Smithco Sweep Star 48H Quick start guide

Sweep Star 48H
48-500-A
SN: GH5288
April 2020
Product Support: Hwy SS & Poplar Ave; Cameron WI 54822
1-800-891-9435 [e-mail]
Parts & Service

Introduction Service Diagrams Parts Accessories Reference
CONTENTS
Introduction ................................................................................................1-3
Safe Practices .......................................................................................... 2
Specication ............................................................................................. 3
Optional Equipment .................................................................................. 3
Service ......................................................................................................4-10
Maintenance ..........................................................................................4-6
Service Chart............................................................................................ 7
End User’s Service Chart ......................................................................... 8
Adjustments.............................................................................................. 9
Storage ..................................................................................................... 9
Reel Height Adjustment .......................................................................... 10
Diagrams................................................................................................. 11-15
Wiring Diagram..................................................................................12-13
Hydraulic Diagram High Lift...............................................................14-15
Parts ........................................................................................................16-90
Smithco Engineered Roll Over Protection .........................................16-17
Nose Cone.........................................................................................18-19
Steering ............................................................................................20-21
Front Fork ..........................................................................................22-23
Foot Pedal Linkage...........................................................................24-25
Seat and Console ..............................................................................26-27
Fuel and Oil Tank ..............................................................................28-29
Hopper Lift Cylinder...........................................................................30-31
Reel Lift Cylinder ...............................................................................30-31
Tailgate Cylinder ................................................................................30-31
Engine and Exhaust ........................................................................32-35
Electric Clutch Driven Belt Drive and Mu󰀪er ....................................36-37
Finger / Brush Reel............................................................................38-39
Rear Axle ...........................................................................................40-41
Hopper and Tailgate ..........................................................................42-43
48-267 Hydrostatic Pump .................................................................44-45
48-267 Repair Instructions ................................................................46-54
48-266 Gear Pump ................................................................................. 55
48-266 Repair Instructions ................................................................56-66
76-238 Rear Wheel Motor .................................................................... 67
76-238 Repair Instructions ................................................................68-89
48-258 3-Bank Hydraulic Valve ........................................................... 90
Accessory.................................................................................................... 91
45-501 Hopper Dust Cover..................................................................... 91
Reference................................................................................................93-94
Decal List................................................................................................ 93
Quick Reference Replacement Parts ..................................................... 54

1
Introduction
INTRODUCTION
Thank you for purchasing a Smithco product.
Read this manual and all other manuals pertaining to the Sweep Star 48H carefully as they have safety, op-
erating, 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. Refer to engine manual for placement of engine serial number.
For product and accessory information, help nding a dealer, or to register your procuct please contact us at
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.
SMITHCO CUSTOMER SERVICE 1-800-891-9435
WARNING
Failure to follow cautious operating practices
can result 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,
hands and feet. Operate the machine only in daylight or in good articial light.
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.
9. Fuel is highly ammable, handle with care.
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
adjusted correctly. Shut engine o󰀨 and readjust so the machine does not move when in neutral position.
13. Never use your hands to search for oil leaks. Hydraulic uid under pressure can penetrate the skin and
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.
C. Set park brake.
D. Shut engine o󰀨 and remove the ignition key.
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
SPECIFICATIONS FOR SWEEP STAR 48H
WEIGHTS AND DIMENSIONS HIGH LIFT
Length 121" (307 cm)
Width 60" (153 cm)
Height with Hopper Down 63" (160 cm)
Height with Hopper Up 126" (320 cm)
Wheel Base 70" (179 cm)
Weight 1900 lb (862 kg)
SOUND LEVEL
At ear level 90 dB
ENGINE
Make Briggs & Stratton
Model# 356447
Type / Spec# 0263G1
Horsepower 18 Hp (13kW)
Fuel Unleaded 87 Octane Gasoline Minimum
Cooling System Air Cooled
Lubrication System Full Pressure
Alternator 16 Amp
WHEELS & TIRE Front: One 18 x 9.50 x 8 Multi-rib (20 psi (1.4 bar))
Rear: Two 22 x 11.00 - 10 4-ply (20 psi (1.4 bar))
Castor: 9 x 3.50 - 4 (20 psi (1.4 bar))
SPEED
Forward Speed 0 to 10 m.p.h. (0-16 kph)
Reverse Speed 0 to 4 m.p.h. (0-6 kph)
BATTERY Automotive IBS 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)
FLUID CAPACITY
Crankcase Oil See Engine Manual
Fuel 6 gallon (22,7 liters)
Hydraulic Fluid 5 gallon (19 liters)
Grade of Hydraulic Fluid SAE 10W-40 API Service SJ or higher Motor Oil
OPTIONAL EQUIPMENT
48-502 48" Brush Reel Kit (includes pillow blocks and pulley drive)
48-503 48" Finger Reel Kit (includes pillow blocks and pulley drive)
48-501 Hopper Dust Shield

Service
4
MAINTENANCE
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.
LUBRICATION
Use No. 2 General Purpose Lithium Base Grease and lubricate every 100 hours. The Sweep Star 48H has
fteen grease ttings.
A. One on the top of each tower.
B. One on the center of park brake relay on rear axle.
C. One on each pedal under the oorboard.
D. One on the pillow block bearing on each end of nger/brush reel.
E. One on caster wheel mount bracket.
F. One on reel clutch relay. One on reel clutch belt tightener.
G. One on pedal pivot arm.
H. One on rod end of the tailgate cylinder.
I. Pump idler Arm.

Service
5
MAINTENANCE
HYDRAULIC OIL
1. Use SAE 10W-40 API Service SG motor oil.
2. For proper warranty, change oil every 500 hours or annually, which ever is rst and change the lter
after the rst 50 hours, then every 250 hours thereafter.
3. The oil level should be 2" to 21/2" (5 - 6.4 cm) from top of ll neck when uid is cold. Do not overll.
4. After changing oil and/or lter, run the machine for a few minutes. Check oil level and for leaks.
5. Always use caution when lling 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.
6. If natural color of uid is now black or smells burnt, it is possible that an overheating problem exists.
7. If uid becomes milky, water contamination may be a problem.
8. If either of the above conditions happen, change oil and lter immediately after uid is cool and nd
cause. Take uid level readings when system is cold.
9. In extreme temperatures you can use straight weight oil. We recommend SAE 30W API Service SG
when hot (above 90°F (33°C)) and SAE 10W API Service SG 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. Mark tank ll area as to
which type you put in.
ENGINE OIL
Change and add oil according to chart below. Do not overll. Engine oil capacity is 2 quarts. We recommend
high-quality detergent oils classied for service SF, SG, SH, SJ or higher. Do not use special additives. Out-
door temperatures determine the proper oil viscosity for the engine. Use the chart to select the best viscosity
for the outdoor temperature range expected.
SAE Viscosity Grades
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.

6
Service
MAINTENANCE
TIRE PRESSURE
Caution must be used when inating a low tire to recommended pressure. Over inating can cause tires to ex-
plode. Front and rear tires and caster wheel should be 20 psi (1.4bar) maximum. Improper ination will reduce
tire life considerably.
WHEEL MOUNTING PROCEDURE
REAR WHEELS
1. Set park brake. Turn machine o󰀨 and remove key.
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.
6. Torque nuts to 64-74 ft/lb (87-100Nm) using a cross pattern. Re-torque after rst 8 hours and every 250
hours thereafter.
7. Lower machine to ground and remove blocks and jack.
FRONT WHEEL
1. Set park brake. Turn machine o󰀨 and remove key.
2. Block one of the other wheels.
3. Remove cotter pins from each end of the axle.
4. Remove axle nuts, machine bushings and axle locks.
5. Jack up front of machine being careful not to damage underside of machine.
6. Wheel and axle will come out of slots in the u-bracket, pull wheel forward.
7. Place new wheel on hub lining up bolt holes.
8. Torque nuts to 64-74 ft/lb (87-100Nm) using a cross pattern. Re-torque after rst 8 hours and every 250
hours thereafter.
9. Place wheel back on front fork. Tighten all bolts.
10. Lower machine to ground and remove blocks and jack.
SWEEPING
While sweeping close tailgate frequently to ensure tailgate does not creep open. While operating the sweeper
head it is important to disengage the head before raising. If the sweeper head is raised while engaged, it can
cause the belt to slip o󰀨 the pulleys. This can result in belt failure and engine crankshaft failure.
DISENGAGE THE SWEEPER HEAD BEFORE RAISING.

Service
7
MAINTENANCE
BATTERY
Batteries normally produce explosive gases which can cause personal injury. Do not allow ames, 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 rst and replace it last. Avoid hazards by:
1. Filling batteries in well-ventilated areas.
2. Wear eye protection and rubber gloves.
3. Avoid breathing fumes when electrolyte is added.
4. Avoid spilling or dripping electrolyte.
Battery Electrolyte is an acidic solution and should be handled with care. If
electrolyte is splashed on any part of your body, ush all contact areas imme-
diately with liberal amounts of water. Get medical attention immediately.
JUMP STARTING
Use of booster battery and jumper cables. Particular care should be used
when connecting a booster battery. Use proper polarity in order to prevent
sparks.
To jump start (negative grounded battery):
1. Shield eyes.
2. Connect ends of one cable to positive (+) terminals of
each battery, rst (A) then (B).
3. Connect one end of other cable to negative (-) terminal
of "good" battery (C).
4. Connect other end of cable (D) to engine block on unit
being started (NOT to negative (-) terminal of battery)
To prevent damage to other electrical components on unit being started, make certain that engine is at idle
speed before disconnecting jumper cables.
TOWING
When it is necessary to move the Sweep Star 48H without engine running, the bypass valve built into hydro-
static pump must be “open” by turning it 1/4 turn. An “open” valve allows uid to pass through the wheels free-
ly. When normal, driven, operation is desired, valve should be closed by turning it 1/4 turn. Failure to “close” the
valve with engine running means no power to wheels. Tow slowly. 2 m.p.h. or less.
The bypass valve is a 3/8 diameter shaft with two at spots on the sides so you can turn it. On the high lift it is
on the top of the hydrostatic.
FILTER PACK
Filters can be removed and cleaned by shaking or use a low pressure water hose. Filter will disintegrate if
cleaned under high pressure.

Service
8
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.
The suggested maintenance checklist is not o󰀨ered 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 cover-
age. In adverse conditions such as dirt, mud or extreme temperatures, maintenance should be more frequent.
Maintenance Service Interval Maintenance Procedure
Aer 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 muer and controls.
Check the hydraulic uid level.
Check the tire pressure.
Check and clean Debris Filter Pack1
Check condition of hydraulic hoses and ttings.
Inspect and clean the machine.
Aer 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 muer 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 oen.