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Instructional Manual

1. Mark the universal joints on the cardan shafts Place a drip tray under the axial piston unit and gearbox assembly to collect any hydraulic fluid or lubricating oil that may escape The axial piston unit and gearbox assembly can be removed from the vehicle from above using a lifting device or from below from an installation pit Remove the axial piston unit and gearbox assembly Use a suitable lifting device Completely empty the axial piston unit and gearbox assembly Dispose of the hydraulic fluid as necessary in accordance with the environmental regulations of the respective country see chapter 12 Disposal on page 87 Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Disposal 87 112 10 Plug all openings 11 When installing new HRB components observe the corresponding installation il instructions in chapter 7 Installation on page 28 The system may need to be recommissioned after replacing HRB components 12 Disposal Careless disposal of the HRB components the hydraulic fluid and the packaging material could lead to pollution of the environment The following points are to be observed when disposing of HRB components 1 Completely empty the hydraulic components pressure accumulator HRB manifold axial piston unit and gearbox assembly reservoir Dispose of the HRB components and the packaging material in accordance with the national regulations in your country Dispose of the hydraulic fluid and lubricating
2. Measures failure occurs if difference between pump and accumulator pressure is too big because of erroneous signals or hydraulic leakage between pump and accumulator 1 check pressure sensors and signals according to P3004 and P3006 2 check hydraulic system 2 1 check all connections components for leakage 2 2 check functionality of empty valve EV active if HCU without error specification solenoid coil 24 V 22 W 2 3 check functionality of drive accumulator valve AV See P3019 diagnosis 50 bar fort gt 5 s gt yellow status indicator 1 check swivel angle signal see P3008 2 check pump speed sensor see P3003 3 check the clutch open pClutch O bar 3 1 check operationality of pilot pressure valve PV specification solenoid coil V 24 V R 28 5 Q P 20 W Imax 0 61 0 85 A 3 2 check operationality of clutch valve CV specification solenoid coil V 24 V R 22 5 Q Imax 0 7 A current in the diagnosis tool Clutch valve 3 3 check the operation of the hydraulic system an the pipe work pressure measurement at gearbox manifold minimess connection MB at 3 3 pClutch 27 30 bar 4 Empty valve electrically interchanged with prefill valve or accumulator valve 4 1 prefill valve or accumulator valve activated when ignition is on but the vehicle is in stand still 5 Leakage of check valve while body hydraulics is active 6 Leakage of prefill valve 7 Leakage of accumula
3. Only commission the HRB hydrostatic regenerative braking system if the documentation marked with the book symbol is available to you and you have understood and observed it Table 1 Required and supplementary documentation LU B B B B Title Hydraulic hybrid from Rexroth HRB hydrostatic regenerative braking system Contains the permissible technical data Installation drawings Contains the outer dimensions and details of all ports for the HRB These documents are sent once only with the initial documentation Electrical circuit diagram Electrical circuit diagram for the HRB This document will be sent once only with the initial documentation Hydraulic circuit diagram Hydraulic circuit diagram for the HRB This document will be sent once only with the initial documentation Hydraulic hybrid from Rexroth HRB hydrostatic regenerative braking system Describes the interfaces between the vehicle and the HRB This document will be sent once only with the initial documentation Document number RE 94850 RE 94850 40 B Document type Data sheet Installation drawings Electrical circuit diagram Hydraulic circuit diagram Interface description data network concept If you do not have the initial documentation in its entirety on hand contact your responsible Bosch Rexroth sales organization 1 3 Display of information Standardized safety instructions symbols terms and abbreviations are used so th
4. 1 check operationality of empty valve EV if ignition is deactivated no voltage solenoid coil specification 24 V 22 W 2 check the controller feed in during the postdrive power supply of accumulator pressure sensor 5 V see also P3006 pin configuration according to the connection diagram check sensor connectivity of gearbox oil temperature sensor GT 1 GT 2 GT 3 crosscheck the temperature If the oil temperature is too low temperature at reservoir or APU lt 10 the system is being deactivated If the drive accumulator shell temperature is below 15 C the HRB will also be deactivated This state is visualised to the driver by the yellow HRB status indicator high low temperature lamp This is not a failure state 1 crosscheck the temperatures reservoir oil temperature sensor RTS APU suction pressure temperature sensor PTS drive accumulator shell temperature sensor ATS 2 check sensors and signals 2 1 drive accumulator shell temperature sensor ATS 2 2 reservoir oil temperature sensor RTS 2 3 APU suction pressure temperature Sensor PTS 3 execute the warm up operation RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 96 112 Troubleshooting Table 19 Error code list P code 3032 3033 3101 3102 3103 3104 3105 3106 3107 3108 3109 3110 3111 3112 3113 3114 3115 3116 3117 3118 3119 3120 3121 3122 Description
5. 22 Port overview of HRB components RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 48 112 Installation Fig 24 Case drain port on axial piston unit installation position rotated 90 counter clockwise counter clockwise It must be guaranteed that the minimum oil level in the reservoir is always higher than the highest point of the axial piston unit This will prevent the axial piston unit from being drained through the case drain line while at a standstill port K2p il Note the reservoir position axial piston unit and gearbox assembly is turned 90 Bosch Rexroth AG HRB RE 94850 01 B 10 2012 il Tightening torques Installation 49 112 Table 11 Hydraulic ports HRB Designation Function As Pilot oil port on pilot oil supply manifold Bil Pressure port on axial piston unit G1to G6 Oil inlet outlet and oil level see chapter 7 3 Installation positions on page 35 HD1 High pressure gaugeport on HRB manifold HD3 High pressure gauge port on HRB manifold HD Reservoir port on HRB manifold K2p Case drain port on axial piston unit installation position rotated 0 90 counter clockwise MB Clutch line gauge port in gearbox control block MP Pilot oil line gauge port in gearbox control block MP Pressure line gauge port on HRB manifold MSs Pilot oil line gauge port on pilot oil supply manifold Pi Pressure port 1 on pilot oil supply manifold Pi Pilot oil port on HRB manifold P25 Pressure port 2 on pilot o
6. 49 7308 72 74 info brm boschrexroth de www boschrexroth com hrb Bosch Rexroth AG Mobile Applications An den Kelterwiesen 14 72160 Horb a N Germany Tel 49 7451 92 0 Fax 49 7451 82 21 info brm boschrexroth de www boschrexroth com hrb Your local contact can be found at www boschrexroth com addresses Subject to change Printed in Germany RE 94850 01 B 10 2012 The Drive amp Control Company Rexroth Bosch Group
7. C to 20 C e Minimum storage temperature 40 C e Maximum storage temperature 60 C e Avoid high light irradiation e g bright windows or direct fluorescent lighting e Store the HRB components shock proof do not stack them e Do not store the HRB components on flanges or add on parts e g sensors or valves e HRB control units must be stored with an average relative humidity of 60 and at a temperature between 10 C and 30 C A storage temperature range of 20 C to 40 C is permissible for a short period of 100 h After a storage time of more than 5 years the HRB control unit must be checked by the manufacturer before use If the HRB control unit is dropped continued use is not permissible because unseen damage may affect its reliability e For further storage conditions see tTable 7 Check the HRB components monthly to ensure proper storage The HRB components are provided ex works with corrosion protection packaging corrosion protection film In Table 7 you will find the maximum permissible storage times for the originally packaged HRB components RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 32 112 Transport and storage Table 7 Storage time with factory corrosion protection Storage conditions Standard corrosion protection Closed dry room uniform temperature Maximum 12 months between 5 C and 20 C Undamaged and closed corrosion protection film Entitlement to warranty will be render
8. P3007 check the speed sensors like in P3002 P3003 check the speed sensors like in P3002 P3003 check the operation of the body builder CAN and the signals according to the specified interface preparation pin assignment electrical HRB circuit diagram vehicle body interface NEJO N check the operation of the body builder CAN and the signals according to the specified interface preparation CAN Message for the torque limitation must be available in the following messages TSC1 KSM1_A GPM23 1 check the operation of the body builder CAN and the signals according to the specified interface preparation pin assignment electrical HRB circuit diagram vehicle body interface execute the dignosis procedures like in P3187 P3191 Check the connection of the swivel angle and pressure sensors 1 check fuse F3 VBAT 2 controller problem contact Bosch Rexroth Service 1 check fuse F3 VBAT 2 controller problem contact Bosch Rexroth Service controller problem contact Bosch Rexroth Service controller problem contact Bosch Rexroth Service check operationality of solenoids wiring of APU A motor direction SA via breakoutbox an controller connector pumpmagnet A in the diagnosis tool specification solenoid coil voltage resistance current 24 V 21 7 Q 0 73 A diagnosis like inP3197 diagnosis like inP3197 diagnosis like inP3197 diagnosis like inP
9. tor HRB ready il luminates but HRB without function State HRB Fct 3000 3001 3002 3003 Description Diagnostics Tool 1 Pilot accumulator pressure Auxiliary accumulator pressure lt 42 bar 2 Signal HRB Fct status UNEQUAL 0x00 Normal function 3 Signal Engine running NOT 4 Signal ABS monitoring status ACTIVE 5 Digital HRB Level switch 1 also with analog torque selector Retarder lever NOT ACTIVE 5a Digital HRB Level switch Current value of retarder stage O 5b Analogue torque selector Analogue torque selector Voltage 0 mV 6 Cruise control ACTIVE 7 Hardware input plausibil monitoring 1 Driveshaft speed not plausible 2 Pump speed not plausible 4 APU high pressure not plausible 8 APU swivel angle not plausible 16 Voltage of APS not plausible 32 Voltage of PPS not plausible 64 Voltage of AS2 not plausible 128 Voltage of AS1 not plausible 8 Signal Ignition NOT ACTIVE 9 Signal ADC monitoring status UNEQUAL 10 Signal HRB NOT PERMITTED 11 Signal HRB release status monitoring NOT RELEASED relevant for acceleration with HRB 12 Drive torque coord VMD_trqDes and HRB specified torque during braking and or accelerating with HRB EQUAL O NM Description of HRB status on off 0x00 Normal function 0x01 Deactivation without errors 0x02 Error without po
10. water ingress via the wiring harness must also be prevented Further information can be found on the installation drawing Make sure that the HRB control unit does not contact the vehicle installation case The HRB control unit must be fixed at eight points Bosch Rexroth recommends the use of a damper First tighten the mounting bolts by hand Tighten the mounting bolts with a tightening torque of 10 Nm in bolt sequence 1 to 8 Make sure that the cable harnesses are mechanically absorbed on the same vibration plane as the HRB control unit at a maximum distance of 150 mm after the cable outlet WARNING Risk of toxication and suffocation The emission of nitrogen in closed or insufficiently ventilated rooms may lead to fatal or hazardous concentrations of nitrogen in the air gt j N Ol The hydro pneumatic pressure accumulators must be positioned so that no high concentrations of nitrogen may form in the passenger compartment Install the brackets for the hydro pneumatic pressure accumulator to the vehicle frame and or body Select the installation location for the hydro pneumatic pressure accumulator as close as possible to the axial piston unit and gearbox assembly For optimal operation of the hydro pneumatic pressure accumulator the climatic conditions should be taken into account for installation The preferred installation position of the hydro pneumatic pressure accumulator is vertical with gas v
11. 2012 HRB Bosch Rexroth AG Table 13 HRB electrical connections see Fig 25 Designation Function APS AS1 AS2 ATS AV BPS CV DS EPV EV FS GT1 or GT2 or GT3 HCU1 HCU2 LS OBD PAS PFV PPS PS PTS PV RTS SA SB Accumulator pressure sensor Axial piston unit swivel angle sensor 1 Axial piston unit swivel angle sensor 2 Accumulator temperature sensor Drive accumulator valve Brake pressure sensor Clutch pressure valve Cardan shaft speed sensor External pilot oil pressure Empty valve Filter signal Gearbox oil temperature sensor HCU connector 1 HCU connector 2 Reservoir fill level OBD diagnostics socket Pilot oil accumulator pressure sensor Prefill valve Axial piston unit pressure sensor Axial piston unit speed sensor Axial piston unit suction pressure temperature sensor Pilot oil valve Reservoir oil temperature sensor Axial piston unit solenoid A Axial piston unit solenoid B The OBD diagnostics socket is to be placed in the cab and labeled as HRB diagnostics socket Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Installation 53 112 HRB control unit HCU User interface see Table 14 Power supply see Table 14 Vehicle interface see Table 14 Axial piston pump motor and gearbox assembly Pilot oil supply manifold with pilot oil accumulator Fig 25 HRB electrical connections Table 14 Interfaces power supply User interface Red HRB status indicator Yell
12. Connect the HRB components that can move relative to each other with flexible hydraulic hoses that allow for motion compensation Bosch Rexroth AG HRB RE 94850 01 B 10 2012 il Notes on routing the lines Installation 43 112 Insufficient suction pressure For axial piston units and gearbox assemblies a minimum permissible suction pressure in pump mode and a minimum permissible back pressure in motor mode at port Sp are generally specified for all installation positions see chapter 7 2 Installation conditions on page 33 If the pressure at port Sp falls below the specified values damage could occur that could lead to the destruction of the axial piston units and gearbox assemblies Make sure that the necessary suction pressure in pump mode and the necessary back pressure in motor mode are maintained This is influenced by the piping e g suction cross section pipe diameter length of suction line the position of the reservoir The body or vehicle manufacturer is responsible for designing the lines The HRB components must if necessary be connected to the rest of the hydraulic system in accordance with the hydraulic circuit diagram of the body or vehicle manufacturer and in accordance with the HRB hydraulic circuit diagram The ports and fastening threads are designed for the maximum pressure specified in the data sheet The body or vehicle manufacturer must ensure that the connecting elements and lines correspond
13. Diagnostics Tool HRB oil Temperature too high Maximum number of braking cycles exceeded Communication with AccelPedalAngle ACAN Message not plausible Intelligent battery sensor above upper limit Intelligent battery sensor below lower limit Service brake signal improbable CAN message brake signal Brake signal implausible SPI and COM error from Cy146 SPI and COM error from Cy146 SPI and COM error from Cy146 SPI and COM error from Cy146 SPI and COM error from Cy146 SPI communication in Cy320 driver faulty Actual specified HRB torque dynamics faulty Step test termination by battery voltage voltage too high Step test termination by battery voltage voltage too low faulty faulty faulty faulty faulty DIG_A 1 short to earth open circuit DIG_A 1 Temperature too high DIG_A 1 short to B DIG_A 1 faulty short to earth open circuit DIG_A 2 open circuit DIG_A 2 Temperature too high DIG_A 2 short to B DIG_A 2 short to earth Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Measures If the oil temperature exceeds 75 C the system will be deactivated This state is visualised to the driver by the optional yellow HRB status indicator high low temperature lamp This is not a failure state 1 crosscheck the temperatures step by step reservoir oil temperature sensor RTS APU suction pressure temperature sensor PTS drive accumulator she
14. Fig 51 Level switch version e g MAN TGS Bosch Rexroth AG HRB RE 94850 01 B 10 2012 105 112 RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 106 112 Alphabetical index 16 Alphabetical index gt A Abbreviations 8 Axial piston unit and gearbox assembly 18 gt C Care 68 Cleaning 68 Commissioning 55 First 55 Connecting Electrical 51 Hydraulic 42 Conversion 88 Corrosion protection 32 Corrosion protection film 31 gt D Damage to equipment 15 Data network concept 6 Delivery contents 18 Designations 8 Dimensions 28 37 Disposal 87 gt E Electrical circuit diagram 6 gt F Forklift truck 29 Function principle 20 gt H HRB control unit 18 HRB manifold 18 Hydraulic circuit diagram 6 Hydro pneumatic pressure accumulator 18 Bosch Rexroth AG HRB RE 94850 01 B 10 2012 gt Inspection Installation Completing General instructions HRB components Preparation Installation conditions Installation drawings Installation positions Installing Instructions General Intended use Interface description L Lifting device M Maintenance O Operation P Pilot oil supply manifold Q Qualifications R Recommissioning after standstill Removal Performing Preparing Repair Replacement Required documentation Ring screws 68 69 33 41 37 38 37 33 35 37 37 29 71 60 18 10 99 86 86 86 85 86 29 Alphabetical in
15. RE 94850 01 B 10 2012 Maintenance and repair 81 112 Fig 44 Inserting the fluid valve 7 Insert the split rubber ring retaining ring into the vessel and slide it onto the fluid valve Pull the fluid valve back so that it makes contact with the inside of the vessel 8 Install the O ring and the spacer ring gt r SR Tar en Fig 45 Installing the O ring and the spacer ring 9 Screw on the ring nut Center the parts by carefully striking the fluid valve from different sides with a plastic hammer and at the same time continuing to screw on the ring nut by hand RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 82 112 Maintenance and repair Fig 46 Screwing on the ring nut 10 Securely tighten the ring nut Fig 47 Tightening the ring nut 11 Before installing the reducer on the liquid side the bladder must slowly be filled with nitrogen at a pressure of 1 1 5 bar using the testing and filling unit Operate the testing and filling unit in accordance with the relevant operating instructions 12 Make sure that the fluid valve closes properly by checking the movement of the valve tappet 13 Install the venting screw with seal not present on all models Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Maintenance and repair 83 112 Fig 48 Installing the venting screw 14 Securely tighten the company plate and the nut of the gas filling valve Fig 49 Tightening the company plate nut and g
16. connections and seals Perform the system commissioning as described in chapter 8 1 First commissioning on page 55 Hydro pneumatic pressure accumulators are subject to certain government pressure vessel regulations These regulations require pressure accumulators to be subjected to regular examination The interval for these examinations varies from one jurisdiction to another Check the relevant intervals for your company from the responsible authorities 10 6 2 Replacing the complete hydro pneumatic pressure accumulator 4 1 am i To remove the hydro pneumatic pressure accumulator proceed as described in chapter 10 4 4 Removing the hydro pneumatic pressure accumulators and replacing the accumulator bladders on page 75 steps 1 to 6 Install the new hydro pneumatic pressure accumulator according to chapter 7 Installation on page 28 Fill the hydro pneumatic pressure accumulator as described in the instructions for the hydro pneumatic pressure accumulator In Germany the serial number of the new hydro pneumatic pressure accumulator must be entered by the named office in the assembly group approval Please comply with valid national regulations in the country concerned When installing a new hydro pneumatic pressure accumulator the cycle counter in the HRB control unit must be reset by the vehicle manufacturer If anew pressure accumulator is installed the serial number must be entered by the named o
17. horizontally in place in a vise or similar clamping system Make sure that the shell is not damaged 3 Unscrew the gas filling valve Fig 34 Unscrewing the gas filling valve 4 Unscrew the nut from the gas filling valve and remove the company plate Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Maintenance and repair 77 112 Fig 35 Removing the gas filling valve 5 Unscrew the flange or the reducer from the liquid side Remove the venting screw not present on all models without damaging the sealing ring Fig 36 Removing the venting screw 6 With the pressure accumulator fully relieved gas and liquid the fluid valve is either open or it can be opened by hand If this cannot be determined no further work is to be performed Contact Bosch Rexroth Service see chapter 10 8 Spare parts on page 85 for address RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 78 112 Maintenance and repair Fig 37 Opening the fluid valve 7 Unscrew the ring nut and remove the spacer ring Fig 38 Removing the ring nut and the spacer ring 8 Carefully press the fluid valve into the body Fig 39 Pressing in the fluid valve 9 Remove the O ring Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Maintenance and repair 79 112 10 Unscrew the split rubber ring retaining ring from the body of the fluid valve fold it together carefully and pull it out of the vessel Fig 40 Unscrewing rubber ring 11 Remove th
18. of the hydraulic oil is reached The brake torque suppression is then reversed The HRB only then triggers an acceleration torque if an HRB level level 3 4 or 5 is engaged at the level switch At the same time the acceleration torque is independent of the level set at the level switch The permanent brake HRB status indicator does not go out when ABS and TCS are active To prevent excessive temperatures in the hydraulic system the HRB braking torque is continually reduced after a few seconds both shortly before the maximum temperature of the hydraulic fluid 75 C is reached and when braking with the accumulators already fully charged The engine brake is reactivated when the HRB limiting torque is exceeded The level switch in the form of the retarder lever is used to select the intensity of the braking effect of the HRB and of the engine brake Levels 1 and 2 of the lever are the equivalent to the levels of the standard engine brake The three HRB levels are selected with levels 3 4 and 5 see Fig 50 Fig 50 Level switch example Mercedes Benz Actros RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 104 112 Technical data As soon as a torque is preselected the symbol for the continuous brake lights up in the central indicator instrument see Fig 27 on page 60 The symbol may flash if the lever was previously pressed while the ignition was on The flashing will stop if the lever is move once to the neutral position A
19. parts MA CAUTION Use of unsuitable spare parts Spare parts that do not meet the technical requirements specified by Bosch Rexroth may cause personal injury or property damage gt Use only original spare parts from Rexroth to repair the HRB components The functional reliability of the HRB cannot otherwise be guaranteed and the warranty is rendered void The spare part lists of the HRB components are system specific When ordering spare parts state the material and serial numbers of the HRB components as well as the material numbers of the spare parts Address all questions regarding spare parts to your responsible Bosch Rexroth Service partner or the service department of the plant that manufactures the HRB components Bosch Rexroth AG An den Kelterwiesen 14 D 72160 Horb a N Germany Tel 49 7451 92 0 Fax 49 711 811 513 9382 svm support boschrexroth de For the addresses of foreign subsidiaries please refer to www boschrexroth com addresses RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 86 112 Removal and replacement 11 Removal and replacement 11 1 Required tools Removal can be performed with standard tools No special tools are necessary 11 2 Preparing for removal 1 Secure the vehicle apply the handbrake use chocks and remove the ignition key Disconnect the vehicle battery as described in the documentation provided by the vehicle manufacturer Manually relieve the hydro pneumatic p
20. piston unit and gearbox assembly must be connected to a lifting device by the ring screws Please note the chain lifting gear length to ensure that the angle of spread is less than 120 For transportation two ring screws 1 must be screwed into the gear case If required another ring screw can be screwed into the case of the axial piston unit On the reverse side of the axial piston unit there are four threaded bores for a third ring screw gt For all female threads use a threaded plug from the same system of units and of the correct size The thread size is stated in the installation drawing gt Todo this screw M16 x 1 5 C15E fine thread ring screws 1 according to DIN 580 completely into the female threads located in the case of the axial piston unit and gearbox assembly Make sure that the ring screw is adequately dimensioned for the weight of axial piston unit and gearbox assembly The axial piston unit and gearbox assembly can be lifted using the screwed in ring screws as shown in Fig 8 RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 30 112 Transport and storage Fig 8 Ring screws on the gear case of the axial piston unit and gearbox assembly il Transport with lifting strap 6 2 3 Transporting the HRB manifold The HRB manifold is delivered with the ring screws 1 pre installed Use these ring screws for transporting the HRB manifold Join two opposite ring screws for safe transport with a lifting dev
21. the pressure accumulator is completely empty This is not a malfunction but rather a feature of the control strategy Vehicle or manufacturer specific explanations can be found in chapter 15 1 Vehicle and manufacturer specific details on page 103 5 3 1 Starting activating for drive mode The control of the HRB is activated via the ignition key After the control unit test cycle has been completed pressure must be built up in the pilot oil supply to actuate the coupling and the axial piston unit in case the pilot oil pressure in the accumulator is insufficient This is performed either with an additional HRB pilot oil pump or manually via a connection to the existing body hydraulics As a rule it is only necessary to recharge the pilot oil accumulator with an additional HRB pilot oil pump or via the body hydraulics after one or more days of HRB inactivity The HRB can be deactivated at any time by pressing the button marked HRB the HRB button 5 3 2 Torque distribution An important task of the HRB control is to distribute torque between the combustion engine and the HRB Here the objective is to make maximum savings possible with the same performance as that achieved without HRB 5 3 3 Delaying Between approx 1 km h and 50 km h the actual values may differ according to the vehicle concerned the driver can set the HRB braking torque in any of several different levels similar to when using a retarder This is automatically activ
22. the return line filter is plugged perform filter maintenance if necessary Check the oil level in the HRB reservoir Add hydraulic fluid if necessary Use one of the oil types specified in the data sheet Check the HRB fuses and replace any defective fuse s Check the oil level with completely emptied pressure accumulators To do this park the vehicle on a flat surface and deactivate the ignition Wait approx 5 minutes before reading the oil level to allow the accumulators to empty completely RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 90 112 Troubleshooting 14 2 Error code list Table 19 Error code list P code Description Diagnostics Tool Measures HRB behavior measures see P3186 HRB does not work when ignition on 5 times sound of a switching solenoid of the empty valve EV Display CAN all indicators on timeout fault of HCU1 message if timeout diagnosis is implemented in display HRB status indicators LEDs red and yellow status indicators illuminated for 10 s other indicator flashing 5 times with approx 1 Hz KTS diagnostic tool no fault P code signal State HRB 4 powerstages switched off DCAN Send routine of DCAN messages terminated values of last sent signals State FSM 7 powerstages switched off Com_stLmpCtl 31 all indicators on Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Table 19 Error code list P code Green HRB status indica
23. this It may be necessary to replace the HRB control unit HCU Bosch Rexroth AG HRB RE 94850 01 B 10 2012 14 Troubleshooting Troubleshooting 89 112 Please contact a Bosch Rexroth Service partner in the event of a malfunction or if you have any questions about diagnosis options and tools The address can be found in chapter 10 8 Spare parts on page 85 Depending on the vehicle configuration the error codes can be read out viaa diagnostics device see data sheet RE 94850 section HRB accessory parts or via a display if present 14 1 Easy to rectify causes of errors self help Table Table 18 Easy to rectify causes of errors self help includes easy to rectify causes of errors If the described error scenarios occur perform the corresponding measures If the faulty system behavior cannot be rectified using these measures determine the corresponding error code s and proceed as described in Table 19 Error code list on page 90 Contact your Bosch Rexroth Service partner if necessary Table 18 Easy to rectify causes of errors self help Indicator system behavior HRB indicators and HRB without function Green HRB status indicator HRB ready and HRB without function Yellow HRB status indicator service Measure Check the HRB fuses and replace any defective fuse s If the hydraulic circuit of HRB and body hydraulics are identical actuate the body hydraulics to charge the pilot oil accumulator once Check whether
24. to B Green HRB status indicator HRB ready check pin green status indicator L HRB ready for short circuit to B 1 If error occurs in combination with P3014 P3134 P3209 P324E and P3259 see P324E 2 green HRB status indicator HRB ready check pin green status indicator L HRB ready for short circuit to B drive accumulator valve AV check pin drive accumulator valve H for short circuit to earth empty valve EV check pin empty valve H for short circuit to earth clutch valve CV and prefill valve PFV check pins clutch valve H and prefill valve H for short circuit to earth APU B pump direction SB check pin APU B pump direction H for short circuit to earth APU A motor direction SA check pin APU A motor direction H for short circuit to earth red HRB status indicator check pin red status indicator L for short circuit to B red HRB status indicator check pin red status indicator L for short circuit to earth signal retarder active check pin retarder active L for short circuit to B white HRB status indicator launch gear recommendation check pin white HRB status indicator L launch gear recommendation for short circuit to B white HRB status indicator launch gear recommendation check pin white HRB status indicator L launch gear recommendation for short circuit to earth yellow HRB status indicator
25. to vehicle operating instructions for symbol A level gt O was selected at the level switch The status indicator is permanently active even if there is currently no braking activity After the ignition was switched on the yellow status indicator for the continuous il brake may flash if the lever was not in the neutral position The flashing will stop if the lever is moved once to the neutral position This indicator depends on the vehicle concerned Please note the information given in the vehicle operating instructions 9 1 3 HRB button The HRB is automatically activated when the vehicle ignition is switched on To deactivate the system the HRB button 1 see Fig 29 must be pressed The green status indicator HRB ready then goes out Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Level switch preselector Control of braking deceleration depending of vehicle weight Operation 63 112 The status indicator is active regardless of whether or not the combustion engine is running STOP vow 12V OFF Fig 29 HRB button example Mercedes Benz Actros To reactivate the system press the HRB button 1 again The green status indicator HRB ready is again active 9 1 4 Setting the HRB braking effect The intensity of the HRB braking effect is selected with the level switch The HRB level switch can be permanently preselected and can even remain in the desired position when accelerating The braking
26. torque is automatically activated when the accelerator pedal is released The level switch can be implemented digitally in predefined torque levels or steplessly and analog as a continuous preselector For the switching logic of the level switch please also observe the current electric circuit diagram of the HRB There is a linear relationship between the analog voltage signal of the preselector and the HRB braking torque As an alternative to the level switch it is also possible with a suitable vehicle configuration to set a defined braking deceleration as a function of the vehicle weight In this case the braking torque is adjusted to the current vehicle weight 9 2 How the HRB works The HRB is automatically activated when the vehicle is started As soon as the vehicle s combustion engine is started the green status indicator HRB ready illuminates The status indicator HRB ready goes out as soon as an error occurs or the system is deactivated The service brake can be used at any time in addition to the HRB to decelerate the vehicle as they work completely independently The ABS and traction control ASC safety systems are also unaffected by the HRB To optimize fuel savings and intelligent control strategy is employed for the HRB depending on temperature mission profile etc That means for example that the HRB may not be able to provide support until the pressure accumulator is completely empty This is not a malfunction but rathe
27. unit high pressure line 4 Hydro pneumatic pressure 11 Manual drain valve accumulators high pressure 12 Accumulator safety valve optional several in parallel 13 High pressure accumulator line 5 Differential input 14 Pilot oil supply manifold 6 HRB manifold 7 Reservoir with filter Bosch Rexroth AG HRB RE 94850 01 B 10 2012 About this product 21 112 The HRB is designed for use in commercial vehicles or mobile working machines e g refuse trucks The HRB is installed by the body or chassis manufacturer Here the HRB gearbox is installed in the cardan shaft line The HRB gearbox is secured by a 3 point suspension on the vehicle frame The other system components are also secured to the vehicle frame body and or cab The components of the system electric hydraulic are designed so that no detrimental effect is to be expected due to water spray The system was developed in accordance with the specification defined in the body guidelines of each vehicle manufacturer 5 3 Operating conditions To achieve maximum savings brake applications should be performed in a collective cycle using high HRB switch levels i e high HRB brake performance deceleration Increased use of the service brake decreases the attainable fuel savings To optimize fuel savings and intelligent control strategy is employed for the HRB depending on temperature mission profile etc That means for example that the HRB may not be able to provide support until
28. 3197 Table 19 Error code list P code 3201 3202 3203 3204 3205 3206 3207 3208 3209 3210 3211 3212 3213 3214 3215 3216 3217 3218 3219 3220 3221 3222 3223 3224 3225 3226 3227 3228 Description Diagnostics Tool PWM_A 2 open circuit PWM_A 2 Temperature too high PWM_A 2 short to B PWM_A 2 short to earth PWM_A 2 Value outside tolerance PWM_A 3 open circuit PWM_A 3 Temperature too high PWM_A 3 short to B PWM_A 3 short to earth PWM_A 3 Value outside tolerance MSC Fehler in R2S2 vor Lesen Shortname not found in textmap Analog preselector lever above upper limit Analog preselector lever below lower limit Digital preselector lever Implausible stage Analog preselector lever signal too high Analog preselector lever signal too low RetCtl_bRtdrActv open circuit RetCtl_bRtdrActv Temperature too high RetCtl_bRtdrActv short to B RetCtl_bRtdrActv short to earth Internal power supply 1 faulty Internal power supply 2 faulty Internal power supply 3 faulty Visibility of SW resets in DSM faulty Visibility of SW resets in DSM faulty Visibility of SW resets in DSM faulty Control unit temperature sensor upper limit Control unit temperature sensor lower limit Troubleshooting 99 112 Measures check operationality of solenoids wiring of APU B pump direction SB via breakoutbox an controller connector pumpmagnet
29. Atmospheric pressure sensor lower limit Atmospheric pressure sensor above upper limit Atmospheric pressure sensor below lower limit Communication with nEng ACAN Message not plausible Communication with GbxInfo ACAN Message not plausible EEPDatal system pressure calculation faulty Control unit temperature Temperature too high HRB button faulty Monitoring module faulty Troubleshooting 97 112 Measures check operationality of drive accumulator valve AV via breakoutbox and controller connectors gt see P3124 see P3124 gt see P3124 check operationality of empty valve EV via breakoutbox and controller connectors specification solenoid coil voltage resistance 24 V 22 W see P3128 see P3128 see P3128 check the solenoid coil of the prefill valve PFV via breakoutbox and controller connectors pin configuration H L 1 22 1 24 specification solenoid coil voltage resistance 24 V 22 W gt see P3131 see P3131 1 If error occurs in combination with P3014 P3209 P324B P324E and P3259 gt see P324E 2 gt diagnosis as in P3131 controller problem contact Bosch Rexroth Service controller problem contact Bosch Rexroth Service controller problem contact Bosch Rexroth Service 1 check connectivity of inhibit engine brake H and inhibit engine brake L 2 ensure the interface preparation see P3169 see
30. B in the diagnosis tool specification solenoid coil voltage resistance current 24 V 21 7 Q 0 73 A diagnosis like in P3021 diagnosis like in P3021 diagnosis like in P3021 diagnosis like in P3021 check operationality of clutch valve CV specification solenoid coil voltage resistance current 24 V 22 5 Q 0 7 A visualization of the solenoid current via diagnosis tool Clutch coil PRV diagnosis like in P3206 diagnosis like in P3206 1 If error occurs in combination with P3014 P3134 P324B P324E and P3259 gt see P324E 2 diagnosis like in P3206 diagnosis like in P3206 controller problem contact Bosch Rexroth Service Demanded HRB torque Nm too high Check connectivity of analogue torque selector Check the chosen characteristics for the analogue torque selector preselector lever in the diagnosis tool diagnosis like in P3212 Wiring HRB level switch digital Proper order Level 1 Level 2 Level 3 check connectivity of analogue torque selector signal must be between O V and 5 V diagnosis like in P3215 check connectivity of retarder active H and retarder active L diagnosis like in P3217 diagnosis like in P3217 diagnosis like in P3217 Check the sensor supply voltage 5 V drive accumulator pressure APS APU swivel angle 2 AS2 APU swivel angle 1 AS1 APU suction pressure tempera
31. B braking torque is independent of the current gear engaged The capacity of the pressure accumulator is limited For this reason the HRB torque is continually reduced on lengthy downhill stretches as soon as the pressure accumulator is charged In order to continue heavy braking of the vehicle the driver must initiate suitable measures e g gear shifting activate the engine brake or service brake This is true on all vehicles il Increased use of the service brake decreases the attainable fuel savings Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Operation 65 112 9 2 2 Acceleration MA CAUTION Risk of accident If the axial piston unit and gearbox assembly blocks unusually high resistance may be encountered when accelerating As a result vehicle movement with the aid of the combustion engine may be limited gt In this case manually switch to a lower launch gear The vehicle can thereby be moved out of a danger zone Deactivate the HRB The vehicle is fully available without HRB Check the HRB status indicators and contact Bosch Rexroth Service Acceleration depends on the pressure accumulator charging state If the accumulator charge is insufficient to make a significant contribution to accelerating the vehicle s response will be unchanged Acceleration will be provided by the combustion engine alone If the accelerator pedal is depressed and the HRB is available and active green status indicator HRB ready illumi
32. G3 See data sheet Port is marked on the axial piston unit and gearbox assembly Depending on climatic conditions other hydraulic oils may also be used upon consultation with Bosch Rexroth RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 36 112 Installation Installation position rotated 90 counter clockwise plan view Fig 13 HRB installation position rotated counter clockwise plan view Table 9 Filling and air bleeding of axial piston unit and gearbox assembly for installation position rotated 90 counter clockwise Components Air bleed Filling Oil drain Oil level check Oil type Axial piston unit Te Te R L 1p Axial piston unit must be completely HLP 32 filled via the filling port Other fluids only upon request Gearbox _ G2 G3 G4 G1 G6 See data sheet G5 Port is marked on the axial piston unit and gearbox assembly Depending on climatic conditions other hydraulic oils may also be used upon consultation with Bosch Rexroth Installation position rotated to right by 90 view from above Fig 14 HRB installation position rotated 90 clockwise plan view Table 10 Filling and air bleeding of axial piston unit and gearbox assembly for installation position rotated 90 clockwise Components Air bleed Filling Oil drain Oil level check Oil type Axial piston unit R L 1p R L 1p Te Axial piston unit must be completely HLP32 filled via the filling port Other fluids only upon reque
33. GT 3 2 check the sensor Gearbox oil temperature sensor GT 1 GT 2 GT 3 on gearbox 3 signal range T 30 130 C R 900 0 1700 Q 1 check sensor connectivity of drive accumulator shell temperature sensor ATS 2 check the sensor Accumulator temperature sensor ATS on accumulator surface 3 signal range T 30 130 C R 900 0 1700 Q 1 service and maintenance of the oil filter reverse flow filter 2 check the filter circuit breaker FS battery voltage 24 V filter ok when filter failure contact open O V 3 check fuse F3 VBAT Table 19 Error code list P code 3014 3015 3016 3017 3018 Description Diagnostics Tool Oil level sensor Fluid level too low Function sequence engage clutch Duration too long Charge auxiliary accumulator Duration too long Auxiliary accumulator pressure Pressure too high Pump propshaft speed Speed comparison not plausible Troubleshooting 93 112 Measures 1 check the oil level via the glass sight gauge before commissioning the HRB System oil type conform to HRB specification 2 check sensor connectivity of reservoir oil level sensor LS 3 check fuse F3 VBAT 4 if error occurs in combination with P3134 P3209 P324B P324E and P3259 see P324E 1 check the pressure of the auxiliary accumulator p gt 42 bar if necessary load with auxiliary pump pressure must be stable 2 check operati
34. HRB RE 94850 01 B 10 2012 Safety instructions 11 112 e You may only commission the product if it has been determined that the end product e g machinery or a system into which the Rexroth products are installed complies with the country specific provisions safety regulations and standards of the application 2 6 Product specific safety instructions The following safety instructions apply for chapters 6 to 14 A DANGER Vehicles that are 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 e g 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 Make sure all the vehicle is relieved of all hydraulic load Please comply with the specifications of the vehicle manufacturer The HRB may only be installed by qualified personnel see chapter 2 4 Personnel qualifications on page 10 Risk of injury from freely accessible HRB components Freely accessible HRB components constitute an increased risk of injury e g through burning on hot parts or similar Also in
35. Installing the pressure accumulator temperature sensor Completing installation Hydraulically connecting the HRB Electrically connecting HRB components Preparing electrical interfaces Commissioning First commissioning Hydraulic mechanical commissioning Filling the HRB clutch Air bleeding the system Electrical commissioning System commissioning Recommissioning after standstill Operation Control and indicator elements Indicators Meaning of HRB status indicators HRB button Setting the HRB braking effect How the HRB works Brakes Acceleration Stopping the vehicle Manually draining the pressure accumulator Manually draining the pilot oil accumulator Bosch Rexroth AG HRB RE 94850 01 B 10 2012 28 28 28 29 29 30 30 31 33 33 33 35 37 37 37 37 38 40 41 42 51 54 55 55 56 57 58 59 99 59 60 60 60 61 62 63 63 64 65 65 66 67 Contents 10 Maintenance and repair 10 1 Cleaning and care 10 2 Inspection 10 3 Maintenance 10 4 Maintenance instructions 10 4 1 Gear oil change 10 4 2 Hydraulic fluid change 10 4 3 Checking the interior of the hydro pneumatic pressure accumulator 10 4 4 Removing the hydro pneumatic pressure accumulators and replacing the accumulator bladders 10 5 Cleaning checking and repairing 10 6 Assembly of the hydro pneumatic pressure accumulator 10 6 1 Recommissioning the hydro pneumatic pressure accumulator 10 6 2 Replacing the complete hydro pneumatic pressure accu
36. P3169 see P3169 see P3169 1 crosscheck the ambient pressure 400 1150 hPa 2 contact Bosch Rexroth 1 crosscheck the ambient pressure 400 1150 hPa 2 contact Bosch Rexroth 1 crosscheck the ambient pressure 400 1150 hPa 2 contact Bosch Rexroth 1 crosscheck the ambient pressure 400 1150 hPa 2 contact Bosch Rexroth 1 check the body builder CAN bus resistance 600 2 interface preparation of the Chassis builder must provide this signal 1 check the body builder CAN bus resistance 600 2 interface preparation of the Chassis builder must provide this signal controller problem contact Bosch Rexroth Service Check the temperature of the ECU 1 check the push button model according to the connection diagram 2 check the pin assignment of the push button according to the specification for digital analogue module controller problem contact Bosch Rexroth Service RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 98 112 Troubleshooting Table 19 Error code list P code 3186 3187 3188 3189 3190 3191 3192 3193 3194 3195 3196 3197 3198 3199 3200 Description Diagnostics Tool Pressure monitor faulty Monitoring Actual torque E1 E2 faulty Monitoring Specified torque E1 E2 faulty Monitoring Torque split Diesel HRB faulty Monitoring Specified actual torque Diesel E2 faulty Monitoring Specified actual torque HRB E2 faulty Internal power supply t
37. PR2 160GS05 10 R902603031 PAS 4 change pilot oil supply manifold suspicion DB valve 2 4 with max 75 bar defect if failure occurs without P3002 P3003 sensor failure and P3228 plausibility of cardan shaft speed with ACAN Signal vehicle velocity possibly clutch slip is present 1 check the clutch closing characteristics 1 1 pilot pressure valve PV specification solenoid coil voltage resistance power current 24 V 28 5 Q 20 W 0 61 0 85 A 1 2 clutch valve CV specification solenoid coil voltage resistance current 24 V 22 5 Q 0 7 A visualisation of the solenoid coil current in the diagnosis tool Kupplungsmagnet 1 3 check the operation of the hydraulic system an check the pipe works Pressure measurement at gearbox valve block Minimess connection MB at 3 3 p_clutch 27 30 bar stable RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 94 112 Troubleshooting Table 19 Error code list P code Description Diagnostics Tool 3019 Pump accumulator pressure Differential pressure implausible 3020 Pump accumulator pressure Differential pressure implausible 3021 Pump pressure in neutral too high 3022 Pump pressure greater than 320 bar too high 3023 Pump suction pressure too high 3024 Swivel angle set actual value comparison Value outside tolerance 3025 Direction of pump propshaft rotation wrong direction of rotation detected Bosch Rexroth AG HRB RE 94850 01 B 10 2012
38. The Drive amp Control Company Rex rot h Bosch Group Hydraulic Hybrid from Rexroth Hydrostatic Regenerative Braking System HRB Mat No R902490697 Instruction manual Replaces 08 11 RE 94850 01 B 10 2012 English The data specified above serve to describe the product Should information be provided on use these are only examples of applications and suggestions Information from the catalog are not assured properties The information given does not release the user from the obligation of own judgment and verification Our products are subject to a natural wear and aging process This document as well as the data specifications and other information set forth in it are the exclusive property of Bosch Rexroth AG It may not be reproduced or given to third parties without its consent The cover shows an example application The product delivered may differ from the image on the cover The original instruction manual was created in the German language Contents Contents 1 1 1 2 143 1 3 1 1 3 2 133 3 1 3 4 2 1 2 2 2 3 2 4 2 2 6 20 5 1 5 2 5 3 9 3 1 9 3 2 9 3 3 5 3 4 5 3 5 5 3 6 9 341 5 3 8 3 3 9 5 4 5 5 Doe 9 2 9 9 8 5 9 4 5 6 Oat About this manual Validity of the documentation Required and supplementary documentation Display of information Safety instructions Symbols Designations Abbreviations Safety instructions About this chapter Intended use Improper use Per
39. a sheet RE 94850 see Table 11 e Drain line Always route the reservoir lines so that the case is constantly filled with hydraulic fluid and to ensure that no air gets through the shaft seal even during extended standstill periods The case internal pressure must not exceed the limit values listed for the axial piston unit and gearbox assembly in the data sheet under any operating conditions The reservoir line joint in the reservoir must always be below the minimum fluid level under all conditions see chapter 7 3 Installation positions on page 35 CAUTION Fire hazard There is a risk of fire if oil lines are routed close to high temperature components Do not route the oil lines close to high temperature components e g exhaust system If necessary fit screening plates e Make sure that no oil lines are installed close to ignition sources the exhaust system or screening plates e If the axial piston unit and gearbox assembly is equipped with installed screw fittings these must not be unscrewed Screw the threaded plug of the fitting directly into the installed screw fitting Risk of mix ups with The HRB components are used in regions using the metric measuring system in threaded connections regions using the Anglo American imperial measuring system and in regions using the Japanese JIS Japan Industrial Standard measuring system Moreover various kinds of seal are used The system of units the kind of seal and
40. alve facing upward In addition installation positions between vertical gas valve facing upward and horizontal minimum angle 7 gas valve facing upward are possible Protect the hydro pneumatic pressure accumulator against heat sources electrical and magnetic fields lightning moisture and other negative ambient conditions The brackets for the hydro pneumatic pressure accumulator are not included in the delivery contents of the HRB Information about the permissible securing options can be found in the data sheet Install the hydro pneumatic pressure accumulator so that it is unable to make any uncontrolled movement and so that no external forces can act on it When installing the hydro pneumatic pressure accumulator make sure that all markings and labels are easily visible and readable Leave at least 200 mm of space in the longitudinal direction to the gas valves of the hydro pneumatic pressure accumulator for testing and filling equipment RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 40 112 Installation Installing the HRB manifold and pilot oil supply manifold il il 1 N i u Install the brackets for the HRB manifold and the pilot oil supply manifold to the vehicle frame When doing so comply with the instructions of the vehicle manufacturer and with the information given in the installation drawing The brackets for the HRB manifold and the pilot oil supply manifold are not included in the delivery co
41. an installation pit e During installation of the axial piston unit and gearbox assembly when using installation pits lifting devices with large travel lengths may be necessary Independent of this it is recommended that a sufficiently dimensioned service hatch be provided in the assembly to facilitate access to the installed axial piston unit and gearbox assembly It should be possible to remove the axial piston unit and gearbox assembly upward through this service hatch with a crane or similar lifting device The HRB manifold is supplied with ring screws installed to make it easier to transport and position on the vehicle If the ring screws are removed the surfaces of the HRB manifold that were previously covered by the ring screws and which are now unprotected should be painted for reasons of corrosion protection Also observe the notes for improving the corrosion properties in section Improving corrosion characteristics on page 50 Other unpainted surfaces of the HRB components and sensor e g ventilation filter name and identification plates and notices red protective caps manual drain valve etc are not to be painted in the event of subsequent painting and must not generally be painted over e The HRB components must be secured to the vehicle frame and or body using special brackets see installation drawing and specifications in the data sheet These brackets are not part of the delivery contents of the HRB HRB components must n
42. as valve body 15 Then install the pressure accumulator according to chapter 7 Installation on page 33 10 6 1 Recommissioning the hydro pneumatic pressure accumulator MA CAUTION Mechanical properties must not be changed It is not permissible to perform any maintenance work that could change the mechanical properties of the hydro pneumatic pressure accumulator This could result in the hydro pneumatic pressure accumulator bursting which could cause severe personal injury and material damage gt Do not do anything to the hydro pneumatic pressure accumulator that could change its mechanical properties welding soldering drilling Do not modify the hydro pneumatic pressure accumulator or its components RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 84 112 Maintenance and repair il 4 O1 The hydro pneumatic pressure accumulators and equipment may only be commissioned by qualified personnel see chapter 2 4 Personnel qualifications on page 10 Fill the hydro pneumatic pressure accumulator with nitrogen as described in the instructions for the hydro pneumatic pressure accumulator 2 Slowly open the manual drain valve Before pressurizing the system it should be air bled via the venting screw if fitted Carefully retighten the venting screw if fitted as soon as the hydraulic fluid starts to escape Then pressurize the hydraulic system to maximum pressure and check that there are no leaks at the
43. at you can use this documentation to work quickly and safely with your product To give you a better understanding they are explained in the sections below Bosch Rexroth AG HRB RE 94850 01 B 10 2012 About this manual 7 112 1 3 1 Safety instructions This documentation includes safety instructions in chapter 2 6 Product specific safety instructions on page 11 and in chapter 3 General instructions on damage to equipment and the product on page 15 and before a sequence of actions or an instruction for action involving a risk of personal injury or damage to equipment The described danger prevention measures must be observed Safety instructions are set out as follows A SIGNAL WORD Type and source of danger Consequences in case of noncompliance gt Measure for danger prevention gt lt List gt e Safety signs draw attention to danger e Signal word identifies the degree of the danger Type and source of danger identifies the type and source of the danger e Consequences describes what occurs if the safety instructions are not complied with e Precautions states how the 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 A DANG ER serious injuries if it is not avoided Identifies a dangerous situation that may result in death or A WARNING serious injuries if it is not avoided Iden
44. ated as soon as the accelerator pedal is released However in contrast to a retarder RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 22 112 About this product a torque is specified that is controlled independently of the current gear engaged in the vehicle gearbox The deceleration torque is set by the swivel angle of the axial piston unit and is limited by the current available deceleration torque which is determined by the current accumulator pressure The maximum pressure in the system is limited by a pressure relief valve On reaching the maximum pressure the equivalent of maximally charged hydro pneumatic pressure accumulators and continued braking with HRB no more braking energy is stored The HRB does however continue to supply a delaying torque In such cases heat is specifically induced into the hydraulic system via the pressure relief valve until the maximum operating temperature of the hydraulic oil is reached To prevent excessive temperatures in the hydraulic system the HRB braking torque is continually reduced after a few seconds both shortly before the maximum temperature of the hydraulic fluid 75 C is reached and when braking with the accumulators already fully charged The temporary inactivity of the HRB is displayed in the vehicle The green HRB status indicator HRB ready goes out in this case If installed the yellow HRB status indicator high low temperature lamp also illuminates By actuating the brake pe
45. ator content volume 3 Test station identifier 8 Maximum operating pressure 4 Test stamp 9 Temperature range 5 Year of manufacture 10 System designation RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 28 112 Transport and storage 6 Transport and storage Always observe the required ambient conditions for transport and storage see chapter 6 3 Storing HRB components on page 31 For information on the correct storage of the HRB components please also see il Notes on unpacking can be found in chapter 7 1 Unpacking on page 33 il the data sheet of the HRB 6 1 Dimensions and weights Table 6 Dimensions and weights of the HRB components Components Weights in kg Axial piston unit and gearbox assembly 210 Hydro pneumatic pressure accumulator 32 liters 1 piece 85 HRB manifold 48 HRB control unit HCU 2 Pilot oil supply manifold including pilot oil accumulator 10 Total weight of HRB main components without hoses and wiring etc approx 440 when using two pressure accumulators The dimensions of the HRB components can be found in the installation drawing This installation drawing will be sent once only with the initial documentation 6 2 Transporting the HRB A CAUTION Risk of damage Attaching the lifting strap to add on units e g flange of axial piston unit and gearbox assembly gas valve for hydro pneumatic pressure accumulator control valves can damage the HRB components The add on units of the HRB compon
46. ature sensor Oil temperature too high HRB oil Temperature too low Troubleshooting 95 112 Measures 1 speed sensor check signal P3003 2 check the characteristics of the clutch closing 2 1 check sensor connectivity of pilot pressure valve PV specification solenoid coil voltage resistance power current 24 V 28 5 O 20 W 0 61 0 85 A 2 2 Verkabelung des Kupplungsdruckventils CV prufen specification solenoid coil voltage resistance current 24 V 22 5 Q 0 7 A visualisation of the solenoid coil current in the diagnosis tool Kupplungsmagnet 2 3 check the operation of the hydraulic system an check the pipe works pressure measurement at gearbox valve block Minimess connection MB at 3 3 p_Kupplung p_clutch 27 30 bar check the prefill pressure of the bladder accumulators use the control set refill if necessary If the precharge pressure is back to 120 bar set the default value for the precharge pressure 115 bar with the diagnosis tool Information without resetting the precharge pressure it is not possible to delete the error 1 check the state of the manual discharging valve is it completely closed 2 check operationality of prefill valve PFV while braking it is not activated 0 V solenoid coil specification 24 V 22 W 3 check operationality of accumulator discharging valve EV while braking it has to be activated 24 V solenoid coil specification 24 V 22 W
47. cedes Benz vehicles or the KSM on MAN vehicles As arule the interface architecture depends on the vehicle manufacturer and is implemented on the basis of ISO 11992 Part 3 or SAE J1939 The concrete realization by the vehicle manufacturer e g availability of individual signals etc must also be separately examined for each vehicle type in order to guarantee the full functionality and safety of the system Details of the prerequisites required for specific vehicles manufacturers can be found in the description of interfaces Make certain that the description of interfaces with the vehicle stated and specified for installation in the order confirmation Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Commissioning 55 112 S Commissioning A WARNING Risk when working in the danger zone of a vehicle Danger to life risk of injury or serious injuries Pay attention to and rectify potential danger sources before operating the vehicle Nobody is to be present in the danger zone of the vehicle Always follow the instructions of the vehicle manufacturer during commissioning A CAUTION Commissioning of an incorrectly installed product Risk of injury and damage to equipment Make sure that all electrical and hydraulic ports are connected or plugged Only commission a completely installed fault free product with original accessories from Bosch Rexroth Prior to the first commissioning check with your Bosch Rexroth Ser
48. comply with relevant safety regulations when working with nitrogen gas in the hydro pneumatic pressure accumulator Please note further documentation about working with hydro pneumatic pressure accumulators Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Safety instructions 13 112 A WARNING Escaping oil mist Risk of explosion fire health hazard environmental pollution Depressurize the vehicle and repair the leak Only perform welding work then the vehicle is depressurized and the vehicle battery is completely disconnected Keep hydraulic lines and HRB components away from open flames and ignition sources If hydraulic lines and HRB components are to be situated in the vicinity of ignition sources or powerful thermal radiators a shield must be erected to ensure that any escaped hydraulic fluid cannot ignite and to protect hose lines from premature aging Electrical voltage Risk of injury due to electric shock or damage to equipment Always de energize the vehicle ignition off if necessary vehicle battery disconnected before installing the product or connecting disconnecting connectors Secure the vehicle against being switched back on again RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 14 112 Safety instructions MA CAUTION High noise development in operation Danger of hearing damage deafness Noise emissions from the axial piston unit and gearbox assembly depend on among other factors speed operatin
49. connecting the hydro pneumatic pressure accumulator make sure that the gas pressure is completely relieved 3 Manually drain the hydro pneumatic pressure accumulator by slowly opening the drain valve see chapter 9 2 4 Manually draining the pressure accumulator on page 66 A pressure measuring device e g gauge must be used at one of the provided ports port HD1 2 on the HRB manifold to verify that the pressure has been completely released see Fig 32 on page 73 4 If the hydraulic fluid has not been drained from the hydraulic system the drain valve will have to be closed immediately before disconnecting the pressure accumulators This is necessary to prevent the oil from flowing out of the RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 76 112 Maintenance and repair hydraulic reservoir Check that the pressure is reduced to O bar at port HD1 once more after you have closed the drain valve 5 Remove the protective cap s from the gas filling valve and if necessary the lead seal 6 Release the pre charge pressure in the bladder using a testing and filling unit Make sure the testing and filling unit is used in accordance with the operating instructions Fig 33 Letting off the pre charge pressure Removing the pressure 1 If the pressure remains at O bar at port HD1 when the drain valve is closed accumulator carefully disconnect the hydro pneumatic pressure accumulator 2 Fix the hydro pneumatic pressure accumulator
50. crushing or broken bones or damage to the product Make certain that the forklift truck or lifting device has adequate lifting capacity Never stand under or put you hands under suspended loads Ensure your position is stable during transportation Use your personal protective equipment e g safety glasses safety gloves suitable working clothes safety shoes Use suitable lifting devices for transportation Observe the prescribed position of the lifting strap Observe the national laws and regulations on work and health protection and transportation Pressurized vehicle Danger to life or risk of injury serious injuries when working on a vehicle that is not shutdown Damage to equipment Secure the vehicle against being switched back on again If present always depressurize the body hydraulics Comply with the specifications of the body or vehicle manufacturer Do not disconnect any line connections ports and components while the vehicle is pressurized Switch off all power transmitting components and ports electric pneumatic hydraulic mechanical in accordance with the manufacturer s instruction and secure them against being switched back on Pressure accumulators are pressurized Danger to life or risk of injury serious injuries when working on hydro pneumatic pressure accumulators Damage to equipment Note that hydro pneumatic pressure accumulators remain under high pressure even when the system is switched off Please
51. ctivity of APU suction pressure temperature sensor SPTO 2 check signal range PTS p 0 5 10 bar U 0 5 4 5 V normal p 0 8 1 1 bar absolute pressure U 0 6 0 9 V T 10 75 C R 9395 3740 5 1 check sensor connectivity of drive accumulator pressure sensor 2 check the sensor APS pressure sensor PR2 600GS05 10 R902603034 3 signal range p 0 600 bar U 0 5 4 5 V 1 check sensor connectivity of pilot accumulator pressure sensor PAS 2 check the sensor PAS pressure sensor PR2 160GS05 10 R902603031 3 signal range p 0 160 bar U 0 5 4 5 V normal p 0 75 bar U 0 5 2 375 V 1 check sensor connectivity of APU swivel angle sensor AS1 AS2 signal range sensor type DWS10 9 AS1 AS2 angle 15 7 15 7 U 0 42 4 57 V zero angle 0 2 5 V signal range sensor type A15 SA AS1 AS2 angle 15 7 15 7 U 0 93 4 07 V zero angle 0 2 5 V 2 Check functionality of the axial piston unit s APU swivel angle adjustment in both directions 1 check sensor connectivity of reservoir oil temperature sensor RTS 2 check the sensor Reservoir oil temperature sensor RTS on oil tank 3 signal range T 30 130 C R 900 0 1700 Q failure counter measures according to P3005 combined temperature suction pressure sensor PTS 1 check sensor connectivity of gearbox oil temperature sensor GT 1 GT 2
52. curing options and external forces can be found in the installation drawing and in the data sheet Make certain that the installation location is clean and free from dirt and contaminants Position the axial piston unit and gearbox assembly in the required installation position with a suitable lifting device and attachment equipment see chapter 7 3 Installation positions on page 35 Make sure that the gauge port on the axial piston unit and gearbox assembly see Fig 31 on page 67 which is used for draining relieving pressure in the pilot oil accumulator is easily accessible Secure the axial piston unit and gearbox assembly by the harness and tighten the screw connections Install the new cardan shafts in accordance with the instructions of the cardan shaft manufacturer The new shortened cardan shafts are not included in the delivery contents of the HRB design as per vehicle manufacturer specifications Now install the additional control and indicator elements to the vehicle The additional control and indicator elements are not in the delivery contents of the HRB Now install the HRB control unit to the vehicle in accordance with the installation drawing Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Installing the hydro pneumatic pressure accumulators fi Installation 39 112 Please note that the HRB control unit cannot be operated in standing or permanently running water In addition
53. dal additional braking torque can be generated by the vehicle s service brake system that is independent of the HRB The HRB does not interfere with the function of the service brake system 5 3 4 Acceleration Starting from the driver s command or from the driver s specified torque the proportions of the drive torque to be supplied are assigned to the combustion engine and the HRB by the HRB control In doing so the torque output by the combustion engine is reduced and replaced by the output torque of the axial piston unit which acts as a motor The prompt from the driver is transmitted via for example the accelerator pedal of the vehicle The output torque of the hydraulic motor is regulated as requested by the driver up to the maximum possible output torque which is dependent on the charge state The HRB will not increase the total drive torque of the vehicle except during switching operations in the vehicle gearbox The following factors play a special role in reducing fuel consumption a Acceleration losses are reduced b Change in shifting timing towards lower combustion engine speeds The shift points are automatically adjusted by the gearbox shift regulator because the shift points are defined by the load torque and rpm If the HRB is active this results in a reduced load and in turn a reduced injection amount in the combustion engine This will then lead to earlier gearbox upshifts On vehicles with semi automatic gearb
54. dex 107 112 gt S Safety instructions 9 General 10 Product specific 11 Signal word 7 Spare parts 85 Storage 28 Storage time 32 Storing En Symbols 7 System description 19 gt T Technical data 102 Tightening torques 49 Tools 86 Transport 28 By hand 29 With lifting strap 30 With ring screw 29 Transporting 28 Troubleshooting 89 gt U Unpacking 33 gt W Warranty 17 88 Weight 28 RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 108 112 Bosch Rexroth AG HRB RE 94850 01 B 10 2012 109 112 RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 110 112 Bosch Rexroth AG HRB RE 94850 01 B 10 2012 111 112 Rexroth Bosch Group EC declaration of conformity Doc No 001 Translation of the original EC declaration of conformity Date 03 07 2012 in accordance with Machinery Directive 2006 42 EC in accordance with Low Voltage Directive 2006 95 EC in accordance with EMC Directive 2004 108 EC in accordance with Pressure Equipment Directive 97 23 EC in accordance with ATEX Directive 94 9 EC OOWOOO The manufacturer Bosch Rexroth AG Business location Heidehofstrasse 31 70184 Stuttgart Business address Zum Eisengiesser 1 97816 Lohr am Main Registered seat Stuttgart District Court HRB23192 Division of Mobile Applications with business location in Glockeraustrasse 2 4 89275 Elchingen hereby declares that the product below Name Assembly group Pressure accumulator system Function Hydrosta
55. e fluid valve 12 Remove the bladder through the opening on the liquid side at yY r Fig 41 Removing the bladder 10 5 Cleaning checking and repairing 1 Clean all metal parts of the pressure accumulator carefully and dry them with compressed air Make sure that the inside of the vessel shows no sign of damage Press on the valve collar to check that the valve is working correctly Make sure that the retaining nut for the valve tappet is firmly seated Make sure that the O rings have absolutely no signs of abrasion or other damage Make sure that the bladder has no signs of damage Replace it if necessary Never attempt to repair the bladder ee SS SP Replace all parts that show signs of wear or damage RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 80 112 Maintenance and repair 10 6 Assembly of the hydro pneumatic pressure accumulator 1 Make sure there are no contaminants remaining in the pressure accumulator 2 To make reinstallation of the bladder easier lubricate it and the inside of the vessel liberally with the operating fluid 3 Squeeze the upper section of the bladder and insert it through the opening on the liquid side Fig 42 Squeezing the bladder 4 Loosely screw on the company plate and the nut of the gas filling valve Fig 43 Company plate of the gas filling valve 5 Make sure that the bladder is not folded or twisted 6 Insert the fluid valve into the vessel Bosch Rexroth AG HRB
56. ears and after pressure accumulators accumulators see chapter 10 4 3 Checking an interval specified by the interior of the hydro pneumatic pressure a named office accumulator on page 75 Replace bladder Is indicated by the yellow status indicator service Gearbox Change lubricating oil in axial piston unit and Every 50 000 km or no gearbox assembly later than one year of if degree of cleanliness of 20 18 15 according to ISO 4406 is no longer guaranteed RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 72 112 Maintenance and repair Task to be carried out Interval Hydraulic system Change hydraulic fluid in hydraulic system Annually every 2000 operating hours or if degree of cleanliness of 19 17 14 according to ISO 4406 is no longer guaranteed Pressure relief valve on Check function together with accumulator Every 10 years accumulator if fitted maintenance 1 When performing maintenance on the hydro pneumatic pressure accumulators the national legislation in the respective country must be observed 2 The multi plate clutch is maintenance free Table 17 Periodic technical monitoring official offices Task to be carried out Check the electric wiring system for routing and signs of damage visual check Visual check of hydraulic lines for routing leaks and damage abrasion cuts cracks Check of lamp statuses in case of yellow or red faults the system is to be repaired by an authorized specialist compan
57. ed void if the requirements and storage conditions are not adhered to or after expiration of the maximum storage time see Table 7 Procedure after expiry of the maximum storage time Check all HRB components for damage and corrosion prior to installation N Consult your Bosch Rexroth Service partner when storage times have expired to ensure that the HRB components remain fully functional 3 If a storage time of 24 months is exceeded the shaft seal rings of the axial piston unit and gearbox assembly must be replaced After expiration of the maximum storage time we recommend that you have the HRB components inspected by your responsible Bosch Rexroth Service partner Should you have any questions about repairs or spare parts please contact your responsible Bosch Rexroth Service partner Please refer to chapter 10 8 Spare parts on page 85 Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Installation 33 112 Installation Prior to installation the following documents must be ready at hand e Technical documents including installation drawings of the HRB components hydraulic and electric circuit diagram s e Order confirmation contains the order related technical data of the HRB 7 1 Unpacking The HRB components are delivered in a corrosion protection film made of polyethylene material PE CAUTION Danger from parts falling out If the packaging is not opened correctly parts may fall out and damage the
58. ee P3186 otherwise see P Code s 0x08 solve the problem according to P Code s contact Bosch Rexroth Service controller problem contact Bosch Rexroth Service 1 check sensor connectivity of driveshaft speed sensor DS 2 check the sensor type DS HALL speed sensor HDD2L32ND 20 HRB R913005507 3 signal range n 0 3000 rpm f 5 1500 Hz 1 check sensor connectivity of pump speed sensor PS 2 check the sensor type PS HALL speed sensor HDD2L32ND 20 HRB R913005507 3 signal range n 0 3000 rpm f 5 1500 Hz RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 92 112 Troubleshooting Table 19 Error code list P code 3004 3005 3006 3007 3008 3009 3010 3011 3012 3013 Description Diagnostics Tool Pump pressure sensor faulty Suction pressure pump pressure sensor faulty Pressure sensor accumulator faulty Auxiliary accumulator pressure sensor faulty Pump angle sensor faulty Oil tank temperature sensor faulty Suction pump temperature sensor faulty Transmission oil temperat sensor faulty Accumulator sleeve temperature sensor faulty Return filter Filter full Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Measures 1 check sensor connectivity of APU high pressure sensor PPS 2 check the sensor type PPS pressure sensor PR2 400GS05 10 R902603033 3 signal range p 0 400 bar U 0 5 4 5 V 1 check sensor conne
59. ehicle manufacturer e g availability of individual signals etc must also be separately examined for each vehicle type in order to guarantee the full functionality and safety of the system HRB indicators gt uf HRB level switch Clamp 15 clamp 30 Diagnostics HRB control unit HCU e HRB torque control n e Torque control pi av Pap e Control unit body manufacturer HRB button Fig 4 Electronic interfaces for HRB example Mercedes Benz Actros A WARNING Unexpected vehicle behavior A possible shut down or the failure of the HRB control unit could cause CAN messages to stop being transmitted or looped through by the HRB control unit gt A possible shut down failure of the HRB control must be taken into account in the safety concept of the body vehicle manufacturer Other vehicle types Alternatively to the body CAN the HRB can directly access the vehicle CAN if this is approved by the vehicle manufacturer Here the CAN bus must be implemented in accordance with the J1939 SAE standard RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 26 112 About this product 5 5 3 Operation The software includes the operational scope listed in chapter 9 1 Control and indicator elements on page 60 5 5 4 Diagnostics For the driver operator the HRB indicators are available for simple diagnostics see chapter 9 1 Control and indicator elements on page 60 More detailed diagnostics for troubleshootin
60. els could otherwise lock and the vehicle could start to skid 5 3 8 Deactivating the HRB The HRB is deactivated via the ignition switch If installed the HRB can also be deactivated via the HRB button If the system is deactivated using the HRB button any accumulator pressure will be retained If on the other hand the ignition is deactivated the high pressure from the hydro pneumatic pressure accumulator will be relieved within about 5 minutes as a safety precaution Note that after an ignition start following the deactivation the HRB must again be deactivated since the HRB is automatically active on ignition start 5 3 9 Heat management To prevent excessively high temperatures in the hydraulic system the HRB braking torque is continually reduced when the temperature of the hydraulic fluid nears 75 C If mounted the HRB high low temperature indicator signals this to the driver The green status indicator HRB ready goes out in this case To avoid frequent excess temperatures the braking torque of the HRB without cooler is continually relieved after a few seconds with the brakes are applied with the pressure accumulators already charged If the hydraulic oil temperature is below the minimum temperature 10 C the system will be inactive If mounted the HRB high low temperature indicator signals this to the driver The green status indicator HRB ready goes out in this case At temperatures below 10 C the HRB does not warm up auto
61. ents are not to be used as attachment equipment for transport purposes Only transport the axial piston unit and gearbox assembly by the ring screws as shown in this chapter The gas valve of the hydro pneumatic pressure accumulator must not be used as attachment equipment and on no account should be damaged Check the attachment equipment that you wish to use for signs of wear or damage before transport Do not fix the lifting strap to the flanges Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Transport with ring screws Transport and storage 29 112 The transportation options below exist depending on the weight and duration of the transport e Transporting by hand e Transporting with lifting device ring screw or lifting strap e Transporting with a forklift truck 6 2 1 Transporting by hand HRB components weighing up to 15 kg may be briefly transported by hand if necessary CAUTION Danger from heavy loads There is a danger of health damage when carrying HRB components Use suitable lifting placement and relocation equipment Use your personal protective equipment e g safety glasses safety gloves suitable working clothes safety shoes Do not transport the HRB components at sensitive add on parts e g sensors or valves gt Carefully place the HRB components on the seating to prevent them from being damaged 6 2 2 Transporting the axial piston unit and gearbox assembly For transport the axial
62. eration of the vehicle is no longer guaranteed Do not make any changes to the electrical interfaces architecture of the vehicle A WARNING Unexpected vehicle behavior The HRB control is configured for the respective electric interface architecture in particular the CAN configuration In case of changes or interventions reliable operation of the vehicle is no longer guaranteed Do not make any changes to the electrical interfaces architecture of the vehicle 5 5 Software 5 5 1 Prerequisite The software is specific to the vehicle and places certain basic prerequisites on the vehicle s electrical interfaces The specifications can be found in the description of interfaces il The software can only be replaced and modified by changing the control unit 5 5 2 Function HRB The software controls regulates and monitors the full range of functions of the HRB Vehicle interfaces Vehicle interfaces are defined in the description of interfaces Bosch Rexroth AG HRB RE 94850 01 B 10 2012 About this product 25 112 Refuse trucks Europe On refuse trucks in Europe the interface to the vehicle that is relevant to the function is the body interface control unit e g the PSM on Mercedes Benz vehicles or the KSM on MAN vehicles together with the body CAN As a rule the interface architecture depends on the vehicle manufacturer and is implemented on the basis of ISO 11992 Part 3 or SAE J1939 The concrete realization by the v
63. ffice in the assembly group approval 10 6 3 Replacing the HRB control unit When removing the control unit or disconnecting the control unit plug first remove fuses in the following order clamp 15 clamp 30 This ensures that the control unit will not be damaged and that no misdiagnoses are stored within the control unit Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Maintenance and repair 85 112 ae 1 Switch off the ignition 2 Remove the HRB fuses in the following order clamp 15 clamp 30 J Disconnect the HCU1 connector EN Les J e Disconnect the HCU2 connector Remove the old control unit it is fastened with 8 screws oO e e Install the new control unit it is to be fastened with 8 screws Connect the HCU2 connector am 0 0 o Connect the HCU1 connector Plug the HRB fuses back in 10 Activate the ignition e All HRB status indicators should first illuminate briefly on the display The green status indicator should then illuminate continuously 10 7 Repair Components may only be repaired by a Bosch Rexroth Service partner See chapter 10 8 Spare parts on page 85 for address The system may need to be recommissioned after replacing or servicing components If any of the plastic cover on the pressure accumulators are damaged the valve should be examined for damage rust and correct function If the valve is intact the damaged cover is to be replaced 10 8 Spare
64. for completeness and or up to dateness Observe the notes and document references in the HRB documentation as well as special requirements regarding the design of the used hydraulic components such as hoses and connections and for the protection of operators persons Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Installation position not rotated plan view Installation 35 112 7 3 Installation positions Three installation positions are permissible for the HRB axial piston unit and gearbox assembly e not rotated fig 12 e rotated 90 counter clockwise fig 13 e rotated 90 clockwise fig 14 Gear bleeding is performed automatically via a separate air bleed vent mounted on the gear case Depending on the installation position the bleed valve will vary in relation to the gearbox The orientation will always be the same in relation to the vehicle axles For this reason only one specific installation position is permissible for each axial piston unit and gearbox assembly see the relevant installation drawing Fig 12 HRB installation position not rotated plan view Table 8 Filling and air bleeding of axial piston unit and gearbox assembly for installation position not rotated Components Axial piston unit Gearbox Air bleed K2p Filling Oil drain Oil level check Oil type K2 K1 Axial piston unit must be completely HLP 32 filled via the filling port Other fluids only upon request G1 G3 G4 G2
65. g pressure and installation conditions The sound pressure level may rise above 70 dBA during normal application conditions Always wear hearing protection when in the vicinity of the operating axial piston unit and gearbox assembly Hot surfaces on the HRB components Risk of burns gt Allow the HRB components to cool down sufficiently before touching them Wear heat resistant protective clothing e g gloves Improper routing of cables and lines Tripping hazard and damage to equipment Lay cables and lines so that they can not be damaged and nobody can trip over them Contact with hydraulic fluids or lubricating oil Hazard to health health impairment e g eye injuries skin damage toxication during inhalation Avoid contact with hydraulic fluids or lubricating oil When working with hydraulic fluids and lubricating oils strictly observe the manufacturer s safety instructions Use your personal protective equipment e g safety glasses safety gloves suitable working clothes safety shoes If hydraulic fluid or lubricating oil should nevertheless come into contact with your eyes or bloodstream or is swallowed consult a doctor immediately Escaping hydraulic fluid or lubricating oil due to vehicle leakage Risk of burns and risk of injury due to escaping oil jet Depressurize the vehicle and repair the leak Never attempt to block or seal the leak or oil jet with a cloth 2 7 Personal protective equipmen
66. g purposes is performed by Bosch Rexroth Service The address can be found in chapter 10 8 Spare parts on page 85 Information on reading out error codes is provided in chapter 14 Troubleshooting on page 89 5 6 Component overview Fig 5 HRB components Axial piston unit and gearbox assembly Pilot oil supply manifold with pilot oil accumulator HRB manifold HRB control unit HCU Hydro pneumatic pressure accumulator ah WN P 5 7 Product identification The system can be identified from the system name plate and the CE plate The name plate is located on the axial piston unit and gearbox assembly The following example shows an HRB system name plate Bosch Rexroth AG HRB RE 94850 01 B 10 2012 About this product 27 112 e Rexroth DE 72160 Horb TYP L HRBH1IR 10EU1L321A1204A064PS100S2 0 SYN R902485592 SN 12345678 FD 2010W29 e BNI Made in Germany Fig 6 HRB system name plate 1 Manufacturer 5 Production date 2 HRB system number 6 Serialnumber 3 Internal plant designation 7 Ordering code A Bar code The CE plate must be attached to a place on the vehicle where it is easily visible The following example shows a CE plate Bosch Rexroth Ab 892 5 Elchingen ne ratel C QO35 zul Temperaturbereich T 20 100 L max Betriebsdruck PS 315 bar Inhalt der Uruckbehdlter V 1201 SN 12345678 Fig 7 CE plate 1 Manufacturer 6 Serial number 2 CE conformity sign 7 Pressure accumul
67. ge port in an oil vessel Slowly connect the line to miniature gauge port MP pilot oil gauge port on the axial piston unit and gearbox assembly Drain the pilot oil accumulator and the line completely 8 To refill the system all opened threaded plugs are to be tightened again with the corresponding torques Close the drain valve that was opened to manually drain the hydro pneumatic pressure accumulators 9 The system is to be filled via the ports specified in chapter 7 3 Installation positions on page 35 10 The system is to be commissioned according to chapter 8 2 Recommissioning after standstill on page 59 Dispose of the hydraulic fluid and lubricating oil in accordance with the currently applicable environmental regulations in your country Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Maintenance and repair 75 112 10 4 3 Checking the interior of the hydro pneumatic pressure accumulator e The interior check of hydro pneumatic pressure accumulator must be performed by a named office in compliance with the pressure vessel directive Please comply with this and with any local legislation valid in the country concerned e After the interior check the named office will specify a new inspection interval at which the hydro pneumatic pressure accumulator is to be subjected to another interior check 10 4 4 Removing the hydro pneumatic pressure accumulators and replacing the accumulator bladders DANGER Risk of fatal inju
68. he order confirmation The product may only be commissioned after it has been installed in the vehicle When the HRB is in use kinetic energy is converted into potential energy and stored in hydro pneumatic pressure accumulators During subsequent acceleration the stored energy is fed back into the travel drive relieving the driving combustion engine The product may be used as follows The HRB may only be installed in the vehicle defined in the order confirmation gt Observe the technical data application and operating conditions and performance limits as specified in data sheet RE 94850 and in the order confirmation gt 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 on page 9 2 3 Improper use Any use other than that described as intended use shall be considered as improper and is therefore impermissible Bosch Rexroth AG shall accept no liability whatsoever for damage resulting from improper use The user shall bear all risks arising from improper use Improper use of the product includes gt Use in an explosive environment Use in hazardous goods transporters RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 10 112 Safety instructions 2 4 Personnel q
69. iant handling faulty Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Measures crosscheck controller temperature 35 150 C contact Bosch Rexroth Service crosscheck controller temperature 35 150 C contact Bosch Rexroth Service check message from the body builder CAN GPM13 or EEC1 interface preparation of the chassis builder must provide this message check message from the body builder CAN GPM13 or EEC1 interface preparation of the chassis builder must provide this message check message from the body builder CAN GPM15 or EC1 interface preparation of the chassis builder must provide this message check signal from the body builder CAN interface preparation of the chassis builder must provide the TSC1 message make sure that no further body builder CAN participant overwrites the TSC1 message on the body builder CAN crosscheck the interface preparation 1 If there are no other CAN errors check the availability and the functioning of the message from the body builder ECU e g GPM23H or KSM1_AH 2 Check the availablity and function of the Body Builder Vehicle CAN 3 Check the termination impedance of the ACAN according to e connections Check message from the body builder CAN GPM13 or CCVS interface preparation of the chassis builder must provide this signal 1 Check body builder CAN Signal vVeh 2 Check sensor and signal from the Cardan shaft speed sensor gt P3002 3 Check r
70. ice Use a chain or another suitable form of lifting gear Fig 9 Transporting the HRB manifold Please note the chain lifting gear length to ensure that the angle of spread is less than 120 6 2 4 Transporting the pressure accumulator A lifting strap can be used for transporting the hydro pneumatic pressure accumulator This is to be connected to a lifting device The following must be noted when transporting with a lifting strap WARNING Risk of injury During transport with a lifting strap the pressure accumulator could tip or slip out of the loop causing injury gt Hold the pressure accumulator tight with your hands during transport to prevent it from tipping slipping out of the loop gt Use the widest possible lifting strap gt Place the lifting strap around the pressure accumulator so that it is not routed over add on units and is not caught on add on units Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Requirement After delivery Transport and storage 31 112 Fig 10 Transporting the pressure accumulator with lifting strap 6 3 Storing HRB components e The storage areas must be free from corrosive materials and gases e To prevent damage to the seals ozone forming equipment e g mercury vapor lamps high voltage equipment electric motors sources of electrical sparks or electrical discharges must not be operated in storage areas e The storage areas must be dry e Ideal storage temperature 5
71. ignals see P3008 and P3024 check battery voltage VBAT 18 32 V check battery voltage VBAT 18 32 V check operationality of pilot pressure valve PV via breakoutbox and controller connectors specification of solenoid coil voltage resistance power current 24 V 28 5 O 20 W 0 61 0 85 A see P3115 gt see P3115 see P3115 check operationality of external pilot pressure valve EPV optional via breakoutbox and controller connectors see P3119 see P3119 see P3119 Table 19 Error code list P code 3123 3124 3125 3126 3127 3128 3129 3130 3131 3132 3133 3134 3165 3166 3167 3168 3169 3170 3171 3172 3173 3174 3175 3176 3177 3179 3180 3181 3182 3185 Description Diagnostics Tool DIG_A 3 open circuit short to earth DIG_A 3 Temperature too high DIG_A 3 short to B DIG_A 3 short to earth open circuit DIG_A 4 open circuit DIG_A 4 Temperature too high DIG_A 4 short to B DIG_A 4 short to earth DIG_A 5 open circuit DIG_A 5 Temperature too high DIG_A 5 short to B DIG_A 5 short to earth EEP read error Several blocks EEP read error Several blocks EEP write error One block Engine brake open circuit RetCtl_bEngBrkPtd RetCtl_bEngBrkPtd RetCtl_bEngBrkPtd RetCtl_bEngBrkPtd Atmospheric pressure sensor upper limit Temperature too high open circuit short to B short to earth
72. il supply manifold Pa Pressure accumulator oil port PE Pressure port on external pilot oil supply Po Pressure port on gearbox control block Psv Pressure port on pressure sequence valve block Py HRB manifold pressure port R L 1r Case drain port on axial piston unit installation position rotated 90 clockwise Se Suction port for external pilot oil supply Sp Axial piston unit suction port Te Reservoir port on gearbox control block Ts Case drain port on pilot oil supply manifold Tsy Reservoir port on pressure sequence valve block Ty HRB manifold reservoir port Vy HRB manifold drain port Note that the indices for the identification of ports in this document are not present on the components themselves For instance the pilot oil port in the pilot oil supply manifold As is only marked with A on the pilot oil supply block The following tightening torques apply please refer to installation drawing for assignment to fasteners e Female thread in the axial piston unit and gearbox assembly The maximum permissible tightening torques of the female threads must not be exceeded Notes on the tightening torques can be found in the technical installation drawing and in section Installation positions general instructions for axial piston units of the HRB data sheet RE 94850 e Fittings Observe the manufacturer s instructions regarding the tightening torques of the fittings used e Mounting bolts For mounting bolts with metric ISO th
73. ion It must be ensured that the corresponding signal is immediately detected and displayed Depending on the specific vehicle model up to three additional status indicators are mounted in the vehicle that may also be located in the peripheral field of view To check the status indicators all status indicators light up briefly when the ignition is switched on Then only the green status indicator HRB ready status indicator lights up Fig 27 HRB status indicators example Mercedes Benz Actros The direct field of vision covers the area directly in front of the driver near the steering wheel e g the central display The peripheral field of vision requires a noticeable head movement it is possible to change the arrangement of the indicators e g in the center console or further way Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Operation 61 112 Fig 28 HRB status indicators 9 1 2 Meaning of HRB status indicators Red status indicator Do not continue the journey Stop the vehicle immediately in a safe place taking the current traffic situation into account and contact your responsible Bosch Rexroth Service partner see chapter 10 8 Spare parts on page 85 for address To move the vehicle from the stop location proceed as described below further travel even at walking pace is not permissible CAUTION Risk of excessive pressure in the system or of damage to the axial piston unit If the red sta
74. k is performed on a hydraulic system or pressure accumulator that has not been depressurized and or in the event of damage caused by an accident there is an increased risk of injury from the pressure accumulator bursting or from hydraulic fluid escaping under high pressure Before performing maintenance work of the hydraulic system and in the event of accident damage close to the pressure accumulator the hydraulic pressure in the hydro pneumatic pressure accumulators must be completely relieved Before performing maintenance work switch the ignition off and wait until the pressure is completely drained Risk of suffocation through nitrogen There is a risk of suffocation when letting off nitrogen Only let nitrogen off from the pressure accumulators in well ventilated places Risk of personal injury and damage to equipment The pressure accumulators will remain charged with nitrogen after the oil has been drained The pressure will be at least 120 bar After performing maintenance work close the valve on the hydro pneumatic pressure accumulator again The hydraulic pressure in the HRB primary accumulators can be manually relieved by opening the drain valve 1 in the HRB manifold see Fig 30 In doing so the valve is to be opened slowly Fig 30 Drain valve pressure accumulator 1 Drain valve 2 Gauge port HD1 The accumulator pressure can be checked with a gauge at the gauge port 2 The port is labeled
75. leaks damage and correctly seated components In addition the oil level must be checked and the electrical wiring system examined Oil leakage damage to components due to bladder burst with non deactivated HRB Following a bladder burst in one of the pressure accumulators the release of the nitrogen may result in a large increase in volume and cause foaming in the reservoir If operation of the HRB continues following a bladder burst considerable oil leakage is possible via the ventilation filter on the reservoir A bladder burst can be detected by increased operating noise of the axial piston unit and gearbox assembly If a bladder burst is suspected immediately deactivate the HRB Note that after an ignition start following such an event the HRB must again be deactivated since the HRB is automatically active on ignition start In this case do not open the manual drain valve To guarantee lasting and reliable function of the HRB Bosch Rexroth recommends regularly checking the hydraulic system and the hydro pneumatic pressure accumulator as well as the axial piston unit and gearbox assembly For inspection intervals see Table 15 RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 70 112 Maintenance and repair Table 15 Inspection schedule Task to be carried out Hydraulic system Filter with contamination indicator Electrical wiring and hydraulic lines Hydropneumatic pressure accumulator Axial piston unit and gearbo
76. ll temperature sensor ATS 2 check sensors and signals 2 1 drive accumulator shell temperature sensor ATS 2 2 reservoir oil temperature sensor RTS 2 3 APU suction pressure temperature Sensor PTS 3 execute the warm up operation 1 perform maintenance according to user s manual 2 reset the counter in the controller with the diagnostic tool check message from the body builder CAN GPM14 or EEC2 interface preparation of the chassis builder must provide this message check battery voltage VBAT 6 36 V check battery voltage VBAT 6 36 V Braking signal from the body builder CAN and from the hardware pins is not plausible check the parameterization according to the interface specification message CCVS on body builder CAN check sensor connectivity of pneumatic braking pressure sensor BPS Braking signal from the body builder CAN and from the hardware pins is not plausible check the parameterization according to the interface specification message CCVS on body builder CAN check sensor connectivity of pneumatic braking pressure sensor BPS controller problem contact Bosch Rexroth Service controller problem contact Bosch Rexroth Service controller problem contact Bosch Rexroth Service controller problem contact Bosch Rexroth Service controller problem contact Bosch Rexroth Service controller problem contact Bosch Rexroth Service check swivel angle s
77. lso for start up support from the HRB there must be an HRB level level 3 4 or 5 pre selected at the level switch In doing so the torque actually triggered is not dependent on the level but rather complies with the driver s prompt The prompt from the driver is transmitted via for example the accelerator pedal of the vehicle Amendment to chapter 9 2 1 Information How the engine brake works in levels 1 and 2 of the retarder lever is not Brakes on page 64 described here as this is no different from the function on the standard vehicle The HRB is active under a defined vehicle speed of approx 50 km h In addition In addition braking is effected with engine brake level 2 regardless of whether HRB level 3 4 or 5 is preselected The capacity of the pressure accumulator is limited For this reason the HRB torque is continually reduced on lengthy downhill stretches as soon as the pressure accumulators are charged The system changes to engine brake level 2 15 1 2 MAN Amendment to chapter 5 3 3 Engine braking will not be suppressed if the vehicle is decelerated using the HRB Delaying on page 21 Amendment to chapter 9 1 4 f the service brake is used a possible HRB reserve torque is activated up to the Setting the HRB braking maximum possible HRB total torque in order to increase the degree of recuperation effect section Level switch Fig 51 illustrates a possible MAN integration of the HRB level switch 1 preselector on page 63
78. matically if the hydraulic circuit of the HRB and body hydraulics are identical it is possible to warm up the hydraulic oil by actuating the body hydraulics RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 24 112 About this product Cooling The system is passively cooled by a radiation to the component surfaces supported by the airflow Warm up While the HRB warms up to operating temperature at hydraulic oil temperatures below 10 C there is no acceleration capability available for a short time even though the green status indicator HRB ready is illuminated 5 4 Interfaces The HRB requires electrical energy from and data connections to the vehicle The exact description of the interfaces can be found in the description of interfaces The guidelines of the vehicle manufacturer with respect to retrofitting electrical equipment still have to be observed These are not part of the Rexroth system documentation Mechanical interfaces for securing components and for power transmission can be found in the installation drawing and data sheet Again here the guidelines of the vehicle manufacturer with respect to the installation of mechanical components must be observed Corresponding investigations must be performed for the installation in the vehicle Unexpected vehicle behavior The HRB control is configured for the respective electric interface architecture in particular the CAN configuration In case of changes or interventions reliable op
79. mulator 10 6 3 Replacing the HRB control unit 10 7 Repair 10 8 Spare parts 11 Removal and replacement 11 1 Required tools 11 2 Preparing for removal 11 3 Removing the axial piston unit 12 Disposal 13 Extension and conversion 14 Troubleshooting 14 1 Easy to rectify causes of errors self help 14 2 Error code list 15 Technical data 15 1 Vehicle and manufacturer specific details 15 1 1 Mercedes Benz 15 1 2 MAN 16 Alphabetical index 5 112 68 68 69 71 12 13 74 19 19 19 80 83 84 84 85 85 86 86 86 86 87 88 89 89 90 102 103 103 104 106 RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 6 112 About this manual 1 About this manual 1 1 Validity of the documentation This documentation applies to the following products e Hydrostatic Regenerative Braking System HRB This documentation is intended for vehicle manufacturers fitters and service technicians This documentation contains important information on the safe and appropriate transport installation commissioning operation maintenance removal and simple troubleshooting of the HRB hydrostatic regenerative braking system Read this documentation completely in particular chapter 2 Safety instructions on page 9 and chapter 3 General instructions on damage to equipment and the product on page 15 before you start work with the HRB hydrostatic regenerative braking system 1 2 Required and supplementary documentation
80. n capable components e g the chassis using elastic elements Make sure that the suction pressure does not drop below a minimum value of 0 8 bar absolute for the axial piston unit and gearbox assembly in all installation positions and locations in pump mode and on cold start and that the back pressure does not fall below a minimum value of 1 1 bar absolute at port Sp in motor mode see Fig 11 RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 34 112 Installation Fig 11 Suction pressure 1 Absolute pressure gauge 2 Standard pressure gauge relative Make sure that the working environment at the installation site is fully free of dust and foreign substances HRB components must be in a clean condition when they are installed Contamination of the hydraulic fluid or of the lubricating oil can have a considerable impact on the service life and function of the HRB Use lint free cloths for cleaning Use suitable mild detergents to remove lubricating oil and other difficult to remove contamination Cleaning agents must not enter the hydraulic system Observe all relevant standards directives legal requirements and other documents relevant to your application case for refuse trucks e g DIN EN 1501 The implementation is the responsibility of the body or vehicle manufacturer Such documents are subject to changes and additions at any time The standards and documents listed in the documentation of the HRB therefore make no claim
81. nated and an HRB level is preselected the HRB automatically generates an acceleration torque provided there is sufficient accumulator charging As on a conventional vehicle this acceleration torque depends on the position of the accelerator pedal If the driver calls for more torque than the HRB can generate the difference will be supplied by the combustion engine When the pressure accumulator is discharged the HRB will automatically be canceled and the combustion engine will supply the full drive torque Depending on the charge state of the pressure accumulator the HRB can also generate so much power that the vehicle can pull away in a higher gear with an semi automatic gear shifts This will reduce fuel consumption and emissions further Whether or not this is possible is checked when the vehicle is at a standstill and if mounted is indicated by the white status indicator launch gear recommendation in the instrument cluster see chapter 9 1 1 Indicators on page 60 9 2 3 Stopping the vehicle After the vehicle has been stopped and the ignition switched off the hydraulic pressure in the reservoir will automatically be relieved Relieving can be heard by a hissing noise and takes about 5 minutes with a charged accumulator volume of 64 I RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 66 112 Operation 9 2 4 Manually draining the pressure accumulator MA CAUTION Risk of personal injury and damage to equipment If maintenance wor
82. nd every combination of connecting pieces couplings or connecting points with hoses or pipes to ensure they are in condition for safe working To improve the corrosion properties it is urgently recommended to paint the flange at ports Py Ty and HD and the open unpainted surfaces of the HRB manifold or to give them corrosion protection treatment after hydraulically connecting the components Also observe the notes for ring screws in chapter 7 4 3 General instructions on page 37 Other unpainted surfaces of the HRB components and sensors e g ventilation filter name and identification plates and notices red protective caps manual drain valve etc are not to be painted in the event of subsequent painting and must not generally be painted over Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Installation 51 112 7 4 8 Electrically connecting HRB components Short circuit in event of penetrating hydraulic fluid Fluid can penetrate the product and cause a short circuit gt Do not install axial piston units with electric components e g electric controls sensors in a reservoir below the fluid level inside reservoir installation After completing the pressure system pressure accumulator port to hydraulic system a commissioning examination must be conducted in Germany for example by an approved monitoring office ZUS The examination must be performed by an expert assessor from the field of systems technology He
83. ng the HRB on page 42 The hydraulic lines of the system must also be filled Make certain that all ports are either piped up or plugged according to the hydraulic circuit diagram 4 Fill the reservoir in accordance with the manufacturer s instructions 5 Remove the oil filler screw and the oil level screw when filling the gearbox assembly with lubricating oil see chapter 7 3 Installation positions on page 35 Fill the gearbox assembly via the oil filler screw Add lubricating oil until the necessary oil level is reached at the oil level screw or until lubricating oil starts to escape Plug the oil filler opening and the borehole for the oil level screw 8 1 2 Filling the HRB clutch Before a vehicle with installed HRB is moved for the first time the clutch of the HRB is to be filled with oil in order to prevent damage This also applies for towing procedures performed prior to the first commissioning in which the drive axle turns In the event of damages that result from insufficient lubrication all warranty and liability claims against Bosch Rexroth are rendered void Please contact Bosch Rexroth Service if you have questions The HRB clutch is part of the hydraulic circuit When filling use a filling unit with filter grade of 3 um Observe the notes on the required cleanliness of the oil according to the hydraulic fluid RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 58 112 Commissioning Preparation Filling operati
84. nit and gearbox assembly with insufficient hydraulic fluid or lubricating oil Make sure in particular that the rotary group has sufficient lubrication When commissioning the vehicle make sure that the case and the suction and service lines of the axial piston unit and gearbox assembly are filled with hydraulic fluid or lubricating oil and remain filled during operation Check the level of the hydraulic fluid and lubricating oil regularly if necessary recommission Make sure that the suction line is always filled with hydraulic fluid during commissioning and operation and that it is free of leaks Make sure that the axial piston unit really does suck in hydraulic fluid and build up pressure RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 16 112 General instructions on damage to equipment and the product Mixing of hydraulic fluids Product can be damaged Before installation remove all fluids from the axial piston unit to prevent mixing with the hydraulic fluid used in the machine system Any mixing of hydraulic fluids of different manufacturers or different types of the same manufacturer is not permissible in general Contamination of the hydraulic fluid or of the lubricating oil The cleanliness of the hydraulic fluid and lubricating oil has a considerable impact on the cleanliness and service life of the hydraulic system Contamination of the hydraulic fluid could cause premature wear and malfunctions Make sure that
85. nt Check fastener elements for tight seating All fasteners have to be checked when the system is switched off depressurized and cooled down Interval Daily Weekly Yearly or every 2000 h whichever occurs first Daily Yearly Weekly during the first month following commissioning monthly thereafter Weekly Weekly Weekly after charging in the first month then half yearly or every 1000 h whichever comes first Half yearly or every 1000 h whichever occurs first Weekly Daily Monthly Maintenance and repair 71 112 Task to be carried out Interval Gearbox Check the quality of the lubricating oil At a Every 50 000 km or minimum degree of cleanliness of 20 18 15 at the latest after one according to ISO 4406 must be ensured year Fasteners and brackets Check the fasteners and brackets including Half yearly or every the fasteners for the pressure accumulator 1000 h whichever temperature sensor for firm seating occurs first corrosion and fractures Check the oil level with completely emptied pressure accumulators To do this park the vehicle on a flat surface and deactivate the ignition Wait approx 5 minutes before reading the oil level to allow the accumulators to empty completely 2 Note that a soiled filter may in some cases only be indicated while the engine is running 3 When performing maintenance on the hydro pneumatic pressure accumulators the national legislation in the res
86. nt and the product 17 112 Environmental pollution due to incorrect disposal Careless disposal of the product the hydraulic fluid the lubricating oil and the packaging material could lead to pollution of the environment Forthis reason dispose of the product the hydraulic fluid and lubricating oil as well as the packaging in accordance with the currently applicable environmental regulations in your country Dispose of the hydraulic fluid and lubricating oil in accordance with the applicable safety data sheet for the hydraulic fluid and lubricating oil manufacturer In particular make sure that the oil and gas pressure accumulators are depressurized Escaping or spilling hydraulic fluid or lubricating oil Environmental pollution and contamination of the ground water When filling and draining the hydraulic fluid or lubrication oil always place a drip tray under the axial piston unit and gearbox assembly Use an oil binding agent if hydraulic fluid or lubricating oil is spilled Observe the information in the safety data sheet for the hydraulic fluid and lubricating oil and the specifications provided by the system manufacturer The warranty applies only to the delivered configuration The entitlement to warranty cover will be rendered void if the product is incorrectly installed commissioned or operated or if it is used or handled improperly RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 18 112 Delivery contents 4 Delive
87. ntents of the HRB Information about the permissible securing options can be found in the data sheet Install the HRB manifold pilot oil supply manifold at the specified installation location Position the HRB manifold so that the manual drain valve see Fig 16 on page 42 is easily accessible at all times For reasons of corrosion protection make sure that the pilot oil supply manifold is installed in such a way that the pilot oil accumulator points vertically up Otherwise investigations are to be performed into the corrosion behavior According to the national regulations a note e g pictogram is to be attached to the manual drain valve that provides information on function and operation Now route the hydraulic lines and hoses and connect the HRB components as described in the installation drawings and the hydraulic circuit diagram see also chapter 7 4 7 Hydraulically connecting the HRB on page 42 7 4 5 Installing the pressure accumulator temperature sensor Position the temperature sensor for the pressure accumulator half way along the pressure accumulator as shown in Fig 15 Make sure that the contact surface is against the shell of the pressure accumulator If two pressure accumulators are fitted it is important for the sensor to be located between the two pressure accumulators Protect the sensor from sunlight as much as possible Secure the sensor with a suitable wire tie To relieve tension secure the sens
88. o verify that the pressure has been completely released If maintenance work is to be performed on the pilot oil supply the pressure in the pilot oil accumulator must first be released To do this proceed as described in chapter 9 2 5 Manually draining the pilot oil accumulator on page 67 10 4 1 Gear oil change Oiltype see data sheet Oil quantity 3 3 liters if installation position not rotated 4 5 liters if installation position is rotated 90 clockwise counter clockwise e The gear oil is to be drained off at the port defined in chapter 7 3 Installation positions on page 35 The gear oil is to be collected in a suitable vessel and disposed of in accordance with the environmental regulations valid in your country e The gearbox is also filled and the oil level checked at the ports defined in chapter 7 3 Installation positions on page 35 The procedure is specified in chapter 8 1 1 Hydraulic mechanical commissioning on page 56 RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 74 112 Maintenance and repair 10 4 2 Hydraulic fluid change A DANGER Risk of fatal injury due to maintenance work on pressurized hydraulic system Risk of fatal injury due to maintenance work on pressurized hydraulic system Performing maintenance work on a hydraulic system that has not been depressurized or on pressurized hydraulic components could cause severe injuries or burns gt Before performing maintenance work switch the ignition off and
89. oil in accordance with the currently applicable environmental regulations in your country Also observe the applicable safety data sheet for the hydraulic fluid and the lubricating oil Remove the components from the vehicle then disassemble them into their constituent parts for recycling Separate according to for instance Cast parts Steel Aluminum Non ferrous metal Electronic waste Plastic Seals Before the hydro pneumatic pressure accumulators are disposed of the nitrogen they contain must be completely drained see chapter 10 3 Maintenance on page 71 RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 88 112 Extension and conversion 13 Extension and conversion The HRB components and their fittings must not be modified This also includes modification of the setting screws The Bosch Rexroth warranty only applies for the delivered configuration In case of conversion or extension the entitlement under warranty will be rendered void The setting screws are protected against unintentional resetting by means of il caps Changing the settings of the setting screws will void the warranty If you need to change the setting contact your responsible Bosch Rexroth Service partner see chapter 10 8 Spare parts on page 85 for address A subsequent change of wheel tire size is possible only upon consultation with Bosch Rexroth In any case an adjustment via the diagnostics tool is necessary in order to do
90. on Air bleeding the axial piston unit Air bleeding the HRB manifold Air bleeding the hose lines 1 Install the axial piston unit and gearbox assembly in the vehicle 2 Connect all hoses 3 Ensure the oil supply as for normal commissioning Fig 26 Filling the HRB clutch 1 Flush oil port Y 4 Reservoir 2 Port Te 5 Pilot oil supply 3 Port Pe 1 Release the fitting of flush oil port Yp air bleed the unit 2 Fill the clutch via the case drain port at Tg maximum 3 bar 3 Conclude the filling operation when the oil runs uniformly and free of air bubbles form flush oil port Yp 4 Plug flush oil port Y with 18 Nm 13ft Ibs 8 1 3 Air bleeding the system Fill and air bleed the axial piston unit and gearbox assembly via the appropriate ports see chapter 7 3 Installation positions on page 35 and chapter 7 4 7 Hydraulically connecting the HRB on page 42 The axial piston unit must be completely filled with hydraulic fluid The HRB manifold is to be air bled via port HD2 Place a drip tray under the HRB manifold to collect any hydraulic fluid that may escape The hydraulic lines of the system must be filled and air bled Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Checking wiring Checking fuses il Checking visual indicators Checking HRB button Commissioning 59 112 8 1 4 Electrical commissioning Check whether all electrical connections and cable ties are correctly seated Check wiring for sign
91. onality of pilot pressure valve PV specification of the solenoid coil voltage resistance power current 24 V 28 5 O 20 W 0 61 0 85 A 3 check operationality of clutch valve CV Specification of the solenoid coil voltage resistance current 24 V 22 5 Q 0 7 A visualisation of solenoid current with the diagnostic tool Kupplungsmagnet 4 clutch pressure measurement on gearbox valve block component 3 in hydraulic scheme port MB p_clutch 27 30 bar 5 speed sensors check supply signal and cabling with the breakout box and at the sensor driveshaft see P3002 pump see P3003 1 check the prefill pressure of the auxiliary accumulator pAccumPrecharge 30 bar pilot hose to clutch must be pressureless 2 check the functionality of body hydraulics pressure gt 30 bar must be transferred over change valve 2 1 and pressure reduction valve 2 2 to pilot accumulator 2 5 3 check sensor connectivity of pilot accumulator pressure sensor PAS 4 check connectivity of external pilot pressure H and external pilot pressure L EPV 1 check the automatic discharging on ignition start if pilot accum pres is gt 65 bar pilot pressure valve PV is closed for pilot pressure discharge 2 check operationality of the pilot pressure valve PV specification solenoid coil voltage resistance power current 24 V 28 5 Q 20 W 0 61 0 85 A 3 check pressure sensor
92. oo high Internal power supply too low Main relay stuck Main relay Switch sticking PWM_A 1 open circuit PWM_A 1 Temperature too high PWM_A 1 short to B PWM_A 1 short to earth PWM_A 1 Value outside tolerance Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Measures 1 check all 3 PWM solenoid coils 1 1 check operationality of clutch valve CV specification solenoid coil voltage resistance current 24 V 22 5 Q 0 7 A visualization of the solenoid current via diagnostic tool Kupplungsmagnet 1 2 check operationality of solenoids wiring of APU A motor direction SA and APU B pump direction SB specification solenoid coil voltage resistance current 24 V 21 7 Q 0 73 A 2 checkup of the pressure sensors accumulator pump this means also to check if the right sensor is mounted background difference between pump and accumulator pressure is monitored accumulator gt P3006 pump P3004 3 check the blow off valve adjustment P3022 1 check the swivel angle signals of the pump like in P3008 braking forwards loading magnet B active in KTS Swivel angle gt 0 SA1 gt 2 5 V SA2 lt 2 5 V on the D CAN Swivel angle is negative difference to KTS Accelerating forwards magnet A active Im KTS Swivel angle lt 0 SW1 lt 2 5 V SW2 gt 2 5 V On the D CAN Swivel angle is positive difference to KTS check the pressure sensors like in P3004
93. or correct position Check the tightening torques of the hydraulic fittings in accordance with the manufacturer s instructions Check system gt Carry out a visual inspection of the entire hydraulic system of the HRB for signs of for leaks leakage Setting checking pre charge pressure DANGER The use of liquid nitrogen oxygen or compressed air to charge the pressure accumulator could cause severe or even fatal injury Danger to life gt Do not use liquid nitrogen oxygen or compressed air to charge the pressure accumulator A CAUTION Risk of damage to the product Commissioning a pressure accumulator that is not pre charged will permanently damage the accumulator bladder Pre charge the pressure accumulator before commissioning Check the pre charge pressure in the pressure accumulator as described below Set check the pre charge pressure in all pressure accumulators as specified in this manual and correct as necessary To prevent the gas valve from being compressed when charging only open the il valve as far as necessary for the gauge to show pressure When charging make sure that the charging device is correctly sealed to the gas valve Check the gas valve for damage after charging as a damaged gas valve could fail later Hydro pneumatic pressure accumulator for hybrid drive 120 bar at 20 C For correct function Use nitrogen with a purity of at least 99 8 for pre charging the high pressure acc
94. or wire about 10 cm underneath the sensor position e g with plastic cable ties Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Installation 41 112 Liota PFN 2 approx 10 cm Fig 15 Securing the pressure accumulator temperature sensor 7 4 6 Completing installation 1 Remove any mounted transport screws CAUTION Operation with protective plug Operating the axial piston unit and gearbox assembly with protective plugs could cause injury or damage to the axial piston unit and gearbox assembly gt Before commissioning remove all protective plugs and replace them with suitable pressure proof metal threaded plugs 2 Remove the transport protection The axial piston unit and gearbox assembly is delivered with protective covers and protective plugs They are not pressure resistant therefore they have to be removed prior to connection Use a suitable tool for this to prevent damage to the sealing and functional surfaces If sealing or functional surfaces are damaged contact your responsible Bosch Rexroth Service partner or the service department of the manufacturer s plant for the HRB components Ports intended for connecting lines are covered by protective plugs or threaded plugs which serve as transport protection All ports required for functional operation must be connected see Table 11 Hydraulic ports HRB on page 49 If this requirement is disregarded malfunction or damage may result If a port is not connec
95. ot be installed close to hot vehicle components The HRB components must be installed in accordance with the relevant vehicle manufacturer s guidelines e The HRB components must be installed so that all filters ports and sensors are easily accessible For servicing and maintenance work it may be necessary to replace filters filter cartridges sensors actuators and lines RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 38 112 Installation Installing the axial piston unit and gearbox assembly il il Installing the control and indicator elements il Installing the HRB control unit e Take constructive measures to protect exposed components of the HRB hoses gt cables connectors and sensors etc from damage that could result from whirled up contaminants depending on the respective installation position e g stone impacts Please note also the specifications for installation connecting and integrating the HRB stated in the data sheet 7 4 4 Installing the HRB components A detailed description of how to install the HRB components is provided in the following A un O1 Remove the original cardan shaft in accordance with the manufacturer s instructions Install the brackets for the axial piston unit and gearbox assembly on the vehicle frame The brackets for the axial piston unit and gearbox assembly are not included in the delivery contents of the HRB Information about permissible se
96. otation of the Cardan shaft 4 Compare in the vehicle and in the chosen variant menu adjustments settings wheel diameter differential ratio gearbox 1 check wiring from vehicle interface PSM KSM etc to the HRB controller ABS state ASR state 2 ensure the correct parameterization of the vehicle interface 1 Check signals from swivel angle transducer when not connected between pins 1 3 5 6 V when between pins 1 2 24 V VBAT between pins 4 6 0 V when between pins 4 5 24 V VBAT 2 crosscheck the signal from pump pressure signal 3 voltage measure 4 controller problem contact Bosch Rexroth Service From version 3 Check the actual value Status info from ADC monitoring O everything OK Bit 2 Test voltage out of range Bit 4 Compare test of the swivel angle sensors or pressure sensor not passed Bit 7 An additional error set check the parameterization with the diagnosis tool chosen variant menu adjustments settings variant coding Table 19 Error code list P code 3242 3243 3244 3247 3248 3249 324A 324B 324C 324D 324E 324F 3250 3251 3252 3253 3254 3255 3256 3257 3258 3259 33FF Description Diagnostics Tool Variant criterion Preselector lever Version invalid Variant criterion Joint operation Version invalid Variant criterion Parameter set Version invalid Fault check SCG pilot pressure val
97. ow HRB status indicator service Yellow HRB status indicator high low temperature Green HRB status indicator HRB ready White HRB status indicator launch gear recommendation HRB button Signal analog preselector GND analog preselector 5V analog preselector Digital level switch 1 Digital level switch 2 Digital level switch 3 U battery at user interface RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 54 112 Installation Power supply U battery GND battery Ignition Vehicle interface ABS ASR Engine running ACAN H ACAN L Retarder active Retarder active GND Engine brake deactivation Engine brake GND deactivation 7 4 9 Preparing electrical interfaces A WARNING Danger through incorrect HRB function Reprogramming or subsequently modifying the vehicle interface is not permissible Contact Bosch Rexroth Service to clarify the extent to which any planned modification to the vehicle interface could affect the HRB function Danger through incorrect HRB function Retrofitting of control units on the vehicle CAN is not permissible during HRB integration on the vehicle CAN Contact Bosch Rexroth Service to clarify the extent to which any planned modification to the body interface or the vehicle CAN could affect the HRB function The HRB requires the vehicle interfaces to be prepared On refuse trucks in Europe the interface to the vehicle that is relevant to the function is the body interface control unit e g the PSM on Mer
98. oxes a launch gear recommendation can be displayed for the driver when the vehicle is at a standstill to help the driver select the best possible launch gear e g via a symbol in the auxiliary display of the body manufacturer Bosch Rexroth AG HRB RE 94850 01 B 10 2012 il High temperature Low temperature About this product 23 112 5 3 5 Normal drive mode Normal drive mode refers to driving without HRB This is the case when the hydro pneumatic pressure accumulator is empty or the maximum speed approx 50 km h the actual value may vary depending on the vehicle concerned for operating the HRB is exceeded In this case the HRB is separated from the drive train by opening the clutch 5 3 6 Standstill The HRB is inactive in standstill ignition on motor running Any accumulator pressure present will be maintained so that the system remains available for launch assistance 5 3 7 Driving dynamics The HRB is automatically deactivated during ABS closed loop control Also in the critical event of combustion engine torque being reduced by the TCS the HRB will be temporarily deactivated These ABS and TCS incidents are detected via the vehicle interface The green status indicator HRB ready goes out In addition the same note applies to the HRB that is defined in the vehicle operating instructions for the retarder engine brake Deactivate the continuous brake engine brake retarder and HRB on slippery road surfaces The whe
99. parts or even cause injuries gt Place the packaging on a flat and solid underground Only open the packaging from the top Remove the packaging from the HRB components Check the HRB components for transport damages and completeness see chapter 4 Delivery contents on page 18 Dispose of the packaging according to the national regulations of your country 7 2 Installation conditions Installation position and location of the axial piston unit and gearbox assembly of the HRB play a decisive role in determining the procedure to be applied for installation and commissioning e g when filling and air bleeding the axial piston unit and gearbox assembly Note the specified installation position which is shown on the respective installation drawing and comply with the notes on the data sheet gt HRB components must not be installed close to hot vehicle components The HRB components must be installed in accordance with the relevant vehicle manufacturer s guidelines Make certain that the case of the axial piston unit and gearbox assembly is air bled and filled with hydraulic fluid and lubricating oil during commissioning This is also to be observed following relatively long standstill periods as the hydraulically operated parts of the axial piston unit and gearbox assembly may empty via the hydraulic lines To achieve favorable noise values isolate all connecting lines and the HRB components from all vibratio
100. pective country must be observed 10 3 Maintenance The HRB components require very little maintenance if they are used as intended The service life of the hydraulic HRB components is heavily dependent on the quality of the hydraulic fluid For this reason we recommend changing the hydraulic fluid at least once per year or every 2000 operating hours whichever occurs first or having it analyzed by the hydraulic fluid manufacturer or a laboratory to determine its suitability for further use at a minimum degree of cleanliness of 19 17 14 according to ISO 4406 optimum is 17 15 11 see data sheet The service life of the axial piston unit and gearbox assembly is limited by the service life of the built in bearings The service life on the basis of the load cycle can be requested from the responsible Bosch Rexroth Service partner see chapter 10 8 Spare parts on page 85 for address Based on these details a maintenance period is to be determined by the vehicle manufacturer for the replacement of the bearings and included in the maintenance schedule of the hydraulic system The service life may differ depending on the hose system fitted Always comply with the manufacturer s instructions Table 16 Maintenance schedule Task to be carried out Interval Electrical wiring and Renew all hydraulic lines Every 6 years or every hydraulic lines 12 000 h whichever occurs first Hydro pneumatic Perform an internal check of the pressure After 10 y
101. perature is outside the permissible range As soon as the oil temperature returns to a level within the permissible limits the status indicator will go out and the system will be available again Depending on the vehicle configuration the yellow status indicator high low il temperature may not be mounted The temperature related HRB status can however always be seen on the green status indicator The green indicator goes out until the system is again within the permissible temperature limits Green status indicator HRB ready The HRB is active The HRB can be deactivated via the HRB button see Fig 29 Depending on the vehicle configuration the status indicator HRB ready is located in the HRB button Under certain circumstances the status indicator may not be green While the HRB heats up to operating temperature there may briefly be no acceleration capability available under certain circumstances even though the green status indicator HRB ready is illuminated il White status indicator launch gear recommendation optional The vehicle is at a standstill A higher launch gear can be selected on account of the accumulator charging state The white status indicator launch gear recommendation is only available in vehicles with semi automatic gear shifts as these are the only gearboxes on which the launch gear can be influenced Continuous brake indicator display and function depend on the respective vehicle please refer
102. r part of the control strategy RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 64 112 Operation 9 2 1 Brakes A WARNING Risk of accident The HRB cannot be used to brake the vehicle to a standstill You must be ready to use the service brake whenever the vehicle is braked with the HRB Risk of accident on a slippery road surface If the continuous brake engine brake retarder or the HRB is applied on a slippery road surface the wheels could lock and the vehicle could start to skid Do not switch on or deactivate the continuous brake engine brake retarder and HRB on a slippery road surface When using antiskid chains snow chains do not switch on or deactivate the continuous brake engine brake retarder and HRB When braking an HRB deceleration torque can be selected on the level switch preselector The timing of the preselection is of no relevance as the braking action is not initiated until the accelerator pedal is released The level switch preselector can also be changed during the braking action The HRB is active under a defined vehicle speed of approx 50 km h As soon as the vehicle speed drops below the HRB maximum speed the HRB will intervene and brake the vehicle practically constantly with the selected braking torque until a minimum speed of approx 1 km h is reached To stop the vehicle especially when driving downhill the service brake also needs to be used In contrast to the engine brake the HR
103. re the serial numbers of the pressure accumulators will be recorded the connection and configuration examined and the examination interval for the pressure accumulators defined usually 10 years In this connection please note the national requirements in your country Use suitable seals and gaskets for electric plug connections as a precaution against corrosion and resulting short circuits The body or vehicle manufacturer is responsible for the selection and installation of the electrical wiring For electrically controlled HRB components the electrical wiring must be connected in accordance with both the circuit diagram of the vehicle manufacturer and the HRB circuit diagram Please comply with the notes on electric wiring in the data sheet Switch the relevant body and vehicle parts to voltage free Electrically connect the HRB components Before connecting check that the connectors including all seals are intact When connecting the control unit make sure that socket HCU2 is electrically connected first followed by socket HCU1 N e e Malfunctions could occur if the control unit sockets are electrically connected in the wrong order In such cases individual status indicators will light up For this reason pay great attention to the correct connection order when electrically connecting the control unit Proceed in the reverse order when disconnecting the control unit first disconnect HCU1 then HCU2 RE 94850 01 B 10
104. read according to DIN 13 or thread according to ASME B1 1 we recommend checking the tightening torque in individual cases in accordance with VDI 2230 RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 50 112 Installation Procedure Improving corrosion characteristics il e Threaded plugs For the metal threaded plugs supplied with the axial piston unit and gearbox assembly the required tightening torques of threaded plugs M apply Values see Table 12 Table 12 Threaded plug tightening torques Threaded port sizes Required tightening torque of the threaded plugs M Axial piston unit and gearbox assembly G 3 4 DIN 3852 90 5 Nm M33 x 2 DIN 3852 225 5 Nm Valve blocks G 1 4 DIN 3852 30 5 Nm G 1 4 screw coupling DIN 3852 40 5 Nm To connect the HRB components to the hydraulic system 1 Remove the protective plugs and threaded plugs at the ports at which the connections are to be made according to the hydraulic circuit diagram Make sure that the sealing surfaces of the hydraulic ports and functional surfaces are not damaged 3 Use only clean hydraulic lines 4 Connect the lines in accordance with the installation drawing and the machine or system circuit diagram Check whether all ports are connected or plugged with threaded plugs Tighten the fittings correctly note tightening torques Mark all correctly tightened fittings e g with a permanent marker Check all pipes and hose lines a
105. ressure accumulators see chapter 9 2 4 Manually draining the pressure accumulator on page 66 Leave the drain valve open during removal Check whether the axial piston unit and gearbox assembly and the hydraulic hoses have cooled down sufficiently for them to be removed safely 11 3 Removing the axial piston unit Proceed as follows to remove the axial piston unit and gearbox assembly W Relieve the hydraulic system according to chapter 9 2 4 Manually draining the pressure accumulator on page 66 Drain the hydraulic system according to chapter 10 4 2 Hydraulic fluid change on page 74 steps 1 to 7 Remove the hydraulic hoses from the components to be removed To do this loosen the hydraulic lines and collect the escaping hydraulic fluid in the collector The hydraulic hoses could still be filled with hydraulic fluid Care must therefore be taken during removal Remove the oil drain screw from the gearbox assembly see chapter 7 3 Installation positions on page 35 and drain the lubricating oil completely into a prepared drip tray CAUTION Damage to the cardan shafts If the universal joints on the cardan shafts are installed in a different orientation during a subsequent installation this could damage the cardan shafts gt gt Re orienting the universal joints on the cardan shafts is therefore not permissible Before removing mark the position of the universal joints on the cardan shafts
106. rking cycles fuel consumption can be reduced by up to 25 Another effective economic benefit of the HRB is considerably reduced brake wear and tear and thus longer intervals between replacement and maintenance The HRB unit described here is suitable for vehicles with both automatic and semi automatic gearboxes Refer to the data sheet and order confirmation for the technical data operating conditions and operating limits of the axial piston unit and gearbox assembly RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 20 112 About this product 5 2 Function principle The principle of the HRB hydrostatic parallel hybrid solution which is also suitable for retrofitting is shown in Fig 3 The components shown in blue are included in the HRB delivery contents Here a hydrostatic axial piston unit 3 is coupled in the drive train to the gearbox output 1 via a shiftable gear 2 In pump mode this charges a hydro pneumatic pressure accumulator 4 to generate a braking torque at the output drive 5 or which can utilize the accumulator pressure in motor mode to add an acceleration torque to the cardan shaft In addition an HRB manifold 6 provides the necessary pressure safeguarding and shut down functions 3 12611 14 Fig 3 Examples of installation situation of an HRB from front left 1 Vehicle output drive 8 Reservoir return flow line 2 Gearbox with clutch 9 Axial piston unit low pressure line 3 Axial piston unit 10 Axial piston
107. ry contents Fig 1 Delivery contents of the HRB hydrostatic regenerative braking system The following components of the HRB are included in the delivery contents e Axial piston unit and gearbox assembly pre installed 1 e Pilot oil supply manifold with pilot oil accumulator ready and pre charged 2 e HRB manifold 3 e HRB control unit HCU e Pressure sensors for accumulator pressure pressure at axial piston unit pilot oil pressure e Temperature sensors for accumulator shell and reservoir e Plastic plugs threaded plugs for all hydraulic components e Hydro pneumatic pressure accumulator pre charged with approx 5 see figFig 2 e Mating connector with contacts for all electric components Fig 2 Delivery contents of hydro pneumatic pressure accumulator Bosch Rexroth AG HRB RE 94850 01 B 10 2012 About this product 19 112 5 About this product 5 1 General system description The regeneration of braking energy is a useful way of optimizing the total efficiency of a mechanical drive train The greatest optimization potential is realized in cyclical driving operation frequent braking and acceleration The cycles encountered in refuse collection applications are especially suitable For applications with high power conversion and only very low quantities of energy hydraulic solutions are superior to other solutions because of the high power density When this system is used in applications with extremely short wo
108. ry due to maintenance work on pressurized hydraulic system Performing maintenance work on a hydraulic system that has not been depressurized or on pressurized hydraulic components could cause severe injuries or burns Before performing maintenance work switch the ignition off and wait until the pressure is completely drained Before beginning the maintenance work pressure must be relieved in the hydraulic system and the hydraulic components via the specified ports see chapter 9 2 4 Manually draining the pressure accumulator on page 66 1 Check whether axial piston unit and gearbox assembly and the hydraulic hoses and the pressure accumulators have cooled down sufficiently for the hydraulic fluid to be drained off safely Wear suitable protective clothing as hot hydraulic fluid could cause burns Place a drip tray under the components to be drained to collect any hydraulic fluid that may escape DANGER Risk of injury from hydraulic system under pressure When the drain valve is closed a very high pressure can build up due to the effect of heating and this could cause severe injuries when disconnecting the hydro pneumatic pressure accumulator Check the pressure at the hydro pneumatic pressure accumulator immediately before disconnecting Before disconnecting the hydro pneumatic pressure accumulator from the system make sure that the hydro pneumatic pressure accumulator is completely depressurized Before dis
109. s For cleaning and care of the HRB observe the following gt Check whether all seals and fittings on the connections are securely seated to ensure that no moisture can penetrate into the HRB components during cleaning Use only water and if necessary a mild detergent to clean the HRB components Never use solvents or aggressive detergents Remove external coarse dirt and keep sensitive and important components such as solenoids valves indicators and sensors clean Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Maintenance and repair 69 112 10 2 Inspection A CAUTION Malfunctions complete HRB system failure following an accident After an accident malfunctions and or a complete HRB system failure could occur After an accident stop the vehicle apply the parking brake switch off the ignition and slowly open the manual drain valve of the HRB Check the HRB for signs of leaking oil and initiate containment measures accordingly e g notify emergency services and or drain off the hydraulic oil from the hydraulic reservoir Damaged high pressure components are to repaired on the spot or the vehicle will have to be towed away If high pressure components are defective the vehicle can only be towed away with the cardan shaft removed between the HRB gearbox and the rear axle differential The ignition should be switched off Have a detailed inspection of the HRB performed Here the complete system is to be checked for
110. s given by Bosch Rexroth Service Please consult your responsible Bosch Rexroth Customer Support Agent Operation of the HRB requires extensive knowledge of the information given in chapter 9 Operation on page 60 of this document 2 5 General safety instructions e Observe the applicable accident prevention and environmental protection regulations e Observe the safety regulations and provisions of the country in which the product is used operated e Use Rexroth products only when they are in good technical order and condition e Observe all notes on the product e Persons who install commission operate remove or maintain Rexroth products must not consume any alcohol drugs or pharmaceuticals that may affect their ability to respond e Only use Rexroth original accessories and spare parts to ensure there is no risk to persons from unsuitable spare parts e Conform to the technical data and ambient conditions specified in the product documentation e If unsuitable products are installed or used in applications that are of relevance to safety unexpected operating conditions may occur in the application which could result in injury to persons or property damage For this reason only use the product in a safety relevant application if this use is expressly specified and permitted in the product documentation for example in ex protection applications or in safety related parts of a control system functional safety Bosch Rexroth AG
111. s may occur in the HRB components which make recommissioning necessary Among others the following criteria may make recommissioning necessary e Longer vehicle standstill periods e Air and or water in the hydraulic system e Old hydraulic fluid e Other contamination Before recommissioning proceed as described in chapter 8 1 First commissioning on page 55 RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 60 112 Operation 9 Operation Vehicle or manufacturer specific explanations can be found in the appendix under chapter 15 1 Vehicle and manufacturer specific details on page 103 9 1 Control and indicator elements 9 1 1 Indicators A WARNING Danger due to undisplayed system errors If the status indicators are not functional system errors are not displayed for the driver If the status indicators do not illuminate briefly after starting the ignition and as a result the indicator test fails contact your Bosch Rexroth Service partner There are up to five status indicators in the vehicle that are relevant to the HRB see Fig 27 and Fig 28 Fig 27 shows an example of a central indicator instrument on the Mercedes Benz Actros The red status indicator and the yellow status indicator service must always be directly in the driver s field of vision Please note if the red status indicator and the yellow status indicator service are only shown via a display it must be directly in the driver s field of vis
112. s of damage and for correct seating gt Use the data sheet and the electric circuit diagram to check whether the fuses were properly dimensioned and correctly installed Make sure that the vehicle battery is connected and the ignition is switched on before testing the Visual indicators and the HRB button Check that all visual indicators for the HRB components are connected and that they light up correctly when they are activated gt Press the HRB button The green status indicator HRB ready goes out 8 1 5 System commissioning To commission the system you will need several tools for specifications please consult your Bosch Rexroth Service partner see chapter 10 8 Spare parts on page 85 or the data sheet for address Please also contact your Bosch Rexroth Service partner for instructions on how to perform commissioning and the related documents for the acceptance tests that have to be conducted on all vehicles 8 2 Recommissioning after standstill MA CAUTION Risk of damage by hydraulic fluid loss After long standstill periods the axial piston unit and gearbox assembly may drain via the case drain line air enters via the shaft seal ring or via the service line gap leakage The bearings are thus insufficiently lubricated for recommissioning Check the hydraulic fluid level in the hydraulic reservoir regularly if necessary recommission Depending on the installation conditions and ambient conditions change
113. service check pin yellow status indicator L service for short circuit to B yellow HRB status indicator service check pin yellow status indicator L service for short circuit to earth yellow HRB status indicator high low temperature check pin yellow status indicator L high low temperature for short circuit to B 1 If error occurs in combination with P3014 P3134 P3209 P324E and P3259 see P324E 2 yellow status indicator L high low temperature check pin yellow status indicator L high low temperature for short circuit to earth contact Bosch Rexroth Service RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 102 112 Technical data 15 Technical data Maximum hydraulic pressure Operating speed range HRB torques on cardan shaft Hydro pneumatic pressure accumulator HRB control unit SRC6 32 Ambient temperature in operation Additional weight System service life 325 bar pressure safeguarding approx 1 km h to HRB limiting speed depends on gearbox configuration Depends on gearbox ratio Satisfies pressure vessel directive 97 23 EC Satisfies EMC directive 72 245 EEC 20 C to 50 C approx 500 kg depending on system approx 10 years for refuse vehicles in rear loader configuration 2 shift operations and 200 working days per year service life of pressure accumulator in accordance with pressure accumulator system approval The permissible technical data of the HRB can be found in da
114. sonnel qualifications General safety instructions Product specific safety instructions Personal protective equipment General instructions on damage to equipment and the product Delivery contents About this product General system description Function principle Operating conditions Starting activating for drive mode Torque distribution Delaying Acceleration Normal drive mode Standstill Driving dynamics Deactivating the HRB Heat management Interfaces Software Prerequisite Function Operation Diagnostics Component overview Product identification 3 112 OOO O WO ON N DODD OW DDD NYY NYNYNYNNYNNYNNYNYVNYNNYNNNYNNY YN KF FP FP PR RFP KF BF 9 oO Oo Oo KR BP PPwWWwWBwWBwWWNHRR RFR TOO OO WOK POO RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 4 112 Contents 6 1 6 2 6 2 1 6 2 2 6 2 3 6 2 4 6 3 7 1 7 2 1 3 7 4 17 4 1 1 4 2 7 4 3 7 4 4 7 4 5 7 4 6 1 4 7 7 4 8 7 4 9 8 1 8 1 1 8 1 2 8 1 3 8 1 4 8 1 5 8 2 9 1 9 1 1 9 1 2 91 3 9 1 4 9 2 9 2 1 9 22 9 2 3 9 2 4 9 2 9 Transport and storage Dimensions and weights Transporting the HRB Transporting by hand Transporting the axial piston unit and gearbox assembly Transporting the HRB manifold Transporting the pressure accumulator Storing HRB components Installation Unpacking Installation conditions Installation positions Installing the HRB Preparation Dimensions General instructions Installing the HRB components
115. st Gearbox _ G1 G2 G6 Gd G5 See data sheet Port is marked on the axial piston unit and gearbox assembly Depending on climatic conditions other hydraulic oils may also be used upon consultation with Bosch Rexroth Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Installation 37 112 7 4 Installing the HRB 7 4 1 Preparation 1 Compare the material number designation ordering code and configuration of the intended vehicle with the specifications in the order confirmation If the material numbers of the components do not correspond to those in the order confirmation contact Bosch Rexroth Service for clarification see chapter 10 8 Spare parts on page 85 for address Secure the vehicle apply the handbrake use chocks and remove the ignition key e e Disconnect the vehicle battery in accordance with the vehicle manufacturer s instructions 7 4 2 Dimensions The installation locations for the HRB manifold pilot oil supply hydro pneumatic pressure accumulator and HRB control unit depend on the vehicle type and vehicle body The installation drawing contains dimensions for all ports for HRB components and the permissible securing options Also observe the manuals provided by the manufacturers of the other hydraulic components when selecting the required tools 7 4 3 General instructions e The axial piston unit and gearbox assembly can be installed in the vehicle from above using a lifting device or from below from
116. t The personal protective equipment is the responsibility of the user of the HRB Observe the safety regulations and provisions of your country All components of the personal protective equipment must be intact Bosch Rexroth AG HRB RE 94850 01 B 10 2012 General instructions on damage to equipment and the product 15 112 3 General instructions on damage to eauipment and the product The following instructions apply for chapters 6 to 14 Danger from improper handling Product can be damaged gt Do not expose the product to an impermissible mechanical load Never use the product as a handle or step Do not place lay any objects on the product Do not strike the flange of the axial piston unit and gearbox assembly Do not place or set the axial piston unit and gearbox assembly down on the flange Carefully set down the axial piston unit and gearbox assembly Do not strike fittings e g sensors or valves Do not strike sealing surfaces e g service line ports Leave the protective covers on the axial piston unit until shortly before the lines are connected Before performing any electro welding and painting operations on the vehicle the battery must be completely disconnected Make certain that the electronic components e g sensors do not become electrostatically charged e g during painting operations Damage to equipment due to improper lubrication Product can be damaged or destroyed Never operate the axial piston u
117. ta sheet RE 94850 If you do not have the data sheet request it from your responsible contact partner at Bosch Rexroth Further information can be found on website www boschrexroth com hrb Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Amendment to chapter 5 3 Operating conditions on p 21 Amendment to chapter 5 3 3 Delaying on page 21 Amendment to chapter 5 3 4 Acceleration on page 22 Amendment to chapter 5 3 7 Driving dynamics on page 23 Amendment to chapter 5 3 9 Heat management on page 23 Amendment to chapter 9 1 4 Setting the HRB braking effect section Level switch preselector on page 63 Technical data 103 112 15 1 Vehicle and manufacturer specific details 15 1 1 Mercedes Benz The function of the HRB level switch is realized using levels 3 4 and 5 of the retarder lever Levels 1 and 2 of the retarder lever are reserved for the engine brake If the vehicle is decelerated by the HRB a brake torque output from the combustion engine is suppressed The maximum pressure in the system is limited by a pressure relief valve On reaching the maximum pressure the equivalent of maximally charged hydro pneumatic pressure accumulators and continued braking with HRB no more braking energy is stored The HRB does however continue to supply a delaying torque In such cases heat is specifically induced into the hydraulic system via the pressure relief valve until the maximum operating temperature
118. ted it must be plugged with a threaded plug because protective plugs are not pressure resistant RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 42 112 Installation 7 4 7 Hydraulically connecting the HRB A DANGER Risk of personal injury and damage to equipment If installation work is performed on a hydraulic system or pressure accumulator that has not been depressurized and or in the event of damage caused by an accident there is an increased risk of injury from the pressure accumulator bursting or from hydraulic fluid escaping under high pressure Before hydraulically connecting the HRB the manual drain valve 1 for the hydro pneumatic pressure accumulator in the HRB manifold must be opened see Fig 16 Open the valve slowly Fig 16 HRB manifold with manual drain valve 1 Drain valve 2 Gauge port HD1 MA CAUTION Risk of damage to the HRB components When installing hydraulic lines and hoses under mechanical stress they are exposed to additional mechanical forces during operation which reduce the service life of the HRB components and of the entire vehicle Install hydraulic lines and hoses without mechanical stress Damage to hydraulic lines system and oil leaks Rigid piping between HRB components that can move relative to each other could develop leaks or burst Make sure that relative movement is possible even between HRB components that are securely fixed to the vehicle frame at different positions
119. the event of a malfunction burst high pressure components e g hoses hydro pneumatic pressure accumulator etc or leakage within the hydraulic system could cause injury The HRB components must be installed so that they are not freely accessible Make sure that the high pressure components are suitably protected against bursting e g by protective hoses and screening plates Pressure 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 hydro pneumatic pressure accumulators Do not modify the hydro pneumatic pressure accumulator or its components RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 12 112 Safety instructions A WARNING Danger from excessively high pressure Danger to life or risk of injury damage to equipment Incorrectly changing the factory pressure setting can cause pressure to increase beyond the permissible maximum pressure Operating the unit above the permissible maximum pressure can cause components to burst and hydraulic fluid to escape under high pressure Changes to the factory settings must only be made by Bosch Rexroth specialist personnel Danger from suspended loads Danger to life or risk of injury damage to equipment Improper transportation may cause the HRB to fall down and could lead to injuries e 2 8
120. the size of female thread and threaded plugs e g locking screw must all match Due to the limited options for visually detecting differences there is a risk of mix ups WARNING Leaking or popped out threaded plugs If a threaded plug which is of a different measurement system kind of seal and size with respect to the female thread is pressurized the threaded plug may loosen itself or even be ejected from the hole in a projectile like manner This can result in serious injury and damage to equipment Hydraulic fluid or lubricating oil could escape from this leakage point Use the drawings installation drawing to determine the required threaded plug for each fitting Make certain that there are no mix ups when installing fittings mounting bolts and threaded plugs For all female threads use a threaded plug from the same system of units and of the correct size Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Port overview Installation 45 112 In the following figures and tables the ports to the HRB components are illustrated and specified Fig 17 Port overview of HRB components Detail 1 Fig 18 Port overview detail 1 RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 46 112 Installation Fig 19 Port overview of HRB components Fig 20 Port overview of HRB components Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Installation 47 112 Fig 21 Port overview of HRB components Fig
121. the working environment at the installation site is fully free of dust and foreign substances in order to prevent contaminants from getting into the hydraulic lines and causing product wear and malfunctions The HRB components must be installed in a clean condition Use only clean ports hydraulic lines and attachments e g measuring device No contaminants may enter the ports when they are plugged Before commissioning make sure that all hydraulic connections are tight and that all of the connection seals and plugs are installed correctly to ensure that they are leakproof and fluids and contaminants are prevented from penetrating the product To fill the axial piston unit and the HRB clutch with hydraulic fluid use a fine filter filling unit with a microglass element and a fineness of 3 um To fill the gearbox with lubricating oil use a fine filter filling element with a microglass element and a fineness 3 um Improper cleaning Product can be damaged Plug all openings with the appropriate protective equipment in order to prevent detergents from entering the hydraulic system Never use solvents or aggressive detergents Use only water and if necessary a mild detergent to clean the HRB components Do not point the power washer at sensitive components e g seals electrical components and plug connections Use lint free cloths for cleaning Bosch Rexroth AG HRB RE 94850 01 B 10 2012 General instructions on damage to equipme
122. tic regenerative braking system Model Type HRB series 1 index 0 Serial number Ordering code and part number according to delivery note Trade name Hydraulic hybrid from Rexroth Hydrostatic regenerative braking system HRB Year of construction since 2009 was developed designed and manufactured in compliance with the above mentioned EU directive Harmonized Standards applied DIN EN 14359 National Standards and Technical Specifications applied AD 2000 Notified body that has conducted the EC type examination procedure in accordance with the above mentioned directive approved the full quality assurance system in accordance with the above mentioned directive Name TUV Rheinland Industrie Service GmbH Address Am Grauen Stein DE 51105 Cologne Identification number 0035 No of EC type examination certificate 12 K641 2897 058 The individual below is authorized to compile the relevant technical files Name Address Further explanations The notes in documents RE 94850 instruction manual data sheet interface description data network concept and any others must absolutely be observed Place date signature as indicated in the original declaration We reserve the right to make changes to the content of the Declaration of Conformity Current issue on request RE 94850 01 B 10 2012 HRB Bosch Rexroth AG Bosch Rexroth AG Mobile Applications Glockeraustra e 4 89275 Elchingen Germany Tel 49 7308 82 0 Fax
123. tifies a dangerous situation that may result in minor to A CAUTION moderate injuries if it is not avoided NOTE Property damage The product or the environment may be damaged 1 3 2 Symbols The following symbols mark notes that are not safety relevant but which increase the understanding of the documentation Table 3 Meaning of the symbols Symbol Meaning If this information is disregarded the product can not be used and or operated to the optimum extent Single independent step Numbered instruction The numbers specify that the steps are completed one after the other me RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 8 112 About this manual 1 3 3 Designations This documentation uses the following designations Table 4 Designations Designation Meaning HRB Hydrostatic Regenerative Brake system hydraulic hybrid Threaded plug Metal screw pressure resistant Protective plug Made out of plastic not pressure resistant only for transportation The designation HRB will be used as an umbrella term for the HRB hydrostatic regenerative braking system 1 3 4 Abbreviations This documentation uses the following abbreviations Table 5 Abbreviations Abbreviation Meaning ABS Anti locking Brake System ADR Accord europ en relatif au transport international des marchandises Dangereuses par Route European agreement concerning the international transportation of hazard goods on the road CAN Controller Area Ne
124. to the specified application conditions pressure flow hydraulic fluid temperature with the necessary safety factors High pressure components that could cause injury to persons on account of their position are to be suitably shielded e g with protective hoses or screening plates Connect only hydraulic lines that are appropriate for the ports of the HRB components pressure level size system of units Observe the following notes when routing the suction pressure and reservoir lines e Lines and hoses must be installed without pre charge pressure so that no further mechanical forces are applied during operation that will reduce the service life of the axial piston unit and gearbox assembly and if applicable the vehicle Use suitable seals as sealing material Suction line pipe or hose The suction line should be as short and straight as possible Measure the line cross section of the suction line so that the pressure at the suction port does not drop below the minimum permissible pressure Make sure that the maximum suction pressure is not exceeded e g when pre filling Make sure the connections and connecting elements are air tight The hose must be pressure resistant also for external air pressure RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 44 112 Installation e Pressure line For the pressure lines use only pipes hoses and connecting elements rated for the operating pressure range specified in dat
125. tor valve 8 The pilot oil accumulator cannot be loaded through the prefill valve in the state neutral in less than 5 sec 9 check pump pressure sensor signal see P3004 1 reducing the pressure via adjusting the blow off valve Check the operation of the blow off valve while braking signal accumulator pressure 2 check the blow off valve adjustment and correct the adjustment to max 305 bar approx 95 SOC if necessary check sensor connectivity of APU suction pressure temperature sensor PTS according to P3005 check the prefill pressure check the accumulator bladder 1 check sensor connectivity of APU swivel angle sensors according to P3008 2 check the offset in the neutral position sensor calibration signal swivel angle 1 and 2 pump 3 check operationality of solenoids wiring of APU A motor direction SA and APU B pump direction SB specification solenoid coil voltage resistance current 24 V 21 7 Q 0 73 A auxiliary accumulator supply and pump activation 4 check fuses check the speed sensors and signals pin configuration see P3002 and P3003 Table 19 Error code list P code 3026 3027 3028 3029 3030 3031 Description Diagnostics Tool Pump turns when clutch released Pressure supply preload pressure Preload pressure too low Pressure drop on braking faulty Pressure reduction in accumulator Duration too long Transmission oil temper
126. ture sensor PTS Check the sensor supply voltage 5 V APU high pressure PPS Pilot accumulator pressure PAS Check the sensor supply voltage 5 V Analogue torque selector Braking pressure BPS controller problem contact Bosch Rexroth Service controller problem contact Bosch Rexroth Service controller problem contact Bosch Rexroth Service crosscheck controller temperature 35 150 C contact Bosch Rexroth Service crosscheck controller temperature 35 150 C contact Bosch Rexroth Service RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 100 112 Troubleshooting Table 19 Error code list P code 3229 3230 3231 3232 3233 3234 3235 3236 3237 3238 3239 3240 3241 Description Diagnostics Tool Control unit temperature sensor above upper limit Control unit temperature sensor below lower limit Communication with ActEngTorque ACAN Message not plausible Communication with DesEngTorque ACAN Message not plausible Communication with RefEngTorque ACAN Message not plausible Communication with TSC 1 ACAN faulty TSC 1 Message overwritten faulty CAN data bus F malfunction faulty Communication with vVeh ACAN Message not plausible CAN speed and gear with respect to propshaft speed signal improbable Monitoring ABS ASR diagnosis in run on faulty Monitoring Fault in ADC faulty Monitoring Var
127. tus indicator is lit the axial piston unit could be damaged when towing Before towing remove the cardan shaft between the HRB gearbox and the rear axle differential if the red status indicator is illuminated The ignition must be switched off for towing CAUTION Transport a vehicle with HRB on a low loader Compressed gas containers are transported with the vehicle meaning that the relevant hazardous goods regulations valid in the country concerned must always be observed However because the pressure accumulator is installed in the vehicle transport is not covered by the ADR regulations regulations for hazardous goods on the road SO no measures are necessary in this regard The vehicle can be towed away To do this either the HRB gearbox must be disconnected from the rear axle differential remove rear cardan shaft ora recovery trailer is to be used on which the vehicle can be loaded so that the rear axle of the transported vehicle does not turn during transport Yellow status indicator service The HRB is due for maintenance The HRB is not available but this does not represent a risk Have the cause checked and eliminated as quickly as possible by your Bosch Rexroth Service partner see chapter 10 8 Spare parts on page 85 for address RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 62 112 Operation Yellow status indicator high low temperature optional The system is temporarily unavailable The oil tem
128. twork CCM Customer Control Module DIN Deutsche Industrie Norm German Institute for Standardization EN European Norm standard h Operating hours HCU HRB control unit HRB Control Unit ISO International Organization for Standardization PSM Programmable Special Module RE Rexroth document in the English language SOC State Of Charge TCS Traction Control System VDI 2230 Directive for the systematic calculation of high duty bolted joints and joints with one cylindrical bolt from the VDI Verein Deutscher Ingenieure Association of German Engineers Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Safety instructions 9 112 2 Safety instructions 2 1 About this chapter The HRB has been developed in accordance with the generally accepted rules of current technology There is however still a danger of personal injury or damage to equipment if this chapter and the safety instructions in this documentation are not complied with Read this documentation completely and thoroughly before commissioning the HRB Keep this documentation in a location where it is accessible to all users at all times gt If the vehicle in which the HRB 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 HRB is designed for use in commercial vehicles and mobile working machines The product is exclusively intended to be installed in the vehicle type specified in t
129. ualifications The activities described in this documentation require basic mechanical electrical and hydraulic knowledge as well as knowledge of the associated technical terms For transporting and handling the product additional knowledge is necessary with regard to working with a lifting device and the corresponding attachment equipment In order to ensure safe use these activities may therefore only be performed by appropriate qualified personnel or an instructed person under the direction and supervision of qualified personnel Qualified personnel are those who can recognize possible hazards and institute the appropriate 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 Qualified personnel must observe the rules relevant to the subject area and have the necessary hydraulic knowledge Hydraulic knowledge means for instance e reading and fully understanding hydraulic plans e fully understanding in particular the interrelationships regarding safety devices and e having knowledge on the function and assembly of hydraulic components Installation commissioning removal care and maintenance of the HRB must only be performed in accordance with the Rexroth specifications in this manual and with the documents listed in Table 1 Required and supplementary documentation on page 6 or in accordance with instruction
130. umulator Filling the axial piston unit To prevent damage to the axial piston unit and gearbox assembly and to maintain and gearbox assembly correct function professional filling and air bleeding is necessary Bosch Rexroth AG HRB RE 94850 01 B 10 2012 il Commissioning 57 112 Gearboxes and hydraulic circuits are two separate systems Observe the respective requirements for cleanliness of the used fluids When filling use appropriate filling units with a microglass element Make certain that the suction line is always filled with hydraulic fluid during commissioning and operation filter grade of filling unit 3 um The axial piston unit and gearbox assembly should be filled with a filling unit 3 um filter grade Bosch Rexroth recommends that all filters be of a type with microglass element in order to maintain the required filtration rates During commissioning and during operation the gearbox must also always be filled with lubricating oil Observe the notes on filling the HRB clutch prior to moving the vehicle The approved hydraulic fluids for the hydraulic circuit and the lubricating oil for the gearbox can be found in the data sheet e Place a drip tray under the axial piston gear unit to collect any hydraulic fluid that may escape Fill and air bleed the axial piston unit and gearbox assembly via the appropriate ports see chapter 7 3 Installation positions on page 35 and chapter 7 4 7 Hydraulically connecti
131. ve high Fault check SCG external pilot pressure high Fault check SCB engine brake not permitted low Fault check SCB green lamp Fault check SCG green lamp Fault check SCG power relay 1 Fault check SCG power relay 2 Fault check SCG power relay 3 Fault check SCG power relay 4 Fault check SCG power relay 5 Fault check SCB red lamp Fault check SCG red lamp Fault check SCB retarder active low Fault check SCB white lamp Fault check SCG white lamp Fault check SCB yellow lamp Fault check SCG yellow lamp Fault check SCB yellow temperature lamp Fault check SCG yellow temperature lamp KTS connected to Hybrid control unit Troubleshooting 101 112 Measures check the parameterization of the retarder steps with the diagnosis tool concerns the analogue torque selector retarder lever gt menu adjustments settings preselector lever check the parameterization of of the collecting mode in the diagnosis tool menu adjustments settings joint operation collecting mode check the parameterization of the vehicle variant in the diagnosis tool menu adjustments settings variant coding Pilot pressure valve PV check pin pilot pressure valve H for short ciruit to earth External pilot pressure valve EPV check pin external pilot pressure H for short circuit to earth Signal inhibit engine brake check pin inhibit engine brake L for short circuit
132. vice partner see chapter 10 8 Spare parts on page 85 for address about the necessary commissioning accessories e g testing and filling equipment for the hydro pneumatic pressure accumulator control unit measuring adapter diagnostics tester software etc see data sheet 8 1 First commissioning A CAUTION Risk of damage to the product Dry running roller bearings and sealing elements lead to wear and damage of components gt Before operating the vehicle always perform HRB commissioning During this process the axial piston unit and gearbox assembly is filled with hydraulic fluid and lubricating oil During all work for commissioning the HRB components observe the general safety instructions and intended use detailed in chapter 2 Safety instructions on page 9 During the commissioning process monitor the temperature of the hydraulic fluid in the reservoir to ensure that it lies within the permissible viscosity limits RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 56 112 Commissioning 8 1 1 Hydraulic mechanical commissioning Perform hydraulic mechanical commissioning as described in the following sections Check component gt Make sure that all mounting bolts for the HRB components are tightened in fasteners accordance with the tightening torques stated in the installation drawing Checking hydraulic Check all hydraulic connections as stated in the hydraulic circuit diagram for connections damage and f
133. wait until the pressure is completely drained gt Before beginning the maintenance work pressure must be relieved in the hydraulic system and the hydraulic components via the specified ports see chapter 9 2 4 Manually draining the pressure accumulator on page 66 The following notes about changing hydraulic fluid are to be observed 1 The hydro pneumatic pressure accumulators are to be drained manually see chapter 9 2 4 Manually draining the pressure accumulator on page 66 Slowly open the drain valve and leave the drain valve open throughout the entire maintenance process 2 Check whether the axial piston unit and gearbox assembly and the hydraulic hoses have cooled down sufficiently for oil to be drained off safely Wear suitable protective clothing as hot oil could cause burns 3 Place a drip tray under the components to be drained to collect any hydraulic fluid that may escape 4 Drain off the hydraulic fluid from the hydraulic reservoir through the relevant port in accordance with the manufacturer s instructions 5 The hydraulic fluid in the axial piston unit is to be drained at the port defined in chapter 7 3 Installation positions on page 35 6 The hydraulic fluid in the hydraulic lines between the hydro pneumatic pressure accumulators and the HRB manifold can be drained via port HD2 on the HRB manifold 7 Drain off the pressure in the pilot oil system as follows Hold a pressure gauge line with a miniature gau
134. werstage switched off 0x04 Error with powerstage switched off 0x08 No HRB release or monitoring control fault not defined Global parameter Value outside tolerance Propshaft speed sensor faulty Pump speed sensor faulty Troubleshooting 91 112 Measures 1 Load pilot oil supply or see P3016 2 See below decription of HRB Fct Status 3 Check wiring of Engine running ACTIVE gt 5 V INACTIVE lt 1 V 4 See P3239 5 Activate HRB torque level switch or analogue torque selector otherwise see P3214 5a Activate HRB torque level switch and check wiring 5b Activate analogue HRB torque selector and check wiring 6 Disable cruise control and check wiring ACTIVE gt 5 V INACTIVE lt 1 V 7 see P3002 see P3003 see P3004 P3005 P30019 P3186 see P3008 P3024 16 see P3006 32 see P3004 64 see P3008 128 see P3008 8 Check wiring of Ignition and fuse F3 9 See P3240 10 Is HCU installed in right vehicle Is the right variant chosen Further see points 2 4 5 11 Check if vehicle speed is in the valid range a gear is selected unequal Neutral and there is no clutch slip vehicle clutch 12 Contact Bosch Rexroth Service CO KR NM FB 0x00 no troubleshooting needed Ox01 activate HRB by HRB button and check if the vehicle is in the valid velocity range 0x02 solve the problem according to P Code s 0x04 when no yellow status indicator than s
135. with HD1 at the HRB manifold see Fig 30 Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Operation 67 112 9 2 5 Manually draining the pilot oil accumulator A CAUTION Risk of personal injury and damage to equipment The accumulator will remain charged with nitrogen after the oil has been drained The pressure will be at least 30 bar After performing maintenance work close the miniature gauge port again The hydraulic pressure in the pilot oil accumulator can be manually relieved at the gauge port 1 in the gearbox control block see Fig 31 Fig 31 Accumulator drain valve 1 Gauge port MPG RE 94850 01 B 10 2012 HRB Bosch Rexroth AG 68 112 Maintenance and repair 10 Maintenance and repair Inspection and maintenance work carried out too late Damage to equipment Carry out the specified inspection and maintenance work at the intervals described in this manual 10 1 Cleaning and care A WARNING Risk of personal injury and damage to equipment Improper repairs and maintenance could cause damage to the vehicle and or personal injury Do not attempt to repair or service the HRB without the necessary technical knowledge and tools Damage to seals and electrical system by mechanical effects The water jet of a power washer may damage the seals and electrical system of the HRB components Do not point a power washer at sensitive components e g seals electrical components and plug connection
136. x assembly Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Check level of the hydraulic fluid in the reservoir Check the normal operating temperature comparable load condition Check quality of the hydraulic fluid At a minimum degree of cleanliness of 19 17 14 according to ISO 4406 must be ensured optimum is 17 15 11 see data sheet Check the HRB for leakage Early detection of a loss of hydraulic fluid can help to identify and eliminate errors on the HRB For this reason Bosch Rexroth recommends that the hydraulic system always be kept in a clean condition Check the manual drain valve for free movement and function If installed check the mechanical contamination indicator of the filter perform filter maintenance if necessary Check the electric wiring system for routing and signs of damage visual check Visual check of hydraulic lines for routing leaks and damage abrasion cuts cracks Check the pre charge pressure Po and set to the correct value The status of the accumulator bladder must be checked regularly This status depends on the number of cycles completed Visual check for rust mechanical damage leaks secure mounting If rust is found on the gas filling valve this must be replaced To do this observe the instructions in chapter 10 4 3 Checking the interior of the hydro pneumatic pressure accumulator on page 75 Check the axial piston unit and gearbox assembly for noise developme
137. y 10 4 Maintenance instructions A CAUTION Risk of personal injury and damage to equipment Performing maintenance work on HRB components that are not depressurized could cause hydraulic fluid to escape under high pressure which could cause injury or property damage Before performing maintenance work switch the ignition off and wait until the pressure is completely drained Before performing maintenance work the pressure in the hydro pneumatic pressure accumulator must be completely discharged The HRB components can be transported with a forklift truck or with a lifting device Before transport make certain that the forklift truck or lifting device has adequate lifting capacity Before performing maintenance work on the hydraulic system the pressure in the hydro pneumatic pressure accumulator must be completely discharged As a rule this happens automatically within about 5 minutes with a filled reservoir volume of 64 after switching off the ignition audible whirring noise However for reasons of safety the manual drain valve 1 must also be opened slowly after this time has elapsed This is fitted to the HRB manifold see Fig 32 Bosch Rexroth AG HRB RE 94850 01 B 10 2012 Maintenance and repair 73 112 Fig 32 Manual drain valve 1 Drain valve 2 Gauge port HD1 A pressure measuring device e g pressure gage must be used at one of the provided ports port HD1 2 on the HRB manifold see Fig 32 t

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