Genie DPL-25S DPL-30S DPL-35S Super Series Service Manual 40462 – PDF DOWNLOAD
Language : English
Pages : 104
Downloadable : Yes
File Type : PDF
Table of Contents:
Genie DPL-25S DPL-30S DPL-35S Super Series Service Manual 40462 – PDF DOWNLOAD
Front Cover................................................................................................ 1 Introduction............................................................................................... 2 Serial Number Legend....................................................................................... 3 Safety Rules............................................................................................... 4 Table of Contents.......................................................................................... 6 Section Two • Specifications............................................................................... 10 Bolt Torque Specifications............................................................................. 11 Section Three • Scheduled Maintenance Inspections.......................................................... 12 Introduction........................................................................................... 12 Maintenance Tables..................................................................................... 13 Maintenance Inspection Report.......................................................................... 16 Section Four • Scheduled Maintenance Procedures............................................................ 18 Introduction........................................................................................... 18 Table A Procedures..................................................................................... 19 A-1 Inspect the Operator's and Responsibility Manuals............................................. 19 A-2 Inspect the Decals and Placards............................................................... 19 A-3 Inspect for Damage and Loose or Missing Parts................................................. 19 A-4 Check for Hydraulic Leaks..................................................................... 20 A-5 Check the Auxiliary Platform Lowering Operation............................................... 20 A-6 Check the Manual Platform Lowering Operation.................................................. 20 A-7 Inspect the Battery and Battery Charger - DC Models........................................... 21 A-8 Inspect the Columns for Damage................................................................ 21 A-9 Check the Sequencing Cables................................................................... 21 A-10 Check the Interlock System for Proper Operation.............................................. 22 A-11 Test the Power and Function Controls......................................................... 22 A-12 Inspect the Lifting Chains and Idler Wheels.................................................. 23 A-13 Inspect the Breather Cap..................................................................... 23 Table B Procedures..................................................................................... 24 B-1 Inspect the Electrical Wiring................................................................. 24 B-2 Inspect All Welds............................................................................. 24 B-3 Check the Lifting Chain Adjustments........................................................... 25 B-4 Check the Battery - DC Models................................................................. 25 B-5 Clean and Lubricate the Columns............................................................... 26 B-6 Test the Lifting Capacity..................................................................... 26 B-7 Test the Power to Platform Operation.......................................................... 27 B-8 Adjust the Sequencing Cables.................................................................. 27 B-9 Check for Proper Outrigger Length............................................................. 28 Table C Procedures..................................................................................... 29 C-1 Inspect and Lubricate the Casters............................................................. 29 C-2 Inspect the Mast Assemblies for Wear.......................................................... 29 C-3 Lubricate the Lifting Chains.................................................................. 30 C-4 Replace the Hydraulic Oil..................................................................... 30 C-5 Replace the Auxiliary Platform Lowering Batteries............................................. 31 Section Five • Troubleshooting Flow Charts................................................................. 32 Introduction........................................................................................... 32 Chart 1 Power Light Will Not Turn On - AC Models...................................................... 34 Chart 2 Power Light Will Not Turn On - DC Models...................................................... 36 Chart 3 Interlock Lights Will Not Turn On............................................................. 38 Chart 4 Machine Will Not Lift - AC Models............................................................. 41 Chart 5 Machine Will Not Lift, But Power Unit Will Operate - AC Models................................ 44 Chart 6 Machine Will Not Lift - DC Models............................................................. 46 Chart 7 Machine Will Not Lift, But Power Unit Will Operate - DC Models................................ 49 Chart 8 Machine Will Not Lower - Up Function Operates................................................. 51 Chart 9 Platform Will Not Hold In Up Position......................................................... 53 Chart 10 Power Unit Will Not Lift Rated Load.......................................................... 54 Chart 11 Auxiliary Platform Lowering Will Not Operate................................................. 55 Section Six • Schematics................................................................................... 56 Introduction........................................................................................... 56 Electrical Legend...................................................................................... 57 Hydraulic Legend....................................................................................... 58 Electrical Schematic - DPL Super Series DC Models (before serial number DPL07-1499)................... 60 Electrical Schematic - DPL Super Series DC Models (after serial number DPL07-1498).................... 62 Electrical Schematic - DPL Super Series DC CE Models (after serial number DPL07-1498)................. 64 Electrical Schematic - DPL Super Series AC Models (before serial number DPL07-1499)................... 66 Electrical Schematic - DPL Super Series AC Models (from serial number DPL07-1499 to DPL07-1562)....... 68 Electrical Schematic - DPL Super Series AC Models (after serial number DPL07-1562).................... 70 Electrical Schematic - DPL Super Series AC CE Models (from serial number DPL07-1499 to DPL07-1562).... 72 Electrical Schematic - DPL Super Series AC CE Models (after serial number DPL07-1562)................. 74 Hydraulic Schematic - DPL Super Series ANSI Models..................................................... 76 Hydraulic Schematic - DPL Super Series CE Models....................................................... 78 Section Seven • Repair Procedures.......................................................................... 80 Introduction........................................................................................... 80 Base Assembly.......................................................................................... 81 1-1 Interlocks.................................................................................... 81 1-2 Base Components............................................................................... 81 1-3 How to Check the Resistance of a Valve Coil................................................... 82 Ground Control Box..................................................................................... 83 2-1 How to Test the Transformer - AC Models....................................................... 83 2-2 How to Test the AC Contactor - AC Models...................................................... 83 Hydraulic Power Units.................................................................................. 85 3-1 Hydraulic Power Unit Components - AC Models................................................... 85 3-2 Hydraulic Power Unit Components - DC Models................................................... 87 3-3 How to Remove the Hydraulic Power Unit - AC Models............................................ 89 3-4 How to Remove the Hydraulic Power Unit - DC Models............................................ 89 3-5 How to Remove the Hydraulic Pump.............................................................. 90 3-6 How to Adjust the Pressure Relief Valve....................................................... 91 3-7 How to Check the Resistance of a Valve Coil................................................... 92 3-8 How to Test the Motor Start Solenoid - DC Models.............................................. 92 Mast Assembly.......................................................................................... 93 4-1 Lift Cylinder................................................................................. 94 4-2 How to Remove a Mast Assembly................................................................. 95 4-3 How to Adjust the Lifting Chains.............................................................. 98 4-4 How to Adjust the Glide Pads.................................................................. 98 4-5 How to Inspect the Lifting Chains............................................................. 99 Platform...............................................................................................101 5-1 How to Remove the Platform....................................................................101 5-2 Platform Control Box..........................................................................101 Back Cover.................................................................................................104
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