Smithco SPRAY STAR 1610P User manual

OPERATOR’S
MANUAL
SPRAY STAR 1600P
Model 1610P
November, 1999
Revised 2-8-02
SMITHCO PRODUCT SUPPORT
1-800-891-9435
Hwy SS and Poplar Avenue, Cameron WI 54822
E-mail: productsupport@smithco.

Introduction Operation Maintenance SprayingProcedure Nozzle Charts Reference
CONTENTS
Introduction.............................................................................................. 1-10
Introduction .................................................................................................1
Symbols.................................................................................................. 2-3
GeneralSafePractices...............................................................................4
Safe Spraying Practices .............................................................................5
Specifications .............................................................................................6
OptionalSpray Equipment...........................................................................6
Set Up .................................................................................................... 7-8
Controls&Instruments .......................................................................... 9-10
Operation.................................................................................................11-17
Schematics............................................................................................. 18-19
HydraulicSchematic .................................................................................18
WiringSchematic......................................................................................19
Spraying Procedure .............................................................................. 20-26
SprayingIntroduction.................................................................................20
TurfManagement ......................................................................................20
Hose& Handgun Spraying ........................................................................21
Nozzles ............................................................................................... 21-22
CalibrationIntroduction .............................................................................23
TheNozzle ChartMethodofCalibration .............................................. 24-25
The“128”MethodofBoomSprayerCalibration................................... 25-26
Nozzle Charts ........................................................................................ 28-33
NozzlePerformance Chart#1 ...................................................................28
NozzlePerformance Chart#2 ...................................................................29
NozzlePerformance Chart#3 ...................................................................30
NozzlePerformance Chart#4 ...................................................................31
NozzlePerformance Chart#5 ...................................................................32
NozzlePerformance Chart#6 ...................................................................33
Reference ............................................................................................... 34-35
AbbreviationsandConversions ................................................................34
DeclarationofConformity..........................................................................35
LimitedWarranty.............................................................. InsideBackCover

1
Introduction
Information needed when ordering replacement parts:
1. Model Number of machine.
2. Serial Number of machine.
3. Name and Part Number of part.
4. Quantity of parts.
INTRODUCTION
Thank you for purchasing a product.
Read this manual and all other manuals pertaining to the Spray Star carefully as they have safety, operating,
assembly and maintenance instructions. Failure to do so could result in personal injury or equipment damage.
Keep manuals in a safe place after operator and maintenance personnel have read them. Right and left sides
are from the operator’s seat, facing forward.
All machines have a Serial Number and Model Number. Both numbers are needed when ordering
parts. The serial number plate on the Spray Star is located on the front left side of the main frame. Refer to
engine manual for placement of engine serial number.
For easy access record your Serial and Model numbers here.

2
Introduction
SYMBOLS
Park Brake Park Brake
Release Hydraulic Oil
Level
Choke - OpenChoke - ClosedHand Throttle
Hour Meter Hour Meter Fuse
Glow PlugGlow Plug - OffGlow Plug - On
RPM Gasoline Diesel
Water
Temperature
Temperature
Light
Engine Oil
Engine - Stop Engine - Start Engine - Run
No Electrical
Power
Electrical Power
Read
Operator’s
Manual

3
Introduction
SYMBOLS
No Smoking Moving Parts Manual
Operation
Pinch Point Step Hot Surface
HydraulicFluid
Penetration Lift Arm Tractor
Engage Disengage PTO
Ground Speed 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. Never allow anyone to operate or service the machine or its optional equipment without proper training
and instructions. Never allow minors to operate any equipment.
3. Learn the proper use of the machine, the location and purpose of all the controls and gauges before you
operate the equipment. 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.
Beware of overhead obstructions and underground obstacles. Stay alert for hidden hazards.
6. Never operate equipment that is not in perfect working order or without decals, guards, shields, or other
protective devices in place.
7. Never disconnect or bypass any switch.
8. Carbon monoxide in the exhaust fumes can be fatal when inhaled, never operate a machine without
properventilation.
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. Disengage all drives and set park brake before starting the engine.
12. Never use your hands to search for oil leaks. Hydraulic fluid under pressure can penetrate the skin and
cause serious injury.
13. This machine demands your attention. To prevent loss of 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. Before leaving operator’s position:
A. Disengage all drives.
B. Set park brake.
C. Shut engine off and remove the ignition key.
D. If engine has to run to perform any maintenance keep hands, feet, clothing and all other parts of
body away from moving parts.
15. Keep hands, feet and clothing away from moving parts. Wait for all movement to stop before you clean,
adjust or service the machine.
16. Keep the area of operation clear of all bystanders.
17. Never carry passengers.
18. Stop engine before making repairs/adjustments or checking/adding oil to the 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.
This machine is intended for turf maintenance. Other use is forbidden.

5
Introduction
SAFESPRAYINGPRACTICES
Persons engaged in the handling, preparation or application of chemicals must follow accepted practices to
insure the safety of themselves and others,
1. WEAR protective clothing including: gloves, hat, respirator, eye protection and skin covering suitable for
protection from chemicals being used.
2. BATHE thoroughly after any exposure to chemicals, giving particular attention to eyes, nose, ears and
mouth.
3. CLEAN equipment and materials in accordance with employer, municipal and state regulations. Use
only approved areas and drains.
4. DISPOSE of chemicals and rinse solutions by approved and legal means.
5. PROVIDE methods and materials for operators to wash eyes and hands immediately during the spray-
ing process.
6. PROVIDE methods and materials for control, safe dilution and neutralization of chemical spills during
preparation, spraying, transporting and cleanup.
7. Always check and follow the directions and safety warnings of the chemicals to be used.
8. Secure the discharge lines before starting the pump.An unsecured 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 fittings rated for maximum pressure or pressure at which pressure 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. Do not use these pumps for pumping water or other liquids for human or 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 all exposed moving 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. Protect pump from freezing conditions by draining liquid and pumping rust inhibiting antifreeze solution
through the system, coating the pump interior.

6
Introduction
SPECIFICATIONS
WEIGHTSANDDIMENSIONS
Length 112" (285 cm)
Width 61" (155 cm) Width With Booms Down 230" (584 cm)
Height 50" (127 cm) Height With Booms Up 126" (320 cm)
Wheel Base 60" (152 cm)
Weight Empty 1200 lb (544 kg) Weight Loaded 2500 lb (1134 kg)
SOUNDLEVEL AT3400RPM
At ear level 84 dB
At 3 ft. (0.914 m) 82 dB
At 30 ft (9.14 m) 68 dB
At 23 ft (7 m) pass by 70 dB
ENGINE
Make Kohler
Model# Command CH20S
Type / Spec# 64558
Horsepower 20 hp (15 kW)
Fuel Unleaded 87 Octane Gasoline Minimum
Cooling System Air cooled
Lubrication System Full pressure
Alternator 25 Amp
WHEELS&TIRE Front (2) 20 x 1000 x 10 Multi-rib 20 psi (1.4 bar)
Rear (2) 24 x 1300 x 12 Super Soft 18 psi (1.3 bar)
Ground Pressure: 8.2 psi with 160 gallons
SPEED
Working Speed 1st gear 0-3 m.p.h. (0-5 kph)
2nd gear 2-6 m.p.h. (3-10 kph)
Transport Speed 3rd gear 4-10 m.p.h. (6-16 kph)
Reverse Speed 0-3 m.p.h. (0-5 kph)
BATTERY Automotive type 24F-12 volt
BCI Group Size 24
Cold Cranking Amps 575 minimum
Ground Terminal Polarity Negative (-)
Maximum Length 10.25" (26 cm)
Maximum Width 6.88" (17 cm)
Maximum Height 10" (25 cm)
FLUIDCAPACITY
Crankcase Oil 2.1 quart (2 liters) with filter
Fuel 8 gallon (30.25 liters)
Hydraulic Fluid 1 gallon (3.785 liters)
Grade of Fluid SAE 10W-40 API Service SJ or higher motor oil
OPTIONALSPRAYEQUIPMENT
14-100 Super Boom 20' (6 meter) Long 10-300 18' Terrain Following Boom
15-363 Fresh Water Wash Tank 10-301 15' Terrain Following Boom
15-425 Hose Reel Mounting Frame 15-493 Auto-Boom 18' (5.5 m) Long
15-571 15' Tri-Section Electric Lift Star Shield Boom 14-301 440 Spray System (1602P)
15-572 15' Dual Section Electric Lift Star Shield Boom 14-302 203 Spray System (1604P)
15-573 15' Manual Lift Star Shield Boom 14-303 Manual Spray System (1610P)
16-856 Tank Rinsing System 14-304 844 Spray System (1607P)
16-129 Hose Reel 200' (61 m) capacity (to be used with 15-425)15-499 Foam Marker System (Dealer Installed)
16-906 Hose Reel 12 volt electric rewind 200' (61 m) 15-501 Foam Marker System (Factory Installed)
capacity (to be used with 15-425)

7
Introduction
SETUP
The Model 1600P Prime Mover arrives from setup and ready for service. Depending on freight
conditions the tires, wheels and steering wheel may need to be installed.
The spray system is normally shipped attached to the 1600P Prime Mover. If a spray system is to be retrofitted
to a 1600P Prime Mover by a dealer or owner, assemble and attach the components in accordance with the
parts drawings in the Spray Star 1600P Parts/Service Manual.
1. Remove the top and sides from the shipping crate then remove the banding from the Spray Star.
Banding is under tension.
2. Lift front end using a hydraulic jack, taking care that the jack is not placed in
a location that would damage any steering system components, install front
wheels and torque nuts to 64-74 ft/lb (87-100 Nm). Then raise rear axle
using a hydraulic jack and install rear wheels and tires, torque lug nuts
to 64-74 ft/lb (87-100 Nm). Torque again after the first 10 hours and
every 200 hours thereafter.
3. Set park brake.
4. Check the tire pressure. The front tires are 20 psi (1.4 bar) and
the rear tires are 18 psi (1.3 bar).
5. Remove the tape holding woodruff key (Ref B) to the shaft. Put
steering wheel (RefA) on the shaft of the steering mechanism
(Ref C). Tighten nut to 30-40 ft/lb (41 - 54 Nm). Do not over
tighten.
6. Install the seat with the stud going through the engine cover and the flat washers, lock washers and
nuts. Use the front set of holes for shorter drivers and use the back set of holes for taller drivers.
7. Be sure battery (automotive type 24F-12 volt; 575 cold cranking
AMPS minimum; 10.25" (260 mm) long x 6.88" (175 mm) wide x
10" (254 mm) high maximum case) is installed in proper position
in the battery box, which is located on the left side of the engine
compartment. Battery posts should be 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.
8. Check the engine oil and add as necessary. The dip stick is located in cutout hole behind the seat on the
left side. Oil fill is located on top of valve cover, use SAE 10W-40API Service SJ or higher motor oil. DO
NOT OVERFILL.
9. Fill fuel tank, located on right side, with Unleaded 87 Octane gasoline (minimum).
Gasoline is flammable, caution must be used when storing or handling it. Do not fill fuel tank
while engine is running or an enclosed area, fumes are explosive and dangerous to inhale.
DO NOT SMOKE while filling the fuel tank. DO NOT OVERFILL.

8
Introduction
SETUP (CONTINUED)
10. Check brake fluid in master cylinder by removing round plug on floorboard.Add brake fluid if necessary.
DOT 3.
11. Check hydraulic fluid. The hydraulic power unit is located between the engine and the spray tank on the
left hand side. Remove breather plug and add SAE 10W-40 API Service SJ or higher motor oil if neces-
sary. Fluid level should be about 1.5" (38 mm) below top of tank when cold.
12. Check the transmission fill plug on the right hand side of the transmission and check the rear axle fill
plug located on the back side. They should be filled with SAE 80W-90 Gear Lube API Service GL-5, GL-
4 so that the level is even or a little below the bottom of the fill hole.
13. Machine should be greased before starting, refer to Spray Star 1600P Parts/Service Manual for location.
14. Attach the Spray Boom and any other Optional Equipment to the Prime Mover, in accordance with
instructions in the Spray Star 1600P Parts/Service Manual.The nozzles must be the correct distance
above the turf as described in Spraying Procedure of this manual. The spray boom must operate
properly and the outer sections must break away safely if an object is struck by them, they must then
return to normal operation position.
15. Be sure to double check boom heights, nozzle spacing and displacement before spraying.
16. Fill tank with water and retighten the four bolts used to hold the tank in place.
17. Read operating instructions before 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.
DAILYCHECKLIST
1. Check park brake adjustment. Adjust as required.
2. Check engine oil level. Add as needed. DO NOT OVERFILL.
3. Tire pressure should be 20 psi (1.4 bar) front and 18 psi (1.3 bar) rear maximum.
4. Inspect electrical system for loose connections or frayed wiring, including battery cables. Replace any
faulty equipment or tighten if loose.
5. Check hardware for loose or missing nuts, bolts, screws, etc., and tighten or replace as needed.
6. Inspect hydraulic lines for damage or leaks. Never use hands to inspect leaks.
7. Check brake fluid in master cylinder by removing round plug on floorboard. Add DOT 3 brake fluid if
necessary.
8. Check hydraulic fluid. The hydraulic power unit is located between the engine and the spray tank on the
left side. Remove breather plug and add SAE 10W-40API Service SJ or higher motor oil if necessary.
Fluid level should be about 1.5" (4 cm) below top of tank when cold.
9. Check the transmission fill plug on the right side of the transmission and check the rear axle fill plug
located on the back side. They should be filled with SAE 80W-90 Gear Lube API Service GL-5, GL-4 so
that the level is even or a little below the bottom of the fill hole.
10. Inspect steering, throttle and shift linkages for good hookups and clear travel.
11. Check anti-vibration mounts on engine frame.
12. Check controls for smooth, proper working operation. Lubricate as needed.