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PARTS & SERVICE MANUAL

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1. XL SIN 1 ALTERNATOR PARTS LIST PART DESCRIPTION QUANTITY 15 473 Alternator 63Amp 1 15 475 Alternator Adjustment Bracket 1 15 344 Pump Mount Plate 1 15 478 Wire Harness Voltmeter to Alternator 1 15 479 Wire Battery on Starter Solenoid to Alternator 1 40 019 Belt 1 22 069 Nylon Ties 8 8 HB 38 16 275 Bolt 3 s 16 23 4 1 HB 516 18 125 Bolt 2 16 18 11 4 2 HN 10 32 Nut 10 32 1 HN 516 18 Nut 5 6 18 2 HNTL 38 16 Lock Nut s 16 1 HSM 10 32 100 Machine Screw 10 32 x 1 1 HW 516 Washer 6 1 HWL 10 Lockwasher 10 1 HWL 516 Lockwasher 6 2 INSTALLATION INSTRUCTIONS 1 Remove key set park brake and block rear wheels 2 Disconnect negative battery cable at battery 3 If you jack up machine be sure to use jack stands before you go under machine 4 Onleftside of machine is the spray pump Remove guard 5 Placeadrain pan under hydraulic pump and disconnect both hydraulic hoses from pump Do Not Drain Hydraulic Fluid When Hot WARNING 6 Loosen both bolts holding pump mount plate to frame Raise pump to loosen belt and remove belt Remove both bolts and take pump and plate out from under machine 7 Place pump mount plate on bench Loosen both set screws in pulley and remove pulley from pump Be careful not to loosen the woodruff key 8 Remove both bolts that hold pump to pump mount plate and remove plate 9 Stand pump on end with shaft pointing
2. Hose Reel Adjustments Electric Hose Reel Wiring Diagram 14 283 Foam Marker Installation 14 291 iuo einen 15 505 Motor Sub Assembly 15 511 Foam Nozzle Sub Assembly 15 363 Fresh Water Tank For 1602P and 1604P 116 117 10 106 Fresh Water Tank For 1610P 118 119 14 305 eee tet ltda 120 125 15 Star Shield 126 128 Reference 129 130 Decal Quick Reference Replacement Parts Limited Warranty 130 Introduction 1 3 0 A 1 36 32 DEDE 1 General Safe Practices 2 Specifications 3 Optional Spray Equipment 3 0000010 4 12 Maintenance ansehen 4 6 Axle Shaft Disassembly 7 8 Axle Shaft Assembly 8 9 Service CHAM 10 End User s Service Chart 11 Adj stients i cii e 12 Storage ea 12 018012
3. OND We gt Hose Clamps 18 040 8887 14 Orange Hose Center Boom 2 8887 92 Orange Hose Right 8 Left Booms 14 100 PLUMBING 709 422 NOZZLE KIT DRAWING TURBO TURFJET TIPS 14 100 PLUMBING amp 16 80 7NOZZLEKIT PARTS LIST TURBO TURFJET TIPS REF PART DESCRIPTION QUANTITY 1 14 100 Boom 1 2 16 795 Square clamp 1 12 3 16 796 Diaphragm Check Valve Single complete with 8 amp 9 6 4 16 797 Diaphragm Check Valve Double complete with 8 amp 9 6 5 8888 19 Orange Hose 1 2 4 6 18 224 Hose Clamp 1 2 28 7 16 137 Fitting 2 MPT x 1 2 HB 6 8 16 798 End Cap 12 9 16 920 06 Diaphragm 12 10 8888 8 Orange Hose 1 2 6 11 15 558 Raindrop 4 RAS all sizes available 12 12 16 800 Gasket 12 13 16 921 Quick TeeJet Cap 1 4 FPT 12 14 16 199 45 Street Elbow 1 4 PT 12 15 18 133 Fitting 2 MPT x 3 4 HB 3 18 077 Hose Clamp 3 16 16 200 Ball Valve 2 16 136 Fitting 4 MPT x 2 HB 4 17 8888 9 Orange PVC Hose 1 2 4 1 16 807 Nozzle Kit 12 each PLUMBING NOZZLE KIT INSTALLATION RAINDROP TIPS All measurements are done from the fitting on center boom with booms in line Nozzles are exactly 20 apart 1 Install check valves A and B above the square tubing and pointing to the rear 20 20 20 20 20 10 10 20 20 20 20 20 AO MES M E NEL MON UA T
4. ger 2 5 a i a E 5 2 A B B A A B C B A A B B A Left Boom Center Boom Right Boom Single Ended Check Valve 3 and Clamp Refs 2 install with fitting toward middle of boom Double Ended Check Valve 4 and Clamp 2 Fitting 17 Ball Valve and Fitting 15 2 Place ball valve D between the outer check valves on both right and left booms Connect 45 1 5 the check valves together using the hose 1 NL and hose clamps Horizontal vom 3 Install Raindrop nozzles into nylon 45 elbow Install nylon elbow into threaded quickjet caps Attach caps and gaskets to the check valve Position Raindrop nozzles so they point to the rear and 45 down from horizontal 4 Fill the tank 2 full of water Place unit on a hard and level surface Adjust boom height according to the Nozzle Selection Chart Turn on spray and observe the amount of overlapping spray between adjoining nozzles There should be 100 overlap The edge of the spray from one nozzle should reach to the center of the adjoining nozzle If required adjust boom height until the correct overlap is achieved Strainers are not supplied with Raindrop nozzles Use 50 mesh slotted strainers 16 802 on nozzle tips smaller than standard gt 791 A Ma lt lt Hose Clamps 18 040 8887 14 Orange Hose Center Boom
5. ubricate Flush Spray Systems Water Chemical Tanks C Check or Clean at specified intervals Replace at specified intervals Tire pressure Front 20 psi 1 4 bar Rear 18 psi 1 3 bar T Torque tire nuts after the first 10 hours and every 200 hours there after 64 to 74 87 100 Nm Change oil after first 5 hours a Clean more often under dusty conditions or when airborne debris is present replace air cleaner parts if very dirty Remove cooling shrouds and clean cooling areas more frequently under extremely dusty dirty conditions Gap 0 40 1 02 mm Torque to 18 22 24 4 29 8 Nm ADJUSTMENTS INTERLOCK SWITCH Located on the front below the floorboard and behind the clutch The Interlock Switch is in the electrical circuit between the starter solenoid and the starter on the ignition switch When the clutch pedal is depressed it pushes the plunger on the interlock switch in which creates a circuit Thus allowing the engine to start When the clutch pedal is released the plunger on the interlock switch comes out which breaks the circuit To adjust loosen the two nuts holding the interlock switch and move the interlock switch towards or away from the clutch pedal as needed HYDRAULIC POWER UNIT BELT Located to the rear and left of the engine Should have approximately 4 6 5 mm of deflection in the center of the top strand To adjust loosen the bolt holding the hydraulic po
6. QUANTITY 4 NN N HH WH PH a DESCRIPTION Windshield Clamp Wiper Blade Wiper Motor Wiper Arm Door Handle Black Plastic Knob Roof Fan Panel Louver 3 Speed Rotary Switch Blower Knob Inside Top 1 4 Black Poly Grommet Snap Bushing Filter Retainer Assembly Blower Rear Window Clamp Rear Side Window Top Rear Side Retainer Bolt 3 16 2 Washer 8 Lock Nut s 16 Door Self Adhesive Velcro Hook on Frame Self Adhesive Velcro Loop on Door Door Hinge Loom Clamp Ring Terminal 5 16 Filter Element Complete Bubble Trim Seal 191 on Edges of All Windows Channel Window Single 14 Inside of Window Channels Clip on Rubber Trim 25 on Window Sides PART 15 429 17 15 429 23 15 429 03 15 429 01 15 429 02 15 429 20 15 429 07 15 429 24 15 429 25 15 429 04 15 429 05 15 429 06 15 429 08 15 429 13 15 429 14 15 429 15 15 429 19 15 429 23 15 429 18 15 429 22 HB 38 16 250 HW 38 HNTL 38 16 15 429 16 15 429 09 15 429 10 15 429 21 HLC A58 8857 16 909 15 429 11 15 429 12 33 262 05 1 2 3 10 11 FOR MACHINES SERIALNUMBER 562 ANDUP Locate the end of the wire harness with the inline fuse and ring terminals Remove fuse holder and ring terminals Replace with the two 2 female spade connectors Insert fuse into fuse panel and SPECIFICATIONS Gray Safety Glass Large Rea
7. PUMPS AND EXHAUST DRAWING PUMPS AND EXHAUST PARTS LIST M SIN QUANTITY ANNA dc dd ld N NN AH AH dd py DESCRIPTION Muffler Clamp Exhaust Pipe Muffler Clamp 11 4 Muffler Bracket Universal Exhaust Hanger Pan Head Drill Screw 1 Tank Carrier Muffler Clamp 11 2 Tail Pipe Hose Clamps Engine Kohler Command 20 hp Exhaust Manifold Kohler 24 164 11 Pulley BH72 x 1 s Socket Head Set Screw x 1 2 Machine Key 1 4 1 4 2 Pulley with Hub BK30H 1 Machine Key 1 4 1 4 2 Bolt 1 4 20 3 4 Pump Mount Plate Carriage Bolt 3 16 11 4 Lockwasher 6 Nut s 16 Pump Arm 11 16 x9 16 Straight Thread Connector 11 16 x 9 16 90 Straight Thread Elbow Filler Breather part of 15 315 3 s Coupler 3 s Pipe Nipple x 2 Hydraulic Power Unit Repair Kit Woodruff Key Rear Mount Plate Bolt 3 16 4 Washer s Lock Nut s 16 Top Filter Bracket Cross 11 4 Muffler Clamp Strainer Bottom Filter Bracket Bolt 3 16 2 Lock Nut s 16 Close Nipple 11 4 Elbow 11 4 Belt Guard Hypro Pump Bolt 1 2 13 x 41 2 Center Lock Nut 1 2 13 Machine Bushing z x 14GA Pulley BK30 x 2 Socket Head Set Screw 5 16 18 x 1 2 Bolt 3 16 4 Lock Nut s 16 Belt 5L230 Belt L447 PART 15 371 13 498 15 379 18 2
8. Machine Key 1 4 1 4 x 11 2 Belt Pulley 4 4 OD with Hub Machine Key 1 4 1 4 2 Rubber Bumper Bolt 1 2 x 3 Engine Frame Rubber Bushing Spacer Flange Whiz Lock Nut 2 3 Washer 5 Washer 6 Left Side Panel Pan Head Drill Screw SS 1 4 x 1 Bolt 3 16 x 1 Washer 3 Lock Nut s 16 Bolt 5 6 18 4 Lockwasher 6 Nut 5Ae 18 Battery Box Battery Black Battery Cable Battery Box Front Right Side Panel Pan Head Drill Screw SS x 1 Bottom Mount Bracket Continued on next page PART 15 356 8803 41 16 755 15 472 15 329 14 366 HB 14 20 075 HW 14 HNTL 14 20 15 335 16 046 15 373 8800 9 18 186 50 403 HB 38 16 175 HW 38 HNTL 38 16 15 316 HKSQ 14 150 15 318 HKSQ 14 150 16 827 16 820 HKSQ 14 150 15 013 HB 12 13 300 15 357 60 107 60 168 HNFL 12 13 HW 58 HW 716 14 349 HSDPS 14 100 HB 38 16 100 HW 38 HNTL 38 16 HB 516 18 125 HWL 516 HN 516 18 15 330 33 216 22 054 15 388 14 350 HSDPS 14 100 15 482 REF 1 2 NO 01 10 11 12 13 14 15 16 17 18 19 20 21 24 ENGINEAND CONTROL PANEL DRAWING ENGINEAND CONTROL PARTS LIST M QUANTITY HH a a AP DESCRIPTION BeltGuard Top Mounting Bracket Left BeltGuard Guard Mount Idler Pulley Magnetic Sensor Pulley 71 2 OD with Hub Woodruff Key 1 4 x 6 Red Battery Cable Throttle Cable
9. 15 493 STAINLESS STEEL 18 AUTO BOOM PARTS LIST DESCRIPTION QUANTITY 30 11 178 Linear Actuator with 4 Stroke 2 31 33 307 Left Cam Stop must also order 33 306 2 18 268 Oilite Bushing part of 33 307 2 32 HBS 12 13 550 Stainless Steel Bolt 2 13 51 2 2 HNCL 12 13 Center Lock Nut 2 13 2 33 18 289 Bushing s ID 2OD x 5 s 4 34 HB 38 16 225 Bolt 3 16 x 14 2 HNTL 38 16 Lock Nut s 16 2 35 10 247 Right Boom Stabilizer 1 36 21 212 Extension Spring 1 37 HB 38 16 300 Bolt 9 s 16 x 8 1 HW 38 Washer 3 2 HNTL 38 16 Lock Nut s 16 1 38 10 162 Boom Support 1 39 HB 516 18 225 Bolt 546 4 2 HNTL 516 18 Lock Nut 546 18 2 40 10 246 Left Boom Stabilizer 1 INSTALLATION INSTRUCTIONS For best results use teflon tape on all fittings 1 Thethree boom assemblies are not on the packing list but are in carton The long boom assemblies are the right and left booms The labels are located on right and left pivot brackets Ref 13 and 25 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 2 Mount small boom assembly to rear upright support on sprayer using four boom brackets Ref 8 four bolts 3 16 x 5 2 and four lock nuts s 16 Ref 7 One boom bracket should go on boom assembly and one on upright support of sprayer Do the same for right and left side Place boom at desired level approximately 20
10. INSTALLATIONINSTRUCTIONS For best result use 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 13 and 26 The small boom assembly 1 the center boom Each assembly is shipped with the nozzle bodies 16 996 attached The remainder part of the nozzles need to be installed You can NOT order these boom assemblies as one unit Please refer to parts drawing for individual parts 2 Mount small boom assembly to the boom carriers on sprayer using four boom brackets Ref 8 four bolts 3 16x 5 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 51 cm nozzle height and center Tighten bolts 3 Put the actuator brackets Ref 20 and 22 on the center mount Ref 21 using s 16 x 11 4 bolts washers and lock nuts with washers over the slots Snug up the bolts so that you can adjust actuator brackets with the set screws Ref A on the center mount after booms have been mounted 4 Take right boom and slide pivot bracket Ref 24 in center mount Ref 21 and hold in place with 2 13 x 5 2 bolt and 13 center lock nut Ref 32 Do not over tighten boom must be able to move up and down Repeat for left boom 5 Install boom li
11. 14 371 16 998 16 166 18 160 16 825 15 385 8896 42 18 222 16 161 8897 50 18 116 8889 22 18 116 16 955 16 159 16 958 07 16 288 16 163 16 183 10 199 15 552 15 552 07 16 995 16 164 16 158 10 194 HW 14 HNTL 14 20 8887 36 5 18 040 8887 28 18 040 15 553 15 553 01 15 553 02 8887 42 18 040 8896 70 18 222 18 279 16 852 24 25 26 27 28 16 10 PLUMBING DRAWING MANUAL M SIN 1610P PLUMBINGPARTS LIST PART DESCRIPTION QUANTITY 1 10 263 Front Valve Bracket 1 2 10 264 Rear Valve Bracket 1 3 16 1 Liquid Filled Gauge 1 4 16 268 13 90 Elbo x 1HB with Nut comes with 10 268 Valve 3 5 8896 4 Discharge Hose 1 x 4 1 18 222 Hose Clamp 3 16 x 11 2 2 6 8887 122 Orange PVC Hose 2 4 x 122 right boom 1 18 040 Hose Clamp HS 12 1 7 8896 10 Discharge Hose 1 x 10 1 18 222 Hose Clamp 3 16 x 11 2 2 8 10 269 Plastic Tee 1 x 1 x 1HB 1 9 8896 20 Discharge Hose 1 x 20 1 18 222 Hose Clamp 9 16 x 11 2 2 10 16 155 Elbow 3 4 MPT x 1 HB 1 11 8896 42 Discharge Hose 1 x 42 1 18 222 Hose Clamp 19 16 x 11 2 2 12 8889 22 Suction Hose 11 4 x 22 1 18 116 Hose Clamp HS 24 2 13 16 825 Reducer Bushing 1 2 11 4 1 14 18 098 Pipe Plug 1 15 16 998 Hypro Pump 1 16 8896 32 5 Discharge Hose 1 x 321 2 1 18 222 Hose Clamp 3 16 x 11 2 2 17 8887 109 Orange PVC Hose 3 4 x 109 center boom 1 18 040 Hose Clamp HS 12 1 18 8887 130 Orange PVC Hose 3
12. 2 8887 92 Orange Hose Right amp Left Booms 9 A Papo ota 14 101 PLUMBING amp 709 420 NOZZLE KIT PARTS DRAWING TEEJET TIPS 14 101PLUMBING amp 709 420 NOZZLEKIT PARTS LIST TEEJET TIPS PART DESCRIPTION QUANTITY 1 14 101 Boom 1 2 16 795 Square Clamp 1 12 3 16 796 Diaphragm Check Valve Single includes 8 amp 9 6 4 16 797 Diaphragm Check Valve Double includes 8 amp 9 6 5 8888 19 Orange PVC Hose 1 2 4 6 18 224 Hose Clamp 28 7 16 137 Fitting 2 MPT x 1 2 HB 6 8 16 798 End Cap 12 9 16 920 06 Diaphragm 12 10 16 802 Strainer 12 11 16 800 Gasket 12 12 16 803 TeeJet Tip XR8004 Standard all sizes available 12 13 16 804 Quick TeeJet Cap white 12 14 8888 8 Orange PVC hose 2 6 15 16 200 Ball Valve 4 FPT 2 16 136 Fitting 4 MPT x 1 2 HB 4 16 8888 9 Orange Hose 1 2 4 17 16 135 Fitting MPT x 3 4 HB 3 18 077 Hose Clamp 3 T 709 420 Nozzle Kit 12 each PLUMBING 6 NOZZLE KIT INSTALLATION TEEJET TIPS All measurements are done from the fitting on center boom with booms in line Nozzles are exactly 20 apart 1 Install check valves A and B behind the square tubing and pointing down 20 20 20 20 20 10 10 20 20 20 20 20 ANGE AE a E UN UM TR ca a 2 5 2 a 5 2 a A B B A A B C B A A B B A Left Boom Center Boom Right Boom Single Ended Check Valve
13. Phillips Truss Head Machine Screw 1 4 20 x 4 Washer 1 4 Lockwasher 1 4 Nut 1 4 20 Choke Cable Pan Head Drill Screw SS 1 4 x 1 Rear Engine Cover Cable Clamp Wire Block PART 15 481 15 483 15 555 15 556 16 013 16 883 16 821 HWK 14 1125 50 323 13 568 HSTP 14 20 075 HW 14 HWL 14 HN 14 20 11 086 HSDPS 14 100 14 326 17 154 21 161 REF 25 26 27 28 29 30 31 32 33 34 35 36 37 NS NS Mg 290 GAS TANK DRAWING GAS TANK PARTS LIST M QUANTITY 1 1 1 NARRAR DESCRIPTION Cap with Gauge 5 Gallon gas Tank Gas Tank Bracket Main Frame Bolt x 1 Washer 6 Lock Nut s 16 Bolt 1 4 20 x 3 4 Washer Lockwasher 1 4 Hose Clamp Fuel Hose 1 4 x 25 Fuel Valve Reducer Bushing 1 4 s PART 15 492 15 491 14 337 HB 38 16 100 HW 38 HNTL 38 16 HB 14 20 075 HW 14 HWL 14 18 186 8800 25 15 039 18 042 REF TURBOQUADAGITATOR DRAWING SIN TURBO QUAD AGITATOR PARTS LIST DESCRIPTION QUANTITY 1 16 036 Agitator Jets includes one each s 5 2 and 3 16 orifices 4 2 Interchangeable Nozzles 3 16 factory installed 4 3 16 173 Reducer 3 4 x 4 4 16 158 Close Nipple 3 4 2 5 16 157 Tee Female Pipe Thread 3 4 x 3 4 x 3 4 3 6 16 172 Nylon Nipple 3 4 NPT x 31 2 1 One each comes with 16 036 Agitator Jet 14 371
14. 1 gallon 3 785 liters SAE 10W 40 API Service SJ or higher motor oil WEIGHTS AND DIMENSIONS Length Width Height Wheel Base Weight Empty SOUND LEVEL AT 3400 RPM At ear level At 3 ft 0 914 m At 30 ft 9 14 m At 23 ft 7 m pass by ENGINE Make Model Spec Horsepower Fuel Cooling System Lubrication System Alternator WHEELS amp TIRE SPEED Working Speed Transport Speed Reverse Speed BATTERY BCI Group Cold Cranking Amps Ground Terminal Polarity Maximum Length Maximum Width Maximum Height FLUIDCAPACITY Crankcase Oil Fuel Hydraulic Fluid Grade of Fluid OPTIONAL SPRAY EQUIPMENT 10 300 18 Terrain Following Boom 14 100 Super Boom 20 6 m Long 33 216 Battery 24F 12 Volt 15 363 Fresh Water Wash Tank 14 311 Hose Reel Mounting Kit 15 493 Auto Boom 18 5 5 m Long 15 571 15 Tri Section Electric Lift Star Shield Boom 15 577 18 Manual Lift Boom 15 572 15 Dual Section Electric Lift Star Shield Boom 14 301 440 Spray System 1602P 14 302 203 Spray System 1604P 14 303 Manual Spray System 1610P 14 305 Operator Protection Enclosure 14 283 Foam Marker System Factory Installed 14 285 Foam Marker System Dealer Installed 15 573 15 Manual Lift Star Shield Boom 16 856 Tank Rinsing System 16 129 Manual Hose Reel 200 61 m capacity to be used with 14 311 16 906 Hose Reel 12 volt electric rewind 200 61 m capacity to be used with 14 311 MAINTENANCE Bef
15. 16 159 16 971 16 524 16 851 15 552 15 552 07 16 162 10 194 HNTL 14 20 HW 14 8887 36 5 18 040 8887 28 18 040 15 553 15 553 01 15 553 02 8887 42 18 040 15 365 25 26 27 28 jo 16047 PLUMBING DRAWING RAVEN 203 1604P PLUMBING PARTS LIST SA ON QUANTITY 00 00 He HH NM HHH oc DESCRIPTION Strainer Hypro Pump Hex Plug 3 4 Close Nipple 4 Reducer Bushing 11 2 x 11 4 Elbow 11 4 Discharge Hose 1 x 42 Hose Clamp 3 16 x 11 2 Fitting 11 4 MPT x 11 4 HB Discharge Hose 11 4 x 50 Hose Clamp HS 24 Suction Hose 11 4 x 22 Hose Clamp HS 24 Tube Fitting 1 MPT x 1 4 HB Male Fitting Reducer Bushing 3 4 x 1 4 Reducer Bushing 1 x 3 4 Tee FPT1x1x1 Shield Manifold Ball Valve Steel Mounting Bracket comes with ball valve Motorized Control Valve Elbow 1 MPT x 1HB Close Nipple 4 U Bolt Washer 1 4 Lock Nut 4 20 Orange PVC Hose 3 4 x 361 2 to right boom Hose Clamp HS 12 Orange PVC Hose 3 4 x 28 to center boom Hose Clamp HS 12 Hose Barb 4 90 comes with ball valve Clip part of 15 553 O ring part of 15 553 Orange PVC Hose 2 4 x 42 to left Boom Hose Clamp HS 12 Discharge Hose 1 x 70 Hose Clamp t346 x 11 4 Ball Valve 11 4 Raven 203 Computer with Accessories all items PART
16. 3 and Clamp Refs 2 install with fitting toward middle of boom Double Ended Check Valve 4 and Clamp 2 Fitting 17 Ball Valve and Fitting 15 2 Install strainer gasket nozzles into cap and connect to the check valve Strainers may be omitted if XR8008 8010 8015 or 8020 nozzle tips are used 3 Place ball valve D between the outer check valves on both right and left booms Connect the check valves together using the 2 hose and hose clamps 4 Fill the tank 2 full of water Place unit on a hard and level surface Adjust boom height according to the Nozzle Selection Chart Turn on spray and observe the amount of overlapping spray between adjoining nozzles There should be 30 overlap The edge of the spray from one nozzle should reach approximate 5 of the way to the next nozzle If required adjust boom height until the correct overlap is achieved TURBOTURFJET TIPS This is a wide angle 1109 hollow cone drift reduction nozzle Replaces conventional flooding nozzles in broad cast applications FEATURES Color coding makes it easy to match nozzle flow rates for easy identification Color coding is available in sizes 1 4 TTJO2 VS through 4 TTJ15 VS Uniform spray distribution Alarge orifice opening and passages minimize clogging The Turbo TurfJet nozzle s patented design element a secondary swirl chamber in the nozzle cap alter
17. 51cm nozzle height and center Tighten bolts 3 Putthe actuator brackets Ref 20 and 22 on the center mount Ref 21 using 3 16 x1 4 bolts washers and lock nuts with washers over the slots Snug up the bolts so that you can adjust actuator brackets with the set screws Ref A on the center mount after booms have been mounted 4 Take right boom and slide pivot bracket Ref 27 in center mount Ref 21 and hold in place with 1 2 13 x 5 2 bolt and 1 2 13 center lock nut Ref 32 Do not over tighten boom must be able to move up and down 5 Mount actuator Ref 30 fixed end to actuator bracket and ram end to pivot bracket using 1 2 x 21 4 clevis pins and X 1 cotter pins Ref 28 It may be necessary to lift boom slightly for proper fit Repeat process for other boom 6 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 boom The left hose from sprayer goes to straight fitting on left boom Be sure all clamps are tight Connect wire harness to actuator Use two nylon ties 22 075 to hold wire to fixed end of actuators Use boom switches to completely extend actuator and lower booms Using set screws Ref A 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
18. SIDE VIEW 22 9 10 268 3 WAY MANUAL VALVEPARTS LIST REF PART DESCRIPTION QUANTITY 1 10 268 07 BoomLever 3 2 10 268 16 Bolt and Washer 18 3 10 268 17 Boom Lever Plate 3 4 10 268 06 Spring Clip 5 8 6 5 10 268 05 Cap 3 10 268 21 O Ring included with 10 268 19 Seal Kit 3 6 10 268 02 Main Body 3 10 268 19 Seal Kit 1 per body 7 10 268 24 O Ring for Main Body 3 8 10 268 27 Main Pressure Adjust 1 9 10 268 29 Pressure Adjust Body 1 10 10 268 09 Main Boom Lever 1 11 10 268 30 Master Boom Lever 56 1 12 10 268 25 Boom Lever Pin 3 13 10 268 22 O Ring included with 10 268 19 Seal Kit 3 14 10 268 03 Hose Barb 3 4 3 15 10 268 04 Spring Clip 7 8 3 16 10 268 23 O Ring included with 10 268 12 and 10 268 14 4 17 10 268 11 Boom Pressure Adjust threaded end 1 18 10 268 12 Boom Pressure Adjust middle 1 19 10 268 14 Boom Pressure Adjust capped 1 20 10 268 21 O Ring 3 21 10 268 01 Gage Elbow 1 22 10 268 13 Elbow 90 1 Hose Barb w Nut 3 23 16 281 Liquid Filled Gauge not included with 10 268 valve 1 24 10 268 26 Boom Lever Guts 3 25 10 268 28 Bolt amp Washer 6 Not Shown 10 268 15 Tie Rod with Nuts and Washer 4 M Me lt lt RS 14 348 SOLENOID VALVE DRAWING 14 348 SOLENOIDPARTS LIST PART DESCRIPTION QUANTITY 1 14 348 02 Coil Assembly 1 2 16 879 07 Upper Diaphragm Housing 1 3 14 348 03 Armature Type 430fr Stainless Steel 1 4 14 348 04 Spring Type 302 Stainless Steel 1 5 14 348 05 Retaini
19. 1 1 1 DESCRIPTION Nylon Ring Nut Nylon Hose Barb Viton O ring Flow Meter Body Turbine Insert Assembly Flow Meter Pickup Hose Barb Assembly PART 15 515 02 15 515 03 15 515 04 15 515 05 15 515 06 15 515 07 15 515 01 REF x 2 8 4 5 6 16 524 AND16 995 MOTORIZED CONTROL VALVEDRAWING 16 524 AND 16 995 MOTORIZEDCONTROL VALVEPARTS LIST PART DESCRIPTION QUANTITY 1 16 870 Valve Cover 1 2 16 524 01 6 Self Tapping Screw 34 Long 6 3 16 897 Seal Tetraseal 1 4 16 875 Motor Assembly For 16 524 on Spray Star 3002 1 4 16 866 01 Motor Assembly For 16 866 on Spray Star 3004 1 5 16 957 Woodruff Key 1 6 16 524 04 Isolation Flange Assembly 1 1 16 524 02 Coupler Shaft 1 8 16 956 Butterfly 1 9 16 524 03 Valve Body Assembly for 16 524 1 16 995 01 Valve Body Assembly for 16 995 1 10 16 995 01 2 16 524 05 1 Valve ISO Body Kit for 15 524 16 955 02 1 Valve ISO Body Kit for 16 995 WHENSERVICINGVALVE Replace
20. 13 16 928 Right and Left Tube 2 14 33 301 Right Pivot Bracket 1 HMBS 100 10 Stainless Steel Machine Bushing 1 x 10GA 1 HMBS 100 14 Stainless Steel Machine Bushing 1 x 14GA 2 HRPS 14 150 Stainless Steel Roll Pin x 1 2 15 42 537 Spade Bolt 3 8 16 4 HW 38 Washer 3 8 4 HWL 38 Lockwasher 3 8 4 HN 38 16 Nut 2 8 16 4 16 33 308 Right Center Tube Mount 1 HBS 38 16 125 Stainless Steel Bolt 3 8 16 x 11 4 2 HWS 38 Stainless Steel Washer 86 2 HNTL 38 16 Lock Nut 3 8 16 2 17 16 925 Stainless Steel Pipe Elbow x 90 3 18 249 Barb Fitting 3 18 040 Hose Clamp HS 12 3 18 HBS 38 16 550 Stainless Steel Bolt 9 8 16 51 2 4 HNTL 38 16 Lock 16 4 19 10 304 Boom Bracket 4 20 10 305 Center Boom Mount 1 21 16 927 Center Tube 1 A HSSQS 38 16 150 Stainless Steel Set Screw 3 8 16 11 2 part of 10 305 2 HN 38 16 Nut 3 8 16 part of 10 305 2 22 33 309 Left Center Tube Mount 1 HBS 38 16 125 Stainless Steel Bolt 3 8 16 x 11 4 2 HWS 38 Stainless Steel 68 2 HNTL 38 16 Lock Nut 3 8 16 2 23 HBS 12 13 600 Stainless Steel Bolt 13x 6 2 HNTL 12 13 Lock Nut 2 13 2 24 10 313 Extension Spring 2 25 HCPS 12 275 Stainless Steel Pin x 23 4 2 HMB 12 14 Machine Bushing x 4 HPS 18 100 Stainless Steel Cotter Pin 1 8 x 1 2 A Continue on Next Page lt S Z 773 11 178 Linear Actuator Ref 33 11 158 03 Motor 12VDC 10 300 16 TERRAIN FOLLOWING BOOM DRAWING 10 300 18 TERRAIN FOLLOWING BO
21. 18 100 Stainless Steel Cotter Pin 1 8 x 1 2 41 10 309 Left Cam Stop must also order 10 308 2 18 268 Oilite Bushing part of 10 309 2 HG 14 28 180 Grease Fitting 28 x 180 part of 10 309 2 42 10 308 Right Cam Stop must also order 10 309 2 18 268 Oilite Bushing part of 10 308 2 HG 14 28 180 Grease Fitting 28 x 180 part of 10 308 2 43 16 024 U Bolt 5 6 24 6 HWLS 516 Stainless Steel Lockwasher 5 16 12 HNS 516 24 Stainless Steel Nut 5 24 12 44 10 306 Right Brush Guard 1 45 10 332 Stabilizer 2 46 10 331 Center Stabilizer Mount 1 HB 38 16 300 Bolt 3 5 16 x 3 1 HW 38 Washer 3 8 2 HNTL 38 16 Lock Nut 3 8 16 1 47 HB 58 11 300 Bolt 5 5 11 x 3 4 HMB 58 14 Machine Bushing 5 x 14GA 8 HNTL 58 11 Lock Nut 5 8 11 4 10 300 18 TERRAIN FOLLOWING BOOM DRAWING INSTALLATIONINSTRUCTIONS For best results use Teflon Tape on all fittings 1 Thethree boom assemblies are not on the packing list but are in carton You can NOT order these boom assemblies as one unit Please refer to parts drawing for individual parts The long boom assemblies are the right and left booms The labels are located on right and left pivot brackets Ref 14 and 26 The small boom assembly 1 the center boom Each assembly is shipped with the nozzle bodies 16 996 The remainder parts ofthe nozzles need to be installed 2 Mount small boom assembly to the boom carriers on sprayer using the four boom brackets Ref 19 four 3
22. 31 16 335 Snap Ring small 1 32 16 334 Snap Ring large 1 33 16 333 Bearing M D Gear 1 34 16 332 Oil Baffle 1 35 16 331 Gear M D keyed input shaft 1 36 16 347 Bolt 14 x 1 black 4 37 Washer 7 16 star burst 4 38 16 314 Rear Bearing Retainer 1 39 16 326 Gasket M D retainer 1 16 328 Synchronized Assembly with BR Rings 1 T 16 299 Transmission Cover Assembly Continued on next page M SIN 15 409 3 SPEED TRANSMISSION DRAWING 15 409 3 SPEEDTRANSMISSIONPARTS LIST M SIN o _ Spacer speedometer Snap Ring Rear Bearing Main Shaft Gear M S low 8 reverse Gear M S 2 Syncro Ring M S 2nd 8 3rd Snap Ring Needle Bearing 13 rollers per set Steel Washer Thrust Washer Main Needle Bearing 20 rollers per set Cluster Gear Shaft C S Cluster Spacer Tube Gear C S cluster Reverse Gear Shaft Lockplate Reverse Idler Gear Thrust Washer Thrust Washer Synchronized Assembly with BR Rings 16 309 16 305 16 304 16 303 16 310 16 311 16 312 16 329 16 327 16 325 16 317 16 318 16 324 16 323 16 322 16 321 16 320 16 319 16 316 16 315 16 328 40 41 Se UN 16 998 HYPROPUMP DRAWING 16 998 HYPRO PUMP PARTS LIST M 5 PART DESCRIPTION QUANTITY 1 16 998 01 Drain Plug 4 2 16 998 02 Pump Casing 1 3 16 998 03 Impeller Nut 1 4 16 966 16 Impeller 1 5 16 998 04 0 Ring 1 6 16 998 05 Mechanical S
23. 8 16 x 5 2 bolts and lock nuts Ref 18 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 51 cm and be sure it is centered Tighten bolts 3 Putthe boom holders Ref 32 and 35 on the center mount Ref 20 using ys 16 x 11 4 bolts washers and lock nuts Ref 34 with washers next to slots Center the bolts in the slots and tighten The set screws Ref A on the center mount should be tightened to the stop It is used to set the up and down movement of the boom at the castor wheel The range of the boom is approximately 32 total 16 up and 16 down This can be adjusted by moving the boom holders In will increase the up range Out will increase the down range 4 Take right boom and slide pivot bracket Ref 38 in the center mount Ref 20 and hold in place with 2 3 6 bolt and lock nut Ref 23 Do not over tighten boom must be able to move up and down Repeat for left boom Yu may need to loosen the pivot Ref 40 to install 2 13 x 6 bolt due to interference with the cam stops Ref 41 and 42 5 Mount the actuator Ref 33 with the fixed end to the right and left boom holders Ref 35 and 32 using x 2 clevis pin and cotter pin Mount the ram end to the pivot brackets Ref 38 using 2x 23 4 clevis pin and cotter pin Ref 25 with the 2 x 14GA machine bushing on the outside of the pivot brackets 6 Hook hoses to the re
24. Slide on Terminal 1 8962 Heat Shrink 9 15 X 11 4 1 21 33 494 Elbow MPT 16 HB 1 22 HB 12 13 450 Bolt 1 2 13 x 41 2 1 23 HMB 12 14 Machine Bushing 2 x 14GA 6 24 18 259 Cross 11 4 1 25 HSSQ 38 16 250 Square Head Set Screw s x 2 2 1 HN 38 16 Nut s 16 1 26 15 457 Ground Wire 1 M YN Ma UN FRONT AXLE DRAWING FRONTAXLEPARTS LIST M SN QUANTITY NNN N N HAHA oo Po ap Hea 00 DESCRIPTION Left Front Fender Carriage Bolt 5 16 18 x 1 Washer 6 Lock Washer 6 Nut 5 6 18 Dust 01160 Jam Nut 1 14 Bearing Hub includes Ref 2 4 6 9 10 Oil Seal Spacer Cotter Pin 11 2 Stud 1 2 20 Lug Nut 2 20 Left Front Fender Bracket Front Rubber Bumper Bushing part of 14 343 Axle Pin Bolt 5 16 18 4 Lock Nut 5 6 18 Right Front Fender Carriage Bolt 5 16 18 x 1 Washer 5 16 Lockwasher 6 Nut 5 1 18 Hydraulic Cylinder Seal Kit Clevis Pin 5 s x 11 2 Cotter Pin s x 1 11 16 x 90 Staight Thread Elbow Slotted Axle Nut 1 14 Machine Bushing 1 x 10GA Jam Nut 5 s 18 Bolt 5 s 11 x 21 2 Rod End Machine Bushing 14 Right Front Fender Bracket Front Lock Nut 11 Bolt 5 6 18 11 4 Washer Lock Nut 5 e 18 Right Front Fender Bracket Rear King Pin Rod End Metric Nut M12 x 1 25 Right Spindle Grease Fittin
25. booms into the forward position M Mio lt lt 11 178 Linear Actuator Ref 30 11 158 03 Motor 12VDC Hose Clamps 18 040 8887 40 Orange Hose Center Boom 2 8887 55 Orange Hose Right amp Left Booms 15 493 STAINLESS STEEL 18 AUTOBOOM DRAWING 15 493 STAINLESS STEEL 18 AUTOBOOM PARTS LIST M QUANTITY PANDNARARNARANON ANNNAARZ NNIARAAI NNN NNNA 00D0DyDODAAA NnN0 DESCRIPTION Stainless Steel Cap 3 4 U Bolt Kit Right and Left Tube Left Brush Guard Right Brush Guard Stainless Steel Bolt ys 16 x 51 2 Lock Nut s 16 Boom Brackets U Bolt 5 16 24 Stainless Steel Lockwasher 5 16 Stainless Steel Nut 9 16 24 Barb Fitting Stainless Steel Pipe Elbow 4x 90 Right Pivot Bracket Machine Bushing 1 x 14GA Machine Bushing 1 x 10GA Extension Spring Right Cam Stop must also order 33 307 Right Center Tube Bracket Stainless Steel Bolt 3 16 x 11 4 Stainless Steel Washer s Lock Nut 3 s 16 Center Tube Right Actuator Bracket Stainless Steel Bolt 3 16 x 4 Stainless Steel Washer 3 Lock Nut s 16 Center Mount Stainless Steel Set Screw s 16 x 11 2 part of 33 329 Nut 3 s 16 part of 33 329 Left Actuator Bracket Stainless Steel Bolt 3 16 11 4 Stainless Steel Washer 3 Lock Nut s 16 Left Center Tube Bracket Stainless Steel Bolt 3 16 11 4 Stainless Steel Washer s Lock Nut
26. cover retaining knob HYDRAULIC OIL 1 Use SAE 10W 40 API Service SJ or higher motor oil 2 Forproper warranty change oil every 500 hours or annually which ever is first 3 Oil level should be 1 5 4 cm from top of tank when fluid is cold Do not overfill 4 After changing oil run the machine for a few minutes Check oil level and for leaks 5 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 of the 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 30W Service SJ or higher when hot above 90 F 33 C and SAE 10W Service SJ or higher when cold below 32 0 C ambient temperature Use either motor oil or hydraulic oil but do not mix MO 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 MAINTENANCE ENGINEOIL Change and add oil according to chart below based on air temperature at the time of operation Do not overfill Us
27. engine is still warm from operation 3 Thefuel 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 lt Vw NOTES HYDRAULIC DIAGRAM M IN HYDRAULIC DIAGRAM PARTS LIST PART DESCRIPTION QUANTITY 1 14 352 Hydraulic Hose 54 1 2 14 351 Hydraulic Hose 46 1 3 50 456 Hydraulic Cylinder 1 2 x 7 1 14 267 Seal Kit 4 18 171 11 16 x 9 90 Straight Thread Elbow 3 5 14 355 Hydraulic Hose 81 1 6 14 354 Hydraulic Hose 84 1 7 18 306 11 16 x9 16 Straight Thread Connector 5 8 15 315 Hydraulic Power Unit 1 15 315 01 Repair Kit 9 27 059 Filler Breather part of 15 315 1 18 314 3 s Pipe Coupler 1 18 287 3 s Pipe Nipple x 2 1 10 HBM 6 16 Metric Bolt M
28. 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 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 SMITHED Wayne Pennsylvania 19087 AZ SMITHCO
29. original mounting bracket from switch box and discard 2 mount switch box Ref 1 you will have to remove the 4 bolt Ref 4 and the 12 4 Bolt Ref 2 holding the park brake bracket Ref 5 to the side seat frame Place the switch box bracket next to the park brake bracket and replace the 4 and 13 4 bolts 3 Mount the switch box on the bracket facing towards the seat using the two wing nuts that came with the switch box Use the extension wire 10 222 to connect the compressor to the switch box 5 Mountthe two foamer end brackets Ref 6 to the tank brackets Ref G in the first and third holes on the right side Use two sse 18 x 1 bolts and flange whiz lock nuts Ref 5 Mount the foamer center bracket Ref 8 to the slot on the tank carrier support leg Put the cross bar Ref 7 across the ends of the end and center brackets Bolt center brackets to cross bar using two 5 1 18 x 1 bolts and flange whiz lock nuts Ref 9 8 Place foamer assembly on the foamer end brackets and bolt in place with four 5 16 18 1 bolts and flange whiz lock nuts 9 Make sure all bolts are tightened WIRING Use dielectric grease on all electrical connections Connect extension wire to the pig tail on the switch box and compressor Connect power cable 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 n
30. remove key from ignition CAUTION Follow all procedures and ONLY use parts prescribed by the manufacturer Read the engine manual before maintenance gt gt E o e gt gt 0 0 0 0 0 5 I 9 R R kat S Engine Oil Engine for Leaks and Loose Parts Air Cleaner Paper Elemen C C C Pre Cleaner Every 25 hours C C C C Spark Plugs R fec C Air Cooling System 1 C C C Belts and Hoses fel Tire Pressure C C C Fuellevel 6 6 Fuel Fiter R Hydraulic Ol C Hydraulic Oil Filter Hydraulic System for Leaks and Loose Parts C Battery Electrolyte Level Clean Battery Terminals 1 Torque Lug Nuts Rear Axle Gear Lube Ic Heus 200 Hours 250 Hours B 1 E o lol fol el Lubricate jejej Flush Spray Systems Water Chemical Tanks C Check or Clean at specified intervals Replace at specified intervals Tire pressure Front 20 psi 1 4 bar Rear 18 psi 1 3 bar T Torque tire nuts after the first 10 hours and every 200 hours there after 64 to 74 87 100 Nm Change oil after first 5 hours Clean more often under dusty conditions or when airbo
31. the 34 hex plugs and install into tank Bolt tank bracket to seat support tube where you drilled the 0 holes oa gt Bolt up support brace to tank bracket and side panel as shown DN SUN Me 10 106 FRESHWATER WASH TANK DRAWING 10 106 FRESHWATER WASH TANK PARTS LIST TO BE USED WITH 1610P PART DESCRIPTION QUANTITY 1 HB 516 18 075 Bolt 5 16 18 4 4 HWL 516 Lock Washer 5 16 4 HW 516 Washer 6 4 2 10 216 Fresh Water Tank Bracket 1 3 HB 38 16 200 Bolt ys 16 x 2 2 HNTL 38 16 Lock Nut s 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 4 1 7 16 151 Elbow x 3 4 1 INSTALLATION INS TRUCTI ONS 1 Fresh Water Wash Tank mounts on the right side of the machine 2 Insertthe close nipple into the bottom of the tank Then place the elbow on the close nipple so it is pointing away from the machine Place the spigot into the elbow For best results use plumbers tape on all fittings 3 Place the mount bracket onto the right side panel using the two s bolts and lock nuts 4 Line holes on the tank with holes on the mount bracket and use the 5 5 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 DN EIN 14 305 OPERATOR S PROTECTIVEENCLOSUREPARTS LIST
32. the shaft to remove excess oil Remove the pump manifold remove the diaphragm retaining bolt support washer and diaphragm To replace the diaphragms order appropriate repair kit from parts list 6 Turnthe crankshaft to bring the piston to its upstroke to replace the diaphragm Use the downstroke to seat the new diaphragm into the sleeve groove Install retaining washer and tighten nut 7 Replacethe pulsation dampener diaphragm by first bleeding the air from the dampener After replacing the diaphragm recharge dampener to 20 of operating pressure 8 Refill crankcase with oil Rotate shaft slowly forward and reverse to distribute oil and fill to proper level MAINTENANCE CONTINUED TIREPRESSURE Caution must be used when inflating a low tire to recommended pressure Over inflating can cause tires to ex plode Front tires should be 20 psi 1 4 bar and rear tires should be 18 psi 1 3 bar Improper inflation will re duce 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 Torque to 64 74 ft lb 87 100 Nm using a cross pattern Torque again after first 10 hours and every 200 hours thereafter 7 Lower machine to ground and remove blocks and jack BATTERY Batteries
33. through with lock nut on inside Do the same without loom clamp on right side 7 Use holes in rear of cab as a guide and drill a 3 2 hole through rear engine cover and both walls of tubing each side Make sure cab is still centered before drilling Put washers on top and run bolts down through with lock nuts under tubing Tighten all four bolts Find red wire that comes out bottom of left front support tube on cab Place a 8853 slide on connector on the end of wire Route wire through loom clamp under the floorboard in with wire harness and hoses up to the fuse block 10 Plug wire into fuse block on an empty terminal and place a 30 Amp auto blade type fuse 33 273 into same position in fuse block 11 Checkto see that both the wiper and blower work If not check ground and fuse When handling the filter to insure safety of yourself and others follow all accepted practices of chemicals that the filter has been exposed to WARNING 12 Thefilter element is located in front and above the driver It is serviced from the outside of cab To service filter remove from cab 13 The filter can be taken apart for cleaning and washed in soap and water 14 To reassemble filter place orange and white 11 2 dust lock pad into case first with orange side next to the screen then place polysord carbon and retainer 15 Place filter back into cab with polysord carbon facing up and screen down tighten clamps Boom Manifold Ball Valve Spray System
34. valve body with ISO Body Kit if valve has been leaking internally Replace motor assembly if the motor will not run the printed circuit board is corroded Before reassembling valve remove the coupler shaft from the valve body Apply Loctite to coupler shaft and woo druff key Place the coupler shaft Ref 7 and the woodruff key Ref 5 onto the motor shaft Plug motor into the valve connector coming from Sprayer Control Console Check that the motor rotates in both directions Motor must stop when coupler CAM releases printed circuit board switch button When reassembling valve grease both sealing surfaces of coupler shaft Insert coupler shaft into Iso flange and be sure seal properly seats on shaft Install on valve body and apply RTV 738 to mounting holes Reassemble remaining items as shown in parts diagram on opposite side 16 456 FLOW METER PARTS LIST FOR SERIAL NUMBER UP TO SS1124 PART DESCRIPTION QUANTITY 1 16 456 03 O Ring Viton 2 2 16 456 04 RFM55 dual O Ring XDCR assembly 1 3 16 456 05 RFM55 turbine 1 4 16 456 06 Turbine hub bearing assembly 1 5 16 143 Turbine stud assembly 1 6 16 456 01 Sensor housing 1 7 16 456 02 10 32 x 3 4 stainless steel screw 12 8 16 144 O Ring Viton 1 9 16 456 07 Hub housing with inserts 1 16 456 08 Mounting bracket RFM 55 1 16 456 09 Thread sealer 1 16 456 10 O Ring Transducer Kit A 10 268 3 WAY MANUAL VALVEDRAWING 00000 A
35. with Gasket part of tank 1 16 953 01 Gasket for 16 953 1 16 169 Strainer Basket 16 1 ML SIN TANK AND REAR FENDER DRAWING TANK AND REAR FENDER PARTS LIST M QUANTITY DD PPPDPDDOO OOODDPPP PDDDDPRLRTu as needed dl dl A DESCRIPTION Rear Tank Strap 160 Gallon Poly Tank Bolt 3 s 16 2 Lock Nut s 16 Square Cap Boom Carrier Double Threaded Fitting 3 4 bottom fitting only part of tank Elbow 3 4 MPT x 1 HB Bolt 9 16 18 11 4 Washer 6 Lockwasher 6 Nut 5 16 18 Boom Carrier Latch Machine Screw 8 32 2 Lockwasher 8 Nut 8 32 Left Fender Bolt 5 46 18 x 3 4 Lock Nut 5 16 18 Bolt 9 16 18 x 1 Lock Nut 5 6 18 Fender Mount Bolt 4 20 4 Lock Nut 4 20 Left Fender Brace Right Fender Brace Bolt 5 6 18 x 1 Lock Nut se 18 Washer 5 16 Tank Carrier Tank Spacer Hypro Pump Elbow 11 4 MPT x 1 HB Anti Vortex Fitting 11 4 part of tank Right Fender Clear Hose 3 1 ID Elbow MPT x 9 16 HB Reducer Bushing 2 MPT x Bulkhead Fitting Front Tank Strap Aluminum Adapter 1 Female thread Aluminum Coupler 1 Male Thread 1 Buna N Gasket part of 16 962 Air Gap Filler 16 Hinged Lid Well with Gasket part of tank Gasket for 16 953 Strainer Basket not included with tank PART 14 322 14 451 HB 38 16 250 HNTL 38 16 16 557 14 325 16
36. 0 01 Nozzle Mounting Rods 2 44 15 511 02 Foam Sponge 1 5T Stainless Steel Screen 1 e t 15 511 04 Stainless Steel Snap Ring 1 7 Drop Tube 1 T 15 511 01 Foam Nozzle Inlet Sub Assembly 15 511 06 Foam includes 2 each items DN 1 4 0 Me TUBE SEAT SUPPORT 11 lt o LLI a DRILL 11 32 15 363 FRESH WATER TANK DRAWING 15 363 FRESHWATER TANK PARTS LIST TO BE USED WITH 1602P 1604P AND 1607P PART DESCRIPTION QUANTITY 1 HB 516 18 075 Bolt 5 16 x 2 4 4 HWL 516 Lockwasher 5 16 4 HW 516 Washer 5 16 4 2 HB 516 18 225 Bolt 5 16 18 21 4 2 HW 516 Washer 5 16 2 HNTL 516 18 Lock Nut 5 16 18 2 3 15 488 Wash Tank includes all items 1 16 166 Hex Plug 3 4 2 4 15 486 Tank Bracket 1 5 HB 14 20 100 Bolt 4 20 x 1 1 HNTL 14 20 Lock Nut 4 20 1 6 15 487 Support Brace 1 7 HB 14 20 100 Bolt 1 4 20 x 1 1 HWL 14 Lockwasher 1 4 1 HW 14 Washer 1 4 1 8 16 960 Spigot part of 15 488 1 9 15 488 01 Cap part of 15 488 1 10 15 488 02 Cover Assembly part of 15 488 1 INSTALLATIONINSTRUCTIONS Drill two s2 holes through both walls of left side panel and seat support tube as shown in drawing Remove drill screw from bottom edge in middle of side panel Run a 1 4 20 tap through this hole Bolt tank to tank bracket using four 16 18 3 4 bolts 5 16 lockwasher and 5 Use Teflon tape on each of
37. 150 16 155 HB 516 18 125 HW 516 HWL 516 HN 516 18 15 328 15 437 HSM 8 32 150 HWL 8 HN 8 32 15 447 HB 516 18 075 HNTL 516 18 HB 516 18 100 HNTL 516 18 14 324 HB 14 20 075 HNTL 14 20 14 341 14 340 HB 516 18 100 HNTL 516 18 HW 516 14 321 14 512 16 998 16 156 16 194 15 446 8954 26 33 494 33 496 33 495 14 327 16 961 16 962 16 962 01 14 365 16 953 16 953 01 16 169 REF 11 12 13 14 15 16 17 Ma EN NOSECONEDRAWING NOSECONEPARTS LIST M SIN QUANTITY 4 4 4 ANDABA sl N pad H dd DESCRIPTION Jam Nut 5 s 18 Woodruff Key 3 16 Steering Wheel Steering Wheel Cap Black Boot Mini Tilt Steering Speedometer see wiring for terminals Rubber Grommet Key Switch Kohler 25 099 04 part of engine Set of Keys Hourmeter Console Decal Console Black Trim with Lace Bolt 5 16 18 x 1 Washer 5 16 Lockwasher 6 Nut 5 16 18 Bolt 1 4 20 x 1 Lockwasher Nut 1 4 20 Pedal Pad Bolt 1 4 20 2 Lockwasher Nut 1 4 20 Foot Pedal Bolt 5 16 18 x 1 Lock Nut 5 6 18 Foot Pedal Spring Bracket Floor Board Black Trim 2 Plug Button 3 s 90 Swivel Nut Elbow Straight Thread Connector Orbital Stub Shaft Buzzer see wiring for terminals Metric Bolt M6 1 x 16 Metric Lockwasher M6 Machine Screw 10 32 x 5 s Lockwasher 10 Nut 10 32 Buss Bar Toggle Switch Switch Boot Continued on n
38. 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 HSSQS 38 16 150 HN 38 16 33 331 HBS 38 16 125 HWS 38 HNTL 38 16 33 309 HBS 38 16 125 HWS 38 HNTL 38 16 33 295 15 494 18 036 HSSQS 38 16 150 HN 38 16 HRPS 14 150 33 302 HCPS 12 225 HPS 18 100 33 305 HMB 58 14 HPS 18 100 HBS 38 16 125 HWS 38 HNTL 38 16 1 19 20 22 23 24 25 26 27 28 15 577STAINLESS STEEL 18 MANUAL BOOM DRAWING 2 2 2 2 2 2 2 2 1 SJ IT 15 577STAINLESS STEEL 18 MANUAL BOOM PARTS LIST PART DESCRIPTION QUANTITY 29 15 014 Shift Knob 2 30 HB 38 16 175 Bolt 9 s 16 13 4 2 HN 38 16 Nut 3 16 2 31 15 561 Boom Lift 2 32 HBS 12 13 550 Stainless Steel Bolt 2 13 x 5 2 2 HNCL 12 13 Center Lock Nut 1 2 13 2 33 33 307 Left Cam Stop must also order 33 306 2 18 268 Oilite Bushing part of 33 307 2 34 18 289 Bushing s ID 2 OD x 4 35 HB 38 16 225 Bolt 9 s 16 4 2 HNTL 38 16 Lock Nut s 16 2 36 10 247 Right Boom Stabilizer 1 37 21 212 Extension Spring 1 38 HB 38 16 300 Bolt 9 s 16 x 3 1 HW 38 Washer 6 2 HNTL 38 16 Lock Nut s 16 1 39 10 162 Boom Support 1 40 HB 516 18 225 Bolt 9 16 18 21 4 2 HNTL 516 18 Lock Nut 16 18 2 41 10 246 Left Boom Stabilizer 1
39. 20 15 386 33 159 HSDPS 14 100 14 321 50 111 15 387 18 147 15 373 15 373 01 15 316 HSSHS 516 50 HKSQ 14 150 15 318 HKSQ 14 150 HB 14 20 075 15 344 HBC 38 16 125 HWL 38 HN 38 16 15 580 18 306 18 171 27 059 18 314 18 287 15 315 15 315 01 HWK 18 063 15 465 HB 38 16 125 HW 38 HNTL 38 16 15 521 18 259 50 394 14 371 15 522 HB 38 16 250 HNTL 38 16 18 160 15 385 15 345 16 998 HB 12 13 450 HNCL 12 13 HMB 12 14 15 414 HSSHS 516 18 050 HB 38 16 125 HNTL 38 16 15 320 16 869 REF O 000 12 13 14 35 36 37 38 SPRAY PUMP DRAWING 7 lt A gt WN 1 lt SI 8 4 1 4 Sas E 2 s 7 Mo SIN SPRAY PUMP PARTS LIST PART DESCRIPTION QUANTITY 1 15 580 PumpArm 1 2 HB 38 16 150 Bolt ys 16x 11 2 2 HW 38 Washer s 2 HNTL 38 16 Lock Nut s 16 2 3 14 353 Main Frame 1 4 HNCL 12 13 Center Lock Nut 1 2 13 1 5 33 480 Pressure Switch 1 6 18 260 Bushing 11 4 x 3 4 2 7 16 825 Reducer Bushing 1 2 x 11 4 1 8 15 385 Elbow 11 4 2 9 18 160 Close Nipple 11 4 3 10 16 170 Gate Valve 11 4 1 11 18 236 Nipple 11 4 x 4 1 12 16 161 Fitting 11 4 MPT x 11 4 HB 1 13 18 219 Tee 4 1 14 16 180 Quick Coupler 1 Male 1 15 16 935 Quick Coupler Cap 1 16 16 155 Elbow 3 4 MPT x 1HB 1 17 16 859 Ball Valve 4 1 18 18 073 Close Nipple 54 1 19 14 371 Strainer 1 20 16 998 Hypro Pump 1 8859 Male
40. 22 HB 38 16 100 HW 38 16 906 27 16 906 21 16 906 20 HWL 516 HB 516 18 075 16 129 09 16 129 10 HNTL 38 16 HNTL 516 18 16 129 08 HB 516 18 075 HW 516 16 129 07 16 906 08 16 906 24 16 906 07 16 906 23 16 906 30 16 980 HB 516 18 175 HW 516 HNTL 516 18 REF 14 311HOSE REEL MOUNT AND 16 10 PLUMBING DRAWING Figure 3 1610 Va 2 1 Y N 4 Figure 1 Figure 2 1607 1602 ae U 14 311HOSE REEL PARTS LIST PART DESCRIPTION QUANTITY 1 HB 38 16 350 Bolt 3 s 16 2 2 HNTL 38 16 Lock Nut 3 s 16 2 2 14 325 Boom Carrier part of machine 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 1 6 HB 516 18 150 Bolt 5 16 18 x 2 4 HNTL 516 18 Lock Nut 5 1 18 4 7 HB 38 16 250 Bolt 3 s 16 x 2 2 HNTL 38 16 Lock Nut s 16 2 8 16 158 Close Nipple 4 2 9 16 151 Elbow F P T 3 4x 3 4 1 10 16 859 Ball Valve 3 4 Brass 1 11 16 154 Fitting 3 4 MPT 3 4 1 12 8887 90 Orange PVC Hose 4 1 18 040 Hose Clamp 2 13 18 260 Bushing 11 4 x 4 1 14 18 073 Pipe Nipple 4 1 INSTALLATI ONINS TRUCTI ONS 1 Wear protective clothing when draining the tank and taking apart the lines 2 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 3 Remove key from ignition set park brake and block wheels Remove square ru
41. 31115 1 1 14 7 Hydraulic Diagram 14 15 Wiring Diagram eie 16 17 PARS t 18 55 Body Frame naar Re 18 19 Tank Rear Fenders 20 21 NOSE COME as sn e See e a 22 5 851835650 AI RD 26 27 Pumps And Exhaust 28 9 Spray PUMP u nee en 30 31 Front AXle a 32 33 Clutch Linkage 34 35 Engine and Control Panel 36 39 Gas Tank 40 41 Turbo Quad 42 43 14 37 eem 42 43 15 30 T OFDI OE means E 44 45 15 409 3 Speed Transmission 46 49 16 998 Hypro 50 1 16 037 Rear Axle 52 53 Brake Assembly 54 5 INTRODUCTION Thank you for purchasing SMITHEO product Read this manual and all other manuals pertaining to the Spray Star carefully as they have safety operating assembly and maintenance instructions Failure to do so could result personal injury or equipment damage Keep manuals in a safe place after operator and maintenance personnel have read them Right and left sides are from the operator s seat facing forward All SMITHEO machines have a S
42. 4 x 130 left boom 1 18 040 Hose Clamp HS 12 1 19 10 268 3 Way Manual Valve 1 20 16 196 Hose Barb 3 4 MPT x 1 HB 1 21 16 859 Ball Valve 3 4 Brass 1 22 16 158 Close Nipple 3 4 2 23 16 151 Elbow 3 4 1 M YN CONTROLS 1602 SYSTEM DRAWING RAVEN 440 8 II Ke CONSOLE 5 Vi Bl s 4 Br bi 2 E W 7 0 RIIW v a TO GROUND UNDER ENGINE FRAME di TO POSITIVE BATTERY 25 ON STARTER SOLENOID e 15 o i Es Grn Grn 0 TO POSITIVE BATTERY R ON STARTER SOLENOID TO GROUND UNDER 19 ENGINE FRAME 7 3 e 4 gt 62 xy CONTROLS 1602 SYSTEM PARTS LIST PART DESCRIPTION QUANTITY 1 16 558 Mounting Knob 2 2 16 525 Console only 1 16 234 Computer Cover 1 3 15 370 03 Turret Assembly 2 4 15 370 04 Speed Sensor Rod 1 5 HN 14 20 Nut 1 4 20 2 6 HWL 14 Lockwasher 1
43. 4 2 7 16 457 Magnetic Sensor 1 8 15 370 01 Red Magnet Assembly north 1 i 15 370 02 Black Magnet Assembly south 1 15 370 07 Small Clamp 2 9 14 370 Drive Line Spray Star 1 10 14 348 Solenoid Valve 1 11 16 524 Motorized Control Valve 1 12 15 369 Console Control Cable 1 13 33 271 Fuse Block 1 14 10 237 Mounting Bracket 1 15 18 373 Flow Meter 1 16 33 508 Auto Blade Type Fuse 15 amp 1 15 370 08 Drive Shaft Hardware Kit for speed sensor Use Dielectric Grease On All Electrical Connections CONTROL 1604P SYSTEM PARTS LIST PART DESCRIPTION QUANTITY 1 16 958 01 Mounting Bracket 1 2 16 898 Boom Switch 3 3 16 900 Mounting Knob 2 4 16 899 Master Switch 1 5 16 958 Console only 1 6 33 090 02 Liquid Filled Pressure Gauge 1 7 16 958 02 Fuse Holder 1 16 525 03 Fuse 15 AMP 1 8 16 895 Pressure Switch 1 9 16 958 04 Cable Assembly 8ft Enclosure Hook Up 1 10 16 958 05 Union Fitting 1 11 16 995 Motorized Control Valve 1 12 15 552 Manifold Ball Valve 1 13 16 183 Tee FPT1x1x1 1 14 16 955 Tubing 1 15 16 902 Cable Assembly 72 Solenoid Hook Up 1 16 33 271 Fuse Block 1 17 33 284 Auto Blade Type Fuse 5 amp 1 18 10 225 Wire Harness fuse block to electric valve 1 19 33 508 Auto Blade Type Fuse 15 Amp 1 16 852 203 Sprayer Control Kit includes all items Use Dielectric Grease On All Electrical Connections SA eJ 15 515 FLOW METER DRAWING M SUN 15 515 FLOW METER PARTS LIST M ES QUANTITY 2 2 2
44. 4GA Oilite Bushing part of 15 337 Nut 3 s 4 Lockwasher s Clutch Relay Bolt 2 13 x 23 4 Lock Nut 1 2 13 Ball Joint 24 Long Clutch Rod Nut 3 16 Interlock Switch Cotter Pin s x 1 Bushing part of 15 360 amp 15 341 Rubber Bumper Lockwasher Nut 1 4 20 Clutch Pedal Floor Board Pedal Pedal Pad Short Clutch Rod Lock Nut 2 13 Clutch Arm Grease Fitting 4 28 x 180 PART 15 482 HB 38 16 100 HWL 38 15 483 HN 516 18 HW 516 HB 38 16 125 HW 38 HNTL 38 16 15 481 20 008 16 830 HB 12 13 300 16 013 15 376 HMB 12 14 10 007 HN 38 24 HWL 38 15 337 HB 12 13 275 HNTL 12 13 21 173 15 348 HN 38 16 22 002 HP 18 100 20 019 15 013 HWL 14 HN 14 20 15 360 14 328 16 062 15 015 15 349 HNTL 12 13 15 341 HG 14 28 180 ENGINEAND CONTROL PANEL DRAWING ENGINEAND CONTROL PARTS LIST M SUN QUANTITY oa 00 0 APS AH th yy DESCRIPTION Engine Seat Cover Trim Boom Control Switch Switch Boot Control Panel Decal Control Panel Bolt 4 20 x 3 4 Washer 1 4 Lock Nut 4 20 Governor Linkage Arm Extension Spring Kohler 20 hp Command Engine Fuel Hose Hose Clamp Fuel Filter Bolt 3 s 16 x 13 4 Washer 3 Lock Nut s 16 Pulley BK72 x 1 s Machine Key 1 4 1 4 11 2 Pulley with Hub 1
45. 6 1 x 16 4 HWLM 6 Lockwasher M6 4 11 15 301 Orbitor 1 15 301 01 Seal Kit 12 18 309 Swivel Nut 1 FITTING TORQUE CHARTS Seal Lok Straight and Adjustable Fitting Steel Torque Ratings SAE Tube Tube Side Size 6 sie as 9 o To Pe ae a es 2 s Over tightened fittings will result crushing the cone which will create a leak Charts Developed by Parker Henniphin M lN WIRINGDIAGRAM MAIN WIRE HARNESS LOOKING AT TERMINALS 1 i 3 251 PLUG 8 GRN W R Ric FUEL Color Code Chart Bl Blue Br Brown Y Yellow Grn Green Orange Red Black Purple White Green amp White 2 5 0 FORWARD z ay POS 5 44 29 4 TU E 8 8 0 E Use dielectric grease on all electrical connections To reset circuit breaker on ball valve you must disconnect power to the computer Boom Lift Spray System Manifold Valve Foamer Hose Reel WIRINGDIAGRAM
46. 6 1 8958 Male Slide On Terminal 1 8963 Heat Shrink 2 N S 22 017 Cable Black transmission to frame 1 14 336 Main Wire Harness Includes all wire colors with 1 M BAN BODY FRAMEDRAWING BODY amp FRAME PARTS LIST PART DESCRIPTION QUANTITY 1 16 857 Front Tire amp Wheel 2 16 857 01 Tire 20 x 10 00 10NHS 4 2 16 857 02 Wheel 2 HNL 12 20 Lug Nut 1 2 20 10 2 10 180 Front Fender 1 3 14 350 Right Side Panel 1 14 349 Left Side panel 1 4 15 491 5 Gallon Gas Tank 1 15 492 Cap with Gauge 1 5 15 182 Cross part of 14 370 2 16 024 U Bolt Kit 4 HWL 516 Lockwasher 5 16 part of 16 024 8 HN 516 24 Nut 5 16 24 part of 16 024 8 6 16 883 Magnetic Sensor 1 7 14 370 Driveline complete 1 8 16 225 Rear Tire amp Wheel 2 16 225 01 Tire 24 x 13 00 12NHS 4 2 16 225 02 Wheel 2 HNL 716 20 Lug Nut 7 16 20 10 9 16 037 Axle with Brakes 1 10 14 353 Main Frame 1 11 15 315 Hydraulic Power Unit 1 15 315 01 Repair Kit 1 12 18 259 Cross 11 4 1 13 14 371 Strainer 1 14 15 521 Top Filter Bracket 1 15 16 998 Hypro Pump 1 16 14 322 Rear Tank Strap 1 17 14 326 Rear Engine Cover 1 18 10 180 Front Fender 1 19 15 356 Engine Cover Seat 1 20 14 270 Seat with Adjusters 1 21 14 321 Tank Carrier 1 22 14 328 Floorboard 1 23 13 718 Steering Wheel 1 13 726 Steering Wheel 1 24 14 327 Front Tank Strap 1 25 14 451 160 Gallon Poly Tank 1 26 14 365 Air Gap Filler 1 27 16 953 16 Hinged Lid Well
47. 8 and 16 921 cap are in the small parts bag SIN lt lt o0 IS 14 100 BOOM DRAWING 14 100 BOOM PARTS LIST M QUANTITY 10 18 AND DESCRIPTION Bolt M8 x 25 Nut M8 Arm Tie Bar Knob Left Hinge Bracket Flange Bushing 4 Plate Yoke Bolt M8 x 45 Boom Bracket Bolt 3 16 2 Lockwasher 6 Nut s 16 Boom Frame Pin D10 x 35 Flat Washer 2 Stud M12 Top Lock Nut M12 Right Hinge Bracket Flange Bushing 3 4 Bolt M8 x 50 Right Side Boom Boom Arm Yoke Bolt M10 x 25 Spacer Hinge Base Flat Washer 6 Bolt M8 x 60 Aluminum Ball Bearing Boom Washer Yoke Support 1 Hinge Ball D 25 4 Spring Ball Retainer Spring Center Boom Top Lock Nut M8 Left Side Boom Boom Arm Support Bracket Bolt 3 16 2 Center Lock Nut 3 16 Hinge Assembly 14 100 6 Meter Boom includes the 16 807 Nozzle Kit Raindrop Tips 14 101 6 Meter Boom includes the 16 806 Nozzle Kit TeeJet Tips PART HBM 8 25 HNM 8 16 770 16 775 16 790 10 025 16 774 16 782 HBM 8 45 16 761 HB 38 16 550 HWL 38 HN 38 16 16 791 16 784 HW 12 16 773 1 2 16 789 10 025 8 50 16 793 16 788 10 25 16 787 16 786 HW 516 HBM 8 60 16 785 16 781 16 783 16 780 16 779 16 778 16 792 HNTLM 8 16 794 16 212 HB 38 16 350 HNCL 38 16 16 914 REF
48. OM PARTS LIST M ax DESCRIPTION QUANTITY 26 33 302 Left Pivot Bracket 1 HMBS 100 10 Stainless Steel Machine Bushing 1 x 10GA 1 HMBS 100 14 Stainless Steel Machine Bushing 1 x 14GA 2 HRPS 14 150 Stainless Steel Roll Pin 11 2 2 27 16 024 U Bolt 5 16 24 2 HWLS 516 Stainless Steel Lockwasher 5 16 4 HNS 516 24 Stainless Steel Nut 5 6 24 4 28 10 311 Left Castor Wheel Bracket 1 18 035 Bushing part of 10 311 2 HG 14 28 180 Grease Fitting 2 8 x 180 part of 10 311 1 29 10 307 Left Brush Guard 1 30 15 013 Rubber Bumper 2 HWL 14 Lockwasher 1 4 2 HN 14 20 Nut 1 4 20 2 31 10 318 Grip Pad 4 32 10 316 Left Boom Holder 1 33 11 178 Linear Actuator 2 HCPS 12 200 Stainless Steel Clevis Pin 1 2 x 2 2 HPS 18 100 Stainless Steel Cotter Pin 1 8 x 1 2 34 HBS 38 16 125 Stainless Steel Bolt 3 8 16 x 11 4 8 HWS 38 Stainless Steel Washer 6 8 HNTL 38 16 Lock Nut 8 16 8 35 10 317 Right Boom Holder 1 36 Boom Carrier part of machine 38 10 330 Pivot Bracket 2 15 494 Nylon Flange Bushing 1 ID 2 per 10 330 4 18 036 Oilite Bushing ID 2 per 10 330 4 HG 14 28 180 Grease Fitting 28 x 180 2 per 10 330 4 HN 38 16 Nut 3 8 16 1 per 10 330 2 B HSSQS 38 16 150 Stainless Steel Set Screw 3 8 16 x 11 2 1 per 10 330 2 39 HBS 38 16 125 Stainless Steel Bolt 28 16 x 11 4 4 HWS 38 Stainless Steel Washer 3 8 4 HNTL 38 16 Lock Nut 8 16 4 40 10 303 Pivot 2 HMBS 58 14 Stainless Steel Machine Bushing x 8 HPS
49. PARTS LIST PART DESCRIPTION QUANTITY 1 34 146 Panel Mounted Circuit Breaker 1 34 145 Circuit Breaker Boot 1 2 8935 Buss Bar 1 3 13 288 Ignition Switch Kohler 25 099 04 part of engine 1 76 310 Key Set 1 4 16 882 Speedometer 1 8854 Fork Terminal 2 8963 Heat Shrink 2 5 14 332 Speedometer Ground Wire 1 6 16 883 Magnetic Sensor 1 7 14 333 Speedometer B Wire 1 8 8935 Buss Bar 1 9 14 331 Hour Voltmeter Ground Wire 1 10 12 017 Hourmeter 1 11 14 330 Hour Voltmeter B Wire 1 12 Oil Sender part of engine 13 Ignition Module part of engine 14 Fuel Shut Off Solenoid part of engine 15 Rectifier part of engine 16 Starter part of engine 17 50 323 Red Battery Cable 1 18 33 216 Battery 1 19 22 054 Ground Battery Cable 1 20 15 484 Wire Assembly Fuse Block To Bat on solenoid 1 21 15 485 Wire Assembly Fuse Block To Ground 1 22 33 271 Fuse Block 1 23 Wire With Fuse part of engine Fuse AGC 30 24 22 002 Interlock Switch 1 25 14 334 Ignition Switch Ground Wire 1 26 33 480 Pressure Switch 1 27 16 994 Hypro Pump With Electric Clutch 1 8958 Male Slide on Terminal 1 8963 Heat Shrink 1 28 15 457 Ground Wire 1 29 77 207 Buzzer 1 8849 3 Black Wire 1 8860 String Connector 1 8859 Ring Terminal 6 1 8853 Slide On Connector 1 8963 Heat Shrink 2 30 14 335 Spray Pump Switch B Wire 1 31 15 314 Toggle Switch 1 15 472 Switch Boot 1 32 50 359 Oil Warning Light 1 8850 12 Red Wire 1 8860 String Connector 1 8859 Ring Terminal 3 1
50. PTION Double Switch Box Fuse F10A 250V Switch Bolt 9 16 18 x 13 4 part of machine Lock Nut 5 6 18 part of machine Foamer Switch Bracket Bolt 9 15 18 4 part of machine Center Lock Nut 5 16 18 part of machine Park Brake Bracket part of machine Foamer End Bracket Foamer Cross Bar Foamer Center Bracket Bolt 5 1 18 x 1 Flange Whiz Lock Nut 5 16 18 Compressor Only Black Cover Foamer Tank Cap Assembly Blue Tube Clear Tube Extension Wire Tank Bracket Foamer 14 291 05 15 506 01 15 506 02 516 18 175 HNTL 516 18 14 431 HB 516 18 400 HNCL 516 18 14 393 14 286 14 288 14 287 HB 516 18 100 HNFL 516 18 14 291 03 14 291 01 14 291 05 14 284 02 10 222 14 291 04 14 291 1 Po oono B C D E G FOAM MARKER WIRING PARTS LIST DAN QUANTITY 4 aa ob c DESCRIPTION Compressor Wiring Harness Extension Wire Switch Box Fuse F10A 250V Switch Power Cable Fuse Block part of machine Auto Blade Type Fuse 10 amp PART 14 291 03 15 504 04 10 222 14 291 05 15 506 01 15 506 02 15 509 33 271 33 507 REF 1 2 3 4 O fe Fes 14 283 FOAM MARKER FOR 1600 DRAWING INSTALLATIONINSTRUCTIONS Safety Before working on machine stop engine set park brake remove key from ignition and block wheels Disconnect negative battery terminal 1 Remove
51. Pinion Lock Nut s 16 Frame Assembly Mounting Pillow Block Bottom Bearing Mounting Pillow Block Top Disc 2 Swivel Assembly 3 4 Seal Kit For 16 906 23 Bracket 12VDC Mount Bracket Bolt 5 16 18 x 13 4 Washer 6 Lock Nut 5 16 18 Electric Hose Reel only PART 16 906 25 16 906 22 HB 38 16 100 HW 38 16 906 27 16 906 21 12 015 HB 14 20 075 HWL 14 HN 14 20 33 251 16 906 19 HB 516 18 075 16 906 26 HWL 516 HW 516 33 252 HB 516 18 075 HW 516 HWL 516 HN 516 18 HNTL 516 18 HB 516 18 100 16 906 17 16 906 29 HNTL 38 16 16 906 18 16 906 08 16 906 24 16 906 07 16 906 20 16 906 23 16 906 30 16 906 28 16 980 HB 516 18 175 HW 516 HNTL 516 18 16 982 REF N loo 16 129 HOSEREELDRAWING 16 129 HOSE REEL PARTS LIST M QUANTITY DESCRIPTION Disc 171 2 Retaining Ring Axle Assembly 4 Bolt 3 16 x 1 Washer 3 Trim Drum Edge Drum Center Disc 17 1 2 Crank Side Lockwasher 5 16 Bolt 5 18 x 4 Crank Assembly 3 4 Brake Assembly 4 Lock Nut s 16 Lock Nut 5 18 Lock Pin Assembly Bolt 2 1 18 x 3 4 Washer 6 Frame Assembly Mounting Pillow Block Bottom Bearing Mounting Pillow Block Top Swivel Assembly 3 4 Seal For 16 906 23 Mount Bracket Bolt 5 16 18 x 13 4 Washer 6 Lock Nut 5 16 18 PART 16 129 11 16 906 25 16 906
52. SMITHED Wayne Pennsylvania 19087 PARTS amp SERVICE MANUAL Spray Star Model 1600 PRIME MOVER Starting Serial 1125 February 2006 SMITHCO PRODUCT SUPPORT 1 800 891 9435 Hwy SS and Poplar Avenue Cameron WI 54822 E mail productsupport smithco com CONTENTS Accessories Plumbing 1602 System Raven 440 Plumbing 1604 System Raven 203 Plumbing 1610P System Manual Controls 1602P System Raven 440 Control 1604P System Raven 203 15 515 Flow 16 524 amp 16 995 Motorized Control Valve 16 456 Flow 10 268 3 Way Manual Valve 14 348 Solenoid Valve 10 300 18 Terrain Following Boom 15 493 Stainless Steel 18 Auto Boom 15 577 Stainless Steel 18 Manual Boom 10 300 and 15 493 Boom Wiring Diagram Nozzle Assembly 14 100 Boorn 14 100 Plumbing amp 16 807 Nozzle Kit Plumbing Nozzle Kit Installation 14 101 Plumbing 8 709 420 Nozzle Plumbing Nozzle Kit Installation Turbo TurtJet TIPS teet XR TEEJET TIPS cocinada 16 906 Electric Hose 16 129 Hose Heel 14 311 Hose Reel Installation
53. STRAINER PARTS LIST REF PART DESCRIPTION QUANTITY 1 14 371 01 Head 11 4 Poly 1 2 16 968 02 Gasket 1 3 16 968 03 Screen 1 4 14 371 02 Bowl 1 M SIN 15 30 10RBITOR DRAWING xy 15 3010RBITOR PARTS LIST M SN QUANTITY N A A oo 2 DESCRIPTION O Ring Seal Quad Seal Bearing Kit Bearing Race Bearing 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 70 bar Housing Dust Seal Wear Plate Drive Spacer Gerotor O Ring Seal End Cap Cap Screw Seal Kit 1015 psi 70 bar 150 psi 10 bar 2007 93 4 gpm 15 1 m 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 15 301 01 15 301 ORBITOR SPECIFICATIONS Maximum System Pressure Maximum Back Pressure Maximum System Operating Temperature Maximum Flow Maximum Temperature Differential between 50 F 28 C 15 25 Ib in 100 psi tank pressure 2 3 Nm 7 bar 60 Ib ft 81 Nm None SAE 10W 40 API Service SJ or higher Motor Oil Yes 1015 psi 70 bar 91 18 SAE O Rin
54. To prevent damage to other electrical components on Dead p g p Battery Jumper Cable 1 unit being started make certain that engine is at idle speed before disconnecting jumper cables Use of booster battery and jumper cables Particular care should be used when connecting a ARNING booster battery Use proper polarity in order to prevent sparks y Je LE SHAFT DISASSEMBLY 1 After the wheel is removed remove the brake drum 2 Using 31 2 socket line up the hole in the axle shaft flange to remove the backing plate nuts which hold the axle shaft assembly to the axle 3 Toremove the axle shaft assembly grasp the axle shaft 4 Removeinner Axle shaft seal using puller as shown assembly with both hands the assembly includes axle Discard Seal and replace with new one at time of shaft oil seal brake assembly gasket bearing and assembly retainer and pull the axle shaft free 5 Place Axle shaft assembly in a vise Center punch the 6 Drill 51 hole in the outside of the retainer ring to a outside of the retaining ring depth approximately 3 4 the thickness of the ring Drilling Completely through retainer ring will damage the shaft AXLE SHAFT DISASSEMBLY CONTINUED JA A rts gt Dm 7 After drilling position chisel across the hole and 8 Support the axle shaft assembly in a suitable press strike sharply to break the ring Replace with a new Press on the
55. a ELECTRIC HOSE REEL WIRINGPARTS LIST DESCRIPTION QUANTITY 8843 132 Flexguard s ID 1 1 8919 144 10GA Red Wire 144 1 8901 Slide On Connector 1 2 16 979 Wire Switch to Solenoid Hot Terminal 1 3 33 251 Push Button Switch 1 4 16 978 Wire Switch to Solenoid Start Terminal 1 6 12 015 Solenoid 1 SOLENOID TERMINALS HN 516 24 5 16 24 Hex Nut 2 HN 10 32 10 32 Hex Nut 1 7 8931 144 10GA White Wire 144 1 8901 Slide On Connector 1 8 33 273 Auto Blade Type Fuse 30Amp 1 CONNECTION INSTRUCTIONS Route wire harness along side of tank and over to fuse block taking care to stay clear of moving parts or hot engine components Cut off excess wire and strip back s Place one 8963 heat shrink 1 4 x 11 4 on each wire before crimping 8901 slide on connectors to the red and white wires Connect the two wires to the fuse block first the red to the positive and the white to the negative Put the 33 273 auto blade type fuse 30 amp into fuse block 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 WARNING Use Dielectric Grease On All Electrical Connections ML SIN WIRINGDRAWING 14 283 FOAM MARKER FOR 1600P DRAWING 14 283 FOAM MARKER FOR 1600P PARTS LIST QUANTITY Na td Apo do DESCRI
56. alert for hidden hazards 6 Never operate equipment that is not in perfect working order or without decals guards shields or other protective devices in place Never disconnect or bypass any switch Carbon monoxide in the exhaust fumes can be fatal when inhaled never operate a machine without proper ventilation 9 Fuelis highly flammable handle with care 10 Keep engine clean Allow the engine to cool before storing and always remove the ignition key 11 Disengage all drives and set park brake before starting the engine 12 Never use your hands to search for oil leaks Hydraulic fluid under pressure can penetrate the skin and cause serious injury 13 This machine demands your attention To prevent loss of control or tipping of the vehicle A Use extra caution in backing up the vehicle Ensure area is clear B Do not stop or start suddenly on any slope C Reduce speed on slopes and in sharp turns Use caution when changing directions on slopes D Stay alert for holes in the terrain and other hidden hazards 14 Before leaving operator s position A Disengage all drives B 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 15 Keep hands feet and clothing away from moving parts Wait for all movement to stop before you clean adjust or service the machine 16 Keep the area of
57. bber covers on boom carriers 5 Place hose reel bracket inside the boom carrier tube on left side and outside on right side with arms pointing toward front of machine 6 Lower bracket until top hole in bracket lines up with hole in upright Bolt as shown Put hose reel on hose reel bracket with fitting on left side of machine Use four bolts 16 18 6 four 5 1 18 lock nuts to hold in place Tighten bolts 8 Put 18 249 barb fitting into hose reels side 9 Use 8887 90 hose to connect reel to ball valve clamp with 18 040 hose clamps 10 Use 22 075 nylon ties to tie hose to main feed hose 11 For1610P Remove pipe plug D Insert the bushing pipe nipple and ball valve Place the hose barb fitting into the ball valve and connect the hose See Figure 3 12 For1602P and 1607P Remove hose from elbow on throttling valve Remove throttling valve gauge and elbow Re assemble as shown in Figure 1 using parts C Assemble throttling valve with gauge and elbow into top of tee and reconnect the hose 135 For 1604P Remove hex plug from A and assemble as shown in Figure 2 Continued on next page DN SN ELECTRIC HOSE REEL WIRING DIAGRAM 1 8 HOSEREELADJ US TMENTS OPERATI ONAL CHECK Pull hose off drum at least one full revolution A clicking noise should be heard from locking mechanism Let the hose retract Pull the hose off until the first click is heard Drum should lock when the hose tension is r
58. ck 18 Strip and connect slide on connectors to each wire and use the heat shrink 19 Connect black negative wire to the ground and connect red wire to the positive 20 Insert 10 amp fuse into slot which red wire was attached to ML SIN 14 291 FOAM MARKER RAWING Wwe 14 29 1FOAM MARKER PARTS LIST PART DESCRIPTION QUANTITY 1 15 507 Foamer Tubing 2 2 14 291 02 Tank 1 3 14 291 01 Black Cover 1 14 291 03 Compressor 1 4 14 284 02 Cap Assembly 1 5 14 291 04 Tank Bracket 1 6 14 291 05 Double Switch Box 1 7 15 511 Foam Nozzle 1 8 15 510 01 Nozzle Mounting Rod 1 9 16 987 Foam Nozzle Mounting Kit 1 DN EN 15 505 MOTOR SUB ASSEMBLY DRAWING 15 505 MOTOR SUB ASSEMBLY LIST REF PART DESCRIPTION QUANTITY 1 Bolt 6 2 Head 1 3 15 505 01 Exhaust Manifold Gasket 1 4 Exhaust Manifold 1 5 Manifold Screw 8 6 15 505 03 Diaphragm 1 71 Piston 1 8 Brush Retainer 2 9 15 505 06 Brush 2 10 15 505 07 12 Volt Electric Motor 1 11 15 505 05 Stainless Steel Bearing 1 12 Block 1 13 Cover 1 14 Cover Screw 2 15 Exhaust Reed Valve 1 164 Washer 2 174 Split 1 184 Intake Valve Screw 1 19 Exhaust Valve 1 15 505 02 Intake Exhaust Valve Sub Assembly T 15 505 04 Intake Piston Sub Assembly al 15 5 11FOAM NOZA ESUB ASSEMBLY DRAWING SC 2 15 5 11FOAM NOZZLESUB ASSEMBLY PARTS LIST REF PART DESCRIPTION QUANTITY 1 Nut 1 21 Screw 1 31 Foam Nozzle Inlet Body 1 15 51
59. draulic hoses back up to pump 18 Locate red wire coming from rectifier on lower right front of engine Disconnect wire at coupler 19 Remove jack stands and lower machine if you have raised it 20 Route wire harness voltmeter to alternator over to steering column and under floorboard back to alternator Be sure harness is not touching any moving or hot parts Plug both connectors on to terminals on bottom of alternator 21 Connectremaining wire to terminal on back of alternator and other end to battery cable terminal on starter solenoid Be sure wires are not touching any moving or hot parts 22 Use nylon ties to tie wiring up and out of way 23 Putspray pump guard back on 24 Connect negative battery cable back up Make absolutely certain you are connecting positive to positive negative too negative while attaching power leads If you do not observe polarity damage will result to electrical WARNING components 25 Turn key on Look at voltmeter it should read 12 volts Turn key to start with engine cranking voltmeter should read 10 volts With engine running above idle voltmeter should read around 14 volts 26 With engine running park brake set and transmission in neutral check for hydraulic fluid leaks at pump hose fittings Correct if needed with engine off Do not check for leaks with our hand Use a narrow flat piece of wood to locate leaks WARNING Serious injury can occur from pressurized h
60. e a high quality detergent oil classified For Service SJ or higher oil Use no special additives with recom mended oils Do not mix oil with gasoline SAEViscosity Grades 10W 30 104 40 9W 20 5W 30 Starting Temperature Range Anticipated Before Next Oil Change DIRECTO VALVES 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 removing the valve from the sprayer HYPROPUMP 1 After use flush pump with clean water 2 Hypro diaphragm pumps come with oil in the crankcase Hypro recommends changing oil after 40 hours of break in operation and every three months or 500 hours whichever comes first Hypro recommends a high grade nondetergent SAE 30 weight oil 3 Forwinter storage or if a freezing condition will be encountered flush pump with a 50 50 mixture of water and antifreeze DIAPHRAGM AND VALVE REPLACEMENT 1 Occasionally debris can cause the valves to not seal properly or damage the O rings 2 Tocheckfor this remove the pump manifold With manifold removed valves can readily be removed and checked for debris or wear To replace valves or o rings refer to the Parts List for appropriate kits 3 Hypro recommends changing diaphragms every 500 hours or three months whichever comes first Drain the oil from the pump by removing drain plug Rotate
61. eal Silicon Carbide 1 8 16 966 06 Slinger Ring 1 9 16 998 06 Mounting Flange 1 11 16 998 07 Bolt 4 12 16 998 12 Ball Bearing 2 13 16 998 08 Key 1 14 16 998 09 Pump Shaft 1 15 16 822 20 Key 1 16 16 966 13 Bearing Retainer 1 17 16 998 10 Gasket 1 18 16 994 01 Clutch 1 16 967 Silicone Carbon Seal Kit When servicing the spray pump or filter all control valves must be shut off if there 1 liquid in the tank 16 03 7REAR AXLE DRAWING M DIN 16 03 7 AXLEPARTS LIST PART DESCRIPTION QUANTITY 1 16 510 Wheel Bolt 10 16 562 Lock Nut 2 2 16 511 Axle Shaft Left and Right 2 3 16 513 Oil Seal 2 4 Part of Brake Dust Shield 5 16 518 RTV Gasket Eliminator Loctite Brand As Required 6 16 515 Bearing 2 7 16 516 Wheel Bearing Retainer Ring 2 8 16 519 Oil Seal 2 9 16 495 Pinion Mate 2 10 16 496 Thrust Washer 2 11 16 494 Side Gear 2 12 16 493 Thrust Washer 2 13 16 501 Carrier 1 14 16 502 Oil Plug 2 15 16 503 Sleeve Spacer 1 16 16 504 Shim Set of 4 2 4 17 16 506 Bearing Cone 1 18 16 508 Oil Seal 1 19 16 816 Flat Washer 1 20 HNA 58 18 Axle Nut ss 8 1 21 HP 18 150 Cotter Pin s x 2 1 22 16 509 End Yoke 1 23 16 507 Shim 1 24 16 505 Bearing Cup 1 25 16 489 Drive Gear Screw 14 26 16 488 Shim Set of 4 4 6 27 16 487 Bearing Cone 2 28 16 492 Pinion Mate Shaft 1 29 16 486 Bearing Cup 2 30 Bearing Cap 31 16 484 Bearing Cup Screw 4 32 16 481 Vent Assembly 1 33 16 963 Bolt Kit Includes Bolt Washer and N
62. eeded 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 Insert 10 amp fuse into slot which has red wire attached to it CONNECTI NGTHECAP 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 5 cm 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 facing 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 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 cm and inserting blue and clear tubes for the left boom section 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 compre
63. emoved Continue pulling the hose no more than one revolution until no clicking is heard Hose should rewind when tension is removed SPRING TENSION ADJUSTMENT 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 Make sure spring is locked Disconnect inlet hose to permit the hose to go around the drum To adjust the spring tension add or remove the wraps of the hose from the drum one wrap at a time until the desired tension is obtained 1 2 3 4 ROLLER BRACKET ADJ USTMENT All hose reels are shipped with the roller bracket in the ceiling 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 HOSE REPLACEMENT PROCEDURE 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 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 Remove check ball from old hose and install on replacement hose Carefully keeping the tension on the hose pull the hose to release the locking mechanism Let the hose wind on the drum 1 e N T
64. end of the axle shaft until the wheel retainer ring when reassembly bearing and brake assembly is removed AXLE SHAFT ASSEMBLY 1 Inspect the shaft for possible damage In the following 2 Support the bearing assembly in a suitable press order place new oil seal brake assembly new grease packed bearing assembly with unit bearing rib ring toward fanged end of shaft on the axle shaft The retaining ring will be placed on the shaft later up 3 Press assembly until bearing is firmly seated against 4 Slide new retaining ring on the axle shaft and support axle shaft shoulder the shaft in suitable press 4 gt lt 8 AXLE SHAFT ASSEMBLY CONTINUED 5 Press the retaining ring firmly against bearing 6 Assembly new grease seal into housing to original depth After seal has been assembled grease lip of seal 7 Assemble bearing retainer bolts and new gasket 8 Start nuts on bolts by hand Tighten nuts a manner axle housing Then install axle shaft assembly into axle that assures the seal and bearing assembly are drawn housing Care should be taken not to damage gasket evenly into axle housing Use a torque wrench and oil seal and bearing Line up holes of brake assembly torque nuts to 16 20 ft Ib 21 27Nm and oil seal Push axle shaft as far as possible into axle housing SERVICE CHART Before servicing or making adjustments to the machine stop engine set park brak and
65. erial Number and Model Number Both numbers are needed when ordering parts The serial number plate on the Spray Star is located on the front left side of the main frame Refer to engine manual for placement of engine serial number For easy access record your Serial and Model numbers here WAYNE PENNSYLVANIA 19087 USA 610 688 4009 Fax 610 688 6069 0 YEAR OF O SERIAL NO kW hp MODEL NO 2 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 GENERALSAFEPRACTICES It is your responsibility to read this manual and all publications associated with this machine 2 Never allow anyone to operate or service the machine or its optional equipment without proper training and instructions Never allow minors to operate any equipment 3 Learn the proper use of the machine the location and purpose of all the controls and gauges before you operate the equipment Working with unfamiliar equipment can lead to accidents 4 Wear all the necessary protective clothing and personal safety devises to protect your head eyes ears hands and feet Operate the machine only in daylight or in good artificial light 5 Inspect the area where the equipment will be used Pick up all debris you can find before operating Beware of overhead obstructions and underground obstacles Stay
66. ext page PART HNJ 58 18 HWK 316 075 13 718 13 726 76 364 76 362 16 882 50 400 13 288 76 310 12 017 14 329 14 346 8803 8 HB 516 18 100 HW 516 HWL 516 HN 516 18 HB 14 20 100 HWL 14 HN 14 20 15 459 HB 14 20 250 HWL 14 HN 14 20 15 336 HB 516 18 100 HNTL 516 18 15 353 14 328 8803 16 25 199 18 309 18 306 15 301 42 187 77 207 HBM 6 1 16 HWLM 6 HSM 10 32 063 HWL 10 HN 10 32 8935 15 314 15 472 1 2 3 OND 10 12 13 14 15 16 17 18 19 Me 8 NOSECONEDRAWING NOSECONEPARTS LIST M DESCRIPTION QUANTITY 30 50 359 Warning Light see wiring for terminals 1 31 34 146 Circuit Breaker 30 Amp 1 32 34 145 Circuit Breaker Boot 1 33 HB 516 18 100 Bolt 9 16 18 x 1 4 HW 516 Washer 6 4 HNTL 516 18 Lock Nut 5 16 18 4 34 15 496 Brake Pedal 1 16 062 Pedal 1 15 015 Pedal Pad 1 35 10 200 Tower Plate 1 36 HSA 8 075 Tapping Screw 8 3 4 6 37 16 046 Extension Spring 1 38 HCP 14 075 Clevis Pin 1 4 x 3 4 1 39 17 153 Clevis 1 40 15 310 Throttle Cable 1 41 HB 14 20 100 Bolt 1 4 20 x 1 1 HWL 14 Lockwasher 1 HN 14 20 Nut 1 4 20 1 42 17 154 Cable Clamp 1 43 17 155 Retainer 1 HN 516 24 Nut 5 16 24 2 BRAKEDRAWING 5 2 i gy 10 A LAS Oo E 34 SN BRAKEPARTS LIST M SIN QUANTITY A A tl tl
67. f each wing lift frame will be two 14 bolts and lock washers to mount the columns with 2 Attach and route the 37 hose from the flow monitor to the appropriate sprayer solenoid Secure hoses with the plastic quick clamps Tie the hose in place along the lift frame with the supplied cable ties to avoid pinching or getting caught during folding 3 Attach and route hose from flow monitor to spray nozzle Take care to ensure that each column is routed to the appropriate spray nozzle 4 Testfolding of all sections of the sprayer for possible problems in the routing of the sprayer hose Continued on next page DN INSTALLATIONINSTRUCTIONS ELECTRICAL LIFT OPTION Attach electric actuators If the spray vehicle has the appropriate electric controls you may use these otherwise continue from step number 4 Hook these control up so that each switch moves the appropriate section and up and down in the direction indicated by the switch If a boom section moves in the wrong direction the electrical connector for that section will require swapping the incoming wires Mount the control box in an accessible spot near the operators seat Route the wires with the fuse link to the battery of the vehicle Place the red wire on the positive terminal and the blue wire on the negative battery terminal Tie wires securely in place away from excessive sources of heat or pinch points Route the three sets of wire from the control box to
68. fts Ref 31 using clevis pin and cotter pin Ref 27 so the bushing end hooks to the pivot bracket Ref 24 and the slotted end hooks to the actuator bracket Ref 20 and 22 6 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 boom The left hose from sprayer goes to straight fitting on left boom Be sure all clamps are tight 7 Use the adjustment slots on the boom lifts to completely lift and lower booms 8 Using set screws Ref A 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 9 To install boom carriers 15 328 and latch 15 437 see drawing The boom holders should point upward and latch pointing outward Use 8 32 x 11 2 machine screws nuts and washers to install latch to boom carriers 10 To put booms into boom carriers booms must be down Push booms towards front of machine and lift boom slightly to clear fenders Disconnect latch and put it over brush guard and reconnect 11 Putthe viton gaskets 16 800 Raindrop tips 16 805 and quick TeeJet caps 16 921 on the nozzle bodies 16 996 the three boom sections Z 22 12 Make certain set screws on both sides are completely screwed in and locked with the lock nut Switch Switc
69. g 4 28 x 180 Tie Rod Front Axle Grease Fitting 4 28 x 180 Machine Bushing 11 4 x 10GA Left Front Fender Bracket Rear Left Spindle Grease Fitting 4 28 x 180 Bushing part of 10 294 amp 10 295 Axle Nut 11 4 12 Machine Bushing 1 x 14GA Cotter Pin s x 2 PART 10 180 HBC 516 18 100 HW 516 HWL 516 HN 516 18 80 167 HNAR 100 14 11 043 80 019 11 041 11 042 HP 18 150 27 022 02 HNL 12 20 14 368 50 081 18 153 14 344 HB 516 18 125 HNTL 516 18 10 159 HBC 516 18 100 HW 516 HWL 516 HN 516 18 50 456 14 267 HCP 58 150 HP 18 100 18 171 HNA 100 14 HMB 100 10 HNJ 58 18 HB 58 11 250 18 154 HMB 58 14 14 367 HNTL 58 11 HB 516 18 125 HW 14 HNTL 516 18 14 356 16 076 16 565 HNM 12 125 10 295 HG 14 28 180 14 345 14 457 HG 14 28 180 HMB 114 10 14 357 10 294 HG 14 28 180 33 086 HNA 114 12 HMB 100 14 HP 18 200 REF Ws CLUTCHLINKAGE DRAWING CLUTCH LINKAGEPARTS LIST M QUANTITY As Required A tl dl 20 DESCRIPTION Part of Main Frame Bottom Mount Bracket Bolt 3 s x 1 Lockwasher s Top Mount Bracket Nut 5 16 18 Washer 5 16 Bolt 3 s 16 11 4 Washer 3 Lock Nut s 16 Belt Guard Eye Bolt 9 16 18 Spring Bolt 1 2 13x 3 Idler Pulley Clutch Arm Spacer Machine Bushing 2 x 1
70. g 4 Ports 61 cu in R 100 cu cm R Steering Unit and System Input Torque Powered Input Torque Maximum Non powered Rotation Limits Fluid Check Valve for Manual Steering Relief Valve Setting Ports Displacement 15 409 3 SPEED TRANSMISSION DRAWING 15 409 3 SPEEDTRANSMISSIONPARTS LIST PART DESCRIPTION QUANTITY 1 16 1 3 s detent 2 21 16 342 Poppet Spring 2 31 16 348 Low Reverse Shift Fork 1 4 16 343 Rail Pin 2 16 344 Shift Spring 1 6 16 308 Pin 1 7 HWL 516 Lockwasher 5 16 7 8t HB 516 18 075 Bolt 5 16 18 x 3 4 7 9 15 458 Shift Lever 1 101 16 259 Shift Knob not included with 15 409 1 16 011 Decal Shift not included with 15 409 1 11 16 301 Transmission Housing Cover 1 121 16 039 Rubber Rain Dust Boot not included with 15 409 1 131 16 340 Plug Cap 4 14 16 302 Housing Cover Gasket 1 15 16 330 Top Shifttype Case 1 16 16 313 Seal M S rear 1 17 16 004 Yoke 1 18 16 306 Washer M S 1 19 HWL 34 Lockwasher 3 4 1 20 16 307 Nut 1 21 16 336 Drain Fill Plug 2 221 16 337 High amp Inter Shift Fork 1 231 16 338 High amp Inter Shift Rail 1 247 16 339 Low amp Reverse Shift Rail 1 25 16 351 Syncro Snap Ring 2 26 16 352 Syncro Hub 1 27 16 350 Shift Plate 3 28 16 908 Sleeve 1 29 16 054 Tran Bearing Housing not included with 15 409 1 16 008 Bearing part of 16 054 1 HB 38 16 125 Bolt 3 11 4 3 8 Washer s 3 30 16 218 Gasket not included with 15 409 1
71. g of the main lift frame Lock the pivot arm into place by tightening the bolts and locking with the jam nut 7 Attach center actuator For this step it will help to have someone to hold the main frame level or support the boom with blocks so the actuator can be pinned easily 8 Begin by pinning the rod end of the actuator to the center actuator mount plates on the lift frame Use the center hole NOTE sure there is a spacer on each side of the center actuator shaft otherwise severe damage could occur to the actuator 9 Pin the motor end of the actuator to the main frame Locate the motor above the rod of the actuator for clearance LEVELSPRAYER 1 When all three booms in the spray position adjust the booms to be level with the ground Loosen the four nuts holding the center actuator pin plates and adjust position by sliding plates on slot and tighten securely NOTE Center actuator should be fully retracted while adjusting 2 Ifyou require more range than sliding the plates can give use the next hole in the plate If further adjust ment is required the right and left plates may be swapped giving further range PLUMBING 1 Attach flow meter columns 2 Thecenter column assembly attaches on the solenoid bar at the rear the vehicle The center flow indicator has the necessary nut and bolt in the backing plate WING FLOW METERS 1 The flow indicator for each wing attaches to the wing lift frame for that wing On the back o
72. h BOOM WIRING DIAGRAM for 10 300 15 493 Booms lool Fuse Block Ground Hot E M UN for 10 300 15 493 Booms BOOM WIRING PARTS LIST DESCRIPTION QUANTITY 8853 Female Spade Connectors 2 15 472 Switch Boot 2 11 178 Linear Actuator with 4 stroke 2 16 755 Switch 2 16 810 Wiring Harness for Spray Star 1600 1 33 190 Wiring Harness for Spray Star 3000 1 22 075 Nylon Tie 10 33 273 Fuse 30 amp 1 Use Dielectric Grease On All Electrical Connections NOZZLE ASSEMBLY PARTS LIST PART DESCRIPTION QUANTITY 17 16 920 03 O Ring 1 2 16 920 05 Diaphragm Teflon Optional 1 3 16 920 06 Diaphragm EPDM Rubber Standard 1 4 16 798 Chemsaver End 1 5 16 800 Gasket Viton 1 6 16 921 Cap 1 7 15 588 Turbo Turf Jet Tip 8 1 2 16 996 Body 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 51 cm apart on the right left and center tubes There are predrilled holes in all tubes The Nozzle should be at a 45 angle to the ground for proper application For all 18 Booms The eleven 16 996 bodies are installed on the boom sections The eleven 16 800 viton gasket 15 588 Turbo Turf Jet Tip 8 and 16 921 cap are in the small parts bag For all 15 Booms The nine 16 996 bodies are installed on the boom sections The nine 16 800 viton gasket 15 588 Turbo Turf Jet Tip
73. ide of tank back of Tank Hang From Steering Wheel Seat Panel Tank Sides Shift Knob Pump Guard Strainer Bracket Left Front Tank In Front of seat Left Side Dashboard by Steering Column Under Seat Cover Left and Right Side Panel Right Exhaust Guard Right Side of Frame Next to Muffler Below Gas Tank Engine Side Front Tires Rear Tires Front Nose Cone Main Frame Steering Wheel Left Exhaust Guard by Dipstick Left Side Frame by Oil Reservoir Multiple Warning Sprayer Dash Control Panel Tank Volume Side Tank Volume Back Hang Tag Spray Pump Spray Star 1600 Shift Knob Moving Parts Hot Bowl 8 Screen Tank Flush Not a Motor Vehicle Caution Steering Safety Warning Pinch Point Warning Hot Gas Refuel Engine Speed Tire Pressure 18PSI Tire Pressure 20PSI Smithco Technical Assistance Smithco Round Hydraulic Oil Oil Filter Kohler 12 050 01 Air Cleaner Kohler 47 083 03 Pre Cleaner Kohler 24 083 02 Fuel Filter Key Switch Kohler 25 099 04 Key Set Foot Clutch Belt Spray Pump Belt Hydraulic Pump Belt Hydraulic Power Unit Repair Kit Power Steering Orbital Motor Seal Kit Hydraulic Cylinder Seal Kit Linear Actuators Seal Kit Brake Master Cylinder Brake Master Cylinder Repair Kit Dot 3 SAE 10W 40 API Service SJ or higher Motor Oil 10W 40 API Service or higher Motor Oil 80W 90 Gear Lube Service GL 5 GL 4 Hinged Cover On Tank with Gasket Gas
74. inless Steel Bolt s 16 x 5 2 Lock Nut s 16 Boom Brackets U Bolt 9 16 24 Stainless Steel Lockwasher Stainless Steel Nut 5 16 24 Barb Fitting Hose Clamp Stainless Steel Pipe Elbow 3 4 x 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 part of 33 306 Right Center Tube Bracket Stainless Steel Bolt s 16 x 11 4 Stainless Steel Washer 9 Lock Nut s 16 Center Tube Right Actuator Bracket Stainless Steel Bolt 3 s 16 x 11 4 Stainless Steel Washer 6 Lock Nut s 16 Center Mount Stainless Steel Set Screw s 16 x 11 2 part of 33 329 Nut s 16 part of 33 329 Left Actuator Bracket Stainless Steel Bolt 38 16 11 4 Stainless Steel Washer 3 Lock Nut s 16 Left Center Tube Bracket Stainless Steel Bolt 38 16 11 4 Stainless Steel Washer 3 Lock Nut s 16 Pivot Bracket Nylon Flange Bushing part of 33 295 Oilite Bushing part of 33 295 Stainless Steel Set Screw s 16 1 2 Nut 3 s 16 Stainless Steel Roll Pin Left Pivot Bracket Stainless Steel Clevis Pin 1 2 4 Stainless Steel Cotter Pin ys x 1 Pivot Machine Bushing s x Stainless Steel Cotter Pin s x 1 Stainless Steel Bolt s 16 x 11 4 Stainless Steel Washer s Lock Nut s 16 Continued on next page PART 16 926 13 498 16 928 33 333 33 332 HBS 38 16 550 HNTL 38 16 16 761 16 024 HWLS 516 HNS 516 24
75. ket For Cover Spark Plugs Champion type RC12YC Gap 0 040 inch 1 02mm QUICK REFERENCE REPLACEMENT PARTS REPLACEMENT FILTERS 78 090 78 088 78 089 50 403 13 288 76 310 REPLACEMENT BELTS 16 827 16 869 15 320 SEAL KITS 15 315 15 315 01 15 301 15 301 01 50 456 14 267 11 158 and 16 754 11 158 01 50 123 50 123 02 FLUIDS Brake Fluid Engine Oil Hydraulic Fluid Rear Axle Fluid OTHER PARTS 16 953 16 953 01 DAN 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 claims must be handled through a SMITHCO authorized dealer or by SMITHCO INC All transportation charges must be paid by the purchaser There 1 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
76. ng Ring Steel 1 6 16 879 11 Diaphragm Viton Rubber 1 7 14 348 06 Seat Washer Retainer Stainless Steel 1 8 14 348 07 Seat Washer Viton Rubber 2 9 14 348 08 Spacer Stainless Steel 1 10 14 348 09 Body Polypropylene Black 1 11 14 348 10 Stem Stainless Steel 1 12 14 348 11 Washer Stainless Steel 1 13 16 879 12 Lower Diaphragm Piston Stainless Steel 1 14 16 879 13 Lower Diaphragm Housing 1 15 14 348 12 Screw Stainless Steel 4 16 16 879 14 Connecting Nipple Nylon Black 1 14 348 01 Single Unit 3 T 14 348 13 Spare Parts Kit 1 M YN 11 178 Linear Actuator Ref 33 11 158 03 Motor 12VDC ex 10 300 18 TERRAIN FOLLOWING BOOM DRAWING 10 300 18 TERRAIN FOLLOWING BOOM PARTS LIST DESCRIPTION QUANTITY 1 13 498 Muffler Clamp 2 HWL 516 Lockwasher 5 16 4 HN 516 18 Nut 9 18 18 part of 13 498 4 2 42 539 Lynch Pin 2 3 29 584 1 2 Spacer 4 4 16 926 Stainless Steel Cap 3 5 29 585 1 Spacer 4 6 10 312 Castor Fork 2 100 10 Machine Bushing 1 x 10GA 3 per fork 6 7 42 202 Tire and Wheel 2 42 202 01 Tire 2 42 202 02 Wheel 2 8 42 213 Axle Bearing 2 9 42 212 Castor Wheel Spacer 4 10 HBS 12 13 600 Stainless Steel Bolt 1 2 13x 6 2 HNTL 12 13 Lock Nut 1 2 13 2 11 10 310 Right Castor Wheel Bracket 1 18 035 Bushing part of 10 310 2 HG 14 28 180 Grease Fitting 28x 180 part of 10 310 1 12 HBS 38 16 175 Stainless Steel Bolt 9 8 16 13 4 4 HNTL 38 16 Lock Nut 3 8 6 4
77. normally produce explosive gases which can cause personal injury Do not allow flames sparks or any ignited objects 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 charg ing 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 AN 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 WARNING of water Get medical attention immediately JUMP STARTING To jump start negative grounded battery Shield eyes Disconnect computer supply leads Connect ends of one cable to positive terminals of each battery first A then B Engine D 4 Connect end of other cable to negative terminal of good battery C Booster Battery 5 Connect other end of cable D to engine block Jumper Cable 2 on unit being started NOT to negative terminal of battery or 5 o
78. operation clear of all bystanders 17 Never carry passengers 18 Stop engine before making repairs adjustments or checking adding oil to the crankcase 19 Use parts and materials supplied SMITHGO only Do not modify any function or part 20 Use caution when booms are down as they extend out beyond the center line of the machine approxi mately 10 ft 3 m 21 Thetankis a confined space take precaution 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 as to the suitability for any task is expressed or implied A Da SPECIFICATIONS SPRAY STAR 1600P 112 285 cm 61 155 cm Width With Booms Down 230 584 cm 50 127 cm Height With Booms Up 126 320 cm 60 152 cm 1200 Ib 544 kg Weight Loaded 2500 Ib 1134 kg 84 dB 82 dB 68 dB 70 dB Kohler Command CH20S 64558 20 hp 15 kW Unleaded 87 Octane Gasoline Minimum Air cooled Full pressure 25 Amp Front 2 20 x 1000 x 10 Multi rib 20 psi 1 4 bar Rear 2 24 x 1300 x 12 Super Soft 18 psi 1 3 bar Ground Pressure 8 2 psi with 160 gallons 1st gear 0 3 m p h 0 5 kph 2nd gear 2 6 m p h 3 10 kph 3rd gear 4 10 m p h 6 16 kph 0 3 m p h 0 5 kph Automotive type 24F 12 volt Size 24 575 minimum Negative 10 25 26 cm 6 88 17 cm 10 25 cm 2 1 quart 2 liters with filter 5 gallon 19 liters
79. ore servicing or making adjustments to machine stop engine and remove key from ignition When servicing the spray pump or filter all control valves must be shut off if there is liquid in the tank CAUTION 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 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 TD LUBRICATION Use No 2 General purpose Lithium Base Grease and lubricate every 100 hours The Spray Star 1600P has 7 grease fittings A One onthe rod end of hydraulic cylinder B Oneon each the right and left spindles C One on the front axle D One on clutch idler arm each end of the drive line AIR CLEANER 1 Loosen cover retaining knob and remove cover 2 Remove precleaner from paper element 3 Check paper element Replace element as necessary 4 Wash precleaner in warm water with detergent Rinse precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow precleaner to air dry 5 Saturate precleaner with new engine oil Squeeze out all excess oil 6 Reinstall precleaner over paper element 7 Reinstall air cleaner cover Secure cover with
80. orward M AN 1602P PLUMBING DRAWING RAVEN 440 1602P PLUMBING PARTS LIST A QUANTITY HAH AH DESCRIPTION Pump Liquid Filled Gauge Throttling Valve Spare Parts Kit for 16 034 Elbow 3 4 MPT x 1 HB Discharge Hose 1 Hose Clamp 16 x 1 2 Reducer Bushing 1 2 x 11 4 Elbow 11 4 Discharge Hose 1 Hose Clamp 11 2 Discharge Hose 11 4 Hose Clamp HS 24 Barb Fitting Flow Meter Discharge Hose 11 4 Hose Clamp HS 24 Reducer Suction Hose 11 4 Hose Clamp HS 24 Fitting 1 4 MPT x 11 4 HB Strainer Fitting 1 MPT X 11 4 HB 45 Elbow 1 FPT x 1 MPT Motorized Control Valve Reducer 3 4 FPT x 1 MPT Manifold Ball Valve Steel Mount ing Bracket comes with 15 552 Pipe Plug U Bolt Lock Nut 4 20 Washer 1 4 Orange PVC Hose 4x 341 2 to right boom Hose Clamp HS 12 Orange PVC Hose 4x 28 to center boom Hose Clamp HS 12 3 4 90 Hose Barb comes with 15 552 Clip O Ring Orange PVC Hose 4x 42 to left boom Hose Clamp HS 12 Raven 440 Computer with Accessories includes all items PART 16 998 16 281 16 034 16 034 01 16 155 8896 33 18 222 16 825 15 385 8896 42 18 222 8897 15 18 116 16 161 18 373 8897 30 18 116 16 973 8889 22 18 116 16 161 14 371
81. ozzle Slide wing nut back to the threads and hand tighten Follow the same steps for the clear tube and tube nut 6 Route the tubing along underside of main frame using tie downs as necessary 7 Install opposite ends of air liquid tubes to compressor again cutting back the oversleeve approximately 2 5 cm and inserting blue and clear tubes for the left boom section into the tubing connectors Ref A on the right side of compressor as far as possible 8 Follow the same steps for the right boom tubing Notice the right boom is inserted into left side of compressor To release tubing from compressor hold black ring around tubing and pull tube out 9 must be routed on bottom of the boom square tubing 10 Mark 6 inches in from inside edge of foamer nozzle mounting bracket on square boom tubing 11 Place hose guard Ref 1 flush with top of square tubing with edge on previous mark The channel covers hoses on the bottom of the square tubing 12 Install hose guard using 2 drill screws you may want to drill a 3 pilot hole first 13 Place another hose guard against first and install in same manner 14 Repeat process for other boom side 15 Connect small plastic electrical plug under compressor to electrical extension cable 16 For Spray Star 1600 route extension cable under engine along the mainframe cross bar using tie downs as necessary 17 Cut cable and strip casing allowing enough length to connect to fuse blo
82. plets 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 Available in stainless steel and hardened stainless steel in 80 and 110 tip spray angles with VisiFlo color coding RECOMM ENDED OVERLAP Adjust nozzle spray height to overlap 3096 of each edge of pattern NOZA E HEIGHT 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 M 16 906 ELECTRIC HOSEREEL DRAWING M oJ 16 906 ELECTRIC HOSE REEL PARTS LIST M SIN QUANTITY ARAL 00 5 DESCRIPTION Retaining Ring Axle Assembly Bolt 7 16 x 1 Washer s Trim Drum Edge Drum Center Solenoid Bolt 4 20 x 3 4 Lockwasher 1 4 Nut 4 20 Switch Disc and Gear Assembly Bolt 5 16 18 x 9 4 Pipe Cap 3 4 Lockwasher 5 16 Motor 12VDC Washer 5 16 Switch and Solenoid Brkt Bolt 5 46 18 x 3 4 Washer 6 Lockwasher 6 Nut 5 16 18 Lock Nut 5 16 18 Bolt 5 16 18 x 1 Key Set Screw
83. py DESCRIPTION Brake Lever Bolt 3 s 16 13 4 Washer 6 Lockwasher s Bolt 3 s 16 x 13 4 Washer 6 Lockwasher 6 Nut 3 6 Yoke Nut 5 16 24 Brake Rod Clevis Pin 1 Cotter Pin x 1 Park Brake relay Bellows Brake Pedal Spring Bracket Right Brake Cable Right Brake Assembly comes with 16 037 Brake Line 9 16 x 12 steel Tee Rear Axle Brake Line 3 16 x 34 steel Brake Drum comes with 16 037 Left Brake Assembly comes with 16 037 Left Brake Cable Brake Line 9 16 4 Brake Cylinder Cap Master Cylinder Brake Master Cylinder Kit Bolt s 16 x 4 Lock Nut s 16 Brake Rod Brake Bracket Bolt s 16 x 11 2 Lock Nut s 16 Cotter Pin s x 1 Bushing comes with 15 496 Extension Spring Brake Pedal Bolt ys 16 x 1 Lock Nut s 16 Pedal Pad Pedal Clevis Pin 5 16 x 11 4 comes 60 106 Cotter Pin s x 1 Washer PART 60 106 HB 38 16 175 HW 38 HWL 38 HB 38 16 175 HW 38 HWL 38 HN 38 16 11 100 HN 516 24 15 347 HCP 516 100 HP 18 100 15 331 60 536 15 354 14 338 16 554 16 187 18 089 16 037 16 188 16 559 16 514 14 339 15 312 50 123 50 123 01 50 123 02 HB 38 16 125 HNTL 38 16 16 060 15 497 HB 38 16 150 HNTL 38 16 HP 18 100 20 019 11 050 15 496 HB 38 16 100 HNTL 38 16 15 015 16 062 HCP 516 125 HP 18 100 HW 516 REF 1 2 E
84. r Window Made of Lexan 12 Volt Single Speed Front Intake Fresh Air Induction With Replaceable Charcoal Filter 3 Speed Blower Dual Wheel 235 CFM 12 Volt Directional Air Flow Control 2 Large Easy Access Doors Made Of Y Lexan Tubular Steel Satin Black Finish Foam Rubber Head Liner In Line Fuse Protected 78 On Machine connect the lead wire from the accessories Red to positive and black too negative Windshield Windshield Wiper Filter Blower Doors Frame Overall Height N AV 7 9 6 OPERATOR S PROTECTIVEENCLOSUREINSTALLATION Remove cab from shipping pallet Carefully remove band holding doors closed and save Bands must be used to keep doors closed when in transport Park Spray Star on a level surface set park brake and remove key Remove two screws from rear of engine cover furthest from seat With three to four people lift cab over front of machine and move it to rear until lower cross member of cab comes into contact with front bumper Lower cab until front rests on tow hook and back on the rear engine cover 5 Center cab left to right Clamp cab to front bumper of Spray Star Make sure that it is still centered Using mount holes cab as guides drill two 3 32 holes through both walls of bumper 6 Bolt cab to bumper On left side of Spray Star place loom clamp with loop pointing down and a 3 washer toward outside put a 16 x 21 2 bolt
85. rne debris is present replace air cleaner parts if very dirty Remove cooling shrouds and clean cooling areas more frequently under extremely dusty dirty conditions 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 Gap 0 40 1 02 mm Torque to 18 22 ft Ib 24 4 29 8 Nm adverse conditions such as dirt mud or extreme temperatures maintenance should be more frequent 10 END USER S SERVICE CHART very 500 Hours Yearly s Required 00 Hours 00 Hours 50 Hours 00 Hours 00 Hours gt gt A 5 2 SEngneOllFiter Engine for Leaks and Loose Pats Air Cleaner Paper Elemen Pre Cleaner Every 25 hours SprPus ldeSped Ar Cooling System J Belts and Hoses TrePesue 0 Fuel Level J Fuel Filter Hydraulic Ol Hydraulic Oil Filter YO Hydraulic System for Leaks and Loose Pats BatteryElectroyteLevel Clean Battery Terminals t Torque Lug Nuts Rear Axle Gear lube 0 0
86. s 16 Stainless Steel Roll Pin 4 x Left Pivot Bracket Pivot Stainless Steel Machine Bushing 5 8 14 Stainless Steel Cotter 1 Stainless Steel Bolt 3 16 x 11 4 Stainless Steel Washer 3 Lock Nut ys 16 Pivot Bracket Nylon Flange Bushing part of 33 295 Oilite Bushing part of 33 295 Stainless Steel Set Screw s 16 x 11 2 Nut 3 16 Stainless Steel Clevis Pin z 4 Stainless Steel Cotter Pin s x 1 Continued on next page PART 16 926 13 498 16 928 33 333 33 332 HBS 38 16 550 HNTL 38 16 16 761 16 024 HWLS 516 HNS 516 24 18 249 16 925 33 301 HMB 100 14 HMB 100 10 15 495 33 306 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 HSSQS 38 16 150 HN 38 16 33 331 HBS 38 16 125 HWS 38 HNTL 38 16 33 309 HBS 38 16 125 HWS 38 HNTL 38 16 HRPS 14 150 33 302 33 305 HMBS 58 14 HPS 18 100 HBS 38 16 125 HWS 38 HNTL 38 16 33 295 15 494 18 036 HSSQS 38 16 150 HN 38 16 HCPS 12 225 HPS 18 100 1 U OP 23 24 26 27 28 HSM 8 32 150 15 437 REAR FENDER P HSM 8 32 150 HN 8 32 HWL 8 HN 516 18 15 328 Spray Star 1600 HB 516 18 125 HWL 516 BOOM CARRIER DRAWING 9 1 5 N fe 7 B gt NY DS 1 2 No N 15 493 STAINLESS STEEL 18 AUTOBOOM DRAWING
87. s the swirling action of the liquid so that the fewer driftable lines are discharged from the secondary orifice Spraying Pressure 25 75 PSI 1 5 5 bar NOZAETILT Delavan s extensive research on spray patterns has proven that a tilt of about 45 for flood Nozzles or tips 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 NOZA EHEI GHT Adjust spray height in the field to overlap a minimum of 30926 of each edge of pattern Adjust nozzle height until this is achieved If a decision to tilt the nozzle is made do it before measuring the width of the spray on the ground and adjusting nozzle height See example below DRIFTABLEFINES PRODUCED 0 5 gpm at 40 psi Nozzle Percent of Spray Volume 5 gpm Output less than 200 microns Turbo TurfJet 196 4 xy ES 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 dro
88. set screws 10 Make certain set screws B on both sides are completely screwed in Raise booms with boom switches all the way up adjust set screws A so they contact the stop 11 To install boom carriers 15 328 and latch 15 437 see diagram The boom holders should point upward and latch pointing outward Use 8 32 x 11 2 machine screws nuts and washers to install latch to boom carriers 12 To put booms into boom carriers booms must be down Push booms towards front of machine and lift boom slightly to clear fenders Disconnect latch and put it over brush guard and reconnect Vax 15 577STAINLESS STEEL 18 MANUAL BOOM DRAWING 1 1 1 POS 1 9 1 Ir SS p un 4 N ES AG ES 7 aN 592 J OY gat 3 NS 5 _ Y 7 4 SS gt 2 AEN gt 3 RIZ 1 y 6 ASA XA A Dm SIS ES M NIN 15 577STAINLESS STEEL 18 MANUAL BOOM PARTS LIST ML QUANTITY 3 OR N N N FH 2 NNN 09 DESCRIPTION Stainless Steel Cap 4 U Bolt Kit Right and Left Boom Tube Left Brush Guard Right Brush Guard Boom Carrier part of the truck Sta
89. spective fittings using hose clamps 18 040 The hose coming from the right side of the sprayer goes to the straight fitting on the right boom The center hose from the sprayer goes to the straight fitting on the center boom The left hose from the sprayer goes to the straight fitting on the left boom Be sure all hose clamps are tight Now install the wiring harness Refer to the wiring diagram Lower the booms so that the ends are at a height that you can work at Put the left castor wheel bracket Ref 28 onto the left boom as shown Using two 3 16 x 134 bolts and lock nuts Ref 12 and one u bolt two ss stainless steel lockwashers and stainless steel 5 24 nuts Ref 27 Repeat for the right boom with the right castor wheel bracket Ref 11 using the same hardware 10 Putthe assembled castor forks into the castor wheel brackets adjusting the spacers to get the boom height you desire 11 Make certain set screws Ref B on both sides are completely screwed in Raise booms with boom switches all the way up Adjust set screws Ref B so they contact the stop and lock 12 Install center stabilizer mount Ref 45 onto center boom Ref 20 with the s 16 x 3 bolt washers and lock nuts 13 Place stabilizers Ref 46 into pivot brackets Ref 38 with5 8 11 x 3 bolts machine bushings and lock nuts Ref 47 Place rod end of stabilizers into center stabilizer mount Make sure all bolts are tight We do not recommend putting these
90. ssor To release tubing from compressor hold black ring around tubing and pull tube out DN MS aS TUBING ROUTE FOAMER NOZZLEMOUNT amp HOSEGUARD MOUNT DRAWING 14 283 FOAM MARKER PARTS LIST REF PART DESCRIPTION QUANTITY 1 15 537 Foamer Hose Guard 31 2 10 256 Foamer Hose Guard 16 2 HSDPS 14 075 Stainless Steel Pan Head Drill Screw 4 8 2 16 987 Foam Nozzle Mounting Kit 1 per boom 3 15 507 Foamer Tubing 2 4 Clear Tubing 5 15 511 Foam Nozzle 2 6 Blue Tubing 7 15 510 01 Nozzle Mounting Rod 2 8 Boom 9 16 795 Square Clamp 4 INSTALLATIONINSTRUCTIONS Slide hose clamp onto drop tube of foam nozzle and attach restrictor bell 2 Place splined end of Nozzle mounting rod Ref 7 into top of foam nozzle Ref 5 Tighten screw 3 Slide two foam nozzle mounts Ref 2 onto the rod Place square clamps Ref 9 on foam nozzle mounts and mount the square clamps to the boom Ref 8 Adjust foam nozzle mounts and clamps so nozzle assembly will clear end of boom Tighten foam nozzle mounts and square clamps to prevent side to side movement Do the same to the other side 4 Being careful not to cut the tubing Ref 3 cut the oversleeve back approximately 2 5 cm to expose blue Ref 6 and clear tubing Ref 4 5 Remove blue wing nut from top connector of foam nozzle and slide it on the blue tube with the threads facing toward end of tube Slide blue tube all the way over the top of the small tube on foam n
91. the electric actuators The red and black pair of wires go to the right wing The green and black wires go to the center actuator The Yellow and black wires go to the left wing 1 2 CURTAIN INSTALLATION Attach curtains to booms while in the transport position Use generous amounts of lubricant on the end or top of the curtain Spray silicone recommended Start by placing one end of the curtain into the slot at the middle rear of the shield Slide the curtain through the slot Take care to keep feeding curtain into the slot from the start point otherwise the curtain will come out at the start point Pull curtain until the start of the curtain meets and overlaps with the end of the curtain by 1 2 If the curtain has excess length double check that the curtain has not been pulled too tight and is putting extreme stress on the curtain and shield If the curtain is to tight keep feeding curtain either forwards or backwards to release tension so the curtain hangs straight Turn curtain support straps on underside of boom down so they are pointing at the ground These give the curtain extra support in the event of severe wind conditions Repeat for the remaining boom sections 1 xy e DECAL LIST This is a list of decals located on the Spray Star 1600P Part number description and location will help in reor dering decals Right Side of Seat in Front of Controls Facing Operator Dashboard Control Panel S
92. up and elbow and fill plug facing you Set new pump mount plate on pump with the both slots to the left and the slot on the end away from you 10 Bolt pump mount plate to pump with heads of the bolts up against plate 11 Put pulley on pump shaft be sure the woodruff key is in place With hub away from pump mount plate and 1 18 inch of clearance between pulley and heads of bolts Tighten set screws 12 Put ys 16 x 23 4 bolt in hole on right side furthest from you with head on same side of pump mount plate that the pump pulley is on Place alternator long boss part on bolt using s 16 top lock nut to snug it up 13 Place alternator adjustment bracket on pump mount plate on same side as alternator Use one 5 16 18 x 1 4 bolt 5 s lockwasher and 16 18 nut with head of bolt on pump mount plate Just snug up 14 Use the other 16 18 x 11 4 bolt with a washer over slot to bolt alternator adjustment bracket to alternator with a 5 s lockwasher and e 18 nut Just snug up N INSTALLATIONINSTRUCTIONS CONTINUED 15 Bolt pump mount bracket with pump and alternator to back side of angle on frame that the old one came off of Center slots and tighten 16 Place new belt around pulleys on engine pump and alternator Adjust belt tension by pivoting alternator so there is inch deflection on belt in middle of longest span Tighten all bolts Check belt tension after 10 hours of use 17 Connect both hy
93. ut Replace all 8 when replacing one 8 34 18 069 Plug 2 NPT 1 35 16 480 Rear Axle Housing 1 36 16 815 Housing Bolt 8 16 561 Hex Nut 8 16 563 Lockwasher 8 37 16 482 RTV Sealant As Required 38 16 490 Differential Case 1 39 16 491 Pinion Lock Pin 1 40 16 497 Gear and Pinion Assembly 12 25 1 Ratio Matched Set 1 41 16 498 Bearing Cone 1 42 16 499 Bearing Cup 1 43 16 500 Spacer Set of 3 2 4 16 037 Includes Brakes and Drums M SIN BRAKEASSEMBLY DRAWING 4 BRAKEASSEMBLYPARTS LIST PART DESCRIPTION QUANTITY 1 16 704 Shoe Return Spring Green 1 2 16 725 Shoe and Lining Kit 2 required 3 16 705 Shoe Return Spring Red 1 4 16 723 Spider Torque Kit 1 5 16 709 Dust Shield and Bearing Retainer 1 6 16 713 Brake Lever Kit Right or Left 1 7 16 719 Adjusting Spring 1 8 16 720 Adjusting Screw Kit 1 16 514 Left Brake Assembly part of 16 037 1 16 554 Right Brake Assembly part of 16 037 1 16 559 Brake Drum part of 16 037 2 16 723 01 Cylinder Kit Includes Boot and Cup 2 per side 1 For Left brake assembly with star wheel of adjusting screw Ref 8 towards the front of the brake as shown opposite for Right brake Red Spring Assemble to front of brake on right side assembly opposite for left Green Spring Assemble to rear of brake on right side assembly opposite for left Brake actuating lever Ref 6 shown for right assembly reverse for left assembly Bent arm stays up double arm switches to f
94. wer unit bracket to the frame and adjust the belt tension as required Retighten the bolt after the adjustments made FOOT CLUTCH BELT See belt and pulley drawing in this book Belt retainer should be adjusted so that there is to to 5 mm clearance between the belt and retainer with the clutch fully engaged This is just a starting point Start the engine with the transmission in neutral and the park brake set Engage and disengage the clutch check to see if the belt has stopped and is against the retainers If not shut engine off and readjust the retainers Adjust the clutch rods as required to shorten turn the ball joints in and out to lengthen SPRAY PUMP WITH ELECTRIC CLUTCH BELT Located to the rear and left of the engine Should have approximately 1 2 13 mm of deflection in the center of the top strand Loosen and tighten the s x 21 2 set screw located on the frame pushing against the pump arm PARK BRAKE Adjust on lever Adjust on clevis BRAKES Can be adjusted from outside of brake drum with a brake tool SPEED CALIBRATION NUMBERS The speed calibration number for the Spray Star 1602 is 114 This is measured off the drive shaft The speed calibration number for the Spray Star 1607 is 621 This is measured off the drive shaft 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
95. ydraulic fluid breaking through the skin 27 Check oil level in hydraulic pump reservoir remove fill plug on top and fluid level should be about 11 2 inch from the top when fluid is cold If fluid is needed add SAE 10W 40 API Service SJ or higher motor oil 28 Remove blocks from wheels DN BUN STAR SHIELD ASSEMBLY DRAWING Figure 2 Lift frame attachment on Spray Star 1600 vehicle Figure 10 Center actuator position and level adjustment M SUN INSTALLATIONINSTRUCTIONS 1 Locate the pivot plate The pivot plate is shipped attached with two U bolts and 1 pinned to the pivot arm with a 1 top link pin 2 The mount the plate horizontal The center of the pin should be about 11 Y inches from the ground and as close to the rear wheels of the utility vehicle as possible 3 The pivot plate may be mounted higher or lower than suggested By mounting the pivot plate higher than suggested increases how tight the sprayer folds into the transport position Placing the plate lower increases the amount of down float for the sprayer 4 Locating the sprayer closer to the vehicle s rear wheels increases sprayer float but you must make sure that there is enough clearance for the sprayer to float up i e avoid frame tank solenoids or other installed attachments The plate may be mounted to the utility vehicle by U bolting around 2 inch tubing uprights Adjust the pivot arm position by loosening the two lock bolts and sliding over the tubin

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