Miller | MA290013M | Owner Manual | Miller ENPAK User manual

Miller ENPAK User manual
OM-240 113J
2010−07
Description
Mobile Utility Unit With Air Compressor,
Hydraulic Pump, And Auxiliary Power
Capability
EnPakt Mechanic Series
File: Mobile Utility
Visit our website at
www.EnPak.com
From Miller to You
Thank you and congratulations on choosing EnPakt by Miller. Now
you can get the job done and get it done right. We know you don’t have
time to do it any other way.
That’s why when Niels Miller first started building arc welders in 1929,
he made sure his products offered long-lasting value and superior
quality. Like you, his customers couldn’t afford anything less. Miller
products had to be more than the best they could be. They had to be the
best you could buy.
Today, the people that build and sell Miller products continue the
tradition. They’re just as committed to providing equipment and service
that meets the high standards of quality and value established in 1929.
This Owner’s Manual is designed to help you get the most out of your
Miller products. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.
We’ve made installation and operation quick
and easy. With Miller you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will
help you figure out what the problem is. The
Miller is the first welding parts list will then help you to decide the
equipment manufacturer in exact part you may need to fix the problem.
the U.S.A. to be registered to
the ISO 9001 Quality System Warranty and service information for your
Standard.
particular model are also provided.
Miller Electric manufactures a full line
of welders and welding related equipment.
For information on other quality Miller
products, contact your local Miller distributor to receive the latest full
line catalog or individual specification sheets. To locate your nearest
distributor or service agency call 1-800-4-A-Miller, or visit us at
www.MillerWelds.com on the web.
EnPak_Thank 2009−10
Working as hard as you do −
every Miller product is
backed by the most hasslefree warranty in the business.
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Hydraulic Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-8. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-9. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers relatifs au soudage à l’arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’hydraulique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-6. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-7. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-8. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-9. Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Auxiliary Power And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Air Compressor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Hydraulic Specifications (Models With Hydraulic Power Source) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Sound Level Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Fuel Consumption Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Auxiliary Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Alternator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Air Compressor Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Hydraulic Pressure Curves (Models With Hydraulic Power Source) . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − PRESTART CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Hydraulic System Prestart Checks (Models With Hydraulic Power Source) . . . . . . . . . . . . . . . . . . . .
5-2. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-3. Compressor Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Remote Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Operation And Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Cold Weather Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Safety Interlock (Models With Hydraulic Power Source) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Hydraulic Pump Operation (Models With Hydraulic Power Source) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − COMPRESSOR OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Air Compressor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Compressor Blow Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Servicing Engine Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Safety Interlock Monthly Check (Models With Hydraulic Power Source) . . . . . . . . . . . . . . . . . . . . . . .
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12
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14
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15
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TABLE OF CONTENTS
8-5. Changing Engine Oil, Oil Filter, And Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-6. Engine Sensors And Governor Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-7. Changing Compressor Oil, Air Cleaner, And Air/Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Generator Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Compressor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-4. Hydraulic Troubleshooting (Models With Hydraulic Power Source) . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − AUTHORIZED DEALER INSTALLATION INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Installing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Mounting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − HYDRAULIC SYSTEM PREPARATION (MODELS WITH HYDRAULIC
POWER SOURCE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Hydraulic System Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Hydraulic Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3. Priming Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-4. Load Sense Line Bleeding (Closed Center Systems Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − ENGINE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1. Connecting the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-2. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3. Fuel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − AIR COMPRESSOR SYSTEM PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-1. Air Compressor System Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-2. Compressor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
13-3. Compressor Safety Valve Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 − REMOTE DEVICES CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
14-1. Remote Devices Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 15 − AUXILIARY POWER SYSTEM CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-1. Grounding Auxiliary Power System To Truck Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
15-2. Auxiliary Power System Connections And Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 16 − DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 17 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 18 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
rom_2010−03
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! − Indicates a hazardous situation which, if
not avoided, will result in death or serious injury. The
possible hazards are shown in the adjoining symbols
or explained in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained in the text.
NOTICE − Indicates statements not related to personal injury.
. Indicates special instructions.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the
hazards.
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions
to avoid the hazard. The safety information given below is
only a summary of the more complete safety information
found in the Safety Standards listed in Section 1-8. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this unit.
During operation, keep everybody, especially children, away.
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks or
severe burns. The electrode and work circuit is
electrically live whenever the output is on. The input
power circuit and machine internal circuits are also live
when power is on. In semiautomatic or automatic wire
welding, the wire, wire reel, drive roll housing, and all
metal parts touching the welding wire are electrically
live. Incorrectly installed or improperly grounded
equipment is a hazard.
D Do not touch live electrical parts.
D Wear dry, hole-free insulating gloves and body protection.
D Insulate yourself from work and ground using dry insulating mats
or covers big enough to prevent any physical contact with the work
or ground.
D Do not use AC output in damp areas, if movement is confined, or if
there is a danger of falling.
D Use AC output ONLY if required for the welding process.
D If AC output is required, use remote output control if present on
unit.
D Additional safety precautions are required when any of the following electrically hazardous conditions are present: in damp
locations or while wearing wet clothing; on metal structures such
as floors, gratings, or scaffolds; when in cramped positions such
as sitting, kneeling, or lying; or when there is a high risk of unavoidable or accidental contact with the workpiece or ground. For these
conditions, use the following equipment in order presented: 1) a
semiautomatic DC constant voltage (wire) welder, 2) a DC manual
(stick) welder, or 3) an AC welder with reduced open-circuit voltage. In most situations, use of a DC, constant voltage wire welder
is recommended. And, do not work alone!
D Disconnect input power or stop engine before installing or
servicing this equipment. Lockout/tagout input power according to
OSHA 29 CFR 1910.147 (see Safety Standards).
D Properly install and ground this equipment according to its
Owner’s Manual and national, state, and local codes.
D Always verify the supply ground — check and be sure that input
power cord ground wire is properly connected to ground terminal in
disconnect box or that cord plug is connected to a properly
grounded receptacle outlet.
D When making input connections, attach proper grounding conductor first − double-check connections.
D Keep cords dry, free of oil and grease, and protected from hot metal
and sparks.
D Frequently inspect input power cord for damage or bare wiring —
replace cord immediately if damaged — bare wiring can kill.
D Turn off all equipment when not in use.
D Do not use worn, damaged, undersized, or poorly spliced cables.
D Do not drape cables over your body.
D If earth grounding of the workpiece is required, ground it directly
with a separate cable.
D Do not touch electrode if you are in contact with the work, ground,
or another electrode from a different machine.
D Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
D Do not touch electrode holders connected to two welding machines at the same time since double open-circuit voltage will be
present.
D Wear a safety harness if working above floor level.
D Keep all panels and covers securely in place.
D Clamp work cable with good metal-to-metal contact to workpiece
or worktable as near the weld as practical.
D Insulate work clamp when not connected to workpiece to prevent
contact with any metal object.
D Do not connect more than one electrode or work cable to any
single weld output terminal.
SIGNIFICANT DC VOLTAGE exists in inverter power
sources AFTER stopping engine.
D Stop engine on inverter and discharge input capacitors according
to instructions in Maintenance Section before touching any parts.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
FLYING METAL or DIRT can injure eyes.
D Welding, chipping, wire brushing, and grinding
cause sparks and flying metal. As welds cool,
they can throw off slag.
D Wear approved safety glasses with side shields even under your
welding helmet.
OM-240 113 Page 1
FUMES AND GASES can be hazardous.
Welding produces fumes and gases. Breathing these
fumes and gases can be hazardous to your health.
D Keep your head out of the fumes. Do not breathe the fumes.
D If inside, ventilate the area and/or use local forced ventilation at the
arc to remove welding fumes and gases.
D If ventilation is poor, wear an approved air-supplied respirator.
D Read and understand the Material Safety Data Sheets (MSDSs)
and the manufacturer’s instructions for metals, consumables,
coatings, cleaners, and degreasers.
D Work in a confined space only if it is well ventilated, or while
wearing an air-supplied respirator. Always have a trained watchperson nearby. Welding fumes and gases can displace air and
lower the oxygen level causing injury or death. Be sure the breathing air is safe.
D Do not weld in locations near degreasing, cleaning, or spraying operations. The heat and rays of the arc can react with vapors to form
highly toxic and irritating gases.
D Do not weld on coated metals, such as galvanized, lead, or
cadmium plated steel, unless the coating is removed from the weld
area, the area is well ventilated, and while wearing an air-supplied
respirator. The coatings and any metals containing these elements
can give off toxic fumes if welded.
D Do not weld on closed containers such as tanks, drums, or pipes,
unless they are properly prepared according to AWS F4.1 (see
Safety Standards).
D Do not weld where the atmosphere may contain flammable dust,
gas, or liquid vapors (such as gasoline).
D Connect work cable to the work as close to the welding area as
practical to prevent welding current from traveling long, possibly
unknown paths and causing electric shock, sparks, and fire hazards.
D Do not use welder to thaw frozen pipes.
D Remove stick electrode from holder or cut off welding wire at
contact tip when not in use.
D Wear oil-free protective garments such as leather gloves, heavy
shirt, cuffless trousers, high shoes, and a cap.
D Remove any combustibles, such as a butane lighter or matches,
from your person before doing any welding.
D After completion of work, inspect area to ensure it is free of sparks,
glowing embers, and flames.
D Use only correct fuses or circuit breakers. Do not oversize or bypass them.
D Follow requirements in OSHA 1910.252 (a) (2) (iv) and NFPA 51B
for hot work and have a fire watcher and extinguisher nearby.
NOISE can damage hearing.
BUILDUP OF GAS can injure or kill.
Noise from some processes or equipment can damage hearing.
D Shut off shielding gas supply when not in use.
D Always ventilate confined spaces or use approved air-supplied respirator.
D Wear approved ear protection if noise level is
high.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
ARC RAYS can burn eyes and skin.
D
D
D
D
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays that
can burn eyes and skin. Sparks fly off from the weld.
Wear an approved welding helmet fitted with a proper shade of filter
lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
Wear approved safety glasses with side shields under your
helmet.
Use protective screens or barriers to protect others from flash,
glare, and sparks; warn others not to watch the arc.
Wear protective clothing made from durable, flame-resistant material (leather, heavy cotton, or wool) and foot protection.
WELDING can cause fire or explosion.
Welding on closed containers, such as tanks, drums,
or pipes, can cause them to blow up. Sparks can fly off
from the welding arc. The flying sparks, hot workpiece,
and hot equipment can cause fires and burns. Accidental contact of
electrode to metal objects can cause sparks, explosion, overheating,
or fire. Check and be sure the area is safe before doing any welding.
D Remove all flammables within 35 ft (10.7 m) of the welding arc. If
this is not possible, tightly cover them with approved covers.
D Do not weld where flying sparks can strike flammable material.
D Protect yourself and others from flying sparks and hot metal.
D Be alert that welding sparks and hot materials from welding can
easily go through small cracks and openings to adjacent areas.
D Watch for fire, and keep a fire extinguisher nearby.
D Be aware that welding on a ceiling, floor, bulkhead, or partition can
cause fire on the hidden side.
OM-240 113 Page 2
D Wearers of Pacemakers and other Implanted
Medical Devices should keep away.
D Implanted Medical Device wearers should consult their doctor
and the device manufacturer before going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating
operations.
CYLINDERS can explode if damaged.
D
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Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas
cylinders are normally part of the welding process, be
sure to treat them carefully.
Protect compressed gas cylinders from excessive heat, mechanical shocks, physical damage, slag, open flames, sparks, and arcs.
Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Keep cylinders away from any welding or other electrical circuits.
Never drape a welding torch over a gas cylinder.
Never allow a welding electrode to touch any cylinder.
Never weld on a pressurized cylinder — explosion will result.
D Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them and
associated parts in good condition.
D Turn face away from valve outlet when opening cylinder valve.
D Keep protective cap in place over valve except when cylinder is in
use or connected for use.
D Use the right equipment, correct procedures, and sufficient number of persons to lift and move cylinders.
D Read and follow instructions on compressed gas cylinders,
associated equipment, and Compressed Gas Association (CGA)
publication P-1 listed in Safety Standards.
1-3. Engine Hazards
BATTERY EXPLOSION can injure.
D Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
D Stop engine before disconnecting or connecting battery cables, battery charging cables (if
applicable), or servicing battery.
D Do not allow tools to cause sparks when working on a battery.
D Do not use welder to charge batteries or jump start vehicles unless the unit has a battery charging feature designed for this purpose.
D Observe correct polarity (+ and −) on batteries.
D Disconnect negative (−) cable first and connect it last.
D Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
D Follow battery manufacturer’s instructions when working on or
near a battery.
BATTERY CHARGING OUTPUT can injure.
(Battery charging feature not present on all models.)
D Have only qualified persons do battery charging work.
D Charge lead-acid batteries only. Do not use battery charger to
supply power to an extra-low-voltage electrical system or to
charge dry cell batteries.
D Do not charge a frozen battery.
D Do not use damaged charging cables.
D Do not charge a battery that has loose terminals or one showing
damage such as a cracked case or cover.
D Before charging battery, select correct charger voltage to match
battery voltage.
D Set battery charging controls to the Off position before connecting to battery. Do not allow battery charging clips to touch each
other.
D Keep charging cables away from vehicle hood, door, or moving
parts.
FUEL can cause fire or explosion.
D Stop engine and let it cool off before checking or
adding fuel.
D Do not add fuel while smoking or if unit is near
any sparks or open flames.
D
D
D
D
Do not overfill tank — allow room for fuel to expand.
Do not spill fuel. If fuel is spilled, clean up before starting engine.
Dispose of rags in a fireproof container.
Always keep nozzle in contact with tank when fueling.
MOVING PARTS can injure.
EXHAUST SPARKS can cause fire.
D Do not let engine exhaust sparks cause fire.
D Use approved engine exhaust spark arrestor in
required areas — see applicable codes.
HOT PARTS can burn.
D Do not touch hot parts bare handed.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or
wear heavy, insulated welding gloves and
clothing to prevent burns.
STEAM AND HOT COOLANT can burn.
D If possible, check coolant level when engine is
cold to avoid scalding.
D Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).
D If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
D Wear safety glasses and gloves and put a rag over radiator cap.
D Turn cap slightly and let pressure escape slowly before
completely removing cap.
Using a generator indoors CAN KILL
YOU IN MINUTES.
D Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
D NEVER use inside a home or garage, EVEN IF
doors and windows are open.
D Only use OUTSIDE and far away from windows, doors, and
vents.
BATTERY ACID can BURN SKIN and EYES.
D Do not tip battery.
D Replace damaged battery.
D Flush eyes and skin immediately with water.
ENGINE HEAT can cause fire.
D Do not locate unit on, over, or near combustible
surfaces or flammables.
D Keep exhaust and exhaust pipes way from
flammables.
D Keep away from moving parts such as fans,
belts, and rotors.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Stop engine before installing or connecting unit.
D Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
D To prevent accidental starting during servicing, disconnect
negative (−) battery cable from battery.
D Keep hands, hair, loose clothing, and tools away from moving
parts.
D Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
D Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
D Block flywheel so that it will not turn while working on generator
components.
OM-240 113 Page 3
1-4. Hydraulic Hazards
HYDRAULIC EQUIPMENT can injure
or kill.
D
D
D
D
D
D
D Incorrect installation or operation of this unit
could result in equipment failure and personal
injury. Only qualified persons should install, operate, and service this unit according to its
Owner’s Manual, industry standards, and national, state, and local codes.
Do not exceed the rated output or capacity of the hydraulic pump
or any equipment in the hydraulic system. Design hydraulic system so failure of any hydraulic component will not put people or
property at risk.
Before working on hydraulic system, turn off and lockout/tagout
unit, release pressure, and be sure hydraulic pressure cannot be
accidentally applied.
Do not work on hydraulic system with unit running unless you are
a qualified person and following the manufacturer’s instructions.
Do not modify or alter hydraulic pump or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the hydraulic system.
Use only components/accessories approved by the manufacturer.
Keep away from potential pinch points or crush points created by
equipment connected to the hydraulic system.
D Do not work under or around any equipment that is supported
only by hydraulic pressure. Properly support equipment by
mechanical means.
HYDRAULIC FLUID can injure or kill.
D Before working on hydraulic system, turn off and
lockout/tagout unit, release pressure, and be sure
hydraulic pressure cannot be accidentally applied.
D Relieve pressure before disconnecting or connecting hydraulic lines.
D Check hydraulic system components and all connections and hoses for damage, leaks, and wear
before operating unit.
D Wear protective equipment such as safety
glasses, leather gloves, heavy shirt and trousers,
high shoes, and a cap when working on hydraulic
system.
D Use a piece of paper or cardboard to search for leaks−−never use
bare hands. Do not use equipment if leaks are found.
D HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics
near sparks or flames; do not smoke near hydraulic fluid.
D Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
D If ANY fluid is injected into the skin, it must be surgically removed
within a few hours by a doctor familiar with this type of injury or gangrene may result.
MOVING PARTS can injure.
D Keep away from moving parts such as fans,
belts and rotors.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Keep hands, hair, loose clothing, and tools away from moving
parts.
D Before working on hydraulic system, turn off and lockout/tagout
unit, release pressure, and be sure hydraulic pressure cannot be
accidentally applied.
D Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
HOT PARTS AND FLUID can burn.
D Do not touch hot parts bare handed or allow hot
fluid to contact skin.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
1-5. Compressed Air Hazards
COMPRESSED AIR EQUIPMENT can
injure or kill.
D Incorrect installation or operation of this unit
could result in equipment failure and personal
injury. Only qualified persons should install, operate, and service this unit according to its
Owner’s Manual, industry standards, and national, state, and local codes.
D Do not exceed the rated output or capacity of the compressor or
any equipment in the compressed air system. Design compressed
air system so failure of any component will not put people or property at risk.
D Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
OM-240 113 Page 4
D Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s instructions.
D Do not modify or alter compressor or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system.
D Use only components and accessories approved by the manufacturer.
D Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
D Do not work under or around any equipment that is supported only
by air pressure. Properly support equipment by mechanical
means.
HOT METAL from air arc cutting and
gouging can cause fire or explosion.
D Do not cut or gouge near flammables.
D Watch for fire; keep extinguisher nearby.
COMPRESSED AIR can injure or kill.
D Before working on compressed air system,
turn off and lockout/tagout unit, release pressure, and be sure air pressure cannot be accidentally applied.
D Relieve pressure before disconnecting or connecting air lines.
D Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
D Do not direct air stream toward self or others.
D Wear protective equipment such as safety glasses, hearing protection, leather gloves, heavy shirt and trousers, high shoes, and
a cap when working on compressed air system.
D Use soapy water or an ultrasonic detector to search for leaks−−
never use bare hands. Do not use equipment if leaks are found.
D Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
D If ANY air is injected into the skin or body seek medical help immediately.
BREATHING COMPRESSED AIR can injure or kill.
D Do not use compressed air for breathing.
D Use only for cutting, gouging, and tools.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
D Release air pressure from tools and system before servicing, adding or changing attachments, or opening compressor oil drain or oil fill
cap.
MOVING PARTS can injure.
D Keep away from moving parts such as fans,
belts and rotors.
D Keep all doors, panels, covers, and guards
closed and securely in place.
D Keep hands, hair, loose clothing, and tools away from moving
parts.
D Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
D Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
D Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
HOT PARTS can burn.
D Do not touch hot compressor or air system
parts.
D Allow cooling period before working on equipment.
D To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
1-6. Additional Symbols For Installation, Operation, And Maintenance
FIRE OR EXPLOSION hazard.
D Do not install or place unit on, over, or near
combustible surfaces.
D Do not install unit near flammables.
D Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
OVERHEATING can damage motors.
D Turn off or unplug equipment before starting or
stopping engine.
D Do not let low voltage and frequency caused by
low engine speed damage electric motors.
D Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle
where applicable.
FALLING EQUIPMENT can injure.
D Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
D Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
D Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
FLYING SPARKS can injure.
D Wear a face shield to protect eyes and face.
D Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
D Sparks can cause fires — keep flammables away.
MOVING PARTS can injure.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
OM-240 113 Page 5
WELDING WIRE can injure.
H.F. RADIATION can cause interference.
D Do not press gun trigger until instructed to do
so.
D Do not point gun toward any part of the body,
other people, or any metal when threading
welding wire.
OVERUSE can cause OVERHEATING.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
D
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D
D
STATIC (ESD) can damage PC boards.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment perform this installation.
The user is responsible for having a qualified electrician
promptly correct any interference problem resulting from the
installation.
If notified by the FCC about interference, stop using the
equipment at once.
Have the installation regularly checked and maintained.
Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
ARC WELDING can cause interference.
TILTING OF TRAILER can injure.
D Use tongue jack or blocks to support weight.
D Properly install welding generator onto trailer
according to instructions supplied with trailer.
READ INSTRUCTIONS.
D Read and follow all labels and the Owner’s
Manual carefully before installing, operating, or
servicing unit. Read the safety information at
the beginning of the manual and in each
section.
D Use only genuine replacement parts from the manufacturer.
D Perform maintenance and service according to the Owner’s
Manuals, industry standards, and national, state, and local
codes.
D
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D Electromagnetic energy can interfere with
sensitive electronic equipment such as microprocessors, computers, and computer-driven
equipment such as robots.
D Be sure all equipment in the welding area is
electromagnetically compatible.
To reduce possible interference, keep weld cables as short as
possible, close together, and down low, such as on the floor.
Locate welding operation 100 meters from any sensitive electronic equipment.
Be sure this welding machine is installed and grounded
according to this manual.
If interference still occurs, the user must take extra measures
such as moving the welding machine, using shielded cables,
using line filters, or shielding the work area.
1-7. California Proposition 65 Warnings
Welding or cutting equipment produces fumes or gases
which contain chemicals known to the State of California to
cause birth defects and, in some cases, cancer. (California
Health & Safety Code Section 25249.5 et seq.)
Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
This product contains chemicals, including lead, known to
the state of California to cause cancer, birth defects, or other
reproductive harm. Wash hands after use.
OM-240 113 Page 6
For Gasoline Engines:
Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive harm.
For Diesel Engines:
Diesel engine exhaust and some of its constituents are
known to the State of California to cause cancer, birth
defects, and other reproductive harm.
1-8. Principal Safety Standards
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website:
www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
For Standards about hydraulic systems, contact the National Fluid
Power Association, Publications Department, 3333 North Mayfair
Road, Suite 211, Milwaukee, WI 53222-3219 (phone: (414) 778-3344,
website: www.nfpa.com).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
1-9. EMF Information
Electric current flowing through any conductor causes localized electric
and magnetic fields (EMF). Welding current creates an EMF field
around the welding circuit and welding equipment. EMF fields may interfere with some medical implants, e.g. pacemakers. Protective
measures for persons wearing medical implants have to be taken. For
example, access restrictions for passers−by or individual risk assessment for welders. All welders should use the following procedures in
order to minimize exposure to EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the
welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding, spot
welding, gouging, plasma arc cutting, or induction heating operations.
If cleared by your doctor, then following the above procedures is recommended.
OM-240 113 Page 7
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
fre_rom_2010−03
Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Signification des symboles
DANGER! − Indique une situation dangereuse qui si on
l’évite pas peut donner la mort ou des blessures graves.
Les dangers possibles sont montrés par les symboles
joints ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas
peut donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou
sont expliqués dans le texte.
NOTE − Indique des déclarations pas en relation avec des blessures
personnelles.
. Indique des instructions spécifiques.
Ce groupe de symboles veut dire Avertissement! Attention! DANGER
DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES
CHAUDES. Consulter les symboles et les instructions ci-dessous y
afférant pour les actions nécessaires afin d’éviter le danger.
2-2. Dangers relatifs au soudage à l’arc
Les symboles présentés ci-après sont utilisés tout au long du
présent manuel pour attirer votre attention et identifier les risques de danger. Lorsque vous voyez un symbole, soyez
vigilant et suivez les directives mentionnées afin d’éviter tout
danger. Les consignes de sécurité présentées ci-après ne
font que résumer l’information contenue dans les normes de
sécurité énumérées à la section 2-8. Veuillez lire et respecter
toutes ces normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées.
D
D
D
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves. L’électrode et le circuit de soudage sont sous
tension dès que l’appareil est sur ON. Le circuit
d’entrée et les circuits internes de l’appareil sont
également sous tension à ce moment-là. En soudage
semi-automatique ou automatique, le fil, le dévidoir, le
logement des galets d’entraînement et les pièces
métalliques en contact avec le fil de soudage sont
sous tension. Des matériels mal installés ou mal mis
à la terre présentent un danger.
D
D
D
D
D
D
D
D Ne jamais toucher les pièces électriques sous tension.
D Porter des gants et des vêtements de protection secs ne comportant pas de trous.
D
D S’isoler de la pièce et de la terre au moyen de tapis ou d’autres
moyens isolants suffisamment grands pour empêcher le contact
physique éventuel avec la pièce ou la terre.
D Ne pas se servir de source électrique à courant électrique dans les
zones humides, dans les endroits confinés ou là où on risque de
tomber.
D Se servir d’une source électrique à courant électrique UNIQUEMENT si le procédé de soudage le demande.
D Si l’utilisation d’une source électrique à courant électrique s’avère
nécessaire, se servir de la fonction de télécommande si l’appareil
en est équipé.
D
D Des précautions de sécurité supplémentaires sont requises dans
des environnements à risque comme: les endroits humides ou
lorsque l’on porte des vêtements mouillés; sur des structures métalliques au sol, grillages et échafaudages; dans des positions
assises, à genoux et allongées; ou quand il y a un risque important
de contact accidentel avec la pièce ou le sol. Dans ces cas utiliser
les appareils suivants dans l’ordre de préférence: 1) un poste à
OM-240 113 Page 8
D
D
D
D
D
souder DC semi−automatique de type CV (MIG/MAG), 2) un poste
à souder manuel (électrode enrobée) DC, 3) un poste à souder
manuel AC avec tension à vide réduite. Dans la plupart des cas, un
poste courant continu de type CV est recommandé. Et, ne pas travailler seul!
Couper l’alimentation ou arrêter le moteur avant de procéder à
l’installation, à la réparation ou à l’entretien de l’appareil.
Déverrouiller l’alimentation selon la norme OSHA 29 CFR
1910.147 (voir normes de sécurité).
Installer et mettre à la terre correctement cet appareil conformément à son manuel d’utilisation et aux codes nationaux,
provinciaux et municipaux.
Toujours vérifier la terre du cordon d’alimentation − Vérifier et
s’assurer que le fil de terre du cordon d’alimentation est bien
raccordé à la borne de terre du sectionneur ou que la fiche du
cordon est raccordée à une prise correctement mise à la terre.
En effectuant les raccordements d’entrée fixer d’abord le conducteur de mise à la terre approprié et contre-vérifier les connexions.
Les câbles doivent être exempts d’humidité, d’huile et de graisse;
protégez−les contre les étincelles et les pièces métalliques chaudes.
Vérifier fréquemment le cordon d’alimentation pour voir s’il n’est
pas endommagé ou dénudé − remplacer le cordon immédiatement
s’il est endommagé − un câble dénudé peut provoquer une électrocution.
Mettre l’appareil hors tension quand on ne l’utilise pas.
Ne pas utiliser des câbles usés, endommagés, de grosseur insuffisante ou mal épissés.
Ne pas enrouler les câbles autour du corps.
Si la pièce soudée doit être mise à la terre, le faire directement
avec un câble distinct − ne pas utiliser le connecteur de pièce ou le
câble de retour.
Ne pas toucher l’électrode quand on est en contact avec la pièce,
la terre ou une électrode provenant d’une autre machine.
Ne pas toucher des porte électrodes connectés à deux machines
en même temps à cause de la présence d’une tension à vide doublée.
N’utiliser qu’un matériel en bon état. Réparer ou remplacer
sur-le-champ les pièces endommagées. Entretenir l’appareil
conformément à ce manuel.
Porter un harnais de sécurité quand on travaille en hauteur.
Maintenir solidement en place tous les panneaux et capots.
Fixer le câble de retour de façon à obtenir un bon contact métalmétal avec la pièce à souder ou la table de travail, le plus près possible de la soudure.
Isoler la pince de masse quand pas mis à la pièce pour éviter le
contact avec tout objet métallique.
Il reste une TENSION DC NON NÉGLIGEABLE dans les
sources de soudage onduleur UNE FOIS le moteur coupé.
D Couper l’alimentation du poste et décharger les condensateurs
d’entrée comme indiqué dans la Section Maintenance avant de
toucher des composants.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher à mains nues les parties chaudes.
D Prévoir une période de refroidissement avant
de travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
DES PIECES DE METAL ou DES
SALETES peuvent provoquer
des blessures dans les yeux.
D Le soudage, l’écaillement, le passage de la pièce à la brosse en
fil de fer, et le meulage génèrent des étincelles et des particules
métalliques volantes. Pendant la période de refroidissement des
soudures, elles risquent de projeter du laitier.
D Porter des lunettes de sécurité avec écrans latéraux ou un écran
facial.
LES FUMÉES ET LES GAZ peuvent être dangereux.
Le soudage génère des fumées et des gaz. Leur
inhalation peut être dangereux pour votre santé.
D Eloigner votre tête des fumées. Ne pas respirer les fumées.
D À l’intérieur, ventiler la zone et/ou utiliser une ventilation forcée au
niveau de l’arc pour l’évacuation des fumées et des gaz de soudage.
D Si la ventilation est médiocre, porter un respirateur anti-vapeurs
approuvé.
D Lire et comprendre les spécifications de sécurité des matériaux
(MSDS) et les instructions du fabricant concernant les métaux, les
consommables, les revêtements, les nettoyants et les dégraisseurs.
D Travailler dans un espace fermé seulement s’il est bien ventilé ou
en portant un respirateur à alimentation d’air. Demander toujours à
un surveillant dûment formé de se tenir à proximité. Des fumées et
des gaz de soudage peuvent déplacer l’air et abaisser le niveau
d’oxygène provoquant des blessures ou des accidents mortels.
S’assurer que l’air de respiration ne présente aucun danger.
D Ne pas souder dans des endroits situés à proximité d’opérations
de dégraissage, de nettoyage ou de pulvérisation. La chaleur et
les rayons de l’arc peuvent réagir en présence de vapeurs et former des gaz hautement toxiques et irritants.
D Ne pas souder des métaux munis d’un revêtement, tels que l’acier
galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit
bien ventilé, et en portant un respirateur à alimentation d’air. Les
revêtements et tous les métaux renfermant ces éléments peuvent
dégager des fumées toxiques en cas de soudage.
D Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pour protéger votre visage
et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1
et Z87.1 énuméré dans les normes de sécurité).
D Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
D Avoir recours à des écrans protecteurs ou à des rideaux pour
protéger les autres contre les rayonnements les éblouissements
et les étincelles ; prévenir toute personne sur les lieux de ne pas
regarder l’arc.
D Porter des vêtements confectionnés avec des matières résistantes et ignifuges (cuir, coton lourd ou laine) et des bottes de
protection.
LE SOUDAGE peut provoquer un
incendie ou une explosion.
Le soudage effectué sur des conteneurs fermés tels
que des réservoirs, tambours ou des conduites peut
provoquer leur éclatement. Des étincelles peuvent
être projetées de l’arc de soudure. La projection d’étincelles, des
pièces chaudes et des équipements chauds peut provoquer des
incendies et des brûlures. Le contact accidentel de l’électrode avec
des objets métalliques peut provoquer des étincelles, une explosion,
un surchauffement ou un incendie. Avant de commencer le soudage,
vérifier et s’assurer que l’endroit ne présente pas de danger.
D Déplacer toutes les substances inflammables à une distance de
10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir
soigneusement avec des protections homologués.
D Ne pas souder dans un endroit là où des étincelles peuvent tomber
sur des substances inflammables.
D Se protéger et d’autres personnes de la projection d’étincelles et
de métal chaud.
D Des étincelles et des matériaux chauds du soudage peuvent
facilement passer dans d’autres zones en traversant de petites
fissures et des ouvertures.
D Surveiller tout déclenchement d’incendie et tenir un extincteur à
proximité.
D Le soudage effectué sur un plafond, plancher, paroi ou séparation
peut déclencher un incendie de l’autre côté.
D Ne pas effectuer le soudage sur des conteneurs fermés tels que
des réservoirs, tambours, ou conduites, à moins qu’ils n’aient été
préparés correctement conformément à AWS F4.1 (voir les normes de sécurité).
D Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple).
D Brancher le câble de masse sur la pièce le plus près possible de la
zone de soudage pour éviter le transport du courant sur une
longue distance par des chemins inconnus éventuels en provoquant des risques d’électrocution, d’étincelles et d’incendie.
D Ne pas utiliser le poste de soudage pour dégeler des conduites gelées.
D En cas de non utilisation, enlever la baguette d’électrode du porteélectrode ou couper le fil à la pointe de contact.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
D Porter des vêtements de protection dépourvus d’huile tels que des
gants en cuir, une chemise en matériau lourd, des pantalons sans
revers, des chaussures hautes et un couvre chef.
D Avant de souder, retirer toute substance combustible de vos poches telles qu’un allumeur au butane ou des allumettes.
D Fermer l’alimentation du gaz protecteur en cas
de non utilisation.
D Une fois le travail achevé, assurez−vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes.
D Veiller toujours à bien aérer les espaces confinés ou se servir
d’un respirateur d’adduction d’air homologué.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
D Utiliser exclusivement des fusibles ou coupe−circuits appropriés.
Ne pas augmenter leur puissance; ne pas les ponter.
D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et
NFPA 51B pour les travaux à chaud et avoir de la surveillance et un
extincteur à proximité.
LE BRUIT peut affecter l’ouïe.
Le bruit des processus et des équipements peut
affecter l’ouïe.
D Porter des protections approuvés pour les
oreilles si le niveau sonore est trop élevé.
OM-240 113 Page 9
Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)
peuvent affecter les implants médicaux.
D Les porteurs de stimulateurs cardiaques et
autres implants médicaux doivent rester à
distance.
D Les porteurs d’implants médicaux doivent consulter leur
médecin et le fabricant du dispositif avant de s’approcher de la
zone où se déroule du soudage à l’arc, du soudage par points, du
gougeage, de la découpe plasma ou une opération de chauffage
par induction.
Si des BOUTEILLES sont endommagées, elles pourront exploser.
Des bouteilles de gaz protecteur contiennent du gaz
sous haute pression. Si une bouteille est endommagée, elle peut exploser. Du fait que les bouteilles de gaz font
normalement partie du procédé de soudage, les manipuler avec
précaution.
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive,
des chocs mécaniques, des dommages physiques, du laitier, des
flammes ouvertes, des étincelles et des arcs.
D Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte-bouteilles pour les empêcher de tomber ou
de se renverser.
D Tenir les bouteilles éloignées des circuits de soudage ou autres
circuits électriques.
D Ne jamais placer une torche de soudage sur une bouteille à gaz.
D Une électrode de soudage ne doit jamais entrer en contact avec
une bouteille.
D Ne jamais souder une bouteille pressurisée − risque d’explosion.
D Utiliser seulement des bouteilles de gaz protecteur, régulateurs,
tuyaux et raccords convenables pour cette application spécifique;
les maintenir ainsi que les éléments associés en bon état.
D Ne pas tenir la tête en face de la sortie en ouvrant la soupape de la
bouteille.
D Maintenir le chapeau de protection sur la soupape, sauf en cas
d’utilisation ou de branchement de la bouteille.
D Utiliser les équipements corrects, les bonnes procédures et suffisamment de personnes pour soulever et déplacer les bouteilles.
D Lire et suivre les instructions sur les bouteilles de gaz comprimé,
l’équipement connexe et le dépliant P-1 de la CGA (Compressed
Gas Association) mentionné dans les principales normes de sécurité.
2-3. Dangers existant en relation avec le moteur
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
D Ranger les câbles de charge à distance du capot, des portes et
des pièces mobiles du véhicule.
LE CARBURANT MOTEUR peut provoquer un incendie ou une explosion.
D Toujours porter une protection faciale, des
gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
D Arrêter le moteur avant de débrancher ou de brancher des câbles
de batterie, des câbles de chargeur de batterie (le cas échéant) ou
de batterie d’entretien.
D
D Eviter de provoquer des étincelles avec les outils en travaillant sur
la batterie.
D
D Ne pas utiliser l’appareil de soudage pour charger des batteries ou
faire démarrer des véhicules à l’aide de câbles de démarrage, sauf
si l’appareil dispose d’une fonctionnalité de charge de batterie
destinée à cet usage.
D
D Observer la polarité correcte (+ et −) sur les batteries.
D Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
D Les sources d’étincelles, flammes nues, cigarettes et autres
sources d’inflammation doivent être maintenues à l’écart des
batteries. Ces dernières produisent des gaz explosifs en
fonctionnement normal et en cours de charge.
D Respecter les consignes du fabricant de la batterie pour
travailler sur une batterie ou à proximité.
Le COURANT DE CHARGE DE BATTERIE peut
provoquer des blessures (la fonctionnalité de charge de
batterie n’est pas disponible sur tous les modèles).
D Les opérations de charge de batterie ne doivent être effectuées
que par des personnes qualifiées.
D Ne charger que des batteries plomb−acide. Ne pas utiliser le
chargeur de batterie pour alimenter un autre circuit électrique
basse tension ou pour charger des batteries sèches.
D Ne pas charger une batterie gelée.
D
D
D Arrêter le moteur avant de vérifier le niveau de
carburant ou de faire le plein.
Ne pas faire le plein en fumant ou proche d’une source d’étincelles ou d’une flamme nue.
Ne pas faire le plein de carburant à ras bord; prévoir de l’espace
pour son expansion.
Faire attention de ne pas renverser de carburant. Nettoyer tout
carburant renversé avant de faire démarrer le moteur.
Jeter les chiffons dans un récipient ignifuge.
Toujours garder le pistolet en contact avec le réservoir lors du
remplissage.
Les PIÈCES MOBILES peuvent causer
des blessures.
D S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
D Maintenir fermés et verrouillés les portes,
recouvrements et dispositifs de protection.
panneaux,
D Arrêter le moteur avant d’installer ou brancher l’appareil.
D Lorsque cela est nécessaire pour des travaux d entretien et de
dépannage, faire retirer les portes, panneaux, recouvrements ou
dispositifs de protection uniquement par du personnel qualifié.
D Pour empêcher tout démarrage accidentel pendant les travaux
d’entretien, débrancher le câble négatif (−) de batterie de la borne.
D Ne pas utiliser de câbles de charge endommagés.
D Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
D Ne pas charger une batterie dont les bornes sont desserrées ou
présentant une détérioration comme par exemple un boîtier ou un
couvercle fissuré.
D Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant de
mettre le moteur en marche.
D Avant de charger une batterie, sélectionner la tension de charge
correspondant à la tension de la batterie.
D Régler les commandes de charge de batterie sur la position d’arrêt
avant de brancher la batterie. Veiller à ce que les pinces de charge
ne se touchent pas.
OM-240 113 Page 10
D Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
mise en route accidentelle du moteur.
D Bloquer le volant moteur pour éviter sa rotation lors d’une
intervention sur le générateur.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
D Empêcher les étincelles d’échappement du
moteur de provoquer un incendie.
D Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
D Ne pas toucher des parties chaudes à mains
nues.
D Prévoir une période de refroidissement avant de
travailler à l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et porter des gants de soudage et des vêtements épais pour
éviter les brûlures.
LA VAPEUR ET LE LIQUIDE DE
REFROIDISSEMENT CHAUD peuvent
provoquer des brûlures.
D Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter
de se brûler.
D Toujours vérifier le niveau de liquide de refroidissement dans le
vase d’expansion (si présent), et non dans le radiateur (sauf si précisé autrement dans la section maintenance du manuel du
moteur).
D Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.
D Mettre des lunettes de sécurité et des gants, placer un torchon sur
le bouchon du radiateur.
D Dévisser le bouchon légèrement et laisser la vapeur s’échapper
avant d’enlever le bouchon.
L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
D Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison invisible et inodore.
D JAMAIS utiliser dans une maison ou garage,
même avec les portes et fenêtres ouvertes.
D Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
D Ne pas renverser la batterie.
D Remplacer une batterie endommagée.
D Rincer immédiatement les yeux et la peau à l’eau.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
D Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces inflammables.
D Tenir à distance les produits inflammables de l’échappement.
2-4. Dangers liés à l’hydraulique
Les ÉQUIPEMENTS HYDRAULIQUES
peuvent provoquer des blessures ou
même la mort.
D Une installation ou une utilisation incorrecte
de cet appareil pourrait conduire à des dégâts
matériels ou corporels. Seul un personnel
qualifié est autorisé à installer, faire fonctionner
et réparer cet appareil conformément à son
manuel d’utilisation, aux normes industrielles
et aux codes nationaux, d’état ou locaux.
D Ne pas dépasser le débit nominal ou la capacité de la pompe
hydraulique ou de tout équipement du circuit hydraulique.
Concevoir le circuit hydraulique de telle sorte que la défaillance
d’un composant hydraulique ne risque pas de provoquer
un accident matériel ou corporel.
D Avant d’intervenir sur le circuit hydraulique, couper l’alimentation
électrique, verrouiller et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit hydraulique ne peut être remis sous
pression par inadvertance.
D Ne pas intervenir sur le circuit hydraulique lorsque l’appareil
fonctionne. Seul un personnel qualifié et appliquant les consignes
du fabricant est autorisé le faire.
D Ne pas modifier ou altérer la pompe hydraulique ou
les équipements fournis par le fabricant. Ne pas débrancher,
désactiver ou neutraliser les équipements de sécurité du circuit
hydraulique.
D Utiliser uniquement des composants et accessoires homologués
par le fabricant.
D Se tenir à l’écart de tout point présentant un danger de pincement
ou d’écrasement créé par l’équipement raccordé au circuit
hydraulique.
D Ne pas intervenir sous ou autour d’un équipement qui n’est
soutenu que par la pression hydraulique. Soutenir l’équipement
de façon appropriée par un moyen mécanique.
Le LIQUIDE HYDRAULIQUE risque de
provoquer des blessures ou même la mort.
D Avant d’intervenir sur le circuit hydraulique,
couper l’alimentation électrique, verrouiller
et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit hydraulique ne peut
être remis sous pression par inadvertance.
D Détendre la pression avant de débrancher ou
de brancher des canalisations hydrauliques.
D Avant
d’utiliser
l’appareil,
contrôler
les composants du circuit hydraulique,
les branchements et les flexibles en recherchant
tout signe de détérioration, de fuite et d’usure.
D Pour intervenir sur un circuit hydraulique, porter un équipement
de protection tel que des lunettes de sécurité, des gants de cuir,
une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.
D Pour rechercher des fuites, utiliser un morceau de papier ou
de carton, jamais les mains nues. En cas de détection de fuite,
ne pas utiliser l’équipement.
D Le LIQUIDE HYDRAULIQUE est INFLAMMABLE. Ne pas
intervenir sur des composants hydrauliques à proximité
d’étincelles ou de flammes; ne pas fumer à proximité de liquide
hydraulique.
D Remettre les portes, panneaux, recouvrements ou dispositifs
de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.
D En cas de pénétration d’un QUELCONQUE liquide dans la peau,
celui−ci doit être retiré chirurgicalement sous quelques heures par
OM-240 113 Page 11
un médecin familiarisé avec ce type de blessure, faute de quoi
la gangrène pourrait apparaître.
Les PIÈCES MOBILES peuvent causer
des blessures.
D S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs
de protection.
D Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
D Avant d’intervenir sur le circuit hydraulique, couper l’alimentation
électrique, verrouiller et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit hydraulique ne peut être remis sous
pression par inadvertance.
D Demander seulement à un personnel qualifié d’enlever
les dispositifs de sécurité ou les recouvrements pour effectuer,
s’il y a lieu, des travaux d’entretien et de dépannage.
D Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant
de mettre le moteur en marche.
LES PIÈCES ET LIQUIDES CHAUDS
peuvent provoquer des brûlures.
D Ne pas toucher les pièces chaudes à main nue
ni laisser des liquides chauds entrer en contact
avec la peau.
D Prévoir une période de refroidissement avant d’intervenir
sur l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils
recommandés et porter des gants de soudage et des vêtements
épais pour éviter les brûlures.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
2-5. Dangers liés à l’air comprimé
Un ÉQUIPEMENT PNEUMATIQUE risque
de provoquer des blessures ou même
la mort.
D Une installation ou une utilisation incorrecte de
cet appareil pourrait conduire à des dégâts
matériels ou corporels. Seul un personnel
qualifié est autorisé à installer, utiliser et
entretenir cet appareil conformément à son
manuel d’utilisation, aux normes industrielles et
aux codes nationaux, d’état ou locaux.
D Ne pas dépasser le débit nominal ou la capacité du compresseur
ou de tout équipement du circuit d’air comprimé. Concevoir
le circuit d’air comprimé de telle sorte que la défaillance
d’un composant ne risque pas de provoquer un accident
matériel ou corporel.
D Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
D Ne pas intervenir sur le circuit d’air comprimé lorsque l’appareil
fonctionne. Seul un personnel qualifié est autorisé, et appliquant
les consignes du fabricant.
D Ne pas modifier ou altérer le compresseur ou les équipements
fournis par le fabricant. Ne pas débrancher, désactiver ou
neutraliser les équipements de sécurité du circuit d’air
comprimé.
D Utiliser uniquement des composants et accessoires
homologués par le fabricant.
D Se tenir à l’écart de tout point présentant un danger de pincement
ou d’écrasement créé par l’équipement raccordé au circuit d’air
comprimé.
D Ne pas intervenir sous ou autour d’un équipement qui n’est
soutenu que par la pression pneumatique. Soutenir l’équipement
de façon appropriée par un moyen mécanique.
MÉTAL CHAUD provenant du découpage ou du gougeage à l’arc risque de
provoquer un incendie ou une explosion.
D Ne pas découper ou gouger à proximité de
produits inflammables.
D Attention aux risques d’incendie: tenir un extincteur à proximité.
OM-240 113 Page 12
L’AIR COMPRIMÉ risque de provoquer
des blessures ou même la mort.
D Avant d’intervenir sur le circuit d’air comprimé,
couper l’alimentation électrique, verrouiller
et étiqueter l’appareil, détendre la pression
et s’assurer que le circuit d’air ne peut être mis
sous pression par inadvertance.
D Détendre la pression avant de débrancher ou
de brancher des canalisations d’air.
D Avant
d’utiliser
l’appareil,
contrôler
les composants du circuit d’air comprimé,
les branchements et les flexibles en
recherchant tout signe de détérioration, de fuite
et d’usure.
D Ne pas diriger un jet d’air vers soi−même ou vers autrui.
D Pour intervenir sur un circuit d’air comprimé, porter un équipement
de protection tel que des lunettes de sécurité, des gants de cuir,
une chemise et un pantalon en tissu résistant, des chaussures
montantes et une coiffe.
D Pour rechercher des fuites, utiliser de l’eau savonneuse ou
un détecteur à ultrasons, jamais les mains nues. En cas
de détection de fuite, ne pas utiliser l’équipement.
D Remettre les portes, panneaux, recouvrements ou dispositifs
de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.
D En cas d’injection d’air dans la peau ou le corps, demander
immédiatement une assistance médicale.
L’INHALATION D’AIR COMPRIMÉ risque
de provoquer des blessures ou même
la mort.
D Ne pas inhaler d’air comprimé.
D Utiliser l’air comprimé uniquement pour
découper ou gouger ainsi que pour l’outillage
pneumatique.
Une PRESSION D’AIR RÉSIDUELLE
ET DES FLEXIBLES QUI FOUETTENT
risquent de provoquer des blessures.
D Détendre la pression pneumatique des outils et
circuits avant d’entretenir, ajouter ou changer
des accessoires et avant d’ouvrir le bouchon
de vidange ou de remplissage d’huile
du compresseur.
Les PIÈCES MOBILES peuvent causer
des blessures.
D S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
D Maintenir fermés et verrouillés les portes,
panneaux, recouvrements et dispositifs
de protection.
D Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
D Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
D Demander seulement à un personnel qualifié d’enlever
les dispositifs de sécurité ou les recouvrements pour effectuer,
s’il y a lieu, des travaux d’entretien et de dépannage.
D Remettre en place les portes, panneaux, recouvrements ou
dispositifs de protection à la fin des travaux d’entretien et avant
de mettre le moteur en marche.
DES PIÈCES CHAUDES peuvent
provoquer des brûlures graves.
D Ne pas toucher de pièces chaudes
du compresseur ou du circuit d’air.
D Prévoir une période de refroidissement
avant d’intervenir sur l’équipement.
D Ne pas toucher aux pièces chaudes, utiliser les outils
recommandés et porter des gants de soudage et
des vêtements épais pour éviter les brûlures.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
2-6. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
Risque D’INCENDIE OU
D’EXPLOSION.
D Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
D Ne pas installer l’appareil à proximité de produits inflammables.
D Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.
LA CHUTE DE L’ÉQUIPEMENT
peut provoquer des blessures.
D
D
D
D
D Utiliser l’anneau de levage pour lever l’appareil
et les accessoires correctement installées
seuls, PAS les bouteilles de gaz. Ne pas dépasser le poids nominal maximal de l’œilleton
(voir les spécifications).
Utiliser un équipement de levage de capacité suffisante pour
lever l’appareil.
En utilisant des fourches de levage pour déplacer l’unité, s’assurer que les fourches sont suffisamment longues pour dépasser
du côté opposé de l’appareil.
Tenir l’équipement (câbles et cordons) à distance des véhicules
mobiles lors de toute opération en hauteur.
Suivre les consignes du Manuel des applications pour l’équation
de levage NIOSH révisée (Publication Nº94−110) lors du levage
manuelle de pièces ou équipements lourds.
LE SURCHAUFFEMENT peut
endommager le moteur électrique.
D Arrêter ou déconnecter l’équipement avant de
démarrer ou d’arrêter le moteur.
D Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.
D Ne pas brancher de moteur de 50 ou de 60 Hz à la prise de 100 Hz,
s’il y a lieu.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
D Porter un écran facial pour protéger le visage et
les yeux.
D Affûter l’électrode au tungstène uniquement à
la meuleuse dotée de protecteurs. Cette manœuvre est à exécuter dans un endroit sûr lorsque l’on porte l’équipement homologué de protection du visage, des mains et du corps.
D Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
Les PIÈCES MOBILES peuvent
causer des blessures.
D Ne pas s’approcher des organes mobiles.
D Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
D Ne pas appuyer sur la gâchette avant d’en
avoir reçu l’instruction.
D Ne pas diriger le pistolet vers soi, d’autres personnes ou toute pièce mécanique en engageant le fil de soudage.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
D Laisser l’équipement refroidir ; respecter le facteur de marche nominal.
D Réduire le courant ou le facteur de marche
avant de poursuivre le soudage.
D Ne pas obstruer les passages d’air du poste.
OM-240 113 Page 13
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
D Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
D Utiliser des pochettes et des boîtes antistatiques pour stocker,
déplacer ou expédier des cartes de circuits imprimes.
UNE REMORQUE QUI BASCULE peut
provoquer des blessures.
D Utiliser les supports de la remorque ou des
blocs pour soutenir le poids.
D Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant.
D Demander seulement à des personnes qualifiées familiarisées
avec des équipements électroniques de faire fonctionner l’installation.
D L’utilisateur est tenu de faire corriger rapidement par un électricien
qualifié les interférences résultant de l’installation.
D Si le FCC signale des interférences, arrêter immédiatement l’appareil.
D Effectuer régulièrement le contrôle et l’entretien de l’installation.
D Maintenir soigneusement fermés les portes et les panneaux des
sources de haute fréquence, maintenir les éclateurs à une distance correcte et utiliser une terre et un blindage pour réduire les
interférences éventuelles.
LE SOUDAGE À L’ARC risque de
provoquer des interférences.
LIRE LES INSTRUCTIONS.
D Lire et appliquer les instructions sur les
étiquettes et le Mode d’emploi avant
l’installation, l’utilisation ou l’entretien de
l’appareil. Lire les informations de sécurité au
début du manuel et dans chaque section.
D N’utiliser que les pièces de rechange recommandées par le
constructeur.
D Effectuer l’entretien en respectant les manuels d’utilisation,
les normes industrielles et les codes nationaux, d’état et locaux.
LE RAYONNEMENT HAUTE FRÉQUENCE (H.F.) risque de provoquer
des interférences.
D Le rayonnement haute fréquence (H.F.) peut
provoquer des interférences avec les équipements de radio−navigation et de communication, les services de sécurité et les ordinateurs.
D
D
D
D
D
D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique sensible tel que les ordinateurs et
l’équipement commandé par ordinateur tel que
les robots.
Veiller à ce que tout l’équipement de la zone de soudage soit
compatible électromagnétiquement.
Pour réduire la possibilité d’interférence, maintenir les câbles de
soudage aussi courts que possible, les grouper, et les poser
aussi bas que possible (ex. par terre).
Veiller à souder à une distance de 100 mètres de tout équipement électronique sensible.
Veiller à ce que ce poste de soudage soit posé et mis à la terre
conformément à ce mode d’emploi.
En cas d’interférences après avoir pris les mesures précédentes, il incombe à l’utilisateur de prendre des mesures supplémentaires telles que le déplacement du poste, l’utilisation de câbles blindés, l’utilisation de filtres de ligne ou la pose de protecteurs dans la zone de travail.
2-7. Proposition californienne 65 Avertissements
cancérogène ainsi que provoquant des malformations
congénitales ou autres problèmes de procréation. Se laver
les mains après toute manipulation.
Les équipements de soudage et de coupage produisent des
fumées et des gaz qui contiennent des produits chimiques
dont l’État de Californie reconnaît qu’ils provoquent des malformations congénitales et, dans certains cas, des cancers.
(Code de santé et de sécurité de Californie, chapitre 25249.5
et suivants)
Pour les moteurs à essence :
Les batteries, les bornes et autres accessoires contiennent
du plomb et des composés à base de plomb, produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des
cancers et des malformations congénitales ou autres
problèmes de procréation. Se laver les mains après manipulation.
Pour les moteurs diesel :
Ce produit contient des éléments chimiques, dont le plomb,
reconnus par l’État de Californie pour leur caractère
OM-240 113 Page 14
Les gaz d’échappement des moteurs contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils
provoquent des cancers et des malformations congénitales
ou autres problèmes de procréation.
Les gaz d’échappement des moteurs diesel et certains de
leurs composants sont reconnus par l’État de Californie comme provoquant des cancers et des malformations
congénitales ou autres problèmes de procréation.
2-8. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,
from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
Safe Practices for the Preparation of Containers and Piping for Welding
and Cutting, American Welding Society Standard AWS F4.1, from Global Engineering Documents (phone: 1-877-413-5184, website:
www.global.ihs.com).
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02269 (phone: 1-800-344-3555, website:
www.nfpa.org and www. sparky.org).
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1,
from Compressed Gas Association, 4221 Walney Road, 5th Floor,
Chantilly, VA 20151 (phone: 703-788-2700, website:www.cganet.com).
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2, from Canadian Standards Association, Standards Sales, 5060
Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone:
800-463-6727, website: www.csa-international.org).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Ontario, Canada L4W 5NS (phone: 800-463-6727, website:
www.csa-international.org).
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute,
25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, website: www.ansi.org).
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B, from National Fire Protection Association,
Quincy, MA 02269 (phone: 1-800-344-3555, website: www.nfpa.org.
For Standards about hydraulic systems, contact the National Fluid
Power Association, Publications Department, 3333 North Mayfair
Road, Suite 211, Milwaukee, WI 53222-3219 (phone: (414) 778-3344,
website: www.nfpa.com).
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910, Subpart Q,
and Part 1926, Subpart J, from U.S. Government Printing Office, Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA 15250-7954
(phone: 1-866-512-1800) (there are 10 OSHA Regional Offices—
phone for Region 5, Chicago, is 312-353-2220, website:
www.osha.gov).
U.S. Consumer Product Safety Commission (CPSC), 4330 East West
Highway, Bethesda, MD 20814 (phone: 301-504-7923, website:
www.cpsc.gov).
Applications Manual for the Revised NIOSH Lifting Equation, The National Institute for Occupational Safety and Health (NIOSH), 1600
Clifton Rd, Atlanta, GA 30333 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
2-9. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des champs
électromagnétiques (CEM) à certains endroits. Le courant de soudage
crée un CEM autour du circuit et du matériel de soudage. Les CEM
peuvent créer des interférences avec certains implants médicaux
comme des stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple, des
restrictions d’accès pour les passants ou une évaluation individuelle
des risques pour les soudeurs. Tous les soudeurs doivent appliquer les
procédures suivantes pour minimiser l’exposition aux CEM provenant
du circuit de soudage:
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les
câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
En ce qui concerne les implants médicaux :
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni
s’asseoir ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les
procédures précédentes.
OM-240 113 Page 15
SECTION 3 − DEFINITIONS
3-1. Symbol Definitions
Engine Cooling
Engine Air Filter
Glow Plugs
Protective Earth
(Ground)
Engine Oil
Fuel
Check Valve
Clearance
Battery (Engine)
Engine
Read Operator’s
Manual
Alternating Current
(AC)
Direct Current
(DC)
Air Compressor
Air Pressure
Engine Belt
Hydraulic Pump
Crank Engine
SECTION 4 − SPECIFICATIONS
4-1. Auxiliary Power And Engine Specifications
Standard Generator Power Rating
Optional EnVertert AC To AC Converter
Power Rating
Single-Phase,
6 kVA/kW at 3600 RPM
120/240 V AC, 50/25 A,
60 Hz, Continuous
2.4 kVa/kW, 20 A at 2600 to 3600 RPM,
300 Watts at 1800 RPM
120 V AC Pure Sine Wave, Continuous
Engine
Kubota D1105−E3B, 3−Cylinder, 27.7 HP,
Liquid−Cooled, Diesel Engine w/Electronic
Governor
Combined Maximum Auxiliary Power Output (Standard Generator And EnVerter) Is 6kVA/kW
4-2. Air Compressor Specifications
Compressor Type
Air Output At Effective
Working Pressure
Rotary Screw
40 scfm @ 100 psi (1.13 m3
min−1 @ 689 kPa),
100% Duty Cycle, 3600 RPM
Pressure
Safety Relief
Valve Setting
Air Compressor
Oil Capacity
Range: 90−175 psi
(620−1206 kPa)
Auto Shutoff: 200 psi
(1379 kPa)
Factory set at 120 psi
(827 kPa)
Pressure Relief: 210 psi
(1448 kPa)
2 qt (1.9 L)
4-3. Hydraulic Specifications (Models With Hydraulic Power Source)
Pump Type
Rated
Output
Maximum Pressure
Maximum Flow Rate
Variable Displacement Piston
8.5 GPM at 3000 psi at 3200
RPM, 50% Duty Cycle*
3500 psi (241.3 bar)
20 GPM (75.7 lpm)
*Dependant on system cooling capacity.
4-4. Sound Level Table
Air Compressor On
OM-240 113 Page 16
Idle Speed
1800 rpm
2600 rpm
3200 rpm
3600 rpm
63 dB
68 dB
73 dB
75 dB
4-5. Dimensions, Weights, and Operating Angles
!
Do not exceed tilt angles or engine
could be damaged or unit could
tip.
!
Do not move or operate unit where
it could tip.
!
Do not operate suspended from
lifting eye.
Weight: 955 lb (433 kg) Fully Equipped
767 lb (348 kg) Without
Hydraulic Power Source
Lifting Eye Weight Rating: 1000 lb (454
kg)
15°
15°
15°
15°
287 139-D
OM-240 113 Page 17
4-6. Fuel Consumption Curves
Compressor
1.80
1.60
U. S.. GAL./HR.
1.40
1.20
1.00
0.80
0.60
0.40
0.20
0.00
0
5
10
15
20
25
30
35
CUBIC FEET PER MINUTE (CFM)
40
45
50
Auxiliary Power
1.80
1.60
U. S.. GAL./HR.
1.40
1.20
1.00
0.80
0.60
0.40
0.20
0.00
0.0
1.0
2.0
3.0
4.0
AUXILIARY POWER IN KILOWATTS
5.0
6.0
Standard Auxiliary Power
Optional EnVertert Auxiliary Power
. Combined
maximum auxiliary power output
(standard generator and EnVerter) is 6kVA/kW.
243 168-A / 243 169-A
OM-240 113 Page 18
4-7. Auxiliary Power Curves
The AC generator power curves
show the generator power available
in amperes.
. Combined
EnVertert Power
240 VAC Auxiliary Power
120 VAC Auxiliary Power
maximum
auxiliary power output
(standard generator and
EnVerter) is 6kVA/kW.
The EnVertert power curve shows
the power available in amperes.
Tools and motors are designed to
operate within 10% of 120/240
VAC.
300
. When the EnPak is running at
1800 RPM, the voltage output
of the generator is too low to activate some electric machines
that require the full 120 VAC or
240 VAC for operation. If the
electric machine that you are
using is not recognized as a
load by the EnPak, and does
not turn on, place the EnPak in
high speed. This will bring the
output of the generator up to
the normal 120 VAC or 240
VAC level, and the machine
that is plugged into the generator should work normally. This is
for the standard generator
power only, and does not apply
to the EnVerter power output
which is 120 VAC regardless of
engine RPM.
250
VOLTS
200
150
100
50
0
0
20
40
60
80
AMPS
242 594-A
4-8. Alternator Power Curve
The alternator volt−ampere curve
shows the available alternator output at various engine rpm.
15
14.5
14
VOLTS
1800 RPM
13.5
3200 RPM
13
2600 RPM
3600 RPM
12.5
. Combined
12
0
20
40
60
80
100
maximum
auxiliary power output
(standard generator and
EnVerter) is 6kVA/kW.
AMPS
242 595-A
OM-240 113 Page 19
4-9. Air Compressor Curves
CUBIC FEET PER MINUTE (CFM)
CFM VS ENGINE RPM
50
45
43
40
39
35
32
30
25
20
24
15
10
5
0
1800
2600
3200
ENGINE SPEED (RPM)
3600
CUBIC FEET PER MINUTE (CFM)
CFM VS PSI
50
48
46
44
42
43
40
42
41
38
40
36
34
32
30
100
125
150
PRESSURE (PSI)
175
Ref. 220 807−A
OM-240 113 Page 20
4-10. Hydraulic Pressure Curves (Models With Hydraulic Power Source)
. Curves are typical. Output will
vary depending on system
pressure losses to load sense
pressure location.
Fluid: ISO 32 Hydraulic Oil
Fluid Temperature: 49° C (120° F)
Load Sense Pressure:
Closed Center − 400 PSID
(27.6 bar)
Open Center − 200 PSID (13.8
bar)
Closed Center
20.0
Hydraulic Load Only
18.0
16.0
FLOW (GPM)
14.0
12.0
10.0
Hydraulic +40 CFM @ 100 PSI Compressor Load
8.0
6.0
Hydraulic Load Only − Manual Mode
4.0
2.0
0.0
0
500
1000
1500
2000
PRESSURE (PSI)
2500
3000
3500
Open Center
12.0
Hydraulic Load Only
10.0
Hydraulic +40 CFM @ 100 PSI Compressor Load
FLOW (GPM)
8.0
6.0
Hydraulic Load Only − Manual Mode
4.0
Hydraulic Load Only − 1800 RPM (Outriggers)
2.0
0.0
0
500
1000
1500
2000
PRESSURE (PSI)
2500
3000
3500
242 506-A / 242 507-A
OM-240 113 Page 21
SECTION 5 − PRESTART CHECKS
5-1. Hydraulic System Prestart Checks (Models With Hydraulic Power Source)
NOTICE − Ensure hydraulic system is properly connected with valves open before starting unit. Damage will result if unit is run before hydraulic system
is complete. Hydraulic pump does not disengage via clutch.
5-2. Engine Prestart Checks
Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.
2
1
. Follow run-in procedure in engine
manual.
. This unit
has a low oil pressure
shutdown switch. However, some
conditions may cause engine damage before the engine shuts down.
Check oil level often and do not use
the oil pressure shutdown system
to monitor oil level.
Open top cover and service side door.
1
2
3
4
Oil Dipstick
Oil Fill
Coolant Overflow Bottle
Radiator Cap
Fuel
Be sure fuel connections are made and
tight. Be sure fuel tank utilized for unit
operation is full.
Coolant
Check coolant level in radiator and
overflow bottle. If coolant is below Low
level in overflow bottle, add coolant until
level in bottle is between Low and Full
levels. If overflow bottle coolant level
was low, check coolant level in radiator.
3
Engine Oil
Check oil with unit on level surface. If oil
is not up to full mark on dipstick, add oil
(see maintenance label).
Use remote panel to determine hours
until next recommended oil change
(see Section 6-1).
. For cold weather starting informa4
tion, see Section 6-3.
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
Continue initial system checks, see
Section 5-3.
805 444
OM-240 113 Page 22
5-3. Compressor Prestart Checks
. The compressor is equipped with high
oil temperature shutdown. High oil
temperature can be caused by low oil
or hot air recirculation.
. Do not open oil fill cap until unit has
been off for 10 minutes. Do not open
while running.
NOTICE − Do not mix oil types. Do not
overfill.
1
Air Compressor Oil Fill Cap
Hand tighten oil fill cap. Using excess
force can damage o−ring.
2
The unit is shipped with oil in the compressor reservoir. Minimum oil level is half
way up the sight hole. Maximum oil level is
in threaded area of oil fill pipe. Check level
frequently. If oil needs to be added, be
sure unit is off for 10 minutes before removing fill cap.
Air Compressor Oil Sight Hole
2
1
. Minimum com-
pressor oil level
is half way up
the sight hole.
Maximum oil
level
is
in
threaded area
of oil fill pipe.
805 444
OM-240 113 Page 23
SECTION 6 − OPERATION
O
6-1. Remote Panel
1
4
5
11
2
6
3
10
7
9
8
239 661-1-A
1
Alpha−Numeric Display
During the start sequence, the following
appears:
SYSTEMon
GLOWPLUG
GLOWdone
CRANKING
NO CRANK
See Section 6-2 for error messages that
appear.
2 Engine Status LED
Lights when display is showing engine related information.
3 Compressor Status LED
Lights when display is showing compressor related information.
4 Engine Off LED
Lights when engine is off.
5 Engine Shutdown LED
Lights when display is showing an engine
error.
6 Compressor Shutdown LED
Lights when display is showing a compressor error.
7 Power/Start Push Button
Press and release to cycle display until
OM-240 113 Page 24
display reads GLOWPLUG. When display
reads GLOWdone, press and hold to start
engine.
Press and release to turn on power to the
display only. This allows access to the display menu.
With engine running, press and release to
toggle between low speed and high speed.
The display will flash HIGH SPd when engine is locked in high speed.
8 Engine Off Push Button
Press when engine is running to stop engine.
9 Compressor On/Off Push Button
When engine is running, press twice to
turn compressor on or off.
When engine is not running, Press and release to display MinPRESS. Press and
hold to increment minimum pressure setting.
RPM
Current fuel usage (Gallons Per Hour)
Engine hours
Engine maintenance hours (Counts down
from 400 hours)
Engine temperature
Compressor hours
Compressor maintenance hours (Counts
down from 500 hours)
. Compressor minimum pressure is set
Press and hold Status Select push button
until the error is flashed on the display.
through the control program. Compressor maximum working pressure is
set at the Air Pressure Regulator
(P−PRV). See Section 7-1.
10 Status Select Push Button
Press and release to cycle through the following displays:
. Current fuel
usage is for reference
only. Variables such as ambient temperature, altitude and fuel blend affect
actual usage.
11 Error Stored In Memory Indicator
Lights when an error message has been
stored in memory. To access the error,
place the display in RPM mode with the engine off. The display does not cycle past
RPM when the Status Select push button
is pushed repeatedly.
To erase the error, press and hold the
Status Select push button again until the
display reads SYSTEMon, and the indicator is off. The display will now cycle normally when the Status Select push button
is pushed.
6-2. Operation And Error Messages
1
2
239 661-1-A
1 Alpha−Numeric Display
The following operational messages
may appear:
CHNG OIL
Indicates an oil change is needed. This light
flashes after the first 50 hours of operation
and then at normal oil change intervals
thereafter.
If SHUTDOWNS ENGINE LED is on, engine oil change time interval has counted
down to zero, indicating it is time to change
engine oil.
To reset display after oil change, see Section 8-5.
If SHUTDOWNS COMPRESSOR LED is
on, compressor oil change time interval has
counted down to zero, indicating it is time to
change compressor oil.
To reset display after oil change, see Section 8-7.
HIGH SPd
Indicates engine is locked in high speed.
With engine running, press Power/Start
button to toggle speed.
The following error messages may appear:
. If
error message appears, consult
troubleshooting section for remedial
actions.
Hi TEMP
Indicates high compressor temperature if
SHUTDOWNS COMPRESSOR LED is
on.
OVErPRES
Indicates the compressor has an over pressure error.
OVErSPEEd
Indicates an engine over speed error.
LOW OIL
Indicates a low oil pressure condition in the
engine.
NoCHARGE
Indicates an alternator problem.
HiTEMP 1
Indicates high engine temperature if
SHUTDOWNS ENGINE LED is on. The
temperature switch has indicated high temperature.
HiTEMP 2
Indicates high engine temperature if
SHUTDOWNS ENGINE LED is on. The
temperature sensor has indicated high
temperature.
SPd SENS
Indicates a problem with the engine speed
sensor.
GovCNTRL
Indicates a problem with the engine governor control.
SEN OPEN
Indicates coolant sensor is open.
SENSHORT
Indicates coolant sensor is shorted.
ALTRNATR
Indicates an open condition in the alternator.
HiVOLTiN
Indicates high input voltage from the battery.
LoVOLTiN
Indicates low input voltage from the battery.
Optional EnVertert Power System
The following messages may appear if the
unit is equipped with the optional EnVertert power system.
ENVRT hot
Indicates the EnVerter power system is
overheated.
ENVRT com
Indicates a communication error.
ENVRT ok
Indicates the EnVerter power system is
functioning. Press Power/Start button to
enable.
HYdCAbLE
Indicates problem with crane remote interconnecting cable, plug, receptacle, or adapter harness.
2 Error Stored In Memory Indicator
Indicates error message has been stored in
memory. See Section 6-1 for information on
accessing and erasing error message.
OM-240 113 Page 25
6-3. Cold Weather Operation
The engine has glow plugs to aid starting.
Ambient Temperature
Above 50° F (10° C)
0° F to 50° F (−18° C to 10° C)
Below 0° F (−18° C)
Afterglow
Starting engine remotely − glow plug
timing automatic.
Not needed
1 to 13 seconds
20 seconds
0 to 6 seconds
Starting engine from Service Panel −
manually holding Glow Plugs switch.
Not needed
Up to 10 seconds
Up to 20 seconds
0
Plug engine block heater into 120 volts AC when unit is not running. Do not use engine block heater while unit is running.
An optional compressor oil heater is required if the unit is normally operated in temperatures below −13° F (−25° C).
6-4. Safety Interlock (Models With Hydraulic Power Source)
The safety interlock system must be engaged before the EnPak engine can be started Contact dealer for detailed description of supplied system.
. Test safety interlock monthly, see Section 8-4.
Notes
OM-240 113 Page 26
6-5. Service Panel
2
3
1
4
5
6
7
8
9
10
11
12
1
!
Manual/Remote Switch
When working on unit, always
move Manual/Remote switch to
Manual position to prevent remote
starting.
This unit can be started from a remote location when this switch is in the Remote position. Place switch in Manual position when
service side panel is open or when Remote
Panel is disconnected.
When this switch is in the Remote position,
the remaining switches on the service panel do not function.
2 Engine Speed Switch
High position is 3600 RPM and is used
when generator power is required or the
compressor or hydraulic system will be
loaded.
Low position is 2600 RPM and is used
when light loads are present.
3
Fuel Pump Switch
Use switch to power the engine ECU module and turn fuel pump on.
4
Glow Plug Switch
Push up to turn glow plugs on. See Section
6-3 for appropriate glow plug timing. Push
down to engage engine starter. Once engine has started, allow switch to return to
center position.
5
Compressor Switch
Use switch to turn compressor (clutch and
valve) on during manual operation.
6
Compressor Temperature LED
Indicates the compressor oil temperature
is too high
7
Compressor Pressure LED
239 667-1-A
Indicates the compressor pressure is too
high.
. If both the Compressor Temperature
and Pressure LEDs are lit, the compressor Pressure Safety Switch
(P−PSW) may be at fault.
8 Engine Error LED
Indicates an engine error. See Table 6-1 for
blink pattern.
9 Glow Plug LED
Indicates the glow plug is on.
10 Compressor On LED
Indicates the compressor is on.
11 Engine Crank LED
Indicates the engine is cranking.
12 Engine On LED
Indicates the engine is running.
OM-240 113 Page 27
Table 6-1. Engine Error LED Blinking Pattern
Engine errors will cause the engine to shutdown. In Manual mode, the LED will continue to blink until power is turned off and back on. In Remote mode,
the LED blinks for approximately 5 seconds; however, the error message associated with the error flashes on the alpha−numeric display for one
minute.
. If error message appears, consult troubleshooting section for remedial actions.
Blinking Pattern
Symptom
Error Message
1 Long − 1 Short
Engine over speed
OVErSPEEd
Check actuator
1 Long − 2 Short
Low oil pressure
LOW OIL
Check oil pressure sensor
1 Long − 3 Short
Low battery voltage
NoCHARGE
Check alternator terminal L
1 Long − 4 Short
High coolant temperature
HiTEMP 1
Check coolant temperature
switch
1 Long − 6 Short
High coolant temperature
HiTEMP2
Check coolant temperature
sensor
Remedy
2 Long − 1 Short
Abnormal engine speed
SPd SENS
Check engine speed sensor
2 Long − 2 Short
Engine does not run properly
GovCNTRL
Check actuator for current problem
2 Long − 4 Short
No coolant temperature signal
SEN OPEN
Check coolant temperature
sensor for open−circuit
2 Long − 5 Short
Coolant temperature signal always on
SENSHORT
Check coolant temperature
sensor for short−circuit
2 Long − 6 Short
Connection at alternator terminal
L open
ALTRNATR
Alternator disconnected at
terminal L
2 Long − 7 Short
Battery voltage too high
HiVOLTiN
Check alternator
2 Long − 8 Short
Battery voltage too low
LoVOLTiN
Check alternator
6-6. Hydraulic Pump Operation (Models With Hydraulic Power Source)
There are 3 modes that the EnPak can be placed in to deliver hydraulic output as required. This is done using the crane pendant.
NOTICE − Check crane manufacturer information to confirm the following operation.
1
Automatic speed control:
Most crane systems default to automatic speed control when first started. To place the EnPak in automatic speed control, if it is not there already, place
the crane pendant speed switch in high speed.
For open center systems, the EnPak will deliver only the required hydraulic output, based on the trigger command from the crane pendant. So for small
trigger commands from the crane pendant, the EnPak will stay at 1800 RPM and deliver up to 5 GPM of flow from the hydraulic pump. For medium
trigger pulls, the EnPak will go to 2600 RPM and deliver up to 6 GPM. For higher trigger commands from the crane pendant, the EnPak will go to 3200
RPM and deliver up to 10 GPM.
Closed center systems do not have a proportional signal available, so there is no operation at 2600 RPM.
2
Low speed lock:
For both open and close centered systems: Placing the crane pendant speed switch in the low speed position will lock the EnPak at 1800 RPM for
crane loads. If other loads are applied at the same time, the EnPak will go to the required RPM. When the EnPak is locked at 1800 RPM for crane
loads, the hydraulic output is limited to a maximum of 5 GPM.
3
High speed lock:
For both open and close centered systems: The EnPak can still be locked at 3200 RPM on most systems, by toggling the crane pendant speed switch
into high, then into low, and then back to high within 3 seconds. The EnPak will then be locked at 3200 RPM and have maximum hydraulic output.
Some crane pendants require that the speed switch is held for 3 seconds before the signal from the crane changes. This results in having just low
speed lock and automatic speed control. There would be no high speed lock for this system.
EnPak starting with hydraulic load:
To aid in starting the engine during cold weather, the proportional hydraulic valve on the EnPak pump is turned off until the speed of the engine is greater
than 1700 RPM.
SECTION 7 − COMPRESSOR OPERATION
OM-240 113 Page 28
7-1. Air Compressor Controls
1
2
805 444 / 805 451-A
!
The air pressure gauge reads the air
compressor case pressure. Case
pressure can be high even when external reservoir pressure is zero.
Wait 10 minutes for compressor
blow down cycle to complete before
checking/adding oil or performing
maintenance.
1 Air Pressure Regulator (P-PRV)
2 Air Compressor Gauge (P−PG)
Adjust system maximum pressure with the
pressure regulator. Set pressure in the noflow condition only. Set at lowest possible
pressure for the job to reduce engine loading.
. Pressure is factory set for 120 psi. Do
not set pressure above 175 psi.
Do not set pressure below 90 psi. Compressor will supply 90 psi regardless of
setting below 90 psi.
At pressures above 180 psi, the compressor clutch will temporarily disengage to prevent further pressure build-up, and OVerPRES shows temporarily on the remote
panel display. Once the compressor outlet
pressure is reduced below 175 psi, the
compressor controls reset and resume normal operation.
If pressure reaches 200 psi, the compressor clutch will disengage and shut
down. Once the compressor pressure is reduced below 175 psi, the compressor can
be manually re-started.
The compressor is also equipped with a
mechanical safety valve (P−SV) that will
open if pressure approaches 210 psi.
If the compressor continues to overpressure and disengage, see Section 9.
If compressor shuts down due to overtemperature, it automatically resets when it
cools.
OM-240 113 Page 29
7-2. Compressor Blow Down
. To prevent foaming or sudden release of pressure, allow 10 minutes after shutdown before opening the compressor oil fill cap or performing other
compressor maintenance.
To control the release of air in the compressor, the compressor goes through a blow down cycle. Blow down depressurizes the compressor case when
not running; this provides safe release of case pressure and allows reduced load at restart. Blow down also occurs when the compressor is running
but air is not required.
In ambient temperatures below freezing, compressor unload and blow down time is extended to build up heat in the compressor. This helps increase
oil temperature and remove moisture from the compressor oil.
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in.)
22 Gauge (.031 in.)
20 Gauge (.037 in.)
18 Gauge (.050 in.)
16 Gauge (.063 in.)
14 Gauge (.078 in.)
1/8 in. (.125 in.)
3/16 in. (.188 in.)
1/4 in. (.25 in.)
5/16 in. (.313 in.)
3/8 in. (.375 in.)
1/2 in. (.5 in.)
OM-240 113 Page 30
SECTION 8 − MAINTENANCE
8-1. Maintenance Label
!
When working on unit, always move Manual Remote switch on Service Panel to Manual position to prevent remote starting.
OM-240 113 Page 31
8-2. Routine Maintenance
. Use information displayed on the Alpha−Numeric display to assist in scheduling maintenance (see Section 6-1).
Engine speed is regulated by an electronic governor. Engine speed adjustments may only be performed by the engine manufacturer’s Factory
Authorized Service Agent.
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period.
. Replace engine and air compressor oil and filters after the first 50 hours of operation.
. For models with hydraulic power source, test safety interlock monthly, see Section 8-4.
!
Recycle fluids.
Stop engine before maintaining.
. See
equipment manuals and Maintenance
Label for important start-up, service, and
storage information. Service equipment
more often if used in severe conditions.
n = Check Z = Change ~ = Clean
* If unit is so equipped
Reference
Every
8
Hours
Section 5-2,
5-3, 8-1
n Remote Panel display for
maintenance information
n Coolant Level
n Truck Fuel Tank Level
~ Fluid Spills
n Engine Oil Level
n Compressor Oil Level
View oil level in sight hole.
After
First
50
Hours
Section 8-5,
8-7, Engine
Manual
Z Engine Oil
Z Compressor Oil
Z Engine Oil Filter
Every
100
Hours
Z Compressor Oil Filter
Section 8-3,
13-3
~ Air Cleaner Element
n Air Cleaner Hoses
Test Safety Valve
Every
400
Hours
Engine
Manual,
Section 8-5
Z Engine Oil
Z Engine Oil Filter
Z Fuel Filters
Every
500
Hours
or
Yearly
Section 8-7
Z Compressor Oil
Z Compressor Oil Filter
Every
1000
Hours
or
Yearly
Z Compressor Air Filter
Section 8-7
Z Air/Oil Separator
OM-240 113 Page 32
Z Hydraulic Fluid*
8-3. Servicing Engine Air Cleaner
Blow
2
1
3
Keep nozzle
2 in. (51 mm)
from element.
4
Optional
5
Inspect
REF: aircleaner1 9/02− ST-153 929-B / ST-153 585 / Ref. S-0698-B
!
Stop engine.
!
Do not run engine without air cleaner or with dirty element. Engine
damage caused by using a damaged element is not covered by the
warranty.
. The air cleaner primary element can be
cleaned but the dirt holding capacity of
the filter is reduced with each cleaning.
The chance of dirt reaching the clean
side of the filter while cleaning and the
possibility of filter damage makes
cleaning a risk. Consider the risk of unwarrantable equipment damage when
determining whether to clean or replace the primary element.
If you decide to clean the primary ele-
ment, we strongly recommend installing an optional safety element to provide additional engine protection. Never clean a safety element. Replace
the safety element after servicing the
primary element three times.
Clean or replace primary element if dirty
(see note above before cleaning). Replace primary element if damaged. Replace primary element yearly or after six
cleanings.
1
Housing
2
Safety Element (Optional)
3
Primary Element
4
Cover
5
Dust Ejector
To clean air filter:
Wipe off cover and housing. Remove cover
and dump out dust. Remove element(s).
Wipe dust from inside cover and housing
with damp cloth. Reinstall safety element (if
present). Reinstall cover.
!
Do not clean housing with air hose.
Clean primary element with compressed
air only.
Air pressure must not exceed 100 psi (690
kPa). Use 1/8 in. (3 mm) nozzle and keep
nozzle at least 2 in. (51 mm) from inside of
element. Replace primary element if it has
holes or damaged gaskets.
Reinstall primary element and cover (dust
ejector down).
8-4. Safety Interlock Monthly Check (Models With Hydraulic Power Source)
With the EnPak engine running, turn off
+12 volts DC power to the crane system.
The EnPak engine should stop.
. Check with dealer for detailed descrip-
tion of system supplied.
Power to the crane system will be sup-
plied by relays located under the hood
of the truck and activated by switches
on the parking brake or neutral transmission position; and a truck-mounted
console switch if so equipped.
Try to start the EnPak engine from the
crane remote pendant or the EnPak re-
mote control panel. The safety interlock is
working properly if the Enpak engine does
not crank or start, and the remote control
panel does not have power to it.
Restore +12 volts DC power to the crane
system. The EnPak should start and function properly.
OM-240 113 Page 33
8-5. Changing Engine Oil, Oil Filter, And Fuel Filters
!
Stop engine and let cool.
1
Oil Drain Valve
2
Oil Filter
Change engine oil and filter according to engine manual.
Tools Needed:
!
Close valve and valve cap
before adding oil and running engine.
Fill crankcase with new oil to full
mark on dipstick (see Section 5-2).
5
3
In-Line Fuel Filter
4
Fuel Line
5
Primary Fuel Filter
Replace line if cracked or worn.
Install new filters. Wipe up any
spilled fuel.
Start engine, and check for fuel
leaks.
!
Stop engine, tighten connections as necessary, and wipe
up fuel.
To reset engine maintenance
hours: Use the Status Select push
button on Remote Panel and scroll
to the Engine Maintenance Hours.
When the display shows engine
maintenance hours, press and hold
the Status Select button. This will
go through two displays that ask
RESET ??, and then RESETHr? If
the operator continues to hold the
button, dONE appears on the display and the engine maintenance
hours are reset to 400.
2
3
1
4
805 444 / S-0842
OM-240 113 Page 34
8-6. Engine Sensors And Governor Locations
1
2
3
4
1
5
6
Coolant Temperature Sensor
Actuator/Governor
Engine Speed Sensor
Coolant Temperature
Shutdown Switch
Oil Pressure Sensor
Alternator
2
3
4
6
5
805 452-A / 805 444-A
OM-240 113 Page 35
8-7. Changing Compressor Oil, Air Cleaner, And Air/Oil Separator
Tools Needed:
5/16 in.
!
Stop engine.
!
Wait 10 minutes for compressor
blow down cycle to complete before performing maintenance.
Check compressor gauge before
performing maintenance.
!
Do not run air compressor without
air cleaner or with dirty element.
Compressor damage caused by
using a damaged element is not
covered by the warranty.
1/4 in.
1
Compressor Air Cleaner Cover
2
Air Cleaner Element
Wipe off cover. Remove cover and element. Wipe dust from cover and housing
with damp cloth. Inspect element and
install new element if necessary. Reinstall cover.
!
Do not clean element with compressed air.
3
Air/Oil Separator
To replace air/oil separator:
Turn filter counterclockwise. Remove filter.
Apply thin coat of oil to gasket on new filter. Install filter and turn clockwise 1/2 to
3/4 turn after gasket contact is made.
3
1
4
Air Compressor Oil Filter
5
Air Compressor Oil Drain Fitting
6
Air Compressor Oil Fill Cap
To change compressor oil and filter:
Drain compressor oil while compressor is
still warm.
Remove fill cap and plug from oil drain fitting and drain oil into a suitable container.
Reinstall oil drain plug.
2
Remove filter by turning filter counterclockwise. Fill new oil filter with oil and apply thin coat of oil to gasket on new filter.
Install new filter and turn clockwise 1/2 to
3/4 turn after gasket contact is made.
6
Add recommended oil until oil level is half
full in sight hole (see compressor maintenance label for oil specifications). Reinstall oil fill cap. Hand−tighten cap to prevent pressure release.
Start engine, run air compressor, and
check for oil leaks.
!
Stop engine.
Check oil level and top off to fill line if necessary.
4
5
To reset compressor maintenance hours:
Use the Status Select push button on Remote Panel and scroll to the Compressor
Maintenance Hours. When the display
shows compressor maintenance hours,
press and hold the Status Select button.
This will go through two displays that ask
RESET ??, and then RESETHr? If the operator continues to hold the button, dONE
appears on the display and the compressor maintenance hours are reset to
500.
805 444 / 805 453
OM-240 113 Page 36
SECTION 9 − TROUBLESHOOTING
9-1. Generator Power Troubleshooting
Trouble
No power output.
Remedy
Reset supplementary protectors CB1, CB2 and/or CB3 (see Section 15-2).
Have Factory Authorized Service Agent check generator.
Low power output.
Check and clean engine air cleaner as necessary.
Have Factory Authorized Service Agent check engine speed.
See engine manual.
High power output.
Have Factory Authorized Service Agent check engine speed.
Erratic power output.
Have Factory Authorized Service Agent check engine speed.
Check wiring and connections.
GFCI device trips at low speed.
GFCI receptacle or extension cord not proper type for application. Replace with Miller approved GFCI
device (see Parts List).
Machine plugged into regular generator
auxiliary power does not work.
Engine speed too low and load is not recognized. Using crane remote or EnPak remote panel, manually place engine in high speed (see Section 6-1 item 7 for EnPak remote panel).
9-2. Engine Troubleshooting
Trouble
Engine will not crank.
Remedy
Check battery connections and tighten if necessary.
Check battery voltage.
Check Manual/Remote switch on Service Panel.
Check to ensure crane power switch and safety interlock are working (see Section 8-4).
Have Factory Authorized Service Agent check Remote Panel.
Engine does not start.
Check fuel level.
Check battery and replace if necessary.
Check engine charging system according to engine manual.
Have Factory Authorized Service Agent check fuel pump.
See engine manual.
Engine starts but stops.
Check oil level (see Section 5-2). Low oil pressure shutdown stops engine if oil pressure is too low.
Use correct grade oil for operating temperature. (see Section 8-1).
Have Factory Authorized Service Agent check low oil pressure shutdown switch S2.
Engine stopped during normal
operation.
Check fuel level (see Section 5-2).
Check oil level (see Section 5-2). Low oil pressure shutdown stops engine if oil pressure is too low.
Oil level too high reduces capacity of the fuel pump.
Have Factory Authorized Service Agent check throttle solenoid TS1 according to engine manual.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S2.
Engine does not return to idle speed.
Remove all generator power loads, compressor loads, and hydraulic loads.
Check remote panel and crane pendant to see if system is locked in high speed.
OM-240 113 Page 37
Trouble
Remedy
Engine does not return to idle speed
(Continued).
Have Factory Authorized Service Agent check circuit board PC2 and current transformer CT1.
Engine speed does not remain constant.
GFCI receptacle or extension cord not proper type for application. Replace with Miller approved GFCI
device (see Parts List).
Engine does not remain at power
speed when a load is applied with
crane pendant speed switch in the Low
or Idle position.
For small loads, place crane pendant speed control switch in the High or Fast position, or push Power
Start button on remote control panel to lock in high speed.
During operation in near freezing temperatures, engine starts and goes to
idle but stalls after a few minutes.
Place crane pendant speed control switch in the High or Fast position until unit has been in operation
and loaded for a period of time.
During operation in severe cold weather, engine starts and goes to idle but
stalls after a few minutes.
Install engine manufacturer’s kit for cold-weather operation. Normal maximum glow plug time is 10
seconds. In ambient temperatures below 0° F, glow plug time is 20 seconds maximum. Check glow
plug timing to ensure proper heating before cranking engine.
9-3. Compressor Troubleshooting
Trouble
Remedy
Air compressor does not operate; no air Cycle compressor to on position.
pressure on gauge.
Check compressor belt tension. Be sure correct belt is used and is properly installed.
Have Factory Authorized Service Agent check inlet valve P-IC.
Have Factory Authorized Service Agent check air compressor control circuit and clutch.
Air compressor stops after short period Automatic shutdown stops compressor if compressor temperature is too high or over−pressure condition
of operation.
occurs.
Check compressor oil level (see Section 5-3). Check for clogged oil cooler. Clean debris from oil cooler.
Recirculation or open covers may cause overheating. Be sure all covers, panels, and doors are in place.
Operate in area with proper airflow.
Check for over-pressure condition by turning on compressor and monitoring air pressure and remote display for error messages.
Low air pressure.
Check for leaks in air lines and hoses, including control line.
Adjust compressor air pressure using pressure regulator (P-PRV) (see Section 7-1).
Check air compressor air cleaner (see Section 8-7).
Have Factory Authorized Service Agent check compressor for rated output.
High air pressure.
Adjust compressor air pressure using pressure regulator (P-PRV) (see Section 7-1).
Be sure control line is connected at proportional control (P-PC), and unload solenoid valve (P-USV).
Check for frozen pressure regulator (P-PRV) at proportional control (P-PC), frozen intake control (P-IC),
or frozen control lines.
Oil in air from compressor.
Check compressor oil level (see Section 5-3). If oil level is too high, system becomes saturated with oil.
Change compressor air/oil separator if close to replacement hours (see Section 8-7).
Oil in compressor air cleaner.
Have Factory Authorized Service Agent check for blocked separator scavenge check valve/filter orifice.
Have Factory Authorized Service Agent verify compressor intake valve P-IC is operating properly.
Water in compressor oil.
OM-240 113 Page 38
Have Factory Authorized Service Agent check thermostat operation.
9-4.
Hydraulic Troubleshooting (Models With Hydraulic Power Source)
Trouble
Remedy
No crane operation.
No oil in system. Add oil.
No crane operation (continued).
Suction line valve closed. Open valve.
Hydraulic system not primed. Prime system (see Section ). Check reservoir height meets requirements (see Section 11-1).
Flow control valve H−FC1 not functioning. Check to make sure solenoid is plugged in. Check wiring
harness to solenoid coil. Have Factory Authorized Service agent check solenoid coil.
Flow control valve H−FC1 plugged with contaminants. Replace valve and flush system.
Belt to pump failed. Replace belt.
Tensioner for belt to pump failed. Replace tensioner.
Pulleys for pump failed. Replace pulleys and/or keys.
Slow crane operation; unit comes up to
higher speed.
Other functions in use and unit is power−managing. Unit functioning correctly.
Flow control valve H−FC1 is partially plugged with contaminates causing higher pressure drop across
the valve. Replace valve and flush system.
Differential pressure setting of pump (load sense) set too low. Have Factory Authorized Service Agent
check setting and correct as necessary.
Displacement setting of pump set too low. Have Factory Authorized Service Agent check setting and
correct as necessary.
Check crane model hydraulic requirements. Pump may need to be reset (consult Factory Authorized
Service Agent).
Flow being dumped through crane relief valve instead of being directed to system, possibly caused by
system contamination. See crane manufacturer’s owners manual.
Hydraulic oil viscosity too high. See Section 11-1 for correct fluid viscosity recommendations at specific ambient temperatures.
Slow crane operation; unit remains at
low speed.
Open−Center systems: No trigger signal from crane pendant present. Have Factory Authorized Service Agent check for trigger signal.
Closed−Center systems: Pressure switch H−PS1 not functioning . Have Factory Authorized Service
Agent check pressure switch and replace as necessary.
Slow response for unit to come up to
higher speed (Closed−Center systems).
Air trapped in load sense line. Bleed load sense line according to Section 11-4.
Fast crane operation.
Differential pressure setting of pump (load sense) set too high. Have Factory Authorized Service
Agent check setting and correct as necessary.
Displacement setting of pump set too high. Have Factory Authorized Service Agent check setting and
correct as necessary.
Check crane model hydraulic requirements. Pump may need to be reset (consult Factory Authorized
Service Agent).
Hydraulic oil viscosity too low. Consult Section 11-1 for correct fluid viscosity recommendations at
specific ambient temperatures.
No outrigger operation.
No oil in system. Add oil.
Suction line valve closed. Open valve.
Hydraulic system not primed. Prime system (see Section11-3). Check reservoir height meets requirements of Section 11-1.
Flow control valve H−FC1 not functioning. Check to make sure solenoid is plugged in. Check wiring
harness to solenoid coil. Have Factory Authorized Service Agent check solenoid coil integrity.
Flow control valve H−FC1 plugged with contaminants. Replace valve and flush system.
Belt to pump failed. Replace belt.
Tensioner for belt to pump failed. Replace tensioner.
Pulleys for pump failed. Replace pulleys and/or keys.
OM-240 113 Page 39
Trouble
Slow outrigger operation.
Remedy
Flow control valve H−FC1 is partially plugged with contaminates causing higher pressure drop across
the valve. Replace valve and flush system.
Differential pressure setting of pump (load sense) set too low. Have Factory Authorized Service Agent
check setting and correct as necessary.
Flow being dumped through crane relief valve instead of being directed to system, possibly caused by
system contamination. See crane manufacturer’s owners manual.
Hydraulic oil viscosity too high. Consult Section11-1 for correct fluid viscosity recommendations at
specific ambient temperatures.
Fast outrigger operation.
Differential pressure setting of pump (load sense) set too high. Have Factory Authorized Service
Agent check setting and correct as necessary.
Hydraulic oil viscosity too low. Consult Section 11-1 for correct fluid viscosity recommendations at
specific ambient temperatures.
Crane lifting capacity not met (low
pressure).
Pump maximum pressure setting too low. Check setting and correct as necessary.
Check crane model hydraulic requirements. Pump may need to be reset (consult Factory Authorized
Service Agent).
Relief valve in crane system set too low. See crane owner’s manual to correct.
Relief valve in crane system stuck open from contamination. See crane owner’s manual to correct.
Hydraulic pump belt slipping. Replace belt and/or tensioner.
Notes
OM-240 113 Page 40
SECTION 10 − AUTHORIZED DEALER INSTALLATION
INFORMATION
10-1. Serial Number And Rating Label Location
The serial number and rating information for this product is located on the service side base. Use rating label to determine rated output. For future
reference, write serial number in space provided on back cover of this manual.
10-2. Installing Unit
Movement
!
Do not move or operate unit
where it could tip.
!
Always securely fasten unit
onto transport vehicle and
comply with all DOT and other
applicable codes.
NOTICE − Do not install unit where
air flow is restricted or engine may
overheat.
. See Section 10-3 for mounting
OR
information. See Section 4-5 for
dimensions.
1
2
Location/Airflow Clearance
Typical hydraulic reservoir placement in relation to EnPak. See Section 11-1 for complete reservoir requirements.
2
1
Hydraulic Reservoir (Models
With Hydraulic Power Source)
EnPak
1
2
18 in.
(460 mm)
7 in. (178 mm) Maintenance
4 in. (102 mm) Operation
1 in.
(25 mm)
!
!
Hot air.
Hot air.
1 in.
(25 mm)
!
Hot air.
7 in. (178 mm) Maintenance
4 in. (102 mm) Operation
Ref: install3 2008-01 − 805 454-A / 805 442-A
OM-240 113 Page 41
10-3. Mounting Unit
NOTICE − Do not mount unit by
supporting the base only at the four
mounting brackets. Use cross-supports to adequately support unit
and prevent damage to base.
Supporting The Unit
. See
Section 4-5 for dimensions.
Mounting Surface:
1
2
2
Cross-Supports
Mounting Brackets (Supplied)
Mount unit on flat surface or use
cross-supports to support base.
Secure unit with mounting brackets.
3
OR
4
1/2 in Bolt And Washer
(Minimum − Not Supplied)
3/8-16 x 1 in. Screws
(Supplied)
To Bolt Unit In Place:
1
Remove hardware securing the
four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
Mount unit to vehicle with 1/2 in. (12
mm) or larger hardware (not supplied).
To Weld Unit In Place:
Weld unit to vehicle only at the four
mounting brackets.
1
Using Mounting Brackets
2
Welding Unit In Place
Bolting Unit In Place
3
2
Tools Needed:
9/16 in
4
Ref: install3 2008--01 803 274 / 200 864-A / 803 231
OM-240 113 Page 42
SECTION 11 − HYDRAULIC SYSTEM PREPARATION
(MODELS WITH HYDRAULIC POWER SOURCE)
11-1. Hydraulic System Integration
A. General Information − Minimum Requirements
The system recommendations are intended for operating a crane of a low duty cycle, such as used on a mechanics truck. The system recommendations are based on intermittent use. Auxiliary tools or operations that need continuous or high duty cycle operation will require additional cooling
capacity.
For use with a mechanics truck crane, the system should at a minimum include the following items:
1
2
3
4
Reservoir of 20 gal (76 L) or more capacity
Pressure relief valve
Properly sized hoses and fittings, restrained and protected
Return line filter to maintain an ISO 4406:1999 Cleanliness Code of 18/16/13.
B. Reservoir
Minimum reservoir size is 20 gal (76 L) with a minimum fluid height of 24 in. ( 610 mm) above base of unit. To accommodate changes in volume due to
cylinder displacement, a filtered breather must be used and vented to atmosphere. This filter should be 10 micron.
The design of the reservoir must allow for adequate oil circulation to disperse entrapped air and to maintain sufficient cooling through the use of baffles.
Changes in oil volume due to cylinder displacement also needs to be accounted for by allowing adequate air space inside the reservoir. The unit must
operate properly at up to a 15° angle.
Place reservoir as near as possible to the unit, see Section 10-2. Suction line length greater than 72 in. (1829 mm) is NOT recommended.
The suction port should be at least 3 in. (76 mm) above the bottom of the reservoir to prevent any debris on the bottom of the reservoir from being drawn
into the suction line. Also, the suction port should be at least 6 in. (152 mm) below the top level of the fluid to prevent vortexing. Oil volume changes
during operation and the 15° maximum operating angle must be considered.
A suction strainer is not recommended by the hydraulic pump manufacturer. If a suction strainer is used, diligent preventive maintenance is required to
prevent the strainer from clogging.
System return lines and drain lines should terminate below the minimum fluid level to prevent aeration of the oil. Return lines should be located away
from the suction line to prevent interaction.
Allowance for a properly sized immersion heater may be necessary in some climates.
C. Pressure Relief Valve
. With the use of a pressure compensated pump, the use of a relief valve is recommended in the main circuit to suppress hydraulic shock loads
and add additional system protection.
Open−Centered Systems:
The system relief valve should be set according to the crane manufacturer’s recommendations. The maximum pressure of the pump should be set 200
psi (1.38 MPa) above the system relief valve to prevent interaction. For settings above 3800 psi (26.2 MPa), consult the factory.
In this configuration, the system relief valve is the primary relief and the pump maximum pressure setting is secondary.
Closed−Centered Systems:
For most closed−centered systems, the pump maximum pressure setting is the primary relief and the system relief valve is secondary. Therefore, the
pump maximum pressure setting should be set at a level recommended by the crane manufacturer. The system relief valve should also be set according to the crane manufacturer’s recommendations. In general, this will be approximately 200 psi (1.38 MPa) greater than the pump maximum pressure
setting.
D. Hoses And Fittings
All hoses should be sized appropriately according to flow capacity and pressure loss. See Table 11-1 as a guide. Higher system pressures may require
higher pressure hoses.
For the suction line, use sweep elbows to prevent fluid turbulence and reduce the possibility of cavitation at the pump inlet.
Use of quick disconnects in any line is not recommended. Using quick disconnects will cause higher system losses, result in elevated fluid temperature,
and reduced system performance.
OM-240 113 Page 43
Obtain hoses of the proper length and type with appropriate fittings for the installation according to Table 11-1.
Table 11-1. Hydraulic Hoses Specifications
Hydraulic Hoses
System Flow Rate
Hose ID
Suction Line1
up to 10 gpm
over 10 gpm, up to 20 gpm
up to 10gpm
over 10 gpm, up to 20 gpm
All flow rates
All flow rates
in. / mm
1.25 / 31.76
1.5 / 38.1
0.5 / 12.7
0.75 / 19.05
0.625 / 15.88
0.25 / 6.35
Pressure Line2
Minimum
Working
Pressure
psi / MPa
150 / 1.03
Minimum
Burst
Pressure
psi / MPa
600 / 4.14
3000 / 20.68
12000 / 82.74
Vacuum Service
Operating
Temperature
Inches of Hg / kPa
28 / 94.82
Degree C
−40 to 100
−40 to 100
Case Drain3
350 / 2.41
1400 / 9.65
−40 to 100
Load Sense
3000 / 20.68
12000 / 82.74
−40 to 100
(Closed Center)4
Return Line Less
up to 10 gpm
0.625 . 15.88
−40 to 100
Than 10 gpm5
over 10 gpm, up to 20 gpm
0.75 / 19.05
1 − Based on 2−4 fps velocity. Sweep elbows required. Barbed fittings acceptable with two hose clamps. Connection: JIC (37°)−24,
1-7/8−12 thread, torque 160 ft. lb.
2 − Based on 15−20 fps velocity. Connection: JIC (37°)−12, 1−1/16 −12, torque 80 ft. lb.
3 − Based on 2 gpm with a pressure drop of less than 10 psi and length less than 10 ft. Connection: JIC (37°)−10, 7/8−14, torque 60 ft. lb.
4 − Applicable only to closed−center system. Connection: JIC (37°)−4, 7/16 −20, torque 12 ft. lb.
5 − Based on 10−15 fps velocity. The line should connect directly back to reservoir through a return filter. Filter cleanliness code: 18/16/13
or better.
E. Filtration
System filtration requirements are to maintain a cleanliness code of 18/16/13 per ISO 4406:1999.
Filtration should be met with the use of a return line filter. Per the pump manufacturer, the use of suction line strainer is not recommended due to clogging
issues.
The filter must be compatible with all petroleum and synthetic hydraulic fluids. The filter should operate in a temperature range of −30°C to 121°C.
Consideration should be given to the filter bypass rating. Excessive bypass at low temperatures should be avoided.
F. Hydraulic Fluid
Premium grade petroleum−based fluid that contains anti−wear agents, rust inhibitors, anti−foaming agents, and oxidation inhibitors and has an ISO VG
rating as recommended.
Table 11-2. Hydraulic Fluid Specifications
Ambient Temperature
Viscosity Grade
0° F to 90° F (−18° C to 32° C)
ISO 32
Less than 0° F (less than−18° C)
ISO 15
Greater than 90° F (greater than 32° C)
ISO 46
General fluid recommendations:
Recommended operating viscosity: 16−40 cSt
Maximum continuous viscosity: 430 cSt
Maximum start−up viscosity: 2100 cSt
Minimum intermittent viscosity: 6 cSt
Viscosity Index (VI): Greater than 120
OM-240 113 Page 44
11-2. Hydraulic Hose Connections
!
Hydraulic fluid is flammable.
Do not work on hydraulics
near sparks or flames; do not
smoke near hydraulic fluid.
Route all hoses away from
hot, sharp or moving parts.
Check all connections and
hoses for damage, leaks, and
wear.
1
2
3
4
Suction Line Connection
Case Drain Connection
Pressure Line Connection
Load Sense Line Connection
(If Applicable)
Connect hoses and torque connections.
1
2
Hose
Torque
Suction
160 ft lb (217 N⋅m)
Case Drain
60 ft lb (81 N⋅m)
Pressure Line
80 ft lb (108 N⋅m)
Load Sense
12 ft lb (16 N⋅m)
Tools Needed:
4
3
2-1/4. 1-1/4. 1, 9/16 in.
(57, 31, 25, 14 mm)
805 443-A / 287 097-C
OM-240 113 Page 45
11-3. Priming Hydraulic Pump
2
1
3
4
5
243 965-A / 805 444 / 239 667-1-A
!
When working on unit, always
move Manual/Remote switch to
Manual position to prevent remote
starting. See Section 6-5.
1
Proportional Valve Assembly
2
Manual Override Screw Adjust
3
Service Panel
4
Manual Override Switch
5
Fuel Pump Switch
Make hydraulic system connections according to Section 11-2.
OM-240 113 Page 46
Fill hydraulic pump case with oil at its
highest point.
Fully open suction line valve at the reservoir. Screw manual override screw fully
clockwise (fully opens proportional valve).
On Service Panel, place Manual/Remote
switch in the Manual position. Place the
Fuel Pump switch in the Off position.
Crank the engine for 10 seconds, pause,
crank again for 10 seconds, pause and
crank for an additional 10 seconds. This
should prime the hydraulic pump.
Screw the manual override screw fully
counterclockwise.
Place the Service Panel Manual/Remote
switch in the Remote position. Place the
Fuel Pump switch in the On position.
Start the engine using the remote panel.
Let the engine run 5 to 10 minutes with no
load.
Pressure and displacement are set at the
factory and should not require initial adjustment. Have Factory Authorized Service Agent correct pressure or displacement settings.
11-4. Load Sense Line Bleeding (Closed Center Systems Only)
1
Load Sense Line Bleeding
Valve
For systems utilizing closed−center
valving and load sensing, the load
sense line must be bled of air near
the pump. This is accomplished using the push−activated valve on the
load sense line.
Remove the spout cap from the
valve. Attach a 3/16 in. (4.7 mm)
tube to the spout and drain to a suitable container. While the unit is running, operate a crane function with
pressure below 700 psi (4.8 MPa)
and simultaneously press the valve
in. Continue this until all air is removed from the line. Release valve
and replace cap.
1
Top View
805 444
OM-240 113 Page 47
SECTION 12 − ENGINE PREPARATION
12-1. Connecting the Battery
1
!
Route battery cables
away from hot, sharp, or
moving parts.
!
Connect negative (−)
cable last.
1
Battery Cable Strain
Relief
EnPak Engine Block
Starter
2
3
Route cables from vehicle battery through strain relief.
Connect positive (+) cable to
engine starter. Connect negative (−) cable to unit engine
block.
Battery Specification:
12 V, 650 CCA at 0° F
Battery Cable Specification:
1
1/0 AWG
2
3
Tools Needed:
1/2 in
805 444 / 287 097-B
OM-240 113 Page 48
12-2. Installing Exhaust Pipe
!
Engine backfire can cause severe burns or other injuries.
Keep away from exhaust outlet.
!
Do not point exhaust pipe toward any compressed gas
tank.
. Point exhaust pipe in desired di-
2
1
3
rection but always away from direction of travel.
1 Exhaust Pipe
2 Clamp
3 Nut
Exhaust pipe, clamp and hardware
are shipped separately. Install exhaust pipe as shown.
Tools Needed:
1/2 in
805 445-A
Notes
OM-240 113 Page 49
12-3. Fuel Connections
!
Route all hoses away from
hot, sharp or moving parts.
Check all connections and
hoses for damage, leaks, and
wear.
1
2
Fuel Pickup Connection
Fuel Return Connection
Select hose rated to SAE 30R7,
and certified to section 2754
(a)(1)(C) of the California Air Resources Board 2006 Emission
Regulations.
Fuel pickup hose should be 5/16 in.
(7.9 mm) ID minimum.
Fuel return hose should be 1/4 in.
(6.3 mm) ID minimum.
Connect hoses and secure hose
clamps.
Tools Needed:
2
1
805 443-A / 287 097
OM-240 113 Page 50
SECTION 13 − AIR COMPRESSOR SYSTEM PREPARATION
13-1. Air Compressor System Integration
A. General Information − Minimum Requirements
For use with a mechanics truck crane, the system should at a minimum include the following items:
1 Reservoir of 20 gal (76 L) or more capacity
2 Safety relief valve
3 Properly sized hoses and fittings, restrained and protected
Depending on the desired compressed air quality, air conditioning components such as separators, filters or dryers may be required.
No check valve should be installed.
B. Reservoir
Recommended reservoir size is 20 gal (78 L) or larger. The addition of an air reservoir provides air delivery capacity and aids in reducing the amount of
water and contaminates discharged to the rest of the system by condensing out these contaminants. The reservoir should be ASME Code for 200 psi
working pressure. A drain valve should also be installed for draining water and contaminants.
The reservoir must have a safety relief valve installed of appropriate relieving pressure and capacity of the system. Also, relief valve must comply with
vessel and code under which the vessel is constructed and inspected.
C. Hoses And Fittings
Obtain hoses of the proper length and type with appropriate fittings for the installation according to Table 13-1.
Table 13-1. Air Compressor Hose Specification
Hose ID
in. / mm
0.5 / 12.7
Minimum
Working
Pressure
psi / MPa
350 / 2.41
Minimum
Burst
Pressure
psi / MPa
1400 / 9.65
Operating
Temperature
Degree C
−40 to 100
D. Compressor Oil
. Mobil 1 Synthetic ATF is recommended. Do not mix oil types.
The cooling oil must have high ageing stability, corrosion protection, and dispersive capacity; low emulsification tendency, and minimum foaming. Viscosity class ISO VG 68 is recommended.
OM-240 113 Page 51
13-2. Compressor Connections
!
Stop engine and release air
pressure before servicing
compressor.
1
Air Compressor Connection
Connect and secure hose. After
hand-tightening connections, tighten 2 to 3 full turns.
Tools Needed:
1-1/6 in. (27 mm)
1
805 443-A / 287 097
OM-240 113 Page 52
13-3. Compressor Safety Valve Testing
1
Safety Valve (P−SV)
. The safety valve is factory set
for 210 psi maximum. Do not alter.
The safety valve is mounted on the
separator receiver in front of the air/
oil separator filter. The safety valve
should be tested frequently at regular intervals to ensure it is in good
working order.
The valve is type−tested and
leaded. It is spring weighted. It is
equipped with a testing device.
To test the valve, turn the knurled
screw on top counterclockwise until
an audible discharge is heard. Reset by turning clockwise until it
stops.
1
Top View
805 444
OM-240 113 Page 53
SECTION 14 − REMOTE DEVICES CONNECTIONS
14-1. Remote Devices Connections
1
EnPak Remote Panel
Connection Receptacle RC12
Mount remote panel inside of truck
body cabinets where easily accessible. Connect interconnecting
cable Part No. 238027 between remote panel and RC12.
2
1
Crane Remote Connection
Receptacle RC13
NOTICE − Connect to this receptacle only when EnPak is equipped
with hydraulic power source used
to power a hydraulic crane apparatus.
2
Crane remote control provided by
crane manufacturer. Connect appropriate harness adapter into the
crane harness (see instructions
provided with harness adapter kit).
Connect interconnecting cable Part
No. 244283 between crane remote
and RC13.
See end of Section 18 for list of harness adapters available.
Bottom View
805 443-A / 287 097
OM-240 113 Page 54
SECTION 15 − AUXILIARY POWER SYSTEM CONNECTIONS
15-1. Grounding Auxiliary Power System To Truck Frame
!
Always ground auxiliary
power system to vehicle
frame to prevent electric
shock and static electricity
hazards.
!
Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
1
Auxiliary Power System
Ground
Route auxiliary power cables and
grounding cable away from hot,
sharp or moving parts.
2
3
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
Connect cable from auxiliary power
system ground to metal vehicle
frame. Use #8 AWG or larger insulated copper wire.
. Electrically
bond generator
frame to vehicle frame by metal-to-metal contact.
1
240V
120V
120V/60HZ
!
Always connect a ground
wire from the auxiliary power
system ground to bare metal
on the vehicle frame as
shown.
!
If a GFCI receptacle is installed, it must be a Millerrecommended GFCI receptacle (see Parts List). The
generator does not provide
usable power at engine idle
speed (1800 rpm). Other
GFCI receptacles cannot be
used. The low frequency/low
voltage may prevent other
GFCI receptacles from operating properly.
!
If unit powers GFCI receptacles, test at least once a
month by running engine at
high speed and pressing
Test button to verify GFCI is
working properly.
!
If unit does not power GFCI
receptacles, use GFCI-protected extension cord. Lock
engine in high speed to
provide the GFCI with correct voltage and frequency
to function properly.
At least once a month, run
engine at high speed and
press Test button to verify
GFCI is working properly.
120V
E
120V/60HZ
EnVertert
SUPPLY
D
C
120V/240V
NEUTRAL
NEUTRAL
2
B
A
120V/240V
F
NEUTRAL
BONDED
TOFRAME
3
805 444 / 805 447-A / Ref 287 066
OM-240 113 Page 55
15-2. Auxiliary Power System Connections And Overload Protection
240V
120V
B
A
GROUND
120V/240V
NEUTRAL
120V/240V
120V/60HZ
EnVertert
SUPPLY
C
NEUTRAL
F E D
Stop engine and let cool.
!
Keep wiring away from hot, sharp, or
moving parts.
1
Terminal Block 1T
120 VAC power is available between 1TA and
1TD or 1TE and 1TD.
120V
120V/60HZ
!
NEUTRAL
BONDED
TOFRAME
NOTICE − If the high speed (3600 RPM)
120V/20A circuit is used, a supplementary
protector must be installed to match the amperage rating of the receptacle. See
Figure 16-6.
240 VAC power is available between 1TA and
1TE, with terminal 1TC as neutral.
Optional 120 VAC EnVertert power is available between 1TF and 1TD.
See truck wiring diagram Figure 16-6.
Combined output of all generator loads cannot exceed 6 kVA/kW. Combined output of all
EnVerter power loads cannot exceed 2.4
kVA/kW.
Route conductors through strain relief in right
side of unit to auxiliary power box for connection.
2
3
4
Supplementary protector CB1 protects the
generator winding from overload when a
120/240 VAC load is connected.
Tools Needed:
Supplementary protector CB2 protects the
optional EnVerter power supply from overload
when a 120 VAC load is connected.
3
2
4
1
Supplementary Protector CB2
Supplementary Protector CB3
Supplementary Protector CB1
Supplementary protector CB3 protects the
generator winding from overload if the compressor heater fails.
. If supplementary protector
continues to
open, contact Factory Authorized Service Agent.
. When the EnPak is running at 1800 RPM,
the voltage output of the generator is too
low to activate some electric machines
that require the full 120 VAC or 240 VAC
for operation. If the electric machine that
you are using is not recognized as a load
by the EnPak, and does not turn on, place
the EnPak in high speed. This will bring
the output of the generator up to the normal 120 VAC or 240 VAC level, and the
machine that is plugged into the generator should work normally. This is for the
standard generator power only, and does
not apply to the EnVerter power output
which is 120 VAC regardless of engine
RPM.
805 444 / 287 066 / 287 097-D
OM-240 113 Page 56
Notes
MATERIAL THICKNESS REFERENCE CHART
24 Gauge (.025 in)
22 Gauge (.031 in)
20 Gauge (.037 in)
18 Gauge (.050 in)
16 Gauge (.063 in)
14 Gauge (.078 in)
1/8 in (.125 in)
3/16 in (.188 in)
1/4 in (.25 in)
5/16 in (.313 in)
3/8 in (.375 in)
1/2 in (.5 in)
OM-240 113 Page 57
SECTION 16 − DIAGRAMS
Figure 16-1. EnPak Circuit Diagram
OM-240 113 Page 58
241 852-F
OM-240 113 Page 59
OM-240 113 Page 60
Figure 16-2. Compressor Circuit Diagram
240 859-C
238 945-B1
Figure 16-3. Hydraulic Circuit Diagram Page 1 (Models With Hydraulic Power Source)
OM-240 113 Page 61
238 945-B2
Figure 16-4. Hydraulic Circuit Diagram Page 2: Typical Open−Center Configuration
(Models With Hydraulic Power Source)
OM-240 113 Page 62
238 945-B3
Figure 16-5. Hydraulic Circuit Diagram Page 3: Typical Closed−Center With Load Sense Configuration
(Models With Hydraulic Power Source)
OM-240 113 Page 63
242 500-C
Figure 16-6. EnPak Truck Wiring Diagram
OM-240 113 Page 64
SECTION 17 − GENERATOR POWER GUIDELINES
. The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown.
17-1. Selecting Equipment
1
2
3
1
Generator Power Receptacles
− Neutral Bonded To Frame
3-Prong Plug From Case
Grounded Equipment
2-Prong Plug From Double
Insulated Equipment
. Be sure equipment has double
insulated symbol and/or wording on it.
2
!
Do not use 2-prong plug unless equipment is double insulated.
3
OR
gen_pwr 2010−04 − ST-800 577
17-2. Grounding Generator To Truck Or Trailer Frame
!
Always ground generator
frame to vehicle frame to prevent electric shock and static
electricity hazards.
!
Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
1
Equipment Grounding
Terminal (On Front Panel)
Grounding Cable (Not
Supplied)
Metal Vehicle Frame
2
3
1
2
GND/PE
Connect cable from equipment
ground terminal to metal vehicle
frame. Use #8 AWG or larger insulated copper wire.
. Electrically
bond generator
frame to vehicle frame by metal-to-metal contact.
3
!
Bed liners, shipping skids,
and some running gear insulate the welding generator
from the vehicle frame. Always connect a ground wire
from the generator equipment grounding terminal to
bare metal on the vehicle
frame as shown.
!
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
800 652-D
OM-240 113 Page 65
17-3. Grounding When Supplying Building Systems
1
1
2
2
GND/PE
Equipment Grounding
Terminal
Grounding Cable
Use #8 AWG or larger insulated
copper wire.
3
Ground Device
. Use ground device as stated in
electrical codes.
2
!
Ground generator to system
earth ground if supplying
power to a premises (home,
shop, farm) wiring system.
!
Also see AWS Safety &
Health Fact Sheet No. 29,
Grounding of Portable And
Vehicle Mounted Welding
Generators.
3
ST-800 576-B
17-4. How Much Power Does Equipment Require?
1
Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2
3
2
1
VOLTS 115
AMPS 4.5
Hz
60
Non-Resistive Load
Equipment with a motor is a non-resistive load and requires approximately six times more power while
starting the motor than when running
(see Section 17-8).
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
Amperes x Volts = Watts
3
Example 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Example 1, add the individual loads to
calculate total load.
(3 x 200W) + 520 W = 1120 W
The total load applied by the three
flood lamps and drill is 1120 watts.
S-0623
OM-240 113 Page 66
17-5. Approximate Power Requirements For Industrial Motors
Industrial Motors
Split Phase
Capacitor Start-Induction Run
Capacitor Start-Capacitor Run
Fan Duty
Rating
Starting Watts
Running Watts
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/8 HP
1/6 HP
1/4 HP
1/3 HP
1/2 HP
800
1225
1600
2100
3175
2020
3075
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
400
550
650
800
1100
17-6. Approximate Power Requirements For Farm/Home Equipment
Farm/Home Equipment
Stock Tank De-Icer
Grain Cleaner
Portable Conveyor
Grain Elevator
Milk Cooler
Milker (Vacuum Pump)
FARM DUTY MOTORS
Std. (e.g. Conveyors,
Feed Augers, Air
Compressors)
High Torque (e.g. Barn
Cleaners, Silo Unloaders,
Silo Hoists, Bunk Feeders)
3-1/2 cu. ft. Mixer
High Pressure 1.8 Gal/Min
Washer 2 gal/min
2 gal/min
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
Rating
1/4 HP
1/2 HP
3/4 HP
2 HP
1/3 HP
1/2 HP
3/4 HP
1 HP
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
5 HP
7-1/2 HP
10 HP
1/2 HP
500 PSI
550 PSI
700 PSI
1/3 HP
1/2 HP
1/3 HP
1/2 HP
Starting Watts
Running Watts
1000
1650
3400
4400
2900
10500
1720
2575
4500
6100
8200
10550
15900
23300
8100
23300
35000
46700
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
650
1000
1400
1100
2800
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10700
1000
950
1400
1600
800
750
1000
800
1050
OM-240 113 Page 67
17-7. Approximate Power Requirements For Contractor Equipment
Contractor
Hand Drill
Circular Saw
Table Saw
Band Saw
Bench Grinder
Air Compressor
Electric Chain Saw
Electric Trimmer
Electric Cultivator
Elec. Hedge Trimmer
Flood Lights
Submersible Pump
Centrifugal Pump
Floor Polisher
High Pressure Washer
55 gal Drum Mixer
Wet & Dry Vac
OM-240 113 Page 68
Rating
Starting Watts
Running Watts
1/4 in
3/8 in
1/2 in
6-1/2 in
7-1/4 in
8-1/4 in
9 in
10 in
14 in
6 in
8 in
10 in
1/2 HP
1 HP
1-1/2 HP
2 HP
1-1/2 HP, 12 in
2 HP, 14 in
Standard 9 in
Heavy Duty 12 in
1/3 HP
18 in
HID
Metal Halide
Mercury
Sodium
Vapor
400 gph
900 gph
3/4 HP, 16 in
1 HP, 20 in
1/2 HP
3/4 HP
1 HP
1/4 HP
1.7 HP
2-1/2 HP
350
400
600
500
900
1400
4500
6300
2500
1720
3900
5200
3000
6000
8200
10500
1100
1100
350
500
2100
400
125
313
1000
1400
1250
600
900
4500
6100
3150
4500
6100
1900
900
1300
350
400
600
500
900
1400
1500
1800
1100
720
1400
1600
1000
1500
2200
2800
1100
1100
350
500
700
400
100
250
1000
200
500
1400
1600
950
1400
1600
700
900
1300
17-8. Power Required To Start Motor
Single-Phase Induction Motor Starting Requirements
Motor Start
Code
G
H
J
K
L
M
N
P
KVA/HP
6.3
7.1
8.0
9.0
10.0
11.2
12.5
14.0
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
1
2
3
4
2
Motor Start Code
Running Amperage
Motor HP
Motor Voltage
To find starting amperage:
Step 1: Find code and use table to
find kVA/HP. If code is not listed,
multiply running amperage by six to
find starting amperage.
Step 2: Find Motor HP and Volts.
Step 3: Determine starting amperage (see example).
Welding generator amperage output must be at least twice the
motor’s running amperage.
(kVA/HP x HP x 1000) / Volts =
Starting Amperage
Example: Calculate starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M.
Volts = 230, HP = 1/4, kVA/HP =
11.2
(11.2 x 1/4 x 1000) / 230 = 12.2A
Starting the motor requires 12.2
amperes.
S-0624
17-9. How Much Power Can Generator Supply?
1
1
Limit Load To 90% Of
Generator Output
Always start non-resistive (motor)
loads in order from largest to smallest, and add resistive loads last.
2
2
5 Second Rule
If motor does not start within 5
seconds, turn off power to prevent
motor damage. Motor requires
more power than generator can
supply.
Ref. ST-800 396-A / S-0625
OM-240 113 Page 69
17-10. Typical Connections To Supply Standby Power
1
2
Utility
Electrical
Service
Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
!
Properly install and ground
this equipment according to
its Owner’s Manual and national, state, and local codes.
4
3
Transfer Switch
!
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
. Customer-supplied equipment
is required if generator will supply standby power during
emergencies or power outages.
5
Essential
Loads
1 Utility Electrical Service
2 Transfer Switch (Double-Throw)
Switch transfers the electrical load
from electric utility service to the
generator. Transfer load back to
electric utility when service is restored.
Install correct switch (customersupplied). Switch rating must be
same as or greater than the branch
overcurrent protection.
3 Fused Disconnect Switch
Install correct switch (customersupplied) if required by electrical
code.
4 Welding Generator Output
Generator output voltage and wiring must be consistent with regular
(utility) system voltage and wiring.
Connect generator with temporary
or permanent wiring suitable for the
installation.
Turn off or unplug all equipment
connected to generator before
starting or stopping engine. When
starting or stopping, the engine has
low speed which causes low voltage and frequency.
5 Essential Loads
Generator output may not meet the
electrical requirements of the premises. If generator does not produce
enough output to meet all requirements, connect only essential
loads (pumps, freezers, heaters,
etc. − See Section 17-4).
OM-240 113 Page 70
17-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
600
7
840
10
1200
15
4
6
8
10
12
14
350 (106)
225 (68)
137 (42)
100 (30)
400 (122)
250 (76)
150 (46)
100 (30)
62 (19)
400 (122)
275 (84)
175 (53)
112 (34)
62 (19)
50 (15)
1800
300 (91)
175 (53)
112 (34)
75 (23)
37 (11)
30 (9)
20
2400
225 (68)
137 (42)
87 (26)
50 (15)
30 (9)
25
3000
175 (53)
112 (34)
62 (19)
37 (11)
30
3600
150 (46)
87 (26)
50 (15)
37 (11)
35
4200
125 (38)
75 (23)
50 (15)
40
4800
112 (34)
62 (19)
37 (11)
45
5400
100 (30)
62 (19)
50
6000
87 (26)
50 (15)
*Conductor size is based on maximum 2% voltage drop
Cord Lengths for 240 Volt Loads
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)*
Current
(Amperes)
Load (Watts)
5
1200
7
1680
10
2400
15
4
6
8
10
12
14
700 (213)
450 (137)
225 (84)
200 (61)
800 (244)
500 (152)
300 (91)
200 (61)
125 (38)
800 (244)
550 (168)
350 (107)
225 (69)
125 (38)
100 (31)
3600
600 (183)
350 (107)
225 (69)
150 (46)
75 (23)
60 (18)
20
4800
450 (137)
275 (84)
175 (53)
100 (31)
60 (18)
25
6000
350 (107)
225 (69)
125 (38)
75 (23)
30
7000
300 (91)
175 (53)
100 (31)
75 (23)
35
8400
250 (76)
150 (46)
100 (31)
40
9600
225 (69)
125 (38)
75 (23)
45
10,800
200 (61)
125 (38)
50
12,000
175 (53)
100 (31)
*Conductor size is based on maximum 2% voltage drop
OM-240 113 Page 71
SECTION 18 − PARTS LIST
. Hardware
is common and not
available unless listed.
. Unit shown is fully equipped. Some
parts may not be applicable on units
without hyrdraulic power source.
1
2
3
4
5
6
7
8
11
12
13
9
10
73
14
72
53
54
71
70
67
66
65
64
63
55
56
62
68
69
Figure 18-1. Main Assembly
OM-240 113 Page 72
61
60
59
58
57
29
27
30
28
26
25
19 20
21
22
24
23
18
17
15
16
34
33
35
32
31
36
41
52
40
39
37
51
50
49
38
48
47
46
45
44
43
42
242 707-A
OM-240 113 Page 73
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-1. Main Assembly
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...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
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1
2
3
4
5
6
7
8
9
10
11
12
13
14
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
. . . . . . . . . . 239038 . . Panel, End Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239049 . . Baffle, Bottom Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239334 . . Foam, Acoustical Exit Baffle Middle Lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239048 . . Baffle, Middle Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239333 . . Foam, Acoustical Exit Baffle Middle Upper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239047 . . Baffle, Upper Exit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239328 . . Foam, Acoustical Top Exit Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239054 . . Clamp, Upper Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . 239332 . . Foam, Acoustical Bottom Exit Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239056 . . Clamp, Lower Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239050 . . Mount, Radiator Bottom . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 198245 . . Nut, Conduit .750 Npt Pld 1.388 Od X .150 Thk . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . ♦241008 . . Inverter Aux Power . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . 239066 . . Bracket, Fitting Capture (Fully equipped models) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 247256 . . Bracket, Fitting Capture (Models without hydraulic power source) . . . . . . . . . . 1
. . . . . . . . . . 239040 . . Crossmember, Front Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 208141 . . Bumper, Door 1.000 Od X .500 High Nprn 50 Duro . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . 239042 . . Crossmember, Radiator Mount . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239041 . . Mount, Air Filter Lid Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 201882 . . Pipe, Exhaust Elbow . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 203260 . . Label, Caution Do Not Use Ether . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239546 . . Bushing, Nylon .290x.674x.093 Flg .50x.187 Bush . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . 079625 . . Washer, Wave .500idx0.750odx.015t Stl Lbs . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . 239547 . . Washer, Flat Nylon .516 Id X 1.250 Od X .062 Thk . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . 239043 . . Bar, Lid Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239548 . . Washer, Flat Nylon .506 Id X .940 Od X .064 Thk . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . 239044 . . Brace, Lid Pivot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239330 . . Foam, Acoustical Top Cover Left . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . . . . . . Label, Circuit Diagram (Order by Model and Serial No.) . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239033 . . Cover, Top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 194320 . . Latch, Lever Flush Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . 189975 . . Hinge, Door Access 180 Deg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . . . . . . . . 200448 . . Label, Warning Steam And Hot Coolant Can Burn . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239331 . . Foam, Acoustical Top Cover Right . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239039 . . Crossmember, Rear Hinge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . Figure 18-3 . . Air Compressor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . Figure 18-4 . . Hydraulic Assembly
. . . . . . . . . . 239327 . . Foam, Acoustical Non−service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239482 . . Foam, Acoustical Non−service Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239057 . . Baffle, Door (Non−service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239323 . . Foam, Acoustical Non−service Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239034 . . Panel, Side (Non−service) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239037 . . Panel, End Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239322 . . Foam, Acoustical Service Door Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . 239045 . . Baffle, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 187490 . . Screw, 437−14x3.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . 187489 . . Nut, 438−14 .62hex .45h Stl Pld Elastic Stop Nut . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . 187486 . . Washer, Flat .510idx2.000odx.125t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . . . . 239018 . . Mount, Eng/Gen Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . . . . . Figure 18-7 . . Generator Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . Figure 18-6 . . Engine Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 217395 . . Bumper, Door .500 Od X .250 High Nprn 70 Duro . . . . . . . . . . . . . . . . . . . . . . . 6
. . . . . . . . . . 239058 . . Plate, Fittings Cover . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239748 . . Cap, Protective Stl Jic− 4(F) (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239749 . . Cap, Protective Stl Jic−12(F) (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239751 . . Cap, Protective Stl Jic−10(F) (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 239750 . . Cap, Protective Stl Jic−24(F) (If equipped) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . 216366 . . Bushing, Snap−in Nyl .500 Id X .625 Mtg Hole . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-240 113 Page 74
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-1. Main Assembly (Continued)
. . . 59 . . . . . . . . . . 073432
. . . 60 . . . . . . . . . . 053525
. . . 61 . . . . . . . . . . . 201155
. . . 62 . . . . . . . . . . 236047
. . . 63 . . . . . . . . . . 213668
. . . 64 . . . . . . . . . . 239059
. . . . . . . . . . . . . . . . 287097
. . . 65 . . . . . . . . . . 239325
. . . 66 . . . . . . . . . . 239324
. . . 67 . . . . . . . . . . 239046
. . . 68 . . . . . . . . . . 239322
. . . 69 . . . . . . . . . . 239036
. . 70 . . . . . . . . . 239035
. . . 71 . . . . . . . . . . 287063
. . . 72 . . . . . . . . . . 233088
. . . 73 . . . . . . . . . . 239326
. . Ftg, Hose Brs Barbed M 3/16 Tbg X 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ftg, Hose Brs Barbed M 5/16 Tbg X 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bushing, Strain Relief .450/.709 Id X1.068 Mtg Hole . . . . . . . . . . . . . . . . . . . . .
. . Bushing, Snap−in Nyl 1.750 Id X 2.000 Mtg Hole . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Mtg Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Base Assy, Welded . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Connections EnPak . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Foam,Acoustical Service Side Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Foam, Acoustical Service Side Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Baffle, Service Door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Foam, Acoustical Service Door Baffle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Door, Side (Service Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Panel, Side (Service Side) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning General Precautionary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Danger Using A Generator Indoors Can Kill You In Minutes (Unit) . . .
. . Foam, Acoustical Radiator Seal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
4
1
4
1
1
1
1
1
2
1
1
1
1
1
♦Optional
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-240 113 Page 75
. Hardware is common and
not available unless listed.
9
1
2
3
4
5
6
7
8
11
10
12
13
14
15
16
18
19
17
20
21
22
23
35
24
25
34
26
33
32
27
31
30
29
28
242 678-B
Figure 18-2. Controls/Remote Assemblies
OM-240 113 Page 76
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
NO TAG. Controls/Remote Assemblies
. . . . . . . . . . . . . . . . 239667 . . Circuit Card Assy, Service Panel W/Enclosure (Includes) . . . . . . . . . . . . . . 1
. . . 1 . . . . . . . . . . 239068 . . . Enclosure Assy ,Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 287065 . . . Label, Warning Unexpected Starting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . . 151187 . . . Latch, Slide Flush Mtg Hole 1.000 Widex 1.500 Lg . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . PC1 . . 234729 . . . Circuit Card Assy, Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 287057 . . . Nameplate, Enpak Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . F3, F5 . 239347 . . . Fuse, 20 Amp Ato Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 7 . F1, 2, 4 239348 . . . Fuse, 10 Amp Ato Type . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 8 . . . . . . . . . . 239346 . . . Relay, Encl 12vdc Spdt 30a/20a 5pin Flange Mtg . . . . . . . . . . . . . . . . . . . 4
. . . 9 . . . PC2 . . 239668 . . Circuit Card Assy, Main Control W/Enclosure . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 239661 . . Circuit Card Assy, Remote Panel W/Enclosure (Includes) . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 239686 . . . Enclosure, Rear Remote Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 239662 . . . Circuit Card Assy, Remote Panel W/Program . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 239685 . . . Enclosure, Front Remote Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 287070 . . . Screw, 250−20x .50 Hexwhd.50d Stl Tap−rw Zinc Clr . . . . . . . . . . . . . . . 4
. . . 15 . . . . . . . . . . 287056 . . . Nameplate, Enpak Remote Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 231297 . . . Actuator Push Button Assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 238027 . . Cable, Interconnecting Power 30 Ft (Remote Panel) . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 244283 . . Cable, Interconnecting Power 30 Ft 6/C (Crane Remote) . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 237882 . . Bracket, W/Components/Harness (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 287064 . . . Label, Warning Electric Shock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 237883 . . . Bracket, Mtg Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 057357 . . . Bushing, Snap−in Nyl .937 Id X 1.125 Mtg Hole . . . . . . . . . . . . . . . . . . . 4
. . . 21 . . . . . . . . . . 173734 . . . Link, Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 22 . . . . 1T . . 172661 . . . Block, Stud Connection 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 23 . . . CB2 . . 083432 . . . Supplementary Pro, Man Reset 1p 10a 250vac Frict . . . . . . . . . . . . . . . . 1
. . . 24 . . . CB3 . . 093996 . . . Supplementary Pro, Man Reset 1p 20a 250vac Frict . . . . . . . . . . . . . . . . 1
. . . 25 . . . CB1 . . 241885 . . . Supplementary Protector, Man Reset 2p 25a 240vac . . . . . . . . . . . . . . . 1
. . . 26 . . . . . . . . . . 239021 . . . Cover, Aux Power Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . 287066 . . . Label, Warning Electric Shock W/Terminal Strip . . . . . . . . . . . . . . . . . . . . 1
. . . 28 . . . . . . . . . . 190058 . . . Nut, 250−20 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 29 . . . . . . . . . . 239020 . . . Bracket, Cap Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 30 . . C1, C2 237884 . . . Capacitor, Polyp Met Film 60. Uf 440 Vac . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 31 . . . CB4 . . 190374 . . . Circuit Breaker, Auto Reset 12vdc 40 Amp . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 32 . . . CR1 . . 197325 . . . Relay, Encl 12vdc Spst 70a 4pin Flange Mtg . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 33 . . . CT1 . . 237905 . . . Xfmr, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 34 . . . . . . . . . . 204737 . . . Cable Tie Mount, Winged Push . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 35 . . . . . . . . . . 034055 . . . Screw, 250−20x2.50 Hex Hd−pln Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
MILLER Recommended GFCI Receptacles
Hubbell /Bryant GF20 series only
Typical part numbers for 20 ampere receptacles:
. . . . . . . . Brown . . . . . . . . . . . . . GF20LA
. . . . . . . . Almond . . . . . . . . . . . . GF20ALLA
. . . . . . . . Black . . . . . . . . . . . . . GF20BKLA
. . . . . . . . . Gray . . . . . . . . . . . . . GF20GYLA
. . . . . . . . . Ivory . . . . . . . . . . . . . GF20ILA
. . . . . . . . White . . . . . . . . . . . . . GF20WLA
Pass and Seymour 2095 series only
Typical part numbers for 20 ampere receptacles:
. . . . . . . . Ivory . . . . . . . . . . . . . 2095-ICC10
. . . . . . . . White . . . . . . . . . . . . . 2095-WCC10
. . . . . . . . Brown . . . . . . . . . . . . 2095-CC10
. . . . . . . . Gray . . . . . . . . . . . . . 2095-GRYCC10
. . . . . Light Almond . . . . . . . . . 2095-LACC10
. . . . . . . . Black . . . . . . . . . . . . . 2095-BKCC10
OM-240 113 Page 77
. Hardware is common and
not available unless listed.
9
14
A
B
4
12
8
5 7
6
3
10
13
11
C
50
2
49
40
41
44
46
42
1
48 25
47 45
15
16
43
20
17
18
19
28
36
37
35 34
31
33
20
21
29
30
27 26
32
52 25
24
51
23
22
38
39
805 456-E
Figure 18-3. Air Compressor
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-3. Air Compressor
. . . 1 . . P−AC . 238869 . . Compressor, Ap 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 244487 . . Maintenance Kit, Shaft Sealing (AP40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 2 . . P−PC . *240394 . . Assy, Pneumatic Proportional Control Ap 40 (Includes) . . . . . . . . . . . . . . . . . . .
. . . 3 . . P−USV 242848 . . . . Valve, Solenoid Unload Pneumatic, 12vdc, 10w, 2wno . . . . . . . . . . . . . . . . .
. . . 4 . . . . . . . . . . . . . . . . . . . . . . . Heater Control, Pneumatic (Consisting Of)
. . . . . . . . P−HC . 245807 . . . . . Heater, Cartridge Compressor 150w/120v 1/2in X 3in . . . . . . . . . . . . . . . . .
. . . . . . . . . HTC . . 248448 . . . . . Switch, Temp No Open 55f Close 45f 1/4−18npt . . . . . . . . . . . . . . . . . . . . .
. . . 5 . . P−PRV 242847 . . . . Valve, Relief Proportional Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 6 . . . . . . . . . . 242542 . . Washer, Flat Bonded Seal 1/4 Bspp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 7 . . P−SV . *239563 . . Valve, Safety Air Compressor 1/4 Bspp 210 Psi . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 8 . . . P−IC . *242849 . . Valve, Control Intake Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 9 . . . . . . . . . . *232208 . . Filter, Inlet Air Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 10 . . . . . . . . . . 239309 . . Tensioner, Belt W/Pulley 6 Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 11 . . . . . . . . . . 167788 . . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . . . . . . .
. . . 12 . . . . . . . . . . 239307 . . Bushing, 25mm Taper Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-240 113 Page 78
1
0
1
1
1
1
1
1
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-3. Air Compressor (Continued)
. . . 13 . . . . . . . . . . 239304 . . Pulley, Micro−v 6 Rib 2.938 Pd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 14 . . . . . . . . . . *239315 . . Belt, Micro−v 6 Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 15 . . . . . . . . . . 242508 . . Screw, 312−18x2.00 Hex Hd−pln Gr8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . 602211 . . Washer, Lock .318idx0.586odx.078t Stl Pld Split.312 . . . . . . . . . . . . . . . . . . . .
. . . 16 . . . . . . . . . . 242850 . . Cap, Oil Fill Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 17 . . . . . . . . . . 270205 . . Washer, Flat Bonded Seal 1/2 Bspp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 18 . . . . . . . . . . 239483 . . Ftg, Stl Drain 1/2−bspp(M) Sae−6(F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 19 . . . . . . . . . . 239567 . . Ftg, Stl Plug Sae−6 Flush Hex Socket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 20 . . . . . . . . . . 239560 . . Ftg, Stl Adapter 1/8−bspp(M) X 1/8 Npt(F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 21 . P−PSW *237799 . . Switch, Pressure Safety Ultra Ps 5000 Metripack Nc . . . . . . . . . . . . . . . . . . . . .
. . . 22 . . P−PG . 239566 . . Gauge, Pressure 1−1/2 0−300 Psi 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 23 . . . . . . . . . . 239569 . . Ftg, Brs Tee 1/8 Npt(F) X 1/8 Npt(M) X 1/8 Npt(F) . . . . . . . . . . . . . . . . . . . . . . .
. . . 24 . . . . . . . . . . 239561 . . Pin, Spring Dowel Cs .312 Id X .750 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 25 . . . . . . . . . . 171773 . . Ftg, Brass 90 Deg 1/4 Npt Male To 1/4 Npt Female . . . . . . . . . . . . . . . . . . . . . .
. . . 26 . . P−PS . *237834 . . Sender, Pressure Air 0− 200 Psi . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 27 . . . . . . . . . . 239559 . . Ftg, Stl Adapter 1/4−bspp(M) X 1/4 Npt(F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 28 . P−MPCV *239562 . . Maintenance Kit, Separator Head & MPCV (Air Compressor) . . . . . . . . . . . . .
. . . 29 . . . . . . . . . . 239555 . . Ftg, Stl 90 Deg 1/2−bspp(M/S) X Jic−8(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 30 . . . . . . . . . . 239489 . . Hose Assy, Air Compressor (−10) Air L Ine . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 31 . . . . . . . . . . 239554 . . Ftg, Stl 90 Deg 1/2−bspp(M/S) X Jic−10(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 32 . . . . . . . . . . 239485 . . Hose Assy, Oil Compressor (−8) Comp To Thermostat . . . . . . . . . . . . . . . . . . .
. . . 33 . . . . . . . . . . 239484 . . Hose Assy, Oil Compressor (−8) Thermostat To Filter . . . . . . . . . . . . . . . . . . . .
. . . 34 . . . . . . . . . . 239555 . . Ftg, Stl 90 Deg 1/2−bspp(M/S) X Jic−8(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 35 . . . . . . . . . . 239558 . . Ftg, Stl Adapter 1/2−bspp(M) X Jic−8(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 36 . . P−OT . 239564 . . Thermostat, Oil Air Compressor 71 Deg C . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 37 . . . . . . . . . . 239558 . . Ftg, Stl Adapter 1/2−bspp(M) X Jic−8(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 38 . . . . . . . . . . 239557 . . Ftg, Stl Tee Jic−8(F/S) X Jic−8(M) X Jic−8(M) . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 39 . . . . . . . . . . 239486 . . Hose Assy, Oil Compressor (−8) Cooler To Thermostat . . . . . . . . . . . . . . . . . .
. . . 40 . . . . . . . . . . 239487 . . Hose Assy, Oil Compressor (−8) Thermostat To Cooler . . . . . . . . . . . . . . . . . .
. . . 41 . . . . . . . . . . 239555 . . Ftg, Stl 90 Deg 1/2−bspp(M/S) X Jic−8(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 42 . . . . . . . . . . 239321 . . Bracket, Mtg Thermostat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 43 . . . . . . . . . . *232207 . . Filter, Oil Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 44 . P−TSW *237835 . . Switch, Temp Shutdown Nc 120c Open . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 45 . . . . . . . . . . *232209 . . Separator, Oil/Air Rotory Screw Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 46 . . . . . . . . . . 240443 . . Ftg, Push−in 90 Deg 3/8 Od Tube To 1/8 Npt (M) . . . . . . . . . . . . . . . . . . . . . . . .
. . . 47 . . . . . . . . . . 240551 . . Tubing, Nyl .275 Id X .375 Od X 8.875 Lg Blue . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 48 . . . . . . . . . . 209854 . . Ftg, Pipe Stl Adapter M 1/4 Npt X 1/4 Line . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 49 . . . . . . . . . . 270197 . . Screw, M 4− .7x 55 Soc Hd−hex 12.9 Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 50 . . . . . . . . . . 010954 . . Washer, Flat .406idx1.250odx.125t Stl Pld (As Needed) . . . . . . . . . . . . . . . . . .
. . . 51 . . . . . . . . . . 248042 . . Ftg, Stl Elbow 90 Deg 2mnpt X 2fnpt Fgd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . 52 . . . . . . . . . . 248043 . . Ftg, Stl Elbow 45 Deg 4mnpt X 4fnpt Sw Fgd . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . A . . . . . . . . . . . . . . . . . . . . . O-Ring, 012 70 Durometer (1/16 in. Dia, 3/8 in. ID) . . . . . . . . . . . . . . . . . . . . . .
. . . B . . . . . . . . . . . . . . . . . . . . . O-Ring, 008 70 Durometer (1/16 in. Dia, 3/16 in. ID) . . . . . . . . . . . . . . . . . . . . .
. . . C . . . . . . . . . . . . . . . . . . . . . O-Ring, 132 70 Durometer (3/32 in. Dia, 1-3/4 in. ID) . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . ♦300774 . . Air Pak 40 Heater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . ♦241262 . . Valve, Control Intake Compressor Cold Weather Assy (Ambient
. . . . . . . . . . . . . . . . . . . . . . . . . . . . Temperature Below −20°F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 235202 . . Filter/Separator Kit, Compressor (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 232209 . . Separator, Oil/Air Rotory Screw Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 232208 . . Filter, Inlet Air Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . 232207 . . Filter, Oil Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
♦OPTIONAL
1
1
3
3
1
1
1
1
2
1
1
1
3
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
4
1
1
1
1
1
1
0
0
0
1
1
1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-240 113 Page 79
. Hardware is common and
not available unless listed.
3
6
2
1
7
5
9
17
4
8
10
16
9
15
11
14
12
13
805 457-A
Figure 18-4. Hydraulic System Open Center (If Equipped)
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-4. Hydraulic System Open Center (If Equipped)
. . . 1 . . H−P1 . 239014 . . Pump, Hyd Piston W/Load Sense Eaton 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 239105 . . Ftg, Stl 90 Deg Long Sae−12(M/S) X Jic−12(M) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 239012 . . Hose Assy, Hyd Case Drain (−10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 239024 . . Ftg, Stl Sae−24(M) X Jic−24(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 239010 . . Hose Assy, Hyd Suction (−24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . H−FC1 239023 . . Valve Assembly, Hyd Proportional 12vdc 2way Nc . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 239027 . . Ftg, Stl Elbow 90 Sae−12(M/S) X Jic−12(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . 239011 . . Hose Assy, Hyd Pressure (−12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 239015 . . Ftg, Stl Elbow 90 Sae−4(M/S) X Jic−4(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 10 . . . . . . . . . . 239022 . . Ftg, Stl Sae−16(M/S) X Sae−16(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 239306 . . Pulley, Micro−v 8 Rib 5.938 Pd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 239308 . . Tensioner, Belt W/Pulley 8 Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . *239316 . . Belt, Micro−v 8 Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 270207 . . Screw, 375−24x1.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 287136 . . Washer, Flat .406idx1.500odx.250t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 241851 . . Key, Stl .250 X .250 X .750 Form A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 239013 . . Hose Assy, Hyd Load Sense (−4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-240 113 Page 80
. Hardware is common and
not available unless listed.
17
18
19
20
6
21
3
22
7
5
2
4
8
1
10
16
9
15
11
14
12
13
243 166-A
Figure 18-5. Hydraulic System Closed Center (If Equipped)
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-4. Hydraulic System Closed Center (If Equipped)
. . . 1 . . H−P1 . 239014 . . Pump, Hyd Piston W/Load Sense Eaton 420 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 2 . . . . . . . . . . 239105 . . Ftg, Stl 90 Deg Long Sae−12(M/S) X Jic−12(M) . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . . . . . . . . . 239012 . . Hose Assy, Hyd Case Drain (−10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 239024 . . Ftg, Stl Sae−24(M) X Jic−24(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 5 . . . . . . . . . . 239010 . . Hose Assy, Hyd Suction (−24) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . H−FC1 239023 . . Valve Assembly, Hyd Proportional 12vdc 2way Nc . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . . . . . . . . . 239027 . . Ftg, Stl Elbow 90 Sae−12(M/S) X Jic−12(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . . . . . . . . . 239011 . . Hose Assy, Hyd Pressure (−12) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . 239106 . . Ftg, Stl Plug Sae−4(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 239022 . . Ftg, Stl Sae−16(M/S) X Sae−16(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 239306 . . Pulley, Micro−v 8 Rib 5.938 Pd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 239308 . . Tensioner, Belt W/Pulley 8 Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . *239316 . . Belt, Micro−v 8 Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 270207 . . Screw, 375−24x1.00 Hex Hd−pln Gr5 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 287136 . . Washer, Flat .406idx1.500odx.250t Stl Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 241851 . . Key, Stl .250 X .250 X .750 Form A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 17 . . . . . . . . . . 239108 . . Hose Assy, Hyd Load Sense (−4) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 239104 . . Ftg, Stl Sae−4(M) X Jic−4(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 239360 . . Valve, Hyd Bleed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 239103 . . Ftg, Stl Tee Sae−4(F) X Sae−4(F) X Sae−4(M/S) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 239102 . . Ftg, Stl Tee Sae−4(M/S) X Sae−4(F) X Sae−4(F) . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . H−PS1 239359 . . Switch, Pressure Hyd 100 Psi Spst/No . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-240 113 Page 81
. Hardware is common and
not available unless listed.
18
20
21
22
44
23
17
15 16
13
19
14
45
46
12
24
11
25
10
9
8
2
26
27
3
28
4
7
5
29
30
6
1
31
3
34
32
35
33
36
37
42
38
39
40
41
43
805 458-B
Figure 18-6. Engine
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-6. Engine
... 1 ..........
... 2 ..........
... 3 ..........
... 4 ..........
... 5 ..........
... 6 ..........
... 7 ..........
... 8 ..........
... 9 ..........
. . . 10 . . . . . . . . . .
................
................
OM-240 113 Page 82
239329
187120
243021
243022
239819
239313
239312
239065
239310
239550
243262
243263
. . Assy, Radiator And Shroud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Cap, Radiator Pressure 14lb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Steam And Hot Coolant Can Burn . . . . . . . . . . . . . . . . . . .
. . Guard, Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Radiator Lower Kubota D1105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Radiator Upper Kubota D1105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Mtg Engine Rh Kubota D1105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Fan, Engine Cooling 15.000 8 Blade Pusher . . . . . . . . . . . . . . . . . . . . . . . . .
. . Engine, Kubota Dsl Elec D1105 E2bb T4 W/Elec Gov . . . . . . . . . . . . . . . . .
. . . Starter, Engine Kubota 05 Series 12v 1.2kw . . . . . . . . . . . . . . . . . . . . . . . .
. . . Alternator, Kubota 05 Series, 12v 60 Amp . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
2
1
1
1
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-6. Engine
. . . . . . . . . . . . . . . . *197197
. . . . . . . . . . . . . . . . *196428
. . . 11 . . . . . . . . . . 239553
. . . 12 . . . . . . . . . . 239314
. . . 13 . . . . . . . . . . 220000
. . . . . . . . . . . . . . . . *197676
. . . 14 . . . . . . . . . . 197829
. . . 15 . . . . . . . . . . . 216811
. . . 16 . . . . . . . . . . 049525
. . . 17 . . . . . . . . . . 239051
. . . 18 . . . . . . . . . . 224368
. . . 19 . . . . . . . . . . 197671
. . . 20 . . . . . . . . . . 239052
. . . 21 . . . . . . . . . . *207715
. . . 22 . . . . . . . . . . 239053
. . . 23 . . . . . . . . . . *239552
. . . 24 . . . . . . . . . . 239055
. . . 25 . . . . . . . . . . 240251
. . . 26 . . . . . . . . . . *242954
. . . . . . . . . . . . . . . . 243886
. . . 27 . . . . . . . . . . 237000
. . . 28 . . . . . . . . . . 240444
. . . 29 . . . . . . . . . . 240445
. . . 30 . . . . . . . . . . 239317
. . . 31 . . . . . . . . . . 073432
. . . 32 . . . . . . . . . . 053525
. . . 33 . . . . . . . . . . 199507
. . . 34 . . . . . . . . . . 238000
. . . 35 . . . . . . . . . . 240609
. . . . . . . . . . . . . . . . 240463
. . . . . . . . . . . . . . . . 010323
. . . 36 . . . . . . . . . . 239064
. . . 37 . . . . . . . . . . *213858
. . . 38 . . . . . . . . . . *239311
. . . 39 . . . . . . . . . . 239076
. . . 40 . . . . . . . . . . 209057
. . . 41 . . . . . . . . . . 239077
. . . 42 . . . . . . . . . . 239069
. . . 43 . . . . . . . . . . 239549
. . . 44 . . . . . . . . . . 246634
. . . 45 . . . . . . . . . . 246633
. . . 46 . . . . . . . . . . 220059
. . . . . . . . . . . . . . . . 249288
. . . . . . . . . . . . . . . . 197676
. . . . . . . . . . . . . . . . 207715
. . . . . . . . . . . . . . . . 196428
. . . . . . . . . . . . . . . . 213858
. . Belt, Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Check Valve, Fuel Kubota . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Air Intake . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Air Cleaner, Intake 5 In W/Steel Latches . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Mtg Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clip, Nut Retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nut, 312−18 U−nut Multi−thread . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer, Overflow Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bottle, Coolant Overflow & Bracket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label,Coolant Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Mount, Fuel Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Filter, Fuel (Spin−on,Cartrige Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Mount, Engine Ecu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Module, Control Governor (Programed) Kubota D1105 . . . . . . . . . . . . . . . .
. . Brace, Alternator End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Brace, Manifold End . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Block Heater, Engine Kubota 05 Series Head Type . . . . . . . . . . . . . . . . . . .
. . Tubing, Corrugated Plastic Slit .375 Dia X 30.000 . . . . . . . . . . . . . . . . . . . .
. . Ftg, Stl Adapter 12mm X 1.25 (M) To Jic−6 (M) . . . . . . . . . . . . . . . . . . . . . . .
. . Ftg, Stl Elbow 90 Deg Jic−6(F/S) X 1/4 Npt(F) . . . . . . . . . . . . . . . . . . . . . . .
. . Ftg, Brs Barbed M 1/2 Tbg X 1/4 Npt(M) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ftg, Brs Union 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ftg, Hose Brs Barbed M 3/16 Tbg X 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ftg, Hose Brs Barbed M 5/16 Tbg X 1/8 Npt . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose Assy, Oil Drain 20.000 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ftg, Stl Reducer 1 Npt(M) To 3/8 Npt(F) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ftg, Hose Brs Elbow 3/8 Tbg X 3/8 Npt(M) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Hose, Sae .375 Id X .620 Od X 4.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Hose .250 − .625 Clp Dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bracket, Mtg Engine Lh Kubota D1105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pump, Fuel Electric 12v . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pipe, Exhaust Flexible . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clamp, Muffler 1.625 Dia U Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Muffler, Exhaust Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Pipe, Exhaust Vertical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Mount, Isolation Radiator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ftg, Stl Elbow 90 M14−1.5(M/S) X Jic−6(M) . . . . . . . . . . . . . . . . . . . . . . . . .
. . Ftg, Hose Brs Barbed M 3/16 Tbg X Jic−6(F) .040 Id Orf . . . . . . . . . . . . . .
. . Fitting, Gas Nylon Barbed Tee .187 X .187 X .187 . . . . . . . . . . . . . . . . . . . .
. . Tune−up & Filter Kit, Kubota (D1105 E2 Bb T4) (Includes) . . . . . . . . . . . . .
. . . Air Filter Element . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Filter, Fuel (Spin−on,Cartrige Type) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Filter, Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Filter, Fuel In−line 5/16x5/16 Mic 125 −175 . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
2
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
2
1
1
1
1
3
1
1
2
1
1
1
0
1
1
1
1
*Recommended Spare Parts.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-240 113 Page 83
. Hardware is common and
3
1
not available unless listed.
2
4
5
6
7
8
9
29
11
10
12
27
26
25
24
13
14
15
16
17
18
19
23
28
22
21
20
242 679-C
Figure 18-7. Generator Assembly
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-7. Generator Assembly
. . . 1 . . . . . . . . . . 208497
. . . 2 . . . . . . . . . . 239746
. . . 3 . . . . . . . . . . 239740
. . . 4 . . . . . . . . . . 192686
. . . 5 . . . . . . . . . . 083883
. . . 6 . . . . . . . . . . 270203
. . . . . . . . . . . . . . . . 240468
. . . . . . . . . . . . . . . . 239007
. . . 7 . . . . . . . . . . 239009
. . . 8 . . . . . . . . . . 239019
. . . . . . . . . . . . . . . . 241851
. . . 9 . . . . . . . . . . 244932
. . . 10 . . . . . . . . . . 238950
. . . 11 . . . . . . . . . . 239017
. . . 12 . . . . . . . . . . 167788
. . . 13 . . . . . . . . . . 183419
. . . 14 . . . . . . . . . . 244921
. . . 15 . . . . . . . . . . *244682
. . . 16 . . . . . . . . . . 138253
. . . 17 . . . . . . . . . ◊244931
. . . 18 . . . . . . . . . . 244933
. . . 19 . . . . . . . . . . 244970
. . . 20 . . . . . . . . . . 241782
. . . 21 . . . . . . . . . . 244930
. . . 22 . . . . . . . . . . 225120
OM-240 113 Page 84
. . Nut, M08−1.2 13mmhex 8.3mm T Stl Pld Sem Con Washer . . . . . . . . . . . . . .
. . Pin, Spring Dowel Cs 8mm Odx12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Lift Eye, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Screw, M 8−1.25x 25 Hex Hd−pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Lock .402idx0.709odx.087t Stl Pln Split10mm . . . . . . . . . . . . . . . . . . .
. . Screw, M10−1.25x45 Hex Hd−pln 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Rotor Assembly (Includes)
. . . Rotor, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Fan, Rotor Gen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Bearing, Ball Rdl Sgl Row 1.000 X 2.047 X .591 . . . . . . . . . . . . . . . . . . . . . . .
. . . Key, Stl .250 X .250 X .750 Form A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Key, Stl .187 X .250 X .687 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Stator, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Mount, Rear Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Nut, 375−16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . . . . . . .
. . O−ring, 1.984 Id X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Spacer, Nylon 1.120 Od X 1.014 Id X .375 Lg . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Clutch, Electro Magnetic 12vdc W/6.25 Dia Pulley . . . . . . . . . . . . . . . . . . . . . .
. . Screw, 250−20x .37 Hexwhd.52d Stl Pld Lkg Serr . . . . . . . . . . . . . . . . . . . . . . .
. . Nut, Taper Clutch Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Washer, Nylon 1.031 Id X 1.218 Od X .040 Thk . . . . . . . . . . . . . . . . . . . . . . . .
. . Pulley, Micro−v 8 Rib 4.750 Pd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bushing, 1.000 Taper Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Bushing, Stl Taper Clutch 1.000 Id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . . . .
2
2
1
3
2
2
1
1
1
1
1
1
1
4
1
1
1
3
1
1
1
1
1
1
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 18-7. Generator Assembly (Continued)
. . . 23 . . . . . . . . . . 239067 . . Stud, Stl .375−16 X 13.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 24 . . . . . . . . . . 270204 . . Screw, M10−1.25 x 60 Soc Hd−hx 12.9 Stl . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
. . . 25 . . . . . . . . . . 083883 . . Washer, Lock .402 id x 0.709 od x.087t Stl Pln Split10mm . . . . . . . . . . . . . . . . 6
. . . 26 . . . . . . . . . . 238947 . . Adapter, Engine Kubota D1105 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 27 . . . . . . . . . . 196484 . . Screw, M 8−1.2 x 55 Hex Hd−pln 8.8 Pln Full Thd . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 28 . . . . . . . . . }240463 . . Hose, Sae .375 Id X .620 Od X 4.000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
. . . 29 . . . . . . . . . }247255 . . Bracket, Support Pump Mtg Flange . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
*Recommended Spare Parts.
◊ Use Loctite® 271 (MILLER Part No. 152 242) to secure when replacing these parts.
} Models without hydraulic power source.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
OM-240 113 Page 85
. Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase
components separately or as part of the associated wiring harness.
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Wiring Harnesses
. . . . . . . . . . . . . . . . 237885
. . . . . . . . PLG 2 . 215261
. . . . . . . . . . . . . . . . 215265
. . . . . . . . RC 11 . 239682
. . . . . . . . . RC 9 . 239682
. . . . . . . . . . . . . . . . 239683
. . . . . . . . . . . . . . . . 237888
. . . . . . . ALTPLG 192170
. . . . . . . . . . . . . . . . 192169
. . . . . . . . PLG 1 . 237889
. . . . . . . . PLG 3 . 237889
. . . . . . . PLG 15 237892
. . . . . . . . . . . . . . . . 237893
. . . . . . . . . . . . . . . . 237894
. . . . . . . . PLG 8 . 237895
. . . . . . . . PLG 7 . 237897
. . . . . . . . PLG 6 . 237901
. . . . . . . . . . . . . . . . 237903
. . . . . . . . . . . . . . . . 237904
. . . . . . . . . CT 1 . 237905
. . . . . . . . PLG 4 . . 238411
. . . . . . . . RC 12 . . 239114
. . . . . . . . RC 13 . . 239114
. . . . . . . . . . . . . . . . . 239115
. . . . . . . PLG 10 . 212116
. . . . . . . . . . . . . . . . . 212117
. . . . . . . . RC 14 . 239441
. . . . . . . . . . . . . . . . 239442
. . . . . . . PLG 16 240032
. . . . . . . . . . . . . . . . 237898
. . . . . . . . . . . . . . . . 240033
. . . . . . . . . . . . . . . . . 240511
. . . . . . . . . . . . . . . . 240512
. . . . . . . . . . . . . . . . 237896
. . . . . . . . . CR2 . . 173069
. . . . . . . . . . . . . . . . 240383
Item
No.
Dia.
Mkgs.
. . Harness, Wrg Unit (Includes) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Deutsch 12p 2row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Deutsch Wedge Lock 12 Position . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Body 2 Pos Rcpt Weather Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Body 2 Pos Rcpt Weather Pack . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Term Male 14ga−16ga Weather Pack . . . . . . . . . . . . . . . . . . . . . . . .
. . . Seal, Conn Weather Pack Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Rect 250 2skt 2row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Rect 250 1skt 1row Plug Cable Lkg . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Amp Superseal 34p 4row Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Amp Superseal 34p 4row Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Pack 2p 1row Plg Metri−pack . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Skt Female 1 −.5mm W/P 3.11mm Od Tin/Brass . . . . . . . . . . . . . .
. . . Seal, Conn Metri−pack Dark Red . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Pack 3p 1row Plg Yazaki . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Amp Econoseal 2p 1row Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Body 2 Pin Sealed Sumitomo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Skt Female .5 −1.25mm 1.6−2.6mmod Tin/Brass . . . . . . . . . . . . .
. . . Seal, Conn Sumitomo Dark Green . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Xfmr, Current Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn,Deutsch Drc 50 Pin Plg Key #1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Deutsch 6p 2row Rcpt Flange Mnt . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Deutsch 6p 2row Rcpt Flange Mnt . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Deutsch Wedge Lock 6 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Deutsch 2p 1row Female Plug . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Deutsch Wedge Lock 2 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Deutsch 4p 2row Rcpt . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Deutsch Wedge Lock 4 Position . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Body 150 Series 3 Pos M/P Female Terms Sealed . . . . . . . . . . . .
. . . Conn, Skt Amp Econoseal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Skt 150 Series M/P 18−20ga .08−.10 Od . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Rear Clip Yazaki . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Seal, Conn Yazaki . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Conn, Skt Female Yazaki . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . Relay, Encl 12vdc Spdt 30a/20a 5pin Flng Mtg (Fully Equipped Models)
. . . Seal, Conn 20ga−16ga . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Part
No.
Description
Crane Remote Harness Adapters
..............
..............
..............
..............
..............
..............
..............
..............
OM-240 113 Page 86
300551
300552
300772
300553
300773
300554
300555
300556
....
....
....
....
....
....
....
....
1
1
1
2
2
4
4
1
1
2
2
1
2
2
1
1
1
2
2
1
1
2
2
2
1
1
1
1
1
2
3
1
3
3
1
2
Quantity
(1 Required For
Applicable Crane
Manufacturer)
Adapter, Auto Crane Tethered . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adapter, Auto Crane Wireless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adapter, Auto Crane Nexstar Wireless . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adapter, IMT Tethered and Wireless . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adapter, IMT (PRE 2004) Tethered and Wireless . . . . . . . . . . . . . . . . . . . .
Adapter, Maintainer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adapter, Venturo . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Adapter, Stellar . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
ENPAK EQUIPMENT
LIMITED WARRANTY
Effective January 1, 2010
(Equipment with a serial number preface of MA or newer)
This limited warranty supersedes all previous EnPak warranties and is exclusive with no other
guarantees or warranties expressed or implied.
LIMITED WARRANTY − Subject to the express terms
and conditions set forth below, Miller Electric Mfg. Co.
(“Miller”), of Appleton, Wisconsin (USA), warrants to the
original retail purchaser of new EnPak equipment (sold
after the effective date of this Limited Warranty) that
such equipment is free from defects in materials and
workmanship when shipped by Miller.
Visit our website at
www.EnPak.com
to locate an EnPak supplier.
For warranty claims received by Miller within the
applicable warranty periods described below, Miller will
repair or replace any warranted equipment, parts or
components that fail due to defects in material or
workmanship or refund the purchase price for the
equipment. Miller must be notified in writing within thirty
(30) days of such defect or failure, at which time Miller
will provide instructions on the warranty claim
procedures to be followed.
Miller shall honor warranty claims on warranted
equipment in the event of such failure within the
applicable warranty periods. All warranty time periods
start on the delivery date of the equipment to the original
end−user purchaser, and shall not commence more
than one (1) year following that date on which the
equipment is shipped to a North American distributor, or
more than eighteen (18) months following that date on
which the equipment is shipped to an international
distributor.
1. 1 Year — Parts and Labor Unless Otherwise
Specified
* Engine Driven Generators (NOTE: engines are
warranted separately by the engine
manufacturer.)
* Field options (NOTE: field options are covered
for the remaining warranty period of the product
they are installed in, or for a minimum of one year
— whichever is greater.)
2. 90 Days — Parts
* Remote Controls
* Accessory (Kits)
* Replacement Parts (No labor)
* Canvas Covers
This Limited Warranty shall not apply to:
(i) consumable components, such as contactors, relays
or parts that fail due to normal wear and use; (ii) items
furnished by Miller, but manufactured by others, such as
engines and trade accessories (these items are
covered by the manufacturer’s warranty, if any); and (iii)
equipment that has been modified by any party other
than Miller, or equipment that has been improperly
installed, improperly operated or misused based upon
industry standards; or equipment which has not been
used and maintained in accordance with Miller’s
specifications; or equipment which has been operated
outside of Miller’s specifications for the equipment.
Miller products are intended for purchase and use by
commercial/industrial users and persons trained and
experienced in the use and maintenance of industrial
equipment.
In the event of a warranty claim covered by this Limited
Warranty, the exclusive remedies shall be, at Miller’s
sole discretion: (i) repair; or (ii) replacement; (iii) where
authorized in writing by Miller in appropriate cases, the
reasonable cost of repair or replacement at an
authorized EnPak service facility; or (iv) payment of (or
credit for) the purchase price (less reasonable
depreciation based upon actual use) upon return of the
equipment at the warranty claimant’s risk and expense.
Miller’s option of repair or replacement will be F.O.B.,
Appleton, Wisconsin; (USA), or F.O.B. an EnPak
authorized service facility designated in writing by Miller.
No compensation or reimbursement for transportation
costs of any kind will be allowed.
TO THE GREATEST EXTENT PERMITTED BY
APPLICABLE LAW, THE REMEDIES PROVIDED
HEREIN ARE THE SOLE AND EXCLUSIVE
REMEDIES APPLICABLE TO THE ENPAK
EQUIPMENT. IN NO EVENT SHALL MILLER
BECOME LIABLE FOR DIRECT, INDIRECT,
SPECIAL,
PUNITIVE,
INCIDENTAL
OR
CONSEQUENTIAL DAMAGES (INCLUDING LOSS
OF PROFIT OR LOST BUSINESS OPPORTUNITY),
WHETHER BASED IN CONTRACT, TORT OR ANY
OTHER LEGAL THEORY. IN NO EVENT SHALL
MILLER BECOME OBLIGATED TO PAY MORE ON
ANY WARRANTY CLAIM THAN THE PURCHASE
PRICE ACTUALLY PAID BY THE ORIGINAL RETAIL
PURCHASER.
THIS LIMITED WARRANTY IS MADE IN LIEU OF ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING
THE
WARRANTIES
OF
MERCHANTABILITY AND/OR FITNESS FOR A
PARTICULAR PURPOSE, OR ANY OTHER
WARRANTY OR GUARANTEE ARISING BY
OPERATION OF LAW. ANY WARRANTY NOT
EXPRESSLY PROVIDED HEREIN, IMPLIED
WARRANTY,
GUARANTY
AND
ANY
OR
REPRESENTATION
REGARDING
THE
PERFORMANCE OF THE EQUIPMENT, AND ANY
REMEDY FOR BREACH OF CONTRACT, IN TORT,
OR ANY OTHER LEGAL THEORY WHICH, BUT FOR
THIS PROVISION, MIGHT ARISE BY IMPLICATION,
OPERATION OF LAW, CUSTOM OF TRADE, OR
COURSE OF DEALING ARE EXCLUDED AND
DISCLAIMED BY MILLER.
Some states in the United States of America do not
allow limitations of how long an implied warranty lasts,
or the exclusion of incidental, indirect, special or
consequential damages, such the above limitations and
exclusions may not apply to you. This warranty provides
specific legal rights. Other rights may be available to
you, but may vary from state to state.
In Canada, legislation in some provinces provides for
certain additional warranties or remedies other than as
stated herein, and to the extent that they may not be
waived, the limitations and exclusions set out above
may not apply. This Limited Warranty provides specific
legal rights, and other rights may be available, but may
vary from province to province.
EnPak_warr 2010−01
Owner’s Record
Please complete and retain with your personal records.
Model Name
Serial/Style Number
Purchase Date
(Date which equipment was delivered to original
customer.)
Distributor
Address
City
State
Zip
Visit www.EnPak.com to locate an
EnPak supplier.
Contact your Truck Equipment Distributor for:
Options and Accessories
Service and Repair
Replacement Parts
Training (Schools, Videos, Books)
Technical Manuals (Servicing Information and Parts)
Circuit Diagrams
Always provide Model Name and Serial/Style Number.
Miller Electric Mfg. Co.
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
Contact the Delivering Carrier to:
File a claim for loss or damage during
shipment.
For assistance in filing or settling claims, contact
your distributor and/or equipment manufacturer’s
Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA
© 2010 Miller Electric Mfg. Co.
2010−01
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