Smithco TCV 5000 Guide de démarrage rapide

Operators

TCV 5000

Turf Care Vehicle

Model 31-000-C

SN: DT310032

June 2014

Product Support: Hwy SS & Poplar Ave; Cameron WI 54822

1-800-891-9435 productsupport@smithco.com

Parts & Service

Introduction Service Diagrams Parts Accessories Reference

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

Wheel Creep .........................................................................10

Adjustments...........................................................................10

Service Chart....................................................................11-12

Storage ..................................................................................13

Diagrams ........................................................................... 14-17

Wiring Diagram................................................................ 14-15

Hydraulic Diagram ........................................................... 16-17

Parts................................................................................... 18-47

Body and Frame .............................................................. 18-19

Nose Cone....................................................................... 20-21

Front Axle ......................................................................... 22-23

Oil and Fuel Tank ............................................................. 24-25

Seat Panel........................................................................ 26-27

Engine and Pumps........................................................... 28-29

Cooler and Exhaust.......................................................... 30-31

Gondola Box .................................................................... 32-33

Cargo Tailgate Box........................................................... 34-35

31-043 SIngle-bank Valve ............................................... 36-37

15-301 Orbitrol................................................................. 38-39

76-197 Gear Pump .......................................................... 40-41

30-102 Eaton Pump......................................................... 42-45

30-101 Eaton Motor ......................................................... 46-47

Reference .......................................................................... 48-50

Decal List ...............................................................................48

Quick Reference....................................................................50

Warranty .....................................................................................

Introduction

INTRODUCTION

Thank you for purchasing a SmithcoSmithco

SmithcoSmithco

Smithco

product.

Read this manual and all other manuals pertaining to theTCV 5000 carefully as they contain safety, operating,

assembly and maintenance instructions. Failure to do so could result in personal injury or equipment damage.

Keepmanualsin asafeplace afteroperatorand maintenance personnelhave read them.Right and leftsidesare

fromthe operator’sseat,facing forward.

All SmithcoSmithco

SmithcoSmithco

Smithco machineshavea Serial Number andModelNumber. Both numbers areneededwhen ordering

parts. Referto enginemanualfor placementofengine serialnumber.

For product and accessory information, help finding a dealer, or to register your procuct please contact us at

www.Smithco.com.

Informationneeded whenorderingreplacementparts:

1. ModelNumber ofmachine

2. SerialNumber ofmachine

3. Nameand Part Numberof part

4. Quantityof parts

For easy access record your Serial and Model numbers here.

CALIFORNIA

Proposition 65 Warning

Engineexhaust andsome ofits constituents

are known to the State of California to

cause cancer, birth defects, and other

reproductive harm.

WARNING

lb/kg Empty lb/kg Full

Introduction

SAFEPRACTICES

1. It is your responsibility to read this manual and all publications associated with this machine.

2. Neverallowanyone tooperate or servicethe machineorits optionalequipmentwithout propertrainingand

instructions.Neverallow minorstooperate anyequipment.

3. Learnthe proper useofthe machine, thelocationand purpose ofallthe controls andgaugesbefore you

operatetheequipment. Working withunfamiliar equipment canleadto accidents.

4. Wear all the necessary protective clothing and personal safety devises to protect your head, eyes, ears,

hands and feet. Operate the machine only in daylight or in good artificial light.

5. Inspect the area where the equipment will be used. Pick up all debris you can find before operating.

Bewareof overheadobstructionsand undergroundobstacles.Stayalert forhiddenhazards.

6. Neveroperate equipment thatisnot in perfectworking order orwithoutdecals, guards, shields,orother

protectivedevices inplace.

7. Never disconnect or bypass any switch.

8. Carbonmonoxidein theexhaust fumes canbe fatalwheninhaled, neveroperatea machinewithoutproper

ventilation.

9. Fuel is highly flammable, handle with care.

10. Keep engine clean.Allowtheengine to coolbeforestoring and always removethe ignition key.

11. Disengageall drivesand set parkbrake before startingtheengine.

12. Never use your handstosearch for oil leaks.Hydraulic fluid under pressurecanpenetrate the skin and

cause serious injury.

13. This machine demandsyourattention.Topreventloss of controlortipping of thevehicle:

A. Use extra caution in backing up the vehicle. Ensure area is clear.

B. Do not stop or start suddenly on any slope.

C. Reduce speed on slopes and in sharp turns. Use caution when changing directions on slopes.

D. Stay alert for holes in the terrain and other hidden hazards.

14. Beforeleaving operator’sposition:

A. Disengagealldrives.

B. Set park brake.

C. Shut engineoff andremove the ignitionkey.

D. If engine has to run to perform any maintenance keep hands, feet, clothing and all other parts of body

awayfrom movingparts.

15. Keep hands, feetandclothing away frommovingparts. Wait forallmovement to stopbeforeyou clean,

adjustorservice the machine.

16. Keep the areaofoperation clear ofallbystanders.

17. Stop enginebeforemaking repairs/adjustmentsor checking/addingoilto the crankcase.

18. Use parts and materials supplied by SmithcoSmithco

SmithcoSmithco

Smithco only. Do not modify any function or part.

These machines are intended for professional maintenance on golf courses, sports turf, and any other

area maintained turf and related trails, paths and lots. No guaranty as to the suitability for any task is

expressed or implied.

Introduction

SPECIFICATIONS

WEIGHTSANDDIMENSIONS

Length 128"(325cm)

Width 72"(183cm)

Heightw/ROPS 84" (213 cm)

Wheel Base 68" (173 cm)

Weight Empty 2355lbs(1068 kg)

Weight Full 7355lbs(3336 kg)

SOUNDLEVEL(DBA)

At earlevel 88.4 dBA

ENGINE

Make Kubota

Model# V1505

Code/Spec# 1G994-0000

Horsepower 35.5 hp (26.6 kW)

Fuel(EMISSIONS) No.1-D or No. 2-D, S500: Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%

No1-D or No.2-D, S15: Ultra Low Sulfur Diesel (ULSD) less than 15 ppm or 0.0015 wt.%

CoolingSystem LiquidCooled

LubricationSystem FullPressure

Alternator 40Amp

WHEELS&TIRE Front: Two 20 x 11.00 x 10 Turf; 20 psi (1.4 bar)

Rear: Two 29 x 14.00 x 15 Multi-Trac; 30 psi (2.0 bar)

SPEED

Infinitely Variable 0-10m.p.h. (0-18 kph)

BATTERY Automotivetype24F -12volt

BCIGroup Size 24

ColdCrankingAmps 900 minimum

GroundTerminal Polarity Negative(-)

MaximumLength 10.25" (26 cm)

Maximum Width 6.88" (17 cm)

MaximumHeight 10" (25 cm)

FLUIDCAPACITY

CrankcaseOil See EngineManual

Fuel 7 gallon(26.5liters)

HydraulicFluid 10 gallon (37.8liters)

Grade of Hydraulic Fluid SAE 10W-40API Service SJ or higher Motor Oil

Introduction

SETUP

TheDumpTruck arrivesfrom Smithco setupandready forservice. Dependingonfreight conditionsbatterymay

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).

2. Battery is located on right side of machine in front of rear tire. This is a negative grounding system.

Connecting battery cables to the wrong post could result in personal injury and/or damage

to the electrical system. Make sure battery and cables do not interfere or rub on any moving

part. Connect red positive (+) cable (A) to battery first. When disconnecting remove black

negative (-) cable (B) first.

3. Check hydraulic fluid level in tank located under the seat.

Removecapand addSAE10W-40APIServiceSJ or

highermotoroil if necessary. Fluid levelshouldbe about

2-21/2" (5-6.4 cm) from the top of the tank when cold. DO

NOTOVERFILL.

4. Fill fuel tank, located on right side, with No. 2 diesel

Fuel is flammable, caution must be used when

storing or handling it. Do not fill fuel tank while

engine is running or an enclosed area, fumes

are explosive and dangerous to inhale. DO NOT

SMOKE while filling the fuel tank. DO NOT

OVERFILL

5. Machineshouldbe greasedbefore starting, referto Maintenance forgreasefitting location.

6. Readoperating instructionsbeforestarting.

FUEL

CHECKEMISSION REGULATIONS OFYOURAREA

With Emission control now in effect diesel fuel specification type and sulfur content % (ppm) used must be in

compliant with all applicable emission regulations for the area in which the engine is operated.

Use of diesel fuel with sulfur content less than 0.10% (1000 ppm) is strongly recommended.

If high sulfur fuel is used, change oil and oil filters twice as often.

DONOTUSE Fuelsthathave sulfurcontentgreater than 1.0%(10000 ppm).

Dieselfuelsspecified inEN590 orASTMD975are recommended.

Since KUBOTAdiesel engines of less than 56kW (75 hp) utilize EPATire 4 and InterimTier 4 Standards, the use

oflowsulfur fuel orultra low sulfurfuelis mandatory fortheseengines, when operatedin US EPAregulatedar-

eas.Therefore,use No.2-DS500or S15dieselfuel asaalternative toe No.2-D for ambienttemperatures below -

10°C(14° F).

TOWING

When it is necessary to move the dump truck without the engine running, there are 2 things that need to be

done. First, the bypass valve built into hydrostatic pump must be "open" by turning it 1/4turn to open. The valve

is located on the back side of the pump.An "open" valve allows fluid to pass through the wheels freely. When

normaldrivenoperation is desired,valve should be"closed"by turning itclockwise. Failure to"close"the valve

withenginerunning means nopower to wheels.Secondly, the handbrakeneeds tobemanually released.The

hand brake is located under the engine. To manually release the brake you must loosen the locknut and screw

in the stem to the bottom. Tighten the lock nut and pump handle until hard.

Introduction

A. HourMeter- The hourmeter indicates hoursofmachine operation. Itoperates only whentheignition

switch is on.

B. Glow Plug - When ignition is turned on, glow plug lights when ready to start.

C. Ignition Switch - The ignition switch has three positions: Off - Run - Start.

D. TiltSteering-Holdlever downandadjust steeringwheelto desiredpositionand releaselever.

E. 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

engineoffimmediately andfindthe cause.

F. WaterTemperature Light - Temperature light will come on and a buzzer will sound when the engine starts

tooverheat.

G. Lights - This rocker switch turns lights on by pushing on the top and off by pushing on the bottom.

H. Speedometer -The Speedometer indicates

groundspeedof thevehiclein milesperhour

andkilometers per hour.

I. Cup Holder -Holds2 x-large cups.

J. Hand Throttle - The hand throttle is used to

regulateengine speed.

K. Park Brake Toggle Switch - This toggle switch

willengage park brake.Lift toggle coverand

moveswitchforward.DO NOTENGAGE

WHILE IN MOTION.

L. DumpBox Lever -Liftsand lowers dumpbox.

MANUALBRAKEHANDPUMPMANIFOLD

Thehandbrake is locatedunder the engine.Thehand brake iscon-

nectedtohe seat switch andautomaticallyengages when operator

gets up from the seat. So when machine is not being driven, the ma-

chine is locked down. If engine is not running or you are towing the

machine you will have to manually release the brake. To manually

release the brake you must loosen the locknut and screw in the

stem to the bottom. Tighten the lock nut and pump handle until hard.

Run machine at half-throttle minimum, prior to operating

tration pedal. This will ensure proper brake release.

CONTROLS&INSTRUMENTS

Service

OPERATION

Before operating the Smithco Dump Truck, become familiar with all controls and functions.Also complete all

maintenancerequirements andread all safetywarnings. Knowing theDumpTruckthoroughly, howitoperates,

and by doing the prescribed maintenance steps, you can expect trouble free operation for years to come.

SAFETY

Operatorneedsto alwaysbethe concern ofan operator ofamoving vehicleorany machinewithmoving parts.

1. Keep all shields and guards in place.

2. Keeptheparking brakeengagedany timetheoperator isawayfrom thevehicleor wheneverserviceis

performed.

3. Alwayswearthe necessaryprotectiveclothing andequipment.

4. Turnengine offwhenrefuelingorperformingmaintenance notspecifically requiringengine power.

DAILYCHECKLIST

1. Checktheengine oillevel.Add asneeded.DO NOT OVERFILL. Referto engine owner'smanual for oil

gradeandprocedure.

2. Tire pressure should be 20 psi (1.4 bar) on front and 30 psi (2.0 bar) on back.

3. Inspect the electrical system and battery cables for loose connections or frayed wiring. Replace any faulty

equipmentortighten if loose.

4. Check hardware for loose or missing nuts, bolts, screws, etc., and tighten or replace as needed.

5. Inspect hydraulic lines for damage or leaks. Never use hands to inspect for leaks.

6. Checkthe hydraulic fluidlevel.The hydraulic fluidtankis located undertheseat. The fluidlevelshould be

2"-2½" (5 - 6.4 cm) from the top of the tank when cold. Use only SAE 10W-40API Service SJ or higher

Motor Oil.

7. Inspectthesteering, throttle and shiftlinkagesfor good hookups

andclear travel.

8. Checkcontrolsfor smooth,properworking operation.Lubricateas

needed.

9. Checkanti-vibration mountson engineframe.

STARTINGTHEENGINE

1. The ignition switch is located on the dashboard. Insert the key (A)

and turn clockwise to (B). When glow plug light goes off Turn key

to (C) until the engine starts. Release the key and it will return to

the run position (B).

2. Allowengineto idle andwarm up beforeselectingdirection of

travel.

STOPPINGTHEENGINE

If the engine has been running under high power, let it run at slow idle speed a few minutes

to cool the engine down, before turning the ignition switch to the OFF position.

1. Movethe throttle lever to“slow” and turn ignitionkey to the “off”position.

2. Removetheignition keyandengage theparkbrake.

Never leave the vehicle unattended with the engine running. Always bring the vehicle to a

complete stop, engage park brake, turn key off and remove key.

Service

OPERATION

Run machine at half-throttle minimum, prior to operating tration pedal. This will ensure

proper brake release.

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°.

DUMPING

Whendumping,the recieverhitchcan interfer withbox.Remove reciever hitchbefore dumping. Faiureto do so

will cause damage to the tailgate or box.

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. When charging or working near battery, always shield your eyes and always pro-

vide proper ventilation.

Battery cable should be disconnected before using “Fast Charge”.

Charge battery at 15 amps for 10 minutes or 7 amps for 30 minutes. Do not exceed the recommended charging rate. If

electrolyte starts boiling over, decrease charging.

Always remove grounded (-) battery clamp first and replace it last. Avoid hazards by:

1. Filling batteries in well-ventilated areas.

2. Wear eye protection and rubber gloves.

3. Avoid breathing fumes when electrolyte is added.

4. Avoid spilling or dripping electrolyte.

Battery Electrolyte is an acidic solution and should be handled with care. If electrolyte is splashed on

any part of your body, flush all contact areas immediately with liberal amounts of water. Get medical

attention immediately.

JUMP STARTING

Use of booster battery and jumper cables.

Particular care should be used when connecting

a booster battery. Use proper polarity in order to

prevent sparks.

To jump start (negative grounded battery):

1. Shield eyes.

2. Connect ends of one cable to positive (+) terminals of

each battery, first (A) then (B).

3. Connect one end of other cable to negative (-) terminal

of "good" battery (C).

4. Connect other end of cable (D) to engine block on unit being started (NOT to negative (-) terminal of battery)

To prevent damage to other electrical components on unit being started, make certain that engine is at idle speed

before disconnecting jumper cables.

Service

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

UseNo.2 General purposelithiumbase grease andlubricate every 100hours.The dump truckhas7

greasefittings.

A. Oneonthe rod end ofhydrauliccylinder.

B. One on each the right and left spindles.

C. One onthecenter frontpivot.

D. One on the idler arm.

E. One on each of the pedal relays.

ELECTRICALCONNECTIONS

Use dielectric grease on all electrical connections.

AIRCLEANERONENGINE

Since the air cleaner on this engine is a dry type, never apply oil to it.

1. Openevacuator valve (seeengine manual)oncea weekto remove largeparticles ofdustand dirt.

2. Wipe the inside of the air cleaner with a cloth if it gets wet or dirty.

3. Avoidtouchingthe elementexceptwhen cleaning.

4. When dust adheres to the element, gently tap element on flat surface.

5. Whencarbonor oil adheres totheelementclean according to enginemanual.

6. Replacetheelement everyyearor every6months.

7. IMPORTANT - Make sure wing bolt for the element is tight enough. If it is loose, dust and dirt may be

suckedin,wearing down the cylinder linerandpiston ring, resulting inpoorpower output.

Do not use petroleum solvents, e.g.., kerosene, which will cause cartridge to deteriorate. Do

not use pressurized air to clean cartridge. Pressurized air can damage cartridge.

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