TFC 45 Training

History of the reach stacker
1978:
The CNC company is a part of the SNCF (FRENCH NATIONAL Few time later, PPM develop the 20 CMI of capacity 15 tons and
RAILWAY COMPANY). They did a tender for equipment able to allowing to concurrence everything of industrial handlings.
handling and storing containers of 10 ' with a load capacity of 9 t In this period the market was limited with two manufacturers:
BELOTTI, PPM.
PPM confide the studies to the special division dept. Birth of the Front of BELOTTI, PPM took the main part of this market with
10GMI (Grue mobile industrielle) the production of about forty machines.
the first REACH STACKER machine used a telescopic boom of 2 This contract demonstrate the technical and economic
elements and it equipped with a Top/pick spreader able of advantages of the concept Reach Stacker in front of typical
answering the CNC company specifications. wagons forklift dating of the 50s.
Terex® Reach Stacker : History of the SUPER STACKER 2

1982: This machine used the components similar at the automotive
The market of the sea transport by container increase quickly. cranes of this period : DEUTZ engine with air cooling and ZF
-PPM makes a market study and decides to develop a heavy lift gear box.
trucks able to raise containers up to 40 tons with a telescopic This new look recognized as modern and innovative PPM
Top/pick spreader able to reach 20 or 40 foot containers. distance clearly the only European competitor BELOTTI.
- birth of Stacker 40 GMI, which is going to conquer the - the leading product for the heavy containers was going to make
European ,African and Asian ports. its road...

1987: Sérial 17000
PPM decide to penetrate into the USA market and the machine SPECIFICATIONS
is completely revised to offer a concept full USA technology with
the assembly of an engine Cummins LT10-250 of 250CV, one
Clark 32410 gear box and an axle Rockwell PRC5324.
one machine is painted in the colors of the American’s flag. A
campaign of demonstration in the new continent was realized.
It is also the first advertising campaign engaged by PPM for a
global distribution of this product.
The design is also totally revised to integrate round and squat
forms to prove our spirit of simplicity and robustness.
The product is renamed STACKER and this logo is going to be
quickly used to place PPM in front of the other products.

1995 : purchase of PPM by TEREX Below, a stacker serial 17000
reach a container to 8 heights
Development of a complete stacker’s range:
- for pile the empty containers in big height: serial

17700 to 17788
The machine was built with short chassis, 2 elements
telescopic, a top / pick spreader 7.5 tons capacity
This machine was able to reach 8’6’’ container at 8
height.
- for pile of the full containers in height: series 170000 -
170599
The machine was built with short chassis, with a boom
5 heights 9 ' 6 " containers and spreader top / pick of 45
tons capacity. 170600 Serial and next
- the railway market
The machine was built with long chassis with telescopic
boom and Piggy back spreader for customer CNC
- the siderurgie market:
for tubes or squall metallic long with electromagnets or
mechanical or hydraulic crowbars.

1996 evolution of the serial 170500
The TFC 45 is equipped of the engine Cummins

M11 as a replacement of LT10-250 cause the
new emission low in USA
PPM replace gear box Clark 32410 by one
36432.
To permit the absorption of 290 Hp of M11, the
company change the Rockwell axle PRC 5324 by
one PRC 5334.
Main evolutions
- engine CUM M11-290CV

–CLARK Gear box 36432
- throttle system by cable changed to a hydraulic
system.
- filter type" Cyclon "
- hydraulic reservoir 30l for brake cooling
- oil hydraulics cooler
- chassis
- Assembly of oil filters for accessibility
- auxiliary pumps 40+12cm3
- engine radiator thickness 112mm instead of 92mm

Few dates:
April, 97: steering cylinder generation 2 January, 2000. Creation of tires options :
1800X25 GY EV4S
May, 97:creation of the Caterpillar motorization (option) 1800X25 GY EV5S
1800X25 BRID VSMS
January, 98: steering cylinder generation 3. Creation of
the option wheels 1800x33 March, 2000: addition of 2 protection valve 5b and
10b on cooling circuits (hydraulic and brake)
May, 98: strengthened Axle PPM
May, 2000:Création new legs of approach containers
November / December, 98: improvement of the strengthened, shorter and possibility of regulation
counterweight fixations 1750 kg. Evolution of the gear container width 2.50m.
selector APC 100 + steering column
September, 2002 / December, 2005:
January 99: the cabin is assembling back of 250mm. -creation Motorization QSM11 (TIER 2) 320HP.
The counterweight design in “L form” 16,8 Tons - Replacement of the engine radiator SIRC by
radiator NISSENS 3 circuit (Cooling-hydraulic oil- Air)
February 99: intensification of the spreader chassis - hydraulics full PARKER with hydraulic or electric
extremities. piloting which replaces:
- the Pump Linde
August 99: Modification of the line escape - the Distributor Marrel
- valve Rexroth.
October 99: replacement of the axle PRC 5334 by the
MERITOR ( Rockwell ) type PRC 7534

2005/2006: Increasing our speeds movements of 30 % 2011:
Introduction of the engine QSM11 tiers 3 + - Production of a new model TFC45MR to offer 35t it 2
Transmission TE27418 which replaces the QSM11 tiers row.
2 and the gear box HR36432. - Production of a new Boom 6 heights Dry version - -
Introduction of the new motorization Tier 4 by Scania
2007/2008: Development and production of the first with transmission TE27418 full Flow.
machine able of storing 6 containers High (45Tons) This
machine can exploit the 3rd row with a container full of
23 in 25 tons.
2009-2010: Creation and commercial provision of the

model TFC46 MSX - 6 heights 9 ' 6 " and completing
the offer already in the catalog with the model
TFC46MX .Introduction of the new safety standard
machines EN15000 and applicable on all type of forklift
truck

Summary
Of control system Stacker
Terex® SUPER STACKER : CONTROL SYSTEM TFC45 H/HC/ EN15000

TFC 45 H/HC version
Machines Serial 175000+20000 : Application end of 2005 to October 2009
The TFC 45 H (Hydraulic joystick) don’t have any display and control device .
In option, It can be equipped of the 3B6 LMI (type TOP SHIPPER)
The safety is realize by the anti tipping sensor on the rear axle
Shut down mov
the TFC 45 HC (High comfort: electric joystick) is equipped of the IQAN PARKER (central unit MDM/ extension module XP/
electric joystick LL).
the safety is realize by the anti tipping sensor. The operator can check some values with the MDM display (boom length,
angle , actual load ,ETC…) .
Terex® SUPER STACKER : CONTROL SYSTEM TFC45 H/HC/ EN15000 2

Simplified schematic of IQAN system
Module I/O
capteurs
Central Unit
-Boom lenght
CAN ICP* -Angle
-Pressure
CAN J1939 CAN ICP* sensor
engine Gear box

-Anti tipping
sensor
Electric
Joystick
* ICP : IQAN CAN PROTOCOL

H/HC Version
Machines Serial 176000: application 2009
Serial 177000+20500: application 2010 “NEW GENERATION”
Now the TFC 45 H is equip in serial production of the MD3 display. The possibilities for driver to have
engine and gear box information. The LMI option is available just in add pressure sensor and length sensor
Control Unit Simplified drawing Sensors
-Boom Length
(Option LMI) -Angle
-Pressure sensor
CAN J1939

H VERSION
Hydraulic Joystick
Hydraulic pilot
-Axle switch
The shut down movement is still realize by the anti tipping sensor

H VERSION
serial 175000 serial 177000

HC VERSION
The TFC 45 HC is equipped LMI MD3 in serial, the display give to the operator information about
joystick position, pump flow, cylinder pressure, boom length ETC…) .
Shut down movement is realize by the anti tipping movement
Simplified schematic
Control Unit I/O Unit XA2 Sensors
-Boom length
CAN ICP* -Angle
-Pressure sensor
CAN J1939
CAN ICP*
Engine Gear Box
Electric Joystick
-Anti tipping
sensor

VERSION HC
serial 177000
serial 175000

TFC 45 HC EN 15000
Serial 176000+177000+20500: application November 2010
the last generation of the TFC 45 HC EN 15000 is equipped of the IQAN technology . One more module is
necessary to manage the device.
Simplified schematic
-Length sensor x2
-Angle x2
CAN ICP*
-Pressure
sensor
CAN J1939 -Anti tipping

sensor

CAN BUS SYSTEME

VERSION HC EN 15000
The shut down movement is realize by the MC3 module .Load chart is integrated in the program.
The anti tipping sensor is still used to cut the movement
SIMPLIFIED SCHEMATIC
+ 24V DIN - A DIN - B 0V
Boom Active
E287
R1
DOUT -
A
R1 Boom Active
DRET - E289
A
DOUT - 0V
B
R2
DRET - Telescope Active
B E292
R2

EVOLUTION 2010 – SERIAL 177000
Terex® Reach Stackers : EVOLUTIONS 2010

New optimising boom quality process-
TIG welding refusion
New 100% S355 material
-Steel optimising
-New design
-Reforced quality New spreader reforced
process design and best wheigt
-New comproved
technology
New steering std axle 50t capacity
Actual steering axle Finite

element
42t capacity analysis
New alternative front motored axle wet disc by Actual Kessler D102 New look with 3700 l capacity
OMCI axle
Terex® Reach Stackers : EVOLUTIONS 2010 2

Evolutions, comfort, accessibility
New commun cab for TFC46M&TFC45 New suspended bracket cab

Seat operator in axle truck noise performance – under 70dbA
New system airco
New MD3 display
Visibility EEC EN 13564-2
New pedals more confort
APC 200 control in front panel
No risk sun reflection with flat windscreen
Roof sun shade
New engine cover with best insulation

noise & engine accessibility
Inside cab: 66 dbA instead actual 70 dbA
New front
pannel
MD3 display
In all TFC45+46M
models
New pedals

Airco installation
Evaporator &
ventilator new design Condensor in left side
machine with hyd oil cooler
Global best performances with:

Best air diffusion to windscreen
Best cab flow air

Security function
Control Unit
(hc and h Version) I/O Unit
(hc version only)
CAN BUS
MD3
security
functions
Security Switch in HC
(Input)
version
Valves (Output)

Difference MD3 in the 2 versions models
MD3 Display
more visual confort
Preparation for EN 15000 safety norm-sept 2010
HC Version h Version
Or
Engine & gearbox
H Version Diagnostic
with Terex integrated LMI
(add 2 pressure sensors+1cable reel)

New oil filters for best pollution protection
New filter in piloted line pressure

–indice F4
NEW FILTER IN STEERING

LINE PRESSURE –indice F2
Actual filter with double capacity

40CN to 80CN–indice F1
New filter in general return tank

line –indice F3
New filter in line pressure to hyd joystick-indice F5

New filter added on tank return flow
New renforced oil cooling filtration

Indice F3 in CR108081 hydraulic diagram
IN500
L12

New steering filter
New renforced 28P1 filter in steering pressure line

New filter 80CN1 replace actual 40CN1
More capacity &long life filter in principal filtration

Original 175000 serial machines
line
Filter type 80CN1
instead actual 40CN1
New filter 177000 serial machines

New filters in the secondary lines pressure
New two oil filters in pressure piloted line

Filter 3/8G 80 microns in
Filter 3/8G 80microns in LS90
hyd bloc control
Steering pressure

TRANSMISSION DANA :
« VFS Booster Valve »
Terex® Reach Stackers : Transmission VFS Booster Valve

TRANSMISSION DANA 15.7-TE 27000
Model designation WEIGHT : 865kg

LENGHT : 94O mm
WIDTH : 665 mm
HEIGHT : 970 mm
OIL CAPACITY: 60 L
CIRCUIT CAPACITY: 10L
Terex® Reach Stackers : Transmission VFS Booster Valve 2

TECHNICAL SPÉCIFICATIONS
Converter / transmission Oil System
Capacity (Approximate: mesured at 600 RPM input speed and oil Temp
between 60 and 70 C)
→Short drop 60L
→Long drop 75L (Line and cooler not included)
Type d’huile→ ONLY ATF Dexron III approved

viscosity at 40 C: 33 →38 Cst (stokes)
viscosity at 100 C: 7 →8 Cst
flash point: min 160 C
pour point: max – 42 C
Oil change→ 1000 heures

Filtration → 2 x Spin On
500 hours life
1st change: 50 et 250 hrs or after rebuild

TEMPERATURE AND PRESSURE SPECIFICATIONS
Normal operating temperature 70 -120 C

maximum allowed transmission temperature: 120 c
Transmission regulator pressure

600 RPM 17 bars minimum
2200 RPM 25,5 bars maximum
Pilote solenoid pressure between 8,5-11,5 bar

by-pass filter adjust to 4,1 and 4,5 bar
Lube pressure between 1,8 - 2,6 bar at 73l/min ( converter flow)
clutch pump Flow: 100,5 l/mn at 2000 RPM

Lube pump Flow: 85,1 l/mn at 2000 RPM

ELECTRIC SPÉCIFICATION
VFS: Valve Force Solénoïde
-VFS 2nd /4th

-VFS 1st /3rd
-VFS FW
-VFS REV
Coil résistance: 4,35 0,35Ώ at. 25 C
ON/OFF solénoïde
- Total neutral
-1st /3rd
-2nd/4th
Coil résistance : 28 2Ώ at. 2O C

SPEED SENSORS
Type Magneto resistive sensor.

Sensing distance 0 - 1.8 mm
Sensor signal generates a square current
with a fixed amplitude changing between 7
and 14 mA.
Drum speed sensor

Combined engine speed sensor and temperature
Turbine and output (x2) speed sensor

Command Valve
VFS 2nd/4th 1
VFS FW 2
VFS 1st/3rd 3
VFS REV 4
Total neutral
selector
2nd/4th selector
1st/3rd selector
Pressure switch
VFS = Variable Force Solenoïde

Command Valve
VFS 2/4
VFS FWD
VFS 1st/3rd
VFS REV
Total neutral selector
2nd/4th selector
Pressure switch
1st/3rd selector

Check ports control valve
Checkport 4/4 SPEED (TE32)
31a Regulator pressure (before
total neutral)
55
G65 51 VFS reverse
A
F
50/52 VFS 3rd /1st
F64
54
B
59
54 VFS FWD
N
60/62
50/52H
55 VFS 2ND/4TH
C
56
K 56 System pressure (after Total
D
51
61
Neutral)
E
57 57 Pilot pressure
31a L
58 J
M 58 Range clutches
59 Direction clutches
61 Pressure intencifier rev
60/62 Pressure intencifier 1st/3rd
64 Pressure intencifier FWD
65 Pressure intencifier 2nd /4th

Checkports - right view
Reg. Pressure To cooler

Converter In Pressure Fwd clutch
From cooler
From filter 2

Hydraulic cooler line specifications
HYDRAULIC COOLER LINES SPECIFICATIONS.

Minimum 32 mm internal diameter for lines and fittings.
Suitable for operation from ambient to 120 C continuous
operating temperature.
Must withstand 30 bar continuous pressure and 45 bar
intermittent surges.
Conform SAE J1019 and SAE J517, 100RI.

Checkports - rear view
From filter 1 To cooler
Temp switch
Converter out
3rd clutch pressure

Checkports - left view
Pressure check port 1st clutch
Oil level check port

Checkports - front view
2nd clutch pressure
Rev clutch pressure
Lube pressure port

2ND clutch pressure

Engine speed & transmission temperature
New Sensors with fixed

clamps.
Drum speed
Part Numbers
sensor
Engine : 4209784
Output : 4209750
Turbine : 4209751
Drum : 4209752
Turbine speed sensor

Output speed sensor

THE TRANSMISSION ASSEMBLY

VFS Fwd VFS 2/4 VFS Rev VFS 1/3

THE TRANSMISSION CONTROLS (REFER TO HYDRAULIC DIAGRAM)
The transmission is controlled by an APC200 box. This unit has a microprocessor that receives certain inputs
(gear selector position, speed sensors,...), which are processed and will give output signals to the control valve.
Operation of the valve

Regulated pressure 22.5 - 25.5 bar [326 - 370 PSI] is directed to the total neutral shift spool and the pressure
reducer that will decrease the pressure to 10 bar [145 psi].
This reduced pressure will be used to supply the variable force solenoids (VFS), total neutral solenoid, 3rd/1st
solenoid and 4th/2nd solenoid.
When activated the VFS will give an output pressure curve from 0 to 6 bar [0-87PSI] proportional to a current
from 1000mA to 0 mA. The pressure intensifiers with a ratio of 3.5:1 will multiply this pressure curve so that
a curve from 0 to 20 bar [290 PSI] is available for each directional and range clutches. Between each VFS a
pressure intensifier is placed and an accumulator to dampen any hydraulic vibration.
Directional selection
When a direction (forward or reverse) is selected, the total neutral solenoid is activated and the required
directional VFS will provide a pressure rise from 0 to 6 bar. The directional clutch is then fed with modulated
pressure supplied through the pressure intensifier.
Range selection
When 1st clutch is selected, the 3rd/1st and 4th/2nd solenoids are activated. The 1st/3rd VFS will provide a
pressure curve from 0 to 6 bar. The pressure intensifier will multiply this pressure and will feed 1st clutch via the
activated 3rd/1st spool.
When 2nd clutch is selected, the 3rd/1st VFS will decrease pressure from 6 to0 bar, thus releasing the 1st clutch
in a controlled fashion.
At the same time the 4th/2nd VFS will provide a pressure curve from 0 to 6 bar. This
pressure is fed to the 2nd clutch via the pressure intensifier, which will provide clutch overlap.
When the shift is finalized the 3rd/1st solenoid is deactivated.
When 3rd clutch is selected the 3rd/1st solenoid is not activated. The 1st/3rd VFS will provide a pressure curve
from 0 to 6 bar and will feed the 3rd clutch via a pressure intensifier and the deactivated 3rd/1st spool. At the
same time the 4th/2nd VFS will decrease pressure from 6 to 0 bar providing clutch overlap.
When the shift is finalized the 4th/2nd solenoid is deactivated.
When 4th clutch is selected, the 4th/2nd VFS will provide a pressure curve from 0 to 6 bar and will feed 4th
clutch via a pressure intensifier and the deactivated 4th/2nd spool. At the same time the 3rd/1st VFS will decrease
pressure from 6 to 0 bar providing the clutch overlap.
Neutral selection
When neutral is selected (1st, 2nd, 3rd or 4th) the total neutral solenoid is activated and the VFS's for forward
and reverse are fed by a 1000mA current which will result in a 0 bar output. Thus providing 0 bar pressure to the
forward and reverse clutch. The range clutches 1st, 2nd, 3rd or 4th remain activated by their respective VFS.
Total neutral selection

Total neutral is only selected by the APC200 in case a severe error is detected which will cause a shutdown.
When total neutral is selected, the total neutral solenoid is not activated and as a result no pressure is supplied
to the pressure intensifiers.

Solenoids activated
speed solenoids on /off VFS clutch

engaged engaged engaged engaged
Forward 4 Total neutral Reverse, 1/3 Forward, 4th

Forward 3 Total neutral Reverse, 2/4 Forward, 3rd
Forward 2 Total neutral, 2/4 selector Reverse, 1/3 Forward, 2nd
Forward 1 Total neutral,1/3,selector Reverse, 2/4 Forward, 1st
Neutral 4 Total neutral Forward, Reverse, 1/3 4th

Neutral 3 Total neutral Forward, Reverse, 2/4 3rd
Neutral 2 Total neutral, 2/4 selector Forward, Reverse, 1/3 2nd
Neutral 1 Total neutral,1/3,selector Forward, Reverse, 2/4 1st
Reverse 4 Total neutral Forward, 1/3 Reverse, 4th

Reverse 3 Total neutral Forward, 2/4 Reverse, 3rd
Reverse 2 Total neutral, 2/4 selector Forward, 1/3 Reverse, 2nd
Reverse 1 Total neutral,1/3,selector Forward, 2/4 Reverse, 1st






APC200 CONTROLLER

Block diagram APC 200
Total Neutral
2/4 Sel
1/3 Sel
VFS Fwd
VFS 2nd/4th
VFS Rev
VFS 1st /3rd
Aux 1
Aux 2
Aux 3
Total Neutral
S

Reach stacker diagram

NORMAL MODE

NORMAL MODE

NORMAL MODE

TRANSMISSION DANA TE27418:
FULL FLOW
Terex® Reach Stackers : Transmission Full Flow

TE27/TE32 : VFS/Booster Full flow valve
1000 mA = 0 bar
0 mA = 0 bar
Terex® Reach Stackers : Transmission Full Flow 2

TE27/TE32 : VFS/Booster
Distributeur d’intensification 2nd/4thd

ou « Booster »
Accumulateur 2nd/4th VFS 2nd/4th
VFS Fwd
VFS 1st/3rd
VFS Rev
Total neutral
selector
2nd/4th selector
1st/3rd selector
Pressure switch
VFS = Variable Force Soleniod

TE27/TE32 : Full flow valve
Couple de serrage des bobines : 6.8 – 9.5 Nm
Fwd / N / Rev selector
Rev Fwd
Prop Fwd/Rev
Prop 2nd/4th
Prop 1st/3rd
1st/3rd selector
2nd/4th selector
Pressure Pressure
sensor 2nd/4th sensor 1st/3rd Prop = proportional pressure reducing valve

Proportionnel 1st/3rd Accumulateur 1st/3rd
Selecteur 1st/3rd

Check port pressure
regulator
Check port Fwd
REG
FWD
F/R
Check port Fwd/Rev REV
Check port Rev 2/4
Check port 2nd/4th

1/3
Check port 1st/3rd 3RD

Check port 3rd 1ST
1ST
Check port 1st 4TH
2ND
Check port 4th
Check port 2nd

TE27 / TE32 : Full flow – pressure error level
There are 2 pressure error levels for

the range clutches :
• when the range clutch is activated

the pressure must be above 19 bar
(if not correct : error : 2x.00)
• when the range clutch is NOT

activated the pressure must be
below 1 bar
(if not correct : error : 2x.01)
Note there is a different error code list for full flow

Full flow hydraulic schematic

TE27 / TE32 : VFS/Booster Full flow valve
APC210
APC211 APC216-R8
APC212
APC213
Different program – No exchange

TE27 / TE32 : VFS/Booster – schéma de cablage
APC210
APC211
APC212
APC213
Analog Out 0 : VFS Fwd Digital Out 0 : Total neutral + side Analog In 0 : Pressure
Analog Out 1 : VFS 2nd/4th Digital Out 1 : Selector 2nd/4th feedback switch
Analog Out 2 : VFS Rev Digital Out 2 : Selector 1st/3rd
Analog Out 3 : VFS 1st/3rd Digital Out 3 : Total neutral - side

TE27 / TE32 : Full flow – schéma de cablage
Production
APC216-R8
Analog Out 0 : Prop Fwd/Rev Digital Out 0 : Selector Fwd Analog In 0 : Pressure
Analog Out 1 : Prop 1st/3rd Digital Out 1 : Selector Rev sensor 1st/3rd
Analog Out 2 : Prop 2nd/4th Digital Out 2 : Selector 1st/3rd Analog In 6 : Pressure
Analog Out 3 : - Digital Out 3 : Selector 2nd/4th sensor 2nd/4th

TE27 / TE32 : VFS/Booster – wiring diagram
Combined sensor for engine speed and

sump temperature
APC210
APC211
APC212
APC213

TE27 / TE32 : Full flow – wiring diagram
Not a combined sensor for engine speed

and sump temperature
Engine speed signal ground and sump

temperature ground changed to A30
Turbine speed signal changed to A27
Switched power on B11
Two Permanent Powers (on A01 & B12)
APC216-R8

PRIORITY BLOCK + L90LS VALVE
Terex® Reach Stackers : priority valves + L90LS

FUNCTIONS
-Accumulator charge
-Accumulator Relief
-Main relief valve
-cold start solenoid
-parking brake
-priority valve
-steering reducer valve
Pressure reducer steering
Terex® Reach Stackers : priority valves + L90LS 2

LOCALIZATION

DESIGNATION

DESIGNATION

HYDRAULIC REPRESENTATION

VALVE DESCRIPTION

STEERING PRIORITY FUNCTIONS

BRAKING CHARGING FUNCTION

PILOTE FILTER

RELIEF VALVE 35 BARS AND RESTRICTION

STEERING PRIORITY SHUTTLE VALVE

LS SHUTTLE VALVE

LOCK COVER

VFS RESTRICTION E1 AND E284

RESTRICTION

CIRCUIT SELECTOR VALVES E1/E284
This shuttle valve can not be dismounted

VALVES DETAILS

LS RESTRICTION 0,7MM

RESTRICTION 2,5 MM

TEREX-PPM STACKERS
PARKER M402LS Mobile directional valve
Terex® Reach Stackers : PARKER M402LS

Mobile Directional Control Valve
The M402LS is a directional valve

intended for machines such as large
wheeled-loaders, fork-lift,trucks, etc.
It is designed for use in closed-centre (LS)
hydraulic systems with variable pumps,
The valve is equipped with double service
ports at 180 , which eliminates T-
connectors and gives the shortest and
simplest path to the cylinders.
It is cast in high quality material to enable it
to withstand high pressures without
deformation. The valve is of the spool type
to give safe and precise regulation of the
flow.
Terex® Reach Stackers : PARKER M402LS 2

TECHNICAL DATA
Filtration
Filtration must be arranged so that Target Contamination Class
20/18/14 according to ISO 4406 is not exceeded. For the pilot
circuit, Target Contamination Class 18/16/13 according to ISO
4406 must not be exceeded.
Hydraulic fluids
Best performance is obtained using mineral-base oil of high
quality and cleanness in the hydraulic system.
Hydraulic fluids of type HLP (DIN 51524), oil for automatic

gearboxes Type A and engine oil type API CD can be used.
Viscosity, working range 15-380 mm2/s****
Weight
Valve complete with spool actuator for
hydraulic servo and with float position option: 95 kg (210 lb).
Technical information is applicable at an oil viscosity of 30 Pressure

mm2/s (cst) and temperature of 50 C (122 F) using nitrile Pump connection max. 375 bar* (5440 psi)
rubber seals. Service port max. 400 bar* (5800 psi)
Tank connection, max. 20 bar (290 psi)
Pressure in drain line recommended 1 bar (14.5 psi)
Temperature
Oil temperature, working range +20 to +90 C*** (68 to 194 F)
Cold start

DESIGNATION

VIEW
TOP VIEW
BACK VIEW

VIEW
LEFT VIEW RIGHT VIEW

HYDRAULIC SCHEMATIC

HYDRAULIC PILOT
Both section 1 and section 2 have hydraulic, proportionally controlled, spring- centre
spool actuators

ELECTRO-HYDRAULICALLY PILOT
Both section 1 and section 2 have electro-hydraulically, proportionally controlled,

spring- centred spool actuators

PILOT CONNECTION
PILOT CONNECTION PSS/PS

PILOT CONNECTION PSL/PL

TEREX-PPM STACKERS
Manipulator valve
Terex® Reach Stacker: manipulator valve

MANIPULATOR VALVE CONNECTIONS
Terex® Reach Stacker: manipulator valve 2

JOYSTICK FUNCTION
1 / Multi-function joystick
This joystick operates the boom telescoping in/out and derricking
up/down functions.
1/A – Raise boom

1/B – Lower boom
1 /C – Telescope in
1 /D – Telescope out
Some of these functions can be used while handling a container.

Moving the joystick to a 45° angle enables combined movements, ex:
raising the boom/telescoping in.
side shifting
1/1 – Side shifting to the left.

Press this button to side shift the spreader to the left.
1/2 – Side shifting to the right.
Press this button to side shift the spreader
1/3 – Slewing to the left.

Press this button to slew the spreader to the left.
1/4 – Slewing to the right.
Press this button to slew the spreader to the right.
slewing
JOYSTICK : REAR VIEW
/ Audible warning (Hydraulic and Electric version)

Always sound the horn before starting the engine
Wait a few seconds to allow anyone inside the machine operating
zone to move out of the way.
/ Audible warning (Hydraulic version only)

or
/ High speed boom function control (Electric version)
This control operates the following boom functions at increased
speed:
Derricking up – Telescoping out – Telescoping in

JOYSTICK: DESCRIPTION
E311 E320 E321

E310
accumulator
pressure
reductor
pilot pressure
sensor 5b
filter
E323

JOYSTICK: SIMPLIFIED SCHEMATIC
3b at iddle
15 b at max Rpm

3b at idle
15 b at max
Rpm

COOLING SYSTEM
Terex® reach stacker: cooling system

Cooler hydraulic circuit
PUMP 28 +8 cm3
PUMP 40+12 cm3

MAIN HYDRAULIC TANK
BRAKE
RADIATOR OIL / BRAKE CIRCUIT
HYDRAULIC
RADIATOR WATER/AIR/OIL
Terex® reach stacker: cooling system 2

Cooler simplified schematic

Brake/hydraulic oil circuit

“Fast speed” cooling system

“slow speed” cooling system

Electric diagram
“Cooler speed” “warning light”
Brake oil
pressure
brake
Oil T

Gear box/coolant/air charge cooling circuit
Normal speed
VALVE OPEN

Gear box/coolant/air charge cooling circuit
Fast speed
VALVE CLOSE

BRAKES CIRCUIT
Terex® Reach Stacker : brake circuit

BRAKE HYDRAULIC CIRCUIT
Terex® Reach Stacker : brake circuit 2

BRAKE SIMPLIFIED SCHEMATIC

“STAND BY “POSITION

BRAKE ACTIVATION

PARKING BRAKE RELEASING

TEREX-PPM STACKERS
STEERING SYSTEM
Terex® Reach Stacker: steering system

Terex® Reach Stacker: steering system 2
STEERING SYSTEM CONNECTIONS
Steering valve
Orbitrol valve
Priority valve
Steering cylinder
L90LS

STEERING VALVE

STEERING VALVE

NEUTRAL POSITION

STEERING RIGHT POSITION

STEERING LEFT POSITION

SPREADER FUNCTIONS
Terex® reach stacker: spreader movements

SIDE SHIFT SPREADER
E16/E17: side shift left / right
Terex® reach stacker: spreader movements 2

SIDE SHIFT LEFT

SIDE SHIFT RIGHT

SPREADER ROTATION
CONNECTION

LEFT ROTATION

RIGHT ROTATION

TELESCOPE SPREADER
CONNECTION
Telescoping chains
Retracting chains

TELESCOPE OUT SPREADER « FAST SPEED »

TELESCOPE OUT SPREADER « LOW SPEED »

TELESCOPE IN SPREADER « FAST SPEED »

TELESCOPE IN SPREADER « LOW SPEED »

TWIST LOCK

TWIST LOCK CONNECTION

TWIST LOCK OPEN

TWIST LOCK CLOSE

SPREADER DAMPED

TEREX-PPM STACKERS
Telescoping system
Terex® Reach Stacker: Telescoping system

LOCALISATION
Terex® Reach Stacker: Telescoping system 2

BLOCK VALVE DESCRIPTION
regenerative
valve
E285
Check valves
holding valves

TFC 45 H BOOM SPECIFICATIONS
boom retracted: 11,14m

boom extended:17,585m
Teles extension time:
- Without load: 23s (0,31m/s)
-With load (30T): 23s
Teles retraction time:
-without load: 18s( 0,40m/s)
- With load: 17s( 0,41m/s)

TFC 45 H simplified schematic

TFC 45 H telescope retraction

TFC 45 H telescope extension

REGENERATION SYSTEM
Note: this device is only possible

with a Montan cylinder in H version
REGENERATION NOT
ACTIVED
FROM M400 LS TO TANK

REGENERATION SYSTEM
Note: this device is only

possible with TFC45 HC version
regeneration active
FROM M400 LS
TFC 45 H Electric condition “ TELES EXTENSION”

Electric condition TELES EXTENSION

ENGINE ON condition: ID
ID

SELECTION SPREADER condition: I3
I3

ANTI TYPPING SAFETY condition: I1
I1
option

TELES EXTENSION TFC 45H: Output 2 logic module

TELES EXTENSION TFC 45 HC: XA2 module PIN 17

TELES EXTENSION TFC 45 HC “EN 15000”:MC3 module C4 pin 5

TELES EXTENSION TFC 45 HC “EN 15000”

BOOM HOIST
Terex® Reach Stacker: Boom hoist up

Terex® Reach Stacker: Boom hoist up 2
BOOM HOIST DOWN
Pressure releasing
Boom hoist down

SIMPLIFIED SCHEMATIC “BOOM HOIST DOWN”

SIMPLIFIED SCHEMATIC “BOOM HOIST UP”

anti tipping safety condition: i1
option I1

engine on condition: id

selection spreader condition: i3
I3

Standard Hydraulic selection condition: i7
I7

Boom hoist down pressure sensor condition: i8
I8

BOOM DOWN TFC 45H: Output 4 and 5

BOOM DOWN TFC 45H: Output 2
I7

BOOM DOWN TFC 45 HC: PIN 20,35 and 36 XP module

BOOM HOIST DOWN TFC 45 HC “EN 15000”

BOOM HOIST DOWN TFC 45 HC “EN 15000”

BOOM HOIST DOWN PRESSURE REALINSING TFC 45 HC “EN 15000”

TFC 45 Training

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History of the reach stacker

Terex® Reach Stacker : History of the SUPER STACKER 2

Terex® Reach Stacker : History of the SUPER STACKER 3

Terex® Reach Stacker : History of the SUPER STACKER 4

- for pile the empty containers in big height: serial

Terex® Reach Stacker : History of the SUPER STACKER 5

The TFC 45 is equipped of the engine Cummins

- engine CUM M11-290CV

Terex® Reach Stacker : History of the SUPER STACKER 6

Terex® Reach Stacker : History of the SUPER STACKER 7

2009-2010: Creation and commercial provision of the

Terex® Reach Stacker : History of the SUPER STACKER 8

Terex® SUPER STACKER : CONTROL SYSTEM TFC45 H/HC/ EN15000

Machines Serial 175000+20000 : Application end of 2005 to October 2009

Terex® SUPER STACKER : CONTROL SYSTEM TFC45 H/HC/ EN15000 2

engine Gear box

* ICP : IQAN CAN PROTOCOL

Terex® SUPER STACKER : CONTROL SYSTEM TFC45 H/HC/ EN15000 3

Control Unit Simplified drawing Sensors

Terex® SUPER STACKER : CONTROL SYSTEM TFC45 H/HC/ EN15000 4

Terex® SUPER STACKER : CONTROL SYSTEM TFC45 H/HC/ EN15000 5

serial 175000 serial 177000

Terex® SUPER STACKER : CONTROL SYSTEM TFC45 H/HC/ EN15000 6

* ICP : IQAN CAN PROTOCOL

Terex® SUPER STACKER : CONTROL SYSTEM TFC45 H/HC/ EN15000 7

Terex® SUPER STACKER : CONTROL SYSTEM TFC45 H/HC/ EN15000 8

Serial 176000+177000+20500: application November 2010

CAN J1939 -Anti tipping

* ICP : IQAN CAN PROTOCOL

Terex® SUPER STACKER : CONTROL SYSTEM TFC45 H/HC/ EN15000 9

Terex® SUPER STACKER : CONTROL SYSTEM TFC45 H/HC/ EN15000 10

+ 24V DIN - A DIN - B 0V

Terex® SUPER STACKER : CONTROL SYSTEM TFC45 H/HC/ EN15000 11

Terex® Reach Stackers : EVOLUTIONS 2010

Actual steering axle Finite

Terex® Reach Stackers : EVOLUTIONS 2010 2

New commun cab for TFC46M&TFC45 New suspended bracket cab

New engine cover with best insulation

Terex® Reach Stackers : EVOLUTIONS 2010 3

Global best performances with:

Terex® Reach Stackers : EVOLUTIONS 2010 4

Terex® Reach Stackers : EVOLUTIONS 2010 5

Terex® Reach Stackers : EVOLUTIONS 2010 6

New filter in piloted line pressure

NEW FILTER IN STEERING

Actual filter with double capacity

New filter in general return tank

New filter in line pressure to hyd joystick-indice F5

Terex® Reach Stackers : EVOLUTIONS 2010 7

New renforced oil cooling filtration

Terex® Reach Stackers : EVOLUTIONS 2010 8

New renforced 28P1 filter in steering pressure line

Indice F2 in CR108081 hydraulic diagram

Terex® Reach Stackers : EVOLUTIONS 2010 9

More capacity &long life filter in principal filtration

New filter 177000 serial machines

Indice F1 in CR108081 hydraulic diagram

Terex® Reach Stackers : EVOLUTIONS 2010 10

New two oil filters in pressure piloted line

Indice F4 in CR108081 hydraulic diagram

Terex® Reach Stackers : EVOLUTIONS 2010 11

Terex® Reach Stackers : Transmission VFS Booster Valve

Model designation WEIGHT : 865kg

Terex® Reach Stackers : Transmission VFS Booster Valve 2