Smithco SWEEP STAR 60 Service Manual

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Summary of Contents for Smithco SWEEP STAR 60

Page 1 PARTS & SERVICE MANUAL SWEEP STAR 60 GAS & DIESEL with Electric Clutch Models 76-000-B and 77-100-B Starting Serial #: D or G 1538 August, 2002 SMITHCO PRODUCT SUPPORT 1-800-891-9435 Hwy SS and Poplar Avenue, Cameron WI 54822 E-mail: productsupport@smithco.com...
Page 2: Table Of Contents
CONTENTS Introduction ......... 1-10 Introduction ................. 1-3 Safe Practices ................2 Specifications ................3 Optional Equipment ..............3 Service ..................4-11 Maintenance ................4-6 Service Chart Kohler Command 25 hp ........7 Service Chart Kubota Diesel 18.8 hp .......... 8 End User’s Service Chart ............
Page 3: Introduction
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. Refer to engine manual for placement of engine serial number.
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 66" (168 cm) Height with Hopper Up 127" (323 cm) Wheel Base 68.5" (174 cm) Weight 2200 lbs (998 kg)
Page 6: Service
MAINTENANCE LUBRICATION Use No. 2 General Purpose Lithium Base Grease and lubricate every 100 hours. The Sweep Star 60 has ten grease fittings. One on the outside of each tower. One on the center of park brake relay on rear axle.
Page 7 TOWING When it is necessary to move the Sweep Star 60 without engine running, the bypass valve built into hydrostatic pump must be “open” by turning it counterclockwise. The valve is located on bottom left of pump. An “open” valve allows fluid to pass through the wheels freely.
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 Kohler Command 25 Hp
SERVICE CHART KOHLER COMMAND 25 HP 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.
Page 10: Service Chart Kubota Diesel 18.8 Hp
SERVICE CHART KUBOTA DIESEL 18.8 HP 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.
Page 11: End User's Service Chart
END USER’S SERVICE CHART Engine Oil w/ Filter Engine Oil Filter Engine for Leaks and Loose Parts Air Cleaner (Paper Element) Pre-Cleaner (Every 25 hours) Spark Plugs Idle Speed Cooling System Belts and Hoses Tire Pressure Visual Inspection of Tires Fuel Level Fuel Filter Hydraulic Oil...
Page 12: 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 13: Notes
NOTES...
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 22-054 Black Battery Cable 75-518 Red Battery Cable 8892-40 Hose Wrap x 40 50-359 Warning Indicator Lights 77-209 Hour Meter to Ground Wire 12-017 Hour Meter 34-146 Panel Mount Circuit Breaker 34-145 Circuit Breaker Boot 17-068...
Page 16: Gas Wiring Diagram/Schematic
GAS WIRING DIAGRAM Color Code Chart Blue Brown Yellow Green Orange Black Purple White...
Page 17 GAS WIRING PARTS LIST REF# PART# DESCRIPTION QUANTITY 22-003 Ammeter 76-269 Power Wire to Hour Meter 12-017 Hour Meter 76-259 Ground Wire for Hour Meter 76-260 Ground Wire for Ignition Switch 34-146 Panel Mount Circuit Breaker 34-145 Circuit Breaker Boot 13-288 Key Switch with Hardware (Kohler #25 099 04)
Page 18: Hydraulic Diagram/Schematic
HYDRAULIC DIAGRAM 76-023 Hydraulic Valve Relief Valve set at 2000 psi (137.93 bar) 76-100 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 76-242 Hydraulic Cylinder 76-115 Hydraulic Hose 76-114 Hydraulic Hose 76-238 Wheel Motor 34-057 76-208 Hydraulic Hose 8832-21 Suction Hose 18-040 Hose Clamp 8895-22 1" Hose Wrap (Gas Unit Only) 8895-20 1" Hose Wrap (Diesel Unit Only) 18-222 Hose Clamp...
Page 20: Hydraulic Schematic
HYDRAULIC SCHEMATIC...
Page 21 NOTES...
Page 22: Parts
BODY AND FRAME DRAWING...
Page 23 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 76-302 Steering Wheel w/ Cap 76-265...
Page 24: Steering
STEERING DRAWING...
Page 25 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 (comes with 76-362) 76-302 Steering Wheel with Cap 76-303 Cap Nut - 18 75-833 Universal Joint HRP-532-150 Roll Pin HSSHS-38-16-038 Socket Head Set Screw - 16 x...
Page 26: Front Fork
FRONT FORK DRAWING...
Page 27 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 28: Linkage
LINKAGE DRAWING...
Page 29 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 ( Start Serial Number 1120) 18-234 Oilite Bushing...
Page 30: Gas Console
GAS CONSOLE DRAWING...
Page 31 GAS CONSOLE PARTS LIST REF# PART# DESCRIPTION QUANTITY 34-146 Panel Mount Circuit Breaker 34-145 Circuit Breaker Boot 12-017 Hour Meter 22-003 Ammeter 13-288 Key Switch (with hardware Kohler# 25 099 04) 76-310 Key Set 34-160 Throttle 48" 34-159 Throttle Mounting Bracket HSM-10-32-063 Machine Screw 10 - 32 x HSM-10-32-100...
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 34-146 Panel Mount Circuit Breaker 34-145 Circuit Breaker Boot 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 HSM-10-32-100 Machine Screw 10 - 32 x 1 HWL-10...
Page 34: Fuel Tank And Oil Tank
FUEL TANK AND OIL TANK DRAWING...
Page 35 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 18-140...
Page 36 OIL FILTER DRAWING HYDRAULIC LIFT CYLINDER DRAWING...
Page 37: 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 38: Reel Lift Cylinder
REEL LIFT CYLINDER DRAWING TAILGATE CYLINDER DRAWING...
Page 39 REEL LIFT CYLINDER PARTS LIST REF# PART# DESCRIPTION QUANTITY HNTL-38-16 Lock Nut - 16 18-169 Adapter 75-634 Hydraulic Cylinder 2 x 7 x HP-18-100 Cotter Pin HCP-12-350 Clevis Pin 75-827 Cylinder Bracket HB-38-16-150 Bolt - 16 x 1 8820-6 Machine Chain St. Link HB-38-16-350 Bolt - 16 x 3...
Page 40: Kohler Gas Engine And Exhaust
KOHLER GAS ENGINE AND EXHAUST DRAWING...
Page 41 KOHLER GAS 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° 18-204 Elbow 90° 18-168 Elbow 90° 23-130 Elbow 90° 76-266 Engine Cover 18-220 Muffler Clamp 76-348 Muffler...
Page 42: Kubota Diesel Engine And Exhaust
KUBOTA DIESEL ENGINE AND EXHAUST DRAWING...
Page 43 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° 77-130 Mounting Kit 76-100 Hydrostatic Pump 18-204 Elbow 90° 18-168 Elbow 90° 23-130 Elbow 90°...
Page 44 KUBOTA DIESEL ENGINE AND EXHAUST DRAWING (CONTINUED)
Page 45 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 76-228 Beater Relay 77-184 Cable Bracket HBM-8-1-25 Metric Bolt #8 - 1 - 25 HWLI-516 Internal Lockwasher HBM-6-1-16...
Page 46: Belt Drive
MANUAL BELT DRIVE DRAWING...
Page 47 MANUAL BELT DRIVE PARTS LIST REF# PART# DESCRIPTION QUANTITY 21-173 Ball Joint - 24 76-228 Beater Relay HN-38-24 - 24 HWL-38 Lockwasher 76-283 Beater Clutch Rod HN-38-24 - 24 76-212 Belt Guard HB-38-16-300 Bolt - 16 x 3 HW-38 Washer HWL-38 Lockwasher HN-38-16...
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 76-337 Electric Clutch 16-013 Idler Pulley 76-217 Idler Arm 76-298 Spacer HB-12-13-300 Bolt - 13 x 3 HW-12 Washer HNTL-12-13 Lock Nut...
Page 50 FINGER REEL DRAWING...
Page 51: Finger Reel
FINGER 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 29-585 Spacer Height Adjustment 18-223 Bushing 2 per (part of 76-355) 76-355 29-584 Height Adjustment Spacer ”...
Page 52 REAR AXLE DRAWING Torque to 160 ft/lbs(208Nm)
Page 53: Rear Axle
REAR AXLE PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-218 Brake Cable Bracket HB-38-16-125 Bolt - 16 x 1 HW-38 Washer HNTL-38-16 Lock Nut - 16 HB-12-13-450 Bolt - 13 x 4 HNTL-12-13 Lock Nut - 13 HB-12-13-400 Bolt - 13 x 4 76-229 Park Brake Relay HN-516-24...
Page 54 HOPPER DRAWING...
Page 55: Hopper
HOPPER PARTS LIST REF# PART# DESCRIPTION QUANTITY 75-566 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-516-18-100 Bolt -18 x 1 HNFL-516-18 Flange Whiz Lock Nut - 18 75-653 Hopper Safety Lift HB-38-16-250 Bolt...
Page 56 TAILGATE DRAWING...
Page 57: 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-38-16-100...
Page 58: 76-100 Eaton Hydrostatic Pump
76-100 EATON HYDROSTATIC PUMP DRAWING (MODEL 70145-RBF)
Page 59 76-100 EATON HYDROSTATIC PUMP PARTS LIST (MODEL 70145-RBF) REF# PART# DESCRIPTION QUANTITY 60-343-01 Retaining Ring 60-343-02 Shaft Seal 60-343-03 Washer 60-343-05 Bearing Race 60-343-52 Drive Shaft (splined) 60-343-08 Needle Bearing (with housing) 60-343-10 Thrust Bearing 60-343-11 Washer 60-343-33 O-Ring Cover 60-343-18 Trunnion Cover 60-343-14...
Page 60: 76-197 Eaton Gear Pump
76-197 EATON GEAR PUMP DRAWING (MODEL 26001-RZJ)
Page 61 76-197 EATON GEAR PUMP PARTS LIST (MODEL 26001-RZJ) 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...
Page 62: 76-238 Rear Wheel Motor
76-238 REAR WHEEL MOTOR DRAWING (14.5 CI)
Page 63 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 64: 76-023 3-Bank Hydraulic Valve
76-023 3 -BANK HYDRAULIC VALVE DRAWING...
Page 65 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 66: Accessories
76-198 ROLLOVER PROTECTION DRAWING...
Page 67: Installation Instructions
76-198 ROLLOVER PROTECTION PARTS LIST REF# PART# DESCRIPTION QUANTITY 76-198-01 Right Seat Belt Bracket HB-38-16-200 Bolt - 16 x 2 HWL-38 Lockwasher HN-38-16 - 16 HB-716-14-100 Bolt - 14 x 1 HWL-716 Lockwasher HN-716-14 - 14 76-198-03 Seat Belt 76-198-04 Right Support 76-198-05 Roll Bar...
Page 68: 76-271 Dust/Dirt Filtration Pack
76-271 DUST/DIRT FILTRATION SYSTEM...
Page 69 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 70: Reference
NOTES...
Page 71: Decal List
DECAL LIST This is a list of decals located on the Sweep Star 60. Part number, description and location will help in reordering de- cals. 16-088* Moving Parts Hot Belt Guard 17-066 Diesel Side Panel (diesel only) 25-078 Caution No Riders...
Page 72: Quick Reference Replacement Parts
QUICK REFERENCE REPLACEMENT PARTS REPLACEMENT FILTERS KOHLER ENGINE 23-031 Hydraulic Oil Filter 78-090 Oil filter Kohler# 12 050 01 76-311 Air Filter Element Kohler# 24 083 03 76-312 Pre-Cleaner Kohler# 24 083 05 50-403 Fuel Filter for Kohler REPLACEMENT FILTERS KUBOTA ENGINE 77-215 Oil Filter Cartridge Kubota# 15841-32439...
Page 73: Limited Warranty
Batteries. Wheels and tires. A copy of the warranty for the above items is furnished if necessary with each SMITHCO product. Some states do not allow limitations on how long an implied warranty lasts, or the exclusion or limitations of incidental or consequential damages, so the above limitations or exclusions may not apply to you.

This manual is also suitable for:

76-000-b 77-100-b

Smithco SWEEP STAR 60 Service Manual

Introduction

Service

Diagrams

Parts

Accessories

Reference