PARTS & SERVICE MANUAL
Contents
1. NY 10 105 FOAM MARKER INSTALLATION Left Boom Shown C3 FOAMER NOZA EASSEMBLY Slide hose clamp onto drop tube and attach restrictor bell FOAMERNOZAEM OUNTING Place splined end of rod Z into top of foam nozzle assembly Slide one locking collar U onto rod Slide rod into mounting bracket V on boom Slide second locking collar onto rod Adjust locking collars and rod so nozzle assembly will clear end of boom Tighten lock collar bolts to prevent side to side movement HOSEGUARD Hose s must be routed on bottom of square tubing Mark 8 inches in from cap on end of square tubing front side Clamp hose guard flush with top of square tubing with edge on previous mark The channel covers hoses Install using drill screws you may drill a 9 16 pilot hole first Place another hose guard against first and install in same manner Repeat process for other boom WIRING Use dielectric grease on all electrical connections Connect extension wire 10 222 to the pig tail on the switch box and compressor Connect power cabel 15 509 to the switch box Turn the switch off Route the power wire to the fuse block on the inside of the engine cover out of the way of any heat or moving parts Use nylon ties as needed Cut the power wire with enough length to connect the fuse block Put the slide on terminal with heat shrink onto the wire ends and connect to fuse block Red to positive black to negative Inser2. HYDRAULIC DIAGRAM x gf 1 S HYDRAULIC DIAGRAM PARTS LIST REF OONOOARWND PART 10 143 10 135 10 141 34 103 10 144 10 142 18 190 34 105 10 145 10 116 10 123 8832 12 18 222 23 006 23 031 8832 14 18 222 10 196 48 135 10 140 10 117 DESCRIPTION Hydraulic Hose Hydraulic Cylinder Hydraulic Hose Orbitrol Motor Hydraulic Hose Hydraulic Hose Tee Oil Cooler Hydraulic Hose Wheel Motor Hydraulic Hose Hose 3 4 ID Hose Clamp Oil Filter Replacement Filter Hose 3 4 ID Hose Clamp Hydraulic Hose Oil Tank Hydraulic Hose Hydrostatic Pump QUANTITY 2 1 1 1 1 1 1 1 1 2 4 1 2 1 1 2 1 1 2 1 1 BI BODY amp FRAME DRAWING 30 29 7 28 27 26 25 24 23 22 21 20 M Y 19 3 4 5 6 T 8 S 9 10 11 N 12 13 14 15 16 17 18 BODY amp FRAME PARTS LIST QUANTITY REF 1 2 3 4 ou 23 30 PART 10 111 10 193 10 191 14 269 HB 516 18 125 HW 516 HWL 516 HN 516 18 10 120 48 135 23 095 10 214 HSD 14 075 15 030 10 180 HBC 516 18 100 HW 516 HWL 516 HN 516 18 76 299 10 113 10 201 10 163 10 164 10 137 10 159 516 18 100 HW 516 HWL 516 HN 516 18 34 105 HB 14 20 100 HWL
3. PART 10 187 14 273 10 230 10 146 34 103 13 261 13 262 10 143 18 190 34 105 10 144 10 104 INSTALLATION INSTRUCTIONS 1 2 3 Shut machine off Set park brake Allow system to cool down DESCRIPTION Hydraulic Cylinder Seal Kit Hydraulic Hose 108 Hose 28 Orbitrol Valve Handle set of 2 Hydraulic Hose Tee Oil Cooler Hydraulic Hose Hydraulic Lift Kit 2 1 per 4 l Loch ol QUANTITY Remove the boom lifts from boom and replace with hydraulic cylinder Ref 2 Use the existing hardware Refer to the valve drawing for placement of fittings The valve mounts in the seat panel on the right side Use two 20 x 2 bolts washers lock washers and nuts Refer to the decal for correct placement Remove the hose from the bottom of the oil cooler that comes out of the top of the tee This hose traces back to the top of the orbitol Place that hose to the inlet side of the hydraulic valve Use the short hose 10 146 Ref 3 to connect the outlet side of the valve to the tee on the oil cooler Use the four other hoses to connect the valve to the hydlauic cylinders Refer to the hydraluic drawing M SEN 16 906 ELECTRIC HOSE REEL DRAWING Mg 16 906 ELECTRIC HOSE REEL PARTS LIST QUANTITY REF PART HNCL 516 18 16 906 12 16 906 11 HB 516 18 075 16 906 13 16 906 03 HB 516 18 125 16 906 04 16 906 05 HRP 25 200 16 906 02 HW 516 HB 38 16 100 HW
4. END USER S SERVICE CHART Engine Oil w Filter AAN Cleaner PaperElemem Pre Cleaner Every 25hours Spark Plugs o 0 ldeSped _ J CoolingSystem J Bets and Y TrePresue Visual Inspection of Tres Fuel Level Einer gt gt Hydraulic TT draulic Oil Filter Hydraulic System for Leaks and Loose Pats attery Electrolyte Level Clean Battery Terminas Torque Lug Nuts lubricate C Check or Clean at specified intervals R Replace at specified intervals Tire pressure 20 psi 1 4 bar Rear 22 psi 1 5 bar Front T Replace hydraulic filter after the first 20 100 and every 250 there after Torque tire nuts after the first 10 hours and every 200 hours there after 64 to 74 87 100Nm Change Oil and Filter after first 5 hours Clean more often under dusty conditions or when airborne debris is present replace air cleaner parts if very dirty oo Hours 0 oo Hours Every 500 Hours Yearly As Required 100 Hours MEN 250 Hours Daily Nr 8 ADJUSTMENTS WHEELCREEP Creep is when the engine is running and hydrostatic transmission is in neutral but due to
5. REF 1 2 3 12 13 14 15 PART 15 030 15 031 76 294 76 293 HB 516 18 150 HNTL 516 18 HWK 316 075 13 288 76 310 34 146 34 145 42 064 50 359 10 113 18 202 HB 516 18 150 HB 516 18 275 HNTL 516 18 10 163 48 066 10 164 48 132 10 137 10 200 HSA 8 075 34 103 HBM 6 1 16 HWLM 6 34 167 18 169 77 207 15 314 15 472 10 202 25 347 50 400 HNJ 58 18 10 235 HBM 8 1 25 40 HWLM 8 HNM 8 32 10 236 10 108 DESCRIPTION Steering Wheel with Cap Steering Wheel Cap Replacement Only 90 Black Boot Tilt Steering Mechanism Bolt 5 6 18 x 11 2 Lock Nut 5 e 18 Woodruff Key 3 16 3 4 Key Switch with hardware Kohler 25 099 04 Key Set Circuit Breaker Circuit Breaker Boot Hour Voltmeter Oil Warning Indicator Light Console Elbow Bolt 5 16 18 x 11 2 Bolt Sie 18 x 23 4 Lock Nut Sie 18 Forward Foot Pedal Pedal Pad Reverse Pedal Short Pedal Pad Main Frame Tower Plate Tapping Screw 8 3 4 Orbitrol Metric Bolt M6 1 x 16 Metric Lock Washer M6 Stub Shaft Adapter s SAE Buzzer Toggle Switch Switch Boot Speedometer Optional Decal Console Rubber Grommet Jam Nut 5 s 18 Speedometer Plug Button Metric Bolt M8 1 25 x 40 Metric Lock Washer M8 Metric Nut M8 32 Strong Back Speedometer Kit 1 A A ll dl ld dl dl ld UI A P P AQ tl HH ANP YD sch sch AH sch sch sch sch sch sch D AH sch Al ISP FRONT AXLE DRAWING PS FRONT A
6. 16 194 Anti Vortex Fitting 11 4 16 156 Elbow 11 4 MPT 1 HB 16 181 Quick Coupler 11 4 Female 8896 65 Discharge Hose 1 18 222 Hose Clamp 8889 27 Suction Hose 11 4 18 116 Hose Clamp 8889 24 Suction Hose 11 4 18 116 Hose Clamp 16 966 Hypro Pump 8896 45 Discharge Hose 1 18 222 Hose Clamp 16 161 Fitting 11 4 NPT x 11 4 HB 10 111 110 Gallon Poly Tank 16 953 16 Hinged Lid Well with Gasket 16 953 01 Gasket for 16 953 16 169 Strainer Basket 16 16 155 Elbow 4 x 10 227 834 Sprayer Control Kit Comes with 110 Gallon Poly Tank QUANTITY 1 1 1 1 1 1 1 2 1 2 1 2 1 1 2 1 1 1 1 1 1 1 7 yw 1004 MANUAL PLUMBING DRAWING DIO 4 ex 2 Ga M SIN 1004 MANUAL PLUMBING PARTS LIST REF 1 PART 8887 40 18 040 16 151 16 172 16 157 16 153 8887 35 18 040 HLC 100 HSD 14 075 16 196 8896 16 18 222 10 147 16 968 10 210 16 168 HB 38 16 300 HNTL 38 16 8896 65 15 553 10 208 10 207 HB 14 20 250 HNTL 14 20 16 163 16 281 16 034 16 155 16 150 16 153 16 194 16 156 10 111 16 953 16 953 01 16 169 8896 35 18 222 8889 27 18 116 8889 24 18 116 16 966 16 181 16 180 16 182 16 880 16 170 18 296 16 161 8887 44 18 040 8896 45 18 222 DESCRIPTION Orange PVC Hose 2 4 to right and left boom Hose Clamp Elbow 3 4x 3 4 Nylon Nipple 9 4 x 31 2 Tee 9 4 x 9 4 x 3 4 Elbow 3 4 x 9 4 HB Orange PVC
7. QUANTITY REF 1 10 PART 10 201 25 348 42 116 48 066 10 163 HMB 12 14 HP 18 075 76 296 18 234 HG 14 28 180 48 132 10 164 HMB 12 14 HP 18 075 21 462 HN 516 24 10 148 HN 516 24 HP 18 075 10 178 18 234 HG 14 28 180 HMB 12 14 HP 18 075 18 115 HWL 14 HN 14 28 10 149 M HN 516 24 HP 18 075 HST 516 18 075 HNTL 516 18 42 063 HB 516 18 400 HNTL 516 18 10 228 10 134 10 190 10 166 11 100 HN 516 24 HCP 516 100 HP 18 100 10 151 10 137 10 189 18 289 10 206 22 073 DESCRIPTION Seat Panel Decal Control Panel Rubber Insert Pedal Pad Forward Foot Pedal Machine Bushing 2 14GA Cotter Pin s x 3 4 Pedal Mount Bushing Grease Fitting 4 28 x 180 Short Pedal Pad Reverse Foot Pedal Machine Bushing 2 14GA Cotter Pin t s x 3 4 Ball Joint Nut 9 16 24 Reverse Linkage Nut Sie 24 Cotter Pin 3 4 Relay Bushing Grease Fitting 1 4 28 x 180 Machine Bushing zx14GA Cotter Pin 3 4 Ball Joint 1 4 NF Lock Washer 1 4 Nut 7 4 28 Forward Linkage Nut 5 16 24 Cotter Pin 3 4 Truss Head Machine Screw 16 18 3 4 Lock Nut 16 18 Cable with Nuts Bolt 9 15 18 x 4 Lock Nut 16 18 Spray Boss Control Spacer Cable Spray Boss Control Rear Engine Mount Yoke 5 16 Nut 5 16 24 Clevis Pin 916 x 1 Cotter Pin 1 Swash Plate Main Frame Speed Boss Bushing Hood Rod Bracket Battery Optional M sch MAMM MI sch sch MI sch MM
8. cast applications FEATURES e Color coding makes it easy to match nozzle flow rates for easy identification Color coding is available in sizes 4 1 4 RA15 Uniform spray distribution A large orifice opening and passages minimize clogging The Raindrop nozzle s patented design element a secondary swirl chamber in the nozzle cap alters the swirling action of the liquid so that the fewer driftable lines are discharged from the secondary orifice Maximum recommended pressure for Nylon is 100 psi 70bar Maximum recommended temperature is 120 F 50 C NOZAETILT Delavan s extensive research on spray patterns has proven that a tilt of about 45 for flood Nozzles or tips RA Raindrop and WRW Whirl Rain nozzles will significantly improve the spray pattern uniformity The nozzle tilt reduces the effect of boom height variation and allows the spray nozzle to maintain a more fully developed pattern even when the nozzle outlet is below the recommended height for the best spray pattern uni formity RECOMMENDED OVERLAP AND NOZZLE HEIGHT 100 overlap of spray pattern is recommended for RA Raindrop and WRW Whirl Rain Nozzles for uniform coverage Nozzle height is determined by measuring the width of the spray pattern as it hits the ground This width should be 10096 greater or twice as wide as the nozzle spacing Adjust nozzle height until this is achieved If a decision to tilt the nozzle is made do it before measuring the wi
9. 18 Lock Nut 5 1 18 2 41 10 246 Left Boom Stabilizer 1 INSTALLATION INSTRUCTIONS For best result use plumber s tape on all fittings 1 The three boom assemblies are not on the packing list but are in the carton The long boom assemblies are the right and left booms The labels are located on the pivot brackets Ref 24 The small boom assembly is the center boom You can NOT order these boom assemblies as one unit Please refer to parts drawing for individual parts Mount small boom assembly to the boom carriers on sprayer using four boom brackets Ref 8 four bolts 3 16 x 5 2 and four lock nuts 3 16 Ref 7 One boom bracket should go on boom assembly and one on boom carrier Do the same for right and left side Place boom at desired level approximately 20 51cm nozzle height and center Tighten bolts Take right boom and slide pivot bracket Ref 13 in center mount Ref 24 and hold in place with 2 13 x 5 2 bolt and 2 13 center lock nut Ref 32 Do not over tighten boom must be able to move up and down Install boom lifts Ref 31 using clevis pin and cotter pin Ref 27 so the slotted end hooks to the pivot bracket Ref 24 and the bushing end hooks to the actuator bracket Ref 20 amp 22 Hook hoses to respective fittings using hose clamps 18 040 The hose coming from right side of sprayer goes to straight fitting on right boom Center hose from sprayer goes to straight fitting on center bo
10. 277 5 6 4cm from top of the fill tube when fluid is cold Do not overfill After changing oil run the machine for a few minutes Check oil level and for leaks GE 760 Always use extreme caution when filling 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 condi tions 6 Ifthe natural color of the fluid has become black or smells burnt it is possible that an overheating problem exists If fluid becomes milky water contamination may be a problem If either ofthe above conditions happen change oil immediately after fluid is cool and find the cause Take fluid level readings when the system is cold 9 In extreme temperatures you can use straight weight oil We recommend SAE API Service SG when hot above 90 F 33 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 the tank fill area as to which type you put in DIRECTOVALVES Directo Valves should be disassembled cleaned inspected and a service kit installed annually More often depending on the chemicals being used and the frequency of use In most cases this can be done without re moving the valve from the sprayer Nr MAINTENANCE TIREPRESSURE Caution must be used when inflating
11. 38 16 906 10 16 906 07 16 906 09 16 906 08 HNCL 38 16 16 906 01 16 906 06 16 129 06 16 906 16 16 906 17 HW 516 HB 516 18 100 16 906 14 HB 516 18 075 DESCRIPTION Lock Nut 5 6 18 Chain Assembly Sprocket Bolt 5 46 18 3 4 Spacer Disc Assembly Bolt 5 16 18 x 11 4 Pop Rivet Drum Center Axle Assembly Roll Pin 1 4 x 2 Disc Assembly Lockwasher 5 16 Bolt 3 s 16 x 1 Washer 3 Retaining Ring Mounting Pillow Block Top Bearing Mounting Pillow Block Bottom Lock Nut s 16 Frame Assembly Swivel Seal Kit for swivel Sprocket Key Washer 5 16 Bolt 5 1 18 x 1 Mounting Bracket Bolt 9 16 18 3 4 Electric Motor 12VDC 12 mRNA oo 0 BY 16 129 HOSE REEL DRAWING M IN 16 129 HOSEREEL PARTS LIST REF PART HB 516 18 075 HWL 516 16 129 01 16 906 04 16 906 05 16 906 02 HRP 25 200 HB 38 16 100 16 129 04 16 906 07 16 906 09 16 906 08 16 129 03 HW 516 HNCL 516 18 16 129 05 16 906 01 HNCL 38 16 16 906 10 16 129 02 16 129 06 HW 38 DESCRIPTION Bolt 5 16 18 x 3 4 Lockwasher 5 16 Disc Assembly Drum center Pop Rivet Axle Assembly Disc Assembly Roll Pin 2 Bolt 3 s 16 x 1 Hand Crank Mounting Pillow Block Top Bearing Mounting Pillow Block Bottom Lock Pin Assembly Washer 5 16 Lock Nut Sie 18 Brake Assembly Frame Assembly
12. 527 33 271 33 508 10 227 DESCRIPTION 834 Console only Speed Sensor Left Spindle Pressure Transducer Pressure Regulating Valve Manifold Ball Valve Power Cord Fuse Block Auto Blade Type Fuse 15 AMP 834 Sprayer Control Kit 4 add 16 968 STRAINER PARTS LIST RE87F 1 2 3 4 PART 16 968 01 16 968 02 16 968 03 16 968 04 DESCRIPTION Head 11 4 Gasket Screen Bowl 4 4 1 1 QUANTITY M SIN xy 15 552 MANIFOLD BALL VALVE 3 UNIT DRAWING BY 15 552 MANIFOLD BALL VALVE 3 UNIT PARTS LIST REF PART 15 531 06 15 552 12 15 552 06 15 517 04 15 552 03 15 517 06 15 517 07 15 552 02 15 517 09 15 517 10 15 517 11 15 552 04 15 517 13 15 552 05 15 517 16 15 517 17 15 552 13 15 517 19 15 517 20 15 552 08 15 517 22 15 517 23 15 517 24 15 552 09 15 552 11 15 517 31 15 517 32 15 552 07 15 552 10 15 552 01 DESCRIPTION Polypropylene Cover Stailess Steel Phillips Square Pan Head Screw Motor Sub Assembly Stainless Steel Self Cinching Stud Cell Sponge Rubber Gasket Neoprene Motor Mount Nylon Mounting Plate EPDM Rubber Grommet Polypropylene Grommet Retainer Stainless Steel Slotted Hex Washer Screw Teflon Thrust Washer Stainless Steel Ball Valve Stem Stainless Steel Spring Pin Teflon Coated Viton O ring Nylon Body Dense Felt Dust Plug Viton Gasket Carbon Filled Teflon Seal Viton O ring Nylon End Cap Stainless Steel Hex Head Cap S
13. Accessories 38 87 1006 Plumbing TeeJet 834 38 41 1004 Plumbing 42 43 1006 Controls TeeJet 834 44 45 16 968 Strainer EE 44 45 15 552 Manifold Ball Valve 46 47 15 531 Control 48 49 10 160 Stainless Steel BOOM 50 53 Nozzle Assembly 54 55 Tips een 56 XR TEEJET TIPS ana 57 10 103 Electric Lift Kit 58 59 10 104 Hydraulic Lift 60 63 16 906 Electric Hose 64 65 16 129 Hose 66 67 10 107 Hose Reel Mounting Instructions 68 69 Hose Reel Plumbing see 70 71 Electric Hose Reel Wiring 72 73 Hose Reel Adjustments 72 10 105 Foam Marker 74 77 15 504 Compressor 78 79 15 505 heri da 80 81 2218 enit tons 82 83 10 108 Speedometer Kit 84 85 10 106 Clear Water Wash Tank 86 87 Reference e 88 90 List eiae a eee iets 89 Quick Reference Replacement Parts 90 Limited Wa
14. Box 21 464 Foamer Tank 16 939 Tank Strap Blue Tube Clear Tube G 10 222 Extension Wire CONNECTINGTHECAP ASSEMBLY Connect the blue tube to the tank cap connector which is also connected to the large blue tube which hangs below the cap This is the soap outlet tube Connect the clear tube to the other connector on the tank cap This is the air input tube Tighten connectors hand tight assembly tank cap onto tank HOSES Being careful not to cut the tubing cut the oversleeve back approximately 2 5cm to expose blue and clear tubing Remove blue wing nut from top connector of foam nozzle and slide it on the blue tube with the threads fac ing toward end of tube Slide blue tube all the way over the top of the small tube on foam nozzle Slide wing nut back to the threads and hand tighten Follow the same steps for the clear tube and tube nut Dom gt Route the tubing along underside of main frame using tie downs as necessary Install opposite ends of air liquid tubes to compressor again cutting back the oversleeve approximately 2 5 and inserting blue and clear tubes for the left boom sec tion into the tubing connectors on the right side of com pressor as far as possible Follow the same steps for the right boom tubing Notice the right boom is inserted into left side of compressor To release tubing from compres sor hold black ring around tubing and pull tube out 10 105 FOAM MARKER WIRING DRAWING
15. inadequate align ment wheels still move Do the following procedure to stop this motion 1 Lift up and support machine so rear wheels are off the ground and can turn freely 2 Inthe engine compartment the hydrostatic transmission is on the left side The swash plate D is under the transmission and comes out forward The idler arm B has a bearing that runs in the notch of the swash plate Loosen bolt A 3 With engine running move bearing B so it centers on the swash plate D and wheel creep stops 4 Tighten all fasteners and test by using foot pedal linkage to see that creep is removed 5 Turn engine off and lower machine SPRAY PUMP WITH ELECTRIC CLUTCH BELT Located to the rear and right of the engine Should have approximately 2 13mm of deflection in the center of the top strand Loosen and tighten the se 18 x 11 4 set screw located on the foot of the pump mount PARK BRAKE Turn knob clockwise on end of park brake to tighten Turn it counter clockwise to loosen If finer adjustment is needed turn clevis on brake cable to adjust length of cable SPEED CALIBRATION NUMBERS The speed calibration numbers for the Spray Star 1006 is 965 The speed calibration numbers for Spray Star 1008 is 612 STORAGE If the engine will be out of service for two or more months use the following storage procedure 1 Clean the exterior surfaces of the engine 2 Change the oil and filter while the engine is still warm from
16. mount position For either floor or wall mount simply remove the guide arm that is attached to the support frame and rotate it 90 then reinstall HOSEREPLACEMENT PROCEDURE 1 Facing swivel turn the hose drum clockwise until all of the hose is removed from the drum and the drum is held by locking mechanism Make sure spring is locked Remove hose clamps and disconnect hose from swivel Remove old hose 3 Insert new hose through roller guide connect to swivel and reinstall hose clamps Use spring guard over hose to protect the hose from being cut by the drum 4 Remove check ball from old hose and install on replacement hose 5 Carefully keeping the tension on the hose pull the hose to release the locking mechanism Let the hose wind on the drum gt 72 ELECTRIC HOSE REEL WIRING PARTS LIST QUANTITY REF 4 8 PART DESCRIPTION 8879 132 Flexguard 2 ID 8919 144 10GA Red Wire 144 8928 5 18 Wire Terminal Yellow 8901 Slide On Yellow Connector 8850 4 14GA Red Wire 4 8859 3 16 Wire Terminal Blue 33 251 Push Button Switch 8850 4 14GA Red Wire 4 8859 3 15 Wire Terminal Blue 8857 5 18 Wire Terminal Blue 8928 5 18 Wire Terminal Yellow On Motor Leads 12 015 Solenoid 33 252 Switch and Solenoid Mounting Bracket BOLT BRACKET TO FRAME HB 516 18 075 5 16 18 x 3 4 Hex Bolt HN 516 18 5 16 18 Hex Nut HW 516 5 15 Flat Washer HWL 516 5 16 Lockwasher BOLT SOLENOID TO BRACKET HB 14 20 075 1 4 20 x 3 4 Hex
17. operation The fuel system must be completely emptied or the gasoline must be treated with a stabilizer to prevent deterioration If you choose to use a stabilizer follow manufacturers recommendations and add the correct amount for the capacity of fuel system Fill fuel tank with clean fresh gasoline Run engine for 2 3 minutes to get stabilized fuel into carburetor Close fuel shut off valve when unit is being stored or transported To empty the system drain fuel tank and carburetor or run engine until tank and system are empty 4 Remove the spark plugs Add one tablespoon of engine oil into each spark plug hole Install plugs but do not connect the plug leads Crank the engine two or three revolutions 5 Store machine in a clean dry place WIRING DIAGRAM Color Code Chart Blue Brown Yellow Green Orange Red Black Purple White FOAMER Use dielectric grease on all electrical connections 197 gt 10 WIRING PARTS LIST REF 1t 25 27 28 29T 30T 311 PART 10 202 8859 8962 8935 13 288 76 310 34 146 34 145 8935 42 064 10 182 50 359 8849 2 88
18. sharp turns Use caution when changing directions on slopes D Stay alert for holes in the terrain and other hidden hazards Before leaving operator s position A Disengage all drives Set park brake C Shut engine off and remove the ignition key D If engine has to run to perform any maintenance keep hands feet clothing and all other parts of body away from moving parts Keep hands feet and clothing away from moving parts Wait for all movement to stop before you clean adjust or service the machine Keep the area of operation clear of all bystanders Never carry passengers Stop engine before making repairs adjustments or checking adding oil to the crankcase Use parts and materials supplied SMITHEO only Do not modify any function or part Use caution when booms are down as they extend out beyond the center line of the machine The tank is a confined space take precaution This machine is intended for turf maintenance Other use is forbidden 197 SPECIFICATIONS WEIGHTS AND DIMENSIONS Length Width Width With Boom Open Height Wheel Base Weight Empty Weight Full SOUND LEVEL DBA At ear level At3 ft 0 914 m At 30 ft 9 14 ENGINE Make Model Type Spec Horsepower Fuel Cooling System Lubrication System Alternator WHEELS amp TIRE BRAKES PARK BRAKE SPEED Forward Speed Reverse Speed BATTERY Cold Cranking Amps Ground Terminal Polarity Maximum Length Maximum Width M
19. 0 227 DESCRIPTION Elbow 1 MPT x 1 HB Tee FPT1x1x1 Drill Screw 1 Valve Mount Hose Clamp Hose Clamp Elbow 1 4MPT x 1HB Pressure Transducer Reducer Bushing 3 1 4 Close Nipple 9 4 x 3 4 Reducer Bushing 1 x 3 4 Shield Bolt 9 16 18 x 1 Washer 5 16 Lock Nut 5 6 18 Manifold Ball Valve Steel Mounting Bracket comes with Ref 16 Close Nipple 1 Pressure Regulating Valve U bolt Washer 1 4 Lock Washer 1 4 Nut 4 20 Orange Hose 4 to right and left boom 3 4 90 Hose Barb Orange Hose 4 to center boom Tee 3 4X 9 4 x 3 4 Elbow 3 4 x 1 HB Discharge Hose 1 Muffler Clamp 21 2 Strainer 50 Mesh Strainer Mount Bolt ys 16 x 3 Washer 3 8 Lock Nut 3 16 Discharge Hose 1 Fitting 3 4 x 3 4 HB Ball Valve 3 4 Brass Muffler Clamp 13 4 Elbow Black Pipe Nipple 11 4 x 5 Gate Valve 17 4 Close Nipple 11 4 Orange Hose 3 4 Hose Clamp Continued on next page 834 Sprayer Control Kit Comes with 110 Gallon Poly Tank D DW a i CON bb AMA At 00 00 amp 00 xl Suz xy 1006 834 PLUMBINGDRAWING D A 227 20 PUR GER 1006 834 PLUMBING PARTS LIST REF 40 41 421 431 44 45 46 47 48 49 50 51 521 DESCRIPTION 16 180 Quick Coupler 17 4 Male 16 153 Elbow 3 4 MPT x 3 4 HB 16 150 Double Threaded Fitting 3 4
20. 1 2 Lock Nut 2 13 Bolt 9 16 18 x1 a Washer 5 16 Lock Nut Sie 18 Tee Hydraulic Hose Boom Carrier Square Cap Pad Kit with 2 Pads and Steel Backing Plates 10 PR ma DDND mon 2 Kits Req d Axle 2 gt 29 TANK DRAWING TANK PARTS LIST REF 1 2 PART 15 437 HSM 8 32 100 HWL 8 HN 8 32 10 193 10 191 HB 38 16 400 HB 38 16 100 HNTL 38 16 33 495 33 496 33 494 8954 30 16 194 16 156 10 112 16 966 16 153 16 150 10 111 38 16 125 38 16 16 953 16 953 01 16 169 16 155 DESCRIPTION Latch Machine Screw 8 32 x 1 Lock Washer 8 Nut 8 32 Horizontal Boom Support Tank Strap Bolt 3 16 x 4 Bolt 3 s 16 x 1 Lock Nut s 16 Bulkhead Fitting Reducer Bushing 2x s Male Elbow Clear Hose 3 16 ID Anti Vortex Fitting 11 4 Elbow 11 4 MPT 17 HB Tank Carrier Hypro Pump Elbow 3 4 MPT x 3 4 HB Double Threaded Fitting 2 4 110 Gallon Poly Tank Bolt ys 16 x 11 4 Lock Nut 3 16 16 Hinged Lid Well with Gasket Gasket for 16 953 Strainer Basket 16 Elbow 3 4 MPT x 1 HB QUANTITY pp ry sch M sch 58 Comes with 110 Gallon Poly Tank only one 16 150 Double Threaded Fitting in bottom of tank TURBO QUAD AGITATOR PARTS LIST REF 1 oR OW PART
21. 10GA Speedometer Kit _ QUANTITY xy FUEL TANK DRAWING Sys FUEL TANK PARTS LIST QUANTITY REF 1 2 3 4 5 PART 10 231 10 115 15 039 18 003 8800 28 HB 14 20 075 HW 14 HWL 14 10 127 10 220 DESCRIPTION Gas Tank Neck Gas Tank Fuel Valve Hose Clamp 1 4 Fuel Hose 1 4 Bolt 1 4 20 x 3 4 Washer 1 4 Lock Washer 1 4 Tank Mount Gas Cap with Gauge 4 A P OIL TANK amp OIL FILTER PARTS LIST QUANTITY REF PART 23 095 48 135 18 246 10 196 16 161 16 182 18 118 18 296 16 170 50 394 HB 14 20 075 HW 14 HWL 14 16 880 HB 14 20 100 HW 14 HWL 14 16 180 16 181 10 128 34 123 18 069 18 260 10 127 23 006 23 031 18 249 18 222 8832 14 DESCRIPTION Breather Oil Tank Male Elbow Hydraulic Hose Fitting 11 x 11 4 HB to spray tank Elbow Pipe Plug Black Pipe Nipple 1 4 x 5 Gate Valve 17 4 Muffler Clamp 17 4 Bolt 1 4 20 x 3 4 Washer 1 4 Lock Washer 1 4 Close Nipple 17 4 Bolt 4 20 x 1 Washer 1 4 Lock Washer 1 4 Quick Coupler 1 Male Quick Coupler 11 4 Female to pump intake Valve Mount Elbow 1 2 Pipe Plug Reducer 1 4 x Tank Mount Oil Filter Replacement Filter Barb Fitting Hose Clamp 11 2 Hydraulic Hose 3 4 ID 4 AA py FOOT PEDAL LINKAGE DRAWING Ma E FOOT PEDAL LINKAGE PARTS LIST
22. 14 HN 14 20 10 215 HSD 14 075 10 130 34 160 10 228 10 115 10 220 10 114 10 114 01 10 114 02 10 168 516 18 100 HW 516 HWL 516 HN 516 18 10 104 DESCRIPTION 110 Gallon Poly Tank Horizontal Boom Support Tank Starp Seat Bolt 5 16 18 x 11 4 Washer 5 16 Lock Washer 5 16 Nut 5 16 18 Park Brake Handle Oil Tank Filler Breather Left Screen Drill Screw 1 4 3 4 Steering Wheel Left Front Fender Carriage Bolt 5 18 x 1 Washer 5 16 Lock Washer 5 16 Nut Sie 18 Black Boot Console Seat Panel Forward Foot Pedal Reverse Foot Pedal Main Frame Choke Two Bank Valve Valve Handles Kohler 25hp Engine Tee Tire and Wheel Tire 20 x 10 10NHS 4Ply Wheel Front Cooler Mount Right Front Fender Carriage Bolt 9 1 18 x 1 Washer 5 16 Lock Washer 5 16 Nut Sie 18 Oil Cooler Bolt 1 4 20 x 1 Lock Washer 1 4 Nut 1 4 20 Right Screen Drill Screw 1 4 3 4 Rear Cooler Mount Throttle Control with Cable Spray Boss Control Gas Tank Gas Cap Tire and Wheel Tire 24 12 12NHS Wheel Rear Fender Carriage Bolt 5 18 x 1 Washer 5 16 Lock Washer 5 16 Nut Sie 18 Hydraulic Lift Kit ooooommmDPR DDN gt NOSE CONE DRAWING Mio BS NOSE CONE PARTS LIST QUANTITY
23. 16 036 16 036 01 16 036 02 16 036 03 16 173 16 158 16 157 16 172 DESCRIPTION Agitator Jet factory installed large orfice 3 4 Set of 4 Interchangable Orfices 1 Interchangable Orfices s2 Interchangable Orfices 3 16 Reducer 3 4 x 1 2 Close Nipple 3 4 x 3 4 Female Pipe Thread Tee 9 4 x 3 4 x 3 4 Nylon Nipple 3 4 NPT x 31 2 QUANTITY D Mi P SH sch xl 34 103 ORBITROL DRAWING 34 103 ORBITROL PARTS LIST QUANTITY REF PART 17 2 3 15 301 14 4 5 15 301 13 6 15 301 15 7 15 301 08 8 9 10 15 301 11 11 15 301 12 12 13 14 15 301 06 15 15 301 07 16 15 301 05 17 15 301 04 18 19 20 15 301 03 21 15 301 02 i 15 301 01 15 3010RBITOR SPECIFICATIONS Maximum System Pressure Maximum Back Pressure DESCRIPTION O Ring Seal Quad Seal Bearing Kit Bearing Race Bearing Spool External Retaining Ring Spring Centering Kit Includes Ref 9 Spring Spacer Centering Spring Spring Retaining Ring Pin Sleeve Retainer Plug and O ring O Ring Seal Plug Relief Valve Check 1015 psi 70bar Housing Dust Seal Wear Plate Drive Spacer Gerotor O Ring Seal End Cap Cap Screw Seal Kit 1015 psi 70 150 psi 10bar Maximum System Operating Temperature 200 F 93 C Maximum Flow 4 gpm 15 lpm Maximum Temperature Differential between Steering Unit and System Input Torque Powered Input Torque Maximum Non powered Rotation Limits Fluid
24. 3 s 16 2 6 10 127 Tank Mount 1 7 HB 38 16 225 Bolt 3 s 16 x 21 4 2 HNTL 38 16 Lock Nut 3 s 16 2 8 10 213 Foamer Compressor Bracket 1 FOAM MARKER INS TALLATI ON 1 Before working on machine stop engine set park brake remove key from ignition and block wheels Disconnect negative battery terminal 2 To mount the control box on the right side tube you need to drill hole in the center of the tube even with the seat Use a 20 x 2 bolt and lock nut to bolt the bracket 1 that comes with the control box to the side panel Now mountthe foamer compressor bracket 8 to the horizontal boom support Use two 16 x 27 bolts and lock nuts 4 Remove the original mounting bracket from the compressor saving the hardware and mount the com pressor on the bracket you just put on the boom support Use existing hardware 5 Usethe extension wire 10 222 to connect the compressor to the control box 6 Between the gas tank and the machine there are extra holes in the gas tank mount Ref 6 Place the foamer tank bracket Ref 3 on top of the gas tank mount and bolt down with 16 x 1 bolts washers and lock nuts 7 Place the foamer tank 21 464 on the foamer tank bracket Ref 3 and hold in place with the tank strap Ref 4 using two 18 x 2 bolts and lock nuts Continued On Next Page 10 105 FOAM MARKER INSTALLATION 15 504 Compressor Sub Assembly 15 506 Switch
25. 6 10 166 HRP 14 100 10 151 10 134 14 266 18 270 HB 38 16 225 HNTL 38 16 18 133 34 044 23 127 18 267 10 136 18 234 HG 14 28 180 HMB 12 14 HP 18 100 18 210 10 177 21 212 10 118 DESCRIPTION O Ring Plug 45 Elbow Hydrostat Pump Socket Screw 2 13 x 13 4 Muffler Clamp 11 4 Muffler Kohler 24 786 11 Heat Shield Cable Bracket Machine Key 1 Pulley BK57 Belt Rubber Bushing Spacer Exhaust Pipe Bolt 16 x 11 2 Washer s Lock Nut 3 s 16 Pump Mount Machine Bushing 14GA Cotter Pin 1 Elbow 17 Hypro Pump Pressure Switch Reducer Bushing 1 2x 17 4 Fitting 1 44 MPTx 1 4HB Male Elbow Adjustment Screw s 16 x 1 Nut 3 s 16 Pivot Grease Fitting 4 28 x 180 Bushing Bolt s 16 x 1 Lock Nut 2 16 Rear Engine Mount Roll Pin x 1 Swash Plate Spacer Ball Bearing 1 OD sID Oilite Bushing 5 3 OD x 10 Bolt ys 16 x 21 4 Lock Nut s 16 Barb Fitting NPTx HB Elbow Elbow Straight Thread Connector Idler Arm Oilite Bushing Grease Fitting 4 28 x 180 Machine Bushing 14GA Cotter Pin 1 Tee Front Engine Mount Spring Engine Kohler 25HP sch M sch M td dl sch dl SB POND sch sch sch ll sch zk dl sch D Kt KH 00 ck sch sch BM sch sch oo DS PARK BRAKE AND REAR AXLE DRAWING MAIN FRAME TORQUE TO 160FT LBS 208Nm
26. 60 8859 8853 8962 10 167 22 073 76 327 10 204 33 271 10 203 77 207 8845 3 5 8860 8859 8853 8962 33 480 15 314 15 472 16 966 10 183 16 883 10 209 10 181 10 224 10 108 DESCRIPTION Speedometer Ring Terminal 3 16 Heat Shrink Buss Bar Ignition Switch Kohler 25 099 04 Key Set Panel Mounted Circuit Breaker Circuit Breaker Boot Buss Bartz Speedometer To Buss Bar Buss Bar to Hour Voltmeter Hour Voltmeter Combo Hot Wire Hour Voltmeter Oil Warning Light Black Wire String Connector Ring Terminal 3 16 Slide On Connector Heat Shrink 3 16 Oil Sender Part Of Engine Ignition Module Part Of Engine Fuel Shut Off Solenoid Part Of Engine Rectifier Part Of Engine Starter Part Of Engine Red Battery Cable Battery Optional Ground Battery Cable Fuse Block Ground Wire Fuse Block Fuse Block Hot Wire Wire With Fuse Part Of Engine Fuse AGC 30 Buss Bar to Ignition Switch Buzzer White Wire String Connector Ring Terminal 3 16 Slide On Connector Heat Shrink Wire Toggle Switch To Buss Bar Pressure Switch Toggle Switch Switch Boot Hypro Pump With Electric Clutch Wire Speedometer Ground Magnetic Sensor Speedometer Wire Harness Wire Harness Includes all wire colors with Console Wire Harness Speedometer Kit optional 4 Oona sch sch sch sch PD Lo oo b QUANTITY xl
27. Bolt HN 14 20 1 4 20 Hex Nut HW 14 1 4 Flat Washer HWL 14 1 4 Lockwasher SOLENOID TERMINALS HN 516 24 5 16 24 Hex Nut HW 516 5 16 Lockwasher HN 10 32 10 32 Hex Nut HWL 10 10 Lockwasher 8931 144 10GA White Wire 144 8928 5 18 Wire Terminal Yellow 8901 Slide On Yellow Connector 33 273 Auto Blade Type Fuse 30Amp CONNECTION INSTRUCTIONS Route wire harness along side of tank and over to battery taking care to stay clear of moving parts or hot engine components Cut off excess wire and strip back 3 Place one 8901 slide on yellow connector on red wire and one on the white wire Connect the two wires to the fuse block first the red to the positive and the white to the negative Use dielectric grease on all electrical connections Make certain you are connecting positive to positive negative to negative while attaching power leads If you do not observe polarity damage will result to electrical com ponents sch lt N sch sch sch sch sch sch mm mm NN xl ay 10 105 FOAM MARKER MOUNTING DRAWING 10 105 FOAM MARKER PARTS LIST REF PART DESCRIPTION QUANTITY 1 Control Box Bracket 1 2 HB 14 20 225 Bolt 1 4 20 x 21 4 1 HNTL 14 20 Lock Nut 14 20 1 3 10 198 Foamer Tank Bracket 1 4 16 939 Tank Strap 1 HB 516 18 200 Bolt 5 e 18x 2 2 HNTL 516 18 Lock Nut 5 16 18 2 5 HB 38 16 125 Bolt 3 s 16 x 11 4 2 HW 38 Washer 3 2 HNTL 38 16 Lock Nut
28. Check Valve for Manual Steering Relief Valve Setting Ports Displacement 50 F 28 C 15 25lb in 100psi tank pressure 2 3Nm 7bar 60lb ft 81 Nm None SAE 10W 40 API Service SG Yes 1015 psi 70bar 916 18 SAE O Ring five 61 cu in R 100 cu cm R sch sch l l l l sch sch sch tt sch sch sch sch sch sch xl 10 117 HYDRAULIC PUMP DRAWING Ws po 10 117 HYDRAULIC PUMP PARTS LIST QUANTITY PART 42 003 01 14 130 13 110 01 14 115 42 003 16 42 003 02 42 003 03 13 110 05 14 069 42 003 04 42 003 05 14 220 14 105 13 110 10 10 117 02 14 234 14 235 13 110 14 42 003 07 14 054 13 110 13 42 003 08 13 110 10 14 212 42 003 09 42 003 10 14 132 14 221 14 216 14 114 14 215 14 217 14 107 10 117 01 42 003 11 10 117 04 10 117 05 10 117 03 42 003 12 42 003 13 42 003 17 14 098 42 003 14 DESCRIPTION O Ring Ring By Pass Valve Valve Plate Cylinder Block Kit Pump Shaft Plug Pipe Plug Needle Bearing Lip Seal Washer Truncated Shaft long 2 holes Retaining Ring Plug O Ring Shim Pack Kit Release Valve Spring Release Valve Cone Hex Head Screw Needle Bearing Lip Seal Charge Pump Housing Geroter O Ring O Ring Plug Truncated Shaft short 1 hole Retaining Ring Ball Bearing Retaining Ring Variable Swash Plate Spring Pin Thrust Plate Pin Roller Bearing Gasket Pump End Cap O Ring Hex H
29. ER TANK DRAWING 10 106 CLEAR WATER TANK PARTS LIST REF PART DESCRIPTION QUANTITY 1 HB 516 18 075 Bolt 5 16 18 3 4 4 HWL 516 Lock Washer 16 4 HW 516 Washer 5 16 4 2 10 216 Clear Water Tank Bracket 1 3 HB 38 16 150 Bolt 3 s 16 x 17 2 2 HNTL 38 16 Lock Nut 38 16 2 4 10 234 3 Gallon Rectangular Tank 1 5 16 158 Close Nipple 3 4 x 3 4 1 6 16 960 Spigot 3 4 NPT 1 7 16 151 Elbow FPT 3 4 x 3 4 1 CLEAR WATER TANK INSTALLATION 1 Clear Water Tank mounts on the left side of the horizontal boom support 2 Insert the close nipple into the bottom of the tank Then place the elbow on the close nipple so it is pointnig away from the machine Place the spigot into the elbow For best results use plumbers tape on all fittings Place the mount bracket onto the boom support using the two bolts and lock nuts 4 Line holes on the tank with holes on the mount bracket and use the bolts to fasten tank to mount bracket 5 Rinse tank with clear water and check for leaks around fittings This tank is for fresh clear water ONLY Do not put chemicals in this tank M SIN NOTES Me Les DECAL LIST This is a list of decals located on the Spray Star 1000 Part number description and location will help in reorder ing a decals 25 344 75 699 25 347 25 322 25 348 13 063 25 298 27 092 16 231 25 308 76 304 25 345 25 307 Decal 3 Star Decal Smithco Decal Dash Decal Made in USA Decal Control Pa
30. Hose 3 4 center boom Hose Clamp Loom Clamp 1 Drill Screw 1 4 3 4 Hose Barb 4 MPT x 1 HB Discharge Hose 1 Hose Clamp Muffler Clamp 21 2 Strainer 50 Mesh Strainer Mount Elbow 1 sMPT x 1 HB Bolt ys 16 x 3 Lock Nut 38 16 Discharge Hose 1 9 4 90 Hose Barb 1 90 Hose Barb Manual Ball Valve Bolt 14 20 x 21 2 Lock Nut 4 20 Reducer Bushing 1 x 4 Liquid Filled Gauge Throttling Valve Elbow 3 4 x 1 HB Double Threaded Fitting Elbow 3 4 x 3 4 HB Anti Vortex Fitting 11 4 Elbow 11 4MPT x 1 4 HB 110 Gallon Poly Tank 16 Hinged Lid Well with Gasket Gasket for 16 953 Strainer Basket 16 Discharge Hose 1 Hose Clamp Suction Hose 11 4 Hose Clamp Suction Hose 11 4 Hose Clamp Hypro Pump Quick Coupler 1 Female Quick Coupler 11 4 Male Elbow Close Nipple 11 4 Gate Valve 11 4 Black Pipe Nipple 17 4 x 5 Fitting 1 4 NPT x 17 HB Orange Hose 3 4 Hose Clamp Discharge Hose 1 Hose Clamp Comes with 10 207 Manual Ball Valve Comes with 10 111 110 Gallon Poly Tank 4 pHs aaa ch 4 P A A A A P QUANTITY xl xy CONTROL 1006 834 SYSTEM DRAWING 16 968 STRAINER DRAWING BL CONTROLS 1006 834 SYSTEM PARTS LIST QUANTITY REF 4 2 3 An 5 6 7 8 9 PART 10 233 10 232 10 152 15 569 15 531 15 552 15
31. LUG NUT Y ff y y ff Z 2 I GR Q AT 7 Me PARK BRAKEAND REAR AXLE PARTS LIST QUANTITY REF 28 29 30 31 PART 60 268 76 239 18 265 76 240 10 124 HB 12 13 800 76 241 14 265 HNTL 12 13 10 116 HB 12 13 125 HNJ 12 13 HB 12 13 750 HWK 516 100 10 154 11 100 HN 516 24 HCP 516 100 HP 18 100 10 121 HB 516 18 400 HCP 516 138 HP 18 100 10 120 HN 516 18 10 134 23 006 23 031 HB 14 20 075 HW 14 HWL 14 10 126 10 125 HG 14 28 180 HB 12 13 150 HW 12 HNTL 12 13 HB 516 18 125 HW 516 HNTL 516 18 34 057 10 123 10 205 16 557 34 101 02 DESCRIPTION Lug Bolt 4 20 x 15 16 8 Brake Disk 5 hole 45 Elbow Left Caliper ccw Rear Axle Bolt 1 2 13x 8 Cam Side Pad Right Caliper CW Carrier Side Pad Carrier Side Pad Support Cam Side Pad Support Nut 1 20 included with Ref 14 Lock Nut 1 2 13 Wheel Motor includes Refs 12 amp 17 Bolt z 18 17 4 Jam Nut 2 13 Bolt 1 2 13 x 71 2 Woodruff Key 5 16 x 1 included with 14 Fender Brackets Linkage Yokes 5 16 Nut 16 24 Clevis Pin 5 16 x 1 Cotter Pin 1 Brake Cable with Nuts Bolt Sie 18 x 4 Clevis Pin 5 16 13 8 Cotter Pin 1 Park Brake Handle Nut Sie 16 Spacer Oil Filter Replacement Filter Bolt 1 4 20 x 3 4 Washer 1 4 Lock Washer 1 4 Brake Rod Sie 24 Brake Relay Grease Fitting 4 28 x 180 Bolt 2 13 x 11 2 Washer
32. Lock Nut s 16 Retaining Ring Swivel Seal Kit for swivel Washer s QUANTITY 10 Sch bb SS HOSE REEL MOUNT PARTS LIST REF PART DESCRIPTION QUANTITY 1 HB 38 16 375 Bolt 3 s 16 x 33 4 4 HNTL 38 16 Lock Nut 3 s 16 4 2 10 205 Boom Carrier 2 3 10 221 Hose Reel Mount 1 4 16 906 Electric Hose Reel 1 16 129 Manual Hose Reel 1 5 18 249 Brass Fitting 3 4 x 3 4 HB 1 6 HB 516 18 150 Bolt 9 15 18 x 11 2 4 HNTL 516 18 Lock Nut Sie 18 4 HOSE REEL MOUNTING INSTRUCTIONS P N 13 Wear protective clothing when draining the tank and taking apart the lines Drain tank and spray system in a safe and approved method insuring that no chemical or water remain in tank as you will be taking apart lines Remove key from ignition set park brake and block wheels Remove square rubber covers on boom carriers Place hose reel bracket inside the boom carrier tubes with arms pointing toward front of machine Lower bracket until top hole in bracket lines up with hole in upright Use four s 16 x 33 4 bolts and four 3 s 16 lock nuts with nuts on inside of uprights Put hose reel on hose reel bracket with fitting on left side of machine Use four bolts 16 18 x 1 2and four 5 18 18 lock nuts to hold in place Tighten bolts To put handle on drive roll pin out of the shaft on right side put handle over shaft and line up
33. Power Cable Also Order Two 8853 Female Connectors Boom Mounting Bracket Accessories Includes Two 15 510 01 Nozzle Mounting Rods and Four Lock Collars with Bolts Cover Sub Asseembly Valve Manifold Sub Assembly 15 505 MOTOR SUB ASSEMBLY DRAWING N a 15 505 MOTOR SUB ASSEMBLY PARTS LIST QUANTITY REF 1t PART 15 505 01 15 505 03 15 505 06 15 505 05 15 505 02 15 505 04 DESCRIPTION Manifold Screw Exhaust Manifold Exhaust Reed Valve Washer Exhaust Valve Screw Exhaust Manifold Gasket Head Bolt L Tubing Connector Intake Valve Screw Split Lockwasher Intake Reed Valve Diaphragm Piston Connecting Rod Nut Connecting Rod Bolt Brush Retainer Brush 12 Volt Electric Motor Stainless Steel Bearing Block Motor Bolt Motor Nut Cover Cover Screw Intake Exhaust Valve Sub Assembly Intake Piston Sub Assembly N N N sch N N M xy FOAM NOZZLE SUB ASSEMBLY DRAWING Cut Here To Shorten Nozzle SI FOAM NOZZLE SUB ASSEMBLY PARTS LIST REF 1 2 4 5 64 7 8 9 15 510 01 15 511 02 15 511 03 15 511 04 18 123 15 511 05 15 511 15 511 01 DESCRIPTION Nut Screw Foam Nozzle Inlet Body Nozzle Mounting Rods Foam Sponge Stainless Steel Screen Stainless Steel Snap Ring Hose Clamp Drop Tube Restrictor Bell Foam Nozzle Sub Assembly On
34. SMITHEU Wayne Pennsylvania 19087 PARTS amp SERVICE MANUAL Spray Star Model 1000 PRIME MOVER Starting Serial 100100 November 1998 SMITHCO PRODUCT SUPPORT 800 891 9435 wy SS and Poplar Avenue Cameron WI 54822 mail productsupport smithco com SS E 0 Q ES 8 3 1 Introduction raras 1 3 Sale See 2 3 Optional 3 Service iii 4 9 Maintenance bs dit 4 6 CHAN esas 7 End User s Service 8 fo UE iniri 9 iolage TT EES 9 Diagrams 10 13 Wiring Diagram ient eene 10 11 Hydraulic Diagram see 12 13 esi do bind KU ERES UNE 14 37 Body Frame 14 15 Nose CONE caian ea 16 17 in ee UR USD Modes 18 19 Fuel Tank unie Ee ree 20 21 Hydraulie Tan iiie ee 20 21 Foot Pedal Linkage 22 25 Engine Pumps and Exhaust 26 27 Park Brake and Rear 28 29 Poly Tank iiie ER ERR 30 31 Turbo Quad Agitator pp 30 31 4 Lu Wale Te 32 33 10 117 Hydraulic 34 35 16 966 Hypro 36 37 CONTENTS
35. STEEL BOOM DRAWING We lt Les 10 160 STAINLESS STEEL BOOM PARTS LIST QUANTITY REF NOOR 10 19 20 21 22 23 24 PART 16 926 13 498 15 562 15 565 15 564 10 205 HBS 38 16 550 HNTL 38 16 16 761 HSSQ 38 16 150 HN 38 16 16 024 HWS 516 HN 516 24 18 249 18 040 16 925 33 301 HMB 100 14 HMB 100 10 15 495 33 306 18 268 33 308 HBS 38 16 125 HWS 38 HNTL 38 16 16 927 33 330 HBS 38 16 125 HWS 38 HNTL 38 16 33 329 33 331 HB 38 16 125 HW 38 HNTL 38 16 33 309 HBS 38 16 125 HWS 38 HNTL 38 16 33 295 15 494 18 036 HSSQ 38 16 150 HRP 14 150 33 302 HCPS 12 225 HPS 18 100 33 305 HBS 38 16 125 HWS 38 HNTL 38 16 DESCRIPTION Stainless Steel Cap 2 4 U Bolt Kit 17 8 Right and Left Boom Tube Left Brush Guard Right Brush Guard Boom Carrier part of the truck Stainless Steel Bolt ys 16 x 51 2 Lock Nut s 16 Boom Brackets Square Head Set Screw 3 16 x 11 2 Nut 3 16 U Bolt 5 16 24 Stainless Steel Washer 5 16 Nut 5 16 24 Barb Fitting Hose Clamp Stainless Steel Pipe Elbow 34 90 Right Pivot Bracket Machine Bushing 1 x 14GA Machine Bushing 1 x 10GA Extension Spring Right Cam Stop must also order 33 307 Oilite Bushing Right Center Tube Bracket Stainless Steel Bolt 3 16 x 174 Stainless Steel Washer s Lock Nut 16 Center Tube Right Actuator Bracket Stain
36. XLE PARTS LIST REF Y PART 80 167 HNAR 100 14 11 043 80 019 10 186 HSSHS 516 18 038 11 041 11 042 10 152 HG 14 28 180 18 035 HNA 100 14 HP 18 150 HMB 100 14 10 158 50 081 HCP 58 175 18 153 10 138 HP 18 100 18 188 10 135 14 267 18 168 HNJ 58 18 HB 58 11 250 18 154 10 156 HMB 58 14 10 153 HG 14 28 180 HNTL 58 11 16 076 16 565 HNM 12 125 10 155 10 131 HG 14 28 180 10 139 HNAJ 114 12 16 883 HNJ 34 16 10 157 27 022 02 HNL 12 20 HMB 100 10 10 108 DESCRIPTION Dust Cap Slotted Jam Nut 1 14 Bearing Hub includes Ref 1 3 6 38 amp 39 Hub with Sprocket Socket Head Set Screw 5 16 18 Oil Seal Spacer Left Spindle Grease Fitting 4 28 x 180 Bushing Slotted Nut 1 14 Cotter Pin 11 2 Machine Bushing 1 x 14GA Left Front Fender Bracket Front Rubber Insulator Clevis Pin 5 s 13 4 Bushing Axle Pin Cotter Pin 1 45 Elbow Hydraulic Cylinder Seal Kit 90 Elbow Jam Nut 5 s 18 Bolt Sie 11 x 21 2 Rod End Right Front Fender Bracket Front Machine Bushing sx 14GA Right Spindle Grease Fitting 4 28 x 180 Lock Nut 5 s 11 King Pin Rod End Metric Nut M12 1 25 Right Front Fender Bracket Back Front Axle Grease Fitting 4 28 x 180 Tie Rod Slotted Jam 114 12 Magnetic Sensor Optional Jam Nut 3 4 16 Left Front Fender Bracket Back Stud 2 20 Lug Nut 2 20 Machine Bushing 1 X
37. a low tire to recommended pressure Over inflating can cause tires to ex plode Front tires should be 20 psi 1 4bar and rear tires should be 22 psi 1 5bar Improper inflation will reduce tire life considerably WHEEL MOUNTING PROCEDURE 1 Setpark brake Turn machine off and remove key Block wheel on opposite corner Loosen nuts slightly on wheel to be removed Jack up machine being careful not to damage underside of machine Place wheel on hub lining up bolt holes om to Torque to 64 74 ft lb 87 100Nm using a cross pattern Retorque after first 10 hours and every 200 hours thereafter 7 Lower machine to ground and remove blocks and jack 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 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 first 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 acid
38. a supple ment You must adhere to guidelines established by manufacturer for warranty coverage In adverse conditions such as dirt mud or extreme temperatures maintenance should be more frequent DAILY CHECKLIST 1 7 8 9 10 Check the engine oil level Add as needed DO NOT OVERFILL Refer to engine owner s manual for oil grade and procedure Tire pressure should be 20 psi 1 4 bar maximum in the rear tires 22 psi 1 5 bar maximum in the front tires Inspect the electrical system and battery cables for loose connections or frayed wiring Replace any faulty equipment or tighten if loose Check hardware for loose or missing nuts bolts screws etc and tighten or replace as needed Inspect hydraulic lines for damage or leaks Never use hands to inspect for leaks Check the hydraulic fluid level The hydraulic fluid tank is located on the left side of the machine The fluid level should be 2 212 5 6 4 cm from the top of the fill tube when cold Use only SAE 10W 40 Service SG Motor Oil Inspect the steering throttle and shift linkages for good hookups and clear travel Check controls for smooth proper working operation Lubricate as needed Check park brake adjustments Adjust as required Check anti vibration mounts on engine frame LUBRICATION Use No 2 General purpose lithium base grease and lubricate every 100 hours The Spray Star 1000 has 9 grease fittings A Di D One on the
39. all the way to the right On the inside of the left front wheel there is a sprocket From the rear of the machine place the magnetic sensor into the hole on the bracket of the spindle that lines up with the teeth on the sprocket Adjust the magnetic sensor so that it is between s and 9 16 inch away from the sprocket Connect the ring terminals on the wire harness to the terminals on the magnetic sensor Run the wire harness to the center of the machine along the front axle up through the hole in the floorboard up the console and through the hole for the speedometer Use the nylon ties to tie the wire harness to the axle so that it will not hang loose or rub on anything Cut off the excess ties Bring the speedometer up to the dashboard Connect the speedometer wire harness to the center terminal of the speedometer Under the dashboard there is a red wire with a fork terminal that is not connected to anything Bring it up to the speedometer and connect it to the positive terminal Remove the hold down from the speedometer and slide the speedometer through the hole Make sure that the speedometer is straight Put the holddown back on keeping the speedometer straight and not touching any of the wires Connect the white ground wire from the speedometer to the ground buss bar on the left hand side of the steering column Reconnect the negative battery cable Speedometer should work If not check sensor clearing M 10 106 CLEAR WAT
40. aximum Height FLUID CAPACITY Crankcase Oil Fuel Hydraulic Fluid Grade of Hydraulic Fluid 112 285 cm 70 178 cm 15 4 57 m 48 122 cm 53 135 cm 1283 Ibs 582 kg 2200 Ibs 998 kg 88 dba 84 dba 72 dba Kohler Command CH25S PA 68620 25HP 18 kw Unleaded 87 Octane Gasoline Minimum Air Cooled Full Pressure 25 Amp Front Two 20 x 10 00 x 10 NHS Multi Rib Rear Two 24 x 12 00 x 12 NHS Multi Trac Dynamic Through Hydrostat Hand Operated Lever Discs on Rear Axle 0 8 mph 0 12 8 kph 0 3 mph 0 4 8 kph 12 Volt Automotive type 24F 700 minimum Negative 10 25 4 cm 7 17 8 cm 91 2 24 13 cm See Engine Manual 5 gallon 19 liters 5 gallon 19 liters SAE 10W 40 API Service SG Motor Oil OPTIONAL EQUIPMENT 10 101 834 Spray System 1006 10 106 Fresh Water Tank 10 102 Manual Spray System 1004 10 107 Hose Reel Mounting Kit 10 103 Electric Actuator Lift Kit 10 108 Speedometer Kit 10 104 Hydraulic Actuator Lift Kit 10 110 440 Spray System 1008 10 105 Foam Marker 10 160 15 Stainless Steel Boom 16 129 Hose Reel 200 61 m capacity to be used with 10 107 MAINTENANCE CAUTION 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 before operation The suggested maintenance checklist is not offered as a replacement for the manufacturer s but as
41. crew Stainless Steel Hex Nut Stainless Steel Lockwasher Polypropylene Ball Manifold Body Nylon Fuse Holder Glass Fuse Steel Mounting Bracket Spare Parts Kit Single Unit Comes with three 15 553 3 4 90 Hose Barbs OO P sch DNN sch H AH sch zk ck M zk KH sch M sch QUANTITY A 15 53 1CONTROL VALVE DRAWING N lle EN 15 53 1CONTROL VALVE PARTS LIST REF PART 15 517 10 15 517 09 15 517 08 15 517 04 15 517 05 15 517 06 15 517 07 15 517 11 15 517 13 15 531 04 15 517 14 15 517 15 15 517 16 15 517 17 15 531 06 15 517 26 15 531 05 15 517 22 15 531 03 15 517 20 15 517 19 15 517 18 15 517 23 15 517 24 15 531 02 15 531 01 DESCRIPTION Stainless Steel Slotted Hex Washer Screw Polypropylene Grommet Retainer EPDM Rubber Grommet Stainless Steel Self Cinching Stud Cell Sponge Rubber Gasket Neoprene Motor Mount Nylon Mounting Plate Teflon Thrust Washer Stainless Steel Spring Pin Nylon Ball Valve Stem Viton O ring Teflon Coated Viton O ring Nylon Body Dense Felt Dust Plug Polypropylene Cover Phoneolic Limit Switch Motor Sub Assembly Stainless Steel Hex Head Cap Screw Nylon End Cap Viton O ring Carbon Filled Teflon Seal Viton O ring Stainless Steel Hex Nut Stainless Steel Lockwasher Polypropylene Ball Spare Parts Kit Aa HHH sch KH HK sch zk ck sch M sch M sp QUANTITY Sy 10 160 STAINLESS
42. dth of the spray on the ground and adjusting nozzle height See example below NOZZLETYPEDROPLET SIZECOMPARISONS Volume median diameter in microns For Nozzles with a 0 5 gpm Output Spraying Pressure 20 psi 40 psi RA Raindrop Drift Reduction Nozzle 810 810 LF Flat Fan Tip 510 400 D Flooding Tip 450 315 WRW Whirl Rain Cone Spray Nozzle 350 2251 DRIFTABLEFINES PRODUCED 0 5 gpm at 40 psi Nozzle Percent of Spray Volume 5 gpm Output less than 200 microns RA Raindrop Drift Reduction Nozzle 0 7 LF Flat Fan Tip 7 20 depending on spray angle XR TEEJET TIPS This is an extended range flat spray tip It is excellent for Contact Pesticides and Growth Regulators and good for Systemic Pesticides Contact Pesticides and Growth Regulators At medium pressures 20 30 psi provides medium size droplets for good surface coverage and less drift At higher pressures 30 60 psi produces smaller droplets for better coverage Wide angle 110 tips produce slightly smaller droplets than 80 tips at equal pressures Systemic Pesticides At lower pressures 15 20 psi produces larger spray droplets and reduces drift while still providing uniform coverage along the boom FEATURES Excellent spray distribution over a wide range of pressures 15 60 psi Ideal for rigs equipped with sprayer controllers Reduces drift at lower pressures better coverage at higher pressures e Available in stainless steel and hardened stainle
43. ead Screw Valve Relief Valve Spring O Ring Relief Valve Plug Plug Washer Housing Assembly includes 9 amp 10 Seal Kit Charge Pump po po PO MPM AND HH sch FH sch HS sch sch sch sch sch sch MAMA M ND sch HH HK sch oe xl xy 16 966 HYPRO PUMP DRAWING 36 16 966 HYPRO PUMP PARTS LIST REF PART 16 966 01 16 966 02 16 966 03 16 966 04 16 966 05 16 966 06 16 966 07 16 966 08 16 966 09 16 966 10 16 966 11 16 966 12 16 822 20 16 966 13 16 966 14 16 967 16 966 15 DESCRIPTION Drain Plug Pump Casing Impeller Nut Impeller 0 Ring Mechanical Seal Silicon Carbide Seal Retainer Slinger Ring Mounting Flange Name Plate Bolt Ball Bearing Key Pump Shaft Key Bearing Retainer Gasket Clutch Silicone Carbon Seal Kit Pump Only A A ld sch P A sch zk zk zk zk zk zk zk DB QUANTITY SIS 1006 834 PLUMBING DRAWING co V S 96 Y 5 40 30 PUR M oN 1006 834 PLUMBING PARTS LIST QUANTITY PART 16 164 16 183 HSD 14 100 10 226 18 222 18 040 16 168 15 569 16 288 16 158 16 163 10 199 HB 516 18 100 HW 516 HNTL 516 18 15 552 15 552 07 16 851 15 531 10 194 HW 14 HWL 14 HN 14 20 8887 40 15 553 8887 35 16 157 16 155 8896 9 10 147 16 968 10 210 HB 38 16 300 HW 38 HNTL 38 16 8896 62 16 154 16 859 50 394 16 182 18 296 16 170 16 880 8887 37 18 040 1
44. ement Pre Cleaner Every 25hours C C C C C C R 100 Hours 200 Hours aforo 400 Hours Every 500 Hours Yearly O Spark Plugs dle Speed 1200 ET 0 Ic Cooling System Belts and Hoses Tire Pressure Visual Inspection of Tres El Fulleel 1 odeje Fuel Fiter Hydraulic pel tHydraulic OilFilter R R Hydraulic System for Leaks and Loose Parts C Battery ElectrolyteLevel C C C Clean Battery Terminais TT 0 Ic 5 Torque Lug Nuts Lubricate 1 elelc C Check or Clean at specified intervals R Replace at specified intervals Tire pressure 20 psi 1 4 bar Rear 22 psi 1 5 bar Front t Replace hydraulic filter after the first 20 100 and every 250 there after Torque tire nuts after the first 10 hours and every 200 hours there after 64 to 74 87 100Nm x Change Oil and Filter after first 5 hours Clean more often under dusty conditions or when airborne debris is present replace air cleaner parts if very dirty The suggested maintenance checklist is not offered 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 coverage In adverse conditions such as dirt mud or extreme temperatures maintenance should be more frequent
45. er to the decal for correct placement Use the 14 Nylon Ties to bind wire harness to main frame so that it does not drag Use dielectric grease on all electrical connections 10 103 ELECTRIC LIFT WIRING PARTS LIST PART DESCRIPTION QUANTITY 8853 Female Spade Connectors 2 15 472 Switch Boot 2 11 158 Linear Actuator with 4 stroke 2 16 755 Switch 2 16 810 Wiring Harness 1 22 075 Nylon 14 2 12 33 272 Fuse 20Amp 1 11 158 02 11 158 06 Rear Housing Gear Kit 20 1 11 158 03 Motor 12Vdc 11 158 Linear Actuator Ref 5 M SES xy 10 104 HYRAULIC LIFT KIT DRAWING Boom Lift To Be Removed 10 104 HYDRAULIC LIFT KIT PARTS LIST REF 1 2 3 4 5 6 PART 18 168 10 187 14 273 33 331 33 330 HCPS 12 225 HPS 18 100 33 329 HSSQ 38 16 150 HN 38 16 Part of 10 160 Boom INSTALLATION INSTRUCTIONS Shut machine off Set park brake Allow system to cool down 1 2 3 DESCRIPTION Elbow 3 Straight Thread Hydraulic Cylinder Seal Kit Left Actuator Bracket Right Actuator Bracket Stainless Steel Clevis Pin 1 2 x 21 4 Stainless Steel Cotter Pin 1 Center Mount Square Head Set Screw 3 16 x 11 2 Nut ys 16 QUANTITY 4 2 1 per IS nd Hrs Remove the boom lifts from boom and replace with hydraulic cylinder Ref 2 Use the existing hardware Refer to the valve drawing for placement of fittings The valve mounts in the seat panel o
46. holes and replace the roll pin Put 18 249 fitting into hose reel For 1006 System Remove pressure regulating valve from manifold ball valve Use a 1 close nipple onn each side of the tee Place reducer bushing 3 4 close nipple ball valve and hose into tee pointing upward For 1004 System From the back of the machine remove the two elbows at the end of the spray fittings Insert the 3 4 tee pointing toward the back of the machine Insert the 2 4 hose barb elbow into the top of the tee This goes the the right boom section Place a 3 close nipple into the open end of the tee and add the 3 4 elbow pointing upward Insert the 74 reducer bushing ball valve and hose barb Use 8887 46 hose to connect reel to ball valve clamp with 18 040 hose clamps Use 22 075 cable ties to tie hose to main feed hose Continued on next page M ej xy 1006 HOSE REEL PLUMBING DRAWING 1004 HOSE REEL PLUMBING DRAWING ay HOSE REEL PLUMBING PARTS LIST REF PART DESCRIPTION QUANTITY 1 15 552 Manifold Ball Valve 1 2 16 851 Close Nipple 1 1006 only 2 3 16 154 Fitting 3 4 x 9 4 HB 1 4 16 859 Ball Valve 3 4 Brass 1 5 16 158 Close Nipple 3 4 2 6 16 163 Reducer Bushing 1 x 3 4 1006 only 1 16 183 Tee FPT 1 x 1 x 1 1006 only 1 8 15 531 Pressure Regulating Valve 1 9 16 164 Elbow 1 MPT x 1 HB 1 10 16 151 Elbow 3 4 x 3 4 1 11 16 157 Tee 3 4 x 3 4 x 3 4 1004 only 1 12 16 153 E
47. ic 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 WARNING of water Get medical attention immediately Use of booster battery and jumper cables Particular care should be Engine D WARNING used when connecting a booster battery Use proper polarity in order to prevent sparks Y Jumper Cable 2 START NEGATIVEGROUNDED BATTERY A Shield eyes 5 5 2 Connect ends of one cable to positive Battery 3 Jumper Cable 1 terminals of each battery first A then B 3 Connect one end of other cable to negative terminal of good battery C 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 7 IM 6 a SERVICE CHART KOHLER COMMAND 25 HP Before servicing or making adjustments to the machine stop engine set park break block wheels and remove key from ignition CAUTION y 9 Follow all procedures and ONLY use parts prescribed by the manufacturer Read the engine manual before maintenance 5 Gio lt Engine Oil w Filter 2 194 2 Engine OilFilter Engine for Leaks and Loose Parts C Air Cleaner Paper El
48. inors to operate any equipment Learn the proper use ofthe machine the location and purpose of all the controls and gauges before you operate the equipment Working with unfamiliar equipment can lead to accidents 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 Inspectthe area where the equipment will be used Pick up all debris you can find before operating Beware of overhead obstructions and underground obstacles Stay alert for hidden hazards Never operate equipment that is not in perfect working order or without decals guards shields or other protective devices in place Never disconnect or bypass any switch Carbon monoxide in the exhaust fumes can be fatal when inhaled never operate a machine without proper ventilation Fuel is highly flammable handle with care Keep engine clean Allow the engine to cool before storing and always remove the ignition key Disengage all drives and set park brake before starting the engine Never use your hands to search for oil leaks Hydraulic fluid under pressure can penetrate the skin and cause serious injury 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 Do stop or start suddenly on any slope C Reduce speed on slopes and in
49. laims must be handled through a SMITHCO authorized dealer or by SMITHCO INC All transportation charges must be paid by the purchaser There is no further express warranty All implied warranties including those of merchantability and fitness for a particular purpose are limited to one year 60 days if product is used for rental pur poses from the date of purchase by the original user and to the extent permitted by law any and all implied warranties are excluded and disclaimed after the expiration of such period All incidental and consequential damages including pickup and delivery of the unit communica tion mileage charges and or rental of a replacement unit during repair are not covered under this warranty nor is any loss of income and or other loss resulting from the failure of the product to function due to a warranty defect The following items are not covered under the SMITHCO warranty and are warranted by their respective manufacturer Engine and engine parts including starters generators alternators and filters Transaxle differentials gear boxes and mechanical pumps Hydrostatic transmissions hydraulic pumps and motors Batteries Wheels and tires A copy of the warranty for the above items is furnished if necessary with each SMITHCO product Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitations of incidental or consequential damages so the above limitations
50. lbow 3 4 MPT x 3 4 HB 1 13 16 172 Nylon Nipple 3 x 31 2 1 ii 10 107 Hose Reel Mounting Kit includes only 1 16 851 Close Nipple HOSEREEL MOUNTINGINSTRUCTIONS ro N 13 Wear protective clothing when draining the tank and taking apart the lines Drain tank and spray system in safe and approved method insuring that no chemical or water remain in tank as you will be taking apart lines Remove key from ignition set park brake and block wheels Remove square rubber covers on boom carriers Place hose reel bracket inside the boom carrier tubes with arms pointing toward front of machine Lower bracket until top hole in bracket lines up with hole in upright Use four 16 x 33 4 bolts and four 3 s 16 lock nuts with nuts on inside of uprights Put hose reel on hose reel bracket with fitting on left side of machine Use four bolts 16 18 1 2 and four 5 18 18 lock nuts to hold in place Tighten bolts To put handle on drive roll pin out of the shaft on right side put handle over shaft and line up holes and replace the roll pin Put 16 153 elbow into hose reel For 1006 System Remove pressure regulating valve from manifold ball valve Use a 1 close nipple on each side of the tee Place reducer bushing 3 4 close nipple ball valve and hose barb into tee pointing upward For 1004 System From the back of the machine remove the two elbows atthe end of the spray fittings Insert the 3 4 tee poin
51. less Steel Bolt s 16 x 11 4 Stainless Steel Washer s Lock Nut 38 16 Center Mount Left Actuator Bracket Bolt 3 16 11 4 Washer 3 Lock Nut s 16 Left Center Tube Bracket Stainless Steel Bolt 16 17 4 Stainless Steel Washer s Lock Nut 3 16 Pivot Bracket Nylon Flange Bushing Oilite Bushing Set Screw s 16 x 11 2 Roll Pin 4 x 11 2 Left Pivot Bracket Stainless Steel Clevis Pin 1 2 x 27 4 Stainless Steel Cotter Pin 1 Pivot Stainless Steel Bolt s 16 x 11 4 Stainless Steel Washer s Lock Nut 3 16 3 PRANMARFHANAANNNNHAARAAHAARRARAANNNANYNNN WHOWHHPVAONNAHRANDA ND 10 160 STAINLESS STEEL BOOM DRAWING CONTINUED Me Les 10 160 STAINLESS STEEL BOOM PARTS LIST CONTINUED REF PART DESCRIPTION QUANTITY 29 15 014 Shift Knob 2 30 HB 38 16 175 Bolt 3 16 x 13 4 2 HN 38 16 Nut 3 s 16 2 31 15 561 Boom Lift 2 32 HBS 12 13 550 Stainless Steel Bolt 2 13 x 51 2 2 HNTL 12 13 Lock Nut 1 2 13 2 33 33 307 Left Cam Stop must also order 33 306 2 18 268 Oilite Bushing 2 34 18 289 Bushing 3 ID 2OD x 7 4 35 HB 38 16 225 Bolt 3 s 16 x 21 4 2 HNTL 38 16 Lock Nut 3 16 2 36 10 247 Right Boom Stabilizer 1 37 21 212 Extension Spring 1 38 HB 38 16 300 Bolt 16 x 3 1 HW 38 Washer 2 2 HNTL 38 16 Lock Nut ys 16 1 39 10 162 Boom Support 1 40 HB 516 18 225 Bolt 9 16 18 21 4 2 HNTL 516
52. ly one 7 Foam Nozzle Inlet Sub Assembly QUANTITY 1 1 1 2 1 1 1 2 1 1 10 108 SPEEDOMETER KIT DRAWING 7 BL BL 4 9 SPEEDOMETER LOCATION j O Place Speedometer Here d 9 8 M wk 10 108 SPEEDOMETER KIT PARTS LIST REF PART DESCRIPTION QUANTITY 1 10 202 Speedometer 1 8854 Fork Terminal 2 8962 Heat Shrink 2 2 8935 Buss Bar 1 3 8935 Buss Bar 1 4 Speedometer to Buss Bar of console wire harness 10 224 5 10 183 Speedometer Ground Wire 1 6 10 152 Left Spindle 1 7 16 883 Magnetic Sensor 1 8 10 209 Speedometer Wire Harness 1 Part of 10 108 Speedometer Kit SPEEDOMETER KIT INSTALLATION Shut off machine remove key set park brake remove negative battery cable from battery Using a utility knife cut out decal covering hole on left side of dashboard Remove plug from speedometer hole Put the heat shrink on the red and black wires on speedometer Put the fork terminals on the wires slide heat shrink over the ends of terminals and apply heat to shrink Connect the ground wire 10 183 to the negative terminal on the speedometer using the fork terminal Use dieelctric grease on all electrical connections Turn the steering wheel
53. n the right side Use two 20 x 2 bolts washers lock washers and nuts Refer to the decal for correct placement Remove the hose from the bottom of the oil cooler that comes out of the top of the tee This hose traces back to the top of the orbitrol Place that hose to the inlet side of the hydraulic valve Use the short hose 10 146 Ref 3 to connect the outlet side of the valve to the tee on the oil cooler Use the four other hoses to connect the valve to the hydlauic cylinders Refer to the hydraluic drawing 13 261 HYDRAULIC VALVE PARTS LIST REF 4 2 37 4 5 6 7 8 9 10 1 12 13 14 PART 14 106 14 062 13 261 03 18 168 13 261 07 13 261 06 13 261 05 18 202 13 262 18 169 14 203 13 261 02 13 261 01 14 204 13 261 DESCRIPTION Relief Assembly Kit Seal Kit N R Plug Elbow 3 s Straight Thread Plunger Spring Plug Elbow Handle set of 2 Adapter SAE Spring Center Kit Plug Housing Linkage Kit includes hitch pin clevis pin and link Hydraulic Valve Continued On Next Page QUANTITY A 1 1 1 2 2 ES 10 104 HYDRAULIC DRAWING M NIN 10 104 HYDRAULIC DRAWING PARTS LIST REF 1 2 4 5 o JO
54. nel Decal Warnings Decal Warning Hot Decal Lift Hood Decal Computer Cables Decal Engine RPM Decal Crush Pinch Decal Spray Star 1000 Decal Gas Front Nose Cone Front Nose Cone Dashboard Dashboard Control Panel In Front of Seat Hood Bak Edge Both Sides Hood Back Edge Middle Front Edge Engine Front Side of Tank Right and Left Tank Sides Gas Tank M SIN xy QUICK REFERENCE REPLACEMENT PARTS REPLACEMENT FILTERS 23 031 78 090 76 311 76 312 13 288 REPLACEMENT BELTS 10 179 SEALKITS FLUIDS 34 103 15 315 01 10 135 14 267 10 116 10 117 10 187 14 273 Brake Fluid Engine Oil Hydraulic Fluid Rear Axle Fluid OTHER PARTS o 16 953 16 953 01 Hydraulic Oil Filter Oil Filter Air Filter Element Pre Cleaner Key Switch Belt Orbitor Repair Kit Hydraulic Cylinder Seal Kit Wheel Motor Pump Hydraulic Cylinder Seal Kit Dot Kohler 12 050 01 Kohler 24 083 03 Kohler 24 083 05 SAE 10W 40 API Service SG Motor Oil SAE 10W 40 API Service SG Motor Oil SAE 80W 90 Gear Lube API Service GL 5 GL 4 Hinged Cover On Tank with Gasket Gasket For Cover Spark Plugs Champion type RC12YC Gap 0 030 inch 76mm LIMITED WARRANTY SMITHCO warrants this product to be free from defects in material and workmanship under normal use for one year from the date of purchase by the original user 60 days if product is used for rental purposes All warranty c
55. om The left hose from sprayer goes to straight fitting on left boom Be sure all clamps are tight Use the adjustment slots on the boom lifts to completely lift and lower booms Using set screws Ref 9 adjust actuator brackets so nozzles of booms are at same height with nozzles of center section Tighten bolts holding actuator brackets to center mount and locknuts on set screws Rubber boom carrier and latch are located on the horizontal boom supoort on top of tank M SEN NOZZLEASSEMBLY DRAWING es De gt M wk NOZZLEASSEMBLY PARTS LIST REF PART DESCRIPTION QUANTITY 1 16 920 01 Screw 2 2 16 920 02 Upper Clamp 1 3 16 920 03 O Ring 1 4 16 920 04 Body with Lower Clamp 1 5 16 920 05 Diaphragm Teflon Optional 1 6 16 920 06 Diaphragm EPDM Rubber Standard 1 16 920 07 Diaphragm Viton Optional 1 7 16 798 Chemsaver End 1 8 16 800 Gasket Viton 1 9 16 921 Cap 1 10 16 805 Raindrop 4 RAS 1 5 16 920 1 When the 16 920 05 Teflon Diaphragm is used it is placed in the assembly in front of the 16 920 06 EPDM Rubber Diaphragm Nozzles are located 20 51cm apart on the right left and center tubes 16 927 and 16 928 There are pre drilled holes in all tubes The Nozzle should be at a 45 angle to the ground for proper application M AN xy RA RAINDROP TIPS This is a wide angle 120 hollow cone drift reduction nozzle Replaces conventional flooding nozzles in broad
56. or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which may vary from state to state Federal law now requires disclosure of the warranty which applies to this product prior to the sale to a customer Please leave this statement attached to the product and allow the buyer to remove it after purchase SMITHCO Wayne Pennsylvania 19087 Al 2 SMITHCO ar 120498
57. rod end of hydraulic cylinder One on each the right and left spindles One on the center front pivot One on the pump pivot One on the brake relay One on the pedal relay One on the reverse pedal One on the forward pedal EELCTRICALCONNECTIONS Use dielectric grease on all electrical connections 197 7e MAINTENANCE AIR CLEANER Loosen cover retaining knob and remove cover 2 Remove pre cleaner from paper element 3 Check paper element Replace element as necessary 4 Wash pre cleaner in warm water with detergent Rinse pre cleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow pre cleaner to air dry 5 Saturate pre cleaner with new engine oil Squeeze out all excess oil 6 Reinstall pre cleaner over paper element 7 Reinstall air cleaner cover Secure cover with cover retaining knob ENGINEOIL Change and add oil according to chart below based on air temperature at the time of operation Do not overfill Use a high quality detergent oil classified For Service SF SG SH oil Use no special additives with recom mended oils Do not mix oil with gasoline SAEViscosity Grades 10W 30 10W 40 5W 20 SW 30 Starting Temperature Range Anticipated Before Next Oil Change HYDRAULIC OIL 1 Use SAE 10W 40 API Service SG motor oil For proper warranty change oil every 500 hours or annually which ever is first Oil level should be 2
58. rranty Inside Back Cover INTRODUCTION Thank you for purchasing a SMITHEO product Read this manual and all other manuals pertaining to the Spray Star 1000 carefully as they have safety operat ing assembly and maintenance instructions Failure to do so could result in personal injury or equipment dam age 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 SMITHGO machines have a Serial Number and Model Number Both numbers are needed when ordering parts The serial number plate on the Spray Star 1000 is located on the right main frame in front of the oil tank Refer to engine manual for placement of engine serial number For easy access record your Serial and Model numbers here SMITHCO WAYNE PENNSYLVANIA 19087 USA 610 688 4009 Fax 610 688 6069 o SERIAL NO kW hp S MODEL NO kg lb 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 2 SS SAFE PRACTICES 1 2 15 16 17 18 19 20 21 It is your responsibility to read this manual and all publications associated with this machine Never allow anyone to operate or service the machine or its optional equipment without proper training and instructions Never allow m
59. sch P HH HA P MM sch M sch HHA MM NM sch sch BAND sch OO HK sch xl FOOT PEDAL LINKAGE DRAWING Ws Sol FOOT PEDAL LINKAGE PARTS LIST QUANTITY REF 24 25 26 27 28 29 30 PART 10 150 HN 14 20 10 195 HW 516 HP 18 100 10 192 HST 14 20 075 HW 14 HWL 14 HN 14 20 10 211 HST 14 20 075 HWL 14 HN 14 20 HB 516 18 350 HNTL 516 18 34 162 HSM 10 32 063 HWL 10 HN 10 32 HST 14 20 075 HWL 14 HN 14 20 DESCRIPTION Battery Hold Down Nut 1 4 20 Hood Rod Washer 5 16 Cotter Pin 1 Seat Hinge Truss Head Machine Screw 1 4 20 x 3 4 Washer 1 4 Lock Washer 1 4 Nut a 20 Hood Rod Mount Truss Head Machine Screw 14 20 x 3 4 Lock Washer 1 4 Nut 1 4 20 Bolt 5 16 18 x 11 2 Lock Nut 5 16 18 Throttle Bracket Machine Screw 10 32 x 5 s Lock Washer 10 Nut 10 32 Truss Head Machine Screw 1 4 20 x 3 4 Lock Washer 1 4 Nut 4 20 NNN 0 00 0 xl ENGINE PUMPS AND EXHAUST DRAWING 0 Y id ED A 2 FRAM LF SN 26 xy ENGINE PUMPS AND EXHAUST PARTS LIST QUANTITY REF PART 23 126 18 188 10 117 HSSH 12 13 175 18 220 10 118 01 10 229 34 163 HKSQ 14 100 10 212 10 179 60 107 60 168 10 197 HB 38 16 150 HW 38 HNTL 38 16 10 245 HMB 58 14 HP 18 100 16 168 16 966 33 480 16 825 16 161 33 494 HSSQ 38 16 150 HN 38 16 10 133 HG 14 28 180 18 268 HB 38 16 100 HNTL 38 1
60. ss steel in 80 and 110 tip spray angles with VisiFlo color coding RECOMMENDEDOVERLAP Adjust nozzle spray height to overlap 30 of each edge of pattern GHT Suggested spray nozzle height with 20 spacing tip spray angle of 80 should be 17 19 tip spray angle of 110 should be 12 14 SA SIN 10 103 ELECTRIC LIFT KIT DRAWING 10 103 ELECTRIC LIFT WIRING Left Actuator oon Ground Hot 1 m9 ooo Grn R et IT lt R P y Be Switch Right Actuator Switch M oN 10 103 ELECTRIC LIFT KIT PARTS LIST REF PART DESCRIPTION QUANTITY 1 HCPS 12 225 Stainless Steel Clevis Pin 1 2 x 21 4 4 HPS 18 100 Stainless Steel Cotter Pin s x 1 4 2 33 295 Pivot Brakcet 2 3 16 919 Black Boot 2 22 069 Nylon Tie 8 2 4 18 123 Hose Clamp 2 5 11 158 Linear actuator 2 11 158 01 Seal Kit 1 per 6 33 331 Left Actuator Bracket 1 de 33 330 Right Actuator Bracket 1 8 15 561 Boom Lift 2 15 014 Shift Knob 2 HB 38 16 175 Bolt 3 16 x 13 4 2 HN 38 16 Nut s 16 2 9 HSSQ 38 16 150 Square Head Set Screw 3 16 x 11 2 2 HN 38 16 Nut s 16 2 10 33 329 Center Mount 1 7 of 10 160 Boom IINSTALLATIONINSTRUCTIONS Remove Boom Lift Ref 8 from boom and replace with the Linear Actuators Ref 5 Use the existing hardware Refer to the wiring diagram below to hook up the wire harness The switches mount in the seat panel on the right side Ref
61. t 10AMP fuse into slot which has red wire attached to it 10 105 FOAM MARKER WIRING PARTS LIST REF PART DESCRIPTION QUANTITY 1 15 504 Compressor 1 2 15 504 04 Wiring Harness 1 3 10 222 Extension Wire 1 4 15 506 Switch Box 1 15 506 01 Fuse F10A 250V 1 5 15 509 Power Cable 1 6 33 271 Fuse Block 1 33 507 Auto Blade Type Fuse 10 1 M AWN 15 504 COMPRESSOR SUB ASSEMBLY DRAWING SNS 28 34 eA 15 504 COMPRESSOR SUB ASSEMBLY PARTS LIST DESCRIPTION QUANTITY REF 4 5t et PART 15 504 01 15 504 03 15 504 07 15 525 15 504 04 15 505 15 504 06 15 512 02 15 512 01 15 504 10 15 504 09 15 504 08 15 512 21 464 15 506 15 507 15 508 15 509 15 510 15 504 01 15 504 05 Tubing Cover Seal Compressor Cover Cover Screw Air Filter Needle Valve Sub Assembly Tubing Connectors Gasket Manifold Cover Gasket Mounting Plate Front Foam Pad Nut Washer Washer Bolt Threaded Rod Bushing Bracket Discard Original Bracket Use 15 524 Switch Box Mount Wiring Harness Rear Foam Pad Grommet L Tubing Connector Tube 4 Motor Sub Assembly Solenoid Valve Sub Assembly Strainer Manifold Block Tube O ring EPR Rubber Body Tubing Connector Pressure Relief Valve Cap Tank includes 26 054 Bushing amp 26 055 Shut off Valve a A ANA pp sch SB HSB sch zk SM OO 50 51 n Switch Box Tubing Compressor Extension Cable Optional
62. ting toward the back of the machine Insert the 3 4 hose barb elbow into the middle of the tee This goes the the right boom section Place a 3 close nipple into the open end of the tee and add the 3 4 elbow pointing upward Insert the 3 4 close nipple ball valve and hose barb Use 8887 46 hose to connect reel to ball valve clamp with 18 040 hose clamps Use 22 075 cable ties to tie hose to main feed hose Continued on next page M ELECTRIC HOSE REEL WIRING DIAGRAM xy RM N 7 6 5 OPERATIONAL CHECK Pull hose off drum at least on full revolution A clicking noise should be heard from locking mechanism 2 the hose retract 3 Pull the hose off until the first click is heard Drum should lock when the hose tension is removed 4 Continue pulling the hose no more than one revolution until no clicking is heard Hose should rewind when tension is removed SPRINGTENSI ON AD USTMENT Reels are shipped with three winds of tension adequate for most application However if your usage requires either more or less initial tension perform the following 1 Make sure spring is locked 2 Disconnect inlet hose to permit the hose to go around the drum 3 adjust the spring tension add or remove the wraps of the hose from the drum one wrap ata time until the desired tension is obtained ROLLER BRACKET AD USTMENT All hose reels are shipped with the roller bracket in the ceiling
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