Smithco TCV 2200 32-000, Parts & Service & Operators Manual

Page 1: ...Product Support Hwy SS Poplar Ave Cameron WI 54822 1 800 891 9435 productsupport smithco com Parts Service OPERATORSMANUAL TCV 2200 Super Truck Turf Care Vehicle Model 32 000 SN DT2213 August 2013 ...

Page 2: ...6 17 Parts 18 45 Main Drawing 18 19 Nose Cone Drawing 20 21 Pedal Linkage Drawing 22 23 Front Axle Drawing 24 25 Gast Tank Drawing 26 Oil Tank Drawing 27 Seat Panel Drawing 28 29 Engine Drawing 30 33 Rear Axle Drawing 34 35 31 043 Single Bank Valve 36 37 34 103 Orbitrol 38 39 76 238 Wheel Motor 40 41 76 197 Gear Pump 42 43 76 482 Hydrostat Pump 44 45 Accessories 46 48 32 001 Gondola Box 46 32 002 ...

Page 3: ...nstructions Failure to do so could result in personal injury or equipment damage Keep manuals in a safe place after operator and maintenance personnel have read them Right and left sides are from the operator s seat facing forward All Smithco Smithco Smithco Smithco Smithco machines have a Serial Number and Model Number Both numbers are needed when ordering parts The serial number plate on the Dum...

Page 4: ...ake before starting the engine 12 Never use your hands to search for oil leaks Hydraulic fluid under pressure can penetrate the skin and cause serious injury 13 This machine demands your attention To prevent loss of control or tipping of 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 ...

Page 5: ...ling System Air Cooled Lubrication System Full Pressure Alternator 15Amp WHEELS TIRE Front 2 22 x 11 10 Turf Type 18 psi 1 2 bar Rear 2 24 x 12 12 Turf Type 20 psi 1 4 bar SPEED Infinitely Variable 0 12 m p h 0 19 kph BATTERY Automotive type 45 12 volt BCI Group Size 45 Cold CrankingAmps 480 minimum Ground Terminal Polarity Negative Maximum Length 9 23 cm Maximum Width 5 38 14 cm Maximum Height 9 ...

Page 6: ...located on left side with Unleaded 87 Octane gasoline mini mum Your fuel tank is CARB compliant Please check vent alignment in fill cup 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 Machine should be greased be...

Page 7: ... cups G Park Brake The park brake is only a parking brake Pull back to release push forward to apply H Dump Box Lever The dump box lift lever is used to raise and lower the dump box Pull back to raise the dump box Push forward to lower the dump box I Choke The choke is used in starting the engine Pull choke out to close choke plate when starting a cold engine Push in when engine starts A warm engi...

Page 8: ...e 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 Check the hydraulic fluid level The hydraulic fluid tank is located on the right side of the machine The fluid level should be 2 2 5 6 4 cm from the top of the tank when cold Use only SAE 10W 40 API Service SJ or higher Motor Oil 7 Inspe...

Page 9: ... 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 jum...

Page 10: ...the tensioner arm B One onthe steering relay C One on steering ram D One on both ends of steering arms 4 E One on each front spindle F One on the forward reverse relay G One on each pedal mount 2 H One on each control arm ELECTRICALCONNECTIONS Use dielectric grease on all electrical connections TIREPRESSURE Caution must be used when inflating a low tire to recommended pressure Over inflating can c...

Page 11: ...oil 2 For proper warranty change oil every 500 hours or annually which ever is first 3 Oil level should be 2 2 5 6 4cm from top of the tank when fluid is 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 fr...

Page 12: ...n the bottom of the pump The tensioner arm has a bearing that rides in the vee of the shift arm Loosen bolt A 3 With engine running move bearing so it centers on the shift arm and wheel creep stops 4 Tighten all fasteners and test by using foot pedal linkage to see that creep is removed 5 Turn engine off and lower machine PARKBRAKEADJUSTMENT By turning knob on end of park brake lever you can tight...

Page 13: ...heck the hydraulic fluid level Check the tire pressure Check condition of hydraulic hoses and fittings Inspect and clean the machine Inspect cooling system Check the battery fluid level and cable connections Change oil when operating under heavy load or high ambient temperatures Change the engine oil and filter Change hydraulic filter Check engine for leaks or loose parts Check air cleaner Check t...

Page 14: ...ine 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 Ensure all warning decals are intact Item Date Information Maintence Check Item For...

Page 15: ... 8 Drain crankcase completely and refill with recommended engine oil or equivalent 9 Run engine until completely out of gasoline then restart and run on stabilizer mixed with unleaded gasoline for at least 10 minutes 10 Lubricate all grease points 11 Seal all openings in engine and accessories with non hygroscopic material Mask off all areas to be used for electrical contact 12 Tape all openings a...

Page 16: ...14 Diagrams WIRINGDIAGRAM Use dielectric grease on all electrical connections ...

Page 17: ...2 13 488 Ignition Switch 1 3 32 014 Head Lights 2 4 15 727 Switch Actuator 1 15 782 Rocker Switch 1 5 12 017 Hour Meter 1 6 50 359 Warning Light Oil 1 7 8975 30AMP Breaker 1 8977 Boot 1 8 76 327 Negative Battery cable 1 9 22 073 Battery 1 10 50 323 Red Battery Cable 1 32 087 Wire Harness 1 ...

Page 18: ...16 Diagrams HYDRAULICDIAGRAM Letter Code Chart C Center I Inside O Outside T Top B Bottom ...

Page 19: ...k 1 13 586 03 Filler Neck 1 13 747 Filler Breather 1 13 15 624 Oil Cooler 1 18 168 Straight Thread Elbow 2 14 23 006 Oil Filter 1 23 031 Replacement Filter 1 15 8832 32 3 4 Suction Hose 32 1 18 040 Hose Clamp 2 16 8832 28 3 4 Suction Hose 28 1 18 040 Hose Clamp 2 17 8917 11 5 8 Suction Hose 11 1 18 040 Hose Clamp 2 18 76 238 Wheel Motors 2 34 122 Short Elbow 4 19 76 242 Hydraulic Cylinders 2 76 24...

Page 20: ...18 Parts MAINFRAMEDRAWING ...

Page 21: ... Wheel 2 43 123 01 Tire 22 11 x 10 2 43 058 01 Wheel 2 12 76 198 03 Seat Belts 2 HBC 516 18 100 Carriage Bolt 5 16 18 x 1 4 HNFL 516 18 Flange Whiz Lock Nut 5 16 18 4 13 32 046 Restraint Bar 1 14 32 027 ROPS 1 HB 38 16 100 Bolt 3 8 16 x 1 8 HNTL 38 16 Lock Nut 3 8 16 8 15 32 063 Cover Plate 1 HSTP 516 18 075 Truss Head Screw 5 16 18 3 4 6 HNFL 516 18 Flange Whiz Lock Nut 5 16 18 6 16 60 473 Oil Ta...

Page 22: ...20 Parts NOSECONEDRAWING ...

Page 23: ...achine Screw 5 16 18 x 1 2 HNFL 516 18 Flange Lock Nut 5 16 18 x 1 2 13 15 781 X Large Drink Holder 2 14 32 105 Cup Box 1 HSM 10 32 100 Machine Screw 10 32 x 1 3 HNFL 10 32 Flange Lock Nut 10 32 x 1 3 15 32 017 Dashboard 1 32 018 Decal Dashboard 1 16 32 014 Head Light 2 HSM 10 32 100 Machine Screw 10 32 x 1 8 HNFL 10 32 Flange Lock Nut 10 32 x 1 8 17 32 030 Nose Cone 1 34 147 Decal Smithco Logo 1 ...

Page 24: ...22 Parts PEDALLINKAGEDRAWING ...

Page 25: ... Mount 2 HSTP 516 18 075 Truss Head Screw 5 16 18 x 3 4 4 HNFL 516 18 Flange Whiz Lock Nut 5 16 18 4 14 48 132 Pedal Grip Short 1 15 32 039 Reverse Pedal 1 16 21 462 Ball Joint 5 16 24 4 HN 516 24 Nut 5 16 24 8 17 32 113 Pedal Link 1 18 18 115 Ball Joint 1 4 NF 2 HN 14 20 Nut 1 4 20 2 19 32 023 Push Pull Cable 1 20 32 037 Forward Reverse Relay 1 21 32 025 Razorback Front Calipers 2 22 32 045 Contr...

Page 26: ...24 Parts FRONTAXLEDRAWING ...

Page 27: ... 10 025 Bushing 2 18 32 058 RH Control Arm 1 10 025 Bushing 2 19 32 097 Pivot Sleeve 2 20 32 011 Suspension Pivot Shaft 2 21 HG 14 28 90 90 Grease Zerk 2 22 32 115 Hose Clamp Mount 2 HB 14 20 075 Bolt 1 4 20 x 3 4 4 HNFL 14 20 Flange Lock Nut 1 4 20 4 23 32 101 Flange 2 24 HNL 12 20 Lug Nut 1 2 20 10 25 HNAR 100 14 Slotted Jam Nut 1 14 2 26 27 022 02 Stud 1 2 20 10 27 32 100 Brake Rotor 2 28 32 09...

Page 28: ... 18 x 3 8 2 HNFL 516 18 Flange Lock Nut 5 16 18 2 6 8 688 Carbon Canister Mount 1 7 8 689 Carbon Canister 1 8 32 051 RH Gas Tank Mount 1 9 32 081 Tank Strap 2 10 HB 516 18 100 Bolt 5 16 18 x 1 4 HNFL 516 18 Flange Lock Nut 5 16 18 4 A 8800 51 Fuel Hose tank to fuel filter on engine 1 18 186 Hose Clamp 2 B 8800 38 Fuel Hose CARB canister to air cleaner 1 18 186 Hose Clamp 2 C 8800 10 Fuel Hose CARB...

Page 29: ... 4 HB 516 18 125 Bolt 5 16 18 x 11 4 2 HNFL 516 18 Flange Lock Nut 5 16 18 2 5 32 049 LH Tank Mount 1 6 32 050 Tank Mount Bracket 2 7 13 747 Filler Breather 1 8 13 586 03 Filler Neck 1 9 HB 38 16 250 Bolt 3 8 16 x 21 2 4 HNFL 38 16 Flange Lock Nut 3 8 16 4 10 32 048 RH Tank Mount 1 11 60 473 Oil Tank 1 12 60 213 Strainer 1 13 23 142 Connector 1 ...

Page 30: ...28 Parts SEATPANELDRAWING ...

Page 31: ...7 LH Park Brake Mount 1 7 HSTP 516 18 075 Truss Head Screw 5 16 18 x 3 4 2 HNFL 516 18 Flange Whiz Lock Nut 5 16 18 2 8 60 106 Brake Lever 1 9 32 056 RH Park Brake Mount 1 10 HB 38 16 125 Bolt 3 8 16 x 11 4 4 HNTL 38 16 Lock Nut 3 8 16 4 11 32 020 3 8 Branch Tee 2 12 18 169 3 8 Adapter 2 13 18 168 3 8 Straight Thread Elbow 1 14 31 043 Single Bank Hydraulic Valve 1 78 417 Handle 1 15 18 188 45 Elbo...

Page 32: ...30 Parts ENGINEDRAWING ...

Page 33: ... 76 484 Engine Briggs Stratton 31 HP 1 76 270 Throttle Cable Mount 1 76 466 01 Stub Shaft 1 21 161 Wire Block 1 19 32 088 2 Heater Hose 1 20 32 112 Air Cleaner 1 42 076 03 Filter Element 1 21 32 054 Oil Cooler Plate 1 22 18 168 Straight Thread Elbow 2 23 15 624 Oil Cooler 1 24 32 036 Oil Cooler Guard 1 HBFL 516 18 075 Flange Bolt 5 16 18 x 3 4 4 HNFL 516 18 Flange Whiz Lock Nut 5 16 18 4 25 18 190...

Page 34: ...32 Parts ENGINEDRAWING ...

Page 35: ... 11 2 4 HWL 716 Lock Washer 7 16 4 34 32 045 Control Arm 1 35 32 123 Relay Bracket 1 36 32 124 Fuel Pump Mount 1 37 76 465 Coupling Complete 1 76 466 7 8 Coupler Half 1 76 467 11 8 Coupler Half 1 76 468 Sleeve M42 1 38 32 026 PumpAdapter 1 39 18 273 Fitting 1 40 23 145 O ring 1 41 23 133 90 Adjustable Elbow 1 ...

Page 36: ...34 Parts REARAXLEDRAWING ...

Page 37: ...FL 12 13 Flange Lock Nut 1 2 13 4 8 76 238 Wheel Motor 2 9 Carrier Side Pad 1 10 Carrier Side Pad Support 1 11 Cam Side Pad Support 1 12 Cam Side Pad 1 13 10 516 Brake Cable 2 14 32 079 Park Brake Equalizer 1 15 11 100 Linkage Yoke 1 HCP 516 100 Clevis Pin5 16 x 1 1 HP 18 075 Cotter Pin 1 8 x 3 4 1 16 32 013 Park Brake Rod 1 17 60 106 Brake Lever w Kit 1 18 HB 12 13 125 Bolt 1 2 13 x 11 4 4 HNFL 1...

Page 38: ...36 Parts 31 043SINGLE BANKHYDRAULICVALVEDRAWING ...

Page 39: ...13 731 03 Spool 1 7 78 415 11 Positioner 1 8 78 415 08 Plug 3 9 78 415 09 Lever Group HDS11 3 10 78 415 10 Metric Socket Screw M5 x 8 x 45 2 11 13 731 04 1 4 Ball 1 12 13 731 05 Check Valve 1 13 18 188 45 Elbow 1 14 78 417 Straight Handle 1 15 32 020 3 8 Branch Tee 2 16 18 169 3 8 Adapter 2 17 18 168 3 8 Straight Elbow 1 31 043 Single Bank Hydraulic Valve includes all items 13 731 01 Actuator Hous...

Page 40: ...38 Parts 34 103ORBITROLDRAWING ...

Page 41: ...ncludes Ref 9 1 Spring Spacer 2 Centering Spring 6 Spring Retaining Ring 1 7 15 301 08 Pin 1 8 Sleeve 1 9 Retainer 1 10 15 301 11 Plug and O ring 1 O Ring Seal 1 Plug 1 11 15 301 12 Relief Valve Check 1015 psi 70 bar 1 12 Housing 1 13 Dust Seal 1 14 15 301 06 Wear Plate 1 15 15 301 07 Drive 1 16 15 301 05 Spacer 1 17 15 301 04 Gerotor 1 18 O Ring 1 19 Seal 1 20 15 301 03 End Cap 1 21 15 301 02 Cap...

Page 42: ...40 Parts 76 238WHEELMOTORDRAWING 14 5CI ...

Page 43: ...Seal 5 9 13 032 31 Manifold 1 10 13 032 32 Commulator Assembly matched set 1 11 13 032 33 End Cover 1 12 76 238 01 Bolt 7 13 Commulator Seal matches with 10 1 14 76 238 02 Rotor Set matched set 1 15 13 032 35 Plate Wear 1 16 13 615 04 Coupling Shaft 1 HWK 516 100 Woodruff Key 5 16 x 1 1 14 265 Nut 1 20 1 17 13 032 37 Thrust Washer 2 18 Backup Washer 1 19 Backup Washer 1 20 13 032 38 Outer Bearing ...

Page 44: ...42 Parts 76 197EATONGEARPUMPDRAWING ...

Page 45: ...2 76 197 01 Front Plate 1 3 Washer 4 4 76 197 06 Cap Screw 8 5 76 197 07 Retaining Ring 1 6 Shaft Seal 1 7 33 061 15 Washer 1 8 O Ring 2 9 Backup Gasket 1 10 Seal 1 11 Wear Plate 1 12 76 197 04 Shaft comes with Idler Gear 1 13 76 197 02 Back Plate 1 14 Plug 1 76 197 08 Seal Kit ...

Page 46: ...44 Parts 76 482HYDROSTATICPUMPDRAWING ...

Page 47: ... 13 77 239 10 Crush Ring 1 14 60 343 12 Shaft Seal 1 15 77 239 11 Seal Cover 1 16 77 239 12 Key 1 17 77 239 13 Gasket 1 18 76 482 01 Back Plate 1 19 33 058 27 Dowel Pin 2 20 60 343 23 Bearing 1 21 77 239 15 Relief Valve 2 22 77 239 16 Tow ValveAssembly 1 23 76 160 Charge PumpAdaptor 1 24 77 239 17 Cap Screw 2 26 77 239 18 Cap Screw 2 27 77 239 19 O Ring 1 28 60 343 43 Gerotor and Coupler 1 29 77 2...

Page 48: ...NDOLABOX PARTSLIST REF PART DESCRIPTION QUANTITY 1 32 102 Gondola Box 1 2 76 242 Cylinder 2 76 242 01 Seal Kit 32 042 Spacer 2 3 76 242 02 Clevis Pin w Clip 4 4 50 081 Rubber Bumper 2 HNFL 38 16 Flange Whiz Lock Nut 3 8 16 2 ...

Page 49: ...2 3 76 242 02 Clevis Pin w Clip 4 4 32 043 Lock 2 5 HB 14 20 075 Bolt 1 4 20 x 3 4 2 HW 14 Washer 1 4 2 HNTL 14 20 Lock Nut 1 4 20 2 6 32 033 Gate Hook 2 8892 10 5 Chain Wrap 2 7 HBFL 516 18 075 Flange Bolt 5 16 18 x 3 4 2 HNFL 516 18 Flange Whiz Lock Nut 5 16 18 2 8 32 078 Tailgate 1 9 50 081 Rubber Bumper 2 HNFL 38 16 Flange Whiz Lock Nut 3 8 16 2 ...

Page 50: ...3 Flat Bed 1 2 76 242 Cylinder 2 76 242 01 Seal Kit 32 042 Spacer 2 3 76 242 02 Clevis Pin w Clip 4 4 50 081 Rubber Bumper 2 HNFL 38 16 Flange Whiz Lock Nut 3 8 16 2 5 HBFL 516 18 075 Flange Bolt 5 16 18 x 3 4 2 HNFL 516 18 Flange Whiz Lock Nut 5 16 18 2 6 32 118 Front Guard 1 ...

Page 51: ... 25 355 Decal Tire Pressure 18PSI Front Tires 25 356 Decal Tire Pressure 20 PSI Rear Tires 25 358 Decal Smithco 12 Rear Dump Box 25 381 Decal dBA 96 Seat Panel 27 077 Decal Round Smithco Steering Cap 32 018 Decal Dash Board Dash Board 32 029 Decal TCV 2200 Dump Box Sides 32 085 Decal Warning Strip Cup Holder 34 147 Decal Smithco Logo Nose Cone 51 183 Decal Dump Box Between Seats ...

Page 52: ...y Filter Cartridge Briggs 821136 50 403 Fuel Filter SEALKITS 34 103 Power Steering Orbital Motor 14 098 Seal Kit 76 238 Wheel Motors 14 080 Seal Kit 76 482 Hydrostat Pump 77 239 22 Seal Kit 76 197 Gear Pump 76 197 08 Seal Kit 10 554 Hydraulic Cylinder 14 529 Seal Kit 76 242 Hydraulic Cylinder 76 242 01 Seal Kit 31 043 Single Bank Valve 31 731 01 Seal Kit FLUIDS Engine Oil SAE 10W 40 API Service SJ...

Page 53: ...f 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 W Poplar PO Box 487 Cameron Wisconsin 54822 Telephone 1 800 891 9435 E Mail ProductSupport smithco com Maintenance Parts Parts scheduled for replacement as required maintenance Maintenance Parts are warra...

Page 54: ...nty gives you specific legal rights and you may also have other rights which vary from state to state THERE ARE NO OTHER EXPRESS WARRANTIES OTHER THAN THOSE SET FORTH ABOVE ALL IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR USE ARE LIMITED TO THE DURATION OF THE LIMITED WARRANTIES CONTAINED HEREIN Some states may not allow limitations on how long an implied warranty lasts so the above limit...