Gravely 950001 Maintenance Manual Download Page 1

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Summary of Contents for 950001

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Page 2: ...ulic Fluid Level 4 16 4 19 Change Hydraulic Fluid 4 16 4 20 Change Hydraulic Filters 4 17 4 21 Check Hydraulic Lines 4 17 4 22 Check Traction Drive Chain Tension 4 18 4 23 Check Battery Electrolyte 4...

Page 3: ...rry out the directive provided in the communication The types of communication are Service Letter General technical information for the dealer Technical information on how to service the product and p...

Page 4: ...mportant for efficient work A clean work area at the start of each job will allow you to perform service repairs easily and quickly Organization is a key part of proper reassembly To reduce the incide...

Page 5: ...slowly Always look down and behind before and while backing Never leave a running unit unattended ALWAYS shut off auxiliary power lower throttle setting and stop engine before leaving unit ALWAYS rem...

Page 6: ...with the arms in the raised position Maintenance ALWAYS maintain unit in safe operating condition Damaged or worn out muffler can cause fire or explosion Check the conditions of the unit at the end o...

Page 7: ...Manual See Engine Manual Fuel Tank Capacity 10 gals 38 l 10 gals 38 l 10 gals 38 l Electrical Ignition 12 volt 12 volt 12 volt Battery CCA 350 350 350 Drive System Hydraulic wheel motors 29 cubic inch...

Page 8: ...ontrol 6 Auxiliary Hydraulic Control 7 Operator Hand Grips 8 Hydraulic Activator Switch 9 Ignition Switch and Key 10 Throttle Control 11 Choke Control 12 Fuel Caps 2 13 Operator Platform 14 Fuel Tanks...

Page 9: ...GENERAL LUBRICATION Main Frame Maintenance After every 4 weeks of operation clean the mainframe with high pressure water or steam Carefully inspect the mainframe for cracks or other damage and repair...

Page 10: ...a general purpose oil 10w30 onto the upper and lower chain that is exposed 3 Start the unit and move it forward to expose the sections of the chain that are not lubricated 4 Stop the engine 5 Apply oi...

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Page 12: ...he lift arms lowered the engine off and the key removed 2 Clean dirt from around oil dipstick 3 Remove dipstick and wipe off excess oil 4 Insert dipstick completely into the filler tube and remove Ins...

Page 13: ...peration and every 50 hours thereafter Crankcase Capacity with filter 1 gal 3 8 l Oil Type MIL L 2104C or equivalent API classification CC CD CE grades Viscosity See table below 1 The unit should be p...

Page 14: ...the coolant level is low add 50 50 mixture of fresh water and anti freeze only up to the FULL level 4 Replace radiator cap and securely retighten If the system leaks consult your dealer CHANGE COOLANT...

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Page 17: ...igh Pressure Filter 1 Start engine and raise lift arms 2 Stop engine and remove key 3 Lower cylinder lock into position over the top of cylinder body 4 Use a 13 mm wrench and remove capscrews that fas...

Page 18: ...f the main frame above it the chain is too slack 4 If slack is correct in both chains proceed to step 11 If chain s are too slack follow steps 5 10 for the chain s that must be adjusted To adjust chai...

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Page 20: ...l a dirty filter 1 Lower the lift arms and stop the engine 2 Clamp the fuel line to block fuel flow to filter 3 Remove the hose clamps and slide them away from the filter 4 Place a drain pan under the...

Page 21: ...erate pressure to the belt between the pulleys 3 If tension is not correct loosen the alternator mounting bolts and pull the alternator out until the deflection of the belt falls within acceptable lim...

Page 22: ...Faulty suction pipe 2 Bad electrical connection 23 Sticking throttle restricted movement 44 Choked oil filter 3 Faulty starter motor 24 Exhaust pipe restriction 45 Bad solenoid switch 4 Incorrect grad...

Page 23: ...ed fitting on each side Be prepared to catch or clean up any spilled gasoline 8 Remove the exhaust pipe extension Unscrew the bolt for the clamp and slide the extension off 9 Unscrew the four 4 mounti...

Page 24: ...l Drain Hose The engine oil drain hose is permanently attached and stored on the floor of the main frame It is readily assessable for oil changes Engine Torque Reaction Arm The diesel engine is secure...

Page 25: ...ve the fuel line across the bottom of the engine mounts Be prepared to catch or clean up any spilled fuel 8 Mark the wiring connectors and disconnect the engine 9 Disconnect the throttle control cable...

Page 26: ...from the engine 14 The engine can now be lifted out of the back of the frame 5 6 DIESEL ENGINE INSTALLATION To install the diesel engine reverse the previous steps Use clean coolant to refill the rad...

Page 27: ...ce The machined rim edge of the pump half coupling is used as a datum point when measuring for correct position of the engine half coupling 6 2 REMOVAL OF THE HYDRAULIC PUMP BELL HOUSING AND COUPLING...

Page 28: ...ousing as shown then give a sharp tap with a hammer to the pump shaft to unlock it from the pump half coupling 12 Remove spider insert prying it out with a screwdriver if necessary Inspect it for wear...

Page 29: ...If it is check key height and depth of keyways The key corners must not cut into the fillet of the keyway Check side clearance in coupling Coupling Engagement Measurements 1 Measure and record the di...

Page 30: ...equires replacement of the pump Nicking grooving or fretting of the teeth surfaces also necessitates pump replacement When the pump is disassembled for inspection the shaft seal and face seals should...

Page 31: ...front flange or the pump body Do not remove Keep the rear bearing block in the pump body as shown above Check the front face seal for damage Lift the gear set and front bearing block away from the fr...

Page 32: ...y 27 mm outside dia or a suitably size socket wrench socket as a mandrel for pushing the seal into the front flange recess Partially enter the seal using hand pressure to ensure the seal is square wit...

Page 33: ...four hexagon nuts and washers Before torquing hardware be sure align ment marks on the case match Use standard torque for hardware grade Install the woodruff key and the shaft nut tab washer 6 6 DRIV...

Page 34: ...ver 2 is equipped with shuttle valve components remove the two plugs 6 Thoroughly wash end cover 2 in proper solvent and blow dry Be sure the end cover valve apertures including the internal orifice p...

Page 35: ...become disassembled during service procedures NOTE A polished pattern on the wear plate from rotor rotation is normal 12 Place rotor set 8 and wear plate 9 on a flat surface and center rotor 8A in sta...

Page 36: ...ss approved Torqmotor distributors contact your machine dealer for availability NOTE Unless otherwise indicated do not oil or grease parts before assembly Wash all parts in clean petroleum based solve...

Page 37: ...es The studs can be made by cutting off the heads of either 318 24 UNF 2A or 5116 24 UNF 2A bolts as required that are over 5 inch 12 7 mm longer than the bolts 1 1A 1B or 1C used in the Torqmotor 12...

Page 38: ...FINAL DRIVE TRAIN Wheel Removal NOTE If using a powered impact device for removing wheel nuts skip Step 1 and go straight to Step 2 1 Using a socket wrench loosen the wheel nuts half a turn see note...

Page 39: ...chain for damage such as broken rollers or signs of galling Replace with new chains if wear or damage is excessive NOTE Also while the chain is off the sprocket check the sprockets for wear see below...

Page 40: ...b 5 Fit castellated nut on the stub axle and while rotating the hub tighten the nut to a torque of 33 8 Nm 25 ft lb 6 Slacken of the nut until the end float in the hub bearing is 0 025 mm 0 001 7 Fit...

Page 41: ...he pump output deliv ery Directional Control Valve Bank The directional control valve bank is the control center of the machine The six section valve bank is located at the operators console Hydraulic...

Page 42: ...r all directional valve levers are in neutral position Although the system is doing no productive work this mode is useful by circulating oil through both the pressure and return line filters and remo...

Page 43: ...e motor valve section is fitted with a Parallel spool and the parallel passage is not plugged This function can operate at the same time as the Lift function because the lift function is fitted with a...

Page 44: ...a Series spool However for safety reasons it is recommended travel is not attempted with the lift arms and attachment raised Note how the valve flow for the left hand drive motor doubles back through...

Page 45: ...the machine will rotate about its own axis in this mode Note how the valve flow for the left hand drive motor doubles back through the series spool to connect with the parallel valve of the right han...

Page 46: ...allowing the crowd function to operate at the same time while the lift cylinder is moving LIFT CYL INDER Note The cross hatched area of the valve section indicates the spool has shifted from neutral i...

Page 47: ...is valve function is fitted with a series spool allowing the crowd function to operate at the same time while the lift cylinder is moving Note The cross hatched area of the valve section indicates the...

Page 48: ...lve bank s exterior after which the port plugs can be removed Mark The Valve Bank 1 Before disassembly is started the end covers and each section must be marked to ensure the correct arrangement and o...

Page 49: ...e and lift the front cap away from the work section The lever mechanism will disengage from the spool Take care not to loosen the location dowels 5 Valve Back Cap Remove the two 2 screws which fasten...

Page 50: ...st replace the section Minor surface damage on the control spool may be carefully polished away with very fine cloth 2 Examine the machined surfaces of the valve housing for nicks and burrs that could...

Page 51: ...Step 7 see below 4 In 1 Bucket Spool Section 7 Only This spring centered spool mechanism must be fitted with the 1 5mm 0 060 spacer that restricts spool travel see below Load Check Valve Check the mov...

Page 52: ...ove With the engine running at normal operating speed select the Lift function raise When the cylinder is fully extended continue to hold the lever in the Lift raise position The pressure gauge should...

Page 53: ...gging commences The setting of Item 2 would normally be above the travel speed that you want to trench at because trenching speed will be limited to the speed setting if digging in very easy soft grou...

Page 54: ...7 54 3 2 7 5 1 2 1 6 4 4 5 TRENCHER VALVE DRAWING SHOWING PORT POSITIONS 4 5 6 7 3 2 1 Item numbers relate to trencher circuit sketches opposite...

Page 55: ...flow directly back to tank NOTE The over center valve Item 4 is in the fully open position at this point With its setting of 3000 psi and a 4 25 1 ratio it opened at 705 psi The pressure compensated...

Page 56: ...ill running and the engine sound should indicate it is under load Summary With trencher running above ground it should Engine should run freely with trencher running in forward cutting direction Engin...

Page 57: ...Do not clamp on the cylinder barrel Then unscrew the external gland retaining nut using a C wrench see below 2 Remove the gland retaining nut 3 Pull the piston rod and gland assembly out from the cyl...

Page 58: ...the thread and hold the nut captive see below 5 Use the edge of a small angle grinder to remove the deformed thread area see below 6 Remove the piston retaining nut see below 7 When the piston retaini...

Page 59: ...Wiper seal Gland body seal and the Rod Gland Lipseals It is essential that the Rod Gland Lipseal cup end faces the direction of the piston The sketch below illustrates the orientation of each seal 10...

Page 60: ...o 3 times to ensure a complete coating of Locktite to both surfaces Then apply Locktite to the piston rod threaded area see below 5 Replace and tighten the piston retaining nut see below 6 Firmly clam...

Page 61: ...en purged from the cylinder Fully retract the cylinder and raise the pressure to 210 bar 3000 psi checking for leaks at the rod end of the cylinder Then fully extend the cylinder again raising the pre...

Page 62: ...Retainer Reassembly Enter the drive end of the retaining ring into the gland drilling and then rotate the gland bearing clockwise until the end of the retaining ring is visible in the access window Th...

Page 63: ...ide the coupling halves that oppose each other As the coupling halves separate the poppet valve in each half snaps shut to close off and seal the lines on the implement and the machine Connection of t...

Page 64: ...age is even in each tank NOTE The fuel tank breather pipes enter the mainframe and rise to the top of the frame on both sides The hydraulic reservoir also has a breather that enters the left hand side...

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Gravely 950001, Maintenance Manual

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