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Smithco 76-000-D Parts & Service

Gas and diesel
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Parts & Service
Sweep Star 60
Gas and Diesel
76-000-D and 77-100-C
SN: 2242
October 2010
Product Support:
Hwy SS & Poplar Ave; Cameron WI 54822
1-800-891-9435
productsupport@smithco.com

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  • Page 1 Parts & Service Sweep Star 60 Gas and Diesel 76-000-D and 77-100-C SN: 2242 October 2010 Product Support: Hwy SS & Poplar Ave; Cameron WI 54822 1-800-891-9435 productsupport@smithco.com...

  • Page 2: Table Of Contents

    CONTENTS Introduction .......... 1-10 Introduction ................... 1-3 Safe Practices ................2 Specifications ................3 Optional Equipment ..............3 Service ..................4-9 Maintenance ................4-6 Service Chart ................7 End User’s Service Chart ............. 8 Adjustments ................9 Storage ..................9 Diagrams ...................

  • Page 3: Introduction

    INTRODUCTION Thank you for purchasing a product. Read this manual and all other manuals pertaining to the Sweep Star 60 carefully as they have safety, operating, assembly and maintenance instructions. Failure to do so could result in personal injury or equipment damage. Keep manuals in a safe place after operator and maintenance personnel have read them.

  • Page 4: Safe Practices

    19. Stop engine before making repairs/adjustments or checking/adding oil to the crankcase. 20. Use parts and materials supplied by SMITHCO only. Do not modify any function or part. 21. Do not remove the radiator cap when the engine is hot. When cooled, loosen cap slightly to the stop to relieve any pressure before removing the cap completely.

  • Page 5: Specifications

    SPECIFICATIONS FOR SWEEP STAR 60 GAS & DIESEL WEIGHTS AND DIMENSIONS Length 129" (328 cm) Width 74.5" (179 cm) Height with Hopper Down 82" (208 cm) Height with Hopper Up 127" (323 cm) Wheel Base 68.5" (174 cm) Weight 2200 lbs (998 kg) ROLL OVER PROTECTION BAR Standard on all Machines SOUND LEVEL...

  • Page 6: Service

    MAINTENANCE LUBRICATION Use No. 2 General Purpose Lithium Base Grease and lubricate every 100 hours. The Sweep Star 60 has eleven grease fittings. A. One on the outside of each tower. B. One on hydrostatic forward and reverse relay. C. One on the center of park brake relay on rear axle. D.
  • Page 7 MAINTENANCE (CONTINUED) TIRE PRESSURE Caution must be used when inflating a low tire to recommended pressure. Over inflating can cause tires to ex- plode. Front tires and castor wheel should be 20 psi (1.4 bar), rear tires should be 18 psi (1.3 bar) maximum. Improper inflation will reduce tire life considerably.
  • Page 8 MAINTENANCE (CONTINUED) WHEEL MOUNTING PROCEDURE REAR WHEELS 1. Set park brake. Turn machine off and remove key. 2. Block one of the other wheels. 3. Loosen nuts slightly on wheel to be removed. 4. Jack up machine being careful not to damage underside of machine. 5.

  • Page 9: Service Chart

    SERVICE CHART Before servicing or making adjustments to the machine, stop engine, set park break, 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 10: End User's 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 11: Adjustments

    ADJUSTMENTS PARK BRAKE ADJUSTMENT By turning knob on end of park brake lever you can tighten or loosen brake a small amount. To tighten turn the knob clockwise. To loosen turn counter clock- wise. If this is not enough turn clevis on brake cable to adjust length of cable. STEERING CHAIN ADJUSTMENT Steering Sprockets (A) should be level with each other.

  • Page 12: Diagrams

    DIESEL WIRING DIAGRAM Color Code Chart Blue Brown Yellow Green Orange Black Purple White...
  • Page 13 DIESEL WIRING PARTS LIST REF# PART# DESCRIPTION QUANTITY 22-073 Battery 48-166 Battery Holddown 48-147 Black Battery Cable 48-157 Red Battery Cable 8892-46.5 Hose Wrap x 46.5 50-359 Warning Indicator Lights 77-209 Hour Meter to Ground Wire 12-017 Hour Meter 76-337 Electric Clutch 17-271 Pigtail...

  • Page 14: Gas Wiring Diagram

    GAS WIRING DIAGRAM Color Code Chart Blue Brown Yellow Green Orange Black Purple White...
  • Page 15 GAS WIRING PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-397 Voltmeter 76-269 Power Wire to Hour Meter 12-017 Hour Meter 76-209 Ground Wire for Hour Meter 76-260 Ground Wire for Ignition Switch 77-261 Circuit Breaker 40 AMP 8977 Circuit Breaker Boot 13-488 Key Switch with Hardware 50-359...

  • Page 16: Hydraulic Diagram

    HYDRAULIC DIAGRAM 76-023 Hydraulic Valve Relief Valve set at 2000 psi (137.93 bar) 76-398 Hydrostatic Pump Displacement Variable to 1.44 in /R (23.6 cm 22.44 gpm (84.94 lpm) at 3600 rpm Max Operating Speed 3600 rpm Rated Pressure 3000 psi (206.8 bar) Max Pressure 5000 psi (344.7 bar) Max Inlet Vacuum...

  • Page 17: Parts

    HYDRAULIC DIAGRAM PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-242 Hydraulic Cylinder 76-115 Hydraulic Hose 76-114 Hydraulic Hose 76-238 Wheel Motor 34-057 76-208 Hydraulic Hose 8832-18.5 Suction Hose (gas) 8832-24 Suction Hose (diesel) 18-040 Hose Clamp 76-209 Hydraulic Hose 8895-48 1" Hose Wrap 76-398 Hydrostatic Pump (Gas)

  • Page 18: Body And Frame

    BODY AND FRAME DRAWING When Filtration System is to be installed, Ref. 9 Hopper Screen Cover is to be removed. When Filters are used, 76-262 Tailgate Screen is replaced by 76-249 Tailgate Filter Screen. 76-261 Hopper Screen is replaced by 76-248 Hopper Filter Screen.
  • Page 19 BODY AND FRAME PARTS LIST REF# PART# DESCRIPTION QUANTITY 1§ 60-130 Tire and Wheel 60-130-01 Tire 18 x 9.50 - 8 60-130-02 Wheel 8839 Windshield Washer Fluid or Equivalent 28 pints 76-264 Nose Cone 76-354 # ABC Dry Chemical Fire Extinguisher 76-372 Inclinometer 76-373...

  • Page 20: Roll Over Protection (Rops)

    ROLL-OVER PROTECTION DRAWING...
  • Page 21 ROLL-OVER PROTECTION PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-377 Right Seat Belt Bracket HB-38-16-200 Bolt - 16 x 2 HNTL-38-16 Lock Nut - 16 HB-716-14-100 Bolt - 14 x 1 HNTL-716-14 Lock Nut - 14 76-198-03 Seat Belt 76-379 Right Support 76-381 Roll Bar HB-12-13-125...

  • Page 22: Steering

    STEERING DRAWING...
  • Page 23 STEERING PARTS LIST REF# PART# DESCRIPTION QUANTITY 48-186 Steering Shaft HWK-316-075 Woodruff Key 76-362 Tilt Steering Mechanism 76-364 Tilt Steering Boot 13-718 Steering Wheel 13-726 Steering Wheel Cap HN-58-18 - 18 75-833 Universal Joint HSSHS-516-18-038 Socket Head Set Screw - 18 x 75-813 Bottom Steering Shaft HWK-316-075...

  • Page 24: Front Fork

    FRONT FORK DRAWING...
  • Page 25 FRONT FORK PARTS LIST REF# PART# DESCRIPTION QUANTITY HW-38 Washer (as Req'd) HB-38-16-200 Bolt - 16 x 2 HNTL-38-16 Locknut - 16 HB-38-16-250 Bolt - 16 x 2 HNTL-38-16 Locknut - 16 75-715 Shock Absorber 75-715-01 Bushing with Insert 2 per Shock HN-38-16 - 16 HB-38-16-100...

  • Page 26: Gasoline Linkage

    GAS LINKAGE DRAWING...
  • Page 27 GAS LINKAGE PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-299 Pedal Pad Long HB-516-18-075 Bolt - 18 x HW-516 Washer HNTL-516-18 Lock Nut - 18 76-296 Pedal Mount 18-234 Oilite Bushing HG-14-28-180 Grease Fitting - 28 x 180° 48-059 Foot Pedal 18-234 Oilite Bushing 76-282...

  • Page 28: Diesel Linkage

    DIESEL LINKAGE DRAWING...
  • Page 29 DIESEL LINKAGE PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-299 Pedal Pad Long HB-516-18-075 Bolt - 18 x HW-516 Washer HNTL-516-18 Lock Nut - 18 76-296 Pedal Mount 18-234 Oilite Bushing HG-14-28-180 Grease Fitting - 28 x 180° 48-059 Foot Pedal 18-234 Oilite Bushing 76-282...

  • Page 30: Gas Console

    GAS CONSOLE DRAWING...
  • Page 31 GAS CONSOLE PARTS LIST REF# PART# DESCRIPTION QUANTITY 77-261 Circuit Breaker 8977 Circuit Breaker Boot 12-017 Hour Meter 76-397 Voltmeter 13-488 Key Switch 76-310 Key Set 76-461 Throttle 34-159 Throttle Mounting Bracket HSM-10-32-063 Machine Screw 10 - 32 x HWL-10 Lockwasher 10 HN-10-32 Nut 10 - 32...

  • Page 32: Diesel Console

    DIESEL CONSOLE DRAWING...
  • Page 33 DIESEL CONSOLE PARTS LIST REF# PART# DESCRIPTION QUANTITY 50-359 Warning Indicator Light 12-017 Hour Meter HSA-8-075 Tapping Screw #8 x 17-068 Key Switch 17-079 Key Set 34-160 Throttle 48" 34-159 Throttle Mounting Bracket HSM-10-32-063 Machine Screw 10 - 32 x HWL-10 Lockwasher 10 HN-10-32...

  • Page 34: Gas Tank And Oil Tank

    GASTANK AND OIL TANK DRAWING...
  • Page 35 GAS TANK AND OIL TANK PARTS LIST REF# PART# DESCRIPTION QUANTITY 18-133 Barb Fitting 18-009 Street Elbow 18-008 Pipe Reducer 18-093 Male Run Tee 18-140 Street Elbow 60-213 Strainer 75-792 Mounts HB-516-18-150 Bolt - 18 x 1 HW-516 Washer HNTL-516-18 Lock Nut - 18 18-069...

  • Page 36: Fuel Tank And Oil Tank

    DIESEL FUEL TANK AND OIL TANK DRAWING...
  • Page 37 DIESEL FUEL TANK AND OIL TANK PARTS LIST REF# PART# DESCRIPTION QUANTITY 15-491 Fuel Tank HB 14-20-075 Bolt - 20 x HWL-14 Lockwasher HW-14 Washer 15-492 Gas Cap with Gauge 77-179 Diesel Fuel Cap with Gauge 15-039 Fuel Valve 18-042 Reducer Bushing 76-221 Tank Mount...
  • Page 38 OIL FILTER DRAWING HYDRAULIC LIFT CYLINDER DRAWING...

  • Page 39: Oil Filter

    OIL FILTER PARTS LIST REF# PART# DESCRIPTION QUANTITY 23-006 Oil Filter 23-031 Filter Element (replacement only) 18-008 Pipe Reducer 23-142 Connector HB-14-20-075 Bolt - 20 x HWL-14 Lockwasher HW-14 Washer 75-806 Filter Bracket 23-183 Male Connector 18-190 HYDRAULIC LIFT CYLINDER PARTS LIST REF# PART# DESCRIPTION...

  • Page 40: Reel Lift Cylinder

    REEL LIFT CYLINDER DRAWING TAILGATE CYLINDER DRAWING...
  • Page 41 REEL LIFT CYLINDER PARTS LIST REF# PART# DESCRIPTION QUANTITY HNTL-38-16 Lock Nut - 16 18-188 Elbow 76-478 Hydraulic Cylinder 2 x 7 x 14-531 Seal Kit HP-18-100 Cotter Pin HCP-12-350 Clevis Pin 75-827 Cylinder Bracket HB-38-16-150 Bolt - 16 x 1 8820-8 Machine Chain St.

  • Page 42: Vanguard Gas Engine And Exhaust

    GAS ENGINE AND EXHAUST DRAWING...
  • Page 43 GAS ENGINE AND EXHAUST PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-197 Gear Pump 23-133 Adjustable Elbow 90° 18-133 Barb Fitting 23-145 O-Ring 3 ID x 3 18-204 Elbow 90° 23-130 Elbow 90° 18-241 Straight Thread Connector 18-202 Elbow 76-465 Pump Coupling Complete 76-466 Coupling Half 76-467...

  • Page 44: Kubota Diesel Engine And Exhaust

    KUBOTA DIESEL ENGINE AND EXHAUST DRAWING...
  • Page 45 KUBOTA DIESEL ENGINE AND EXHAUST PARTS LIST REF# PART# DESCRIPTION QUANTITY 23-188 Male Connector 23-129 Elbow 90° 76-197 Gear Pump 18-133 Barb Fitting 23-133 Adjustable Elbow 90° 23-145 O-Ring 77-239 Hydrostatic Pump 18-204 Elbow 90° 18-202 Elbow 23-130 Elbow 90° 77-249 Diesel Air Intake 42-004-02...
  • Page 46 KUBOTA DIESEL ENGINE AND EXHAUST DRAWING (CONTINUED)
  • Page 47 KUBOTA DIESEL ENGINE AND EXHAUST PARTS LIST (CONTINUED) REF# PART# DESCRIPTION QUANTITY 77-185 Front Engine Mount HB-38-16-175 Bolt - 16 x 1 HNTL-38-16 Lock Nut - 16 8951-24 Lower Radiator Hose 77-243 Radiator Mount 77-208-04 Goose Neck (part of engine) 77-184 Cable Bracket HBM-8-1.25 x 20...

  • Page 48: Electric Clutch Driven Belt Drive

    ELECTRIC CLUTCH DRIVEN BELT DRIVE DRAWING...
  • Page 49 ELECTRIC CLUTCH DRIVEN BELT DRIVE PARTS LIST REF# PART# DESCRIPTION QUANTITY 48-038 Spring Bracket HMB-100-10 Machine Bushing 1 x 10GA 21-445 Spring 9020-8.5 Heat Shrink Tubing 76-412 Electric Clutch (Gas) 76-337 Electric Clutch (Diesel) 17-271 Pigtail (Diesel) 16-013 Idler Pulley 76-217 Idler Arm 76-298...

  • Page 50: Finger/Brush Reel

    FINGER/BRUSH REEL DRAWING...
  • Page 51 FINGER /BRUSH REEL PARTS LIST REF# PART# DESCRIPTION QUANTITY HB-34-10-550 Bolt - 10 x 5 HNTL-34-10 Lock Nut - 10 33-435 Tire and Wheel 48-046 Castor Fork HMB-100-10 Machine Bushing 1 x 10GA 29-585 Spacer Height Adjustment 18-223 Bushing 2 per (part of 76-355) 76-355 29-584...
  • Page 52 REAR AXLE DRAWING Torque to 160 ft/lbs(208Nm)
  • Page 53 REAR AXLE PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-233 Rear Beater Panel HB-38-16-125 Bolt - 16 x 1 HW-38 Washer HNTL-38-16 Lock Nut - 16 13-099 Hose Clamp HB-516-18-125 Bolt - 18 x 1 HWL-516 Lockwasher HB-516-18-150 Bolt - 18 x 1 HNTL-516-18 Lock Nut - 18...
  • Page 54 REAR AXLE DRAWING Torque to 160 ft/lbs(208Nm)

  • Page 55: Rear Axle

    REAR AXLE PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-238 Wheel Motor HWK-516-100 Woodruff Key 60-268 Lug Nut - 20 x 1 14-265 Nut 1 - 20 76-208 Hydraulic Hose 23.5" 34-057 Tee Fitting 76-385 Brace HNTL-12-13 Lock Nut - 13 76-240 Left Caliper Counterclockwise 29-118...
  • Page 56 HOPPER DRAWING...

  • Page 57: Hopper

    HOPPER PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-414 Left Tailgate Dump Bar HMB-114-10 Machine Bushing 1 x 10 GA 76-237 Hopper 76-261 Hopper Screen 76-359 Hopper Screen Cover HB-516-18-075 Bolt -18 x HW-516 Washer HNTL-516-18 Lock Nut - 18 75-653 Hopper Safety Lift HB-38-16-225 Bolt...
  • Page 58 HOPPER DRAWING...
  • Page 59 HOPPER PARTS LIST REF# PART# DESCRIPTION QUANTITY HMB-114-10 Machine Bushing 1 x 10GA 2 As Req’d HKSQ-14-150 Machine Key HSSHS-516-18-038 Set Screw - 18 x HRP-38-250 Roll Pin HB-58-11-200 Bolt - 11 x 2 HMB-58-14 Machine Bushing x 14GA HNCL-58-11 Center Lock Nut - 11 76-288...
  • Page 60 TAILGATE DRAWING...

  • Page 61: Tailgate

    TAILGATE PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-262 Tailgate Screen 76-243 Tailgate HB-12-13-300 Bolt - 13 x 3 HMB-12-14 Machine Bushing x 14GA 75-565 Tailgate Hinge Strap HN-12-13 - 13 75-564 Tailgate Hinge HNCL-12-13 Center Lock Nut - 13 HNCL-38-16 Center Lock Nut - 16 HB-38-16-075...

  • Page 62: 77-239 Eaton Hydrostatic Pump (Diesel)

    77-239 EATON HYDROSTATIC PUMP DRAWING (DIESEL)
  • Page 63 77-239 EATON HYDROSTATIC PUMP PARTS LIST (DIESEL) REF# PART# DESCRIPTION QUANTITY 60-343-52 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...

  • Page 64: 76-398 Eaton Hydrostatic Pump (Gas)

    76-398 EATON HYDROSTATIC PUMP DRAWING (GAS)
  • Page 65 76-398 EATON HYDROSTATIC PUMP PARTS LIST (GAS) 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...

  • Page 66: 76-197 Eaton Gear Pump

    76-197 EATON GEAR PUMP DRAWING...
  • Page 67 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 68: 76-238 Rear Wheel Motor

    76-238 REAR WHEEL MOTOR DRAWING (14.5 CI)
  • Page 69 76-238 REAR 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...

  • Page 70: 76-023 3-Bank Hydraulic Valve

    76-023 3 -BANK HYDRAULIC VALVE DRAWING...
  • Page 71 76-023 3 -BANK HYDRAULIC VALVE PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-023-03 Mounting Bracket HN-516-18 Hex Nut - 18 HW-14 Washer 76-023-06 Tie Rod 18-188 Elbow 45° 18-168 Elbow 90° Linkage (comes with handle) 76-309 Valve Handle (sold as a set of 3) 76-125-01 Knob 1 per handle...

  • Page 72: Accessories

    76-271 DUST/DIRT FILTRATION SYSTEM...
  • Page 73 76-271 DUST/DIRT FILTRATION SYSTEM REF# PART# DESCRIPTION QUANTITY 76-249 Tailgate Screen for Filter (28 x 58) *15-437-01 Keeper HRS-316-1125 Steel Rivet 76-247 Tailgate Filter (28 x 57) 76-246 Hopper Filter (24 x 57) 76-248 Hopper Screen for Filter (24 x 28) 76-263 Hopper Screen Cover (Serial Number 1000-1497)

  • Page 74: Reference

    NOTES...

  • Page 75: Decal List

    Front Wheel and Castor Wheel 25-359 Smithco Tailgate 25-362 Danger Fire Hopper 25-376 98 dBA Console 27-077 Round Smithco Steering Wheel 27-093* Hydraulic Oil Level Console Back Above Hydraulic Tank 30-117 Ultra Fuel Fuel Tank (diesel only) 34-147 Smithco Star Front Nose Cone...

  • Page 76: Quick Reference Replacement Parts

    QUICK REFERENCE REPLACEMENT PARTS REPLACEMENT FILTERS 23-031 Hydraulic Oil Filter 13-531 Oil filter 76-395-01 Air Cleaner Cartridge Briggs # 841497 76-395-02 Safety Filter Cartridge Briggs # 821136 50-403 Fuel Filter REPLACEMENT FILTERS KUBOTA ENGINE 17-255 Oil Filter Cartridge 77-213 Air Cleaner Element (steel canister) Kubota# 70000-11221 42-076-03 Air Cleaner Element (plastic canister)
  • Page 77 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 78 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.

This manual is also suitable for:

Sweep star 6077-100-c

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