Driver s Manual Stored Energy Solutions Hydraulic Hybrid intellidrive System Applies To: intellidrive 3000 intellidrive 1500 Issue: 1.0 2016
Congratulations! Your vehicle is equipped with a Stored Energy Solutions Hydraulic Hybrid intellidrive System. Attached to the driveline of the vehicle, the system provides auxiliary braking, launch boost, increased safety, and reliable, highly efficient regenerative braking. intellidrive supplies the vehicle with additional braking power that works in tandem with the factory installed air brakes, allowing the system to store the kinetic energy while braking to help aid acceleration of the vehicle during takeoffs. Its benefits include, but are not limited to, extending brake component life, better fuel economy due to reduced power demand on the vehicle s engine, lowering maintenance costs, and decreasing route times. Using the intellidrive is very simple and rewarding. With only a few minor modifications to your driving style, you will soon reap the benefits of increased productivity and efficiency. Please take a moment to read this guide before operating the vehicle. This manual will explain how to operate the System. 2
Table of Contents 1 About this manual... 4 2 Safety instructions... 4 2.1 Intended use... 4 2.2 Improper use... 5 2.3 Personnel qualifications... 5 2.4 General safety instructions... 5 2.5 Product-specific safety instructions... 6 2.6 Personal protective equipment (PPE)... 7 3 How intellidrive Works... 8 4 Controls... 9 4.1 Brake Pedal... 9 4.2 Accelerator (Gas) Pedal... 10 4.3 Controller Display... 10 4.4 ABS Interface... 11 5 Component Identification... 12 5.1 Gearbox... 13 5.2 Hydraulic Hybrid Drive Unit... 13 5.3 Accumulators... 14 5.4 Manifold... 14 5.5 Hydraulic Reservoir... 14 6 How to use the intellidrive system... 15 6.1 Turning System ON/OFF... 15 6.2 Gearbox Engagement... 15 6.3 Acceleration... 16 6.4 Braking (Deceleration)... 16 6.5 Creep Mode... 16 6.6 Brake Pedal Trainer... 17 6.7 Snow Mode... 17 6.8 System Faults... 17 7 Routine Maintenance Checklist... 19 3
7.1 Daily Items... 19 7.1.1 Visual Inspection of Oil Level... 19 7.1.2 Visual Inspection for Leaks... 20 7.1.3 Visual Inspection of Driveshaft... 20 7.1.4 Inspect System Display for Faults... 20 7.2 Weekly Items... 20 7.2.1 Check bracketry... 20 7.2.2 Check Cooling Fan Shrouds... 20 7.3 Monthly Items... 20 7.3.1 Condition of Rubber Mounts and Hoses... 20 7.3.2 Condition of Wiring Harness... 20 Notes... 21 1 About this manual The contents of this documentation applies to the intellidrive Hydraulic Hybrid System. The instructions contained in this document are intended for authorized operators. This manual describes how to safely operate the intellidrive system and its components. Prior to getting behind the wheel of the intellidrive system, please read this document in its entirety and ensure full understanding of its contents for safety purposes. For questions contact your local SES distributor or contact SES directly at 317-602-1188. 2 Safety instructions 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 can result in personal injury and/or damage to the equipment. 2.1 Intended use The intellidrive system has been developed for use on Class 6 and Class 8 commercial vehicles and it s components can be retrofitted on vehicles approved by SES. The system provides the vehicle with primary braking power that is able to be stored in hydraulic accumulators. The stored energy is then used to accelerate the vehicle upon takeoff, which in 4
turn reduces the power demand on the engine and transmission, resulting in improved fuel economy while extending the life of the drive components on the vehicle. The intellidrive system should not be installed on vehicles that are not approved by Stored Energy Solutions. 2.2 Improper use Using the intellidrive system or its components for anything other than their specified use should be considered improper and is impermissible by Stored Energy Solutions. Improper use of the equipment voids the warranty and Stored Energy Solutions does not accept responsibility for any damage and/or injury that results from improper use. 2.3 Personnel qualifications Ensure the driver of the vehicle is permitted to operate it on all county, state, and federal roadways and is in compliance with all local laws and regulations regarding the vehicle type. 2.4 General safety instructions Do not use Stored Energy Solutions products if they are not in good working condition. Personnel operating SES products must not consume any substance that may affect their ability to respond e.g. alcohol, drugs or pharmaceuticals. Ensure that the installation, operation, and maintenance of the intellidrive system conforms to all safety regulations and technical data. Observe and comply with the safety regulations and provisions of the municipality, county, state or country in which the product is used/operated. Observe and comply with the applicable accident prevention and environmental protection regulations. 5
2.5 Product-specific safety instructions 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 2.3 "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. 6
2.6 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 2.7 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. Highpressure 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 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. 7
3 How intellidrive Works The intellidrive system is permanently connected to the chassis of the vehicle and is able to apply torque to the driveshaft in either direction. The intellidrive system contains a hydraulic pump and gearbox that convert the kinetic energy that is normally wasted by braking friction and stores it as potential energy in specialized accumulators (Figure 1). Since the pump is connected to the driveshaft through the gearbox, it is able to create a backwards torque on the rear wheels, thus helping to slow the vehicle down while pumping high pressure oil into the accumulators. Figure 1: Energy being stored in accumulators When the accelerator pedal is pressed, the high pressure oil is released back to the pump, which is now acting as a motor, to apply a positive torque to the driveshaft and rear wheels until the stored energy has been exhausted (Figure 2). This cycle continues for each stop and start sequence. Figure 2: Energy being released back to pump 8
4 Controls intellidrive uses several components that require the operator to have a basic understanding of in order to correctly operate the vehicle safely and efficiently. Below are the major components and their function within the intellidrive system. 4.1 Brake Pedal The brake pedal travel is now split up into two zones. The first half of pedal travel, shown below in figure 3 in green, corresponds with 0 100% capacity of hydraulic braking only. The second half of pedal travel, shown below in red, corresponds with 0 100% of the air brake capacity, plus the full 100% of the hydraulic braking capacity. This allows the full pedal travel to be progressive as any operator would expect it to be; the further the pedal is pressed, the more braking power there is. Figure 3: Brake Pedal travel 9
4.2 Accelerator (Gas) Pedal The accelerator pedal is used as normal. With the intellidrive system engaged, the pump will utilize the energy stored from the previous stop until it is exhausted. Once the stored energy is consumed, the system will go into a standby mode until the operator depresses the brake pedal again and more energy can be stored. 4.3 Controller Display The Controller Display is located inside the cab of the vehicle. This display will show the accumulator charge, brake pedal position, oil temperature status, pump engagement status, system ON/OFF status, and displays error messages. 1 2 3 4 5 Button Functions: 1 ~ ON/OFF and Fault clearing 2 ~ Display screen settings 3 ~ Toggle different screens 4 ~ Unused 5 ~ LED lights displaying system status 10
4.4 ABS Interface The intellidrive system is equipped with an electronic interface that is engineered to work with your vehicle s Anti-Lock Braking System (ABS). During an ABS event (an ABS event is defined as: any wheel or multiple wheel lock-up.) the intellidrive system will immediately be notified and remove any torque it is currently applying. This allows the vehicle s ABS system to control the brakes. During the event, an ABS symbol will appear on the display, confirming that the system recognizes the ABS signal and is taking appropriate actions. After the ABS event is resolved, the intellidrive system will attempt to reactivate at the next available opportunity. 11
5 Component Identification This section will help locate and identify the major components of the intellidrive system. 12
5.1 Gearbox The gearbox is located inside the frame rails of the vehicle; in-between the transmission and the rear differential. 5.2 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. 13
5.3 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. Accumulators Manifold 5.4 Manifold The Manifold is specialized just for your specific use on each vehicle. Each model design takes into consideration the accumulators, pump, and other specific needs to make the optimum power out of your intellidrive system. 5.5 Hydraulic Reservoir Depending on the options selected during the purchase, your intellidrive system may utilize the hydraulic reservoir already located on the side of the vehicle s frame for the body hydraulics or it may use its own separate reservoir. 14
6 How to use the intellidrive system 6.1 Turning System ON/OFF Once the vehicle engine is started, and the Control Display boots up, the intellidrive system is available for use. To turn the system ON, push the far left button towards the bottom of the display. Your selection will be confirmed by flashing yellow LED s on both sides of the display. This indicates that the system is in a standby mode and will attempt to engage at the next opportunity. To turn the system OFF, simply press the bottom left button again. This selection can be confirmed by the LED s turning red. 6.2 Gearbox Engagement NOTE** - Some vehicles have an engine driven clutch pump with a toggle switch near the hybrid system display in the cab. Ensure this pump switch is in the ON position prior to gearbox engagement. If this pump is not turned on, the system will not be able to engage. After the truck has been started and the system turned on as described in 6.1, the system will be in a standby mode with the LED lights flashing yellow. This flashing pattern is indicating that the system s gearbox hasn t fully engaged. To engage the gearbox, simply prepare the truck for movement by releasing the parking brake and shifting the transmission into gear. Once the truck is in gear, the system will attempt to engage the gearbox. Once the gearbox has fully engaged, the LED lights will turn a solid greenish yellow, confirming that the system is ready for operation. Sometimes the system may not engage automatically. If this occurs, simply allow the truck to move slightly, helping the gears to align themselves and to slide into place. Any time the transmission is shifted into a neutral position the system will disengage and the flashing LED s will confirm the status on the display. Once the transmission is shifted back into a non-neutral gear and the vehicle speed is very low, the system will attempt re-engagement. 6.2.1 Gearbox Disengagement due to over speed condition Once the gearbox has been engaged, it will remain engaged until the truck is either put into neutral, the system is turned off or has a fault, or if the truck reaches a speed of 28+ MPH. If the vehicle speed is greater than ~28 MPH, the pump becomes at risk of over speed, so the system will disengage the gearbox to protect itself. Once the gearbox has disengaged itself due to over speed, a re-engagement cannot be attempted until the vehicle speed is below 1 MPH. **NOTE** If the gearbox has disengaged due to an over speed condition, the system is no longer able to generate torque. Since the system cannot apply torque, it also cannot 15
aid in deceleration and therefore the air brakes will have to be used exclusively. Be mindful that a further pedal travel will be required for air braking only, compared to braking with both the system and the air brakes. 6.3 Acceleration Accelerating the vehicle with the system on requires no change in driving style from the operator. Simply press the gas pedal as required. If the system has available charge from a previous stop, it will be used proportionally to the gas pedal command the operator is demanding to assist the engine in accelerating the vehicle. 6.4 Braking (Deceleration) Braking is also very similar to a normal vehicle. The further the brake pedal is depressed, the harder the vehicle will stop. The system simply acts in the first half of the pedal travel to proportionally create a reverse torque on the driveshaft to help the vehicle stop. If more braking is needed, simply push harder on the pedal. In the second half of pedal travel the system will be creating its maximum braking torque and the vehicle s normal air brakes will also be activated to create additional braking power. There will be a bar chart on the main page of the display that depicts brake pedal travel. The further the pedal is depressed, the higher the bar will go. The top of the chart indicates the point in the pedal travel of where 100% of hydraulic braking will occur. Any travel past this point will begin to utilize the vehicle s air braking system in addition to the full hydraulic braking capacity. The system was designed to be supplemental to the traditional air braking systems utilized on large trucks, but, if utilized efficiently, can provide nearly all the braking requirements without use of the airbrakes until the vehicle has stopped completely. If the system is on and the gearbox has been engaged, a braking event will generate a charge of oil in the accumulator bank. The display will show a visual graph corresponding to the amount of charge that was captured during the last braking event. 6.5 Creep Mode If your vehicle has a manual transmission, you have the option to have the system apply a creep torque subsystem that can aid in vehicle control and driver stamina. Creep torque is simply a limited system launch of the vehicle and will occur if the following conditions are met: 1. Creep Mode is activated from the display buttons 2. The clutch is depressed and transmission is in a forward gear 3. The brake pedal is pressed less than half way down 16
4. The accelerator pedal is not pressed If there is sufficient pressure in the accumulators, creep torque will be applied if the conditions above are met. To help the driver know whether creep torque is available, an audible beeping will occur once pressure in the accumulators gets to a low level. This beeping can be toggled on/off via the buttons on the display unit. 6.6 Brake Pedal Trainer Each system has a training mode that can help the driver to achieve the maximum benefit of the system for the vehicle. This mode is able to be toggled on/off via the display buttons. This training mode will alert the operator as to whether or not the vehicle s foundation brakes are being utilized too much. An audible beeping will be heard during a braking event when the pedal is being depressed into the foundation brakes. This trainer is designed to help a new driver get a feel for where the transition zone is between the hydraulic and air brakes. 6.7 Snow Mode Some intellidrive systems will come with an integral snow mode that can be toggled on/off via the display buttons. Snow mode tries to assist the vehicle in maintaining traction by turning on a user calibratable off pedal braking action to help the vehicle stop slowly. This mode also limits the launching power of the system to help prevent wheel slippage. 6.8 System Faults 6.8.1 Display Fault Codes Faults are triggered when something unexpected happens. The fault ID will be shown on the system display unit in the cab. 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 17
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 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 18
7 Routine Maintenance Checklist 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 Daily Weekly Monthly Check Oil Level Check Under Vehicle for Leaks Ensure Main Ball Valve is OPEN Verify that the Driveline is Clear of Debris Check for Fault Messages on Display Check Brackets for Deformation Verify that the cooling fans are clear of debris Check Condition on Rubber (Shock) Mounts Check Wear Skin on Hoses Check for Holes in Hoses Check Wiring Loom for Splits or Defects 7.1 Daily Items 7.1.1 Visual Inspection of Oil Level The hydraulic reservoir mounted to the frame rail of the vehicle contains the oil utilized by the system. Some vehicles are equipped with a dedicated tank to serve the system only, while other vehicles utilize a shared reservoir between the system and the body hydraulics. In either case, a sight glass is usually mounted on the reservoir to indicate the current oil level. Ensure that the oil level is near the top of the sight glass before operating the system. 19
7.1.2 Visual Inspection for Leaks Inspect the underside of the vehicle chassis, as well as the ground under the vehicle for areas of oil leakage. If leakage is noticed, contact the maintenance department or your SES representative for further instruction. 7.1.3 Visual Inspection of Driveshaft Ensure the drive lines between the vehicle transmission, gearbox, and rear axle are clear of debris and can rotate freely. 7.1.4 Inspect System Display for Faults Make sure the display in the cab does not show any indication of a system fault before attempting operation. 7.2 Weekly Items 7.2.1 Check bracketry Visually inspect the bracketry of the system to check for any deformation or cracking. This would include the accumulator rack mounted to the outside of the frame rail, the gearbox brackets in between the frame rails, and cooler mounts inside the frame rails. Any noted instances should be reported to the proper maintenance personnel immediately. 7.2.2 Check Cooling Fan Shrouds Visually inspect the cooler fan shrouds to ensure they are clear of debris and air can move through them easily. 7.3 Monthly Items 7.3.1 Condition of Rubber Mounts and Hoses Inspect the condition of all system hoses and note any locations of excessive wear. Inspect the rubber isolator pads(4) under the gearbox brackets that connect it to the frame rails for cracking or wear spots. 7.3.2 Condition of Wiring Harness Inspect the system s wiring harness for any areas of excessive wear or defects caused by flying debris. 20
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STORED ENERGY SOLUTIONS 3807 Madison Ave. Indianapolis, IN 46227 317.602.1188 www.ses-hydraulichybrid.com 23