Hi, i wonder if anyone could be so kind to help me. I have a S80 2000-model s/n 20089. When i raise the boom or extend the boom it will only allow me to travel about half a metre and then it will stop. I found that the voltage drop relay looses its power feed from the LS2 switch(NC as soon as it raises and the switch open all power gone), therefore my lift dump valve loose its power feed. All boom up/down or extend or retract solenoids have power. Now my question is where do the lift dump valve get its power supply other than the LS2 switch.:Banghead Also if i get the boom up or extend my drive speed is suppose to reduce for safety but this also does not happen it stays in high range(fast speed). Please help just give me some direction here. Thx
I am thinking there is one too many zeros in the serial number. 2089 maybe? Are the axles extended all the way? When the axles are retracted, the primary boom is only allowed to raise to a horizontal position. There will be no other boom functions except boom down and/or in when the axles are retracted and LS2 is activated. First the drive issue When the boom is elevated or extended past the limit switches, ground (battery negative) is put on Terminal 6 of the Anti-Stall Board. This causes the output from Terminal 10 to drop to the adjusted value of the Elevated Drive Speed trimpot. This should be adjusted so the machine drives at a speed of about one foot per second. (that's 1.0km/h so hang on!) When the boom is in the stowed position, the ground (battery negative) is removed from Terminal 6 of the Anti-Stall Board. This causes the output from Terminal 10 to output the adjusted value of the Stowed High-Drive Speed trimpot. It should be adjusted so the machine drives when in the stowed position at a speed of about 5.0km/h. (Feel the wind in your hair?) In the case of this machine, it appears that the ground (battery negative) is not being applied to Terminal 6 of the Anti-Stall Board. To determine if it is the limit switches/wiring ot the anti-stall board: Remove the ORANGE wire from Terminal 6 of the Anti-Stall Board. Temporarily attach one end of a jumper wire to Terminal 6 and connect the other end of the jumper wire to a known good ground (battery negative) point. The machine should drive at a reduced speed at this point. If it doesn't, turn the Elevated Drive Speed Trimpot counter-clockwise about ten turns and see if that reduces the drive speed. If not, then the Anti-Stall Board is defective. If the drive speed does reduce as desired then the Limit Switch circuit is suspect. To test the limit switch circuit, simply place a Voltmeter Positive lead on a known good battery positive point. The E-Stop switch is a good place. Place the Voltmeter Negative lead on the ORANGE wire removed from Terminal 6 of the Anti-Stall Board. With the boom in the stowed position, there should be no ground present on the ORANGE wire. The Voltmeter will be reading close to zero volts. When the boom is extended or elevated past the limit switches, there should be a ground present on the ORANGE wire. The Voltmeter should read close to battery voltage. If this is not the outcome of the test then the Limit Switch circuit is defective. One half of LS2 limit switch (normally-opened side) provides a Negative (ground) to Terminal 6 of the Anti-Stall Board when the machine is in the Elevated position. The other half of LS2 limit switch (normally-closed side) provides a battery Positive to the Voltage Drop Relay when the machine is in the Stowed position. To answer the question of where the Voltage Drop Relay gets the power from when the boom is elevated or extended: Relay CR8 brings power to the Voltage Drop Relay when the Primary Boom toggle switch or Joystick are deployed. The relay was installed in the machines to combat voltage drop when the axles were retracted. When the axles are retracted on this model S80, the Primary boom is only allowed to come up to a horizontal position governed by LS2. Without the axles extended, the Primary Boom would sometimes not come down from this horizontal position. This is due to the fact that without the axles extended, the dump valves as well as the primary boom down directional valve and proportional valve had to be opened simultaneously causing a considerable voltage drop. This caused one or more of the valves to not open completely, causing the boom to not come down. Long story short, when LS2 (Normally Closed) is open, the Voltage Drop Relay (CR20) gets its power through CR8 from terminal 2 of the terminal strip in the Lower Control Box. Terminal 2 of this terminal strip is energized when Primary Down is activated. LS2 is a focal point of both these circuits. Suspected wiring or components might be LS2 wiring or physical condition, the diode at terminal 2 of the lower control box terminal, or the improper installation/wiring of a limit switch upgrade that was current during the time this machine was in its infancy. These circuits are relatively easy to follow. If you do not have schematics or the service manual for the machine here is a link to the manual: http://manuals.gogenielift.com/Parts And Service Manuals/data/Service/Stick Booms/72062.pdf edit: This is a beginning point of diagnostics. We may get lucky and find it early or perhaps later. We are a patient bunch here.
Thank you very much for this very descriptive reply.This was my first post and I really received an awesome reply,thx. I am sure this will help me a lot in finding the problem. We bought this machine a week ago and is busy trying to fix all the problems which doesn't seem to be to much, only this problem was giving us a lot of grey hairs. Myself and one of my colleagues have been working on this problem now for about 2 days. But we will tackle this machine again on Monday with new meaning and with your good guidance. I will let know what the outcome was and if it is fixed. I think i could also have a problem with one of the (4x2)drive wheels brake mechanism, it releases later than the opposite wheel when driving. But for now I want the boom problem sorted first then I will get to that. Regards
Hi Voodoomojo Just a quick feed back. We started on the horse power limiter today . Found out that the previous owners put a + jumper from the E-stop straight to the hi/lo range switch, therefore it received constant full voltage, it didn't matter what I did to the trimpots nothing changed. It look like the hi/lo range switch was faulty and instead of replacing it they jumped it with constant power. But to be honest it took us a while to figure this out. Tomorrow we will start to attempt limit switches.
Hi I am still battling with the problem of getting the boom up past horizontal or extending it more than a foot. I do get power at TB2 once I activate TS17(down) but there is no power going to CR8 if want to raise the boom or extend it??? I lose power at CR20 if LS2 open, then I must get power from CR8 but CR8 only get power from TB2 by operating the boom DOWN switch TS17, that is how I understand it. Please tell me if there is another angle from which I could approach this problem.:beatsme
Problem fixed. After many days of battling with this problem we found that the pressure relieve valve on the Jack/Axle extend manifold was faulty. Therefore the pressure that went to the function manifold was too low. But now how to test the hyd. limit switches pressure circuit. I know it must be 24.1bar but where do i test it. There is only one test port on the function manifold.