EN

16TAN tag axle 16T

Service manual
REV 2.5
 © Terberg Techniek IJsselstein, Nederland
All rights reserved. No part of this book may be reproduced, stored in
database or retrieval system, or published, in any form or in any way,
electronically, mechanically, by print, photoprint, microfilm or any other
means without prior written permission from the publisher.

Terberg Techniek B.V. is registered by:

• Lloyds Register – Quality Assurance; ISO9001 & ISO14001
• RDW – Rijksdienst voor het Wegverkeer; registered manufacturer
of category N3 vehicles, Terberg Techniek B.V.

REVISION HISTORY
Revision Date Chapter Remark
2.5 2017.04.06 All several changes
2.4 2017.02.28 5.5 changed: 25 tons was 200 bar

Industrieweg 9 P.O. Box 23

3401 MA IJsselstein 3400 AA IJsselstein
T +31 (0)30 600 62 60
E info@terbergtechniek.nl
I www.terbergtechniek.nl
CONTENTS
CONTENTS
1 SYSTEM EXPLANATION 5
1.1 General working 5
1.2 Installation diagram 6
1.3 Fuses and relays 7
1.4 Schematics 8
1.5 Tools 9
1.6 PDI (Pre-delivery inspection) 10
2 MAINTENANCE 11
2.1 Warning 11
2.2 Service intervals 11
2.3 Service check list 13
2.4 Service checks 14
2.4.1 Visual check tag axle & testdrive 14
2.4.2 State of hoses and pipes 14
2.4.3 Check oil level 14
2.4.4 Oil sample procedure (when needed) 14
2.4.6 Replace filters 16
2.4.7 Oil and nitrogen pressures 17
2.4.8 Critical bolt Connections 21
2.4.9 Warning lights 23
2.4.10 Working of the load transfer switch 24
2.4.11 Mounting of the level sensor 24
16TAN-H2 SERVICE MANUAL V2.5
3 COMPONENT INFORMATION 29
4 ERRORS & DIAGNOSTICS 35
4.1 Warning 35
4.2 Diagnostics 35
4.3 L
 ED indication TCM, PCM and DCM 36
5 REPAIRS 39
5.1 Warning 39
5.2 Work clean 39
5.3 Replacing the suspension cylinder 40
5.4 Replacing the steering cylinder 42
5.5 Replacing the cylinder bushing 43
5.6 Replacing hydraulic hoses 44
5.7 Replacing cartridges 45
5.8 Replacing coils 45
5.9 Flushing the system 45
5.10 Steering 45
5.11 Replacing steering sensor 46
CONTACT
Service Department Terberg Techniek BV
+31 (0)30 600 62 60
service@terbergtechniek.nl
3
4
1 SYSTEM EXPLANATION

1 SYSTEM EXPLANATION
1.1 GENERAL WORKING
This service manual is a guide for repair & main-
tenance concerning Volvo trucks with the Terberg
16TAN-H2 5th axle system.
The 16TAN TAG axle is hydraulic steered and sus-
pended and increases the GVW by 16 ton. Lowering
the TAG axle is automatically executed when the
payload of the truck increases the predetermined axle
load of both drive axles.
axle load of both drive axles. So after tipping, the axle
will lift automatically.
STABILITY
Steering is set to the centre position and blocks when
the axle is lifted. When the axle lowers, it automatical-
ly will go to the correct steering angle.
While tipping (when the PTO is engaged) the axle is in
blocked position to provide more tipping stability.
• From 40 km/h and up, the axle is in cross position
(straight ahead) for the highest dynamic stability.
ENERGY SYSTEM
The oil pressure in the energy system is provided by
the hydraulic pump. The steering and suspension val-
ves distribute the oil to the steering and suspension
cylinders on the 5th axle.
(see energy system in Figure 1)

Lifting the TAG axle is automatically executed when For dynamic stability the steering is speed dependent. In the hydraulic tank assembly both temperature and
the payload of the truck drops below a predetermined • From 0 till 25 km/h the steering angle decreases linearly. pressure are monitored.

To absorb system oilpeaks, creating a buffer and

giving ride comfort, the system contains four accu-
mulators. Two main accumulators and two extra
suspension accumulators.

CHEMICAL MECHANICAL HYDRAULIC MECHANICAL

ENERGY ENERGY ENERGY ENERGY

Figure 2 - Main accumulator (left) and suspension accumulator (right)

ENGINE PUMP VALVE BLOCKS 5TH AXLE Behind the cabin is the hydraulic tank assembly that
provides the oil system (see Figure 3 for the location).
Both main accumulators are on this assembly.
Figure 1 - Energy system

16TAN-H2 SERVICE MANUAL V2.5 5

 1 SYSTEM EXPLANATION

1.2 INSTALLATION DIAGRAM

DESCRIPTION
1 Hydraulic tank
2 Cooler
3 High pressure oil filter
4 Return filter

21 22 5 Breather filter
4
6 Hydraulic valves for steering (L+R)
5
7 Hydraulic valve for suspension
20 18
8 TCM Control Unit
3
9 PCM steering control
2 16
10 DCM level control
1 11 Level sensor

15 14 9 12 Steering cylinder with position sensor

10 13 Suspension cylinder
11
14 Pressure sensor
7
6 15 Temperature sensor
8
16 Pump with by-pass
17 16TAN rear axle
17
19 18 Main accumulators
19 Suspension accumulators
12
20 Load transfer switch + warninglights (in cabin)

Figure 3 - Component locations 21 Service connector (in cabin)

13 22 Fuses and relays (in cabin) see 1.3 fuses and relays

See 3. Component information for more detailed information on the

individual components

6
1 SYSTEM EXPLANATION

1.3 FUSES AND RELAYS

The figures below show the locations of the fuses 1.3.1 FUSES AND RELAYS FM
and relays for the 16TAN system. The locations 2
shown represent the majority of the installations. It is 2
possible the positions are inaccurate for some trucks
due to original Volvo use of these locations or modifi-
cations done by an external (body)builder.
The Terberg program
connector and service
switch.
A095S *
program connector

For the correct fuse positions refer to Volvo VBI 1

service switch
The Terberg fuses and relays occupy the open spaces on
Figure 4 - Fuses and relays FM the right of the last volvo relay.

Fuse positions
A - E 10A
1 A095S B - F 10A
C 7,5A G 10A
D 5A H 10A
3 relays fuses
*if already occupied relays move to right

Fuse position
A02X 5A

Figure 5 - Service connector in FM

16TAN-H2 SERVICE MANUAL V2.5 7

 1 SYSTEM EXPLANATION

1.4 SCHEMATICS
1.3.2 FUSES AND RELAYS FH The electric and hydraulic schematics of the Terberg
16TAN system can be found in the Terberg 16TAN
Parts Manual.
The Terberg program
connector and service Or see the Volvo schematics: TA/TB/TC/TD
switch.

program connector

service switch

Figure 7 - Service connector in FH

The Terberg fuses and
relays occupy the open
1 spaces below the last
volvo relay.

2 A095S

3 relays

fuses
Fuse position
A02X 5A
Fuse positions
A - E 10A
B - F 10A
C 7,5A G 10A
D 5A H 10A

Figure 6 - Fuses and relays FH

8
1 SYSTEM EXPLANATION

1.5 TOOLS
The following service tools are recommended

1 1 1 1 2 2 2 2 3 3 3 3 4 4 4 4

1b 1b 1b 1b

1a 1a 1a 1a

NR PARTNR VOLVONR DESCRIPTION QTY REMARK

1 tt000099427 23014157 IDE Lite service software kit 1 set
1a tt000095095 23014159 programming connector 1
1b tt000098089 23014158 programming cable 1 For calibrating the level sensor,
2 tt000020560 nitrogen test kit complete 1 set incl. pressure reducing valve scales are a necessity.
3 tt000020561 22580114 nitrogen test kit 1 set
4 tt000098486 oil pressure meter 1

16TAN-H2 SERVICE MANUAL V2.5 9

 1 SYSTEM EXPLANATION

1.6 PDI (PRE-DELIVERY INSPECTION)

OK POINTS OF INSPECTION
NOTE
This inspection must be
performed after installing the
Level sensor check and calibration 2.4.11
body and prior to delivery of the
truck Check oil level 2.4.3
Visual check & testdrive 2.4.1

REMARKS

ORDERNUMMER checked by

Name
CLIENT Date Signed

MODEL
for approval
CHASSIS NR. Name
Date Signed

10
2 MAINTENANCE

2 MAINTENANCE
2.1 WARNING
BEFORE MAINTENANCE
• Take all necessary safety (people and
machines) and comply with safety
regulations.
• Confirm that the hydraulic systems
energy generator (engine) is stopped
and electric power is disconnected.
• Before conducting maintenance,
make sure that the truck is unladen
and activate the service switch.
• Lay out a safety perimeter.
DURING DIAGNOSTIC
• Even if engine is shut-off, circuit can
be pressurized.
• Unless special conditions stipulated
in manual, all measures must be
undertaken with the engine on.
• The troubleshooting steps must be
performed in correct order.
BEFORE REPAIR
• Do not perform work on a hydraulic
system that is hot or under pressure
(discharge the accumulators).
• All component modifications or
replacement must be done while
the vehicle is stationary, park brake
applied, engine shut-off.
SAFETY
Keep clear from rotating parts, moving parts
and steered axles when operating the system, to
avoid entrapment.
SAFETY
The Terberg hydraulic system operates under
high pressure. High pressure can cause severe
injury. Fluid pressure over 400 bar (5800 psi) is
possible.
Wear proper protective equipment!
2.2 SERVICE INTERVALS
Service 5th axle at least every 2000 hours.
• Execute service check list (2.3).
• Inspect the oil quality (2.4.3).
• Check and calibrate the level sensor (2.4.11).
FILTERS
• 150 hours after start-up of the truck: change
oilfilters.
CAUTION
For arctic operations, special filters might be
required, contact Terberg Techniek for more
information.
• Afterwards change oil filters every 2000 hours.
High pressure filter
Return filter
Breather filter
For partnumbers of the filters see the 16TAN Spare
Parts Manual.

16TAN-H2 SERVICE MANUAL V2.5 11

 2 MAINTENANCE

OIL
• Change oil every 4000
hours or 2 years, dependent
on what comes first.
• Use Shell Tellus 46.

Next oils are equivalents of

Shell Tellus 46
• BP Bartran HV46
• Total EQuivis ZS 46
• Texaco Rando HDZ46 Figure 8 - Shell Tellus 46

CAUTION
For arctic operations, special oil might be
required, contact Terberg Techniek for more
information.

CAUTION
Do not mix oils of different quality!

12
2 MAINTENANCE

2.3 SERVICE CHECK LIST

OK NOT OK NOT POINTS OF INSPECTION

APPLICABLE ORDERNR.
2000 HOURS / 1 YEAR
CLIENT
Visual inspection TAG axle 2.4.1
Leakages, state of hoses & pipes 2.4.2 MODEL
Check oil 2.4.3
Replace filters (3x) 2.4.6 CHASSIS NR.
Accumulators 2.4.7
Critical bolt connections 2.4.8
Warninglights 2.4.9
Level sensor check and calibration 2.4.11
Testdrive 2.4.1
4000 HOURS / 2 YEAR
Change oil 2.4.5

REMARKS
checked by

Name
Date Signed

for approval

Name
Date Signed

16TAN-H2 SERVICE MANUAL V2.5 13

 2 MAINTENANCE

2.4 SERVICE CHECKS

2.4.1 VISUAL CHECK TAG AXLE & TESTDRIVE
Walk around the 16TAN TAG axle and look for pos-
sible damages or leakages. A testdrive should be
executed to check steering at idling and the function
of the service switch.
2.4.2 STATE OF HOSES AND PIPES
Check for leakages under the truck. Also check the
state of the hoses and the pipes.
2.4.4 OIL SAMPLE PROCEDURE (WHEN NEEDED)
To take an oil sample, the vehicle must run in
stationary mode.
Connect a hose to the test connector before the pressure
filter. Before filling a sample container, let some oil
poor out to flush the drain.

If couplings need to be tightened see 2.4.8 Critical

bolt connections for torques.

2.4.3 CHECK OIL LEVEL
Conditions:
• running engine
• f ull functional system
(no error messages)
The maximum oil level
is 2cm below the top of
the oil level gauge (see
Figure 9)
The minimum oil level is
at 50% of the gauge. Also
check the warning light
on the dashboard (see Figure 9 - Gauge
2.4.9 warning lights)
Figure 11 - Taking an oil sample from the test connector
2CM
MAX ATTENTION
When starting the
Figure 10 - Location of the test connector
engine, after approx.
MIN A sample of 100ml should be sufficient. The oil drips 10 seconds there is a
very slowly from the hose, apart from a pressure short pressure peak
peak right after starting the engine, when the engine (see Figure 12). Make
is started after the connection of the hose (see: Figu- sure to hold the hose
re 12 attention). firmly.
Figure 12 - Pressure gauge*
After taking the sample, check the oil and eventually
correct the oil level.

*For part numbers of the tools available see 1.5

Tools

14
2 MAINTENANCE

2.4.5 O IL CHANGE AND TOPPING UP Close the plug (with a

OIL CHANGE: EVERY 4000H/ 2YEAR torque of 35Nm±5Nm) and
Turn engine off. Make remove the breather filter
sure that the system on top of the hydraulic NOTE
is depressurized: Open tank. Add the new oil Do not forget to:
the manual relief valve (Shell Tellus 46 or equi- • close the manual relief valve handle
handle near the tank to valent, see 2.2 intervals) next to the hydraulic tank
relieve the pressure in the through the opening of • place the breather filter back and tigh-
hydraulic system. Handle the breather filter. ten it handtight (approx. 5Nm)
in Figure 13 is closed
(down) Figure 15 - Remove breather The system will pressurize itself again after star-
filter
ting the truck.
Figure 13 - Handle in closed
Close the manual relief valve handle and start the
position
engine to fill the system. Open the manual relief valve
Open the plug on the bottom side of the hydraulic tank handle and top up the oil (see 2.4.3 check oil level for
to let the oil run out in a large container (min. 50L). oil levels).

Figure 14 - Remove plug on bottom of the hydraulic tank Figure 16 - Topping up the oil

16TAN-H2 SERVICE MANUAL V2.5 15

 2 MAINTENANCE

2.4.6 R EPLACE FILTERS

Remove the filter and install a new (see Figure 18) also
replace the seal.

always use Terberg Techniek genuine parts!

NOTE
Do not forget to close the manual relief
2.4.6.1 High pressure filter
valve handle next to the oil tank again.
Turn engine off. Make sure that the
system is depressurized: Open the
The system will pressurize itself again after star-
manual relief valve handle near the
ting the truck.
tank to relieve the pressure in the
hydraulic system. Seal
2.4.6.2 Return filter
Put an oil can below the filter (see Figure 17) and Remove the cover of the return filter.
remove the bottom part of the filter housing.
Take out the filter and install a new, also replace the
seal in the cover (see Figure 21).
Figure 18 - Pressure filter

ATTENTION
Always replace the seal together with the filter!

Tighten the filter housing with 20Nm and then turn

back a stroke of 90 degrees.
Figure 17 - Remove the filter housing

Figure 19 - Remove cover of return filter

16
2 MAINTENANCE

2.4.6.3 Breather filter 2.4.7.1 Checking nitrogen pressures: accumulators

Remove the cover of the filter and replace it completely To check the nitrogen pressure in the accumulators, a
with a new. The cover assembly contains the breather Terberg Techniek charging and testing unit or com-
filter. Tighten the filter handtight (approx. 5Nm) parable is required. Make sure this tool is checked and
calibrated regularly!

For part numbers of the tools available see 1.5 Tools

Checking pressure: main accumulator

Step 1
Turn engine off. Make sure the
Figure 20 - Return filter
hydraulic pressure on the fluid side
of the accumulator is ± 0. Open the
manual relief valve handle near the
tank to relieve the pressure in the
hydraulic system.

Figure 22 - Breather filter

2.4.7 OIL AND NITROGEN PRESSURES

The nitrogen in the accumulators will get compres-
sed when oil pressure on the oil side of the membra-
Figure 21 - Also replace seal in cover ne increases.

Without the (correct functioning) accumulator, pres-

sure peaks can occur. This will give a continuous en-
gagement and disengagement of the by-pass valve.
ATTENTION (thumping sound)
Always replace the seal together with the filter!

Tighten the filter cover with 20Nm.

16TAN-H2 SERVICE MANUAL V2.5 17

 2 MAINTENANCE

Step 2 Step 3 Step 4

Undo the cap from the accumulator. Remove any Make sure all valves on the bottle and testing unit Open the valve on the top of the testing unit and
rust, dirt or grease from the accumulator valve (allen are closed. Connect the testing unit* to the nitrogen turn it counter clockwise. This will open the accu-
bolt). bottle and then on to the accumulator. mulator. If correct, the gauge will show the nitrogen
pressure in the accumulator.

Figure 24 - Test set-up

Figure 23 - Check movement of the accumulator valve Figure 26 - Check pressure

Untighten the valve a little counter clockwise to check The right pressure is found on the label on the bottom
if it moves, do not open the valve! side of the accumulator.

Main accumulator: 100 bar

Checking pressure: suspension accumulators

Step 1
NOTE Turn engine off. Make sure that the
Do not screw the accumulator valve open wide, system is depressurized: The ignition
nitrogen might excape. must be off. Open the manual relief
Figure 25 - Connecting the nitrogen bottles
valve handle near the tank to relieve the
*For part numbers of the tools available see 1.5 pressure in the hydraulic system.
Tools

18
2 MAINTENANCE

To relieve the pressure in the suspension accumulators, The right pressure is found on the label on the bottom
remove all caps of the cartridges in the main valveblock side of the accumulators.
and turn the valves by hand fully open counter clockwi-
se. (see Figure 28) Suspension accumulator: 50 bar

2.4.7.2 Adjusting nitrogen pressure

If the pressure is not according to the right values,
this must be adjusted. If the pressure is too high:
relief the pressure, if it is too low: fill the system.

Filling
Open the nitrogen bottle and set the pressure to the
correct value, make sure the pressure never exceeds
the right pressure.
Figure 29 - Valve blocks

Step 2 - 4
Figure 28 - Opening the valves See the main accumulator instructions and repeat
steps 2 to 4.
Also on the lifting valveblocks, remove the caps
marked with 1 and turn the cartridge valves the same
way. After the valves are open, press on the caps
marked with 2. (See Figure 29)

Figure 27 - Adjusting the pressure

ATTENTION
When the axle is lifted, the axle will come down
during depressurizing.
Figure 30 - Location of the two suspension accumulators between
fifth axle and tandem axles

16TAN-H2 SERVICE MANUAL V2.5 19

 2 MAINTENANCE

When the accumulator 2.4.7.3 Checking oil pressure

is internally damaged, The pressure can be checked in two ways: OIL PRESSURE
nitrogen could be blown 1 With a pressure gauge The system oil pressure must be between 190
in the hydraulic system. Connect the pres- and 240bar.
Close the nitrogen bottle sure gauge tot the
and check if the pressure test nipple below the
remains the same. If the pressure filter, on the
NOTE
pressure is stable, close accumulator side (see
There can be a difference between the
the accumulator by scre- Figure 33).
values in Terberg Techniek IDE and on
wing the valve clockwise.
the gauge. This difference should not
Figure 31 - Close accumulator
valves
exceed ±5 bar.
Close the other valves and disconnect the testing Figure 33 - Position test nipple
unit. Close all opened hydraulic valves and put all
caps back on top. Test the system. 2 In Terberg Techniek IDE (see Figure 32)
Press the fill (on) button and the pressure will appear
in the top right box pressure.

OIL PRESSURE
NOTE
Do not forget to:
• close the manual relief valve handle
next to the oil tank again.
• close the cartridge valves handtight
(approx. 5Nm)
• close the accumulator valves (approx. 10Nm)

The system will pressurize itself again after star-

ting the vehicle.

Figure 32 - Terberg IDE: oil pressure

20
2 MAINTENANCE

2.4.8 CRITICAL BOLT CONNECTIONS

All critical bolt connections have been tightened with For V-stay assembly (see Figure 34) also see the Volvo
torque. Visually check the bolt connections yearly. installation requirements: 22493234

NOTE
If tightening torques are not specified in the follo-
wing instructions, use the torques in the Terberg
ATTENTION Assembly parameters standards:
When in doubt or after replacement of a
component, follow the specified tightening TN008 Hydraulic Assembly Parameters
torques. TN009 Bolts & Nuts Assembly Parameters

Some bolt connections are mechanically Both parameter standards are available from the
locked, visually check the connections Terberg Techniek Service Department.
regularly.

Original Volvo mountings must be tightened

according to Volvo specifications.

torque 620Nm±20
M20
torque 310Nm±20
M18
Figure 35 - Mounting suspension cylinders (top)

torque 490Nm±20
M20

Figure 34 - Mounting V-stay

16TAN-H2 SERVICE MANUAL V2.5 21

 2 MAINTENANCE

torque 175Nm±20 torque 175Nm±20 torque 540Nm±20

M14 M14 M20

Figure 36 - Mounting bracket suspension cylinders Figure 38 - Mounting suspension cylinders (bottom) Figure 40 - Mounting steering cylinders (axle side)

torque 560Nm±20 torque 540Nm±20 BACK

M20 M20

torque 175Nm±20 torque 310Nm±20

M14 M18

Figure 37 - Mounting suspension cylinders (bottom) Figure 39 - Mounting steering cylinder brackets (axle side) Figure 41 - Mounting steering cylinders (support side)

22
2 MAINTENANCE

2.4.9 WARNING LIGHTS

On the dashboard two warning lights are available, WARNING
(see Figure 43). illuminates Computer communication
continuously error.
Possible cause
- Wiring issue
- Programming issue

Action

WARNING
Stop vehicle at next
safe place to stop and
switch off the engine!

- Do not continue driving,

Figure 43 Warning lights loading or unloading without
torque 480Nm±20 proper diagnose.
M20
Terberg warnings are blinks 4 sec on/1 oil temperature oil temperature is too high
also displayed on the sec off 5th axle
Figure 42 - Mounting support steering cylinder brackets Driver information dis- Possible cause
- Wiring issue.
play: software release 9 - Sensor issue.
- Pump pressure.
or later applicable (see - Valve issue.
Figure 44). Action

Figure 44 Driver information WARNING

The working of the warn- Stop vehicle at next
display
ing lights can be checked safe place to stop and
switch off the engine!
by turning the ignition “ON”. The lower light will light
- Do not continue driving,
up shortly and the upper light will light up about five loading or unloading without
seconds. proper diagnose.

After five seconds both lights won’t light up anymore,

otherwise a failure is active. See table on the right, the
numbers of columns correspont with the numbers of
the warning lights (see figures above).

16TAN-H2 SERVICE MANUAL V2.5 23

 2 MAINTENANCE

WARNING 2.4.10 W ORKING OF THE LOAD TRANSFER 2.4.11 MOUNTING OF THE LEVEL SENSOR
SWITCH Check the mounting of the sensor to its support, the
blinks 1 sec steering 5 axle
th
steering is not working
on/1 sec off Check the the working of the load transfer switch. levers position related to the sensor,
Possible cause the ball joints at the lever, bracket at the bottom side
- Wiring issue.
- Sensor issue. and the mounting to the axle support.
- Pump pressure.
- Valve issue.

Action
- Stop vehicle and check
system
- Do not continue driving,
loading or unloading without
proper diagnose.
blinks 4 sec suspension 5th suspension is not working
on/4 sec off axle
Possible cause
- Wiring issue. Figure 45 - Switch
- Sensor issue.
- Pump pressure.
- Valve issue. Conditions
Action
1. Vehicle speed < 7 km/h*
- Stop vehicle and check 2. Axle on the ground
system
- Do not continue driving,
loading or unloading without
proper diagnose.
Press the lower part of the switch
illuminates Check oil level** The function load Figure 47 - Level sensor
continuously transfer is activated and
If oil level is too low (no oil
present in the oil level gauge,
the status warning light When the outcome of the inspection of the mounting
for location see: 3.1 Hydraulic illuminates. of the level sensor is uncertain or changes are made
tank), check for leakages
first before filling the level. to the mounting of the angle sensor, calibrate the
Low oil levels can lead to
damage to the pump and
The “Increase traction” angle sensor. See instruction on the right.
other components. function remains activa-
ted for 30 sec.
NOTE
Figure 46 - Warning light The level sensor needs to be calibrated
*required vehicle speed can be set between 0 and 15km/h, default
yearly, see 2.3 Service check list.
is: 7 km/h.

24
2 MAINTENANCE

CALIBRATING THE LEVEL SENSOR  Click on “Tree”

 Click on “Overview” in the column axle load.

When a truck comes for maintenance, it is

recommended to check the level sensor for
accurate measurements. This can be done
using the Terberg IDE software.

Conditions

1 Tipper empty 2 5th axle lifted Connect the computer and open Terberg IDE*,
open RunWin. Make sure the correct project
“Widespread_A.v50” is loaded.
 Look at the value at “Actual load” under
Open the project file “your project” in C:\SBC\ Master. This represents a theoretical pressu-
TerbergT\Widespread_A.v50 and click on Ok. re, equal to the load (Kg) on one axle of the
tandem.
3 Flat surface 4 No service mode
/ ignition on

5 Parking brake off 6 Weighing tandem

(use stoppers!) axles

*For part numbers of the software kits available

see the 16TAN spare parts manual

16TAN-H2 SERVICE MANUAL V2.5 25

 2 MAINTENANCE

 Find the correct pressure belonging to the step should be preformed with the vehicle exact-
axle load in the graph below. The value in the ly level.
“Overview” should not be off more than 5%. If
this is the case, adjust the sensor. STEP 3
Determine the Volt value with the diagram and ATTENTION
comparison list (example 7200kg). The value It is also possible to calibrate the bogie load sen-
that belongs to 7200Kg = 65bar (see next pages sor by turning the green clamp carefully until the
for diagrams) corresponding voltage is reached.
(in this case 2.56V on pin 3 and 4)
STEP 4
Unscrew the green For this you need a multi meter and the Volvo
clamp slightly so that special tool: 9998534 (see Figure 50)
is can be turned with a
little force.
Turn the clamp until
ADJUSTING THE LEVEL SENSOR the wanted value is
The values mentioned are from a test truck. reached. (65bar at
7200kg for the test
STEP 1 truck) Than tighten the
Check if the level sensor as- clamp.
sembly is as shown below.
(could be angled if vehicle
is loaded, see Figure 47).
Figure 49 - Green clamp

STEP 2
The empty vehicle bogie
should be weighed. Divi-
ded by two you have the
Figure 50 - Volvo special tool
axle weight which can be Figure 48 - Rod length, may
used later (in this vehicle differ from truck
14400/2 = 7200kg). This to truck

26
2 MAINTENANCE

24000

22000

20000

18000 AXLE LOAD [KG]

16000

14000

12000

10000

8000

6000

4000

2000

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230

16TAN-H2 SERVICE MANUAL V2.5 27

 2 MAINTENANCE

4,2

4,0

3,8

3,6

3,4

3,2

3,0

2,8 VOLT [V]

2,6

2,4

2,2

2,0

10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200 210 220 230

28
2 MAINTENANCE

3 COMPONENT INFORMATION
COMPONENT OVERVIEW
Basically, the system consists of the following The cooler is used to cool the hydraulic system, it is
basic components. This chapter describes the main situated on top of the hydraulic tank.
features of every component listed below.
Incoming T 700C
3.1 HYDRAULIC TANK Outgoing T 500C
Reservoir with breather filter, return filter and level
gauge. Power supply
Cooler and fan get the powersupply from the fusebox
RETURN BREATHER behind the batteries.
FILTER FILTER

3.3 HIGH PRESSURE OIL FILTER

Figure 52 - Schematic hydraulic tank The high pressure oil
filter, mounted in the
hydraulic tank assembly,
3.2 COOLER & FAN protects the steering
cylinder and the hydraulic
valves against pollution.

When the oil pump is

OIL LEVEL exchanged, the high
GAUGE pressure filter must also
be renewed.

Figure 54 - Schematic The oil filter is situated

Figure 55 - High pressure oil
cooler behind the hydraulic tank. filter

Figure 53 - Cooler
Figure 51 - Hydraulic tank
Figure 56 - Schematic pressure
filter

16TAN-H2 SERVICE MANUAL V2.5 29

 3 COMPONENT INFORMATION

3.4 HYDRAULIC VALVE BLOCK FOR STEERING 3.5 H

 YDRAULIC VALVE BLOCK FOR 3.6 H YDRAULIC VALVE BLOCKS FOR
There are two valves for each steering cylinder (left SUSPENSION LIFTING/STABILIZING
and right). This is one valve block for both suspension cylinders
(left and right).

Figure 59 - Hydraulic valve block for suspension

Figure 57 - Hydraulic valve for steering

The valve block is

situated in the chassis
between the tandem and
5th axle.

Figure 61 - Schematic lifting valve blocks

The valve blocks are used for lifting and stabilizing.

The blocks are situated in the chassis between the
tandem and 5th axle.

Figure 58 - Schematic steering Figure 60 - Schematic suspension valve block

valve block
The valve block is used for suspension. The block is si-
tuated in the chassis between the tandem and 5th axle.

30
3 COMPONENT INFORMATION

3.7 T ERBERG CONTROL MODULE (TCM) 3.9 D IGITAL CONTROL MODULE (DCM)
CONTROL UNIT LEVEL CONTROL
The TCM is the main computer module which The DCM is an in- and output module for controlling
communicates with the other ECUs for steering and the digital valves for suspension.
suspension.
The TCM is situated in The DCM is situated in
the chassis between the the chassis between the
tandem axles. tandem axles.

Figure 66 - Level sensor

Figure 62 - TCM Figure 64 - DCM

3.8 P ROPORTIONAL CONTROL MODULE 3.10 LEVEL SENSOR 3.11 S

 TEERING CYLINDER WITH POSITION
(PCM) STEERING CONTROL (2X) A potentiometer detects the axle load of the leaf SENSOR
suspended bogie in order to determine the needed
The PCMs are in- and output modules which control pressure in the suspension cylinders of the TAG axle.
the proportional valves for the steering.
The PCMs are situated in A ratio-parameter is
the chassis between the loaded in the software for
tandem axles. every single vehicle type.

The level sensor is situa-

ted under the chassis bet-
ween the tandem axles.
Figure 67 - Steering cylinder

Figure 65 - Schematic sensor

Figure 68 - Schematic steering
Figure 63 - PCM cylinder

16TAN-H2 SERVICE MANUAL V2.5 31

 3 COMPONENT INFORMATION

3.12 SUSPENSION CYLINDER 3.13 PRESSURE SENSORS

location in tank
assembly

Figure 75 - Schematic tempera-

ture sensor

Figure 70 - Schematic suspension

cylinder
3.15 PRESSURE RELIEF VALVE (HANDLE)
Figure 72 - Pressure sensor
location in lifting
valve assembly The pressure relief valve
(handle) is situated on
the front side of the tank
assembly.
Figure 69 - Suspension cylinder

Recognizing the pressure “P” and return “R” side of Figure 73 - Schematic pressure
the cylinder: see the marking on the head of the cylin- sensor
der (Figure 71).
3.14 TEMPERATURE SENSOR

location in tank
assembly
open / no pressure

closed / pressure
Figure 76 - Pressure relief valve (in work)

Figure 71 - “P” marking on cylinder Figure 74 - Temperature sensor

32
3 COMPONENT INFORMATION

3.16 PRESSURE RELIEF VALVE 3.17 PUMP WITH BY-PASS 3.18 MAIN ACCUMULATOR
The pressure relief valve is for safety, to limit the sys- The main accumulator keeps a steady pressure in the
tem pressure at 280 bar (standard setting). main hydraulic system.

location in tank
assembly

Figure 79 - Pump

The pump is mounted Figure 81 - Main accumulator

Figure 77 - Pressure relief valve
on the rear side of the
engine. V 3,5 L
P 100 bar
pressure setting
P 280 bar The main accumulator
is situated behind the
hydraulic tank.

Figure 80 - Schematic pump

by-pass Figure 82 - Schematic

When the system is pressurized, the pump can run
without resistance by using the by-pass. As a result,
the pump does not require power from the engine.
Figure 78 - Schematic pressure
relief valve
accumulator
The accumulators use nitrogen to keep the hydraulic
system pressurized. When the fluid is pumped into an
accumulator the nitrogen inside the accumulator is
compressed.

16TAN-H2 SERVICE MANUAL V2.5 33

 3 COMPONENT INFORMATION

3.19 SUSPENSION ACCUMULATOR 3.20 LOAD TRANSFER SWITCH

The piston accumulator keeps a steady pressure in (IN CABIN)
the suspension cylinders.
NOTE
See 1.3 Fuses and relays for the location of the
service connector and switch

Figure 85 - Switch
Figure 83 - Suspension accumulator

V 2,0 L 3.21 S
 ERVICE CONNECTOR AND SWITCH
P 50 bar (IN CABIN)

The piston accumulator

is situated under the
cross member of the
TAG axle.

Figure 84 - Schematic
accumulator

Figure 86 - Service connector

34
4 ERRORS & DIAGNOSTICS

4 ERRORS & DIAGNOSTICS

4.1 WARNING 4.2 DIAGNOSTICS
BEFORE DIAGNOSTIC Malfunctioning of the system can be divided into
• Take all necessary safety (people and machines) three parts:
and comply with safety regulations. • Mechanical
• Confirm that the hydraulic systems’ energy • Electrical
generator (engine) is stopped and electric power is • Hydraulic
disconnected.
• Lay out a safety perimeter. For mechanical malfunctions and oil leakages, see
chapter 5. See also 2.4.9 for warnings.
DURING DIAGNOSTIC
• Even if engine is shut-off, circuit can be pressurized.
• To prevent unexpected movement, the driver must
stay in the cab during measurements.
• Unless special conditions stipulated in control, all
measures must be undertaken with the engine on.
• The troubleshooting steps must be performed in
order.

NOTE
• Some error codes are only active when
the assistance is engaged.
• Check the display after each step to see if
the error code persists.

BEFORE REPAIRS
• Do not perform work on a hydraulic system that is
hot or under pressure (discharge the accumulators).
• All component modifications or replacement must
be done with the vehicle stationary, park brake
applied, engine shut-off.

16TAN-H2 SERVICE MANUAL V2.5 35

 4 ERRORS & DIAGNOSTICS

4.3 L ED INDICATION TCM, PCM AND DCM

Both the TCM and the PCM and DCM modules of the GENERAL PRINCIPLE
Terberg Techniek system have LED indications to To start the CAN network TCM sends a “go to run”
check whether some basic functions are O.K. 1 message from the CAN1 bus. This will start all CAN1
2 modules. The TCM handles the CAN1 modules in the
configured addresses. The CAN1 modules respond to
the message according to the master / slave principle.
1
If a module does not respond, the TCM will stop
2 transmitting and start from beginning with a new "go
to run" message.
3
PCM and DCM
4 Figure 88 - PCM & DCM
The green LED is the RUN LED. The amber LED is
5 COLOR the CAN LED. If both LEDs flash quickly, (Because
1 RUN green the LEDs blink quickly they seem to be continuously
2 CAN orange illuminated), the CAN network has been successfully
Figure 87 - TCM
started and did not have any downtime.
1 •L
 it continuously/ fast blinking when O.K.
COLOR (≈24V) If the orange LED flashes very rapidly and the green LED
1 ON green •B
 linking every 2 seconds when network failu- flashes periodically (one second on, one second off)
re or software modification. To reset: turn off the CAN network successfully launched and runs well.
2 CAN 1 communication with Terberg orange
Techniek PCM and DCM supply voltage and turn on again. However, the CAN module has had an interruption of
the flow of messages while the CAN module was live.
3 CAN 2 communication with BBM orange
module for vehicle informati- 2 •L  it continuously/ fast blinking when commu-
on which is connected to our nication is active. TROUBLESHOOTING
system •B  linking every 2 seconds when the module is Switch off power of all the modules and the TCM.
4 CAN 3 not used orange waiting for starting communication. The TCM Measure the resistance between L and H of the CAN
5 CAN 4 communication with the orange starts every module as it is the master. All bus. This must be 60 Ω.
master sensor in the steering modules are slaves.
column (SAS sensor) for • Irregular blinking when the TCM tries to start If the measured resistance is different you can check
steering angles
up the module. the number of terminating resistors in the system by
dividing 120 by the measured value.

36
4 ERRORS & DIAGNOSTICS

There should always be two terminating resistors. One
at the beginning of the CAN-bus and one at the end of
the CAN-bus.
Messages on the CAN modules
On the CAN modules several messages are possible:
1 The green LED illuminates and the orange LED
flashes regularly (1 second on, 1 second off). The
TCM is turned off, or settings are not correct.
If the messages still persist after following these
steps, please contact the Terberg Techniek Service
Department.

2 Both LEDs flash regularly (1 second on, 1 second

NOTE
The second resistance is activated using an
external bridge. The resistance can not be
measured directly on the pin L+H connection of
the controller.
off) the module is not selected by the TCM. The
module is not selected by the TCM.
3 The orange LED flashes slowly (2 seconds on, 2
seconds off) interspersed with brief flashes, and the
green LED flashes regularly (1 second on, 1 second
off). The module has no contact with the network.

4 2 4 The orange LED flashes slowly (2 seconds on, 2

seconds off) and the green LED flashes regularly
(1 second on, 1 second off). Settings are not
correct.

For all the messages, the following procedure

applies:
5 6 7 8 Figure 89 Internal lay out
PCM & DCM Step 1
Update the software and parameters*.

Step 2
Replace the module and update the software up-
date and also the parameters*.

*See the Terberg IDE Software Manual

16TAN-H2 SERVICE MANUAL V2.5 37

 4 ERRORS & DIAGNOSTICS

38
5 REPAIRS

5 REPAIRS
5.1 WARNING 5.2 WORK CLEAN
BEFORE DIAGNOSTIC • Keep your workplace clean to avoid contamination of • Protect dismounted electrical connectors against
• Take all necessary safety (people and machines) the Terberg components. contamination.
and comply with safety regulations. • Clean the surfaces of Terberg hydraulic and electric
• Confirm that the hydraulic systems’ energy components before removal to avoid contamination.
generator (engine) is stopped and electric power is Use universal cleaner and a low pressure air hose.
disconnected.
• Lay out a safety perimeter.

DURING DIAGNOSTIC
• Even if engine is shut-off, circuit can be pressurized.
• To prevent unexpected movement, the driver must
stay in the cab during measurements.
• Unless special conditions stipulated in control, all
measures must be undertaken with the engine on. Figure 92 - Protect electrical connectors
• The troubleshooting steps must be performed in
order. • Also clean the surfaces of the components after the
repair to remove any spilled oil.
Figure 90 - Cleaning surfaces
NOTE • After dismounting the hydraulic hose connections,
• Some error codes are only active when
cap both sides of the connection.
the assistance is engaged. NOTE
• Check the display after each step to see if Make sure that all components are
the error code persists. clean when mounting and dismounting.
Dirt in the system can cause serious
damage to the internal components
BEFORE REPAIRS
and / or leakages.
• Do not perform work on a hydraulic system that is
hot or under pressure (discharge the accumulators).
• All component modifications or replacement must
be done with the vehicle stationary, park brake
applied, engine shut-off.

Figure 91 - Cap hydraulic connections

16TAN-H2 SERVICE MANUAL V2.5 39


5.3 REPLACING THE SUSPENSION CYLINDER
Step 1
Turn engine off. Make sure that the
system is depressurized: Open the
manual relief valve handle near the
tank to relieve the pressure in the
main accumulator.
Figure 93 - Opening the valves
To relieve the pressure in the suspension accumu-
lators, remove all caps of the cartridges in the main
valveblock and turn the valves by hand fully open
counter clockwise.
40
5 REPAIRS
On the other valveblocks, remove the caps marked
with 1 and turn the valves the same way. After the
valves are open, press on the caps marked with 2.
Figure 95 - Put caps on both ends
Step 3
Remove the lower end pressure hose connector on the
rear side of the cylinder. Place the container under the
end of the hose and put a cap on the connector in the
chassis.
Figure 94 - Valveblocks
Step 2
Place a container under the cylinder which is to be re-
placed. Remove the pressure hose connector on the front
of the suspension cylinder. Put caps on the ends of the
hose and the connector on the cylinder (see Figure 95).
Figure 96 - Remove connector and
place a cap
5 REPAIRS

Step 3 The oil will run out of the The cylinder must be fully
Remove the nuts on the top joint of the cylinder. Also hose, until the cylinder is depressed before place-
remove the nuts on the bottom. fully depressed. ment. Use compressed air
to extend the cylinder to its
Now the cylinder can be place.
removed the and repaired
or replaced. First attach a hose on the
return side of the cylinder
to let the oil run out in
a container (see Figure
101).
Figure 99 - Oil running out

Step 4
When placing a cylinder, be sure to place the cylinder
Figure 97 - Remove the nuts on top with the pressure side (marked with a “P”) to the front Figure 101 - Attach a hose to the
(cabin side) see Figure 100. return side
The cylinder will now press very slowly, to accelerate
the process, push down on the top of the cylinder. Now attach a hose with
a non-return valve to the
pressure inlet of the cylin-
der. Blow the air in cylinder
until it is in place (see
Figure 102).

Figure 100 - Marking “P” on cylinder Figure 102 - Blow air in the
Figure 98 - Push on the cylinder cylinder

16TAN-H2 SERVICE MANUAL V2.5 41


Step 5
Mount the cylinder when it is in place. Also assemble
the pressure hoses again and close the valves and the
manual relief valve handle.
NOTE
Do not forget to close the valves in the
chassis and the manual relief valve
handle next to the oil tank.
The system will pressurize itself again after star-
ting the truck.
42
5.4 REPLACING THE STEERING CYLINDER
Step 1
Turn engine off. While the engine is off, there is no
pressure on the system for the steering cylinders.
Place a container under the cylinder which is to be
replaced. Remove both the pressure hose connectors
on the cylinder and put a
cap on the ends.
Figure 103 - Remove both connectors
Figure 104 - Remove cover of sensor housing
5 REPAIRS
Step 2
Remove the cover of the sensor housing, by loosening
the four hexagon bolts (see Figure 104).
Disconnect the cable connector and protect it with a cap.
Figure 105 - Put a cap on the cable connector
Step 3
Now the cylinder can be dismounted. Unscrew the bolts
on the front side and the nuts on the rear side.
Figure 106 - Remove bolts on the front side
5 REPAIRS

5.5 REPLACING THE CYLINDER BUSHING

Step 1
Remove dirt from the cylinder bushing which is to
be replaced. The circlip with both holes should be
visible.
TOOLS

Suspension cylinder
OUT: 80mm / IN: 74mm

Steering cylinder
OUT: 72mm / IN: 64mm

Figure 107 - Remove nuts on the rear side

Now the cylinder can be removed and be repaired or Step 2

replaced. See 2.4.8 Critical bolt connections for the
torques of the mounting of the cylinder. Place the co-
ver of the sensor housing back and tighten the bolts
with: 21Nm (use grease). See also 5.11 replacing
steering sensor.
Place the cylinder in the press and place the tool on
the cylinder bushing. Be sure to put the side with the
Figure 108 - Circlip circlip on top.
Choose the right tool for the cylinder bushing. Press the cylinder bushing with 25 tons.

IN

OUT

Figure 109 - Tool Figure 110 - Press the bushing

16TAN-H2 SERVICE MANUAL V2.5 43


Figure 111 - Remove the circlip
Remove the washer and lift the press (see Figure 111).
The bushing can now be removed.
Step 3
Lubricate the rubber of the new bushing with soap wa-
ter. Place the bushing in de cylinder and press it in place.
Figure 112 - Press the bushing
44
Step 4
Lift the press and place both the seal and the circlip
in place. Press the bushing again with 25 tons and
assemble the washer.
Figure 113 - Place the seal and circlip
Figure 114 - Assemble the circlip
The cylinder can be assembled again. See 2.4.2 Check
critical bolts at torque for the torques of the mountings.
5 REPAIRS
5.6 REPLACING HYDRAULIC HOSES
Make sure that the system is depressurized. See 5.3
Replace suspension cylinder or 5.4 Replace steering
cylinder for the steps to take to depressurize the
specific location of the hydraulic hose. Place a
container under the hose which is to be replaced.
Remove the connectors of the hose, and put caps
on the connectors in the chassis as long as the new
hose is not assembled yet.
Figure 115 - Put caps on connectors
The system will pressurize itself again after starting
the vehicle.
5 REPAIRS
5.7 REPLACING CARTRIDGES
Make sure that the system is depressurized. See 5.3
Replace suspension cylinder or 5.4 Replace steering
cylinder for the steps to take to depressurize the
suspension valve block or the steering valve block.
Place a container under the cartridge which is to be
replaced.
Remove the cap of the valve and slide the coil from
the cartridge. Keep the connector on the coil to
protect the connector from dirt and oil.
Figure 116 - Replace the cartridge
Place a new cartridge and assemble the valve.
The system will pressurize itself again after starting
the vehicle.
16TAN-H2 SERVICE MANUAL V2.5
5.8 REPLACING COILS
Remove the cap of the valve and slide the coil from
the cartridge. Remove the connector from the coil
and connect to a new coil. Assemble the valve.
Figure 117 - Replace coil
5.9 FLUSHING THE SYSTEM
When components are internally damaged, or other
influences have caused for dirt or debris has come
into the system, the system must be flushed. Before
putting the installation to use, perform a comple-
te rinsing of the hydraulic circuit to remove all the
impurities that could accumulate while connecting
components.
The filters must be equipped with a system that al-
lows checking the filters state (clogging indicator).
NOTE
When you are uncertain of performing
this procedure, contact your local hydrau-
lic specialist for further information.
5.10 S TEERING
Start the engine and lower the 5th axle (use the
service switch, see. 1.3 Fuses and relays for the
location.
Use an allen key to activate the steering valves. See
Figure 118 and Figure 119:
For the controlling the LHS steering cylinder:
Insert the allen key in the front valve (B) and press to
steer the left side of the axle to the back (1) and press
the rear valve (A) to steer the left side to the front (2).
A
B
Figure 118 - Activating the steering valve
45
 5 REPAIRS

5.11 REPLACING STEERING SENSOR

Turn engine off. Tighten the nuts and bolts with the following torques:
Remove the cover of the sensor housing, by loosening Sensor: 2 hexagon nuts: 21Nm (use grease)
the four hexagon bolts. Cover: 4 hexagon bolts: 21Nm (use grease)

Figure 119 - Activating the steering valve, the left cylinder presses
the axle to the rear (1)

There is also a steering valve block for the right cylin- Figure 120 - Remove cover of sensor housing
der. See Figure 119 (3).
Replace the sensor. Figure 122 - Hexagon nuts sensor mounting

SAFETY
Keep clear from the steered axles when
operating the system, to avoid entrapment.

Figure 121 - Remove sensor Figure 123 - Mounting positions cover of the sensor housing

46
5 REPAIRS

When also the complete sensor housing has been

replaced, tighten the lock nuts on the U-bolts with
5Nm±2Nm (use grease).

Figure 124 - Tightening the U-bolts

16TAN-H2 SERVICE MANUAL V2.5 47

48
FEEDBACK

Our goal is to constantly improve our products and its documentation. Therefore the
opinion and experiences of the users of our products and documentation is always more
than welcome and will be greatly appreciated.

Please notify us if you have any suggestions and/or comments on this document.
Please send your comments by mail, telefax, or hard-copy to the address listed below.

Terberg Techniek BV
Dept. Engineering
P.O. BOX 23
3400AA IJsselstein
The Netherlands

F +31 30 688 55 23
E documentation@terbergtechniek.nl

REMARKS, PROPOSALS

16TAN-H2 SERVICE MANUAL V2.5 49

Industrieweg 9-10 P.O. Box 23 T +31 (0)30 600 62 60 I www.terbergtechniek.nl
3401 MA IJsselstein 3400 AA IJsselstein E info@terbergtechniek.nl