Hi guys, We bought 1 Genie S85 S/N 1708 4WD year 1999 and we have 1 problem with Hydraulic system. When we operated the functions, if there was no voltage went to Valve item G , all of the functions didn't operate. If we bypass the electronic signal and provide electric to Valve G, we can operate the functions. However, the hydraulic temperature will increase rapidly and after 30mins - 1hour the machine will stop working. We have checked 1 Genie S85 year 2000 S/N 1895 and found out the Valve G received electric only when we lower the main boom. All remaining functions, the valve received no electric. We tried to replace the valves with similar valves but couldn't fix the problem. We have also tested the wiring diagrams and made sure it stays the same with Genie S85 year 2000. Did anyone face the same problem with us ?? We have been fixing this machine for half a year but didn't make and progress. We also contacted local Genie Dealer but they didn't support used machine. Here is the schematic of the hydraulic system ( we downloaded on Genie).
Can't really read the schematic, but enough of it I'm pretty sure that "G" is the dump valve, it has to close when any function is engaged to provide pressure. When you activate the valve with your bypass wire of 12V, it closes and if you are not using any functions, the oil flow is bypassing through the relief valve, which is the reason you have so much heat. With the valve not activated does the steering and drive still function? Does this have extendable axles and are they in fact extended fully before attempting to operate?
Dear lantraxco, Very appreciated you reply. This machine has extendable axles and we extracted the axles before operating. All functions didn't operate unless Valve G received voltage. We tested with another Genie S85 year 2000, Valve G only received voltage when lower the main boom. Others functions ( include steer & drive), Valve G didn't received voltage. The machine worked normally. On the schematic and service manual Valve G named Solenoid Valve-no poppet - Hydraulic Limit Switch. I don't understand the hydraulic limit switch function in the machine ? is it the limit switch of the axles ??? Please check the full 4WD schematic : Valve types : Valve G and Valve SS are connected ( if valve G receives voltage, Valve SS also receives voltage).
These manuals are very poor in my opinion. I think I am beginning to somewhat understand some of the systems here. I think this is mostly an electrical problem, may I make some suggestion? I think Limit switch 2 is your problem, this is the limit switch on the side of the boom that is activated by the cable track I think? It senses that the boom is retracted to a certain point or shorter. The activating wire for the boom down function ties in after Limit switch 2, all other feeds are previous to it, so I am guessing either the switch is faulty or you have a broken wire. Please test Limit switch 1, which is the boom raise switch, check that power is present on at least one wire, the switch functions, and it is in proper position. Please do the same with Limit switch 2, which is the boom extend switch, same checks. With the engine running, boom down and in, you should have power going in and out of both limit switches? If the switches check out, please do these tests with the engine running: Test TB 46 for +12V If there is no power, check for a break in the white wire from the alternator to this point. Once you have 12V at TB46 please test TB42 for +12V, this test point is after the Limit switch 1, the boom must be fully down. Again once you have 12V at TB42, if the machine is not now functioning continue on.... Remove relay CR20, test for +12V at terminal 85, this is after Limit switch 2, the boom must be fully retracted. If there is no power, try testing while activating the boom down switch, this should provide +12V since you state that this function does work. There may be a broken wire between Limit switch 2 and this point, schematic says "Red 6". I hope some of this is helpful. In addition there are two hydraulic limit valves one on each axle that when both axles are fully extended, if they are functioning correctly and properly adjusted, send 350 psi pressure to valve "M" in the manifold which performs the same function as valve "G" closing off the dump line to tank and creating pressure for the boom and rotate, etc. functions. This needs to happen in order for the machine to function beyond the point where the limit switches open, it's a safety measure designed to prevent operation with the boom up and out if you do not fully extend the axles for stability. The two systems, electrical and hydraulic limit switches work together. Let me know what you find out!
If you get the machine working and still have heat problems, check valve Y, it seems to be a compensator which keeps pressure low until a function is activated, bypassing oil to tank at a much lower pressure than the relief valve would.
Dear lantraxco, Thanks for your help !!! We will try your suggestions and let you know the outcome.
Broken wire found Dear Lantraxco, We followed your instructions and found out that wire connect LS2 with CR20 was broken. After repairing the wire we finally can operate the machine. However, we faced another problem. We can't extend the boom, we have followed the Troubleshoot from Genie but everything was normal. Moreover, the Leveling function couldn't auto leveling the platform when we operated the main boom up. Plus the Steering function worked very poor and it steered very slow. I hope you could give us some good advices. Once again, we very appreciate your help !
We have found the problem that disabled boom extend function and got it fixed. There was 1 broken diode connected to valve. After replacing it we now can operate the machine
Yay! Well done. So, which things are still a problem? The auto leveling, and steering?
Dear Lantraxco, Yes we still have problem with steering function. It works quite slow comparing to other machines. Furthermore, the auto leveling didn't work when we raised the boom. We have check the voltage at the valves and didn't found anything. I hope you could give some advices !
Is the steering weak also, or just slow to function? Have you verified main relief valve is set to 2,900 psi? Valve CC is a priority flow divider, sends 5 gallons per minute oil to the steering manifold, valve YY splits oil off for the chassis jacks and axle extension, maybe you can check somehow. Other possibilities are bad piston seals in the steering cylinders, bad seals in the rotary coupler, malfunction in steering valve VV. Bad O-rings on any valve cartridge in the steering manifold or valve CC in the main manifold could be a problem. Can you level the basket with the controls, but the auto level does not work when raising and lowering the boom? If so then bad piston seals in the master leveling cylinder underneath the boom at the back end, behind the boom lift cylinder would be my guess. Almost done!
Dear Lantraxco, Thanks for your advices, For the Steering function : It worked but the tires moved slower than others machines. We haven't checked the relief valve yet. We also thought about the O-ring and we are checking that. For the auto leveling : We can level the basket with control but only when we lower the main boom. When the main boom raised, that function was disabled. Others machines also have the same result. Level function worked when lowered the main boom, when the main boom raised, the basket will auto-leveling.
Okay, so still working on the steering. For the leveling you are saying that the auto leveling works as the boom goes up and down, and the levelling switches will manually level the basket as long as the boom is down? You mentioned testing, is there no voltage at the steering valve when the boom is up and you operate one of the levelling switches? I found in the schematic and operation manual reference to: Machines equipped with Platform Level Control Disable Function: The platform level toggle switch will not operate when the boom is raised or extended past the drive speed limit switches Perhaps this machine is so equipped?
Dear Lantraxco, Sorry for my late reply. We have just returned to work after holiday. Up to now, the machine still have problem with steering ( i think we could handle that issue). However, we had another issue that needed to be fixed : the engine will shut down after 6~8 mins. There was a problem with terminal #9 to relays CR2. If we bypassed that wire (provide 12V to CR2), the engine will continue working. I think the problem has something related to Alternator since we had to remove it once when checking the engine. The engine also gives us a big headache, it emitted thick black smoke when the machine runs through a rough terrain. I think we have to maintain it as well. That is the updated information about the machine so far. We now begin with checking every wires for errors or broken wires. Then we will check the wires to drive valves since the machine was likely moving when we switch to drive mode even though we didn't activate the drive joystick. Lastly we will check the steering valves and the pressure as you recommended and hopefully the engine as well. We are so thankful for your kindness when helping us. We hope you have a successful business and happy life !!! Nick,
For the power to CR2, if i am looking at the correct schematic it looks like you could have a bad ign/start module, bad wire from alternator to terminal #2, or problem with terminal #10 being grounded by a short in the wiring or faulty switch, either oil pressure or coolant temperature. #2 senses alternator pulses as a tachometer input, makes sure engine is turning, #10 is safety for low oil pressure or overheat. Any fault will turn off ignition and fuel pump (if present) Since it runs for a time before shutting off I would suspect the coolant switch or low oil pressure switch. You might try disconnecting wire from terminal #10 and see if it keeps running, but be sure to watch temperature and put a pressure gauge on the oil, don't want to ruin the engine if oil pressure IS actually low. Thank you for the kind words, I try to help where I can. Life is short and the world is small yes? Do you ever deal in Morooka dumpers? Cheers, Don
Dear Don, Thanks for your helps. We have tested the oil pressure and heat sensor and they worked normally. When we replaced the ignition/start module with another ones in Genie S80, Tthe symptom disappeared. We are checking the machine under great precaution. Up to now the machine works ok and we are testing it in working environment. I hope we can finally get it back to work since it costed so much efforts !!! We rarely see Morooka Dumpers in our place. Maybe, it is used in mining industry. Regards, Nick,
Hi Don, Do you know the pressure inside the function manifold when we start the engine ??? I've checked the service manual specifications. It only mentioned 3 types of pressure relief valves : System (2900psi), boom down(2300psi), boom extend ( 2500psi). When we start the engine, the pressure inside function manifold raised up to 2500psi ( which is extremely high compared with 1000psi in one Genie S80). I think we have wiring problem to the valve G. Since i checked the schematic, valve G will receive 12V when we operate any functions. But when we start the engine, it received 12V immediately. Up to now, the machine work normally for 1~2 hours, then we cannot drive the machine since the hydraulic fluid became excessive hot. I think it somehow related to valve G ( Since it always received 12V when we started the engine, therefore, the pressure built up in the system went high and made the hydraulic fluid very hot). I think we can fix this problem by checking the wiring system in 1 same Genie S85 unit. We will update information for you.
No, valve G receives power at all times when engine is running and limit switches are closed. Also valve M will be closed any time the axles are fully extended. Main relief Z is set with function enable switch activated and also boom retract, should be 2,900 psi. There is a pressure regulating valve, valve Y, if you can swap in one from another machine this may give you a lower pressure reading. Valve Y reads load pressure from any activated function and modulates system pressure to be just high enough to move the load, so oil is not flowing over the relief valve all the time. There may also be an issue of the sense line for valve Y having a high pressure all the time, valve L is a bleed off and may be restricted?
Dear Don, Did you check the wiring diagram ?? Since we have tested 3 different Genie S80 and Valve G only received power when we lowered the main boom ??? If Valve G receives power all the time, the pressure inside function manifold will be 2,500~2,600 psi. That is very high compared with other Genie S80/85 since we the pressure is 1000~1200psi when we started the engine. Once more thing, we have another problem with the engine, when we operated the engine for 3~4hrs and switch off. We couldn't start the engine afterwards and we had to wait for 30mins. Then we could start the engine and continued working. We have checked everything but we couldn't find any faults. The weird part was if we just worked continuously without switching off the engine, it still worked normally. But, by doing that, the engine will wear off very fast and will be broken. We assumed that the engine became so hot than the system automatically stopped. If so, do we have any tricks to fix this problem and let the engine starts( remove the heat sending unit, or pressure sending unit) ??? Regards,
Yes, and if I am looking at the correct diagram, as long as both the boom up and extend limit switches are closed, you will always have power to valve G. Also, valve M is closed any time the axles are fully extended. If you are getting about 1,000 psi on other machines in standby then as I suggested before you probably have a problem with valve Y or the bleed valve L which works with valve Y, valve Y lowers the standby pressure and only raises it enough to move the load when a function is activated. When the axles are not extended, if you extend the boom far enough to open the limit switch, LS1, that should remove power to valve G I think which will help, but I am fairly sure you need to address valve Y and it's associated circuitry to lower the standby pressure. Which engine does this machine have, and what fuel? When you attempt to start it while hot, does it spin at a normal speed but just fails to start, or does it struggle to turn over?
Dear Don, Thanks for your reply ! We are checking the wiring diagram on Genie S85 1999 to check for any broken wires once more time. All of our machines have Deutz F4L1011F Engine fueled by Diesel. When we attempt to start when the engine is hot, there is nothing happens. The engine doesn't crank over. We are testing by removing 3 wires that connected to Pressure sending unit and Temperature sending unit. Maybe, it will help.
I don't think those switches, which are connected to the engine fault input #10 on the ignition/start module should prevent cranking. The oil pressure switch should be closed with no oil pressure, which grounds terminal #10 on the module, so with the engine off, it starts out in a fault state until oil pressure comes up. I don't know how smart the module is, if the motor will start cold with the wire removed from terminal #10 on the ignition/start module then I don't think the oil pressure or oil temp switches are the problem? Easy enough to try. When hot check power to the module at terminal #6 and the start relay CR1 pin 30, comes from circuit breaker CB1 . Check module terminal #1 for power out and at relay CR1 for power from the module on pin 85 when trying to start. While still hot, jumper pins 30 and 87 to test the starter solenoid. Hope that helps...
Hi Don, We hope you had a great holiday. As we were very busy since October, we couldn't check the machine. Up to now, we still face the same problem with the hydraulic system : 1. Valve G - We tested and it worked normally.(We also checked the wiring diagram. We believe it only has voltage when lower the main boom and retract the boom). We checked the wiring diagram many times and we can assure that. 2. Our technician tried to wire directly to Valve G to force it always received voltage. The results were : all functions worked; the hydraulic became very hot after few minutes; the main pressure built up inside the manifold was extremely high). At the moment, we face another problem with the manifold. When the mechanic tested the manifold to identify the problem. He wired directly to valve G. When he was testing some functions. The manifold was stucked and all functions are now inoperative. We had to shut off the engine since we scared that the manifold could be broken because of that. Now, when we start the machine, the manifold has a strange sound ( it looked like 1 valve closed and blocked the fluid flows). Could you please give us some useful advice for this problem ? The machine are bombarding us with many problems. We only used it for 1 month since we bought it 1,5 year ago. Regards, Nick,
I would start by removing all valve cartridges one at a time, inspect for bad o-rings, reinstall. Pay particular attention to valve Y and valve L, also the system relief, if possible try known good substitutes one at a time from another machine?
Dear Don, Really thanksful for your reply. We will try your suggestion and let you know the result. On the schematic, What is the main function of valve G ? Is there any valve that returns the flow back to the tank beside valve G ? What is the status of valve G when the machine runs and no functions are activated ? Regards, Nick
Valve G dumps oil back to tank. Valve M dumps oil through valve G to tank when valve G is not activated unless valve M is closed by the axle limit switch valve activating it. Valve Y is supposed to dump some oil back to tank regulating pressure to be only as high as needed to move the load, it is controlled by load sense lines from check valves for each circuit. And of course the main relief valve Z
Dear Don, Look at the Diagram, we see that the Dump Valve (G) receiving power only when the CR20 actived ( when power supply to #85 of CR 20). the power come to #85 from: 1. red/blk wire only when primary boom down. 2. all power through LS2 (Normally closed). the power thourgh LS2 come from TB42 & blk/wht wire only when the boom Retract. Power through TB42 come from org/red-1 & through LS1 (Normally Open hold Closed NO HC) +Org/red-1 come from # R of BP1 ( platform control joysitk boom up/down & turn table rotate left/right)- it means only when we turn to platfrom box control will have power in. +Power through LS only when the LS1 actived ( boom up/down fully) So that is why we said the Power to G ( only when boom down and Retract) We want to hear your comment again. Thanks steven
Dear Don, If the G (dump valve) always receiving power 12V. Do you think the coil of G valve will become very hot. Is it ok if working 03-04 hour/1 time? Regards Steven
I think we are saying the same thing in different ways, yes power goes to valve G when the boom is down and not extended. Once either of those limit switches opens then power is only sent to valve G when certain functions are engaged. Since having the boom down and retracted at all times would not be normal operation then the coil of valve G would not be powered continuously except in very rare circumstances. Still if your pressure is above 2,000 psi with valve G or valve M closed and no functions engaged, then there is a problem elsewhere, as I mentioned before possibly with valve Y?
I think we are saying the same thing in different ways, yes power goes to valve G when the boom is down and not extended. Once either of those limit switches opens then power is only sent to valve G when certain functions are engaged. Since having the boom down and retracted at all times would not be normal operation then the coil of valve G would not be powered continuously except in very rare circumstances. Still if your pressure is above 2,000 psi with valve G or valve M closed and no functions engaged, then there is a problem elsewhere, as I mentioned before possibly with valve Y? [Dear Don, We Can understand a little bit your explain. When the boom is down and boom retract. the valve G is received 12V is confirmed. We understand it But if in another working such when the boom up/extend, turn table... ( not boom down and retract). The Valve G still received 12V directly when any function is engaged. Or just the function valve on Manifold function received power when function engaged. Further More, We still confused that what is the Limit switch LS1 (boom extend limit) N.O.H.C? Our understand is the Limit switch LS 1 is always is in Closed position ( have power through) to LS2 in most normal working. It just Open ( No Power) when Boom is in ( Max Boom extend (Limit function). Is it, right? So The Power through LS1 now mostly come from TB21. So if TB21 is in Power then the LS1 have power through LS1, LS2 and G Valve. We see TB21 is always have power because CR2 is always in closed if engine is running. Some more share with us your understand about Limit Switch. Can you explain? 1. Limit Switch 1 (boom extend limit) LS1 NOHC. Our understand is in normally working (boom extend/retract) not touch the limit ( boom not totally extend) the power always is through in Diagram. 2. Limit Switch 1 (boom extend limit) LS1 NCHO is against 1. 3. Limit switch 2 ( Boom Up) NC- normally closed. it is always power through in diagram when boom up/down. it is open ( not power) when boom is touch limit( max boom up) 4. Limit switch 2 ( Boom Up) NO- normally Open. it is not power through in diagram when boom up/down. it is closed ( power) when boom is touch limit( max boom up) want to hear your idea]
Dear Don, We Can understand a little bit your explain. When the boom is down and boom retract. the valve G is received 12V is confirmed. We understand it But if in another working such when the boom up/extend, turn table... ( not boom down and retract). The Valve G still received 12V directly when any function is engaged. Or just the function valve on Manifold function received power when function engaged. Further More, We still confused that what is the Limit switch LS1 (boom extend limit) N.O.H.C? Our understand is the Limit switch LS 1 is always is in Closed position ( have power through) to LS2 in most normal working. It just Open ( No Power) when Boom is in ( Max Boom extend (Limit function). Is it, right? So The Power through LS1 now mostly come from TB21. So if TB21 is in Power then the LS1 have power through LS1, LS2 and G Valve. We see TB21 is always have power because CR2 is always in closed if engine is running. Some more share with us your understand about Limit Switch. Can you explain? 1. Limit Switch 1 (boom extend limit) LS1 NOHC. Our understand is in normally working (boom extend/retract) not touch the limit ( boom not totally extend) the power always is through in Diagram. 2. Limit Switch 1 (boom extend limit) LS1 NCHO is against 1. 3. Limit switch 2 ( Boom Up) NC- normally closed. it is always power through in diagram when boom up/down. it is open ( not power) when boom is touch limit( max boom up) 4. Limit switch 2 ( Boom Up) NO- normally Open. it is not power through in diagram when boom up/down. it is closed ( power) when boom is touch limit( max boom up) We are looking for your reply Regards Steven
Please give me a little time, I need to go back and study the schematics more as it has been some time since I looked at them last.
The manual gives some conflicting information but this is my understanding: Test the Extendable Axles Limit switch functions: 7 Hold the function enable switch to either side and activate the boom raise function. Result: The boom should raise to horizontal and then stop. The boom should not raise above the limit switch unless both axles are extended. 8 Hold the function enable switch to either side and activate the boom lower function. Result: The boom should lower and return to the stowed position. 9 Hold the function enable switch to either side and activate the boom extend function. Result: The boom should extend no more than 6 inches (15 cm) and then stop. The boom should not extend beyond the limit switch unless both axles are extended. 10 Hold the function enable switch to either side and activate the boom retract function. Result: The boom should retract. Testing limit switches: 8 Turn the key switch to platform controls and fully retract the boom. 9 Move the lift/drive selector switch to the drive position (if equipped). 10 Press down the foot switch and slowly move the drive controller off center. Result: The machine should move at normal drive speeds. 11 Move the lift/drive selector switch to the lift position (if equipped). 12 Raise the boom to just above horizontal. 13 Move the lift/drive selector switch to the drive position (if equipped). 14 Slowly move the drive controller off center. Result: The machine should move at a reduced drive speed. 15 Move the lift/drive selector switch to the lift position (if equipped). 16 Lower the boom to the stowed position, then extend the boom 3 feet (0.9 m). 17 Move the lift/drive selector switch to the drive position (if equipped). 18 Slowly move the drive controller off center. Result: The machine should move at a reduced drive speed. LS2 the boom lift limit switch, the NC (Normally Closed) contacts are closed with the boom fully down (switch NOT activated) and should open as the boom lifts up to a level position where the switch activates, and remain open from level on up to maximum lift. The LS2 NO (Normally Open) contacts will close at the same time the NC contacts open and remain closed on up to maximum lift. LS1 the boom retract limit switch, the NOHC (Normally Open, Held Closed) contacts are closed with the boom fully retracted (switch activated) and will open as the boom is extended, according to the manual within the first 6 to 8 inches (Switch released). The NCHO (Normally Closed Held Open) contacts of course will of course close at the same time. Both of these switches are designed to activate at the minimum limit, not maximum lift or maximum extension.
Dear Lantaxco, Noted your information, so we have some final issue that: 1. if the boom up to NOHC (acitived) and LS2 (NC) no actived ( machine in normally working condition) we see the power will only go to the G valve when we retracted boom. 2. What is the problem if we disable the LS1, LS2? do you think machine still in working condition? with all function. Regards Nick
Dear Don, As you explained so... G valve will received Power whenever the function engaged, right? Whenever we operate such boom up/down, turn table left/right, .... the G valve will receiving power (12V)? How about the driving and steering function? Do the G Valve still receiving power at the time? We face a another problem such as belows: 1. We have another similiar machine, we do not supply G valve whenever we operate another function but boom down and retract only. and the machine still working more than 02 month and have no problem 2. We also have another machine, we also try to disable the power to G valve as above 1 but the machine just working around 04 days. later on, if we did not supply power to G valve all function can not operate. Before we also follow your sugest that G valve will received power when function engaged. but the hyd system become hot rapidly if we do like that please give your ideas Regards Steven
These limit switches are supposed to prevent the operator from raising or extending the boom too far without the axles fully extended, there is a hydraulic limit switch on the axles that actuates valve M. it performs the same function as valve G. Once the axles are fully extended all functions should work regardless of power supplied to valve G or not.
The steering should not be affected as the steering flow is divided off before the function valves, the drive is a separate pump entirely so there is no connection between the work functions and the drive functions. Again, unless the axles are fully extended and the hydraulic limit system actuates valve M, then functions will only work with valve G actuated, this is the way the safety system works on these machines. Apologies if I have not answered all your questions, please let me know if you have new information.
Dear Don, How are you? Once again we need your support! Yeah, We already bought and replaced new L, Y Valve for this machine. Then the result is: 1. when we start engine, no power in G dump valve, the Hydraulic is normal, hydraulic system pressure at 600 PSI around ( no noisy), very smooth 2. As soon we want to active the function, we suppy power 12V to G valve, if we do not active function the hydraulic system sound very noisy ( the sound is: huuuuuuuuhhuu) then we try to active function, it is not huuuuuuuh any more. Before that: we already reset the relief pressure: a. System relief valve, set at 2800 PSI ( 2900 PSI as specification ) b. Boom down function,set at: around 2300 PSI ( 2300 PSI as specification ) c. Boom extend function, set at: 2400 PSI (2500 PSI as specification) Do you think we need to set as correctted in specification on another machine, if we supply power to G and no active function the hydraulic system sound not huuuuuuuuhhh, it is quite silent. it is only teeeheheeh We think: may be, the system relief got damage or one of valves is died But we dont know how to check it out So we hope to receive your ideas! Regards Steven
Hi Don, We hope to receive your idea, We already bought new Valve Y, L and also dump valve (G) replace the old one At the begining. As soon we replaced the brand new Y,L and also G valve. When we supply 12V and no active any function. The hydraulic system sound is normally ( only sheeeeee) we tried to active the function all function working, driving also but not the steering and jack chassing no working. we see the hydraulic pressure is only 600 psi at the time. But if we active boom down, up hydraulic pressure begin to come up to 1500 PSI, and 2900 PSI if retract boom. 10 minutes testing and then If we no acitive the pressure is coming down, but the hydraulic become sound noisy (huuuuuu) if we no active function and still supply power to G valve. Remember, if supply power to G valve, no active any function, the Hyd system pressure only 600 PSI plus We think the problem is the system relief valve but we dont know which is the valve relief got damaged? We hope your support again because we need to repair it to take out for rental but we can not repair sucessfully until now! Regards Steven
Am I understanding that the steering and jacks are not working now? If that is true check flow divider valve CC, it sends 5 gallons per minute to the steering valve, and on to the jack system. If the valve is not sending oil to the steering, then there maybe excessive flow through the function manifold which could cause the noise issue. Cheers, Don
Dear Don, Follow your instruction, We already inspected the CC valve. We replaced another CC valve from Similar machine. Now we can active steering left/right is ok. for the Jack chasis. We only can Jack up but not Jack down. it mean. The jack cylinder can extend but not retract For another information When engine running, no power to G valve, no active any function. the stand by pressure is 600 PSI At the end. If we actived G valve with Power, no acitive any function, Hydraulic system (manifold function) still sound huhhhhhhhh but smaller Please share your ideas Regards Steven
Dear Don, Another thing. When no Power to G valve, no active any function the pressure is only 600 PSI When power to G valve, no active any function, the pressure is up to 800PSI boom up, pressure up to 1500 PSI Boom down fully, pressure is 2300 PSI Boom fully retracted, pressure 2900 PSI Regards Steven
Dear Don, How are you? Long time no have contact you. We just replaced the seal of the 02 cylinder of Secondary boom of below machine, before that all function in normally working condition But after replace the seal, we faced a problem with Genie Z45/25 IC Year 2000, serial: 15327. that we need your advice: "The problem is: Secondary boom , the up/down function , only Up function with Normally speed, down function at very very slow speed" all another function is in normal working condition Below is the photos of Electric diagram and Hydraulic diagram: We did some repair and test as follow: 1. we exchange the the flow regulator valve C ( secondary boom) by flow regulator valve I (primary boom)--result is the same ( down function is still slow speed) 2. we exchange the the coil and proportional Valve B ( secondary boom) by the the coil and proportional Valve LL(primary boom)--result is the same ( down function is still slow speed), (evenly we used the electric ( input and ground wire) from the primary boom switch control) 3. we exchange the 02 coil and solenoid valve 03 position, 04 way II (secondary boom) by the 02 coil and solenoid valve 03 position, 04 way DD (primary boom)--result is same( down function is still slow speed), (evenly we used the electric ( input and ground wire) from the primary boom switch control) 4. We exchange the check Valve D (secondary boom) by the check Valve Y (primary boom)--result is same( down function is still slow speed) 5. We open the JJ (check valve) and replace another JJ from another Genie Z45/25 serial 15634--result is same( down function is still slow speed) The result after all checked, we think the problem is the orifice 0.04 in (1mm), so we open the S1 on manifold, we see and check the hole have any sand, or dirty but we did not found any doubt The pressure in the manifold when we control up function secondary boom is 3200 PSI, When we control down function secondary boom, pressure is 1800 PSI -the reference, the pressure when control up/down primary boom is 3200 PSI- 6. we open and remove 02 hose S1,S2 for up/down secondary boom on the manifold function to the up/down primary boom P1,P2 port (on function manifold) so the speed are normally Now-it is ok So Now we dont know how to repair it, await your reply Regards Steven