Seven Gehl articulated loaders, the AL 140 through AL 540 plus the EU-spec 240 and 440 builds, are covered by this 180-page Gehl AL 540 operator manual PDF, OEM ID 918496. Maintenance takes up roughly a quarter of the book: check, lubrication and filter intervals for the engine, hydraulics, planetary axles and brakes, plus fuse locations and drive control module error codes. Your operating chapters cover the instrument panel and warning indicators, All-Tach and Power-A-Tach quick-attach connection, auxiliary hydraulics pressure relief and float positions, and the troubleshooting charts sort engine, hydraulic, hydrostatic drive and electrical faults. Fill an AL 500 or 400 series crankcase with 7.4 L (7.8 qts.) of oil; the fuel tank on those machines takes 68 L (18 gal.). A made-up fitting torque is how hoses blow. This bookmarked PDF has a text layer and the real fitting torque tables, and once you buy it, it stays yours for the life of your loader.
What's Inside This Gehl AL 140–540 Series Operator Manual
| System | Pages | Key Topics |
|---|---|---|
| General Information | 9-16 | Safety Symbol, Contents and Use of This Manual, Ownership Change, Manufacturer Information, Machine Designation, Serial Number Plate Location, Loader Information |
| Safety | 17-38 | 2-Post ROPS/FOPS Warning, Mandatory Safety Shutdown Procedure, Before Starting, During Operation (Provision for Stability/Avoiding Rollover Accidents, Electrical Energy) |
| Specifications | 39-58 | Fluid Capacities/Lubricants, Maximum Slopes of Engine Operation, SAE Weights and Capacities, ISO 6016 Weights and Capacities, Engine, Coolant Compound Table, Hydraulics |
| Operation | 59-88 | Operating Controls (Controls and Switches, Instrument Panel and Indicators, Cab Controls) |
| Attachments | 89-101 | Connect/Disconnect Attachments (All-Tach® System Hitch Connection, All-Tach® System Hitch Disconnection, Hydraulic Power-A-Tach® System Hitch Connection, Hydraulic Power-A-Tach® System Hitch Disconnection) |
| Towing the Loader | 102-104 | Precautions, Towing AL 100 Series Machines (Preparation), Towing AL 300 Series Machines (Preparation), Towing AL 500 and AL 400 Series Machines (Preparation), Towing Procedure |
| Loading and Transporting | 105-110 | Crane Lifting |
| Maintenance | 111-154 | Maintenance Schedule (Check, Clean and Inspect, Leakage Check, Lubrication and Filter Changes, Functional Check), Dealer Service |
| Maintenance Log | 155-160 | |
| Troubleshooting | 161-172 | Engine Troubleshooting, Hydraulic System Troubleshooting, Hydrostatic Drive System Troubleshooting, Electrical Troubleshooting |
| Torque Specifications | 177-178 | Hydraulic Fittings, Light Application, Heavy Application, Fine-Pitch Thread, Coarse-Pitch Thread |
| EC Declaration of Conformity | 179-180 | Manufacturer, Technical Construction File, EC Directives, EN/ISO Standards, Conformity Assessment Procedure |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| AL 500/400 Series | ||
| Diesel Engine Oil Capacity (AL 500/400 Series) | 7.4 L (7.8 qts.) | p. 39 |
| Diesel Fuel Capacity (AL 500/400 Series) | 68 L (18 gal.) | p. 39 |
| Wheel Fastener Torque (AL 500/400 Series) | 319 N•m (235 lbf-ft) | p. 46 |
| AL 300 Series | ||
| Diesel Engine Oil Capacity (AL 300 Series) | 6.7 L (7.2 qts.) | p. 39 |
| Diesel Fuel Capacity (AL 300 Series) | 57 L (15 gal.) | p. 39 |
| AL 100 Series | ||
| Diesel Engine Oil Capacity (AL 100 Series) | 4.4 L (4.6 qts.) | p. 39 |
| Diesel Fuel Capacity (AL 100 Series) | 26 L (7 gal.) | p. 39 |
| All Models | ||
| Continuous Engine Operation Slope | 25° for all directions | p. 40 |
| Intermittent Engine Operation Slope (<3 minutes) | 30° for all directions | p. 40 |
| Bypass Valve Tightening Torque | 70 Nm (52 lbf-ft) | p. 104 |
| Axle Drain/Fill Plug Tightening Torque | 70 N•m (52 lbf-ft) | p. 134 |
| AL 100/200 Series | ||
| Wheel Fastener Torque (AL 100/200 Series) | 165 N•m (122 lbf-ft) | p. 46 |
Gehl AL 140–540 Series Common Problems This Manual Covers
Gehl AL series articulated loader engine does not turn over when the key switch is turned
Check that the drive direction switch is in neutral, the operator's seat is occupied, the parking brake is applied and the auxiliary hydraulics pressure relief valve lever is in neutral (later machines), following page 161. Reset a tripped circuit breaker, replace a blown fuse and close the battery disconnect switch. Before charging or replacing a dead battery, disconnect the negative battery cable as page 26 directs.
Manual Section: Engine Troubleshooting p. 161Diesel engine turns over but will not start, especially in cold winter weather
Replace a plugged fuel filter and switch to winter grade diesel if paraffin separation is the cause (page 162). Fill an empty tank and vent the fuel system. Tighten fuel line connections and clamps, then check the glow plug module connection and voltage and the fuel shut-off solenoid voltage. Shut the engine off before fueling and keep sparks away from fuel work (page 27). Contact your dealer for fuel pump faults.
Manual Section: Engine Troubleshooting p. 162Engine overheating and water temperature indicator lamp lights up on the instrument panel
Check the coolant level and add coolant only after the engine cools. Page 25 warns never to remove the radiator cap at operating temperature or when overheated. Clean a dirty radiator, replace a restricted air filter, tighten a loose fan belt and adjust the crankcase oil level per page 163. With the engine off, remove any cooling air restriction. Contact your dealer if the fan shroud is out of position.
Manual Section: Engine Troubleshooting p. 163Hydraulic oil temperature indicator lamp comes on and the hydraulic system runs hot
Clean the hydraulic oil cooler, check the radiator for debris, then check the hydraulic oil level and top up if low, per pages 164 and 166. Let the components cool first; page 25 warns that recently operated hydraulic parts can cause burns. Reduce the load if you are overworking the machine. On AL 100 Series machines, verify both hydraulic tanks are evenly filled.
Manual Section: Hydraulic System Troubleshooting p. 166Lift arm and tilt functions slow, inconsistent or jerky under normal operation
Check the hydraulic oil level, add oil and look for leaks, following page 166. Never search for a leak with your hands; page 25 warns that escaping fluid under pressure can penetrate skin. Increase engine speed if it is too low. For jerky action, cycle the lift and tilt cylinders to maximum stroke and hold pressure briefly to clear air. Contact your dealer for cylinder or pump faults.
Manual Section: Hydraulic System Troubleshooting p. 166Travel drive will not operate in either direction with the engine running
Check that the parking brake is released and the hydraulic oil level is correct, following page 168. Verify the brake/inch pedal is not stuck, inspect the throttle pedal linkage, and check the electrical connections and harness. On AL 400/500 Series machines, check the drive controller error code and force pedal calibration if needed. Contact your dealer for low charge pressure.
Manual Section: Hydrostatic Drive System Troubleshooting p. 168Frequently Asked Questions
What are the torque specifications for wheel nuts on a Gehl AL loader?
For the AL 500/400 series, the wheel fastener torque is 319 N•m (235 lbf-ft). For the AL 100/200 series, the torque is 165 N•m (122 lbf-ft). p. 46
What are the replacement specs for the hydraulic oil filter on a Gehl AL 140-540 Series articulated loader?
The hydraulic oil and return filter should be replaced after 500 hours or one year of use, or if the oil becomes contaminated. Refer to page 131 for the detailed procedure for changing the hydraulic oil and filter. p. 114
What are the engine oil filter replacement specifications for the Gehl AL 140–540 Series?
The engine oil and filter should be changed after the first 50 hours of use, and every 250 hours thereafter. Refer to page 118 for the step-by-step procedure. p. 118
What is the diesel fuel tank capacity for the AL 500/400 models in the Gehl AL 140-540 Series?
The diesel fuel tank capacity for the AL 500/400 series is 68 L (18 gal.). p. 39
What is the correct engine oil capacity for the Gehl AL 300 in the AL 140-540 Series?
The engine oil capacity for the AL 300 series is 6.7 L (7.2 qts.). p. 39
Will this Gehl AL 140 Operator Manual download right away?
Delivery is instant: a 180-page searchable PDF is yours the second checkout clears. Laptop, tablet, or phone, all fine.
Is printing allowed for this Gehl AL 140 Operator Manual?
Yes. It prints from any PDF reader, so run off the pages you need for your own repair work.
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