Installation Instructions

ALC500 Software Update

Refer to Models Included for

model and serial number
information

Original Instructions
First Edition
First Printing
Part No. 1303566GT
May 2022
Instructions First Edition • First Printing

Introduction
Intro ductio n

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

Observe and Obey: Europe: UK + 44 1476 584 333

France + 33 237 260 986
 This procedure shall be completed by a
person trained and qualified on the repair of Germany + 49 421 3770 9890
this machine. Iberica + 34 900 808 110

 Immediately tag and remove from service a Italy + 39 075 941 8184
damaged or malfunctioning machine. Scandinavia + 44 1476 584 333

 Repair any machine damage or malfunction Other locations + 31 165 51 93 22

before operating the machine. Middle East: + 97 143 990 381 or
+ 97 150 459 7937

Before Starting Installation: Australia: + 61 7 3456 4444

Brazil: + 0 800 031 0100
 Read, understand and obey the safety rules South America - other + 56 9 6431 2110
and operating instructions in the appropriate locations
operator's manual.
All other locations + 1 425-881 1800
 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.

Copyright © 2022 by Terex Corporation

First Edition: First Printing, May 2022
Genie, "S" and "Z" are registered trademarks of Terex South
Dakota, Inc. in the U.S.A. and many other countries.
"XC" and "TraX" are trademarks of Terex South Dakota, Inc.

2 ALC500 Software Update Part No. 1303566GT

First Edition • First Printing Instructions

Introduction
Models Included Z-45/25 (J) Z4525-21180
Z452507B-101
Model From serial number
Z452513D-101
S-40 S40-7001
Z4525F-58605
S4016H-21933
Z452516M-5453
S-45 S45-7002
Z452516N-55299
S-60 / S-65 / S-60HC S6003-9154
Z-45 XC Z4525XCF-101
S6014D-101
Z4525XCM-101
S6016H-35001
Z-51/30 Z513005-101
S6014M-101
Z-60/34 Z60-4001
S6016N-31261
Z-62/40 Z6215A-101
S-60X S60X10-21001
Z62H-3000
S-60XC S60XC10-21001 to 45000
Z62D-150
S-60 TraX S60TX08-17768
Z62M-400
S60TX14D-101
S-65 TraX S65TX10-20410
S65TX14D-101
S65TXM-101
S-80 / S-85 S80-3082
S8014D-101
S85D-340
S8016H-13258
S-80X S80X10-8500
S80X15D-101

Part No. 1303566GT ALC500 Software Update 3

Instructions First Edition • First Printing

Introduction
Tools Required:
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)
USB to DB9M cable available from Genie.
(1252193GT, ordered separately)
WebGPI™ software
(215336GT, ordered separately)
Note: The WebGPI™ software kit must be
purchased if it is not already installed on your
computer.
3/8 inch wrench
7/16 inch wrench
3/8 inch socket
7/16 inch socket
Ratchet
Service and Repair Manual

4 ALC500 Software Update Part No. 1303566GT

First Edition • First Printing Instructions

Procedure
Firmware Site Download PCON Software Update
Proced ure

Note: Access to the internet is required to 1 Open the platform control box.
perform this procedure. 2 Connect the computer DB9 cable to the
Note: Turning off your pop up blocker may be PCON PCB.
required to perform this procedure.
1 Go to the Genie Firmware site.
https://www.genielift.com/en/support/firmware
2 From the drop down list, choose the model
that is appropriate for your machine.
3 Under Application Firmware, select the
Firmware File for Control System Type
3 At the TCON, turn the key switch to platform
ALC500.
controls and pull out the red Emergency Stop
4 Follow the prompts for Terms of Service and buttons at both control boxes.
Submit.
4 Open WebGPI™ and click on the Connect
5 Navigate to your Downloads folder on your icon.
computer and locate the .zip folder.
Note: The current application software file will be
6 Double click on the file to open it. shown at the top of the screen. (Example:
S08xxxxx)
7 Double click on the Application file and
select Run. Note: If the current machine application file is not
Note: For Windows 10 or higher, you may receive installed on the computer, it must be installed in
this message, "Windows protected your PC". order to connect to the PCON PCB and prior to
Select More info, then select Run anyway. On updating the application software.
the next screen select Yes. Note: If Check power and serial connection is
8 Select Install. displayed, confirm power is on at the TCON and
check the connection between the computer and
9 Select Finish to exit setup. PCON.
10 Close your internet browser. Note: If Attempting to establish connection is
displayed, check your serial port COM settings.
The COM port settings can vary between
computers.
5 Click on the Application icon.

Part No. 1303566GT ALC500 Software Update 5

Instructions First Edition • First Printing

Procedure
6 Use the attached Machine Parameters 9 Click on the Search button, navigate to the
document to record the following parameters: operating system file and locate the
application software.
Setup / Models
C:\Program Files (x86)\Sauer-
• Machine Model Danfoss\WebGPI\S08xxxxx
• Engine Model 10 Select All Files (*.*) and then select the .HEX
• Market Selection file. Click on Open.
Setup / Options 11 Click on the Download button.

• Steer Input 12 When the Kernel file is at 100%, click on the

Disconnect icon.
• Lift Drive Option
13 Click on the Connect icon and then the
• Platform Level Cutout Out of Stowed Application icon.
• Alarm Option 14 Select Set All Defaults. Select Ok. Follow the
on screen prompts.
Setup / Speed Multipliers
15 Enter the machine parameters that were
• Speed, Dir 1
recorded.
• Speed, Dir 2 16 Click on the Disconnect icon.
Valve parameters 17 Push in the red Emergency Stop button to the
• Boom 1 off position at the PCON and disconnect the
DB9 cable from the PCON PCB.
• Boom 2
18 Close the platform control box and securely
• Rotate tighten the retaining fasteners.
• Propel 19 Calibrate the machine. Refer to the
7 Click on the Disconnect icon. Click on the calibration procedures in the appropriate
Connect icon. Click on the Download icon. Service and Repair Manual for your
machine.
8 Select File type: Kernel.

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First Edition • First Printing Instructions

Procedure
Machine Parameters Note: System parameters not listed on this
document are default settings and must not be
Read and record the following parameters that are altered.
appropriate for your machine.
Note: Boom 2 valve parameters will vary
Setup Models depending on machine model.
Machine Model Instru ctions Part No. 130 356 6GT
First Editi on • Fi rst Prin ting
ALC500 Sof twar e Upd ate

Engine Model
Market Selection
Setup Options
Note: Some options may be listed under Setup / Models and
Setup / Machine.
Steer Input
Lift Drive Option
Platform Level Cutout Out of
Stowed
Alarm Option
Setup Speed Multipliers
Speed, Dir 1 Speed, Dir 2
Boom 1

Boom 2
Rotate Stowed

Rotate Not Stowed

Propel Stowed

Propel Not Stowed

Boom 1 Valve Up Down

Output Min (Thresholds)

Boom 2 Valve Up Down

Output Min (Thresholds)

Boom 2 Valve Extend Retract

Output Min (Thresholds)

Rotate Valve CW CCW

Output Min (Thresholds)

Propel Valve Forward Reverse

Output Min (Thresholds)

Part No. 1303566GT ALC500 Software Update 7