Bosch CS 550 User manual

CS 550,551,550i,551i/150RC
Spreader Joystick Controller Installation Manual

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Table of Contents
1
System Components
3
2
Spreader System Layout
4
3
Joystick System Layout
4
4
Mounting
5
4.1
Microcontroller
5
4.2
Display and Joystick
6
5
Dimensions
7
5.1
Display
7
5.2
Joystick
7
6
Connector Details
8
6.1
Microcontroller Connection
8
6.2
Solenoid Connection
8
7
Cable Connections
9
7.1
Cable Connections
9
7.2
Main Harness Connections
9
8
Cable Function Chart
11
9
Installation Notes
13
9.1
Step 1
13
9.2
Step 2
13
10
Installation Test Checklist
15
11
Warning
16
12
Appendix – Detailed CS550/150 System Layout

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Bosch Rexroth Canada Corp. reserves the right to revise this information at any time and for any
reason and reserves the right to make changes at any time, without notice or obligation, to any of the
information contained in this piece of literature.
Please check for updates at: www.boschrexroth.ca/compu-spread

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1System Components

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2 550i Spreader System Layout
See Appendix (CS-550i System Layout Drawing).
3 Joystick System Layout
See Appendix (CS550i-150RC System Layout Drawing).
4 551i System Layout
See Appendix (CS551i-150RC System Layout Drawing).

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The following is a detailed navigation chart for the system layout. See Appendix for the
detailed system layout including all the components and part numbers.
CS-550 / 150 ELECTRONIC SYSTEM BUILDER
TABLE OF CONTENTS
COORDINATES
ITEM DESCRIPTION X.Y DETAILS
550 SPREADER
1SPREADER PACKAGES E1 DISPLAY AND RC INCLUDED
2MAIN HARNESS D7 ADVANCED OR LITE
3CANBUS CABLES C2
4SENSOR EXTENSIONS B6
5SENSOR NETWORK C6 PULL-UP RESISTOR (WHITE MOTOR)
6VEHICLE SPEED B7
7VALVE EXTENSIONS E6 IF RC LOCATED IN CAB
8550 AUXILIARY CABLE E3 MATERIAL DETECT / CHANGE
9VALVE ADAPTER E6 (C4M TO ITT) FOR OLD SCB/MP18
150 ARMREST
1RCE CABLES A3 IN-VALVE OR IN-CAB
2POWER FLOAT C4 NO ADAPTERS FOR NEW C4 BLOCK
3150 AUXILIARY B2
4CANBUS CABLE C2
5LOW OIL, SPIN. REV. C3 ADAPTERS REQUIRED
SPECIAL FUNCTIONS
1PRESSURE/TEMP/CHUTE D3 HYDRAULIC MONITORING
2ROAD TEMP D0 ROAD AND AMBIENT TEMP
3WIFI D2 NEED EXTENSION?
4GPS PUCK E0
5ANTI-ICE E4 USE C4-C4 EXTENSIONS (CUT END)
TOW PLOW
1TP SPREADER PKG E1 INCLUDES TWO 4-4's
2MAIN HARNESS D9
3CANBUS SPLITTER D6
4SENSOR EXTENSIONS B6 RC ON TRUCK OR TRAILER?
5SENSOR NETWORK C6 IF PULL-UP RESISTORS REQUIRED
6VALVE EXTENSIONS E6 RC ON TRUCK OR TRAILER?

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5Mounting
5.1 Microcontroller
1. The microcontrollers(s) can be mounted horizontal or with the connectors oriented to
the bottom. The controller cannot be mounted with the connectors facing upwards.
2. The mounting surface must be flat and all four bracket holes used.
3. Sufficient space must be allowed for the mating and un-mating of the connectors.
4. If the controller is mounted in the cab, valve extension cables are required to be routed
into the valve enclosure.
5. If the controller is mounted in the valve enclosure, the main harness leads will
terminate directly to the valve solenoid.
6. The mount hole spacing is 188mm (7.4”) by 59mm (2.32”).
7. See the “Installation Notes” for additional recommendations (page 15).

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5.2 Display, Encoder Box and Joystick
1. Both 550i and 551i displays utilize a ball mount where 4 holes of the flange must be
secured. (See hole array.)
2. A similar ball mount is used when the display is coupled to the armrest – one long arm
and one short.
3. The joystick armrest console utilizes a tube mount that slips over 1-7/8” O/D pedestal
tubing.
4. The tube mount can slide forward and back 1.7” to optimize the armrest position.
(Loosen the ¼-20 nuts.)
5. The ratchet clamp can be used to lock the rotation of the tube and bracket.
6. See the “Installation Notes” for additional recommendations (page 15).

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5 Dimensions
5.1 Display
5.2 Joystick

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6 Connector Details
6.1 Microcontroller Connection
1. Extend sliding tabs.
2. Partially insert connector into socket and ensure the 4 coding posts align into housing.
3. Push sliding tabs in and the connector will fully insert and lock itself.
4. To remove, pull the tabs out and the connector will un-mate.
Note: The RC4-4 “Spreader” controller uses only the larger connector, while the RCE
“Joystick” controller uses both.
6.2 Solenoid Connection
1. Push on the connector to mate.
2. Press metal retainer to un-mate.

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7 Cable Connections
7.1 Cable Connections
Connect the CANBUS EXTENSION from CAN1 to the CANBUS lead on the main harness
or to the FEMALE CONNECTOR on the armrest (if equipped).
Connect the MALE CONNECTOR to CAN2 of the RCE harness.
If switches are present: Connect the power harness to the ignition, disconnect then to the 2
PIN CONNECTOR.
•P3 interconnects with the 16 PIN ARMREST CONNECTOR. Connect the power
harness to battery or ignition disconnect.
•P5 is for the AUXILIARY CABLE with bare leads. (See OSD for pinouts.)

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7.2 Main Harness Connections
All 2 POSITION MOLDED CONNECTORS with diagnostic LEDs are for solenoids. Each
leg has a function label.
Note: Valve extensions are required if the microcontroller is mounted in the cab (see page
7, note 4, 5).
•All 5 POSITION THREAD-ON connectors are for sensors.
•The 8 POSITION THREAD-ON connectors are for CANBUS and auxiliary digital
inputs. (See layouts on pages 4 to 6.)
•See system layout for Auxiliary Cable and Remote Pause/Blast.
•See installation notes for routing details (page 15).
•See function chart for connection details (page 13, 14).

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NOTE: INLINE SENSOR NETWORK(PN:R987376742) NEEDS TO BE
INSTALLED FOR SENSORS REQUIRING A PULL UP RESISTOR , SUCH AS
WHITE MOTOR TYPES.
8 Cable Function Chart
Standard CS550 Cable Harness (PN: R987376368)
*Wiring changes with Spinner reverse mode on firmware 99 and above
Cable Label
Primary Function
Secondary Function
S5 SPINNER Spinner Feed Prewet(Spn Rvs)
S4 CONV.
Conveyor/Auger Feed
S12 ANTI-ICE
Anti-ice Feed, Boom L
Cross CONV(Cross Cnv, Metric)

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CS550Lite Cable Harness (PN: R987376367)
Spinner Rvs (Spn Rvs RC Firmware 98 and lower)
*Gate Lower (Spn Rvs with RC firmware 99 and up)
S11 LIQUID Pre-wet Feed Boom L (3Boom Anti-icing)
Spinner Fwd (Spn Rvs RC Firmware 98 and lower)
*Gate Raise (Spn Rvs with RC firmware 99 and up)
G1 GATE RAISE
Gate Raise Feed
Cross CONV1(Cross Cnv, Imperial)
Boom L (Liquid+)
Gate Raise (Spn Rvs with RC firmware 98 and lower)
*Spinner Fwd (Spn Rvs with RC firmware 99 and up)
G2 GATE LOWER Gate Lower Feed Cross CONV2( Cross Cnv, Imperial)
Boom Right(Liquid+)
Gate Lower (Spn Rvs with RC firmware 98 and lower)
*Spinner Reverse (Spn Rvs with RC firmware 99 and
up)
GS 12V 12V Output W/GS Boom C(3 Boom Anti-icing)
Chute Left(Pattern)
Air Gate(Air Gate)
Boom C(Liquid+)
Cross Cnv Dig(Cross Cnv, Metric)
REVERSE Auger Reverse Feed Boom R(3 Boom Anti-icing)
Chute Right(Pattern)
Cross Dig(Cross Cnv, Metric)
S3 GSS
Ground Speed Input
S6 CSS
Conv Speed feedback
S9 LSS
Pre-wet Flow Feedback
Spinner Motor Speed (Wt/Area)
S10 GATE SS
Gate Pos Feedback
S8 SPIN SS
Anti-ice Flow
Feedback
AUX SS Temp &Pressure Inputs Chute Position Input (Pattern)
*Spinner Fwd/Rvs select Pin 5 (Spn Rvs with RC
firmware 99 and up)
Cable Label
Primary Function
Secondary Function
S5 SPINNER Spinner Feed Boom L(3 Boom Anti-icing)
Prewet(Spn Rvs)
S4 CONV.
Conveyor/Auger Feed
Boom R(3 Boom Anti-icing)
S11 LIQUID
Pre-wet Feed
Boom C( 3 Boom Anti-icing)
Spinner Fwd(Spn Rvs)

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S7 REVERSE
Anti-icing/Auger Reverse
/GS12/Air Gate
Option selectable, one function only
S3 GSS
Ground Speed Pulse
S6 CSS
Conveyor Speed Feedback
S9 LSS
Pre-wet Flow Meter Feedback
S8 SPIN SS
Spinner Speed Feedback
Anti-ice Flow Feedback
AUX SS
Pressure Input

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9 Installation Notes
9.1 Step 1
Unpack all the supplied parts and check the packing list for completeness.
9.2 Step 2
Untie and layout all the cables supplied, to ensure proper lengths.
Note: Electromagnetic devices such as relays, magnetic switches and solenoids, can
generate large negative voltage spikes. These large spikes are conducted into the vehicle’s
electrical system and may adversely affect all electronic devices including engine
computers. It is strongly recommended that these electromagnetic devices be electrically
suppressed. See warnings and instructions in Body Builder manuals.
1. Connect the Controller 12V power supply and the ground wire using a dedicated circuit
only. (Connect to the ignition disconnect, if available. Otherwise, connect directly to the
battery.)
2. Ensure wiring for transmission devices such as radios, etc. are not attached to the
controller or bundled with the controller wiring.
3. A sufficiently large distance to radio systems must be maintained.
4. Make sure all mounting posts are properly grounded; a direct ground wire to the
negative battery post is recommended. Floor mats and undercoating will interfere with
proper grounding.
5. Disconnect the battery terminals before welding on a vehicle with electronic equipment.
6. Disconnect the negative battery terminal when wiring electronic devices.
7. Mount the consoles so that they do not interfere with vehicle controls or obstruct
visibility.
8. Mount microcontrollers so that oil and salt spray do not contact the housing.
9. Route cables so that they will not be abused, damaged or immersed in oil.
10. When routing cables through metal opening, always use grommets to prevent cable
damage.
11. When running wires around a dump box pivot point, ensure no connectors can be
separated when the hoist is activated.
12. Tie cables clear of all moving parts like drive-axles or conveyor chains.
13. Observe the cable labeling (under the clear cover) for the proper termination of inputs
and outputs.
14. Use dielectric grease on all external cable connections and pins to ensure proper
corrosion protection.
15. Thoroughly clean all power and ground terminals before connecting power harness.
16. Stand clear of any hydraulic functions when first powering up the system
17. DO NOT drill holes in any of the enclosures.
18. DO NOT mount components onto the sides, top or front of the CS-150.

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19. DO NOT re-wire any of the consoles or cable harnesses.
20. DO NOT weld on the vehicle without completely disconnecting all electronic consoles.
21. The cylindrical post on which the CS-150 console rests is the only point that may be
used for mounting purposes as no circuitry or wiring is present inside it.
Warning:
•DO NOT remove the fuse holder on the main harness.
•Replace fuse with appropriate rating (see fuse chart)
2-2 MAIN HARNESS R987376367 10A
4-4 MAIN HARNESS R987376368 15A
150 RCE IN-VALVE HARNESS R987376374 20A
150 RCE IN-CAB HARNESS R987376369 20A
***Failure to maintain proper fuse protection can lead to
product damage and fire hazard not covered by warranty.
Failure to follow the recommendations will void your warranty.

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10 Installation Test Checklist
Work order #:
Date:
Part number:
Software Version:
Serial number:
Signature:
After all controller cables and hydraulics are plumbed – vehicle hopper empty
OK
NOTES
Start the vehicle – engage hydraulic pump
Power on display, check for backlight and display operation
Press the “speed” field and hold the “up arrow” for 5 seconds – Release (Turning on
simulated ground speed)
Press the up arrow again to increase speed to 20
Rotate all the dials clockwise to 5 – rate should change
Verify that the conveyor/auger is operating – feedback?
Verify that the spinner is operating
Verify that the liquid pump is operating – feedback?
Verify that the gate cylinder and sensor is operating
(if equipped)
Press the speed down arrow to lower the speed to 0 –
press the speed field to exit
Drive the vehicle to check that vehicle speed registers
Activate the joystick as defined in the OSD test drawing –
verify proper actuation
Test special functions – power float, low oil, emergency raise
Test auxiliary switches for proper operation
The above procedure is a simple way to verify system connections,
hydraulics operation, and sensor feedback. It may not work for all the
systems. The reliable way to test is to follow the steps in 550
Calibration Manual.

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11 Warning
This glass LCD touch screen display has been extensively tested and validated against its
intended use. This glass could crack and break if the display is dropped on to a hard
surface or receives a substantial impact. If the glass chips or cracks, discontinue use and
contact Bosch Rexroth Canada to have it replaced - do not touch or attempt to remove the
broken glass. Any misuse/abuse causing damage, whether intended or not, will become the
sole responsibility of the owner/buyer which will render the warranty of this product, void
Notes

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