Installation Instructions

Transcription

1 Installation Software Update Z-135/70 ZX-135/70 Serial Number Range from Z to Z From ZX to ZX Part No November 2015

2 Introduction Introduction Introduction 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. Note: These installation instructions only apply to the Genie models listed on the front cover. Tools Required: Computer or Laptop with Microsoft operating system XP, Windows 8 or Windows 8.1 DB9 serial cable, female to male of suitable length (DB9F to DB9M) USB to DB9 adapter cable (if required) WebGPI software (215336, ordered separately) SCON Tee harness Genie part number /16 inch wrench 7/16 inch socket Ratchet Small flathead screwdriver Z-135/70 Service and Repair Manual Genie part number or ZX-135/70 Service Manual from serial number ZX to ZX (does not include 2463, 2469 and 2531) Genie part number or ZX-135/70 Service and Repair Manual from serial number ZX (includes 2463, 2469 and 2531) Genie part number Glossary of Terms SCON - Safety controller TCON - Turntable controls (Ground controls) PCON - Platform controls 2 Software Update Part No

3 00000 Introduction Machine Software Version Update Requirements Machines equipped with platform overload protection and an operating system with a software version less than 3.00 must install load sense upgrade kit Machines equipped with platform overload protection and an operating system with a software version 3.00 or higher continue to the Application Software Installation. Machines not equipped with platform overload protection continue to the Application Software Installation. Tip-over hazard. Tipping over the machine will result in death or serious injury. Only install software V4.01 on machines equipped with the angle sensor shown below. Before proceeding, verify the Bypass key switch is in Run mode STOP 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: Canada: Europe: UK France Germany Iberica Italy Scandinavia Other locations Middle East: or Australia: All other locations run 2 bypass 3 recovery Part No Software Update 3

4 Note: Perform this procedure on a flat level surface, with the boom and jib in the stowed position. 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). 3 Push in the red Emergency Stop button. Limit Switch Rework For machines equipped with platform overload protection and software version less than 3.00 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 Download the WebGPI software update from the Genie Firmware site Link to Firmware onto the computer or laptop. Note: If the WebGPI Update files are not displayed on your computer, go to My Computer and locate the directory where the files were downloaded. 3 Select each of the three application files one at a time. The platform overload limit switch LSP1OLS must be replaced before proceeding with the software upgrade. Calibration Information After the installation of the Application Software is complete, the machine will have to go through a complete calibration process. Refer to the appropriate Service and Repair Manual for your machine. 4 Software Update Part No

5 4 Select Yes on the License Agreement screen. 6 On the Setup Type screen select Typical, then select Next. 5 On the Choose Destination screen record the default destination folder and select Next. Note: After pressing Next, you will see a series of file names flash across the screen. When the status bar displays 100%, installation is complete. 7 Print and replace the latest version of the machine's operator's manual. The operator's manual can be found on the Genie website: Find a Manual Part No Software Update 5

6 Application Software Installation Perform this procedure with the machine in the fully stowed position, the axles fully retracted and the tires parallel to the drive chassis. 6 Open WebGPI and click on the Connect icon. 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. Note: The current application software file will be shown at the top of the screen. (Example: S for older software.) Note: If Check power and serial connection is displayed, confirm power is on at the TCON and check the connection between the computer and SCON. Note: If Attempting to establish connection is displayed, check your serial port COM settings. The COM port settings can vary between computers. 7 Click on the Application icon. 3 Connect the SCON Tee-Harness (Genie part number ) 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 Software Update Part No

7 8 Select Check Parameters. 13 Select File type: Kernel. 9 Select Tilt Sensors Params. Read and record the Tilt Angle Matrix Gains parameters. Use page 22 as a reference to record the parameters. 14 Click on the Search button and locate application software S HEX. 10 Click on the Disconnect icon. 11 Click on the Connect icon. 12 Click on the Download icon. Part No Software Update 7

8 15 Select S HEX, and then click on Open. 17 Click on the Download button. 16 Click on the Force download button Push in the red Emergency Stop button to the off position at the TCON. Pull the red Emergency Stop button back to the on position. 18 When the Kernel file is at 100%, push in the red Emergency Stop button to the off position at the TCON. Pull the red Emergency Stop button back to the on position.click on the Exit button, then the Application icon. 8 Software Update Part No

9 19 Select Set All Defaults. Select Ok. 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 and set the fasteners aside. 2 Connect the computer DB9 cable to the TCON PCB. 20 When prompted, select Level 2, enter SG81355 for the password and select Accept. 21 Select Check Parameters. 22 Select Tilt Sensors Params. Enter the parameters that were recorded in step 9. Note: The numbers must be entered accurately. The SCON cannot be calibrated in the field. If the numbers are not accurate, the machine will not operate or level properly. 23 When prompted, select Level 3 and enter BSNW for the password. 24 Push in the red Emergency Stop button at the TCON and disconnect the Tee-Harness from the SCON. 3 At the TCON, turn the key switch to ground controls and pull out the red Emergency Stop button. 25 Securely connect the gray J121 connector to the SCON. Part No Software Update 9

10 4 Open WebGPI and click on the Connect icon. 6 Select Pri Boom Ext/Ret and then Valve. Read and record the parameters outlined below. Use page 22 as a reference to record the parameters. Note: The current application software file will be shown at the top of the screen. (Example: S for older software.) Note: If Check power and serial connection is displayed, confirm power is on at the TCON and check the connection between the computer and TCON. 7 Select Pri Boom Ext/Ret and then Data. Read and record the parameters outlined below. 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. 10 Software Update Part No

11 8 Select Pri Boom Up/Down and then Valve. Read and record the parameters outlined below. 10 Select Sec Boom and then Ext/Ret Valve. Read and record the parameters outlined below. 9 Select Pri Boom Up/Down and then Data. Read and record the parameters outlined below. 11 Select Sec Boom and then Up/Down Valve. Read and record the parameters outlined below. Part No Software Update 11

12 12 Select Sec Boom and then Data. Read and record the parameters below. 14 Select Turntable Rotate and then Data. Read and record the parameters below. 13 Select Turntable Rotate and then Valve. Read and record the parameters outlined below. 15 Select Propel and then Valve. Read and record the parameters outlined below. 12 Software Update Part No

13 16 Select Propel and then Data. Read and record the parameters outlined below. 19 Select Jib Up/Down and then Data. Read and record the parameters outlined below. 17 Select Steer and then Angle Sensor Front Left. Read and record the parameters outlined below. 20 Select Setup and then Machine. Read and record the parameters below. 18 Repeat recording parameters for the remaining Steer Angle Sensors (Front Right, Rear Left, and Rear Right). 21 Click on the Disconnect icon. Click on the Connect icon. Click on the Download icon. Part No Software Update 13

14 22 Click on the Search button and locate application software S2-TCON HEX. Select S2-TCON HEX and click on Open. 25 Click on the Application icon. 26 Select Set All Defaults. Select Ok. 23 Click on the Download button. When the download is complete, a warning message will appear. Click on the OK button. 27 When prompted, select Level 2, then enter SG81355 for the password and select Accept. 24 Click on the Exit button then push in the red Emergency Stop Button at the TCON to the off position. Pull the red Emergency Stop Button back to the on position. 14 Software Update Part No

15 28 Select Setup then Machine S/N. Enter the last four digits of the machine serial number and click Send. 30 Enter the parameters that were recorded in steps 6 through 20. Set Speed Cal flags for Primary Boom Extend/Retract, Primary Boom Up/Down, Secondary Boom Up/Down and Turntable rotate to Yes. Note: Speed Cal flags are located in the Data screens of each function. Note: The Setup/Machine screen contains four new items that will be used for future functionality. Make sure the following are all set to "No": Loop Valves, Telematics Disable machine command, Telematics Cripple Drive Speed Command and Telematics Cripple Lift Speed Command. If any of these items are set to "Yes, then select "No" for the item and click send. Note: The serial number must be entered prior to calibration or the machine will not calibrate. 29 Select Setup then Machine. Make sure the serial number is shown in the Machine Serial Number box. Part No Software Update 15

16 PCON Software Update 1 Open the platform control box and set the fasteners aside. 4 Open WebGPI and click on the Connect icon. 2 Connect the computer DB9 cable to the PCON PCB. Note: The current application software file will be shown at the top of the screen. (Example: S for older software.) 3 At the TCON, turn the key switch to platform controls and pull out the red Emergency Stop buttons at both control boxes. Note: If Check power and serial connection is displayed, confirm power is on at the TCON and check the connection between the computer and PCON. 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. 16 Software Update Part No

17 6 Select Platform Level and then Valve. Read and record the parameters outlined below. Use page 23 as a reference to record the parameters. 8 Select Jib Level and then Valve. Read and record the parameters outlined below. 7 Select Platform Level and then Data. Read and record the parameters outlined below. 9 Select Jib and then Valve. Read and record the parameters outlined below. 10 Click on the Disconnect icon. Click on the Connect icon. Click on the Download icon. Part No Software Update 17

18 11 Select File type: Kernel. 13 Select All Files (*.*) and then select S HEX. Click on Open. 12 Click on the Search button and locate application software S HEX. 14 Click on the Force download button. Push in the Red Emergency Stop button to the off position at the TCON. Pull out the red Emergency Stop button back to the on position. 18 Software Update Part No

19 15 Click on the Download button. 18 Select Set All Defaults. Select Ok. 16 When the Kernel file is at 100%, push in the Red Emergency Stop button to the off position at the TCON. Pull out the red Emergency Stop button back to the on position. 17 Click on the Exit button and then the Application icon. 19 When prompted, select Level 2, enter SG81355 for the password and select Accept. 20 Enter the parameters that were recorded in steps Push in the red Emergency Stop button to the off position at the PCON and disconnect the DB9 cable from the PCON PCB. 22 Close the platform control box and securely tighten the retaining fasteners. Calibrate the machine. Refer to Repair, How to Fully Calibrate the Machine in the appropriate Service and Repair Manual for your machine, Z-135/70 models: Note: Refer to the 2 Point Calibration attached to these instructions to calibrate the Primary Boom, Secondary Boom and Jib Boom angle sensors. ZX-135/70 models: Note: Refer to the 2 Point Calibration attached to these instructions or in the appropriate Service Manual or Service and Repair Manual for your machine to calibrate the Primary Boom, Secondary Boom and Jib Boom angle sensors. Part No Software Update 19

20 2 Point Calibration Note: Use this procedure for software versions 4.01 and higher. Note: The angle sensor calibration values will not be saved correctly unless the key switch is in the bypass position and the calibration toggle switch is activated. Note: The chassis X and Y Tilt and Axle sensors must be calibrated before calibrating the angle sensors. Note: Refer to the appropriate service manual of your machine for procedures to calibrate individual angle sensors - Secondary Boom Angle Sensor, Primary Boom Angle Sensor and Jib Boom Bellcrank angle Sensor. Note: Use the following chart to identify the description of each LCD screen control button used in this procedure. Plus Minus Previous Enter 1 Fully extend the axles with the boom in the stowed position. 2 Raise the jib boom to a slightly less than horizontal position. 3 Push in the ground controls red Emergency Stop button to the off position. Do not turn the key switch to the off position. 4 Open the ground control box. 5 Locate the calibration toggle switch at the top of the ground control box. Activate calibration mode by moving the toggle switch in the left direction. 6 Temporarily install a control box door retaining fastener between the door and the box to prevent the control box door from moving the toggle switch while calibrating the machine. 7 Remove the key from the main key switch. Insert the key into the bypass/recovery key switch and turn it to the bypass position Run 2 Bypass 3 Recovery 8 Press and hold the enter button on the ground control panel while pulling out the ground controls red Emergency Stop button to the on position. Hold the enter button for approximately 5 seconds and then release it. 9 Enter sensor calibration mode by pressing the buttons at the ground controls in the following sequence: (plus)(enter)(enter)(plus). 10 Press the enter or previous button on the LCD screen until DELETE SECONDARY BOOM ANGLE SENSOR CALIBRATION is displayed. 11 Lower the secondary boom to the stowed position. 12 Press the enter or previous button on the LCD screen until SECONDARY BOOM FULLY LOWERED is displayed. 20 Software Update Part No

21 13 Press the plus button to select YES, then press the enter button to accept. 14 Press the enter or previous button on the LCD screen until DELETE PRIMARY BOOM ANGLE SENSOR CALIBRATION is displayed. 15 Lower the primary boom to the stowed position. 16 Press the enter or previous button on the LCD screen until PRIMARY BOOM FULLY LOWERED is displayed. 17 Press the plus button to select YES, then press the enter button to accept. 18 Press the enter or previous button on the LCD screen until DELETE JIB LEVEL ANGLE SENSOR CALIBRATION is displayed. 19 Press and hold the platform level up button to fully extend the jib level cylinder until it stops at the end of the cylinder stroke. 20 Press the enter or previous button on the LCD screen until JIB LEVEL CYLINDER FULLY EXTENDED is displayed. 21 Press the plus button to select YES, then press the enter button to accept. 22 Press and hold the platform level down button to fully retract the jib level cylinder until it stops at the end of the cylinder stroke. Note: The jib will need to be raised to prevent the platform from hitting the ground while fully retracting the jib level cylinder. 23 Press the enter or previous button on the LCD screen until JIB LEVEL CYLINDER FULLY RETRACTED is displayed. 24 Press the plus button to select YES, then press the enter button to accept. 25 Fully raise the secondary boom until it stops at the end of the cylinder stroke. 26 Press the enter or previous button on the LCD screen until SECONDARY BOOM FULLY RAISED is displayed. 27 Press the plus button to select YES, then press the enter button to accept. 28 Fully raise the primary boom until it stops at the end of the cylinder stroke. 29 Press the enter or previous button on the LCD screen until PRIMARY BOOM FULLY RAISED is displayed. 30 Press the plus button to select YES, then press the enter button to accept. 31 Press and hold the engine start button for approximately 5 seconds to shut off the engine and to save the calibration settings. Note: Do not turn the engine off with the key switch or red Emergency Stop button or all calibration points or values will not be saved. 32 Press the enter or previous button on the LCD screen until EXIT is displayed. 33 Press the plus button to select YES, then press the enter button to accept. 34 Turn the key back to the run position and remove the key from the bypass/recovery key switch. Insert the key into the main key switch and turn it to ground controls. Note: Be sure that the bypass/recovery key switch is in the run position before attempting to operate the machine. 35 Wait approximately 20 seconds and turn the machine off by pressing the red Emergency Stop button in. 36 Remove the fastener that was temporarily installed. Close the control box door and install the door retaining fasteners. Note: When the control box door is closed, the calibration toggle switch is automatically activated to exit out of calibration mode. 37 Pull out the red Emergency Stop button. Start the engine and lower the boom to the stowed position. Be sure there are no calibration faults shown on the display. Part No Software Update 21

22 Machine Parameters Tilt Angle Matrix Gains -90 Deg Sensor Gain 30 Deg Sensor Gain 150 Deg Sensor Gain Offset Gain Gains to calculate X-axis tilt Gains to calculate Y-axis tilt Gains to calculate tilt error Primary Boom Ext/Ret Valve Extend Retract Output Min (Thresholds) Output Max (2500mA) Primary Boom Ext/Ret Data Extend Speed (%): Extend ramp time (sec): Retract Speed (%): Retract ramp time (sec): Primary Boom Up/Down Valve Up Down Output Min (Thresholds) Output Max (2500mA) Primary Boom Up/Down Data Up Speed Not Retracted (%): Up Speed Retracted (%): Down Speed Not Retracted (%): Down Speed Retracted (%): Dual Down Speed Not Retracted (%): Dual Down Speed Retracted (%): Dual Up Speed Not Retracted (%): Dual Up Speed Retracted (%): End of stroke ramp Angle (deg): Minimum Command (%): Secondary Boom Ext/Ret Valve Extend Retract Output Min (Thresholds) Output Max (2500mA) Secondary Boom Up/Down Valve Extend Retract Output Min (Thresholds) Output Max (2500mA) Secondary Boom Up/Down Data Dual Down Speed Not Retracted (%): Dual Down Speed Retracted (%): Dual Up Speed Not Retracted (%): Dual up speed Retracted (%): Extend Speed (%): Retract Speed (%): End of stroke ramp Angle (deg): Min Command (%): Extend valve off time (sec): Retract ramp time (sec): Turntable Rotate Valve CW CCW Output Min (Thresholds) Output Max (2500mA) Turntable Rotate Data Speed Retracted (%): Speed Extended (%): Speed Not Retracted (%): 22 Software Update Part No

23 Part No Software Update Propel Valve Forward Reverse Output Min (Thresholds) Output Max (2500mA) Propel Data Forward Speed Extended (%): Forward Speed Not Stowed (%) Forward Speed Low (%): Forward Speed High (%): Reverse Speed Extended (%): Reverse Speed Not Stowed (%): Reverse Speed Low (%): Reverse Speed High (%): Steer Neutral (mv) Neutral (mv) Front Left Angle Sensor Front Right Angle Sensor Rear Left Angle Sensor Rear Right Angle Sensor Jib Up/Down Data Up Speed Not Retracted (%): Up Speed Retracted (%): Down Speed Not Retracted (%): Down Speed Retracted (%): Machine Configuration Machine Model Drive Lights Engine Model Steer Mode selection disabled w/ driving Language Rocker Switch Steering System of Units Proximity Kill Switch Generator Platform Overload Sensing Alarm Platform always level to gravity Lift/Drive Axle motion only while driving Chassis Tilt Cutout Boom limit option Work Light Antistall settings option Flashing Beacon Pump Current option Platform Level Valve Up Down Output Min (Thresholds) Output Max (2500mA) Platform Level Data Manual Speed, Up (%): Manual Speed, Down (%): Jib Level Valve Retracted Extended Output Min (Thresholds) Output Max (2500mA) Jib Valve Up Down Output Min (Thresholds) Output Max (2500mA) Part No Software Update 23