Smithco TCV 5000 Quick start guide

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

Introduction Service Diagrams Parts Accessories Reference
CONTENTS
Introduction............................................................................1-5
Introduction..............................................................................1
Safe Practices.........................................................................2
Specifications .......................................................................... 3
Setup .......................................................................................4
Controls & Instruments............................................................5
Service..................................................................................6-15
Operation..............................................................................6-7
Maintenance .........................................................................8-9
Wheel Creep .........................................................................10
Adjustments...........................................................................10
Service Chart....................................................................11-12
Storage ............................................................................ 14-15
Diagrams ........................................................................... 16-19
Wiring Diagram................................................................ 16-17
Hydraulic Diagram ........................................................... 18-19
Parts................................................................................... 20-47
Body and Frame .............................................................. 20-21
Nose Cone....................................................................... 22-23
Front Axle ......................................................................... 24-25
Oil and Fuel Tank ............................................................. 26-27
Seat Panel........................................................................ 28-29
Engine and Pumps........................................................... 30-31
Cooler and Exhaust.......................................................... 32-33
Gondola Box .................................................................... 34-35
Cargo Tailgate Box........................................................... 36-37
13-731 Single Bank Valve................................................ 38-39
15-301 Orbitrol................................................................. 40-41
30-102 Eaton Pump......................................................... 42-45
30-101 Eaton Motor ......................................................... 46-47
Reference .......................................................................... 48-49
Decal List ...............................................................................48
Quick Reference....................................................................49
Warranty ....................................................... Inside Back Cover

1
Introduction
Informationneeded whenorderingreplacementparts:
1. ModelNumber ofmachine
2. SerialNumber ofmachine
3. Nameand Part Numberof part
4. Quantityof parts
INTRODUCTION
Thank you for purchasing a SmithcoSmithco
SmithcoSmithco
Smithco product.
Readthismanual and all other manualspertainingto theDumpTruckcarefullyas they have 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 machines have a Serial Number and Model Number. Both numbers are needed when ordering
parts. The serial number plate on the DumpTruck is located on the left main frame, by front bumper. Refer to
enginemanual forplacementof engineserial number.
For easy access record your Serial and Model numbers here.

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 forhidden hazards.
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 alwaysremovethe ignition key.
11. Disengagealldrives andsetpark brakebeforestarting theengine.
12. Never use yourhandsto search for oilleaks.Hydraulic fluid under pressurecanpenetrate the skin and
cause serious injury.
13. This machine demandsyourattention.To prevent lossof control ortippingof the vehicle:
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 engineoffandremove theignitionkey.
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 ofall bystanders.
17. Nevercarry passengers.
18. Stopenginebefore making repairs/adjustments orchecking/adding oil tothecrankcase.
19. Use parts and materials supplied by SmithcoSmithco
SmithcoSmithco
Smithco only. Do not modify any function or part.
20. Use caution when booms are down as they extend out beyond the center line of the machine.
21. The tank is a confined space, take precaution.
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)
SOUNDLEVEL(DBA)
Atear level 98 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 15Amp
WHEELS&TIRE Front: Two 20 x 11.00 x 10Turf; 20 psi (1.4 bar)
Rear: Two 29 x 14.00 x 15 Multi-Trac; 30 psi (2.0 bar)
SPEED
Infinitely Variable 0-10 m.p.h.(0-18kph)
BATTERY Automotive type 24F-12 volt
BCIGroup Size 24
ColdCrankingAmps 900 minimum
GroundTerminalPolarity 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 under seat. 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 level shouldbe 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 OVER-
FILL
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 Interim Tier 4 Standards, the use
oflowsulfur fuel orultra low sulfurfuelis mandatory fortheseengines, when operatedin US EPAregulated ar-
eas.Therefore,use No.2-DS500or S15dieselfuel asaalternative toe No.2-D for ambienttemperatures below -
10°C(14° F).

5
Introduction
CONTROLS&INSTRUMENTS
A. HourMeter- The hourmeter indicates hoursofmachine operation. Itoperates only whentheignition
switch is on.
B. Speedometer -TheSpeedometer indicatesground speed ofthe vehicle inmilesper hourandkilometers
perhour.
C. Oil Light - The oil light should come on when the ignition is on without the
enginerunningand go out when theengineis running. The oillightwill light
when the oil pressure is low. If oil light should come on, shut engine off
immediately and find the cause.
D. Water Temperature Light-Temperature lightwillcomeon and a buzzerwill
sound whentheengine starts tooverheat.
E. Glow Plug - When ignition is turned on, glow plug lights when ready to start.
F. Ignition Switch -The ignition switch has three positions: Off - Run - Start.
G. TiltSteering-Holdlever down andadjust steering wheeltodesired position
andreleaselever.
H. Lights - This rocker switch turns lights on by pushing on the top and off by
pushingonthebottom.
I. Cup Holder- Holds standardcup.
J. Hand Throttle - Thehandthrottle is usedto regulate engine speed.
X
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, thehandbrake needs tobemanually released.The
handbrakeis located undertheengine.Tomanuallyrelease the brake
you must loosen the locknut and screw in the stem to the bottom.
Tightenthelock nut and pumphandleuntil hard.
MANUALBRAKEHANDPUMPMANIFOLD
Thehandbrake is locatedunder the engine.Thehand brake iscon-
nected to he seat switch and automatically engages when operator gets
up from the seat. So when machine is not being driven, the machine 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 bot-
tom. Tighten the lock nut and pump handle until hard.

6
Service
OPERATION
Before operating the Smithco Dump Truck, become familiar with all controls and functions.Also complete all
maintenancerequirementsandread allsafetywarnings. KnowingtheDumpTruckthoroughly, 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 offwhenrefueling orperforming maintenancenotspecificallyrequiringenginepower.
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. Makesureboth fuelflowvalves are ‘On’.They are locatedonthe
fueltank.
2. 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).
3. 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
HILLSIDE OPERATION
Do NOT stop or start suddenly on any slope. Be especially cautious when changing direction. Do NOT operate on
slopes greater than 10°.
BATTERY
Batteries normally produce explosive gases which can cause personal injury. Do not allow flames, sparks or any ig-
nited object to come near the battery. 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 truckhas6
greasefittings.
A. Oneonthe rod end ofhydrauliccylinder.
B. One on each the right and left spindles.
C. One onthe center frontpivot.
D. One on the idler arm.
E. One on each of the pedal relays.
F. Oneon each planetarydrive.
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.