Terex GTH-1256 AF Service Manual
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Terex GTH-1256 AF Service Manual

Terex GTH-1256 AF Service Manual

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Service Manual
GTH-1256 AF
Serial Number Range
From GTH12AFM-101
Part No. 57.4400.9219
Rev C
September 2017

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Summary of Contents for Terex GTH-1256 AF

  • Page 1 Service Manual Serial Number Range GTH-1256 AF From GTH12AFM-101 Part No. 57.4400.9219 Rev C September 2017...
  • Page 2 Readers are encouraged to notify Genie of errors "Genie" and "GTH" are registered trademarks of and send in suggestions for improvement. All Terex South Dakota, Inc. in the USA and many other communications will be carefully considered for countries. future printings of this and all other manuals.

  • Page 3: Revision History

    Perkins Engine_Section 2_Specifi cations. Electronic Version A-5, B-8, C-1, D-5, E-2_Section 3_Maintenance Procedure. Click on any procedure or page number 4-1, 4-2_Section 4_Repair Procedure. highlighted in blue to view the update. Fault Codes_Section 6. Section 7_Schematic Page #. Part No. 57.4400.9219 GTH-1256 AF...
  • Page 4 Perkins Engine_Section 2_Specifi cations. Electronic Version A-5, B-8, C-1, D-5, E-2_Section 3_Maintenance Procedure. Click on any procedure or page number 4-1, 4-2_Section 4_Repair Procedure. highlighted in blue to view the update. Fault Codes_Section 6. Section 7_Schematic Page #. GTH-1256 AF Part No. 57.4400.9219...

  • Page 5: Serial Number Legend

    September 2017 INTRODUCTION Serial Number legend 3930-01-647-7904 GTH12AF xxxxx 10,000 LBS 12 Mo 39,394 LBS GSA-BPA-GS-07F-DA073 49,394 LBS 1 Model 2 Facility code 3 Sequence number 4 Serial number (stamped on chassis) 5 Identification Plate Part No. 57.4400.9219 GTH-1256 AF...
  • Page 6 September 2017 This page intentionally left blank. GTH-1256 AF Part No. 57.4400.9219...

  • Page 7: Safety Rules

    You read, understand and obey: - manufacturer’s instructions and safety rules - employer’s safety rules and worksite regulations - applicable governmental regulations You have the appropriate tools, lifting equipment and a suitable workshop. Part No. 57.4400.9219 GTH-1256 AF...
  • Page 8 Be sure to wear protective eye wear and other protective clothing if the situation warrants it. Be aware of potential crushing hazards such as moving parts, free swinging or unsecured components when lifting or placing loads. Always wear approved steel-toed shoes. viii GTH-1256 AF Part No. 57.4400.9219...

  • Page 9: Table Of Contents

    SAE and Metric Fasteners Torque Charts ..........2 - 10 Section 3 Scheduled Maintenance Procedures Introduction .....................3 - 1 Pre-delivery Preparation Report .............3 - 3 Maintenance Inspection Report ..............3 - 4 Lubrication Chart ..................3 - 5 Part No. 57.4400.9219 GTH-1256 AF...
  • Page 10 Perform Axle Maintenance ............3 - 16 Inspect the Tires, Wheels and Lug Nut Torque ......3 - 16 Perform Hydraulic Oil Analysis ...........3 - 17 Check the Boom Wear Pads ............3 - 18 Perform Engine Maintenance .............3 - 19 GTH-1256 AF Part No. 57.4400.9219...
  • Page 11 Checklist E Procedures Test or Replace the Hydraulic Oil ..........3 - 29 Perform Engine Maintenance .............3 - 30 Perform Engine Maintenance .............3 - 30 Perform Engine Maintenance .............3 - 31 Perform Engine Maintenance .............3 - 31 Part No. 57.4400.9219 GTH-1256 AF...
  • Page 12 Rear Axle Lockout Cylinder ............4 - 26 Hydraulic pumps Boom and Steering Function Pump ...........4 - 27 Auxiliary Gear Pump ..............4 - 32 Hydrostatic Transmission Pump ..........4 - 35 Manifold Function Manifold ...............4 - 39 Valve coils ..................4 - 42 GTH-1256 AF Part No. 57.4400.9219...
  • Page 13 15-1 Braking circuit ................4 - 55 Section 5 Long Term Storage Recommendation Introduction .....................5 - 1 Section 6 Fault Codes Introduction .....................6 - 1 Diagnostic Display ..................6 - 2 Engine Fault Codes - Perkins 1104D-E44TA Engine ......6 - 3 Part No. 57.4400.9219 GTH-1256 AF xiii...
  • Page 14 September 2017 Section 7 Schematics Introduction .....................7 - 1 Electrical and Hydraulic Symbol Legends ..........7 - 2 Electrical Schematic ................7 - 3 Hydraulic Schematic ................7 - 15 GTH-1256 AF Part No. 57.4400.9219...

  • Page 15: Specifications

    For operational specifi cations, refer to the 135 cm Operator's Manual. Wheel width 18 in 46.5 cm Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. Part No. 57.4400.9219 GTH-1256 AF...

  • Page 16: Performance Specifi Cations

    Fork tilt up 6 seconds Lift capacity, maximum 10000 lbs Fork tilt down 5 seconds 4536 kg Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. GTH-1256 AF Part No. 57.4400.9219...

  • Page 17: Hydraulic Specifi Cations

    Shell Tellus S2 V 32 -20° Shell Tellus S2 V 46 -10° Chevron Aviation A -20° Eni Arnica 32 -20° Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. Part No. 57.4400.9219 GTH-1256 AF...

  • Page 18: Hydraulic Components Specifi Cations

    (measured at test port TP4) Relief valve pressure, maximum 2610 psi (measured at test port TP2) 180 bar Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. GTH-1256 AF Part No. 57.4400.9219...

  • Page 19: Function Manifold Specifi Cations

    3190 psi 220 bar Air Conditioner Refrigerant Specifi cations System Full Charge R134a 2 lbs 3 oz Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. Part No. 57.4400.9219 GTH-1256 AF...

  • Page 20: Perkins 1104D-E44Ta Engine

    For oil requirements, refer rate to the Engine Operation and Maintenance Manual on your machine. Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notic)e. GTH-1256 AF Part No. 57.4400.9219...

  • Page 21: Dana Integral Gear Box

    MOBILFLUID LT following the instruction provided in Dana 213 Axle Service Manual (Dana part number ASM-0026E, Genie part number 57.4700.0028) Continuous improvement of our products is a Genie policy. Product specifi cations are subject to change without notice. Part No. 57.4400.9219 GTH-1256 AF...

  • Page 22: Hydraulic Hose And Fitting Torque Specifi Cations

    37° (Adj / Non-adj) 85 ft-lbs / 115.3 Nm (All types) 135 ft-lbs / 183 Nm (All types) 200 ft-lbs / 271.2 Nm (All types) 250 ft-lbs / 339 Nm (All types) 305 ft-lbs / 413.5 Nm GTH-1256 AF Part No. 57.4400.9219...

  • Page 23: Torque Procedure

    fi tting with a permanent ink marker. Refer to 5 Operate all machine functions and inspect the Figure 1. hoses and fi ttings and related components to confi rm that there are no leaks. Part No. 57.4400.9219 GTH-1256 AF...
  • Page 24 48. 6 64. 9 69. 7 94. 5 92. 2 30. 1 40. 8 54. 3 77. 4 46. 9 63. 6 62. 5 84. 8 64. 5 87. 5 86. 2 1055 1233 2-10 GTH-1256 AF Part No. 57.4400.9219...

  • Page 25: Scheduled Maintenance Procedures

    · Machine parked on a fi rm, level surface · Boom in the stowed position · Key switch in the off position with the key removed · Wheels chocked Part No. 57.4400.9219 GTH-1256 AF...

  • Page 26: Pre-Delivery Preparation Report

    Make copies of the Maintenance Inspection Report to use for each inspection. Maintain completed forms for a minimum of 4 years or in compliance with your employer, job site and governmental regulations and requirements. GTH-1256 AF Part No. 57.4400.9219...
  • Page 27 500 Oak Wood Road The Maltings, Wharf Road Inspector company PO Box 1150 Grantham, Lincolnshire Watertown, SD 57201-6150 NG31- 6BH England (605) 882-4000 (44) 1476-584333 Copyright © 2011 Terex Corporation. Genie® is a registered trademark of Terex South Dakota, Inc. 133192 Rev D...

  • Page 28: Maintenance Inspection Report

    After repair, place a check in the “R” box. Engine maintenance Checklist C Engine maintenance Engine maintenance Engine maintenance Comments Legend Y = yes, acceptable N = no, remove from service R = repaired GTH-1256 AF Part No. 57.4400.9219...

  • Page 29: Lubrication Chart

    DROPBOX OIL CHANGE 75W-80 MOBILFLUID LT EVERY 2000 HOURS COOLANT FILTER CHANGE ---------- ---------- HYDRAULIC OIL CHANGE ---------- SHELL TELLUS S4 VX 32 ---------- 45% WATER + 55% ANTIFREEZE (VANGUARD ICE GUARD -40 SPECIAL) 09.4616.0158 Part No. 57.4400.9219 GTH-1256 AF...

  • Page 30: Checklist A Procedures

    2 Examine the pages of each manual to be sure that they are legible and in good condition. Result: The operator's manual is appropriate for the machine and all manuals are legible and in good condition. GTH-1256 AF Part No. 57.4400.9219...

  • Page 31: Perform Pre-Operation Inspection

    Refer to the Operator's Manual on your machine. Complete information to perform this procedure is available in the appropriate operator's manual. Refer to the Operator's Manual on your machine. Part No. 57.4400.9219 GTH-1256 AF...

  • Page 32: Lubricate The Boom

    3 boom tube lower wear pads. 3 Apply a thin layer of grease to the underside of the number 3 boom tube where it makes contact with the number 2 boom tube lower wear pads. GTH-1256 AF Part No. 57.4400.9219...

  • Page 33: Perform Engine Maintenance

    Manual (Perkins part number SEBU9066-00). is inhibited. Attempt to level the machine. It must not be Perkins 1104D-E44TA Operation and Maintenance possible because chassis levelling is inhibited. Manual Genie part number 57.4700.0029 Part No. 57.4400.9219 GTH-1256 AF...

  • Page 34: Inspect The Pre Filter

    Trunnion bushings - grease Required maintenance procedures and additional axle information are available in the Dana 213 Axle Service Manual (Dana part number ASM-0026E). Dana 213 Axle Service Manual Genie part number 57.4700.0028 3-10 GTH-1256 AF Part No. 57.4400.9219...

  • Page 35: Perform 30 Day Service

    · Check Belt Tension Dana 213 Axle Service Manual · Check The Engine Mounts (Dana part number ASM-0026E). · Check Hose Clamps Dana 213 Axle Service Manual Genie part number 57.4700.0028 Part No. 57.4400.9219 GTH-1256 AF 3-11...

  • Page 36: Perform Gear Box Maintenance

    Dana 367 Gear Box Service Manual axle information are available in the Genie part number 57.4700.0027 Dana 213 Axle Service Manual (Dana part number ASM-0026E). Dana 213 Axle Service Manual Genie part number 57.4700.0028 3-12 GTH-1256 AF Part No. 57.4400.9219...

  • Page 37: Perform Engine Maintenance

    Manual (Perkins part number SEBU9066-00). Perkins 1104D-E44TA Operation and Maintenance Manual (Perkins part number SEBU9066-00). Perkins 1104D-E44TA Operation and Maintenance Manual Perkins 1104D-E44TA Operation and Maintenance Manual Genie part number 57.4700.0029 Genie part number 57.4700.0029 Part No. 57.4400.9219 GTH-1256 AF 3-13...

  • Page 38: Checklist B Procedures

    Turn the machine off. • All harness connectors 3 Start the engine and raise the boom so there is enough room to access and remove all the covers attached to the chassis. 3-14 GTH-1256 AF Part No. 57.4400.9219...

  • Page 39: Gear Box Oil Level

    1 Open the engine access cover. 2 Be sure that all fasteners are tight. 3 Inspect all welds for cracks. 4 Inspect for exhaust leaks - i.e., carbon buildup around seams and joints. 5 Close the engine access cover. Part No. 57.4400.9219 GTH-1256 AF 3-15...

  • Page 40: Perform Axle Maintenance

    2 Check each wheel for damage, bends and cracks. 3 Check each lug nut for proper torque. Refer to Section 2, Specifi cations. 4 Check the air pressure in each tire. Refer to Section 2, Specifi cations. 3-16 GTH-1256 AF Part No. 57.4400.9219...

  • Page 41: Perform Hydraulic Oil Analysis

    If the hydraulic oil is not replaced at the two year inspection, test the oil quarterly. Replace the oil when it fails the test. See E-1, Test or Replace the Hydraulic Oil. Part No. 57.4400.9219 GTH-1256 AF 3-17...

  • Page 42: Check The Boom Wear Pads

    1 mm, replace the worn pad. Refer to Repair Procedure 1-2, How to Replace the Boom Minimum 1 mm Wear Pads. Boom Wear Pad Screws Tightening Specifi cations Screws M10 22 ft-lbs 30 Nm Screws M10 37 ft-lbs 50 Nm 3-18 GTH-1256 AF Part No. 57.4400.9219...

  • Page 43: Perform Engine Maintenance

    Aftercooler core - clean/test Required maintenance procedures and additional engine information are available in the Perkins 1104D-E44TA Operation and Maintenance Manual (Perkins part number SEBU9066-00). Perkins 1104D-E44TA Operation and Maintenance Manual Genie part number 57.4700.0029 Part No. 57.4400.9219 GTH-1256 AF 3-19...

  • Page 44: Checklist C Procedures

    Perkins 1104D-E44TA Operation and Maintenance Manual (Perkins part number SEBU9066-00). Manual (Perkins part number SEBU9066-00). Perkins 1104D-E44TA Operation and Maintenance Perkins 1104D-E44TA Operation and Maintenance Manual Manual Genie part number 57.4700.0029 Genie part number 57.4700.0029 3-20 GTH-1256 AF Part No. 57.4400.9219...

  • Page 45: Perform Engine Maintenance

    Fuel system secondary filter - replace Required maintenance procedures and additional engine information are available in the Perkins 1104D-E44TA Operation and Maintenance Manual (Perkins part number SEBU9066-00). Perkins 1104D-E44TA Operation and Maintenance Manual Genie part number 57.4700.0029 Part No. 57.4400.9219 GTH-1256 AF 3-21...

  • Page 46: Inspect And Lubricate The Sequencing Chains

    • Attempting to "inch" loads which are beyond Note: Please ask the service to know the correct the rated capacity of the vehicle. procedure to better understand the maximum percent of chain elongation. 3-22 GTH-1256 AF Part No. 57.4400.9219...
  • Page 47 fl ooded with lubricant and the boom should be extended and retracted to insure that the lubricant penetrates to the working surfaces. All excess lubricant should be wiped away from the external surfaces. Note: Do not use solvents to remove excess lubricant. Part No. 57.4400.9219 GTH-1256 AF 3-23...

  • Page 48: Checklist D Procedures

    Excessive wear to the forks, fork mount or legible markings Result: If any of the above criteria are not met, forks shall be removed from service until they are repaired or replaced. a - shank b - blade 3-24 GTH-1256 AF Part No. 57.4400.9219...

  • Page 49: Tighten The Boom Chains

    37 ft-lbs / 50 Nm. 5 Check that all chains have been equally tensioned. If not, repeat the operation described above. 6 Lock the chain tensioners by means of a counternut and locknut. Part No. 57.4400.9219 GTH-1256 AF 3-25...

  • Page 50: Replace The Hydraulic Tank Return Filter Element

    3 Unscrew the return fi lter. 4 Install the new fi lter element. 5 Tighten the fi ller/breather cap. 6 Record the hours the fi lter element was replaced and keep with your maintenance records. 7 Start the engine. 3-26 GTH-1256 AF Part No. 57.4400.9219...

  • Page 51: Change Gear Box Oil

    Perkins 1104D-E44TA Operation and Maintenance Stop when oil is level with hole (B). Manual Genie part number 57.4700.0029 6 Refi t and tighten plug (B). 7 Clean the sensor (C) reading zone (every oil change). Part No. 57.4400.9219 GTH-1256 AF 3-27...

  • Page 52: Perform Axle Maintenance

    (Dana part number ASM-0026E). 1 Remove the cover placed behind the cab. Dana 213 Axle Service Manual 2 Remove the bottom dome. Genie part number 57.4700.0028 3 Pull out and replace the fi lter cartridge. 3-28 GTH-1256 AF Part No. 57.4400.9219...

  • Page 53: Checklist E Procedures

    Replace the oil when it fails the test. 1 Lower the boom to the stowed position. 2 Raise the stabilizers (machine resting on wheels). 3 Fully tilt back the forks. Part No. 57.4400.9219 GTH-1256 AF 3-29...

  • Page 54: Perform Engine Maintenance

    Manual (Perkins part number SEBU9066-00). Perkins 1104D-E44TA Operation and Maintenance Manual (Perkins part number SEBU9066-00). Perkins 1104D-E44TA Operation and Maintenance Manual Perkins 1104D-E44TA Operation and Maintenance Genie part number 57.4700.0029 Manual Genie part number 57.4700.0029 3-30 GTH-1256 AF Part No. 57.4400.9219...

  • Page 55: Perform Engine Maintenance

    Manual (Perkins part number SEBU9066-00). Perkins 1104D-E44TA Operation and Maintenance Manual (Perkins part number SEBU9066-00). Perkins 1104D-E44TA Operation and Maintenance Perkins 1104D-E44TA Operation and Maintenance Manual Manual Genie part number 57.4700.0029 Genie part number 57.4700.0029 Part No. 57.4400.9219 GTH-1256 AF 3-31...
  • Page 56 Section 3 • Scheduled Maintenance Procedures September 2017 CHECKLIST E PROCEDURES This page intentionally left blank. 3-32 GTH-1256 AF Part No. 57.4400.9219...
  • Page 57 Note: Used to indicate additional operation or procedure information. Indicates that a specifi c result is expected after performing a series of steps. Indicates that an incorrect result has occurred after performing a series of steps. Part No. 57.4400.9219 GTH-1256 AF...
  • Page 58 2. Remove the spring clips securing the pins to the collar, and remove the pins from the collar. Crushing hazard. Do not work WARNING under a boom which is not properly supported. GTH-1256 AF Part No. 57.4400.9219...

  • Page 59: Boom Components

    8 Using the overhead crane, lift and remove the fork frame from the boom. Crushing hazard. The fork CAUTION frame could fall if not properly supported when the lock pin is removed from the machine. Part No. 57.4400.9219 GTH-1256 AF...
  • Page 60 1 retract chain tensioner boom tube number 2 tube number 2 retract chain tensioner boom tube number 3 boom tube number 4 extend cylinder retract chain tube number 1 retract chain tube number 2 GTH-1256 AF Part No. 57.4400.9219...
  • Page 61 "r". 17 Install block "q" back into the slot on the boom. 18 At the pivot end of the boom, install the upper screws securing the upper chains "f" - "g". Part No. 57.4400.9219 GTH-1256 AF...
  • Page 62 1 extend chain locking device boom tube number 2 tube number 2 extend chain locking device boom tube number 3 boom tube number 4 extend cylinder extend chain tube number 1 extend chain tube number 2 GTH-1256 AF Part No. 57.4400.9219...
  • Page 63 Note: Rope coming loose from the chain during removal may result in a diffi cult reassembly. Be sure the rope is securely attached to the chain and boom structure before pulling the chain out of the boom. Part No. 57.4400.9219 GTH-1256 AF...
  • Page 64 6 Attach a second strap from the overhead crane to the lifting cylinder, rod side, and put some tension on it. 7 Using a soft metal drift, remove the slave cylinder locking pin from the boom support. GTH-1256 AF Part No. 57.4400.9219...
  • Page 65 6 Extend the boom until the inspection holes are accessible on the inner boom section. 7 Inserting a spanner through the inspection holes, remove the screws which fi x the hoses holder block and disconnect the hydraulic hoses on the upper boom side. Part No. 57.4400.9219 GTH-1256 AF...
  • Page 66 18 Set the fi rst and second boom section on a structure capable of supporting it. 19 Let the fi rst boom section slide out of the second one. 20 Set the fi rst boom section on a structure capable of supporting it. 4-10 GTH-1256 AF Part No. 57.4400.9219...

  • Page 67: Boom Lift Cylinder

    Support the cylinder. Do not apply any lifting pressure. 4 Remove the fasteners securing the lift cylinder barrel-end pivot pin to the chassis. 5 Use a soft metal drift to remove the pivot pin. Part No. 57.4400.9219 GTH-1256 AF 4-11...

  • Page 68: Boom Extend Cylinder

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Component damage hazard. NOTICE Hoses can be damaged if they are kinked or pinched. 4-12 GTH-1256 AF Part No. 57.4400.9219...

  • Page 69: Fork Level Slave Cylinder

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Component damage hazard. NOTICE Hoses can be damaged if they are kinked or pinched. Part No. 57.4400.9219 GTH-1256 AF 4-13...
  • Page 70 4 Install the replacement hydraulic hose by pulling the old hydraulic hose out of the pivot end of the boom assembly. 4-14 GTH-1256 AF Part No. 57.4400.9219...

  • Page 71: Fork Tilt Cylinder

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Component damage hazard. NOTICE Hoses can be damaged if they are kinked or pinched. Part No. 57.4400.9219 GTH-1256 AF 4-15...

  • Page 72: Boom Angle Proximity Switch

    5 Securely tighten the fasteners. Do not over tighten. 6 Lower the boom to 45°. Result: the light of the proximity switch assembly is illuminated. 7 Raise the boom to 50°. Confi rm with a digital level. 4-16 GTH-1256 AF Part No. 57.4400.9219...

  • Page 73: Operator's Compartment

    Electrocution/burn hazard. WARNING Contact with electrically charged 11 Remove the cover placed behind the cab. circuits could result in death or serious injury. Remove all rings, watches and other jewelry. Part No. 57.4400.9219 GTH-1256 AF 4-17...
  • Page 74 Do not lift the cab using a strap from an overhead crane. Bolt torque specifi cation Operator's cab mounting bolts 167 ft-lbs 226 Nm (plus Locktite compound) 4-18 GTH-1256 AF Part No. 57.4400.9219...

  • Page 75: Machine Controls

    3 Remove the upper part of the dashboard. 4 Remove the transmission control lever. 5 Remove the light control lever. 6 Remove the screws which secure the steering column to the frame. 7 Remove the steering column. Part No. 57.4400.9219 GTH-1256 AF 4-19...
  • Page 76 5 Remove the fasteners securing the joystick to the mount panel. Remove the joystick. Joystick port orientation 4-20 GTH-1256 AF Part No. 57.4400.9219...
  • Page 77 Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 8 Remove the retaining fasteners securing the brake pedal. Remove the brake pedal. Part No. 57.4400.9219 GTH-1256 AF 4-21...

  • Page 78: Fuel And Hydraulic Tanks

    8 Remove the retaining fasteners securing the tanks to the machine. 9 9 Remove the tank from the machine. Remove the tank from the machine. 4-22 GTH-1256 AF Part No. 57.4400.9219...

  • Page 79: Hydraulic Tank

    Refer to Section 2, Specifi cations. 7 Remove the drain plug from the hydraulic tank and completely drain the tank. Bodily injury hazard. Beware of CAUTION hot oil. Contact with hot oil may cause severe burns. Part No. 57.4400.9219 GTH-1256 AF 4-23...

  • Page 80: Engines

    To learn the specifi cations of and how to use the Perkins 1104D-E44TA Operation and Maintenance fault codes, refer to Section 6, Fault Codes. Manual Genie part number 57.4700.0029 Perkins 1104D-E44TA Disassembly and Assembly Genie part number 57.4700.0030 4-24 GTH-1256 AF Part No. 57.4400.9219...

  • Page 81: Transmission

    Do not allow oil to squirt or spray. 5 Loosen the lug nuts of both wheels on the axle to be removed. Do not remove the lug nuts. Part No. 57.4400.9219 GTH-1256 AF 4-25...

  • Page 82: Rear Axle Lockout Cylinder

    Crushing hazard. The axle will WARNING 5 Tighten the venting valve. fall if not properly supported when the fasteners are removed from the machine. Bolt torque specifi cation Axle mounting bolts 560 ft-lbs 760 Nm 4-26 GTH-1256 AF Part No. 57.4400.9219...

  • Page 83: Hydraulic Pumps

    When testing the pump, crank the engine in one second intervals until the correct pressure is confi rmed. Do not over-pressurize the pump. 6 Remove the pressure gauge and install plug onto port TP1. Part No. 57.4400.9219 GTH-1256 AF 4-27...
  • Page 84 3 Remove the engine cover to easily reach the pumps. Crushing hazard. The pump WARNING will fall if not properly supported when the fasteners are removed from the machine. 4-28 GTH-1256 AF Part No. 57.4400.9219...
  • Page 85 Install the hose retaining rings and fasteners. 4 At the case drain at the top of the pump, fi ll the pump with hydraulic fl uid until it reaches the top of the case drain fi tting. Part No. 57.4400.9219 GTH-1256 AF 4-29...
  • Page 86 Turn the adjustment screw clockwise to increase the pressure or counterclockwise to 6 Shut off the engine and inspect for oil leaks. decrease the pressure. Tighten the set screw. 5 Turn the engine off and remove the pressure gauge. 4-30 GTH-1256 AF Part No. 57.4400.9219...
  • Page 87 300 bar. The pump is good. Proceed to step 9. Pressure is not within specifi cation. The pressure setting needs to be adjusted. Proceed to step 7. 7 Loosen the set screw for the pressure compensator adjustment screw on the pump. Part No. 57.4400.9219 GTH-1256 AF 4-31...

  • Page 88: Auxiliary Gear Pump

    Do not allow oil to squirt or spray. 3 Cap the auxiliary gear pump holes and the hoses ones. 4 Remove the auxiliary gear pump. 4-32 GTH-1256 AF Part No. 57.4400.9219...
  • Page 89 Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 3 Open the hydraulic tank ball valves . Part No. 57.4400.9219 GTH-1256 AF 4-33...
  • Page 90 15 seconds then shut off the engine. 2 Wait 15 seconds, then start the engine again. 3 Allow the engine to run at low idle for 15 seconds and then shut off the engine. 4-34 GTH-1256 AF Part No. 57.4400.9219...

  • Page 91: Hydrostatic Transmission Pump

    Result: the pressure gauge connected to test port TP3 reads 406 psi / 28 bar. Pressure is not within specifi cation. Adjust the boost pressure valve "c" located under the pump. 5 Increase the engine speed to 1100 rpm. Part No. 57.4400.9219 GTH-1256 AF 4-35...
  • Page 92 3 Remove the cover that is under engine. from the machine. 4 Locate the battery disconnect switch and disconnect the battery from the machine. 5 Remove the retaining fasteners that secure the battery disconnect switch mounting plate. 4-36 GTH-1256 AF Part No. 57.4400.9219...
  • Page 93 4 Attach a lifting strap and lift the transmission pump using a overhead crane. 5 Install the hydrostatic transmission pump on the engine. 6 Remove the fi tting caps from the hydrostatic transmission pump. 7 Remove the hoses caps. Part No. 57.4400.9219 GTH-1256 AF 4-37...
  • Page 94 5 Apply the brake pedal and start the engine. Shift the transmission into forward and disengage the emergency brake. 6 Release the brake pedal and slowly increase the engine rpm until the machine starts to move. Apply the brake. 4-38 GTH-1256 AF Part No. 57.4400.9219...

  • Page 95: Manifold

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. 4 Remove the cover above the oil tank. Part No. 57.4400.9219 GTH-1256 AF 4-39...
  • Page 96 5 Moving the joystick, retract the boom. Result: the pressure gauge reads 4060 psi / 280 bar. The pump is good. Pressure is not within specifi cation. Set the valve placed above the manifold. 4-40 GTH-1256 AF Part No. 57.4400.9219...
  • Page 97 Fork tilt down/up Hydraulic proportional control A4 - B4 Attachment hydraulic circuit Hydraulic proportional control A5 - B5 Left Stabilizer Hydraulic proportional control A6 - B6 Right Stabilizer Hydraulic proportional control A7 - B7 Part No. 57.4400.9219 GTH-1256 AF 4-41...

  • Page 98: Valve Coils

    2 Test the coil resistance using a multimeter set to resistance (Ω). Refer to the Valve Coil Resistance Specifi cation table. Result: If the resistance is not within the adjusted specifi cation, plus or minus 10%, replace the coil. 4-42 GTH-1256 AF Part No. 57.4400.9219...
  • Page 99 4 Connect the negative lead to the other terminal on the coil. Note: If testing a single-terminal coil, connect the negative lead to the internal metallic ring at either end of the coil. Part No. 57.4400.9219 GTH-1256 AF 4-43...

  • Page 100: Stabilizers

    Loosen hydraulic connections very slowly to allow the oil pressure to dissipate gradually. Do not allow oil to squirt or spray. Component damage NOTICE hazard. Hoses can be damaged if they are kinked or pinched. 4-44 GTH-1256 AF Part No. 57.4400.9219...

  • Page 101: Forks

    Result: The forks travel synchronously and reach the end of stroke at the same time. Stop the engine. Result: The forks do not travel synchronously. Repeat the procedure described in point 2. Part No. 57.4400.9219 GTH-1256 AF 4-45...

  • Page 102: Power Plant Heaters

    4 Clean the installation area to remove any dirt, 2 Disconnect the power wire of the heating grease or oil - a pressure washer works great element from the oil tank side. for this. 4-46 GTH-1256 AF Part No. 57.4400.9219...
  • Page 103 Do this twice. 11 Apply a small bead of high temperature silicone adhesive (supplied in kit) around the outside edge of the heating pad. Do not force the silicone adhesive under the pad. It is important Part No. 57.4400.9219 GTH-1256 AF 4-47...
  • Page 104 3 Disconnect the power wire from the heating element. 3 Remove the fasteners securing the pad and its support to the lower side of the battery and 4 Loosen the retaining fasteners and remove the remove the pad. heating element. 4-48 GTH-1256 AF Part No. 57.4400.9219...
  • Page 105 4 Cut and remove the ties securing the blanket to 4 Disconnect the wire harness from the battery the battery. terminals. 5 Remove the battery charger. Part No. 57.4400.9219 GTH-1256 AF 4-49...

  • Page 106: Webasto Heater

    fi ttings at the rear of the cabin. 3 Remove the retaining collars and disconnect the drain and fi lter hoses. 4 Disconnect the fuel feed hose. 5 Remove the retaining bolts to free and remove the heater. 4-50 GTH-1256 AF Part No. 57.4400.9219...

  • Page 107: Ac Unit

    6 Set the pump you have in your equipment to fi ll the circuit of the A/C system with 900 grams of Freon gas R134, in accordance to its instruction, and start the A/C fi lling cycle. Part No. 57.4400.9219 GTH-1256 AF 4-51...

  • Page 108: Radiators

    4. Eliminate any sand from the engine compartment through the opening where the cover was removed at step 2. 5. Upon completion of cleaning, reinstall the cover removed at step 2 and close the engine compartment. 4-52 GTH-1256 AF Part No. 57.4400.9219...
  • Page 109 5. Eliminate any sand from the frame through the opening where the grid was removed at step 6. Upon completion of cleaning, reinstall grid removed at step 3 and close the cover a. Part No. 57.4400.9219 GTH-1256 AF 4-53...

  • Page 110: Fuel System

    7 Press again the button "c" and keep the button depressed for approx 2 minutes. After the 2 minutes, the fuel system will be primed and the engine is ready to start. 4-54 GTH-1256 AF Part No. 57.4400.9219...

  • Page 111: Braking Circuit

    2 bleed protective caps. screws (for the service brake). 1 Reach the front axle. Steer the machine wheels for more comfortable access to the service area, if necessary. Part No. 57.4400.9219 GTH-1256 AF 4-55...
  • Page 112 Section 4 • Repair Procedures September 2017 This page intentionally left blank. 4-56 GTH-1256 AF Part No. 57.4400.9219...

  • Page 113: Long Term Storage Recommendation

    Oil left standing in an engine will oxidise and can be contaminated by condensation within the crankcase. Part No. 57.4400.9219 GTH-1256 AF...
  • Page 114 Section 5 • Long Term Storage Recommendation September 2017 This page intentionally left blank. GTH-1256 AF Part No. 57.4400.9219...

  • Page 115: Fault Codes

    Do not allow oil to squirt or spray. General Repair Process Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Inspect Perform service and test Repair problem solved Part No. 57.4400.9219 GTH-1256 AF...

  • Page 116: Diagnostic Display

    Active fault codes, indicating an engine condition or conditions which have not been corrected, are signaled on the LCD display by the word "SERVICE" replacing “GENIE”. Gauge Cluster LCD screen amber warning light stop engine light diagnostic button GTH-1256 AF Part No. 57.4400.9219...

  • Page 117: Engine Fault Codes - Perkins 1104D-E44Ta Engine

    5 Volt DC Power Supply Voltage Below Normal Programmed Parameter Fault Erratic, Intermittent or Incorrect Secondary Engine Speed Sensor Abormal Frequency, Pulse Width or Period 1188 Turbo Wastegate Drive Current Below Normal 1188 Turbo Wastegate Drive Current Above Normal Part No. 57.4400.9219 GTH-1256 AF...
  • Page 118 High Fuel Rail Pressure Low Fuel Rail Pressure High Intake Manifold Air Temperature - Warning High Intake Manifold Air Temperature - Derate Intake Manifold Air Pressure - High Intake Manifold Air Pressure - Low Low Engine Coolant Level GTH-1256 AF Part No. 57.4400.9219...
  • Page 119 Be sure that all necessary tools and test equipment are available and ready for use. Malfunction Identify Troubleshoot discovered symptoms problem still exists Return to Inspect Perform service and test Repair problem solved Part No. 57.4400.9219 GTH-1256 AF...
  • Page 120 Valve coil Valve coil 2 position 4 way 2 position 2 way with diode solenoid valve solenoid valve Diode Switch Joystick Proximity switch Limit switch Counterbalance valve Temperature switch Fuel level sender Pressure switch Battery GTH-1256 AF Part No. 57.4400.9219...
  • Page 121 September 2017 Section 7 • Schematics ELECTRICAL SCHEMATIC From SN GTH12AFM-101 Sheet 1 of 11 Part No. 57.4400.9219 GTH-1256 AF...
  • Page 122 Section 7 • Schematics September 2017 ELECTRICAL SCHEMATIC From SN GTH12AFM-101 Sheet 2 of 11 GTH-1256 AF Part No. 57.4400.9219...
  • Page 123 September 2017 Section 7 • Schematics ELECTRICAL SCHEMATIC From SN GTH12AFM-101 Sheet 3 of 11 Part No. 57.4400.9219 GTH-1256 AF...
  • Page 124 Section 7 • Schematics September 2017 ELECTRICAL SCHEMATIC From SN GTH12AFM-101 Sheet 4 of 11 GTH-1256 AF Part No. 57.4400.9219...
  • Page 125 September 2017 Section 7 • Schematics ELECTRICAL SCHEMATIC From SN GTH12AFM-101 Sheet 5 of 11 Part No. 57.4400.9219 GTH-1256 AF...
  • Page 126 Section 7 • Schematics September 2017 ELECTRICAL SCHEMATIC From SN GTH12AFM-101 Sheet 6 of 11 GTH-1256 AF Part No. 57.4400.9219...
  • Page 127 September 2017 Section 7 • Schematics ELECTRICAL SCHEMATIC From SN GTH12AFM-101 Sheet 7 of 11 Part No. 57.4400.9219 GTH-1256 AF...
  • Page 128 Section 7 • Schematics September 2017 ELECTRICAL SCHEMATIC From SN GTH12AFM-101 Sheet 8 of 11 7-10 GTH-1256 AF Part No. 57.4400.9219...
  • Page 129 September 2017 Section 7 • Schematics ELECTRICAL SCHEMATIC From SN GTH12AFM-101 Sheet 9 of 11 Part No. 57.4400.9219 GTH-1256 AF 7-11...
  • Page 130 Section 7 • Schematics September 2017 ELECTRICAL SCHEMATIC From SN GTH12AFM-101 Sheet 10 of 11 7-12 GTH-1256 AF Part No. 57.4400.9219...
  • Page 131 September 2017 Section 7 • Schematics ELECTRICAL SCHEMATIC From SN GTH12AFM-101 Sheet 11 of 11 Part No. 57.4400.9219 GTH-1256 AF 7-13...
  • Page 132 Section 7 • Schematics September 2017 This page intentionally left blank. 7-14 GTH-1256 AF Part No. 57.4400.9219...
  • Page 133 Section 7 • Schematics September 2017 Hydraulical Schematic - Perkins Engine 7-15 7-16...
  • Page 134 Mechanical gearbox displacement: 1.53 i c /rev (2 speeds) Flushing valve Shutoff valve Shutoff valve Hydraulic fluid Hydrostatic transmission charge pump displacement: 1.20 i c /rev tank (capacity: 53 USG) Suction screen Suction screen 7-16 GTH-1256 AF Part No. 57.4400.9219...

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