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Eaton Hydraulics
LifeSense Master Catalog

LifeSense Master Catalog

Product catalog summary

General Information
The Eaton LifeSense system is a comprehensive hose assembly system designed to provide advanced warning of impending failures due to fatigue and external abrasion. It includes specific hoses and fittings that must be used exclusively to ensure safety and reliability. The manual emphasizes the importance of following the specified installation and maintenance procedures to prevent hose failures that could lead to property damage or personal injury.

Important Safety Information
Flexible hose lines offer advantages such as routing ease and vibration absorption but require careful handling to avoid dangerous failures. Users must adhere to the recommended selection of hoses and fittings, fluid compatibility, and not exceed the minimum bend radius or maximum operating pressure. Only Eaton-approved components should be used to ensure reliable hose assemblies.

Hose Installation and Maintenance
Proper installation and maintenance are crucial for safe hose operation. Key factors include accommodating changes in length, maintaining proper bend radius, and protecting hoses from high temperatures and abrasion. Regular inspections are necessary to identify and retire damaged hoses.

LifeSense Hose Assembly
The LifeSense hose assembly system includes wired and wireless components, each with specific installation and troubleshooting guidelines. The manual provides detailed instructions for assembling, installing, and maintaining these systems to ensure optimal performance.

Component Specifications
The manual outlines the specifications for LifeSense hoses, including part number nomenclature, hose size, and packaging options. It also provides technical data such as operating pressure, burst pressure, and bend radius for different hose sizes.

Assembly Equipment
Proper assembly equipment is essential for creating reliable hose assemblies. The manual includes a crimp chart and guidelines for using Eaton assembly equipment to ensure compatibility and safety.

Warranty and Liability
Eaton disclaims any liability for hose assemblies not produced with genuine LifeSense components. The warranty applies only when approved Eaton hose fittings and compatible hoses are used with Eaton assembly equipment.

Applications

General hydraulics
Agricultural equipment – turf care
Vocational fleets – mobile refuse, mobile cement mixers
Manufacturing – stationary machining centers
Safety barriers
Laboratory test stands – dynamometers, impulse cycle machines

Features

Real-time hose condition monitoring
Failure-related event detection
Advance notification of hose life end

Specifications

LifeSense non-skive fittings for EC502 hose
Two-wire braid hydraulic rubber hose meeting 2SN, EN853 requirements

Components

Female JIC/SAE 37° Swivel (FJ)
Female ORS Swivel straight (FR)
Female ORS Swivel 45° Elbow (FRA)
Female ORS Swivel 90° Short drop elbow (FRB)
Female ORS Swivel 90° Long drop elbow (FRC)

Protective Sleeve

Black Polyolefin with moisture-seal adhesive lining
Abrasion resistant

Hose Diagnostic Unit (HDU)

Monitors hose condition
Complies with various EMC standards
Features LED alerts and internet connectivity

Wireless Components

Wireless gateway with power cable and antennas
Sensor assembly with LED status updates and lithium battery

Assembly Instructions

Cutting: Use a 14” bench mount saw with specific blade for clean cuts.
Hose End Clean Up: Use an orbital guide and belt sander for cleaning.
Isolation Test: Use Eaton’s test gage or a multimeter to check continuity.
Hose Cleaning: Use Eaton’s cleaning kits with foam projectiles.
Hose Assembly: Mark fitting insertion depth and apply lube for ease.

Overview: The document is an installation and service manual for the Eaton LifeSense system, which monitors the condition of hose assemblies in real-time, detecting internal fatigue and external abrasion. It provides detailed instructions for assembling, testing, and installing the LifeSense hose system, including both wired and wireless configurations.

Specifications: The LifeSense system includes hose assemblies, sensors, protective sleeves, cable assemblies, and a hose diagnostic unit (HDU). The HDU can monitor up to 11 hose inputs and requires a 12- or 24-volt DC power supply.

Installation Procedures: The installation process involves several steps:

Depressurizing the hydraulic system and turning off the power supply.
Disconnecting existing hose assemblies and preparing LifeSense hose assemblies.
Numbering hose and cable assemblies for identification.
Connecting cables to sensor pigtails and recording their locations and functions.
Attaching hose assemblies to equipment without inducing twists and securing cables to prevent damage.
Mounting the HDU in a visible location and connecting cables to it.
Connecting the HDU to a power source and performing a cycle check to ensure proper operation.
Re-pressurizing the hydraulic system after installation.

Testing and Verification: The manual outlines tests such as continuity and isolation tests to ensure proper assembly and function. Continuity tests require readings of less than 5 ohms, while isolation tests require readings greater than 5000 ohms.

Sensor Installation: Sensors must be installed carefully to avoid false readings, with specific torque requirements for different sensor types.

LED Indications: The HDU uses LED lights to indicate hose status, with solid red indicating impending failure and flashing red indicating signal issues.

System Reset: A reset button on the HDU allows for clearing alerts and reconfiguring the system when changes are made.

Part Listing: The document includes a detailed part listing with descriptions and part numbers for various components of the LifeSense system.

Safety and Best Practices: The manual emphasizes the importance of following safety instructions and best practices, such as avoiding twists in hoses and ensuring proper cable routing and restraint.

General Information
Eaton LifeSense Wireless is a cloud-based system that uses wireless instrumentation at the hose assembly. It requires an internet connection to communicate alerts and status updates. The system includes a Wireless Gateway that connects data from sensors to the Eaton portal.

System Components
The LifeSense system consists of wireless sensors on each hose, communicating with a Hydraulic Diagnostic Unit (HDU) via 433MHz RF. The HDU manages communication with sensors and the Eaton cloud server. Each HDU can monitor up to 100 hose assemblies.

Installation and Configuration
The installation involves setting up the HDU and sensors, requiring a PC with RS232 or USB adapter, internet connection, and specific tools. The LifeSense Installation Wizard simplifies the process by guiding users through network, machine, and sensor setup.

Wireless System Architecture
The system architecture includes a cloud server, wireless sensors, and a gateway. The HDU can connect to the internet via Ethernet or Wi-Fi, using DHCP or a static IP address.

Regulatory Compliance
The system complies with FCC and Industry Canada regulations, ensuring it does not cause harmful interference and accepts any interference received.

Part Listing
Key components include wireless sensor kits, extra screws and nuts, heat shrink tubing, configuration cables, and the Wireless HDU Kit.

Portal Operation
Users can manage and monitor the system remotely via the LifeSense portal, receiving alerts via text or email. The portal also allows for system updates and configuration management.

Troubleshooting
The manual provides detailed troubleshooting steps for common issues, ensuring efficient system maintenance and operation.

Overview: The document is an installation and service manual for the Eaton LifeSense Wireless System, focusing on the setup, operation, and maintenance of the system's components, including hose assemblies and sensors.

Specifications and Components: The LifeSense system includes wireless sensors, hose assemblies, and a wireless gateway (HDU). The system monitors hose health and communicates status updates via LEDs, a portal dashboard, and alerts.

Installation Procedures:

Sensor Association: Place the key fob over the sensor for 1 second to associate it with the HDU. Successful association is indicated by a long solid flash.
Hose Assembly Installation: Ensure the hydraulic system is depressurized and power is off before disconnecting existing hoses. Install LifeSense hose assemblies without inducing twists, and torque nuts to specified values.
Wireless Gateway Setup: Mount the HDU in a protected area, connect antennas, and ensure the gateway is powered and connected to the network.

Operation and Monitoring: The system uses LEDs to indicate status, with green, amber, and red lights showing different conditions. The portal provides detailed status and recommended actions for issues like poor sensor connections or low battery levels.

Hose Replacement: If a hose alert is issued, follow steps to depressurize the system, disconnect the hose, and install a new hose assembly. Ensure sensors are properly reset and associated with the HDU.

Troubleshooting and Maintenance: If a sensor is faulty, remove it and add a replacement sensor to the LifeSense account. Ensure proper installation to avoid false readings.

Key Recommendations:

Complete sensor association and portal review before hose installation.
Regularly check sensor connections and battery levels.
Follow torque specifications to ensure proper hose installation.

Installation and Configuration Procedures

Sensor Installation: Fasten all six fasteners evenly. Torque specifications differ for Type 1 (17.5 oz.-in.) and Type 2 sensors (80.0 oz-in.).
Power Supply Activation: Follow the equipment owner's manual to turn on the power. The OK LED on the wireless gateway should illuminate green after a two-minute initialization cycle.
Sensor Activity Monitoring: Sensor status will appear on the portal within four hours post-commissioning. If not, repeat the one-second sensor magnet event.

Wireless Gateway (HDU) Replacement

Power Off: Ensure the power supply is off before removing the wireless gateway.
Gateway Removal and Replacement: Disconnect antennas and power cord, then remove the faulty gateway. Configure the replacement gateway using the network configuration instructions.
Power On and Initialization: After installation, turn on the power. The gateway will undergo a two-minute initialization cycle, indicated by the OK LED turning green.
Sensor Re-association: Disassociate sensors from the old gateway using a 17-second magnet event, then associate them with the new gateway using a one-second magnet event.

Accessing Wireless Gateway Without Internet

Configure the PC's network settings to access the gateway directly via Ethernet. Use IP address 192.168.0.1 for setup.
Access the gateway's web page at http://192.168.0.3 to review sensor data and system status.

Troubleshooting Guide

LED Issues: If the OK LED does not illuminate, check the power supply and initialization status. Replace the gateway if necessary.
Sensor Association Failures: Ensure the gateway is powered, antennas are connected, and the sensor UID is correct. Re-attempt association if needed.
Reporting Issues: Verify power and antenna connections. Check sensor proximity and perform a magnet event to test sensor functionality.
Gateway Communication Failures: Confirm gateway power and configuration settings. Test the upload function and contact customer service if issues persist.

Technical Specifications and Crimp Charts

Detailed specifications for hose assembly and crimping tools are provided, including specific tooling and spacer ring requirements for various hose types.

Assembly Equipment Specifications:

ET9300-14-220: A 14-inch benchmount saw with 5 HP, operating at 220 VAC, one-phase, 60 cycle, and 3,600 RPM.
ET0100-005: JET J-4300A vertical belt sander with a 6 x 48 inches belt, 1 1/2 HP, and 2,850 SFPM.
ET0100-006: Similar to ET0100-005 but includes additional features like a shop vac, cabinet, and tool chest.
ET9300C-14-MS: A 14-inch circular saw blade with micro-slotted, double-bevel design for longer life and cleaner cuts.
ET0100-001: Orbital guide for hose end clean up, 110V AC, easy to use, and mountable.
ET9600-001: Mobile Eaton work cart with mounts for saws and equipment, enclosed storage, and pre-wired for 110V, 30AMP supply.

LifeSense Component Specifications:

ET0100-002: Electronic test gage with LED indicators for checking hose assembly continuity and sensor connections.
ET0100-003: Plier test gage for checking braided hose deck separation/isolation.

General Information:

All LifeSense hose preparation equipment requires proper collection and ventilation systems with spark arrestors.

Contact Information:

Eaton provides contact details for their Hydraulics Business in Europe, USA, and Asia Pacific, including addresses, phone numbers, and fax numbers.

Catalog excerpts

Eaton® LifeSense® Master catalog, assembly, installation and service manual F:T*N Powering Business Worldwide

Open the catalog to page 1

Table of contents General information Important safety information Lifesense safety precautions Section A A 3 A 4 Lifesense hose Part number nomenclature Lifesense ec502 Lifesense non-skive fittings Protective sleeve - heat shrink tubing Lifesense wired electronic components Lifesense wireless electronic components Lifesense hose assembly Hose assembly Lifesense wired system General information Part listing Wired system installation Hose replacement Diagnostic unit replacement Sensor replacement Wired troubleshooting guide Lifesense wireless system Lifesense wireless general information Wireless...

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Important safetyinformation Warranty Current warranty information can be found at: www.eaton.com/hydraulics/warranty ik WARNING Flexible hose lines offer many advantages over rigid tubing including routing ease, vibration absorption, sound deadening and the ability to accommodate movement of connected components. However, hose lines require caution in use not only to provide long service, but also to guard against potentially dangerous failure. Important The user should carefully observe the precautions listed in this catalog or brochure, including the recommendations on the selection of hose...

Open the catalog to page 3

LifeSense safety precautions GENERAL INFORMATION Safety first. Before you start... LIFESENSE COMPONENT SPECIFICATIONS LIFESENSE HOSE ASSEMBLY Install the hose assembly into the application utilizing standard hose routing practices. 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. 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...

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GENERAL INFORMATION Part number nomenclature_____________________________________________________ B-6 LifeSense common components__________________________________________ B-7 – B-10 LifeSense wired electronic components _________________________________ B-11 – B-12 TECHNICAL DATA / FAQs ASSEMBLY EQUIPMENT LIFESENSE WIRELESS SYSTEM LIFESENSE WIRED SYSTEM LIFESENSE HOSE ASSEMBLY LifeSense wireless electronic components________________________________ B-13 – B-15 LIFESENSE COMPONENT SPECIFICATIONS Lifesense component specifications EATON LifeSense Installation and Service Manual E-HOOV-TI001-E2...

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GENERAL LIFESENSE COMPONENT I LIFESENSE HOSE LIFESENSE WIRED LIFESENSE WIRELESS ASSEMBLY TECHNICAL INFORMATION^^ SPECIFICATIONS ASSEMBLY SYSTEM SYSTEM EQUIPMENT DATA / FAQs EC502-8 Base Hose Number/Hose Type Hose size (in 16ths of an inch) Base hose number The base hose number is simply the type of LifeSense hose you wish to order. Hose size These are the one or two digits after the base hose number. The hose size code follows industry standards and is the inner diameter of the hose in sixteenths of an inch. Metric equivalents are found within the hose specification charts. Hose length The hose...

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LifeSense EC502 Two-wire braid hydraulic rubber hose Meets and exceeds 2SN, EN853 requirements # Part Number *4:1 burst to working pressure safety factor For fluid compatibility information refer to the Aeroguip or Weatherhead master catalogs Construction Tube: Synthetic rubber Reinforcement: Two-wire braid Cover: Synthetic rubber Operating temperature range Temperature ange -40°C to +100°C (-40°F to +212°F) Application • General hydraulics • Agricultural equipment - turf care • Vocational fleets - mobile refuse, mobile cement mixers • Manufacturing - stationary machining centers • Safety barriers...

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GENERAL LIFESENSE COMPONENT I LIFESENSE HOSE LIFESENSE WIRED LIFESENSE WIRELESS ASSEMBLY TECHNICAL INFORMATION^^ SPECIFICATIONS ASSEMBLY SYSTEM SYSTEM EQUIPMENT DATA / FAQs Lifesense common componentsLifesense non-skive fittingsFemale ORS Swivel straight (FR) Fittings for use with hose: EC502 EATON LifeSense Installation and Service Manual E-HOOV-TI001-E2 October 2015

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Female ORS Swivel 90°Short drop elbow (FRB) Fittings for use with hose: EC502 Part Number Female ORS Swivel 90°Long drop elbow (FRC) Fittings for use with hose: EC502 # Part Number TECHNICAL ASSEMBLY LIFESENSE WIRELESS LIFESENSE WIRED LIFESENSE HOSE LIFESENSE COMPONENT GENERALDATA / FAQs EQUIPMENT SYSTEM SYSTEM ASSEMBL^^^H SPECIFICATIONS INFORMATION EATON LifeSense Installation and Service Manual E-HOOV-TI001-E2 October 2015

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GENERAL LIFESENSE COMPONENT I LIFESENSE HOSE LIFESENSE WIRED LIFESENSE WIRELESS ASSEMBLY TECHNICALINFORMATION^^ SPECIFICATIONS ASSEMBLY SYSTEM SYSTEM EQUIPMENT DATA / FAQs Protective sleeve - Heat shrink tubing Part Number *After shrinking Used on non-sensored end of a LifeSense hose assembly Construction • Black Polyolefin Features • Moisture-seal adhesive lined • Abrasion resistant EATON LifeSense Installation and Service Manual E-HOOV-TI001-E2 October 2015

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Construction • Housing - Clear Ultem® material • Board size 3.25” x 4” dZ-HHld VSn-TTrfl IQSi/Ha • Deutsch sockets - stainless steel (DEUTSCH #462-201-20141) Hose diagnostic unit (HDU) Complies to: BS EN 61326-1:2006 (EMC Requirements) EN 13309: 2000 (Electromagnetic compatibility) ISO 13766: 2006 (Electromagnetic compatibility) EN ISO 14982: 2009 (Electromagnetic compatibility) Directive 2004/108/EC (Electromagnetic compatibility) Directive 2004/104/EC (EMC) Power harness • SXL SAE J128 • ATM two-amp fuse • 18 gauge wire Features • Flat, jacketed PVC • Resistant to oil, grease, acid and gasoline...

Open the catalog to page 11

GENERAL LIFESENSE COMPONENT I LIFESENSE HOSE LIFESENSE WIRED LIFESENSE WIRELESS ASSEMBLY TECHNICAL INFORMATION^^ SPECIFICATIONS ASSEMBLY SYSTEM SYSTEM EQUIPMENT DATA / FAQs Part Number Lifesense wired electronic componentsSensor assembly Each sensor comes with a pre-cut length of protective sleeve. ‘Chassis profile • Housing - Nylon 6-6 • Material - Polyolefin • Hardware - Stainless steel EATON LifeSense Installation and Service Manual E-HOOV-TI001-E2 October 2015

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