SES Hydraulic Hybrid iNTELLIDRIVE...

Service Manual

Applies To:

iNTELLIDRIVE 3000

iNTELLIDRIVE 1500

Issue 1.0 2016

SES Hydraulic Hybrid iNTELLIDRIVE System

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Table of Contents 1 About this manual ........................................................................................................................................ 3

1.1 Validity of the Documentation ............................................................................................................. 3

1.2 Display of information .......................................................................................................................... 3

1.2.1 Safety Instructions ........................................................................................................................ 3

1.2.2 Designation ................................................................................................................................... 4

1.2.3 Abbreviations ................................................................................................................................ 4

2 Safety instructions ........................................................................................................................................ 4

2.1 About this chapter ................................................................................................................................ 4

2.2 Intended use ......................................................................................................................................... 5

2.3 Improper use ........................................................................................................................................ 5

2.4 Personnel qualifications ....................................................................................................................... 6

2.5 General safety instructions ................................................................................................................... 6

2.6 Product-specific safety instructions ..................................................................................................... 7

2.7 Personal protective equipment (PPE)................................................................................................... 8

3 Component Identification............................................................................................................................. 9

3.1 Gearbox .............................................................................................................................................. 10

3.2 Hydraulic Hybrid Drive Unit ................................................................................................................ 10

3.3 Accumulators ...................................................................................................................................... 11

3.4 Accumulator Manifold ........................................................................................................................ 11

3.5 Hydraulic Reservoir ............................................................................................................................. 12

4 Service/Maintenance of System and components ..................................................................................... 13

4.1 Maintaining Hoses/Hose ends/Fittings .......................................................................................... 13

4.4 Maintaining Accumulator System................................................................................................... 19

4.5 Maintaining Coolers ........................................................................................................................ 21

4.6 Maintaining Oil and Air Filters ........................................................................................................ 22

4.7 Maintaining Drive Shafts ................................................................................................................ 22

5 Maintenance Schedule Chart ..................................................................................................................... 25

6 Replacing Components ............................................................................................................................... 25

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1 About this manual

1.1 Validity of the Documentation The contents of this documentation applies to the following products:

• iNTELLIDRIVE™ 3000 • iNTELLIDRIVE™ 1500

This documentation is intended for SES distributors/up fitters, authorized service technicians, and vehicle manufacturers.

This documentation contains important information about how to safely maintain the iNTELLIDRIVE system. It also provides basic trouble shooting procedures.

Prior to working on the iNTELLIDRIVE™ system, please read this document in its entirety and ensure full understanding of its contents for safety purposes.

1.2 Display of information Standardized safety instructions, symbols, terms and abbreviations are used in this document to help you work quickly and safely with your product. The sections below will help you better understand the meanings of these items.

1.2.1 Safety Instructions This documentation includes safety instructions in chapter 2.6 "Product-specific safety instructions" and in chapter 3 "General instructions on damage to equipment and the product". The described danger prevention measures must be observed when performing a sequence of actions that involve a risk of personal injury.

Safety instructions are set out as follows:

• Safety signs: draw attention to danger • Signal word: identifies the degree of the danger • Type and source of danger: identifies the kind and cause of the danger • Consequences: describes results if the safety instructions are not followed • Precautions: states how the, potential danger can be avoided

Table 2: Danger classes in accordance with ANSI Z535.6-2006

Safety sign, signal word Meaning Identifies a dangerous situation that will result in death or

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DANGER

WARNING CAUTION

Serious injuries if it is not avoided.

Identifies a dangerous situation that may result in death or serious injuries if it is not avoided. Identifies a dangerous situation that may result in minor to moderate injuries if it is not avoided.

Property damage: The product or the environment may be damaged.

1.2.2 Designation This Document uses the following designations:

Table 4: Designations Designation Meaning iNTELLIDRIVE™ 3000 Intellidrive Hybrid Drive System for Class 8+ vehicles (hydraulic hybrid) iNTELLIDRIVE™ 1500 Intellidrive Hybrid Drive System for Class 6 vehicles (hydraulic hybrid)

1.2.3 Abbreviations This documentation uses the following abbreviations:

Table 5: Abbreviations

Abbreviation Meaning ABS Anti-locking Brake System CAN Controller Area Network HCM Hybrid Control Module DIN Deuce Industry Norm (German Institute for Standardization) SAE Society of Automotive Engineers (standard) Hrs. Operation Hours ECM Engine Control Module ISO International Organization for Standardization TCS Traction Control System

2 Safety instructions 2.1 About this chapter The iNTELLIDRIVE™ system was developed using the generally accepted rules of current technology and safety standards. However, failure to comply with the safety instructions presented in this document may result in personal injury or damage to equipment.

▶ Read this documentation completely and thoroughly before commissioning the iNTELLIDRIVE™ system.

NOTE

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▶ K e e p this documentation in a location where it is accessible to all users at all times.

▶ If the vehicle in which the iNTELLIDRIVE™ system is fitted is handed over or sold on to a third party, it must always be accompanied by the required documentation.

2.2 Intended use

The iNTELLIDRIVE™ system has been designed for use in commercial vehicles and mobile working machines. The iNTELLIDRIVE™ system and its components are retrofitted for specific vehicle types and should only be installed in the vehicle type specified in the order confirmation.

During operation, the kinetic energy of the vehicle is captured into high pressure accumulators using regenerative braking. When the vehicle begins to launch, the stored pressure is then released back into the system as launch support to reduce the load on the engine.

The iNTELLIDRIVE™ system should not be placed in any other vehicle type than is listed on the order confirmation.

The product may be used as follows:

▶ The iNTELLIDRIVE™ system may only be installed in the vehicle defined in the order confirmation. ▶ Observe the technical data, application and operating conditions and performance

limits as specified in iNTELLIDRIVE™ system data sheet and in the order confirmation. ▶ Only the system components supplied may be installed. These must be used in

accordance with the circuit diagrams for the specific system (see order confirmation and specific vehicle configuration).

Intended use includes having read and understood the complete documentation, especially the chapter 2 "Safety instructions".

2.3 Improper use

Any use of the iNTELLIDRIVE™ system that conflicts with what has been described in this document is considered improper use and is therefore impermissible by Stored Energy Solutions (SES). Improper use of the equipment voids the warranty and SES will not accept responsibility for any damage that results from improper use.

Improper use of the product includes:

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▶ Use in an explosive environment. ▶ Use in hazardous goods transporters. ▶ Installation on a vehicle not specified on the order conformation.

2.4 Personnel qualifications The skillset required for a service technician to properly complete the activities mentioned in this manual include; basic mechanical, electrical and hydraulic knowledge, as well as knowledge of the associated technical terms. It is also necessary to have available a working knowledge of lifting equipment, such as a forklift or engine hoist, for transportation and handling of the System and related equipment.

These activities should only be performed by appropriate qualified personnel to ensure proper completion and to maintain a safe environment.

Qualified personnel are those who can recognize possible hazards and implement the correct safety measures due to their professional training, knowledge, and experience, as well as their understanding of the relevant regulations pertaining to the work to be done.

Activities in this document must be completed, as indicated, in accordance with SES specifications as listed in this manual and documents pertaining to the iNTELLIDRIVE™ system listed in Table 1 “Required and supplementary documentation” or in accordance with instructions given by a representative of SES. Please consult your responsible SES authorized distributor/service center with any questions / clarifications related to the System.

Operation of the iNTELLIDRIVE™ system requires extensive knowledge of the information given in chapter 9 “Operation”.

2.5 General safety instructions

• Do not use SES products if they are not in good working order. • Personnel working with or around SES products must not consume any substance

that may affect their ability to respond. (i.e. alcohol, drugs or pharmaceuticals.) • Ensure that the installation, operation, and maintenance of the iNTELLIDRIVE™

system conforms to all safety regulations and technical data. • Use only SES authorized spare parts or accessories to ensure compatibility with the

iNTELLIDRIVE™ system. • Observe and comply with the safety regulations and provisions of the country in

which the product is used/operated.

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• Observe and comply with the applicable accident prevention and environmental protection regulations.

2.6 Product-specific safety instructions The following safety instructions apply for chapters 1 to 5.

DANGER

Vehicle that is not at a standstill pose a risk of injury!

Working on operating vehicles poses a danger to life and limb. The work steps described in this chapter must only be performed on stationary vehicles. Before beginning work: ▶ Ensure that the engine cannot be switched on. Remove the ignition key. ▶ Secure the vehicle against unexpected movement, (i.e. with chocks). ▶ Ensure that all power-transmitting components and ports (electric, pneumatic, hydraulic) are switched off according to the manufacturer's instructions and are secured against being switched on again. If possible, disconnect the vehicle battery. ▶ Ensure the vehicle is relieved of all hydraulic load. Please comply with the specifications of the vehicle manufacturer and the iNTELLIDRIVE™ system. ▶ The iNTELLIDRIVE™ system may only be installed by qualified personnel (see chapter 2.4 "Personnel qualifications") Risk of injury from freely accessible iNTELLIDRIVE™ components! Freely accessible iNTELLIDRIVE™ components constitute an increased risk of injury, (i.e., through burning on hot parts of similar). Also in the event of a malfunction, the bursting of high-pressure components (i.e., hoses, accumulator, etc.)

▶ The iNTELLIDRIVE™ components must be installed so that they are not freely accessible. ▶ Ensure that the high-pressure components are suitably protected against bursting (i.e. by protective hoses and screening plates). Accumulators are pressurized! Danger to life or risk of injury from bursting or exploding pressure accumulators. ▶ No welding, soldering, drilling or other work that could affect the mechanical properties is to be performed on accumulators. ▶ Do not modify the accumulator or its components.

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2.7 Personal protective equipment (PPE)

It is the responsibility of the user of the iNTELLIDRIVE™ system to supply and maintain their own personal protective equipment. All PPE should be in good condition. Recommended PPE include:

• Steel toe boots • Hard hat or bump cap • Safety glasses • Oil resistant gloves • Ear plugs

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3 Component Identification This section will help locate and identify the major components of the iNTELLIDRIVE™ system.

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3.1 Gearbox The gearbox is located inside the frame rails of the vehicle; in-between the transmission and the rear differential.

3.2 Hydraulic Hybrid Drive Unit The hydraulic hybrid drive unit is attached to the gearbox, this unit is located forward of the gearbox inside the frame rails.

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3.3 Accumulators The accumulators are held in place by the accumulator brackets on the side of the frame rails behind the front wheels. This unit holds 3 accumulators.

3.4 Accumulator Manifold The Accumulator Manifold is located on one end of the accumulators. This manifold contains the main circuit valves.

Accumulators

Manifold

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3.5 Hydraulic Reservoir The iNTELLIDRIVE™ system either utilizes the hydraulic reservoir already located on the side of the vehicle’s frame, or employs its own reservoir that is separate from the truck’s other systems.

3.6 Servo Pump Each system is equipped with a secondary pump that is used to provide control oil to the main drive unit and to send oil to the coolers and filters for conditioning. It can be located either up near the engine and driven by the crankshaft, or mounted on a PTO coming off the transmission.

3.7 Servo Manifold The servo manifold is used to manage the oil coming from the servo pump and is located near the accumulator rack.

3.8 Electrical Enclosure

The main electrical components are located in a sealed container near the accumulator rack.

3.9 Oil Cooler(s) Each system is equipped with 1 or 2 oil coolers that help keep the oil at the ideal operating temperature. These are generally located near the accumulator rack and gearbox and could be inside or outside of the frame rails.

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4 Service/Maintenance of System and components

System Pressure Bleed Down

Before working on any part of the hydraulic system, caution must be taken to ensure that no residual pressure remains in the system. Each iNTELLIDRIVE™ system is equipped with an automatic bleed down function that will activate each time the system is turned off from the display. This function is intended to relieve any residual pressure remaining in the accumulators for safety purposes. While this bleed down is taking place, a hissing sound can be heard coming from the accumulator manifold, indicating that oil is moving. Once the hissing has subsided, the residual pressure should be gone. Confirm on page 3 of the display unit that no pressure reading remains in either P1 or P2. After the hissing has stopped and the display confirms there is no pressure remaining, it is safe to begin work on the system.

Ball Valve Oil Shutoffs

Depending on the exact set up of each system, there will be at least 1 ball valve located near the hydraulic reservoir that can be used for servicing the system.

4.1 Maintaining Hoses/Hose ends/Fittings

Hose life may be significantly reduced without a continuing maintenance program. The significance of the application, risk potential from a possible hose failure, and experience with any hose failures in the application or in similar applications should determine the frequency of the inspection and the replacement for the products so that products are replaced before any failure occurs.

4.1.1 Visual Inspection Hose/Fitting Any of the following conditions require immediate attention and replacement of the Hose Assembly:

• Fitting not in the proper location, • Damaged, cracked, cut or abraded cover (any reinforcement exposed); • Hard, stiff, heat cracked, or charred Hose; • Cracked, damaged, or badly corroded Fittings; • Leaks at Fitting or in Hose; • Kinked, crushed, flattened or twisted Hose; and • Blistered, soft, degraded, or loose cover

4.1.2 Visual Inspection All Other The following items must be tightened, repaired, corrected or replaced immediately:

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• Leaking port conditions; • Excess dirt buildup; • Worn clamps, guards or shields; and • System fluid level, fluid type, and any air entrapment.

4.1.3 Functional Test Operate the System at maximum operating pressure and check for possible malfunctions and leaks. Personnel must avoid potential hazardous areas while testing and using the system.

4.1.4 Replacement Intervals: Hose assemblies and elastomeric seals used on Hose Fittings and adapters will eventually age, harden, wear and deteriorate under thermal cycling and compression set. Hose Assemblies and elastomeric seals should be inspected and replaced at specific replacement intervals, based on previous service life, government or industry recommendations, or when failures could result in unacceptable downtime, damage, or injury risk.

4.1.5 Hydraulic Injection Injury Risks Hydraulic power is accomplished by utilizing high-pressure fluids to transfer energy. Hoses, fittings, and hose assemblies all contribute to this by conducting fluids at high pressures. Fluids under pressure can be dangerous and potentially lethal and, therefore, extreme caution must be exercised when working with fluids under pressure and handling the hoses transporting the fluids. From time to time, hose assemblies will fail if they are not replaced at proper time intervals. Usually these failures are the result of some form of misapplication, abuse, wear, or failure to perform proper maintenance. When hoses fail, generally the high-pressure fluids inside escape in a stream which may or may not be visible to the user. Under no circumstances should the user attempt to locate the leak by “feeling” with their hands or any other part of their body. High-pressure fluids can and will penetrate the skin and cause severe tissue damage and possibly loss of limb. Even seemingly minor hydraulic fluid injection injuries must be treated immediately by a physician with knowledge of the tissue damaging properties of hydraulic fluid. If a Hose failure occurs, immediately shut down the equipment and leave the area until pressure has been completely released from the hose assembly. Simply shutting down the hydraulic pump may or may not eliminate the pressure in the hose assembly. Many times check valves, etc., are employed in a system and can cause pressure to remain in a hose assembly even when pumps or equipment are not

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operating. Tiny holes in the Hose, commonly known as pinholes, can eject small, dangerously powerful but hard to see streams of hydraulic fluid. It may take several minutes or even hours for the pressure to be relieved so that the hose assembly may be examined safely. Once the pressure has been reduced to zero, the hose assembly may be taken off the equipment and examined. It must always be replaced if a failure has occurred. Never attempt to patch or repair a Hose Assembly that has failed. Consult the nearest SES distributor or the appropriate SES division for hose assembly replacement information. Never touch or examine a failed hose assembly unless it is obvious that the Hose no longer contains fluid under pressure. The high-pressure fluid is extremely dangerous and can cause serious and potentially fatal injury.

4.2 Maintaining Pump and Gearbox Assembly

4.2.1 Maintaining Pump There are no maintenance items on the pump that need regular attention. The most important part of maintaining the pump is ensuring the fluid exposed to the pump is clean and cool. This requires good maintenance practices of all filtration and cooler devices.

4.2.2 Maintaining Gear Box – 3000 Series Units PREVENTATIVE MAINTENANCE

Oil flow and circulation in a transfer case is one of the most important features to give all internal parts the maximum life. The transfer case design incorporates several key features from previous designs. When filled to the proper level, oil will be circulated within the box to each set of bearings for smooth operation. Because the pump splines and the input shaft are exposed to the oil within the transfer case.

** All transfer cases are shipped Without Oil **

Verify that the drain plug is tightened to 50 ft-lbs.

1) Fill transfer case to oil level plug level (Fill hole is on top of Transfer Case).

Do not over fill, as this will result in overheating and possible failure of the transfer case.

2) It is recommended to change the oil after the first 500 hours or 3 months of service, whichever occurs first. Thereafter, and under normal operating

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conditions, SES recommends that the oil be changed every 2000 hours or 12 months of service.

3) Stop engine before attempting to check or add oil.

4) Clean around the oil fill hole before checking or adding oil

5) Drain oil while the unit is still warm.

Hot oil can cause severe burns. Use extreme care when removing lubrication plugs and vents.

6) Inspect and clean magnetic drain plug for contamination or metal particles before replacing.

OIL CAPACITY

When changing the oil, some residual remains in the box, this will require less oil to re-fill the box. Only fill to the MAX oil level or to the oil level plug, otherwise overheating may occur. Approximately 5 quarts of oil are needed.

Maximum Operating oil temperature for all standard oils: 210° F (99ºC).

Maximum Operating oil temperature for all synthetic oils: 250ºF (121ºC).

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Lubrication Recommendations:

RECOMMENDED OIL TYPE

Recommended Brands: Mobile SHC 630 Synthetic or equivalent.

Some applications may require an EP additive to be part of the oil being used.

Oil Change Intervals:

Change oil after first 500 hours (or within the first 3 months) then every 2000 hours or 12 months thereafter.

Grease Requirements:

When grease zerks are present, they should be using Lithium based grease appropriate for the operating environment. NLGI Grade 2. Can be supplied with an EP2 rating (as well).

Recommend Brands: Mobil 1 Synthetic Grease of equivalent.

Due to the normal and sometime severe torsional vibrations that Power Take-Off (PTO) units experience, operators should follow a set maintenance schedule for inspections. Failure to service loose bolts or Power Take Off leaks could result in potential auxiliary Power Take-Off or transmission damage. Periodic PTO MAINTENANCE is required by the owner/operator to ensure proper, safe and trouble free operation. Daily: Check all air, hydraulic and working mechanisms before operating PTO Perform maintenance as required. Monthly: Inspect the PTO for possible leaks and tighten all air, hydraulic and mounting hardware, as necessary. Torque all bolts, nuts, etc. to the manufacturer specifications. Ensure that splines are properly lubricated, if applicable. Perform maintenance as required. Warranty: Failure to comply entirely with the provisions set forth in the appropriate Owner’s Manual will result in voiding of ALL Warranty consideration.

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4.2.3 Maintaining Gearbox – 1500 Series Units Lubrication Information

To ensure proper lubrication and operating temperatures in these units, it is most important that the proper lubricants be used and that correct oil levels be maintained

Recommended Lubricants:

Mobil Delvac Synthetic ATF

Do Not Use Extreme Pressure Additives, such as found in multi-purpose or rear axle type lubricants. These additives are not required in our split shafts, and they may in some cases create transmission problems. Multi-purpose oils, as a group, have relatively poor oxidation stability, a high rate of sludge formation and a greater tendency to react on or corrode the steel and bronze parts.

Oil Changes

SES recommends an initial oil change and flush after the split shaft is placed in actual service. This change should be made any time following 1,000 miles, but never to exceed 4,000 miles, of over-the-road service. In off-highway use, the change should be made after 24 and before 100 hours of service have elapsed. There are many factors that influence the following oil change periods, and we have not specified a definite mileage interval.

In general, it is suggested that a drain and flush period be scheduled every 20,000 miles for normal over-the-highway operations. Off-the-highway usually requires an oil change every 30 days. The oil level in the split shaft should be checked every 2,000 miles on-highway, or every 24 hours in off-highway operation. When it is necessary to add oil, we recommend that types or brands of oil not be mixed. The correct oil level in all SES split shafts is established by the filler plug opening. Refill-First, remove all dirt around the filler plug. Then refill with new oil of a grade recommended for the prevailing service.

Overfilling

Do not overfill the gear box. Overfilling usually results in oil breakdown due to excessive heat and aeration from the churning action of the gears. Early breakdown of the oil will resultin heavy varnish and sludge deposits that plug up oil ports and buildup on splines and bearings. Overflow of oil usually escapes

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onto clutch or parking brakes, causing addition trouble.

4.3 Maintaining Bracketry/Hardware Check all bracketry regularly for deformation or cracking. Damaged hardware should be replaced immediately. Ensure that there are no loose bolts.

4.4 Maintaining Accumulator System Each iNTELLIDRIVE system utilizes 3 accumulators to store energy captured from braking. These accumulators require compressed nitrogen gas to be maintained inside of them for proper operation. Regular inspection of the nitrogen pressures inside each accumulator will help ensure the proper pre-charge is maintained for optimal performance of the hybrid system. If the inspection reveals an incorrect pre-charge level, return the pre-charge to the recommended level immediately. Contact your SES representative for the correct pre-charge level if necessary.

It is recommended to check the pre-charge pressure of all accumulators once every 3 months to ensure proper performance levels. The nitrogen gas pressure is subject to change with the ambient temperature and seasonal temperature differences will result in pre-charge pressure fluctuation.

To check pre-charge pressure, first start by ensuring the system is void of any residual pressure in either P1 or P2 by following the guidelines in item 3 above.

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Pre-Charging

Use an inert gas such as nitrogen for pre-charging piston accumulators. Do not use oxygen or shop air.

If water pumped nitrogen is not available, oil-pumped nitrogen may be used. (C.G.A. standards: Nitrogen gas bottles for water pumped nitrogen has a right-hand valve thread which requires charging and gauging assembly †144595XX00 for units up to 3000 psi.

If equipment other than the above listed is used, make sure it is compatible with the gas valve assembly. Nitrogen source and all components must be rated for a pressure at least as high as the nitrogen source. It is strongly recommended that the nitrogen bottle used have the appropriate pressure high pressure regulator (not included).

Make sure nitrogen supply is shut off. Attach hose to nitrogen bottle. If accumulator has a gas valve as shown in Figure 5 follow steps A through L and skip steps F and J. If accumulator has a gas valve as shown in Figure 6, follow steps A through L and skip steps E and I.

Accumulator having gas valve as per Figure 5.

(A) Remove gas valve guard and gas valve cap.

(B) Back gas chuck “T” handle all the way out (counter clockwise) before attaching charging assembly to accumulator gas valve.

(C) Close bleed valve.

(D) While making sure not to loop or twist the hose, attach swivel nut to gas valve and tighten (10-15 in. lb.) (11.5-17 cm kg).

(E) Turn gas chuck “T” handle until the gauge starts showing the pressure in the accumulator. Do not turn the "T" handle all the way down, as it will damage the valve core.

(F) For gas valves as shown in Figure 6, hold gas valve at point “C” with one (1) wrench while un screwing hex nut at point “D” with a second wrench. This will open the poppet inside the gas valve. Note: Three (3) turns will fully open the valve.

(G) Crack open nitrogen bottle valve and slowly fill accumulator. Shut off when gauge indicates desired pre-charge.

(H) Let the pre-charge set for 10 to 15 minutes. This will allow the gas temperature to stabilize. If the desired pre-charge is exceeded, close nitrogen bottle valve, then slowly open bleed valve (Figure 1). Do not reduce pre-charge by depressing valve core with a foreign object. High pressure may rupture rubber valve seat.

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(I) When finished pre-charging accumulator, turn “T” handle all the way out on gas chuck (Figure 1), then open bleed valve.

(J) For gas valves as shown in Figure 6, with a wrench, tighten hex nut at point “D” to close internal poppet (5-8 ft. lbs.) (5.7-9.2 cm kg).

(K) Hold gas valve to keep from turning, loosen swivel nut, and remove assembly. Check for pre-charge leak using a common leak reactant.

(L) Replace gas valve cap (10-15 in. lbs.) (11.5-17 cm kg) and valve guard. (Gas valve cap serves as a secondary seal.) † "XX" Denotes to gauge pressure.

4.5 Maintaining Coolers It is important to ensure unobstructed air flow through each oil cooler to allow the system to maintain proper temperature levels. Each cooler’s radiator should be checked weekly to ensure that no buildup of dirt or debris is occurring in the fins. If some obstruction is noticed, blow out the fins using shop air until all debris has been cleared away. It is especially important to maintain each cooler during warm weather. If a cooler’s radiator fins have collapsed, replace the cooler immediately.

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4.6 Maintaining Oil and Air Filters Each iNTELLIDRIVE system is equipped with 1 or more filters that will require a regular maintenance schedule of replacement.

There is a pressure filter that is utilized to ensure clean oil is provided to the main pump controls. It is a manifold mounted filter. The system display unit in the cab will indicate when the filter is ready to be changed. Acquire the proper replacement filter from your SES representative.

Changing Servo Filters

To replace the servo filter, first ensure there is no residual pressure in the system and that the truck is turned off. Secondly, prepare a drip catch pan underneath the filter bowl to capture any residual oil that is left in the filter. Next, remove the filter bowl with the correct size wrench or socket. There is a hex built into the end of the bowl. Remove the element inside the bowl by gently pulling and moving it back and forth. It is friction fit to the head. Finally, press the new element into the filter head and replace the filter bowl. Torque the bowl to 30 ft-lb.

Return filters

Some SES systems will utilize a separate reservoir from anything that was mounted on the truck prior to system installation. In these cases, a separate return filter is used to maintain oil cleanliness levels. These filters will have a gauge that indicates the correct time for element replacement and should be checked periodically. If the gauge indicates that replacement is necessary (in yellow or red area) while truck is running, acquire the proper replacement element from your SES representative. Ensure there is no system pressure and that the truck is turned off. Remove old element with the correct socket wrench from the reservoir and replace with the new element.

Air breather/Filter

Each SES system will have a reservoir, either isolated or shared with other systems on the vehicle that must be capable of air exchange. Filter/Breathers are utilized to ensure that air coming into the reservoir is clean as to not introduce further contamination to the system. These devices must be maintained and replaced on a regular basis as to prevent further problems.

4.7 Maintaining Drive Shafts Grease drive shafts and U-Joints at least once a quarter, or every 500 hours.

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4.8 Maintaining Electrical Controller and Enclosure 4.8.1 Display Fault Codes

A fault can be cleared by pressing the left most button on the display. If the fault persists, it will re-appear on the display. Some faults require a key switch cycle to clear. If there is a fault, the system will remain in the neutral or standby mode until the issue is resolved to protect system components.

Fault ID Display Text

1 Hybrid Comm. Lost 2 Brake Pedal Range Low 3 Brake Pedal Range High 4 P1 Pressure Range Low 5 P1 Pressure Range High 6 P2 Pressure Range Low 7 P2 Pressure Range High 8 Pump Position Range Low 9 Pump Position Range High

10 Temp. Sensor Range Low 11 Temp. Sensor Range High 12 Pumping Solenoid Open Load 13 Pumping Solenoid Short 14 Motoring Solenoid Open Load 15 Motoring Solenoid Short 16 Sequence Valve Open Load 17 Sequence Valve Short 18 Accelerator Valve Open Load 19 Accelerator Valve Short 20 Clutch Valve Open Load 21 Clutch Valve Short 22 Dump Valve Open Load 23 Dump Valve Short 24 Cooler Relay Open Load 25 Cooler Relay Short 26 Sensor Power High 27 Sensor Power Low 28 ECU Power High 29 ECU Power Low 30 Display Comm. Lost 31 Engine Comm. Lost

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32 Trans. Comm. Lost 33 Body Comm. Lost 34 ABS Comm. Lost 35 ABS Not Operational 36 Pump Speed 37 PTO Disengage 38 PTO Engaged 39 System Pressure 40 System Temp High 41 Main Ball Valve Closed 42 Display Software Version incorrect 43 Oil Level Low 46 Cab Comm. Lost 51 Pump Control 52 Accel Valve Fault

A diagram of the fuse box is located below.

It is not recommended to attempt to repair the system’s wiring harness without contacting your SES representative.

F10 System Controller Fuse – 15A F9 Large Cooler Fuse – 30A F7 Small Cooler Fuse(if equipped) – 15A R5 Large Cooler Relay R4 Key switch signal to Controller – 2A R3 Small Cooler Relay(if equipped)

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4.9 Maintaining Rear Differentials Since the system loads the rear differential in the opposite direction as the engine does for braking the vehicle, SES recommends changing the oil in the rear differential at the same time as the initial oil change for the system gearbox, at 500 hrs. This will help ensure the integrity of the differential oil and assist in prolonging its life.

4.10 Maintaining Hydraulic Oil SES recommends obtaining a lab report of the hydraulic oil once every year to ensure that it meets the standards needed for all system components.

5 Maintenance Schedule Chart

6 Replacing Components Replacement parts are available through SES Inc.

To order a new or reworked part please contact SES or the authorized distributor of your iNTELLIDRIVE™ system. If a part needs to be returned, please contact an authorized distributor to receive a RGA (Return Goods Authorization) prior to returning the part.

If the request is not under warranty a fee will be applied for a rework or replacement. A quote will be issued to determine the cost of the rework or replacement.

It is recommended that the SES iNTELLIDRIVE maintenance list be incorporated into the vehicles regular maintenance schedule. The maintenance intervals may vary depending upon the severity of operation and the annual mileage of the vehicle. The following maintenance schedule is recommended:

Tasks Weekly/150 hrs. 3 Months/500 hrs. Yearly/2000 hrs. Clean Cooler Fins Check Accumulator Pre-charge Initial Oil Change of Gearbox Initial Oil change of Rear Differential Oil Grease Universal Joints Check Filter(s) for replacement Check Brackets for Deformation

Check Hoses for wear Regular Gearbox Oil Change Test Hydraulic oil for replacement

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