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Smithco Super Star 42-001-D Manual

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Super Star 2 Wheel Drive
42-001-D Quick Hitch
SN: 13540
Super Star 3 Wheel Drive
42-000-F Quick Hitch
SN: 5999
September 2011

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Summary of Contents for Smithco Super Star 42-001-D

  • Page 1 Super Star 2 Wheel Drive 42-001-D Quick Hitch SN: 13540 Super Star 3 Wheel Drive 42-000-F Quick Hitch SN: 5999 September 2011...

  • Page 2: Table Of Contents

    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 ......................9-11 Speed Boss ......................... 9 Storage ........................11 Diagrams ......................

  • Page 3: Introduction

    INTRODUCTION Thank you for purchasing a product. Read this manual and all other manuals pertaining to the Super Star carefully as they have safety, operating, 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.

  • Page 4: Safe Practices

    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.
  • Page 5 SPECIFICATIONS SUPERSTAR WEIGHTS AND DIMENSIONS Length 64" (1.63 m) Width 57" (1.45 m) Height 47" (1.19 m) Wheel Base 41" (1.04 m) Weight 950 lbs. ( 451 kg) SOUND LEVEL At Ear Level 84 dB ENGINE Make Briggs and Stratton Vanguard Model# 305447 Type / Spec#...

  • Page 6: Maintenance

    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 Super Star has three grease fittings.
  • Page 7 MAINTENANCE TIRE PRESSURE Caution must be used when inflating a low tire to recommended pressure. Over inflating can cause tires to explode. Tires should be 8 psi (0.54 bar). Improper inflation will reduce tire life considerably. ENGINE Change and add oil according to chart below. Do not overfill. Use a high quality detergent oil classified "For Service SJ or higher"...
  • Page 8 MAINTENANCE WHEEL MOUNTING PROCEDURE 1. Turn machine off 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.

  • Page 9: Service Chart

    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 offered as a replacement for the manufacturer’s engine manual but as a supplement.

  • Page 10: End User's Service Chart

    END USER’S SERVICE CHART Duplicate this page for routine use. For the week of: Maintence Check Item Tues. Wed. Thurs. Fri. Sat. Sun. Check the Safety Seat Switch Check Steering Operation Check the fuel level Check the engine oil level. Check the condition of the air filter Clean the engine cooling fins.

  • Page 11: Adjustments

    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. Replace clevis and cotter pins. Raise and lower Rake Lift to check for proper clearance. When the rear rake attachment is lowered while the machine is in forward motion, the forward speed of the machine will slow drastically.
  • Page 12 ADJUSTMENTS (CONTINUED) PARK BRAKE The park brake is located on the right hand side of the machine and operates a brake on the right rear wheel. Push lever forward to en- gage and pull back to disengage. To adjust turn the knob on the end of the handle. For further adjust- ment you may turn the yokes (A) clockwise to tighten and counter clockwise to loosen.

  • Page 13: Storage

    WHEEL CREEP 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 ground and can turn freely.
  • Page 14 WIRING DRAWING Color Code Chart Blue Brown Yellow Green Orange Black Purple White...

  • Page 15: Parts

    WIRING PARTS LIST REF # PART # DESCRIPTION QUANTITY 50-359 Oil Pressure Warning Light 12-017 Hour/ Volt Meter Combo 13-488 Ignition Switch (B & S# 692318) 76-310 Key Set (comes with 13-488) 14-292 Seat Switch 76-327 Ground Battery Cable Battery (not included) 75-518 Battery Cable...
  • Page 16 2-WHEEL DRIVE HYDRAULIC DRAWING...
  • Page 17 2-WHEEL DRIVE HYDRAULIC PARTS LIST REF # PART # DESCRIPTION QUANTITY 42-265 Aluminum Oil Cooler 42-045 Hydraulic Hose 10-554 Hydraulic Cylinder 18-154 Rod End HNJ-58-18 Jam Nut - 18 42-047 Hydraulic Hose 13-729 2 - Bank Hydraulic Valve 78-417 Valve Handle 42-048 Hydraulic Hose 43-150...
  • Page 18 3-WHEEL DRIVE HYDRAULIC DRAWING...
  • Page 19 3-WHEEL DRIVE HYDRAULIC PARTS LIST REF # PART # DESCRIPTION QUANTITY 76-238 Front Wheel Motor 43-070 Hydraulic Hose 10-554 Hydraulic Cylinder 18-154 Rod End HNJ-58-18 Jam Nut - 18 42-047 Hydraulic Hose 13-729 2 - Bank Hydraulic Valve 78-418 Valve Handle 42-048 Hydraulic Hose 43-150...
  • Page 20 MAIN FRAME COMMON DRAWING...

  • Page 21: Main Frame

    MAIN PARTS COMMON LIST REF# PART# DESCRIPTION QUANTITY 42-813 Foot Pedal 42-780 Floor Panel (fiberglass) 42-767 Right Floor Mat 42-768 Left Floor Mat 12-017 Hour Meter 27-055 Hinge 42-595 Main Frame (3WD) 42-605 Main Frame (2WD) 42-161 Knobby Tire and Wheel 42-161-01 Tire 22 x 11 - 10 Knobby Type 42-161-02...
  • Page 22 3 WHEEL DRIVE FRONT FORK DRAWING...

  • Page 23: Wheel Drive Front Fork

    3 WHEEL DRIVE FRONT FORK PARTS LIST REF# PART# DESCRIPTION QUANTITY 13-718 Steering Wheel 13" 13-726 Center Cap 27-077 Decal, Smithco Round HNJ-58-18 Jam Nut - 18 HWK-316-075 Woodruff Key 76-364 Tilt Steering Boot (comes with 76-362) 76-362 Tilt Steering Mechanism...
  • Page 24 2 WHEEL DRIVE FRONT FORK DRAWING...
  • Page 25 2 WHEEL DRIVE FRONT FORK PARTS LIST REF# PART# DESCRIPTION QUANTITY 13-718 Steering Wheel 13" 13-726 Center Cap 27-077 Decal, Smithco Round HNJ-58-18 Jam Nut - 18 HWK-316-075 Woodruff Key 76-364 Tilt Steering Boot (comes with 76-362) 76-362 Tilt Steering Mechanism...
  • Page 26 LINKAGE DRAWING...

  • Page 27: Linkage

    LINKAGE PARTS LIST REF# PART# DESCRIPTION QUANTITY 42-769 Oil Tank Bracket HB-516-18-100 Bolt - 18 x 1 HNFL-516-18 Flange Whiz Lock Nut - 18 42-076-01 Band 42-076-02 42-076 Air Cleaner 42-076-03 Replacement Filter 13-603 Air Cleaner Base (comes with engine) 18-123 Hose Clamp 8959-26...

  • Page 28: Gas Tank

    GAS TANK DRAWING...
  • Page 29 GAS TANK PARTS LIST REF# PART# DESCRIPTION QUANTITY 42-814-02 42-814-01 Tether 50-081 Rubber Bumper HNFL-38-16 Flange Whiz Lock Nut - 16 42-814 Gas Tank (includes all * items) 42-770 Right Tank Support HB-38-16-200 Bolt - 16 x 2 HW-38 Washer HNFL-38-16 Flange Whiz Lock Nut - 16...

  • Page 30: Oil Tank

    OIL TANK DRAWING...
  • Page 31 OIL TANK PARTS LIST REF# PART# DESCRIPTION QUANTITY 13-747 Filler Breather 13-586-03 Neck HSM10-32-063 Machine Screw #10 - 32 x 42-005 Oil Tank 23-126 #6 Plug 18-240 Adapter 18-072 45° Elbow 18-133 Barb Fitting HB-14-20-075 Bolt - 20 x HW-14 Washer HWL-14 Lock Washer...
  • Page 32 PUMP AND ENGINE DRAWING Solenoid Mounts Here...

  • Page 33: Pump And Engine

    PUMP AND ENGINE PARTS LIST REF# PART# DESCRIPTION QUANTITY 42-353 Belt Guard 78-274 Cage Nut HB-14-20-075 Hex Bolt, -20 x HWL-14 Lock Washer, 42-357 Belt Stop 42-327 Tensioner 16-990 Spacer HKSQ-14-100 Machine Key HB-14-20-125 Bolt - 20 x 1 4 (comes with 42-245 & 42-246) (3 per hub) HW-14 Lockwasher...
  • Page 34 PUMP AND ENGINE DRAWING Solenoid Mounts Here...
  • Page 35 PUMP AND ENGINE PARTS LIST REF# PART# DESCRIPTION QUANTITY HHP-18 Bridge Pin 18-174 Elbow 90° 18-185 Elbow 34-109 Variable Pump (2WD) 42-797 Variable Pump (3WD) HNFL-12-13 Flange Whiz Lock Nut - 13 42-246 HWK-316-075 Woodruff Key 42-361 Tensioner Spacer HB-38-16-275 Hex Bolt, -16 x 2 HNFL-38-16...
  • Page 36 ENGINE DRAWING...

  • Page 37: Engine

    ENGINE PARTS LIST REF # PART # DESCRIPTION QUANTITY 34-109 Variable Pump (2WD) 42-797 Variable Pump (3WD) 42-307 Cable Bracket HB-516-18-100 Bolt - 18 x 1 HW-516 Washer HNTL-516-18 Lock Nut - 18 42-600 Muffler 17-152 Conduit 17-151 Cable 21-161 Wire Block 15-165 Engine B&S 16 hp...
  • Page 38 2 WHEEL DRIVE REAR AXLE DRAWING Torque To 120 ft/lbs(156Nm)

  • Page 39: Wheel Drive Rear Axle

    2 WHEEL DRIVE REAR AXLE PARTS LIST REF# PART# DESCRIPTION QUANTITY 18-344 18-342 Cross 42-818 " Hydraulic Tube 18-343 Adapter 60-106 Brake Lever HCP-516-100 Clevis Pin HP-18-100 Cotter Pin HB-516-18-175 Bolt - 18 x 1 HNFL-516-18 Flange Whiz Lock Nut - 18 HB-516-18-250 Bolt...
  • Page 40 3 WHEEL DRIVE REAR AXLE DRAWING...
  • Page 41 3 WHEEL DRIVE REAR AXLE PARTS LIST REF# PART# DESCRIPTION QUANTITY 60-268 Lug Bolt 14-265 Nut 1-20 76-239 Brake Disc 18-383 45° Adapters 43-095 Hydraulic Tube 18-170 43-094 Hydraulic Tube 13-615 Wheel Motor HWK-14-100 Woodruff Key 1/4 x 1 HB-12-13-750 Bolt -13 x 7 HNTL-12-13...

  • Page 42: Rake Lift

    RAKE LIFT DRAWING...
  • Page 43 RAKE LIFT PARTS LIST REF# PART# DESCRIPTION QUANTITY HHP-18 Bridge Pin HCP-58-175 Clevis Pin 10-554 Hydraulic Cylinder HNJ-58-18 Jam Nut - 18 8-154 Rod End HG-14-28-180 Grease Fitting - 28 x 180° 18-214 45° Elbow 18-169 Adapter HB-12-13-500 Bolt - 13 x 5 HNFL-12-13 Flange Lock Nut - 13...
  • Page 44 13-729 2-BANK HYDRAULIC VALVE DRAWING...

  • Page 45: 13-729 2-Bank Hydraulic Valve

    13-729 2-BANK HYDRAULIC VALVE PARTS LIST REF # PART # DESCRIPTION QUANTITY 78-415-01 Body (complete with spacer and check valve) 78-415-02 Spool HDM10 78-415-03 O-Ring Seal 78-415-04 Flanged Washer HDM10 78-415-05 Spacer 78-415-06 A Type Spool HDS11 78-415-11 Positioner 78-415-08 Plug 78-415-09 Lever Group HDS11...
  • Page 46 76-238 FRONT WHEEL MOTOR DRAWING (14.5 CI)
  • Page 47 76-238 FRONT WHEEL MOTOR PARTS LIST (14.5 CI) REF# PART# DESCRIPTION QUANTITY Water & Dirt Seal 2† 13-615-05 Service Housing Assembly Inner Seal 4† 13-032-27 Thrust Bearing 5† 13-032-28 Inner Bearing 13-032-29 Thrust Bearing 76-238-03 Drive Link Ring Seal 13-032-31 Manifold 13-032-32 Commulator Assembly (matched...

  • Page 48: 13-615 Rear Wheel Motor

    13-615REAR WHEEL MOTOR (7.5 C.I.) DRAWING...
  • Page 49 13-615REAR WHEEL MOTOR (7.5 C.I.) PARTS LIST REF# PART# DESCRIPTION QUANTITY Water & Dirt Seal 13-615-05 Service Housing Assembly (Includes Ref 4, 5, 17(2 req'd) and 20) Inner Seal 13-032-27 Thrust Bearing 13-032-28 Inner Bearing 13-032-29 Thrust Bearing 13-615-03 Drive Link Ring Seal 13-032-31 Manifold...

  • Page 50: 42-002 Rear Wheel Motor

    42-002 REAR WHEEL MOTOR DRAWING (8.0 C.I.)
  • Page 51 42-002 REAR WHEEL MOTOR PARTS LIST (8.0 C.I.) REF # PART # DESCRIPTION QUANTITY Water & Dirt Seal 42-002-01 Service Housing Assembly 42-002-02 Thrust Bearing 42-002-03 Inner Bearing 42-002-04 Drive Link Ring Seal 42-002-05 Manifold 42-002-06 Commulator Assembly (matched set) 42-002-07 End Cap 42-002-08...

  • Page 52: 42-797 Variable Pump

    42-797 VARIABLE PUMP DRAWING...
  • Page 53 42-797 VARIABLE PUMP PARTS LIST REF# PART# DESCRIPTION QUANTITY 10-117-01 End cap 14-263 Implement relief spring 42-003-16 Cylinder block kit Piston assembly Slipper retainer Cylinder block Swashplate 14-114 Thrust plate Charge pump housing assembly 42-003-10 Ball bearing Shaft O-ring 14-217 Roller bearing Plug O-ring...

  • Page 54: Decal List

    Bottom Seat Panel 25-298 Decal, Warning Hot Bottom Seat Panel. Oil Filter Bracket 25-337 Decal, Speed Boss Hang from Steering 25-373 Decal, Smithco Star Nose Cone 25-349 Decal, Foot Pedal Right Side Nose Cone 25-352 Decal, By-Pass Valve Hang Tag...

  • Page 55: Quick Reference

    QUICK REFERENCE REPLACEMENT PARTS REPLACEMENT FILTERS 23-031 Hydraulic Oil Filter 15-165-01 Air Filter Element with Pre-Cleaner Briggs and Stratton# 5050 42-076-03 Air Filter Element Fender Mounted 50-403 Fuel Filter 13-531 Engine Oil Filter Briggs and Stratton# 492932 SEAL KITS 13-615 & 76-238 Wheel Motors 14-080 Seal Kit 13-729...

  • Page 56: Warranty

    30 days from discovery of the condition. If you need help locating an Authorized Smithco Distributor, or if you have questions regarding your warranty rights or responsibilities, you may contact us at: Smithco Product Support Department 200 West Poplar Ave.
  • Page 57 Smithco may require the return of failed parts or components in order to determine the validity of any warranty claim. Smithco will not be obligated to replace components of other manufacturers if inspection by the original component manufacturer indicates that failure was due to normal wear and tear, expected consumption through use or improper care or service.

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