Gehl Articulated Loader AL140 AL240 AL340 Service Manual 918274 – PDF DOWNLOAD

Gehl Articulated Loader AL140 AL240 AL340 Service Manual 918274 – PDF DOWNLOAD

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Gehl Articulated Loader AL140 AL240 AL340 Service Manual 918274 – PDF DOWNLOAD

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Gehl Articulated Loader AL140 AL240 AL340 Service Manual 918274 – PDF DOWNLOAD

INTRODUCTION:Contents and Use of this Manual :

This Service Manual contains information about the safe and proper maintenance, service and troubleshooting for the machine. Additionally, it contains basic operation information, but is not intended as a replacement for the Operator’s Manual that was provided with the machine.

• Refer to the Operator’s Manual for complete and detailed operation information. Major points of safe operation and maintenance are detailed in the Safety chapter of this manual.
• Follow the instructions in the Operator’s Manual Safety, Operation and Maintenance chapters, concerning accident prevention regulations, safety and occupational regulations, and machine and traffic regulations. Manitou Americas is not liable for damage resulting from the failure to follow these regulations.

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, and the safety information in the Operator’s Manual. Additionally, anyone who operates or works on the machine must be familiar with these safety precautions.

• 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.

TABLE OF CONTENTS:

Gehl Articulated Loader AL140 AL240 AL340 Service Manual 918274 – PDF DOWNLOAD

Chapter 1 — Introduction ……………………………………………………………………………………………………..1
Chapter 2 — Safety………………………………………………………………………………………………………………..3
2-Post ROPS/FOPS Warning ……………………………………………………………………………………………………………………….. 4
Mandatory Safety Shutdown Procedure…………………………………………………………………………………………………………. 4
Before Starting……………………………………………………………………………………………………………………………………………. 4
During Operation………………………………………………………………………………………………………………………………………… 5
Provision for Stability/Avoiding Rollover Accidents ………………………………………………………………………………….. 6
Electrical Energy ……………………………………………………………………………………………………………………………………. 7
Service Safety Practices ………………………………………………………………………………………………………………………………. 7
Battery Hazards ……………………………………………………………………………………………………………………………………… 8
Fire Hazards……………………………………………………………………………………………………………………………………………….. 8
Crystalline Silica Exposure ………………………………………………………………………………………………………………………….. 9
Safety Decals ……………………………………………………………………………………………………………………………………………… 9
Chapter 3 — Specifications…………………………………………………………………………………………………..11
Fluid Capacities/Lubricants………………………………………………………………………………………………………………………… 11
Dimensions – AL 300 and AL200 Series ……………………………………………………………………………………………………… 13
Dimensions – AL 100 Series……………………………………………………………………………………………………………………….. 15
SAE (Domestic) Weights and Capacities
AL 100 and AL 300 Series…………………………………………………………………………………………………………………………. 17
ISO (EU) Weights and Capacities
AL 100, AL 200 and AL 300 Series…………………………………………………………………………………………………………….. 18
Engine……………………………………………………………………………………………………………………………………………………… 19
Hydraulics………………………………………………………………………………………………………………………………………………… 19
Electrical System………………………………………………………………………………………………………………………………………. 19
Sound Levels ……………………………………………………………………………………………………………………………………………. 19
Wheels …………………………………………………………………………………………………………………………………………………….. 19
Maximum Slopes of Operation …………………………………………………………………………………………………………………… 20
Wheel/Tire Sets ………………………………………………………………………………………………………………………………………… 20
FOPS……………………………………………………………………………………………………………………………………………………….. 20
Crane Lifting Chain Lengths ………………………………………………………………………………………………………………………. 20
Vibration Levels ……………………………………………………………………………………………………………………………………….. 20
Vibration Information………………………………………………………………………………………………………………………………… 21
Vibration Measurement and Actions ……………………………………………………………………………………………………….. 21
Chapter 4 — Maintenance ……………………………………………………………………………………………………23
Maintenance Schedule……………………………………………………………………………………………………………………………….. 24
Check, Clean and Inspect ………………………………………………………………………………………………………………………. 24
Leakage Check……………………………………………………………………………………………………………………………………… 25
Lubrication and Filter Changes ………………………………………………………………………………………………………………. 25
Functional Check………………………………………………………………………………………………………………………………….. 25
Engine Maintenance ………………………………………………………………………………………………………………………………….. 26
Engine Oil……………………………………………………………………………………………………………………………………………. 26
Air Cleaner…………………………………………………………………………………………………………………………………………… 28
Engine Cooling System …………………………………………………………………………………………………………………………. 29
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Fuel System……………………………………………………………………………………………………………………………………………….31
Adding Fuel…………………………………………………………………………………………………………………………………………..31
Changing Fuel Filter ………………………………………………………………………………………………………………………………31
Water Separator Maintenance………………………………………………………………………………………………………………….32
Checking and Adjusting V-belt Tension ……………………………………………………………………………………………………….33
Hydraulic System Maintenance ……………………………………………………………………………………………………………………34
Hydraulic Oil…………………………………………………………………………………………………………………………………………34
Planetary Axles ………………………………………………………………………………………………………………………………………….36
Changing Planetary Axle Oil (AL 300 Series Only) …………………………………………………………………………………..36
Changing Axle Wheel-Hub Oil (AL 300 Series Only)………………………………………………………………………………..36
Changing Axle Center Oil (AL 300 Series Only)……………………………………………………………………………………….37
Changing Axle Oil (AL 200 and AL 100 Series) ……………………………………………………………………………………….38
Checking Brake Fluid Reservoir Level (AL300 Series Only)………………………………………………………………………38
Wheels and Tires……………………………………………………………………………………………………………………………………39
Lubrication………………………………………………………………………………………………………………………………………………..40
Electrical System ……………………………………………………………………………………………………………………………………….42
Fuse Locations ………………………………………………………………………………………………………………………………………42
Deluxe Steering Column…………………………………………………………………………………………………………………………44
Standard Steering Column ………………………………………………………………………………………………………………………45
Fuse Blocks (s) – Engine Compartment …………………………………………………………………………………………………….46
Battery………………………………………………………………………………………………………………………………………………….47
Storing the Loader ……………………………………………………………………………………………………………………………………..49
Before Storage……………………………………………………………………………………………………………………………………….49
After Storage …………………………………………………………………………………………………………………………………………49
Maintenance Log ……………………………………………………………………………………………………………………………………….50
Chapter 5 — Operation………………………………………………………………………………………………………..53
Operation Safety ………………………………………………………………………………………………………………………………………..53
Controls and Switches ………………………………………………………………………………………………………………………………..54
Instrument Panel and Indicators …………………………………………………………………………………………………………………..56
Cab Controls (Cab only) ……………………………………………………………………………………………………………………………..58
Cab Environment Controls………………………………………………………………………………………………………………………58
Cab Windshield Wiper Controls ………………………………………………………………………………………………………………58
Cab Dome Light…………………………………………………………………………………………………………………………………….58
Cab Defrost …………………………………………………………………………………………………………………………………………..58
Warning Indicators …………………………………………………………………………………………………………………………………….59
Operator’s Seat and Ignition Switch ……………………………………………………………………………………………………………..60
Seat Adjustment …………………………………………………………………………………………………………………………………….60
Seatbelt…………………………………………………………………………………………………………………………………………………60
Ignition Key Switch ……………………………………………………………………………………………………………………………….60
Steering Column ………………………………………………………………………………………………………………………………………..61
Steering Column Adjustment…………………………………………………………………………………………………………………..61
Control Lever ………………………………………………………………………………………………………………………………………..61
Hand Throttle (AL300 Series only) ………………………………………………………………………………………………………………62
Lift Arm Down-Stop (AL200/300 Series)……………………………………………………………………………………………………..62
Boom and Bucket Lock (AL100 Series)………………………………………………………………………………………………………..63
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Chapter 6 — Chassis ……………………………………………………………………………………………………………65
Tilting the Platform …………………………………………………………………………………………………………………………………… 65
AL100 Series Platform Tilting ……………………………………………………………………………………………………………….. 65
AL200 and 300 Series Platform Tilting……………………………………………………………………………………………………. 66
Lowering the Platform……………………………………………………………………………………………………………………………….. 67
AL100 Series Platform Lowering……………………………………………………………………………………………………………. 67
AL200 and 300 Series Platform Lowering……………………………………………………………………………………………….. 68
Repairing or Replacing Platform Switch………………………………………………………………………………………………………. 70
Hood Removal………………………………………………………………………………………………………………………………………….. 71
AL100 Series Hood Removal…………………………………………………………………………………………………………………. 71
AL200 and 300 Series Hood Removal …………………………………………………………………………………………………….. 72
Hood Installation ………………………………………………………………………………………………………………………………………. 73
AL100 Series Hood Installation ……………………………………………………………………………………………………………… 73
AL200 and 300 Series Hood Installation………………………………………………………………………………………………….. 74
Center/Steering Bearing Removal……………………………………………………………………………………………………………….. 75
AL100 Series Center/Steering Bearing Removal………………………………………………………………………………………. 75
AL200 and 300 Series Center/Steering Bearing Removal ………………………………………………………………………….. 78
Center/Steering Bearing Installation ……………………………………………………………………………………………………………. 82
AL100 Series Center/Steering Bearing Installation …………………………………………………………………………………… 82
AL200 and 300 Series Center/Steering Bearing Installation……………………………………………………………………….. 85
Lift Arm Removal …………………………………………………………………………………………………………………………………….. 89
AL100 Series Lift Arm Removal ……………………………………………………………………………………………………………. 90
AL200 and 300 Series Lift Arm Removal………………………………………………………………………………………………… 91
Lift Arm Installation………………………………………………………………………………………………………………………………….. 93
AL100 Series Lift Arm Installation…………………………………………………………………………………………………………. 93
AL200 and 300 Series Lift Arm Installation …………………………………………………………………………………………….. 96
Attachment Plate Removal …………………………………………………………………………………………………………………………. 99
Attachment Plate Installation ……………………………………………………………………………………………………………………. 100
Chapter 7 — Engine …………………………………………………………………………………………………………..101
Engine Removal ……………………………………………………………………………………………………………………………………… 101
Engine Removal Preparation ………………………………………………………………………………………………………………… 101
AL100 Series Engine Removal …………………………………………………………………………………………………………….. 101
AL200 Series Engine Removal …………………………………………………………………………………………………………….. 108
AL300 Series Engine Removal …………………………………………………………………………………………………………….. 113
Engine Installation…………………………………………………………………………………………………………………………………… 118
AL100 Series Engine Installation………………………………………………………………………………………………………….. 118
AL200 Series Engine Installation………………………………………………………………………………………………………….. 125
AL300 Series Engine Installation………………………………………………………………………………………………………….. 130
Engine Installation Completion …………………………………………………………………………………………………………….. 134
Drive Coupling Removal………………………………………………………………………………………………………………………….. 135
Drive Coupling Installation ………………………………………………………………………………………………………………………. 136
Starter Removal ………………………………………………………………………………………………………………………………………. 137
Starter Installation …………………………………………………………………………………………………………………………………… 138
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Chapter 8 — Cooling System………………………………………………………………………………………………139
Radiator/Oil Cooler Removal …………………………………………………………………………………………………………………….139
AL100 Series Radiator/Oil Cooler Removal ……………………………………………………………………………………………139
AL200 and 300 Series Radiator/Oil Cooler Removal ……………………………………………………………………………….142
Radiator/Oil Cooler Installation………………………………………………………………………………………………………………….145
AL100 Series Radiator/Oil Cooler Installation…………………………………………………………………………………………145
AL200 and 300 Series Radiator/Oil Cooler Installation…………………………………………………………………………….148
Radiator/Oil Cooler Installation Completion……………………………………………………………………………………………150
Chapter 9 — Axles……………………………………………………………………………………………………………..151
Service Brake Adjustment …………………………………………………………………………………………………………………………151
AL 100/200 Series Service Brake Adjustment …………………………………………………………………………………………151
AL 300 Series Service Brake Adjustment ……………………………………………………………………………………………….151
Front Axle Removal………………………………………………………………………………………………………………………………….153
AL100 Series Front Axle Removal…………………………………………………………………………………………………………153
AL200 Series Front Axle Removal…………………………………………………………………………………………………………155
AL300 Series Front Axle Removal…………………………………………………………………………………………………………157
Front Axle Installation ………………………………………………………………………………………………………………………………159
AL100 Series Front Axle Installation ……………………………………………………………………………………………………..159
AL200 Series Front Axle Installation ……………………………………………………………………………………………………..161
AL300 Series Front Axle Installation ……………………………………………………………………………………………………..162
Rear Axle Removal…………………………………………………………………………………………………………………………………..164
AL100 Series Rear Axle Removal………………………………………………………………………………………………………….164
AL200 Series Rear Axle Removal………………………………………………………………………………………………………….165
AL300 Series Rear Axle Removal………………………………………………………………………………………………………….167
Rear Axle Installation ……………………………………………………………………………………………………………………………….168
AL100 Series Rear Axle Installation ………………………………………………………………………………………………………168
AL200 Series Rear Axle Installation ………………………………………………………………………………………………………170
AL300 Series Rear Axle Installation ………………………………………………………………………………………………………171
Chapter 10 — Hydraulics …………………………………………………………………………………………………..173
Work Hydraulics Troubleshooting ……………………………………………………………………………………………………………..173
Hydrostatic Drive System………………………………………………………………………………………………………………………….175
Hydraulics Troubleshooting Diagnostic Flow Charts ……………………………………………………………………………………178
Lift and Tilt Hydraulics Diagnostics – AL100 (SN 11257 and up), AL200 (SN 21244 and Up),
AL300 (SN 31365 and Up) Series ………………………………………………………………………………………………………..178
Steering Hydraulics Diagnostics – AL100 (SN 11257 and up), AL200 (SN 21244 and Up),
AL300 (SN 31365 and Up) Series ………………………………………………………………………………………………………..180
Auxiliary Hydraulics Diagnostics – AL100 (SN 11257 and up), AL200 (SN 21244 and Up),
AL300 (SN 31365 and Up) Series ………………………………………………………………………………………………………..182
Work and Steering Hydraulics Diagnostics – AL100 (SN 11256 and before), AL200 (SN 21243 and before),
AL300 (SN 31364 and before) Series……………………………………………………………………………………………………184
Drive Hydraulics Diagnostics – AL100 (All Serial Numbers) and AL200 (SN 21243 and before) Series ………186
Drive Hydraulics Diagnostics – AL300 and AL200 (SN 21244 and Up) Series ………………………………………….188
Hydraulic Piston/Drive Pump Diagnostics – AL100 (SN 11257 and up) Series……………………………………………190
Hydraulic Piston/Drive Pump Diagnostics – AL200 (SN 21244 and up) Series……………………………………………192
Hydraulic Piston/Drive Pump Diagnostics – AL100 (SN 11256 and before),
AL200 (SN 21243 and before) Series …………………………………………………………………………………………………..194
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Hydraulic Piston/Drive Pump Diagnostics – AL300 Series………………………………………………………………………. 196
Hydrostatic Motor Diagnostics – AL100 (SN 11257 and up), AL200 (SN 21244 and up) Series ………………….. 198
Hydrostatic Motor Diagnostics – AL100 (SN 11256 and before), 200 (SN 21243 and before) Series ……………. 200
Hydrostatic Motor Diagnostics – AL300 Series………………………………………………………………………………………. 202
Series Hydrostatic Motor Diagnostics – AL100 (SN 11257 and up) Series ………………………………………………… 204
Hydrostatic Motor Diagnostics – AL200 (SN 21244 and up) Series ………………………………………………………….. 206
Hydrostatic Motor Diagnostics – AL100 (SN 11256 and before), AL200 (SN 21243 and before) Series……….. 208
Hydrostatic Motor Diagnostics – AL300 Series………………………………………………………………………………………. 210
Drive System Electrical Diagnostics ……………………………………………………………………………………………………… 212
Drive System Components — AL100 Series ……………………………………………………………………………………………….. 214
Drive System Components — AL200 Series ……………………………………………………………………………………………….. 215
Drive System Components — AL300 Series ……………………………………………………………………………………………….. 216
Charge Pump/Pilot Pressure Tests……………………………………………………………………………………………………………… 217
Charge Pump Pressure Test – AL100 Series, SN 11257 and Up ……………………………………………………………….. 217
Charge Pump Pressure Test – AL100 Series, SN 11256 and Before ………………………………………………………….. 218
Charge Pump and Pilot Pressure Test – AL200 Series, SN 21244 and Up………………………………………………….. 219
Charge Pump and Pilot Pressure Test – AL200 Series, SN 21243 and Before…………………………………………….. 219
Charge Pump Pressure Test – AL300 Series, SN 31365 and Up ……………………………………………………………….. 220
Charge Pump Pressure Test – AL300 Series, SN 31364 and Before ………………………………………………………….. 221
AL 300 Series Pilot Pressure Test – AL300 Series, SN 31365 and Up ………………………………………………………. 222
AL 300 Series Pilot Pressure Test – AL300 Series, SN 31364 and Before …………………………………………………. 222
Drive Pressure Tests ………………………………………………………………………………………………………………………………… 223
Drive Pressure Test – AL100 Series………………………………………………………………………………………………………. 223
Drive Pressure Test – AL200 Series………………………………………………………………………………………………………. 224
Drive Pressure Test – AL300 Series………………………………………………………………………………………………………. 225
Work System Pressure Tests …………………………………………………………………………………………………………………….. 226
Work Pressure Test – AL100 Series………………………………………………………………………………………………………. 226
Work Pressure Test – AL200 Series………………………………………………………………………………………………………. 227
Work Pressure Test – AL300 Series………………………………………………………………………………………………………. 228
Work Cylinder Leakage Test…………………………………………………………………………………………………………………….. 229
2-Spool Control Valve Removal ……………………………………………………………………………………………………………….. 230
AL 100 Series — Serial Numbers 11257 and Up
AL 200 Series — Serial Numbers 21244 and Up
AL 300 Series — Serial Numbers 31365 and Up…………………………………………………………………………………….. 230
AL 300 Series …………………………………………………………………………………………………………………………………….. 230
3-Spool Control Valve Removal ……………………………………………………………………………………………………………….. 232
AL 100 Series — Serial Numbers 11256 and Below
AL 200 Series — Serial Numbers 21243 and Below
AL 300 Series — Serial Numbers 31364 and Below……………………………………………………………………………….. 232
2-Spool Control Valve Installation…………………………………………………………………………………………………………….. 234
AL 100 Series — Serial Numbers 11257 and Up
AL 200 Series — Serial Numbers 21244 and Up
AL 300 Series — Serial Numbers 31365 and Up…………………………………………………………………………………….. 234
AL 300 Series …………………………………………………………………………………………………………………………………….. 234
3-Spool Control Valve Installation…………………………………………………………………………………………………………….. 236
AL 100 Series — Serial Numbers 11256 and Below
AL 200 Series — Serial Numbers 21243 and Below
AL 300 Series — Serial Numbers 31364 and Below……………………………………………………………………………….. 236
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Lift/Tilt Lock, Power-A-Tach® System and Auxiliary Hydraulics Valve Locations…………………………………………238
Lift/Tilt Lock Valves ……………………………………………………………………………………………………………………………238
Power-A-Tach® System Hydraulic Valve……………………………………………………………………………………………….238
Auxiliary Hydraulic Valve…………………………………………………………………………………………………………………….238
Lift Cylinder Removal ………………………………………………………………………………………………………………………………239
AL100 Series Lift Cylinder Removal ……………………………………………………………………………………………………..239
AL200 and 300 Series Lift Cylinder Removal …………………………………………………………………………………………240
Lift Cylinder Installation …………………………………………………………………………………………………………………………..241
AL100 Series Lift Cylinder Installation…………………………………………………………………………………………………..241
AL200 and 300 Series Lift Cylinder Installation………………………………………………………………………………………243
Tilt Cylinder Removal ………………………………………………………………………………………………………………………………244
AL100 Series Tilt Cylinder Removal ……………………………………………………………………………………………………..244
AL200 and 300 Series Tilt Cylinder Removal………………………………………………………………………………………….245
Tilt Cylinder Installation……………………………………………………………………………………………………………………………246
AL100 Series Tilt Cylinder Installation…………………………………………………………………………………………………..246
AL200 and 300 Series Tilt Cylinder Installation ………………………………………………………………………………………247
Steering Cylinder Removal………………………………………………………………………………………………………………………..248
Steering Cylinder Installation …………………………………………………………………………………………………………………….249
Hydraulic Cylinder Disassembly/Assembly…………………………………………………………………………………………………251
Cylinder Disassembly …………………………………………………………………………………………………………………………..251
Cylinder Assembly……………………………………………………………………………………………………………………………….255
Gear/Work Hydraulic Pump Removal…………………………………………………………………………………………………………258
Gear/Work Hydraulic Pump Installation ……………………………………………………………………………………………………..260
Piston/Drive Hydraulic Pump Removal ………………………………………………………………………………………………………262
AL100 Series Piston/Drive Hydraulic Pump Removal………………………………………………………………………………262
AL200 Series Piston/Drive Hydraulic Pump Removal………………………………………………………………………………262
AL300 Series Piston/Drive Hydraulic Pump Removal – Serial Numbers 31365 and Up……………………………….264
AL300 Series Piston/Drive Hydraulic Pump Removal – Serial Numbers 31364 and Below ………………………….266
Piston/Drive Hydraulic Pump Installation ……………………………………………………………………………………………………269
AL100 Series Piston/Drive Hydraulic Pump Installation …………………………………………………………………………..269
AL200 Series Piston/Drive Hydraulic Pump Installation …………………………………………………………………………..269
AL300 Series Piston/Drive Hydraulic Pump Installation – Serial Numbers 31365 and Up ……………………………271
AL300 Series Piston/Drive Hydraulic Pump Installation – Serial Numbers 31364 and Below……………………….273
Hydrostatic Motor Removal ………………………………………………………………………………………………………………………276
AL100 Series Hydrostatic Motor Removal ……………………………………………………………………………………………..276
AL200 Series Hydrostatic Motor Removal ……………………………………………………………………………………………..277
AL300 Series Hydrostatic Motor Removal – Serial Numbers 31365 and Up……………………………………………….278
AL300 Series Hydrostatic Motor Removal – Serial Numbers 31364 and Below ………………………………………….279
Hydrostatic Motor Installation……………………………………………………………………………………………………………………281
AL100 Series Hydrostatic Motor Installation…………………………………………………………………………………………..281
AL200 Series Hydrostatic Motor Installation…………………………………………………………………………………………..282
AL300 Series Hydrostatic Motor Installation – Serial Numbers 31365 and Up ……………………………………………282
AL300 Series Hydrostatic Motor Installation – Serial Numbers 31364 and Below……………………………………….284
Steering Control Valve Removal………………………………………………………………………………………………………………..285
AL100 Series Steering Control Valve Removal ……………………………………………………………………………………….285
AL200 and 300 Series Steering Control Valve Removal …………………………………………………………………………..286
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Steering Control Valve Installation ……………………………………………………………………………………………………………. 287
AL100 Series Steering Control Valve Installation …………………………………………………………………………………… 287
AL200 and 300 Series Steering Control Valve Installation ………………………………………………………………………. 288
Raising Machine for Drive System Troubleshooting……………………………………………………………………………………. 290
AL100 Series Hydraulic Schematic – SN 11257 and Up………………………………………………………………………………. 293
AL100 Series Hydraulic Schematic – SN 11256 and Before…………………………………………………………………………. 294
AL200 Series Hydraulic Schematic – SN 21244 and Up………………………………………………………………………………. 295
AL200 Series Hydraulic Schematic – SN 21243 and Before…………………………………………………………………………. 296
AL300 Series Hydraulic Schematic – SN 31365 and Up………………………………………………………………………………. 297
AL300 Series Hydraulic Schematic – SN 31364 and Before…………………………………………………………………………. 298
Chapter 11 — Electrical System………………………………………………………………………………………….299
Battery Removal……………………………………………………………………………………………………………………………………… 299
Battery Installation ………………………………………………………………………………………………………………………………….. 300
Machine Controller………………………………………………………………………………………………………………………………….. 302
Machine Controller LED/Indicator Assignments…………………………………………………………………………………….. 302
Machine Controller Logic…………………………………………………………………………………………………………………….. 304
AL100 Series Complete Electrical Schematic – With Standard Steering Column (SN 11257 and Up) ………………. 307
AL100 Series Complete Electrical Schematic – With Deluxe Steering Column (SN 11257 and Up) ………………… 308
AL100 Series Standard Steering Column Electrical Schematic (SN 11257 and Up) ……………………………………….. 309
AL100 Series Deluxe Steering Column Electrical Schematic (SN 11257 and Up) ………………………………………….. 310
AL100 Series Chassis Electrical Schematic (SN 11257 and Up) ………………………………………………………………….. 311
AL100 Series Engine Electrical Schematic (SN 11257 and Up) …………………………………………………………………… 312
AL100 Series Road Homologation Electrical Schematic (SN 11257 and Up) ………………………………………………… 313
AL200 Series Complete Electrical Schematic – With Standard Steering Column (SN 21244 and Up) ………………. 314
AL200 Series Complete Electrical Schematic – With Deluxe Steering Column (SN 21244 and Up) ………………… 315
AL200 Series Standard Steering Column Electrical Schematic (SN 21244 and Up) ……………………………………….. 316
AL200 Series Deluxe Steering Column Electrical Schematic (SN 21244 and Up) ………………………………………….. 317
AL200 Series Chassis Electrical Schematic (SN 21244 and Up) ………………………………………………………………….. 318
AL200 Series Engine and 4-Post ROPS Electrical Schematic (SN 21244 and Up) …………………………………………. 319
AL200 Series Road Homologation Electrical Schematic (SN 21244 and Up) ………………………………………………… 320
AL100 and 200 Series Complete Electrical Schematic – Without Road Homologation
(AL100 Series – SN 10255-11256; AL200 Series – SN 20235-21243) …………………………………………………………. 321
AL100 and 200 Series Complete Electrical Schematic – Without Road Homologation
(AL100 Series – SN 10254 and before; AL200 Series – SN 20234 and before) …………………………………………….. 322
AL100 and 200 Series Complete Electrical Schematic – With Road Homologation
(AL100 Series – SN 10255-11256; 200 Series – SN 20235-21243)……………………………………………………………… 323
AL100 and 200 Series Complete Electrical Schematic – With Road Homologation
(AL100 Series – SN 10254 and Before; 200 Series – SN 20234 and Before) …………………………………………………. 324
AL300 Series Complete Electrical Schematic (SN 31365 and Up) ………………………………………………………………… 325
AL300 Series Steering Column Electrical Schematic (SN 31365 and Up) ……………………………………………………… 326
AL300 Series Engine Schematic (SN 31365 and Up)…………………………………………………………………………………… 327
AL300 Series Chassis Electrical Schematics (SN 31365 and Up)………………………………………………………………….. 328
AL300 Series Tail Light, Radio, Power-A-Tach® System Harness 4-Post ROPS and
Cab Electrical Schematics (SN 31365 and Up)………………………………………………………………………………………….. 329
AL300 Series Complete Electrical Schematic (SN 30310-31364) …………………………………………………………………. 330
AL300 Series Complete Electrical Schematic (SN 30309 and Before) …………………………………………………………… 331
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Chapter 12 — Troubleshooting …………………………………………………………………………………………..333
Engine …………………………………………………………………………………………………………………………………………………….333
Indicator Lamps / Seals and Hoses ……………………………………………………………………………………………………………..335
Indicator Lamps …………………………………………………………………………………………………………………………………..335
Seals and Hoses……………………………………………………………………………………………………………………………………335
Hydraulic System……………………………………………………………………………………………………………………………………..336
Hydrostatic Drive System………………………………………………………………………………………………………………………….339
Electrical …………………………………………………………………………………………………………………………………………….340