Smithco 45-204C User manual

Sand Star IV
Model 45-204-C
3WD-Series Parallel
Hydraulic Steering
sn: 4HS0380
Product Support: Hwy SS & Poplar Ave; Cameron WI 54822
1-800-891-9435 productsupport@smithco.com
Parts & Service

Introduction Service Diagrams Parts Accessories Reference
CONTENTS
Introduction������������������������������������������������������������������������������������������������������������������������������ 1-3
Introduction�������������������������������������������������������������������������������������������������������������������������������� 1
Safe Practices ��������������������������������������������������������������������������������������������������������������������������� 2
��������������������������������������������������������������������������������������������������������������������������� 3
Service������������������������������������������������������������������������������������������������������������������������������������ 4-11
Maintenance ��������������������������������������������������������������������������������������������������������������������������� 4-6
Service Chart����������������������������������������������������������������������������������������������������������������������������� 7
End User’s Service Chart ���������������������������������������������������������������������������������������������������������� 8
Adjustments�������������������������������������������������������������������������������������������������������������������������� 9-10
Storage �������������������������������������������������������������������������������������������������������������������������������������11
Diagrams ������������������������������������������������������������������������������������������������������������������������������ 12-15
Wiring Diagram������������������������������������������������������������������������������������������������������������������� 12-13
Hydraulic Diagram �������������������������������������������������������������������������������������������������������������� 14-15
Parts�������������������������������������������������������������������������������������������������������������������������������������� 16-51
Main Frame ���������������������������������������������������������������������������������������������������������������������� 16-17
Seat Panel �������������������������������������������������������������������������������������������������������������������������� 18-19
Front Fork ��������������������������������������������������������������������������������������������������������������������������� 20-21
Dashboard �������������������������������������������������������������������������������������������������������������������������� 22-23
Foot Pedal Linkage ������������������������������������������������������������������������������������������������������������ 24-25
Fuel Tank ���������������������������������������������������������������������������������������������������������������������������� 26-27
Oil Tank������������������������������������������������������������������������������������������������������������������������������� 28-29
Belts and Pulleys ���������������������������������������������������������������������������������������������������������������� 30-31
18 HP Engine���������������������������������������������������������������������������������������������������������������������� 32-33
Pump ���������������������������������������������������������������������������������������������������������������������������������� 34-35
Rear Axle ���������������������������������������������������������������������������������������������������������������������������� 36-37
Rear Rake Lift��������������������������������������������������������������������������������������������������������������������� 38-39
Center Lift ������������������������������������������������������������������������������������������������������������������������������� 40
13-729 Valve �������������������������������������������������������������������������������������������������������������������������� 41
34-103 Orbitrol������������������������������������������������������������������������������������������������������������������� 42-43
34-103 Orbitol Repair Instructions�������������������������������������������������������������������������������������� 44-45
Rear Wheel Motors������������������������������������������������������������������������������������������������������������� 46-47
45-373 Piston Pump ����������������������������������������������������������������������������������������������������������� 48-49
Decals�������������������������������������������������������������������������������������������������������������������������������������� 50
Quick Reference���������������������������������������������������������������������������������������������������������������������� 51
Accessories ������������������������������������������������������������������������������������������������������������������������� 52-55
Roll Bars ����������������������������������������������������������������������������������������������������������������������������� 52-53
Light Kit for ROPS �������������������������������������������������������������������������������������������������������������� 54-55
Light Kit ����������������������������������������������������������������������������������������������������������������������������������� 56
Attachments������������������������������������������������������������������������������������������������������������������������ A-B-C
Warranty ����������������������������������������������������������������������������������������������������������������������������������������

1
Introduction
INTRODUCTION
Thank you for purchasing a Smithco product�
Read this manual and all other manuals pertaining to the Bunker Rake carefully as they contain safety, oper-
ating, assembly and maintenance instructions� 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 machines have a Serial Number and Model Number� Both numbers are needed when ordering
parts� Serial number tag is located on left rear ROPs mount post� Refer to engine manual for placement of
engine serial number�
www�Smithco�com�
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
For easy access record your Serial and Model numbers here�
WARNING
Failure to follow cautious operating practices can re-
sult in serious injury to the operator or other persons.
The owner must understand these instructions, and
must allow only trained persons who understand these
instructions to operate this vehicle.
WARNING:
Engine exhaust and some of its constituents are
known to the State of California to cause cancer,
birth defects, and other reproductive harm�
For more information visit
www.P65Warning.ca.gov

2
Introduction
SAFE PRACTICES
1� It is your responsibility to read this manual and all publications associated with this machine (engine,
accessories and attachments)�
2� Never allow anyone to operate or service the machine or its attachments without proper training and
instructions� Never allow minors to operate any equipment�
3� 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�
4� Wear all the necessary protective clothing and personal safety devises to protect your head, eyes, ears,
5� Inspect the area where the equipment will be used� Beware of overhead obstructions and underground
obstacles� Stay alert for hidden hazards�
6� Never operate equipment that is not in perfect working order or without decals, guards, shields, or other
protective devices in place�
7� Never disconnect or bypass any switch�
8� Carbon monoxide in the exhaust fumes can be fatal when inhaled, never operate a machine without
proper ventilation�
10� Keep engine clean� Allow the engine to cool before storing and always remove the ignition key�
11� After engine has started, machine must not move� If movement is evident, the neutral mechanism is not
cause serious injury�
14� 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 turns� Use caution when changing directions on slopes�
D� Stay alert for holes in the terrain and other hidden hazards�
15� Before leaving operator’s position for any reason:
A� Disengage all drives�
B� Lower all attachments to the ground�
16� Keep hands, feet and clothing away from moving parts� Wait for all movement to stop before you clean,
adjust or service the machine�
17� Keep the area of operation clear of all bystanders�
18� Never carry passengers�
19� Stop engine before making repairs/adjustments or checking/adding oil to the crankcase�
20� Use parts and materials supplied by Smithco only� Do not modify any function or part�
These machines are intended for professional maintenance on golf courses, sports turf, and any other
area maintained turf and related trails, paths and lots. No guaranty as to the suitability for any task is
expressed or implied.

3
Introduction
SAND STAR SPECIFICATIONS
WEIGHTS AND DIMENSIONS
Length 68" (1�73 m)
Width 58" (1�47 m)
Height 52" (1�2 m)
Wheel Base 42" (1�07m)
Ground Clearance 5�5" - 7" (13 -18 cm) - under cultivator depending on attachment
Weight 3WD - 915 lbs� ( 415 kg)
SOUND LEVEL (EAR PROTECTION REQUIRED)
At Ear Level 87 dB
ENGINE
Make Briggs and Stratton Vanguard
Model# 356447
Type / Spec# 0263 G
Horsepower 18 hp (13 kW)
Fuel Unleaded 87 Octane Gasoline Minimum
Lubrication System Full Pressure
Alternator 16 amp
WHEELS & TIRE Three: 22 X 11 - 10�0 Knobby Tires 5 psi (�34 bar)
Optional: 23-10�50 x 12 Turf Tires 5 psi (�34 bar)Smithco # 48-265
SPEED
Forward Speed 0 to 10 m�p�h� (0-16 kph)
Reverse Speed 0 to 5 m�p�h� (0-8 kph)
BATTERY Automotive Type SP 35
BCI Group Size 35
Cold Cranking Amps 300
Ground Terminal Polarity Negative (-)
Maximum Length 7�5" (19 cm)
Maximum Width 5" (12,7 cm)
Maximum Height 7�5" (19 cm)
FLUID CAPACITY
Crankcase Oil See Engine Manual
Fuel 20 quarts (18�93 liters)
Hydraulic Fluid 20 quarts (18�93 liters)
Grade of Hydraulic Fluid SAE 10W-40 API Service SJ or higher Motor Oil
ROPS CERTIFICATION
Rops ISO 21299
Seatbelts OSHA 1928�51
HYDRAULIC PRESSURES
Piston Pump Displacement �913 in3Charge Pump Displacement �33 in3/rev
Pump Input Speed (up to) 3300rpm Max� Inlet Vacuum 5 in� Hg
Max� Operating Pressure 3000 peak psi Max� Case Pressure 25 psi
Implement Setting 345 psi Relief Valve Pressure (set at) 1230 psi
13-729 Hydraulic Valve (2 bank) 900 psi

4
Service
MAINTENANCE
Before servicing or making adjustments to machine, stop engine and remove
key from ignition�
Use all procedures and parts prescribed by the manufacturer's� Read the engine
manual�
LUBRICATION
Use No� 2 General purpose Lithium Base Grease and lubricate every 100 hours� The Sand Star has four
cylinder�
REMOTE AIR CLEANER
1� Un-clip the two clips, remove the cover and pull out the element�
3� Clean out the inside of the body and cover�
4� Place the element into the body and put the cover back on�
TOWING
When it is necessary to move the Sand Star without engine running, bypass valve built into hydrostatic pump
must be "open" by turning it counterclockwise� The valve is located on the right side of the pump� An "open"
be "closed by turning it clockwise� Failure to "close" the valve with engine running means no power to wheels�
do not recommend this as a
standard procedure� When towing do not tow the machine faster than 2-3 MPH (3-5 km/h) because the drive
system may be damaged� The tires may lock up if the machine is towed too fast� If this occurs, stop towing
the machine� If the machine must be moved a considerable distance, transport it on a truck or trailer�

5
Service
MAINTENANCE
TIRE PRESSURE
ENGINE
Service SJ or higher" SAE 30 oil� Use no special additives with recommended oils� Do not mix oil with gaso-
line�
SAE VISCOSITY GRADES
Starting Temperature Range Anticipated Before Next Oil Change 18-462-P
Use of multi-viscosity oils (10W-30, etc�) Above 80° F (27° C) will result in high oil consumption and possible
engine damage� Check oil level more frequently if using these types of oils�
SAE 30 oil, if used below 40° F (4° C), will result in hard starting and possible engine bore damage due to
inadequate lubrication�
HYDRAULIC OIL
1� Use SAE 10W-40 API Service SJ or higher motor oil�
3� The oil level should be 2" to 21/2
Check and service more frequently when operating in extremely cold, hot or dusty conditions�
cause�
9� 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°C) ambient temperature� Use either motor oil or hydraulic oil, but do not mix�
10� Oil being added to the system must be the same as what is already in the tank�
which type you put in�

6
Service
MAINTENANCE
WHEEL MOUNTING PROCEDURE
2� Block one of the other wheels�
3� Loosen nuts slightly on wheel to be removed�
4� Jack up machine being careful not to damage underside of machine�
5� Remove nuts� Remove wheel�
5� Place new wheel on hub lining up bolt holes�
hours thereafter�
7� Lower machine to ground and remove blocks and jack�
BATTERY
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�
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, ush all contact
areas immediately with liberal amounts of water� Get medical atten-
tion 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
post of booster battery� (B)�
3� Connect one end of other cable to negative (-) termi-
nal of booster battery (C)�
4� Connect other end of cable (D) to engine block on
unit being started�
To prevent damage to other electrical components on unit
being started, make certain that engine is at idle speed
before disconnecting jumper cables�

7
Service
SERVICE CHART
Before servicing or making adjustments to the machine, stop engine, set park
break, block wheels and remove key from ignition�
Follow all procedures and ONLY use parts prescribed by the manufacturer�
Read the engine manual before maintenance�
but as a supplement� You must adhere to the guidelines established by the manufacturer for warranty cover-
age� In adverse conditions such as dirt, mud or extreme temperatures, maintenance should be more frequent�
Maintenance Service Interval Maintenance Procedure
Aer the rst 8 operating hours Torque the wheel lug nuts. (64-74 /lb (87-100 Nm))
Change the engine oil lter.
Before each use daily Check the engine oil level.
Clean area around muer and controls.
Check the hydraulic uid level.
Check the tire pressure.
Check condition of hydraulic hoses and ttings.
Inspect and clean the machine.
Aer the rst 50 hours Change Hydraulic Oil Filter.
Every 100 hours Clean or change air lter.1
Clean pre-cleaner.1
Change engine oil and lter.
Replace spark plug .
Lubricate machine.
Clean or change remote air cleaner.
Check the battery uid level and cable connections..
Check muer and spark arrestor.
Check belt tension .
Every 250 hours Check engine valve clearance and adjust if necessary.
Check idle speed.
Clean battery terminals.
Change hydraulic oil lter.
Torque the wheel lug nuts. (64-74 /lb (87-100 Nm))
Every 500 hours or yearly Change fuel lter.
Change hydraulic oil and lter.
Clean oil cooler ns.1
Clean air cooling system.1
Check safety lter in remote air cleaner.
1 In dusty conditions or when airborne debris is present, clean more oen.

8
Service
END USER’S SERVICE CHART
Duplicate this page for routine use.
Maintenance Check Item For the week of:
Mon Tues. We d. urs. Fri. Sat. Sun.
Check the Safety Seat Switch
Check Steering Operation
Check the fuel level
Check the engine oil level.
Clean the air lter
Clean the engine cooling ns.
Check for unusual engine noises
Check the hydraulic oil level
Check hydraulic hoses and ttings for
damage
Check for uid leaks.
Check the tire pressure
Check the Instrumentation
Inspect electrical system for frayed wires
Check park brake adjustment
Change oil lter.
Change oil.
Lubricate Machine
Ensure all warning decals are intact.
Areas of Concern
Inspection Performed by:
Item Date Information

9
Service
ADJUSTMENTS
RAKE LIFT CYLINDER
Completely lower Rake Lift� Remove the clevis pin (A)� Twist lift
linkage (C) so clevis pin end of cylinder extension lines up with
holes in attachment lift arm (B)� Replace clevis and cotter pins�
Tighten Jam Nut (D)� Raise and lower Rake Lift to check for
proper clearance�
quick hitch and will not move in full up position�
When the rear rake attachment is lowered while the ma-
chine is in forward motion, the forward speed of the ma-
chine will slow drastically� Operator should be prepared for
a rapid change in speed�
PARK BRAKE
The park brake is located on the left hand side of the
machine and operates both rear wheels� Pull lever back
to engage and push forward to disengage�
To adjust, turn the knob on the end of the handle�
DRUM BRAKE ADJUSTMENT
The brake can be adjusted through the access hole in
the backing plate� Remove the rubber plug from the
backing plate� Using a drum brake adjusting tool, or a
towards the axle shaft to expand the shoes,one click at a
time� Expand the shoes until slight contact is made with
the drum� It is highly recommended that you adjust 1 click at a time� Rotate the drum back and forth to insure
is used it will seat in� Test after each adjustment�

10
Service
ADJUSTMENTS
WHEEL ‘CREEP’ ADJUSTMENT
‘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�
the ground and can turn freely�
2� On the top of the pump there is a Creep Arm� Loos-
en bolts�
3� With engine running adjust the creep arm side to
side in slot so centering arm centers on the swash
plate�
4� Tighten all fasteners and test by using foot pedal
linkage to see that the "creep" is removed�
TO ADJUST FOOT PEDAL THROTTLE CABLE
ground� (Use jack stands)
2� Start the engine, make certain that the hand throttle
is in the idle position (1200 engine RPM)�
3� Engine speed must increase as soon as the foot
pedal begins to move in either direction� At the full forward position, the engine RPM must be 3300RPM
± 100�
4� Minor adjustment can be made by backing out (unscrewing) Retainer (Ref A) until you reach full engine
RPM with the foot pedal fully depressed in the forward position� Be sure to recheck after the nuts are
fully tightened�
5� Major adjustment needs to be made by pulling the slack out of the cable� Loosen the screw in the wire
block on the engine that is clamped onto the end of the cable and sliding it up to the cable block that is
through the throttle plate� Do not let the throttle plate move to increase idle speed� Tighten the screw�
6� Test run to determine that there is no binding and that engine idle speed is 1200 RPM and that it is
3300RPM at full forward position of the foot pedal�

11
Service
ADJUSTMENTS
SPEED BOSS
Speed Boss allows the machine to operate at
a proper speed while raking sand traps on golf
courses� This speed boss has been factory set at
an average speed of 3-4 m�p�h� (5-6�5 kph)� The
Speed Boss will only limit the speed while the
rake is lowered into the operating position� The
speed setting may be adjusted by turning the
Ball Joint (A) counterclockwise to make the ma-
chine operate slower or turn clockwise to go fast-
er� Tighten jam nut� Check to make sure nothing
is binding and test drive to check desired speed�
For RBS System, Spiker and Grader Box remove
the speed boss arm and the speed boss rod from
machine so it does not interfere with other opera-
tions�
STORAGE
When storing, remove the key from the key switch to avoid unauthorized persons from operating machine�
1� Before storing clean machine thoroughly�
2� Check bolts and nuts, tighten as necessary�
3� Make all repairs that are needed and remove any debris�
4� Remove the battery, adjust the electrolyte level and recharge it� Store the battery in a dry, dark place�
5� 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�

12
Diagrams
Color Code Chart
Bl Blue
Br Brown
Y Yellow
Grn Green
O Orange
R Red
B Black
P Purple
W White
WIRING DRAWING

13
Diagrams
WIRING PARTS LIST
REF # PART # DESCRIPTION QUANTITY
1 12-804 Hour Meter 1
2* Lights Switch (Optional)
15-727 Switch Actuator, no light 1
15-782 Rocker Switch, Unlit 1
3* 34-201 Lights (Optional) 3
43-505 Lights Wire Harness 1
4 13-488 Ignition Switch 1
5 8975 Circuit Breaker, 30AMP 1
8977 Breaker Boot 1
6 45-119 Red Battery Cable 1
7 Battery (not included) 1
8 22-065 Black Battery Cable 1
9 13-750 Starter Solenoid w/ Connector 1
10 22-017 Starter Cable 1
11 43-024 18hp Briggs & Stratton 1
12 14-292 Seat Switch 1
13 50-359 Warning Indicator Lights 1
NS 45-042 Wire Harness 1
* 45-016 Light Kit

14
Diagrams
45-204 HYDRAULIC DRAWING

15
Diagrams
45-204 HYDRAULIC PARTS LIST
REF # PART # DESCRIPTION QUANTITY
1 10-554 Steering Cylinder 2
18-154 Rod End 2
2 45-136 Hydraulic Hose, 24" 1
3 34-103 Orbitol 1
4 45-024 Hydraulic Hose, 37�5" 1
5 45-029 Hydraulic Hose, 27" 1
6 45-028 Hydraulic Hose, 31�5" 1
7 13-729 2-Bank Hydraulic Valve 1
8 45-030 Hydraulic Hose, 47" 1
9 45-031 Hydraulic Hose, 50" 1
10 43-150 Rake Cylinder 1
42-040 Yoke End 1
11 45-382 Cooler 1
12 45-186 Hydraulic Hose, 70" 1
13 45-032 Hydraulic Hose, 15�5" 1
14 45-187 Hydraulic Hose, 58" 1
15 76-238 Front Wheel Motor 1
16 45-027 Hydraulic Hose, 40" 1
17 45-023 Hydraulic Hose, 45" 1
18 45-025 Hydraulic Hose, 29" 1
19 23-006 Oil Filter 1
23-031 Replacement Filter only 1
20 8832-37 3/4" Suction Hose, x 37" 1
18-040 Hose Clamp 2
21 45-373 Piston Pump 1
22 45-365 Hydraulic Hose, 16" 1
23 45-385 Hydraulic Hose, 11�5" 1
25 45-041 Right Upper Steel Tube 1
26 45-065 Right Wheel Motor w/ Brake 1
27 45-040 Right Lower Steel Tube 1
28 18-170 Tee 2
29 45-038 Left Lower Steel Tube 1
30 18-337 Tee 1
31 45-037 Hydraulic Hose, 12�5" 1
32 45-366 Hydraulic Hose, 54" 1
33 45-039 Left Upper Steel Tube 1
34 42-005 Oil Tank 1
13-747 Filler Breather 1
35 45-066 Left Wheel Motor w/ Brake 1
HYDRAULIC PRESSURES
Piston Pump Displacement �913 in3Charge Pump Displacement �33 in3/rev
Pump Input Speed (up to) 3300rpm Max� Inlet Vacuum 5 in� Hg
Max� Operating Pressure 3000 peak psi Max� Case Pressure 25 psi
Implement Setting 345 psi Relief Valve Pressure (set at) 1230 psi
13-729 Hydraulic Valve (2 bank) 900 psi

16
Parts
MAIN FRAME DRAWING

17
Parts
MAIN PARTS LIST
REF# PART# DESCRIPTION QUANTITY
1 HNL-12-20 Lug Nut, 1/2- 20 10
2 14-265 Axle Nut (part of wheel motor) 3
3 45-021 Knobby Tire and Wheel 3
45-021-01 Tire, 22 x 11 - 10 3
45-021-02 Wheel 3
4 42-833 Fuel Tank 1
5 15-781 Cup Holder 1
6 45-123 Rake Holder 1
7 45-043 RH Fender 1
8803-11 Black Trim, 11" 1
8 8-532 Crate 1
9 42-834 Air Cleaner 1
42-834-01 Band 1
42-834-02 Hood 1
42-834-03 Safety Filter 1
42-076-03 Replacement Filter 1
10 60-106 Park Brake Lever 1
11 8959-26 Flex Hose 1
18-116 Hose Clamp 2
12 13-747 Filler Breather 1
13-586-03 Neck 1
13 42-005 Oil Tank 1
14 45-044 LH Fender 1
15 13-718 Steering Wheel 1
13-726 Center Cap 1
16 76-364 90° Black Boot (comes with 76-362) 1
76-362 Tilt Steering Mechanism 1
17 45-026 Nose Cone 1
8803-45 Black Trim, 45" 1
18 45-047 Foot Rest Plate 1
45-132 Foot Rest Grip 1
19 45-099 LH Floorboard 1
45-064 LH Floor Mat 1
20 45-022 Molded Foot Pedal 2
21 45-098 RH Floorboard 1
45-063 RH Floor Mat 1
22 45-145 Floorboard Frame 1
23 45-085 Seat Panel 1
24 14-293 Adjustable Low Back Seat 1
25 45-401 Main Frame 1
26 42-814-02 Fuel Cap 1
27 18-436 Lock Hole Plug 1
OPTIONAL TURF TIRES
48-265 Tire & Wheel 3
43-123-01 Turf Tires 5 psi (�34 bar) 3
16-857-02 Wheel, 23-10�50 x 12 3

18
Parts
SEAT PANEL DRAWING
This manual suits for next models
1
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