Page 1 Parts & Service SweepStar 60 Gas and Diesel 76-000-F and 77-100-D SN: 2654 February 2023 Product Support: Hwy SS & Poplar Ave; Cameron WI 54822 1-800-891-9435 productsupport@smithco.com...
Page 2: Table Of Contents
CONTENTS Introduction ............1-3 Reel Lift Cylinder ............42 Safe Practices ............2 Tailgate Cylinder .............43 Steering Cylinder ............44 Specifications ............3 Vanguard Gas Engine and Exhaust ....46-47 Optional Equipment ..........3 Kubota Diesel Engine and Exhaust ....48-51 Service ..............4-11 Electric Clutch Driven Belt Drive......52-53 Maintenance ............4-6 Finger/Brush Reel ..........54-55 Service Chart ............7-8...
Page 3: Introduction
All Smithco machines have a Serial Number and Model Number. Both numbers are needed when ordering parts. The serial number plate on the Sweep Star 60 is located on the left front main frame, in front of the engine.
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) 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. For Kubota Diesel engine use oil classified “For Service CC, CD or CE”...
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 GAS 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 SERVICE CHART DIESEL 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 11: End User's Service Chart
END USER SERVICE CHART Duplicate this page for routine use. Maintenance Check Item For the week of: Tues. Wed. Thurs. Fri. Sat. Sun. Check the Safety Seat Switch Check Steering Operation Check the fuel level Check the engine oil level. Clean the air filter Clean the engine cooling fins.
Page 12 END USER SERVICE CHART Duplicate this page for routine use. Maintenance Check Item For the week of: Tues. Wed. Thurs. Fri. Sat. Sun. Check the Safety Seat Switch Check Steering Operation Check the fuel level Check the engine oil level. Clean the air filter Clean the engine cooling fins.
Page 13: 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 clockwise. If this is not enough turn clevis on brake cable to adjust length of cable.
Page 14: Diagrams
DIESEL WIRING DIAGRAM Color Code Chart Blue Brown Yellow Green Orange Black Purple White...
Page 15 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 Hose Wrap 48" 50-359 Warning Indicator Lights 77-209 Hour Meter to Ground Wire 12-804 Hour Meter 76-337 Electric Clutch 17-271 Pigtail 15-314...
Page 16: Gas Wiring Diagram
GAS WIRING DIAGRAM Color Code Chart Blue Brown Yellow Green Orange Black Purple White Engine Harness Yellow Start Green Oil Light Brown Ground Rectifier Black Magneto Gray Fuel Solenoid...
Page 17 GAS WIRING PARTS LIST REF# PART# DESCRIPTION QUANTITY 13-488 Key Switch with Hardware 14-292 Seat Switch 77-261 Circuit Breaker 40 AMP 8977 Circuit Breaker Boot 48-144 Circuit Breaker Wire 76-636 Briggs & Stratton 35hp Gas Engine 48-157 Red Battery Cable 8892 Hose Wrap 48"...
Page 18: Hydraulic Diagram
HYDRAULIC DIAGRAM 76-023 Hydraulic Valve Relief Valve set at 2000 psi (137.93 bar) 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 19 HYDRAULIC DIAGRAM PARTS LIST REF# PART# DESCRIPTION QUANTITY 34-103 Oribitrol 18-188 45° Oring Elbow 76-654 Hose, 82" 76-651 Hose, 86 15-839 Hydraulic Cylinder 23-172 Cooler 76-458 Cooler Mount Kit 60-473 Oil Tank 8917 Suction Hose 38" 18-040 Hose Clamp 76-652 Hydraulic Hose, 35"...
Page 20: Parts
BODY AND FRAME DRAWING When Filtration System is to be installed, Ref. 13 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 21 # ABC Dry Chemical Fire Extinguisher 76-372 Inclinometer 76-373 Inclinometer Bracket 76-643 Steering Column 20-057 Steering Wheel, 15" 20-129 Center Cap 27-077 Decal, "Smithco" 76-265 Gas Console 77-193 Diesel Console 14-294 Seat 75-561 Right Tower 75-570 Cross Bar 76-359 Hopper Screen Cover...
Page 22: Roll Over Protection (Rops)
ROLL-OVER PROTECTION DRAWING...
Page 23 ROLL-OVER PROTECTION PARTS LIST REF# PART# DESCRIPTION QUANTITY HB-12-13-450 Hex Bolt, 1/2 - 13 41/2 HW-12 Flat Washer, 1/2 HNTL-12-13 Lock Nut, 1/2 - 13 75-561 Right Tower 76-379 Right Support HB-12-13-125 Hex Bolt, - 13 x 1 HW-12 Flat Washer, HNTL-12-13 Lock Nut, - 13...
Page 24: Steering
STEERING DRAWING...
Page 25 HB-14-20-100 Hex Bolt, 1/4 - 20 x 1 HNTL-14-20 Nylon Lock Nut, 1/4 - 20 45-155 Flange Bearing 20-129 Steering Wheel Cap 27-077 Decal, "Smithco" 20-057 Steering Wheel,15" 76-301 Rubber Cap HNA-114-12 Axle Nut, 1 - 12 HP-18-150 Cotter Pin, 18-188 45°...
Page 26 FRONT FORK DRAWING...
Page 27: Front Fork
FRONT FORK PARTS LIST REF# PART# DESCRIPTION QUANTITY 60-130 Tire & Wheel 60-130-01 Tire, 18 x 9.5 - 8 60-130-02 Wheel 8839 Windshield Washer Fluid or Equivalent 28 pints 11-040 Spacer HNJ-34-16 Jam Nut, - 16 60-511 Axle Lock HNA-34-16 Axle Nut, - 16 HMB-34-10...
Page 28: Cooler And Steps
COOLER AND STEP DRAWING...
Page 29 COOLER AND STEP PARTS LIST REF# PART# DESCRIPTION QUANTITY 48-159 Battery Box Cover 48-164 Magnet 8803 Black Trim 10" HB-38-16-300 Hex Bolt, -16 x 3 HW-38 Flat Washer, HNTL-38-16 Nylon Lock Nut, - 16 76-458 Cooler Mount Bracket 23-184 Male Connector 23-172 Oil Cooler 48-165...
Page 30: Gasoline Linkage
GAS LINKAGE DRAWING...
Page 31 GAS LINKAGE PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-299 Pedal Pad Long HB-516-18-075 Hex Bolt, - 18 x HW-516 Flat Washer, HNTL-516-18 Nylon 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...
Page 32 DIESEL LINKAGE DRAWING...
Page 33: Diesel Linkage
DIESEL LINKAGE PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-299 Pedal Pad Long HB-516-18-075 Hex Bolt, - 18 x HW-516 Flat Washer, HNTL-516-18 Nylon 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...
Page 34: Gas Console
GAS CONSOLE DRAWING...
Page 35 GAS CONSOLE PARTS LIST REF# PART# DESCRIPTION QUANTITY 77-261 Circuit Breaker 8977 Circuit Breaker Boot 12-804 Hour Meter 76-397 Voltmeter 13-488 Key Switch 76-310 Key Set 76-528 Throttle Cable HSM-10-32-063 Machine Screw, 10 - 32 x HWL-10 Lock Washer, 10 HN-10-32 Hex Nut, 10 - 32 80-020...
Page 36: Diesel Console
DIESEL CONSOLE DRAWING...
Page 37 DIESEL CONSOLE PARTS LIST REF# PART# DESCRIPTION QUANTITY 50-359 Warning Indicator Light 12-804 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 Lock Washer, 10 HN-10-32...
Page 38: Gas Tank And Oil Tank
GAS TANK AND OIL TANK DRAWING...
Page 39 GAS TANK AND OIL TANK PARTS LIST REF# PART# DESCRIPTION QUANTITY 18-009 Street Elbow 18-133 Barb Fitting 18-008 Pipe Reducer, 18-093 Male Run Tee, 18-140 Street Elbow, 60-213 Strainer 17-019 Elbow HB-516-18-150 Hex Bolt, - 18 x 1 HW-516 Flat Washer, HNTL-516-18 Nylon Lock Nut, - 18...
Page 40: Fuel Tank And Oil Tank
DIESEL FUEL TANK AND OIL TANK DRAWING...
Page 41 DIESEL FUEL TANK AND OIL TANK PARTS LIST REF# PART# DESCRIPTION QUANTITY 8800 Fuel Hose, " 24" 15-491 Fuel Tank HB 14-20-075 Hex Bolt, - 20 x HWL-14 Lock Washer, HW-14 Flat Washer, 77-179 Diesel Fuel Cap with Gauge 26-054 Bushing Insert (part of tank) 26-055...
Page 42: Oil Filter
23-006 OIL FILTER ASSEMBLY 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 Hex Bolt, - 20 x HWL-14 Lock Washer, HW-14 Flat Washer, 75-806 Filter Bracket 23-183 Male Connector 18-190...
Page 43: 76-627 Hydraulic Lift Cylinder
76-627 HYDRAULIC LIFT CYLINDER REF# PART# DESCRIPTION QUANTITY 18-202 Elbow 23-167 Elbow 76-627 Hydraulic Cylinder 76-242-01 Seal Kit HCP-100-325 Clevis Pin, 1 x 3 HHP-.177 Bridge Pin NOTE: 2 Cylinders per Machine. Torque Specification Piston Nut 165 ft/lbs (214.5 Nm) Tie Rod Nut 30 ft/lbs (39 Nm) Clevis Nut...
Page 44: 76-478 Reel Lift Cylinder
76-478 REEL LIFT CYLINDER REF# PART# DESCRIPTION QUANTITY HNTL-38-16 Nylon 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 Hex Bolt, - 16 x 1 8820 Machine Chain St.
Page 45: 77-263 Tailgate Cylinder
77-263 TAILGATE CYLINDER REF# PART# DESCRIPTION QUANTITY HHP-18 Bridge Pin, 77-263 Hydraulic Cylinder, 1 14-530 Seal Kit HNJ-58-18 Jam Nut, 18-154 Rod End HG-14-28-180 Grease Fitting, - 28 x 180° HNTL-58-11 Nylon Lock Nut, - 11GA HMB-58-14 Machine Bushing, - 14GA HB-58-11-200 Hex Bolt, - 11 x 2...
Page 46: 15-839 Steering Cylinder
15-839 STEERING CYLINDER REF# PART# DESCRIPTION QUANTITY HB-58-11-250 Hex Bolt, ⁵/8 - 11 x 21/2 HNTL-58-11 Nylon Lock Nut, ⁵/8 - 11 HMB-58-14 Machine Bushing, ⁵/8 - 14GA HNJ-58-18 Jam Nut, ⁵/8 - 18 18-169 ³/8 Adapter HCP-58-175 Clevis Pin, ⁵/8 x 1³/4 HHP-18 Bridge Pin, 1/8 15-839...
Page 47 NOTES...
Page 48: Vanguard Gas Engine And Exhaust
GAS ENGINE AND EXHAUST DRAWING...
Page 49 GAS ENGINE AND EXHAUST PARTS LIST REF# PART# DESCRIPTION QUANTITY 18-133 Barb Fitting 23-133 Adjustable Elbow, 90° 76-197 Gear Pump 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 50-394` Muffler Clamp 76-448...
Page 50: Kubota Diesel Engine And Exhaust
KUBOTA DIESEL ENGINE AND EXHAUST DRAWING...
Page 51 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 77-266 Hydrostatic Pump 18-204 Elbow 90° 18-202 Elbow 23-130 Elbow, 90° 77-249 Diesel Air Intake 42-004-02...
Page 52 KUBOTA DIESEL ENGINE AND EXHAUST DRAWING (CONTINUED)
Page 53 KUBOTA DIESEL ENGINE AND EXHAUST PARTS LIST (CONTINUED) REF# PART# DESCRIPTION QUANTITY 77-185 Front Engine Mount HB-38-16-175 Hex Bolt, - 16 x 1 HNTL-38-16 Nylon Lock Nut, - 16 8951 Lower Radiator Hose 26" 77-243 Radiator Mount 77-208-04 Goose Neck (part of engine) 77-184 Cable Bracket...
Page 54: Electric Clutch Driven Belt Drive
ELECTRIC CLUTCH DRIVEN BELT DRIVE DRAWING...
Page 55 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 Heat Shrink Tubing 8.5" 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 56: Finger/Brush Reel
FINGER/BRUSH REEL DRAWING Do not lift reel head while engaged. Turn off reel before lifting or lowering.
Page 57 FINGER /BRUSH REEL PARTS LIST REF# PART# DESCRIPTION QUANTITY HB-34-10-550 Hex Bolt, - 10 x 5 HNTL-34-10 Nylon Lock Nut, - 10 33-435 Tire and Wheel 33-435-02 Wheel with Roller Bearing 33-435-03 Roller Bearing 33-435-04 Bushing 48-046 Castor Fork HMB-100-10 Machine Bushing, 1 x 10GA 29-585 Spacer Height Adjustment...
Page 58: Rear Axle
REAR AXLE DRAWING Torque to 160 ft/lbs(208Nm)
Page 59 REAR AXLE PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-233 Rear Beater Panel HB-38-16-125 Hex Bolt, - 16 x 1 HW-38 Flat Washer, HNTL-38-16 Nylon Lock Nut, - 16 13-099 Hose Clamp HB-516-18-125 Hex Bolt, - 18 x 1 HWL-516 Lock Washer, HB-516-18-150 Hex Bolt, - 18 x 1...
Page 60 REAR AXLE DRAWING Torque to 160 ft/lbs(208Nm)
Page 61 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 Nylon Lock Nut, - 13 76-240 Left Caliper Counterclockwise 29-118...
Page 62 HOPPER DRAWING...
Page 63: 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 Hex Bolt, -18 x HW-516 Flat Washer, HNTL-516-18 Nylon Lock Nut, - 18 75-653 Hopper Safety Lift...
Page 64 HOPPER DRAWING...
Page 65 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 Hex Bolt, - 11 x 2 HMB-58-14 Machine Bushing, x 14GA HNCL-58-11 Center Nylon Lock Nut, - 11...
Page 66 TAILGATE DRAWING...
Page 67: Tailgate
TAILGATE PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-262 Tailgate Screen 76-243 Tailgate HB-12-13-300 Hex Bolt, - 13 x 3 HMB-12-14 Machine Bushing, x 14GA 75-565 Tailgate Hinge Strap HN-12-13 Hex Nut, - 13 75-564 Tailgate Hinge HNCL-12-13 Center Nylon Lock Nut, - 13 HNTL-38-16 Nylon Lock Nut,...
Page 68: Orbitrol
34-103 ORBITAL DRAWING...
Page 69 34-103 ORBITAL PARTS LIST REF # PART # DESCRIPTION QUANTITY Dust Seal Housing O-Ring Seal Quad Seal 10-576-03 Thrust Bearing 10-576-02 Bearing Race Manual Steering Relief Valve O-ring Plug 10‡ Standard Torque Centering Springs Sleeve 15-301-06 Wear Plate 10-576-01 Drive 15-301-08 Drive Pin Spool...
Page 70 Ro u n d an d 34-103 ORBITAL REPAIR DISASSEMBLY Squ ar e Ho u si n g w i t h Si d e Po r t s - Disassem bly Disassem bly Disassem bly Cleanliness is extremely impor- 2.
Page 71 Ro u n d an d 34-103 ORBITAL REPAIR REASSEMBLY Squ ar e Ho u si n g w i t h Si d e Po r t s - Reassem bly Reassem bly 19. Apply a light coating of Figure 4 clean hydraulic fluid to Check all mating surfaces.
Page 72: Eaton Hydrostatic Pump (Diesel)
77-266 EATON HYDROSTATIC PUMP DRAWING (DIESEL)
Page 73 77-266 EATON HYDROSTATIC PUMP PARTS LIST (DIESEL) REF# PART# DESCRIPTION QUANTITY 60-343-52 Drive Shaft (splined) 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...
Page 74: Eaton Hydrostatic Pump (Gas)
76-638 EATON HYDROSTATIC PUMP DRAWING (GAS)
Page 75 76-638 EATON HYDROSTATIC PUMP PARTS LIST (GAS) REF# PART# DESCRIPTION QUANTITY 76-398-01 Drive Shaft (splined) 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...
Page 76: Hydrostatic Pump Repair Instructions
76-638/77-266 REPAIR DISASSEMBLY INSTRUCTIONS Model 70160 Repair Information - Disassembly The same charge pressure relief valve spring retainer is used Disassembly with either the standard or high The following disassembly procedure applies to a single pump pressure (see Figure 6). with or without gear pump The Figure 6 repair procedure for tandem...
Page 77 76-638/77-266 REPAIR DISASSEMBLY INSTRUCTIONS Model 70160 Repair Information - Disassembly 21 Remove the valve plate from the piston block assembly. 13 When the needle bearing Numbered End Flange Note: This valve plate may have stuck to the backplate assembly is replaced, the assembly that was previously removed.
Page 78 76-638\77-266 REPAIR DISASSEMBLY INSTRUCTIONS Model 70160 Repair Information - Disassembly 28 With the retaining ring Figure 25 Figure 31 removed, use a small press to press the shaft seal and input shaft assembly from the housing assembly. Figure 32 29 With the input shaft assembly removed, disassemble the 34 Use an o-ring pick or similar tool to remove the o-ring assembly for inspection by...
Page 79 76-638/77-266 REPAIR REASSEMBLY INSTRUCTIONS Model 70160 Repair Information - Reassembly Reassembly Lubricate and install the o-ring seal into counter-bore of housing Before reassembling the pump, replace all worn and (see Figure 41). damaged parts, assemblies, seals and o-rings. Lubricate the seals and o-rings with petroleum jelly to help retain them 10 Install the trunnion cover over during reassembly and to provide lubrication to the input and...
Page 80 76-638/77-266 REPAIR REASSEMBLY INSTRUCTIONS Model 70160 Repair Information - Reassembly 18 Lubricate and install the 25 Align the spline of the Figure 47 Figure 53 thrustplate over the input shaft gerotor’s inner ring, then lubricate assembly and into the camplate. and install the inner ring and outer The thrustplate must rest firmly in ring over the input shaft and onto...
Page 81 76-638/77-266 TROUBLE SHOOTING Model 70160 Fault - Logic Troubleshooting Explanatory This fault - logic troubleshooting guide is a Diagram diagnostic aid in locating transmission problems. Symptom: Match the transmission symptoms with the problem Action statements and follow the action steps shown in the Step box diagrams.
Page 82 76-638/77-266 TROUBLESHOOTING Model 70160 Fault - Logic Troubleshooting Symptom: Neutral Difficult or Impossible to Find Inspect Inspect External Control Servo Control Linkage (If used) Defective Defective Repair Repair Replace Replace Symptom: System Operating Hot Inspect Heat Check Inspect Check Exchanger Oil Level in Heat Charge...
Page 83 76-638/77-266 TROUBLESHOOTING Model 70160 Fault - Logic Troubleshooting Symptom: Operates in One Direction Only Inspect Inspect Inspect External Control Servo Control System Relief Linkage (If used) Valves Defective Defective Defective Repair Repair Repair Replace Replace Replace Symptom: System Response Sluggish Check Inspect Inspect Pump...
Page 84 76-638/77-266 TROUBLESHOOTING Model 70160 Fault - Logic Troubleshooting Symptom: System Will Not Operate In Either Direction Inspect Pump Check Check External Check Bypass Valve Oil Level in Control Charge (If used) Reservoir Linkage Pressure Below Level Defective Defective Fill to Repair Repair Proper...
Page 85 76-638/77-266 TROUBLESHOOTING...
Page 86 76-638/77-266 START-UP PROCEDURE Model 70160 Start-up Procedure When starting a new or rebuilt transmission system, it is 6 After the system starts to show signs of fill, slowly move extremely important to follow the start-up procedure. It pump camplate to a slight cam angle. Continue to operate prevents the chance of damaging the unit which might occur if system slowly with no load on motors until system the system was not properly purged of air before start-up.
Page 87: Gear Pump
76-197 EATON GEAR PUMP DRAWING 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 88: Gear Pump Repair Instructions
76-197 REPAIR DISASSEMBLY INSTRUCTIONS 7. Remove backplate.
Page 89 76-197 REPAIR DISASSEMBLY INSTRUCTIONS...
Page 90 76-197 REPAIR INSPECTION...
Page 91 76-197 REPAIR REASSEMBLY INSTRUCTIONS...
Page 92 76-197 REPAIR REASSEMBLY INSTRUCTIONS 76-197 REPAIR TROUBLESHOOTING...
Page 93 76-197 REPAIR TROUBLESHOOTING...
Page 94: Rear Wheel Motor
76-238 REAR WHEEL MOTOR DRAWING (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 95: Wheel Motor Repair Instructions
76-238 TROUBLESHOOTING CHECKLIST Torqmotor™ Service Procedure HY13-1527-M1/US Troubleshooting Checklist TF, TG, TH and TL Series Trouble Cause Remedy Oil Leakage 1. Hose fittings loose, worn or Check & replace damaged damaged. fittings or “O” Rings. Torque to manufacturers specifications. 2. Oil seal rings (4) deteriorated by Replace oil seal rings by disassembling excess heat.
Page 96 Torqmotor™ Service Procedure HY13-1527-M1/US 76-238 SERVICING TOOL LIST Tools and Materials Required for Servicing TF, TG, TH and TL Series • Clean, petroleum-based solvent • Emery paper • Vise with soft jaws • Air pressure source Torqmotor™ Service Procedure • Arbor press HY13-1527-M1/US Technical Information TF, TG, TH and TL Series...
Page 97 76-238 ASSEMBLY REFERENCE DRAWING Torqmotor™ Service Procedure HY13-1527-M1/US Torqmotor™ Exploded View TF, TG, TH and TL Series Typical Assembly Item Description Wear Plate 18. Housing Special Bolts (5, 6, or 7) 10. Drive Link 18a. O-Ring (2) 1a. Special Bolts (7) 11.
Page 98 76-238 DISASSEMBLY AND INSPECTION Torqmotor™ Service Procedure HY13-1527-M1/US Disassembly and Inspection TF, TG, TH and TL Series Preparation Before Disassembly • Before you disassemble the Torqmotor™ unit or any of its components read this entire manual. It provides important information on parts and procedures you will need to know to service the Torqmotor™. •...
Page 99 76-238 DISASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Disassembly and Inspection TF, TG, TH and TL Series Reference Exploded Assembly View Place 1. Place the Torqmotor™ in a soft jawed vise, with coupling shaft (12) pointed down and Torqmotor the vise jaws clamping firmly on the sides in a vise of the housing (18) mounting flange or port bosses.
Page 100 76-238 DISASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Disassembly and Inspection TF, TG, TH and TL Series Remove end 4. Remove end cover assembly (2) and seal cover & ring (4). Discard seal ring. SEE FIGURE 6. inspect bolts NOTE NOTE: Refer to the appropriate “alternate cover construction”...
Page 101 76-238 DISASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Disassembly and Inspection TF, TG, TH and TL Series Remove & 8. Remove commutator (5) and seal ring (3) inspect Remove seal ring from commutator, using commutator an air hose to blow air into ring groove until seal ring is lifted out and discard seal ring.
Page 102 76-238 DISASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Disassembly and Inspection TF, TG, TH and TL Series NOTE NOTE: Series TG or TH may have a rotor set with two stator halves (8B & 8D) with a seal ring (4) between them and two sets of seven vanes (8C &...
Page 103 76-238 DISASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Disassembly and Inspection TF, TG, TH and TL Series Check coupling 14. Check exposed portion of coupling shaft shaft for rust or (12) to be sure you have removed all signs corrosion of rust and corrosion which might prevent its withdrawal through the seal and bearing.
Page 104 76-238 DISASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Disassembly and Inspection TF, TG, TH and TL Series Remove shaft 17. Remove shaft seal (16), backup ring (17), seal, backup and backup washer (25) from housing washer & backup by working them around unseated thrust ring washers (14) and thrust bearing (15) and out of the housing.
Page 105 76-238 DISASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Disassembly and Inspection TF, TG, TH and TL Series Inspect housing 20. If the housing (18) assembly has passed bearing inspection to this point, inspect the housing bearings (19) and (13) and if they are captured in the housing cavity the two thrust washers (14) and thrust bearing (15).
Page 106 76-238 ASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Torqmotor™ Assembly TF, TG, TH and TL Series • Replace all seals and seal rings with new ones each time you reassemble the Torqmotor™ unit. Lubricate all seals and seal rings with SAE 10W40 oil or clean grease before assembly. •...
Page 107 76-238 ASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Torqmotor™ Assembly TF, TG, TH and TL Series NOTE NOTE: Bearing mandrel must be pressed against the lettered end of bearing shell. Take care that the housing bore is square with the press base and the bearing is not cocked when pressing a bearing into the housing.
Page 108 76-238 ASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Torqmotor™ Assembly TF, TG, TH and TL Series Place housing 4. Invert housing (18) assembly into a soft assembly into jawed vise with the coupling shaft bore vise down, clamping against the mounting flange.
Page 109 76-238 ASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Torqmotor™ Assembly TF, TG, TH and TL Series Assemble backup 6. A housing (18) that did not require washer & seal replacement of the bearing package will require that the two “captured” thrust washers (14) and thrust bearing (15) be unseated and vertical to the counterbore and the new backup ring (17), new backup...
Page 110 76-238 ASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Torqmotor™ Assembly TF, TG, TH and TL Series Install coupling 8. Be sure that a generous amount of clean shaft corrosion resistant grease has been applied to the lower (outer) housing bearing (19). Install the coupling shaft (12) into housing (18), seating it against the second thrust washer (14).
Page 111 76-238 ASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Torqmotor™ Assembly TF, TG, TH and TL Series Install drive link 11. Install drive link (10) the long splined end down into the coupling shaft (12) and engage the drive link splines into mesh with the coupling shaft splines.
Page 112 76-238 ASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Torqmotor™ Assembly TF, TG, TH and TL Series Apply clean grease to a new seal ring (4) and assemble it in the seal ring groove in the rotor set contact side of manifold (7). SEE FIGURE 46.
Page 113 76-238 ASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Torqmotor™ Assembly TF, TG, TH and TL Series Assemble seal & 16. Assemble a new seal ring (3) flat side commutator up, into commutator (5) and assemble commutator over the end of drive link (10) onto manifold (7) with seal ring side up.
Page 114 76-238 ASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Torqmotor™ Assembly TF, TG, TH and TL Series Assemble seal 19. Assemble a new seal ring (4) into end ring & end cover cover (2) and assemble end cover onto the commutator set. SEE FIGURES 54 and 55. Figure 54 NOTE NOTE: If the end cover has a valve (24),...
Page 115 76-238 ASSEMBLY INSTRUCTIONS Torqmotor™ Service Procedure HY13-1527-M1/US Torqmotor™ Assembly TF, TG, TH and TL Series NOTE NOTE: The special bolts required for use with the relief or shuttle valve (24) end cover assembly (2) are longer than the bolts required with standard and cover assembly.
Page 116 76-238 ASSEMBLY FINAL CHECKS Torqmotor™ Service Procedure HY13-1527-M1/US Final Checks TF, TG, TH and TL Series Final Checks • Pressurize the Torqmotor™ with 100 p.s.i. dry air or nitrogen and submerge in solvent to check for external leaks. • Check Torqmotor™ for rotation. Torque required to rotate coupling shaft should not be more than 50 ft.
Page 117: 3-Bank Hydraulic Valve
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 Flat 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 118: Accessories
76-271 DUST/DIRT FILTRATION SYSTEM...
Page 119 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) *15-437-01 Keeper 76-263...
Page 120: French Brush Reel
76-488 FRENCH BRUSH REEL KIT PART# DESCRIPTION QUANTITY HB-516-18-175 Bolt - 18 x 1 HW-14 Washer 75-686 Spacer 75-511 Pillow Block HNTL-516-18 Lock Nut - 18 75-834 Spacer 76-102 Pulley with Hub 76-102-01 Hub Only HKSQ-14-150 Square Key 76-456 Brush Reel Frame 76-455 Brush...
Page 121: Reference
Tire Pressure 20 psi 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 122: Quick Reference Replacement Parts
QUICK REFERENCE REPLACEMENT PARTS REPLACEMENT FILTERS 23-031 Hydraulic Oil Filter 76-487 Engine Oil filter Briggs # 842921 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...
Page 123 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: Smithco Product Support Department 200 West Poplar Ave.
Page 124 This warranty does not apply to normal “wear and tear” items. Normal “Wear and Tear” includes, but is not limited 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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