Smithco 1002 User manual

OPERATOR’S
MANUAL
Spray Star 1000
Model 1002
Requires 10-160 Boom
Starting Serial #100100 March, 1999
SMITHCOPRODUCTSUPPORT
1-800-891-9435
HwySS and PoplarAvenue,CameronWI54822
E-mail:[email protected]

Introduction Operation Schematics SprayingProcedures Nozzle Charts Reference
CONTENTS
Introduction.................................................................. 1-9
Introduction ................................................................. 1
Symbols................................................................... 2-3
General Safe Practices............................................... 4
Safe Spraying Practices ............................................. 5
Specifications.............................................................. 6
Optional Spray Equipment .......................................... 6
Set Up ...................................................................... 7-8
Controls & Instruments............................................ 8-9
Operation ................................................................. 10-15
Operating Instructions.......................................... 10-12
Initial System Set Up................................................. 12
Console Features ..................................................... 13
Calibrating The Pressure Gauge .............................. 13
Spray Operation................................................... 14-15
Schematics.................................................................... 16
Wiring Schematic ..................................................... 16
Hydraulic Schematic................................................. 16
Spraying Procedure ................................................ 17-23
SprayingIntroduction ................................................ 17
Turf Management ...................................................... 17
Hose & Handgun Spraying........................................ 18
Nozzles................................................................ 18-19
CalibrationIntroduction ............................................. 20
The Nozzle Chart Method of Calibration .............. 21-22
The “128” Method of Boom Sprayer Calibration... 22-23
Nozzle Charts .......................................................... 24-31
Nozzle Performance Chart #1 .................................. 24
Nozzle Performance Chart #2 .................................. 25
Nozzle Performance Chart #3 .................................. 26
Nozzle Performance Chart #4 .................................. 27
Nozzle Performance Chart #5 .................................. 28
Nozzle Performance Chart #6 .................................. 29
Nozzle Performance Chart #7 .................................. 30
Nozzle Performance Chart #8 .................................. 31
Reference ................................................................ 32-34
Abbreviations and Conversions ................................ 32
Declaration of Conformity ......................................... 34
Limited Warranty.............................. Inside Back Cover

1
Introduction
Informationneeded whenorderingreplacement parts:
1. Model Number of machine.
2. Serial Number of machine.
3. Name and Part Number of part.
4. Quantity of parts.
INTRODUCTION
Thankyouforpurchasing a product.
Read this manual and all other manuals pertaining to the Spray Star 1000 carefully as they have safety, operat-
ing, assembly and maintenance instructions. Failure to do so could result in personal injury or equipment dam-
age.
Keepmanualsinasafeplaceafteroperator and maintenance personnel have read them. Right and left sides are
fromthe operator’s seat, facing forward.
All machineshavea Serial Number and Model Number.Bothnumbers 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.
Referto engine manual for placement of engineserialnumber.
For easy access record your Serial and Model numbers here.

2
Introduction
SYMBOLS
ParkBrake ParkBrake
Release HydraulicOil
Level
Choke- OpenChoke- ClosedHandThrottle
HourMeter HourMeter Fuse
GlowPlugGlowPlug-OffGlow Plug - On
RPM Gasoline Diesel
Water
Temperature
Temperature
Light
EngineOil
Engine - Stop Engine - Start Engine - Run
No Electrical
Power
ElectricalPower
ReadOperator’s
Manual

3
Introduction
SYMBOLS
NoSmoking Moving Parts Manual
Operation
Pinch Point Step HotSurface
HydraulicFluid
Penetration LiftArm Tractor
Engage Disengage PTO
GroundSpeed Fast Slow
HHigh LLow FForward
RReverse NNeutral Warning
Danger
Caution
Up/RaiseDown/LowerUp/DownArrow

4
Introduction
SAFE PRACTICES
1. It is your responsibility to read this manual and all publications associated with this machine.
2. Neverallowanyoneto operate or service the machine or its optional equipment without proper training and
instructions.Neverallowminorstooperateanyequipment.
3. Learnthe properuse ofthe machine,the locationand purposeof allthe controlsand gaugesbefore you
operatetheequipment.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 artificial light.
5. Inspect the area where the equipment will be used. Pick up all debris you can find before operating.
Bewareof overhead obstructions and underground obstacles. Stay alertforhiddenhazards.
6. Neveroperateequipmentthat is not in perfect working order or withoutdecals, guards, shields,or other
protectivedevices in place.
7. Never disconnect or bypass any switch.
8. Carbonmonoxideinthe exhaust fumes can be fatal when inhaled, never operate a machine without proper
ventilation.
9. Fuel is highly flammable, handle with care.
10. Keep engine clean.Allow the engine to cool before storing and always remove the ignition key.
11. Disengagealldrivesandsetparkbrakebeforestartingtheengine.
12. Never use yourhands tosearchfor oil leaks. Hydraulic fluidunder pressurecanpenetrate the skin and
cause serious injury.
13. This machine demands your attention.Topreventlossofcontrol 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. Beforeleavingoperator’sposition:
A. Disengagealldrives.
B. Set park brake.
C. Shut engine offand remove the ignition key.
D. If engine has to run to perform any maintenance keep hands, feet, clothing and all other parts of body
awayfrom moving parts.
15. Keep hands, feet andclothing awayfrom movingparts. Waitfor allmovement tostop beforeyouclean,
adjustorservicethe machine.
16. Keep the area of operationclear ofall bystanders.
17. Nevercarrypassengers.
18. Stop engine before making repairs/adjustmentsor checking/addingoil to thecrankcase.
19. Use parts and materials supplied by 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 confined space, take precaution.
This machine is intended for turf maintenance. Other use is forbidden.

5
Introduction
SAFESPRAYINGPRACTICES
Personsengagedin the handling, preparation or application of chemicals mustfollow acceptedpractices to
insurethesafetyof themselves and others,
1. WEAR protectiveclothingincluding:gloves,hat,respirator, eye protection and skin covering suitablefor
protectionfromchemicalsbeingused.
2. BATHEthoroughly afterany exposure to chemicals, giving particular attention to eyes, nose, ears and
mouth.
3. CLEAN equipmentandmaterialsin accordance with employer,municipaland stateregulations. Use only
approvedareasanddrains.
4. DISPOSE ofchemicalsandrinse solutions by approved and legal means.
5. PROVIDE methodsandmaterialsfor operators to wash eyes and hands immediately duringthe spraying
process.
6. PROVIDE methodsandmaterialsfor control, safe dilution and neutralization of chemical spillsduring
preparation,spraying, transporting and cleanup.
7. Always check and follow the directions and safety warnings of the chemicals to be used.
8. Securethedischarge lines before starting thepump. An unsecured discharge linemay whip.
9. Periodically inspect the pump and the system components.
10. Check hoses for weak or worn condition before each use. Make certain that all connections are tight and
secure.
11. Do not operate unit with leaks, frayed, kinked hoses or tubing. Repair or replace immediately.
12. Use only pipe, hose andfittings ratedfor maximum pressureor pressureat which pressurerelief valveis
set at. When replacing pipe, hose or fittings, use new product.
13. Do not operate a gasoline engine in an enclosed area. Be sure the area is well ventilated.
14. Do not use these pumpsfor pumpingwater orother liquidsfor humanor animalconsumption.
15. Do not pump flammable or explosive fluids such as gasoline, fuel oil, kerosene, etc.
Do not use in explosive atmospheres. The pump should be used only with liquids
compatible with the pump component materials.
16. Be sure all exposed moving partsare guarded and that allcoupling devices are securely attachedbefore
applyingpower.
17. Before servicing, disconnect all power, make sure all pressure in the system is relieved, drain all liquids
from the system and flush.
18. Protect pump from freezing conditions by drainingliquid and pumping rust inhibiting antifreeze solution
through the system, coating the pump interior.

6
Introduction
SPECIFICATIONS
WEIGHTSANDDIMENSIONS
Length 112" (285 cm)
Width 70"(178cm)
Width With Boom Open 180" (457 cm)
Height 48"(122cm)
Wheel Base 53" (135 cm)
Weight Empty 1200 lbs (544 kg)
Weight Full 2200 lbs(998 kg)
SOUNDLEVEL(DB)
Atear level 88 dB
At 3 ft (0.914 m) 84 dB
At 30 ft (9.14 m) 72 dB
ENGINE
Make Kohler
Model# CommandCH25S
Type/ Spec# PA68673
Horsepower 25 hp (18 kW)
Fuel Unleaded87 Octane Gasoline Minimum
CoolingSystem AirCooled
LubricationSystem FullPressure
Alternator 25 amp
WHEELS&TIRE Front: Two 20 x 10.00 x 10 NHS Multi-Rib; 20 psi (1.4 bar)
Rear: Two 24 x 12.00 x 12 NHS Multi-Trac; 20 psi (1.4 bar)
SPEED
Forward Speed 0-8 m.p.h. (0-12.8 kph)
Reverse Speed 0-3 m.p.h. (0-4.8 kph)
BATTERY Automotive type 24F - 12 volt
BCI Group Size 24
ColdCrankingAmps 575minimum
GroundTerminal Polarity Negative (-)
MaximumLength 10.25" (26 cm)
MaximumWidth 6.88" (17 cm)
MaximumHeight 10" (25 cm)
FLUID CAPACITY
CrankcaseOil See Engine Manual
Fuel 5 gallon(19liters)
HydraulicFluid 5 gallon (19 liters)
Grade of Hydraulic Fluid SAE 10W-40API Service SJ or higher Motor Oil
OPTIONAL EQUIPMENT
10-108 Speedometer Kit 10-260 203 Spray System (1002)
10-106 Fresh Water Tank 10-102 Manual Spray System (1004)
10-103 Electric Actuator Lift Kit 10-101 834 Spray System (1006)
10-297 Hydraulic Actuator Lift Kit 10-110 440 Spray System (1008)
10-105 FoamMarker 10-270 3-Way Manual System (1010)
10-160 15'StainlessSteelBoom- manual 33-216 BatteryAutomotiveType24F-12volt
10-301 15'Terrain Following Boom
10-107 HoseReel Mounting Kit
16-906 Hose Reel 12 volt electric rewind 200' (61 m) capacity (to be used with 10-107)
16-129 Hose Reel 200'(61 m) capacity (to be used with 10-107)

7
Introduction
SETUP
The Spray Star 1000 arrives from setup and ready for service. Depending on freight conditions
thetires, wheels, and steering wheel may havetobe installed.
The spray system is normally shipped attached to the 1000 Prime Mover. If a spray system is to be fitted to a
Prime Mover by a dealer or owner, assemble and attach the components in accordance with the parts drawings
inthismanual.
1. Remove the top and sides from the shipping crate then remove the banding from the Spray Star.
Banding is under tension.
2. Remove the seat, steering wheel and anything else that is in the crate.
3. Lift front end using a hydraulic jack, taking care that the jack is not placed in
alocationthatwould damage any steering system components, install front
wheelsandtorquenutsto64-74ft/lb (87-100 Nm). Then raise rear axle
using a hydraulic jack and install rear wheels and tires, torque lug nuts
to64-74ft/lb(87-100 Nm). Re-torque after the first 10 hours and every
200hours thereafter.
4. Set park brake.
5. Check the tire pressure. The front and rear tires are 20 psi (1.4
bar).
6. Remove the tape holding (Ref B) woodruff key to the shaft. Put
steeringwheel(Ref A) on the shaft of thesteering mechanism
(Ref C). Tighten nut to 30-40 ft/lbs (41-54 Nm). Do not over
tighten.
7. Installtheseat with the stud goingthrough theenginecover
and the flat washers, lockwashers and nuts. Use front set
of holes for shortest distance from foot pedals to seat. Use
back set of holes for longest distance from foot pedal to
seat.
8. Battery NOT furnished.Installa battery automotive type
24F-12 volt; 575 cold cranking amps minimum; (10.25" (26
cm) long x 6.88" (17 cm) wide x 10" (25 cm) high maxi-
mum case) into the battery box, which is located on the left
side of the engine compartment. Place battery into battery
box with posts to the rear. This is a negative grounding
system.
Connecting battery cables to the wrong post
could result in personal injury and/or damage to the electrical system. Make sure battery and
cables do not interfere or rub on any moving part. Connect red positive (+) cable (A) to
battery first. When disconnecting remove black negative (-) cable (B) first.
9. Check hydraulic fluid level in tank located on the left side. Remove cap and add SAE 10W-40API
Service SJ or higher motor oil if necessary. Fluid level should be about 2-21/2" (5-6.4 cm) from the top of
thetankwhencold.DONOTOVERFILL.
10. Fill fuel tank, located on right side, with Unleaded 87 Octane gasoline (minimum).
Gasoline is flammable, caution must be used when storing or handling it. Do not fill fuel tank
while engine is running or an enclosed area, fumes are explosive and dangerous to inhale.
DO NOT SMOKE while filling the fuel tank. DO NOT OVERFILL.

8
Introduction
SET UP (CONTINUED)
11. Machine shouldbe greased beforestarting, referto Spray Star 1000 Parts/Service Manualforlocation.
12. Attach the Spray Boom and any other Optional Equipment to the Prime Mover, in accordance with
instructions in the Spray Star 1000 Parts/Service Manual. The nozzles must be the correct distance above
theturf as described inTurf Spraying Guide.Thespray boommustoperate properly and the outersec-
tions must break away safely if an object is struck by them, they must then return to normal operation
position.
13. Be sure to double check boom heights, nozzle spacing and displacement before spraying.
14. Machine is shipped with windshield washer fluid in to prevent freezing. Flush system completely with clear
water. Fill tank with water and retighten the four bolts used to hold the tank in place.
15. Readoperatinginstructions before starting.
Never allow pump to run dry! The valve on the suction side of the pump (between the pump
and tank) must be fully open whenever the pump is operated.
CONTROLS&INSTRUMENTS
A. Buzzer - The buzzer sounds if the pump is running dry.
B. PumpOn/OffSwitch - Turns pump on or off.
C. Speedometer-TheSpeedometerindicatesgroundspeedofthevehicleinmilesperhourandkilometers
perhour.(OPTIONAL)
D. Circuit Breaker - The circuit breaker is a resetable fuse. To reset push down on it.
E. HourMeter/Volt Meter -Thehourmeter indicates hours of machine operation. Itoperates onlywhen the
ignition switch is on. The volt meter indicates battery voltage. When starting, the battery voltage should
not drop below 9 volts. With key on, engine not running, the voltage should be 12 volts. With engine
runningat3600 rpm the voltage should read around 14 volts.
F. Oil Light - The oil light should come on when the ignition is on without the engine running and go out when
the engine is running. The oil light will light when the oil pressure is low. If oil light should come on, shut
engineoffimmediatelyandfindthecause.
G. Ignition Switch - The ignition switch has three positions: Off - Run - Start.
H. TiltSteering - Hold lever down andadjust steering wheel to desired position and release lever.

9
Introduction
CONTROLS & INSTRUMENTS (CONTINUED)
I. Spray Boss Control - Engages and disengages speed boss. Forward is
engage and all the way back is disengage. When the lever is engaged it
sets a stop for the accelerator. The accelerator pedal must be used to
maintain this speed.To adjust speed use the knob on the end of the lever,
counter clockwise increases speed and clockwise decreases speed. Disen-
gagethe lever and you will have full acceleratorpedalrange.
J. Hand Throttle - The hand throttle is usedto regulateengine speed.
K. Choke - The choke is used in starting the engine. Pull choke out to close
choke plate when starting a cold engine. Push in when engine starts. A warm
engine may not require "choking" to start.
L. Boom Switches (Electric Lift Kit)
M. Boom Levers (Hydraulic Lift Kit)
N. Park Brake - The park brake is only a parking brake. Pull back to release,
push forward to apply. Some adjustment can be made by turning the knob
clockwise to tighten and counter clockwise to loosen.
O. Accelerator Pedal - This pedal controls ground speed. Press pedal to
increasespeed.Varyingthe amount of movement of the pedal will vary
theground speed.
P. ReversePedal-This pedal controls ground speed in the reverse
direction.
When pedals are released the hydrostatic transmission centers and
stops the vehicle with a braking action.
MASTERBOOMSWITCH
The master boom switch (R), located on the left floorboard is used
to override the master switch on the computer console of the spray
systems. By pushing down it will turn on/off the booms. For 834
Systems the Master Switch on the computer must be on for the
master boom control switch to work. For the 440 System the Mas-
ter Switch on the computer must be off for the master boom con-
trol switch to work.

10
Operation
OPERATION
Before operating the Spray Star 1000, become familiar with all controls and functions.Also complete all mainte-
nancerequirementsand read allsafety warnings.Knowing theSprayStar 1000 thoroughly, how it operates,and
by doing the prescribed maintenance steps, you can expect trouble free operation for years to come.
SAFETY
0 needs to always be the concern of an operator of a moving vehicle or any machine with moving parts.
1. Keep all shields and guards in place.
2. Keep the parking brake engaged any time the operator is away from the vehicle or whenever service is
performed.
3. Alwayswearthenecessaryprotectiveclothingandequipment.
4. Turn engine offwhen refueling orperformingmaintenance not specifically requiringenginepower.
DAILYCHECKLIST
1. Check theengine oil level. Addas needed.DO NOT OVERFILL. Refer to engine owner's manual for oil
gradeandprocedure.
2. Tire pressure should be 20 psi (1.4 bar) maximum.
3. Inspect the electrical system and battery cables for loose connections or frayed wiring. Replace any faulty
equipmentortightenif loose.
4. Check hardware for loose or missing nuts, bolts, screws, etc., and tighten or replace as needed.
5. Inspect hydraulic lines for damage or leaks. Never use hands to inspect for leaks.
6. Check the hydraulic fluid level. The hydraulic fluid tank is located on the left side of the machine. The fluid
level should be 2"-2½" (5 - 6.4 cm) from the top of the tank when cold. Use only SAE 10W-40API Service
SJ or higher Motor Oil.
7. Inspect the steering, throttle and shift linkages for good hookups and
cleartravel.
8. Check controls for smooth,proper working operation. Lubricateas
needed.
9. Check park brake adjustments. Adjust as required.
10. Checkanti-vibrationmounts on engine frame.
STARTINGTHEENGINE
1. Make sure the fuel flow valve is ‘On’. It is located on the fuel tank.
2. The ignition switch is located on the dashboard. Insert the key (A) and
turn clockwise until the engine starts (C). Release the key and it will
return to the run position (B). Use the choke and hand throttle as nec-
essary.
3. Allowenginetoidleandwarmupbeforeselectingdirectionof travel.
STOPPINGTHEENGINE
If the engine has been running under high power, let it run at slow idle speed a few minutes
to cool the engine down, before turning the ignition switch to the OFF position.
1. Disengagespray pump.
2. Movethe throttlelever to“slow”andturn ignition key to the “off” position.
3. Removetheignitionkeyandengagetheparkbrake.
Never leave the vehicle unattended with the engine running. Always bring the vehicle to a
complete stop, engage park brake, turn key off and remove key.

11
Operation
OPERATION (CONTINUED)
Before using the Spray Star, the operator and spray technician must familiarize themselves with all of the information
on chemical spraying contained in the Turf Spray Guide.
All testing and calibrating of sprayers is to be done with water, not chemicals. This insures the safety
to all involved in performing the calibration operation. Only after all calibration procedures are
completed should chemical be added to the sprayer.
TOWING UNIT
Whenit is necessary to move the Spray Star1000without the enginerunning, the bypass valve builtinto hydrostatic pump
mustbe "open" by turningit counterclockwise.The valve is locatedon the bottom of the pump.An"open"valveallows fluid to
passthroughthewheelsfreely. When normaldriven operation isdesired, valve should be"closed" by turningit clockwise.
Failureto "close" the valvewith engine running meansno power to wheels.
HILLSIDEOPERATION
Do NOT stop or start suddenly on any slope. Be especially cautious when changing direction. Do NOT operate on
slopesgreater than 20°.
BATTERY
Batteries normally produce explosive gases which can cause personal injury. Do not allow flames, sparks or any ig-
nited object to come near the battery. When charging or working near battery, always shield your eyes and always pro-
vide 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 first 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, flush all contact areas immediately with liberal amounts of water. Get medical
attention immediately.
JUMP STARTING
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 (+) terminals of each
battery, first (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 discon-
necting jumper cables.

12
Operation
OPERATION (CONTINUED)
SPRAYER VALVE SETTINGS AND SPRAY TANK AGITATION
The gate valve on the suction side of the pump, between the tank and the pump must be open before pump is
engaged. Close this valve only when necessary to clean the filter with spray material in the spray tank.
There is one manual flow control valve on the discharge side of the spray system. This valve controls the agita-
tor. This valve may be opened as much as necessary to provide hydraulic agitation through the quadrajet agita-
tor in the tank bottom. This valve may be partially closed to prevent or reduce foam buildup from the spray ma-
terials inside the tank. When the liquid level in the spray tank reaches a certain level (usually 1-25 gallons
(3.8-95 Liters) depending on terrain and other conditions) it may be necessary to close the valve in the agitator
line in order to prevent loss of suction prime.
IfyourSprayStarisfittedwithahosereel,thereisa secondball valveon thedischarge systemto supplymaterial to
thehosereel.
TheQuadrajetagitationsystemoperateswith fourventurijetsinthetankbottom.These jetshavereplaceableorifice
discswhichdischargethefollowingamounts ofspaymaterial.
Input to Input to Agitator Agitator Agitator Agitator
Nozzle Agitator Agitator Pressure Pressure Output Output
Diameter in gpm in L/min in psi in bar in gpm in L/min
1/8" 1.9 7.2 25 1.7 6.3 23.8
1/8" 2.7 10.2 50 3.4 10.0 37.9
1/8" 3.8 14.4 100 6.9 15.0 56.8
5/32" 2.8 10.6 25 1.7 7.6 28.8
5/32" 4.2 15.9 50 3.4 12.2 46.2
5/32" 5.5 20.8 100 6.9 17.5 66.2
3/16" 3.6 13.6 25 1.7 9.1 34.4
3/16" 5.6 21.2 50 33.4 14.3 54.1
3/16" 7.9 29.9 100 6.9 18.7 70.8
You can change orifice disc sizes to enhance spray system performance. Smaller discs reduce amount of agita-
tion (desirable in some foaming materials) and make more dischargeable liquid available for nozzles. Larger (or
none) discs increase amount of agitation and make less dischargeable liquid available for nozzles.
INITIAL SYSTEM SETUP
1. Fill tank with water only.
2. PlaceMaster On/Offswitch toOn,BoomOn/Off switches to Off, and open tankshut-off valves.
3. WithPump not running,fully openmain line handvalve andtotally close agitatorline handvalve.
4. Verifythateach boom solenoid valve operates by operating Boom On/Off switches and that no nozzles are
plugged.
5. Place all Boom On/Off switches On.
6. Hold the Pressure Adjust switch in the increase position until the pressure stops increasing and begins to
decrease.
7. Adjustagitator line hand valve for desired agitation.
8. Closethe mainline handvalve, if necessary, to set the maximum desired operating pressure.(The
maximum pressure should be approximately 10 psi (69 kPA), above the normal spraying pressure.)
9. Hold the Pressure Adjust switch in the decrease position until the pressure stops decreasing and begins
to increase. If desired minimum pressure cannot be obtained, install larger bypass hose.
10. Verify the desired maximum pressure of the sprayer system by repeating step 6.

13
Operation
CONSOLEFEATURES
A. Master Boom Switch - Activates or stops boom spraying.
B. Individual Boom Switches - Used to activate any of up to 3 booms on a sprayer.
C. PSI Gauge - Indicates the pressure of fluid in the system.
D. Pressure Switch - Used to activate the motorized control valve
E. FuseHolder- The fuse holder holds one 15 Amp fuse.
CALIBRATING THE PRESSURE GAUGE
The pressure tap on the Raven Sprayer Control system is located away from the nozzles, thus, there can be a
pressuredifferencebetween nozzle pressure and gauge pressure at the console. Therefore, for best results,
Ravenrecommends thefollowing procedure:
1. When the sprayer is ready and the tank is filled with water (No chemicals at this time), attach an accu-
rate pressure gauge to a nozzle in place of the spray tip.
2. Startup thepump,turnon the electric shut-off valves andadjust thepressure controlvalvesothat the
desired pressure is maintained on the gauge at the nozzle.
3. Because of pressure drops through the system, the pressure shown on the gauge in the console may
read slightly higher than the gauge at the nozzle. Use this console pressure reading as your reference
pointfor maintaining the desired pressure atthe nozzle.

14
Operation
SPRAY OPERATION
SPRAY OPERATION (After Proper Setup and Calibration)
1. Add 1/2the amount of water required for the spray operation to tank using air gap filler.
2. Start engine, set engine speed below 2000 RPM, and engage pump after taking all previously described
safetyandoperationprecautions.
3. Open agitatorvalve.
4. Add chemicals (taking all precautions described in this manual and by the chemical manufacturer).
a. Liquids may be poured directly into tank.
b. Wettable powder chemicals must be pre-mixed with water in a container to form a slurry. The mixture
is then added to the tank through the fillwell strainer.
c. Chemical in soluble packs are place into the fillwell strainer basket and dissolved by adding water
through the basket.
The balance of the water required for the spray operation is added to the tank through the fillwell strainer,
using the air gap filler. This will wash any undissolved chemical into the tank.
5. Transport to sprayer site with and agitator operating.
6. SetEnginespeedbetween2000-3200RPM.
7. (Optional)Engagegroundspeedcontrol.
8. Obtain desired spraying speed before activating spray with switches on spray control console.
9. The master boom switch, located on the left floorboard is used to override the master switch on the
computer console of the spray systems. By pushing down it will turn on/off the booms. For 834 Systems
the Master Switch on the computer must be on for the master boom control switch to work. For the 440
System the Master Switch on the computer must be off for the master boom control switch to work.
Review the capacity of nozzles being used. Total capacity of all nozzles plus agitation
system must not exceed pumping system capabilities refer to Spraying Procedure section of
this manual. FLUSH PUMP AFTER USE
Shut-Off 20GPM 40GPM 60GPM 80GPM 100GPM
120psi 100psi 80psi 60psi 30psi 10psi
100psi 95psi 76psi 52psi 26psi 5psi
80psi 75psi 62psi 45psi 21psi -
60psi 55psi 40psi 25psi 5psi -
To determine the correct performance data for your application, first shut off all flow on discharge side of pump and
detemine the shut-off pressure at the pump. Use this Shut-Off pressure to determine which line of data applies.

15
Operation
SPRAYOPERATION (CONTINUED)
Oneof the most commoncauses for faulty-pump performance iscorrosion inside the pump.Flushthe pump and
entire system with a solution that will chemically neutralize the liquid pumped. Mix according to manufacturer’s
directions.This will dissolve mostresidue remaining in the pump,leaving the inside of thepump clean for the
next use.
TOPREVENTCORROSION
Aftercleaning the pump asdirected,flush it with a permanenttype automobile antifreeze (Prestone, Zerex,etc.)
containing a rust inhibitor. Use a 50% solution that is, half antifreeze and half water. Then coat the interior of the
pump with a substance which will prevent corrosion such as Fluid Film or WD40. If unit will not be used for an
extended period of time, disconnect hoses into and out of the pump, seal openings to the pump with caps or
tape. Dispose of fluids according to all federal, state and local regulations.
All chemicals and chemical residue must be removed after each use. Dispose of fluids and
residue according to all federal, state and local regulations.
SPRAYERCLEANING
Empty tank and clean unit thoroughly after each use following these instructions:
1. Removecouplingandrinseinsideoftankthoroughly with clean water,replacecoupling.
2. Fill tank ten percent full with clean water, start pump and discharge water through spray hose or spray
boom(withnozzlesremoved),untilempty.
3. Removedrain coupling again and rinse tankinterior thoroughly.
4. Rinseexteriorofsprayerthoroughlywithcleanwater.
5. Remove bowl from sprayer filter (on operators left hand side of the spray tank). Remove stainless steel
screen. Wash bowl and screen thoroughly.Apply thin layer of petroleum jelly to O-ring or gasket. Replace
screen and bowl, taking care to position O-ring or gasket properly. Hand tighten.
MANUALHOSE REEL
Located at the back of the Spray Star behind the tank. Open the ball valve located near the pump to allow fluid
to flow into the hose reel. Place the lockout pin in the unlocked position by pulling and turning it half a turn, this
willallow you to pullout additional hose or touse the handle and windup the hose.To preventmovement during
transport or storage place the lockout pin in the locked position.
ELECTRICHOSEREEL
Located at the back of the Spray Star behind the tank. Open the ball valve located near the pump to allow fluid
to flow into the hose reel. To unwind hose just pull on the hose to get the desired amount.To wind up the hose
make sure the toggle switch is in the ON position, push the momentary push button switch until you have reeled
in the amount of hose desire. Turn off the safety switch when not in use.
FOAMMARKER
Located to the right of the control panel. Use lever (A) to designate which boom is
to be used to dispense foam. Use dial (B) located on top of foamer to adjust pres-
sure for the amount of foam that will be dispensed. Switch (A) also turns foamer
on or off.

16
Schematics
WIRING SCHEMATIC
HYDRAULIC SCHEMATIC

17
SprayingProcedures
SPRAYING INTRODUCTION
This section is intended to offer practical guidelines for the distribution of liquid chemicals over an area of
turfgrass such as golf courses, park land, school grounds and lawns. SMITHCO makes no representation as to
the suitability of any technique or product for any particular situation. This section is suitable for self-propelled
sprayvehiclesorsprayersmountedontovehicles.
Boom Spraying is the most effective, accurate and efficient method of applying chemicals to large turf areas. It
may be done by means of:
• Adedicatedsprayvehicle
• Asprayer mounted upon autilityvehicle
Sprayers are typically equipped with wide spray booms. Generally these booms are between 15 feet (4.5 m)
and 20 feet (6 m) in width. They are divided into three sections, with hinges that permit the long outer sections
to automatically move out of the way and reset if an obstacle such as a tree or fence is in you path.
To minimize the chance for missed areas or double application use a device to mark the outside boundaries of
eachsprayswath. Foam markers and dye markers are advisable.
TURFMANAGEMENT
Turfmanagement chemicals are madeforfourgeneral purposes:
1. Fungicides: Preventorcurefungusonturfgrass. They are made in 2 general types:
• Systemic - Chemicals enter the plant system and protect or cure it of, fungus.
• Contact - Kills fungus with which it comes into contact.
2. Insecticides: Eliminate damaging insects and worms (such as grubs, beetles, ants, etc.)
3. Herbicides: Controlandeliminate undesirable weeds and grass from turf areas and non-turf areas such
as bunkers, trails, fences, etc.
4. Nutrients & Fertilizer: Promotegrowth, beauty and color inturfgrass.
Some materials have to be applied so that they get into the soil below the plant leaves, This is called "soil appli-
cation". In order to do this, they are best applied with a large volume of water. They are often then watered-in
using the irrigation system. This type of chemical material includes systemic chemicals and chemicals de-
signed to destroy pests which live in the thatch and the soil.
Other materials must be applied to reach a problem that is present on the plant leaves. This is called “Foliar
Application”andrequiresalowervolumeofwater. Instead of irrigation water, thesematerialsarefurtheractivated
by dry air and sunshine. They include contact fungicide and many herbicides.
The user of sprayers and chemicals must follow the directions provided with the spray material. It is the only
waytoinsure safe and effective results. It providesinformationonhow much chemical and how much wateris to
be applied to the area to be sprayed.
Though there are many types and sizes of nozzles, two specific types have proven most successful in turfgrass
management.
• The first type is target-directed. It sprays material in a direct line downwards to the target turfgrass.
These are flat fan nozzles, commonly referred to as TeeJet nozzles.They are available in a wide variety
of sizes for any required discharge volume rate. They are the best for many contact or foliar applied
pesticides. They are spaced either 10" (25 cm) or 20" (51 cm) apart and overlap one another by about 1/
3.
• The second type useful in turf management are broadcast type nozzles. They are commonly referred to
asraindroporfloodjetnozzles.They spray a hollow-cone shaped pattern of much larger droplets which fall
quickly to the turf under their own weight. They are best for systemic pesticides or any material requiring a
largevolumeof water for soil application. The larger droplets arenot as subjectto driftfrom windand are a
safer, more environmentally friendly choice in many situations.

18
SprayingProcedures
HOSE & HANDGUN SPRAYING
A handgun (hand-nozzle or hand-lance) is used to control and direct the spray pattern to the ground, shrub or
tree. They must be constructed of long lasting and noncorrosive materials such as brass, stainless or aluminum.
The handgun fits to a hose of any length from the sprayer allowing operator mobility. The hose should be as
shortaspossiblewhile still permitting operator mobility.
Liquid looses pressure due to friction as it travels through the hose, 1-3 psi (0.07-0.21 bar) for each foot (30
cm) of hose. For most operations 1/2" (1.25 cm) inside diameter hose is adequate. Trees over 40 ft (12 m) high
require 3/4" (2 cm) inside diameter hose and a sprayer pump capable of delivering a volume of at least 20 gpm
(75 lpm) and a pressure of at least 400 psi (28 bar).
NOZZLES
Always be alert to the possibility of a plugged or damaged nozzles. Serious misapplications may result. Check
nozzleoutputperiodically.
Modernnozzlesusespringanddiaphragm check valves to insure positive cutoff of chemicals without drip.
Snap-oncapsmake replacing and cleaning nozzles, quick, easy and fool proofwith properreinstallation.
An operator can see at a glance if all nozzles are the same size by the color code.
3FUNCTIONSFORASPRAYBOOMNOZZLE
1. Regulating the flow is done through size of the orifice (opening) within the nozzle. All nozzles, regardless
oftype, have some point within them thatregulatesthe flow of liquid. Obviously, the larger the openingthe
greaterthe rate of flow volume.Volume is expressed inGallons Per Minute (gpm) or LitersPerMinute
(lpm).Donotconfuse the term volume with application rate, which will be coveredlater.
Aspressure increases, the flow volume in agivennozzlealso increases. For example, an averagesize
nozzle which discharges 0.52 gpm (1.4 lpm) at 30 psi (2 bar), will discharge 0.73 gpm (2 lpm) at 60 psi
(4 bar). In this example, an increase in pressure of 100% has caused an increase in discharge of 40%.
Somenozzlesdelivera small volume (for example: 0.2 gpm (0.75 lpm)). Some nozzles deliver arelatively
large volume (for example: 1.5 gpm (5.7 lpm)), or 71/2times as much as the smaller nozzle in this ex-
ample.
Theamount of material (volume) tobeapplied is determined by theeffectthe chemical has on theturf.
2. The nozzle on a sprayer is to form the liquid into droplets. The size of the droplet is determined by two
factorsdesignand system pressure (psi/bar).
Particular applications are done best by big droplets such as systemic fungicides, insecticides and some
herbicidesin order to reduce drift. Other applicationsrequire smalldropletslikecontact fungicides and
some herbicides. Again, this is determined by whether the chemical is foliar applied or soil applied. Large
dropletsforsoilappliedmaterial,small droplets for foliar applied materials that evenly cover the plant
better.
Pressure also affects droplet size. More pressure at the same nozzle produces smaller droplets, more
subject to drift. The general rule on pressure is to use the lowest pressure possible with just enough to
formadequatespraynozzlepatterns.