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.

2
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

3
Introduction
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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
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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.

5
Introduction
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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.

6
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

7
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.

8
Introduction
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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.