Smithco Spray Star 1600P (sn 0979 – 0991) Parts & Serv User Manual

PARTS & SERVICEMANUALSpray StarModel 1600PPRIME MOVERStarting Serial # 979 May, 2001SMITHCO PRODUCT SUPPORT1-800-891-9435Hwy SS and Poplar Avenue,

Service87. After drilling, position a chisel across the hole andstrike sharply to break the ring. Replace with a newretainer ring when reassembly.8. S

98Accessories8887-92 Orange Hose (Right & Left Booms) 28887-14 Orange Hose (Center Boom) 118-040 Hose Clamps 614-100 PLUMBING & 709-422 NOZZLE

99Accessories14-100 PLUMBING & 709-422 NOZZLE KIT PARTS LIST (RAINDROP TIPS)REF# PART# DESCRIPTION QUANTITY1 14-100 Boom 12 16-795 Square clamp 1

100Accessories8887-92 Orange Hose (Right & Left Booms) 28887-14 Orange Hose (Center Boom) 118-040 Hose Clamps 614-101 PLUMBING & 709-420 NOZZL

101Accessories14-101 PLUMBING & 709-420 NOZZLE KIT PARTS LIST (TEEJET TIPS)REF# PART# DESCRIPTION QUANTITY1 14-101 Boom 12 16-795 Square Clamp 1 1

102AccessoriesRA RAINDROP® TIPSThis is a wide-angle (120°), hollow-cone, drift-reduction nozzle. Replaces conventional flooding nozzles in broad-cast

103AccessoriesXR TEEJET TIPSThis is an extended range flat spray tip. It is excellent for Contact Pesticides and Growth Regulators and goodfor Systemi

104Accessories16-906 ELECTRIC HOSE REEL DRAWING

105Accessories16-906 ELECTRIC HOSE REEL PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-906-25 Retaining Ring 22 16-906-22 Axle Assembly 13 HB-38-16-100

106Accessories16-129 HOSE REEL DRAWING

107Accessories16-129 HOSE REEL PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-129-11 Disc 171/2 12 16-906-25 Retaining Ring 23 16-906-22 Axle Assembly

9Service5. Press the retaining ring firmly against bearing. 6. Assembly new grease seal into housing to originaldepth. After seal has been assembled,

108Accessories14-311 HOSE REEL MOUNT AND 1610 PLUMBING DRAWINGHOSE REEL PLUMBINGFigure 1 Figure 21607, 1602 1604Figure 31610

109Accessories14-311 HOSE REEL PARTS LISTREF# PART# DESCRIPTION QUANTITY1 HB-38-16-350 Bolt 3/8 - 16 x 31/2 2HNTL-38-16 Lock Nut 3/8 - 16 22 14-325 B

ELECTRIC HOSE REEL WIRING DIAGRAMHOSE REEL ADJUSTMENTSOPERATIONAL CHECK:1. Pull hose off drum at least one full revolution. A clicking noise should be

ELECTRIC HOSE REEL WIRING PARTS LISTREF# PART# DESCRIPTION QUANTITY8843-132 Flexguard 3/8 ID 11 8919-144 10GA Red Wire 144" 18901 Slide-On Connec

112AccessoriesFOAM MARKER COMPRESSOR AND CONTROL BOX FOR 1600 DRAWING

113AccessoriesCOMPRESSOR AND CONTROL BOX PARTS LISTREF# PART# DESCRIPTION QUANTITY1* HN-14-20 Nut 1/4 - 20 42 15-524 Foamer Bracket 13* 15-504 Compres

114Accessories1600P FOAMER TANK MOUNT DRAWING

115Accessories1600P FOAMER TANK MOUNT PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-938 Tank Mount Base 12 21-464 4 Gallon Poly Tank 126-054 Bushing (

116AccessoriesFOAMER NOZZLE MOUNT & HOSE GUARD MOUNT DRAWINGCONNECTING TUBING TO COMPRESSOR AND TANKTUBING ROUTE

117Accessories15-499 FOAM MARKER PARTS LISTREF# PART# DESCRIPTION QUANTITY1 15-537 Foamer Hose Guard 31" 210-256 Foamer Hose Guard 16" 2HSD

Service10SERVICE CHARTBefore servicing or making adjustments to the machine, stop engine, set park brak andremove key from ignition.Follow all procedu

118Accessories15-504 COMPRESSOR SUB ASSEMBLY DRAWING

119Accessories15-504 COMPRESSOR SUB ASSEMBLY PARTS LISTREF# PART# DESCRIPTION QUANTITY1* Tubing Cover Seal 22* 15-504-01 Compressor Cover 13* Cover Sc

120Accessories15-505 MOTOR SUB ASSEMBLY DRAWING

121Accessories15-505 MOTOR SUB ASSEMBLY PARTS LISTREF# PART# DESCRIPTION QUANTITY1† Manifold Screw 82 Exhaust Manifold 13* Exhaust Reed Valve 14*† Was

122Accessories15-511 FOAM NOZZLE SUB ASSEMBLY DRAWING

123Accessories15-511 FOAM NOZZLE SUB ASSEMBLY PARTS LISTREF# PART# DESCRIPTION QUANTITY1† Nut 12† Screw 13† Foam Nozzle Inlet Body 115-510-01 Nozzle M

124Accessories15-363 FRESH WATER TANK DRAWING

125Accessories15-363 FRESH WATER TANK PARTS LISTTO BE USED WITH 1602P, 1604P AND 1607PREF# PART# DESCRIPTION QUANTITY1 HB-516-18-075 Bolt 5/16 - 18 x

126Accessories0-106 FRESH WATER WASH TANK DRAWING

127Accessories10-106 FRESH WATER WASH TANK PARTS LISTTO BE USED WITH 1610PREF# PART# DESCRIPTION QUANTITY1 HB-516-18-075 Bolt 5/16 - 18 x 3/4 4HWL-516

11ServiceEND USER’S SERVICE CHARTC=Check or Clean at specified intervalsR=Replace at specified intervals* Tire pressure: Front 20 psi (1.4 bar), Rear

128Accessories14-305 OPERATOR'S PROTECTIVE ENCLOSURE DRAWING

129Accessories14-305 OPERATOR'S PROTECTIVE ENCLOSURE PARTS LISTREF# PART# DESCRIPTION QUANTITY1 15-429-17 Windshield 115-429-23 Clamp 12 15-429-0

130Accessories14-305 OPERATOR'S PROTECTIVE ENCLOSURE DRAWING

131AccessoriesOPERATOR'S PROTECTIVE ENCLOSURE INSTALLATION1. Remove cab from shipping pallet. Carefully remove band holding doors closed and save

132Accessories ALTERNATOR PARTS LISTPART# DESCRIPTION QUANTITY15-473 Alternator 63Amp 115-475 Alternator Adjustment Bracket 115-344 Pump Mount Plate

133AccessoriesINSTALLATION INSTRUCTIONS (CONTINUED)15. Bolt pump mount bracket with pump and alternator to back side of angle on frame that the old on

134AccessoriesSTAR SHIELD ASSEMBLY DRAWINGFigure 2: Lift frame attachment on Spray Star 1600 vehicle.Figure 10: Center actuator position and level adj

135AccessoriesINSTALLATION INSTRUCTIONS1. Locate the pivot plate. The pivot plate is shipped attached with two U-bolts and is pinned to the pivot armw

136AccessoriesINSTALLATION INSTRUCTIONSELECTRICAL LIFT OPTION1. Attach electric actuators.2. If the spray vehicle has the appropriate electric control

137ReferenceDECAL LISTThis is a list of decals located on the Spray Star 1600P. Part number, description and location will help in reor-dering decals.

Service12ADJUSTMENTSINTERLOCK SWITCHLocated on the front, below the floorboard and behind the clutch. The Interlock Switch is in the electrical circui

138ReferenceQUICK REFERENCE REPLACEMENT PARTSREPLACEMENT FILTERS78-090 Oil Filter Kohler # 12 050 0178-088 Air Cleaner Kohler # 47 083 0378-089 Pre-Cl

LIMITED WARRANTYSMITHCO warrants this product to be free from defects in material and workmanship under normaluse for one year from the date of purcha

13NOTES

14DiagramsHYDRAULIC DIAGRAM

15DiagramsHYDRAULIC DIAGRAM PARTS LISTREF# PART# DESCRIPTION QUANTITY1 14-352 Hydraulic Hose 54" 12 14-351 Hydraulic Hose 46" 13 50-456 Hydr

16DiagramsWIRING DIAGRAMColor Code ChartBl BlueBr BrownY YellowGrn GreenO OrangeR RedB BlackP PurpleW WhiteG/W Green &WhiteUse dielectric grease o

17DiagramsWIRING DIAGRAM PARTS LISTREF# PART# DESCRIPTION QUANTITY1 34-146 Panel Mounted Circuit Breaker 134-145 Circuit Breaker Boot 12 8935 Buss Bar

Introduction Service Diagrams Parts Accessories ReferenceCONTENTSIntroduction ... 1-3Introduction ...

18DiagramsHYDRAULIC SCHEMATIC

19DiagramsWIRING SCHEMATIC

20PartsBODY & FRAME DRAWING

Parts21BODY & FRAME PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-857 Front Tire & Wheel 216-857-01 Tire 20 x 10.00 - 10NHS 4 Ply 216-857-02 W

22PartsTANK AND REAR FENDER DRAWING

Parts23TANK AND REAR FENDER PARTS LISTREF# PART# DESCRIPTION QUANTITY1 14-322 Rear Tank Strap 12 HB-38-16-250 Bolt 3/8 - 16 x 21/2 4HNTL-38-16 Lock Nu

24PartsNOSE CONE DRAWING

Parts25NOSE CONE PARTS LISTREF# PART# DESCRIPTION QUANTITY1 HNJ-58-18 Jam Nut 5/8 - 18 12 HWK-316-075 Woodruff Key 3/16 x 3/413 15-030 Steering Wheel

26PartsNOSE CONE DRAWING

Parts27NOSE CONE PARTS LISTREF# PART# DESCRIPTION QUANTITY30 50-359 Warning Light (see wiring for terminals) 131 34-146 Circuit Breaker 30 Amp 132 34

1IntroductionInformation needed when ordering replacement parts:1. Model number of machine.2. Serial number of machine.3. Name and part number of part

28PartsBRAKE DRAWING

Parts29BRAKE PARTS LISTREF# PART# DESCRIPTION QUANTITY1 60-106 Brake Lever 12 HB-38-16-175 Bolt 3/8 - 16 x 13/4 1HW-38 Washer 3/8 1HWL-38 Lockwasher 3

30PartsPUMPS AND EXHAUST DRAWING

Parts31PUMPS AND EXHAUST PARTS LISTREF# PART# DESCRIPTION QUANTITY1 15-371 Muffler 12 13-498 Muffler Clamp 11/8 23 15-379 Exhaust Pipe 14 18-220 Muffl

32PartsSPRAY PUMP DRAWING

Parts33SPRAY PUMP PARTS LISTREF# PART# DESCRIPTION QUANTITY1 15-580 Pump Arm 12 HB-38-16-150 Bolt 3/8 - 16 x 11/2 2HW-38 Washer 3/8 2HNTL-38-16 Lock N

34PartsFRONT AXLE DRAWING

Parts35FRONT AXLE PARTS LISTREF# PART# DESCRIPTION QUANTITY1 10-180 Left Front Fender 1HBC-516-18-100 Carriage Bolt 5/16 - 18 x 1 4HW-516 Washer 5/16

36PartsCLUTCH LINKAGE DRAWING

Parts37CLUTCH LINKAGE PARTS LISTREF# PART# DESCRIPTION QUANTITY1 Part of Main Frame2 15-482 Bottom Mount Bracket 13 HB-38-16-100 Bolt 3/8 - 16 x 1 2HW

2IntroductionGENERAL SAFE PRACTICES1. It is your responsibility to read this manual and all publications associated with this machine.2. Never allow a

38PartsENGINE AND CONTROL PANEL DRAWING

Parts39ENGINE AND CONTROL PANEL PARTS LISTREF# PART# DESCRIPTION QUANTITY1 15-356 Engine/Seat Cover 18803-41 Trim 12 16-755 Boom Control Switch 215-47

40PartsENGINE AND CONTROL PANEL DRAWING

Parts41ENGINE AND CONTROL PANEL PARTS LISTREF# PART# DESCRIPTION QUANTITY25 15-481 Belt Guard 126 15-483 Top Mounting Bracket 127 15-555 Left Belt Gua

42PartsGAS TANK DRAWING

Parts43GAS TANK PARTS LISTREF# PART# DESCRIPTION QUANTITY1 15-492 Cap with Gauge 12 15-491 5 Gallon gas Tank 13 14-337 Gas Tank Bracket 14 Main Frame5

44PartsTURBO QUAD AGITATOR DRAWING14-371 STRAINER DRAWING

Parts45TURBO QUAD AGITATOR PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-036 Agitator Jets (includes one each 1/8", 5/32", and 3/16" or

46PartsTorque to150 in/lb(17Nm)Torque to 140-160 in/lb (16-18Nm)15-301 ORBITOR DRAWING

Parts4715-301 ORBITOR PARTS LISTREF# PART# DESCRIPTION QUANTITY1* O-Ring Seal 32* Quad Seal 13 15-301-14 Bearing Kit 1Bearing Race 2Bearing 14 Spool 1

3IntroductionSPECIFICATIONSWEIGHTS AND DIMENSIONSLength 112" (285 cm)Width 61" (155 cm) Width With Booms Down 230" (584 cm)Height 50&qu

48Parts15-409 3-SPEED TRANSMISSION DRAWING

Parts4915-409 3-SPEED TRANSMISSION PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-341 Ball 3/8 detent 22 16-342 Poppet Spring 23 16-348 Low & Rever

50Parts15-409 3-SPEED TRANSMISSION DRAWING

Parts5115-409 3-SPEED TRANSMISSION PARTS LIST40 16-309 Spacer (speedometer) 141 16-305 Snap Ring 142 16-304 Rear Bearing 143 16-303 Main Shaft 144 16-

52PartsTorque 75-100 in/lb(8.25-11Nm)Torque 75-100 in/lb(8.25-11Nm)Torque 190-210 in/lb(21-23Nm)15-315 HYDRAULIC PUMP DRAWING

Parts5315-315 HYDRAULIC PUMP PARTS LISTREF# PART# DESCRIPTION QUANTITY1 15-315-18 Cap Screw 12 15-315-17 Washer 43* Stato-Seal 14 18-060 Pipe Plug 3/8

54Parts16-989 HYPRO PUMP DRAWING

Parts5516-989 HYPRO ® PUMP PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-966-01 Drain Plug 42 16-966-02 Pump Cassing 13 16-966-03 Impeller Nut 14 16-

56Parts16-037 REAR AXLE DRAWING

Parts5716-037 REAR AXLE PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-510 Wheel Bolt 1016-562 Lock Nut 22 16-511 Axle Shaft (Left and Right) 23 16-513

Service4MAINTENANCEBefore servicing or making adjustments to machine, stop engine and remove key fromignition. When servicing the spray pump or filter

58PartsBRAKE ASSEMBLY DRAWING

Parts59BRAKE ASSEMBLY PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-704 Shoe Return Spring (Green) 12 16-725 Shoe and Lining Kit 2 sets required3 16-7

60Accessories1602P PLUMBING DRAWING(RAVEN 440)

61Accessories1602P PLUMBING PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-989 Hypro® Pump 12 16-281 Liquid Filled Gauge 13 16-034 Throttling Valve 116

62Accessories1604P PLUMBING DRAWING (RAVEN 203)

63Accessories1604P PLUMBING PARTS LISTREF# PART# DESCRIPTION QUANTITY1 14-371 Strainer 12 16-989 Hypro® Pump 13 16-166 Hex Plug 3/4 MPT 14 16-825 Redu

64Accessories1607P PLUMBING DRAWING (TEE JET 844)

65Accessories1607P PLUMBING PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-989 Hypro® Pump 12 16-281 Liquid Filled Gauge 13 16-034 Throttling Valve 116

66Accessories1610P PLUMBING DRAWING (MANUAL)

67Accessories1610P PLUMBING PARTS LISTREF# PART# DESCRIPTION QUANTITY1 10-263 Front Valve Bracket 12 10-264 Rear Valve Bracket 13 16-281 Liquid Filled

5ServiceMAINTENANCEENGINE OILChange and add oil according to chart below based on air temperature at the time of operation. Do not overfill.Use a high

68AccessoriesCONTROLS 1602P SYSTEM DRAWING (RAVEN 440)CONTROL 1604P SYSTEM DRAWING (RAVEN 203)WBBrWWWYYGrnGrnBl1234567891011121415RW16WRTO GROUND UNDE

69AccessoriesCONTROLS 1602P SYSTEM PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-558 Mounting Knob 22 16-525 Console (only) 116-234 Computer Cover 13*

70AccessoriesCONTROL 1607P SYSTEM DRAWING (TEE JET 844)15-515 FLOW METER DRAWING

71AccessoriesCONTROL 1607P SYSTEM PART LISTREF# PART# DESCRIPTION QUANTITY1* 16-985 Computer Console (Only) 116-234 Computer Cover 12* 10-286 Direct W

72Accessories16-524 AND 16-866 MOTORIZED CONTROL VALVE DRAWING16-456 FLOW METER DRAWING

73Accessories16-524 AND 16-866 MOTORIZED CONTROL VALVE PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-870 Valve Cover 12* 16-524-01 #6 Self Tapping Sc

74Accessories10-268 3-WAY MANUAL VALVE DRAWING

75Accessories10-268 3-WAY MANUAL VALVE PARTS LISTREF# PART# DESCRIPTION QUANTITY1 10-268-07 Boom Lever 32 10-268-16 Bolt and Washer 223 10-268-17 Boom

76Accessories14-348 SOLENOID VALVE DRAWING

77Accessories14-348 SOLENOID PARTS LISTREF# PART# DESCRIPTION QUANTITY1 14-348-02 Coil Assembly 12 16-879-07 Upper Diaphragm Housing 13 14-348-03 Arma

Service6MAINTENANCE (CONTINUED)TIRE PRESSURECaution must be used when inflating a low tire to recommended pressure. Over inflating can cause tires toe

78Accessories16-986 REGULATING BUTTERFLY VALVE DRAWING

79Accessories16-986 REGULATING BUTTERFLY VALVE PARTS LISTREF# PART# DESCRIPTION QUANTITY1 15-531-06 Polypropylene Cover 12 15-552-12 Stainless Steel P

80Accessories10-300 18' TERRAIN FOLLOWING BOOM DRAWING11-158-04Gear Kit 20:111-158-02Rear Housing11-158-03Motor 12VDC11-158 Linear ActuatorRef# 3

81Accessories10-300 18' TERRAIN FOLLOWING BOOM PARTS LISTREF# PART# DESCRIPTION QUANTITY1 13-498 Muffler Clamp 11/82HWL-516 Lockwasher 5/164HN-51

82Accessories10-300 18' TERRAIN FOLLOWING BOOM DRAWING11-158-04Gear Kit 20:111-158-02Rear Housing11-158-03Motor 12VDC11-158 Linear ActuatorRef# 3

83Accessories10-300 18' TERRAIN FOLLOWING BOOM PARTS LISTREF# PART# DESCRIPTION QUANTITY26 33-302 Left Pivot Bracket 1HMBS-100-10 Stainless Steel

84Accessories10-300 18' TERRAIN FOLLOWING BOOM DRAWING

85AccessoriesINSTALLATION INSTRUCTIONSFor best results use Teflon® Tape on all fittings.1. The three boom assemblies are not on the packing list but

86Accessories11-158-04Gear Kit 20:111-158-02Rear Housing11-158-03Motor 12VDC11-158 Linear ActuatorRef# 3015-493 STAINLESS STEEL 18' AUTO BOOM DR

87Accessories15-493 STAINLESS STEEL 18' AUTO BOOM PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-926 Stainless Steel Cap 3/4 32 13-498 U-Bolt Kit

7Service1. After the wheel is removed, remove the brake drum. 2. Using a 1/2" socket, line up the hole in the axle shaftflange to remove the back

88Accessories15-493 STAINLESS STEEL 18' AUTO BOOM DRAWINGBOOM CARRIER DRAWING

89Accessories15-493 STAINLESS STEEL 18' AUTO BOOM PARTS LISTREF# PART# DESCRIPTION QUANTITY30 11-158 Linear Actuator with 4" Stroke 231 33-3

90Accessories15-577 STAINLESS STEEL 18' MANUAL BOOM DRAWING

91Accessories15-577 STAINLESS STEEL 18' MANUAL BOOM PARTS LISTREF# PART# DESCRIPTION QUANTITY1 16-926 Stainless Steel Cap 3/4 32 13-498 U-Bolt Ki

92Accessories15-577 STAINLESS STEEL 18' MANUAL BOOM DRAWING

93Accessories15-577 STAINLESS STEEL 18' MANUAL BOOM PARTS LISTREF# PART# DESCRIPTION QUANTITY29 15-014 Shift Knob 230 HB-38-16-175 Bolt 3/8 - 16

94AccessoriesBOOM WIRING DIAGRAM (for 10-300/15-493 Booms)NOZZLE ASSEMBLY DRAWING

95Accessories(for 10-300/15-493 Booms) BOOM WIRING PARTS LISTPART# DESCRIPTION QUANTITY8853 Female Spade Connectors 215-472 Switch Boot 211-158 Linear

96Accessories14-100 BOOM DRAWING

97Accessories14-100 BOOM PARTS LISTREF# PART# DESCRIPTION QUANTITY1 HBM-8-25 Bolt M8 x 25 102 HNM-8 Nut M8 183 16-770 Arm Tie Bar 24 16-775 Knob 25 16