GRADALL Bodas-service Installation and...
Transcript of GRADALL Bodas-service Installation and...
Gradall Industries, Inc.Gradall Industries, Inc.
GRADALL Bodas-service Installation and Operation
Bodas Software Installation and Operation for GRADALLHydraulic Excavators & Industrial Maintenance Machines
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Bodas-service Software
Bodas-service Software (P/N 80414109) is available to allow configuration and diagnostics of all machines equipped with processor aided hydraulic systems.
Bodas-service is an upgrade of the Bodem software. Bodas is backwards compatible. No programming skills are needed to use Bodas-service.
In addition to the software, you will also need cable kit (P/N 80364206). For some laptops, you will also need a serial/USB adapter and driver. A kit is available from Cables to Go: (http://www.cablestogo.com/) or equivalent.
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Bodas-service Software
Bodas-service installation requires the Bodas-service CD and security key (Do not install the security key until instructed!). Insert CD into your CD drive and use one of 2 methods to install:
1.Click START, RUN, and type ..SETUP.EXE
2. ..or Browse to the CD and double click setup.exe
Then click OK for English
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Bodas-service Software
Click Next at Setup Wizard
Then click Next to accept license
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Bodas-service Software
Click Next for Full Install
Then click Next for default path
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Bodas-service Software
Click Install to accept default Menu Folder
BODAS CD then installs the files
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Bodas-service Software
When this screen appears, Install is complete! Just
click Finish
* At this point you can install (Plug In) the USB Security Key included in the package with the software CD.
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Bodas-service Diagnosis
Open program from Programs, Bosch Rexroth, BODAS-service
3.0
Click the magnify glass and Accept License agreement
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Bodas-service Diagnosis
To change from Demo mode, click File -
Interface
..then uncheck Demo and select COM
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Bodas-service Diagnosis
And then accept the LOL (Limitation of Liability
Click Magnify again to scan for Processors
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Bodas-service Diagnosis
Bodas-service scans for controllers
Then lists all processors found along with software
version
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Bodas-service Diagnosis
NOTE! different colors represent different status
To open controller, click “+” to the left. Then click, (Get controller data) button in Login section
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Bodas-service Installation
Click parameter display/edit and note the Menus section is
empty, DONT PANIC!
..click File, then Language
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Bodas-service Installation
Make sure the Program Language = English, and Controller Language =
2
Repeat process to open processor and display
parameters..
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Bodas-service Diagnosis
Note – the menus of the processer should now show up
properly.
Click one of the menu categories to open the options.
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Bodas-service Installation
Note – processdata values are now dynamic and processer is
live.
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Bodas-service Diagnosis
Actual errors / Saved errors can be checked
Live errors show up in RED
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Bodas-service Diagnosis
Datalogger opens a CSV file and lets you choose the
categories to log
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Bodas-service Diagnosis
After logging the chart can be viewed in full.
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Bodas-service Diagnosis
If any parameters are changed, the values must be saved or
they will be erased.
Click on the controller and (Save to eprom)
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Gradall Industries, Inc.Gradall Industries, Inc.
XL SERIES III
ON HIGHWAY ELECTRICAL SWITCH LOCATIONS
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Right Hand Dash Panel
1. Information Display Area2. Ignition3. Travel / Remote Switch4. Fan Speed5. Temperature Control6. Light Switch7. Engine Brake Switch (if equipped)8. Travel / Remote Display Area 9. Rotating Beacon (if equipped)10. A/C Switch (if equipped)
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Information Center
1. Engine Stop Indicator: Illuminates red and a pulsing alarm is activated to indicate excessive engine temperature or low engine oil pressure.
2. Check Engine Indicator: Illuminates yellow to indicate an engine malfunction.3. Engine Preheat Indicator: If so equipped;
Engine cranking detection during Preheating will stop the Preheating process and the canceling of the Cold Start Function. The cold start function will also be canceled when low battery voltage codes are active. When the Preheat time has elapsed, the Wait to Start lamp will go off and the engine is ready to start.
4. Chassis Key Indicator:5. Upperstructure Key Indicator:6. Air Condition Indicator: If equipped7. Inter-Axle Drive Indicator:8. Front Axle Drive Indicator: If equipped9. Axle Differential Lock Indicator:10. Engine Brake Indicator: If equipped11. Beacon Light Indicator: If equipped12. Low Air Indicator: Illuminates red indicate air system pressure is below minimum operating
pressure. An audible is also activated.
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Lower Cab Assembly
1
2
3
4
5
6
1. Chassis Printed Circuit Board (PCB)2. RC 4 - 4 Chassis processor3. ADM 2 4. If equipped with a exhaust brake switch location will be
at the clutch master cylinder5. Remote Solenoid 6. Travel Solenoid
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Lower Cab Assembly Air Switches
4
3
1. Axle Switch (access behind instrument panel)2. Park Brake Switch (access behind instrument panel)3. Stop Light Switch4. Low Air Switch
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Left Hand Side Power Unit
1 32
1. PLD Engine Controller2. Remote Drive High Range Solenoid3. Left Hand PTO Air Valve and Indicator Switch
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Right Hand Side Power Unit
1 2 3 4 5 6
1. Right Hand PTO Air Valve and Indicator Switch
2. High Low Range Air Cylinder (travel and remote)
3. Engine Brake High Horse Power ( 4100 III and 5100 III only )
4. Main Hydraulic Pump Indicator Switch5. Starting Motor and Solenoid6. Alternator
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Transmission Switches
1 2 3
1. Neutral Start Switch2. Remote High Range Solenoid3. Reverse Warning Switch
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Remote Steering Valve
Steer Right Top Cartridge
Steer Left Bottom Cartridge
Remote Steering Power
Accessing the remote steering. Open engine compartment valve located top of right hand frame rail.
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Oscillation Valve
Oscillation valve locate inner left hand frame railbefore front axle assembly.
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Brake Interface & Emergency Brake
Location for the two air valves left hand frame railjust behind the operators chassis cab. Dig brake relay is located in the same area.
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Battery Box
1 2
1. VEC (Vehicle Electrical Center)2. Start Relay3. Grid Heater Fuses and Relays (if so equipped)
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Transfer Case & Front Rear Tandem
Location of Inter-Axle lock switch remember that the differential engagement switch is located on the back side
of air valve on instrument panel
The same transfer case is used on the 3100 III 4x4And the 4100 III & 5100 III 6x6 units
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Upper Structure Instruments
1.Fuel Level Indicator: Illuminates red if fuel falls below 25% of capacity2. Mini Siren: Pulsing sound indicates engine shut down has been initiated. Steady sound
indicates low air pressure or travel lock out condition.3. Hydraulic Oil Level Indicator: Illuminates red if falls below acceptable level.4. Parking Brake Indicator: Illuminates red if applied5. Travel Lockout Indicator: Illuminated yellow and audible active if travel motor PTO or range gear
are not engaged.6. Engine Preheat Indicator (if equipped): Illuminates yellow to indicate grid heaters are warming
intake manifold to proper starting temperature. 7. Joystick Control Pattern: Ignition key must be in the off piston before and change can be made.8. Ignition:9. Check Engine Indicator: Illuminates yellow in indicate and malfunction.10. Engine Stop Indicator: Illuminates red and a pulsing alarm is activated to indicate excessive
engine temperature or low engine oil pressure.11. Low Air Indicator: Illuminates red to indicate air pressure is below minimum operating pressure.12. Hydraulic Oil Temperature Indicator: Flashes red to indicate below normal hydraulic oil
operating temperature. Operate machine at reduced engine rpm until display no longer flashes. Illuminates red if hydraulic oil temperature is above safe operating temperature.
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Arm Pods
1. Boom Tilt Speed2. Park Brake Switch3. AM/FM Radio
LEFT HAND SIDE
1. Engine Speed 2. Mode Selection Switch ( I ) Fine Grading ( II )Dig Mode1. Fan Speed2. Air Conditioning3. Auto Idle4. Boom Lights5. Work Lights6. Intermittent Wiper / Washer7. Temperature Control8. Travel Speed
RIGHT HAND SIDE
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Joystick
Handle with switches
Plungers
Position Sensors
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Remote Travel & Remote Steering
Position Sensors
Pedal
Plunger
Cover Removed for Clarity
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Upper Frame Structure Switches
RC 12-4 UPPER EXPANSION MODULE
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Upper Heater / AC Units
1
2
3
1. Heater Temperature Probe2. AC Thermostat3. HIGH/LOW Pressure Switch
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HIGHWAY SPEEDPROCESSOR OPERATION
XL SERIES III
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Processor Installation
Processor RC 6-9 Processor RC 12-4
Processors are mounted at the front of the valve compartment. Each processor has specific functions assigned. A CAN Bus circuit is used for primary communication between processors, engine, controls, and control valves.
Highway speed machines also have a processor mounted on the front of the chassis cab. It is known as Processor RC 4-4.
Software is preloaded onto the processors. Parameters are loaded at assembly to set defaults on the machine.
A communication port is provided in the cab. Processor status and operation can be read using a BB3 hand held unit, Bodem software, or Bodas software.
Other inputs and outputs are used at the processor to provide assorted machine functions.
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Basic Processor Operation
The processor uses inputs and software to provide necessary signals to the machine for proper operation. A microcontroller and memory chips process signals and work with preloaded software to provide correct outputs.
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Processor & Software
The processors are similar in function and operation. Switches, potentiometers, sensors, and the components located on the CAN bus provide input to the processors. The processor uses the signals to provide proportional outputs to the control valve end caps and other signals to other parts of the machine as needed.
The software and preloaded parameters control the output signals. Parameters determine controls ramps, control acceleration & deceleration, time delays, and other outputs. The operation of the software and parameters can be read through the diagnostic port provided.
Use of a BB3, Bodem software, or Bodas software allows access to the system to check operation and parameters.
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Processor 6-9 Inputs
INPUTS DESCRIPTION FUNCTION ACTIVESTATE
INACTIVE STATE
Analog 2 STEER RIGHT INPUT SWITCH INPUT 12V+ OV
Analog 3 ENGINE SPEED POT POTENTIOMETER INPUT - Throttle Potentiometer
Analog 4 STEER LEFT INPUT SWITCH INPUT 12V+ OV
Analog 6 HEATER POT POTENTIOMETER INPUT - Heater Potentiometer
Analog 7 TRAVEL PEDAL SIGNAL
POTENTIOMETER INPUT - Travel Pedal Signal for travel speed
Analog 8 UPPER KEY START REQ SWITCH INPUT 12V+ OV
Current 1 GRADALL CONTROL PATTERN SWITCH INPUT - @ Monitor 12V+ 0V
Current 2JOHN DEERE
CONTROL PATTERN
SWITCH INPUT - @ Monitor 12V+ 0V
Current 3 GRADE MODE SWITCH SWITCH INPUT - @ Monitor 12V+ 0V
Current 4 AC POWER ON SWITCH INPUT - @ Console 12V+ 0V
Pulse 1 BUCKET SHAKE INPUT SWITCH INPUT - @ Left Joystick 12V+ 0V
Pulse 2 HEATER ON SWITCH INPUT - From Heater Switch 12V+ 0V
Switch 1 PILOT LEVER SWITCH INPUT- Switch in LH Console 12V+ 0V
Switch 2 AUTO IDLE ENABLE SWITCH INPUT - Switch at RH Console 12V+ 0V
Switch 3 UPPER SHIFT SWITCH INPUT - Switch at RH Console 12V+ 0V
Switch 5 AUX SWITCH INPUT - Switch at Joystick 12V+ 0V
Switch 6 HOIST UP PROXIMITY SWITCH
SWITCH INPUT - Switch on Frame @ Boom 12V+ 0V
Switch 7 TRAVEL FORWARD SWITCH
SWITCH INPUT - Limit Switch in Travel Pedal 5V+ 0V
Switch 8 TRAVEL REVERSE SWITCH
SWITCH INPUT - Limit Switch in Travel Pedal 5V+ 0V
The Input/Output Charts for each processor show the specific functions controlled by the processors. If the function is not listed on these charts, the function is not processor controlled. Measurable values for each processor function are listed.
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Outputs from Processor 6-9
OUTPUTS DESCRIPTION FUNCTION ACTIVE STATE
INACTIVESTATE
Prop 1 BOOM IN PROPORTIONAL OUTPUT - Boom In Solenoid
Prop 2 BOOM OUT PROPORTIONAL OUTPUT - Boom Out Solenoid
Prop 3 TOOL OPEN PROPORTIONAL OUTPUT - Tool Open Solenoid
Prop 4 TOOL CLOSE PROPORTIONAL OUTPUT - Tool Closed Solenoid
Prop 5 HOIST UP PROPORTIONAL OUTPUT - Hoist Up Solenoid
Prop 6 HOIST DOWN PROPORTIONAL OUTPUT - Hoist Down Solenoid
Switched 1 PILOT ENABLE SWITCHED OUTPUT - Signal to Pilot Cutoff Solenoid (Pilot Manifold) 12V+ 0V
Switched 2 WAIT START LIGHT
SWITCHED OUTPUT - Powers 12V Indicator Light 12V+ 0V
Switched 3 CHECK ENGINE LIGHT
SWITCHED OUTPUT - Powers 12V Indicator Light 12V+ 0V
Switched 4 ENGINE STOP LIGHT
SWITCHED OUTPUT - Powers 12V Indicator Light 12V+ 0V
Switched 5 LOW AIR LIGHT SWITCHED OUTPUT - Powers 12V Indicator Light - From Low Air Signal @ Chassis 12V+ 0V
Switched 7 HF LEVEL LIGHT
SWITCHED OUTPUT - Powers 12V Indicator Light - From HF Level switch on chassis 12V+ 0V
Switched 8 HF TEMP LIGHT SWITCHED OUTPUT - Signal to travel alarm when travel pedal active 12V+ 0V
CAN L(1939) CAN BUS Communicates with processor RC4-4
(chassis), engine processors, joysticks
CAN H(1939) CAN BUS Communicates with processor RC4-4
(chassis), engine processors, joysticks
1939L-RC CAN BUS CAN - To processor 12-4
1939H-RC CAN BUS CAN - To processor 12-4
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Processor 12-4 Inputs
INPUTS DESCRIPTION FUNCTION ACTIVE STATE
INACTIVE STATE
Resistor 1
HYDRAULIC OIL TEMP Temperature Sender Input (900 - 1800 Ω)
Resistor 2 HEATER TEMP Temperature Sender Input (900 - 1800 Ω)
TEMP SENDER POWER
Regulated 5V power to Oil Temp Sender & Heater Temp Sender +5V
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Processor 12-4 Outputs
OUTPUTS DESCRIPTION FUNCTION ACTIVE
STATE INACTIVE
STATE
Prop 1 SWING RIGHT PROPORTIONAL OUTPUT- Swing Right Solenoid
Prop 2 SWING LEFT PROPORTIONAL OUTPUT - Swing Left Solenoid
Prop 3TRAVEL
FORWARD PROPORTIONAL OUTPUT - Travel Forward Solenoid
Prop 4TRAVEL
REVERSE PROPORTIONAL OUTPUT - Travel Reverse Solenoid
Prop 5HEATER/AC
FLOWPROPORTIONAL OUTPUT - Flow Control Valve @
Heater/AC Manifold
Prop 7 OIL COOLER FANPROPORTIONAL OUTPUT - Flow Control Valve for
fan on Pilot Manifold
Prop 9 SWING LIGHT - ASWITCHED OUTPUT - Powers 12V Light, Active with
Swing Brake Release signal 12V+ 0V
Prop 10 SWING LIGHT - BSWITCHED OUTPUT - Powers 12V Light, Active with
Swing Brake Release signal 12V+ 0V
Prop 11SWING BRAKE
RELEASESWITCHED OUTPUT - Active anytime swing is
activated. Has time delay for brake set 12V+ 0V
Switched 1 WARNING ALARMSWITCHED OUTPUT - Active with low air, travel
Lockout, or engine stop 12V+ 0V
Switched 2 PARK BRAKE ONSWITCHED OUTPUT - Powers 12V Indicator Light if
park brake is on 12V+ 0V
Switched 3
TRAVEL LOCKOUT LIGHT
SWITCHED OUTPUT - Powers 12V Indicator Light if either travel motor is disengaged 12V+ 0V
Switched 4 FLUSHING VALVESWITCHED OUTPUT - Powers 12V Solenoid when
upper key is on with time delay 12V+ 0V
1939L-RC CAN BUS CAN to Processor RC 6-9
1939H-RC CAN BUS CAN to Processor RC 6-9
1939L-RC CAN BUS CAN to Internal resistor.
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Chassis Processor 4-4 Inputs
INPUTS DESCRIPTION FUNCTION ACTIVE STATE
INACTIVESTATE
Analog 1 Hi/LOW RANGE SWITCH
MECHANICAL LIMIT SWITCH - Active with Hi/Low Engaged 12V+ 0V
Analog 2 NEUTRAL SWITCH
MECHANICAL LIMIT SWITCH - Active with Trans in Neutral 12V+ 0V
Analog 3 TRAVEL MODE REQUEST
SWITCH INPUT - Active with cab switch set for travel mode 12V+ 0V
Analog 4 PUMP ENGAGED SWITCH
MECHANICAL LIMIT SWITCH - Active with pump engaged 12V+ 0V
Analog 5 PARK BRAKE ON SWITCH
AIR PRESSURE SWITCH - Active with park brake set 12V+ 0V
Pulse 1 LEFT MOTOR ENGAGED
MECHANICAL LIMIT SWITCH - Active when left PTO is engaged 12V+ 0V
Pulse 2 RIGHT MOTOR ENGAGED
MECHANICAL LIMIT SWITCH - Active when right PTO is engaged 12V+ 0V
Pulse 3 REMOTE MODE REQUEST
SWITCH INPUT - Active with cab switch set for remote mode 12V+ 0V
Switch 1 LOW AIR SWITCH AIR PRESSURE SWITCH - GND air pressure < 60 psi. > 60 PSI - 0V GND 0V
Switch 2 HF LEVEL SWITCH
FLUID LEVEL SWITCH - GND = Low, Float (0V) = Fluid level ok GND 0V
Switch 3 RETURN FILTER SWITCH
HYD PRESSURE SWITCH - GND - Filters Plugged, Float (0V) - OK GND 0V
Switch 4 SUCTION SWITCH
HYD PRESS SWITCH - GND=Hi Suction Pressure, Float (0V) - Suction pressure OK
GND 0V
Switch 5 FUEL LEVEL FLUID LEVEL SWITCH - GND = Low, Float (0V) = Fluid level ok GND 0V
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Chassis Processor 4-4 Outputs
OUTPUTS DESCRIPTION FUNCTION ACTIVESTATE
INACTIVESTATE
Prop 1 UPPER SHIFTSWITCHED OUTPUT - Powers 12V on/off
solenoid (based upon upper shift from CAN)
12V+ 0V
Prop 2 TRAVEL MODE ENGAGE
SWITCHED OUTPUT - 12V output to switch air valve to travel mode 12V+ 0V
Switched 1 STEER RIGHT OUTPUT
SWITCHED OUTPUT - Powers 12V solenoid for right steer (Based on CAN signal)
12V+ 0V
Switched 2 STEER LEFT OUTPUT
SWITCHED OUTPUT - Powers 12V solenoid for left steer (Based on CAN signal)
12V+ 0V
Switched 3 STARTER RELAY SWITCHED OUTPUT - 12V output to starter relay (See Logic Chart) 12V+ 0V
Switched 4 DIG BRAKE SIGNAL SWITCHED OUTPUT - Powers 12V on/off solenoid (See Logic Chart) 12V+ 0V
RS232-TXD DATA CONNECTOR POS C
RS232-RXD DATA CONNECTOR POS D
LOGIC GND DATA CONNCETOR POS B
PULL-UP DATA CONNECTOR POS H
CAN H1 DATA CONNECTOR POS G
CAN L1 DATA CONNECTOR POS F
CAN L (1939) CAN BUS Communicates with Processor 6-9, engine processors, joysticks
CAN H (1939) CAN BUS Communicates with Processor 6-9, engine processors, joysticks
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Chassis Processor LogicChassis Start Circuit
Function Pin Logic Required Output Notes
Chassis Start -Travel
5A. Travel mode selected - Pin #8 @ 12+V
Starter Relay Output becomes active - Pin #5 @ 12+V
B. Transmission in Neutral - Pin 46 @ 12+V
C. Park Brake Set -Pin #19 @ 12+V
D. Pump PTO disengaged - Pin #20 @ 0V
E. Chassis Key Start Active - Pin #34 @ 12+V
Logic Charts give the interaction of various circuits affecting specific circuit function at the processor. If certain conditions are not met, then the processor will prevent a specific function from operating.
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Chassis Processor LogicUpper Start Circuit – Pump Disengaged
Function Pin Logic Required Output Notes
Chassis Start –Remote 5
A. Remote mode selected -Pin #18 @ 12+V
Pump Disengaged
B. Pilot lever in upper off (inactive) -Pin #37 @ 0V - Upper processor "A"
Starter Relay Output becomes active - Pin #5 @ 12+V
Pin #5 will be active for 2 seconds to allow pump to engage.
C. Transmission in neutral Pin #46 @ 12+V
If pump does not engage, upper key start, Pin # 9 @ upper processor "A" must become inactive (0V) to reset
D. Park Brake Set - Pin #19 @ 12+V
E. Pump PTO disengaged - Pin #20 @ 0V
When Pump PTO engages - Pin #20 @12+V, applies.
F. Upper key start active - Pin 9 @ 12+V Upper Processor "A"
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Chassis Processor LogicUpper Start Circuit – Pump Engaged
Function Pin Logic Required Output Notes
Chassis Start-
Remote5
A. Remote mode selected -Pin #18 @ 12+V
Pump engaged
B. Pilot lever in upper off (inactive) - Pin #37 @ 0V - Upper processor "A"
C. Transmission in neutral Pin #46 @ 12+V
Starter Relay Output becomes
active - Pin #5 @ 12+V
D. Park Brake Set - Pin #19 @ 12+V
E. Pump PTO engaged -Pin #20 @ 12+V
F. Upper key start active -Pin 9 @ 12+V Upper Processor "A"
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Chassis Processor LogicTravel & Remote Engage Circuits
Function Pin Logic Required Output Notes
Travel Mode Engage
30
A. Travel mode selected - Pin #8 @ 12+V
Travel mode engage becomes active - Pin #30 @ 12+V
This function will "latch" even with power off..
B. Park Brake Set - Pin #19 @ 12+V
Function Pin Logic Required Output Notes
Remote Mode Engage
4
A. Remote mode selected - Pin #18 @ 12+V
Remote Mode engage becomes active - Pin #4 @ 12+V
This function will "latch" even with power off.
B. Park Brake Set - Pin #19 @ 12+V
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Chassis Processor LogicDig Brake Signal Circuit
Function Pin Logic Required Output Notes
Dig Brake Signal
6A. Remote mode active -
Pin #4 @ 12+V
B. Pump PTO engaged -Pin #20 @ 12+V
C. Left PTO engaged - Pin #33 @ 12+V
D. Right PTO engaged -Pin #44 @ 12+V
F. High/Low Range engaged - Pin #35 @ 12+V
Dig brake signal becomes active –
Pin # 6 @ 12+V
G. Upper park brake released - Pin #10 @
12+V Upper Processor "A"
H. Travel pedal forward is active – Pin #61 @
5V upper processor "A"
OR
H. Travel pedal reverse is active – Pin #60 @
5V upper processor "A"
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Chassis Processor LogicUpper Shift & Steering Circuits
Function Pin Logic Required Output Notes
Upper Shift
31A. Remote mode active -Pin #4 @ 12+V
B. Dig brake set - Pin #6 @ 0V
C. Travel pedal forward is inactive - Pin #61 @ 0V upper processor "A"
Upper shift becomes active -Pin # 31 @ 12+V
D. Travel pedal reverse is inactive - Pin #60 @ 0V upper processor "A"
Function Pin Logic Required Output Notes
Steer Right
29A. Steer right active -Pin #46 @ 12+V Upper processor "A"
Steer right becomes active -Pin #29 @ 12+V
Processor "C" in chassis receives signal via CAN
Function Pin Logic Required Output Notes
Steer Left 15A. Steer left active - Pin #20 @ 12+V Upper processor "A"
Steer left becomes active - Pin #15 @ 12+V
Processor "C" in chassis receives signal via CAN
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