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Bozzio Joysteer Generation 1.0 Manual Download Page 11

Universal System Manual 

Bozzio AG * joysteer® 

page 11 of 56 

4.2 

Converter module steer, brake 

 

The positioning is vehicle specific. Refer to the vehicle specific manuals for details. In each 
case the order from top to bottom is 

always

 as following: 

 

S1 

= 

Steering converter module 1 

S2 

= 

Steering converter module 2 

B1 

= 

Braking converter module 1 

B2 

= 

Braking converter module 2 

 

Important: 

The housing needs to be grounded by connecting it to the vehicle chassis. If this is 
done with a cable, its cross section must be at least 2.5 mm

2

. The cable is to be as 

short as possible. 

 

 

Summary of Contents for Joysteer Generation 1.0

Page 1: ...a product of the company Bozzio AG Universal System Manual EN_Universal_System_Manual_2_V15 190131 docx Aarbergstrasse 5 2560 Nidau Switzerland ...

Page 2: ...odule SAM 14 4 6 Brake actuator module BAM 16 4 7 Pulse test box 17 4 8 Display module 18 4 9 Steering sensor module 19 4 10 SmartGas2 20 4 11 Software and Servicemanager 21 5 MMI S MEN MACHINE INTERFACE 24 5 1 MMI Micro wheel 24 5 2 MMI One hand joystick 24 5 3 MMI Two hand joystick 25 5 4 MMI Gas brake slide 26 5 5 MMI Handlebar 27 5 6 MMI Low force joystick 32 5 7 MMI 4 way joystick 33 5 8 MMI ...

Page 3: ... 7 3 Remote access Kit 38 7 4 Module rack 40 7 5 Instructor Switch 41 7 6 Quick exchange Kit 42 7 7 8 shaped brackets 42 7 8 Instructor Plug Kit 43 8 SAFETY INFORMATION 44 9 FUNCTIONAL TEST 45 10 ANNEX 1 SYSTEM ERROR MESSAGES AND TROUBLESHOOTING 46 11 DOCUMENT INFORMATION 55 11 1 Fundamentals 55 11 2 Document history 55 ...

Page 4: ...whereby all points need to be carried out as described This document describes all non vehicle specific installation steps Refer to the corresponding vehicle specific manuals for details This document applies to the joysteer system generation 2 0 The main change from generation 1 0 to generation 2 0 is as following Display module Alarm module joysteer generation 2 0 joysteer generation 1 0 ...

Page 5: ...airs by companies not trained by Bozzio AG Installation maintenance repairs by personnel not trained by Bozzio AG Installation maintenance repairs not according to the manuals Installation maintenance repairs of components modules which are not mentioned in the part list Installation maintenance repairs of any MMI Man Machine Interface which has not been released by Bozzio AG in written form Usage...

Page 6: ...tems remain therefore driving by using the steering wheel and pedals is still possible joysteer is modular The system can be upgraded with further modules at any given time 3 2 Conventional driving with J PAS function The vehicle can either be driven by with the MMI or conventionally with the steering wheel When driving with the steering wheel the motors are also commutated with the J PAS function...

Page 7: ...Universal System Manual Bozzio AG joysteer page 7 of 56 3 3 System overview Important The backup battery is not included in joysteer s delivery pack storage and security aspects CAN Adapter ...

Page 8: ...dules or to modify them in any way In case of any faulty parts the entire module is replaced and repaired by the producer of joysteer only Nominated car adaption companies are not allowed to repair any modules Exchanging of modules can only be carried out by the nominated car adaptation company Exception EnergyAlarm module This module contains electrical fuses Nominated car adaption companies are ...

Page 9: ...nd backup battery Refer to the vehicle specific manual for the correct positioning of the EnergyAlarm module Important To fix the cable harness to the EnergyAlarm module only lock nuts are to be used Connections are to be sufficiently insulated Risk of short circuit The ground cable of the vehicle electric system and backup electric system has to be connected to the battery The housing needs to be...

Page 10: ...uator 30 A F8 BACKUP Braking converter 30 A F7 BOARD Braking converter 20 A F1 BOARD BACKUP Connection 20 A F2 BOARD BACKUP Connection 30 A F3 BOARD Steering converter 30 A F4 BACKUP Steering converter 10 A F5 BOARD Steering sensor 10 A F6 BACKUP Steering sensor F10 BACKUP Steering braking actuator 5 A F12 BACKUP Energy alarm 5 A F11 BOARD Energy alarm F10 F9 F8 F7 F1 F2 F12 F11 F3 F4 F5 F6 ...

Page 11: ... each case the order from top to bottom is always as following S1 Steering converter module 1 S2 Steering converter module 2 B1 Braking converter module 1 B2 Braking converter module 2 Important The housing needs to be grounded by connecting it to the vehicle chassis If this is done with a cable its cross section must be at least 2 5 mm2 The cable is to be as short as possible ...

Page 12: ...ing diagrams manual It is necessary to ensure that the harness is not damaged or it could be damaged by any sharp edges If required the cables are to be protected with an appropriate product It is important to ensure that the plugs don t experience any tension The shielding of the cable harness has to be grounded by connecting it to the vehicle chassis Important The cable harness is not allowed to...

Page 13: ...e Speed Signal The Park Signal is detected with the separate mechanical and redundant P Switches CA2B Park Shutdown behaviour 1 There are no P Switches to be mounted and the Gear in Park signal is read from the CAN Adapter For safety reasons the shutdown behaviour is confirmed with a button operated by the user The detailed description for installation can be found in the enclosed description with...

Page 14: ...g 3 Mounting of the brackets refer to vehicle specific manual Temporarily only tighten the screws by hand 4 Mounting of the steering actuator module straight ahead position The steering actuator module should not be rotated Four complete rotations are possible therefore the centre position is pre set The respective seal is only to be removed immediately prior to installation 5 Ensure all functiona...

Page 15: ...he motors are rotated passively there is an increase of friction Whilst the joysteer system is turned off the friction of the steering actuator should not increase significantly If this is the case the steering actuator is misaligned and the screws of the brackets need to be loosened slightly By sequential tightening of the screws the alignment of the steering column to the steering actuator is en...

Page 16: ...positioning is vehicle specific Refer to the vehicle specific manuals for details Important After installation of the brake actuator module the pedals need to be protected against accidental pushing operation or jamming of the user s feet Suitable covering is not included in the delivery pack ...

Page 17: ...y The length of the double core cable to the plug X331 can be adapted to the vehicle Following the provided plug type Super Seal is to be placed according to the schematic below Important Both 10mm2 cables are not to be shortened nor lengthened Puls Test Box Backup Battery 10mm2 10mm2 125 A Adjust length EnergyAlarm module X 331 ...

Page 18: ...vides visual and acoustic signals regarding the safety status of the joysteer system The display module is to be connected directly to the EnergyAlarm module Important The housing needs to be grounded by connecting it to the vehicle chassis If this is done with a cable its cross section must be at least 2 5 mm2 The cable is to be as short as possible ...

Page 19: ...while positioning the steering sensor module No hindrance of the airbag functionality Otherwise the airbag needs to be deactivated by a professional dealer Solid mechanical form fit fixations to the vehicle Proper laying of the cables to avoid damage by the user Important The housing needs to be grounded by connecting it to vehicle chassis If this is done with the cables the cable cross section mu...

Page 20: ...Universal System Manual Bozzio AG joysteer page 20 of 56 4 10 SmartGas2 See universal and car specific SmartGas2 manual ...

Page 21: ...contact Bozzio AG Important The M16C flasher has to be installed and released by Bozzio The dealer is not allowed to transfer the installation to other computers There is a risk to completely and definitively erase the controller Operating System The M16C flasher has to be configured as shown on the print screen below Content of a software release The following components are included in a softwar...

Page 22: ... 7 Start up the joysteer System 8 Connect the Programming Box to one of the Converter Modules or to the EnergyAlarmModule Check if the red stripe from the ribbon cable is on the right position 9 Put the switch on the Programming Box on prog and press the reset button 10 Repeat step 8 10 for all Modules 11 Open the folder Hex Files and go into the folder corresponding to your joysteer system Instal...

Page 23: ...emanager is compatible with the software version of the joysteer system For nominated car adaption companies the newest releases are available for download on www joysteer ch In order for the Servicemanager to be able to communicate with the joysteer system a CAN dongle needs to be connected to the notebook By using the Servicemanager a system can be parameterised and the system status can be anal...

Page 24: ... There is no mechanical stop The stops are electronic and defined via the Servicemanager 5 2 MMI One hand joystick The one hand joystick is available for the functions steer brake and accelerating For steer only there is a corresponding version without the rocker switch The joystick can be used with the left or the right hand The thumb rest of the plastic handle can be oriented to the left of the ...

Page 25: ...he required lengths the rods are delivered excess length 2 Cut the two rods to two equal lengths each 3 Cut a thread of M5 in the middle of each rod 4 In the centre a threaded rod M5 is placed tightened with locknuts on both ends and secure with Loctite 243 This is the set point for fracture for the airbag deployment 5 Mount to the swivel heads with lock nuts Secure with Loctite 243 For demo vehic...

Page 26: ...gas brake slide can be configured to suit different requirements 1 push accelerate or 2 push brake The gas brake slide is delivered with configuration 2 Following steps need to be taken to amend to configuration 1 1 Rotation of the gas brake slide front to back by 180 around its vertical axis 2 Unscrew the lid with handle and rotate by 180 around its vertical axis again lid and handle are therefor...

Page 27: ...io AG joysteer page 27 of 56 5 5 MMI Handlebar MMI Handlebar with gas brake MMI Handlebar steer only The installation is always carried in combination with a cantilever The steering sensor module is installed inside the cantilever ...

Page 28: ...ured to suit different requirements There are the following 4 combinations 1 Left gas right brake 2 Left brake right gas 3 Left brake and gas 4 Right brake and gas Depending on the combination the basic sensor unit gas or basic sensor unit brake requires to be adjusted see images below Ensure that the washers and the circlips are placed properly Basic sensor unit brake ...

Page 29: ...Universal System Manual Bozzio AG joysteer page 29 of 56 Basic sensor unit gas The torsion spring can be mounted in 2 positions and is always required Apply Loctite 243 to the Allan screw ...

Page 30: ...Universal System Manual Bozzio AG joysteer page 30 of 56 Configuration handlebar 1 Left gas right brake Configuration handlebar 2 Left brake right gas ...

Page 31: ...Universal System Manual Bozzio AG joysteer page 31 of 56 Configuration handlebar 3 Left brake and gas Configuration handlebar 4 Right brake and gas ...

Page 32: ... available of the Low force joystick LFJ steer brake gas LFJ steer only LFJ gas brake Important As this MMI is an electronic solution and needs to be protected from spray water it is absolutely not allowed to open the module or remove the joystick from the casing The top part Nubsi is delivered in a non mounted position This allows to mount custom specific top parts For safety reasons assure to fi...

Page 33: ...he steering sensor module can also be mounted vice versa 4 way joystick at the front steering sensor module at the rear In this case the steering sensor module can be used as armrest The gas brake movements have to be inverted mechanically the steering movements can be inverted electronically via Servicemanager The 4 way joystick can be used with very low force feedback therefore 2 mechanical stop...

Page 34: ... 34 of 56 5 8 MMI Gas brake Tilter This MMI is only used for the function of accelerating and brake 5 9 MMI 2 way joystick This MMI is only used for the steering function Configuration of the steering movement Refer to chapter 5 7 MMI 4 way joystick ...

Page 35: ...ontacts may break Always screw by rotating the thread of the sensor Always untwist the sensor cable before plugging in X51 X54 on the cable harness 1 Put the MMI in max gas position and adjust X51 30 2 Put the MMI in zero position and adjust X52 X51 10 3 Put the MMI in zero position and adjust X53 X51 4 Put the MMI in zero position and adjust X54 X53 10 5 Move the MMI from max gas to max brake The...

Page 36: ... following types are to be used as backup battery The Parameters Capacity Low and Capacity Insufficient has to be set correctly depending on the choice made Type designation Parameters Opel Battery 12 Volt 60 Ah Opel order 12 01 003 or GM order 93 19 79 05 Capacity Low mV 10 200 Capacity Insufficient mV 10 000 Optima Yellow top YTS 4 2 12 V 55Ah Capacity Low mV 11 200 Capacity Insufficient mV 10 9...

Page 37: ...stem to set the parameters The RS 232 program box is required to perform a SW update The communication toolbox does not include a computer The communication toolbox is required only once per each dealer and is not related to one specific joysteer system 7 2 CAN Dongle The CAN dongle is required to communicate between the Servicemanager and the joysteer system to set change the parameters The CAN d...

Page 38: ... 7 3 Remote access Kit The remote access Kit RAK allows the dealer to remotely connect to the customer car without having the car in the workshop The Servicemanager can be operated remotely changing parameters reading log etc For remote access the end customer has to plug in his personal Laptop into the USB slot The internet connection goes via local Wi Fi or a Hot Spot Mobile phone With the deliv...

Page 39: ...extension cable 1 8m 1 x USB adapter female female 1 x CAN Dongle CD 03 A 7 3 2 Installation and configuration Connect the USB CAN Dongle to the joysteer system connector X301 Install the dashboard plug in the car Use the USB adapter to connect the dashboard plug and the CAN dongle together The USB extension cable is used to connect your computer with the dashboard plug Use the end customer s Lapt...

Page 40: ...l System Manual Bozzio AG joysteer page 40 of 56 7 4 Module rack Optional device to mount the converters and the EnergyAlarm module available for the following car types For Installation see car specific manual ...

Page 41: ...r plug Installation Connect both adapter cables in between the connectors X21 and X22 of the steering actuator By pressing the switch during the normal operation of the joysteer system both motors of the steering actuator will be immediately disabled and the steering wheel can be controlled conventional Once the switch was activated switch off the joysteer system pull out the Instructor Switch bac...

Page 42: ...nstruction cars It eases the exchange of MMIs Includes a set for 4 MMI s Not needed for exchanging Low force MMI s 7 7 8 shaped brackets The 8 shaped brackets are to be used to place the MMI s into the correct position The only use is for evaluation demo and instruction cars Includes one fixation pin for each bracket Usually four 8 shaped brackets are needed per hand four left and four right ...

Page 43: ...X52 3 white F X53 1 red G X53 2 black H X53 3 blue J X54 1 red K X54 2 black L X54 3 blue M 12pin connector male contacts standard MMI A X51 1 brown B X51 2 blue C X51 3 black D X52 1 brown E X52 2 blue F X52 3 black G X53 1 brown H X53 2 blue J X53 3 black K X54 1 brown L X54 2 blue M X54 3 black X51 X52 X53 X54 Standard MMI 12pin connector male contacts For LFJ A X51 1 turquoise B X51 2 blue C X...

Page 44: ...d to the repair shop with the system switched off Important For safety reasons the vehicle speed is reduced 10 Minutes after the alarm sound and the red lamp lighting up The vehicle speed is then limited to 40km h 3 The user must be instructed to check the visual and acoustic alarms when starting the system 4 A functional test is defined for the staff carrying out the regular technical inspection ...

Page 45: ...Universal System Manual Bozzio AG joysteer page 45 of 56 9 Functional test After the installation the system needs to be tested according to a strict procedure Please refer to the maintenance manual ...

Page 46: ...anager and check if all modules S1 S2 B1 B2 EAM are correctly booted up Variable Description 𝑈𝑃𝑢𝑙𝑠𝑡𝑒𝑠𝑡 Battery voltage after pulse test 𝑃 𝑃𝑎𝑟𝑎𝑚𝑒𝑡𝑒𝑟 𝑁𝑎𝑚𝑒 A specific parameter in the Servicemanager 𝐼𝑆𝐴𝑀 Steering actuator module SAM motor current 𝐼𝐵𝐴𝑀 Braking actuator module BAM motor current 𝑢𝐵𝑜𝑎𝑟𝑑 Board battery voltage 𝑢𝐵𝑎𝑐𝑘𝑢𝑝 Backup battery voltage 𝑃𝑎𝑟𝑘𝑆𝑤𝑖𝑡𝑐ℎ1 Park switch 1 𝑃𝑎𝑟𝑘𝑆𝑤𝑖𝑡𝑐ℎ2 Park switch...

Page 47: ...ge the backup battery Backup battery capacity is low 𝑈𝑃𝑢𝑙𝑠𝑡𝑒𝑠𝑡 𝑃 𝐸𝐴𝑀 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝑙𝑜𝑤 Error X066 EAM Park Check the two park position switches and the wiring Park gear reading failed 𝑃𝑎𝑟𝑘𝑆𝑤𝑖𝑡𝑐ℎ1 𝑃𝑎𝑟𝑘𝑆𝑤𝑖𝑡𝑐ℎ2 𝑙𝑜𝑛𝑔𝑒𝑟 𝑡ℎ𝑎𝑛 1𝑠 Error X067 SAM Overload Average steering torque is to high Check the power steering of the vehicle Check parameter Actuator Overload Current Apply correct steering input 𝑖𝑜𝑣𝑒𝑟𝑙𝑜𝑎𝑑 𝑃 ...

Page 48: ...re is higher than 70 C Error X073 EAM Speed to high Adjust speed between Servicemanager and car speed Speed is higher than 220km h Error X074 EAM No Speed Signal Check Speed sensors or CAN Adapter No speed signal longer than 10min Error X075 BAM Stroke to big Readjust Brackets Stroke has to be shorter than 80 mm Error X076 EAM Test Charge the backup battery Set parameter Minimal drop pulse test mV...

Page 49: ...fferent states Error X136 BS Gas Brake Check if the brake pedal always goes back in the zero position Check mechanical friction within the brackets If handlebar is mounted then check the calibration Brake pressure remains during driving Accelerating is not possible If the gas output is higher than 15 and the pressure is bigger than 0 bar for longer than 30 s Error X198 SSM Enc Start up test has fa...

Page 50: ...nd the corresponding cable to the brake pressure sensors Check the mechanical and hydraulic connections of the Sensors Check Output Pressure in the Servicemanager Pressure difference between brake circuit 1 and 2 The difference of Pressure Sensor 1 and Pressure Sensor 2 is bigger than 20bar Pressure Sensor 1 or 2 measures more than 199bar or less than 8bar One more of these conditions are true for...

Page 51: ...km h Error X215 EAM Bat Charge the backup battery Change backup battery Backup battery capacity is insufficient 𝑈𝑃𝑢𝑙𝑠𝑡𝑒𝑠𝑡 𝑃 𝐸𝐴𝑀 𝐶𝑎𝑝𝑎𝑐𝑖𝑡𝑦 𝐼𝑛𝑠𝑢𝑓𝑓𝑖𝑐𝑖𝑒𝑛𝑡 Error X216 EAM Measure Replace EAM Voltage measurement failed At the beginning of the pulse test 𝑎𝑏𝑠𝑜𝑙𝑢𝑡𝑒 𝑢𝑏𝑎𝑐𝑘𝑢𝑝1 𝑢𝑏𝑎𝑐𝑘𝑢𝑝2 1𝑉 𝑎𝑏𝑠𝑜𝑙𝑢𝑡𝑒 𝑢𝑏𝑜𝑎𝑟𝑑1 𝑢𝑏𝑜𝑎𝑟𝑑2 1𝑉 When the system is running 𝑎𝑏𝑠𝑜𝑙𝑢𝑡𝑒 𝑢𝑏𝑎𝑐𝑘𝑢𝑝1 𝑢𝑏𝑎𝑐𝑘𝑢𝑝2 1𝑉 𝑎𝑏𝑠𝑜𝑙𝑢𝑡𝑒 𝑢𝑏𝑜𝑎𝑟𝑑1 𝑢𝑏𝑜𝑎𝑟𝑑2 1𝑉 𝑎𝑏𝑠𝑜𝑙𝑢𝑡𝑒 𝑢...

Page 52: ...chdog communication Error Error X228 CT SW Assure that all modules have the same SW versions Check fuses Check in Servicemanager if all modules are running Different SW versions installed During Start up The modules don t have the same software version or doesn t send an answer Error X229 CT SP Load complete Parameterset Different Service Parameter installed Board and backup module haven t the sam...

Page 53: ...iring on P Ignition and Velocity Check P Switch Park Ignition or Velocity Signal are wrong Speed 15km h AND Park gear 1 is in Park Park gear 2 is in Park Ignition is off Ignition is off AND Park gear 1 is not in Park Park gear 2 is not in Park Error X238 Unsafe Car Put vehicle in Park position and restart System Check Park Switch Check in Servicemanager if all modules are running Check fuses Befor...

Page 54: ...onnection Shutdown Button is pressed during driving or start up Error X245 SAM Phase Check SAM cables Control if the instructor Switch is pushed Check if the SAM is mechanically properly mounted low friction Check if the SAM has to much friction non mounted SAM needs to much current to steer Error X246 SAM Overload Check Power steering check installation If LFJ is mounted then call joysteer servic...

Page 55: ...west naming convention Update and edit of document V02 02 12 2009 Hem Revision including graphics photos Additions and completions V02 09 12 2009 Arc Document naming change Update steer brake function V03 14 01 2010 Hem Update annex 1 and annex 2 V04 14 06 2010 Hem Update annex 2 according to last SW version V05 02 11 2010 Kam Revision V06 10 11 2010 Hem Update of document corrections English tran...

Page 56: ...ate on SM Java 8 and SW update Precaution regarding Issue 784 31 03 2015 V13 17 05 2016 Hem Update in conjunction with a general revision new cable tree Smart Gas2 new Shutdown behaviour 31 05 2015 V14 02 05 2017 Hem Update in relation with a new SW release with additional diagnosis 31 05 2017 V15 29 01 2017 Hem Update of Error List with enhanced descriptions 31 01 2019 ...

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