PARTS & SERVICE MANUAL SWEEP STAR 60 GAS
Contents
1. DID CD FUEL TANK ANDOIL TANK DRAWING Injection Nozzles Injection Pump M SN FUEL TANK AND OIL TANK PARTS LIST REF PART 1 15 491 HB 14 20 075 HWL 14 HW 14 2 15 492 77 179 3 15 039 18 042 76 221 18 140 60 213 48 135 13 586 Y 13 586 01 13 586 02 9 23 142 18 040 8917 38 10 18 118 11 18 069 12 18 093 13 18 008 14 18 133 15 18 009 18 26 054 26 055 26 8800 64 8983 67 18 222 Diesel Sweeper Only 19 18 186 20 8800 14 21 50 403 22 8800 49 23 8800 16 24 77 214 17 043 25 8800 11 26 8800 51 DESCRIPTION Fuel Tank Bolt 1 4 20 x 3 4 Lockwasher 1 4 Washer 1 4 Gas Cap with Gauge Diesel Fuel Cap with Gauge Fuel Valve Reducer Bushing 1 4 Vs Tank Mount Street Elbow 3 4 Strainer Oil Tank Filler Breather Cap Gasket Bottom Gasket Connector Hose Clamp Suction Hose 5 s ID Pipe Plug e Pipe Plug 1 2 Male Run Tee 3 4 Pipe Reducer 3 4 x 1 2 Barb Fitting Street Elbow 7 2 Bushing Insert part of tank Shut Off Valve part of tank Fuel Hose 64 Fire Sleeve Hose Clamp Hose Clamp 7 32 Fuel Hose 14 In Line Fuel Filter Fuel Hose 4x 49 Fuel Hose 4x 16 Fuel Filter Assembly Fuel Filter Element Fuel Hose 4x 11 Fuel Hose 4 x 51 Nasa Any Sl S dd do od do dd do dd PPP i O QUANTITY BY2. 6 271DUST DIRT FILTRATION SYSTEM M gt A 6 2 71DUST DIRT FILTRATION SYSTEM REF PART DESCRIPTION QUANTITY 1 76 249 Tailgate Screen for Filter 28 x 58 1 15 437 01 Keeper 2 HRS 316 1125 Steel Rivet 2 1 11 s 2 2 76 247 Tailgate Filter 28 x 57 1 3 76 246 Hopper Filter 24 x 57 1 4 76 248 Hopper Screen for Filter 24 x 28 1 5 76 263 Hopper Screen Cover Serial Number 1000 1497 1 76 359 Hopper Screen Cover Serial Number 1498 and Up 1 6 76 261 Hopper Screen 1 7 76 262 Tailgate Screen 1 8 15 437 02 Handle and Bracket 2 HRS 316 1125 Steel Rivet 3 1 x 11 s 4 15 437 Latch comes with 15 437 01 and 15 437 02 2 INSTALLATIONINSTRUCTIONS 11 12 If your sweeper has a latch Ref 8 on the tailgate screen release the latch There is enough rubber trim to place on each short ends of the hopper and tailgate screens This will make a tighter seal Do this before installing screens Remove tailgate screen Ref 7 from tailgate Unwedge the top and lift out of the bottom tab If your machine does not have the latch please install it using the two steel 2 16 x 1 s rivets we provide First place the cloth filter Ref 2 onto the tailgate screen then place tailgate filter screen Ref 1 over the top of the cloth filter by placing the screen in to the bottom tab and wedging it into the top tab The keeper part of the latch is already riveted onto the tailgate
3. FRONT FORK DRAWING Q mir A A Us 5 E mmy e O 6 Am gt EE e SS SUN uN FRONT FORK PARTS LIST REF 1 2 20 21 23 25 PART HW 38 HB 38 16 200 HNTL 38 16 HB 38 16 250 HNTL 38 16 75 715 75 715 01 HN 38 16 HB 38 16 100 20 142 HNAT 114 12 18 150 20 143 20 141 HWL 38 76 155 27 022 02 HNL 12 20 11 039 11 040 HB 58 18 350 HNJ 34 16 HNA 34 16 HMB 34 10 HMB 34 14 60 511 60 510 60 407 11 038 11 010 60 130 60 130 01 60 130 02 8839 60 128 60 406 HW 58 HNTL 58 18 76 158 HP 18 200 DESCRIPTION Washer s as Req d Bolt ys 16 x 2 Locknut 3 16 Bolt ys 16 x 21 2 Locknut s 16 Shock Absorber Bushing with Insert Nut s 16 Bolt 3 s 16 x 1 Grease Seal 11 4 Thick Axle Nut 11 4 12 Cotter Pin s x 11 2 Bearing Cup and Cone 11 4ID Spacer 15 s OD x 11 4 ID x 7 16 Lockwasher s Front Fork Bolt Stud 1 2 20 x 1 2 just bolt comes with Ref 24 Lug Nut 1 2 20 Grease Seal 1 s ID comes with Ref 24 Spacer 1 s OD x 3 4 ID x 7 32 Bolt s 18 x 3 2 Jam Nut 9 4 16 Axle Nut 3 4 16 Machine Bushing 4 x 10GA Machine Bushing 3 4 x 14GA Axle Lock U Bracket Front Axle Bearing Cup and Cone 3 4 ID comes with Ref 24 Wheel Hub includes items Tire amp Wheel Tire 18 x 9 5 8 6 Ply Wheel Windshield Washer Fluid or Equivalent Rubber Bushing S
4. 555555 gt 550505005060505050500505050 9 gt OR gt lt 55555995 SOR OK TR HOPPER PARTS LIST QUANTITY REF 1 2 3 4 13 14 15 16 17 18 19 21 22 23 25 26 27 A Spacer MUST be to the outside of the tab on the Pivot Arm with the tab and the spacer inside the cylinder yoke L 53 PART 75 566 HMB 114 10 76 237 76 261 76 359 HB 516 18 100 HNFL 516 18 75 653 HB 38 16 250 HNW 38 16 76 230 HNA 100 14 HB 34 10 400 HMB 34 10 HNTL 34 10 HNAT 125 12 76 242 02 76 242 76 211 76 161 HSDPS 14 075 76 159 HSDPS 14 075 HMB 100 10 HNA 100 14 HP 18 150 75 632 HMB 34 14 HMB 34 10 HP 18 150 75 704 50 456 18 168 18 154 HG 14 28 180 HCP 58 175 HHP 18 76 215 76 216 75 569 75 568 HN 38 16 HWL 38 HB 38 16 100 HB 12 13 300 HN 12 13 HNCL 12 13 HMB 114 10 HKSQ 14 150 HSSHS 38 16 038 HRP 38 250 HB 58 11 200 HMB 58 14 HNCL 58 11 76 288 15 437 HRS 316 1125 HW 8 HW 10 DESCRIPTION Tailgate Dump Bar Machine Bushing 1 4x 10 GA Hopper Hopper Screen Hopper Screen Cover Bolt 5 6 18 x 1 Flange Whiz Lock Nut 5 6 18 Hopper Safety Lift Bolt ys 16 x 21 2 Wing Nut 16 Hopper Dump Arm Slotted Hex Nut 1 14 Bolt 3 4 10 x 4 Machine Bushing 3 4 10GA Lock Nut 3 4 10 Thick Axle Nut 11 4 12 Clevis Pin with Clip Hydraulic Cylinder Arm Pivot Tube
5. x Change Oil and Filter after first 50 hours Clean more often under dusty conditions or when airborne debris is present replace air cleaner parts if very dirty The suggested maintenance checklist is not offered as a replacement for the manufacturer s engine manual but as a supplement You must adhere to the guidelines established by the manufacturer for warranty coverage In adverse conditions such as dirt mud or extreme temperatures maintenance should be more frequent 197 e ENDUSER 5 SERVICECHART Engine Oil Filter 10211111 Engine for Leaks and Loose Paris Air Cleaner Paper Pre Cleaner Every 25 hours Spark Plugs 111111114 As Required 100 Hours Every 500 Hours Yearly 200 Hours 250 Hours 300 Hours E Daily Idle Speed J Cooling System o Belts and Hoses O o Tire Pressure Visual Inspection of Tires Inspection of Tires Fuel Level Hydraulic Oil Filter Hydraulic System for Leaks and Loose Battery Electrolyte Level 211111 Clean Battery Terminals Torque Lug Nuts J lubricate 11 14 Lubricate Splines on Gas Hydrostatic Pump Every 500 Hours ADJUSTMENTS PARK BRAKEADJ
6. 25 a eS lt lt ob ates x a se e ne lt lt ta lt amp 2 lt 2 2 TAILGATE PARTS LIST REF NS PART 76 262 76 243 HB 12 13 300 HMB 12 14 75 565 HN 12 13 75 564 HNCL 12 13 HNCL 38 16 HB 38 16 100 HNTL 58 18 HNJ 58 18 HB 58 18 325 HMB 58 14 15 437 HRS 316 1125 HW 10 8828 60 DESCRIPTION Tailgate Screen Tailgate Bolt 1 2 13 x 3 Machine Bushing 2 x 14GA Tailgate Hinge Strap Nut 1 2 13 Tailgate Hinge Center Lock Nut 2 13 Center Lock Nut s 16 Bolt 9 s 16 x 1 Lock Nut 5 s 18 Jam Nut ss 18 Bolt 9 s 18 31 4 Machine Bushing s x 14GA Latch Rivet Steel 9 16 x 11 s Washer 10 Weather Stripping 60 QUANTITY 1 1 2 6 2 2 2 2 6 6 2 2 2 4 2 3 3 1 2 BY 77 239 EATONHYDROS TATIC PUMP DRAWING 35 77 239 EATON HYDROSTATIC PUMP PARTS LIST REF PART 60 343 52 60 343 08 77 239 01 77 239 02 77 239 03 77 239 04 77 239 05 77 239 06 77 239 07 77 239 08 77 239 09 60 343 21 77 239 10 60 343 12 77 239 11 77 239 12 77 239 13 77 239 14 33 058 27 60 343 23 77 239 15 77 239 16 76 160 77 239 17 77 130 77 239 18 77 239 19 60 343 43 77 239 20 77 239 21 60 343 05 60 343 06 60 343 03 60 343 02 60 343 01 77 23
7. 77 215 77 213 77 214 17 043 REPLACEMENT BELTS 76 200 77 212 SEALKITS BY 76 023 14 096 76 100 60 343 54 76 197 76 197 08 76 238 14 080 76 242 76 242 01 Oil Filter Cartridge Kubota 15841 32439 Air Cleaner Element Kubota 70000 11221 Fuel Filter Assembly Kubota 19204 43013 Fuel Filter Element Kubota 15231 4356 0 Finger Reel Belt 2 A74 Kubota Fan Belt Kubota 15881 97011 3 Bank Hydraulic Valve O Ring Seal Kit Hydrostatic Pump Seal Kit Gear Pump Seal Kit Wheel Motor Seal Kit Hydraulic Cylinder Seal Kit Both Cylinders have the part number stamped on them Look at the rod end it will have either a retaining ring or a spanner nut Cylinders with a Spanner Nut 50 456 75 634 Hydraulic Cylinder Use 14 267 Seal Kit Hydraulic Cylinder Use 14 268 Seal Kit Cylinders with a Retaining Ring 50 456 75 634 FLUIDS Hydraulic Cylinder Use 14 253 Seal Kit Hydraulic Cylinder Use 14 254 Seal Kit Engine Oil Kohler SJ or Higher 10W 30 Engine Oil Kubota CC CD 10W 40 Hydraulic Fluid Anti Freeze OTHER PARTS 13 288 17 068 Spline Grease 76 354 SJ or Higher 10W 40 Use permanent type mixed with water The anti freeze mixing ratio must be less than 50 Key Switch Kohler Kohler 25 099 04 Key Switch Kubota Spark Plugs Champion type RC 12 YC or Equivalent Gap 0 030 76 mm Torque 18 22 ft lbs 24 4 29 8 Nm 77 Assembly Paste Kohler 25 357 12 s 2 2 AB
8. OILFILTER DRAWING 2 AN AZ HYDRAULIC LIFT CYLINDER DRAWING M a SN OIL FILTER PARTS LIST DESCRIPTION QUANTITY REF 1 2 3 4 NOOO PART 23 006 23 031 18 008 23 142 14 20 075 HWL 14 HW 14 75 806 23 183 18 190 Oil Filter Filter Element replacement only Pipe Reducer 3 4 x 1 2 Connector Bolt 1 4 20 x 3 4 Lockwasher 1 4 Washer 1 4 Filter Bracket Male Connector Tee po po po das a HYDRAULIC LIFT CYLINDER PARTS LIST PART 18 202 23 167 76 242 76 242 01 76 242 02 DESCRIPTION QUANTITY Elbow 1 Elbow 2 Hydraulic Cylinder 1 Seal Kit 1 Clevis pin with Clip 2 Torque Specification Piston Nut 165 ft lbs 214 5 Nm Tie Rod Nut 30 ft lbs 39 Nm Clevis Nut 46 ftlbs 59 8 Nm SUC REEL LIFT CYLINDER DRAWING BY REEL LIFT CYLINDER PARTS LIST QUANTITY REF PART DESCRIPTION 1 HNTL 38 16 Lock Nut s 16 2 18 169 Adapter s SAE 3 75 634 Hydraulic Cylinder 2 x 7 x 3 4 4 HP 18 100 Cotter Pin s x 1 5 HCP 12 350 Clevis Pin 1 2 31 2 6 75 827 Cylinder Bracket 7 HB 38 16 150 Bolt 3 s 16 x 11 2 8 8820 6 Machine Chain St Link 9 HB 38 16 350 Bolt ys 16 x 3 10 HMB 12 14 Machine Bushing 2x 14GA Both Cylinders have the part number stamped on them Look at the rod end it will have either a retaining ring or a spanner nut Cylinders with a Spanner Nut 50 456 Hydraulic Cylinder Use
9. Hose Guard Short Stainless Steel Pan Head Drill Screw 1 4 x 3 4 Hose Guard Long Drill Screw 1 4 x 3 4 Stainless Steel Pan Head Machine Bushing 1 x 10GA Slotted Hex Nut 1 14 Cotter Pin s x 11 2 Adjustment Sleeve Machine Bushing 2 4 x 14GA Machine Bushing 3 4 x 10GA Cotter Pin s x 11 2 Castle Nut 1 14 Hydraulic Cylinder 1 2 x 7 Elbow Rod End Grease Fitting 1 4 28 x 180 part of rod end Clevis Pin 5 s x 13 4 Bridge Pin Right Hinge Strap Shown Left Hinge Strap Swivel Pin Right Tailgate Dump Bar Nut ys 16 Lockwasher s Bolt ys 16 x 1 Bolt 7 2 13 3 Nut 2 13 Center Lock Nut 7 2 13 Machine Bushing 11 4 x 10GA Machine Key 11 2 Set Screw s 16 3 Roll Pin 3 s x 27 2 Bolt 11x 2 Machine Bushing 5 x 14GA Center Lock Nut 5 s 11 Spacer Latch Rivet 3 16X 1 s Washer 8 Washer 10 i Sa HH HH NHANHNNANNNNNNH_NHH NNNNNNNNAANODOH HHH 2 As MW aaa TAILGATE DRAWING gt lt lt 25 i 25 tat 25 s co 25 25 lt lt gt x i o lt lt i lt lt e i 5555 amp 25 ob OO e SRS Aet lt O A 555506 25 2 2 o 5550 e 25 eS lt se a oo te ob 25
10. 4 s 225 9 P ART 8 5 8 0 7 dj A A N UE 2 es oom d ANG ST O87 2 7 AK Y gt 29 S gt Py Qa Ne 7 N WS KUBOTA DIESEL ENGINE AND EXHAUST PARTS LIST QUANTITY REF 14 15 16 17 18 19 21 23 25 26 27 28 PART 23 188 23 129 76 197 18 133 23 133 77 130 77 239 18 204 18 202 23 130 77 196 50 394 11 132 14 20 075 HWL 14 HN 14 20 77 221 77 213 77 181 HBM 8 1 25 77 208 77 208 02 77 208 03 77 208 05 77 182 HB 38 16 100 HNTL 38 16 77 236 77 194 38 16 100 HW 38 HWL 38 HN 38 16 50 111 77 192 11 021 77 186 HB 38 16 175 HNTL 38 16 77 216 77 217 77 212 21 461 HWK 14 100 77 242 HWLI 516 HSSHSM 8 1 25 20 DESCRIPTION Male Connector s Elbow 90 Gear Pump Barb Fitting Adjustable Elbow 90 Mounting Kit Hydrostatic Pump Elbow 90 Elbow Elbow 90 Diesel Air Intake Muffler Clamp 13 4 Mounting Band part of engine Bolt 1 4 20 x 3 4 Lockwasher 1 4 Nut 1 4 20 Air Cleaner Assembly part of engine Air Cleaner Element Air Cleaner Mount Metric Bolt 8 1 25 D 722 Diesel Kubota Engine Pump Housing Drive Shaft Air Pack Switch part of engine Hood Hinge Mount Bolt s 16 x 1 Lock Nut s 16 Hood Hinge Engine Cover Bolt Ys 16 x 1 Washer s Lockwasher s Nut 3 16 Muffler Clamp 1 2 Mu
11. 75 634 Hydraulic Cylinder Use Cylinders with a Retaining Ring 50 456 Hydraulic Cylinder Use 75 634 Hydraulic Cylinder Use 14 267 Seal Kit 14 268 Seal Kit 14 253 Seal Kit 14 254 Seal Kit aa a cl c cl NN TAILGATE CYLINDER PARTS LIST QUANTITY REF PART DESCRIPTION 1 HHP 18 Bridge Pin s 2 50 456 Hydraulic Cylinder 1 2 x 7 3 HNJ 58 18 Jam Nut 18 4 18 154 Rod End HG 14 28 180 Grease Fitting 4 28 x 180 5 58 11 Oval Lock ss 11GA 6 HMB 58 14 Machine Bushing 14GA 7 HB 58 11 200 Bolt ss 11x2 8 18 168 Elbow 9 HCP 58 175 Clevis Pin s x 13 4 Both Cylinders have the part number stamped on them Look at the rod end it will have either a retaining ring or a spanner nut Cylinders with a Spanner Nut 50 456 Hydraulic Cylinder Use 75 634 Hydraulic Cylinder Use Cylinders with a Retaining Ring 50 456 Hydraulic Cylinder Use 75 634 Hydraulic Cylinder Use 14 267 Seal Kit 14 268 Seal Kit 14 253 Seal Kit 14 254 Seal Kit 1 N cl Sys KOHLER GAS ENGINE AND EXHAUST DRAWING N 2 AN e VA 2 2 2 CN JE La ZK y 9 WSLS B KOHLER GAS ENGINE AND EXHAUST PARTS LIST REF 13 14 15 16 17 18 19 20 21 PART 23 188 23 129 76 197 18 133 23 133 18 204 18 202 23 130 76 266 18 220 76 348 76 276 HST 38 16 100 HW 38 HWL 38 HN 38 16 50 111 76 236 HB 38 16 10
12. 1 1 DD KD HYD HH Ba FINGER REEL DRAWING 5 FINGER REEL PARTS LIST REF 19 27 28 29 PART HB 34 10 550 HNTL 34 10 33 435 48 046 29 585 18 223 76 355 29 584 20 019 76 119 29 541 75 799 18 221 75 686 75 506 75 780 75 834 HB 38 16 300 HB 38 16 275 HW 38 HNTL 38 16 HB 38 16 450 HW 38 HWL 38 HN 38 16 75 800 75 787 75 511 76 102 76 102 01 HMB 114 10 HMB 114 14 76 210 76 213 HB 12 13 350 HW 12 HNCL 12 13 HB 38 16 350 HW 38 HNTL 38 16 75 808 76 278 HB 38 16 300 HWL 38 HN 38 16 76 277 76 279 76 330 HB 516 18 125 HNTL 516 18 76 313 76 336 HB 516 18 100 HW 516 HNTL 516 18 76 356 12 150 18 DESCRIPTION Bolt 3 4 10 x 5 2 Lock Nut 3 4 10 Tire and Wheel Castor Fork Spacer Height Adjustment Bushing part of 76 355 Arm Height Adjustment Spacer 1 2 Bushing part of 76 355 Mud Guard Lock Pin 1 4 Side Plate RH Flange Bushing part of 75 787 Spacer 1 x ID x 13 s Sweeper Finger Finger Reel Spacer 11 410 x 1 s Bolt ys 16 x Bolt 3 s 16 x 23 4 Washer s Lock Nut s 16 Bolt 3 s 16 x 41 2 Washer 3 Lockwasher s Nut 3 s 16 Left Side Plate Reel Frame Pillow Block 11 4 Bore Pulley with Hub Hub 11 410 Machine Bushing 1 4 x 10 GA Machine Bushing 17 x 14 GA Matting 7 2x 18 Reel Guard Strap Bolt 1 2 13 x 31 2 Washer 1 2 Center Lock Nut 1 2 13 Bolt 9 s 16 x 31 2 Washer 3 Lo
13. 105 8895 19 18 222 8917 38 18 040 48 135 76 202 8892 26 76 204 8892 26 76 023 76 205 8892 31 76 206 8895 27 18 222 75 634 18 173 76 117 50 456 76 203 8892 26 76 116 8832 19 5 18 040 8895 22 8895 20 18 222 DESCRIPTION Hydraulic Cylinder Hydraulic Hose Hydraulic Hose Wheel Motor Tee Hydraulic Hose Suction Hose Hose Clamp Hydraulic Hose 1 Hose Wrap Top of Axle 1 Hose Wrap Bottom of Axle Hose Clamp Hydrostatic Pump Hydraulic Hose 1 Hose Wrap Hose Clamp Gear Pump Hydraulic Hose 1 Hose Wrap Hose Clamp Oil Filter Filter Element Replacement Only Hydraulic Hose 1 Hose Wrap Hose Clamp Suction Hose ss ID Hose Clamp Oil Tank Hydraulic Hose 1 4 Hose Wrap Hydraulic Hose 1 4 Hose Wrap Hydraulic Valve Hydraulic Hose 1 4 Hose Wrap Hydraulic Hose 1 Hose Wrap Hose Clamp Hydraulic Cylinder Tee 3 Junction Union Hydraulic Hose Hydraulic Cylinder Hydraulic Hose 1 4 Hose Wrap Hydraulic Hose Suction Hose Hose Clamp 1 Hose Wrap Gas Unit Only 1 Hose Clamp Diesel Unit Only Hose Clamp QUANTITY PP Nm xl gt BODY AND FRAMEDRAWING When Filtration System is to be installed Ref 9 Hopper Screen Cover is to be removed When Filters are used 76 262 Tailgate Screen is replaced by
14. 31 it dt 32 33 Fuel Tank and Oil Tank muncea nea nene manea 34 35 i 36 37 Hydraulic Lift Cylinder 36 37 Reel Lift Cylinder ceea c 38 39 Tailgate Cylinder 38 39 Kohler Gas Engine and Exhaust 40 41 Kubota Diesel Engine and Exhaust 42 45 Electric Clutch Driven Belt Drive 46 47 Finger REEL 48 49 Rear i e 50 51 Hoppe 52 53 VAIN cuire oa O ot ata au 54 b5 77 239 Eaton Hydrostatic 56 57 76 197 Eaton Gear 58 59 76 238 Rear Wheel 60 61 76 023 3 Bank Hydraulic Valve 62 63 ACCesSOries qe 64 65 76 271 Dust Dirt Filtration Pack 64 65 irem 67 68 5 RET 67 Quick Reference Replacement Parts 68 INTRODUCTION Thank you for purchasing a BMITHCO product Read this manual and all other manuals pertaining to the Sweep Star 60 carefully as they have safety operating assembly and maintenance instructions Failure to do so could result in personal injury or e
15. SDDDERB GUANTITY STEERING DRAW A D d i PAS sd Mg STEERING PARTS LIST QUANTITY REF 1 2 3 4 17 18 19 20 21 PART 48 186 HWK 316 075 76 362 76 364 13 718 13 726 HNJ 58 18 75 833 HRP 532 150 HSSHS 38 16 038 75 813 HWK 316 075 76 301 HNAT 114 12 18 150 11 040 11 039 11 038 76 156 38 16 175 HW 38 HWL 38 HN 38 16 HMB 58 14 76 153 HWK 316 063 HNA 58 18 HP 18 150 8827 59 18 032 75 803 HSTP 516 18 100 HW 516 HWL 516 HN 516 18 76 155 DESCRIPTION Steering Shaft Woodruff Key 3 16 x 3 4 Tilt Steering Mechanism Tilt Steering Boot Steering Wheel Steering Wheel Cap Jam Nut s 18 Universal Joint Roll Pin 5 32 x 11 2 Socket Head Set Screw s 16 x 3 s Bottom Steering Shaft Woodruff Key 3 16 x 3 4 Main Frame Rubber Cap Thick Axle Nut 11 4 12 Cotter Pin x 11 2 Spacer 3 4 Seal Bearing Cup and Cone Sprocket Bolt 3 16 x 13 4 Washer s Lockwasher 3 Nut s 16 Machine Bushing s 14 Sprocket Woodruff Key 3 16 5 s Axle Nut s 18 Cotter Pin 1 2 Roller Chain Master Link 440 Chain Guard Phillips Truss Machine Screw 16 18 1 Washer 5 16 Lockwasher 5 16 Nut sie 18 Front Fork 4 4 4 4 4 4 4 4 2 2 4 4 as Req d
16. Switch part of engine Buzzer Electric Fan Bosch Power Relay Wire 17 to 19 Ignition Switch Temperature Sender part of engine Oil Sender part of engine 30Amp Circuit Breaker Circuit Breaker Boot Circuit Breaker Wire Thermostat Wire Harness Toggle Switch Boot Electric Clutch Clutch Wire Harness Wire Harness contains all wires except 4 4 amp 15 Thermostat Kit gt L dl do dl 2 ld a SS BI GAS WIRING DIAGRAM sET0JO Color Code Chart Blue Brown Yellow Green Orange Red Black Purple White ON OFF JA JA lo la ka ine M gt Y BL NEG 15 GAS WIRINGPARTS LIST REF 17 18 19 20 PART 22 003 76 269 12 017 76 259 76 260 34 146 34 145 13 288 50 359 22 073 48 166 22 054 75 518 8892 40 76 337 15 314 15 472 76 342 76 258 DESCRIPTION Ammeter Power Wire to Hour Meter Hour Meter Ground Wire for Hour Meter Ground Wire for Ignition Switch Panel Mount Circuit Breaker Circuit Breaker Boot Key Switch with Hardware Kohler 25 099 04 Warning Indicator Light Oil Sen
17. USTMENT 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 STEERINGCHAIN ADJ USTMENT Steering Sprockets A should be level with each other Check with straight edge Make any adjustments Slide Idler Pulley so that it is snug onto the chain Tighten all nuts and bolts in place WHEEL CREEP USTMENT Creep is when engine is running and hydrostatic transmission is in neutral but due to inadequate alignment wheels still move Do the following procedures to stop this motion 1 Lift up and support the unit so rear wheels are off the ground and can turn freely 2 side of hydrostatic transmission is the Shift Arm In the V shaped notch of shift arm rests and Idler Pulley D This Pulley is mounted onan Idler Arm E 3 Loosen bolt and nut holding Pulley to Idler Arm Leave finger tight With engine running slide the Pulley in Idler Arm slot until it centers on Shift Arm on hydrostatic and wheel creep stops 5 Tighten all fasteners and test by using foot pedal linkage to see that the creep is removed 6 Turn the engine off and lower the machine STORAGE When storing remove the key from the key switch to avoid unauthorized persons from operating machine 1 Before storing clean machine
18. 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 warranty gives you specific legal rights and you may also have other rights which may vary from state to state Federal law now requires disclosure of the warranty which applies to this product prior to the sale to a customer Please leave this statement attached to the product and allow the buyer to remove it after purchase SMITHED Wayne Pennsylvania 19087 MA m SMITHCO
19. eto 11 2 Upper Radiator Hose O Ring 3 4 ID x 3 sOD Shift Arm Socket Head Set Screw 5 1 18 x 1 2 Bolt s 16 x 11 4 Washer 3 Lockwasher s Straight Thread Connector Thermostat Kit includes items QUANTITY DDD Pa a a 00 00 00 DD a a DID SS ey ELECTRIC CLUTCH DRIVEN BELT DRIVE DRAWING BY O 629 K paci 2 N Zi ELECTRIC CLUTCH DRIVEN BELT DRIVE PARTS LIST QUANTITY REF 10 11 12 13 14 15 16 17 PART 48 038 HMB 100 10 21 445 76 337 16 013 76 217 76 298 HB 12 13 300 HW 12 HNTL 12 13 HMB 12 14 HP 18 150 76 102 76 102 01 HKSQ 14 150 76 200 HB 38 16 175 HWL 38 76 340 HB 516 18 100 HW 516 HNTL 516 18 76 339 HB 38 16 300 HW 38 HWL 38 HN 38 16 76 338 76 349 77 242 DESCRIPTION Spring Bracket Machine Bushing 1 x 10GA Spring Electric Clutch Idler Pulley Idler Arm Spacer Bolt 13 x 3 Washer Lock Nut 13 Machine Bushing x 14GA Cotter Pin x 17 Pulley 2AK104H Hub 1 4ID Machine Key 1 4 x 1 4 11 2 Belt 2 A74 Bolt 3 16 x 13 4 Lock Washer 3 Clutch Strap Bolt 9 16 18 x 1 Washer 5 16 Lock Nut e 18 Belt Guard Support Bolt 3 s 16 x 3 Washer 3 s Lock Washer 3 Nut ys 16 Clutch Mount Stub Shaft Gas Stub Shaft Diesel pp DD WWW gt AH AH 15
20. filter screen HANDLE END Place the handle and bracket onto the keeper and bend over 15 437 01 KEEPER the side of the tailgate to the desired tension mark where the two holes from the handle and bracket line up on the tailgate side panel 15 437 02 HANDLE AND BRACKET You need to drill two 1s holes where your marks are approximately centered on the curve and 1 from edge of material on each tailgate side Release handle end from keeper and place bracket end of latch handle over holes you drilled attach with two steel rivets Do this too both sides Remove the hopper screen cover Ref 5 by unwedging the top and pulling it out of the bottom tab You cannot use this cover with the filtration kit Remove the hopper screen Ref 6 from the hopper by unwedging the top and pulling it out the bottom tab Place the cloth filter Ref 3 onto the hopper then place the hopper filter screen Ref 4 over the top of the cloth filter by placing the screen in to the bottom tab and wedging it into the top tab gt 65 NOTES Mg E 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 17 066 25 078 25 277 25 286 25 307 25 308 25 313 25 320 25 321 25 352 25 355 25 356 25 359 25 261 25 362 27 093 34 147 75 651 75 865 76 199 76 245 76 304 76 305 76 306 76 307 76 315 77 178 48 136 Mo
21. 0 HW 38 HWL 38 HN 38 16 76 267 76 267 02 76 349 76 353 HB 14 20 100 HW 14 HWL 14 HN 14 20 76 350 HB 38 16 175 HNTL 38 16 76 369 8800 64 18 186 8963 67 18 222 76 270 HB 14 20 075 HNTL 14 20 21 161 23 145 77 239 77 241 HB 38 16 125 HW 38 HWL 38 77 130 76 351 76 352 76 349 18 241 DESCRIPTION Male Connector s Elbow 90 Gear Pump Barb Fitting Adjustable Elbow 90 Elbow 90 Elbow Elbow 90 Engine Cover Muffler Clamp Muffler Hood Support Truss Machine Screw s 16 x 1 Washer 3 s Lockwasher 3 Nut 3 s 16 Muffler Clamp Exhaust Bracket Bolt 3 8 16 x 1 Washer 3 8 Lockwasher s Nut ys 16 Kohler Command 25 hp Engine Crankshaft Splined Insert part of engine Stub Shaft part of engine Front Engine Guard Bolt 1 4 20 x 1 Washer 1 4 Lock Washer 1 4 Nut 1 4 20 Debris Shield Bolt 3 s 16 x 19 4 Lock Nut s 16 Motor Mount Fuel Hose 1 4 x 64 Hose Clamp 1 4 Fire Sleeve Hose Clamp Throttle Cable Mount Bolt 1 4 20 x 3 4 Lock Nut 4 20 Wire Block O Ring 3 4 ID x 3 sOD Hydrostatic Pump Shift Arm Bolt s 16 x 11 4 Washer 3 Lockwasher s Mounting Kit Manifold Guard Bottom Plate Stub Shaft part of engine Straight Thread Connector QUANTITY JJ S He KH Kr KM BRR 00 02 WW td I J NNNN SOS AO py KUBOTA DIESEL ENGI NE AND EXHAUST DRAWING O
22. 2 13 032 33 76 238 01 76 238 02 13 032 35 13 615 04 HWK 516 100 14 265 13 032 37 13 032 38 14 080 DESCRIPTION Water amp Dirt Seal Service Housing Assembly Inner Seal Thrust Bearing Inner Bearing Thrust Bearing Drive Link Ring Seal Manifold Commulator Assembly matched set End Cover Bolt Commulator Seal matches with 10 Rotor Set matched set Plate Wear Coupling Shaft Woodruff Key 16x 1 Nut 1 20 Thrust Washer Backup Washer Backup Washer Outer Bearing Seal Kit Included in 13 615 05 Service Housing Assembly AN DDD NO Coes Ce a4 76 023 3 BANK HYDRAULIC VALVE DRAWING la CS 76 023 3 BANK HYDRAULIC VALVE PARTS LIST QUANTITY REF PART 76 023 03 HN 516 18 HW 14 76 023 06 18 188 18 168 76 309 76 125 01 76 023 07 76 023 08 18 169 76 023 01 76 023 02 76 023 09 76 023 10 18 214 14 096 DESCRIPTION Mounting Bracket Hex Nut 5 6 18 Washer 1 4 Tie Rod Elbow 45 Elbow 90 Linkage comes with handle Valve Handle sold as a set of 3 Knob Body and Spool matching set In body O Ring O Ring Inlet Kit load check and relief 2000 psi Inlet with Load Check Adapter Mylar Shim O Ring Spring type 10 spool Spring Cap Spring Shaft Spring Guide Outlet Open Center Elbow 45 O Ring Seal Kit includes all items OD PP 1 1 per handle NE 00 0000
23. 76 023 Valve Lockwasher s Nut ys 16 Decal Control Panel Console Warning Indicator Light Electric Clutch Switch Switch Boot FP HH RH So ao BB HH Ja QUANTITY DIESEL CONSOLEDRAWING DIESEL CONSOLE PARTS LIST QUANTITY 10 11 12 13 14 15 16 17 18 19 PART 50 359 12 017 34 146 34 145 17 068 17 079 34 160 34 159 HSM 10 32 063 HSM 10 32 100 HWL 10 HN 10 32 77 178 76 214 HSA 8 100 76 309 76 023 76 224 60 106 HB 38 16 250 HW 38 HN 38 16 11 100 HP 18 100 HCP 516 125 76 225 60 536 HB 38 16 100 HWL 38 HN 38 16 77 193 15 314 15 472 77 206 18 275 77 211 DESCRIPTION Warning Indicator Light Hour Meter Panel Mount Circuit Breaker Circuit Breaker Boot Key Switch Key Set Throttle 48 Throttle Mounting Bracket Machine Screw 10 32 x 5 s Machine Screw 10 32 x 1 Lockwasher 10 Nut 10 32 Decal Control Panel Side Panel Tapping Screw 8 x 1 Valve Handle with Linkage Kit Hydraulic Valve 3 bank Park Brake Handle Mount Brake Lever Bolt 9 s 16 x 21 2 Washer 3 Nut ys 16 Linkage Yoke 5 16 Cotter Pin sx 1 Clevis Pin 5 16 x 17 4 Brake Cable with nuts Bellows one each end of brake cable Bolt 3 s 16 x 1 holds 76 023 Valve Lockwasher s Nut ys 16 Console Electric Clutch Toggle Switch Boot Kill Control Ball Joint Glow Plug Indicator Light
24. 76 249 Tailgate Filter Screen 76 261 Hopper Screen is replaced by 76 248 Hopper Filter Screen JR BODY ANDFRAME PARTS LIST REF 1 NS NS Y 01 14 15 16 17 18 19 PART 60 130 60 130 01 60 130 02 8839 76 264 76 354 76 372 76 373 13 718 76 265 77 193 76 219 76 151 75 561 75 570 76 211 76 359 HB 516 18 100 HNFL 516 18 76 249 76 247 75 564 75 568 76 248 76 246 16 225 16 225 01 16 225 02 75 629 76 235 8947 60 8842 14 76 341 48 047 76 267 77 208 76 290 77 244 76 231 76 266 77 194 14 270 76 289 77 180 HB 38 16 300 HW 38 HNTL 38 16 48 160 8803 10 HRS 18 050 HW 6 48 164 48 165 48 159 48 158 48 161 DESCRIPTION Tire and Wheel Tire 18 x 9 50 8 Wheel Windshield Washer Fluid or Equivalent Nose Cone 2 2 ABC Dry Chemical Fire Extinguisher Inclinometer Inclinometer Bracket Steering Wheel Gas Console Diesel Console Console Support Washer Right Tower Arm Pivot Tube Cross Bar Hopper Screen Cover Bolt 5 6 18 x 1 Flange Whiz Lock Nut 5 6 18 Tailgate Filter Screen Tailgate Filter Pack Tailgate Hinge Right Tailgate Dump Arm Hopper Filter Screen Hopper Filter Pack Tire and Wheel Tire 24 x 13 12NHS Wheel Left Tower Grass Chute Frame Trim Seal Foam Tape Side Belt Guard Side Blet Guard Tab Diesel only Kohler Command 25 hp Gas Engine D 722 Diesel Kubota Engine Main Frame Gas Only Main Fr
25. 9 22 DESCRIPTION Drive Shaft splined Needle Bearing with housing Housing O Ring Thrust Bearing Trunnion Cover Pan Head Screw Washer Cone Bearing Cam Plate Swash Plate Insert Rotating Kit Crush Ring Shaft Seal Seal Cover Key Gasket Back Plate Dowel Pin Bearing Relief Valve 4000 psi Tow Valve Assembly Charge Pump Adaptor Cap Screw O Ring mounting kit Cap Screw O Ring Gerotor and Coupler Endcover Assembly Retaining Ring Bearing Race Thrust Bearing Washer Shaft Seal Retaining Ring Seal Kit A hw PO gt 5 4 aS POM hw H QUANTITY SUC 76 19 7EATON GEAR PUMP DRAWING AS OX do SN NN E 13 M e A 76 19 7 EATON GEAR PUMP PARTS LIST REF PART DESCRIPTION QUANTITY 1 Body 1 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 lt 59 76 238 REAR WHEEL MOTOR DRAWING 14 5 Assemble seal with flat side out as shown M 5 76 238 REAR WHEEL MOTOR PARTS LIST 14 5 QUANTITY REF za 2f a 4t 5 171 18 19 201 PART 13 615 05 13 032 27 13 032 28 13 032 29 76 238 03 13 032 31 13 032 3
26. C Dry Chemical Fire Extinguisher UMITED WARRANTY SMITHCO warrants this product to be free from defects in material and workmanship under normal use for one year from the date of purchase by the original user 60 days if product is used for rental purposes All warranty claims must be handled through a SMITHCO authorized dealer or by INC All transportation charges must be paid by the purchaser There is no further express warranty All implied warranties including those of merchantability and fitness for a particular purpose are limited to one year 60 days if product is used for rental pur poses from the date of purchase by the original user and to the extent permitted by law any and all implied warranties are excluded and disclaimed after the expiration of such period All incidental and consequential damages including pickup and delivery of the unit communica tion mileage charges and or rental of a replacement unit during repair are not covered under this warranty nor is any loss of income and or other loss resulting from the failure of the product to function due to a warranty defect The following items are not covered under the SMITHCO warranty and are warranted by their respective manufacturer Engine and engine parts including starters generators alternators and filters Transaxle differentials gear boxes and mechanical pumps Hydrostatic transmissions hydraulic pumps and motors Batteries Wheels
27. L ENGINE At ear level 92 dB 98 dB At 3 ft 0 914 m 86 dB 96 dB At 30 ft 9 14 m 64 dB 74 dB ENGINE GAS DIESEL Make Kohler Kubota Model Command CH25S D 722B 1 Specs PA 68525 Horsepower 25 Hp 18 kw 18 8 Hp 14 kw Fuel Unleaded 87 Octane No 2 Diesel Gasoline Minimum Cooling System Air Cooled Liquid Cooled Lubrication System Full Pressure Full Pressure Alternator 15 Amp 15 Amp Tire amp Wheels Front One 18 x 9 50 x 8 Multi rib 20 psi 1 4 bar Front tire and wheel fluid filled to 50 Ibs total 28 pints of windshield washer fluid or equivalent Rear Two 24 x 13 00 x 12 Super Soft 18 psi 1 3 bar Castor 9 x 3 5 4 20 psi 1 4 bar SPEED Forward Speed 0 to 12 m p h 0 19 kph Reverse Speed 0 to 4 m p h 0 6 kph BATTERY Automotive type 45 12 volt BCI Group Size 45 Cold Cranking Amps 480 minimum Ground Terminal Polarity Negative Maximum Length 9 23 cm Maximum Width 5 38 14 cm Maximum Height 9 23 cm FLUIDCAPACITY Crankcase Oil Fuel Hydraulic Fluid Cooling Grade of Hydraulic Fluid See Engine Manual 5 gallon 19 liters 5 gallon 19 liters Kubota approximately 1 gallon 3 8 liters SAE 10W 40 API Service SJ or higher Motor Oil OPTIONAL EQUIPMENT 77 328 60 Brush Kit 76 329 60 Finger Reel Kit 76 271 Filtration Pack 77 218 Triple Castor Wheel Kit MAINTENANCE LUBRICATION Use No 2 General Purpose Lithium Base Grease and lubricate every 100 hours The Sweep Star 60 has ten gre
28. Nut 1 2 13 Tee Fitting Hydraulic Hose 23 5 Short 90 Elbow Woodruff Key 5 16 x 1 Ball Joint 5 16 24 Brake Rod Nut 5 16 24 Linkage Yoke 5 16 Clevis Pin 5 16 x 1 Cotter Pin x 3 4 Right Caliper Clockwise Cam Side Pad Cam Side Pad Support Carrier Side Pad Support Carrier Side Pad Brake Disk 8 5 Hole Bolt 1 2 13 x 71 2 Lock Nut 1 2 13 Rubber Bumper Nut 3 s 16 Rear Axle Rear Skid Clevis Pin 1 2 21 4 Bridge Pin Bolt 1 2 13 x 8 Wheel Motor Includes Ref 11 amp Ref 29 Lug Nut 1 2 20 x 15 16 Nut 1 20 Lock Nut 1 2 13 Left Caliper Counterclockwise Zinc Plated Spring Clevis Pin 5 16 x 1 Linkage Yoke 5 16 Nut 5 16 24 Bellows Brake Cable with Nuts Hose Clamp Bolt 5 6 18 x 11 4 Lockwasher 5 16 Bolt 9 16 18 x 11 2 Lock Nut 5 e 18 Hose Clamp Bolt 9 16 18 x 11 2 Lock Nut 5 16 18 Rear Chute Baffle Rear Beater Panel Pad Kit with 2 Pads and Steel Backing Plates QUANTITY i HHH HNNNANNNAANNNNNH_NNNDNM FP AA nn 00 aA Ap 2 Kits Req d B pie HOPPER DRAWING 2 SER RE RD so0090909000000090900000000000000000000002 Rn RN RE Co00000000000000000000000000000000000000 SS 555555555555 555555555555 555555555550 lt
29. OD Spacer Mainframe Motor Mount Spring Bolt 3 16 x 2 Washer 3 Lock Nut s 16 Idler Arm Bushing part of 76 370 Grease Fitting 4 28 x 180 Cotter Pin 3 4 Machine Bushing 2 x 14GA Linkage Plate Bolt 1 2 13 x 23 4 Lock Nut 2 13 Pedal Pad Short AA A pp a tl tl dy A A ll dl dl dl 38584558 1 10 1 BY GAS CONSOLE DRAWING GAS CONSOLE PARTS LIST REF 1 2 3 4 10 11 12 13 14 15 PART 34 146 34 145 12 017 22 003 13 288 76 310 34 160 34 159 HSM 10 32 063 HSM 10 32 100 HWL 10 HN 10 32 80 020 76 214 HSA 8 100 76 309 76 023 76 224 60 106 HB 38 16 250 HW 38 HN 38 16 11 100 HP 18 100 HCP 516 125 76 225 60 536 HB 38 16 100 HWL 38 HN 38 16 76 199 76 265 50 359 15 314 15 472 DESCRIPTION Panel Mount Circuit Breaker Circuit Breaker Boot Hour Meter Ammeter Key Switch with hardware Kohler 25 099 04 Key Set Throttle 48 Throttle Mounting Bracket Machine Screw 10 32 x 5 s Machine Screw 10 32 x 1 Lockwasher 10 Nut 10 32 Choke Cable Side Panel Tapping Screw 8 x 1 Valve Handle with Linkage Kit Hydraulic Valve 3 bank Park Brake Handle Mount Brake Lever Bolt 9 s 16 x 21 2 Washer 3 Nut ys 16 Linkage Yoke 5 16 Cotter Pin sx 1 Clevis Pin 5 16 x 17 4 Brake Cable with nuts Bellows one each end of brake cable Bolt 9 s 16 x 1 holds
30. Pressure Visual Inspection of Tires Fuel Level Fuel Filter Hydraulic Oil tHydraulic Oil Filter Hydraulic System for Leaks and Loose Parts Battery Electrolyte Level Clean Battery Terminals Torque Lug Nuts Lubricate Lubricate Splines on Hydrostatic Pump 5 jeje pones 181 8 8111 5 8 pones ole lele le ol How fol fel dl Jef m lt lt gt O o C Check or Clean at specified intervals R Replace at specified intervals Tire pressure 20 psi 1 4 bar Front and Castor 18 psi 1 3 bar Rear T Replace hydraulic filter after the first 20 100 and every 250 there after Torque tire nuts after the first 10 hours and every 200 hours there after 64 to 74 87 100 x Change Oil and Filter after first 5 hours Clean more often under dusty conditions or when airborne debris is present replace air cleaner parts if very dirty The suggested maintenance checklist is not offered as a replacement for the manufacturer s engine manual but as a supplement You must adhere to the guidelines established by the manufacturer for warranty coverage In adverse conditions such as dirt mud or extreme temperatures maintenance should be more frequent SERVICE CHART K
31. SMITHEU Wayne Pennsylvania 19087 PARTS amp SERVICE MANUAL SWEEP STAR 60 GAS amp DIESEL with Electric Clutch Models 76 000 C and 77 100 C Starting Serial 4 D G 1745 July 2004 SMITHCO PRODUCT SUPPORT 1 800 891 9435 Hwy SS and Poplar Avenue Cameron WI 54822 E mail productsupport smithco com n 0 si 0 CONTENTS introdu tiON ep 1 3 Safe Practices 2 PL 3 Optional Equipment a cat a n n a eta 3 SOR VIGO aaa 4 11 Maitena PR 4 6 Service Chart Kohler Command 25 7 Service Chart Kubota Diesel 18 8 8 End User s Service 9 A ERE a pa d TT 10 aa 10 11 Diagrams c aaa aaa 12 17 Diesel Wiring Diagram pp 12 13 Gas Wiring Diagram sse 14 15 Hydraulic Did gra sesizati a iii 16 17 PariS ii 18 63 Body and nnns 18 19 Roll Over Protection ROPS 20 21 RT ERE 22 23 Se ER 24 25 Gasoline 26 27 Diesel Linkage 44000 ainan iis 28 29 Gas c ni act a at a ai 30
32. UBOTA DIESEL 18 8 Before servicing or making adjustments to the machine stop engine set park break block wheels and remove key from ignition CAUTION y 9 Follow all procedures and ONLY use parts prescribed by the manufacturer Read the engine manual before maintenance a Engine Oil w Filter 4qt 3 8 a Engine Oil Filter Engine for Leaks andLooseParts Air Cleaner Paper Element 400 Hours Every 500 Hours Yearly o Daily dle Speed 1200RPM Cooling System _ C C C BeltsandHoses Tire Pressure Visual InspectionofTires Fuellevel Fuel Fier LCI CIR Hydraulic Ol tHydraulic Oil Filter R R Hydraulic System for Leaks and Loose Parts C C C C Battery Electrolyte Level 11 Clean Battery Terminas 5 TorguelugNus fefc lubricate 10101 ejeje C Check Clean at specified intervals R Replace at specified intervals Tire pressure 20 psi 1 4 bar Front and Castor 18 psi 1 3 bar Rear T Replace hydraulic filter after the first 20 100 and every 250 there after Torque tire nuts after the first 10 hours and every 200 hours there after 64 to 74 87 100
33. ame Diesel Only Step right side Gas Engine Cover Diesel Engine Cover Seat Seat Assembly Belt Guard diesel only Bolt 9 s 16 x Washer s Lock Nut s 16 Right Step Black Trim 10 Rivet 1 8 1 2 Washer 6 Magnet Magnet Bracket Battery Box Cover Front Cover Left Step Front tire and wheel fluid filled to 50 lbs total Optional 76 271 Filtration System includes Ref 10 and 13 1 1 1 28 pints 2 4 410 5 5 PMNMAMABRHABADOOHi Aaa aa QUANTITY SS OI 76 3 75 ROLLOVER PROTECTION DRAWING SV 76 375 ROLLOVER PROTECTION PARTS LIST REF 1 2 10 11 12 13 PART 76 377 HB 38 16 200 HWL 38 HN 38 16 HB 716 14 100 HWL 716 HN 716 14 76 198 03 76 379 76 381 12 13 125 HW 12 HWL 12 HN 12 13 76 376 HB 38 16 100 HWL 38 HN 38 16 HB 38 16 300 HWL 38 HN 38 16 HB 12 13 300 HWL 12 HN 12 13 76 380 76 378 DESCRIPTION Right Seat Belt Bracket Bolt 3 8 16 x 2 Lockwasher 3 Nut 3 16 Bolt 7 16 14 x 1 Lockwasher 7 16 Nut 7 16 14 Seat Belt Right Support Roll Bar Bolt 1 2 13 11 4 Washer 2 Lockwasher 1 gt Nut 1 2 13 Strap Bolt 3 s 16 x 1 Lockwasher s Nut ys 16 Bolt 3 8 16 x 3 Lockwasher s Nut ys 16 Bolt 1 2 13 x 3 Lockwasher 1 2 Nut 2 13 Left Support Left Seat Belt Bracket OOONNNREREREDNRERRBR
34. ange directions of travel on any slope F Do not operate debris hopper lift or tailgate while on slopes G Stay alert for holes in the terrain and other hidden hazards Before leaving operator s position for any reason A Disengage all drives B Lower all attachments to the ground C Set park brake D Shut engine off and remove the ignition key Keep hands feet and clothing away from moving parts Wait for all movement to stop before you clean adjust or service the machine Keep the area of operation clear of all bystanders Never carry passengers Stop engine before making repairs adjustments or checking adding oil to the crankcase Use parts and materials supplied by SMITHCO only Do not modify any function or part 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 These machines are intended for operation by well trained persons performing 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 e SPECIFICATIONS FOR SWEEP STAR 60 GAS amp DIESEL WEIGHTS AND DIMENSIONS Length 129 328 cm Width 74 5 179 cm Height with Hopper Down 66 168 Height with Hopper Up 127 323 cm Wheel Base 68 5 174 cm Weight 2200 lbs 998 kg SOUND LEVEL GAS ENGINE DIESE
35. ase fittings One on the outside of each tower One on the center of park brake relay on rear axle One on hydrostatic pedal under the floorboard One on the pillow block bearing on each end of finger reel One on castor wheel mount bracket One on hydrostatic forward and reverse relay One on reel clutch belt tightener One on rod end of the tailgate cylinder Every 500 hours of operation separate the hydrostatic pump from the engine Clean the splined areas and lightly grease the male portion of the pump spline Use either Dow Corning G N Metal Assembly Paste or 77 Assembly Paste Kohler 25 357 12 s As you remount the pump to the engine be certain the mating surface are clean and free of any foreign material and that the pump is correctly aligned HYDRAULIC OIL 1 2 Use SAE 10W 40 Service SJ or higher motor oil For proper warranty change oil every 500 hours or annually which ever is first and change the filter after the first 20 hours then at 100 hours then every 250 hours thereafter The oil level should be 2 to 21 2 from top of the tank when fluid is cold Do not overfill After changing oil and or filter run the machine for a few minutes Check oil level and for leaks Always use 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 conditions If natural color of fluid is
36. ck Nut s 16 Front Baffle Bottom Mount Bolt 3 16 x Lockwasher s Nut 3 16 Height Indicator Rod Top Mount Brush Bolt 5 6 18 x 11 4 Lock Nut 5 6 18 Clamp Hose Clamp Bolt 9 16 18 x 1 Washer 5 16 Lock Nut 5 e 18 Castor Mount Bracket Clevis Pin 1 gt 11 2 Bridge Pin QUANTITY Sd o o NINE 2 As 1 As oo NA mm M SIN REAR AXLE DRAWING Tower Main Frame Torque to 160 ft lbs 208Nm SE le nd REAR AXLE PARTS LIST REF 1 2 38 39 PART 76 218 HB 38 16 125 HW 38 HNTL 38 16 HB 12 13 450 HNTL 12 13 HB 12 13 400 76 229 HN 516 24 HWL 516 HW 12 HNTL 12 13 34 057 76 208 34 122 HWK 516 100 21 462 76 300 HN 516 24 11 100 HCP 516 100 HP 18 075 76 241 76 239 HB 12 13 750 HNTL 12 13 50 081 HN 38 16 76 226 75 723 HCP 12 225 HHP 18 HB 12 13 800 76 238 60 268 14 265 HNTL 12 13 76 240 29 118 HCP 516 100 11 100 HN 516 24 60 536 76 225 13 099 HB 516 18 125 HWL 516 HB 516 18 150 HNTL 516 18 75 614 HB 516 18 150 HNTL 516 18 76 234 76 233 34 101 02 DESCRIPTION Brake Cable Bracket Bolt 3 s 16 x 11 4 Washer 3 Lock Nut s 16 Bolt 1 2 13 x 41 2 Lock Nut 1 2 13 Bolt 1 2 13 x 4 Park Brake Relay Nut 5 16 24 Lockwasher 5 16 Washer 7 gt Lock
37. d and remove blocks and jack JUMP STARTING Use of booster battery and jumper cables Particular care should be used when connecting a WARNING 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 termi Engine D nals of each battery first A then B 3 Connect one end of other cable to negative terminal of good battery C Booster Battery Jumper Cable 2 4 Connect other end of cable D to engine block on unit being started NOT to negative terminal of A ox batter 9 y E Jumper Cable 1 To prevent damage to other electrical components on dne unit being started make certain that engine is at idle speed before disconnecting jumper cables SWEEPING While sweeping close tailgate frequently to ensure tailgate does not creep open 7e SERVICECHART KOHLER COMMAND 25 HP Before servicing or making adjustments to the machine stop engine set park break block wheels and remove key from ignition CAUTION y 9 Follow all procedures and ONLY use paris prescribed by the manufacturer Read the engine manual before maintenance a Engine Oil w Filter 2 1qt 2 a Engine Oil Filter Engine for Leaks and Loose Parts Air Cleaner Paper Element Pre Cleaner Every 25 hours Spark Plugs Idle Speed 1200 RPM Cooling System Belts and Hoses Tire
38. der Part of Engine Ignition Module Part of Engine Fuel Shut Off Solenoid Part of Engine Rectifier Part of Engine Starter Part of Engine Battery Battery Holddown Black Battery Cable Red Battery Cable Hose Wrap 1 4 x 40 Wire With Fuse Part of Engine Fuse AGC 30 Electric Clutch Toggle Switch Switch Boot Wire Switch to Ammeter Wire Harness Includes all wire color with QUANTITY 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 ap HYDRAULIC DIAGRAM 12 28 13 14 45 6 11 9 Top Bottom Middle Levers Top of Axle Bottom of Axle 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 R 22 44 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 Inlet Vacuum Hg 203 bar Inlet Temperature 225 107 Allowable 25 1 72 76 197 Displacement 40 in R 6 6 cm R 6 23 gpm 25 39 lpm A gt 16 HYDRAULIC DIAGRAM PARTS LIST REF 13 14 15 16 17 18 19 20 21 PART 76 242 76 115 76 114 76 238 34 057 76 208 8832 21 5 18 040 76 209 8895 50 8895 48 18 222 77 239 76 207 8895 21 18 222 76 197 76 104 8895 29 18 222 23 006 23 031 76
39. ffler Brace Rubber Mount Rear Engine Mount Bolt 3 s 16 x 13 4 Lock Nut s 16 Muffler Assembly part of engine Muffler Gasket part of engine Fan Belt part of engine Pulley 2AK41 x 1 Woodruff Key 4 x 1 Stub Shaft Internal Lockwasher 5 16 Socket Set Cap Screw Metric 8 1 25 x 20 Continued on Next Page UO Sasa NND 3 S 3585 JI 1 JOS 1 1 140 11 BY KUBOTA DIESEL ENGINEAND EXHAUST DRAWING CONTINUED M gt Y REF 30 31 33 35 36 38 KUBOTA DIESEL ENGI NE AND EXHAUST PARTS LIST CONTINUED PART 77 185 HB 38 16 175 HNTL 38 16 8951 24 77 243 77 208 04 77 184 HBM 8 1 25 HWLI 516 HBM 6 1 16 HW 14 HWL 14 HNM 6 60 406 HBM 10 1 25 110 77 201 77 201 01 77 201 02 77 201 03 77 238 15 013 HWL 14 HN 14 20 77 237 77 225 18 222 8951 11 23 145 76 227 HSSHS 516 18 050 HB 38 16 125 HW 38 HWL 38 18 241 77 235 DESCRIPTION Front Engine Mount Bolt 3 s 16 x 13 4 Lock Nut 3 s 16 Lower Radiator Hose Radiator Mount Gooseneck part of engine Cable Bracket Metric Bolt 8 1 25 Internal Lockwasher 5 16 Metric Bolt 6 1 16 Washer 7 4 Lockwasher 1 4 Metric Nut M6 Spacer Metric Bolt 10 1 25 x 110 Electric Fan Motor Only 150 Watt Fan Blade Fan Shroud Radiator Mount Rubber Bumper Lockwasher 1 4 Nut 1 4 20 Radiator on engine Radiator Brace Hose Clamp
40. ine bore damage due to inad equate lubrication SAEViscosity Grades Kohler Gas Engine Kubota Diesel Engine Starting Temperature Range Anticipated Before Next Oil Change 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 When normal driven operation is desired valve should be closed by turning it clockwise Failure to close the valve with engine running means no power to wheels BATTERY Batteries normally produce explosive gases which can cause personal injury Do not allow flames sparks or any ignited object to come near the battery When charging or working near battery always shield your eyes and always provide 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 Electr
41. now black or smells burnt it is possible that an overheating problem exists If fluid becomes milky water contamination may be a problem If either of the above conditions happen change oil and filter immediately after fluid is cool and find cause Take fluid level readings when system is cold In extreme temperatures you can use straight weight oil We recommend SAE 30W API Service SJ or higher when hot above 90 F 33 C and SAE 10W API Service SJ or higher when cold below 32 F 0 ambient temperature Use either motor oil or hydraulic oil but do not mix Oil being added to the system must be the same as what is already in the tank Mark tank fill area as to which type you put in MAINTENANCE CONTINUED TIREPRESSURE Caution must be used when inflating a low tire to recommended pressure Over inflating can cause tires to ex plode Front tires and castor wheel should be 20 psi 1 4 bar rear tires should be 18 psi 1 3 bar maximum Improper inflation will reduce tire life considerably ENGINE OIL FOR KOHLER Change and add oil according to charts below Do not overfill Use a high quality detergent oil For Kohler engine use oil classified For Service SJ or higher SAE 30 oil For Kubota Diesel engine use oil classified For Service CC CD or CE API oil Use no special additives with recommended oils Do not mix oil with gasoline SAE 30 oil if used below 40 F 4 C will result in hard starting and possible eng
42. olyte 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 WARNING of water Get medical attention immediately FILTER PACK Filter pack may be cleaned by shaking or spraying off with low pressure water Filter will disintegrate if high pressure is used on it MAINTENANCE CONTINUED WHEELMOUNTINGPROCEDURE REAR WHEELS 1 Setpark brake Turn machine off and remove key Block one of the other wheels Loosen nuts slightly on wheel to be removed Jack up machine being careful not to damage underside of machine Remove nuts remove wheel Place new wheel on hub lining up bolt holes B wp Torque nuts to 64 74 ft lb 87 100 Nm using a cross pattern Torque again after first 10 hours and every 200 hours thereafter 7 Lower machine to ground and remove blocks and jack FRONT WHEEL Set park brake Turn machine off and remove key Block one of the other wheels Remove cotter pins from each end of the axle Remove axle nuts machine bushings and axle locks Jack up front of machine being careful not to damage underside of machine Wheel and axle will come out of slots in the u bracket pull wheel forward Place new wheel on hub lining up bolt holes NO Torque nuts to 64 74 ft lb 87 100 Nm using a cross pattern Torque again after first 10 hours and every 200 hours thereafter 9 Lower machine to groun
43. pacer 1 OD x Ys ID x 2 Washer 5 s Lock Nut s 18 Spacer Seal Cotter Pin s x 2 Front tire and wheel fluid filled to 50 lbs total QUANTITY 14 2 2 2 2 2 2 per Shock 00 ints BY GAS LINKAGE DRAWING GAS LINKAGE PARTS LIST QUANTITY REF 1 2 24 25 26 27 PART 76 299 HB 516 18 075 HW 516 HNTL 516 18 76 296 18 234 HG 14 28 180 48 059 18 234 76 282 HN 38 24 75 791 10 007 HN 38 24 HWL 38 21 173 76 284 HN 38 24 HSDPS 14 075 13 569 26 034 15 013 HWL 14 HN 14 20 76 351 77 241 HSSHS 14 28 031 14 266 76 275 76 369 48 109 HB 38 16 200 HW 38 HNTL 38 16 76 370 10 007 HG 14 28 180 HP 18 075 HMB 12 14 76 368 HB 12 13 275 HNTL 12 13 76 332 DESCRIPTION Pedal Pad Long Bolt 5 16 18 x Washer 5 16 Lock Nut 5 16 18 Pedal Mount Oilite Bushing Grease Fitting 4 28 x 180 Foot Pedal Oilite Bushing Foot Pedal Rod Nut 3 s 24 Shift Relay Bushing Nut 3 s 24 Lockwasher s Ball Joint 3 s 24 Rear Linkage Rod Nut s 24 Stainless Steel Pan Head Drill Screw 1 4 x 3 4 Gas Spring 60 Ball Stud Rubber Bumper Lockwasher 1 4 Nut 4 20 Manifold Guard Shift Arm Set Screw 1 4 28 x 5 16 comes with 77 241 Ball Bearing 5 s ID x 13 4 OD Spacer Mainframe Motor Mo
44. quipment 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 SMITHGO machines have a 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 For easy access record your Serial and Model numbers here SMITHCO WAYNE PENNSYLVANIA 19087 USA 610 688 4009 Fax 610 688 6069 SERIAL NO kWhp 5 MODEL NO kg lb Information needed when ordering replacement parts 1 Model Number of machine 2 Serial Number of machine 3 Name and Part Number of part 4 Quantity of parts SS SAFE PRACTICES It is your responsibility to read this manual and all publications associated with this machine engine accessories 10 11 13 14 15 16 17 18 19 20 21 and attachments Never allow anyone to operate or service the machine or its attachments without proper training and instructions Never allow minors to operate any equipment Learn the proper use of the machine the location and purpose of all the controls and gauges before you operate the equipment Working with unfamiliar equipment can lead to accidents Wear all the necessary protective clothing and personal safet
45. thoroughly Check bolts and nuts tighten as necessary Make all repairs that are needed and remove any debris Remove the battery adjust the electrolyte level and recharge it Store the battery in a dry dark place Store in a clean and dry area but NOT near a stove furnace or water heater which uses a pilot light or any device that can create a spark 6 Engines stored over 30 days need to be protected or drained of fuel to prevent gum from forming in a fuel system or on essential carburetor parts Check the engine manual and follow the instructions for the storage of the engine NOTES we PR DIESEL WIRING DIAGRAM Color Code Chart Blue Brown Yellow Green DIESEL WIRING PARTS LIST QUANTITY REF PART 22 073 22 054 75 518 8892 40 50 359 77 209 12 017 34 146 34 145 17 068 17 079 77 223 77 211 77 208 05 77 207 77 201 77 233 77 226 77 208 01 8975 8977 48 144 77 203 15 314 15 472 76 337 77 245 77 205 77 235 DESCRIPTION Battery Black Battery Cable Red Battery Cable Hose Wrap 1 4 x 40 Warning Indicator Lights Hour Meter to Ground Wire Hour Meter Panel Mount Circuit Breaker Circuit Breaker Boot Key Switch Key Set Glow Lamp Timer Glow Plug Indicator Air Pack
46. unt Spring Bolt 3 16 x 2 Washer 3 Lock Nut s 16 Idler Arm Bushing part of 76 370 Grease Fitting 4 28 x 180 Cotter Pin 3 4 Machine Bushing 2 x 14GA Linkage Plate Bolt 1 2 13 x 23 4 Lock Nut 2 13 Pedal Pad Short AA A pp a tl tl dy A A ll dl dl dl 38584558 1 10 1 DIESEL LINKAGE DRAWING Me EN DIESEL LINKAGE PARTS LIST QUANTITY REF 1 2 24 25 26 27 PART 76 299 HB 516 18 075 HW 516 HNTL 516 18 76 296 18 234 HG 14 28 180 48 059 18 234 76 282 HN 38 24 75 791 10 007 HN 38 24 HWL 38 21 173 76 284 HN 38 24 HSDPS 14 075 13 569 26 034 15 013 HWL 14 HN 14 20 76 351 77 241 HSSHS 14 28 031 14 266 76 275 76 369 48 109 HB 38 16 200 HW 38 HNTL 38 16 76 370 10 007 HG 14 28 180 HP 18 075 HMB 12 14 76 371 HB 12 13 275 HNTL 12 13 76 332 DESCRIPTION Pedal Pad Long Bolt 5 16 18 x Washer 5 16 Lock Nut 5 6 18 Pedal Mount Oilite Bushing Grease Fitting 4 28 x 180 Foot Pedal Oilite Bushing Foot Pedal Rod Nut 3 s 24 Shift Relay Bushing Nut 3 s 24 Lockwasher s Ball Joint 3 s 24 Rear Linkage Rod Nut s 24 Stainless Steel Pan Head Drill Screw 1 4 x 3 4 Gas Spring 60 Ball Stud Rubber Bumper Lockwasher 1 4 Nut 4 20 Manifold Guard Shift Arm Set Screw 1 4 28 x 5 16 comes with 77 241 Ball Bearing 5 s ID x 13 4
47. ving Parts Hot Diesel Caution No Riders Alternator Battery Pinch point Gasoline Engine Speed Slope 20 Max Load Limit Diesel Fuel Only By Pass valve Tire Pressure 18 psi Tire Pressure 20 psi Smithco Technical Assistance Danger Fire Hydraulic Oil Level Smithco Star Hopper Lift Safety Sweep Star 60 Control Panel Reel Height Crush Pinch Rotating Parts Attachment Clutch Tower Warning Belt Routing Control Panel Belt Guard Side Panel diesel only Engine Cover Under Seat on Hopper Panel On Each Side Bottom Tailgate Console Back Above Fuel Tank gas only Engine gas only Nose Cone Left Hopper Front Console Back Above Fuel Tank diesel only Hang Tag Rear Wheels Front Wheel and Castor Wheel Tailgate Main Frame Hopper Console Back Above Hydraulic Tank Front Nose Cone One on each Side of Hopper Hopper Lift Safety Bar One each Side of Hopper Control Panel gas only Right Tower on Front Right and Left Hopper Front Right and Left Sides of Grass Chute Engine Cover diesel only Left and Right Towers Behind Belt Guard Control Panel diesel only Decal Sweeper Set all items QUICK REFERENCE REPLACEM ENT PARTS REPLACEMENT FILTERS KOHLER ENGINE 23 031 78 090 76 311 76 312 50 403 Hydraulic Cil Filter Oil filter Kohler 12 050 01 Air Filter Element Kohler 24 083 03 Pre Cleaner Kohler 24 083 05 FuelFilter for Kohler REPLACEMENT FILTERS KUBOTA ENGI NE
48. y devises to protect your head eyes ears hands and feet Operate the machine only in daylight or in good artificial light Inspect the area where the equipment will be used Beware of overhead obstructions and underground ob stacles Stay alert for hidden hazards Never operate equipment that is not in perfect working order or without decals guards shields or other protec tive devices in place Never disconnect or bypass any switch Carbon monoxide in the exhaust fumes can be fatal when inhaled never operate a machine without proper ventilation Fuel is highly flammable handle with care Keep engine clean Allow the engine to cool before storing and always remove the ignition key After engine has started machine must not move If movement is evident the neutral mechanism is not ad justed correctly Shut engine off and readjust so the machine does not move when in neutral position Never use your hands to search for oil leaks Hydraulic fluid under pressure can penetrate the skin and cause serious injury 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 operate on a slope greater than 10 Pay carefuk attention to the inclinometer on you machine C Do not stop or start suddenly on sloped surfaces D Reduce speed on slopes and in all turns Use caution when changing directions on all surfaces E Do not ch
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