User Manual - Envirostar
Contents
1. 10 Use of the Blower Specific Hazards Flying Debris Eye Protection When blowing material always wear Eye protection Ensure that all personnel are at least 15m from the operations Use of the Bagger Specific Hazards Sharp Objects Use the appropriate filter to ensure that dust hazards are kept within acceptable limits If using the ENVIROSTAR to pick up glass cans rubbish or similar materials exercise extra caution when changing or handling the bag as sharp objects may penetrate the bag Do not overfill the bag as the filter assembly and the output duct may become clogged When handling heavy bags ensure that the correct lifting technique is used If in doubt get help before attempting to lift bags and if necessary consider using mechanical lifting aids 11 Use of the Chipper Specific Hazards Wear Eye Machine Blockages Protection Hazardous substances Wear Hand Vibration Protection Flying Debris Wear Ear Protection Some plant material may be poisonous or may cause skin or eye irritation Checks may be needed before work begins It is Suggested that skin is kept fully covered eye protection is used and that suitable gloves are used to protect the hands during this work The chipper input chute has been designed to minimise the risks of anyone reaching moving machine parts Operators should however use the custom designed prodder supplied to push materials into the cutters rather than reaching2. Remove the bolt 1 and washer 1 from the inner cover Lift the inner cover clear of the fan housing Use a service tool to hold open the output access panel Use a 7 2 square drive socket mounted 8mm AF Allan key to hold the countersunk headed screws which retain the blade to the fan back plate Remove the Nyloc nuts which retain the blade Remove the blade Place the new blade in position and replace the fastenings tighten to a torque of 75 80Nm Repeat for the second blade Refit the inner cover Refit the access panel Remove the service tool from the output access panel Test the safety switches Test run the unit 8 15 Greasing the Bearings The main fan chipper shaft has two bearings both of which should be lubricated with good quality multi purpose lithium based grease such as Castrol LM 67 Remove the four bolts from the access panel located on the left hand side of the power unit Remove the cover Locate the bearings grease points 2 Using a grease gun pump in grease If regular servicing has been conducted only one or two repetitions should be required Replace the covers 68 8 16 Trailer The trailer tyres should be inspected daily for wear damage and correct inflation Tyre Pressures Wide Road Tyre 35 P S I 2 5Kg cm Narrow Road Tyre 35 P S I 2 5Kg cm ATV Tyre 10 P S I 0 7Kg cm 69 9 TROUBLESHOOTING Before commencing any work on the machine switch off the engin
3. acceptable oil for all temperatures USE OF SYNTHETIC OIL DOES NOT ALTER REQUIRED OIL CHANGE INTERVALS Air cooled engines run hotter than automotive engines The use of non synthetic multi viscosity oils SW 30 1OW 30 Etc in temperatures above 4 C 40 F will result in higher than normal oil consumption When using a multi viscosity oil check oil level more frequently SAE30 oil if used below 4 C 40 F will result in hard Starting and possible engine bore damage due to inadequate lubrication Check oil level Approximate capacities Model Series 85400 06 BIB 2O SO 1154 1174 1184 4 138400 O IS 30 a 235400 amp 245400 Place the ENVIROSTAR on level ground if mounted on a trailer ensure that the trailer is level clean around the oil fill Remove the dipstick and wipe clean with a clean cloth Insert the dipstick into the oil fill tighten down if oil fill is High do not tighten down if the oil level is low remove the dipstick to check the oil level Oil should be at the FULL mark If oil is required add slowly Do not over fill Tighten dipstick firmly before restarting the engine 26 Starting Before starting the engine check the oil level See above Do not use a pressurised starting fluid Always start store use and fuel the ENVIROSTAR in a level position Before Attempting to starting the ENVIROSTAR check that the emergency stop switch has not been activated To reset turn the swit
4. block The switch action can be monitored by connecting a multi meter set on resistance across the Grey and Black wires Moving the access panel towards the open position by approximately 2mm should activate the micro switch The switch is Short circuit when the door is open Check that when the door is released the springs cause the door to Shut and the short circuit is removed by switch activation If the access door does not fully close investigate the cause and rectify See section 8 12 Replace the top cover 63 8 11 Replacing the emergency stop switch Remove the top cover The emergency stop switch is mounted on a bracket To remove the switch disconnect the two wires Pull the U clip Between the switch and the body until the clip is approximately 6mm long The switch can now be pulled clear of the actuator Push the new switch into position and return the U clip to its Original position Check that the switch is secured to the actuator Replace the wires Check that the circuit is functioning with a multi meter Stop short circuit Run Open circuit To fit a new actuator Remove the switch as per above Loosen the bezel amp remove the bezel ring Extract the actuator body Fit the new actuator and bezel ring Refit the switch and wiring Ensure the switch is released Turn the switch top in the direction of the arrows 64 8 12 Safety Circuit Schematic To Briggs amp Stratton Sto
5. caught in chipped material vacuum unit Collecting Bag is full Empty collecting bag Speed at which Chipper blades are blunt Have chipper blades sharpened or shredded material is replaced ejected has reduced considerably or vibration increased when using chipper Reduced suction in Something is stuck in Remove cause of blockage vacuum vacuum hose Pressure Washer Pressure adjustment knob Locate pressure adjustment knob on does not provide full is turned down top of the unit and turn it up pressure Lance adjustment k knob Turn on the black adjustment knob set to detergent setting on the end of the lance NB this knob must be turned OFF when applying an additive and turned back ON when full washing pressure iS required 70
6. operation The direction quadrant can be removed and re positioned to direct the output sideways Removing the Output Chute A First ensure that the engine is stopped Move to the chute to the right swing the left hand edge clear of the access panel opening Carefully move the chute to the left Disconnect the chute bar from the two 2 lugs on the access panel 38 6 8 The Bagger Fitting the Bagger A First ensure that the engine is stopped The bagging unit attaches to the front access panel of the power unit The end of the bagger connector has a bar which engages with the two 2 lugs on the right hand side access panel Having engaged the bar into the lugs the bagger connector is moved to the right against the spring action and this opens the access panel The connector pivots on the bar and closes across the access panel and engages in the housing making sure that the connector is in contact with the safety switch within the housing The ENVIROSTAR must not be operated with the Bagger in place but without both an Air Filter and Bag fitted Once the bagger attachment is in position a bag can be attached Open the lower over lever buckle insert the open end of the bag between the securing strap and the body of the bagger closing the buckle secures the bag in position Do not change bags with the engine running Retaining Strap for Removable bagger support 39 The bagger has been designed to opera
7. s and the overload breaker is recommended A qualified electrical engineer should repair any damage immediately The generator produces 115 or 230 volt The output voltage is factory set The supply frequency is 50 hertz The power available is 2 2KVA Never plug the generator directly into household circuits Always ensure that the Envirostar earthing point is connected to a Suitable earth Never operate the generator at maximum power for more than 30 minutes Using the generator Connect the appliance to the correct socket Either 115 or 230 volts Ensure the rocker switch located above the sockets within the generator housing is switched to the correct setting either 115 or 230v Turn the alternator On Off switch located on the top of the main power unit to On Adjust the engine speed to until 50Hz is indicated on the frequency meter N B The speed may need to be adjusted once load is being drawn from the alternator Test that the appliance operates 44 If the appliance is drawing excessive current the overload trip will operate If this is happening check that the power rating of the appliance is within the supply limits of the alternator If the appliance is within the alternators capacity and the overload trip is still being automatically turned Off when the appliance Is operated contact qualified electrical engineer and have the equipment tested When electrical power is no longer required turn the On
8. side of the power unit Allow the end of the duct nearest the left hand side of the power unit to rise clear of the entry access panel then allow the duct to move towards the left hand side of the power unit until the access panel is fully closed Unhook the duct from the two 2 lugs on the access panel 36 6 7 The Output Swan Neck Chute A Caution Material leaving the output duct may travel up to 15 Metres and is capable of causing injury ensure that all personnel are aware of this and keep clear of the output area and that the containment provided is capable of arresting all debris produced by the ENVIROSTAR Fitting the Output Swan Neck Chute A First ensure that the engine is stopped The output chute mounts onto the front of the power unit The end of the chute has a bar which engages with the two 2 lugs on the right hand side access panel Having engaged the bar into the lugs the hose assembly end fitting is moved to the right against the spring action and this opens the access panel The chute pivots on the bar and closes across the access panel and engages in the housing making sure that the connector is in contact with the safety switch within the housing 37 Positioning the Output Chute The output of the chute can be directed downwards by adjusting the direction quadrant Loosen the wing nut on the direction quadrant adjust to the desired position then retighten the wing nut to prevent movement during
9. which can be badly damaged by the force of water Do not use the washer at temperatures lower than 4 C 13 Use of the Generator N Warning In common With all electrical equipment a risk of electrical shock exists when using this generator Always check and where necessary replace power cords plugs and equipment before attaching them to the ENVIROSTAR Periodic inspection of the power outlet sockets and the overload breaker is recommended A qualified electrical engineer should repair any damage immediately Never plug the generator directly into household circuits Always ensure that the ENVIROSTAR earthing point is connected to a suitable earth Never operate the generator at maximum power for more than 30 minutes When using extension cords ensure that they are suitable for outdoor use adequately rated and provide earth continuity Do not allow the ENVIROSTAR to generate electricity if it cannot be protected from adverse weather conditions 14 Inspection and maintenance See Section 8 for maintenance intervals and details of items requiring maintenance and inspection Additional Inspection In addition to user checks before use See above routine inspections are advised to ensure that the machine and its ancillaries remain safe for use The frequency of such inspections will vary with the nature and frequency of use of the equipment but Should include Inspection of all guards and testing of safety
10. Envirostar Model ES10 Operating Maintenance and Spares Manual Envirostar Limited PO Box2 Sheriff Hutton York YO60 6WZ Phone 08450 066099 E mail info envirostar co uk www envirostar co uk General information statement ENVIROSTAR LTD has a policy of continuous product improvement and reserves the right to modify and amend the specification and content of the ENVI ROSTAR The name and logo ENVIROSTAR are registered trademarks The name ENVIROSTAR is copyright and belongs to ENVI ROSTAR LTD Patents are currently pending on the ENVIROSTAR models Information on the Briggs and Stratton engine is reproduced by the kind permission of Briggs and Stratton U K Information contained in this manual is the property of ENVIROSTAR LTD and is not to be reproduced without prior permission For further information about ENVI ROSTAR products please call your local dealer or contact ENVI ROSTAR direct Telephone number 08450 066 099 Email info envirostar co uk Website WWW ENVIROSTAR CO UK THE ENVIROSTAR MULTI FUNCTION MACHINE Contents 1 SAFETY NOTICES amp ADVISE ON SAFE USE OF MACHINE 2 CE CONFORMANCE STATEMENT 3 ENVIRONMENTAL PROTECTION 4 GENERAL DESCRIPTION OF FEATURES 5 LAYOUT OF MAIN FEATURES V ING THE ENVI ROSTAR General Precautions Fuelling Starting amp Stopping the engine Vacuum Hose Assembly Blower Hose Assembly Chipper Chute Swan Neck Output Chute The Bagger T
11. FEATURES Fork Lift Handles Generator Vacuum Input Access Panel Engine Exhaust Pressure Washer Water Input Output Cleaning Agent Input Vacuum amp Blower Output Panel Trailer Mounting Plate Generator for Optional Frequency Trailed Vacuum Meter Head Maintenance Access Panel 21 Lever for Pump Drive on Pressure Washer Chipper Input Access Panel Washer Pressure Adjustment Valve Emergency Stop Button Petrol Filler Cap enerator amp Gauge On Off Switch 22 2 USI NG THE ENVI ROSTAR General Precautions Fuelling Starting and Stopping the engine The 150mm Vacuum Hose assembly The 150mm Blower Hose assembly The Chipper Input Chute The Mulcher Input Chute The Output Swan Neck Chute The Bagger The Pressure Washer The Generator Tool Carrying Tray Hose Carrier FPEOONOURWNE Nhe 6 1 General Precautions Warning Before commencing operations with the ENVIROSTAR ensure that the proposed work site is clear of all spectators livestock and pets that the unit is securely located that the transport trailers wheels are chocked and that all necessary personal protection equipment is being worn by all personnel involved in the operations It is recommended that certified ear eye hand and foot protection is worn when operating the ENVIROSTAR When operating the ENVIROSTAR the power unit should always be within the view of the operator who should periodically monit
12. Off switch on top of the main power unit to Off and remove the electrical plug s from the socket s Generator Housing and Electrical Outlet Frequency Meter Toggle switch to alternate between 115 230v supply 115v Socket 230v Socket Overload Trip Buttons 45 6 11 Tool Carrying Tray Attachment and use of the tool carrying tray Caution The attachment hooks could cause injury to the hand if care is not exercised Wear appropriate protective gloves The tool carrying tray allows various tools to be carried whilst in transit between work sites Typically the chipper input and output chute The galvanised steel structure is located onto the forward brace bar of the power unit using the open hooks The unit is lowered in to position on the top of the power unit and secured using the strap provided The tools that are placed on the tray should be secured using bungee straps or similar restraints Tool Carrying Tray 46 6 12 Hose Carrier Attachment and use of the hose carrier tray Caution The attachment hooks could cause injury to O the hand if care is not exercised Wear appropriate protective gloves The hose carrier tray allows the 150mm vacuum hose to remain attached to the power unit whilst in transit between work sites It is not suitable for use on roadways The galvanised steel structure is located onto the rear brace bar of the power unit using the open hooks The unit is lower
13. The chipper input chute fits onto the access panel on the top plate of the power unit The duct has a bar which engages into the two 2 lugs on the top plate access panel The duct assembly is moved towards the right hand side of the power unit until it is possible to engage the opposite edge of the duct into the access panel housing The duct is held in place by the spring action of the access panel Using the Input Chipper Chute When using the ENVIROSTAR do not wear scarves ties or other loose items of clothing which may become entangled Always use anti vibration gloves when feeding material into the chipper input chute The chipper is capable of handling material up to 65mm diameter Material is fed into the unit via the input duct where it is turned into chippings amp ejected from the output duct into a suitable containment Experience will be the users best guide to the rate at which material can be processed a useful guide to how much material the chipper can cope with is the engine revolutions if they fall dramatically reduce the amount of material being fed in Adjusting the engine Speed control may help but permanently running the engine at maximum revolutions will reduce engine life 32 If excessive vibration is felt when processing material through the chipper check that the chipper blades are sharp Materials should be pushed down the input duct using the flat end pusher supplied Never under any circumsta
14. and ground it before attempting adjustments Also disconnect the Negative terminal of the battery In all maintenance routines the engine is not to be run when the covers are removed 50 8 1 8 2 8 3 8 4 8 5 8 6 8 7 8 8 8 9 8 10 8 11 8 12 8 13 8 14 8 15 8 16 Service intervals Engine adjustments Oil Change Air Filter Change Spark Plug Change Removing the covers Fan Chipper Drive Belt Adjustment amp Replacement Washer Pump Belt Adjustment amp Replacement Generator Belt Adjustment amp Replacement Replacing access door micro switches Replacing the emergency stop switch Safety Circuit Schematic Replacing access door springs Replacing Chipper Blades Greasing the bearings Trailer 51 8 1 Service intervals The ENVIROSTAR should be serviced in accordance with the following table More frequent service is required when operating in adverse conditions After the first 5 hours of operation change the Oil Daily Check the oil level Test the access panel door switches amp Emergency stop switch or around the exhaust Weekly or every 25 operating hours Daily routine plus Monthly or every 50 operating hours Check the tension of the drive V belts Fan chopper amp washer drive amp Alternator Check the operation of all access panel doors and grease the slides Check the security of all hose attachments 52 3 monthly or every 100 ope
15. and in relation to any maintenance work the manual highlights specific hazards which are not discussed in this general safety guide Children should not operate this machine Young persons as defined by 94 33 EC should be supervised Young persons should have their proposed scope of work made the subject to an individual risk assessment Careful thought should be given where young people are to use the machine or where lone working is involved Before commencing operations with the ENVIROSTAR ensure that the proposed work site is clear of all spectators livestock and pets that the unit is securely located that the transport trailers wheels are chocked and that all necessary personal protection equipment is being worn by all personnel involved in the operations Before use the machine should be subject to a visual inspection by the operator to ensure that all guards are in place all fastenings are secure that hoses and ancillaries do not contain any residual debris from previous work and that there are no signs of blockages or of fuel or oil Spills Where the machine is trailer mounted and is to be towed to the workplace normal road user checks of tyres lights and security of the trailer and any ancillaries or tools carried on it should be completed before moving off Where it is mounted or carried on some other equipment it should be checked for security and to ensure that the load conforms to road transport regulations before
16. being taken onto public roads When operating the ENVIROSTAR the power unit should always be within the view of the operator who should periodically monitor that the power unit remains in a safe and stable position Do not leave the machine unattended with the engine running In most if not all modes of use ear protection should be provided for operators and eye protection will be needed where there is any risk from flying debris Footwear should be chosen to minimise risks of slipping and to provide suitable protection to the operator s feet circumstances will vary with specific work tasks Do not operate the power unit in a confined space or any area where exhaust fumes may build up No adjustments or repairs are to undertaken whilst the engine is running Only spares authorised by ENVIROSTAR Ltd should be used in the repair or servicing of the ENVIROSTAR the use c of un authorised parts will render any warranty claims void De ter asia is a All moving parts on the equipment are guarded and the engine is automatically cut out when guards are opened The equipment should never be used when any of the safety devices are inoperative Despite the safeguards operative should never attempt to reach inside any part of the equipment without turning off the engine and removing the key Operators should avoid wearing loose clothing such as ties scarves etc The Place of Work When used at a static works
17. ch in the direction indicated by the arrows Also check that the access panel safety switches are being correctly activated See section 8 for further details on the safety systems AUNE See diagram in Section 7 2 Move the choke control 1 to the CHOKE position Move the throttle control 2 to the FAST position Turn the fuel shut off valve 3 to the ON position Turn the key to the start position until the engine starts then release repeat if necessary When the engine is running shut off the choke and set the speed to the desired RPM for the work being undertaken If the battery has become discharged and the engine will not turn over the engine can be started manually If engine floods set choke to OPEN RUN position place throttle in FAST and crank until engine starts Manual start _ Proceed as above steps 1 to 3 Grasp the rope handle pull cord slowly until resistance is felt then pull rapidly to overcome compression prevent kickback and start the engine Repeat if necessary with the choke in the RUN position and the throttle set at FAST When the engine is running set the speed to the desired RPM for the work being undertaken 27 Stopping Do not use the choke control to stop the engine Move the throttle to the idle slow position Turn the key to the OFF position When the engine has stopped close the fuel shut OFF valve Always remove the key f
18. ct oil type see section 6 2 After refilling allow the oil to settle and recheck the level Caution Dispose of used oil correctly DO NOT put into a surface water draining system or burn contact your local council for advice on disposal 54 8 4 Air Filter Change see diagram in 7 2 Caution Oil products can cause skin conditions wear protective gloves Replace the pre air cleaner and or cartridge if very dirty or damaged Loosen screws remove the cover and air cleaner assembly from base Remove the cartridge retainer 4 if equipped and pre cleaner To service pre cleaner wash in liquid detergent and water Squeeze dry in a clean cloth Saturate in clean engine oil Squeeze in clean absorbent cloth to remove ALL EXCESS oil To service the cartridge clean by tapping gently on a flat surface Warning DO NOT use petrol or petroleum based solvents these will cause the cartridge to deteriorate DO NOT use pressurised air as this can damage the cartridge DO NOT oil the cartridge Reinstall pre cleaner on retainer Install pre cleaner in the cover with the mesh side towards the cartridge install the cartridge in the cover or onto the base Seat the cover and air cleaner assembly squarely onto the base locate tabs into slots Tighten the cover screws securely 55 8 5 Spark Plug Change see diagram in 7 2 Warning A DO NOT check for a spark with spark plug removed Use a spark tester to check fo
19. cut outs Inspection of top bolts securing the lifting points Inspection and testing of the emergency cut off switch Check the security and sharpness of cutting blades At not less than weekly intervals 15 2 CE CONFORMANCE STATEMENT For all countries using this product is subject to the approval by the authorities concerned The approval appears on the label affixed to the main power unit on the Right side panel to the left of the engine The CE marking on the product certifies compliance with technical regulations applicable at the date of approval In accordance with the following guidelines and standards The Machinery Directive 89 392 EEC The EMC directive 89 336 EEC The Noise Emission in the Environment by Equipment for use Outdoors Regulations Statutory Instrument 2001 No 1701 as Amended by Statutory Instrument 2001 No 3958 16 3 ENVIRONMENTAL PROTECTION Please remember to observe the local regulations regarding the disposal of your packaging materials exhausted batteries oil oil filters and other items replaced during servicing If in doubt on the proper method of disposal please contact your local council regarding arrangements in your area 17 4 GENERAL DESCRIPTION OF FEATURES The ENVIROSTAR multi function unit has been designed to undertake the following tasks Vacuuming Blowing Chipping Mulching Pressure Washing Power Generation Bagging The power unit has access panels to allow f
20. d plate of the alternator cover remain attached to the alternator Cover Bolts Loosen the four bolts which retain in the alternator to the mounting tray and slide the alternator assembly towards the main shaft until the belt can be removed from the drive pulley Retention bolts Inspect the condition of the drive and driven pulleys before fitting the new belt 61 Adjust the belt tension by moving the alternator tray away from the drive shaft The correct free play is 3mm When tensioned correctly tighten the retention bolts to a torque of 40 50Nm Refit the alternator cover and cover bolts check that the trailing wires are not trapped under any part of the cover and have not moved into a position that will bring them into contact with any moving part Refit the side access panel Test run the unit 62 Caution It is recommended that the following safety related items are only replaced and adjusted by an authorised ENVIROSTAR agent 8 10 Replacing the access door micro switches Remove the top cover The switches are located at the extremity of the access door travel Disconnect the Grey amp Black wire from the connector block on the fan casing Remove and retain the 2 screws washers amp nuts Fit the new switch using the 2 screws washers amp nuts Do not over tighten as this can cause the switch to seize The switch action has an audible click when operated Connect the wires to the connector
21. e wait until all moving parts have come to a standstill pull off the connector on the spark plug so that it is impossible for the engine to start unintentionally Problem Possible Causes Remedy Engine will not start Fuel tank is empty or fuel is Remove old fuel and fill tank with too old fresh clean fuel Is the fuel tap turned on Turn on fuel tap Battery discharged Charge battery Is the Emergency Stop Reset the switch Switch activated Are the access panel safety Open amp re close all access panels Switches engaged ensuring the safety switches are properly engaged Ignition cable is not Connect ignition cable to spark plug connected Clean plug and reset gap or replace Defective spark plug plug If engine is cold Choke lever not set to CHOKE Set choke lever to CHOKE Reduction in power Generator or power washer Check both switches levers to engine does not run Switches activated whilst ensure they are in the correct smoothly not in use position for current activity Engine is running with Set choke lever to RUN choke lever set to CHOKE Clean fuel line fill tank with fresh Fuel line is blocked or fuel clean fuel is too old Disconnect fuel line and drain fuel Water or dirt inside fuel tank Fill tank with fresh fuel system Clean air filter Dirty air filter Machine does not Outlet chute is blocked or Remove cause of blockage eject shredded or something is
22. ed in to position on the top of the power unit and secured using the strap provided The 150mm hose is connected to the input duct Starting at the front of the power unit the hose is laid across the top to the rear a loop is then formed at the rear of the power unit the lowest part of the loop should not be lower than the rear member of the trailer the hose is then returned to the front of the power unit l Hose Carrier lodded Hose Carrier with 150mm wander Tray unladen hose 47 7 THE ENGINE 7 1 Description 7 2 Engine diagram 7 3 Storage 7 1 Description The engine is a Briggs amp Stratton 9 H P single cylinder air cooled petrol engine model type 185400 for exact model see the engines identification plate it is fitted with both electric and manual pull Start 7 2 Engine diagram 1 Fuel shut off 8 Blower Housing 2 Rope handle 9 Oil Drain plug 3 Air cleaner 10 Exhaust guard Exhaust 4 Engine Model Type Code 11 Carburettor 5 Throttle and choke controls 12 Spark plug Lead 6 Fuel filler 13 Oil filler Dipstick 7 14 12 Volt Electric Starter 48 7 3 Storage Engines stored over 30 days need to be protected or drained of fuel to prevent gum from forming in the fuel system or on essential carburettor parts For engine protection we recommend the use of Briggs and Stratton Fuel Stabiliser available from authorised Briggs and Stratton service dealers or from ENVIROSTAR Mix stabiliser with the fu
23. el in the fuel tank or fuel storage container Run the engine for a short time to circulate the stabiliser through the carburettor The engine and treated fuel can now be safely stored for up to 24 months Note If the fuel stabiliser is not used or the engine is operating on petrol containing alcohol EG Gasohol remove all the fuel from the tank and run the engine until it stops due to lack of fuel 1 Change the oil See oil service See figs 2 7 2 Remove the spark plug and pour about 15ml 1 2 oz of clean engine oil into the cylinder Replace the spark plug and crank slowly to distribute the oil 3 Clean chaff and debris from the cylinder and cylinder head fins under the finger guard and behind the exhaust 4 Store in a clean dry area but NOT near a stove furnace or water heater which uses a pilot light or any device that can create a Spark 49 8 MAINTENANCE All maintenance should be carried out by suitably qualified personnel If in any doubt about any aspect of maintaining the ENVIROSTAR please contact your authorised service agent or ENVIROSTAR LTD A Warning Running engines produces heat Engine parts especially the exhaust become extremely hot Severe thermal burns can occur on contact Allow the exhaust engine cylinder and fins to cool before touching Remove accumulated combustibles from the exhaust area and the cylinder area A Warning To prevent accidental starting remove the sparking plug lead 1
24. f any of these bolts becomes damaged or is lost it must be replaced with one of the same grade Use an 8mm AF Allan key to remove the 12 bolts and washers Remove the fork pocket mounting brackets Lift the cover carefully to avoid damaging the emergency stop switch Replacement is a reversal of the above procedure After replacing the lid test the emergency stop To remove the Right or Left hand side cover Remove the top cover Remove the two joining bolts in the front and rear panels Remove the seven bolts from the chassis plate Lower edge Remove the two bolts from each handle The panel can now be removed To refit reverse the procedure To remove the rear cover Remove the top cover Remove the four side plate joining bolts Remove the three chassis bolts Do Not remove the engine positioning bolt Carefully pull the panel away from the power unit Remove the supply and return diesel fuel pipes from their connectors The panel can now be removed To remove the front cover Remove the top cover Remove the four side plate joining bolts Remove the three chassis bolts The panel can now be removed Case bolts should be tightened to 60 65 Nm with the exception of the bolts which retain the rubber bumper strips these should only be tightened to a torque of 30Nm Maximum Case bolts which also retain the fork lift pocket lift points should be tightened to a torque of 65 7ONm 57 8 7 Chipper Fan Drive Belt
25. ge is present in the engine ignition circuits and the generator Ear protection must be worn Face protection must be worn Safety boots must be worn Safety gloves must be worn Eye protection must be worn Caution possibility of entrapment exists inside the power unit SY No naked lights or smoking when fuelling the engine or the burner D00 aO Environmental Parameters for ES10 Minimum Operating Temperature Minus 10 C Maximum Operating Temperature 40 C Humidity range 25 85 RH Note Minimum Operating Temperature when using the pressure washer 4 C Storage Minimum Temperature Minus 25 C Maximum Temperature 45 C Humidity Range 20 95 RH SAFE USE OF THE ENVIROSTAR General Machine Use Hazards Rotating machine parts Flying debris Noise Electricity Vibration General Please read the operating instructions carefully before using the machine for the first time Observe all safety information while operating the machine Make sure that you are familiar with all safety information all users of the machine have been made aware of and understand the safety information Use of the ENVIROSTAR should be restricted to authorised persons who have been briefed on the safe use of the machine based on the user manual these notes and assessments of the specific work tasks which are to be carried out Note that the user manual should be carefully consulted before use of the machine
26. he Pressure Washer The Generator Tool Carrier Tray Hose Carrier AAAAAAAAAAAS Hib omoNauawrb ER GI NE Description Engine Diagram Storage N NM W N e 8 INTENANCE Service schedule Engine Adjustments Oil Change Air Filter Change Spark Plug Change Removing the covers Fan Chipper Drive Belts Adjust amp Replacement Washer Pump Drive Belt Adjust amp Replacement Alternator Drive Belt Adjust amp Replacement Replacing Access Door Micro switches Replacing Emergency Stop Switch safety Circuit Schematic Replacing Access Door Springs Chipper Blade Replacement Greasing the Bearings Trailer po 69 69 69 po 09 09 09 09 09 09 09 09 09 09 0 Z heehee P POON OUAWNE D lle ale ee 9 TROUBLESHOOTING 1 SAFETY The following symbols are used on the ENVI ROSTAR and within this manual PP e e e gt The safety alert symbol is used to identify safety information about hazards that can result in personal injury DANGER Indicates a hazard which if not avoided will result in death or serious injury WARNING Indicates a hazard which if not avoided will result in death or serious injury CAUTION Indicates a hazard which if not avoided might result in minor or moderate injury Flammable Material and High Temperatures are present in the form of fuel and exhaust gases Biological hazard may be present in those tools and assemblies that are involved in the movement of waste High volta
27. ine is stopped Connect the input hose to the input quick connect ensure an adequate water supply is provided then connect the output hose to the output quick connect Output Hose connected to Lance Pressure Gauge Detergent Input Hose Covers for Hose connection Point when not in Use Input Hose from Water Supply Detergent Additive I nput If required connect the detergent input The black adjustment knob on the end of the lance must be turned OFF in order for the detergent pump to be engaged Turn it back ON when full washing pressure is required 42 Start the engine and engage the pump drive with the lever located on top of the main power unit Wait a few seconds for the pump to prime then use the pressure adjuster in conjunction with the pressure gauge to set the washing pressure Pull the trigger on the lance to commence washing Disconnecting the pressure washer A First ensure that the engine is stopped Pull the trigger on the lance to release the pressure Disconnect the hoses and replace the covers over the valves Disengage the pump drive with the lever on top of the main power unit 43 6 10The Generator Warning In common with all electrical equipment a risk of electrical shock exists when using this generator Always check and where necessary replace defective power cords plugs and equipment before attaching them to the Envirostar Periodic inspection of the power outlet socket
28. into the hopper Material leaving the output duct may travel up to 15m and is capable of causing injury Ensure that all personnel are aware of this and keep clear of the output area and that the containment provided is capable of arresting all debris produced by the ENVIROSTAR Anti Vibration protective gloves should be worn at all times by operators whilst feeding material into the chipper chute 12 Use of the High Pressure Washer Specific Hazards High Pressure Wear Eye Protection Never direct the spray jet at any person or animal Never hold a finger or any other body part over the high pressure nozzle Never direct the spray jet at the ENVIROSTAR itself or at any electrical equipment After use release the pressure in the high pressure hose by operating the pistol trigger Do not attempt to disconnect any hose or coupling with pressure still in the hose When not in use disconnect the drive to the unit Never supply any liquid other than water to the water inlet Use only chemical cleaning agents detergents approved for power washing when using the chemical injection system Never use the chemical injection facility to introduce solvents eg paint thinner Do not operate the pressure washer standing on ladders Use a platform or scaffolding Children should not operate the pressure washer Wear eye protection when using the pressure washer Do not use the high pressure spray on vehicle tyre walls
29. l precautions may be needed The potential effect of noise and dust on others working or passing nearby should be carefully considered Any spare fuel or oils which are taken to work sites should be carefully stored well away from heat or ignition sources and with smoking prohibited in such areas Where ENVIROSTAR is to be re fuelled it should be switched off and allowed to cool for a few minutes before the cap is removed from any fuel container and fuel iS poured Use of the Vacuum Specific hazards A Fire Hazard Do not use the vacuum to collect materials that are on fire or Smouldering embers ashes etc as this may cause fire in the machine or the collection receptacle Ensure that the collection receptacle is sufficiently robust to cope with any potential puncture hazard which may be associated with the material which it is proposed to collect It is essential that sufficient air is allowed to access the vacuum pickup head in order that maximum efficiency is maintained Do not attempt to use the vacuum on loose gravel or on liquids Work involving animal waste Biological Contaminants Specific Hazards Where the equipment is used in the disposal of animal or other waste which may pose biological hazards specific assessments Should be undertaken and methods of work devised to ensure the Safety not only of those undertaking this work but of others who may use inspect or maintain the equipment Biological Hazards
30. moved towards the right hand side of the power unit until it is possible to engage the opposite edge of the duct into the access panel housing The duct is held in place by the spring action of the access panel Using the Mulching Chute When using the ENVIROSTAR do not wear scarves ties or other loose items of clothing which may become entangled The mulcher is capable of handling soft pliable material Do not feed hard materials into the chute as it will cause damage to the machine and could potentially cause injury to the operator Material fed into the chute Is is ejected from the output duct into suitable containment Experience will be the users best guide to the rate at which material can be processed a useful guide to how much material the mulch chute can cope with is the engine revolutions if they fall dramatically reduce the amount of material being fed in Adjusting the engine speed control may help but permanently running the engine at maximum revolutions will reduce engine life If material gets stuck in the chute use the prodder to push the material into the machine Materials should be pushed down the input duct using the flat end pusher supplied Never under any circumstances push material down the chute with your hand Do not lean over and reach into the chute 35 Removal of Mulch Input Chute First ensure that the engine is stopped To remove the cMulch input chute Pull the duct towards the right hand
31. nces push material down the chute with your hand Do not lean over and reach into the chute The pusher dimensions are A minimum of 500mm long The end must be at least 130mm square See Minimum PS 130mmx 130mm ie vv r k z z x a a i d k ze sy i e z a 1 Ps 7 z i n A Tia O TA pr A lt p 7 ion 5 ri gt i a aa gt 7 k aet 3 7 pr x a id o ded F d L a a 7 z F A p i js 3 r F m o E 7 p Pe as a brag e 4 j T a j m r P in e a fae 3 HALRA aes p rs bt i ag AN inimum m a i rd ai E 4 500mm ss a P 4 2 33 Removal of Chipper Input Chute First ensure that the engine is stopped To remove the chipper input chute Pull the duct towards the right hand side of the power unit Allow the end of the duct nearest the left hand side of the power unit to rise clear of the entry access panel then allow the duct to move towards the left hand side of the power unit until the access panel is fully closed Unhook the duct from the two 2 lugs on the access panel 34 6 6 The Mulcher Input Chute Fitting the Mulcher Input Chute N First ensure that the engine is stopped The mulcher input chute fits onto the access panel on the engine side of the power unit The duct has a bar which engages into the two 2 lugs on the top plate access panel The duct assembly is
32. nt and belt tension has been achieved Check of all fastening torques Replace the engines sparking plug Refit the top cover Test run the unit 59 8 8 Washer Pump Drive Belts Adjustment amp Replacement First remove the top and right hand covers Ensure the pump on off lever is in the OFF position Loosen the bolts securing the belt guides and move the guides clear Remove the belt Check the condition of the pulleys Fit the new belt Reposition the belt guides Move the drive on off to ON and check the tension of the belt Check that the belts are aligned correctly with the pulleys by observing their motion whilst carefully turning the engine over by hand It may be necessary to remove the sparking plug s to allow the engine to be rotated by hand Caution Great care is required when turning the belts as the guard assembly is removed there is an increase risk of entrapment in the belt assembly Replace the covers Test the emergency stop Test run the pump Belt Guide Belt guide 60 8 9 Generator Drive Belt Adjustment Replacement The alternator is driven from the main shaft by a single V belt To replace the belt Remove the side access panel then remove the six hex head set screws which retain the alternator cover then remove the cover from the main casing Care should be exercised when removing the cover as the electrical wiring for the outlet and circuit breaker fitted to the en
33. o ensure that the petrol is free of all foreign matter Fill the tank to approximately 4cms 172 below the top of the neck to allow for fuel expansion Be careful not to over fill Stay away from naked flames when filling the tank and do not smoke or do anything that could generate sparks On completion of fuelling ensure that the engine fuel tank filler cap IS correctly replaced If spillage of fuel occurs ensure that all spilt fuel is removed before continuing Be sure spark plug fuel cap and air cleaner are in place Do not crank engine with spark plug removed Recommended Fuel The engine is a four stroke unit and requires unleaded petrol Use clean fresh Lead free petrol with a minimum 85 octane Do not use fuels that contain Methanol Do not mix oil with the petrol 25 Recommended Oil Engines shipped from ENVIROSTAR are filled to the correct level with an appropriate grade of oil Always check the oil level before Starting the engine Do not overfill Use a high quality detergent oil classified for service SF SG SH SJ or higher such as Briggs and Stratton 30W Do not use special additives with recommended oils Do not mix oil with petrol Choose the SAE viscosity grade of oil from the chart that matches the starting temperature anticipated before the next oil change Note Synthetic oil meeting ILSAC GF 2 API certification mark and API service symbol with S CF ENERGY CONSERVING or higher is
34. or that the power unit remains in a safe and stable position Warning Do not operate the power unit in a confined space or any area where exhaust fumes may build up Engines give off carbon monoxide an odourless colourless poison gas Breathing carbon monoxide can cause nausea fainting or death 23 N Warning Do not wear loose fitting clothing or dangling items that could become caught N Warning Running engines produces heat Engine parts especially the exhaust become extremely hot Severe thermal burns can occur on contact Combustible debris such as leaves grass brush etc can catch fire Allow the exhaust engine cylinder and fins to cool before touching Remove accumulated combustibles from the exhaust area and the cylinder area A Danger Items leaving the output duct or hose do so with extreme velocity and should be directed into a suitable containment personnel Should be kept clear at all times 24 6 2 Fuelling Starting and Stopping the engine Take care when handling petrol Petrol is highly inflammable and the vapours that it gives off are explosive Store petrol in properly approved containers only in a room to which children have no access in a room that is protected from heat or sparks Do not refill the fuel tank in an enclosed space or while the engine is running or hot Clean around the fuel filler cap before removing When filling use a fine gauze funnel t
35. p switch Emergency Stop Door Switch 1 Door Switch 2 Door Switch 3 Chassis connection 65 8 13 The Access Panel Assemblies The access panels are slide mechanisms with springs positioned to ensure positive closure Maintenance is confined to periodic lubrication of the slides replacement of the safety micro switches see section 8 5 and replacement off the springs The access panel doors are not user serviceable Please contact your agent or ENVIROSTAR direct if these items require attention The sliding edges should be lubricated with good quality multi purpose lithium based grease such as Castrol LM To apply remove the top cover Insert the service tool into the access panel to be lubricated this exposes the sides of the slide and allows the grease to be applied Apply sufficient grease to ensure smooth operation Replacing the springs Use long nosed engineers pliers to remove the spring from the Spigot end Remove the spring from the mounting location hole Fitting the spring is the reverse procedure Check the operation of the access panel 66 8 14 Replacing Chipper Blades GA Warning Two people are required to carry out this procedure Ensure the engine has been stopped for more than 2 minutes Remove the ignition key and disconnect the spark plug lead before attempting this procedure Remove the four bolts from the access panel located on the left hand side of the power unit Remove the cover
36. r spark DO NOT crank engine with the spark plug removed If the engine is flooded place the throttle in FAST and crank until engine starts Spark plug gap should be 0 76mm of 0 030 inches Replace the spark plug every 100 hours or every season which ever occurs first If a Suppression resistor is fitted in the ignition lead ensure that any replacement contains the same arrangement Keep engine clean Periodically remove chaff and debris build up from the ENVIROSTAR and the engine Do not spray the engine with water to clean it as water may contaminate fuel Clean using a hand brush or compressed air To assure smooth operation keep the governor linkage springs and controls free of debris Accumulation of debris around the exhaust could cause a fire Inspect before every use If the exhaust Is fitted with a spark arrester remove the spark arrester screen for cleaning and inspection every 50 hours or every season Replace if damaged Clean the engine cooling system of all chaff and debris especially after prolonged operations Internal cooling fins and surfaces may require cleaning to prevent over heating and engine damage Remove the blower housing and clean as shown 56 8 6 Removing the covers The top cover is secured to the side panels by 12 off M10 grade 12 9cap head bolts The bolt grade is important to the safe handling of the main power unit as they not only secure the lid but also retain the lifting points I
37. rating hours Check the L frame for signs of damage Check the transport trailer for damage to the frame and tyres Touch up damaged paint Check the lid bolts are grade 8 8 Annually 3 monthly routines plus Check the engine valve clearances Check all side panel bolts are secure 8 2 Engine Adjustments Throttle control adjustments See Diagram in 7 2 Manual friction throttle control If adjustment is required loosen or tighten locknut until the throttle control moves easily but stays set in position Fixed governor control The adjustable governor control has been set for the ENVIROSTAR and should not be adjusted with out our permission Carburettor adjustment fe Caution The maximum speed of the engine has been set by ENVIROSTAR and should not be exceeded please contact us before attempting any adjustments 53 8 3 Oil Change See Diagram in Section 7 2 Check the oil level regularly Be sure that the oil level is maintained Check daily before starting the engine and every 8 hours of operating J Caution Oil products can cause skin conditions wear protective gloves Change the oil at the intervals specified in the Maintenance Schedule To change the oil remove the oil filler dip stick assembly Ensure that a suitable tray is positioned to catch the oil Remove the oil drain plug and allow the oil to drain When draining is completed replace the drain plug Refill with the corre
38. rom the switch when the equipment IS not in use or it is left unattended When the ENVIROSTAR is transported always close the fuel Shut off valve UI BB LUNS ek O Caution On completion of vacuuming or chipping operations please ensure that sufficient time is allowed for all debris and materials to be cleared from the piping ducting before shutting down the engine Before commencing blowing or drying operations ensure that the path through the machine is clear of loose materials or debris from previous operations 28 6 3 The 150 mm Vacuum Hose assembly Fitting the 150mm Vacuum Hose A First ensure that the engine is stopped The 150mm vacuum hose connects to the right hand side access panel on the main power unit The end of the hose assembly has a bar which engages with the two 2 lugs on the right hand side access panel Having engaged the bar into the lugs the hose assembly end fitting is moved to the right against the spring action and this opens the access panel The hose assembly pivots on the bar and closes across the access panel and engages in the housing making sure that the connector is in contact with the safety switch within the housing 29 To remove the 150mm vacuum hose assembly First ensure that the engine is stopped Move to the connector to the right swing the left hand edge clear of the access panel opening Carefully move the connector to the left Disconnect the hose as
39. s Adjustment amp Replacement First remove the top cover Loosen the engine mounting bolts and move the engine towards the fan chopper assembly by turning the positioning tension adjustor located at the lower edge of the mounting plate This will allow damaged belts to be removed from the driving pulley Remove the fan chopper assembly shaft bearing by removing the two 2 bolts retaining the bearing to the bearing spacer release the bearing to shaft retention and sliding the bearing off the shaft It will now be possible to remove the V belt s Inspect both the driving and driven pulley for damage Install the new V belt s onto both pulleys Replace the bearing onto the fan chopper assembly shaft Replace the two 2 bearing retention bolts and tighten To a torque of SONm Tighten the bearing to shaft retention Adjust the belt tension engine until the free movement at the mid point on the V belts is between 8 amp 10 mm Tighten the engine retaining bolts To a torque of 40 45Nm Check that the belts are aligned correctly with the pulleys by observing their motion whilst carefully turning the engine over by hand It may be necessary to remove the sparking plug s to allow the engine to be rotated by hand GA Caution Great care is required when turning the belts as the guard assembly is removed and there is an increase risk of entrapment in the belt assembly 58 Once the correct alignme
40. sembly bar from the two 2 lugs on the access panel 30 6 4 The 150 mm Blower Hose Assembly Where conditions are unsuitable for the vacuum function debris can be blown to a more Suitable location Fitting the 150mm Blower Hose N First ensure that the engine is stopped To use the blower function connect the 150mm hose to the outlet access panel The 150mm Blower hose connects to the outlet access panel on the main power unit The end of the hose assembly has a bar which engages with the two 2 lugs on the right hand side access panel Having engaged the bar into the lugs the hose assembly end fitting is moved to the right against the spring action and this opens the access panel The hose assembly pivots on the bar and closes across the access panel and engages in the housing making sure that the connector is in contact with the safety switch within the housing Before using the blower ensure that all loose debris A from previous vacuuming and chipping operations have cleared through the system To remove the 150mm vacuum hose assembly N First ensure that the engine is stopped Move to the connector to the right swing the left hand edge clear of the access panel opening Carefully move the connector to the left Disconnect the hose assembly bar from the two 2 lugs on the access panel 31 6 5 The Chipper Input Chute Fitting the Chipper Input Chute N First ensure that the engine is stopped
41. site ENVIROSTAR should always be positioned on firm level ground and should be chocked or made secure in some other way to avoid movement as a result of vibration or other cause Where the machine is mounted on some other equipment rather than on its own trailer similar precautions will be needed to ensure stability and to avoid unwanted movement during use The machine should always be sited so that the output duct is directed into a safe area which is clear of workers members of the public or materials which might be damaged by flying debris Where there is any doubt that this area can be kept clear the need for signs or barriers should be considered The engine should only be run in well ventilated areas normally outdoors Similar precautions may be needed to keep people clear of areas in which hoses are being used whether for blowing vacuuming or washing Ancillary tools should never be used close to other individuals nor should they ever be pointed at them If hoses or the output duct become blocked or appear to be blocked the machine MUST be switched off before any attempt is made to inspect or clear any part of the equipment Before beginning work a general inspection should be undertaken of any areas of proposed blowing or vacuuming work for any unexpected materials such as metal fragments glass stones etc ENVIROSTAR will blow or vacuum most materials of this type but risks from flying debris will be increased and additiona
42. te with bags 500mm wide by 800mm long The measurements are taken with a bag laid on flat surface the bag is made from reinforced polypropylene and are widely available from agricultural merchants In the event that these are not available locally supplies can be obtained via ENVIROSTAR A removable metal support is also provided which simply hooks over the trailer tow bar beneath the bagger position Care should be taken if the ENVIROSTAR is moved whilst this support is in place to avoid it catching on the floor and causing damage Removing the Bagger A First ensure that the engine is stopped Move to the bagger connector to the right swing the left hand edge clear of the access panel opening Carefully move the bagger to the left Disconnect the connector bar from the two 2 lugs on the access panel Air Filter The air filter is fitted and retained in the same manner as the bag Air Filter Retaining Strap for Filter 40 6 9 The Pressure Washer The pressure washer consists of a high pressure pump mounted inside the main power unit The connections for water input high pressure output and detergent input are all made using conventional quick disconnects Provision is made to adjust the washing pressure Safety precautions Never direct the spray jet at any person or animal Never hold a finger or any other body part over the high pressure nozzle Never direct the spray jet at the machine itself or at an
43. uel filling oil level checking starting and the connection of the various tools Dimensions Power unit Length 1 2m Trailer mounted Length 2 3 m Width 0 55 m Width 1 2m Height 0 70 m Height 1 1m Weight 300Kgs Weight 370Kgs Performance Vacuum 150mm Vacuum Maximum pull 6Kg Maximum flow rate 21 m s Hose length 6 m Blower Maximum flow 150mm hose 26 m s Chipper Maximum capacity 65mm Maximum Chipping Rate 20 m s Bagger Bag size 500mm wide by 800mm long polypropylene reinforced Easy bag and filter changing system Power Washer Pump type Triplex plunger Pump Maximum Pressure 100 bars Maximum flow 12 L min 18 Generator 110 or 220 Volt factory set 50Hz 2 2Kva Engine specification Briggs And Stratton Single cylinder Air cooled 9 1 2 Horsepower Fuel Consumption 3 15 L hr at full power output Electric start Built in fuel gauge Safety Features Centrally located Emergency stop switch Panic button Locking type All entry ports are continually monitored for correct operation All moving parts fully enclosed Transportation Trailer 600kg rated Fitted with independent suspension Road or ATV tyres amp all necessary lights wiring and plug for standard trailer socket Tow ball attachment or garden tractor fork and pin tow hitch 19 Choke amp Throttle Controls Engine Washer Pressure Gauge Maintenance Access Panel for Oil amp Battery 20 LAYOUT OF MAIN
44. y electrical equipment After use release the pressure in the high pressure hose by operating the pistol trigger When not in use disconnect the drive to the unit Never supply any liquid other than water to the water inlet Use only chemical cleaning agents detergents approved for power washing when using the chemical injection system Never use the chemical injection facility to introduce solvents e g paint thinners petrol or oil Do not attempt to disconnect any hose or coupling with pressure still in the hose Do not operate the pressure washer standing on ladders Use a platform tower or scaffolding Children should not operate the pressure washer Wear eye protection when using the pressure washer Do not use the high pressure spray on vehicle tyre walls which can be badly damaged by the force of water Do not use the pressure washer at temperatures lower than 4 C On no account must the pump be run dry for longer than a few seconds The ENVIROSTAR pressure washer pump is Self priming and can be connected to a mains water supply tap or to a suitable reservoir e g a tank or bowser Although self priming it has been found that having the water source slightly higher than the input on the ENVIROSTAR allows quicker starting and reduces wear in the water pump The detergent input is also self priming NB Turn OFF black lance knob to use additive 41 Connecting to the pressure washer fh First ensure that the eng
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