Rev September 2016 - June 2017

GTH-1544 (Perkins Tier 4i)
Serial Number Range:
From GTH1513B-001 To GTH1515B-339
From GTH1516M-340 To GTH1516M-599
From GTH15M-600

GTH-1544 (Deutz Tier 4i)
Serial Number Range:
From GTH1513B-001 To GTH1515B-339 plus 24273
From GTH1516M-340 To GTH1516M-599
From GTH15M-600

Content for Service Manual:
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 Component Specifications
Function Manifold Specifications
Air Conditioner Refrigerant Specifications
Perkins 1204E-E44TA Engine
Deutz TCD 4.1 L4 Engine
Dana Integral Gear Box Shift on Fly
Dana Axle
Hydraulic Hose and Fitting Torque Specifications
Torque Procedure
SAE and Metric Fasteners Torque Charts

Section 3. REPAIR PROCEDURES
Introduction
Boom Components
1-1 Boom Proximity Switch
1-2 Boom
1-3 Boom Lift Cylinder
1-4 Boom Extend Cylinder
Repair Procedures, continued
1-5 Fork Level Cylinder
1-6 Fork Tilt Cylinder
Operators compartment
2-1 Operators Compartment
2-2 Machine Controls
Fuel and Hydraulic Tanks
3-1 Fuel and hydraulic tanks
Engines
4-1 Engines
4-2 Engine Fault Codes
Transmission
5-1 Gearbox
5-2 Axle
Hydraulic pumps
6-1 Boom and Steering Function Pump
6-2 Auxiliary Gear Pump
6-3 Hydrostatic Transmission Pump
Manifolds
7-1 Function Manifold
7-2 Valve coils

Section 4. FAULT CODES
Introduction
Diagnostic Display
Engine Fault Codes - Models with Deutz TCD 4.1 L4
How to Troubleshoot the Perkins 1204E-E44TA Engine

Section 5. SCHEMATICS
Introduction
Electrical and Hydraulic Symbol Legends
Electrical Schematic
Hydraulic Schematic - Deutz Engine
Hydraulic Schematic - Perkins Engine
___________________

Content for Parts List Manual:
How to Read Your Serial Number
Parts Stocking List
How to Order Parts
Service Parts Fax Order Form

100 Decals
101.1 607520 Decals, View 1
102.1 607521 Decals, View 2

200 Drive Chassis Components
201.1 607522 Rear Chassis
202.1 607523 Left Chassis
203.1 607524 Right Chassis
204.1 607525 Hydraulic Oil And Diesel Tanks
205.1 607526 Drive Chassis And Wheels
206.1 607527 Front Axle - Differential
207.1 607528 Front Axle - Brakes
208.1 607529 Front And Rear Axle - Central Housing
209.1 607530 Front And Rear Axle - Hub Reduction
210.1 607531 Front And Rear Axle - Steering Cylinder
211.1 607532 Front And Rear Axle - Trunion
212.1 607533 Front And Rear Axle - Gear Box
213.1 607534 Rear Axle - Differential
214.1 607535 Rear Axle - Brakes

300 Engine Components
301.1 607537 Diesel Engine - Deutz Version
302.1 607538 Diesel Engine - Perkins Version
303.1 607539 Air Filter
304.1 607540 Fuel Circuit - Deutz Version
305.1 607541 Fuel Circuit - Perkins Version
306.1 607542 Exhaust System - Deutz Version
307.1 607543 Exhaust System - Perkins Version
308.1 607544 Cooling System, Radiator - Deutz Version
309.1 607545 Cooling System, Radiator Hoses - Deutz Version
310.1 607546 Cooling System, Radiator - Perkins Version
311.1 607547 Cooling System, Radiator Hoses - Perkins Version
312.1 607548 Hydraulic Pumps

400 Cab Components
401.1 607550 Cab, View 1 - Standard Version
402.1 607551 Cab, View 2 - Standard Version
403.1 607552 Cab, View 3 - Standard Version
404.1 607553 Cab, View 1 - Close Version
405.1 607554 Cab, View 2 - Close Version
406.1 607555 Cab, View 3 - Close Version
407.1 607556 Cab, View 4 - Close Version

500 Boom Components
501.1 607560 1st Telescopic Element
502.1 607561 2nd - 3rd Telescopic Element
503.1 607562 Chain Unit
506.1 607565 Lifting Cylinder - Extension Cylinder
507.1 607566 Forks Tilt Cylinder - Forks Level Slave Cylinder
508.1 607567 Left & Right Chassis Sway Cylinder - Rear Axle Locking Cylinder
510 Fork and Frame Components
510.1 607563 Coupling Unit
510.2 607564 Fork Frame
510.3 607595 Fork Frame, Rotate Attachment
510.4 607596 Truss Boom 7 Feet, 4,400 LBS
510.5 607597 Truss Boom 14 Feet, 2,000 LBS
510.6 607598 Rubbish Bucket

600 Hydraulic System
601.1 607570 Boom Extension Cylinder
602.1 607571 Forks Tilt Cylinder - Forks Level Slave Cylinder
603.1 607572 Attachment Hydraulic Circuit
604.1 607573 Chassis Sway Cylinder
605.1 607574 Rear Axle Lock Cylinder
606.1 607575 Boom Lift Cylinder
607.1 607576 Power Steering
608.1 607577 Service Brake
609.1 607578 Parking Brake
610.1 607579 Gear Box
611.1 607580 Hydraulic Oil Radiator
612.1 607581 Hydraulic Oil Radiator Circuit
613.1 607582 Hydraulic Pumps - Deutz Version
614.1 607583 Hydraulic Pumps - Perkins Version
615.1 607584 Boom Hydraulic Control
616.1 607585 Transmission
617.1 607586 Primary Functions Manifold
619.1 607587 Auxiliary Functions Manifold

700 Electric Installation
701.1 607590 Cabin Fuse-Relay Box
702.1 607591 Dashboard
703.1 607592 Wirings - View 1
704.1 607593 Wirings - View 2

800 Optionals
801.1 607599 Air Conditioning - Deutz Engine - Part 1
802.1 607600 Air Conditioning - Perkins Engine - Part 1
803.1 607601 Air Conditioning - Part 2
804.1 607602 Air Conditioning - Part 3
805.1 607605 Hydraulic Quick Coupling - Part 1
806.1 607606 Hydraulic Quick Coupling - Part 2
807.1 607612 Rear Video Camera
808.1 607613 Telematics
809.1 607608 Road Lights - Part 1
810.1 607609 Road Lights - Part 2
811.1 607610 Work Lights - Part 1
812.1 607611 Work Lights - Part 2

Indices
Part Number Index
Part Description Index
Cross References
Fittings Cross Reference
Part