Gen3 - Software - Overload At Maximum Boom Angle

Gen3 - Software - Overload At Maximum Boom Angle

When the lift cylinder reaches the end of its stroke the hydraulic motor will try to increase the hydraulic pressure to continue to extend the lift cylinder. The Gen3 system reads this increased pressure as an increase in load causing the Gen3 to go into overload and produces a hydraulic cutout. Engage the override switch in order to lower the boom. This will decrease the lift cylinder pressure back to a normal range and return the Gen3 to normal operation.

The following is only applicable to machines that support a Boom Raise cutout.
Goto System Menu -> System Tests -> Test Boom Raise Cutout
Check if boom raise is disabled when the cutout is enabled

The Gen3 will engage the boom raise cutout before the lift cylinder reaches the end of it's stroke, thus preventing the overload cutout.
However depending on the operating speed of the boom, the boom raise cutout threshold may need to be adjusted.
There are a few factors to consider when adjusting the boom raise cutout threshold
  1. If the threshold is set too high then the cutout will not engage before the Gen3 goes into overload
  2. If the threshold is set too low then the machine will be restricted from reaching maximum boom angle
  3. If the machine is used to transport small quick loads then the boom movement speed will be faster, requiring a lower cutout threshold to allow the Gen3 enough time to engage the cutout before reaching overload
  4. If the machine is used to transport very heavy loads then the boom movement speed will be slower, allowing for a higher cutout threshold to ensure the Gen3 does not cutout prematurely reducing the maximum boom angle
Before adjusting the maximum boom angle threshold confirm the carrier angle and boom angle calibrations are correct

Follow the instructions below to adjust the boom raise cutout threshold
  1. Download and install Notepad++ from this link
  2. Remove the SD card from the Gen3 display and insert into a laptop
  3. Open the file constant.cfg using Notepad++
  4. Locate the [Dimensions] section towards the top of the file
  5. Locate the following key
    MaxBoomAngle=XXX
    The value is in 0.1 degree increments eg. 650 = 65.0 degrees
  6. Change the value by 1 degree (add or subtract 10 units from the value)
  7. Save the file
  8. Click Safely Remove Hardware from the system tray to safely remove the SD card from the laptop
  9. Insert the SD card into the Gen3 display
  10. Raise the boom at the operational speed and make sure the cutout occurs before the overload and that it is able to reach the maximum angle
  11. Repeats steps 2 through 10 until the right balance of maximum angle without overload is obtained
Do not edit anything else in the constant.cfg except the lines as instructed above. Modifications to the Gen3 configuration files may cause the Gen3 to exhibit unknown or unpredictable behaviour negating the safety function.

After using the Gen3 Configuration Tool to update the model configuration, the boom raise cutout threshold will be returned to the default value


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