Genie S-600 Boom Lift Platform Overload Triggers Intermittent Control Lockout

[MikePhua]

Overloading the platform on a Genie S-600 boom lift can trigger a protective lockout that disables platform controls intermittently, even after the excess weight is removed. This behavior is tied to the deadman switch and load-sensing system, which may require reset or inspection to restore full functionality.
Genie S-600 background and overload protection system
The Genie S-600 is part of Genie’s S-series telescopic boom lifts, designed for high-reach access in construction, maintenance, and industrial settings. Introduced in the early 2000s, the S-600 features:

• A working height of up to 60 ft (18.3 m)
  
• Platform capacity of 500–600 lbs depending on configuration
  
• Hydraulic drive with proportional joystick controls
  
• Ground and platform control stations
  
• Load-sensing system with platform overload protection
  
• Deadman foot switch to confirm operator presence
  

Genie Industries, founded in 1966 and acquired by Terex Corporation in 2002, pioneered pneumatic and hydraulic lifting systems. The S-series remains one of its most widely deployed boom lift families, with thousands of units sold globally.
Symptoms of overload-triggered control lockout
In one reported case, after the platform was overloaded, the machine continued to function normally from the ground control station. However, when operating from the platform:

• Controls worked briefly, then stopped responding
  
• Stepping off the deadman switch and re-engaging it temporarily restored function
  
• No fault codes or alarms were displayed
  

This intermittent behavior suggests that the overload condition triggered a persistent fault state in the platform control logic, likely tied to the deadman switch or load sensor reset logic.
Deadman switch and load-sensing interaction
The deadman switch is a pressure-sensitive foot pedal that must be depressed for platform controls to activate. When the platform is overloaded, the load-sensing system disables control functions to prevent unsafe operation.
Even after removing the excess weight, the system may remain in a fault state until:

• The deadman switch is cycled
  
• The control logic resets
  
• The load sensor recalibrates
  

This can result in a frustrating loop where controls work for a few seconds, then shut off again.
Recommended inspection and reset procedure
To resolve the issue:

• Ensure the platform is empty and within rated capacity
  
• Power down the machine completely and disconnect the battery for 5 minutes
  
• Inspect the deadman switch for wear, debris, or misalignment
  
• Check the load sensor wiring and connector at the platform base
  
• Cycle the key switch from ground to platform mode slowly
  
• Depress the deadman switch firmly and hold for 10 seconds before activating any controls
  

If the issue persists, consult the service manual for load sensor calibration procedures. Some Genie models require a technician to reset the overload fault using a handheld diagnostic tool or laptop interface.
Preventive measures and operator training

• Always verify platform load before operation
  
• Avoid sudden shifts in weight that may trigger false overloads
  
• Train operators to recognize overload symptoms and reset procedures
  
• Inspect deadman switch and load sensor monthly
  
• Keep platform floor clean to ensure proper pedal engagement
  

One contractor in Arizona noted that his crew overloaded a Genie S-600 with roofing materials, triggering a lockout that took hours to diagnose. After cleaning the deadman switch and cycling the power, the lift returned to normal operation.
Conclusion
Platform overload on a Genie S-600 boom lift can cause intermittent control lockout due to lingering fault states in the load-sensing and deadman switch systems. Ground controls may remain functional, but platform operation requires careful reset and inspection. With proper handling and preventive care, these systems can be restored without component replacement.