Covers both Series II machines, the SL5635 and SL6635, across 198 pages (OEM #907846), from drive chain adjustment all the way to hydrostatic pump R&R. You'll find hydraulic and hydrostatic schematics for SX and DX configurations, full wiring diagrams with electrical troubleshooting, and 25 pages of exploded views covering mainframe, wheel drives, controls, and cylinders. Another 60 pages lay out step-by-step procedures, with 12 pages of troubleshooting across the hydrostatic system, hydraulic circuits, engine, and electrical. Torque the axle nut to 150 ft-lbs (200 N•m), pull the hydrostatic pump capscrews to 55 ft-lbs (73 N•m), and confirm the 60.5-liter hydraulic reservoir sits at spec before you button anything up. Search any spec by keyword, bookmark straight to the system you're working on, and stop guessing.
What's Inside This Gehl SL5635, SL6635 Manual
| System | Pages | Key Topics |
|---|---|---|
| Lubrication | 2 | Hydraulic Oil Reservoir, Crankcase Oil, Chaincases, Change Chaincase Oil, Grease Fitting Locations, Grease Every 10 Hours of Operation |
| Specifications | 2 | Engine Specifications, Fluid Capacities, Hydraulic System Performance, Overall Dimensions, Tire Options, Bucket Capacities |
| Safety | 3 | Signal Words, Additional Safety Reminders, Mandatory Safety Shutdown Procedure, Loader Stability, Loaded Bucket/Fork, Exhaust Gases, Engine, People |
| Mainframe | 3 | Introduction, Rollover & Falling Objects - Protective Structure Components, Engine Access Cover Removal and Installation (Removal Procedure, Installation Procedure) |
| Wheel Drives | 3 | Introduction, Wheel Drives Components, Drive Chain Adjustment (Adjustment Procedure), Drive Chain Components |
| Controls | 4 | Introduction, Equipment Identification, Hand/Foot Controls, T-Bar Controls, Dual Hand Controls, Two-Speed Controls, T-Bar Control Models, Hand/foot Control Models |
| Hydrostatic System | 4 | Introduction, Hydrostatic System - Single Speed Model Components, Hydrostatic System - Two Speed Model Components, Troubleshooting Guide, Case Drain Test (Test Procedure) |
| Hydraulic System | 5 | Introduction, Hydraulic System - Main Control Valve - T-Bar and Dual Hand Models, Hydraulic System - Main Control Valve - Hand/foot Models |
| Electrical System | 5-6 | Operation, Troubleshooting Guide, Glow Control Relay Operation, Relay Test (Test Procedure), Seat Switch Removal and Installation (Removal Procedure, Installation Procedure) |
Quick Reference Specifications
| Specification | Value | Page |
|---|---|---|
| All Models | ||
| Axle nut torque | 150 ft-lbs (200 N•m) | p. 48 |
| Hydrostatic pump to flywheel housing capscrew torque | 55 ft-lbs (73 N•m) | p. 106 |
| Breaker rating | 20 ampere | p. 158 |
| Engine Displacement | 178 CID (2,9 L) | p. 7 |
| Hydraulic Reservoir Capacity | 16 US gal (60,5 L) | p. 7 |
| Engine Oil Capacity | 10.5 US quarts (10 L) | p. 7 |
| Main Hydraulic System Pressure | 3000 psi (207 bar) | p. 7 |
| DX models | ||
| High-Flow Rate (Dual - DX models) | 36 gpm (136 L/min) | p. 7 |
| two-speed option models | ||
| Travel Speed - Two-Speed Option | 0 to 12.5 mph (0 to 20,1 km/h) | p. 7 |
| SL6635SXT/DXT | ||
| SAE-Rated Operating Load | 2350 lbs (1066 kg) | p. 7 |
| SL5635 Series II | ||
| Wheelbase | 42 inches (1069 millimeters) | p. 8 |
| SL6635 Series II | ||
| Wheelbase | 48 inches (1219 millimeters) | p. 8 |
Gehl SL5635, SL6635 Common Problems This Manual Covers
Gehl SL6635 loses all hydraulics and drive suddenly, machine won't move or operate attachments p. 106
Remove the hydrostatic pump from the flywheel housing and inspect the coupler for cracks, stripped splines, or shear failure. Replace any damaged parts, then reinstall and torque the pump-to-flywheel housing capscrews to 55 ft-lbs (73 N•m) per page 106. Confirm full hydraulic and drive response before returning to service.
Manual Section: Hydrostatic SystemEntire electrical system dead with no instrument panel lights or starter response p. 158
Verify the battery disconnect switch is in the ON position. Locate the 20-ampere breakers per page 158 and check each for a tripped or open condition. Reset any tripped breakers, then inspect wiring harness connections for pinched or corroded wires using the diagram. If breakers keep tripping, trace the short circuit before installing replacements.
Manual Section: Electrical System Troubleshooting GuideHydrostatic drive sluggish or unresponsive under load, traction on one or both sides weak
Check hydraulic oil level first: the reservoir holds 16 US gal (60.5 L), and low fluid starves the hydrostatic circuit immediately. Inspect both wheel motors for internal bypass using the troubleshooting guide. On single-side drive loss, swap motor connections to isolate whether the fault sits in the pump or the motor.
Manual Section: Hydrostatic System Troubleshooting GuideLift arm won't raise or lowers slowly, bucket drifts from set position
Confirm hydraulic oil level, then inspect the main control valve for external leaks or contaminated fluid. System pressure should reach 3000 psi (207 bar) at the test port; low pressure points to relief valve wear or reduced pump output. Reference the hydraulic schematic to trace the liftarm circuit and find any stuck or leaking internal valves.
Manual Section: Hydraulic System Troubleshooting GuideDamaged or missing grease fittings at pivot points, joints squeak and bind during operation
Inspect all grease fitting locations per the maintenance schedule and replace any missing or damaged fittings before greasing. Pivot points need service every 10 hours of operation. Apply grease until fresh lubricant purges from each joint. Any fitting that won't accept grease has a blocked passage and needs immediate replacement to prevent accelerated joint wear.
Manual Section: LubricationFrequently Asked Questions
What is the torque spec for wheel nuts on a GEHL SL5635/SL6635?
Torque specs cover the axle nuts and the axle housing nuts, though wheel nuts (lug nuts) aren't called out explicitly. Set the axle nut to 150 ft-lbs (200 N•m) per page 49, and the nuts holding the axle housing to the chassis to 90 ft-lbs (122 N•m) per page 48.
What are the replacement specifications for engine-to-pump coupling / coupler?
Page 106 covers removing the flywheel coupling, the link between the engine and the hydrostatic pump. Step 3 reads: "Remove six capscrews attaching coupling to flywheel. Fig. 7-22." The Engine Components diagram on page 169 also lists "Flywheel Coupling" (item 20). The manual doesn't provide replacement specs for the coupling itself, such as part numbers or detailed technical data.
What are the replacement specifications for hydraulic pumps?
You'll find removal and installation procedures for the Hydrostatic Pump (page 105) and the Gear Pump (page 138). For internal repair or replacement specifications on these major hydrostatic system components, though, the manual directs you to "consult the GEHL Service Department and/or the hydraulic component manufacturer’s service manual." Performing unauthorized repair will void the warranty.
How quickly can I access this Gehl SL5635, SL6635 manual after buying?
This is a 198-page searchable PDF, ready to download the moment you buy. It works on any device, so pull it up on your phone while you're under the hood. No shipping, no waiting.
Are there any print restrictions on this Gehl SL5635, SL6635 manual?
Yes. With no DRM restrictions, you can print any page or section you need for the shop. It works with any standard printer.
Can I find hydraulic circuit diagrams in this Gehl SL5635, SL6635 manual?
Yes, this Gehl SL5635, SL6635 Service Manual includes hydraulic system diagrams, circuit schematics, and component specifications.
Document Quality
This document is a high-quality scanned PDF with an OCR layer, allowing you to search and copy the full text. All text is consistently crisp and easy to read, ensuring clarity throughout. The diagrams and illustrations are a good mix of sharp vector graphics and clear, detailed photos, with all labels clearly readable even when zoomed in. Pages are clean, free of scan artifacts, stains, or skewed content. Please note that there are several blank "NOTES" pages interspersed throughout the manual.
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