Gehl AL 540 - Page 158

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150 918496/GP0313

Date Hours Service Procedure

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Table of Contents3
General Information9
Safety Symbol9
Contents and Use of this Manual9
Ownership Change10
Manufacturer Information10
Machine Designation10
Serial Number Plate Location11
Loader Information11
Proper Machine Use12
Using Attachments12
Component Identification13
Service/Dealership Network14
Vibration Information14
Vibration Measurement and Actions15
Vibration Levels15
Safety17
2-Post ROPS/FOPS Warning18
Mandatory Safety Shutdown Procedure18
Before Starting19
During Operation20
Provision for Stability/Avoiding Rollover Accidents23
Electrical Energy24
Service Safety Practices24
Battery Hazards26
Fire Hazards27
Crystalline Silica Exposure28
Transporting the Machine28
Lifting the Machine with a Crane28
Hazard and Hazard Avoidance Symbols29
Safety Decals30
New Decal Application30
ANSI-Style and Common Safety Decal Locations30
ISO-Style Safety Decal Locations35
Specifications39
Fluid Capacities/Lubricants39
Maximum Slopes of Engine Operation40
SAE (Domestic) Weights and Capacities al 500 and al 300 Series41
ISO 6016 (EU) Weights and Capacities al 500, al 400 and al 300 Series42
SAE (Domestic) Weights and Capacities43
AL 100 Series43
ISO (EU) Weights and Capacities al 100 and al 200 Series44
Engine45
Coolant Compound Table45
Hydraulics46
Electrical System46
Sound Levels46
Wheels46
Wheel/Tire Sets47
ROPS and FOPS48
Vibration Levels48
AL 500, al 400 Series Dimensions49
AL 300, al 200 Series Dimensions51
AL 100 Series Dimensions53
Standard Features55
Optional Features56
Common Materials and Densities57
Operation59
Operating Controls60
Controls and Switches60
Instrument Panel and Indicators62
Cab Controls (Cab Only)64
Cab Environment Controls64
Air Conditioning Control (Option)64
Cab Windshield Wiper65
Controls65
Cab Dome Light65
Cab Defrost65
Warning Indicators66
Operator's Seat Adjustment67
Seat Belt68
Ignition Key Switch68
Steering Column Adjustment68
Control Lever69
Hand Throttle69
12V Accessory Power Outlet70
Operation71
Pre-Operation Checklist71
Extend the ROPS72
Restore the ROPS to the Raised Position72
4-Post ROPS Side Gates (Option)73
Entering and Exiting74
Engine Start75
Engine Shut down77
Warm-Up77
New Machines78
Driving on Public Roads78
Lift Arm Down-Stop82
Travel82
Slow/Fast Travel Speed Mode Selection84
Differential Lock Operation84
Load Handling85
Parking the Loader85
Multi-Purpose Joystick86
Feature87
AL 500 Series Limited Self-Leveling87
Float Positions88
Attachments89
General Instructions89
Connect/Disconnect Attachments89
All-Tach® System Hitch Connection89
All-Tach® System Hitch Disconnection90
Hydraulic Power-A-Tach® System Hitch Connection91
Hydraulic Power-A-Tach® System Hitch Disconnection93
Auxiliary Hydraulics94
Auxiliary Circuit Pressure Relief94
Auxiliary Hydraulics Connections96
Auxiliary Hydraulics Control Buttons97
Operating Attachments100
Bucket100
Loading Loose Material100
Scraping Soft Material100
Scraping Hard Material101
Towing the Loader102
Precautions102
Towing al 100 Series Machines102
Preparation102
Towing al 300 Series Machines103
Preparation103
Towing al 500 and al 400 Series Machines103
Towing Procedure104
After Towing104
Loading and Transporting105
Crane Lifting107
Maintenance111
Maintenance Schedule112
Check, Clean and Inspect112
Leakage Check113
Lubrication and Filter Changes114
Functional Check114
Dealer Service115
Tilting the Platform115
Tilting up the Platform115
Tilting the Platform down116
Engine Maintenance117
Engine Oil117
Checking Engine Oil Level117
Changing Engine Oil and Filter118
Air Cleaner120
Accessing the Outer and Inner Filter Elements121
Changing the Filter Elements121
Engine Cooling System122
Checking Coolant Level122
Cleaning Cooling System122
Draining/Refilling Cooling System123
Fuel System124
Adding Fuel124
Changing Fuel Filter124
Water Separator Maintenance125
Checking and Adjusting V-Belt Tension127
Air Conditioning V-Belt127
Air Conditioning Maintenance128
Filter Replacement128
Windshield Washer Reservoir (Cab Only)129
Hydraulic System Maintenance130
Hydraulic Oil130
Checking Hydraulic Oil Level130
Changing Hydraulic Oil and Filter131
Hydraulic Hose Maintenance132
Planetary Axles133
Changing Planetary Axle Oil133
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 Level136
Wheels and Tires136
Wheel Fasteners136
Tires137
Tire Rotation137
Checking Tire Pressure137
Liquid Tire Ballast (al 500 Series)137
Lubrication138
Electrical System142
Fuses142
Steering Column Fuses - al 500/400/300 Series143
AL 100 (EU), al 200 Optional143
Steering Column Fuses - al 100 Series and al 200 Standard144
Cab and In-Line Fuses145
Control Modules147
Machine Control Module147
Drive Control Module (al 500/400 Series)147
Drive Control Module Error Codes148
Battery149
Using a Booster Battery (Jump-Starting)150
Remote Battery Terminal151
Storing the Loader152
Before Storage152
After Storage152
Final Shutdown / Decommissioning153
Before Disposal153
Machine Disposal154
Maintenance Log155
Troubleshooting161
Index173
Torque Specifications177
EC Declaration of Conformity179

Gehl AL 540 - Page 158

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