Gravely 950001, Maintenance Manual

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Section 1 - Introduction . . . . . . . . . . . . . . . . . . 1-3
1.1 The Manual . . . . . . . . . . . . . . . . . . . . . . . . 1-3
1.2 Technical Service Communications . . . . . . 1-3
1.3 Product Registration . . . . . . . . . . . . . . . . . 1-3
1.4 Unauthorized Replacement Parts . . . . . . . 1-3
1.5 Disclaimer . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Section 2 - Safety . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.1 Safety Alerts . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.2 Signal Words . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.3 Notations . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.4 Practices and Laws . . . . . . . . . . . . . . . . . . 2-4
2.5 Required Operator Training . . . . . . . . . . . . 2-4
2.6 Preparation . . . . . . . . . . . . . . . . . . . . . . . . 2-4
2.7 Service Position . . . . . . . . . . . . . . . . . . . . . 2-4
2.8 Cleaning and Storage . . . . . . . . . . . . . . . . 2-4
2.9 Safety Rules. . . . . . . . . . . . . . . . . . . . . . . . 2-5
Section 3 - Specifications . . . . . . . . . . . . . . . . 3-7
Section 4 - General Maintenance &
Adjustments. . . . . . . . . . . . . . . . . . . . . . . . . 4.8
4.1 Controls and Features . . . . . . . . . . . . . . . . 4-8
4.2 Filling The Fuel Tank . . . . . . . . . . . . . . . . . 4-9
4.3 General Lubrication . . . . . . . . . . . . . . . . . . 4-9
4.4 Lubricate Traction Drive Chain. . . . . . . . . 4-10
4.5 Lubricate Rear Hubs . . . . . . . . . . . . . . . . 4-10
4.6 Check Wheel Nuts . . . . . . . . . . . . . . . . . . 4-11
4.7 Grease Chassis . . . . . . . . . . . . . . . . . . . . 4-11
4.8 Check Engine Oil Level-Gasoline . . . . . . 4-12
4.9 Check Engine Oil Level-Diesel. . . . . . . . . 4-12
4.10 Change Engine Oil- Gasoline . . . . . . . . 4-12
4.11 Change Engine Oil- Diesel . . . . . . . . . . 4-13
4.12 Change Engine Oil Filter . . . . . . . . . . . . 4-13
4.13 Checking Engine Cooling. . . . . . . . . . . . 4-14
4.14 Check Radiator Hoses & Clamps-Diesel 4-15
4.15 Service Air Cleaner-Gasoline . . . . . . . . 4-15
4.16 Service Air Cleaner- Diesel . . . . . . . . . . 4-15
4.17 Checking Tire Pressure . . . . . . . . . . . . . 4-16
4.18 Check Hydraulic 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 . . . . . . . . . . . 4-19
4.24 Charge Battery. . . . . . . . . . . . . . . . . . . . 4-20
4.25 Replacing Fuel Filter- Gasoline . . . . . . . 4-20
4.26 Clean Fuel Filter-Diesel . . . . . . . . . . . . . 4-20
4.27 Adjust Fan Belt- Diesel . . . . . . . . . . . . . 4-21
Section 5 - Engine . . . . . . . . . . . . . . . . . . . . . . 5-22
5.1 Engine Troubleshooting . . . . . . . . . . . . . . 5-22
5.2 Gasoline Engine Removal . . . . . . . . . . . . 5-23
5.3 Gasoline Engine Installation . . . . . . . . . . 5-23
5.4 Diesel Engine. . . . . . . . . . . . . . . . . . . . . . 5-23
5.5 Diesel Engine Removal . . . . . . . . . . . . . . 5-25
5.6 Diesel Engine Installation. . . . . . . . . . . . . 5-26
Section 6 - Drive Train . . . . . . . . . . . . . . . . . . 6-27
6.1 Bell Housing & Coupling . . . . . . . . . . . . . 6-27
6.2 Removal Of The Hydraulic Pump Bell Housing
And Coupling . . . . . . . . . . . . . . . . . . . . . . . . . 6-27
6.3 Pump To Coupling Reassembly . . . . . . . . 6-29
6.4 Hydraulic Pump Removal. . . . . . . . . . . . . 6-30
6.5 Pump Reassembly . . . . . . . . . . . . . . . . . . 6-32
6.6 Drive Motor . . . . . . . . . . . . . . . . . . . . . . . 6-33
6.7 Final Drive Train . . . . . . . . . . . . . . . . . . . . 6-38
Section 7 - Hydraulic System. . . . . . . . . . . . . 7-41
7.1 General Description . . . . . . . . . . . . . . . . . 7-41
7.2 Stand-By Mode (Neutral) . . . . . . . . . . . . . 7-42
7.3 Crowd Function-Bucket Tilt Down . . . . . . 7-43
7.4 Travel Forward Function . . . . . . . . . . . . . . 7-44
7.5 Travel Function - Rotate . . . . . . . . . . . . . . 7-45
7.6 Lift Function - Lift Arms Raise . . . . . . . . . 7-46
7.7 Lift Function- Lift Arms Lower . . . . . . . . . 7-47
7.8 Valve Bank Disassembly . . . . . . . . . . . . . 7-48
7.9 Trenching Valve . . . . . . . . . . . . . . . . . . . . 7-52
7.10 Hydraulic Cylinders . . . . . . . . . . . . . . . . 7-57
7.11 Overcenter Valve . . . . . . . . . . . . . . . . . . 7-62
7.12 Quick Disconnect Couplings . . . . . . . . . 7-63
Section 8 - Fuel System . . . . . . . . . . . . . . . . . 8-64
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