Installation Guide. Eaton Hydraulic Launch Assist (HLA) TRIG1200 EN-US June 2012

Transcription

1 Installation Guide Eaton Hydraulic Launch Assist (HLA) TRIG1200 EN-US June 2012

2

3 Table of Contents Warnings and Cautions General Information How to Use this Guide Hydraulic Hybrid Overview Major Subsystems and Components. 3 Typical Installation and Configuration. 5 Installation Summary Component Installation Communications Commissioning Special Tools Installation Requirements Chassis Requirements Engine Controller Driveline Break Pressure Sensor Anti-Lock Breaking System (ABS). 10 Pneumatic Supply Component Installation HLA System Requirements Pump/Motor and Transfer Case (PMTC) Subsystem Accumulator and Reservoir Lifting Requirements Reservoir Subsystem Breather Installation and Use Instructions Reservoir Installation Accumulator Subsystem Accumulator Installation Cooler Subsystem Cooler Installation Hose Subsystem Hose Definitions Electrical Requirements Chassis Requirements Ignition Line Voltage Interface Wiring HLA ECU Connector HLA Cooler Interface Connector. 37 Power Requirements Harness Routing Requirements Harness Design Recommendations 39 Data Link Requirements Messages In-Cab Display HLA System Harness Connection Reservoir Connections Accumulator and Cooler Connections Chassis Harness Connection to HLA System In-Cab Display evu End Of Line (EOL) Inspection Commissioning Procedure Pre-commission Inspection Oil Fill Procedure System Air Purge Necessary Hardware Pre-Delivery Inspection (PDI) Real Time Warranty Pre-Call Checklist.. 54 Installer Capabilities Material Handling Table of Contents i

4

5 Warnings and Cautions Warnings and Cautions The description and specifications contained in this service publication are current at the time of printing. Eaton Corporation reserves the right to discontinue or modify its models and/or procedures and to change specifications at any time without notice. Any reference to brand name in this publication is made as an example of the types of tools and materials recommended for use and should not be considered an endorsement. Equivalents may be used. WARNING Warning indicates you will be severely Injured or Killed if you do not follow the indicated procedure. Warnings and Cautions CAUTION Caution indicates an Immediate Hazard, which could result in Severe Personal Injury if you do not follow the indicated procedure. IMPORTANT Important indicates Vehicle or Property Damage could occur if you do not follow the indicated procedure. Note: Note indicates additional detail that will aid in the service or repair of component or system. WARNING HLA system will not stop vehicle. Driver must be prepared to apply brakes anytime the HLA system is in regenerative braking. Before doing maintenance: Shut off the engine. Chock the wheels. Set the parking brake. Oil level must stabilize before reading the volume. Improper oil level will result in damage to HLA system components. When the vehicle is turned off, the oil in the accumulator will drain back to the reservoir. This process takes approximately ten seconds. When the oil level has stabilized, read the oil level through the sight glass. Fill to the top of the sight glass. Use only HLA system approved Hydraulic Fluid 5W-20 OS in the HLA system. Other fluids may damage components or reduce performance. Use only full synthetic 75W-90 per full efficient axle fluid spec SHAES 256 Rev C in the Transfer Case. Damage may result with other fluids. Do not use liquid nitrogen, oxygen or compressed shop air to charge accumulator. Failure to properly install the thermal relief fuse cap could result in an accumulator burst event if the accumulator becomes overheated. Avoid suffocation. Nitrogen asphyxiates. Move to ventilated area upon opening the vent. See MSDS for more information on nitrogen gas. 1

6 Warnings and Cautions Improper nitrogen gas pressure will result in reduced HLA system performance. Add nitrogen slowly for first 7 bar (100 psi) to new or rebuilt accumulator. Do not exceed 2 bar (30 psi) per minute. Bladder damage may result if rapidly inflated. No other vehicle components may be in contact with the HLA system. The HLA system may not be used to support other vehicle components. CAUTION Escaping nitrogen gas is extremely cold and may freeze skin. Avoid skin contact with the nitrogen gas to prevent freezing damage to skin tissues. IMPORTANT For proper operation, use only dry industrial grade nitrogen to charge accumulator. 2

7 General Information General Information How to Use this Guide This Eaton publication is intended to be a reference guide for the installation of the HLA system. This information benefits the installer by providing the correct installation requirements and procedures to ensure the utmost in satisfactory operation and long service life. For additional information, see the Suggested Tools section. Attention: Risk of voiding warranty. WARNING This Installation Guide provides installation procedures, requirements, and recommendations which are collectively required and necessary for the proper functioning of Eaton HLA Systems. Failure to follow these procedures, recommendations, and requirements will void the warranty in certain cases. Please contact your Eaton representative before taking any action departing from this Installation Guide. General Information The HLA system is compatible with electronically governed engines equipped with an SAE J1939 data link and certified by Eaton Corporation. Installed HLA systems must meet the requirements in this guide and be approved by Eaton Application Engineering Team. Contact Eaton Application Engineering Team or the installer's Application Engineering department for the proper application form. All applications must be submitted for approval. Hydraulic Hybrid Overview The Hydraulic Launch Assist (HLA ) is a hybrid system designed to increase fuel economy and increase vehicle brake life in vehicles with heavy start-stop drive cycles. The system does this by capturing energy during braking and then reusing the energy to launch the vehicle. HLA is a parallel system which means the vehicle can operate like a non-hybrid vehicle if the HLA shuts down. Another benefit of the parallel architecture is both the engine and the HLA system can turn the drive axle (together or independently). The HLA system is an addition to existing drivelines and does not replace the conventional vehicle transmission. Major Subsystems and Components The HLA system consists of five major subsystems, each with numerous subcomponents. The subsystems and major subcomponents are listed below. The list is for reference only and should not be mistaken for a complete bill of materials. Pump/Motor and Transfer Case Subsystem Pump/Motor Assembly Transfer Case Assembly Mounting Brackets ECU Enclosure HLA Wire Harness Accumulator Subsystem Accumulator Mounting Clamps 3

8 General Information Reservoir Subsystem Reservoir Filter Breather Cooler Subsystem Cooler Mounting Brackets Cooler Subassembly Wire Harness Hose Subsystem Filter Block Subassembly Suction Hose Subassembly Cooler Inlet Hose Subassembly Cooler Outlet Hose Subassembly Case Drain Hose Subassembly Low Pressure Hose Subassembly High Pressure Hose Subassembly The following table illustrates the approximate subsystem weights. Subsystems Approximate Weight (lbs) Pump/Motor Transfer Case 942 Accumulator 382 Reservoir 176 Hose 104 Cooler 60 It is recommended that the installation be conducted in the following order: 1. Install all hardware components to the chassis. It is to the installer's discretion to determine the order of hardware installation (front to rear, inside to outside, etc.). 2. Install all hose subassemblies. 3. Make wire harness connections. 4

9 General Information Typical Installation and Configuration General Information Point of Use Filter Pump/Motor Reservoir Transfer Case Filter Sight Level Gauge Gas Port Accumulator ECU Cooler 5

10 6 General Information

11 Installation Summary Installation Summary The following is a brief summary of items required on the host chassis that are to be provided by the installer. Details are provided throughout the document on each item in the list. Component Installation 1. Installation holes, mounting brackets, mounting hardware, and torque specifications to secure Pump/Motor and Transfer Case (PMTC) to chassis 2. Installation holes, mounting brackets, mounting hardware, and torque specifications to secure Accumulator to chassis 3. Installation holes, mounting hardware, and torque specifications to secure Cooler to chassis 4. Installation holes, mounting hardware and torque specifications to secure Reservoir to chassis 5. Input and output driveshafts 6. Pneumatic supply to the Pump/Motor and Transfer Case (PMTC) 7. Design and installation of the electrical harness from the chassis to HLA 8. Design and installation of the electrical harness to the in-cab display 9. Selection and installation of an in-cab display 10. Selection and installation of a brake pressure sensor 11. Selection and installation of an isolation mount 12. Installation of the HLA harness to the HLA components 13. Installation of the HLA fluid into the system 14. Installation of the Transfer Case fluid into the Transfer Case Installation Summary Part Name Manufacturer Part Number Quantity Required evu Driver Display Eaton/Cutler Hammer e00fp evu Driver Display connector Eaton/Cutler Hammer evu Driver Display terminal Tyco Electronics/AMP Brake pressure transducer Sensata Technologies Bendix: TI: 6CP3-1 1 Isolation mounts Lord CB HLA fluid Cognis (drum) 21 gallons/system (tote) Transfer case fluid Cognis Roadranger FE 75-W90 or equivalent 7.25 quarts/system Accumulator brackets 3 Pump/Motor brackets 2 or 4 (depending on design) Retrofit harness Eaton (optional) 7

12 Installation Summary Communications 1. The engine controller must accept speed and torque limit requests per SAE J The chassis must have an ABS system and the ABS system must be SAE J compliant. 3. The driver display must be able to receive the in-cab display message and display the signal information described in the Data Link Requirements section. Commissioning Run the purge process using the ServiceRanger tool on each vehicle. Special Tools Part Name Manufacturer Part Number Quantity Required Transfer pump filter cart (3 micron elements with 1000 beta ratio) Eaton CC0FRS Quick disconnect Aeroquip S 1 ServiceRanger software for commissioning/ Eaton Version 3.2 or later 1 troubleshooting (PC based) Nexiq USB link and vehicle interface adapter Nexiq Nitrogen charging kit Eaton 100AV00093A 1 1 8

13 Installation Requirements Installation Requirements Chassis Requirements Engine Controller The engine controller must accept speed and torque limit requests from source address 239: PGN 0 per SAE J See Data Link Requirements section for details. Driveline The driveline is the responsibility of the installer. There is a recommended minimum driveline length of 92 inches, as measured from the transmission output yoke to the drive axle input yoke, in order to install the HLA system. The HLA is supplied with a Spicer 1810 series driveline full-round yoke on the rear (axle side) and the option of an 1810 full-round or 1760 half-round yoke on the front (transmission side). Contact Eaton Application Engineering Team for additional driveline configuration requests. The installer is responsible for placement of the HLA system such that the driveline angles are acceptable. The input and output of mechanical power is accomplished via the host vehicle driveline. The following table illustrates the additional torque the HLA system imparts on the lower power train. Installation Requirements Requirement Max. Unit Notes HLA retarding torque 2750 ft-lb 1 HLA accelerating torque 2550 ft-lb 2 Notes 1 The vehicle driveline (from rear wheels to HLA system) must be capable of handling the retarding torque generated by the HLA system plus upper power train (engine + transmission) retarding torque. 2 The vehicle driveline must be capable of handling drive torque provided by the upper power train plus the assist torque provided by the HLA system. The following figure illustrates a typical installation, where the front of the vehicle is located to the right of the figure. 9

14 Installation Requirements Brake Pressure Sensor In order for the HLA system to function properly, it must know the amount of braking effort being input from the driver. The HLA requires the installation of a brake pressure sensor by the installer. This sensor will measure the brake system pressure that is being applied to the brakes. The wiring for this sensor is included in the electrical requirements section. The installer shall provide the brake pressure sensor and the associated wiring between the sensor and the chassis-to-hla connector. The brake pressure sensor shall meet the following requirements. It is the installer's responsibility to provide any additional wiring and the mating connector for the sensor. Power Supply Voltage: 4.75 / 5.25 VDC Supply Current: 12 ma Max Operating Temperature: -40 to 125 C Output Load: 51k Ohm Pull Down Output Signal Transfer Function:. Where P in is the sensor output in PSI, this translates to 0 psi reading at 0.5 volts and 150 psi at 4.5 volts Note: A Texas Instruments / Sensata 6CP3-1 pressure sensor is recommended for this application. Anti-Lock Braking System (ABS) The HLA system requires the chassis to have an Anti-Lock Braking System (ABS) and the ABS controller must be SAE J1939 compliant. The ABS must broadcast PGN per SAE J See Data Link Requirements section for details. Pneumatic Supply The HLA system requires a connection to the truck air supply. The air supply is used to activate a pneumatic valve on the transfer case clutch. The installer shall supply a connection from the chassis air supply to a pneumatic valve mounted on the transfer case. The chassis pneumatic system shall meet the following requirements: Pneumatic System Air Pressure: 60 psi minimum and 150 psi maximum. Pneumatic System Air Volume Delivery: 79 CC Port Fitting on Valve: ¼" Push-to-Connect (PTC) Component Installation The installer is responsible for ensuring proper installation of the HLA system components to the chassis. Any necessary installation holes, as well as, bolts, nuts, and tightening torques are the responsibility of the installer. If assistance is needed, the Eaton Application Engineering Team is available to provide recommendations. 10

15 Installation Requirements HLA System Requirements WARNING All screen shots shown throughout this document shall be considered as reference only. The screen shots are of a "typical" installation, but do not intend to define the only installation possible. All dimensions shown throughout this document shall be considered as reference only and are provided for the installer's benefit. Installation drawings provide the detailed dimensions of the HLA system. Contact the Eaton Application Engineering Team for more information. Pump/Motor and Transfer Case (PMTC) Subsystem Installation Requirements 11

16 Installation Requirements The following figures show the mechanical interfaces of the PMTC subsystem. Top View 17.7 in [450 mm] 26.7 in [678 mm] 23.6 in [599 mm] Right View Connects to Suction Hose 27.4 in [697 mm] 12

17 Installation Requirements Front View Oil Fill/Quick Disconnect Connects to Case Drain Hose Connects to High Pressure Hose Connects to Low Pressure Hose Installation Requirements A (see table) Connects to Cooler Yoke Combination 40.0 in [1015 mm] Engine Side Rear Side "A" in in. 13

18 Installation Requirements Accumulator and Reservoir Lifting Requirements The Pump/Motor and Transfer Case (PMTC) assembly must be oriented in the vehicle such that the transfer case is located on the transmission side of the driveline with the driveline underneath the assembly. The installer is responsible for selecting suitable bolt, nut, and torque specifications for mounting the PMTC to the chassis. The following figure is an example of a typical installation. The installer is responsible for brackets or mounting hardware necessary to install the PMTC to the chassis. The HLA system wire harness comes attached to the PMTC and bundled together. Do not unbundle the harness until after installation. 1 Use lifting eyes to raise pump/motor above chassis frame rails. 14

19 Installation Requirements Eaton has performed NVH analysis and recommends the installer utilize Lord CB isolation mounts between the PMTC mounting brackets and the chassis. These isolation mounts will help to minimize noise transmission from the HLA system to the chassis. Part Number Color Code Maximum Axial Static Load Rating Load Deflection A ±.03 B ±.01 C ±.015 D E ±.015 F ±.02 lbs N in mm in mm in mm in mm in mm in mm in mm CB Yellow Installation Requirements Part Dimensions Recommended Bolt Information Installation Requirements in H ±.03 mm in T ±.03 mm R ±.015 I D min. dia. in mm in mm K D min. dia. S D min. dia. in mm in mm English Metric SAE J249 Grade or Class ft lb F ± /2 M Size SAE J249 Nm AXIAL LOAD DIRECTION B DIA. A DIA. F I D SUPPORTED MEMBER H D E C DIA. T R S D K D SUPPORTING MEMBER 15

20 Installation Requirements The transfer case uses the existing vehicle pneumatic supply to engage or disengage the transfer case. Connection of the transfer case to the vehicle pneumatics is shown in the following figure. Connect OEM Air Supply 1 Connect OEM-supplied air line: Push air line through resistance into push-lock fitting. Tug air line to make sure connection is secure. 16

21 Installation Requirements Reservoir Subsystem While installing the reservoir, make sure the reservoir is oriented in such a way that the breather is on the top side. Ensure that the breather red pin is not visible. If red pin is visible, reset the indicator by gently tapping the base of the unit until the red pin is out of sight. Please refer to the following pictures for resetting the indicator. The installer is responsible for selecting suitable bolt, nut, and torque specifications for mounting the reservoir to the chassis. Breather Installation Requirements Breather Installation and Use Instructions 1 2 This unit has a change out indicator. If red pin is visible, reset indicator by gently tapping unit base until red pin is out of sight. Screw adapter on to threaded flange assembly on reservoir fill port. Caution: Hand tighten only. Do not use tools. Note: Replace water-gate when red pin is visible in top of dome or six months after installation date, whichever occurs first. 17

22 Installation Requirements The reservoir interface is described in the following figures. Left View 25.8 in [654 mm] 23.6 in [599 mm] 6.25 in [158 mm] Reservoir Mounting Face Temperature Sensor 26.3 in [668 mm] Filter 0.1 in [2.54 mm] Connects to Suction Hose Front View in [692 mm] Oil Level Sensor Filter 18

23 Installation Requirements Reservoir Installation 1 Install mounting studs: Align and thread studs through openings. Torque to 60 ± 6 ft-lb. 2 Align reservoir mounting bracket with chassis frame holes. 3 Install reservoir: Secure with washers and nuts. Torque to OEM specifi cation. Installation Requirements Clear Damaged 4 Verify breather indicator filter is clear. Note: Breather indicator may be red due to shipping damage. Contact Eaton quality representative for repair strategy. 19

24 Installation Requirements Accumulator Subsystem WARNING Please read the Material Handling section for details regarding handling pressurized accumulators. The Accumulator shall be mounted with the clamps described in the following figures. The clamps are part of the Accumulator subsystem and will be provided by Eaton. The installer is responsible for creating the mounting brackets to secure the clamps to the chassis. The installer is responsible for selecting suitable bolt, nut, and torque specifications for mounting the accumulator to the chassis. A minimum of three clamps are required for the steel accumulator. The clamp dimensions are shown and the allowable location of the three clamps are identified in orange. Note that the middle clamp should be placed in the center of the accumulator as detailed in the following figures. The accumulator orientation during installation shall be such that the two sensors that are installed at the hydraulic end of the accumulator are in a horizontal position relative to the ground. This ensures that the sensor guard is in the correct position to provide protection to the sensors from road debris. 20

25 Installation Requirements 76.3 in [1939 mm] Ø 9.5 in [241 mm] 27.6 in [700 mm] 24.9 in [632 mm] in [870 mm] 27.6 in [700 mm] 24.9 in [632 mm] Installation Requirements Nitrogen Fill Location and Thermal Relief Valve Pressure Sensor Proximity Sensor Connects to HP Hose Z D Torque to 35 ± 3.5 Nm (26 ± 2.6 ft. lbs) C H ØL B A K 21

26 Installation Requirements Accumulator Installation 1 Install mounting bracket to hanger and secure with bolts. Torque bolts to OEM specification. 2 Position accumulator into mounting brackets. 3 Install outer brackets to mounting brackets and secure with bolts. Torque bolts to 26 ft-lb. 4 Install accumulator shield after: Hoses are installed. Harnesses are connected. Note: Use tie wrap to secure harnesses to shield. 22

27 Installation Requirements Cooler Subsystem The cooler subassembly shall be mounted using the interface dimensions in the following figures. The installer is responsible for selecting suitable bolt, nut, and torque specifications for mounting the cooler to the chassis. Front View 20.8 in [528 mm] Cooler Inlet Installation Requirements Mounting Face 17.3 in [440 mm] Cooler Outlet Right View 3.9 in [100 mm] 6.3 in [160 mm] 9.25 in [235 mm] 23

28 Installation Requirements Cooler Installation 1 Align cooler mounting bracket with chassis frame holes. 3 Torque mounting hardware per OEM specifi cation. 2 Install mounting hardware. 24

29 Installation Requirements Hose Subsystem Eaton offers multiple hose packages to accommodate various installation configurations. Only hose packages approved and released by the Eaton Application Engineering Team can be used on the HLA system. If a change to the placement of HLA subsystems is desired which would alter the hose package design please contact the Eaton Application Engineering Team or representative. While routing hoses, do not exceed the minimum bend radius. Exceeding the minimum bend radius reduces hose life, causes additional stress on the fittings, could reduce HLA performance and may lead to an oil leak. Avoid bending the hose immediately after the fitting. This may cause excessive stress on the hose and fittings. Make sure all hoses are properly tied. Hoses should not be twisted during installation. Hoses should be kept/handled clean before installation to avoid any particle ingression. Installation Requirements The HLA system hose subsystem consists of six (6) hoses, including flange kits, O-rings, mounting hardware, and the filter block subassembly. The details for each hose location and installation can be found in the following figures and tables. The following pages will also detail the various hose assemblies and their installations. It should be noted that the installation screen shots are to illustrate where each hose in the hose subsystem needs to be installed. The screen shots do not depict actual installation routing. -24 Split Flange Case Drain Hose -32 Split Flange Cooler Inlet Hose -40 Split Flange Suction Hose Low Pressure Hose High Pressure Hose Cooler Outlet Hose 25

30 Installation Requirements Hose Definitions The hose size nomenclature utilizes the 16-inch system. The actual size of the hose is determined by placing the stated size in a fraction over the value of 16. Furthermore, a hose size indicates the internal diameter of the hose, not the outside diameter. For example, a -8 hose size is read as "dash eight" and it means the hose is an 8/16-inch, or a half-inch hose, and has an internal diameter of half an inch. Hose end types can consist of male or female fittings. A straight hose end type is a fitting that does not change the direction of the fluid as it exits or enters the hose. An elbow hose end type is a fitting that abruptly changes the direction of the fluid as it exits or enters the hose. Typical elbow arrangements include 45 and 90 transitions. A sweep hose end type is a fitting that gradually changes the direction of the fluid as it exits or enters the hose. Typical sweep configurations include 45 and 90 transitions. See the following figure for examples. Elbow Fitting Sweep Fitting 26

31 Installation Requirements Low Pressure Hose Size -32 Minimum Bend Radius 6.00 in [152.4 mm] Hose End A Hose End B Location To Reservoir To Pump/Motor Torque 60.4 ± 6.3 ft-lb [81.9 ± 8.5 Nm] 60.4 ± 6.3 ft-lb [81.9 ± 8.5 Nm] Type 45 Sweep, Code 61 Flange 90 Sweep, Code 61 Flange Installation Requirements End B End A 27

32 Installation Requirements The low pressure hose connection to the reservoir is integral to the connection of the filter block subassembly. The flange kit bolts are to be replaced by threaded studs, as shown in the following figure. Follow the steps below to install the low pressure hose and filter block subassembly. Low Pressure Hose Flange Clamps Nuts Filter Block Subassembly O-ring Studs 1. Install threaded studs into reservoir subassembly using same installation torque as low pressure hose, 60.4 ± 6.3 ft-lb [81.9 ± 8.5 Nm]. 2. Install O-ring between filter block subassembly and reservoir subassembly. 3. Install filter block subassembly over studs until flush with reservoir subassembly. Ensure that O-ring is not pinched. 4. Install reservoir end of low pressure hose to filter block subassembly. 5. Install flange clamps around reservoir end of low pressure hose so threaded studs come through flange clamp thruholes. Ensure flange clamps are properly seated on end of low pressure hose. 6. Install nuts onto end of threaded studs. 7. Install O-ring on End A of hose. 8. Install flanges on End A and secure to pump/motor subassembly with bolts. 9. Install O-ring on End B of hose. 10. Install flanges on End B and secure to reservoir subassembly with bolts. 11. Torque hose ends to specifications in preceding table. 28

33 Installation Requirements Cooler Outlet Hose Size -16 Minimum Bend Radius 3.00 in [76.2 mm] Hose End A Hose End B Location To Reservoir To Cooler Torque ± 2.5 ft-lb [151 ± 3 Nm] ± 2.5 ft-lb [151 ± 3 Nm] Type 90 Elbow, Straight Thread, Male Straight, 37 JIC Swivel, Female 1. Thread End B onto cooler fitting and torque to specification in preceding table. 2. Thread End A onto filter block subassembly fitting and torque to specification in preceding table. Note: The table indicates End A has a 90 elbow. The figure shows the elbow already installed on the filter block subassembly. The specified torque applies to the hose-to-elbow connection as well as the elbow-to-filter block connection. Installation Requirements End A End B 29

34 Installation Requirements Cooler Inlet Hose Size -16 Minimum Bend Radius 3.00 in [76.2 mm] Hose End A Hose End B Location To Pump/Motor To Cooler Torque ± 2.5 ft-lb [151 ± 3 Nm] ± 2.5 ft-lb [151 ± 3 Nm] Type 90 Elbow, 37 JIC Swivel, Female 90 Sweep, 37 JIC Swivel, Female 1. Thread End B onto cooler fitting and torque to specification in preceding table. 2. Thread End A onto pump/motor fitting and torque to specification in preceding table. End B End A 30

35 Installation Requirements Case Drain Hose Size -16 Minimum Bend Radius 3.00 in [76.2 mm] Hose End A Hose End B Location To Reservoir To Pump/Motor Torque ± 2.5 ft-lb [151 ± 3 Nm] ± 2.5 ft-lb [151 ± 3 Nm] Type Straight, 37 JIC Swivel, Female 90 Long Sweep, 37 JIC Swivel, Female 1. Thread End B onto pump/motor fitting and torque to specification in preceding table. 2. Thread End A onto filter block subassembly fitting and torque to specification in preceding table. Installation Requirements End B End A 31

36 Installation Requirements Suction Hose Size -40 Minimum Bend Radius in [355.6 mm] Hose End A Hose End B Location To Pump/Motor To Reservoir Torque 85.4 ± 6.2 ft-lb [115.8 ± 8.4 Nm] 85.4 ± 6.2 ft-lb [115.8 ± 8.4 Nm] Type Straight, Code 61 Flange 45 Sweep, Code 61 Flange 1. Install O-ring on End B of hose. 2. Install flanges on End B and secure to reservoir subassembly with bolts. 3. Install O-ring on End A of hose. 4. Install flanges on End A and secure to pump/motor subassembly with bolts. 5. Torque hose ends to specifications in preceding table. End A End B 32

37 Installation Requirements High Pressure Hose Size -24 Minimum Bend Radius in [508 mm] Hose End A Hose End B Location To Pump/Motor To Accumulator Torque ± 8.3 ft-lb [169.4 ± 11.3 Nm] ± 8.3 ft-lb [169.4 ± 11.3 Nm] Type 90 Sweep, Code 62 Flange 160 Custom Sweep, Code 62 Flange 1. Install O-ring on End B of hose. 2. Install flanges on End B and secure to accumulator subassembly with bolts. 3. Install O-ring on End A of hose. 4. Install flanges on End A and secure to pump/motor subassembly with bolts. 5. Torque hose ends to specifications in preceding table. Installation Requirements End A End B 33

38 34 Installation Requirements

39 Electrical Requirements Electrical Requirements Note: "Power" refers to both Power Positive and Power Negative supply. (This is typically Battery Plus and Battery Negative.) Note: "Switched Ignition" refers to power that is enabled with ignition key operation. Chassis Requirements The HLA system requires a specific electrical interface with the chassis. The following electrical schematic illustrates the wiring the HLA system requires. The following sections provide added details. Electrical Requirements Ignition Line Voltage The installer shall provide an ignition line voltage. This connection shall be connected to battery voltage when the ignition is switched on, and is disconnected and allowed to float when the ignition is off. This signal will not have a load (0.25 amp max.) but will be used to provide system power-up information to the HLA system. The switched ignition to the HLA system shall not be switched off during the engine start process. 35

40 Electrical Requirements Interface Wiring The HLA system interfaces with the chassis electrical system through two connectors. One connector provides power to the cooler subsystem and the second provides power and data to the HLA electronic control unit (ECU). The chassis-hla OEM connector shall be a Deutsch HDP PN or equivalent. The chassis-hla cooler interface connector shall be Delphi Metri-Pack 280 series The connectors shall be designed for use in the commercial vehicle industry, conforming to SAE J2030 and SAE J1455. The connectors shall be fully mated and latches shall be completely locked. Unused connectors and terminal cavities shall have sealed mating connectors or be plugged. The HLA OEM Deutsch (or equivalent) connector's size 16 pins shall have nickel plated terminals and be used for power signal and communication circuits. The HLA cooler interface Delphi (or equivalent) connector's pins shall have nickel plated terminals and be used for power circuits. OEM Connector W V U T X H G A F E S R J K B C D P L M N Pin Side View Deutsch HDP PN Description From Pin # To Pin # DRVP Relay HLA ECU A 20A Fused Relay Not Used B Plug Ignition Switch HLA ECU C Ignition Bus Not Used D Plug Not Used E Plug Battery (+) HLA ECU F Battery (+) Not Used G Plug MPRD HLA ECU H 20A Fused Relay Brake Ground HLA ECU J Brake Pressure Sensor Ground 36

41 Electrical Requirements Description From Pin # To Pin # Brake Out HLA ECU K Brake Pressure Sensor Output Brake Supply HLA ECU L Brake Pressure Sensor Supply (+5V) J1939 High (CAN) HLA ECU M Splice into J1939 J1939 Low (CAN) HLA ECU N Splice into J1939 Data High (CAN) HLA ECU P Data CAN A Data Low (CAN) HLA ECU R Data CAN B Not Used HLA ECU S Plug Not Used HLA ECU T Plug Ground HLA ECU U Battery (-) Ground HLA ECU V Battery (-) DRVP Relay HLA ECU W 20A Fused Relay Not Used HLA ECU X Plug Electrical Requirements HLA Cooler Interface Connector A B Pin Side View Metri-Pak Description From Pin # To Pin # Battery (+) HLA Cooler A 20A Fused Battery (+) Ground HLA Cooler B Battery (-) 37

42 Electrical Requirements Power Requirements The vehicle shall have a negative ground power system. The primary ground connection shall be at the vehicle battery. Two (2) ground wires are required to be connected to the HLA OEM connector J06. These wires should be run independently from the chassis connector J06 pins U and V all the way to the primary HLA ground connection Each of these wires shall be sized to handle 15 amps. One ground wire is required to be connected from the primary HLA ground connection to the HLA cooling fan connector pin B. This wire shall be sized to handle 20 amps. The vehicle primary power system shall be 12 volts DC. The installer shall provide a battery connection. The battery voltage shall be within 9 volts to 14 volts. The supplied voltage shall not exceed a steady state voltage of 18 volts DC. Power to the HLA ECU shall not be switched off during the engine start process. The HLA system has the following operating characteristics: Active ECU current: 12 amps Power down sequence: 6 to 10 amps Cooling fan: 11 amps The installer shall provide a battery connection to HLA OEM connector J06 pin F that is always on or on when the battery disconnect switch (if equipped) is on. This connection provides power to operate the HLA ECU. The installer shall circuit protect this chassis connection to 20 amp maximum. It is critical for correct HLA operation that this power shall be available for at least 90 seconds after the ignition voltage is shut off. This connection will draw less than amp no later than 90 seconds after the ignition voltage is switched off. This chassis connection shall not be switched off during the engine start process. The installer shall provide power wiring to the HLA ECU such that the differential voltage (HLA negative subtracted from HLA positive) shall exceed 10 volts DC at a steady state load of 1 amps as configured for a 12 volt base system. The installer shall provide a battery connection to the HLA cooling fan pin A that is always on or on when the battery disconnect switch (if equipped) is on. This connection provides power to operate the HLA cooling fan. The installer shall circuit protect this chassis connection to 20 amp maximum. This wire must be run separate from the battery connection to HLA cooling fan pin A. The installer shall provide power wiring to the cooling fan such that the differential voltage (ECA positive minus ECA negative) shall exceed 9 volts DC at a steady state load of 20 amps as configured for a 12 volt base system. If the installer is interested in including a load reduction relay for HLA system power, please contact the Eaton Application Engineering Team. 38

43 Electrical Requirements Harness Routing Requirements Harness and in-line connectors shall be anchored to prevent free movement. Eaton recommends that an anchor point be 3 inches [7.62 cm] from a connector. The length of an unanchored section of harness should be no more than 12 inches [30.48 cm]. Do not mount or tie additional components to cable, cable tie, mounting studs, or lifting eyes under any circumstances. Use tie wraps on harness covering only, not individual wires. Do not anchor harness with tie wraps in contact with wire insulation. Tie wraps shall not pull on the harness so that connector cable seals are distorted. Allow cable to exit connector body without pulling on the connector. A bend radius of six times the harness diameter is recommended. Eaton recommends use of the fixed clip points on chassis harness Fir trees, J-clips, P-clips. Electrical Requirements Harness routing shall not interfere with oil fill plugs, sensor locations, manufacturing fixtures or heat exchanger systems of vehicle. Harness Design Recommendations Do not use more than three (3) ring terminals per mounting stud. Terminals such as ring, bullet, spade, etc., shall be sized for the correct current capacity of the circuit as stated by the manufacturer. Terminals shall be plated and non-insulated. Sleeves shall be insulated with a double wall shrink tubing. Sealing dielectric grease over the top of the ring is recommended. Do not use lock washers or star washers for contact surfaces. Crimps shall be applied with a tool specified by the manufacturer of the terminal and in accordance to the manufacturer's specifications. The cable for the Deutsch connector (HDP SN) should be: 18 GXL max. / 18 TXL min. for Communication and Control wires 14 GXL or 16 SXL for Power Supply wires The cable for the 2-Way Metri Pack connector should be: 12 SXL for Power Supply wires to ECA Note: These sizes ensure proper connector sealing and current carrying capacity. Splices must be ultrasonically welded per IPC / WHMA-A-620 and encapsulated and sealed to meet SAE-J1455. Convoluted conduit shall have a service temperature of at least 257 F (125 C). Braided loom shall have a service temperature of at least 280 F (138 C). There shall be a minimum coverage of 10 / maximum of 12 picks per inch. Twisted cables: 2 cables = 10 twists / 25.4 cm 3 cables = 8 twists / 25.4 cm (16 and 18 gauge cable only) 39

44 Electrical Requirements SAE Wire SAE Wire Nominal Outside Diameter (mm) Nominal Outside Diameter (in) Size mm2 Size No. TXL GXL SXL TXL GXL SXL Cable Connector (Deutsch) HDP SN Seal Range (mm)/(in) Contact Size Description Cable Diameter Min. (mm2) Cable Diameter Max. (mm2) TXL GXL SXL / Power, Signal NR / Not Used Cable Connector (Metri-Pack) 2-Way Seal Range (mm)/(in) Contact Size Description Cable Diameter Min. (mm2) Cable Diameter Max. (mm2) TXL GXL SXL / Cooler Fan Power NR

45 Electrical Requirements Data Link Requirements The HLA system interfaces with many components installed on the vehicle. The HLA Chassis Harness requires connection to two CAN buses: The vehicle CANbus for control and a data CANbus for the user interface and servicing. Both CANbus connections shall be made with J1939 compatible twisted pair wiring. Twisting shall be 0.75 ± 0.25 turns per inch. The vehicle CANbus shall connect to the HLA Chassis Harness connector RJ-01, a Deutsch DT03-3S J "Plug- A-" connector. - No 120 ohm termination resistor is installed in the HLA ECU. It is the installer's responsibility to determine if a termination resistor is required by the vehicle bus architecture and, if necessary, to install the correct termination resistor either at connector J06 pins M and N or at the connector RJ Mating connector information for connector RJ-01: * Supplier: Deutsch or equivalent * Connector Part Number: DT04-3P-E008 (gray) or DT-3P-EE01 (black) * Wedge: W3P * Contacts: or equivalent, nickel plated recommended The data CANbus shall connect to the HLA Chassis Harness connector RJ-05, a Deutsch DT03-3S J "Plug-A- " connector. - If the user interface is a driver display, the CAN connections are pins 9 and 10 for CAN High and CAN Low on the driver display connector, respectively. - A 120 ohm termination resistor is installed in the J tee connector RJ-15. The installer may need to remove this termination resistor to achieve the proper bus termination based on the data bus architecture. - No 120 ohm termination resistor is required at the HLA ECU connector J06. The HLA ECU incorporates an internal 120 ohm termination resistor on the data CANbus. - Mating connector information for connector RJ-05: * Supplier: Deutsch or equivalent * Connector Part Number: DT04-3P-E008 (gray) or DT-3P-EE01 (black) * Wedge: W3P * Contacts: or equivalent, nickel plated recommended Note: The ABS controller must be J1939 compliant. The ABS system must broadcast PGN per J Note: The engine controller must accept speed and torque limit requests from source address 239: PGN 0 per J Electrical Requirements Messages The following table illustrates the SAE J1939 standard messages that the HLA system either transmits or receives. For specifics about the messages, please refer to the J specification. J1939 Message Name Short Name Specification Transmit Period [ms] Receive Torque / Speed Control #1 TSC1 J Yes 10 Yes** Electronic Retarder Controller** ERC1 J Yes 10 No 41

46 Electrical Requirements J1939 Message Name Short Name Specification Transmit Period [ms] Receive Electronic Brake Controller #1 EBC1 J No N/A Yes Electronic Transmission Controller #1 ETC1 J No N/A Yes Electronic Engine Controller #2 EEC2 J No N/A Yes Electronic Engine Controller #1 EEC1 J No N/A Yes Electronic Transmission Controller #2 ETC2 J No N/A Yes Retarder Configuration** N/A J Yes 5000 No Engine Configuration N/A J No N/A Yes Cruise Control / Vehicle Speed N/A J No N/A Yes **Only applicable in configuration utilizing Brake Blend The HLA system uses one proprietary message. The detailed information pertaining to that message can be found in the following table. In-Cab Display (0x18FFFBEF) Transmission Repetition Rate 100 ms Data Length 8 Data Page 0 PDU Format 255 PDU Specific 0 Default Priority 6 Byte Bits Signal Scale Offset Min Max Unit Description 1 all State of Charge % Accumulator % of maximum charge 2 all HLA Diagnostic Code Proprietary diagnostic codes visible to operator 3 all HLA Service Light Control = off, 1 = slow blink, 2 = fast blink, 3 = on 4 all HLA Stop Light Control = off, 1 = on 5 all HLA Mode = off, 1 = economy, 2 = productivity 6-8 all Not used Not used 42

47 Electrical Requirements HLA System Harness Connection The HLA system harness is delivered installed on the PMTC, connected to all PMTC sensors, with the remaining portion of the harness bundled together to facilitate system installation. After installation of all subassemblies, including all of the hydraulic hoses, the harness can be unbundled on the PMTC. WARNING Do not apply paint to the HLA system prior to completing installation. The HLA system shall be fully installed, including all mechanical and electrical connections, prior to any painting process. 1 Release harness bundles. Harness Bundles Identifi cation Electrical Requirements Reservoir J29 Reservoir Oil Temperature Sensor J27 Reservoir Oil Level Sensor J57 Filter Delta Pressure Sensor Accumulator J31 High Pressure Sensor J33 Accumulator Proximity Sensor Cooler Fan J69 Cooler Fan J74 OEM Power Supply 43

48 Electrical Requirements Reservoir Connections 1 Connect reservoir oil temperature sensor (J29). 2 Connect reservoir oil level sensor (J27). 3 Connect filter delta pressure sensor (J57). 4 Route and clip all harnesses per OEM requirements. 44

49 Electrical Requirements Accumulator and Cooler Connections 1 Connect high pressure sensor (J31). 2 Connect accumulator proximity sensor (J33). 1 Connect OEM power supply (J74). 2 Connect cooler fan (J69). Electrical Requirements 45

50 Electrical Requirements Chassis Harness Connection to HLA System WARNING If the installer utilizes an electro-static paint process, the shipping plug must remain connected to the HLA system during paint. 1 Remove shipping plug from ECU and discard. 2 Connect OEM harness and twist to lock in place. 46

51 Electrical Requirements In-Cab Display The installer is responsible for providing an in-cab display that can communicate system health. Displays diagnostic code(s) with a numeric display. Shows HLA system state of charge with a horizontal bar graph. Indicates system mode state (OFF, ECON, PROD) using a green light. A yellow light and the word 'Service' in yellow backlit text to indicate service is needed. A red light and the word 'Stop' in red backlit text to indicate an urgent problem. The in-cab display must be able to receive the in-cab display message as described in the Data Link Requirements section. Electrical Requirements 47

52 Electrical Requirements evu Eaton can provide an in-cab display (called the evu, pronounced e-view ) that meets all of the necessary requirements. The evu display can be purchased separately from Eaton's Vehicle Controls and Sensors division. Part ordering information and installation information for the evu can be found below. HLA System E SOC F OFF ECON PROD SERVICE STOP Part Name Manufacturer Part Number Quantity Required evu Driver Display Eaton/Cutler Hammer e00fp evu Driver Display connector Eaton/Cutler Hammer evu Driver Display terminal Tyco Electronics/AMP The panel opening for the driver display is defined in the following figure. Panel Opening in [44.04 mm] in [22.02 mm] Note: 1. Views are dual dimensioned in [mm]. 2. Product is designed to mount in panels between in and in [1 mm and 4 mm ] thick. The installer shall provide an independent battery connection to provide power to the driver display. Battery voltage shall be within 9 volts to 14 volts. The connection shall be capable of supplying a max current draw of 1 amp. The line shall be fused to 1 amp. The required wiring to support the driver display option can be found in the electrical schematic. It is the installer's responsibility to provide the wire harness for the driver display. The pin connection details for the driver display, including connector type and terminals, are defined below. NGR Connector: NGR Terminals: AWG: AMP part number or ; AWG: AMP part number or

53 Electrical Requirements The driver display requires 5 connections: Power shall be supplied to the driver display connector pin 5. This power shall be fused to 1 amp, and may switch on and off with vehicle ignition switch. Ground shall be supplied to the driver display connector pin 4. This connection shall be continuously connected to a ground connection. A connection from the vehicle dimmer switch to the driver display connector pin 2 will allow the display to be dimmed with the vehicle instrument panel. A CANbus connection to the HLA Chassis Harness shall connect from the driver display connector pins 9 and 10 to the HLA Chassis Harness connector RJ-05 pins A and B for CAN High and CAN Low, respectively. Mating connector information for connector RJ-05: - Supplier: Deutsch or equivalent - Connector Part Number: DT04-3P-E008 (gray) or DT-3P-EE01 (black) - Wedge: W3P - Contacts: or equivalent, nickel plated recommended Driver Display Electrical Requirements 6 5 Red V(BATT) 7 4 Black COM 8 3 J Yellow 9 2 Blue To Dimmer J Green

54 50 Electrical Requirements

55 EOL Inspection End Of Line (EOL) Inspection Commissioning Procedure Pre-commission Inspection 1. Verify all subsystem components are properly installed and torqued. 2. Verify all electrical wire harness connections have been properly mated. 3. Verify all hoses have been properly installed and torqued. 4. Verify the HLA OEM connector and cooler interface connector are properly mated to the chassis harness. Oil Fill Procedure EOL Inspection 1. Use the HLA filter cart to ensure that clean HLA oil is added to the system. 2. Attach the quick disconnect from the filter cart to the pump quick disconnect. 3. Use filter cart to fill system with HLA oil. 4. Fill the system until the oil level is at the top of the sight gauge on the reservoir. 5. Disconnect filter cart quick disconnect from pump. 6. Push down on pump quick disconnect check valve seat to relieve air from the system before start-up. 7. Install protective cap on pump quick disconnect. Note: Oil level will drop to mid-range of the sight gauge after commissioning the HLA system. Push to Relieve Air Quick Disconnect 51

56 EOL Inspection System Air Purge The purging process is an automated sequence preprogrammed into the HLA that will purge the system of any air within the system. The procedure requires the vehicle and HLA systems to be operational, and requires sufficient space so the vehicle can be driven between 5-10 mph for approximately one minute. The process can also be run while the vehicle is on a chassis dynamometer. Necessary Hardware PC or Laptop Nexiq USB-Link ServiceRanger version 3.2 or later (Latest version can be downloaded from Procedure 1. Start vehicle. 2. Connect PC to vehicle CAN using Nexiq USB-Link. 3. Start ServiceRanger on PC. 4. Launch APF for Hydraulic Launch Assist. 5. Select Purge from the Operations Menu. 6. Select Instructions link for detailed instructions. Note: If a fault code is present, refer to TRTS1200 Eaton HLA Troubleshooting Guide and TRSM1200 Eaton HLA Service Manual. (Latest versions can be downloaded from After the purge sequence is completed, the HLA system is ready for operational use. 52