Terex Genie SX-135 XC User manual

Terex Aerial Work Platforms, 6464 185th Ave NE Redmond WA 98073, Ph: 800-536-1800, 425-881-1800
1 of 2
First Notice
Product Notice 170016
Mandatory Action Required North America
Asia-Pacific
Date: August 21, 2017
Models Affected: SX-135 XC
Serial Numbers Affected: SX135H-101 to 159
SX135H-161 to 168
SX135H-170, SX135H-173 and SX135H-174
Subject: Load Cell Replacement and Software Update
Allowable Hours: 6 hours
Issue:
Genie has become aware of the following issues on the machines referenced above.
The software installed on the machines referenced above does not fully comply with the prevailing
standards EN280 and AS1418. The control system software must be updated on the affected
machines.
In extreme temperature conditions, the load sensing system installed on the machines referenced above
may deviate from the load cell engineering specification. This can result in nuisance faults of the load
sensing system.
Action(s) Required:
1 Locate the affected machines referenced above within your fleet.
2 Order Load Cell Kit PN 1280949GT and install on your machine.
Note: Updating the control system is included in the instructions to replace the load cell.
Completion of this Product Notice must take place as soon as possible, but no later than 90 days from
receipt of the kit.
3 Fill out and sign the completion form attached to the installation instructions and fax or email to Terex AWP
Warranty Department. This will serve as verification that you have completed this Product Notice.
Continued Use Instructions:
The machine may remain in service.

Terex Aerial Work Platforms, 6464 185th Ave NE Redmond WA 98073, Ph: 800-536-1800, 425-881-1800
2 of 2
First Notice
Product Notice 170016
Mandatory Action Required North America
Asia-Pacific
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]
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:
Link to Dealer Search http://www.genielift.com/dealersearch/
Warranty:
The labor and travel miles required to perform this Product Notice are covered under the provisions of our LIMITED
PRODUCT WARRANTY statement. Warranty claims can be submitted online, by paper claims, fax or email. If you need
more information about filing a warranty claim, please contact Terex AWP Warranty Department at:
Email (North America): [email protected]
Email (Asia-Pacific): [email protected]
Email (Brazil): [email protected]
Email (all others): [email protected]
United States: + 1-800-536-1800
Canada: + 1-425-881-1800
Asia-Pacific: + 86-21-347028555
Brazil: + 0-800-031-0100
South America (except Brazil): + 56-9-6431-2110
All other locations: + 1-425-881-1800
Genie and local industry standards (e.g. ANSI, CSA) 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. Use the Owner Update Form attached to the bulletin to indicate the new location or status of
any of your machines. You may also visit our website to register your machine.
Machine Registration_ANSI http://www.genielift.com/en/service-support/product-registration/index.htm
Genie, OSHA and local industry standards, also require that the manufacturer’s Product Notice 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 Product Notice or have any questions, please contact Genie Product Support at:
United States: + 1-800-536-1800
Canada: + 1-425-881-1800
Asia-Pacific: + 86-21-347028555
Brazil: + 0-800-031-0100
South America (except Brazil): + 56-9-6431-2110
All other locations: + 1-425-881-1800
Enclosures:
Customer Machine List
New Owner Update Form
NORTH AMERICA Terex Aerial Work P latforms, 6464185th Ave NE Redmond WA 98073, Ph: 800-536-180 0,
425-881-1800 Issue 157 Product Notice
First Notice
Mandatory Action Requir ed

Product Notice 170016
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 new owner's name, address and phone number, for each machine.
List complete model and serial number (ex. SX135H-120, SX135H-165)
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 Other (explain)
- - - -
- - - -
- - - -
- - - -
Fax to: United States: 1 877-738-7530 Latin America: + 55 11 3246-9760
Canada: 1 425-498-7530
Central America: + 1 425 498 7530
Mexico: 1 425-498-7530
Asia-Pacific: + 1 425 498 7530
Carribean: + 1 425 498 7530 All other locations: + 1 425 498 7530

Installation Instructions
Software Update and Load Cell
Replacement
SX-135 XC
Part No. 1280793GT
Re
v A

Instructions Rev A
Introduction
2 Software Update and Load Cell Replacement Part No. 1280793GT
Intr od ucti o n
Intr od ucti o n
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 that an incorrect result has occurred
after performing a series of steps.
Note: These installation instructions only apply
to the Genie models listed on the front cover,
as required by Product Notice 170016.
If you have any further questions regarding these
instructions or need assistance, please contact
Genie Product Support at one of the following
telephone numbers:
United States:
+ 800 536 1800
Canada:
+ 425 881 1800
Europe:
UK
+ 44 1476 584 333
France
+ 33 237 260 986
Germany
+ 49
4221 491 810
Iberica
+ 34 935 725 090
Italy
+ 39 075 941 8132
Scandinavia
+ 46 3157 5154
Other locations
+ 31 165 51 93 22
Middle East:
+ 97 143 391 800 o
r
+ 97 150 459 7937
Australia:
+ 61 7 3456 4444
Brazil
+0 800 031 0100
South America
- other
locations
+ 56 9 6431 2110
All other locations
+ 1 425-
881 1800
Glossary of Terms
DCON - Drive Controller. This ECM is located in
the drive chassis.
TCON - Turntable Controller. This ECM is located
at the ground controls.
PCON - Platform Controller. This ECM is located at
the platform controls.
SCON - Safety Controller. This ECM is located at
the turntable.

Rev A Instructions
Introduction
Part No. 1280793GT Software Update and Load Cell Replacement 3
Tools Required:
Software Update:
Computer or Laptop with Microsoft operating
system XP or newer
DB9 serial cable, female to male of suitable length
(DB9F to DB9M)
USB to DB9 adapter cable (if required)
Internet access
WebGPI™ software
Note: WebGPI™ software must be installed on
your computer before proceeding.
SCON Tee harness
(107647GT, ordered separately)
3/8 inch socket
Ratchet
Service and Repair Manual
(Genie part number 1263383GT)
Load Cell Replacement:
9/16 inch socket
¾ inch socket
Ratchet
Socket extension
¾ inch wrench (x2)
Components of Kit 1280949GT
Load Cell
Genie part number 1270278GT
Qty. 1
Installation instructions
Genie part number 1280793GT
Qty. 1

Instructions Rev A
Procedure
4 Software Update and Load Cell Replacement Part No. 1280793GT
Proc ed ur e
SX-135 XC Models
Before proceeding, verify the Bypass
key switch is in Run mode.
1 Run
2 Bypass
3 Recovery
Note: Perform this procedure with the axles fully
retracted, the boom in the stowed position and the
platform raised 18 inches / 43cm above the ground.
Software Version
Note: Before proceeding, verify the version of
software installed on your machine.
1 At the TCON, turn the key switch to ground
controls and pull out the red Emergency Stop
button.
2 Read and record the scroll message on the
display (example: VER 2_10 is version 2.10).
1 Push in the red Emergency Stop button.
Calibration Information
After the installation of the Application Software is
complete, the machine will have to go through a
complete calibration process. Refer Repair
procedure, How to Fully Calibrate the Machine in
the appropriate Service and Repair Manual for your
machine.

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

Rev A Instructions
Procedure
Part No. 1280793GT Software Update and Load Cell Replacement 5
Firmware Site Download
Note: Access to the internet is required to
perform this procedure.
1 Click on the Hyperlink below or open an
internet browser and copy and paste the link
into the address bar and press enter.
http://firmware.genielift.com/
2 Select Machine Model: SX135 XC. Select
Search.
3 Select PCON Service Tool Software
1271477A.zip. Select I Accept. Select Save
As and save it to your desktop.
4 When download is complete, select Close.
5 Select TCON Service Tool Software
1271476A.zip. Select I Accept. Select Save
As and save it to your desktop.
6 When download is complete, select Close.
7 Select SCON Service Tool Software
1271478A.zip. Select I Accept. Select Save
As and save it to your desktop.
8 When download is complete, select Close.
9 Select PCON Application Software
1271477.zip. Select I Accept. Select Save As
and save it to your desktop.
10 When download is complete, select Close.
11 Select TCON Application Software
1271476.zip. Select I Accept. Select Save As
and save it to your desktop.
12 When download is complete, select Close.

Instructions Rev A
Procedure
6 Software Update and Load Cell Replacement Part No. 1280793GT
13 Select SCON Application Software
1271478.zip. Select I Accept. Select Save As
and save it to your desktop.
14 When download is complete, select Close.
15 Close your internet browser.
Loading the Software onto a
Computer or Laptop
Note: Loading software onto your computer
requires that you must have administrative
rights to download executable files.
1 Turn on the computer or laptop.
2 Locate the 1271477A.zip file saved on your
desktop. Right click on the file and select
Extract All.
3 Check the box Show extracted files when
complete. Select Extract.
4 When the window appears, open the folder
where the file was extracted. Select the .exe
file. Select Run.

Rev A Instructions
Procedure
Part No. 1280793GT Software Update and Load Cell Replacement 7
5 On the Ready to Install screen, select Install.
6 When the software installation is complete
select Finish.
7 Repeat this procedure for the remaining .zip
files located on your desktop. 1271477.zip,
1271476A.zip,1271476.zip, 1271478A.zip
and 1271478.zip.
8 Delete the .zip folders from your desktop.

Instructions Rev A
Procedure
8 Software Update and Load Cell Replacement Part No. 1280793GT
Application Software Installation
SCON Software Update
Note: The key switch must be in the off
position, and the red Emergency Stop Button
pushed in before disconnecting the harness
from the SCON.
1 Locate the SCON mounted on the frame
behind and to the right of the function manifold
on the ground controls side of the machine.
2 Disconnect the gray J121 connector from the
SCON.
3 Connect the SCON Tee-Harness (Genie part
number 107647GT) between the gray
connector and the SCON.
4 Connect the laptop DB9 cable to the
Tee-Harness.
5 At the TCON, turn the key switch to ground
controls and pull out the red Emergency Stop
button.
6 Open WebGPI™ and click on the Connect
icon.
Note: The current application software file will be
shown at the top of the screen. (example:
S0856100 or older software)
Note: If Device not responding is displayed,
check the following.
•confirm power is on at the TCON
•check the connection between the
computer and SCON
•check your serial port COM settings. COM
port settings can vary between computers.
7 Click on the Application icon.

Rev A Instructions
Procedure
Part No. 1280793GT Software Update and Load Cell Replacement 9
8 Select Check Parameters. Under Check
Parameters select Tilt Sensors Params.
Read and record the following parameters.
-
90 Deg
30 Deg
150 Deg
Offset
Gains to
calculate
X
-axis tilt
Gains to
calculate
Y-axis tilt
Gains to
calculate tilt
error
9 Click on the Disconnect icon.
10 Click on the Connect icon.
11 Click on the Download icon.

Instructions Rev A
Procedure
10 Software Update and Load Cell Replacement Part No. 1280793GT
12 Select File Type: Kernel.
13 Click on the Search button and locate
application software S0856110.HEX.
14 Select All Files (*.*). Select the
application .HEX file and click Open.
S0856110.HEX.
15 Click on the Force download button. Cycle
the power off, then back on at the red
Emergency Stop Button at the TCON.

Rev A Instructions
Procedure
Part No. 1280793GT Software Update and Load Cell Replacement 11
16 Click on the Download button.
17 When the Kernel file is at 100%, cycle the
power off, then back on at the red Emergency
Stop Button at the TCON. Click on the Exit
button, then the Application icon.
18 Select Set All Defaults. Select Ok.
19 When prompted, select Level 2, enter
SG81355 for the password and select Accept.
20 Select Check Parameters. Under Check
Parameters select Tilt Sensors Params.
Enter the parameters that were recorded in
step 8.
Note: The numbers must be entered accurately.
If the numbers are not accurate, the machine
will not operate or level properly.
21 When prompted, select Level 3 and enter
BSNW for the password and select Accept.
22 Push in the red Emergency Stop button at the
TCON and disconnect the Tee-Harness from
the SCON.
23 Connect the gray J121 connector to the
SCON.

Instructions Rev A
Procedure
12 Software Update and Load Cell Replacement Part No. 1280793GT
TCON Software Update
Note: Before installation, go to your computers
Control Panel and increase your computers time
out period to more than 30 minutes.
1 Open the ground control box.
2 Connect the computer DB9 cable to the TCON
PCB.
3 At the TCON, turn the key switch to ground
controls and pull out the red Emergency Stop
button.
4 Open WebGPI™ and click on the Connect
icon.
Note: The current application software file will be
shown at the top of the screen. (example:
S0854100 for older software)
Note: If Device not responding is displayed,
check the following.
•confirm power is on at the TCON
•check the connection between the
computer and TCON
•check your serial port COM settings. COM
port settings can vary between computers.
5 Click on the Application icon.

Rev A Instructions
Procedure
Part No. 1280793GT Software Update and Load Cell Replacement 13
6 Select Pri Boom Ext/Ret. Under Pri Boom
Ext/Ret select Valve. Read and record the
following parameters.
Output Min (Thresholds)
Extend
Output Min (Thresholds)
Retract
Output Max
(2500mA)
Extend
Output Max (2500mA)
Retract
7 Under Pri Boom Ext/Ret select Data. Read
and record the following parameters.
Extend Speed (%)
Retract Speed (%)
Extend ramp time (sec)
Retract ramp time (sec)
8 Select Pri Boom Up/Down. Under Pri Boom
Up/Down select Up Speed Limit. Read and
record the following parameters.
1
2
3
Input (In)
Output (Pct)
4 5 6
Input (In)
Output (Pct)

Instructions Rev A
Procedure
14 Software Update and Load Cell Replacement Part No. 1280793GT
9 Under Pri Boom Up/Down select Down
Speed Limit. Read and record the following
parameters.
1 2 3
Input (In)
Output (Pct)
4 5 6
Input (In)
Output (Pct)
10 Under Pri Boom Up/Down select Data. Read
and record the following parameters.
End of stroke Up ramp Angle (deg)
End of stroke Down ramp Angle
(deg)
Up Minimum Command (%)
Down Minimum Command (%)
11 Select Turntable Rotate. Under Turntable
Rotate select Valve. Read and record the
following parameters.
Output Min (Thresholds) CW
Output Min (Thresholds) CCW
Output Max (2500mA) CW
Output Max (2500mA)
CCW
12 Under Turntable Rotate select Data. Read
and record the following parameters.
Speed Extended (%)
Speed Not Retracted (%)
Speed Retracted (%)

Rev A Instructions
Procedure
Part No. 1280793GT Software Update and Load Cell Replacement 15
13 Select Propel. Under Propel select Valve.
Read and record the following parameters.
Output Min
(Thresholds)
Forward
Output Min (Thresholds)
Reverse
Output Max (2500mA)
Forward
Output Max (2500mA)
Reverse
14 Under Propel select Data. Read and record
the following parameters.
Forward Speed Extended (%)
Reverse Speed Extended (%)
Forward
Speed Not Stowed (%)
Reverse Speed Not Stowed (%)
Forward Speed Low (%)
Reverse Speed Low (%)
Forward Speed High (%)
Reverse Speed High (%)
15 Select Steer. Under Steer select Angle
Sensor Front Left. Read and record the
following parameters.
Neutral (mV)

Instructions Rev A
Procedure
16 Software Update and Load Cell Replacement Part No. 1280793GT
16 Under Steer select Angle Sensor Front
Right. Read and record the following
parameters.
Neutral (mV)
17 Under Steer select Angle Sensor Rear Left.
Read and record the following parameters.
Neutral (mV)
18 Under Steer select Angle Sensor Rear
Right. Read and record the following
parameters.
Neutral (mV)
19 Select Jib Up/Down. Under Jib Up/Down
select Data. Read and record the following
parameters.
Up Speed Not Retracted (%)
Down Speed Not Retracted (%)
Up Speed (%)
Down Speed
(%)