Gen3 - Installation - Generic Cutout Overide

When the hydraulic cutout is engaged it may be necessary to override the cutout function in order to move the boom into a safe position. 

The following sections serve to illustrate common electrical connections from the Gen 3 safety system to the existing electronics in the machine. The purpose of this Tech Doc is not to provide a wiring setup for any specific telehandler, but rather to provide generic guidance for customers when trying to troubleshoot/install electrical cutout overrides. Wire colors may not match your machine and are used here as convenient aids.

To complete all of the steps within this Tech Doc, you should either be an auto electrician or have the services of an auto electrician.

EQSS accepts no responsibility for ultimate wiring outcomes by unqualified personnel

There is usually an existing key or push button switch in the cabin to perform the override function for the LMI. When the switch is triggered, it connects the switch common line to the normally open line on the switch - which then sends the signal to the machine ECU to override the cutout. This switch can be used to perform the override function on the Gen3 LMS. When the override switch is triggered, the Gen3 LMS starts a countdown timer. When the countdown expires, the line is rendered open - disabling the override function (until the switch is released and activated again). Then after a period, the Override will again need to be activated. It must be stressed that the Override feature should only be used to move the boom out of the cutout state. It should never be used to complete a boom movement when a cutout has already occurred. 

During the Gen 3 infancy stage, a 4-Pin connector with 4 bare wires was supplied with the kit (called the machine input connector). The following instructions were supplied with these early kits:

Cut the line from the normally open terminal of the switch (which runs to the machine ECU). Splice the Violet wire going into Pin-3 of the machine input connector into the switch side of the line and splice the White wire going into pin 4 of the machine input connector - into the machine ECU side of the line. 

Most current kits include harnesses that have been engineered for specific makes and models of machines. Therefore, minimal (if any) splicing is required. 

Using Existing Switch

The other wires on the machine input connector are for the drive direction signals and may need to be extended 

Some machine's don't have an override switch, or the switch is integrated into the existing LMI. In this case the supplied override switch will need to be fitted. Connect the common line of the switch to a 12V power supply line from the machine and connect the violet wire going into pin 3 of the machine input connector (into the normally open switch line). The White wire going into pin 4 of the machine input connector is not used in this configuration. 

Note: On some Manitou machines, it's not possible to override a cutout with Gen 3. These machines have a Manitou override switch next the the seat.

Using Supplied Switch

The override switch must be have a momentary/spring return switching action that requires the operator to apply constant pressure on the switch to maintain the override function. If the switch is just an on/off action it must be replaced to be compliant with the AS1418.19 standard.

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