this safety notice contains information about …firmware.genielift.com/drivers/150003.pdf ·...

Safety Notice 150003

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THIS SAFETY NOTICE CONTAINS INFORMATION ABOUT MANDATORY CHANGES OR CHECKS RELATED TO THE SAFE USE OF OUR PRODUCT.

Date: July 17, 2015

Models Affected: GS-2669DC & BE, CE and AUS certified GS-3369DC & BE, CE and AUS certified GS-4069DC & BE, CE and AUS certified

Serial Numbers Affected: GS6912-355 to GS6912-1308 GS6913-1756 to GS6913-3501 GS6914-3255 to GS6914-6059 GS6915-6080-GS6915-6167

Replacement Parts Affected: See Table 1 on page 4

Subject: Lift and Elevated Drive Off-Level

Allowable Hours: 60 minutes

Issue:

Genie has determined that a malfunction in the control system in the above referenced machines can occur. This malfunction prevents the ground slope monitoring portion of the control system from functioning properly. If this occurs while the machine is elevated on an unlevel surface, the machine could tip over.

Continued Use Instructions:

All machine operators must be notified of these continued use requirements.

The machine may remain in service until this Safety Notice is completed, provided the operator lowers the machine and moves it to firm level ground anytime the lift's slope warning system activates.

Action(s) Required:

This safety notice requires updating the control system software installed on all of the affected machines, GCON assemblies and PC boards in your inventory referenced above.

Installation of the new software must take place as soon as possible but no later than 30 days from receipt of the new software.


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Work Instructions:

Tools Required

Torx T10 screw driver

Cat5 Ethernet Cable

PC or Laptop with an Ethernet Port and Internet Browser

1 Locate all affected machines referenced on page 1 in your fleet. Also locate the affected GCON assemblies and PC board in your inventory.

2 Access http://firmware.genielift.com.

3 Select "Safety Notice".


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4 Enter "150003" in the "Safety Notice Number" box and click on "Search".

5 Under the "Application Firmware" column, download and save the firmware file by clicking on the software version appropriate for your machine and/or GCON assembly in your inventory.

137641AC or newer for machines or GCON assemblies equipped with "2-Speed Lift' control system

1256792F or newer for machines or GCON assemblies equipped with "Proportional Lift" control system

Note: Refer to page 4 to identify the control system installed on the machine or GCON assemblies in your inventory.

Important: Note the location on the computer where you downloaded the file. You will need it when performing the software update.

6 Update the software.

If updating the software installed on the GCON assembly or PC board from your inventory, start with the instructions on page 4.

If updating the software installed on the machine, start with the instructions on page 8.


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Updating affected GCON Assemblies and PC Board

To update the GCON assembly from your inventory, the GCON must be connected to a machine with the same control system (see table 1). The control system type is also on the serial label located on the back of the GCON assembly (Illustration 1).

To update the PC Board, connect the PC Board to a compatible GCON and follow the GCON update procedure.

Table 1. Affected GCON Assemblies and PC Boards

GCON Assembly Part Numbers

PC Board Part Numbers

Control System

1256721 and 1256722 - N/A - Proportional Lift

237616 - 237618 - 2-Speed Lift

137692 - 137604 - 2-Speed Lift

217992 and 137644 - 137564 - 2-Speed Lift

Note the serial number of the affected GCON assembly and PC board from your inventory. You will need this information when filling out the completion form.

Illustration 1

1 GCON serial label

2 GCON serial number

3 GCON control system type

Illustration 2

1 PC board serial label

2 PC board serial number


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Identifying the machine's control system Machines starting from GS6914-5500 were manufactured with the "Proportional Lift" control system. Use any of these machines to update the GCONs with "Proportional Lift" control system.

Machines from GS6912-355 to GS6914-5499 were originally manufactured with the "2-Speed Lift" control system. However, some machines may have been updated with the "Proportional Lift" control system. Inspect the PCON control panel to determine the control system installed.

If the PCON control panel decal is any of what is shown below, the machine has been updated with the "Proportional Lift" control system. Use any of these machines to update the GCONs with "Proportional Lift" control system.

Illustration 3

If the PCON control panel decal is any of what is shown below, the machine is equipped with the "2-Speed Lift" control system. Use any of these machines to update the GCONs with "2-Speed Lift" control system.

Illustration 4

1256710 B

=+ -

1256709 B

=+ -

236360

== + -+ -

1 2

3 4

237127

== + -+ -

1 2

3 4


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Connecting the GCON to a compatible machine. 1 Remove the retaining fastener on the left side of the GCON enclosure and set aside. Open the front panel.

Illustration 5

1 retaining fastener

2 GCON

2 Disconnect the harnesses from the back of the GCON.

Illustration 6

1 models without outriggers

2 GCON

3 models with outriggers

1 2

��

1 2 3


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3 Connect the harnesses to the GCON from inventory.

Illustration 7

1 brown

2 black

3 gray

4 green (models with outriggers)

4 Update the software. Refer to Updating the Software on page 8.

1 2 3 4


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Updating the Software Before proceeding with the update, verify the version of the software currently installed on your machine or GCON's from your inventory.

1 Pull out the red Emergency Stop buttons at both the ground controls(GCON) and platform controls (PCON).

2 At the GCON, turn the key switch to ground controls.

The display at the PCON will show "CH"

The display at the GCON will show the machine model and hour meter information

1 GCON LCD

2 Scroll down button

== + -+ -

READY . GS3369

00000.0 Hours

137562

��

2

1


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3 Press the ground control scroll down button to display the software version and hour meter information. After 3 seconds, the GCON LCD will return to the machine model and hour meter information. Press the scroll down button to display the software version again.

If the software version displayed is any of the following:

137641 Rev AC or newer

1256792 Rev F or newer

The machine or GCON from your inventory does not need this update.

a Push in the red Emergency Stop button to the off position at the GCON and PCON and turn the key switch to the off position.

Note: If updating the GCON assembly from your inventory, disconnect the GCON from the machine and reinstall the original GCON.

b Fill out and sign the attached completion form and fax or email toTerex AWP Warranty Department. This will serve as verification that you have completed Safety Notice 150003.

If the software version displayed is any of the following:

137641 Rev A to 137641 Rev AB

237620 (all versions)

1256792 Rev A to E

The machine or GCON from your inventory needs the update. Continue on to step 4.

4 Push in the Emergency Stop button to the off position.

5 Turn the computer on.

Note: Disable all external internet or network connections before continuing.

SOFTWARE REV

00000.0 Hours


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6 At the GCON, press and hold the Enter and Escape buttons. Pull out the red Emergency Stop button to the on position.

Illustration 8

1 LCD

2 Enter button

3 Escape button

Result: The GCON LCD will display the following screen.

7 Locate the diagnostic port on the side of the GCON.

Illustration 9

1 Diagnostic Port

137562

4321

1

2

3

1


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8 Remove one of the fasteners securing the cover and set aside. Loosen the other fastener. Do not remove it.

9 Connect one end of a CAT5 Ethernet cable into the diagnostic port. Connect the other end into a PC or laptop.

Result: The GCON LCD will display the following screen.

10 Read and record the IP address.

11 Launch a web browser such as Internet Explorer® or Firefox® on your PC or laptop. Type in the IP address from step 10 into the web browser address bar and press Enter.

Result: The following screen will be displayed.

12 Select the Browse button. Navigate to the firmware file located on your hard disk and select the file. Firmware number :

137641AC or newer for machines or GCON assemblies with 2-Speed Lift control system

1256792F or newer for machines or GCON assemblies with Proportional Lift control system

Note: Depending on your web browser, this button may be shown as Choose File.

Example:

1 file extension

2 revision level

3 part number

Y


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13 Select the Load Flash File button.

Note: Verify it is the correct flash file.

Result: The following screen will be displayed.

14 Select the Reprogram Device (s) button to start the ECM software update.

Result: The following screen will be displayed after the software update is complete.

Note: Do not turn off power while the ECM is being reprogrammed. This process may take up to 5 minutes.

Note: Verify that the firmware number is displayed in the box marked "Current:". Firmware number. Refer to step 12 for the Firmware number.

15 Select the Run application button to exit the software update mode.

16 Push in the red Emergency Stop button at the GCON and disconnect the CAT5 cable.

17 Secure the diagnostic port cover using the retaining fasteners removed in step 8. Do not over tighten.

18 Perform function test. Refer to the Operator's Manual located on your machine.

19 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 150003.

Y

Y

Y


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Warranty:

The labor and travel distance required to perform this Safety Notice 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 Safety Notice. Only Terex AWP authorized dealers will be reimbursed for labor or any other costs associated with this Safety Notice 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: + 44 1476 584 333

France: + 33 237 260 986

Germany: + 49 422 149 1810

Iberica: + 34 935 725 090

Italy: + 39 075 941 8184

Sweden: + 46 3157 5100

Middle East: + 97 143 990 381 or + 97 150 459 7937

All other locations: + 31 653 221 908

Enclosures:

Machine List

New Owner Update Form

Completion Form

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150003

Safety Notice


Completion Form Your signature on this form verifies that you have completed Safety Notice 150003 on the machines and part numbers listed below.

Please note that this is not a Warranty Claim Form. A Warranty Claim Form must be submitted to the Terex AWP Warranty Department for reimbursement under the provisions of our standard warranty terms and conditions.

Fax to: United States: 1 877-738-7530 United Kingdom 0044 1476 584 330

Canada: 1 425-498-7530 France: + 33 237 260 998

Mexico: + 1 425 498 7530 Germany: + 49 4221 491 820

Latin America: + 55 11 3246-9760 Italy: + 39 075 941 8146

Central America: + 1 425 498 7530 Iberica: + 34 935 725 080

Carribean: + 1 425 498 7530 Scandinavia + 46 3157 5104

Asia-Pacific: + 1 425 498 7530 Middle East: + 97 143 990 382


Email to: [email protected]

Date:

Company Name:

Account # (if applicable):

Address:

(street):

(city):

(state, zip code):

Phone:

Please list the complete machine serial number (ex.GS6912-1307 or GS6914-3394).

Model Machine Serial Number Model Machine Serial Number

= = = =

= = = = = =

= =

Please list the complete serial number of the GCONs or PC Boards from your inventory.

GCON or PC Board Part Number

Serial Number

GCON or PC Board Part Number

Serial Number

= =

= = = =

Print (service manager) Signature Date


New Owner Update Form (for updating machine owner information only)

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.

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. GS6912-1307 or GS6914-3394).

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: France: + 33 237 260 998 Italy: + 39 075 941 8146

Germany: + 49 4221 491 820 Sweden: + 46 3157 5104

Iberica: + 34 935 725 080 Middle East: + 97 143 990 382


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