Smithco 1010 User manual

OPERATOR’S
MANUAL
SPRAYSTAR1000
Model 1010
Requires 10-160 Boom
June, 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
SafePractices.............................................................................4
SafeSpraying Practices ..............................................................5
Specifications ..............................................................................6
OptionalEquipment .....................................................................6
Setup .......................................................................................7-8
Controls& Instruments .............................................................8-9
Operation .................................................................................. 10-14
Schematics ....................................................................................15
Wiring Schematic ......................................................................15
HydraulicSchematic .................................................................15
Spraying Procedure ................................................................. 16-22
SprayingIntroduction .................................................................16
TurfManagement.......................................................................16
Hose &Handgun Spraying .........................................................17
Nozzles ................................................................................ 17-18
CalibrationIntroduction ..............................................................19
TheNozzleChart Method ..................................................... 20-21
The“128”Methood................................................................ 21-22
Nozzle Charts............................................................................ 24-29
NozzlePerformanceChart #1 ....................................................24
NozzlePerformanceChart #2 ....................................................25
NozzlePerformanceChart #3 ....................................................26
NozzlePerformanceChart #4 ....................................................27
NozzlePerformanceChart #5 ....................................................28
NozzlePerformanceChart #6 ....................................................29
Reference.................................................................................. 30-32
AbbreviationsandConversions ..................................................30
DeclarationofConformity...........................................................32
Warranty ...........................................................InsideBack Cover

1
Introduction
Informationneededwhenordering replacementparts:
1. ModelNumberof machine
2. SerialNumberof machine
3. Nameand PartNumberofpart
4. Quantityof parts
INTRODUCTION
Thankyou forpurchasinga 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.
Keepmanuals inasafe placeafteroperator andmaintenancepersonnel havereadthem. Rightandleft sidesare
fromthe operator’s seat,facingforward.
All machineshave aSerialNumberand ModelNumber. Bothnumbersare neededwhenordering
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 manualforplacement of engineserialnumber.
For easy access record your Serial and Model numbers here.

2
Introduction
SYMBOLS
ParkBrake Park Brake
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 MovingParts 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. Neverallow anyonetooperate or servicethemachine oritsoptional equipmentwithoutpropertraining and
instructions.Never allowminorsto operateanyequipment.
3. Learnthe properuseof themachine, the locationand purposeofall thecontrols and gaugesbefore you
operatethe equipment.Workingwith unfamiliarequipment can leadto 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 obstructionsandunderground obstacles.Stay alertforhidden hazards.
6. Neveroperate equipmentthatis notin perfect workingorder orwithoutdecals, guards,shields,or other
protectivedevices in place.
7. Never disconnect or bypass any switch.
8. Carbonmonoxide intheexhaust fumes canbefatal wheninhaled,never operateamachinewithout 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. Disengageall drivesandset parkbrakebefore startingtheengine.
12. Never use yourhands tosearch foroilleaks. Hydraulicfluid underpressurecan penetratethe skinand
cause serious injury.
13. Thismachine demandsyour attention.To preventlossof controlor tipping ofthe 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. Beforeleaving operator’s position:
A. Disengageall drives.
B. Set park brake.
C. Shut engineoffandremove theignitionkey.
D. If engine has to run to perform any maintenance keep hands, feet, clothing and all other parts of body
awayfrommoving parts.
15. Keephands, feetand clothingawayfrom movingparts.Wait forall movementtostop beforeyou clean,
adjustor servicethemachine.
16. Keepthe areaof operation clearof allbystanders.
17. Nevercarry passengers.
18. Stopengine beforemaking repairs/adjustments orchecking/adding oiltothe crankcase.
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
Personsengaged inthe handling, preparationor applicationofchemicals mustfollowaccepted practicesto
insurethe safetyofthemselves andothers,
1. WEAR protectiveclothing including:gloves,hat, respirator, eyeprotectionand skin coveringsuitablefor
protectionfrom chemicalsbeingused.
2. BATHE thoroughly after anyexposure tochemicals,giving particular attentionto eyes,nose,ears and
mouth.
3. CLEAN equipmentand materialsinaccordance withemployer, municipaland state regulations.Useonly
approvedareasanddrains.
4. DISPOSE ofchemicals andrinsesolutions byapproved and legalmeans.
5. PROVIDE methodsand materialsforoperators towash eyes andhands immediatelyduringthe spraying
process.
6. PROVIDE methodsand materialsforcontrol, safedilution and neutralizationof chemicalspillsduring
preparation,spraying, transporting andcleanup.
7. Always check and follow the directions and safety warnings of the chemicals to be used.
8. Securethe dischargelines beforestarting the pump.An unsecureddischarge 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. Useonly pipe,hose and fittingsrated formaximumpressure orpressureat whichpressure relief 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. Donot usethese pumpsforpumping waterorother liquidsfor human oranimal consumption.
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 allexposed moving partsare guarded andthat all couplingdevices are securelyattached before
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 fromfreezingconditions bydrainingliquid andpumpingrust inhibitingantifreezesolution
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 Unleaded87Octane GasolineMinimum
CoolingSystem Air Cooled
LubricationSystem Full Pressure
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 Automotivetype 24F-12 volt
BCI Group Size 24
ColdCrankingAmps 575minimum
GroundTerminalPolarity Negative (-)
MaximumLength 10.25" (26 cm)
MaximumWidth 6.88" (17 cm)
MaximumHeight 10" (25 cm)
FLUID CAPACITY
CrankcaseOil See EngineManual
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 SpeedometerKit 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'StainlessSteel Boom- manual 33-216 BatteryAutomotiveType24F-12 volt
10-301 15'Terrain Following Boom
10-107 HoseReelMounting 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 steeringwheelmay haveto beinstalled.
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
inthis manual.
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
alocation thatwoulddamage anysteering 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 seatwith thestudgoing throughthe engine
coverand theflat washers,lockwashers andnuts.Use
front set of holes for shortest distance from foot pedals to
seat. Use back set of holes for longest distance from foot
pedalto seat.
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-40 API
Service SJ or higher motor oil if necessary. Fluid level should be about 2-21/2" (5-6.4 cm) from the top of
thetank whencold.DO NOTOVERFILL.
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 should begreased beforestarting, refer to SprayStar1000 Parts/ServiceManualforlocation.
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 asdescribed inTurf Spraying Guide.The spray boommust operateproperly andthe outer sec-
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. Read operatinginstructions 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. PumpOn/Off Switch-Turns pumpon or off.
C. Speedometer- TheSpeedometerindicates groundspeedof thevehiclein milesperhour and kilometers
perhour. (OPTIONAL)
D. Circuit Breaker - The circuit breaker is a resetable fuse. To reset push down on it.
E. HourMeter/ Volt Meter-Thehour meterindicates hours ofmachine 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
runningat 3600rpm thevoltageshould readaround14volts.
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
engineoff immediatelyandfind thecause.
G. Ignition Switch - The ignition switch has three positions: Off - Run - Start.
H. TiltSteering - Holdlever down andadjuststeering wheeltodesired positionandrelease 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 andyouwill havefull acceleratorpedalrange.
J. Hand Throttle - Thehand throttleisused toregulate engine 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(HydraulicLift 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. Varyingtheamount ofmovementof thepedalwill vary
thegroundspeed.
P. ReversePedal -Thispedalcontrols groundspeedin the reverse
direction.
When pedals are released the hydrostatic transmission centers and
stops the vehicle with a braking action.

10
Operation
OPERATION
Before operating the Spray Star 1000, become familiar with all controls and functions.Also complete all mainte-
nancerequirements and readall safetywarnings.Knowing theSpray Star 1000thoroughly,how itoperates,and
by doing the prescribed maintenance steps, you can expect trouble free operation for years to come.
SAFETY
Safetyneeds toalwaysbe theconcern ofanoperator ofamoving vehicleor any machinewith movingparts.
1. Keep all shields and guards in place.
2. Keepthe parkingbrakeengaged anytimethe operatorisaway from thevehicleor wheneverserviceis
performed.
3. Alwayswear thenecessaryprotective clothingandequipment.
4. Turnengine off when refuelingorperformingmaintenance not specificallyrequiringenginepower.
DAILYCHECKLIST
1. Check the engineoil level. Addasneeded.DO NOT OVERFILL.Refer toengineowner's manualforoil
gradeandprocedure.
2. Tire pressure should be 20 psi (1.4 bar) maximum on all tires.
3. Inspect the electrical system and battery cables for loose connections or frayed wiring. Replace any faulty
equipmentor tightenifloose.
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-40 API Service
SJ or higher Motor Oil.
7. Inspect the steering, throttle and shift linkages for good hookups and
cleartravel.
8. Check controls for smooth, properworking operation. Lubricateas
needed.
9. Check park brake adjustments. Adjust as required.
10. Check anti-vibrationmounts onengineframe.
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. Allowengine toidleand warmupbefore selectingdirectionof 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. Disengagespraypump.
2. Movethe throttleleverto “slow”and turnignitionkey tothe “off” position.
3. Removethe ignitionkeyand engagethepark brake.
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)
Beforeusingthe Spray Star, theoperatorandspray technician must familiarize themselves withalloftheinformation on
chemicalsprayingcontainedin 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
Whenitis necessary to move the Spray Star1000 without the enginerunning,thebypass valve built intohydrostaticpump
mustbe"open" by turning it counterclockwise.The valve islocatedonthe bottom of the pump.An "open" valve allowsfluidto
passthrough the wheelsfreely. When normal drivenoperationisdesired, valve should be "closed"byturningit clockwise.
Failureto"close" the valve with enginerunningmeansno power to wheels.
HILLSIDEOPERATION
Do NOT stop or start suddenly on any slope. Be especially cautious when changing direction. Do NOT operate on
slopesgreaterthan 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)
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.
FrontView BackView
A. Main PressureAdjustment -Turn to adjust desired pressure on the pressure gauge.
B. Main Boom Lever -Allows pressure to enter the system. Down is engage, up is disengage.
C. Pressure Gauge - indicates in PSI when spraying.
D. Boom Levers - Three levers that turn on each boom section, right - center - left.
E. Boom PressureAdjustment -Three adjustmentknobsthat adjustthe pressureforeach boom.They
match the boom lever that is above them. To raise pressure close knob. To lower pressure open knob.
SPRAYER VALVE SETTING
1. Engage the main boom lever (B) to allow pressure into the system.
2. Flip all boom levers (D) up to engage.
3. Adjust the main pressure (A) to show desired pressure on pressure gauge (C).
4. Doing one boom section at a time, Push the first boom lever (D) down or shut off. If pressure gauge
drops in psi close the boom pressure knob (E) below boom lever. If pressure rises open boom pressure
knob. Objective is to have equalized pressure when the boom lever is flipped. Do this with all three boom
levers.
5. When pressure is equalized an all three booms the valve has been configured for spraying.

13
Operation
OPERATION (CONTINUED)
IfyourSprayStarisfittedwithahosereel,thereisathirdballvalveonthedischargesystemtosupplymaterialtothe
hosereel.
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.
SPRAYOPERATION(AfterProperSetupandCalibration)
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
safetyand operationprecautions.
3. Open agitator valve.
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. SetEngine speedbetween2000-3200 RPM.
7. (Optional)Engage groundspeedcontrol.
8. Obtain desired spraying speed before activating spray with switches on spray control console.
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.

14
Operation
OPERATION (CONTINUED)
One of the most common causes for faulty-pump performance is corrosion inside the pump. Flush the pump
and entire system with a solution that will chemically neutralize the liquid pumped. Mix according to
manufacturer’s directions.This will dissolve most residue remaining in the pump, leaving the inside of the pump
clean for the next use.
TO PREVENT CORROSION
Aftercleaning thepump asdirected, flushit withapermanent typeautomobile 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. Removecoupling andrinseinside oftankthoroughlywith cleanwater, replacecoupling.
2. Fill tank ten percent full with clean water, start pump and discharge water through spray hose or spray
boom(with nozzlesremoved),until empty.
3. Removedrain coupling againandrinse tankinterior thoroughly.
4. Rinseexterior ofsprayerthoroughly withcleanwater.
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.
MANUALHOSEREEL
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 youto pullout additionalhose orto use thehandle andwind upthe 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.

15
Schematics
WIRING SCHEMATIC
HYDRAULIC SCHEMATIC

16
SprayingProcedures
SPRAYINGINTRODUCTION
Thissection isintended to offerpractical guidelinesforthe distributionofliquid chemicalsover anareaof
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
sprayvehicles orsprayersmounted ontovehicles.
Boom Spraying is the most effective, accurate and efficient method of applying chemicals to large turf areas. It
may be done by means of:
• Adedicated sprayvehicle
• Asprayer mountedupon autility vehicle
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
eachspray swath.Foammarkers anddye markersareadvisable.
TURFMANAGEMENT
Turfmanagementchemicals aremadeforfour general purposes:
1. Fungicides: Preventor curefunguson turfgrass.Theyare madein2 generaltypes:
• 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: Controland eliminateundesirableweedsand grassfromturf areasandnon-turf areas such
as bunkers, trails, fences, etc.
4. Nutrients & Fertilizer: Promotegrowth, beautyand colorin turfgrass.
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”and requiresalower volumeofwater.Instead ofirrigationwater,these materialsarefurtheractivated
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
wayto insuresafe andeffectiveresults. Itprovidesinformation onhow muchchemicaland howmuch water isto
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
asturfjet orfloodjetnozzles. Theyspray ahollow-coneshaped patternofmuch largerdropletswhich fall
quickly to the turf under their own weight. They are best for systemic pesticides or any material requiring a
largevolume ofwaterfor soilapplication. Thelargerdroplets arenotas subjectto drift fromwind andarea
safer, more environmentally friendly choice in many situations.

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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
shortas possiblewhilestill permittingoperatormobility.
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
nozzleoutput periodically.
Modernnozzles usespringand diaphragmcheckvalves toinsurepositive cutoffofchemicals withoutdrip.
Snap-oncaps makereplacingand cleaningnozzles, quick,easyand foolproofwith 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, havesome pointwithinthem thatregulates theflowof liquid.Obviously,the largerthe openingthe
greaterthe rateof flowvolume. Volume isexpressedin GallonsPer Minute(gpm) orLitersPer Minute
(lpm).Do notconfusethe termvolume with applicationrate, whichwillbe coveredlater.
Aspressure increases,the flowvolumein agiven nozzlealsoincreases. Forexample, 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%.
Somenozzles deliverasmall volume(forexample: 0.2gpm (0.75 lpm)).Some nozzles delivera relatively
large volume (for example: 1.5 gpm (5.7 lpm)), or 71/2times as much as the smaller nozzle in this ex-
ample.
Theamount ofmaterial (volume)to beappliedis determinedby theeffect thechemicalhas onthe turf.
2. The nozzle on a sprayer is to form the liquid into droplets. The size of the droplet is determined by two
factorsdesign andsystem pressure (psi/bar).
Particular applications are done best by big droplets such as systemic fungicides, insecticides and some
herbicidesin orderto reducedrift.Other applicationsrequire small dropletslike contactfungicidesand
some herbicides. Again, this is determined by whether the chemical is foliar applied or soil applied. Large
dropletsfor soilappliedmaterial, smalldropletsfor foliarappliedmaterials thatevenlycover theplant
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
formadequate spraynozzlepatterns.

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SprayingProcedures
NOZZLES (CONTINUED)
3. Disperse the material in a specific pattern that will insure even distribution of chemical across the swath
coveredby the boom.
As shown (to the right) the pattern formed by flat
fan(TeeJet) nozzleswouldshow mostliquid
concentratedat thecenter, then tapering off where
itbegins tooverlapwith thenextnozzle-approxi-
mately 1/3. The pattern of liquid dispersed by the
hollow-cone is more even across its width. Each
nozzleoverlaps theadjoiningnozzle by100%.
That is to say the area covered by each nozzle
extends to the center of the two nozzles on either
side.
Inorder toproperly developtheir spray pattern,each nozzlemust betheproper distancefrom thenext
nozzle(spacing) and theproperheight abovethe ground.
NOZZLESCREENS(STRAINERS)
Smallernozzles requirenozzlescreens orstrainers to preventclogging.
• Teejet type nozzles size 8001 and 80015 require 100 mesh screens.
• Teejet type nozzles from size 8002 through 8008 require 50 mesh screens.
• TurboTurfJet Nozzles Size1/4TTJ02-VS andlarger donotrequire strainers.
• TurboFloodjet NozzlesTF-VS2throughTF-VS3 require50mesh screens.
• TurboFloodjet NozzlesTF-VS4and larger donotrequire screens.
SPACING
Turf spray nozzles are normally 20" (51 cm) apart. Some cases 40" (101 cm), depending on the type of spray
boom and type of area to be sprayed.
Very fine, level areas (golf greens and tees, bowling lawns, tennis courts, etc.) may be sprayed with nozzles
spaced every 10" (25 cm).
BOOMHEIGHT
Height is very important in permitting spray nozzles to develop their proper spray pattern. If nozzles are too high,
excessive overlap develops. If nozzles are too low, there is not enough overlapping of nozzle spray patterns.
NOZZLE NOZZLE HEIGHTABOVE
TYPE SPACING THEGROUND
80° Flat Fan 20" (51 cm) 18" (45 cm)
65° Flat Fan 20" (51 cm) 12" (30 cm)
TurboTurfJet 20" (51 cm) 15" (38 cm)
TurboTurfJet 40" (101 cm) 19" (48 cm)
TurboFloodjet 20" (51 cm) 16" (41 cm)
TurboFloodjet 40" (100cm) 18" (45 cm)
Impropernozzle heightorspacingprevents properapplicationof chemical.Someareas are undertreatedand
chemicalsare ineffective.Someareas are overtreatedwithwasted chemicalandpossible turfdamage.
Operating your sprayer at a desired speed and pressure on a hard, dry surface is a good method of checking
sprayingconsistency. Observenozzlesin operation,observeif the areadries evenly. Ifthereare alternatingwet
and dry streaks, raise or lower the spray boom. If the wet streaks are directly under the nozzle, the boom is too
low. If the wet streaks are between the nozzles, the boom is too high.