This is the Gehl AL 440 and AL 540 service manual (Form 918275), a 220 page PDF for these articulated loaders. It covers the machines powered by the Yanmar 4TNV88-BKGWL diesel, with serial number prefixes 41250 and 51242, and runs from safety and specifications through full component repair.Chapters cover maintenance, operation, chassis, engine, cooling system, axles, hydraulics, the machine and drive controllers, and the electrical system. You get hydraulic and hydrostatic troubleshooting flow charts, drive and work system pressure tests, planetary axle service, and a full electrical schematic.A dedicated torque specifications chapter and clear diagrams round it out. Whether you are chasing a loss of drive, hot hydraulics, hard steering, or a brake problem on an AL 440 or AL 540, the procedures and values are written for the person doing the repair.
What's Inside This Gehl AL 440, AL 540 Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 7-8 | Safety Symbol, Signal Words, Danger, Warning, Caution, Contents and Use of This Manual, Machine Orientation, Service Parts |
| Safety | 9-16 | - |
| 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
Loss of drive or weak propulsion
Weak or one sided drive usually traces to hydrostatic drive wear, low or contaminated oil, or a drive motor or pump problem. The Hydraulics chapter covers the hydrostatic drive system and the drive system pressure tests.
Manual Section: Hydraulics p. 109Slow or jerky loader arm hydraulics
Arms that lift or curl slowly, jerk, or stall under load point to oil condition, clogged filters, a relief valve, or cylinder problems. The Hydraulics chapter includes the work system pressure tests and diagnostic flow charts.
Manual Section: Hydraulics p. 109Overheating or hot hydraulic system
Running hot can mean low fluid, restricted cooling, or dirty filters. The Cooling System chapter covers the radiator and oil cooler removal and service.
Manual Section: Cooling System p. 95Hard or erratic steering
Steering that goes heavy or unresponsive often involves the center and steering bearing or the steering hydraulic circuit. The Chassis chapter covers center and steering bearing removal and installation.
Manual Section: Chassis p. 67Parking brake will not hold
A brake that will not hold can be wear, adjustment, contamination, or a hydraulic fault. The Axles chapter covers the planetary axles and related service.
Manual Section: Axles p. 101Loose wheel fasteners
Wheel fasteners that loosen risk damage and unsafe operation, so they must be set to spec. The Torque Specifications chapter lists the wheel fastener and hydraulic fitting torque values.
Manual Section: Torque Specifications p. 215Frequently Asked Questions
Which models and engine does this manual cover?
It covers the Gehl AL 440 and AL 540 articulated loaders, serial prefixes 41250 and 51242, powered by the Yanmar 4TNV88-BKGWL diesel. The PDF is 220 pages.
Does it include torque specifications?
Yes. A dedicated Torque Specifications chapter lists hydraulic fitting torques for various seals and thread pitches, along with the wheel fastener torque. p. 215
Are hydraulic pressure tests and troubleshooting included?
Yes. The Hydraulics chapter provides drive and work system pressure tests and hydraulic troubleshooting diagnostic flow charts. p. 109
How do I get it after purchase?
You download the PDF right after buying, so nothing ships and there is no wait. The file is yours to keep and reprint.
What format is this 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 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, 540 manual?
Yes — full electrical schematics are included with wire colors, connector locations, and circuit descriptions.
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