Genie S85 Boom Lift: Troubleshooting Brake Wheel Locking Issues

[MikePhua]

The Genie S85 is a popular model of articulated boom lifts used in a variety of industries, including construction, maintenance, and facilities management. Known for its ability to provide height access in tight spaces, the S85 is designed for both indoor and outdoor use. However, like any complex piece of equipment, it may encounter mechanical issues from time to time. One common issue faced by operators is the locking of the brake wheel, which can affect the maneuverability and safety of the machine.
In this article, we will explore the potential causes and solutions for brake wheel locking issues on the Genie S85, providing detailed steps for troubleshooting and repairs. Additionally, we’ll dive into the system components involved in this issue and offer advice for preventive maintenance.
Overview of the Genie S85 Articulated Boom Lift
The Genie S85 is part of the S-series of articulating boom lifts produced by Genie, a company that has been at the forefront of aerial access equipment since the early 1960s. The S85 is widely used for tasks that require height and reach, such as building maintenance, construction, and installation projects. Its articulated arm design allows for superior flexibility and precision, especially when navigating obstacles like buildings, trees, or other structures.
Key Features of the Genie S85:

• Working Height: 85 feet (25.9 meters)
  
• Platform Capacity: 500 pounds (227 kg)
  
• Horizontal Reach: 60 feet (18.3 meters)
  
• Rotation: 360° continuous rotation
  
• Drive: Four-wheel drive for better traction on rough terrains
  
• Stabilizers: Outriggers to ensure stability on uneven surfaces
  

While the Genie S85 is designed for heavy-duty use, some mechanical problems can arise over time, such as issues with its brake system, including the brake wheel locking up.
Understanding the Brake System of the Genie S85
The brake system in a machine like the Genie S85 is essential for safe operation, particularly when the unit is stationary or needs to be locked in place. The brake system ensures that the machine remains securely in position when parked, preventing unintended movement.
In the case of the Genie S85, the system includes:

• Wheel Brakes: These are typically disc brakes that are engaged when the machine is stopped.
  
• Parking Brake: A secondary brake system designed to keep the lift stationary, typically activated when the machine is not in operation.
  
• Hydraulic Components: These provide pressure to engage and disengage the braking mechanisms.
  

When the brake wheel locks up, it can prevent the machine from moving, making it difficult to reposition or perform necessary tasks. This problem can stem from a variety of issues, such as hydraulic pressure loss, brake fluid leaks, or mechanical failures in the brake components.
Common Causes of Brake Wheel Locking
Several factors can contribute to the brake wheel locking up on a Genie S85 articulated boom lift. Understanding these potential causes can help in identifying the root of the problem.

1. Hydraulic Pressure Loss:
   The braking system of the S85 relies on hydraulic pressure to engage and disengage the brakes. If there is a drop in hydraulic pressure due to a fluid leak or a malfunctioning pump, the brake wheel may become stuck or locked in place.
   
2. Brake Fluid Contamination or Leaks:
   Over time, brake fluid can become contaminated with debris or moisture, causing a loss in braking efficiency. Additionally, leaks in the brake lines or seals can cause the fluid to drain, which will also result in brake wheel locking.
   
3. Worn or Damaged Brake Components:
   Like any mechanical system, the brake components in the S85 can wear out over time, particularly if the machine is used frequently. Worn brake pads, damaged rotors, or broken cables can cause the brake mechanism to malfunction, resulting in a locked wheel.
   
4. Faulty Parking Brake Mechanism:
   The parking brake mechanism on the S85 may become stuck or malfunction due to improper maintenance or component failure. This can prevent the brake from releasing fully, resulting in the locking of the brake wheel.
   
5. Electrical or Sensor Failures:
   The S85’s brake system may also include electronic sensors that monitor and control the brake application. If these sensors malfunction, they could trigger an incorrect brake response, causing the wheels to lock.
   

Troubleshooting and Repair Solutions
If you’re facing issues with the brake wheel locking on a Genie S85, the following troubleshooting steps can help identify the problem and guide you toward an effective solution.

1. Check Hydraulic Fluid Levels:
   Start by checking the hydraulic fluid levels in the machine. Low fluid levels can lead to insufficient pressure in the brake system, causing the wheels to lock. If the fluid is low, top it up with the recommended type of hydraulic fluid and check for leaks around the system.
   
2. Inspect for Leaks:
   Examine the brake lines and seals for signs of leaks or damage. If you find any, replace the damaged components and top off the hydraulic fluid as needed.
   
3. Test the Parking Brake Mechanism:
   Inspect the parking brake for any issues, such as a stuck lever or faulty components. You may need to manually disengage the brake or replace worn parts to restore proper functionality.
   
4. Clean or Replace Brake Components:
   Over time, brake pads and other components can become worn down. Check the condition of the brake pads and rotors, and replace them if they show significant wear. Cleaning the components may also help improve braking performance.
   
5. Check for Electrical or Sensor Malfunctions:
   If the issue seems to be electrical, inspect the brake sensors and wiring for any faults. A malfunctioning sensor or damaged wiring could be preventing the brake from releasing properly. In this case, repair or replace the faulty electrical components.
   

Preventive Maintenance to Avoid Brake Wheel Locking Issues
Preventing brake wheel locking issues on the Genie S85 can be achieved through regular maintenance and care. Some preventive steps include:

1. Regular Fluid Checks:
   Perform routine checks on hydraulic fluid levels and quality. Change the fluid according to the manufacturer’s recommendations to prevent contamination and ensure the system operates at peak performance.
   
2. Periodic Brake Inspections:
   Inspect the brake system periodically to ensure the components are in good condition. Look for signs of wear, cracks, or rust, and replace parts as needed.
   
3. Proper Storage and Use:
   Ensure the machine is stored properly and used according to the manufacturer’s guidelines. Overuse or improper storage can accelerate wear and tear on the brake system.
   
4. Training Operators:
   Ensure that all operators are properly trained to handle the equipment safely. This includes understanding the brake system and how to engage and disengage it properly.
   

Conclusion
The Genie S85 is a versatile and reliable piece of equipment widely used in various industries. However, like any complex machine, it is subject to issues such as brake wheel locking, which can hinder its operation. By understanding the causes of brake wheel locking, performing regular maintenance, and troubleshooting common issues, operators can keep their Genie S85 running smoothly and efficiently. Regular care and prompt attention to potential problems will extend the machine's life and ensure that it continues to provide safe and effective service on job sites.