Smithco 1008 User manual

OPERATOR’S
MANUAL
Spray Star 1000
Model 1008
Requires 10-160 Boom
Starting Serial #100100 March 2002
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 ................................................................. 10-22
Operating Instructions.......................................... 10-12
Console Features ..................................................... 13
Console Programming.............................................. 14
Console Calibration.............................................. 14-15
Initial Programming of Console Computer........... 16-20
InitialConsoleSetup ................................................. 20
Spray Operation ................................................... 21-22
Schematics.................................................................... 23
Wiring Schematic ..................................................... 23
Hydraulic Schematic................................................. 23
Spraying Procedure ................................................ 24-30
SprayingIntroduction................................................. 24
Turf Management ...................................................... 24
Hose & Handgun Spraying ........................................ 25
Nozzles................................................................ 25-26
CalibrationIntroduction ............................................. 27
The Nozzle Chart Method of Calibration .............. 28-29
The “128” Method of Boom Sprayer Calibration ... 29-30
Nozzle Charts .......................................................... 31-36
Nozzle Performance Chart #1 .................................. 31
Nozzle Performance Chart #2 .................................. 32
Nozzle Performance Chart #3 .................................. 33
Nozzle Performance Chart #4 .................................. 34
Nozzle Performance Chart #5 .................................. 35
Nozzle Performance Chart #6 .................................. 36
Reference ................................................................ 37-38
Abbreviations and Conversions ................................ 37
Declaration of Conformity ......................................... 38
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.
These machines are intended for professional maintenance on golf courses, sports turf, and any other
area maintained turf and related trails, paths and lots. No guaranty as to the suitability for any task is
expressed or implied.

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. BATHE thoroughly afteranyexposure 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" (178 cm)
Width With Boom Open 180" (457 cm)
Height 48" (122 cm)
Wheel Base 53" (135 cm)
Weight Empty 1200 lbs (544 kg)
WeightFull 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 GasolineMinimum
CoolingSystem Air Cooled
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 SeeEngineManual
Fuel 5 gallon (19 liters)
Hydraulic Fluid 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
TheSprayStar1000 arrives from setup and ready for service.Dependingonfreightconditionsthe
tires, wheels, and steering wheel may have to be 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
wheels and torque nuts to 64-74 ft/lb (87-100 Nm). Then raise rear axle
using a hydraulic jack and install rear wheels and tires, torque lug nuts
to 64-74 ft/lb (87-100 Nm). Re-torque after the first 10 hours and
every 200 hours 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
steering wheel (RefA) on the shaft of the steering mechanism
(Ref C). Tighten nut to 30-40 ft/lbs (41-54 Nm). Do not over
tighten.
7. Install the seat with the stud going throughthe engine
coverand the flat washers, lockwashersandnuts. Use
front set of holes for shortest distance from foot pedals to
seat. Use back set of holes for longest distance from foot
pedaltoseat.
8. Battery NOT furnished. Install a 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
SETUP(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 the turf as described in Turf Spraying Guide. The spray boom must operate properly and the outer
sections 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. Readoperating instructions beforestarting.
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. Pump On/Off Switch - Turns pump on or off.
C. Speedometer - The Speedometer indicates ground speed of the vehicle in miles per hour and kilometers
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.Varying the 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 over-
ride 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.

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
Safetyneedsto always be the concern of an operator ofa moving vehicleor anymachine withmoving parts.
1. Keep all shields and guards in place.
2. Keeptheparkingbrakeengagedanytimetheoperatorisawayfromthevehicleorwheneverserviceis
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 on all rear tires.
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)
SPRAYERVALVESETTINGSANDSPRAYTANKAGITATION
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.
Therearetwo manual flow control valves on the discharge side ofthe spraysystem.
There is a manual flow control valve on the discharge side of the spray system that controls the agitator. This
valvemaybeopenedasmuch as necessary to provide hydraulic agitation through the quadrajet agitator in the
tankbottom.This valve may be partially closed to prevent orreduce foam buildupfrom thespray materialsinside
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
preventlossofsuctionprime.
If your Spray Star is fitted with a hose reel, there is a third ball valve on the discharge system to supply material
to the hose reel.
The Quadrajet agitation system operates with four venturi jets in the tank bottom. These jets have replaceable
orifice discs which discharge the following amounts of spay material.
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.

13
Operation
CONSOLEFEATURES
This Console (PGM F) requires selection of US (acres); SI (hectares) or TU (1,000 sq ft) area
and SP1 (wheel drive, etc).
A. POWER-Turns Console power OFF or ON. Turning ConsoleOFF doesnot affectthe datastored in
thecomputer.
B. Select manual or fully automatic control. This can automatically control two rates.
C. Manualoverridecontrolprovides capability for spot spraying.
D. Booms can be controlled individually, or all at once with MASTER ON/OFF Switch
E. DisplaysoperatingrateofapplicationandflashingTip Fault.
F. Displaysfunction and calibration data.
G. CE - Use like you do CE (clear entry) key on a calculator. This key is also used to select an area
basemeasurementof US (acres), SI (Hectares) or TU (1,000 sq ft).
H. ENTER - Used only to enter the data into the Console.
Calibration Keys: (TopRow) Used to enter Function Keys: (Bottom Row) Used to display data.
data into console to calibrate the system.
BOOM1CAL Length of Boom 1 TOTALAREA Total Area Sprayed
BOOM2CAL Length of Boom 2 FIELDAREA Field Area Sprayed
BOOM3CAL Length of Boom 3 FIELDVOLUME Volume Applied to Field
SPEED CAL MeasuredOffDriveLine (688) DISTANCE DistanceTraveled
METERCAL Flow Meter Calibration Number SPEED Speed of Vehicle
VALVECAL Control Valve Response Time VOLUME/TANK Volume Remaining in Carrier Tank
RATE1CAL Target Application Rate TIME 24 hour clock (military time)
RATE2CAL Target Application Rate TIPMONITOR Use to Display Tip Faults
SELFTEST Simulates Vehicle Speed

14
Operation
CONSOLEPROGRAMMING
When entering data into the Console computer, the entry sequence is always the same. Data must be entered
into the first eight keys.
1. Depress the key which you wish to enter data. 2. Depress the “Enter” key.An “E” will illuminate
in the DATA display.
3. Depress the keys corresponding to the 4. Complete the entry byagain depressing the
number you wish to enter (i.e. “5”, “7”, “2”). “ENTER”key.
Thenumberswill be displayed in the DATA
display as they are entered.
CONSOLECALIBRATION
CALCULATING“BOOMCAL”(BOOM1,BOOM2,BOOM3)
Calculate the width of each boom in inches (centimeters) by multiplying the number of tips times the spacing.
Writethese boom widthsdown for future reference when programming the Consolecomputer.TheConsoleis
capableofcontrolling up to three (3) booms.
CALCULATING“SPEEDCAL"
1. Enter Speed Cal in key of 688.
2. Place Master and Boom 1 switches to on.
3. Enter “0” in key .
4. Drive 1 mile. Do not use vehicle odometer to determine distance, use section lines or highway markers.
5. Itshouldreadavalueofapproximately5280.Ifitreadsbetween5200-5350,theSpeedCalforthisvehicle
is 688.
IftheDistancedisplayreadsanyothervalue, divide Speed Cal by the value observed in Distance, then
multiply by 5280. This will give you the correct value to enter for Speed Cal. You must round off to the
nearest3digit number (use 120 not 120.3).

15
Operation
CONSOLE CALIBRATION (CONTINUED)
6. Recheck the new Speed Cal numbers. Zero out Distance display as in step 3. Enter the new Speed Cal
number as in step 1. Repeat steps 4 and 5.
MEASURE CAREFULLY. Be sure tire is properly inflated before measuring. Measure tire in
type of soil in which you will be spraying. Circumference of tire will vary when measured in
soft soil versus hard packed soil. For best results, measure several times and average the
results. Re-measure periodically.
CALCULATING“METERCAL”
The Flow Meter calibration number is stamped on the label attached to each Flow Meter; this number is to be
usedforgallonperarea applications.To convert original METER CALfrom gallons to desired units of measure
(oz,lbs or liters per area)seeAbbreviations and Conversions section ofthis manual. Write down thiscalibration
numberfor futurereferencewhenprogramming the console.
CALCULATING"VALVECAL”
The initial Control Valve calibration number is 2123.After operating the system, you may desire to refine this
number.Seedefinitionsbelow.
Valve Backlash Controls the time of the first correction pulse after a change in correction direction is detected.
Incr to Decr or Decr to Incr Range: 1 to 9, 1-Short Pulse, 9-Long Pulse
Valve Speed Digit Controls the Speed of the Control Valve motor.
Running the Control Valve too fast will cause the system to oscillate.
Range: 1 to 9, 1-slow, 9-Fast
Brake Point Digit Percent Sets the point at which the Control Valve motor begins braking, so as not to over
shoot the desired rate. Digit is percent away from target rate. Range: 0 to 9, 0=5%, 1=10%, 9=90%,
DeadbandDigitAllowabledifference between target and actual application rate, where rate correction is not
performed. Range: 1 to 9, 1 = 1%, 9 = 9%
CALCULATING"RATE1ANDRATE2CAL"(See SprayingProcedure section)
Determine the application rate at which your chemical should be sprayed. Consult with your Dealer to insure
your spray nozzles are capable of applying at this target rate.
Using CAPACITY = .35 GPM (1.67 lit/min) and pressure = 30 PSI (20 bar) you would select tip number
XR8004 from the Nozzle Charts Section, since it comes closest to providing the desired output.
VERIFYINGFLOWRATELIMITS
The flow rate of the sprayer must be within the range of 1 to 55 GPM (4 to 210 lit/min).

16
Operation
INITIALPROGRAMMINGOFCONSOLECOMPUTER
Whenyoufirstturn on Console power, afterall installationprocedureshavebeencompleted,the Console will
flash “CAL” in the RATE display and “US” in the DATAdisplay. This means you must “calibrate” or program the
Consolebeforeit can be operated.
(This is a one time operation which does not have to be repeated unless you disconnect your battery wires.
Turning OFF the POWER ON/OFF switch does not affect the Console memory.All data is retained).The follow-
ing steps must now be followed.
If an entry selection error is made during steps 1, 2, 3, or 4, the Console can be reset by depressing for
20 seconds (Data displays US and RATE displays CAL.).
1. DisplayingUS,SIor TU
a. Depressing momentarily Steps the DATAdisplay from US (acres) to SI.
b. Depressing momentarily Steps the DATAdisplay from SI (Hectares) toTU.
c. Depressing momentarily Steps the DATAdisplay from TU (1000 sq ft) to US.
2. Selecting US, SI or TU
a. To select US, SI, or TU, step until the desired code is displayed in DATAdisplay.
b. Momentarily depress the DATAdisplay will now display SP1.
3. Displaying SP1 or SP2
a. Depressing momentarily steps the DATAdisplay from SP1 (wheel drives, etc.) to SP2.
b. Depressing momentarily steps the DATAdisplay from SP2 (radar sensor) to SP1.
4. Selecting SP1 OR SP2
a. To select SP1 or SP2, step with until desired code is displayed in DATA display.
b. Momentarily depress the DATAdisplay will now display 0.
5. Enter width in inches (cm) of BOOM 1 in the key labeled:
6. Enter width in inches (cm) of BOOM 2 in the key labeled: If there is only one boom, enter "0" for
width of BOOM 2.
7. Enter width in inches (cm) of BOOM 3 in the key labeled: If there is only one or two boom, enter “0”
forwidth of BOOM 3.

17
Operation
INITIALPROGRAMMINGOFCONSOLECOMPUTER (CONTINUED)
8. Enter SPEED CAL of 688 in key labeled:
9. EnterMETER CAL calibration number inkey labeled:
10. Enter VALVE CAL calibration number (2123) in key labeled:
11. Enter the target RATE 1 (GPA) (lit/ha) (GPK) you want to spray in the key labeled:
12. Enter the target RATE 2 (GPA) (lit/ha) (GPK) you want to spray in the key labeled: (If you do not
use a second rate, enter same rate as RATE 1 CAL). RATE 2 should not be more than 20% different from
RATE 1 or else spray pattern may suffer.
YOUHAVE NOW COMPLETED PROGRAMMINGTHE CONSOLE.
The flashing “CAL” will now extinguish. If not, repeat procedure starting at step 5.You may also wish to enter
data in the keys labeled: and although it is not required for the operation of the system.
13. Enter the estimated total Volume-in-Tank when you start spraying in key labeled: Each time the
tank is refilled, this number must be reentered.
14. Enter the TIME of day in the key labeled: . This is a 24 hour clock. Therefore, all time after 12:59 pm,
add 12 hours. Thus, 8:30 am is entered as 8:30, but 1:30 pm is entered as 13:30 in the keyboard.
OTHERDISPLAYFEATURES
1. To display TOTALAREAcovered, momentarily depress key labeled: To “zero out” this total, at any
time, enter a “0” in this key.
2. To displayTOTAL VOLUME sprayed, momentarily depress key labeled: To “zero out” this total, at
any time, enter a “0” in this key.
3. To display FIELDAREAcovered, momentarily depress key labeled: To “zero out” this total, at any
time, enter a “0” in this key.
4. To display FIELD VOLUME sprayed, momentarily depress key labeled: To “zero out” this total, at
any time enter a “0” in this key.
5. To display DISTANCE(feet(meters)traveled) momentarilydepress key labeled: To “zeroout” this
total, at any time, enter a “0” in this key.

18
Operation
INITIALPROGRAMMINGOFCONSOLECOMPUTER (CONTINUED)
6. To display SPEED, momentarily depress the key labeled:
7. To display VOL/MIN., momentarily depress the key labeled:
8. To displayAREA/HOUR, momentarily depress key labeled: This is an actual calculation ofAREA/
HOURatthe present speed you are going. Itis notan averageover time.
9. To displayTIP MONITORfault, momentarilydepress the key labeled: SeeTIP MONITORmanual
formoredetaileddiscussion. (Purchase the TIP MONITOR option if this function is desired.)
10. To display US, SI or TU and SPI or SP2 after being selected depress: These selections will be
alternatelydisplayed.
SELFTESTFEATURE
SELF-TEST allows speed simulation for testing the system while the vehicle is not moving. Enter the simulated
operating speed in the key labeled: If 6 MPH (10 km/h) is desired, enter 6.0 (10.0). Verify speed by
depressing key labeled: SPEED
The SELF-TEST speed will clear itself when motion of vehicle is detected by the Speed Sensor.ASPEED CAL
Value of 900 (230) or greater is recommended when operating in this mode.
SEQUENCETOACTIVATEDATA-LOCK*
1. Depress for 5 seconds, NEW CODE message will appear.
2. Enter 4 digit code within 15 seconds.
EXAMPLE: For 1085, depress and
SEQUENCETOCHANGEDATA-LOCK
1. Depress for5 seconds, OLDCODE messagewill appear.
2. Enter 4 digit OLD CODE within 15 seconds.
EXAMPLE: depress and
NEW CODE message will appear. Enter 4 digit code within 15 seconds.
EXAMPLE: For 1285, depress and