Genie DPL-25S Service Manual
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Genie DPL-25S Service Manual

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See also: Operator's Manual
Service Manual
DPL-25S
DPL-30S
DPL-35S
Super Series
Serial Number Range
from 1596-101
to 1501-915
from DPL02-916
to DPL16-2311
from DPL16G-2312
to DPL16G-2599
from DPLG-2600
Part No. 40462
Rev A6
September 2016

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Summary of Contents for Genie DPL-25S

  • Page 1 Service Manual Serial Number Range DPL-25S from 1596-101 to 1501-915 from DPL02-916 DPL-30S to DPL16-2311 from DPL16G-2312 to DPL16G-2599 DPL-35S from DPLG-2600 Super Series Part No. 40462 Rev A6 September 2016...

  • Page 2: Introduction

    Machine Design Life Unrestricted with proper opeation, inspection and scheduled maintenance. Technical Publications Genie has endeavored to deliver the highest degree of accuracy possible. However, continuous improvement of our products is a Genie policy. Therefore, product specifications are subject to change without notice.

  • Page 3: From

    Maximum Wind Speed: Indoor: Outdoor: Gradeability: Maximum allowable side force: Maximum platform height: 1 Model 4 Serial number (stamped on chassis) 2 Facility code 5 Serial label 3 Sequence number Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series...
  • Page 4 September 2016 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.
  • Page 5 Be sure to properly dispose of old oil or placing loads. Always wear approved steel-toed other fluids. Use an approved container. shoes. Please be mindful of the environment. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series...

  • Page 6: Table Of Contents

    Check the Sequencing Cables ................ 4 - 4 A-10 Check the Interlock System for Proper Operation ........... 4 - 5 A-11 Test the Power and Function Controls ............4 - 5 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...
  • Page 7 Platform Will Not Hold In Up Position ............5 - 22 Power Unit Will Not Lift Rated Load .............. 5 - 23 Auxiliary Platform Lowering Will Not Operate ..........5 - 24 Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series...
  • Page 8 Electrical Schematic - DPL Super Series AC - CE Models (after serial number DPL07-1562) ................6 - 12 Hydraulic Schematic - ANSI ................... 6 - 13 Hydraulic Schematic - CE ..................6 - 14 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462 viii...
  • Page 9 How to Adjust the Glide Pads ................ 7 - 19 How to Inspect the Lifting Chains ..............7 - 20 Platform How to Remove the Platform ................. 7 - 22 How to Test the Contactors ................7 - 22 Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series...

  • Page 10: Specifications

    September 2016 Section 2 - Specifications Specifications Model DPL-25S DPL-30S DPL-35S 31 ft 4 in 36 ft 40 ft 9 in Height, 9.5 m 11 m 12.4 m maximum working Height, 25 ft 4 in 30 ft 34 ft 9 in maximum platform 7.7 m...

  • Page 11: Bolt Torque Specification

    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 DPL-25S • DPL-30S • DPL35S Super Series Part No. 40462...

  • Page 12: Scheduled Maintenance Inspections

    Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with your employer, jobsite and governmental regulations and requirements. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 3 - 1...
  • Page 13 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 DPL-25S 30S • DPL-35S Super Series Part No. 40462...
  • Page 14 Check the Battery - DC Models Clean and Lubricate the Columns Test the Lifting Capacity Test the Power To Platform Operation Adjust the Sequencing Cables Inspect for Proper Outrigger Length Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 3 - 3...
  • Page 15 Complete all procedures in Table A and Table B Inspect and Lubricate the Casters and Wheels Inspect the Mast Assembly for Wear Lubricate the Lifting Chains Replace the Hydraulic Oil Replace the Auxiliary Platform Lowering Batteries 3 - 4 DPL-25S 30S • DPL-35S Super Series Part No. 40462...

  • Page 16: Maintenance Inspection Report

    After repair, place a check in the “R” box. Legend Y = yes, acceptable N = no, unacceptable R = repaired Comments Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 3 - 5...
  • Page 17 Section 3 - Scheduled Maintenance Inspections September 2016 Dealer Tools are New parts service required required suggested This page intentionally left blank. 3 - 6 DPL-25S 30S • DPL-35S Super Series Part No. 40462...

  • Page 18: Scheduled Maintenance Procedures

    Indicates that a specific result is expected after damaged or malfunctioning machine. performing a series of steps. Repair any machine damage or malfunction before operating machine. Keep records on all inspections for three years. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 4 - 1...

  • Page 19: Inspect The Operator's And Responsibility Manuals

    Section 4 - Scheduled Maintenance Procedures September 2016 Table A Procedures 1 Refer to the Decals section in the Genie DPL Super Series Operator's Manual and use the Inspect the Operator’s and decal list and illustrations to determine that all Responsibility Manuals decals and placards are in place.

  • Page 20: Check For Hydraulic Leaks

    1 Raise the platform slightly. 2 Disconnect the power source from the machine. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 4 - 3...

  • Page 21: Inspect The Battery And Battery Charger - Dc Models

    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. 4 - 4 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 22: Check The Interlock System For Proper Operation

    Result: Up/down function should not operate. Confirm that the corresponding light is on. 5 Repeat steps 3 and 4 for each of the remaining outriggers. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 4 - 5...

  • Page 23: Inspect The Lifting Chains And Idler Wheels

    (hidden from view) termination rod (hidden from view) column 4 - 6 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 24: Inspect The Electrical Wiring

    • Hydraulic power unit • All external machine electrical cables • Inside of the platform control box • DC models: battery and charger • AC power supply cord Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 4 - 7...

  • Page 25: Check The Lifting Chain Adjustments

    8 Observe charger ammeter after one hour to confirm charging amperage has dropped. Note: If amperage does not drop, the battery is bad and needs to be replaced. 4 - 8 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 26: Clean And Lubricate The Columns

    3 If needed, lubricate the inner and outer channels of the columns with a dry silicone spray or silicone wax (Genie part no. 90337). Note: 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.

  • Page 27: Test The Power-To-Platform Operation

    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. 4 - 10 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 28: Inspect For Proper Outrigger Length

    66 cm DPL-35S 26 inches 66 cm DPLS Models (models that meet CSA) DPL-25S inches 77 cm DPL-30S 36 inches 91 cm DPL-35S 36 inches 91 cm Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 4 - 11...

  • Page 29: Inspect And Lubricate The Casters

    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). 4 - 12 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 30: Lubricate The Lifting Chains

    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 new one. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 4 - 13...

  • Page 31: Replacing The Auxiliary Platform Lowering Batteries

    5.6 liters 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 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 32: Troubleshooting Flow Charts

    Do not 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 DPL-25S • DPL-30S • DPL-35S Super Series 5 - 1...
  • Page 33 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. 5 - 2 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 34: Power Light Will Not Turn On - Ac Models

    Emergency Stop brown transformer wire. button and the transformer OR replace the transformer because 110V AC of a faulty thermal fuse. Continued on the next page. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 5 - 3...
  • Page 35 If there is voltage on both sides of the fuse and the power light is not turned on, replace P.C. board OR consult Genie Industries Service Department. 5 - 4 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 36: Power Light Will Not Turn On - Dc Models

    3 pole terminal strip (J2). terminal strip (J2) back to the Emergency Stop button N.C. contact and repair open in the wire. 12V DC Continued on the next page. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 5 - 5...
  • Page 37 If there is voltage on both sides of the fuse and the power light is not turned on, replace P.C. board OR consult Genie Industries Service Department. 5 - 6 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 38: Interlock Lights Will Not Turn On

    0V DC connected together with a because of open circuit in wire nut in the ladder-end black wire. junction box. 12V DC Continued on the next page. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 5 - 7...
  • Page 39 0V DC because of open circuit in wire nut located in the black wire. steer handle-end junction box. 12 V DC Continued on the next page. 5 - 8 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...
  • Page 40 13 pole terminal strip (J1) in the ground control box. 12V DC Replace P.C. board OR consult Genie Industries Service Department. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 5 - 9...

  • Page 41: Machine Will Not Lift - Ac Models

    Replace control activate holding control activate switch N.O. contact switch, check for power block. at terminal 3 of control activate switch contact. 12V DC Continued on the next page. 5 - 10 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...
  • Page 42 Put Neg. lead (J1). of the voltage meter on terminal 0 green/yellow 12V DC wire. Repair open circuit in 12V DC green/yellow wire. Continued on the next page. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 5 - 11...
  • Page 43 N.O. damaged contacts. terminals (white and black wires) on the motor contactor. 110V AC Check the motor wiring OR consult Genie Industries Service Department. 5 - 12 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 44: Machine Will Not Lift, But Power Unit Will Operate - Ac Models

    12V DC pressure. Replace defective N.O. less than 1800 psi contact block for down function in platform control box. Continued on the next page. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 5 - 13...
  • Page 45 Adjust the pressure relief valve. See Repair procedure, How to Adjust the Pressure Relief Valve, and then perform pressure test again. less than 1800 psi Consult Genie Industries Service Department. 5 - 14 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 46: Machine Will Not Lift - Dc Models

    Replace the control activate switch, check for activate switch N.O. power at terminal 3 of the contact block. control activate switch contact. 12V DC Continued on the next page. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 5 - 15...
  • Page 47 11 (white wire) of the 13 pole terminal strip (J1) in the ground control box. 12V DC Continued on the next page. 5 - 16 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...
  • Page 48 Replace the motor across the 12 volt motor. brushes OR the 12 volt DC motor. continuity Check the condition of the battery OR consult Genie Industries Service Department. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 5 - 17...

  • Page 49: Machine Will Not Lift, But Power Unit Will Operate - Dc Models

    12V DC Replace defective N.O. less than 1800 psi contact block for down function in the platform control box. Continued on the next page. 5 - 18 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...
  • Page 50 Adjust the pressure relief valve. See Repair procedure, How to Adjust the Pressure Relief Valve and then perform pressure test again. less than 1800 psi Consult Genie Industries Service Department. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 5 - 19...

  • Page 51: Machine Will Not Lower - Up Function Operates

    Replace the red jumper 0V DC N.O. contact block wire because of an open located in the platform circuit. control box. 12V DC Continued on the next page. 5 - 20 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...
  • Page 52 Inspect pin 5 for a defect in the quick disconnect located under the ground control box OR replace the 18/7 cable because of open circuit in the yellow wire. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 5 - 21...

  • Page 53: Platform Will Not Hold In Up Position

    Remove the lifting cylinders and replace damaged piston seal OR contact Genie Industries Service Department. 5 - 22 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 54: Power Unit Will Not Lift Rated Load

    See valve. See Repair incorrect Maintenance procedure, procedure, How to Adjust Test the Lifting Capacity. the Pressure Relief Valve. correct Consult Genie Industries Service Department. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 5 - 23...

  • Page 55: Auxiliary Platform Lowering Will Not Operate

    OR repair the base work and not from the red wire from terminal 9a ground control box. of 13 pole terminal strip (J1). 5 - 24 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...
  • Page 56 Be sure that all necessary tools and test equipment are available and ready for use. problem still exists Return to Inspect Perform service and test repair problem solved Part No. 404632 DPL-25S • DPL-30S • DPL-35S Super Series 6 - 1...

  • Page 57: Electrical Legend

    Circuit Breaker Connection with no terminal 12V Battery(s) Connector Relay Power Relay (function pump) PLATFORM MODE Flashing Beacon F11 Fuse SWITCH Horn or Alarm BASE MODE Key Switch 6 - 2 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 58: Hydraulic Legend

    Section 6 • Schematics Hydraulic Legend 2 position 2 way directional valve Motor Pump Filter Pressure compensated Solenoid operated Adjustable relief valve flow control dump valve Cylinder Check Valve Part No. 404632 DPL-25S • DPL-30S • DPL-35S Super Series 6 - 3...
  • Page 59 Section 6 • Schematics September 2016 WIRE COLOR LEGEND Color Description Blue Black Note: Use this legend GN/YL Green/Yellow  Orange for the schematic on the opposing page. White Yellow 6 - 4 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 60: Electrical Schematic - Dpl Super Series Dc - All Models

    September 2016 Section 6 • Schematics Electrical Schematic DPL Super Series DC Models (before serial number DPL07-1499 Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 6 - 5...

  • Page 61: (Before Serial Number Dpl07-1499)

    Section 6 • Schematics September 2016 Electrical Schematic DPL Super Series DC Models (before serial number DPL07-1499) ABBREVIATION LEGEND Item Description Battery B2 = 12V Battery B4 = 8 AA Batteries Power supply AC Enclosure EN1 = Platform control box EN2 = Ground control box EN4 = Power to platform GFCI receptacle Fuse, 175 AMP...

  • Page 62: (After Serial Number Dpl07-1498)

    POWER UNIT MOTOR WARNING CONTACTOR LIGHT BATTERY 12V DC OPTIONAL WARNING LIGHT MOTOR DESCENT ALARM BATTERY 175 AMP FUSE CHARGER NON U.S. PLUGS N.O. DUMP VALVE ES0074_J INPUT Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 6 - 6...

  • Page 63: (After Serial Number Dpl07-1498)

    Section 6 • Schematics September 2016 Electrical Schematic DPL Super Series DC Models (after serial number DPL07-1498) Note: Use these 2  legends for the schematic on the opposing page.
  • Page 64 PLATFORM OVERLOAD LIGHT PRESSURE SWITCH BATTERY 12V DC OPTIONAL WARNING LIGHT MOTOR DESCENT ALARM BATTERY 175 AMP FUSE CHARGER NON U.S. PLUGS N.O. DUMP VALVE ES0074_J INPUT Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 6 - 7...
  • Page 65 Section 6 • Schematics September 2016 Electrical Schematic DPL Super Series DC CE Models (after serial number DPL07-1498) Note: Use this legend  for the schematic on the opposing page.

  • Page 66: Electrical Schematic - Dpl Super Series Ac - All Models

    September 2016 Section 6 • Schematics Electrical Schematic DPL Super Series AC Models (before serial number DPL07-1499) Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 6 - 8...
  • Page 67 Section 6 • Schematics September 2016 Electrical Schematic DPL Super Series AC Models (before serial number DPL07-1499) Note: Use these 2  legends for the schematic on the opposing page.

  • Page 68: (From Serial Number Dpl07-1499 To Dpl07-1562)

    N.O. WARNING DUMP DUMP LIGHT J-BOX J-BOX VALVE VALVE OPTIONAL WARNING LIGHT *N10 MOTOR MOTOR DESCENT ALARM 110V AC 220 V AC MOTOR DETAIL MOTOR DETAIL ES0075_H Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 6 - 9...
  • Page 69 Section 6 • Schematics September 2016 Electrical Schematic DPL Super Series DC CE Models (from serial number DPL07-1499 to DPL07-1562) Note: Use these 2  legends for the schematic on the opposing page.

  • Page 70: (After Serial Number Dpl07-1562)

    N.O. WARNING DUMP DUMP LIGHT J-BOX J-BOX VALVE VALVE OPTIONAL WARNING LIGHT *N10 DESCENT ALARM MOTOR MOTOR 110V AC 220 V AC MOTOR DETAIL MOTOR DETAIL ES0075_M Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 6 - 10...

  • Page 71: Electrical Schematic - Dpl Super Series Ac - Ce Models

    Section 6 • Schematics September 2016 Electrical Schematic DPL Super Series AC Models (after serial number DPL07-1562) Note: Use these 2  legends for the schematic on the opposing page.
  • Page 72 J-BOX J-BOX VALVE VALVE DOWN OPTIONAL LIMIT SWITCH WARNING LIGHT *N10 CE ONLY MOTOR MOTOR DESCENT ALARM 110V AC 220 V AC MOTOR DETAIL MOTOR DETAIL ES0075_H Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 6 - 11...
  • Page 73 Section 6 • Schematics September 2016 Electrical Schematic DPL Super Series AC Models (from serial number DPL07-1499 to DPL07 -1562) Note: Use these 2  legends for the schematic on the opposing page.
  • Page 74 J-BOX J-BOX VALVE VALVE DOWN OPTIONAL LIMIT SWITCH WARNING LIGHT CE ONLY *N10 DESCENT ALARM MOTOR MOTOR 110V AC 220 V AC MOTOR DETAIL MOTOR DETAIL ES0075_M Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 6 - 12...
  • Page 75 Section 6 • Schematics September 2016 Electrical Schematic DPL Super Series AC CE Models (after serial number DPL07-1562)
  • Page 76 Section 6 • Schematics September 2016 Hydraulic Schematic DPL Super Series ANSI Models Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 6 - 13...
  • Page 77 Section 6 • Schematics September 2016 Hydraulic Schematic DPL Super Series ANSI Models...
  • Page 78 Section 6 • Schematics September 2016 Hydraulic Schematic DPL Super Series CE Models Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 6 - 14...
  • Page 79 Section 6 • Schematics September 2016 Hydraulic Schematic DPL Super Series CE Models...
  • Page 80 Indicates special operation or maintenance information. Indicates that a specific result is expected after performing a series of steps. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 7 - 1...

  • Page 81: Base Assembly

    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 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 82: How To Check The Resistance Of A Valve Coil

    2 Connect the leads from an ohmmeter to the valve coil terminals. Valve coil specifications 7.8 to 9.5 Ω Solenoid operated N.C. valve, 10V Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 7 - 3...

  • Page 83: Ground Control Box

    0.5 to 1.5 Ω red wire no. 1 to red wire no. 2 0.5 to 1.5 Ω yellow wire to black wire all other wire combinations no continuity (infinite Ω) 7 - 4 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...
  • Page 84 September 2016 Section 7 - Repair Procedures This page intentionally left blank. Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 7 - 5...

  • Page 85: Hydraulic Power Units

    Pump ..............0.5 to 0.6 gallons per minute at 2000 psi 1.89 to 2.27 liters per minute at 138 bar Motor seal ............Seals motor from contaminants Motor bearing ........... Aligns motor shaft into pump 7 - 6 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...
  • Page 86 September 2016 Section 7 - Repair Procedures HYDRAULIC POWER UNITS Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 7 - 7...

  • Page 87: Hydraulic Power Unit Components - Dc Models

    Pump ..............0.7 to 1 gallons per minute at 2000 psi 2.6 to 3.76 liters per minute at 138 bar Motor seal ............Seals motor from contaminants Motor bearing ........... Aligns motor shaft into pump 7 - 8 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...
  • Page 88 September 2016 Section 7 - Repair Procedures HYDRAULIC POWER UNITS Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 7 - 9...

  • Page 89: How To Remove The Hydraulic Power Unit - Ac Models

    How to Adjust the Pressure Relief Valve. Note: 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. 7 - 10 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 90: How To Remove The Hydraulic Pump

    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 DPL-25S • DPL-30S • DPL-35S Super Series 7 - 11...

  • Page 91: How To Adjust The Pressure Relief Valve

    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. 7 - 12 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 92: How To Check The Resistance Of A Valve Coil

    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 continuity (zero Ω) 2 large posts Part No. 40462 DPL-25S • DPL-30S • DPL-35S Super Series 7 - 13...

  • Page 93: Mast Assembly

    5 column number 1 column number 5 column idler wheel assembly number 2 column number 6 column idler wheel assembly number 3 column number 6 column 7 - 14 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...

  • Page 94: How To Remove A Lift Cylinder

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Part No. 40462 DPL-25S • DPL-30S • DPL-25S Super Series 7 - 15...

  • Page 95: How To Remove A Mast Assembly

    1 Remove the mast. See How to Remove a Mast Assembly. 2 Remove the mounting fasteners from the cylinder mounting plates. 7 - 16 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...
  • Page 96 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. Part No. 40462 DPL-25S • DPL-30S • DPL-25S Super Series 7 - 17...
  • Page 97 Replace worn shims if necessary. 3 Apply a generous amount of Boe-lube wax 16 Follow steps 14 and 15 for each remaining idler (Genie part number 90337) to the inside and wheel assembly. outside channels of each column. 17 Be sure that all of the idler wheel axle mounting 4 Slide the number 2 column into the number 1 fasteners are flush with the column.

  • Page 98: How To Adjust The Lifting Chains

    Note: Make sure glide pad bolts are adjusted evenly on each side to maintain squareness of the columns. Part No. 40462 DPL-25S • DPL-30S • DPL-25S Super Series 7 - 19...

  • Page 99: How To Inspect The Lifting Chains

    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. 7 - 20 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...
  • Page 100 Cracked Link Plates Replace both chains on plates for cracks. plate. that column section. Replace entire chain. Do not repair just the affected portion of the chain. Part No. 40462 DPL-25S • DPL-30S • DPL-25S Super Series 7 - 21...

  • Page 101: Platform

    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 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...
  • Page 102 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 DPL-25S • DPL-30S • DPL-25S Super Series 7 - 23...
  • Page 103 Section 7 - Repair Procedures September 2016 This page intentionally left blank. 7 - 24 DPL-25S • DPL-30S • DPL-35S Super Series Part No. 40462...
  • Page 104 California Proposition 65 WARNING Operating, servicing and maintaining this equipment, passenger vehicle or off-highway motor vehicle can expose you to chemicals including engine exhaust, carbon monoxide, phthalates, and lead, which are known to the State of California to cause cancer and birth defects or other reproductive harm.

This manual is also suitable for:

Dpl-35sDpl-30sSuper series

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