SERVICE MANUAL

TERBERG

FIFTHWHEEL

90-2-2”
90-3-2”

Oranje Nassaustraat 10 Tel : 0031-348-459211

P.O. Box 2 Fax : 0031-348-451934 General
3405 ZG Benschop 0031-348-451554 Warehouse
The Netherlands E-mail: info@terbergbenschop.nl
TD 1297-01 26-03-2004 Internet: www.terbergbenschop.nl
 for Terberg 90-2-2" and 90-3-2"

Failure to follow these maintenance

instructions can lead to a not properly
operating fifth wheel and to
PERSONAL INJURY

(part no. T24140184)

relubricate the entire fifth wheel as shown in both

pictures on this page.

AFTER APPROX. 8000 hours of Service

After approx. 8000 hours of service, depending on
operation conditions and actual number of couplings,
is it strongly recommended to completely overhaul
the fifth wheel. Use one of the following rebuild kits and
follow the instructions in this service manual.

1
the original Terberg

Note: Rebuilt kit T27056298 or T27056308 is

ONLY for use on Terberg 90-2-2" or 90-3-2"
Fifthwheels

2
Important:90-2-2" fifth wheels are
not fitted with pocket inserts
(item 27) and will require item 24

T27056298 Full Overhaul Kit, does not include items 26-31

T27056308 Full Overhaul Kit, does not include items 10, 20, 21, 26-32
Please refer to the Terberg partsmanual for partnumbers.

3
 3 Unhook double s pring as s embly from
camplate and the pos t on the fifth wheel
T o complete the replacement cas ting. R emove the yoke bolt and dis card
all components
W AR NING procedures , the tractor mus t be
s afely parked in an area clear
of pers ons and obs tacles . NOT E : If carrying out s ervice work and not
If the lifting arm is rais ed for repairs , us ing a full repair kit the yoke bolt mus t be
it mus t be s afely blocked to prevent it replaced and not re-us ed
from lowering during the repair operation.

R E P AIR P R OC E DUR E S Y OK E B OLT DISCARD

USED BOLT
DO NOT RE-USE!
1 Dis connect the air line and electronic s ens or
cables . C los e the locks by prying each of the locks
as s hown below until the yoke s naps clos ed. In cas e
of is olated replacements of lock parts item no. 13 to
19, pleas e jump to picture no. 7 and leave yoke open.
T hen follow the ins tructions until picture no. 12.
DOUB LE
S P R ING
C AM
P LAT E

P R Y LOC K
IN HE R E

P R Y LOC K
IN HE R E
4 R emove the cam plate pivot bolt (s ee figure
below). Dis card the bolt, was hers , roller,
T he locking mechanis m is under cam plate, and locknut.
s trong s pring pres s ure.
K E E P HANDS AND F ING E R S C AM P LAT E
AWAY F R OM LOC K ING
W AR NING ME C HANIS M.
P IV OT B OLT

2 Dis connect the air cylinder from the cam plate

and the mounting tab on the cas ting. C AM
P LAT E

MOUNT ING C AM
T AB ON B OLT P LAT E
C AS T ING
AIR
C Y LINDE R

WAS HE R C LE V IS
LOC K NUT P IN

C AM P LAT E
AT T AC HME NT
LUG
When us ing full repair kit T 27056298 thes e parts
can be dis carded, if us ing T 27056308 retain the
air cylinder and hardware for re-as s embly.

4
6 R emove the yoke s haft out throught the front 9 Lubricate the lock pin holes of the NE W lock
of the fifth wheel top plate. Next, us ing both jaws with Never-S eez (provided in kit).
hands carefully remove the yoke s pring. DO NOT S UB S T IT UT E .

C AUT ION: T he yoke s pring is under compres s ion, T horoughly lubricate holes
with Never-S eez
us e care when removing. Dis card the yoke s haft
and s pring.

Y OK E S HAF T
14
NE W
LOC K
J AWS

S P R ING
10 Align the lock
jaws in the
cas ting as
s hown.

P os ition lock jaws

s o that the
"kingpin guides " 14
7 R emove the nuts , lock was hers , and greas e fittings are facing
oppos ite the
from both lock pins and carefully drive the lock
top of the
pins out of the cas ting.
fifth wheel
Dis card all components K ING P IN
(toward the G UIDE
G R E AS E ground).
NOT E : If thes e parts F IT T ING UP
are to be re-us ed take
care to prevent LOC K NUT
damage to the LOC K
lock pins . WAS HE R
11 C arefully drive the lock pins into the cas ting
until the heads of the lock pins are flus h
with face of cas ting. Us e care to prevent
chipping or damage
to lock pins . G R E AS E
F IT T ING
LOC K
J AWS
NUT
LOC K
WAS HE R
LOC K
P IN

LOC K
8 R emove and dis card the lock jaws and lock J AWS
return s pring.

LOC K
P IN

S ecure the lock pins us ing the lock was hers

and nuts . R e-ins tall the greas e fittings .

5
12 Ins tall lock 15 Next, align the cam plate "track" over the
s pring as threaded hole in the yoke s haft.
s hown.
13
16 S lide the s pacer 2
LOC K
S P R ING
was her between
the yoke and 4
cam plate. P lace
a roller into the 3
cam plate . T hen
place a was her
over the roller.
.
13 Ins tall yoke s pring and ins ert yoke
s haft into the cas ting and through
the s pring as T HR E ADE D
HOLE 5
s hown below. IN Y OK E
Y OK E S HAF T
S HAF T
Align the 17 C heck the
reces s ed hole alignment of
in the s haft the threaded
with the reces s ed hole
threaded in the cam
hole in the plate.
Y OK E
yoke.
6
Y OK E S P R ING 18 Ins tall a new bolt through the was hers , roller,
cam plate, yoke, and into the threaded hole
in the yoke s haft.

Make s ure the bolt enters the threaded reces s ed

hole in the yoke s haft as s hown below.

USE NEW BOLT ONLY !!!

14 P os ition the pivot hole of the cam plate
C lean thread properly and apply Loctite 242.
over the cas ting lug as s hown.
T ighten the bolt s ecurely, then check for free
S lide a was her
movement of the cam plate and was her.
between the cam
plate and the
1-2 mm 2-3 mm
cas ting with the
gap allowed gap allowed
rounded s ide of
the was her facing 2
1
the cam plate. 9 4 C AM P LAT E
3
C AM P LAT E R OLLE R
P IV OT HOLE 5
IN C AS T ING

NOT E : When ins talling Y OK E

Y OK E
was hers , the rounded S HAF T B OLT MUS T B OT T OM OUT
IN Y OK E S HAF T
edge of the was hers
MUS T always face
the cam plate. C heck gaps under bolt head and was her as s hown
in the above illus tration - gaps which are too big
may indicate that the bolt has not bottomed out in
the yoke s haft correctly

R OUNDE D E DG E

6
19 Attach double s pring to pos t on fifth wheel cas ting 23 C ouple the fifth wheel to a kingpin and verify
and pos t on camplate. that the locks are properly clos ed around the
kingpin as s hown below.

C AM
DOUB LE P LAT E
S P R ING

LOC K S C OMP LE T E LY C LOS E D AR OUND K ING P IN

Activate the lock releas e s witch in the cab and

remove the fifth wheel from the kingpin.

R epeat this s tep three times to verify

proper operation.

F inally, verify that the electronic s ens ors in the

cab are indicating the correct s tatus of the fifth
wheel both when locked and unlocked.

T he fifth wheel is now ready for operation.

20 R e-connect the clevis end of the air cylinder
to the cam plate and then connect the oppos ite
end of the air cylinder to the mounting tab
on the cas ting.

MOUNT ING
T AB ON B OLT
C AM
P LAT E W AR NING
C AS T ING
AIR
C Y LINDE R
If the fifth wheel does
WAS HE R C LE V IS
P IN
not operate properly
LOC K NUT
DO NOT US E IT !
E ither dis as s emble
21 B efore re-as s embling fifth wheel onto truck clean and repeat rebuilding
the bearing s urfaces on the lifting arm and apply
greas e - NLG I clas s 2. procedures or contact
your neares t T E R B E R G
R e-as s enble fifth wheel top plate onto tractor
repres entative.

22 C onnect the air line to the air cylinder and

re-connect the cables for the electronic lock
s ens ors .