This manual covers the Terex GTH-1256 AF Telehandler, a robust machine designed for efficient material handling. Built with precision engineering, this telehandler exemplifies reliability and advanced functionality, making it a trusted choice for demanding operational environments. Its design prioritizes performance and durability, ensuring it meets the rigorous requirements of various industrial and construction applications.
This comprehensive manual provides essential information for the operation, maintenance, and repair of your GTH-1256 AF Telehandler. It details scheduled maintenance procedures, including lubrication charts and inspection reports, along with specific checklists for engine, hydraulic, and drivetrain components. Furthermore, the manual includes in-depth repair procedures for key systems, diagnostic information such as engine fault codes, and detailed schematics for electrical and hydraulic systems, empowering owners and technicians to maintain optimal performance and longevity of the equipment.
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
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
