Gehl SL3635 Operator's Manual
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Gehl SL3635 Operator's Manual

Skid-steer loader
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SL3635
SL3935
SKID-STEER
LOADER
SL3635 SN 00001175 & LATER
SL3935 SN 00001337 & LATER
OPERATOR'S MANUAL
Form No.
908268/
BP0904
English

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Summary of Contents for Gehl SL3635

  • Page 1 Form No. SL3635 908268/ BP0904 English SL3935 SKID-STEER LOADER SL3635 SN 00001175 & LATER SL3935 SN 00001337 & LATER OPERATOR’S MANUAL...
  • Page 2 Untrained operators can cause injury or death. Never use loader without ROPS/FOPS. Never modify Gehl, in cooperation with the American Society of Agricultural the ROPS/FOPS structure. Engineers and the Society of Automotive Engineers, has adopted this Safety Alert Symbol to pinpoint precautions which, if not properly followed, can create a safety hazard.

  • Page 3: Table Of Contents

    Torque Specifications ....76 Loader Model Number Loader Serial Number Engine Serial Number All-Tach™ and Hydraloc™ are trademarks of Gehl Company. Gehl® and Powerview® are registered trademarks of Gehl Company.

  • Page 4: Introduction

    The Gehl dealership network stands ready to provide you with any assistance you may require, including providing genuine Gehl service parts. All service parts should be obtained from your Gehl dealer. Give complete information about the part and include the model and serial numbers of your machine.
  • Page 5 If this machine was purchased “used,” or if the owner’s address has changed, please provide your Gehl dealer or Gehl Company Service Department with the owner’s name and current address, along with the machine model and serial number. This will allow the registered owner information to be updated, so that the owner can be notified directly in case of an important product issue, such as a safety update program.
  • Page 6 Model Identification Front Work Lights Upright Hand Holds Restraint Bar Hydraulic Auxiliary Couplers Lift Cylinder Tilt Cylinder Hitch Tires Roll Over/ Falling Object Engine Cover Protective Structure (ROPS/FOPS) Tail Lights Lift Arm Rear Work Lights Rear Door 908268/BP0904...
  • Page 7 Control/Indicator Symbols Power Off Power On Engine Start Hazard Flasher Worklight Worklight Read Operator’s w/Flasher Battery Charge Parking Brake Manual Horn Volume - Full Volume- Half Full Volume - Empty Pre-Heat Diesel Fuel Seatbelt - Lap Lift Point Neutral Safety Alert Chaincase Oil Only Engine Oil...
  • Page 8 Notes 908268/BP0904...

  • Page 9: Safety

    Such hazards include, but are not limited to, hillside operation, overloading, instability of the load, poor maintenance and using the equipment for a purpose for which it is not intended or designed. Gehl considers the operator’s safety when designing its machinery ALWAYS and guards exposed moving parts for the operator’s protection.
  • Page 10 Ü To ensure safe operation, replace damaged or worn-out parts with genuine Gehl service parts. Ü Gehl skid steer loaders are designed and intended to be used only with Gehl attachments or approved referral attachments. Gehl cannot be responsible for operator safety if the loader is used with a non-approved attachment.
  • Page 11 During Operation Ü The terrain, engine speed, load being carried and abrupt control movements can affect machine stability. IF MISUSED, ANY OF THE ABOVE FACTORS CAN CAUSE THE LOADER TO TIP, THROWING YOU FORWARD OR OUT OF THE UNIT, CAUSING DEATH OR SERIOUS Therefore, always have the operator restraint bar lowered and INJURY.
  • Page 12 Ü Always wear safety glasses with side shields when striking metal against metal. In addition, it is recommended that a softer (chip resistant) material be used to cushion the blow. Failure to heed could lead to serious injury to the eyes or other parts of the body. Ü...
  • Page 13 These decals must be kept legible. If missing or illegible, they must be replaced promptly. Replacements may be obtained from your Gehl dealer. New equipment must have all decals specified by the manufacturer affixed to their proper place.
  • Page 14 Safety Decals inside the ROPS 137628 - Located on the manual box, operator’s right 137683 - Located on ROPS left panel 137647 - Located on operator’s lower left side 137639 - Located on ROPS left panel 908268/BP0904...
  • Page 15 Safety Decals on the Outside of the Skid Loader 137637 - Lift arm support device, loader left side 184214 - Under ROPS 137655 - Front of loader 137720 - Front of loader 908268/BP0904...
  • Page 16 Safety Decals in the Engine Compartment 137657 - Right of hydraulic filter 137658 - On radiator 908268/BP0904...
  • Page 17 Product and Component Plate Location Product and Component Plates 1. Engine plate: with e.g. type designation, product- and serial number 2. Operator protection system plate: with e.g. model, certification and operator protection system serial number 3. Product plate: with Product Identification Number and e.g. model/type designation 4.
  • Page 18 Notes 908268/BP0904...

  • Page 19: Controls And Safety Equipment

    Know how to stop loader operation before starting it. This Gehl loader is designed and intended to be used only with a Gehl attachment or a Gehl-approved referral attachment or accessory. Gehl cannot be responsible for operator safety if the loader is used with a non-approved attachment.
  • Page 20 Safety Interlock System WARNING NEVER defeat the safety interlock system by mechanically or electrically bypassing any switches, relays or solenoid valves. An interlock system is used on the loader for operator safety. Together with solenoid valves, switches and relays, the interlock system: »...
  • Page 21 ROPS/FOPS The ROPS/FOPS (Roll Over/Falling Object Protective Structure) is designed to provide protection for the operator from falling objects and in case the loader tips or rolls over, provided the operator is secured inside the ROPS by the seatbelt and restraint bar. WARNING Never operate the loader with the ROPS removed or locked back.
  • Page 22 Instead, have someone store the support device for you. Then, contact your Gehl dealer immediately to determine why the lift arm lowers while the keyswitch is...
  • Page 23 Disengagement WARNING Never leave operator’s compartment disengage the lift arm support device with the engine running. To return the lift arm support device to its storage position: 1. Raise the lift arm completely. 2. Stop the engine, remove the key and take it with you.
  • Page 24 Instrument Panel The instrument panel contains the following switches and indicators. Symbols on the panel represent various functions and conditions, and are visible only when indicator lamps are 1. Hourmeter - Indicates the total operating hours of the loader. 2. Fuel Level Gauge - Indicates the amount of fuel in the tank.
  • Page 25 9. Hydraulic Oil Temperature - Lights if the hydraulic oil becomes too hot, warning the operator to stop engine. Allow the hydraulic system to cool and determine the cause of the high temperature. During normal operation, this indicator should be OFF.
  • Page 26 T-Bar Controls Your Gehl loader may be equipped with the T-Bar control option. The left T-Bar controls the drive and the right T-Bar controls the lift/tilt. Drive Control Forward, reverse, speed and turning maneuvers are accomplished by Fig. 9: T-Bar Controls movement of the left T-Bar.
  • Page 27 Lift/Tilt Control Moving the lift arm and tilting the attachment are accomplished by movement of the right T-Bar. To raise the lift arm, pull the control straight rearward; to lower the lift arm, push the control straight forward. To tilt the attachment downward, twist the control clockwise;...
  • Page 28 Hand/Foot Controls Your Gehl loader may be equipped with the hand/foot control option. The handles control the drive and the foot pedals control the lift/tilt. Drive Controls Forward, reverse, speed and turning Fig. 10: Hand/Foot Controls maneuvers are accomplished by 1.
  • Page 29 Lift/Tilt Controls Moving the lift arm and tilting the attachment are accomplished by movement of the foot pedals. The left pedal raises and lowers the lift arm; the right pedal tilts the attachment. To raise the lift arm, use your heel to push down on the left pedal;...
  • Page 30 Dual Hand Controls Your Gehl loader may be equipped with the dual hand control option. The left handle controls the left side drive and the lift. The right handle controls the right side drive and the tilt. Drive Control Forward, reverse, speed and turning maneuvers are accomplished by pushing and pulling the handles.
  • Page 31 Lift/Tilt Control Moving the lift arm and tilting the attachment are accomplished by rotating the control handles. To raise the lift arm, rotate the left control up; to lower the lift arm, rotate the left control down. To tilt the attachment downward, rotate the right control up;...
  • Page 32 Auxiliary Hydraulic Controls Auxiliary hydraulics are used with an attachment that has a mechanism requiring hydraulic power of its own. Important: Always be sure the auxiliary hydraulic control is in neutral before starting the loader or removing the auxiliary hydraulic couplers. Coupler hookup is located on the left lift arm.
  • Page 33 Attachment Mounting The Gehl loader is equipped with a two-pin All-Tach™ attaching mechanism (hitch) for mounting a bucket or other attachment. Two latch levers secure the attachment. Rotate the levers until they are horizontal to engage the lock pins. Rotate the levers until they are vertical to disengage the lock pins.
  • Page 34 Notes 908268/BP0904...

  • Page 35: Operation

    OPERATION WARNING Before starting the engine and operating the loader, review and comply with all safety recommendations in the Safety chapter of this manual. Know how to stop the loader before starting it. Also, be sure to fasten and properly adjust the seatbelt and lower the operator restraint bar.
  • Page 36 Cold Starting Procedure WARNING Do not use starting fluid (ether) with preheat systems. An explosion can result which can cause engine damage, injury or death. Push the button on the instrument panel for a maximum of 30 PREHEAT seconds to preheat the engine. If the temperature is below 32° F (0° C), try the following to make starting the engine easier: »...
  • Page 37 Jump Starting the Battery If the battery becomes discharged or does not have enough power to start the engine, use jumper cables and the following procedure to jump start the engine. WARNING The only safe method for jump starting a discharged battery is for two people to perform the following procedure.
  • Page 38 Changing Attachments WARNING To prevent unexpected attachment release from the hitch, be sure to properly secure the hitch lock pins by rotating the latch levers to a horizontal position. The skid loader features a All-Tach™ attaching mechanism (hitch) for mounting a bucket or other attachment. Two latch levers secure the attachment.
  • Page 39 Connect Auxiliary Hydraulic Couplings Note: With the engine , key in the position and the restraint bar down, the auxiliary hydraulic control can be moved to relieve any pressure in the hydraulic system. Coupler hookup is located on the left lift arm. “A” port is pressure, “B” port is return when the auxiliary control is in the detent position.
  • Page 40 Using a Bucket WARNING Always maintain a safe distance from electric power lines and avoid contact with any electrically charged conductor or gas line. Accidental contact or rupture can result in electrocution or an explosion. Contact the “Digger’s Hotline” or proper local authorities for utility line locations before starting to dig.
  • Page 41 Dumping the Load Onto a Pile Carry a loaded bucket as low as possible until reaching the pile. Gradually stop forward motion and raise the lift arm high enough so that the bucket clears the top of the pile. Then, slowly move the loader ahead to position the bucket to dump the material on top of the pile.
  • Page 42 Lifting the Loader The loader can be lifted using a four-point lift kit, which is available from your authorized Gehl dealer. Storing the Loader If your skid loader is to be stored for a long period of time, the following procedure is suggested: 1.
  • Page 43 Transporting the Loader WARNING Park the truck or trailer on a level surface. Be sure the vehicle and its ramps have the weight capacity to support the loader. Make sure the vehicle surface and its ramps are clear of debris and slippery material that may reduce traction.

  • Page 44: Service

    The following areas of component service, replacement and adjustments require special tools and knowledge for proper servicing and should be performed only by your authorized Gehl skid steer loader dealer: Hydrostatic Components, Hydraulic System Gear Pump, Valves, Cylinders, Electrical Components (other than the battery, circuit breakers) .
  • Page 45 Tilting the ROPS Back For service, unbolt the two anchor bolts at the front of the ROPS and tilt it back slowly, moving the control handles out of the way. A gas-charged spring helps tilt it back. A self-actuating lock mechanism engages to lock the ROPS in a rolled-back position.
  • Page 46 Loader Raising Procedure To raise the skid loader so all four tires are not contacting the ground, use the procedure below: WARNING Do not rely on a jack or hoist to maintain the “raised” position without additional blocking and supports. Serious personal injury could result from improperly raising or blocking the skid loader.
  • Page 47 170-35067 Engine Oil Filter Element 162558 Fuel Filter Cartridge 425-34636 Note: Part numbers may change. Your Gehl dealer will always have the latest part numbers. Adjustments Control Handles The control handles do not require routine adjustment. Refer to the Service Manual for the initial setup procedure.
  • Page 48 Lubrication Listed below are the locations, temperature ranges and types of recommended lubricants to be used when servicing this machine. Refer to the separate engine manual for more information regarding recommended engine lubricants, quantities required and grades. Use Mobil DTE 15M or equivalent which contains anti-rust, anti-foam and anti-oxidation additives, and Hydraulic System Oil conforms to ISO VG46.
  • Page 49 Engine Air Cleaner Important: Failure follow proper filter servicing instructions could result in catastrophic engine damage. The air cleaner consists of an outer (primary) filter element and an inner (secondary) filter element. An air filter restriction indicator monitoring the condition of the elements is located on the right side Fig.
  • Page 50 Note: Gehl does not recommend cleaning the outer element. 4. Use a trouble light inside the outer element to inspect for spots, pinholes or ruptures. Replace the outer element if any damage is noted. The outer element must be replaced if it is oil- or soot-laden.
  • Page 51 Refer to the Maintenance Interval Chart (page 65) for the service interval for replacing the engine oil and filter. Change Engine Oil and Filter 1. Run the engine until it is at operating temperature. Stop the engine. Remove the rear belly pan. 2.
  • Page 52 Hydraulic System Check Hydraulic Oil Level The loader has a hydraulic oil level sight gauge located on the left side of the engine compartment. Check the fluid level with the lift arm lowered and the attachment on the ground. When hydraulic fluid is required, allow the system to cool.
  • Page 53 7. Start the engine and operate the hydraulic controls. 8. Stop the engine and check for leaks at the filter and reservoir drain plug. 9. Check the fluid level and add fluid if needed. Cooling System Important: Check the cooling system every day to prevent overheating, loss of performance or engine damage.
  • Page 54 Note: Protect the cooling system by adding premixed 50% water and 50% ethylene glycol to the system. This mixture will protect the cooling system to -34°F (-36°C). 5. Fill the radiator fully and the recovery tank half full with the premixed coolant.
  • Page 55 Spark Arrestor Muffler Important: The loader is factory-equipped with a spark arrestor style muffler. Muffler maintenance is required to keep it in working condition. Refer to local laws and regulations for spark arrestor requirements. 1. Stop the engine, open the rear door and engine cover. 2.
  • Page 56 The tread bar of all tires must face the same direction. Mounting Tires WARNING Inflating or servicing tires can be dangerous. When possible, trained personnel should service and mount tires. To avoid possible death or serious injury, follow the safety precautions below: 1.
  • Page 57 Electrical System Circuit Breakers The circuit breakers for the loader are located on the right instrument panel. There is also a 35 amp main circuit breaker located on the right side of the engine compartment, directly behind the ROPS. Battery WARNING Before servicing the battery or electrical system, be sure the battery disconnect switch (if equipped) is in the “OFF”...
  • Page 58 Notes 908268/BP0904...

  • Page 59: Troubleshooting

    TROUBLESHOOTING Electrical System Problem Possible Cause Remedy Battery disconnect switch is Turn battery disconnect switch to 15 ampere breakers are Check circuit and locate tripped. trouble before resetting breaker. Entire electrical Main wiring harness Check main harness system does not connectors at rear of ROPS connectors.
  • Page 60 Electrical System Problem Possible Cause Remedy Seat or restraint bar switch Replace switches as needed. malfunctioning or not If engine still doesn’t start, activated. contact your dealer. Verify relay connections. Poor connections to starter relay in instrument panel. Clean terminals, cables and Battery terminals or cables retighten.
  • Page 61 Engine Problem Possible Cause Remedy Engine cranking speed too Battery requires recharging slow. or replacing, or, in cold temperatures, pre-warm the engine. Auxiliary valve engaged. Return the control valves to neutral. Fuel tank empty or faulty fuel Refill fuel tank. Replace fuel gauge sender.
  • Page 62 Hydrostatic System Problem Possible Cause Remedy Hydraulic oil viscosity is Allow longer warm-up or replace too heavy. existing oil with the proper No response from viscosity oil. either the hydrostatic drive Hydraulic oil supply is too Check for low oil level in or the lift/tilt low.
  • Page 63 Drive system overloaded Improve efficiency of operation. continuously. Improve efficiency of operation. Lift/tilt or auxiliary system overloaded continuously. Contact your dealer. Drive motor(s) or hydrostatic pump(s) have Hydrostatic drive internal damage or is overheating. leakage. Clean oil cooler fins. Oil cooler fins are plugged with debris.
  • Page 64 Hydrostatic System Problem Possible Cause Remedy Hydraulic oil viscosity is too Allow longer warm-up or heavy. replace existing oil with the proper viscosity oil. Air in hydraulic system. Cycle lift and tilt cylinders to maximum stroke and maintain pressure for a short Hydrostatic (drive) time to clear air from system.
  • Page 65 Hydraulic System Problem Possible Cause Remedy Hydraulic oil viscosity is too Allow longer warm-up or heavy. replace with proper viscosity oil. Hydraulic oil level is low. Check oil level in reservoir. If oil is low, check for an Lift/Tilt controls external leak.
  • Page 66 Bucket does not Self-leveling valve Contact your dealer. level on the lift misadjusted or cycle. malfunctioning. Hydraulic System Seat or restraint bar switch Check electrical connections malfunction. to the switches. Replace as needed. Air in the hydraulic system. Cycle lift/tilt cylinders to Jerky lift arm and maximum stroke and bucket action.
  • Page 67 Hydraulic System Problem Possible Cause Remedy Lift solenoid valve could be Check electrical connections malfunctioning. to lift solenoid and repair connections as needed. If lift Lift arm does not solenoid valve is still not raise, bucket tilt functioning properly, contact works properly.

  • Page 68: Maintenance Schedule

    MAINTENANCE SCHEDULE This Maintenance Interval Chart was developed to match the Service chapter of this manual. Detailed information on each service procedure may be found in the Service chapter. A Maintenance Log follows the chart for recording the maintenance performed. Recording the 10 hour (or daily) service intervals would be impractical and is therefore not recommended.
  • Page 69 Maintenance Log Date Hours Service Procedure 908268/BP0904...
  • Page 70 Maintenance Log Date Hours Service Procedure 908268/BP0904...

  • Page 71: Specifications

    SPECIFICATIONS Loader Specifications Operating Weight 3635 4400 lb (1996 kg) 3935 4600 lb (2087 kg) Shipping Weight 3635 3970 lb (1801 kg) 3935 4170 lb (1892 kg) SAE Rated Operating Load 3635 1050 lb (476 kg) 3935 1260 lb (572 kg) Engine Make Yanmar...
  • Page 72 Standard Features Ü Ü Choice of three controls: Hydraloc™ System - Brakes and T-Bar, Dual Hand or Hand/Foot Interlock For Starter, Lift/Tilt Ü Cylinders, Auxiliary Hydraulics, and Fuel Gauge Wheel Drives Ü All-Tach™ Attachment System Ü Adjustable Seatbelt (Universal-Style) Ü Ü...
  • Page 73 Dimensional Specifications 3635 3935 Inches (mm) Inches (mm) 139.8 (3550) 141.8 (3600) Overall Operation Height - Fully Raised 108.0 (2743) 110.0 (2794) Height to Hinge Pin - Fully Raised 70.3 (1784) 72.3 (1835) Overall Height - Top of ROPS (152) (203) Ground Clearance - to Chassis (Between Wheels) 114.0...
  • Page 74 Capacities and Ratings Note: Use the Table of Common Materials and Densities (page 72) for selecting the appropriate bucket. Dirt / Construction Buckets Part 3635 3935 Description Weight Rating* Rating* 255 lb 1050 lb 1260 lb 54/55.5" 9.5 ft (1372/1410 mm 0.27 m with Spillguard 808248 (116 kg)

  • Page 75: Table Of Common Materials And Densities

    Table of Common Materials and Densities Density Material (lb/ft (kg/m Ashes 35-50 560-800 Brick-common 1792 Cement 1760 Charcoal Clay, Wet-Dry 80-100 1280-1600 Coal 53-63 848-1008 Concrete 1840 Cinders Coal-anthracite 1504 Coke Earth-dry loam 70-90 1121-1442 Earth-wet loam 80-100 1281-1602 Granite 93-111 1488-1776 Gravel-dry...
  • Page 76 To use the table, find the material name and see what its maximum density is. Then, multiply the loader rating of the attachment by the material density to determine if the attachment can safely be used. See page 71 for a listing of attachments and their loader ratings.

  • Page 77: Index

    INDEX Accessory Plug ....20 Dealer Services ....41 Adjustments .
  • Page 78 Lubrication ..... 45 T-Bar Controls ....23 Drive Control .

  • Page 79: Torque Specifications

    TORQUE SPECIFICATIONS Use these torque values when tightening hardware (excluding: locknuts, and self-tapping, thread forming and sheet metal screws) unless otherwise specified. UNIFIED GRADE 2 GRADE 5 GRADE 8 NATIONAL LUBED LUBED LUBED THREAD 8-32 8-36 10-24 10-32 1/4-20 1/4-28 5/16-18 5/16-24 3/8-16...
  • Page 80 No agent, employee or representative of Gehl has any authority to bind Gehl to any warranty except as specifically set forth herein. Any of these limitations excluded by local law shall be deemed deleted from this warranty; all other terms will continue to apply.
  • Page 81 WRONG WRONG Always carry attachments Never exceed rated as low as possible. Do not operating load. travel or turn with the lift arms raised. Load, unload and turn on flat level WRONG WRONG Never carry riders. Never modify equipment. Keep bystanders away from work area.
  • Page 82 State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling battery. ® Gehl Company 143 Water Street, P.O. Box 179, West Bend, WI 53095-0179 U.S.A. 908268/BP0904 © 2004 GEHL COMPANY PRINTED IN USA All Rights.

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