User Manuals: Gehl AL 540 Wheel Loader

Manuals and User Guides for Gehl AL 540 Wheel Loader. We have 1 Gehl AL 540 Wheel Loader manual available for free PDF download: Operator's Manual

Gehl AL 540 Operator's Manual (180 pages)

Articulated Loaders

Brand: Gehl | Category: Construction Equipment | Size: 3 MB

Table of Contents
3
General Information
9
Safety Symbol
9
Contents and Use of this Manual
9
Ownership Change
10
Manufacturer Information
10
Machine Designation
10
Serial Number Plate Location
11
Loader Information
11
Proper Machine Use
12
Using Attachments
12
Component Identification
13
Service/Dealership Network
14
Vibration Information
14
Vibration Measurement and Actions
15
Vibration Levels
15
Safety
17
2-Post ROPS/FOPS Warning
18
Mandatory Safety Shutdown Procedure
18
Before Starting
19
During Operation
20
Provision for Stability/Avoiding Rollover Accidents
23
Electrical Energy
24
Service Safety Practices
24
Battery Hazards
26
Fire Hazards
27
Crystalline Silica Exposure
28
Transporting the Machine
28
Lifting the Machine with a Crane
28
Hazard and Hazard Avoidance Symbols
29
Safety Decals
30
New Decal Application
30
ANSI-Style and Common Safety Decal Locations
30
ISO-Style Safety Decal Locations
35
Specifications
39
Fluid Capacities/Lubricants
39
Maximum Slopes of Engine Operation
40
SAE (Domestic) Weights and Capacities al 500 and al 300 Series
41
ISO 6016 (EU) Weights and Capacities al 500, al 400 and al 300 Series
42
SAE (Domestic) Weights and Capacities
43
AL 100 Series
43
ISO (EU) Weights and Capacities al 100 and al 200 Series
44
Engine
45
Coolant Compound Table
45
Hydraulics
46
Electrical System
46
Sound Levels
46
Wheels
46
Wheel/Tire Sets
47
ROPS and FOPS
48
Vibration Levels
48
AL 500, al 400 Series Dimensions
49
AL 300, al 200 Series Dimensions
51
AL 100 Series Dimensions
53
Standard Features
55
Optional Features
56
Common Materials and Densities
57
Operation
59
Operating Controls
60
Controls and Switches
60
Instrument Panel and Indicators
62
Cab Controls (Cab Only)
64
Cab Environment Controls
64
Air Conditioning Control (Option)
64
Cab Windshield Wiper
65
Controls
65
Cab Dome Light
65
Cab Defrost
65
Warning Indicators
66
Operator's Seat Adjustment
67
Seat Belt
68
Ignition Key Switch
68
Steering Column Adjustment
68
Control Lever
69
Hand Throttle
69
12V Accessory Power Outlet
70
Operation
71
Pre-Operation Checklist
71
Extend the ROPS
72
Restore the ROPS to the Raised Position
72
4-Post ROPS Side Gates (Option)
73
Entering and Exiting
74
Engine Start
75
Engine Shut down
77
Warm-Up
77
New Machines
78
Driving on Public Roads
78
Lift Arm Down-Stop
82
Travel
82
Slow/Fast Travel Speed Mode Selection
84
Differential Lock Operation
84
Load Handling
85
Parking the Loader
85
Multi-Purpose Joystick
86
Feature
87
AL 500 Series Limited Self-Leveling
87
Float Positions
88
Attachments
89
General Instructions
89
Connect/Disconnect Attachments
89
All-Tach® System Hitch Connection
89
All-Tach® System Hitch Disconnection
90
Hydraulic Power-A-Tach® System Hitch Connection
91
Hydraulic Power-A-Tach® System Hitch Disconnection
93
Auxiliary Hydraulics
94
Auxiliary Circuit Pressure Relief
94
Auxiliary Hydraulics Connections
96
Auxiliary Hydraulics Control Buttons
97
Operating Attachments
100
Bucket
100
Loading Loose Material
100
Scraping Soft Material
100
Scraping Hard Material
101
Towing the Loader
102
Precautions
102
Towing al 100 Series Machines
102
Preparation
102
Towing al 300 Series Machines
103
Preparation
103
Towing al 500 and al 400 Series Machines
103
Towing Procedure
104
After Towing
104
Loading and Transporting
105
Crane Lifting
107
Maintenance
111
Maintenance Schedule
112
Check, Clean and Inspect
112
Leakage Check
113
Lubrication and Filter Changes
114
Functional Check
114
Dealer Service
115
Tilting the Platform
115
Tilting up the Platform
115
Tilting the Platform down
116
Engine Maintenance
117
Engine Oil
117
Checking Engine Oil Level
117
Changing Engine Oil and Filter
118
Air Cleaner
120
Accessing the Outer and Inner Filter Elements
121
Changing the Filter Elements
121
Engine Cooling System
122
Checking Coolant Level
122
Cleaning Cooling System
122
Draining/Refilling Cooling System
123
Fuel System
124
Adding Fuel
124
Changing Fuel Filter
124
Water Separator Maintenance
125
Checking and Adjusting V-Belt Tension
127
Air Conditioning V-Belt
127
Air Conditioning Maintenance
128
Filter Replacement
128
Windshield Washer Reservoir (Cab Only)
129
Hydraulic System Maintenance
130
Hydraulic Oil
130
Checking Hydraulic Oil Level
130
Changing Hydraulic Oil and Filter
131
Hydraulic Hose Maintenance
132
Planetary Axles
133
Changing Planetary Axle Oil
133
Changing Axle Wheel-Hub Oil (al 500, al 400 and al 300 Series)
133
Changing Axle Center Oil (al 500, al 400 and al 300 Series)
134
Changing Axle Oil (al 200 and al 100 Series)
135
Brake Fluid Reservoir (al 300, al 400 and al 500 Series)
136
Checking Brake Fluid Reservoir Level
136
Wheels and Tires
136
Wheel Fasteners
136
Tires
137
Tire Rotation
137
Checking Tire Pressure
137
Liquid Tire Ballast (al 500 Series)
137
Lubrication
138
Electrical System
142
Fuses
142
Steering Column Fuses - al 500/400/300 Series
143
AL 100 (EU), al 200 Optional
143
Steering Column Fuses - al 100 Series and al 200 Standard
144
Cab and In-Line Fuses
145
Control Modules
147
Machine Control Module
147
Drive Control Module (al 500/400 Series)
147
Drive Control Module Error Codes
148
Battery
149
Using a Booster Battery (Jump-Starting)
150
Remote Battery Terminal
151
Storing the Loader
152
Before Storage
152
After Storage
152
Final Shutdown / Decommissioning
153
Before Disposal
153
Machine Disposal
154
Maintenance Log
155
Troubleshooting
161
Index
173
Torque Specifications
177
EC Declaration of Conformity
179

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User Manuals: Gehl AL 540 Wheel Loader

Gehl AL 540 Operator's Manual (180 pages)

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