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