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 > [email protected]

SERVICE MANUAL

HYDRAULIC SYSTEM
YT xx2 Series

DOCUMENT > TD1413-03 E

EDITION > 01-2019
 HYDRAULIC SYSTEMS OF TERBERG TERMINAL TRACTORS
TYPE YTxx2

Contents:

1. THE PUMP .................................................................................................................................................2

2. THE RESERVOIR ......................................................................................................................................2
2.1 GENERALITY ............................................................................................................................................... 2
2.2 THE RETURN OIL FILTER ........................................................................................................................... 3
2.3 THE BREATHER FILTER / FILLING ACCESS ............................................................................................. 3
2.4 OIL ................................................................................................................................................................ 3
3. THE STEERING SYSTEM ........................................................................................................................4
3.1 THE PRIORITY VALVE ................................................................................................................................. 4
3.2 THE STEERING UNIT .................................................................................................................................. 4
3.2.1. STEERING UNIT EQUIPPED WITH A DYNAMIC LS SIGNAL. ............................................................. 5
3.2.2. DUAL DISPLACEMENT STEERING UNIT EQUIPPED WITH A DYNAMIC LS SIGNAL ..................... 6
3.2.3. STEERING UNIT WITHOUT DYNAMIC LS SIGNAL. .......................................................................... 7
3.3 STEERING CYLINDERS .............................................................................................................................. 8
4. THE LIFT FRAME OPERATING HYDRAULICS......................................................................................9
4.1 VALVE FOR LIFTING AND LOWERING .................................................................................................... 10
4.1.1 PRESSURELESS CIRCULATION PRESSURE RELIEF VALVE ........................................................ 10
4.1.2 LIFTING ............................................................................................................................................... 11
4.1.3. HEIGHT LIMITING.............................................................................................................................. 11
4.1.4. LOWERING ........................................................................................................................................ 11
4.1.5. LOW LIMITING ................................................................................................................................... 11
4.2 THE LIFT CYLINDERS ............................................................................................................................... 12
4.3 EXTRA HYDRAULIC ................................................................................................................................... 12
5. HOSES, FLANGES AND NIPPLES ....................................................................................................... 13
6. LIST OF FAILURES................................................................................................................................ 14
6.1 THE LIFT FRAME WITH THE FIFTH-WHEEL DOES NOT LIFT ................................................................ 14
6.2 THE LIFT FRAME WITH THE FIFTH-WHEEL DOES NOT LOWERT........................................................ 15
6.3 THE VEHICLE CAN NOT BE STEERED .................................................................................................... 16
6.4 THE STEERING IS TOUGHER THAN NORMAL ........................................................................................ 16
6.5 THE STEERING WHEEL SLIPS THROUGH AT THE STOPS OF THE CYLINDERS ................................ 17
6.6 OIL LEVEL IN THE HYDRAULIC TANK IS FREQUENTLY TOO LOW ...................................................... 18
TABLE 6.1 SURVEY ON TROUBLE SHOOTING ............................................................................................. 19

APPENDICE 1:
SYSTEM WITH STEERING UNIT WITH DYNAMIC LS SIGNAL AND STD. LIFTING SYSTEM

Figure 1: Oil pressures and position of the valves during steering and lowering
Figure 2: Oil pressures and position of the valves during lifting
Figure 3: Oil pressures during emergency steering and neutral position of the lift part
Figure 4: Oil pressures during no steering and neutral position of the lift part

APPENDICE 2:
SYSTEM WITH STEERING UNIT WITHOUT DYNAMIC LS SIGNAL

Figure 1: Oil pressures and position of the valves during no steering

Figure 2: Oil pressures and position of the valves during steering
Figure 3: Oil pressures during emergency steering

1
 1. THE PUMP

The hydraulic system has got one pump to convert kinetic energy into hydraulic energy (oil flow and oil
pressure), which can be used to effect a movement of a hydraulic actuator (a cylinder or a hydraulic
motor) of the system. A gear pump is applied for this purpose.

The pumps are free of maintenance, provided that a hydraulic oil is used, according to the specification of
section 2.4.

The splines on the outgoing shaft of the pump need to be lubricated with a grease like lithium EP 1
or an equivalent, when assembling the pump.
M
An exact (detailed) specification of the pump has been added to the parts catalogue.

The pump can be mounted to the engine or the transmission.

2. THE RESERVOIR

2.1 GENERALITY

The oil reservoir has got the following functions:

1. Storage of hydraulic oil.
2. Buffering of the variation of oil quantity in the other hydraulic components.
3. Cooling the hydraulic oil.
4. Separation of the air, carried by the hydraulic oil
5. Separation of pollution

There are two types of oil reservoirs: 2

 Oil reservoir integrated into the fuel tank
 Separate oil reservoir
See parts manual for capacity of the oil reservoir. 11

The reservoir is provided with a gauge glass. The oil level must point
approximately halfway the gauge glass, when the lift frame has been
put into the lowest position.
12

The oil tank is always assembled on the right hand side of the vehicle 7
and forms a whole, together with the fuel tank. A double-walled partition
provides the necessary separation between the two liquid reservoirs.
Between the two walls of this partition, there is a drain plug.
By loosening this plug, information can be got whether there is a leak in one of the walls of the partition.
Normally, this plug must always remain tight.

2
 2
11
The hydraulic reservoir has also got a drain plug. By means of this plug,
the hydraulic oil can be drained. There can be checked for water in the
hydraulic system, draining a small amount of liquid from the reservoir, 7 12
by the drain plug.

The reservoir and the accompanying parts are represented in the parts catalogue.

2.2 THE RETURN OIL FILTER

The function of the return oil filter is to remove the insoluble pollution from the hydraulic oil and to store
them (temporarily) inside the filter element. Besides, the return filter acts as a filling opening for the
hydraulic system. The filter consists of a filter body and an exchangeable filter element.

Return filter classification: ß10  75. (10 µm absolute)

2
To replace the filter element, it is of great importance to carefully clean the filter and its
surroundings, before opening the filter at the top (by loosening the four bolts).

The filter element must be replaced, according to the scheme, represented in the
maintenance manual.

The discharge opening of the filter in the tank must be equipped with an extended outlet opening, which
is a piece of a hose, attached to the discharge opening of the filter, by a hose clip. This piece of hose
prevents the oil from foaming.

2.3 THE BREATHER FILTER / FILLING ACCESS

Air can flow out of or into the reservoir, due to deviations of the
11
temperature- or the oil level, inside the oil reservoir. The breather filter has
got the task to trap the dirt particles in the air, penetrating the inside of the
filter. By an inefficient filter, dirt can enter, this can cause failures to the
hydraulic system.

The breather filter has got a 10 µm, exchangeable filter element. The filter element can be replaced by
loosening the top of the filter and subsequently removing the filter element.

The filter element must be replaced according to the scheme, being part of the maintenance manual.

Use the breather filter as access for changing or refilling hydraulic oil.
Remove the breather filter cover and breather filter element. Be sure that the gauze tube is in place to
prevent dirt into the hydraulic tank. Clean the filling access and its surroundings, before changing/refilling
the oil.

2.4 OIL

Type of oil: Shell Tellus T32 or similar.(See maintenance manual)

Oil purity: ISO 18/13, or preferably according to ISO4406

Put the lift frame with the fifth-wheel into the lowest position, before changing the oil.
The oil must be changed according to the scheme represented in the maintenance manual.

3
 3. THE STEERING SYSTEM

3.1 THE PRIORITY VALVE

The priority valve regulates the flow of oil from the pump to the steering and lifting systems as well as
to any auxiliary hydraulic systems on the vehicle. The priority valve always gives preference to the
steering system. That part of the oil flow that is not needed for steering can be utilised by the lifting
system and any other hydraulic systems on the vehicle.

The steering system generates a dynamic load-sensing CF

signal if it requires oil. This dynamic load sensing signal is
a hydraulic signal, which puts the priority valve in such a
LS EF
position (through the LS connection of the priority valve),
that an exactly sufficient amount of oil will flow to the
steering unit through the CF connection of the priority
T
valve. The oil, supplied by the pump but not used by the
steering system, flows through the EF-exit of the priority
172bar 3
valve to the other hydraulics.
P
The oil flow to the steering system is independent of the pressure in the steering system. If necessary,
all the oil delivered by the pump can flow to the steering system.

If the steering system does not require oil, because, for example, the
vehicle is not being steered, the priority valve will then direct the oil
flow, via the EF connection, to the other hydraulics. It is also possible
that part of the oil flow will go to the steering system and part to the
other hydraulics.

The LS connection must be bleeded on the steering unit side when

first fitting and after repair or replacement of the hose between the
steering unit and the LS connection of the priority valve.

This valve is to be found in de middle of the chassis underneath the lift frame hinges.

3.2 THE STEERING UNIT

In the steering unit, the rotation of the steering wheel is converted into an oil flow to the steering cylinders,
which generate the steering motion. The steering unit delivers a fixed quantity of oil, for each steering
rotation, put on the desired pressure by the pump. The quantity of oil depends on the type of steering unit,
selected.

There are three types of steering units:

 Steering unit equipped with a dynamic LS signal (standard)
 Dual displacement steering unit equipped with a dynamic LS signal (optional)
 Steering unit without dynamic LS signal. (optional for vehicles without lift frame or any other auxiliary
hydraulic systems)
See parts manual for the type of steering unit.

The integrated valves secure a good performance and preserve the steering unit from damage.
Hereafter, a list of the available valves follows.

Since this steering unit is a precision element, it is of the utmost importance to guarantee an assembly in
a clean environment. Besides, the entering shaft of the steering unit must be assembled, without pre-
stress.
Figure 1 (see appendix at the end of this manual) shows how the oil pressure behaves during some
steering movements

4
 3.2.1. STEERING UNIT EQUIPPED WITH A DYNAMIC LS SIGNAL.

This steering unit is used in a standard YT-serie tractor with lift frame. The priority valve regulates the
flow of oil from the pump to the steering and lifting systems as well as to any auxiliary hydraulic
systems on the vehicle depending of the dynamic load sensing signal of this steering unit (LS).

A- Short circuit valve. This valve is working as a check C

valve. Its function consists of the supply of the L R
steering unit with oil, in case of an emergency. In
B
principle, it is possible to steer with the pump broken 210bar 210bar
down, because the oil can be sucked through this
valve. This valve operates automatically if the
pressure in the P connection drops below the T
connection.

B- Two shock valves for the cylinder connections.

These valves protect the steering unit, the cylinders
and the hoses between these, against excessive
pressures, which can occur whenever the wheels get
in touch with big irregularities of the road surface. LS
The valves are pressure relief valves.
T P
C- Two feed-through valves for the cylinders. These
valves prevent cavitation at the cylinders. Both valves A D
are non-return valves.

D- An inlet check valve is positioned in de P-connection to attend of a good filled steering unit, also
after a long period of time standing still.

5
 3.2.2. DUAL DISPLACEMENT STEERING UNIT EQUIPPED WITH A DYNAMIC LS
SIGNAL

By using two displacements in one unit, a solution is created to manually steer a vehicle in an
unpowered mode without the need of a back-up power system.
The dual displacement steering unit uses two rotating valves (manual gerotor 1 and added gerotor 2)
and a pressure controlled logic valve (3). The logic valve switches between two displacements, one
displacement for manual steering and the total of both displacements for powered operation. The logic
valve is spring returned to the smaller manual displacement when inlet pressure falls below 8 bar.
Above 8 bar the logic valve connects both gerotors to provide full powered displacement.

A- See section 3.2.1 C

L R
B- See section 3.2.1

C- See section 3.2.1

2
D- See section 3.2.1 B
3

LS

T P
A
D

6
 3.2.3. STEERING UNIT WITHOUT DYNAMIC LS SIGNAL.

This steering unit is used in a YT-serie tractor without a lift frame or any auxiliary hydraulic systems.
With only the steering system as hydraulic system in the vehicle there is no priority valve needed. Also
the dynamic load sensing (LS ) is not needed. Therefor this steering unit is not equipped with dynamic
load sensing signal.

A- See section 3.2.1 C

L R
B- See section 3.2.1

C- See section 3.2.1

D- See section 3.2.1 B

E- One pressure relief valve is mounted between the pressure

line and the return line inside the steering unit. Limits
maximum pressure drop across the steering unit protecting
the steering circuit

T P
A D
E

7
 3.3 STEERING CYLINDERS

The steering cylinders convert hydraulic energy into kinetic energy, so the
oil flow, controlled by the steering unit, can be converted into a motion of
5
the steering cylinders, which causes the wheels to steer.

YT types:
The YT types have one steering cylinder on the front axle with a piston
diameter of 80 mm and a rod diameter of 55 mm. L R
It is of great importance that the entire sealing packet of a cylinder is replaced, when the cylinder is
leaking. It is not just because of the bad impact on the environment, but there is also a risk that additional
dirt will fall on the piston rods in the hydraulic system. This dirt can cause failures.

Steering cylinder below shows the sealings (A, B, C, D, E, F), which are included in the sealing set as
described in the parts manual.

A B C D E F D C B A

8
 4. THE LIFT FRAME OPERATING HYDRAULICS

This part of the hydraulic system takes care of the lifting and lowering of the lift frame, with the fifth-wheel
attached to it. This system consists of two parts:

1) Pneumatic part
2) Hydraulic part

The pneumatic part consists of a joystick (9) and optional height limiting(14)
The hydraulic part consists of a valve for lifting or lowering (6), pressure measurement point (13),
optional low limiting (10) and the lift cylinders (8),

OPTIONAL
HEIGHT LIMITING

14

T
13
B
10
OPTIONAL
LOW LIMITING

T P

9
 4.1 VALVE FOR LIFTING AND LOWERING

One valve is necessary to lift or lower the lift frame. This valve can be found in de middle of the chassis
underneath the lift frame hinges. It is possible to remove some chassis plates, in order to obtain a better
accessibility to the valve.

The valve is provided with an 1/4 BSP

minimess test connection mP (13), which B
can measure the pressure in the P Pressure limiting P
connection of the valves block. It is
mounted directly on the valve (nearby
connection B). This connection can be
used, e.g. for the adjustment of the
pressure relief valve or for trouble shooting.

The Valve offers the possibility to connect

additional hydraulics. Additional valves can
be mounted between for application of extra Lowering
hydraulics.
Lifting
R (T)
The main oil flow for the valve comes from
the EF connection of the priority valve. The
return oil flow of the valves block runs through the R connection to the return oil filter, as described in
section 2.2.
Connection B provides the supply and the return oil of the lift cylinders, as described under section 4.2.

4.1.1 PRESSURELESS CIRCULATION PRESSURE RELIEF VALVE

The vehicles are equipped with a fixed pump. This fixed pump always delivers a fixed amount of oil for
every rotation, when the diesel motor is running. This oil must be discharged through the filter to the tank,
with a minimal resistance.

The middle position of the valve (see scheme belonging to chapter 4) takes care that the oil flows, from
the pressure side to the return side of the hydraulic system, with a minimal pressure loss (approx. 7 bar).
The pressureless circulation pressure relief valve is in operation when the joy-stick in de cabin is idle

Integrated in this valve is a pressure security valve to protect the hydraulic system
The pressure on the pressure side of the hydraulic system can vary from a few bar till to the preset
pressure value of the relief valve.
This valve has been preset on a standard value in the factory (normally on 250 bar), and it is not allowed
to change this setting, without written permission of Terberg.

10
 4.1.2 LIFTING

Moving the joystick will activate the valve for lifting or lowering. The joystick operation is proportional. This
means that the speed of lifting is proportional controlled with the joystick.

When lifting, the oil pressure is going from the pump trough the priority valve and lifting valve to the
cylinders.

In unexcited condition, the valve is not really closed, this means that a minimal value of oil is leaking
through this valve. This also means that, when the fifth-wheel is heavily loaded, oil is leaking through this
valve, so the fifth-wheel can lower very slowly.

In figure 2 (see appendix at the end of this manual) is shown how the oil pressures behave during lifting.
Besides, the schematic position of the valves is shown.

4.1.3. HEIGHT LIMITING

As optional a height limiter can be mounted to limit the max. height of the fifth wheel. The height limiter
is a pneumatically valve which is electronically actuated. The height limiter can be activated by several
electronically detecting or switch commands.

4.1.4. LOWERING

Moving the joystick will activate the valve for lifting or lowering. The joystick operation is proportional. This
means that the speed of lowering is proportional controlled with the joystick. However the speed of
lowering also dependents on the fifth wheel load.

There is NO oil pressure by lowering. The gravity will lower the lift frame.

4.1.5. LOW LIMITING

As optional a low limiter can be mounted to limit the min. height of the fifth wheel. The low limiter is a
pneumatically valve which is electronically actuated. The low limiter can be activated by several
electronically detecting or switch commands.

11
 4.2 THE LIFT CYLINDERS

In the lift cylinders, hydraulic energy is converted into kinetic energy, so that it is possible to convert the oil
flow, from the hydraulic system to the cylinders, into a motion of the fifth wheel.

Two cylinders are assembled with the following specification:

Type: Single operated cylinder (one step)
Effective diameter: 125 mm

The cylinder is provided with a pivoting bearing with a lubricating nipple on the bottom, as well as on the
top. This way, the radial forces on the cylinder will remain small. The bottom is attached to the chassis.
The top is attached to the lift frame.

In case of leakage by one of the sealings, the entire sealing packet of the cylinders must be replaced.

Additional information on the lift cylinders is enclosed in the parts catalogue.

4.3 EXTRA HYDRAULIC

It is possible to add an additional section (6a) for activating extra hydraulic applications. See below for
an example of extra hydraulic application.

LIFTVALVE CONTROL EXTRA HYDRAULICS CONTROL

9 9

TILT CILINDERS

6a

8 8
6

P
P
T

12
 5. HOSES, FLANGES AND NIPPLES

The several hydraulic components, described in the chapters 1 up to and inclusive 4, are connected to
each other by hoses, flanges and nipples. Every hose, flange and nipple has been selected, carefully.
Only assemble the components indicated by Terberg, if a hose, flange or nipple needs to be replaced.
Never use any other type or product.

Take good care, when assembling the hoses, flanges and nipples. Snapped or twisted hoses can affect
the functioning of the system. Incorrectly assembled hoses, flanges and nipples can cause leakage.
Retighten the new hose by all the available clamping blocks, hose clips etc, after the replacement of a
hose.

Take utmost care when assembling the suction hose from the pump to the hydraulic tank. Fasten the
hose clips correctly, in order to clamp the hose tight enough on the suction pipe of the pump and the
tank. In case, this has not been done in the right way, the pump will suck air and starts to cavitate, so the
pump will soon be broken.

The specification of the hoses, flanges and nipples is to be found in the parts catalogue.

Figure 3 (see appendix) shows the entire hydraulic scheme.

13
 6. LIST OF FAILURES

The valve numbers, mentioned in this chapter, refer to the numbers shown in figure 3 (see appendix).
Table 6,1 is added on the end of this chapter, in which chapter 6 is summarised. A cause for a possible
failure can quickly be found, by using this table. A more extensive description of the possible cause and
remedy for a certain failure can be found in chapter 6. Always read the corresponding description in
chapter 6, after having been looking for a possible cause in the table.

6.1 THE LIFT FRAME WITH THE FIFTH-WHEEL DOES NOT LIFT

6.1.1 Possible cause:

a) Valve no. 6 does not switch
b) Valve no. 9 does not switch
c) The pump does not generate pressure
d) The load on the fifth-wheel is too heavy.
e) The optional height limiting is switch on (Optional)

6.1.2 How to determine the cause:

a) In the measure point 13, a pressure is measured equal to ±10 bar. Hereby, the fifth-wheel may not
be in the highest position and the joy-stick in the cabin must be set to lifting. In the air tube from valve
9 air pressure is generate when the joystick is moving to lifting. Check the air pressure by releasing
the tube. When air is going out the tube, the air pressure is alright.
b) In the measure point 13, a pressure is measured equal to ±10 bar. Hereby, the fifth-wheel may not
be in the highest position and the joy-stick in the cabin must be set to lifting. In the air tube from valve
9 air pressure is generate when the joystick is moving to lifting. Check the air pressure by releasing
the tube. When air is going out the tube, the air pressure is alright.
c) Set the joystick in the cabin in the position lifting. In the measure point 13, a pressure is measured
which is lower than 200 bar (engine running idle), so the present load cannot be lifted. The pump is
probably broken, when the vehicle cannot be steered either or when the steering is very tough.
d) In principle, the lift system is in order, as far as the fifth-wheel can lift in unloaded condition and the
pressure on measure point 13 runs to about 210 bar, with the fifth-wheel in the highest position. The
load on the fifth-wheel is too heavy , when the fifth-wheel does not lift, under loaded condition.
e) Lowering the lift frame, if it can lift but not reach the highest position probably the height limiting is
switch on (Optional)

6.1.3 Remedy:
a1) The air cylinder mounted on valve 6 is the problem. Repair or replace the air cylinder.
a2) The valve 6 is stuck, due to dirt. The dirt must be removed, not only the dirt found in this valve, but
also in the rest of the system. Probably, the filter element of the return filter and maybe the breather
filter must be replaced. Check the sealings of the valve for damage, when the valve has been
assembled again.
a3) The integrated pressure limiting in valve 6 is damaged. The oil can not generate pressure.
Replace valve 6.
b1) De joystick valve 9 is damaged and must be replace.
b2) The pressure in the air tank is too low. Start the engine and keep him on a few minutes. If the
joystick still doesn’t work check the air system.
c) The pump is out of order and must be replaced.
d1) The maximum pressure of the system in order to boost the lifting capacity, can only be increased
by written permission of Terberg.
d2) The trailer is overloaded and its load must be lessened.
e) This is no failure, if the height limiting must be adjust, it can be done in a little margin.

14
 6.2 THE LIFT FRAME WITH THE FIFTH-WHEEL DOES NOT LOWER

6.2.1 Possible cause:

a) Valve no. 6 does not switch.
b) Valve no. 9 does not switch.
c) The lift frame runs heavily.
d) One of the pivoting bearing in the cylinders is jammed.

6.2.2 How to determine the cause:

a) The fifth-wheel may not be in the lowest position and the joy-stick in the cabin must be set to
lowering. In the air tube from valve 9 air pressure is generate when the joystick is moving to
lowering. Check the air pressure by releasing the tube. When air is going out the tube, the air
pressure is alright.
b) The fifth-wheel may not be in the lowest position and the joy-stick in the cabin must be set to
lowering. In the air tube from valve 9 air pressure is generate when the joystick is moving to
lowering. Check the air pressure by releasing the tube. When air is going out the tube, the air
pressure is alright.
c) It is possible that the lift frame runs heavily, when cause a, b could not have been determined. The
hinges of the lift frame are insufficiently lubricated, when the lift frame will not lower in unloaded
condition.
d) If one of the pivoting bearings of the lift cylinder is not well lubricated, it is likely that the pivoting
bearing is jammed. This can be checked, by shuffling the cylinder by hand and so to check if the
pivoting bearing can be moved. It must be possible to move the pivoting bearing, without the help of
any kind of tool.

6.2.3 Remedy:
a1) The air cylinder mounted on valve 6 is the problem. Repair or replace the air cylinder.
a2) The valve 6 is stuck, due to dirt, the dirt must be removed, not only the dirt found in this valve, but
also in the rest of the system. Probably, the filter element of the return filter and maybe the breather
filter must be replaced. Check the sealings of the valve for damage, when the valve has been
assembled again.
b1) De joystick valve 9 is damaged and must be replace.
b2) The pressure in the air tank is too low. Start the engine and keep him on a few minutes. If the
joystick still doesn’t work check the air system.
c) Lubricate or replace the hinges. Check after lubrication, if the hinge moves smooth enough. If this is
the case, the lift frame will lower in unloaded condition.
d) Remove the dirt from the pivoting bearings and check them for damage. The respective pivoting
bearing must be replaced, if it is damaged. Lubricate it, in case it is not damaged and check if it can
easily be moved.

15
 6.3 THE VEHICLE CAN NOT BE STEERED

6.3.1 Possible causes:

a) The pump does not generate any pressure.
b) The priority valve does not switch
c) The rotating valve (gerotor) in the steering unit is jammed, due to pollution.

6.3.2 How to determine the cause:

a) Set the joystick in the cabin in the position lifting and the lift frame in the highest position (the engine
must run idle). In the measure point 13, a pressure has been measured which is lower than 200 bar.
The pump is probably out of order, as the vehicle cannot be steered well, either.
b) It is possible to lift and to lower the loaded fifth-wheel. Possibility b and c are the remaining possible
causes. Most likely, the priority valve cannot switch.
c) It is possible to lift and to lower the loaded fifth-wheel. The priority valve has been cleaned and can
be switched. Probably, the rotating valve in the steering unit cannot move to each other, due to dirt
e.g., as soon as the vehicle cannot be steered.

6.3.3 Remedy:
a) The pump is out of order and must be replaced.
b) The priority valve is stuck, due to dirt. The dirt must be removed, not only the dirt found in this valve,
but also in the rest of the system. Probably, the filter element of the return filter and maybe the
breather filter must be replaced. Check for damage the sealings of the valve, when the valve is
assembled again.
c) The rotating valve is stuck, due to dirt. The dirt must be removed, not only the dirt found in this valve,
but also in the rest of the steering unit and the rest of the hydraulic system. Probably, the filter
element of the return filter and maybe the breather filter must be replaced. Check for damage the
sealings of the valve. It is not allowed to disassemble the steering unit, without any permission of
Terberg.

6.4 THE STEERING IS TOUGHER THAN NORMAL

6.4.1 Possible causes:

a) The mechanism between steering wheel and the entering shaft of the steering unit runs heavily.
b) The hydraulic hoses have been snapped.
c) The pump does not function as it should.
d) The priority valve is polluted.
e) The bolts in the bottom plate of the steering unit are assembled by a torque which is too high, so the
movable part in the steering unit sticks and turns heavily.
f) The steering unit is polluted.

6.4.2 How to determine the cause:

a) Disengage the steering unit from the mechanism between the steering wheel and the entering shaft
of the steering unit. The cause must be found in the mechanism, if the motion of the steering wheel is
now irregular or tough.
b) Check for snapping of the hoses from the steering system.
c) Set the joystick in the cabin in the position lifting and the lift frame in the highest position (the engine
must run idle). In the measure point 13, a pressure has been measured which is lower than 200 bar.
The pump is probably out of order, as the vehicle cannot be steered well, either.
d) The priority valve has probably become polluted or does not function well, after having determined
that a, b and c cannot be the cause.
e) By the disengagement, as described under a, the steering mechanism runs smoothly and the turning
of the steering unit is tough (There can only be steered by using a tool as a lever to turn the steering
unit) and if the engine is running. In that case, one of the possible causes is that the bolts of the
bottom plate have been tightened by a too high torque. This cause cannot be checked, until it has

16
 been determined that a, c, e and f could not have been the cause of the problem.
f) The steering unit runs heavy, due to dirt. By disassembling the steering unit there can be determined
if dirt is the cause of the heavy way of running. Only disassemble the steering unit with the
permission of Terberg and after checking every other possible cause.

6.4.3 Remedy:
a) Lubricate and adjust the bearing-mounted parts in the mechanism, between steering wheel and the
entering shaft of the steering unit.
b) Remove the snap in the hose. Carefully check the hose for damage. Assemble a new hose, in case
it is damaged.
c) The pump is out of order and must be replaced.
d) Disassemble the plunger and check the orifices of the valve and the plunger for dirt. Remove the dirt,
if it has been located. Check the plunger for damage (scratches). Assemble a new priority valve, if a
damage is detected. Assemble the plunger again, in case no damage can be detected.
e) Loosen the bolts a bit and tighten them subsequently by a torque of 25 Nm. Mind that the bottom
plate does not get disassembled. The point is just to tighten the bolts by the correct torque.
f) Dirt must be removed, not only the dirt found in the steering unit, but also in the rest of the hydraulic
system. Probably, the filter element of the return filter, the pressure filter and maybe the breather filter
must be replaced. Check the sealings of the steering unit for damage.

6.5 THE STEERING WHEEL SLIPS THROUGH AT THE STOPS OF THE CYLINDERS

The wheels can be steered that far, up to the moment they meet a stop. It is normal, that the steering
wheel still can be moved very slowly, while being turned further. If it is possible to turn the steering wheel
at normal speed when the wheels meet the stop, the situation can be as follows.

6.5.1 Possible cause:

a) The pressure regulation of the priority valve or steering unit is incorrect.

6.5.2 How to determine the cause:

a) Measure the pressure of the pressure line from the pump to the priority valve. The pressure
regulation is incorrect, if the pressure exceeds 185 bar, at the moment the wheels meet the stop and
it is still possible to steer. In this case the pressure relief valve (see chapter 3.1 or see E chapter
3.2.3) or shock valves (see B chapter 3.2) are damaged / polluted.

6.5.3 Remedy:
a) Check and clean the pressure relief valve and the shock valves. When the cause is not determined,
replace the pressure relief valve or shock valves or complete valve.

17
 6.6 OIL LEVEL IN THE HYDRAULIC TANK IS FREQUENTLY TOO LOW

6.6.1 Possible cause:

a) The oil has not been refilled, after replacement/ repair of hydraulic components
b) There is a leakage in the system.

6.6.2 How to determine the cause:

a+b) Check the hydraulic system for leakage, by checking every component, hoses and lines for leakage.
Probably, the oil has not been refilled after maintenance/repair works, if no clear leakage can be
detected. The pump can also leak hydraulic oil to the transmission. The transmission oil will contain
hydraulic oil, whenever this has happened.

6.6.3 Remedy:
a) Refill the oil.
b) Eliminate the leakage by mounting new sealings, if this is the cause of the leakage. In the majority of
the cases, this is the cause of the leakage. Some times it happens that a hose loosens by vibration.
This leakage can be eliminated, in a simple way by retightening of the respective hose. Refill the oil.

18
 TABLE 6.1 SURVEY ON TROUBLE SHOOTING

Kind of
Possible cause How to determine the cause Remedy
failer
6.1
a) Valve no. 6 does a) In the measure point 13, a pressure is a1) Repair or replace the air
Liftframe
not switch measured equal to ±10 bar. Check the air cylinder.
does not
b) Valve no. 9 does pressure by releasing the tube. a2) The valve 6 is stuck,
lift.
not switch b) In the measure point 13, a pressure is due to dirt, the dirt must
c) The pump does measured equal to ±10 bar. Check the air be removed.
not generate pressure by releasing the tube. a3) The integrated pressure
pressure c) In the measure point 13, a pressure is limiting in valve 6 is
d) The load on the measured which is lower than 200 bar damaged.
fifth-wheel is too (engine running idle), so the present load b1) De joystick valve is
heavy. cannot be lifted. damaged and must be
e) The optional d) The load on the fifth-wheel is too heavy , replace.
height limiting is when the fifth-wheel does not lift, under b2) The pressure in the air
switch on loaded condition. tank is too low.
(Optional) e) Lowering the lift frame, if it can lift but not c) The pump is out of order
reach the highest position probably the and must be replaced.
height limiting is switch on (Optional) d1) The maximum pressure
of the system in order
to boost the lifting
capacity, can only be
increased by written
permission of Terberg.
d2) The trailer is overloaded
and its load must be
lessened.
e) This is no failure.

6.2
a) Valve no. 6 does a) Check the air pressure by releasing the a1) Repair or replace the air
The
not switch. tube. cylinder on valve 6.
liftframe
b) Valve no. 9 does a2) The valve 6 is stuck,
with the b) Check the air pressure by releasing the
not switch. due to dirt, the dirt must
fifth-wheel tube.
c) The lift frame be removed.
does not
runs heavily. c) It is possible that the lift frame runs b1) De joystick valve is
lowert.
d) One of the heavily, when cause a, b could not have damaged and must be
pivoting bearing been determined. replace.
in the cylinders is b2) The pressure in the air
d) If one of the pivoting bearings of the lift
jammed. tank is too low.
cylinder is not well lubricated, it is likely
c) Lubricate or replace the
that the pivoting bearing is jammed.
hinges.
d) Remove the dirt from
the pivoting bearings
and check them for
damage.

19
6.3
a) The pump does a) In the measure point 13, a pressure has (a) The pump is out of order
The
not generate any been measured which is lower than 200 and must be replaced.
vehicle can
pressure. bar. Lift frame in highest position and (b) The valve is stuck, due to
not be
b) The priority valve engine idle. dirt, the dirt must be
steered
does not switch b) It is possible to lift and to lower the loaded removed.
c) The rotating fifth-wheel. Possibility b and c are the (c) The valve is stuck, due
valve in the remaining possible causes. to dirt, the dirt must be
steering unit is c) It is possible to lift and to lower the loaded removed.
jammed, due to fifth-wheel. The priority valve has been
pollution. cleaned and can be switched. Probably,
the rotating valve in the steering unit
cannot move to each other, due to dirt
e.g., as soon as the vehicle cannot be
steered.

6.4
a) The mechanism a) Disengage the steering unit from the a) Lubricate and adjust the
The
between steering mechanism between the steering wheel bearing-mounted parts in
steering is
wheel and the and the entering shaft of the steering unit. the mechanism, between
tougher
entering shaft of b) Check for snapping of the hoses from steering wheel and the
than
the steering unit the steering system. entering shaft of the
normal
runs heavily. c) In the measure point 13, a pressure has steering unit.
b) The hydraulic been measured which is lower than 200 b) Remove the snap in the
hoses have been bar. Lift frame in highest position and hose.
snapped. engine idle. c) The pump is out of order
c) The pump does d) The priority valve has probably become and must be replaced.
not function as it polluted or does not function well. d) Disassemble the plunger
should. e) By the disengagement, as described and check the orifices of
d) The priority valve under a, the steering mechanism runs the valve and the plunger
is polluted. smoothly and the turning of the steering for dirt.
e) The bolts in the unit is tough. In that case, one of the e) Loosen the bolts a bit
bottom plate of possible causes is that the bolts of the and tighten them
the steering unit bottom plate have been tightened by a too subsequently by a torque
are assembled high torque. of 25 Nm.
by a torque f) The steering unit runs heavy, due to dirt. f) Dirt must be removed.
which is too high. By disassembling the steering unit there
f) The steering unit can be determined if dirt is the cause of
is polluted. the heavy way of running. (Permission of
Terberg necessary)

6.5
a) The pressure a) Measure the pressure of the pressure line a) Check and clean the
The
regulation of the from the pump to the priority valve. The pressure relief valve and
steering
priority valve or pressure regulation is incorrect, if the the shock valves. When
wheel slips
steering unit is pressure exceeds 185 bar, at the moment the cause is not
through at
incorrect. the wheels meet the stop and it is still determined, replace the
the stops
possible to steer. pressure relief valve or
of the
shock valves or complete
cylinders
valve.

20
6.6 a) Refill the oil by the filling
a) The oil has not a+b) Check the hydraulic system for leakage,
Oil level in cap of the return filter.
been refilled, by checking every component, hoses
the b) Eliminate the leakage by
after and lines for leakage. The pump can
hydraulic mounting new sealings.
replacement/ also leak hydraulic oil to the
tank is Refill the oil.
repair of transmission.
fregeuntly
hydraulic
too low
components
b) There is a
leakage in the
system.

21
APPENDICE 1:
SYSTEM WITH STEERING UNIT WITH DYNAMIC LS SIGNAL AND STD. LIFTING SYSTEM

STEERING DESCEND

8 8
5

L R
4 9
210bar 210bar

Optional
14 Height limiting

T 10

T P Optional
LS CF 13 Low limiting
3 172 bar
EF
T
250 bar 6
P P

1
M 2
11

12
7

(blue) : Low pressure

(green) : Suction line

(blue) : Return line

(orange): Command line

Figure 1 (red) : High pressure

22
APPENDICE 1:
SYSTEM WITH STEERING UNIT WITH DYNAMIC LS SIGNAL AND STD. LIFTING SYSTEM

NO STEERING LIFTING

8 8
5

L R
4 9
210bar 210bar

Optional
14 Height limiting

T 10

B 1 2

T P Optional
LS CF 13 Low limiting
3 EF
172 bar
T
250 bar
6
P
P

1
M 2
11

12
7

(blue) : Low pressure

(green) : Suction line
(blue) : Return line
(orange): Command line
Figure 2 (red) : High pressure

23
APPENDICE 1:
SYSTEM WITH STEERING UNIT WITH DYNAMIC LS SIGNAL AND STD. LIFTING SYSTEM

EMERGENCY STEERING + NEUTRAL

STEERING REVERSAL

8 8
5

L R
4 9
210bar 210bar

Optional
14 Height limiting

T 10

B 1 2

T P
Optional
LS CF 13 Low limiting
3 EF
172 bar

T 6
250 bar

P
P

1
M 2
11

12
7

(blue) : Low pressure

(green) : Suction line
(blue) : Return line
(orange): Command line
Figure 3 (red) : High pressure

24
APPENDICE 1:
SYSTEM WITH STEERING UNIT WITH DYNAMIC LS SIGNAL AND STD. LIFTING SYSTEM

NO STEERING NEUTRAL

8 8
5

L R
4 9
210bar 210bar

Optional
14 Height limiting

T 10

B 1 2

T P Optional
LS CF 13 Low limiting
3 EF
172 bar
T
250 bar
6
P
P

1
M 2
11

12
7

(blue) : Low pressure

(green) : Suction line
(blue) : Return line
(orange): Command line
Figure 4 (red) : High pressure

25
APPENDICE 2:
SYSTEM WITH STEERING UNIT WITHOUT DYNAMIC LS SIGNAL

STEERING

4 L R
234bar 234bar

175bar

T P

2 1
11
M 7
12

(blue) : Low pressure

(green) : Suction line

(blue) : Return line

(orange): Command line

Figure 1 (red) : High pressure

26
APPENDICE 2:
SYSTEM WITH STEERING UNIT WITHOUT DYNAMIC LS SIGNAL

EMERGENCY STEERING

4 L R
234bar 234bar

175bar

T P

2 1
11
M 7
12

(blue) : Low pressure

(green) : Suction line

(blue) : Return line

(orange): Command line

Figure 2 (red) : High pressure

27
APPENDICE 2:
SYSTEM WITH STEERING UNIT WITHOUT DYNAMIC LS SIGNAL

NO STEERING

4 L R
234bar 234bar

175bar

T P

2 1
11
M 7
12

(blue) : Low pressure

(green) : Suction line

(blue) : Return line

(orange): Command line

Figure 3 (red) : High pressure

28