Looking for the factory Gehl SL5635/6635 shop manual PDF? This 188-page Skid Loader Shop Manual (OEM #907285) walks you through both frames in SX/DX and SXT/DXT trim, from hydrostatic pump teardown to ROPS removal and installation. Inside: wiring diagrams for the full electrical system, hydraulic and hydrostatic schematics, troubleshooting guides for every major system, and a factory torque reference. You get step-by-step procedures for drive chain adjustment, axle bearing rebuilds, control handle tracking, charge pressure testing, case drain tests, and lift cylinder checks. Replace the engine oil filter every 500 hours of service, and set control linkage Dim. "A" to .73 in (185 mm) before you blame the pump. No more chasing electrical gremlins with a multimeter and forum guesses. Bookmarked and keyword-searchable; open it on any device, walk out to the machine, and start wrenching.
What's Inside This Gehl 5635SX/DX, 5635SXT/DXT, 6635SXT/DXT Manual
| System | Pages | Key Topics |
|---|---|---|
| Specifications | 7-8 | General Specifications |
| Safety | 9-22 | General Information, Mandatory Safety Shutdown Procedure, Lift Cylinder Mechanical Lock, Cylinder Lock Disengagement, ROPS Raising, Relieving Hydraulic Pressure |
| Lubrication | 23-26 | General Information, Hydraulic Oil Reservoir, Chaincases |
| Mainframe | 27-46 | Introduction, Engine Access Cover Removal and Installation, ROPS Removal and Installation, Seat Removal and Installation, ROPS Rear Window Removal and Installation |
| Wheel Drives | 47-56 | Introduction, Drive Chain Adjustment, Drive Chain Removal and Installation, Axle Housing Assembly Removal and Installation, Axle and Wheel Bearing Disassembly and Assembly |
| Controls | 57-94 | Introduction, Control Handle Removal and Installation, Control Handle Position Adjustment, Control Handle Tracking Adjustment, Traction Controls, Left Control Handle Assembly |
| Hydrostatic System | 95-108 | Introduction, Troubleshooting Guide, Case Drain Test, Charge Pressure Test and Adjustment, Hydrostatic Pump Relief Valves, Hydrostatic Pump Removal and Installation |
| Hydraulic System | 109-150 | Introduction, Troubleshooting Guide, Relief Pressure Test, Control Valve and High Flow (Dx Models), Tilt Cylinder Test, Self-Leveling Valve Test, Lift Cylinder Test |
| Electrical System | 151-162 | Description of Operation, Troubleshooting Guide, Glow Control Relay Operation, Seat Switch Removal and Installation, Restraint Bar Switch Removal and Installation |
| Engine | 163-178 | Introduction, Troubleshooting Guide, Oil Filter Element Removal and Installation, Air Cleaner Assembly Removal and Installation, Air Filter Element Removal and Installation |
| Gehl Warranty | 187 | Genuine Gehl Parts, Labor Costs, Used Equipment, Normal Maintenance Service, Improper Use, Unauthorized Attachments |
| California Proposition 65 Warning | 188 | Diesel Engine Exhaust, Constituents, Cancer, Birth Defects, Reproductive Harm |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| Oil Filter Element Removal and Installation | 10-4 | p. 6 |
| Fan Belt Adjustment | 10-10 | p. 6 |
| Hydraulic System Troubleshooting Guide | 8-2 | p. 5 |
| Engine oil filter replacement | every 500 hours of service | p. 24 |
| Dim. "A" | .73" (185mm) | p. 61 |
| Dim. "B" | 1.25" (317mm) | p. 61 |
| Crosstube shaft endplay | .03" to .06" | p. 74 |
| Restraint Bar Switch or Seat Switch malfunction | Check Switches and wiring. Replace as needed. | p. 110 |
| Lift/Tilt Controls fail to respond. Hydraulic oil viscosity is too heavy. | Allow longer warm-up or replace with proper viscosity oil. | p. 110 |
| Glow Plugs automatically cycle ON and OFF when the Key is "ON". Glow Plugs Will NOT cycle if Ambient temperature is above 32°F (0°C). | 32°F (0°C) | p. 151 |
| Seat or Restraint Bar Switch are not activated or malfunctioning. | Replace Switches as needed | p. 153 |
| Faulty Light Switch or Poor Ground. | Replace Light Switch. | p. 153 |
Gehl 5635SX/DX, 5635SXT/DXT, 6635SXT/DXT Common Problems This Manual Covers
Gehl 5635 skid loader cranks but will not start, glow indicator lamp never lights
Check the seat switch and restraint bar switch wiring before anything else; the electrical troubleshooting chart on page 153 calls for replacing faulty switches. Verify glow plug operation next: the plugs only cycle when ambient temperature is below 32°F (0°C), covered on page 151. Test battery condition on the 12 volt DC system and clean the starter circuit connections.
Manual Section: Electrical System p. 153Lift and tilt controls sluggish or dead after cold start, bucket barely moves
Check hydraulic oil level in the reservoir and look for external leaks if it is down. Allow a longer warm-up in cold weather or replace heavy oil with the proper viscosity. Test gear pump flow at high idle: you should see 20 GPM at 2800 RPM per the chart on page 111. Repair or replace a worn pump.
Manual Section: Hydraulic System p. 110Traction drive will not operate in either direction, engine runs and lift works
Inspect the control rod linkage at the control levers for disconnected or worn joints, then check the neutral centering mechanisms. Verify crosstube shaft end play measures .03 to .06 inch so the handles operate correctly, per the specification on page 74. Work through the hydrostatic troubleshooting procedures starting on page 96 if linkage checks out.
Manual Section: Hydrostatic System p. 96Engine overheats under load, temperature gauge climbs within thirty minutes of work
Check crankcase oil level first; the engine holds 10.5 quarts (10 liters), and low, high, or dirty oil drives temperatures up. Clean debris from the oil cooler fins and confirm the fan shroud is positioned correctly. Test fan belt tension midway between alternator and crankshaft pulley: deflection should be 1/2 inch (13 mm) under a 20 lb (9 kg) load, per page 172.
Manual Section: Engine p. 165Lift arm drops slowly with control in neutral, bucket drifts down when loaded
Perform the lift cylinder test on page 112 and inspect the cylinder tube bore for scoring; replace seals or the tube as needed. Inspect hoses, tubes, and fittings between the control valve and cylinders for leaks, tightening fittings as you go. Top off the reservoir if low; it holds 16 U.S. gallons (61 liters). Check the self-leveling valve last.
Manual Section: Hydraulic System p. 112Frequently Asked Questions
What is the torque specification for the Lock Nut securing the Head Gland and Piston on the Cylinder Rod in the Gehl SL5635/6635 Skid Loaders?
The Lock Nut that secures the Head Gland and Piston on the Cylinder Rod should be torqued to 350 lb-ft (474 Nm). For 3/4" Lock Nuts, the torque should be 145 lb-ft (196 Nm). p. 134
What is the capacity of the Hydraulic Oil Reservoir for the Gehl SL5635/6635 Skid Loaders?
The Hydraulic Oil Reservoir for the loader Hydraulic and Hydrostatic systems has a capacity of 16 U.S. gallons (61 liters). This reservoir is crucial for maintaining the hydraulic oil level. p. 24
What is the crankcase oil capacity for the Deutz Diesel Engine in the Gehl SL5635/6635 Skid Loaders?
The Deutz Diesel Engine Crankcase has a capacity of 10.5 quarts (10 liters). It is important to maintain this oil level for proper engine operation. p. 24
What is the oil capacity for each chaincase in the Gehl SL5635/6635 Skid Loaders?
Each chaincase requires 2 gallons (7.6 liters) of SAE motor oil. This quantity of oil should be maintained at all times for proper lubrication of the drive chains and sprockets. p. 25
What is the correct deflection for the drive chain on the Gehl SL5635/6635 Skid Loaders?
Correct Chain deflection is 1/2" @ 20 lbs. (12.70cm @9kg) on the side opposite from the Idler, 1/2 way between the Sprockets. Overtightening the drive chain can cause premature wear to the Drive Chain and Axle Sprocket. p. 49
How will I receive this Gehl SL5635/6635 Shop Manual?
You get a 188-page searchable PDF that downloads instantly after checkout. Open it on your laptop, tablet, or phone, and bring it right to the shop floor.
Can I print specific sections of this Gehl SL5635/6635?
Yes, print as many copies as you want, and there are no restrictions. Many mechanics print the section they need and bring it to the shop floor.
Reviews
There are no reviews yet.