Terex GTH-1256 AF Telehandler Service Repair Workshop Manual

Part No. 57.4400.9219 Rev C, September 2017 Serial Number Range From GTH12AFM-101 Content: INTRODUCTION Important Information Revision History Serial Number Legend Section 1. SAFETY RULES General Safety Rules Section 2. SPECIFICATIONS Machine Specifications Performance Specifications Hydraulic Specifications Hydraulic Components Specifications Function Manifold Specifications Air Conditioner Refrigerant Specifications Perkins 1104D-E44TA Engine Dana Integral Gear Box Dana Axle Hydraulic Hose and Fitting Torque Specifications Torque Procedure SAE and Metric Fasteners Torque Charts Section 3. SCHEDULED MAINTENANCE PROCEDURES Introduction Pre-delivery Preparation Report Maintenance Inspection Report Lubrication Chart Checklist A Procedures A-1 Inspect the Manuals and Decals A-2 Perform Pre-operation Inspection A-3 Perform Function Tests A-4 Lubricate the Boom A-5 Perform Engine Maintenance A-6 Safety Devices A-7 Inspect the Pre Filter A-8 Perform Axle Maintenance A-9 Perform 30 Day Service A-10 Perform Axle Maintenance A-11 Perform Gear Box Maintenance A-12 Perform Axle Maintenance A-13 Perform Engine Maintenance A-14 Perform Engine Maintenance Checklist B Procedures B-1 Inspect the Electrical Wiring B-2 Gear Box Oil Level B-3 Check the Exhaust System B-4 Perform Axle Maintenance B-5 Inspect the Tires, Wheels and Lug Nut Torque B-6 Perform Hydraulic Oil Analysis B-7 Check the Boom Wear Pads B-8 Perform Engine Maintenance Checklist C Procedures C-1 Perform Engine Maintenance C-2 Perform Engine Maintenance C-3 Perform Engine Maintenance C-4 Perform Axle Maintenance C-5 Inspect and Lubricate the Sequencing Chains Checklist D Procedures D-1 Inspect the Forks D-2 Tighten the Boom Chains D-3 Replace the Hydraulic Tank Return Filter Element D-4 Change Gear Box Oil D-5 Perform Engine Maintenance D-6 Perform Axle Maintenance D-7 Replace Coolant Filter Element Checklist E Procedures E-1 Test or Replace the Hydraulic Oil E-2 Perform Engine Maintenance E-3 Perform Engine Maintenance E-4 Perform Engine Maintenance E-5 Perform Engine Maintenance Section 4. REPAIR PROCEDURES Introduction Boom Components 1-1 Boom 1-2 Boom Lift Cylinder 1-3 Boom Extend Cylinder 1-4 Fork Level Slave Cylinder 1-5 Fork Tilt Cylinder 1-6 Boom Angle Proximity switch Operators compartment 2-1 Operators Compartment 2-2 Machine Controls Fuel and Hydraulic Tanks 3-1 Fuel tank 3-2 Hydraulic tank Engines 4-1 Engine 4-2 Engine Fault Codes Transmission 5-1 Gear Box 5-2 Axle 5-3 Rear Axle Lockout Cylinder Hydraulic pumps 6-1 Boom and Steering Function Pump 6-2 Auxiliary Gear Pump 6-3 Hydrostatic Transmission Pump Manifold 7-1 Function Manifold 7-2 Valve coils Stabilizers 8-1 Stabilizers Forks 9-1 Forks Power Plant Heaters 10-1 Power Plant Heaters Webasto Heater 11-1 Webasto Heater AC Unit 12-1 AC Unit Radiators 13-1 Radiators Fuel System 14-1 Fuel System Prime Braking Circuit 15-1 Braking circuit Section 5. LONG TERM STORAGE RECOMMENDATION Introduction Section 6. FAULT CODES Introduction Diagnostic Display Engine Fault Codes - Perkins 1104D-E44TA Engine Section 7. SCHEMATICS Introduction Electrical and Hydraulic Symbol Legends Electrical Schematic Hydraulic Schematic