Terex TR60 Maintenance Manual page 441

4. Attach tank return line to 'T' port of valve body (20).
5. Attach output ports 'B1' and 'B2' to test lines. Check
that all ports are used.
6. Set supply line pressure to 159 bar (2 300 lbf/in²).
7. Set pilot supply pressure to 159 bar (2 300 lbf/in²).
8. Return line pressure during this test is not to exceed
0.34 bar (5 lbf/in²).
9. Test valve with 10W hydraulic oil at 50° + 6° C
(120° + 10° F).
Setting Manual and Pilot Pressure
1. Install pivot pin (38) in actuator base (46) by itself
without installing pedal (50) assembly.
2. By taking a screw driver or pry bar and placing it
under pivot pin (38) and on top of actuator plunger (2)
assembly, you will be able to actuate each circuit
individually. See Fig. 10.
3. Gradually apply pressure on each circuit to check
for leaks. Make sure adjustment collar (1) is screwed
all the way down on the threads.
4. Adjust adjustment collar (1) up (anticlockwise)
starting with one turn increments until the output
pressure is 159 bar (2 300 lbf/in²) at port 'B1' with
adjustment collar (1) contacting actuator base (46)
(fully actuated). See Fig. 10. Fine adjustment will
require only turning the collar in 1/8 turn increments.
5. Adjust adjustment collar (1) up (anticlockwise)
starting with one turn increments until the output
pressure is 52 bar (750 lbf/in²) at port 'B2' with
adjustment collar (1) contacting actuator base (46)
(fully actuated). See Fig. 10. Fine adjustment will
require only turning the collar in 1/8 turn increments.
6. Cycle each circuit 50 times using pilot apply.
7. Recheck pressures after cycling. If they have
changed, readjust.
8. Tighten the capscrews in adjustment collars (1) to
3 - 3.5 Nm (25 - 30 lbf in). You may have to rotate
entire actuator plunger (2) to get to the capscrews.
9. Check pressures again after tightening the
capscrews. If the pressures have altered, loosen the
appropriate capscrew and readjust.
SM 1225 Rev 1 9-99
Braking System - Treadle Valve
FINAL ASSEMBLY
Numbers in parentheses refer to Fig. 1.
Note: Tighten all fasteners without special torques
specified to standard torques listed in Section
300-0080, STANDARD BOLT AND NUT TORQUE
SPECIFICATIONS.
1. Remove pivot pin (38) from actuator base (46).
2. Assemble actuator cap (41), boot (42) and retainer
plate (44) to actuator base (46) and secure with
screws (43).
3. Insert pivot pin (38) through the hole in actuator
base (46), through the holes in 'U' bolts (32), and
through the pivot pin hole in the other side of actuator
base (46). As pivot pin (38) is being inserted, install
pedal return springs (39 & 40).
4. Centre pivot pin (38) and secure with nuts (30) and
washers (31) on 'U' bolts (32). Tighten nuts (30) to a
torque of 16 - 17 Nm (140 - 150 lbf in).
5. Install pedal (50) assembly on actuator cam (36)
and secure with capscrews (51), washers (49) and
nuts (48).
ADDITIONAL TESTING AND ADJUSTMENT
Numbers in parentheses refer to Fig. 1.
1. Depress pedal (50) as quickly as possible. The
output pressure on the circuits must reach 159 bar
(2 300 lbf/in²) at port 'B1' and 52 bar (750 lbf/in²) at
port 'B2' within 10 seconds. Measurement of time
begins the moment force is applied to move pedal (50).
2. Back-off deadband adjustment screw (35)
(anticlockwise) so that adjustment screw (35) is not
touching actuator cap (41). Apply Loctite 243 to
adjustment screw (35) prior to setting the deadband.
3. Set the deadband by placing a 0.64 mm (0.025 in)
shim between the pedal return stop and the boss on
the actuator base return stop. See Fig. 11.
4. Turn adjustment screw (35) down (clockwise) until it
is touching actuator cap (41).
5. Continue turning adjustment screw (35) clockwise
until you start to see a pressure reading on the
pressure gauge then back-off adjustment screw (35)
1/8 turn (anticlockwise).
Section 250-0070
9