Gravely Skidster 200 Maintenance Manual
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Gravely Skidster 200 Maintenance Manual

Gravely Skidster 200 Maintenance Manual

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  • Page 2: Table Of Contents

    TABLE OF CONTENTS Section 1 - Introduction ....1-3 Section 5 - Engine ..... . 5-22 1.1 The Manual .

  • Page 3: Section 1 - Introduction

    DANGER, WARNING, and affect the performance, durability, or safety of this unit CAUTION messages found in manuals and on safety and may void the warranty. Gravely disclaims liability decals. for any claims or damages, whether warranty, property...

  • Page 4: Section 2 - Safety

    SECTION 2 - SAFETY 2.1 SAFETY ALERTS SPARK ARRESTER Look for these symbols to point out This product is equipped with an internal combustion important safety precautions. They type engine. DO NOT use unit on or near any mean: unimproved, forest-covered, or brush covered land unless exhaust system is equipped with a spark Attention! arrester meeting applicable local, state, or federal laws.

  • Page 5: Safety Rules

    When taking unit out of extended storage: DO NOT travel at too fast a rate. DO NOT change engine governor settings or over-speed engine. 1. Check for any damage or loose parts. Repair, replace, or tighten hardware before operation, Always back up slowly. Always look down and behind especially blade attachment bolts.
  • Page 6 • Training includes actual operation. When performing service which requires arms to be raised, make sure cylinder lock is in position and • Clearly understand instructions. secure. • Be alert! Conditions can change. Keep nuts and bolts tight and keep equipment in safe NEVER operate unit after or during the use of operating conditions.

  • Page 7: Section 3 - Specifications

    SECTION 3 - SPECIFICATIONS 950001 950002 950003 Skidster 200 Skidster 200 Skidster 200 Performance Rated lift capacity w/ 300 lbs. (130 kg) 300 lbs. (130 kg) 300 lbs. (130 kg) standard bucket Travel speed 3.75 mph (6 kph) 3.75 mph (6 kph) 3.75 mph (6 kph)

  • Page 8: Section 4 - General Maintenance & Adjustments

    SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS 4.1 CONTROLS AND FEATURES Skidster 200 Skidster 200D Skidster 200 Skidster 200 ENGLISH 1. Auxiliary Cylinder Control 13.Operator Platform 24.Temperature Warning Light** 2. Lift Arm Control 14.Fuel Tanks (2) 25.Oil Pressure Warning Light** 3.

  • Page 9: Filling The Fuel Tank

    4.2 FILLING THE FUEL TANK Two “T” shaped fuel tanks are located on the unit, above the drive wheels on each side. Each tank is fitted with a filler cap, breather pipe, baffles, and a connecting balance pipe. The balance pipe ensures fuel usage is even from each tank.

  • Page 10: Lubricate Traction Drive Chain

    Pin Wear tolerance 25 - 24 mm Attachment Plate Bushings 4.4 LUBRICATE TRACTION DRIVE CHAIN 1. Lower the lift arms and stop the engine. 2. Apply a general purpose oil (10w30) onto the upper and lower chain that is exposed. 3.

  • Page 12: Check Engine Oil Level-Gasoline

    8. Start the engine 9. Lower the lift arms. 10.Stop the engine and remove the key. 4.8 CHECK ENGINE OIL LEVEL-GASOLINE Change oil after every 25 operating hours. Change more frequently when operating conditions are extremely dusty. The engine has a plugged drain line hose permanently attached to the engine sump to facilitate easy draining of the engine oil.

  • Page 13: Change Engine Oil- Diesel

    4.11 CHANGE ENGINE OIL- DIESEL Change oil after the first 20 hours of operation 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. SAE30 or SAE 10W-30 above 77...

  • Page 14: Checking Engine Cooling

    2. Remove the old filter by turning counterclockwise 2. Check the coolant level of the reserve tank. When and let the remaining oil drain out. Properly discard the reserve tank registers between “FULL” and the oil filter. Wipe filter base clean. “LOW”...

  • Page 17: Change Hydraulic Filters

    IMPORTANT: Do not substitute automotive oil. 3. Lower cylinder lock into position over the top of Hydraulic system damage may result. cylinder body. 2. Place a drain pan under the drain plug that will hold 4. Use a 13 mm wrench and remove capscrews that at least 17 gallons (67 l).

  • Page 18: Check Traction Drive Chain Tension

    4.22 CHECK TRACTION DRIVE CHAIN TENSION IMPORTANT: If conditions are sandy, an additional 1/2 To adjust chain tension: inch of slack should improve chain performance. 5. If chain is too slack, first try reversing tensioner Each front hub is direct-coupled to a hydraulic motor. blocks.

  • Page 20: Charge Battery

    Adding Water to the Battery 6. Un-clamp the fuel line. Under normal operating conditions the battery fluid lev- 4.26 CLEAN FUEL FILTER-DIESEL els may become lower. To bring the fluid up to the required level, add distilled water. Check and completely clean the fuel filter with clean fuel oil if it is contaminated with deposits, water, etc.

  • Page 21: Adjust Fan Belt- Diesel

    Top of Fuel Filter O-ring Element Spring Filter Filter Bowl Screw 4.27 ADJUST FAN BELT- DIESEL CAUTION: To avoid personal injury, be sure to stop the engine before checking belt tension. The fan belt has proper tension if there is a deflection of between 0.28 to 0.35 in.

  • Page 22: Section 5 - Engine

    The troubleshooting key is generic and can be used for isolate engine problems and give possible causes and several types of engines. Use only those possible corrective action responses. causes and corrective actions that apply to the Skidster 200. TROUBLE POSSIBLE CAUSES CORRECTIVE ACTION (Refer to Key Below)

  • Page 23: Gasoline Engine Removal

    5.2 GASOLINE ENGINE REMOVAL 5.3 GASOLINE ENGINE INSTALLATION To install the engine, reverse the previous steps. Engine Flexible Mountings Be certain that the operator presence plate moves Check the engine flexible mountings for condition and freely and that the fuel lines do not leak. security.
  • Page 24 Engine Torque Reaction Arm The diesel engine is secured to the main frame floor using flexible mounts. To resist the torque reaction of excessive engine movements an arm is attached to the top of the engine using flexible mounts. The opposite end of the arm is secured to the main frame.

  • Page 25: Diesel Engine Removal

    GLOW PLUG INDICATOR OIL PRESSURE LIGHT KEY SWITCH ALTERNATOR LIGHT HOUR METER TOP HOSE CONNECTION POINT STOP TIMER NOTE: The “Stop timer” cuts off fuel for 7 seconds to stop the engine. ie. The normally open fuel valve is energized closed for 7 secs.

  • Page 26: Diesel Engine Installation

    FLEXIBLE EXHAUST PIPE 11.Loosen the clamp for the air intake pipe at the engine and slide the pipe off the intake. 12.Unbolt the four (4) mounting nuts at the frame. Leave the extended mounting brackets attached to the engine. 13.Unbolt the engine torque arm from the engine. 14.The engine can now be lifted out of the back of the frame.

  • Page 27: Section 6 - Drive Train

    SECTION 6 - DRIVE TRAIN 6.1 BELL HOUSING & COUPLING 3. Drain the hydraulic fluid from the reservoir until the oil is below the pump suction hose. Pump Mounting 4. Disconnect and remove the suction hose. A machined cast aluminum bell housing is used to 5.
  • Page 28 13.Loosen the set screw and remove the coupling half from the engine shaft. Use a puller if necessary 10.Remove the four (4) socket head cap screws (see below). holding the pump to the bell housing (see below). 14.Inspect the shaft, key and keyway for wear or 11.Twist the pump and the bell housing at an angle to damage (see below).

  • Page 29: Pump To Coupling Reassembly

    6.3 PUMP TO COUPLING REASSEMBLY Coupling Engagement Measurements 1. Measure and record the dimension “A” i.e. the To reassemble the pump to the coupling, reverse the distance from the pump half coupling “rim” (see previous steps. When reassembling the pump and cou- figure 2 page 61) to the recessed face of the bell pling to the engine, the following checks and measure- housing.

  • Page 30: Hydraulic Pump Removal

    6.4 HYDRAULIC PUMP REMOVAL IDENTIFICATION OF PUMP PARTS FRONT BEARING BLOCK PUMP BODY DOWEL PIN SHAFT SEAL REAR BEARING BLOCK WOODRUFF KEY TAB WASHER REAR COVER SHAFT NUT CIRCLIP HEX. NUT & WASHER GEAR SET FRONT FACE SEAL TIE BOLTS FRONT FLANGE Hydraulic Pump Servicing Seal Replacement...
  • Page 31 Lift the gear set and front bearing block away from the Remove the rear cover and check the rear face seals front flange. Keep these grouped together to ensure for damage. No dowels are required for rear cover loca- correct reassembly. tion.

  • Page 32: Pump Reassembly

    6.5 PUMP REASSEMBLY Partially enter the seal using hand pressure to ensure the seal is square with the bore of the seal recess. Reassembly of the pump is simply a reversal of the previous procedure taking care to assemble the parts in the same order.

  • Page 33: Drive Motor

    Check the snap ring around its diameter to ensure it is Install the rear cover onto the pump body and check for seated and fully captive in the groove. proper location of rear face seals. No dowels are required for rear cover location. Place the gear set and front bearing block into the front The tie bolts will locate the rear cover onto the pump flange.
  • Page 34 Torqmotor Exploded Assembly 8 MATCHED SET Item Description Item Description Item Description Special Bolts Rotor Set Thrust Bearing End Cover Wear Plate Seal Seal Ring-Commutator Drive Backup Washer Seal Ring Thrust Bearing Housing Commutator Coupling Shaft O-Ring Commutator Ring Bearing/Bushing, Outer Bearing/Bushing, Outer Manifold Thrust Washer...
  • Page 35 thermal shock, or excess speed and require system center-line. Check the rotor lobe to roller vane investigation for cause and close inspection of end clearance with a feeler gage at this common cover, commutator, manifold, and rotor set. centerline. If there is more than .005 inches (0.13 mm) of clearance, replace rotor set.
  • Page 36 21.Inspect housing (18) assembly for cracks, the machined surfaces for nicks, burrs or corrosion. Remove burrs that can be removed without changing dimensional characteristics. Inspect tapped holes for thread damage. If the housing is defective in these areas, discard the housing assembly.
  • Page 37 3. Apply a small amount of clean grease to a new dirt NOTE: One or two alignment studs screwed finger tight and water seal (20) and press it into the housing into housing (18) bolt holes, approximately 180 (18) outer bearing counterbore. degrees apart, will facilitate the assembly and alignment of components as required in the following 4.

  • Page 38: Final Drive Train

    18.Apply grease to a new seal ring (4) and insert it in the seal ring groove exposed on the manifold. 19.Assemble the commutator ring (6) over alignment, studs onto the manifold. 20.Assemble a new seal ring (3) flat side up, into commutator (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up.
  • Page 39 Disassembly And Inspection 4. Remove the split pins from the “Half Links” then remove one or both half links from the chain as Roller Chain required (see below). 1. Remove the three hex. head bolts and two torque prevailing nuts that secure the chain guard. Then remove the chain guard (see below).
  • Page 40 3. Carefully tap the inner cone and roller assembly NOTE: The castellated nut lock must be selectively out of the inner bearing, together with the hub positioned to line up with the split pin hole. grease retainer. Removal Of Front Drive Hub 4.

  • Page 41: Section 7 - Hydraulic System

    SECTION 7 - HYDRAULIC SYSTEM 7.1 GENERAL DESCRIPTION Hydraulic Reservoir The large hydraulic reservoir (56 liters) is an integral The hydraulic system can be described as a basic part of the machine main frame. Fluid level is moni- open circuit. This simply means that oil is drawn from tored with the aid of a dip-stick.

  • Page 42: Stand-By Mode (Neutral)

    7.2 STAND-BY MODE (NEUTRAL) With all directional valves in the neutral position, and productive work, this mode is useful, by circulating oil the engine/pump running, the system is in the stand-by through both the pressure and return line filters and mode.

  • Page 43: Crowd Function-Bucket Tilt Down

    7.3 CROWD FUNCTION-BUCKET TILT DOWN The circuit segment below shows the flow path when plugged. This function can operate at the same time as the “Crowd” function lever is pushed forward to tilt the the “Lift” function because the lift function is fitted with a bucket or attachment down.

  • Page 44: Travel Forward Function

    7.4 TRAVEL FORWARD FUNCTION The circuit segment below shows the flow path when not attempted with the lift arms and attachment raised. both the travel function levers are pushed forward to Note how the valve flow for the left hand drive motor drive the machine in the forward direction.

  • Page 45: Travel Function - Rotate

    7.5 TRAVEL FUNCTION - ROTATE The circuit segment below shows the flow path when left hand drive motor doubles back through the series one travel function lever is pushed forward and the spool to connect with the parallel valve of the right hand other is pulled backwards.

  • Page 46: Lift Function - Lift Arms Raise

    7.6 LIFT FUNCTION - LIFT ARMS RAISE The circuit segment below shows the flow path “Lift” spool allowing the crowd function to operate at the function lever is pulled backward to lift the bucket or same time while the lift cylinder is moving. attachment up.

  • Page 47: Lift Function- Lift Arms Lower

    7.7 LIFT FUNCTION- LIFT ARMS LOWER The circuit segment below shows the flow path when operate at the same time while the lift cylinder is the “Lift” function lever is pushed forward to lower the moving. bucket or attachment down. This valve function is fitted with a series spool allowing the crowd function to CROWD CYLINDER...

  • Page 48: Valve Bank Disassembly

    7.8 VALVE BANK DISASSEMBLY Mark The Valve Bank 1. Before disassembly is started the end covers and The 6 section valve bank is the control center of the each section must be marked to ensure the correct machine. It is a specially built assembly that is arrangement and orientation when reassembling configured specifically for the machine.
  • Page 49 2. Tie Bolts - Remove the three (3) tie bolts which 5. Valve Back Cap - Remove the two (2) screws which hold the bank together, then separate the sections. fasten the back cap to the work section and then Remove the four (4) O-ring face seals, these remove the back cap.
  • Page 50 8. O-ring Retainer - Remove the O-ring retaining washer from each end of the work section. 9. Spool O-rings - Remove both O-rings from each RELIEF VALVE CARTRIDGE end of the working section and discard them. 10.Load Check - Remove the load check valve from the working section.
  • Page 51 Tie Rod Tightening Take care to tighten the three (3) tie rods evenly, failure to do so can cause the valve spools to jam through dis- PRESS POPPET tortion of the working sections. Also take care not to pinch the section O-ring face seals. After the tie rods have been tightened, operate each spool lever check- ing for free and smooth spool movements.

  • Page 52: Trenching Valve

    With the engine running at normal operating speed Service Port Relief Valve Adjustment select the Crowd function. When the cylinder is fully Attach a pressure gauge (0-4000 psi) to the pressure extended continue to hold the lever in the Crowd test point at the hydraulic pump outlet.
  • Page 53 Trencher Connections “A” & “C” When using other PTO functions on “A” & “B” couplings, valve Item 5 makes it possible to still get 210 Connection “A” must be used to power the trencher bar. (3000 psi) from coupling “B”, because its outlet is motor, note this is a female coupling to avoid incorrect now effectively blocked by counterbalance valve Item 4 connection with “C”...
  • Page 54 TRENCHER VALVE DRAWING SHOWING PORT POSITIONS Item numbers relate to trencher circuit sketches opposite 7 - 54...
  • Page 55 Trencher Valve Circuit Description When the PTO is engaged to power the trencher oil flow from the “a” port of the PTO valve is directed to the CIRCUIT SKETCH 2 VLVA port of the trencher valve. (regulated flow) Pilot pressure builds against the pressure compensated valve Item 7 to shift its spool diverting pressure and flow to the trencher motor via coupling “A”.
  • Page 56 Pressure Compensator Cartridge Description 2. Attach trencher to loader and connect hose into auxiliary hoses. The cartridge is a pressure compensating element, used with a variable orifice to yield a three port (by- 3. Set engine rpm to full speed. pass type) pressure compensated, flow regulating 4.

  • Page 57: Hydraulic Cylinders

    3. Adjust Sequence Valve 1. This cartridge is one of the two cartridges located on the top of the manifold and is silver in color. With the trencher motor running in reverse and a gage located at the pump, loosen the lock nut and turn the allen screw adjustment until the pressure on the gage is 2700 psi.
  • Page 58 GLAND PISTON 4. Firmly hold the piston rod in a soft jawed vice at the rod clevis end. Note the piston retaining nut has two centre punch marks to deform the thread and hold the nut captive (see below). 6. Remove the piston retaining nut (see below). 5.
  • Page 59 Rod Gand Lipseal “cup end” 8. Thoroughly remove and clean all old “Locktite” Dirt shedding Rod Wiper seal away from the piston and the inside diameter of the piston. Remove seals and thoroughly wash all cylinder parts with a petroleum based solvent. 10.Using a new seal kit replace the Piston seal and its two back-up rings.
  • Page 60 Cylinder Assembly 1. Firmly hold the piston rod in a soft jawed vice. CAUTION: Be sure to put the Gland retainer and Gland bearing onto the piston rod first before attaching the piston and piston retaining nut (see below). 5. Replace and tighten the piston retaining nut (see below).
  • Page 61 7. Clamp the clevis end of the cylinder barrel in a soft jawed vice and apply hydraulic oil to the cylinder bore and piston (see below). Final Check If available connect the cylinder to a test stand and stroke the cylinder in and out several times checking for smoothness of operation after the air has been purged from the cylinder.

  • Page 62: Overcenter Valve

    3. Then rotate the peg wrench counter clockwise until the “drive end” of the retaining ring is opposite the access window. Remove the retaining ring. N.B. Inspect the drilling in the gland bearing that receives the “drive end” of the retaining ring (see below).

  • Page 63: Quick Disconnect Couplings

    2. Back off the adjusting screw lock nut and use an 7.12 QUICK DISCONNECT COUPLINGS Allen wrench for adjustment (see below). The only maintenance on the male and female coupling halves is replacement. Replacement of the Quick Disconnect coupling is carried out with the system shut down.

  • Page 64: Section 8 - Fuel System

    SECTION 8 - FUEL SYSTEM The two "T" shaped fuel tanks are located on each side The balance pipe between each tank ensures fuel of the unit attached to the main frame above the drive usage is even in each tank. wheels.
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