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

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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

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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.

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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.