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Smithco TCV 5000 Parts & Service Operators

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Parts & Service
Operators
TCV 5000
Super Truck Turf Care Vehicle
Model 31-000
SN: DT310001
June 2009
Revised Jan 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 Operators TCV 5000 Super Truck Turf Care Vehicle Model 31-000 SN: DT310001 June 2009 Revised Jan 2010 Product Support: Hwy SS & Poplar Ave; Cameron WI 54822 1-800-891-9435 productsupport@smithco.com...

  • Page 2: Table Of Contents

    CONTENTS Introduction................1-5 Introduction ................1 Safe Practices ................. 2 Specifications ................3 Setup ..................4 Controls & Instruments ............5 Service ..................6-15 Operation ................6-7 Maintenance ................. 8-9 Wheel Creep ................. 10 Adjustments ................10 Service Chart ..............11-12 Storage ................

  • 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. Never carry passengers. 18. Stop engine before making repairs/adjustments or checking/adding oil to the crankcase. 19. Use parts and materials supplied by Smithco Smithco only. Do not modify any function or part. Smithco Smithco Smithco 20.

  • Page 5: Specifications

    SPECIFICATIONS WEIGHTS AND DIMENSIONS Length 128" (325 cm) Width 72" (183 cm) Height w/ ROPS 84" (213 cm) Wheel Base 68" (173 cm) Weight Empty 2355 lbs (1068 kg) SOUND LEVEL (DBA) At ear level 98 dBA ENGINE Make Kubota Model# V1505 Code / Spec#...

  • 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 20 psi (1.4 bar) and rear tires are 30 psi (2.0 bar).

  • Page 7: Controls & Instruments

    CONTROLS & INSTRUMENTS A. Hour Meter - The hour meter indicates hours of machine operation. It operates only when the ignition switch is on. Speedometer - The Speedometer indicates ground speed of the vehicle in miles per hour and kilometers per hour.

  • Page 8: Operation

    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 6 grease fittings.
  • Page 11 MAINTENANCE ENGINE OIL With strict emission control regulations now in effect, the CF-4 and CG-4 engine oils have been developed for use with low sulfur fuels, for On-Highway vehicle engines. When Non-Road engines run on high sulfur fuel, it is advisable to use a "CF or better"...

  • Page 12: Wheel Creep

    WHEEL CREEP WHEEL CREEP "Creep" is when the engine is running and hydrostatic transmission is in neutral, but due to inadequate alignment, 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 NOTES...

  • Page 14: 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 15 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 16 STORAGE To prevent damage from freezing, pour window washer fluid into spray systems tank and operate pump to circulate mix through gun and hose back to tank. Open boom control to circulate through rest of spray system. UP TO ONE MONTH 1.

  • Page 17: Storage

    STORAGE (CONTINUED) EXTENDED STORAGE 1. Check for any damaged parts or missing decals. Replace as needed. 2. Drain crankcase completely and refill with recommended engine oil or equivalent. 3. Run engine until completely out of gasoline, then restart and run on stabilizer mixed with unleaded gasoline for at least 10 minutes.

  • Page 18: Wiring Diagram

    WIRING DIAGRAM Color Code Chart Blue Brown Yellow Green Orange Black Purple White...
  • Page 19 WIRING DIAGRAM REF# PART# DESCRIPTION QUANTITY 77-223 Timer 30-042-06 Relay 50-359 Warning Light 10-556 Speedometer 12-017 Hour Meter 14-292 Seat Switch 13-488 Ignition Switch 17-524 Lights 10-421 Pigtail 15-725 Mount Panel End 15-727 Switch Actuator 15-782 Rocker Switch, Unlit 48-147 Ground Battery Cable 33-216 Battery...

  • Page 20: Hydraulic Diagram

    HYDRAULIC DIAGRAM Use dielectric grease on all electrical connections. Letter Code Chart Center Inside Outside Bottom...

  • Page 21: Parts

    HYDRAULIC DIAGRAM PARTS LIST REF# PART# DESCRIPTION QUANTITY 30-092 Hydraulic Hose 30-091 Hydraulic Hose 15-301 Orbitrol 30-094 Hydraulic Hose 75-714 Hydraulic Cylinder 14-254 Seal Kit 18-171 Seal Loc Adapter 30-025 Oil Tank 13-747 Filler Breather 13-586-03 Neck 8833-9 Suction Hose 18-222 Hose Clamp 8833-13...
  • Page 22 BODY & FRAME DRAWING...
  • Page 23 BODY & FRAME PARTS LIST REF# PART# DESCRIPTION QUANTITY 31-015 Gondola Dump Box (Optional) 30-030 Roll Bar 30-075 Engine Hood 27-055 Flush Hinge 31-016 Back Panel 14-519 Seat 14-292 Seat Switch 13-718 15" Steering Wheel 13-726 Center Cap 30-114 Left Front Fender 15-822 Nose Cone (Fiberglass) 50-400...
  • Page 24 NOSE CONE DRAWING...
  • Page 25 NOSE CONE PARTS LIST REF# PART# DESCRIPTION QUANTITY 15-751 Right Step 30-049 Control Rod HSTP-516-18-150 Machine Screw - 18 x 1 HNFL-516-18 Flange Lock Nut - 18 15-822 Nose Cone (Fiberglass) 13-488 Key Switch 12-017 Hour Meter 10-556 Speedometer 50-359 Warning Indicator Lights 76-362 Tilt Steering Column...

  • Page 26: Front Axle

    FRONT AXLE DRAWING...
  • Page 27 FRONT AXLE PARTS LIST REF# PART# DESCRIPTION QUANTITY HP-18-150 Cotter Pin HNJ-58-18 Jam Nut - 18 30-071 Hub Assembly HNAR-100-14 Slotted Jam Nut 1 - 14 30-070 Left Spindle 50-081 Rubber Insulator 30-039 Front Axle 18-153 Bushing 14-344 Axle Pin HB-516-18-125 Bolt -18 x 1...
  • Page 28 OIL AND FUEL TANK DRAWING...

  • Page 29: Oil And Fuel Tank

    OIL AND FUEL TANK PARTS LIST REF# PART# DESCRIPTION QUANTITY 33-216 Battery 30-074 Battery Hold Down HNW-14-20 Wing Nut - 20 13-747 Filler Breather 13-586-03 Fuel Tank Neck HSM-10-32-063 Machine Screw #10-32 x HWL-10 Lock Washer #10 30-025 Oil Tank 18-069 Pipe Plug 60-213...

  • Page 30: Seat Panel

    SEAT PANEL DRAWING...
  • Page 31 SEAT PANEL PARTS LIST REF# PART# DESCRIPTION QUANTITY 15-751 Step - RH 15-786 Hood Rod HW-38 Flat Washer, HP-18-075 Cotter Pin, 30-022 Side Panel - RH HSDPS-14-100 Pan Head Drill Screw, 34-160 Throttle Cable 34-160-01 Inner Cable 42-766 Throttle Bracket HSTP-14-20-075 Phillips Head Machine Screw, - 20 x...
  • Page 32 ENGINE AND PUMPS DRAWING...

  • Page 33: Engine And Pumps

    ENGINE, AND PUMPS PARTS LIST REF# PART# DESCRIPTION QUANTITY 30-042 Kubota Diesel Engine 33.5 HP 23-145 O'ring 30-033 Throttle Cable Mount HBM-8-1.25-25 Bolt #8-1.25 x 25 HWLM-8 #8 Lock Washer 42-004-02 Air Cleaner Cap 30-041 Right Engine Mount 48-109 Spring 30-037 Shift Arm HB-14-20-075...
  • Page 34 COOLER AND EXHAUST DRAWING...

  • Page 35: Cooler And Exhaust

    COOLER AND EXHAUST PARTS LIST REF# PART# DESCRIPTION QUANTITY 30-133 Muffler 31-034 Muffler Hanger HBFL-516-18-075 Flange Bolt, - 18 x HNFL-516-18 Flange Nut, - 18 31-012 Muffler Mount 30-042-06 Relay (part of engine) 77-223 Timer (part of engine) HBM-6-1-16 Metric Bolt M6 - 1 - 16 HWLM-6 Metric Washer M6 HW-14...
  • Page 36 31-015 GONDOLA DUMP BOX DRAWING...
  • Page 37 31-015 GONDOLA DUMP BOX PARTS LIST REF# PART# DESCRIPTION QUANTITY 31-035 Dump Box HCP-100-325 Clevis Pin 1 x 3 HHP-18 Bridge Pin 31-011 Box Base HB-38-16-300 Bolt, -16 x 3 HNTL-38-16 Lock Nut, - 16 31-025 Main Frame 72-040 Hydraulic Cylinder 72-040-01 Seal Kit 23-184...
  • Page 38 31-028 CARGO TAILGATE BOX DRAWING...
  • Page 39 31-028 CARGO TAILGATE BOX PARTS LIST REF# PART# DESCRIPTION QUANTITY 31-036 Cargo Box HCP-100-325 Clevis Pin 1 x 3 HHP-18 Bridge Pin 31-011 Box Base HB-38-16-300 Bolt, -16 x 3 HNTL-38-16 Lock Nut, - 16 31-025 Main Frame 72-040 Hydraulic Cylinder 72-040-01 Seal Kit 23-184...
  • Page 40 13-731 SINGLE-BANK HYDRAULIC VALVE DRAWING...
  • Page 41 13-731 SINGLE-BANK HYDRAULIC VALVE PARTS LIST REF # PART # DESCRIPTION QUANTITY 13-731-01 Actuator Housing Assembly 13-731-02 Valve Plug 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...
  • Page 42 15-301 ORBITROL DRAWING...

  • Page 43: 15-301 Orbitrol

    15-301 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...
  • Page 44 30-102 EATON PUMP DRAWING...

  • Page 45: 30-102 Eaton Pump

    30-102 EATON PUMP PARTS LIST REF# PART# DESCRIPTION QUANTITY 33-058-16 Valve Plate (CW Rotation) 33-058-26 Bearing (Press Fit) 33-058-25 Back Plate Assembly 33-058-12 Relief Valve S/A O-Ring Molded O-Ring 33-058-38 Inner Ring Gerotor 33-058-39 Outer Ring Gerotor 33-058-35 Charge Pump Adapter Assembly 33-058-46 Bearing (Press Fit) Bolt and Washer...
  • Page 46 30-102 EATON PUMP DRAWING...
  • Page 47 30-102 EATON PUMP PARTS LIST REF# PART# DESCRIPTION QUANTITY 33-058-03 Cap Screw #10 - 24 x 1 33-058-02 Jam Nut 33-058-42 Washer Seal Washer Retaining Ring 33-058-10 Thrust Race 33-058-11 Thrust Bearing 33-058-31 Washer 33-058-52 Shaft Seal Retaining Ring 33-058-28 Drive Shaft 33-058-17 Housing Assembly...
  • Page 48 30-101 EATON MOTOR DRAWING...

  • Page 49: 30-101 Eaton Motor

    30-101 EATON MOTOR PARTS LIST REF# PART# DESCRIPTION QUANTITY 30-101-01 Shaft and Bearing Kit (7/8 splined 13T) Seal Exclusion Seal Shaft Seal Back Up Ring 30-101-02 Bearing Housing Shaft Face Seal 30-101-03 Wear Plate 30-101-04 Main Drive 30-101-05 Geroler 30-101-06 Valve Plate 14-207 Valve Drive...

  • Page 50: Decal List

    25-376 Decal, 98 dBA Panel Behind Seat 25-380 Decal, Tire Pressure 30psi Rear Tires 27-077 Decal Smithco Steering Wheel 27-093 Decal, Hydraulic Oil Level Oil Tank 31-026 Decal, Dashboard Dashboard 30-117 Decal, Ultra Fuel Fuel Tank 34-147 Decal, Smithco Logo Nose Cone...

  • Page 51: Quick Reference

    QUICK REFERENCE REPLACEMENT PARTS REPLACEMENT FILTERS 60-215 Hydraulic Oil Filter Assembly 60-334 Oil Filter 30-042-05 Air Cleaner Cartridge 13-488 Key Switch 30-042-08 Fuel Filter Element 30-042-09 Engine Oil Filter 77-217 Exhaust Muffler Gasket REPLACEMENT BELTS SEAL KITS 15-301 Power Steering Orbital Motor 15-301-01 Seal Kit 30-101...

  • Page 52: Warranty

    January 1, 2007, to be free from defects in materials or workmanship for the period of time listed below. Where a warrantable condition exists, Smithco will repair the Product at no cost to you including diagnosis, labor (at the Smithco standard labor rate, subject to the Smithco flat rate schedule), and parts.
  • Page 53 Smithco may require the return of failed parts or components in order to determine the validity of any warranty claim. Smithco will not be obligated to replace components of other manufacturers if inspection by the original component manufacturer indicates that failure was due to normal wear and tear, expected consumption through use or improper care or service.

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