Smithco Super Star Diesel Quick start guide

Super Star Diesel
Quick Hitch
43-001
SN: 14270
July 2010
Parts & Service
Product Support: Hwy SS & Poplar Ave; Cameron WI 54822
1-800-891-9435 [e-mail]

Introduction Service Diagrams Parts Accessories Reference
CONTENTS
Introduction........................................................................................... 1-3
Introduction ...............................................................................................1
Safe Practices ..........................................................................................2
Specifications............................................................................................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 ................................................................................................... 16-47
Main Frame ....................................................................................... 16-17
ROPS................................................................................................ 18-19
Front Fork.......................................................................................... 20-21
Linkage.............................................................................................. 22-25
Gas Tank ........................................................................................... 26-27
Oil Tank ............................................................................................. 28-29
Engine............................................................................................... 30-33
Rear Axle........................................................................................... 34-35
Rake Lift............................................................................................ 36-37
13-729 2-Bank Hydraulic Valve 38-39
43-116 Front Wheel Motor................................................................ 40-41
43-117 Rear Wheel Motor ................................................................ 42-43
42-797 Variable Pump...................................................................... 44-45
Decals.....................................................................................................46
Quick Reference.....................................................................................47

1
Introduction
Informationneeded whenordering replacementparts:
1. ModelNumber ofmachine
2. SerialNumber ofmachine
3. Nameand PartNumber ofpart
4. Quantityof parts
INTRODUCTION
Thank you for purchasing a SmithcoSmithco
SmithcoSmithco
Smithco product.
Readthismanual andall othermanualspertainingto the Diesel Super Starcarefully as theyhave safety,operat-
ing, assembly and maintenance instructions. Failure to do so could result in personal injury or equipment dam-
age.
Keepmanualsinasafeplace after operator and maintenance personnel have read them. Right and left sides are
fromthe operator’s seat, facing forward.
All SmithcoSmithco
SmithcoSmithco
Smithco machines have a Serial Number and Model Number. Both numbers are needed when ordering
parts. The serial number plate on the Super Star is located on the rear axle. Refer to engine manual for place-
mentof engine serial number.
For easy access record your Serial and Model numbers here.

2
Introduction
SAFEPRACTICES
1. It is your responsibility to read this manual and all publications associated with this machine (engine,
accessoriesand attachments).
2. Neverallowanyonetooperateorservice the machine or its attachments without proper training and
instructions.Neverallowminorstooperateanyequipment.
3. Learnthe properuse ofthe machine,thelocationand purpose of all the controls andgaugesbeforeyou
operatetheequipment. 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 artificial light.
5. Inspectthe area where the equipment will beused.Bewareofoverhead obstructions and underground
obstacles. Stay alert for hidden hazards.
6. Neveroperate equipmentthat is notin perfectworking orderor withoutdecals, guards, shields,or other
protectivedevices in place.
7. Never disconnect or bypass any switch.
8. Carbonmonoxide in the exhaust fumes can be fatal when inhaled, never operate a machine without proper
ventilation.
9. Fuel is highly flammable, handle with care.
10. Keep engine clean.Allow the engine tocoolbefore storing and always remove theignitionkey.
11. Afterengine has started,machine must not move. Ifmovementis evident, the neutral mechanismis not
adjustedcorrectly.Shut engineoffand readjust sothe machine does not movewhen in neutral position.
13. Never use your handstosearch for oil leaks. Hydraulicfluidunder pressure can penetrate theskinand
cause serious injury.
14. This machine demands your attention.Toprevent loss of controlor tippingof thevehicle:
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. Beforeleaving operator’s positionforanyreason:
A.Disengage all drives.
B. Lower all attachments to the ground.
C.Shutengine offand remove the ignition key.
16. Keep hands, feet and clothingaway frommovingparts.Wait for all movement to stopbefore youclean,
adjustorservicethe machine.
17. Keep the area of operation clearof allbystanders.
18. Nevercarry passengers.
19. Stop engine before making repairs/adjustmentsor 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 DIESELSUPERSTAR
WEIGHTSANDDIMENSIONS
Length 68" (1.7 m)
Width 60" (1.5 m)
Height 50" (1.2 m)
Wheel Base 44" (1.1 m)
Weight 1010 lbs. ( 458 kg)
SOUNDLEVEL (EAR PROTECTION REQUIRED)
AtEar Level 94 dB
At 3ft (.914 m) 90 dB
At 30 ft (9.14 m) 85 dB
ENGINE
Make BriggsandStratton Diesel
Model# 522447
Type/Spec# 0206
Horsepower 23 hp (17 kW)
Fuel Diesel40Octane Minimum
CoolingSystem LiquidCooled
LubricationSystem FullPressure
Alternator 16 amp
WHEELS&TIRE Three: 22 X 11 - 10.0 Knobby Tires 8 psi (.55 bar)
Optional:23-10.50 x 12Turf Tires 8 psi (.55bar)
43-124 Front tire fluid filled to 80 lbs. total 45.5 pints of windshield washer fluid
orequivalent. 42-158Rear Tires.
Speed
ForwardSpeed 0 to 11 m.p.h. (0-18 kph)
ReverseSpeed 0 to 5 m.p.h. (0-8 kph)
BATTERY AutomotiveType 45-12 Volt
BCIGroup Size 45
ColdCrankingAmps 480
GroundTerminalPolarity Negative(-)
MaximumLength 9" (23 cm)
Maximum Width 5.38" (14 cm)
MaximumHeight 9" (23 cm)
FLUIDCAPACITY
CrankcaseOil See Engine Manual
Fuel 20 quarts (18.93 liters)
HydraulicFluid 20 quarts (18.93 liters)
Gradeof HydraulicFluid SAE 10W-40API Service SJ or higher Motor Oil

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
UseNo.2GeneralpurposeLithium Base Grease and lubricate every 100 hours.The Diesel Super Starhasfive
grease fittings. One is located on the foot pedal. One located on the steering cyclinder, two on the rake lift and
one is located on the steering chain tensioner. Access to the steering chain tensioner is available through the
plugs located on hte right side of the nosecone.
REMOTEAIRCLEANER
1. Unclip the two clips, remove the cover and pull out the element.
2. To service, clean by tapping gently on flat surface. Do not oil. Replace if very dirty or damaged.
3. Cleanout theinside ofthe bodyand cover.
4. Place the element into the body and put the cover back on.
TOWING
When it is necessary to move the Super 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"
valveallows 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. The
machine can be moved for a short distance with the engine off, but we 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
TIREPRESSURE
Cautionmust be used when inflatinga lowtire to recommended pressure. Over inflatingcan cause tires to
explode.Tiresshouldbe8 psi(0.55bar).Improper inflation will reduce tire life considerably.
ENGINE
Changeand add oil according tochart below. Do notoverfill. Use a high qualitydetergent oil classified "For Ser-
vice SJ or higher" SAE 30 oil. Use no special additives with recommended oils. Do not mix oil with gasoline.
SAEVISCOSITYGRADES
Starting Temperature Range Anticipated Before Next Oil Change
Use of multi-viscosity oils (10W-30, etc.) above 40° F (4° C) will result in high oil consumption and possible
enginedamage. Check oil levelmore frequently if usingthese 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 inad-
equatelubrication.
HYDRAULICOIL
1. Use SAE 10W-40API Service SJ or higher motor oil.
2. Forproperwarranty,changeoil every 500 hours or annually,whicheverisfirst and change filter afterthe
first20hours,then at 100 hours, then every 250 hours thereafter.
3. The oil level should be 2" to 21/2" from top of tank when fluid is cold. Do not overfill.
4. After changing oil and/or filter, run the machine for a few minutes. Check oil level and for leaks.
5. Always use caution when filling hydraulic oil tank or checking level to keep system free of contaminants.
Checkand service more frequently when operating inextremely cold,hotor dusty conditions.
6. If natural color of fluid is black or smells burnt, it is possible that an overheating problem exists.
7. If fluid becomes milky, water contamination may be a problem.
8. Ifeither ofthe aboveconditions happen,change oiland filterimmediately afterfluid iscool andfind cause.
Take fluid level readings when system is cold.
9. In extreme temperatures you can use straight weight oil. We recommend SAE 30WAPI Service SJ or
higherwhen hot (above 90°F (33°C)) and SAE 10WAPIServiceSJorhigherwhencold (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 fill area as to
which type you put in.

6
Service
MAINTENANCE
WHEELMOUNTINGPROCEDURE
1. Turnmachine offandremovekey.
2. Block one of the other wheels.
3. Loosennuts slightlyon wheelto beremoved.
4. Jackupmachinebeingcareful not to damage underside of machine.
5. Removenuts. Removewheel.
5. Place new wheel on hub lining up bolt holes.
6. Torquenutsto 64-74 ft/lb(87-100Nm) using a cross pattern.Re-torque afterfirst 10 hours and every 200
hoursthereafter.
7. Lowermachinetogroundandremoveblocksandjack.
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
alwaysprovideproperventilation.
Batterycableshould 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.Ifelectrolytestartsboilingover, decrease charging.
Alwaysremove grounded (-) battery clamp first andreplace itlast.Avoidhazards by:
1. Fillingbatteries in well-ventilated areas.
2. Weareye protection and rubber gloves.
3. Avoidbreathing fumes when electrolyte is added.
4. Avoidspilling or dripping electrolyte.
Battery Electrolyte is an acidic solution and should be handled with care. If electrolyte is
splashed on any part of your body, flush all contact areas immediately with liberal amounts
of water. Get medical attention immediately.
JUMPSTARTING
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.
Tojump start(negativegroundedbattery):
1. Shield eyes.
2. Connect ends of one cable to positive (+) terminals of each battery, first (A) then (B).
3. Connectoneendofother cable to negative (-) terminal of "good" battery (C).
4. Connectother endof cable (D) to engine blockon
unitbeing started (NOT to negative (-) terminal of
battery)
Toprevent damage to other electrical componentson
unit being started, make certain that engine is at idle
speedbefore disconnecting jumper cables.

7
Service
SERVICECHART
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.
Thesuggestedmaintenancechecklistis not offered as a replacement for the manufacturer’s engine manual but
asasupplement.Youmust adhere to the guidelines establishedby the manufacturerfor warrantycoverage. In
adverseconditionssuchasdirt, mud or extreme temperatures, maintenance should be more frequent.
Clean more often under dusty conditions or when airborne debris is present , replace air cleaner parts, if very dirty.
Maintenance Service Interval Maintenance Procedure
After the first 8 operating hours Torque the wheel lug nuts. (64-74 ft/lb (87-100 Nm))
Change the engine oil filter.
Change the hydraulic filter.
After the first 20 operating hours Change oil filter after first 20 and first 100 hours.
Before each use daily Check the engine oil.
Check the hydraulic fluid level.
Check the tire pressure.
Check condition of hydraulic hoses and fittings.
Inspect and clean the machine.
Inspect cooling system.
Every 25 hours Check the battery fluid level and cable connections.
Change oil when operating under heavy load or high
bi t t t
Every 50 hours Change the engine oil and filter.
Every 100 hours Check engine for leaks or loose parts.
Clean/Replace air cleaner.
Check tire pressure (5 psi).
Torque the wheel lug nuts. (64-74 ft/lb (87-100 Nm))
Grease Machine.
Check belt tension (where needed)
Every 250 hours Change oil filter
Change hydraulic filter
Clean battery terminals
Every 400 hours or yearly Lubricate machine
Check spark plugs
Visual inspection of machine and hydraulic hoses
Change oil.
Torque lug nuts.
Check battery terminals and electrolyte level.
Replace all filters.

8
Service
ENDUSER’SSERVICECHART
Duplicate this page for routine use.
Mon Tues. Wed. Thurs. Fri. Sat. Sun.
Check the Safety Seat Switch
Check Steering Operation
Check the fuel level
Check the engine oil level.
Clean the air filter
Clean the engine cooling fins.
Check for unusual engine noises
Check the hydraulic oil level
Check hydraulic hoses and fittings for damage
Check for fluid leaks.
Check the tire pressure (5 psi)
Check the Instrumentation
Inspect electrical system for frayed wires
Check park brake adjustment
Change oil filter.
Change oil.
Lubricate Machine
Ensure all warning decals are intact.
Item Date Information
For the week of:
Maintence Check Item
Areas of Concern
Inspection Performed by:

9
Service
ADJUSTMENTSPEEDBOSS
RAKELIFTCYLINDER
CompletelylowerRake Lift.Remove theclevis pin(A). Twist lift linkage
(C) so clevis pin end of cylinder extension lines up with holes in attach-
ment lift arm. Replace clevis and cotter pins. Raise and lower Rake Lift
tocheckforproperclearance.
When the rear rake attachment is lowered while the
machine is in forward motion, the forward speed of the
machine will slow drastically. Operator should be pre-
pared for a rapid change in speed.
SPEEDBOSS
Speed Boss allows the machine to operate
ataproper speed while raking sand traps
on golf courses. This speed boss has been
factorysetatanaveragespeed of 3-4
m.p.h. (5-6.5 kph). The Speed Boss will
only limit the speed while the rake is low-
eredintotheoperatingposition.
Quick Disconnect Ball Joints (A) are used
inapplications where the housing needs
to be easily disconnected from the ball
stud. This is accomplished by pulling
backthespring-loaded outer housing.
The speed setting may be adjusted by
turning the Ball Joint (A) counterclockwise
tomake the machine operate slower or
turn clockwise to go faster. Tighten jam
nut. Check to make sure nothing is bind-
ing and test drive to check desired speed.
For RBS System, Spiker and Grader Box
removethespeedbossarm and the speed
bossrodfrommachinesoitdoes not interfere with other operations.spring-loaded outer housing.
The speed setting may be adjusted by turning the Ball Joint (A) counterclockwise to make the machine oper-
ate slower or turn clockwise to go faster. Reconnect the ball joint. 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
itdoesnot interfer with other operations.

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.
1. Lift up and support machine so all wheels are off the
groundand can turn freely.
2. On the top of the pump there is a ball bearing on a
creep arm. Loosen the bolt (A).
3. Withengine runningadjust theballbearingright or left
in slot so ball bearing centers on the swash arm.
4. Tighten all fasteners and test by using foot pedal
linkage to see that the "creep" is removed.
5. Turnengine offandlowermachine.
PARKBRAKE
The park brake is located on the right hand side of the machine and operates a
brakeontheright rear wheel. Push lever forward to engage and pullback todisen-
gage.
To adjust turn the knob on the end of the handle. For further adjustment you may
turn the yokes (A) clockwise to tighten and counter clockwise to loosen.
TOADJUSTFOOTPEDALTHROTTLECABLE
1. Jack up unit so that all drive wheel are off the 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
forwardposition,the engine RPM must be 3600 RPM
±100.
4. Minor adjustment can be made by backing out
(unscrewing)(RefA) until you reach full engine RPM
withthefootpedalfullydepressedinthe forward
position. Be sure to recheck after the nuts are fully
tightened.
5. Major adjustment needs to be made at (Ref B) by pulling the slack out of the cable. Loosen the screw in
the wire block 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 3600
RPMatfullforward position of the foot pedal.

11
Service
1. Beforestoring clean machine thoroughly.
2. Check bolts and nuts, tighten as necessary.
3. Makeallrepairsthatareneededandremove 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. Enginesstoredover30days need to be protected or drained of fuel to prevent gum fromforming in a fuel
system or on essential carburetor parts. Check the engine manual and follow the instructions for the
storageof the engine.
STORAGE
Whenstoring,removethe key from the key switch to avoid unauthorized personsfrom operatingmachine.

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

13
Diagrams
WIRINGPARTSLIST
REF # PART # DESCRIPTION QUANTITY
1 13-488 Ignition Switch (B & S# 496603) 1
76-310 Key Set (comes with 13-488) 1
2 17-171 Glow Plug (comes with engine)1
3 50-359 GlowPlug Indicator Light 1
4 8975 Breaker 1
8977 BreakerBoot
5 After Fire Solenoid (on engine) 1
6 14-292 Seat Switch 1
7 Starter (on engine)
8 Battery (not included)
9 13-491 Oil Sender (on engine B & S# 491657) 1
10 50-359 OilPressure WarningLight 1
11 50-359 Water Tempature Light 1
12 Dynamo Alternator (comes with engine) 1
13 Temp Sender (comes with engine)
14 12-017 HourMeter 1
15 8935 Bus Bar 1
16 22-054 GroundBattery CableBlack 1
17 22-055 BatteryCable Red 1
18 12-003 Toggle Switch 1
15-472 Switch Boot 1
19 42-319 LightWire Harness 1
20 42-317 Lights 2
42-317-01 ReplacementBulb 1
43-073 Wire Harness (includes all wire colors with *) 1

14
Diagrams
HYDRAULICDRAWING

15
Diagrams
HYDRAULICPARTSLIST
REF # PART # DESCRIPTION QUANTITY
1 34-105 Cooler 1
2 43-034 HydraulicHose - 32" 1
3 43-033 HydraulicHose - 48" 1
4 43-029 HydraulicHose - 24" 1
5 43-035 Hydraulic Hose - 20" 1
6 34-103 Orbitol 1
7 43-036 HydraulicHose - 55" 1
8 10-554 AttachmentLiftCylinder 1
18-154 RodEnd 1
HNJ-58-18 JamNut 5/8-18 1
9 42-047 HydraulicHose - 32" 2
10 42-048 HydraulicHose- 14" 2
11 13-729 2-BankValve 1
12 42-045 HydraulicHose- 41" 1
13 43-116 Front Wheel Motor, 17.1 in31
14 15-839 Steering Cylinder 1
15 43-071 Hydraulic Hose - 691/2"1
16 43-094 HydraulicLine - RH 2
17 43-117 RearWheelMotor, 8.6 in32
18 43-125 HydraulicHose -22.5" 1
19 43-070 HydraulicHose- 98" 1
20 8832-11 3/4" Suction Hose - 12 1
18-222 HoseClamp 2
21 23-006 Oil Filter 1
23-031 ReplacementFilter only
22 42-787 HydraulicHose -361/2"1
23 8832-50 3/4" Suction Hose - 49" 1
18-222 HoseClamp 2
24 42-005 OilTank 1
13-747 FillerBreather 1
25 42-045 HydraulicHose- 41" 1
26 43-150 RakeCylinder 1
42-040 Yoke End 1
HNJ-34-16 Jam Nut 3/4- 16 2
27 43-095 HydraulicLine - LH 2
28 42-797 HydrostaticPump 1
PumpDisplacement .913in3/rev ChargePump Displacement .33in3/rev
PumpInput Speed(upto) 3600rpm Max. Inlet Vacuum 5 in. Hg
Max.OperatingPressure 3000peakpsi Max. Case Pressure 25 psi
ImplementSetting 700-1000 psi Relief ValvePressure (set at) 3000 psi
13-729Hydraulic Valve(2bank) 900 psi

16
Parts
MAINFRAMEDRAWING

17
Parts
MAIN PARTSCOMMONLIST
REF# PART# DESCRIPTION QUANTITY
1 43-087 FootPedal 1
2 42-780 Floor Panel (fiberglass) 1
3 42-767 RightFloorMat 1
42-768 LeftFloorMat 1
4 12-017 HourMeter 1
5 27-055 Hinge 2
6 43-180 MainFrame 1
7* 43-058 TireandWheel 3
42-161-01 Tire 22 x 11 - 10 Knobby Type 3
43-058-01 Wheel 3
25-383 Wheel Bolt 10
8 60-106 ParkBrake Lever 1
9 42-814 Fuel Tank 1
10 42-778 ValveHandle 2
11 42-772 Seat Panel 1
8803-17 Trim w/ Black Lace 1
12 14-269 Adjustable Low Back Seat 1
13 43-080 Seat Panel (fiberglass) 1
14 42-005 OilTank 1
13-747 FillerBreather 1
13-586-03 Neck 1
15 13-718 Steering Wheel 1
16 76-364 90° Black Boot (comes with 76-362) 1
76-362 TiltSteeringMechanism 1
17 42-782 Console (fiberglass) 1
18 42-471 Nose Cone (fiberglass) 1
HSTP-14-20-100 Phillips Machine Screw 1/4- 20 x 1 6
HNTL-14-20 Lock Nut 1/4- 20 6
19 42-801 ROPS 1
20 76-198-03 Seat Belt 1
21 18-436 Plastic Cap Plug 2
* OptionalTires
Front 43-124 TurfTire 1
Rear 42-158 TurfTire 2

18
Parts
ROPSDRAWING