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.