This 220-page Gehl AL 440 and AL 540 Service Manual (OEM #918275) covers everything from chassis teardown to Plus+1 drive controller calibration. It includes hydraulic schematics for both AL 400 and AL 500 series across serial number breaks, along with 11 pages of wiring diagrams tracing circuits from engine electrics to FOPS and Power-A-Tach. Diagnostic flow charts span 12 pages for hydrostatic drive, work hydraulics, and steering troubleshooting. You will also find 50 pages of step-by-step procedures and a dedicated error codes chapter. Factory specifications are clearly listed, such as the front lug nut torque of 202 lb-ft (315 N•m) and the 500-hour hydraulic fluid replacement interval. Stop relying on forum guesses. This bookmarked, searchable PDF lets you pull up exact factory numbers on any device.
What's Inside This Gehl AL 440, AL 540 Manual
| System | Pages | Key Topics |
|---|---|---|
| Safety | 9-16 | Safety Symbol, Signal Words, Schematics, Electrical, Hydraulic, Seat Belt, Slow Speed, Dimensions |
| Specifications | 17-22 | Fluid Capacities/Lubricants, Dimensions, Weights and Capacities, Engine, Hydraulics, Electrical System, Sound Levels, Wheels, Fops |
| Maintenance | 23-54 | Maintenance Introduction, Maintenance Schedule, Engine Maintenance, Air Cleaner, Engine Cooling System, Fuel System, Checking and Adjusting V-Belt Tension, Air Conditioning Maintenance, Hydraulic System Maintenance, Planetary Axles, Brake Fluid Reservoir, Wheels and Tires, Lubrication, Electrical System, Storing the Loader, Maintenance Log |
| Operation | 55-66 | Operation Safety, Controls and Switches, Instrument Panel and Indicators, Cab Controls (Cab Only), Warning Indicators, Operator's Seat and Ignition Switch, Steering Column, Hand Throttle, Lift Arm Down-Stop, Lift/Tilt Lock |
| Chassis | 67-84 | Tilting the Platform, Lowering the Platform, Repairing or Replacing Platform Switch, Hood Removal, Hood Installation, Center/Steering Bearing Removal, Center/Steering Bearing Installation, Lift Arm Removal, Lift Arm Installation, Attachment Plate Hydraulics Removal, Attachment Plate Hydraulics Installation |
| Engine | 85-94 | Engine Removal, Engine Installation, Drive Coupling Removal, Starter Removal |
| Cooling System | 95-100 | Cab, Environment Controls, Windshield Wiper Controls, Center/Steering Bearing, Installation, Removal, Contents and Use of This Manual, Control Lever |
| Axles | 101-108 | Safety Symbol, Signal Words, Schematics, Electrical, Hydraulic, Seat Belt, Slow Speed, Dimensions |
| Hydraulics | 109-172 | Work Hydraulics Troubleshooting, Hydrostatic Drive System, Hydraulics Troubleshooting Diagnostic Flow Charts, Drive System Pressure Tests, Work System Pressure Tests |
| Machine/Drive Controllers | 173-188 | Hand Throttle, Hazard Light Switch, Hazard Lights, Hood, Installation, Removal, Hour Meter, Hydraulic Drive System Components |
| Electrical System | 189-202 | Battery Removal, Battery Installation, Al 400 Series (Serial Numbers 41250 and Up) Complete Electrical Schematic |
| Troubleshooting | 203-210 | Hand Throttle, Hazard Light Switch, Hazard Lights, Hood, Installation, Removal, Hour Meter, Hydraulic Drive System Components |
| Torque Specifications | 215-220 | Hydraulic Fittings with Various Seals, With Coarse-Pitch Thread, With Fine-Pitch Thread |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Front Axle Lug Nut Torque | 202 lb-ft (315 N•m) | p. 104 |
| Rear Axle Lug Nut Torque | 232 lb-ft (315 N•m) | p. 108 |
| Hydrostatic Motor Fittings Torque | 66 lb-ft (90 N•m) | p. 161 |
| Hydraulic Fluid and Return Filter Replacement Interval | 500 Hours (or annually) | p. 25 |
| Drive Coupler Bolts Torque | 33 lb-ft (45 N•m) | p. 93 |
| Hydrostatic Motor Mounting Bolts Torque | 92 lb-ft (125 N•m) | p. 161 |
| Wheel Fastener Torque | 319 Nm (235 lbf-ft) | p. 22 |
| Maximum Inflation Pressure to Seat Beads | 35 psi (2.4 bar) | p. 39 |
| Hydraulic Oil System/Tank Capacity | 40 L (10.6 gal.) | p. 17 |
| Diesel Engine Oil Capacity | 7.4 L (2.0 gal.) | p. 17 |
| Engine Coolant System/Radiator Capacity | 6.4 L (6.8 qts.) | p. 17 |
| Engine Oil Capacity | 7.4 L (2.0 gal.) | p. 17 |
Gehl AL 440, AL 540 Common Problems This Manual Covers
Hydrostatic drive shows no response or total loss of propulsion in either direction p. 203
Check the hydraulic oil level first; the system holds 40 L (10.6 gal.) and low fluid is a common starting point. Verify drive system pressure reaches 410 bar (5946 psi) per the specifications on page 17. Follow the hydrostatic drive troubleshooting steps on page 203, inspecting for contaminated fluid, worn pump, and hydrostatic motor faults.
Manual Section: Hydrostatic Drive System TroubleshootingLoader arms raise slowly, jerk under load, or attachment tilt stops responding p. 109
Inspect the hydraulic return filter and replace it if past the 500-hour or annual interval listed on page 25. Fill the hydraulic oil to the full 40 L (10.6 gal.) mark. Verify work system pressure at 207 bar (3000 psi) per page 21. If pressure is low, check the relief valve setting and look for cylinder seal leakage using the Hydraulics section starting on page 109.
Manual Section: Hydraulic System TroubleshootingHydraulic oil temperature warning lamp activates during normal operation or fluid runs hot p. 203
Drain and refill the hydraulic tank to the correct 40 L (10.6 gal.) level. Check the engine coolant, which has a capacity of 6.4 L (6.8 qts.) per page 17. Clean the radiator and hydraulic cooler of debris. Inspect the hydraulic filter and replace it at the 500-hour interval on page 25. If overheating persists, look for pump wear or excessive internal bypass.
Manual Section: Hydraulic System TroubleshootingSteering feels stiff, pulls to one side, or becomes erratic during turns p. 109
Verify hydraulic oil is at the correct 40 L (10.6 gal.) level and the fluid is clean and uncontaminated. Inspect steering circuit hoses for damage or restriction. Check work system pressure at 207 bar (3000 psi) per page 21; low supply pressure directly degrades steering response. Review the hydraulic diagnostic flow charts in the Hydraulics section on page 109.
Manual Section: Hydraulic System TroubleshootingFrequently Asked Questions
How to clear fault codes on a GEHL AL 540?
To clear corrected error codes, turn the ignition "Off" and then back on to the run or start positions, which temporarily cuts power to the drive module. For resetting error counters and timestamps, navigate to the "System Definition" screen, select "Parameter Functions > Error history reset," change the "Reset Error History" field from "0" to "1" and then back to "0," clicking the download button after each change. This procedure is detailed on page 184.
What do GEHL AL 440 hydraulic error codes mean?
The manual lists error codes for the Drive Controller, which manages the hydrostatic drive system. Examples include Watchdog Ready Error (13), Battery Voltage or Sensor Voltage Error (15), Pump Current Forward Error (19), Pump Current Reverse Error (23), Motor Current Error (27), Engine Speed RPM Error (31), FNR Shortcut Error (35), Inching Error (39), Driving Pedal Error (43), Mode Switch-2 Error (47), Brake Pressure Defeat Error (55), Motor RPM and Direction Error (59), and General CAN Receive Error (70). These codes are indicated by flashing LEDs on the module.
What is the torque spec for GEHL AL 540 wheel lug nuts?
For the GEHL AL 540, the general wheel fastener torque is 319 Nm (235 lbf-ft). More specifically, during installation, front axle lug nuts should be tightened to 202 lb-ft (315 N•m), and rear axle lug nuts should be tightened to 232 lb-ft (315 N•m).
how to reset gehl al 440 fault codes
To clear corrected error codes, turn the ignition "Off" and then back on to the run or start positions, which temporarily cuts power to the drive module. For resetting error counters and timestamps, navigate to the "System Definition" screen, select "Parameter Functions > Error history reset," change the "Reset Error History" field from "0" to "1" and then back to "0," clicking the download button after each change. This procedure is detailed on page 184.
What format is this Gehl AL 440, AL 540 manual in?
Immediate download of the complete 220-page searchable Service Manual. Access it on any device — laptop at your desk or phone in the field.
Am I able to print pages from this Gehl AL 440, AL 540 manual?
Yes. The PDF has no DRM restrictions — print any page or section you need for your shop. Works with any standard printer.
Can I find wiring schematics in this Gehl AL 440, AL 540 manual?
Yes — full electrical schematics are included with wire colors, connector locations, and circuit descriptions.
Document Quality
This document is a scanned PDF with an OCR text layer, allowing you to search and copy text. The text quality is crisp and easy to read throughout the manual. Diagrams and illustrations, including electrical schematics and photos of machine parts, are raster images; while generally clear, some small labels may lose sharpness at high zoom levels. Pages are clean and well-aligned, free from significant scan artifacts or marks. There are a few blank pages, primarily at the beginning, end, and as section separators, which serve as filler.
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