AL 140

(SN 11257 and Up)

AL 240(EU)

(SN 21244 and Up)

AL 340

(SN 31365 and Up)

AL 440(EU)

(SN 41250 and Up)

AL 540

(SN 51242 and Up)

Articulated Loaders

Form No.

918496

GP0313

English

Revision G

Original

Instructions

–––

Supersedes

918447

GEHL COMPANY

WARRANTY

GEHL COMPANY, hereinafter referred to as Gehl, warrants new Gehl equipment to the Original Retail Purchaser to be free from defects in material and workmanship for a period of twelve (12) months from the

Warranty Start Date.

GEHL WARRANTY SERVICE INCLUDES:

Genuine Gehl parts and labor costs required to repair or replace equipment at the selling dealer’s business location.

GEHL MAKES NO REPRESENTATIONS OR WARRANTIES OF ANY

KIND, EXPRESS OR IMPLIED (INCLUDING THE IMPLIED

WARRANTIES OF MERCHANTABILITY AND FITNESS FOR

PARTICULAR PURPOSE), EXCEPT AS EXPRESSLY STATED IN

THIS WARRANTY STATEMENT.

ANY OF THESE LIMITATIONS EXCLUDED BY LOCAL LAW SHALL

BE DEEMED DELETED FROM THIS WARRANTY; ALL OTHER

TERMS WILL CONTINUE TO APPLY.

SOME STATES DO NOT PERMIT THE EXCLUSION OR LIMITATION

OF THESE WARRANTIES AND YOU MAY HAVE GREATER RIGHTS

UNDER YOUR STATE LAW.

GEHL WARRANTY DOES NOT INCLUDE:

1. Transportation to selling dealer’s business location or, at the option of the Original Retail Purchaser, the cost of a service call.

3. Components covered by their own non-Gehl warranties, such as tires, batteries, trade accessories and engines.

4. Normal maintenance service and expendable, high-wear items.

5. Repairs or adjustments caused by: improper use; failure to follow recommended maintenance procedures; use of unauthorized attachments; accident or other casualty.

6. Liability for incidental or consequential damages of any type, including, but not limited to lost profits or expenses of acquiring replacement equipment.

No agent, employee or representative of Gehl has any authority to bind

Gehl to any warranty except as specifically set forth herein.

204927/AP0407

All-Tach ® , Power-A-Tach ® and Gehl ® are registered trademarks of Manitou Americas, Inc. The products described in this manual manufactured by Manitou Americas, Inc.

AL 140, AL 240 (EU), AL 340, AL 440 (EU), AL 540

Articulated Loaders Operator’s Manual

TABLE OF CONTENTS

General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Safety Symbol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

Contents and Use of this Manual . . . . . . . . . . . . . . . . . . . . . . . . . 1

Ownership Change . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Manufacturer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Machine Designation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2

Serial Number Plate Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Loader Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Proper Machine Use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Using Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

Component Identification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

Service/Dealership Network . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Vibration Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

Vibration Measurement and Actions . . . . . . . . . . . . . . . . . . . . . 7

Vibration Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

2-Post ROPS/FOPS Warning . . . . . . . . . . . . . . . . . . . . . . . . . 10

Mandatory Safety Shutdown Procedure . . . . . . . . . . . . . . . . . . . 10

Before Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

During Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Provision for Stability/Avoiding Rollover Accidents . . . . . . . . . 15

Electrical Energy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Service Safety Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Battery Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Fire Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Crystalline Silica Exposure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Transporting the Machine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Lifting the Machine with a Crane. . . . . . . . . . . . . . . . . . . . . . . . . 20

Hazard and Hazard Avoidance Symbols . . . . . . . . . . . . . . . . . . 21

Safety Decals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

New Decal Application . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

ANSI-Style and Common Safety Decal Locations . . . . . . . . . 22

ISO-Style Safety Decal Locations . . . . . . . . . . . . . . . . . . . . . . 27

918496/GP0313 1

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Fluid Capacities/Lubricants. . . . . . . . . . . . . . . . . . . . . . . . . . . .31

Maximum Slopes of Engine Operation . . . . . . . . . . . . . . . . . . .32

SAE (Domestic) Weights and Capacities

AL 500 and AL 300 Series . . . . . . . . . . . . . . . . . . . . . . . . . .33

ISO 6016 (EU) Weights and Capacities

AL 500, AL 400 and AL 300 Series . . . . . . . . . . . . . . . . . . . .34

SAE (Domestic) Weights and Capacities

AL 100 Series . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .35

ISO (EU) Weights and Capacities

AL 100 and AL 200 Series . . . . . . . . . . . . . . . . . . . . . . . . . .36

Engine. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Coolant Compound Table. . . . . . . . . . . . . . . . . . . . . . . . . . . . .37

Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Sound Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Wheels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .38

Wheel/Tire Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .39

ROPS and FOPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

Vibration Levels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40

AL 500, AL 400 Series Dimensions . . . . . . . . . . . . . . . . . . . . .41

AL 300, AL 200 Series Dimensions . . . . . . . . . . . . . . . . . . . . .43

AL 100 Series Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . .45

Standard Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .47

Optional Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .48

Common Materials and Densities. . . . . . . . . . . . . . . . . . . . . . .49

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .51

Operating Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Controls and Switches . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .52

Instrument Panel and Indicators . . . . . . . . . . . . . . . . . . . . . . . .54

Cab Controls (Cab only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Cab Environment Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . .56

Air Conditioning Control (option). . . . . . . . . . . . . . . . . . . . . . . .56

Cab Windshield Wiper

Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Cab Dome Light . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Cab Defrost. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .57

Warning Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .58

Operator’s Seat Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . .59

Seat Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

Ignition Key Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .60

2 918496/GP0313

Steering Column Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . 60

Control Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

Hand Throttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

12V Accessory Power Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . 62

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Pre-Operation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Extend the ROPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Restore the ROPS to the raised position . . . . . . . . . . . . . . . . 64

4-Post ROPS Side Gates (Option) . . . . . . . . . . . . . . . . . . . . . 65

Entering and Exiting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Engine Start. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

Engine Shut Down. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Warm-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

New Machines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Driving on Public Roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Lift Arm Down-Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Travel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Slow/Fast Travel Speed Mode Selection . . . . . . . . . . . . . . . . 76

Differential Lock Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Load Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Parking the Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Multi-purpose Joystick. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

AL 100, AL 200(EU), AL 300, AL 400(EU) Self-Leveling

Feature. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

AL 500 Series Limited Self-Leveling . . . . . . . . . . . . . . . . . . . . 79

Float Positions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

General Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Connect/Disconnect Attachments . . . . . . . . . . . . . . . . . . . . . . 81

All-Tach® System Hitch Connection . . . . . . . . . . . . . . . . . . . . 81

All-Tach® System Hitch Disconnection. . . . . . . . . . . . . . . . . . 82

Hydraulic Power-A-Tach® System Hitch Connection . . . . . . . 83

Hydraulic Power-A-Tach® System Hitch Disconnection . . . . . 85

Auxiliary Hydraulics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Auxiliary Circuit Pressure Relief . . . . . . . . . . . . . . . . . . . . . . . 86

Auxiliary Hydraulics Connections . . . . . . . . . . . . . . . . . . . . . . 88

Auxiliary Hydraulics Control Buttons . . . . . . . . . . . . . . . . . . . . 89

Operating Attachments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Bucket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Loading Loose Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Scraping Soft Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

918496/GP0313 3

Scraping Hard Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93

Towing the Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Towing AL 100 Series Machines . . . . . . . . . . . . . . . . . . . . . . .94

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94

Towing AL 300 Series Machines . . . . . . . . . . . . . . . . . . . . . . .95

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Towing AL 500 and AL 400 Series Machines. . . . . . . . . . . . . .95

Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .95

Towing Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

After Towing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .96

Loading and Transporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .97

Crane Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .99

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .103

Maintenance Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .104

Check, Clean and Inspect. . . . . . . . . . . . . . . . . . . . . . . . . . . .104

Leakage Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .105

Lubrication and Filter Changes. . . . . . . . . . . . . . . . . . . . . . . .106

Functional Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .106

Dealer Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Tilting the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Tilting Up the Platform . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .107

Tilting the Platform Down . . . . . . . . . . . . . . . . . . . . . . . . . . . .108

Engine Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Engine Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Checking Engine Oil Level . . . . . . . . . . . . . . . . . . . . . . . . . . .109

Changing Engine Oil and Filter. . . . . . . . . . . . . . . . . . . . . . . .110

Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .112

Accessing the Outer and Inner Filter Elements . . . . . . . . . . .113

Changing the Filter Elements . . . . . . . . . . . . . . . . . . . . . . . . .113

Engine Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Checking Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Cleaning Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . .114

Draining/Refilling Cooling System . . . . . . . . . . . . . . . . . . . . .115

Fuel System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

Adding Fuel. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

Changing Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .116

Water Separator Maintenance . . . . . . . . . . . . . . . . . . . . . . . .117

Checking and Adjusting V-belt Tension . . . . . . . . . . . . . . . . .119

Air Conditioning V-Belt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .119

Air Conditioning Maintenance. . . . . . . . . . . . . . . . . . . . . . . . .120

4 918496/GP0313

Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Windshield Washer Reservoir (Cab Only). . . . . . . . . . . . . . . 121

Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . 122

Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . 122

Changing Hydraulic Oil and Filter . . . . . . . . . . . . . . . . . . . . . 123

Hydraulic Hose Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Planetary Axles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Changing Planetary Axle Oil . . . . . . . . . . . . . . . . . . . . . . . . . 125

Changing Axle Wheel-Hub Oil (AL 500, AL 400 and

AL 300 Series). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Changing Axle Center Oil (AL 500, AL 400 and

AL 300 Series). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Changing Axle Oil (AL 200 and AL 100 Series) . . . . . . . . . . 127

Brake Fluid Reservoir (AL 300, AL 400 and AL 500 Series). . . 128

Checking Brake Fluid Reservoir Level . . . . . . . . . . . . . . . . . 128

Wheels and Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Wheel Fasteners . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

Tires . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Tire Rotation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Checking Tire Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Liquid Tire Ballast (AL 500 Series) . . . . . . . . . . . . . . . . . . . . 129

Lubrication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Electrical System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Steering Column Fuses – AL 500/400/300 Series;

AL 100 (EU), AL 200 Optional. . . . . . . . . . . . . . . . . . . . . . . 135

Steering Column Fuses – AL 100 Series and AL 200

Standard . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Cab and In-Line Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Control Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Machine Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Drive Control Module (AL 500/400 Series) . . . . . . . . . . . . . . 139

Drive Control Module Error Codes . . . . . . . . . . . . . . . . . . . . 140

Battery. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Using a Booster Battery (Jump-Starting). . . . . . . . . . . . . . . . 142

Remote Battery Terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . 143

Storing the Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Before Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

After Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Final Shutdown / Decommissioning . . . . . . . . . . . . . . . . . . . . . 145

918496/GP0313 5

Before Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145

Machine Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165

Torque Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .169

EC Declaration of Conformity. . . . . . . . . . . . . . . . . . . . . . . . . . .171

6 918496/GP0313

CHAPTER 1

GENERAL INFORMATION

Safety Symbol

Manitou Americas, in cooperation with the Society of Automotive Engineers, as adopted this safety alert symbol. This symbol identifies potential safety hazards, which, if not properly avoided, could result in injury. When you see this symbol in this manual or on the machine, your are reminded to BE ALERT!

Your personal safety is involved!

Contents and Use of this Manual

This operator’s manual provides detailed operating procedures for safe, effective and proper machine use. Safe operation is detailed in the Safety chapter of this manual, beginning on page 9. Specification, maintenance and troubleshooting information is also included in this manual.

Improper operation, inspection and maintenance of the machine can result in injury or death. Read and understand the contents of this manual completely and become familiar with the machine before operation. Contact your authorized dealer with any questions about information in this manual, if extra manuals are required, or about availability of manuals in other languages.

Throughout this manual, information is provided set in or italic type and introduced by the words Notice or Important. Carefully read and follow these messages to improve operating and maintenance efficiency, to avoid breakdowns and damage, and extend the life of the machine.

Note: Because of ongoing product improvements, illustrations and listings in this manual may not exactly match the machine. Manitou Americas reserves the right to modify and improve products at any time without notice.

A storage box (A, Fig. 1) behind the seat is provided for manual storage. Store the operator’s manual in this box at all times.

A

Note: AL500 Series machines with air conditioning use a cylindrical manual storage container located next to the operator’s seat.

This manual is considered a permanent part of the machine and should be with the machine at all times. Replace this manual promptly if it becomes damaged, lost, or stolen.

Figure 1 – Manual Storage

Location (except AL500 Series with air conditioning)

918496/GP0313 1

Ownership Change

If the machine is resold, include this operator’s manual as part of the sale.

If the machine was purchased “used,” or if the owner’s address has changed, please provide your dealer or Manitou Americas Service Department with the owner’s name and current address, along with the machine model and serial numbers. This will allow the registered owner information to be updated, so that the owner can be notified directly in case of an important product issue, such as a safety update program.

Manufacturer Information

Products described in this manual manufactured by Manitou Americas, Inc.

Machine Designation

Earth-Moving Machinery/Loaders/Compact/Seated Operator

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Serial Number Plate Location

The serial number placard is located on the front frame on the right side of the machine (B, Fig. 2).

B

Figure 2 – Serial

Number Plate

Earth-Moving Machinery/Loaders/Compact/Seated Operator

Product

Identification

Number

Series

Net power

Operating mass

Max axle load-front

Max axle load-rear kW kg kg kg hp lbs.

lbs.

lbs.

Max speed km/h

Year of Construction

Manufactured by Manitou Americas, Inc.

One Gehl Way

West Bend, WI 53095-0179 USA mph

Additionally, the following components also have identification placards:

• Engine

• Hydraulic pump

• Hydraulic drive motor(s)

• Axles

Loader Information

Use the spaces provided below to record purchase location and date, model and serial number information.

Purchased from

Date of Purchase

Loader Model Number

Loader Serial Number

Engine Serial Number

Hydraulic Pump Identification Number

Drive Motor Identification Number(s)

Axle Identification Number

918496/GP0313 3

Proper Machine Use

WARNING

Improper use of the machine can result in property damage, injury or death.

The machine is designed only for digging, picking up, lifting, transporting and unloading materials. Use with approved attachments is also allowed. Use in any other way is considered as contrary to the intended use. Compliance with, and strict adherence to, the conditions of operation, service and repair, as specified by the manufacturer, also constitute essential elements of the intended use.

The machine was designed and built according to the best available technology and approved safety regulations in the countries where it is sold. However, it is impossible to completely safeguard against abusive and/or improper use. The operator must always consider potential safety risks and hazards during operation. Accident prevention regulations, all other generally recognized regulations on safety and occupational medicine, and all road traffic regulations, must be observed at all times.

The machine must be maintained in proper operating condition. Any damaged or malfunctioning parts must be repaired or replaced immediately.

Any arbitrary modifications carried out to the machine may relieve the manufacturer of liability for any resulting damage or injury.

Using Attachments

Read all documentation provided with attachments to learn how to safely operate and maintain them.

Do not use the machine for any applications or purposes other than those described in this manual or manuals supplied with attachments. Contact the

Manitou Americas Service Department before using attachments or equipment not approved by Manitou Americas, or if there are any questions about approved attachments. Use of non-approved attachments or unauthorized modifications is prohibited.

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Component Identification

8

1

3

4

5

10

7 6

9

2

Figure 3 – Component Identification (AL 500 Series Model Shown)

1. Engine cover

2. Multi-purpose joystick

3. Steering column

4. Road lights (4 locations)

5. Lift arm

6. Speed control pedal (brake/inch pedal on left side)

7. Manual storage box

8. Parking brake (left side)

9. Fuel filler neck

10. All-Tach ® system bracket levers (2 locations)

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Service/Dealership Network

Your dealership network stands ready to provide any assistance that may be required, including providing genuine service parts. All service parts should be obtained from your dealer. Provide complete information about the part and include the machine model and serial numbers. Record these numbers in the spaces provided in “Loader Information” on page 3. Refer to the parts manual for a complete listing of service parts.

Manitou Americas strives to continuously improve its products and reserves the right to make changes and improvements in the design and construction of any part without incurring the obligation to install such changes on any previously delivered machine.

Vibration Information

Compact construction equipment is generally used in harsh environments. This type of usage can expose an operator to uncomfortable levels of vibration. It is useful to understand exposure to vibration levels when operating compact equipment and what can be done to reduce vibration exposure. As a result, equipment operation can be more efficient, productive and safe.

An operator’s exposure to vibration occurs in two ways:

• Whole-Body Vibration (WBV)

• Hand-Arm Vibration (HAV)

WBV issues are primarily addressed in this manual, because evaluations have shown that operation of mobile compact construction equipment on work sites typically results in HAV levels less than the allowed exposure limit of 2.5 m/s 2 .

Member States of the European Union must comply with the Physical Agents

(vibration) Directive, 2002/44/EC.

Effective control of vibration exposure for an operator involves more than just vibration levels on the machine. The work site, how the machine is used, and proper training all play important roles in reducing vibration exposure.

Vibration exposure results from:

• Work site conditions.

• How the machine is operated.

• The machine characteristics.

Common causes of high WBV levels:

• Using a machine that is improper for the task.

• Work site with potholes, ruts and debris.

• Improper operating techniques, such as driving too fast.

• Incorrect adjustment of the seat and controls.

• Other physical activities while using the machine.

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Vibration Measurement and Actions

The vibration directive places the responsibility for compliance on employers.

Actions that should be followed by employers include:

• Assess the levels of vibration exposure.

• Determine from this assessment if operators will be exposed to vibration levels above the limits stated in the directive.

• Take appropriate actions to reduce operator’s exposure to vibration.

• Provide operators with information and training to reduce their exposure to vibration.

• Keep good records and update operations and training on a regular basis.

If the assessment concludes that vibration level exposure is too high, one or more of the following actions may be necessary:

1. Train operators

• Perform operations (accelerating, steering, braking, etc.) in a smooth manner.

• Adjust the controls, mirrors and seat suspension for comfortable operation.

• Travel across the smoothest parts of the work site and avoid ruts and potholes.

2. Choose proper equipment for the job

• Use machines with the proper power and capacity.

• Select machines with good suspension seats.

• Look for controls that are easy to use.

• Ensure good visibility from the operator’s position.

3. Maintain the work site

• Smooth ruts and fill potholes in traffic areas whenever possible.

• Clean up debris frequently.

• Vary traffic patterns to avoid exposure to rough terrain.

4. Maintain the equipment

• Ensure correct tire pressures.

• Check that seat suspension and all controls work smoothly and properly.

Vibration Levels

The table lists typical whole-body vibration levels for the machine. See

“Vibration Levels” on page 40.

918496/GP0313 7

Notes

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CHAPTER 2

SAFETY

This manual and decals on the machine warn of safety hazards and should be read and observed closely.

Before operating the machine, first read and study the safety information in this manual. Additionally, anyone who operates or works on the machine must be familiar with these safety precautions.

This safety alert symbol means ATTENTION! ALWAYS BE

ALERT! YOUR SAFETY IS INVOLVED! This symbol is used throughout this operator’s manual and on the decals on the machine.

DANGER

“DANGER” indicates an imminently hazardous situation, which, if not avoided, will result in death or serious injury.

WARNING

“WARNING” indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.

CAUTION

“CAUTION” indicates a potentially hazardous situation, which, if not avoided, may result in minor injury or property damage. It is also used to alert users of unsafe practices.

It is essential that operators are thoroughly trained in the safe operation of the machine and handling loads. Operators must not be physically or mentally impaired. Do not allow minors or unqualified personnel to operate the machine, or to be near the machine unless they are properly supervised. It is recommended that the operator be capable of obtaining a valid motor vehicle operator’s license.

Use of this machine is subject to certain hazards that cannot be eliminated by mechanical means, but only by exercising intelligence, care and common sense.

Such hazards include: hillside operation, overloading, load instability, poor maintenance, and using the machine for a purpose for which it was not intended or designed.

Manitou Americas always takes operator’s safety into consideration during the design process. Guards and shields are provided, which protect the operator and bystanders from moving parts and other hazards. Operators must be alert, however, because some areas cannot be guarded or shielded without preventing or interfering with proper operation.

Different applications may require optional safety equipment. Be sure you know the work site hazards and equip the machine and the operator as necessary. The information in this manual does not replace any applicable safety rules and laws.

Before operating the machine, learn the rules and laws for your area. Make sure the machine is equipped as required according to these rules/laws.

918496/GP0313 9

Remember that some risks to our health may not be immediately apparent.

Exhaust gases and noise pollution may not be visible, but these hazards can cause permanent injuries.

Some photographs in this manual may show doors, guards and shields open or removed for the purposes of illustration only. Be sure that all doors, guards and shields are in the proper operating positions before starting the engine to operate the machine.

2-Post ROPS/FOPS Warning

WARNING

The machine MUST be equipped with a Falling-

Object Protective Structure (FOPS) when the machine is intended for use in applications where there is a risk of falling objects.

Machines equipped with two-post ROPS MUST NOT be used where there is a risk of falling objects. A risk of falling objects existing whenever a load is lifted above the operator’s head. A two-post

ROPS does NOT protect against falling objects. A four-post FOPS

MUST be installed on machines used where there is a risk of falling objects.

Mandatory Safety Shutdown Procedure

BEFORE cleaning, adjusting, lubricating, fueling, or servicing the machine, or leaving it unattended:

1. Bring the machine to a complete stop on a level surface. Avoid parking on an incline or hillside, but if this is not possible, park across the slope and block the tires.

2. Be sure all working equipment and/or attachments are stopped and the auxiliary valve is in neutral.

3. Lower the lift arm and attachment completely.

4. Place forward/reverse drive switch (on top of the joystick) into the neutral position.

5. Apply the parking brake.

6. Move the throttle to low idle position and shut off the engine.

7. Wait for all movement to stop. Turn the ignition key to the “

I” or RUN position and move the multi-purpose joystick in all directions to verify that the hydraulic system is de-pressurized.

8. If so equipped, press the auxiliary hydraulics pressure relief control. After pressing, make sure this control returns to the neutral position.

9. Turn off the ignition.

10. Unfasten the seat belt and remove the ignition key and take it with you. Exit the machine using the hand holds.

ONLY when these precautions have been taken can you be sure it is safe to proceed. Failure to follow this procedure could result in death or serious injury.

10 918496/GP0313

Before Starting

• Do not remove or modify the Roll-Over Protective Structure (“ROPS”) unless instructed to do so in approved installation instructions.

Modifications, such as welding, drilling or cutting, can weaken the structure and reduce the protection it provides. A damaged ROPS cannot be repaired – it must be replaced.

• Never operate the machine without a ROPS or FOPS installed.

• To ensure safe operation, replace damaged or worn-out parts with genuine service parts.

• The machine is designed and intended to be used only with approved attachments. To avoid possible personal injury, equipment damage and performance problems, use only attachments that are approved for use on and within the operating capacity of the machine (see weights and capacity information, starting on page 33). Contact the Manitou Americas service department for information on attachment approval and compatibility with specific machine models. Manitou Americas cannot be responsible if the machine is used with a non-approved attachment.

• Remove all trash and debris from the machine every day, especially in the engine compartment, to minimize the risk of fire.

• Always face the machine and use the hand holds and steps when entering and exiting the machine. Do not jump off the machine. See “Entering and

Exiting” on page 66.

• Never use starting aids. Engine pre-heating is used for cold weather starting. Engine pre-heating can cause either or other starting fluid to detonate, causing injury or damage.

• Walk around the machine and inspect it before using it. Look for damage, loose or missing parts, leaks, etc.

• Warn all nearby personnel before starting the machine.

• Check for proper tire pressure in all four tires before operating the machine and add air if necessary. Improperly pressurized tires adversely affect machine stability. Regularly check wheel fasteners for tightness.

See “Wheel Fastener Torque” on page 38.

• Contact the proper local authorities for utility line locations BEFORE starting to dig. In North America, contact the North American One-Call

Referral System at 8-1-1 in the U.S., or 1-888-258-0808 in the U.S. and

Canada.

• Below-ground hazards also include water mains, tunnels and buried foundations. Know what is underneath the work site before starting to dig.

• Before working near power lines (either above-ground or buried cabletype), always contact the power utility and establish a safety plan with them.

• If temperatures are changing, be cautious of dark and wet patches when working or traveling over frozen ground. Stay away from ditches, overhangs and other weak support surfaces.

918496/GP0313 11

• The operator’s area, steps and hand holds must be free of oil, dirt, ice and unsecured objects.

• If a lighting system is installed, check its operation before working in darkness.

• Always keep lights, mirrors and windows clean. Poor visibility can cause accidents.

• NEVER start the engine if there is any indication that maintenance or service work is in progress, or if a warning tag is attached to the controls.

• Replace damaged safety decals and a lost or damaged operator’s manual.

• Terrain and soil conditions at the work site, approaching traffic, weatherrelated hazards and any above-or below-ground obstacles and hazards should be observed and monitored by all work crew members.

• Adjust the seat to allow full actuation of all controls. Never adjust the seat during machine operation.

• Read the operator’s manual provided with each attachment used with the machine before starting the engine.

• Before working on or with the machine, remove jewelry, tie back long hair, and do not war loose-fitting garments, such as, scarves, ties, unzipped jackets, etc., which could become caught in the moving parts of the machine and cause injury.

During Operation

12

• ALWAYS fasten the seat belt securely and properly. Never operate the machine without the seat belt fastened around the operator.

• Check indicators and displays for normal conditions after starting the engine. Listen for unusual sounds and remain alert for other potentially hazardous conditions.

• Control the machine cautiously and gradually until fully familiar with all the controls and handling.

• Do not overload the machine. See weights and capacities information starting on page 33 for the load limits.

• If the machine is equipped with a 2-post ROPS, do not overfill the attachment and lift loads higher than the operator’s head. Objects can fall out of the attachment and roll down the lift arm toward the operator causing severe injury. Install a a Falling-Object Protective Structure

(FOPS) if the machine is used to lift loads above the operator’s head.

• Do not raise or drop a loaded bucket or attachment suddenly. Abrupt movements under load can cause serious instability.

• Check that attachments are securely fastened to the attachment hitch before working.

• Never activate the float function with the bucket or attachment loaded or raised, because this will cause the lift arm to lower or bucket to dump rapidly.

• Never operate the machine without a ROPS or FOPS installed.

918496/GP0313

• Machine stability is affected by: the weight of the load being carried, height of the load, machine speed, turn angle, width of the machine across the tires, abrupt control movements and driving over uneven terrain.

DISREGARDING ANY OF THESE FACTORS CAN CAUSE THE

MACHINE TO TIP, THROWING THE OPERATOR OUT OF THE

SEAT OR MACHINE, RESULTING IN DEATH OR SERIOUS INJURY.

Therefore: ALWAYS operate with the seat belt fastened around the operator.

• Do not exceed the machine’s rated operating capacity; refer to operating capacity tables beginning on page 33. Be aware that effective operating capacity is reduced when the machine is turned.

• Machine stability is reduced when the machine is turned.

• Be aware that attachments effect the handling and balance of the machine.

Adjust the operation of the machine as necessary when using attachments.

• Carry the load low. Move the controls smoothly and gradually, and operate at speeds appropriate for the conditions.

• Do not use the machine to lift or transport people. Do not allow others to ride on the machine or attachments, because they could fall or cause an accident.

• Always look to the rear, over both shoulders, before backing up.

• Only start the engine while seated in the operator’s seat with the seat belt fastened around the operator.

• Only operate the controls while seated in the operator’s seat with the seat belt properly fastened.

• Always keep hands and feet inside the operator’s compartment while operating the machine.

• New operators must first operate the machine in an open area away from bystanders. Practice with the controls until the machine can be operated safely and efficiently.

• Wear safety goggles, ear and head protection as needed while operating the machine. Operator must wear protective clothing when appropriate.

• Exhaust fumes can kill. Do not operate the machine in an enclosed area without adequate ventilation. Internal combustion engines deplete the oxygen supply within enclosed spaces and may create a serious hazard unless the oxygen is replaced.

• Do not drive too close to an excavation or ditch. Be sure that the surrounding ground has adequate strength to support the weight of the machine and the load.

• Never allow anyone under a raised lift arm. Lowering the lift arm or a falling load can result in death or serious personal injury.

• Avoid slowing suddenly while carrying a load. Sudden slowing can cause the load to drop off the attachment, or cause the machine to tip over.

918496/GP0313 13

14

• Be aware of overhead obstacles. Any object near the lift arm could represent a potential hazard, or cause the operator to react suddenly and cause an accident. Use a spotter or signal person when working near bridges, phone lines, work site scaffolds, or other obstructions.

• Slow down the work cycle and use slower travel speeds in congested or populated areas. Use commonly understood signals so that other members of the work crew can warn the operator to slow or halt work in a potentially hazardous situation.

• Use a signal person if you cannot see the entire work area clearly, in high traffic areas and whenever the operator’s view is not clear.

• Do not place limbs near moving parts. Severing of body parts can result.

• Do not use the loader to lift or transport people.

• Stay alert for people moving through the work area. When loading a truck, the operator should always know where the driver is.

• Exposed hydraulic hoses could react with explosive force if struck by a falling or overhead items. NEVER allow hoses to be hit, bent or interfered with. Replace any hoses that are damaged.

• Do not drive into materials at high speeds to avoid being thrown forward and injured.

• Do not turn off the ignition switch while traveling. Turning off the ignition will cause sudden hydrostatic braking, which may cause possible loss of control, injury and/or tipping of the machine.

• Unless necessary for servicing the machine, the engine hood must not be opened while the engine is running.

• In cold weather, avoid sudden travel movements and stay away from even slight slopes. The machine can slide sideways on icy slopes.

• Snow accumulation can hide potential hazards. Use care while operating and while using the machine to clear snow.

• If the machine becomes damaged or malfunctions, stop the machine immediately and lock and tag it. Repair the damage or malfunction before using the machine again.

• Never jump off the machine. Never get on or off a moving machine.

Always leave the machine while facing the machine using the steps and hand-holds as described in “Entering and Exiting” on page 66.

918496/GP0313

Provision for Stability/Avoiding Rollover Accidents

• Machine stability is affected by: the weight and center of gravity of the load being carried, height of the load, machine speed, turn angle, width of the machine across the tires, abrupt control movements and driving over uneven and/or soft terrain. DISREGARDING ANY OF THESE

FACTORS CAN CAUSE THE MACHINE TO TIP, THROWING THE

OPERATOR OUT OF THE SEAT OR MACHINE, RESULTING IN

DEATH OR SERIOUS INJURY. Do not exceed the machine’s rated operating capacity, especially when turning, because this reduces the load that will cause the machine to tip over. Carry the load low, and operate at speeds appropriate for the conditions.

• Operate the controls smoothly to prevent jerking or bouncing. Operate on level, stable surfaces. Load, unload and turn on solid, level ground.

• Drive up and down inclines, not across them. Drive slowly on inclines.

Keep the heavy end of the machine pointed uphill.

• Evenly distribute the load on the attachment. Secure unstable loads so they do not shift or fall.

• Do not make sharp turns on inclines. Avoid steep inclines.

• Use care on loose ground. Loose, soft ground or uneven, broken terrain can cause dangerous side-load conditions and possible tipover and injury.

• If you must drive across railroad tracks, ditches, curbs or similar surfaces, cross perpendicular and drive slowly.

• Stay away from steep edges on loading docks, ramps, ditches, retaining walls and trenches.

• Avoid sharp turns and high speeds while carrying loads. The stability of the machine is greatly reduced during sharp turns. Additionally, the load may shift to the side during turns, greatly increasing the possibility of a rollover.

• When unloading trucks or lifting loads off elevated surfaces, approach the load straight ahead and back straight away with the load. Slowly lower the load to the lowest possible transport position before turning.

• To avoid tipping, keep loads as low as possible during transport and while turning. Keep the bottom of the bucket or load no higher than wheel axle height during transport and turning.

• Do not turn the machine when lifting loads. As loads are lifted, a drastic shift in stability can occur, which can greatly increase the possibility of a tip-over or rollover.

• Keep tires inflated to recommended pressure.

• If the machine becomes unstable and starts to tip, keep the seat belt fastened, hold on firmly and brace yourself. Lean away from the point of impact and stay with the machine. If tipping occurs, DO NOT jump from the machine. The machine is equipped with rollover protection, which can only protect the operator while in the operator’s seat. Trying to escape from a tipping machine can result in death or serious personal injury.

918496/GP0313 15

• The ROPS must be replaced if a overturn incident occurs. The protection offered by the ROPS will be impaired if it has been damaged in an overturn incident.

• Never operate the machine without a ROPS or FOPS installed.

Electrical Energy

• Stay away from high-voltage lines. Serious injury or death can result from contact or proximity to high-voltage electric lines. The machine does not have to make physical contact with power lines for current to be transmitted. Use a spotter and hand signals to keep away from power lines not clearly visible to the operator.

• Depending upon the voltage in the power line and atmospheric conditions, strong current shocks can occur if the bucket is closer than 3 m (10 ft.) to the power line. Very high voltage and rainy weather can further increase the safe operating distance.

• If the machine comes into contact with a live wire:

Do not leave the machine.

If possible, drive the machine out of the danger area.

Warn others not to approach or touch the machine.

Have the live wire de-energized.

Do not leave the machine until the wire has been safely de-energized.

• Work on the machine’s electrical system must be performed only by trained technicians.

• Inspect and check the machine’s electrical equipment at regular intervals.

Problems found, such as loose connections or scorched cables, much be repaired before using the machine.

• Only use proper, original equipment fuses/circuit breakers with the specified current rating. Turn off the machine immediately if there is any indication of a problem with the electrical system.

Service Safety Practices

• Only trained and authorized personnel, with a full awareness of safe procedures, should be allowed to operate or perform maintenance or service on the machine.

• Use warning tag/control lockout procedures during service. Alert others that service or maintenance is being performed by tagging operator’s controls — and other machine areas if required — with a warning notice.

• Never attempt to bypass the keyswitch to start the engine. Use only the proper jump-starting procedure explained in “Using a Booster Battery

(Jump-Starting)” on page 142.

16 918496/GP0313

• Never use your hands to search for hydraulic fluid leaks. Instead, use a piece of paper or cardboard. Escaping fluid under pressure can be invisible and can penetrate the skin and cause serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid must be surgically removed by a doctor or gangrene may result.

• Always wear safety glasses with side shields when striking metal against metal. In addition, it is recommended that a softer (chip-resistant) material be used to cushion the blow, otherwise, serious injury to the eyes or other parts of the body could result.

• Stay clear from underneath the operator’s platform as it is tilted.

• Always secure the operator’s platform in the tilted position with the tilt support. Never allow anyone under the operator platform if the tilt support is not in place.

• Always secure the operator’s platform to the chassis with anchor bolts, nuts and washers before driving and using the machine.

• Check operator’s platform tilt components and tilt support components at regular intervals. Replace damaged or worn parts immediately.

• Do not smoke or have any spark- or flame-producing equipment or materials in the area while filling the fuel tank or working on the fuel or hydraulic systems.

• Keep fuel and other fluid reservoir caps tight. Do not start the engine until caps have been secured.

• Always lower lift arm or elevated items, or securely support/secure them, before performing any maintenance or service on the machine.

• Do not attempt to loosen or disconnect any hydraulic lines, hoses, fittings, covers or caps without first relieving hydraulic circuit pressure. Relieve hydraulic pressure by performing the Mandatory Safety Shutdown

Procedure (page 10) and slowly loosening the hydraulic reservoir filler cap. Be careful not to touch any hydraulic components that have been in recent operation, because they can be hot and cause burns.

• Do not attempt to remove the radiator cap after the engine has reached operating temperature or if it is overheated. At operating temperatures, engine coolant is extremely hot and under pressure. Always wait for the engine to cool before attempting to relieve pressure and remove the radiator cap. Failure to heed this warning could result in severe burns.

• Use solid support blocking. Never rely on jacks or other inadequate supports when maintenance work is being done. Never work under any equipment supported only by jacks.

• Refer to the parts manual for information about assembly of components.

Always use the correct parts and the proper torques — incorrect fastener connections can dangerously weaken assemblies.

• Exhaust fumes can kill. Do not operate the machine in an enclosed area unless there is adequate ventilation.

• Operators should also be aware of any open windows, doors or ductwork into which exhaust gases may be carried, exposing others to danger.

918496/GP0313 17

• Do not run the engine if repairs are being performed alone. There should always be at least two people working together if the engine must be run during service.

• Always use adequate tools while working on the machine. Inappropriate tools could break or slip, causing injury, or they may not adequately perform intended functions.

• Unless necessary for servicing the engine, do not open the engine cover while the engine is running.

• Do not use the machine when maintenance is scheduled to be performed.

Postponing maintenance can result in a serious reduction of the service life of the machine, more serious and costly equipment failures, and contribute to unsafe operating conditions.

• Only tow the machine as described in this manual. See “Towing the

Loader” on page 94.

• Do not work on hot engines, cooling systems or hydraulic systems. Wait for the engine to cool. When engine lubrication oil, gearbox lubricant or other fluids require changing, wait for fluid temperatures to decrease to a moderate level before removing drain plugs.

• All safety equipment must be maintained so it is always in good condition.

• Safety-critical parts must be periodically replaced. Replace the following potentially fire-related components as soon as they begin to show signs of deterioration:

Fuel system flexible hoses, fuel tank overflow drain hose and the fuel filler cap.

Hydraulic system hoses, especially the pump outlet lines. Replace hydraulic hoses every 6 years from the date of manufacture (month or quarter, and year) is indicated on the hydraulic hoses.

• Keep mounting brackets and hose and cable routing straps tight. Hose routing should have gradual bends.

• After cleaning the machine, examine all fuel, lubricant and hydraulic oil lines for leaks, chafe marks and damage. Tighten any loose connections and repair or replace parts as necessary.

• When handling oil, grease and other chemical substances, follow the product-related safety requirements Material Safety Data Sheet (MSDS) carefully to prevent burning or scalding.

• Do not use the machine in an environment where the hot muffler could present a fire hazard, such as hay or straw storage facilities.

Battery Hazards

• Use the battery disconnect switch, or disconnect the negative battery cable from the negative battery terminal, before performing electrical service or electrical welding on the machine. See “Engine Start” on page 67.

18 918496/GP0313

• When disconnecting at the battery terminals, remove the cable connected to the negative terminal first. When installing a battery, connect the positive terminal cable first.

• Sparks and open flames can set off explosive battery gas from incidental contact or static discharge. Turn off all switches and the engine when working on batteries. Keep battery terminals tight. Contact between a loose terminal and post can create an explosive spark.

• When jump-starting from another machine, do not allow the machines to touch. Wear safety glasses or goggles while battery connections are made.

• Never jump-start the machine if it has a frozen battery. The battery could explode. Thaw a frozen battery before charging it or attaching jumper cables.

• Flush eyes with water for 10-15 minutes if battery acid is splashed in the face. Anyone swallowing battery acid must have immediate medical aid.

Call the Poison Control Center at 1-800-222-1222 in the United States.

Fire Hazards

• The machine must be cleaned on a regular basis to avoid the buildup of flammable debris, such as leaves, straw, etc. Accumulated debris, particularly in the engine compartment, creates a fire hazard.

• The machine has several components that operate at high temperatures under normal operating conditions, primarily the engine and exhaust systems. Also, the electrical system, if not properly maintained or if damaged, can arc or produce sparks. These conditions make it extremely important to avoid circumstances where explosive dust or gases can be ignited by arcs, sparks or heat.

• Add fuel, oil, antifreeze and hydraulic fluid to the machine only in wellventilated areas. The machine must be parked with controls, lights and switches turned off. The engine must be turned off before fueling.

• Do not smoke while filling the fuel tank, while working on the fuel or hydraulic systems, or while working around the battery.

• Take care to avoid spilling combustible fluids, such as oil or fuel, on a hot engine.

• Static electricity can produce dangerous sparks at the fuel-filling nozzle.

In very cold, dry weather or other conditions that could produce static discharge, keep the tip of the fuel nozzle in constant contact with the fuel filler neck, to provide a ground. Be sure that a ground wire is connected from the machine to the service truck before fueling begins.

• Keep fuel and other fluid reservoir caps tight and do not start the engine until caps have been secured.

• It is recommended that a 2.27 kg (5 lbs.) or larger, multi-purpose “A/B/C” fire extinguisher be mounted within reach of the operator. Check the fire extinguisher periodically and be sure that work site crew members are trained in its use.

918496/GP0313 19

• Oil leaks can ignite on hot components. Repair any damaged or leaking components before using machine.

Crystalline Silica Exposure

Exposure to crystalline silica (found in sand, soil and rocks) has been associated with silicosis, a debilitating and often fatal lung disease. A Hazard Review (Pub.

No. 2002-129) by the U.S. National Institute for Occupational Safety and Health

(NIOSH) indicates a significant risk of chronic silicosis for workers exposed to inhaled crystalline silica over a working lifetime. NIOSH recommends an exposure limit of 0.05 mg/m 3 as a time-weighted average for up to a 10-hr workday during a 40-hr work week. NIOSH also recommends substituting less hazardous materials when feasible, using respiratory protection and regular medical examinations for exposed workers.

Transporting the Machine

Obey federal, state and local over-the-road regulations. Check restrictions regarding weight, height, width and length of a load. The hauling vehicle, trailer and load must all be in compliance with applicable regulations. See “Loading and

Transporting” on page 97.

Lifting the Machine with a Crane

Only lift the machine according to the following guidelines:

• The crane and rigging equipment must have sufficient capacity. See

“Weights and Capacities”, starting on page 33.

• Secure the machine against unintentional movement. Use taglines as needed.

• Do not lift the machine with persons on or in the machine.

• Any person guiding the crane operator must be within sight or sound of the crane operator.

• Lift the machine only with the standard bucket installed, with the bucket empty and in the transport position.

• Persons must stay clear of, and not under, the machine when it is lifted.

• Fasten the rigging equipment so the machine is horizontal when it is lifted.

• Do not lift the machine by the cab. Attach the rigging equipment only at the lift points identified by this symbol:

20

• Lift the machine according to “Crane Lifting” on page 99.

918496/GP0313

Hazard and Hazard Avoidance Symbols

Safety Hazard Fire Hazard Run-Over Hazard Injected Fluid

Hazard

Hot Liquids Hazard

Poisonous Vapors

Hazard

No Smoking No Open Flames Read Operator’s

Manual

Wear Seatbelt

Keep Distance

Wear Eye

Protection

Avoid Power Lines Remove Key Crush Hazard

Read Maintenance/Service

Information

Crush Hazard

Hot Surface

Hazard

Rotating Fan

Keep Away

Safety Lock

Falling Object

Hazard

918496/GP0313 21

Safety Decals

The machine has decals around the machine that provide safety information and precautions. These decals must be kept legible. If missing or illegible, they must be replaced promptly. Replacements can be obtained from your dealer. Refer to the Parts Manual for decal part numbers and ordering information.

New Decal Application

Surfaces must be free of dirt, dust, grease and foreign material before applying the decal. Remove the smaller portion of the decal backing paper and apply the exposed adhesive to the clean surface, maintaining proper position and alignment. Peel the rest of the backing paper and apply hand pressure to smooth out the decal surface. Refer to the following pages for proper decal locations.

If replacing a part that has a decal on it, ensure that the replacement part has the same decal.

ANSI-Style and Common Safety Decal Locations

E

B

R C

A

D

E

F

G

E

A

C

Q

S

RIGHT LEFT

B

A

K

A

H

INSIDE

ENGINE

COMPARTMENT

J

L

M

N

CONTROL

COLUMN

P

CAB/4-POST

ROPS

BACK

Figure 4 – ANSI-Style and Common Safety Decal Locations

(AL 500 Series Shown — Other Series Similar)

E

22 918496/GP0313

ANSI-Style and Common Safety Decal Locations (Cont.)

Note: Refer to Fig. 4 for decal locations.

A Lift Point Decal

• Located at the rear of the machine and near the lift holes/rods near the top of the front frame.

• Apply lift hooks only in these location See

“Crane Lifting” on page 99.

B

WARNING

THE PROTECTION OFFERED BY THIS ROPS

WILL BE IMPAIRED IF IT HAS BEEN

SUBJECTED TO ANY MODIFICATION,

STRUCTURAL DAMAGE, OR HAS BEEN

INVOLVED IN AN OVERTURN INCIDENT, THIS

ROPS MUST BE REPLACED AFTER A ROLL-

OVER. SEAT BELTS MUST BE WORN WHILE

OPERATING VEHICLE.

201078

C

WARNING: Do not modify ROPS; replace damaged

ROPS; wear seat belt

• Located inside the ROPS structure.

• The protection offered by this ROPS will be impaired if it has been subjected to any modification, structural damage, or has been involved in an overturn incident, this ROPS must be replaced after a rollover. Seat belts must be worn while operating vehicle.

WARNING: Crush Hazard

• Located on top of the articulation joint on both sides.

• Keep away from machine when it is being operated.

• Lock frames together when machine is serviced or shipped.

D

USE DIESEL FUEL ONLY!

Located next to the fuel filler neck.

E

Tie-down point, located on lift arm (front, both sides) and frame (rear, both sides). Only use tie-down points indicated on loader when transporting loader.

F IMPORTANT

• Located next to the fuel filler neck.

• Use ONLY Low Sulfur Diesel (LSD) or

Ultra-Low Sulfur Diesel (ULSD) fuel.

• Use of diesel fuel with more than 500 PPM of sulfur will damage the engine. See

“Fuel System” on page 116.

918496/GP0313 23

Note: Refer to Fig. 4 on page 22 for decal locations.

G WARNING: Crush Hazard

• Located on both side of the lift arm.

• Before operating, verify full engagement of loader attachment bracket locking pin to the attachment.

H

USE HYDRAULIC FLUID ONLY!

Located next to the hydraulic fluid reservoir filler neck.

J

K

WARNING: Rotating Fan / Hot Surface

Hazards

• Located on the right side of the firewall inside the engine compartment; on machines with air conditioning, located on the back of the air conditioning enclosure.

• Keep hands out or stop engine.

• Do not touch hot engine or hydraulic system parts.

WARNING: Avoid Injury or Death

• Located on the left side of the firewall inside the engine compartment; on machines with air conditioning, located on the back of the air conditioning enclosure.

• Keep safety devices working.

• Jump start per Operator’s Manual procedure.

• Keep guards, screens and windows in place.

• Do not smoke while fueling or servicing machine.

• Clean debris from engine compartment daily to avoid fire.

Keep fire extinguisher nearby.

• Do not use hand to find hydraulic leaks. Escaping oil under pressure can be invisible and penetrate skin.

• Allow radiator to cool before removing cap. Loosen cap slowly to avoid burns.

24 918496/GP0313

ANSI-Style and Common Safety Decal Locations (Cont.)

Note: Refer to Fig. 4 on page 22 for decal locations.

L IMPORTANT

• Located on top of the radiator inside the engine compartment.

• Do not use ether or other starting fluids to start this engine — warranty may be voided.

M

Located on the left side of the control column.

WARNING: Avoid Injury or Death

• ALWAYS wear seatbelt.

• No riders! Never use work tool as work platform.

• Keep out from under lift arm unless lift arm is supported.

• Operate only from operator’s seat.

• Prevent load rolling down lift arm onto operator.

WARNING: Avoid Overturn

Side stability is reduced when:

1) turning; 2) operating on rough terrain or side slopes; and 3) carrying load raised.

• Carry load low.

• Do not exceed Rated Operating

Capacity.

• Avoid steep slopes and high speed turns.

• Travel up and down slopes with heavy end uphill.

N

3

WARNING

1

AVOID INJURY OR DEATH

Always follow "Mandatory

Safety Shutdown Procedure."

2

P

4

STOP

N

1. Lower equipment to ground.

2. Reduce throttle, apply parking brake.

3. Shift to neutral.

4. Stop engine, remove key.

274507

Located on the control column, facing the operator.

WARNING: Avoid Injury or Death

Always follow “Mandatory Safety Shutdown Procedure.”

1) Lower equipment to ground.

2) Reduce throttle, apply parking brake.

3) Shift to neutral.

4) Stop engine, remove key.

918496/GP0313 25

Note: Refer to Fig. 4 on page 22 for decal locations.

P

Located on the control column, facing the operator.

WARNING: Avoid Injury or Death

• Maintain 3-point contact during entry and exit.

• Inspect work area; avoid all hazards.

• Look in the direction of travel. Keep children and bystanders away.

• Start and operate machine only from seat.

• Never carry riders. Do not lift personnel in bucket.

• Operate only in well ventilated area.

• Keep away from electric power lines, avoid contact.

• Do not wear loose clothing while operating or servicing machine.

• Wear any needed Personal Protective Equipment.

Q WARNING: Crush Hazard

• Located under the operator’s platform on top of the left rear wheel well.

• Be sure lock mechanism is securely engaged before working under ROPS/FOPS.

• Read instructions for use in Operator’s Manual.

R

S

WARNING

FALLING-OBJECT HAZARD

WARNING: Read Operator’s Manual

• Located behind the operator’s seat on the document box cover.

• Read Operator’s Manual and all safety signs before using machine.

• The owner is responsible to ensure all users are instructed on safe use and maintenance.

• Check machine before operating. Service per Operator’s Manual.

• Contact dealer (or manufacturer) for information and service parts.

WARNING: Falling Object Hazard

• 2-Post ROPS machines only.

• Located under the parking hand brake lever.

• Falling-Object Protective Structure (FOPS) must be installed if there is a risk of falling objects.

Falling-Object Protective Structure

(FOPS) must be installed if there is a risk of falling objects.

274572

26 918496/GP0313

ISO-Style Safety Decal Locations

BB

T

T

Z CC

U

RIGHT LEFT

W

V

X

Y

CONTROL

COLUMN

AA

BACK

INSIDE ENGINE

COMPARTMENT

Figure 5 – ISO-Style Safety Decal Locations

(AL 500 Series Shown — Other Series Similar)

Note: Refer to Fig. 5 for decal locations.

T WARNING: Crush Hazard

• Located on top of the articulation joint on both sides.

• Keep away from the articulation joint when the machine is being operated.

• Lock frames together using the steering lock bar when machine is serviced or shipped.

U WARNING: Crush Hazard

• Located on both sides of the lift arm.

• Before operating, verify full engagement of loader attachment bracket locking pin to the attachment.

918496/GP0313 27

Note: Refer to Fig. 5 on page 27 for decal locations.

V

A B

C

D E

WARNING: Rotating Fan / Hot Surface

Hazards

• Located on the right side of the firewall inside the engine compartment; on machines with air conditioning, located on the back of the air conditioning enclosure.

A) Rotating fan hazard.

B) Keep hands away.

C) Stop engine.

D) Hot surface hazard.

E) Do not touch hot engine or hydraulic system parts.

W

A B C D E F

WARNING: Avoid Injury or Death

• Located on the left side of the firewall inside the engine compartment; on machines with air conditioning, located on the back of the air conditioning enclosure.

A) Safety alert / Keep safety devices in place and in working order.

B) Fire hazard / Do not smoke while fueling or servicing the machine.

Clean debris from the engine compartment to avoid fires. Keep fire extinguisher nearby.

C) Run-over hazard / Jump-start the machine only according to the operator’s manual. See “Using a

Booster Battery (Jump-Starting)” on page 142.

D) Oil injection hazard / Do not use hands to find hydraulic leaks. Escaping oil under pressure can penetrate skin.

Use a piece of cardboard to find leaks.

E) Burn hazard / Allow radiator to cool before removing cap. Loosen cap slowly to avoid burns.

F) Suffocation hazard / Operate only in a well-ventilated area.

28 918496/GP0313

ISO-Style Safety Decal Locations (Cont.)

Note: Refer to Fig. 5 on page 27 for decal locations.

X

A B C D

273901

General Operating Warnings

• Located on the left side of the control column.

A) Crush hazard / Keep out from under lift arm unless lift arm is supported.

B) Side tip hazard / Avoid steep slopes and high-speed turns. Travel up and down slopes with heavy end uphill.

Fasten seat belt.

C) Forward tip hazard / Carry load low. Do not exceed rated operating capacity.

D) Fall hazard / No riders! Never use attachment as work platform.

Y

1

3

N

2

P

4

STOP

274564

General Safety Shutdown Warning

• Located on the control column, facing the operator.

• Read the Operator’s Manual and all safety signs before using the machine.

• Shutdown Procedure:

1) Lower equipment to the ground.

2) Reduce the throttle and apply the parking brake.

3) Shift to Neutral.

4) Stop the engine and remove the key.

Z

WARNING: Crush Hazard

• Located under the operator’s platform on top of the left rear wheel well.

• Be sure cab tilt support is securely engaged before working under operator’s platform. See

“Tilting the Platform” on page 107.

184711

918496/GP0313 29

Note: Refer to Fig. 5 on page 27 for decal locations.

AA

A

C

E

B

D

F

General Operating Warnings

• Located on the control column, facing the operator.

A) Check machine before operating. Service according to Operator’s Manual. Contact dealer (or manufacturer) for information and service parts.

B) Maintain 3-point contact during entry and exit. Do not grasp steering wheel during entry and exit.

C) Inspect work area. Avoid all hazards. Look in the direction of travel. Keep children and bystanders away.

D) Start and operate machine only from operator’s seat.

E) Keep away from power lines.

F) Wear personal protective equipment as needed. Do not wear loose clothing while operating or servicing machine.

BB

137842

WARNING: Read Operator’s Manual

• Located behind the operator’s seat on the document box cover.

• Be sure all users are instructed on safe use and maintenance. Service machine according to the Operator’s Manual.

Contact dealer (or manufacturer) for information and service parts.

CC WARNING: Falling Object Hazard

• Located under the parking brake lever.

• For 2-Post ROPS machines only.

• Falling-Object Protective Structure (FOPS) must be installed if there is a risk of falling objects.

274028

30 918496/GP0313

CHAPTER 3

SPECIFICATIONS

Fluid Capacities/Lubricants

AL

500/400

Series

AL 300

Series

Diesel Engine Oil

AL 200

Series

Specification

Season/Temp.

Range

Capacity

Diesel Fuel

Specification

AL 100

Series

API CD or Higher (United States)

ACEA E-3, E-4, E-5 (European Union)

SAE 10W-30: -20°C (-4°F) to 30°C (86°F)

SAE 15W-40: -15°C (5°F) to 40°C (104°F)

SAE 20W-50: -10°C (14°F) to 50°C (122°F)

7.4 L (7.8 qts.)

6.7 L

(7.2 qts.)

4.4 L

(4.6 qts.)

LSD or ULSD 1 low sulfur or ultra-low sulfur, below

500 PPM. Up to 5% (B5) mixture of BioDiesel allowed.

1-D or 2-D, ASTM D975-94 (United States)

EN 590:96 (European Union)

ISO 8217 DMX (International)

BS 2869-A1 or A2 (United Kingdom)

Season/Temp.

Range

Dependent on Outside Temperatures

Capacity

68 L

(18 gal.)

57 L

(15 gal.)

26 L

(7 gal.)

Hydraulic Oil 2

System/Tank

Hydraulic Oil

Specification

Season/Temp.

Range

Biodegradable Oil

Specification

Season/Temp.

Range

UTTO Fluid (Mobil 424 or equivalent)

Year-Round

Panolin Biofluid LS

Year-Round

Capacity

40 L

(10.6 gal.)

26 L

(6.9 gal.)

34 L

(9.0 gal.)

1. Ultra-Low Sulfur Diesel (ULSD) fuel lubricity must have a maximum scar diameter of 0.45 mm, as measured by ASTM D6079 or ISO 12156-1, or a minimum of 3100 grams, as measured by ASTM D6078. Contact your fuel supplier for details.

2. IMPORTANT! – When adding hydraulic oil, hydraulic tanks in AL 100 Series machines must be vented by removing oil filter cap and lifting oil filter or tanks will not fill evenly. See “Checking Hydraulic Oil Level” on page 122.

918496/GP0313 31

AL

500/400

Series

AL 300

Series

AL 200

Series

AL 100

Series

Axle Oil

Hubs (each)

Front Center

Rear Center

Grease

Specification

Season/Temp.

Range

Capacity

Engine Coolant

System/Radiator

Specification

0.4 L (0.4 qt.) UTTO

Fluid (Mobil 424 or equivalent)

2.5 L (2.6 qt.) UTTO

Fluid (Mobil 424 or equivalent)

3.2 L (3.4 qt.) UTTO

Fluid (Mobil 424 or equivalent)

N/A

3.78 L (4 qts.) 75W90 gear oil or UTTO Fluid

(Mobil 424 or equivalent)

KF2K-25 Lithium

Year-Round

As Required

Season/Temp.

Range

Capacity

Windshield Washer

Specification

Season/Temp.

Range

Capacity

6.4 L (6.8 qts.)

Long-life coolant ASTM D4985,

D6210 (United States)

SAE J814C, J1941, J1034 or

J2036 (International)

Year-Round

5.3 L (5.6 qts.)

Windshield Washer Fluid

Year-Round

1.3 L (1.4 qts.) N/A

Maximum Slopes of Engine Operation

Continuous Engine Operation

Intermittent Engine Operation (<3 minutes)

25° for all directions

30° for all directions

WARNING

The maximum slopes of engine operation listed here may exceed safe operation. See

“Provision for Stability/Avoiding Rollover Accidents” on page 15.

32 918496/GP0313

SAE (Domestic) Weights and Capacities

AL 500 and AL 300 Series

Description

Operating Weight

Shipping Weight

2-Post

ROPS

3307

(7290)

3182

(7016)

1118

(2466)

AL 500 Series

4-Post

ROPS

3357

(7400)

3235

(7131)

1145

(2460)

3452

(7610)

3380

(7451)

1165

(2560) kg (lbs.) 1

Cab

2-Post

ROPS

2472

(5450)

2358

(5199)

798

(1760)

AL 300 Series

4-Post

ROPS

2520

(5555)

2406

(5304)

834

(1840)

Cab

2649

(5840)

2535

(5589)

857

(1890)

Rated Operating

Capacity 1, 2

Static Tipping Loads

Standard Bucket 2

- Straight

SAE J732 Standard Bucket 2 -

45° Turn

(Domestic)

Standard Pallet

Forks 3 - Straight

SAE J1197 Standard Pallet Forks 3

- 45°Turn

(Domestic)

2237

(4932)

1771

(3904)

1634

(3602)

1278

(2817)

2290

(5049)

1800

(3969)

1682

(3708)

1333

(2939)

2330

(5136)

1860

(4101)

1703

(3755)

1352

(2981)

1597

(3521)

1244

(2743)

1098

(2420)

857

(1889)

1670

(3681)

1280

(2821)

1169

(2578)

909

(2005)

1721

(3794)

1319

(2907)

1247

(2750)

977

(2155)

1. Measured on firm and level ground. Equipped with full fluids and 75 kg (165 lbs.) operator.

AL 500 Series equipped with 33x15.5-16.5 tires, fluid-filled rear tires (air-filled

rear tires have reduced capacities) and counterweight.

AL 300 Series equipped with 30.5X12.5-16.5 tires.

2. AL 500 Series equipped w/ 1524 mm (60”) dirt/construction bucket.

AL 300 Series equipped w/ 1372 mm (54”) dirt/construction bucket.

3. Equipped w/ pallet forks with 1067 mm (42”) tines and 533 mm (21”) load center.

918496/GP0313 33

ISO 6016 (EU) Weights and Capacities

AL 500, AL 400 and AL 300 Series

Description

Operating Weight

Shipping Weight

AL 500 Series

2-Post

ROPS

3307

(6732)

3021

(6660)

1118

(2466)

4-Post

ROPS

3106

(6847)

3071

(6770)

1145

(2460)

Cab

3502

(7202)

3166

(6980)

1165

(2560) kg (lbs.) 1

AL

400 Series

2-Post

ROPS

2740

(6041)

2618

(5772)

4-Post

ROPS

2790

(6151)

2668

(5882)

901

(1987)

901

(1987)

Rated Operating

Capacity 1, 2

Static Tipping Loads

Standard

Bucket 2 -

Straight

ISO 6016

Standard

Bucket 2 - 45°

Turn (EU)

Standard Pallet Forks 3 -

Straight

ISO 6016

Standard Pallet Forks 3 -

45° Turn (EU)

1993

(4394)

1357

(2992)

1532

(3377)

1041

(2295)

1993

(4394)

1357

(2992)

1532

(3377)

1041

(2295)

1993

(4394)

1357

(2992)

1532

(3377)

1041

(2295)

1802

(3973)

1181

(2603)

1332

(2937)

874

(1927)

1802

(3973)

1181

(2603)

1332

(2937)

874

(1927)

AL 300 Series

2-Post

ROPS

2360

(5201)

2206

(4864)

798

(1760)

1652

(3642)

1110

(2447)

1270

(2800)

840

(1852)

4-Post

ROPS

2434

(5368)

2254

(4969)

834

(1840)

1652

(3642)

1110

(2447)

1270

(2800)

840

(1852)

Cab

2561

(5646)

2383

(5254)

857

(1890)

1652

(3642)

1110

(2447)

1270

(2800)

840

(1852)

1. Measured on firm and level ground. Equipped with full fluids and 75 kg (165 lbs.) operator.

AL 500 Series equipped with 31x15.5x16.5 tires.

AL 400 Series equipped with 12 x 16.5.

AL 300 Series equipped with 10x16.5 EM tires.

2. AL 500/AL 400 Series equipped w/ 1524 mm (60”) dirt/construction bucket.

AL 300 Series equipped w/ 1372 mm (54”) dirt/construction bucket.

3. Equipped w/ pallet forks with 1067 mm (42”) tines and 533 mm (21”) load center.

34 918496/GP0313

SAE (Domestic) Weights and Capacities

AL 100 Series

Operating Weight

Shipping Weight

Description

Rated Operating Capacity 1, 2 kg (lbs.) 1

AL 100 Series

2-Post

ROPS

1744

(3845)

4-Post

ROPS

1774

(3910)

1651

(3640)

435

(960)

1681

(3705)

435

(960)

Static Tipping Loads

Standard Bucket 2 - Straight

SAE J732 Standard Bucket 2 - 45° Turn

(Angle) (Domestic)

Standard Pallet Forks 3 - Straight

SAE J1197 Standard Pallet Forks 3 - 45°

Turn (Domestic)

873

(1924)

692

(1526)

629

(1386)

497

(1096)

975

(1929)

702

(1547)

643

(1417)

508.5

(1121)

1. Measured on firm and level ground. Equipped with full fluids, 75 kg (165 lbs.) operator and 27x10.50-15 tires.

2. Equipped w/ 1118 mm (44”) dirt/construction bucket.

3. Equipped w/ pallet forks with 1067 mm (42”) tines and 533 mm (21”) load center.

918496/GP0313 35

ISO (EU) Weights and Capacities

AL 100 and AL 200 Series

Description

Operating Weight

Shipping Weight

Rated Operating Capacity 1, 2 kg (lbs.) 1

AL 200 Series

2-Post

ROPS

4-Post

ROPS

2108

(4647)

1994

(4396)

714

(1574)

2169

(4782)

2055

(4531)

714

(1574)

AL 100 Series

2-Post

ROPS

4-Post

ROPS

1690

(3728)

1534

(3382)

435

(960)

1721

(3794)

1564

(3447)

435

(960)

Static Tipping Loads

Standard Bucket 2 - Straight

ISO 6016 Standard

Bucket 2 - 45° Turn (EU)

Standard Pallet Forks 3 -

Straight

ISO 6016 Standard Pallet

Forks 3 - 45° Turn

1428

(3148)

816

(1799)

1099

(2423)

645

(1422)

1428

(3148)

816

(1799)

1099

(2423)

645

(1422)

892.5

(1968)

438

(965)

660

(1454)

334

(737)

858

(1891)

438

(965)

660

(1454)

334

(737)

1. Measured on firm and level ground. Equipped with full fluids and 75 kg (165 lbs.) operator.

AL 100 Series equipped with 27x8.50-15 tires.

AL 200 Series equipped with 27x10.50-15 tires.

2. Equipped w/ 1118 mm (44”) dirt/construction bucket.

3. Equipped w/ pallet forks with 1067 mm (42”) tines and 533 mm (21”) load center.

36 918496/GP0313

Engine

AL 500/

AL 400

Series

AL 300

Series

AL 200

Series

AL 100

Series

Manufacturer Yanmar

Type

Engine Model

Displacement

Cyl. Bore x Stroke

Gross Power @

Manuf. Rated rpm

Adjusted High Idle

Combustion

4-cylinder, 4cycle, In-line,

Water-cooled

Diesel

4TNV88-

BKGWL

2190 cc

(133.6 cid)

35 kW (47 hp)

@ 2800 rpm

2700 rpm

3-cylinder, 4-cycle, In-line, Water-cooled

Diesel

3TNV88-BKGWL

1642 cc (100.2 cid)

88 x 90 mm

(3.5 x 3.5”)

26 kW (35 hp) @ 2800 rpm

2800 rpm

Direct Injection

3TNV76-

KGWL

1116 cc (68.1 cid)

76 x 82 mm

(3.0 x 3.2”)

17.4 kW (23.3 hp) @ 2800 rpm

3000 rpm

Indirect Injection

Starting Aid

Max. Travel Speed

20 km/h

(12.4 mph)

Pre-heating Glow Plug

18.5 km/h

(11.5 mph)

13.5 km/h

(8.4 mph)

12.5 km/h

(7.8 mph)

Operating Range–

Ambient Temperature 1

-15°C (+5°F) – +45°C (+113°F)

1. Operation above temperature range may result in overheating; operation below temperature range may result in hard-starting. Contact your dealer before operating the machine outside temperature range.

Coolant Compound Table

Outside

Temp.

Water

Up to ºF (ºC) %by Volume

Anti-Corrosion Agent in 3 /gal

(cm 3 /L)

Antifreeze

%by Volume %by Volume

39 (4)

14 (-10)

-4 (-20)

-13 (-25)

-22 (-30)

-44 (-42)

59

55

55

99

79

65

2.6 (10) 1

40

45

50

-

20

34

918496/GP0313 37

Hydraulics

AL 500/

AL 400

Series

AL 300

Series

Auxiliary Hydraulics (at 100% theoretical flow)

Hydraulic

System

57 L/min

(14 gpm)

45 L/min

(12 gpm)

System

Pressure

Drive Hydraulics

207 bar

(3000 psi)

AL 200

Series

Hydraulic

System

System

Pressure

Reservoir

Capacity

117 L/min

(31 gpm)

410 bar

(5940 psi)

42 L (11 gals.)

79 L/min

(21 gpm)

350 bar

(5075 psi)

101 L/min

(26.7 gpm)

320 bar

(4640 psi)

79 L/min

(21 gpm)

26 L (7 gals.)

AL 100

Series

30 L/min

(8 gpm)

193 bar

(2800 psi)

34L (9 gals.)

Drive Hydraulics

10749 lbf

(47.8 kN)

5705 lbf

(25.4 kN)

5273 lbf

(23.5 kN)

2433 lbf

(10.8 kN)

Electrical System

Alternator

Starter

Battery

Sound Levels

12V - 55 A

12V - 2.3 kW

850 CCA - 74 Ah

All

Series

<101 dB(A)

< 85 dB(A)

ISO 6395 A-Weighted Sound Power Level

A-Weighted Emission Sound Pressure

Level at the Operator’s Position

Wheels

Wheel Fastener

Torque

AL 500/

AL 400

Series

319 N•m

(235 lbf-ft)

AL 300

Series

AL 200

Series

165 N•m

(122 lbf-ft)

AL 100

Series

38 918496/GP0313

Wheel/Tire Sets

Description

27x8.50-15, 8-ply

27x10.50-15, 8-ply

27x10.50-15, 10-ply (turf)

30.5x12.5-16.5, 8-ply

10x16.5, 8-ply

29x12.5-15 8-ply (turf)

33x15.5-16.5

12x16.5

33x13.5-16 NHS 12-ply

(turf)

Model

AL 100 Series

AL 100 Series

AL 100 Series

AL 300 Series

AL 300 Series

AL 300 Series

AL 500 Series

AL 500 Series

AL500 Series

Machine Width

Millimeters (Inches)

1044 (41.1)

1049 (41.3)

1049 (41.3)

1280 (50.4)

1280 (50.4)

1285 (50.6)

1400 (55.1)

1200/1346 (47.2/53.0)

1368 (53.9)

W/T Set 27x10.50-15

W/T Set 27x10.50-15

(wide-stance wheel option)

W/T Set 27x10.50-16

W/T Set 10.0x16.5

W/T Set 10.0x16.5

W/T Set 29x12.50-15

W/T Set 31x15.50-16.5

31x15.5-16.5

12x16.5

31x15.5-15

(EU Only)

AL 100 Series

AL 200 Series

AL 100 Series

AL 200 Series

AL 100 Series

AL 200 Series

AL 100 Series

AL 200 Series

AL 300 Series

AL 300 Series

AL 300 Series

AL 500 Series

AL 400 Series

AL 500 Series

AL 400 Series

AL 500 Series

AL 400 Series

958/1079 (37.7/42.5)

990/1010 (39.0/39.8)

988/1050 (38.9/41.3)

948/1097 (37.3/43.2)

1145/1274 (45.1/50.2)

1150/1349 (45.3/53.1)

1325/1372 (52.2/54.0)

1282/1415 (50.5/55.7)

1200/1346 (47.2/53.0)

1282/1415 (50.5/55.7)

Note: See tire sidewall for inflation pressures, except where noted.

Important: AL 500 Series machines with fluid-filled rear tires have increased load capacities.

918496/GP0313 39

ROPS and FOPS

FOPS Rating Level 1

Vibration Levels

AL100

Whole Body

Vibration

(ISO 2631-1) m/s

Hand-Arm Vibration

(ISO 5349-1) m/s 2

< 1.03 m/s²

(+ 0.41k)

< 2.00 m/s²

(+ 1.00k)

AL200

< 0.89 m/s²

(+ 0.45k)

< 1.37 m/s²

(+ 0.69k)

AL300

< 0.75 m/s²

(+ 0.38k)

AL400

< 0.88 m/s²

(+ 0.44k)

AL500

< 0.82 m/s²

(+ 0.41k)

< 1.37 m/s²

(+ 0.69k)

< 1.70 m/s²

(+ 0.85k)

< 2.23 m/s²

(+ 1.12k)

40 918496/GP0313

AL 500, AL 400 Series Dimensions

F

H

BB

E

S

D

B

A

AA

C

N

X

Y

M

L

K

J

Z

F

G

F

W

R

V

U

T

P

CC

400 Series

918496/GP0313 41

AL 500, AL 400 Series Dimensions

Ref.

Description

Millimeters (Inches) unless otherwise noted

AL 400 Series AL 500 Series

2-Post

ROPS

4-Post

ROPS/

Cab

2-Post

ROPS

4-Post

ROPS

4511 (177.6) 4224 (166.3) A Length with Bucket on Ground

B

Shipping Length (without bucket)

C

Front Wheel Center to Pivot

Point

D Wheelbase

E Rear Overhang

3790 (149.2)

723 (28.5)

3550 (139.8)

570 (22.4)

F Height to Top of ROPS/Cab

G Folded 2-Post ROPS Height

H Hood Height

J Maximum Reach Height

K Bucket Hinge Pin Height

L

Ground Plane to Bucket Edge

Height

M Dump Clearance at Full Height

N Dump Reach at Full Height

P Width Over Tires 1

1741 (68.5)

2473

(97.4)

1895

(74.6)

1184 (46.6)

2310

(90.9)

2473

(97.4)

—

1895

(74.6)

1521 (59.9)

3617 (142.4)

3055 (120.3)

1617 (63.7)

2310

(90.9)

—

3550 (139.8)

3002 (118.2)

2860 (112.6) 2770 (109.1)

R ROPS Width

S Ground Clearance

T Turning Radius w/ Bucket

U Outer Turning Radius

V Inner Turning Radius

W Articulation Angle from Center

X Rollback at Height

Y

Maximum Dump Angle at Full

Height

Z Bucket Rollback at Ground

AA Attachment Pivot Clearance

BB Wheel Radius

CC Bucket Width (standard)

2300 (90.6)

445 (17.5)

1380 (54.3)

985

(38.8)

1030 /

1081

(40.6) /

(42.6)

2215 (87.2)

267 (10.5)

1195 (47.0)

985

(38.8)

1030

(40.6)

265 (10.4)

3220 (126.8)

246 (9.7)

3123 (123.0)

2750 (108.3) 2643 (104.1)

1365 (53.7)

45°

45°

47° 53°

40°

212 (8.3) 203 (8.0)

405 (15.9)

1524 (60.0)

385 (15.2)

1. AL 500 Series wide tire option shown

42 918496/GP0313

AL 300, AL 200 Series Dimensions

F

G

H

BB

E

N

S

D

B

A

AA

C

R

X

Y

Z

M

L

K

J

R

W

P

CC

U

T

V

F

918496/GP0313 43

AL 300, AL 200 Series Dimensions

Millimeters (Inches) unless otherwise noted

AL 300 Series

2-Post

ROPS

4-Post

ROPS

/Cab

AL 200 Series

2-Post

ROPS

4-Post

ROPS

Ref.

Description

A Length with Bucket on Ground

B Shipping Length (without bucket)

C Front Wheel Center to Pivot Pin

D Wheelbase

E Rear Overhang

F Height to Top of ROPS/Cab

G Folded 2-Post ROPS Height

4050 (159.4) 4040 (159.1)

3351 (131.9)

517 (20.4)

1627 (64.1)

2420

(95.3)

1842

(72.5)

1468 (57.8)

1065 (41.9)

2257

(88.9)

—

2371

(93.3)

1773

(69.9)

2212

(87.1)

—

1412 (55.6) H Hood Height

J Maximum Reach Height

K Bucket Hinge Pin Height

L Ground Plane to Bucket Edge

Height

3415 (134.4)

2855 (112.4)

2650 (104.3)

3255 (128.1)

2790 (109.9)

2565 (101.0)

M Dump Clearance at Full Height

N Dump Reach at Full Height

P Width Over Tires

R ROPS Width

S Ground Clearance

T Turning Radius w/ Bucket

U Outer Turning Radius

V Inner Turning Radius

W Articulation Angle from Center

X Rollback Angle at Height

Y Maximum Dump Angle at Full

Height

Z Bucket Rollback Angle at

Ground

AA Attachment Pivot Clearance

BB Wheel Radius

CC Bucket Width (standard)

2143 (84.4)

312 (12.3)

1280 (50.4)

990

(39)

1030 /

1081

(40.6) /

(42.6)

244 (9.6)

3000 (118.1)

2630 (103.2)

1321 (52.0)

45°

39.7°

43°

215 (8.5)

383 (15.1)

1372 (54.0)

37°

2045 (80.5)

135 (5.3)

1058 (41.7)

990

(39)

1030

(40.6)

235 (9.3)

2530 (99.6)

2120 (83.5)

1030 (40.6)

29°

53°

157 (6.2)

340 (13.4)

1050 (41.3)

44 918496/GP0313

AL 100 Series Dimensions

F

G

H

BB

E

S

D

B

A

C

AA

R

N

Y

X

Z

M

L

K

J

R

P

CC

W

F

V

U T

918496/GP0313 45

AL 100 Series Dimensions

Ref.

Description

A Length with Bucket on Ground

B Shipping Length (without bucket)

C Front Wheel Center to Pivot Pin

D Wheelbase

E Rear Overhang

F Height to Top of ROPS/Cab

G Folded 2-Post ROPS Height

H Hood Height

J Maximum Reach Height

K Bucket Hinge Pin Height

L Ground Plane to Bucket Edge Height

M Dump Clearance at Full Height

N Dump Reach at Full Height

P Width Over Tires

R ROPS Width

S Ground Clearance

T Turning Radius w/ Bucket

U Outer Turning Radius

V Inner Turning Radius

W Articulation Angle from Center

X Rollback at Height

Y Maximum Dump Angle at Full Height

Z Bucket Rollback at Ground

AA Attachment Pivot Clearance

BB Wheel Radius

CC Bucket Width (standard)

Millimeters (Inches) unless otherwise noted

2-Post ROPS 4-Post ROPS

3419 (134.6)

2741 (107.9)

489 (19.3)

1348 (53.1)

738 (29.1)

2340 (92.1)

1863 (73.3)

2190 (86.2)

—

1359 (53.5)

3277 (129.0)

2705 (106.5)

2504 (98.6)

1969 (77.5)

394 (15.5)

1049 (41.3)

824 (32.4) 786 (30.9)

191 (7.5)

2530 (99.6)

2100 (82.7

1120 (44.1)

45°

40°

45°

40°

197 (7.8)

324 (12.8)

1118 (44.0)

46 918496/GP0313

Standard Features

• Fuel Level Gauge

• Hourmeter

• Front Auxiliary Hydraulics with Flat-face

Couplers

• Dual-Element Air Cleaner with Visual

Indicator

• Pre-heat Starting Assist • Hydraulic Oil Filter Indicator Lamp

(AL 500, AL 400 and AL 300 Series

• High/Low Speed Ranges

(AL 500, AL 400 and AL 300 Series

• Voltmeter

(AL 500, AL 400 and AL 300 Series;

AL 100 (EU) and AL 200 Series

Optional)

• Engine Oil Temperature Gauge (AL

500, AL 400 and AL 300 Series; AL

100 (EU) and AL 200 Series

Optional)

• Tachometer

(AL 500, AL 400 and AL 300 Series;

AL 100 (EU) and AL 200 Series

Optional)

• Engine Oil Pressure Indicator Lamp

(AL 500, AL 400 and AL 300 Series;

AL 100 (EU) and AL 200 Series

Optional)

• Interior Dome Light

(Cab only)

• Automotive-style Hydraulic Drive (All

Models Except AL200 Series)

• Battery Disconnect Switch (EU only)

• Lockable Fuel Cap

• Lift and Tilt Cylinder w/Nitrosteel der Rods

• Two-inch Wide Seat Belt

™ Cylin-

• Lockable Engine Cover

• Five-way Adjustable Seat

• Skid-Steer Loader Type Mechanical All-

Tach ® or Hydraulic Power-A-Tach ®

Quick-Attach System (4-Point Available

EU Only)

• Heavy-Duty Axles with Differential Lock

(AL 500, AL 400 and AL 300 Series)

• Limited-Slip Differential Axles

(AL 100 and AL 200 Series)

• Remote Battery Terminal (EU Only) • Up and Down Attachment Self-leveling (Limited Self-leveling on AL500

Series)

• Front/Rear Tie-Downs

• Steering / Frame Transport Lock

• Braking / Inching Pedal

• Multi-Function Joystick

• Hand and Foot Throttle (Hand Throttle

AL 500, AL 400 and AL 300 Series)

• Operator Presence Seat Switch

• Tiltable Seat Deck for Service

• 2-Post ROPS, or 4-Post ROPS/FOPS or

Cab Level 1 (Cab AL 500 and AL 300

Series)

• Horn

918496/GP0313 47

Optional Features

• Three-inch Wide Seat Belt (Where

Required by State Law)

• Battery Disconnect Switch Kit

• Engine Block Heater

• Radio (AL 500 and AL 300 Series;

4-Post ROPS and Cab only)

• Counterweight (AL 500 Series standard; AL 400 and AL 300 Series optional; AL100 and AL200 Series not available)

• Backup Alarm

• Strobe Light Kit

• Road Lights (Standard with Cab)

• Rear View Mirror Kit (4-Post ROPS and

Cab only; Mirror Kit Included with Cab)

48 918496/GP0313

Common Materials and Densities

Material

Ashes

Brick-common

Cement

Charcoal

Clay, wet-dry

Coal

Concrete

Cinders

Coal-anthracite

Coke

Earth-dry loam

Earth-wet loam

Granite

Gravel-dry

Gravel-wet

Gypsum-crushed

Iron ore

Lime

Lime stone

Manure-liquid

Manure-solid

Peat-solid

Phosphate-granular

Potash

Quartz-granular

Salt-dry

Salt-rock-solid

Sand-dry

Sand-wet

Sand-foundry

Shale-crushed

Slag-crushed

Snow

Taconite

Note: The densities listed are average values and intended only as a guide for bucket selection. For a material that is not in the table, obtain its density value before selecting the appropriate bucket.

Density kg/m 3

560-800

1792

1760

368

1280-1600

848-1008

1840

800

1504

480

1121-1442

1281-1602

1488-1776

1602

1922

1840

2320

960

1440

1040

720

752

1440

1088

1760

1602

2160

1728

2000

1520

1440

1120

240-800

1712

90

68

110

100

135

108

125

95

90

65

45

47

120

115

145

60

90

70

15-50

107 lbs./ft.

3

35-50

112

110

23

80-100

53-63

115

50

94

30

70-90

80-100

93-111

100

918496/GP0313 49

Notes

50 918496/GP0313

CHAPTER 4

OPERATION

WARNING and maintenance. Failure to follow instructions can result in injury or death. Read and understand all safety and instructional decals before operation.

Read and understand this entire manual.

Follow warnings and instructions for operation

Do not operate the machine unless all guards and shields are in place. Know how to stop the machine before starting.

Use only approved accessories and attachments. Contact the

Manitou Americas Service Department for information about approved attachments. Use of non-approved attachments or unauthorized modifications is prohibited.

Check for correct function after adjustments or maintenance.

If any warning indicators illuminate when the engine is running, turn off the engine immediately. Correct the problem before re-starting the engine.

Never adjust the operator’s seat or the steering column when the engine is running.

If the machine is equipped with a folding 2-post ROPS, only fold the

ROPS temporarily if necessary during transport or for operation inside structures with low overhead doors or clearances.

Always operate the machine with the seat belt fastened. Repair or replace any damaged seat belt and buckle parts before operation.

Position the load as low as possible while traveling. Never make turns with the load raised higher than the axles or tipping could occur, which could result in severe injury or death.

If the machine becomes unstable and starts to tip, keep the seat belt fastened, hold on firmly and brace yourself. Lean away from the point of impact and stay with the machine. If tipping occurs, DO NOT jump from the machine. The machine is equipped with rollover protection, which only protects the operator while in the operator’s seat. Trying to escape from a tipping machine can result in death or serious personal injury.

Travel cautiously, under complete control at all times. Avoid sudden changes of direction while traveling.

918496/GP0313 51

Operating Controls

Controls and Switches

16

1

9

3

2

10

8

7

15

6

4 21

18

18

5

22

19

21

22

20

Located

Behind Joystick

11

17

23

OPTION

14

Located Inside

Engine Compartment

13

12

52

Note: Controls 11, 12, 13 and 17 are located on the steering column, below instrument panel 2.

918496/GP0313

3

4

5

No. Item

1 Steering knob

2

Description

Use to turn steering wheel.

Instrument panel Contains warning indicators, operation indicators, and gauges (page 54).

Steering wheel

Accelerator pedal

Multi-purpose joystick

Turn to control travel direction.

Press to control engine/travel speed.

Use to control lift arm/attachment maneuvering and loader drive direction (page 78).

6

7

8

Auxiliary hydraulics control buttons

Parking brake lever

Operator’s seat

Use to activate auxiliary hydraulics control circuit

(page 92).

Use to engage parking brake (page 67).

Adjust operator’s seat position (page 59).

9 Brake/inch pedal Press to control gradual travel and braking (page 74).

10 Steering column tilt Use to adjust steering column tilt (page 60).

AL 300, AL 400, AL 500; AL 100 (EU), AL 200 optional.

11 Hazard light switch Press to activate hazard lights.

AL 300, AL 400, AL 500; AL 100 (EU), AL 200 optional.

12 Work light switch Press switch to ON position to activate work lights.

13 Rotating beacon switch (option)

Press switch to ON position to activate optional rotating beacon.

14 Battery disconnect switch

(option)

Use switch to connect/disconnect the battery and electrical circuit (page 67).

EU models only.

15 Seat belt

16 Control lever

Always fasten seat belt before operating loader (page 12).

Controls road lights, directional indicators and horn

(page 61).

AL 300, AL 400, AL 500; AL 100 (EU), AL 200 optional.

Use to lock/unlock attachment.

17 Power-A-Tach ® system lock/unlock

(option)

18 Drive direction switch

19 Seat plate

20 Hand throttle

Use to control forward/reverse drive direction (page 74).

21

22

23

Slow/fast speed toggle switch

Differential lock switch

Horn

Seat plate according to ISO 7096 (located on seat).

Controls engine speed independently from the accelerator pedal. Does not control travel speed (page 61).

AL 300, AL 400, AL 500.

Toggles between slow/fast travel speed modes. Indicators

11 and 14 (page 54) illuminate to show selection

(page 76).

AL 300, AL 400, AL 500

Engages differential lock when depressed. Indicator lamp

5 (page 54) illuminates when the differential lock is engaged (page 76).

AL 300, AL 400, AL 500

Press to activate horn.

AL 100 Series only; horn button located on “16 – Control Lever” on other models.

918496/GP0313 53

Instrument Panel and Indicators

10

16

3/15

AL 100 Series, AL 200

Series Standard

18

1

9

2

54

13

14

18

19

12

17

15

16

17 1

11

20

10

9

7

2

13

3

AL 500, AL 400,

AL 300 Series;

AL 100 (EU), AL 200

Series Optional

4

5

7

6

8

21

918496/GP0313

17

18

19

7

8

No.

1

2

3

4

5

Indicator

Forward travel

Pre-heat

Description

Drive direction thumb switch on joystick is in forward position (page 68) – the machine will move forward when the travel pedal is pressed when this lamp is lit.

Illuminates when the ignition key is in the “I” (Run) position, goes out when engine pre-heat is complete (page 68).

See page 58.

Coolant temperature warning

Hydraulic oil filter

See page 58.

AL 300, AL 400, AL 500; AL 200 optional.

Differential lock Differential lock engaged (page 76).

AL 300, AL 400, AL 500.

6 Right turn/ hazard lights

9

10

11

12

13

14

Parking brake

Road lights

Rearward travel

Alternator

Slow speed

Left turn/ hazard lights

Fuel level

Fast speed

Right turn signal engaged (page 74).

Hazard lights (page 52).

AL 300, AL 400, AL 500; AL 100 (EU), AL 200 optional.

Parking brake engaged (page 67).

Road lights upper beam engaged (page 52, page 61).

AL 300, AL 400, AL 500; AL 100 (EU), AL 200 optional.

Drive direction thumb switch on joystick is in

Reverse position (page 67)– the machine will move rearward when the travel pedal is pressed when this lamp is lit.

Alternator not charging.

Low speed drive engaged. See item 22 on page 52.

AL 300, AL 400, AL 500.

Left turn signal engaged (page 74).

Hazard lights (page 52).

AL 300, AL 400, AL 500; AL 100 (EU), AL 200 optional.

Displays the amount of fuel in the tank.

High speed drive engaged. See item 22 on page 52.

AL 300, AL 400, AL 500; AL 100 (EU), AL 200 optional.

15

16

Hydraulic oil temperature

Engine oil pressure

Hour meter

Low fuel

Engine rpm

See page 58.

Engine oil pressure too low.

20

21

Volt meter

Engine oil temperature

Displays hours of operation.

Fuel level too low.

Displays engine rpm.

AL 300, AL 400, AL 500; AL 100 (EU), AL 200 optional.

Displays system voltage level.

Start-up - 3 bars illuminate, if battery is fully charged.

During operation - 4-5 bars illuminate.

Alternator overheat - 6 bars illuminate, see page 58.

AL 300, AL 400, AL 500; AL 100 (EU), AL 200 optional.

Displays temperature level.

AL 300, AL 400, AL 500; AL 200 optional.

918496/GP0313 55

Cab Controls (Cab only)

Cab Environment Controls

To operate the cab heater and air circulation fan:

1. Move lever (C, Fig. 6) rearward to increase heat; forward to reduce heat.

2. Turn the fan control (D, Fig. 6) clockwise to increase circulation fan speed; counter-clockwise to decrease circulation fan speed.

C

Figure 6 – Cab Environment

Controls

D

Air Conditioning Control (option)

Optional air conditioning is controlled by a knob located on the windshield wiper control panel. To operate the air conditioning system:

1. Rotate the air conditioning control knob clockwise to turn on the air conditioning system. The knob has three positions, from off at the “0” position, to full speed at the “3” position.

2. Rotate the air conditioning control knob counterclockwise to the

“0” position to turn off the air conditioning system.

OFF

ON

MAXIMUM

Important: Do not operate the air conditioning and the cab heater at the same time. Doing so will exceed the capacity of the electrical system and discharge the battery.

Figure 7 – Air Conditioning

Control

56 918496/GP0313

Cab Windshield Wiper

Controls

Press the icon side of the wiper switches to the first detent to activate the wiper blades. Press the icon side of the switches past the detent to activate the washer fluid.

E: Activates the front wiper and washer.

F: Activates the rear wiper and washer.

E

F

Cab Dome Light

The dome light is located on the cab ceiling. Push button (G, Fig. 9) to turn the light on/off.

Figure 8 – Cab Wiper/Windshield

Washer Controls

Cab Defrost

Turn the vents (H, Fig. 10), located on the left and right sides of the cab, toward the window to defrost the window.

H

G

Figure 9 – Cab Dome Light

Figure 10 – Vent

918496/GP0313 57

Warning Indicators

Important: If any of the following indicators illuminate when the engine is running, turn off the engine immediately. Correct the problem before re-starting the engine. During normal operation these indicators should be OFF.

3

2

1/4

4

3

1

5

2

AL 100. AL 200 Series

Standard

AL 500, AL 400, AL 300 Series;

AL 100 (EU), AL 200 Series

Optional

Figure 11 – Warning Indicators

Description

Temperature is too hot.

3

4

No.

Indicator

1 Engine coolant temperature warning

2 Volt meter

5

Engine oil pressure

Hydraulic oil temperature

Hydraulic oil filter

Alternator overheat (when bezel icon and 6 bars are lit).

Pressure is too low.

Temperature is too hot.

Hydraulic oil filter service required.

AL 300, AL 400, AL 500.

58 918496/GP0313

Operator’s Seat Adjustment

WARNING

Never adjust the operator’s seat when the engine is running.

Adjust the operator’s seat so all controls are easy to reach and the pedals can be completely depressed with your back against the seat back.

A. Forward/rearward adjust-

ment: Pull the lever up, adjust the seat and release the lever. Check that the seat is locked in place.

B. Weight adjustment: While sitting in the seat, rotate the knob until the desired tension is reached.

C. Recline adjustment: Pull the front lever up, recline the seat back as desired and release the lever. Check that the seat is locked in place.

D. Height adjustment (AL

400/500 Series): Rotate knob until the desired seat height is reached.

E. Seat Belt: See the following section.

F. Seat tension indicator (AL

100/200/300 Series): Adjust weight adjustment knob (B) until seat tension indicator is centered.

A

D

B

AL 500, AL 400 Series

E

AL 100, AL 200, AL 300 Series

A

F

E

C

C

918496/GP0313

B

A. Forward/rearward lever

B. Weight adjustment knob

C. Recline lever

D. Height adjustment knob

E. Seat belt

F. Seat tension indicator

Figure 12 – Operator’s Seat Adjustment

59

Seat Belt

WARNING

Always fasten the seat belt securely and properly. Never operate the machine without the seat belt fastened around the operator.

Important: Inspect the seat belt for damage before use. Replace if damaged.

Keep the seat belt (E, Fig. 12) clean. Use only soap and water to wash seat belt.

Cleaning solvents can damage seat belt.

Ignition Key Switch

“

0” position: All power off. Key can be inserted/removed.

“

I” position: Run position.

“

II” position: Start position. Holding the switch in this position starts the engine. See

“Engine Start” on page 67.

Note: Switch must be returned to “

0” posi- tion between starting attempts to reset the start safety interlock.

0

I

II

Figure 13 – Ignition Key

Switch

Important: The drive direction switch on the joystick must be in the neutral position and the operator’s seat must be occupied and/or the parking brake must be applied before the engine will start.

Steering Column Adjustment

(AL 300, AL 400, AL 500 Series; AL100 (EU), AL 200 Series Optional)

WARNING

Never adjust the steering column when the engine is running.

Adjust the steering column for visibility, utility and comfort.

1. Push the adjustment lever (J, Fig.

14) downward.

2. Adjust the steering column to the desired position.

3. Release the adjustment lever.

4. Check that the steering column is locked in place.

J

Figure 14 – Steering Column Adjustment

60 918496/GP0313

Control Lever

(AL 300, AL 400, AL 500 Series; AL 100 (EU), AL 200 Series Optional)

The control lever on the steering column controls the following functions:

1. Push the control lever in to activate the horn (K, Fig. 15).

2. Twist the end of the control lever to activate the position lights (L).

3. Push the control lever forward or rearward to activate the turn signals (M).

4. Push the control lever downward to activate the road light “high” beams.

5. Pull the control lever upward to activate the road light “low” beams.

K

L

M

Figure 15 – Control Lever

Hand Throttle

(AL 300, AL 400, AL 500 Series)

The hand throttle, located to the right of the operator’s seat, controls engine speed independently from the accelerator pedal. The hand throttle does not control travel speed.

1. Loosen the throttle lock ring (N, Fig. 16).

2. Press the red throttle release button (P).

3. Pull/push the throttle control knob (R) and the throttle release button as a unit.

R

Note: The throttle can be quickly placed into the idle position by firmly pushing against the throttle release button. For normal operation, move the throttle release button (P) and the throttle control knob (R) as a unit to prevent undue wear on the throttle mechanism.

N

P

Figure 16 – Hand Throttle

4. For fine adjustments, rotate the throttle control knob (R).

5. Tighten the throttle lock ring (N) to lock the throttle in position.

918496/GP0313 61

12V Accessory Power Outlet

Use the 12V accessory power outlet

(S, Fig. 17), on the steering column.

See “Battery” on page 141 for fuse and amperage information.

Figure 17 – Electric Socket

S

62 918496/GP0313

Operation

Pre-Operation Checklist

Check the following before starting the machine (for all fluid level checks, fill if required):

• Fuel, hydraulic, radiator, and engine oil caps for tightness.

• Fluid leaks: fuel, hydraulic oil, engine oil, coolant, etc.

• Radiator coolant level. See “Fluid Capacities/Lubricants” on page 31 for proper mixture.

• Engine coolant level and system for leaks.

• Hydraulic system for leaks.

• Fuel level. See “Fuel System” on page 116.

• Engine oil level. See “Checking Engine Oil Level” on page 109.

• Hydraulic fluid level. See “Checking Hydraulic Oil Level” on page 122.

• Engine cover latch securely fastened.

• Clean engine area of flammable materials.

• Engine fan and accessory belts.

• Air cleaner (air filter restriction indicator). See “Air Cleaner” on page 112.

• Intake hoses.

• Hydraulic hose condition.

• Brake fluid level.

• Tire condition and pressure.

• Condition of any attachments to be used.

• Lift arm and cylinder condition (look for bends/cracks/etc.).

• Frame condition (look for bends/cracks/etc.).

• Cab / ROPS (Rollover Protective Structure).

• FOPS (Falling Object Protective Structure).

• Guards.

• Safety decals (replace as required).

• Safety warnings (securely attached and readable).

• Seat belt (check for proper function/binding) and mounting hardware.

• Horn

• Lights.

• Pivot points for proper operation.

• Broken and/or loose parts (repair as required).

918496/GP0313 63

Extend the ROPS

WARNING

If the machine is equipped with a folding 2-Post

ROPS, only fold the ROPS temporarily if necessary during transport or if necessary for use inside structures with low overhead doors or clearances. Operating with the ROPS folded back increases the risk of injury or death if a roll-over would occur.

Secure the ROPS into the transport position:

1. Remove the spring pins (both sides) (T, Fig. 18).

2. Remove the clevis pins (both sides) (U, Fig. 18).

3. Fold the ROPS rearward.

WARNING

Do not allow the ROPS to fall rearward, or damage to the engine cover or injury to nearby persons may occur. Stay clear from underneath the ROPS as it is folded.

U

4. Insert the clevis pins (both sides) into transport lock position (V, Fig. 19).

5. Insert the spring pins (both sides) to secure the clevis pins (both sides).

T

Restore the ROPS to the raised position

Figure 18 – ROPS Fully Raised

1. Remove the cotter pins (T, Fig. 18)

(both sides) from the clevis pins (both sides) (U, Fig. 18).

2. Remove the clevis pins (both sides) (U).

3. Fold the ROPS upward and forward.

4. Insert the clevis pins (both sides) (U).

5. Insert the cotter pins (both sides) (T).

V

64

Figure 19 – ROPS Transport

Position

918496/GP0313

4-Post ROPS Side Gates (Option)

Optional side gates for the 4-Post ROPS provide the operator additional protection.

100 Series

X

200/300/400/500 Series

X

Figure 20 – 4-Post ROPS Side

Gates

To open the side gates, lift latch (Y). When closing, pull side gates in until they latch securely.

100 Series 200/300/400/500 Series

Y

Y

918496/GP0313

Figure 21 – 4-Post ROPS Side Gates Latches

65

Entering and Exiting

WARNING

Maintain three-point contact and face the machine at all times when entering and exiting. Do not use the steering wheel for entry or exit. Never jump from the machine. Never enter or exit a moving machine.

Failure to maintain three-point contact may result in injury.

NOTE: Photos may not exactly match all machines

2-Post ROPS

A

C

B

4-Post ROPS/Cab

A

C

66

B

A. Left hand hold

B. Step for right foot

C. Right hand hold

Figure 22 – Three-Point

Mount/Dismount

918496/GP0313

Engine Start

Important: The machine cannot be tow-started because there is no direct mechanical connection between the wheels and the engine. Attempting to towstart the machine can damage the drive system.

WARNING

Always fasten the seat belt before operating the machine. Repair or replace any damaged seat belt and lock parts before operation.

CAUTION

Do not use starting fluid (ether) with preheat systems. An explosion can result, which can cause engine damage, injury or death.

1. If the machine is equipped with the optional battery disconnect switch

(Y, Fig. 23), check that switch (Y) is.

turned clockwise to the notched position “ON” position (Z).

Note: To disconnect battery and lock out all electrical functions, turn switch (Y) counter-clockwise to the

“OFF” (A) position.

2. Adjust the operator’s seat (see

“Operator’s Seat Adjustment” on page 59) and fasten the seat belt.

3. Adjust the steering column (see

“Steering Column Adjustment” on page 60).

4. Engage the parking brake (W, Fig.

24), lift the lever (X) into the upright position as shown.

Note: When the parking brake is engaged, travel drive is disconnected.

W

Y

A

Z

Located Inside Engine Compartment

Figure 23 – Optional Battery Disconnect Switch

X

Figure 24 – Parking Brake

VERY IMPORTANT!

On AL 300 Series machines, the parking brake must be engaged before starting a cold engine, and the brake must be left engaged for three minutes after starting, or damage to the hydraulic pump may result.

918496/GP0313 67

5. Place forward/reverse drive switch

(Fig. 25) on the top of the joystick into the neutral position.

Forward

Reverse

Figure 25 – Drive Direction

6. Turn the ignition key to the “

I” (Run) position (Fig. 26).

7. When the pre-heat indicator light (B,

Fig. 26) goes off, turn the ignition key to the “ II” (Start) position.

Release the key when the engine starts.

8. If the engine does not start after 15 seconds, turn the key back to the “

0”

(off) position, wait one minute and repeat steps 6-7. If the engine does not start after several attempts, see

“Troubleshooting” on page 153.

0

I

B

II

Note: Return switch to the “

0” position between starting attempts.

Figure 26 – Ignition/Pre-Heat

9. Immediately after starting the engine, all warning indicator lamps should go off (see “Warning Indicators” on page 58).

10. Proceed to “Warm-up” on page 69.

68 918496/GP0313

Engine Shut Down

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. Perform a visual inspection:

• Hydraulic system leaks?

• Coolant system leaks?

• Fuel system leaks?

• Damage to machine (tires, attachment hitch, attachment, etc.)?

3. Completely fill the fuel tank.

Warm-up

VERY IMPORTANT!

On AL 300 Series machines, the parking brake must be left engaged for three minutes after starting a cold engine, or damage to the hydraulic pump may result.

Note: The operator may leave the operator’s seat while warming a cold engine.

Apply the parking brake before leaving the operator’s position; the engine will stop if the operator’s seat is not occupied and the parking brake is not applied.

Important: Do not run a cold engine under load; engine life may be shortened.

1. Run the engine at a low, consistent speed for a few minutes before operating any controls. Check for any unusual sounds and vibrations.

2. Check if any indicators illuminate (see “Warning Indicators” on page 58).

Important: If unusual sounds or vibrations occur, or if any warning indicators illuminate, stop the engine immediately and determine the cause. Repair or replace parts as necessary before re-starting the engine.

3. Exhaust gas color should be light blue or colorless.

Note: Black exhaust indicates possible engine malfunction. See “Engine Troubleshooting” on page 153.

Important: Do not run a malfunctioning engine under load; engine life may be shortened.

4. During warm-up, test the following for proper function:

• Brake/Inch pedal. See “Controls and Switches” on page 52. See “Travel” on page 74.

• Steering. See “Controls and Switches” on page 52.

• Accelerator pedal. See “Controls and Switches” on page 52.

• Multi-purpose joystick. See “Multi-purpose Joystick” on page 78.

• Forward/reverse drive switch on multi-purpose joystick. See “Travel” on page 74.

918496/GP0313 69

New Machines

1. After starting the engine for the first time, let the engine idle for 15 minutes.

2. After 15 minutes, perform the “Mandatory Safety Shutdown Procedure” on page 10.

3. Check for proper engine oil pressure, engine oil level, diesel fuel leaks, engine oil leaks, coolant leaks, and indicator/gauge operation.

4. During the first hour of operation, vary the engine speed and the load, with short periods of maximum load and engine speed operation.

5. During the first four to five hours of operation, avoid long periods of minimum or maximum load and engine speed operation.

6. During the first 50 hours of operation, check the engine oil pressure and engine temperature frequently.

7. After the first 50 hours of operation, replace engine oil and engine oil filter, and check and adjust cooling fan v-belt. See “Changing Engine Oil and Filter” on page 110, and see “Checking and Adjusting V-belt Tension” on page 119

8. Check the engine oil and coolant levels frequently and refill as necessary. See

“Checking Engine Oil Level” on page 109, and “Checking Coolant Level” on page 114.

Driving on Public Roads

Follow the applicable legal regulations of the country where the machine is being used. Regulations are specified in the operation license or in the vehicle papers.

Important: Only the attachments listed in the operation license or vehicle papers are admissible for driving on public roads.

1. Follow mandatory accident prevention regulations. Complete a functional check of:

• Brakes

• Steering

• Lights

2. Empty the bucket (if applicable).

3. On AL 100 Series machines: a. Lower the lift arm all the way and tilt the attachment hitch back until holes

(C, Fig. 30) in the lift arm align with holes (D) in the tilt pivot arm.

70 918496/GP0313

b. Perform the “Mandatory Safety

Shutdown Procedure” on page 10.

c. Remove a spring pin (A, Fig. 30) from the end of the lift arm lock bar (B). Remove lift arm lock bar

(B) from the storage bracket.

d. Slide the lock bar (B) all the way through holes (C, Fig. 30) in the lift arm and holes (D) in the tilt pivot arm.

B

D

C

A

Figure 27 – 100 Series Lift Arm

Tilt Lock e. Replace the spring pin (A) into the end of the lock bar (B).

Important: Lock bar (B) must pass all the way through holes (C) in the lift arm and holes (D) in the tilt pivot arm, with spring pins (A) installed in lock bar (B) on outsides of the lift arm.

A

B

Figure 28 – AL 100 Series Lift

Arm Lock Bar Storage

4. On AL 200 and AL 300 Series machines: a. If necessary, raise the lift arm to allow for down-stop lock bar (A, Fig. 29) removal.

b. Remove spring pins (A) from both ends of the down-stop lock bar (B).

Remove lift arm lock bar (B) from the machine.

c. Lower the lift arm all the way. Tilt the attachment hitch all the way back.

Note: Holes (C) in the frame, in the lift arm and holes (D) in the tilt pivot arm must align to allow down-stop lock bar (A) to pass completely through all the holes.

918496/GP0313 71

d. Perform the “Mandatory Safety

Shutdown Procedure” on page 10.

e. Slide the down-stop lock bar (B) all the way through holes (C) in the frame, holes in the lift arm and holes (D) in the tilt pivot arm.

B

C

D f. Replace the lock pins (A) into both ends of the down-stop lock bar

(B).

A

Important: Down stop lock bar

(B) must pass all the way through

Figure 29 – AL 200/300 Series

Lift Arm Down-Stop holes (C) in the frame, holes in the lift arm and holes (D) in the tilt pivot arm, with spring pins (A) installed in down stop lock bar (B) on outsides of the frame arm.

72 918496/GP0313

5. On AL 500 Series machines: a. Remove the retainer (C, Fig. 30), and lift the cylinder stop channel (D) off the machine.

D

J

C

D

C

E

Figure 30 – Tilt Lock Mechanism (AL 500 Series) b. Tilt the attachment/hitch back as required and place the cylinder stop channel (D) under tilt indicator (J) and over the tilt cylinder (E) to brace the tilt cylinder in the extended position.

c. Replace the retainer (C) into the cylinder stop channel so it passes under the tilt cylinder rod.

d. Lower the lift arm as low as possible, but still high enough for required ground clearance.

6. On AL 400 Series machines: a. Remove the quick-release pins (F, Fig. 31), and remove the tilt lock pin

(G) from the front of the machine.

F G

F

G

F

H

I

Figure 31 – Tilt Lock Mechanism (AL 400 Series) b. Tilt the attachment/hitch as required to align holes (H) in tilt bracket with holes (I) in both sides of the lift arm.

c. Slide tilt lock pin (G) through holes (H) and (I) so it passes all the way through both sides of the lift arm and tilt bracket. Secure tilt lock pin (G) at both ends with spring pins (F) d. Lower the lift arm as low as possible, but still high enough for required ground clearance.

918496/GP0313 73

Lift Arm Down-Stop

The lift arm down stop is designed to limit lift arm downward travel. This feature is useful when changing tire sizes, or when driving the machine over long distances.

1. Empty the bucket (if applicable).

2. Position the lift arm above the down stop hole (A, Fig. 29) position where you want to limit travel, and also high enough to allow removal of the down-stop lock bar (B).

3. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

4. Remove the lock pin (A), and pull the lock bar (B) from the machine.

C

C

5. Slide the lock bar (B) all the way through the desired down-stop holes

(C).

6. Replace the lock pin (A) into the lock bar.

A

B

Figure 32 – Lift Arm Down-Stop

Travel

WARNING

Do not move the drive direction switch (Fig. 34) while traveling. The machine may react suddenly, causing an accident.

Change drive direction only when stopped. Refer to the drive direction lamps when changing travel direction. See “Controls and

Switches” on page 52, and “Instrument Panel and Indicators” on page 54.

Important: If the optional backup alarm is installed, and the parking brake is released, the backup alarm activates when the drive direction switch is in reverse.

F

1. Be sure that the area around the loader is clear of bystanders and obstacles.

2. Using the multi-purpose joystick, raise the lift arm/attachment. Keep the attachment as near to the ground as possible for good stability and visibility. See

“Load Handling” on page 77.

3. Release the parking brake. Lift lever (G,

Fig. 33) slightly and press button (F) and press lever (G) downward. Release the button.

G

Figure 33 – Parking Brake

74 918496/GP0313

Note: When the parking brake is engaged, travel drive is disabled.

4. Use the drive direction switch to change the loader drive direction.

Note: The drive direction indicators should be lit when the drive direction switch is in forward and rearward positions.

Forward

Reverse

Drive direction switch position

Forward

Middle

Rearward

Indicator for forward drive is on; loader drive is in forward.

Loader drive is in neutral.

Indicator for reverse drive is on; loader drive is in reverse.

H

Figure 34 – Drive Direction and Fast/Slow Speed

Switches

5. (AL 300, AL 400, AL 500 Series) Select either the high or low drive speed using the slow/fast speed switch (H, Fig. 34) according to the job and work site conditions.

6. Slowly press the accelerator pedal. Driving speed is proportional to accelerator pedal movement.

WARNING while traveling.

Travel cautiously and under complete control at all times. Avoid sudden directional changes

Note: (AL 400/500 Series) Sluggish or inoperative throttle pedal control could indicate the throttle pedal is out of calibration. See your local service center for throttle pedal calibration.

Important: If the machine is equipped with a hand throttle, use the accelerator pedal to control travel speed and use the hand throttle to control engine speed.

See “Hand Throttle” on page 61.

7. Use the brake/inch pedal gradually to regulate travel speeds and braking.

Important: Do not use the brake/inch pedal as a footrest.

Note: (AL 400/500 Series) Sluggish or inoperative brake/inch pedal control could indicate the brake/inch pedal is out of calibration. See your local service center for brake/inch pedal calibration.

918496/GP0313 75

Slow/Fast Travel Speed Mode Selection

(AL 300, AL 400, AL 500 Series)

WARNING

Machine stability is affected by machine speed, especially on rough or hilly terrain, while carrying heavy loads, and while carrying loads raised above the height of the wheel axles. Always operate the machine at speeds appropriate for the conditions, Move the controls smoothly and gradually. Avoid sudden directional changes while traveling in the fast-speed mode.

Always use the slow travel speed mode in congested or populated areas.

To toggle between slow/fast travel speed modes, press the switch (Z, Fig. 35) and hold for one second. Z

Figure 35 – Slow/Fast Speed

Selection Switch

Differential Lock Operation

(AL 300, AL 400, AL 500 Series)

Important: Stop the machine before engaging the differential lock. Do not engage the differential lock if turning on smooth, dry pavement. Damage to the axles may result.

The differential lock can provide increased traction on loose and slippery surfaces.

Note: The differential lock is engages on both front and rear axles.

To engage the differential lock, press and hold the differential lock switch (J, Fig.

36). Release the switch to disengage the differential lock.

J

Figure 36 – Differential Lock

Switch

76 918496/GP0313

Load Handling

WARNING

Position the load as low as possible, especially while traveling. Never make turns with the load raised higher than the axles or tipping could occur, resulting in severe injury or death.

Do not exceed the rated operating capacity of the machine. See weights and capacities information starting on page 33.

If the machine becomes unstable and starts to tip, keep the seat belt fastened, hold on firmly and brace yourself. Lean away from the point of impact and stay with the machine. If tipping occurs, DO NOT jump from the machine. The machine is equipped with rollover protection, which only protects the operator while in the operator’s seat. Trying to escape from a tipping machine can result in death or serious personal injury.

If a tipover occurs:

• Restore the loader to an upright position immediately to prevent oil and fuel leakage. Clean up any fluid leakage.

• Inspect and repair any damage before re-starting the engine.

Parking the Loader

Park the loader away from traffic on level ground. If this is not possible, park the loader across the incline and block the tires to prevent movement. See

“Mandatory Safety Shutdown Procedure” on page 10.

918496/GP0313 77

Multi-purpose Joystick

Use the multi-purpose joystick to control lift arm/attachment hydraulic movements. Speed of movement is proportional to how far the joystick is moved and engine speed.

Lift arm:

A. Move the joystick rearward

(A, Fig. 37, Fig. 38) to raise the lift arm.

B. Move the joystick forward (B) to lower the lift arm.

Attachments:

C. Move the joystick to the left (C) to tilt attachments rearward.

D. Move the joystick to the right (D) to tilt attachments forward.

C

B

A

D

Figure 37 – Multi-purpose

Joystick

B

D

C

A

Figure 38 – Joystick Function

Decal

78 918496/GP0313

AL 100, AL 200(EU),

AL 300, AL 400(EU)

Self-Leveling

Feature

The self-leveling feature maintains the attachment tilt angle as the lift arm is raised/lowered (Fig. 39)

Figure 39 – Self-

Leveling Feature

AL 500 Series Limited Self-Leveling

WARNING

Without self-leveling, unintentional dumping

(tilting forward) of the attachment can occur when the lift arm is raised or lowered. The pointer on self-level indicator (B, Fig. 40) must be within in the zone of self-level decal (A) or the attachment will not maintain the same attachment tilt angle when the lift arm is raised and lowered.

Self-Level Indicator

A

AL 500 Series machines use a special lift arm design to enhance bucket breakout forces and improve digging ability.

With this lift arm design, the tilt cylinder must be positioned so self-leveling is maintained.To maintain self-leveling on AL 500

Series machines, adjust the tilt cylinder until self-level indicator pointer is within the zone of self-level decal

(X).

B

Figure 40 – AL 500 Series Limited

Self-Leveling

WARNING

Use of forks or unapproved attachments may not allow self-leveling activation due to the orientation of the All-Tach ® to the attachment.

918496/GP0313 79

Float Positions

WARNING

Never engage “float” with the lift arm raised.

This will cause the lift arm to fall.

Push the joystick past the first position and into front detent (E, Fig. 41, Fig. 42) and right detent (F) positions to activate the lift (E) and tilt (F) float functions.

To disengage float functions, pull the joystick to center position.

Note: Lift float may decrease ability to turn.

F

E

Figure 41 – Joystick Float Positions

E

F

Figure 42 – Joystick Function

Decal - Float Positions

80 918496/GP0313

Attachments

General Instructions

WARNING

Use only approved attachments. Contact the

Manitou Americas Service Department about information about approved attachments. Manitou Americas cannot be responsible if the machine is used with non-approved attachments. Read the operator’s manual provided with all attachments used with the machine before starting the engine. A loaded attachment changes the center-of-gravity of the machine.

Use caution! Never exceed the rated operating capacity – refer to weights and capacities information starting on page 33. Before using an attachment, check that the attachment is undamaged and properly connected and locked.

WARNING

Practice using an attachment before working with it.

Connect/Disconnect Attachments

WARNING locked.

Check that hitch pins and auxiliary hydraulic connections are properly connected and

All-Tach ® System Hitch Connection

1. Position the attachment so the attachment flange fits over the top lip of the hitch (Fig. 43).

2. Pull the joystick rearward until the attachment is flush against the hitch surface.

3. Perform “Mandatory Safety Shutdown

Procedure” on page 10.

Figure 43 – Standard All-Tach ®

System Hitch Positioning

918496/GP0313 81

4. Push the locking handles

(K, Fig. 44) inward and downward until the attachment is locked onto the hitch as shown.

5. Check that the attachment is securely locked onto the hitch: the lip on the attachment must be completely engaged over the top of the hitch, and the locking pins on the bottom of the hitch must be fully engaged down into the attachment.

K

Figure 44 – Standard All-Tach ®

System Hitch Locked

WARNING death could result.

Check that attachments are securely fastened to the hitch before working, or serious injury or

6. Perform “Engine Start” on page 67.

All-Tach ® System Hitch Disconnection

1. Lower the attachment to the ground.

See “Multi-purpose Joystick” on page 78.

2. Turn off the engine. Move the multipurpose joystick several times in all directions to depressurize the hydraulic system.

3. Pull the locking handles upward until the pins disengage from the attachment (Fig. 45) Perform “Engine Start” on page 67.

Figure 45 – Standard All-Tach ®

System Hitch Unlocked

82 918496/GP0313

4. Tilt the hitch forward (see “Multi-purpose Joystick” on page 78) and back away from the attachment (Fig. 46).

Figure 46 – Standard All-Tach ®

System Hitch Removal

Hydraulic Power-A-Tach ® System Hitch Connection

CAUTION

The hydraulic Power-A-Tach ® system hitch lock switch activates the auxiliary hydraulic circuit. Connect the auxiliary hydraulic connections (see “Auxiliary

Hydraulics” on page 86) to the attachment after connecting the attachment to the Power-A-Tach ® system hitch.

1. Position the attachment so the attachment flange fits over the top lip of the hitch (Fig. 47).

2. Pull the joystick rearward until the attachment is flush against the hitch surface.

Figure 47 – Hydraulic Power-A-

Tach ® System Hitch Positioning

918496/GP0313 83

3. Push the side of the Power-A-Tach ® system hitch lock switch (L, Fig. 48) to lock the attachment onto the hitch.

a. AL 100 Series machines only:

Press and hold the bottom auxiliary hydraulics control button (Z, Fig. 49) and then push the side of the

Power-A-Tach ® system hitch lock switch (L, Fig. 48) to lock the attachment onto the hitch.

Note: Due to ongoing product improvement and variations during production, it may be necessary to hold the top auxiliary hydraulics control button instead of the bottom button to enable the hitch lock switch on AL 100 Series machines.

4. Make sure the attachment is securely locked onto the hitch: the locking handles (K, Fig. 44) must be horizontal, with the lip on the attachment completely engaged over the top of the hitch, and the hitch pins on the bottom of the hitch fully engaged down into the attachment.

Note: 4-point hitch (EU only) locking pins engage out through the sides of the attachment.

L

Figure 48 – Hydraulic Power-

A-Tach ® System Hitch Lock

Switch

Z

Figure 49 – AL 100 Series

Bottom Auxiliary Hydraulics

Control Button (Power-A-

Tach® System Hitch Lock

Switch Enable Button)

84 918496/GP0313

Hydraulic Power-A-Tach ® System Hitch Disconnection

CAUTION

Disconnect the auxiliary hydraulic connections

(see “Auxiliary Hydraulics” on page 86) before disconnecting the attachment from the Power-A-Tach ® system hitch.

1. Lower the attachment to the ground. See “Multi-purpose Joystick” on page 78.

2. Press the side of the Power-A-

Tach ® system hitch lock switch (M,

Fig. 50) to unlock the attachment on the hitch.

M

AL 100 Series machines: Press and hold the bottom auxiliary hydraulics control button and then push the side of the Power-A-

Tach ® system hitch lock switch (L,

Fig. 48) to unlock the attachment.

Note: Due to ongoing product improvement and variations during production, it may be necessary to hold the top auxiliary hydraulics control button instead of the bottom button to enable the hitch lock switch on AL 100 Series machines.

Figure 50 – Hydraulic Power-

A-Tach ® System Hitch Unlock

Switch

Z

3. Tilt the hitch forward (see “Multi-purpose Joystick” on page 78) and back away from the attachment (Fig. 52).

Figure 51 – AL 100 Series

Bottom Auxiliary Hydraulics Control Button (Power-

A-Tach® System Hitch

Lock Switch Enable Button)

918496/GP0313

Figure 52 – Hydraulic Power-A-

Tach ® System Hitch Removal

85

Auxiliary Hydraulics

Auxiliary hydraulics are used for hydraulically-powered attachments. The auxiliary hydraulic circuit must be connected to hydraulically-powered attachments before the attachments can be used.

Auxiliary Circuit Pressure Relief

Relieve pressure in the auxiliary hydraulic circuit before connecting / disconnecting hydraulically powered attachment hoses.

AL 100 Series

For the following machines:

K

• AL 100 Series - Serial Numbers

11480 and Up

• AL 200 (EU) Series - Serial Number

21293 and Up

• AL 300 Series - Serial Numbers

31822 and Up

• AL 400 (EU) Series - Serial Numbers

41374 and Up

• AL 500 Series - Serial Numbers

51590 and Up

Stop the engine, push down and pull up on the pressure relief control (K, Fig. 53).

AL 200/300 Series

K

AL 400/500 Series

K

Figure 53 – Auxiliary Hydraulics

Pressure Relief Lever

WARNING

Be sure no one is near the machine when relieving pressure from the auxiliary hydraulics circuit. Stored pressure may cause connected hydraulicallypowered attachments to move when the circuit is de-pressurized.

86 918496/GP0313

For the following machines:

• AL 100 Series - Serial Numbers 11479 and Before

• AL 200 (EU) Series - Serial Number 21292 and Before

• AL 300 Series - Serial Numbers 31821 and Before

• AL 400 (EU) Series - Serial Numbers 41373 and Before

• AL 500 Series - Serial Numbers 51589 and Before

1. Lower the lift arm to the ground.

2. When disconnecting a hydraulically-powered attachment, position it in the storage position. (e.g., bucket grapple should be closed.)

3. With the engine at idle, pull the joystick to the rear as far as it will go and hold it in this position.

4. While the lift arm is rising: a. Press and hold one of the auxiliary hydraulics control buttons (P, Fig.

54) for three or more seconds.

b. Release the button, and then press and hold the other auxiliary hydraulics control button for three or more seconds.

5. Move the joystick to the neutral position.

6. Lower the lift arm to the ground.

7. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

P

Figure 54 – Auxiliary Hydraulics

Control Buttons

918496/GP0313 87

Auxiliary Hydraulics Connections

Important: Relieve pressure in the auxiliary hydraulic circuit before connecting / disconnecting hydraulically powered attachment hoses. See “Auxiliary Circuit

Pressure Relief” on page 86.

Important: Be sure that the hydraulic connections are clean. Hydraulic oil contamination can damage the hydraulic system.

CAUTION

If a Power-A-Tach ® system hitch is installed, connect the auxiliary hydraulic connections to the attachment after connecting the attachment to the Power-A-

Tach ® system hitch. Disconnect the auxiliary hydraulic connections before disconnecting the attachment from the Power-A-Tach ® system hitch.

To connect: Press the hose connections firmly down into the auxiliary hydraulic connections until they snap into place.

To disconnect: Push down on the locking rings (N, Fig. 55) until the hose connections release.

Important: Always cap the hydraulics

(Fig. 39) after disconnecting, to protect against hydraulic oil contamination.

Note: Connect attachment connectors together when the attachment is not being used, to keep pressure from building in the attachment and to keep the connector mating surfaces clean.

N

Figure 55 – Auxiliary Hydraulic

Connections

88 918496/GP0313

Auxiliary Hydraulics Control Buttons

Auxiliary hydraulics fluid flow is controlled by two buttons (P, Fig. 56) on the front of the joystick.

1. Top Button: Press the top button to activate the auxiliary hydraulics flow in the direction opposite of when pressing the bottom button. Release the button to stop the flow.

2. Bottom Button: Press the bottom button to activate the auxiliary hydraulics flow in the direction opposite of when pressing the top button. Release the button to stop the flow.

P

3. Continuous flow in “Top Button”

Direction: Press the top button, and

Figure 56 – Auxiliary Hydraulics

Control Buttons then press and hold both buttons for two seconds to activate continuous auxiliary hydraulic flow in the “Top Button” direction. Momentarily press either button to stop the flow.

4. Continuous flow in “Bottom Button” Direction: Press the bottom button, and then press and hold both buttons for two seconds to activate continuous auxiliary hydraulic flow in the “Bottom Button” direction. Momentarily press either button to stop the flow.

918496/GP0313 89

Auxiliary Hydraulics Flow and Proportional Control

For the following machines ONLY:

• AL 100 Series - Serial Numbers 11480 and Up

• AL 200 (EU) Series - Serial Number 21293 and Up

• AL 300 Series - Serial Numbers 31822 and Up

• AL 400 (EU) Series - Serial Numbers 41374 and Up

• AL 500 Series - Serial Numbers 51590 and Up

The pressure relief control (K, Fig. 57) can be used for auxiliary hydraulics flow control.

Pulling up on the pressure relief control (K) activates auxiliary hydraulics in one direction; pushing down on the pressure relief control (K) activates auxiliary hydraulics in the other direction.

90 918496/GP0313

Depending upon the distance the pressure relief control (K) is pulled up/pressed down controls the auxiliary hydraulics flow rate: the further the control is moved, the greater the flow rate.

AL 100 Series

K

AL 200/300 Series

K

AL 400/500 Series

K

Figure 57 – Auxiliary Hydraulics

Flow and Proportional Control

918496/GP0313 91

Operating Attachments

WARNING information about approved attachments. Manitou Americas cannot be responsible for safety if the unit is used with non-approved attachments.

Use only approved attachments. Contact the

Manitou Americas Service Department about

Some general guidelines for attachments are included in this section. These guidelines are not a replacement for the attachment manufacturer’s operating instructions.

Before installing, operating and servicing attachments, carefully read the manufacturer’s operating instructions. Contact the responsible representative for more information.

Contact the Manitou Americas Service Department for more information about approved attachments. Observe maximum operating load capacities. See weights and capacities information starting on page 31.

Bucket

See “Load Handling” on page 77 for information about driving with a load.

Loading Loose Material

1. Lower the bucket and adjust the cutting edge to be parallel to the ground.

2. Drive toward the material to be loaded. Determine the correct driving speed according to the type of material and working conditions.

3. As the cutting edge penetrates the material, raise the lift arm slightly, to load the front axle and to minimize slipping.

Note: If the bucket has difficulties penetrating the material, use the joystick to raise and lower the bucket.

4. Tilt back the bucket when it is full.

5. Move the bucket into transport position.

Scraping Soft Material

1. Lower the bucket onto the material.

2. Tilt the bucket forward to the desired digging angle.

3. Drive forward so that the edge of the bucket penetrates the material.

4. Reduce the forward angle to cut an even layer of material and to avoid slipping.

92 918496/GP0313

Scraping Hard Material

1. Lower the bucket onto the material.

2. Tilt the bucket forward to the desired digging angle.

3. Drive forward, press the bucket slightly downward so that the bucket penetrates the material.

Note: Avoid extreme tire slipping.

4. Reduce the tipping angle.

5. While driving forward, operate the joystick to lower and raise the bucket, and to constantly load the front axle.

918496/GP0313 93

Towing the Loader

WARNING

Do not use the loader for towing (other vehicles, trailers, equipment, etc.).

Important: The machine cannot be tow-started because there is no direct mechanical connection between the wheels and the engine. Attempting to towstart the machine may damage the drive system.

Precautions

Only tow the loader if the steering and brakes are functional, if it cannot be repaired on-site, and if it cannot be transported using any other method. Only tow the loader until it is moved to a location where it can be safely repaired.

Important: If moving the loader more than a few hundred meters, use a flatbed truck or similar vehicle to transport the loader, to prevent overheating the hydraulic system. See “Loading and Transporting” on page 97.

Towing AL 100 Series

Machines

Preparation

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. Tilt up the operator’s platform. See

“Tilting Up the Platform” on page 107.

3. Loosen the hydraulic system bypass valve (D, Fig. 58) one to two turns.

D

Figure 58 – Hydraulic System

Bypass Valve (AL 100 Series)

CAUTION

Do not loosen the bypass valve bolts more than one to two turns. The bypass valve can come out of the pump, resulting in a rapid loss of hydraulic fluid.

4. Tilt and secure the operator’s platform back into the operating position. See

“Tilting the Platform Down” on page 108.

94 918496/GP0313

Towing AL 300 Series

Machines

C A

Preparation

1. Perform the “Mandatory

Safety Shutdown Procedure” on page 10.

2. Disconnect hoses (B) and the electrical connector from the motor. Cap the ends of the hoses to prevent hydraulic fluid loss.

3. Remove bolts (A, Fig. 59) securing drive motor (C).

Note: Record the position of the hoses for re-assembly.

4. Remove hydraulic motor (C) from the axle. Support the motor during towing.

5. After towing the machine, replace the motor in the axle and secure the motor with bolts (A).

6. Reconnect hoses (B) and the electrical connector to the motor.

Note: Reconnect hoses (B) in the same positions where they were removed.

B

A

Figure 59 – Hydraulic Motor

Removal (AL 300 Series)

R

Towing AL 500 and AL 400

Series Machines

Preparation

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. Tilt up the operator’s platform. See

“Tilting Up the Platform” on page 107.

3. Loosen the bypass valve bolts (R, Fig.

60) three turns.

Figure 60 – Hydraulic Pump

Bypass Valve (AL 400\500

Series)

CAUTION

Do not loosen the bypass valve bolts more than three turns. The bypass valve bolts can come out of the pump, resulting in a rapid loss of hydraulic fluid.

4. Tilt and secure the operator’s platform back into the operating position. See

“Tilting the Platform Down” on page 108.

918496/GP0313 95

Towing Procedure

1. Attach the tow bar/cable to the front/rear frame tie-down points or the tow hitch (Fig. 61 and Fig. 62) located at the rear of the loader.

Important: Only use a tow bar or tow cable of sufficient capacity.

2. Tow the unit slowly and with caution.

Do not tow continuously for longer than three minutes at a time.

Figure 61 – Rear Tow/Tie-

Down Points

(AL 100 Series)

Important: Tow the machine with another vehicle ONLY. Do not tow loads or other vehicles with the machine.

Figure 62 – Tow Hitch

(AL200, 300, 400, 500 Series)

WARNING

Do not allow anyone near the tow bar or tow cable while the loader is being towed. Use a tow cable/tow bar with a capacity of at least three times greater than the towing vehicle’s pulling power. Do not exceed 5 km/h (3 mph) while towing, or damage to the hydraulic system could occur.

After Towing

1. Tilt up the operator’s platform. See “Tilting Up the Platform” on page 107.

2. Tighten the bypass valve bolts to 70 Nm (52 lbf-ft).

Note: Do not over-torque the bypass valve bolts.

3. Tilt and secure the operator’s platform back into the operating position. See

“Tilting the Platform Down” on page 108.

4. Secure the loader against rolling away and unauthorized use.

96 918496/GP0313

Loading and Transporting

CAUTION

Obey all applicable over-the-road regulations when transporting the machine. Check restrictions regarding weight, width and load length. The hauling vehicle, trailer and load must all be in compliance with regulations.

Make sure the transport vehicle and the loading ramp are in proper working condition and have sufficient capacity for the load.

1. Park the transport vehicle on solid, even ground when loading.

2. Clean the loader and transport vehicle.

3. Attach ramps securely to the transport vehicle to prevent them from slipping during loading.

CAUTION

Do not use ramps inclined at an angle greater than 17° (30%). Clean dirt, mud, ice and snow from the ramps. Use metal loading ramps with a slip-resistant surface and beveled ends to prevent damage to the tires.

4. Engage the transport vehicle parking brake and chock the wheels.

5. Complete all steps in “Driving on Public Roads” on page 70.

6. Carefully back the loader onto the transport vehicle, so that the heavy end of the loader is near the cab of the transport vehicle.

WARNING

Do NOT adjust travel direction while driving up ramps.

Instead, back off the ramps and realign the machine with the ramps.

Do not allow anyone to walk beside, behind or in front of the loader during loading and unloading. Always use the “slow” travel speed when loading the machine.

AL 200/300 Series

AL 100 Series similar

S

AL 500 Series; AL 400

Series Similar 7. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

8. Secure the steering lock bar in the transport position using the spring pins (S, Fig. 63) provided.

9. Lock the cab, if so equipped.

10. Chock the machine’s tires to prevent the machine from rolling.

S

Figure 63 – Steering/Frame Lock

Bar in Locked Position

918496/GP0313 97

11. Secure the machine to the transport vehicle at the tie-down points (T, Fig.

64 and U, Fig. 65) to prevent the machine from moving during transport in accordance with applicable over-the-road hauling regulations.

AL 200/300 Series

(AL 100 Series similar)

T

AL 400/500 Series

T

Figure 64 – Front Tie-down

Points (both sides)

AL 200/300 Series

(AL 100 Series similar)

98

U

AL 400/500 Series

U

Figure 65 – Rear Tie-down

Points (both sides)

918496/GP0313

Crane Lifting

WARNING

Always close the cab doors (if applicable) and engine cover before lifting the machine with a crane. Stay clear from underneath the machine as it is lifted. Do not lift machine without proper equipment.

WARNING

The crane must have a capacity greater than the weight of the machine. For machine weights, see weights and capacities information starting on page 33.

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. Secure the steering lock bar in the transport position using the spring pins (S, Fig. 66) provided.

AL 200/300 Series

(AL 100 Series similar)

3. Lock the cab, if so equipped.

4. Close the engine cover, if necessary.

S

AL 500 Series; AL 400

Series Similar

S

Figure 66 – Steering/Frame Lock

Bar in Locked Position

918496/GP0313 99

AL 500, AL 400, AL 300 and AL 200 Series:

5. Connect spreader bar and chains to front and rear lift points as shown (Fig.

68). The spreader bar should be long enough to prevent the chains from rubbing on the engine hood and the chains should be long enough to clear the

ROPS structure.

6. Lift the machine so it remains level (Fig. 67 and Fig. 68).

Important: Chains must be routed over the rear bumper to prevent damage to machine.

AL 400/500 Series

A

D

C

A

B

AL 200/300 Series

D

C

B

A. Chain - rear

B. Lift points - rear (2)

C. Lift points - front (2)

D. Chain - front

E. Spreader bar

Figure 67 – Crane Lifting

AL 500, AL 400, AL 300 and AL 200 Series

100

A

Back

B

918496/GP0313

AL 100 Series:

1. Connect chains to lift points (B, Fig. 68) as shown.

2. Lift the machine as shown in Fig. 68.

A

B

A. Chain

B. Lift points (2)

Figure 68 – Crane Lifting

(AL 100 Series)

918496/GP0313 101

Notes

102 918496/GP0313

CHAPTER 5

MAINTENANCE

Proper care and service improves machine operational readiness and service life.

Perform maintenance as indicated in the “Maintenance Schedule” on page 104, or earlier if required by conditions.

WARNING

Read and understand the Safety Chapter, starting on page 9, before servicing the machine. Follow all applicable warnings and instructions. Check for correct function after servicing the machine. Failure to follow instructions can result in injury or death.

WARNING

Fluid leaks from hydraulic hoses or pressurized components can be difficult to see, but pressurized oil can have enough force to pierce the skin and cause serious injury. Always use a piece of wood or cardboard to check for suspected hydraulic leaks. Never use your hands.

Obtain immediate medical attention if pressurized oil pierces the skin. Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

CAUTION

Do not use the machine when maintenance is due. Postponed maintenance can result in a serious reduction of the service life of the machine, costly equipment failures, and contribute to unsafe operating conditions.

CAUTION

Allow only trained and authorized personnel, with full knowledge of safe procedures, to perform machine maintenance and service.

Important: Malfunctions caused by unauthorized modifications and alterations are not covered under warranty.

918496/GP0313 103

Maintenance Schedule

Use the following table with the procedures included in the this chapter, beginning on page 103. For new machine operating guidelines, see “New

Machines” on page 70.

Important: The following maintenance intervals apply to average operating conditions and loads. Under extreme operating conditions, more frequent maintenance may be required. The hourmeter indicates total operating time; use the hourmeter to determine when scheduled maintenance is due.

CAUTION

Do not postpone maintenance. Postponed maintenance can result in a serious reduction to the service life of the machine, more serious and costly equipment failures, and contribute to unsafe operating conditions.

Check, Clean and Inspect

Service Procedure 10 Hours

(or daily)

Maximum Interval

50 Hours

(or weekly)

Monthly

250 Hours

(or every six months)

500 Hours

(or annually) x x

Clean machine

Check machine for general wear/damage

Check attachments for wear/damage

Check engine oil level and condition

Check coolant level and condition

Check brake fluid level

Check hydraulic fluid level

Check windshield washer system

Check exhaust for excessive smoke emission

Clean air filter; replace if necessary

Check tire condition and pressure

Check wheel fasteners for damage/tightness

Check hydraulic cylinder piston rods for wear/damage; clean if necessary

Check ROPS structure (all fasteners must be installed and securely tightened) x x x x x x x x x x 1 x x x

104 918496/GP0313

Check, Clean and Inspect

Service Procedure 10 Hours

(or daily)

Maximum Interval

50 Hours

(or weekly)

Monthly

250 Hours

(or every six months)

500 Hours

(or annually)

Check coolant system for leaks, dirt and debris; hoses for cracks/damage

Check battery electrolyte level (if applicable)

Check engine and engine mounts

Check for hydraulic system for leaks, proper routing

Check anti-freeze mixture

Check V-belt tension and condition

Check engine cover lock

Check engine idle

Replace fuel filter

Check hinge pins, joint bushings, pivot bolts and bearings

Check for exhaust system damage

Clean battery terminals

Check timing belt

Check fuel injectors

Check electrical system for damage, wiring routing x x x x x x x x x x x x

1. Check before first use and every two hours after tightening until fastener torque stabilizes; every month thereafter.

x x x

Leakage Check

Service Procedure

Check engine for oil/coolant leaks

Check cooling system for leaks

Check hydraulic system for leaks

Check axles for leaks

10 Hours

(or daily)

Maximum Interval

50 Hours

(or weekly)

Monthly

250 Hours

(or every six months)

500 Hours

(or annually) x x x x

918496/GP0313 105

Lubrication and Filter Changes

Service Procedure

10

Hours

(or daily)

50

Hours

(or weekly)

Maximum Interval

Monthly

250

Hours

(or every six months)

500

Hours

(or annually)

1500

Hours

(or annually)

Lubricate grease zerks according to lubrication diagram

Lubricate all levers, cables and hinges with oil

Lubricate driveshaft universal and slip joint

Change engine oil/filter

Change axle oil

Change hydraulic fluid and return filter

Change fuel filter; clean pre-filter

Change coolant

Change cabin air filter

Change oil in the axles x x x

1

2

1. After first 50 hours; every 250 hours thereafter.

2. Replace if needed.

x x x x x x x x

Functional Check

Service Procedure

Check seat belt

Check foot brake and parking brake functions; adjust if necessary

Check steering

Check windshield wipers

Check instruments, indicator lights and audible warning devices

Check lighting system

(if installed)

10 Hours

(or daily)

Maximum Interval

50 Hours

(or weekly)

Monthly

250 Hours

(or every six months)

500 Hours

(or annually) x x x x x x

106 918496/GP0313

Dealer Service

The following service items require special tools and knowledge and should be performed only by an authorized dealer:

• Engine service not included in this manual

• Hydrostatic components

• Hydraulic system pumps

• Hydraulic valves

• Hydraulic cylinders

• Electrical components other than battery and circuit breakers

Tilting the Platform

WARNING

Always close the cab doors (if applicable) and open the engine cover before tilting the platform. Stay clear from underneath the platform as it is tilted.

Always secure the tilt support when platform is tilted.

Tilting Up the Platform

1. Complete “Mandatory Safety

Shutdown Procedure” on page 10.

2. Open engine cover (D, Fig.

69).

Note: The platform is locked in the lowered position when the engine cover is closed.

3. Remove the platform lockdown hardware from the left front (A) and left rear (C) of the platform (B).

Note: AL 100 Series machines, have lock-down hardware at both the right and left front of the platform at position (A).

E

A B C D

A. Platform, Front Mounting

B. Platform

C. Platform, Rear Mounting

D. Engine Cover

E. Steering Lock Bar Lever Insert

Figure 69 – Tilted Platform

918496/GP0313 107

4. Securely close the cab doors (if applicable).

5. Using the ROPS, cab frame, and/or handles, manually tilt the platform upward.

Note: The steering lock bar (W, Fig. 71) can be inserted in bracket (E) to provide additional leverage for tilting the platform.

A

Front

Rear

6. Engage tilt support (W, Fig. 72).

C

Tilting the Platform Down

1. Slightly lift the platform using the steering lock bar (W, Fig. 71) to relieve pressure on the tilt lock to allow it to be disengaged.

Figure 70 – Platform Mounting

Hardware

E

2. Disengage the tilt lock (W). Carefully lower the platform.

W

Figure 71 – Steering Lock

Bar/Platform Tilt Bracket

AL 200/300/400/500 Series

3. Install platform lock-down nuts, bolts and washers onto the left front and left rear (A and C, Fig. 69) of the platform.

4. Close engine cover (D, Fig. 69).

108

W

AL 100

Series

Figure 72 – Tilt Support Lock

918496/GP0313

Engine Maintenance

WARNING

Allow engine and hydraulic system components to cool before maintenance.

Engine Oil

Checking Engine Oil Level

1. Position the machine on a level surface.

2. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

3. Wait until the machine has cooled. See “Service Safety Practices” on page 16.

4. Open engine cover.

AL 100 Series

5. Remove the dipstick (Y, Fig. 73). Wipe dipstick with a clean cloth.

6. Insert the dipstick until it is fully seated, and remove.

7. Read markings on the dipstick, markings represent FULL and LOW (add oil) levels.

See “Maintenance Schedule” on

page 104 for the service interval for replacing the engine oil and filter.

Y

AL 200/300 Series

Y

Y

AL 400/500 Series

918496/GP0313

Figure 73 – Engine Oil Dipstick

109

Changing Engine Oil and Filter

Change the engine oil and filter after the first 50 hours of use, and every 250 hours thereafter.

1. Position the machine on a level surface.

2. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

3. Wait until the machine has cooled. See

“Service Safety Practices” on page 16.

4. Remove the engine access panel (A,

Fig. 74).

Notice: Removing engine access panel requires two people.

5. Position a waste oil collection container to catch draining oil (B, Fig.

75).

A

Figure 74 – Engine Access

Panel

Important: Dispose of waste engine oil according to environmental laws or take to a recycling center for proper disposal.

DO NOT pour waste engine oil onto the ground or down a drain.

6. Remove the drain plug (C, Fig. 76) from the oil pan and allow the oil to drain into the waste oil collection container.

7. Remove the oil filter, using a filter wrench as necessary.

8. Put clean oil on the new oil filter gasket. Install the filter and tighten 3/4 turn past the point where the gasket contacts the filter head.

9. Reinstall and tighten the drain plug.

10. Reinstall the engine access panel (A,

Fig. 74).

Notice: Reinstalling engine access panel requires two people.

B

Figure 75 – Waste Oil Collection Container

C

Figure 76 – Oil Pan Drain Plug

110 918496/GP0313

11. Remove the oil fill cap (Z, Fig. 77) and add the recommended oil. See

“Fluid Capacities/Lubricants” on page 31. Replace cap (Z).

12. Start the engine and let it run for several minutes at low idle. Stop the engine. Wait until the machine has cooled. See “Service Safety Practices” on page 16.

13. Check for leaks at the oil filter and drain plug. Check the oil level. If necessary, add oil until the oil level is at the full mark on the dipstick.

Z

AL 100 Series

AL 200/300 Series

Z

AL 400/500 Series

Z

Figure 77 – Engine Oil Dipstick

918496/GP0313 111

Air Cleaner

Important: Do not operate the engine without the air cleaner components installed or damage to the engine could occur. Failure to follow air cleaner servicing instructions can cause engine damage.

The air cleaner consists of an outer (primary) filter element, an inner (secondary) filter element, an air filter restriction indicator and a dust valve. If the air cleaner becomes restricted, the air filter restriction indicator (A, Fig. 78) turns red to warn the operator that the element(s) require service. Push the reset button located on the end of the indicator after installing a clean filter element(s). Pinching the dust valve

(B, Fig. 78) opens a slit at the end of the valve, allowing accumulated dust in the end of the element cover to drop out without removing the cover.

AL 500 Series shown, other machines similar

A

D

C

B

F

G

E

A. Air Filter Restriction Indicator

B. Dust Valve

C. Element Cover

D. Clamp

E. Air Cleaner Housing

F. Outer Filter Element

G. Inner Filter Element

Figure 78 – Dual-Element Air Cleaner

Only replace the inner element every third time the outer element is replaced, unless the outer element is damaged or the inner element is visibly dirty.

Be sure that the restriction indicator, air cleaner intake hose, clamps and mounting bracket hardware are properly tightened.

112 918496/GP0313

Accessing the Outer and Inner Filter Elements

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. Open the engine cover.

3. Unlatch the clamps on the air cleaner housing and remove the element cover.

4. Clean any debris from the cover.

Changing the Filter Elements

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. Carefully remove the outer filter element (F, Fig. 78). Do not remove the inner filter element (G) unless it is to be replaced. If the inner filter element will not be replaced, skip to step 8.

3. Before removing inner filter element (G) from the housing, clean away any dirt built up in the housing. Leave the inner filter element installed during this step to prevent debris from entering the engine intake manifold.

4. Remove the inner filter element.

5. Clean dust and debris from housing (E) and cover (C). Leave the inner filter element installed during this step to prevent debris from entering the engine intake manifold.

6. Check the inside of the housing for any damage that may interfere with the elements.

7. Remove the old inner filter element and install the new inner filter element.

8. Reinstall/replace the outer filter element.

9. Latch clamps (D) to secure cove (C).

10. Check the hose connections and be sure they are all clamped and tightened properly.

918496/GP0313 113

Engine Cooling System

Checking Coolant Level

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. Open the engine cover (J, Fig. 79).

Check the coolant level in the expansion reservoir (H, Fig. 79). The expansion reservoir must be 1/3 to 1/2 full for a cold engine and 2/3 to 3/4 full for a hot engine. Add coolant to the expansion reservoir as required.

AL 500 Series shown

(other machines similar)

H

Note: Use a low-silicate ethylene glycolbased coolant, mixed with quality water and supplemental coolant additives

(SCAs) suitable for heavy-duty diesel engines. See the engine manual for additional information.

J

Figure 79 – Cooling System

WARNING

Do not remove the radiator cap when the coolant is hot. Serious burns may occur.

3. Slowly loosen the cap and allow pressure to escape.

4. Remove the cap and add coolant as necessary. See “Fluid Capacities/Lubricants” on page 31 for coolant specification.

5. Reinstall the cap.

Cleaning Cooling System

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. Allow engine to cool.

3. Open engine cover.

4. Clean radiator and oil cooler by blowing air/water through the fins.

Important: High pressure may bend radiator fins; proceed with caution. Blow air/water in opposite direction of cooling fan to dislodge debris.

114 918496/GP0313

Draining/Refilling Cooling System

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. Allow engine to cool.

3. Open engine cover.

WARNING

Do not remove radiator cap when the coolant is hot. Serious burns may occur.

4. Slowly loosen radiator cap (K, Fig.

80) and allow pressure to escape.

Remove cap.

5. Remove the engine access panel. See

“Changing Engine Oil and Filter” on page 110, step 4.

6. Position a collection container, with a capacity of at least 8 L (2 gal.), underneath the radiator drain.

K

Figure 80 – Radiator Cap

7. Open radiator drain valve (L, Fig. 81).

Drain valve is located at bottom of radiator, above frame member. The drain valve opening points toward the front of the machine.

AL 500 Series shown

(other machines similar)

Important: Drain the coolant into the container. Always dispose of coolant according to environmental laws. DO

NOT pour onto the ground or down a drain.

L

8. Close radiator drain valve.

9. Fill the radiator using a low-silicate ethylene glycol-based coolant, mixed with quality water and supplemental coolant additives (SCAs) suitable for heavy-duty diesel engines. See the engine manual for additional information.

10. Replace engine access panel.

Figure 81 – Cooling System

11. Reinstall radiator cap and tighten securely.

12. Complete all steps in “Checking Coolant Level” on page 114.

13. Run the engine until it is at operating temperature.

14. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

15. Allow the engine to cool.

16. Open the engine cover.

17. Check the coolant level in the expansion reservoir. The reservoir must be 1/3 to 1/2 full for a cold engine and 2/3 to 3/4 full for a hot engine.

918496/GP0313 115

Fuel System

WARNING

Use only proper types and grades of diesel fuel

(See “Fluid Capacities/Lubricants” on page 31). Diesel fuel is flammable. Keep the machine away from open flames. Do not smoke when refueling or when working on the engine. Stop the engine before fueling. Failure to follow instructions can cause fire and result in injury or death.

Important: The fuel tank is filled at the factory with United States off-road grade diesel fuel, which is dyed red for identification. It may take several fillings of the fuel tank before the red dye is purged from the fuel system.

Adding Fuel

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. Remove fuel cap (M, Fig. 82).

3. Inspect the wire-mesh fuel strainer located in the filler neck and remove any accumulated residue that may be present. Replace the strainer if damaged.

4. Add fuel into fuel filler neck (N).

M

N

Figure 82 – Fuel Fill Neck

Important: The engine requires low sulfur or ultra-low sulfur diesel fuel (below 500 PPM recommended). BioDiesel mixtures of up to a 5% (B5) are acceptable. Ultra-Low Sulfur Diesel (ULSD) fuel lubricity must have a maximum scar diameter of 0.45 mm, as measured by ASTM

D6079 or ISO 12156-1, or a minimum of 3100 grams, as measured by ASTM

D6078. Contact your fuel supplier for details.

Changing Fuel Filter

The fuel filter (P, Fig. 83) is located in the fuel line before the fuel pump. Access the fuel filter by opening the engine cover and tilting the platform. See “Tilting Up the

Platform” on page 107. Replace the fuel filter at the interval specified in the

“Maintenance Schedule” on page 104

The fuel filter is located on the left side of the loader.

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. Allow the machine to cool completely.

AL 500 Series shown

(other machines similar)

Figure 83 – Fuel Filter

P

WARNING

Fuel spilled on hot components can cause fire and severe burns. Allow the machine to cool completely before removing the fuel filter.

116 918496/GP0313

3. Shut off the fuel supply by turning the fuel shut-off valve on top of the water separator to OFF.

4. Remove the fuel filter.

WARNING

Watch for, and catch, any fuel drips or leaks.

Wipe up spilled fuel and immediately dispose of rags used to clean up fuel spills. Fuel vapors can ignite and cause severe burns.

5. Clean the fuel filter gasket and the fuel filter mounting surfaces where they contact each other with a clean cloth.

6. Lubricate new fuel filter gasket with diesel fuel.

7. Install and tighten the filter 3/4 turn past the point the where the gasket contacts the filter head.

8. Turn shut-off valve on water separator to ON.

9. The engine is self-priming: to remove air from the fuel line before starting, turn the ignition key to the ON position for 30 seconds.

Water Separator Maintenance

The water separator contains an indicator ring that floats on top of accumulated water. Under normal conditions, this ring sits at the bottom of the separator. If the ring is somewhere between the bottom of the separator and white ring (B, Fig.

84), then accumulated water must be drained.

Important: Water in the fuel system can cause severe engine damage. Drain water from the fuel filter/water separator anytime water is present.

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. View the water separator through the slot in front of the right-rear tire, near the step.

3. Access the water separator from underneath the loader, near the right-rear wheel. Check for water in water separator by checking the level of the float in the water separator bowl. If water is present, complete steps 4-7.

4. Turn the fuel shut-off valve lever (A, Fig. 84) on the water separator to the

OFF position.

918496/GP0313 117

5. Place a container underneath the drain plug (C, Fig. 84). Loosen the plug until water begins draining. Allow water to drain until the indicator ring returns to the bottom of the water separator.

6. Tighten the drain plug and discard fuel/water according to environmental laws. DO NOT pour the fuel/water onto the ground or down a drain.

7. Turn the fuel shut-off valve lever

(A) on the water separator to the

ON position.

A

B

C

ON

A. Fuel shut-off valve lever

B. Indicator ring

C. Drain plug

OFF

Figure 84 – Water Separator

118 918496/GP0313

Checking and Adjusting V-belt Tension

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. Open the engine cover.

3. Inspect V-belts (R, Fig. 85) for damage. If damaged, have belts replaced by your dealer.

AL 500 Series shown

(other machines similar)

T

4. Press on V-belts (R) mid-way between pulleys to check deflection. Belts should deflect no more than 8 mm (5/16").

S

5. If deflection is more than 8 mm

(5/16"): Loosen the adjustment bolt (S) and rotate the alternator

(T) outward until V-belt tension is correct. Tighten bolt (S) and recheck V-belt tension.

R

Figure 85 – V-belt Tension

Air Conditioning V-Belt

Inspect and service the air conditioning V-belt (X, Fig. 86) the same as directed in Checking and

Adjusting V-belt Tension.

To adjust the air conditioning V-belt tension, Loosen the adjustment bolt

(Y) and rotate the air conditioning compressor (W) downward until Vbelt tension is correct. Tighten bolt

(S) and re-check V-belt tension.

X

W

Y

Figure 86 – Air Conditioning V-Belt

918496/GP0313 119

Air Conditioning Maintenance

Test air conditioning function weekly. Reduced air conditioning function could indicate a low refrigerant level. Low refrigerant or refrigerant leaks can cause air conditioning compressor overheating and failure.

Important: Air conditioning system should be filled only by technicians trained in the air conditioning fill processes.

Filter Replacement

Air conditioning outside air intake filter element replacement:

Air Conditioning Outside Air

Filter

1. Perform the “Mandatory Safety

Shutdown Procedure” on page 10.

2. Open the engine cover.

3. Insert a thin screwdriver into hole

(L, Fig. 87) on the right side of the outside air filter housing and push to start moving filter element (M) out of the filter housing.

4. On the left side of the outside air filter housing, pull air filter element (M) out of the air conditioning unit.

5. Replace with a new filter element.

Make sure the new element is seated all the way into the filter housing, with the outside edge of the filter element flush with the left side of the filter housing.

M

L

Air Conditioning Cab Air Filter

Air conditioning cab air filter element replacement:

P

1. Slide the operator’s seat as far forward as it will go to provide access to the cab wall behind the seat.

Figure 87 – Air Conditioning

System Filters

2. Using a screwdriver, carefully pry the old cab air filter element (P) out of the cab wall. Remove and discard the old filter element.

3. Press the new filter element (P) into the opening in the cab wall. Make sure the filter element is completed seated in the opening.

120 918496/GP0313

Windshield Washer Reservoir (Cab Only)

The cab windshield washer reservoir is located inside the engine compartment.

Z

1. Perform the “Mandatory Safety

Shutdown Procedure” on page 10.

2. Open the engine cover.

3. As necessary, remove cap (Z, Fig.

88) from the windshield washer reservoir and fill with windshield washer fluid.

4. Replace cap (Z) and close the engine cover.

Figure 88 – Windshield Washer Reservoir (Cab Only)

918496/GP0313 121

Hydraulic System Maintenance

WARNING

Never use your hands to search for hydraulic fluid leaks; use a piece of paper or cardboard to find leaks. Escaping fluid under pressure can be invisible and can penetrate the skin, causing serious injury. If any fluid is injected into your skin, see a doctor at once. Injected fluid MUST be surgically removed, or gangrene may result.

Hydraulic Oil

Checking Hydraulic Oil Level

1. Completely lower the lift arm and attachment.

2. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

3. Open the hood.

AL 500 Series shown

(other machines similar)

4. Check the hydraulic oil level by removing the dipstick (U, Fig. 89), located on the left in the engine compartment.

5. If hydraulic oil is required, allow the system to cool.

6. Slowly remove the oil fill cap (V, Fig.

89). Allow the pressure to escape before completely removing the cap.

W U V

Figure 89 – Hydraulic Oil Service

Important: On AL 100 Series machines, remove the hydraulic oil filter cap (W, Fig.

89) and lift the hydraulic oil filter (A, Fig.

90) slightly before adding oil. Lifting the oil filter breaks the air seal and allows the hydraulic tanks to vent, allowing the tanks on both sides of the machine to fill evenly, otherwise, the hydraulic tanks will not fill evenly or completely.

A

AL 100 Series

7. Add hydraulic fluid as required.

See “Fluid Capacities/Lubricants” on page 31.

Figure 90 – Hydraulic Oil Filter

Note: Do not mix different types/grades of hydraulic fluids.

8. Reinstall the oil fill cap. On AL 100 Series machines, re-seat the hydraulic oil filter and reinstall the hydraulic oil filter cap.

122 918496/GP0313

Changing Hydraulic Oil and Filter

Note: The hydraulic oil filter can be changed without changing the hydraulic oil or draining the hydraulic reservoir.

Replace the hydraulic oil if it becomes contaminated, after major repairs, and after 500 hours or one year of use.

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. Open the hood.

3. Slowly remove the oil fill cap (V, Fig. 89). Allow the pressure to escape before completely removing the cap.

4. Position a waste oil collection container with a capacity of at least

45 liters (11 gallons) underneath the hydraulic oil reservoir.

Important: Always dispose of hydraulic fluids according to environmental laws or take to a recycling center for proper disposal. DO NOT pour onto the ground or down a drain.

5. Remove the drain plug (X, Fig. 91) and allow the oil to drain completely.

6. Unscrew the filter cover (W, Fig. 89).

7. Remove the old filter element (Y, Fig.

92). Cover the filter opening on the filter housing with a clean rag while adding oil.

8. Refill the reservoir until the oil is between the two lines on the dipstick

(U, Fig. 89).

9. Remove the rag from the filter opening and clean the surface of the filter housing where the element seal contacts the housing. Put clean oil on the rubber gasket of the new filter element (Y, Fig. 92).

10. Install the new filter element (Y, Fig.

92).

11. Reinstall the drain plug.

12. Reinstall the filter cover.

X

Figure 91 – Hydraulic Oil Drain

AL 500 Series shown

(other machines similar)

Y

Figure 92 – Hydraulic Oil

Service

Note: Do not mix different types/grades of hydraulic fluids.

13. Start the engine and operate the hydraulic controls.

14. Stop the engine and check for leaks at the hydraulic oil filter and reservoir drain plug.

15. Check the oil level and add oil if necessary.

918496/GP0313 123

Hydraulic Hose Maintenance

WARNING

Hydraulic hoses and connections must be inspected by a trained technician before the first use of the machine, and at least annually thereafter, for leaks and/or damage.

Leakages and damaged pressure hose/lines must be immediately repaired or replaced by an authorized service center.

Never use your hands to check for suspected hydraulic leaks. Always use a piece of wood or cardboard.

Leaks from hydraulic hoses or pressurized components can be difficult to see, but pressurized oil can have enough force to pierce the skin and cause serious injury.

Obtain immediate medical attention if pressurized oil pierces the skin. Failure to obtain prompt medical assistance could result in gangrene or other serious damage to tissue.

Always relieve hydraulic system pressure before performing any maintenance on the machine. Do not tighten leaking connections when the hydraulic system is under pressure.

Never weld or solder damaged or leaking pressure lines and/or screw connections. Always replace damaged hydraulic components.

Hydraulic hoses must be replaced every six years from the date of manufacture, even if they do not appear damaged.

The date of manufacture

(month or quarter and year) is indicated on hydraulic hoses.

See Figure 93.

1 Q/05

Figure 93 – Hydraulic Hose Manufacture Date

124 918496/GP0313

Planetary Axles

Changing Planetary Axle Oil

Replace the oil in the axles if it becomes contaminated, after the first 500 hours of service, and every 1500 hours or annually thereafter.

1. Warm the axles to operating temperature.

2. Perform the “Mandatory Safety Shutdown Procedure” on page 10. The machine must be parked on a level surface.

3. Complete the following procedures as appropriate for the model machine.

Changing Axle Wheel-Hub Oil (AL 500, AL 400 and AL 300 Series)

Note: Removing the tires and raising the machine on jackstands can make hub oil changing easier.

1. Rotate the oil drain/fill plugs (A, Fig.

94) on the wheel hubs so they are positioned at the top as shown in the figure. Thoroughly clean the area around the plugs and slowly loosen and remove the plugs.

2. Position a waste oil collection containers, capacity 0.5 liters (0.5 quarts) each, underneath the wheel hubs, to catch oil as it drains.

A

Important: Always dispose of waste oil according to environmental laws or take to a recycling center for proper disposal.

DO NOT pour onto the ground or down a drain.

3. Rotate the oil drain holes (B, Fig. 95) on the wheel hubs so they are positioned at the bottom as shown in the figure. Allow the oil to completely drain from the hubs.

4. Rotate the holes on the wheel ends so they are positioned to the side as shown (C, Fig. 96).

5. Add oil through the holes to the level line (D) stamped on the hub and shown in Fig. 96. See “Fluid Capacities/Lubricants” on page 31 for the specific oil type and grade.

Figure 94 – Wheel-Hub Oil Drain

Plug Removal Position

B

Figure 95 – Wheel-Hub Oil Drain

Position

918496/GP0313 125

6. Thoroughly clean the oil drain/fill plugs. Replace the plugs with new Orings and tighten to 70 N•m (52 lbf.ft.).

C

D

Figure 96 – Wheel-End Axle Oil

Level Check

Changing Axle Center Oil (AL 500, AL 400 and AL 300 Series)

Note: Remove the optional counterweight, if it is installed.

1. Position waste oil collection containers, with a capacity of at least 2.5 liters

(2.6 quarts) front and 3.2 liters (3.4 quarts) rear, underneath the axle centers to catch oil as it drains.

2. Thoroughly clean the area around the axle center fill plugs (E, Fig. 97),

Slowly loosen and remove the plugs.

Front Axle

Important: Always dispose of waste oil according to environmental laws or take to a recycling center for proper disposal.

DO NOT pour onto the ground or down a drain.

E

Rear Axle

3. Thoroughly clean the area around the axle center drain plugs (F, Fig. 97) and slowly loosen and remove the plugs.

Allow the oil to completely drain from the axle centers.

F

4. Thoroughly clean the axle center oil drain plugs. Replace the plugs with new O-rings and tighten the plugs to

70 N•m (52 lbf.-ft.).

Figure 97 – Axle Center Oil

Level Check

5. Add oil through the oil fill holes (E) until it reaches the bottom of the holes.

See “Fluid Capacities/Lubricants” on page 31 for the specific oil type and grade.

6. Thoroughly clean the axle center oil fill plugs (E). Replace the plugs with new O-rings and tighten to 70 N•m (52 lbf.-ft.).

126 918496/GP0313

Changing Axle Oil (AL 200 and AL 100 Series)

1. Position waste oil collection containers, with capacities of at least 5 liters (5 quarts) underneath the axle centers to catch oil as it drains.

2. Thoroughly clean around axle drain plugs (M, Fig. 98) and remove the plugs.

3. Thoroughly clean around axle fill plugs (O) and remove the plugs. Allow the oil to completely drain.

Important: Always dispose of waste oil according to environmental laws or take to a recycling center for proper disposal.

DO NOT pour onto the ground or down a drain.

4. Thoroughly clean axle drain plugs.

Replace and tighten the plugs.

5. Add oil through the oil fill holes (O) until it reaches the bottom of the holes. See “Fluid Capacities/Lubricants” on page 31 for the specific oil type and grade.

6. Thoroughly clean fill plugs (O).

Replace and tighten the plugs.

O

M

Figure 98 – Axle Oil Drain/Fill

918496/GP0313 127

Brake Fluid Reservoir (AL 300, AL 400 and AL 500

Series)

Checking Brake Fluid Reservoir Level

1. Perform the “Mandatory Safety Shutdown Procedure” on page 10.

2. Open the engine hood.

3. The brake fluid reservoir (G, Fig. 99) is located against the platform at the front of the engine compartment.

H

Note: On machines equipped with air conditioning, the brake fluid reservoir is located on the back of the air conditioning enclosure.

4. Carefully remove the brake fluid reservoir fill cap (H). Be careful not to allow dirt to fall into the reservoir.

5. The brake fluid reservoir fluid level should not fall below 1/2 full. Add automatic transmission fluid as required.

G

Figure 99 – Brake Fluid

Reservoir (AL 500 Series without Air Conditioning Shown)

Wheels and Tires

Wheel Fasteners

Wheel fastener torque must be checked before initial operation and every two hours thereafter until the wheel mounting hardware torque stabilizes. Torque the wheel fasteners in the order shown (Fig.

100). When tires are removed and replaced, this procedure must be repeated.

See “Wheels” on page 38 for wheel fastener torque specifications, wheel rim dimensions and wheel offset measurements.

6

1

3

5

4

2

Figure 100 – Wheel Fasteners

Tightening Order

128 918496/GP0313

Tires

WARNING mount tires.

Inflating or servicing tires can be dangerous.

Only trained personnel should service and

Important: Keep the same size tire on each side of the loader to prevent excessive wear on tires.

Tire Rotation

To keep tire wear even, rotate the tires from front to rear and rear to front.

Important: The tread bar of all tires should face the same direction.

Checking Tire Pressure

Correct tire pressure should be maintained for all tires to enhance operating stability and extend tire life. Use a clip-on tire chuck with remote hose and gauge and stand clear of the tire during inflation.

Note: See tire sidewall for recommended inflation pressure.

Liquid Tire Ballast (AL 500 Series)

WARNING

On AL 500

Series machines equipped with 33x15.5-

16.5 and 31x15.5-16.5 (EU) tires, can have liquid ballast installed in the rear tires to maximum capacity performance.

To prevent corrosion and freezing, use only a good grade of calcium chloride or equivalent fluid as tire ballast.

Mix the liquid tire ballast product according to the manufacturer’s instructions. Fill to the level shown in Fig.

101.

Figure 101 – Fluid-Filled Rear

Tires Fill Level

918496/GP0313 129

Lubrication

Important: Use of lubricants not corresponding to manufacturer recommendations may invalidate warranty claims. Always dispose of waste lubrication oils and hydraulic fluids according to environmental laws or take to a recycling center for proper disposal. DO NOT pour fluids onto the ground or down a drain.

Refer to the following figures for grease fitting locations. See “Fluid Capacities/Lubricants” on page 31 for proper grease specifications. Wipe dirt from the fittings before greasing them to prevent contamination. Replace any missing or damaged fittings. Avoid excessive greasing to minimize dirt build-up.

AL 500 Series (AL 400 Series Similar)

G

I

H H

F

A

B

E

B

A

D

C

A. All-Tach ® System Pins (2)

B. All-Tach ® System Pivots - Lower (2)

C. Lower Link Pivot - Front

D. Upper Link Pivot - Front

E. Lower Link Pivot - Rear

F. Loader Pivot

G. Tilt Cylinder - Front

H. LIft Cylinder - Front (2)

I. Upper Link Pivot - Rear

Figure 102 – AL 500 Series – Grease Every 10 Hours (or daily)

130 918496/GP0313

J

L

AL 500 Series (AL 400 Series Similar)

J

L

N

M

K

P

O

M

Q

R

J. Lift Arm - Upper Pivot (2)

K. Tilt Cylinder - Rear Pivot

L. Lift Cylinder - Rear Pivot (2)

M. Articulation Pivot - Upper (2)

N. Steering Cylinder - Front

O. Articulation Pivot - Lower

P. Driveshaft - Center Telescoping

Section

Q. Driveshaft - Both Ends

R. Steering Cylinder - Rear (2)

Figure 103 – AL 500 Series – Grease Every 10 Hours (or daily)

918496/GP0313 131

AL 200/300 Series Shown (AL 100 Series Similar)

G

C

D

B

E

D

E

8

A

H

F

A. Pivot Arm - Lower

B. Link Pivot - Upper

C. Tilt Cylinder - Rear

D. Lift Arm Pivot (2)

E. Lift Cylinder - Rear (2)

F. Attachment Pivot - Upper

G. Tilt Cylinder - Front

H. Lift Cylinder - Front (2)

Figure 104 – AL 300/200/100 Series – Grease Every 10 Hours (or daily)

132 918496/GP0313

AL 200/300 Series Shown (AL 100 Series Similar)

J

O

N

L

K

M

R

AL 300 Series

P

Q

J. Articulation Pivot - Upper Front

K. Articulation Pivot - Upper Rear

L. Steering Cylinder - Front

M. Articulation Pivot - Lower

N. All-Tach ® System Pins (2)

O. All-Tach ® System Pivots - Lower (2)

P. Steering Cylinder - Rear

Q. Drive Shaft Ends

R. Drive Shaft Center Telescoping

Section (AL 300 Series)

Figure 105 – AL300/200/100 Series–Grease Every 10 Hours (or daily)

918496/GP0313 133

Electrical System

Fuses

The main system fuse (J, Fig. 106) is located behind the battery and connected to the positive (+) battery terminal.

AL 500 Series shown

(other machines similar)

J

The primary fuse panel (K, Fig. 107) is located at the left side of the steering column.

• For details see “Steering Column

Fuses – AL 500/400/300 Series; AL

100 (EU), AL 200 Optional” on page 135 and “Steering Column Fuses

– AL 100 Series and AL 200

Standard” on page 136.

Figure 106 – Main System Fuse

AL 100; AL 200 Standard

AL 500/400/300; AL 100 (EU),

AL 200 Option

134

K

Figure 107 – Steering Column

Fuse Panel

918496/GP0313

Steering Column Fuses – AL 500/400/300 Series; AL 100 (EU), AL

200 Optional

12 11 10 9 8 7 6 5 4 3 2 1

13 14 15 16 TOP

Fuse

No.

Rated

Current

(Amp)

1.

2.

5

10

3. 5

4. 7.5

5. 5

6. 10

7. 5

8. 10

9. 20

10.

11.

10

10

12. 7.5

13. 10

14. 10

15. 5

16. 10

Protected Circuit

Instrument panel, differential lock, cab relay

Joystick, control module relay

Fuel pump, fuel solenoid hold

Work light switch, work light relays

Power-A-Tach ® system

Rear work light

Front work light

12V accessory power outlet

918496/GP0313 135

Steering Column Fuses – AL 100 Series and AL 200 Standard

11

10

9

2

1

4

3

4

11

3

10

2

9

1

8

7

6

5

8

7

6

5

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

11.

Fuse

No.

5

20

10

10

7.5

5

7.5

5

10

5

5

Rated

Current

(Amp)

Protected Circuit

Instrument panel, drive forward and reverse relays

Joystick

Fuel pump, glow module, fuel solenoid hold

Horn, beacon

Steering column switch lights

Power-A-Tach ® system

Starter relay

Ignition switch

Rear work light

Front work light

12V accessory power outlet

136 918496/GP0313

Cab and In-Line Fuses

Cab fuses (L, Fig. 108) are located in the engine compartment at the right rear corner of the operator’s platform. Open the engine cover to access these fuses.

Additional in-line fuses are located in the wire harness under the platform.

L

Figure 108 – Cab Fuse Block

(inside engine compartment)

In-line Fuses (located under platform near engine compartment)

Cab Fuses

(located inside engine compartment)

2

3

4

1

5

7

Main and In-line

Fuses (located under platform)

AL 500 Series

Shown - other machines similar

9

8

6

Figure 109 – Cab, Drive, Starter, Glow and Main Fuses

918496/GP0313 137

Note: Refer to Fig. 108 and Fig. 109.

Fuse

No.

Rated

Current

(Amp)

1. 5

2. 7.5

3. 10

4. 25

5. 15

6. 40

7. 25

8. 30

9. 60

Rear motor

Protected Circuit

Heater

Drive module (AL 400/AL 500 Series only)

138 918496/GP0313

Control Modules

The control modules, located behind the operator’s seat on the right, (all models except AL 100 Series), or under the operator’s platform (AL 100 Series) provide switching, control logic and diagnostic functions.

Machine Control Module

The machine controller (N, Fig. 110) provides the following functions:

N

Z

• Glow plug control

• Starter logic

• Sends forward/reverse signal to drive controller

• Safety logic control

P

Figure 110 – Control Modules

Drive Control Module (AL 500/400

Series)

The drive control module provides computerized control of the drive system, and provides error-reporting functionality.

LEDs inside the cover indicate the following:

• Green steady on — Indicates power to the drive controller

• Red/green flashing — Indicates an error in the system

918496/GP0313 139

Drive Control Module Error Codes

Malfunctioning drive function may indicate a control module error condition.

The table on page 140 describes control module error codes. Error codes are indicated by flashing LEDs (Z, Fig. 110) located near the electrical connectors at the bottom of the module.

The LED flash pattern for error messages starts with four medium-length flashes, which signal the start of the message, followed by a pause. After the pause, a number of long flashes may occur, indicating the first digit for the code. After another pause, a number of short flashes occur indicating the second digit for the code. After a final pause, the flash pattern then repeats.

More than one error code may be displayed, one after the other.

To illustrate, the flash pattern for error code “13” would be: Four medium flashes

(message start), pause, one long flash (first digit of error code), pause, three short flashes (second digit of error code), pause. The flash pattern then repeats.

27

31

35

39

13

15

19

23

43

47

55

Error Flash

Code

59

70

Description

Watchdog Ready Error

Battery Voltage or Sensor Voltage Error

Pump Current Forward Error

Pump Current Reverse Error

Motor Current Error

Engine Speed RPM Error

FNR Shortcut Error

Inching Error

Driving Pedal Error

Mode Switch-2 Error

Brake Pressure Defeat Error (or Parking Brake Error or Brake Light Error)

Motor RPM and Direction Error

General CAN Receive Error

140 918496/GP0313

Battery

WARNING

Before servicing the battery or electrical system, disconnect the negative battery cable from the negative battery terminal and tie the cable away from the negative battery terminal to prevent sparking and accidental re-connection. Alternately, if the machine is equipped with the optional battery disconnect switch, turn the battery disconnect switch to the

“OFF” position.

Refer to “Electrical System” on page 38 for battery specifications. To access the battery, tilt the platform. See “Tilting the Platform” on page 107.

The battery top must be kept clean. Clean it with an alkaline solution (ammonia or baking soda and water). After foaming has stopped, wipe the battery top with a damp towel. Clean corrosion from terminals and cable connection by disconnecting the cables and cleaning the terminals and clamps with the same alkaline solution. Thoroughly dry the battery and cables using a clean towel.

WARNING

Explosive gas is produced while a battery is in use or being charged. Keep flames or sparks away from the battery area. ALWAYS charge the battery in a wellventilated area.

Never lay a metal object on top of a battery, because a short circuit can result.

Battery acid is harmful to skin and fabrics. If acid spills, follow these first-aid tips:

1. Immediately remove any clothing on which acid spill.

2. If acid contacts skin, rinse the affected area with running water for 10 to 15 minutes.

3. If acid contacts eyes, flood eyes with running water for 10 to 15 minutes. See a doctor at once. Never use any medication or eye drops unless prescribed by the doctor.

4. To neutralize battery acid spills, use one of the following mixtures: a. 0.5 kg (1 lbs.) of baking soda in 4 L (4 qts.) of water b. 0.5 L (0.5 qts.) of household ammonia in 4 L (4 qts.) of water

When removing the battery, disconnect the negative (-) battery cable first and re-connect it last during installation.

918496/GP0313 141

Using a Booster Battery (Jump-Starting)

Note: The machine may be equipped with the remote battery terminal, allowing for easy access to booster terminals. See “Remote Battery Terminal” on page 143.

Important: Only complete these steps if the loader cannot be started using the ignition key switch. See “Engine Start” on page 67.

If the loader does not start because of a “dead” (discharged) battery, start the loader using a battery jumper cable connected to the battery of another vehicle.

Important: The loader cannot be tow-started because no direct mechanical connection exists between the wheels and the engine. Attempting to tow-start the machine may damage the drive system.

WARNING

10°C (14°F).

Do not jump-start a frozen battery, or it may explode. A discharged battery can freeze at

Note: Before jump-starting, check that the battery disconnect switch is not turned off.

The booster battery must have a nominal voltage of 12-volts. The capacity (Amphour rating) of the booster battery must be approximately equal to that of the discharged battery. Check the label on the discharged battery for the battery capacity.

WARNING

Keep metal parts on your clothing and metal watchbands away from the positive (+) terminal of the battery — risk of short circuit.

1. Turn the key switches of both machines to OFF. Be sure the machines are in neutral and NOT touching each other.

2. Connect the positive jumper cable to the positive (+) terminal on the discharged battery.

3. Connect the negative jumper cable to the negative (-) terminal on the discharged battery.

Note: If the machine is equipped with the optional remote battery terminal, connect the cables to the terminal studs on the remote battery terminal. See

“Remote Battery Terminal” on page 143.

4. Connect the free end of the positive jumper cable to the positive (+) terminal on the booster battery.

5. Connect the free end of the negative jumper cable to a convenient ground on the machine carrying the booster battery.

6. Start the machine with the discharged battery. See “Engine Start” on page 67.

If the engine does not start immediately, stop cranking after 10 seconds and repeat starting procedure after approximately 30 seconds.

142 918496/GP0313

WARNING

When the engine is running, components in the engine compartment rotate. Before removing the jumper cables, be sure that no loose clothing can become caught in the rotating components.

7. After the engine is running, remove the negative jumper cable connected to the booster machine ground.

Important: DO NOT allow the booster cable ends to touch when removing them.

Arcs and direct short circuits can cause severe damage to the electrical system.

8. Disconnect the jumper cables from the machine with the discharged battery.

9. Remove the positive jumper cable from the booster battery.

10. Close the engine cover and confirm it is latched securely.

11. Allow the machine to run for at least 30 minutes to re-charge the battery.

Remote Battery Terminal

The optional remote battery terminal allows access to the battery terminals for jump-starting purposes.

Open the engine hood to access the remote battery terminal. Remove cap (T,

Fig. 111) for access to the remote connection for the positive battery terminal stud. Stud (U) provides a remote connection to the machine ground.

U

AL 100 Series

T

AL 500/400/300/200 Series

T

U

918496/GP0313

Figure 111 – Optional Remote

Battery Terminal

143

Storing the Loader

Before Storage

If the loader is to be stored for a long period, in excess of two months, the following procedures are suggested:

1. Wash the entire machine.

2. Perform all steps for long-term engine storage according to the engine operator’s manual.

3. Properly inflate the tires. See tire sidewall for recommended inflation pressure.

4. Lubricate all grease fittings.

5. Check all fluid levels and replenish as necessary.

6. Add stabilizer to the fuel per the fuel supplier’s recommendations.

7. Remove the battery, charge fully and store in a cool, dry location.

8. If the machine will not be operated for a month or longer, apply grease to all exposed hydraulic cylinder rod areas or retract all cylinders so rod exposure is minimized. Apply grease to any remaining rod areas.

9. Protect exposed cylinder rods.

10. Protect against extreme weather conditions such as moisture, sunlight and temperature.

11. Fill the engine coolant system with the proper mix of antifreeze and water as required for expected temperatures according to “Coolant Compound Table” on page 37.

Important: Contact your dealer for additional storage preparation information if the machine will be stored in an environment where temperatures could range below -42°C (-44°F), and/or above 49°C (120°F).

After Storage

1. Check the tire air pressure and adjust inflation as necessary. See tire sidewall for recommended inflation pressure.

2. Replace and re-connect the battery.

3. Check the V-belt tension; adjust as necessary.

4. Check all fluid levels (engine oil, transmission/hydraulic oil, engine coolant and any attached implements); adjust as necessary.

5. Start the engine. Observe all indicators. If all indicators are functioning properly and reading normally, move the machine outside.

6. When outside, park the machine and let the engine idle for at least five minutes.

7. Shut off the engine and walk around machine. Make a visual inspection looking for evidence of leaks.

144 918496/GP0313

Final Shutdown / Decommissioning

Important: Dispose of all materials properly. Used oils/fluids/gases/refrigerant are environmental contaminants and may only be disposed of at approved collection facilities. Never drain any oils/fluids onto the ground, dispose of in municipal waste collection containers, or in metropolitan sewer systems or landfills. Check state and local regulations for other material disposal requirements.

If the machine will no longer be used as intended, shutdown, decommission and dispose of it according to the valid regulations.

Before Disposal

1. Shutdown the machine according to valid regulations regarding proper shutdown.

2. Park the machine on level, dry ground. Ensure the surface can support the weight of the machine. Ensure the location is protected against access by unauthorized persons.

3. Lower the lift arm completely. Remove any attachments.

4. Place forward/reverse drive switch (on top of the joystick) into the neutral position and apply the parking brake.

5. Move the throttle to the low-idle position and allow the engine to cool for approximately 2 minutes.

6. Shut off the engine.

7. Wait for all movement to stop. Turn the ignition key to the “I” or RUN position and move the multi-purpose joystick in all directions to verify that the hydraulic system is de-pressurized. Verify that the joystick does not cause movement of the lift arm.

8. If so equipped, press the auxiliary hydraulics pressure relief control. After pressing, make sure this control returns to the neutral position.

9. Turn off the ignition. Switch off all electrical switches.

10. Unfasten the seat belt, remove the ignition key and take it with you.

11. Ensure the machine cannot be operated after shutdown until further disposal.

12. Ensure no environmentally hazardous materials, fluids and/or fuel can escape the machine. Specifically check for leaks form the engine, the hydraulic system and the coolant system.

13. Ensure the machine poses no dangers in the place where it is standing.

14. Remove any dirt and/or debris from the engine compartment, the chassis and the cylinder rod surfaces.

15. Remove the battery.

16. If so equipped, lock the cab door. Lock the engine compartment. Remove the key(s) and take it/them with you.

918496/GP0313 145

Machine Disposal

Make sure all materials are disposed of in an ecologically sound manner.

Recycling the machine in accordance with the current state of the art at the time of recycling. Observe all accident prevention regulations.

Dispose of all parts at the at the recycling sites specific to the material of the part.

Take care to separate different materials for recycling.

146 918496/GP0313

Maintenance Log

Date Hours Service Procedure

918496/GP0313 147

Date Hours Service Procedure

148 918496/GP0313

Date Hours Service Procedure

918496/GP0313 149

Date Hours Service Procedure

150 918496/GP0313

Date Hours Service Procedure

918496/GP0313 151

Date Hours Service Procedure

152 918496/GP0313

CHAPTER 6

TROUBLESHOOTING

Engine Troubleshooting

Problem

Engine does not turn over

Engine stops when operator leaves seat

Possible Cause

Drive direction switch in forward/reverse

Tripped circuit breaker

Blown fuse

Dead battery

Operator not in operator’s seat

Battery disconnect switch in open position or malfunctioning

Malfunctioning seat switch

Operator not in seat

- or -

Parking brake not applied

- or -

Auxiliary hydraulics pressure relief valve lever not in neutral (later machines only)

Parking brake not applied or parking brake malfunction

Corrective Action

Place drive direction switch in neutral

Reset circuit breaker

Replace fuse.

Charge or replace battery—see “Using a

Booster Battery (Jump-

Starting)” on page 142

Operator’s seat must be occupied for engine to start

Place battery disconnect switch into closed position— Repair or replace if necessary

Replace seat switch

Sit in operator’s seat

- or -

Apply parking brake

- or -

Place auxiliary hydraulics pressure relief valve lever in neutral

Apply or repair parking brake

918496/GP0313 153

Engine Troubleshooting

Problem

Engine turns over but will not start

Possible Cause

Engine cranking speed too slow

Fuel tank empty

Fuel filter plugged or restricted

Paraffin separation in winter

Fuel line leakage

Glow plug module malfunction

Fuel shut-off solenoid not energizing

Fuel filter restricted

Fuel pump malfunction

Corrective Action

Check battery and charge/replace as necessary—tighten battery terminals

Fill tank and vent fuel system if necessary

Change fuel filter

Use winter grade diesel fuel

Tighten all threaded connections and clamps

Check connection and voltage—replace as necessary

Check electrical connections/voltage to shut-off solenoid

Replace filter

Contact dealer

154 918496/GP0313

Engine Troubleshooting

Problem

Engine overheating

Engine running but loader will not drive

Possible Cause Corrective Action

Crankcase oil level incorrect Adjust oil level

Cooling air circulation restricted

With engine off, remove restriction

Contact dealer Fan shroud improperly positioned

Improper oil grade or oil excessively dirty

Exhaust restricted

Change engine oil—see

“Fluid

Capacities/Lubricants” on page 31 for proper oil grade

Allow exhaust to cool; remove restriction

Air filter restricted

Low coolant level

Loose fan belt

Dirty radiator

Replace filter(s)

Add coolant

Tighten fan belt

Clean radiator

Thermostat malfunction

Parking brake applied

Parking brake switch malfunction

Blown fuse

Replace thermostat

Release parking brake

Replace parking brake switch

Check circuit and replace fuse

Replace joystick handle Joystick drive direction slider switch malfunction

(AL 400/500 Series)

Drive system component malfunction

Operator not in seat

Check drive controller error code

Sit in operator seat

918496/GP0313 155

Indicator Lamp Troubleshooting

Indicator Activated

Engine oil pressure

Possible Cause

Engine oil pressure too low

Hydraulic oil temperature

Hydraulic oil filter

Engine oil level too low

Oil pump malfunction

Temperature is too hot

Corrective Action

Stop engine immediately; check oil level and add oil if necessary; check oil pump

Add oil

Contact dealer

Check cooling system for debris in radiator

Check hydraulic oil level

Replace filter

Water temperature

Battery voltage

Low fuel

Hydraulic oil filter service required

Coolant level too low

Air filter plugged

Engine overheating

Alternator not charging properly

Low fuel

Add coolant

Replace air filter

Check cooling system

Adjust v-belt tension; check alternator

Add fuel

156 918496/GP0313

Seal and Hose Troubleshooting

Problem

Oil, coolant or fuel leakage

Hydraulic fluid leakage

Possible Cause

Loose hose connection(s)

Damaged seals or hoses

Loose fittings

Seals, hoses or lines damaged

Corrective Action

Tighten hose connections

Change seals/hoses as necessary

Tighten hydraulic connections

Change seals, hoses or lines as necessary

Hydraulic System Troubleshooting

Problem

Hydraulics do not work or work only at a low performance level

Possible Cause

Low hydraulic fluid level

Hydraulic fluid is not warm

Engine to pump coupling or hydraulic pump damaged

Pressure limiting valves set too low or damaged

Hydraulic cylinder damaged

Control valves damaged

Engine speed is too low

Dirty/restricted air filter(s)

Incorrect fuel grade

Travel drive system does not work or works only at a low performance level

AL 100 Series hydraulic tanks not evenly filled

Corrective Action

Add hydraulic fluid

Allow longer warm-up

Contact dealer

Contact dealer

Contact dealer

Contact dealer

Adjust engine speed— see “Accelerator pedal” on page 53 and “Hand

Throttle” on page 61

Replace filter(s)

Change the fuel—see

“Fluid

Capacities/Lubricants” on page 31 for proper fuel grade

See “Checking Hydraulic

Oil Level” on page 122.

918496/GP0313 157

Hydraulic System Troubleshooting

Problem

Attachment tilts down with tilt control in neutral

Lift arm does not raise/lower

Attachment tilt not working but lift arm works properly

Lift arm does not raise but tilt works properly

Hydraulic system overheating

Lift and/or tilt functions too slow

Lift and/or tilt functions inconsistent/jerky

Travel drive performance inconsistent/jerky

Possible Cause

Oil leaking past tilt cylinder seals (internal or external)

Leaking hydraulic hoses, tubes or fittings between control valve and cylinders

Lift spool in control valve not actuated or leaking

Hydraulic oil leaking past cylinder piston seals

Tilt spool in control valve not actuated or leaking

Lift spool in control valve not actuated or leaking

Hydraulic oil cooler is dirty

Hydraulic oil level is too low

Load too high

AL 100 Series hydraulic tanks not evenly filled

Low engine speed

Low hydraulic oil level

Hydraulic oil leaking past cylinder piston seals

Hydraulic pump malfunction

Air in hydraulic system

Corrective Action

Contact dealer

Repair as required

Contact dealer

Contact dealer

Contact dealer

Contact dealer

Clean hydraulic oil cooler

Add hydraulic oil

Reduce load

See “Checking Hydraulic

Oil Level” on page 122.

Increase engine speed

Add oil and check for leaks

Contact dealer

Low hydraulic oil level

Cylinder(s) malfunction

AL 100 Series hydraulic tanks not evenly filled

Contact dealer

Cycle lift and tilt cylinders to maximum stroke and maintain pressure for short time to clear air from system

Add oil and check for leaks

Contact dealer

See “Checking Hydraulic

Oil Level” on page 122.

158 918496/GP0313

Hydraulic System Troubleshooting

Problem

Lift arm does not maintain raised position with multipurpose joystick centered

(neutral)

Auxiliary hydraulics do not function

Auxiliary hydraulics connections difficult to connect/disconnect

Possible Cause

Oil leaking past lift cylinder seals (internal or external)

Oil leaking past lift spool in control valve

Leaking hydraulic hoses, tubes or fittings between control valve and cylinders

Spool in control valve not actuated or leaking

Hydraulic oil leaking past seals

Auxiliary hydraulic connections improperly connected

Auxiliary hydraulics circuit under pressure

Corrective Action

Contact dealer

Contact dealer

Contact dealer

Contact dealer

Contact dealer

Correct hydraulic connections

Relieve auxiliary hydraulics circuit pressure—see “Auxiliary

Circuit Pressure Relief” on page 86

Hydrostatic Drive System Troubleshooting

Problem

No response from either hydrostatic drive or the lift/tilt systems

Possible Cause

Hydraulic oil viscosity too heavy

Dynamic braking not effective when drive pedal in neutral

Sticking flushing valve

(AL100/200/300 series)

Corrective Action

Allow longer warm-up

Replace with proper grade hydraulic oil—see

“Fluid

Capacities/Lubricants” on page 31 for proper oil grade

Repair/replace flushing valve

918496/GP0313 159

Hydrostatic Drive System Troubleshooting

Problem

Travel drive will not operate in either direction

Possible Cause

Parking brake is applied

Low hydraulic oil level

Low or no charge pressure

Hydrostatic pump(s) relief valves malfunction

Brake/inch pedal stuck or malfunctioning

Corrective Action

Release parking brake

Add oil

Contact dealer

Contact dealer

Throttle pedal linkage

Electrical connections

AL 100 Series hydraulic tanks not evenly filled

1. Check/release brake/inch pedal

2. (AL 400/500 Series only) Check drive error code

3. (AL 400/500 Series only) Force brake pedal calibration, if necessary

Check/repair throttle pedal linkage

(AL 400/500 Series only)

Check drive controller error code; force throttle pedal calibration, if necessary

Check/inspect electrical connection and harness

See “Checking Hydraulic

Oil Level” on page 122

160 918496/GP0313

Hydrostatic Drive System Troubleshooting

Problem

Travel drive system noisy

Sluggish travel drive acceleration

Possible Cause

Hydraulic oil viscosity too heavy

Low hydraulic oil level

AL 100 Series hydraulic tanks not evenly filled

Air in hydraulic system

Corrective Action

Allow longer warm-up

See “Fluid

Capacities/Lubricants” on page 31 for proper oil grade

Add oil

See “Checking Hydraulic

Oil Level” on page 122

Cycle lift and tilt cylinders to maximum stroke and maintain pressure for short time to clear from system

Contact dealer Drive motor(s) or hydrostatic pump(s) internal damage/ leakage

Low hydraulic oil level

Low hydrostatic system charge pressure

Drive motor or hydrostatic pump internal damage/ leakage

Brake/inch or throttle pedal applied, stuck or malfunctioning

Add oil

Contact dealer

Contact dealer

Engine running rough

Sticking flushing valve

(AL100/200/300 series)

AL 100 Series hydraulic tanks not evenly filled

Release/repair the brake/inch pedal

(AL 400/500 Series only)

Force pedal calibration, if necessary

Poor fuel quality or incorrect grade—See

“Fluid

Capacities/Lubricants” on page 31 for proper fuel grade

Repair/replace flushing valve

See “Checking Hydraulic

Oil Level” on page 122

918496/GP0313 161

Hydrostatic Drive System Troubleshooting

Problem

Travel drive overheating

Possible Cause

Drive system continuously overloaded

Lift/tilt or auxiliary system continuously overloaded

Drive motor(s) or hydrostatic pump(s) internal damage/ leakage

Oil cooler fins restricted

Hydraulic oil filter restricted

Sticking flushing valve

(AL100/200/300 series)

AL 100 Series hydraulic tanks not evenly filled

Corrective Action

Improve operation procedure

Improve operation procedure

Contact dealer

Clean oil cooler fins

Replace filter

Repair/replace flushing valve

See “Checking Hydraulic

Oil Level” on page 122

Electrical Troubleshooting

Problem

Electrical system does not function

Possible Cause

Battery disconnect switch is in OFF position

Battery terminals or cables loose or corroded

Battery malfunction

Instrument display does not activate with key switch on

Blown main fuse

Blown fuse

Fuel gauge does not work

Battery terminals/cables loose/corroded

Fuel gauge sender malfunction

Loose wiring/terminal connections

Blown fuse

Corrective Action

Turn battery disconnect switch to ON

Clean battery terminals and cables and retighten

Test battery—recharge/ replace as necessary

Replace main fuse

Check circuit and replace fuse

Clean battery terminals and cables and tighten

Replace fuel gauge sender

Check wiring connections

Check circuit and replace fuse

162 918496/GP0313

Electrical Troubleshooting

Problem

Engine temperature gauge does not work

Hour meter does not work

Starter does not engage when key switch turned to

START

Work/road lights malfunction

Possible Cause

Temperature sender malfunction

Loose wiring/terminal connections

Blown fuse

Loose wiring/terminal connections

Alternator malfunction

Poor electrical connections to starter

Battery terminals/cables loose/corroded

Starter relay malfunction

Battery malfunction

Starter solenoid malfunction

Starter or pinion malfunctioning

Drive direction switch in forward/reverse

Various

Auxiliary hydraulics pressure relief valve lever not in neutral (later machines only)

Single light not working— light bulb burned out, faulty wiring

No lights—blown fuse

Defective light switch or poor ground

Corrective Action

Replace temperature sender

Check wiring connections

Check circuit and replace fuse

Check wiring connections

Repair/replace alternator

Check connections

Clean battery terminals and cables and tighten

Contact dealer

Test battery—recharge/ replace as necessary

Contact dealer

Repair/replace as needed

Place drive direction switch in neutral

See “Engine does not turn over” on page 153

Place auxiliary hydraulics pressure relief valve lever in neutral

Check and replace light bulb as needed, check wiring connections

Check circuit and replace fuse

Check ground wire connections, replace light switch

918496/GP0313 163

Notes

164 918496/GP0313

A

Accelerator Pedal . . . . . . . . . . 53

,

75

Air Cleaner Dust Valve . . . . . . . . 112

Air Filter Restriction Indicator . . . 112

All-Tach Hitch . . . . . . . . . . . . . 81

,

82

Alternator . . . . . . . . . . . . . . . . 55 , 58

Attachments . . . . . . . . . . . . . . 78

,

81

Connecting . . . . . . . . . . . . . . . 81

Disconnecting . . . . . . . . . . . . . 85

Hydraulic Power-A-Tach

Hitch Connection . . . . . . . . . 83

Hydraulic Power-A-Tach

Hitch Disconnection . . . . . . . 85

Operation . . . . . . . . . . . . . . . . 92

Standard Hitch Connection . . 81

Standard Hitch Disconnection 85

Auxiliary Hydraulics . . . . . . . . . . . 86

Control Buttons . . . . . . . . . . . . 89

Control Lever . . . . . . . . . . . . . 92

Auxiliary Hydraulics Circuit

Pressure Relief . . . . . . . . . . . . . . 86

Auxiliary Hydraulics Control

Lever . . . . . . . . . . . . . . . . . . . . . 53

Auxiliary Hydraulics Flow and

Proportional Control . . . . . . . . . . 90

Axles . . . . . . . . . . . . . . . . . . . . . 125

Change Oil . . . . . . . . . . . . . . 125

B

Battery . . . . . . . . . . . . . . . . . . . . 141

Remote Battery Terminal

Option . . . . . . . . . . . . . . . . . 143

Battery Disconnect

Switch . . . . . . . . . . . . . .53

, 67 , 142

Beacon Switch . . . . . . . . . . . . . . . 53

Biodegradable Oil . . . . . . . . . . . . . 31

Booster Battery . . . . . . . . . . . . . 142

Brake/inch Pedal . . . . . . . . . . . . . 53

Brakes . . . . . . . . . . . . . . . . . . . . 130

INDEX

Bypass Valve . . . . . . . . . . . . . . . . 95

C

Cab . . . . . . . . . . . . . . . . . . . . . . . 57

Air Conditioning Control . . . . . 56

Environment Controls . . . . . . 56

Windshield Wiper Controls . . . 57

Checklist

Pre-Operation . . . . . . . . . . . . 63

Component Identification . . . . . . . . 5

Control Lever . . . . . . . . . . . . . 53 , 61

Control Modules . . . . . . . . . . . . 139

Coolant . . . . . . . . . . . . . . . . . . . . 32

Radiator . . . . . . . . . . . . . . . . . 32

Cooling System . . . . . . . . . . . . . 114

Check Coolant Level . . . . . . 114

Clean . . . . . . . . . . . . . . . . . . 114

Drain/Flush . . . . . . . . . . . . . . 115

Crane Lifting, Chain Lengths . . . . 40

D

Dealer Service . . . . . . . . . . . . . . 107

Densities . . . . . . . . . . . . . . . . . . . 49

Differential Lock . . . . . . . . . . . . . . 55

Differential Lock Operation . . . . . 76

Dimensions . . . . . . . .41

,

43

,

44

,

46

Dome Light . . . . . . . . . . . . . . . . . 57

Drive Control Module . . . . . . . . . 139

Error Codes . . . . . . . . . . . . . 140

Drive Direction Switch . . . 53

,

68

,

75

Drive Speed Switch . . . . . . . . . . . 75

Dust Valve . . . . . . . . . . . . . . . . . 112

E

Electrical System . . . . . . . . . . . . 134

Fuses and Fuse Locations . . 134

Steering Column

Fuses . . . . . . . . . . . . . 135

,

136

Engine Access Panel . . . . . . . . . 110

Engine Cooling System . . . . . . . 114

Engine Maintenance

918496/GP0313 165

Change Oil and Filter . . . . . . 110

Engine Oil Pressure . . . . . . . . 55 , 58

Engine Oil Temperature . . . . 55

,

58

Engine Oil Type . . . . . . . . . . . . . . 31

Engine rpm . . . . . . . . . . . . . . . . . 55

Engine Service

Change Fuel Filter . . . . . . . . 116

Engine Shut Down . . . . . . . . . . . . 69

Engine Start . . . . . . . . . . . . . . . . . 67

F

Fast Speed . . . . . . . . . . . . . . . . . 55

Filter Changes . . . . . . . . . . . . . . 106

First 50 Hours of Operation . . . . . 70

Fluid Capacities . . . . . . . . . . . . . . 31

FOPS . . . . . . . . . . . . . . . . . . . . . . 40

Forward Travel . . . . . . . . . . . . . . 55

Fuel Level . . . . . . . . . . . . . . . . . . 55

Fuel System . . . . . . . . . . . . . . . . 116

Adding Fuel . . . . . . . . . . . . . 116

Fuel Shut-off Valve Lever . . 118

Fuel Specifications . . . . . 31

,

116

Fuel Strainer . . . . . . . . . . . . 116

Low Sulfur Diesel . . . . . . . . . 116

Ultra-low Sulfur Diesel . . . . . 116

Functional Check . . . . . . . . . . . . 106

Fuse Locations . . . . . . . . . . . . . 134

Fuse Panel, Steering Column . . 134

G

General Information . . . . . . . . . . . . 1

German Road Regulations . . . . . . 4

Grease . . . . . . . . . . . . . . . . . . . . . 32

H

Hand Throttle . . . . . . . . . . . . . 53

,

61

Hazard Light Switch . . . . . . . . . . . 53

Hazard Lights . . . . . . . . . . . . . . . 55

Hour Meter . . . . . . . . . . . . . . . . . . 55

Hydraulic Oil . . . . . . . . . . . . 31 , 122

Filter . . . . . . . . . . . . . . . . . . . 123

Hydraulic Oil Filter Indicator . 55

,

58

Hydraulic Oil Pressure . . . . . . . . . 55

Hydraulic Oil Temperature . . . . . . 58

166

Hydraulic Power-A-Tach Hitch

Connection . . . . . . . . . . . . . . . . .83

Hydraulic Power-A-Tach Hitch

Disconnection . . . . . . . . . . . . . . .85

Hydraulic System

Change Oil . . . . . . . . . . . . . .123

Check Oil Level . . . . . . . . . . .122

I

Ignition Key . . . . . . . . . . . . . . . . . .68

Ignition Key Switch . . . . . . . . . . . .60

Inner Filter Element . . . . . . . . . . .113

Instrument Panel . . . . . . . . . . . . . .53

Instruments and Indicators . . . . . .54

Introduction . . . . . . . . . . . . . . . . . . .1

J

Jump-Starting . . . . . . . . . . . . . . .142

L

Leakage Check . . . . . . . . . . . . . .105

Left Turn . . . . . . . . . . . . . . . . . . . .55

Lift Arm . . . . . . . . . . . . . . . . . . . . .78

Down-stop . . . . . . . . . . . . . . . .74

Load Handling . . . . . . . . . . . . . . . .77

Loading and Transporting . . . . . . .97

Low Fuel . . . . . . . . . . . . . . . . . . . .55

Lubricants . . . . . . . . . . . . . . . . . . .31

Lubrication . . . . . . . . . . . . . 106

,

130

M

Machine Control Module . . . . . . .139

Main System Fuse . . . . . . . . . . .134

Maintenance . . . . . . . . . . . . . . . .103

Engine Air Cleaner . . . . . . . .112

Engine Maintenance . . . . . . .109

Engine Oil . . . . . . . . . 109

Maintenance Log . . . . . . . . . . . . .147

Maintenance Schedule . . . . . . . .104

Check, Clean and Inspect . . .104

Functional Check . . . . . . . . . .106

Leakage Check . . . . . . . . . . .105

Lubrication and Filter

Changes . . . . . . . . . . . . . . .106

Maintenance Log . . . . . . . . . .147

918496/GP0313

Maximum Slopes of Operation . . . 32

Model Identification . . . . . . . . . . . . 5

Multi-Purpose Joystick . . . . . . 53

,

78

Float Positions . . . . . . . . . . . . 80

N

New Machines . . . . . . . . . . . . . . . 70

O

Oil . . . . . . . . . . . . . . . . . . . . . . . . 109

Biodegradable Oil . . . . . . . . . . 31

Engine Oil . . . . . . . . . . . . . . . . 31

Hydraulic Oil . . . . . . . . . . . 31

,

32

Oil Dipstick . . . . . . . . . . . . . . . . . 109

Oil Pan Drain Plug . . . . . . . . . . . 110

Operation . . . . . . . . . . . . . . . . 51 , 63

Operator’s Manual Overview . . . . . 1

Operator’s Seat . . . . . . . . . . . . . . 53

Outer Filter Element . . . . . . . . . . 113

P

Parking Brake . . . . . . 55 , 66 , 67 , 74

Parking Brake Lever . . . . . . . . . . . 53

Power-A-Tach Lock/Unlock . . . . . 53

Pre-Heat . . . . . . . . . . . . . . . . . 55

,

68

Pre-Operation Checklist . . . . . . . . 63

R

Radiator . . . . . . . . . . . . . . . . . . . . 32

Radiator Cap . . . . . . . . . . . . . . . 115

Radiator Drain Valve . . . . . . . . . 115

Rearward Travel . . . . . . . . . . . . . . 55

Remote Battery Terminal

Option . . . . . . . . . . . . . . . . . . . . 143

Right Turn . . . . . . . . . . . . . . . . . . 55

Road Lights . . . . . . . . . . . . . 55 , 163

ROPS . . . . . . . . . . . . . . . .39

,

51

,

64

4-Post Side Gates . . . . . . . . . 65

Extending . . . . . . . . . . . . . . . . 64

S

Safety . . . . . . . . . . . . . . . . . . . . . . . 9

ANSI-Style Safety Decals . . . . 22

Before Starting . . . . . . . . . . . . 11

Crystalline Silica Exposure . . . 20

918496/GP0313

During Operation . . . . . . . . . . 12

Avoiding Rollover

Accidents . . . . . . . . . 15

Electrical Energy . . . . 16

Fire Hazards . . . . . . . . . . . . . 19

Hazard Symbols . . . . . . . . . . . 21

ISO-Style Safety Decals . . . . 27

Mandatory Safe Shutdown

Procedure . . . . . . . . . . . . . . 10

Safety Decals . . . . . . . . . . 21 , 22

Service Safety Practices . . . . 16

Battery Hazards . . . . 18

Seat Belt . . . . . . . . . . . . . . . . . . . 53

Seat Plate . . . . . . . . . . . . . . . . . . 53

Slow Speed . . . . . . . . . . . . . . . . . 55

Specifications . . . . . . . . . . . . . . . 31

Axle Oil . . . . . . . . . . . . . . . . . . 32

Biodegradable Oil . . . . . . . . . 31

Common Materials and

Densities . . . . . . . . . . . . . . . 49

Coolant . . . . . . . . . . . . . . . 32

,

37

Diesel Fuel . . . . . . . . . . . . . . . 31

Dimensions . . . . . . . . . . . 41

,

43

Electrical System . . . . . . . 37 , 38

Engine Oil . . . . . . . . . . . . . . . 31

Grease . . . . . . . . . . . . . . . . . . 32

Hydraulic Oil . . . . . . . . . . . . . . 31

Hydraulics . . . . . . . . . . . . . . . 38

Maximum Slopes of

Operation . . . . . . . . . . . . . . . 32

Optional Features . . . . . . . . . 48

Sound Levels . . . . . . . . . . . . . 38

Standard Features . . . . . . . . . 45

Tires . . . . . . . . . . . . . . . . . . . . 39

Wheel Fastener Torque . . . . . 38

Wheels . . . . . . . . . . . . . . . . . . 39

Windshield Washer . . . . . . . . 32

Standard Hitch Connection . . . . . 81

Standard Hitch Disconnection . . . 85

Steering Column . . . . . . . . . . . . . 53

Control Lever . . . . . . . . . . . . . 61

Steering Column Adjustment . . . . 60

167

Steering Wheel . . . . . . . . . . . . . . 53

Steering/Frame Lock Bar . . . . 97 , 99

Storage . . . . . . . . . . . . . . . . . . . 144

Preparing . . . . . . . . . . . . . . . 144

Removing . . . . . . . . . . . . . . . 144

Switches . . . . . . . . . . . . . . . . . . . 52

T

Tie-down Points . . . . . . . . . . . . . . 98

Tilting the Platform . . . . . . . . . . . 107

Down . . . . . . . . . . . . . . . . . . 108

Up . . . . . . . . . . . . . . . . . . . . 107

Tipover . . . . . . . . . . . . . . . . . . . . . 77

Tire Pressure . . . . . . . . . . . . . . . . 39

Tires . . . . . . . . . . . . . . . . . . . . . . 128

Tow Hitch . . . . . . . . . . . . . . . . . . . 96

Towing . . . . . . . . . . . . . . . . . . . . . 94

Transport Vehicle . . . . . . . . . . . . 98

Transporting . . . . . . . . . . . . . . . . 97

Travel . . . . . . . . . . . . . . . . . . . . . . 74

Troubleshooting . . . . . . . . . . . . . 153

Electrical . . . . . . . . . . . . . . . 162

Engine . . . . . . . . . . . . . . . . . 153

Hydraulic System . . . . . . . . . 157

Hydrostatic Drive System . . . 159

Indicator Lamp . . . . . . . . . . . 156

Indicator Lamps . . . . . . . . . . 156

Seal and Hose . . . . . . . . . . . 157

Seals and Hoses . . . . . . . . . 157

Turning Knob . . . . . . . . . . . . . . . . 53

V

V-belt Tension

Checking and Adjusting . . . . 119

Volt Meter . . . . . . . . . . . . . . . 55

,

58

W

Warmup . . . . . . . . . . . . . . . . . . . . 69

Warning Indicators . . . . . . . . . . . . 58

Water Separator

Fuel Shut-off Valve Lever . . 118

Wheel Fasteners . . . . . . . . . . . . 128

Wheel Rims . . . . . . . . . . . . . . . . . 38

Wheels . . . . . . . . . . . . . . . . . . . . 128

168

Windshield Washer . . . . . . . . . . . .32

918496/GP0313

Torque Specifications

Note: Use these torque values when tightening hardware (excluding: locknuts and self-tapping, thread forming and sheet metal screws) unless specified otherwise.

Hydraulic fittings with various seals (light application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Straight pipe fitting with thread and screwed plug (GE)

Thread

M42X2.0

M48X2.0

G1/8A

G1/4A

G3/8A

G1/2A

G3/4A

G1A

G1 1/4A

G1 1/2A

M10X1.0

M12X1.5

M14X1.5

M16X1.5

M18X1.5

M22X1.5

M27X2.0

M33X2.0

Sealing washer

177 (240)

214 (290)

7 (9)

26 (35)

33 (45)

48 (65)

66 (90)

111 (150)

177 (240)

214 (290)

7 (9)

15 (20)

26 (35)

33 (45)

41 (55)

48 (65)

66 (90)

111 (150)

Elastic seal

332 (450)

398 (540)

13 (18)

26 (35)

52 (70)

66 (90)

133 (180)

229 (310)

332 (450)

398 (540)

13 (18)

18 (25)

33 (45)

41 (55)

52 (70)

92 (125)

133 (180)

229 (310)

O-ring

155 (210)

192 (260)

11 (15)

22 (30)

33 (45)

41 (55)

74 (100)

118 (160)

155 (210)

192 (260)

11 (15)

18 (25)

26 (35)

30 (40)

33 (45)

44 (60)

74 (100)

118 (160)

Non-return valve with elastic seal

266 (360)

398 (540)

13 (18)

26 (35)

37 (50)

48 (65)

103 (140)

140 (190)

266 (360)

398 (540)

13 (18)

18 (25)

26 (35)

37 (50)

52 (70)

92 (125)

107 (145)

155 (210)

Identification aid outside Ø

0.4 in. (10 mm)

0.5 in. (12 mm)

0.6 in. (14 mm)

0.6 in. (16 mm)

0.7 in. (18 mm)

0.9 in. (22 mm)

1.0 in. (27 mm)

1.3 in. (33 mm)

1.7 in. (42 mm)

1.9 in. (48 mm)

0.4 in. (9.73 mm)

0.5 in. (13.16 mm)

0.7 in. (16.66 mm)

0.8 in. (20.96 mm)

1.0 in. (26.44 mm)

1.3 in. (33.25 mm)

1.7 in. (41.91 mm)

1.9 in. (47.80 mm)

Hydraulic fittings with various seals (heavy application). All torque values are in lb.-ft. (Nm) unless marked otherwise.

Thread

M12X1.5

M14X1.5

M16X1.5

M18X1.5

M20X1.5

M22X1.5

M27X2.0

M33X2.0

M42X2.0

M48X2.0

G1/8A

G1/4A

G3/8A

G1/2A

G3/4A

G1A

G1 1/4A

Straight pipe fitting with thread and screwed plug (GE)

Sealing washer

15 (20)

26 (35)

33 (45)

41 (55)

41 (55)

48 (65)

66 (90)

111 (150)

177 (240)

214 (290)

26 (35)

33 (45)

48 (65)

66 (90)

111 (150)

177 (240)

214 (290)

Elastic seal

26 (35)

41 (55)

52 (70)

66 (90)

92 (125)

100 (135)

133 (180)

229 (310)

332 (450)

398 (540)

41 (55)

59 (80)

85 (115)

133 (180)

229 (310)

332 (450)

398 (540)

O-ring

26 (35)

33 (45)

41 (55)

52 (70)

59 (80)

74 (100)

125 (170)

229 (310)

243 (330)

310 (420)

33 (45)

44 (60)

55 (75)

125 (170)

229 (310)

243 (330)

310 (420)

Non-return valve with elastic seal

26 (35)

33 (45)

41 (55)

52 (70)

74 (100)

92 (125)

100 (135)

155 (210)

266 (360)

398 (540)

33 (45)

44 (60)

74 (100)

107 (145)

192 (260)

266 (360)

398 (540)

Identification aid outside Ø

0.5 in. (12 mm)

0.6 in. (14 mm)

0.6 in. (16 mm)

0.7 in. (18 mm)

0.8 in. (20 mm)

0.9 in. (22 mm)

1.0 in. (27 mm)

1.3 in. (33 mm)

1.7 in. (42 mm)

1.9 in. (48 mm)

0.5 in. (13.16 mm)

0.7 in. (16.66 mm)

0.8 in. (20.96 mm)

1.0 in. (26.44 mm)

1.3 in. (33.25 mm)

1.7 in. (41.91 mm)

1.9 in. (47.80 mm)

918496/GP0313 169

Thread

M8X1.0

M10X1.0

M10X1.25

M12X1.25

M12X1.5

M14X1.5

M16X1.5

M18X1.5

M20X1.5

M22X1.5

M24X2.0

M27X2.0

M30X2.0

With fine-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Threads according to DIN 912, DIN 931, DIN 933, etc.

Threads according to DIN 7984

8.8

18 (25)

37 (50)

36 (49)

64 (87)

61 (83)

100 (135)

155 (210)

232 (315)

325 (440)

435 (590)

546 (740)

811 (1100)

1106 (1500)

10.9

27 (37)

55 (75)

52 (71)

96 (130)

92 (125)

148 (200)

229 (310)

332 (450)

465 (630)

620 (840)

789 (1070)

1143 (1550)

1586 (2150)

12.9

32 (43)

65 (88)

61 (83)

111 (150)

107 (145)

173 (235)

266 (360)

391 (530)

538 (730)

723 (980)

922 (1250)

1328 (1800)

1844 (2500)

8.8

16 (22)

32 (43)

31 (42)

55 (75)

53 (72)

89 (120)

133 (180)

199 (270)

277 (375)

369 (500)

465 (630)

679 (920)

959 (1300)

10.9

24 (32)

48 (65)

46 (62)

81 (110)

77 (105)

129 (175)

195 (265)

284 (385)

391 (530)

524 (710)

664 (900)

959 (1300)

1364 (1850)

Thread

M16

M18

M20

M22

M24

M27

M30

M5

M6

M8

M10

M12

M14

With coarse-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise.

Threads according to DIN 912, DIN 931, DIN 933, etc.

8.8

4.1 (5.5)

7 (10)

18 (25)

33 (45)

64 (87)

100 (135)

155 (210)

207 (280)

302 (410)

406 (550)

524 (710)

767 (1040)

1047 (1420)

10.9

6 (8)

10 (14)

26 (35)

48 (65)

81 (110)

133 (180)

203 (275)

302 (410)

420 (570)

575 (780)

738 (1000)

1092 (1480)

1482 (2010)

12.9

7 (10)

13 (17)

31 (42)

59 (80)

108 (147)

170 (230)

258 (350)

354 (480)

509 (690)

686 (930)

878 (1190)

1305 (1770)

1770 (2400)

Threads according to DIN 7984

8.8

4 (5)

6.3 (8.5)

15 (20)

30 (40)

51 (69)

81 (110)

125 (170)

181 (245)

251 (340)

339 (460)

435 (590)

642 (870)

885 (1200)

10.9

5 (7)

9 (12)

22 (30)

44 (59)

74 (100)

118 (160)

184 (250)

254 (345)

361 (490)

487 (660)

620 (840)

922 (1250)

1254 (1700)

170 918496/GP0313

EC DECLARATION OF CONFORMITY

1.

2.

Manufacturer:

Address:

Manitou Americas, Inc.

One Gehl Way

West Bend, WI 53095-0179 U.S.A.

3.

Technical Construction File Location:

Manitou Americas, Inc.

One Gehl Way

West Bend, WI 53095-0179

U.S.A.

4.

Authorized Representative:

5.

Address:

6.

We hereby declare that the machine listed below conforms to

EC Directives: 2004/108/EC (EMC), 97/23/EC (Pressure

Equipment), 2006/42/EC (Machinery) and 2000/14/EC (Noise

Emission), as amended by 2005/88/EC.

7.

In accordance with EN/ISO Standards:

EN ISO 3450:1996, ISO 6165

8.

Category: EARTH-MOVING MACHINERY/

LOADERS/COMPACT/SEATED OPERATOR

9.

Models: AL 140, AL 240, AL 340, AL 440, AL 540

10. Directive/Conformity Assessment Procedure/Notified Body:

2004/108/EC Type-test Self-certification

97/23/EC Self-certification ----------

2006/42/EC Self-certification ----------

2000/14/EC Annex VIII – Full TÜV Industrie Service

Quality

Assurance

GmbH – TÜV SÜD Group

Westendst. 199, D-80686

München, GERMANY

918496/GP0313 171

WARNING

THIS OPERATOR’S MANUAL IS

PROVIDED FOR OPERATOR USE

DO NOT REMOVE FROM THIS MACHINE

Do not start, operate or work on this machine until you carefully read and thoroughly understand the contents of this

Operator’s Manual.

Failure to follow safety, operating and maintenance instructions can result in serious injury to the operator or bystanders, poor operation, and costly breakdowns.

If you have any questions on proper operation, adjustment or maintenance of this machine, contact your dealer or the Gehl

Company Service Department before starting or continuing operation.

918496/GP0313

®

Manitou Americas, Inc.

One Gehl Way

PO Box 179

West Bend, WI 53095-0179 U.S.A.

www.gehl.de/ (Gehl Europe) www.gehl.com (Gehl USA)

© 2013 All Rights Reserved.

PRINTED IN U.S.A.