Smithco Spray Star 2004 User manual

Spray Star 2004/2004D
with Raven 203 System
SN: 200G137
February 2015
Operator’s
Product Support: Hwy SS & Poplar Ave; Cameron WI 54822
1-800-891-9435 [e-mail]

Introduction Operation SprayingProcedures Nozzle Charts Reference
CONTENTS
Introduction................................................................ 1-11
Introduction ................................................................. 1
Symbols................................................................... 2-3
General Safe Practices............................................... 4
Safe Spraying Practices ............................................. 5
2000 Gas Specifications ............................................. 6
2000G Optional Spray Equipment............................... 6
2000 Diesel SPecifications ......................................... 7
2000D Optional Spray Equipment............................... 7
Set Up ......................................................................... 8
Controls & Instruments.........................................10-11
Operation ................................................................. 12-17
Operating Instructions.......................................... 12-14
Console Features ..................................................... 15
Spray Operation ................................................... 16-17
Spraying Procedure ................................................ 18-24
Spraying Introduction................................................. 18
TurfManagement ...................................................... 18
Hose & Handgun Spraying ........................................ 19
Nozzles................................................................ 19-20
CalibrationIntroduction ............................................. 21
The Nozzle Chart Method of Calibration .............. 22-23
The “128” Method of Boom Sprayer Calibration ... 23-24
Nozzle Charts .......................................................... 25-30
Nozzle Performance Chart #1 .................................. 25
Nozzle Performance Chart #2 .................................. 26
Nozzle Performance Chart #3 .................................. 27
Nozzle Performance Chart #4 .................................. 28
Nozzle Performance Chart #5 .................................. 29
Nozzle Performance Chart #6 .................................. 30
Reference ................................................................ 32-36
Declaration of Conformity ......................................32-35
Quick Reference .................................................................36

1
Introduction
PARTS MANUALS AVAILABLE ONLINEAT smithco.com
INTRODUCTION
Thank you for purchasing a SmithcoSmithco
SmithcoSmithco
Smithco product.
Read this manual and all other manuals pertaining to the Spray Star 2000 carefully as they contain safety, oper-
ating, assembly and maintenance instructions. Failure to do so could result in personal injury or equipment
damage.
Keepmanualsinasafe place afteroperator and maintenancepersonnel have readthem. Right andleft sides are
fromthe operator’sseat, facingforward.
All SmithcoSmithco
SmithcoSmithco
Smithco machineshavea Serial Number andModelNumber. Both numbers areneeded when ordering
parts. Referto enginemanualfor placementof engine serialnumber.
For product and accessory information, help finding a dealer, or to register your procuct please contact us at
www.Smithco.com.
Informationneededwhenorderingreplacement parts:
1. ModelNumber ofmachine
2. SerialNumber ofmachine
3. Nameand PartNumberof part
4. Quantityof parts
lb/kg Empty lb/kg Full
Failureto follow cautiousoperatingpracticescan
resultinserious injury to the operator or other
persons.The owner must understand these instruc-
tions,andmustallow onlytrainedpersons whounder-
standtheseinstructionstooperatethis vehicle.
WARNING
CALIFORNIA
Proposition 65 Warning
Engineexhaust andsome of itsconstituents
are known to the State of California to
cause cancer, birth defects, and other
reproductive harm.
WARNING

2
Introduction
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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
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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
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SAFEPRACTICES
1. It is your responsibility to read this manual and all publications associated with this machine.
2. Neverallow anyone tooperate orservice the machineor itsoptionalequipment withoutproper training and
instructions.Never allow minorsto operateanyequipment.
3. Learnthe proper useofthe machine, thelocation and purposeofall the controlsandgauges before you
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 and undergroundobstacles.Stayalert forhidden hazards.
6. Neveroperate equipment thatis not inperfectworking order orwithout decals, guards,shields, or other
protectivedevices inplace.
7. Never disconnect or bypass any switch.
8. Carbonmonoxide in theexhaust fumescan be fatalwhen inhaled,neveroperate amachine without proper
ventilation.
9. Fuel is highly flammable, handle with care.
10. Keepengine clean.Allow theengine to cool beforestoring and always removethe ignition key.
11. Disengageall drivesand set parkbrake before startingthe engine.
12. Neveruse your hands tosearchfor oil leaks. Hydraulicfluid under pressure canpenetratethe skin and
cause serious injury.
13. Thismachine demands yourattention.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. Disengageall drives.
B. Set park brake.
C. Shut engineoff andremovethe ignitionkey.
D. If engine has to run to perform any maintenance keep hands, feet, clothing and all other parts of body
awayfrom movingparts.
15. Keephands, feet andclothingaway from movingparts.Wait for allmovement to stop beforeyou clean,
adjustor service themachine.
16. Keepthe area ofoperationclear of allbystanders.
17. Nevercarry passengers.
18. Stop engine beforemakingrepairs/adjustmentsor checking/adding oilto 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.
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
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SAFESPRAYINGPRACTICES
Personsengaged in the handling,preparation or applicationof chemicals must followaccepted practices to
insurethe safety ofthemselvesand others,
1. WEAR protectiveclothing including: gloves,hat, respirator,eyeprotection andskin covering suitablefor
protectionfrom chemicals beingused.
2. BATHE thoroughly afteranyexposure to chemicals,giving particularattentionto eyes, nose,ears and
mouth.
3. CLEAN equipmentand materials inaccordancewith employer,municipal andstate regulations.Useonly
approvedareasand drains.
4. DISPOSE ofchemicals and rinsesolutionsby approved andlegal means.
5. PROVIDE methodsand materials foroperatorsto wash eyesand hands immediatelyduringthe spraying
process.
6. PROVIDE methodsand materials forcontrol,safe dilution andneutralization of chemicalspillsduring
preparation,spraying, transportingand cleanup.
7. Always check and follow the directions and safety warnings of the chemicals to be used.
8. Securethe discharge lines before startingthe pump.Anunsecureddischarge 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. Useonly pipe, hoseandfittings rated formaximum pressure orpressureat which pressurerelief valve is
set at. When replacing pipe, hose or fittings, use new product.
13. Do not operate any fuel engines in an enclosed area. Be sure the area is well ventilated.
14. Donot use thesepumpsfor pumping wateror other liquids forhuman or animalconsumption.
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. Besure all exposedmoving parts areguardedand thatallcoupling devicesaresecurely attachedbefore
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. Protectpump from freezingconditions by drainingliquid and pumpingrust inhibiting antifreezesolution
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
raisedin transit theycanfall forwardorbackward when comingto a stopor while travelingon uneven
terrain.

6
Introduction
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SPECIFICATIONS SPRAYSTAR2000GAS
WEIGHTSANDDIMENSIONS
Length 132" (335cm) - w/ booms 137" (348 cm) - w/ Cleanload 151" (384 cm)
Width 72"(183cm)
Heightw/ Booms Folded 110"(279cm)
Wheel Base 61"(155cm)
Weight Empty 1990lbs (903 kg)
WeightLoaded 3605 lbs(1635 kg)
SOUNDLEVEL(DB)
Atear level 84 dBA
ENGINE
Make Briggs & Stratton
Model# 543477
Type / Spec# 01143E1
Horsepower 31 hp (23 kW)
Fuel Unleaded87 OctaneGasoline Minimum
CoolingSystem Air Cooled
LubricationSystem Full Pressure
Alternator 20Amp
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; 20 psi (1.4 bar)
SPEED
Infinitely Variable 0-10 m.p.h.(0-16 kph)
BATTERY Automotive type24F - 12volt
BCIGroup Size 24
ColdCrankingAmps 900minimum
GroundTerminalPolarity Negative(-)
MaximumLength 10.25" (26 cm)
Maximum Width 6.88" (17 cm)
MaximumHeight 10" (25 cm)
FLUIDCAPACITY
CrankcaseOil See EngineManual
Fuel 6 gallon(22.7 liters)
HydraulicFluid 5 gallon(19liters)
Grade of Hydraulic Fluid SAE 10W-40API Service SJ or higher Motor Oil
OPTIONALEQUIPMENT
15-618 Water Meter Kit (liters) 14-515 Water Meter Kit (Gallons)
20-503 ChemicalCleanload SafeFill 15-850 Sunshade Canopy
30-009 ManualRewind HoseReel, 200-foot/61-metercapacity
30-010 ElectricRewind HoseReel,200-foot/61-meter capacity
30-004 FoamMarker 30-006 Clear waterWashTank
15-835 Tank Rinsing System 30-141 26 Gal Wash System
17-585 18'HDSuperBoom 17-580 20'HD SuperBoom
17-590 Lazer-BeamAutomatic Boom forHD Booms 31-004 All Weather Top

7
Introduction
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SPECIFICATIONS SPRAYSTAR2000DIESEL
WEIGHTSANDDIMENSIONS
Length 132" (335cm) - w/ booms 137" (348 cm) - w/ Cleanload 151" (384 cm)
Width 72"(183cm)
Heightw/ Booms Folded 110" (279 cm)
Wheel Base 61"(155cm)
Weight Empty 1990lbs (903 kg)
WeightLoaded 3605 lbs(1635 kg)
SOUNDLEVEL(DB)
Atear level 98 dBA
ENGINE
Make Kubota
Model# D1105-E3B
Horsepower 25 hp (18.5 kW)
Fuel No.1-D or No. 2-D, S500: Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%
No1-D or No.2-D, S15: Ultra Low Sulfur Diesel (ULSD) less than 15 ppm or 0.0015 wt.%
CoolingSystem Liquid Cooled
LubricationSystem Full Pressure
Alternator 15Amp
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
Infinitely Variable 0-10 m.p.h.(0-16 kph)
BATTERY Automotive type24F - 12volt
BCIGroup Size 24
ColdCrankingAmps 900minimum
GroundTerminal Polarity 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
15-618 Water Meter Kit (liters) 14-515 Water Meter Kit (Gallons)
20-503 ChemicalCleanload SafeFill 15-850 Sunshade Canopy
30-009 ManualRewind HoseReel, 200-foot/61-metercapacity
30-010 ElectricRewind HoseReel,200-foot/61-meter capacity
30-004 FoamMarker 30-006 Clear waterWashTank
15-835 Tank Rinsing System 30-141 26 Gal Wash System
17-585 18' HDSuperBoom 17-580 20'HD SuperBoom
17-590 Lazer-BeamAutomatic Boomfor HD Booms 31-004 All Weather Top

8
Introduction
PARTS MANUALS AVAILABLE ONLINE AT smithco.com
SETUP
TheSprayStar2000 arrives from setupand readyfor service. Dependingon freightconditionsthe
battery may have to be installed.
The spray system is normally shipped attached to the 2000 Prime Mover. If a spray system is to be fitted to a
Prime Mover by a dealer or factory, assemble and attach the compo-
nents in accordance with the parts drawings in the Spray Star 2000
Parts/ServiceManual.
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 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 discon-
necting remove black negative (-) cable (B) first.
3. Checkhydraulic fluid level intank locatedunderthe seat. Remove capand add SAE 10W-40API Service
SJ or higher motor oil if necessary. Fluid level should be about 2-21/2" (5-6.4 cm) from the top of the tank
whencold. DONOT OVERFILL.
4. Fillfuel tank, located onthe left side, withGAS: Unleaded87 Octane gasoline(minimum)DIESEL: No.1-
D or No. 2-D, S500: Low Sulfur Diesel (LSD) less than 500 ppm or 0.05 wt.%. No1-D or No.2-D, S15: Ultra
Low Sulfur Diesel (ULSD) less than 15 ppm or 0.0015 wt.%
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. Machine shouldbe greasedbefore starting, referto Spray Star 2000Parts/Service Manualfor location.
6. Attach the Spray Boom and any other Optional Equipment to the Prime Mover, in accordance with
instructions in the Spray Star 2000 Parts/Service Manual. The nozzles must be the correct distance above
theturfas described in Turf Spraying Guide.The sprayboom must operate properly andthe 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.
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.
9. Readoperating instructionsbefore starting.

9
Introduction
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NOTES

10
Introduction
PARTS MANUALS AVAILABLE ONLINE AT smithco.com
CONTROLS&INSTRUMENTS 2000
A. HourMeter - Thehour meter indicateshoursof machine operation.It operates onlywhen the ignition
switch is on.
B. Speedometer- TheSpeedometerindicatesground speedof the vehiclein miles 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- Holdleverdown andadjuststeering wheelto desired
positionand releaselever.
F. Lights - This rocker switch turns lights on by pushing on the top and
off by pushing on the bottom.
G. Buzzer - The buzzer sounds if the pump is running dry.
H. Ground Speed(Cruise) Control -This rockerswitch initiates cruise
control by pushing on the top and turning it off by pushing on the
bottom. Works with ground Speed Control Foot switch.
I. Spray Pump - This toggle switch turns the spray pump on by pushing
on the top and off by pushing on the bottom.
J. Left Boom Switch - This rocker switch lifts and lowers the left boom.
K. Right Boom Switch - This rocker switch lifts and lowers the right
boom.
L. HandThrottle - The hand throttleis used toregulateengine speed.
M. 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.
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.

11
Introduction
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CONTROLS&INSTRUMENTS 2000
O. 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
increasesspeed and clockwisedecreases speed. Disengagethe lever andyou will havefull accelerator
pedalrange.
P. Cup Holder -Holds two x-alrgecups.
Q. Ground Speed (Cruise) Control Foot Switch - When rocker switch is truned on and desired speed is
obtained, push foot speed control switch to set cruise.
R. Master Boom Switch - 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 440 System only
the Master Switch on the computer must be off for the master boom control switch to work.
S. Accelerator Pedal - This pedal controls ground speed. Press pedal to increase speed. Varying the amount
ofmovement ofthepedal willvary theground speed.
T. ReversePedal - Thispedal controlsreverse. Press pedalto movemachine in reverse.
Y. WaterTemperature Light (Diesel Only)- Temperature light will come on and a buzzer will sound when the
enginestarts tooverheat.
Z. Glow Plug (Diesel Only)- When ignition is turned on, glow plug lights when ready to start.
GROUNDSPEEDCONTROL
Thegroundspeed control does notworkthe same as anautomotive type cruise. The groundspeed control is
locatedon the center floorboardand is used tolock forward speed.
TOENGAGE:
1. Flip rocker switch ‘On’ (green light).
2. Obtaindesired speed withfoot pedal.
3. Step on foot switch to lock speed.
4. Push foot switch again to disengage.
To avoid abrupt stop, place foot on traction pedal before disengaging speed control.

12
Operation
PARTS MANUALS AVAILABLE ONLINEAT smithco.com
OPERATION
Beforeoperatingthe Spray Star2000, become familiar withall controls and functions.Alsocompleteall mainte-
nancerequirements andreadall safetywarnings.Knowing the SprayStar2000 thoroughly, how itoperates, and
by doing the prescribed maintenance steps, you can expect trouble free operation for years to come.
SAFETY
Safetyneeds to always bethe concern ofan operator of amoving vehicle orany machine with movingparts.
1. Keep all shields and guards in place.
2. Keepthe parking brakeengaged any timethe operatorisaway fromthevehicle orwheneverservice is
performed.
3. Alwayswear the necessaryprotective clothing andequipment.
4. Turnengine offwhenrefueling orperforming maintenancenot specificallyrequiring enginepower.
DAILYCHECKLIST
1. Checkthe engine oillevel. Add asneeded. DO NOT OVERFILL.Refer to engineowner's manual foroil
gradeandprocedure.
2. Tirepressure should be20 psi (1.4 bar)maximum.
3. Inspect the electrical system and battery cables for loose connections or frayed wiring. Replace any faulty
equipmentor tighten ifloose.
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. Inspectthe steering, throttle and shiftlinkages for good hookups and
cleartravel.
8. Checkcontrols for smooth,proper working operation.Lubricate as
needed.
9. Check park brake adjustments. Adjust as required.
10. Check anti-vibrationmounts onengine frame.
STARTINGTHEENGINE
1. Gas - 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
necessary.
2. Diesel - Insert the key (A) and turn clockwise to (B). When glow plug
light goes off Turn key to (C) until the engine starts. Release the key
and it will return to the run position (B).
3. Allowengine to idleand warm upbefore selecting directionof 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. Disengagespray pump.
2. Movethe throttle leverto“slow” and turnignitionkey to the“off” position.
3. Removethe ignition keyand engage thepark 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.

13
Operation
PARTS MANUALS AVAILABLE ONLINE AT smithco.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
completed should chemical be added to the sprayer.
TOWING UNIT
When it is necessary to move the Spray Star 1750 without the engine running, the bypass valve located on the back of
the hydrostatic pump must be "open" by turning it 1/4turn to open. 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 10°.
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.

14
Operation
PARTS MANUALS AVAILABLE ONLINEAT smithco.com
OPERATION (CONTINUED)
SPRAYERVALVESETTINGSANDSPRAYTANKAGITATION
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.
Thereis one manualflowcontrol valve onthe discharge sideof the spraysystem.This valve controlsthe agita-
tor.This valve maybe opened asmuch as necessaryto provide hydraulicagitationthrough the quadrajetagitator
inthe tank bottom. Thisvalve may be partiallyclosed to preventorreduce foam buildupfromthe spray materials
inside the tank. When the liquid level in the spray tank reaches a certain level (usually 1-25 gallons (3.8-95 Li-
ters) depending on terrain and other conditions) it may be necessary to close the valve in the agitator line in
orderto prevent lossofsuction prime.
If your Spray Star is fitted with a hose reel, there is a second ball valve on the discharge system to supply mate-
rial 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.
INITIALSYSTEMSETUP
1. Fill tank with water only.
2. PlaceMaster On/Off switchtoOn, Boom On/Offswitchesto Off, andopen tank shut-off valves.
3. WithPump not running, fullyopen main line handvalve and totallyclose agitator line handvalve.
4. Verify that eachboom solenoid valveoperatesby operating BoomOn/Offswitches and thatnonozzles are
plugged.
5. Place all Boom On/Off switches On.
6. Hold the PressureAdjust switch in the increase position until the pressure stops increasing and begins to
decrease.
7. Adjustagitator linehand valve fordesired agitation.
8. Closethe main linehand valve, ifnecessary,to set themaximumdesired operating pressure.(The
maximumpressure should beapproximately10 psi(69 kPA), above thenormal spraying pressure.)
9. Hold the PressureAdjust switch in the decrease position until the pressure stops decreasing and begins
to increase. If desired minimum pressure cannot be obtained, install larger bypass hose.
10. Verify the desired maximum pressure of the sprayer system by repeating step 6.

15
Operation
PARTS MANUALS AVAILABLE ONLINE AT smithco.com
CONSOLEFEATURES
A. Master Boom Switch -Activates or stops boom spraying.
B. Individual Boom Switches - Used to activate any of up to 3 booms on a sprayer.
C. PSI Gauge - Indicates the pressure of fluid in the system.
D. Pressure Switch-Used to activatethe motorized controlvalve
E. FuseHolder -The fuseholderholds one 15Amp fuse.
CALIBRATINGTHEPRESSUREGAUGE
The pressure tap on the Raven Sprayer Control system is located away from the nozzles, thus, there can be a pressure
difference between nozzle pressure and gauge pressure at the console. Therefore, for best results, Raven recom-
mends the following procedure:
1. When the sprayer is ready and the tank is filled with water (No chemicals at this time), attach an accurate
pressure gauge to a nozzle in place of the spray tip.
2. Start up the pump, turn on the electric shut-off valves and adjust the pressure control valve so that the desired
pressure is maintained on the gauge at the nozzle.
3. Because of pressure drops through the system, the pressure shown on the gauge in the console may read
slightly higher than the gauge at the nozzle. Use this console pressure reading as your reference point for
maintaining the desired pressure at the nozzle.
PROCEDURETORE-CALIBRATEFLOWMETER
1. Enter a Meter Cal number of 10 in Meter Cal Button
2. Enter a Total Volume of Calibrating the Pressure Gauge in Total Volume button
3. Switch Off all booms.
4. Remove a boom hose and place in calibrated 5 gallon container
5. Switch on appropriate boom switch and master switch. Pump exactly 10 gallons.
6. Readout in Total Volume is the new Meter Cal Number. Should be within 3% of number stamped on flowmeter.
7. Repeat the procedure several times to ensure accuracy.
8. To verify calibration, fill applicator tank with predetermined amount of measured liquid. DO NOT RELAY ON
GRADUATION NUMBERS ON TANK. Empty tank under normal operatin conditions. If the number under totla
volume is different from the predetermined amount of measure by more than 3% compete calculation in back of
book.
9. Enter corrected Meter Cal before resumin application.

16
Operation
PARTS MANUALS AVAILABLE ONLINEAT smithco.com
SPRAYOPERATION
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 operation precautions.
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. SetEngine speed between2000-3200 RPM.
7. (Optional)Engageground speedcontrol.
8. Obtain desired spraying speed before activating spray with switches on spray control console.
9. The master boom switch, 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 834 Systems
the Master Switch on the computer must be on for the master boom control switch to work. For the 440
System the Master Switch on the computer must be off for the master boom control switch to work.
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.

17
Operation
PARTS MANUALS AVAILABLE ONLINE AT smithco.com
SPRAYOPERATION
Oneofthe most common causes for faulty-pumpperformanceis corrosion inside the pump.Flushthe pump and
entire system with a solution that will chemically neutralize the liquid pumped. Mix according to manufacturer’s
directions.Thiswill dissolve most residue remaining inthepump, leaving the inside ofthepump clean for the
next use.
TOPREVENTCORROSION
Aftercleaningthe pump as directed, flushitwith a permanent type automobileantifreeze(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 and rinseinside of tankthoroughly withclean water,replace coupling.
2. Fill tank ten percent full with clean water, start pump and discharge water through spray hose or spray
boom(with nozzles removed),until empty.
3. Removedrain couplingagain and rinsetankinterior thoroughly.
4. Rinseexterior of sprayerthoroughly with cleanwater.
5. Removebowl from sprayerfilter (on operatorslefthand sideofthe spraytank).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 will
allowyouto pull outadditionalhose or tousethe handle andwindup the hose.Topreventmovement 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 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 be dispensed.
Switch on the compressor also turns foamer on or off.

18
SprayingProcedures
PARTS MANUALS AVAILABLE ONLINE AT smithco.com
SPRAYINGINTRODUCTION
Thissection is intended tooffer practical guidelinesforthe distribution ofliquid chemicals overanarea 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
sprayvehicles or sprayersmounted 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 mounted upona utility vehicle
Sprayers are typically equippedwith wide spraybooms.Generally these boomsare 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. Foam markersand dye markersare advisable.
TURFMANAGEMENT
Turfmanagement chemicalsare madefor fourgeneral purposes:
1. Fungicides: Preventor cure funguson turfgrass. Theyare made in2general 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: Controland eliminateundesirableweeds andgrass from turfareas andnon-turf areas such
as bunkers, trails, fences, etc.
4. Nutrients & Fertilizer: Promotegrowth,beauty and color in 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”andrequires alower volume ofwater.Instead of irrigationwater,these materials arefurther 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 andeffective results. It providesinformation on how muchchemical and how muchwater is 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.
Theseare flat fannozzles,commonly referredtoasTeeJet nozzles.They areavailable in awide variety of
sizesfor any required dischargevolume rate. They arethe best formanycontact or foliarapplied pesti-
cides. They are spaced either 10" (25 cm) or 20" (51 cm) apart and overlap one another by about 1/3.
• Thesecond type usefulinturf management arebroadcast typenozzles. They arecommonlyreferred to
asraindrop or floodjetnozzles. They sprayahollow-cone shapedpatternof much largerdroplets which fall
quickly to the turf under their own weight. They are best for systemic pesticides or any material requiring a
largevolume of water forsoil application. Thelarger droplets are notas subject todriftfrom wind andare a
safer, more environmentallyfriendly choice inmany situations.