manuallowering lever 21 Battery charger plug in 22 Base 23 Caster with swivel lock 24 Base cover 25 Mast 26 Steerhandle 27 Platform guard rail locking handle Genie DPL Super Series PartNo 82799 Second Edition First Printing Operator s Manual Pre operation Inspection Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform a pre operation inspection Know and understand the pre operation inspection before going on to the next section 3 Always perform the function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended Breather Cap AC amp DC Models Component damage will occur if the machine is operated without a breather cap The first time this machine is set up for use the pipe plug in the hydraulic reservoir under the battery cover must be removed and permanently replaced with a breather cap A breather cap is supplied and can be found in an envelope taped to the mast Fundamentals It is the responsibility of the operator to perform a pre operation inspection and routine maintenance
29. ravel PartNo 82799 Genie DPL Super Series 19 Operators Manual Second Edition First Printing OPERATINGINSTRUCTIONS Manual Lowering 1 Activate the manual lowering lever Auxiliary Platform Lowering AC amp DC Models 1 Turn the key switch to ground control Pull out the red Emergency Stop button to the on position 2 Activate the auxiliary platform lowering button at the ground controls Platform Overload Indicator Light if equipped Light flashing indicates the platform is overloaded and no functions will operate An alarm will sound at the platform controls The machine must be reset before functions will operate To reset the machine 1 Remove load from the platform 2 Push in then twist to release the red Emergency Stop button at the platform controls 3 Operate the machine If the load in the platform is below the rated capacity the machine will operate Fall Protection Personal fall protection equipment PFPE is not required when operating this machine If PFPE is required by job site or employer rules the following shall apply All PFPE must comply with applicable governmental regulations and mustbe inspected and used in accordance with the manufacturer s instructions After Each Use 1 Select a safe storage location firm level surface weather protected clear of obstruction and traffic 2 Remove the key to secure from unauthorized use 3 DC models Recharge th
30. uthorized personnel other possible unsafe conditions PartNo 82799 Genie DPL Super Series 17 Operator s Manual Second Edition First Printing Operating Instructions Do Not Operate Unless M You learn and practice the principles of safe machine operation contained in this operator s manual 1 Avoid hazardous situations 2 Always perform apre operation inspection 3 Always perform function tests prior to use 4 Inspect the workplace 5 Only use the machine as it was intended Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation It is the operator s responsibility to follow all the safety rules and instructions in the operator s safety and responsibilities manuals Using the machine for anything other than lifting personnel along with their tools and materials to an aerial work site is unsafe and dangerous Only trained and authorized personnel should be permitted to operate a machine If more than one operator is expected to use a machine at different times in the same work shift they must all be qualified operators and are all expected to follow all safety rules and instructions in the operator s safety and responsibilities manuals That means every new operator should perform a pre operation inspection function tests and a workplace inspection before using the machine 18 Genie DPL Super Series Part No 82799 Second Editio
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