Rev A2, April 2017

Serial Number Range:
from GTH0813-16606 to GTH0816-21572
from GTH0816E-10000 to GTH0816E-10699
from GTH08E-10700

Content:
INTRODUCTION
Important Information
Find a Manual for this Model
Serial Number Legend

Section 1. SAFETY RULES
General Safety Rules

Section 2. SPECIFICATIONS
Machine Specifications
Performance Specifications
Hydraulic Oil Specifications
Hydraulic Component Specifications
Manifold Component Specifications
Air Conditioner Refrigerant Specifications
DEF Storage Specifications
Deutz TCD3.6 L4 Engine Specifications
Deutz TCD3.6 L4 T4F Engine Specifications
Perkins 1104D-E44TA Engine Specifications
Perkins 854E-E34TA Engine Specifications
Dana VDT12000 Transmission Specifications
Carraro 26.27M Drive Axle Specifications
Hydraulic Hose and Fitting Torque Specifications
Torque Procedure

Section 3. REPAIR PROCEDURES
Introduction
Boom Components
1-1 Boom Proximity Switch
How to Test a Proximity Switch
How to Adjust the Boom Angle Proximity Switch
1-2 Boom
How to Replace the Boom Wear Pads
How to Remove the Lifting Fork Frame
How to Replace the Retraction Chain
How to Replace the Extension Chains
How to Remove the Boom
How to Disassemble the Boom
1-3 Boom Lift Cylinder
1-4 Boom Extension Cylinder
1-5 Fork Level Cylinder
1-6 Hydraulic Hoses
How to Adjust the Fork Level Cylinder and/or Auxiliary Hose
How to Replace the Fork Level Cylinder and/or Auxiliary Hoses
Operators Compartment
2-1 Operators Compartment
2-2 Machine Controls
How to Remove the Steering Column
How to Remove the Steering Wheel
How to Remove the Steer Orbitral
How to Remove the Joystick - Models with Single Joystick
How to Remove the Joystick - Models with Dual Joysticks
How to Remove the Brake Pedal Assembly
How to Remove the Gauge Cluster Assembly
Fuel and Hydraulic Tanks
3-1 Fuel and Hydraulic Tanks
Engines
4-1 Engines
How to Repair the Perkins 1104D-E44TA Engine
How to Repair the Perkins 854E-34TA Engine
How to Repair the Deutz TCD3.6 Engine
4-2 Engine Fault Codes
Transmission
5-1 Transmission
Hydraulic Pump
6-1 Hydraulic Pump
How to Test the Function Pump
How to Remove the Function Pump
How to Install the Function
How to Prime the Function Pump
How to Adjust the Function Pump Standby Pressure
How to Adjust the Function Pump Pressure Compensator
Manifolds
7-1 Primary Function Manifold Components - Models with Single Joystick
7-2 Primary Function Manifold Components - Models with Dual Joysticks
7-3 Secondary Function Manifold Components
7-4 Auxiliary Manifold (option) and Brake Manifold Components
7-5 Valve Adjustments - Secondary Function Manifold
How to Set the Steer System Pressure
How to Set the Parking Brake System Pressure
How to Set the Differential Lock/Joystick System Pressure
How to Set the Rear Lock-up System Pressure
7-6 Valve Coils
Axle
8-1 Axles

Section 4. FAULT CODES
Introduction
Diagnostic Display
Diagnostic Display
Deutz TCD3.6 Engine Fault Codes
Perkins 1104 Engine Fault Codes

Section 5. SCHEMATICS
Introduction
Fuse Panel Layout (to 20629)
Fuse Panel Layout (from 20630 to 21535)
Deutz TCD3.6 T4F Module (from 21536, 16E-10000)
Electrical Component & Wire Color Abbreviation Legend
Telematics Connector Pin Legend
Electrical Symbol Legend
Hydraulic Symbols Legend
Electrical Schematics - Harness Maps
Harness Map - Control System Power Single Joystick (to 15-20661)
Harness Map - Control System Ground Single Joystick (to 15-20661)
Harness Map - Control System Power Single Joystick (from 15-20662 to 21535)
Harness Map - Control System Ground Single Joystick (from 15-20662 to 21535)
Harness Map - Control System Power Single Joystick (from 15-21536, 16E-10000)
Harness Map - Control System Ground Single Joystick (from 15-21536, 16E-10000)
Harness Map - Control System Power Dual Joystick (to 15-20661)
Harness Map - Control System Ground Dual Joystick (to 15-20661)
Harness Map - Control System Power Dual Joystick (from 15-20662 to 21535)
Harness Map - Control System Ground Dual Joystick (from 15-20662 to 21535)
Harness Map - Control System Power Dual Joystick (from 15-21536, 16E-10000)
Harness Map - Control System Ground Dual Joystick (from 15-21536, 16E-10000)
Harness Map - Deutz TCD3.6 T3_T4i Engine Battery Power and Ground
Harness Map - Deutz TCD3.6 T4F Engine Battery Power and Ground
Harness Map - Perkins 1104D Engine Battery Power and Ground
Harness Map - Perkins 854E T4i Engine Battery Power and Ground
Harness Map - Perkins 854E T4i Engine Battery Power and Ground
Harness Map - Options Auxiliary Hydraulics, Beacon and 3rd Gear Lockout
Harness Map - Options Work Lights (to 15-21456)
Harness Map - Options Work Lights (from 15-21457, 16E-10000)
Harness Map - Options Road Lights (to 15-20456)
Harness Map - Options Road Lights (from 15-21457, 16E-10000)
Harness Map - Options Enclosed Cab with Heater
Harness Map - Options Enclosed Cab with HVAC
Electrical Schematics
Electrical Schematic - View 1 (to 15-20661)
Electrical Schematic - View 2 (to 15-20661)
Electrical Schematic - View 1 (from 15-20662 to 21456)
Electrical Schematic - View 2 (from 15-20662 to 21456)
Electrical Schematic - View 1 (from 15-21457 to 21535)
Electrical Schematic - View 2 (from 21457 to 21535)
Electrical Schematic - View 1 (from 15-21536, 16E-10000)
Electrical Schematic - View 2 (from 21536, 16E-10000)
Hydraulic Schematics
Hydraulic Schematic - Single Joystick (to 19528)
Hydraulic Schematic - Single Joystick (from 19529, 16E-10000)
Hydraulic Schematic - Dual Joystick (to 19528)
Hydraulic Schematic - Dual Joystick (from 19529, 16E-10000)