OPERATOR’S MANUAL Spray Star 3000 Model 3007 January, 1999 SMITHCO PRODUCT SUPPORT 1-800-891-9435 Hwy SS and Poplar Avenue, Cameron WI 54822 E-mail: productsupport@smithco.
CONTENTS Introduction Operation Introduction.................................................................. 1-9 Introduction ................................................................. 1 Symbols ................................................................... 2-3 General Safe Practices ............................................... 4 Safe Spraying Practices ............................................. 5 Specifications ..............................................................
Thank you for purchasing a Introduction INTRODUCTION product. Read this manual and all other manuals pertaining to the Spray Star carefully as they have safety, operating, assembly and maintenance instructions. Failure to do so could result in personal injury or equipment damage. Keep manuals in a safe place after operator and maintenance personnel have read them. Right and left sides are from the operator’s seat, facing forward. All machines have a Serial Number and Model Number.
SYMBOLS Introduction 2 Read Operator’s Manual Electrical Power No Electrical Power Engine - Stop Engine - Start Engine - Run Engine Oil Temperature Light Water Temperature RPM Gasoline Diesel Glow Plug - On Glow Plug - Off Glow Plug Hour Meter Hour Meter Hand Throttle Choke - Closed Choke - Open Park Brake Park Brake Release Hydraulic Oil Level Fuse
H R Introduction SYMBOLS Up/Down Arrow Down/Lower Up/Raise No Smoking Moving Parts Manual Operation Pinch Point Step Hot Surface Hydraulic Fluid Penetration Lift Arm Tractor Engage Disengage PTO Ground Speed Fast Slow High Reverse L N Low Neutral F Forward Warning Danger Caution 3
GENERAL SAFE PRACTICES Introduction 1. It is your responsibility to read this manual and all publications associated with this machine. 2. Never allow anyone to operate or service the machine or its optional equipment without proper training and instructions. Never allow minors to operate any equipment. 3. Learn the proper use of the machine, the location and purpose of all the controls and gauges before you operate the equipment. Working with unfamiliar equipment can lead to accidents. 4.
Persons engaged in the handling, preparation or application of chemicals must follow accepted practices to insure the safety of themselves and others, 1. WEAR protective clothing including: gloves, hat, respirator, eye protection and skin covering suitable for protection from chemicals being used. 2. BATHE thoroughly after any exposure to chemicals, giving particular attention to eyes, nose, ears and mouth. 3. CLEAN equipment and materials in accordance with employer, municipal and state regulations.
SPECIFICATIONS Introduction WEIGHTS AND DIMENSIONS Length Width Width With Booms Open Height Wheel Base Weight Empty Weight Loaded 144" (366 cm) 72" (183 cm) 230" (584 cm) 53" (135 cm) 84" (213 cm) 2500 lbs (1134 kg) 5000 lbs (2268 kg) SOUND LEVEL At ear level At 3 ft. (0.914 m) At 30 ft. (9.14 m) At 23 ft. (7 m). pass by 85 dB 88 dB 73 dB 74 dB ENGINE Make Model# Type / Spec# Horsepower Fuel Cooling System Belt Tension Lubrication System Alternator WHEELS & TIRE Ford 1.
The Model 3000 Prime Mover arrives from setup and ready for service. The spray system is normally shipped attached to the 3000 Prime Mover. If a spray system is to be retrofitted to a 3000 Prime Mover by a dealer or owner, assemble and attach the components in accordance with the parts drawings in the Spray Star 3000 Parts/Service Manual. 1. Set park brake. 2. Check the tire pressure. The front tires are 20 PSI (1.4 bar) and the rear tires are 18 PSI (1.3 bar). 3.
CONTROLS & INSTRUMENTS Introduction INSTRUMENTS LOCATED ON THE DASHBOARD A. Hour Meter: Located in tachometer. The Hour Meter indicates the hours of machine operation. The Hour Meter operates when the ignition switch is on. B. Tachometer: Indicates engine RPM. C. Speedometer: The Speedometer indicates ground speed of vehicle in miles per hour. D. Speed Control: On top is the on/off switch. In the middle is the indicator light. Bottom is the set push button. E.
Introduction CONTROLS & INSTRUMENTS (continued) CONTROL PANEL Located on right side of seat. The following are located on the control panel. A. Hand Throttle: Located outside top corner. This hand throttle is used for hose/handgun spraying, spraying and sprayer calibration. It controls engine RPM, forward for fast, opposite direction for slow. 3200 RPM maximum sprayer output. This does NOT control speed of travel. B. Choke: Located at the bottom outside corner.
OPERATING INSTRUCTIONS Introduction Before operating your Spray Star 3000, become familiar with all controls and functions of the unit. Also complete all maintenance requirements and read all safety warnings. By knowing the Spray Star 3000 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 moving vehicle or any machine with moving parts. 1.
OPERATING INSTRUCTIONS (continued) Before using the Spray Star, the operator or spray technician must familiarize themselves with all of the information on chemical spraying contained in Spraying Procedure of this manual. GROUND SPEED CONTROL The ground speed control does not work the same as an automotive type cruise. This control sets the hydrostatic linkage. It does not contain a resume position. Whenever you push on the brake or turn the toggle switch off your control will disengage.
OPERATING INSTRUCTIONS (CONTINUED) SPRAYER VALVE SETTINGS AND SPRAY TANK AGITATION 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. Operation There are two manual flow control valves on the discharge side of the spray system. One controls the agitator.
Operation CONSOLE FEATURES A. Program Key - Used to access the programming mode. B. Auto/ Manual Key - Allows you to manually or automatically enter data. C. Master Boom Switch - Activates or stops boom spraying. D. Individual Boom Switches - Used to activate any up to 5 booms on the sprayer. E. LCD Display - In program mode, the default values are displayed. In operation mode, actual values are displayed. F.
PROGRAMMING GUIDELINES IMPORTANT PRELIMINARY INFORMATION Before you begin, we recommend that you review the following Programming Guidelines that control the programming process. 1. For your convenience, the programming of the 844 has been divided into two programming categories; System Setup Mode and Application Setup Mode. 2. Depressing the key once will flash “PRO“ in the upper left hand corner of the display window.
PROGRAMMING THE 844 SPRAYER CONTROL SYSTEM SYSTEM SETUP MODE The System Setup Mode contains the programming steps that customize the controller to the sprayer or sprayer components. These include calibration steps and parameters that, once programmed, will likely never change. To enter the System Setup Mode, press and hold the keys in, depress the keys simultaneously. While holding the key twice (within 3 seconds) to enter the System Setup Mode. Operation and and SETTING YOUR PROGRAM MODE (U.S.
PROGRAMMING THE 844 SPRAYER CONTROL SYSTEM (CONTINUED) NOZZLE SPACING Default = 20 1. While in the Nozzle Spacing step, the symbol will be flashing at the top of the console display. 2. Nozzle spacing should be recorded in inches. 3. If the default value is correct, depress the key to accept the value. 4. If the nozzle spacing is different than that shown as a default, then add or reduce this number by using Operation the or keys to record the new value.
PROGRAMMING THE 844 SPRAYER CONTROL SYSTEM (CONTINUED) USER PROGRAMMABLE TIP Default = 0.00 1. While in the User Programmable Tip step, the of the display. !symbol will be flashing above the P tab at the bottom 3. Use the ing the or key to adjust flow rate in Gallons Per Minute of a single spray tip at 40 psi. Depress- and keys simultaneously will clear the value to zero. To accept the value, depress the key to advance to the next programming step.
PROGRAMMING THE 844 SPRAYER CONTROL SYSTEM (CONTINUED) BOOM CONTROL VALVE TYPE Default = 2 Way 1. While the Boom Control Valve Type step, the symbol will be flashing at the top of the display. The programmable information (2 Way or 3 Way) will be displayed at the left in the console display. 2. This programming step is used to distinguish the type of on-off boom control valves you have on your system. There are two types of valves that can be used, 2-way control valves or 3-way control valves.
PROGRAMMING THE 844 SPRAYER CONTROL SYSTEM (CONTINUED) SPEED SENSOR TYPE Default = 250 Speed Calibration = 621 While in the Speed Calibration Programming Step, the symbol will be flashing at the top of the display. The programmable value (250) will be displayed in the lower right corner of the display. MAGNETIC PULSES The speed sensor needs to be calibrated in order to provide the proper speed and area readings. The value for this step is the number of pulses generated by the speed sensor in 300 feet.
PROGRAMMING THE 844 SPRAYER CONTROL SYSTEM (CONTINUED) RADAR SPEED PULSES Automatic Calibration: The automatic calibration of a Radar speed sensor is similar to the automatic calibration of a wheel speed sensor. Refer to the directions above. When the console has determined that a Radar Speed Sensor is being used, "RAD "will be displayed in the lower left of the console display.
PROGRAMMING THE 844 SPRAYER CONTROL SYSTEM (CONTINUED) APPLICATION SETUP MODE 1. The Application Setup Mode contains the programming steps that are most frequently changed (target application rate, and nozzles used). Spraying Systems Co. has added this separate setup mode to speed the programming process when minor changes are made in the spraying operation (i.e. changing fields, switching nozzles, changing crops, etc.). The operator can now avoid toggling through all of the programming steps unnecessarily.
PROGRAMMING THE 844 SPRAYER CONTROL SYSTEM (CONTINUED) NOZZLE SELECTION Default = Red or 0.40 GPM 1. While in the nozzle selection step, the display will remain the same as above except the !symbol will be flashing at the bottom of the display just above a color coded strip. The tabbed color strip along the bottom of the display represents color coding for TeeJet VisiFlo spray tips. Operation 2. Select the representative color to match the spray tips being used to apply the desired application rate.
PROGRAMMING THE 844 SPRAYER CONTROL SYSTEM (CONTINUED) CALCULATION/WHAT IF? STEP This Programming Step is a diagnostic tool only and has no effect on the operation of the TeeJet 844 Sprayer Control. It allows the user to adjust the indicated pressure to see what effects it would have on the operating speed; or the user can adjust the speed to see what pressure would need to the used to maintain the target application rate.
OPERATING INSTRUCTIONS SPRAYER CHECKOUT Before spraying check all connections related to the Sprayer Control assembly. Particular attention should be given to the speed sensor to be sure the sensor and magnets are in line, and properly secured. Very important: Whenever you are working around a sprayer or farm chemicals, be sure to wear protective clothing and eye wear. Operation 1.
OPERATING INSTRUCTIONS (CONTINUED) THE SPRAYING OPERATION You have filled the sprayer tank and have thoroughly mixed the chemical(s). Your application rate has been determined as well as the spray tip you will be using, with the sprayer data programmed into the computer. 1. Switch the computer on by depressing the key on the display panel. 2. Toggle the boom switches to their “on” position, for each of the booms on your sprayer. 4. The Auto/Manual key should be switched to “AUTO”. 5.
FEATURES (CONTINUED) BOOST MODE (CONTINUED) 4. The application rate changes are monitored in the display, as you make them. The display will show UP 10, UP 20, dn 20, dn 30, etc. This will be displayed for approximately 3 seconds before the display returns to reading actual application rates. When making the application rate changes, it is not necessary to set the Auto/Man to “MAN” mode. 5.
SPRAY OPERATION (AFTER PROPER SETUP AND CALIBRATION) 1. Add 1/2 the 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 safety and operation precautions. 3. Open agitator valve. 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.
SPRAY OPERATION (CONTINUED) TO PREVENT 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.
Schematics HYDRAULIC SCHEMATIC WIRING SCHEMATIC 29
SPRAYING INTRODUCTION 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 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 spray vehicles or sprayers mounted onto vehicles.
HOSE & 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 aluminum. The handgun fits to a hose of any length from the sprayer allowing operator mobility. The hose should be as short as possible while still permitting operator mobility. Liquid looses pressure due to friction as it travels through the hose, 1-3 psi (0.07-0.
NOZZLES (CONTINUED) 3. DISPERSE THE MATERIAL IN A SPECIFIC PATTern that will insure even distribution of chemical across the 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 it begins to overlap with the next nozzle-approximately 1/3. The pattern of liquid dispersed by the hollow-cone (Raindrop) is more even across its width. Each nozzle overlaps the adjoining nozzle by 100%.
CALIBRATION INTRODUCTION 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 (lph) (1 US gpa = 9.
THE NOZZLE CHART METHOD OF 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 OF CALIBRATION (CONTINUED) 5. For Sprayer with Electronic Spray Control Systems. On sprayers equipped with Electronic Spray Control 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.
THE “128” METHOD OF BOOM SPRAYER CALIBRATION (CONTINUED) 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.
NOZZLE PERFORMANCE CHART #1 SMITHCO NOZZLE PERFORMANCE CHART #1 Color Orange Size XR8001 Green XR80015 DG8002 Yellow XR8002 DG8002 Blue XR8003 DG8003 Red XR8004 DG8004 Brown XR8005 DG8005 Gray XR8006 White XR8008 Steel SS8010 XR Teejet & DG Teejet 20 inch (51cm) US Gal/Acre (GPA) & US Gal/1,000 Square Feet (GPT) Application Rate GPA Application Rate GPT Nozzle Speed MPH (KPH) Speed MPH (KPH) Pressure Capacity psi (Gal/Min) 2 (3) 3 (5) 4 (6) 5 (8) 2 (3) 3 (5) 4 (6) 5 (8) 20 (1.4) 0.07 10.
NOZZLE PERFORMANCE CHART #2 SMITHCO NOZZLE PERFORMANCE CHART #2 Nozzle Type: Spacing: Calibration: Nozzle Charts 38 Color Orange Size XR8001 Green XR80015 DG8002 Yellow XR8002 DG8002 Blue XR8003 DG8003 Red XR8004 DG8004 Brown XR8005 DG8005 Gray XR8006 White XR8008 Steel SS8010 XR Teejet & DG Teejet 20 inch (51cm) Liters Per Hectare Application Rate LPH Nozzle Speed KPH (MPH) Pressure Capacity psi (bar) (L/Min) 3 (2) 5 (3) 6 (4) 8 (5) 20 (1.4) 0.26 97 65 5.2 4.2 30 (2.1) 0.
NOZZLE PERFORMANCE CHART #3 SMITHCO NOZZLE PERFORMANCE CHART #1 Color Orange Size XR8001 Green XR80015 DG80015 Yellow XR8002 DG8002 Blue XR8003 DG8003 Red XR8004 DG8004 Brown XR8005 DG8005 Gray XR8006 White XR8008 Steel SS8010 XR Teejet & DG Teejet 10 inch (25cm) US Gal/Acre (GPA) & US Gal/1,000 Square Feet (GPT) Application Rate GPA Application Rate GPT Nozzle Speed MPH (KPH) Speed MPH (KPH) Pressure Capacity psi (Gal/Min) 2 (3) 3 (5) 4 (6) 2 (3) 3 (5) 4 (6) 20 (1.4) 0.07 21 14 10 0.
NOZZLE PERFORMANCE CHART #4 SMITHCO NOZZLE PERFORMANCE CHART #2 Nozzle Type: Spacing: Calibration: Nozzle Charts 40 Color Orange Size XR8001 Green XR80015 DG80015 Yellow XR8002 DG8002 Blue XR8003 DG8003 Red XR8004 DG8004 Brown XR8005 DG8005 Gray XR8006 White XR8008 Steel SS8010 XR Teejet & DG Teejet 10 inch (51cm) Liters Per Hectare Application Rate LPH Nozzle Speed KPH (MPH) Pressure Capacity psi (bar) (L/Min) 3 (2) 5 (3) 6 (4) 20 (1.4) 0.26 194 130 98 30 (2.1) 0.34 250 166 126 40 (2.
NOZZLE PERFORMANCE CHART #5 SMITHCO NOZZLE PERFORMANCE CHART #1 Color Yellow Grey Size RA-2 Yellow Red RA-4 Brown Dk Blue RA-5 Gray Green RA-6 Red White RA-8 Tan RA-10 Lt Blue RA-15 Raindrop 1/4" 20 inch (51cm) US Gal/Acre (GPA) & 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) 2 (3) 3 (5) 4 (6) 5 (8) 2 (3) 3 (5) 4 (6) 5 (8) 20 (1.4) 0.14 21 14 10.5 8.4 0.48 0.32 0.24 0.19 30 (2.1) 0.
NOZZLE PERFORMANCE CHART #6 SMITHCO NOZZLE PERFORMANCE CHART #1 Nozzle Type: Spacing: Calibration: Nozzle Charts 42 Color Grey Yellow Size RA-2 Yellow Red RA-4 Dk Blue Brown RA-5 Green Gray RA-6 Red White RA-8 Tan RA-10 Lt Blue RA-15 Raindrop 1/4" 20 inch (51cm) Liters Per Hectare Nozzle Application Rate LPH Pressure Capacity Speed KPH (MPH) psi (bar) (L/Min) 3 (2) 5 (3) 6 (4) 8 (5) 20 (1.4) 0.53 196 131 98 79 30 (2.1) 0.64 243 159 122 96 40 (2.9) 0.76 279 185 139 111 50 (3.6) 0.
NOZZLE PERFORMANCE CHART #7 SMITHCO NOZZLE PERFORMANCE CHART #1 Color Red Size TF-VS2 Brown TF-VS2.5 Gray TF-VS3 White TF-VS4 Blue TF-VS5 Green TF-VS7.5 Black TF-VS10 Turbo Floodjet 30 inch (76cm) US Gal/Acre (GPA) & 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) 20 (1.4) 0.28 19 14 11 9 0.40 0.30 0.25 0.20 30 (2.1) 0.35 23 17 14 11 0.50 0.40 0.
NOZZLE PERFORMANCE CHART #8 SMITHCO NOZZLE PERFORMANCE CHART #1 Nozzle Type: Spacing: Calibration: Nozzle Charts 44 Color Red Size TF-VS2 Brown TF-VS2.5 Gray TF-VS3 White TF-VS4 Blue TF-VS5 Green TF-VS7.5 Black TF-VS10 Turbo Floodjet 30 inch (76cm) Liters Per Hectare Nozzle Application Rate LPH Pressure Capacity Speed KPH (MPH) psi (bar) (L/Min) 5 (3) 6 (4) 8 (5) 6 (10) 20 (1.4) 1.06 178 131 103 84.2 30 (2.1) 1.32 215 159 131 103 20 (1.4) 1.32 219 165 131 109 30 (2.1) 1.
ABBREVIATIONS AND CONVERSIONS 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 m.p.h. 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 & SPEED Distance (feet) x 0.68 = Travel Speed (m.p.h.
EC De c larat io n o f Co n fo rm it y a ccor din g t o Dir ect ive 89/392/E E C We S MITHCO INC. (N am e of su pplier) 3 4 We s t Ave .
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.
