Terex Genie Z-135/70 User manual

Dear valued customers, the firmware site has changed.
To complete this bulletin, install the most current version of the software.
1 Access the firmware website address below:
Link to Firmware site https://www.genielift.com/en/support/firmware
2 From the drop-down menu, select the model that is appropriate for your machine.
3 Locate and download the appropriate firmware/software file for your machine.
If you need assistance, contact your local Genie Product Support Team.
Mandatory Action Required

SAFETY NOTICE 120007
Rev 4_12_2013
Terex Aerial Work Platforms, 18340 NE 76th Street Redmond WA 98052, Ph: 800-536-1800, 425-881-1800
1 of 4
Original Release Date: February 4, 2013
Revision Release Date: April 15, 2013
Models and Serial Numbers Affected:
Z-135: Z13505-101 to Z13505-181
Z13506-182 to Z13506-376
Z13507-377 to Z13507-604
Z13508-605 to Z13508-978
Z13509-979 to Z13509-1126
Z13510-1127 to Z13510-1324
Z13511-1325 to Z13511-1570
Subject: Control System Software Update
Allowable Hours: 90 minutes
Issue:
Genie has determined that inadequate maintenance of the redundant secondary boom control
circuit on the above referenced machines may cause the circuit to malfunction. Amalfunctioning
circuit can lead to machine instability resulting in the machine tipping over.
This safety notice supersedes CB 080016(enclosed).
Action Required:
This safety notice requires updating the control system software installed on your machine.
Installation of the new software must take place as soon as possible but no later than 30
days from receipt of the kit.
Continued Use:
Machines may remain in service while waiting for the kit, if a routine inspection and maintenance is
performed on this circuit. Refer to Section 3 B-19 (Test the Safety Envelope Limit Switches) of the
machine Service Manual P/N 106783.

SAFETY NOTICE 120007
Rev 4_12_2013
Terex Aerial Work Platforms, 18340 NE 76th Street Redmond WA 98052, Ph: 800-536-1800, 425-881-1800
2 of 4
Work Instructions:
You will need the following to perform the software update on your machine:
•Laptop with Microsoft XP or higher operating system equipped with a USB port.
•USB to DB9 adapter cable
•DB9 cable, female to male
Important: For units before, Z13510-1154, check the version of the control system installed on your
machine. If you have software VER 1_00 or VER 1_11, order the SCON Tee Harness (Genie P/N
107647) separately.
How to determine the Control System version installed on your machine:
•At the TCON, turn the key switch to ground controls.
•Pull out the red Emergency Stop button
•Read and record the scroll message on the display.
•If the message display is VER 1_00 or VER1_11, order the SCON TEE Harness
(Genie P/N 107647) separately.
1. Locate all machines referenced above.
2. Access http://firmware.genielift.com.
Note: If you cannot access the website, you may order the thumb drive kit P/N 216863. One kit
can be used on multiple machines.
3. Using the drop down arrow in the “Machine Model” select field, select “Z-135”. Click on the
search button.
Note: Do not select a “Controller Type”

SAFETY NOTICE 120007
Rev 4_12_2013
Terex Aerial Work Platforms, 18340 NE 76th Street Redmond WA 98052, Ph: 800-536-1800, 425-881-1800
3 of 4
4. Under the “Application Firmware”, download and save the firmware file 214626E or
higher.
Important: Note the location on the computer where you downloaded the files
5. Unzip the file.
6. Locate and follow installation instructions 214625 to update the control system in your machine.
Note: You can download the latest version of the service manual from the Genie website located at:
http://www.genieindustries.com/en/service-support/manuals/index.htm
`
To order parts:
Machine owners with a valid Genie account can contact the Terex AWP parts department to place
an order through one of the following:
Genie Website: www.gogenielift.com
Fax: [phone]
Phone: [phone]
Reimbursement:
Only Genie Dealers will be reimbursed for labor or any other costs associated with this bulletin
under the provisions of our LIMITED PRODUCT WARRANTY statement.
Machine owners without a valid Genie account can contact their nearest Terex AWP dealership or
Terex AWP Service Centers for assistance.
Search for your nearest Terex AWP dealership by visiting our website at:
http://www.genielift.com/dealersearch/

SAFETY NOTICE 120007
Rev 4_12_2013
Terex Aerial Work Platforms, 18340 NE 76th Street Redmond WA 98052, Ph: 800-536-1800, 425-881-1800
4 of 4
Warranty:
The labor and travel miles required to perform this inspection and installation are covered under the
provisions of our LIMITED PRODUCT WARRANTY statement. Warranty claims can be submitted
by paper claims, fax or email. If you need more information about filing a warranty claim, call Terex
AWP Warranty department.
Genie and ANSI requires that the seller of a Genie machine report to Genie the model and serial
number of each machine sold, as well as the name, address, and telephone number of the new
owner, within 60 days of the sale. OSHA and ANSI also require that the manufacturer’s safety
notices be completed. It is your responsibility to communicate this important information to all
machine owners and applicable branches. If you require additional copies of this safety notice or
have any questions, please contact Genie’s service department at:
United States 800-536-1800
Canada 425-881-1800
Europe [phone]
Australia 61 733751660
All other locations 001-425-881-1800
Enclosures:
Machine List Report
New Owner Update Form
Procedure: Test the Safety Envelope Limit Switches (excerpt from machine Service Manual P/N 106783)
CB 080016

Terex Aerial Work Platforms, 18340 NE 76th Street Redmond WA 98052, Ph: 800-536-1800, 425-881-1800
Safety Notice 120007
New Owner Update Form
(for updating machine owner information only)
Genie and ANSI requires that the seller of a Genie machine report to Genie the model and serial number of
each machine sold, as well as the name, address, and telephone number of the new owner, within 60 days of
the sale.
•If you have sold a machine, list the complete model and serial number (examples: Z13505-162 or Z13508-
729 or Z13511-1411) and the name, address and phone number of the new owner.
New Owner Information:
Machine 1 Machine 2 Machine 3
Model*
Serial Number*
Owner Name*
Address 1*
Address 2
City/State/Zip*
Phone Number*
Contact Person
* Required fields.
Seller Information:
Date:
Company Name:
Account #:
Address:
(street)
(city)
State, zip code
Phone #:
•List any machines that could not be inspected or repaired because of the following:
Model & Serial Number Scrapped Exported Stolen Others (explain)
- - - -
- - - -
- - - -
- - - -
Fax to: United States 877-738-7530
Canada 425-498-7530
All other locations 001-425-498-7530

Installation Instructions
S
oftware Update
Z
-
135/70
Part No. 214625
Rev E

Rev. E Instructions
Introduction
2 Z-135/70 Part No. 214625
Introducti on
Observe and Obey:
This procedure shall be completed by a person
trained and qualified on the repair of this
machine.
Immediately tag and remove from service a
damaged or malfunctioning machine.
Repair any machine damage or malfunction
before operating the machine.
Before Starting Installation:
Read, understand and obey the safety rules
and operating instructions in the appropriate
operator's manual.
Be sure that all necessary tools and parts are
available and ready for use.
Read this procedure completely and adhere to
the instructions. Attempting shortcuts may
produce hazardous conditions.
Indicates that a specific result is expected after
performing a series of steps.
Indicates than an incorrect result has occurred
after performing a series of steps.
Note: These installation instructions only apply
to the Genie models listed below, as required
by Safety Notice 120007.
Z-135/70
Tools Required:
Computer or Laptop with Microsoft operating
system XP or newer
DB9 cable, female to male of suitable length (DB9F
to DB9M)
7/16" wrench
7/16" socket
Ratchet
Small flathead screwdriver
USB to DB9 adapter cable (if required)
SCON Tee harness (if required)
(107647, ordered separately)
Glossary of Terms
SCON - Safety controller
TCON - Turntable controls (Ground controls)
PCON - Platform controls
Machine Software Version Update
Requirements
For version 1.00, and 1.11 the SCON, TCON
and PCON must be updated.
For version 2.00 and 2.01, only the TCON and
PCON must be updated.

Rev. E Instructions
Introduction
Part No. 214625 Z-135/70 3
Components of Kit 216863
Printing Instructions
Genie part number 216864
Qty. 1
Thumb drive
Genie part number 214626
Qty. 1
Includes:
Auto update software
Genie part number 214624
Qty. 1
Installation instructions, Z-135/70
Genie part number 214625
Qty. 1
The auto update software is designed to upload the
calibration parameters of the machine, download
the software update and reload the calibration
parameters. This eliminates the need to recalibrate
the machine functions.
The installation
instructions and screen
prompts must be
followed.
Failure to follow these instructions and
the screen prompts could result in the
loss of application files and will require
calibration of the machine.
If this should occur it would require
that you have WebGPI™ software
loaded on your computer which is only
available from Sauer Danfoss and may
require replacement of the SCON.
Before proceeding, verify the Service
Bypass key switch is in Run mode.
NOTICE
STOP
00000
Run
Service
Bypass
Recovery

Rev. E Instructions
Procedure
4 Z-135/70 Part No. 214625
Procedure
Perform this procedure on a flat level surface, with
the boom and jib in the stowed position.
Software Version
Note: Before proceeding, verify the version of
software installed on your machine.
1At the TCON, turn the key switch to ground
controls and pull out the red Emergency Stop
button.
2Read and record the scroll message on the
display (example: VER 1_10 is version 1.10).
3Push in the red Emergency Stop button.
Limit Switch Rework
For machines with software version 1.00
The primary boom retract operational limit switch
LSP1RO must be reworked before proceeding with
the software upgrade. Proceed to page 14 for limit
switch rework instructions.
Loading the Software onto a
Computer or Laptop.
1Turn on the computer or laptop.
Note: If the WebGPI Auto Update Zip file has been
downloaded from the website, unzip the file and
continue to step 3.
2Insert the thumb drive (Genie part number
214626) into the computer or laptop.
Note: If the WebGPI Auto Update files are not
displayed on your computer, go to My Computer
and locate the Removable Disk.
3Open the file LVRTE2010sp1std.exe. Select
OK, then select Unzip.
4When the files have been extracted, select OK.
5When the LabVIEW 2010 screen appears,
continue to select Next until the License
Agreement is displayed.
6Select I accept the License Agreement, then
select Next. Installation will begin.
Note: Depending on your operating system, this
process may take up to 10 minutes.
7When the installation is complete, select
Finish. Then select Restart Later.
8Open the file visa 501runtime.exe. Select OK,
then select Unzip.
9When the files have been extracted, select OK.
10 When the NI-VISA screen appears, continue to
select Next until the License Agreement is
displayed.

Rev. E Instructions
Procedure
Part No. 214625 Z-135/70 5
11 Select I accept the License Agreement, then
select Next until the Installation begins.
12 When the installation is complete select
Finish. Then select Restart Later.
13 Open the folder WebGPI Auto Update 2.0.15.
14 Open the file setup.exe, then select Next until
the Installation begins.
15 When the installation is complete, select
Finish.
16 Remove the thumb drive from the laptop and
close all programs. Restart the computer.
Note: After the installation is complete, a WebGPI
Auto Update icon will be installed on your desktop.
SCON Software Update
For machines with software version 1.00 or 1.11
The auto update software is designed to upload the
calibration parameters of the machine, download
the software update and reload the calibration
parameters. This eliminates the need to recalibrate
the machine functions.
1Locate the SCON mounted on the bulkhead
behind and to the right of the function manifold
on the ground controls side of the machine.
2Disconnect the gray J121 connector from the
SCON.
3Connect the SCON Tee-Harness (Genie part
number 107647) between the gray connector
and the SCON.
4Connect the laptop DB9 cable to the
Tee-Harness.
5At the TCON, turn the key switch to ground
controls and pull out the red Emergency Stop
button.
6Double-click on the Auto Update icon to
activate the software.
GRAY J121 CONNECTORGRAY J121 CONNECTOR

Rev. E Instructions
Procedure
6 Z-135/70 Part No. 214625
7Click on the Update button.
Note: If Check power and serial connection is
displayed, confirm power is on at the TCON and
check the connection between the laptop and the
SCON.
Note: If Attempting to establish connection is
displayed, check your serial port COM settings.
8Select software file S0677200 from the
application selection window and click OK.
9The turn power off message will appear.
Push in the red Emergency Stop button and
click OK.
Note: Do not turn the power on until the power on
message appears.

Rev. E Instructions
Procedure
Part No. 214625 Z-135/70 7
10 The turn power on message will appear. Pull
out the red Emergency Stop button and click
OK.
11 The application update should start.
Note: If the update fails to start, close the program
and return to step 6 and follow the instructions.
12 When the update is complete disconnect the
laptop from Tee-Harness. Push in the red
Emergency Stop button, then pull it back out to
save updates.
13 Close the auto update program.
14 Push in the red Emergency Stop button and
disconnect the Tee-Harness from the SCON.
15 Securely reconnect the gray J121 connector to
the SCON.
16 Continue to TCON Software Update.

Rev. E Instructions
Procedure
8 Z-135/70 Part No. 214625
TCON Software Update
For machines with all software versions
The auto update software is designed to upload the
calibration parameters of the machine, download
the software update and reload the calibration
parameters. This eliminates the need to recalibrate
the machine functions.
1Open the ground control box and set the
fasteners aside.
2Connect the laptop DB9 cable to the TCON
PCB.
3At the TCON, turn the key switch to ground
controls and pull out the red Emergency Stop
button.
4Double-click on the Auto Update icon to
activate the software.
5Click on the Update button.
Note: If Check power and serial connection is
displayed, confirm power is on at the TCON and
check the connection between the laptop and the
TCON.
Note: If Attempting to establish connection is
displayed, check your serial port COM settings.

Rev. E Instructions
Procedure
Part No. 214625 Z-135/70 9
6Select software file S0677202 from the
application selection window and click OK.
7The application update should start.
Note: If the update fails to start, close the program
and return to step 4 and follow the instructions.
8The turn power off message will appear.
Push in the red Emergency Stop button and
click OK.
Note: Do not turn the power on until the power on
message appears.
9The turn power on message will appear. Pull
out the red Emergency Stop button and click
OK.

Rev. E Instructions
Procedure
10 Z-135/70 Part No. 214625
10 The object files will begin to update.
11 When the update is complete, disconnect the
laptop from the TCON. Push in the red
Emergency Stop button, then pull it back out to
save updates.
12 Close the auto update program.
13 Push in the red Emergency Stop button.
14 Close the ground control box and securely
tighten the retaining fasteners.
15 Continue to PCON Software Update.
PCON Software Update
For machines with all software versions
The auto update software is designed to upload the
calibration parameters of the machine, download
the software update and reload the calibration
parameters. This eliminates the need to recalibrate
the machine functions.
1Open the platform control box and set the
fasteners aside.
2Connect the laptop DB9 cable to the PCON
PCB.
3At the TCON, turn the key switch to platform
controls and pull out the red Emergency Stop
buttons at both control boxes.
4Double-click on the Auto Update icon to
activate the software.

Rev. E Instructions
Procedure
Part No. 214625 Z-135/70 11
5Click on the Update button.
Note: If Check power and serial connection is
displayed, confirm power is on at the PCON and
check the connection between the laptop and the
PCON.
6Select software file S0676201 from the
application selection window and click OK.
7The turn power off message will appear.
Push in the red Emergency Stop button at the
platform and click OK.
Note: Do not turn the power on until the power on
message appears.

Rev. E Instructions
Procedure
12 Z-135/70 Part No. 214625
8The turn power on message will appear. Pull
out the red Emergency Stop button at the
platform and click OK.
9The application update should start.
Note: If the update fails to start, close the program
and return to step 4 and follow the instructions.
10 When the update is complete, disconnect the
laptop from the PCON. Push in the red
Emergency Stop button, then pull it back out to
save updates.
11 Close the auto update program.
12 Close the platform control box and securely
tighten the retaining fasteners.
13 At the TCON, turn the key switch to ground
controls and pull out the red Emergency Stop
button. Verify the software version.
The display shows VER 2_02 and no faults are
displayed, continue to step 18.
The display shows an LSS1RO or LSS1RS
fault. Continue with step 14.
14 Push in the red Emergency Stop button at the
TCON. Press and hold the button and pull
out the red Emergency Stop button.

Rev. E Instructions
Procedure
Part No. 214625 Z-135/70 13
15 Release the button and press
.
16 Press the button and scroll to RESET
FAULTS. Press the button to change the
screen from NO to YES.
17 Press the button to exit. Press the
button to change the screen from NO to YES.
18 Press the button to return to the operators
screen. Push in the red Emergency Stop
button. Repeat step 13.
19 Perform function test. Refer to the Operator's
Manual on your machine.
20 Return the machine to service.
21 Fill out and sign the attached completion form
and fax or email to Terex AWP Warranty
Department. This will serve as verification that
you have completed Safety Notice 120007.
If you have any further questions regarding these
instructions or need assistance, please contact the
Genie Service Department at one of the following
telephone numbers:
United States: 800-536-1800
Canada: 425-881-1800
Europe: UK 0044 1476 584 333
France 0033 237 260 986
Germany 49 4221 491 821
Iberica 0034 935 725 090
Italy 0039 075 941 8171
Scandinavia 0046 3157 5154
Other locations 0031 653 221 908
Middle East: 0097 143 391 800 or
0097 150 459 7937
Australia: 61 7 3456 4444
All other locations 001-425-881-1800

Rev. E Instructions
Procedure
14 Z-135/70 Part No. 214625
Limit Switch Rework
For machines with software version 1.00
1Locate and remove the primary boom cover
and set aside.
2Locate LSP1RO limit switch inside the primary
boom.
3Disconnect the boom harness from the limit
switch harness.
4Remove the two white weather plugs and set
aside.
5Remove the secondary lock from the end of
the connector and set aside.
For machines before serial number Z13505-130.
6Move the white wire from position 1 to
position 3 and the blue wire from position 2
to position 4.
For machines after serial number Z13505-129.
7Move the orange/black wire from position 1 to
position 3 and the red/black wire from position
2 to position 4.
8Install the secondary lock removed in step 5.
Note: Give a slight tug on each wire to confirm they
are properly seated into the connector.
9Install the two white weather plugs removed in
step 4 or step 6 into positions 1 and 2.
10 Connect the boom harness to the limit switch
harness.
11 Install the primary boom cover that was
removed in step 1.
Proceed to page 4, Loading the Software onto a
Laptop.
LSP1RO