Refurbishing a Genie S-60 Manlift Demands Mechanical Precision and Electrical Patience

[MikePhua]

The Genie S-60 and Its Place in Aerial Work History
The Genie S-60 telescopic boom lift was introduced by Genie Industries in the late 1990s as part of their expanding lineup of self-propelled aerial work platforms. Designed for outdoor construction, maintenance, and industrial applications, the S-60 offers a working height of 66 feet and a horizontal reach of 50 feet. Genie, founded in 1966 in Washington State, became a global leader in lifting solutions and was acquired by Terex Corporation in 2002. The S-series boom lifts, including the S-40, S-60, and S-80, have sold tens of thousands of units worldwide and remain staples on job sites from Dubai to Detroit.
Terminology note:

• Telescopic boom lift: An aerial platform with a straight extendable arm, offering long horizontal reach and vertical access.
  
• Self-propelled: A machine that can drive itself without external towing, using onboard hydraulic motors.
  

Assessing a Used S-60 for Refurbishment
Refurbishing a Genie S-60 begins with a thorough inspection. Many units in the used market have logged thousands of hours and show signs of hydraulic leaks, electrical corrosion, and structural fatigue. The first step is to evaluate:

• Hour meter reading and service history
  
• Boom welds and pivot points for cracks or distortion
  
• Hydraulic cylinders for scoring or seal leakage
  
• Drive motors and wheel hubs for gear wear
  
• Control box and wiring harness for brittle insulation or rodent damage
  

A technician in Nevada shared that his S-60 had sat idle for three years. After replacing the batteries and flushing the hydraulic tank, he discovered the platform rotation motor had seized due to water ingress—a common issue in neglected lifts.
Hydraulic System Restoration
The S-60 uses a closed-center hydraulic system powered by a gear pump and controlled via proportional valves. Key components include:

• Lift and extend cylinders
  
• Platform rotation motor
  
• Drive motors
  
• Steering cylinder
  
• Boom swing motor
  

Steps for hydraulic restoration:

• Drain and flush the reservoir
  
• Replace all filters and inspect suction screens
  
• Test pressure relief valves and adjust to factory specs (~3,000 psi)
  
• Rebuild cylinders with OEM seal kits
  
• Replace hoses showing surface cracking or bulging
  

Suggestions:

• Use ISO 46 hydraulic fluid unless operating in extreme cold
  
• Label hose routing during disassembly to avoid cross-connection
  
• Install magnetic drain plugs to monitor metal wear
  

Terminology note:

• Closed-center system: A hydraulic configuration where fluid flow is blocked until a valve is activated, improving efficiency.
  
• Proportional valve: A valve that adjusts flow based on input signal strength, allowing smooth control.
  

Electrical System Troubleshooting
The S-60’s electrical system includes:

• Ground control panel
  
• Platform control box
  
• Limit switches and sensors
  
• Joystick controllers
  
• ECU (Electronic Control Unit)
  

Common issues include:

• Corroded connectors causing intermittent faults
  
• Blown fuses or relays in the control panel
  
• Faulty joystick potentiometers leading to erratic movement
  
• Broken wires near articulation points due to flexing
  

Recommendations:

• Use a multimeter to test continuity and voltage at each control point
  
• Replace connectors with weather-sealed Deutsch plugs
  
• Clean terminals with contact cleaner and apply dielectric grease
  
• Update firmware if ECU supports it
  

A rental company in Ohio reported that after replacing the platform joystick and recalibrating the boom sensors, their refurbished S-60 passed ANSI inspection and returned to service within a week.
Structural and Safety Restoration
The boom structure and chassis must be inspected for integrity and compliance. Key areas include:

• Boom welds and telescoping sections
  
• Platform guardrails and entry gate
  
• Counterweight bolts and frame welds
  
• Tire condition and wheel torque
  
• Emergency lowering system and alarms
  

Suggestions:

• Sandblast and repaint boom sections to prevent rust
  
• Replace platform decals and load charts for clarity
  
• Test tilt sensor and emergency stop functions
  
• Verify platform leveling mechanism during full extension
  

Terminology note:

• Tilt sensor: A device that detects unsafe machine angles and disables boom functions to prevent tip-over.
  
• Emergency lowering system: A manual or battery-powered system that retracts the boom in case of power failure.
  

Engine and Drive System Overhaul
Depending on the model year, the S-60 may be equipped with a Deutz, Perkins, or Ford industrial engine. These engines are typically diesel-powered and coupled to a hydraulic pump via a bell housing.
Steps for engine service:

• Replace fuel, oil, and air filters
  
• Inspect glow plugs and starter motor
  
• Clean radiator and check coolant flow
  
• Adjust throttle linkage and governor settings
  
• Test alternator and battery charging system
  

Drive system tips:

• Inspect drive motors for seal leakage
  
• Check wheel bearings and planetary gear oil
  
• Test steering response and cylinder alignment
  
• Replace tires if tread depth is below spec or sidewalls are cracked
  

Conclusion
Refurbishing a Genie S-60 manlift is a rewarding but detail-intensive process. From hydraulic cylinders to joystick wiring, every subsystem must be restored with precision and care. When done properly, a refurbished S-60 can deliver years of reliable service at a fraction of the cost of a new unit. Whether lifting HVAC units or painting stadium lights, this boom lift proves that with the right hands, even old iron can rise again.