Gehl SL3635 User manual

OPERATOR’S MANUAL
SL3635
SL3935
SKID-STEER
LOADER
®
Form No.
908268/
BP0904
English
SL3635 SN 00001175 & LATER
SL3935 SN 00001337 & LATER

Read Operator’s
Manual before
using machine.
Gehl, in cooperation with the
American Society of Agricultural
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.
When you see this symbol in this
manual or on the machine itself, you
are reminded to BE ALERT! Your
personal safety is involved!
Always fasten seatbelt
snugly. Always keep
feet on the floor/pedals
when operating loader.
Never use loader without
ROPS/FOPS. Never modify
the ROPS/FOPS structure.
Never use the loader to lift
personnel.
Do not use loader around
explosive dust or gas, or
where exhaust can contact
flammable material.
Operators must have instructions
before running the machine.
Untrained operators can cause
injury or death.
WRONG
WRONG
WRONG
CORRECT
CORRECT

TABLE OF CONTENTS
Introduction .........................1
Safety ...........................6
Controls and Safety Equipment ..............16
Operation .........................32
Service ..........................41
Troubleshooting ......................56
Maintenance Schedule ..................65
Specifications .......................68
Table of Common Materials and Densities ........72
Index ...........................74
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.
SL3635 and SL3935 Skid-Steer Loader
Operator’s Manual

INTRODUCTION
This Operator’s Manual gives the owner/operator information about
maintaining and servicing SL3635 and SL3935 skid steer loader models.
More importantly, this manual provides an operating plan for safe and proper
use of the machine. Major points of safe operation are detailed in the Safety
chapter of this manual.
We ask that you read and understand the contents of this manual completely
and become familiar with your new machine before operating it. See your
authorized Gehl dealer if you have any questions concerning information in
the manual, require extra manuals or for information concerning the
availability of manuals in other languages.
Throughout this manual, information is provided which is set in italic type
and introduced by the word Note or Important. Read carefully and comply
with the message — it will improve your operating and maintenance
efficiency, help avoid breakdowns and damage, and extend your machine’s
life.
A manual storage box in the operator’s compartment holds the Operator’s
Manual and EMI Safety Manual. Please return the manuals to this box and
keep them with the unit at all times. If this machine is resold, we recommend
that these manuals be given to the new owner.
The attachments and equipment available for use with this machine have a
wide variety of potential applications. Read the manual provided with the
attachment to learn how to safely maintain and operate the equipment. Be
sure the machine is suitably equipped for the type of work to be performed.
Do not use this machine for any applications or purposes other than those
described in this manual or applicable for approved attachments. If the
machine is to be used with special attachments or equipment other than those
approved by Gehl Company, consult your Gehl dealer. Any person using
non-approved attachments or making unauthorized modifications is
responsible for the consequences.
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.
Record these numbers in the space provided on the Table of Contents page, as
a handy reference.
Please be aware that Gehl strives to continuously improve its products and
reserves the right to make changes and improvements in the design and
construction of any part without incurring the obligation to install such
changes on any unit previously delivered.
1 908268/BP0904

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.
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Model Identification
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Front Work Lights
Hand Holds
Restraint Bar
Tilt
Cylinder
Hitch
Tires
Hydraulic
Auxiliary
Couplers
Lift Cylinder
Upright
Engine Cover
Tail Lights
Rear Door
Lift Arm
Roll Over/
Falling Object
Protective
Structure
(ROPS/FOPS)
Rear Work
Lights

Control/Indicator Symbols
Power Off Power On Engine Start Hazard Flasher Worklight
Worklight
w/Flasher Battery Charge Parking Brake
Read Operator’s
Manual Horn
Volume - Full Volume- Half Full Volume - Empty Pre-Heat Diesel Fuel
Lift Point Neutral Safety Alert Chaincase Oil
Seatbelt - Lap
Only
Engine Air Filter Engine Oil Engine Oil Filter
Engine Oil
Pressure Fuel Filter
Engine Coolant
Temperature Hydraulic System
Hydraulic Oil
Temperature
Hydraulic Oil
Filter
Grease
Lubrication Point
Tie-Down
Machine Travel -
Forward
Machine Travel -
Reverse
Clockwise
Rotation
Counterclockwise
Rotation
Fast Slow Bucket - Lower Bucket - Raise Bucket - Float
Bucket - Rollback Bucket - Dump
908268/BP0904 4
N

Notes
5 908268/BP0904

SAFETY
This safety alert symbol means Attention! Become alert! Your safety
is involved! It stresses an attitude of “Heads Up for Safety” and can
be found throughout this Operator’s Manual and on the decals on the
machine.
Before operating this machine, read and study the following safety
information. In addition, be sure that everyone who operates or works with
this machine, whether family member or employee, is familiar with these
safety precautions. It is essential to have competent and careful operators,
who are not physically or mentally impaired, and who are thoroughly trained
in the safe operation of the machine and the handling of loads. It is
recommended that the operator be capable of obtaining a valid motor vehicle
operator’s license.
The use of skid steer loaders is subject to certain hazards that cannot be
eliminated by mechanical means, but only by exercising intelligence, care
and common sense. 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 ALWAYS considers the operator’s safety when designing its machinery
and guards exposed moving parts for the operator’s protection. However,
some areas cannot be guarded or shielded in order to assure proper operation.
Furthermore, this Operator’s Manual and the decals on the machine warn of
additional hazards and they should be read and observed closely.
Some photographs in this manual may show doors, guards and shields open
or removed for illustrative purposes only. Be sure that all doors, guards and
shields are in their proper operating positions before starting the engine to
operate the unit.
Different applications may require optional safety equipment, such as a
back-up alarm, horn, mirror, strobe light or an impact-resistant front door. Be
sure you know the job site hazards and equip your machine as needed.
“DANGER” indicates an imminently hazardous
situation which, if not avoided, will result in death or serious
injury.
“WARNING” indicates a potentially hazardous
situation which, if not avoided, could result in death or serious
injury.
908268/BP0904 6
DANGER
WARNING

“CAUTION” indicates a potentially hazardous
situation which, if not avoided may result in minor or moderate
injury. May also alert against unsafe practices.
Mandatory Safety Shutdown Procedure
Before cleaning, adjusting, lubricating, servicing the unit or leaving it
unattended:
1. Move the drive control handle(s) to the “neutral” position.
2. Lower the lift arm and attachment completely. If the lift arm must be left
in the “raised” position, BE SURE to properly engage the lift arm support
device (page 18).
3. Move the throttle to the low idle position, shut off the engine and remove
the key.
4. Before exiting, move the lift/tilt control(s) to verify that the controls do
not cause movement of the lift arm and hitch.
Safety Reminders
Before Starting
ÜDo not modify the ROPS/FOPS unless instructed to do so in installation
instructions. Modifications such as welding, drilling or cutting can weaken
the structure and reduce the protection it provides. A damaged
ROPS/FOPS cannot be repaired — it must be replaced.
ÜTo ensure safe operation, replace damaged or worn-out parts with genuine
Gehl service parts.
ÜGehl 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.
ÜRemove all trash and debris from the machine each day, especially in the
engine compartment, to minimize the risk of fire.
ÜAlways face the loader and use the hand holds and steps when getting on
and off the loader. Do not jump off the loader.
ÜNever use starting fluid (ether).
ÜWalk around the machine and warn all nearby personnel before starting the
machine.
ÜAlways perform a daily inspection of the machine before using it. Look for
damage, loose or missing parts, leaks, etc.
7 908268/BP0904
CAUTION

During Operation
ÜThe 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
INJURY. Therefore, always have the operator restraint bar lowered and
wear the seatbelt. Operate the controls smoothly and gradually at an
appropriate engine speed that matches the operating conditions.
ÜAlways travel with the heavier end of the loader toward the top of the
incline for additional stability when operating on inclines or ramps.
ÜDo not raise or drop a loaded bucket or fork suddenly. Abrupt movements
under load can cause serious instability.
ÜNever push the lift control into the “float” position with the bucket or
attachment loaded or raised, because this will cause the lift arm to lower
rapidly.
ÜDo not drive too close to an excavation or ditch; be sure that the
surrounding ground has adequate strength to support the weight of the
loader and the load.
ÜNever carry riders. Do not allow others to ride on the machine or
attachments, because they could fall or cause an accident.
ÜAlways look to the rear before backing up the skid steer loader.
ÜOperate the controls only from the operator’s seat.
ÜDo not exceed the rated operating load of the machine.
ÜAlways keep hands and feet inside the operator’s compartment while
operating the machine.
ÜNew operators must operate the loader in an open area away from
bystanders. Practice with the controls until the loader can be operated
safely and efficiently.
ÜExhaust fumes can kill. Do not operate this machine in an enclosed area
unless there is adequate ventilation.
ÜWhen you park the machine and before you leave the seat, check the
restraint bar for proper operation. The restraint bar, when raised, applies the
parking brake and deactivates the lift/tilt controls.
Maintenance
ÜNever attempt to by-pass the keyswitch to start the engine. Use only the
jump starting procedure detailed in the Service chapter of this manual.
ÜNever use your hands to search for hydraulic fluid leaks. Instead, use a
piece of paper or cardboard. Escaping fluid under pressure can be invisible
and can penetrate the skin and cause serious injury. If any fluid is injected
into your skin, see a doctor at once. Injected fluid must be surgically
removed by a doctor or gangrene may result.
908268/BP0904 8

ÜAlways 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.
ÜDo not smoke or have any spark producing equipment in the area while
filling the fuel tank or while working on the fuel or hydraulic systems.
9 908268/BP0904

Potential Hazards
A skid steer loader operator must ALWAYS be conscious of the working
00environment. Operator actions, the environmental conditions and the job
at hand require the full attention of the operator so that safety precautions can
be taken.
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 North
American One Call Referral System at [phone] for the local
“Digger’s Hotline” number or the proper local authorities for utility line
locations BEFORE starting to dig!
Exposure to crystalline silica (found in sand, soil and rocks) has been
associated with silicosis, a debilitating and often fatal lung disease. A Hazard
Review (Pub. No. 2002-129) by the U.S. National Institute for Occupational
Safety and Health (NIOSH) indicates a significant risk of chronic silicosis for
workers exposed to inhaled crystalline silica over a working lifetime.
NIOSH recommends an exposure limit of 0.05 mg/m3as a time-weighted
average for up to a 10-hr workday during a 40-hr workweek. NIOSH also
recommends substituting less hazardous materials when feasible, using
respiratory protection and regular medical examinations for exposed
workers.
Safety Decals
The skid steer loader has decals that provide safety information and
precautions around the loader. 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.
Note: Contact your dealer for information concerning the availability of
warning decals in other languages.
New Decal Application
Surfaces must be free of dirt, dust, grease and foreign material before
applying the decal. Remove the smaller portion of the decal backing paper
and apply the exposed adhesive to the clean surface, maintaining proper
position and alignment. Peel the rest of the backing paper and apply hand
pressure to smooth out the decal surface. Refer to the following pages for
proper decal location. Text decals begin on page ; Non-text decals begin on
page .
908268/BP0904 10

Safety Decals inside the ROPS
11 908268/BP0904
137628 - Located on the manual box, operator’s
right
137683 - Located on
ROPS left panel
137639 - Located on
ROPS left panel
137647 - Located on operator’s lower left side

Safety Decals on the Outside of the Skid Loader
908268/BP0904 12
137720 - Front of loader
137655 - Front of loader
184214 - Under ROPS
137637 - Lift arm support device, loader left side

Safety Decals in the Engine Compartment
13 908268/BP0904
137657 - Right of hydraulic filter
137658 - On radiator

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. Seat plate according to ISO 7096
5. Component plate rear drive axel : with e.g. product- and serial number
6. Component plate front drive axel : with e.g. product- and serial number
7. Component plate transmission: with e.g. product- and serial number
Product and Component Plate Location
908268/BP0904 14
3
1
5
7
2
4
6

Notes
15 908268/BP0904

CONTROLS and SAFETY EQUIPMENT
Become familiar with and know how to use all safety
devices and controls on the skid steer loader before operating it. 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.
Guards and Shields
Whenever possible and without affecting loader operation, guards and
shields are provided to protect against potentially hazardous areas. In many
places, safety decals are also provided to warn of potential hazards and/or to
display special operating procedures.
Read and thoroughly understand all safety decals on
the loader before operating it. Do not operate the loader unless all
factory-installed guards and shields are properly secured in place.
Operator Restraint Bar
Lower the restraint bar after entering the operator’s compartment. The
restraint bar is securely anchored to the ROPS. The restraint bar switch is
wired in series with the seat switch
forming an interlock for the lift arm, tilt,
drive and starter circuits (refer to the
“Safety Interlock System” topic on page
17 for more information).
Never defeat the
operator restraint bar or seat switch
electrically or mechanically. Always
wear your seatbelt.
Operator’s Seat
The seat is mounted on rails for
backward or forward repositioning. A
spring-loaded latch handle activates the
seat adjustment mechanism.
Suspension seat (optional): A weight adjustment knob is provided with this
seat for operator comfort.
908268/BP0904 16
CAUTION
WARNING
WARNING
Fig. 1: Operator’s Seat
1. Restraint Bar
2. Seatbelt
3. Seat Adjustment Lever
4. Suspension Seat Knob (optional)
1
3
2
4

Safety Interlock System
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:
»Prevents the engine from starting unless the operator is sitting on the seat
and the operator restraint bar is down.
»Disables the lift arm, attachment tilt and wheel drives anytime the operator
leaves the seat, turns the keyswitch to OFF or raises the restraint bar.
»Disables the engagement of the auxiliary hydraulics anytime the restraint
bar is raised or the keyswitch is OFF.
Testing the Safety Interlock System
Before leaving a parked machine, check the safety interlock system for
proper operation:
Restraint Bar
With the engine running, raise the restraint bar. Test each of the controls.
There should be not more than a slight movement of the lift arm, hitch and
machine. If there is any significant movement, troubleshoot and correct
the problem immediately. Contact your dealer if necessary.
Seat Switch
With the engine off and the restraint bar lowered, unfasten your seatbelt.
Lift your weight up off the seat. Try to start the engine. If the engine starts,
turn off the engine, and troubleshoot and correct the problem. Contact
your dealer if necessary.
17 908268/BP0904
WARNING