® Form No. 918412 AL 540 Revision C March 2011 Articulated Loader (SN 51242 and Up) l a u n a M s t r a P © 2011 Gehl Company • All Rights Reserved • Printed in USA When ordering service parts, specify the correct • (SN 1000 - 2000 except 1996 including 997) - part number, full description, quantity required, the indicates serial numbers between 1000 and unit model number and serial number. For your 2000, INCLUDING 997 EXCEPT 1996. safety and continued proper operation, use only • (SN 2001 and up including 1996) - indicates genuine Gehl service parts. serial numbers including 2001 and after, The model and serial number for this unit are INCLUDING 1996. located on a panel on the upper right side of the Unless otherwise specified, all cap screws, nuts, front frame. and bolts are Grade 8.8, cadmium or zinc plated. ''Right'' and ''left'' are determined from a position NOTE:The following abbreviations may be sitting on the seat and facing forward. used herein: Gehl Company reserves the right to make changes ASSD......................Assembled or improvements in the design or construction of any part of the unit without ASSY......................Assembly incurring the obligation to install such changes AR..........................As Required on any previously delivered units. CB...........................Carriage Bolt Refer to the abbreviations table located on this CP...........................Cotter Pin page for the various fastener descriptions. CS...........................Cap Screw (Hexagon Head) Standard attaching hardware torque values are also CYL........................Cylinder provided on the inside back cover. Metric torque DIA.........................Diameter values shown in the illustrations are in Newton- FHCS......................Flat Head Cap Screw meters and can be converted to foot-pounds by GR..........................Grade multiplying by 0.738. HB..........................Hex Bolt Specific Reference Numbers, indicating a HLN........................Hex Lock Nut complete assembly, are circled in some illustra- tions. A small bag, pictured in some illustrations, HN..........................Hex Nut indicates a seal kit (seals, o-rings, etc.). In the HP...........................High Pressure exploded view parts list, additional information HYD.......................Hydraulic may follow the Reference Number. INS.........................Insert LN...........................Lock Nut Serial number breaks are indicated as follows: LT...........................Left • (SN 999 and before) - indicates serial numbers LW..........................Lock Washer up to and including 999. M............................Meter or Meters • (SN 1000 - 2000) - indicates serial numbers MM/mm.................Millimeter from 1000 to 2000. NPT........................National Pipe Thread • (SN 999 and up) - indicates serial numbers RT...........................Right including 999 and after. SHCS......................Socket Head Cap Screw Serial number exceptions and inclusions are SLTD......................Slotted indicated as follows: SN...........................Serial Number or Slotted Nut • (SN 999 and before except 997) - indicates SQ...........................Square serial numbers up to and including 999, W/...........................With EXCEPT 997. W/O........................Without All-Tach®, Power-A-TachTM and Gehl® are trademarks of Gehl Company. TABLE OF CONTENTS Tools............................................................1 Controls......................................................37 Tools/Paint/Special Service Parts Differential Lock..................................37 and Kits..................................................1 Inching - Brake....................................38 Filters...........................................................2 Parking Brake......................................39 All Filters...............................................2 Throttle.................................................40 Return Filter - 274912............................3 Axles..........................................................41 Cab...............................................................4 Front and Rear Axles...........................41 Cab Assembly........................................4 Driveshaft.............................................42 Doors - 270067 & 270071.....................6 Wheels and Tires.................................43 Wipers....................................................7 Internal Components............................44 Heater.....................................................8 Notes....................................................50 Air Conditioning..................................10 Lift Arm.....................................................51 Completing Components.....................12 Lift Arm Assembly..............................51 Mirrors.......................................................13 Hydraulics............................................52 Steering......................................................14 Hydraulics..................................................54 Steering Column - Deluxe...................14 Hydraulic Tank....................................54 Operator’s Platform...................................15 Hydraulic Drive...................................55 Operator’s Platform - Upper................15 Power Steering.....................................56 Operator’s Platform - Lower................16 Control Valve.......................................57 ROPS.........................................................18 Auxiliary Valve....................................58 ROPS - Two-Post - 201024.................18 Axial Piston Hydraulic Pump..............59 ROPS - Four-Post - 201025.................19 Bent Axis Motor..................................61 Isolation Mats ............................................20 Hydraulic Cylinders...................................63 Isolation Mats Lift Cylinder........................................63 (EU all, Domestic w/Cab)....................20 Tilt Cylinder.........................................64 Work Lights...............................................21 Steering Cylinder.................................65 Strobe Lights..............................................22 Power-A-Tach Cylinder.......................66 Strobe Light Kits - 809568, 809571 4-Point Quick Attach Cylinder (Domestic only).................................22 (EU only).............................................67 Radio..........................................................23 Attachments...............................................68 Radio Kit - 809574 (Domestic only)...23 All-Tach...............................................68 Chassis.......................................................24 Attachment Hydraulics........................69 Front Frame..........................................24 Power-A-Tach......................................70 Rear Frame...........................................25 4-Point Quick Attach (EU only)..........71 Covers..................................................26 Buckets (Domestic Only).....................72 Electrical..............................................28 Pallet Forks (Domestic Only)..............73 Electrical - Fuses..................................29 Decals.........................................................74 Headlights/Tail Lights (Option)...........30 Common Decals...................................75 Remote Battery Terminal Kit ANSI-Style Decals...............................77 (Domestic-Std, EU-Option))................31 Iso-Style Decals...................................79 Battery Disconnect Engine........................................................81 (EU-Std, Domestic-Option).................32 Engine Assembly.................................81 Backup Alarm Kit (Option).................33 Cylinder Head and Cover....................82 Block Heater Kit Cylinder Block.....................................84 (Option - Domestic Only)....................34 Gear Housing.......................................85 Rear Bumper........................................35 Flywheel Housing/Oil Pan...................86 Counterweight Kit ...............................36 Intake Manifold....................................87 Printed in U.S.A. I 918412/CP0311 TABLE OF CONTENTS Exhaust Manifold.................................88 Camshaft..............................................89 Crankshaft, Piston................................90 Intake/Exhaust Components................91 Cooling System....................................92 Lubrication...........................................94 Fuel Line..............................................96 Fuel Injection Pump.............................98 Fuel Injection Valve...........................100 Governor............................................101 Alternator...........................................102 Starter.................................................103 Radiator..............................................104 Fittings / O-Rings / Seal Rings................105 Hose / O-Ring Compatibility...................106 Abbreviations and Descriptions for Fittings...............................................107 Notes........................................................108 Schematics...............................................109 Hydraulics..........................................109 Complete Electrical Schematic..........110 Steering Column Electrical Schematic111 Chassis Electrical Schematic.............112 Engine-Radio Electrical Schematic...113 4-Post ROPS, Cab, Power-A-Tach and Tail Light Electrical Schematics........114 Air Conditioning Electrical Schematic...........................................115 Notes..................................................116 Index........................................................117 Numerical Index......................................119 Torque Specifications......Inside Back Cover 918412/CP0311 II Printed in U.S.A. AL 540 - TOOLS TOOLS/PAINT/SPECIAL SERVICE PARTS AND KITS Ref. No. Part No. Description Qty. 3 184467 HYDRAULIC GAUGE KIT 1 4 186011 TEST PORT, 4MP-M16X2, 1 1/4 NPT 5 183877 TEST PORT, 3/4-16 UNF 1 6 184472 TEST GAUGE, 1000PSI 1 7 184473 TEST GAUGE, 6000PSI 1 8 184475 TEST HOSE, 120" 1 (Used with Gauge Kits) 9 184476 ADAPTER, 4FP-M16X2BLKHD 1 (Used with Gauge Kits) 10 184474 TEST GAUGE, 10,000PSI 1 11 420-34912 ROD SEAL INSTALL TOOL, 3/4" 1 X 1-1/4" DIAMETER SEALS 12 420-34913 ROD SEAL INSTALL TOOL, 1 1-1/2" X 2" DIAMETER SEALS 13 420-34914 ROD SEAL INSTALL TOOL, 1 2" X 3" DIAMETER SEALS 14 272814 OIL VACUUM PUMP (incl. in 1 Engine Oil Analysis Kit) 15 272815 COOLANT VACUUM PUMP 1 (incl. in Coolant Analysis Kit) 16 272816 1/4" PLASTIC TUBING, 100' 1 (incl. in Analysis Kit) 21 195387 DIAL INDICATOR (incl. in 1 195348 Timing Kit Tool) 31 272813 FIELD TEST COOLANT STRIP 1 (1 Kit from Coolant Analysis Kit) 32 272806 HYDRAULIC OIL ANALYSIS Set of 10 KIT (GEHL)* 33 272809 ENGINE OIL ANALYSIS KIT Set of 10 (GEHL)* 34 272811 FUEL ANALYSIS KIT (GEHL)* 1 35 272812 COOLANT ANALYSIS KIT Set of 10 (GEHL)* 36 167788 4-PACK CONSTRUCTION YEL- 1 qt. LOW PAINT (GEHL) 37 167754 4-PACK GUNMETAL GRAY 1 qt. PAINT (GEHL) 38 167789 6-PACK YELLOW SPRAY 12.8 oz. PAINT (GEHL) 39 167755 6-PACK GUNMETAL GRAY 12.8 oz. SPRAY PAINT (GEHL) 40 50300055 DIAGNOSTIC/MALE 1 *Analysis Kits - Contact your dealer. Only available for US customers. Printed in U.S.A. 1 918412/CP0311 AL 540 - FILTERS ALL FILTERS Ref. Ref. No. Part No. Description Qty. No. Part No. Description Qty. 1 195568 OIL FILTER 1 7 184709 FILTER/ CAB RECIRCULATION 1 (HEATER) 2 270979 FILTER/FUEL OIL 1 8 275915 FILTER/CAB RECIRCULATION (AIR 1 3 270900 ELEMENT/FILTER (RETURN FILTER) 1 CONDITIONING) 4 203822 FILTER ELEMENT 1 9 275688 FILTER (FRESH AIR INTAKE / AIR 1 (WATER SEPARATOR) CONDITIONING) 5 270741 FILTER/SAFETY (SECONDARY AIR) 1 6 270740 FILTER/PRIMARY (PRIMARY AIR) 1 918412/CP0311 2 Printed in U.S.A. AL 540 - FILTERS RETURN FILTER - 274912 0 1 2 3 4 5 6 274912 Ref. Ref. No. Part No. Description Qty. No. Part No. Description Qty. 0 274912 FILTER/RETURN COMPLETE 1 5 270901 O-RING 84X4 1 1 270896 CAP 1 6 270902 O-RING 23X4 1 2 270897 SEAL 1 3 270899 O-RING 72X3 1 4 270900 ELEMENT/FILTER 1 Printed in U.S.A. 3 918412/CP0311 AL 540 - CAB CAB ASSEMBLY 0 4 33 39 22 40 88 37 64 56 62 63 58 42 18 4 9 59 55 5 (both sides) 23 9 23 3 42 23 6 63 37 62 44 23 34 64 88 5 7 40 22 8 46 71 86 34 57 54 65 7 23 65 8 34 94 92 60 93 71 65 92 20 93 49 Cab Back 12 and Top 14 21 67 79 19 91 13 49 50 66 Door Latch 19 (Both Sides) 176400 918412/CP0311 4 Printed in U.S.A. AL 540 - CAB CAB ASSEMBLY Ref. Ref. No. Part No. Description Qty. No. Part No. Description Qty. 0 176400 ENCLOSED CAB ASSY * 1 54 203020 WINDSHIELD 1 3 202557 LOCKWASHER 1 55 203021 SKYLIGHT 1 4 654004 FW 5/16 AWZY 4 56 203022 REAR WINDOW/SIDE RT 1 5 202570 GROMMET 3 57 203023 REAR WINDOW/SIDE LT 1 6 202974 HOOK 1 58 203024 REAR WINDOW 1 7 L500048 HEX BOLT 3/8-16X4-1/2 G8 4 59 270071 DOOR ASSY RT 1 8 L500049 HEX NUT .38-16 G5 4 60 270067 DOOR ASSY LT 1 9 202571 GROMMET 2 62 270633 SOFT WASHER 2 12 202980 FLAT WASHER 4 63 270683 PLATE/BACKING 2 13 650965 CS 3/8X1-1/4 C8 2 64 270698 SPACER 2 14 651448 LN INS M10-1.5 C8 ZY DIN6924 2 65 202568 KIT/FOAM 1 18 202986 BRACKET 1 66 272078 FOAM/REAR PANEL 1 19 202987 STRIKER, .375-16, INT. THREAD 4 67 203031 FOAM PANEL 1 20 651297 CS 3/8X1 C8ZY 2 71 203062 FOAM SEAL 2 21 202989 STRIKER BOLT GUARD 2 79 203063 BRACKET, DOOR ARRESTER 2 22 L500022 FLAT WASHER 2 86 201377 HARNESS/4 POST ROPS 1 23 138281 SETTING BLOCK, 1/8 X 1/4 X 2 18 88 270701 SOFT WASHER 2 33 101793 FLANGE BOLT, M8 X 1.25 X 20 4 91 270691 FOAM/HEADLINER 1 34 203002 HEX DOME CAP, 3/8 8 92 656019 CS M12-1.75X45 C10.9 ZY 4 37 270699 SPACER 2 93 651708 LN INST FL M12-1.75 C8 ZY 4 39 203007 PAN HEAD BOLT, M6 X 1 X 35 1 94 0004412533 WINDOW PANE ADHESIVE SET 1 SIKA TACK 40 270687 BUMPER/RUBBER 2 * Includes all parts on this page except ref. nos. 42 202560 NUT, M6X1 - DIN 1587 2 66, 92 & 93. 44 182116 BRASS WASHER 8 Also includes all parts on Page6, Page7 and Page8. 46 202564 PAN HEAD BOLT, M6X60 1 49 203016 WASHER 10 50 203017 TRUSS HEAD SCREW 2 Printed in U.S.A. 5 918412/CP0311 AL 540 - CAB DOORS - 270067 & 270071 0 RIGHT DOOR SHOWN 16 17 25 18 18 19 16 22 20 21 6 10 25 3 21 6 8 13 11 6 25 17 11 25 9 6 4 2 5 12 4 1 1 14/30 24 27/34 4 11 15 4 3 7 26/33 29 23/32 1 4 28 6 25 21 270067, 270071 Ref. Ref. No. Part No. Description Qty. No. Part No. Description Qty. 0 270067 ASSY/DOOR LT 1 18 270629 PAD/DOOR HINGE 4 0 270071 ASSY/DOOR RT 1 19 270627 SEAL/DOOR BULB 2 1 202557 LOCKWASHER 3 20 270630 PLATE/HINGE BACKING 2 2 656047 HN M6-1 C8 ZY DIN934 1 21 270633 SOFT WASHER 4 3 L500022 WASHER/FLAT BLACK 5 22 270683 PLATE/BACKING 2 4 651683 BHSCS M6-1.00X25 C10.9 BO 10 23 270631 WLDMT/LATCH MOUNT RT 1 5 656139 CS M6-1X35 C8.8 ZY DIN931 1 24 270632 PAD/LATCH MOUNT BOX 1 6 270699 SPACER 8 25 270698 TUBE/SPACER 8 7 270687 BUMPER/RUBBER 1 26 270693 WLDMT/LATCH COVER RT 1 8 270628 LATCH 1 27 270626 GLASS /DOOR RT 1 9 176736 GASKET/HANDLE 1 28 270701 SOFT WASHER 1 10 202560 NUT, M6 X 1 DIN1587 4 29 270703 PLATE/BUMPER 4 11 202561 RNT/M6X1.0 HEX 9.53P 4.2-6.6 ST YZ 3 30 202566 HANDLE/GRAB W/LATCH LT 338MM 1 12 202562 SEAL/GRAB HANDLE GASKET 2 32 270637 WLDMT/LATCH MOUNT LT 1 13 176809 HANDLE/BUTTON/PUSH 1 33 270692 WLDMT/LATCH COVER LT 1 14 202563 HANDLE/GRAB W/LATCH RT 338MM 1 34 270635 GLASS /DOOR LT 1 15 202564 PAN HEAD BOLT, M6 X 60 1 16 202565 BOLT,M6 X 30 SKT HX DWG C12.9 6 17 270634 HINGE/DOOR 2 918412/CP0311 6 Printed in U.S.A.