Genie S-60 Platform Auxiliary Control Issues and Solutions

[MikePhua]

The Genie S-60 is a versatile, self-propelled aerial platform widely used in construction and maintenance applications. This machine is known for its ability to lift workers to elevated heights, offering both reach and stability. However, as with any complex machinery, the Genie S-60 can experience operational issues. One commonly reported problem is the failure of the auxiliary hydraulic system to operate the boom controls. In this article, we will explore the causes of this issue, potential solutions, and general maintenance practices to avoid such problems in the future.
Overview of the Genie S-60 Aerial Platform
The Genie S-60 is part of the Genie Super Series, designed to provide outstanding outreach and flexibility. With a platform height of up to 60 feet and a horizontal reach of up to 40 feet, this machine is often used in construction sites, warehouses, and facilities that require workers to perform tasks at elevated levels.
Key Features:

• Hydraulic Boom: The Genie S-60 features a hydraulically operated boom that extends and elevates to reach hard-to-access areas. The boom is powered by a hydraulic system, which allows precise control over movement.
  
• Auxiliary Hydraulic System: This system is designed to provide additional hydraulic power to operate the boom, steering, and other auxiliary functions. The auxiliary system ensures that the lift is stable and safe during operation.
  
• Drive and Steering: The S-60 is equipped with four-wheel drive and four-wheel steering, enabling excellent maneuverability on uneven terrain and around obstacles.
  
• Platform Capacity: The platform on the Genie S-60 can support up to 500 pounds of equipment and personnel, making it ideal for both maintenance and construction applications.
  

Common Auxiliary Control Issues
Auxiliary hydraulic issues in the Genie S-60, particularly when the boom controls fail, are a common problem faced by operators. There are several reasons why this issue might occur, and addressing it promptly can prevent costly downtime and repairs.
1. Hydraulic Fluid Problems
Hydraulic fluid is the lifeblood of the system, powering all hydraulic functions, including the boom and auxiliary controls. If the fluid is low, contaminated, or of poor quality, it can lead to a lack of response or erratic behavior from the boom controls.
Potential Causes:

• Low hydraulic fluid levels
  
• Contaminated hydraulic fluid
  
• Old or degraded fluid that no longer performs efficiently
  

Solution:
Check the hydraulic fluid levels regularly. Use high-quality, manufacturer-recommended fluid to ensure proper system function. If the fluid looks dirty or has particles, perform a full hydraulic system flush and replace the fluid.
2. Faulty Solenoid Valve
The solenoid valve controls the flow of hydraulic fluid to the auxiliary functions, including the boom control. If the solenoid valve becomes stuck, worn, or faulty, it may prevent the boom from operating correctly.
Potential Causes:

• Electrical issues affecting the solenoid valve
  
• Physical wear on the valve over time
  
• Dirt and debris clogging the valve
  

Solution:
Inspect the solenoid valve for signs of wear or damage. Clean the valve and its connections to ensure there is no dirt or debris obstructing the flow. If the solenoid valve is faulty, it may need to be replaced.
3. Faulty Wiring or Electrical Connections
The auxiliary hydraulic system in the Genie S-60 is electrically controlled. A problem with the wiring or electrical connections can disrupt the flow of power to the hydraulic system, causing the boom to fail to operate.
Potential Causes:

• Loose, corroded, or broken electrical connections
  
• Faulty wiring or blown fuses
  
• Electrical short circuits
  

Solution:
Inspect the wiring and electrical components for signs of wear or corrosion. Ensure that all connectors are clean and securely attached. Replace any damaged or frayed wires, and check for blown fuses or relays that may have interrupted the power supply to the hydraulic system.
4. Pump and Motor Issues
The hydraulic pump and motor are responsible for generating the power needed to operate the boom and other controls. If the pump or motor becomes damaged or worn, the hydraulic pressure can drop, leading to failure in auxiliary operations.
Potential Causes:

• Worn-out hydraulic pump or motor
  
• Lack of maintenance causing excessive wear
  
• Oil starvation or improper lubrication
  

Solution:
Check the hydraulic pump and motor for proper function. Look for any unusual noises, such as grinding or whining, which may indicate wear or damage. If the pump is faulty, it will need to be replaced or repaired by a certified technician.
5. Control Valve Malfunction
The control valve governs the operation of the boom, lifting, and other hydraulic functions. If the control valve malfunctions, it can lead to the boom not responding to inputs or operating erratically.
Potential Causes:

• Blocked or sticking control valves
  
• Improper adjustment of the valve settings
  
• Internal damage due to pressure surges or contamination
  

Solution:
Inspect the control valve for blockages or obstructions. If necessary, clean the valve or replace any worn components. Ensure the valve is correctly calibrated and set to the proper specifications for optimal operation.
Preventative Maintenance to Avoid Auxiliary Hydraulic Issues
Preventing auxiliary hydraulic failures on the Genie S-60 starts with regular maintenance and proper care. Follow these tips to keep the hydraulic system running smoothly and avoid operational downtime.

1. Regular Fluid Checks: Always check the hydraulic fluid levels before operating the machine. Ensure that the fluid is clean and at the proper level to prevent strain on the system.
   
2. Clean the System: Over time, debris and contaminants can build up in the hydraulic system. Regularly clean the filters and inspect the system for signs of dirt or grime buildup.
   
3. Lubricate Moving Parts: Proper lubrication of moving components reduces friction and wear, extending the life of the hydraulic system and other mechanical parts.
   
4. Electrical Inspections: Regularly inspect the wiring, relays, and fuses for signs of wear or corrosion. Clean the connections and replace any damaged components to ensure consistent power delivery to the hydraulic system.
   
5. Service the Pump and Motor: The hydraulic pump and motor should be serviced periodically. Check for wear, clean any debris, and replace any components showing signs of failure.
   

Conclusion
Auxiliary hydraulic system failures in the Genie S-60, particularly related to boom control, can cause significant downtime on the job site. However, by understanding the common causes of these issues and taking preventative steps, operators can minimize the risk of breakdowns and keep their equipment in peak condition. Regular maintenance, prompt troubleshooting, and proper care of hydraulic components will ensure the continued reliability and performance of this versatile aerial platform for years to come.
When issues arise, such as a malfunctioning boom control, thorough inspection of the hydraulic fluid, solenoid valve, wiring, pump, motor, and control valves is essential. Addressing these components with the appropriate solutions will often resolve the problem and allow the Genie S-60 to return to service quickly. By following these tips and maintaining the machine correctly, you can extend the life of your Genie S-60 and avoid costly repairs.