This Gehl shop manual covers the 5635 and 6635 skid loaders, including the 5635SX, 5635DX, 5635SXT, 5635DXT, 6635SXT, and 6635DXT variants, all powered by the Deutz F4M1011F diesel. Its 188 pages run through the machine: the mainframe and lift arms, the wheel drives and drive chains, the control handles, the hydrostatic and main hydraulic systems, the electrical system, and the engine.Each system opens with a troubleshooting guide and moves into removal, testing, adjustment, and installation, with the pressures, clearances, and torque values a real repair needs. You can chase a loss of hydraulic drive to the engine to pump coupling, test relief pressure, adjust a stretched drive chain, or check the glow control relay. It is a searchable PDF you can open on a phone, tablet, or shop computer, or print for the bench, and it stays with the machine for as long as you own it.
What's Inside This Gehl 5635–6635 Manual
| System | Pages | Key Topics |
|---|---|---|
| Introduction | 2-7 | Purpose of the Shop Manual, Manual Organization and Navigation, Contacting GEHL Service, Tire Options, Buckets and Capacities, Safety, Lubrication, Mainframe |
| Specifications | 8-9 | Tire Options, Buckets and Capacities |
| Safety | 10-23 | - |
| Lubrication | 24-27 | General Information, Hydraulic Oil Reservoir, Chaincases, Grease Fitting Locations |
| Mainframe | 28-47 | Introduction, Engine Access Cover Removal and Installation, Rollover Protective Structure Removal and Installation, Seat Removal and Installation, Seat Slide Replacement |
| Wheel Drives | 48-57 | Introduction, Drive Chain Adjustment, Drive Chain Removal and Installation, Axle Housing Assembly Removal and Installation, Axle and Wheel Bearing Disassembly and Assembly |
| Controls | 58-95 | Introduction, Control Handle Removal and Installation, Control Handle Position Adjustment, Control Handle Tracking Adjustment, Traction Controls, Left Control Handle Assembly |
| Hydrostatic System | 96-110 | Introduction, Troubleshooting Guide, Case Drain Test, Charge Pressure Test and Adjustment, Hydrostatic Pump Relief Valves, Hydrostatic Pump Removal and Installation |
| Hydraulic System | 111-152 | Introduction, Troubleshooting Guide, Relief Pressure Test, Control Valve and High Flow, Tilt Cylinder Test, Self-Leveling Valve Test, Lift Cylinder Test, Solenoid Valve Test |
| Electrical System | 153-164 | Operation, Troubleshooting Guide, Glow Control Relay Operation, Relay Test, Seat Switch Removal and Installation, Restraint Bar Switch Removal and Installation |
| Engine | 165-179 | Introduction, Troubleshooting Guide, Oil Filter Element Removal and Installation, Air Cleaner Assembly Removal and Installation, Air Filter Element Removal and Installation |
| Gehl Warranty | 188 | GEHL Warranty Service Includes, GEHL Warranty Service Does Not Include |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Axle Nut Torque | 150 lb-ft (200 Nm) | p. 54 |
| Hydrostatic Pump Arm Cap Screw Torque | 30 lb.-ft. (40.7 Nm) | p. 76 |
| Coupling Hub Clearance (between Housing assembly and Hub) | 3/16" (2mm) | p. 107 |
| Hydrostatic Pump Relief Valves Quantity | four (4) Hydrostatic Pump Relief Valves total (two (2) High Pressure Relief Valves per Hydrostatic Pump) | p. 104 |
| Troubleshooting Remedy for 'Traction Drive will not operate in either direction' | Check Parking Brake, Hydraulic oil level in Reservoir, Control Rod Linkage connection, and Hydrostatic Pump Relief Valves. Refer to pages 97-98 for detailed troubleshooting steps. | p. 97 |
| Displacement | 178 CID (2.9L) | p. 8 |
| Hydraulic Reservoir Capacity | 16 Gallons (60.5 liters) | p. 8 |
| Engine Crankcase Capacity | 10.5 Quarts (10 liters) | p. 8 |
| DX Models | ||
| High-Flow Manifold Valve Solenoid and Relief Valve Cartridges Torque | 70 lb-ft (88 Nm) | p. 149 |
| 5635SX/DX | ||
| Horsepower-Gross | 60hp (45kW)@2650rpm | p. 8 |
| Max Torque | 130 ft/lbs (176Nm) @1800rpm | p. 8 |
Gehl 5635–6635 Common Problems This Manual Covers
Sudden loss of hydraulic drive
A stripped or broken engine to pump coupling can cause a sudden loss of hydraulic drive in either direction. The Hydrostatic System section covers troubleshooting, relief valves, and pump service.
Manual Section: Hydrostatic System p. 96Engine bogs with white smoke
A sudden bog with thick white smoke points to a fueling or combustion fault. The Engine section provides a troubleshooting guide and service procedures.
Manual Section: Engine p. 165Weak lift or tilt
Low relief pressure or a worn control valve weakens lift and tilt. The Hydraulic System section has the relief pressure test and control valve service.
Manual Section: Hydraulic System p. 111Drive chain slack
Stretched drive chains cause slack and uneven tracking. The Wheel Drives section covers chain adjustment, removal, and installation.
Manual Section: Wheel Drives p. 48Cold start trouble
Hard cold starts often trace to the glow control relay or its circuit. The Electrical System section covers glow control relay operation and relay tests.
Manual Section: Electrical System p. 153Control handles drift or track poorly
Worn linkage makes the control handles drift or track unevenly. The Controls section covers handle position and tracking adjustment.
Manual Section: Controls p. 58Frequently Asked Questions
Which models does this shop manual cover?
It is the Gehl shop manual, publication 907285, for the 5635 and 6635 skid loaders, including the SX, DX, SXT, and DXT variants, all powered by the Deutz F4M1011F diesel.
What is the difference between standard and high flow?
The Specifications section lists 20 gpm (76 l/m) standard flow and 33 gpm (129 l/m) high flow on the DX models. Both run the same base hydraulic system. p. 8
Can it help with a loss of hydraulic drive?
Yes. The Hydrostatic System section covers troubleshooting and the engine to pump coupling, a common cause of sudden drive loss, with a hub clearance of 3/16 in (2 mm). p. 96
How is the manual delivered?
You download the PDF immediately after checkout. Nothing ships, and the file is yours to keep and reopen on any device.
How will I receive this Gehl 5635SX & variants Shop Manual?
Instant PDF download. You get the full 188-page searchable Shop Manual immediately after payment. Open it on your laptop, tablet, or phone right in the shop.
Is this Gehl 5635SX & variants Shop Manual printable?
Absolutely. No DRM or copy protection. Print the whole manual or just the pages you need. Any home or office printer works.
Can I find hydraulic circuit diagrams in this Gehl 5635SX & variants manual?
Full hydraulic system diagrams are included, covering circuits, valve locations, and hydraulic component specs for the Gehl 5635SX & variants.
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