Smithco TCV 5000 Quick start guide

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 [e-mail]
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 .....................................................................................

1
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

2
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.

3
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

4
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.

5
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

6
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.

7
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.

8
Service
F
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.

9
Service
MAINTENANCE
ENGINEOIL
With strict emission control regulations now in effect, the CF-
4and CG-4engineoils havebeen developedforusewithlow
sulfurfuels, forOn-Highway vehicleengines. WhenNon-Road
engines run on high sulfur fuel, it is advisable to use a "CF or
better" classification engine oil with Total Base Number (a
minimumTBNof 10is recommended).
Check the engine oil before starting or more than 5 minutes
afterstopping theengine.If oillevelis low, removeoilfiller
plugand add newoil totheprescribed level.Donot overfill.Engine oil shouldbe MIL-L2104Corhave properties
ofAPIClassificationsCD grades orhigher. Changethetype of Engine oil accordingtothe ambient temperature.
Starting Temperature Range Anticipated Before Next Oil Change
HYDRAULICOIL
1. Use SAE 10W-40API Service SJ or higher motor oil.
2. Forproperwarranty,changeoil every500hours orannually,whichever is first.
3. Oillevelshould be 2-2½" (5-6.4cm)fromtopof the tank whenfluidis cold. Do not overfill.
4. After changing oil, run the machine for a few minutes. Check oil level and for leaks.
5. Always use extreme caution when filling hydraulic oil tank or checking level to keep system free of
contaminants. Check and service more frequently when operating in extremely cold, hot or dusty condi-
tions.
6. If the natural color of the fluid has become black or smells burnt, it is possible that an overheating problem
exists.
7. If fluid becomes milky, water contamination may be a problem.
8. Ifeither of the aboveconditionshappen, change oilimmediatelyafter fluid iscool and find thecause.Take
fluid level readings when the system is cold.
9. In extreme temperatures you can use straight weight oil. We recommend SAE 30WAPI Service SG when
hot(above 90°F (33°C))and SAE10WAPI ServiceSJor higherwhencold (below32°F (0°C)ambient
temperature. Use either motor oil or hydraulic oil, but do not mix.
10. Oil being added to the system must be the same as what is already in the tank. Mark the tank fill area as
to which type you put in.
TIREPRESSURE
Caution must be used when inflating a low tire to recommended pressure. Over inflating can cause tires to ex-
plode.Fronttires should be20psi (1.4bar)andrear tires shouldbe30 psi (2.0bar).Improperinflation will reduce
tirelifeconsiderably.
O= Recommended X= Not Recommende
d
Lubricating Oil Class
CF-4 O X
CG-4 O X
Fuel

10
Service
WHEELCREEP
WHEELCREEP
"Creep" is when the engine is running and hydrostatic transmission is in neutral,
butdueto inadequatealignment,wheels stillmove.Do the followingprocedure to
stop this motion.
1. Liftup and supportmachineso rear wheelsareoff the groundand can turn
freely.
2. In the engine compartment, the hydrostatic pump is on the right side. The
shift arm (D) is on top of the pump The idler arm (B) has a bearing that rides
in the vee of the shift arm. Loosen bolt (A).
3. With engine running, move bearing (B) so it centers on the shift arm (D) and
'wheelcreep' stops.
4. Tighten all fasteners and test by using foot pedal linkage to see that 'creep'
isremoved.
5. Turnengine offand lowermachine.
ADJUSTMENTS
SAFETYINTERLOCKSWITCH
To adjust the interlock switch on the back hydrostatic pump loosen the set screw on the front half of the switch,
with the ignition switch OFF. With a continuity tester connected across the switch, it should light with the shift
arm centered. Move the shift arm to the right or left and the light should go off. By turning the back half of the
switch clockwise it will reduce the amount of travel on the shift arm that is required for the light to remain on. The
light must be on ONLY with the shift arm centered.
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.
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.
DUMPING
Whendumping,the recieverhitchcan interfer withbox.Remove reciever hitchbefore dumping. Faiureto do so
will cause damage to the tailgate or box.

11
Service
STORAGE
TWOMONTHS
1. Cleantheexterior surfacesofthe engine.
2. Changetheoil and filter whiletheengine is still warmfromoperation.
3. Draincoolant from the radiator. Opencockat the bottom oftheradiator,and removethepressure cap to
drain water completely. Leave the cock open. Hang a not written "No Water" on the pressure cap. Since
water freezes when temperature drops below 0°C (32° F) it is important that no water is left in the ma-
chine.
4. Removebatteryfrom the engine, adjust theelectrolytelevel, and recharge it. Store battery in adrydark
place.
5. Store machine in a clean, dry place.
EXTENDEDSTORAGE
1. Check for any damaged parts or missing decals. Replace as needed.
2. Draincrankcase completely andrefill withrecommendedengine oilorequivalent.
3. Lubricateallgrease points.
4. Checkcoolant protection andlevel.
5. Cleanexterior surfaceofengine.
6. Seal all openings in engine and accessories with non-hygroscopic material. Mask off all areas to be used
for electrical contact.
7. Tape all openings and make sure all surfaces are dry. Then spray all taped openings, all engine accesso-
riesincludingignition wiring,andall exteriorsurfacesof enginewithInsulation Compound.
8. Disconnect, remove and clean battery. Check electrolyte level. Charge the battery and store in a cool dry
place(NOTdirectly on cement).
9. Put blocks or stands under the machine to take weight off tires.
AFTERSTORAGE
1. Check for any damaged parts or missing decals. Replace as needed.
2. Lubricateallgrease points.
3. Cleanexterior surfaceofengine.
4. Removeall tape andobstructions fromexteriorengine surfaces.
5. Chargeand replacebattery.
6. Checktirepressure.
7. Removeblocksor supportsfrom under themachine.
8. Checkengineoil levelandcoolant level andlubricate all greasepoints.
9. Fill fuel tank.
10. Check belt tension.
11. Runengine approximately5 minutesbeforeputting theengine underload.ServiceChart

12
Service
SERVICECHART
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.
Thesuggestedmaintenance checklistisnot offered asa replacement forthemanufacturer’s enginemanualbut
asasupplement.Youmustadhere totheguidelines establishedby themanufacturerfor warranty coverage.In
adverseconditionssuch asdirt,mud or extremetemperatures, maintenance shouldbe more frequent.
Duplicate this page for routine use
Mon 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.
Check for unusual engine noises
Check the hydraulic oil level
Check hydraulic hoses and fittings for damage
Check for fluid leaks.
Check the tire pressure (20-30 psi)
Check the Instrumentation
Inspect electrical system for frayed wires
Check neutral start
Change oil filter.
Change oil.
Lubricate Machine and Booms
Ensure all warning decals are intact.
Item Date Information
Maintenance Check Item For the week of:
Areas of Concern
Inspection Performed by:

13
Service
SERVICECHART
Item Maintenance Procedure
Torque the wheel lug nuts. (64-74 ft/lb (87-100 Nm))
Change the engine oil filter.
Check the engine oil level.
Clean area around muffler and controls.
Check the hydraulic fluid level.
Check the tire pressure.
Check condition of hydraulic hoses and fittings.
Check for oil or water leaks.
Proper function of glow lamp timer.
Afterthe first 50 hours Change Hydraulic Oil Filter.
Change Engine oil and filter.
Clean or change air filter.1&2
Clean fuel filter element.1
Lubricate machine.
Check the battery fluid level and cable connections..
Check fan belt tension and damage.
Check radiator hoses and clamp bands.
Change engine oil.1
Check idle speed.
Replace oil filter cartridge.1
Change hydraulic oil filter.1
Check air intake line.1
Torque the wheel lug nuts. (64-74 ft/lb (87-100 Nm))
Clean Water Jacket and radiator interior.
Replace fan belt.
Every800 hours Check valve clearance.
Every1500 hours Check injection nozzle pressure.
Check turbo charger.
Check injection pump.
Check injection timing.
Change radiator coolant (L.L.C.)
Replace radiator hoses and clamp bands.
Replace fuel hoses and clamps.
Replace intake air lines.
2
Replace after every 6 times of cleaning
Every3000 hours
Every2 years
Every100 hours
Every200 hours
Every500 hours or yearly
1
In dusty conditions or when airborne debris is present, clean more often.
Afterthe first 8 operating hours
Before eachuse daily

14
Diagrams
WIRINGDIAGRAM
Color Code Chart
Bl Blue
Br Brown
Y Yellow
G Green
O Orange
R Red
B Black
P Purple
W White
Use dielectric grease on all electrical connections.

15
Diagrams
WIRINGDIAGRAM
REF# PART# DESCRIPTION QUANTITY
1 77-223 Timer 1
30-042-06 Relay 1
2 50-359 Warning Light 3
3 10-556 Speedometer 1
31-071 SpeedometerWire 1
4 12-017 HourMeter 1
5 14-292 Seat Switch 1
6 13-488 IgnitionSwitch 1
7 32-014 Lights 2
8 15-725 MountPanelEnd 1
15-727 SwitchActuator 1
15-782 Rocker Switch, Unlit 1
9 48-147 GroundBattery Cable 1
10 33-216 Battery 1
11 76-326 PositiveBattery Cable 1
12 30-104 ManualHandBrake 1
13 16-883 SpeedSensor 1
14 31-071 RedPowerWire 1
15 12-003 Park Brake Toggle Switch 1
30-143 Toggle SwitchGuard 1
16 30-130 Fuel Pump 1
NA 30-148 Main Wire Harness 1
NA 30-149 Engine WireHarness 1
77-261 40 AMP Circuit Breaker 1
8977 CircuitBreakerBoot 1

16
Diagrams
HYDRAULICDIAGRAM
Letter Code Chart
C Center
I Inside
O Outside
TTop
B Bottom

17
Diagrams
HYDRAULICDIAGRAMPARTSLIST
REF# PART# DESCRIPTION QUANTITY
1 30-092 HydraulicHose 1
2 30-091 HydraulicHose 1
3 15-301 Orbitrol 1
4 30-094 HydraulicHose 2
5 15-839 HydraulicCylinder 1
14-531 Seal Kit 1
18-171 3/8Seal LocAdapter 2
6 30-025 OilTank 1
13-747 FillerBreather 1
13-586-03 Neck 1
7 8833-9 SuctionHose 2
18-222 HoseClamp 4
8 8833-13 SuctionHose 1
18-222 HoseClamp 1
9 30-093 HydraulicHose 1
10 76-197 GearPump 1
11 30-102 EatonClosed Loop Pump 1
12 18-405 RunTee 1
13 30-086 HydraulicHose 1
14 30-085 HydraulicHose 1
15 30-090 HydraulicHose 2
16 30-087 HydraulicHose 2
17 30-099 WheelDrive 2
18 30-100 HydraulicReleaseBrakes 2
19 30-101 Eaton Wheel Motors 2
20 30-089 HydraulicHose 4
21 30-103 Hot OilShuttleManifold 1
22 18-395 UnionTee 1
23 30-088 HydraulicHose 1
24 60-215 Oil Filter Assembly 1
60-334 ReplacementElement 1
25 8833-23 Suction Hose 1
18-222 HoseClamp 2
26 30-105 Oil toAir Heat Exchanger 1
27 18-308 SwivelTee 1
28 30-104 BrakeandManual HandPump Manifold 1
29 8917-15.5 SuctionHose 1
18-040 HoseClamp 2
30 31-043 SingleBankValve 1
31 31-021 HydraulicHose 1
32 31-020 HydraulicHose 1
33 31-019 HydraulicHose 1
34 72-040 HydraulicCylinder 1

18
Diagrams