Service Manual
Serial Number Range
DPL-25S
DPL-30S
DPL-35S
Super Series
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
September 2016
Introduction
Important
Read, understand and obey the safety rules and
operating instructions in the appropriate operator's
manual on your machine before attempting any
maintenance or repair procedure.
This manual provides detailed scheduled
maintenance information for the machine owner and
user. It also provides troubleshooting and repair
procedures for qualified service professionals.
Basic mechanical, hydraulic and electrical skills are
required to perform most procedures. However,
several procedures require specialized skills, tools,
lifting equipment and a suitable workshop. In these
instances, we strongly recommend that
maintenance and repair be performed at an
authorized Genie dealer service center.
Compliance
Machine Classification
Group A/Type 1 as defined by ISO 16368
Machine Design Life
Unrestricted with proper opeation, inspection and
scheduled maintenance.
Technical Publications
Genie has endeavored to deliver the highest degree
of accuracy possible. However, continuous
improvement of our products is a Genie policy.
Therefore, product specifications are subject to
change without notice.
Readers are encouraged to notify Genie of errors
and send in suggestions for improvement. All
communications will be carefully considered for
future printings of this and all other manuals.
First Edition, First Printing, August 1996
Genie is a registered trademark of Terex South
Dakota, Inc in the USA and many other
countries.
Printed on recycled paper
Contact Us:
http://www.genlift.com
e-mail: awp.techpub@terex.com
ii
Copyright © 2011 Terex Corporation
Printed in U.S.A.
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Serial Number Legend
To August 31, 2016
DPL 16 G - 1234
1
Serial number: DPL16G-1234
Model:
Manufacture date: 01/02/2010
Model year: 2016
Elec/Hydr Schematic:
Power supply voltage/Pneumatic Pressure:
Nominal Power:
Machine unladen weight:
Max Load:
Occupants and Equipment must not exceed:
2
3
4
5
Maximum allowable inclination of the chassis:
Maximum Wind Speed:
Indoor:
Outdoor:
Gradeability:
Maximum allowable side force:
Maximum platform height:
6
1 Model
2 Model year
3 Facility code
4 Sequence number
5 Serial number (stamped on chassis)
6 Serial label
From September 1, 2016
DPL G - 1234
Serial number: DPLG-1234
Model:
Year of Manufacture : 2016
Elec/Hydr Schematic:
Power supply voltage/Pneumatic Pressure:
Nominal Power:
Machine unladen weight:
Max Load:
Occupants and Equipment must not exceed:
1
2
3
4
Maximum allowable inclination of the chassis:
Maximum Wind Speed:
Indoor:
Outdoor:
Gradeability:
Maximum allowable side force:
Maximum platform height:
5
1 Model
2 Facility code
3 Sequence number
Part No. 40462
4 Serial number (stamped on chassis)
5 Serial label
DPL-25S • DPL-30S • DPL-35S Super Series
iii
September 2016
Section 1 - Safety Rules
Safety Rules
Danger
Failure to obey the instructions and safety rules
in this manual and the Genie DPL Super Series
Operator's Manual will cause death or serious
injury.
Many of the hazards identified in the
operator’s manuals are also safety hazards
when maintenance and repair procedures
are performed.
Do Not Perform Maintenance
Unless:
You are trained and qualified to perform
maintenance on this machine.
You read, understand and obey:
- manufacturer’s instructions and safety rules
- employer’s safety rules and worksite
regulations
- applicable governmental regulations
You have the appropriate tools, lifting
equipment and a suitable workshop.
iv
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 1 - Safety Rules
SAFETY RULES
Personal Safety
Workplace 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.
Be sure to keep sparks, flames and
lighted tobacco away from flammable and
combustible materials like battery gases.
Always have an approved fire extinguisher within
easy reach.
Read each procedure thoroughly. This
manual and the decals on the machine
use signal words to identify the following:
Indicates the presence of
a hazard that will cause
death or serious injury.
Indicates the presence of
a hazard that may cause
death or serious injury.
Indicates the presence of
a hazard that will or may
cause serious injury or
damage to the machine.
Indicates special
operation or maintenance
information.
Be sure to wear protective eye wear and
other protective clothing if the situation
warrants it.
Be aware of potential crushing hazards
such as moving parts, free-swinging or
unsecured components when lifting or
placing loads. Always wear approved steel-toed
shoes.
Part No. 40462
Be sure that all tools and working areas
are properly maintained and ready for
use. Keep work surfaces clean and free of
debris that could get into machine components and
cause damage.
Be sure that your workshop or work area
is well ventilated and safely and
adequately illuminated.
Be sure any forklift, overhead crane or
other lifting or supporting device is fully
capable of supporting and stabilizing the
weight to be lifted. Use only chains or straps that
are in good condition and of ample load capacity.
Be sure that fasteners intended for
one-time use (i.e., cotter pins and
self-locking nuts) are not reused. These
components may fail if they are used a second
time.
Be sure to properly dispose of old oil or
other fluids. Use an approved container.
Please be mindful of the environment.
DPL-25S • DPL-30S • DPL-35S Super Series
v
September 2016
Table of Contents
Introduction
Important Information ...................................................................................................... ii
Section One
Safety Rules
General Safety Rules ..................................................................................................... iv
Section Two
Specifications
DPL-25S ................................................................................................................... 2 - 1
DPL-30S ................................................................................................................... 2 - 1
DPL-35S ................................................................................................................... 2 - 1
Bolt Torque Specification .......................................................................................... 2 - 2
Section Three
Scheduled Maintenance Inspections
Introduction ............................................................................................................... 3 - 1
Table A ..................................................................................................................... 3 - 2
Table B ..................................................................................................................... 3 - 3
Table C ..................................................................................................................... 3 - 4
Maintenance Inspection Report ................................................................................. 3 - 5
Section Four
Scheduled Maintenance Procedures
Introduction ............................................................................................................... 4 - 1
A-1
Inspect the Operator's and Responsibility Manuals including storage container ............................................................................. 4 - 2
A-2
Inspect the Decals and Placards ..................................................................... 4 - 2
A-3
Inspect for Damage, Loose or Missing Parts ................................................... 4 - 2
A-4
Check for Hydraulic Leaks .............................................................................. 4 - 3
A-5
Check the Auxiliary Platform Lowering Operation ........................................... 4 - 3
A-6
Check the Platform Manual Lowering Operation ............................................. 4 - 3
A-7
Inspect the Battery and Battery Charger - DC Models .................................... 4 - 4
A-8
Inspect the Columns for Damage .................................................................... 4 - 4
A-9
Check the Sequencing Cables ........................................................................ 4 - 4
A-10 Check the Interlock System for Proper Operation ........................................... 4 - 5
A-11 Test the Power and Function Controls ............................................................ 4 - 5
vi
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
TABLE OF CONTENTS
Section Four
Scheduled Maintenance Procedures, continued
A-12 Inspect the Lifting Chains and Idler Wheels .................................................... 4 - 6
A-13 Inspect the Breather Cap ................................................................................ 4 - 6
Section Five
B-1
Inspect the Electrical Wiring ............................................................................ 4 - 7
B-2
Inspect All Welds ............................................................................................ 4 - 7
B-3
Check the Lifting Chain Adjustments .............................................................. 4 - 8
B-4
Check the Battery - DC Models ....................................................................... 4 - 8
B-5
Clean and Lubricate the Columns ................................................................... 4 - 9
B-6
Test the Lifting Capacity .................................................................................. 4 - 9
B-7
Test the Power-To-Platform Operation ......................................................... 4 - 10
B-8
Adjust the Sequencing Cables ...................................................................... 4 - 10
B-9
Inspect for Proper Outrigger Length .............................................................. 4 - 11
C-1
Inspect and Lubricate the Casters ................................................................. 4 - 12
C-2
Inspect the Mast Assemblies for Wear .......................................................... 4 - 12
C-3
Lubricate the Lifting Chains ........................................................................... 4 - 13
C-4
Replace the Hydraulic Oil .............................................................................. 4 - 13
C-5
Replacing the Auxiliary Platform Lowering Batteries ..................................... 4 - 14
Troubleshooting Flow Charts
Introduction ............................................................................................................... 5 - 1
Part No. 40462
1
Power Light Will Not Turn On - AC Models ..................................................... 5 - 3
2
Power Light Will Not Turn On - DC Models ..................................................... 5 - 5
3
Interlock Lights Will Not Turn On ..................................................................... 5 - 7
4
Machine Will Not Lift - AC Models ................................................................. 5 - 10
5
Machine Will Not Lift, But Power Unit Will Operate - AC Models ................... 5 - 13
6
Machine Will Not Lift - DC Models ................................................................. 5 - 15
7
Machine Will Not Lift, But Power Unit Will Operate - DC Models ................... 5 - 18
8
Machine Will Not Lower - Up Function Operates ........................................... 5 - 20
9
Platform Will Not Hold In Up Position ............................................................ 5 - 22
10
Power Unit Will Not Lift Rated Load .............................................................. 5 - 23
11
Auxiliary Platform Lowering Will Not Operate ................................................ 5 - 24
DPL-25S • DPL-30S • DPL-35S Super Series
vii
September 2016
TABLE OF CONTENTS
Section Six
Schematics
Introduction ............................................................................................................... 6 - 1
Electrical Legend ...................................................................................................... 6 - 2
Hydraulic Legend ...................................................................................................... 6 - 3
Electrical Schematic - DPL Super Series DC - All Models
(before serial number DPL07-1499) ......................................................................... 6 - 5
Electrical Schematic - DPL Super Series DC - ANSI Models
(after serial number DPL07-1498) ............................................................................ 6 - 6
Electrical Schematic - DPL Super Series DC - CE Models
(after serial number DPL07-1498) ............................................................................ 6 - 7
Electrical Schematic - DPL Super Series AC - All Models
(before serial number DPL07-1499) ......................................................................... 6 - 8
Electrical Schematic - DPL Super Series AC - ANSI Models
(from serial number DPL07-1499 to DPL07-1562) .................................................... 6 - 9
Electrical Schematic - DPL Super Series AC - ANSI Models
(after serial number DPL07-1562) .......................................................................... 6 - 10
Electrical Schematic - DPL Super Series AC - CE Models
(from serial number DPL07-1499 to DPL07-1562) .................................................. 6 - 11
Electrical Schematic - DPL Super Series AC - CE Models
(after serial number DPL07-1562) .......................................................................... 6 - 12
Hydraulic Schematic - ANSI ................................................................................... 6 - 13
Hydraulic Schematic - CE ....................................................................................... 6 - 14
viii
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
TABLE OF CONTENTS
Section Seven
Repair Procedures
Introduction ............................................................................................................... 7 - 1
Base Assembly
1-1
Interlocks ........................................................................................................ 7 - 2
1-2
Platform Manual Lowering Cable ..................................................................... 7 - 2
1-3
How to Check the Resistance of a Valve Coil .................................................. 7 - 3
Ground Control Box
2-1
How to Test the Transformer - AC Models ....................................................... 7 - 4
2-2
How to Test the AC Contactor - AC Models ..................................................... 7 - 4
Hydraulic Power Units
3-1
Hydraulic Power Unit Components - AC Models .............................................. 7 - 6
3-2
Hydraulic Power Unit Components - DC Models .............................................. 7 - 8
3-3
How to Remove the Hydraulic Power Unit - AC Models ................................. 7 - 10
3-4
How to Remove the Hydraulic Power Unit - DC Models ................................. 7 - 10
3-5
How to Remove the Hydraulic Pump ............................................................. 7 - 11
3-6
How to Adjust the Pressure Relief Valve ....................................................... 7 - 12
3-7
How to Check the Resistance of a Valve Coil ................................................ 7 - 13
3-8
How to Test the Motor Start Solenoid ............................................................ 7 - 13
Mast Assembly
Mast Illustrations .................................................................................................... 7 - 14
4-1
How to Remove a Lift Cylinder ...................................................................... 7 - 15
4-2
How to Remove a Mast Assembly ................................................................. 7 - 16
4-3
How to Adjust the Lifting Chains .................................................................... 7 - 19
4-4
How to Adjust the Glide Pads ........................................................................ 7 - 19
4-5
How to Inspect the Lifting Chains .................................................................. 7 - 20
Platform
Part No. 40462
5-1
How to Remove the Platform ......................................................................... 7 - 22
5-2
How to Test the Contactors ........................................................................... 7 - 22
DPL-25S • DPL-30S • DPL-35S Super Series
ix
September 2016
Section 2 - Specifications
Specifications
Model
DPL-25S
DPL-30S
DPL-35S
Height,
maximum working
31 ft 4 in
9.5 m
36 ft
11 m
40 ft 9 in
12.4 m
Height,
maximum platform
25 ft 4 in
7.7 m
30 ft
9.2 m
34 ft 9 in
10.6 m
Height,
guard rails stowed
78 in
197.8 cm
78 in
197.8 cm
78 in
197.8 cm
Length,
outriggers stowed
813/4 in
207.6 cm
813/4 in
207.6 cm
813/4 in
207.6 cm
Width,
outriggers stowed
311/2 in
80 cm
311/2 in
80 cm
311/2 in
80 cm
Outrigger footprint
(l x w)
82 x 561/2 in
208.3 x 143.5 cm
861/4 x 673/4 in
218.7 x 172.1 cm
861/4 x 673/4 in
218.7 x 172.1 cm
72 x 271/2 in
182.9 x 69.9 cm
72 x 271/2 in
182.9 x 69.9 cm
72 x 271/2 in
182.9 x 69.9 cm
750 lbs
340 kg
750 lbs
340 kg
600 lbs
272 kg
12V DC or
220V or 115V AC
12V DC or
220V or 115V AC
12V DC or
220V or 115V AC
1375 / 1450 lbs
624 / 658 kg
1475 / 1550 lbs
669 / 703 kg
1575 / 1650 lbs
714 / 748 kg
750 lbs / 340 kg
750 lbs / 340 kg
600 lbs / 272 kg
750 lbs / 340 kg
750 lbs / 340 kg
600 lbs / 272 kg
600 lbs / 272 kg
600 lbs / 272 kg
500 lbs / 227 kg
Platform dimensions
(l x w)
Lift capacity
Power source
Shipping weight
(AC / DC)
Maximum capacity
ANSI
CE
CSA
Ambient operating
temperature
-20°F to 135°F
-29°C to 57°C
Airborne noise emissions
80 dB
Maximum sound level at normal operating workstations
(A-weighted)
Current Protection Rating
220V AC models
110V AC models
DC models
Part No. 40462
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
DPL25S • DPL-30S • DPL-35S Super Series
2-1
Section 2 - Specifications
September 2016
SPECIFICATIONS
Bolt Torque Specifications
Size
10
1 /4
5/16
3 /8
7/16
1 /2
9/16
5 /8
3 /4
7 /8
1
Threads
per inch
SAE Grade 5 Bolts
Torque - Dry
inch-pounds
Torque - Dry
foot-pounds
SAE Grade 8 Bolts
Torque - Dry
Newton meters
Torque - Dry
inch-pounds
Torque - Dry
foot-pounds
Torque - Dry
Newton meters
24
43
5
60
7
32
49
6
68
8
20
96
11
144
16
28
120
14
168
19
18
17
23
25
34
24
19
28
25
34
16
30
41
45
61
24
35
48
50
68
14
50
68
70
95
20
55
75
80
109
13
75
102
110
149
20
90
122
120
163
12
110
149
150
204
18
120
163
170
231
11
150
204
220
298
18
170
231
240
326
10
260
353
380
515
16
300
407
420
570
9
430
583
600
814
14
470
637
660
895
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
DPL-25S • DPL-30S • DPL35S Super Series
Part No. 40462
September 2016
Section 3 - Scheduled Maintenance Inspections
Scheduled Maintenance Inspections
About This Section
Schedule
Observe and Obey:
Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of this machine.
Scheduled maintenance inspections shall be
completed daily, quarterly and annually as
specified on the Maintenance Inspection
Report.
Tools are
required
New parts
required
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
Quarterly (every 150 hours or three months)
Failure to properly complete each
inspection when required may
result in death, serious injury or
substantial machine damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating machine.
Machines that have been out of service for a
period longer than 3 months must have a
quarterly inspection.
Dealer
service
suggested
Annual
A
A+B
A+B+C
Maintenance Tables
The maintenance tables contained in this section
provide summary information on the specific
physical requirements for each inspection.
Complete step-by-step instructions for each
scheduled maintenance procedure are provided in
section 4, Scheduled Maintenance Procedures.
Maintenance Inspection Report
The Maintenance Inspection Report contains
checklists for each type of scheduled inspection.
Make copies of the Maintenance Inspection Report
to use for each inspection. Maintain completed
forms for a minimum of 4 years or in compliance
with your employer, jobsite and governmental
regulations and requirements.
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
3-1
Section 3 - Scheduled Maintenance Inspections
September 2016
Maintenance Tables
Table A
Tools are
required
A-1
Inspect the Operator's and Responsibility Manuals
A-2
Inspect the Decals and Placards
A-3
Inspect for Damage and Loose or Missing Parts
A-4
Check for Hydraulic Leaks
A-5
Check the Auxiliary Platform Lowering Operation
A-6
Check the Manual Platform Lowering Operation
A-7
Inspect the Battery and Battery Charger
- DC Models
A-8
Inspect the Columns for Damage
A-9
Check the Sequencing Cables
A-10
Check the Interlock System for Proper Operation
A-11
Test the Power and Function Controls
A-12
Inspect the Lifting Chains and Idler Wheels
A-13
Inspect the Breather Cap
3-2
DPL-25S 30S • DPL-35S Super Series
New parts
required
Dealer
service
suggested
Part No. 40462
September 2016
Section 3 - Scheduled Maintenance Inspections
MAINTENANCE TABLES
Table B
Tools are
required
—
Complete all procedures in Table A
B-1
Inspect the Electrical Wiring
B-2
Inspect All Welds
B-3
Check the Lifting Chain Adjustments
B-4
Check the Battery - DC Models
B-5
Clean and Lubricate the Columns
B-6
Test the Lifting Capacity
B-7
Test the Power To Platform Operation
B-8
Adjust the Sequencing Cables
B-9
Inspect for Proper Outrigger Length
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
New parts
required
Dealer
service
suggested
3-3
Section 3 - Scheduled Maintenance Inspections
September 2016
MAINTENANCE TABLES
Table C
Tools are
required
—
Complete all procedures in Table A and Table B
C-1
Inspect and Lubricate the Casters and Wheels
C-2
Inspect the Mast Assembly for Wear
C-3
Lubricate the Lifting Chains
C-4
Replace the Hydraulic Oil
C-5
Replace the Auxiliary Platform Lowering Batteries
3-4
DPL-25S 30S • DPL-35S Super Series
New parts
required
Dealer
service
suggested
Part No. 40462
September 2016
Section 3 - Scheduled Maintenance Inspections
Maintenance Inspection Report
Model
Checklist A
Serial number
Date
A-1
Operator's
and Responsibility
manuals
B-1
Electrical wiring
B-2
Welds
A-2
Decals and placards
B-3
Lifting chain
adjustments
A-3
Damage, loose or
missing parts
B-4
Battery
A-4
Hydraulic leaks
B-5
Clean and lubricate
columns
A-5
Auxiliary lowering
operation
B-6
Lifting capacity
A-6
Manual lowering
operation
B-7
Power to platform
operation
A-7
Battery and charger
- DC models
B-8
Sequencing cables
B-9
Proper outrigger
length
Inspector company
Instructions
• Make copies of this page to use for
each inspection.
• Select the appropriate checklist(s) for
the type of inspection to be
performed.
Y Dealer
N R
Refer to Table A
Inspector signature
Inspector title
Checklist B
Tools are
Referrequired
to Table
Machine owner
Inspected by (print)
Y N R
A-8
Columns
A-9
Sequencing cables
B
New parts
required
Checklist C
Quarterly Inspection: A+B
A-10 Interlock system
operation
Annual Inspection: A+B+C
A-11 Power and
function controls
C-1
Casters and wheels
C-2
Mast assembly
C-3
Lifting chains
C-4
Hydraulic oil
C-5
Auxiliary platform
lowering batteries
Daily Inspection: A
• Place a check in the appropriate box
after each inspection procedure is
completed.
• Use the maintenance tables in this
section and the step-by-step
procedures in section 4 to learn how to
perform these inspections.
A-12 Lifting chains
and idler wheels
A-13 Breather cap
service
suggested
Y N R
Refer to Table C
• 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
DPL-25S • DPL-30S • DPL-35S Super Series
3-5
Section 3 - Scheduled Maintenance Inspections
September 2016
Tools are
required
New parts
required
Dealer
service
suggested
This page intentionally left blank.
3-6
DPL-25S 30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 4 - Scheduled Maintenance Procedures
Scheduled Maintenance Procedures
About This Section
This section contains detailed procedures for each
scheduled maintenance inspection.
Each procedure includes a description, safety
warnings and step-by-step instructions.
Observe and Obey:
Symbols Legend
Maintenance inspections shall be completed by
a person trained and qualified on the
maintenance of these machines.
Indicates the presence of a hazard
that will cause death or serious
injury.
Scheduled maintenance inspections shall be
completed daily, frequently (every 3 months),
and annually as specified on the maintenance
report.
Indicates the presence of a hazard
that may cause death or serious
injury.
Failure to properly complete each
inspection when required may
result in death, serious injury or
substantial machine damage.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Indicates the presence of a hazard
that will or may cause serious
injury or damage to the machine.
Indicates special operation or
maintenance information.
Indicates that a specific result is expected after
performing a series of steps.
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
September 2016
Section 4 - Scheduled Maintenance Procedures
Table A Procedures
A-1
Inspect the Operator’s and
Responsibility Manuals
1 Refer to the Decals section in the Genie DPL
Super Series Operator's Manual and use the
decal list and illustrations to determine that all
decals and placards are in place.
Maintaining the operator’s and responsibility
manuals in good condition is essential to safe
machine operation. Manuals are included with
each machine and should be stored in the
container provided at the platform. An illegible or
missing manual will not provide safety and
operational information necessary for a safe
operating condition.
2 Inspect all decals for legibility and damage.
Replace any damaged or illegible decal
immediately.
1 Check to be sure the storage container and lid
are present and in good condition.
A-3
Inspect for Damage and Loose or
Missing Parts
2 Check to make sure that the operator’s and
responsibility manuals are present and
complete in the storage container at the
platform.
3 Examine the pages of each manual to be sure
that they are legible and in good condition.
4 Always return the manuals to the storage
container after use.
Note: Contact your authorized Genie distributor or
Genie if replacement manuals are needed.
A-2
Inspect the Decals and Placards
Maintaining all of the safety and instructional
decals and placards in good condition is essential
for safe machine operation. Decals alert operators
and personnel to the many possible hazards
associated with using a machine. They also
provide users with operation and maintenance
information. An illegible decal will fail to alert
personnel of a procedure or hazard and could
result in unsafe operating conditions.
4-2
Note: Contact your authorized Genie distributor or
Genie if replacement decals are needed.
Daily machine condition inspections are essential
to safe machine operation and good machine
performance. Failure to locate and repair damage,
and discover loose or missing parts may result in
an unsafe operating condition.
1 Inspect the entire machine for damage and
improperly installed or missing parts including:
• Electrical components and wiring
• Coil cord (if equipped)
• Hydraulic power unit, hoses, fittings and
cylinders
• Manual lowering lever and components
• Platform end guard rail, platform side guard
rails and platform entry gate
• Guard rail lock handles
• Sequencing cables and pulleys
• Lifting chains and idler wheels
• Nuts, bolts and other fasteners
• Mast and mast braces
• Breather cap
• Outriggers, leveling jacks and footpads
• Guard rail lift arm
• Platform entry ladder
• Dents or damage to machine
• Corrosion or oxidation
• Cracks in welds or structural components
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 4 - Scheduled Maintenance Procedures
TABLE A
A-4
Check for Hydraulic Leaks
PROCEDURES
3 Activate the auxiliary platform lowering button at
the ground controls.
Result: Platform should lower.
Detecting hydraulic fluid leaks is essential to
operational safety and good machine performance.
Undiscovered leaks can develop into hazardous
conditions, impair machine functions and damage
machine components.
1 Inspect for hydraulic oil puddles, dripping or
residue on or around the following areas:
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.
• 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
A-6
Check the Platform Manual
Lowering Operation
Detection of a platform manual lowering
malfunction is essential for safe machine
operation. An unsafe working condition exists if the
manual lowering function does not operate in the
event of a main and auxiliary power failure.
1 Raise the platform slightly.
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.
2 Activate the manual lowering lever.
Result: Platform should lower.
1 Raise the platform slightly.
2 Disconnect the power source from the machine.
Part No. 40462
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September 2016
Section 4 - Scheduled Maintenance Procedures
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.
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 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.
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.
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.
4-4
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 4 - Scheduled Maintenance Procedures
TABLE A
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
A-11
Test the Power and
Function Controls
2 Check to be sure of the following:
• Cables are on the pulleys
• Cable ends are properly secured
• Mounting brackets are properly secured
1 Turn the key switch to the ON position and pull
out the red Emergency Stop button to the ON
position.
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.
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
smoothly and be free of hesitation, jerking and
unusual noise.
Result: The power light should be on.
2 Twist to release the red Emergency Stop button
at the platform controls.
3 Push in the control activate button and rotate to
the UP position, then the DOWN position.
Result: Platform up and down functions should
operate smoothly.
4 Push in the Emergency Stop button at the
platform controls to the OFF 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 OFF position. Then test up
and down functions.
Result: Up/down function should not operate.
5 Repeat steps 3 and 4 for each of the remaining
outriggers.
Part No. 40462
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September 2016
Section 4 - Scheduled Maintenance Procedures
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:
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.
• Excessive corrosion 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.
a
b
c
d
a
b
c
d
4-6
chain tensioner bracket
adjustment nut (hidden from view)
termination rod (hidden from view)
column
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 4 - Scheduled Maintenance Procedures
Table B Procedures
B-1
Inspect the Electrical Wiring
B-2
Inspect All Welds
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
component damage.
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.
Electrocution/burn hazard. Contact
with hot or live circuits may cause
death or serious injury. Remove
all rings, watches and other
jewelry.
1 Visually inspect the welds in the following
locations:
• Platform and platform components
• Base
• Mast brace mounting brackets
• Ladder mounting bracket
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
Part No. 40462
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September 2016
Section 4 - Scheduled Maintenance Procedures
TABLE
B
PROCEDURES
B-3
Check the Lifting Chain
Adjustments
B-4
Check the Battery - DC Models
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 Lower the platform side guard rails to the
stowed position.
Batteries contain acid. Avoid
spilling or contacting battery acid.
Neutralize battery acid spills with
baking soda and water.
1 Put on protective clothing and eye wear.
3 Measure the maximum height of the machine.
Result: The machine should be no taller than
specification.
Note: If measurement does not meet specification,
adjust the chains. See Repair procedure 5-3, How
to Adjust the Lifting Chains.
Specifications
Model
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.
Height
DPL-25S
78 inches
197.8 cm
DPL-30S
78 inches
197.8 cm
DPL-35S
78 inches
197.8 cm
2 Slide open the battery cover to access the
charger and the battery. The cover must
remain open for the entire charging cycle.
3 Remove the battery vent caps and check the
specific gravity with a hydrometer.
4 Check the battery acid level. If needed,
replenish with distilled water to cover the
battery plates. Do not overfill.
5 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.
7 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 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
September 2016
Section 4 - Scheduled Maintenance Procedures
TABLE B
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
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).
Part No. 40462
PROCEDURES
B-6
Test the Lifting Capacity
Proper lifting capacity is essential to safe machine
operation. Improper lifting capacity adjustment
could allow machine to be overloaded and may
cause death or serious injury.
This procedure requires specific
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 operator's 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.
Result: The hydraulic power unit should raise
the platform.
3 Fully lower the platform.
4 Add an additional 30 pounds (14 kg) to the
platform. Secure the additional weight.
5 Raise the platform slightly.
Result: The hydraulic power unit should not be
able to raise the platform.
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.
DPL-25S • DPL-30S • DPL-35S Super Series
4-9
September 2016
Section 4 - Scheduled Maintenance Procedures
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 In the platform, plug a power drill (or similar
tool) into the AC outlet.
Result: The tool should operate normally.
Note: 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
Maximum Deflection
11/2 to 21/2 inches
3.8 to 6.4 cm
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
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.
4 - 10
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 4 - Scheduled Maintenance Procedures
TABLE B
PROCEDURES
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
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
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September 2016
Section 4 - Scheduled Maintenance Procedures
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.
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
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
a
b
c
C-2
Inspect the Mast Assemblies
for Wear
a
b
c
idler wheel
spacer
lifting chain
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.
Note: If idler wheel inspection results in a
measurement that is not within specification, refer
to Repair procedure 5-2, How to Assemble the
Mast.
1 Raise the platform until 3 to 5 inches (7.6 to
12.7 cm) of the top of each column is visible.
6 Adjust the sequencing cables. See B-8, Adjust
the Sequencing Cables.
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.
Note: 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).
4 - 12
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 4 - Scheduled Maintenance Procedures
TABLE C
PROCEDURES
C-3
Lubricate the Lifting Chains
C-4
Replace the Hydraulic Oil
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.
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 Raise the platform to the maximum height.
2 Lubricate each chain with a dry type spray
lubricant.
This procedure will require the use
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.
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 new one.
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
4 - 13
September 2016
Section 4 - Scheduled Maintenance Procedures
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
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
Hydraulic reservoir capacity
AC models
DC models
Dexron equivalent
5 quarts
5 quarts
4.7 liters
4.7 liters
Hydraulic System Capacity (includes reservoir)
AC models
DPL-25S
DPL-30S
DPL-35S
6 quarts
6 quarts
6 quarts
5.6 liters
5.6 liters
5.6 liters
DC models
DPL-25S
DPL-30S
DPL-35S
6 quarts
6 quarts
6 quarts
5.6 liters
5.6 liters
5.6 liters
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
to damage the wires.
6 Remove the old batteries from the pack.
7 Insert new batteries into the pack.
Make sure the batteries are
installed correctly by following the
diagram on the inside of the
battery pack.
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
September 2016
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:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Read each appropiate flow chart thoroughly.
Attempting shortcuts may produce hazardous
conditions.
Be aware of the following hazards and follow
generally accepted safe workshop practices.
Electrocution/burn hazard. Contact
with electrically charged circuits
may result in death or serious
injury. Remove all rings, watches
and other jewelry.
Bodily injury hazard. Spraying
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.
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
September 2016
Section 5 - Troubleshooting Flow Charts
TROUBLESHOOTING FLOW CHARTS
General Repair Process
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.
Malfunction
discovered
Identify
symptoms
Troubleshoot
problem
still exists
Return to
service
problem
solved
Inspect
and test
Perform
repair
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.
5-2
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 5 - Troubleshooting Flow Charts
Chart 1
Power Light Will
Not Turn On 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 ground
control box PC board
fuse is not blown.
Check the power supply 0V AC
with a voltage meter.
Plug into a different
power supply and
recheck the voltage.
110V AC
Check the voltage at
terminal 3 on the key
0V AC
switch N.O. contact. Put
Pos. lead of voltage
meter on terminal 3 and
Neg. lead on the white
wire from the AC power
cord.
Repair or replace the AC
power cord and/or the 12/
3 cable.
110V AC
Check the voltage at
terminal 4 on the key
switch N.O. contact.
0V AC
Replace the key switch
N.O. contact.
110V AC
Check the voltage at
terminal 1 on the
Emergency Stop button
N.C. contact.
0V AC
110V AC
Check the voltage at
terminal 2 on the
Emergency Stop button
N.C. contact.
0V AC
Trace the black wire from
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.
110V AC
Check the voltage at the
black transformer wire
where it connects to the
brown transformer wire.
110V AC
0V AC
Repair open in the yellow
transformer wire between
the Emergency Stop
button and the
transformer OR replace
the transformer because
of a faulty thermal fuse.
Continued on the next
page.
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
5-3
September 2016
Section 5 - Troubleshooting Flow Charts
CHART 1
Continued from the
previous page.
Check the voltage at
terminals 1 and 3 of 13
pole terminal strip (J1).
Put Pos. lead of voltage
meter on terminal 1 and
Neg. lead on terminal 3.
0V AC
Repair the transformer
wires OR replace the
transformer.
14 to 16V AC
Check the voltage on
both sides of the 5 amp
P.C. board fuse. Put
Neg. lead of voltage
meter on grounding
terminal 10 of the 13
pole terminal strip (J1).
12V DC
on one
side
Replace the 5amp fuse.
12V DC
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
September 2016
Section 5 - Troubleshooting Flow Charts
Chart 2
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
voltage.
0V DC
Charge the battery OR
check the battery
condition and replace a
bad battery.
12V DC
Check the voltage at
terminal 3 on the key
0V DC
switch N.O. contact. Put
Neg. lead of voltage
meter on grounding
terminal 10 of the 13 pole
terminal strip (J1).
Trace the black input wire
back to the motor start
solenoid and repair open
in the wire.
12V DC
Check the voltage at
terminal 4 on the key
switch N.O. contact.
0V DC
Replace the key switch
N.O. contact.
12V DC
Check the voltage at
terminal 1 on the
Emergency Stop button
N.C. contact.
0V DC
12V DC
Check the voltage at
terminal 2 on the
Emergency Stop button
N.C. contact.
0V DC
Trace the black wire from
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.
12V DC
Check the voltage at
terminal 3 (black wire) of 0V DC
3 pole terminal strip (J2).
12V DC
Trace the black wire from
terminal 3 of the 3 pole
terminal strip (J2) back to
the Emergency Stop
button N.C. contact and
repair open in the wire.
Continued on the next
page.
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
5-5
September 2016
Section 5 - Troubleshooting Flow Charts
CHART 2
Continued from the
previous page.
Check the voltage on
both sides of the 5amp
P.C. board fuse. Put
Neg. lead of voltage
meter on grounding
terminal 10 of the 13
pole terminal strip (J1).
12V DC
on one
side
Replace the 5amp fuse.
12V DC
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
September 2016
Section 5 - Troubleshooting Flow Charts
Chart 3
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 off
Refer to either Chart 1 or
Chart 2.
light on
Check for power at
terminal 8 (black wire) on
the 13 pole terminal strip
(J1) located in the ground
0V DC
control box. Put Neg.
lead of voltage meter on
grounding terminal 10
(green/yellow wire).
Replace the P.C. board.
12V DC
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.
bad
Repair or replace
damaged connectors.
good
Check for power at the
black wires that are
0V DC
connected together with a
wire nut in the ladder-end
junction box.
Replace 18/7 cable from
the ground control box
because of open circuit in
black wire.
12V DC
Continued on the next
page.
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
5-7
September 2016
Section 5 - Troubleshooting Flow Charts
CHART 3
Continued from the
previous page.
If LED 2 is not on, check
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
3 connects to the blue
wire.
Inspect the outrigger
interlock contacts and the bad
base interlock contacts
for damage.
Repair or replace
damaged interlock
contacts.
good
Repair open circuit in the
black wire or the red wire
from base interlock
contacts.
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
ground control box.
Replace 18/7 cable from
the ladder-end junction
box because of open
circuit in orange wire or
blue wire .
12 V DC
Replace P.C. board OR
consult Genie Industries
Service Department.
If LED 1 or 4 are not
on, continue from here
Check for power at the
black wires that are
connected together with a 0V DC
wire nut located in the
steer handle-end junction
box.
Replace 18/7 cable from
ladder-end junction box
because of open circuit in
black wire.
12 V DC
Continued on the next
page.
5-8
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 5 - Troubleshooting Flow Charts
CHART 3
Continued from the
previous page.
If LED 1 is not on, check 0V DC
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 wire nut where the
red wire from switch 4
connects to the red
wire.
Inspect the outrigger
bad
interlock contacts and the
base interlock contacts
for damage.
Repair or replace
damaged interlock
contacts.
good
Repair open circuit in the
black wire or the red wire
from base interlock
contacts.
12V DC
If LED 1 is not on, check
for power at the wire nut
where the white wires
connect in the ladder-end 0V DC
junction box. If LED 4 is
not on, check for power
at the wire nut where the
red wires connect.
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.
12V DC
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). 0V DC
These terminals are on
the 13 pole terminal strip
(J1) in the ground control
box.
Replace the 18/7 cable
from the ladder-end
junction box because of
open circuit in white wire
or in the red wire.
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
September 2016
Section 5 - Troubleshooting Flow Charts
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
control box circuit
breaker has been
reset.
In ground control box,
check for power at
terminal 9 (red wire) of 13 0V DC
pole terminal strip (J1).
Put Neg. lead of voltage
meter on terminal 10
(grounding terminal).
Replace the P.C. board.
12V DC
Check for power at
terminal 1 of Emergency
Stop switch contact in
platform control box. Put
0V DC
Neg. lead of voltage
meter on terminal 10
(green/yellow wire) of 13
pole terminal strip [J1] in
base control box.
Replace 16/6 cable
because of open in red
wire OR repair open in
quick disconnect under
ground control box.
12V 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.
0V DC
Replace Emergency Stop
switch N.C. contact
block.
Replace red wire because
of open circuit between
Emergency Stop switch
contact block and control
activate switch contact
block.
12V DC
While pushing in and
holding control activate
switch, check for power
at terminal 3 of control
activate switch contact.
0V DC Replace control activate
switch N.O. contact
block.
12V DC
Continued on the next
page.
5 - 10
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 5 - Troubleshooting Flow Charts
CHART 4
Continued from the
previous page.
While pushing in and
holding the control
0V DC
activate switch, check for
power at terminal 4 of the
up switch contact.
Replace the red wire
(because of open circuit)
between the control
activate switch contact
block and the up switch
contact block.
12V DC
While pushing in the
control activate switch
and activating the up
function, hold both
0V DC
switches and check for
power at terminal 3 of up
switch contact.
Replace up switch N.O.
contact block.
12V DC
While pushing in the
control activate switch
and activating the up
function, hold both
switches and check for
0V DC
power at terminal 13
(orange wire) of 13 pole
terminal strip (J1)in base
control box.
Replace 16/6 cable
because of open in
orange wire OR repair
open in quick disconnect
under ground control box.
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.
0V DC
Replace P.C. board OR
consult Genie Industries
Service Department.
12V DC
While pushing in the
control activate switch
and activating the up
function, hold both
switches and check for 0V DC
power at the motor
contactor coil (terminal 1
red wire). Put Neg. lead
of the voltage meter on
terminal 0 green/yellow
wire.
12V DC
Relocate Neg. lead of the
voltage meter at terminal 0V DC
10 (green/yellow wire) of
the 13 pole terminal strip
(J1).
Repair open circuit in red
wire.
12V DC
Repair open circuit in
green/yellow wire.
Continued on the next
page.
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
5 - 11
September 2016
Section 5 - Troubleshooting Flow Charts
CHART 4
Continued from the
previous page.
Perform a continuity test no
across the motor
continuity Replace the motor
contactor coil (terminals 1
contactor.
and 0).
continuity
Check for 110 volts AC
at the common terminals 0V AC
(white and black wires) of
the motor contactor.
Replace faulty circuit
breaker.
110V AC
While pushing in the
control activate switch
and activating the up
function, hold both
0V AC
switches and check for
power at the N.O.
terminals (white and
black wires) on the motor
contactor.
Replace the motor
contactor because of
damaged contacts.
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
September 2016
Section 5 - Troubleshooting Flow Charts
Chart 5
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 0V DC
input voltage at the N.O.
valve coil on the power
unit. Wait 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.
Replace P.C. board.
12V DC
Replace or repair black
wire because of an open
circuit.
12V DC
Check the resistance of
the N.O. valve coil.
While pushing in the
control activate switch
and activating the up
function, hold both
switches and check for 0V DC
power at terminal 12
(black wire) of the 13 pole
terminal strip (J1). This is
a 1 second ON time
delayed terminal.
infinite
ohms
Replace N.O. valve coil.
7 ohms
Tee in pressure gauge at
Inspect the mast
pressure port (stamped 1800 to assemblies for a
P) of power unit. Push in 2000 psi mechanical bind such as
the control activate
foriegn objects that could
switch, activate the up
have fallen in between
function, hold both
columns.
switches and check the
pressure.
less than 1800 psi
On the power unit,
remove the return to tank
hose off of the T port
Activate the up function
fitting and plug the hose 1800 to and check for voltage at
fitting, leaving 3000 psi 2000 psi the N.C. down valve coils
gauge teed in at the P
(yellow wire) at the barrel 0V DC
port fitting. Push in the
end of each lifting
control activate switch,
cylinder.
activate the up function,
hold and check the
12V DC
pressure.
less than 1800 psi
Continued on the next
page.
Part No. 40462
Replace defective N.O.
contact block for down
function in platform
control box.
DPL-25S • DPL-30S • DPL-35S Super Series
5 - 13
September 2016
Section 5 - Troubleshooting Flow Charts
CHART 5
Continued from the
previous page.
On the power unit,
remove and inspect the
N.O. valve for
contamination or damage.
Clean, repair or replace
valve and then perform
pressure test again.
less than 1800 psi
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
September 2016
Section 5 - Troubleshooting Flow Charts
Chart 6
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
pole terminal strip (J1). 0V DC
Put Neg. lead of voltage
meter on terminal 10
(ground terminal).
Replace the P.C. board.
12V DC
Check for power at
terminal 1 of Emergency
Stop switch contact in
platform control box. Put 0V DC
Neg. lead of voltage
meter on terminal 10
(green/yellow wire) of 13
pole terminal strip (J1) in
ground control box.
Replace 16/6 cable
because of open in red
wire OR repair open in
quick disconnect under
ground 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.
0V DC
Replace Emergency Stop
switch N.C. contact
block.
0V DC
Replace the red wire
(because of open circuit)
between the Emergency
Stop switch contact
block and the control
activate switch contact
block.
12V DC
Check for power at
terminal 4 of control
activate switch.
12V DC
While pushing in and
holding the control
0V DC
activate switch, check for
power at terminal 3 of the
control activate switch
contact.
Replace the control
activate switch N.O.
contact block.
12V DC
Continued on the next
page.
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
5 - 15
September 2016
Section 5 - Troubleshooting Flow Charts
CHART 6
Continued from the
previous page.
While pushing in and
holding the control
activate switch, check for 0V DC
power at terminal 4 of the
up switch contact.
Replace the red wire
(because of open circuit)
between the control
activate switch contact
block and the up switch
contact block.
12V DC
While pushing in the
control activate switch
and activating the up
0V DC
function, hold both
switches and check for
power at terminal 3 of the
up switch contact.
Replace the up switch
N.O. contact block.
12V DC
While pushing in the
control activate switch
and activating the up
function, hold both
0V DC
switches and check for
power at terminal 13
(orange wire) of the 13
pole terminal strip (J1) in
the ground control box.
Replace the 16/6 cable
because of open in the
orange wire OR repair
open in the quick
disconnect under ground
control box.
12V DC
While pushing in the
0V DC
control activate switch
and activating the up
function, hold both
switches and check for
power at terminal 11
(white wire) of the 13 pole
terminal strip (J1) in the
ground control box.
Replace P.C. board OR
consult Genie Industries
service Department.
12V DC
Continued on the next
page.
5 - 16
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 5 - Troubleshooting Flow Charts
CHART 6
Continued from the
previous page.
While pushing in the
control activate switch
and activating the up
0V DC
function, hold both
switches and check for
power at the motor
contactor coil (positive
terminal white wire). Put
Neg. lead of the voltage
meter on the negative
terminal (green/yellow
wire).
Relocate the Neg. lead of 0V DC
the voltage meter at
terminal 10 (green/yellow
wire) of the 13 pole
terminal strip (J1) in the
ground control box.
Repair open circuit in the
red wire.
12V DC
Repair open circuit in the
green/yellow wire.
12V DC
no
Perform a continuity test continuity
Replace the motor
across the motor
contactor.
contactor coil.
continuity
While pushing in the
control activate switch
0V DC
and activating the up
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).
Replace the motor
contactor because of
damaged contacts.
12V DC
no
Perform a continuity test continuity 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
September 2016
Section 5 - Troubleshooting Flow Charts
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. 0V 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.
Replace or repair the
white wire between the
motor contactor coil and
the N.O. valve coil
because of an open
circuit.
12V DC
Check the resistance of
the N.O. valve coil.
infinite
ohms
Replace the N.O. valve
coil.
7 ohms
Tee in a 3000 psi
Inspect the mast
pressure gauge at the
assemblies for a
pressure port fitting
1800 to mechanical bind such as
(stamped P) of the power 2000 psi foreign objects that could
unit. Push in the control
have fallen in between
activate switch, activate
the columns.
the up function, hold both
switches and check the
pressure.
less tnan 1800 psi
On the power unit,
remove the return to tank
hose off of the T port
Activate the up function
fitting and plug the hose
and check for voltage at
1800
to
fitting, leaving the 3000
psi gauge teed in at the P 2000 psi the N.C. down valve coils 0V DC
(yellow wire) at the barrel
port fitting. Push in the
end of each lift cylinder.
control activate switch,
activate the up function,
hold both switches and
check the pressure.
12V DC
less than 1800 psi
Remove the N.C. down
valves and inspect for
contamination or damage
OR consult Genie
Industries Service
Department.
Replace defective N.O.
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
September 2016
Section 5 - Troubleshooting Flow Charts
CHART 7
Continued from the
previous page.
On the power unit,
remove and inspect the
N.O. valve for
contamination or damage.
Clean, repair or replace
valve and then perform
pressure test again.
less than 1800 psi
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
September 2016
Section 5 - Troubleshooting Flow Charts
Chart 8
Machine Will
Not Lower Up Function
Operates
While pushing in the
12V DC
control activate switch
and activating the down
function, hold both
switches and check for
power at the N.C. down
valve coils at the barrel
end of the lifting
cylinders. Put Pos. lead
of the voltage meter on
the yellow wire and Neg.
lead on the green/yellow
grounding wire.
infinite
ohms
Replace the coil because
of an open circuit.
7 ohms
Pull the manual lowering platform One or both of the N.C.
lever (red handle) located lowers
down valves are
on the base.
damaged or possibly
contaminated. Consult
Genie Industries Service
Department.
platform will not lower
One or both flow control
valves at the barrel end
of the lifting cylinders are
possibly contaminated.
Consult Genie Industries
Service Department.
0V DC
Repeat the test but
relocate the Neg. lead of
the voltage meter at the
12V DC
ground terminal 10
(green/yellow wire) of the
13 pole terminal strip (J1)
in the ground control box.
0V DC
Check the voltage at
terminal 3 on the down
N.O. contact block
located in the platform
control box.
Check the resistance of
the N.C. down valve
coils.
0V DC
Check for a loose
connection at the
grounding stud in the
ground control box OR
check for a bad pin
connection at the quick
disconnect under the
base control box OR
replace 18/7 cable
because of an open
circuit in the green/yellow
grounding wire.
Replace the red jumper
wire because of an open
circuit.
12V DC
Continued on the next
page.
5 - 20
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 5 - Troubleshooting Flow Charts
CHART 8
Continued from the
previous page.
Activate the down
function and check the 0V DC
voltage at terminal 4 (blue
wire) of the N.O. down
contact block.
Replace the N.O. down
contact block because of
an open circuit.
12V DC
Check the voltage at
terminal 2 on the N.O.
0V DC
auxilary down contact
block in the base control
box.
12V DC
Inspect pin 2 for a defect
in the quick disconnect
located under the ground
control box OR replace
the 16/6 cable because of
an open circuit in the blue
wire.
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
September 2016
Section 5 - Troubleshooting Flow Charts
Chart 9
Platform Will
Not Hold In
Up Position
Be sure manual
lowering cable is
properly adjusted.
Activate the platform up
function while
platform
simultaneously activating holds up Inspect the hydraulic
system for
the manual lowering
contamination.
valve. Test the unit.
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
and activate the platfom
up function. Check for
leaking from the hose.
Replace or repair both
N.C. down valves.
not leaking
While platform is drifting, yes
is the motor spinning
backwards?
no
Replace or repair all 3
check valves.The first
and second are located in
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
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 5 - Troubleshooting Flow Charts
Chart 10
Power Unit
Will Not Lift
Rated Load
Check the power source.
Note on DC models the low
low battery indicator (red voltage
LED) light would be on
indicting a low voltage
condition.
Charge the battery OR
check battery condition
and replace bad battery
OR use the appropriate
power cord OR consult
Genie Industries Service
Department.
good
Check the pressure relief
Adjust the pressure relief
valve setting. See
incorrect valve. See Repair
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
September 2016
Section 5 - Troubleshooting Flow Charts
Chart 11
Auxiliary
Platform
Lowering
Will Not
Operate
Check the low auxillary
battery indicator (red
LED) light. If on, it is
showing a low voltage
condition.
on
Replace the 8 -1.5V, AA
size batteries.
off
Check the auxillary
lowering battery holder to
make sure that the
no
batteries have been
installed.
Install the 8 - 1.5V, AA
size batteries.
yes
Disconnect the main
power source. Check for
power at terminal 9 and
9A of the 13 pole terminal
strip (J1) located in the 0V DC
ground control box.
Check for power at
terminal 1 of the 3 pole
terminal strip (J2) in the
ground control box.Put 0V DC
the positive lead of
voltage meter on terminal
1 and the negative lead
on terminal 2 the
grounding terminal.
12V DC
Replace the P.C. board
OR contact Genie
Industries Service
Department.
12V DC
If power is seen then the
symptom would be that
the auxillary lowering
from the platform would
work and not from the
ground control box.
5 - 24
wont
lower
from
base
Check the auxillary
lowering battery holder
wires (red wire connects
to terminal 1 and black
wire connects to terminal
2) for loose connections
at the J2 terminal strip
OR check for defects in
the battery holder and its
wires.
bad
Correct the loose
connections at the J2
terminal strip OR
Replace the battery
holder.
Replace the auxillary
down N.O. contact block
located in the ground
control box OR repair the
red wire from terminal 9a
of 13 pole terminal strip
(J1).
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 6 • Schematics
Schematics
About This Section
There are two groups of schematics in this section.
Electrical Schematics
Electrocution/burn hazard. Contact
with electrically charged circuits
may result in death or serious
injury. Remove all rings, watches
and other jewelry.
Observe and Obey:
Troubleshooting and repair procedures shall be
completed by a person trained and qualified on
the repair of this machine.
Hydraulic Schematics
Bodily injury hazard. Spraying
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.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Troubleshooting:
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.
General Repair Process
Be sure that all necessary tools and test
equipment are available and ready for use.
Troubleshoot
problem
still exists
Return to
service
Part No. 404632
Identify
symptoms
Malfunction
discovered
problem
solved
DPL-25S • DPL-30S • DPL-35S Super Series
Inspect
and test
Perform
repair
6-1
Section 6 • Schematics
September 2016
Electrical Legend
U9
TRANSFORMER
RD/YL
RD
BL
RD
RD
Limit Switch
N.O.
YL
BK
BN
WH
LEVEL SENSOR
CIRCUIT BOARD
S7
Transformer
LEVEL
SENSOR
Level Sensor
Wire with
description
Switch or Button
MOTOR
Motor
+
U9
Circuits crossing
no connection
Toggle Switch
-
Battery Charger
Diode
Red Emergency
Stop Button
Solenoid Valve
with Diode
NC
Pressure Switch
-
CB2
+
+
Circuit Breaker
30
87A
Connector
Flashing Beacon
8 AA Batteries
87
86
85
Relay
F11 Fuse
Power Relay
(function pump)
Horn or Alarm
WH
PLATFORM
MODE
KS1
KEY
SWITCH
3
4
BK
LED
12V Battery(s)
PR4
RD
BK
BK
Connection with
no terminal
C
NO
B1
B
2
WH
BASE
MODE
BN
1
Key Switch
6-2
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 6 • Schematics
Hydraulic Legend
Motor
Pump
Solenoid operated
dump valve
2 position 2 way
directional valve
Filter
Pressure compensated
flow control
Adjustable relief valve
Cylinder
Check Valve
Part No. 404632
DPL-25S • DPL-30S • DPL-35S Super Series
6-3
Section 6 • Schematics
September 2016
WIRE COLOR LEGEND
Color
Description
BL
Blue
BK
Black
GN/YL
Green/Yellow
OR
Orange
RD
Red
WH
White
YL
Yellow
6-4
Note: Use this legend
for the schematic on
the opposing page.

DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
Section 6 • Schematics
September 2016
Electrical Schematic
DPL Super Series DC Models
(before serial number DPL07-1499
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
6-5
Section 6 • Schematics
September 2016
Electrical Schematic
DPL Super Series DC Models
(before serial number DPL07-1499)
ABBREVIATION LEGEND
Item
Description
B
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
Warning light
Ground
Descent alarm
Key switch 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)
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
D5
EN
F11
FB2
GND
H4
KS1
L
M5
N.C.
N.O
*N
P
QD
SW
U
W
Y
Quick disconnect
QD1 = Battery 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
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
Valve coil
Y7 = Platform down
Y30 = Normally open dump valve
Note: Use these 2
legends for the
schematic on the
opposing page.

Section 6 • Schematics
September 2016
Electrical Schematic
DPL Super Series DC Models
(after serial number DPL07-1498)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
RD/BLK
1
KS1
KEY
SWITCH
P2
B
BN
BK
WH
1
RD
1
N.C.
RD
P1
EMERGENCY
STOP
SW8
BK
RD
BK
BK
16.0V DC INPUT
1
2
3
LEVELING
INDICATORS
BK
B4
N.C.
8 AA
BATTERIES
WH
L13 L15
L6
LOW BATTERY
INDICATOR FOR
AUXILIARY LOWERING
MODEL:
L12 L14 DC
LOW BATTERY
INDICATOR
L5
SW12
DOWN
12V DC OUTPUT
8
12V DC OUTPUT
9
12V DC OUTPUT
9A
10
11
UP SIGNAL OUTPUT (DELAYED)
12
UP SIGNAL INPUT
13
U10
BL
J BOX
BK
RD/BLK
Y7
YL
GN/YL
N.C.
PLATFORM
DOWN
YL
WHT
J BOX
GN/YL
RD
YL
YL
GN/YL
WH
WH
WH
RD
RD
RD
OR
RD
BL
RD
YL
OR
W4
BK
BK
BK
BK
3
GN/YL
YL
SW15
BK
BK
BK
SW13
RD
RD
SW14
4
SW16
WH
WH
GND
GROUND
STUD
GND
GN/YL
W5
6
7
RD
BK
OR
4 5
GN/YL
1 2 3
BL
7
WHT
6
7
BK
6
6
RD
BN
5
5
WH
4
4
YL
GN/YL
OR
3
3
OR
BL
2
1
2
BL
WH
WH
1
5
BK
WH
GN/YL
GN/YL
7
RD
BN
RD
RD
BN
GN/YL
OR
BL
BL
BL
GROUND
STUD
4 5
BK
6
STRAIN RELIEF
STRAIN RELIEF
1 2 3
BK
WH
WH
*N27
QD3
GROUND
CONTROL
BOX
TERMINAL
STRIP
UNITS WITHOUT PLUG
WH AND BK WIRES
REPLACE BL(1) AND BN(7) WIRES.
QD4
EN2
BK
WH
GROUND
STUD
RD
EN4
RD
RD
BL
WH
BK
BL
OR
2
RD
BK
POWER TO
PLATFORM
GFCI
RECEPTACLE
BK
7
BN
BN
RD
GN/YL
LED 12 FRONT LEFT
N.O.
*N17
NARROW PLATFORM UNITS
WH AND BK WIRES REPLACE
BL(2) AND OR(3) WIRES.
6
GROUND
N.C.
PLATFORM
DOWN
OR
5
UP SIGNAL OUTPUT
Y7
WH
4
LED 14 REAR LEFT
PC BOARD
AUXILIARY
DOWN
3
LED 15 REAR RIGHT
L7
POWER INDICATOR
UP
LEVELING
INDICATOR
INPUTS
OR
BK
RD
W3
CENTER TAP INPUT
12V DC POWER INPUT
NEGATIVE 12V DC AUX. INPUT
16.0V DC INPUT
POSITIVE 12V DC AUX. INPUT
LED 13 FRONT RIGHT
2
WH
PLATFORM
UP/DOWN
2
BASE
MODE
RD
CONTROL
ACTIVATE
SW11
3 RD
+
PLATFORM
CONTROL
BOX
B1
EMERGENCY
STOP
WH
BK
4 BK
BK
EN1
WH
BK
RD/BLK
RD
PLATFORM
MODE
TO PLUG
TO MOTOR
D5
POWER
SUPPLY
AC
WH
GN/YL
H4
7
DESCENT
ALARM
POWER UNIT
OR
RD
WH
FB2
BK
RD
WARNING
LIGHT
OPTIONAL
WARNING LIGHT
AND
DESCENT ALARM
RD
BK
B2
U9
BATTERY
CHARGER
AC
INPUT
+
-
RD
BATTERY
12V DC
+
QD1
RD
BK
BK
-
RD
BK
MOTOR
CONTACTOR
8
M5
F11
175 AMP FUSE
NON U.S. PLUGS
MOTOR
WH
Y30
N.O.
DUMP
VALVE
ES0074_J
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
6-6
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.

September 2016
Section 6 • Schematics
Electrical Schematic
DPL Super Series DC CE Models
(after serial number DPL07-1498)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
RD/BLK
1
KS1
KEY
SWITCH
BN
RD
1
RD
RD
RD
BK
BK
16.0V DC INPUT
1
2
3
LEVELING
INDICATORS
BK
B4
N.C.
8 AA
BATTERIES
WH
L13 L15
L6
MODEL:
L12 L14 DC
LOW BATTERY
INDICATOR
SW12
*N17
WH
RD
BL
WH
BK
BL
OR
WH
9
12V DC OUTPUT
9A
GROUND
10
UP SIGNAL OUTPUT
11
UP SIGNAL OUTPUT (DELAYED)
12
UP SIGNAL INPUT
13
U10
J BOX
RD/BLK
GN/YL
GN/YL
J BOX
GN/YL
RD
YL
YL
GN/YL
WH
WH
WH
RD
RD
RD
OR
RD
BL
RD
YL
OR
W4
STRAIN RELIEF
BK
D5
POWER
SUPPLY
AC
GN/YL
H4
H6
RD
BL
OR
YL
CR95
GUARDRAIL
LATCH
LS6
RD
FB2
7
BK
6
6
RD
SW15
BK
BK
BK
SW13
RD
RD
SW14
4
SW16
86
87A
85
BN
5
5
WH
4
4
YL
GN/YL
OR
3
3
OR
BL
2
1
2
BL
WH
30
30
87
1
6
WH
GN/YL
BK
86
87A
87
5
85
CR95
GUARDRAIL
LATCH
DOWN
LIMIT SWITCH
CE ONLY
BK
RD
OPTIONAL
WARNING LIGHT
AND
DESCENT ALARM
RD
BK
B2
U9
BATTERY
CHARGER
AC
INPUT
+
-
RD
BATTERY
12V DC
+
QD1
RD
BK
BK
-
RD
BK
WH
7
87
NC
WH
WARNING
LIGHT
30
BK
LOAD SENSE
POWER UNIT
OR
86
GN/YL 87A
CR27
DESCENT
ALARM
GN/YL
PLATFORM
OVERLOAD
ALARM
85
TO MOTOR
WH
WH
7
7
RD
WH
BK
GN/YL
RD
OR
TO PLUG
BK
6
BK
4 5
RD
1 2 3
YL
7
GN/YL
6
BL
4 5
OR
1 2 3
WH
QD3
BK
GN/YL
RD
BK
BK
WH
BK
WH
GN/YL
GN/YL
RD
WH
BK
WH
BN
BL
RD
BN
RD
GN/YL
OR
BL
WH
TERMINAL
STRIP
STRAIN RELIEF
RD
3
GN/YL
YL
QD4
W5
*N27
BL
WH
GROUND
STUD
PLATFORM
OVERLOAD
LED
Y7
N.C.
PLATFORM
DOWN
YL
GND
GND
L68
YL
GROUND
STUD
UNITS WITHOUT PLUG
WH AND BK WIRES
REPLACE BL(1) AND BN(7) WIRES.
WH
8
12V DC OUTPUT
BK
GN/YL
WH
BK
12V DC OUTPUT
RD
BK
EN4
GN/YL
7
BN
BN
POWER TO
PLATFORM
GFCI
RECEPTACLE
GROUND
STUD
LED 12 FRONT LEFT
N.C.
PLATFORM
DOWN
BL
BK
BK
BK
RD
BK
6
N.O.
NARROW PLATFORM UNITS
WH AND BK WIRES REPLACE
BL(2) AND OR(3) WIRES.
GN/YL
OR
5
2
Y7
WH
4
LED 14 REAR LEFT
PC BOARD
AUXILIARY
DOWN
3
LED 15 REAR RIGHT
L7
L5
DOWN
LEVELING
INDICATOR
INPUTS
LOW BATTERY
INDICATOR FOR
AUXILIARY LOWERING
POWER INDICATOR
UP
BK
W3
CENTER TAP INPUT
12V DC POWER INPUT
NEGATIVE 12V DC AUX. INPUT
16.0V DC INPUT
POSITIVE 12V DC AUX. INPUT
LED 13 FRONT RIGHT
2
+
EMERGENCY
STOP
BK
PLATFORM
UP/DOWN
WH
1
P1
SW8
EN2
GROUND
CONTROL
BOX
BK
N.C.
CONTROL
ACTIVATE
SW11
2
BASE
MODE
RD
WH
PLATFORM
CONTROL
BOX
B1
B
EMERGENCY
STOP
EN1
BK
3 RD
4 BK
BK
P2
WH
BK
RD/BLK
RD
PLATFORM
MODE
NO
C
PS2
MOTOR
CONTACTOR
PLATFORM OVERLOAD
PRESSURE SWITCH
8
M5
F11
175 AMP FUSE
NON U.S. PLUGS
MOTOR
WH
Y30
N.O.
DUMP
VALVE
ES0074_J
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
6-7
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.

Section 6 • Schematics
September 2016
Electrical Schematic
DPL Super Series AC Models
(before serial number DPL07-1499)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
6-8
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.

September 2016
Section 6 • Schematics
Electrical Schematic
DPL Super Series AC Models
(from serial number DPL07-1499 to DPL07-1562)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
RD/BLK
1
KEY
SWITCH
P2
RD
BN
P1
BK
1
BK
8 AA
BATTERIES
RD
RD
BL
WH
WH
BK
RD
BL
2
GN/YL
OR
5
6
LED 12 FRONT LEFT
7
12V DC OUTPUT
8
12V DC OUTPUT
9
12V DC OUTPUT
9A
BL
RD
BK
RD/BLK
GROUND
10
UP SIGNAL OUTPUT
11
UP SIGNAL OUTPUT (DELAYED)
12
UP SIGNAL INPUT
RD/YL
WH
4
LED 14 REAR LEFT
YL
13
BK
GN/YL
OR
YL
RD
OR
EN4
8A CIRCUIT BREAKER
220V AC MODELS
15A CIRCUIT BREAKER
110V AC MODELS
CB4
WH
WH
RD
RD
OR
RD
BL
RD
WH
WH
WH
WH
BL
BK
BK
BK
BK
SW13
RD
RD
4
SW14
SW16
7
7
BK
RD
6
6
RD
5
BN
110V AC / 220V AC
TERMINAL STRIP
DETAIL
5
WH
4
4
YL
GN/YL
OR
3
3
OR
BL
2
1
2
BL
WH
1
5
6
W5 TERMINAL
STRIP
GN/YL
BN
WH
BK
H4
GND
GN/YL
WH
GN/YL
BK
WH
STRAIN RELIEF
DESCENT
ALARM
GROUND
STUD
7
TO MOTOR
RD
OPTIONAL
WARNING LIGHT
AND
DESCENT ALARM
BL
OR
WH
YL
1
3
BK
N.O.
DUMP
VALVE
BL
*N8
MOTOR
110V AC
MOTOR DETAIL
2
4
GND
OR
YL
EN6
WH
1
3
BK
J-BOX
WH
M5
GROUND
SCREW
Y30
GN/YL
J-BOX
WH
EN5
GN/YL
WARNING
LIGHT
BK
GROUND
SCREW
BK
BK
FB2
WH
BN
BL
D5
POWER
SUPPLY
AC
SW15
GROUND
STUD
TO PLUG
WH
7
BK
6
RD
OR
4 5
GN/YL
BL
WHT
1 2 3
WH
RD
BK
BK
BK
GN/YL
YL
BK
7
WH
GN/YL
6
RD
RD
BK
GN/YL
OR
BL
WHT
GN/YL
GROUND
STUD
QD3
4 5
GN/YL
WH
BN
STRAIN RELIEF
1 2 3
*N30
BK
WH
WH
WH
*N27
YL
YL
QD4
BK
UNITS WITHOUT PLUG
WH AND BK WIRES
REPLACE BL(1) AND BN(7) WIRES.
3
J BOX
PR4
BK
BK
BL
OR
WH
POWER TO
PLATFORM
GFCI
RECEPTACLE
N.C.
PLATFORM
DOWN
OR
BK
WH
Y7
WHT
OR
GND
Y7
N.C.
PLATFORM
DOWN
J BOX
W4
PC BOARD
GROUND
STUD
BK
3
YL
BK
BN
WH
FOR 240 V OPERATION
JUMPER BROWN TO WHITE
THROUGH TERMINAL STRIP
AND LEAVE BLACK UNCONNECTED
AS SHOWN
BN
*N17
GN/YL
TRANSFORMER
RD
LED 15 REAR RIGHT
U10
POWER INDICATOR
N.O.
BN
NARROW PLATFORM UNITS
WH AND BK WIRES REPLACE
BL(2) AND OR(3) WIRES.
L6
LOW BATTERY
INDICATOR FOR
AUXILIARY LOWERING
INDICATOR
L5
SW12
AUXILIARY
DOWN
LEVELING
INDICATOR
INPUTS
L7
MODEL:
L12 L14 DC
LOW BATTERY
WH
DOWN
2
L13 L15
B4
YL
N.C.
UP
CENTER TAP INPUT
12V DC POWER INPUT
NEGATIVE 12V DC AUX. INPUT
16.0V AC INPUT
POSITIVE 12V DC AUX. INPUT
LED 13 FRONT RIGHT
BL
BK
1
3
RD
RD
BK
W3
16.0V AC INPUT
2
LEVELING
INDICATORS
+
EMERGENCY
STOP
RD
U11
WH
1
N.C.
SW8
PLATFORM
UP/DOWN
2
BASE
MODE
CONTROL
ACTIVATE
SW11
BK
B
GROUND CONTROL BOX
BK
RD
PLATFORM
CONTROL
BOX
B1
EMERGENCY
STOP
WH
EN2
3 RD
4 BK
BK
EN1
WH
YL
PLATFORM
MODE
-
RD/BLK
KS1
M5
Y30
N.O.
DUMP
VALVE
8
*N10
MOTOR
220 V AC
MOTOR DETAIL
2
4
GND
ES0075_H
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
6-9
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.

September 2016
Section 6 • Schematics
Electrical Schematic
DPL Super Series AC Models
(after serial number DPL07-1562)
N
M
L
K
J
I
H
G
F
E
D
C
B
A
*N28
BK
1
P1
BK
SW11
BK
PLATFORM
UP/DOWN
N.C.
WH
RD
6
2
GN/YL
RD
8
12V DC OUTPUT
9
L7
MODEL:
L12 L14 DC
LOW BATTERY
12V DC OUTPUT
9A
BK
RD/BLK
GROUND
10
UP SIGNAL OUTPUT
11
UP SIGNAL OUTPUT (DELAYED)
12
UP SIGNAL INPUT
13
U10
WH
BL
7
INDICATOR
RD
OR
12V DC OUTPUT
BL
WH
GND
WH
Y7
N.C.
PLATFORM
DOWN
YL
OR
BK
OR
YL
YL
YL
GN/YL
WH
WH
WH
RD
RD
RD
OR
RD
BL
RD
BK
3
J BOX
GN/YL
PR4
BK
6A CIRCUIT BREAKER
110V AC MODELS
N.C.
PLATFORM
DOWN
WHT
OR
WH
Y7
J BOX
BL
W4
PC BOARD
GROUND
STUD
RD
WH
BK
5
LED 14 REAR LEFT
RD/YL
WH
4
LED 12 FRONT LEFT
RD
*N17
BL
3
LED 15 REAR RIGHT
YL
BK
BN
BL
BN
BN
OR
LEVELING
INDICATOR
INPUTS
TRANSFORMER
RD
FOR
L13 L15 INDICATOR
AUXILIARY LOWERING
N.O.
NARROW PLATFORM UNITS
WH AND BK WIRES REPLACE
BL(2) AND OR(3) WIRES.
L6
POWER INDICATOR
AUXILIARY
DOWN
DOWN
2
3
L5
SW12
UP
CENTER TAP INPUT
12V DC POWER INPUT
NEGATIVE 12V DC AUX. INPUT
16.0V AC INPUT
POSITIVE 12V DC AUX. INPUT
LED 13 FRONT LEFT
LOW BATTERY
8 AA
BATTERIES
YL
BK
CONTROL
ACTIVATE
B4
RD
RD
RD
SW8
1
LEVELING
INDICATORS
+
EMERGENCY
STOP
W3
16.0V AC INPUT
FOR 120V OPERATION JUMPER BROWN TO
BLACK AND BLUE TO WHITE AS
SHOWN WITH DASHED LINES
(CB4 = 15A, CB9 = 6A)
U11
GROUND CONTROL BOX
2
1
YL
BN
BASE
MODE
N.C.
WH
1
-
PLATFORM
CONTROL
BOX
RD/BLK
RD
WH
EN2
2
BK
P2
EMERGENCY
STOP
EN1
B1
BK
3 RD
RD
BL
KEY
SWITCH
WH
BK
KS1
PLATFORM
MODE
FOR 240 V OPERATION
JUMPER BROWN TO WHITE
THROUGH TERMINAL STRIP AND LEAVE
BLACK UNCONNECTED AS SHOWN
CB4 = 8A, CB9 = 3A)
BK
BK
BK
GN/YL
YL
SW15
BK
BK
BK
SW13
RD
RD
SW14
4
SW16
WH
CB9
3A CIRCUIT BREAKER
220V AC MODELS
EN4
QD4
WH
*N30
GN/YL
WH
WH
WH
WH
BL
N
110V AC / 220V AC
TERMINAL STRIP
DETAIL
GN/YL
GN/YL
GN/YL
WH
WH
GN/YL
N
BN
WH
BK
N
BK
7
7
BK
RD
6
6
RD
BN
5
5
WH
4
4
YL
GN/YL
OR
3
3
OR
BL
2
1
2
BL
WH
WH
1
5
*N29
W5
6
(N) DENOTES A NEUTRAL
WIRE TO BE TAGGED
WITH AN (N) SLEEVE
TERMINAL
STRIP
OR
WH
H4
7
STRAIN RELIEF
DESCENT
ALARM
TO MOTOR
RD
BL
OR
WH
YL
1
3
BL
*N8
MOTOR
110V AC
MOTOR DETAIL
2
4
GND
OR
YL
EN6
WH
1
3
BK
J-BOX
WH
M5
BK
J-BOX
N.O.
DUMP
VALVE
GN/YL
OPTIONAL
WARNING LIGHT
AND
DESCENT ALARM
EN5
GROUND
SCREW
Y30
WH
WARNING
LIGHT
BK
GROUND
SCREW
BK
WH
FB2
GN/YL
*N27
UNITS WITHOUT PLUG
WH AND BK WIRES REPLACE
BL AND BN WIRES.
GN/YL
GN/YL
BK
D5
POWER
SUPPLY
AC
WH
BK
7
N
TO PLUG
WH
6
7
BK
4 5
6
RD
BL
OR
WHT
1 2 3
4 5
GN/YL
1 2 3
N
BL
WH
GN/YL
BK
RD
STRAIN RELIEF
QD3
N
BK
RD
BN
BL
BK
GN/YL
OR
BL
WHT
GN/YL
220V AC MODELS
BK
BN
WH
BK
CB4 8A CIRCUIT BREAKER
GROUND
STUD
GN/YL
15A CIRCUIT BREAKER
110V AC MODELS
WH
POWER TO
PLATFORM
GFCI
RECEPTACLE
M5
Y30
N.O.
DUMP
VALVE
8
*N10
MOTOR
220 V AC
MOTOR DETAIL
2
4
GND
ES0075_M
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
6 - 10
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.

September 2016
Section 6 • Schematics
Electrical Schematic
DPL Super Series AC CE Models
(from serial number DPL07-1499 to DPL07-1562)
M
L
K
J
I
H
G
F
E
D
C
B
KS1
PLATFORM
MODE
BK
P2
B1
B
PLATFORM
CONTROL
BOX
BASE
MODE
RD
WH
BK
BK
1
16.0V AC INPUT
1
2
3
RD
+
L13 L15
B4
YL
8 AA
BATTERIES
N.C.
LOW BATTERY
INDICATOR FOR
AUXILIARY LOWERING
L7
MODEL:
L12 L14 DC
LOW BATTERY
INDICATOR
L5
SW12
U11
TRANSFORMER
RD
RD
5
6
LED 12 FRONT LEFT
7
12V DC OUTPUT
8
12V DC OUTPUT
9
12V DC OUTPUT
9A
GROUND
10
UP SIGNAL OUTPUT
11
UP SIGNAL OUTPUT (DELAYED)
12
UP SIGNAL INPUT
RD
BL
QD4
GN/YL
BK
7
7
BK
WH
RD
6
6
RD
WH
BN
5
5
OR
WH
4
4
YL
GN/YL
OR
3
3
OR
BL
2
1
2
BL
WH
WH
1
SW15
BK
BK
BK
RD
RD
SW14
SW16
BL
WH
CR95
GUARDRAIL
LATCH
GN/YL
PR4
GROUND
STUD
87A
BK
GN/YL
BN
WH
WH
30
STRAIN RELIEF
DESCENT
ALARM
BK
WH
87
NC
OPTIONAL
WARNING LIGHT
AND
DESCENT ALARM
BL
OR
WH
YL
1
3
BL
*N8
MOTOR
110V AC
MOTOR DETAIL
2
4
GND
OR
YL
EN6
WH
1
3
M5
Y30
N.O.
DUMP
VALVE
*N10
MOTOR
WH
BK
BK
J-BOX
WH
BK
N.O.
DUMP
VALVE
GN/YL
M5
GROUND
SCREW
Y30
WH
J-BOX
WH
BK
EN5
BK
GROUND
SCREW
GN/YL
RD
OR
YL
GND
30
NO
7
C
PS2
BK
WARNING
LIGHT
BL
BK 87A
GN/YL
86
TO MOTOR
WH
FB2
6
GN
85
BK
RD
PLATFORM
OVERLOAD
ALARM
CR95
GUARDRAIL
LATCH
LOAD SENSE
WH
GROUND
STUD
GN/YL
H6
86
WH
BK
GN/YL
CR27
GND
GN/YL
GN/YL
85
BK
GN/YL
BK
GN/YL
WH
H4
WH/BK
WH
WH
WH
BL
BK
BK
BK
BK
WH
GN/YL
RD
W5
WH
WH
BK
POWER
SUPPLY
AC
87A
87
TERMINAL
STRIP
TO PLUG
D5
5
WH
GN/YL
GROUND
STUD
BK
RD
YL
7
GN/YL
7
6
BL
6
4 5
OR
4 5
1 2 3
WHT
1 2 3
86
GN/YL
110V AC / 220V AC
TERMINAL STRIP
DETAIL
WH
BN
BL
BN
GN/YL
BK
WH/BK
RD
GN/YL
OR
BL
WHT
*N30
GN/YL
BL
WH
QD3
85
WH/BK
STRAIN RELIEF
RD
30
BK/WH
*N27
PLATFORM
OVERLOAD
LED
RD
BK
UNITS WITHOUT PLUG
WH AND BK WIRES
REPLACE BL(1) AND BN(7) WIRES.
L68
8A CIRCUIT BREAKER
220V AC MODELS
15A CIRCUIT BREAKER
110V AC MODELS
CB4
GND
POWER TO
PLATFORM
GFCI
RECEPTACLE
WH
RD
2
SW13
3
OR
OR
WH
RD
BL
OR
WH
87
BK
RD
4
EN4
GN/YL
RD
OR
OR
BK
GROUND
STUD
WH
BN
BK
WH
BN
NARROW PLATFORM UNITS
WH AND BK WIRES REPLACE
BL(2) AND OR(3) WIRES.
BK
WH
BK
BK
BK
GN/YL
N.O.
*N17
GN/YL
1
YL
RD
BK
RD/BLK
GN/YL
WH
BK
RD
YL
YL
RD
BL
BL
13
N.C.
PLATFORM
DOWN
J BOX
GN/YL
YL
OR
W4
PC BOARD
AUXILIARY
DOWN
RD/YL
Y7
N.C.
PLATFORM
DOWN
YL
FOR 240 V OPERATION
JUMPER BROWN TO WHITE
THROUGH TERMINAL STRIP
AND LEAVE BLACK UNCONNECTED
AS SHOWN
WH
4
LED 14 REAR LEFT
YL
BK
BN
WH
RD
3
LED 15 REAR RIGHT
U10
POWER INDICATOR
UP
DOWN
LEVELING
INDICATOR
INPUTS
L6
RD
RD
BK
W3
CENTER TAP INPUT
12V DC POWER INPUT
NEGATIVE 12V DC AUX. INPUT
16.0V AC INPUT
POSITIVE 12V DC AUX. INPUT
LED 13 FRONT RIGHT
2
LEVELING
INDICATORS
WH
BK
PLATFORM
UP/DOWN
1
P1
SW8
GROUND CONTROL BOX
WH
EMERGENCY
STOP
RD
J BOX
EN2
BK
N.C.
CONTROL
ACTIVATE
SW11
2
BN
EMERGENCY
STOP
EN1
BK
KEY
SWITCH
RD
RD
3
BK
4
Y7
GN/YL
WH
-
RD/BLK
RD/BLK
A
YL
N
PLATFORM OVERLOAD
PRESSURE SWITCH
LS6
8
DOWN
LIMIT SWITCH
CE ONLY
220 V AC
MOTOR DETAIL
2
4
GND
ES0075_H
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
6 - 11
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.

September 2016
Section 6 • Schematics
Electrical Schematic
DPL Super Series AC CE Models
(after serial number DPL07-1562)
M
L
K
J
I
H
G
F
E
D
C
B
*N28
BK
1
BK
+
B4
N.C.
RD
N.O.
BN
OR
LED 15 REAR RIGHT
5
LED 14 REAR LEFT
6
LED 12 FRONT LEFT
7
12V DC OUTPUT
8
12V DC OUTPUT
9
12V DC OUTPUT
9A
BK
RD/BLK
11
UP SIGNAL OUTPUT (DELAYED)
12
UP SIGNAL INPUT
13
GN/YL
WH
WH
RD
RD
OR
RD
RD
BK
BK
BK
QD4
BL
GN/YL
BK
7
7
BK
WH
RD
6
6
RD
WH
BN
5
5
OR
WH
4
4
YL
GN/YL
OR
3
3
OR
BL
2
1
2
BL
WH
W4
WH
1
GN/YL
YL
WH
BK
RD
YL
YL
RD
BL
BL
10
SW15
BK
BK
BK
2
SW13
RD
RD
SW14
SW16
3
BL
WH
CR95
OR
WH
WH
4
GUARDRAIL
LATCH
PR4
BK
85
87A
87
RD
WH
30
86
BK/WH
3A CIRCUIT BREAKER
220V AC MODELS
GN/YL
5
GN/YL
GN/YL
GN/YL
WH
WH
W5
GN/YL
OR
87A
87
TERMINAL
STRIP
30
85
86
GN/YL
WH
GN/YL
WH
WH
WH
WH
GN/YL
WH
BN
BL
BK
*N29
(N) DENOTES A NEUTRAL
WIRE TO BE TAGGED
WITH AN (N) SLEEVE
CR95
BK
GN/YL
GUARDRAIL
LATCH
WH
GN/YL
H4
DESCENT
ALARM
GN
BK 87A
GN/YL
BK
TO MOTOR
CR27
LOAD SENSE
BL
OR
WH
YL
1
3
BK
BK
BL
*N8
MOTOR
110V AC
MOTOR DETAIL
2
4
GND
OR
YL
EN6
WH
1
3
BK
J-BOX
WH
M5
N.O.
DUMP
VALVE
GN/YL
J-BOX
GROUND
SCREW
Y30
WH
EN5
BK
GROUND
SCREW
BK
M5
*N10
MOTOR
WH
RD
OPTIONAL
WARNING LIGHT
AND
DESCENT ALARM
6
85
WH
STRAIN RELIEF
WH
BK
GN/YL
BK
WH
BK
WH
RD
N
WH
GN/YL
WARNING
LIGHT
BL
*N30
110V AC / 220V AC
TERMINAL STRIP
DETAIL
WH
GN/YL
*N27
UNITS WITHOUT PLUG
WH AND BK WIRES REPLACE
BL AND BN WIRES.
OR
N
BK
BK
YL
D5
POWER
SUPPLY
AC
FB2
YL
N
OR
BK
H6
PLATFORM
OVERLOAD
ALARM
N
TO PLUG
WH
GN/YL
RD
7
GN/YL
7
6
BL
6
4 5
OR
4 5
1 2 3
WHT
BK
1 2 3
N
BL
BN
WH
GN/YL
BK
STRAIN RELIEF
QD3
N
BK
RD
BN
RD
WH/BK
BL
BK
GN/YL
OR
BL
WHT
RD
GN/YL
L68
PLATFORM
OVERLOAD
LED
BK
15A CIRCUIT BREAKER
110V AC MODELS
WH
WH/BK
220V AC MODELS
WH
WH
CB9
WH
BK
GN/YL
RD
1
J BOX
GN/YL
YL
WH
4
GROUND
6A CIRCUIT BREAKER
110V AC MODELS
RD
BK
WH
BL
OR
GND
CB4 8A CIRCUIT BREAKER
GROUND
STUD
3
PC BOARD
GROUND
STUD
POWER TO
PLATFORM
GFCI
RECEPTACLE
BK
RD/YL
RD
UP SIGNAL OUTPUT
U10
YL
BK
BN
BL
N.C.
PLATFORM
DOWN
BN
EN4
GN/YL
INDICATOR
RD
*N17
NARROW PLATFORM UNITS
WH AND BK WIRES REPLACE
BL(2) AND OR(3) WIRES.
L6
LEVELING
INDICATOR
INPUTS
LOW BATTERY
INDICATOR FOR
AUXILIARY LOWERING
POWER INDICATOR
AUXILIARY
DOWN
DOWN
2
L5
SW12
UP
1
L7
MODEL:
L12 L14 DC
LOW BATTERY
WH
BK
16.0V AC INPUT
3
L13 L15
8 AA
BATTERIES
YL
BK
W3
CENTER TAP INPUT
12V DC POWER INPUT
NEGATIVE 12V DC AUX. INPUT
16.0V AC INPUT
POSITIVE 12V DC AUX. INPUT
LED 13 FRONT LEFT
2
LEVELING
INDICATORS
RD
RD
RD
SW8
PLATFORM
UP/DOWN
BK
P1
EMERGENCY
STOP
CONTROL
ACTIVATE
SW11
BN
BASE
MODE
N.C.
WH
1
TRANSFORMER
Y7
N.C.
PLATFORM
DOWN
YL
FOR 120V OPERATION JUMPER BROWN TO
BLACK AND BLUE TO WHITE AS
SHOWN WITH DASHED LINES
(CB4 = 15A, CB9 = 6A)
U11
GROUND CONTROL BOX
J BOX
WH/BK
PLATFORM
CONTROL
BOX
RD/BLK
RD
WH
2
-
EMERGENCY
STOP
EN1
B1
BK
P2
Y7
GN/YL
FOR 240 V OPERATION
JUMPER BROWN TO WHITE
THROUGH TERMINAL STRIP AND LEAVE
BLACK UNCONNECTED AS SHOWN
(CB4 = 8A, CB9 = 3A)
EN2
3 RD
RD
BL
KEY
SWITCH
WH
BK
KS1
PLATFORM
MODE
A
YL
N
Y30
N.O.
DUMP
VALVE
LS6
86
GND
30
WH
87
7
NC
NO
C
PS2
PLATFORM OVERLOAD
PRESSURE SWITCH
8
DOWN
LIMIT SWITCH
CE ONLY
220 V AC
MOTOR DETAIL
2
4
GND
ES0075_M
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
6 - 12
Section 6 • Schematics
September 2016
Electrical Schematic
DPL Super Series AC CE Models
(after serial number DPL07-1562)
Section 6 • Schematics
September 2016
Hydraulic Schematic
DPL Super Series ANSI Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
6 - 13
Section 6 • Schematics
September 2016
Hydraulic Schematic
DPL Super Series ANSI Models
Section 6 • Schematics
September 2016
Hydraulic Schematic
DPL Super Series CE Models
N
M
L
K
J
I
H
G
F
E
D
C
B
A
1
2
3
4
5
6
7
8
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
6 - 14
Section 6 • Schematics
September 2016
Hydraulic Schematic
DPL Super Series CE Models
September 2016
Section 7 - Repair Procedures
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.
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 a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
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
Before Repairs Start:
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.
Identify
symptoms
Malfunction
discovered
Troubleshoot
problem
still exists
Return to
service
problem
solved
Inspect
and test
Perform
repair
Symbols Legend
Indicates the presence of a hazard
that will cause death or serious
injury.
Indicates the presence of a hazard
that may cause death or serious
injury.
Indicates the presence of a hazard
that will or may cause serious
injury or damage to the machine.
Indicates special operation or
maintenance information.
Indicates that a specific result is expected after
performing a series of steps.
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
7-1
September 2016
Section 7 - Repair Procedures
Base Assembly
1-1
Interlocks
1-2
Base Components
The interlock contact brackets indicate proper
installation of the outriggers and only allow the
machine to operate when the outriggers are
properly installed and adjusted.
How to Adjust the Platform
Manual Lowering Cable
How to Remove an Interlock
Contact Bracket
1 Fully lower the platform, turn the machine off
and remove the key.
2 Store the outriggers in the storage sockets.
3 Trace the interlock contact bracket wires into
the junction box.
4 Label and disconnect the contact bracket wires.
5 Remove the interlock contact bracket mounting
fasteners from the outrigger base socket.
6 Grasp the interlock contact bracket inside the
base outrigger socket and pull it out with the
wires.
1 Remove the base-end covers to access the
platform manual lowering cable.
2 Check to be sure:
Steer handle end:
• Actuator bracket is connected to the base
and the manual lowering valve
• Manual lowering cable is connected to the
base with two lock nuts
• Manual lowering cable is attached to the
actuator bracket
Ladder end:
• Actuator bracket is connected to the base
and the manual lowering valve
• 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
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 7 - Repair Procedures
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 Lower the platform, turn the machine off and
remove the key.
2 Connect the leads from an ohmmeter to the
valve coil terminals.
Valve coil specifications
Solenoid operated N.C. valve, 10V
Part No. 40462
7.8 to 9.5 Ω
DPL-25S • DPL-30S • DPL-35S Super Series
7-3
September 2016
Section 7 - Repair Procedures
Ground Control Box
2-1
How to Test the Transformer
- AC Models
2-2
How to Test the AC Contactor
- AC Models
1 Fully lower the platform, turn the key switch off
and disconnect the power supply.
1 Fully lower the platform, turn the key switch off
and disconnect the power supply.
2 Open the ground control box and locate the
transformer.
2 Open the ground control box and locate the AC
contactor.
3 Label and then disconnect all wiring from the
transformer.
3 Label and then disconnect all wiring from the
contactor.
4 Connect the leads from an ohmmeter to the
following terminal combinations and check the
resistance.
4 Connect the leads from an ohmmeter to the
following terminal combinations and check the
continuity/resistance.
h
g
f
1
8
6
2
e
d
c
a
b
c
d
e
f
g
h
b
a
yellow wire
black wire
white wire
brown wire
blue wire
red wire no. 1
red/yellow wire
red wire no. 2
0
Test
terminal 0 to 1
Test
Desired result
brown wire to blue wire
20 to 22 Ω
black wire to white wire
16 to 19 Ω
yellow wire to white wire
16 to 19 Ω
red/yellow wire to red wire no. 1
0.5 to 1.5 Ω
red/yellow wire to red wire no. 2
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
0.5 to 1.5 Ω
all other wire combinations
7-4
all other terminal combinations
4
Desired result
80 to 85 Ω
no continuity
(infinite Ω)
no continuity
(infinite Ω)
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 7 - Repair Procedures
This page intentionally left blank.
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
7-5
September 2016
Section 7 - Repair Procedures
Hydraulic Power Units
3-1
Hydraulic Power Unit Components - AC Models
Index
No.
Description
1
115-230V AC electric motor ............................. Single phase - 2850/3450 rpm, 50/60 Hz
2
Capacitor .......................................................... 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 DC coil ....................................................... Activates N.O. dump valve
6
Breather cap ..................................................... Reservoir vent
7
Sight gauge ...................................................... Hydraulic fluid level
8
Reservoir .......................................................... 1.3 gallons (4.9 liters)
9
Pipe plug ........................................................... Drains reservoir
10
Pick-up filter ...................................................... Filters hydraulic fluid
11
O-ring ................................................................ Seals reservoir
12
Check valve ...................................................... One-way valve for pump output
13
Pump ................................................................ 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 ......................................................... Seals motor from contaminants
15
Motor bearing ................................................... Aligns motor shaft into pump
7-6
Function
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 7 - Repair Procedures
HYDRAULIC POWER UNITS
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
7-7
September 2016
Section 7 - Repair Procedures
HYDRAULIC POWER UNITS
3-2
Hydraulic Power Unit Components - DC Models
Index
No.
Description
Function
1
12V DC electric motor ...................................... 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 DC coil ....................................................... Activates N.O. dump valve
6
Breather cap ..................................................... Reservoir vent
7
Sight gauge ...................................................... Hydraulic fluid level
8
Reservoir .......................................................... 1.3 gallons (4.9 liters)
9
Pipe plug ........................................................... Drains reservoir
10
Pick-up filter ...................................................... Filters hydraulic fluid
11
O-ring ................................................................ Seals reservoir
12
Check valve ...................................................... One way valve for pump output
13
Pump ................................................................ 0.7 to 1 gallons per minute at 2000 psi
2.6 to 3.76 liters per minute at 138 bar
14
Motor seal ......................................................... Seals motor from contaminants
15
Motor bearing ................................................... Aligns motor shaft into pump
7-8
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 7 - Repair Procedures
HYDRAULIC POWER UNITS
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
7-9
September 2016
Section 7 - Repair Procedures
HYDRAULIC POWER UNITS
3-3
How to Remove the Hydraulic
Power Unit - AC Models
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.
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.
2 Remove the base cover from the power unit.
3 Tag, disconnect and plug the hydraulic hoses.
Cap the fittings on the power unit.
3 Tag, disconnect and plug the hydraulic hoses.
Cap the fittings on the power unit.
Bodily injury hazard. Spraying
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/burn hazard. Contact
with electrically charged circuits
may result in death or serious
injury. Remove all rings, watches
and other jewelry.
Bodily injury hazard. Spraying
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
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.
5 Tag and disconnect the electrical wiring from
the motor start solenoid.
6 Remove the power unit mounting fasteners.
6 Support the hydraulic power unit with a lifting
device.
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
will fall unless it is properly
supported.
7 Remove the power unit mounting fasteners,
then remove the power unit from the machine.
Crushing hazard. The power unit
will fall unless it is properly
supported.
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.
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
September 2016
Section 7 - Repair Procedures
HYDRAULIC POWER UNITS
3-5
How to 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.
Note: 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
DPL-25S • DPL-30S • DPL-35S Super Series
7 - 11
September 2016
Section 7 - Repair Procedures
HYDRAULIC POWER UNITS
3-6
How to Adjust the Pressure
Relief Valve
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.
1 Remove the base cover.
13 Hold the relief valve screw and tighten the lock
nut. Be sure the relief valve screw does not
turn.
2 Remove the breather cap from the reservoir.
3 Fill the reservoir up to the sight gauge with
Dexron ATF hydraulic oil equivalent.
4 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 lbs
340 kg
750 lbs
340 kg
600 lbs
272 kg
DPL-30S
750 lbs
340 kg
750 lbs
340 kg
600 lbs
272 kg
DPL-35S
600 lbs
272 kg
600 lbs
272 kg
500 lbs
227 kg
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
not continue to operate the
machine if the hydraulic pump is
cavitating.
15 Install the breather cap and the base cover.
Note: 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.
7 - 12
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 7 - Repair Procedures
HYDRAULIC POWER UNITS
3-7
How to Check the Resistance
of a Valve Coil
3-8
How to Test the Motor Start
Solenoid - DC Models
1 Fully lower the platform, turn the machine off
and remove the key.
Electrocution/burn hazard. Contact
with electrically charged circuits
may result in death or serious
injury. Remove all rings, watches
and other jewelry.
2 Connect the leads from an ohmmeter to the
valve coil terminals.
Electrocution/burn hazard.
Disconnect 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
13 to 17 Ω
Small post to ground
Valve coil specifications
Solenoid operated N.O. valve, 10V
5.9 to 7.2 Ω
Lowering valve, 10V
(located at base of cylinder)
7.8 to 9.5 Ω
2 large posts
no continuity
(infinite Ω)
Small post to
any large post
no continuity
(infinite Ω)
b
a
a
b
a
high amp power contact terminal
(large post)
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
2 large posts
Part No. 40462
DPL-25S • DPL-30S • DPL-35S Super Series
Desired result
continuity (zero Ω)
7 - 13
September 2016
Section 7 - Repair Procedures
Mast Assembly
DPL-25S
DPL-30S
DPL-35S
Mast Components
a number 4 column idler wheel assembly
b number 3 column idler wheel assembly
c number 2 column idler wheel assembly
d number 1 column
e number 2 column
f
number 3 column
7 - 14
g
h
i
j
k
l
number 4 column
carriage
number 5 column
number 5 column idler wheel assembly
number 6 column idler wheel assembly
number 6 column
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 7 - Repair Procedures
MAST ASSEMBLY
3 Remove the cylinder mounting fasteners from
the cylinder barrel end.
4-1
Lift Cylinder
4 Loosen the cylinder bracket mounting fasteners.
How to Remove a Lift Cylinder
a
This procedure requires specific
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 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.
d
c
b
a
b
c
d
bracket mounting fasteners
cylinder mounting fasteners
hydraulic cylinder
cylinder mounting plate
5 Support the cylinder and carefully slide it out of
the bottom of the mast.
a
Crushing hazard. The lift cylinder
will fall unless it is properly
supported.
b
c
a
b
c
top of no. 1 column
retaining bolt
clevis block
Bodily injury hazard. Spraying
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.
Part No. 40462
DPL-25S • DPL-30S • DPL-25S Super Series
7 - 15
September 2016
Section 7 - Repair Procedures
MAST ASSEMBLY
4-2
How to Remove a Mast Assembly
8 Tag, disconnect and cap the lift cylinder
hydraulic hoses. Remove the flow control valve
from the cylinder. Plug the cylinder ports.
This procedure requires specific
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.
Bodily injury hazard. Spraying
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.
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.
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
unless it is properly supported.
Mast assembly - steer handle end:
12 Place two saw horses under the mast.
5 Remove the junction box from 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.
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.
How to Disassemble the Mast
This procedure requires specific
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.
7 - 16
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 7 - Repair Procedures
MAST ASSEMBLY
3 Remove the socket head retaining bolt from the
clevis block on the lift cylinder rod end.
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.
a
12 Remove the adjustment nuts from the chain
tension rocker on the column.
b
13 Slide the column out the bottom of the mast.
c
14 Push the next column toward the top of the
mast to access the idler wheel assembly
mounting fasteners.
a
b
c
top of no. 1 column
retaining bolt
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, then remove the
idler wheel assembly.
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.
Note: If the chains are removed, be sure to mark
the location and label each chain before removal.
Note: 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.
Part No. 40462
DPL-25S • DPL-30S • DPL-25S Super Series
7 - 17
September 2016
Section 7 - Repair Procedures
MAST ASSEMBLY
How to Assemble the Mast
This procedure requires specific
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 Thoroughly clean all columns.
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 number 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.
2 Secure the number 1 column to the saw horses
and lay the chains out on the floor at the top.
Note: 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.
3 Apply a generous amount of Boe-lube wax
(Genie part number 90337) to the inside and
outside channels of each column.
16 Follow steps 14 and 15 for each remaining idler
wheel assembly.
4 Slide the number 2 column into the number 1
column.
17 Be sure that all of the idler wheel axle mounting
fasteners are flush with the 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.
Component damage hazard. The
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 4-3, How to Adjust the Lifting
Chains.
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.
7 - 18
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 7 - Repair Procedures
MAST ASSEMBLY
4-3
How to Adjust the Lifting Chains
4-4
How to Adjust the Glide Pads
When adjusting the lifting chains, it is very
important to maintain equal adjustment for both
mast assemblies.
When adjusting the glide pads, 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.
1 Fully lower the platform, turn off the machine
and remove the key.
To adjust column chains:
2 Mark the 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
alignment 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.
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-lbs
(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.
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
September 2016
Section 7 - Repair Procedures
MAST ASSEMBLY
4-5
How to Inspect the Lifting Chains
Inspection
Procedure
Inspection Failure
Inspection Remedy
Wear
Count out 16 chain links
and measure pin to pin
centerline dimension with
a steel tape.
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.
Replace both chains on
that column section.
Replace entire chain. Do
not repair just the
affected portion of the
chain.
Visually inspect the
chains for rust and
corrosion.
Evidence of rust or
corrosion.
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.
When external surfaces
are not protected with a
layer of oil.
Lubricate chain with
motor oil (SAE 40).
Inspect chain link joints
for easy movement.
Joints that do not flex
freely or are bound up.
If rust and corrosion is
found , refer to "Failure
Remedy" for rust and
corrosion.
Note: Be sure to
measure a section of
chain that moves over
the idler wheels.
Rust and Corrosion
Tight Joints
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
September 2016
Section 7 - Repair Procedures
MAST ASSEMBLY
Inspection
Procedure
Inspection Failure
Inspection Remedy
Raised or Turned Pins
Visually inspect for raised
pins.
Raised pins.
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.
Misalignment of flats on
all "V" heads.
Replace both chains on
that column section. Do
not repair just the
affected portion of the
chain.
Visually inspect for wear
patterns on heads of link
pins and outside link
plates where they contact
the idler wheel.
Wear on pin heads or
noticeable wear in the
profile of the outside link
plate.
Replace both chains on
that column section. Do
not repair just the
affected portion of the
chain.
Chain Side
Check alignment of chain
anchors and idler wheels.
link plate wear
Chain Terminals
chain
terminals
Idler Wheels
Visually inspect chain
terminals.
threaded
rod
Visually inspect chain idler
wheels.
idler
wheel
Cracked Link Plates
Part No. 40462
Visually inspect chain link
plates for cracks.
Broken chain
terminals fingers.
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 inspection hole.
Replace chain terminal
and threaded rod.
Idler wheels have badly
worn flanges.
Replace idler wheel and
check chain alignment.
Idler wheels have
grooves worn into chain
contact surface.
Replace idler
wheel.
Cracks in any chain link
plate.
Replace both chains on
that column section.
Replace entire chain. Do
not repair just the affected
portion of the chain.
DPL-25S • DPL-30S • DPL-25S Super Series
7 - 21
September 2016
Section 7 - Repair Procedures
Platform
5-1
How to Remove the Platform
5-2
Platform Control Box
1 Remove the cover from the platform control box
and the AC outlet to access the mounting
screws.
How to Test the Contactors
2 Remove the control box and AC outlet.
1 Fully lower the platform, turn the key switch off
and disconnect the power supply.
3 Remove the platform control cable clamps from
the platform.
2 Loosen the platform control box lid fasteners
and open the control box.
4 Rotate the platform guard rails to the upright
position. Close and latch the platform entry gate
and the platform end guard rail.
3 Observe the markings on the contactor to be
checked. The N.O. marking designates the
switch as normally open and N.C. designates
the switch as normally closed.
5 Attach an overhead crane or similar lifting
device to the platform.
6 Remove the platform mounting fasteners.
7 Remove the platform from the machine.
Crushing Hazard. The platform will
fall if it is not properly supported
with the overhead crane.
If a platform is being replaced, be
sure that all appropriate safety and
instructional decals are applied to
the new platform.
7 - 22
4 Connect a continuity tester to the exposed
screw terminals.
Result: Normally open contactors should have
no continuity. Normally closed contactors
should have full continuity.
5 Push the small triangular button on the top of
the contactor and check the continuity.
Result: Normally open contactors should have
full continuity. Normally closed contactors
should have no continuity.
DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462
September 2016
Section 7 - Repair Procedures
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 0V 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
DPL-25S • DPL-30S • DPL-25S Super Series
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September 2016
Section 7 - Repair Procedures
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DPL-25S • DPL-30S • DPL-35S Super Series
Part No. 40462