1

Product Training
Rigid Dump Truck (RDT)
TR100

Steering System

020710

Terex Centre of Excellence

Terex Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
United Kingdom
Technical Online Assistance: http://constructionsupport.terex.com
 2

WARNING
2

HIGH
PRESSURE

PRIOR TO SERVICE WORK & ROUTINE

MAINTENANCE BEING CARRIED OUT
ON THE STEERING CIRCUIT

DEPLETE STORED PRESSURE BY

TURNING STEERING WHEEL BACK
AND FORTH UNTIL STEERING LOCKS.
 3

RDT Steering Control Schematic

3

1. STEERING HYDRAULIC TANK

2. STEERING PUMP
3. STEERING ACCUMULATOR
4. ACCUMULATOR VALVE
5. STEERING ORBITROL VALVE
6. DOUBLE RELIEF VALVE (SHOCK)
7. STEERING CYLINDERS
8. STEERING PRESSURE SWITCH.
9. OIL LEVEL SWITCH.
10.OIL PRESSURE RESTRICTION
SWITCH.
11.OIL TEMPERATURE SWITCH.
12.STEERING PRESSURE FILTER
 4

Steering Control Pressure Chart

4

TR45 TR60 TR70 TR100

SYSTEM PRESSURE bar 159 159 159 159
psi 2300 2300 2300 2300
DOUBLE RELIEF VALVE bar 172 172 172 172
psi 2500 2500 2500 2500
LOW STEERING WARNING bar 82 82 82 82
psi 1200 1200 1200 1200
SECONDARY RELIEF bar 206 206 206 206
psi 3000 3000 3000 3000
ACCUMULATOR NITROGEN bar 55 55 55 55
o
PRECHARGE @ 21 C psi 800 800 800 800
PUMP CAPACITY @ REV/MIN L/Min 84 84 105 120
Rev/Min 2100 2100 2100 2100
 5

Steering System Main Pressure Check Point

5

Steering Pressure = 159 bar (2300 psi)

 6

Steering/Brake Actuation Tank

6

CHECK WITH ENGINE RUNNING

AND ACCUMULATOR
CHARGED. OIL SHOULD BE
VISIBLE IN THIS SIGHT GAUGE.
IF NOT, SHUT OFF ENGINE.
RETURN ACCUMULATOR OIL
TO TANK BY STEERING THE
VEHICLE AND CHECK OIL ON
UPPER SIGHT GAUGES.
 7

Steering/Brake Actuation Tank

7

FILTER

NSS

NSS

SUCTION
SCREEN
 8

Steering/Brake Actuation Tank Filter Switches

8

11 - OIL TEMPERATURE - 50°C (TOP)

10 - FILTER RESTRICTION SWITCH - 2.7 BAR (39 PSI)
(BOTTOM)

Steering Filter
Restriction
 9

Service Intervals
9
Recommended Service Intervals
Daily / 10 hrs
Check Oil Level – Add if low

1000 hrs
Remove and Replace Steering Pressure Filter Element – Clean Filter Housing

2000 hrs
Drain and Re-Fill Oil
Replace Tank Filter Element
Remove and Clean Suction Screen

Oil Type
-18°C to +32°C 10 W Oil
+32°C and above 30 W Oil

10 W Recommended Oils
KUWAIT TO4 SHELL DONAX TC ESSO TORQUE FLUID
TEXACO TEXTRAN TOTAL TRANSMISSION AC MOBILTRANS HD
CASTROL TFC BP AUTRAN 4
 10

Main Piston (Steering) Pump

10
Main steering and brake actuation flow is
delivered by the main piston pump (2). PUMP MOUNTED OFF TRANSMISSION PTO (RHS OF TRUCK)

Main Piston Pump Adjustments;

1. Attach appropriate pressure gauge
to steering diagnostic point.
2. Start engine and allow steering
accumulator to charge.
3. Record pressure, target pressure
159 bar (2300 psi)
4. Make any necessary adjustment at
pump compensator.
5. Note: It is recommended to set COMPENSATOR SET
pressure on the increase. 159 BAR (2300 psi)

Always ensure that the pump is primed (lubed) prior to

initial start up.
It is recommended to back off the compensator
pressure to minimum displacement at initial start up.
Pump should be increased slowly to target pressure.
Failure to follow these instruction could result in
catastrophic failure of the pump within a short working
period.
 11

Steering Pump – Variable Displacement

11
 12

Steering Pump – Compensator Layout

12
1 PUMP OUTLET PRESSURE
2 BIAS PISTON
3 PUMP COMPENSATOR
4 COMPENSATOR LIMITING SPOOL
5 COMPENSATOR SPRING
6 COMPENSATOR ADJUSTMENT
7 ACTUATION VALVE (STEERING
ORBITROL/BRAKE VALVE)
8 CONTROL PISTON

MAXIMUM SHOE PLATE ANGLE DECREASED SHOE PLATE ANGLE ZERO SHOE PLATE ANGLE
(MAXIMUM DISPLACEMENT) (PARTIAL DISPLACEMENT) (MINIMUML DISPLACEMENT)
 13

Steering Pressure Filter

13

6 7 1

4
Visual Indicator

1. FILTER HEAD
5
2. FILTER CAN
3. FILTER ELEMENT
4. O-RING
2
5. MAGNETS (Option)
6. BYPASS VALVE
7. INDICATOR LINK
3
CHANGE OUT ELEMENT IF INDICATOR IN YELLOW
OR AFTER 1000 Hrs.
Whatever comes first.
 14

Steering Accumulator Valve (4)

14

Relief valve in line to protect pressure surge

(spike) in steering circuit.
To check Relief Valve Setting:
1. Attach appropriate pressure gauge to
steering diagnostic point.
2. Remove cap from relief valve and turn
relief valve to maximum pressure setting.
3. Adjust steering pump pressure to >207
bar (3000 psi).
4. Screw relief valve back out and adjust
until pressure drops to 207 bar (3000 psi).
RELIEF VALVE
5. Pressure relief valve is now set correctly.
6. Adjust steering pump to correct
operating pressure of 159 bar (2300 psi).
7. Remove pressure gauge and secure pump
compensator and relief valve. RELIEF VALVE SETTING
207 BAR (3000 psi)
 15

Low Steering Pressure Switch (8)

15

TYPICAL INSTALLATIONS

82 Bar (1200 psi)

Pressure switch can be installed either behind the steering pressure diagnostic connector
or direct at the steering accumulator valve.
 16

Steering Accumulator Valve Schematic

16

FROM PORT-T TO PORT-P ON

ON ORBITROL ORBITROL

STEERING SYSTEM ENERGISED STEERING SYSTEM DE-ENERGISED

 17

Steering Accumulator
17
HIGH
PRESSURE

NITROGEN PRECHARGE
55 BAR (800 PSI)
@ 21°C AMBIENT

Service Kits:
TR45 (T881) 15500633
PISTON
TR60 (T882) 15500633
TR70 (T913) 15500629
TR100 (T783/831) 15500629
Part numbers correct at time of training conception.

For latest ‘live’ part numbers and parts updates

please refer to Terex Technical Online Assistance
http://constructionsupport.terex.com
 18

TR70/TR100 Steering Accumulator

18

TRI-STACK ACCUMULATOR
TR70 T7891075 to T7891092
TR100 T7831187 to T7831226

LEGEND
1 100mm PISTON ACCUMULATOR - 2 OFF
2 127mm PISTON ACCUMULATOR - 1 OFF
3 OIL MANIFOLD BLOCK
4 SUPPORT PLATE
5 MOUNTING PLATE

OIL CAPACITIES
100mm PISTON ACCUMULATOR = 7.42 l/EACH
127mm PISTON ACCUMULATOR = 11.23 l
TOTAL CAPACITY = 26.07 l

NITROGEN PRE-CHARGE
3 X PISTON ACCUMULATORS = 55 b (800 lbft2)

HIGH
PRESSURE
 19

Accumulator Charge Valves

19

POPPET-TYPE VALVE
DUST CAP

GAS VALVE

ADJUSTER
LOCK NUT

Terex charge valves are recessed

into accumulator end cap. Charging
kit’s extension valve must be used.
SCHRADER-TYPE VALVE
 20

Nitrogen Charge Kit

20
Complete charging kit assembly for
checking and adjusting all nitrogen
charged accumulators and
suspension ride struts mounted on
Terex Off-Highway Trucks.

1 - 09359489 Standard Charge Kit (A)(B)

Includes all parts shown that are not individually identified.

2 - 15269788 Hose Assembly (B)

3 - 15269789 Inflation (Chuck) Valve (B)
4 - 15269790 Extension Valve (A)
5 - 15503560 Shut Off Valve (B)
6 - 00454145 Tee Piece Connector (B)
7 - 00444355 Coupling (B)

(A) The Charging Kit; 09359489, along with the

Extension Valve; 15269790 are required for checking
and adjusting hydraulic accumulators only.

(B) The Charging Kit; 09359489, and all above

auxiliary parts are required for checking and
adjusting the ride struts. It is recommended to charge
ride struts simultaneously.
 21

Nitrogen Charge/Test Procedure

21

Poppet-Type Gas Valve

1. Relieve pressure from all charged circuits by turning steering wheel and/or depressing brake
pedal several times.
2. Remove protective cover and dust cap from accumulator to obtain access to the gas valve.
3. Ensure bleeder valve is closed on the charge kit and does not leak.
4. Ensure both accumulator and cylinder shut-off valves are closed on the charge kit.
5. Ensure inflation valve is fully raised on charge kit by turning T-bar counter clockwise.
6. Screw inflation valve and charge kit onto gas charge valve.
7. Open poppet-type gas valve by loosening the adjuster lock nut.
8. Open inflation valve by turning T-bar clockwise, this begins to open the gas valve.
9. To read accumulator nitrogen precharge, slowly open the accumulator shut-off valve and
observe maximum pressure registered on gauge.
10. Maximum pressure reading observed on the gauge is the accumulator nitrogen precharge.
Precharge pressure OK
11 Turn inflation valve counter clockwise to raise valve.
12 Lock adjuster nut on poppet-type valve.
13 Open bleeder valve to dissipate gauge pressure.
14 Close accumulator shut-off valve.
15 Remove charging kit from poppet-type valve. DO NOT REMOVE
16 Ensure poppet-type valve is sealing effectively. CHARGING KIT UNTIL
17 Replace dust cap and protective cover. ALL EXCESS NITROGEN
HAS BEEN DISIPATED
 22

Nitrogen Charge Vs Ambient Temperature

22

AMBIENT TEMPERATURE NITROGEN PRECHARGE PRESSURE

°C °F bar lbf/in²
-18 0 47.7 692
-12 10 48.8 708
-7 20 49.8 723
-1 30 50.9 738
5 40 52 754
10 50 53 769
16 60 54.1 785
21 70 55 800
27 80 56.2 815
32 90 57.3 831
38 100 58.3 846
43 110 59.4 862
49 120 60.5 877
54 130 61.5 892
 23

Steering Orbitrol Valve

23

Steering Orbitrol valve

 24

Steering Orbitrol Valve – Sleeve/Spool

24

RIGHT LEFT
SYSTEM TURN TURN
PRESSURE FEED FEED
METER TANK
GERATOR GERATOR PORTS RETURN
GEAR HOUSING

POCKETS

GERATOR GEAR SET SPOOL AND SLEEVE PORTING

 25

Orbitrol Steering Valve – Neutral Steer

25
 26

Orbitrol Steering Valve – Left Steer

26
 27

Orbitrol Steering Valve – Right Steer

27
 28

Double Relief (Shock) Valve

28

DOUBLE RELIEF VALVE (SHOCK)

 29

Double Relief (Shock) Valve

29

ADJUSTMENT
A SCREW

LOCK
NUT

B
RELIEF VALVES SETTING - 172 BAR (2500 PSI)

COMPRESSED
SPRINGS
 30

Double Relief (Shock) Valve - Schematic

30
NEUTRAL POSITION

STG. CYL. STG. CYL.

BASE END ROD END

STG. CYL. STG. CYL.

ROD END BASE END

LH PORT ON RH PORT ON
STG. VALVE STG. VALVE

STG. CYL. STG. CYL.

BASE END ROD END

STG. CYL. STG. CYL.

ROD END BASE END

LH PORT ON RH PORT ON
STG. VALVE STG. VALVE

ACTIVE POSITION
 31

Steering Mechanism
31

STEERING ARM/TIE-ROD
 32

Wheel Alignment
32

DIMENSION ‘Y’
X-PLY RADIAL
TR45 10-16 10-16
TR60 10-16 10-16
TR70 13-19 10-16
TR100 13-19 13-19
(mm)
 33

Steering Cylinders
33

Service Kits:
TR45 (T881) 15273474
TR60 (T882) 15273474
TR70 (T913) 15274213
TR100 (T783/831) 15274213
Part numbers correct at time of training conception.

For latest ‘live’ part numbers and parts updates please refer to Terex
Technical Online Assistance http://constructionsupport.terex.com
 34

Steering System - Neutral

34

TR45
TR60
TR70
TR100
 35

Steering System – Left Turn

35

TR45
TR60
TR70
TR100
 36

Steering System – Right Turn

36

TR45
TR60
TR70
TR100
 37

Steering System – Shock Load

37

TR45
TR60
TR70
TR100
 38

38

Product Training
Rigid Dump Truck (RDT)
TR100

Brake System

020710

Terex Centre of Excellence

Terex Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
United Kingdom
38 Technical Online Assistance: http://constructionsupport.terex.com
 39

WARNING
39

HIGH
PRESSURE

PRIOR TO SERVICE WORK & ROUTINE

MAINTENANCE BEING CARRIED OUT
ON THE BRAKING CIRCUIT

DEPLETE STORED PRESSURE BY

PRESSING BRAKE PEDAL UP AND
DOWN UNTIL ACCUMULATORS ARE
DEPLETED.

39
 40

RDT Braking Systems

40
TR100

FRONT BRAKE

REAR BRAKE – Oil Cooled Disc Brake

(OCDB) 40
 41

RDT Rear Braking System

41
DANGER!
SPRING FORCE
PARK BRAKE PISTON
SERVICE BRAKE PISTON
PARK BRAKE SPRINGS

SPLINED DISCS AND FRICTION PLATES

OIL COOLED

SERVICE PISTON RETURN SPRINGS

SERVICE BRAKE RESIDUAL 3.0 bar (44 psi)

SERVICE BRAKE APPLY 52 bar (750 psi)
PARK BRAKE HOLD OFF PRESSURE
82 bar (1200 psi)

41
 42

Park Brake Piston

42

TR45 21 SPRINGS
DANGER! TR60 54 SPRINGS
SPRING FORCE TR70 54 SPRINGS
TR100 54 SPRINGS
42
 43

Service Brake Piston

43

DANGER!
SPRING FORCE
43
 44

Service Piston Spring Tool

44

44
 45

Service Piston Spring Tool

45
1. Screw ‘T’ bar of service piston spring tool into
threaded hole on top of retaining pin. Ensure not to
screw in too deep as this will lock the pin to be
removed.
2. Lift retaining pin, overcoming spring pressure to
reveal small ‘cross drilled’ pin. Push ‘cross drilled’
pin out of hole. WARNING! Ensure not to snap
retaining pin down on finger. Advise using small
screw driver.
3. Complete operation (2) for all retaining pins. Removal of Service Piston Retaining Pins
Using Service Piston Spring Tool
4. Remove service brake piston. Pressurise hydraulic
pressure face with air pressure to pop the piston out.
Alternatively 2 heal bars can be used to exert force Service Piston Removed Reveals Spring
on under side of service piston. Ensure not to Clamping Plates
damage any machined surfaces.
5. Removal of service piston will reveal spring
clamping plates. Remove 2 bolts at each retaining
pin to access spring. WARNING! Beware of spring
force behind clamping plate.

DANGER!
SPRING FORCE
45
 46

OCDB Circuit
46

TR100 REAR
BRAKES

COOLER

PUMP

FILTERS H.P.C.O.

HYDRAULIC REAR
TANK BRAKES

High Pressure Carry

46
Over (HPCO)
 47

OCDB Filters
47

Check indicators daily / 10 hrs

Replace elements if necessary
Or replace elements every 1000 hrs

Located LHS engine bay

47
 48

OCDB Coolers
48

48
 49

OCDB Rear Axle

49

RHS Â

A
B

B
A = Park Brake
B = Rear Service Brake
ÁLHS
49
 50

OCDB Rear Brake Seals

50
A – Face to Face Seal
B – Face to Face Seal
C
C – Park Brake Seal
D – Service Piston Seal
PARK BRAKE PISTON
SERVICE BRAKE PISTON
PARK BRAKE SPRINGS
D

B
A SPLINED DISCS AND FRICTION PLATES

End View –
See following page

SERVICE PISTON RETURN SPRINGS

SERVICE BRAKE RESIDUAL 3.5 bar (50 psi)

SERVICE BRAKE APPLY 52 bar (750 psi)
PARK BRAKE HOLD OFF PRESSURE
82 bar (1200 psi)

50
 51

OCDB – Cooling Paths

51

51
 52

OCDB Piston Housing Inlets/Outlets

52

52
 53

OCDB Cooling Oil Paths

53
Cooling oil enters
brake via piston
housing and forced
through holes in wheel
driver onto brake
discs.

Wheel driver and brake discs in position.

Piston housing installed detailing inlet and outlet flow paths.

53
 54

Park Brake Piston Seal Installation (C)

54
1. Thoroughly clean and degrease all metal parts.
2. Lay parking piston on it’s side with seal groove
uppermost and fit red silicon O Ring. Fit PTFE bronze
Sealing Ring using fitting tapes. (ref. 1). Ensure sealing
lip points towards pressure (ref. 2).
3. Fit guide band to parking piston after exposing adhesive
transfer tape on the inside. Starting in the middle and
moving to the two ends. It is recommended that 2 people
are needed for this operation.
4. Fit O Ring into groove on disc housing. Fit PTFE bronze
seal using kidney shaping technique (ref. 3 and 4).
Smooth the kinked portion of the seal back to a circular
shape. Ensure sealing lip points towards pressure, as
above.
5. After exposing the adhesive transfer tape, fit the guide
band to the disc housing as Step 3, noting that the
transfer tape is on the outside. Oil all parts including
seals and carefully offer piston into disc driver.

Numbers Based on TR60/TR100 Installation

54
 55

Face to Face Seal (A)

Seal Installation Instruction for Mechanical Face Seals 55
For Seal Kit 15302752 Use Fitting Tool 15265301
Reference 15302752 (TR60/70/100) & 15302753 (TR45)
For Seal Kit 15302753 Use Fitting Tool 15269781

Inboard Half.
1. Remove face seal from packaging.
2. Thoroughly degrease seal rings, torics and housings with
a non petroleum based solvent prior to assembly. Wipe
dry and ensure the toric rings are not twisted when
replaced back on seal rings.
3. Insert one half of new face seal into split fitting tool.
4. Pass over spindle and press into disc driver housing using
an even pressure on tool. Seal should pop into housing.
5. Remove split fitting tool.

Outboard Half.
1. Remove and clean face seal as in points 1 & 2 above.
2. Insert other half of new face seal into split fitting tool.
3. Using even pressure, press face seal into inner seal
housing as before.
4. Remove split fitting tool.

Note. Both seal faces should sit parallel with the housing. Toric ring
should not be twisted or partly bulged out of housing. Immediately
prior to assembly, clean seal face with a lint free wiper and apply a
thin film of clean oil to sealing face. Oil must not wet any other
surface.
To ease assembly of face seals into housing, a non petroleum based
solvent can be wiped on toric prior to assembly. Recommended
assembly lubricant – Isopropyl Alcohol.
55
 56

Face to Face Seal (B)

56
Seal Installation Instruction for Mechanical Face Seals
Reference 15247216 (TR60/70/100) & 15249832 (TR45)
Seal Driver
Inboard Half.
1. Tear plastic film from cardboard backing. It is not necessary
to cut seal from package which could damage toric rings. Seal Sleeve
2. Thoroughly degrease seal rings, torics and housings with a
non petroleum based solvent immediately prior to assembly.
Wipe dry and ensure the toric rings are not twisted when
replaced back on seal rings.
3. Insert ‘seal sleeve’ tool into spring housing as far as it will go. Seal Kit
4. Insert seal installation ‘garter spring’ on one half of face seal 15247216 –
between toric and seal ring. It is recommended that you wrap Fitting Kit
some tape or ribbon around the spring to provide easy removal 15267573
once in position.
5. Place assembly into bottom of ‘seal sleeve’ and press into Seal Kit
face seal housing using ‘seal driver’. 15249832 –
6. Remove ‘seal driver’ and ‘seal sleeve’ from spring housing. Fitting Kit
Remove ‘spring’ from face seal. 15269783
Seal Driver / Sleeve In Position

Garter Spring

56
 57

Face to Face Seal (B)

57
Seal Installation Instruction for Mechanical Face Seals For Seal Kit 15247216 Use Fitting Tool 15265300
Reference 15247216 (TR60/70/100) & 15249832 (TR45) For Seal Kit 15249832 Use Fitting Tool 15269782

Outboard Half.
Split Fitting Tool
1. Remove seal from packaging and clean as in points 1 & 2
above.
2. Insert assembled seal into split fitting tool.
3. Place squarely over seal housing and with even pressure,
press home.
4. Remove split fitting tool.

Note. Both seal faces should sit parallel with the housing.
Toric ring should not be twisted or partly bulged out of
housing. Immediately prior to assembly, clean seal face with a
lint free wiper and apply a thin film of clean oil to sealing face.
Oil must not wet any other surface.
To ease assembly of face seal into housing, a non petroleum
based solvent can wiper on toric prior to assembly.
Recommended assembly lubricant – Isopropyl alcohol.

Split Fitting Tool Located onto Seal

57
 58

Service Piston Seal (D)

58

58
 59

Rear Brake Wear Measurement Point

59
1. Release the park/emergency brake. This will
pressurise parking brake cavity compressing
park brake springs.
2. Depress service brake treadle or, with
1
retarder selection mode switch (if fitted) in
the disc brake position, place retarder
control lever in the applied position. This will
pressurise the service brake piston cavity.
3. Carefully remove pipe plug (1) from piston
housing. tu re
u fac ion
4. Insert a depth micrometer into the pipe plug n
hole and measure distance from end of M a m e ns
Di
retainer pin to machined surface on piston
housing. This is dimension 'A'. Record this
dimension.
REAR BRAKE WEAR
5. Record the dimension that is stamped on
piston housing. Subtract dimension ‘A’ (Ref. FRICTION SPLINED MAX
Step 4) from the stamped dimension. The DISCS PLATES WEAR
difference is the amount of brake wear. Refer TR45 7 6 6.35mm
to 'Disc Brake Wear Limits' table for
permissible wear limits.
TR60 7 6 6.35mm
TR70 10 9 8.22mm
TR100 13 12 10.16mm
59
 60

New & Worn Disc Wear Limits

60

Friction Disc Thickness

New Disc ……………………………………….5.08 ± 0.13 mm (0.200 ± 0.005 in)
Worn Disc – Minimum Permissible Size …4.57 mm (0.180 in)

Splined Plate Thickness

New Plate ……………………………………... 2.413 ± 0.064 mm (0.095 ± 0.0025 in)
Worn Plate – Minimum Permissible Size…2.29 mm (0.090 in)

Damper Plate Thickness

New Damper Plate …………………………… 6.9 ± 0.051 mm (0.270 ± 0.020 in)
Compression 'Set' after use………………… 5.84 mm (0.230 in)

60
 61

Front Brake Parts

61
Service Kits; For latest ‘live’ part numbers and parts
updates please refer to Terex Technical
TR45(T881) / TR60(T882) / TR70(T913)
Online Assistance
Item 11 – 15265529 Seal Service Kit http://constructionsupport.terex.com
TR100(T783/883)
Item 11 – 15271389 Spring Service Kit
Part numbers correct at
time of training conception.

Allowable Front Brake Wear

TR45/60/70 Discs <16mm Maximum acceptable disc run out for disc
speeds lower than 100 rev/min is 0.762 mm
TR100 Discs <22mm
(0.030 in) total. Replace disc or repair hub
Pads <3mm 61 if necessary to correct this condition.
 62

Brake Burnishing
62
When new brake pads are installed on a truck, the brake pad friction material
should be burnished in accordance with the following procedure to achieve
maximum braking performance:

a) Drive truck at 8 - 15 kph (5 - 10 mph) with brakes applied at just enough

pressure to produce a noticeable drag. Heavy smoke and foul odour from
the brake pad friction material is normal during this procedure. Note: An
infrared thermometer pointed at the disc after stopping, can safely and
easily determine the brake disc temperature.

b) Continue cycle until the brake disc achieves a temperature of 315 – 370°C
(600 – 700°F).

c) Permit the brake disc to cool to a temperature of less than 95°C (200°F).

d) Repeat Steps a and b.

e) Allow brake disc to cool to within 10o C (50o F) of ambient temperature.

f) Repeat Steps a and b until full braking performance (per applicable

government regulations) is achieved.

62
 63

RDT Rear Brake Schematic

63

1 STEERING PUMP
2 BRAKE ACCUMULATORS
3 BRAKE MANIFOLD VALVE
4 TREADLE VALVE
5 FRONT BRAKE CALIPERS
6 SHUTTLE VALVE
7 REAR BRAKE PACKS
8 MONO-BLOCK VALVE
9 DIRECTIONAL CONTROL VALVE
10 RETARDER APPLY VALVE
11 RETARDER SELECT SOLENOID
12 RETARDER VALVE (TRANS)
13 STOP LAMP PRESS. SW.
14 REAR BRAKE ACCUMULATOR
PRESS. SW.
15 FRONT BRAKE ACCUMULATOR
PRESS. SW.
16 PARK BRAKE PRESS. SW.
17 LOCK UP DROP OUT PRESS.
SWITCH
18 RETARDER PRESS. SW.
19 50% FRONT BRAK VALVE

63
 64
TR100 Brake System Schematic –
Engine Shutdown
64

TR100 2 - 50% REDUCTION VALVE

3 - QUICK DUMP VALVE

1 - SPOTTING PARK VALVE

4 - DIRECTIONAL CONTROL VALVE

64
 65

RDT Brake Pressure Chart

65
TR45 TR60 TR70 TR100
SYSTEM PRESSURE bar 159 159 159 159
psi 2300 2300 2300 2300
FRONT SERVICE PRESSURE bar 159 159 110 159
psi 2300 2300 1600 2300
REAR SERVICE PRESSURE bar 52 52 52 52
psi 750 750 750 750
PARK BRAKE HOLD bar 82 82 82 82
OFF PRESSURE psi 1200 1200 1200 1200
REAR BRAKE RETARDER bar 33 33 33 33
PRESSURE psi 480 480 480 480
REAR BRAKE RESIDUAL bar 3 3 3 3
PRESSURE psi 44 44 44 44
FRONT BRAKE REDUCTION bar - - 55 (opt) 79
psi - - 800 (opt) 1150
ACCUMULATOR NITROGEN bar 55 55 55 55
o
PRECHARGE @ 21 C psi 800 800 800 800
65
 66

Brake System Pressure Check Points

66

66
 67

Steering/Brake Actuation Tank

67

CHECK WITH ENGINE RUNNING

AND ACCUMULATOR
CHARGED. OIL SHOULD BE
VISIBLE IN THIS SIGHT GAUGE.
IF NOT, SHUT OFF ENGINE.
RETURN ACCUMULATOR OIL
TO TANK BY STEERING THE
VEHICLE AND CHECK OIL ON
UPPER SIGHT GAUGES.

67
 68

Brake System Components

68
PUMP MOUNTED OFF TRANSMISSION PTO (RHS OF TRUCK) SCHEMATIC IDENTIFICATION (X)

MAIN PISTON (STEERING) PUMP (1)

Park/Emergency Solenoid

VALVE MOUNTED OFF LHS FRAME RAIL

BRAKE MANIFOLD VALVE (3)

68
 69

Brake Manifold Valve Warning Switches

69

15

14 ACC2 Pressure Switch PS2 16

82 bar (1190 psi) Falling
15 ACC1 Pressure Switch PS1
125 bar (1812 psi) Falling
16 Park Brake Pressure Switch PS3
64 bar (930 psi) Falling
14

69
 70

Brake Accumulators
70

ACC1 ACC2

Service Kits;
For all current production trucks;
Item 2 - 15502740
Part numbers correct at time of training conception.

For latest ‘live’ part numbers and parts

updates please refer to Terex Technical
Online Assistance
http://constructionsupport.terex.com
70
 71

Directional Control Valve & Shuttle Valve

71

6. Shuttle Valve
9. Directional Control Valve

Mounted On Underside Of Cab

B B

Porting A A
a Transmission Pilot Pressure
b Plugged a a

A Plugged
B To ‘Px’ Port On Treadle
P Supply Line From Brake Manifold T P T P
T Tank Return
Energised De-Energised
71
 72

Brake (Treadle) Valve & Mono-Block Valve

72
13 Stop Light Pressure Switch
17 Lock Up Drop Out Switch - 20bar
17

13 Park Brake Release

82 bar (1200 psi)

BRAKE TREADLE VALVE (4)

Rear Brake Residual

3.0 bar (44 psi)

72 MONO-BLOCK VALVE (8)

 73

Brake (Treadle) Valve

73
Service Kits;
For all current production trucks;
Item 3 – 15268373
Seal Service Kit
Item 4 – 15268372
Spring Service Kit
Item 6 – 15268375
Spool/Sleeve Service Kit
Part numbers correct at
time of training conception.

For latest ‘live’ part numbers and parts updates please refer to Terex
Technical Online Assistance http://constructionsupport.terex.com
73
 74

Mono-Block Valve - Schematic

74
(2) 3.0 bar (44 psi)

3/4
5

3 1

2
(1) 82 bar (1200 psi)

1 – Park Brake Hold Off Pressure Valve

2 – Service Brake Residual Pressure Valve
3 – Internal Filter Screen
4 – Orifice 5
5 – Shuttle Valve 74
 75

Rear Brake Pack Pressure

75

A = Park Brake
82 bar (1200 psi)

B = Rear Service Brake

52 bar (750 psi)
B = Brake Retarder
A 33 bar (480 psi)
B = Rear Brake Residual
3.0 bar (44 psi)

75
 76

Retarder Request
76
Retarder select switch controls the retarder select solenoid - directing
actuation pressure between rear brake and transmission retardation.
Press top to select rear brake retarder, press bottom to select
transmission retarder.

Retarder Select
Solenoid (11)

Retarder Select

Retarder ‘HI’ Relay

Retarder ‘HI’ relay signals the

transmission ECU when the
transmission retarder is
applied. The transmission will Retarder Pressure Switch
enter the preselected
downshift mode on this signal.
Retarder pressure switch activates the retarder lamp
on the dashboard and the rear of the vehicle.

INSIDE
76 CENTRE CONSOLE
 77

Retarder Control Valve

77

T Return To Tank
R To Retarder
P From Brake Manifold Valve
77
 78

Retarder Selection Solenoid Valve

78

12

SERVICE BRAKES
P

TO REAR
B

11
A
10

P From Retarder Control (Hidden) B To Transmission Retarder

A To Rear Brake Retardation T Return to Tank
78
 79

Transmission Retarder Selection

79

Retarder Actuation Pressure

79
 80

Retarder ‘HI’ Temperature Switch

80
Retarder ‘HI’ temperature switch signals the
transmission ECU when the brake cooling
oil reaches 100°C during brake retarder
operation. The transmission will enter the
preselected downshift mode on this signal.

100°C (212°F)
Retarder ‘HI’
Signal

121°C (250°F)
A

Temperature switch (13) activates dash warning lamp when

121°C oil temperature is sensed.
80
 81

TR100 Spotting Brake Valve

81
1

1. Spotting Brake Valve

The spotting brake valve is controlled by a
solenoid coil activated from the switch on the
centre console.
When the switch is activated the park
brake/emergency brake circuit is
activated along with the spotting brake
solenoid valve.
The spotting brake valve shuts off the front
service brake line so only the park brake and
rear service brakes are activated.
This function should be used during spotting
to prevent front brake wear caused by
vehicle rocking motion.

81
 82

TR100 50% Front Brake Reduction

82
2 2. 50% Front Brake Reduction
The 50% front brake reduction
valve is controlled by a solenoid
coil activated from the switch on
the dash.
When the solenoid is energised
front brake service application
pressure is reduced by 50%.
This results in increased operator
control in wet conditions by
reducing the chance of the front
wheels locking up.

To Front Brake OFF To Front Brake ON

Calipers Calipers

To
From Brake Tank From Brake To
Treadle Valve Treadle Valve Tank

82
 83

TR100 Quick Dump Valve

83

3 3. Quick Dump Valve

The quick dump valve is controlled by a
solenoid coil connected to a timer relay.
The solenoid is energised for 6 seconds
when the ignition switch is switched OFF.
This allows the rear service brake oil to
return to tank directly, allowing the park
brake to apply immediately.

83
 84

TR100 Directional Control Valve

84

4 4. Directional Control Solenoid Valve

The TR100 directional control valve is
controlled by a solenoid coil in addition
to the transmission pilot pressure.
The solenoid is energised when the
ignition switch is ON.
This allows an emergency brake
application after engine power loss, if
the key switch is not switched off.
The solenoid is connected to a timer
relay and will remain live for 6 seconds,
after key OFF, allowing the operator to
make a safe emergency brake apply.

84
 85

TR100 Timer Relays

85

Timer Relay - Timer Relay -

Quick Dump Valve Directional Control Valve

Retarder ‘HI’ Relay

SET TO 6 SECONDS

85
 86
TR100 Brake System Schematic –
Engine Shutdown
86

TR100 2 - 50% REDUCTION VALVE

3 - QUICK DUMP VALVE

1 - SPOTTING PARK VALVE

4 - DIRECTIONAL CONTROL VALVE

86
 87
TR100 Brake System Schematic –
Park/Emergency Apply
87

TR100

87
 88
TR100 Brake System Schematic –
Park/Emergency Brake Released
88

TR100

88
 89

TR100 Brake System Schematic –

Service Brake Apply
89

TR100

89
 90

Product Training
Rigid Dump Truck (RDT)
TR100

Body Control System

Inc. Rear Brake Cooling
(OCDB)

020710

Terex Centre of Excellence

Terex Equipment Limited
Newhouse Industrial Estate
Motherwell, ML1 5RY
United Kingdom
Technical Online Assistance: http://constructionsupport.terex.com
 Body Control System Schematic
91

TR100

1 HYDRAULIC TANK
2 BODY GEAR PUMP
3 BODY CONTROL VALVE
4 H.P.C.O. MANIFOLD
5 BODY TIP CYLINDERS
6 KICK OVER RELIEF VALVE
7 O.C.D.B. FILTER
8 O.C.D.B. COOLER
9 BODY CONTROL LEVER
10 RELIEF VALVE
11 SECONDARY RELIEF VALVE
12 HYDRAULIC TANK BREATHER
13 O.C.D.B. TEMPERATURE SW.
14 SERVO PILOT PRESSURE VALVE
15 BRAKE COOLING GEAR PUMP
Body System Pressure Chart
92

TR45 TR60 TR70 TR100

SYSTEM RELIEF PRESSURE bar 190 190 190 190
psi 2750 2750 2750 2750
SECONDARY RELIEF bar 207 207 190 190
psi 3000 3000 2750 2750
KICK OVER PRESSURE – bar 172 172 90 90
RELIEF MANIFOLD (TR70/100) psi 2500 2500 1300 1300
SERVO SYSTEM PRESSURE bar 30-35 30-35 30-35 30-35
psi 435-508 435-508 435-508 435-508
SERVO SYSTEM RELIEF bar 40 40 40 40
psi 580 580 580 580
PUMP CAPACITY @ REV/MIN L/MIN 227 227 365 366
REV/MIN 2100 2100 2100 2100
Body System Pressure Check Points
93

Main body pressure checked

holding body over relief.
Target pressure = 190 bar (2750psi)
Main Hydraulic Control & Cooling Tank
94

Engine off and body down on the

chassis, it is recommended that
the oil level is mid-way between
Max & Min lines.
Oil level will naturally increase
as oil warms (oil expansion).
Oil level will decrease as oil
cools and / or body cylinders are
charged.
 Hydraulic Tank Assembly – TR100
95

NSS

NSS

RELIEF
FILTER VALVE (10)
ELEMENTS

SUCTION SCREENS

FILTER BY-PASS 1.7 BAR (25 psi) OCDB RELIEF VALVE (10) 3.1 BAR (45 psi)
 Hydraulic Tank Assembly - Maintenance
96
Recommended Service Intervals
Daily / 10 hrs
Check Oil Level – Add if low

1000 hrs
Remove and Replace Filter Element – Clean Filter Housing

2000 hrs
Drain and Re-Fill Oil
Remove and Clean Suction Screen

Oil Type
-18°C to +32°C 10 W Oil
+32°C and above 30 W Oil

10 W Recommended Oils
KUWAIT TO4 TEXACO TEXTRAN TOTAL TRANSMISSION AC
SHELL DONAX TC MOBILTRANS HD BP AUTRAN 4
ESSO TORQUE FLUID CASTROL TFC
TR100 Pump Arrangement
97

Main Body Pump (2)

OCDB Pump (15)

 Body Control Servo Pilot Lines
Pressure From Pump 98

Servo Pilot Pressure to Pilot Control Valve

PILOT
Servo Pilot Pressure to Raise SUPPLY
VALVE (14)
Servo Pilot Pressure to Lower
Tank Return
TANK RETURN

(LOWER) (RAISE)

BODY CONTROL VALVE (3)

BODY FROM
CONTROL PISTON PUMP BRAKE
LEVER (9) MANIFOLD
VALVE

APPLIES TO ALL RDT SYSTEMS

 Servo Pilot Pressure Control Valve
99

30-35 bar
(435-508 psi)

(PV) To Body
Control Lever

(P2) From Piston Pump

(T) Tank Returns
(P1) Plugged
Body Control Lever
100

P - Pressure from Pilot

Supply Valve
T - Tank Return T
1 - Lower Circuit
2 - Raise Circuit P

2
RAISE

HOLD

FLOAT

LOWER (Power Down)

Body Servo Control Pilot Pressures
101

RAISE
15.9 – 17.8 bar 0 bar
(230 to 258 psi)

HOLD

0 bar 0 bar

FLOAT

0 bar 13 bar
(188 psi)

LOWER (Power Down)

22.6 – 25.6 bar
0 bar
(328 to 371 psi)
 Body Hoist Cylinders
102
Service Kits;
TR45(T881) 15275094
TR60(T882) 15273769
TR70(T913) 15265278
TR100(T783/883) 15265278
Part numbers correct at
time of training conception.

For latest ‘live’ part numbers and parts

updates please refer to Terex Technical
Online Assistance
http://constructionsupport.terex.com
 Body Shimming
103
When it becomes necessary, body pads should be replaced 2/3
as a set to maintain load distribution along the chassis. 2
Existing body pads will have taken a compression 'set' and a
new pad shimmed to match existing pads will not carry its
share of the load, resulting in uneven load distribution along
the chassis. The body guides should also be inspected and Pin
rebuilt with shims as necessary at this time.

1. Raise body assembly clear of the frame and position

body pads roughly in position on the frame rails. Lower
body assembly onto body pads. 5
Shim
2. Shim the two rear body pads with shims until body hinge
pins are just touching at the top of body assembly bores.
3. Shim remaining body pads with shims to ensure body
assembly is resting parallel on the frame.
4. Secure body pads and shims to body assembly with
bolts, washers, hardened washers and locknuts.
5. Centralise body assembly on the frame rails, remove
body hinge pins and reinstall with shims to obtain a
maximum gap of 1.5 mm (0.060”) between inner leg and 6
body pivot. Secure body hinge pins with bolts and
hardened washers.
6. Ensure body assembly is centralised on the frame rails
and measure gap between body guides on the frame and Shim
the body guides. Secure shims to body guides on body
assembly using bolts, washers and nuts. Leave a gap of
3.3 mm (0.12”) between body and frame guides.
 TR100 Body Control Valve
104

Secondary
Relief Valve (11)

Installation from S/N;

TR100 T7831349
TR100 T8831019
Similar Install for TR70 T9131013

No Secondary Relief
Valve Installed

HPCO Manifold (4)

Installation up to S/N;
TR100 T7831348
TR100 T8831018

Primary Relief
Valve
 TR100 Body Control Valve
105
A - BODY LOWER CIRCUIT
B - BODY RAISE CIRCUIT
C - INLET PUMP SUPPLY
D - TANK RETURN H
C F A J
E - TO OCDB (HPCO) G
F - SECONDARY RELIEF VALVE
B D
G - CHECK VALVE ASSEMBLY
H - SYSTEM RELIEF VALVE
J - PLUGGED E

Installation up to S/N;
TR70 T9131012
TR100 T7831348
DIAGRAM BASED ON
TR100 T8831018 TR70 INSTALLATION
 TR100 Body System Relief Valve
Installation up to S/N; 106
DETAIL VIEW- SYSTEM RELIEF VALVE
TR70 T9131012
TR100 T7831348
TR100 T8831018
Shims

Spring Loaded
Relief Valve.

1. Screw 2nd relief valve (11) in completely to remove relieving pressure.

2. Install appropriate pressure gauge on the body system pressure check point.
3. Check system pressure with engine at 1000 RPM, raising body over relief. Record pressure.
4. Set 2nd relief valve (11) at 1000 RPM. Screw 2nd relief valve out until pressure start to drop. Screw 2nd relief valve
back in slightly until pressure measured equals that recorded in step 3.
5. Finally check body relief pressure with body over relief and maximum RPM. Should be 190 b (2750 psi).
6. Should the pressure be too high, a shim should be removed from system relief valve (h) as shown in detail .
NOTE: Retain any shim(s) removed for future use if required.
 TR100 Body System Relief Valve
107

1. Install appropriate pressure gauge

on the body system pressure
check point.

2. Check system pressure with truck

at max RPM, raising body over
relief. Record pressure. Should be
190 b (2750 psi)

3. Make any pressure adjustments at

the relief cartridge .

Body Relief
Adjustment
Installation from S/N;
TR70 T9131013
TR100 T7831349
TR100 T8831019
TR100 Body Relief Manifold
108

Diagnostic
Check Point

RAISE CIRCUIT

LOWER CIRCUIT

TANK RETURN

Valve
Adjustment
 TR100 Body Relief Manifold
109

1. Install appropriate pressure gauge on diagnostic

connector.

2. Start the engine and check manifold relief valve

relief pressure is 90 bar (1300 psi), at maximum
rev/min and as body cylinders extend through
second stage.

3. If manifold relief valve relief pressure is not as

above, it can be adjusted.

4. Note: Relief valve cartridge is preset and sealed. (RAISE)

a. Break seal around relief cartridge and
(LOWER)
unscrew the cap.
b. Slacken the lock nut on relief valve cartridge
and adjust screw in, or out, until the correct
pressure reading is showing on the pressure Relief valve setting 90 bar (1300 psi)
gauge. Tighten the lock nut and re-check the Relief setting maintained in 2nd stage of tip
pressure setting. Install the cap on relief cylinders
valve cartridge.
OCDB Circuit
110

TR100 REAR
BRAKES

COOLER

PUMP

FILTERS H.P.C.O.

HYDRAULIC REAR
TANK BRAKES
OCDB Tank Return Temperature Switch
111

100°C (212°F)
Retarder ‘Hi’
Signal

121°C (250°F)
A

Temperature switch (13) activates dash warning lamp when

121°C oil temperature is sensed.
OCDB Filters
112

Check indicators daily / 10 hrs

Replace elements if necessary
Or replace elements 1000 hrs

Located LHS engine bay

OCDB Coolers
113
Body Schematic Raise Position
114

TR100
Body Schematic Hold Position
115

TR100
Body Schematic Lower Position
116

TR100
Body Schematic Float Position
117

TR100
 118

Terex Equipment Limited

Motherwell, ML1 5RY
Scotland
+44 (0)1698 732121
+44 (0)1698 734046

Web
www.terex.com

Technical Online Assistance

http://constructionsupport.terex.com