Parker HY33-8327-IB/UK User manual

Mounting and maintenance
Instruction book
Publ no HY33-8327-IB/UK
Edition 2013-04-16

ii
Contents
Instruction book, Mounting and maintenance
Contents
1 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
Overview of relevant documentation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Start-up, maintenance, and diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 Wiring components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Wire for mobile electronics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Recommended wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
CAN-bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
CAN-bus terminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Deutsch connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AMP/Tyco connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
AMP/Tyco connectors with latch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Mating and unmating connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Locating the harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Attaching the harness . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Crimping tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Amp/Tyco crimping tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Deutsch crimping tool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Extraction tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
AMP/Tyco extraction tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Miscellaneous tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
IQAN tools usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6 Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Crimping pins on cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Connector wire sealing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Plugging unused connector positions . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Mounting the connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Inspection for proper crimping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Building the connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Deutsch assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Deutsch disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
AMP assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
AMP disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
7 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
During operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Regular inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
8 Start-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Start-up procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Starting the control system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Prepare for system start . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Start the system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

1
Warnings
1 Introduction
Instruction book, IQAN
1 Introduction
These instructions are to be used as a reference tool for the vehicle manufacturer’s
design, production, and service personnel.
The user of these instructions should have basic knowledge in the handling of
electronic equipment.
Warnings
Sections marked with a symbol in the left margin, must be read and understood by
everyone using the system, carrying out service work, or making changes to hardware
and software.
The different symbols used in this manual are defined below.
WARNING
Sections labeled WARNING with a caution symbol in the left margin, indicate that a
hazardous situation exists. We use warnings, marked with the warning symbol, in two
ways.
• As a strong recommendation about work practices when using the product in the
machine (e.g. routines when updating an application). This use is common to the
term 'hazardous situation', that a person is exposed to a hazard.
• As a way of pointing out important information for the machine designer that in
some way relates to safety. This includes the design of the physical machine, and
also the application program being developed for the control system.
Not all document sections that contain information about safety are marked with a
warning symbol (there would be warnings everywhere). Failure to comply with the
recommendations can cause unintentional, and unexpected behavior of the control
system. This can potentially cause death, serious injury or property damage.
NOTICE
Sections labeled NOTICE with a notice symbol in the left margin, indicate there is
important information about the product. Ignoring this could result in less than optimal
performance, or damage to the product.
Contact the manufacturer if there is anything you are not sure about or if you have any
questions regarding the product and its handling or maintenance.
The term "manufacturer" refers to Parker Hannifin Corporation.

2
Overview of relevant documentation
1 Introduction
Instruction book, IQAN
Overview of relevant documentation
The following publications are relevant for users of this product.
The main documentation contains information that is not found elsewhere.
The additional documentation contains product information in a compact format, for
details on the information found in those documents, consult this manual.
The IQAN module documentation system.
Compact
Documentation
Main
Documentation
IQANdesign/
IQANrun
User Manuals
IQAN module
Instruction Book
HY33-8nnn-IB
IQAN module
Catalogue Datasheet
HY33-8nnn
IQAN module
Installation Sheet
HY33-8nnn-IS
IQAN module
Electrical Schematic
HY33-8nnn-ES
Mounting and Maintenance
Instruction Book
HY33-8327-IB

3
2 Precautions
Instruction book, Mounting and maintenance
2 Precautions
Work on the hydraulics control electronics may only be carried out by trained
personnel who are well-acquainted with the control system, the machine and its safety
regulations.
WARNING
Make sure that you have sufficient knowledge before designing, modifiying or
servicing the control system.
Read the relevant sections of this document before conducting any work on the control
system.
WARNING
The controller units are not field repairable.
NOTICE
As much as possible of the welding work on the chassis should be done before the
installation of the system. If welding has to be done afterwards, the electrical
connections on the system must be disconnected from other equipment. The negative
cable must always be disconnected from the battery before disconnecting the positive
cable. The ground wire of the welder shall be positioned as close as possible to the
place of the welding. The cables on the welding unit shall never be placed near the
electrical wires of the control system.
Start-up, maintenance, and diagnostics
For all personnel carrying out installation, commissioning, maintenance or
troubleshooting.
WARNING
Work on the hydraulics control electronics may only be carried out by trained
personnel who are well-acquainted with the control system, the machine and its safety
regulations.
Before you start,
Read section "Start-up".
Additional information for service
The respective installed product instruction books.
Additional information for diagnosing the system
Read section "System diagnostics", and see "Appendix B", in the installed product
instruction books.

4
Wire for mobile electronics
3 Wiring components
Instruction book, Mounting and maintenance
3 Wiring components
Wire for mobile electronics
NOTICE
Always use stranded wire, never use solid conductor wire.
Stranded wire is flexible and can withstand vibration and movements typical to
machines.
Recommended wire
Machine manufacturers and wire harness fabricators have their own specifications for
wire and cable used on equipment.The following information is general in nature and is
not a requirement for the IQAN installation to work properly. It represents "good
practice" guidelines for service technicians unfamiliar with electronic controls wiring.
The wire will agree with FLRY according to DIN 72551
• FL=automotive
• R=reduced insulation thickness
• Y=PVC insulator material
This specification of wire is sometimes called automotive type TXL. It has the
following characteristics:
• Conductor: Stranded copper wire - bare is preferred.
• Insulator: DIN ISO 6722, class A (PVC).
• Temp. range: -40 to +105 °C.
NOTICE
If there is a risk of prolonged contact with oil.
Use cabling with sheathing and insulators in oil-resistant material, e.g. PUR or PTFE.
Signal wires
For signal transmission (I/O) and communication purposes, use wire with a cross
sectional area of 0 ,75 mm² (AWG 18). The stranding should be 19x0,23 (19x30). The
wire outer Ø will be nominal 1,9 mm (.075") and the insulator thickness 0,30 mm
(.012").
Power supply wires
For modules that do not have high power outputs (>1A), wire with a cross sectional
area of 0 ,75 mm² (AWG 18) may be used. The stranding should be 19x0,23 (19x30).
The wire outer Ø will be nominal 1,9 mm (.075") and the insulator thickness 0,30 mm
(.012").
For +BAT or -BAT on modules with high power outputs, use wire with a cross
sectional area of 2,00 mm² (AWG 14). The stranding should be 19x0,35 (19x27). The
wire outer Ø will be nominal 2,8 mm (.110") and the insulator thickness 0,45 mm
(.018").

5
Connectors
3 Wiring components
Instruction book, Mounting and maintenance
CAN-bus
The conductors for CAN-H and CAN-L should be a twisted pair, 40 twists per meter.
This is made to minimize the risk of EMI interference. Shielded cables must not be
used. The maximum length of the bus between modules is 100 meters (325 ft.). The
recommended nominal length is 40 meters (130 ft.).
CAN-bus terminator
The end of the CAN bus must be terminated. Termination is usually done inside the
IQAN expansion units, determined by the use of an idTag. Some modules may not have
this feature and require a terminating resistor. If the terminator is not bought from the
manufacturer, it must have a resistance of 120 ohms. The resistor must be able to
handle a power loss of 8 watts in case of a short-circuit between chassis and +24 Vdc.
Connectors
The connectors in IQAN systems are of two main types:
• Deutsch transportation connectors.
• AMP/Tyco automotive connectors.
The AMP connectors use two sizes of pins, JPT (Junior Power Timer) and MT (Micro
Timer) pins.
The following connector descriptions and crimping information will be general in
nature, for more detailed AMP/Tyco connector and crimping information, please visit
the AMP/Tyco website, www.tycoelectronics.com.
For Deutsch connector and crimping information, please visit the Deutsch website,
www.deutschipd.com.
Deutsch connectors
The IQAN modules that are equipped with Deutsch connectors use either DT or DTM
types. These are keyed and equipped with a locking mechanism. The lock for the
connectors is either a single or dual plastic clip.
Deutsch connectors, IQAN-MD3, IQAN-LST/LSL, sensors
AMP/Tyco connectors
There are a few non-automotive AMP connectors used for IQAN products. These are
keyed and equipped with a locking mechanism. The lock for the non-automotive
connectors are either a spring clip or plastic clip.
AMP connectors, IQAN-LM/LL, IQAN-SP

6
Connectors
3 Wiring components
Instruction book, Mounting and maintenance
AMP/Tyco connectors with latch
The AMP automotive connectors used on most IQAN modules also are keyed and
equipped with a locking mechanism. The automotive connector locking mechanism
consists of a different coloured sliding latch, mounted on one end of the connector.
This type of locking mechanism helps to press the plug and receptacle of the
connectors together. This minimizes risk of damage to the pins.
AMP connectors with a sliding latch, IQAN-MDL/X_2/TOC8, IQAN-MDM, IQAN-LSL/LST.
Mating and unmating connectors
CAUTION
Risk of damage to the units' electronics.
Do not mate / un-mate while units are under power.
Mate the latched connectors as follows:
1 Pull out the wire harness mounted connector's sliding latch.
2 Check that the connectors and pins are clean and undamaged. The pins should all
appear to be flush with the mounting face. If any pins are recessed, push the corre-
sponding wire from the back of the connector to seat the pin properly.
3 Verify that only one face seal (if used) is installed in the module’s connector.
4 Put the two connectors together so that the keying passes into the corresponding
track. Wiggle the connector to ensure that all pins and their mates are aligned.
5 Push the latch in while applying force to the connector shell, so that the two connec-
tors are pressed together. The more pins the connectors contain, the greater the
power which is required to push in the latch.
NOTICE
Do not rely on the latch alone to assemble the connector!
The force applied by the latch on the keys could damage the module’s connector.
6 Push in the latch completely so that the plastic hooks secure the latch position.
Unmate the latched connectors as follows:
1 Pull out the connector's latch while also pulling the connector away from the mod-
ule. The more pins the connectors contain, the greater the power required to pull the
latch apart. The connectors remain locked together until the latch is pulled out to the
maximum extent. It is not possible to pull the connectors apart before the latch is
pulled all of the way out.
2 Check that the connectors and pins are undamaged. Check carefully the plastic
hooks which secure the latch in its pushed-in position.
3 Damaged connectors must be changed.

7
Connectors
4 Mounting
Instruction book, Mounting and maintenance
4 Mounting
For mounting instructions for the respective modules, see the installation sheet that is
packed with the unit upon delivery. See also the separate instruction books for each
unit.
WARNING
Risk of unexpected and uncontrolled movements.
An incorrectly located or mounted harness can be affected by radio signals which can
interfere with the system’s functions.
Locating the harness
NOTICE
Install the harness per the following guidelines:
• Protect the harness against radio signals which can interfere with the system's func-
tions. Avoid putting the control system's harness close to communications equip-
ment, antennas, generators or other high-frequency electrical interference sources.
Note that antenna cables can also interfere with the system. Separate the cabling
from the antenna cable.
• Separate the control system's current supply from the communication equipment's
current supply.
• Locate the harness so that, as much as possible, it is shielded by sheet metal with
good electrical connection to the battery's negative terminal. Place the harness in
beams or channels enclosed by sheet. If this is not possible, locate the harness in the
in-most corner of the channel. If there are no beams or channels, locate the harness
towards sheet metal surfaces.
• Protect the harness against mechanical wear.
• Avoid free-hanging cables. Free-hanging cables must be placed so there is no risk
that it can be folded or crushed.
• When the harness passes sharp edges, the harness must be protected with an edge
list or lead-in wire. An opening through a bulkhead is an example of an edge.
Attaching the harness
NOTICE
Fix the harness to the machine per the following guidelines:
• Use a conduit or loom to hold the wires/cables together.
• Fix the harness with binding tape, clips, glue or another type of fastener. The dis-
tance between the fastening points must be adapted so that the harness is free from
vibrations to the frame.
• When movement is required, the length of the cabling is adapted so that a bend is
formed. The radius should be as big as possible. The cabling must not be in danger
of being fully stretched. The radius in the bend of the cabling must not be less than
the is recommended by the manufacturer, (e.g.20 times the diameter of the cabling).

8
Crimping tools
5 Tools
Instruction book, Mounting and maintenance
5 Tools
The following tools, which are available in the IQAN toolkit, or equivalent tools
recommended by the connector’s manufacturer, should be used:
• Different models of crimping tool adapted to crimping of the different types of pins.
• Extraction tools adapted to the removal of the different types of pins.
• Miscellaneous wire preparation tools and common service tools.
Crimping tools
The crimping tools are used to fix the pins to the conductor and insulator of the
individual wires.
Amp/Tyco crimping tools
The crimping tools in the IQAN toolkit are designed to work with AMP/Tyco
connectors used in IQAN modules. In some cases the insulator has a single wire seal
installed which is attached and held by crimping the pin. They are color coded to
identify which is used for the crimping of different types of pin.
Example of an IQAN crimping tool for AMP/Tyco connectors.
• Red - for crimping Junior Power Timer pins with individual wire seals.
• Yellow - for crimping Junior Power Timer pins without seals.
• Blue - for crimping Micro Timer pins with individual wire seals.