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PARTS & SERVICE MANUAL

1. O un TO GROUND UNDER ENGINE FRAME TO POSITIVE BATTERY R ON STARTER SOLENOID I 119 CONTROL 1604P SYSTEM DRAWING RAVEN 203 11 Y O TO GROUND UNDER ENGINE FRAME TO POSITIVE BATTERY ON STARTER SOLENOID SN 68 xy CONTROLS 1602P SYSTEM PARTS LIST QUANTITY 1 2 4 5 6 7 PART 16 558 16 525 16 234 15 370 03 15 370 04 HN 14 20 HWL 14 16 883 15 370 01 15 370 02 15 370 07 14 370 14 348 16 524 15 369 33 271 10 237 16 456 33 508 15 370 08 DESCRIPTION Mounting Knob Console only Computer Cover Turret Assembly Speed Sensor Rod Nut 1 4 20 Lockwasher 1 4 Magnetic Sensor Red Magnet Assembly north Black Magnet Assembly south Small Band Clamp Drive Line Spray Star Solenoid Valve Motorized Control Valve Console Control Cable Fuse Block Mounting Bracket Flow Meter Auto Blade Type Fuse 15 amp Drive Shaft Hardware Kit for speed sensor Use Dielectric Grease On All Electrical Connections A E 41 4 CONTROL 1604P SYSTEM PARTS LIST QUANTITY PART 16 958 01 716 898 716 900 716 899 716 958 716 234 33 090 02 16 958 02 716 525 03 716 895 716 958 04 716 958
2. 15 493 Stainless Steel 18 Auto Boom 15 577 Stainless Steel 18 Manual Boom 10 300 and 15 493 Boom Wiring Diagram Nozzle Assembly ee a 14 100 Boom ne 14 100 Plumbing amp 709 422 Nozzle Kit RAINDROP TIPS eere ERR EHE 98 99 Plumbing amp Nozzle Kit Installation RAINDROP TIPS 99 14 101 Plumbing amp 709 420 Nozzle Kit TEBJET TIPS e s teet aa eee etel 100 101 Plumbing amp Nozzle Kit Installation TEEJET TIPS 101 RA Raindrop Tips pp 102 TEEJET Tips nat 103 16 906 Electric Hose 104 105 16 129 Hose Reel 106 107 14 311 Hose Reel Installation 108 109 Hose Reel Adjustments 110 Electric Hose Reel Wiring Diagram 110 111 15 499 Foam Marker Installation 112 117 15 504 Compressor Sub Assembly 118 119 15 505 Motor Sub Assembly 120 121 15 511 Foam Nozzle Sub Assembly 122 123 15 363 Fresh Water 124 125 14 305 Cab 126 131 15 Star Shield Boom 132 134 Reference 135 136 Decal List da 135 Quick Reference Replacement Parts 136 Limited Warrant
3. DESCRIPTION QUANTITY 30 11 158 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 x 51 2 2 HNCL 12 13 Center Lock Nut 2 13 2 33 18 289 Bushing s ID OD x 5 e 4 34 HB 38 16 225 Bolt s 16 x 27 2 HNTL 38 16 Lock Nut 38 16 2 35 10 247 Right Boom Stabilizer 1 36 21 212 Extension Spring 1 37 HB 38 16 300 Bolt ys 16 x 3 1 HW 38 Washer 3 2 HNTL 38 16 Lock Nut 16 1 38 10 162 Boom Support 1 39 HB 516 18 225 Bolt 9 15 18 x 21 4 2 HNTL 516 18 Lock Nut 5 1 18 2 40 10 246 Left Boom Stabilizer 1 INSTALLATION INSTRUCTI ONS For best results use teflon tape on all fittings 1 12 13 The three 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 Mount small boom assembly to rear upright support on sprayer using four boom brackets Ref 8 four bolts s 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 51cm nozzle height and cente
4. 4 00 KH 141 KH 1 1 5 At dl 4 1 HD KH HK HDS HK py py xl SPRAY PUMP DRAWING eg 5 A fl al m lt A B S Fe Sa M DIN SPRAY PUMP PARTS LIST QUANTITY PART 15 415 HB 38 16 150 HW 38 HNTL 38 16 14 353 HNCL 12 13 33 480 18 260 16 825 15 385 18 160 16 170 18 236 16 161 18 219 16 180 16 935 16 155 16 859 18 073 14 371 16 966 8859 8962 33 494 HB 12 13 450 HMB 12 14 18 259 HSSQ 38 16 250 HN 38 16 15 457 DESCRIPTION Pump Arm Bolt 3 s 16 x 11 2 Washer 3 Lock Nut 38 16 Main Frame Center Lock Nut 1 2 13 Pressure Switch Bushing 11 4 x 3 4 Reducer Bushing 11 2 x 11 4 Elbow 11 4 Close Nipple 11 4 Gate Valve 11 4 Nipple 1 4 x 4 Fitting 11 4 MPT x 11 4 HB Tee 11 4 Quick Coupler 11 4 Male Quick Coupler Cap Elbow 3 4 x Ball Valve 3 4 Close Nipple 54 Strainer Hypro Pump Male Slide on Terminal Heat Shrink 3 16 X 11 4 Elbow s MPT x 3 6 HB Bolt 2 13 x 41 2 Machine Bushing 2 14GA Cross 11 4 Square Head Set Screw s 16 x 2 2 Nut s 16 Ground Wire A A gy A A ld dl dl ld dd ld dl Sl xl gt FRONT AXLE DRAWING Vw FRONT PARTS LIST QUANTITY 1 PART 10 180 HBC 516 18 100 HW 516 HWL 516 HN 516 18 80 167 HNAR 100 14 14 344
5. 2 M SUN Hot Fuse Block Switch for 10 300 15 493 Booms BOOM WIRING PARTS LIST PART DESCRIPTION QUANTITY 8853 Female Spade Connectors 2 15 472 Switch Boot 2 11 158 Linear Actuator with 4 stroke 2 16 755 Switch 2 16 810 Wiring Harness for Spray Star 1600 1 33 190 Wiring Harness for Spray Star 3000 1 22 075 Nylon Tie 10 33 272 Fuse 20 amp 1 Use Dielectric Grease On All Electrical Connections NOZZLE ASSEMBLY PARTS LIST PART DESCRIPTION QUANTITY 16 920 01 Screw 2 2 16 920 02 Upper Clamp 1 3 16 920 03 O Ring 1 4 16 920 04 Body with Lower Clamp 1 5 16 920 05 Diaphragm Optional 1 6 16 920 06 Diaphragm EPDM Rubber Standard 1 16 920 07 Diaphragm Viton Optional 1 7 16 798 Chemsaver End 1 8 16 800 Gasket Viton 1 9 16 921 Cap 1 10 16 805 Raindrop 4 1 T 16 920 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 51cm apart on the right left and center tubes 15 562 16 927 and 16 928 There are predrilled holes in all tubes The Nozzle should be at a 45 angle to the ground for proper application 9 Nozzles are used on the 10 300 and 15 493 15 Booms 11 nozzles are used on the 10 301 18 Boom For all 18 Booms The eleven 16 920 bodies are installed on the boom sections The eleven 16 800 viton gasket 16 805 Raindrop
6. TIPS S 16 01 2 8887 92 Orange Hose Right amp 8887 14 Orange Hose Center Boom 18 040 Hose Clamps o 14 101PLUMBING amp 709 420 NOZZLEKIT PARTS LIST TEEJET TIPS QUANTITY 1 14 101 2 16 795 3 16 796 4 16 797 5 8888 19 6 18 224 7 16 137 8 16 798 9 16 799 10 16 802 11 16 800 12 16 803 13 16 804 14 8888 8 15 16 200 16 136 16 8888 9 17 16 135 18 077 709 420 DESCRIPTION Boom Square Clamp 1 Diaphragm Check Valve Single includes 8 amp 9 Diaphragm Check Valve Double includes 8 amp 9 Orange PVC Hose 1 2 Hose Clamp Fitting 1 2 MPT x 1 2 HB End Cap Diaphragm Strainer Gasket TeeJet Tip XR8004 Standard all sizes available Quick TeeJet Cap white Orange hose 1 2 Ball Valve 4 FPT Fitting 4 MPT 2 HB Orange PVC Hose 1 2 Fitting x 3 4 HB Hose Clamp Nozzle Kit 4 12 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 2 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 a i alas uu C ca a 2 5 2 a 5 2 5 2 a A B B A A B L
7. 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 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 Connectone end of other cable to negative terminal
8. 3 4 HB 1 12 8887 90 Orange PVC Hose 2 4 1 18 040 Hose Clamp 2 13 18 260 Bushing 11 4 x 3 4 1 14 18 073 Pipe Nipple 3 4 1 INSTALLATI ONINS TRUCTI ONS 10 11 12 135 Wear protective clothing when draining the tank and taking apart the lines Drain tank and spray system in a safe and approved method insuring that no chemical or water remain in tank as you will be taking apart lines Remove key from ignition set park brake and block wheels Remove square rubber covers on boom carriers Place hose reel bracket inside the boom carrier tube on left side and outside on right side with arms pointing toward front of machine 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 x 1 2and four 5 6 18 lock nuts to hold in place Tighten bolts Put 18 249 barb fitting into hose reels side Use 8887 90 hose to connect reel to ball valve clamp with 18 040 hose clamps Use 22 075 nylon ties to tie hose to main feed hose For 1610P 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 For 1602P 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 te
9. 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 DESCRIPTION Rear Tank Strap Bolt 16 x 21 2 Lock Nut s 16 160 Gallon Poly Tank Square Cap Boom Carrier Double Threaded Fitting 3 4 bottom fitting only part of 14 347 Elbow 3 4 x 1 HB Bolt 5 6 18 x 11 4 Washer 5 16 Lockwasher 5 16 Nut 5 16 18 Boom Carrier Latch Machine Screw 8 32 x 11 2 Lockwasher 8 Nut 8 32 Left Fender Bolt 5 46 18 x 3 4 Lock Nut 5 1 18 Bolt 9 16 18 x 1 Lock Nut 5 6 18 Fender Mount Bolt 20 3 4 Lock Nut 4 20 Bolt 9 16 18 x 1 Lock Nut 5 1 18 Washer 5 16 Left Fender Brace Right Fender Brace Tank Carrier Hypro Pump Elbow 11 4 MPT 1 4 HB Anti Vortex Fitting 11 4 part of 14 347 Right Fender Clear Hose 9 16 ID Elbow MPT x 9 16 HB Reducer Bushing 2 MPT x a 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 14 347 Gasket for 16 953 Strainer Basket not included with 14 347 MNARA DDH 45 45 A as needed A A ld dl ld dl do QUANTITY xl NOSE CONE DRAWING 9 G EN ET Xo 7 Me NOSE CONE PARTS
10. 7 After drilling position chisel across the hole and E ee m 8 Support the axle shaft assembly in a suitable press strike sharply to break the ring Replace with a new Press on the 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 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 Je 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 e A 7 Assemble bearing retainer bolts and new gasket on 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
11. 14 328 15 030 15 031 14 327 14 347 14 365 16 953 16 953 01 16 169 DESCRIPTION Front Tire amp Wheel Tire 20 x 10 00 10NHS 4 Wheel Lug Nut 2 20 Right Front Fender Right Side Panel Left Side panel 5 Gallon Gas Tank Cap with Gauge Cross part of 14 370 U Bolt Kit Lockwasher 5 16 part of 16 024 Nut 5 16 24 part of 16 024 Magnetic Sensor Driveline complete Rear Tire amp Wheel Tire 24 x 13 00 12NHS 4 Wheel Lug Nut 7 16 20 Axle with Brakes Main Frame Hydraulic Power Unit Cross 11 4 Strainer Top Filter Bracket Hypro Pump Rear Tank Strap Rear Engine Cover Left Front Fender Engine Cover Seat Seat with Adjusters Tank Carrier Floorboard Steering Wheel Steering Wheel Cap replacement only Front Tank Strap 160 Gallon Poly Tank Air Gap Filler 16 Hinged Lid Well with Gasket part of 14 347 Gasket for 16 953 Strainer Basket 16 TANK AND REAR FENDER DRAWING Ma TANK AND REAR FENDER PARTS LIST 1 2 10 11 13 14 15 16 17 PART 14 322 HB 38 16 250 HNTL 38 16 14 347 16 557 14 325 16 150 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 HB 516 18 100 HNTL 516 18 HW 516 14 341 14 340 14 321 16 966 16 156 16 194
12. 22 23 NOSE CONE e 24 27 Brake Acts chutes Re PES 28 29 Pumps And Exhaust 30 31 Spray PUMP sospetto cete ee ee 32 33 e E 34 35 Clutch Linkage 36 37 Engine and Control 38 41 Gas Tank ii ib 42 43 Turbo Quad 44 45 ESA 44 45 er 46 47 15 409 3 Speed 48 51 15 315 Hydraulic Pump pp 52 53 16 966 Hypro sse 54 55 16 037 Rear Axle 56 57 Brake Assembly 58 59 Accessories Plumbing 1602P System Raven 440 Plumbing 1604P System Raven 203 Plumbing 1607P System TeeJet 844 Plumbing 1610P System Manual Controls 1602P System Raven 440 Control 1604P System Raven 203 Control 1607P System TeeJet 844 15 551 Flow Meter 16 524 amp 16 866 Motorized Control Valve 16 456 Flow 10 268 3 Way Manual Valve 14 348 Solenoid Valve 15 531 Pressure Regulating Valve 10 300 18 Terrain Following Boom
13. 8887 28 18 040 16 186 8887 42 18 040 15 365 DESCRIPTION Pump Liquid Filled Gauge Throttling Valve Spare Parts Kit for 16 034 Elbow 3 4 MPT 1 HB Discharge Hose 1 Hose Clamp 13 1 x 11 2 Reducer Bushing 1 x 11 4 Elbow 11 4 Discharge Hose 1 Hose Clamp x 11 2 Discharge Hose 11 4 Hose Clamp HS 24 Hose Clamp HS 24 Flow Meter Mounting Bracket Discharge Hose 11 4 Hose Clamp HS 24 Flow Meter Mount Bolt 9 16 18 x 1 Lock Nut 5 1 18 Suction Hose 11 4 Hose Clamp HS 24 Fitting 17 MPT 17 HB Strainer Fitting 1 MPT X 1 4 HB 45 Elbow 1 FPT x 1 MPT Motorized Control Valve Reducer 4 FPT x 1 MPT Close Nipple 3 4 MPT x 9 4 MPT Main Frame U Bolt Lock Nut 4 20 Washer 1 4 Metric Bolt M6 1 00 x 16 Metric Nut M6 Metric Lockwasher M6 Solenoid Mount Solenoid Valve Hex Plug 3 4 MPT Orange Hose 4x 341 2 to right boom Hose Clamp HS 12 Orange Hose 4x 28 to center boom Hose Clamp HS 12 Elbow 2 MPT x 3 4 HB Orange PVC Hose 4 x 42 to left boom Hose Clamp HS 12 NGANGA np odo gt SH BP Raven 440 Computer with Accessories includes all items 1604P PLUMBING DRAWING RAVEN 203 Ma lt lt o 1604P PLUMBINGPARTS LIST DO PP PART 14 371 16 966 16 166 16 825 15 385 8896 42 18 222 16 161 889
14. 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 DESCRIPTION Disc 171 2 Retaining Ring Axle Assembly 3 4 Bolt 3 s 16 x 1 Washer 3 Trim Drum Edge Drum Center Disc 17 2 Crank Side Lockwasher 5 16 Bolt 5 6 18 x 3 4 Crank Assembly 3 4 Brake Assembly 3 4 Lock Nut s 16 Lock Nut 5 18 Lock Pin Assembly Bolt 9 16 18 x 3 4 Washer 16 Frame Assembly Mounting Pillow Block Bottom Bearing Mounting Pillow Block Top Swivel Assembly 3 4 Seal Kit For 16 906 23 5 00 00 ARANDA 14 311HOSE REEL MOUNT AND 1610 PLUMBING DRAWING Figure 3 1610 141 S W Figure 1 1607 1602 Figure 2 1604 14 311HOSE REEL PARTS LIST DESCRIPTION QUANTITY 1 HB 38 16 350 Bolt 3 s 16 x 3 2 2 HNTL 38 16 Lock Nut 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 9 4 9 4 HB 1 6 HB 516 18 150 Bolt 9 15 18 x 11 2 4 HNTL 516 18 Lock Nut 5 1 18 4 7 HB 38 16 250 Bolt 3 s 16 x 21 2 2 HNTL 38 16 Lock Nut s 16 2 8 16 158 Close Nipple 3 4 2 9 16 151 Elbow F P T 3 4 3 4 1 10 16 859 Ball Valve 3 4 Brass 1 11 16 154 Fitting 9 4 MPT
15. 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 In extreme temperatures you can use straight weight oil We recommend SAE 30W Service SJ higher when hot above 90 F 33 C and SAE 10W Service SJ or higher when cold below 32 F 0 C ambient temperature Use either motor oil or hydraulic oil but do not mix Oil being added to the system must be the same as what is already in the tank Mark the tank fill area as to which type you put in DIRECTOVALVES Directo Valves should be disassembled cleaned inspected and a service kit installed annually More often depending on the chemicals being used and the frequency of use In most cases this can be done without removing the valve from the sprayer MAINTENANCE CONTINUED TIRE PRESSURE Caution must be used when inflating a low tire to recommended pressure Over inflating can cause tires to explode Front tires should be 20 psi 1 4 bar and rear tires should be 18 psi 1 3 bar Improper inflation will reduce tire life considerably WHEELMOUNTING PROCEDURE 1 Set park 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
16. 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 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 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 alert for hidden hazards Never operate equipment that is not in perfect working order or without decals guards shields or other protective devices in place Never disconnect or bypass any switch Carbon monoxide in the exhaust fumes can be fatal when inhaled never operate a machine without proper ventilation Fuel is highly flammable handle with care Keep engine clean Allow the engine to cool before storing and always remove the ignition key Disengage all drives and set park brake before starting the engine Never use your hands to search for oil leaks Hydraulic fluid under pressure can penetrate the skin and cause serious injury This machine demands your attention To prevent loss of control or tipping of the vehicle A Use extra caution in backing up the vehicle Ensure area is clear B Do not stop or start suddenly on any slope C Reduce speed on slopes and in sharp turns Use caution when chan
17. 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 1 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 16 920 on the three boom sections Z 493 12 Make certain set screws B on both sides are completely screwed in and locked with the lock nut BOOM WIRING DIAGRAM for 10 300 15 493 Booms Left Actuator poo Ground 9
18. 10GA Left Front Fender Bracket Rear Left Spindle Grease Fitting 4 28 x 180 Bushing part of 10 294 amp 10 295 Axle Nut 1 4 12 Machine Bushing 1 x 14GA Cotter Pin s x 2 ABNMHANMNANNA HAHAH E oo A DD 2 2 DB RR amp SB 1 5 0 00 xl xy CLUTCHLINKAGE DRAWING CLUTCH LINKAGEPARTS LIST 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 DESCRIPTION Part of Main Frame Bottom Mount Bracket Bolt 3 8 16 x 1 Lockwasher s Top Mount Bracket Nut 5 6 18 Washer 5 16 Bolt 3 16 x 11 4 Washer 3 s Lock Nut 38 16 Belt Guard Eye Bolt 5 16 18 Spring Bolt 1 2 13x 3 Idler Pulley Clutch Arm Spacer Machine Bushing 2 x 14GA Oilite Bushing part of 15 337 Nut 3 s 24 Lockwasher s Clutch Relay Bolt 1 2 13 x 23 4 Lock Nut 1 2 13 Ball Joint 3 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 1 4 Nut 1 4 20 Clutch Pedal Floor Board Pedal Pedal Pad Short
19. 16 18 x 11 4 bolt with a 9 15 washer over slot to bolt alternator adjustment bracket to alternator with 5s lockwasher and se 18 nut Just snug up INSTALLATIONINSTRUCTIONS CONTINUED 15 16 17 18 19 20 21 22 23 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 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 Connect both hydraulic hoses back up to pump Locate red wire coming from rectifier on lower right front of engine Disconnect wire at coupler Remove jack stands and lower machine if you have raised it 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 Connect remaining 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 Use nylon ties to tie wiring up and out of way Put spray pump guard back on Connect negative battery cable back up Make absolutely certain you are connecting positive to positive negative too negative w
20. 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 Spacer speedometer Snap Ring Rear Bearing Main Shaft Gear M S low 8 reverse Gear M S 2nd 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 5 Lockplate Reverse Idler Gear Thrust Washer Thrust Washer Synchronized Assembly with BR Rings mk ao oon ar a i iP num APN Ad So _ o xl 15 315 HYDRAULIC PUMP DRAWING Torque 75 100 in Ib 8 25 11Nm Torque 75 100 in Ib 8 25 11Nm D e S Ns E E WIG 8 75 aN N SS M SIN 15 315 HYDRAULIC PUMP PARTS LIST DESCRIPTION QUANTITY REFA 1 2 3 4 5 6 15 315 18 15 315 17 18 060 15 315 10 15 315 20 15 315 11 15 315 13 15 315 12 15 315 15 27 059 15 315 09 15 315 05 15 315 04 HWK 18 063 15 315 07 15 315 06 15 315 16 15 315 21 15 315 08 15 315 19 15 315 14 15 315 03 15 315 02 15 315 22 18 287 18 314 15 315 01 Cap Screw Washer Stato Seal Pipe Plug s NPT Tank End O Ring Tube Tank Elbow Nipple Spacer Assembly Filler Breather Tank End Tank Pump Driven Gear Assembly Drive Gear Assembly Woodru
21. 18 222 8896 16 18 116 18 116 15 551 HLC A 200 8896 30 8889 22 18 116 16 824 14 371 16 828 15 531 16 163 16 158 10 194 HNTL 14 20 HW 14 HBM 6 1 16 HNM 6 HWLM 6 14 342 14 348 16 166 8887 36 5 18 040 8887 28 18 040 16 186 8887 42 18 040 16 971 33 312 DESCRIPTION Hypro Pump Liquid Filled Gauge Throttling Valve Spare Parts Kit for 16 034 Elbow 3 4 MPT x 1 HB Discharge Hose 1 Hose Clamp 3 16 x 11 2 Reducer Bushing 11 2 x 11 4 Elbow 11 4 Discharge Hose 1 Hose Clamp 13 16 x 11 2 Discharge Hose 1 Hose Clamp HS 24 Hose Clamp HS 24 Flow Meter Loom Clamp Discharge Hose 1 Suction Hose 11 4 Hose Clamp HS 24 Reducer 1 4 MPT x 1 Strainer Fitting 1 MPT X 1 HB Pressure Regulating Valve Reducer 3 4 FPT x 1 Close Nipple 3 4 x 3 4 Main Frame U Bolt Lock Nut 4 20 Washer 1 4 Metric Bolt M6 1 00 x 16 Metric Nut 6 Metric Lockwasher M6 Solenoid Mount Solenoid Valve Hex Plug 3 4 MPT Orange Hose 4x 341 2 to right boom Hose Clamp HS 12 Orange Hose 4x 28 to center boom Hose Clamp HS 12 Elbow 2 MPT x 3 4 HB Orange Hose 4 x 42 to left boom Hose Clamp HS 12 45 Elbow QUANTITY SD YD H DD AH iP SS eS es a ee A A We HSH SH PB BP Spray Systems 844 Computer with Accessories includes all items xy 16 10P PLUMBING DRAWING MANUAL ST 1610P PLUMBIN
22. 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 DESCRIPTION Stainless Steel Cap 2 4 U Bolt Kit 1 Right and Left Boom Tube Left Brush Guard Right Brush Guard Boom Carrier part of the truck Stainless Steel Bolt s 16 x 51 2 Lock Nut s 16 Boom Brackets U Bolt 9 16 24 Stainless Steel Lockwasher 16 Stainless Steel Nut 5 16 24 Barb Fitting Hose Clamp Stainless Steel Pipe Elbow 34 90 Right Pivot Bracket Machine Bushing 1 x 14GA Machine Bushing 1 x 10GA Extension Spring Right Cam Stop must also order 33 307 Oilite Bushing part of 33 306 Right Center Tube Bracket Stainless Steel Bolt s 16 x 11 4 Stainless Steel Washer 3 Lock Nut s 16 Center Tube Right Actuator Bracket Stainless Steel Bolt 3 s 16 x 11 4 Stainless Steel Washer 3 Lock Nut s 16 Center Mount Stainless Steel Set Screw s 16 x 1 2 part of 33 329 Nut s 16 part of 33 329 Left Actuator Bracket Stainless Steel Bolt s 16 x 11 4 Stainless Steel Washer 3 Lock Nut s 16 Left Center Tube Bracket Stainless Steel Bolt 3 16 x 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 1 4 x 11 2 Left Pivot B
23. Fuse Block Auto Blade Type Fuse 15Amp Auto Blade Type Fuse 5 Amp Solenoid Valve Pressure Regulating Valve 844 Sprayer Control Kit includes all items Use Dielectric Grease On All Electrical Connections 1 oA woo L LE E SS 15 551FLOW METER PARTS LIST QUANTITY REFA 1 o 3 4 5 PART 15 515 02 15 515 03 15 515 04 15 551 01 15 551 02 15 515 01 DESCRIPTION Nylon Ring Nut Nylon Hose Barb Viton O ring Flow Meter Body Flow Meter Pickup Hose Barb Assembly 2 xl SD 16 524 AND 16 866 MOTORIZED CONTROL VALVEDRAWING x 16 524 AND 16 866 MOTORIZED CONTROL VALVE PARTS LIST PART DESCRIPTION QUANTITY 1 16 870 Valve Cover 1 2 16 524 01 6 Self Tapping Screw 3 4 Long 6 3 16 897 Seal Tetraseal 1 4 16 875 Motor Assembly For 16 524 on 1602P 1 4 16 866 01 Motor Assembly For 16 866 on 1604P 1 5 16 957 Woodruff Key 1 6 16 524 04 Isolation Flange Assembly 1 7 16 524 02 Cou
24. Gauge not included with 10 268 valve Boom Lever Guts Tie Rod with Nuts and Washer 3 22 02 1 per body wow HH HH gt 14 348 SOLENOID VALVE DRAWING gt 12 Sa Mio lt lt RS 14 348 SOLENOID PARTS LIST QUANTITY 1 2 PART 14 348 02 16 879 07 14 348 03 14 348 04 14 348 05 16 879 11 14 348 06 14 348 07 14 348 08 14 348 09 14 348 10 14 348 11 16 879 12 16 879 13 14 348 12 16 879 14 14 348 01 14 348 18 DESCRIPTION Coil Assembly Upper Diaphragm Housing Armature Type 430fr Stainless Steel Spring Type 302 Stainless Steel Retaining Ring Steel Diaphragm Viton Rubber Seat Washer Retainer Stainless Steel Seat Washer Viton Rubber Spacer Stainless Steel Body Polypropylene Black Stem Stainless Steel Washer Stainless Steel Lower Diaphragm Piston Stainless Steel Lower Diaphragm Housing Screw Stainless Steel Connecting Nipple Nylon Black Single Unit Spare Parts Kit Ba a au a l WM a lx lx xl SIC 15 531 PRESSURE REGULATING VALVE DRAWING N WR 15 531PRESSUREREGULATING VALVE PARTS LIST PART 15 517 10 15 517 09 15 517 08 15 517 04 15 517 05 15 517 06 15 517 07 15 517 11 15 517 13 15 531 04 15 517 14 15 517 15 15 517 16 15 517 17 15 531 06 15 517 26 15 531 05 15 517 22 15 531 03 15 517 20 15 517 19 1
25. HB 516 18 125 HNTL 516 18 10 159 HBC 516 18 100 HW 516 HWL 516 HN 516 18 10 135 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 14 343 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 DESCRIPTION Left Front Fender Carriage Bolt 1s 18 x 1 Washer 16 Lock Washer 5 16 Nut 5 6 18 Dust Cap Slotted Jam Nut 1 14 Bearing Hub includes Ref 2 4 6 9 10 Oil Seal Spacer Cotter Pin Vs x 11 2 Stud 20 Lug Nut 1 2 20 Left Front Fender Bracket Front Rubber Bumper Bushing part of 14 343 Axle Pin Bolt 5 6 18 11 4 Lock Nut 5 6 18 Right Front Fender Carriage Bolt 5 16 18 x 1 Washer 16 Lockwasher 16 Nut 16 18 Hydraulic Cylinder Seal Kit Clevis Pin 5 s x 11 2 Cotter Pin s x 1 11 16 x 9 16 90 Staight Thread Elbow Slotted Axle Nut 1 14 Machine Bushing 1 x 10GA Jam Nut ss 18 Bolt 5 s 11 x 21 2 Rod End Machine Bushing 14 Right Front Fender Bracket Front Lock Nut ss 11 Bolt 5 6 18 11 4 Washer 1 4 Lock Nut 5 e 18 Right Front Fender Bracket Rear King Pin Rod End Metric Nut M12 x 1 25 Right Spindle Grease Fitting 4 28 x 180 Tie Rod Front Axle Grease Fitting 4 28 x 180 Machine Bushing 11 4 x
26. Rain Cone Spray Nozzle 350 2251 DRIFTABLE FINES PRODUCED 0 5 gpm at 40 psi Nozzle Percent of Spray Volume 5 gpm Output less than 200 microns RA Raindrop Drift Reduction Nozzle 0 7 LF Flat Fan Tip 7 20 depending on spray angle TEEJET TIPS This is an extended range flat spray tip is excellent for Contact Pesticides and Growth Regulators and good for Systemic Pesticides Contact Pesticides and Growth Regulators At medium pressures 20 30 psi provides medium size droplets for good surface coverage and less drift At higher pressures 30 60 psi produces smaller droplets for better coverage Wide angle 110 tips produce slightly smaller droplets than 80 tips at equal pressures Systemic Pesticides At lower pressures 15 20 psi produces larger spray droplets and reduces drift while still providing uniform coverage along the boom FEATURES Excellent spray distribution over a wide range of pressures 15 60 psi Ideal for rigs equipped with sprayer controllers Reduces drift at lower pressures better coverage at higher pressures 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 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 DN SIN 16 9
27. Washer 2 8 Lock Nut 38 16 Stainless Steel Bolt 1 2 13x 6 Lock Nut 1 2 13 Extension Spring Stainless Steel Clevis Pin 23 4 Machine Bushing x 14GA Stainless Steel Cotter Pin x 1 Continue on Next Page 45 HF 10 300 18 TERRAIN FOLLOWING BOOM DRAWING d 8050 VE SEY v p 11 158 03 Motor 12VDC 11 158 02 Rear Housing 11 158 04 Gear Kit 20 1 11 158 Linear Actuator Ref 33 Ma S 10 300 18 TERRAIN FOLLOWING BOOM PARTS LIST 26 27 28 29 30 31 32 41 42 08 47 PART 33 302 HMBS 100 10 HMBS 100 14 HRPS 14 150 16 024 HWLS 516 HNS 516 24 10 311 18 035 HG 14 28 180 10 307 15 013 HWL 14 HN 14 20 10 318 10 316 11 158 HCPS 12 200 HPS 18 100 HBS 38 16 125 HWS 38 HNTL 38 16 10 317 10 319 10 330 15 494 18 036 HG 14 28 180 HN 38 16 HSSQS 38 16 150 HBS 38 16 125 HWS 38 HNTL 38 16 10 303 HMBS 58 14 HPS 18 100 10 309 18 268 HG 14 28 180 10 308 18 268 HG 14 28 180 16 024 HWLS 516 HNS 516 24 10 306 10 322 10 331 38 16 300 HW 38 HNTL 38 16 HB 58 11 300 HMB 58 14 HNTL 58 11 DESCRIPTION Left Pivot Bracket Stainless Steel Machine Bushing 1 x 10GA Stainless Steel Machine Bushing 1 x 14GA Stainless Steel R
28. further express warranty All implied warranties including those of merchantability and fitness for a particular purpose are limited to one year 60 days if product is used for rental pur poses from the date of purchase by the original user and to the extent permitted by law any and all implied warranties are excluded and disclaimed after the expiration of such period All incidental and consequential damages including pickup and delivery of the unit communica tion mileage charges and or rental of a replacement unit during repair are not covered under this warranty nor is any loss of income and or other loss resulting from the failure of the product to function due to a warranty defect The following items are not covered under the SMITHCO warranty and are warranted by their respective manufacturer Engine and engine parts including starters generators alternators and filters Transaxle differentials gear boxes and mechanical pumps Hydrostatic transmissions hydraulic pumps and motors Batteries Wheels and tires A copy of the warranty for the above items is furnished if necessary with each SMITHCO product Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitations of incidental or consequential damages so the above limitations 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 st
29. needed HYDRAULIC POWER UNIT BELT Located to the rear and left of the engine Should have approximately 1 4 6 5 mm of deflection in the center of the top strand To adjust loosen the bolt holding the hydraulic power 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 1 4 3 25 to 6 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 2 13 mm of deflection in the center of the top strand Loosen and tighten the s x 2 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 Thi
30. 0 HW 516 DESCRIPTION Brake Lever Bolt 3 s 16 13 4 Washer Lockwasher s Bolt 3 s 16 13 4 Washer s Lockwasher s Nut 3 16 Yoke Nut 5 15 24 Brake Rod Clevis Pin 5 16 x 1 Cotter Pin s 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 2 16 34 steel Brake Drum comes with 16 037 Left Brake Assembly comes with 16 037 Left Brake Cable Brake Line 9 16 x 84 Brake Oylinder Cap Master Cylinder Brake Master Cylinder Kit Bolt s 16 x 11 4 Lock Nut 38 16 Brake Rod Brake Bracket Bolt 3 16 x 1 2 Lock Nut s 16 Cotter Pin 1 Bushing comes with 15 496 Extension Spring Brake Pedal Bolt ys 16 x 1 Lock Nut 38 16 Pedal Pad Pedal Pin 9 16 x 11 4 comes 60 106 Cotter Pin s x 1 Washer 5 16 QUANTITY AA A Al n dl dl gt ADNDNA A gt py mad cmlpszgaSaO SA o dl do do xl Sys PUMPS AND EXHAUST DRAWING Mo TW PUMPS AND EXHAUST PARTS LIST QUANTITY REF 3 0 ON 10 12 13 14 35 36 37 38 PART 15 371 13 498 15 379 18 220 15 386 33 159 HSDPS 14 100 14 321 50 111 15 387 18 147 15 373 15 316 HSSHS 516 50 HKSQ 14 150 15 318 HKSQ 14 150 HB 14 20 075 15 344 HBC 38 16 100 HWL 38 HN 38 16 15 415
31. 05 16 866 14 348 16 955 16 958 07 16 902 33 271 33 508 16 852 DESCRIPTION Mounting Bracket Boom Switch Mounting Knob Master Switch Console only Computer Cover Liquid Filled Pressure Gage Fuse Holder Fuse 15 AMP Pressure Switch Cable Assembly 8ft Enclosure Hook Up Union Fitting Motorized Control Valve Solenoid Valve Tubing Male Fitting Cable Assembly 72 Solenoid Hook Up Fuse Block Auto Blade Type Fuse 15 amp 203 Sprayer Control Kit includes all items Use Dielectric Grease On All Electrical Connections l l l l l l l l l l l l l Y BI CONTROL 160 7P SYSTEM DRAWING TEE JET 844 Magnet Must Be Mounted with S Towards the Sensor LEFT 15 551FLOW METER DRAWING SA CONTROL 1607P SYSTEM PART LIST QUANTITY 1 2 3 4 5 6 7 8 9 10 11 12 13 PART 15 534 16 234 15 532 15 527 15 533 15 528 02 HRS 18 050 14 370 15 528 15 528 01 15 551 33 271 33 508 33 284 14 348 15 531 33 312 DESCRIPTION Computer Console Only Computer Cover Sensor Cable Power Cord End Valve Cable Magnet Steel Rivet 8 1 2 Drive Line Spray Star 1600P Speed Sensor Kit Speed Sensor Flow Meter
32. 06 ELECTRIC HOSEREEL DRAWING MS AR 16 906 ELECTRIC HOSE REEL PARTS LIST QUANTITY 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 18 100 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 16 982 DESCRIPTION Retaining Ring Axle Assembly Bolt 3 s 16 x 1 Washer s Trim Drum Edge Drum Center Solenoid Bolt 1 4 20 x 3 4 Lockwasher 1 4 Nut 1 4 20 Switch Disc and Gear Assembly Bolt 5 16 18 3 4 Pipe Cap 3 4 Lockwasher 5 16 Motor 12VDC Washer 5 16 Switch and Solenoid Brkt Bolt 9 16 18 x 1 Washer 5 16 Lockwasher 5 16 Nut 5 16 18 Lock Nut e 18 Bolt 9 16 18 x 1 Key Set Screw Pinion Lock Nut s 16 Frame Assembly Mounting Pillow Block Bottom Bearing Mounting Pillow Block Top Disc 17 2 Swivel Assembly 3 4 Seal Kit For 16 906 23 Bracket 12VDC Electric Hose Reel only 5 02 A NS 16 129 HOSEREEL DRAWING Wis I 16 129 HOSE REEL PARTS LIST QUANTITY PART 16 129 11 16 906 25 16 906 22 HB 38 16 100 HW 38 16 906 27 16 906 21 16 906 20
33. 158 04 Gear Kit 20 1 11 158 03 Motor 12VDC 11 158 Linear Actuator 30 M AN 15 493 STAINLESS STEEL 18 AUTOBOOM PARTS LIST 1 N 23 24 26 27 28 29 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 38 16 HCPS 12 225 HPS 18 100 10 319 DESCRIPTION Stainless Steel 2 4 U Bolt Kit 11 Right and Left Tube Left Brush Guard Right Brush Guard Stainless Steel Bolt s 16 x 51 2 Lock Nut s 16 Boom Brackets U Bolt 5 16 24 Stainless Steel Lockwasher 5 16 Stainless Steel Nut 5 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 16 x 11 4 Stainless Steel Washer 3 8 Lock Nut 3 s 16 Center Tube Right Actuator Bracket Stainless Steel Bolt 3 s 16 x 11 4 Stainless Steel Washer s Lock Nut 38
34. 16 Center Mount Stainless Steel Set Screw s 16 x 1 2 part of 33 329 Nut 3 s 16 part of 33 329 Left Actuator Bracket Stainless Steel Bolt 16 11 4 Stainless Steel Washer 3 8 Lock Nut s 16 Left Center Tube Bracket Stainless Steel Bolt s 16 1 a Stainless Steel Washer s Lock Nut 38 16 Stainless Steel Roll Pin x 11 2 Left Pivot Bracket Pivot Stainless Steel Machine Bushing 5 9 14 Stainless Steel Cotter Pin 1 8 x 1 Stainless Steel Bolt 3 s 16 x 11 4 Stainless Steel Washer s Lock Nut s 16 Pivot Bracket Nylon Flange Bushing part of 33 295 Oilite Bushing part of 33 295 Stainless Steel Set Screw 3 16 11 2 Nut 3 16 Stainless Steel Clevis Pin 1 2 x 21 4 Stainless Steel Cotter Pin s x 1 Actuator Cover Continued on next page 4 5 45 00 QUANTITY Sm 15 493 STAINLESS STEEL 18 AUTOBOOM DRAWING BOOM CARRIER DRAWING 8 32 150 15 437 1 11 2 REAR FENDER a 44 HSM 8 32 150 My HN 8 32 HWL 8 15 328 Spray Star 1600 p j 2 516 18 125 HW 516 HWL 516 HN 516 18 Sa ay 44 Me lt lt 00 15 493 STAINLESS STEEL 18 AUTO BOOM PARTS LIST
35. 18 306 18 171 27 059 18 314 18 287 15 315 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 16 966 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 DESCRIPTION Muffler Muffler Clamp 1 s Exhaust Pipe Muffler Clamp 11 4 Muffler Bracket Universal Exhaust Hanger Pan Head Drill Screw SS 4 x 1 Tank Carrier Muffler Clamp 11 2 Tail Pipe Hose Clamps Engine Kohler Command 20 hp Pulley BH72 x 11 s Socket Head Set Screw 5 16 1 2 Machine Key 1 4 x 11 2 Pulley with Hub BK30H 1 s Machine Key 1 4 x 11 2 Bolt 1 4 20 x Pump Mount Plate Carriage Bolt 3 16 x 1 Lockwasher 3 Nut s 16 Pump Arm 11 16 x 9 16 Straight Thread Connector 11 16 x hs 90 Straight Thread Elbow Filler Breather part of 15 315 3 s Coupler 3 s Pipe Nipple x 2 Hydraulic Power Unit Woodruff Key s x s Rear Mount Plate Bolt 3 16 x 11 4 Washer s Lock Nut s 16 Top Filter Bracket Cross 11 4 Muffler Clamp Strainer Bottom Filter Bracket Bolt 3 16 x 2 2 Lock Nut s 16 Close Nipple 11 4 Elbow 11 4 Belt Guard Hypro Pump Bolt 2 13 41 2 Center Lock Nut 2 13 Machine Bushing z x 14GA Pulley BK30 x 2 Socket Head Set Screw 16 18 x 1 2 Bolt 3 16 x 11 4 Lock Nut s 16 Belt 5L230 Belt L447
36. 2 Buss Bar Toggle Switch Switch Boot Continued on next page 1 1 1 dc se os po wpe oo oo dd SS NOSECONEDRAWING We aN NOSECONEPARTS LIST 30 31 32 33 PART 50 359 34 146 34 145 HB 516 18 100 HW 516 HNTL 516 18 15 496 16 062 15 015 10 200 HSA 8 075 16 046 14 075 17 153 15 310 14 20 100 HWL 14 HN 14 20 17 154 17 155 HN 516 24 76 293 01 DESCRIPTION Warning Light see wiring for terminals Circuit Breaker 30 Amp Circuit Breaker Boot Bolt 5 6 18 x 1 Washer 5 16 Lock Nut 5 6 18 Brake Pedal Pedal Pedal Pad Tower Plate Tapping Screw 8 x 3 4 Extension Spring Clevis Pin 1 4 x 3 4 Clevis Throttle Cable Bolt 1 4 20 x 1 Lockwasher 1 4 Nut 1 4 20 Cable Clamp Retainer Nut 5 16 24 Release Lever part of 76 293 po Hf eS dt A 2 QUANTITY xl NUS BRAKEDRAWING Me BRAKEPARTS LIST 1 2 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 10
37. 4 16 307 16 336 16 337 16 338 16 339 16 351 16 352 16 350 16 908 16 054 16 008 HB 38 16 125 HW 38 16 218 16 335 16 334 16 333 16 332 16 331 16 347 16 314 16 326 16 328 DESCRIPTION Ball 3 s detent Poppet Spring Low amp Reverse Shift Fork Rail Pin Shift Spring Pin Lockwasher 5 16 Bolt 9 16 18 3 4 Shift Lever Shift Knob not included with 15 409 Decal Shift not included with 15 409 Transmission Housing Cover Rubber Rain Dust Boot not included with 15 409 Plug Cap Housing Cover Gasket Top Shift type Case Seal M S rear Yoke Washer M S Lockwasher 3 4 Nut Drain Fill Plug High amp Inter Shift Fork High amp Inter Shift Rail Low amp Reverse Shift Rail Syncro Snap Ring Syncro Hub Shift Plate Sleeve Tran Bearing Housing not included with 15 409 Bearing part of 16 054 Bolt 3 16 x 11 4 Washer s Gasket not included with 15 409 Snap Ring small Snap Ring large Bearing M D Gear Oil Baffle Gear M D keyed input shaft Bolt 7 16 14 1 black Washer 7 16 star burst Rear Bearing Retainer Gasket M D retainer Synchronized Assembly with BR Rings Continued on next page CO 00 He AQ ANA HH KH pd SBP dl dd BAN NCH DD S Sy 15 409 3 SPEED TRANSMISSION DRAWING 15 409 3 SPEEDTRANSMISSIONPARTS LIST 40 41 16 309 16 305 16 304 16 303 16 310 16 311
38. 42 537 HW 38 HWL 38 HN 38 16 33 308 HBS 38 16 125 5 38 HNTL 38 16 16 925 18 249 18 040 HBS 38 16 550 HNTL 38 16 10 304 10 305 16 927 HSSQS 38 16 150 HN 38 16 33 309 HBS 38 16 125 HWS 38 HNTL 38 16 HBS 12 13 600 HNTL 12 13 10 313 HCPS 12 275 HMB 12 14 5 18 100 DESCRIPTION Muffler Clamp 11 8 Lockwasher 5 16 Nut 9 18 18 part of 13 498 Lynch Pin 1 2 Spacer Stainless Steel Cap 1 Spacer Castor Fork Machine Bushing 1 x 10GA 3 per fork Tire and Wheel Tire Wheel Axle Bearing Castor Wheel Spacer Stainless Steel Bolt 13x 6 Lock Nut 1 2 13 Right Castor Wheel Bracket Bushing part of 10 310 Grease Fitting 28 x 180 part of 10 310 Stainless Steel Bolt 9 8 16 x 13 4 Lock Nut 3 16 Right and Left Tube Right Pivot Bracket Stainless Steel Machine Bushing 1 x 10GA Stainless Steel Machine Bushing 1 x 14GA Stainless Steel Roll Pin 1 4 x 11 2 Spade Bolt 16 Washer 3 8 Lockwasher 3 8 Nut 2 8 16 Right Center Tube Mount Stainless Steel Bolt 9 8 16 x 1 Stainless Steel Washer 2 8 Lock Nut 2 8 16 Stainless Steel Pipe Elbow 90 Barb Fitting Hose Clamp HS 12 Stainless Steel Bolt 3 8 16 x 51 2 Lock Nut 16 Boom Bracket Center Boom Mount Center Tube Stainless Steel Set Screw 3 8 16 x 11 2 part of 10 305 Nut 3 8 16 part of 10 305 Left Center Tube Mount Stainless Steel Bolt 9 8 16 x 1 Stainless Steel
39. 5 517 18 15 517 23 15 517 24 15 531 02 15 531 01 DESCRIPTION Stainless Steel Slotted Hex Washer Screw Polypropylene Grommet Retainer EPDM Rubber Grommet Stainless Steel Self Cinching Stud Cell Sponge Rubber Gasket Neoprene Motor Mount Nylon Mounting Plate Teflon Thrust Washer Stainless Steel Spring Pin Nylon Ball Valve Stem Viton O ring Teflon Coated Viton O ring Nylon Body Dense Felt Dust Plug Polypropylene Cover Phoneolic Limit Switch Motor Sub Assembly Stainless Steel Hex Head Cap Screw Nylon End Cap Viton O ring Carbon Filled Teflon Seal Viton O ring Stainless Steel Hex Nut Stainless Steel Lockwasher Polypropylene Ball Spare Parts Kit Aa HH HH KH KH dl dd A yn ps QUANTITY Soy 10 300 18 TERRAIN FOLLOWING BOOM DRAWING R A 800 M N 2 11 158 04 20 1 11 158 02 Rear Housing 11 158 03 Motor 12VDC 11 158 Linear Actuator 33 10 300 18 TERRAIN FOLLOWING BOOM PARTS LIST QUANTITY 1 11 12 13 14 15 16 17 18 19 21 23 24 25 13 498 HWL 516 HN 516 18 42 539 29 584 16 926 29 585 10 312 HMB 100 10 42 202 42 202 01 42 202 02 42 213 42 212 HBS 12 13 600 HNTL 12 13 10 310 18 035 HG 14 28 180 HBS 38 16 175 HNTL 38 16 16 928 33 301 HMBS 100 10 HMBS 100 14 HRPS 14 150
40. 506 16 508 16 816 68 18 18 150 16 509 16 507 16 505 16 489 16 488 16 487 16 492 16 486 16 484 16 481 16 963 18 069 16 480 16 815 16 561 16 563 16 482 16 490 16 491 16 497 16 498 16 499 16 500 DESCRIPTION Wheel Bolt Lock Nut Axle Shaft Left and Right Oil Seal Part of Brake Dust Shield RTV Gasket Eliminator Loctite Brand Bearing Wheel Bearing Retainer Ring Oil Seal Pinion Mate Thrust Washer Side Gear Thrust Washer Carrier Oil Plug Sleeve Spacer Shim Set of 4 Bearing Cone Oil Seal Flat Washer Axle Nut s 18 Cotter Pin 11 2 End Yoke Shim Bearing Cup Drive Gear Screw Shim Set of 4 Bearing Cone Pinion Mate 5 Bearing Cup Bearing Cap Bearing Cup Screw Vent Assembly Bolt Kit Includes Bolt Washer and Nut Replace all 8 when replacing one Plug 2 Rear Axle Housing Housing Bolt Hex Nut Lockwasher RTV Sealant Differential Case Pinion Lock Pin Gear and Pinion Assembly 12 25 1 Ratio Matched Set Bearing Cone Bearing Cup Spacer Set of 3 16 037 Includes Brakes and Drums 10 2 2 2 2 _ EA ce cA LE n p 8 1 1 8 8 8 1 1 1 1 1 2 4 QUANTITY As Required As Required xl SIS xy BRAKE ASSEMBLY DRAWING 4 gt 58 BRAKE ASSEMBLY PARTS LIST PART DESCRIPTION QUANTITY 1 16 704 Shoe Return Spring Green 1 2 16 725 Sho
41. 54 Hydraulic Hose 84 18 306 11 16 x9 16 Straight Thread Connector 15 315 Hydraulic Power Unit 15 315 01 Repair Kit 27 059 Filler Breather part of 15 315 18 314 3 s Pipe Coupler 18 287 3 s Pipe Nipple x 2 HBM 6 16 Metric Bolt M6 1 x 16 HWLM 6 Lockwasher M6 15 301 Orbitor 15 301 01 Seal Kit 18 309 Swivel Nut 1 1 1 01 W FITTING TORQUE CHARTS Seal Lok Straight and Adjustable Fitting Steel Torque Ratings SAE Tube Tube Side Size ft 16 6 9 8 Presto so co w Pie 1 mew 8 wo ae wu es ate m Over tightened fittings will result crushing the cone which will create a leak Charts Developed by Parker Henniphin WIRINGDIAGRAM R FORWARD 7 o ay 5 MAIN WIRE HARNESS LOOKING AT TERMINALS 2 9 ER 2 2 5 N O 20 2 477 E E m m POS Color Code Chart Use dielec
42. 6 456 10 O Ring Transducer Kit Lis 10 268 3 WAY MANUAL VALVE DRAWING CN Eam m 0 1 am 0 GOOD Os 00022 Mz 0682 O E ll cede a 7 o E 2160 SIDE VIEW RS 10 268 3 WAY MANUAL VALVE PARTS LIST QUANTITY gt Shown PART 10 268 07 10 268 16 10 268 17 10 268 06 10 268 05 10 268 21 10 268 02 10 268 19 10 268 24 10 268 08 10 268 20 10 268 10 10 268 09 10 268 18 10 268 25 10 268 22 10 268 03 10 268 04 10 268 23 10 268 11 10 268 12 10 268 14 10 268 21 10 268 01 10 268 13 16 281 10 268 26 10 268 15 DESCRIPTION BoomLever Bolt and Washer Boom Lever Plate Spring Clip 5 8 Cap O Ring included with 10 268 19 Seal Kit Main Body Seal Kit O Ring for Main Body Main Pressure Adjust Seal Kit Pressure Adjust Body Main Boom Lever Master Boom Lever Guts Boom Lever Pin O Ring included with 10 268 19 Seal Kit Hose Barb Spring Clip 7 8 O Ring included with 10 268 12 and 10 268 14 Boom Pressure Adjust threaded end Boom Pressure Adjust middle Boom Pressure Adjust capped O Ring Gage Elbow Elbow 90 1 Hose Barb w Nut Liquid Filled
43. 7 50 18 116 8889 22 18 116 16 159 16 151 16 288 16 158 16 163 16 183 14 342 14 348 10 194 HW 14 HNTL 14 20 HBM 6 1 16 HWLM 6 HNM 6 8896 70 18 222 16 164 16 866 8887 36 5 8887 28 16 186 18 040 8887 42 18 160 18 279 16 852 DESCRIPTION Strainer Hypro Pump Hex Plug 3 4 Reducer Bushing 11 2 x 11 4 Elbow 11 4 Discharge Hose 1 x 42 Hose Clamp 13 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 Fitting 1 MPT x 1 4 HB 90 Elbow 3 4 Reducer Bushing 3 4 x 1 4 Close Nipple 3 4 Reducer Bushing 1 x 3 4 Tee FPT1x1x1 Solenoid Mount Solenoid Valve Main Frame U Bolt Washer 1 4 Lock Nut 1 4 20 Metric Bolt M6 1 x 16 Metric Lockwasher M6 Metric Nut M6 Discharge Hose 1 x 70 Hose Clamp x 11 4 Elbow 1 MPT x 1HB Motorized Control Valve Orange PVC Hose 3 4 x 36 2 to right boom Orange PVC Hose 34 x 28 to center boom Elbow gt MPT x 3 4 HB Hose Clamp HS 12 Orange PVC Hose 2 4 x 42 to left Boom Close Nipple 11 4 Ball Valve 11 4 Raven 203 Computer with Accessories all items QUANTITY Wha PO HAHNMHNM HH NM HAH AH AH WWH HH 160 7P PLUMBING DRAWING JET 844 uN 160 P PLUMBING PARTS LIST 28 29 30 PART 16 966 16 281 16 034 16 034 01 16 155 8896 33 18 222 16 825 15 385 8896 42
44. 8 042 DESCRIPTION Cap with Gauge 5 Gallon gas Tank Gas Tank Bracket Main Frame Bolt 9 s 16 x 1 Washer s Lock Nut 38 16 Bolt 1 4 20 x 74 Washer 1 4 Lockwasher 1 4 Hose Clamp Fuel Hose 1 4 x 25 Fuel Valve Reducer Bushing 1 4 x QUANTITY 1 1 1 BIS xy TURBO QUAD AGITATOR DRAWING Ey TURBO QUAD AGITATOR PARTS LIST 1 2 PART 16 036 16 036 03 16 036 01 16 036 02 16 173 16 158 16 157 16 172 DESCRIPTION QUANTITY Agitator Jets includes one each s 5 and 2 1 orifices Interchangeable Nozzles 3 16 factory installed Interchangeable Nozzles 1 Interchangeable Nozzles 5 Reducer 3 4 x 2 Close Nipple 34 Tee Female Pipe Thread 3 4 x 3 4 x 3 4 Nylon Nipple 3 4 NPT x 31 2 Nm One each comes with 16 036 Agitator Jet 14 371 STRAINER PARTS LIST 1 2 3 4 PART 14 371 01 16 968 02 16 968 03 16 968 04 DESCRIPTION QUANTITY Head 11 4 Poly 1 Gasket 1 Screen 1 Bowl 1 A 15 301 ORBITOR DRAWING 15 301 ORBITOR PARTS LIST QUANTITY 1 o 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
45. 9 3 Black Wire 1 8860 String Connector 1 8859 Ring Terminal 9 16 1 8853 Slide On Connector 1 8962 Heat Shrink 2 8963 Heat Shrink 1 30 14 335 Spray Pump Switch 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 9 16 1 8958 Male Slide On Terminal 1 8962 Heat Shrink 9 16 2 8963 Heat Shrink 1 4 1 N S 22 017 Cable Black transmission to frame 1 14 336 Main Wire Harness Includes all wire colors with 1 ML SIN HYDRAULIC SCHEMATIC 2 WIRINGSCHEMATIC oel 09 gt ya oe EL La BODY FRAMEDRAWING Mo BODY amp FRAME PARTS LIST QUANTITY 1 Y PART 16 857 16 857 01 16 857 02 HNL 12 20 10 159 14 350 14 349 15 491 15 492 15 182 16 024 HWL 516 HN 516 24 16 883 14 370 16 225 16 225 01 16 225 02 HNL 716 20 16 037 14 353 15 315 18 259 14 371 15 521 16 966 14 322 14 326 10 180 15 356 14 270 14 321
46. ARTS LIST QUANTITY 1f Nut 1 21 Screw 1 31 Foam Nozzle Inlet Body 1 15 510 01 Nozzle Mounting Rods 2 4T 15 511 02 Foam Sponge 1 15 511 03 Stainless Steel Screen 1 61 15 511 04 Stainless Steel Snap Ring 1 7 18 123 Hose Clamp 2 8 Drop Tube 1 9 15 511 05 Restrictor Bell 1 T 15 511 01 Foam Nozzle Inlet Sub Assembly NOTE When using the Star Shield you will need to leave the drop tube Ref 8 the full length For all other booms the drop tube will need to be shortened to half its length SIN 15 363 FRESH WATER TANK DRAWING DRILL 11 32 SIDE PANEL SEAT SUPPORT TUBE N 1 4 20 M NAN 15 363 FRESHWATER TANK PARTS LIST DESCRIPTION QUANTITY 1 HB 516 18 075 Bolt 9 16 18 x 4 HWL 516 Lockwasher 5 16 4 HW 516 Washer 5 16 4 2 HB 516 18 225 Bolt 5 16 18 x 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 1 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 of 15 488 1 10 15 488 02 Cover Assembly part of 15 488 1 INSTALLATIONINSTRUCTIONS Drill two holes through both walls of left side pa
47. Clutch Rod Lock Nut 1 2 13 Clutch Arm Grease Fitting 4 28 x 180 QUANTITY As Required E xl SIS ENGINE AND CONTROL PANEL DRAWING ENGINE AND CONTROL PANEL PARTS LIST QUANTITY 1 2 NO 10 11 12 13 14 15 16 17 18 19 20 21 24 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 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 DESCRIPTION Engine Seat Cover Trim Boom Control Switch Switch Boot Control Panel Decal Control Panel Bolt 1 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 ss Lock Nut s 16 Pulley BK72 1 s Machine Key 1 4 x 1 4 x 1 2 Pulley BK30H with Hub 1 s Machine Key 1 4 x 1 4 x 11 2 Belt Pulley 41 4 OD with Hub Machine Key 1 4 1 4 11 2 Rubber Bumper Bolt 2 13 x 3 Engine Frame Rubber Bushing Spacer Flange Whiz Lock Nut 2 13 Washer 5 e W
48. GPARTS LIST 19 21 23 10 263 10 264 16 281 16 268 13 8896 4 18 222 8887 122 18 040 8896 10 18 222 10 269 8896 20 18 222 16 155 8896 42 18 222 8889 22 18 116 16 825 18 098 16 966 8896 32 5 18 222 8887 109 18 040 8887 130 18 040 10 268 16 196 16 859 16 158 16 151 DESCRIPTION Front Valve Bracket Rear Valve Bracket Liquid Filled Gauge 90 Elbo x 1HB with Nut comes with 10 268 Valve Discharge Hose 1 x 4 Hose Clamp 9 16 x 11 2 Orange PVC Hose 2 4 x 122 right boom Hose Clamp HS 12 Discharge Hose 1 x 10 Hose Clamp 3 16 x 11 2 Plastic Tee 1 x 1 x 1HB Discharge Hose 1 x 20 Hose Clamp 9 16 x 11 2 Elbow 3 4 MPT x 1 HB Discharge Hose 1 x 42 Hose Clamp 13 6 x 11 2 Suction Hose 11 4 x 22 Hose Clamp HS 24 Reducer Bushing 11 2 x 11 4 Pipe Plug Hypro Pump Discharge Hose 1 x 321 2 Hose Clamp 3 16 x 11 2 Orange Hose 3 4 x 109 center boom Hose Clamp HS 12 Orange PVC Hose 3 4 x 130 left boom Hose Clamp HS 12 3 Way Manual Valve Hose Barb 3 4 MPT x 1 HB Ball Valve 3 4 Brass Close Nipple 3 4 Elbow 3 4 po A Se Ss HS SH SB sp gt mp HK i Kt 00 QUANTITY SN CONTROLS 1602P SYSTEM DRAWING RAVEN 440 8 on ES ni M nt M CONSOLE BACK ie
49. Ib 21 27Nm and oil seal Push axle shaft as far as possible into axle housing A SERVICE CHART Before servicing or making adjustments to the machine stop engine set park brak and remove key from ignition CAUTION Follow all procedures and ONLY use parts prescribed by the manufacturer Read the engine xy manual before maintenance S Engine Oil c C C Air Cleaner Paper Elemen Pre Cleaner Every 25 hours t Spark Plugs R lidleSpeed __ Air Cooling System EC C C C Bets and Tire Pressure C C C Fuel level RS R Hydraulic Ol e Hydraulic OilFitter R Hydraulic System for Leaks and Loose Parts C C C C C C Battery ElectrolyteLevel C C Clean Battery Terminals t Torque Lug Nuts feje Rear Axle Gear Lube C C C lubricate Jejeje 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 ft Ib 87 100 Nm Change oil after first 5 hours Clean mo
50. LIST QUANTITY OND 10 12 13 14 15 16 17 18 19 PART HNJ 58 18 HWK 316 075 15 030 15 031 76 294 HB 516 18 125 HWL 516 HN 516 18 76 293 16 882 50 400 13 288 76 310 42 064 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 34 167 77 207 HBM 6 1 16 HWLM 6 HSM 10 32 063 HWL 10 HN 10 32 8935 15 314 15 472 DESCRIPTION Jam Nut 5 18 Woodruff Key 3 16 3 4 Steering Wheel with Cap Steering Wheel Cap replacement only 90 Boot Bolt 5 6 18 x 11 4 Lockwasher 5 16 Nut 546 18 Tilt Steering Speedometer see wiring for terminals Rubber Grommet Key Switch Kohler 25 099 04 part of engine Set of Keys Hour Voltmeter Console Decal Console Black Trim with Lace Bolt 5 46 18 x 1 Washer 16 Lockwasher 5 16 Nut 5 16 18 Bolt 1 4 20 x 1 Lockwasher 1 4 Nut 1 4 20 Pedal Pad Bolt 1 4 20 x 2 2 Lockwasher 1 4 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 s Lockwasher 10 Nut 10 3
51. Maximum System Pressure Maximum Back Pressure Maximum System Operating Temperature Maximum Flow DESCRIPTION O Ring Seal Quad Seal Bearing Kit Bearing Race Bearing Spool External Retaining Ring Spring Centering Kit Includes Ref 9 Spring Spacer Centering Spring Spring Retaining Ring Pin Sleeve Retainer Plug and O ring O Ring Seal Plug Relief Valve Check 1015 psi 70 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 200 F 93 C 4 gpm 15 Maximum Temperature Differential between 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 50 F 28 C 15 25 Ib in 100 psi tank pressure 2 3 Nm 7 bar 60 Ib ft 81 Nm None o I l l l l l ll l ol c i an SAE 10W 40 API Service SJ or higher Motor Oil Yes 1015 psi 70 bar 91 18 SAE O Ring 4 Ports 61 cu in R 100 cu cm R NUS 15 409 3 SPEED TRANSMISSION DRAWING 15 409 3 SPEED TRANSMISSION PARTS LIST QUANTITY mk PART 16 341 16 342 16 348 16 343 16 344 16 308 HWL 516 HB 516 18 075 15 458 16 259 16 011 16 301 16 039 16 340 16 302 16 330 16 313 16 004 16 306 HWL 3
52. SMITHEU Wayne Pennsylvania 19087 PARTS amp SERVICE MANUAL Spray Star Model 1600P PRIME MOVER Starting Serial 900 December 1999 SMITHCO PRODUCT SUPPORT 1 800 891 9435 Hwy SS and Poplar Avenue Cameron WI 54822 E mail productsupport smithco com gen Q af CONTENTS Introduction 1 3 ee 1 General Safe Practices 2 vostra 3 Optional Spray Equipment 3 lj 4 13 ni 4 6 Axle Shaft Disassembly 7 8 Axle Shaft Assembly 8 9 Service kai 10 End User s Service 11 Adjusiments ia 12 12 Procedure to Test 16 456 Flow Meter Cables 13 Flow Meter Maintenance and Adjustment Procedure 13 Procedure to Re Calibrate Flow 13 Diagrams ee 14 19 Hydraulic Diagram se 14 15 Wiring Diagram u a 16 17 Hydraulic Schematic 18 Wiring SchematiG eerte ee 19 p mE 20 59 Body amp Frame reete ede cecus 20 21 Tank amp Rear Fenders
53. Y SIS 10 300 18 TERRAIN FOLLOWING BOOM DRAWING 8 04 S 9 2 ve jr NIN xen v Es ISO 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 is the center boom Each assembly is shipped with the nozzle bodies 16 920 The remainder parts of the 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 s 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 s 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 ce
54. amber in the nozzle cap alters the swirling action of the liquid so that the fewer driftable lines are discharged from the secondary orifice Maximum recommended pressure for Nylon is 100 psi 70bar Maximum recommended temperature is 120 50 NOZAETILT Delavan s extensive research on spray patterns has proven that a tilt of about 45 for flood Nozzles or tips RA Raindrop and WRW Whirl Rain nozzles will significantly improve the spray pattern uniformity The nozzle tilt reduces the effect of boom height variation and allows the spray nozzle to maintain a more fully developed pattern even when the nozzle outlet is below the recommended height for the best spray pattern uni formity RECOMMENDED OVERLAP AND NOZA EHEI GHT 100 overlap of spray pattern is recommended for RA Raindrop and WRW Whirl Rain Nozzles for uniform coverage Nozzle height is determined by measuring the width of the spray pattern as it hits the ground This width should be 10096 greater or twice as wide as the nozzle spacing Adjust nozzle height until this is achieved If a decision to tilt the nozzle is made do it before measuring the width of the spray on the ground and adjusting nozzle height See example below NOZZLE TYPE DROPLET SIZE COMPARISONS Volume median diameter in microns For Nozzles with 0 5 gom Output Spraying Pressure 20 psi 40 psi RA Raindrop Drift Reduction Nozzle 810 810 LF Flat Fan Tip 510 400 D Flooding Tip 450 315 WRW Whirl
55. asher 7 16 Left Side Panel Pan Head Drill Screw SS 1 4 x 1 Bolt 9 s 16x 1 Washer 3 Lock Nut s 16 Bolt 5 16 18 x 11 4 Lockwasher 5 16 Nut 5Ae 18 Battery Box Battery Black Battery Cable Battery Box Front Right Side Panel Pan Head Drill Screw SS 1 4 x 1 Bottom Mount Bracket Continued on next page 5 5 101 0 0 35 5 5 00 5 5 5 ae ae HSH HN KH xl ENGINEAND CONTROL PANEL DRAWING ENGINEAND CONTROL PANEL PARTS LIST QUANTITY 25 26 27 28 29 30 31 32 33 34 35 36 37 NS NS 15 481 15 483 15 555 15 556 16 013 16 883 16 821 HWK 14 1125 50 323 13 568 HST 14 20 075 HW 14 HWL 14 HN 14 20 11 086 HSDPS 14 100 14 326 17 154 21 161 DESCRIPTION Belt Guard Top Mounting Bracket Left Belt Guard Guard Mount Idler Pulley Magnetic Sensor Pulley 7 2 OD with Hub Woodruff Key 1 4 x 1 Red Battery Cable Throttle Cable Truss Head Machine Screw 1 4 20 x 3 4 Washer 1 4 Lockwasher 1 4 Nut 1 4 20 Choke Cable Pan Head Drill Screw SS 4 1 Rear Engine Cover Cable Clamp Wire Block 5 ARB AP H AH HH ass GAS TANK DRAWING Me YN GAS TANK PARTS LIST 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 1
56. ate 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 MA lt lt SMITHCO
57. 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 FOAM MARKER COMPRESSOR ANDCONTROLBOXFOR 1600 DRAWING DAN SUN COMPRESSOR AND CONTROL BOX PARTS LIST DESCRIPTION QUANTITY 1 HN 14 20 Nut 1 4 20 4 2 15 524 Foamer Bracket 1 3 15 504 Compressor 1 4 15 506 Switch Box 1 15 506 01 Fuse F10A 250V 1 15 506 02 Switch 1 5 HB 14 20 100 4 20 x 1 2 HW 14 Washer 1 4 2 HWL 14 Lockwasher 1 4 2 HN 14 20 Nut 4 20 2 6 15 525 Switch Box Mount 1 Wing Nut 2 8 HB 14 20 100 Bolt 4 20 x 1 1 HW 14 Washer 1 4 1 HWL 14 Lockwasher 1 4 1 n 15 500 Foamer 1 INSTALLATION INSTRUCTI ONS Safely Before working on machine stop engine set park brake remove key from ignition and block wheels Disconnect negative battery terminal 1 Remove original mounting bracket if one was provided from bottom of compressor and discard Place compressor Ref 3 on mounting bracket Ref 2 with controls facing the front Finger tighten a nylon lock nut Ref 1 on each of the two bolts closest to the side panel Place mounting bracket Ref 2 onto side panel as shown Hole B is threaded Insert one 14 20 x 1 bolt with lockwasher and washer Ref 8 into hole B Insert the other two 4 20 x 1 bolts and washers Ref 5 in
58. dhesive 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 1 A 5 HK 2 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 connect the lead wire from the accessories Red to positive and black too negative Windshield Windshield Wiper Filter Blower Doors Frame Overall Height SPECIFICATIONS Gray Safety Glass Large Rear 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 N D EA IN J WS 4 Y Q y OPERATOR S PROTECTI VEENCLOSUREINS TALLATI ON 1 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
59. e and Lining Kit 2 sets 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 Oylinder 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 forward M SN 1602P PLUMBING DRAWING RAVEN 440 7 O Q 2 A af 4 M 1602 PLUMBING PARTS LIST QUANTITY Y 10 11 12 13 PART 16 966 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 18 116 16 456 16 456 08 8897 30 18 116 15 327 HB 516 18 100 HNTL 516 18 8889 22 18 116 16 161 14 371 16 159 16 971 16 524 16 163 16 158 10 194 HNTL 14 20 HW 14 HBM 6 1 16 HNM 6 HWLM 6 14 342 14 348 16 166 8887 36 5 18 040
60. e and reconnect the hose For 1604P Remove hex plug from A and assemble as shown in Figure 2 Continued on next page M S JN ELECTRIC HOSE REEL WIRING DIAGRAM li HOSEREELADJ US TMENTS OPERATIONAL CHECK 1 2 3 4 Pull hose off drum at least full revolution 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 removed 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 ROLLER BRACKET 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 1 Facing swivel turn the hose drum clockwise until all of the hose is removed from the drum and the drum 1 held by lock
61. eft Boom Center Boom Right Boom A Single Ended Check Valve 3 and Clamp Ref 2 install with fitting toward middle of boom Double Ended Check Valve 4 and Clamp 2 C Fitting Ref 17 D Ball Valve and Fitting Ref 15 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 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 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 3096 overlap The edge of the spray from one nozzle should reach approximate of the way to the next nozzle If required adjust boom height until the correct overlap is achieved 7 xy RARAINDROP TIPS This is a wide angle 12079 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 4 1 4 RA15 Uniform spray distribution A large orifice opening and passages minimize clogging The Raindrop nozzle s patented design element a secondary swirl ch
62. ets 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 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 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 1 2 machine screws nuts and washers to install latch to boom carriers 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 A 3 89 15 577STAINLESS STEEL 18 MANUAL BOOM DRAWING eius m x 1 ta 19 12 M SIN 15 577STAINLESS STEEL 18 MANUAL BOOM PARTS LIST QUANTITY 1 N 19 20 22 23 24 25 26 27 28 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 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
63. ff Key s x Molded O Ring Back Cover Relief Valve Sub Plate Incudes 1 Sub Plate 4 Mounting Bolts 3 O Rings and 1 Plug Tank Pump Gasket Baffle Cap Screw Strainer Center Section O Ring Wear Plate Heat Shield Gasket V seal Front Cover Shaft Seal Pipe Nipple x 2 Pipe Coupler l ll l l l a l l Boa ol ll l 24 l l ll Repair Kit For Pump and Tank xl ENS 16 966 HYPRO PUMP DRAWING 16 966 HYPRO PUMP PARTS LIST QUANTITY PART 16 966 01 16 966 02 16 966 03 16 966 16 16 966 05 16 966 06 16 966 07 16 966 08 16 966 09 16 966 10 16 966 11 16 966 12 16 822 20 16 966 13 16 966 14 16 967 16 966 15 DESCRIPTION Drain Plug Pump Cassing Impeller Nut Impeller 0 Mechanical Seal Silicon Carbide Seal Retainer Slinger Ring Mounting Flange Name Plate Bolt Ball Bearing Key Pump Shaft Key Bearing Retainer Gasket Clutch Silicone Carbon Seal Kit Pump Only When servicing the spray pump or filter all control valves must be shut off if there is liquid in the tank xl 16 037 REAR AXLE DRAWING M 16 037 AXLE PARTS LIST 16 510 16 562 16 511 16 513 16 518 16 515 16 516 16 519 16 495 16 496 16 494 16 493 16 501 16 502 16 503 16 504 16
64. for Leaks and Loose Pats BatteryElectroyteLevel Clean Battery Terminals t Torque Lug Nuts 0 Rear Axle Gear Lube Lubricate 111111 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 present replace air cleaner parts 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 Sf vi ADJUSTMENTS INTERLOCK SWITCH Located on the front below the floorboard and behind the clutch The Interlock Switch 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
65. g 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 10 Putthe left castor wheel bracket Ref 28 onto the left boom as shown Using two s 16 x 13 4 bolts and lock nuts Ref 12 and one u bolt two s 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 11 Putthe assembled castor forks into the castor wheel brackets adjusting the spacers to get the boom height you desire 12 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 13 Install center stabilizer mount Ref 45 onto center boom Ref 20 with the 16 x 3 bolt washers and lock nuts 14 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 booms into the forward position XL 15 493 STAINLESS STEEL 18 AUTOBOOM DRAWING 8887 55 Orange Hose Right amp Left Booms 2 8887 40 Orange Hose Center Boom 1 ze 18 040 Hose Clamps 6 2 11 158 02 Rear Housing 11
66. ging directions on slopes D Stay alert for holes in the terrain and other hidden hazards 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 Keep hands feet and clothing away from moving parts Wait for all movement to stop before you clean adjust or service the machine Keep the area of operation clear of all bystanders Never carry passengers Stop engine before making repairs adjustments or checking adding oil to the crankcase Use parts and materials supplied by only Do not modify any function or part Use caution when booms are down as they extend out beyond the center line of the machine approxi mately 10 ft 3 m The tank is a confined space take precaution This machine is intended for turf maintenance Other use is forbidden SPECIFICATIONS WEIGHTS ANDDIMENSIONS Length Width Height Wheel Base Weight Empty SOUND LEVEL AT 3400 RPM Atearlevel At 3 ft 0 914 m At 30 ft 9 14 m At 23 ft 7 m pass by ENGINE Make Model Type Spec Horsepower Fuel Cooling System Lubrication System Alternator WHEELS amp TIRE SPEED Working Speed Transport Speed Reverse Speed BATTERY Group Cold Cranking Amps Ground Terminal Polarity Maximum Length Maximum Width Maximum Heigh
67. hile attaching power leads If you do not observe polarity damage will result to electrical WARNING components 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 With engine running park brake set and transmission in neutral check for hydraulic fluid leaks at pump Do not check for leaks with our hand Use a narrow flat piece of wood to locate leaks 25 26 hose fittings Correct if needed with engine off WARNING Serious injury can occur from pressurized hydraulic 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 Service SJ or higher motor oil 28 Remove blocks from wheels eu STAR SHIELDASSEMBLY DRAWING Figure 2 Lift frame attachment on Spray Star 1600 vehicle Figure 10 Center actuator position and level adjustment DAN ex INSTALLATIONINSTRUCTIONS 1 Locate the pivot plate The pivot plate is shipped attached with two U bolts and is pinned to the pivot arm with a 1 top link pin 2 The plate horizontal The center of the pin should be about 11 Yinches from the ground as close to the rear wheels of the utility vehicle as possible 3 The pivot plate may be mou
68. his is the air input tube Tighten connectors hand tight assembly tank cap onto tank Connect small plastic electrical plug under compressor to electrical extension cable For Spray Star 1600 route extension cable under engine along the mainframe cross bar using tie downs as neces sary Cut cable and strip casing allowing enough length to connect to fuse block Strip and connect spade type terminals to each wire and use the heat shrink Connect black negative wire to the ground and connect red wire to the positive vi Insert 20 amp fuse into slot which red wire was attached to xy 15 504 COMPRESSOR SUB ASSEMBLY DRAWING gt el N 2 6 3 RE 15 504 COMPRESSOR SUB ASSEMBLYPARTS LIST DESCRIPTION QUANTITY 1 o gr 4 5t et PART 15 504 01 15 504 03 15 504 07 15 504 11 15 525 15 504 04 15 505 15 504 06 15 512 02 15 512 01 15 504 10 15 504 09 15 504 08 15 512 21 464 15 506 15 506 01 15 506 02 15 507 15 508 15 509 15 510 15 504 01 15 504 05 Tubing Cover Seal Compressor Cover Cover Screw Air Filter Needle Valve Sub Assembly Tubing Connectors Gasket Manifold Cover Gasket Mounting Plate Front Foam Pad Nut Washer Washer Bolt Threaded Rod Bushing Bracket Discard Original Bracket Use 15 524 Switch Box Mount Wiring Harness Rear Foam Pad Grommet L Tubing Connector Tube 4 Motor Sub Assembly Solenoid Val
69. ine 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 up and elbow and fill plug facing you Set new pump mount plate M N on pump with the both slots to the left and the slot on the end away from you Bolt pump mount plate to pump with heads of the bolts up against plate 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 Put s 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 Place alternator adjustment bracket on pump mount plate on same side as alternator Use one 5 16 18 x 11 4 bolt 5 15 lockwasher and 5 16 18 nut with head of bolt on pump mount plate Just snug up Use the other
70. ing 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 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 CONNECTIONINSTRUCTIONS 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 3 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 the 33 273 auto blade type fuse 30 amp into fuse block Make certain you are
71. lide 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 5cm and inserting blue and clear tubes for the left boom section into the tubing connectors Ref A on the right side of compres sor as far as possible Follow the same steps for the right boom tubing Notice the right boom is inserted into left side Ref B of compressor Ref C To release tubing from compressor hold black ring around tubing and pull tube out Hose s must be routed on bottom of the boom square tubing Mark 6 inches in from inside edge of foamer nozzle mounting bracket on square boom tubing Screw 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 Install hose guard using 3 drill screws you may want to drill a pilot hole first Place another hose guard against first and install in same manner Repeat process for other boom side Connect the blue tube Ref D to the tank cap connector Ref F which is also connected to the large blue tube which hangs below the cap This is the soap outlet tube Connect the clear tube Ref E to the other connector on the tank cap T
72. m 14 304 844 Spray System 1607P capacity to be used with 14 311 14 305 Operator Protection Enclosure 16 906 Hose Reel 12 volt electric rewind 200 61 m 15 501 Foam Marker System Factory Installed capacity to be used with 14 311 15 499 Foam Marker System Dealer Installed 13 210 Battery pe MAINTENANCE CAUTION Before 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 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 LUBRICATION Use No 2 General purpose Lithium Base Grease and lubricate every 100 hours The Spray Star 1600P has 7 grease fittings A One on the rod end of hydraulic cylinder One on each the right and left spindles C One on the front axle One clutch idler arm E 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 wa
73. m includes the 16 806 Nozzle Kit TeeJet Tips QUANTITY 10 18 45 14 100 PLUMBING 709 422 NOZZLE KIT DRAWING RAINDROP TIPS 2 8887 92 Orange Hose Right amp Left Booms 8887 14 Orange Hose Center Boom 18 040 Hose Clamps Mo lt lt 14 100 PLUMBING amp 709 422 NOZZLE KIT PARTS LIST RAINDROP TIPS 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 16 799 Diaphragm 12 10 8888 8 Orange PVC Hose 1 2 6 11 16 805 Raindrop 1 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 1 4 2 16 136 Fitting 4 MPT x 2 HB 4 17 8888 9 Orange PVC Hose 1 2 4 709 422 Nozzle Kit 12 each PLUMBING NOZALE 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 pointi
74. nel and seat support tube as shown in drawing Remove drill screw from bottom edge in middle of side panel Run a 4 20 tap through this hole Bolt tank to tank bracket using four 16 18 3 4 bolts 5 16 lockwasher and 5 washers Use Teflon tape on each of the 34 hex plugs and install into tank Bolt tank bracket to seat support tube where you drilled the two 1 holes oa fF Bolt up support brace to tank bracket and side panel as shown DAN BUN E va 2 LAS 7 IN 14 305 OPERATOR S PROTECTIVEENCLOSUREPARTS LIST QUANTITY 1 2 3 10 11 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 FOR MACHINES SERIAL NUMBER 562 ANDUP 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 x 2 2 Washer s Lock Nut s 16 Door Self Adhesive Velcro Hook on Frame Self A
75. ng to the rear 20 10 DT a I d Right Boom A Single Ended Check Valve 3 and Clamp Ref 2 install with fitting toward middle of boom B Double Ended Check Valve 4 and Clamp C Fitting Ref 17 Ball Valve and Fitting 15 2 Place ball valve D between the outer check valves on both right and left booms Connect qin the check valves together using the 2 hose and hose clamps 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 2 gt 9 14 101PLUMBING amp 709 420 NOZZLEKIT PARTS DRAWING
76. nted 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 tubing 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 Pinthe 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 are in the spray position adjust the booms to be level with the ground Loosen the four nuts holding the center actuator pin plates and adju
77. nter 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 13 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 Actuator cover Ref 37 has a velcro opening on the bottom Place each actuator Ref 33 into the actuator covers with both rod ends coming out the holes in the cover Fasten velcro in place 6 Mount the actuator Ref 33 with the fixed end to the right and left boom holders Ref 35 and 32 using 2 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 1 2 x 14GA machine bushing on the outside of the pivot brackets 7 Hook hoses to the respective 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 fittin
78. of good battery C Booster Battery 5 Connect other end of cable D to engine block Jumper Cable 2 9 on unit being started NOT to negative terminal of battery OF 5 To prevent damage to other electrical components on Dead 0 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 5 DISASSEMBLY 1 After the wheel is removed remove the brake drum 2 Using a 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 Remove inner 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 a hole 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 ER i C
79. oll Pin x 11 2 U Bolt 5 16 24 Stainless Steel Lockwasher 5 16 Stainless Steel Nut 18 24 Left Castor Wheel Bracket Bushing part of 10 311 Grease Fitting 2 8 x 180 part of 10 311 Left Brush Guard Rubber Bumper Lockwasher Nut 4 20 Grip Pad Left Boom Holder Linear Actuator Stainless Steel Clevis Pin 1 2 x 2 Stainless Steel Cotter Pin 9 x 1 Stainless Steel Bolt 9 8 16 x 11 4 Stainless Steel Washer 3 8 Lock Nut 8 16 Right Boom Holder Boom Carrier part of machine Actuator Cover Pivot Bracket Nylon Flange Bushing 1 ID 2 per 10 330 Oilite Bushing ID 2 per 10 330 Grease Fitting 28 x 180 2 per 10 330 Nut 3 8 16 1 per 10 330 Stainless Steel Set Screw 3 8 16 x 11 2 1 per 10 330 Stainless Steel Bolt 3 8 16 x 11 4 Stainless Steel Washer 3 8 Lock Nut 2 8 16 Stainless Steel Machine Bushing x 14GA Stainless Steel Cotter Pin 1 8 x 1 Left Cam Stop must also order 10 308 Oilite Bushing part of 10 309 Grease Fitting 28 x 180 part of 10 309 Right Cam Stop must also order 10 309 Oilite Bushing part of 10 308 Grease Fitting 28 x 180 part of 10 308 U Bolt 5 16 24 Stainless Steel Lockwasher 5 16 Stainless Steel Nut 5 15 24 Right Brush Guard Stabilizer Center Stabilizer Mount Bolt 3 5 16 x 3 Washer 3 8 Lock Nut 3 8 16 Bolt 9 2 11 x 3 Machine Bushing 5 9 x 14GA Lock Nut 5 8 11 QUANTIT
80. olt Ref 4 in back and lock nut on bottom of plate just start the nut 6 Put 5 16 18 x 1 2 bolt Ref 4 in front with lock nut on the bottom of plate just start the nut Now completely tighten back bolt then tighten front bolt N DN FOAMER NOZZLEMOUNT amp HOSEGUARD MOUNT DRAWING xy a 15 499 FOAM MARKER PARTS LIST 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 1 4 3 4 8 2 15 510 02 Locking Collar 4 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 15 510 Bracket Accessory Bag INSTALLATION INSTRUCTIONS Slide hose clamp onto drop tube of foam nozzle and attach restrictor bell Place splined end of Nozzle mounting rod Ref 7 into top of foam nozzle Ref 5 Tighten screw Slide one locking collar Ref 2 onto rod Slide rod into mounting bracket on boom Ref 8 Slide second locking collar onto rod Adjust locking collars and rod so nozzle assembly will clear end of boom Tighten lock collar bolts to prevent side to side movement Being careful not to cut the tubing Ref 3 cut the oversleeve back approximately 2 5cm to expose blue Ref 6 and clear tubing Ref 4 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 S
81. oo 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 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 25 356 27 077 27 093 25 358 Multiple Warning Sprayer Dash Control Panel Hang Tag Spray Pump Spray Star 1600 Shift Knob Moving Parts Hot Bowl 8 Screen Tank Flush Not a Motor Vehicle Computer Cables Caution Steering Safety Warning Pinch Point Warning Hot Gas Refuel Engine Speed Tire Pressure 18PSI Tire Pressure 20PSI Smithco Round Hydraulic Oil Smithco Right Side of Seat in Front of Controls Facing Operator Dashboard Control Panel Hang From Steering Wheel Seat Panel Tank Sides Shift Knob Pump Guard Strainer Bracket Left Front Tank In Front of seat Left Side Left Side of Machine on Top of Seat Bracket 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 Steering Wheel Left Exhaust Guard by Dipstick Left Side Frame by Oil Rese
82. pler Shaft 1 8 16 956 Butterfly 1 9 16 524 03 Valve Body Mod 1 a 16 524 05 1 Valve ISO Body Kit WHEN SERVICING VALVE Replace valve body with iso body kit 16 524 05 if valve has been leaking internally Replace motor assembly if the motor will not run or if the printed circuit board is corroded Before reassembling valve remove the coupler shaft from the valve body Apply Loctite to coupler shaft and woodruff 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 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 ij 1
83. r Tighten bolts Put the actuator brackets Ref 20 and 22 on the center mount Ref 21 using s 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 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 2 13 center lock nut Ref 32 Do not over tighten boom must be able to move up and down Actuator cover Ref 29 has a velcro opening on the bottom Place each actuator Ref 30 into the actuator covers with both rod ends coming out the holes in the cover Fasten velcro in place Mount actuator Ref 30 fixed end to actuator bracket and ram end to pivot bracket using 2 x 2 4 clevis pins and t s x 1 cotter pins Ref 28 It may be necessary to lift boom slightly for proper fit Repeat process for other boom 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 brack
84. racket Stainless Steel Clevis Pin 1 2 x 21 4 Stainless Steel Cotter Pin t s x 1 Pivot Machine Bushing s x 14GA Stainless Steel Cotter Pin s x 1 Stainless Steel Bolt 3 16 x 11 4 Stainless Steel Washer s Lock Nut 3 s 16 Continued on next page 3 4 2 000 lt gt 15 577STAINLESS STEEL 18 MANUAL BOOM DRAWING 5 7 7 7 1 M NIN 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 x 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 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 1 20D x s 4 35 HB 38 16 225 Bolt 3 s 16 x 21 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 s 2 HNTL 38 16 Lock Nut s 16 1 39 10 162 Boom Support 1 40 HB 516 18 225 Bolt 9 16 18 x 21 4 2 HNTL 516 18 Lock Nut 5 e 18 2 41 10 246 Left Boom Stabilizer 1 INSTALLATION INS TRUCTI ONS For best result use Teflon tape on all fittings 1 The th
85. re 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 gt gt 5 I LO gt _ gt 200 Hours e 400 Hours The suggested maintenance checklist is not offered as a replacement for the manufacturer s engine manual but as a supplement You must adhere to the guidelines established by the manufacturer for warranty coverage In adverse conditions such as dirt mud or extreme temperatures maintenance should be more frequent 17 gt 10 END USER S SERVICE CHART very 500 Hours Yearly s Required 00 Hours 00 Hours 50 Hours 00 Hours 00 Hours QILI AININ u 5 Engine Oil SEngneOllFiter Engine for Leaks and LooseParts_ Air Cleaner Paper Element Pre Cleaner Every 25 hours 0 SprPus deSpeed Ar Cooling System Belts and Hoses Tire Pressure Fuel Level 2Pl TT Fuel Filter 0 5 HydraulicoilFter 1 1 Hydraulic System
86. 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 in cab as guides drill two 3 2 holes through both walls of bumper 6 Boltcab to bumper On left side of Spray Star place loom clamp with loop pointing down and 3 washer toward outside put a 38 16 x 2 2 bolt 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 other
87. ree 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 is the center boom Each assembly is shipped with the nozzle bodies 16 920 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 s 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 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 12 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 lifts Ref 31 using clevis pin and cotter pin Ref 27 so the bushing end hooks to the pivot bracket
88. rvoir Front Nose Cone xy 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 10 135 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 By 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 SAE 10W 40 API Service SJ or higher Motor Oil SAE 80W 90 Gear Lube API Service GL 5 GL 4 Hinged Cover On Tank with Gasket Gasket For Cover Spark Plugs Champion type RC12YC Gap 0 040 inch 1 02mm 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 16 no
89. s follow all accepted practices of chemicals that the filter has been exposed to WARNING 12 Thefilter elementis located in front and above the driver It is serviced from the outside of cab To service filter remove from cab 13 Thefilter can be taken apart for cleaning and washed in soap and water 14 To reassemble filter place orange and white 1 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 DAN ALTERNATOR PARTS LIST 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 x 23 4 1 HB 516 18 125 Bolt 5 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 5 16 1 HWL 10 Lockwasher 10 1 HWL 516 Lockwasher 5 1 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 mach
90. s 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 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 NOTES HYDRAULIC DIAGRAM ML AN HYDRAULIC DIAGRAM PARTS LIST QUANTITY 1 2 3 10 11 12 14 352 Hydraulic Hose 54 14 351 Hydraulic Hose 46 10 135 Hydraulic Cylinder 11 2 x 7 14 267 Seal Kit 18 171 11 16 x 9 1 90 Straight Thread Elbow 14 355 Hydraulic Hose 81 14 3
91. st 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 of each wing lift frame will be two 4 bolts and lock washers to mount the columns with Attach and route the 34 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 Attach and route 15 hose from flow monitor to spray nozzle Take to ensure that each column is routed to the appropriate spray nozzle Test folding of all sections of the sprayer for possible problems in the routing of the sprayer hose Continued on next page INSTALLATIONINSTRUCTIONS ELECTRICAL LIFT OPTION xy 1 2 1 Attach electric actuators If the spray vehicle has the appropriate electric controls you may use these o
92. t FLUIDCAPACITY Crankcase Oil Fuel Hydraulic Fluid Grade of Fluid 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 Weight Loaded 250016 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 1 gallon 3 785 liters SAE 10W 40 API Service SJ or higher motor oil OPTIONAL SPRAY EQUIPMENT 33 216 Battery 24F 12 Volt 10 300 18 Terrain Following Boom 15 363 Fresh Water Wash Tank 14 100 Super Boom 20 6 m Long 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 15 573 15 Manual Lift Star Shield Boom 14 302 203 Spray System 1604P 16 856 Tank Rinsing System 14 303 Manual Spray System 1610P 16 129 Manual Hose Reel 200 61
93. ter with detergent Rinse precleaner thoroughly until all traces of detergent are eliminated Squeeze out excess water do not wring Allow precleaner to air dry Saturate precleaner with new engine oil Squeeze out all excess oil 6 Reinstall precleaner over paper element Reinstall air cleaner cover Secure cover with cover retaining knob 2 gt MAINTENANCE ENGINE OIL Change and add oil according to chart below based on air temperature at the time of operation Do not overfill Use a high quality detergent oil classified For Service SJ or higher oil Use no special additives with recom mended oils Do not mix oil with gasoline SAEViscosity Grades 10W 30 10W 40 Starting Temperature Range Anticipated Before Next Oil Change HYDRAULIC OIL de 10 Use SAE 10 40 Service SJ higher motor oil For proper warranty change oil every 500 hours or annually which ever 1 first Oil level should be 1 5 4 cm from top of tank when fluid is cold Do not overfill After changing oil run the machine for a few minutes Check oil level and for leaks 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 If the natural color of the fluid has become black or smells burnt itis possible that an overheating prob lem exists
94. therwise 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 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 CURTAIN INSTALLATI ON Attach curtains to booms while in the transport position Use generous amounts of lubricant on the rope 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 t
95. tip and 16 921 cap are in the small parts bag For all 15 Booms The nine 16 920 bodies are installed on the boom sections The nine 16 800 viton gasket 16 805 Raindrop tip and 16 921 cap are in the small parts bag 4 gt 95 14 100 BOOM DRAWING Mo lt 14 100 BOOM PARTS LIST OND 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 HNTLM 1 2 16 789 10 025 HBM 8 50 16 793 16 788 HBM 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 DESCRIPTION Bolt M8 x 25 Nut M8 Arm Tie Bar Knob Left Hinge Bracket Flange Bushing 3 4 Plate Yoke Bolt M8 x 45 Boom Bracket Bolt 3 16 x 51 2 Lockwasher s Nut s 16 Boom Frame Pin 010 x 35 Flat Washer 1 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 5 1 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 x 31 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 Boo
96. to hole A with lockwasher and nut on the inside panel Place switch box mount Ref 6 on bolts furthest from side panel Place one nylon lock nut Ref 1 on each of the two bolts Tighten all four nuts on compressor bottom Place control box Ref 4 on control bracket and tighten wing nut Ref 7 Connect the large plastic electrical plugs on compressor and control box DN al 5 1600P FOAMER TANK MOUNT DRAWING ME N 1600P FOAMER TANK MOUNT PARTS LIST DESCRIPTION QUANTITY 1 16 938 Tank Mount Base 1 2 21 464 4 Gallon Poly Tank 1 26 054 Bushing part of tank 1 26 055 Shut Off Valve part of tank 1 3 16 939 Foam Tank Strap 1 4 HB 516 18 150 Bolt 5 6 18 11 2 2 HNTL 516 18 Lock Nut 5 e 18 2 6 HB 38 16 125 Bolt ys 16 x 1 part of machine 2 T Main Frame INSTALLATION INSTRUCTIONS For Spray Star 1600 Remove the two outside bolts Ref 6 from the gas tank bracket angles 2 Liftthe leg from the gas tank bracket Ref 6 and slide the arm of the tank mount base Ref 1 between the leg of the gas tank bracket and the angle iron on the frame Ref 7 Be sure the plate end of the foamer tank bracket is pointing to the rear of the machine and parallel with the ground 3 Using the same bolts and lock nuts Ref 6 re bolt tank and foamer tank bracket to angle iron 4 Place foamer tank Ref 2 over plate on tank mount base Ref 1 5 With tank strap Ref 3 over tank use 16 18 x 1 2 b
97. tric grease on all electrical connections 29 gt Bl Blue Br Brown Y Yellow Grn Green Boom Lift R Red Spray System B Black Manifold Valve P Purple Foamer White G W Green 8 Hose Reel White WIRINGDIAGRAM PARTS LIST 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 8962 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 42 064 Hour Voltmeter Combo 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 optional 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 16 966 Hypro Pump With Electric Clutch 1 8958 Male Slide on Terminal 1 8962 Heat Shrink 9 16 1 28 15 457 Ground Wire 1 29 77 207 Buzzer 1 884
98. ve Sub Assembly Strainer Manifold Block Tube O ring EPR Rubber Body Tubing Connector Pressure Relief Valve Cap Tank Includes 26 054 bushing amp 26 055 shut off valve Switch Box Fuse F10A 20V Switch Tubing Compressor Extension Cable Optional Power Cable Also Order Two 8853 Female Connectors Boom Mounting Bracket Accessories Includes Two 15 510 01 Nozzle Mounting Rods and Four Lock Collars with Bolts Cover Sub Assembly Valve Manifold Sub Assembly Po Se HSH SH SB KSB PH HSB SB EP 5 OOO BRO gt 15 505 MOTOR SUB ASSEMBLY DRAWING NS WR 15 505 MOTOR SUB ASSEMBLYPARTS LIST QUANTITY REF 1t PART 15 505 01 15 505 03 15 505 06 15 505 05 15 505 02 15 505 04 DESCRIPTION Manifold Screw Exhaust Manifold Exhaust Reed Valve Washer Exhaust Valve Screw Exhaust Manifold Gasket Head Bolt L Tubing Connector Intake Valve Screw Split Lockwasher Intake Reed Valve Diaphragm Piston Connecting Rod Nut Connecting Rod Bolt Brush Retainer Brush 12 Volt Electric Motor Stainless Steel Bearing Block Motor Bolt Motor Nut Cover Cover Screw Intake Exhaust Valve Sub Assembly Intake Piston Sub Assembly N N N a N N zz M RIX xy 15 511 FOAM ASSEMBLY DRAWING Cut Here To Shorten Nozzle By 15 5 NOZZLESUB ASSEMBLY P
99. y Inside Back Cover INTRODUCTION Thank you for purchasing a 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 in 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 Serial 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 YEAR OF O SERIAL NO kWihp MODEL NO kg lb p 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 GENERAL SAFE PRACTICES 10 11 12 13 14 It is your responsibility to read this manual and all publications associated with this machine Never allow anyone to operate or service the machine or its optional equipment without proper training and instructions Never allow minors to operate any equipment

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PARTS & SERVICE MANUAL