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Smith Corona 1602HD User's Manual

1. There is one manual flow control valves on the discharge side of the spray system This valve controls the agitator This valve may be opened as much as necessary to provide hydraulic agitation through the quadrajet agitator in the tank bottom This valve may be partially closed to prevent or reduce foam buildup from the spray materials inside the tank When the liquid level in the spray tank reaches a certain level usually 1 25 gallons 3 8 95 Liters depending on terrain and other conditions it may be necessary to close the valve in the agitator line in order to prevent loss of suction prime If your Spray Star is fitted with a hose reel there is a second ball valve on the discharge system to supply ma terial 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 Inputto Agitator Agitator Agitator Agitator Nozzle Agitator Agitator Pressure Pressure Output Output Diameter ingpm in L min in psi in bar ingpm in L min 1 8 1 9 7 2 25 1 7 6 3 23 8 CH 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 a
2. IN TIALCO BQLESETUP 1 Fill tank with water only If positive displacement type pump is used fully open pressure relief valve PRV Open gate valve between the tank and pump Place MASTER On Off to On and Boom On Off switches to Off Place MAN RATE 1 RATE 2 switch to MAN Place POWER On Off switch to On Verify correct boom widths speed calibration meter calibration valve calibration 2123 RATE 1 calibra tion and RATE 2 calibration have been entered in console Enter into SELF TEST the normal sprayer operating speed aro hn Run pump at normal operating RPM 7 Verify that each boom solenoid valve operates and that no nozzles are plugged by operating Boom On Off switches Place all Boom On Off switches to On Hold the MAN ADJ switch in INCR position for approximately 12 seconds This assures motorized control valve is fully open Verify maximum pressure and RATE 10 Adjust agitator line hand valve for desired agitation Use the pressure gage on the rear of the machine to verify maximum pressure is still present 11 Hold the MAN ADJ switch in DECR position for approximately 12 seconds This assures motorized control valve is fully closed Verify minimum pressure and RATE can be achieved If not consider bypass plumbing system in Appendix 3 M CO SQLEHA DTEST I 2 Drive down field or road at target speed with sprayer booms off to verify SPEED readout on Console Turn on sprayer and booms and place the RATE
3. 2 Determine the Desired Application Rate This is determined from the information on chemical labels or other technical information available from a variety of sources 3 Determine an Acceptable Ground Speed Conditions over which the sprayer will operate generally dictate the appropriate ground speed Within the limits of practicality and efficiency spraying should generally be done at lowest possible speed This increases operator safety and contributes to more precise application of chemicals For example golf greens and tees and hill areas would generally be sprayed in the range of 2 2 to 3 2 mph 4 6 kph Larger open and more level areas such as golf fairways and park or school grounds would be sprayed at 4 2 to 6 mph 7 10 kph The vehicle which carries or tows the sprayer should be equipped with a precise low speed speedom eter If it is not exact ground speed at a given engine speed must be determined by timing the travel of the sprayer over a measured distance 4 Determine Nozzle Size Refer to the appropriate nozzle chart in the back of this manual for your nozzle TYPE the type of nozzle you have or type you wish to use nozzle SPACING and CALIBRATION TYPE gpm opt or Iph You will note from the chart that application rates from any given nozzle decrease as the ground speed increases In other words the faster you drive the less material you are applying Application rates are shown in the columns to the right
4. 25 30 40 50 25 30 40 50 25 30 40 50 25 30 40 50 aah om bh Mi SIN S Nozzle Type Turbo TurfJet Spacing 20 inch 51cm Calibration Liters Per Hectare Nozzle Application Rate l ha Pressure Capacity Speed KPH MPH 91 0 68 3 111 83 3 1 4 TTJ04 VS f 129 95 8 119 min 4 2 5 6 4 86 NO S 1 1 1 85 5 105 VS Brown 1 4 TIJO5 V l 121 148 E 103 126 Gray 1 4 TTJO6 VS l 146 237 178 182 137 223 167 1 4 TTJ08 VS WE 257 193 315 236 228 171 279 209 VS L Blue 1 4 TTJ10 V 322 249 E 395 295 342 257 419 314 VS L Green 1 4 TTJ15 V l 484 363 E 592 444 GA o ABBREVIATIONSANDCOWERSIONS gpm Gallons per minute cm Centimeters lit min Liters per minute dm Decimeters dl min Deciliter per minute m Meter psi Pounds per square inch mm Millimeters km Kilometers mph Miles per hour gpa Gallon per acre km h Kilometers per hour lit ha Liters per hectare us Volume per ACRE ml ha Milliliter per hectare Si Volume per Hectare gpk Gallons per 1 000 sq ft TU Volume per 1 000 sq ft AREA amp SPEED Distance feet x 0 68 Travel Speed MPH Travel Time seconds Time Required in Seconds to Travel a Distance of Speed MPH 100 Ft 200 Ft 300 Ft 1 0 68 136 205 1 5 46 92 136 2 0 34 68 103 25 27 54 82 3 0 23 46 68 3 5 20 40 58 4 0 17 34 52 4 5 15 30 46 5 0 13 28 41 UQUID VOLUME 1 US Gallon x 128 Fluid Ounces 1 US Gallon x 3 785 Lite
5. All incidental and consequential damages including pickup and delivery of the unit communica tion mileage charges and or rental of a replacement unit during repair are not covered under this warranty nor is any loss of income and or other loss resulting from the failure of the product to function due to a warranty defect The following items are not covered under the SMITHCO warranty and are warranted by their respective manufacturer Engine and engine parts including starters generators alternators and filters Transaxle differentials gear boxes and mechanical pumps Hydrostatic transmissions hydraulic pumps and motors Batteries Wheels and tires A copy of the warranty for the above items is furnished if necessary with each SMITHCO product Some states do not allow limitations on how long an implied warranty lasts or the exclusion or limitations of incidental or consequential damages so the above limitations or exclusions may not apply to you This warranty gives you specific legal rights and you may also have other rights which may vary from state to state Federal law now requires disclosure of the warranty which applies to this product prior to the sale to a customer Please leave this statement attached to the product and allow the buyer to remove it after purchase SMITHEO Wayne Pennsylvania 19087 HZ demo
6. PROVIDE methods and materials for operators to wash eyes and hands immediately during the spraying process PROVIDE methods and materials for control safe dilution and neutralization of chemical spills during preparation spraying transporting and cleanup Always check and follow the directions and safety warnings of the chemicals to be used Secure the discharge lines before starting the pump An unsecured discharge line may whip Periodically inspect the pump and the system components Check hoses for weak or worn condition before each use Make certain that all connections are tight and secure Do not operate unit with leaks frayed kinked hoses or tubing Repair or replace immediately 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 Do not operate a gasoline engine in an enclosed area Be sure the area is well ventilated Do not use these pumps for pumping water or other liquids for human or animal consumption 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 WARNING compatible with the pump component materials Be sure all exposed moving parts are guarded and that all coupling devices are securely attached before applying power Before servicing disconnect all power make sure all pressure in the
7. 1 RATE 2 MAN switch to RATE 1 Increase or decrease speed by one MPH 2 kph The system should automatically correct to the target application rate If for any reason the system is unable to correct to the desired RATE check for an empty tank a plugged line a malfunctioning pump improper vehicle speed or a defect in the system If the system does not appear to be correcting properly first review Initial Console Setup then refer to Troubleshooting in the Parts Service Manual At the end of each row shut off flow with the Master On Off switch This also shuts off area totalizer Verify area covered and volume used SPRAY CPERATIOV AFTER PROPER SETUP AND CALIBRATION ch ER En 8 Add gt the amount of water required for the spray operation to tank using air gap filler Start engine set engine speed below 2000 RPM and engage pump after taking all previously described safety and operation precautions Open agitator valve 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 thr
8. 10 4 8 7 7 4 30 0 35 13 0 10 4 8 7 7 4 30 Pom Del o os teo ae soe oy a 20 0 42 15 6 12 5 10 4 8 9 36 White 20 0 57 21 0 16 9 14 1 12 1 48 TF VS4 30 0 69 26 0 20 0 17 1 14 6 59 20 0 71 26 0 21 0 17 6 15 1 DO 20 1 06 39 0 31 0 26 0 22 0 90 20 1 41 52 0 42 0 35 0 30 0 1 20 M SINY A NOM EPERFORMANCECHART 4 Nozzle Type Turbo FloodJet Spacing 40 inch 100cm Calibration Liters Per Hectare Application Rate l ha Application Rate GPT Pressure a Speed km h rn MPH bar 6 j a 0 MN 1 5 1 11 r 111 83 3 66 6 leet Zille DD 1 5 1 EN 210 140 105 84 0 ez so 164 ae ve ve see T poe reves ao rs or soe nas e to Jeer asr sos oor Le xo e reves oo am eo sea ae oso joven rrvsrs on ass vas aoe mo zo e Joel ao eas soo sas Le BU NOQZZLEPERFORMANCECEART 5 Nozzle Type Turbo TurfJet Spacing 20 inch 51cm Calibration US Gal Acre GPA amp US Gal 1 000 Square Feet GPT Nozzle Application Rate GPA Application Rate GPT Pressure Capacity Speed MPH KPH Speed MPH KPH psi Gal Min 3 5 4 6 5 8 6 10 3 5 4 6 5 8 6 10 25 a 9 5 7 9 36 27 22 18 30 Yellow 1 4 TTJ02 VS Ea 40 19 0 15 8 21 17 3 24 19 8 27 24 26 30 33 28 o ole oo 36 M sch aja SS sch aS sch i OJON OW A N gt j O 50 25 30 40 50 25 30 40 50
9. BOOM 1 in the key labeled F BOOM C 2 6 Enter width in inches cm of BOOM 2 in the key labeled If there is only one boom enter 0 for width of BOOM 2 BOOM 3 7 Enter width in inches cm of BOOM 3 in the key labeled If there is only one or two boon enter 0 for width of BOOM 3 As gt 17 A INTIAL PROGRAMMING CF CO BQLE COMPUTER CONTINUED SPEED 8 Enter SPEED CAL of 612 in key labeled 4 METER 9 Enter METER CAL calibration number in key labeled 5 VALVE CAL Enter VALVE CAL calibration number 2123 in key labeled e RATE 1 CAL Enter the target RATE 1 GPA litfha GPK you want to spray in the key labeled 7 RATE 2 Enter the target RATE 2 GPA lit na GPK you want to spray in the key labeled g If you do not use a second rate enter same rate as RATE 1 CAL RATE 2 should not be more than 20 different from RATE 1 or else spray pattern may suffer YOU HAVE NOW COMPLETED PROGRAMMING THE CONSOLE The flashing CAL will now extinguish If not repeat procedure starting at step 5 You may also wish to enter VOL data in the keys labeled o and although it is not required for the operation of the system VOL 13 Enter the estimated total Volume in Tank when you start spraying in key labeled Each time the tank is refilled this number must be reentered 14 Enter the TIME of day in the key labeled fi This is a 24 hour clock Therefore all time after 12 59 pm add 12
10. Enter key An E will illuminate in the DATA display FLOW CONTROL BOOM BOOM2 BOOM3 MASTER RATE 1 INC RATE 2 e MAN aL AL DATA 5 d FLOW CONTROL BOOM1 BOOM2 BOOM3 MASTER 8 ON v or i MEME BOOM BOOM2 OOM SPEED METER VAVE apen RATEZ VOL ue SELE z n s n BOOMS SPEED METER VALVE mr RATE A8 wu CAL CAL CAL CAL TEST CAL CAL CAL CAL CAL TANK 8 e e e o mo CAL CAL CAL CAL TANK 1 ig RH WH FIELD rem VOL AREA DISTANCE SPEED WH ja a TOTAL TOTAL FIELD FIELD D VOL AREAL TP JME AREA VOLUME MIN A do CE AREA VOLUME AREA VOLUME DISTANCE SPEED MN HOUR MONITOR cE DATOR ENTER 3 Depress the keys corresponding to the 4 Complete the entry by again depressing the number you wish to enter i e 5 7 2 ENTER key The numbers will be displayed in the DATA display as they are entered CONSQECALBRATION CALCULATI NG BOOM CAL BOOM 1 BOOM 2 BOOM 3 Calculate the width of each boom in inches centimeters by multiplying the number of tips times the spacing Write these boom widths down for future reference when programming the Console computer The Console is capable of controlling up to three 3 booms CALCULATI NG SPED CAL SPEED 1 Enter Speed Cal in key 4 of 612 2 Place Master and Boom 1 switches to on 3 Enter 0 in key bo Drive 1 mile Do not use vehicle odometer to determine distance use section line
11. amp Fertilizer Promote growth beauty and color in turf grass 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 and requires a lower volume of water Instead of irrigation water these materials are further acti vated 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 way to insure safe and effective results It provides information on how much chemical and how much water 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 turf grass management The first type is target directed It sprays material in a direct line downwards to the target turf grass These are flat fan nozzles commonly referred to as TeeJet nozzles They are available in a wide variety of sizes for any required discharge volume rate They are the best for many contact or foliar ap
12. hours Thus 8 30 am is entered as 8 30 but 1 30 pm is entered as 13 30 in the keyboard OTHER DISPLAY FEATURES 1 To display TOTAL AREA covered momentarily depress key labeled AREA To zero out this total at any time enter a 0 in this key 2 To display TOTAL VOLUME sprayed momentarily depress key labeled To zero out this total at any time enter a 0 in this key 3 To display FIELD AREA covered momentarily depress key labeled AREA To zero out this total at any time enter a 0 in this key 4 To display FIELD VOLUME sprayed momentarily depress key labeled To zero out this total at any time enter a 0 in this key 5 To display DISTANCE feet meters traveled momentarily depress key labeled To zero out this total at any time enter a 0 in this key SH oo q IN TIAL PROGRAVIMINGOF CO BQLECOMIPUTER CONTINUED 6 To display SPEED momentarily depress the key labeled VOL MIN 7 To display VOL MIN momentarily depress the key labeled EN AREA 8 To display AREA HOUR momentarily depress key labeled Ji This is an actual calculation of AREA HOUR at the present speed you are going It is not an average over time 9 To display TIP MONITOR fault momentarily depress the key labeled See TIP MONITOR manual for more detailed discussion Purchase the TIP MONITOR option if this function is desired SELF 10 To display US SI or TU and
13. moving vehicle or any machine with moving parts 1 Keep all shields and guards in place 2 Keep the parking brake engaged any time the operator is away from the vehicle or whenever service is performed 3 Always wear the necessary protective clothing and equipment Turn engine off when refueling or performing maintenance not specifically requiring engine power STARTING THEENG NE Make sure the fuel flow valve is On It is located on the fuel tank Make sure the spray pump is disengaged Depress the clutch pedal to activate the interlock switch Place shift lever in neutral aR ON The ignition switch is located to the right of the steering column In sert the key A and turn clockwise until the engine starts C Re lease the key and it will return to the run position B Use the choke and hand throttle as necessary 6 Allow engine to idle and warm up before selecting direction of travel 7 Make sure the park brake is disengaged STOPPING THEENG NE 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 Disengage spray pump 2 Move the throttle lever to slow and turn ignition key to the off position 3 Remove the ignition key and engage the park brake Never leave the vehicle unattended with the engine running Always bring the vehicle to a complete stop engage par
14. of the charts Once the desired application rate is decided upon it should be located as nearly as possible in one of these columns on the appropriate chart for your operation It could well be that the approximate rate desired would be obtained from the nozzles already installed in the boom If this is not possible then nozzles will need to be changed When selecting a new nozzle size refer to the Discharge Rate Column on the nozzle charts The Discharge Rate gpm or Ipm multiplied by the number of nozzles should not exceed 75 of the actual discharge volume of the sprayer pump i e if you need to use nozzles which discharge 0 8 gpm 3 0 Ipm and the spray boom is equipped with 12 nozzles the sprayer pump would have to produce an actual discharge volume of 13 gpm 49 Ipm in order to properly supply these nozzles If the collective volume of the spray boom nozzles exceeds the actual discharge volume of the pump inadequate pressure and poor nozzle distribution patterns may result Once nozzle type and size have been determined those nozzles are installed in the sprayer boom Nozzles should be expected to be replaced after 15 20 hours of actual sprayer operation After nozzles are installed make trial application of water over a known area to check application rate 4 28 VA THENOZLECEART METHODCF CALIBRATION CONTINUED 5 For Sprayer with Electronic Spray Control Systems On sprayers equipped with Electronic Spray Cont
15. rate may be made by increasing or decreasing the travel speed of the sprayer if conditions permit Slower speeds increase application rate Faster speeds decrease application rate 9 Nozzle sizes can be changed to provide the correct application rate Refer to the nozzle charts in this book for the desired nozzle type 10 Re calibrate the sprayer steps 2 6 after any adjustments are made As previously discussed there are other acceptable methods of Turf Sprayer Calibration Chemical suppliers Agricultural Extension Agents Universities and consultants of various types offer helpful advice on this subject Technical catalogues are available from nozzle manufacturers TRANSFERRING THE 128 METHOD NTOMETRIC LITERS PER HECTARE The same steps are used that are used when calibrating in gallons per acre First a relationship between a measurable amount milliliters and the calibration amount liter is determined That ratio is 1 1000 Now an area which is 1 1000th of a hectare must be measured On spray booms with 51 cm 20 inch spacing mark off an area which is 20 meters 65 6 feet long The area formed by that length and the width of one spray nozzle 20 meters by 0 5 meters is 10 square meters which is 1 1000 of a hectare Therefore the amount of spray material applied to this small area in milliliters is equal to the amount applied to one hectare in liters Then follow the remaining steps 2 10 substituting milliliters for oun
16. sprayer is to form the liquid into droplets The size of the droplet is determined by two factors design and system pressure psi bar Particular applications are done best by big droplets such as systemic fungicides insecticides and some herbicides in order to reduce drift Other applications require small droplets like contact fungicides and some herbicides Again this is determined by whether the chemical is foliar applied or soil applied Large droplets for soil applied material 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 form adequate spray nozzle patterns SH lw NQZAES CONTINUED 3 Disperse the material in a specific pattern that will insure even distribution of chemical across the Spacing e swath covered by the boom As shown to the right the pattern formed by flat fan TeeJet nozzles would show most liquid concentrated at the center then tapering off where Spray it begins to overlap with the next nozzle approxi Height mately s The pattern of liquid dispersed by the E hollow cone is more even across its width Each nozzle overlaps the adjoining nozzle by 100 That is to say the area covered by each nozzle extends to the center of the two nozzles on either side In orde
17. system is relieved drain all liquids from the system and flush Protect pump from freezing conditions by draining liquid and pumping rust inhibiting antifreeze solution through the system coating the pump interior SS SPECIACATIONS WEGHTS AND DIMENSIONS Length Width Height Wheel Base Weight Empty SOUNDLEVEL AT 3400 RPM At ear level At 3 ft 0 914 m At 30 ft 9 14 m NGNE Make Model Type Spec Horsepower Fuel Cooling System Lubrication System Alternator WEED GE TIRE SPEED Forward Speed Reverse Speed BATTERY BCI Group Cold Cranking Amps Ground Terminal Polarity Maximum Length Maximum Width Maximum Height FLUIDCAPACITY Crankcase Oil Fuel Hydraulic Fluid Grade of Fluid 112 285 cm 61 155 cm Width With Booms Down 230 584 cm 50 127 cm Height With Booms Up 126 320 cm 60 152 cm 1200 Ib 544 kg Weight Loaded 2500 Ib 1134 kg 88 dB 84 dB 72 dB Kohler Command CH25S PA 68666 25 hp 18 6 kW Unleaded 87 Octane Gasoline Minimum Air cooled Full pressure 25 Amp 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 0 10 m p h 0 16 kph 0 3 m p h 0 5 kph Automotive type 24F 12 volt Size 24 575 minimum Negative 10 25 26 cm 6 88 17 cm 10 25 cm 2 1 quart 2 liters with filter 5 gallon 19 liters 5 gallon 19 liters SAE 10W 40 API Servic
18. 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 Never operate equipment that is not in perfect working order or without decals guards shields or other protective devices in place Never disconnect or bypass any switch Carbon monoxide in the exhaust fumes can be fatal when inhaled never operate a machine without proper ventilation Fuel is highly flammable handle with care Keep engine clean Allow the engine to cool before storing and always remove the ignition key Disengage all drives and set park brake before starting the engine Never use your hands to search for oil leaks Hydraulic fluid under pressure can penetrate the skin and cause serious injury 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 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 Keep hands feet and clothi
19. 4 Be sure to double check boom heights nozzle spacing and displacement before spraying 15 Fill tank with water and retighten the four bolts used to hold the tank in place 16 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 DAILY CHECKLIST 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 Check hardware for loose or missing nuts bolts screws etc and tighten or replace as needed Inspect hydraulic lines for damage or leaks Never use hands to inspect leaks 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 40 API Service SJ or higher motor oil if necessary Fluid level should be 2 to 2 s 5 to 6 04cm from the top of tank when cold 9 Inspect steering throttle and shift linkages for good hookups and clear travel 10 Check anti vibration mounts on engine frame 11 Check controls for smooth
20. DE The DATA LOCK CODE may be cleared by entering a code of 0 or by removing Console power POMER DOWN DELAY TIME FEATURE If the console is not used for 10 days it will go into a power down low power mode of operation In this mode all data will be retained but the time of day clock will reset to 1 00 The delay time is initially set at 10 days but can be changed by the user 1 DISPLAYING DELAY TIME Depress for 5 seconds the current delay time in days will appear 2 CHANGING DELAY TIME TIME a Depress FOR 5 seconds the current delay time will appear b Enter new delay time 0 to 200 days using the same procedure as that for entering other data In the event of console power loss the power down delay time will default to 10 days CONSOLEALARM FEATURE Console alarm sounds if application rate is 30 or more away from target application rate for 5 seconds ALARM MENU BOOM 1 Depress for 5 seconds until DATA display shows A on Depressing momentarily key steps the DATA display between A on and AoFF A on means alarm is enabled AoFF means alarm is disabled DISPLAY MENU BOOM 1 Depress for 7 seconds until DATA display shows d on Depress momentarily key steps the DATA display between d on and doFF d on means RATE displays target rate when actual rate is within a per centage of target rate This percentage is determined by third digit of Valve CAL value as shown B
21. SMITHCO Wayne Pennsylvania 19087 OPERATOR S MANUAL SPRAY STAR 1600HD Model 1602HD April 2002 SMITHCO PRODUCT SUPPORT 1 800 891 9435 Hwy SS and Poplar Avenue Cameron WI 54822 E mail productsupport smithco com a Q dl d m PP 1 10 al oe 1 ei E VINDO IE e di 2 3 General Sate die 4 Safe Spraying Practices os ccna catccectmacepeceensscnctenctensseneneneste cuenastncencteeeemecenmuance 5 EIERE EE 6 Optional Spray Equipment ee 6 Eege 7 8 Controls amp Heer Ee 9 10 Operati n WE 11 23 Machine Operation elek 11 13 Console Feature S enecens etenen Rane eege 14 Console Programimihg seenen 15 e Console Calibration seent 15 16 Initial Programming NORRIS SRA SAP UR RR e kgtetEngke 17 21 Initial Console EE 21 a Console Field Test eege 22 Spray Op rati f sissa ae aa E A EEEE 22 23 lg ln Ne DC 24 30 E Spraying TMT CIC OI eer 24 lt BIR EE ps apr Rca q RR RR RR E ES 24 a Hose amp Handgun Spraying E 25 d NOZZICS iii 25 26 D Calibration JEE enger pro ora errre nenna N 27 a The Nozzle Chart Method of Calibration 28 29 The 128 Method of Boom Sprayer Calibration 29 30 Nozzle Chars iiitssusitsasssatsisnincnsassencnsasnttaxtunnadnihainstavinaandbeddeniaunshducwssaniasaana 31 36 S Nozzle Performance Chart 8 31 D Nozzle Ferenc 32 a Nozzle Performance Chart 3 EE 33 G Nozzle Performance Chart 84 AAA 34 Nozzle Performance Chart Z ss EeeteeEeeEEEENESEEEN EEUNNNENENEEEeEEN 35 Nozz
22. SPI or SP2 after being selected depress These selections will be alternately displayed SELF TEST FEATURE SELF TEST allows speed simulation for testing the system while the vehicle is not moving Enter the simulated SELF operating speed in the key labeled If 6 MPH 10 km h is desired enter 6 0 10 0 Verify speed by de pressing key labeled SPEED The SELF TEST speed will clear itself when motion of vehicle is detected by the Speed Sensor A SPEED CAL Value of 900 230 or greater is recommended when operating in this mode SEQUENCE TOACTIVATEDATA LOOK 1 Depress for 5 seconds NEW CODE message will appear 2 Enter 4 digit code within 15 seconds BOOM 1 TIME RATE 2 METER EXAMPLE For 1085 depress 2 Sg eee and fe 1 0 8 5 SEQUENCE TOCHANCE DATA LOCK 1 Depress for 5 seconds OLD CODE message will appear 2 Enter 4 digit OLD CODE within 15 seconds Co Ga Ea Em E EXAMPLE depress 1 0 8 5 and NEW CODE message will appear Enter 4 digit code within 15 seconds BOOM 1 BOOM 2 RATE2 METER EXAMPLE For 1285 depress F gt 2 S and fae M SIN IN TIAL PROGRAVIMINGOF CO BQLECOMIPUTER CONTINUED ENTER MODESEQUENCEWITHACTI VATED DATA LOCK 1 Depress the key into which you wish to enter data 2 Depress CODE message will appear Enter your DATA LOCK CODE If code is correct E will appear Now enter data normally mm The DATA LOCK feature prohibits the entry of data without first entering the DATA LOCK CO
23. Throttle Park Brake a H w G Electrical Power Engine Start Temperature Light Gasoline Glow Plug Off Hour Meter Choke Closed Park Brake Release BR E No Electrical Power Engine Run Water Temperature Diesel Glow Plug Fuse Choke Open Hydraulic Oil Level SYMBAS Up Down Arrow No Smoking Pinch Point Hydraulic Fluid Penetration Engage Ground Speed High Reverse id Down Lower SE Moving Parts D Cf Arm Ip Disengage Fast Low Neutral Pnpgagk ye Up Raise Manual Operation Hot Surface Tractor PTO Slow Forward Warning Danger Caution GENERAL SAFEPRACTICES 10 11 12 13 14 15 16 17 18 19 20 21 It is your responsibility to read this manual and all publications associated with this machine 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 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 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 Inspect the area
24. aged nozzles Serious misapplications may result Check nozzle output periodically Modern nozzles use spring and diaphragm check valves to insure positive cutoff of chemicals without drip Snap on caps make replacing and cleaning nozzles quick easy and fool proof with proper reinstallation An operator can see at a glance if all nozzles are the same size by the color code 3 FUNCTIONS FORASPRAY BOOM NOZZLE 1 Regulating the flow is done through size of the orifice opening within the nozzle All nozzles regardless of type have some point within them that regulates the flow of liquid Obviously the larger the opening the greater the rate of flow volume Volume is expressed in Gallons Per Minute gpm or Liters Per Minute lpm Do not confuse the term volume with application rate which will be covered later As pressure increases the flow volume in a given nozzle also increases For example an average size nozzle which discharges 0 52 gpm 1 4 Ipm 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 Some nozzles deliver a small volume for example 0 2 gpm 0 75 Ipm Some nozzles deliver a rela tively large volume for example 1 5 gpm 5 7 lpm or dit times as much as the smaller nozzle in this example The amount of material volume to be applied is determined by the effect the chemical has on the turf 2 The nozzle on a
25. aking care to position o ring or gasket properly Hand tighten 6 Remove and clean Flow Meter turbine and inlet hub Clean off all metal filings and wettable powders which have hardened on the plastic and metal parts Check the inlet hub and turbine assembly for worn or damaged turbine blades and bearings Flush Flow Meter with clear water and drain MANUAL HOSE REEL Located at the back of the Spray Star behind the tank Open the ball valve located on the left side of the mani fold ball valve 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 allow you to pull out additional hose or to use the handle and wind up the hose To prevent movement during transport or storage place the lockout pin in the locked position HECTRI C HOSEREEL Located at the back of the Spray Star behind the tank Open the ball valve located on the left side of the mani fold ball valve 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 M SEN SPRAYINGINTRODUCTION This section is intended to offer practical guidelines for the distribution of liquid chemicals over an area of turf grass such as golf courses park land school groun
26. al to 340 square feet which is equal to 1 128 acre Therefore the amount of material applied to this area by one nozzle in OUNCES is the same amount of material applied to an acre in GALLONS gpa On nozzles with 10 inch 25 cm spacing the measure distance is 408 feet 124 meters e On nozzles with 30 inch 76 cm spacing the measured distance is 136 feet 41 meters CALIBRATINGFOR APPLICATION 1 Fill the sprayer tank with water Run the sprayer inspect it for leaks and make sure all systems function properly Drive the sprayer through the measured distance discussed above at normal spraying speed record the travel time required to cover the measured distance in seconds with a stopwatch hus VEX VA IFE GG METHODCF BOOVISPRAYER CALIBRATION The carrying or towing vehicle is to be traveling at the desired speed when it crosses the start line of the measured course Repeat this procedure and determine the average of the two times 3 With the sprayer parked run the sprayer at the required pressure level Catch the output of each nozzle in a container which is marked or graduated in Ounces for the exact same period of time which it took the sprayer to cover the measured course in step 2 It is necessary to operate the vehicle engine at spraying speed using a hand throttle 4 Observe the volume of water in the collection bottle The number of OUNCES collected in the time it takes to cover the marked course Take the
27. average nozzle output by adding the outputs of each nozzle and then dividing that sum by the number of nozzles The NUMBER OF OUNCES collected in the time required to cover the SMALL AREA is equal to the NUMBER OF GALLONS applied per ACRE For example if an average of 40 ounces of water is collected in the time required to cover the 1 128 acre area the application rate is 40 gallons per acre gpa As a practical matter if high application rates are desired above 75 gpa the measured course length should be reduced by half i e 102 ft 31 m for 20 inch 52 cm spaced nozzles The volume collected above is then doubled multiplied by 2 AVERAGE OUTPUT Ounces APPLICATION RATE gpa 5 Observe individual nozzle output volumes If an individual nozzle is 10 above or below the average output check for blockages in the nozzle or in the nozzle strainer If the nozzle is worn or damaged replace it 6 Compare this actual application rate with the recommended rate If the actual rate is more than 5 higher or lower than the intended rate adjustments must be made 7 Minor adjustments in application rate may be made by increasing or decreasing the spraying pressure Lowering spraying pressure decreases application rate Increasing spraying pressure increases applica tion rate This procedure normally does not apply to spray systems controlled by an Electronic Spray Control System which governs flow rate 8 Adjustments in application
28. b G Located behind the seat on the right side on top of the foamer Use this knob to adjust pressure of the foam that will be dispensed ELECTRONIC SPRAY CONTROLSYSTEM Pressure must be set with sprayer in operation booms on Increase pres sure by pushing the pressure adjustment handle upwards Once the console reaches maximum pressure the motorized control valve in the sprayer then begins to open and pressure begins to decrease Push switch in either direc tion until desired pressure is reached The system provides operation of one two or three booms and it controls sprayer pressure indicated by a wet pres sure gauge on the vehicle The pressure gauge reads the pressure in psi The control system is operated by the 12 volt electrical system of the vehicle The master switch controls all boom switches Boom switch 1 controls left boom boom switch 2 controls center boom and boom switch 3 controls right boom Pressure switch increases or decreases spraying pressure through the motorized control valve As gt 10 S4 CPERATINGINSTRUCTIONS Before operating the Spray Star 1600H become familiar with all controls and functions Also complete all main tenance requirements and read all safety warnings Knowing the Spray Star 1600H thoroughly how it operates and by doing the prescribed maintenance steps you can expect trouble free operation for years to come SAFETY Safety needs to always be the concern of an operator of a
29. cation 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 not greatly affect performance Pressure is established and maintained by a pressure control valve or by a flow control valve located on the sprayer NOZZLECAPAQTY VOLUME We have covered the different types of spray patterns of various nozzles and made our selection of type ac cordingly 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 TRAVE SPHD Increased travel speed decreases the application rate gpa gpt or Iph Travel speed must be safe and appro priate for the area to be sprayed Unlike pressure changes which have only a minor effect on application rate ground speed changes have a more major and direct effect For example 50 decrease in ground speed means a 100 increase in applica tion rate If the vehicle does not have an accurate speedometer correct speed must be determined by timing the sprayer travel over a measured distance Refer to the page in this manual titled Abbreviations and Con versions To calibrate a sprayer the user must Understand the Variables Set those variables using one of the proven methods available Make a trial run and measure the output use water not chemical Pole IN eS Det
30. ces liters for gallons square meters for square feet and hectares for acres AVERAGE OUTPUT Milliliters APPLICATION RATE LITERS HECTARE MA Ze 30 Nozzle Type XR TeeJet amp DG TeeJet Spacing 20 inch 51cm Calibration US Gal Acre GPA amp US Gal 1 000 Square Feet GPT Application Rate GPA Application Rate GPT Pressure Capacity Speed MPH Speed MPH Color Green XR80015 DG80015 Yellow APRO DG8002 Blue XR8003 DG8003 XR8004 DG8004 Brown ARBUUS DG8005 a White XR8008 1 RES 128 74 0 59 0 50 0 3 40 2 30 1 70 1 40 M NOM EPERFORMANCECHART 2 Nozzle Type Spacing 20 inch 51cm Calibration Liters Per hectare Pressure Capacity Color bar i Se XR80015 Green 5gg0015 E D XR8002 DG8002 XR8004 DG8004 Ei E EI 50 395 1185 345 720 e XR8005 DG8005 XR8006 XR8008 XR TeeJet amp DG TeeJet 117 135 126 144 177 204 168 195 93 6 108 101 115 142 163 134 156 190 218 72 0 82 3 101 117 96 0 111 135 156 84 0 96 0 118 136 112 130 158 182 273 249 199 166 142 288 230 192 165 354 283 236 202 408 326 272 233 336 269 224 387 310 258 Ss e ay 192 221 NOQZZLEPERFORMANCECFART 3 Nozzle Type Turbo FloodJet Spacing 40 inch 100cm Calibration US Gal Acre GPA amp US Gal 1 000 Square Feet GPT a Pree Capacity ET MPH Speed MPH Color psi Gal Min 4 Ma om wee e feelers fer O 0 35 13 0
31. ds 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 spray vehicles or sprayers mounted onto vehicles Boom Spraying is the most effective accurate and efficient method of applying chemicals to large turf areas It may be done by means of e A dedicated spray vehicle e A sprayer mounted upon a utility vehicle Sprayers are typically equipped with wide spray booms Generally these booms are 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 each spray swath Foam markers and dye markers are advisable VA Turf management chemicals are made for four general purposes 1 Fungicides Prevent or cure fungus on turf grass They are made in 2 general types e Systemic Chemicals enter the plant system and protect or cure it of fungus e Contact Kills fungus with which it comes into contact 2 Insecticides Eliminate damaging insects and worms such as grubs beetles ants etc 3 Herbicides Control and eliminate undesirable weeds and grass from turf areas and non turf areas such as bunkers trails fences etc 4 Nutrients
32. e SJ or higher motor oil OPTIONAL SPRAY EQUIPMENT 33 216 14 315 14 319 15 571 15 572 15 573 16 856 16 129 16 906 4 je Battery 24F 12 Volt Fresh Water Wash Tank Hose Reel Mounting Frame 15 Tri Section Electric Lift Star Shield Boom 15 Dual Section Electric Lift Star Shield Boom 15 Manual Lift Star Shield Boom Tank Rinsing System Hose Reel 200 61 m capacity to be used with 14 319 Hose Reel 12 volt electric rewind 200 61 m capacity to be used with 14 319 14 100 Super Boom 20 6 meter Long 10 300 18 Terrain Following Boom 15 493 Auto Boom 18 5 5 m Long 15 577 18 Manual Lift Boom 14 481 440 Spray System 1602HD 14 483 203 Spray System 1604HD 14 312 Speedometer Kit 14 283 Foam Marker System Dealer Installed 14 285 Foam Marker System Factory Installed SETUP The Model 1600H Prime Mover arrives from SMITHGO 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 1600H Prime Mover If a spray system is to be retrofitted to a 1600H Prime Mover by a dealer or owner assemble and attach the components in accordance with the parts drawings in the Spray Star 1600H 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 CAUTION 2 Lift front end using a hydraulic jack taking care that th
33. e 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 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 Ref A 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 fir
34. e the system Function Keys Bottom Row Used to display data BOOM 1 CAL Length of Boom 1 TOTAL AREA Total Area Sprayed BOOM 2 CAL Length of Boom 2 FIELD AREA Field Area Sprayed BOOM 3 CAL Length of Boom 3 FIELD VOLUME Volume Applied to Field SPEED CAL Measured Off Drive Line 114 DISTANCE Distance Traveled METER CAL Flow Meter Calibration Number SPEED Speed of Vehicle VALVE CAL Control Valve Response Time VOLUME TANK Volume Remaining in Carrier Tank RATE1CAL Target Application Rate TIME 24 hour clock military time RATE 2 CAL Target Application Rate TIP MONITOR Use to Display Tip Faults SELF TEST Simulates Vehicle Speed Z Jir CO BOLEPROGRAMMING When entering data into the Console computer the entry sequence is always the same Data must be entered into the first eight keys FLOW CONTROL BOOM BOOM2 BOOM3 MASTER INC DEC FLOW CONTROL BOOM 1 BOOM2 BOOM3 MASTER RATE 1 INC RAED e 8 9 8 MAN DEC rove Tw Di BOOM1 BOOM2 BOOM3 SPEED METER VALVE nei RATE2 VOL ype SELF CAL o CAL CAL CAL CAL CAL CAL TANK TEST ssa a ssa TOTAL TOTAL FIELD FIELD o VOL AREA TP CE AREA VOLUME AREA VOLUME D ED MN HOUR Montor ENTER BOOM BOOM2 BOOM3 SPEED METER VALVE RATEI RATE2 VOL ye SELF CAL CAL CAL CAL CAL CAL CAL o TANK TEST TOTAL TOTAL FIELD een VOL AREA TP CE AREA VOLUME AREA volume DSTANCE SPEED my Hour Motor ENTER L J 1 Depress the key which you wish to enter data 2 Depress the
35. eed is 6 MPH Use the application rate column for 3 MPH a divide by 2 Converting Nozzle Chart Method to British Gallons To convert any of the Gallon Per Acre rates to Imperial Gallons per acre Imp gpa multiply by 0 83 To convert any of the Liter Per Hectare rates to Imperial Gallons Per Hectare Imp GPH multiply by 0 22 Checking the Actual Application Rate After the combination of ground speed nozzle size and operating pressure has been selected the sprayer should be operated with water only to determine if the target application rate is achieved IFE 28 METHODOF BOOM SPRAYER CALIBRATION The 128 Method is useful for calibrating sprayers and also for checking the calibration of sprayer calibrated by the Nozzle Chart Method and sprayers using Electronic Spray Control Systems The 128 is based on a convenient mathematical relationship that exists between US Gallons liquid ounces and acres An ounce is 1 128th of a US gallon If an area which was 1 128th of an acre could be found the number of ounces applied to that small area would be equal to the number of gallons applied to the acre Thus no math ematical computations would be required To determine an area which is 1 128 of an acre e On nozzles with 20 inch 51 cm spacing measure off a distance of 204 ft 62 meters Mark a START and a STOP line The rectangle formed by this distance and the spraying width of one nozzle 20 51 cm is equ
36. ents of the Directive 89 392 EEC if applicable and to the requirements of the other Directives EN292 1 339 93 EEC EN292 2 91 368 EEC EN294 2000 14 EC EN349 98 37 Title and or number and date of issue of the other Directives if applicable For the relevant implementation of the safety and health requirements mentioned in the Directives the following standard s and or technical specification s has have been respected ISO 37 1983 PREN 836 ISO 1219 1976 SAE HS 2800 SAE J1362 Title and or number and date of issue of standard s and or technical specification s Cameron Wisconsin USA March 19 1995 Place and date of issue GE of the authorized person LIMITED WARRANTY SMITHCO warrants this product to be free from defects in material and workmanship under normal use for one year from the date of purchase by the original user 60 days if product is used for rental purposes All warranty claims must be handled through a SMITHCO authorized dealer or by SMITHCO INC All transportation charges must be paid by the purchaser There is no further express warranty All implied warranties including those of merchantability and fitness for a particular purpose are limited to one year 60 days if product is used for rental pur poses from the date of purchase by the original user and to the extent permitted by law any and all implied warranties are excluded and disclaimed after the expiration of such period
37. er treated and chemicals are ineffective Some areas are overtreated with wasted chemical and possible turf damage Operating your sprayer at a desired speed and pressure on a hard dry surface is a good method of checking spraying consistency Observe nozzles in operation observe if the area dries evenly 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 Ml CALIBRATIONINTRODUCTION Calibrating simply means to adjust a set of variables on the sprayer in order to deliver the desired amount of chemical to a known area of turf The job of calibrating the sprayer consists of balancing these variables so that your sprayer 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 pb 1 US gpa 9 35 Iph Anumber of acceptable methods for calibrating a turf sprayer are widely available The calibration method chosen must take these variables into account They must include known ground speed by measurement or from an accurate speedometer and nozzle output gpm or Ipm from a nozzle chart or from actual measure ment The variables are PRESSURE Just as pressure increases the volume discharge rate it also increases the appli
38. ermine the output 5 Make adjustments to the 3 variables until the output is at the desired level This covers the principles of 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 compe tence of the operator SH SIN IFEN EZE HOT METHODO CALIBRATION The Nozzle Chart Method is useful when the sprayer nozzles are new or nearly new It is also the most useful method to employ when the sprayer is equipped with an Electronic Spray Control System The Electronic Spray Control System does most of the calibration work it is up to the operator to select the proper combination of nozzle size and ground speed which will deliver the desired application rate The nozzle chart method requires the use of the appropriate nozzle charts which are found in the back of this manual Nozzle Charts 1 through 8 Nozzle charts for other nozzles are available from the manufacturer CAUBRATIONSTEPS 1 Determine HOW your sprayer is to be calibrated from the list of variables below a Nozzle Type Teejet Turbo Turf Turbo Flood b Spacing 10 25 cm or 20 51 cm or 30 76 cm c Expression of Application Rate gpa or gpt or Iph The answers to these three questions will direct you to the appropriate nozzle chart for your application The correct nozzle chart MUST be used
39. finitions below Valve Backlash ee Valve N Digit Brake Point Digit Deadband Digit Valve Backlash Controls the time of the first correction pulse after a change in correction direction is detected Incr to Decr or Decr to Incr Range 1 to 9 1 Short Pulse 9 Long Pulse Valve Speed Digit Controls the Speed of the Control Valve motor Running the Control Valve too fast will cause the system to oscillate cauTion Range 1 to 9 1 slow 9 Fast Brake Point Digit Percent Sets the point at which the Control Valve motor begins braking so as not to over shoot the desired rate Digit is percent away from target rate Range 0 to 9 0 5 1 10 9 90 Deadband Digit Allowable difference between target and actual application rate where rate correction is not performed Range 1 to 9 1 1 9 9 CALCULATING RATE 1ANDRATE2 CAL See Spraying Procedure section Determine the application rate at which your chemical should be sprayed Consult with your Dealer to insure your spray nozzles are capable of applying at this target rate Using CAPACITY 35 GPM 1 67 lit min and pressure 30 PSI 20 bar you would select tip number XR8004 from the Nozzle Charts Section since it comes closest to providing the desired output VERIFYINGFLOWRATELMITS The flow rate of the sprayer must be within the range of 1 to 55 GPM 4 to 210 lit min INTIAL PROGRAMMING OF CO NSQLE COMPUTER When you first turn on Console power after all installation proced
40. gh gear Tilt Steering Hold lever down and adjust steering wheel to desired position Low Speed Light When green light is on it indicates machine is in low gear Accelerator Pedal Located on the right side of floor board This pedal controls ground speed Press pedal to increase engine RPM varying the amount of movement of the pedal will vary the ground speed Reverse Pedal Located on the outside right floorboard This pedal controls ground speed in the reverse direction Master Boom Switch The master boom switch is 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 844 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 Speed Switch Come to a complete stop press to change gears Lights on dashboard indicate which gear the machine is running in When accelerator pedal and reverse pedal are released the hydrostatic transmission centers and stops the vehicle with a braking action E CONTROLS amp INSTRUMENTS CONTINUED CONTROLPANEL Located on right side of seat The following are located on or near the control panel A Choke The choke is used in starting the engine Pull choke out to close choke plate when starting cold engine push in when e
41. k brake turn key off and remove key CAUTION p p engage p y y It is recommended that you run the machine at idle speed for 5 10 minutes prior to operating This allows the oil to warm up which allows easier steering SH ZA OPERATINGINSTRUCTIONS CONTINUED Before using the Spray Star the operator or spray technician must familiarize themselves with all of the infor mation on chemical spraying contained in Spraying Procedure of this manual NOTE All testing and calibration 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 proce dures are completed should chemical be added to the sprayer GROUNDSPEEDCONTROL 1 Select the gear to be used 2 Place the Ground Speed Control lever to fast 3 Push the foot accelerator fully to the floor 4 While the foot accelerator is fully depressed begin moving the Ground Speed Control lever towards slow until the correct operating speed is attained The desired speed will be maintained as long as the foot accelerator is fully depressed 6 Vehicle will return to the established ground speed whenever the foot accelerator is fully depressed unless the Ground Speed Control lever has been moved to a different setting 7 To operate the Spray Star at higher speed for transport the Ground Speed Control lever should be returned to the fast position HANDTHROTTLECONTROLLEVER Park brake m
42. le Performance Chart 6 0 cs0 ccc ccnnncecasteaseseeccnceensnnndsccnasenecemncemeseencens 36 Referente misrin a aa aaa aaa aia a aaa a 37 38 Abbreviations and Conversions ara 37 a Declaration Of Conformity rien 38 a Limited Warranty E Inside Back Cover INTRODUCTION Thank you for purchasing a SMITHGO 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 SMITHGO 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 S WAYNE PENNSYLVANIA 19087 USA 610 688 4009 Fax 610 688 6069 o YEAR OF MFG O SERIAL NO kWihp MODEL NO kg lb 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 Read Operator s Manual Engine Stop Engine Oil RPM Glow Plug On Hour Meter Hand
43. mount of agi tation 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 M SN This Console PGM F requires selection of US acres SI hectares or TU 1 000 sq ft area and SP1 wheel drive etc A POWER Turns Console power OFF or ON Turning Console OFF does not affect the data stored in the computer Select manual or fully automatic control This can automatically control two rates Manual override control provides capability for spot spraying Booms can be controlled individually or all at once with MASTER ON OFF Switch Displays operating rate of application and flashing Tip Fault Displays function and calibration data mm DO D CE Use like you do CE clear entry key on a calculator This key is also used to select an area base measurement of US acres SI Hectares or TU 1 000 sq ft H ENTER Used only to enter the data into the Console FLOW CONTROL 0 0 PA 00 E d RATE 1 INC _ ON RATE 2 f o MAN DEC L OFF BOOM1 BOOM2 BOOM3 SPEED METER VALVE RATE1 RATE2 VOL CAL CAL CAL CAL CAL CAL CAL CAL TANK 1 Wm wm ww e ew CE TOTAL TOTAL RATE DATA 6 0 0 fe FIELD FIELD AREA AREA VOLUME DISTANCE SPEED VOL TIP MIN HOUR MONITOR AREA VOLUME Calibration Keys Top Row Used to enter data into console to calibrat
44. mp clean for the next use VA hs Es 22 SPRAY OPERATION CONTINUED TOPREVENT CORROSION After cleaning the pump as directed 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 SPRAYER CLEAN NG Empty tank and clean unit thoroughly after each use following these instructions 1 Remove coupling and rinse inside of tank thoroughly with clean 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 Remove drain coupling again and rinse tank interior thoroughly Rinse exterior of sprayer thoroughly with clean water Remove bowl from sprayer filter on operators right hand side of the spray tank Remove stainless steel screen Wash bowl and screen thoroughly Apply thin layer of petroleum jelly to O ring or gasket Replace screen and bowl t
45. ng away from moving parts Wait for all movement to stop before you clean adjust or service the machine Keep the area of operation clear of all bystanders Never carry passengers Stop engine before making repairs adjustments or checking adding oil to the crankcase Use parts and materials supplied by SMITHGO only Do not modify any function or part Use caution when booms are down as they extend out beyond the center line of the machine approxi mately 10 ft 3 m 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 4 expressed or implied ig lt SAFESPRAYINGPRACTICES Persons engaged in the handling preparation or application of chemicals must follow accepted practices to insure the safety of themselves and others 1 11 12 13 14 15 16 17 18 WEAR protective clothing including gloves hat respirator eye protection and skin covering suitable for protection from chemicals being used BATHE thoroughly after any exposure to chemicals giving particular attention to eyes nose ears and mouth CLEAN equipment and materials in accordance with employer municipal and state regulations Use only approved areas and drains DISPOSE of chemicals and rinse solutions by approved and legal means
46. ngine starts Awarm engine may not require choking to start B Hand Throttle This hand throttle is used for hose handgun spraying boom spraying and sprayer calibration It controls engine RPM forward for fast opposite direction for slow Not to be used when in motion C 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 increases speed and clockwise decreases speed Disengage the lever and you will have full accelerator pedal range D Right and Left Boom Switches These toggle switches are used to raise and lower the right and left electric actuated booms E Boom Levers Hydraulic Lift Kit F Park Brake Push to the front and down to set park brake and pull back to release Some adjustments can be made to park brake by turning knob on the of the lever To tighten turn knob clockwise To loosen turn counter clockwise FOAM MARKER CONTROLS Foamer ON OFF Switch Located to the right of the control panel Used to turn on and off the foam marker Also used to designate which boom is to be used to dispense foam With lever pointing toward the seat foam will dispense from right boom and with lever pointing forward foam will dispense from the left boom Foamer Adjustment Kno
47. ough the fillwell strainer using the air gap filler This will wash any undissolved chemical into the tank Transport to sprayer site with and agitator operating Set Engine speed between 2000 3600 RPM Optional Engage ground speed control Obtain desired spraying speed before activating spray with switches on spray control console In some extreme situations it may be necessary to decrease or completely close the flow of material to the agita tor system in order to maintain desired pressure If agitation is absolutely essential a change may have to be made in some combination of ground speed nozzle size or system pressure to maintain the necessary application rate Review the capacity of nozzles being used Total capacity of all nozzles plus agitation system must not exceed pumping system capabilities refer to Soraying Procedure section of this CAUTION manual FLUSH PUMP AFTER USE Pump Pressure Engine Shaft GPM at GPM at GPM at GPM at Max RPM RPM 20psi 30psi 40psi 60psi HP 2300 3200 70 55 5 1 4 2750 3800 75 71 60 10 1 8 3200 4400 80 78 72 60 3 0 Pump RPM Engine RPM x 1 38 One of the most common causes for faulty pump performance is corrosion inside the pump Flush pump and entire system with a solution that will chemically neutralize the liquid pumped Mix according to the manufacturer s directions This will dissolve most residue remaining in the pump leaving the inside of the pu
48. plied pesticides They are spaced either 10 25 m or 20 51 cm apart and overlap one another by about t s The second type useful in turf management are broadcast type nozzles They are commonly referred to as raindrop or floodjet nozzles They spray a hollow cone shaped pattern of much larger droplets which fall quickly to the turf under their own weight They are best for systemic pesticides or any material requiring a large volume of water for soil application The larger droplets are not as subject to drift from wind and are a safer more environmentally friendly choice in many situations BIL HOSE amp HANDGUN SPRAYING A handgun hand nozzle or hand lance is used to control and direct the spray pattern to the ground shrub or tree They must be constructed of long lasting and noncorrosive materials such as brass stainless or alumi num 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 2 1 25 cm inside diameter hose is adequate Trees over 40 ft 12 m high require 3 4 2 cm inside diameter hose and a sprayer pump capable of delivering a volume of at least 20 gpm 75 lpm and a pressure of at least 400 psi 28 bar Always be alert to the possibility of a plugged or dam
49. proper working operation Lubricate as needed SEAT AD USTMENT Adjustment lever is located under the front of the seat on the right side It allows the seat to be adjusted forward or back wards for the operator s comfort For further adjustment unbolt seat from seat panel move to other set of holes and re bolt STEERING Hydraulic steering Before operating acquaint yourself with the steering Avoid sharp turns at high speeds on slopes or unsafe terrain WARNING zs tonn o r Oil Light The oil light should come on when the ignition is on without the engine running and should go out when the engine is running The oil light will light when the oil pressure is low If it does come on shut off the engine and find the cause immediately Circuit Breaker The circuit breaker is a resetable fuse To reset push down Hour Volt Meter The hour meter indicates the hours of machine operation The hour meter operates when the ignition switch is on The volt meter indicates battery voltage When starting the battery voltage should not drop below 9 volts With key on engine running the voltage should be 12 volts With engine running at 3600 rpm the voltage should read about 14 volts Speedometer optional The speedometer indicates ground speed of vehicle in miles per hour and kilometer per hour Ignition Switch The ignition switch has three positions Off Run Start High Speed Light When green light is on it indicates machine is in hi
50. r to properly develop their spray pattern each nozzle must be the proper distance from the next nozzle spacing and the proper height above the ground NOZZLESCREBNS STRAINERS Smaller nozzles require nozzle screens or strainers to prevent clogging Teejet type nozzles size 8001 and 80015 require 100 mesh screens e Teejet type nozzles from size 8002 through 8008 require 50 mesh screens Turbo TurfJet Nozzles Size 1 4 TTJ02 VS and larger do not require strainers Turbo Floodjet Nozzles TF VS2 through TF VS3 require 50 mesh screens Turbo Floodjet Nozzles TF VS4 and larger do not require screens 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 spaced every 10 25 cm BOOM A GHT 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 HEIGHT ABOVE TYPE SPACING THE GROUND 80 Flat Fan 20 51 cm 18 45 cm 65 Flat Fan 20 51 cm Turbo TurfJet 20 51 cm Turbo TurfJet 40 101 cm Turbo Floodjet 20 51 cm Turbo Floodjet 40 100 cm Improper nozzle height or spacing prevents proper application of chemical Some areas are und
51. rake point digit 8rd digit of Valve CAL2 123 O 1 Deadband 4 20 Deadband 8 40 Deadband 1 3 Deadband 5 25 Deadband 9 45 Deadband 2 7 Deadband 6 30 Deadband 3 10 Deadband 7 35 Deadband Actual rate is displayed if unit does not reach deadband with in 10 seconds doFF means RATE displays ac tual rate at all times M S Y INTIAL PROGRAVIMINGOF CO BQLECOMIPUTER CONTINUED LOW LIMIT FLOW SET PA NT ANDLOW LIMIT ALARM VOL Depress until DATA display flashes A low limit flow rate may now be entered If actual volume Per minute falls below this limit the Control Valve stops closing the Alarm sounds and the rate display flashes LL The low limit value should be determined with all Booms on This value is automatically proportional to the percentage of Booms that are on i e If the entered low limit is 4 CAL MIN and half the Total Boom length is shut off the Console automatically reduces the low limit to 2 GAL MIN CONTROLVALVEDELAY SPEED Depress until DATA display flashes The first digit XOOO is the Control Valve delay digit This feature allows the user to set a delay between the time the Booms are turned on and when the Console begins to con trol the flow rate A value of 1 9 means a delay of 1 9 seconds test respectively A value of O means no delay This delay is active if the time between turning off and turning on the Booms is less than 30 seconds
52. rol Systems such as those manufactured by Raven Ind Micro Trak Co and Dickey John Co it is still important to select the right type and size of nozzle for the required operation Electronic Spray Control Systems cannot function properly if the nozzles are not capable of delivering the programmed desired application rate Nozzles which are too large will not develop adequate pressure or satisfactory spray patterns Nozzles which are too small will not allow the discharge of spray material at the programmed application rate Further when calibrating sprayers which are equipped with Electronic Spray Control Systems care must be taken to use the mode of operation on the Spray Control System Gallons per acre US Mode Gallons per 1 000 Square Feet Turf Mode or Liters per Hectare Standard International Model which corresponds with the nozzle calibration charts gpa gpt or Iph Using the Nozzle Charts Select the correct chart based on your nozzle type nozzle spacing and desired expression of application rate gpa gpt or Iph If the desired operating speed is not found on the nozzle chart it is simple to determine application rate at different speeds by estimating from the known facts Example 1 If the desired speed is 2 2 MPH 4 kph on a sprayer using TurfJet nozzles Chart 5 The average between the application rates for 2 MPH and 3 MPH may be assumed to be the application rate for 2 2 MPH Example 2 The desired sp
53. rs 1 US Gallon x 0 83267 Imperial Gallons 1 US Gallon x 8 34 Pounds Water 1 Gallon Per Acre 2 9 Fluid Ounces per 1 000 Square Feet 9 35 Liters Per Hectare 1 Gallon Per 1 000 Square Feet 43 56 Gallons Per Acre 1 Gallon 128 Fluid Ounces 8 Pints 4 Quarts 3 79 Liters 0 83 Imperial Gallons 5940 x GPM per nozzle gpa MPH x Nozzle Spacing Width inches MPH x Nozzle Spacing Width inches 136 x GPM per nozzle GAL 1 000 Square Feet MPH x Nozzle Spacing Width inches LENGTH DISTANCE AREA 1 millimeter mm 0 039 inch 1 square meter 10 764 sq feet 1 centimeter cm 0 393 inch 1 hectare ha 2 471 acres 10 000 sq meters 1 meter m 3 281 feet 1 acre 0 405 hectare 43 560 Square Feet 1 kilometer km 0 621 mile 1 sq mile 640 acres 258 9 hectares 1 inch 25 4 millimeters 2 54 centimeters 1 mile 5280 Feet 1610 Meters 1 609 Kilometers PRESSURE 1 Pound Per Square Inch 0 069 Bar M SIN S EC Declaration of Conformity according to Directive 89 392 EEC We SMITHCO INC Name of supplier 34 West Ave Wayne PA 19087 USA Full address of the manufacture authorized representative established in the Community must also give the business name and address of the manufacture declare under our sole responsibility that the product Spray Star 1600HD 14 310 B Make Model to which this declaration relates corresponds to the relevant basic safety and health requirem
54. s or highway markers 5 Itshould read a value of approximately 5280 If it reads between 5200 5350 the Speed Cal for this vehicle is 612 If the Distance display reads any other value divide Speed Cal by the value observed in Distance then multiply by 5280 This will give you the correct value to enter for Soeed Cal You must round off to the nearest 3 digit number use 120 not 120 3 T sic 715 CO SQLE CALIBRATION CONTINUED 6 Recheck the new Speed Cal numbers Zero out Distance display as in step 3 Enter the new Speed Cal number as in step 1 Repeat steps 4 and 5 MEASURE CAREFULLY Be sure tire is properly inflated before measuring Measure tire in type of soil in which you will be spraying Circumference of tire will vary when measured in soft soil versus hard packed soil For best results measure several times and average the results Re measure periodically CALCULATING METER CAL The Flow Meter calibration number is stamped on the label attached to each Flow Meter this number is to be used for gallon per area applications To convert original METER CAL from gallons to desired units of measure oz lbs or liters per area see Abbreviations and Conversions section of this manual Write down this calibra tion number for future reference when programming the console CALCULATING VALVECAL The initial Control Valve calibration number is 2123 After operating the system you may desire to refine this number See de
55. st 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 40 API 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 DANGER NOT SMOKE while filling the fuel tank DO NOT OVERFILL 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 oil tank is on the right side Fluid level should be 2 to 21 2 5 to 6 04cm from the top of tank when cold 12 Machine should be greased before starting refer to Spray Star 1600H Parts Service Manual for location 13 Attach the Spray Boom and any other Optional Equipment to the Prime Mover in accordance with instructions in the Spray Star 1600HD 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 prop erly and the outer sections must break away safely if an object is struck by them they must then return to normal operation position 1
56. ures have been completed the Console will flash CAL in the RATE display and US in the DATA display This means you must calibrate or program the Console before it can be operated This is a one time operation which does not have to be repeated unless you disconnect your battery wires Turning OFF the POWER ON OFF switch does not affect the Console memory All data is retained The fol lowing steps must now be followed SELF H an entry selection error is made during steps 1 2 3 or 4 the Console can be reset by depressing Ss for 20 seconds Data displays US and RATE displays CAL 1 Displaying US Slor TU a Depressing momentarily Steps the DATA display from US acres to SI c Depressing momentarily Steps the DATA display from TU 1000 sq ft to US b Depressing momentarily Steps the DATA display from SI Hectares to TU 2 Selecting US SI or TU a To select US Sl or TU step until the desired code is displayed in DATA display b Momentarily depress the DATA display will now display SP1 3 Displaying SP1 or SP2 a Depressing momentarily steps the DATA display from SP1 wheel drives etc to SP2 b Depressing momentarily steps the DATA display from SP2 radar sensor to SP1 4 Selecting SP1 OR SP2 a To select SP1 or SP2 step with until desired code is displayed in DATA display b Momentarily depress the DATA display will now display 0 BOOM 1 5 Enter width in inches cm of
57. ust be set when engine throttle control is used a To increase the engine speed without holding your foot pedal down use the engine throttle control lever on the right hand control panel Push the lever forward until the desired rpm is attained This procedure will set the RPM allowing the operator to use the remote hose and handgun It will also permit the operator to check the operation of the spray boom by observing it from the rear of the vehicle To release throttle control pull back on the Lever allowing the engine to return to idle HLLSIDEOPERATION Do NOT stop or start suddenly on any slope Be especially cautious when changing direction Do NOT operate vehicle on slopes greater than 20 TOMNGUNT When it is necessary to move the Spray Star 1600H 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 md N OPERATINGINSTRUCTIONS CONTINUED SPRAYER VALVESETTINGS ANDSPRAY TANK AG TATION 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

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