Gen3 - Hardware - Boom Cutout Not Working or Swapped Around

This article applies to machine's which support cutout of the individual boom movement function raise (luff up), lower (luff down) and extend (tele out).

In these machines the 3 individual cutout harnesses are connected into the hydraulic proportional valve block rather than a cutout signal into the ECU or pilot valve.

Solenoid Connections

Some telehandler hydraulic blocks have connections to many hydraulic lines. The sheer bulk of the many hydraulic lines can obscure the underneath solenoid connections. When a new Gen3 system is being installed, the installer MUST properly identify ALL available solenoid ports before installing the Gen3 cutout T-Connectors. Erroneously connecting Gen3 cutouts to the wrong hydraulic solenoids will result in unpredictable Gen3 cutout behavior. Therefore, before completing the solenoid connections, check the install manual for your particular machine and make sure that you account for all hydraulic block solenoids and their precise locations.

Possible Non Standard Hydraulic Block Configuration

The Gen3 hydraulic cutouts are connected into the valve block, which contains all the proportional valves that control each boom movement. As the electrical and hydraulic connections for all proportional valves are the same, they can easily be swapped around to change the machine operation. For example swapping ether the electrical or hydraulic connectors for the extend and tilt cylinders will swap the tilt and extend functions on the joystick.

The installation manual provided with the Gen3 for each machine, is based on a locally sourced representative of this machine. The Gen3 kit was then engineered for that machine. If the hydraulic or electrical connections differ from this first machine, then instructions for the cutout connector locations will be incorrect and will cutout the wrong boom functions.

Example below of a JCB 540-140 hydraulic block and associated cutout solenoids

      

Solenoid  Cutout Diagnosis Steps

Follow the steps below to diagnose or confirm the correct connector for each boom function.

1. Move the boom into a position that will allow testing of each boom function without going into RCL cutout. Typically boom at 20 degrees and extended 0.5m will be sufficient.
   
2. Navigate to System Menu -> System Tests
   
3. Confirm all boom functions connected to the valve block are operational. This should include boom raise/lower, extend/retract, tilt up/down and aux in/out.
   
4. Select the Test Boom Extend Cutout option and Enable (Red Highlight)
   
5. Confirm all boom functions are operational except for boom extension (tele out)
   
6. Select the Test Boom Raise Cutout option and Enable
   
7. Confirm all boom functions are operational except for boom raise (luff up)
   
8. Select the Test Primary Cutout option and Enable
   
9. Confirm all boom functions are operational except for boom lower (luff down) and boom extension (tele out)
   Note: Depending on the attachment selected and the configuration settings, boom raise (luff up) may also be in cutout

If any of the corresponding functions are not in cutout, but another boom operation is in cutout while the test is performed, then swap the corresponding cutout tee connection in the valve block and repeat the test.

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