Norstar RS 6000 User manual

COPYRIGHT NORSTAR INDUSTRIES INC. 1996-2008 ALL RIGHTS RESERVED
RS 6000 Injection Sprayer Manual
NORSTAR INDUSTRIES,INC.
Western US Location
Eastern US Location
2302 “A” Street SE
Auburn WA 98002
Phone ............. [phone]
Toll Free ......... [phone]
Fax .................. [phone]
934 E Main Street
Headland AL 36345
Phone ............ [phone]
Toll Free ........ [phone]
Fax ................. [phone]
www.norstarind.com
Gasoline Driven Injection Skid with Cable Plug Set v6.1

i
TABLE OF CONTENTS
SECTION 1: OVERVIEW
Introduction .....................................................................................................................1
General Description.........................................................................................................2
RS 6000 Operating Specifications ..................................................................................2
SECTION 2: OPERATION
Start-up ...........................................................................................................................3
Chemical Loading
Standard Loading.......................................................................................................4
Closed Loading System
Load Chemical Tank(s) ........................................................................................4
Unload Chemical Tank(s).....................................................................................5
Transfer Chemical Between Onboard Tanks........................................................5
System Flush........................................................................................................6
Sotera 850 Digital Meter CAL Factor Selection Procedure...................................6
Calibration (CAL) Factor Table.............................................................................8
Chemical Rates...............................................................................................................9
Single Chemicals.......................................................................................................9
Multiple Chemicals In One Tank................................................................................9
Wettable Powders and Granulars............................................................................10
Chemical Tank Level Indicators ....................................................................................11
Drift Control System......................................................................................................11
Shutdown......................................................................................................................12
SECTION 3: MAINTENANCE
Maintenance Schedule..................................................................................................13
Water Pump Pressure Adjustment................................................................................14
Sprayhead Nozzle Pressure Adjustment.......................................................................15
Sprayhead Nozzle Setup...............................................................................................16
Winterizing ....................................................................................................................17

ii
SECTION 4: APPENDICES
Handgun Operation.......................................................................................................18
TASC Calibration Procedures
Chemical Pump Tube Installation ............................................................................21
Chemical Pump Calibration Numbers & Tube Selection..........................................21
Chemical Pump Calibration Procedure....................................................................22
Distance Calibration Procedure ...............................................................................23
NSC-20108 Nutating Sprayhead Setup.........................................................................26
NSC-20108 35 GPA Nutating Sprayhead Pattern.........................................................27
NSC-20108 25 GPA Nutating Sprayhead Pattern.........................................................28
NSC-20108 50 GPA Nutating Sprayhead Pattern.........................................................29
NSC-90500 Rear Spraybar Pattern...............................................................................30
NSC-20320 Guard Rail Drop Nozzle Pattern................................................................31
RS 6000 Master Schematic...........................................................................................32
RS 6000 Cable Plug Set ...............................................................................................33
RS 6000 Wiring Diagram...............................................................................................34
RS 6000 Console Rear Panel Wiring............................................................................35

iii
SECTION 5: ASSEMBLY DRAWINGS /REPAIR INSTRUCTIONS
7 Section Nutating Sprayhead.......................................................................................36
Nutating Sprayhead Sub Assemblies.......................................................................38
Sprayhead Fold........................................................................................................39
Solenoid Regulator Assembly.......................................................................................40
Flow Switch..............................................................................................................42
Solenoid Valve.........................................................................................................43
Pressure Regulator..................................................................................................45
Gasoline Driven Water Pump
Honda Engine Water Pump.....................................................................................47
Hypro 9203 Water Pump .........................................................................................48
Hypro Water Pump Repair Instructions....................................................................49
Water Pump Inlet Plumbing .....................................................................................50
Water Pump Outlet Plumbing ..................................................................................52
Chemical Tank & Injection Pump
Chemical Tank Plumbing.........................................................................................54
Chemical Tank Agitation..........................................................................................56
Chemical Closed Loading
Closed Loading Manifold & Pump............................................................................58
Sotera Series 400 Diaphragm Pump
Sotera Diaphragm Pump....................................................................................60
Sotera Diaphragm Pump Repair Instructions .....................................................62
Sotera Diaphragm Pump Troubleshooting Guide...............................................63
Sotera Model 850 Digital Meter
Sotera Digital Meter............................................................................................64
Sotera Digital Meter Recalibration Procedure ....................................................65
Sotera Digital Meter Battery Replacement Procedure........................................65
Sotera Digital Meter Troubleshooting Guide.......................................................66
Closed Loading Hose Routing .................................................................................67
Chemical Probe .......................................................................................................68
Rear Spraybar...............................................................................................................69
Guardrail Drop Nozzle...................................................................................................70
Norstar Industries Warranty Statement.........................................................................71

1
RS 6000 ROADSIDE SPRAYER
INTRODUCTION
Congratulations on the purchase of your Norstar RS6000 Roadside Sprayer. This is a state of
the art sprayer for the precise application of herbicides to roadside vegetation. The RS6000
Sprayer uses a TASC 6300 chemical injection system to automatically monitor and control the
precise amount of chemical being applied per acre. Each chemical is stored in a separate
chemical tank then automatically injected into the water pump at the rate set by the operator.
The use of the injection system eliminates any need for premixing the chemical in the sprayer
water tank. The mixture is then applied through a low drift boomless sprayhead. This allows
the operator to make changes in rates as needed to eliminate over or under application.
We are continually striving to make improvements on the Norstar RS6000 system to keep it
the best unit available today. To do this we welcome input from our users so please phone or
drop us a line with your comments.

2
GENERAL DESCRIPTION
The Norstar RS6000 sprayer provides precise chemical application from a boomless
sprayhead mounted behind the operator. The sprayhead contains 7 individually controlled
boom sections. The sprayhead can be tilted from an in-cab control console to compensate for
changes in ditch or embankment slopes.
The RS6000 sprayer has the ability to inject up to three chemicals at a time (6 available with
optional Tasc 6600 console). The system injects chemical accurately by using a computer to
monitor vehicle ground speed, spray width, and the pre-set chemical application rates. The
chemicals are injected at the water pump inlet and thoroughly mixed with water. The mixture
is then distributed through the boomless sprayhead manifold to multiple nozzle assemblies.
Regardless of changes in ground speed or spray width the computer will automatically
maintain chemical injection at the operator‟s preset application rates.
RS6000 SPRAYER OPERATING SPECIFICATIONS
Sprayhead is mounted behind the operator to maximize operator safety and to minimize
chemical injection lag time.
All solid stream nozzles are used requiring maximum operating pressures of only 15 to 30
P.S.I.
Multiple spray sections provide superior spray width flexibility.
Centrifugal water pump capable of providing 70 to 100 P.S.I.

3
OPERATION START-UP
NOTE: Before initial start-up of this machine both the RS6000 manual and the TASC manual
should be read completely. For training, calibration, and testing NORSTAR
INDUSTRIES INC. recommends water be used in lieu of chemical until the operators
feel comfortable with the operation of the machine.
1. Before filling make sure all valves are in the closed position.
2. Fill the main water tank with water.
3. Load chemical into the desired chemical tank(s), refer to the Chemical Loading section for
instructions.
4. To install the chemical pump tube, release the tube retaining strap and lift it up and away
from the tube rollers.
5. Clean the chemical pump tube rollers and retaining strap with a cloth to remove any dirt or
grit from the tube running area.
6. Lubricate the pump tube with tube lube then attach one hose quick disconnect fitting to the
left hose connection. Loop the tube over the rollers and down between the tube rollers and
tube strap hinge (there is not enough space to between the tube roller assembly and the
tube strap hinge to slip the tube in from the front without the possibility of damaging the
tube). Stretch the tube enough to lock the right hose quick disconnect fitting in place. To
prevent air leaks in the chemical lines, make sure the gaskets does not fall out or get
twisted and that both fittings are tightened securely. Swivel the tube retaining strap back
into place and secure with the latch.
7. Open the chemical tank valves ONLY after the tube retaining strap has been secured with
the latch.
8. Open both water tank outlet valves, and then momentarily open the tank drain valve at the
water pump inlet to purge the lines of air for initial priming.
9. Start the water pump engine or vehicle engine if the water pump is hydraulically driven.
10.Turn all chemical pump switches off on the TASC Console. Turn on the master switch and
a boom switch on the RS6000 console. Now turn the water pump switch on for 45
seconds. This should be enough time to see water discharging through the sprayhead
nozzles that you turned on. If not, turn off the water pump switch, open the small drain
cock on top of the water pump and allow it to run until air is bled out. This process may
have to be repeated several times to completely purge the air out of the system.
WARNING: Running the pump without water will cause damage to the pump seals.
11.Once the water pump is primed each sprayhead boom switch should be turned on and off
several times to bleed the air out of the solenoid diaphragms. Bleeding air from the
solenoids may be required each time the unit runs out of water.
WARNING: Do not allow the water pump to run for more than a 5 minutes with all boom
switches off. This can cause water pump damage due to overheating.
12.At this point the machine is ready for calibration, (refer to page 23).
CAUTION: Calibration is necessary on initial start-up, or when a pump tube is replaced.
Also check calibration if application rates seem to be off.

4
CHEMICAL LOADING
WARNING: Protective gear should be worn when handling any chemical.
STANDARD LOADING
1. Close all valves on the chemical tanks.
2. Remove the lid.
3. Pour the desired amount of liquid chemical into the chemical tank and replace the lid.
4. Powders and granular chemicals must be mixed with water. Add water to the chemical
tank first, then add the chemical. The chemical should be poured in slowly while agitating
until a thoroughly mixed slurry is achieved.
NOTE: Constant agitation is required to keep powders and granular chemicals in suspension.
CLOSED LOADING SYSTEM (OPTIONAL)
LOAD CHEMICAL TANK(S)
At the closed load manifold:
1. Attach the chemical probe hose to the flat face quick disconnect located at the bottom of
the manifold.
2. Place the chemical probe in the product container.
3. Turn the ball valve for the chemical probe to “Load” as indicated on the label.
4. Turn the ball valve for the desired chemical tank to “Load” as indicated on the label.
At the bottom of the chemical tank to be filled:
5. Close the ball valve to the chemical pump.
6. Open the ball valve to the chemical tank.
7. Ensure the drain ball valve is closed.
At the transfer pump:
8. Select the proper calibration factor on the meter. See Sotera Model 850 Meter CAL
Factor Selection Procedure for instructions (refer to page 6).
9. Turn the transfer pump on and fill until the desired quantity of product is in the tank.
10.When finished, turn the pump off and move the ball valves on the closed loading
manifold to the off position.

5
UNLOAD CHEMICAL TANK(S)
At the closed load manifold:
1. Attach the chemical probe hose to the flat face quick disconnect located at the bottom of
the manifold.
2. Place the chemical probe in the product container.
3. Turn the ball valve for the chemical probe to “Unload” as indicated on the label.
4. Turn the ball valve for the chemical tank to be unloaded to “Unload” as indicated on the
label.
At the bottom of the chemical tank to be emptied:
5. Close the ball valve to the chemical pump.
6. Open the ball valve to the chemical tank.
7. Ensure the drain ball valve is closed.
At the transfer pump:
8. Turn the transfer pump on.
9. When finished, turn the ball valves on the closed loading manifold to their off positions.
Transfer Chemical Between Onboard Tanks
At the closed load manifold:
1. Turn the ball valve for the chemical tank to transfer FROM to “Unload” as indicated on
the label.
2. Turn the ball valve for the chemical tank to transfer TO to “Load” as indicated on the
label.
At the bottom of the chemical tank to transfer to and transfer from:
3. Close the ball valve to the chemical pump.
4. Open the ball valve to the chemical tank.
5. Ensure the drain ball valve is closed.
At the transfer pump:
6. Turn the transfer pump on until the desired amount of product is transferred.
7. When finished, turn the ball valves on the closed loading manifold to their off positions.

6
System Flush
At the closed load manifold:
1. Turn the ball valve(s) for the chemical tank line(s) to be flushed to “Load” as indicated
on the label.
2. Turn the water ball valve on the top of the manifold on.
At the bottom of the chemical tanks whose lines are to be flushed:
3. Turn the ball valve to the chemical pump on.
4. Turn the ball valve to the chemical tank off.
5. Ensure the drain ball valve is closed.
At the transfer pump:
8. Turn the transfer pump on.
9. Continue normal spraying with the chemical pumps on until the chemical lines are clear.
10. When finished, turn the ball valves on the closed loading manifold to their off positions.
WARNING: All ball valves on the closed loading manifold should be in the OFF position when
not in use or chemical mixing between tanks can occur.
Sotera 850 Digital Meter CAL Factor Selection Procedure
Change Calibration Factor
1. Turn the meter on.
2. Press and hold button 3 for 3 seconds. Only CAL and the number below it will be
displayed.
3. Use the supplied chemical chart to select the proper calibration factor based upon the
chemical being used and the temperature.
4. Press button 3 repeatedly to change the number to the desired calibration factor. The
number will return to zero after reaching 19.
5. Press button 2 to set the number –the meter is now ready to use.
Product Not Listed On Chart
If a product does not appear on the supplied chart, a calibration (CAL) factor can be
selected using a calibration container. Each CAL factor represents 1% accuracy; so on a 5
gallon calibration container 1% is 0.05 gallons. Follow the procedure listed below to
determine the correct CAL factor.
1. Turn the meter on.
2. Change the CAL factor to 4.
3. Prime the system so no air is present.
4. Dispense the product into a calibration container.

7
5. Determine the amount of product that was dispensed into the container and compare to
the meter reading. If the volume displayed on the meter is less than the amount
dispensed, select a lower CAL factor. If the volume displayed on the meter is higher
than the amount dispensed select a higher CAL factor.
6. Subtract the measured value from the meter reading to obtain the difference.
7. Divide the difference by the accuracy value (1% of the calibration container volume) to
find how much to change the CAL factor.
8. Add the result to the current CAL factor to obtain the correct CAL factor for the product.
Example:
With the CAL factor set at 4, a product is dispensed into a 5-gallon calibration container.
The calibration container reads 5.00 gallons and the meter reads 5.35 gallons. Therefore, a
higher calibration factor is needed.
The difference is then 0.35 gallons:
gallonsvaluemeasuredgallonsreadingmetergallons 35.0)(00.5)(35.5
The CAL factor change would then be 7:
7
5%1 35.0
7
05.0 35.0 gallons
gallons
or
gallons
gallons
The correct CAL factor for the product would now be 11:
11)(7)(4 valuechangecalculatednumberCALprevious
Sotera 850 digital meter recalibration procedure, battery replacement, parts
drawing and troubleshooting guide can be found on pages 66 - 68.

8
Calibration (CAL) Factor Table
Fluid Temperature †
Product
30º F
40º F
50º F
60º F
70º F
80º F
Banvel SGF®
5
Roundup®
15
Roundup® Ultra
16
16
16
15
15
14
†Fluid temperature in mini bulk tanks stored outdoors will be approximately the average of the daily high and low temperatures.

9
CHEMICAL RATES
The Norstar system provides the ability to make speed and width changes without effecting the
chemical application rate. The TASC console monitors ground speed and spray widths,
automatically increasing or decreasing the speed of each chemical injection pump to maintain
preset chemical application rates. Application rates for the water (carrier) differs from chemical in
that it is fixed. The gallon per acre (GPA) of water increases as the vehicle speed decreases.
NOTE: Care must be taken in the selection of chemical rates to insure the label rates for carrier
and chemicals are followed.
FLUID OUNCES CONVERSION TABLE
1 Pint
=
16 Fluid Ounces
2 Pints = 1 Quart
=
32 Fluid Ounces
4 Pints = 2 Quarts
=
64 Fluid Ounces
8 Pints = 4 Quarts = 1 Gallon
=
128 Fluid Ounces
SINGLE CHEMICALS
The single chemical is loaded in the chemical tank, then the ounces per acre application rate is
installed in that chemical pump application rate position on the TASC console.
MULTIPLE CHEMICALS IN ONE TANK
WARNING: Chemical compatibility should be checked prior to mixing in the chemical tank.
Contact the chemical supplier for their recommendation and also mix up a test
batch.
Herbicides and additives are commonly mixed in one tank when they are normally dispensed at
the same time. For example: if your application rate is 2 Quarts (64 oz.) per acre of herbicide and
1 Pint (16 oz.) per acre of surfactant, then both go into the tank at that ratio. The chemical rate
you put in the computer would be the total of both application rates or 80 oz. per acre.
NOTE: Accumulated values will be the total of all chemicals in tank.

10
WETTABLE POWDERS AND GRANULARS
Label rates for powders and granular chemicals are generally labeled in ounces or pounds per
acre. To inject these chemicals a slurry must be made by mixing water with the chemical. We
suggest using a small quantity to start. For example, start with 1 gallon of water, then add 1 lb.
of measured powder and mix thoroughly. Measure the total liquid volume of the mixture. The
total liquid volume will be greater than the 1 gallon of water. For example: 128 oz. of water
mixed with 1 lb. of powder could possibly make a slurry with a total volume of 132 oz. This is
the rate you put in the TASC console if you are applying one pound of chemical per acre.
APPLICATION TIPS:
1. Periodic calibrations should be performed to ensure an accurate application.
2. Use suspenders and anti-foam agents very carefully.
3. Do not allow mixture to stand in tank without agitation for long periods.
4. Mix only what you will use in that day, and flush tank and lines after use to eliminate a
blockage.
NOTE: Multiple chemicals can be added same as the liquids described on previous page using
the same ratio.
WARNING: DO NOT add drift control agents to the slurry mixture or problems can occur.

11
CHEMICAL TANK LEVEL INDICATORS (OPTIONAL)
Six indicator lights are located in the RS6000 control console. The lights are wired to float
switches in the bottom of each chemical tank. When the material level drops below the float
level, the tank indicator will come on.
WARNING: Care must be taken not to damage float switch in tank bottom when mixing
chemical with anything other than standard agitator.
NOTE: Due to chemical residue accumulating around the float switch, fresh water rinsing is
required on a regular basis to insure proper operation.
DRIFT CONTROL SYSTEM (OPTIONAL)
The drift control system uses a venturi to draw the material out of a chemical tank, through a
flow control and solenoid valve, and injects it at the inlet of the water pump. The solenoid
valve opens and closes with the master switch on the TASC 6300 console. This will eliminate
loading the water pump up with material when sprayhead solenoids are closed but the water
pump is still running. The flow control is used to regulate the rate of material being used.
Operation
1. Fill the drift control tank with product.
2. Open the tank shut off valve
3. To adjust the flow control valve to the desired injection rate, start at the lowest setting (first
color ring) and working up by monitoring the usage over a few tanks of water.
NOTE: Use only drift control products in the 1-% concentrate category like Exacto's Formula 358,
Nalco's Sta-Put or similar products.
WARNING: When the drift control tank is empty, the shut off valve must be closed for proper
water pump operation.

12
OPERATION SHUTDOWN
1. If granular or dry flowable chemicals are used we recommend you flush the chemical tank
and lines with water before step #2.
NOTE: With optional closed loading system, close the valve at the bottom of the chemical
tank and open the valve to the chemical pump. At the closed loading panel select the
water position, open valve on the panel for chemical tank to be flushed, and turn on
power switch. Repeat for each chemical pump.
2. Run all the chemical pumps until all sprayhead nozzles show clear water.
NOTE: Cycling boom solenoids off and on several times works the best for a system flush.
3. Close all water tank and chemical tank outlet valves.
WARNING: All valves must be closed when sprayer is not being used to ensure
chemical does not contaminate main water tank.
4. Release the tube retaining strap on Legacy chemical pumps. Remove tubes from under
rollers on older style chemical pumps.
5. Turn the power switches on the TASC and the RS6000 consoles to the off position. This
will prevent battery drain.
6. Unit is ready for storage at above freezing temperatures. For below freezing temperatures
see the winterizing section.

13
MAINTENANCE SCHEDULE
DAILY
1. Check the oil in the auxiliary engine or hydraulic tank as required.
2. Inspect the nozzles on the sprayhead for build up and clean with a soft bristled brush if
necessary.
3. Check the spray pattern for uniform coverage and adjust as needed.
4. Check operating pressures of the sprayhead boom sections at regulator gauges.
5. Inspect all chemical tanks and lines for possible damage.
6. Clean and inspect the chemical pump tubes, rollers and housing for wear or damage.
7. Lubricate the chemical pump tube with the correct tube lube only.
8. Check all calibration numbers in the TASC 6300 console.
WEEKLY
1. Clean the face of the radar unit with a damp soft cloth.
2. Clean the water pump inlet and outlet strainers (daily when water quality is poor).
AS REQUIRED
1. Disassemble, clean, and inspect the solenoids, replacing diaphragms as needed.
2. Remove and clean the regulator screens located under the large hex, behind the gauge on
each regulator.
3. Check pressures of individual sprayhead boom sections using a calibration gauge.
4. Clean the air filter and change the oil in auxiliary engine if so equipped (see engine owners
manual).
5. Change the hydraulic return filter after the first 150 hours, then 500 hours after that if so
equipped.
6. Clear ¼” bypass line between water pump and injection point at the water pump at least
once a season. More often if powders are used.
WARNING: Disconnect all battery cables to the RS6000 system if ANY WELDING is done on
chassis. Disconnecting the power will not erase the information stored in the
console.

14
WATER PUMP PRESSURE ADJUSTMENT
NOTE: Maximum water pump pressure is 100 PSI with solenoids closed (deadheaded).
ENGINE DRIVEN
1. Start auxiliary engine and allow the engine to warm up.
2. Turn on the water pump switch and run water through a few sprayhead boom sections to
ensure no air is trapped in the pump.
3. With all sprayhead boom switches off (deadheaded), the pressure on the main system
gauge should indicate 75 - 80 PSI.
4. To change the pressure increase or decrease the engine throttle as required.
HYDRAULIC DRIVEN
1. Start chassis engine and set throttle at high idle (1000 RPM).
2. Turn on the water pump switch and run water through a few boom sections to ensure no air
is trapped in the pump.
3. With all boom sections off (deadheaded), the pressure on the main system gauge should
indicate 75 - 80 PSI.
4. To change the pressure, loosen the jamb nut on the water pump speed control knob
(hydraulic flow control), make the required adjustment and tighten jamb nut.