This Gehl SL4640–SL6640 Series Service Manual PDF (OEM #917002) puts all 232 pages of factory service data for the SL4640, SL4840, SL5640, and SL6640 skid-steer loaders in one file. You get full hydraulic schematics with fluid routing for each loader variant, chassis and ROPS/FOPS wiring diagrams, and 100 pages of step-by-step procedures covering controls, hydrostatic drives, liftarm cylinders, and engine removal. Inside: embedded torque specifications throughout procedures and component diagrams, 40 pages of exploded component views, and a troubleshooting section that walks through charge pressure tests, solenoid valve diagnostics, and interlock module truth tables. The hydraulic reservoir holds 12 US gal (45 L) on the SL4640 and SL4840; top your engine oil to 8.3 US qts (7.9 L) before startup. Chasing an electrical fault without a schematic wastes hours you don't have. Bookmarked by section and keyword-searchable: jump straight to hydrostatics, electrical, or controls without scrolling through 200 pages.
What's Inside This Gehl SL4640–SL6640 Series Manual
| System | Pages | Key Topics |
|---|---|---|
| A | 222 | Additional Safety Reminders 2-1, Air Cleaner and Exhaust Components - SL4640 Naturally Aspirated 10-6, Air Cleaner and Exhaust Components - SL4640 Turbocharged 10-7 |
| B | 222 | Battery Removal and Installation 10-18 |
| C | 223 | Chaincases 3-3, Charge Pressure Test and Adjustment 7-11, Chassis Components 4-3, Chassis Electrical Components 9-5, Control Arm Assembly Removal and Installation 6-19 |
| D | 224 | Operation - Right and Left Instrument Panels 9-1, Dimensional Specifications 1-2, Dome Light Bulb Replacement 9-25, Drive Chain Adjustment 5-2 |
| E | 225 | Electric Auxiliary Hydraulics Control - Hand/Foot Components 6-26, Electrical Lights Components 9-23, Electrical System Chapter, Electrical System Schematic - Chassis 9-27 |
| F | 225 | Fan Belt Adjustment 10-21, Fan Shroud Adjustment 10-25, Fan Shroud Removal and Installation 10-24, Foot Throttle Adjustment - T-Bar and Dual Hand 6-38 |
| G | 225 | Gear Pump Removal and Installation 8-34, Glow Control Module 9-11, Glow Control Module Test 9-12, Glow Control Module Time/Temp Cycle 9-11, Glow Relay Test 9-12 |
| H | 226 | Hand Throttle Adjustment - Hand/Foot 6-37, Hand Throttle and Throttle Cable Removal and Installation - Hand/foot 6-36, Hand Throttle Tension Adjustment 6-35, Hand Throttle |
| I | 227 | Ignition Switch Electrical Components 9-7, Interlock Control Module Test 9-14, Interlock Control Module Truth Table 9-15, Introduction 1-2 |
| L | 228 | Lift and Tilt Solenoid Valve - Disassembly and Assembly 8-41, Lift Cylinder Components 8-31, Lift Cylinder Removal and Installation 8-29, Lift Cylinder Test 8-22 |
| M | 228 | Mainframe Chapter, Mandatory Safety Shutdown Procedure 2-2, Master Circuit Breaker/Glow Circuit Breaker Test 9-8 |
| N | 228 | Neutral Centering Device Adjustment 6-18 |
| O | 229 | Oil Cooler Components - SL4640 and SL4840 Naturally Aspirated 10-11, Oil Cooler Components - SL4640 Turbocharged 10-12 |
| P | 229 | Pilot Valve Removal and Installation - Hand/foot Models 8-48, Pivot Tube Removal and Installation - T-Bar, Hand/Foot and Dual Hand 6-16, Power Relay Test 9-9 |
| R | 229 | Rear Grille and Engine Cover Components 4-5, Rear Grille Latch Removal and Installation 4-24, Rear Grille Removal and Installation 4-24, Rear Work Light Bulb Replacement 9-24 |
| S | 230 | Safety Chapter, Safety Lock Valves - Removal and Installation 8-39, Seat Removal and Installation 4-7, Seat Slide Replacement 4-7, Seat Switch Removal and Installation 9-19 |
| T | 230 | Table of Contents 1-I, T-Bar Control Handle Assembly 6-9, T-Bar Control Models - Lift and Tilt Components 6-2, Throttle Components - Hand and Foot Components 6-32 |
| W | 231-232 | Wheel Drives Chapter, Wheel Drives Components 5-1 |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Hydrostatic system fittings torque | 55 ft-lbs | p. 91 |
| Solenoid coil retaining nut torque | 45 in-lbs (5.1 N•m) | p. 147 |
| Chaincases (each) Capacity | 8 US qts (7,5 L) | p. 7 |
| Battery CCA | 950 CCA | p. 7 |
| Alternator Output | 95 A | p. 7 |
| Axle Housing Locknuts Torque | 280 ft-lbs (380 N•m) | p. 46 |
| Wheel Nut Torque | 180 ft-lbs (244 N•m) | p. 46 |
| SL4640 | ||
| Operating Load - SAE | 1500 lbs (680 kg) | p. 7 |
| SL4640/4840 | ||
| Hydraulic Reservoir Capacity | 12 US gal (45 L) | p. 7 |
| Engine Oil Capacity | 8.3 US qts (7,9 L) | p. 7 |
| Hydraulic System Pressure | 2750 PSI (190 bar) | p. 7 |
| SL4840 | ||
| Fuel Tank Capacity | 17 US gal (64,4 L) | p. 7 |
Gehl SL4640–SL6640 Series Common Problems This Manual Covers
Gehl SL4640 hydraulic pump output weak, bucket lifts slowly or won't lift
Check the hydraulic reservoir level first; the SL4640/4840 reservoir holds 12 US gal (45 L) and running it low starves the pump. Inspect every hose, tube, and fitting for active leaks while the engine is off. Work through the Hydraulic System Troubleshooting Guide to isolate the fault before condemning internal pump or valve components.
Manual Section: Hydraulic System Troubleshooting GuideBucket won't tilt in either direction while lift arm raises and lowers normally p. 147
Test the tilt solenoid valve electrical connections first. Check the harness connector for corrosion, pushed-back pins, or chafed wires, then verify the solenoid coil has continuity. If replacing the coil, torque the retaining nut to 45 in-lbs (5.1 N•m) as specified on page 147. Confirm 12V supply reaches the solenoid terminal before ordering a new valve.
Manual Section: Hydraulic System Solenoid Valve Test - Tilt, Lift, Brake and Two-SpeedHydraulic oil level keeps dropping between service intervals, system performance falls off
Inspect all hoses, tubes, and fittings for weeping or active drips with the system pressurized. Check lift and tilt cylinder rods for oil film, which indicates failed rod seals. Refill to the full mark; SL4640/4840 reservoir capacity is 12 US gal (45 L). Pressure-test after topping off to confirm there is no internal bypass condition.
Manual Section: Hydraulic System Troubleshooting GuideEngine cranks slowly or won't start, glow indicator stays on too long
Check battery condition; minimum specification is 950 CCA cold-cranking amperes. Clean both terminals and inspect cable clamps for looseness. Verify the glow relay is cycling through its full pre-heat sequence before cranking. If fuel delivery is suspect, pull and inspect the fuel filter and confirm diesel is not gelled in cold-weather conditions.
Manual Section: Engine Troubleshooting GuideDrive chain skipping, jerky travel, or clunking noise from inside the chaincase p. 46
Open the chaincase and measure chain deflection at the midpoint between sprockets. Correct deflection is 1/2" (13 mm) with 20 lbs (89 N) applied force per page 46. Reposition the axle housing to hit that spec, then torque the axle housing locknuts to 280 ft-lbs (380 N•m). Check chaincase oil level before closing the cover.
Manual Section: Drive Chain AdjustmentMachine won't operate lift or travel, all controls dead with operator seated
Check the operator presence circuit: verify the seat switch makes solid contact and the seat belt is buckled. Test for 12V supply at the seat switch connector, then trace the harness via the pinout. A corroded or misaligned seat switch is the most common fault; the interlock module cuts all outputs when the circuit opens.
Manual Section: Electrical System Troubleshooting GuideFrequently Asked Questions
How do I reset the hydraulic system on a Gehl SL4640/SL4840/SL5640/SL6640?
After removing or replacing any components of the lift and tilt system, you should prime the hydraulic system. This is done by operating the liftarm attachment (NO LOAD) slowly up and down for several cycles. Always check for hydraulic oil leaks and fill the hydraulic reservoir until fluid is visible in the hydraulic oil level indicator on the inside right rear riser.
What does the no-crank / starter solenoid issue mean on a Gehl SL6640?
A no-crank / starter solenoid issue indicates that the starter solenoid in the chassis is malfunctioning. To address this, you should troubleshoot the circuit using the wiring diagram to locate the trouble, and then repair or replace the starter solenoid as needed.
Where is the starter solenoid located on a Gehl SL4840?
The starter solenoid is located on the starter motor itself, which is on the engine. You can see its connection points in diagrams related to starter removal and electrical components.
How do I test or bypass the starter relay on a Gehl SL5640?
To test the starter relay (referred to as starter solenoid in the manual), disconnect the white “S” wire. With the keyswitch in OFF, there should be 12 VDC on the large copper stud with #1 red wire. Turning the keyswitch to START should provide 12 VDC on the “S” terminal (#21 green wire) and produce an audible “click” from the solenoid. The manual does not provide a procedure to bypass the starter relay.
How will I receive this Gehl SL4640–SL6640 Series Service Manual?
Immediate download of the complete 232-page searchable Service Manual. Access it on any device — laptop at your desk or phone in the field.
Am I able to print pages from this Gehl SL4640–SL6640 Series manual?
No restrictions at all. Print individual pages, full chapters, or the entire manual. The PDF is completely unlocked.
Are there hydraulic schematics in this Gehl SL4640–SL6640 Series manual?
Yes — complete hydraulic schematics with flow diagrams, valve configurations, and pressure specifications are included.
Document Quality
This document appears to be a high-quality scanned reproduction of a physical manual, featuring an OCR layer that allows you to search and copy the full text. The text throughout is crisp and very easy to read. Diagrams and illustrations are raster images, but their labels and details are generally clear and legible. Pages are clean with no noticeable scan artifacts or skew. There is one intentionally blank page included.
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