Smithco SPRAY STAR 1002 with Raven 203 System User manual

SPRAY STAR 1002
with Raven 203 System
SN: 100413
December 2008

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
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
Spraying Procedure ................................................ 16-22
SprayingIntroduction................................................. 16
Turf Management ...................................................... 16
Hose & Handgun Spraying ........................................ 17
Nozzles................................................................ 17-18
CalibrationIntroduction ............................................. 19
The Nozzle Chart Method of Calibration .............. 20-21
The “128” Method of Boom Sprayer Calibration ... 21-22
Nozzle Charts .......................................................... 23-28
Nozzle Performance Chart #1 .................................. 23
Nozzle Performance Chart #2 .................................. 24
Nozzle Performance Chart #3 .................................. 25
Nozzle Performance Chart #4 .................................. 26
Nozzle Performance Chart #5 .................................. 27
Nozzle Performance Chart #6 .................................. 28
Reference ................................................................ 29-30
Abbreviations and Conversions ................................ 29
EC Declaration of Conformity ................................... 30

1
Introduction
Informationneededwhen orderingreplacementparts:
1. ModelNumberofmachine.
2. SerialNumber ofmachine.
3. Nameand PartNumberof part.
4. Quantity of parts.
INTRODUCTION
Thankyou for purchasinga product.
Readthismanual and all othermanualspertaining totheSpray Star1000 carefully asthey have safety,operat-
ing, assembly and maintenance instructions. Failure to do so could result in personal injury or equipment dam-
age.
Keepmanuals in asafe place afteroperator and maintenancepersonnel have readthem. Rightandleft sidesare
fromthe operator’sseat, facingforward.
All machineshave aSerialNumber andModel Number. Bothnumbers areneeded 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 enginemanual forplacement ofengineserial number.
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 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
SAFEPRACTICES
1. It is your responsibility to read this manual and all publications associated with this machine.
2. Neverallow anyonetooperate orservice themachineor itsoptional equipment withoutproper trainingand
instructions.Never allow minorsto operateany equipment.
3. Learnthe proper useof the machine, thelocation and purposeof all the controlsand gauges beforeyou
operatethe equipment. Workingwithunfamiliar equipment canlead 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 overheadobstructions andundergroundobstacles.Stayalertfor hiddenhazards.
6. Neveroperate equipment thatis not inperfect working orderorwithout decals, guards,shields, or other
protectivedevices inplace.
7. Never disconnect or bypass any switch.
8. Carbonmonoxide intheexhaust fumescan befatalwhen inhaled,never operate amachine withoutproper
ventilation.
9. Fuel is highly flammable, handle with care.
10. Keep engine clean.Allowthe engine tocool before storing andalways remove the ignitionkey.
11. Disengageall drives andset park brakebefore startingtheengine.
12. Never use yourhandsto search for oilleaks. Hydraulic fluid underpressure can penetrate the skinand
cause serious injury.
13. This machine demandsyour attention.To preventloss of controlor tipping ofthevehicle:
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’sposition:
A. Disengagealldrives.
B. Set park brake.
C. Shut engineoffand removetheignition key.
D. If engine has to run to perform any maintenance keep hands, feet, clothing and all other parts of body
awayfrom movingparts.
15. Keep hands, feetand clothing awayfrommoving parts. Waitfor all movement tostop before youclean,
adjustor service themachine.
16. Keep the areaof operation clearof all bystanders.
17. Nevercarry passengers.
18. Stop engine beforemakingrepairs/adjustmentsor checking/adding oilto the crankcase.
19. Use parts and materials supplied by only Smithco. 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 in thehandling,preparation or applicationof chemicals mustfollowaccepted practices to
insurethe safety ofthemselves and others,
1. WEAR protectiveclothing including: gloves,hat, respirator, eye protectionand skincoveringsuitablefor
protectionfrom chemicals beingused.
2. BATHEthoroughlyafterany exposureto chemicals, givingparticular attentiontoeyes, nose, earsand
mouth.
3. CLEAN equipmentand materials inaccordance with employer, municipaland stateregulations.Use only
approvedareasand drains.
4. DISPOSE ofchemicals and rinsesolutions by approvedandlegal means.
5. PROVIDE methodsand materials foroperatorsto wash eyesand hands immediatelyduring the spraying
process.
6. PROVIDE methodsand materials forcontrol,safe dilution andneutralization of chemicalspills during
preparation,spraying, transportingand cleanup.
7. Always check and follow the directions and safety warnings of the chemicals to be used.
8. Securethe discharge lines beforestartingthe pump.Anunsecured discharge line may 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 and fittingsrated for maximum pressureor pressure atwhich pressure reliefvalve is
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 usethese pumps forpumping water or otherliquids for humanor animal 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 fromfreezing conditions bydraining liquidandpumping rustinhibitingantifreeze solution
through the system, coating the pump interior.

6
Introduction
SPECIFICATIONS
WEIGHTSANDDIMENSIONS
Length 112" (285cm)
Width 70"(178 cm)
Width With Boom Open 180"(457 cm)
Height 48"(122 cm)
Wheel Base 53" (135 cm)
Weight Empty 1200lbs (544 kg)
Weight Full 2200 lbs(998 kg)
SOUNDLEVEL(DB)
At earlevel 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 OctaneGasoline Minimum
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 0-3m.p.h. (0-4.8kph)
BATTERY Automotivetype 24F -12 volt
BCIGroup Size 24
ColdCrankingAmps 575minimum
GroundTerminalPolarity Negative(-)
MaximumLength 10.25" (26 cm)
Maximum Width 6.88" (17 cm)
MaximumHeight 10" (25 cm)
FLUIDCAPACITY
CrankcaseOil See EngineManual
Fuel 7 gallon(26.5 liters)
HydraulicFluid 5 gallon(19liters)
Grade of Hydraulic Fluid SAE 10W-40API Service SJ or higher Motor Oil
OPTIONALEQUIPMENT
10-417 ChemicalCleanload Safe FillSystem 1002 203 Spray System
10-419 Fresh Water Tank 1008 440 Spray System
10-103 Electric Actuator Lift Kit 1010 3-Way Manual System
10-160 15' Stainless Steel Boom - manual 10-378 FoamMarker
10-301 15'TerrainFollowing Boom 15-622 WeatherCanopy
10-365 WaterMeter KIt (gallons) 10-370 Water Meter Kit (liters)
10-377 Hose Reel Mounting Kit 33-541 Triple Nozzle Kit for 15ft/5m 9 nozzle Boom
16-129 ManualRewind HoseReel, 200-foot/61-metercapacity
16-906 ElectricRewind HoseReel, 200-foot/61-meter capacity

7
Introduction
SETUP
TheSprayStar1000 arrivesfrom Smithco setup andready forservice.Depending onfreight conditionsthe
battery 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 end user, assemble and attach the components in accordance with the parts draw-
ingsin the SprayStar1000 Parts/Service Manual.
1. Check the tire pressure. The front and rear tires are 20 psi
(1.4bar).
2. Battery is located under the seat. This is a negative
groundingsystem.
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. Con-
nect red positive (+) cable (A) to battery first.
When disconnecting remove black negative (-)
cable (B) first.
3. Check hydraulic fluid level in tank located on the left side of
the seat. Remove cap and add SAE 10W-40API Service SJ or higher motor oil if necessary. Fluid level
shouldbeabout 2-21/2" (5-6.4 cm)fromthe top of thetank when cold. DO NOTOVERFILL.
4. Fill fuel tank, located on the right side, with Unleaded 87 Octane gasoline (minimum).
Fuel 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.
5. Machineshould be greasedbefore starting,refer to SprayStar 1000 Parts/ServiceManual for location.
6. 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
theturfas described in Turf Spraying Guide.The spray boommust operate properly and theouter sec-
tions must break away safely if an object is struck by them, they must then return to normal operation
position.
7. Be sure to double check boom heights, nozzle spacing and displacement before spraying.
8. Machine is shipped with windshield washer fluid in Spray System 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.
9. Readoperating instructionsbefore 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.

8
Introduction
CONTROLS$INSTRUCMENTS
A. HourMeter -The hour meterindicates hours ofmachine operation. Itoperates only whenthe ignition
switch is on.
B. Speedometer -The Speedometer indicates groundspeed of thevehicle inmilesper hourandkilometers
perhour.
C. 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 immediately andfind the cause.
D. Ignition Switch - The ignition switch has three positions: Off - Run - Start.
E. Tilt Steering -Hold leverdown and adjuststeering wheel todesired positionand release lever.
F. Buzzer - The buzzer sounds if the pump is running dry.
G. Lights - This rocker switch turns lights on by pushing on the top and off by pushing on the bottom.
H. Spray Pump - This toggle switch turns the spray pump on by pushing on the top and off by pushing on the
bottom.
I. Left Boom Switch - This rocker switch lifts and lowers the left
boom.
J. Right Boom Switch - This rocker switch lifts and lowers the right
boom.
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.Awarm engine may not require "choking" to start.
L. Hand Throttle - Thehand throttle isused to regulateengine
speed.
M. 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.