Professional Documents
Culture Documents
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.
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
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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
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1 SAFETY
Failure to follow these instructions may result in damage for which Tridec accepts no
liability.
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.
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2 TECHNICAL DATA
2.1 ELECTRICAL SYSTEM
In-vehicle voltage 24 V
Fuses in switch box 7,5 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.
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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.
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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.
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.
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3.2 MANUAL STEERING
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.
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4 OPERATION
4.1 COMPACT MANUAL STEERING
4.1.1 Shunting
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)!
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4.2 EMERGENCY OPERATION
As long as the hydraulic system is working properly the wheels will co-steer, as usual, while
driving.
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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.
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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.
− 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.
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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.
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)
− 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".
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.
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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.
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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.
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6.2 ELECTRICAL DIAGRAMS AND CONNECTIONS IN SWITCH BOX
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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
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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.
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.
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− 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.
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
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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.
− 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.
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.
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
EXAMPLE
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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
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
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
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.
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
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8 PARTS
8.1 ORDERING PARTS
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.
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8.3 CONTROL BOX
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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
HY-404-En 04-08 33
8.4 POWER PACK BOX
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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