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 productsupport@smithco.com

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

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.

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.

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

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.

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.

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.

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.

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:

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