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Smithco TCV 2200 32-000 Parts & Service & Operators Manual

Super truck turf care vehicle
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Parts & Service
& OPERATORS MANUAL
TCV 2200
Super Truck Turf Care Vehicle
Model 32-000
SN: DT2213
August 2013
Product Support:
Hwy SS & Poplar Ave; Cameron WI 54822
1-800-891-9435
productsupport@smithco.com

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  • Page 1 Parts & Service & OPERATORS MANUAL TCV 2200 Super Truck Turf Care Vehicle Model 32-000 SN: DT2213 August 2013 Product Support: Hwy SS & Poplar Ave; Cameron WI 54822 1-800-891-9435 productsupport@smithco.com...

  • Page 2: Table Of Contents

    CONTENTS Introduction................1-5 Introduction ................1 Safe Practices ................. 2 Specifications ................3 Setup ..................4 Controls & Instruments ............5 Service ..................6-13 Operation ................6-7 Maintenance ................. 8-9 Adjustments................10 Service Chart ..............11-12 Storage .................. 13 Diagrams ................14-17 Wiring Diagram ..............

  • Page 3: Introduction

    INTRODUCTION Smithco Smithco Smithco Smithco Smithco Thank you for purchasing a product. Read this manual and all other manuals pertaining to the Dump Truck carefully as they have safety, operating, assembly and maintenance instructions. Failure to do so could result in personal injury or equipment damage.

  • Page 4: Safe Practices

    16. Keep the area of operation clear of all bystanders. 17. Stop engine before making repairs/adjustments or checking/adding oil to the crankcase. 18. Use parts and materials supplied by Smithco Smithco only. Do not modify any function or part. Smithco Smithco Smithco 19.

  • Page 5: Specifications

    SPECIFICATIONS WEIGHTS AND DIMENSIONS Length 108" (274 cm) Width 60" (152 cm) Height w/ ROPS 71" (180 cm) Inside Turn Circle 120" (305cm) Outside Turn Circle 230" (584 cm) Weight Empty 1289 lbs (585 kg) Payload 2200 lbs (998 kg) SOUND LEVEL (DBA) At ear level 96 dBA...

  • Page 6: Setup

    SET UP The Dump Truck arrives from Smithco setup and ready for service. Depending on freight conditions battery may need to be installed. 1. Check the tire pressure. The front tires are 18 psi (1.2 bar) and rear tires are 20 psi (1.4 bar).

  • Page 7: Controls & Instruments

    CONTROLS & INSTRUMENTS A. Oil Light - The oil light should come on when the ignition is on without the engine running and go out when the engine is running. The oil light will light when the oil pressure is low. If oil light should come on, shut engine off immediately and find the cause.

  • Page 8: Service

    OPERATION Before operating the Smithco Dump Truck, become familiar with all controls and functions. Also complete all maintenance requirements and read all safety warnings. Knowing the Dump Truck thoroughly, how it operates, and by doing the prescribed maintenance steps, you can expect trouble free operation for years to come.
  • Page 9 OPERATION HILLSIDE OPERATION Do NOT stop or start suddenly on any slope. Be especially cautious when changing direction. Do NOT operate on slopes greater than 10°. BATTERY Batteries normally produce explosive gases which can cause personal injury. Do not allow flames, sparks or any ig- nited object to come near the battery.

  • Page 10: Maintenance

    MAINTENANCE Before servicing or making adjustments to machine, stop engine and remove key from ignition. Use all procedures and parts prescribed by the manufacturer's. Read the engine manual before operation. LUBRICATION Use No. 2 General purpose lithium base grease and lubricate every 100 hours. The dump truck has 14 grease fittings.
  • Page 11 MAINTENANCE ENGINE OIL Change and add oil according to charts below. Do not overfill. Use a high quality detergent oil. For Briggs engine use oil classified “For Service SJ or higher” SAE 30 oil. SAE 30 oil, if used below 40° F (4° C), will result in hard starting and possible engine bore damage due to inad- equate lubrication.

  • Page 12: Adjustments

    ADJUSTMENTS WHEEL CREEP "Creep" is when the engine is running and hydrostatic transmission is in neutral, but due to inadequate align- ment, wheels still move. Do the following procedure to stop this motion. 1. Lift up and support machine so rear wheels are off the ground and can turn freely.

  • Page 13: Service Chart

    SERVICE CHART Before servicing or making adjustments to the machine, stop engine, block wheels and remove key from ignition. Follow all procedures and ONLY use parts prescribed by the manufacturer. Read the engine manual before maintenance. The suggested maintenance checklist is not offered as a replacement for the manufacturer’s engine manual but as a supplement.

  • Page 14: Service Chart

    END USER SERVICE CHART Duplicate this page for routine use For the week of: Maintence Check Item Tues. Wed. Thurs. Fri. Sat. Sun. Check the Safety Seat Switch Check Steering Operation Check the fuel level Check the engine oil level. Check the condition of the air filter Clean the engine cooling fins.

  • Page 15: Storage

    STORAGE UP TO ONE MONTH 1. While engine is running, treat upper cylinders by spraying engine fogging agent into the air intake (NOT through air cleaner) for about two minutes. Fogging agent can be obtained from your local after market supplier.

  • Page 16: Diagrams

    WIRING DIAGRAM Use dielectric grease on all electrical connections.
  • Page 17 WIRING DIAGRAM PARTS LIST REF# PART# DESCRIPTION QUANTITY 14-292 Seat Switch 13-488 Ignition Switch 32-014 Head Lights 15-727 Switch Actuator 15-782 Rocker Switch 12-017 Hour Meter 50-359 Warning Light - Oil 8975 30 AMP Breaker 8977 Boot 76-327 Negative Battery cable 22-073 Battery 50-323...

  • Page 18: Hydraulic Diagram

    HYDRAULIC DIAGRAM Letter Code Chart Center Inside Outside Bottom...

  • Page 19: Diagrams

    HYDRAULIC DIAGRAM PARTS LIST REF# PART# DESCRIPTION QUANTITY 34-103 Orbitrol 32-069 Hydraulic Hose - 74" 32-071 Hydraulic Hose - 87" 32-065 Hydraulic Hose - 39.5" 32-066 Hydraulic Hose - 56.5" 32-072 Hydraulic Hose - 144" 32-070 Hydraulic Hose - 116.5" 31-043 Single Bank Valve 32-073...

  • Page 20: Parts

    MAIN FRAME DRAWING...
  • Page 21 MAIN FRAME PARTS LIST REF# PART# DESCRIPTION QUANTITY 32-001 Gondola Box (optional) 32-002 Tailgate Box (optional) 32-003 Flatbed (optional) 13-718 Steering Wheel 32-105 Cup Box 32-017 Dashboard 32-018 Decal, Dashboard 32-014 Headlight 32-030 Nose Cone 32-061 Floorboard 32-055 Skid Plate HB-516-18-250 Bolt - 18 x 2...

  • Page 22: Nose Cone Drawing

    NOSE CONE DRAWING...
  • Page 23 NOSE CONE PARTS LIST REF# PART# DESCRIPTION QUANTITY 13-726 Center Cap 27-077 Decal, Smithco Round 13-718 15" Steering Wheel 76-364 Square Boot 76-362 Mini Tilt Steering 50-359 Warning Indicator Light 13-488 Ignition Switch 32-107 Tilt Column Spacer 15-725 Panel Mount End...

  • Page 24: Pedal Linkage Drawing

    PEDAL LINKAGE DRAWING...
  • Page 25 PEDAL LINKAGE PARTS LIST REF# PART# DESCRIPTION QUANTITY 32-084 Master Cylinder 32-082 Banjo Adapter 32-083 Banjo Bolt 32-028 Brake Pedal 32-089 30" Brake Hose 32-080 Brake Cylinder Adapter HB-516-18-075 Bolt -18 x HNFL-516-18 Flange Whiz Lock Nut - 18 HCP-12-200 Clevis Pin HMB-12-14 Machine Bushing...

  • Page 26: Front Axle Drawing

    FRONT AXLE DRAWING...
  • Page 27 FRONT AXLE PARTS LIST REF# PART# DESCRIPTION QUANTITY 80-167 Dust Cap 11-043 Bearing 11-041 Seal 32-114 Front Hub (includes all * items) 32-025 Razorback Front Caliper 32-025-01 32-096 Grease Bolt HB-38-16-200 Bolt - 16 x 2 HNTL-38-16 Lock Nut 32-086 Coil-Over Shock 32-104 Spacer...

  • Page 28: Gast Tank Drawing

    GAS TANK DRAWING GAS TANK PARTS LIST REF# PART# DESCRIPTION QUANTITY 15-838 CARB Gas tank 32-052 LH Gas Tank Mount HB-38-16-250 Bolt - 16 x 2 HNFL-38-16 Flange Lock Nut - 16 32-050 Tank Mount Bracket HB-516-18-075 Bolt - 18 x HNFL-516-18 Flange Lock Nut 8-688...

  • Page 29: Oil Tank Drawing

    OIL TANK DRAWING OIL TANK PARTS LIST REF# PART# DESCRIPTION QUANTITY 18-249 Barb Fitting 18-093 Straight Tee 75-792 Tank Hold Down HB-516-18-125 Bolt - 18 x 1 HNFL-516-18 Flange Lock Nut - 18 32-049 LH Tank Mount 32-050 Tank Mount Bracket 13-747 Filler Breather 13-586-03...

  • Page 30: Seat Panel Drawing

    SEAT PANEL DRAWING...
  • Page 31 SEAT PANEL PARTS LIST REF# PART# DESCRIPTION QUANTITY 10-516 Brake Cable 32-079 Park Brake Equalizer HCP-516-100 Clevis Pin HP-18-075 Cotter Pin 11-100 Linkage Yoke, 32-013 Park Brake Rod 32-057 LH Park Brake Mount HSTP-516-18-075 Truss Head Screw -18 x HNFL-516-18 Flange Whiz Lock Nut - 18 60-106...

  • Page 32: Engine Drawing

    ENGINE DRAWING...
  • Page 33 ENGINE PARTS LIST REF# PART# DESCRIPTION QUANTITY 32-022 Straight Thread Elbow 76-197 Gear Pump 18-133 Barb Fitting 23-130 Elbow 32-021 Straight Thread Branch Tee 76-482 Hydrostatic Pump 18-241 Straight Thread Connector 32-024 Tail Pipe 50-394 Muffler Clamp 76-447 Center Mount Muffler 32-019 Air Inlet Tube 18-123...
  • Page 34 ENGINE DRAWING...
  • Page 35 ENGINE PARTS LIST REF# PART# DESCRIPTION QUANTITY 32-060 Engine Plate HB-716-14-150 Bolt -14 x 1 HWL-716 Lock Washer 32-045 Control Arm 32-123 Relay Bracket 32-124 Fuel Pump Mount 76-465 Coupling Complete 76-466 " Coupler Half 76-467 " Coupler Half 76-468 Sleeve, M42 32-026 Pump Adapter...

  • Page 36: Rear Axle Drawing

    REAR AXLE DRAWING...
  • Page 37 REAR AXLE PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-241 Right Caliper CW 34-122 Short Elbow 32-016 Rear Axle 76-240 Left Caliper CCW 76-239 8" Brake Disc HB-12-13-750 Bolt - 13 x 7 HNFL-12-13 Flange Lock Nut - 13 HB-12-13-800 Bolt -13 x 8 HNFL-12-13 Flange Lock Nut...

  • Page 38: 31-043 Single-Bank Valve

    31-043 SINGLE-BANK HYDRAULIC VALVE DRAWING...
  • Page 39 31-043 SINGLE-BANK HYDRAULIC VALVE PARTS LIST REF # PART # DESCRIPTION QUANTITY 13-731-01 Actuator Housing Assembly Relief Valve 3*† 78-415-03 O-Ring Seal 4*† 78-415-05 Spacer 78-415-04 Flanged Washer HDM10 13-731-03 Spool 78-415-11 Positioner 78-415-08 Plug 78-415-09 Lever Group HDS11 78-415-10 Metric Socket Screw M5 x .8 x 45 13-731-04 1/4"...

  • Page 40: 34-103 Orbitrol

    34-103 ORBITROL DRAWING...

  • Page 41: Orbitrol

    34-103 ORBITROL PARTS LIST REF# PART# DESCRIPTION QUANTITY O-Ring Seal Quad Seal 15-301-14 Bearing Kit Bearing Race Bearing Spool 15-301-13 External Retaining Ring 15-301-15 Spring Centering Kit (Includes Ref# 9) Spring Spacer Centering Spring Spring Retaining Ring 15-301-08 Sleeve Retainer 15-301-11 Plug and O-ring O-Ring Seal...

  • Page 42: 76-238 Wheel Motor

    76-238 WHEEL MOTOR DRAWING (14.5 CI)

  • Page 43: Wheel Motor

    76-238 WHEEL MOTOR PARTS LIST (14.5 CI) REF# PART# DESCRIPTION QUANTITY Water & Dirt Seal 2† 13-615-05 Service Housing Assembly Inner Seal 4† 13-032-27 Thrust Bearing 5† 13-032-28 Inner Bearing 13-032-29 Thrust Bearing 76-238-03 Drive Link Ring Seal 13-032-31 Manifold 13-032-32 Commulator Assembly (matched set)
  • Page 44 76-197 EATON GEAR PUMP DRAWING...
  • Page 45 76-197 EATON GEAR PUMP PARTS LIST REF# PART# DESCRIPTION QUANTITY Body 76-197-01 Front Plate Washer 76-197-06 Cap Screw 76-197-07 Retaining Ring Shaft Seal 33-061-15 Washer O-Ring Backup Gasket Seal Wear Plate 76-197-04 Shaft (comes with Idler Gear) 76-197-02 Back Plate Plug 76-197-08 Seal Kit...
  • Page 46 76-482HYDROSTATIC PUMP DRAWING...
  • Page 47 76-482HYDROSTATIC PUMP PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-398-01 Drive Shaft (splined) 60-343-08 Needle Bearing (with housing) 77-239-01 Housing 77-239-02 O-Ring 77-239-03 Thrust Bearing 77-239-04 Trunnion Cover 77-239-05 Pan Head Screw 77-239-06 Washer 77-239-07 Cone Bearing 77-239-08 Cam Plate 77-239-09 Swash Plate Insert 60-343-21 Rotating Kit...

  • Page 48: Accessories

    32-001 GONDOLA BOX PARTS LIST REF# PART# DESCRIPTION QUANTITY 32-102 Gondola Box 76-242 Cylinder 76-242-01 Seal Kit 32-042 Spacer 76-242-02 Clevis Pin w/ Clip 50-081 Rubber Bumper HNFL-38-16 Flange Whiz Lock Nut...

  • Page 49: 32-002 Tailgate Box

    32-002 TAILGATE BOX PARTS LIST REF# PART# DESCRIPTION QUANTITY 32-062 Tailgate Box 76-242 Cylinder 76-242-01 Seal Kit 32-042 Spacer 76-242-02 Clevis Pin w/ Clip 32-043 Lock HB-14-20-075 Bolt - 20 x HW-14 Washer HNTL-14-20 Lock Nut - 20 32-033 Gate Hook 8892-10.5 Chain Wrap HBFL-516-18-075...

  • Page 50: 32-003 Flat Bed

    32-003 FLATBED PARTS LIST REF# PART# DESCRIPTION QUANTITY 32-103 Flat Bed 76-242 Cylinder 76-242-01 Seal Kit 32-042 Spacer 76-242-02 Clevis Pin w/ Clip 50-081 Rubber Bumper HNFL-38-16 Flange Whiz Lock Nut HBFL-516-18-075 Flange Bolt -18 x HNFL-516-18 Flange Whiz Lock Nut - 18 32-118 Front Guard...

  • Page 51: Reference

    25-277 Decal, Battery Warning Battery 25-355 Decal, Tire Pressure 18PSI Front Tires 25-356 Decal, Tire Pressure 20 PSI Rear Tires 25-358 Decal, Smithco 12" Rear Dump Box 25-381 Decal, dBA 96 Seat Panel 27-077 Decal, Round Smithco Steering Cap 32-018 Decal, Dash Board...

  • Page 52: 76-197 Gear Pump

    QUICK REFERENCE REPLACEMENT PARTS REPLACEMENT FILTERS 23-031 Hydraulic Oil Filter Replacement 42-076-03 Air Filter Element 13-531 Engine Oil Filter 76-395-01 Air Cleaner Cartridge Briggs # 841497 76-395-02 Safety Filter Cartridge Briggs # 821136 50-403 Fuel Filter SEAL KITS 34-103 Power Steering Orbital Motor 14-098 Seal Kit 76-238...

  • Page 53: Warranty

    30 days from discovery of the condition. If you need help locating an Authorized Smithco Distributor, or if you have questions regarding your warranty rights or responsibilities, you may contact us at:...
  • Page 54 This warranty does not apply to normal “wear and tear” items. Normal “Wear and Tear” includes, but is not lim- ited to, damage to seats due to wear or abrasion, worn painted surfaces, scratched decals or windows, etc. Smithco may require the return of failed parts or components in order to determine the validity of any warranty claim.

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