Page 1 AL 140 (SN 11257 and Up) Form No. AL 240(EU) 918496 GP0313 English (SN 21244 and Up) Revision G AL 340 Original Instructions ––– (SN 31365 and Up) Supersedes AL 440(EU) 918447 (SN 41250 and Up) AL 540 (SN 51242 and Up) Articulated Loaders https://tractormanualz.com/...
Page 2 6. Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment. No agent, employee or representative of Gehl has any authority to bind Gehl to any warranty except as specifically set forth herein. 204927/AP0407 ®...
Page 3: Table Of Contents
AL 140, AL 240 (EU), AL 340, AL 440 (EU), AL 540 Articulated Loaders Operator’s Manual TABLE OF CONTENTS General Information ........1 Safety Symbol.
Page 4 Specifications ........31 Fluid Capacities/Lubricants.
Page 5 Steering Column Adjustment......60 Control Lever........61 Hand Throttle.
Page 6 Scraping Hard Material .......93 Towing the Loader ........94 Precautions.
Page 7 Filter Replacement ....... . 120 Windshield Washer Reservoir (Cab Only)....121 Hydraulic System Maintenance .
Page 8 Before Disposal ........145 Machine Disposal ........146 Maintenance Log .
Page 9: General Information
CHAPTER 1 GENERAL INFORMATION Safety Symbol Manitou Americas, in cooperation with the Society of Auto- motive Engineers, as adopted this safety alert symbol. This symbol identifies potential safety hazards, which, if not properly avoided, could result in injury. When you see this symbol in this manual or on the machine, your are reminded to BE ALERT! Your personal safety is involved! Contents and Use of this Manual...
Page 10: Ownership Change
Ownership Change If the machine is resold, include this operator’s manual as part of the sale. If the machine was purchased “used,” or if the owner’s address has changed, please provide your dealer or Manitou Americas Service Department with the owner’s name and current address, along with the machine model and serial numbers.
Page 11: Serial Number Plate Location
Max speed Year of Construction Figure 2 – Serial Manufactured by Manitou Americas, Inc. One Gehl Way Number Plate West Bend, WI 53095-0179 USA Additionally, the following components also have identification placards: • Engine • Hydraulic pump • Hydraulic drive motor(s) •...
Page 12: Proper Machine Use
Proper Machine Use Improper use of the machine can result in WARNING property damage, injury or death. The machine is designed only for digging, picking up, lifting, transporting and unloading materials. Use with approved attachments is also allowed. Use in any other way is considered as contrary to the intended use.
Page 13: Component Identification
Component Identification Figure 3 – Component Identification (AL 500 Series Model Shown) 1. Engine cover 7. Manual storage box 2. Multi-purpose joystick 8. Parking brake (left side) 3. Steering column 9. Fuel filler neck 4. Road lights (4 locations) 10. All-Tach ®...
Page 14: Service/Dealership Network
Service/Dealership Network Your dealership network stands ready to provide any assistance that may be required, including providing genuine service parts. All service parts should be obtained from your dealer. Provide complete information about the part and include the machine model and serial numbers. Record these numbers in the spaces provided in “Loader Information”...
Page 15: Vibration Measurement And Actions
Vibration Measurement and Actions The vibration directive places the responsibility for compliance on employers. Actions that should be followed by employers include: • Assess the levels of vibration exposure. • Determine from this assessment if operators will be exposed to vibration levels above the limits stated in the directive.
Page 16 Notes 918496/GP0313 https://tractormanualz.com/...
Page 17: Safety
CHAPTER 2 SAFETY This manual and decals on the machine warn of safety hazards and should be read and observed closely. Before operating the machine, first read and study the safety information in this manual. Additionally, anyone who operates or works on the machine must be familiar with these safety precautions.
Page 18: 2-Post Rops/Fops Warning
Remember that some risks to our health may not be immediately apparent. Exhaust gases and noise pollution may not be visible, but these hazards can cause permanent injuries. Some photographs in this manual may show doors, guards and shields open or removed for the purposes of illustration only.
Page 19: Before Starting
Before Starting • Do not remove or modify the Roll-Over Protective Structure (“ROPS”) unless instructed to do so in approved installation instructions. Modifications, such as welding, drilling or cutting, can weaken the structure and reduce the protection it provides. A damaged ROPS cannot be repaired –...
Page 20: During Operation
• The operator’s area, steps and hand holds must be free of oil, dirt, ice and unsecured objects. • If a lighting system is installed, check its operation before working in darkness. • Always keep lights, mirrors and windows clean. Poor visibility can cause accidents.
Page 21 • Machine stability is affected by: the weight of the load being carried, height of the load, machine speed, turn angle, width of the machine across the tires, abrupt control movements and driving over uneven terrain. DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE MACHINE TO TIP, THROWING THE OPERATOR OUT OF THE SEAT OR MACHINE, RESULTING IN DEATH OR SERIOUS INJURY.
Page 22 • Be aware of overhead obstacles. Any object near the lift arm could represent a potential hazard, or cause the operator to react suddenly and cause an accident. Use a spotter or signal person when working near bridges, phone lines, work site scaffolds, or other obstructions. •...
Page 23: Provision For Stability/Avoiding Rollover Accidents
Provision for Stability/Avoiding Rollover Accidents • Machine stability is affected by: the weight and center of gravity of the load being carried, height of the load, machine speed, turn angle, width of the machine across the tires, abrupt control movements and driving over uneven and/or soft terrain.
Page 24: Electrical Energy
• The ROPS must be replaced if a overturn incident occurs. The protection offered by the ROPS will be impaired if it has been damaged in an overturn incident. • Never operate the machine without a ROPS or FOPS installed. Electrical Energy •...
Page 25 • Never use your hands to search for hydraulic fluid leaks. Instead, use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and can penetrate the skin and cause serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid must be surgically removed by a doctor or gangrene may result.
Page 26: Battery Hazards
• Do not run the engine if repairs are being performed alone. There should always be at least two people working together if the engine must be run during service. • Always use adequate tools while working on the machine. Inappropriate tools could break or slip, causing injury, or they may not adequately perform intended functions.
Page 27: Fire Hazards
• When disconnecting at the battery terminals, remove the cable connected to the negative terminal first. When installing a battery, connect the positive terminal cable first. • Sparks and open flames can set off explosive battery gas from incidental contact or static discharge. Turn off all switches and the engine when working on batteries.
Page 28: Crystalline Silica Exposure
• Oil leaks can ignite on hot components. Repair any damaged or leaking components before using machine. Crystalline Silica Exposure Exposure to crystalline silica (found in sand, soil and rocks) has been associated with silicosis, a debilitating and often fatal lung disease. A Hazard Review (Pub. No.
Page 29: Hazard And Hazard Avoidance Symbols
Hazard and Hazard Avoidance Symbols Injected Fluid Safety Hazard Fire Hazard Run-Over Hazard Hot Liquids Hazard Hazard Poisonous Vapors Read Operator’s Wear Seatbelt No Open Flames No Smoking Hazard Manual Keep Distance Remove Key Crush Hazard Avoid Power Lines Wear Eye Protection Read Maint- Safety Lock...
Page 30: Safety Decals
Safety Decals The machine has decals around the machine that provide safety information and precautions. These decals must be kept legible. If missing or illegible, they must be replaced promptly. Replacements can be obtained from your dealer. Refer to the Parts Manual for decal part numbers and ordering information. New Decal Application Surfaces must be free of dirt, dust, grease and foreign material before applying the decal.
Page 31 ANSI-Style and Common Safety Decal Locations (Cont.) Note: Refer to Fig. 4 for decal locations. Lift Point Decal • Located at the rear of the machine and near the lift holes/rods near the top of the front frame. • Apply lift hooks only in these location See “Crane Lifting”...
Page 32 Note: Refer to Fig. 4 on page 22 for decal locations. WARNING: Crush Hazard • Located on both side of the lift arm. • Before operating, verify full engagement of loader attachment bracket locking pin to the attachment. USE HYDRAULIC FLUID ONLY! Located next to the hydraulic fluid reservoir filler neck.
Page 33 ANSI-Style and Common Safety Decal Locations (Cont.) Note: Refer to Fig. 4 on page 22 for decal locations. IMPORTANT • Located on top of the radiator inside the engine compartment. • Do not use ether or other starting fluids to start this engine —...
Page 34 Note: Refer to Fig. 4 on page 22 for decal locations. Located on the control column, facing the operator. WARNING: Avoid Injury or Death • Maintain 3-point contact during entry and exit. • Inspect work area; avoid all hazards. • Look in the direction of travel. Keep children and bystanders away.
Page 35: Iso-Style Safety Decal Locations
ISO-Style Safety Decal Locations RIGHT LEFT CONTROL BACK COLUMN INSIDE ENGINE COMPARTMENT Figure 5 – ISO-Style Safety Decal Locations (AL 500 Series Shown — Other Series Similar) Note: Refer to Fig. 5 for decal locations. WARNING: Crush Hazard • Located on top of the articulation joint on both sides.
Page 36 Note: Refer to Fig. 5 on page 27 for decal locations. WARNING: Rotating Fan / Hot Surface Hazards • Located on the right side of the firewall inside the engine compartment; on machines with air conditioning, located on the back of the air conditioning enclosure.
Page 37 ISO-Style Safety Decal Locations (Cont.) Note: Refer to Fig. 5 on page 27 for decal locations. General Operating Warnings • Located on the left side of the control column. A) Crush hazard / Keep out from under lift arm unless lift arm is supported. B) Side tip hazard / Avoid steep slopes and high-speed turns.
Page 38 Note: Refer to Fig. 5 on page 27 for decal locations. General Operating Warnings • Located on the control column, facing the operator. A) Check machine before operating. Service according to Operator’s Manual. Contact dealer (or manufacturer) for information and service parts. B) Maintain 3-point contact during entry and exit.
Page 39: Specifications
CHAPTER 3 SPECIFICATIONS Fluid Capacities/Lubricants AL 300 AL 200 AL 100 500/400 Series Series Series Series Diesel Engine Oil API CD or Higher (United States) Specification ACEA E-3, E-4, E-5 (European Union) SAE 10W-30: -20°C (-4°F) to 30°C (86°F) Season/Temp. SAE 15W-40: -15°C (5°F) to 40°C (104°F) Range SAE 20W-50: -10°C (14°F) to 50°C (122°F)
Page 40: Maximum Slopes Of Engine Operation
AL 300 AL 200 AL 100 500/400 Series Series Series Series Axle Oil 0.4 L (0.4 qt.) UTTO Hubs (each) Fluid (Mobil 424 or equivalent) 2.5 L (2.6 qt.) UTTO Front Center Fluid (Mobil 424 or 3.78 L (4 qts.) 75W90 equivalent) gear oil or UTTO Fluid 3.2 L (3.4 qt.) UTTO...
Page 41: Sae (Domestic) Weights And Capacities Al 500 And Al 300 Series
SAE (Domestic) Weights and Capacities AL 500 and AL 300 Series kg (lbs.) AL 500 Series AL 300 Series Description 2-Post 4-Post 2-Post 4-Post ROPS ROPS ROPS ROPS 3307 3357 3452 2472 2520 2649 Operating Weight (7290) (7400) (7610) (5450) (5555) (5840) 3182...
Page 42: Iso 6016 (Eu) Weights And Capacities Al 500, Al 400 And Al 300 Series
ISO 6016 (EU) Weights and Capacities AL 500, AL 400 and AL 300 Series kg (lbs.) AL 500 Series AL 300 Series Description 400 Series 2-Post 4-Post 2-Post 4-Post 2-Post 4-Post ROPS ROPS ROPS ROPS ROPS ROPS 3307 3106 3502 2740 2790 2360...
Page 43: Sae (Domestic) Weights And Capacities
SAE (Domestic) Weights and Capacities AL 100 Series kg (lbs.) AL 100 Series Description 2-Post 4-Post ROPS ROPS 1744 1774 Operating Weight (3845) (3910) 1651 1681 Shipping Weight (3640) (3705) Rated Operating Capacity 1, 2 (960) (960) Static Tipping Loads Standard Bucket - Straight (1924)
Page 44: Iso (Eu) Weights And Capacities Al 100 And Al 200 Series
ISO (EU) Weights and Capacities AL 100 and AL 200 Series kg (lbs.) AL 200 Series AL 100 Series Description 2-Post 4-Post 2-Post 4-Post ROPS ROPS ROPS ROPS 2108 2169 1690 1721 Operating Weight (4647) (4782) (3728) (3794) 1994 2055 1534 1564 Shipping Weight...
Page 45: Engine
Engine AL 500/ AL 300 AL 200 AL 100 AL 400 Series Series Series Series Manufacturer Yanmar 4-cylinder, 4- cycle, In-line, 3-cylinder, 4-cycle, In-line, Water-cooled Type Water-cooled Diesel Diesel 4TNV88- 3TNV76- Engine Model 3TNV88-BKGWL BKGWL KGWL 2190 cc 1116 cc (68.1 Displacement 1642 cc (100.2 cid) (133.6 cid)
Page 46: Hydraulics
Hydraulics AL 500/ AL 300 AL 200 AL 100 AL 400 Series Series Series Series Auxiliary Hydraulics (at 100% theoretical flow) Hydraulic 57 L/min 45 L/min 30 L/min System (14 gpm) (12 gpm) (8 gpm) System 207 bar 193 bar Pressure (3000 psi) (2800 psi)
Page 47: Wheel/Tire Sets
Wheel/Tire Sets Machine Width Description Model Millimeters (Inches) 27x8.50-15, 8-ply AL 100 Series 1044 (41.1) 27x10.50-15, 8-ply AL 100 Series 1049 (41.3) 27x10.50-15, 10-ply (turf) AL 100 Series 1049 (41.3) 30.5x12.5-16.5, 8-ply AL 300 Series 1280 (50.4) 10x16.5, 8-ply AL 300 Series 1280 (50.4) 29x12.5-15 8-ply (turf) AL 300 Series...
Page 48: Rops And Fops
ROPS and FOPS FOPS Rating Level 1 Vibration Levels AL100 AL200 AL300 AL400 AL500 Whole Body < 1.03 m/s² < 0.89 m/s² < 0.75 m/s² < 0.88 m/s² < 0.82 m/s² Vibration (+ 0.41k) (+ 0.45k) (+ 0.38k) (+ 0.44k) (+ 0.41k) (ISO 2631-1) m/s Hand-Arm Vibra-...
Page 49: Al 500, Al 400 Series Dimensions
AL 500, AL 400 Series Dimensions 400 Series 918496/GP0313 https://tractormanualz.com/...
Page 50 AL 500, AL 400 Series Dimensions Millimeters (Inches) unless otherwise noted AL 500 Series AL 400 Series Description Ref. 4-Post 2-Post 2-Post 4-Post ROPS/ ROPS ROPS ROPS Length with Bucket on Ground 4511 (177.6) 4224 (166.3) Shipping Length (without 3790 (149.2) 3550 (139.8) bucket) Front Wheel Center to Pivot...
Page 51: Al 300, Al 200 Series Dimensions
AL 300, AL 200 Series Dimensions 918496/GP0313 https://tractormanualz.com/...
Page 52 AL 300, AL 200 Series Dimensions Millimeters (Inches) unless otherwise noted AL 300 Series AL 200 Series 2-Post 4-Post 2-Post 4-Post ROPS ROPS ROPS ROPS Ref. Description /Cab Length with Bucket on Ground 4050 (159.4) 4040 (159.1) Shipping Length (without bucket) 3351 (131.9) Front Wheel Center to Pivot Pin 517 (20.4)
Page 53: Al 100 Series Dimensions
AL 100 Series Dimensions 918496/GP0313 https://tractormanualz.com/...
Page 54 AL 100 Series Dimensions Millimeters (Inches) unless otherwise noted Ref. Description 2-Post ROPS 4-Post ROPS Length with Bucket on Ground 3419 (134.6) Shipping Length (without bucket) 2741 (107.9) Front Wheel Center to Pivot Pin 489 (19.3) Wheelbase 1348 (53.1) Rear Overhang 738 (29.1) Height to Top of ROPS/Cab 2340 (92.1)
Page 55: Standard Features
Standard Features • Fuel Level Gauge • Front Auxiliary Hydraulics with Flat-face Couplers • Hourmeter • Dual-Element Air Cleaner with Visual Indicator • Hydraulic Oil Filter Indicator Lamp • Pre-heat Starting Assist (AL 500, AL 400 and AL 300 Series •...
Page 56: Optional Features
Optional Features • Three-inch Wide Seat Belt (Where • Backup Alarm Required by State Law) • Battery Disconnect Switch Kit • Strobe Light Kit • Engine Block Heater • Road Lights (Standard with Cab) • Radio (AL 500 and AL 300 Series; •...
Page 57: Common Materials And Densities
Common Materials and Densities Density Material lbs./ft. kg/m Ashes 35-50 560-800 Brick-common 1792 Cement 1760 Charcoal Clay, wet-dry 80-100 1280-1600 Coal 53-63 848-1008 Concrete 1840 Cinders Coal-anthracite 1504 Coke Earth-dry loam 70-90 1121-1442 Earth-wet loam 80-100 1281-1602 Granite 93-111 1488-1776 Gravel-dry 1602 Gravel-wet...
Page 58 Notes 918496/GP0313 https://tractormanualz.com/...
Page 59: Operation
CHAPTER 4 OPERATION Read and understand this entire manual. WARNING Follow warnings and instructions for operation and maintenance. Failure to follow instructions can result in injury or death. Read and understand all safety and instructional decals before operation. Do not operate the machine unless all guards and shields are in place.
Page 60: Operating Controls
Operating Controls Controls and Switches OPTION Located Located Inside Behind Joy- Engine Com- stick partment Note: Controls 11, 12, 13 and 17 are located on the steering column, below instrument panel 2. 918496/GP0313 https://tractormanualz.com/...
Page 61 No. Item Description Steering knob Use to turn steering wheel. Instrument panel Contains warning indicators, operation indicators, and gauges (page 54). Steering wheel Turn to control travel direction. Accelerator pedal Press to control engine/travel speed. Multi-purpose joy- Use to control lift arm/attachment maneuvering and loader stick drive direction (page 78).
Page 62: Instrument Panel And Indicators
Instrument Panel and Indicators 3/15 AL 100 Series, AL 200 Series Standard AL 500, AL 400, AL 300 Series; AL 100 (EU), AL 200 Series Optional 918496/GP0313 https://tractormanualz.com/...
Page 63 Indicator Description Forward travel Drive direction thumb switch on joystick is in forward posi- tion (page 68) – the machine will move forward when the travel pedal is pressed when this lamp is lit. Pre-heat Illuminates when the ignition key is in the “I” (Run) position, goes out when engine pre-heat is complete (page 68).
Page 64: Cab Controls (Cab Only)
Cab Controls (Cab only) Cab Environment Controls To operate the cab heater and air circulation fan: 1. Move lever (C, Fig. 6) rearward to increase heat; forward to reduce heat. 2. Turn the fan control (D, Fig. 6) clockwise to increase circulation fan speed;...
Page 65: Cab Windshield Wiper
Cab Windshield Wiper Controls Press the icon side of the wiper switches to the first detent to activate the wiper blades. Press the icon side of the switches past the detent to activate the washer fluid. E: Activates the front wiper and washer. F: Activates the rear wiper and washer.
Page 66: Warning Indicators
Warning Indicators Important: If any of the following indicators illuminate when the engine is running, turn off the engine immediately. Correct the problem before re-starting the engine. During normal operation these indicators should be OFF . AL 100. AL 200 Series AL 500, AL 400, AL 300 Series;...
Page 67: Operator's Seat Adjustment
Operator’s Seat Adjustment Never adjust the operator’s seat when the WARNING engine is running. Adjust the operator’s seat so all controls are easy to reach and the pedals can be completely depressed with your back against the seat back. A. Forward/rearward adjust- AL 500, AL 400 Series ment: Pull the lever up, adjust the seat and release...
Page 68: Seat Belt
Seat Belt Always fasten the seat belt securely and WARNING properly. Never operate the machine without the seat belt fastened around the operator. Important: Inspect the seat belt for damage before use. Replace if damaged. Keep the seat belt (E, Fig. 12) clean. Use only soap and water to wash seat belt. Cleaning solvents can damage seat belt.
Page 69: Control Lever
Control Lever (AL 300, AL 400, AL 500 Series; AL 100 (EU), AL 200 Series Optional) The control lever on the steering column controls the following functions: 1. Push the control lever in to activate the horn (K, Fig. 15). 2.
Page 70: 12V Accessory Power Outlet
12V Accessory Power Outlet Use the 12V accessory power outlet (S, Fig. 17), on the steering column. See “Battery” on page 141 for fuse and amperage information. Figure 17 – Electric Socket 918496/GP0313 https://tractormanualz.com/...
Page 71: Operation
Operation Pre-Operation Checklist Check the following before starting the machine (for all fluid level checks, fill if required): • Fuel, hydraulic, radiator, and engine oil caps for tightness. • Fluid leaks: fuel, hydraulic oil, engine oil, coolant, etc. • Radiator coolant level. See “Fluid Capacities/Lubricants” on page 31 for proper mixture.
Page 72: Extend The Rops
Extend the ROPS If the machine is equipped with a folding 2-Post WARNING ROPS, only fold the ROPS temporarily if necessary during transport or if necessary for use inside structures with low overhead doors or clearances. Operating with the ROPS folded back increases the risk of injury or death if a roll-over would occur.
Page 73: 4-Post Rops Side Gates (Option)
4-Post ROPS Side Gates (Option) Optional side gates for the 4-Post ROPS 100 Series provide operator additional protection. 200/300/400/500 Series Figure 20 – 4-Post ROPS Side Gates To open the side gates, lift latch (Y). When closing, pull side gates in until they latch securely.
Page 74: Entering And Exiting
Entering and Exiting Maintain WARNING NOTE: Photos may not three-point exactly match all machines contact and face the machine at all times when entering and exiting. Do not use the steering 2-Post ROPS wheel for entry or exit. Never jump from the machine. Never enter or exit a moving machine.
Page 75: Engine Start
Engine Start Important: The machine cannot be tow-started because there is no direct mechanical connection between the wheels and the engine. Attempting to tow- start the machine can damage the drive system. Always fasten the seat belt before operating WARNING the machine.
Page 76 5. Place forward/reverse drive switch Forward (Fig. 25) on the top of the joystick into the neutral position. Forward Neutral Reverse Figure 25 – Drive Direction 6. Turn the ignition key to the “I” (Run) position (Fig. 26). 7. When the pre-heat indicator light (B, Fig.
Page 77: Engine Shut Down
Engine Shut Down 1. Perform the “Mandatory Safety Shutdown Procedure” on page 10. 2. Perform a visual inspection: • Hydraulic system leaks? • Coolant system leaks? • Fuel system leaks? • Damage to machine (tires, attachment hitch, attachment, etc.)? 3. Completely fill the fuel tank. Warm-up On AL 300 Series machines, the parking VERY IMPORTANT!
Page 78: New Machines
New Machines 1. After starting the engine for the first time, let the engine idle for 15 minutes. 2. After 15 minutes, perform the “Mandatory Safety Shutdown Procedure” on page 10. 3. Check for proper engine oil pressure, engine oil level, diesel fuel leaks, engine oil leaks, coolant leaks, and indicator/gauge operation.
Page 79 b. Perform the “Mandatory Safety Shutdown Procedure” on page 10. c. Remove a spring pin (A, Fig. 30) from the end of the lift arm lock bar (B). Remove lift arm lock bar (B) from the storage bracket. d. Slide the lock bar (B) all the way through holes (C, Fig.
Page 80 d. Perform the “Mandatory Safety Shutdown Procedure” on page 10. e. Slide the down-stop lock bar (B) all the way through holes (C) in the frame, holes in the lift arm and holes (D) in the tilt pivot arm. f. Replace the lock pins (A) into both ends of the down-stop lock bar (B).
Page 81 5. On AL 500 Series machines: a. Remove the retainer (C, Fig. 30), and lift the cylinder stop channel (D) off the machine. Figure 30 – Tilt Lock Mechanism (AL 500 Series) b. Tilt the attachment/hitch back as required and place the cylinder stop channel (D) under tilt indicator (J) and over the tilt cylinder (E) to brace the tilt cylinder in the extended position.
Page 82: Lift Arm Down-Stop
Lift Arm Down-Stop The lift arm down stop is designed to limit lift arm downward travel. This feature is useful when changing tire sizes, or when driving the machine over long distances. 1. Empty the bucket (if applicable). 2. Position the lift arm above the down stop hole (A, Fig. 29) position where you want to limit travel, and also high enough to allow removal of the down-stop lock bar (B).
Page 83 Note: When the parking brake is engaged, Forward travel drive is disabled. 4. Use the drive direction switch to change Forward Neutral the loader drive direction. Note: The drive direction indicators should Reverse be lit when the drive direction switch is in forward and rearward positions.
Page 84: Slow/Fast Travel Speed Mode Selection
Slow/Fast Travel Speed Mode Selection (AL 300, AL 400, AL 500 Series) Machine stability is affected by machine speed, WARNING especially on rough or hilly terrain, while carrying heavy loads, and while carrying loads raised above the height of the wheel axles. Always operate the machine at speeds appropriate for the conditions, Move the controls smoothly and gradually.
Page 85: Load Handling
Load Handling Position the load as low as possible, especially WARNING while traveling. Never make turns with the load raised higher than the axles or tipping could occur, resulting in severe injury or death. Do not exceed the rated operating capacity of the machine. See weights and capacities information starting on page 33.
Page 86: Multi-Purpose Joystick
Multi-purpose Joystick Use the multi-purpose joystick to control lift arm/attachment hydraulic movements. Speed of movement is proportional to how far the joystick is moved and engine speed. Lift arm: A. Move the joystick rearward (A, Fig. 37, Fig. 38) to raise the lift arm.
Page 87: Feature
AL 100, AL 200(EU), AL 300, AL 400(EU) Self-Leveling Feature Figure 39 – Self- Leveling Feature The self-leveling feature maintains the attachment tilt angle as the lift arm is raised/lowered (Fig. 39) AL 500 Series Limited Self-Leveling Without self-leveling, unintentional dumping WARNING (tilting forward) of the attachment can occur when the lift arm is raised or lowered.
Page 88: Float Positions
Float Positions Never engage “float” with the lift arm raised. WARNING This will cause the lift arm to fall. Push the joystick past the first position and into front detent (E, Fig. 41, Fig. 42) and right detent (F) positions to activate the lift (E) and tilt (F) float functions. To disengage float functions, pull the joystick to center position.
Page 89: Attachments
Attachments General Instructions Use only approved attachments. Contact the WARNING Manitou Americas Service Department about information about approved attachments. Manitou Americas cannot be responsible if the machine is used with non-approved attachments. Read the operator’s manual provided with all attachments used with the machine before starting the engine. A loaded attachment changes the center-of-gravity of the machine.
Page 90: All-Tach® System Hitch Disconnection
4. Push the locking handles (K, Fig. 44) inward and downward until the attachment is locked onto the hitch as shown. 5. Check that the attachment is securely locked onto the hitch: the lip on the attachment must completely engaged over the top of the hitch, and the locking pins on the bottom of the hitch must be fully engaged down into the attachment.
Page 91: Hydraulic Power-A-Tach® System Hitch Connection
4. Tilt the hitch forward (see “Multi-pur- pose Joystick” on page 78) and back away from the attachment (Fig. 46). Figure 46 – Standard All-Tach ® System Hitch Removal Hydraulic Power-A-Tach ® System Hitch Connection The hydraulic Power-A-Tach system hitch ®...
Page 92 ® 3. Push the side of the Power-A-Tach system hitch lock switch (L, Fig. 48) to lock the attachment onto the hitch. a. AL 100 Series machines only: Press and hold the bottom auxiliary hydraulics control button (Z, Fig. 49) and then push the side of the Figure 48 –...
Page 93: Hydraulic Power-A-Tach® System Hitch Disconnection
Hydraulic Power-A-Tach ® System Hitch Disconnection Disconnect the auxiliary hydraulic connections CAUTION (see “Auxiliary Hydraulics” on page 86) before disconnecting the attachment from the Power-A-Tach system ® hitch. 1. Lower the attachment to the ground. See “Multi-purpose Joystick” on page 78. 2.
Page 94: Auxiliary Hydraulics
Auxiliary Hydraulics Auxiliary hydraulics are used for hydraulically-powered attachments. The auxiliary hydraulic circuit must be connected to hydraulically-powered attachments before the attachments can be used. Auxiliary Circuit Pressure Relief AL 100 Series Relieve pressure in the auxiliary hydraulic circuit before connecting / disconnecting hydraulically powered attachment hoses.
Page 95 For the following machines: • AL 100 Series - Serial Numbers 11479 and Before • AL 200 (EU) Series - Serial Number 21292 and Before • AL 300 Series - Serial Numbers 31821 and Before • AL 400 (EU) Series - Serial Numbers 41373 and Before •...
Page 96: Auxiliary Hydraulics Connections
Auxiliary Hydraulics Connections Important: Relieve pressure in the auxiliary hydraulic circuit before connecting / disconnecting hydraulically powered attachment hoses. See “Auxiliary Circuit Pressure Relief” on page 86. Important: Be sure that the hydraulic connections are clean. Hydraulic oil contamination can damage the hydraulic system. If a Power-A-Tach ®...
Page 97: Auxiliary Hydraulics Control Buttons
Auxiliary Hydraulics Control Buttons Auxiliary hydraulics fluid flow is controlled by two buttons (P , Fig. 56) on the front of the joystick. 1. Top Button: Press the top button to activate the auxiliary hydraulics flow in the direction opposite of when pressing the bottom button.
Page 98 Auxiliary Hydraulics Flow and Proportional Control For the following machines ONLY: • AL 100 Series - Serial Numbers 11480 and Up • AL 200 (EU) Series - Serial Number 21293 and Up • AL 300 Series - Serial Numbers 31822 and Up •...
Page 99 Depending upon the distance the pressure AL 100 Series relief control (K) is pulled up/pressed down controls the auxiliary hydraulics flow rate: the further the control is moved, the greater the flow rate. AL 200/300 Series AL 400/500 Series Figure 57 – Auxiliary Hydraulics Flow and Proportional Control 918496/GP0313 https://tractormanualz.com/...
Page 100: Operating Attachments
Operating Attachments Use only approved attachments. Contact the WARNING Manitou Americas Service Department about information about approved attachments. Manitou Americas cannot be responsible for safety if the unit is used with non-approved attachments. Some general guidelines for attachments are included in this section. These guidelines are not a replacement for the attachment manufacturer’s operating instructions.
Page 101: Scraping Hard Material
Scraping Hard Material 1. Lower the bucket onto the material. 2. Tilt the bucket forward to the desired digging angle. 3. Drive forward, press the bucket slightly downward so that the bucket pene- trates the material. Note: Avoid extreme tire slipping. 4.
Page 102: Towing The Loader
Towing the Loader Do not use the loader for towing (other WARNING vehicles, trailers, equipment, etc.). Important: The machine cannot be tow-started because there is no direct mechanical connection between the wheels and the engine. Attempting to tow- start the machine may damage the drive system. Precautions Only tow the loader if the steering and brakes are functional, if it cannot be repaired on-site, and if it cannot be transported using any other method.
Page 103: Towing Al 300 Series Machines
Towing AL 300 Series Machines Preparation 1. Perform “Mandatory Safety Shutdown Procedure” on page 10. 2. Disconnect hoses (B) and the electrical connector from the motor. Cap the ends of the Figure 59 – Hydraulic Motor hoses to prevent hydraulic Removal (AL 300 Series) fluid loss.
Page 104: Towing Procedure
Towing Procedure 1. Attach the tow bar/cable to the front/rear frame tie-down points or the tow hitch (Fig. 61 and Fig. 62) located at the rear of the loader. Important: Only use a tow bar or tow cable of sufficient capacity. 2.
Page 105: Loading And Transporting
Loading and Transporting Obey all applicable over-the-road regulations CAUTION when transporting machine. Check restrictions regarding weight, width and load length. The hauling vehicle, trailer and load must all be in compliance with regulations. Make sure the transport vehicle and the loading ramp are in proper working condition and have sufficient capacity for the load.
Page 106 11. Secure the machine to the transport AL 200/300 Series vehicle at the tie-down points (T, Fig. (AL 100 Series similar) 64 and U, Fig. 65) to prevent the machine from moving during trans- port in accordance with applicable over-the-road hauling regulations. AL 400/500 Series Figure 64 –...
Page 107: Crane Lifting
Crane Lifting Always close the cab doors (if applicable) and WARNING engine cover before lifting the machine with a crane. Stay clear from underneath the machine as it is lifted. Do not lift machine without proper equipment. The crane must have a capacity greater than WARNING the weight of the machine.
Page 108 AL 500, AL 400, AL 300 and AL 200 Series: 5. Connect spreader bar and chains to front and rear lift points as shown (Fig. 68). The spreader bar should be long enough to prevent the chains from rub- bing on the engine hood and the chains should be long enough to clear the ROPS structure.
Page 109 AL 100 Series: 1. Connect chains to lift points (B, Fig. 68) as shown. 2. Lift the machine as shown in Fig. 68. A. Chain B. Lift points (2) Figure 68 – Crane Lifting (AL 100 Series) 918496/GP0313 https://tractormanualz.com/...
Page 110 Notes 918496/GP0313 https://tractormanualz.com/...
Page 111: Maintenance
CHAPTER 5 MAINTENANCE Proper care and service improves machine operational readiness and service life. Perform maintenance as indicated in the “Maintenance Schedule” on page 104, or earlier if required by conditions. Read and understand the Safety Chapter, WARNING starting page 9, before servicing machine.
Page 112: Maintenance Schedule
Maintenance Schedule Use the following table with the procedures included in the this chapter, beginning on page 103. For new machine operating guidelines, see “New Machines” on page 70. Important: The following maintenance intervals apply to average operating conditions and loads. Under extreme operating conditions, more frequent maintenance may be required.
Page 113: Leakage Check
Check, Clean and Inspect Maximum Interval 250 Hours 50 Hours 500 Hours Service Procedure 10 Hours (or every Monthly (or daily) weekly) annually) months) Check coolant system for leaks, dirt and debris; hoses for cracks/damage Check battery electrolyte level (if applicable) Check engine and engine mounts Check for hydraulic system...
Page 114: Lubrication And Filter Changes
Lubrication and Filter Changes Maximum Interval 1500 Hours Service Procedure Hours Hours Hours Hours Monthly (or every (or daily) weekly) annually) annually) months) Lubricate grease zerks according to lubrication diagram Lubricate all levers, cables and hinges with Lubricate driveshaft universal and slip joint Change engine oil/filter Change axle oil Change hydraulic fluid...
Page 115: Dealer Service
Dealer Service The following service items require special tools and knowledge and should be performed only by an authorized dealer: • Engine service not included in this manual • Hydrostatic components • Hydraulic system pumps • Hydraulic valves • Hydraulic cylinders •...
Page 116: Tilting The Platform Down
4. Securely close the cab doors (if appli- Front cable). 5. Using the ROPS, cab frame, and/or handles, manually tilt the platform upward. Note: The steering lock bar (W, Fig. 71) can be inserted in bracket (E) to provide Rear additional leverage for tilting the plat- form.
Page 117: Engine Maintenance
Engine Maintenance Allow engine and hydraulic system compo- WARNING nents to cool before maintenance. Engine Oil Checking Engine Oil Level 1. Position the machine on a level surface. 2. Perform the “Mandatory Safety Shutdown Procedure” on page 10. 3. Wait until the machine has cooled. See “Service Safety Practices” on page 16. 4.
Page 118: Changing Engine Oil And Filter
Changing Engine Oil and Filter Change the engine oil and filter after the first 50 hours of use, and every 250 hours thereafter. 1. Position the machine on a level sur- face. 2. Perform the “Mandatory Safety Shut- down Procedure” on page 10. 3.
Page 119 11. Remove the oil fill cap (Z, Fig. 77) AL 100 Series and add the recommended oil. See “Fluid Capacities/Lubricants” page 31. Replace cap (Z). 12. Start the engine and let it run for sev- eral minutes at low idle. Stop the engine.
Page 120: Air Cleaner
Air Cleaner Important: Do not operate the engine without the air cleaner components installed or damage to the engine could occur. Failure to follow air cleaner ser- vicing instructions can cause engine damage. The air cleaner consists of an outer (primary) filter element, an inner (secondary) filter element, an air filter restriction indicator and a dust valve.
Page 121: Accessing The Outer And Inner Filter Elements
Accessing the Outer and Inner Filter Elements 1. Perform the “Mandatory Safety Shutdown Procedure” on page 10. 2. Open the engine cover. 3. Unlatch the clamps on the air cleaner housing and remove the element cover. 4. Clean any debris from the cover. Changing the Filter Elements 1.
Page 122: Engine Cooling System
Engine Cooling System Checking Coolant Level 1. Perform the “Mandatory Safety Shutdown Procedure” on page 10. 2. Open the engine cover (J, Fig. 79). AL 500 Series shown Check the coolant level in the expan- (other machines similar) sion reservoir (H, Fig. 79). The expan- sion reservoir must be 1/3 to 1/2 full for a cold engine and 2/3 to 3/4 full for a hot engine.
Page 123: Draining/Refilling Cooling System
Draining/Refilling Cooling System 1. Perform the “Mandatory Safety Shutdown Procedure” on page 10. 2. Allow engine to cool. 3. Open engine cover. Do not remove radiator cap when the coolant is WARNING hot. Serious burns may occur. 4. Slowly loosen radiator cap (K, Fig. 80) and allow pressure to escape.
Page 124: Fuel System
Fuel System Use only proper types and grades of diesel fuel WARNING (See “Fluid Capacities/Lubricants” page 31). Diesel fuel is flammable. Keep the machine away from open flames. Do not smoke when refueling or when working on the engine. Stop the engine before fueling. Failure to follow instructions can cause fire and result in injury or death.
Page 125: Water Separator Maintenance
3. Shut off the fuel supply by turning the fuel shut-off valve on top of the water separator to OFF. 4. Remove the fuel filter. Watch for, and catch, any fuel drips or leaks. WARNING Wipe up spilled fuel and immediately dispose of rags used to clean up fuel spills.
Page 126 5. Place a container underneath the drain plug (C, Fig. 84). Loosen the plug until water begins drain- ing. Allow water to drain until the indicator ring returns to the bot- tom of the water separator. 6. Tighten the drain plug and discard fuel/water according to environ- mental laws.
Page 127: Checking And Adjusting V-Belt Tension
Checking and Adjusting V-belt Tension 1. Perform the “Mandatory Safety Shutdown Procedure” on page 10. 2. Open the engine cover. AL 500 Series shown 3. Inspect V-belts (R, Fig. 85) for (other machines similar) damage. If damaged, have belts replaced by your dealer. 4.
Page 128: Air Conditioning Maintenance
Air Conditioning Maintenance Test air conditioning function weekly. Reduced air conditioning function could indicate a low refrigerant level. Low refrigerant or refrigerant leaks can cause air conditioning compressor overheating and failure. Important: Air conditioning system should be filled only by technicians trained in the air conditioning fill processes.
Page 129: Windshield Washer Reservoir (Cab Only)
Windshield Washer Reservoir (Cab Only) The cab windshield washer reservoir located inside engine compartment. 1. Perform the “Mandatory Safety Shutdown Procedure” on page 10. 2. Open the engine cover. 3. As necessary, remove cap (Z, Fig. 88) from the windshield washer reservoir and fill with windshield washer fluid.
Page 130: Hydraulic System Maintenance
Hydraulic System Maintenance Never use your hands to search for WARNING hydraulic fluid leaks; use a piece of paper or cardboard to find leaks. Escaping fluid under pressure can be invisible and can penetrate the skin, causing serious injury. If any fluid is injected into your skin, see a doctor at once.
Page 131: Changing Hydraulic Oil And Filter
Changing Hydraulic Oil and Filter Note: The hydraulic oil filter can be changed without changing the hydraulic oil or draining the hydraulic reservoir. Replace the hydraulic oil if it becomes contaminated, after major repairs, and after 500 hours or one year of use. 1.
Page 132: Hydraulic Hose Maintenance
Hydraulic Hose Maintenance Hydraulic hoses and connections must WARNING be inspected by a trained technician before the first use of the machine, and at least annually thereafter, for leaks and/or damage. Leakages and damaged pressure hose/lines must be immediately repaired or replaced by an authorized service center.
Page 133: Planetary Axles
Planetary Axles Changing Planetary Axle Oil Replace the oil in the axles if it becomes contaminated, after the first 500 hours of service, and every 1500 hours or annually thereafter. 1. Warm the axles to operating temperature. 2. Perform the “Mandatory Safety Shutdown Procedure” on page 10. The machine must be parked on a level surface.
Page 134: Changing Axle Center Oil (Al 500, Al 400 And Al 300 Series)
6. Thoroughly clean the oil drain/fill plugs. Replace the plugs with new O- rings and tighten to 70 N•m (52 lbf.- ft.). Figure 96 – Wheel-End Axle Oil Level Check Changing Axle Center Oil (AL 500, AL 400 and AL 300 Series) Note: Remove the optional counterweight, if it is installed.
Page 135: Changing Axle Oil (Al 200 And Al 100 Series)
Changing Axle Oil (AL 200 and AL 100 Series) 1. Position waste oil collection containers, with capacities of at least 5 liters (5 quarts) underneath the axle centers to catch oil as it drains. 2. Thoroughly clean around axle drain plugs (M, Fig.
Page 136: Brake Fluid Reservoir (Al 300, Al 400 And Al 500 Series)
Brake Fluid Reservoir (AL 300, AL 400 and AL 500 Series) Checking Brake Fluid Reservoir Level 1. Perform the “Mandatory Safety Shutdown Procedure” on page 10. 2. Open the engine hood. 3. The brake fluid reservoir (G, Fig. 99) is located against the platform at the front of the engine compartment.
Page 137: Tires
Tires Inflating or servicing tires can be dangerous. WARNING Only trained personnel should service and mount tires. Important: Keep the same size tire on each side of the loader to prevent excessive wear on tires. Tire Rotation To keep tire wear even, rotate the tires from front to rear and rear to front. Important: The tread bar of all tires should face the same direction.
Page 138: Lubrication
Lubrication Important: lubricants corresponding manufacturer recommendations may invalidate warranty claims. Always dispose of waste lubrication oils and hydraulic fluids according to environmental laws or take to a recycling center for proper disposal. DO NOT pour fluids onto the ground or down a drain.
Page 139 AL 500 Series (AL 400 Series Similar) J. Lift Arm - Upper Pivot (2) O. Articulation Pivot - Lower K. Tilt Cylinder - Rear Pivot P. Driveshaft - Center Telescoping Section L. Lift Cylinder - Rear Pivot (2) Q. Driveshaft - Both Ends M.
Page 140 AL 200/300 Series Shown (AL 100 Series Similar) A. Pivot Arm - Lower E. Lift Cylinder - Rear (2) B. Link Pivot - Upper F. Attachment Pivot - Upper C. Tilt Cylinder - Rear G. Tilt Cylinder - Front D. Lift Arm Pivot (2) H.
Page 141 AL 200/300 Series Shown (AL 100 Series Similar) AL 300 Series J. Articulation Pivot - Upper Front O. All-Tach System Pivots - Lower (2) ® K. Articulation Pivot - Upper Rear P. Steering Cylinder - Rear L. Steering Cylinder - Front Q.
Page 142: Electrical System
Electrical System Fuses The main system fuse (J, Fig. 106) is AL 500 Series shown located behind the battery and connected (other machines similar) to the positive (+) battery terminal. Figure 106 – Main System Fuse The primary fuse panel (K, Fig. 107) is AL 100;...
Page 143: Steering Column Fuses - Al 500/400/300 Series
Steering Column Fuses – AL 500/400/300 Series; AL 100 (EU), AL 200 Optional Rated Fuse Current Protected Circuit (Amp) Instrument panel, differential lock, cab relay Joystick, control module relay Fuel pump, fuel solenoid hold Horn, beacon Work light switch, work light relays Power-A-Tach ®...
Page 144: Steering Column Fuses - Al 100 Series And Al 200 Standard
Steering Column Fuses – AL 100 Series and AL 200 Standard Rated Fuse Current Protected Circuit (Amp) Instrument panel, drive forward and reverse relays Joystick Fuel pump, glow module, fuel solenoid hold Horn, beacon Steering column switch lights Power-A-Tach system ®...
Page 145: Cab And In-Line Fuses
Cab and In-Line Fuses Cab fuses (L, Fig. 108) are located in the engine compartment at the right rear corner of the operator’s platform. Open the engine cover to access these fuses. Additional in-line fuses are located in the wire harness under the platform. Figure 108 –...
Page 146 Note: Refer to Fig. 108 and Fig. 109. Rated Fuse Current Protected Circuit (Amp) Dome light Rear wiper motor Front wiper motor Heater Drive module (AL 400/AL 500 Series only) Glow plugs Control module Starter solenoid Main Fuse 918496/GP0313 https://tractormanualz.com/...
Page 147: Control Modules
Control Modules The control modules, located behind the operator’s seat on the right, (all models except AL 100 Series), or under the operator’s platform (AL 100 Series) provide switching, control logic and diagnostic functions. Machine Control Module The machine controller (N, Fig. 110) provides the following functions: •...
Page 148: Drive Control Module Error Codes
Drive Control Module Error Codes Malfunctioning drive function may indicate a control module error condition. The table on page 140 describes control module error codes. Error codes are indicated by flashing LEDs (Z, Fig. 110) located near the electrical connectors at the bottom of the module.
Page 149: Battery
Battery Before servicing the battery or electrical WARNING system, disconnect the negative battery cable from the negative battery terminal and tie the cable away from the negative battery terminal to prevent sparking and accidental re-con- nection. Alternately, if the machine is equipped with the optional bat- tery disconnect switch, turn the battery disconnect switch to the “OFF”...
Page 150: Using A Booster Battery (Jump-Starting)
Using a Booster Battery (Jump-Starting) Note: The machine may be equipped with the remote battery terminal, allowing for easy access to booster terminals. See “Remote Battery Terminal” on page 143. Important: Only complete these steps if the loader cannot be started using the ignition key switch.
Page 151: Remote Battery Terminal
When the engine is running, components in the WARNING engine compartment rotate. Before removing the jumper cables, be sure that no loose clothing can become caught in the rotating components. 7. After the engine is running, remove the negative jumper cable connected to the booster machine ground.
Page 152: Storing The Loader
Storing the Loader Before Storage If the loader is to be stored for a long period, in excess of two months, the following procedures are suggested: 1. Wash the entire machine. 2. Perform all steps for long-term engine storage according to the engine opera- tor’s manual.
Page 153: Final Shutdown / Decommissioning
Final Shutdown / Decommissioning Important: Dispose of all materials properly. Used oils/fluids/gases/refrigerant are environmental contaminants and may only be disposed of at approved collection facilities. Never drain any oils/fluids onto the ground, dispose of in municipal waste collection containers, or in metropolitan sewer systems or landfills.
Page 154: Machine Disposal
Machine Disposal Make sure all materials are disposed of in an ecologically sound manner. Recycling the machine in accordance with the current state of the art at the time of recycling. Observe all accident prevention regulations. Dispose of all parts at the at the recycling sites specific to the material of the part. Take care to separate different materials for recycling.
Page 155: Maintenance Log
Maintenance Log Date Hours Service Procedure 918496/GP0313 https://tractormanualz.com/...
Page 156 Date Hours Service Procedure 918496/GP0313 https://tractormanualz.com/...
Page 157 Date Hours Service Procedure 918496/GP0313 https://tractormanualz.com/...
Page 158 Date Hours Service Procedure 918496/GP0313 https://tractormanualz.com/...
Page 159 Date Hours Service Procedure 918496/GP0313 https://tractormanualz.com/...
Page 160 Date Hours Service Procedure 918496/GP0313 https://tractormanualz.com/...
Page 161: Troubleshooting
CHAPTER 6 TROUBLESHOOTING Engine Troubleshooting Problem Possible Cause Corrective Action Engine does not turn over Drive direction switch in Place drive direction forward/reverse switch in neutral Tripped circuit breaker Reset circuit breaker Blown fuse Replace fuse. Dead battery Charge or replace battery—see “Using a Booster Battery (Jump- Starting)”...
Page 162 Engine Troubleshooting Problem Possible Cause Corrective Action Engine turns over but will Engine cranking speed too Check battery and not start slow charge/replace as necessary—tighten battery terminals Fuel tank empty Fill tank and vent fuel system if necessary Fuel filter plugged or Change fuel filter restricted Use winter grade diesel...
Page 163 Engine Troubleshooting Problem Possible Cause Corrective Action Engine overheating Crankcase oil level incorrect Adjust oil level Cooling air circulation With engine off, remove restricted restriction Fan shroud improperly Contact dealer positioned Improper oil grade or oil Change engine oil—see excessively dirty “Fluid Capacities/Lubricants”...
Page 164 Indicator Lamp Troubleshooting Indicator Activated Possible Cause Corrective Action Engine oil pressure Engine oil pressure too low Stop engine immediately; check oil level and add oil if necessary; check oil pump Engine oil level too low Add oil Oil pump malfunction Contact dealer Hydraulic oil temperature Temperature is too hot...
Page 165 Seal and Hose Troubleshooting Problem Possible Cause Corrective Action Oil, coolant or fuel leakage Loose hose connection(s) Tighten hose connections Damaged seals or hoses Change seals/hoses as necessary Hydraulic fluid leakage Loose fittings Tighten hydraulic connections Seals, hoses or lines Change seals, hoses or damaged lines as necessary...
Page 166 Hydraulic System Troubleshooting Problem Possible Cause Corrective Action Attachment tilts down with Oil leaking past tilt cylinder Contact dealer tilt control in neutral seals (internal or external) Leaking hydraulic hoses, Repair as required tubes or fittings between control valve and cylinders Lift arm does not Lift spool in control valve not Contact dealer...
Page 167 Hydraulic System Troubleshooting Problem Possible Cause Corrective Action Lift arm does not maintain Oil leaking past lift cylinder Contact dealer raised position with multi- seals (internal or external) purpose joystick centered Oil leaking past lift spool in Contact dealer (neutral) control valve Leaking hydraulic hoses, Contact dealer...
Page 168 Hydrostatic Drive System Troubleshooting Problem Possible Cause Corrective Action Travel drive will not operate Parking brake is applied Release parking brake in either direction Low hydraulic oil level Add oil Low or no charge pressure Contact dealer Hydrostatic pump(s) relief Contact dealer valves malfunction Brake/inch pedal stuck or...
Page 169 Hydrostatic Drive System Troubleshooting Problem Possible Cause Corrective Action Travel drive system noisy Hydraulic oil viscosity too Allow longer warm-up heavy See “Fluid Capacities/Lubricants” on page 31 for proper oil grade Low hydraulic oil level Add oil AL 100 Series hydraulic See “Checking Hydraulic tanks not evenly filled Oil Level”...
Page 170 Hydrostatic Drive System Troubleshooting Problem Possible Cause Corrective Action Travel drive overheating Drive system continuously Improve operation overloaded procedure Lift/tilt or auxiliary system Improve operation continuously overloaded procedure Drive motor(s) or hydrostatic Contact dealer pump(s) internal damage/ leakage Oil cooler fins restricted Clean oil cooler fins Hydraulic oil filter restricted Replace filter...
Page 171 Electrical Troubleshooting Problem Possible Cause Corrective Action Engine temperature gauge Temperature sender Replace temperature does not work malfunction sender Loose wiring/terminal Check wiring connections connections Blown fuse Check circuit and replace fuse Hour meter does not work Loose wiring/terminal Check wiring connections connections Alternator malfunction...
Page 172 Notes 918496/GP0313 https://tractormanualz.com/...
Page 173: Index
INDEX Bypass Valve ....95 Accelerator Pedal ..53 Air Cleaner Dust Valve ..112 Cab .
Page 174 Change Oil and Filter ..110 Hydraulic Power-A-Tach Hitch Engine Oil Pressure ..55 Connection ....83 Engine Oil Temperature .
Page 175 Maximum Slopes of Operation . . . 32 During Operation ..12 Model Identification ... . 5 Avoiding Rollover Accidents ..Multi-Purpose Joystick .
Page 176 Steering Wheel ....53 Windshield Washer ... .32 Steering/Frame Lock Bar ..97 Storage ....144 Preparing .
Page 177: Torque Specifications
Torque Specifications Note: Use these torque values when tightening hardware (excluding: locknuts and self-tapping, thread forming and sheet metal screws) unless specified otherwise. Hydraulic fittings with various seals (light application). All torque values are in lb.-ft. (Nm) unless marked otherwise. Straight pipe fitting with thread and screwed plug (GE) Non-return valve Identification aid...
Page 178 With fine-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise. Threads according to DIN 912, DIN 931, DIN 933, etc. Threads according to DIN 7984 Thread 10.9 12.9 10.9 M8X1.0 18 (25) 27 (37) 32 (43) 16 (22) 24 (32) M10X1.0 37 (50)
Page 179: Ec Declaration Of Conformity
Emission), as amended by 2005/88/EC. In accordance with EN/ISO Standards: EN ISO 3450:1996, ISO 6165 Category: EARTH-MOVING MACHINERY/ LOADERS/COMPACT/SEATED OPERATOR Models: AL 140, AL 240, AL 340, AL 440, AL 540 10. Directive/Conformity Assessment Procedure/Notified Body: 2004/108/EC Type-test Self-certification 97/23/EC Self-certification ----------...
Page 180 If you have any questions on proper operation, adjustment or maintenance of this machine, contact your dealer or the Gehl Company Service Department before starting or continuing operation.

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