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Smithco 32-500 Service Manual

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Parts & Service
Spray Star 5200
Model 32-500
SN: 520G001
July 2020
Product Support:
Hwy SS & Poplar Ave; Cameron WI 54822
1-800-891-9435
productsupport@smithco.com

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Summary of Contents for Smithco 32-500

  • Page 1 Parts & Service Spray Star 5200 Model 32-500 SN: 520G001 July 2020 Product Support: Hwy SS & Poplar Ave; Cameron WI 54822 1-800-891-9435 productsupport@smithco.com...

  • Page 2: Table Of Contents

    CONTENTS Introduction ..........1-3 Accessories ........56-111 Plumbing 5220/5224 System ........56-57 Introduction ................ 1 Plumbing Star Command System ......58-59 General Safe Practices............2 5220/5224 Wiring TeeJet Radion ........60 ® Specifications ..............3 5287/5288 Rear Module Mount ........61 Optional Spray Equipment..........3 5287/5288 DynaJet Wiring ..........

  • Page 3: Introduction

    All Smithco machines have a Serial Number and Model Number. Serial tag is located on right main frame be- low hydrostatic pump. Both numbers are needed when ordering parts. Refer to engine manual for placement of engine serial number.
  • Page 4 17. Stop engine before making repairs/adjustments or checking/adding oil to the crankcase. 18. Use parts and materials supplied by Smithco only. Do not modify any function or part. 19. Use caution when booms are down as they extend out beyond the center line of the machine.

  • Page 5: Specifications

    SPECIFICATIONS SPRAY STAR 5200 WEIGHTS AND DIMENSIONS Length 174" (4.42m) Width 89" (2.26m) Width w/ Booms Open 20' - 260" (6.6m) 24' - 308" (7.8m) Height w/ ROPS 84" (2.1m) Height w/ Booms Up 20' - 106" (2.7m) 24' - 118" (3.0m) Wheel Base 88"...

  • Page 6: Maintenance

    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 5200 has 9 grease fittings.
  • Page 7 MAINTENANCE ENGINE OIL Change and add oil according to chart below based on air temperature at the time of operation. Do not over- fill. Use a high quality detergent oil classified "For Service use API classification SL or higher" oil. Use no special additives with recommended oils.
  • Page 8 MAINTENANCE BATTERY Batteries normally produce explosive gases which can cause personal injury. Do not allow flames, 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”.

  • Page 9: Adjustments

    ADJUSTMENTS GROUND SPEED CONTROL The ground speed is regulated by the for- ward foot pedal and the toggle switches (A & B) on the center console. TO ENGAGE: 1. Push top of rocker switch(A) down. This turns speed control ‘On’ (amber light).

  • Page 10: Service Chart

    SERVICE CHART Before servicing or making adjustments to the machine, stop engine, 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 offered as a replacement for the manufacturer’s engine manual but as a supplement.
  • Page 11 SERVICE CHART Item Maintenance Procedure Torque the wheel lug nuts. (64-74 ft/lb (87-100 Nm)) After the first 8 operating hours Change the engine oil filter. Check the engine oil level. Clean area around muffler and controls. Check the hydraulic fluid level. Before each use daily Check the tire pressure.

  • Page 12: Storage

    STORAGE To prevent damage from freezing, pour window washer fluid into spray sys- tems tank and operate pump to circulate mix through gun and hose back to tank. Open boom control to circulate through rest of spray system. 1. Clean the exterior surfaces of the engine. 2.

  • Page 13: Engine Wire Harness

    ENGINE WIRE HARNESS...

  • Page 14: Wiring Diagram

    WIRING DIAGRAM Color Code Chart Blue Brown Yellow Green Orange Black Purple White...
  • Page 15 WIRING DIAGRAM PARTS LIST REF# PART# DESCRIPTION QUANTITY 20-730-01 GPS Antenna (part of speedometer) 30-356 GPS Speedometer 8945 Closed End Connector 33-084 Magnetic Coil CRUISE ON 15-726 Lighted Switch 15-731 Rocker, Amber CRUISE LOCK 15-726 Lighted Switch 15-731 Rocker, Amber SPRAY PUMP 15-726 Lighted Switch...

  • Page 16: Hydraulic Diagram

    HYDRAULIC DIAGRAM Use dielectric grease on all electrical connections.
  • Page 17 HYDRAULIC PARTS LIST REF# PART# DESCRIPTION QUANTITY 32-553 Hydraulic Hose, 194.5" 32-559 Hydraulic Hose, 125.5" 15-301 Orbital 15-301-01 Seal Kit 32-554 Hydraulic Hose, 69.5" 15-839 Steering Cylinder 15-839-01 Seal Kit 8833-48 1" Suction Hose x 48" 18-116 Hose Clamp 32-547 Hydraulic Hose, 45"...
  • Page 18 NOSE CONE DRAWING...

  • Page 19: Parts

    PART# DESCRIPTION QUANTITY 76-364 Square Boot 10-751 Steering Wheel HNJ-58-18 Jam Nut, - 18 27-077 Decal, Smithco Round 76-362 Mini Tilt Steering(includes * items) HB-516-18-125 Hex Bolt, - 18 x 1 HNFL-516-18 Flange Whiz-loc Nut, 15-844 Tilt Steering Spacer 31-056...

  • Page 20: Orbital Drawing

    ORBITAL DRAWING REF# PART# DESCRIPTION QUANTITY 76-362 Mini Tilt Steering 15-844 Tilt Steering Spacer 48-187 Stub Shaft 31-056 Tilt Steering Plate 31-057 Steering Spacer 15-301 Orbital 18-169 Straight Thread Connector HBM-6-1-16 Metric Hex Bolt, M6-1-16 HWLM-6 Metric Lock Washer, M6 HB-516-18-125 Hex Bolt, - 18 x 1...

  • Page 21: Fuel Tank

    FUEL TANK DRAWING REF# PART# DESCRIPTION QUANTITY 8940-64 " Fuel Hose x 64" (manifold to engine) Fuel Manifold Regulator (part of engine) 8940-14 " Fuel Hose x 14" (return) 18-498 Barb Fitting 32-642 Front Tank Mount 20-694 Fuel Cap 32-647 Level Sensor Assembly 32-531 20 gal.

  • Page 22: Foot Pedal Linkage

    FOOT PEDAL LINKAGE DRAWING...
  • Page 23 FOOT PEDAL LINKAGE PARTS LIST REF# PART# DESCRIPTION QUANTITY 32-571 RH & LH Brake Set 18-487 Elbow 32-545 Brake Hose, 34" 18-486 HP-18-100 Cotter Pin, HMB-58-14 Machine Bushing, x 14GA 32-676 Pedal Relay 30-152 Push-Pull Cable 18-115 Ball Joint, HN-14-28 Hex Nut, - 28 33-084...
  • Page 24 FRONT AXLE DRAWING...

  • Page 25: Front Axle

    FRONT AXLE PARTS LIST REF# PART# DESCRIPTION QUANTITY 33-073-02 Dust Cap HNAR-100-14 Slotted Jam Nut, 1 - 14 HP-18-150 Cotter Pin, 72-204 Tire and Wheel 72-204-01 Tire 72-204-02 Wheel 32-571 RH & LH Brake Set Brake Caliper 32-617 King Pin HMB-114-10 Machine Bushing, 1 x 10GA...

  • Page 26: Oil Tank And Cooler

    OIL TANK AND COOLER DRAWING...
  • Page 27 OIL TANK AND COOLER PARTS LIST REF# PART# DESCRIPTION QUANTITY 33-216 Battery 48-268 Black Battery Cable (Negative) 8-603 Battery Strap 78-325 Red Battery Cable (Positive) 13-747 Filler Breather 13-586-02 Bottom Gasket 13-586-03 Fuel Tank Neck HSM-10-32-063 Machine Screw, #10-32 x HWL-10 Lock Washer, #10 13-586-01...
  • Page 28 CONTROL PANEL DRAWING...

  • Page 29: Control Panel

    CONTROL PANEL PARTS LIST REF# PART# DESCRIPTION QUANTITY 32-695 Adjustable Hinge 32-688 Hinge Spacer 42-176 Low Head Cap Screw, -20 x HNFL-14-20 Flange Whiz-loc Nut, 32-594 Control Panel 77-207 Buzzer 32-534 Decal, Control Panel 15-725 Mount Panel End 15-730 Panel Plug 15-725 Mount Panel End 15-729...
  • Page 30 SEAT PANEL DRAWING...

  • Page 31: Seat Panel

    SEAT PANEL PARTS LIST REF# PART# DESCRIPTION QUANTITY 32-535 Roll Bar 10-706 Arm Rest Kit 32-588 Seat Body - Fiberglass 14-294 Seat Kit (includes * items) *14-800 Seat Rail Set *HSP-1260-340-250 Seat Spacer *14-292 Seat Switch 32-688 Hinge Spacer 32-695 Adjustable Hinge 42-176 Low Head Cap Screw,...

  • Page 32: Engine Hood

    ENGINE HOOD DRAWING...
  • Page 33 ENGINE HOOD PARTS LIST REF# PART# DESCRIPTION QUANTITY 50-081 Rubber Bumper HNFL-516-18 Flange Whiz-loc Nut, 32-664 LH Hood Rest 15-437-02 Rubber Latch HSM-10-32-112 Machine Screw, 10-32 x 1 HNFL-10-32 Flange Whiz-loc Nut, 10-32 HB-38-16-150 Hex Bolt, - 16 x 1 HW-38 Flat Washer, HNFL-38-16...
  • Page 34 ENGINE & EXHAUST DRAWING...
  • Page 35 ENGINE & EXHAUST PARTS LIST REF# PART# DESCRIPTION QUANTITY 32-569 Top Cooler Mount 32-658 Front Engine Mount Leg 30-042-14 Engine Isolator HB-38-16-100 Hex Bolt, - 16 x 1 HNFL-38-16 Flange Whiz-loc Nut, - 16 30-105 Oil to Air Heat Exchanger 30-064 Motor Washer 32-568...
  • Page 36 HYDROSTATIC & GEAR PUMP DRAWING...
  • Page 37 HYDROSTATIC & GEAR PUMP PARTS LIST REF# PART# DESCRIPTION QUANTITY Kubota WG3800 Engine Plate 18-115 Ball Joint, HN-14-28 Hex Nut, 32-590 Cable Mount 30-152 Cable 32-541 Air Cleaner Bracket 11-050 Extension Spring 42-537 Spade Bolt HNFL-38-16 Flange Whiz-loc Nut, - 16 HP-18-100 Cotter Pin, HMB-12-14...
  • Page 38 REAR AXLE DRAWING REF# PART# DESCRIPTION QUANTITY 18-392 Orifice 18-168 Str. Thd Elbow 13-406 Hydraulic Cylinder 14-267 Seal Kit 17-614 Boom Spacer HB-516-18-100 Hex Bolt, - 18 x 1 HW-516 Flat Washer, HNFL-516-18 Flange Whiz-loc Nut, 20-657 Mud Flap HB-14-20-075 Hex Bolt, - 20 x HNFL-14-20...
  • Page 39 REAR DRIVE ASSEMBLY DRAWING REF# PART# DESCRIPTION QUANTITY 32-548 LH Brake Release Hose, 30.75" 32-557 Return Hose, 33.5" 18-190 18-241 Straight Thread Connector 18-185 90° Elbow 32-612 Auxiliary Manifold 32-551 Supply Hose,13.5" 32-549 RH Brake Release Hose, 42" 18-169 Adapter 32-677 Boom Control Valve 18-188...
  • Page 40 SPRAY PUMP DRAWING When servicing the spray pump or filter, all control valves must be shut off if there is liquid in the tank. REF# PART# DESCRIPTION QUANTITY 18-494 Fork 18-481 18-492 Oring 18-480 Male Tee 18-482 Female Barb 33-480 Pressure Switch 18-042 Reducer Bushing,...

  • Page 41: Turbo Quad Agitator

    TURBO-QUAD AGITATOR REF# PART# DESCRIPTION QUANTITY 18-510 Mini Eductor 16-288 Reducer, 16-158 Close Nipple, 16-157 Female Pipe Thread Tee, 18-507 Nylon Nipple, NPT x 8...

  • Page 42: Spray Tank

    SPRAY TANK DRAWING...
  • Page 43 TANK PARTS LIST REF# PART# DESCRIPTION QUANTITY HB-38-16-300 Hex Bolt, -16 x 3 HW-38 Flat Washer, HNFL-38-16 Flange Whiz-loc Nut, - 16 32-533 Accessory Mount 16-953 Hinged Lid HRS-316-1125 Rivet, HW-316 Flat Washer, 20-663 EPDM Tank Gasket 16-169 16" Strainer Basket 16-945 1"...
  • Page 44 15-301 ORBITAL DRAWING...
  • Page 45 15-301 ORBITAL PARTS LIST REF # PART # DESCRIPTION QUANTITY Dust Seal Housing O-Ring Seal Quad Seal 10-576-03 Thrust Bearing 10-576-02 Bearing Race Manual Steering Relief Valve O-ring Plug 10‡ Standard Torque Centering Springs Sleeve 15-301-06 Wear Plate 10-576-01 Drive 15-301-08 Drive Pin Spool...
  • Page 46 15-301 REPAIR DISASSEMBLY INSTRUCTIONS...
  • Page 47 15-301 REPAIR REASSEMBLY INSTRUCTIONS...
  • Page 48 15-301 2-PIECE SHAFT SEAL INSTRUCTIONS...

  • Page 49: Eaton Gear Pump

    76-197 EATON GEAR PUMP REF# PART# DESCRIPTION QUANTITY Body 76-197-01 Front Plate Washer 76-197-06 Cap Screw 76-197-07 Retaining Ring Shaft Seal 33-061-15 Washer O-Ring Backup Gasket Seal Wear Plate 76-197-04 Shaft (comes with Idler Gear) 76-197-02 Back Plate Plug 76-197-08 Seal Kit...
  • Page 50 76-197 REPAIR DISSASSEMBLY INSTRUCTIONS 7. Remove backplate.
  • Page 51 76-197 RERPAIR DISASSEMBLY INSTRUCTINOS...
  • Page 52 76-197 REPAIR INSPECTION...
  • Page 53 76-197 REPAIR REASSEMBLY INSTRUCTIONS...
  • Page 54 76-197 REPAIR REASSEMBLY INSTRUCTIONS 76-197 REPAIR TROUBLESHOOTING...
  • Page 55 76-197 REPAIR TROUBLESHOOTING...

  • Page 56: Front Brake

    32-571 FRONT BRAKE REF# PART# DESCRIPTION QUANTITY Standard #84 Spindle Standard #84 Brake Flange Hub Rotor Inner Bearing Cone Inner Bearing Cup Outer Bearing Cone 27-023-30 Outer Bearing Cup Seal 27-022-02 Lug Studs, - 20 Spindle Washer Dust Cap Caliper Mounting Bracket HB-38-16-100 Hex Bolt, - 16 x 1...
  • Page 57 20-684-P FLOW METER REF# PART# DESCRIPTION QUANTITY 20-684-01 Sensor, PCB Assembly Washer, Seal Guide Vane Bearing Turbine Assembly Flat HEad Screw, #6 - 5/8 Pin, Retaining 20-684-04 Body Insert, Body Endcap 20-684-02 Oring 20-684-03 802 Flowmeter Repair Kit (includes all * items) MOTOR PARTS LIST...
  • Page 58 5220&5224 PLUMBING DRAWING (RADION 8140) 15-817 #50 Fitting O-ring 15-818 #75 Fitting O-ring 20' Boom 24' Boom 9032-128 " Black Hose x 128" (left boom) 9032-148 " Black Hose x 148" (left boom) 9032-96 " Black Hose x 96" (center boom) 9032-96 "...

  • Page 59: Flow Meter

    5220 & 5224 PLUMBING PARTS LIST ® (RADION 8140) REF# PART# DESCRIPTION QUANTITY 8897-47 " Discharge Hose 47" 18-116 Hose Clamp 14-671 1" Hose Barb Outlet 15-553-01 Clip 15-553-02 O-ring 14-801 Agitator Line Strainer, 50 Mesh 14-802 Replacement 50 Mesh Screen 15-825 #50 Male Quick Coupler 15-740...
  • Page 60 STAR COMMAND PLUMBING DRAWING DynaJet Plumbing Drawing (for Aeros 9040 or radion 8140) ® ® ® 15-817 #50 Fitting O-ring 15-818 #75 Fitting O-ring 20' Boom 24' Boom 9032-128 " Black Hose x 128" (left boom) 9032-148 " Black Hose x 148" (left boom) 9032-96 "...
  • Page 61 STAR COMMAND PLUMBING PARTS LIST REF# PART# DESCRIPTION QUANTITY 8897-47 " Discharge Hose 47" 18-116 Hose Clamp 14-671 1" Hose Barb Outlet 15-553-01 Clip 15-553-02 O-ring 14-801 Agitator Line Strainer, 50 Mesh 14-802 Replacement 50 Mesh Screen 15-825 #50 Male Quick Coupler 15-740 #50 Series Clamp 15-735...

  • Page 62: 5220/5224 Wiring Teejet

    5220/5224 WIRING [RADION 8140] If using Simulated Speed with a Radion 8140, one needs to change back to Ground Speed for proper rate control when spraying. REF# PART# DESCRIPTION QUANTITY Antenna 20-687-02 GPS Speed Sensor 20-697-01 Radion 8140 Console 20-697-02 Wire Harness 15-743 Manifold Valve...
  • Page 63 STAR COMMAND I MODULE MOUNTS REF# PART# DESCRIPTION QUANTITY 20-665 Drive Module Bracket 20-664 Z Bracket HSTP-14-20-075 Machine Screw, - 20 x HNFL-14-20 Flange Whiz-loc Nut, Center Boom Mount 17-614 Boom Spacer HB-516-18-100 Hex Bolt, -18 x 1 HNTL-516-18 Nylon Lock Nut, 32-542 Module Mount 32-543...
  • Page 64 5287/5288 DYNAJET WIRING STAR COMMAND I...
  • Page 65 NOTES...
  • Page 66 5285/5286 DYNAJET WIRING STAR COMMAND II REF# PART# DESCRIPTION QUANTITY DynaJet IUC7140 Module Harness, IC7140 to IC35 Cable, Pressure Sensor 20-670-04 Pressure Sensor CAN Extension Cable 20-670-08 CAN Terminator End RIght Harness, DJ Driver Center Harness, DJ Driver Left Harness, DJ Driver CAN Terminator Start 20-670-05 DynaJet Driver...

  • Page 67: 5285/5286 Aeros Wiring

    5285/5286 AEROS WIRING STAR COMMAND II REF# PART# DESCRIPTION QUANTITY 20-540 Ram Mount Aeros Harness w/ ISO CAN RAM Base Aeros Console 20-736-01 Antenna Cable 20-767 RX720 Receiver Switch box Power Cable 20-670-04 Pressure Sensor 20-684 Flow Meter Terminator Terminator DynaJet Interface Boom Harness IC18 Sprayer Module IC18 Harness...
  • Page 68 STAR COMMAND II MODULE MOUNTS REF# PART# DESCRIPTION QUANTITY 17-562 LH Break-Away Arm 11-050 Spring 17-560 Hinge Mount 17-559 Break-Away Mount 20-796 Bracket Cover 20-795 LH Driver Module Bracket HB-516-18-150 Hex Bolt, -18 x 1 HNFL-516-18 Flange Whiz-loc Nut, 20-794 Module Cover Bracket 10-625 Module Mount Bracket...

  • Page 69: Regulator Valve

    20-785 REGULATOR VALVE REF# PART# DESCRIPTION QUANTITY 20-785-01 6RPM Motor 15-552-24 Retaining Clip Socket Head Cap Screw, Stainless Steel 15-552-26 Motor Adapter, Polypropylene 15-517-11 Thrust Washer, Teflon 15-552-27 Stem, Stainless Steel 15-552-05 O-ring, Viton 15-517-16 Body, Nylon Lock Nut, Stainless Steel Ball, Polypropylene 15-552-13 Gasket, Viton...

  • Page 70: Manifold Ball Valve

    15-743 MANIFOLD BALL VALVE REF# PART# DESCRIPTION QUANTITY 15-552-23 Motor 15-878 Metri-Pack Cable (comes with motor) 15-552-24 Retaining Clip 15-552-25 Socket Head Cap Screw, Stainless Steel 15-552-26 Motor Adapter, Polypropylene 15-517-11 Thrust Washer, Teflon 15-552-27 Stem, Stainless Steel 15-552-05 O-ring, Viton 15-517-16 Body, Nylon Lock Nut, Stainless Steel...

  • Page 71: Shut-Off Valve

    14-673 SHUT OFF VALVE REF# PART# DESCRIPTION QUANTITY Motor 15-552-24 Retaining Clip Socket Head Cap Screw, Stainless Steel 15-552-26 Motor Adapter, Polypropylene 15-517-11 Thrust Washer, Teflon 15-552-27 Stem, Stainless Steel 15-552-05 O-ring, Viton 15-517-16 Body, Nylon Lock Nut, Stainless Steel 15-743-04 Ball, Polypropylene 15-552-13...
  • Page 72 15-737/14-628 FLANGED STRAINER REF# PART# DESCRIPTION QUANTITY 15-737-01 Strainer Head 75 Series 16-968-03 50 Mesh Screen 16-968-05 80 Mesh S 14-521-02 EPDM Gasket 14-521-03 Bowl 1" NPT 14-521-04 EPDM Rubber gasket 14-521-05 15-737 Flanged Strainer Assembly with 50 Mesh Screen 14-628 Flanged Strainer Assembly with 80 Mesh Screen...

  • Page 73: 14-801/14-607 Strainer

    14-801/14-607 STRAINER ASSEMBLY REF# PART# DESCRIPTION QUANTITY QC Strainer Head 14-801-01 Bowl Strainer QC Retaining Clip 14-802 50 Mesh Screen 14-609 100 Mesh Screen 14-801-02 Viton Oring 15-553-01 Retaining Clip 15-553-02 Viton Oring 14-801 Agitation Strainer Assembly with 50 Mesh Screen 14-607 QC Strainer Assembly with 100 Mesh Screen...
  • Page 74 32-505 20' RIGHT BOOM DRAWING...
  • Page 75 32-505 20' RIGHT BOOM PARTS LIST REF# PART# DESCRIPTION QUANTITY 30-258 1" 10-14GA Ribbed Plug 17-653 Boom Arm, RH 17-559 Break-Away Mount 17-561 RH Break-Away Arm HB-516-18-075 Bolt, - 18 x 4 or 8 HNTL-516-18 Lock Nut, - 18 4 or 8 11-050 Spring 17-560...
  • Page 76 32-505 20' LEFT BOOM DRAWING Star Command II Star Command I Standard Boom...
  • Page 77 32-505 20' LEFT BOOM PARTS LIST REF# PART# DESCRIPTION QUANTITY 30-258 1" 10-14ga Ribbed Plug 11-055 Spring 32-633 LH Site Gage 74-156 Decal, Reflective HB-14-20-250 Bolt, - 20 x 2 HW-14 Flat Washer, HNTL-14-20 Lock Nut, - 20 HB-516-18-075 Bolt, - 18 x 4 or 8 HNTL-516-18...
  • Page 78 32-565 24' RIGHT BOOM DRAWING...
  • Page 79 32-565 24' RIGHT BOOM PARTS LIST REF# PART# DESCRIPTION QUANTITY 32-561 Boom Arm, RH HB-516-18-075 Bolt, - 18 x 5 or 10 HNTL-516-18 Lock Nut, - 18 5 or 10 17-559 Break-Away Mount 17-561 RH Break-Away Arm 11-050 Spring 17-560 Hinge Mount HB-14-20-125 Bolt...
  • Page 80 32-565 24' LEFT BOOM DRAWING...
  • Page 81 32-565 24' LEFT BOOM PARTS LIST REF# PART# DESCRIPTION QUANTITY 30-258 1" 10-14ga Ribbed Plug 11-055 Spring 32-633 LH Site Gage 74-156 Decal, Reflective HB-14-20-250 Bolt, - 20 x 2 HW-14 Flat Washer, HNTL-14-20 Lock Nut, - 20 HB-516-18-075 Bolt, - 18 x 5 or 10 HNTL-516-18...

  • Page 82: Center Boom (Common)

    CENTER BOOM DRAWING (COMMON FOR BOTH 20' AND 24' BOOM)
  • Page 83 CENTER BOOM PARTS LIST (COMMON FOR BOTH 20' AND 24' BOOM) REF# PART# DESCRIPTION QUANTITY HB-516-18-100 Bolt, - 18 x 1 HNFL-516-18 Flange Lock Nut, - 18 17-596 Hinge pin w/ Spacer 17-598 LH Torsion Spring 32-544 Arm Pivot Hinge HB-38-16-100 Bolt, - 16 x 1...

  • Page 84: Boom Lock Assembly (Common)

    BOOM LOCK ASSEMBLY REF# PART# DESCRIPTION QUANTITY 32-564 Boom Lock HB-516-18-100 Bolt, -18 x 1 HW-516 Flat Washer, HNFL-516-18 Flange Lock Nut, - 18 17-592 Lock Hinge, LH 17-593 Limit Hinge, LH 42-116 Rubber Insert 8803-2.75 Trim, black w/ lace 17-589 Limit Hinge, RH 17-588...
  • Page 85 17-632-K HINGE ASSEMBLED 2 HINGE ASSEMBLIES PER BOOM 17-632-K Boom Hinge Complete REF# PART# DESCRIPTION QUANTITY 32-544 Arm Pivot Hinge 9026-2 Poly Rubber Duct Hose 2" 17-527 Boom Hinge 17-539 Compression Spring 17-540 Tapped Bolt HW-34 Flat Washer, HNCL-34-10 Center Lock Nut - 10 HG-14-28-180 Grease Zerk,...
  • Page 86 BOOM NEST ASSEMBLED REF# PART# DESCRIPTION QUANTITY 17-619 Push in Plug 18-297 Cap Plug 32-566 Boom Cradle HB-38-16-300 Bolt, - 16 x 3 HNFL-38-16 Flange Lock Nut, - 16 17-578 V-Boom Nest Post 17-537 Square U-bolt HB-516-18-100 Bolt, - 18 x 1 HW-516 Flat Washer, HNFL-516-18...
  • Page 87 BOOM LOCK AND CYLINDER ASSEMBLY REF# PART# DESCRIPTION QUANTITY HB-516-18-100 Bolt, - 18 x 1 HNFL-516-18 Flange Lock Nut, - 18 17-596 Hinge Pin w/Spacer HP-18-100 Cotter Pin, 17-632 Boom Hinge Complete HB-58-11-400 Bolt, - 11 x 4 HNCL-58-11 Center Lock Nut, - 11 HB-38-16-100 Bolt,...
  • Page 88 STAR COMMAND I NOZZLE DRAWING REF# PART# DESCRIPTION QUANTITY Nylon Black Nut 303 Stainless Steel Washer 20-673-09 12V Coil Assembly Tube Sub Assembly 302 Stainless Steel Spring Viton Oring Plunger 303 Stainless Steel Cap 20-673-02 E-Chemsaver Solenoid 20-673-04 " Mount Assembly Pan Head Screw 18-417 Single Barb (part of 20-674-P and 20-675-P)

  • Page 89: Star Command I Nozzle Assembly

    STAR COMMAND I NOZZLE ASSEMBLY REF# PART# DESCRIPTION QUANTITY 20-673-02 E-Chemsaver® 20-673-04 " Bottom Mount Nozzle Body 3† 18-417 Single Barb 20-676 Turbo TeeJet Tip 20-677 QT White Cap and Washer 6‡ 18-416 Double Hose Barb Quantity is per nozzle body. For 20' booms multiply quantity by 12. Quantity is per nozzle body.

  • Page 90: Standard Nozzle Assembly

    33-506 STANDARD NOZZLE ASSEMBLY DRAWING REF# PART# DESCRIPTION QUANTITY 16-988 Cap Assembly 16-920-06 Diaphragm, EPDM Stainless Steel Screw Upper Clamp 16-920-03 O-ring Pivot Pin, Stainless Steel Turret, 3-Outlet, Nylon O-ring, EPDM Plug E-clip 33-538 Cap - White 33-554 Nozzle Tip - White (XR11008-VS) 16-800 Viton Gasket O-ring, Teflon...
  • Page 91 20-807 STAR COMMAND II NOZZLE DRAWING REF# PART# DESCRIPTION QUANTITY 20-807-01 e-Chemsaver 20-673-09 12V Coil Stainless Steel Screw Upper Clamp 16-920-03 O-ring Pivot Pin, Stainless Steel Turret, 3-Outlet, Nylon O-ring, EPDM Plug E-clip 20-838 Cap - Gray 20-837 Turbo Twinjet Nozzle Tip, Cap & Gasket - Gray 16-800 Viton Gasket O-ring, Teflon...
  • Page 92 32-510 ELECTRIC HOSE REEL DRAWING...
  • Page 93 32-510 ELECTRIC HOSE REEL PARTS LIST REF# PART# DESCRIPTION QUANTITY 16-906-25 Retaining Ring 16-906-22 Axle Assembly HB-38-16-100 Hex Bolt, - 16 x 1 HW-38 Flat Washer, 16-906-27 Trim, Drum Edge 16-906-21 Drum Center 13-750 Solenoid HB-14-20-075 Hex Bolt, - 20 x HWL-14 Lock Washer, HN-14-20...
  • Page 94 ELECTRIC HOSE REEL WIRING DIAGRAM REF# PART# DESCRIPTION QUANTITY 8843-132 Flexguard 8919-144 10GA Red Wire 144" 8912 Ring Terminal 16-979 Wire, Switch to Solenoid Hot Terminal 33-251 Push Button Switch 16-978 Wire, Switch to Solenoid Start Terminal 13-750 Solenoid SOLENOID TERMINALS HN -516-24 Hex Nut , - 24...
  • Page 95 32-509 MANUAL HOSE REEL DRAWING REF# PART# DESCRIPTION QUANTITY 16-129-11 Disc, 17 " 16-906-25 Retaining Ring 16-906-22 Axle Assembly HB-38-16-100 Hex Bolt, - 16 x 1 HW-38 Flat Washer, 16-906-27 Trim, Drum Edge 16-906-21 Drum Center 16-906-20 Disc 17 ", Crank Side HWL-516 Lock Washer, HB-516-18-075...
  • Page 96 HOSE REEL MOUNT DRAWING...

  • Page 97: Electric Hose Reel

    HOSE REEL MOUNT PARTS LIST REF# PART# DESCRIPTION QUANTITY 18-249 Barb Fitting 16-129 Manual Crank Hose Reel 16-982 Electric Hose Reel HB-516-18-150 Hex Bolt, -18 x 1 HW-516 Flat Washer, HNTL-516-18 Nylon Lock Nut, - 18 16-295 Hose Fitting, 9032-125 Black Hose, "...
  • Page 98 32-508 FOAM MARKER DRAWING...

  • Page 99: Foam Marker Parts List

    32-508 FOAM MARKER PARTS LIST REF# PART# DESCRIPTION QUANTITY HB-516-18-175 Bolt, -18 x 1 (part of machine) HNFL-516-18 Flange Lock Nut, - 18 (part of machine) 32-533 Accessory Mount (part of machine) HN-14-20-075 Hex Bolt, -20 x HBFL-14-20 Flange Lock Nut, 14-291-04 Tank Bracket 14-291-02...
  • Page 100 32-508 FOAM MARKER DRAWING Ref 10&11 RH 3-wire Switch Ref 8&9 LH 7-wire Switch...
  • Page 101 32-508 FOAM MARKER PARTS LIST REF# PART# DESCRIPTION QUANTITY 14-291-03 Compressor 15-507 Tubing -Blue and white 20-769 Mount Bracket 14-699 Male Coupler 14-291-09 Blue Fly Nut 14-702 Red Washer HSM-10-32-075 Machine Screw, #10-32 x 3/4 HNFL-10-32 Flange Whiz-loc Nut, #10-32 15-504-04 Foam Marker Wiring Harness 32-574...
  • Page 102 FOAMER NOZZLE MOUNT & HOSE GUARD MOUNT DRAWING...
  • Page 103 32-508 MARKER PARTS LIST REF# PART# DESCRIPTION QUANTITY 16-987 Foam Nozzle Mounting Kit 1 per boom 15-507 Foamer Tubing Clear Tubing 15-511 Foam Nozzle Blue Tubing 15-510-01 Nozzle Mounting Rod Boom 16-795 Square Clamp INSTALLATION INSTRUCTIONS 1. Slide hose clamp onto drop tube of foam nozzle and attach restricter bell. 2.
  • Page 104 14-291 FOAMER REPLACEMENT PARTS...
  • Page 105 14-291 FOAMER REPLACEMENT PARTS REF# PART# DESCRIPTION QUANTITY 14-291-01 Black Cover 14-291-08 White Fly Nut 14-291-09 Blue Fly Nut 14-284-10 Tubing Connector 14-291-17 M6 Tubing Connector 14-536 Compressor Complete 14-291-11 Diaphragm Replacement Kit 15-505-08 Brush Retainer 15-505-06 Brush 15-505-07 12V Electric Motor 15-511-02 Foam Sponge 14-284-02...
  • Page 106 FOAMER FLOW REGULATOR VALVE REF# PART# DESCRIPTION QUANTITY 14-284-13 Flow Regulating Valve 14-699 Male Coupling 15-507 Tubing 20-769 Regulating Valve Bracket 14-702 Red Washer 14-291-09 Replacement Blue Wing Nut...

  • Page 107: Water Meter Kit (Gallons)

    14-515 WATER METER KIT (GALLONS) 15-618 WATER METER KIT (LITERS) REF # PART # DESCRIPTION QUANTITY 14-524 Filler Outlet 14-514 Water Meter (Gallons) 14-527 Water Meter (Liters) 14-525 Filler Inlet 16-962 1" Quick Coupler (already on machine) 16-961 1" Adapter Quick Coupler (already on machine) 16-851 1"...
  • Page 108 32-511 50 GALLON TANK RINSING SYSTEM Drill 1-3/4" hole in center of flat part of tank.
  • Page 109 32-511 50 GAL TANK RINSING SYSTEM REF# PART# DESCRIPTION QUANTITY 16-937 Elbow, MPT x 33-495 Bulkhead Fitting 30-247 PVC Nipple, x 8" 30-246 Tank Rinsing Nozzle 9050-84 " PVC Tube x 84" 18-186 Hose Clamp 9050-36 " PVC Tube x 36" 18-224 Hose Clamp 32-633...

  • Page 110: Chemical Clean-Load

    32-512 CHEMICAL CLEAN-LOAD DRAWING REF# PART # DESCRIPTION QUANTITY 16-159 Hose Barb 8897-54 " Discharge Hose x 54" 18-116 Hose Clamp HB-516-18-100 Hex Bolt, - 18 x 1 HNFL-516-18 Flange Lock Nut, - 18 15-620 Clean-load Assembly 16-972 90° Elbow 18-391 Coupling 16-156...
  • Page 111 OPERATING INSTRUCTION START-UP 1. All Clean-load valves must be closed prior to starting: inlet ball valve, knife valve and hopper rinse ball valve. 2. Open lid to check for foreign objects which may hinder performance or contaminate the system. 3. Close and lock lid by turning cover clockwise. 4.
  • Page 112 15-620 CHEMICAL CLEAN LOAD PARTS DRAWING ®...
  • Page 113 15-620 CHEMICAL CLEAN LOAD PARTS LIST ® REF# PART# DESCRIPTION QUANTITY 15-620-21 Tank Screw, #6 x 1” 15-620-02 Tank Lid 15-620-22 ProClean Container Nozzle 15-620-23 ProClean Push Valve Assembly 15-620-19 Tank Rinse 15-620-20 Gasket, 1” FNPT Coupler Thread Nipple ProClean Tank Wash Nozzle Splash Retainer O-ring Breather Nut, Breather...
  • Page 114 NOTES...

  • Page 115: Decal List

    25-307 Decal, Fuel Only 32-619 Decal, Dash Panel 32-534 Decal, Control Panel 25-380 Decal, Tire Pressure 30psi 25-373 Decal, 7" Smithco Logo 27-077 Decal Smithco Round 27-093 Decal, Hydraulic Oil Level 32-629 Decal, Spray Star 5200 32-631 Decal, Site Gauge 25-374 Decal, 12"...

  • Page 116: Quick Reference Replacement Parts

    QUICK REFERENCE REPLACEMENT PARTS REPLACEMENT FILTERS 72-146 Hydraulic Oil Filter Assembly 60-334 Replacement Oil Filter Element 17-068 Ignition Switch 32-651-02 Outer Air Filter 32-651-03 Inner Air Filter 32-521-04 Fuel Filter Assembly 32-521-05 Muffler Gasket 30-042-09 Engine oil Filter Cartridge REPLACEMENT BELTS 32-575 Spray Pump V-Belt SEAL KITS...
  • Page 117 30 days from discovery of the condition. If you need help locating an Authorized Smithco Distributor, or if you have questions regarding your warranty rights or responsibilities, you may contact us at: Smithco Product Support Department 200 West Poplar Ave.
  • Page 118 This warranty does not apply to normal “wear and tear” items. Normal “Wear and Tear” includes, but is not limited to, damage to seats due to wear or abrasion, worn painted surfaces, scratched decals or windows, etc. Smithco may require the return of failed parts or components in order to determine the validity of any warranty claim.

This manual is also suitable for:

Spray star 5200

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