Smithco Spray Star 1000 Quick start guide

Spray Star 1000
10-100-D w/ TeeJet System
SN: 100621
December 2017
Parts & Service
Product Support: Hwy SS & Poplar Ave; Cameron WI 54822
1-800-891-9435 [e-mail]

Introduction Service Diagrams Parts Accessories Reference
CONTENTS
Introduction..........................................................1-3
Safe Practices ..........................................................2
Specication .............................................................3
Optional 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
Fitting Torque Charts ..............................................13
Parts..................................................................14-43
Body and Frame ...............................................14-15
Nose Cone ........................................................16-17
Front Axle .........................................................18-19
Seat Console and ROPS...................................20-21
Fuel Tank ...........................................................22-23
Oil Tank-Oil Filter-Oil cooler...............................24-25
Foot Pedal Linkage............................................26-27
Pump .................................................................28-29
Engine and Exhaust ..........................................30-31
Park Brake.........................................................32-33
Rear Axle ...........................................................34-35
Spray Tank.........................................................36-37
Turbo-Quad Agitator ..........................................36-37
10-576 Orbitrol...................................................38-39
42-797 Hydraulic Pump.....................................40-41
16-998 Hypro® Pump..............................................42
10-510 Wheel Motor...............................................43
Accessories ....................................... 44-106
1010 Plumbing (Manual Valve)...................................44-45
1002 Plumbing (TeeJet® 744).....................................46-47
1008 Plumbing (TeeJet® Radion 8140).......................48-49
1002 Controls (TeeJet® 744)............................................ 50
1008 Controls (TeeJet® Radion 8140) ............................. 51
1016 Plumbing (TeeJet® DynaJet + Aeros) ................52-55
TeeJet® DynaJet Module Mounts................................56-57
TeeJet® Aeros Wiring ....................................................... 58
TeeJet® DynaJet Wiring................................................... 59
16-524 Motorized Control Valve ...................................... 60
15-737 Strainer................................................................ 61
10-648 3-Way Manual Valve.......................................62-63
15-743 Manifold Ball Valve ............................................. 64
20-685 Regulator Valve ................................................... 65
14-801 Agitator Strainer................................................... 66
Turbo TurfJet Tips............................................................ 67
XR TEEJET Tips ............................................................. 67
17-585 18’ Heavy Duty Boom.....................................68-71
17-585 Plumbing ........................................................72-73
17-601 15’ Heavy Duty Boom....................................74-77
17-601 Plumbing ........................................................78-79
QJS Nozzle Drawing ....................................................... 80
QJS Bottom mounted Nozzle Assembly.......................... 81
Triple Nozzle Assembly ................................................... 82
10-370/10-365 Water Fill Meter Kit.................................. 83
16-906 Electric Hose Reel.......................................... 84-85
16-129 Hose Reel............................................................ 86
10-422 Hose Reel Mount (for HD Super Booms)................ 87
Hose Reel Plumbing................................................... 88-89
Electric Hose Reel Wiring................................................ 90
Hose Reel Adjustments ................................................... 91
10-378 Foam Marker Kit ............................................ 92-97
14-291Foamer............................................................98-99
30-006 Fresh Water Wash Tank ................................... 100
10-417 Chemical Cleanload®..................................101-103
15-620 Chemical Cleanload® Eductor .................... 104-105
15-835 Tank Rinsing System........................................ 106
Reference .......................................107-108
Decal List....................................................................... 107
Quick Reference Replacement Parts ............................ 108

1
Introduction
INTRODUCTION
Thank you for purchasing a Smithco product.
Read this manual and all other manuals pertaining to the Spray Star 1000 carefully as they contain safety,
operating, assembly and maintenance instructions. Failure to do so could result in personal injury or equip-
ment 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 1000 is located on the right main frame, in front of the oil
tank. Refer to engine manual for placement of engine serial number. 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 1000
WEIGHTS AND DIMENSIONS
Length 112" (285 cm)
Width 70" (178 cm)
Height With 18' Boom 110" (240 cm)
Height 48" (122 cm)
Wheel Base 53" (135 cm)
Weight Empty 1480lbs (675 kg)
Weight Full 2248 lbs (1025 kg)
SOUND LEVEL (DBA)
At ear level 85 dba
At 3 ft (0.914 m) 83 dba
At 30 ft (9.14 m) 72 dba
ENGINE
Make Briggs & Stratton
Model# 386447
Type / Spec# 0058 G1
Horsepower 23HP (17 kw)
Fuel Unleaded 87 Octane Gasoline Minimum
Cooling System Air Cooled
Lubrication System Full Pressure
Alternator 25 Amp
WHEELS & TIRE Front: Two 20 x 10.00 x 10 NHS Multi-Rib; 20psi (1.4 bar)
Rear: Two 24 x 13.00 x 12 NHS Multi-Trac; 20 psi (1.4 bar)
PARK BRAKE Hand Operated Lever, Discs on Rear Axle Speed 0 to 3 mph (0-4.8
kph)
SPEED
Forward Speed 0-8 mph (0-12.8 kph)
Reverse Speed 0-3 mph (0-4.8 kph)
BATTERY Automotive type 24F-12 Volt
BCI Group Size 24
Cold Cranking Amps 575 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 6 gallon (22.7 liters)
Hydraulic Fluid 5 gallon (19 liters)
Grade of Hydraulic Fluid SAE 10W-40 API Service SJ or higher Motor Oil
OPTIONAL EQUIPMENT
10-417 Chemical Clean-load Safe Fill System 1002 203 Spray System
10-419 Fresh Water Tank 1008 440 Spray System
17-601 15' Heavy Duty Boom 1010 3-Way Manual System
15-835 Tank Rinsing System 1011 Sharp Shooter + 440 Spray System
17-585 18' Heavy Duty Boom 10-378 Foam Marker
10-370 Water Meter Kit (liters) 30-141 26 Gal. Wash System
10-365 Water Meter Kit (gallons)
10-422 Hose Reel Mount Kit
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 1000 has 10
grease ttings.
A. One on the rod end of hydraulic cylinder.
B. One on each the right and left spindles.
C. One on the center front pivot.
D. One on each end of tie rod.
E. One on the pedal relay.
F. One on the forward pedal.
G. One on the reverse pedal.
ELECTRICAL CONNECTIONS
Use dielectric grease on all electrical connections.
AIR CLEANER
1. Loosen cover retaining snaps and remove
cover.
2. Remove pre-cleaner from paper element.
3. Check paper element. Replace element as necessary.
4. Wash pre-cleaner in warm water with detergent. Rinse pre-cleaner thoroughly until all traces of deter-
gent are eliminated. Squeeze out excess water (do not wring). Allow pre-cleaner to air dry.
5. Saturate pre-cleaner with new engine oil. Squeeze out all excess oil.
6. Reinstall pre-cleaner over paper element.
7. Reinstall air cleaner cover. Secure cover with cover retaining knob.
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 8 hours and every 250
hours thereafter.
7. Lower machine to ground and remove blocks and jack.
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.

5
Service
MAINTENANCE
ENGINE OIL
Change and add oil according to chart below. Do not overll. Engine oil capacity is 2 quarts. We recommend
high-quality detergent oils classied for service SF, SG, SH, SJ or higher. Do not use special additives. Out-
door temperatures determine the proper oil viscosity for the engine. Use the chart to select the best viscosity
for the outdoor temperature range expected
SAE VISCOSITY GRADES
Use of multi-viscosity oils (10W-30, etc.) above 80° F (27° C) will result in high oil consumption and possible
engine damage. Check oil level more frequently if using these types of oils.
SAE 30 oil, if used below 40° F (4° C), will result in hard starting and possible engine bore damage due to
inadequate lubrication.
HYDRAULIC OIL
1. Use SAE 10W-40 API Service SJ or higher motor oil.
2. For proper warranty, change oil every 500 hours or annually, which ever is rst. Change the lter after
the rst 50 hours, then every 250 hours thereafter.
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.

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 immediately with liberal
amounts of water. Get medical attention immediately.
Use of booster battery and jumper cables. Particular care should be used when con-
necting 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 (-) terminal of
battery)
To prevent damage to other electrical components on
unit being started, make certain that engine is at idle
speed before disconnecting jumper cables.
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 pre-
vent 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-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 connect 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.
Maintenance Service Interval Maintenance Procedure
Aer the rst 8 operating hours Torque the wheel lug nuts. (64-74 /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.
Aer the rst 50 hours Change Hydraulic Oil Filter.
Every 100 hours Clean or change air lter.1
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..
Check muer and spark arrestor.
Check belt tension .
Every 250 hours Check engine valve clearance and adjust if necessary.
Check idle speed.
Clean battery terminals.
Change hydraulic oil lter.
Torque the wheel lug nuts. (64-74 /lb (87-100 Nm))
Every 500 hours or yearly Change fuel lter.
Change hydraulic oil and lter.
Clean oil cooler ns.1
Clean air cooling system.1
Check safety lter in remote air cleaner.
1 In dusty conditions or when airborne debris is present, clean more oen.

8
Service
END USER'S SERVICE CHART
Duplicate this page for routine use
Maintenance Check Item For the week of:
Mon Tues. Wed. urs. 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