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 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 |
