Gravely Skidster 200 User manual

2
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
TABLE OF CONTENTS

1 - 3
1.1 THE MANUAL
It is the purpose of this manual to provide complete
instructions for service, maintenance, disassembly,
repair, and installation of the mechanical components
for the Skidster 200.
Dealer trained service personnel should use this
manual as a supplement to and reminder of the training
sessions conducted by the company.
Read all information for servicing a part of system
before repair work is started to avoid needless
disassembly.
Operation
Before operation of the unit, carefully and completely
read manuals supplied with the unit. The contents will
provide you with an understanding of safety
instructions and controls during normal operation and
maintenance.
Safety Messages
For your safety and the safety of others always read,
understand, and follow all DANGER, WARNING, and
CAUTION messages found in manuals and on safety
decals.
Directional Reference
All reference to left, right, front, or rear are given from
the operator in the operator position and facing the
direction of forward travel.
Notation Definitions
NOTE: General reference information for proper
operation and maintenance practices.
IMPORTANT: Specific procedures or information
required to prevent damage to the unit or the
attachment.
1.2 TECHNICAL SERVICE
COMMUNICATIONS
Ariens Technical Service communicates information to
the field using Service Letters, Service Bulletins,
Product Notices, and Campaigns. Each communication
signifies a type of information and priority. The dealer is
responsible to carry 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 product
improvements.
Service Bulletin
Notification to update products to resolve certain
issues or a notification of a policy change.
Product Notices
Notification of limited product located in a certain
region. This is a limited distribution to only those who
received the product involved.
Campaigns
Notification of a safety related issue. All product must
be updated and are tracked by the factory until all units
are corrected.
1.3 PRODUCT REGISTRATION
A warranty registration card must be filled out, signed,
and returned at the time of purchse. This card activates
the warranty. Claims meeting requirements during
limited warranty period will be honored.
1.4 UNAUTHORIZED REPLACEMENT
PARTS
Use only Gravely replacement parts. The replacement
of any part on this vehicle with anything other than a
Gravely authorized replacement part may adversely
affect the performance, durability, or safety of this unit
and may void the warranty. Gravely disclaims liability
for any claims or damages, whether warranty, property
damage, personal injury, or death arising out of the use
of unauthorized replacement parts.
1.5 DISCLAIMER
Gravely reserves the right to discontinue, make
changes to, and add improvements upon its products
at any time without public notice or obligation. The
descriptions and specifications contained in this
manual were in effect at printing. Equipment described
within this manual may be optional. Some illustrations
may not be applicable to your unit.
SECTION 1 - INTRODUCTION

2 - 4
2.1 SAFETY ALERTS
Look for these symbols to point out
important safety precautions. They
mean:
Attention!
Personal Safety Is Involved!
Become Alert!
Obey The Message!
2.2 SIGNAL WORDS
The safety alert symbol is used in decals on the unit
and with proper operation procedures in this manual.
They alert you to the existence and relative degree of
hazards.
Understand the safety message. It contains important
information about personal safety on or near the unit.
2.3 NOTATIONS
NOTE: General reference information for proper
operation and maintenance practices.
IMPORTANT: Specific procedures or information
required to prevent damage to unit or attachment.
2.4 PRACTICES AND LAWS
Practice usual and customary safe working
precautions, for the benefit of yourself and others.
Understand and follow all safety messages. Be alert to
unsafe conditions and the possibility of minor,
moderate, or serious injury or death. Learn applicable
rules and laws in your area.
2.5 REQUIRED OPERATOR TRAINING
Original purchaser of this unit was instructed by the
seller on safe and proper operation. If unit is to be used
by someone other than original purchaser (loaned,
rented or sold) ALWAYS provide this manual and any
needed safety training before operation.
SPARK ARRESTER
This product is equipped with an internal combustion
type engine. DO NOT use unit on or near any
unimproved, forest-covered, or brush covered land
unless exhaust system is equipped with a spark
arrester meeting applicable local, state, or federal laws.
A spark arrester, if it is used, must be maintained in
effective working order by operator.
2.6 PREPARATION
Before starting any removal of parts, proper
preparation is very important 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 incidence of misplaced tools or parts: place
removed components with all attaching hardware in the
order of disassembly on a clean work surface.
Tools, instruments, and parts needed for the job should
be gathered before work is started. Interrupting a job to
locate tools or parts is a needless delay. A list of
required special tools has been included in this
manual.
2.7 SERVICE POSITION
To ensure the unit is positioned in the proper service
position:
1. Place jack stands under rear transaxles only.
2. If jacks are not available, place support blocks
under under the frame at the rear of the unit.
2.8 CLEANING AND STORAGE
IMPORTANT: Never spray unit with water or store unit
outdoors. Water can seep into sealed bearings, which
are sealed against dirt and debris only, causing
reduced component life.
A unit that is excessively dirty should be cleaned before
work starts. Cleaning will occasionally uncover trouble
sources. Dirt and abrasive dust reduce the efficient
work life of parts and can lead to costly replacement.
SECTION 2 - SAFETY
DANGER: IMMINENTLY HAZARDOUS
SITUATION! If not avoided, WILL RESULT in
death or serious injury.
WARNING: POTENTIALLY HAZARDOUS
SITUATION! If not avoided, COULD RESULT
in death or serious injury.
CAUTION: POTENTIALLY HAZARDOUS
SITUATION! If not avoided, MAY RESULT in
minor or moderate injury. It may also be used
to alert against unsafe practices.
WARNING: ALWAYS block wheels and know
that jack stands or blocks used are stable,
strong, or secure and will hold the weight of
the unit during maintenance.
WARNING: AVOID SHARP EDGES which
can cut. Movement of parts can cut off fingers
or a hand. Wrap blade(s), wear gloves, and
use extreme caution when servicing.

2 - 5
When taking unit out of extended storage:
1. Check for any damage or loose parts. Repair,
replace, or tighten hardware before operation,
especially blade attachment bolts.
2. If a preservative fluid was used in fuel tank, drain
and discard. Fill fuel tank with fresh new fuel.
2.9 SAFETY RULES
Walk Around Inspection
Complete a walk around inspection of unit and work
area to understand:
• Work area.
• Your unit.
• All safety decals.
Work Area
ALWAYS check overhead and side clearances carefully
before operation. ALWAYS be aware of traffic when
operating along streets or curbs.
ALWAYS keep hands and feet within the limits of the
unit.
Keep children, people, and animals away. Keep
children out of work area and under watchful care of a
responsible adult.
Keep area of operation clear of all toys, pets, and
debris. Objects can cause vehicle instability and injury.
Check for weak spots on dock, ramps or floors. Avoid
uneven work areas and rough terrain. Stay alert for
hidden hazards.
DO NOT run engine in an enclosed area. Always
provide good ventilation.
Mark and know location of all utility lines before
operation. Always check with local utilities before
digging.
Unit
ALWAYS keep protective structures, guards, and
panels in good repair, in place and securely fastened.
NEVER modify or remove safety devices.
Check Safety Interlock System for proper operation
daily (see Operation section). Do not operate unless
system operates properly.
Operation
Understand:
• How to operate all controls
• The functions of all controls
• How to STOP in an Emergency
• Speed ranges
Do not operate any of the control levers or auxiliary
power take-off unless both feet are standing on the
platform.
Before starting engine, disengage auxiliary power.
DO NOT travel at too fast a rate. DO NOT change
engine governor settings or over-speed engine.
Always back up 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 remove key to
prevent unauthorized use.
Never carry passengers on any part of unit.
Avoid uneven and rough terrain. DO NOT operate near
drop offs, ditches, or embankments. Unit can suddenly
turn over if a wheel is over the edge of a cliff or ditch, or
if an edge caves in.
Check the capacity of the attachment in use.
Exceeding this limit may cause instability.
If tires lose traction, turn off auxiliary power and
proceed slowly straight down slope. Avoid wet
surfaces.
Avoid parking on a slope. If necessary, use wheel
chocks.
DO NOT leave unit unattended on a slope ALWAYS
use wheel chocks when leaving unit.
ALWAYS operate unit with good visibility and light.
Fuel is highly flammable and its vapors can explode.
Use ONLY approved fuel containers.
NO Smoking!
NO Sparks!
NO Flames!
Allow engine to cool before servicing.
NEVER fill fuel tank when engine is running, hot, or
unit is indoors.
Abnormal Vibrations are a warning of trouble. Striking a
foreign object can damage unit. Lower attachment,
immediately stop unit and engine. Remove key and
wait for all moving parts to stop. Remove wire from
spark plug. Inspect unit and make any necessary
repairs before restart.
Hazardous Slopes
DO NOT operate on steep slopes. Avoid operating on
slopes. When you must operate on a slope, travel up
and down the slope. Never operate cross a slope. With
a loaded bucket, operate with the bucket uphill. With an
unloaded bucket, operate with the bucket down hill.
Always move the vehicle with the lift arms in its lowest
operating position. Never operate on a slope greater
than 10 degrees.
Child Safety
NEVER allow children to operate or play on or near
unit. Be alert and shut off unit if children enter area.
Personal Safety
Read and obey all warning, caution, and instructions
on the unit and in provided manuals.
• Only trained adults may operate unit.

2 - 6
• Training includes actual operation.
• Clearly understand instructions.
• Be alert! Conditions can change.
NEVER operate unit after or during the use of
medication, drugs or alcohol. Safe operation requires
your complete and unimpaired attention at all times.
NEVER allow anyone to operate the unit when their
alertness or coordination is impaired.
DO NOT operate unit without wearing adequate outer
garments. Wear adequate safety gear and protective
gloves. Wear proper footwear to improve footing on
slippery surfaces.
Protect eyes, face, and head from objects that may be
thrown from unit. Wear appropriate hearing protection.
Avoid Sharp Edges. Sharp edges can cut. Moving
parts can cut or amputate fingers or a hand. Wear
gloves to service unit when handling sharp edges.
ALWAYS keep hands away from any pinch points.
ALWAYS keep hands and feet away from all moving
parts during operation. Moving parts can cut off body
parts.
DO NOT touch unit parts which might be hot from
operation. Allow parts to cool before attempting to
maintain, adjust, or service.
Keep the operator platform free of dirt, grease, or mud.
NEVER place feet under the platform.
Do not tie yourself to the unit.
Controls
Come to a complete stop before reversing.
Never jerk the control levers. Always use a steady even
action to achieve smooth control.
When using attachments, ensure that they are
attached correctly with latch pins engaged and practice
the operation before beginning work.
Always be aware of obstructions that may cause injury
to operator or damage to the unit.
Avoid loss of control or tipping. Do not carry a load with
the lift arms raised. Always carry load close to ground.
Do not step off the platform when lift arms are raised.
Always ensure there is ample overhead clearance.
Keep alert with eyes fixed in direction of travel.
Do not travel 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 of each day
and repair any damage or defects.
ALWAYS block wheels and know all jack stands are
strong and secure and will hold weight of unit during
maintenance.
When performing service which requires arms to be
raised, make sure cylinder lock is in position and
secure.
Keep nuts and bolts tight and keep equipment in safe
operating conditions.
Before maintenance, adjustments, or service (except
where specifically recommended), shut off engine.
Allow hot parts to cool.
Keep unit free of dirt, stones, and other debris. Clean
up oil or fuel spills.
Storage
DO NOT store unit inside a building with fuel in the fuel
tank where any ignition sources are present. Allow unit
to cool completely.
ALWAYS clean unit before extended storage. See
Engine Manual for proper storage.
Battery
Avoid Electric Shock. DO NOT reverse battery
connections.
Explosive Gases! Poisonous battery fluid contains
sulfuric acid and its contact with skin, eyes, or clothing
can cause severe burns.
No flames. No sparks. No smoking near battery.
Always wear safety glasses and protective gear near
battery.
DO NOT TIP battery beyond a 45oangle in any
direction.
ALWAYS KEEP BATTERIES OUT OF REACH of
children.
Transport
Use extra care when loading or unloading unit onto
trailer or truck. Secure unit chassis to transport vehicle.
Always use the tie down lugs provided on each side of
the unit to secure the unit when transporting by truck or
trailer.
NEVER secure from rods or linkages that could be
damaged.
Always use the lifting lug at the top of the unit when
lifting the unit with an appropriate crane on a
construction site.
DO NOT transport with attachment in raised position.
Lower attachment when unit is parked or stored unless
a positive mechanical lock is used.
Attachments and Accessories
Use only attachments or accessories designed for your
unit.

3 - 7
SECTION 3 - SPECIFICATIONS
950001
Skidster 200 950002 Skidster 200 950003 Skidster 200
Performance
Rated lift capacity w/
standard bucket 300 lbs. (130 kg) 300 lbs. (130 kg) 300 lbs. (130 kg)
Travel speed 3.75 mph (6 kph) 3.75 mph (6 kph) 3.75 mph (6 kph)
Operating weight 1430 - 1540 lbs. (650
0700 kg.) 1430 - 1540 lbs. (650 0700 kg.) 1430 - 1540 lbs. (650 0700 kg.)
Engine
Honda 20 hp 20 hp
Kubota (water cooled) 19.7 hp
Fuel Type See Engine Manual See Engine 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 29 cubic inch 29 cubic inch
Drive chains ASA 60 ASA 60 ASA 60
Hydraulics
Hydraulic gear pump 11 cc 11 cc 11 cc
Total output rating 10.5 gpm (40 l) 10.5 gpm (40 l) 10.5 gpm (40 l)
System relief pressure 2950 psi (200 bar) 2950 psi (200 bar) 2950 psi (200 bar)
Reservoir capacity 15 gals (56 l) 15 gals (56 l) 15 gals (56 l)
Filtration 10 micron 10 micron 10 micron
Standard Bucket
Capacity 3.5 cu. ft. (.100 cu m) 3.5 cu. ft. (.100 cu m) 3.5 cu. ft. (.100 cu m)

4 - 8
4.1 CONTROLS AND FEATURES
SECTION 4 - GENERAL MAINTENANCE & ADJUSTMENTS
11 12
20
15
14
12
19
16
14 18
17 13
Skidster 200 Skidster 200
Skidster 200
Skidster 200D
ENGLISH
1. Auxiliary Cylinder Control
2. Lift Arm Control
3. Left Traction Control Lever
4. Right Traction Control Lever
5. Attachment Tilt Control
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 (2)
15.Muffler
16.Lift Arms
17.Crowding Cylinder
18.Standard Bucket
19.Lift Lug
20.Tie Down Lugs (2)
21.Throttle Control**
22.Traction Selector Knob
(Optional)
23.Hour Meter**
24.Temperature Warning Light**
25.Oil Pressure Warning Light**
26.Glow Plug**
27.Ignition Switch**
* Gasoline Models Only
**Diesel Models Only

4 - 9
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.
Store fuel in an approved container. Keep out of reach
of children.
1. The unit should be parked on a level surface with
the lift arms lowered, the engine off, and the key
removed.
2. Clean around the fuel tank cap on each tank before
removing. Refer to Engine Manual for correct type
and grade of fuel. Leave 1 to 2 inches (25mm to
50mm) of air space below the bottom of the filler
neck. Air space in the tank will allow the fuel to
expand. Never fill the fuel tank completely full.
3. Replace the fuel tank cap on each tank securely.
Wipe up any fuel that may have spilled.
4.3 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 as required. Check all pivot points
for wear or elongation, pivot pins for wear, and
bushings for security.
Bushings
The bushing protect the mainframe and other major
fabricated components from wear. These bushings,
although unlikely to wear, can be pressed out and
replaced if worn or damaged. The following illustrations
indicate the location of bushings.
WARNING: POTENTIAL HAZARDOUS! Fuel
is extremely flammable and highly explosive.
Personal injury and property damage may
result if not handled properly.
• Fill the fuel tank outdoors in an open area.
Do not fill when the engine is hot. Wipe up
any fuel spills.
• Never fill the fuel tank completely full.
Empty space in tank allows fuel to
expand.
• Never smoke when handling fuel. Stay
away from open flames. Fuel fumes can
be ignited by sparks.
Bushing
Lift Cylinder Lower Pivot Point
Bushings

4 - 10
Pivot Pin Maintenance
The pivot pins are fitted with a grease nipple leading to
a radial drilling that lubricates the bearing surfaces of
the pin and its mating hardened bushing. All pivot pins
should be greased weekly.
Pivot Pin Wear Tolerance
The pivot pins are not as hard as the bushings they
rotate within and therefore more likely to show signs of
wear after a long period of working operations. The
main diameter of the pin will measure 25 mm (0.984”)
when new. Permissible wear before replacement will
measure 24 mm (0.945”) diameter, beyond this the pin
must be replaced.
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. Start the unit and move it forward to expose the
sections of the chain that are not lubricated.
4. Stop the engine.
5. Apply oil to the newly exposed chain.
4.5 LUBRICATE REAR HUBS
Disassemble Hubs
1. Place the unit on jackstands. Remove the wheels
from the unit.
2. Remove the hub grease cap, take out the split pin
and remove the slotted nut from the end of the
axle.
3. Withdraw the hub from the stub axle and remove
the outer bearing cone assembly from the hub.
4. Carefully tap the inner bearing cone out of the hub,
together with the grease seal.
5. Using a suitable drift punch, drive the two bearing
cups out of the hub. The inner bearing cup is
removed from the outer end of the hub and the
outer bearing cup from the inner end of the hub.
Attachment Plate
Bushings
Pin Wear tolerance 25 - 24 mm

4 - 12
To grease items 1-4:
1. Lower the lift arms and turn the ignition key to
“OFF” to stop the engine. Remove the key.
2. Clean the grease fittings by wiping with a rag.
3. Connect a grease gun to the fitting. Pump grease
into the fittings until grease begins to visually ooze
out of the bearings.
4. Wipe up any excess grease.
To grease lift arm cylinder:
1. Raise lift arms by starting unit.
2. Stop the engine and the remove key.
3. Engage the cylinder lock.
4. Remove the front panel that is ahead of the
cylinder by removing the 4 capscrews securing it.
5. Apply grease as outlined above, to the upper and
lower fittings.
6. Replace the panel.
7. Disengage and secure the cylinder lock.
8. Start the engine
9. Lower the lift arms.
10.Stop the engine and remove the key.
4.8 CHECKENGINEOILLEVEL-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.
1. The unit should be parked on a level surface with
the 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. Inspect end for oil level and add crankcase
oil as needed. DO NOT OVERFILL.
4.9 CHECK ENGINE OIL LEVEL-DIESEL
Check the engine oil level before starting the machine.
Wait a minimum of five minutes after stopping the unit
to check the oil level.
1. The unit should be parked on a level surface with
the 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. Inspect end for oil level and add crankcase
oil as needed. DO NOT OVERFILL.
IMPORTANT: When using oil that is different from that
in the unit, be sure to drain all oil before adding the new
type, refer to Change Engine Oil-Diesel Models.
5. After adding oil, wait 5 minutes and check the oil
level again.
4.10 CHANGE ENGINE OIL- GASOLINE
Change oil after every 25 operating hours. Change
more frequently when operating conditions are
extremely dusty.
Crankcase Capacity: with filter, 1.3 qt. (1.2 l)
Oil Type: Detergent oil (API service SG or SH)
Viscosity: See table below.
12
3
3
4(One each
side)
Lower

4 - 13
The engine has a plugged drain line hose permanently
attached to the engine sump to facilitate easy draining
of the engine oil.
1. Warm the oil by running the engine for five to ten
minutes.
2. The unit should be positioned and parked so the
drain plug is on the lowest side.
3. Lower the lift arms and chock the wheels. Stop the
engine and remove the key.
4. Remove the oil filler cap.
5. The drain hose is stored on the main frame floor of
the unit. Pull the hose out, hold the end of the hose
up above the engine oil level and remove the hose
plug. Then direct the hose end into a suitable
container.
6. When oil has drained completely, replace the hose
drain plug and tighten securely.
NOTE: Dispose of used oil at a certified recycling
center.
7. Pour 80 to 90% of the new oil, 1.3 qt. (1.2 l) into the
filler tube.
8. Start the engine and move the unit to level ground.
Stop engine.
9. Check the oil level and add engine oil as needed.
Refer to Check Engine Oil. Do not overfill.
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.
1. The unit should be positioned and parked so the
drain plug is on the lowest side.
2. Lower the lift arms and chock the wheels. Stop the
engine and remove the key.
3. Remove the oil filler cap.
4. The drain hose is stored on the main frame floor of
the unit. Pull the hose out, hold the end of the hose
up above the engine oil level and remove the hose
plug. Then direct the hose end into a suitable
container.
5. When oil has drained completely, replace the hose
drain plug and tighten securely.
6. Add new engine oil up to the upper level on the oil
level gauge.
4.12 CHANGE ENGINE OIL FILTER
Replace the oil filter every 25 hours, or each time the
engine oil is changed.
1. Drain the oil from the engine. The drain hose is
stored on the main frame floor of the unit. Pull the
hose out, hold the end of the hose up above the
engine oil level and remove the hose plug. Then
direct the hose end into a suitable container.
above 77oF (25oC) SAE30 or SAE 10W-30
32 to 77oF (0 to 25oC) SAE20 or SAE 10W-30
SAE 10W-40
below 32oF (0oC) SAE10W or SAE 10W-30
SAE 10W-40
Drain Hose
Cap

4 - 14
2. Remove the old filter by turning counterclockwise
and let the remaining oil drain out. Properly discard
the oil filter. Wipe filter base clean.
3. Lubricate the new filter’s O-ring with a thin coat of
fresh oil.
4. Screw the new filter clockwise until it makes
contact with the sealing surface. Tighten filter
another 1/2 turn.
5. Fill the crankcase to the proper level with oil. Do
not overfill.
6. Start the engine and check the filter for leaks.
7. Stop the engine and recheck the oil level, adding if
necessary, to bring to the proper level.
4.13 CHECKING ENGINE COOLING
CHECK COOLANT LEVEL- Diesel
Check the coolant level before every operation.
1. Remove the radiator cap and check to see that
coolant reaches the supply port.
2. Check the coolant level of the reserve tank. When
the reserve tank registers between “FULL” and
“LOW” the coolant is at the correct level.
3. When 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- Diesel
Capacity: 0.82 gal (3.1 l)
1. Remove radiator cap.
2. Place suitable containers under the two drain
cocks and open.
3. Remove the overflow pipe from the reserve tank to
drain the tank.
4. Close drain cocks and replace the overflow pipe.
5. Fill the radiator and reserve tank to the proper
level, refer to Check Coolant Level-Diesel Models.
6. Reinstall radiator cap being sure the proper seal is
made to prevent loss of coolant.
WARNING: To avoid personal injury DO NOT
remove the radiator cap when the engine is
hot. When safe, loosen cap slightly to the first
stop to relieve any excess pressure before
removing cap completely.
Diesel Models
Oil Filter
WARNING: To avoid personal injury DO NOT
remove the radiator cap when the engine is
hot. When safe, loosen cap slightly to the first
stop to relieve any excess pressure before
removing cap completely.
Drain Cock
Drain Cock

4 - 17
IMPORTANT: Do not substitute automotive oil.
Hydraulic system damage may result.
2. Place a drain pan under the drain plug that will hold
at least 17 gallons (67 l).
3. Remove the drain plug. Allow the fluid to
completely drain out.
4. Reinstall the drain plug.
5. Fill the hydraulic tank with approximately 15 gal.
(57 l) of ISO 68 or equivalent (refer to Check
Hydraulic Fluid).
NOTE: Dispose of used oil at a certified recycling
center.
4.20 CHANGE HYDRAULIC FILTERS
The hydraulic system is protected by two filters, a high
pressure filter immediately down stream of the gear
pump and a spin-on return line filter mounted on a
stand-pipe at the right hand side of the reservoir
(opposite the dip-stick fill point). Both filters are fitted
with 10 micron elements.
Change the hydraulic filters after the first 8 operating
hours and again after every 100 operating hours.
Spin-on Filter
1. Position unit on a level surface, lower the lift arms,
stop the engine, and remove key from ignition
switch.
IMPORTANT: Do not substitute automotive oil.
Hydraulic system damage may result.
2. Place drain pan under filter.
3. Turn old filter counterclockwise to remove.
4. Wipe unit mating surface clean.
5. Lubricate the rubber gasket on the new filter with a
thin coat of hydraulic fluid.
6. Turn the new filter clockwise until it makes contact
with the sealing surface. Tighten filter another 1/2
turn.
High 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
fasten the flat plate over wheel motors.
5. Place oil pan below canister.
6. Remove oil canister with a 1” wrench.
7. Replace filter element.
8. Reinstall filter canister and flat panel.
9. Clean up any spilled fluids.
10.To remove air from the system, start the engine
and run for two to three minutes.
11.Observe fluid level and add oil as needed. Do not
fill past “Full” mark on dipstick.
4.21 CHECK HYDRAULIC LINES
Check hydraulic lines after every 100 hours of opera-
tion. Inspect for wear, cracks, loose connections, leaks,
etc. If hydraulic components require service, stop
engine and move all hydraulic controls in both direc-
tions before any disassembly. Repair hoses as needed.
Moving hydraulic hoses should be replaced every two
years or as wear dictates.
Spin-on
Oil Filter
WARNING: HYDRAULIC FLUID UNDER
PRESSURE can penetrate skin and cause
severe burns that can result in death or
serious injury.
ALWAYS keep body and hands away from pin
holes or nozzles which eject hydraulic fluid
under pressure. ALWAYS use paper or card-
board and not hands to search for leaks.
KNOW that all hydraulic fluid connections are
tight and all hydraulic hoses and lines are in
good condition BEFORE applying pressure to
system.
Foreign fluid injected into skin must be surgi-
cally removed within a few hours by a doctor
familiar with this form of injury or gangrene
may result.
High
Pressure
Filter

4 - 18
4.22 CHECK TRACTION DRIVE CHAIN
TENSION
IMPORTANT: If conditions are sandy, an additional 1/2
inch of slack should improve chain performance.
Each front hub is direct-coupled to a hydraulic motor.
The rear hubs are mounted on a fixed axle with the
hubs running on tapered rolled bearings. The front hub
drives are connected to the rear hubs by a roller chain.
A sliding chain tensioner takes up slack in the chain.
The chain tensioner is self compensating for direction
of travel. The drive chains are enclosed with a steel
chain guard. Each of the two roller chains are fitted with
two “half links” that can be removed to shorten the
chain as wear and slack increase.
To check chain tension:
1. Place the unit on jackstands. Remove the wheels
from the unit.
2. Remove the three hex head bolts and two nuts that
secure each chain guard. Remove the guards.
3. On each side, check chain for proper slack by lifting
the chain tensioner up by hand. If the top plastic
slider of the chain tensioner comes within 1/2”
(13 mm) of 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 chain tension:
5. If chain is too slack, first try reversing tensioner
blocks. If this is insufficient, removal of chain half
links is required.
6. Remove the split pins from the “half links” then
remove one or both half links as needed.
NOTE: The split pins on the right hand side are
arranged to oppose the pins on the left hand side. This
is important to prevent the pins from being “snagged”
during chain movements.
NOTE: While the chain is off the sprocket check for
damage such as broken rollers. Replace if wear or
damage is excessive.
7. Wash the chain in a petroleum based solvent.
Allow to dry, then soak in oil.
8. Install the chain around the sprockets and
between the tensioners.
FINAL DRIVE TRAINRear Hub
Chain Tensioner
Front Hub
Note how the split pins on the right hand
side are arranged to oppose the pins on the
left hand side, this is important in preventing
the pins from being “snagged” during chain
movements causing possible pin removal.
Split Pins
Normal Sprocket Worn Sprocket
Normal Sprocket Worn Sprocket

4 - 20
Adding Water to the Battery
Under normal operating conditions the battery fluid lev-
els may become lower. To bring the fluid up to the
required level, add distilled water.
1. Clean the top of the battery and remove the filler
caps.
2. Inspect each cell to determine the fluid level. The
level should be even with the bottom of the fill
tubes.
3. Add distilled water to each cell as needed.
4. Replace the filler caps. Clean up spills with water
and paper towels.
Measuring Specific Gravity
Using a hydrometer, measure the specific gravity of the
electrolyte in each cell. When the reading is below
1.2 at 68 oF (20 oC), recharge the battery.
4.24 CHARGE BATTERY
IMPORTANT: Always keep the battery charged
(1.26 specific gravity) to prevent battery damage when
the temperature is below 32 oF (0 oC).
1. Before charging, check the electrolyte level, refer to
Checking Electrolyte Level.
2. Follow the charger manufacturer’s instructions for
safe procedures. It is advisable that the battery be
charged as slowly as possible since quick charging
will shorten the battery service life. When the
battery has to be charged quickly, the charging
current should be held to 2.0A maximum.
3. Connect the battery charger to the battery posts.
Do not overcharge the battery.
4. After charging, flush the outside of the battery with
water.
4.25 REPLACINGFUELFILTER-GASOLINE
Replace the fuel filter once each year or after every 200
operating hours whichever occurs first. Never install 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 fuel filter to catch any
drips and remove the filter.
5. Install a new filter and reattach the hoses. Move
the hose clamps close to the filter.
6. Un-clamp the fuel line.
4.26 CLEAN FUEL FILTER-DIESEL
Check and completely clean the fuel filter with clean
fuel oil if it is contaminated with deposits, water, etc.
The filter element should be replaced every 500 ser-
vice hours, or sooner if it is stained or broken. If the fuel
appears to be contaminated, check the filter carefully
and replace it even if the maximum number of service
hours has not been reached.
1. Close the fuel filter.
2. Remove the top cap and rinse the inside with
diesel fuel.
3. Remove the element and rinse it with diesel fuel.
4. After cleaning, reinstall the fuel filter.
5. The filter is equipped with an automatic vent. any
air in the fuel system will be pumped out through a
check valve in the top of the fuel filter.
WARNING: FROZEN BATTERIES CAN
EXPLODE and result in death or serious
injury.
DO NOT charge a frozen battery. Let the
battery thaw out before putting on a charger.
Clean inside filter Every 300 hours 100 hours (First
time)
Replace filter
element Every 500 hours
Applicable
Model 2,3TN66E 3TNA72E 3TN75E, 3TNC78E, 3,4TN82(84)(T)E
Type Paper
Filtration
Area 67 in2
(432 cm2)67 in2 (432 cm2)139.5 in2(900 cm2)
Filtration
grain
diameter
10 - 15µ8 - 9µ8 - 9µ
Air venting
method Plug Auto-air venting Auto-air venting
Element
Code 124550- 55700 119810- 55650 129100-55650
Lever
Fuel Filter