PDF Service Manual Gehl SL3635 SL3935 Skid Loader - 2 MB
This service manual contains comprehensive repair and maintenance instructions for the Gehl SL3635 and SL3935 skid loaders.
It is an essential guide for technicians, providing detailed information on hydraulics, engine, and electrical systems.
Keep your Gehl skid loaders in top working condition with the procedures outlined in this manual.
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--- Page 1 ---
SL3635
Form No.
908269
and SL3935
Skid Loaders
®
Service Manual
--- Page 3 ---
SL3635/3935 SAFETY
Liftarm Support Device
WARNING
BEFORE leaving the operator’s compartment
to work on the loader with the liftarm raised,
SAFETY
ALWAYS engage the liftarm support device.
Turn the keyswitch to OFF, remove the key
and take it with you.
Many service procedures require a raised liftarm to
Liftarm Support Device allow easier access to loader components. For operator
Fig. 2-1 The locking pin secures the liftarm support and service personnel safety, a liftarm support device is
device underneath and inside the liftarm in the standard on GEHL skid loaders. Used as a cylinder
“storage” position. block, it helps prevent a raised liftarm from
unexpectedly lowering.
BE SURE to engage the liftarm support device
whenever the liftarm is raised. When the device is not
being used, secure it to the anchor pin on the underside
of the liftarm using the lock pin and retainer provided.
The liftarm support device is a safety device which must
be kept in proper operating condition at ALL times.
The following procedures outline the correct way to
engage and disengage the liftarm support device.
Liftarm Support Device Engagement
1. Lower liftarm until contact with loader frame.
Fig. 2-2 Grab o-ring tether on locking pin and pull it
out of the liftarm, allowing the support device 2. Turn keyswitch to OFF position to stop engine.
to lie on the lift cylinder. Remove key and take it with you.
3. Leave operator’s compartment. Press in and hold
lock pin button to release its locking mechanism.
Remove lock pin holding support device up against
liftarm. Allow support device to come down into
contact with lift cylinder. Figs. 2-1 and 2-2
4. Return to operator’s compartment and restart
engine.
5. Use lift control to raise liftarm until lift arm support
device drops over end of lift cylinder and around
cylinder rod. Slowly lower liftarm until free end of
support device contacts top end of lift cylinder.
Figs. 2-3 and 2-4
6. Make sure liftarm support device is secure against
Fig. 2-3 Start the loader and raise the liftarm until the cylinder end. Then, stop loader engine, remove key
support device drops onto the lift cylinder rod, and leave operator’s compartment.
above the lift cylinder tube.
PRINTED IN USA 2-3 908269/AP1102
--- Page 4 ---
SL3635/3935 MAINFRAME
Introduction
Gehl SL3635/3935 skid loaders have a welded steel Oil is used inside these cases to ensure the chains always
mainframe. Maintenance, service and repair can be receive proper lubrication.
performed through standard access panels. The left rear The liftarm and the lift and tilt cylinders are mounted
mainframe riser serves as the hydraulic reservoir. A with pivot pins. Capscrews are used to secure the pivot
plastic tank bolted to the mainframe behind the ROPS pins. A Rollover Protective Structure/Falling Object
serves as the fuel tank. Protective Structure (ROPS/FOPS) is standard for
Two side cases provide mounting for the drive motors operator safety, and both the seat and restraint bar
and for the front and rear axles. The side cases also serve include safety interlock switches.
as sealed housings for the drive chains and sprockets.
Rollover & Falling Object - Protective Structure (ROPS/FOPS) Components
MAINFRAME
1 - ROPS 11 - Seal 21 - Gas Spring
2 - Capscrew 12 - Locking Strip 22 - Access Cover
30 3 - Bushing 13 - Rip Cord 23 - Support Plate
4 - Locknut 14 - Grab Handle 24 - Manual Holder
5 - Set Screw 15 - Headlight 25 - Carriage Bolt
6 - Washer 16 - Bulb 26 - Flat Nut
7 - Rubber Mount 17 - Connector 27 - Tether
8 - Window 18 - Secondary Lock 28 - Instrument Panel
9 - Gasket/Edge 19 - Grommet 29 - Ball Stud
10 - Truss Screw 20 - Harness Shield 30 - Engine Cover
9
29
4
21 11
4 29
12
2
6 3 8 8
4 10
21
16 2
17 10
18 9
15 19 15 23 9
13
2
1
4
26
25 4
5
14 2
14 3 2
2 4
2
2
10 6
10
2 22
2
7
20 6 10 22
4
28
27 24 4
Fig. 4-1 Assembly view of ROPS components.
PRINTED IN USA 4-1 908269/AP1102
--- Page 5 ---
SL3635/3935 MAINFRAME
12. Using a suitable hoist, raise liftarm to gain access to
Aux Bracket
hydraulic hoses and tube fittings.
13. Disconnect hydraulic hoses attached to hydraulic
tubes found underneath the liftarm (at back of
liftarm). Fig. 4-32
14. Remove capscrews, line clips, and locknuts
securing hydraulic tubes to liftarm. Remove
hydraulic tubes from liftarm. Figs. 4-30, 4-33
15. Remove two capscrews and locknuts securing two
Capscrews liftarm pivot pins to mainframe. Figs. 4-32, 4-34
16. Drive liftarm pivot pins out of mainframe.
17. Remove liftarm assembly from loader with a
MAINFRAME
Fig. 4-31 Location of auxiliary hydraulic tubes
connected at back of auxiliary coupler bracket suitable hoist.
to 90° elbows.
Installation Procedure
1. Use a suitable hoist to position liftarm assembly on
mainframe.
NOTE: Align the liftarm in a manner that allows access
to the hydraulic hose and tilt tube fittings that will be
attached to the underside of the liftarm.
2. Secure liftarm to mainframe with two pivot pins.
Pivot Pin Fig. 4-34
NOTE: Refer to liftarm bushing installation procedure
in this chapter if bushings require replacement.
3. Secure liftarm pivot pin in place with two capscrews
Fig. 4-32 Location underneath liftarm where hydraulic
and locknuts. Figs. 4-32, 4-34
hoses connect to hydraulic tubes. 4. Before assembly, clean all hydraulic fittings to
prevent contamination of hydraulic system.
NOTE: For location of the hydraulic hose and tube
mounting hardware refer to the hydraulics chapter.
5. Attach hydraulic tubes to liftarm with capscrews,
line clips and locknuts. Figs. 4-30, 4-33
6. Connect hydraulic tubes to hydraulic hose
assemblies according to markings made at removal.
If no markings were made prior to removal refer to
Line Clip
the Hydraulic System chapter for correct fit up. Fig.
4-32
7. With three capscrews, bolt in auxiliary coupler
bracket on front of left liftarm. Fig. 4-31
8. Connect auxiliary hydraulic tubes to 90° elbows at
Fig. 4-33 Some of the hardware connecting hydraulic back of auxiliary coupler bracket. Fig. 4-35
tubes underneath the liftarm.
9. Attach hex screws, line clips and tee fittings to tilt
hoses on liftarm crossmember. Fig. 4-30
PRINTED IN USA 4-11 908269/AP1102
--- Page 6 ---
SL3635/3935 WHEEL DRIVES
Introduction
This chapter covers removal, installation, assembly, and fixed-displacement hydrostatic drive motors. The drive
adjustment procedures for wheel drive system motors are directly connected to chaincases. Each motor
components on GEHL SL3635/3935 skid loaders. drives one set of wheels on each side of the loader
Wheel drive components covered in this chapter are through a chain and sprocket system.
shown below. Service procedures related to the hydrostatic pump and
SL3635/3935 skid loaders are equipped with a drive motors can be found in the Hydrostatic System
hydrostatic pump assembly coupled to the diesel engine chapter.
providing hydrostatic power to the two
Wheel Drives Components
WHEEL DRIVES
17
16
15
19
12
9 9
18 10 8
18 11
20
9 5
7 6
6
8 5
7
14
8
13
4
13
12 2
3
1
Fig. 5-1 Assembly view of the wheel drive components (left side shown, right side typical).
1 - Axle 6 - Bearing Cup 11 - Sprocket 16 - Gasket
2 - Lug Bolt 7 - Sprocket Weldment 12 - Roller Chain 17 - Gasket Plate
3 - Lug Nut 8 - Washer 13 - Capscrew 18 - O-Ring
4 - Seal 9 - Locknut 14 - Snap Ring 19 -Hub Bolt
5 - Bearing Cone 10 - Cotter Pin 15 - Mount Plate 20 - Set Screw
PRINTED IN USA 5-1 908269/AP1102
--- Page 7 ---
SL3635/3935 CONTROLS
T-Bar Control (Late) Models - Auxiliary Hydraulics
CONTROLS
1 - Control Mount Weldment
2 - Capscrew
3 - Auxiliary Pedal Weldment
4 - Bushing
5 - Capscrew
6 - Auxiliary Control Cable
7 - Ball Joint
8 - Locknut
9 - Floor Plate
10 - Auxiliary Pivot Weldment
11 - Carriage Bolt
12 - Flanged Locknut
13 - Female Rod End
14 - Capscrew
15 - Washer
16 - Locknut
17 - Control Rod
18 - Locknut
19 - Auxiliary Spool Lock Linkage
20 - Clevis Pin
21 - Rue Pin
22 - Solenoid Mount Bracket
23 - Locknut
24 - Spool Lock Solenoid
25 - Jam Nut
26 - Self-Tapping Capscrew
Fig. 6-5 Assembly view of late model T-Bar auxiliary hydraulics components.
PRINTED IN USA 6-5 908269/AP1102
--- Page 8 ---
SL3635/3935 CONTROLS
Dual Control Weldment Removal and
Installation - T-Bar Only
The dual control weldment in T-Bar skid loaders houses
Capscrew the left control handle pivots and provides a conduit for
control of skid loader traction functions.
Pivot
Removal Procedure
Locknut
Center Control Rod
WARNING
BEFORE beginning this service procedure,
perform the following SAFETY procedures:
Fig. 6-20 Location of locknuts on studded rod ends
connecting hydrostatic pump arms to pivot. q Raise liftarm, engage liftarm support
device.
q Shut off the engine.
q Roll ROPS back until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual).
CONTROLS
Centering Device
1. Remove floor cover and kick plate per the procedure
in the Mainframe chapter.
2. Remove control handles per the procedure in this
chapter.
3. Remove locknuts on rod ends attaching hydrostatic
pump arms to pivot weldment. Fig. 6-20
4. At front of dual control weldment, remove two
Fig. 6-21 Location to disconnect centering device on
locknuts on studded rod ends on center control rod,
dual control weldment.
attached between two pivots. Figs. 6-11, 6-20
5. Remove locknut and washer securing centering
device to welded tab on dual control weldment. Fig.
6-21
Dual Control Weldment 6. Remove shoulder screw and two washers securing
shock absorber to welded tab on dual control
weldment. Fig. 6-21
7. Remove capscrew, spacer and locknut on lower
right flange bearing of dual control weldment. Fig.
6-22
8. Remove capscrew securing lower left portion of
dual control weldment to mainframe. Fig. 6-20
Installation Procedure - follow all WARNINGS first,
Fig. 6-22 Location of capscrew, spacer and locknut then reverse the removal steps
securing dual control weldment on lower right
side.
PRINTED IN USA 6-15 908269/AP1102
--- Page 9 ---
SL3635/3935 CONTROLS
Hand Throttle, Hand Throttle Cable and
Foot Throttle Cable Throttle Rod Removal and Installation
Removal Procedure
Weld Tab
WARNING
BEFORE beginning this service procedure,
Hand Throttle Cable perform the following SAFETY procedures:
q Raise liftarm, engage liftarm support
device.
Fig. 6-50 Locations to remove hand throttle cable and
q Shut off the engine.
foot throttle cable from pivots. q Roll ROPS back until lock engages.
(For detailed instructions, refer to the Safety
chapter of this manual).
1. Remove floor cover and kick plate per the procedure
in the Mainframe chapter.
2. Remove clevis pin and cotter pin on throttle cable
CONTROLS
yoke end secured to throttle handle. Fig. 6-49
3. Remove locknut, capscrew and three washers
securing hand throttle lever to chassis. Note
orientation of two Belleville washers for reassembly
later. Remove hand throttle lever.
4. Loosen jam nut on throttle cable below control
handle and lift cable out of slot in mainframe. Fig.
Fig. 6-51 Location of throttle rod ball joint on ball stud. 6-49
5. At engine mount weldment, remove clevis pin and
cotter pin on yoke end attaching other end of throttle
cable to hand throttle pivot. Fig. 6-50
Fuel Injector Arm NOTE: T-Bar and Dual Hand model skid loaders will
have the foot pedal throttle cable attached to its own
throttle pivot at same place. Perform “Foot Throttle
Removal and Installation” procedure in this chapter to
remove that cable. Fig. 6-50
6. Loosen jam nut securing hand throttle cable to tab
welded on engine mount weldment. Fig. 6-50
7. Remove the cable. If replacing cable, remove yoke
ends, washers and jam nuts from old cable.
8. Next, disconnect ball joint on ball stud securing
throttle control rod to throttle pivot. Fig. 6-51
Fig. 6-52 Location of throttle rod connection to the 9. Raise engine cover and open rear grille. Locate
engine. throttle rod connection on rear lower left of engine.
Fig. 6-52
PRINTED IN USA 6-25 908269/AP1102
--- Page 11 ---
SL3635/3935 HYDROSTATIC SYSTEM
Problem Possible Cause Remedy
Neutral is difficult to Ball joints loose on centering mechanism Check and tighten or replace components.
maintain. or servo rod.
Neutral centering mechanism(s) out of Adjust neutral centering mechanism(s).
adjustment. See Controls chapter for procedure.
Key is missing in one or both control arm Install key.
assemblies.
Clamping bolt is loose. Torque capscrew on the pump arm to 30
ft.-lbs. (40 N•m.)
Hydrostatic pump out of adjustment. See hydrostatic pump manual.
Sluggish response to Air in the hydraulic system. Cycle the lift and tilt cylinders to maximum
acceleration. stroke and maintain pressure for a short
time to clear air from system. Check
hydraulic oil reservoir, fill as needed.
Hydraulic oil supply is too low. Check hydraulic oil reservoir. Add oil, if
necessary.
Low hydrostatic system charge pressure. See hydrostatic pump manual.
HYDROSTATIC
Drive motor(s) or hydrostatic pump(s) Refer to component manufacturer’s
have internal damage or leakage. service manual.