AL 140 (SN 11257 and Up) AL 240(EU) (SN 21244 and Up) AL 340 (SN 31365 and Up) AL 440(EU) Form No.
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.
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 . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . .
Steering Column Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . Control Lever. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hand Throttle. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12V Accessory Power Outlet. . . . . . . . . . . . . . . . . . . . . . . . . . Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Pre-Operation Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Scraping Hard Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .93 Towing the Loader . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Towing AL 100 Series Machines . . . . . . . . . . . . . . . . . . . . . . .94 Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .94 Towing AL 300 Series Machines . . . . . . . . . . . . . . . . . . .
Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Windshield Washer Reservoir (Cab Only). . . . . . . . . . . . . . . Hydraulic System Maintenance . . . . . . . . . . . . . . . . . . . . . . . . Hydraulic Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Checking Hydraulic Oil Level . . . . . . . . . . . . . . . . . . . . . . . . Changing Hydraulic Oil and Filter . . . . . . . . . . . . . . . . . . . . . Hydraulic Hose Maintenance . . . . . . . .
Before Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .145 Machine Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .146 Maintenance Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .147 Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .153 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .165 Torque Specifications . . . . . . . . . . . . . . . .
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.
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.
Serial Number Plate Location The serial number placard is located on the front frame on the right side of the machine (B, Fig. 2). Earth-Moving Machinery/Loaders/Compact/Seated Operator Product Identification Number Series Net power B kW hp Operating mass kg lbs. Max axle load-front kg lbs. Max axle load-rear kg lbs. km/h mph Max speed Year of Construction Figure 2 – Serial Number Plate Manufactured by Manitou Americas, Inc.
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.
Component Identification 8 3 1 4 5 10 7 6 2 9 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) 918496/GP0313 7. Manual storage box 8. Parking brake (left side) 9. Fuel filler neck 10.
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.
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.
Notes 8 918496/GP0313
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.
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.
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 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.
• 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.
• 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.
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.
• 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.
• 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.
• 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.
• 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.
• 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.
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 Safety Lock Rotating Fan Keep Away 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.
ANSI-Style and Common Safety Decal Locations (Cont.) Note: Refer to Fig. 4 for decal locations. Lift Point Decal A • 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.
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.
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 Overturn WARNING: Avoid Injury or Death • ALWAYS wear seatbelt. • No riders! Never use work tool as work platform.
Note: Refer to Fig. 4 on page 22 for decal locations. Located on the control column, facing the operator. P 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.
ISO-Style Safety Decal Locations Z BB CC T T U RIGHT W LEFT V X AA Y CONTROL COLUMN 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.
Note: Refer to Fig. 5 on page 27 for decal locations. WARNING: Rotating Fan / Hot Surface Hazards V A B D E • 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. C B) Keep hands away. C) Stop engine. D) Hot surface hazard. E) Do not touch hot engine or hydraulic system parts.
ISO-Style Safety Decal Locations (Cont.) Note: Refer to Fig. 5 on page 27 for decal locations. General Operating Warnings X A B C • Located on the left side of the control column. D A) Crush hazard / Keep out from under lift arm unless lift arm is supported. 273901 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.
Note: Refer to Fig. 5 on page 27 for decal locations. General Operating Warnings AA • 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. A B B) Maintain 3-point contact during entry and exit. Do not grasp steering wheel during entry and exit. C D C) Inspect work area. Avoid all hazards. Look in the direction of travel. Keep children and bystanders away.
CHAPTER 3 SPECIFICATIONS Fluid Capacities/Lubricants AL 500/400 Series AL 300 Series AL 200 Series AL 100 Series Diesel Engine Oil Specification Season/Temp. Range Capacity Diesel Fuel Specification Season/Temp. Range Capacity Hydraulic Oil 2 System/Tank Hydraulic Oil Specification Season/Temp. Range Biodegradable Oil Specification Season/Temp.
AL 500/400 Series AL 300 Series AL 200 Series AL 100 Series Axle Oil Hubs (each) Front Center Rear Center 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) Grease Specification Season/Temp. Range Capacity Engine Coolant System/Radiator Year-Round As Required Long-life coolant ASTM D4985, D6210 (United States) SAE J814C, J1941, J1034 or J2036 (International) Season/Temp.
SAE (Domestic) Weights and Capacities AL 500 and AL 300 Series kg (lbs.
ISO 6016 (EU) Weights and Capacities AL 500, AL 400 and AL 300 Series Description Operating Weight Shipping Weight Rated Operating Capacity1, 2 Static Tipping Loads Standard Bucket2 Straight ISO 6016 Standard Bucket2 - 45° Turn (EU) Standard Pallet Forks3 Straight ISO 6016 Standard Pallet Forks3 45° Turn (EU) 2-Post ROPS 3307 (6732) 3021 (6660) 1118 (2466) 4-Post ROPS 3106 (6847) 3071 (6770) 1145 (2460) 3502 (7202) 3166 (6980) 1165 (2560) kg (lbs.
SAE (Domestic) Weights and Capacities AL 100 Series Description Operating Weight Shipping Weight Rated Operating Capacity1, 2 kg (lbs.
ISO (EU) Weights and Capacities AL 100 and AL 200 Series Description Operating Weight Shipping Weight Rated Operating Capacity1, 2 kg (lbs.
Engine AL 500/ AL 400 Series AL 300 Series Manufacturer AL 200 Series AL 100 Series Yanmar 4-cylinder, 4cycle, In-line, Water-cooled Diesel 4TNV88BKGWL 2190 cc (133.6 cid) Type Engine Model Displacement 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”) Cyl. Bore x Stroke Gross Power @ Manuf.
Hydraulics AL 500/ AL 300 AL 200 AL 100 AL 400 Series Series Series Series Auxiliary Hydraulics (at 100% theoretical flow) Hydraulic 57 L/min 45 L/min 30 L/min System (14 gpm) (12 gpm) (8 gpm) System 207 bar 193 bar Pressure (3000 psi) (2800 psi) Drive Hydraulics Hydraulic 117 L/min 79 L/min 101 L/min 79 L/min System (31 gpm) (21 gpm) (26.7 gpm) (21 gpm) System 410 bar 350 bar 320 bar Pressure (5940 psi) (5075 psi) (4640 psi) Reservoir 42 L (11 gals.) 26 L (7 gals.) 34L (9 gals.
Wheel/Tire Sets 27x8.50-15, 8-ply 27x10.50-15, 8-ply 27x10.50-15, 10-ply (turf) AL 100 Series AL 100 Series AL 100 Series Machine Width Millimeters (Inches) 1044 (41.1) 1049 (41.3) 1049 (41.3) 30.5x12.5-16.5, 8-ply 10x16.5, 8-ply 29x12.5-15 8-ply (turf) AL 300 Series AL 300 Series AL 300 Series 1280 (50.4) 1280 (50.4) 1285 (50.6) 33x15.5-16.5 12x16.5 33x13.5-16 NHS 12-ply (turf) AL 500 Series AL 500 Series 1400 (55.1) 1200/1346 (47.2/53.0) AL500 Series 1368 (53.9) Description W/T Set 27x10.
ROPS and FOPS FOPS Rating Level 1 Vibration Levels AL100 AL200 AL300 AL400 AL500 < 1.03 m/s² (+ 0.41k) < 0.89 m/s² (+ 0.45k) < 0.75 m/s² (+ 0.38k) < 0.88 m/s² (+ 0.44k) < 0.82 m/s² (+ 0.41k) Hand-Arm Vibra< 2.00 m/s² tion (+ 1.00k) 2 (ISO 5349-1) m/s < 1.37 m/s² (+ 0.69k) < 1.37 m/s² (+ 0.69k) < 1.70 m/s² (+ 0.85k) < 2.23 m/s² (+ 1.
AL 500, AL 400 Series Dimensions X 400 Series Y N L F K J M H Z S BB E F D B A AA C F G W R U T V P CC 918496/GP0313 41
AL 500, AL 400 Series Dimensions Ref.
AL 300, AL 200 Series Dimensions X Y F J K N G L M H Z BB E S D B AA C R A R W P CC U V 918496/GP0313 T F 43
AL 300, AL 200 Series Dimensions Ref.
AL 100 Series Dimensions X Y J K N F L G M H AA BB E S D Z C R B A R P CC W F U T V 918496/GP0313 45
AL 100 Series Dimensions Ref.
Standard Features • Fuel Level Gauge • Hourmeter • 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
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) • 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) • Counterweight (AL 500 Series standard; AL 400 and AL 300 Series optional; AL100 and AL200 Series not available) 48 918496/GP0313
Common Materials and Densities Density 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 lbs./ft.
Notes 50 918496/GP0313
CHAPTER 4 OPERATION Read and understand this entire manual. Follow warnings and instructions for operation and maintenance. Failure to follow instructions can result in injury or death. Read and understand all safety and instructional decals before operation. WARNING 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.
Operating Controls Controls and Switches 22 18 3 6 1 21 16 4 2 9 10 21 18 22 5 8 7 15 19 OPTION 20 14 Located Behind Joystick Located Inside Engine Compartment 11 13 17 12 23 Note: Controls 11, 12, 13 and 17 are located on the steering column, below instrument panel 2.
No. Item Description 1 Steering knob Use to turn steering wheel. 2 Instrument panel Contains warning indicators, operation indicators, and gauges (page 54). 3 Steering wheel Turn to control travel direction. 4 Accelerator pedal Press to control engine/travel speed. 5 Multi-purpose joystick Use to control lift arm/attachment maneuvering and loader drive direction (page 78). 6 Auxiliary hydrauUse to activate auxiliary hydraulics control circuit lics control buttons (page 92).
Instrument Panel and Indicators 10 3/15 16 AL 100 Series, AL 200 Series Standard 18 1 9 7 2 13 17 17 16 1 2 AL 500, AL 400, AL 300 Series; AL 100 (EU), AL 200 Series Optional 3 15 4 14 13 5 18 19 12 6 7 11 20 10 54 9 8 21 918496/GP0313
No.
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 D Figure 6 – Cab Environment Controls Air Conditioning Control (option) Optional air conditioning is controlled by a knob located on the windshield wiper control panel.
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. Cab Dome Light E F Figure 8 – Cab Wiper/Windshield Washer Controls The dome light is located on the cab ceiling. Push button (G, Fig. 9) to turn the light on/off.
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. 2 3 3 1/4 4 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 No.
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 adjustment: 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.
Seat Belt Always fasten the seat belt securely and properly. Never operate the machine without the seat belt fastened around the operator. WARNING 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 “0” position: All power off. Key can be inserted/removed. I II “I” position: Run position. “II” position: Start position.
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 K rearward to activate the turn signals (M). M 4. Push the control lever downward L to activate the road light “high” beams. 5.
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.
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.
Extend the ROPS 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. WARNING 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.
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.
Entering and Exiting 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. WARNING NOTE: Photos may not exactly match all machines 2-Post ROPS A C B 4-Post ROPS/Cab C A B A. Left hand hold B. Step for right foot C.
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. Always fasten the seat belt before operating the machine. Repair or replace any damaged seat belt and lock parts before operation. WARNING Do not use starting fluid (ether) with preheat systems. An explosion can result, which can cause engine damage, injury or death. CAUTION 1.
5. Place forward/reverse drive switch (Fig. 25) on the top of the joystick into the neutral position. Forward Neutral 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.
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.
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.
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. D B C A Figure 27 – 100 Series Lift Arm Tilt Lock e. Replace the spring pin (A) into the end of the lock bar (B).
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. f. Replace the lock pins (A) into both ends of the down-stop lock bar (B).
5. On AL 500 Series machines: a. Remove the retainer (C, Fig. 30), and lift the cylinder stop channel (D) off the machine. J D C C D 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.
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. C 4.
Note: When the parking brake is engaged, travel drive is disabled. Forward 4. Use the drive direction switch to change the loader drive direction. Neutral Forward Note: The drive direction indicators should be lit when the drive direction switch is in forward and rearward positions. Drive direction switch position Indicator for forward drive Forward is on; loader drive is in forward. Middle Loader drive is in neutral. Indicator for reverse drive Rearward is on; loader drive is in reverse.
Slow/Fast Travel Speed Mode Selection (AL 300, AL 400, AL 500 Series) 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.
Load Handling 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. WARNING 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.
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: B D C 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. A 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.
AL 100, AL 200(EU), AL 300, AL 400(EU) Self-Leveling Feature Figure 39 – SelfLeveling Feature The self-leveling feature maintains the attachment tilt angle as the lift arm is raised/lowered (Fig. 39) AL 500 Series Limited Self-Leveling 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.
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. F Note: Lift float may decrease ability to turn.
Attachments General Instructions 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.
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.
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 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. CAUTION 1.
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.
Hydraulic Power-A-Tach® System Hitch Disconnection Disconnect the auxiliary hydraulic connections (see “Auxiliary Hydraulics” on page 86) before disconnecting the attachment from the Power-A-Tach® system hitch. CAUTION 1. Lower the attachment to the ground. See “Multi-purpose Joystick” on page 78. 2. Press the side of the Power-ATach® system hitch lock switch (M, Fig. 50) to unlock the attachment on M the hitch.
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.
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.
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.
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. P 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. 3.
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.
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.
Operating Attachments Use only approved attachments. Contact the Manitou Americas Service Department about information about approved attachments. Manitou Americas cannot be responsible for safety if the unit is used with non-approved attachments. WARNING Some general guidelines for attachments are included in this section. These guidelines are not a replacement for the attachment manufacturer’s operating instructions.
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.
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.
Towing AL 300 Series Machines C 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). A B A Figure 59 – Hydraulic Motor Removal (AL 300 Series) Note: Record the position of the hoses for re-assembly. 4. Remove hydraulic motor (C) from the axle. Support the motor during towing. 5.
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/TieDown Points (AL 100 Series) Important: Tow the machine with another vehicle ONLY. Do not tow loads or other vehicles with the machine.
Loading and Transporting 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. CAUTION 1. Park the transport vehicle on solid, even ground when loading. 2. Clean the loader and transport vehicle. 3.
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.
Crane Lifting 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. WARNING 1. Perform the “Mandatory Safety Shutdown Procedure” on page 10. 2.
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 C D B AL 200/300 Series A C D B A. Chain - rear B.
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.
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. 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.
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. Do not postpone maintenance.
Check, Clean and Inspect Maximum Interval Service Procedure 10 Hours (or daily) 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 50 Hours (or weekly) Monthly 250 Hours 500 Hours (or every (or six annually) months) x x x x x Check V-belt tension and condition Check engine cover lock x x x Check engine idle x Replace fu
Lubrication and Filter Changes Maximum Interval Service Procedure 10 Hours (or daily) 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 50 Hours (or weekly) 250 500 1500 Hours Hours Hours Monthly (or every (or (or six annually) annually) months) x x x x x1 Change axle oil x Change hydraulic fluid and return filter Change fuel filter; clean pre-filter Change coolant x x x C
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 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.
4. Securely close the cab doors (if applicable). 5. Using the ROPS, cab frame, and/or handles, manually tilt the platform upward. Front A Note: The steering lock bar (W, Fig. 71) can be inserted in bracket (E) to provide additional leverage for tilting the platform. Rear 6. Engage tilt support (W, Fig. 72). C Figure 70 – Platform Mounting Hardware Tilting the Platform Down 1. Slightly lift the platform using the steering lock bar (W, Fig.
Engine Maintenance WARNING Allow engine and hydraulic system components to cool before maintenance. Engine Oil Checking Engine Oil Level 1. 2. 3. 4. 5. Position the machine on a level surface. Perform the “Mandatory Safety Shutdown Procedure” on page 10. Wait until the machine has cooled. See “Service Safety Practices” on page 16. Open engine cover. AL 100 Series Remove the dipstick (Y, Fig. 73). Wipe dipstick with a clean cloth. 6. Insert the dipstick until it is fully seated, and remove. Y 7.
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). A Figure 74 – Engine Access Panel Notice: Removing engine access panel requires two people. 5.
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.
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.
Accessing the Outer and Inner Filter Elements 1. 2. 3. 4. Perform the “Mandatory Safety Shutdown Procedure” on page 10. Open the engine cover. Unlatch the clamps on the air cleaner housing and remove the element cover. 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.
Engine Cooling System Checking Coolant Level 1. Perform the “Mandatory Safety Shutdown Procedure” on page 10. 2. Open the engine cover (J, Fig. 79). AL 500 Series shown Check the coolant level in the expan(other machines similar) sion 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 H expansion reservoir as required.
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.
Fuel System 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. WARNING Important: The fuel tank is filled at the factory with United States off-road grade diesel fuel, which is dyed red for identification.
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. 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. WARNING 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.
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. ON OFF A B C A. Fuel shut-off valve lever B. Indicator ring C.
Checking and Adjusting V-belt Tension 1. Perform the “Mandatory Safety Shutdown Procedure” on page 10. 2. Open the engine cover. AL 500 Series shown 3. Inspect V-belts (R, Fig. 85) for (other machines similar) damage. If damaged, have belts replaced by your dealer. T 4. Press on V-belts (R) mid-way between pulleys to check deflecS tion. Belts should deflect no more than 8 mm (5/16"). 5.
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: 1. Perform the “Mandatory Safety Shutdown Procedure” on page 10. 2.
Windshield Washer Reservoir (Cab Only) The cab windshield washer reservoir is located inside the engine compartment. 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.
Hydraulic System Maintenance 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. WARNING Hydraulic Oil Checking Hydraulic Oil Level 1. Completely lower the lift arm and attachment. 2.
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.
Hydraulic Hose Maintenance 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. WARNING 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.
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.
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.
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.
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 H front of the engine compartment. 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).
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.
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.
AL 500 Series (AL 400 Series Similar) M J M J N K L O L P 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.
AL 200/300 Series Shown (AL 100 Series Similar) G C D D B E 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.
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.
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 Figure 106 – Main System Fuse The primary fuse panel (K, Fig. 107) is located at the left side of the steering column.
Steering Column Fuses – AL 500/400/300 Series; AL 100 (EU), AL 200 Optional 12 11 13 Fuse No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. Rated Current (Amp) 5 10 5 7.5 5 10 5 10 20 10 10 7.
Steering Column Fuses – AL 100 Series and AL 200 Standard 4 4 11 3 10 2 9 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 136 5 5 5 7.5 5 10 5 20 10 10 7.5 7 6 6 5 5 9 1 1. 7 10 2 Rated Current (Amp) 8 11 3 Fuse No.
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.
Note: Refer to Fig. 108 and Fig. 109. Fuse No. 1. 2. 3. 4. 5. 6. 7. 8. 9. 138 Rated Current (Amp) 5 7.
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. N Machine Control Module The machine controller (N, Fig.
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.
Battery 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. WARNING Refer to “Electrical System” on page 38 for battery specifications. To access the battery, tilt the platform.
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.
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. WARNING 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.
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.
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.
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.
Maintenance Log Date 918496/GP0313 Hours Service Procedure 147
Date 148 Hours Service Procedure 918496/GP0313
Date 918496/GP0313 Hours Service Procedure 149
Date 150 Hours Service Procedure 918496/GP0313
Date 918496/GP0313 Hours Service Procedure 151
Date 152 Hours Service Procedure 918496/GP0313
CHAPTER 6 TROUBLESHOOTING Engine Troubleshooting Problem Engine does not turn over Engine stops when operator leaves seat 918496/GP0313 Possible Cause Corrective Action Drive direction switch in forward/reverse Place drive direction switch in neutral Tripped circuit breaker Reset circuit breaker Blown fuse Replace fuse.
Engine Troubleshooting Problem Engine turns over but will not start Possible Cause Engine cranking speed too slow Check battery and charge/replace as necessary—tighten battery terminals Fuel tank empty Fill tank and vent fuel system if necessary Fuel filter plugged or restricted Change fuel filter Paraffin separation in winter 154 Corrective Action Use winter grade diesel fuel Fuel line leakage Tighten all threaded connections and clamps Glow plug module malfunction Check connection and voltag
Engine Troubleshooting Problem Engine overheating Engine running but loader will not drive 918496/GP0313 Possible Cause Corrective Action Crankcase oil level incorrect Adjust oil level Cooling air circulation restricted With engine off, remove restriction Fan shroud improperly positioned Contact dealer Improper oil grade or oil excessively dirty Change engine oil—see “Fluid Capacities/Lubricants” on page 31 for proper oil grade Exhaust restricted Allow exhaust to cool; remove restriction Air
Indicator Lamp Troubleshooting Indicator Activated Engine oil pressure Hydraulic oil temperature Possible Cause Corrective Action Engine oil pressure too low Stop engine immediately; check oil level and add oil if necessary; check oil pump Engine oil level too low Add oil Oil pump malfunction Contact dealer Temperature is too hot Check cooling system for debris in radiator Check hydraulic oil level Hydraulic oil filter Hydraulic oil filter service required Replace filter Water temperature Co
Seal and Hose Troubleshooting Problem Oil, coolant or fuel leakage Hydraulic fluid leakage Possible Cause Corrective Action Loose hose connection(s) Tighten hose connections Damaged seals or hoses Change seals/hoses as necessary Loose fittings Tighten hydraulic connections Seals, hoses or lines damaged Change seals, hoses or lines as necessary Hydraulic System Troubleshooting Problem Hydraulics do not work or work only at a low performance level Travel drive system does not work or works only a
Hydraulic System Troubleshooting Problem Attachment tilts down with tilt control in neutral Possible Cause Corrective Action Oil leaking past tilt cylinder seals (internal or external) Contact dealer Leaking hydraulic hoses, tubes or fittings between control valve and cylinders Repair as required Lift spool in control valve not actuated or leaking Contact dealer Hydraulic oil leaking past cylinder piston seals Contact dealer Attachment tilt not working but lift arm works properly Tilt spool in c
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 Corrective Action Oil leaking past lift cylinder seals (internal or external) Contact dealer Oil leaking past lift spool in control valve Contact dealer Leaking hydraulic hoses, tubes or fittings between control valve and cylinders Contact dealer Spool i
Hydrostatic Drive System Troubleshooting Problem Travel drive will not operate in either direction Possible Cause Corrective Action Parking brake is applied Release parking brake Low hydraulic oil level Add oil Low or no charge pressure Contact dealer Hydrostatic pump(s) relief valves malfunction Contact dealer Brake/inch pedal stuck or malfunctioning 1. Check/release brake/inch pedal 2. (AL 400/500 Series only) Check drive error code 3.
Hydrostatic Drive System Troubleshooting Problem Travel drive system noisy Possible Cause Hydraulic oil viscosity too heavy Corrective Action Allow longer warm-up See “Fluid Capacities/Lubricants” on page 31 for proper oil grade Sluggish travel drive acceleration Low hydraulic oil level Add oil AL 100 Series hydraulic tanks not evenly filled See “Checking Hydraulic Oil Level” on page 122 Air in hydraulic system Cycle lift and tilt cylinders to maximum stroke and maintain pressure for short time to
Hydrostatic Drive System Troubleshooting Problem Travel drive overheating Possible Cause Corrective Action Drive system continuously overloaded Improve operation procedure Lift/tilt or auxiliary system continuously overloaded Improve operation procedure Drive motor(s) or hydrostatic pump(s) internal damage/ leakage Contact dealer Oil cooler fins restricted Clean oil cooler fins Hydraulic oil filter restricted Replace filter Sticking flushing valve (AL100/200/300 series) Repair/replace flushing
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 918496/GP0313 Possible Cause Corrective Action Temperature sender malfunction Replace temperature sender Loose wiring/terminal connections Check wiring connections Blown fuse Check circuit and replace fuse Loose wiring/terminal connections Check wiring connections Alternator malfunction Repair/replace alternato
Notes 164 918496/GP0313
INDEX 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 . . . . .
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 . . . . .
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 . . . . . . . . . . .
Steering Wheel . . . . . . . . . . . . . . 53 Steering/Frame Lock Bar . . . . 97, 99 Storage . . . . . . . . . . . . . . . . . . . 144 Preparing . . . . . . . . . . . . . . . 144 Removing . . . . . . . . . . . . . . . 144 Switches . . . . . . . . . . . . . . . . . . . 52 Windshield Washer . . . . . . . . . . . .32 T Tie-down Points . . . . . . . . . . . . . . 98 Tilting the Platform . . . . . . . . . . . 107 Down . . . . . . . . . . . . . . . . . . 108 Up . . . . . . . . . . . . . . . . . . . .
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. Non-return valve with elastic seal Identification aid outside Ø M10X1.0 Straight pipe fitting with thread and screwed plug (GE) Sealing washer Elastic seal O-ring 7 (9) 13 (18) 11 (15) 13 (18) 0.4 in.
With fine-pitch thread. All torque values are in lb.-ft. (Nm) unless marked otherwise. Thread M8X1.0 Threads according to DIN 912, DIN 931, DIN 933, etc. 8.8 10.9 12.9 18 (25) 27 (37) 32 (43) Threads according to DIN 7984 8.8 10.9 16 (22) 24 (32) M10X1.0 37 (50) 55 (75) 65 (88) 32 (43) 48 (65) M10X1.25 36 (49) 52 (71) 61 (83) 31 (42) 46 (62) M12X1.25 64 (87) 96 (130) 111 (150) 55 (75) 81 (110) M12X1.5 61 (83) 92 (125) 107 (145) 53 (72) 77 (105) M14X1.
EC DECLARATION OF CONFORMITY 1. Manufacturer: Manitou Americas, Inc. 2. Address: 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.
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.
