16TAN-H2

non-driven 16T-TAG axle

SERVICE MANUAL
2016.05.04 / V2.0

Industrieweg 9 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
 © 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 Page(s) Remark

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 4
1.1 General working 4
1.2 Installation diagram 5
1.3 Fuses and relays 6
1.4 Schematics 7
2. MAINTENANCE 8
2.1 Warning 8
2.2 Service intervals 8
2.3 Service check list 9
2.4 Service checks 10
2.4.1 Visual check & testdrive 10
2.4.2 State of hoses and pipes 10
2.4.3 Check oil level 10
2.4.4 Oil sample procedure 10
2.4.5 Oil change and topping up 11
2.4.6 Replace filters 12
2.4.7 Oil and accumulator pressures 13
2.4.8 Torque of critical bolts 17
2.4.9 Warning lights 19
2.4.10 Working of the load transfer switch 20
2.4.11 Mounting of the axle load sensor 20
16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0
3. COMPONENT INFORMATION 24
4. ERRORS AND DIAGNOSTICS 30
4.1 Warning 30
4.2 Diagnostics 30
4.3 LED indication on TCM, PCM and DCM 31
5. REPAIRS 33
5.1 Warning 33
5.2 Work clean 33
5.3 Replacing the suspension cylinder 34
5.4 Replacing the steering cylinder 36
5.5 Replacing the cylinder bushing 37
5.6 Replacing hydraulic hoses 38
5.7 Replacing cartridges 38
5.8 Replacing coils 39
5.9 Flushing the system 39
4.10 Steering 39
CONTACT
Service Department Terberg Techniek BV
+31 (0)30 600 62 60
service@terbergtechniek.nl
3

1 SYSTEM EXPLANATION
1.1 GENERAL WORKING
This service manual is a guide for repair & maintenance
concerning Volvo trucks with a non driven Volvo TAG
axle. This manual is valid for the Terberg 16TAN-H2 5th
axle system and will increase the GVW by 16 ton.
The 16TAN TAG axle is hydraulic steered and sus-
pended. Lowering the TAG axle is automatically
executed when the payload of the truck increases the
predetermined axle load of both drive axles.
Lifting the TAG axle is automatically executed when
the payload of the truck drops below a predetermined
CHEMICAL MECHANICAL
ENERGY ENERGY
ENGINE PUMP
Figure 1 - Energy system
4 16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0
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.
For dynamic stability the steering is speed dependent.
• From 0 till 25 km/h the steering angle decreases linearly.
HYDRAULIC MECHANICAL
ENERGY ENERGY
VALVE BLOCKS 5TH AXLE
1 SYSTEM EXPLANATION
• 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)
In the hydraulic tank assembly both temperature and
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.
Figure 2 - Main accumulator (left) and suspension accumulator (right)
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.
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 Axle load 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

16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0 5

 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.
*
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 10A
1 B 10A
C 10A
D 10A
3 relays fuses
*if already occupied relays move to right

Fuse position
A02P 5A

Figure 5 - Service connector in FM

6 16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0

1 SYSTEM EXPLANATION

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

program connector

service switch

The Terberg fuses and

relays occupy the open Figure 7 - Service connector in FH
spaces below the last
volvo relay.

3 relays

fuses
Fuse position
A02P 5A
Fuse positions
A 10A
B 10A
C 10A
D 10A

Figure 6 - Fuses and relays FH

16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0 7


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.
8 16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0
2 MAINTENANCE
2.2 SERVICE INTERVALS
Service 5th axle at least every 2000 hours.
SAFETY
Keep clear from rotating parts, moving parts and • Execute service check (2.3).
steered axles when operating the system, to avoid • Inspect the oil quality (2.5).
entrapment.
• Check and calibrate the axle load sensors (2.4.4).
FILTERS
• At first after start-up of the truck change oil filters
after 150 hours.
• 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.
OIL
SAFETY • Change oil every 4000 hours
The Terberg hydraulic system operates under high or 2 years, dependent on what
pressure. High pressure can cause severe injury. Fluid comes first.
pressure over 400 bar (5800 psi) is possible. • Use Shell Tellus 46.
Wear proper protective equipment!
Next oils are equivalents of Shell
Tellus 46
• BP Bartran HV46
• Total EQuivis ZS 46 Figure 8 - Shell Tellus 46
• Texaco Rando HDZ46
2 MAINTENANCE

2.3 SERVICE CHECK LIST

OK NOT OK NOT POINTS OF INSPECTION

APPLICABLE ORDERNUMMER

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
CHASSIS NR.
Replace filters (3x) 2.4.6
Accumulators 2.4.7
Bolt connections TAG axle 2.4.8
Mounting V-stay 2.4.8
Mounting reaction arms 2.4.8
Warninglights 2.4.9
Axle load sensor (check and calibrate) 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 2016.05.04 / V2.0 9

 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 S TATE 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. The hose can be used from the pressure gauge set.
Before filling a sample container, let some oil poor out
to flush the drain.

If couplings need to be tightened see 2.4.8 Check criti-

cal bolts at torque for torques.

2.4.3 CHECK OIL LEVEL Figure 11 - Taking an oil sample with a hose from the test connector
Conditions:
• running engine
• f ull functional system 2CM
(no error messages)

The maximum oil level ATTENTION

is 2cm below the top of When starting the
the oil level gauge (see engine, after approx.
Figure 9) 10 seconds there is a
Figure 10 - Location of the test connector short pressure peak
For the minimum oil (see Figure 51 number
level: oil must be visible A sample of 100ml should be sufficient. The oil drips 2). Make sure to hold
in the gauge. Also check very slowly from the hose, apart from a pressure the hose firmly. It is
the warning light on the Figure 9 - Gauge peak right after starting the engine (see: attention, advisable to have a
dashboard (see 2.4.9 Figure 51 on the right page). second person holding Figure 12 - Pressure gauge
warning lights) the hose while starting
After taking the sample, check and eventually correct the engine.
the oil level.

10 16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0

2 MAINTENANCE

2.4.5 O IL CHANGE AND TOPPING UP Close the plug and

NOT EVERY SERVICE INTERVAL: EVERY remove the breather
4000H/ 2YEAR filter on top of the
Turn engine off. Open hydraulic tank. Add the NOTE
the manual relief valve new oil (Shell Tellus 46 Do not forget to:
handle near the tank to or equivalent, see 2.2 • close the manual relief valve handle
relieve the pressure in the intervals) through the next to the oil tank
main accumulator. Hand- opening of the breather • place the breather filter back and tigh-
le in Figure 13 is closed filter. ten it handtight (approx. 5Nm)
(down)
Figure 15 - Remove breather The system will pressurize itself again.
filter

Figure 13 - Open handle

Close the manual relief valve handle and start the
engine to fill the system. Open the manual relief valve
Open the plug on the bottom side of the hydraulic tank handle and top the oil up (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 2016.05.04 / V2.0 11

 2.4.6 R EPLACE FILTERS

always use Terberg Techniek genius parts!

NOTE
Do not forget to close the manual relief
valve handle next to the oil tank again.
2.4.6.1 High pressure filter
Turn engine off. Make sure
The system will pressurize itself again.
the hydraulic pressure on
the fluid connection of the
accumulator is ± 0. Open
the manual relief valve 2.4.6.2 Return filter
handle near the tank to Remove the cover of the return filter.
relieve the pressure in the Figure 18 - Remove the filter housing
main accumulator. Take out the filter and install a new, also replace the
Remove the filter and install a new (see Figure 19). seal in the cover (see Figure 21).
Tighten the filter with 20Nm.
Put an oil can below the filter (see Figure 18) and
remove the bottom part of the filter housing.

Figure 17 - Remove cover of return filter

Figure 19 - Pressure filter

12 16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0

 2.4.6.3 Breather filter
Remove the cover of the filter and replace it completely
with a new. The cover assembly contains the breather
filter. Tighten the filter handtight (approx. 5Nm)
CHECKING PRESSURES
To check the nitrogen pressure in the accumulators,
the mechanic should be equipped with a Hydac FPU-
1-250 charging and testing unit or comparable. Make
sure this tool is checked and calibrated regularly.

Hydac FPU-1-250
Terberg part no. tt000020560
Volvo part no.

Oil pressure
The system oil pressure must be between 190 and
Figure 20 - Return filter 240bar.

2.4.7.1 Checking pressure: main accumulator

Figure 21 - Also replace seal in cover
Tighten the filter cover with 20Nm.
Step 1
Make sure the hydraulic
Figure 22 - Breather filter pressure on the fluid
connection of the
2.4.7 OIL AND ACCUMULATOR PRESSURES accumulator is ± 0. The
The nitrogen in the accumulators will get compres- ignition must be off. Open
sed when oil pressure on the oil side of the membra- the manual relief valve
ne increases. handle near the tank to
relieve the pressure in the
Without the (correct functioning) accumulator the main accumulator.
oil pressure produces pressure peaks. And you will
have no oil storage under pressure, this will give a
continuous engagement and disengagement of the
by-pass valve. (thumbing sound)

16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0 13

 Step 2 Step 3 Step 4
Undo the cap from the accumulator. Remove any Connect the testing unit to the nitrogen bottle and Open the valve on the top of the testing unit and
rust, dirt or grease from the accumulator valve (allen then on to the accumulator. Make sure all valves on turn it counter clockwise. This will open the accu-
bolt). the bottle and testing unit are closed. mulator. If correct, the gauge will tell you what the
nitrogen pressure in the accumulator is.

Figure 24 - Test set-up

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

Untighten the accumulator valve. Carefully screw the The right pressure is found on the label on the bottom
bolt a little counter clockwise to check if it moves, do side of the accumulator.
not open the valve!
Main accumulator: 100 bar

ATTENTION
Do not screw the accumulator bolt too open.
The nitrogen can run out.
Figure 25 - Connecting the nitrogen bottles

14 16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0

2.4.7.2 Checking pressure: suspension accumulators Remove all caps of the cartridges on the main valve-
Step 1 block. Turn the valves counter clockwise by hand until
Make sure the hydraulic the end. (see Figure 27)
pressure on the fluid
connection of the Also on the lifting valveblocks, remove the caps ATTENTION
accumulator is ± 0. The marked with 1 and turn the cartridge valves the same When the axle is lifted, the axle will come down
ignition must be off. Open way. After the valves are open, press on the caps during depressurizing.
the manual relief valve marked with 2. (See Figure 28)
handle near the tank to
relieve the pressure in the
main accumulator. Step 2 - 4
See the main accumulator instructions and repeat
To relieve the pressure in the suspension accumulators, steps 2 to 4.
open the valves of the suspension manifold, which is
located in the back of the chassis.

Figure 29 - Location of the two suspension accumulators between

Figure 28 - Valve blocks fifth axle and tandem axles

Figure 27 - Opening the valves The right pressure is found on the label on the bottom
side of the accumulators.

Suspension accumulator: 50 bar

16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0 15

 ADJUSTING 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 30 - Adjusting the pressure
The pressure can be checked on the gauge but also in
Terberg IDE (see Figure 32) Press the fill on button and
see the pressure in the top right box.
When the accumulator is internally damaged, nitrogen
could be blown in the oil system. Close the nitrogen
bottle and check if the pressure remains the same. If
the pressure is stable, relieve the pressure and close the
accumulator by screwing the valve clockwise.
16
Close the other valves and disconnect the testing
OIL PRESSURE
unit. Close all opened hydraulic valves and put all
caps back on top.
To test the system listen to the thumping sound or
look at the oil pressure as described at the beginning
of this paragraph (2.4.7).
NOTE
Do not forget to:
• close the manual relief valve handle Figure 32 - Terberg IDE: oil pressure
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.
Figure 31 - Close accumulator
valves
16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0
2.4.8 TORQUE OF CRITICAL BOLTS
All critical bolt connections have been tightened For V-stay assembly (see Figure 34) also see the Volvo
during modification. After tightening with the right installation requirements: 22493234
torque the connection will be marked with a white,
red or green line with a paint needle (see Figure 33).
NOTE
If tightening torques are not specified in the follo-
wing instructions, use the torques in the Terberg
Assembly parameters standards:

TN008 Hydraulic Assembly Parameters

TN009 Bolts & Nuts Assembly Parameters

Both parameter standards are available from the

Terberg Techniek Service Department.
Figure 33 - Bolt painted lines

Original Volvo mountings must be tightened

If no line can be recognized, the bolt has been
according to Volvo specifications.
loosened. The mark can only be seen as an
indication, always give the bolt connections a visual
check as well and when it does not look reliable:
replace the bolts and nuts.
torque 310Nm±20
M18 12
When the bolts have been loosened and are tightened torque 620Nm±20
with torque again, remove paint and mark with a new line. M20 10.9

Some other bolt connections are mechanically

Figure 35 - Mounting suspension cylinders (top)
locked. Check all marks and locks according to the
following figures.
torque 490Nm±20
M20 10.9

Figure 34 - Mounting V-stay

16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0 17

 torque 175Nm±20 torque 175Nm±20 torque 540Nm±20
M14 10.9 M14 10.9 M20 10.9

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 10.9 M20 10.9

torque 175Nm±20 torque 290Nm±20

M14 10.9 M18 8.8

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

18 16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0

 2.4.9 WARNING LIGHTS
On the dashboard two warning lights are available, WARNING
(see Figure 17). illuminates Computer communication
continuously error.
Possible cause
- Wiring issue
- Programming issue

Action

WARNING
Turn off engine
immediately!

- Contact your local dealer for

more information.
Figure 44 Warning lights - Do not continue driving,
torque 275Nm±20 loading or unloading without
M16 10.9 proper diagnose.
Terberg warnings are
also displayed on the blinks 4 sec on/1 oil temperature oil temperature is too high
Figure 42 - Mounting support steering cylinder brackets sec off 5th axle
Driver information dis- Possible cause
play: software release 9 - Wiring issue.
- Sensor issue.
or later applicable (see - Pump pressure.
Figure 45). - Valve issue.

Action
Figure 45 Driver information
The working of the warn- WARNING
display
ing lights can be checked Turn off engine
immediately!
by turning the ignition “ON”. The lower light will light
- Contact your local dealer for
up shortly and the upper light will light up about five more information.
seconds. - Do not continue driving,
loading or unloading without
proper diagnose.

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

torque 140Nm±20 otherwise a failure is active. See table on the right, the
M14 8.8 numbers of columns correspont with the numbers of
the warning lights (see figures above).
Figure 43 - Assembly valves

16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0 19

 2 MAINTENANCE

WARNING 2.4.10 W ORKING OF THE LOAD TRANSFER 2.4.11 MOUNTING OF THE AXLE LOAD 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 horizontal 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
- Contact your local dealer for
more information.
- Do not continue driving,
loading or unloading without
proper diagnose.
blinks 4 sec suspension 5th suspension is not working
on/4 sec off axle
Figure 46 - Switch
Possible cause
- Wiring issue.
- Sensor issue. Conditions
- Pump pressure.
- Valve issue.
1. Vehicle speed < 7 [km/h]*
2. Axle on the ground
Action
- Stop vehicle and check
system
- Contact your local dealer for
Press the lower part of the switch
more information. The function load Figure 48 - Angle sensors
- Do not continue driving,
loading or unloading without transfer is activated and
proper diagnose. the status warning light When the outcome of the inspection of the mounting
illuminates Check oil level**
continuously illuminates. of the axle load sensor is uncertain or changes are
If oil level is too low (no oil made to the mounting of the angle sensor, calibrate
present in the oil level gauge,
for location see: 3.1 Hydraulic
The “Increase traction” the angle sensor. See instruction on the right.
tank), check for leakages function remains activa-
first before filling the level.
Low oil levels can lead to ted for 30 [sec].
damage to the pump and
other components.
Figure 47 - Warning light
If the level is ok (oil present
in the oil level gauge) but the *required vehicle speed can be set between 0 and 15km/h, default
indicator is still on, contact
your nearest dealer for
is: 7 km/h.
advise.

20 16TAN-H2 SERVICE MANUAL 2016.05.04 / V2.0