Troubleshooting Hydraulic Issues in Genie S-85 Aerial Lifts

[MikePhua]

Genie S-85 aerial lifts are widely recognized for their versatility and reliability, often employed for heavy-duty tasks in construction, maintenance, and other industries that require working at height. However, like all machinery, they can experience technical issues. One of the most common problems faced by operators of these lifts is hydraulic system malfunctions. Hydraulic problems can cause a variety of issues, including sluggish or erratic movement of the boom, or complete failure to function. Identifying and addressing these issues promptly is essential to maintaining machine performance and ensuring operator safety.
Common Hydraulic Issues in the Genie S-85
Hydraulic systems are integral to the operation of an aerial lift, controlling functions such as boom extension, lifting, and steering. The Genie S-85 relies on hydraulic pumps and motors to power its lifting system, and any problems within these components can lead to significant disruptions. Below are some of the most commonly encountered hydraulic issues in the Genie S-85:

1. Slow Boom Movement: This is one of the most frequently reported hydraulic issues. If the boom is moving sluggishly or fails to lift at the expected speed, it may indicate a problem with the hydraulic fluid level or quality. Low or contaminated hydraulic fluid can cause the system to operate inefficiently, leading to slow or jerky movements.
   
2. Inconsistent Steering: The steering system in the Genie S-85 is also hydraulically operated. When the steering system fails to respond consistently, it may be due to hydraulic fluid leaks, air in the system, or malfunctioning steering valves.
   
3. Complete Hydraulic Failure: In some cases, the hydraulic system may fail entirely, rendering the lift inoperable. This can happen due to a catastrophic pump failure, hose rupture, or malfunctioning control valve. A complete hydraulic failure is a serious issue that requires immediate attention from a qualified technician.
   

Diagnosing Hydraulic Problems in the Genie S-85
Diagnosing hydraulic problems involves checking several key components of the system, including the fluid, hoses, pumps, and valves. Here are some troubleshooting steps to help pinpoint the issue:

1. Check Hydraulic Fluid Levels: One of the first steps in diagnosing hydraulic issues is to check the fluid level. Low fluid can cause a variety of issues, including slow boom movement and erratic operation. Always use the recommended hydraulic fluid type for your Genie S-85, as using the wrong fluid can cause further complications.
   
2. Inspect for Leaks: Hydraulic leaks are a common cause of low fluid levels and inconsistent performance. Inspect the hydraulic hoses, connections, and cylinders for visible signs of leakage. If a leak is found, it is crucial to repair it as soon as possible to avoid further damage to the system.
   
3. Check for Contaminated Fluid: Over time, hydraulic fluid can become contaminated with dirt, debris, or moisture. Contaminated fluid can cause significant damage to the hydraulic components and lead to malfunctioning. If the fluid appears cloudy or dirty, it’s a good idea to replace it and flush the system to prevent further damage.
   
4. Test the Hydraulic Pumps and Motors: If the hydraulic fluid and hoses appear to be in good condition, but the boom still operates slowly or erratically, the problem may lie with the hydraulic pumps or motors. These components can wear out over time, especially if the lift is used heavily. A pump that’s no longer providing adequate pressure can lead to sluggish or weak movement, while a malfunctioning motor can affect the boom’s lifting power.
   
5. Check for Air in the System: Air in the hydraulic system can cause irregular operation, including poor boom response and jerky movements. Bleeding the hydraulic system to remove air bubbles may help restore normal operation.
   

Preventing Hydraulic Failures in the Genie S-85
Prevention is always better than repair, especially when dealing with expensive equipment like the Genie S-85. Here are some preventive measures to help keep your hydraulic system running smoothly:

1. Regular Fluid Checks and Maintenance: Regularly check the hydraulic fluid levels and inspect the condition of the fluid. This is especially important in machines that are used frequently or in harsh environments. Replacing fluid and performing system flushes at regular intervals will ensure the longevity and efficiency of the hydraulic system.
   
2. Routine Inspections: Conduct routine inspections of all hydraulic components, including hoses, cylinders, valves, and pumps. Catching small leaks or issues early can prevent larger, more expensive problems down the line.
   
3. Proper Handling: Operator habits can significantly impact the life of the hydraulic system. Avoid overloading the lift, as this can put unnecessary strain on the hydraulic system. Additionally, avoid sudden or jerky movements with the boom to reduce wear and tear on the hydraulics.
   
4. Use the Right Fluid: Always use the manufacturer’s recommended hydraulic fluid for your Genie S-85. Using the wrong fluid can cause problems, such as poor pump performance or damage to seals and o-rings. Be sure to replace fluid that has become contaminated or degraded.
   
5. System Flushing: If there is any sign of contamination or if the hydraulic fluid has become degraded, it’s important to flush the system. Flushing helps remove contaminants and old fluid, which can improve the performance and extend the life of the system.
   

When to Call a Professional
While many hydraulic issues can be diagnosed and addressed by experienced operators, there are situations where professional help is needed. If you’ve checked the fluid levels, inspected for leaks, and performed basic troubleshooting, but the problem persists, it may be time to call a qualified technician. Hydraulic systems can be complex, and attempting a repair without the proper knowledge and tools can lead to further damage or injury.
For example, issues like pump failure, valve malfunction, or complex hydraulic leaks require expertise and specialized tools to fix. A professional technician can accurately diagnose the problem, replace damaged components, and ensure the system is functioning correctly.
Real-World Example: A Hydraulic Issue in Action
In the field, hydraulic issues can be a significant obstacle to project timelines. A construction company in Texas faced delays when their Genie S-85 developed slow boom movement during an important project. The delay led to increased costs due to the machinery being out of operation. Upon inspection, it was discovered that the hydraulic fluid had become contaminated after prolonged use in dusty conditions, leading to clogged filters and inefficient pump operation. The company had to flush the system, replace the fluid, and perform routine maintenance to get the machine back to full operational capacity. By addressing the issue quickly and performing regular maintenance, they were able to avoid further delays.
Conclusion
Hydraulic problems in the Genie S-85, like slow boom movement or inconsistent steering, are common but manageable issues. By staying on top of routine maintenance, checking for leaks, and using the correct hydraulic fluid, operators can extend the life of the hydraulic system and avoid costly repairs. Regular inspections and a proactive approach to fluid maintenance are key to ensuring the lift remains in good working condition. If problems persist, professional help should be sought to avoid further damage and downtime.
With the right approach, you can keep your Genie S-85 aerial lift operating at peak efficiency, reducing downtime and improving overall productivity on the job site.