Hydraulic system

Product group Vehicle equipment

Original
Operating instructions
Hydraulic system
Vehicle and electrohydraulic
system
List no. 1207862-7 Revision 2

These operating instructions are for trained operating and maintenance

personnel.
Keep the operating instructions with the machine.

Valid as of 2002

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CONTENTS

1 General information ............................................................................... 7

1.1 Explanation of symbols ...................................................................... 7

1.2 Abbreviations ..................................................................................... 8
1.3 Conversion table ................................................................................ 9
2 Safety instructions ............................................................................... 10

2.1 Personnel......................................................................................... 10
2.1.1 Requirements for the operator of the hydraulic system .............. 10
2.1.2 Personnel for maintenance and repair work ............................... 11
2.2 Personal protective equipment ......................................................... 11
2.3 Parking the vehicle safely ................................................................ 12
2.4 Intended use .................................................................................... 13
2.4.1 Vehicle hydraulic system ............................................................ 13
2.4.2 Electro-hydraulic system ............................................................ 14
2.5 Safe procedures for operation and maintenance.............................. 14
2.6 General maintenance and warning information ................................ 15
2.7 General safety and accident prevention regulations ......................... 16
2.8 Adjustment and maintenance work .................................................. 16
2.9 Warning signs .................................................................................. 16

3 Installation requirements .................................................................... 18

4 Mechanically driven hydraulic pumps ................................................ 18

4.1 Parts description .............................................................................. 18

4.1.1 Pump versions ........................................................................... 19
4.1.1.1 Single-circuit hydraulic system ............................................. 19
4.1.1.2 Dual-circuit hydraulic system ............................................... 19
4.1.1.3 Triple-circuit hydraulic system .............................................. 19
4.1.1.4 Load-sensing system ........................................................... 20
4.1.2 Drive types ................................................................................. 20
4.1.2.1 Direct drive .......................................................................... 20
4.1.2.2 Drive via cardan shaft .......................................................... 21
4.1.2.3 Drive via belts ...................................................................... 21

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4.1.3 Magnet coupling ........................................................................ 21

4.1.3.1 Mechanical blocking of the magnet coupling ........................ 22
4.1.4 Hydraulic tank ............................................................................ 22
4.1.5 Hydraulic valve block ................................................................. 23
4.1.5.1 Adjust lowering speed .......................................................... 24
4.1.5.2 Adjust the system pressure .................................................. 25
4.1.6 Identification of the hydraulic connections .................................. 26
4.1.6.1 Front connections ................................................................ 26
4.1.6.2 Connections behind the driver's cab .................................... 26
4.1.6.3 Connections between the axles ........................................... 27
4.1.6.4 Connections at the rear........................................................ 27
4.1.6.5 Connection via a coupling system ........................................ 27
4.1.7 Reversing valve ......................................................................... 28
4.1.7.1 Electrical switchover ............................................................ 28
4.1.7.2 Mechanical reversing valve .................................................. 28
4.1.8 Cooler ........................................................................................ 29
4.2 Check before each commissioning .................................................. 30
4.3 Vehicle hydraulics diagram .............................................................. 31
4.3.1 Hydraulic valve block located at the front side ........................... 31
4.3.2 Hydraulic valve block located behind the cab ............................. 32
4.4 Technical data .................................................................................. 32
4.4.1 SCHMIDT Hydraulic valve block ................................................ 32
4.4.2 Hydraulic oil supply .................................................................... 32
5 Electrically driven hydraulic pump ..................................................... 33

5.1 Parts description .............................................................................. 34

5.1.1 Drive via electric motor .............................................................. 34
5.1.2 Hydraulic pump .......................................................................... 34
5.1.3 Hydraulic tank ............................................................................ 35
5.1.4 Hydraulic valve block ................................................................. 35
5.1.5 Identification of the hydraulic connections .................................. 35
5.2 Electrohydraulic system diagram ..................................................... 36
5.3 Check before each operation ........................................................... 36
5.4 Technical data .................................................................................. 37
5.4.1 Electric motor ............................................................................. 37
5.4.2 Hydraulic pump .......................................................................... 37

6 Initial fitting........................................................................................... 37

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7 Transfer of the hydraulic system to the customer............................. 38

7.1 Instructing the operating personnel .................................................. 38

8 Commissioning and use ...................................................................... 39

8.1 Before each commissioning ............................................................. 39

8.2 Commissioning ................................................................................ 39

9 Use ........................................................................................................ 39

10 Maintenance ...................................................................................... 40

10.1 Special tools ................................................................................. 40

10.2 Notes about maintenance work ..................................................... 40
10.3 Lubricant recommendations .......................................................... 41
10.4 Maintenance work, vehicle hydraulic system ................................ 42
10.4.1 Maintenance schedule ............................................................... 42
10.4.2 Description of maintenance work ............................................... 45
10.4.2.1 Filter and oil change............................................................. 45
10.4.2.2 Filter change ........................................................................ 45
10.4.2.3 Changing hydraulic fluid....................................................... 47
10.4.3 Tensioning the belts ................................................................... 48
10.4.4 Tensioning the flat drive belt....................................................... 48
10.5 Electrohydraulic system maintenance work .................................. 49
10.5.1 Maintenance schedule ............................................................... 49
10.5.2 Description of maintenance work ............................................... 50
10.5.2.1 Oil change ........................................................................... 50
10.5.2.2 Fill the hydraulic system with oil ........................................... 51
10.5.3 Clean the oil strainer .................................................................. 51

11 Malfunctions and remedies .............................................................. 52

12 Disposal ............................................................................................. 53

13 Index .................................................................................................. 54

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PREFACE

Keep these operating instructions in a safe place. It must be handed over in

the event that the machine is transferred to a third party.

We reserve the right to make changes to the technical details included in the
specifications and diagrams in these operating instructions. Reproduction,
translation and photocopying in whole or in part without written permission is
forbidden.

Because the scope of delivery is based on the order, the equipment of your
machine can differ in many descriptions and graphic representations.

Our machines are continually under further development. Please understand

that we must retain the right to changes in shape, components and technology.
Therefore, no binding agreements can be derived from the content of this
description.

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1 General information
1.1 Explanation of symbols
The following symbols in the operating
instructions are used to identify
information that contributes to
preventing accidents with bodily injury,
preventing machine damage,
preserving the environment, and
making work easier.

Indicates a dangerous situation which,

- DANGER - if not avoided, will result in death or
serious injury.

Indicates a dangerous situation which,

- WARNING - if not avoided, could result in death or
serious injury.

Indicates a dangerous situation which,

- CAUTION - if not avoided, could result in minor or
moderately serious injury.

- ENVIRONMENT - If not observed, environmental damage.

If not observed, damage to the

- ATTENTION -
machinery

- NOTE - Additional information

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1.2 Abbreviations

Abbreviations used and their meaning

in the operating instructions

Abbreviation / acronym Meaning

R Right
L Left
etc. And so on, etc.
e.g. For example
approx. Approximately
If required If required
min. Minimum
max. Maximum
And / or And / or
DIN German Industry Standards
StVZO German Road Traffic Act
BetrSichV Ordinance on Industrial Safety and
Health
PA Polyamide
rpm Revolutions per minute
sec. Second
min. minute
km/h Kilometres per hour
l/h Litres per hour
km Length measurement in kilometres
cm Length measurement in centimetres
mm Length measurement in millimetres
V Electrical voltage in volts
Nm Torque in newton metres
MA Tightening torque
° Angle annotation
l Litre
g Weight in grams
°C Temperature in degrees Celsius
cpl. Complete
AF Width against flats - spanner size

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1.3 Conversion table

Conversion table for converting into

different units

1 mm= 0.001094 yd.

Length 1 mm= 0.003281 ft.
1 mm= 0.03937 in.
1 m3 = 1.30719 yd3
Volume
1 l = 0.2642 US gallon
Volume flow 1 l/min= 0.03531 ft3/min
Mass 1 kg = 2.2046 lb

Force 1 N = 0.2248 lbf

Pressure 1 bar = 14.504 lbf/in2

Torque 1 Nm = 0.7376 ft lbf

Output 1 kW = 1.36 HP
°F =°Cx1.8+32
Temperature
°K =°C+273.15
Speed 1 km/h =0.62137 mile/h

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2 Safety instructions
2.1 Personnel
The personnel responsible for the
operation and maintenance of the
hydraulic system must be properly
trained, informed of and made
responsible for preventing possible
dangers and they must read the
operating instructions before the
hydraulic system is placed into
operation.

Modifications or changes to the

hydraulic system are not permitted
without written permission of
Aebi Schmidt.

Safety first. Improper or unintended

usage is forbidden!

2.1.1 Requirements for the operator of the hydraulic system

The personnel responsible for the
operation of the hydraulic system must
be properly trained, informed of and
made responsible for preventing
possible dangers and they must read
the operating instructions before the
hydraulic system is placed into
operation.
Once training and instruction in the
hydraulic system has been
successfully completed, this should
be confirmed in writing.
Modifications or changes to the
hydraulic system are not permitted
without written permission of
Aebi Schmidt.

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2.1.2 Personnel for maintenance and repair work

Maintenance and repair work may only
be performed by personnel with the
appropriate training who have been
instructed and trained in how to handle
the device.

2.2 Personal protective equipment

The personal protective equipment
must guarantee safe use. Damaged
protective equipment must not be
used. It must be replaced immediately.

Hearing protection
Hearing protection must be worn from
85 dB(A).

Gloves
Prolonged skin contact with plastics
may lead to skin irritations. Plastics
may contain hazardous materials (such
as adhesives, solvents or hardeners).
Protect hands from the cold. Skin can
freeze onto cold objects.
Sharp or pointed objects can injure
hands.
Sharp edges may arise due to wear,
damage to components, and so on.
These sharp edges may cause hand
injuries, e.g. during cleaning.
Fluids (such as oils, coolant, battery
acid, etc.) can damage hands.
For safety reasons, we recommend
wearing gloves when cleaning the
hydraulic system.

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Safety shoes
Reduce injuries to feet
Improve grip

Reflective clothing, weather

protection and protective clothing
Reflective clothing improves visibility
when outside the vehicle.
Weather protective clothing should
protect against dangers to health when
working in the open air.
Protective clothing improves protection
against damaging influences, for
example during maintenance work,
cleaning the machine, etc.

Facial protection
The wearing of facial protection is
recommended when working with high-
pressure cleaners.
Facial protection protects the eyes, in
particular from splashed dirt particles,
when cleaning the snow-clearing
machine.

2.3 Parking the vehicle safely

The vehicle can be unintentionally set
in motion during work on the hydraulic
system.
The vehicle must be safely parked for
any work performed on it.
 Apply the handbrake.
 Switch off the control panel.
 Turn off the vehicle engine.
 Remove the vehicle ignition key.
 If necessary, place wheel chocks
under the wheels.

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2.4 Intended use

2.4.1 Vehicle hydraulic system

The hydraulic system is designed for
the drive and control of attachments
(e.g. snow plough, gritter, sweeper)
according to DIN EN 15431.
Only Aebi Schmidt machines may be
driven and controlled.
For the control of the hydraulic system
only control panels of the Aebi Schmidt
that have been adapted to the hydraulic
system may be used.

If another machine is operated by the

hydraulic system, a hazard analysis in
connection with the hydraulic system
of Aebi Schmidt must be carried out
by this company. The operating and
maintenance personnel must be
trained accordingly.

Any other use of the hydraulic system,

e.g. as the drive for a wood splitter, or
any other similar hydraulically driven
machines, is considered as improper
use. Aebi Schmidt does not accept
any liability for resultant damage. The
risk is borne solely by the operator.
As a winter operation vehicle, the
vehicle hydraulic system complies
with DIN EN 15431. It is design, for
example, for the operation of snow
ploughs, gritters, etc. depending on
the design of the hydraulic system.
Any other use of the hydraulic system,
e.g. as the drive for a wood splitter, or
any other similar hydraulically driven
machines, is considered as improper
use. Aebi Schmidt does not accept
any liability for resultant damage. The
risk is borne solely by the operator.

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2.4.2 Electro-hydraulic system

The hydraulic system is only suitable
for short-term operation for controlling
a snow plough or for lifting a tipper.
Any other use of the hydraulic system,
e.g. as the drive for a gritter, or any
other hydraulic machines, is consid-
ered as improper use. Aebi Schmidt
does not accept any liability for
resultant damage. The risk is borne
solely by the operator.

2.5 Safe procedures for operation and maintenance

The hydraulic system may only be
operated by thoroughly trained person-
nel with the respective certification.
The hydraulic system must be main-
tained according to the specifications of
the maintenance schedule by expert
personnel who have the appropriate
training. After service or repair work,
the correct installation and functionality
of the parts must be checked.
Before putting the hydraulic system
into operation, the following must be
observed:
The operator of the hydraulic system
must ensure that the hydraulic system
is in a flawless and safe condition.
Movements of machines can be
executed using the hydraulic system.
Ensure that no persons are located in
the danger zone around the machine.

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2.6 General maintenance and warning information

Before starting any maintenance work
on the hydraulic system, ensure that
the vehicle is safely parked.
Wear personal protective equipment
and protective clothing when
performing work on the hydraulic
system. This protects against ingestion
of or soiling with the following
hazardous substances:

• Hydraulic oil is an irritant to the skin

and eyes.
• Used oil contains harmful impurities.

For personal protection

• Keep loose items of clothing away
from moving machinery parts.
• Keep hands and hair away from
moving components.
• Remove wristwatches, rings or other
items of jewellery before starting
work on the vehicle. These could get
caught in moving parts, causing
short circuits or injuries.

A hazard exists if a high-pressure

hydraulic oil leak develops. Pressurised
hydraulic fluid can penetrate deep
inside body tissue through the skin.
This constitutes a serious medical
emergency, which must be treated
promptly by a doctor.

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2.7 General safety and accident prevention regulations

In addition to the instructions in these
operating instructions, please pay
attention to the general safety and
accident prevention regulations.
You must check the operational safety
before each use of the hydraulic
system.

Familiarise yourself with all hydraulic

functions before the start of work. It is
too late to do this once you have started
using the machine.

2.8 Adjustment and maintenance work

Adjustment, cleaning and maintenance
work and the rectification of malfunc-
tions may only be performed when the
machine has been safely parked.

Special attention must be paid to

hydraulic systems with pressure
reservoirs. Pressure reservoirs are
highly pressurised.
Repair work on the hydraulic system
may only be performed by specialised
workshops.
Hydraulic oils leaking under high
pressure can penetrate the skin and
cause serious injuries. If this happens,
seek immediate medical attention as
there is a risk of severe inflammation.

2.9 Warning signs

Danger zones on the hydraulic system
that cannot be made safe by
constructive or protective measures are

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indicated by warning symbols.

The warning symbols should help to
identify a risk of injury.
The illustration on the warning symbols
consists of universally understood
pictograms. If possible, the warning
symbols are placed in the immediate
vicinity of the danger zones.

Danger zones on the machine

Do not remove warning symbols /
safety stickers and always keep them in
a recognisable and legible state.
Replace damaged and obliterated
warning symbols / safety labels
immediately. If parts with warning
symbols / safety labels are replaced,
ensure that the corresponding warning
symbols / safety labels are affixed to
the new parts.

The placing and meaning of warning

symbols is explained as follows:

Item Sign Meaning

Warning - danger of explosion:
The sign is located directly on the
pressure reservoir or in the immediate
vicinity.
1
Hydraulic pressure reservoirs and the
lines are pressurised. Make sure that
all lines are depressurised before
performing any repair work.
Read the operating instructions
The sign is located in the cab.
Before putting into operation, ensure
that you have read and understood the
2
operating instructions and observe
these instructions, paying particular
attention to the Safety Regulations
section.

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3 Installation requirements

Personnel
The hydraulic and electrical installation
may only be carried out by authorised
workshop personnel with specialised
knowledge and experience with
electrical and hydraulic systems and
with the control panel.

Installation
The installation guidelines of the vehicle
manufacturer must be observed.
The hydraulic and electrical installation
must be carried out by Aebi Schmidt
according to approved hydraulic and
electrical plans. The hydraulic hoses
and electrical cables must be run
professionally.

4 Mechanically driven hydraulic pumps

4.1 Parts description

The hydraulic systems (volume flow

- NOTE - rates, pressure, output etc.) are
designed according to DIN EN 15431.

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4.1.1 Pump versions

4.1.1.1 Single-circuit hydraulic system

The hydraulic system is equipped with a
geared pump.
The hydraulic system is designed for
snow plough control. V-belts are used
to transfer the force from the end of the
crankshaft to the pump.

4.1.1.2 Dual-circuit hydraulic system

The hydraulic system is equipped with a

dual geared pump.
Two separate hydraulic circuits of the
hydraulic system are designed for snow
plough control and driving a gritter
(front-mounted device). V-belts are
used to transfer the force from the end
of the crankshaft to the pump.

4.1.1.3 Triple-circuit hydraulic system

The hydraulic system is equipped with
a triple geared pump. The pump
combination can be designed with three
geared pumps or with two geared
pumps and one variable displacement
pump. The hydraulic system designed
is for controlling a front- and side-
mounted snow plough and for driving
the gritter (frontal attachment). The
power take-off of the vehicle's engine
drives the pumps.

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4.1.1.4 Load-sensing system

The load sensing (LS) vehicle hydraulic
system is a hydraulic control system
with volume adjustment to the current
requirements of one or more
consumers.
Consumers could be, for example, a
snow plough, a gritter, a front-mounted
device, etc.

The variable displacement pump

enables a desired feed volume to be
used, even in a lower engine speed
range. Advantages are in the decreased
noise because of lower engine speeds
and in the decreased operating cost
through the fuel savings. If no flow
volume is requested for the system,
(all directional valves in middle position)
then only the load sensing line to the
tank is relieved and the pump switches
to idle. The idling pressure is defined on
the proportional valve (generally
between 5 and 20 bar) to minimise
power loss.

4.1.2 Drive types

4.1.2.1 Direct drive

The hydraulic pump is driven directly

by the auxiliary drive of the vehicle
engine.

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4.1.2.2 Drive via cardan shaft

The hydraulic pump is driven via a

cardan shaft and elastic coupling or
electromagnetic coupling from the
auxiliary drive of the drive motor.

4.1.2.3 Drive via belts

The hydraulic pump is mounted at the

front side and driven via a V-belt.

4.1.3 Magnet coupling

The drive of the hydraulic pump can
be switched on and off using the
magnet coupling. The switching off of
the hydraulic pump affects the
following:
• Lower wear of the hydraulic pump
• Fuel savings

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4.1.3.1 Mechanical blocking of the magnet coupling

Special equipment
If there is a fault in the flow of current
for the magnetic coupling, it can be
blocked mechanically (emergency
operation). In this case, the vehicle
engine must be switched off.
 Remove the two cylinder head
bolts (AF 6) with locknut (AF 13) (1).
 Turn the outer ring (2) until the gap
is above the threaded hole in the
inner ring.
 Screw in the cylinder screws (1)
without locknuts into the two
threaded holes (3) of the inner ring
and tighten. The electromagnetic
coupling is blocked.

4.1.4 Hydraulic tank

The hydraulic pumps are supplied with
oil from the hydraulic tank. Depending
on the operating conditions, the oil
quantities can range from 35 litres to
160 litres. Depending on the design of
the hydraulic tank, the oil level can be
read off via a sight glass.
To ensure any possible contaminants
are selectively deposited, Schmidt
utilizes very large-dimensioned tank
units. To prevent the formation of foam,
our tanks are additionally equipped with
very large outgas zones. Moreover, the
tanks have optimized suction areas
which prevent the ingest of dirt and
minimize loss of suction (unpriming).
In addition, return flow filter units,
engine sump baffles, as well as an
efficient temperature and fill level
monitoring are also integrated.

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4.1.5 Hydraulic valve block

For the control of the front-mounted
machine / device (snow plough), the
hydraulic valve block is located behind
the front-mounting plate.
For the control of the side-mounted
machines (e.g. side snow plough), the
hydraulic valve block is located behind
the cab.
The hydraulic connections (hydraulic
couplings) are supplied with oil via the
individual hydraulic valves of the
hydraulic valve block. The electrical
activation of the individual hydraulic
valves occurs via a control panel.

The attachment machine moves when

the emergency manual override valve is
- WARNING - operated.
 Never allow persons to be in danger
zones of the machine.

If malfunctions occur during operation,

perform troubleshooting on the
- NOTE -
electrical and hydraulic parts of the
system separately.

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4.1.5.1 Adjust lowering speed

There is a crushing risk to persons

during the lowering process.
The lowering process must take at
least 1.5 seconds.
 The lowering process for the
- WARNING - machine is never to occur at a free-
fall (unbraked).
 If the machine lowers unexpectedly,
persons must be able to pull their
feet out of the danger zone, for
example.

The lowering time must take at least

1.5 seconds, independent of the
clearance height of the attached
machine. If this is not the case, the
lowering speed must be adjusted.
32
1 When machine changeovers on the
vehicle occur, the lowering time must
always be checked and, if necessary,
readjusted using the throttle on the
throttle check valve (1).

Adjust lowering time

 Use a stopwatch to measure the
lowering time of the attached
machine. Correct the lowering speed
if the lowering time is less than
1.5 seconds.
 Loosen locknut (2) (spanner size
AF17).
 Use hexagon socket screw (3) to
adjust the required lowering speed
(spanner opening 5).

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4.1.5.2 Adjust the system pressure

The hydraulic system or attached

machine can be damaged. Adjustments
to the hydraulic valve block may only be
- ATTENTION - carried out by a specialist with the
necessary expert knowledge of the
hydraulic system and the attached
machine using measuring tools.

The system pressure of the hydraulic

system is protected by the pressure
3 control valve.
2
1 The pressure control valve (1) is set to
160 bar at the factory.
Depending on the attached machine,
it may be necessary to increase or
decrease the system pressure.

Adjust the pressure control valve

 Loosen locknut (2) (spanner
opening 17).
 Set the specified value (see operat-
ing instructions for the attached
machine) with hexagon socket
screw (3) (spanner opening 5) with
the aid of a pressure gauge.

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4.1.6 Identification of the hydraulic connections

Possible attachment locations for
hydraulic connections on vehicle

1. Front right and left

2. Behind the cab and between
the axles
3. Rear

4.1.6.1 Front connections

For example, connecting a snow plough
or sweeper

Connection Function
1 Raise
2 Lower
3 Pivot left
4 Pivot right
Extension blade Extend
5
snow plough
Extension blade Retract
6
snow plough
Separate return
Pressure connection for
sweeper drive

4.1.6.2 Connections behind the driver's cab

e.g. connecting a gritter

Connection Function
Pressure hose

Separate return

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4.1.6.3 Connections between the axles

e.g. connection of a side snow plough

Connection Function
1 1 Raise
2 Lower
2 3 Extend side snow plough
4 Retract side snow plough
3
4

4.1.6.4 Connections at the rear

e.g. connection of a mobile warning

trailer

Connection Function
Pressure hose

Separate return

4.1.6.5 Connection via a coupling system

Using the coupling system, the
hydraulic lines of the machine are
connected to the hydraulic system of
the vehicle. The coupling system must
be co-ordinated with the machine.
The operating instructions of the
manufacturer of the coupling system
must be observed.

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4.1.7 Reversing valve

The reversing valve allows the oil
flow to be diverted to the various
consumers, for example, to a gritter,
sweeper, tipper, crane, hook-lift roll-off
tipper, etc.

4.1.7.1 Electrical switchover

A solenoid valve switches over the oil
flow from circulation without pressure to
the consumer.
The supply voltage can be 12 V or 24 V
depending on the design.
The reversing valve is equipped with
a pressure control valve. The pressure
limit is set between 200 bar and
250 bar depending on the attached
machine.

4.1.7.2 Mechanical reversing valve

The mechanical reversing valve is
located behind the cab on the left.
The changeover is accomplished by
means of a ball valve. The oil flow can
be diverted from circulation without
pressure to the consumer using the
mechanical reversing valve.

Damage due to overheating of the

hydraulic system.
 If no consumer is connected, the
- ATTENTION - mechanical reversing valve must be
turned to position B (circulation
without pressure) using the ball
valve

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A B In position "B", the oil flow is in no-

pressure circulation.
In position "A", the oil flow is routed to
the consumer. Position "A" is only to be
actuated if a consumer is connected to
the pressure connection.

4.1.8 Cooler
The cooling unit is matched to the
respective hydraulic system. These
units are especially small and space-
saving. The cooler is equipped with a
temperature-dependent, electronic fan
control.

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4.2 Check before each commissioning

Display of incorrect oil level.

Damage due to insufficient oil supply.
- ATTENTION -  The oil level can only be checked
when the vehicle is standing in a
horizontal position.

2
8

8
7

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Item Description of maintenance work

1 Check hydraulic pumps for leaks

2 Check hose lines and screws for leaks

Check hydraulic or quick release coupling (observe manufacturer's
3
operating instructions) for leaks.
4 Check hydraulic valve blocks for leaks
5 Check hydraulic tank for leaks
6 Check on/off switching valve for leaks
Check the oil level in the hydraulic tank through the sight glass.
7 When the cylinders are retracted the oil level must be between the
markings on the sight glass.
Drive via belt
Check the operational noise of the tensioning roller. If this deviates
from the normal noise of operation, the cause must be found and
rectified.
8
Drive via cardan shaft
Check the operational noise of the cardan shaft. If this deviates from
the normal noise of operation, the cause must be found and rectified

4.3 Vehicle hydraulics diagram

4.3.1 Hydraulic valve block located at the front side

1. Control panel
2. Control line for switching the
valves.
4 3 2 3. Power supply for the control panel
4. Hydraulic valve block
1 5. Hydraulic couplings for the oil
5 supply of the attached machine,
e.b. for a side snow plough.

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 Hydraulic system

4.3.2 Hydraulic valve block located behind the cab

4 1. Control panel
2. Control line for switching the
valves.
3 2 3. Power supply for the control panel
4. Hydraulic valve block
1 5. Hydraulic couplings for the oil
5 supply of the attached machine,
e.b. for a side snow plough.

4.4 Technical data

4.4.1 SCHMIDT Hydraulic valve block

Supply voltage:
Pressure control
Primary for snow plough:
Secondary for pivoting cylinder:
Gritter and Sweeper:
12 or 24 V
150 bar
Standard 300 bar (depending on the
snow plough e.g. for model SCHMIDT
SNK the value must be recalibrated)
200 bar

With plough relief, an additional

pressure proportional valve is
required.

4.4.2 Hydraulic oil supply

The hydraulic systems (volume flow

- NOTE - rates, pressure, output etc.) are
designed according to DIN EN 15431.

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 Hydraulic system

Hydraulic system Tank volume (depending on the model)

Single circuit: 10 litres
Dual circuit: 40/55 litres
Triple circuit: 70/90 litres
Load sensing: 90/140/160 litres

5 Electrically driven hydraulic pump

The electric motor can be damaged.

The electrohydraulic system is not
suitable for continuous use. The elec-
- ATTENTION - trohydraulic system is not suitable for
driving sweepers or gritters.
 It can only be used for short-term
operation.

The hydraulic pump is driven by an

electric motor. The power is supplied
via the vehicle battery. The hydraulic
pump, hydraulic tank and electric motor
make up one unit, which is mounted on
the implement plate with the hydraulic
valve block. The system is only suitable
for short-term operation.
The hydraulic system is designed for
snow plough control.
The release pressure for snow plough
relief control is ensured by a time
trigger-controlled hydraulic pump.

33
 Hydraulic system

3
Main components of the
2 electrohydraulic system

1. Hydraulic tank
1 2. Hydraulic pump
3. Electric motor
4 4. Valve block

5.1 Parts description

5.1.1 Drive via electric motor

The electric motor can be damaged.

The maximum admissible continuous
operation of the electrohydraulic pump
- ATTENTION - may not exceed 2 minutes.
Continuous operation exceeding this
time requires the electric motor to be
cooled down over an extended period.

The power supply for the electro-

hydraulic pump occurs via the vehicle
electrical system.

Use to waiting time

1:10 (use to waiting time)

5.1.2 Hydraulic pump

The hydraulic pump is directly driven
by an electric motor and is located in
the hydraulic tank.

34
 Hydraulic system

5.1.3 Hydraulic tank

The hydraulic tank (1) is directly
mounted to the base plate (2) of the
valve and drive unit.
The hydraulic pump is supplied with oil
from the hydraulic tank. Magnets
located in the hydraulic tank capture
and hold the iron filings.

5.1.4 Hydraulic valve block

The hydraulic valve block is directly
mounted to the base plate (2) of the
valve and drive unit.
The hydraulic connections are supplied
with oil via the individual hydraulic
valves of the hydraulic valve block.
The electrical activation of the individual
hydraulic valves occurs via a control
panel.

5.1.5 Identification of the hydraulic connections

e.g. connecting a snow plough

Connection Function
1 1 Raise
2 Lower
2 3 Pivot right
4 Pivot left
3
4

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 Hydraulic system

5.2 Electrohydraulic system diagram

1. Control panel
2. Power supply for electrohydraulic
pump
3
3. Power supply for the control panel
1 4. Electrohydraulic pump with
hydraulic valve block
2 5. Hydraulic couplings for the oil
5 supply of the attached machine,
4 e.b. for a side snow plough.

5.3 Check before each operation

36
 Hydraulic system

Item Description of maintenance work

1 Check electrohydraulic pumps for leaks

2 Check hose lines and screws for leaks

Check hydraulic or quick release coupling (observe manufacturer's
3
operating instructions) for leaks.
Check the oil level using the dipstick.
4 When the cylinders are retracted the oil level must be between the
markings on the dipstick.

5.4 Technical data

5.4.1 Electric motor

Voltage: 12V or 24V

Output: 2000 W
Continuous operation: max. 2 minutes
Use to waiting time 1:10 (Use to waiting time)

5.4.2 Hydraulic pump

Delivery volumes: 1.9 ccm/R

Tank volume: 5 litres

6 Initial fitting
An incorrectly attached machine can
lead to malfunctions.
Mounting for the first time must be
carried out by personnel with specialist
knowledge and experience of the
vehicle and attached machine
(e.g. snow plough). The hydraulic
connections between the attached
machine (e.g. snow plough) and the

37
 Hydraulic system

vehicle must be marked so that it is

not possible to confuse the hydraulic
connections when mounting again.
The controls for executing hydraulic
movements of the attached machine
(e.g. snow plough) are to be
permanently labelled so that
operational mistakes are prevented.

7 Transfer of the hydraulic system to the customer

Before the transfer to the customer,
the hydraulic system must be checked
by the Aebi Schmidt customer service
professional
or an authorized person for correct
installation and functioning.
The instruction about and transfer of
the hydraulic system may only be done
by an Aebi Schmidt customer service
professional or an authorized person.

7.1 Instructing the operating personnel

Scope of the instruction
• Explanation of the functioning of
the hydraulic system
• Practical instruction with the
machine / snow plough to be
controlled.
Operating personnel who have been
trained and instructed in how to use the
attached machine may initially only use
it under the supervision of experienced
persons. Once training and instruction
in the hydraulic system in conjunction
with the machine to be controlled has
been completed successfully, it should
be confirmed in writing.

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 Hydraulic system

8 Commissioning and use

8.1 Before each commissioning
Operating personnel must know the
features, functions, and dangers posed
by the machine.

Movements of machine are executed

using the hydraulic system.
Persons can be caught by the
machine.
- WARNING -
 People are not permitted to be in
the danger zone prior to a
movement of the machine being
executed.

Before commissioning, the operator

must ensure that the hydraulic functions
activated using the control panel match
with the machine movements.

8.2 Commissioning
Perform a test run before each
commissioning.

9 Use
When in use, always observe the
hydraulic movements. In case of
danger or malfunctions, interrupt the
hydraulic movement immediately and
initiate corresponding measures.

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 Hydraulic system

10 Maintenance

Maintenance and repair work may only

be performed by workshop personnel
who have the appropriate training and
instruction for the work being done.

10.1 Special tools

The standard tools in a technical

workshop are required for performing
maintenance tasks. Supports and
lashing straps must be used to fasten
components that might fall.

10.2 Notes about maintenance work

Use only oils that have been approved

- NOTE -
by SCHMIDT.

Used oils are to be disposed of

- ENVIRONMENT -
according to the applicable regulations.

It is possible to have oil quality

checked by a specialist company.
These specialist companies provide
- NOTE -
information about whether oil can still
be cleaned or whether it needs
changing.

40
 Hydraulic system

If oil is sucked out of the hydraulic tank,

- NOTE - the oil should be at a temperature of
approximately 50 °C.

Oil-contaminated filters and lubricants

can get into the environment.
Environmental pollution
- ENVIRONMENT -
 Collect lubricants in suitable
containers. Dispose of lubricants and
filters appropriately.

10.3 Lubricant recommendations

The oil type filled by the factory for

delivery is noted on the hydraulic tank.
- NOTE -
Mixing different types of oil is to be
avoided if at all possible.

HLP 22 hydraulic oil with DIN 51524

Winter Range of application
T2 or ISO VG 22 DIN 51519 increased
operation: -20 °C to 70 °C
corrosion protection.
Range of application
BP AUTRAN DX D-22309
-40 °C to 75 °C
All-year
operation: Range of application
HVLP 46 DIN 51524- T3
-10 °C to 75 °C

HIGH TEMP KP 2 P-20

Grease Useful temperature range: -25 °C to
150 °C
Fitting grease Optimaly Paste White T

41
 Hydraulic system

10.4 Maintenance work, vehicle hydraulic system

10.4.1 Maintenance schedule

13 14

11

4
3

1
8 2
9
10
6
7
12

42
 Hydraulic system

Operating
hours
Description of maintenance
Item Lubricant 50 250 500
work
Check the vehicle hydraulic
system for:
1 • Damage X
• Tightness
• Corrosion on connectors
Check hydraulic hoses and
screw connections for:
2 • Status X
• Routing
• Tightness
Check hydraulic couplings for:
• Status
• Tightness
3 • Operation of the locking X
mechanism
For quick-release couplings, also
refer to the manufacturer's
operating instructions.
Check hydraulic valve block for:
• Damage
4 X
• Tightness
• Corrosion on connectors
Check hydraulics or quick
release coupling for:
• Status
• Tightness
5 • Operation of the locking X
mechanism
(For quick release couplings also
refer to the manufacturer's
operating instructions).
6 Oil change Hydraulic oil X
7 Change oil filter X

43
 Hydraulic system

Operating
hours
Description of maintenance
Item Lubricant 50 250 500
work
Check V-belt / flat drive beltfor:
• Tension
• Cracks
• Oil
8 X
• Wear
We recommend always changing
the flat drive belt and tensioning
roller at the same time.
Check cardan shaft for:
• Play on the universal joint
shafts
• Play on the shapes
9 X
• Bolted joints
(M8 10.9 Tightening torque
35 Nm)
• Protective covering (if present)
Lubricate linkage and Grease
10 longitudinal shift on the cardan 3 lubricating X
shaft nipples
Check electrical lines for:
• Condition and routing
11 X
• Short-circuit
• Corrosion on connectors
Coat spline shaft connection
between the vehicle motor
auxiliary drive and the hydraulic
pump and / or cardan shaft with
fitting grease. Repair or
12 Fitting grease
• Clean the spline shaft of the assembly work
pump and / or cardan shaft.
• Check spline shaft for
damage and coat with fitting
grease

44
 Hydraulic system

Operating
hours
Description of maintenance
Item Lubricant 50 250 500
work
- Paint
Touch up paint damage and
13 - Grease X
grease bare parts.
- Machine oil
Check technical safety in
14 accordance with current accident Annually
prevention guidelines

10.4.2 Description of maintenance work

10.4.2.1 Filter and oil change

Oil-contaminated filters and lubricants

can get into the environment.
Environmental pollution
- ENVIRONMENT -
 Collect lubricants in suitable
containers. Dispose of lubricants
and filters appropriately.

10.4.2.2 Filter change

1
Take out the filter

 Shut off the hydraulic system.

 Have the oil collection pan and
cleaning cloths ready in order to
catch and remove any oil that may
run out.
 Open the ventilated filler cap (1)
in order to get rid of pressure in
the tank.

45
 Hydraulic system

2 1

 Take of the screws (1) on the cover

fastening (4 screws, AF 15) and
remove the cap (2).
 Check the surface of the filter for
residual dirt and larger particles.
These impurities can lead to damage
to hydraulic components.

 Pull the filter element (1) from the

filter housing.
 Clean the housing and cap.
 Check the O rings on the cap for
damage and change them if
necessary.

Install the filter

Installing the filter is carried out by

reversing the disassembly sequence.
Wet the sealing surfaces with clean oil.
The identification markings on the new
filter element must correspond to those
on the old filter element. Turn on
hydraulic system and check the filter for
leakages; check the oil level and fill if
necessary.

46
 Hydraulic system

10.4.2.3 Changing hydraulic fluid

It is possible to have oil quality checked

by an oil analysis carried out by a
specialist company. These specialist
- NOTE -
companies provide information about
whether oil can still be cleaned or
whether it needs changing.

 Open the ventilated filler cap (1)

 Place catch pan under draining
point. Open the oil drainage screw
and empty the tank completely.
 Block the oil drainage point again
with the drain plug and a new seal.
1 2  Fill with new hydraulic fluid.
3 To get any possible dirt particles
out of the new oil, the oil should be
filled using a filter unit or through
the filter (3). After filling, the filter
cover (2) and the ventilated filler
cap (1) are to be closed. Check the
filled oil quantities using the sight
glass or control panel.
 Leave engine running for approx.
1 minute and then switch it off.
Check the oil and add more oil if
necessary.

Repeat the procedure until the oil level

no longer changes.

47
 Hydraulic system

10.4.3 Tensioning the belts

Tighten the V-belt so that you can
press it in approx. 10 mm with your
thumb, e.g. with an axle distance of
590 mm and a force of 41 N. If the
V-belt is too tight or too loose, it will
wear too quickly and damage the belt
pulley bearing.
Check that new V-belts are at the
correct tension after the first few
operating hours and retighten if
necessary.

10.4.4 Tensioning the flat drive belt

The flat drive belt (1) is tensioned

using a tensioning roller (2).
If the flat drive belt is worn, we
recommend that the flat drive belt and
1 tensioning roller are always changed
together.
2

48
 Hydraulic system

10.5 Electrohydraulic system maintenance work

10.5.1 Maintenance schedule

7 8

!
4
1

6
5

Operating hours
Description of maintenance
Item Lubricant 50 250 500
work
Check electrohydraulic system for:
• Damage
1 X
• Tightness
• Corrosion on connectors
Check hydraulic hoses and screw
connections for:
2 • Status X
• Routing
• Tightness

49
 Hydraulic system

Operating hours
Description of maintenance
Item Lubricant 50 250 500
work
Check quick release coupling for:
• Status
• Tightness
3 • Operation of the locking X
mechanism
Observe the manufacturer's
operating instructions.
4 Oil change Hydraulic oil X
5 Clean the oil strainer X
Check electrical lines for:
• Condition and routing
6 X
• Short-circuit
• Corrosion on connectors
- Paint
Touch up paint damage and grease - Multi-pur-
7 X
bare parts. pose grease
- Machine oil
Check technical safety in
8 accordance with current accident Annually
prevention guidelines

10.5.2 Description of maintenance work

10.5.2.1 Oil change

2 Removing the oil
 Warm the hydraulic oil to
3
1 approximately 45 °C by operating
the snow plough.
 Park the vehicle safely.
 Unscrew the filler cap with oil
dipstick (1).
 Suck out the oil with suction
equipment (2). Put the suction
nozzle (3) into the filling opening
and suck out the oil.

50
 Hydraulic system

Draining oil
 Place the oil capture container
under the electrohydraulic pump.
 Carefully loosen the tank by
1 loosening the 4 screws (1) until oil
flows out between the pump flange
and the oil container.
 Remove the tank
 Clean the tank, especially the
magnets that are in the tank.
 Reinstall the tank. Ensure that the
sealing surface is clean and that the
sealing ring has been lightly oiled.

10.5.2.2 Fill the hydraulic system with oil

 Fill with oil (approximately 5 litres)
2
using the filling opening (1).
3
1
 Check oil level using the dipstick (2).
The oil must be between the
markings (3) when the hydraulic
cylinders are retracted.
 Turn on the hydraulic system and
carry out all hydraulic functions.
Check oil level again. Repeat the
procedure until the oil level no longer
changes.

10.5.3 Clean the oil strainer

The oil strainer (2) does not need to be
changed, only cleaned.
 Remove oil from the container (3)
(see "Oil change" chapter).
 Remove the container by loosening
3 the four screws (1).
1  Clean the oil strainer that is
2 released (2) with compressed air and
cleaning agent (petroleum ether).
Note the safety and hazard instruc-
tions before using the cleaning
agent.

51
 Hydraulic system

 Remove the iron filings clinging to

the magnets in the tank.
 Reinstall the tank (3). The sealing
surface between the hydraulic tank
and the hydraulic pump is clean and
the sealing ring is lightly oiled.
 Fill the oil container with oil (see
"Topping up the hydraulic system
with oil" chapter)

11 Malfunctions and remedies

Fault Possible cause / remedy

Hydraulic pump does not run
No oil supply to the consumers
Control panel is not switched on
o Switch on control panel
Control panel defective
o Repair / replace control panel
Power supply interrupted
o Establish power supply
Fuse defective
o Replace fuse
Electric motor (in the electrohydraulic
system) defect
o Repair / replace electric motor
Pump drive defective
o Repair or replace V-belt or cardan
shaft
Hydraulic pump does not run
o See fault "Hydraulic pump does
not run"
Hydraulic valve does not switch
o Repair electrical connection
o Replace solenoid coil
Control panel defective
o Repair / replace control panel

52
 Hydraulic system

12 Disposal

Oils and lubricants

Do not allow oils and lubricants to be
released into the environment.
 Collect oils and lubricants in
suitable, leak-proof containers and
dispose of correctly.

Plastics
Plastics can cause considerable
damage to the environment.
 Plastics must be disposed of
appropriately.
 Indicated plastic parts can be
recycled.

Hydraulic system
Decommissioned hydraulic system
 The hydraulic system must be
disposed of properly by a qualified /
certified company.

53
 Hydraulic system

13 Index

Page
Abbreviations 8
Adjust lowering speed 24
Adjust the system pressure 25
Adjustment and maintenance work 16
Before each commissioning 39
Changing hydraulic fluid 47
Check before each commissioning 30
Check before each operation 36
Clean the oil strainer 51
Commissioning 39
Commissioning and use 39
Connection via a coupling system 27
Connections at the rear 27
Connections behind the driver's cab 26
Connections between the axles 27
Conversion table 9
Cooler 29
Description of maintenance work 45
Description of maintenance work 50
Direct drive 20
Disposal 53
Drive types 20
Drive via belts 21
Drive via cardan shaft 21
Drive via electric motor 34
Dual-circuit hydraulic system 19
Electric motor 37
Electrical switchover 28
Electrically driven hydraulic pump 33
Electro-hydraulic system 14
Electrohydraulic system diagram 36
Electrohydraulic system maintenance work 49
Explanation of symbols 7
Fill the hydraulic system with oil 51

54
 Hydraulic system

Filter and oil change 45

Filter change 45
Front connections 26
General information 7
General maintenance and warning information 15
General safety and accident prevention regulations 16
Hydraulic oil supply 32
Hydraulic pump 34
Hydraulic pump 37
Hydraulic tank 22
Hydraulic tank 35
Hydraulic valve block 23
Hydraulic valve block 35
Hydraulic valve block located at the front side 31
Hydraulic valve block located behind the cab 32
Identification of the hydraulic connections 26
Identification of the hydraulic connections 35
Index 54
Initial fitting 37
Installation requirements 18
Instructing the operating personnel 38
Intended use 13
Load-sensing system 20
Lubricant recommendations 41
Magnet coupling 21
Maintenance 40
Maintenance schedule 42
Maintenance schedule 49
Maintenance work, vehicle hydraulic system 42
Malfunctions and remedies 52
Mechanical blocking of the magnet coupling 22
Mechanical reversing valve 28
Mechanically driven hydraulic pumps 18
Notes about maintenance work 40
Oil change 50
Parking the vehicle safely 12
Parts description 18
Parts description 34

55
 Hydraulic system

Personal protective equipment 11

Personnel 10
Personnel for maintenance and repair work 11
Pump versions 19
Requirements for the operator of the hydraulic system 10
Reversing valve 28
Safe procedures for operation and maintenance 14
Safety instructions 10
SCHMIDT Hydraulic valve block 32
Single-circuit hydraulic system 19
Special tools 40
Technical data 32
Technical data 37
Tensioning the belts 48
Tensioning the flat drive belt 48
Transfer of the hydraulic system to the customer 38
Triple-circuit hydraulic system 19
Use 39
Vehicle hydraulic system 13
Vehicle hydraulics diagram 31
Warning signs 16

56
 Hydraulic system

57
 Hydraulic system

Notes

58
 Hydraulic system

Notes

59
 Hydraulic system

Aebi Schmidt Deutschland GmbH

Albtalstraße 36 , 79837 St. Blasien, Germany
Phone +49 7672 412 0 Internet: www.aebi-schmidt.com
Fax +49 7672 412 230 E-mail: info@aebi-schmidt.com

60