Operator’s Manual with Maintenance Information Second Edition First Printing Part No.
Operator’s Manual Second Edition • First Printing Important Read, understand and obey these safety rules and operating instructions before operating this machine. Only trained and authorized personnel shall be permitted to operate this machine. This manual should be considered a permanent part of your machine and should remain with the machine at all times. If you have any questions, call Genie Industries. Contents Page Safety Rules ..............................................................
Second Edition • First Printing Operator’s Manual Safety Rules Danger Failure to obey the instructions and safety rules in this manual will cause death or serious injury. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator's manual. 1 Avoid hazardous situations. Know and understand the safety rules before going on to the next section. 2 Always perform a pre-operation inspection. 3 Always perform the function tests prior to use.
Operator’s Manual Second Edition • First Printing SAFETY RULES Do not use the machine on a moving or mobile surface or vehicle. Tip-over Hazards Do not raise the platform unless the base is level, all four outriggers are properly set up and the leveling jacks firmly contact the ground. Do not operate the machine in strong or gusty winds. Do not increase the surface area of the platform or the load. Increasing the area exposed to the wind will decrease machine stability.
Second Edition • First Printing Operator’s Manual SAFETY RULES Fall Hazards Maximum capacity - DPL-35S ANSI and CE 600 lbs 272 kg CSA 500 lbs 227 kg Maximum occupants 2 Do not operate the machine near drop-offs, holes, bumps, debris, unstable or slippery surfaces or other possible hazardous conditions. The guard rail system provides fall protection.
Operator’s Manual Second Edition • First Printing SAFETY RULES Allow for platform movement, electrical line sway or sag and movement due to strong or gusty winds. Electrocution Hazards Do not use the machine as a ground for welding. This machine is not electrically insulated and will not provide protection from contact with or proximity to electrical current. Do not operate the machine during lightning or storms.
Second Edition • First Printing Operator’s Manual SAFETY RULES Improper Use Hazard Decal Legend Do not leave the machine unattended unless the key is removed to secure from unauthorized use. Genie product decals use symbols, color coding and signal words to identify the following: Damaged Machine Hazards Do not use a damaged or malfunctioning machine. Conduct a thorough pre-operation inspection of the machine and test all functions before each work shift.
Operator’s Manual Second Edition • First Printing SAFETY RULES Battery and Charger Safety - DC Models Electrocution Hazards Connect the charger to a grounded AC circuit only. Burn Hazards Do not expose the battery or the charger to water or rain. Batteries contain acid. Always wear protective clothing and eye wear when working with batteries. Before each use, inspect for damage. Replace damaged items before operating. Lifting Hazard Avoid spilling or contacting battery acid.
Second Edition • First Printing Operator’s Manual Controls Ground Controls 1 Platform Controls 2 3 4 1 8 9 7 6 5 1 Red Emergency Stop button 5 DC models: Low battery indicator light 2 Key switch 6 Power light 3 Outrigger interlock display lights (four) 7 Auxiliary platform lowering button 4 Low battery indicator light for auxiliary lowering 8 Control activate button Part No.
Operator’s Manual Second Edition • First Printing Legend 1 2 3 4 5 6 7 8 9 10 8 Platform end guard rail Platform side guard rail Manual storage container Platform controls AC outlet Guard rail lifting arm Platform entry gate Platform end gate latch Platform Interlock display 11 AC models: Circuit breaker 12 Platform entry ladder 13 AC models: Power supply for machine DC models: AC power to platform 14 Platform entry ladder lock pin 15 Outrigger with leveling jack 16 Forklift pocket 17 Bubble level 18
Second Edition • First Printing Operator’s Manual Pre-operation Inspection Fundamentals It is the responsibility of the operator to perform a pre-operation inspection and routine maintenance. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator’s manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection. Know and understand the pre-operation inspection before going on to the next section.
Operator’s Manual Second Edition • First Printing PRE-OPERATION INSPECTION Pre-operation Inspection o Be sure that the operator’s, safety and responsibilities manuals are complete, legible and in the storage container located in the platform. o Breather cap o Be sure that all decals are legible and in place. See Decals section. o Platform entry ladder o Check for battery fluid leaks and proper fluid level. Add distilled water if needed. See Maintenance section.
Second Edition • First Printing Operator’s Manual Maintenance Maintenance Symbols Legend The following symbols have been used in this manual to help communicate the intent of the instructions. When one or more of the symbols appear at the beginning of a maintenance procedure, it conveys the meaning below. Observe and Obey: Only routine maintenance items specified in this manual shall be performed by the operator.
Operator’s Manual Second Edition • First Printing MAINTENANCE Check the Battery - DC Models Proper battery condition is essential to good machine performance and safe operation. Improper fluid levels or damaged cables and connections can result in component damage and hazardous conditions. Electrocution hazard. Contact with hot or live circuits could result in death or serious injury. Remove all rings, watches and other jewelry.
Second Edition • First Printing Operator’s Manual MAINTENANCE Scheduled Maintenance Maintenance performed quarterly, annually and every two years must be completed by a person trained and qualified to perform maintenance on this machine according to the procedures found in the service manual for this machine. Machines that have been out of service for more than three months must receive the quarterly inspection before they are put back into service. Part No.
Operator’s Manual Second Edition • First Printing Function Tests Fundamentals The function tests are designed to discover any malfunctions before the machine is put into service. The operator must follow the step-by-step instructions to test all machine functions. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator’s manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection.
Second Edition • First Printing Operator’s Manual FUNCTION TESTS 6 Be sure that all four interlock display lights at the ground controls are on. 7 Use the bubble level and adjust the leveling jacks until the machine base is level. Test Emergency Stop 11 Twist to release the red Emergency Stop button at the platform controls. 12 Push in the red Emergency Stop button at the ground controls to the off position.
Operator’s Manual Second Edition • First Printing FUNCTION TESTS Test Outrigger Interlock 28 Turn the key switch to platform control. 17 Twist to release the red Emergency Stop button at the platform controls. 29 Raise the platform approximately 6 in / 15 cm. 18 Push and hold the control activate button and rotate the up/down switch in the direction of intended travel. 31 Push and hold the control activate button and rotate the up/down switch in the down direction.
Second Edition • First Printing Operator’s Manual Workplace Inspection Workplace Inspection Be aware of and avoid the following hazardous situations: Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator’s manual. 1 Avoid hazardous situations. 2 Always perform a pre-operation inspection. 3 Always perform function tests prior to use. 4 Inspect the workplace. Know and understand the workplace inspection before going on to the next section.
Operator’s Manual Second Edition • First Printing Operating Instructions Fundamentals The Operating Instructions section provides instructions for each aspect of machine operation. It is the operator's responsibility to follow all the safety rules and instructions in the operator's, safety and responsibilities manuals. Do Not Operate Unless: You learn and practice the principles of safe machine operation contained in this operator’s manual. 1 Avoid hazardous situations.
Second Edition • First Printing Operator’s Manual OPERATING INSTRUCTIONS Setup Emergency Stop 1 Position the machine directly below the desired work area. 1 Push in the red Emergency Stop button at the platform controls or at the ground controls to stop the up function. 2 Connect to an appropriate power source: DC models: Connect the battery pack. AC models: Connect to a grounded 15A AC power supply. Use a 12 gauge / 3.3 mm² 3-wire grounded extension cord no longer than 50 feet / 13 m.
Operator’s Manual Second Edition • First Printing OPERATING INSTRUCTIONS Manual Lowering Fall Protection 1 Activate the manual lowering lever. Personal fall protection equipment (PFPE) is not required when operating this machine. If PFPE is required by job site or employer rules, the following shall apply: Auxiliary Platform Lowering - AC & DC Models 1 Turn the key switch to ground control. Pull out the red Emergency Stop button to the on position.
Second Edition • First Printing Operator’s Manual OPERATING INSTRUCTIONS 5 Set the timer based on the amount of use: Light Use (less than 15 lifting cycles): Set to 7 hours. Heavy Use (greater than 15 lifting cycles): Set to the on position. 6 The charger will automatically shut off at the end of the set period. Battery and Charger Instructions Note: If the ammeter drops to 3A or less within the first 15 minutes, the battery is fully charged.
Operator’s Manual Second Edition • First Printing Transport and Lifting Instructions Loading the Machine With a Forklift 1 Lower the platform. Observe and Obey: Common sense and planning must be applied to control the movement of the machine when lifting it with a crane or forklift. The transport vehicle must be parked on a level surface. The transport vehicle must be secured to prevent rolling while the machine is being loaded.
Second Edition • First Printing Operator’s Manual TRANSPORT AND LIFTING INSTRUCTIONS Observe and Obey: Center of gravity X Axis Y Axis Z Axis DPL-25 40.5 in 1.03 m 13.15 in 34.3 cm 32.9 in 83.6 cm DPL-30 40.5 in 1.03 m 13.15 in 34.3 cm 33 in 83.8 cm DPL-35 40.5 in 1.03 m 13.15 in 34.3 cm 33.11 in 84.1 cm Only qualified riggers should rig and lift the machine. Be sure the crane capacity, loading surfaces and straps or lines are sufficient to withstand the machine weight.
Operator’s Manual Second Edition • First Printing Decals Inspection for Decals with Words Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No.
Second Edition • First Printing Operator’s Manual DECALS Part No.
Operator’s Manual Second Edition • First Printing DECALS Inspection for Decals with Symbols Determine whether the decals on your machine have words or symbols. Use the appropriate inspection to verify that all decals are legible and in place. Part No.
Second Edition • First Printing Operator’s Manual DECALS Part No.
Operator’s Manual Second Edition • First Printing 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 9.1 m 34 ft 9 in 10.6 m Height, guard rails stowed 78 in 1.98 m 78 in 1.98 m 78 in 1.98 m Length, outriggers stowed 813/4 in 2.07 m 813/4 in 2.07 m 813/4 in 2.
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