Terex ALC-600 User manual

Installation Instructions
ALC
-600 Software Update
Refer to the inside cover for
models included.
Part No. 1295343GT
Rev A
April 2019

Instructions Rev A
Introduction
2 ALC-600 Software Update Part No. 1295343GT
Intr od ucti on
Intr od ucti 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 that an incorrect result has occurred
after performing a series of steps.
Genie, "S" and "Z" are registered trademarks of
Terex South Dakota, Inc. in the U.S.A. and many
other countries.
"TraX" and "XC" are trademarks of Terex South
Dakota, Inc.
Models Included
Model
From serial number
S
-40 XC S40XCH-
101
S
-40 TraX
S
-45 XC S45XCH-
101
S
-45 TraX
S
-60 XC S60XCH-
45001
S
-60 TraX S60XCM-
101
S
-65 XC S65XCH-
45001
S
-65 TraX S65XCM-
101
S
-80 HF S80XCH-
101
S
-80 XC
S
-85 HF S85XCH-
101
S
-85 XC
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
+ 49 421 3770 9890
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

Rev A Instructions
Introduction
Part No. 1295343GT ALC-600 Software Update 3
Tools Required:
3/8 inch socket
7/16 inch socket
Ratchet
Torx T15 screwdriver
PC or Laptop with Internet Browser
USB flash drive
Note: Refer to Checking the File System Format of
a USB Flash Drive.
Theory of Operation
ALC-600 software consists of two parts, the
application firmware and the bootloader firmware.
The only time an operator will enter bootloader
mode is when updating the firmware.
The machine will always start in application mode.
Firmware can only be updated from bootloader
mode. Bootloader mode can be started from the
ground controls.
Once in bootloader mode, it is possible to update
either the application firmware or the bootloader
firmware.
Genie periodically releases firmware updates.

Instructions Rev A
Procedure
4 ALC-600 Software Update Part No. 1295343GT
Proc ed ur e
ALC-600 Display
1 escape button
2 scroll up button
3 scroll down button
4 OK button
5 Settings
6 Faults
7 LED, fault indicator
8 Maintenance
9 Home
Checking the Application and
Bootloader Revisions from the
Ground Controls.
1 Turn the key switch to ground controls.
2 Press and hold buttons 1 and 4. Pull out the
red Emergency Stop button to the on position.
3 Read and record the firmware revisions.
Bootloader Firmware:
Application Firmware:
Note: The application firmware revision is shown
under Current Firmware.
4 Press Escape. Press OK to exit bootloader
mode.

Rev A Instructions
Procedure
Part No. 1295343GT ALC-600 Software Update 5
Checking the File System Format
of a USB Flash Drive.
Note: Verify the format of the USB flash drive
before downloading the firmware files onto the
flash drive.
Note: File systems such as NTFS and exFAT are
not supported by the ALC-600 operating system.
1 Insert a USB flash drive into a USB port on
your computer.
2 Right click on the drive where the USB flash
drive is located.
example: (E:) Removable Disk)
3 Select Format.
4 Select Under File System, verify that FAT,
FAT16 or FAT32 is selected.
Result: The correct file format is displayed, the
USB flash drive is formatted correctly.
Result: The correct file format is not
displayed, the USB flash drive must be
formatted. Select the drop down and select the
correct file format.
If formating is required, all data on the USB
flash drive will be lost. Copy and save all files
onto a PC or Laptop.
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 the model that is appropriate for your
machine under Machine Model. Select
Search.
3 Select the appropriate Firmware File to be
updated. Select I Accept. Select Save As and
save it to your desktop.
4 Close your internet browser.
5 Insert a USB flash drive into a USB port on
your computer.
Locate the .zip files saved on your desktop. Right
click on the files and select Extract All. Save
the .gff files to the USB flash drive.

Instructions Rev A
Procedure
6 ALC-600 Software Update Part No. 1295343GT
How to Enter ALC-600 Software
Update Mode
1 Open the ground control box. Remove the
retaining fasteners securing the display
controller door.
1 USB port
2 controller door
2 Insert the USB flash drive that the firmware
files were saved on into the USB port of the
display controller.
3 Turn the key switch to ground controls.
4 Press and hold buttons 1 and 4. Pull out the
red Emergency Stop button to the on position.
Note: The firmware files saved on the USB flash
drive will be displayed on the screen.
5 Select the firmware to be updated. Press OK.
Follow the on-screen prompts to start the
update.
6 When complete, press OK.
Note: If the bootloader firmware is also being
updated, press Escape. Select the bootloader
firmware and follow the on-screen prompts. When
complete, press OK. Press OK to Start
Application mode.
Note: If the bootloader firmware is not being
updated, press OK to Start Application mode.
Note: A model Configuration Fault (116-31) will
be displayed after the firmware has been
updated. Push in the red Emergency Stop
button to the off position and continue with
step 7.
7 Remove the USB flash drive. Install the
display controller door and close the ground
control box.
8 Continue to Model Configuration and Region
Settings.

Rev A Instructions
Procedure
Part No. 1295343GT ALC-600 Software Update 7
Model Configuration and Region
Settings
1 Turn the key switch to ground controls.
2 Press and hold buttons 2 and 3. Pull out the
red Emergency Stop button to the on position.
3 You will be prompted for a password.
Enter 3 - 3 - 2 - 4.
4 Press the Settings button to access the
settings menu.
Note: There will be a delay while the menu is being
loaded on the display screen.
5 Select Model Configuration. Press OK.
6 Confirm Models, Tires and Engine are set
correctly for your machine.
7 Select Region. Press OK.
8 Select the appropriate region for your
machine. Press OK.
Note: The region options are ANSI/CSA, AUS and
CE.
9 Press Escape / Escape.
10 Cycle the red Emergency Stop button off, then
back on.
Result: No faults are displayed. Continue with
step 11.
Result: A Model Configuration Fault
(116-31) is displayed, continue to How to
Recover from a Model Configuration Fault.
11 Perform function test. Refer to the Operator's
Manual located on your machine.
12 Return the machine to service.
How to Recover from a Model
Configuration Fault
Note: Only perform this procedure if a
Model Configuration Fault was still displayed
after the Model Configuration and Region
Settings was completed.
Note: When performing this procedure, certain
machine calibration procedures from the
Service and Repair Manual that is appropriate
for your machine will be required.
1 Turn the key switch to ground controls.
2 Press and hold buttons 2 and 3. Pull out the
red Emergency Stop button to the on position.
3 You will be prompted for a password.
Enter 3 - 3 - 2 - 4.
4 Press the Settings button to access the
settings menu.
Note: There will be a delay while the menu is being
loaded on the display screen.
5 Read and record the Options and Speeds
settings on the document included with these
instructions.
Note: The settings must be recorded before
proceeding.
6 Select Restore Defaults. Press OK.
7 Select Reset Models and Options. Press
OK. Follow the prompts displayed on the
screen.
8 Press and hold buttons 2 and 3. Pull out the
red Emergency Stop button to the on position.
9 You will be prompted for a password.
Enter 3 - 3 - 2 - 4.

Instructions Rev A
Procedure
8 ALC-600 Software Update Part No. 1295343GT
10 Press the Settings button to access the
settings menu.
Note: There will be a delay while the menu is being
loaded on the display screen.
11 Select Model Configuration. Press OK.
12 Select the Models, Tires, Engine and Region
that are appropriate for your machine. Press
Escape.
13 Select Options. Press OK.
14 Configure the options settings using the
document they were recorded on. Press
Escape.
15 Select Speeds. Press OK.
16 Configure the speed settings using the
document they were recorded on.
17 Push in the red Emergency Stop button to the
off position.
18 Perform Sensor Calibrations. Refer to the
Repair Procedures in the Service and Repair
Manual that is appropriate for your machine.
•How to Calibrate the Turntable Level
Sensor
•How to Calibrate the Primary Boom Angle
Sensor
•How to Calibrate the Primary Boom Length
Sensor
19 Perform function test. Refer to the Operator's
Manual located on your machine.
20 Return the machine to service.

Rev A Instructions
Procedure
Part No. 1295343GT ALC-600 Software Update 9
Options and Speeds Settings
Options Settings
Foot switch timeout
mins
Drive priority
ON OFF
Drive cutout
ON OFF
Platform level
ON OFF
Generator
Installed Not installed
Contact alarm
ON OFF
Platform recirculation
ON OFF
Units
US Metric
Aircraft proximity
ON OFF
Fuel level sensor
Installed Not installed
Lift connect
Installed Not installed
Alarm setting
ON OFF
Speeds Settings
Drive Speeds
Forward threshold
%
Reverse threshold
%
Forward max
%
Reverse max
%
Forward out of stow max
%
Reverse out of stow max
%
Drive Ramps
Standard
acceleration
ms
Standard deceleration
ms
Torque switching deceleration
ms
Anti-Stall
Threshold
rpm
Drive minimum
%
Range
rpm
Hysteresis
rpm
Primary Lift Speeds
Extend threshold
%
Retract threshold
%
Up threshold
%
Down threshold
%
Extend
max
%
Retract max
%
Up max
%
Down max
%
Primary Lift Ramps
Extend acceleration
ms
Extend deceleration
ms
Retract acceleration
ms
Retract deceleration
ms
Up acceleration
ms
Up deceleration
ms
Down acceleration
ms
Down deceleration
ms
Turntable Speeds
Rotate CW threshold
%
Rotate CCW threshold
%
Rotate CW max
%
Rotate CCW max
%
CW out of stow max
%
CCW out of stow max
%
Turntable Ramps
CW acceleration
ms
CW deceleration
ms
CCW acceleration
ms
CCW deceleration
ms

Instructions Rev A
Procedure
10 ALC-600 Software Update Part No. 1295343GT
Jib & Platform Speeds
Jib up threshold
%
Jib down threshold
%
Platform level up threshold
%
Platform level down threshold
%
Platform rotate CW threshold
%
Platform rotate CCW threshold
%
Jib up max output
%
Jib down max output
%
Platform level up max
output
%
Platform level down max output
%
Platform rotate CW max output
%
Platform rotate CCW max output
%
Jib & Platform Ramps
Jib up/down ramp time
ms
Platform level ramp time
ms
Platform rotate ramp time
ms
Instr uc ti on s
Part No.1295343GT
Re v
A
ALC
-600 So ftw are U p da te