TD1215-05sw Service Manual Maintemance YT-TT-RT

Terberg Benschop B.V.
Oranje Nassaustraat 10
P.O. Box 2 > 3405 ZG Benschop
The Netherlands
T > +31 (0) 348 45 92 11
F > +31 (0) 348 45 19 34
I > www.terbergbenschop.nl
E > info@terbergbenschop.nl
SERVICE MANUAL
MAINTENANCE
YT series & TT-RT series
DOCUMENT > TD1215-05 E

EDITION > 10-2004
CONTENTS
WARNING ............................................................................................................................................... 4
GENERAL SAFETY INSTRUCTIONS .................................................................................................... 5
0 GENERAL INSTRUCTION................................................................................................................... 7
0.1 How to use this manual................................................................................................................. 7
0.2 First Service .................................................................................................................................. 7
0.3 Cleaning ........................................................................................................................................ 7
0.4 Removing corrosion protection ..................................................................................................... 8
1 ENGINE ................................................................................................................................................ 9
1.1 Volvo Diesel engines..................................................................................................................... 9
1.2 Cummins Diesel engines ............................................................................................................ 12
1.3 Cummins Natural Gas engines (LPG) ........................................................................................ 18
1.4 Mercedes-Benz Diesel engines .................................................................................................. 22
1.5 Caterpillar Diesel engines ........................................................................................................... 25
1.6 Air Compressor (all engines)....................................................................................................... 29
1.7 Air dryer....................................................................................................................................... 31
1.8 Cooling system (general for all engines)..................................................................................... 31
1.9 Fuel specification ........................................................................................................................ 34
2 GEARBOX / TRANSMISSION ........................................................................................................... 35

2.1 Allison transmission .................................................................................................................... 35
2.2 ZF gearbox .................................................................................................................................. 38
2.3 Clark-transmission ...................................................................................................................... 40
3 TRANSFER GEARBOX ..................................................................................................................... 42

3.1 Steyr VG1200.............................................................................................................................. 42
3.2 AxleTech T-600 ........................................................................................................................... 43
3.3 Kessler W2500 ............................................................................................................................ 44
4 FRONT AXLE ..................................................................................................................................... 45

4.1 Volvo non-driven front axle ......................................................................................................... 45
4.2 DAF non-driven front axle ........................................................................................................... 45
4.3 Volvo non-driven front axle ......................................................................................................... 45
4.4 AxleTech driven front axle........................................................................................................... 46
4.5 Kessler driven front axle.............................................................................................................. 48
5 REAR AXLE ....................................................................................................................................... 50

5.1 AxleTech driven rear axle ........................................................................................................... 50
5.2 Kessler driven rear axle .............................................................................................................. 51
Terberg Benschop 2
6 CAB LIFTING SYSTEM...................................................................................................................... 52
7 HYDRAULIC SYSTEM ....................................................................................................................... 52
8 GREASE POINTS .............................................................................................................................. 53
9 AUTOMATIC GREASING SYSTEM .................................................................................................. 55

9.1 Interlube ...................................................................................................................................... 55
9.2 Groeneveld.................................................................................................................................. 55
9.3 Vogel ........................................................................................................................................... 55
9.4 Lincoln ......................................................................................................................................... 55
9.5 Beka-Max .................................................................................................................................... 56
10 FIFTH WHEEL.................................................................................................................................. 57
11 SERVICE (first, periodic, annual) ..................................................................................................... 58
12 TIGHTENING TORQUES................................................................................................................. 60
Terberg Benschop 3
WARNING
This symbol means:

Warning – Personal injury and damage to components or the drive mechanism
can result if warnings are not followed
The recommendations and warnings in this service manual must be adhered to. The
recommendations given are those of the manufacturers of the relevant components. No guarantee can
be given if these recommendations are not adhered to. If the prescribed service intervals are
exceeded then guarantee claims are invalid. For more specific and detailed recommendation refer the
maintenance service manual of the supplier of the component.
The list below contains general conditions which must be complied with in order to correctly service
the vehicle.
Always drain off oil when it is warm
The specification of the new oil must always comply with the oil specifications prescribed by the
manufacturer of the drive mechanism.
The viscosity of the oil depends upon the outside temperature in which the vehicle operates.
Extra oil additives may not be used unless this is prescribed in writing by Terberg.
Always fill drive mechanisms with an oil dipstick to the highest mark. Note: some manufacturers
use different marks for cold and warm oil.
Always fill drive mechanisms with an oil level plug using the filler plug until the level plug
overflows. Unless otherwise mentioned in this manual, the height of the bottom of the level plug is
the correct oil level.
The quantities of oil which are indicated are only given as an indication.
The quantity of oil always relates to the level indicated on the oil dipstick or the overflowing of the
level plug.
Service intervals prescribed by the manufacturer must be strictly adhered to.
Services can always be carried out before the prescribed time. Make sure though that the next
period is not longer than the prescribed service interval.
Use the original filters of the manufacturer of the component. (can be obtained from Terberg
spares department)
When changing oil always check the breather for proper operation (only for equipment with
breather).
Always make sure the output flange seal(s) are not leaking. Repair immediately to prevent
damage because of lowering oil level. (for gearbox/transmission, transfercase and axles)
Terberg Benschop 4
GENERAL SAFETY INSTRUCTIONS
Incorrect practice or lack of care can cause burns, wounds, mutilation, suffocation or other
bodily injuries or even death.
Make sure you read and understand all safety measures and warnings before carrying out any repairs.
This list contains general safety measures which must be complied with for personal safety reasons.
Special safety regulations are laid down in the procedures when they are applicable.
Ensure the work area around the product is dry, well lit, ventilated and is free of tools, parts, fires
and hazardous substances. Be aware that a dangerous situation could arise.
Always wear safety glasses and protective shoes when carrying out work.
Never wear loose or torn clothing. Always remove jewellery when working.
Disconnect the battery (negative [-] terminal first) and discharge all capacitors before carrying out
any repairs. Disconnect the air starting motor, if present, to prevent the engine starting by
accident. Place a “Not in use” board in the room in front of the operating panel or on the buttons.
ONLY use the correct engine locking methods when you are turning the crankshaft of the engine.
Do not try to run the engine by pushing or pulling the fan. This can cause serious personal injury,
damage to belongings or damage to the fan vanes, so shortening the lifetime of the fan.
If the engine has been running and the coolant is warm, allow the engine to cool down before
slowly loosening the filler cap and releasing the pressure from the cooling system.
Do not work on anything that is ONLY supported by jacks or a hoist. Always use blocks or real
props to support the product before carrying out any service.
Before removing or disconnecting pipes, fittings or similar items, release all pressure in the air, oil
and cooling systems. Take into account the fact that there may be pressure when disconnecting
any part from a system in which pressure is used. Do not use your hands to check for pressure
leaks. Oil and fuel at high pressure can cause bodily injury.
In order to avoid suffocation and freezing, wear protective clothing and ONLY disconnect
tubes/pipes for liquid coolants (freons) in a well ventilated area. In order to protect the
environment, the systems containing liquid coolant must be correctly filled and emptied using
equipment to prevent coolant vapour (fluorocarbons) being emitted into the air. You are legally
obliged to collect used coolant and recycle it.
In order to prevent personal injury, use a hoist or ask for help when lifting heavy parts. Make sure
that all hoisting equipment such as chains, hooks or ropes are in a good state of repair and that
they have the capacity to bear the load. Make sure that the hooks are correctly positioned. If
necessary, use a brace. The tackle hooks may not be subjected to sideward loads.
Corrosion inhibitors contain alkali. Make sure that no such material gets into your eyes. Avoid long
or repeated contact with the skin. Do not swallow. If contacted with the skin, wash immediately
with soap and water. If contacted with the eyes, immediately flush the eyes with a large amount of
water for at least 15 minutes. IMMEDIATELY CALL IN MEDICAL HELP. KEEP AWAY FROM
CHILDREN.
Naphtha and methyl ethyl ketone (MEK) are flammable substances and they should be handled
with care. Follow the instructions of the manufacturer to use these materials safely. KEEP AWAY
FROM CHILDREN.
In order to prevent burns, watch out for hot parts on components which have just been switched
off and for hot liquids in lines, pipes and compartments.
Terberg Benschop 5
Always use tools which are in a good state of repair. Make sure that you know how to use the
tools before carrying out any work. ONLY use replacement parts from the same brand as the
relevant part.
Always use replacement fittings having the same part number (or equivalent). Use no fitting of
inferior quality if replacement is necessary.
Do not carry out any repairs if you are tired or if you have consumed alcohol or drugs which can
affect your ability to work in the correct manner.
When handling old engine oil, avoid long and repeated contact with the skin. Such long and
repeated contact with skin can cause serious skin irritations or other serious bodily injury. After
contact, wash the skin thoroughly. KEEP AWAY FROM CHILDREN.
PROTECT THE ENVIRONMENT: The handling and cleaning up of spent oil or coolant may be
subject to national, provincial or local laws and regulations. Use authorised waste processing
services, including municipal facilities and garages which provide authorised facilities for the
collection of spent oil. If in doubt, contact the provincial or municipal authorities or the
Environmental Protection Service for guidelines about how to handle correctly and clean up spent
engine oil.
Parts which rotate can cause cuts, mutilations or strangulation.
Always wear protective clothing to prevent bodily injury from burns.
Terberg Benschop 6
0 GENERAL INSTRUCTION
0.1 How to use this manual

This manual is summarises all recommendations of the component
suppliers, which can be fitted in the Terberg Terminal Tractor and RoRo
Tractor range.
The change intervals must be followed up as described depended on oil
specification, duty cycle and sulphur content of fuel. Develop your own
service schedule based on the duty cycle of your vehicle(s) and type of fluids
used. The original component recommendations can also be found in the
service manual of the component supplier.
0.2 First Service

First service after delivery of the vehicle, at 100 operating hours.
The first service should be done to make sure that all components are installed properly and keep
installed properly. Also all oil levels should be checked and corrected.
The first oil and filter changes must be carried out as recommend by the component manufacturer.
However, Terberg recommends to change the engine and transmission oil at the first service, to make
sure that first dirt and wear particles are removed.
See paragraph 11 for the first service checkpoints.

Tightening torque’s of the following points needs especially be checked:
• Bolt connections in the cabin mountings (e.g. shock absorbers)
• Bolt connections in engine and transmission suspension
• Tightening of hose clamps
• Bolt connections in front and rear axle suspension
• Bolt connections in lift-frame mountings
• Tightening of hydraulic couplings
0.3 Cleaning
The vehicle should be washed as soon as it has become dirty,

particularly in the wintertime when road salt and moisture can easily
give rise to corrosion. Chassis and its components can be cleaned by
a high pressure cleaner. Avoid grease build-up around the fifth wheel,
especially the rear axle breather must be free of grease.
Clean the cooler package (radiators) to prevent external pollution.

Cleaning of radiators can be done by air or water.
Be aware that a high-pressure water beam can damage sealing,

electrical equipment, hoses and wiring.
Do not aim the high-pressure water beam at sealing of hydraulic
cylinders and sealing of the drive line components.
Do not aim the high-pressure water beam directly at electrical
equipment.
Do not aim the water beam directly at breathers.
Do not aim a high-pressure water beam too close at a radiator, this
can damage the cooling fins of the radiator.
Terberg Benschop 7
0.4 Removing corrosion protection
When a tractor is transported over sea on a ships upper deck, it has been exposed to the salt oceanic
climate.
In these cases, the tractor is treated with an anti-corrosion fluid as protection, with specification:
American Standards AXS 673, AXS 1759 grades 1 and 2

ISO 6743/8 (1987) : RFF category
US Army MIL-C-972 grade 3
The vehicle is covered with a soft greasy protective film with a water-repellent effect, that assures the
oceanic climate does not cause any difficulty. Application of the fluid can be detected: when examined
under the Wood lamp, parts show a fluorescent yellow.
! WARNING!
BEFORE THE VEHICLE CAN BE USED, THE FILM MUST BE REMOVED.
The protective film can be removed with:

Preferably this should be done by spraying it on to the vehicle.
- solvent (white spirit, petrol, trichlorethelene, etc…)

- wiping with a cloth soaked in solvent.
- soaking in two successive layers for the time required ; in some cases, this may exceed 30
minutes.
- Petrol with 1% of commercially available emulgator: soaking for 20 to 30 minutes, or more if
necessary, draining, washing in hot water, drying.
- Alkaline solutions at 85/95°C: soaking for the time required (15 to 30 minutes or more), washing in
hot water, drying.
We recommend the following formula for the solution:
Silicate of sodium: 0,5 %
Trisodium phosphate: 1 %
Sodium carbonate: 1 to 2 %.
All parts of the vehicle should be cleaned. But, because the film is on oil containing basis, the parts
that will reach high temperatures need to be cleaned very well. This because of fire hazard.
The critical parts are:

• Engine
• Complete Exhaust system
• Radiator (must also be cleaned very carefully to prevent early clogging)
When all parts are cleaned and the critical parts are inspected thoroughly, the vehicle is ready for use.
Terberg Benschop 8
1 ENGINE
1.1 Volvo Diesel engines
Volvo has refined and adapted the old requirement specification (VDS) and adapted it to the so-called
emission controlled engines. This new specification is called Volvo Drain Specification 2 (VDS-2).
VDS-2 also contains viscosity classes 5W-30, 5W-40 and 10W-40. (Refer to the viscosity
recommendations below)
VDS oils can of course be used in Volvo emission controlled engines as well, but with reduced oil
change intervals.
Oil grade
VDS –2
VDS
ACEA E3-96, E2-96
API CD, CE, CF, CF-4, CG-4
Note: No extra oil additives may be used.
Viscosity
Select the viscosity from the table. The temperature values refer to constant ambient air temperatures.
1) Only fully synthetic and/or VDS /VDS-2 oil

2) Only VDS-2 oils
Oil change intervals

The oil change intervals are depend upon the grade of the oil and the amount of sulphur in the fuel. No
oil change interval may be longer than 12 months.
Change the oil in accordance with the following tables.
Terberg Benschop 9
VOLVO D7B - TD71 - TWD740 - TWD1231 engines
Oil grade Sulphur content of fuel
< 0.5% 0.5 – 1.0 % >1.0%
VDS –2 600 operating hours 300 operating hours 150 operating hours
or 12 months or 12 months or 12 months
VDS 400 operating hours 200 operating hours 100 operating hours
ACEA E3-96, E2-96
200 operating hours 100 operating hours 50 operating hours or
API CD, CE, CF
or 12 months or 12 months 12 months
CF-4, CG-4
VOLVO TAD720 engines

Oil grade Sulphur content of fuel
< 0.5% 0.5 – 1.0 % >1.0%
VDS –2
VDS
500 operating hours 250 operating hours 100 operating hours
ACEA E3-96, E2-96
API CD, CE, CF
CF-4, CG-4
Oil change volume

Engine type Oil change volume in litres, including Oil volume in litres between
approximate volume for oil filter dipstick Max-Min markings
D7B 20.5 6.5
TD71 29 8
TAD720VE 20 3
TWD740 VE 29 8
TWD1231 VE 38 9
The oil level is always determined via the indication on the dipstick. The oil quantities given are only an
indication.
Oil filter
Oil filter and by-pass filter* shall be changed at each oil change!
Only use Volvo original oil filters.
Fuel filter
Replace the fuel filter and fuel pre-filter after every 800 hours of operation or every year, whichever is
sooner.
(TAD720 every 1000 hour)
Coolant + filter* change interval

Change the coolant (if engine without coolant filter) after 24 months or after 5.000 hours of operation.
Change the coolant (if engine with coolant filter) after 48 months or after 10.000 hours of operation.
If present, replace the coolant filter every 6 months or every 2nd oil change or after every 1000 hours of
operation.
*
If present
Terberg Benschop 10
Coolant*
The cooling system must be filled with a coolant that protects the engine against internal corrosion and
from freezing if the climate requires it. Never use water alone.
Always use Volvo Penta coolant Type 90, which is available in concentrated form.
1L = V1141645
5L = V1141646
210L = V1141647
Mixing in other types of concentrated coolant can give impaired corrosion protection, which could
damage the engine or block the cooling system.
Always use clean water, which complies with the requirements in ASTM D4985 X1.1. If these
requirements are not complied with, corrosion could occur, which would lead to impaired cooling
performance. (See for specification paragraph 1.8).
The mixture of concentrated coolant and water should contain of 40-55% concentrate in water.
*
Do only use this Volvo Penta recommendation when you do not want to use the Terberg
recommendation with Shell Glycoshell coolant.
Air filter
Primary filter replacement: when the relevant indication lamp lights up, but at least once every
24 months.
Secondary* filter replacement: every 3rd time the primary filter is replaced or at least once every
48 months. The secondary filter shall also be replaced when the
relevant indication lamp lights up.
* If present
Valves, inlet/outlet
The valves must be checked and adjusted in accordance with the instructions given in the Volvo
workshop manual.
Check the valve clearance after the first 100-200 hours.
Adjust the valve clearance every 1200 hours (TAD720 every 1500 hours).
Engine type Valve Valve

clearance*, clearance*,
inlet outlet
D7B 0.40 mm 0.55 mm
TD71 0.40 mm 0.55 mm
TAD720 VE 0.30 mm 0.50 mm
TWD740 VE 0.50 mm 0.65 mm
TWD1231 VE 0.40 mm 0.70 mm
* Valve clearance when the engine is cold
Refer to the Volvo workshop manual for the operating procedure.
Terberg Benschop 11
1.2 Cummins Diesel engines
Oil grade
The lubricating oil prescribed for the engines is Cummins Premium Blue or an
equivalent oil which meets at least the following specifications with a ash
content of 1 to max. 1,3 percent mass.
CES-20071 / 72 (Cummins Engineering Standard)

CES-20076 / 77 / 78 (for ISBE engine)
API CI-4/SK
API CH-4/SJ
ACEA E-5
Viscosity:
For normal outside temperatures (above –10°C), a viscosity of 15W40 is preferred. See also the chart
below.
Single-grade oils
Multigrade oils

6BT(A) 5.9C and 6CT(A) 8.3C and 6CTAA 8.3C
Cummins Premium Blue
CES-20071 / CES-20072
API CI-4/SK
API CH-4/SJ
250 hours of operation or 3 months*
ACEA E-5
* Depending on which is sooner.
Terberg Benschop 12
6BTAA 5.9C QSB - QSC
CES-20071 / CES-20072
API CI-4/SK 500 hours of operation 500 hours of operation
API CH-4/SJ or 6 months* or 6 months*
ACEA E-5
250 hours of operation 250 hours of operation

API CF-4
or 3 months* or 3 months*
ISBE
CES-20071 / 20072 / 20076
/ 20077 / 20078 500 hours of operation
API CH-4 or 6 months*
ACEA E-5
250 hours of operation

API CG-4 / SH
or 3 months*
QSM11 - Oil drain intervals by duty cycle (hours)

Servere Heavy Medium Light
Fuel Consumptiom
> 50 l/hr 38 to 50 l/hr 32 to 38 l/hr <32 l/hr
API CF-4 150 200 250 300
API CG-4 250 300 400 500
API CH-4 or ACEA E5 300 350 500 600
CES20076 or CES20077 350 400 550 700
QSM11 Note:
1. Valvoline Premium Blue and Premium Blue 2000 meet 20076 standards.
2. Limit oil change interval to 250-hour max for all oil grades if 40% of the operating time is in
ambient temperatures above 38°C [100°F] to prevent engine damage due to oil degradation
resulting from high oil temperatures.
3. Cummins does not recommend the use of CE or CD grade oils. If CD or CE oils must be used,
make the oil drain intervals half of the API CF-4 values.
4. Engine oil drain intervals need to be reduced by 50% when fuel sulfur content exceeds 0.5%.
5. Oil filters must meet CES 10065 specifications. LF9001 meets and exceeds CES 10065
specifications.
Terberg Benschop 13
Oil change volume
Engine type Oil change volume in litres Oil volume in litres between
dipstick Max-Min markings
6BT(A) 5.9 14.2 2.0
standard
6BT(A) 5.9 ECT 24 7.5
large center sump
6BTAA 5.9 14.2 2.0
QSB 14.2 2.0
ISBE 17.2 2.8
6CT(A) 8.3 18.9 3.8
standard
6CTAA 8.3 18.9 3.8
QSC 18.9 3.8
QSM 37 8.0
indication.
Oil filter
Oil filters and by-pass filters (if present) shall be changed at each oil change!
Fuel filter
Replace the fuel filter and fuel pre-filter after every 500 hours of operation or every 6 months,
whichever is sooner.
(QSM every 250 hours)
Drain the water plug on the fuel pre-filter daily.
Air filter
Check/Inspect every 250 hours of operation or every 3 months*. Refer to the Cummins “Operation and
Maintenance Manual”.
Replace the air filter when the relevant indication lamp lights up, or after every 500 hours of operation
or every 6 months*.
Coolant change interval

Engine type Coolant change interval
B5.9
QSB Change the coolant after every 2000 hours of operation or every 24 months*
ISBE
C8.3
QSC
QSM Change the coolant after every 6000 hours of operation or every 24 months*
* whichever is sooner.
Terberg Benschop 14
Coolant*
Use low-silicate antifreeze that meets ASTM4985 (GM6038M specification) criteria.
Fully formulated coolant must meet ASTM D-6210/D-6211.
Cummins Inc. recommends using either a 50/50 mixture of good-quality water and fully formulated
antifreeze, or fully formulated coolant when filling the cooling system.
Good-quality water is important for cooling system performance.

Excessive levels of calcium and magnesium contribute to scaling problems, and excessive levels of
chlorides and sulfates cause cooling system corrosion.
Water Quality
Calcium Magnesium Maximum 170 ppm as
(hardness) (CaCO3 + MgCO3)
Chloride 40 ppm as (CI)
Sulfur 100 ppm as (SO4)
Cummins Inc. recommends using Fleetguard® Compleat ES. It is available in both glycol forms
(ethylene and propylene).
Fully formulated antifreeze must be mixed with good-quality water at a 50/50 ratio (40- to 60-percent
working range). A 50/50 mixture of antifreeze and water gives a -36°C freezing point. The actual
lowest freezing point of ethylene glycol antifreeze is at 68 percent.and must never exceeded under
any conditions.
*
Do only use this Cummins Inc. recommendation when you do not want to use the Terberg
Coolant DCA4 additive*

Only for engines with coolant filter:
On each coolant change, use the appropriate amount of liquid DCA4 to make a “heavy duty” coolant
mixture. DCA4 is a collective name for additives which protect the system against corrosion and
cavitation (amongst other things). The concentration must be 0.4 units per litre for optimal protection.
Cooling system Required mixing quantity of DCA4

Capacity (litres) Litres
29-43 1.4
44-58 1.9
T30052450 DCA4 0.5 litres (Fleetguard DCA 60L)

T30052479 DCA4 19 litres (Fleetguard DCA 75L)
*
Do not use this Cummins recommendation in combination with a Shell Glycoshell coolant.
See paragraph 1.8 for Terberg recommendation with Shell Glycoshell coolant.
Terberg Benschop 15
Coolant filter DCA4*
Only present on C8.3 / QSC / QSM engines.
Replace the coolant filter after every 500 hours of operation or 6 months, whichever is sooner.
(QSM every 250 hours of operation or 6 months, whichever is sooner.)
The coolant filter contains DCA4 granules which dissolve in the system to make a “heavy duty” coolant
mixture. The concentration must be 0.4 units per litre for optimal protection.
For a 20-58 litre system, a coolant filter is prescribed with 2-4 units DCA4. Use the service filter with 4
units DCA4: part number CU3315116 (Fleetguard WF2071).
(For QSM use part number CU3100308 (Fleetguard WF2075).
(For QSC use part number CU3100307 (Fleetguard WF2074).
*
Testing for DCA4

The concentration of DCA4 must be tested with a Fleetguard “3-way test kit”.
Part number Description

Kit for testing for DCA4, content: 50 strips (Fleetguard
T24109067
CC2602M)
When do you have to use the test kit?

9 When there is excessive loss of coolant
9 At least twice per year, if desired more frequently.
9 If the concentration is higher than the limit of 0.8 units per litre, a test must be carried out during
each service interval until the concentration is below the limit value.
Follow the instructions of the test kit.
How to use the test kit?

The concentration is above 0.8 units/litre.
Do not replace the service filter or don’t add any DCA4-
liquid until the concentration drops below 0.8 units per
litre.
The concentration is between 0.3 and 0.8 units/litre.

The concentration is within the normal limits.
Add the normal quantity of DCA4 by replacing the filter.
The concentration is below 0.3 units/litre.

Add the normal quantity of DCA4 by replacing the filter,
plus an extra amount in liquid form. This increases the
concentration to an acceptable level.
Important:
There is an expiry date on the test strip packaging. Incorrect results can occur after exceeding the
expiry date. The packaging must always be well sealed to protect the moisture-sensitive strips. The
strips must always be kept stored at a temperature between 0° and 32° Celsius.
*
Terberg Benschop 16
The valves and injectors* must be checked and adjusted in accordance with the instructions given in
the Cummins Operation and Maintenance manual.
Check/adjust the valve clearance after every 1000 hours of operation or after 1 year, whichever is
sooner.
(QSM valves and injectors every 1500 hours of operation or 12 months, whichever is sooner. )
*if present

clearance**, clearance**,
inlet outlet
6BT(A) 5.9 0.25 mm 0.51 mm
(0.010 inch) (0.020 inch)
6BTAA 0.25 mm 0.51 mm
(0.010 inch) (0.020 inch)
QSB 0.25 mm 0.51 mm
(0.010 inch) (0.020 inch)
ISBE 0.25 mm 0.51 mm
(0.010 inch) (0.020 inch)
6CT(A) 8.3 0.31 mm 0.61 mm
(0.012 inch) (0.024 inch)
6CTAA 0.31 mm 0.61 mm
(0.012 inch) (0.024 inch)
QSC 0.31mm 0.56mm
(0.012 inch) (0.022 inch)
QSM 0.36 mm 0.69 mm
(0.014 inch) (0.027 inch)
** Valve clearance when the engine is cold
Refer to the Cummins workshop manual for the operating procedure.
Terberg Benschop 17
1.3 Cummins Natural Gas engines (LPG)
Oil grade
Cummins natural gas engines require a special oil that is
available from major oil suppliers. Careful attention must
be paid to engine oil specifications because natural gas
engine oil has different properties than a diesel engine oil.
WARNING !
Do not use diesel engine oil in a natural gas engine. If
diesel engine oil is used, valve torching, piston scuff-ing,
and reduction of spark plug life will occur.
WARNING !
A sulfated ash limit of 0.6 percent has been placed on
all engine lubricating oil recommended for use in Cummins
natural gas engines. Higher ash oils can cause
valve and/or piston damage and lead to excessive oil
consumption and degradation of the catalyst.
Use oil that conforms to Cummins Engineering Standards:

(CES) 20074 SAE 15W40
Valvoline Premium blue GEO 15W40 CES20074

Terberg part no. T30052800 (18,9 Litre)
Viscosity:
For normal outside temperatures (above –10°C), a viscosity of 15W40 is preferred.

6B LPG Plus
Cummins Premium blue GEO
CES-20074 250 hours of operation or 3
months*
Oil change volume

6B LPG Plus 14,2 2,0
indication.
Oil filter
Oil filters and by-pass filters (if present) shall be changed at each oil change!
Terberg Benschop 18
Fuel filter
Replace the fuel filter (on engine) after every 500 hours of operation or every 6 months, whichever is
sooner.
Closed crankcase ventilation filter

Replace the filter after every 500 hours of operation or every 6 months, whichever is sooner.
Magnetic inline LPG filter

Replace the filter (inside tank compartment) after every 500 hours of operation or every 6 months,
whichever is sooner.
Air filter
Check/Inspect every 250 hours of operation or every 3 months*. Refer to the Cummins “Operation and
Maintenance Manual”.
Replace the air filter when the relevant indication lamp lights up, or after every 500 hours of operation
or every 6 months*.

Engine type Coolant change interval
6B LPG Plus Change the coolant after every 2000 hours of operation or every 24 months*
Coolant*
Use low-silicate antifreeze that meets ASTM4985 (GM6038M specification) criteria.
Fully formulated coolant must meet ASTM D-6210/D-6211.
Cummins Inc. recommends using either a 50/50 mixture of good-quality water and fully formulated
antifreeze, or fully formulated coolant when filling the cooling system.
Good-quality water is important for cooling system performance.

Excessive levels of calcium and magnesium contribute to scaling problems, and excessive levels of
chlorides and sulfates cause cooling system corrosion.
Water Quality
Calcium Magnesium Maximum 170 ppm as
(hardness) (CaCO3 + MgCO3)
Chloride 40 ppm as (CI)
Sulfur 100 ppm as (SO4)
Cummins Inc. recommends using Fleetguard® Compleat ES. It is available in both glycol forms
(ethylene and propylene).
Fully formulated antifreeze must be mixed with good-quality water at a 50/50 ratio (40- to 60-percent
working range). A 50/50 mixture of antifreeze and water gives a -36°C freezing point. The actual
lowest freezing point of ethylene glycol antifreeze is at 68 percent.and must never exceeded under
any conditions.
Do not use antifreeze not compatible with aluminum.
*
Do only use this Cummins Inc. recommendation when you do not want to use the Terberg
Terberg Benschop 19
Spark Plugs
Replace the spark plugs after every 1000 hours of operation or every 12 months, whichever is
sooner.
Replace the spark plug wires after every 2000 hours of operation or every 24 months, whichever is
sooner.
WARNING !
Use only Cummins authorized spark plugs for Scheduled Maintenance or repairs. The use of
unauthorized parts can affect performance and Emission Control System.
The valves must be checked and adjusted in accordance with the instructions given in the Cummins
workshop manual.
Check/adjust the valve clearance after every 1000 hours of operation or after 1 year, whichever is
sooner.

inlet outlet
B LPG Plus 0.31 mm 0.61 mm
(0.012 inch) (0.024 inch)
Refer to the Cummins workshop manual for the operating procedure.
Fuel
This specification covers LPG fuel for use in vehicular spark ignited LPG engines. The
requirements apply to fuel as it is delivered to the engine.
Chemical composition shall be in accordance of Cummins Engineering Standard 14613 (HD10), see
table below.
Chemical Composition
Constituents Requirement Test Method
Propane, volume % 85.0 minimum ASTM D 2163
Propylene, volume % 10.0 maximum ASTM D 2163
Butane & Heavier, volume % 5 maximum ASTM D 2163
Hydrogen Sulfide Pass ASTM D 2420
Total Sulfur ppmw 80 ASTM D 2784
• There are no physical or mechanical property requirements.
• The gas at 100 ºF (38 ºC) shall have a vapor pressure of 208 psig (1430 kPa) maximum, when
determined in accordance with ASTM D 1267.
Volatile residue temperature at 95 % evaporation shall be -37 ºF (-38.3 ºC) maximum, when
determined in accordance with ASTM D 1837.
• The gas shall pass a moisture content requirement in accordance with ASTM D 2713.
• Copper corrosion strip test shall be performed and shall be No. 1 maximum, when determined in
accordance with ASTM D 1838. Note: This method may not accurately determine the presence of
reactive materials (for example H2S) in liquefied petroleum gas if the product contains corrosion
inhibitors or other chemicals which diminish the reaction with the copper strip.
• The fuel shall not contain water, dust, sand, dirt, oils, or any other substance/ constituent in an
amount that is detrimental to the operation of the engine.
Terberg Benschop 20
WARNING!
Liquefied Petroleum Gas (LPG) is normally treated with an odor producing chemical so that users will
be able to smell gas leaks. Always be alert for the smell of gas. If you enter a room or approach a
vehicle and a smell of gas is present, immediately shut off all engines and ignition sources. Avoid
sparks, arcing switches and equipment, cigarettes, pilot lights, flames, and other sources of ignition in
the area and in areas with common ventilation. Provide extra ventilation to the area and do not start
the equipment or nearby equipment until the leak is corrected and the area is ventilated. Avoid leaving
liquefied petroleum gas (LPG) fueled equipment in unvented rooms overnight or for extended periods.
Store and service liquefied petroleum gas (LPG) fueled equipment in large well-ventilated areas or
outside.
WARNING!
Do not troubleshoot or repair gas leaks while the engine is running.
CAUTION!
Liquefied Petroleum Gas (LPG) is heavier than air and can accumulate near the floor, in sumps, and in
low-lying areas.
CAUTION!
Always torque fasteners and fuel connections to the required specifications. Over tightening or under
tightening can allow leakage. These connections are critical to the fuel and air systems.
CAUTION!
Always test for fuel leaks as instructed, as odorant can fade.
CAUTION!
Close the manual fuel valves prior to performing maintenance and repairs and when storing the
vehicle inside.
Terberg Benschop 21
1.4 Mercedes-Benz Diesel engines
Oil grade
Only multi-grade engine oils approved by Mercedes -Benz must be used:
MB 228.5
MB 228.2/3
MB 228.0/1
In order to make the proper choice of a commercial oil, refer the Mercedes-Benz (A5) manual
“Specifications for operating fluids”. All mentioned sheets are described in this Mercedes-Benz
manual. The use of non-approved engine oils could affect warranty rights.
Viscosity
(According MB specification sheet 224.2)
Adhering exactly to the SAE grades in
accordance with the ambient temperatures would
result in frequent engine oil changes. The
temperature ranges of the SAE grades are
therefore to be looked upon as a guide which for
brief periods can be exceeded upward or
downward.
Select the SAE classification of the engine

Mercedes-Benz OM900 series
Sulphur content of fuel
Specification 0% - 0,3% 0,3% – 0,8% 0,8% - >
900 hours of operation 450 hours of operation 270 hours of operation
MB 228.5
or 12 months* or 12 months* or 12 months*
700 hours of operation 350 hours of operation 210 hours of operation
MB 228.2 / 3
500 hours of operation 250 hours op operation 150 hours op operation
MB 228.0 / 1

The engine oil has to be changed at least once a year.
If a different oil grade is used to top up to the correct capacity, the replacement interval is determined
by the lower oil grade. When topping up, only use engine oils of the same grade.
Oil change volume

OM906LA 29 5
indication.
Terberg Benschop 22
Oil filter
Oil filter(s) must be replaced at each oil change!
Replace the oil filter at least once a year.
Fuel filter
Clean the fuel pre-filter every third oil change.
Replace filter element of the fuel filter every third oil change.
Replace filter element of the fuel pre-filter with water trap every third oil change.
Drain the water plug on the fuel pre-filter water trap daily.
Air filter
Replace the air filter when the relevant indication lamp lights up.
The filter element should however generally be renewed.

Change the coolant every three years.
Coolant*
The coolant is a mixture of water and antifreeze/corrosion inhibitor. The coolant
must remain in the cooling system all year round to ensure anti-corrosion protection
and to increase the boiling point.
Use an approved premixed coolant in accordance with Sheet 326.0, 326.2 or 326.3 of the Mercedes-
Benz Specifications for Service Products. Information is also available from any Mercedes-Benz
Service Centre.
Water
Water without additives is not permitted as a coolant, even if antifreeze properties are not necessary.
The coolant water must satisfy certain requirements which are not always fulfilled by drinking water.
If the water is not of sufficient quality, it must be treated.
Information is available from any Mercedes-Benz Service Centre.
Antifreeze/corrosion inhibitor
To prevent damage to the cooling system:
• Only use approved antifreeze/corrosion inhibitor. Use an approved antifreeze/corrosion inhibitor in
accordance with Sheet 325.0 or 325.2 of the Mercedes-Benz Specifications for Service Products.
Information is also available from any Mercedes-Benz Service Centre.
• When topping up (after coolant loss), make sure that the antifreeze/corrosion inhibitor
concentration is 50% by volume (this ensures antifreeze protection down to –37 °C).
If the concentration is too low, there is a risk of engine damage as a result of corrosion/cavitation.
• Do not use an antifreeze/corrosion inhibitor concentration of over 55% by volume (maximum

antifreeze protection). Above this concentration, antifreeze protection deteriorates and heat
dissipation is less effective.
Terberg Benschop 23
Coolant mixing ratio:
Antifreeze Protection Approximately

–37 °C
down to –45 °C
Water % by vol. 50 45
Antifreeze/corrosion maximum
50
Inhibitor % by vol. 55
In exceptional cases, when no antifreeze/ corrosion inhibitor is available and/or no antifreeze

protection is required (in tropical regions), use an approved coolant additive without antifreeze
properties in accordance with Sheet 312.0 of the Mercedes-Benz Specifications for Service Products
(e.g. MB corrosion inhibitor A 000 98913 2510 by DaimlerChrysler AG or an approved additive from
another manufacturer).
In this case, the coolant must be renewed every year.
*
Do only use this Mercedes-Benz recommendation when you do not want to use the Terberg
The valves must be checked and adjusted in accordance with the instructions given in the Mercedes-
Benz Operating instructions.
The valve clearance must be checked / adjusted during the first oil change and then during the 3th,
5th, 7th oil change and so on.

inlet outlet
OM906LA 0.40 mm 0.60 mm
Refer the Mercedes-Benz Operating instructions for the operating procedure.
Terberg Benschop 24
1.5 Caterpillar Diesel engines
Oil grade
Due to significant variations in the quality and in the performance of
commercially available oils, Caterpillar makes the following recommendations:
Caterpillar Diesel Engine Oil (10W30)

Caterpillar Diesel Engine Oil (15W40)
If Caterpillar multigrade Diesel Engine oil is not used, only use commercial
multigrade oils that meets the following classifications:
EMA LRG-1
API CH-4
API CG-4
API CF-4
In order to make the proper choice of a commercial oil, refer the Caterpillar Operation and
Maintenance manual.
Viscosity
The proper SAE viscosity grade of oil is determined by the minimum ambient temperature during colt
engine start-up, and the maximum ambient temperature during engine operation.
Use the highest oil viscosity that is available to meet the requirement for the temperature at start-up.
Engine oil viscosity

Viscosity Ambient Temperature
Grade Minimum Maximum
SAE 0W20 -40°C 10°C
SAE 0W30 -40°C 30°C
SAE 0W40 -40°C 40°C
SAE 5W30 -30°C 30°C
SAE 5W40 -30°C 40°C
SAE 10W30 -20°C 40°C
SAE 15W40 -15°C 50°C

Abnormally harsh operating cycles or harsh environments can shorten the service life of
the engine oil. Arctic temperatures, corrosive environments, or extremely dusty conditions
may require a reduction in engine oil change intervals from the recommendations in the
Table. Poor maintenance of air filters or fuel filters requires reduced oil change intervals. See
your Caterpillar dealer for more information if this product will experience abnormally harsh
operating cycles or harsh environments.
Oil change interval for 3126B engine (1)
Operating Conditions
Severe
Multigrade oil type Fuel Sulphur Altitude above
High load
from 0.3% 1830 m
to 0.5% (6000 ft)
Caterpillar Diesel Engine Oil 500 hours 500 hours 250 hours
API CH-4 500 hours 250 hours 250 hours
API CG-4 250 hours 250 hours 250 hours
API CF-4 250 hours 250 hours 250 hours
(1) For optimising of the oil change intervals refer the Caterpillar Operation and Maintenance manual.
Terberg Benschop 25
Oil change volume
Engine type Oil change volume in litres
3126B 31
indication.
Oil filter
Oil filter(s) must be replaced at each oil change!
Fuel filter
The water separator must be monitored daily and should be drained if water is present.
Replace the fuel filter element regularly. Install a vacuum gauge on the primary filter/water separator.
The primary filter/water separator should be changed if the pressure is more than 50 to 70 kPa.
Air filter
Replace the air filter when the relevant indication lamp lights up.
The filter element should however be renewed at least every year.
Operation conditions (dust, dirt and debris) may require more frequent service of the air filter.

Change the coolant every 3000 hours or every year, whichever is sooner.
For optimising of the coolant change intervals refer the Caterpillar Operation and Maintenance manual
“Coolant recommendations”.
Coolant*
Coolant is normally composed of three elements: water, additives and glycol.
Water
NOTICE:
AII Caterpillar diesel engines equipped with air-to-air aftercooling (ATAAC) require a minimum at 30
percent glycol to prevent water pump cavitation.
NOTICE:
Never use water alone. Water alone is corrosive at engine operating temperatures. Water alone does
not provide adequate protection against boiling or freezing.
Water is used in the cooling system in order to transfer heat.

Distilled water or deionized water is recommended for use in engine cooling systems.
DO NOT use the following types of water in cooling systems: hard water, softened water that has been
conditioned with salt, and sea water.

If distilled water or deionized water is not available, use water with the properties that are listed in the
table below.
For more information refer the Caterpillar Operation and Maintenance manual “Cooling System
Specifications”.
Terberg Benschop 26
Caterpillar Minimum Acceptable Water Reguirements
Property Maximum Limit ASTM Test

40 mg/L “D512”
Chloride (Cl)
(2.4 grains/US gal) “D4327”
100 mg/L
Sulfate (SO4) “D516”
(5.9 grains/US gal)
170 mg/L
Total Hardness “D1126”
(10 grains/US gal)
340 mg/L
Total Solids “D1888”
(20 grains/US gal)
Acidity PH of 5.5 to 9.0 “D1293”
Additives
Additives help to protect the metal surfaces of the cooling system. A jack of coolant additives or
insufficient amounts of additives enable the following conditions to occur:
Corrosion, formation of mineral deposits, rust, scale, pitting and erosion from cavitation of the cylinder
liner, foaming of the coolant.
Many additives are depleted during engine operation. These additives must be replaced periodically.
This can be done by adding Supplemental Coolant Additives (SCA) to Diesel Engine
Antifreeze/Coolant (DEAC) or by adding ELC Extender to Extended Life Coolant (ELC).
Additives must be added at the proper concentration. Overconcentration of additives can cause the
inhibitors to drop out-of-solution.
Specifications”.
Glycol
Glycol in the coolant helps to provide protection against boiling, freezing and cavitation.
For optimum performance, Catterpillar recommends a 50/50 (1:1) mixture of a water glycol solution.
Note: Use a mixture that will provide protection against the lowest ambient temperature.
Ethylene glycol
Freeze Boil
Concentration
Protection Protection
50% -36°C 106°C
60% -51°C 111°C
Specifications”.
Coolant Recommendations
The following two coolants are used in Caterpillar diesel engines:
Preferred -Caterpillar Extended Life Coolant (ELC) or a commercial extended life coolant that meets
the Caterpillar EC-1 specification.
Acceptable -A Caterpillar Diesel Engine Antifreeze/Coolant (DEAC) or a commercial heavy-duty
coolant/antifreeze that meets "ASTM D4985" or "ASTM D5345" specifications.
Terberg Benschop 27
NOTICE
Do not use a commercial coolant / antifreeze that only meets the ASTM D3306 or D4656 specification.
This type of coolant/antifreeze is made for light duty automotive applications.
Caterpillar recommends a 50/50 (1:1) mixture of water and glycol. This mixture of water and glycol will
provide optimum heavy-duty performance as a coolant/antifreeze.
Note: Caterpillar DEAC DOES NOT require a treatment with an SCA at the initial fill.
Commercial heavy-duty coolant/antifreeze that meets "ASTM D4985" or "ASTM D5345" specifications
MAY require a treatment with an SCA at the initial fill. Read the label or the instructions that are
provided by the OEM of the product.
Distilled water or deionized water is preferred. Water which has the recommended properties may be
used.
Specifications”.
*
Do only use this Caterpillar recommendation when you do not want to use the Terberg
The first valve clearance adjustment on new engines , rebuilt engines or manufactured engines is
recommend at the first scheduled oil change.
There after inspect/adjust the valve clearance every 2000 hours of operation or each year, whichever
is sooner.

inlet outlet
3126B 0.38 mm 0.64 mm
(0.015 inch) (0.025 inch)
Refer the Caterpillar “Operating and maintenance” and “Service” manual for the operating procedure.
Terberg Benschop 28
1.6 Air Compressor (all engines)
Air filter (if present)
The compressor air filter must be replaced after every 250 hours of operation or after 3 months,
whichever is sooner. A dirty/blocked air filter causes a large under pressure in the inlet line, causing
the oil consumption to increase. If there is high oil consumption, always replace the air filter on the
compressor first.
Make a note of the date and the number of operating hours on the filter so that it is known when the
filter was last replaced.
Mounting
Inspect the air compressor mounting every 250 hours of operation or 3 months*.
* Depending on which is sooner
Inspect the air compressor mounting nuts, including the tail support bracket, or loose and damaged
hardware.
Discharge lines
Inspect the air discharge line from the air compressor for carbon build up every 1000 hours
or every year, whichever is sooner.
These intervals are based on the assumption that the compressed air system is in good condition
regarding cleanliness and that the system is free from restriction.
Any system that is considered to be suffering from cleanliness or restriction problems must have the
air system repaired, cleaned or replaced to a serviceable condition. The operator must then adopt the
maintenance procedures at half the applicable interval mentioned above.
The 2mm allowable carbon deposit is not applicable whilst the compressor is being maintained at a
half interval. Additionally, If any carbon build up is found at a half interval then the procedure steps 3
and 4 need to be carried out.
When it is seen that no build up of carbon is found in the compressor discharge lines at the half
interval maintenance periods, the operator may adopt the full service interval and the 2mm carbon
build up inspection criteria will apply.
NOTE: AII air compressors have a small amount of oil carry over that lubricates the piston rings and
moving parts. When this oil is exposed to normal air compressor operating temperatures over a period
of time, it will form varnish or carbon deposits. If the inspection is not done, the air compressor piston
rings can be affected by high operating temperatures and pressures and can not seal correctly.
Terberg Benschop 29
Standard procedures:
1. Stop the engine. Release the system residual air pressure by loosen the connection of the
discharge line. Remove the air discharge line from the air compressor.
2. Measure the total carbon deposit thickness inside the air discharge line as shown. If the total
carbon deposit (X + X) exceeds 2 mm [1/16 in], clean and inspect the cylinder head, the valve
assembly, and the discharge line. Replace if necessary. Contact your Engine Supplier Authorized
Repair Location or refer your engine supplier “Service manual” for procedures.
3. If the total carbon deposit exceeds specifications, continue checking the air discharge line
connections up to the first tank until total carbon deposit is less than 2 mm [1/16 in]. Clean or
replace any lines or connections that exceed this specification.
4. Inspect the air dryer, 4-circuit protection valve, and governor for carbon deposits or malfunctioning
parts. Inspect for air leaks. Maintain and repair the parts according to the manufacturer's
specifications.
Terberg Benschop 30
1.7 Air dryer
Drain the air tanks of the brake system weekly. (Depended of the weather
conditions)
Replace the air dryer element at least every 1000 hours of operation or once a year.
(Whichever is sooner) however replace the air dryer element if any water is present
in the brake system.
1.8 Cooling system (general for all engines)

Frost protection
Terberg strongly recommends to use only pre-mixed coolant of
Shell because of constant controlled water quality!
However if you want to mix yourself:
Recommend antifreeze:
Shell Glycoshell Concentrate
Antifreeze must be mixed with water in a 50% / 50% ratio.
The table below gives an indication of the amount of

concentrated coolant required to protect against different
degrees of frost.
Frost protection down Percentage concentrated

to: antifreeze
-25°C 40 %
-30°C 46 %
-40°C 50 %
-46°C 60 %
-46°C is the maximum freezing point lowering. Increasing the quantity of concentrated coolant above
this value adversely affects the protection to frost. Even if the temperature never drops below -40°C,
the above-mentioned mixing ratios must be adhered to. The mixing ratio is required in order to
maintain adequate protection against corrosion. Mix the two liquids in a separate clean container.
Water
Always use clean water which fulfils the requirements in ASTM D4985. If these requirements are not
fulfilled, the cooling system will get blocked again with diminished cooling effect and damage to the
engine as a direct result. If water cannot be cleaned so these requirements are fulfilled, then ready
mixed coolant must be used.
Requirements:
Total fixed particles <340 ppm
Total hardness <9.5 °dH
Chloride <40 ppm
Sulphate <100 ppm
pH value 5.5 – 9
Silicon <20 mg SIO2/l
Iron <0.10 ppm
Manganese <0.05 ppm
Conductivity <500 µS/cm
Organic content, CODMn <15 mg kMnO4/l
< = less than
Terberg Benschop 31
Coolant
Recommended coolant:
Shell Glycoshell Diluted
Glycoshell Diluted of Shell is a ready-to-use pre-mixed coolant (-37°C).

This coolant is used by Terberg.
Shell Glycoshell can be ordered by Terberg or via the worldwide Shell

Network. See www.shell.com for distribution addresses worldwide.
T30052920 Shell Glycoshell Diluted 20L Bidon
Note!
Mixing with concentrated coolant of another type can result in worsening the protection against
corrosion and can result in damaging the engine.
Mixing with an OAT-coolant must absolutely be avoided. This can cause blockages in the system from
gel-like contaminants and can hence cause damage to the engine.
OAT-coolant can be recognised by its pink, orange or reddish colour.
DCA4 additives in combination with Shell Glycoshell are unnecessary and are therefore not
advised.
Use the coolant recommendations of the engine manufacturer if you don’t want to use Shell
Glycoshell coolant or antifreeze. The coolant recommendations are described before.
Use the coolant change interval as recommend by the engine manufacturer as described before.
Use the coolant filter interval as recommend by the engine manufacturer as described before.
Additive filters in combination with Shell Glycoshell are unnecessary and are therefore not advised.
Use Filters without additives in combination with Shell Glycoshell:
Engine Filter with additive Filter without additive

Cummins CU3315116 T28040860
8C (Fleetguard WF2071). (Fleetguard WF2107)
Cummins CU3100307 T28040860
QSC (Fleetguard WF2074). (Fleetguard WF2107)
Cummins CU3100308 T28040860
QSM (Fleetguard WF2075). (Fleetguard WF2107)
Terberg Benschop 32
Shell’s warranty approval for the use of Glycoshell Concentrate and Glycoshell Diluted in Terberg
vehicles.
Terberg Benschop 33
1.9 Fuel specification
Fuel must meet national and international standards as marketed fuel. The minimum requirements are
as follows: (This is according Volvo specifications)
For more specific and detailed recommendations refer the maintenance manual of the engine
manufacturer.
EN590
ASTM-D975-No 1-D, 2-D
JIS KK 2204
Viscosity : 1.5 cSt – 4.5 cSt at 40°C
Density: 810 – 860 kg/m3 at 15°C
Lubrication: maximum 460 µm at 60°C in accordance with the HFRR test (ISO12156)
Cetane number: minimum 45
Sulphur content: According to relevant national statutory requirement. If the sulphur content exceeds
0.5% by weight the oil change interval should be changed.
Water and
particulates: Water and particles may not be present in the fuel.
Additives: The oil companies are responsible at all times for using the correct additives for
good ignition, lubrication and cold-climate characteristics. Additives which are
mixed in the fuel tank are not permitted.
Kerosene: Kerosene may only be used to provide improved cold-climate characteristics. The
maximum amount of kerosene in the fuel tank is 20%.
(This only applies to Volvo engines)
Petrol/alcohol: Petrol and alcohol may never be mixed with diesel fuel
Diesel boosters: It is not permitted to use diesel boosters.
Bio-diesel / RME: It is not permitted to have more than 5% RME in the fuel.
Oil: It is not permitted to mix spent engine oil or two-stroke oil with the fuel
Terberg Benschop 34
2 GEARBOX / TRANSMISSION
2.1 Allison transmission
Oil grade
Transmission oils must comply with following quality requirements:
Transmission model Recommend oil

TRANSYNDTM
MD, HD Series DEXRON-III
C4-approval
TRANSYNDTM
AT500, MT600,HT700 Series DEXRON-III
C4-approval
TRANSYNDTM is a fully synthetic oil developed by Allison Transmission and Castrol Ltd. (allows longer
oil change intervals)
See for approved C4-oil fluids WWW.ALLISONTRANSMISSION.COM.
Viscosity
Choose the correct transmission oil from the table below by selecting the minimum required operating
temperature
Minimum operating
SAE viscosity or oil type
temperature
0W-20 or TRANSYNDTM -30°C
DEXRON-III -25°C
10W -20°C
15W-40 -15°C
SAE 30 0°C
SAE 40 10°C
Service intervals
Allison Transmission prescribes the following intervals for first service.
WT-series (MD, HD) Filters (Main/Lube) 200 hours

AT-series Filter (Auxiliary) 200 hours
MT-series Filter (Auxiliary) 200 hours
HT-series Filter (Main External) 200 hours
After replacement of the filters, the following oil change intervals must be adhered to.
Terberg Benschop 35
Prescribed oil change intervals and filter replacement intervals if NO TRANSYNDTM is used or for the
first filling with TRANSYNDTM:
Filters
Main filter Internal filter By-pass filter
Model Oil (Main) (Internal) (Lube)
500 hours or 6 500 hours or 6 Check / 500 hours or 6
WT (MD, HD)
months months Clean months
500 hours or 6 500 hours or 6 500 hours or 6
AT n.a.
months months months
500 hours or 6 Check/ 500 hours or 6
MT n.a.
months Clean months
1200 hours or 12 600 hours or 6 Check/ 600 hours or 6
HT
Prescribed oil change intervals and filter replacement intervals if TRANSYNDTM is used:
Filters
Main filter Internal filter By-pass filter
Model Oil (Main) (Internal) (Lube)
3000 hours or 36 3000 hours or 36 Check / 3000 hours or 36
WT (MD, HD)
2000 hours or 24 2000 hours or 24 1000 hours or 12
AT n.a.
months months months
2000 hours or 24 Check/ 1000 hours or 12
MT n.a.
months Clean months
1200 hours or 24 600 hours or 6 Check/ 600 hours or 6
HT
All these gearboxes are equipped with a breather filter which ensures that no air pressure builds up
within the gearbox. The breather filter must be kept clean and open. The quantity of material and
dirt determines how frequently the breather filter must be cleaned.
Oil change volume

Gearbox Approximate oil change volume (litres)
MT 643 11
MT 653 14
MD 3060P / 3066P / 3560P 18
HD 4060P / 4560P 37
indication.
Check the oil level with the engine running idle and the transmission in neutral.
Terberg Benschop 36
1 = Oil drain plug
2 = Oil filter cover
Dipstick not shown
Terberg Benschop 37
2.2 ZF gearbox
Oil grade
Transmission oils which comply with the quality requirements of the ZF
lubricant list TE-ML-03 must be used. This list can be requested at all ZF
service stations or Terberg Benschop.
It is also possible to get the lubricant list via the Internet:
www.zf.com.
(Information ⇒ Technical Information ⇒ List of Lubricants)
The following engine oils come into consideration:
API CD/ CE/ CF/ SF/ SG

MIL-L-2104 C/ -D/ -E
MIL-L-46152 C/ -D/ -E
SAE 10W / SAE 10 W-30 / SAE 10W-40 / SAE15W-40 / SAE 20W-20
Only use automatic transmission oils ATF at constant outside temperatures below
-10°C.
Recommend grades: Dexron –IID / -III
Mercon –M
Viscosity
The table below shows the viscosity classes for various outside temperature ranges. Use the correct
oil viscosity for the outside temperature range in which the vehicle operates
VISCOSITY CLASS Temperature range

- ATF -30°C to +30°C
- SAE10W -20°C to +30°C
- SAE10W-30, 10W-40 -20°C to +40°C
- SAE15W-40 -15°C to +40°C
- SAE20W-20 -10°C to +40°C
- SAE30 -5°C to +50°C
Service intervals
Check Oil level weekly.
First oil change after 100 hours of operation.
Each subsequent oil change after 1000 hours of operation or at least once a year, whichever is
sooner.
The oil filter shall be changed at each oil change. Use ZF original filters only.
Oil change volume

Gearbox Approximate oil change volume, litres
(incl. cooler and oil lines)
WG 200 28
WG 201 26
WG 211 30
WG 260 52
indication.
Terberg Benschop 38
Check the oil level with the engine running idle and the transmission in neutral at operating
temperature of the transmission. (About 80° - 90°C). For all procedures refer the ZF service manual.
WG211
1 = Oil level fill tube and dipstick
2 = Oil drain plug
WG201
2 = Oil drain plug
WG260
2 = Oil drain plug
5 = Coarse filter
Terberg Benschop 39
2.3 Clark-transmission
Oil grade
1. Caterpillar TO-4
2. John Deere J20 C, D
3. Military MIL-PRF-2104G
4. Allison C-4
5. Dexron* II equivalent – See warning below
Warning:
Dexron IID may only be used if this complies with the C3 specifications.
Dexron III engine oil or GL-5 is not recommended.
If it is desired to use other oils, this must be approved in writing by the “Application Department” at
Clark-Hurth Components Engineering and the “Marketing Department”
Viscosity
It is recommended to use single-grade lubricant with the highest obtainable viscosity for the prevailing
ambient temperature.
Warning:
Synthetic lubricants can be used if they meet the grades above mentioned.
Service intervals
It is recommended to replace the oil filters after the first 100 hours of operation.
Thereafter replace the oil filter after every 500 operating hours.
Change the oil after every 1000 operating hours.
Terberg Benschop 40
Oil change volume
Gearbox Approximate oil change volume, litres
HR28411 23
HR32411 19
R28621 / R32621 30
R28621+converter / R32621+converter 44
The oil level is always determined via an indication of overflowing of the filler plug. The oil quantities
given are only an indication.
1 = Oil level plug LOW

2 = Oil level plug FULL
Check the oil level with the engine running idle, transmission in neutral and at an oil temperature of 82
– 93°C. The oil level must reach the oil level plug FULL (2).
Oil change procedure:
- Drain the transmission oil.

- Replace the oil filter.
- Fill the transmission up to the oil level plug LOW (1)
- Start the engine and let it run whilst stationary at 500-750 RPM in order to fill the converter and all
lines.
- Recheck the oil level with the engine at 500-750 RPM and top up the oil level to the oil level plug
LOW (1).
- When the oil temperature is up to operating temperature (82-93°C), the oil level must reach the oil
level plug FULL (2). If necessary, top up with oil to the oil level plug FULL (2).
Terberg Benschop 41
3 TRANSFER GEARBOX
3.1 Steyr VG1200
Oil grade:
MIL-L2105 B / C
API GL-4 / GL-5
Viscosity
Select the correct viscosity using the temperature limits
below
Maximum operating
Viscosity Minimum temperature
temperature
SAE 75W-90 -40°C 90°C
SAE 80W-90 -26°C 90°C
SAE 85W-90 -12°C 90°C
SAE 90 90°C
SAE 80W-140 -26°C 110°C
SAE 85W-140 -12°C 110°C
SAE 140 110°C
Oil change intervals:

First change: after 100 operating hours.
Check oil level: every 300 operating hours.
Oil change: every 600 operating hours or after maximum 1 year, whichever is
sooner!
Note: When changing the oil, the breather filter on the gearbox must always be cleaned.
Oil change volume:

Transfer gearbox type Oil change volume in litres
VG1200 approx. 3.5 l
The oil level is always determined via an indication of overflowing of the

filler plug. The oil quantities given are only an indication.
1 = Oil drain plug

2 = Oil filler plug / level plug
3 = Vent
Terberg Benschop 42
3.2 AxleTech T-600
Name changes: Soma => Rockwell => (Arvin) Meritor => AxleTech
Oil grade:
SAE 80W/90
API GL5
MIL-L-2105-D
Note: Never mix different oils in the transfer gearbox
Oil change interval:

First change: after 200 operating hours
Check oil level: every 100 operating hours
Change oil: every 2000 operating hours or annually *
* Depending on whichever is sooner.
Oil change volume:

AxleTech T-600 approx. 3.5 l
Drain off oil when warm and fill to the edge of the level plug on the front of the transfer gearbox.
1 = Drain plug
2 = Filler plug
3 = Level plug
Terberg Benschop 43
3.3 Kessler W2500
Oil grade:
API GL5
MIL-L-2105 B
MIL-L-2105 C /D
Viscosity:
For normal outside temperatures SAE 90 or Multigrade oil
Temperatures below -10°C SAE 75W90 /SAE 75W85 or Multigrade oil
Temperatures above +30°C SAE 140 or Multigrade oil

Check oil level: every month.
Oil change interval: every 1000 operating hours or at least 1x per year*
Oil change volumes:

Kessler W2500 approx. 7 litres excluding lines and filter
Ι = Oil filler plug

ΙΙ = Oil level plug
ΙΙΙ = Oil drain plug
Terberg Benschop 44
4 FRONT AXLE
4.1 Volvo non-driven front axle
Front wheel hub, oil-lubricated.
Oil grade:
Engine oil: SAE 30

Only when repairs have been carried out to the hubs or if dirt has
got into the wheel hubs.
Check oil level at each service / maintenance check.
A = Screw plug
B = Marked level on outside of hub casing
Oil change volume:

Hubs (2x) ± 0.3 l
Grease:
Lubricate kingpin bearings and brake shaft every 250 hours of operation.
Grease should be EP doped on lithium-base, NLGI class 2-2,5.
4.2 DAF non-driven front axle

Front wheel hub, grease-lubricated.
Grease:
Check hubs for grease leakage every maintenance inspection.
Lubricate kingpin bearings every 300 hours of operation.
Grease should be EP doped on lithium-base, NLGI class 2 or NLGI class 00 for central lubrication
systems.
4.3 Volvo non-driven front axle

Front wheel hub, grease-lubricated.
Grease:
Check hubs for grease leakage every maintenance inspection.
Change the grease in the wheel hub only by repair or by contamination
of the grease.
Lubricate kingpin bearings and brake shaft every 250 hours of
operation.
Grease should be EP doped on lithium-base, NLGI class 2-2,5.
Terberg Benschop 45
4.4 AxleTech driven front axle
Oil grade:
API GL-5
MIL-L-2105-D
Viscosity:
VISCOSITY CLASS Minimum outside temperature

- SAE 85W/140 -12°C
- SAE 80W/90 -26°C
- SAE 75W/90 -40°C
- SAE 75W -40°C
- SAE 75W/140 -40°C

First change differential / hub: after 100 operating hours
Check oil level : every 1000 operating hours
Change oil: every 2500 operating hours or at least once a year*.
Oil change volume:

Differential approx. 14 l
Hub (2x) approx. 2.8 l
Note: The differential and hub reducing gear have separate oil reservoirs!
Terberg Benschop 46
Special filling procedure for axle housings / differentials:
• Fill oil (after draining the old oil) using the filler plug until the oil is at the lower edge of the
filling opening
• Wait 10-20 minutes until the oil has well run into the axle body/differential
• Fill the oil if necessary until oil just flows out of the opening
Filling procedure for hubs:

• Turn the hub so that the filler plug is above the middle of the hub.
• Fill the hub with the before mentioned quantity of oil.
• Wait 20 to 30 minutes to be sure that the oil has become completely distributed into the hub.
• Turn the hub until the lower side of the filler plug is in a horizontal position with the centre of
the hub. See figures below.*
• The oil must just flow out of the opening. If necessary fill with oil or drain off oil.
* As of 01-01-98, a level monitoring screw is mounted into the central locking bolt on the hub
cover.(See figure only for AxleTech)
This has been done to simplify checking of the correct oil level.
HUB DESIGNS
Loosen plug when filling Remove bolt for filling the hub
> 01-01-1998
HORIZONTAL
1+2
01-01-1998 >
1
HORIZONTAL
3
dok:olie1.dsf
1 = Filler plug
2 = Level plug
3 = Central bolt (do not rotate)
HORIZONTAL = OIL LEVEL
Terberg Benschop 47
4.5 Kessler driven front axle
Oil grade:
API GL5
MIL-L-2105 B
MIL-L-2105 C / D
Viscosity:
For normal outside temperatures SAE 90
Temperatures below -10°C SAE 75W85
Temperatures above +30°C SAE 140

Oil change interval: 1000 operating hours or at least once a year*.
Oil change volumes:

Axle type Part number Differential (litres) Hub (litres)
LT71PL377 71.8073.3 approx. 14 l (2x) approx. 2.5 l
Terberg Benschop 48
See section 4.4

∗ = Position depends upon axle type
Terberg Benschop 49
5 REAR AXLE
5.1 AxleTech driven rear axle
Oil grade:
API GL-5
MIL-L-2105-D
Viscosity:
VISCOSITY CLASS Minimum outside temperature

- SAE 85W/140 -12°C
- SAE 80W/90 -26°C
- SAE 75W/90 -40°C
- SAE 75W -40°C
- SAE 75W/140 -40°C

First change differential / hub: after 100 operating hours
Check oil level : every 1000 operating hours
Change oil: every 2500 operating hours however at least once a year*.
Oil change volume:

Differential approx. 15 l
Hub (2x) approx. 2.8/3.3 l
Note: The differential and hub reduction gear have separate oil reservoirs!

See section 4.4
Terberg Benschop 50
5.2 Kessler driven rear axle
Oil grade:
API GL5
MIL-L-2105 B
MIL-L-2105 C / D
On the axles with self locking differentials, a noise is produced if normal oils are used. In case of
abnormal noises and in case of operation under bumpy conditions, use gear oil EP with additives of
the “Limited Slip” type conforming to specification M2C-104A
Viscosity:
For normal outside temperatures SAE 90
Temperatures below -10°C SAE 75W85
Temperatures above +30°C SAE 140

Change oil: every 1000 operating hours or at least once a year*
*
Depending on whichever is sooner.
Oil change volume:

Axle type Part number Differential (litres) Hub (litres)
D81PL477 81.8355.3 approx. 17.5 l (2x) approx. 2 l
D81PL477 81.8386.3 approx. 18 l (2x) approx. 1.2 l
D81PL477 81.7182.3 approx. 17.5 l (2x) approx. 2 l
D91PL417/510 91.5360.3 approx. 19 l (2x) approx. 5 l

∗ = Position depends upon axle type
Terberg Benschop 51
See section 4.4
6 CAB LIFTING SYSTEM

Oil grade:
For electrically operated tilting pump:
Shell DONAX TA or equivalent to the following specifications:
DIN HLP 46
GM ATF DEXRON IID 21774
Allison C3-C4
Caterpillar TO-2
Mercedes Benz 236.6
ZF TE-ML 09/11/14
For manual tilting pumps:

Shell TELLUS T15 or equivalent to the following specifications:
HLVP requirements in accordance with DIN 51524/3

ISO class L-HV in accordance with ISO 6743/4, Vickers 1-286-S and 1-2952-S
Service interval:
In principle maintenance-free.
Only needs an oil top up if the oil level is too low or if undergoing repair.
7 HYDRAULIC SYSTEM
Oil grade:
Shell TELLUS T32 or equivalent to the following specifications:
HLVP requirements in accordance with DIN 51524/3

ISO class L-HV in accordance with ISO 6743/4, Vickers 1-286-S and 1-2952-S
Service interval:
First filter replacement: after 500 operating hours
Operating hours a year Oil change Filter(s)

More than 2000 12 months 12 months
Less than 2000 24 months 12 months
Oil change volume:

When the 5th wheel is in the lowermost position, the oil level should be halfway up the gauge glass on
the oil reservoir.
Terberg Benschop 52
8 GREASE POINTS
Non automatic
Grease quality:
A grease must meet the following requirements:
A wheel bearing grease of high quality must be used.

The grease must be based on mineral oil.
The grease must be of the lithium or lithium-complex type.
EP and rust inhibitors must have been added to the grease.
The grease must have a consistency which complies with NLGI No. 2. DIN51804
No solid lubricants must be present, for example graphite, copper or molybdenum sulphide.
The recommended grease is: SHELL RETINAX HD2
Service intervals:
Grease every month or every 250 operating hours, whichever is sooner.
The lubrication plan for Terminal trucks YT/TT/RT is shown on the next page
Always make sure that the respective greasing point is well greased. Grease until the new grease
comes out and is visible. If no grease comes out, something is wrong and this must be rectified
immediately.
Legend for lubrication Symbols

A = Grease = Engine oil
B = Check level
C = Change oil and replace filter = Gearbox oil
1 Engine
= Axle oil
2 Gearbox / Transmission
3 Transfer gearbox
4 Axle (differential and hubs) = Coolant
5 Universal coupling
6 Coolant system
= Hydraulic oil
7 Cab lifting system
8 5th wheel
9 Hinge points lift cylinder
= Grease
10 Hinge points lift frame
11 Hinge points sheeting
12 Swivel axle = Hub oil
13 Front wheel hub, non-driven
14 Spring pin, flat springs
15 Hydraulic oil reservoir
Terberg Benschop 53
C B A A B C
2
1 8
9
6
3
4
4
2
1
8
6 9
14
11
7
12 12
6
13
11
11
15
9
8
4
4
4
Terberg Benschop 54
9 AUTOMATIC GREASING SYSTEM
Refer the supplier documentation for more detailed information.
Periodically with other regular checks of the vehicle, check the

reservoir lubricant level, topping up with the recommend lubricant if
necessary. Combined with normal vehicle maintenance, check the
complete system.
Prevent grease spillage from the fifth wheel top plate on the top of
the rear axle. This collects dirt and blocks the rear axle breather.
9.1 Interlube
Viscosity
Interlube FG3,0 grease (NLGI 000)
SAE90 oil
NLGI grade 000 - NLGI grade 2 grease
9.2 Groeneveld
Viscosity
Greenlube EP-0 (automotive)
Greenlube LT-00 (extreme low temperatures)
Greenlube HT-0 (extreme high temperatures)
Greenlube ZW-0 (Off road/Agriculture)
NLGI grade 0 or 00 classification of EP quality and must not contain graphite, PTFE or MoS2
9.3 Vogel
Viscosity
NLGI grade 000 or 00 or 0
NLGI grade 1
NLGI grade 2
9.4 Lincoln
Viscosity
Lubrication must be free from contamination and should not display a tendency to change their
consistency over time.

NLGI grade 1
NLGI grade 2
Mineral oil up to 40mm2/s (cST).
Terberg Benschop 55
9.5 Beka-Max
Viscosity
NLGI grade 1
NLGI grade 2
Grease must be of EP quality and must not contain solid components such as graphite etc.
Terberg Benschop 56
10 FIFTH WHEEL
Grease quality:
A grease must meet the following requirements:
Water resistant
Lithium-based
Service intervals:
WEEKLY:
1. Apply grease to the bracket supports through the grease fittings as shown below .
2. Lubricate the lock pins through fittings as shown.
3. Be sure the fifth wheel top plate is lubricated.
4. Check operation of the fifth wheel locking mechanism.
5. Keep sensors clean
• = Grease
MONTHLY:
1. Steam clean the entire top plate thoroughly .
2. Inspect the fifth wheel top plate assembly .

• Check for — and replace — any bent, worn, or broken parts.
• Check for cracks in the top plate casting or any component
part.
Replace as required using only TERBERG parts.
3. Check the fifth wheel locking mechanism for proper operation

using a FIFTH WHEEL LOCK TESTER TOOL (part no.
T24140184).
When checking, move the lock tester forward and backward

when closed in the locks. If play exceeds 8 mm, rebuild or
replace the fifth wheel top plate. See your TERBERG distributor
for parts and ordering information.
4. Re-lubricate the entire fifth wheel as shown above.
5. Keep air breather port on the operating cylinder clean.
Warning !
DO NOT use any fifth wheel which does not operate properly.
AFTER 8000 HOURS:

At or before 8000 hours intervals of service, the Terberg 90-03-2” fifth wheel should be completely
overhauled using rebuild kit:
part no.: T27056298 (inclusive air cylinder) or T27056308 (exclusive air cylinder)
Terberg Benschop 57
11 SERVICE (first, periodic, annual)
The preventive maintenance of Terberg comprises:
First service: First service after delivery of the vehicle, after 100 operating hours
Periodic service: Is an interim service for changing the engine oil and filter replacement.
Annual service: Is carried out at least once a year
NAME OF CUSTOMER CHASSIS NUMBER HOURS CLOCKED

Periodic
Annual
First
LUBRICATION, OIL AND LIQUID CHECKS AND CHANGES

0 0 0 Grease all grease points on the chassis and cabin
0 0 0 Change engine oil and replace filters, or check oil level
0 0 0 Change gearbox oil and replace filter, or check oil level
0 0 0 Change gearbox oil, or check oil level
0 0 0 Change oil in the driven front axle, or check oil level
0 0 0 Check for leakage from the oil-lubricated wheel bearings of the non-driven front axle
0 0 0 Change oil in the rear axle, or check oil level
0 0 0 Check level of hydraulic oil or change hydraulic oil
0 0 Replace hydraulic oil filters
0 0 Check the quality of the coolant
0 0 0 Check the coolant level
0 0 0 Check the liquid level in the windscreen wash reservoir
CHECKS DURING THE TEST DRIVE

0 0 0 Check the operation of the brakes and the parking brake
0 0 0 Check the pressure drop on the brake circuits
0 0 0 Check the setting and operation of the swivel chair
0 0 0 Check the seat lock
0 0 0 Check lighting
0 0 0 Check that the wipers and windscreen wash work
0 0 0 Check the gearbox control system
0 0 0 Check the switch protection, forward-reverse gearbox
CHECKS IN THE CABIN

0 0 0 Check the warning and control lamps, switches and meters
0 0 0 Check the warning lamps for the 5th wheel lock
0 0 0 Check the error codes in the control units for the engine and transmission
0 0 0 Check the error codes in the master instrument on the dashboard
EXTERNAL CHECKS
0 0 0 Check outside mirrors
0 0 0 Check air inlet
0 0 0 Check cabin locks, hydraulic/electrical cabin tilting
0 0 0 Check the batteries
0 0 0 Check fuel, -hoses, -pipes, -venting and -suspension
0 0 0 Check pre-filter for the fuel system, drain off condensed water
0 0 0 Check for tyre wear, tyre pressure, tread depth
0 0 0 Check the air dryer by draining the air reservoirs, if necessary replace filter
0 0 0 Check swivel seat mechanism, chain tension
Terberg Benschop 58
ENGINE COMPARTMENT
0 0 Adjust valves
0 0 Replace fuel filter(s)
0 0 Replace air inlet filter, depending on amount of dirt
0 0 Replace compressor filter (if present)
0 0 Check carbon build up in the compressed air circuit
0 0 0 Check the engine for leaks
0 0 0 Check hose clips, tighten
0 0 0 Check the toothed belt, tension and condition
0 0 0 Check the engine suspension and cooler suspension
0 0 0 Check electrical connections and cables for dynamo, starting engine and pre-heating unit
0 0 0 Check drive belts, replace if necessary
0 0 0 Check cooling fan, bearing play, bolt connections, fan cover and fan ring with rubber seal
0 0 0 Check radiator, hoses, pipes and through air flow
0 0 0 Check and clean the external pollution of the radiator
0 0 0 Check fuel lines
0 0 0 Check for leaks of exhaust gas
0 0 Check engine low idle rpm (optimal between 700-800 rpm)
UNDERNEATH THE VEHICLE

0 0 0 Check steering system
0 0 Check shock absorbers
0 0 0 Check wheel bearings, wheel bearing play
0 0 0 Check wheels, tighten
0 0 0 Check tightness and ventilation of the driven axles
0 0 0 Check tightness of hydraulic pump, oil lines.
0 0 0 Check the tightness of the gearbox, the transfer gearbox and check lines
0 0 Clean the ventilation of the gearbox, the transfer gearbox
0 0 0 Check suspension of the transfer gearbox
0 0 0 Check and tighten cardan shafts – couplings, sliding parts and support bearings
0 0 0 Check springs and spring clamps, tighten spring bolts
0 0 0 Check stabiliser bar, tighten
0 0 0 Check suspension units for the front and rear axles
0 0 0 Check air bellows and the height adjustment
0 0 0 Check grease system (central grease system), fill pot for central greasing
0 0 0 Check tightness of the air system
0 0 0 Check differential lock
LIFTING SYSTEM
0 0 0 Tighten retaining studs on the front of the lift frame
0 0 0 Check lift cylinders and their mounting
0 0 0 Check the adjustment and operation of the 5th wheel sensors, clean
0 0 0 Check 5th wheel, operation, spiral springs
0 0 0 Check filter for ventilation of the hydraulic tank
0 0 0 Check tightness of the hydraulic system
Extra work carried out / work still to be carried out.
Job number Date Name of mechanic
Terberg Benschop 59
12 TIGHTENING TORQUES
The table below shows the tightening torques which must be adhered to, for tightening coarse-
threaded metric nuts and bolts.
Coarse metric threads

Tightening torque (Nm) Tightening torque (Nm)
For For
Size Quality For Size Quality For
assembly assembly
assembly assembly
without without
with grease with grease
grease grease
8.8 2.8 2.5 8.8 280 245
M4 10.9 4.1 3.7 M18 10.9 390 350
12.9 4.8 4.3 12.9 460 410
8.8 5.5 4.9 8.8 390 350
M5 10.9 8.1 7.3 M20 10.9 560 490
12.9 9.5 8.5 12.9 650 580
8.8 9.5 8.5 8.8 530 470
M6 10.9 14 12.5 M22 10.9 750 670
12.9 16.5 14.5 12.9 880 780
8.8 15.5 14 8.8 670 600
M7 10.9 23 20.5 M24 10.9 960 850
12.9 27 24 12.9 1120 1000
8.8 23 20.5 8.8 1000 880
M8 10.9 34 30 M27 10.9 1400 1250
12.9 40 35 12.9 1650 1450
8.8 46 41 8.8 1350 1190
M10 10.9 68 60 M30 10.9 1900 1700
12.9 79 71 12.9 2250 2000
8.8 79 71 8.8 1850 1600
M12 10.9 117 104 M33 10.9 2600 2300
12.9 135 121 12.9 3000 2700
8.8 125 113 8.8 2350 2100
M14 10.9 185 165 M36 10.9 3300 3000
12.9 215 195 12.9 3900 3500
8.8 195 170 8.8 3000 2700
M16 10.9 280 250 M39 10.9 4300 3800
12.9 330 300 12.9 5100 4500
Terberg Benschop 60
The table below shows the tightening torques which must be adhered to for tightening fine-threaded
metric nuts and bolts.
Fine metric threads

Tightening torque (Nm) Tightening torque (Nm)
For For
Size Quality For Size Quality For
assembly assembly
assembly assembly
without without
with grease with grease
grease grease
8.8 24.5 22 8.8 760 700
M8 10.9 36 32
M 24 10.9 1090 990
x1 12.9 43 38 x 1.5 12.9 1270 1170
8.8 36 32 8.8 730 640
M9 10.9 53 46
M 24 10.9 1040 920
x1 12.9 62 54 x2 12.9 1220 1070
8.8 52 45 8.8 1110 1010
M 10 10.9 76 67
M 27 10.9 1580 1440
x1 12.9 89 78 x 1.5 12.9 1850 1690
8.8 49 43 8.8 1070 940
M 10 10.9 72 64
M 27 10.9 1500 1350
x 1.25 12.9 84 74 x2 12.9 1800 1550
8.8 87 77 8.8 1540 1410
M 12 10.9 125 112
M 30 10.9 2190 2000
x1.25 12.9 150 130 x 1.5 12.9 2560 2340
8.8 83 74 8.8 1490 1370
M 12 10.9 122 108
M 30 10.9 2120 1940
x 1.5 12.9 145 125 x2 12.9 2480 2270
8.8 135 121 8.8 2050 1880
M 14 10.9 200 175
M 33 10.9 2920 2670
x 1.5 12.9 235 205 x 1.5 12.9 3420 3130
8.8 205 180 8.8 2000 1750
M 16 10.9 300 270
M 33 10.9 2800 2500
x 1.5 12.9 360 310 x2 12.9 3300 2900
8.8 310 270 8.8 2680 2450
M 18 10.9 440 390
M 36 10.9 3820 3490
x 1.5 12.9 520 450 x 1.5 12.9 4470 4090
8.8 290 260 8.8 2500 2200
M 18 10.9 420 370
M 36 10.9 3500 3100
x2 12.9 490 430 x3 12.9 4100 3600
8.8 430 380 8.8 3430 3140
M 20 10.9 620 540
M 39 10.9 4890 4470
x 1.5 12.9 720 630 x 1.5 12.9 5720 5230
8.8 580 510 8.8 3200 2800
M 22 10.9 820 720
M 39 10.9 4600 4000
x 1.5 12.9 960 840 x3 12.9 5300 4700
Terberg Benschop 61
The table below shows the tightening torques which must be adhered to for tightening nuts and bolts
with a NC/NF or UNC/UNF or U.S.S / S.A.E thread.
GRADE 2 STEEL (qual. 4.6) GRADE 5 STEEL (qual. 8.8) GRADE 8 STEEL (qual. 10.9)
TENSILE STRENGTH TENSILE STRENGTH TENSILE STRENGTH
74000 Lbs. 1/4” TO ¾”(510N/mm2) 120000 Lbs. 1/4 TO 1” (827 NImm2) 150000 Lbs. 1/4’ TO 1 1/2.
60000 Lbs. 7/8” TO 11/2”(413N/mm2) 106000 Lbs. 1 TO 1 1/2’ (724 N/mm2) (1034 N/mm2)
COARSE, NC, UNC, U.S.S THREAD

Tightening torque (Nm)
Thread size
Untreated Galvanised Greased Untreated Galvanised Greased Untreated Galvanised Greased
¼”-20 2 1 1 15 11 1 22 16 14
1/18”-18 20 15 12 31 23 19 45 34 27
3/8”-16 37 27 22 58 42 34 79 60 47
7/18”-14 58 43 35 89 66 54 126 95 76
1/2”-13 88 66 53 137 102 81 193 14.4 115
9/18”-12 127 95 76 197 148 118 278 207 167
5/8”-11 175 132 106 271 203 163 384 287 231
3/4”-10 312 233 187 461 361 289 681 510 408
7/8”-9 301 226 180 776 582 465 1096 822 658
1”-8 452 339 271 1163 873 698 1642 1233 986
11/8”-7 640 480 384 1649 1237 990 2328 1747 1397
11/4”-7 903 678 542 2327 1745 1397 3288 2464 1972
13/8”-6 1164 888 711 3051 2288 1631 4307 3230 2583
11/2”-6 1572 1178 944 4049 3037 2430 5717 4288 3429
FINE, NF, UNF, S.A.E. THREAD

Tightening torque (Nm)
Thread size
Untreated Galvanised Greased Untreated Galvanised Greased Untreated Galvanised Greased
1/4”-2 11 1 1 18 14 11 24 19 15
5/16”-24 23 16 14 35 26 20 49 37 30
3/8”-24 41 31 24 64 47 38 89 66 53
7/16”-20 65 49 39 100 75 60 141 106 64
1/2”-20 99 75 60 153 115 92 217 163 130
9/16”-18 142 106 85 220 164 132 309 232 186
5/8”-18 199 149 119 308 231 164 434 325 260
3/4”-16 347 260 209 537 403 323 758 570 456
7/8”-14 332 250 199 856 643 538 1208 907 725
1”-12 495 372 297 1273 955 765 1798 1349 1079
11/8”-12 717 538 431 1850 1387 1109 2610 1958 1566
11/4”-12 1001 750 601 2576 1932 1546 3637 2726 2182
1 3/8”-12 1348 1012 808 3473 2605 2083 4902 3677 2941
11/2”-12 1765 1326 1062 4556 3417 2734 6432 4823 3859
Source: BorstIap
Conversion factors:
1 LBS. = 4.44822 N
1 LBS. = 0.00689475 N/mm2
1 Lb.Ft. = 1.356 Nm
Terberg Benschop 62

TD1215-05sw Service Manual Maintemance YT-TT-RT

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TD1215-05sw Service Manual Maintemance YT-TT-RT

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Terberg Benschop B.V.

YT series & TT-RT series

DOCUMENT > TD1215-05 E

GENERAL SAFETY INSTRUCTIONS .................................................................................................... 5

2 GEARBOX / TRANSMISSION ........................................................................................................... 35

3 TRANSFER GEARBOX ..................................................................................................................... 42

4 FRONT AXLE ..................................................................................................................................... 45

5 REAR AXLE ....................................................................................................................................... 50

7 HYDRAULIC SYSTEM ....................................................................................................................... 52

8 GREASE POINTS .............................................................................................................................. 53

9 AUTOMATIC GREASING SYSTEM .................................................................................................. 55

11 SERVICE (first, periodic, annual) ..................................................................................................... 58

This symbol means:

 Always drain off oil when it is warm

 Service intervals prescribed by the manufacturer must be strictly adhered to.

 Parts which rotate can cause cuts, mutilations or strangulation.

 Always wear protective clothing to prevent bodily injury from burns.

0.1 How to use this manual

0.2 First Service

See paragraph 11 for the first service checkpoints.

The vehicle should be washed as soon as it has become dirty,

Clean the cooler package (radiators) to prevent external pollution.

Be aware that a high-pressure water beam can damage sealing,

American Standards AXS 673, AXS 1759 grades 1 and 2

The protective film can be removed with:

- solvent (white spirit, petrol, trichlorethelene, etc…)

The critical parts are:

Note: No extra oil additives may be used.

1) Only fully synthetic and/or VDS /VDS-2 oil

Oil change intervals

VOLVO TAD720 engines

Oil change volume

Coolant + filter* change interval

Engine type Valve Valve

* Valve clearance when the engine is cold

Refer to the Volvo workshop manual for the operating procedure.

CES-20071 / 72 (Cummins Engineering Standard)

Oil change intervals

* Depending on which is sooner.

250 hours of operation 250 hours of operation

250 hours of operation

* Depending on which is sooner.

QSM11 - Oil drain intervals by duty cycle (hours)

Coolant change interval

Good-quality water is important for cooling system performance.

Coolant DCA4 additive*

Cooling system Required mixing quantity of DCA4

T30052450 DCA4 0.5 litres (Fleetguard DCA 60L)

Testing for DCA4

Part number Description

When do you have to use the test kit?

Follow the instructions of the test kit.

How to use the test kit?

The concentration is between 0.3 and 0.8 units/litre.

The concentration is below 0.3 units/litre.

Engine type Valve Valve

Refer to the Cummins workshop manual for the operating procedure.

Use oil that conforms to Cummins Engineering Standards:

Valvoline Premium blue GEO 15W40 CES20074

Oil change intervals

* Depending on which is sooner.

Oil change volume

Closed crankcase ventilation filter

Magnetic inline LPG filter

Always drain off oil when it is warm

Service intervals prescribed by the manufacturer must be strictly adhered to.

Parts which rotate can cause cuts, mutilations or strangulation.

Always wear protective clothing to prevent bodily injury from burns.