Eaton LifeSense Wired System Quick Setup Guide

Eaton LifeSense Wired System Quick Setup Guide

LifeSense Wired System Quick Setup Guide Each LifeSense kit contains: LifeSense hose assembly (at least one and up to 11) o Sensor assembly (one per hose assembly) o Protective sleeve (one per hose assembly) Cable assembly (one per hose assembly) Hose diagnostic unit (1) o Orange wire wedges (2) o Power harness and grey Deutsch connector (1) o Black Deutsch connector (1) o Socket Deutsch connectors (2) Table of Contents Part Listing... 3-4 Safety Information... 5 Hose Assembly Installation... 6-9 Troubleshooting... 10-11 IMPORTANT: Before you begin the installation of your LifeSense system read through the safety instructions in this guide. For more detailed instructions on installing your system please refer to the complete LifeSense Assembly, Installation and Service Manual (E-HOOV-TI001-E2) available on Eaton's literature library (http://hydliterature.eaton.com/ literature/). Hard copies of the catalog are available through Workflow One (WFO), using the Customer Connect portal, Distributor Resources, Literature. If you are unable to access the literature ordering site please contact WFO by calling 800-625-9100 or e-mailing eatonliterature@workflowone.com and WFO will walk you through the process. 2 EATON LifeSense Wired System Quick Setup Guide E-HOOV-II001-E August 2014

Part Listing 1 2 2 4 3 3 6 4 Sensor Type 2 (-16) 5 7 Sensor Type 1 (-08 and -12) 8 9 10 13 11 12 EATON LifeSense Wired System Quick Setup Guide E-HOOV-II001-E August 2014 3

Part Listing Item No. Qty. Req'd. Description Part Number Material 1 6 Nut FF91117C-33-01 Stainless Steel 2 1 Upper Shell Assembly, -08 Size FF91117SU-08-01* Black Nylon 6-6 1 Upper Shell Assembly, -12 Size FF91117SU-12-01* Black Nylon 6-6 1 Upper Shell Assembly, -16 Size FF91117SU-16-01* Black Nylon 6-6/Overmold Gasket 3 2 Gasket, -08 Size FF91117C-36* Black Santoprene 111-45 2 Gasket, -12 Size FF91117C-70* Black Santoprene 111-45 4 1 Shell- Lower Half, -08 Size FF91117C-48* Black Nylon 6-6 1 Shell- Lower Half, -12 Size FF91117C-57* Black Nylon 6-6 1 Shell- Lower Half, -16 Size FF91117C-63-01* Black Nylon 6-6/Overmold Gasket 5 6 Panhead Machine Screw, -08 & -12 Size FF91117C-68-01 Stainless Steel 6 6 Thread Rolling Screw, -16 Size FF91117C-71-01 Stainless Steel 7 1 Heat-Shrink Tubing For -08 FF91117PS-08-01 Polyolefin 1 Heat-Shrink Tubing For -12 FF91117PS-12-01 Polyolefin 1 Heat-Shrink Tubing For -16 FF91117PS-16-01 Polyolefin 8 1 Cable Assembly (10 Ft.) FF91117CA-010 PVC Jacket 1 Cable Assembly (50 Ft.) FF91117CA-025 PVC Jacket 1 Cable Assembly (25 Ft.) FF91117CA-050 PVC Jacket 1 Cable Assembly (100 Ft.) FF91117CA-100 PVC Jacket 9 1 HDU Assembly FF91117-01 -- 10 1 HDU Power Harness FF91117C-19* -- 11 22 Sealing Plug FF91117C-31* -- 12 1 HDU Black Connector FF91117C-29* -- 13 2 Wedge Lock For 12 Contacts FF91117C-30* -- *Part not sold separately. 4 EATON LifeSense Wired System Quick Setup Guide E-HOOV-II001-E August 2014

Safety Instructions WARNING The Eaton LifeSense system utilizes unique hose and fittings (U.S. Patent No. 7,555,936 and 8,183,872). Only the specified LifeSense hose and fittings can be used in this system. DO NOT use other Eaton hose and hose fittings (e.g., Aeroquip, Weatherhead, or SEL), or hose and hose fittings supplied by another manufacturer with this system. Eaton hereby disclaims any obligation or liability (including incidental and consequential damages) arising from breach of contract, warranty, or tort (under negligence of strict liability theories) should other Eaton hose and hose fittings, or hose and hose fittings supplied by another manufacturer be used interchangeably with this system, or in the event that production, assembly, or installation instructions for each specified component of Eaton LifeSense are not followed. WARNING Failure to follow process and product instructions and limitations could lead to premature hose assembly failures, resulting in property damage, serious injury or death. WARNING Eaton LifeSense is designed to provide advance warning of impending failures due to fatigue and external abrasion. Eaton LifeSense is not designed to provide advance warning of impending failure for every failure mode. For example, failures due to an improper installation of the terminal end to the application will not be alerted by LifeSense. WARNING Verify that the specified equipment is depressurized before installing a hose assembly. PREVENT UNAUTHORIZED OPERATION. Do not permit anyone to operate the LifeSense system unless they have been properly trained and have read and thoroughly understand this manual. PREVENT UNAUTHORIZED SALES, ASSEMBLY, INSTALLATION AND SERVICE. Do not permit anyone to sell, assemble, install or service LifeSense hose assemblies and system unless they have been properly trained. WEAR SAFETY GLASSES 1. Install the hose assembly into the application utilizing standard hose routing practices. 2. All wiring terminals should be properly insulated to prevent short circuits. All terminals should be of insulation grip design to provide a reliable connection and to prevent terminal fatigue. 3. Terminals that are connected where moisture may be present should be of a moisture resistant design. Molded insulators for ring terminals should be used. Molded connectors/ insulators are recommended for use with blade or pin type terminals. 4. Cable routing should avoid areas where temperatures exceed +105 C (+221 F) and a minimum clearance of 100 mm (4.0 ) should be maintained from exhaust system components. Where compliance for this requirement is not possible, heat insulation and heat shields are required. 5. The hose diagnostic unit (HDU) shall be mounted in a location that is easily viewable by the equipment operator. 6. Routing cable into wheel splash areas should be avoided. When such routing cannot be avoided, adequate clipping or protective shielding is required to protect from stone and ice damage. 7. Routing cable under the frame side-members or at points lower than the bottom frame flange should be avoided to prevent damage to the wires in off-road operations. 8. Never add another circuit or splice to the LifeSense hose cables or power cable. 9. Never puncture cable insulation with a probe to verify voltage or to check continuity. 10. Exposed ring terminals for the power supply circuit should be protected from the environment. Dielectric grease is recommended to prevent corrosion. EATON LifeSense Wired System Quick Setup Guide E-HOOV-II001-E August 2014 5

Hose Assembly Installation Step 1: Depressurize Hydraulic System WARNING: Before installing any hose assembly first verify the equipment has been properly depressurized. For depressurization instructions please refer to the equipment owner's manual for specific instructions. Step 2: Turn Off Power Supply Be sure power supply to the equipment is turned off. For proper instructions refer to the equipment owner's manual and/or utilize a certified electrician. Step 6: Number Cable Assemblies Number each cable assembly to its corresponding hose assembly. Step 7: Connect Cable to Sensor Pig Tail Take cable and connect it to sensor pigtail until tab snaps into place. Repeat for all hose assemblies. Step 3: Disconnect Existing Hose Assembly Using the appropriate size wrench disconnect existing hose assembly from equipment. Step 4: Hose Assembly LifeSense Kit(s) Purchased from Eaton: LifeSense kits supplied by Eaton include complete hose assemblies with the protective sleeve and sensor installed. Certified LifeSense Distributors: Only certified LifeSense Distributors are authorized to make LifeSense hose assemblies. For detailed LifeSense hose assembly instructions refer to the LifeSense Assembly, Installation and Service Manual (E-HOOV-TI001-E2). Before numbering and installing the hose assemblies determine where each hose will be located on the piece of equipment. Verify you have enough cable length to reach the mounting location of the HDU from each sensor once the hose assembly is installed. Step 5: Number Hose Assemblies Using a paint pen or indelible marker, and the labels provided (part number PT2351), number each hose assembly one (1) through eleven (11) depending on the number of hoses being connected to the diagnostic unit. As hose assemblies and sensors are mated, record on a piece of paper, or in an electronic spreadsheet, each hose assembly s location on the equipment, its function, and corresponding hose/sensor number. This will aid in future hose replacement and service support. Step 8: Install LifeSense Hose Assembly Note: Utilize standard hose routing and plumbing practices. Starting at one end of the LifeSense hose assembly attach hose to equipment. Torque terminal end nut to the required torque specifications. Refer to Eaton Aeroquip or Weatherhead master catalogs for proper torque specifications by terminal type and size. Step 9: Secure Cable to Hose or Equipment Each cable should be positioned, routed, and restrained in such a manner to protect it from being damaged by an external force or caught by, or entangled in, movable parts. Repeat steps 8 and 9 for all hose assemblies. Step 10: Install Hose Diagnostic Unit (HDU) Mount the HDU in a location that is easily visible to the equipment operator using adhesive Velcro strips or mounting screws. WARNING: The HDU must be installed inside a vehicle cab or other protective area that shields if from the effects of an external environment. 6 EATON LifeSense Wired System Quick Setup Guide E-HOOV-II001-E August 2014

Hose Assembly Installation Installing Deutsch Connectors -- Starting with either the black or white wire, slide one of the two (2) provided Deutsch connectors over the exposed copper wire. Verify wire is visible in the inspection hole and the maximum exposed wire between the contact and wire jacket is between 0.63 to 2.54 mm (0.025 to 0.100). While holding the Deutsch connector in place crimp connector to copper wire. Repeat step for remaining wire. Step 11: Coiling or Trimming Excess Cable Gather all routed cables together. Excess cable can be either coiled and zip tied or can be cut to length. If cutting to length, two (2) additional Deutsch connectors are provided with each cable assembly and must be attached to the trimmed cable wires utilizing a Deutsch crimp tool. Cutting Cable to Length -- if coiling extra cable is undesirable; determine how much extra cable can be trimmed while still maintaining enough length to connect to the diagnostic unit. A minimum length of 15.2 to 30.4 cm (6 to 12 in) is recommended. Mark each cable where it can be trimmed. If the cable identification number falls within the trim portion remark the cable with its identification number at a location prior to the trim mark. Using side cuts cut excess cable length at trim mark. Discard excess cable. Stripping Cable -- beginning at the end of the trimmed cable measure down 5.1 cm (2 in) and place a mark on the outer cable cover with an indelible marker. Using a utility knife make a 5.1 cm (2 in) vertical cut through the outer grey protective cable cover between the black and white wires. At the base of the vertical cut just made, make a horizontal cut circumferentially through the outer protective cable cover taking care not to cut into the protective black or white wire cover. Discard piece of grey cable cover. Step 12: Connect Cables ( Hoses ) to Hose Diagnostic Unit (HDU) Beginning with the grey connector - grey connector connects hoses one through five -- remove connector from the top of the HDU. Using a pair of needle nose pliers remove the orange wedge from the opposite end of the connector. Next remove the appropriate number of red seal inserts from the top of the connector. Discard seal inserts. Measuring from the tip of the exposed wires, strip away between 3.96 to 5.54 mm (0.156 to 0.218 in) of the black and white protective coating using a wire stripping tool. Repeat for each cable in the system EATON LifeSense Wired System Quick Setup Guide E-HOOV-II001-E August 2014 7

Hose Assembly Installation Insert both wires from cable number one (i.e., hose assembly one) into the first wire port of the grey wedge connector at the position illustrated (see figure below), by pushing the metal Deutsch pin into the pin port until it tangibly snaps into place. Continue connecting cable wires into the wedge connector(s), in numerical order, until all cables (i.e., hose assemblies) have been connected. If more than five hose assemblies are being connected to the diagnostic unit repeat these steps for the black connector. Insert the black wedge into the corresponding black wedge port on the top of the diagnostic unit until tabs on side of the wedge snap into place. Record the channel location for each cable/hose on the same hose record created in step seven (7). After all cables are inserted into the Deutsch connectors insert the orange wedge back into the opposite end of the connector. Step 13: Insert Connectors into Hose Diagnostic Unit (HDU) After all cables are inserted into the grey and/or black connector(s), insert the grey wedge into the corresponding grey port on the top of the diagnostic unit until tabs on side of connector click into place. Step 14: Connect Hose Diagnostic Unit (HDU) to Power Source WARNING: The power cable must be connected to a 12- or 24-volt DC power source. Before proceeding ensure the power source is turned off. Connecting to a power source should only be performed by someone with knowledge and training in electrical systems and principles. Connect the red and black power cable to a 12- or 24-volt DC power source. Turn on power supply to equipment, as a described in the equipment owner's manual. Step 15: Hose Diagnostic Unit (HDU) Cycle Check The power light on the diagnostic unit will illuminate green when power is supplied to the unit. Upon startup all 11 hose lights will flash sequentially. 8 EATON LifeSense Wired System Quick Setup Guide E-HOOV-II001-E August 2014

Hose Assembly Installation The hose diagnostic unit is shipped from the factory in installation mode and on initial power up will detect which hoses are connected. These hoses will then illuminate for five (5) seconds to verify they are installed. If the HDU is powered before all hoses are installed it will need to be put back into install mode to identify the hoses. To put the HDU back into install mode press the reset button until all LEDs start flashing, then power down the unit. The HDU is now in install mode and will detect which hoses are connected on its next power up. If the green power light on the diagnostic unit does not illuminate, the hose lights do not successfully go through the initial sequence as previously described, or if the hoses are not detected, please refer to the troubleshooting guide, page #10 - #11 for further instructions. Step 16: Re-pressurize the Hydraulic System For system pressurizing instructions please refer to your equipment owner's manual for specific instructions. EATON LifeSense Wired System Quick Setup Guide E-HOOV-II001-E August 2014 9

Troubleshooting Issue Green LED light on diagnostic unit is not illuminated. Green LED power light is on but no LED test cycle is performed. Flashing red LED light indicating a sensor is losing connection. A red LED light indicates a failed hose error immediately after install. Steps Check fuse on the diagnostic unit power harness. Measure the voltage between pins six (6) and seven (7) on the grey power harness connector. NOTE: Pin six (6) is ground. Pin seven (7) is power. Follow the wiring harness and connections to the power supply. Disconnect the diagnostic unit from power. Wait 15 seconds and reconnect. Check connection of the sensor to the hose fitting. If red LED light continues to flash, disconnect sensor, and remove from hose fitting. Check Deutsch connectors on the diagnostic unit for a loose or not fully seated connection. Check the cable routed from the HDU to the sensor. Verify the white wire is connected into the positive or top input of the Deutsch connector and the black wire is connected to the ground or bottom input of the Deutsch connector. Connect the cable into a different input on the HDU. Check the cable routed from the HDU to the sensor. Look for any damage to the cable. If the fuse is bad replace it with a two (2) amp mini fuse only. If the fuse is good proceed to next step. Voltage should read the same as the input voltage (between 9-32V). The reading should be positive. If a negative voltage reading results the connecting wires are reversed. If the voltage is within the correct range the diagnostic unit needs to be replaced. If there is no voltage reading proceed to next step. Determine where the loss of power originates. If the LED test is still not initiated the diagnostic unit needs to be replaced. Rotate the sensor housing around the fitting to verify contact. Push the reset button on the diagnostic unit for one (1) second. Wait two (2) minutes and verify the flashing red light does not return. Check for any contamination or damage to the ribbon contacts. If contamination is present, remove contamination and connect the sensor back to the hose fitting. Push the reset button on the HDU for one (1) second. Wait for two (2) minutes and verify the flashing red light does not return. If the ribbon contacts are damaged replace the sensor. Push the reset button on the HDU for one (1) second. Wait for two (2) minutes and verify the flashing red light does not return. Look for any damage to the cable. Replace cable if damage is present. Push the reset button on the HDU for one (1) second. Wait for two (2) minutes and verify the red light does not return. Push the reset button on the HDU for one (1) second. Wait for two (2) minutes and verify the red light does not return. Replace cable if damage is present. 10 EATON LifeSense Wired System Quick Setup Guide E-HOOV-II001-E August 2014

Troubleshooting Issue Red LED light for installed hose does not stay lit for five (5) seconds at start up. Steps Disconnect the cable assembly from the HDU and the sensor, measure the resistance between the black and white cables on the cable assembly. Remove the sensor from the hose assembly and measure the resistance between the fitting socket and the fitting terminal end. Put the HDU in install mode to detect the hose by pressing the reset button until all hose LEDs are flashing, then disconnect the unit from power, wait 15 seconds and then reconnect. Check connection of the sensor to the hose fitting. If the HDU continues to not display the hose at startup disconnect sensor and remove from the hose fitting. Check for any contamination or damage to the ribbon contacts. Check the Deutsch connectors on the HDU for a loose or not fully seated connection. Check the cable routed from the HDU to the sensor. Look for any damage to the cable. If the resistance is less than 100 ohms, replace cable assembly If the measurement is less than 100 ohms, replace hose assembly. Verify the hose shows up during the five (5) seconds at startup. Rotate the sensor housing around the fitting to verify contact. Run install mode on the HDU to detect the hose and verify it lights up during the five (5) seconds at startup. If contamination is present, remove contamination and connect the sensor back to the hose fitting. Run install mode on the HDU to detect the hose and verify it lights up during the five (5) seconds at startup. Run install mode on the HDU to detect the hose and verify it lights up during the five (5) seconds at startup. Replace cable if damage is present. EATON LifeSense Wired System Quick Setup Guide E-HOOV-II001-E August 2014 11

Eaton Hydraulics Group USA 14615 Lone Oak Road Eden Prairie, MN 55344 USA Tel: 952-937-9800 Fax: 952-294-7722 Eaton Hydraulics Group Europe Route de la Longeraie 7 1110 Morges Switzerland Tel: +41 (0) 21 811 4600 Fax: +41 (0) 21 811 4601 Eaton Hydraulics Group Asia Pacific Eaton Building No.7 Lane 280 Linhong Road Changning District, Shanghai 200335 China Tel: (+86 21) 5200 0099 Fax: (+86 21) 2230 7240 2014 Eaton All Rights Reserved Printed in USA Document No. E-HOOV-II001-E August 2014