Smithco Spray Star 1200 Quick start guide

Spray Star 1200
Truck Model 20-500-C
Manual System 1201
TeeJet Radion®8140 1202
TeeJet®744 1204
TeeJet Aeros/DynaJet®1215/1218/1220
TeeJet Radion/DynaJet®1207/1208
SN: 12001
Product Support: Hwy SS & Poplar Ave; Cameron WI 54822
1-800-891-9435 [e-mail]
Parts & Service

Introduction Service Diagrams Parts Accessories Reference
CONTENTS
Introduction............................................1-3
Introduction........................................................................ 1
General Safe Practices...................................................... 2
Specications ................................................................... 3
Optional Spray Equipment................................................. 3
Service....................................................4-9
Maintenance...................................................................4-6
Storage.............................................................................. 6
Service Chart..................................................................... 7
End User’s Service Chart .................................................. 8
Adjustments....................................................................... 9
Diagrams ............................................10-13
Wiring Diagram........................................................... 10-11
Hydraulic Diagram......................................................12-13
Parts....................................................14-47
Body & Frame ............................................................14-15
Engine Cover/ Roll Bat ...............................................16-17
Control Panel and Steering ........................................18-19
Foot Pedal Linkage.....................................................20-21
Front Axle .................................................................22-23
Oil Tank and Fuel Tank ...............................................24-25
Seat Panel..................................................................26-27
Hydraulic Pump ..........................................................28-29
Engine and Exhaust ...................................................30-31
Spray Pump................................................................32-33
Spray Tank..................................................................34-35
Turbo Quad Agitator .................................................. 36-37
Park Brake and Rear Axle ..........................................38-39
15-301 Orbital ............................................................40-41
76-638 Hydrostatic Pump...........................................42-43
76-197 Eaton Gear Pump...........................................44-45
15-970 Hypro®Pump .................................................46-47
Spray Systems...................................48-98
Plumbing 1201 Manual System..................................48-49
Plumbing 1202 System (Radion®8140) .......................50-53
Plumbing 1204 System (TeeJet®744) ........................ 54-57
1202 Wiring System(Radion®8140) .................................. 58
1204 Wiring System (TeeJet®744) ................................ 59
Control Mounts ...........................................................60-61
Plumbing 1207/1208/1215/1218/1220 .......................62-63
1207/1208 Wiring System ............................................... 64
1207/1208 Rear Module Mounts ..................................... 65
1215/1218/1220 Wiring ................................................... 66
1215/1218/1220 Rear Module Mounts ............................ 67
14-801/14-607 Strainer.................................................... 68
15-737/14-628 Flanged Strainer...................................... 69
15-743 Manifold Ball Valve.............................................. 70
20-817 Regulaotr Valve................................................... 71
20-785 Regulator Valve................................................... 72
17-580 20’ HD Boom ..................................................74-77
17-580 20’ HD Boom 1202/1204 Plumbing ..................... 78
17-580 20’ HD Boom 1207 Plumbing .............................. 79
17-580 20’ HD Boom 1220 Plumbing .............................. 80
17-585 18’ HD Boom 1218 Plumbing .............................. 81
17-585 18’ HD Boom ..................................................82-85
17-585 18’ HD 1202/1204 Plumbing ............................... 86
17-585 18’ HD Boom 1208 Plumbing .............................. 87
17-601 15’ HD Boom ..................................................88-91
17-601 15’ HD Boom 1202/1204 Plumbing ..................... 92
17-601 15’ HD Boom 1215 Plumbing .............................. 93
Standard Nozzle Assembly.............................................. 95
1207/1208 Nozzle Assembly ......................................96-97
1215/1218/1220 Nozzle Assembly .................................. 98
Accessories .....................................99-124
15-835 Tank Rinsing System........................................... 99
16-906 Electric Hose Reel .....................................100-101
Electric Hose Reel Wiring Diagram ............................... 102
Hose Reel Adjustments ................................................. 103
16-129 Manual Hose Reel ............................................ 104
15-967 Hose Reel for HD Booms ................................. 105
Hose Reel Plumbing...............................................106-107
15-965 Foam Marker Installation............................ 108-111
14-291 Foam Marker Parts List.............................. 112-113
Foam Marker Wiring...................................................... 114
20-815 Water Meter Kit (Gallons).................................. 115
20-816 Water Meter Kit (Liters) ..................................... 115
15-968 20 Gallon Rinse Tank ................................. 116-117
30-006 Fresh Water Tank - Rear Mount ........................ 118
10-653 Fresh Water Tank - Front Mount........................ 119
15-619 Chemical Clean-load System.....................120-124
Reference .......................................125-126
Decal List....................................................................... 125
Quick Reference Replacement Parts ............................ 126
Limited Warranty

1
Introduction
INTRODUCTION
Thank you for purchasing a Smithco product.
Read this manual and all other manuals pertaining to the Spray Star 1200 carefully as they have safety, op-
erating, 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 Smithco machines have a Serial Number and Model Number. Both numbers are needed when ordering
parts. The serial number plate on the Spray Star 1200 is located on right mainframe behind exhaust. Refer to
engine manual for placement of engine serial number.
For product and accessory information, help nding a dealer, or to register your product please contact us at
www.Smithco.com.
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
For easy access record your Serial and Model numbers here.
SMITHCO CUSTOMER SERVICE 1-800-891-9435
 
WARNING
Failure to follow cautious operating practices can re-
sult in serious injury to the operator or other persons.
The owner must understand these instructions, and
must allow only trained persons who understand these
instructions to operate this vehicle.
WARNING:
Engine exhaust and some of its constituents are
known to the State of California to cause cancer,
birth defects, and other reproductive harm.
For more information visit
www.P65Warning.ca.gov

2
Introduction
SAFE PRACTICES
1. It is your responsibility to read this manual and all publications associated with this machine.
2. Never allow anyone to operate or service the machine or its optional equipment without proper training
and instructions. Never allow minors to operate any equipment.
3. Learn the proper use of the machine, the location and purpose of all the controls and gauges before
you operate the equipment. Working with unfamiliar equipment can lead to accidents.
4. Wear all the necessary protective clothing and personal safety devises to protect your head, eyes, ears,
hands and feet. Operate the machine only in daylight or in good articial light.
5. Inspect the area where the equipment will be used. Pick up all debris you can nd before operating.
Beware of overhead obstructions and underground obstacles. Stay alert for hidden hazards.
6. Never operate equipment that is not in perfect working order or without decals, guards, shields, or other
protective devices in place.
7. Never disconnect or bypass any switch.
8. Carbon monoxide in the exhaust fumes can be fatal when inhaled, never operate a machine without
proper ventilation.
9. Fuel is highly ammable, handle with care.
10. Keep engine clean. Allow the engine to cool before storing and always remove the ignition key.
11. Disengage all drives and set park brake before starting the engine.
12. Never use your hands to search for oil leaks. Hydraulic uid under pressure can penetrate the skin and
cause serious injury.
13. This machine demands your attention. To prevent loss of control or tipping of the vehicle:
A. Use extra caution in backing up the vehicle. Ensure area is clear.
B. Do not stop or start suddenly on any slope.
C. Reduce speed on slopes and in sharp turns. Use caution when changing directions on slopes.
D. Stay alert for holes in the terrain and other hidden hazards.
14. Before leaving operator’s position:
A. Disengage all drives.
B. Set park brake.
C. Shut engine o󰀨 and remove the ignition key.
D. If engine has to run to perform any maintenance keep hands, feet, clothing and all other parts of
body away from moving parts.
15. Keep hands, feet and clothing away from moving parts. Wait for all movement to stop before you clean,
adjust or service the machine.
16. Keep the area of operation clear of all bystanders.
17. Never carry passengers.
18. Stop engine before making repairs/adjustments or checking/adding oil to the crankcase.
19. Use parts and materials supplied by Smithco only. Do not modify any function or part.
20. Use caution when booms are down as they extend out beyond the center line of the machine.
21. The tank is a conned space, take precaution.
These machines are intended for professional maintenance on golf courses, sports turf, and any other
area maintained turf and related trails, paths and lots. No guaranty as to the suitability for any task is
expressed or implied.

3
Introduction
SPECIFICATIONS SPRAY STAR 1200
WEIGHTS AND DIMENSIONS
Length 120" (305 cm)
Width 65" (165 cm)
Width With 18' Boom Open 240" (610 cm)
Height w/ Roll Bar 77" (195 cm)
Height w/ 18' Booms Folded 110" (279 cm)
Wheel Base 68" (173 cm)
Weight Empty 1877 lbs (851 kg)
Weight Full 3626 lbs (1645 kg)
SOUND LEVEL (DBA)
At ear level 92 dBA
At 3 ft. (0.914 m) 98 dBA
At 30 ft. (9.14 m) 88 dBA
ENGINE
Make Briggs & Stratton
Model# 613477
Type / Spec# 0271-J1
Horsepower 35 hp (26 kW)
Fuel Unleaded 87 Octane Gasoline Minimum
Cooling System Air Cooled
Lubrication System Full Pressure
Alternator 20 Amp
WHEELS & TIRE Front: Two 20 x 10.00 x 10 NHS Multi-Rib; 20 psi (1.4 bar)
Rear: Two 24 x 13.00 x 12 NHS Multi-Trac; 20 psi (1.4 bar)
SPEED
Innitely Variable 0-12 m.p.h. (0-20 kph)
BATTERY Automotive type 24F - 12 volt
BCI Group Size 24
Cold Cranking Amps 900 minimum
Ground Terminal Polarity Negative (-)
Maximum Length 10.25" (26 cm)
Maximum Width 6.88" (17 cm)
Maximum Height 10" (25 cm)
FLUID CAPACITY
Crankcase Oil See Engine Manual
Fuel 10 gallon (45.46 liters)
Hydraulic Fluid 5 gallon (19 liters)
Grade of Hydraulic Fluid SAE 10W-40 API Service SJ or higher Motor Oil
OPTIONAL EQUIPMENT
20-816 Water Meter Kit (Liters) 20-815 Water Meter Kit (Gallons)
15-619 Chemical Clean-load 10-653 Fresh Water Wash Tank- Front Mount
15-622 Canopy 30-006 Fresh Water Wash Tank - Rear Mount
15-965 Foam Marker 15-968 26 Gal. Wash System with Electric Pump
17-601 15' HD Boom 17-585 18' HD Boom
17-580 20' HD Boom 17-622 Boom Shield for 17-585
15-967 Hose Reel Mount Kit 17-590 Sonic Boom
15-835 Tank Rinsing System
16-129 Manual Rewind Hose Reel, 200-foot/61-meter capacity
16-906 Electric Rewind Hose Reel, 200-foot/61-meter capacity

4
Service
MAINTENANCE
Before servicing or making adjustments to machine, stop engine and remove
key from ignition.
Use all procedures and parts prescribed by the manufacturer's. Read the en-
gine manual before operation.
LUBRICATION
Use No. 2 General purpose lithium base grease and lubricate every 100 hours. The Spray Star 1200 has 7
lube points.
A. One on the rod end of hydraulic cylinder.
B. One on each the right and left spindles.
C. One on the reverse pedal.
D. One on each end of tie rod.
E. One on the forward pedal.
ELECTRICAL CONNECTIONS
Use dielectric grease on all electrical connections.
AIR CLEANER ON ENGINE
1. Unclip the two clips, remove the cover and pull out the element.
2. To service, clean by tapping gently on at surface. Do not oil. Replace if very dirty or damaged.
3. Clean out the inside of the body and cover.
4. Place the element into the body and put the cover back on..
Do not use petroleum solvents, e.g.., kerosene, which will cause cartridge to
deteriorate. Do not use pressurized air to clean cartridge. Pressurized air can
damage cartridge.

5
Service
MAINTENANCE
ENGINE OIL
Change and add oil according to chart below based on air temperature at the time of operation. Do not over-
ll. Use a high-quality detergent oil classied for service SF, SG, SH. SJ or higher. Use no special additives
with recommended oils. Do not mix oil with gasoline.
SAE Viscosity Grades
HYDRAULIC OIL
1. Use SAE 10W-30 API Service SJ or higher motor oil.
2. For proper warranty, change oil every 500 hours or annually, which ever is rst.
3. Oil level should be 2-2½" (5-6.4cm) from top of the tank when uid is cold. Do not overll.
4. After changing oil, run the machine for a few minutes. Check oil level and for leaks.
5. Always use extreme caution when lling hydraulic oil tank or checking level to keep system free of con-
taminants. Check and service more frequently when operating in extremely cold, hot or dusty conditions.
6. If the natural color of the uid has become black or smells burnt, it is possible that an overheating prob-
lem exists.
7. If uid becomes milky, water contamination may be a problem.
8. If either of the above conditions happen, change oil immediately after uid is cool and nd the cause.
Take uid level readings when the system is cold.
9. In extreme temperatures you can use straight weight oil. We recommend SAE 30W API Service SG
when hot (above 90°F (33°C)) and SAE 10W API Service SJ or higher when cold (below 32°F (0°C)
ambient temperature. Use either motor oil or hydraulic oil, but do not mix.
10. Oil being added to the system must be the same as what is already in the tank. Mark the tank ll area
as to which type you put in.
TIRE PRESSURE
Caution must be used when inating a low tire to recommended pressure. Over inating can cause tires to
explode. All tires should be 20 psi (1.4bar). Improper ination will reduce tire life considerably.
WHEEL MOUNTING PROCEDURE
1. Set park brake. Turn machine o󰀨 and remove key.
2. Block wheel on opposite corner.
3. Loosen nuts slightly on wheel to be removed.
4. Jack up machine being careful not to damage underside of machine.
5. Place wheel on hub lining up bolt holes.
6. Torque to 64-74 ft/lb (87-100Nm) using a cross pattern. Re-torque after rst 10 hours and every 200
hours thereafter.
7. Lower machine to ground and remove blocks and jack.

6
Service
MAINTENANCE
BATTERY
Batteries normally produce explosive gases which can cause personal injury. Do not allow ames, sparks or
any ignited object to come near the battery. When charging or working near battery, always shield your eyes
and always provide proper ventilation.
Battery cable should be disconnected before using “Fast Charge.”
Charge battery at 15 amps for 10 minutes or 7 amps for 30 minutes. Do not exceed the recommended
charging rate. If electrolyte starts boiling over, decrease charging.
Always remove grounded (-) battery clamp rst and replace it last. Avoid hazards by:
1. Filling batteries in well-ventilated areas.
2. Wear eye protection and rubber gloves.
3. Avoid breathing fumes when electrolyte is added.
4. Avoid spilling or dripping electrolyte.
Battery Electrolyte is an acidic solution and should be handled with care. If
electrolyte is splashed on any part of your body, ush all contact areas imme-
diately with liberal amounts of water. Get medical attention immediately.
Use of booster battery and jumper cables. Particular care should be used
when connecting a booster battery. Use proper polarity in order to prevent
sparks.
TO JUMP START (NEGATIVE GROUNDED BATTERY):
1. Shield eyes.
2. Connect ends of one cable to positive (+) termi-
nals of each battery, rst (A) then (B).
3. Connect one end of other cable to negative (-)
terminal of "good" battery (C).
4. Connect other end of cable (D) to engine block
on unit being started (NOT to negative (-) termi-
nal of battery)
To prevent damage to other electrical components on
unit being started, make certain that engine is at idle
speed before disconnecting jumper cables.
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 lter while the engine is still warm from operation.
3. The fuel system must be completely emptied, or the gasoline must be treated with a stabilizer to prevent deteriora-
tion.
If you choose to use a stabilizer, follow manufacturers recommendations, and add the correct amount for the ca-
pacity 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-o󰀨 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 con-
nect the plug leads. Crank the engine two or three revolutions.
5. Store machine in a clean, dry place.

7
Service
SERVICE CHART
Before servicing or making adjustments to the machine, stop engine, set park
break, block wheels and remove key from ignition.
Follow all procedures and ONLY use parts prescribed by the manufacturer.
Read the engine manual before maintenance.
The suggested maintenance checklist is not o󰀨ered 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 cover-
age. In adverse conditions such as dirt, mud or extreme temperatures, maintenance should be more frequent.
Maintenance Service Interval Maintenance Procedure
After the rst 8 operating hours Torque the wheel lug nuts. (64-74 ft/lb (87-100 Nm))
Change the engine oil lter.
Before each use daily
Check the engine oil level.
Clean area around mu󰀪er and controls.
Check the hydraulic uid level.
Check the tire pressure.
Check condition of hydraulic hoses and ttings.
Inspect and clean the machine.
After the rst 50 hours Change Hydraulic Oil Filter.
Every 100 hours
Clean or change air lter.1&2
Clean pre-cleaner.1
Change engine oil and lter.
Replace spark plug .
Lubricate machine.
Clean or change remote air cleaner.
Check the battery uid level and cable connections..
Service exhaust sytem.
Check belt tension .
Every 250 hours
Check engine valve clearance and adjust if necessary.
Check idle speed.
Clean battery terminals.
Change hydrauilic oil lter.
Torque the wheel lug nuts. (64-74 ft/lb (87-100 Nm))
Every 500 hours or yearly
Change fuel lter.
Change hydrauilic oil and lter.
Clean oil cooler ns.1
Replace air lter2
Replace fuel lter
Clean air cooling system.1
Check safety lter in remote air cleaner.
1In dusty conditions or when airborne debris is present, clean more often.
2 Every third air lter change, replace the inner safety lter.

8
Service
END USER SERVICE CHART
Duplicate this page for routine use.
Maintenance Check Item For the week of:
Mon Tues. Wed. Thurs. Fri. Sat. Sun.
Check the Safety Seat Switch
Check Steering Operation
Check the fuel level
Check the engine oil level.
Clean the air lter
Clean the engine cooling ns.
Check for unusual engine noises
Check the hydraulic oil level
Check hydraulic hoses and ttings for damage
Check for uid leaks.
Check the tire pressure
Check the Instrumentation
Inspect electrical system for frayed wires
Check park brake adjustment
Change oil lter.
Change oil.
Lubricate Machine
Ensure all warning decals are intact.
Areas of Concern
Inspection Performed by:
Item Date Information