Mechanics turning wrenches on the Gehl 5635SXT, 6635SXT, and related SX/DX series skid loaders need accurate factory data. This 188-page shop manual PDF (OEM #907285) delivers complete hydrostatic system schematics, electrical wiring diagrams, and exploded views covering everything from axle bearings to the high-flow manifold. The guide packs detailed service procedures, detailing mainframe teardowns, wheel drive chain adjustments, hydrostatic pump removal, and lift/tilt cylinder disassembly. It also features troubleshooting guides for hydraulic and electrical faults. Specific factory values are included, such as torquing the axle nut to 150 lb-ft (200 Nm) and tightening the hydrostatic pump arm cap screw to 30 lb-ft (40.7 Nm). Built-in bookmarks let you jump straight to the exact system you are working on directly from a tablet or phone on the shop floor.
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 |
| Hydraulic System Troubleshooting Guide | Refer to pages 112-115 for detailed troubleshooting steps including problems, possible causes, and remedies. | p. 112 |
| 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 complete loss of hydraulic drive, machine won't move or respond to controls p. 107
Inspect the engine-to-pump coupling before pulling the hydrostatic pump. Remove the engine access cover and check the coupling hub clearance; the gap between the housing assembly and hub must be 3/16" (2mm) per page 107. If the coupler is cracked, worn, or out of spec, replace it before any further hydraulic diagnosis.
Manual Section: Hydrostatic SystemEngine bogs hard under load, thick white smoke from exhaust, near stall p. 165
Pull and inspect the air filter element. A clogged element starves the engine and causes white smoke under load. Next, check fuel lines and filters for restrictions. Verify the engine oil level meets the 10.5 quart (10 liter) crankcase capacity. Follow the engine troubleshooting guide on page 165 if those checks come up clean.
Manual Section: EngineTraction drive sluggish or won't operate, one or both sides won't respond p. 97
Confirm the parking brake is fully released, then check the hydrostatic oil level in the reservoir. Follow the troubleshooting guide on page 97, which covers traction drive failures, drive wheels not turning, and a neutral position that is difficult to maintain. If both sides are weak, run the charge pressure test procedure on page 104 to pinpoint pump relief valve issues.
Manual Section: Hydrostatic SystemLift arm raises slowly or won't hold raised position, bucket drifts down p. 112
Check hydraulic oil level first; the reservoir holds 16 gallons (60.5 liters) and low oil is the most common cause of sluggish lift. Follow the hydraulic system troubleshooting guide at page 112, which covers slow cylinder action and lift arm that won't raise a heavy load. Inspect all hose connections for leaks before running pressure tests.
Manual Section: Hydraulic SystemFrequently Asked Questions
What causes a sudden total loss of hydraulic drive on the 5635/6635?
Check the engine-to-pump coupling before pulling the hydrostatic pump. The gap between the housing assembly and the hub must be 3/16" (2 mm) per page 107; replace a cracked, worn, or out-of-spec coupler before any further hydraulic diagnosis.
What are the key torque specs for the 5635/6635 series?
Torque the axle nut to 150 lb-ft (200 Nm) and the hydrostatic pump arm cap screw to 30 lb-ft (40.7 Nm). The hydraulic reservoir holds 16 gallons (60.5 liters).
What is the engine crankcase oil capacity?
The crankcase holds 10.5 quarts (10 liters). Verify the level when diagnosing white smoke or an engine that bogs hard under load, and inspect the air filter element, which is the most common cause of those symptoms.
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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