Sie sind auf Seite 1von 35

USER MANUAL

OPERATION
MAINTENANCE
REPAIR

HYDRAULIC SYSTEM
TRIDEC AXLE STEERING SYSTEMS
WITH MANUAL STEERING

HY-404-En 04-08
This documentation has been compiled with the utmost care.
However, we cannot be held responsible for any inaccuracies or omissions.

© Copyright Tridec b.v. Son, Holland.


No part of this document may be reproduced and/or published by print, photocopy, microfilm
or by any other means without prior written permission from Tridec b.v.

tel: + + 31(0)499 - 491050


TRIDEC® Son-Holland
fax: + + 31(0)499 - 491060

2 04-08 HY-404-En
CONTENTS

1 Safety ..............................................................................................................................5
2 Technical data.................................................................................................................6
2.1 Electrical system.......................................................................................................6
2.2 Hydraulics.................................................................................................................6
2.3 Delivery.....................................................................................................................6
2.4 Special tools .............................................................................................................6
2.5 Oil specifications.......................................................................................................7
3 Description ......................................................................................................................8
3.1 Co-steering wheels...................................................................................................8
3.2 Manual steering ........................................................................................................9
4 Operation ......................................................................................................................10
4.1 Compact manual steering.......................................................................................10
4.1.1 Shunting............................................................................................................10
4.1.2 Setting the wheels in the straight-ahead position after shunting ......................11
4.2 Emergency operation .............................................................................................12
5 Maintenance .................................................................................................................13
5.1 Maintenance intervals.............................................................................................13
5.2 Visual inspection of the system ..............................................................................13
5.3 Draining oil..............................................................................................................13
5.4 Adding oil and bleeding ..........................................................................................14
5.4.1 Primer pump circuit...........................................................................................14
5.4.2 Manual steering circuit......................................................................................14
5.5 Aligning wheels.......................................................................................................15
5.5.1 General .............................................................................................................15
5.5.2 Checking wheel positions .................................................................................15
5.5.3 Straightening the semi-trailer axle(s) ................................................................16
6 RepaIrs .........................................................................................................................17
6.1 Electrical system.....................................................................................................17
6.1.1 Replacing fuses ................................................................................................17
6.1.2 Changing bulb, warning lamp L1, L2 and L3 ....................................................17
6.1.3 Adjusting/replacing sensors..............................................................................17
6.1.4 Electric motor (3 kW) for oil pump ....................................................................18
6.2 Electrical diagrams and connections in switch box ................................................19
6.3 Hydraulic system ....................................................................................................21
6.3.1 Replacing entire power pack box......................................................................21
6.3.2 Replacing oil pump and electric motor (3 kW) ..................................................21
6.3.3 Replacing oil pump ...........................................................................................22
6.3.4 Depressurising hydraulic system for repair.......................................................23
6.3.5 Measuring oil pressure per circuit.....................................................................23
6.3.6 Replacing oil pump in the compact hydraulic block ..........................................23
6.3.7 Replacing pressure switch................................................................................24
6.3.8 Replacing changeover valve.............................................................................24
6.3.9 Replacing bypass cocks ...................................................................................24
6.3.10 Replacing compact hydraulic block...............................................................25
6.4 Line connections in the vehicle...............................................................................25
6.4.1 General .............................................................................................................25
6.4.2 HS, linear implementation.................................................................................26
6.4.3 HS, progressive implementation.......................................................................26

HY-404-En 04-08 3
6.4.4 HF, linear implementation.................................................................................27
6.4.5 HF, progressive implementation .......................................................................27
6.4.6 HF-E, linear implementation .............................................................................28
6.4.7 HF-E, progressive implementation ...................................................................28
6.4.8 Rule of thumb for the connection of hydraulic lines ..........................................28
7 Faults ............................................................................................................................29
7.1 Fault-finding table, hydraulic system ......................................................................29
7.2 Fault-finding table, electrical system ......................................................................30
8 Parts..............................................................................................................................31
8.1 Ordering parts.........................................................................................................31
8.2 Cylinders and lines .................................................................................................31
8.3 Control box .............................................................................................................32
8.4 Power pack box ......................................................................................................34

4 04-08 HY-404-En
1 SAFETY

If this symbol is shown, information is provided that is intended to prevent injury or a


life-threatening situation.

If this symbol is shown, information is provided that is intended to prevent damage


to the system.

Failure to follow these instructions may result in damage for which Tridec accepts no
liability.

Driving with the steering system


− The steering characteristic of a steered semi-trailer differs from that of a non-steered one.
− Remember that when cornering a steered semi-trailer will show different steering
behaviour from a non-steered one.

Maintenance operations on the steering system


− The steering system is a safety-critical system. Carry out the maintenance procedures
carefully. Failure to work carefully may result in damage and/or an accident.
− Chock the wheels of the semi-trailer safely when working underneath it.
− Place solid blocks under the semi-trailer when carrying out work involving the removal of
wheels.
− When removing heavy components, use hoisting apparatus or support them in a safe
manner.
− Avoid unnecessary contact with oil and lubricants.
Apply protective lotion to unprotected body parts.
− Stay at a safe distance from the moving parts when activating the hydraulic components.
− The surface of the cylinder piston rods can easily be damaged.
Damage to the surface will result in leakage.
− To test hydraulic components, use apparatus that is suitable for the high pressures that
occur in the hydraulic system.
− Use only original Tridec parts for maintenance and repair purposes.

Environment
− Do not dump used oil, lubricant or hydraulic fluid in drains, sewers or into the ground.
Such practices are not only illegal, but also seriously pollute the environment.
− Used oil, lubricant and hydraulic fluid should be returned to the designated authority or
appropriate waste chemicals collection company for recycling.
All used fluids should be stored separately.
− Used batteries should be returned to the designated authority or appropriate waste
chemicals collection company for recycling.

HY-404-En 04-08 5
2 TECHNICAL DATA
2.1 ELECTRICAL SYSTEM
In-vehicle voltage 24 V
Fuses in switch box 7,5 A

Power rating of oil pump electric motor 3 kW


Fuse for electric motor (slow-blow) 200 A

2.2 HYDRAULICS
Hydraulic hoses: Ø ½", DIN 20022/4 - 2SN, SAE 100R2AT, EN 853
Bending radius ≥ 180 mm.
Hydraulic lines Ø ½", DIN 2445/2 - 1974.
Tolerances and execution in accordance with DIN 2391 - 1981
Material in St 37.4 to DIN 1630.
Hydraulic couplings DIN 20022/2 -SN

2.3 DELIVERY
For the data relevant to the delivered equipment, see the corresponding shipping order
and/or order specification.

Quant. Name Note


1 Control box, hydraulic steering system
Remote control, hydraulic steering system
1 Generator cabinet with electrically-driven oil pump
*) Oil for generator cabinet with 14 litre tank 10 litres
*) Oil for generator cabinet with 30 litre tank 25 itres
1 Pump actuating rod

*) Dependant on order specs

2.4 SPECIAL TOOLS


Quant. Name Note
4 Oil pressure gauges, cpl. with hose and connection nipples 0 - 250 bar
These are standard hydraulic tools (commercially available).

- Alignment equipment (commercially available).

6 04-08 HY-404-En
2.5 OIL SPECIFICATIONS
Total Equivis ZS 22 oil is applied to Tridec steering systems in the factory. This is a mineral
hydraulic oil with a low zinc content and a very high viscosity index, to which anti-wear, anti-
oxidant, anti-corrosion and anti-foam dopes have been added. This oil is very well suited for
heavy and varied conditions.

ISO 6743/4 - HV category


CETOP RP 91 HV category
DIN 51524 part 3 - HVLP category
DENISON HF-1, HF-2, HF-0
VICKERS M-2950-S and I-286-S
CINCINNATI-MILACRON P68, P69, P70
AFNOR 48-603 HV and 48-691
US STEEL 136, 127
Only lubricate the steering systems using hydraulic oil that meets at least the specifications
given below.
ASTM METHODS CHARACTERISTICS ISO 22
D 4052 Density at 20 ºC 0,86 kg/dm3
D 445 Viscosity at 40 ºC 22,24 mm2/s
D 445 Viscosity at 100 ºC 4,91 mm2 s
D 2270 Viscosity index 152
D 97 Flow point -48 ºC
D 92 Flash point +184 ºC
D 664 TAN, KOH/g 0,5 mg
Ask your oil and lubricant supplier for information about which of his products meet the
requirements specified by Tridec.
TOTAL Equivis ZS 22
ELF Hydrelf 22
SHELL Tellus T22
TEXACO Rando HDZ 22
BP Energol SHF 22
ESSO Univis N22
AGIP Amica 22

Mixing different types of oil is not permitted.


Always consult with TRIDEC before using biodegradable oil.

HY-404-En 04-08 7
3 DESCRIPTION
These installation and maintenance instructions are intended for a semi-trailer with
hydraulically operated co-steering axles in which the wheels can also be steered manually
during manoeuvring. These instructions contain information required for operating and
maintaining the hydraulic part of a TRIDEC hydraulic steering system.

3.1 CO-STEERING WHEELS

Fig. 1 Overview of co-steering wheels


1 Fifth wheel plate 3 Steering cylinders 5 Power pack box
2 Control cylinders 4 Control box

The fifth wheel plate (1) is fitted under the front of the semi-trailer so that it can be rotated.
A push-pull rod connects the fifth wheel plate to two hydraulic control cylinders (2).
Two hydraulic steering cylinders (3) are mounted on the co-steering axle(s). The rod sides of
the control cylinders (2) are connected by hydraulic lines to the rod sides of the steering
cylinders (3). The base sides of the control cylinders (2) are connected by hydraulic lines to
the base sides of the steering cylinders (3).

While the tractor is being steered in, the steering motion is transmitted to the fifth wheel plate
(1) by the kingpin and a wedge that drops into the fifth wheel. This turns the fifth wheel plate
(1) in relation to the frame of the semi-trailer. Because the fifth wheel plate is connected by a
rod to the pistons of both control cylinders (2) the piston of one control cylinder is pulled out
while the piston of the other control cylinder is pushed in.

The oil that is displaced by the control cylinders is transferred through the lines to the
steering cylinders (3) of the co-steering axle. This causes the pistons in the steering cylinders
to move as well. As the pistons are mechanically connected to the wheels by the piston rod,
the wheels are thus co-steered.

A control box (4) and a power pack box (5) are mounted on the side of the semi-trailer for the
purpose of filling the hydraulic system and keeping it pressurised. The power pack box (5)
contains an oil tank and an electrically-driven oil pump. The control box (4) contains a
compact hydraulic block with a primer pump and valves as well as an electrical switch box.
If this system is also used to operate one or more accessories that require a considerable
amount of oil, an extra oil tank can be added.

8 04-08 HY-404-En
3.2 MANUAL STEERING

Fig. 2 Overview of manual steering


1 Fifth wheel plate 3 Steering cylinders 5 Power pack box
2 Control cylinders 4 Control box 6 Remote control

For shunting in poorly accessible areas, such as


loading and unloading locations and construction
sites, the system is equipped with a remote control
(shown here).

1. Remote control, connected to socket (4, Fig. 2).


2. Extra remote control for manual steering of
wheels from the cab.

Fig. 3 Remote controls


These remote controls can be used to manually steer the wheels during shunting operations
(under 20 km/hour).

After the shunting is complete, the wheels of the semi-trailer must be returned to the normal
driving position (with the remote control).

When the vehicle is stationary, manual steering may only be used to pressurise the
system and straighten the wheels.
The BRAKE MUST NOT BE APPLIED and the vehicle must not be loaded.

HY-404-En 04-08 9
4 OPERATION
4.1 COMPACT MANUAL STEERING
4.1.1 Shunting

Fig. 4 Principle of compact manual steering


1 Control box 7 Wheels to the right *)
2 Power pack box 8 Warning lamp, sensor for bogie
3 Remote control in cab 9 Remote control housing
4 On/off switch 10 Key switch, on/off
5 Warning lamp, sensor for kingpin 11 Wheels to the left *)
6 Wheels to the left *) 12 Wheels to the right *)
*) Turning left/right is dependant on the connection to the changeover valve (6, Fig. 20).

A tractor/semi-trailer combination with a single-axle trailer is shown here as an example. The


description is also applicable to double or triple axle semi-trailers.

The wheels of the semi-trailer are also co-steered in the normal manner during shunting
(under 20 km/h). However, with the manual steering system, the driver and/or an assistant
can turn the wheels of the semi-trailer to a different position. This makes manoeuvring in
difficult, narrow places much easier.

If the driver wants to operate the manual steering from the cab, he must turn the on/off switch
(4) to the on position. Then the wheels can be steered manually with push button (6) or (7)
while driving (forwards or backwards).
− Warning lamp (5) lights up as soon as the tractor is directly in front of the semi-trailer.
− Warning lamp (8) lights up as soon as the axle line is in the straight-ahead position.
− Warning lamps (5) and (8) go out as soon as the vehicle speed increases above 20 km/h
(dependant on the setting of the ABS or EBS).

10 04-08 HY-404-En
If desired, an assistant can control the manual steering. He must first open the control box
(1), remove the remote control (9) and activate the remote control with the key switch (10).
The wheels can be steered manually, as required, with buttons (11) and (12)

During shunting, do not ride over the cable for the remote control (9)!

4.1.2 Setting the wheels in the straight-ahead position after shunting


Set the wheels in the straight-ahead position after shunting and before driving on
public roads.

Fig. 5 Setting semi-trailer wheels in straight-ahead position after shunting


Drive the tractor directly ahead of the semi-trailer. When the fifth wheel is exactly in the
straight-ahead position, the green warning lamp (L2) goes on. Continue driving forward
slowly and turn the wheels of the semi-trailer using the buttons on remote control (3), (13) or
(9) so that the wheels return to the straight-ahead position. Once the bogie with the wheels is
in the straight-ahead position, warning lamp (L1) will go on. Therefore, when driving straight-
ahead, warning lamps (L1) and (L2) should be lit.

Switch the voltage off before driving on public roads.

HY-404-En 04-08 11
4.2 EMERGENCY OPERATION

Fig. 6 Emergency operation


If the electronic system should fail for any reason, it is still possible to return the wheels of
the semi-trailer to the straight-ahead position after shunting. Follow these steps:
− Drive the tractor directly in front of the semi-trailer.
− Remove the cover of the control box for the hydraulic system.
− Turn the knurled knob (3) of the changeover valve in until it is seated.
DO NOT TIGHTEN the knob against its seat.
− Insert the pump rod into the eye of the pump (1) and begin to pump.
The pressurised oil will cause the wheels of the semi-trailer to begin to turn.
− If the wheels begin to turn in the wrong direction, the knurled knob (3) must first be turned
out until it reaches the stop and knurled knob (3) must be turned in until it is seated.
− Continue to pump until the wheels are in the desired driving position (directly in line with
the semi-trailer).
− Turn out the knurled knob (2) until it reaches the stop.
− Fit the cover on the control box.

As long as the hydraulic system is working properly the wheels will co-steer, as usual, while
driving.

12 04-08 HY-404-En
5 MAINTENANCE
5.1 MAINTENANCE INTERVALS
Because the system is a closed circuit, it requires virtually no maintenance. However, the oil
in the system does age and deteriorate. It is therefore recommended that the oil in the
system be replaced every two years.

Monthly
− Visual inspection

Two-yearly
− Change the oil.

5.2 VISUAL INSPECTION OF THE SYSTEM


− Check the electrical wiring.
− Switch on the electrical voltage.
− Press button S4; the green warning lamp L3
should now come on.
− Check all oil lines, hoses and couplings for
possible oil leakage.
− Make sure the two bypass cocks on the
hydraulic block (7) are closed (if present).
DO NOT CLOSE TOO TIGHTLY!
− Take a short test drive to see whether the
wheels co-steer correctly.

Fig. 7 Control box


5.3 DRAINING OIL

Fig. 8 Back side of control box Fig. 9 Control/steering cylinder


− Place a receptacle under connections A1, A2, B1 and B2 (Fig. 8) on the back side of the
hydraulic unit.
− Disconnect all connections to A1, A2, B1 and B2 and allow the oil to drain into the
receptacle.
− Unscrew all bleed nipples from the cylinders (1, Fig. 9) and allow the oil to drain out of the
cylinders and lines into the receptacle.

HY-404-En 04-08 13
When all the oil has drained out of the system:
− Re-connect the disconnected lines to the connections on the back side of the control box.
Re-install all the bleed nipples.
− Fill and bleed the system in accordance with the instructions below.

5.4 ADDING OIL AND BLEEDING

Fig. 10 Filling with oil


5.4.1 Primer pump circuit
− Remove the filler cap with dipstick (5) and fill the oil reservoir with clean hydraulic oil (in
accordance with par. 2.5 Oil specifications).
− Loosen the bleeder screw (2) on the side of the compact hydraulic block.
− Insert the pump rod into the lever (1) of the oil pump and pump the oil.
− Close the bleeder screw (2) as soon as oil flows out along the threads of the screw.
The primer pump circuit is now air-free.

5.4.2 Manual steering circuit


− Lock the fifth wheel in the straight-ahead position or connect the semi-trailer to a tractor.
− Open all the bleeder nipples on the hydraulic cylinders.
− Switch on the electrical voltage.
− Push the button (3) so the oil pump begins to run and one part of the hydraulic circuit
begins to fill with oil.
− Hold the button in until clean oil runs out of the lowest bleeder nipple and no more air
comes out. Close this bleeder nipple.
− Bleed the other bleed nipples in order of height from bottom to top.
− Check the oil level regularly and top up if necessary.

− Once the highest bleeder nipple is closed and the wheels begin to turn, the knob (3) can
be released and the other circuit can be filled in the same manner by pressing button (4).
− Pressurise the hydraulic system.
− Use buttons (3) and (4) to position the steered wheels of the semi-trailer in the straight-
ahead position (also see par. 5.5, "Aligning wheels").
− Take a test drive and steer a couple of times to the maximum steering wheel
displacement.
− Bleed the hydraulic system again.
− Pressurise the hydraulic system with the pump again and align the wheels.

14 04-08 HY-404-En
5.5 ALIGNING WHEELS
5.5.1 General
There is a fundamental difference between lining up the steering and checking the wheel
and/or axle positions. Irregularities in the axle positions may occur as a result of, for
example, steering system components that are not mounted in the chassis at right angles.

When the axle is correctly mounted, lining up the steering is the same as aligning the
steering (wheel and axle positions cannot be corrected in this case) for a mechanical
turntable steering system.
Use good-quality alignment equipment that can preferably be calibrated for each
measurement and that provides reproducible results. Record the results on paper.

− A system that is to be aligned must be free of play and if necessary must have been bled.
Make sure the combination is on a flat surface.
− Drive the tractor-trailer combination to the alignment location and park the combination in
a straight line.
− The air suspension of both the tractor and the semi-trailer must be at driving height.
− Make sure that the brakes of the combination are released.
− Chock the wheels securely.
− Check whether the markings on the fifth wheel plate are lined up. If that is not the case,
the coupled tractor must be manoeuvred into position directly in front of the semi-trailer.
− In the event of problems, always check the alignment of the tractor and the position of the
fifth wheel.

5.5.2 Checking wheel positions


− Lift the semi-trailer’s steerable axle(s).
− Connect alignment equipment to the steerable axles in accordance with the supplier's
instructions.
− Check the various wheel positions.
− Where necessary, correct the wheel positions by means of the track rods.
NEVER correct the wheel positions by modifying the lengths of the steering rods between
the various axles without first consulting Tridec. This could cause irregularities in the
geometry and possibly make the steering system go out of true.
Both eventualities fall outside Tridec's responsibility and warranty.

When adjusting the track rods, always make sure that the threaded end of the
steering ball joint remains far enough in or on the rod, so that adequate locking is
assured.

− Tighten the clamping bracket bolts to the specified torque and in the specified position.
For more information see the related technical documentation.

HY-404-En 04-08 15
5.5.3 Straightening the semi-trailer axle(s)

Fig. 11 Straightening the semi-trailer axle(s)


L1 Green warning lamp for axle - is lit when the bogie with the wheels is in the
straight-ahead position.
L2 Green warning lamp for fifth wheel - is lit if the fifth wheel is in the straight-ahead
position.

− Position the tractor directly in front of the semi-trailer so the green warning lamp (L2)
lights up.
− Drive slowly forward and use the remote control to turn the steered axle(s) so the axle(s)
are also in the straight-ahead position. Release the button on the remote control as soon
as the green warning lamp (L1) lights up.

Depending on the oil pressure required for the turning, there will be some measure
of delay in the response of the axle(s), which may cause them to turn slightly past
the straight-ahead position.
If this occurs, the axle position(s) can be corrected by operating the buttons on the
remote control briefly by "feel".

In the case of several steerable axles:


− only one axle line is driven;
− the additional axle line(s) are steered through mechanical couplings.

Therefore, if the axle lines are properly installed in the chassis, the steering rods between the
axle lines on the left and right sides are exactly the same length.
After the driven axle has been aligned all the other axles should also be aligned. Check this
and correct the wheel alignment if this is not the case.

During steering the pressure may rise to about approximately 80 bar, depending on the
weight of the semi-trailer and the condition of the rotating parts. Once the vehicle is in the
straight-ahead position, the pressure will drop to approximately 40 bar. To check the
pressures, manometers must be connected to the compact hydraulic block.

Take a short test drive in a flat, restricted area.


NOT ON PUBLIC ROADS

− Steer a couple of times to the maximum steering wheel displacement.


− During straight-ahead driving, the semi-trailer must return to a position directly behind the
tractor without any corrective action.

16 04-08 HY-404-En
6 REPAIRS
6.1 ELECTRICAL SYSTEM
6.1.1 Replacing fuses
− Open the cover of the electrical switch box in the control box of the hydraulic system.
− Replace fuse Z1 (see Figs. 15) with a new one.
If the new fuse blows, the cause of the failure must be located and repaired before
another new fuse is installed.

6.1.2 Changing bulb, warning lamp L1, L2 and L3


− Tilt the green lens (see Fig. 7) out of the rubber lamp holder.
− Turn and pull the bulb out of the bayonet fitting.
− Replace the bulb (24 V, 5 Watt).
NOTE: The lamp holder has an American bayonet fitting.
− Insert the lens collar on one side into the groove in the lamp holder rubber.
Pull the rubber around the entire collar of the lens.

6.1.3 Adjusting/replacing sensors

1. Fifth wheel plate


2. LED
3. Nut
4. Sensor
5. pointer

Wire colour coding


Zw = black
Br = brown
Bl = blue

A Adjust distance empirical

Fig. 12 Sensor adjustment


Check the adjustment of the sensor as follows:
− Use the two nuts (3) to mount the sensor (4) to the chassis so the tip of the sensor (4)
DOES NOT contact the pointer (5).
− Connect the sensor to the system.
− Switch on the voltage with the key switch.
− Turn the fifth wheel plate:
LED1 (on the back of the sensor) must go on at the exact moment the pointer (5) of the
fifth wheel plate passes the sensor (4).
− Adjust the sensor (4), as required, by repositioning the nuts (3) on the shank of the
sensor.
The sensor on the bogie of the semi-trailer is adjusted in exactly the same manner.

HY-404-En 04-08 17
6.1.4 Electric motor (3 kW) for oil pump
− Remove the oil pump and the electric motor in
accordance with par. 6.3.2 and 6.3.3.

− Remove the protective tape around the electric


motor housing so the carbon brushes (1)
become accessible. If the carbon brushes (1)
are worn (shorter than 12 mm), they must all be
replaced at the same time.

Before replacing the brushes, check that the


collector (2) is not too worn.
If the collector is too worn, the entire electric motor
must be replaced. In that case the intermediate
flange fastened to the rear of the electric motor
must be transferred to the new motor.

Fig. 13 Electric motor (3 kW)


After replacement of the carbon brushes, re-install the electric motor in accordance with par.
6.3.3 and 6.3.2.

18 04-08 HY-404-En
6.2 ELECTRICAL DIAGRAMS AND CONNECTIONS IN SWITCH BOX

Fig. 14 Electrical diagram, compact manual steering 233071


A1 Battery R1 Power pack relay
BK Control box R2-R6 Mini relay
B1 Remote control SD Switch box (see Fig. 15)
B2 Extra remote control S1 Sensor, axle line
D1,D2 Diode S2 Sensor, kingpin
L1 Green warning lamp, axle S3 Pressure switch
L2 Green warning lamp, fifth wheel S4 Control switch for L3
L3 Green warning lamp, pressure too low V1 Changeover valve
M1 Electric motor Z1 Fuse

HY-404-En 04-08 19
Wire colour code
Bl Blue Ge/Gr Yellow/green Wi White
Br Brown Gr Green Zw Black
Ge Yellow Ro Red

Ks Terminal strip
Sp Pump control current

Connections in switch box

Only check the operation of the system once


all hydraulic lines have been connected, the
system has been filled with oil and bled, and
the electrical supply is connected.

Fig. 15 Switch box in control box

20 04-08 HY-404-En
6.3 HYDRAULIC SYSTEM
6.3.1 Replacing entire power pack box
− De-energise the electrical circuit.
− Disconnect the electrical wiring from the
contacts in the power pack box and pull the
wiring out of the power pack box.
− Mark the connections of the pressure and
return lines on the power pack if necessary.
− Drain the oil into a container.
Remove the oil strainer (6) if required.
− Disconnect the oil lines.
− Support the power pack box, remove all
attachment bolts and disconnect the power
pack box from the chassis.
− Replace a new power pack box.
− Re-connect all the oil pipes.
Fig. 16 Replacing power pack
− Re-connect all the wiring.
− Fill the system with oil and check that it is operating properly.

6.3.2 Replacing oil pump and electric motor (3 kW)


Removal
− Deactivate the electrical system.
− Disconnect the two AMP terminals from the
contacts on the oil pump relay (3).
− Disconnect the positive lead from the contact
(4) on the electric motor (9).
− Disconnect the earth strip (7) from the
contact (5) on the electric motor.
− Drain the oil into a container.
Remove the oil strainer (6) if required.
− Disconnect the pressure line (2) from the oil
pump (13).
− Disconnect the return line (12) from the oil
tank.
Fig. 17 Removing oil pump
− Disconnect the overflow line (1) of the pressure relief valve (14) from the oil tank.
− Unfasten the clamping strap (10) and remove the electric motor, complete with relay and
oil pump, from the power pack box.

Installation
− Slide the pump and electric motor into place on the seat and attach the clamping strap
(10). Do not fasten the clamping strap yet.
− Connect the oil return line (12), the pressure line (2) and the overflow line (1). Tighten the
unions on the pipes securely.
− If applicable, fit the oil strainer (6) in the oil tank.
− Note the position of the fastener of the clamping strap (10) and secure the electric motor
on the seat by means of this clamping strap.

HY-404-En 04-08 21
− Connect the electric cables to the contacts on the electric motor and to the electric motor
relay.
− Fill and bleed the system.
− Check that all connections are oil-tight.
− Connect the power and check the operation.

6.3.3 Replacing oil pump


Removal
− Remove the oil pump and the electric motor in
accordance with the above description.
− Remove only the two Allen bolts (1) under which the
thick silver-coloured washers are fitted.
− Pull the oil pump (2) off the intermediate flange (3)
mounted on top of the electric motor.

NOTE the spider (7, Fig. 19) that is released in the


process.

− Replace the entire oil pump (2).

Installation
− Insert the two Allen bolts (1) into the bores in the oil
pump (2).
− Turn the pump over and place it on the workbench with
the forked pump shaft (8) facing upwards.
− Place the spider (7) on the forked pump shaft.
Fig. 18 Oil pump with electric motor
The turned part of the spider (7) fits exactly in
the chamber in the pump housing (2).
− Now place the electric motor with the attached
intermediate flange (3) on top of the oil pump.
Make sure that the slot in the spider (7) slides
properly into the forked part (6) of the electric
motor shaft and the pump housing is tight
against the intermediate flange (3).
− Hand-tighten the two Allen bolts (1) in the
corresponding threaded holes in the
intermediate flange (3).
− Turn the pump and electric motor over and
tighten the two Allen bolts (1) securely.
− Fit the oil pump and the electric motor in the
power pack box in accordance with the above
description.
Fig. 19 Fitting electric motor on oil pump

22 04-08 HY-404-En
6.3.4 Depressurising hydraulic system for repair
− Unscrew the bleed nipples from the circuit from which the pressure is to be released.
− Collect the oil in a container.

6.3.5 Measuring oil pressure per circuit


− Unscrew the protective cap from every
test connection (M1 to M4).
− Connect a pressure gauge (pressure 0
to 250 bar) to every test connection.
− Take a short test drive with the vehicle.

During cornering, the pressure will always


increase proportionally in two circuits.
When the vehicle is stationary, the gauges
on all circuits will indicate virtually the same
residual pressure.

Fig. 20 Measurement connections


6.3.6 Replacing oil pump in the compact hydraulic block
− Remove the oil from the oil
tank.
− Disconnect the union nut from
the oil pump and pull the oil
pump out of the bore in the
compact hydraulic block.
− Replace the oil pump.
− Lubricate the O-rings in the
base of the oil pump with oil.

Fig. 21 Oil pump


The ball in the bore in the base of the oil pump must be visible through the bore in
the leaf spring (see Fig. 21). Otherwise the oil pump may not work properly.

− Slide the oil pump into the bore in the compact hydraulic block and secure the pump with
the union nut.
− Fill the oil tank and bleed the pump section.

HY-404-En 04-08 23
6.3.7 Replacing pressure switch
− Depressurise the system.
− Pull the rubber cover off the contacts
on the defective pressure switch (D1 -
D4).
− Disconnect the two wires.
− Unscrew the defective pressure switch
from the compact hydraulic block.
− Mount a new pressure switch in the
bore in the compact hydraulic block
using Loctite 277.
− Connect the wiring and pull the rubber
cover over the connections.

Fig. 22 Compact hydraulic block


6.3.8 Replacing changeover valve
− Depressurise the system.
− If necessary, disconnect the wiring from the top two pressure switches (D1 and D2).
− Remove the four Allen bolts holding the changeover valve (6) against the front of the
compact hydraulic block.
− Remove and replace the changeover valve.
− Before fitting the changeover valve, fix the four O-rings in the chambers in the
changeover valve with some grease or oil and then secure the valve with the four Allen
bolts using a torque of 8 Nm.
− Pressurise the system again.

6.3.9 Replacing bypass cocks


(if present)
− Depressurise the system.
− Remove the defective cock (7.1 or 7.2) and replace it.
− Pressurise the system again.

24 04-08 HY-404-En
6.3.10 Replacing compact hydraulic block
− Remove the oil from the oil tank.
Depressurise all the circuits in the system.
− Check that all the hose connections at the
rear of the hydraulic unit are correctly and
clearly marked.
− If necessary, put on new markings and
disconnect the hoses from the connection
on the hydraulic unit (collect oil).
− Disconnect the wiring from the four
pressure switches.
− Take the union nut off the connection to
the oil tank on the compact hydraulic block.

Fig. 23 Replacing compact hydraulic block


− Remove the four attachment bolts at the bottom of the hydraulic unit.
− Remove the four attachment bolts at the rear of the hydraulic unit.
− Take the compact hydraulic block out of the hydraulic unit.
− Replace the compact hydraulic block.
− Mount the new hydraulic block in reverse order.
− Fill and bleed the system in accordance with section 5.4.

6.4 LINE CONNECTIONS IN THE VEHICLE


6.4.1 General
The hydraulic line diagram is order specific.
Depending on the nature of the transport, many different versions can be developed
on the basis of a standard line diagram. Therefore it is not possible to include all
those versions in this manual.

For this reason, in addition to the appropriate installation diagram with the electrical diagram
and hydraulic diagram, each order is accompanied by documentation with the identity card,
the CE Declaration and another electrical diagram and hydraulic diagram.

If the hydraulic line diagram is lost for any reason whatsoever, you can request a new line
diagram from TRIDEC at any time by specifying the order number / serial number.

To give you an idea of the versions that are possible, six examples of typical hydraulic line
systems are shown below.

HY-404-En 04-08 25
6.4.2 HS, linear implementation

EXAMPLE

Fig. 24 Line diagram HS, linear implementation with mechanical turntable steering
1 Fifth wheel, linear implementation 3 Power pack box
2 Cabinet, hydraulic unit 4 Mechanical turntable steering

6.4.3 HS, progressive implementation

EXAMPLE

Fig. 25 Line diagram HS, progressive implementation with mechanical turntable


steering
1 Fifth wheel, progressive implementation 3 Power pack box
2 Control box, hydraulic 4 Mechanical turntable steering

26 04-08 HY-404-En
6.4.4 HF, linear implementation

EXAMPLE

Fig. 26 Line diagram HF, linear implementation, axial pivot steering in frame chassis
1 Fifth wheel, linear implementation 3 Generator cabinet
2 Cabinet, hydraulic unit 4 Axial pivot steering

6.4.5 HF, progressive implementation

EXAMPLE

Fig. 27 Line diagram HF, progressive implementation, axial pivot steering in frame
chassis
1 Fifth wheel, progressive implementation 3 Power pack box
2 Cabinet, hydraulic unit 4 Axial pivot steering

HY-404-En 04-08 27
6.4.6 HF-E, linear implementation

EXAMPLE

Fig. 28 Line diagram, linear implementation, axial pivot steering in tubular chassis
1 Fifth wheel, linear implementation 3 Power pack box
2 Cabinet, hydraulic unit 4 Axial pivot steering

6.4.7 HF-E, progressive implementation

EXAMPLE

Fig. 29 Line diagram HF-E, progressive implementation, axial pivot steering in tubular
chassis
1 Fifth wheel, progressive implementation 3 Power pack box
2 Cabinet, hydraulic unit 4 Axial pivot steering

6.4.8 Rule of thumb for the connection of hydraulic lines


Hose connections to control and steering cylinders:
Base side to base side
Rod side to rod side.

28 04-08 HY-404-En
7 FAULTS
7.1 FAULT-FINDING TABLE, HYDRAULIC SYSTEM
The semi-trailer runs left and right out of the path, depending on the road surface
Possible cause Remedy
Mechanical play See installation instructions and maintenance
instructions for the fifth wheel and for the bogie.
Align semi-trailer if necessary.
System pressure too low Check all oil lines for leaks.
Pressurise system.
Align semi-trailer if necessary.

The semi-trailer deviates constantly to one side of the path with regard to the tractor
Possible cause Remedy
Incorrect mechanical wheel alignment Not on public roads!
Only in a flat, restricted area.
Open the two bypass cocks.
Take a test drive.
The semi-trailer should follow the path of the tractor
continuously.
If it does not, align semi-trailer mechanically
(See installation instructions and maintenance
instructions for the bogie).
After the test drive, close the bypass cocks.
System pressure too low Check all oil lines for leaks.
Pressurise system.
Align semi-trailer hydraulically if necessary.
Air in the hydraulic system Bleed the system.
Hydraulic cylinder leaking along piston Replace the hydraulic cylinder.
rod Pressurise system and align semi-trailer.
Hydraulic cylinder leaking internally Replace cylinder.

HY-404-En 04-08 29
System pressure too low:
The system has to be re-pressurised more and more frequently.
Possible cause Remedy
Oil level in tank too low Check the hydraulic system for external leaks.
Eliminate the leak and fill and bleed the hydraulic
system. Align semi-trailer if necessary
Leak in hydraulic system Connect four pressure gauges (0 - 250 bar) to the
measuring points.
Take test drive and see which circuit is leaking.
Check the hydraulic system for leaks. Eliminate the
leak and fill and bleed the hydraulic system. Align
semi-trailer if necessary.
Other valves in the compact hydraulic Replace compact hydraulic block and send for
block are leaking repair.

7.2 FAULT-FINDING TABLE, ELECTRICAL SYSTEM

No power supply
Possible cause Remedy
System is not switched on Switch system on.
Faulty fuse Replace the fuse.
Cable connectors corroded Disconnect cable connectors, clean or replace and
re-connect
Wiring harness and/or distribution Replace wiring harness and/or distribution blocks.
blocks interrupted

30 04-08 HY-404-En
8 PARTS
8.1 ORDERING PARTS

Linear implementation Progressive implementation


1 Serial number (stamped under the central lubrication block)
2 Identification plate (located on rearmost cross member)

When ordering parts, in addition to the part number always indicate the type and the serial
number.

In a few cases, there may be a part in the drawing or in the list that does not have a part
number. If one of these parts must be ordered, you can do so by indicating the position
number, along with the type number and serial number.

For prices and delivery conditions, please consult the TRIDEC parts price list or the sales
department.

8.2 CYLINDERS AND LINES


The part numbers of cylinders and lines differ for each semi-trailer implementation.
Always consult the order specification for the correct part numbers.

HY-404-En 04-08 31
8.3 CONTROL BOX

32 04-08 HY-404-En
Pos. Quant. Number Name Note
1 1 320115 Cover
2 1 311160 Primer pump
3 1 311379 Pump actuating rod
4 4 310309 Plug V15L/S
5 6 311137 Straight coupling
6 1 311148 Compact hydraulic block
7 1 - Flexible pipe L=165
8 2 310235 Lead-through coupling
9 1 208132 Pressure line, hydraulic block
10 2 310466 Bypass cock
11 2 311163 Stop
12 1 209204 Changeover valve, electric
13 4 310065 Pressure switch
14 4 311183 Cap, pressure switch
15 1 208235 *) Switch box
16 2 310491 Push button, complete
310489 Lens, with arrow
17 2 310475 Grommet 19 mm
18 3 310483 Nut, cable lead-through PG16
19 3 310237 Cable lead-through PG16
20 1 207522 Cabinet, hydraulic unit
21 8 310010 Washer M8
22 8 310713 Hex bolt M8x16
23 2 310512 Hex nut M6
24 1 310511 Hex bolt M6x16
25 1 310155 Push button Red
26 1 310156 Cap over push button
27 1 310119 Lamp fitting, complete
- Rubber housing
310195 - Green lens
310200 - Lamp (American bayonet fitting) 24 V
28 2 311182 Grommet 36 mm
29 1 310126 Switch
30 1 310125 Holder
31 1 310124 Lock with key
32 2 310641 EPDM strip L = 400
33 1 208229 Instruction sticker, manual steering
34 2 310159 Sensor

*) When ordering parts, always indicate the serial number.

HY-404-En 04-08 33
8.4 POWER PACK BOX

34 04-08 HY-404-En
Pos. Quant. Number Name Note
1 1 311259 Right-angle coupling
2 1 208881 Line, overflow
3 1 311257 Straight coupling
4 2 311256 Straight coupling
5 3 310238 Right-angle coupling
6 1 208882 Line, pressure
7 1 311351 Electric motor 3 kW
8 1 311216 Oil pump
9 1 310108 Earth strip
10 1 311350 Motor bracket + clamping strap
11 4 310543 Lock nut M8
12 1 310675 Relay + terminal strip 208895
13 1 - Clamping strap, relay 110-130
14 1 207560 Power pack box
15 2 310641 Rubber strip (self-adhesive) L = 400
16 1 310284 Filter
17 3 311137 Straight coupling
18 2 311207 Grommet
19 4 311194 Hex bolt M8
20 8 310558 Washer
21 2 310656 Bush
22 1 310657 Plastic line
23 1 310235 Lead-through coupling
24 1 311182 Grommet
25 1 310516 Rubber ring, oil dipstick 20x26x2
26 1 204797 Oil level gauge

HY-404-En 04-08 35