Smithco Spray Star 1010 User manual

Spray Star 1010
with Manual 3-Way Valve
August 2013
SN: 100549
Product Support: Hwy SS & Poplar Ave; Cameron WI 54822
1-800-891-9435 [e-mail]
Operator’s

Introduction Operation Schematics SprayingProcedures Nozzle Charts Reference
CONTENTS
Introduction...................................................................................1-9
Introduction..................................................................................1
Symbols...................................................................................2-3
SafePractices.............................................................................4
SafeSprayingPractices ..............................................................5
Specifications ..............................................................................6
OptionalEquipment .....................................................................6
Setup ..........................................................................................7
Controls&Instruments .............................................................8-9
Operation .................................................................................. 10-14
Spraying Procedure ................................................................. 15-21
SprayingIntroduction .................................................................15
TurfManagement.......................................................................15
Hose&HandgunSpraying.........................................................16
Nozzles ................................................................................ 16-17
CalibrationIntroduction ..............................................................18
TheNozzleChartMethod ..................................................... 19-20
The“128”Methood................................................................ 20-21
Nozzle Charts............................................................................ 22-27
NozzlePerformanceChart#1 ....................................................22
NozzlePerformanceChart#2 ....................................................23
NozzlePerformanceChart#3 ....................................................24
NozzlePerformanceChart#4 ....................................................25
NozzlePerformanceChart#5 ....................................................26
NozzlePerformanceChart#6 ....................................................27
Reference.................................................................................. 28-29
AbbreviationsandConversions ..................................................28
DeclarationofConformity...............................................................

1
Introduction
PARTSMANUALSAVAILABLEONLINEATsmithco.com
INTRODUCTION
Thank you for purchasing a SmithcoSmithco
SmithcoSmithco
Smithco product.
Readthis manual and all othermanuals pertainingtotheSprayStar1000carefullyas they have safety,operat-
ing, assembly and maintenance instructions. Failure to do so could result in personal injury or equipment dam-
age.
Keepmanualsinasafeplaceafteroperatorand maintenance personnel have read them. Right and left sides are
fromtheoperator’sseat,facingforward.
All SmithcoSmithco
SmithcoSmithco
Smithco machines have a Serial Number and Model Number. Both numbers 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.
Refertoenginemanualforplacementofengineserialnumber.
Informationneededwhenordering replacementparts:
1. ModelNumberofmachine.
2. SerialNumberofmachine.
3. NameandPartNumberofpart.
4. Quantity of parts.
For easy access record your Serial and Model numbers here.

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Introduction
PARTSMANUALSAVAILABLEONLINEATsmithco.com
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

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Introduction
PARTSMANUALSAVAILABLEONLINEATsmithco.com
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

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Introduction
PARTSMANUALSAVAILABLEONLINEATsmithco.com
SAFEPRACTICES
1. It is your responsibility to read this manual and all publications associated with this machine.
2. Neverallowanyonetooperateorservicethemachineoritsoptionalequipmentwithoutpropertrainingand
instructions.Neverallowminorstooperateanyequipment.
3. Learntheproperuseof the machine, the location and purpose ofallthe controls and gauges before 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.
Bewareofoverheadobstructionsandundergroundobstacles. Stayalertforhiddenhazards.
6. Neveroperateequipmentthatisnot in perfect working order or without decals, guards, shields, orother
protectivedevicesinplace.
7. Never disconnect or bypass any switch.
8. Carbonmonoxideintheexhaustfumescanbefatalwheninhaled,neveroperateamachinewithoutproper
ventilation.
9. Fuel is highly flammable, handle with care.
10. Keepengineclean.Allow theengine to cool before storing and alwaysremovethe ignition key.
11. Disengagealldrivesandsetparkbrakebeforestartingtheengine.
12. Neveruse your hands to search foroil leaks. Hydraulic fluid under pressurecan penetrate the skin and
cause serious injury.
13. Thismachinedemandsyour attention.Topreventlossof control 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. Beforeleaving operator’sposition:
A. Disengagealldrives.
B. Set park brake.
C. Shut engine offandremovetheignitionkey.
D. If engine has to run to perform any maintenance keep hands, feet, clothing and all other parts of body
awayfrommovingparts.
15. Keephands,feet and clothing away from moving parts. Waitforall movement to stop before you clean,
adjustorservicethe machine.
16. Keepthearea of operation clear of all bystanders.
17. Nevercarry passengers.
18. Stopenginebeforemakingrepairs/adjustmentsorchecking/addingoiltothecrankcase.
19. Use parts and materials supplied by Smithco 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 guarantee as to the suitability for any task is
expressed or implied.

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Introduction
PARTSMANUALSAVAILABLEONLINEATsmithco.com
SAFESPRAYINGPRACTICES
Personsengagedin the handling, preparation or application of chemicals mustfollowacceptedpractices to
insurethesafetyof themselves and others,
1. WEAR protectiveclothingincluding:gloves,hat,respirator,eyeprotectionandskincoveringsuitablefor
protectionfromchemicalsbeingused.
2. BATHE thoroughly after any exposure to chemicals, giving particularattentiontoeyes,nose,earsand
mouth.
3. CLEAN equipmentandmaterialsin accordance with employer, municipalandstate regulations. Use only
approvedareasanddrains.
4. DISPOSE ofchemicalsandrinse solutions by approved and legal means.
5. PROVIDE methodsandmaterialsfor operators to wash eyes and hands immediately during thespraying
process.
6. PROVIDE methodsandmaterialsfor control, safe dilution and neutralization of chemical spills during
preparation,spraying,transportingandcleanup.
7. Always check and follow the directions and safety warnings of the chemicals to be used.
8. Securethedischarge lines before starting the pump.An unsecured dischargeline 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. Useonlypipe, hose and fittings rated for maximum pressure or pressureatwhichpressure relief valve 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. Donotuse these pumps for pumping water or other liquidsforhumanor 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. Besureallexposedmoving parts are guarded and that all coupling devices are securely attached 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. Protectpumpfromfreezingconditionsby draining liquid and pumping rust inhibiting antifreeze solution
through the system, coating the pump interior.
19. TRANSPORT - Machine must be stopped to raise or lower booms. Because of cam sytem, if booms are
raisedintransittheycan fall forward or backward when coming to a stop or traveling onuneventerrain.

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Introduction
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SPECIFICATIONS
WEIGHTSANDDIMENSIONS
Length 112"(285cm)
Width 70"(178cm)
Width With Boom Open 180"(457cm)
Height 48"(122cm)
Wheel Base 53" (135 cm)
Weight Empty 1200lbs(544kg)
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 23.5 hp (17.78 kW)
Fuel Unleaded87OctaneGasolineMinimum
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 13.00 x 12 NHS Multi-Trac; 18 psi (1.3 bar)
SPEED
Forward Speed 0-8m.p.h.(0-12.8kph)
Reverse Speed 0-3m.p.h.(0-4.8kph)
BATTERY Automotivetype24F-12volt
BCIGroup Size 24
ColdCrankingAmps 575minimum
GroundTerminalPolarity Negative(-)
MaximumLength 10.25"(26cm)
Maximum Width 6.88" (17 cm)
MaximumHeight 10" (25 cm)
FLUIDCAPACITY
CrankcaseOil SeeEngineManual
Fuel 6 gallon(22.7liters)
HydraulicFluid 5gallon(19liters)
Grade of Hydraulic Fluid SAE 10W-40API Service SJ or higher Motor Oil
OPTIONALEQUIPMENT
10-365 WaterMeterKIt(gallons) 10-370 Water Meter Kit (liters)
10-377 Hose Reel Mounting Kit 10-378 FoamMarker
10-417 ChemicalCleanloadSafeFill System 10-419 Fresh Water Tank
10-422 HoseReel Mount Kit for Super Boom 15-622 WeatherCanopy
15-835 TankRisingDevice 30-141 26Gal Wash system with Electric Pump
16-129 ManualRewindHoseReel,200-foot/61-metercapacity
16-906 ElectricRewindHoseReel,200-foot/61-metercapacity
17-601 15'HDSuperBoom
10-160 15' Spray Boom

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Introduction
PARTSMANUALSAVAILABLEONLINEATsmithco.com
SETUP
TheSprayStar1000arrivesfromSmithco setupandreadyforservice. Depending on freight conditions the
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-
ingsinthe Spray Star 1000 Parts/Service Manual.
1. Checkthetirepressure. The front are 20 psi(1.4 bar) and
rear tires are 18 psi (1.3 bar).
2. Battery is located under the seat. This is a negative ground-
ing 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.
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
shouldbe about 2-21/2" (5-6.4 cm)from the 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. Machineshouldbegreasedbeforestarting,refertoSprayStar1000Parts/ServiceManualforlocation.
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
theturf as described inTurf Spraying Guide.Thespray boom must operate properlyand the outer 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. Readoperatinginstructionsbeforestarting.
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.

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Introduction
PARTSMANUALSAVAILABLEONLINEATsmithco.com
CONTROLS$INSTRUCMENTS
A. HourMeter-Thehourmeterindicateshoursofmachineoperation.Itoperatesonly when the ignition
switch is on.
B. Speedometer - The Speedometer indicates ground speed of the vehicle in miles per hour and kilometers
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
engineoffimmediatelyandfindthecause.
D. Ignition Switch - The ignition switch has three positions: Off - Run - Start.
E. TiltSteering-Holdleverdownandadjuststeeringwheeltodesiredpositionandreleaselever.
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 rocker 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. HandThrottle - The hand throttle is used to regulate enginespeed.
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.

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Introduction
PARTSMANUALSAVAILABLEONLINEATsmithco.com
CONTROLS&INSTRUMENTS
N. 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
endof the lever, counter clockwise increasesspeed and clockwise
decreasesspeed.Disengagetheleverandyouwillhavefullaccelera-
torpedalrange.
O. CupHolder-Holdsstandardcup.
P. Master Boom Switch - is used to override the master switch on the
computer console of the spray systems.
Q. ReversePedal-Thispedalcontrolsgroundspeed in the reverse
direction.
R. Accelerator Pedal - This pedal controls ground speed. Press pedal to
increasespeed.Varyingtheamountofmovementofthepedalwill
varythegroundspeed.
MASTERBOOMSWITCH
The master boom switch (P), located on the left floorboard is used to override the master switch on the computer
console of the spray systems. By pushing down it will turn on/off the booms. For the Raven 440 System the
Master Switch on the computer must be off for the master boom control switch to work.

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Introduction
PARTSMANUALSAVAILABLEONLINEATsmithco.com
OPERATION
Beforeoperating the Spray Star 1000, become familiar with all controls and functions.Also complete all mainte-
nancerequirementsandreadallsafetywarnings.KnowingtheSprayStar1000thoroughly,howitoperates,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 of amovingvehicleor any machine with moving parts.
1. Keep all shields and guards in place.
2. Keeptheparkingbrakeengagedanytimetheoperatorisawayfromthevehicleorwheneverserviceis
performed.
3. Alwayswearthenecessaryprotectiveclothingandequipment.
4. Turnengineoffwhen refueling orperformingmaintenancenotspecificallyrequiringenginepower.
DAILYCHECKLIST
1. Checktheengineoillevel.Addasneeded.DO NOT OVERFILL.Refertoengineowner'smanualforoil
gradeandprocedure.
2. Tirepressureshouldbe20 psi (1.4 bar) maximum.
3. Inspect the electrical system and battery cables for loose connections or frayed wiring. Replace any faulty
equipmentortightenif loose.
4. Check hardware for loose or missing nuts, bolts, screws, etc., and tighten or replace as needed.
5. Inspect hydraulic lines for damage or leaks. Never use hands to inspect for leaks.
6. Check the hydraulic fluid level. The hydraulic fluid tank is located on the left side of the machine. The fluid
level should be 2"-2½" (5 - 6.4 cm) from the top of the tank when cold. Use only SAE 10W-40API Service
SJ or higher Motor Oil.
7. Inspectthesteering, throttle and shift linkagesfor good hookups and
cleartravel.
8. Checkcontrolsforsmooth,properworkingoperation.Lubricateas
needed.
9. Check park brake adjustments. Adjust as required.
10. Check anti-vibrationmountsonengineframe.
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 re-
turn to the run position (B). Use the choke and hand throttle as neces-
sary.
3. Allowenginetoidleandwarmupbeforeselectingdirectionoftravel.
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. Movethethrottleleverto “slow” and turn ignition key tothe“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.

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Introduction
PARTSMANUALSAVAILABLEONLINEATsmithco.com
OPERATION
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 com-
pleted should chemical be added to the sprayer.
TOWING UNIT
When it is necessary to move the Spray Star 1000 without the engine running, the bypass valve built into hydrostatic
pump must be "open" by turning it counterclockwise. The valve is located on the bottom of the pump. An "open" valve
allows fluid to pass through the wheels freely. When normal driven operation is desired, valve should be "closed" by
turning it clockwise. Failure to "close" the valve with engine running means no power to wheels.
HILLSIDE OPERATION
Do NOT stop or start suddenly on any slope. Be especially cautious when changing direction. Do NOT operate on
slopes greater 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 disconnect-
ing jumper cables.

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Operation
PARTSMANUALSAVAILABLEONLINEATsmithco.com
OPERATION
SPRAYTANKAGITATION
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 Back View
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 adjustment knobs that adjust the pressure for each boom.They
match the boom lever that is above them. To raise pressure close knob.To lower pressure open knob.
SPRAYERVALVESETTING
1. Engage the main boom lever (B) to allow pressure into the system.
2. Flipallboomlevers(D) up to engage.
3. Adjustthemainpressure(A) to show desired pressure on pressure gauge(C).
4. Doingoneboom section at a time, Push the first boom lever (D) down orshut off. If pressure gauge drops
inpsiclosetheboompressureknob (E) below boom lever. If pressure rises openboompressure knob.
Objectiveistohaveequalized pressure when the boom lever is flipped. Do this with all three boom levers.
5. Whenpressureisequalizedanallthreeboomsthevalvehasbeenconfiguredforspraying.

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Operation
PARTSMANUALSAVAILABLEONLINEATsmithco.com
OPERATION
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.
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
safetyandoperationprecautions.
3. Open agitatorvalve.
4. Add chemicals (taking all precautions described in this manual and by the chemical manufacturer).
a. Liquids may be poured directly into tank.
b. Wettable powder chemicals must be pre-mixed with water in a container to form a slurry. The mixture
is then added to the tank through the fillwell strainer.
c. Chemical in soluble packs are place into the fillwell strainer basket and dissolved by adding water
through the basket.
The balance of the water required for the spray operation is added to the tank through the fillwell strainer,
using the air gap filler. This will wash any undissolved chemical into the tank.
5. Transport to sprayer site with and agitator operating.
6. SetEnginespeedbetween2000-3200RPM.
7. (Optional)Engagegroundspeedcontrol.
8. Obtain desired spraying speed before activating spray with switches on spray control console.
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.

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Operation
PARTSMANUALSAVAILABLEONLINEATsmithco.com
SPRAYOPERATION
Oneof the most commoncauses for faulty-pump performanceis corrosion inside thepump. Flush the pumpand
entire system with a solution that will chemically neutralize the liquid pumped. Mix according to manufacturer’s
directions.This will dissolve mostresidue remaining in thepump, leaving the insideof the pump cleanfor the
next use.
TOPREVENTCORROSION
Aftercleaning the pump asdirected, flush it with a permanent type automobile antifreeze(Prestone, Zerex, etc.)
containing a rust inhibitor. Use a 50% solution that is, half antifreeze and half water. Then coat the interior of the
pump with a substance which will prevent corrosion such as Fluid Film or WD40. If unit will not be used for an
extended period of time, disconnect hoses into and out of the pump, seal openings to the pump with caps or
tape. Dispose of fluids according to all federal, state and local regulations.
All chemicals and chemical residue must be removed after each use. Dispose of fluids and
residue according to all federal, state and local regulations.
SPRAYERCLEANING
Empty tank and clean unit thoroughly after each use following these instructions:
1. Removecouplingandrinseinsideoftankthoroughlywithcleanwater,replacecoupling.
2. Fill tank ten percent full with clean water, start pump and discharge water through spray hose or spray
boom(withnozzlesremoved),untilempty.
3. Removedraincouplingagainandrinsetank interiorthoroughly.
4. Rinseexteriorofsprayerthoroughlywithcleanwater.
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 will
allowyou to pull out additional hose ortouse the handle and wind up thehose.To prevent movement 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
The control box is located to the right of the control panel. Use lever on compressor to designate which boom is
to be used to dispense foam. Use dial located on the foamer to adjust pressure for the amount of foam that will
bedispensed. Switch on compressor alsoturns foamer on or off.

15
SprayingProcedures
PARTSMANUALSAVAILABLEONLINEATsmithco.com
SPRAYINGINTRODUCTION
Thissectionis intended to offer practical guidelines for the distributionofliquid chemicals over an area of
turfgrass such as golf courses, park land, school grounds and lawns.Smithco makes no representation as to
the suitability of any technique or product for any particular situation. This section is suitable for self-propelled
sprayvehiclesorsprayersmountedontovehicles.
Boom Spraying is the most effective, accurate and efficient method of applying chemicals to large turf areas. It
may be done by means of:
• Adedicatedsprayvehicle
• Asprayermounteduponautility vehicle
Sprayersaretypicallyequippedwithwide spray booms. Generally these booms are between15feet (4.5 m) and
20 feet (6 m) in width. They are divided into three sections, with hinges that permit the long outer sections to
automatically move out of the way and reset if an obstacle such as a tree or fence is in you path.
To minimize the chance for missed areas or double application use a device to mark the outside boundaries of
eachsprayswath. Foam markers and dye markers are advisable.
TURFMANAGEMENT
Turfmanagementchemicalsaremadefor four general purposes:
1. Fungicides: Preventorcurefungusonturfgrass.They are made in 2 general types:
• Systemic - Chemicals enter the plant system and protect or cure it of, fungus.
• Contact - Kills fungus with which it comes into contact.
2. Insecticides: Eliminate damaging insects and worms (such as grubs, beetles, ants, etc.)
3. Herbicides: Controlandeliminateundesirableweedsandgrassfromturfareasandnon-turfareassuch
as bunkers, trails, fences, etc.
4. Nutrients & Fertilizer: Promotegrowth, beauty and color inturfgrass.
Some materials have to be applied so that they get into the soil below the plant leaves, This is called "soil appli-
cation". In order to do this, they are best applied with a large volume of water.They are often then watered-in
using the irrigation system. This type of chemical material includes systemic chemicals and chemicals de-
signed to destroy pests which live in the thatch and the soil.
Other materials must be applied to reach a problem that is present on the plant leaves. This is called “Foliar
Application”andrequiresalowervolumeofwater.Instead of irrigation water, these materials are further activated
by dry air and sunshine. They include contact fungicide and many herbicides.
The user of sprayers and chemicals must follow the directions provided with the spray material. It is the only
waytoinsure safe and effective results. It providesinformationon how much chemical and how muchwateris to
be applied to the area to be sprayed.
Though there are many types and sizes of nozzles, two specific types have proven most successful in turfgrass
management.
• The first type is target-directed. It sprays material in a direct line downwards to the target turfgrass.
Theseareflatfannozzles, commonly referred to asTeeJet nozzles.Theyareavailableinawidevariety of
sizesforany required discharge volume rate. They are thebestfor many contact or foliar applied pesti-
cides. They are spaced either 10" (25 cm) or 20" (51 cm) apart and overlap one another by about 1/3.
• Thesecondtypeuseful in turf management are broadcast type nozzles. They are commonly referred to
asturfjetorfloodjet nozzles. They spray a hollow-cone shaped pattern ofmuchlargerdroplets which fall
quickly to the turf under their own weight. They are best for systemic pesticides or any material requiring a
largevolumeof water for soil application. The larger droplets arenotassubject to drift from wind and are a
safer,moreenvironmentally friendly choice in many situations.

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HOSE&HANDGUNSPRAYING
Ahandgun(hand-nozzle or hand-lance) is used to control anddirectthe 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
short as possible while still permitting operator mobility.
Liquid looses pressure due to friction as it travels through the hose, 1-3 psi (0.07-0.21 bar) for each foot (30 cm)
of hose. For most operations 1/2" (1.25 cm) inside diameter hose is adequate. Trees over 40 ft (12 m) high re-
quire 3/4"(2cm) inside diameter hose and a sprayer pumpcapableof delivering a volume of at least 20gpm(75
lpm) and a pressure of at least 400 psi (28 bar).
NOZZLES
Always be alert to the possibility of a plugged or damaged nozzles. Serious misapplications may result. Check
nozzleoutputperiodically.
Modernnozzlesusespringanddiaphragm check valves to insure positive cutoff of chemicals without drip.
Snap-oncapsmake replacing and cleaning nozzles, quick, easy and fool proofwithproperreinstallation.
An operator can see at a glance if all nozzles are the same size by the color code.
3FUNCTIONSFORASPRAYBOOMNOZZLE
1. Regulating the flow is done through size of the orifice (opening) within the nozzle.All nozzles, regardless
oftype, have some point within them thatregulates the flow of liquid. Obviously,thelarger the opening the
greaterthe rate of flow volume.Volumeis expressed in Gallons PerMinute (gpm) or Liters PerMinute
(lpm).Donotconfuse the term volume with application rate, which will be covered later.
Aspressure increases, the flow volume in agivennozzle also increases. For example, anaveragesize
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%.
Somenozzlesdeliverasmallvolume (for example: 0.2 gpm (0.75 lpm)). Some nozzles deliver a 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 of material (volume) tobe applied is determined bythe effect the chemical hason the turf.
2. The nozzle on a sprayer is to form the liquid into droplets. The size of the droplet is determined by two
factorsdesignand system pressure (psi/bar).
Particular applications are done best by big droplets such as systemic fungicides, insecticides and some
herbicidesin order to reduce drift. Other applicationsrequiresmall droplets like contact fungicides and
some herbicides.Again, this is determined by whether the chemical is foliar applied or soil applied. Large
dropletsforsoilappliedmaterial,small droplets for foliar applied materials that evenly cover the plant
better.
Pressure also affects droplet size. More pressure at the same nozzle produces smaller droplets, more
subject to drift. The general rule on pressure is to use the lowest pressure possible with just enough to
formadequatespraynozzlepatterns.

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NOZZLES (CONTINUED)
3. Disperse the material in a specific pattern that will insure even distribution of chemical across the swath
coveredbytheboom.
As shown (to the right) the pattern formed by flat
fan(TeeJet)nozzleswouldshowmostliquid
concentratedatthecenter,thentapering offwhere
itbeginstooverlapwith the next nozzle-approxi-
mately 1/3. The pattern of liquid dispersed by the
hollow-cone is more even across its width. Each
nozzleoverlapstheadjoiningnozzle by 100%.
That is to say the area covered by each nozzle
extends to the center of the two nozzles on either
side.
Inorder to properly develop their spraypattern, each nozzle must be theproper distance from the next
nozzle(spacing)andtheproperheightabovetheground.
NOZZLESCREENS(STRAINERS)
Smallernozzlesrequirenozzle screens or strainers to prevent clogging.
• Teejet typenozzles size 11001and110015 require 100 meshscreens.
• Teejet type nozzles from size 11002 through 11008 require 50 mesh screens.
• TurboTurfJetNozzlesSize1/4TTJ02-VSandlargerdonot require strainers.
• TurboFloodjetNozzlesTF-VS2throughTF-VS3require50meshscreens.
• TurboFloodjetNozzlesTF-VS4andlargerdonotrequirescreens.
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
spacedevery10"(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)
Impropernozzleheightorspacingpreventsproperapplicationofchemical.Someareasareundertreatedand
chemicalsareineffective.Someareasareovertreatedwithwastedchemicalandpossibleturfdamage.
Operating your sprayer at a desired speed and pressure on a hard, dry surface is a good method of checking
sprayingconsistency.Observe nozzles in operation,observeiftheareadriesevenly. If there are alternating wet
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.

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CALIBRATIONINTRODUCTION
Calibratingsimply means to adjust a set of variables onthe sprayer in order to deliver the desired amountof
chemical to a known area of turf.
Thejobof calibrating the sprayer consists of balancing these variables sothatyoursprayer delivers the desired
application rate. That is, an amount of chemical on a given area. It is expressed as:
Gallons Per Acre (gpa) (1 US gpa = 0.83 UK gpa)
or Gallons Per 1,000 Square Feet (gpt)
or Liters Per Hectare (lph) (1 US gpa = 9.35 lph)
Anumberofacceptablemethodsforcalibratingaturfsprayerarewidelyavailable.Thecalibrationmethodcho-
senmust take these variables into account.They must include known ground speed(by measurement or from
anaccuratespeedometer) and nozzle output (gpm or lpm) from a nozzlechartorfrom actual measurement. The
variablesare:
PRESSURE
Just as pressure increases the volume discharge rate, it also increases the application rate. Pressure must
increase by 4 times in order to double the application rate. Small pressure changes of 10 psi (1.4 bar) or less do
notgreatlyaffectperformance.
Pressureisestablishedand maintained by a pressure control valve or by a flow controlvalvelocatedonthe
sprayer.
NOZZLECAPACITY(VOLUME)
Wehavecoveredthedifferent types of spray patterns of various nozzles and made our selection of type accord-
ingly. We now have to choose a size which will provide the correct application rate.
Sizes are available for all requirements. Consult the nozzle chart in this manual for your nozzle type in order to
select the correct size.
TRAVELSPEED
Increasedtravelspeeddecreasestheapplicationrate(gpa,gptorlph).Travelspeedmustbesafeandappropri-
ate for the area to be sprayed.
Unlikepressurechangeswhichhaveonlyaminoreffectonapplicationrate,groundspeedchangeshaveamore
majorand direct effect. For example: 50%decrease in ground speed means a100% increase in application
rate.Ifthe vehicle does not have an accurate speedometer,correctspeedmustbedeterminedbytiming the
sprayertraveloverameasureddistance.(Refertothepageinthis manual titled, “Abbreviations and Conver-
sions”.
To calibrate a sprayer, the user must:
1. Understand the Variables
2. Set thosevariablesusingoneoftheprovenmethodsavailable.
3. Make a trial run and measure the output (use water, not chemical).
4. Determine the output.
5. Make adjustments to the 3 variables until the output is at the desired level.
Thiscoverstheprinciplesof what must be known to prepare a sprayer for operation.
There are other acceptable and proven methods of calibrating a turf sprayer for application.
Other techniques may be more suitable depending on operational needs and technical
competence of the operator.