This is the COMPLETE Service Training Manual for the Linde Reach Stacker 357 Series: C4130/4 TL, C4130/5 TL. This manual provides detailed service information, step-by-step repair instruction and maintenance specifications. it has been prepared as an aid to improve the quality of repairs by giving the operator an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. YOU CAN DO THE REPAIRS YOURSELF AND SAVE MONEY $$$
Covered models:
C4130/4 TL
C4130/5 TL
Service Training Manual Contains:
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1 Diesel engine
1.1 Engine specifications – 357/356
1.2 Explanation of the engine number
1.3 Adjusting the tappet clearances
1.3.1 Checking the compression
1.3.2 Removing the rocker cover
1.4 Drivebelts
1.4.1 Checking and adjusting the alternator and fan drivebelts
1.4.2 Tensioning the drivebelts
1.5 Cylinder head
1.5.1 Removing the cylinder head
1.5.2 Installing the cylinder head
1.7 Checking engine timing
1.8 Injection nozzles
1.8.1 Injection nozzle fault
1.8.2 Removal and installation of the injection nozzle and clamping nut
1.8.3 Correcting the injection nozzles
1.8.4 Injection nozzle assembly
1.8.5 Inspecting the injection nozzles
1.8.6 Assembling the injection nozzle
1.8.7 Check the injection nozzle opening pressure
1.9 Removing and installing the fuel injection pump
1.10 Fuel feed pump
1.11 Engine shutdown solenoid
1.12 Cleaning the turbocharger oil feed
1.13 Perkins by-pass filter
1.14 Thermostat
1.15 Coolant pump
1.16 Fault diagnosis
1.17 Torque loadings
1.18 Special tools
2 Hydrodynamic travel drive
2.1 Schematic diagram of the power train
2.2 Full view of power shift transmission
2.2.1 36000 Series Power shift transmission, 4 speed
2.2.2 Torque converter
2.2.2.1 Purpose of the torque converter
2.2.2.2 Basic design of the torque converter
2.2.2.3 How a torque converter operates
2.2.3 The power shift transmission
2.2.3.1 Four Speed Transmission
2.2.3.2 Oil flow in the power shift transmission
2.2.3.3 Oil flow through the control valve
2.2.3.4 Transmission dump system
2.2.3.5 Upshift inhibitor
2.3 Troubleshooting
2.3.1 Pressure test and connections
2.3.2 Aids for measurements
2.3.3 CLARK 36000 series power shift transmission troubleshooting
2.3.4 Electronic Gear Selector
2.3.4.1 Description of the Electronic Gear Selector
2.3.4.2 EGS fault diagnosis
2.3.4.3 Inductive Sensor adjustment
2.4 D 101 Series Drive axle
2.4.1 Specifications for D 81 PL 478 – NLB
2.4.2 Axle drive settings
2.4.3 Torques for screws and nuts
2.4.4 Utilisation of liquid glue
2.4.5 Disassembly or assembly of wheels with clamping rim fastener
2.4.5.1 Assembly of hub differential
2.4.5.3 Assembly of the face seal
2.4.5.8 Installing the planetary housing
2.4.6 Hub planetary reduction gear
2.4.6.1 Repairing the hub planetary reduction gear
2.4.7 Axle drive
2.4.7.1 Installing and adjusting the spiral bevel gear
2.4.7.2 Adjusting the contact pattern
2.4.7.3 Adjusting the spiral bevel gear taper roller bearing
2.4.7.4 Securing the locknut
2.4.7.5 Assembly of differential
2.4.7.6 Assembly of axle carrier
2.4.7.7 Adjustment of contact pattern of Gleason type gear teeth
2.4.8 Special tools
3 Truck body
3.1 Chassis assembly
3.2 Cabin
3.2.1 Repairing the cabin glass pane
3.2.2 Repairing the cabin window pane (glass-to-glass)
3.2.3 Repairing the cabin window pane with aluminium frame (sliding window)
3.2.4 Repairing the roof window without frame or channels
4 Steering system
4.1 Steer axle Type L 101
4.2 Steering hydraulics circuit diagram
4.3 Description of the steering hydraulics
4.4 Removing and installing the steer axle
4.5 Repairing the steer axle
4.5.1 Renewing the wheel bearings
4.5.2 Adjusting the wheel bearings
4.5.3 Stub axle
4.5.3.1 Removing the stub axle
4.5.3.2 Installing the stub axle
4.5.4 Steering cylinder
4.5.4.1 Removing and installing the steering cylinder
4.5.4.2 Sealing the steering cylinder
4.5.4.3 Changing the steering cylinder seals
4.5.5 Adjusting the steering stops
4.6 Special tools
5 Braking System
5.1 Braking system circuit diagram
5.1.1 Description of the Hydraulic Braking System
5.1.2 Schematic Diagram of the Braking System
5.1.3 Pressure measurements
5.1.4 Accumulator charging valve
5.2 Construction of the Wet Multiple Disc Brake
5.2.1 Checking the Lining Wear
5.2.2 Installation of the Piston Cups
5.2.3 Installation of the Piston into the Brake Anchor Plate
5.2.4 Checking the Air gap
5.2.5 Leakage Test Specification for the Hydraulic Braking System and the Cooling
Oil Compartment
5.2.6 Final Assembly
5.2.7 Parking Brake
5.2.8 Mechanical Floating Caliper Disc Brake
5.2.9 Parking Brake Assembly
5.2.10 Replacement of the Brake Pad
5.2.11 Instructions for Assembly of the Disc Brake
5.3.12 Brake Disc
6 Electrical system
6.1 Wiring diagrams
6.1.1 Legend to wiring diagrams
6.1.2 Truck wiring diagram
6.1.3 Location of Boxes on the truck
6.2 Programmable computer control system
6.2.1 Load safety system panel
6.2.2 Check and adjustment of the computer control
6.2.2.1 Safety precautions for handling the computer control
6.2.2.2 Table of the “Operative” menu (software versions 3.1b and 3.22)
6.2.2.3 “Operative” menu (software version 3.4)
6.2.2.4 Output signal legend
6.2.2.5 Input signal legend
6.2.2.6 Operation of the computer system
6.2.2.7 Installation instructions for potentiometers and sensors
6.2.2.8 Table of the length references for Reach Stacker 4 High and 5 High
6.2.2.9 Replacement of a computer and necessary adjustments
6.2.2.10 Examples of computer programming
6.2.2.10.1 Programming after changing a board of versions 3.1B and 3.22B
6.2.2.10.2 Programming after renewing a board with version 3.4B
6.3 Safety shutoff relay box (B7)
6.3.1 Electric circuit diagram
6.3.2 Wiring diagram of the relay box up to build-month 05/99
6.3.3 Wiring diagram of the relay box from build-month 06/99
6.3.4 Functional description of the relay box
6.4 Self test Codes
6.5 Additional information
7 Hydraulic system
7.1 Legend for hydraulic circuit diagrams
7.2 Hydraulic circuit diagram
7.2.1 Hydraulic circuit diagram with pilot pressure damping
7.2.2 Hydraulic circuit diagram with boost pressure damping
7.3 Working hydraulics Schematic with spreader pilot pressure damping
7.4 Working hydraulics schematic with spreader boost pressure damping
7.5 Pilot circuit schematic with pilot pressure damping of spreader
7.6 Pilot control circuit schematic with spreader boost pressure damping
7.7 Functional description of the hydraulic system
7.8 Functional description of the hydraulic control system
7.9 Schematic of hydraulic system functions
7.9.1 Version with Pilot pressure damping
7.9.2 Version with boost pressure damping
8 Boom and Spreader
8.1 Boom
8.1.1 Description
8.1.2 Boom removal
8.1.3 Boom assembly
8.1.4 Boom repairs
8.1.4.1 Boom extension cylinder
8.1.4.2 Lift cylinder
8.1.4.3 Sliding bearings
8.2 Spreader Model 817
8.2.1 Operation and construction
8.2.2 Technical data and schematic Diagrams
8.2.2.1 Operating and performance data
8.2.2.2 Hydraulic circuit diagrams for spreader model 817
8.2.2.3 Wiring diagrams for spreader model 817
8.2.3 Spreader removal
8.2.4 Spreader Assembly
8.2.5 Spreader repairs
8.2.5.1 Sliding bearings
8.2.5.2 Repairing the twistlocks
8.2.5.3 Beam extension cylinders
8.2.5.4 Sideshift cylinder
8.2.5.5 Levelling cylinder
8.2.5.6 Stop cylinder
8.2.5.7 Slewing gear
8.3 Spreader model 857 (piggyback)
8.3.1 Operation and construction
8.3.2 Technical data
8.3.2.1 Operating and performance data
8.3.2.2 Hydraulic circuit diagram for spreader model 857
8.1.2.3 Wiring diagram for Spreader model 857
8.1.3 Spreader removal and assembly
8.1.4 Repairing the 857 series spreader
9 Optional equipment
9.1 Automatic greasing system
9.1.1 Functional description
9.1.2 Technical data
9.1.3 Position of the distribution blocks and grease points
9.1.4 Wiring diagram
9.1.5 Grease pump
9.1.6 Electronic timer
9.1.6.1 Functional description
9.1.6.2 Adjusting the interval time
9.1.6.3 Testing the timer and the complete system
9.1.6.4 Venting procedure
9.1.6.5 Alarm signals
9.1.7 Dispensers
9.1.7.1 Description
9.1.7.2 Dispenser versions
9.1.7.3 Dispenser operation
9.1.8 Othercomponents
9.1.8.1 Pressure switch
9.1.8.2 Grease reservoir
9.1.8.3 Grease piston
9.1.9 Lubricant
9.1.9.1 Greenlube lubricant specifications
9.1.9.2 Filling the reservoir
9.1.10 Malfunctions and remedies
9.2 Sliding cabin
9.2.1 Hydraulic circuit diagram
9.2.2 Schematic diagram
9.2.3 Electrical system
9.2.5 Adjusting the chain tension
9.2.4 Adjusting the cabin traversing speed
9.3 Vertical Lift
9.3.1 Circuit diagrams
9.3.1.1 Legends
9.3.1.2 Hydraulic circuit diagram and wiring diagram, vertical lift
9.3.1.3 Wiring diagram for Computer box with vertical lift
9.3.2 Computer box signals with vertical lift
9.3.2.1 Input signals
9.3.2.2 Output signals
9.3.3 Schematic representation of hydraulic components for Vertical Lift
9.3.3.1 Extension hydraulics
9.3.3.2 Retraction hydraulics
9.3.3.3 Lift hydraulics
9.3.3.4 Lowering hydraulics
10 Technical Data
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** Model Specification: Linde Reach Stacker 357 Series: C4130/4 TL, C4130/5 TL
** Language: English
** Total Pages: 374
** File Format: PDF
** Requirements: Adobe PDF Reader
** Compatible: All Versions of Windows & Mac, Linux OS, Iphone, Ipad, Android etc…
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