Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE B PROCEDURES

4 Loosen the yoke lock nut, then turn the high idle 6 Turn the key switch to the OFF position.
adjustment nut and solenoid boot
Result: The engine should stop and no
counterclockwise to increase the rpm or
functions should operate.
clockwise to decrease the rpm. Tighten the
yoke lock nut and recheck the rpm. Deutz Diesel models: All functions
should stop immediately. The
Be sure the solenoid fully retracts
engine will shut off after 2 to 3
when activating high idle.
seconds.
Deutz Diesel models

Low idle 1300 rpm B-14

High idle 2300 rpm Test the Emergency
Stop Buttons
Properly functioning Emergency Stop buttons
B-13 are essential for safe machine operation. An
Test the Key Switch improperly operating Emergency Stop button
will fail to shut off power and stop all machine
Proper key switch action and response is essential functions, resulting in a hazardous situation for
to safe machine operation. The machine can be ground and platform personnel.
operated from the ground or platform controls and
the activation of one or the other is accomplished As a safety feature, selecting
with the key switch. Failure of the key switch to and operating the ground controls
activate the appropriate control panel could cause will override the platform controls,
a hazardous operating situation. including the Emergency Stop
button.
1 Pull out the Emergency Stop button to the ON
position at both the ground and platform 1 Start the engine from the ground controls.
controls. 2 Push down the Emergency Stop button to the
2 Turn the key switch to ground control, start the OFF position.

engine and then turn the key switch to platform Result: The engine should shut off and no
control. machine functions should operate.
3 Check any machine function from the ground Deutz Diesel models: All
controls. functions should stop immediately.
The engine will shut off after 2 to 3
Result: The machine functions should not
seconds.
operate.
3 Start the engine from the platform controls.
4 Turn the key switch to ground control.
4 Push down the Emergency Stop button to the
5 Check any machine function from the platform OFF position.
controls.
Result: The engine should shut off and no
Result: The machine functions should not machine functions should operate.
operate.
The ground Emergency Stop
button will stop all machine
operation, even if the key switch
is switched to platform control.
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TABLE B PROCEDURES

B-15 B-16
Test the Ground Control Override Check the Directional Valve
A properly functioning ground control override is Linkage
essential to safe machine operation. The ground Perform this test only on models
control override function is intended to allow equipped with a oscillating axle.
ground personnel to operate the machine from the
ground controls whether or not the Emergency Proper axle oscillation is essential to safe machine
Stop button on the platform controls is in the ON or operation. If the directional valve linkage is not
OFF position. This function is particularly useful if operating correctly, the stability of the machine is
the operator at the platform controls cannot return compromised and it may tip over.
the boom to the stowed position.
1 Remove the drive chassis cover from the
1 Push in the platform Emergency Stop button non-steer end.
to the OFF position.
2 Inspect the linkage for the following:
2 Start the engine from the ground controls.
· Lock nut is tight against yoke
3 Operate each boom function through a · Yoke clevis pins are installed
partial cycle.
· Cotter pins are installed through clevis pins
Result: All boom functions should operate.
· Linkage is properly attached to
directional valve

a directional valve
b clevis pin with cotter pin (hidden)
c yoke
d lock nut

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TABLE B PROCEDURES

B-17 2 Push down the horn button at the platform

controls.
Test the Platform Self-leveling
Result: The horn should sound.
Automatic platform self-leveling throughout
the full cycle of boom raising and lowering is If necessary, the horn can be
essential for safe machine operation. The adjusted to obtain the loudest
platform is maintained at level by the platform volume by turning the adjustment
leveling slave cylinder which operates in a closed screw near the wire terminals on
loop hydraulic circuit with the master cylinder the horn.
located at the base of the boom. A platform self-
leveling failure creates an unsafe working condition
for platform and ground personnel.
B-19
1 Start the engine from the ground controls and Test the Foot Switch
lower the boom into the stowed position.
A properly functioning foot switch is essential to
2 Hold the function enable toggle switch to either
safe machine operation. Machine functions should
side and adjust the platform to a level position
activate and operate smoothly as long as the foot
using the platform level toggle switch.
switch is pressed down, and promptly stop when
3 Raise and lower the boom through the foot switch is released. The foot switch will also
a full cycle. shift the engine into high idle if the idle select is
switched to the rabbit and foot switch symbol. An
Result: The platform should remain level at
improperly functioning foot switch can cause an
all times to within ±5 degrees.
unsafe working condition and endanger platform
and ground personnel.

The engine should not start if the

B-18 foot switch is pressed down.
Test the Horn 1 Turn the keyswitch to platform controls and pull
A functional horn is essential to safe machine out the Emergency Stop button to the ON
operation. The horn is activated at the platform position at both the ground and platform
controls and sounds at the ground as a warning to controls.
ground personnel. An improperly functioning horn 2 Press down the footswitch and attempt to start
will prevent the operator from alerting ground the engine by moving the start toggle switch to
personnel of hazards or unsafe conditions. either side.
1 Turn the key switch to platform control and Result: The engine should not start.
pull out the Emergency Stop button to the 3 Do not press down the footswitch and start the
ON position at both the ground and
engine.
platform controls.
4 Do not press down the footswitch. Check the
machine functions.
Result: The machine functions should not
operate.
5 Press down the foot switch and operate the
machine functions.
Result: The machine functions should operate.

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TABLE B PROCEDURES

B-20 7 Move the engine idle control switch to foot

switch activated high idle (rabbit and foot switch
Test the Engine Idle Select symbol).
A properly operating engine idle select switch Result: The engine should not change to
is essential to good engine performance and safe high idle.
machine operation. There are three settings.
8 Press down the foot switch.
Low idle (turtle symbol) allows the operator to
control individual boom functions only. Drive Result: The engine should change to high idle.
functions do not operate at low idle.
High idle (rabbit symbol) allows the operator
to control multiple boom and/or drive functions B-21
simultaneously. This setting maintains a Test the Fuel Select Operation
consistent high idle and is usually selected only
when the generator option is being used. - Gasoline/LPG Models
Foot switch activated high idle (rabbit and foot The ability to select and switch between
switch symbols) should be used for normal gasoline and LPG fuels as needed is essential to
machine operation. This selection activates high safe machine operation. A fuel selection can be
idle only when the foot switch is pressed down. made when the engine is running or not.
Switching malfunctions and/or the failure of the
1 Pull out the Emergency Stop button to the engine to start and run properly in both fuel
ON position at both the ground and platform modes and through all idle speeds can indicate
controls. fuel system problems that could develop into a
hazardous situation.
2 Start the engine from the ground controls. Then
move the function enable toggle switch to the Perform this test after checking
high idle (rabbit symbol) position and hold in the the gasoline and LPG fuel levels,
ON position. and warming the engine to normal
Result: The engine should change to high idle. operating temperature.

3 Release the function enable toggle switch. 1 Move the fuel select switch to gasoline and then
move the engine idle control switch to foot
Result: The engine should return to low idle. switch activated high idle (rabbit and foot switch
symbol).
4 Turn the key switch to platform controls.
2 Start the engine from the platform controls and
5 At the platform controls, move the engine idle
allow it to run at low idle.
control switch to high idle (rabbit symbol).
3 Press down the foot switch to allow the engine
Result: The engine should change to high idle.
to run at high idle.
6 Move the engine idle control switch to low idle
Result: The engine should start promptly and
(turtle symbol).
operate smoothly in low and high idle.
Result: The engine should change to low idle.
4 Release the foot switch and shut the engine off
by pushing the Emergency Stop button in to the
OFF position.

5 Move the fuel select switch to LPG.

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Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE B PROCEDURES

6 Restart the engine and allow it to run at 4 Hold the drive enable toggle switch to either
low idle. side and slowly move the drive control handle
off center.
7 Press down the foot switch to allow the engine
to run at high idle.
Result: The engine should start promptly and
operate smoothly in low and high idle.
The engine may hesitate
momentarily and then continue
to run on the selected fuel if the Always use the color-coded
fuel source is switched while direction arrows on the
the engine is running. platform control panel and the
drive chassis to identify which
direction the machine will travel.

B-22 Result: The drive function should operate.

Test the Drive Enable System 5 Rotate the turntable to the left until the boom is
past the left non-steering wheel.
Proper drive enable system operation is
essential to safe machine operation. When the Result: The drive enable indicator light should
boom is past the non-steering wheels, drive come on.
movement is stopped and the indicator light turns 6 Repeat steps 3 and 4.
on. The drive enable switch must be to either side
to reactivate the drive function and should inform
the operator that the machine will move in the
opposite direction that the drive and steer controls B-23
are moved. An improperly functioning drive enable
system may allow the machine to be moved into Test the Drive Brakes
an unsafe position. Proper brake action is essential to safe machine
1 Start the engine from the platform controls. operation. The drive brake function should operate
smoothly, free of hesitation, jerking and unusual
2 Rotate the turntable to the right until the boom is noise. Hydrostatic brakes and hydraulically-
past the right non-steering wheel. released individual wheel brakes can appear to
operate normally when they are actually not fully
Result: The drive enable indicator light should
operational.
turn on.
3 Slowly move the drive control handle off center. Be sure that the machine is not in
free-wheel or partial free-wheel
Result: The drive function should not operate. configuration. Refer to B-9 in this
section, Confirm the Proper Brake
Configuration.
Select a test area that is firm, level
and free of obstructions.
1 Mark a test line on the ground for reference.
2 Start the engine from the platform controls.

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TABLE B PROCEDURES

3 Move the engine idle control switch to B-24

foot switch activated high idle (rabbit and
foot switch), then lower the boom into the Test the Drive Speed
stowed position. - Stowed Position
4 Choose a point on the machine; i.e., contact Proper drive function movement is essential to
patch of a tire, as a visual reference for use safe machine operation. The drive function should
when crossing the test line. respond quickly and smoothly to operator control.
5 Bring the machine to top drive speed before Drive performance should also be free of
reaching the test line. Release the drive joystick hesitation, jerking and unusual noise over the
when your reference point on the machine entire proportionally controlled speed range.
crosses the test line. Select a test area that is firm, level
6 Measure the distance between the test line and and free of obstructions.
your machine reference point. 1 Create start and finish lines by marking two
lines on the ground 40 feet (12.2 m) apart.
Braking:
paved surface 2WD 4WD 2 Start the engine from the platform controls.
3 Move the engine idle control switch to
Stopping distance 3 to 5 ft 3 to 5 ft
foot switch activated high idle (rabbit and foot
0.9 to 1.5 m 0.9 to 1.5 m
switch), then lower the boom into the stowed
position.

The brakes must be able to hold 4 Choose a point on the machine; i.e., contact
the machine on any slope it is able patch of a tire, as a visual reference for use
to climb. when crossing the start and finish lines.
5 Bring the machine to top drive speed before
reaching the start line. Begin timing when your
reference point on the machine crosses the
start line.
6 Continue at full speed and note the time when
the machine reference point crosses the finish
line.

Drive speed:
stowed position 2WD 4WD

Gasoline/LPG models 40 ft/6.2 sec 40 ft/9.1 sec

12.2 m/6.2 sec 12.2 m/9.1 sec

Deutz Diesel models 40 ft/6.8 sec 40 ft/9.1 sec

12.2 m/6.8 sec 12.2 m/9.1 sec

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TABLE B PROCEDURES

B-25 5 Press down the foot switch. Move the drive

control handle off center, hold for a moment
Test the Alarm Package and then release it. Move the drive control
- Optional Equipment handle off center in the opposite direction, hold
for a moment and then release it.
The alarm package includes:
Result: The travel alarm should sound when the
· Travel alarm drive control handle is moved off center in
· Descent alarm either direction.
· Flashing beacon
Alarms and a beacon are installed to alert
operators and ground personnel of machine
B-26
proximity and motion. The alarm package is Perform Hydraulic Oil Analysis
installed on the turntable covers.
See D-1, Test or Replace the Hydraulic Oil.
The alarms and beacon will
operate with the engine
running or not running.
B-27
1 Turn the key switch to ground control and pull
out the Emergency Stop button to the ON
Replace the Engine Oil and
position at both the ground and platform Filter - Deutz Diesel Models
controls.
Engine specifications require
Result: The flashing beacon should be on and that this procedure be performed
flashing. every 500 hours. Perform this
procedure more often if dusty
2 Move the function enable toggle switch to either
conditions exist.
side and activate the boom toggle switch in the
DOWN position, hold for a moment and then Periodic replacement of the engine oil and
release it. filter is essential to good engine performance.
Operating the machine with an improper oil level or
Result: The descent alarm should sound when neglecting periodic oil and filter changes can
the switch is held down. damage engine components. A frequent check
3 Turn the key switch to platform control. of elapsed machine hours against the hours
noted on the oil filter will allow the inspector to
Result: The flashing beacon should be on anticipate and perform oil and filter changes at
and flashing. the 500 hour interval.
4 Press down the foot switch. Move the boom
Perform this procedure after
control handle to the DOWN position, hold for a
warming the engine to normal
moment and then release it.
operating temperature.
Result: The descent alarm should sound when
Beware of hot engine parts and oil.
the control handle is held down.
Contact with hot engine oil and/or
engine parts may cause severe
burns.
1 Remove the oil filler cap located above the
dipstick.

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TABLE B PROCEDURES

2 Pull the end of the drain hose out from under 10 Check the oil filter and oil drain hose for leaks.
the engine.
11 Check the engine oil level dipstick. Add oil if
3 Remove the plug from the end of the drain hose needed.
and allow all of the oil from the engine to drain
into a suitable container. See capacity Deutz Engine F4L 1011F 11 quarts
specifications below. Oil capacity (including filter) 10.5 liters
4 Install the plug into the drain hose. Deutz Engine F4L 1011F Oil viscosity requirements
5 Use an oil wrench and remove the oil filter.
Temperature below 60°F / 15.5°C (synthetic) 5W-30

-10°F to 90°F / -23°C to 32°C 10W-40

a
Temperature above -4°F / -34°C 15W-40

Engine oil should have properties of API classification

CC/SE, CD/SE, CC/SF or CD/SF grades.

c b

2 Clean up any fuel that may have spilled.

a engine oil level dipstick

b fuel filter
c oil filter

6 Apply a thin layer of oil to the new filter gasket

(Genie part no. 49924). Then install the filter
and tighten it securely by hand.
7 Use a permanent ink marker to write the date
and number of hours from the hour meter on
the oil filter.
8 Fill the engine with new oil per specifications
and install the oil filler cap.
9 Start the engine from the ground controls. Allow
the engine to run for 30 seconds then turn the
engine off.

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Table C Procedures
C-1 C-2
Check the Boom Check the Turntable Rotation
Wear Pads Bearing Bolts
Maintaining the boom wear pads in good condition Maintaining proper torque on the turntable bearing
is essential to safe machine operation. Wear pads bolts is essential to safe machine operation.
are placed on boom tube surfaces to provide a low Improper bolt torque could result in an unsafe
friction, replaceable wear pad between moving operating condition and component damage.
parts. Improperly shimmed wear pads or continued
use of worn out wear pads may result in 1 Raise the boom and place a safety chock on
component damage and unsafe operating the lift cylinder rod. Carefully lower the boom
conditions. onto the lift cylinder safety chock.
Crushing hazard. Keep hands
If the wear pads are not worn
away from cylinder and all moving
below specification but are still
parts when lowering the boom.
within specification, see Repair
Procedure 4-2, How to Shim the The lift cylinder safety chock is
Boom. available through Genie
(part no. 33484).
1 Start the engine from the ground controls.
2 Be sure that each turntable mounting bolt is
2 Raise the end of the boom to a comfortable
torqued in sequence to 210 foot-pounds
working height (chest high), then extend the
(285 Newton meters).
boom 1 foot (30 cm).
3 Measure each wear pad. Replace the wear pad 28 1
24 5
20 9
if it is less than specification. If the wear pad is 16 13
not less than specification, shim as necessary 12 17
to obtain zero clearance and zero drag. 8 21
4 25
4 Extend and retract the boom through the entire 30 29
range of motion to check for tight spots that 26 3
may cause binding or scraping of the boom. 22 7
18 11
Always maintain squareness 14 15
between the boom outer and inner 10 19
tubes.
6 2 27 23

Bolt torque sequence

Wear pad specifications

Upper wear pads 9/16 inch 14.3 mm

Bottom and side wear pads 11/16 inch 17.5 mm

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TABLE C PROCEDURES

3 Lower the boom to the stowed position. 4 Disengage the torque hubs by turning over the
torque hub disconnect caps on each
4 Check to ensure that each bearing mounting
non-steering wheel hub.
bolt under the drive chassis is torqued in
sequence to 210 foot-pounds disengage position
(285 Newton meters).
1 15
10
13 7

6 12 engage position

18 4 5 Manually rotate each non-steering wheel.

3 17 Result: Each non-steering wheel should rotate

with minimum effort.
11 5

8 14
6 Re-engage the torque hubs by turning over
16 9 the hub disconnect caps. Rotate each wheel to
2
check for engagement. Lift the machine and
Bolt torque sequence remove the jack stands.
Collision hazard. Failure to
re-engage the torque hubs may
cause death or serious injury and
C-3 property damage.
Check the Free-wheel
Steer wheels: 4WD models
Configuration
7 Chock the non-steering wheels to prevent the
Proper use of the free-wheel configuration is machine from rolling.
essential to safe machine operation. The
free-wheel configuration is used primarily for 8 Center a lifting jack of ample capacity
towing. A machine configured to free-wheel without (20,000 lbs/9072 kg) under the drive chassis
operator knowledge may cause death or serious between the non-steer tires.
injury and property damage. 9 Lift the wheels off the ground and then place
Collision hazard. Select a work jack stands under the drive chassis for support.
site that is firm and level. 10 Disengage the torque hubs by turning over the
Non-steering wheels: All models torque hub disconnect caps on each
steer wheel hub.
1 Chock the steer wheels to prevent the machine
from rolling.
disengage position
2 Center a lifting jack of ample capacity
(20,000 lbs/9072 kg) under the drive chassis
between the non-steer tires.
3 Lift the wheels off the ground and then place engage position
jack stands under the drive chassis for support.
11 Manually rotate each steer wheel.
Result: Each steer wheel should rotate with
minimum effort.

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TABLE C PROCEDURES

12 Re-engage the torque hubs by turning over C-4

the hub disconnect caps. Rotate each wheel to
check for engagement. Lift the machine and Grease the Turntable Rotation
remove the jack stands. Bearing and Rotate Gear
Collision hazard. Failure to Yearly application of lubrication to the turntable
re-engage the torque hubs may bearing and rotate gear is essential to good
cause death or serious injury and machine performance and service life. Continued
property damage. use of an improperly greased bearing and gear will
All models: result in component damage.

13 Be sure the free-wheel valve on the drive pump 1 Locate the grease fitting on the platform end of
is closed (clockwise). the tank side bulkhead.

The free-wheel valve is located on 2 Pump grease into the turntable rotation bearing.
the bottom of the drive pump. Rotate the turntable in increments
of 4 to 5 inches (10 to 13 cm) at a time and
repeat this step until the entire bearing has
been greased.
3 Apply grease to each tooth of the drive gear,
d located under the turntable.
a c
Grease type Multipurpose grease
b

a drive pump
b free-wheel valve C-5
c lift pump
d screwdriver Replace the Torque Hub Oil
The free-wheel valve should Replacing the torque hub oil is essential for good
always remain closed. machine performance and service life. Failure to
replace the torque hub oil at yearly intervals may
cause the machine to perform poorly and
continued use may cause component damage.

Drive Torque Hubs:

1 Select the torque hub to be serviced. Then drive
the machine until one of the two plugs is at the
lowest point.
2 Remove both plugs and drain the oil.

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TABLE C PROCEDURES

3 Drive the machine until one plug is at the top Turntable Rotate Torque Hub:
and the other is at 90 degrees.
1 Secure the turntable from rotating with the
turntable rotation lock pin.

4 Fill the hub with oil from the top hole until the oil
level is even with the bottom of the side hole. unlocked locked
Apply pipe thread sealant to the plugs, and then 2 Remove the motor/brake mounting bolts, and
install the plugs. then remove the motor and brake from the
5 Repeat steps 1 through 4 for all the other drive torque hub and set them to the side.
torque hubs. Component damage hazard.
Hoses can be damaged if they are
Oil capacity per hub 44 fl oz kinked or pinched.
1.30 liters
a b
Type: SAE 90 multipurpose hypoid gear oil - API
service classification GL5

f
c

d
e

a motor/brake mounting bolt

b motor
c torque hub
d torque hub mounting bolt
e plug
f brake

3 Remove the torque hub mounting bolts, and

then use a lifting device to remove the torque
hub from the machine.

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TABLE C PROCEDURES

4 Remove the plug from the side of the torque 4 Use a permanent ink marker to write the date
hub. Then drain the oil from the hub. and number of hours from the hour meter on
the oil filter.
5 Install the torque hub. Torque the hub mounting
bolts to 180 foot-pounds (244 Newton meters). 5 Start the engine from the ground controls.
6 Install the brake and motor onto the torque hub. 6 Inspect the filter and related components to
7 Fill the hub with oil from the side hole until the be sure that there are no leaks.
oil level is even with the bottom of the hole.
Apply pipe thread sealant to the plugs, and then
install the plugs.
C-7
8 Adjust turntable rotation gear backlash. See
Repair Procedure 12-1, How to Adjust the
Replace the Drive Loop
Turntable Rotation Gear Backlash. Hydraulic Filter
Replacing the drive loop hydraulic filter is essential
Turntable rotate torque hub
to good machine performance and service life. A
dirty or clogged filter may cause the machine to
Oil capacity 17 fluid ounces
0.51 liters perform poorly and continued use may cause
component damage. Extremely dirty conditions
Type: SAE 90 multipurpose hypoid gear oil - API may require that the filter be replaced more often.
service classification GL5
Beware of hot oil. Contact with
hot oil may cause severe burns.
Perform this procedure with the
engine off.
C-6
1 Open the engine side turntable cover and locate
Replace the Hydraulic Tank Filter the drive loop hydraulic filter mounted on the
Replacement of the hydraulic tank filter is engine near the main pump.
essential for good machine performance and 2 Remove the filter housing by using a wrench on
service life. A dirty or clogged filter may cause the the nut provided on the bottom of the housing.
machine to perform poorly and continued use may
cause component damage. Extremely dirty 3 Remove the filter element from the housing.
conditions may require that the filter be replaced
4 Inspect the housing seal and replace it if
more often.
necessary.
Beware of hot oil. Contact with 5 Install the new filter (Genie part no. 20880) and
hot oil may cause severe burns. hand tighten the housing onto the filter head.
Perform this procedure with the Clean up any oil that may have spilled during
engine off. the installation procedure.

1 Remove the filter with an oil filter wrench. 6 Start the engine from the ground controls.
2 Apply a thin layer of oil to the new oil filter 7 Inspect the filter assembly to be sure that there
gasket. are no leaks.
3 Install the new filter (Genie part no. 46014) and 8 Clean up any oil that may have spilled.
tighten it securely by hand. Clean up any oil
that may have spilled during the installation
procedure.
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TABLE C PROCEDURES

C-8 3 Fill the new filter (Genie part no. 29560) with
fresh diesel fuel and apply a thin layer of oil or
Replace the Diesel Fuel diesel fuel to the new fuel filter gasket.
Filter/Water Separator - Deutz 4 Install the new filter and tighten it securely by
Diesel Models hand. Clean up any diesel fuel that might have
spilled during the procedure.
Replacing the diesel fuel filter is essential to good
engine performance and service life. A dirty or 5 Turn the manual fuel shutoff valve, located at
clogged filter may cause the engine to perform the fuel tank, to the OPEN position.
poorly and continued use may cause component
6 Start the engine from the ground controls, then
damage. Extremely dirty conditions may require
inspect the fuel filter for leaks.
that the filter be replaced more often.
If a fuel leak is discovered, keep
Engine fuels are combustible. any additional personnel from
Replace the fuel filter in an open, entering the area and do not
well-ventilated area away from operate the machine. Repair
heaters, sparks, flames and the leak immediately.
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.
Perform this procedure with the C-9
engine off. Replace the Gasoline Fuel
1 Turn the manual fuel shutoff valve, located at Filter - Gasoline/LPG Models
the fuel tank, to the CLOSED position.
Replacing the gasoline fuel filter is essential to
2 Remove the fuel filter with a filter wrench. good engine performance and service life. A dirty
or clogged filter may cause the engine to perform
poorly and continued use may cause component
damage. Extremely dirty conditions may require
that the filter be replaced more often.
Engine fuels are combustible.
Replace the fuel filter in an open,
well-ventilated area away from
a heaters, sparks, flames and
b lighted tobacco. Always have an
approved fire extinguisher within
easy reach.
Perform this procedure with the
engine off.
a oil filter
b fuel filter/water separator

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TABLE C PROCEDURES

1 Remove the 2 bolts from under the engine pivot 3 Install the new fuel filter (Genie part no. 33971)
plate. Swing the engine pivot plate away from into the fitting on the carburetor.
the machine to access the fuel filter, located
4 Connect the fuel hose to the filter.
near the carburetor.
5 Clean up any fuel that may have spilled during
the installation procedure.
6 Start the machine from the ground controls,
then inspect the fuel filter and hose for leaks.
If a fuel leak is discovered, keep
any additional personnel from
entering the area and do not
operate the machine. Repair
the leak immediately.
7 Swing the engine pivot plate back to its original
position and replace the two retaining bolts.

a b a

a pivot plate retaining bolts

b engine pivot plate

2 Disconnect the fuel hose from the filter, then

remove the filter from the fitting.

a b

a fuel filter
b hose from the fuel pump to
the fuel filter

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TABLE C PROCEDURES

C-10 2 Remove the hose from the PCV valve, then

remove the valve.
Replace the PCV Valve
- Gasoline/LPG Models
Yearly replacement of the PCV valve is essential to
good engine performance. A malfunctioning PCV
valve can impair crankcase ventilation and may
cause engine damage.

Perform this procedure with the

engine off.
1 Remove the 2 engine pivot plate retaining bolts
from under the engine pivot plate. Swing the
engine pivot plate away from the machine to
access the PCV valve.

a PCV valve

3 Install the new PCV valve. Connect the hoses.

4 Swing the engine pivot plate back to its original
position and replace the two retaining bolts.

a b a

a pivot plate retaining bolts

b engine pivot plate

4 - 36 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE C PROCEDURES

C-11 C-12
Replace the Spark Plugs Check and Adjust the Air/LPG
- Gasoline/LPG Models Mixture - Gasoline/LPG Models
Periodic replacement of the spark plugs is Maintaining the proper air-to-fuel mixture during
essential to good engine performance and LPG operation is essential to good engine
service life. Worn, loose or corroded spark plugs performance.
will cause the engine to perform poorly and may
result in component damage. Engine fuels are combustible.
Perform this procedure in an open,
Perform this procedure with the well-ventilated area away from
engine off. heaters, sparks, flames and
lighted tobacco. Always have an
1 Label, then disconnect the plug wires from the
approved fire extinguisher within
spark plugs by grasping the molded boot. Do
easy reach.
not pull on the plug wire.
The engine rpm needs to be
2 Blow out any debris around spark plugs.
preset for gasoline fuel operation
3 Remove all the spark plugs from the engine. before adjusting the LPG idle
mixture. Refer to B-12, Check and
4 Adjust the gap on each new spark plug. Adjust the Engine RPM.
5 Install the new spark plugs, then connect the The engine should be warmed to
wires. Be sure that each spark plug wire is normal operating temperature
attached to the correct spark plug. before performing this procedure.

Spark plug specifications 1 Move the fuel select switch to LPG fuel and
start the engine from the ground controls.
Spark plug type Motorcraft AWSF-52C
2 Loosen the high idle mixture adjustment
lock nut.
Spark plug gap 0.042 to 0.046 inches
1.07 to 1.18 mm a

Spark plug torque 5 to 10 foot-pounds

7 to 14 Nm

a high idle mixture

adjustment screw

Part No. 48412 Genie S-60 & Genie S-65 4 - 37

Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE C PROCEDURES

3 Load the system by activating the boom retract C-13

function, then move the function enable toggle
switch to the high idle (rabbit symbol) position. Check and Adjust the Ignition
4 Adjust the high idle adjustment screw to obtain
Timing - Gasoline/LPG Models
an air-to-fuel mixture ratio of 13.0:1 to 13.2:1, Complete information to perform this procedure is
using an exhaust gas analyzer. available in the Ford LRG-423 2.3 Liter Industrial
Preliminary setting is 1/4 inch of Engine Service Manual (Ford number: PPD-194-
threads showing. Measure from 287). Genie part number 33907.
top of lock nut to top of adjustment
screw.
If an exhaust gas analyzer is not C-14
available, adjust to obtain peak or
optimum rpm.
Check the Engine Valve
Clearances - Deutz Diesel Models
5 Hold the adjustment screw and tighten the
lock nut. Complete information to perform this procedure
is available in the Deutz FL 1011F Workshop
6 Move the engine idle control switch to low idle
Manual (Deutz Number 0297 7195).
(turtle symbol) and adjust the low idle screw to
Genie part number 52229.
obtain an air-to-fuel mixture ratio
of 13.0:1 to 13.2:1.

C-15
Check the Turntable Rotation
Gear Backlash
The turntable rotation torque hub is mounted on an
adjustable plate that controls the gap between the
rotation motor gear and the turntable bearing.
Maintaining proper backlash of the turntable
bearing is essential to safe machine operation.
Improper backlash could result in an unsafe
operating condition and component damage.

See 12-1, How to Adjust the

Turntable Rotation Gear Backlash.

a low idle mixture adjustment screw

Preliminary setting: turn low idle

adjustment screw clockwise all the
way in. Turn low idle adjustment
screw counterclockwise 2 3/4
turns.

4 - 38 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

Table D Procedures
D-1 D-2
Test or Replace the Hydraulic Oil Change or Recondition the
Replacement or testing of the hydraulic oil is Engine Coolant
essential for good machine performance and - Gasoline/LPG Models
service life. Dirty oil and suction strainers may
cause the machine to perform poorly and Replacing or reconditioning the engine coolant is
continued use may cause component damage. essential to good engine performance and service
Extremely dirty conditions may require oil changes life. Old or dirty coolant may cause the engine to
to be performed more often. perform poorly and continued use may cause
engine damage. Extremely dirty conditions may
The machine uses Dexron require coolant to be changed more frequently.
equivalent hydraulic oil. Before
replacing the hydraulic oil, the oil Beware of hot engine parts and
may be tested by an oil distributor coolant. Contact with hot engine
for specific levels of contamination parts and/or coolant will cause
to verify that changing the oil is severe burns.
necessary. If the hydraulic oil is Perform this procedure with the
not replaced at the two year engine off and cooled.
inspection, test the oil quarterly.
Replace the oil when it fails the 1 Put on protective clothing and eye wear.
test.
2 Disconnect the coolant return hose at the
Perform this procedure with the radiator and drain the coolant return tank into a
boom in the stowed position. suitable container.
1 Remove the hydraulic tank. See Repair 3 Slowly remove the radiator cap from the
Procedure 11-2, How to Remove the Hydraulic radiator.
Tank.
Bodily injury hazard. Allow any
The pump needs to primed before pressure to dissipate gradually
starting the engine. See Repair before removing the radiator cap.
Procedure 11-2, How to Remove
the Hydraulic Tank.
Component damage hazard. Be
sure that the hydraulic tank shutoff
valves are in the OPEN position
before priming the pump. The
engine must not be started with
the hydraulic tank shutoff valves in
the CLOSED position or component
damage will occur. If the tank
valves are closed, remove the key
from the key switch and tag the
machine to inform personnel of the
condition.

Part No. 48412 Genie S-60 & Genie S-65 4 - 39

Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE D PROCEDURES

4 Remove the 2 engine pivot plate retaining bolts 10 Disconnect the hose coupler at the fan end from
from under the engine pivot plate. Swing the the tube that is connected to the water pump
engine pivot plate away from the machine to and hold it until coolant starts to come out of the
access the radiator drain valve. open hose. Then immediately reconnect the
hose.

b a

a b a
a tube connected to water pump
b hose coupler
a pivot plate retaining bolts
b engine pivot plate
11 Fill the radiator and then fill the coolant recovery
5 Open the drain valve on the radiator and allow tank to the NORMAL range.
all the coolant to drain into a suitable container. 12 Clean up any coolant spilled during this
6 After all the coolant has drained, close the drain procedure.
valve. Connect the coolant return hose to 13 Start the engine from the ground controls,
the radiator. run it for 30 seconds, and then turn it off.
7 Open the drain valve on the engine block and 14 Inspect for leaks and then check the fluid
allow the coolant to drain into a container. level in the coolant recovery tank. Add
After the fluid is drained, close the drain valve. water if needed.
8 Replace all coolant hoses and clamps. 15 Start the engine from the ground controls
9 Pour the proper coolant mixture (anti-freeze and and run it until reaching normal operating
water) for your climate into the radiator until it is temperature.
full. 16 Allow engine to cool and check the fluid level in
the coolant recovery tank. Add water if needed.

Ford Engine 11.5 quarts

Coolant capacity 10.9 liters

4 - 40 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE D PROCEDURES

D-3 a b b b b b b b

Change the Fuel Lines

Maintaining the fuel lines in good condition is
essential to safe operation and good engine
performance. Failure to detect a worn, cracked or
leaking fuel line may cause an unsafe operating
condition.

Engine fuels are combustible.

Replace the fuel lines in an open,
well-ventilated area away from
heaters, sparks, flames and
lighted tobacco. Always have an
approved fire extinguisher within
easy reach.
Perform this procedure with the
engine off.
1 Close the manual fuel shutoff valve, located
next to the fuel tank.
2 Remove and replace the fuel line hoses and
clamps according to the following illustrations:
Fuel may be expelled under f e d c
pressure. Wrap a cloth around fuel
hoses to absorb leaking fuel Deutz Diesel models
a hose from the injector to
before disconnecting them.
the fuel tank
b hoses connecting injectors
c hose from the fuel shutoff valve
to the fuel pump
d hose from the fuel pump to
the fuel filter
e hose from the fuel filter to the
injection pump
f hose from the injection pump
to the injectors

Part No. 48412 Genie S-60 & Genie S-65 4 - 41

Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE D PROCEDURES

a b c D-4
Check the Engine Valve
Clearance - Gasoline/LPG Models
Complete information to perform this procedure is
available in the Ford LRG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: PPD-194-
287). Genie part number 33907.

D-5
Check the Engine Cylinder
Compression
- Gasoline/LPG Models
Complete information to perform this procedure is
available in the Ford LRG-423 2.3 Liter Industrial
d
Engine Service Manual (Ford number: PPD-194-
Gasoline/LPG 287). Genie part number 33907.
a carburetor
b fuel filter
c hose from the fuel filter to
the fuel pump
d hose from the fuel pump D-6
to the fuel tank (not shown)
Clean the PCV Hoses and
3 Clean up any fuel that may have spilled during
this procedure.
Fittings - Gasoline/LPG Models
Maintaining PCV hoses is essential to good engine
4 Start the engine from the ground controls, then
performance. Improperly functioning PCV hoses
inspect the fuel filter and hoses for leaks.
will fail to ventilate the crankcase and continued
If a fuel leak is discovered, keep use of neglected hoses could result in component
any additional personnel from damage.
entering the area and do not
operate the machine. Repair Perform this procedure with the
the leak immediately. engine off.

4 - 42 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 4 - Scheduled Maintenance Procedures

TABLE D PROCEDURES

1 Remove the 2 engine pivot plate retaining bolts 5 Dry both hoses and inspect them for cracks and
from under the engine pivot plate. Swing the damage. Replace the hoses if they are
engine pivot plate away from the machine to damaged.
access the PCV hoses.

D-7
Check the Fuel Injection Pump
and Injectors - Deutz Diesel
Models
Complete information to perform this procedure is
available in the Deutz FL 1011F Workshop Manual
(Deutz number: 0297 7195).
Genie part number 52229.

a b a
D-8
a pivot plate retaining bolts
Check the Toothed Belt
b engine pivot plate - Deutz Diesel Models
2 Disconnect the hose from the PCV valve, then Complete information to perform this procedure is
disconnect the hose from the engine. available in the Deutz FL 1011 Operation Manual
(Deutz number: 0297 4706 EN).
a
Genie part number 29790.

D-9
Replace the Timing Belt
c
- Gasoline/LPG Models
Complete information to perform this procedure is
available in the Ford LRG-423 2.3 Liter Industrial
Engine Service Manual (Ford number: PPD-194-
b
287). Genie part number 33907.

a carburetor to valve cover hose

b PCV valve
c PCV valve to carburetor hose

3 Disconnect the hose from the carburetor, then

disconnect the hose from the valve cover.
4 Clean the hoses with a mild cleaning solvent.

Part No. 48412 Genie S-60 & Genie S-65 4 - 43

Section 4 - Scheduled Maintenance Procedures Service Manual - Second Edition

TABLE D PROCEDURES

D-10 9 Check for wheel bearing wear by attempting to

move the wheel hub side to side, then up and
Grease the Steer Axle down.
Wheel Bearings - 2WD Models Result: If there is side to side or up and down
Maintaining the steer axle wheel bearings is movement, proceed to step 10 to replace the
essential for safe machine operation and service wheel bearings with new ones.
life. Operating the machine with loose or worn When replacing a wheel bearing,
wheel bearings may cause an unsafe operating both the inner and outer bearings,
condition and continued use may result in including the pressed-in races,
component damage. Extremely wet or dirty must be replaced.
conditions or regular steam cleaning and pressure
washing of the machine may require that this Result: If there is no side to side or up and
procedure be performed more often. down movement, grease the wheel bearings.
10 Remove the castle nut.
1 Loosen the wheel lug nuts. Do not remove
them. 11 Pull the hub off of the spindle. The washer and
outer bearing should fall loose from the hub.
2 Block the non-steering wheels, then center a
lifting jack under the steer axle. 12 Place the hub on a flat surface and gently pry
the bearing seal out of the hub. Remove the
3 Raise the machine 6 inches (15 cm) and place rear bearing.
blocks under the drive chassis for support.
13 Pack both bearings with clean, fresh grease.
4 Remove the lug nuts, then remove the tire and
wheel assembly. 14 Place the large inner bearing into the rear of the
hub.
5 Check for wheel bearing wear by attempting to
move the wheel hub side to side, then up and 15 Install a new bearing grease seal into the hub
down. by pressing it evenly into the hub until it is flush.

Result: There should not be any side to side or Always replace the bearing grease
up and down movement. seal when removing the hub.

Skip to step 10 if there is no movement. 16 Slide the hub onto the yoke spindle.
Component damage. Do not
6 Remove the dust cap from the hub, then
apply excessive force or damage
remove the cotter pin from the castle nut.
to the lip of the seal may occur.
7 Tighten the castle nut to 35 foot-pounds
17 Place the outer bearing into the hub.
(47 Nm) to seat the bearings.
18 Install the washer and slotted nut.
8 Loosen the castle nut, then re-tighten to
8 foot-pounds (11 Nm). 19 Tighten the slotted nut to 35 foot-pounds
(47 Nm) to seat the bearings.
20 Loosen the slotted nut, then re-tighten to
8 foot-pounds (11 Nm).
21 Install a new cotter pin. Bend the cotter pin
to lock it in.
22 Install the dust cap, then the tire and wheel
assembly. Torque the wheel lug nuts to
420 foot-pounds (569.5 Nm).
4 - 44 Genie S-60 & Genie S-65 Part No. 48412
Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Troubleshooting Flow Charts

Before Troubleshooting:
Read, understand and obey the safety rules
and operating instructions printed in the
Genie S-60 & Genie S-65 Operator’s Manual.
Be sure that all necessary tools and test
equipment are available and ready for use.
Observe and Obey:
Read each appropiate flow chart thoroughly.
Troubleshooting and repair procedures shall be Attempting shortcuts may produce hazardous
completed by a person trained and qualified on conditions.
the repair of this machine.
Be aware of the following hazards and follow
Immediately tag and remove from service a generally accepted safe workshop practices.
damaged or malfunctioning machine.
Crushing hazard. When testing
Repair any machine damage or malfunction or replacing any hydraulic
before operating the machine. component, always support
the structure and secure it
Unless otherwise specified, perform each from movement.
repair procedure with the machine in the
following configuration: Electrocution hazard. Contact
with electrically charged circuits
· Machine parked on a flat level surface
may result in death or serious
· Boom in stowed position injury. Remove all rings, watches
· Turntable rotated with the boom between and other jewelry.
the non-steering wheels
Bodily injury hazard. Spraying
· Turntable secured with the turntable hydraulic oil can penetrate and
rotation lock pin burn skin. Loosen hydraulic
· Key switch in the OFF position with the connections very slowly to allow
key removed the oil pressure to dissipate
gradually. Do not allow oil to
· Wheels chocked
squirt or spray.
Perform all troubleshooting on a
firm level surface.
Two persons will be required to
safely perform some
troubleshooting procedures.

Part No. 48412 Genie S-60 & Genie S-65 5-1

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

TROUBLESHOOTING FLOW CHARTS

About This Section General Repair Process

When a malfunction is discovered, the flow charts

in this section will help a service professional Malfunction Identify Troubleshoot
pinpoint the cause of the problem. To use this discovered symptoms
section, basic hand tools and certain pieces of test
equipment are required—voltmeter, ohmmeter,
pressure gauges. problem
still exists
The location of terminals mentioned in this section
can be found on the appropriate electrical or Return to Inspect Perform
hydraulic schematics provided in Section 6, service problem and test repair
Schematics. solved

Since various degrees of a particular function

loss may occur, selecting the appropriate flow
chart may be troublesome. When a function will not
operate with the same speed or power as a
machine in good working condition, refer to the
flow chart which most closely describes the
problem.

5-2 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Chart 1
Engine Will Not less than Check battery condition
Check battery voltage. 12V OR check alternator
Crank Over OR check battery cables
OR replace the battery.
Be sure the key switch
12V or more
is in the appropriate
position.
With the keyswitch Trace circuit back
Be sure that both turned to ground 0V through the key switch,
Emergency Stop controls and both emergency stop button
Emergency Stop buttons and CB2, repair open.
buttons are pulled out to are pulled out to the ON
the ON position. position, check the
voltage at the center
Be sure the circuit terminal on the start
toggle switch TS11.
breakers are not
tripped. 12V
Be sure the battery is
Hold the start toggle Repair open in jumper
fully charged. switch to either side and wire from one side of the
0V
check the voltage at switch to the other OR
either side terminal on replace start toggle
start switch. switch TS11.

12V

Hold the start switch to 0V Repair blk wire circuit

either side and check from start switch TS11
voltage at terminal to TB33.
TB33.

12V

Hold the start switch to Repair blk wire circuit

either side and check 0V from TB33 to terminal
voltage at terminal #3 on #3 on ignition/start
ignition/start module. module.

12V

Hold the start switch to Repair open in red

either side and check 0V power supply wire circuit
voltage at terminal #6 on from CB1 to CR1 to CR2
the ignition/start module. then to terminal #6 to
on ignition/start module.

12V

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5-3

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 1

Continued from the Hold the start switch to 0V Check ground wire to bad Repair open in ground
either side and check terminal #5 on start
previous page. voltage at terminal #1 on lockout module. wire.
ignition/start module.
good

Consult Genie Industries

12V Service Department.

Hold the start switch to Repair open in blk wire

either side and check 0V from terminal #1 on
voltage at terminal #86 ignition/start module to
on CR1. CR1.

12V

Check voltage at 0V Repair open in red wire

terminal #30 on CR1. circuit from battery to
CB1 to CR1 terminal
#30.
12V

Hold the start switch to 0V Check brown ground bad Repair open in brown
either side and check wire to terminal #85 on ground wire circuit to
voltage at terminal #87 CR1. CR1.
on CR1.
good

Replace CR1 relay.

12V

Hold the start switch to 0V Repair open in blk wire

either side and check circuit from CR1 to
voltage at the black wire starter solenoid.
on the starter solenoid.

12V

Check voltage at starter 0V Repair open in battery

cable. cable to starter.

12V

Repair or replace starter

or starter solenoid.

5-4 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Chart 2
Engine Cranks With the keyswitch
less
than Check battery condition
turned to ground OR check alternator OR
Over But Will controls and both
11V
check for short circuits
Not Start - Emergency Stop buttons OR check battery cables
pulled out to the on OR replace the battery.
Gasoline/LPG position, hold start
switch to either side and
Models check battery voltage
while engine is cranking.
Be sure to check the
engine oil level and fill more than 11V
as needed.
Check if engine coolant continuity Check if radiator and/or hot Check engine coolant
Be sure to check fuel temperature sending engine block feels level OR check radiator
unit signal post has excessively hot. fins for clogging OR
levels and engine continuity to ground. check engine fan belts
coolant level. OR see Ford service
manual for
Be sure the gasoline troubleshooting an
not hot overheating engine.
shut-off valve is in the
ON or OPEN position.

Be sure that automatic continuity Replace temperature

Remove wht wire from
choke is not sticking temperature sending switch sender.
closed. unit, check continuity to
ground on temperature
Perform following tests sending unit.
in gasoline mode only.
no continuity
Be sure that the water no continuity
temperature gauge Remove wht wire from continuity Repair short in wht wire
TB24 and check circuit from TB24 to
does not show an continuity to ground. temperature sender.
overheated condition.
no continuity

Repair short in wht wire

circuit from terminal #10
on ignition/start module
to TB24 OR consult
Genie Industries Service
Department.

good
Remove #1 spark plug spark
and ground spark plug Go to Chart 2A.
body. Crank engine and
observe spark.

weak or no spark

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5-5

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 2

Disable starter by See Ford service

Continued from the removing blk wire at the 12V manual for
previous page. starter solenoid, hold the troubleshooting ignition
start switch to either system.
side and check voltage
at the white wire on the
ignition coil plug.

less than 12V

Hold the start switch to 12V Repair open in wht #21

either side and check wire from CR2 to ignition
voltage at wht #21 on coil.
terminal #87 of CR2.

0V

Check voltage at red 0V Repair open in red wire

wire on terminal #30 of circuit from battery to
CR2. TB20 to CB1 to CR1 to
CR2.
12V

Hold the start switch to Hold start switch and Repair open in blk wire
either side and check 0V check voltage at 12V from terminal #86 on
voltage at terminal #86 terminal #9 on ignition/ CR2 to terminal #9 on
of CR2. start module. ignition/start module.

0V

Check voltage at 0V Repair open in power

terminal #6 on ignition/ supply wires from CB1
start module. to CR1 to CR2 to
terminal #6 on ignition/
start module.
12V

no
Check continuity from continuity Repair open in brown
12V ground wire at terminal ground wire to start
#5 on start lockout lockout module.
module to ground.

continuity

Consult Genie Industries

Service Department.

Continued on the next

page.

5-6 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 2

no
Check continuity from continuity Repair open in brown
Continued from the ground to terminal #85 ground wire circuit to
previous page. on CR2. CR2.

continuity

If weak spark still exists,

consult Ford engine
service manual for
troubleshooting engine
with weak spark OR
consult Genie Industries
Service.

Part No. 48412 Genie S-60 & Genie S-65 5-7

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

Chart 2A
Engine Cranks Hold the start switch to Repair open in white
either side and check #21 wire circuit from the
Over But Will the voltage at the white 0V ignition coil plug to the
wire on the choke while automatic choke.
Not Start - cranking the engine.
Gasoline/LPG
12V
Models
Check automatic choke bad Adjust or replace
or for proper adjustment or automatic choke OR
internal damage. consult Genie Industries
Service Department.
Engine Runs
good
While Cranking
Then Dies With keyswitch on and
both Emergency Stop
0V Repair open in red/wht
#23 wire circuit from
buttons pulled out to the TB23 to vacuum switch.
Perform these tests in ON position, check
gasoline mode only. voltage at red/wht #23
wire on vacuum switch.

12V
bad
Remove the blk wire Turn machine off. See Replace vacuum switch.
with diode from terminal 0V Repair section for how
#86 on CR3, hold the the test the vacuum
start switch to either switch.
side and crank the
engine over for 15
seconds and check ok
voltage at red/blk wire bad
on vacuum switch Check vacuum line for Replace vacuum line.
(reconnect blk wire after restrictions or damage.
test).
ok

12V See Ford service

manual to troubleshoot
low manifold vacuum.
With keyswitch on and
both Emergency Stop
buttons pulled out to the
0V Repair open in red/blk
ON position, disconnect
wire circuit from vacuum
wires from vacuum switch to CR6.
switch and connect the
wires together. Check
the voltage at terminal
#86 on CR6.

12V

Continued on the next

page.

5-8 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 2A

With keyswitch on and Repair open in red

Continued from the both Emergency Stop 0V power wire circuit with
previous page. buttons pulled out to the diode to fuel select
ON position, crank toggle switch TS3.
engine and check
voltage at center
terminal on fuel select
switch TS3 in platform
control box.

12V
0V
With keyswitch on and Replace toggle switch.
both Emergency Stop
buttons pulled out to the
ON position, crank
engine and check
voltage on gasoline side
(blu/wht wire) of fuel
select switch.

12V

With keyswitch on and Repair open in blu/wht

both Emergency Stop 0V wire circuit from toggle
buttons pulled out to the TS3 toggle switch to
on position, crank TP38 to TB38.
engine and check
voltage at terminal
TB38.

12V

With keyswitch on and 0V Repair open in blu/wht

both Emergency Stop wire circuit from TB38 to
buttons pulled out to the terminal #30 on CR6.
ON position, crank
engine and check
voltage at blu/wht wire
at terminal #30 on CR6.

12V

With keyswitch on and 0V Check brown ground no good Repair open in brown
both Emergency Stop wire on terminal #85 of ground wire circuit to
buttons pulled out to the CR6. CR6.
ON position, crank the
engine and check
voltage at terminal #87 good
on CR6.
Replace CR6.
12V

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5-9

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 2A

Hold the start switch to 0V Repair open in blu/wht

Continued from the either side and check #38 wire circuit CR6 to
previous page. voltage at blu/wht wire anti-diesel valve.
on anti-diesel valve (on
engine carburetor).

12V
no
Hold the start switch to 0V Check continuity from continuity Repair open in brown
either side and check brown ground wire on ground wire circuit to
voltage at blu/wht #38 fuel pump to ground. fuel pump.
wire on fuel pump.
continuity

Repair open in blu/wht

#38 wire circuit from
12V anti-diesel valve to fuel
pump.

Hold the start switch to Repair open in blu/wht

either side and check 0V #38 wire circuit from fuel
voltage at blu/wht #38 pump to gasoline
wire on gasoline solenoid.
solenoid (at gasoline
tank).

12V

Hold the start switch to no Reconnect the two wires

either side, does engine to vacuum switch and
start? check for fuel line
blockage OR replace
anti-diesel valve OR see
yes Ford service manual for
troubleshooting fuel
Go to chart 2B. pump and/or carburetor
OR Consult Genie
Industries Service
Department.

5 - 10 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Chart 2B
Engine Runs Hold start switch to 0V Crank engine and check 0V Check alternator wiring
either side and check voltage at org/blk #41 OR repair or replace
While Cranking voltage at terminal #2 on wire on alternator. alternator OR contact
start lockout module. Genie Industries Service
Then Dies Department.
6 to 7V

Repair open in org/blk

#41 wire circuit from
alternator to TB41 to
6 to 7V terminal #2 on start
lockout module.

While cranking engine Disconnect wht #24 wire Check oil level OR
for 15 seconds, check from oil pressure sender replace oil pressure
continuity to ground on yes and check continuity to yes sending unit OR refer to
terminal #10 start ground on signal post of Ford service manual for
lockout module. Is sender, while cranking troubleshooting low oil
continuity maintained? the engine. Is continuity pressure.
maintained?

no

Disconnect wht #24 wire Check coolant level OR

from water temperature replace water
sender and check yes temperature sending
continuity to ground on unit OR refer to Ford
signal post of sender, service manual for
while cranking the troubleshooting a
engine. Is continuity overheated engine.
maintained?
no

no

Repair short to ground

in wht #24 wire from
sending units to TB24 to
terminal #10 on ignition/
start module.

Check voltage at 12V Disconnect red wire Replace ignition/start

terminal #4 on ignition/ from terminal #4 on 12V module OR consult
start module. ignition/start module and Genie Industries Service
check voltage at Department.
terminal #4.

0V 0V

Test auxiliary power

toggle switches TS1 and
Replace start lockout TS10. See Repair
module OR consult Section.
Genie Industries Service
Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 11

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

Chart 3
Engine Cranks Hold the start switch to
less
than Check battery condition
either side and check OR check alternator OR
Over But Will battery voltage while
11V
check for short circuits
Not Start - engine is cranking. OR check battery cables
OR replace the battery.
Deutz Diesel 11V or more
Models
Check if engine over- continuity Check if oil cooler Check engine oil level
Be sure to check the temperature sending and/or engine block
hot
OR oil cooler fins for
engine oil level and fill signal post has feels excessively hot. clogging OR check
as needed. continuity to ground. engine fan belts OR see
Deutz service manual
Be sure to check for troubleshooting an
not hot overheating engine.
fuel level.
Be sure the diesel fuel
shut-off valve is in Remove wht wire from continuity Replace temperature
the on position. temperature sending switch sending unit.
unit, check continuity to
Be sure that the battery ground (on sending
is fully charged. unit).

no continuity
no continuity
Remove wht wire from continuity Repair short in wht wire
TB24. circuit from TB24 to
temperature sender.
no continuity

Repair short in wht wire

circuit from ignition/start
module to TB24 OR
consult Genie Industries
Service Department.

0 or
Disable the starter by Turn the machine off infinite Replace the fuel
removing the blk wire at and isolate the fuel ohms solenoid.
12V
the starter solenoid. solenoid. Check the
Hold the start switch to resistance of the
either side and check solenoid.
the voltage at positive
terminal on fuel 3.50 ohms
solenoid.

See Deutz service

manual for
0V troubleshooting fuel
system.

Continued on the next

page.

5 - 12 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 3

Hold start switch and Repair open in wht #21

Continued from the check voltage at wht 12V wire from CR2 to fuel
previous page. #21 wire on terminal #87 solenoid.
of CR2.

0V

Check voltage at red 0V Repair open in red wire

wire on terminal #30 of circuit from battery to
CR2. CB1 to CR1 to CR2.

12V

Hold the start switch to Hold the start switch to Repair open in blk wire
0V either side and check 12V from terminal #86 on
either side and check
voltage at terminal #86 voltage at terminal #9 on CR2 to terminal #9 on
of CR2. the ignition/start module. the ignition/start module.

0V

Check voltage at 0V Repair open in power

terminal #6 and 7 on supply wires to terminal
ignition/start module. #6 and 7 on ignition/start
module.
12V

Check continuity from no Repair open in brown

ground to brown wire at continuity ground wire circuit to
12V terminal #5 on ignition/ terminal #5 on ignition/
start module. start module.

continuity

Replace the ignition/

start module OR consult
Genie Industries Service
Department.

Check continuity from no Repair open in brown

ground to terminal #85 continuity ground wire circuit to
on CR2. CR2.

good

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 13

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 3

Crank engine and check 0V Crank engine and check 0V Repair or replace
Continued from the voltage at org/blk #41 alternator OR contact
previous page. voltage at terminal #2 on
start lockout module. wire on alternator. Genie Industries Service
Department.
6 to 7V

Repair open in org/blk

#41 wire circuit from
6 to 7V alternator to TB41 to
terminal #2 on start
lockout module.

While cranking engine Disconnect wht #24 wire Check oil level OR
for 15 seconds, check from oil pressure sender replace oil pressure
continuity to ground on yes and check continuity to yes sending unit OR refer to
terminal #10 on start ground on signal post of Deutz service manual
lockout module. Is sender, while cranking for troubleshooting low
continuity maintained? the engine. Is continuity oil pressure.
maintained?

no

Disconnect wht #24 wire Check oil level OR

from engine temperature replace engine
sender and check yes temperature sending
continuity to ground on unit OR refer to Deutz
signal post of sender, service manual for
while cranking the troubleshooting a
engine. Is continuity overheated engine.
no maintained?

no

Repair short to ground

in wht #24 wire from
sending units to TB24 to
terminal #10 on ignition/
start module.

Check voltage at 12V Disconnect red wire Replace ignition/start

terminal #4 on ignition/ from terminal #4 on 12V module OR consult
start module. ignition/start module and Genie Industries Service
check voltage at Department.
terminal #4.

0V 0V

Test auxiliary power

toggle switches TS1 and
Replace ignition/start TS10. See Repair
module OR consult Section.
Genie Industries Service
Department.

5 - 14 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Chart 4
Engine Will Not Disconnect LPG supply
line from LPG tank and
Start On LPG, bleed pressure from
line.
But Will Start
On Gasoline -
Gasoline/LPG With keyswitch on and 0V Replace fuel select
Models both Emergency Stop
buttons pulled out to the
switch.
ON position, check
Be sure fuel select voltage at LPG side
switch is switched (blu/red wire) of fuel
to LPG. select switch.

Be sure to check 12V

LPG fuel level.
With keyswitch on and Repair open in blu/red
both Emergency Stop 0V wire circuit from fuel
buttons pulled out to the select switch to TP39 to
ON position, check TB39.
voltage at TB39.

12V

With keyswitch on and 0V Repair open in blu/red

both Emergency Stop wire circuit from TB39 to
buttons pulled out to the terminal #30 on CR7.
ON position, check
voltage at terminal #30
on CR7.

12V

Crank engine for 15 0V Repair open in red/blk

seconds and check wire circuit from vacuum
voltage at terminal #86 switch to CR6 to CR7.
on CR7.

12V

Check continuity from bad Repair open in brown

ground to brown wire on ground wire circuit to
terminal #85 on CR7. terminal #85 on CR7.

good

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 15

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 4

Hold the start switch to 0V

Continued from the Replace CR7 relay.
either side and check
previous page.
voltage at terminal #87
on CR7.

12V

Hold the start switch to Repair open in blu/red

either side and check 0V wire circuit from CR7
voltage at blu/red wire terminal #87 to LPG
on LPG solenoid. solenoid.

12V 0 or
infinite
Check resistance of ohms
Replace LPG solenoid.
LPG solenoid.

9 to 10 ohms

Reconnect LPG tank

and starter then see
Maintenance section for
LPG adjustments OR
consult Genie Industries
Service Department.

5 - 16 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Chart 5
Engine Will With keyswitch on and 0V Replace fuel select
both Emergency Stop switch.
Not Start On switches pulled out to
Gasoline, the ON position, check
voltage at gasoline side
But Will Start (blu/wht wire) of fuel
select switch.
On LPG -
12V
Gasoline/LPG
Models With keyswitch on and Repair open in blu/wht
both Emergency Stop 0V wire circuit from fuel
Be sure fuel select buttons pulled out to the select switch to
ON position, check TP38 to TB38.
switch is switched voltage at TB38.
to gasoline.
12V
Be sure to check
gasoline fuel level. With keyswitch on and Repair open in blu/wht
0V
both Emergency Stop wire circuit from TB38 to
Be sure that engine buttons pulled out to the terminal #30 on CR6.
ON position, check
choke is operating voltage at terminal #30
properly. on CR6.

12V

Crank engine for 15 0V Repair open in red/blk

seconds and check wire circuit from vacuum
voltage at terminal #86 switch to CR6.
on CR6 while cranking.

12V
no
Check continuity from continuity Repair open in brown
ground to brown wire at ground wire circuit to
terminal #85 on CR6. terminal #85 on CR6.

continuity

Hold the start switch to Repair open in blu/wht

either side and check 0V wire circuit from CR6
voltage at blu/wht wire terminal #87
on anti-diesel valve (on to anti-diesel valve OR
carburetor). replace CR6.

12V

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 17

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 5

no
Hold the start switch to 0V Check continuity from continuity Repair open in brown
Continued from the either side and check ground to brown wire at ground wire circuit to the
previous page. voltage at blu/wht wire fuel pump. fuel pump.
on the fuel pump.
continuity

Repair open in blu/wht

wire from anti-diesel
12V solenoid to fuel pump
OR replace fuel pump.

no
Hold the start switch to Check continuity from continuity Repair open in brown
either side and check 0V ground to brown wire at ground wire circuit to the
voltage at blu/wht wire gasoline solenoid. gasoline solenoid.
on gasoline solenoid (at
fuel tank).
continuity

Repair open in blu/wht

wire from fuel pump to
gasoline solenoid OR
12V replace gasoline
solenoid.

0 or
infinite
Check resistance of ohms Replace gasoline
gasoline solenoid. solenoid.

18 to 19 ohms
0 or
infinite
Check resistance of ohms Replace anti-diesel
anti-diesel valve. valve.

24 to 25 ohms

less than
Install a pressure gauge 7 psi Replace fuel pump OR
to the fuel pump. Hold check anti-diesel and
start switch to either fuel valve for defects
side and observe the
pressure on the gauge.

more than 7 psi

Reconnect starter and

see Ford service manual
for carburetor
troubleshooting OR
consult Genie Industries
Service Department.

5 - 18 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Chart 6
Engine Start engine and move Check voltage at center Repair open in power
0V 0V
High Idle the rpm select to high terminal on rpm select supply circuit to center
idle (rabbit symbol) for switch TS4 and TS13. terminal of switch.
Inoperative - following checks. Check
voltage at blk/red wire 12V
Gasoline/LPG on rpm select switch
TS4 and TS13.
Models Replace rpm select
toggle switch.
If high idle operates 12V
on LPG but not on
gasoline, see Ford 0V
Check voltage at TB35. Repair open in blk/red
service manual for wire circuit from toggle
carburetor switch to TP35 to TB35.
troubleshooting. 12V
If high idle operates
on gasoline but not Check voltage at Repair open in blk/red
0V
on LPG, see Repair terminal #85 (blk/red) on wire circuit from
CR4. TB35 to CR4.
section for LPG
regulator adjustments.
12V
Be sure throttle no
linkage from governor Check continuity from continuity Repair open in brown
ground to the brown ground wire circuit to
to carburetor is not wire on terminal #86 of terminal #86 on CR4.
binding. CR4.

Be sure high idle can continuity

be achieved by grasping
the governor actuator Check voltage at 0V Repair open in white
terminal #30 on CR4. #21 power wire from
arm and momentarily terminal 87 on CR2 to
pulling to throttle the CR3 to CR4.
carburetor. 12V

Check voltage at 12V Replace CR4 relay.

terminal 87A on CR4.

0V

Check voltage at 12V Repair short in blk/red

terminal 7 on electronic #R4 wire to terminal #7
governor. on precision governor.

0V

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 19

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 6

Check voltage at 0V Repair open in wht wire

Continued from the circuit from CR2
previous page. terminal #30 on CR3.
terminal #87 to CR3
#30.
12V

Check voltage at 0V Repair open in rd/blk

terminal #86 on CR3. #R6 wire circuit from
vacuumn switch to CR6
to CR7 to terminal #86
on CR3.
12V

no
Check continuity from continuity Repair open in ground
ground to brown wire on wire to terminal #85 on
terminal #85 of CR3. CR3.

continuity

Check voltage to 0V
Replace CR3 relay.
terminal #87 on CR3.

12V

Check voltage at 0V Repair open in red/wht

terminal 1 (red/wht wire) wire circuit from terminal
on electronic governor. #87 on CR3 to terminal
#1 on electronic
governor.
12V

Check voltage at 0V Repair open in red/wht

terminal 1 (red/wht wire) wire circuit from
on governor actuator. electronic governor
terminal #5 to governor
actuator terminal #1.
12V

Check continuity from no Repair open in blu/blk

terminal #6 on precision continuity wire circuit from
governor to blu/blk governor actuator to
terminal #2 on governor electronic governor.
actuator.

full continuity

Continued on the next

page.

5 - 20 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

CHART 6

Check voltage on red/ 0V Repair open in red/wht

Continued from the wht wire on governor wire from governor
previous page. actuator. controller to governor
actuator.
12V

Turn machine off, 0 or

remove both wires infinite
from governor actuator ohms Replace governor
and check resistance actuator.
across governor
actuator terminals.

2 to 3 ohms

Reconnect governor Repair open in brown

wires and restart engine 0V wire circuit from ignition
and check voltage at coil plug to electronic
electronic governor governor.
terminal 3 and 4 (brown
wires).

12V

See Maintenance
section for governor
adjustments OR replace
electronic governor.

Part No. 48412 Genie S-60 & Genie S-65 5 - 21

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

Chart 7
Engine Low Idle Start engine and switch Isolate the ground and
rpm select to low idle platform rpm toggle
Inoperative - (turtle symbol). Check
12V
switches TS4 and TS13,
voltage at terminal #86 check individually and
Gasoline/LPG (blk/rd wire) on CR4. replace defective switch.
Models
0V
If low idle operates
on LPG but not on Check voltage at 0V Repair open in wht wire
gasoline, see Ford terminal #30 on CR4. circuit from terminal #87
on CR2 to CR4 terminal
service manual for #30.
carburetor 12V
troubleshooting.

If low idle operates 0V

Check voltage at Replace CR4 relay.
on gasoline but not terminal #87A on CR4.
on LPG, see Repair
section for LPG 12V
regulator adjustments.
Check voltage at 0V Repair open in blk/red
Be sure throttle terminal #7 on wire circuit from CR4
electronic governor. terminal #87A to
linkage from governor electronic governor
to carburetor is not terminal #7.
binding, see Repair 12V
section.
Check voltage at Repair open in brown
electronic governor 0V wire circuit from ignition
terminal 3 and 4 (brown module to electronic
wires). governor.

12V

Turn machine off, Recheck throttle linkage

remove blu/blk wire from engine goes to high idle (see Repair section) OR
terminal #6 on electronic check and/or replace
governor and restart governor actuator OR
engine. see Ford service manual
for carburetor
troubleshooting.
engine goes to low idle

Recheck electronic
governor adjustments
OR replace electronic
governor.

5 - 22 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Chart 8
Engine Start engine, switch rpm Check high idle
solenoid adjustment (see
select switch to high idle
High Idle (rabbit symbol) and
pulls in Maintenance section) or
check if 2-speed see Deutz workshop
Inoperative - solenoid pulls in. manual to troubleshoot
Deutz Diesel fuel injection system.
solenoid does
Models not pull in

Be sure mechanical Check voltage at blk/red Check voltage on red Repair open in circuit
0V 0V
linkage is not binding wire on rpm select wire at center terminal of supplying 12V to center
or defective. switch TS4 and TS13. rpm select switch. terminal of switch.

Be sure 2-speed 12V

solenoid grounding
wires are free of 12V Replace toggle switch
corrosion and have full
continuity to ground.
0V
Check voltage at TB35. Repair open in blk/red
wire circuit from toggle
switch to TP35 to TB35.
12V

Check voltage at 0V Repair open in blk/red

terminal #30 on CR3. wire circuit from TB35 to
terminal #30 on CR3.
12V

Check voltage to 0V Repair open in wht wire

terminal #86 on CR3. circuit from terminal #87
on CR2 to terminal #86
on CR3.
12V

no
Check continuity from continuity Repair open in brown
ground to brown wire at ground wire circuit to
terminal #85 on CR3. terminal #85 on CR3.

continuity

Check voltage to 0V
terminal #87 on CR3. Replace CR3 relay.

12V

Continued on the next

page.

Part No. 48412 Genie S-60 & Genie S-65 5 - 23

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

CHART 8

Continued from the Check voltage at 0V Repair open in blk/red

previous page. terminal #86 on CR4. wire circuit from
CR3 to CR4.

12V

Check continuity from bad Repair open in brown

ground to brown wire at ground wire circuit to
terminal #85 on CR4. terminal #85 on CR4.

good

Check voltage to 0V Repair open in wht wire

terminal #30 on CR4. circuit from CR2 to CR3
to CR4.
12V

Check voltage at the 0V Replace CR4 relay

blk/red wire on the OR repair open in
2-speed solenoid. blk/red wire circuit from
terminal #87 on CR4 to
2-speed solenoid.
12V

solenoid
Check if 2-speed binds Check linkage or
solenoid moves in and replace solenoid.
out freely.

moves freely

Replace 2-speed
solenoid. Note:
resistance across
solenoid terminals
should be approximately
0.3 ohms.

5 - 24 Genie S-60 & Genie S-65 Part No. 48412

Service Manual - Second Edition Section 5 - Troubleshooting Flow Charts

Chart 9
Engine At platform controls, Isolate the platform and
start engine and switch 12V ground rpm switches,
Low Idle rpm select switch TS4 to check individually and
maintained low idle replace defective switch.
Inoperative - (turtle symbol). Check
Deutz Diesel voltage at blk/red wire
on rpm select switch.
Models
0V
Check if
12V
mechanical linkage Check voltage at the Replace CR4 relay.
from 2-speed red wire on the
2-speed solenoid.
solenoid to fuel
injection system is 0V
binding or defective. solenoid
Check if 2-speed binds Check linkage or
solenoid moves in and replace solenoid.
out freely.

moves freely

Check adjustment of
linkage and fuel injection
system low idle. See
Maintenance section.

ok

See Deutz workshop

manual to troubleshoot
fuel injection system OR
consult Genie Industries
Service Department.

Part No. 48412 Genie S-60 & Genie S-65 5 - 25

Section 5 - Troubleshooting Flow Charts Service Manual - Second Edition

Chart 10
All Functions Check hydraulic low Fill with Dexron
fluid level. equivalent hydraulic
Inoperative, fluid.
Engine Starts ok
and Runs
Check pump suction line closed Do the pumps feel yes If engine has been run
shutoff valves. In the excessively hot? with valves closed, it
open position, the valve may have damaged one
handles should be or both pumps. Please
parallel with hose. contact the Genie
Industries Service
no Department.

Open valves and start

open the engine. Check all
machine functions for
correct operation.

Disconnect ignition coil spline Troubleshoot

connector plug from turns inoperative boom
ignition coils. On Deutz functions and
diesel models, hold inoperative drive
manual fuel shutoff lever functions separately.
to the closed position
(clockwise).
Remove function pump
from main pump but
leave all hoses
connected. Hold start
switch and crank engine
over while observing
spline drive at rear of
main pump.

spline does not turn

Engine to pump flex

plate coupling is
defective OR main
pump is defective.
Consult Genie Industries
Service Department.

5 - 26 Genie S-60 & Genie S-65 Part No. 48412