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
Date: 04-02-2013

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. A malfunctioning
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.

1 of 4
 SAFETY NOTICE 120007
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.
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”

2 of 4
 SAFETY NOTICE 120007
4. Under the “Application Firmware”, download and save the firmware file 214626A.zip

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

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 SAFETY NOTICE 120007
Warranty:

The labor and travel distance required to perform this inspection and installation are covered under
the provisions of our warranty agreement. Warranty claims can be submitted online, fax or e-mail.
Please combine as many machines as possible on one claim form. If you need more information
about filing a warranty claim, call Terex AWP warranty department.

If you are the owner of an affected machine and are not an authorized Terex AWP dealer,
please contact your nearest Terex AWP dealer for assistance in completing this bulletin.
Only Terex AWP Authorized Dealers will be reimbursed for labor or any other costs
associated with this bulletin under the provisions of our standard warranty terms and
conditions.
Local norms and regulations require 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.

UK: 00 44 1476 584 333

France: 00 33 237 260 986
Germany: 00 49 422 149 1821
Iberica: 0034 900 808 110
Italy: 0039 075 941 8171
Sweden: 0046 3157 5101
Middle East: 0097 143 391 381 or
0097 150 459 7937
All other locations: 0031 653 221 908

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

4 of 4
Installation Instructions
Software Update

Z-135/70

Part No. 214625

Rev F
Instructions Rev F

Introduction

Introduction

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
Observe and Obey:
7/16" socket
 This procedure shall be completed by a person
trained and qualified on the repair of this Ratchet
machine. Small flathead screwdriver
 Immediately tag and remove from service a USB to DB9 adapter cable (if required)
damaged or malfunctioning machine.
SCON Tee harness (if required)
 Repair any machine damage or malfunction (107647, ordered separately)
before operating the machine.

Glossary of Terms
Before Starting Installation:
SCON - Safety controller
 Read, understand and obey the safety rules
and operating instructions in the appropriate TCON - Turntable controls (Ground controls)
operator's manual. PCON - Platform controls
 Be sure that all necessary tools and parts are
available and ready for use. Machine Software Version Update
 Read this procedure completely and adhere to Requirements
the instructions. Attempting shortcuts may
produce hazardous conditions. • For version 1.00, and 1.11 the SCON, TCON
and PCON must be updated.
Indicates that a specific result is expected after
performing a series of steps. • For version 2.00 and 2.01, only the TCON and
PCON must be updated.
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

2 Z-135/70 Part No. 214625

Rev F Instructions

Introduction

Components of Kit 216863 The auto update software is designed to upload the
calibration parameters of the machine, download
Printing Instructions the software update and reload the calibration
Genie part number 216864 parameters. This eliminates the need to recalibrate
Qty. 1 the machine functions.
Thumb drive
Genie part number 214626 NOTICE The installation
Qty. 1 instructions and screen
Includes: prompts must be
followed.
Auto update software
Genie part number 214624
Qty. 1
Failure to follow these instructions and
the screen prompts could result in the
Installation instructions, Z-135/70
Genie part number 214625
loss of application files and will require
Qty. 1 calibration of the machine.
If this should occur it would require
that you have WebGPI™ software
loaded on your computer or order
Genie part number 215336 and may
require replacement of the SCON.
Note: The WebGPI™ software kit must
be purchased and is not warrantable
under this Safety Notice.
Before proceeding, verify the Service
Bypass key switch is in Run mode.
STOP

00000

Run

Service
Bypass

Recovery

Part No. 214625 Z-135/70 3

Instructions Rev F

Procedure

Procedure

Perform this procedure on a flat level surface, with Loading the Software onto a
the boom and jib in the stowed position.
Computer or Laptop
1 Turn on the computer or laptop.
Software Version
Note: If the WebGPI Auto Update Zip file has been
Note: Before proceeding, verify the version of
downloaded from the website, unzip the file and
software installed on your machine. continue to step 3.
1 At the TCON, turn the key switch to ground 2 Insert the thumb drive (Genie part number
controls and pull out the red Emergency Stop 214626) into the computer or laptop.
button.
Note: If the WebGPI Auto Update files are not
2 Read and record the scroll message on the
displayed on your computer, go to My Computer
display (example: VER 1_10 is version 1.10).
and locate the Removable Disk.
3 Push in the red Emergency Stop button.
3 Open the file LVRTE2010sp1std.exe. Select
OK, then select Unzip.
Limit Switch Rework 4 When the files have been extracted, select OK.
For machines with software version 1.00 5 When the LabVIEW 2010 screen appears,
The primary boom retract operational limit switch continue to select Next until the License
LSP1RO must be reworked before proceeding with Agreement is displayed.
the software upgrade. Proceed to page 14 for limit 6 Select I accept the License Agreement, then
switch rework instructions. select Next. Installation will begin.
Note: Depending on your operating system, this
process may take up to 10 minutes.
7 When the installation is complete, select
Finish. Then select Restart Later.
8 Open the file visa 501runtime.exe. Select OK,
then select Unzip.
9 When the files have been extracted, select OK.
10 When the NI-VISA screen appears, continue to
select Next until the License Agreement is
displayed.

4 Z-135/70 Part No. 214625

Rev F Instructions

Procedure

11 Select I accept the License Agreement, then SCON Software Update

select Next until the Installation begins.
For machines with software version 1.00 or 1.11
12 When the installation is complete select
Finish. Then select Restart Later. The auto update software is designed to upload the
calibration parameters of the machine, download
13 Open the folder WebGPI Auto Update 2.0.15. the software update and reload the calibration
14 Open the file setup.exe, then select Next until parameters. This eliminates the need to recalibrate
the Installation begins. the machine functions.
15 When the installation is complete, select 1 Locate the SCON mounted on the frame
Finish. behind and to the right of the function manifold
on the ground controls side of the machine.
16 Remove the thumb drive from the laptop and
close all programs. Restart the computer. 2 Disconnect the gray J121 connector from the
SCON.
Note: After the installation is complete, a WebGPI
Auto Update icon will be installed on your desktop.

3 Connect the SCON Tee-Harness (Genie part

number 107647) 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 Double-click on the Auto Update icon to
activate the software.

Part No. 214625 Z-135/70 5

Instructions Rev F

Procedure

7 Click on the Update button. 8 Select software file S0677200 from the
application selection window and click OK.

Note: If Check power and serial connection is

displayed, confirm power is on at the TCON and
9 The turn power off message will appear. Push
check the connection between the laptop and the
in the red Emergency Stop button and click
SCON.
OK.
Note: Do not turn the power on until the power on
message appears.

Note: If Attempting to establish connection is

displayed, check your serial port COM settings.

6 Z-135/70 Part No. 214625

Rev F Instructions

Procedure

10 The turn power on message will appear. Pull 12 When the update is complete disconnect the
out the red Emergency Stop button and click laptop from Tee-Harness. Push in the red
OK. Emergency Stop button, then pull it back out to
save updates.

11 The application update should start.

13 Close the auto update program.
Note: If the update fails to start, close the program
and return to step 6 and follow the instructions. 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.

Part No. 214625 Z-135/70 7

Instructions Rev F

Procedure

TCON Software Update 5 Click on the Update button.

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.
1 Open the ground control box and set the
fasteners aside.
2 Connect the laptop DB9 cable to the TCON
PCB.
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.
3 At the TCON, turn the key switch to ground
controls and pull out the red Emergency Stop
button.
4 Double-click on the Auto Update icon to
activate the software.

8 Z-135/70 Part No. 214625

Rev F Instructions

Procedure

6 Select software file S0677202 from the 8 The turn power off message will appear.
application selection window and click OK. Push in the red Emergency Stop button and
click OK.
Note: Do not turn the power on until the power on
message appears.

7 The application update should start.

Note: If the update fails to start, close the program
and return to step 4 and follow the instructions.
9 The turn power on message will appear. Pull
out the red Emergency Stop button and click
OK.

Part No. 214625 Z-135/70 9

Instructions Rev F

Procedure

10 The object files will begin to 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.
1 Open the platform control box and set the
fasteners aside.
2 Connect the laptop DB9 cable to the PCON
PCB.

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.

3 At the TCON, turn the key switch to platform

controls and pull out the red Emergency Stop
12 Close the auto update program. buttons at both control boxes.

13 Push in the red Emergency Stop button. 4 Double-click on the Auto Update icon to
activate the software.
14 Close the ground control box and securely
tighten the retaining fasteners.
15 Continue to PCON Software Update.

10 Z-135/70 Part No. 214625

Rev F Instructions

Procedure

5 Click on the Update button. 6 Select software file S0676201 from the
application selection window and click OK.

Note: If Check power and serial connection is

displayed, confirm power is on at the PCON and 7 The turn power off message will appear.
check the connection between the laptop and the Push in the red Emergency Stop button at the
PCON. platform and click OK.
Note: Do not turn the power on until the power on
message appears.

Part No. 214625 Z-135/70 11

Instructions Rev F

Procedure

8 The turn power on message will appear. Pull 10 When the update is complete, disconnect the
out the red Emergency Stop button at the laptop from the PCON. Push in the red
platform and click OK. Emergency Stop button, then pull it back out to
save updates.

9 The application update should start.

11 Close the auto update program.
Note: If the update fails to start, close the program
and return to step 4 and follow the instructions. 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 19.
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.

12 Z-135/70 Part No. 214625

Rev F Instructions

Procedure

15 Release the button and press 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:
16 Press the button and scroll to RESET
United States: 800-536-1800
FAULTS. Press the button to change the
screen from NO to YES. Canada: 425-881-1800
Europe: UK 0044 1476 584 333
17 Press the button to exit. Press the France 0033 237 260 986
button to change the screen from NO to YES. Germany 0049 4221 491 821

18 Press the button to return to the operators Iberica 0034 935 725 090
screen. Push in the red Emergency Stop Italy 0039 075 941 8132
button. Repeat step 13. Scandinavia 0046 3157 5154
19 Perform function test. Refer to the Operator's Other locations 0031 653 221 908
Manual on your machine. Middle East: 0097 143 391 800 or
0097 150 459 7937
20 Return the machine to service.
Australia: 61 7 3456 4444
21 Fill out and sign the attached completion form
All other locations 001-425-881-1800
and fax or email to Terex AWP Warranty
Department. This will serve as verification that
you have completed Safety Notice 120007.

Part No. 214625 Z-135/70 13

Instructions Rev F

Procedure

Limit Switch Rework 3 Disconnect the boom harness from the limit
switch harness.
For machines with software version 1.00
4 Remove the two white weather plugs and set
1 Locate and remove the primary boom cover aside.
and set aside.
5 Remove the secondary lock from the end of
the connector and set aside.
For machines before serial number Z13505-130.
6 Move 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.
7 Move the orange/black wire from position 1 to
position 3 and the red/black wire from position
2 to position 4.
8 Install the secondary lock removed in step 5.
Note: Give a slight tug on each wire to confirm they
are properly seated into the connector.
2 Locate LSP1RO limit switch inside the primary 9 Install the two white weather plugs removed in
boom. 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

14 Z-135/70 Part No. 214625

 SAFETY NOTICE
120007
Completion Form
Your signature on this form will verify that you have installed kit P/N 216863.

Fax to: United States 877-738-7530 United Kingdom 0044 1476 584 330
Canada 425-498-7530 France 0033 237 260 998
Australia 61 733751002 Germany 0049 4221 491 820
All other locations 001-425-498-7530 Italy 0039 075 941 8146
Iberica 0034 935 725 080
Scandinavia 0046 3157 5104
Middle East 0097 143 990 382
All other locations 0031 165 510 826

Email to: [email protected]

Date:
Company Name:
Account # (if applicable):
Address:
(street)
(city)
(state, zip code)
Phone:

Please list the complete serial number (example: Z13505-111 or Z13511-1335).

Serial Number: Serial Number:

Print (service manager) Signature Date

Instructions Part No. 214625 Z-135/70
Rev F