Part Number: 101436

Description: Genie Software Matrix

Revision: W
Revision Description: added all stage5 machines, new model Z45FE, ALC1000 kernel

Machine Software (Click a link or use the Tabs at the bottom of the page)

Z33 Z40 Z45/25IC

Z45XC-LoadSense Z45FE Z51M

Z62 Z80 Z135

S40/S45 S60/S65 S60X/S65

S80/S85 S80/S85-2008

SX105 XC SX125 XC SX135 XC

Contact Alarm CAN Gateway and SX Welder Module

WebGPI Instructions

WebGPI Application Install Program Procedure

Boot File Download

Kernel File Download

PDA XML File Installation

PDA HEX File Installation

WebGPI Application Interface Procedure

Plus+1 Instructions

Connecting to S60HC Plus+1 Modules in the field (after S/N 14191)

Obtaining Plus+1 Service and Diagnostic Tool

Connecting to Plus+1 on S60HC

Updating Plus+1 software on S60HC

Connecting to Plus+1 on Z40

Definitions:

Model – Machine model and control module (if applicable)

SER. # – Serial number of the first machine to include listed software (if available).

Inc. Date – Incorporation date for the software or hardware change/release (if available).

Hardware Assembly Part # – Genie part number for the control board with the software loaded with th

Software Revision – Revision level of the software.

Microcontroller Type – The type of processor on each control board. This is used when downloading

PC Install Program – Self-extracting files that install the needed files onto your PC/laptop for use with
The WebGPI program can be ordered from Genie service parts department.

Boot File – This HEX file is needed on some control boards to load the kernel.

Kernel File – This HEX file setups up the Microcontroller to accept the application program.

PDA xml File – The xml file is used with a Palm handheld and WebGPI-PDA program to display and a
board using the PDA screen. The WebGPI-PDA program can be ordered from Genie service parts de

WebGPI/WebGPI-PDA Application File – This HEX file holds all the values for the valve thresholds, va
by the control board. This file is what that the board uses to control the boom functions.

Backward Compatible – The software shown in this column is backward compatible with machine ser
can be downloaded to an older machine without new hardware or wiring. This does not guarantee tha
saved.
Applicable Engines – The engine selections available in the software that the column covers.

Cat5 Cable - An electrical cable used to connect one electronic device to another for signal routing.

Web Browser - A software application for retrieving, presenting, and traversing information resources.
Explorer, Google Chrome and Mozilla Firefox. This is the software used to view the service tool appli
SmartLinkTM- This is the name of the new control systems developed totally in house by the Terex AW
will display the smartLinkTM logo helping to identify the type of control system on the machine.
 <img src="genie_logo_white.png" alt="Genie" width="200" height="94">

E, ALC1000 kernel

of the page)

Z45M Z45-2012

Z60 Z60-37 DC-FE

S60HC S60FE

SuperBoom Shipyard Boom

SX150 SX180

Engine Display

WebGPI PDA Application Interface Procedure

WebGPI Kernel Download Procedure

WebGPI Application Download Procedure

WebGPI Application Download Procedure for ALC500 Gen II PCB

WebGP-PDA Application Download Procedure

Updating Plus+1 software on Z40

Z40 Rev A to Rev C Upgrade Info

 Z40 Rev B to Rev C Software Upgrade Info and Procedure

Z40 Rev C to Rev D Software Upgrade Info and Procedure

Plus One installation instructions (Printable Version)

available).

ase (if available).

th the software loaded with the defined Software Revision.

is is used when downloading boot files, kernel files, or application files.

o your PC/laptop for use with the WebGPI program for that software application.
ment.

kernel.

pplication program.

PDA program to display and adjust the application information on the control
ed from Genie service parts department.

ues for the valve thresholds, valve max output, propel, and all functions controlled
boom functions.

compatible with machine serial numbers that the column covers. This software
. This does not guarantee that calibration parameters will be automatically

at the column covers.

o another for signal routing.

versing information resources. Common types include Microsoft Internet

d to view the service tool application on smartLink TM machines.
ally in house by the Terex AWP Controls Engineering Team. Machine hardware
stem on the machine.
MODEL SER. # Incorp. Date Hardwar Software Micro Compiled Control Service & Diagnostic Backward Comments
e Version Controller Program File Application File {for compatible
Assembly Type Plus1 (*.lhx) Zapi adjusting parameters
Part # (*.h86) and troubleshooting}
(*.p1d)

Z33 Z331815B - 101 10/20/2014 1256909 revA Plus1 1261180A 1297822A yes release notes N/A
TCON
Z331815B - 274 5/14/2015 revB 1261180B
Z331815B - 470 9/9/2015 revC 1261180C
Z331816M - 10/6/2015 revD 1261180D
556
from 7/15/2019 revE 1261180E
Z331816M-947
to Z3318M-
2668 and
Z331816M-919,
Z331816M-923,
Z331816M-926,
Z331816M-929,
Z331816M-933,
Z331816M-934,
Z331816M-937,
Z331816M-938
Z331816M-919
Z3318M-2669 7/12/2019 revF 1261180F Z33 SOFTWARE UPDATE (TCON/PCON ) FOR TELEMATICS. FOR
Z3318M-2801 10/21/2019 revG 1261180G 1294744
new ANSI ( SOFTWARE COMMON SPEC) ECO RE. 190092B7
features
10/12/2020 revH 1261180H Support for Genie Access Manager solution,Added Genie Tech Pro Link
support for active faults and fault history visualization
Z3318M-3361 2.6.0 1314760-2.60 Software version changed to semantic, Integrated Contact Alarm support
3/18/2022 (Amber lights) White Noise speaker support,Improved battery discharge
user experience
2.6.1 1314760-2.61 Color display support. In case of Platform box replacement with a newer
1/11/2022 one, machine configures itself accordingly, Improved GPM calibration
repeatability, Improved service tools page with integrated contact alarm.

Z33 Z331815B - 101 10/20/2014 revA Plus1 1261181A N/A

PCON
Z331815B - 274 5/14/2015 revB 1261181B

Z331815B - 470 9/9/2015 revC 1261181C

 Z331816M - 10/6/2015 revD 1261181D
556
from 7/15/2019 revE 1261181E
Z331816M-947
to Z3318M-
2668 and
Z331816M-919,
Z331816M-923,
Z331816M-926,
Z331816M-929,
Z331816M-933,
Z331816M-934,
Z331816M-937,
Z331816M-938
Z331816M-919
Z3318M-2669 7/12/2019 revF 1261181F
Z3318M-2801 10/21/2019 revG 1261181G
10/12/2020 revH 1261180H
Z3318M-3361 3/18/2022 2.6 1314760-2.60
1/11/2022 2.6.1 1314760-2.61
MODEL SER. # Incorp. Hardwar Software Micro Compiled Control Service & Diagnostic Backward Comments
Date e Version Controller Program File Application File {for compatible
Assembly Type Plus1 (*.lhx) Zapi adjusting parameters
Part # (*.h86) and troubleshooting}
(*.p1d)

Z40 104 04.04.07 110989 Rev A Plus+1 110985A 128571A 110985A Only for use with Rev. A TCON/PCON software.
TCON (Note: Software download procedure similar to S60HC, see links below)
133 07.12.07 Rev B 110985B 110985E Requires Rev B AC Motor Controller Software. See Z40 Rev B to Rev C
425 01.21.08 Rev C 110985C Upgrade Info and Z40 Rev A to Rev C Upgrade Info
1275 07.06.11 Rev D 110985D 230797A Requires 230797A service tool to view Z40 Rev D diagnostics. See
Obtaining Plus+1 Service and Diagnostic Tool and Z40 Rev C to Rev D
2537 02.24.14 Rev E 110985E Upgrade
Update toInfo
coil resistance fault
2762 11.25.14 1256894 Rev A 1256900A 1256910 1256900E Initial release of GEN 2 Controller hardware update.
-Includes EN280:2013 updates
-Requires GEN 2 PCON controller
5752 09.19.19 Rev C 1256900C 1297822A Diagnostic fault code updates, tech pro link capabilities and download,
Telematics
Rev D 1256900D 1297822B 2019 Ansi Support, parameter management, fault code management
Z40NF-6557 (pre-prod), 08.19.21 Rev E 1256900E 1297822C Telematics Access Manager, Tech Pro Link fault display, Calibration
Z40NF-6574 improvement

Z40 104 04.04.07 110990 Rev A Plus+1 110986A 128571A 110986A Only for use with Rev. A TCON/PCON software.
PCON (Note: Software download procedure similar to S60HC, see links below)
133 07.12.07 Rev B 110986B 110986E Requires Rev B AC Motor Controller Software. See Z40 Rev B to Rev C
425 01.21.08 Rev C 110986C Upgrade Info and Z40 Rev A to Rev C Upgrade Info
1275 07.06.11 Rev D 110986D 230797A Requires 230797A service tool to view Z40 Rev D diagnostics. See
Obtaining Plus+1 Service and Diagnostic Tool and Z40 Rev C to Rev D
2537 02.24.14 Rev E 110986E Upgrade
Update toInfo
coil resistance fault
2762 11.25.14 1256897 Rev A 1256908A 1256910 1256900E See TCON
5752 09.19.19 Rev C 1256908C 1297822A See TCON
Rev D 1256908D 1297822B See TCON
Z40NF-6557 (pre-prod), 08.19.21 Rev E 1256908E 1297822C See TCON
Z40NF-6574

Z40 AC 104 04.04.07 110665 Rev 16 Zapi 128053A Use only with Rev A TCON/PCON Software
Master 133 07.12.07 Rev B 128053B Use only with Rev B, Rev C or Rev D TCON/PCON Software

Z40 AC 104 04.04.07 110665 Rev 16 Zapi 128054A Use only with Rev A TCON/PCON Software
Slave 133 07.12.07 Rev B 128054B Use only with Rev B, Rev C or Rev D TCON/PCON Software
 MODEL SER. # Incorp. Hardware Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Date Assembly Version Controller Program (.hex file (.hex) (view/adjust WebGPI- compatible
Part # Type (.exe) used for program on board PDA
Kernel File with PDA) Application
Download) File (.hex)

Z45/25 21180 10.10.02 89353 V2.04 HC12 S0513204 N/A L0082101 S0513204_PDA S0513222 DF31011F V2.04 improves the reset to Z45N anomaly.
IC FORD EFI
21564 02.04.03 V2.22 HC12 S0513222 N/A S0513222 PDA S0513222 P404C See comment above *
22051 06.10.03 94773 V1.00 HC12 S0662100 N/A S0662100 PDA S0662100 S0662100 High current drive output and proportional directional valves, not separate
proportional and directional valves
23385 05.03.04 106348 V1.01 HC12 S0662101 N/A S0662101 PDA S0662101 S0824201 Tier II engines, add rocker steer as a pin select option. Rev. 1.02 never
DEUTZ 3CYL release to production.
27000 09.21.05 110164 V1.03 HC12 S0662103 N/A S0662103 PDA S0662103 FORD EFI Recall all default values when valid model selection jumpers are detected -
P404C Corrected the Motor Speed logic to keep the output ON during the
kSpeedShftLow state -Added an OFF delay feature for the Propel brake -
Modified several default values due to Function Manifold changed–
Modified joystick Cal values –Change Motor shift function.

30142 08.15.06 V1.04 HC12 S662104 N/A S0662104 PDA S0662104 DEUTZ 3CYL Add new 2.3L Ford engine parameters
38093 06.23.08 V1.04 HC12 S662104 N/A S0662104 PDA S0662104 FORD EFI Manually change Pulse/Rev of P404C engine from 8.9 to 10.6
P404C Rev 1.05 never release to production
FORD EFI 2.3L
38511 07.30.08 139502 V1.06 HC12 S0662106 N/A S0662106 PDA S0662106 Add Tier 3 engines, Standardized on Jumper Configuration pins (J5,J6) for
engines and models, Add low/high current propel pump option, Fixed
footswitch issue when set to lockout, Fixed footswitch water ingress
causing “Valve to low” fault.
40522 01.11.11 T110562 V1.00 164/TI S0824100 N/A N/A N/A N/A Initial Release software for ALC500 GenII PCB only, Add footswitch
Ford EFI 2.5L priority
42621 09.29.11 235473 V2.00 164/TI S0824200 N/A N/A N/A N/A Perkins 404C Nuisance Fault GenII - Monitor added to detect floating ground.
Ford EFI 2.3L - Corrected VBatt calculation.
Deutz 2011L03 - Kernel application layer changed to correct random changes to 60%
Perkins 404D current output.
- Fixed Drive Enable operation while transitioning through joystick
neutral.
- Fixed issue with footswitch not forcing timeout when held on startup.
(ecn#11670b)

N/A 09.11.12 V2.01 164/TI S0824201 N/A N/A N/A N/A Ford EFI 2.5L Added Ford MSG 2.3L engine option
Perkins 404C
Ford EFI 2.3L
Deutz 2011L03
Perkins 404D
Ford MSG 2.5L
MODEL SER. # Incorp. Hardware Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Date Assembly Version Controller Program (.hex file (.hex) (view/adjust WebGPI- compatible
Part # Type (.exe) used for program on board PDA
Kernel File with PDA) Application
Download) File (.hex)

Z45M 101 03.29.07 110164 V1.04 HC12 S0662104 N/A L0082101 S0662104 PDA S0662104 S0824201 DEUTZ 3CYL Add new 2.3L Ford engine parameters
FORD EFI
P404C
FORD EFI 2.3L
1423 07.31.08 139502 V1.06 HC12 S0662106 N/A S0662106 PDA S0662106 -Add Tier 3 engines, Standardized on Jumper Configuration pins (J5,J6)
for engines and models, Add low/high current propel pump option, Fixed
footswitch issue when set to lockout, Fixed footswitch water ingress
causing “Valve to low” fault.
Rev 1.05 never release to production

Ford EFI 2.5L

1738 03.05.11 T110562 V1.00 164/TI S0824100 N/A N/A N/A N/A Perkins 404C -Initial Release software for ALC500 GenII PCB only
Ford EFI 2.3L -Add footswitch priority
Deutz 2011L03
2179 09.19.11 235473 V2.00 164/TI S0824200 N/A N/A N/A N/A Perkins 404D -Nuisance Fault GenII - Monitor added to detect floating ground.
Ford MSG 2.5L - Corrected VBatt calculation.
- Kernel application layer changed to correct random changes to 60%
current output.
- Fixed Drive Enable operation while transitioning through joystick
neutral.
- Fixed issue with footswitch not forcing timeout when held on startup.
(ecn#11673b)

N/A 09.11.12 V2.01 164/TI S0824201 N/A N/A N/A N/A Ford EFI 2.5L -Add Ford MSG 2.3L engine option
Perkins 404C
Ford EFI 2.3L
Deutz 2011L03
Perkins 404D
Ford MSG 2.5L
MODEL SER. # Incorp. Hardware Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Date Assembly Version Controller Program (.hex file (.hex) (view/adjust WebGPI-PDA compatible
Part # Type (.exe) used for program on board Application
Kernel File with PDA) File (.hex)
Download)

Z45-2012 47001 12.10.12 218530 V1.00 164/TI S0844100 N/A N/A N/A N/A S0844101 Initial release
N/A 06.24.13 V1.01 164/TI S0844101 N/A N/A N/A N/A Added Tier IV Engine options
53481 01.28.15 V2.00 164/TI S0844200 N/A N/A N/A N/A S0844200 EN280 2013 UPDATE
N/A 17.07.17 V3.05 164/TI S0866301 N/A N/A N/A N/A REVISION CHANGE FOR XC PARAMETERS AND TILT CUTOUT OPTIONS. PWM
NEGATIVE VALVE FAULT CHANGE
Z4525XCF- 843 12.17.19 V3.05 164/TI S0866305 N/A N/A N/A N/A TD 2.2 Stage 5 UPDATE ALC500 SOFTWARE AND SAFETY CONTROLLER SOFTWARE FOR STAGE 5
ENGINES AND Z-45 HF
Z4525XCF- 1501 16.07.20 V3.06 164/TI S0866306 N/A N/A N/A N/A TD 2.2 Stage 5 Fixed the issue on forcing low drive speed at stage V warming level 2 and above.
Fixed WebGPI issue of missing an element on Boom Run 1 & 2 screens.
“Cutout Drive/Lift” be the default selection for Tilt Cutout option at ANSI or
Australia market
S0866309

Z4525XCF-1664 04.14.21 V3.07 164/TI S0866307 N/A N/A N/A N/A Added Lift Guard Sensing solution, Added new engine model Kubota D1105 and
restructured antistall parameters in memory. Set warning level 3 if CAN bus is
lost or received warning level is out of range.

Z4525XCF-1848 1/18/2022 V3.08 164/TI S0866308 N/A N/A N/A N/A ASNI A92 release. Lift functiOn priority
Z4525S-6949 11/16/22 V3.09 164/TI S0866309 N/A N/A N/A N/A Manual Platform level blocked out f stow, Tilt Cutout defaults

Note: Booms feturing Electronic Engines have also a ground display EngineDisp
Note: refer to the following page for Load sense safety controller Z45.25 XC'
MODEL SER. # Incorp. Hardware Software Micro Load Cell, Load Cell,
Date Assembly Version Controller SCON-Safety SCON-
Part # Type (LHX) Operational
(LHX)
Z45 XC 101 4.18.2017 1272806 B Plus1 1275053B 1272803B
843 11.27.2019 1272806 D Plus1 1275053D 1272803D

Note: IMPORTANT: install both Safety and operational firmwares

Note: Please refer to the following page for ALC500 Platform controller Z45-2012
Note: Booms feturing Electronic Engines feature a ground display EngineDisplay
 Comments

Initial Release
UPDATE LOAD SENSE SPEC. AND SOFTWARE FOR SINGLE CAPACITY
MODEL SER. # Incorp. Hardwar Software Micro Compiled Control Service & Diagnostic Backward Comments
Date e Version Controller Program File Application File {for compatible
Assembly Type Plus1 (*.lhx) adjusting parameters
Part # Curtis (*.doc, and troubleshooting}
*.txt) (*.p1d)

Z45FE 101 02.04.2020 1295982 A Plus+1 1294780A 1294780D Initial release

TCON
511 12.05.2020 C 1294780C Telematics improvements, improved calibrations,battery management,
1294792D GTPL fault codes
964 06.01.2022 D 1294780D Add Kohler engine, New contact alarm support, Fullriver AGM battery
support
Z45FE 101 02.04.2020 1295981 A Plus+1 1294781A See TCON
PCON
1294792D 1294781D
511 12.05.2020 C 1294781C
964 06.01.2022 D 1294781D
MODEL SER. # Incorp. Hardware Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Date Assembly Version Controller Program (.exe) (.hex file (.hex) (view/adjust WebGPI- compatible
Part # Type used for program on board PDA
Kernel File with PDA) Application
Download) File (.hex)

Z51M 101 10.03.05 110157 V1.00 HC12 S0717100 N/A L0082101 S0717100 PDA S0717100 S0826201 Deutz 3Cyl Initial release
503 08.01.08 139505 V1.02 HC12 S0717102 N/A S0717102 PDA S0717102 Add Tier 3 engines, standardized on Jumper Configuration pins (J5,J6) for
engines and models, added low/high current propel pump option, fixed
footswitch issue when set to lockout, fixed footswitch water ingress
causing “Valve to low” fault. (Rev 1.01 never release to production)
664 03.05.11 T110563 V1.00 164/TI S0826100 N/A N/A N/A N/A Ford EFI 2.3L Initial Release software for ALC500 GenII PCB only. Added footswitch
Deutz 2011L03 priority
751 12.06.11 235414 V2.00 164/TI S0826200 N/A N/A N/A N/A Perkins 404D Nuisance Fault GenII - Monitor added to detect floating ground, corrected
VBatt calculation, Kernel application layer changed to correct random
changes to 60% current output, fixed Drive Enable operation while
transitioning through joystick neutral, fixed issue with footswitch not
forcing timeout when held on startup. (ecn#11673b)
N/A 09.11.12 V2.01 164/TI S0826201 N/A N/A N/A N/A Ford EFI 2.3L Added Ford MSG 2.3L engine option
Deutz 2011L03
Perkins 404D
Ford MSG 2.5L

Note: Booms feturing Electronic Engines feature a ground display EngineDisp

Note: LEGACY PACKAGES. See Z45.25XC software V3 Z45.25 XC
MODEL SER. # Incorp. Hardwar Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Date e Version Controlle Program (.hex file (.hex) (view/adjust WebGPI- compatible
Assembly r Type (.exe) used for program on PDA
Part # Kernel File board with PDA) Application
Download) File (.hex)

Z60 4001 08.12.02 89353 V2.00 HC12 S0513200 N/A L0082101 S0513200_PDA S0513200 S0513222 Rev. 2.00 and above is capable of high current drive output. Should be
Deutz DF31011F upgraded to Rev. 2.22
V2.04 S0513204 S0513204_PDA S0513204 Ford EFI Rev. 2.04 improves the reset to Z45N anomaly
4169 02.02.03 V2.22 S0513222 S0513222_PDA S0513222 Perkins P404C Rev. 2.22 corrects reset to Z45N and is backward compatible for all 89353
applications
4551 04.08.04 102750 V1.00 S0690100 S0690100_PDA S0690100 S0690103 Deutz 3cyl Separated from S0513222 and is now a low current drive pump
6107 06.03.06 V1.01 S0690101 S0690101_PDA S0690101 Ford EFI Add brake release when steer, brake off delay, rocker steer as a pin
Perkins P404C selection option
6388 08.10.06 V1.02 S0690102 S0690102_PDA S0690102 Deutz 3cyl Add new 2.3L Ford engine parameter choice and Hi / Low Current drive
Ford EFI pump options
Perkins P404C
Ford EFI 2.3L
9699 11.24.08 122924 V1.03 S0690103 S0690103_PDA S0690103 Deutz 2011L03
Perkins 404C Add Tier 3 engines, standardized Jumper Configuration pins (J5,J6) for
Perkins 404D engines and models, added low/high current propel pump option, fixed
Ford EFI 2.5L footswitch issue when set to lockout, fixed footswitch water ingress
Ford EFI 2.3L causing “Valve to low” fault
10179 11.08.10 T110571 V1.00 164/TI S0825100 N/A N/A N/A S0825201 Ford MSG 2.5L Initial Release software for ALC500 GenII PCB ONLY, added footswitch
priority
10813 09.25.11 235476 V2.00 S0825200 Fixed issue with footswitch not forcing timeout when held on startup.
- Convert from prototype WebGPI library to 3.10 released library.
- Nuisance Fault GenII - Monitor added to detect floating ground.
- Corrected VBatt calculation.
- Kernel application layer changed to correct random changes to 60%
current output.
- Fixed Drive Enable operation while transitioning through joystick
neutral.
N/A 07.18.12 V2.01 S0825201 DEUTZ 2011L03 Added Ford MSG 2.3L engine option
PERKINS 404C -corrected High Current Drive pump defaults
PERKINS 404D -widened resistance fault values for low current drive pump
FORD EFI 2.3L
FORD MSG 2.5L
MODEL SER. # Incorp. Hardwar Software Micro Compiled Control Service & Diagnostic Backward Comments
Date e Version Controller Program File Application File {for compatible
Assembly Type Plus1 (*.lhx) adjusting parameters
Part # Curtis (*.doc, and troubleshooting}
*.txt) (*.p1d)

Z60-37 101 TBD 1269369 A Plus+1 1269406A Initial release

TCON 660 10/4/2016 C 1269406C Correction for CE market compliance
2193 6/10/2019 E 1269406E Genie LiftConnect & GTPL
2422 6/1/2020 F 1269406F Limit retracted Cylinder pressures, adjust footswithc timeout, displau
adjustments, telematics update CE update
Z60H-2523 4/5/2019 G 1269406G 1299992D 1269406J ANSI compliance, Battery Management,GTPL support, minor updates
Z60M-294 6/6/2020 H 1269406H Telematics Improvements, Trojan Battery Support, mproved Calibration,
Z60H-2565 Improved Dirve Smoothness, minor updates
Z60M-544 4/13/2021 J 1269406J Smoother speed reduction, battery low voltage protection default, minor
Z60H-2793 updates
11/11/2021 1313503 2.01 1310415-2.01 1310419-2.01 1310415-2.03 Brake Dissipation, Dual output motor controllers,largertcon controller,
Z60E-3101 permanent magnet AC pump/drive motor, Telematics, other improvements
Z60M-1000 1/31/2022 1313504 2.03 1310415-2.03 1310419-2.03 Rough Terrain Energy Efficiency, Undervoltage improvements
Z60H-3187
Z60-37 101 TBD 1269368 A Plus+1 1269405A See TCON
PCON 660 10/4/2016 C 1269405C
2193 6/10/2019 E 1269405E
2422 6/1/2020 F 1269405F
Z60H-2523 4/5/2019 G 1269405G 1299992D 1269405J
Z60M-294 6/6/2020 H 1269405H
Z60H-2565
Z60M-544 4/13/2021 J 1269405J
Z60H-2793
Z60E-3101 11/11/2021 1313503 2.01 1310415-2.01 1310419-2.01 1310415-2.03
Z60M-1000 1/31/2022 1313504 2.03 1310415-2.03 1310419-2.03
Z60H-3187
Z60-37 AC 101 TBD 1263937 B Curtis 1264375A 1264375A Initial release
Traction 147 1264375B

Z60-37 AC 101 TBD 1263938 A Curtis 1264376A 1264376A Initial release

Pump-Gen 147 1264376B
 MODEL SER. # Incorp. Hardware Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Date Assembly Version Controller Program (.hex file used (.hex) (view/adjust WebGPI-PDA compatible
Part # Type (.exe) for Kernel program on board Application
File with PDA) File (.hex)
Download)
Z62 Z62H-101 08.21.14 824665 V1.00 164/TI S0848100 N/A N/A N/A N/A S0848107 Deutz 2011L03 Initial release
Perkins 404C
Perkins 404D
Ford EFI 2.5L (OBS)
Ford DSG 423
Ford MSG 425

Z62H-4056 V1.01 S0848101 Perkins Perkins Release

Z62H-4653 06.12.19 V1.02 S0848102 Deutz Stage 5 Z62 SOFTWARE FOR ANSI RECERTIFICATION
Z62D-632
Z62H-4653 04.30.20 V1.03 S0848103 Added Lift Guard Sensing solution.
Z62H-5056 10.20.20 V1.04 S0848104 Updated the parameters for high current drive pump.
Z62D-842
Z62M-1622 02.24.21 V1.05 S0848105 Update anti-stall defaults for Deutz TD2.2.Set default "No" for lift guard
option. Set "Yes" for lift guard option automatically if lift guard sensing is
detected on CAN bus. Set warning level 3 if CAN bus is lost or received
warning level data is out of range.
Z62H-4850 03.27.21 V1.06 S0848106 Disable platform level for all market selections if any boom function is
Z62M-1744 activated out of stowed.
Z62D-943 04.12.22 V1.07 S0848107 Update anti-stall defaults for Deutz T2.9. Add new engine model Weichai
Z62M-1909 WP3.2.

Note: Booms feturing Electronic Engines feature a ground display EngineDisp

MODEL SER. # Incorp. Date Hardware Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Assembly Version Controller Program (.hex file used (.hex) (view/adjust WebGPI-PDA compatible
Part # Type (.exe) for Kernel program on board Application
File with PDA) File (.hex)
Download)

Z80 101 05.16.02 88055 V1.00 167 S0555100 L0068317 L0060317 S0555100_PDA S0555100 S0555103 Controls set up for prEN280 load sense
TCON - - 94609 V1.01 S0555101 S0555101_PDA N/A Improved leveling. EN280 load sense, used in Europe
258 08.19.03 94946 V1.02 S0555102 S0555102_PDA S0555102 Added one second delay to load sense
454 06.16.04 102410 V1.03 S0555103 S0555103_PDA S0555103 Tier II and 12.5kW welder option
928 05.16.06 111627 V1.04 S0555104 S0555104_PDA S0555104 S0555104 Activate Dual Motion, change parameters, Hi/Low generator package
2501 11.30.09 146356 V1.05 S0555105 S0555105_PDA S0555105 S0555105 Deutz 2011L04i Added Tier III engines
Perkins 804T Steer hunting corrected
Continental TME27 Footswitch Priority
GHG10 Generator added
Prox Kill and Load Sense function separated
Deutz oil PSI shutdown 22psi
Fixed Generator 2 spd motor stroke

2511 01.05.10 146396 V2.00 S0814200 N/A N/A S0814206 Deutz 2011L04i Hardware change, cannot use on older machines
Perkins 804T Safety limit switch monitoring
Continental TME27 Removed Tier II engine
Second window added before resetting all defaults
Load sense system has input to TCON for redundancy
Europe/USA antistall option added
Plat Level threshold auto calibration

4088 02.12.13 219420 V2.02 S0814202 Add load sense options for Australia: Warn, cutout platform, cutout all,
partial operations
4987 08.05.14 V2.03 S0814203 Deutz -Tier IV Engine functionality – CAN Gateway/Display
BF4L2011L04i -New engine option picks – Deutz 2.9T, Perkins 404T
Perkins 804 -Display module to include Perkins regeneration functionality and DPF
Continental TME27 soot% (for Perkins 404T only)
Deutz 2.9T -Tier IV Engine Anti-stall parameters
Perkins 404F -Tier IV Generator functionality

L0068341 L2--60341 Updated Kernel and Boot file for flash memory change on TCON PCB
5306 12.04.14 V2.04 S0814204 ABOVE + Perkins 404D ENGINE OPTION
Perkins 404D EN280:2013 Release.
6086 04.21.16 V2.05 S0814205 GM 3.0L Added GM 3.0L engine
6186 7.11.16 V2.06 S0814206 Added Fuel Level Sensor functionality
7557 7.22.19 V3.00 S0814300 S0814302 Added Lift Connect functionality. Joystick autocalibration.
7733 05.21.20 1296392 V3.01 S0814301 L0060345 Stage V ANSI/CSA Certification – Drive/Lift Tilt Cutout, Load Switch
Deutz 2.2 Stage V Engine – RPM, DPF Regeneration, EOL Test,
Functionality, Messaging,
Fault Handling
 Z80 101 05.16.02 88052 V1.00 HC08A S0556100 L0087100 L0099101 S0556100_PDA S0556100 S0556102 Controls set up for prEN280 load sense
PCON - - 94610 V1.01 S0556101 L0099102 S0556101_PDA N/A Improved leveling. EN280 load sense, used in Europe
258 08.19.03 94947 V1.02 S0556102 S0556102_PDA S0556102 Added one second delay to load sense
928 06.16.04 111628 V1.04 S0556104 S0556104_PDA S0556104 S0556104 Activate Dual Motion, change parameters, Hi/Low generator package
2501 11.30.09 146358 V1.05 S0556105 S0556105_PDA S0556105 S0556105 Added Tier III engines
Steer hunting corrected
Footswitch Priority
GHG10 Generator added
Prox Kill and Load Sense function separated
Deutz oil PSI shutdown 22psi
Fixed Generator 2 spd motor stroke

2511 01.05.10 146394 V2.00 S0815200 N/A N/A S0815205 Hardware change, must be used with TCON V2.00, cannot be used on
older machines
Safety limit switch monitoring
Removed Tier II engine
Second window added before resetting all defaults
Load sense system has input to TCON for redundancy
Europe/USA antistall option added
Plat Level threshold auto calibration

4088 02.12.13 219422 V2.02 S0815202 Add load sense options for Australia: Warn, cutout platform, cutout all,
partial operations
4987 08.05.14 V2.03 S0815203 Lowered Jib Up/Down Minimum Fault Current
Tier IV
5306 12.04.14 V2.04 S0815204 -EN280 Regulatory changes
-Perkins 404D engine option
6086 04.21.16 V2.05 S0815205 Fixed issue with uninitialized variables
7733 05.21.20 219423 V3.01 S0815301 S0815301 Stage V ANSI/CSA Certification – Drive/Lift Tilt Cutout, Load Switch
Deutz 2.2 Stage V Engine – RPM, DPF Regeneration, EOL Test,
Functionality, Messaging,
Fault Handling

Z80 101 05.16.02 50154 V1.01 HC08 S0279101 L0069000 L0047304 N/A N/A S0279101 Initial release
DCON 258 08.19.03 94946 V1.02 HC08A S0613102 L0087100 L0090400 S0613102 Same functions as S0279101 software except used on HC08A
microcontroller
MODEL SER. # Incorp. Hardwar Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Date e Version Controlle Program (.hex file (.hex) (view/adjust WebGPI- compatible
Assembly r Type (.exe) used for program on PDA
Part # Kernel File board with PDA) Application
Download) File (.hex)

Z135 101 3.30.05 101002 V1.00 167 S0675100 L0068317 L0113100 N/A N/A S0675203 Initial release
TCON 471 01.02.07 119789 V1.11 S0675111 The software fixes the following problems:
Duetz engine temperature shutdown changed from 248 deg F to 275 deg F
Corrected recovery circuit to lower the platform to ground
Disable steer mode change while driving not works.
Added three level password to SCON.
Use aux hyd pump to get out of platform overload conditions
the boom cannot be operated with the SCON uncalibrated
Improved error message handling
Eliminated the P12 axle fault message.
1154 12.31.09 139645 V2.00 S0675200 Tier III engines added
Deutz low oil psi changed to 22
LSS1RS/LSS1RO monitoring
Platform Leveling parameters
GHG10 gen added
Load sense and prox kill function separated
N/A N/A 227202 V2.01 S0675201 *NOT RELEASED*
-Added function disables for Platform Rotate, Jib Ext/Ret, Steer, Brake and
Axle functions with valve faults present.
-Fixed the issue of high current pump setting.
-Added missing field in language strings for propel.
-Added Force Neutral for Jib Ext/Ret and Platform Rotate from fault
recovery.
-Changed Axle input default settings.
1571 09.20.11 V2.02 S0675202 Must be used with SCON version 2.00 and PCON version 2.01
-Modified engine state machine to only allow high idle 3 seconds after
starting engine.
-Alarms added for SEVERAL faults
-Engine start is no longer allowed during self-test.
-Modifications to Autoshift function.
-Allow Rabbit or Turtle selection in service bypass mode.
-Steering is now disabled during Proximity cutout and Overload
conditions.
-Added function disables for Platform Rotate, Jib Ext/Ret, Steer, Brake and
Cummins B3.3T -Axle functions with valve faults present.
N/A N/A V2.03 S0675203 Add load sense options for Australia: Warn, cutout platform, cutout all,
Deutz 2011L04i partial operations
Perkins 804T
 Cummins B3.3T
Deutz 2011L04i
Perkins 804T
1712 04.25.12 237071 V3.00 S0827300 S0827312 - Alarms added for P7R, P6R1 and P6R2 faults.
- Alarm added for primary boom switches fault.
- Added Not Calibrated text display for primary or secondary boom safety
angle sensor not calibrated.
- Fixed the misplaced setting between Adjust Jib Up Speed Retracted and
Jib Up/Down Ramp Decel Rate.
- Fixed the misplaced setting between Adjust Turntable Rotate Speed
Retracted and Turntable Rotate Speed Extended.
- Two seconds off delay added when Axle is fully extended or retracted.
- Three seconds delay added for clearing error history or other memory
writing.
- Added jib up/down joystick calibration reset to TCON display menu.
- Modifications to screen text strings in English and their translation in 7
other languages.

N/A N/A V3.02 S0827302 NEVER RELEASED

N/A N/A V3.03 S0827303 Add load sense options for Australia: Warn, cutout platform, cutout all,
partial operations
N/A N/A V3.04 S0827304 CAN Bus message frame rate update
2001 01.01.13 V3.05 S0827305 Added ZX135 option for new drive chassis
2363 06.09.14 V3.06 S0827306 -added Tier IV engine options
-angle sensor active crosschecks
-other software enhancements
L068341 L0113116 Updated Kernel and Boot file for flash memory change on TCON PCB
2559 11.25.14 V3.07 S0827307 EN280:2013 Release.
- - - V3.12 S0827312 Legacy Release. LSS1RO/1RS Improvements, Valve pulsing, Machine ID
2790 11.16.15 1268774 V4.01 S0857401 S0857504 2-Point Calibration, Loop Valves, Valve Pulsing, MachineID. MUST
ONLY BE INSTALLED ON UNITS S/N 1855 AND UP OR HAVE
HAD ANGLE SENSORS UPDATED TO NEW STYLE
2946 06.27.16 V4.02 S0857402 Above + Fuel Level Sensing, LSS1RO/1RS Improvements, Menu updates
3229 11.16.16 V4.11 S0857411 Deutz 2.9 Axle retract enable valve, Incorrect SPN for Tier IV DM1 fixed, Debounce
Perkins 854 for secondary angle between up ramp zone and raised zone, self-recovery
for LSS interlock
3229 3.20.17 V4.12 S0857412 Fixed processor locking up on startup.
4001 4.14.17 V4.20 S0857420 New mini X-Chassis selection for steering and axle sensors, new dynamic
load sense option, selection for load sense evidence of use, additional lift
drive tilt cutout option
4472 3.25.19 V5.00 S0857500
Added Lift Connect solution. Changed overload functionality. Pulsing
turntable rotate valve. Disable primary boom down in or below down
ramp zone if primary boom angle is past the minimum angle and
secondary is not fully lowered.
4645 06.12.19 V5.02 S0857502 Updated dynamic load sense functionality, updated Chassis Tilt Cutout
options for new ANSI, TT Rotate Valve pulsing removed, High drive
speed condition removed, Stage V Engine added.
 4775 02.11.21 V5.03 S0857503

Update Lift Connect functionality, especially to support Access Manager.

Remove None and Cutout Drive from Chassis Tilt Cutout option. Set
overloaded and inconsistent faults if not selecting load cell with a valid
DLC S/N saved.
Update low coolant level functionality without latching the low coolant
level fault. Add more information about load cell calibration status on
WebGPI Common Run screen and Platform Load Run screen.
Above + Remove J4-33 relay output and 5.5 second delay for AC generators
Deutz TD2.2 functionality. Allow high drive speed and axle retract in service bypass if
the stowed points of primary and secondary angles are calibrated and boom
is in lower range. Rename Deutz D2.9 to Deutz TIER IV, which applies to
Deutz TD2.2 Tier IV as well. Rename Deutz TCD2.2 to Deutz Stage V.
Apply functionalities of Water in Fuel and low Coolant level to both Deutz
TIER IV and Deutz Stage V.
5128 10.10.22 V5.04 S0857504
Update Lift Connect functionalities, including Auto detection, functions
meters, etc.
Add China Stage IV functionalities.
Replace PRC-TEL option with CHINA IV Telematics; update China
telematics function and data.
Add White Noise Alarm function.
Add solution to address TCON lock up issue.

Z135 101 03.30.05 101003 V1.00 HCS12 S0676100 N/A L0123101 N/A N/A S0676203 N/A Initial release
PCON 101 08.03.05 V1.00 L0123102 Kernal update only
471 01.02.07 V1.10 S0676110 See TCON Update description
1154 12.31.09 139646 V2.00 S0676200 See TCON Update description
1571 09.20.11 227203 V2.01 S0676201 L0123103 Must use TCON version 2.02 and SCON 2.00
- Jib U/D valve Fault Detect Current to 370mA from 850 mA
- Do not clear valve status if already in error.
N/A N/A V2.03 S0676203 add load sense options for Australia: Warn, cutout platform, cutout all,
partial operations
1712 04.25.12 237072 V3.01 S0828301 L0123104 S0828312 Modifications to load sense function. Requires new loadsense limit switch.
- Backward compatible with non-load sense machines
N/A N/A V3.03 S0828303 add load sense options for Australia: Warn, cutout platform, cutout all,
partial operations
N/A N/A V3.04 S0828304 CAN Bus message frame rate update
2001 01.01.13 V3.05 S0828305 L0123105 added ZX135 option for new drive chassis
2363 06.09.14 V3.06 S0828306 See TCON Update description
2559 11.25.14 V3.07 S0828307 See TCON Update description
- - - V3.12 S0828312 Resolved LSJ1RO faults, added Platform Level > 15 deg fault
2790 11.16.15 1268779 V4.01 S0858401 S0858504 Added Platform Level > 15 deg fault
2946 06.27.16 V4.02 S0858402 Resolved LSJ1RO faults
3229 11.16.16 V4.11 S0858411 L0123106 See TCON Update description
4001 4.14.17 V4.20 S0858420 See TCON Update description
 1268779 S0858504

L0123106

4472 3.25.19 V5.00 S0858500 See TCON Update description

4645 06.12.19 V5.02 S0858502 See TCON Update description
4775 02.11.21 V5.03 S0858503 See TCON Update description
5128 10.10.22 V5.04 S0858504 See TCON Update description

Z135 101 03.30.05 94978 V1.00 HCS12 S0677100 N/A L0125101 N/A N/A S0677203 N/A Initial release
SCON 471 01.02.07 V1.10 S0677110 See TCON Update description
1154 12.31.09 139647 V2.00 S0677200 See TCON Update description
N/A N/A V2.03 S0677203 add load sense options for Australia: Warn, cutout platform, cutout all,
partial operations
1712 04.25.12 237073 V3.00 S0829300 L0125102 S0829312 Modifications to load sense function.
- Added CAN message for primary or secondary boom safety angle sensor
not calibrated
N/A N/A V3.03 S0829303 add load sense options for Australia: Warn, cutout platform, cutout all,
partial operations
N/A N/A V3.04 S0829304 CAN Bus message frame rate update
2001 01.01.13 V3.05 S0829305 L0125103 See TCON Update description
2363 06.09.14 V3.06 S0829306 See TCON Update description
2559 11.25.14 V3.07 S0829307 No changes to SCON just version number
- - - V3.12 S0829312 See TCON Update description
2790 11.16.15 1268784 V4.01 S0859401 S0859504 See TCON Update description
2946 06.27.16 V4.02 S0859402 See TCON Update description
3229 11.16.16 V4.11 S0859411 See TCON Update description
4001 4.14.17 V4.20 S0859420 See TCON Update description
4472 3.25.19 V5.00 S0859500 See TCON Update description
4645 06.12.19 V5.02 S0859502 See TCON Update description
4775 02.11.21 V5.03 S0859503 See TCON Update description
5128 10.10.22 V5.04 S0859504 See TCON Update description

Z135 101 03.30.05 101004 V1.00 HC08A S0681100 L0087100 L0091100 N/A N/A S0681100 Initial Release. Shared with SX150 and SX180.
DCON
 MODEL SER. # Incorp. Hardware Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Date Assembly Version Controller Program (.hex file (.hex) (view/adjust WebGPI- compatible
Part # Type (.exe) used for program on board PDA
Kernel File with PDA) Application
Download) File (.hex)

S40/45 7001 03.07.03 94771 V1.01 HC12 S0648101 N/A L0082101 S0648101_PDA S0648101 S0648101 Deutz 3cyl Initial release
7569 04.01.04 102259 V1.02 S0648102 S0648102_PDA S0648102 S0648106 Ford EFI Tier II parameter and 2 speed implementation.
11189 08.10.06 V1.05 S0648105 S0648105_PDA S0648105 Perkins
Deutz P404C
3cyl Add new 2.3L Ford engine parameter choice and Hi / Low Current drive
Ford EFI pump options; Rev 1.03 and 1.04 never released to production
Perkins P404C
Ford EFI 2.3L
15581 11.24.08 122922 V1.06 S0648106 S0648106_PDA S0648106 Deutz 2011L03 Added Tier 3 engines, standardized on Jumper Configuration pins (J5,J6)
Perkins 404C for engines and models, added low/high current propel pump option, fixed
Perkins 404D footswitch issue when set to lockout, fixed footswitch water ingress
Ford EFI 2.5L causing “Valve to low” fault
Ford EFI 2.3L
15851 11.08.10 T110572 V1.00 164/TI S0823100 N/A N/A N/A S0823204 Initial Release - software for ALC500 GenII PCB only, added footswitch
priority
16325 09.25.11 235321 V2.02 S0823202 DEUTZ 2011L03 Fixed issue with footswitch not forcing timeout when held on startup.
PERKINS 404C - Convert from prototype WebGPI library to 3.10 released library.
PERKINS 404D - Fix issue with incorrect run screen data due to ill placed comment in
FORD EFI 2.5L HTML.
FORD EFI 2.3L - Fixed calibration issue - Boom stow/out of stow propel speed.
Ford MSG 2.5L - Nuisance Fault GenII - Monitor added to detect floating ground.
- Corrected VBatt calculation.
- Kernel application layer changed to correct random changes to 60%
current output.
- Fixed Drive Enable operation while transitioning through joystick
neutral. (ecn11605b)
-added Ford MSG 2.5L engine option

17099 07.18.12 V2.03 S0823203 corrected High Current Drive pump defaults
-widened resistance fault values for low current drive pump
18351 / 08.14.13 V2.04 S0823204 Above + Added TierIV Deutz D2.9 and Tier IV Perkins 404F
18514 Deutz D2.9
Perkins 404F
20505 12.04.14 1260209 V3.00 164/TI S0853300 N/A N/A N/A S0853300 Deutz 2011L03 EN280 update:
Perkins 404D -Model/Capacity selection
Perkins 404F -Chassis Tilt Cutout
Ford MSG425 -Load Sense logging in error history
Deutz D2.9 -CTE cutout
-Platform Level cutout
-Modified C6 jumper default settings
-Added Platform Level operation and fault detection time.
-Added Platform Level, Jib up/down, tilt signal, and load sense to run
screens.
-Add European Anti-stall parameters
12.20.18 V3.02 S0853302 -Added Lift Guard Sensing Option, Applied S Ramp parameters to
primary boom.,negative valve command change
 MODEL SER. # Incorp. Hardware Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Date Assembly Version Controller Program (.hex file (.hex) (view/adjust WebGPI- compatible
Part # Type (.exe) used for program on board PDA
Kernel File with PDA) Application
Download) File (.hex)

S60/65 9154 05.28.03 94772 V1.00 HC12 S0649100 N/A L0082101 S0649100_PDA S0649100 S0816202 Also installed on Pre-pro 1 #, Pre-pro 2 #
9808 04.19.04 V1.00 HC12 N/A Tier II parameters filled in manually
10326 08.30.04 106349 V1.01 HC12 S0649101 N/A S0649101_PDA S0649101 Tier II engines, separate S60 to S60 2WD and S60 4WD, change Motor
shift functions, Brake release when steer, brake off delay, rocker steer as a
Deutz 3Cyl pin select option.
Ford EFI
12272 09.26.05 110161 V1.02 HC12 S0649102 N/A S0649102_PDA S0649102 Perkins P404C Corrected ramping rate on power up, recall all default values when valid
model selection jumpers are detected, turntable ramping in/out Stowed,
update Run Boom Screen , separate CW ,CCW parameters, and Propel not
stowed in Setup/Machine screen, modified several default value, modified
joystick calibration values

14045 08.15.06 V1.03 HC12 S0649103 N/A S0649103_PDA S0649103 Deutz 3Cyl Add new 2.3L Ford engine parameters
19607 06.23.08 V1.03 HC12 N/A Ford EFI Manually change Pulse/Rev of P404C engine from 8.9 to 10.6
20133 08.12.08 139499 V1.04 HC12 S0649104 N/A S0649104_PDA S0649104 Perkins P404C Add Tier 3 engines, standardized on Jumper Configuration pins (J5,J6) for
engines and models, add low/high current propel pump option, fixed
footswitch issue when set to lockout, fixed footswitch water ingress
causing “Valve to low” fault.
Ford EFI 2.5L
9154 to 11.17.10 T110561 V1.00 164/TI S0816100 N/A N/A N/A N/A Perkins 404C Initial Release software for ALC500 GenII PCB only, added footswitch
21000 Ford EFI 2.3L priority. UPGRADE TO V2.01 - V1.00 FOR VIEWING ONLY
Deutz 2011L03
9154 to 09.19.11 235411 V2.01 164/TI S0816201 N/A N/A N/A N/A GM 3.0L Fixed issue with footswitch not forcing timeout when held on startup, fixed
21000 Perkins 404D calibration issue, boom stow/out of stow propel speed, nuisance Fault
and Ford MSG 2.5L GenII - Monitor added to detect floating ground, corrected VBatt
S60HC calculation, kernel application layer changed to correct random changes to
60% current output, fixed Drive Enable operation while transitioning
through joystick neutral. (ecn11670b)

24492 09.11.12 V2.02 164/TI S0816202 N/A N/A N/A N/A Ford EFI 2.5L Added Ford MSG 2.3L engine option
Perkins 404C
Ford EFI 2.3L
Deutz 2011L03
GM 3.0L
Perkins 404D
Ford MSG 2.3L
 MODEL SER. # Incorp. Date Hardware Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Assembly Version Controller Program (.hex file (.hex) (view/adjust WebGPI- compatible
Part # Type (.exe) used for program on board PDA
Kernel File with PDA) Application
Download) File (.hex)

S60X/65 21001 05.25.10 139748 V1.00 164/TI S0818100 N/A N/A N/A S0818100 S0818204 Initial Release software for ALC500 GenII PCB only, add Deutz 2011L04
engine, add Dual Capacity option, add Angle sensor input, add footswitch
priority, change Boom2 input joystick to Rocker Switch. UPGRADE TO
V2.02 - V1.00 FOR VIEWING ONLY
21489 03.17.11 T114160 V1.01 164/TI S0818101 N/A N/A N/A N/A Corrected low voltage issue with Steer and added voltage check for valve
Ford EFI 2.5L power vs. ECU power. UPGRADE TO V2.02 - V1.01 FOR VIEWING
Perkins 404C ONLY
Ford EFI 2.3L
22666 09.19.11 235323 V2.02 164/TI S0818202 N/A N/A N/A N/A Deutz 2011L03 Fixed issue with footswitch not forcing timeout when held on startup,
GM 3.0L convert from prototype WebGPI library to 3.10 released library, added
Perkins 404D missing angle sensor screen to installer, fixed calibration issue - Boom
Deutz 2011L04i stow/out of stow propel speed, Nuisance Fault GenII - Monitor added to
detect floating ground, corrected VBatt calculation, Kernel application
layer changed to correct random changes to 60% current output, fixed
cannot change the stow/out-of-stow values if not in that position, fixed
Drive Enable operation while transitioning through joystick neutral.
(ecn11605b)
24492 09.11.12 V2.03 164/TI S0818203 N/A N/A N/A N/A Ford EFI 2.5L Added Ford MSG 2.3L engine option
Perkins 404C
Ford EFI 2.3L
Deutz 2011L03
GM 3.0L
Perkins 404D
Deutz 2011L04i
Ford MSG 2.5L

26248 07.16.13 V2.04 164/TI S0818204 N/A N/A N/A N/A Ford EFI 2.5L Added Perkins 404F and Deutz D2.9 to Engine Selection
Perkins 404C
Ford EFI 2.3L
Deutz 2011L03
GM 3.0L
Perkins 404D
Deutz 2011L04i
Ford MSG 2.5L
Perkins 404F
Deutz D2.9

S6015A- 12.11.14 1257417 V3.00 164/TI S0849300 N/A N/A N/A N/A S0849303 Ford EFI 2.5L EN280 2013 Changes
29586 Ford EFI 2.3L
12.20.18 Deutz 2011L03
3.02 S0849302
Deutz 2011L04i
Added Lift Guard Sensing solution, negative valve command change
Perkins 404D
Ford MSG 2.5L
Deutz 2.9
Perkins 404F
 Ford EFI 2.3L
Deutz 2011L03
Deutz 2011L04i
Perkins 404D
Ford MSG 2.5L
Deutz 2.9
Perkins 404F
S65D- 09.22.20 3.03 S0849303 Updated the defaults of high current propel valve.
3075
 MODEL SER. # Incorp. Hardware Software Micro Compiled Control Service & Diagnostic Backward Comments
Date Assembly Version Controller Program File Plus1 Application File {for compatible
Part # Type (*.lhx) Zapi (*.h86) adjusting parameters
and troubleshooting}
(*.p1d)

S60HC 13801 06.05.06 110991 Rev A Plus+1 110987A 119607 110987C

TCON 14191 08.24.06 Rev B 110987B
18669 01.21.08 Rev C 110987C
19039 04.21.08 Rev A 139303A 139303B
20305 12.02.08 Rev B 139303B

S60HC 13801 06.05.06 110992 Rev A Plus+1 110988A 119607 110988C

SCON 14191 08.24.06 Rev B 110988B
18669 01.21.08 Rev C 110988C
19039 04.21.08 Rev A 139304A 139304B Requires different string sensor, harness update and additional relay in
ground box
20305 12.02.08 Rev B 139304B
MODEL SER. # Incorp. Date Hardware Software Micro PC Install Backward
Assembly Version Controller Program compatible
Type
S60FE 101 1.0.0 1302862- 1302862-1.0.0
9/15/2021 Plus+1
TCON 1.0.0

S60FE 101 1.0.0 1302860- 1302860-1.0.0

9/15/2021 Plus+1
PCON 1.0.0
 Comments

Initial Release

Initial Release
MODEL SER. # Incorp. Hardware Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Date Assembly Version Controller Program (.hex file (.hex) (view/adjust WebGPI- compatible
Part # Type (.exe) used for program on board PDA
Kernel File with PDA) Application
Download) File (.hex)

S80/85 3082 04.08.02 81542 V1.00 HC12 S0513100 N/A L0082100 S0513100 PDA S0513100 S0513100 Deutz DF4L913 Low current drive output used only on S80/85 S/N’s 3082-3423. Do not
Ford EFI attempt to download Revisions other than 1.00 onto this board. Units that
GM 3.0L have had the boards replaced after 10/15/02 will have revision 2.04 or 2.22
Perkins P704-33 software.
3424 10.15.02 89353 V2.04 S0513204 L0082101 S0513204_PDA N/A S0718103 Rev. 2.04 improves the reset to Z45N anomaly.
3487 02.04.03 V2.22 S0513222 S0513222_PDA S0513222 *Rev. 2.22 corrects reset to Z45N and is backward compatible for all
89353 applications.
4076 01.06.05 102625 V1.00 S0718100 S0718100_PDA S0718100 Deutz 4CYL Separated from S0513222 and add brake release on steer. Tier II
Ford EFI parameters filled in manually until release.
GM 3.0L
Perkins P804C
5861 05.21.07 122271 V1.01 S0718101 S0718101_PDA S0718101 Deutz 4CYL Added Continental TME27 engine option, added turntable rotate Stow/No
Ford EFI stow transition ramp, adjusted turntable rotate default parameters.
5898 06.11.07 V1.02 S0718102 S0718102_PDA S0718102 GM 3.0L Bug fix - removed conditional speed limit for turntable rotate when boom
Perkins P804C angle was greater than 15 degrees
Continental TME27
7140 06.16.08 122730 V1.03 S0718103 S0718103_PDA S0718103 Deutz 2011L04i - Add Tier 3 engines –Standardized on Jumper Configuration pins (J5,J6)
Perkins P804 for engines and models, -Add low/high current propel pump option –Fixed
Continental TME27 footswitch issue when set to lockout –Fixed footswitch water ingress
causing “Valve to low” fault.
7999 11.04.10 T110570 V1.00 164/TI S0821100 N/A N/A N/A S0821201 Initial Release software for ALC500 GenII PCB only, added footswitch
priority ***DO NOT USE***
Upgrade to S0821201
8970 09.25.11 235403 V2.01 S0821201 -Fixed issue with footswitch not forcing timeout when held on startup
-Converted from
prototype WebGPI library to V3.10 released library
-Modifications to footswitch logic and
settings to prevent nuisance faults
-Widened valve max adjustment to pass stowed condition -
Added drive enable timer to allow for propel shuttling without hitting
bypass toggle -Kernel
application layer changed to correct random changes to 60% current output
 MODEL SER. # Incorp. Hardware Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Date Assembly Version Controller Program (.hex file (.hex) (view/adjust WebGPI- compatible
Part # Type (.exe) used for program on board PDA
Kernel File with PDA) Application
Download) File (.hex)

S80/85- 8000 09.22.08 121457 V1.00 HC12 S0780100 N/A L0082101 S0780100_PDA S0780100 S0780100 Initial release
2008 8496 08.31.10 139745 V1.00 164/TI S0819100 N/A N/A N/A S0819204 Initial Release software for ALC500 GenII PCB only, added Dual
Capacity option, added footswitch priority

8611 11.08.10 T115457 V1.01 S0819101 Corrected low voltage issue with Steer
Added voltage check for valve power vs. ECU power
8970 09.25.11 235322 V2.02 S0819202 Fixed issue with footswitch not forcing timeout when held on startup.
-Convert from prototype WebGPI library to 3.10 released library.
Deutz 2011L04i -Added missing angle sensor screen to installer.
Perkins P804 -Fixed calibration issue - Boom stow/out of stow propel speed.
Continental TME27 -Nuisance Fault GenII - Monitor added to detect floating ground.
-Corrected VBatt calculation.
-Fixed - Min fault current does not always follow the higher of the
calibrated thresholds.
-Kernel application layer changed to correct random changes to 60%
current output.
-Fixed - Cannot change the stow/out-of-stow values if not in that position.
-Fixed Drive Enable operation while transitioning through joystick neutral

10755 10.31.13 V2.03 S0819203 Above + Added Deutz 2.9T for Tier IV implentation
Deutz 2.9T
11121 03.18.14 V2.04 S0819204 Added Perkins 404F for Tier IV implementaion
Perkins 404F
12264 12.8.14 1260213 V3.00 164/TI S0850300 N/A N/A N/A N/A S0850301 -Add Perkins 404D
-EN280 update
-Model/Capacity selection
-Chassis Tilt Cutout
DEUTZ 2011L04i -Load Sense logging in error history
Perkins P804 -CTE cutout
Perkins 404D -Platform Level cutout
Continental TME27 -Modified C6 jumper default settings.
Deutz 2.9T -Added Platform Level operation and fault detection time.
Perkins 404F -Added Platform Level, Jib up/down, tilt signal, and load sense to run
screens.
-Add European Anti-stall parameters.

13589 04.11.16 V3.01 S0850301 Above + GM 3.0L Added GM 3.0L engine

MODEL SER. # Incorp. Hardware Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Comments
Date Assembly Version Controlle Program (.hex file (.hex) (view/adjust WebGPI- compatible Engines
Part # r Type (.exe) used for program on board PDA
Kernel File with PDA) Application
Download) File (.hex)

S100/125 101 / 103 04.21.00 / 50153 V1.01 167 S0277101 L0068303 L0060303 N/A N/A * Assembled box with board installed. Replace with S0277108.
TCON 06.20.00 prEN280 load sense.
131 / 313 V1.08 S0277108 L0068304 L0060304 S0277108 * Assembled box with board installed. Improved platform leveling
and calibration screens. prEN280 load sense
186 / 799 06.06.03 V1.10 S0277110 S0277110 * Assembled box with board installed. Removed engine over speed
diagnostics. Added one second delay to load sense. EN280 load
253 / 1018 04.05.04 102696 V1.11 S0277111 S0277111 sense
Tier II and 12.5kW welder option.
253 / 1029 12.07.04 102730 V2.00 S0716200 N/A S0716200 Low current drive pump output instead of the high current output.
SERV 09.04.08 122915 Recovery Keyswitch moved up 0.25" on Control Box Assy
757 / 2667 06.15.09 146134 V2.10 S0716210 S0716212 Added Tier III engines: Cummins B3.3T, Deutz 2011L04i, and
Perkins 804T. Added Chassis Tilt Cutout, GHG10 Generator, and
High Current Drive Pump functionality.
796 / 2693 11.04.09 V2.11 S0716211 Fixed bug in Boom Configuration screen, added Footswitch Priority.
SERV 04.06.10 V2.12 S0716212 Fixed Steering bug.
806 / 2710 01.19.10 146387 V3.00 S0812300 N/A N/A S0812321 Cummins Hardware change, cannot use on older machines. Added Safety limit
B3.3T switch monitoring and removed Tier II engines. Second window
Deutz 2011L04i added before resetting all defaults. Load sense system now has input
Perkins 804T to TCON for redundancy. Added Europe/USA antistall options.
877 / 2907 11.29.10 T109426 V3.10 S0812310 Added Shipyard Boom models S3200 and S3800. Added Numeric
Fault Code display option and Autoshift functionality, restored Propel
Upshift/Downshift Ramping, split Boom Up/Down Speed Limits.
894 / 3012 03.30.11 V3.11 S0812311 Added Steering "Fix" for ShipYard Boom.
940 / 3284 02.20.12 V3.12 S0812312 Fixed nuisance trip of safety limit switch (latching fault) at 100ft.
L0068341 L2--0060341 Updated Kernel and Boot file for flash memory change on TCON
S1051xD- 5.1.14 V3.13 167 S0812313 ABOVE + PCB
Add Perkins 1104-44T engine option
xxx / Perkins 1104
S12514D-
874
S10515D- 10.20.14 V3.14 167 S0812314 Cummins Add TierIV engines
983 / B3.3T -EN280 updates
S120HD15D Deutz 2011L04i -Chassis tilt drive cutout
-208 Perkins 804T -load sense overload recovery message
Perkins 1104 -S120HD & S100HD option picks.
Deutz 2.9T
Perkins 854T
 S105D-1572 10.9.2016 V3.20 167 S0812320 Cummins Telematics databus / ALC1000 update
/ S125D- B3.3T -Add fuel level sensor function
1577 Deutz 2011L04i -Add axle retract enable function
Perkins 804T
Perkins 1104
Deutz 2.9T
Perkins 854T
S105D-1670 5.10.2017 V3.21 167 S0812321 Fixes software bug on service bypass mode function.

S100/125 101 / 103 04.21.00/ 50152 V1.01 HC08 S0278101 L0069000 L0048305 N/A N/A S0278110 N/A Replace with S0278108.
PCON 06.20.00 prEN280 load sense
131 / 313 V1.08 S0278108 L0048310 S0278108 Improved platform leveling and calibration screens. prEN280 load
sense
186 / 799 06.06.03 V1.10 S0278110 S0278110 Added one second delay to load sense. EN280 load sense
V1.08 HC08A S0612108 L0087100 L0089400 N/A S0612210 Same software function as S0278108 except used with HC08A
microcontroller. prEN280 load sense
186 / 799 06.06.03 V1.10 S0612110 Same software function as S0278110 except used with HC08A
microcontroller. EN280 load sense
SERV 11.10.06 122021 Joysticks changed from Amp to Deutsch connectors
757 / 2667 06.15.09 146137 V2.10 S0612210 Numerous bug fixes
806 / 2710 01.19.10 146389 V3.00 S0813300 S0813320 Revised Load Sense System – Added additional signal (to TCON)
and cross-checking between TCON/PCON.
S10515D- 10.20.14 V3.14 S0813314 Platform level fast/slow speed change
983 /
S120HD15D
-208
S105D-1572 10.9.2016 V3.20 S0813320 Software number uniform with TCON
/ S125D-
1577

S100/125 101 / 103 04.21.00/ 50154 V1.01 HC08 S0279101 L0069000 L0047304 N/A N/A S0279101
DCON 06.20.00
V1.02 HC08A S0613102 L0087100 L0090400 S0613102 Same functions as S0279101 software except used on HC08A
microcontroller.
 MODEL SER. # Incorp. Hardware Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Comments
Date Assembly Version Controlle Program (.hex file (.hex) (view/adjust WebGPI- compatible Engines
Part # r Type (.exe) used for program on board PDA
Kernel File with PDA) Application
Download) File (.hex)

S3200 D101 / D101 03.30.11 T109424 V3.11 167 S0812311 L0068304 L0060304 N/A N/A S0812320 Cummins Added Steering "Fix" for ShipYard Boom.
/S3600 B3.3T
TCON D174 / D102 03.01.12 V3.12 S0812312 Deutz 2011L04i Updated
Fixed nuisance
Kerneltrip
andofBoot
safety
filelimit switch
for flash (latching
memory fault)onatTCON
change 100ft.
L0068341 L2--0060341 Perkins 804T PCB
V3.13 S0812313
V3.14 S0812314 Incorporate Perkins 854E engine and Deutz TD2.9 L4 engine, Add
platform overload cutoff function and overload recovery, Update for
EN280
V3.20 S0812320 Add telematics databus, Add ALC1000 fuel level sensor, Add axle
retract enable valve.
1670 V3.21 S0812321
S3200 D101 / D101 03.30.11 146389 V3.00 HC08A S0813300 L0087100 L0089400 N/A N/A S0813300 Revised Load Sense System – Added additional signal (to TCON)
/S3600 and cross-checking between TCON/PCON.
PCON

S3200 D101 / D101 03.30.11 50154 V1.02 HC08A S0613102 L0087100 L0090400 N/A N/A S0613102 Same functions as S0279101 software except used on HC08A
/S3600 microcontroller.
DCON
 MODEL Hardware Assembly Part # Software Bootloader
pn
DISCON 1268327
S-80J, S-60J, TURNTABL 1288795
S65XC, S85XC, E ECU 1302966 1302968
S45XC ECU,
1274155
PLATFORM
MODEL SER. # Incorp. Date Hardware Software Micro PC Install Boot File
Assembly Version Controller Program (.hex file
Part # Type (.exe) used for
Kernel File
Download)

SX105 101 8.22.2017 V1.01 167 S0860100 L0068341

TCON

844 3.25.2019 V2.00 S0860200

1420 17-Apr-20 V2.02 S0860202

1688 11.25.2020 V2.03 S0860203

2479 9.29.2022 V2.04 S0860204

SX105 101 8.22.2017 V1.01 HCS12 S0861100 N/A

PCON 844 3.25.2019 V2.00 S0861200
1420 17-Apr-20 V2.02 S0861202
1688 11.25.2020 V2.03 S0861203
2479 9.29.2022 V2.04 S0861204

SX105 101 8.22.2017 V1.01 HCS12 S0862100 N/A

SCON 844 3.25.2019 V2.00 S0862200
1420 17-Apr-20 V2.02 S0862202
1688 11.25.2020 V2.03 S0862203
2479 9.29.2022 V2.04 S0862204

SX105 101 8.22.2017 101004 V1.00 HC08A S0681100 L0087100

DCON
Kernel File PDA xml File WebGPI / Backward Applicable Engines
(.hex) (view/adjust WebGPI- compatible
program on board PDA
with PDA) Application
File (.hex)

L0113116 N/A N/A S0860204 Deutz TD2011L04i

Perkins 1104
Deutz 2.9T
Perkins 854T
Deutz TD2.2

L0123106 N/A N/A S0861204 N/A

L0125103 N/A N/A S0862204 N/A

L0091100 N/A N/A S0681100 N/A

 Comments

Initial Release.

Removed 'Regen Need is Low' warning. Fixed Description for

LSB3RO/LSB4EO CROSS-CHECK. Changes to overload functionality.
Pulse TT rotate valve and primary boom fine valve. Lift Connect added.
Updated dynamic load sense functionality, updated Chassis Tilt Cutout
options for new ANSI, TT Rotate Valve pulsing removed, High drive
speed condition removed, Stage V Engine added
Update Lift Connect functionality, especially to support Access Manager,
Remove None and Cutout Drive from Chassis Tilt Cutout option, Update
low coolant level functionality without latching the low coolant level fault,
Add more load cell calibration information on WebGPI Common Run
screen and Platform Load Run screen, Move SetDigitalOut command out
of Init function and move static variables' initialization into Init functions.

Update Lift Connect functionalities, including Auto detection, functions

meters, etc, Add China Stage IV functionalities, Replace PRC-TEL option
with CHINA IV Telematics; update China telematics function and data,
Add White Noise Alarm function, Add solution to address TCON lock up
issue.

Initial Release
See TCON Notes
See TCON Notes
See TCON Notes
See TCON Notes

Initial Release
See TCON Notes
See TCON Notes
See TCON Notes
See TCON Notes

Shared with ZX-135, SX-150 and SX-180

MODEL SER. # Incorp. Hardware Software Micro PC Install Boot File
Date Assembly Version Controller Program (.hex file
Part # Type (.exe) used for
Kernel File
Download)

SX125 101 3.6.17 1268383 V1.01 167 S0863101 L0068341

TCON 118 6.19.17 V1.10 S0863110

842 3.25.19 V2.00 S0863200

1390 1.6.2020 V2.01 S0863201

1485 7.14.2020 V2.02 S0863202

2427 7.11.2022 V2.03 S0863203

SX125 101 3.6.17 1268387 V1.01 HCS12 S0864101 N/A

PCON 118 6.19.17 V1.10 S0864110
842 3.25.19 V2.00 S0864200
1390 1.6.2020 V2.01 S0864201
1485 7.14.2020 V2.02 S0864202
2427 7.11.2022 V2.03 S0864203

SX125 101 3.6.17 1278938 V1.01 HCS12 S0865101 N/A

SCON 118 6.19.17 V1.10 S0865110
842 3.25.19 V2.00 S0865200
1390 1.6.2020 V2.01 S0865201
1485 7.14.2020 V2.02 S0865202
2427 7.11.2022 V2.03 S0865203

SX125 101 3.6.17 101004 V1.00 HC08A S0681100 L0087100

DCON
Kernel File PDA xml File WebGPI / Backward Applicable Engines
(.hex) (view/adjust WebGPI- compatible
program on board PDA
with PDA) Application
File (.hex)

L0113116 N/A N/A S0863203 Deutz TD2011L04i

Perkins 1104
Deutz 2.9T
Perkins 854T

Deutz TD2.2
Deutz TD2011L04i
Perkins 1104
Deutz 2.9T
Perkins 854T

L0123106 N/A N/A S0864203 N/A

L0125103 N/A N/A S0865203 N/A

L0091100 N/A N/A S0681100 N/A

 Comments

Initial Release. Update to V1.10

Fixed load cell not calibrating with "Warn Only" selected, fixed platform
manual leveling being operational during overload. Fixed load cell fault
message.
Lift Connect solution added. Changes to overload functionality. Pulsing
turntable rotate valve and primary boom fine valve.
Updated dynamic load sense functionality, updated Chassis Tilt Cutout
options for new ANSI, High drive speed condition removed, Stage V
Engine added.

Update Lift Connect functionality, especially to support Access Manager,

Added PRC-TEL option to support the China Telemactics device, Updated
low coolant level functionality without latching the low coolant level fault,
Fixed CAN ID issue for load cell S/N capture.
Update Lift Connect functionalities, including Auto detection, functions
meters, etc, Add China Stage IV functionalities, Replace PRC-TEL option
with CHINA IV Telematics; update China telematics function and data,
Add White Noise Alarm function, Add solution to address TCON lock up
issue.

Initial Release. Update to V1.10

See TCON notes
See TCON notes
See TCON notes
See TCON notes
See TCON notes

Initial Release. Update to V1.10

See TCON notes
See TCON notes
See TCON notes
See TCON notes
See TCON notes

Shared with ZX-135, SX-150 and SX-180

MODEL SER. # Incorp. Hardware Software Micro PC Install Boot File
Date Assembly Version Controller Program (.hex file
Part # Type (.exe) used for
Kernel File
Download)

SX135 101 11.15.16 1271473 V1.00 167 S0854100 L0068341

TCON 184 4.19.17 V1.10 S0854110

354 7.2.18 V1.21 S0854121

447 3.25.19 V2.00 S0854200

541 03.03.20 V2.01 S0854201

09.08.20 V2.02 S0854202

655 01.25.23 V2.03 S0854203

SX135 101 11.15.16 1271475 V1.00 HCS12 S0855100 N/A
PCON 184 4.19.17 V1.10 S0855110
354 7.2.18 V1.21 S0855121
447 3.25.19 V2.00 S0855200
541 03.03.20 V2.01 S0855201
09.08.20 V2.02 S0855202
655 01.25.23 V2.03 S0855203

SX135 101 11.15.16 1271474 V1.00 HCS12 S0856100 N/A

SCON 184 4.19.17 V1.10 S0856110
354 7.2.18 V1.21 S0856121
447 3.25.19 V2.00 S0856200
541 03.03.20 V2.01 S0856201
09.08.20 V2.02 S0856202
655 01.25.23 V2.03 S0856203

SX135 101 11.15.16 101004 V1.00 HC08A S0681100 L0087100

DCON
Kernel File PDA xml File WebGPI / Backward Applicable Engines
(.hex) (view/adjust WebGPI- compatible
program on board PDA
with PDA) Application
File (.hex)

L0113116 N/A N/A S0854203 Deutz TD2011L04i

Perkins 1104
Deutz 2.9T
Perkins 854T
Deutz TD2.2
L0123106 N/A N/A S0855203 N/A

L0125103 N/A N/A S0856203 N/A

L0091100 N/A N/A S0681100 N/A

 Comments

Initial Release
Load cell updates which includes removing negative load faults, updating
gains and zero parameters, adding 10 second negative load while booming
up fault, and other fixes. Added Platform Overload Evidence of Use
option. Valve pulsing changed to turn off function enable output.
Corrected "Secondary Boom Switches fault". Corrected "Platform Level
Valve" and "Jib Up/Down Valve" nuisance faults. Added debounce to
platform overload zone. Added fault handling for Platform Level Loop
Valve. Revised valve timing to fix issue with Axle Retract while using
Propel with axles fully extended. Corrected issue with RSB1AO Active
Cross-Check.

When tucking the jib, have 20% output to the jib retract to keep it from
extending out. Per jib stowed flag, allow jib down to further tuck even if
the primary boom is not in the angle window. Disable platform rotate
when bellcrank is fully tucked. Changed primary boom angle calibration
window. Updated primary boom up and down speed zones and
descriptions. Hide or unhide calibration screens to force calibration
sequence from TCON menu. Added fine valve pulsing for boom up/down
before each normal operation. Add joystick autocalibration functionality.
Activate platform level to gravity momentarily when untucking jib. Allow
boom going up to 30 degrees with chassis Y direction less than 11 degrees
and X direction less than 4.5 degrees during jib tucking. Boom angle
active cross check only functional from TCON with Rabbit enabled or
from PCON. Fixed abnormal boom down speed above 68 degrees in
boom coordination. Fixed incorrect negative raw data handling for load
cell. Updated parameters for TT rotate valve, jib ext/ret valve and jib
down speed not retracted.

Lift Connect added. Changes to overload functionality. Pulsing turntable

rotate valve.

Updated dynamic load sense functionality, updated Chassis Tilt Cutout

options for new ANSI, High drive speed condition removed, Stage V
Engine added.
Updated Lift Connect functionality, especially to support Access Manager,
Added a new engine model Deutz TCD2.2 T4, Updated low coolant level
functionality without latching the low coolant level fault.
Update Lift Connect functionalities, including Auto detection, functions
meters, etc, Add China Stage IV functionalities, Replace PRC-TEL option
with CHINA IV Telematics; update China telematics function and data,
Add White Noise Alarm function, Add solution to address TCON lock up
issue.
Initial Release
See TCON comments
See TCON comments
See TCON comments
See TCON comments
See TCON comments
See TCON comments

Initial Release
See TCON comments
See TCON comments
See TCON comments
See TCON comments
See TCON comments
See TCON comments

Shared with ZX-135, SX-150 and SX-180

 MODEL SER. # Incorp. Hardware Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Date Assembly Version Controller Program (.hex file (.hex) (view/adjust WebGPI- compatible
Part # Type (.exe) used for program on board PDA
Kernel File with PDA) Application
Download) File (.hex)

SX150 102 04.09.15 1257688 V1.00 167 S0851100 L0068341 L0113116 N/A N/A S0851204 Deutz TD2011L04i Initial Release
TCON 213 05.18.16 V1.01 S0851101 Perkins 1104 Added Fuel Level Sensing, Valve Pulsing, Platform Level > 15 deg
508 11.16.16 V1.10 S0851110 Deutz 2.9T Axle retract enable valve, Activated Prox Switch functionality, Incorrect
Perkins 854T SPN for Tier IV DM1 fixed, Fixed incorrect minimum angle for boom
Deutz TD2.2 coordination
596 3.25.19 V2.00 S0851200 Added dynamic load sense and made software backwards compatible with
load switches. Added joystick auto calibration functionality. Lift Connect
solution added. Changed overload functionality. Pulsing turntable rotate
valve.
621 03.18.20 V2.01 S0851201 Updated dynamic load sense functionality, updated Chassis Tilt Cutout
options for new ANSI, High drive speed condition removed, Stage V
Engine added.
631 02.11.21 V2.02 S0851202 Update Lift Connect functionality, especially to support Access Manager,
Remove Cutout Drive from Chassis Tilt Cutout option, Set overloaded and
inconsistent faults if not selecting load cell with a valid DLC S/N saved,
Update low coolant level functionality without latching the low coolant
level fault, Add additonal load cell calibration information on WebGPI
Common Run screen and Platform Load Run screen, Update the default
valve settings for the high current pump, Rename Deutz D2.9 to Deutz
TIER IV, which applies to Deutz TD2.2 Tier IV as well. Rename Deutz
TCD2.2 to Deutz Stage V, Apply functionalities of Water in Fuel and low
Coolant level to Deutz TIER IV and Deutz Stage V.

649 03.17.22 V2.03 S0851203 To address TCON lock up issue, add one waitstate into Init Application.
672 11.17.22 V2.04 S0851204 Update Lift Connect functionalities, including Auto detection, functions
meters, etc, Add China Stage IV functionalities, Replace PRC-TEL option
with CHINA IV Telematics; update China telematics function and data,
Add White Noise Alarm function, Add solution to address TCON lock up
issue.

SX150 102 04.09.15 214340 V2.01 HCS12 S0833201 N/A L0123106 N/A N/A S0833303 N/A Shared with SX-180
PCON 213 05.18.16 V2.02 S0833202 See TCON Comments
508 11.16.16 V2.11 S0833211 See TCON Comments
596 V2.12 S0833212 Disabled with Kernel 1.05 or older
621 4.11.17 V2.13 S0833213 Maintain full backwards compatibility
631 3.25.19 V3.00 S0833300 See TCON Comments
649 03.03.20 V3.01 S0833301 See TCON Comments
672 10.15.22 V3.02 S0833302 See TCON Comments
12.06.22 V3.03 S0833303 See TCON Comments

SX150 102 04.09.15 1257693 V1.00 HCS12 S0852100 N/A L0125103 N/A N/A S0852204 N/A Initial Release
SCON 213 05.18.16 V1.01 S0852101 See TCON Comments
508 11.16.16 V1.10 S0852110 See TCON Comments
SX150 1257693 HCS12 N/A L0125103 N/A N/A S0852204 N/A
SCON

596 3.25.19 V2.00 S0852200 See TCON Comments

621 03.18.20 V2.01 S0852201 See TCON Comments
631 02.11.21 V2.02 S0852202 See TCON Comments
649 03.17.22 V2.03 S0852203 See TCON Comments
672 11.17.22 V2.04 S0852204 See TCON Comments

SX150 102 04.09.15 101004 V1.00 HC08A S0681100 L0087100 L0091100 N/A N/A S0681100 N/A Shared with ZX-135 and SX-180
DCON
 MODEL SER. # Incorp. Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Date Version Controller Program (.hex file (.hex) (view/adjust WebGPI- compatible
Type (.exe) used for program on board PDA
Kernel File with PDA) Application
Download) File (.hex)

SX180 100 05.27.14 V1.03 167 S0832103 L0068317 L0113100 N/A N/A S0832303 Deutz TD2011L04i Initial Release
TCON 133 07.08.14 V1.04 S0832104 Perkins 1104 Revised Boom Coordination code to allow Boom Down at negative Boom
Angles (below 0)
Changed minimum Boom Angle to -2.6 degrees in Boom Coordination
code (was -2.0 degrees)
Added 1 second delay to Limit Switch Cross-Checks LSB3RO, LSB4EO,
and LSB1DO
Revised Boom Down Ramping at end-of-stroke

L0068341 L0113116 Updated Kernel and Boot file for flash memory change on TCON PCB
220 11.04.14 V2.01 S0832201 + Deutz 2.9T Tier IV + EN280:2013 Release.
357 05.18.16 V2.02 S0832202 Perkins 854T Added Fuel Level Sensing, MachineID, Loop Lock, Valve Pulsing
605 11.16.16 V2.11 S0832211 Deutz TD2.2
Activated Prox Kill option, Fixed minimum angle defect on boom
coordination, added axle retract enable valve
Added Lift Connect. Changes to overload functionality. Pulsing turntable
703 3.25.19 V3.00 S0832300 rotate valve. Added load cell functionalities and made software backwards
compatible with load switches. Added joystick auto calibration
functionality.
764 03.03.20 V3.01 S0832301 Updated dynamic load sense functionality, updated Chassis Tilt Cutout
options for new ANSI, High drive speed condition removed, Stage V
Engine added
785 10.15.22 V3.02 S0832302
Update Lift Connect functionality, especially to support Access Manager,
Remove Cutout Drive from Chassis Tilt Cutout option, Set overloaded and
inconsistent faults if not selecting load cell with a valid DLC S/N saved,
Update low coolant level functionality without latching the low coolant
level fault, Add additonal load cell calibration information on WebGPI
Common Run screen and Platform Load Run screen, Update the default
valve settings for the high current pump.
865 12.06.22 V3.03 S0832303 Update Lift Connect functionalities, including Auto detection, functions
meters, etc, Add China Stage IV functionalities, Replace PRC-TEL option
with CHINA IV Telematics; update China telematics function and data,
Add White Noise Alarm function, Add solution to address TCON lock up
issue.

SX180 100 05.27.14 V1.03 HCS12 S0833103 N/A L0123106 N/A N/A S0833303 N/A Initial Release
PCON 133 07.08.14 V2.01 S0833201 See TCON notes
V2.02 S0833202 Platform Level > 15 deg fault
220 11.04.14 V2.11 S0833211 See TCON notes
357 05.18.16 V2.12 S0833212 Disabled with Kernel 1.05 or older
605 11.16.16 V2.13 S0833213 Maintain full backwards compatibility
703 3.25.19 V3.00 S0833300 See TCON notes
 764 03.03.20 V3.01 S0833301 See TCON notes
785 10.15.22 V3.02 S0833302 See TCON notes
865 12.06.22 V3.03 S0833303 See TCON notes

SX180 100 05.27.14 V1.03 HCS12 S0834103 N/A L0125103 N/A N/A S0834303 N/A Initial Release
SCON 220 11.04.14 V2.01 S0834201 See TCON notes
357 05.18.16 V2.02 S0834202 See TCON notes
605 11.16.16 V2.11 S0834211 See TCON notes
703 3.25.19 V3.00 S0834300 See TCON notes
764 03.03.20 V3.01 S0834301 See TCON notes
785 10.15.22 V3.02 S0834302 See TCON notes
865 12.06.22 V3.03 S0834303 See TCON notes

SX180 100 05.27.14 V1.00 HC08A S0681100 L0087100 L0091100 N/A N/A S0681100 N/A Shared with ZX-135 and SX-150
DCON
 MODEL SER. # Incorp. Hardwar Software Micro PC Install Backward Applicable Engines Comments
Date e Version Controlle Program (.exe) compatible
Assembly r Type
Part #
Z80/SB CAN 4987 08.05.14 823804 V1.00 ARM 70107020V100 70107020V201 DEUTZ 2.9T Initial Release
Gateway PERKINS 404T
N/A N/A V2.00 70107020V200 Added functionality for Superboom Perkins 854T and CAN based
Telematics
DEUTZ 2.9T
6086 04.21.16 V2.01 70107020V201 PERKINS 404T Added functionality for Fuel Level Sensing
PERKINS 854T
7557 7.22.2019 V3.00 70107020V300 GM 3.0L Added functionality for Lift Connect

8625 05.21.2020 V3.01 70107020V301 ANSI/CSA Certification – Drive/Lift Tilt Cutout, Load Switch
70107020V301 Deutz 2.2 Stage V Engine – RPM, DPF Regeneration, EOL Test,
STAGE V Functionality, Messaging,
Fault Handling
ZX/SX CAN 2463 (ZX) 06.09.14 1253317 V1.00 ARM 70114406V100 70114406V203 DEUTZ 2.9T Initial Release
Gateway PERKINS 404T
2790 11.02.15 V1.02 70114406V102 Added functionality for CAN based Telematics
ZX135H- 3.25.19 V2.00 70114406V200 PERKINS 854T Added functionality for Lift Connect
4472
ZX135H- 1.29.20 V2.01 70114406V201 Added Stage V Functionality
4645
ZX135H- 8.30.20 V2.02 70114406V202 Added China Telematics
4697
SX125XC 8.22.22 V2.03 70114406V203 Added Stage IV Telematics
D-2427
SX Hydraulic 2.24.10 SX S0820100 Initial Release
Welder 12.5KW 2.24.10 SX S0820101 Add Valve output monitor and error check
MODEL SER. # Incorp. Hardware Software Micro Program File
Date Assembly Version Controller (LHX)
Part # Type

Contact NA 1278121 A Plus1 1278120

Alarm
 Comments

Initial Release
MODEL SER. # Incorp. Hardware Software Micro Program File
Date Assembly Version Controller (LHX)
Part # Type

DM430 NA 1299398 A Plus1 1296199A

Engine B 1296199B
Display
 Comments

Initial Release
bugfix
WebGPI Application Install Program Procedures

Note: The application installation file loads the software onto your PC/laptop for use with the WebGPI program.

1. Click on the application installation file link in the Software Matrix.

2. When prompted, select Run.
3. When the Software License Agreement window appears, select Yes on the license agreement.
4. Pick the location of the WebGPI folder on your computer (It is recommended to use the default location unless WebGPI has been installed in a different folder). Click Next.
5. On the Setup Type window, “Typical” should already be selected. Select Next.
6. The files will be installed.

Open WebGPI Application Interface Procedure

________________________________________________________________________________________________________________________________________________________

Boot File Download

Note: Boot file download may be performed with PC/laptop using WebGPI 1.01 or higher, or using a Palm handheld with WebGPI-PDA version 1.30, build 27 or higher.

Note: This procedure is to extract the boot hex file onto your PC/laptop or Palm for use with the WebGPI program.

1. Click on the boot file link in the Software Matrix.

2. If prompted about running the file, select Ok. If prompted to run or save, select Run.
3. If a window appears about WinZip Self-Extractor licensing, Select OK.
4. Select Browse and pick the location of the WebGPI folder on your computer (Recommend using the default location for PC/laptop use unless WebGPI has been installed in a
different folder) where you want the file unzipped. For handheld use, pick Browse and select the location of the WebGPI folder in your Palm user directory on your
computer (Example: C:\Palm\{user name}\WebGPI). Select OK.
5. For WinZip Self-Extractor, select Unzip. The file will be extracted to the chosen directory. Select OK.
6. Select Close if required.
7. If using Palm, HotSync Palm to PC/laptop to load the file in WebGPI-PDA program on the Palm.
________________________________________________________________________________________________________________________________________________________

Kernel File Download

Note: A PC/laptop or a Palm OS handheld with WebGPI-PDA version 1.30, build 27 or higher, is needed to download a kernel file to a control board.

Note: This procedure is to extract the kernel file onto your PC/laptop or Palm for use with the WebGPI program.

1. Click on the kernel file link in the Software Matrix.

2. If prompted about running the file, select Ok. If prompted to run or save, select Run.
3. If a window appears about WinZip Self-Extractor licensing, Select OK.
4. Select Browse and navigate to the C:\Program Files\Sauer-Danfoss\WebGPI\KernelFiles (this should be the default location for PC/laptop use unless WebGPI has been installed in a
 different folder) or an alternate directory where you want the file unzipped. For handheld use, pick Browse and select the location of the WebGPI folder in your Palm user directory
on your computer (Example: C:\Palm\{user name}\WebGPI). Select OK.
5. For WinZip Self-Extractor, select Unzip. The file will be extracted to the chosen directory. Select OK.
6. Select Close if required.
7. If using Palm, HotSync Palm to PC/laptop to load the file in WebGPI-PDA program on the Palm.

Open WebGPI Kernel Download Procedure to download to the control card

________________________________________________________________________________________________________________________________________________________

PDA XML File Installation

Note: To use WebGPI-PDA to display or adjust values from a control board with your Palm OS device, you need:
· Palm OS handheld with Palm OS 3.5 or later,
· PC with Windows 95/98/ME/2000/XP/NT (with service pack 3.0 or higher) operating system,
· HotSync serial cable compatible with your handheld (must be serial only, others with a serial and USB split will not work).
· WebGPI-PDA program Version 1.30, Build 10 or higher on your Palm.

Note: This procedure is to load software onto your PDA for use with the WebGPI-PDA program.

1. Click on the PDA XML file link the Software Matrix.

2. If prompted about running the file, select Ok. If prompted to run or save, select Run.
3. If a window appears about WinZip Self-Extractor licensing, pick OK.
4. Pick Browse and select the location of the WebGPI folder in your Palm user directory on your computer (Example: C:\Palm\{user name}\WebGPI). Select OK.
5. For WinZip Self-Extractor, select Unzip. The file will be extracted to the chosen directory. Select OK..
6. Select Close if required.
7. HotSync Palm to PC/laptop to load the file in WebGPI-PDA program on the Palm.

For viewing/adjusting values with a control board using a PDA, click HERE (WebGPI-PDA Application Interface Procedure)
________________________________________________________________________________________________________________________________________________________

PDA HEX File Installation

Note: To use WebGPI-PDA to download software to a control board, you need:

· Palm OS handheld with Palm OS 3.5 or later,
· PC with Windows 95/98/ME/2000/XP/NT (with service pack 3.0 or higher) operating system,
· HotSync serial cable compatible with your handheld (must be serial only, others with a serial and USB split will not work).
· WebGPI-PDA program Version 1.30, Build 10 or higher on your Palm.

Note: This procedure is to load the application software onto your PDA for use with the WebGPI-PDA program.

1. Click on the PDA HEX file link the Software Matrix.

2. If prompted about running the file, select Ok. If prompted to run or save, select Run.
 3. If a window appears about WinZip Self-Extractor licensing, pick OK.
4. Select Browse and pick the location of the WebGPI folder on your computer (Recommend using the default location for PC/laptop use unless WebGPI has been installed in a
different folder) where you want the file unzipped. For handheld use, pick Browse and select the location of the WebGPI folder in your Palm user directory on your
computer (Example: C:\Palm\{user name}\WebGPI). Select OK.
5. For WinZip Self-Extractor, select Unzip. The file will be extracted to the chosen directory. Select OK..
6. Select Close if required.
7. HotSync Palm to PC/laptop to load the file in WebGPI-PDA program on the Palm.

For loading software on a control board using a PDA, click HERE (WebGPI-PDA Application Download Procedure).
________________________________________________________________________________________________________________________________________________________

WebGPI Application Interface Procedure

To interface with a control board, you need:

· WebGPI version 1.01a or later installed on the computer,
· Available COM port,
· RS-232 cable (serial cable, 9-pin),
· For S100/120 machines T-Harness part number 75094,
· Internet Explorer 5.0 or later, and
· The appropriate application (*.exe) installed on the computer.

1. Power up the PC/laptop.

2. Connect RS-232 cable or T-Harness to PC/laptop.
3. Connect other end of RS-232 cable to the control board you want to interface. For S100/120 connect the T-Harness to the control box and the existing harness.
4. Open WebGPI.
5. Power up the control board
6. Select Connect on the buttons at the top of the screen. (If WebGPI fails to connect, make sure there is power to the control board then select Connect again)
7. Select Application button (next to where the Connect button has now changed to read Disconnect).
8. A list of folders/items you can look at displays on the left side of the window.
9. From the menu, select screen to display. ONLY use screens for the machine and engine programmed on the board. Machine model and engine can be found on the Models Specification
screen on the ALC-500 or the Machine screen on the ALC1000 software.
10. If programming the board after a software download, set model and engine configuration first. Machine model and engine can be found in the Setup folder and select Model screen on
the ALC-500 or the Machine screen on the ALC1000 software.
11. Click on a folder and select and item in the list to view in the window.
12. To change an item, highlight the item in the window, type in the new value or pick from the list and select Send to save the change to the control board.
13. To change back to factory defaults values for the screen, select Default.
14. To end connection to the control board, select Disconnect button.
________________________________________________________________________________________________________________________________________________________

WebGPI-PDA Application Interface Procedure

Not available for S100/120 control boards.

Note: To interface with a control board using WebGPI-PDA, you need a
· Palm OS handheld with Palm OS 3.5 or later,
· Gender changer Radio Shack part number 950-025x or equivalent,
· Null Modem cable or adapter Female DB9 – Male DB9,
· appropriate xml or hex file installed on Palm (see above for correct selection of files),
· and a HotSync serial cable compatible with your handheld (must be serial only, others with a serial and USB split will not work).
· WebGPI-PDA program Version 1.30, Build 10 or higher on your Palm.

1. Connect null model cable/adapter to the gender adapter.

2. Connect the gender adapter to the HotSync cable.
3. Connect the null modem (attached to HotSync cable) to the control card.
4. Connect HotSync cable to Palm handheld.
5. Turn on Palm and open WebGPI.
6. From the main menu, select Application.
7. From the menu, select screen to display. ONLY use screens for the machine and engine programmed on the board. Machine model and engine can be found on the Models Specification
screen on the ALC-500 or the Machine screen on the ALC1000 software.
8. If programming the board after a software download, set model and engine configuration first.
9. Click on a folder and select and item in the list to view in the window.
10. To change an item, tap the number/item to be changed. Use the backspace to remove the current value and type in the new value or pick from the list and select Send to save the
change to the control board.
11. To change back to factory defaults values for the screen, select Default.
12. To end connection to the control board, select Disconnect button.
________________________________________________________________________________________________________________________________________________________

WebGPI Kernel Download Procedure

To interface with a control board, you need

· WebGPI version 1.01a or later installed on the computer,
· Available COM port,
· RS-232 cable,
· For S100/120 machines T-Harness part number 75094,
· And the appropriate application (*.exe) installed on the computer.

1. Power up the PC/laptop.

2. Connect RS-232 cable or T-Harness to PC/laptop.
3. Connect other end of RS-232 cable to the control board you want to download to. For S100/120 connect the T-Harness to the control box and the existing harness.
4. Open WebGPI.
5. If you are upgrading software on a machine follow steps 6 through 8, otherwise go to step 9.
6. Select Connect on the buttons at the top of the screen.
7. Select Application.
8. For ALC500, look at each valve function and record the max out value for each function (A list of folders/items you can look at displays on the left side of the window.
Example: Fwd, Rev, Boom 1 Up, Boom 1 Down…). On Z80 and S100/120 machines, record neutral voltage values for each steer sensor, turntable level sensors,
and angle values for the PBAS (Z80 only).
 9. Select Download on the buttons at the top of the screen.
10. Select Microcontroller Type below the buttons. Note: For PC/laptops using WebGPI version 1.01a, use HC08A for HC12 Microcontroller type.
11. For ALC1000 or S100/120, the boot file needs to be downloaded before the kernel can be downloaded.
12. For WebGPI 1.01 download the kernel as an application.
13. Select the kernel file you need to download to the card by using search. Kernel files are found at C:\Program Files\Sauer-Danfoss\WebGPI\KernelFiles\<kernel file>.hex.
NOTE: Downloading a kernel to a control card will wipe out ALL information currently on the card.
14. Click Download to begin downloading to the control board. The HC12 Microcontroller requires a Force Download for the kernel download. If downloading does not begin
in a few seconds and an error message appears, select Force Download and follow the instructions on the screen.
15. Cycle the power to the control card to complete the download process.
16. To end connection to the control board, select Exit button. To load an application, click here to go to the WebGPI Application Download Procedure.
________________________________________________________________________________________________________________________________________________________

WebGPI Application Download Procedure

To download the application to a control board, you need:

· WebGPI version 1.01a or later installed on the computer,
· Available COM port,
· RS-232 cable,
· For S-1XX machines T-Harness part number 75094, and
· The appropriate application (*.exe) installed on the computer.

1. Power up the PC/laptop.

2. Connect RS-232 cable or T-Harness to PC/laptop.
3. Connect other end of RS-232 cable to the control board you want to download to. For S100/120 connect the T-Harness to the control box and the existing harness.
4. Power the control board.
5. Open WebGPI.
6. Select Connect on the buttons at the top of the screen. (Note: Button text changes to Disconnect and penguin to the right of the buttons changes to a flying bird when
WebGPI is connected to the control card.)
7. Select Application.
8. If you are updating the software on the control card, for ALC-500, look at each valve function and record the max out value for each function (Example: Fwd, Rev, Boom 1 Up, Boom 1 Down…).
For Z80 and S100/120 machines, record neutral voltage values for each steer sensor, turntable level sensors (both X and Y), and angle values for the PBAS (Z80 only).
If you are downloading an application after a kernel download, only the program default values will be present and need not be recorded.
9. Select Disconnect.
10. Select Download. (If error message for no Microcontroller selected appears, select Ok)
11. Select Microcontroller Type below the buttons. Note: For PC/Laptops using WebGPI v1.01a, use HC08A for HC12 Microcontroller Type.
12. Select Search next to the Application-File menu and open C:\Program Files\Sauer-Danfoss\WebGPI\<Application Folder>\<Application File>.hex.
13. Select Download.
14. When download is complete, cycle power to the control board.
15. Select Exit.
16. Select Connect.
17. Select Application.
18. Select Set All Defaults for final step of application installation.
19. If values were recorded prior to application download, enter those values into the appropriate screens (See WebGPI Interface Procedure step 10 for changing values.).
 20. To end connection to the control board, select Disconnect button.
________________________________________________________________________________________________________________________________________________________

WebGPI Application Download Procedure for ALC500 Gen II PCB

To download the application to a control board, you need:

· WebGPI version 3.0 or later installed on the computer,
· Available COM port,
· RS-232 cable,
· The appropriate application (*.exe) installed on the computer.

1. Power up the PC/laptop.

2. Connect RS-232 cable or T-Harness to PC/laptop.
3. Connect other end of RS-232 cable to the control board you want to download to.
4. Power the control board.
5. Open WebGPI.
6. Select Connect on the buttons at the top of the screen. (Note: Button text changes to Disconnect and penguin to the right of the buttons changes to a flying bird when WebGPI is connected
to the control card.)
7. Select Application on the buttons at the top of the screen.
a) If you are updating the software on the control card, look at each valve function and record the threshold and max out value for each function (Example: Fwd, Rev, Boom Up, Boom Down, etc.).
8. Select Disconnect on the buttons at the top of the screen.
9. Select Download. (Error message for no Microcontroller selected appears, select Ok, go to step 11)
10. Select Connect. (Microcontroller type will be automatically selected)
11. Select Kernel for File type.
12. Select Search next to the Operating System File menu and open C:\Program Files\Sauer-Danfoss\WebGPI\<Application Folder>\<Application File>.hex.
13. Select Download in the File Type section, next to Exit button.
14. When download is complete, Kernel window will display 100%, cycle power to the control board.
15. Select Exit.
16. Select Connect.
17. Select Application.
18. Select Set All Defaults for final step of application installation.
19. If values were recorded prior to application download, enter those values into the appropriate screens (See WebGPI Interface Procedure step 10 for changing values.).
20. To end connection to the control board, select Disconnect button.
________________________________________________________________________________________________________________________________________________________

WebGPI-PDA Application Download Procedure

Not available for S100/120 control boards and ALC500 Gen II control board

Note: To interface with a control board using WebGPI-PDA, you need a

· Palm OS handheld with Palm OS 3.5 or later,
· Gender changer Radio Shack part number 950-025x or equivalent,
 · Null Modem cable or adapter Female DB9 – Male DB9,
· WebGPI-PDA program Version 1.30, Build 10 or higher on your Palm.
· Appropriate xml and hex file installed on Palm (see table above for correct selection of files), and
· A HotSync serial cable compatible with your handheld (must be serial only, others with a serial and USB split will not work).

1. Connect null model cable/adapter to the gender adapter.

2. Connect the gender adapter to the HotSync cable.
3. Connect the null modem (attached to HotSync cable) to the control card.
4. Connect HotSync cable to Palm handheld.
5. Turn on Palm and open WebGPI.
6. If you are updating the software on the control card, for ALC-500, look at each valve function and record the max out value for each function (Example: Fwd, Rev, Boom 1 Up, Boom 1 Down…).
For Z80 and S100/120 machines, record neutral voltage values for each steer sensor, turntable level sensors (both X and Y), and angle values for the PBAS (Z80 only).
If you are downloading an application after a kernel download, only the program default values will be present and need not be recorded.
7. From the main menu, select App Download.
8. Select Connect. If the PDA will not connect to the control board, go back to step 7, select App Download, select Force Download; then goto Step 10.
9. Select Download.
10. Select Start on the screen giving instructions for a Force Download on the HC12 Microcontroller Type. (Not all versions of WebGPI-PDA will have this screen appear.)
11. Select Microcontroller Type (see table above). NOTE: Some later versions of WebGPI-PDA will automatically detect the Microcontroller Type when the PDA connects to the card.
12. Select OK.
13. WebGPI-PDA 1.30 build 27 or higher: If the Microcontroller selected is HC12, the PDA may automatically start a Force Download process. Follow instructions on the screen.
14. Select the check box to Show All File Types, then select the application file to download to the control board.
15. Select Start. The PDA will begin to download the application.
16. Wait until the screen displays file downloaded with a Close button. Do NOT hit cancel.
17. At the File Downloaded screen, select Close.
18. Select Close.
19. Cycle the power to the control card.
20. From the main menu, select Application.
21. On ALC500 control cards, from the screen menu, select Parameter Defaults.
22. Select send to set all parameters to the factory defaults for the new application you just downloaded. (If no Parameter Defaults screen is available, go through each screen on the menu
and select Default button.)
23. Select Back.

Go to WebGPI-PDA Application Interface Procedure to setup control card.

________________________________________________________________________________________________________________________________________________________
Connecting to S60HC Plus+1 Modules in the field (after S/N 14191)
Note: To interface with a control board using PLUS+1 Service Tool Software, you need a

Laptop
HARNESS PROGRAM CAN PLUS1 (P/N 110803)
CABLE,PROGRAMMING,PLUS1 (P/N 119604)
PLUS+1 Service and Diagnostic Tool PC Software

Obtaining Plus+1 Service and Diagnostic Tool

(NOTE: Internet access required)
1. Fill out the PLUS+1 GUIDE Download Request Form on the Danfoss website.
http://powersolutions.danfoss.com/products/plus-1-guide/
2. After hitting Send check your email for a message from PLUS+1 License Auto Activation. The subject line will be “Plus+1 GUIDE Web Site Registration”. Click on the PLUS+1 download link in the message.
3. The link opens a browser page titled PLUS+1 Software Download & License. Select the GUIDE Service Tool (free service tool only) download and install it on your computer.
The download & license are free and the license does not expire.
4. You should now be able to use the Service Tool part of PLUS+1 GUIDE.

Connecting to Plus+1 on S60HC:

1. Connect CABLE,PROGRAMMING,PLUS1 (P/N 119604) to USB port on laptop.
2. Connect HARNESS PROGRAM CAN PLUS1 (P/N 110803) to cable.
3. Connect harness to S60HC next to ground box.) Unplug the terminating resistor. Insert receptacle on the programming harness unto the plug from which the terminating resistor was removed. Plug the
terminating resistor that was removed unto the plug on the programming harness.

Normal w/ Harness

4. Turn key switch to ground and cycle power.

5. Start Plus+1 Service tool on the PC by clicking on its icon.
a. Plus+1 Service Tool program will scan connected controller automatically. Note: To scan connected Plus 1 controllers again press F8 or select Scan System from File menu.
 6. Green block with word Connect will be displayed at the bottom of the Plus+1 Service Tool program window, indicating successful connection between PC and Plus 1 controller.

7. Click on the file open icon and browse to the directory where the diagnostic file is stored. The diagnostic file has a *.P1D file name extension. The S60HC diagnostic file is
named “TCON-SCON SERVICE TOOL_REVA.P1D.”
a. If “Replace ECU” warning message appears, click Cancel.

Updating Plus+1 software on S60HC

1. Perform instructions in section C.
2. Click File Download icon, or select File Download from File menu.
3. Menu will roll down on the left side of the tool in Diagnostic Navigator tab.
4. Click on Controller Application (in bold) on the menu in the Diagnostic Navigator tab. Select appropriate application to download from Open file for download dialog window and click Open button.
a. Verify the SCON software is going to the correct node.

File Download

SCON: 1st node

5. Plus+1 Service Tool program will read application file and display its information. Make sure correct application file was selected.
a. Note: The following warning message could pop-up: click Ignore button.
 6. Click Start Download button to begin downloading.
a. Note: The follow message pop-up:

b. Confirm new application type. Type in the window: SCON or TCON, depend on which application will be downloaded and press OK. (case sensitive)

7. Running bar in Plus+1 Service Tool will be indicating downloading progress. LED on Plus+1 controller could blink randomly.
8. After downloading is complete (for both SCON and TCON), Plus+1 Service Tool will scan connected controller automatically and display downloaded application information in Diagnostic Navigator tab, under
sub tree Controller Application (click + to expand information sub tree). Make sure: App Id, App Type and App Ver. are the same as current application.
a. Note: To scan connected Plus 1 controllers again press F8 or select Scan System from File menu.

SCON

TCON

9. Close Plus+1 Service Tool program, switch OFF power to Plus 1 controller and unplug the programming harness and replace the terminating resistor receptacle to it’s mating plug on the S60HC
10. Plus+1 controller is programmed.
11. Set defaults.
12. Perform a full system calibration per Service Manual.

Connecting to Plus+1 on Z40

1. Connect CABLE,PROGRAMMING,PLUS1 (P/N 119604) to USB port on laptop.
 2. Connect HARNESS PROGRAM CAN PLUS1 (P/N 110803) to cable.
3. Connect harness to Z40 next to ground box.) Unplug the terminating resistor. Insert receptacle on the programming harness unto the plug from which the terminating resistor was removed. Plug the
terminating resistor that was removed unto the plug on the programming harness.
4. Turn key switch to ground and cycle power.
5. Start Plus+1 Service tool on the PC by clicking on its icon.
a. Plus+1 Service Tool program will scan connected controller automatically. Note: To scan connected Plus 1 controllers again press F8 or select Scan System from File menu.
6. Green block with word Connect will be displayed at the bottom of the Plus+1 Service Tool program window, indicating successful connection between PC and Plus 1 controller.

14. Click on the file open icon and browse to the directory where the diagnostic file is stored. The diagnostic file has a *.P1D file name extension.
a. If “Replace ECU” warning message appears, click Cancel.

Updating Plus+1 software on Z40

1. Perform instructions in section Connecting to Plus+1 on Z40.
2. Click File Download icon, or select File Download from File menu.

File Download

3. The select target ECU box will pop up. Select 0,1 - Z40TurntableControl for the first download. Click OK.

Target Controller
4. Click on Controller Application (TCON 110985) in the Open application for download dialog window and click Open button.

Z40 TCON

Z40 PCON

5. Plus+1 Service Tool program will read application file for download and display its information. Make sure correct application file was selected.
a. Note: The following warning message could pop-up: click Ignore button.

6. Click Start Download button to begin downloading.

 a. Note: The following message may pop-up:

b. Confirm new application type. Type in the window: Z40TCON or PCON, depending on which application will be downloaded and press OK. (case sensitive)
c. Note: The following warning message could pop-up: click Ignore button.

7. Running bar in PLUS+1 Service Tool will be indicating downloading progress. LED on PLUS+1 controller could blink randomly.
8. After downloading is complete (for both TCON and PCON), Plus+1 Service Tool will scan connected controller automatically and display downloaded application information in Diagnostic Navigator tab, under
sub tree ECU List: Z40Turntable/PlatformControl: Application (click + to expand information sub tree). Make sure: App Id, App Type and App Ver. are the same as current application.
a. Note: To scan connected Plus 1 controllers again press F8 or select Scan System from File menu.

TCON

PCON
 9. Close Plus+1 Service Tool program, switch OFF power to Plus 1 controller and unplug the programming harness and replace the terminating resistor receptacle to it’s mating plug on the Z40
10. Plus+1 controller is programmed.
11. Set defaults.
12. Perform a full system calibration per Service Manual.

Z40 Rev A to Rev C Upgrade Info

1. Install AC motor controllers with Rev B Software.

The label it will say version 17 (Rev B) or the motor controller may marked as Rev B with a black permanent marker. Rev A motor controllers are version 16.
2. Modify Right AC motor controller harness. Move the platform level up coil wire, V14PLUA OR, from pin 8 to pin 11. Verify that the flashing beacon, C117FB RD, is connected to pin 8. (Some beacons
were hardwired to the key switch. They can be left hard wired, but the beacon cannot be turned OFF from the VCON menu.)
3. Follow Steps in Rev B to Rev C procedure, except do not capture and restore existing parameters. A complete machine setup is required for upgrading from Rev A to Rev C.

Z40 Rev B to Rev C Software Upgrade Info and Procedure

Notes:
Installing Rev. C TCON & PCON software does not require an update to the Zapi AC motor controller software. It remains Rev. B.

**FOR UNITS WITH REV A SOFTWARE ONLY** (There is a very limited number of Rev. A units in the field.)
To upgrade from TCON/PCON Rev. A, the AC motor controller software must also be upgraded to Rev. B. The best procedure is to swap out the AC motor controllers with units that
already have Rev. B software.

Procedure:

1. Connect to the Z40 with the PC Service tool software - - see Connecting to Plus+1 and Updating Plus+1 Software on the boom software CD, or the Z40 Training PowerPoint. Version 3.0.5.1 or later of the
Sauer Plus1 Guide Service Tool Software is required to run the Rev A service tool file.

2. Open the Z40 service tool file. (file=>128571A.P1D)

3. Upload Calibration Parameters from the TCON & PCON controllers and save each to a separate file. Use the “ALL EE TCON” and “ALL EE PCON” service tool screens in the Guide service tool. A file
with an xml extension (*.xml) is created to contain the parameters uploaded from each controller.

a. click on THE “ALL TCON EE” parameter screen

b. click the “upload from CPU button”
c. click the save parameters to a file button.
d. repeat for the PCON parameters
(The parameters are saved so calibrations can be reloaded after loading new software and setting defaults, which will save time in getting the machine back in operation. This step can be skipped if a full machine
setup is planned after the software upgrade.)

4. Download Rev C TCON Software (file=> 110985C.lhx)

Note: If downloading to a unprogrammed controller, or if the controller is contains a different program- - the application type must be entered in the window that pops up. The Z40 TCON controller application
type is “Z40TCON”

Also, if a message appears that say that “..memory structure is not compatible..” click the “Ignore” button. The parameters will be restored in steps 6 and 7.

5. Download Rev C PCON Software (file=> 110986C.lhx). The Z40 PCON controller application type is “PCON”

6. Set General and Calibration Defaults from the ground controls (now possible in Rev C.) After the startup beep, press and hold both the AUX and Function Enable toggle switches ON for 5 seconds, within
10 seconds after the “system ready” beep. The parameter reset is confirmed by a long alarm “beep.”

NOTE: this step IS NECESSARY to set values to the new parameters added to Rev C software.

7. Load Calibration Parameters back into the machine from *.xml files that were saved in step 3.
(Make sure all of the “download” select boxes are checked on the left side of the screen. If not, right click on the word “download” at the top and select “Check ‘Download’ for all records”)
–OR-
Perform a complete machine set up (GPM calibrate, Pressure Relief Valve Calibrate, Thresholds, Valve Threshold and Maximum Current, etc.)

It is important to verify the values of the new parameters added in Rev C are correct. Enter the ALL EE TCON screen and verify that EE_PLATCUT=0 (unless platform level cutout is desired.) Enter the
ALL EE PCON screen and verify that EE_DITHER_AMPL=300 and EE_DITHER_FREQ=100.

11. Verify Main Pressure Relief Calibration by operating functions against end stops. Secondary Down => 1100 psi | Jib Up => 2100 psi | Primary Retract => 2450 psi.
If not correct, perform a relief valve calibration. {service manual pgs. 90-91}

12. Calibrate both joysticks {service manual page 55}

13. Verify proper operation and function times. (times are listed since the released service manual is not completely up to date) Adjust any functions that are not operating smoothly and at the proper speed.

FUNCTION TARGET TIME

Secondary Boom Up 32 - 36 sec
Secondary Boom Down 32 - 36 sec
Primary Boom Up 26 - 30 sec
Primary Boom Down 26 - 30 sec
Primary Boom Extend 18 - 22 sec
Primary Boom Retract 18 - 22 sec
Jib Boom Up 16 - 20 sec
Jib Boom Down 16 - 20 sec
Platform Rotate(CW/CCW) 10 - 14 sec
 Turntable Rotate(CW/CCW) 62 - 68 sec
Jib Rotate (CW/CCW) 16 - 20 sec

Z40 Rev C to Rev D Software Upgrade Info and Procedure

Notes:
Installing Rev. D TCON & PCON software does not require an update to the Zapi AC motor controller software. It remains Rev. B.

Rev. D TCON & PCON software can be downloaded using service tool file 128571A.P1D with Version 3.0.5.1 or later of the Sauer Plus1 Guide Service Tool Software, but Version 5.0.8.7 or
later of the Sauer Plus+1 Guide Service Tool Software is required to run the Rev. D diagnostic service tool file 230797A.P1D.

Procedure:

1. Connect to the Z40 with the PC Service tool software - - see Connecting to Plus+1 and Updating Plus+1 Software on the boom software CD, or the Z40 Training PowerPoint. Version 5.0.8.7 or
later of the Sauer Plus1 Guide Service Tool Software is required to run the service tool file (see note above).

2. Open the Z40 service tool file. (file=>230797A.P1D)

3. Download Rev D TCON Software (file=> 110985D.lhx)

Note: If downloading to an unprogrammed controller or if the controller contains a different program- - the application type must be entered in the window that pops up. The Z40 TCON controller
application type is “Z40TCON”

Also, if a message appears that says “...memory structure is not compatible...” click the “Ignore” button. The parameters will be restored in steps 6 and 7.

4. Download Rev D PCON Software (file=> 110986D.lhx). )

Note: If downloading to an unprogrammed controller or if the controller contains a different program- - the application type must be entered in the window that pops up. The Z40 PCON controller
application type is “PCON”

5. Set General and Calibration Defaults from the ground controls. After the startup beep, press and hold both the AUX and Function Enable toggle switches ON for 5 seconds, within 10 seconds after
the “system ready” beep. The parameter reset is confirmed by a long alarm “beep.”

NOTE: this step IS NECESSARY to set values to the new parameters added to Rev D software.

6. Perform a complete machine set up (Pressure Relief Valve Calibrate, GPM calibrate, Valve Threshold and Maximum Current, etc.)

7. Verify Main Pressure Relief Calibration by operating functions against end stops. Secondary Down => 1100 psi | Jib Up => 2100 psi | Primary Retract => 2450 psi.
If not correct, perform a relief valve calibration.

8. Verify proper operation and function times. (times are listed since the released service manual is not completely up to date) Adjust any functions that are not operating smoothly and at the proper speed.

FUNCTION TARGET TIME

Secondary Boom Up 32 - 36 sec
Secondary Boom Down 32 - 36 sec
Primary Boom Up 26 - 30 sec
Primary Boom Down 26 - 30 sec
Primary Boom Extend 18 - 22 sec
Primary Boom Retract 18 - 22 sec
Jib Boom Up 16 - 20 sec
Jib Boom Down 16 - 20 sec
Platform Rotate(CW/CCW) 10 - 14 sec
Turntable Rotate(CW/CCW) 62 - 68 sec
Jib Rotate (CW/CCW) 16 - 20 sec
 MODEL SER. # Incorp. Software Micro PC Install Boot File Kernel File PDA xml File WebGPI / Backward Applicable Engines Comments
Date Version Controller Program (.hex file (.hex) (view/adjust WebGPI- compatible
Type (.exe) used for program on board PDA
Kernel File with PDA) Application
Download) File (.hex)

8.25 8.25 8.25 8 8 10 10 10 15 10 10 17 60

HYPERLINK EXAMPLE (use the format below so the links will update automatically)
=hyperlink("Application Installation Files\S0828307.exe","S0828307")
Change the information inside the quotes in RED to "folder name/filename"
Change the information inside the quotes in BLUE to what you want displayed. (See below)
S0828307