Miller | MK090093R | Owner Manual | Miller ENPAK A60 User manual

Miller ENPAK A60 User manual
OM-261050M
2019−01
)
Description
Mobile Utility Unit With Air Compressor,
Hydraulic Pump, And Auxiliary Power
Capability
)
EnPak A60
For product information,
Owner’s Manual translations,
and more, visit
www.MillerWelds.com/EnPak
File: Engine Drive
From Miller to You
Thank you and congratulations on choosing EnPak® 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
parts list will then help you to decide the
exact part you may need to fix the problem.
Warranty and service information for your
particular model are also provided.
Miller is the first welding
equipment manufacturer in
the U.S.A. to be registered to
the ISO 9001 Quality System
Standard.
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/EnPak on the web.
EnPak_Thank 2017−06
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. Hydraulic Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. Compressed Air Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-5. Additional Symbols For Installation, Operation, And Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-6. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-7. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Dangers existant en relation avec le moteur . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Dangers liés à l’hydraulique . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-4. Dangers liés à l’air comprimé . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance . . . . .
2-6. Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-7. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − DEFINITIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Additional Safety Symbol Definitions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Serial Number And Rating Label Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Auxiliary Power And Engine Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Air Compressor Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-4. Hydraulic Specifications (Models With Hydraulic Power Source) . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-5. Environmental Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-6. Fluid Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-7. Dimensions, Weights, and Operating Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-8. Fuel Consumption . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-9. Auxiliary Power Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-10. Alternator Power Curve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-11. Hydraulic Pressure Flow Curves (Models With Hydraulic Power Source) . . . . . . . . . . . . . . . . . . . . . .
4-12. Hydraulic Pressure Flow Curves − Combination Loads (Models With Hydraulic Power Source) . . . .
4-13. Air Compressor Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-1. Installing Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5-2. Mounting Unit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − ENGINE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Connecting the Battery . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Installing Exhaust Pipe . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-3. Fuel Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-4. Engine Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Cold Weather Starting And Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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WARNING: Breathing diesel engine exhaust exposes you to chemicals
known to the State of California to cause cancer and birth defects or
other reproductive harm.
Always start and operate the engine in a well-ventilated area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information go to www.P65warnings.ca.gov/diesel.
TABLE OF CONTENTS
SECTION 7 − HYDRAULIC SYSTEM (MODELS WITH HYDRAULIC POWER SOURCE) . . . . . . . . . . . . . .
7-1. Hydraulic System Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Hydraulic Hose Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Priming Hydraulic Pump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Hydraulic System Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Hydraulic Pump Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Load Sense Line Bleeding (Closed-Center Systems Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − COMPRESSOR SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-1. Air Compressor System Integration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-2. Compressor Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-3. Compressor Prestart Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-4. Air Compressor Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-5. Compressor Blow Down . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − AUXILIARY POWER SYSTEM CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-1. Grounding Auxiliary Power System To Truck Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-2. EnVerter Power System Connections And Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9-3. Generator Power System Connections And Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 10 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-1. Remote Devices Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-2. Remote Panel (Use With Section 10-3) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-3. Remote Panel Operation (Use With Section 10-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-4. Safety Interlock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-5. Operation And Error Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-6. Auto Start/Stop Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-7. Service Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
10-8. Kubota D902 Engine Fault Code Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 11 − MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-1. Maintenance Label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-2. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-3. Servicing Air Cleaner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-4. Changing Engine Oil, Oil Filter, And Fuel Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-5. Changing Compressor Oil, Air Cleaner, And Air/Oil Separator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
11-6. Safety Interlock Monthly Check (Models With Hydraulic Power Source) . . . . . . . . . . . . . . . . . . . . . . .
SECTION 12 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-1. Generator Power Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-2. Engine Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-3. Compressor Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
12-4. Hydraulic Troubleshooting (Models With Hydraulic Power Source) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 13 − DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 14 − GENERATOR POWER GUIDELINES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
WARRANTY
COMPLETE PARTS LIST − Available at www.MillerWelds.com
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING
Enpak_Hydraulic_2018- 06
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. Engine 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 1-7. Read and
follow all Safety Standards.
Only qualified persons should install, operate, maintain, and
repair this equipment. A qualified person is defined as one
who, by possession of a recognized degree, certificate, or
professional standing, or who by extensive knowledge, training and experience, has successfully demonstrated ability to
solve or resolve problems relating to the subject matter, the
work, or the project and has received safety training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children, away.
FUEL can cause fire or explosion.
Stop engine and let it cool off before checking or
adding fuel.
Do not add fuel while smoking or if unit is near
any sparks or open flames.
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.
BATTERY EXPLOSION can injure.
Always wear a face shield, rubber gloves, and
protective clothing when working on a battery.
Stop engine before disconnecting or connecting battery cables, battery charging cables (if
applicable), or servicing battery.
Do not allow tools to cause sparks when working on a battery.
Do not use this unit to charge batteries or jump start vehicles unless it has a battery charging feature designed for this purpose.
Observe correct polarity (+ and −) on batteries.
Disconnect negative (−) cable first and connect it last.
Keep sparks, flames, cigarettes, and other ignition sources
away from batteries. Batteries produce explosive gases during
normal operation and when being charged.
Follow battery manufacturer’s instructions when working on or
near a battery. See Battery Service Manual (listed in Safety
Standards) for additional information.
BATTERY CHARGING OUTPUT can injure.
(Battery charging feature not present on all models.)
Have only qualified persons do battery charging work.
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.
Do not charge a frozen battery.
Do not use damaged charging cables.
MOVING PARTS can injure.
Keep away from moving parts such as fans,
belts, and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Stop engine before installing or connecting unit.
Have only qualified persons remove doors, panels, covers, or
guards for maintenance and troubleshooting as necessary.
To prevent accidental starting during servicing, disconnect
negative (−) battery cable from battery.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
Before working on generator, remove spark plugs or injectors to
keep engine from kicking back or starting.
Block flywheel so that it will not turn while working on generator
components.
Do not charge a battery that has loose terminals or one showing
damage such as a cracked case or cover.
Before charging battery, select correct charger voltage to match
battery voltage.
Set battery charging controls to the Off position before connecting to battery. Do not allow battery charging clips to touch each
other.
Keep charging cables away from vehicle hood, door, or moving
parts.
HOT PARTS can burn.
Do not touch hot parts bare handed.
Allow cooling period before working on
equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
OM-261050 Page 1
EXHAUST SPARKS can cause fire.
Do not let engine exhaust sparks cause fire.
Use approved engine exhaust spark arrestor in
required areas — see applicable codes.
STEAM AND HOT COOLANT can burn.
If possible, check coolant level when engine is
cold to avoid scalding.
Always check coolant level at overflow tank, if
present on unit, instead of radiator (unless told
otherwise in maintenance section or engine
manual).
If the engine is warm, checking is needed, and there is no overflow tank, follow the next two statements.
Wear safety glasses and gloves and put a rag over radiator cap.
Turn cap slightly and let pressure escape slowly before
completely removing cap.
BATTERY ACID can BURN SKIN and EYES.
Do not tip battery.
Replace damaged battery.
Flush eyes and skin immediately with water.
Using a generator indoors CAN KILL
YOU IN MINUTES.
Generator exhaust contains carbon monoxide.
This is a poison you cannot see or smell.
NEVER use inside a home or garage, EVEN IF
doors and windows are open.
Only use OUTSIDE and far away from windows, doors, and
vents.
ENGINE HEAT can cause fire.
Do not locate unit on, over, or near combustible
surfaces or flammables.
Keep exhaust and exhaust pipes way from
flammables.
1-3. Hydraulic Hazards
HYDRAULIC EQUIPMENT can injure
or kill.
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.
Do not work under or around any equipment that is supported
only by hydraulic pressure. Properly support equipment by
mechanical means.
MOVING PARTS can injure.
Keep away from moving parts such as fans,
belts and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Before working on hydraulic system, turn off and lockout/tagout
unit, release pressure, and be sure hydraulic pressure cannot be
accidentally applied.
Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
OM-261050 Page 2
HYDRAULIC FLUID can injure or kill.
Before working on hydraulic system, turn off and
lockout/tagout unit, release pressure, and be sure
hydraulic pressure cannot be accidentally applied.
Relieve pressure before disconnecting or connecting hydraulic lines.
Check hydraulic system components and all connections and hoses for damage, leaks, and wear
before operating unit.
Wear protective equipment such as safety
glasses, leather gloves, heavy shirt and trousers,
high shoes, and a cap when working on hydraulic
system.
Use a piece of paper or cardboard to search for
leaks−−never use bare hands. Do not use equipment if leaks are found.
HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics
near sparks or flames; do not smoke near hydraulic fluid.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
If ANY fluid is injected into the skin or body seek medical help immediately.
HOT PARTS AND FLUID can burn.
Do not touch hot parts bare handed or allow hot
fluid to contact skin.
Allow cooling period before working on
equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
READ INSTRUCTIONS.
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.
Use only genuine replacement parts from the manufacturer.
Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
1-4. Compressed Air Hazards
COMPRESSED AIR EQUIPMENT can
injure or kill.
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 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.
Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s instructions.
Do not modify or alter compressor or manufacturer-supplied
equipment. Do not disconnect, disable, or override any safety
equipment in the compressed air system.
Use only components and accessories approved by the manufacturer.
Keep away from potential pinch points or crush points created by
equipment connected to the compressed air system.
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.
BREATHING COMPRESSED AIR can injure or kill.
Do not use compressed air for breathing.
Use only for cutting, gouging, and tools.
TRAPPED AIR PRESSURE AND WHIPPING
HOSES can injure.
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.
Keep away from moving parts such as fans,
belts and rotors.
Keep all doors, panels, covers, and guards
closed and securely in place.
Keep hands, hair, loose clothing, and tools away from moving
parts.
Before working on compressed air system, turn off and lockout/
tagout unit, release pressure, and be sure air pressure cannot be
accidentally applied.
Have only qualified people remove guards or covers for maintenance and troubleshooting as necessary.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
Do not cut or gouge near flammables.
Watch for fire; keep extinguisher nearby.
HOT PARTS can burn.
COMPRESSED AIR can injure or kill.
Before working on compressed air system,
turn off and lockout/tagout unit, release pressure, and be sure air pressure cannot be accidentally applied.
Relieve pressure before disconnecting or connecting air lines.
Do not touch hot compressor or air system
parts.
Allow cooling period before working on
equipment.
To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.
Check compressed air system components
and all connections and hoses for damage,
leaks, and wear before operating unit.
Do not direct air stream toward self or others.
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.
Use soapy water or an ultrasonic detector to search for
leaks−−never use bare hands. Do not use equipment if leaks are
found.
Reinstall doors, panels, covers, or guards when servicing is
finished and before starting unit.
If ANY air is injected into the skin or body seek medical help immediately.
READ INSTRUCTIONS.
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.
Use only genuine replacement parts from the manufacturer.
Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
OM-261050 Page 3
1-5. Additional Symbols For Installation, Operation, And Maintenance
ELECTRIC SHOCK can kill.
Touching live electrical parts can cause fatal shocks
or severe burns. Machine internal circuits are live
when power is on. Incorrectly installed or improperly
grounded equipment is a hazard.
Do not touch live electrical parts.
Do not use AC weld output in damp, wet, or confined spaces, or if
there is a danger of falling.
Use GFCI protection when operating auxiliary equipment. Test
GFCI receptacles at high speed.
Do not connect to any electrical distribution system normally supplied by utility power unless a proper transfer switch and grounding
procedure are employed.
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).
Properly install, ground, and operate this equipment according to
its Owner’s Manual and national, state, and local codes.
Turn off all equipment when not in use.
Use only well-maintained equipment. Repair or replace damaged
parts at once. Maintain unit according to manual.
Keep all panels and covers securely in place.
FIRE OR EXPLOSION hazard.
Do not install or place unit on, over, or near
combustible surfaces.
Do not install unit near flammables.
Do not overload building wiring − be sure power supply system is
properly sized, rated, and protected to handle this unit.
FALLING EQUIPMENT can injure.
Use lifting eye to lift unit and properly installed
accessories only, NOT gas cylinders. Do not
exceed maximum lift eye weight rating (see
Specifications).
Use correct procedures and equipment of adequate capacity to
lift and support unit.
If using lift forks to move unit, be sure forks are long enough to
extend beyond opposite side of unit.
Keep equipment (cables and cords) away from moving vehicles
when working from an aerial location.
Follow the guidelines in the Applications Manual for the Revised
NIOSH Lifting Equation (Publication No. 94−110) when manually lifting heavy parts or equipment.
HIGH PRESSURE FLUIDS can injure or kill.
Engine fuel system components can be under
high pressure.
Before working on fuel system, turn off engine
to release pressure.
If ANY fluid is injected into the skin or body seek medical help immediately.
OM-261050 Page 4
OVERHEATING can damage motors.
Turn off or unplug equipment before starting or
stopping engine.
Do not let low voltage and frequency caused by
low engine speed damage electric motors.
Use only equipment suitable for operation on 60 or 50/60 Hz
power.
FLYING SPARKS can injure.
Wear a face shield to protect eyes and face.
Shape tungsten electrode only on grinder with
proper guards in a safe location wearing proper
face, hand, and body protection.
Sparks can cause fires — keep flammables away.
MOVING PARTS can injure.
Keep away from moving parts.
Keep away from pinch points such as drive
rolls.
OVERUSE can cause OVERHEATING.
Allow cooling period; follow rated duty cycle.
Do not block or filter airflow to unit.
STATIC (ESD) can damage PC boards.
Put on grounded wrist strap BEFORE handling
boards or parts.
Use proper static-proof bags and boxes to
store, move, or ship PC boards.
TILTING OF TRAILER can injure.
Use tongue jack or blocks to support weight.
Properly install welding generator onto trailer
according to instructions supplied with trailer.
READ INSTRUCTIONS.
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.
Use only genuine replacement parts from the manufacturer.
Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and
local codes.
1-6. California Proposition 65 Warnings
For Diesel Engines:
WARNING: This product can expose you to chemicals including lead, which are known to the state of California to cause
cancer and birth defects or other reproductive harm.
For more information, go to www.P65Warnings.ca.gov.
For more information, go to www.P65Warnings.ca.gov.
WARNING: Breathing diesel engine exhaust exposes you to
chemicals known to the state of California to cause cancer
and birth defects or other reproductive harm.
Always start and operate the engine in a well−ventilated
area.
If in an enclosed area, vent the exhaust to the outside.
Do not modify or tamper with the exhaust system.
Do not idle the engine except as necessary.
For more information, go to www.P65Warnings.ca.gov/diesel.
1-7. Principal Safety Standards
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (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, 14501 George Carter Way, Suite
103, Chantilly, VA 20151 (phone: 703-788-2700, website:
www.cganet.com).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
website: www.csagroup.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).
For Standards regulating hydraulic systems, contact the National Fluid
Power Association, 6737 West Washington St., Suite 2350, Milwaukee,
WI 53214 (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 1910.177 Subpart
N, 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).
Portable Generators Safety Alert, 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 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
Battery Service Manual, Battery Council International, 330 North
Wabash Ave., Suite 2000, Chicago IL 60611 (phone: 1-312-245-1074,
website: www.batterycouncil.org).
OM-261050 Page 5
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT
UTILISATION
Enpak Hydraulic_2018−06_fre
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.
AVIS − 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 existant en relation avec le moteur
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 2-7. 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. Une
personne qualifiée est définie comme celle qui, par la
possession d’un diplôme reconnu, d’un certificat ou d’un
statut professionnel, ou qui, par une connaissance, une formation et une expérience approfondies, a démontré avec
succès sa capacité à résoudre les problèmes liés à la tâche,
le travail ou le projet et a reçu une formation en sécurité afin
de reconnaître et d’éviter les risques inhérents.
Au cours de l’utilisation, tenir toute personne à l’écart et plus
particulièrement les enfants.
Le COURANT DE CHARGE DE BATTERIE peut
provoquer des blessures (la fonctionnalité de charge de
batterie n’est pas disponible sur tous les modèles).
Les opérations de charge de batterie ne doivent être effectuées
que par des personnes qualifiées.
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.
Ne pas charger une batterie gelée.
Ne pas utiliser de câbles de charge endommagés.
Ne pas charger une batterie dont les bornes sont desserrées ou
présentant une détérioration comme par exemple un boîtier ou un
couvercle fissuré.
Avant de charger une batterie, sélectionner la tension de charge
correspondant à la tension de la batterie.
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.
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.
L’EXPLOSION DE LA BATTERIE
peut provoquer des blessures.
Toujours porter une protection faciale, des
gants en caoutchouc et vêtements de protection lors d’une intervention sur la batterie.
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.
Eviter de provoquer des étincelles avec les outils en travaillant sur
la batterie.
Ne pas utiliser l’appareil 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.
Observer la polarité correcte (+ et −) sur les batteries.
Débrancher le câble négatif (–) en premier lieu. Le rebrancher en
dernier lieu.
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.
Suivre les instructions du fabricant de la batterie lors d’opérations
sur une batterie ou à proximité de celle−ci. Voir le manuel de
service de batterie (indiqué dans Normes de sécurité) pour plus d’informations.
OM-261050 Page 6
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.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes, panneaux,
recouvrements et dispositifs de protection.
Arrêter le moteur avant d’installer ou brancher l’appareil.
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.
Pour empêcher tout démarrage accidentel pendant les travaux
d’entretien, débrancher le câble négatif (−) de batterie de la borne.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
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.
Avant d’intervenir, déposer les bougies ou injecteurs pour éviter la
mise en route accidentelle du moteur.
Bloquer le volant moteur pour éviter sa rotation lors d’une
intervention sur le générateur.
Si le moteur est chaud et que le liquide doit être vérifié, opérer
comme suivant.
Mettre des lunettes de sécurité et des gants, placer un torchon sur
le bouchon du radiateur.
Dévisser le bouchon légèrement et laisser la vapeur s’échapper
avant d’enlever le bouchon.
LES ÉTINCELLES À L’ÉCHAPPEMENT
peuvent provoquer un incendie.
L’ACIDE DE LA BATTERIE peut provoquer des brûlures dans les YEUX et
sur la PEAU.
Empêcher les étincelles d’échappement du
moteur de provoquer un incendie.
Utiliser uniquement un pare-étincelles
approuvé − voir codes en vigueur.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
Ne pas toucher des parties chaudes à mains
nues.
Prévoir une période de refroidissement avant de
travailler à l’équipement.
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.
Il est préférable de vérifier le liquide de refroidissement une fois le moteur refroidi pour éviter
de se brûler.
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).
Ne pas renverser la batterie.
Remplacer une batterie endommagée.
Rincer immédiatement les yeux et la peau à l’eau.
L’utilisation d’un groupe autonome
à l’intérieur PEUT VOUS TUER EN
QUELQUES MINUTES.
Les fumées d’un groupe autonome contient du
monoxyde de carbone. C’est un poison
invisible et inodore.
JAMAIS utiliser dans une maison ou garage, même avec les
portes et fenêtres ouvertes.
Uniquement utiliser à l’EXTERIEUR, loin des portes, fenêtres et
bouches aération.
LA CHALEUR DU MOTEUR peut provoquer un incendie.
Ne pas placer l’appareil sur, au-dessus ou à
proximité de surfaces inflammables.
Tenir à distance les produits inflammables de
l’échappement.
2-3. Dangers liés à l’hydraulique
Les ÉQUIPEMENTS HYDRAULIQUES
peuvent provoquer des blessures ou
même la mort.
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.
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.
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.
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.
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.
Utiliser uniquement des composants et accessoires homologués
par le fabricant.
Se tenir à l’écart de tout point présentant un danger de pincement
ou d’écrasement créé par l’équipement raccordé au circuit
hydraulique.
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.
Les PIÈCES MOBILES peuvent causer
des blessures.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
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.
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.
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.
OM-261050 Page 7
Le LIQUIDE HYDRAULIQUE risque de
provoquer des blessures ou même la mort.
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.
Détendre la pression avant de débrancher ou
de brancher des canalisations hydrauliques.
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.
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.
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.
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.
Remettre les portes, panneaux, recouvrements ou dispositifs
de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.
En cas d’injection de tout liquide sous la peau ou dans le corps,
solliciter une aide médicale sur le champ.
LES PIÈCES ET LIQUIDES CHAUDS
peuvent provoquer des brûlures.
Ne pas toucher les pièces chaudes à main nue
ni laisser des liquides chauds entrer en contact
avec la peau.
Prévoir une période de refroidissement avant d’intervenir
sur l’équipement.
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.
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.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
2-4. Dangers liés à l’air comprimé
Un ÉQUIPEMENT PNEUMATIQUE risque
de provoquer des blessures ou même
la mort.
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.
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.
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.
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.
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.
Utiliser uniquement des composants et accessoires homologués
par le fabricant.
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.
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.
OM-261050 Page 8
MÉTAL CHAUD provenant du découpage ou du gougeage à l’arc risque de
provoquer un incendie ou une explosion.
Ne pas découper ou gouger à proximité de produits inflammables.
Attention aux risques d’incendie: tenir un extincteur à proximité.
L’AIR COMPRIMÉ risque de provoquer
des blessures ou même la mort.
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.
Détendre la pression avant de débrancher ou
de brancher des canalisations d’air.
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.
Ne pas diriger un jet d’air vers soi−même ou vers autrui.
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.
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.
Remettre les portes, panneaux, recouvrements ou dispositifs
de protection quand l’entretien est terminé et avant de mettre
en marche l’appareil.
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.
Ne pas inhaler d’air comprimé.
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.
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.
détendre la pression et s’assurer que le circuit d’air ne peut être
mis sous pression par inadvertance.
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.
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.
Ne pas toucher de pièces chaudes
du compresseur ou du circuit d’air.
Prévoir une période de refroidissement
avant d’intervenir sur l’équipement.
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.
Les PIÈCES MOBILES peuvent causer
des blessures.
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.
S’abstenir de toucher des parties mobiles telles
que des ventilateurs, courroies et rotors.
Maintenir fermés et verrouillés les portes, panneaux, recouvrements et dispositifs de protection.
Ne pas approcher les mains, cheveux, vêtements lâches et outils
des organes mobiles.
Avant d’intervenir sur le circuit d’air comprimé, couper
l’alimentation électrique, verrouiller et étiqueter l’appareil,
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance
LA CHUTE DE L’ÉQUIPEMENT
peut provoquer des blessures.
UN CHOC ÉLECTRIQUE peut tuer.
Un simple contact avec des pièces électriques peut
provoquer une électrocution ou des blessures graves. Les circuits internes de l’appareil sont sous
tension à ce moment-là. Des matériels mal installés
ou mal mis à la terre présentent un danger.
Ne jamais toucher les pièces électriques sous tension.
Ne pas utiliser de sortie de soudage CA dans des zones humides
ou confinées ou s’il y a un risque de chute.
Utiliser une protection GFCI lors de l’utilisation d’appareils auxiliaires. Testez les prises GFCI à haute vitesse.
Ne brancher aucun système de distribution électrique normalement fourni par un réseau public à moins qu’un commutateur de
transfert et une procédure de mise à la terre adéquats ne soient
mis en place.
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).
Installez, mettez à la terre et utilisez correctement cet équipement
conformément à son Manuel d’Utilisation et aux réglementations
nationales, gouvernementales et locales.
Mettre l’appareil hors tension quand on ne l’utilise pas.
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.
Risque D’INCENDIE OU
D’EXPLOSION.
Ne pas placer l’appareil sur, au-dessus ou
à proximité de surfaces inflammables.
Ne pas installer l’appareil à proximité de produits inflammables.
Ne pas surcharger l’installation électrique − s’assurer que l’alimentation est correctement dimensionnée et protégée avant de
mettre l’appareil en service.
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).
Utilisez les procédures correctes et des équipements d’une capacité appropriée pour soulever et supporter 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.
LES LIQUIDES PRESSURISÉS peuvent
blesser ou tuer.
Les composants du système d’alimentation
peuvent contenir du carburant sous pression
élevée.
Avant d’intervenir sur le système d’alimentation de carburant,
arrêter le moteur pour dépressuriser le système.
En cas d’injection de tout liquide sous la peau ou dans le corps,
solliciter une aide médicale sur le champ.
OM-261050 Page 9
LE SURCHAUFFEMENT peut
endommager le moteur électrique.
L’EMPLOI EXCESSIF peut
SURCHAUFFER L’ÉQUIPEMENT.
Arrêter ou déconnecter l’équipement avant de
démarrer ou d’arrêter le moteur.
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.
Utiliser uniquement des équipements adéquats pour un
fonctionnement avec une alimentation de 50/60 ou de 60 Hz.
Laisser l’équipement refroidir ; respecter le facteur de marche nominal.
Ne pas obstruer les passages d’air du poste.
LES CHARGES ÉLECTROSTATIQUES peuvent endommager les
circuits imprimés.
Établir la connexion avec la barrette de terre
avant de manipuler des cartes ou des pièces.
Utiliser des pochettes et des boîtes antistatiques pour stocker,
déplacer ou expédier des cartes de circuits imprimes.
LES ÉTINCELLES PROJETÉES
peuvent provoquer des blessures.
Porter un écran facial pour protéger le visage et
les yeux.
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.
Les étincelles risquent de causer un incendie − éloigner toute
substance inflammable.
Les PIÈCES MOBILES peuvent
causer des blessures.
Ne pas s’approcher des organes mobiles.
Ne pas s’approcher des points de coincement
tels que des rouleaux de commande.
UNE REMORQUE QUI BASCULE peut
provoquer des blessures.
Utiliser les supports de la remorque ou des
blocs pour soutenir le poids.
Installer convenablement le poste sur la remorque comme indiqué dans le manuel s’y rapportant.
LIRE LES INSTRUCTIONS.
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.
N’utiliser que les pièces de rechange recommandées par le
constructeur.
Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
2-6. Proposition californienne 65 Avertissements
AVERTISSEMENT : ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations
ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
Pour les moteurs diesel :
AVERTISSEMENT : les gaz d’échappement de moteurs diesel
vous exposent à des produits chimiques, reconnus par l’État
de Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction.
Toujours démarrer et faire tourner le moteur dans une
zone bien aérée.
Si la zone est fermée, diriger l’échappement vers l’extérieur.
Ne pas modifier ni altérer le système d’échappement.
Ne pas faire tourner le moteur au ralenti, sauf si nécessaire.
Pour plus d’informations, consulter www.P65Warnings.ca.gov/
diesel.
2-7. Principales normes de sécurité
National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Quincy, MA 02169 (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).
Battery Chargers, CSA Standard C22.2 NO 107.2−01, from Canadian
Standards Association, Standards Sales, 5060 Spectrum Way, Suite
100, Mississauga, Ontario, Canada L4W 5NS (phone: 800-463-6727,
website: www.csagroup.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).
Pour les normes réglementant les systèmes hydrauliques, communiquez avec National Fluid Power Association, 6737 West
Washington St., Suite 2350, Milwaukee, WI 53214 (téléphone : (414)
778-3344, site web : www.nfpa.com).
OM-261050 Page 10
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, auprès du U.S. Government Printing Office,
Superintendent of Documents, P.O. Box 371954, Pittsburgh, PA
15250-7954 (téléphone : 1-866-512-1800) (il y a 10 bureaux régionaux––le téléphone de la région 5, Chicago, est 3123532220, site Internet
: www.osha.gov).
Portable Generators Safety Alert, 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 30329-4027 (phone: 1-800-232-4636, website:
www.cdc.gov/NIOSH).
Manuel de service de batterie, Battery Council International, 330 North
Wabash Ave., Suite 2000, Chicago IL 60611 (téléphone :
1-312-245-1074, site Web : www.batterycouncil.org).
Complete Parts List available at www.MillerWelds.com
SECTION 3 − DEFINITIONS
3-1. Additional Safety Symbol Definitions
Warning! Watch Out! There are possible hazards as shown by the symbols.
Safe1 2012−05
Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual.
Safe89 2017−04
Moving parts can injure.
Safe100 2012−08
Hot oil and compressed air can injure or kill.
Safe 112 2013−03
Compressed air hazard. If ANY air is injected into the skin or body seek medical help immediately.
Safe108 2012−11
Never use generator inside a home or garage, even if doors and windows are open.
Safe87 2012−07
Only use generator outside and far away from windows, doors, and
vents.
Safe88 2012−07
OM-261050 Page 11
Complete Parts List available at www.MillerWelds.com
3-2. Miscellaneous Symbol Definitions
Amperage
Fuel
Protective Earth
(Ground)
Voltage
Battery (Engine)
Air Pressure
Hertz
Glow Plug
Air Compressor
Single Phase
Alternator
Engine
Air Compressor
Read Operator’s
Manual
Engine RPM
Hydraulic Pump
Engine Coolant
Temperature
Direct Current
(DC)
Check Valve
Clearance
Air Filter
Alternating
Current (AC)
Belt Drive
Engine Oil
OM-261050 Page 12
Complete Parts List available at www.MillerWelds.com
SECTION 4 − SPECIFICATIONS
4-1. 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.
4-2. Auxiliary Power And Engine Specifications
Standard Generator Power Rating
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 D902-E4B, 3-Cylinder, 24.8 HP,
Liquid-Cooled, Diesel Engine w/Electronic
Governor
Combined Maximum Auxiliary Power Output (Standard Generator And EnVerter) Is 6kVA/kW
4-3. Air Compressor Specifications
Compressor
Type
Air Output At Effective
Working Pressure
Rotary Screw
58 scfm @ 100 psi (1.13 m3 min−1
@ 689 kPa),
100% Duty Cycle, 3600 RPM
60 CFM Max. Flow
Pressure
Safety Relief
Valve Setting
Air Compressor
Oil Capacity
Range: 120−175 psi
(827−1206 kPa)
Auto Shutoff: 10 psi
(69 kPa) Above Set Maximum
Factory set at 120 psi
(827 kPa)
Pressure Relief: 200 psi
(1379 kPa)
4 qt (3.79 L)
4-4. Hydraulic Specifications (Models With Hydraulic Power Source)
Pump Type
Rated Output Open
Center
Rated Output Closed
Center
Maximum
Pressure
Maximum Flow Rate
Variable Displacement
Piston
8.0 GPM at 3000 psi at 3200
RPM, 50% Duty Cycle*
7.5 GPM at 2800 psi at 3200
RPM, 50% Duty Cycle*
3500 psi
(241.3 bar)
15 GPM (Open Center)
20 GPM (Closed Center)
*Dependant on system cooling capacity.
Contact Factory Authorized Service Agent for pump flow rate changes.
4-5. Environmental Specifications
A. Temperature Specifications
Operating Temperature Range*
Storage/Transportation Temperature Range
−40 to 120°F (−40 to 49°C)
−50 to 131°F (−45 to 55°C)
*Output is derated at temperatures above 104°F (40°C).
Temp_2016- 07
B. Cold Weather Specifications
NOTICE − Components can be damaged and are not warranted for operation at temperatures below −40°F. Contact Miller Electric Mfg. LLC for further
information regarding extreme low temperature operation
Engines should not be started if ambient temperature is below −40°F, unless measures have been taken to ensure all components inside the EnPak
and the Remote Panel are at temperatures above −40°F, and correct low temperature fluids are being used per chart below.
For continuous weekly operation at/or below −40°F, it is recommended that an enclosure, with a heater, be used to heat the EnPak components
and recirculate engine heat to keep the EnPak within the operating temperature of the oils being used in the engine, compressor, and hydraulic
systems. Engine exhaust would still need to be piped outside the enclosure.
See Section 6-5 for more cold weather operation information.
OM-261050 Page 13
Complete Parts List available at www.MillerWelds.com
4-6. Fluid Specifications
Ambient Temperature
°F
-40
-22
-13
-4
14
32
50
68 (+)
°C
-40
-30
-25
-20
-10
0
10
20
0W -20
5W -30
5W -30
10W -30
10W -30
10W -30
10W -30
10W -30
5W -40
5W -40
10W -40
10W -40
10W -40
10W -40
10W -40
Engine
Oil
Full
Synthetic
Hydraulic (Models With Hydraulic Power Source)
Oil
Oil Viscosity Index
ISO 15
ISO 15
ISO 15
ISO 15
ISO 32
ISO 32
ISO 32
ISO 32
VI ≥ 160
VI ≥ 140
VI ≥ 140
VI ≥ 140
VI ≥ 120
VI ≥ 120
VI ≥ 120
VI ≥ 120
Miller
276620
Miller
276620
Miller
276620
Miller
276620
Miller
276620
Miller
276620
Miller
276620
Miller
276620
Compressor
Oil (Full Synthetic)
NOTICE − For extreme cold (below −305F or −345C), consult with the Miller Service department regarding preheating and suitable lubricants.
* For temperatures below −205F (−295C) an oil heater for the compressor is required. Consult with the Miller Service department. Failure to preheat
the oil as specified may void the warranty.
See Section 6-5 for more engine cold weather operation information.
Notes
OM-261050 Page 14
Complete Parts List available at www.MillerWelds.com
4-7. 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:
832 lb (377 kg)
896 lb (406 kg) Fully Equipped
(w/Packaging)
Lifting Eye Weight Rating:
1000 lb (454 kg)
15°
15°
15°
15°
265 796-A
OM-261050 Page 15
Complete Parts List available at www.MillerWelds.com
4-8. Fuel Consumption
The curve shows typical fuel use
under compressor or power loads.
Compressor
1.60
1.40
U.S. GAL/HR
1.20
1.00
0.80
0.60
0.40
0.20
0.00
0
10
20
30
40
50
60
70
Cubic Feet Per Minute (CFM)
Auxiliary Power
1.40
1.20
Standard Generator Power
U.S. GAL/HR
1.00
0.80
0.60
Synthetic Power
0.40
IDLE
0.20
0.00
0.0
1.0
2.0
3.0
4.0
5.0
6.0
Aux Power KiloWatts at 100% Duty Cycle
261 042
OM-261050 Page 16
Complete Parts List available at www.MillerWelds.com
4-9. Auxiliary Power Curves
Combined
maximum
auxiliary power output
(standard generator and
EnVerter) is 6kVA/kW.
EnVerter Power
240 VAC Auxiliary Power
The AC generator power curves
show the generator power available
in amperes.
The EnVerter power curve shows
the power available in amperes.
Tools and motors are designed to
operate within 10% of 120/240
VAC.
120 VAC Auxiliary Power
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
4-10. 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
12
0
20
40
60
80
100
AMPS
242 595-A
OM-261050 Page 17
Complete Parts List available at www.MillerWelds.com
4-11. Hydraulic Pressure Flow Curves (Models With Hydraulic Power Source)
Curves are typical. Output will
vary depending on system
pressure losses to load sense
pressure location.
Open Center Hydraulic Pressure Flow Curve
Fluid: ISO 32 Hydraulic Oil
16
Fluid Temperature: 120° F (49° C)
Load Sense Pressure:
Closed Center − 400 PSID
(27.6 bar)
Open Center − 200 PSID (13.8
bar)
14
12
Flow (gpm)
10
8
6
4
2
0
0
500
1000
1500
2000
Pressure (psi)
Automatic Mode
2500
3000
3500
Manual Mode
Closed Center Hydraulic PressureFlow Curve
20
18
16
Flow (gpm)
14
12
10
8
6
4
2
0
0
500
1000
1500
2000
Pressure (psi)
Automatic Mode
2500
3000
3500
Manual Mode
261 044-A
OM-261050 Page 18
Complete Parts List available at www.MillerWelds.com
4-12. Hydraulic Pressure Flow Curves − Combination Loads
(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)
Open Center Hydraulic Pressure−Flow Curves (Combination Loads)
16
60
14
50
40
10
8
Air Flow @ 100psi (scfm)
Hydraulic Flow (gpm)
12
30
6
20
4
10
2
0
0
0
500
1000
1500
2000
2500
3000
3500
Hydraulic Pressure (psi)
Pump Flow with Compressor
Pump Flow with 6kW
Air Compressor Flow
Closed Center Hydraulic Pressure−Flow Curves (Combination Loads)
20
60
18
Hydraulic Flow (gpm)
14
40
12
10
30
8
20
6
4
10
2
0
Air Flow @ 100psi (scfm)
50
16
0
0
500
1000
1500
2000
2500
3000
3500
Hydraulic Pressure (psi)
Pump Flow with Compressor
Pump Flow with 6kW
Air Compressor Flow
261 044-A
OM-261050 Page 19
Complete Parts List available at www.MillerWelds.com
4-13. Air Compressor Curves
Standard Conditions:
Pressure = 100 psi (689 kPa)
Temperature = Operating Temperature
Maximum Air Flow
70.0
60.0
Air Flow (scfm)
50.0
40.0
30.0
20.0
10.0
0.0
50
75
120psi Max Setting
100
125
Air Pressure (psi)
150psi Max Setting
150
175
200
175psi Max Setting
261 043-A
Notes
OM-261050 Page 20
Complete Parts List available at www.MillerWelds.com
SECTION 5 − INSTALLATION
5-1. Installing Unit
!
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.
Movement
Go to MillerWelds.com for more
information on truck installations.
NOTICE − Do not install unit where
air flow is restricted or engine may
overheat.
OR
See Section 5-2 for mounting information. See Section 4-7 for dimensions.
See Section 6 through 9 for spe-
Location/Airflow Clearance
cific EnPak systems information.
1
2
2
1
Hydraulic Reservoir
EnPak
Typical hydraulic reservoir placement in relation to EnPak. See Section 7-1 for complete reservoir requirements.
1
18 in.
(460 mm)
7 in. (178 mm) Maintenance
4 in. (102 mm) Operation
!
!
2
1 in.
(25 mm)
Hot air.
Hot air.
1 in.
(25 mm)
!
7 in. (178 mm) Maintenance
4 in. (102 mm) Operation
Hot air.
Ref: install3 2017−03 − 805 454-A / 265 802-A
OM-261050 Page 21
Complete Parts List available at www.MillerWelds.com
5-2. 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 4-7 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)
5/16-18 x 3/4 in. Screws
(Supplied)
To Bolt Unit In Place:
1
Using brackets attached to the
base, mount unit to vehicle with 1/2
in. (12 mm) or larger hardware (not
supplied). There are also 3/8 in.
weld nuts and mounting holes in the
base. See Section 4-7 for mounting
dimensions.
To Weld Unit In Place:
Remove hardware securing the
four mounting brackets to the base.
Reverse brackets and reattach to
base with original hardware.
1
Weld unit to vehicle only at the four
mounting brackets.
Using Mounting Brackets
2
Welding Unit In Place
Bolting Unit In Place
3
2
Tools Needed:
9/16 in.
4
Ref: install3 2017-03 803 274 / 200 864-A / 265 802-A
OM-261050 Page 22
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SECTION 6 − ENGINE PREPARATION
6-1. Connecting the Battery
Battery Specification:
!
Route battery cables
away from hot, sharp, or
moving parts.
!
Connect negative (−)
cable last.
1
Battery Cable Strain
Relief
Starter
Starter Cable Lug
(Supplied)
Engine Block
12 V, 650 CCA at 0° F
Battery Cable Specification:
1/0 AWG
1
2
3
4
Route cables from vehicle battery through strain relief.
Crimp supplied starter cable
lug onto positive (+) cable.
Connect positive (+) cable to
engine starter.
Locate hole in engine block
behind unit center upright.
Connect negative (−) cable to
engine block.
1
2
3
4
Tools Needed:
1/2 in.
265 802-A / 287 097-B
OM-261050 Page 23
Complete Parts List available at www.MillerWelds.com
6-2. 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-261050 Page 24
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6-3. 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
265 802-A / 287 097
OM-261050 Page 25
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6-4. Engine Prestart Checks
Check all fluids daily. Engine must be
cold and on a level surface. Unit is
shipped with 10W30 engine oil.
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 Fill
Coolant Overflow Bottle
Radiator Cap
Oil Dipstick
Fuel
Be sure fuel connections are made and
tight. Be sure fuel tank utilized for unit
operation is full.
1
2
Coolant
3
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.
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 10-2).
For cold weather starting information, see Section 6-5.
Keep battery in good condition.
Store battery in warm area.
Use correct grade oil for cold
weather.
Continue initial system checks. See
Sections 7-4 and 8-3.
2
3
4
265 802-A
OM-261050 Page 26
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6-5. Cold Weather Starting And Operation
Engine Start
See Operation Section for additional remote panel operating instructions.
1
Prior to starting the engine verify that all fluids (fuel, engine coolant, engine oil, hydraulic oil, and compressor oil) are to the correct level and grade/
specification for the ambient temperature indicated. If the ambient temperature is below 14°F (−10°C) engine coolant block heaters and hydraulic oil
heaters may be be required prior to the engine start. See chart below for minimum heater times.
2
When using the Remote Panel or Crane Remote to start the EnPak, turn unit on and initiate starting sequence. The EnPak control system automatically sets the glow plug time for ambient temperature conditions. See chart below when manually starting the unit from the EnPak service panel.
All external loads on the engine should be off when starting the engine. The air compressor should be off until the engine has been started and
warmed up.
3
Start engine. If engine fails to start after 10 seconds, turn unit off and repeat start sequence.
4
Allow engine to warm up prior to loading engine, See Note 1A. When ambient temperatures are below 50°F (10°C), the EnPak goes to 2600 RPM
and remains there until the engine has warmed to 100°F (38°C).
Be sure to warm up engine, not only in the winter, but also in warmer seasons. An insufficiently warmed-up engine can shorten its service life.
Ambient Temperature (At or below)
F
-40
-22
-13
-4
14
32
50
68 (+)
C
-40
-30
-25
-20
-10
0
10
20
Glow Plugs
Auto/
13 sec
Auto/
13 sec
Auto/
13 sec
Auto/
13 sec
Auto/
10 sec
Auto/
10 sec
Auto/
5 sec
-
Oil
0W -20
5W -30
5W -30
10W -30
10W -30
10W -30
10W -30
10W -30
Full
Synthetic
5W -40
5W -40
10W -40
10W -40
10W -40
10W -40
10W -40
Block Heater
60 min
40 min
30 min
20 min
-
-
-
-
Engine Warm-up
7 min
5 min
5 min
3 min
2 min
1 min
1 min
1 min
Engine
Hydraulic (Models With Hydraulic Power Source)
Oil
Oil Viscosity Index
ISO 15
ISO 15
ISO 15
ISO 15
ISO 32
ISO 32
ISO 32
ISO 32
VI ≥ 160
VI ≥ 140
VI ≥ 140
VI ≥ 140
VI ≥ 120
VI ≥ 120
VI ≥ 120
VI ≥ 120
Normal stabilized engine coolant temperatures should be in the range of 160 − 220°F (71 − 104°C). In extreme cold conditions it may become necessary to block a portion of intake cooling air. See Engine Troubleshooting Section for trouble shooting over or under coolant temperature.
1 Glow plugs are automatically activated when the unit is turned on from the EnPak remote or crane remote. Times listed are the maximum recommended glow plug times when starting the EnPak using the manual service panel. Extending the glow plug times beyond those listed can cause
damage to the glow plugs and system.
2
For additional engine oil specification see Engine Maintenance Label or Engine Operators Manual.
3
Times listed are for the standard Miller Part No. 242954, Engine Block Heater, 120V.
4 Maximum start-up viscosity limited to 2100cSt; minimum intermittent viscosity limited to 6cSt. Use of a high viscosity index (VI) fluid is recommended to attain the ISO fluid recommendations listed. Refer to EnPak Technical Bulletin for further details. Never allow fluid temperatures to exceed 160°F
(71°C) during operation (do not exceed 140°F (60°C) for handheld tools).
5
Optional, Miller Part No. 300546, Hydraulic Reservoir Oil Heater. Necessitated only when oil exceeds maximum start-up viscosity of 2100cSt.
−
Not required.
OM-261050 Page 27
Complete Parts List available at www.MillerWelds.com
SECTION 7 − HYDRAULIC SYSTEM
(MODELS WITH HYDRAULIC POWER SOURCE)
7-1. 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 mechanic’s 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 (see Table 7-1)
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 5-1. 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-Center Systems Powering Cranes:
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 3500 psi (24.1 MPa), consult the factory.
In this configuration, the system relief valve is the primary relief and the pump maximum pressure setting is secondary.
Closed-Center Systems And Non-Crane Open-Center Systems:
For most 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 or equipment manufacturer. The system relief valve should also be set according to
the crane or equipment 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 7-1 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.
Obtain hoses of the proper length and type with appropriate fittings for the installation according to Table 7-1.
OM-261050 Page 28
Complete Parts List available at www.MillerWelds.com
Table 7-1. Hydraulic Hoses Specifications
Hydraulic Hoses
Suction
Line1
Pressure
Line2
System Flow Rate
Hose ID
Minimum
Working
Pressure
Minimum
Burst
Pressure
Vacuum Service
Operating
Temperature
in. / mm
psi / MPa
psi / MPa
Inches of Hg / kPa
°C / °F
up to 10 gpm
1.25 / 31.76
150 / 1.03
600 / 4.14
28 / 94.82
−40 to 100 /
−40 to 212
over 10 gpm, up to 20 gpm
1.5 / 38.1
up to 10gpm
0.5 / 12.7
3000 / 20.68
12000 / 82.74
−40 to 100 /
−40 to 212
over 10 gpm, up to 20 gpm
0.75 / 19.05
Drain3
All flow rates
0.625 / 15.88
350 / 2.41
1400 / 9.65
−40 to 100 /
−40 to 212
Load Sense
(Closed Center)4
All flow rates
0.25 / 6.35
3000 / 20.68
12000 / 82.74
−40 to 100 /
−40 to 212
Return Line Less
Than 10 gpm5
up to 10 gpm
0.625 / 15.88
over 10 gpm, up to 20 gpm
0.75 / 19.05
Case
−40 to 100 /
−40 to 212
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 −22°F to 250°F (−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 7-2. Hydraulic Fluid Specifications
NOTICE − Viscosity Index (VI) greater than 120 is recommended.
Ambient Temperature
Viscosity Grade (Viscosity Index Greater Than 120)
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
OM-261050 Page 29
Complete Parts List available at www.MillerWelds.com
7-2. 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
4
3
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:
2-1/4. 1-1/4. 1, 9/16 in.
(57, 31, 25, 14 mm)
265 802-A / 287 097
OM-261050 Page 30
Complete Parts List available at www.MillerWelds.com
7-3. Priming Hydraulic Pump
2
Eaton (Blue) Pump
2
1
3
Casappa (Black) Pump
1
3
4
5
6
265 795-A / 265 802−A / 260 718B / 282108
!
When working on unit, always
move Manual/Remote switch to
Manual position to prevent remote
starting. See Section 10-7.
1
Proportional Valve Assembly
2
Manual Override Screw Adjust
3
Case Drain Port
4
Service Panel
5
Manual/Remote Switch
6
Fuel Pump Switch
Make hydraulic system connections according to Section 7-2.
Before starting the unit for the first time, remove pump case drain hose from pump
body and slowly add 16 oz of hydraulic fluid directly to pump. Reconnect case drain
hose.
Fully open suction line valve at the reservoir. Turn 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.
Turn 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 flow rate are set at the factory and should not require initial adjustment. Have Factory Authorized Service
Agent correct settings.
OM-261050 Page 31
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7-4. Hydraulic System Prestart Checks
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.
Unit is shipped set for 10 GPM. Contact Factory Authorized Service Agent for pump flow rate changes. See Section 10-3.
7-5. Hydraulic Pump Operation
Unit is shipped set for 10 GPM. Contact Factory Authorized Service Agent for pump flow rate changes. See Section 10-3.
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 go to 2600 RPM and deliver up to 6 GPM of flow from the hydraulic pump. For medium trigger
pulls, 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 closed centered systems: Placing the crane pendant speed switch in the low speed position will lock the EnPak at 2600 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 2600 RPM for crane
loads, the hydraulic output is limited to a maximum of 6.5 GPM (open center) or 10 GPM (closed center).
3
High speed lock:
For both open and closed 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 (each switch transition must occur within 3 seconds). The EnPak will then be locked at 3200 RPM and
have maximum hydraulic output. The EnPak can still be locked into high speed from the EnPak Remote Panel.
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.
Notes
OM-261050 Page 32
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7-6. 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
256 802-A / 265 795-A
OM-261050 Page 33
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SECTION 8 − COMPRESSOR SYSTEM
8-1. 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
Required reservoir size is 20 gal (78 L) or larger. Compressor performance may be adversely affected if tank is less than 20 gal (78 L). 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 8-1.
Table 8-1. Air Compressor Hose Specification
Hose ID
0.5 in. / 12.7 mm
Minimum Working Pressure
350 psi / 2.41 MPa
Minimum Burst Pressure
1400 psi / 9.65 MPa
Operating Temperature
−40 to 212°F (−40 to 100°C)
D. Compressor Oil
Miller 276620 synthetic compressor oil is recommended. Do not mix oil types.
The compressor oil must have high ageing stability, corrosion protection, and dispersive capacity; low emulsification tendency, and minimum foaming.
Notes
OM-261050 Page 34
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8-2. Compressor Connections
!
Stop engine, wait 10
minutes, and verify the air
pressure gauge reads 0 psi
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
265 802-A / 287 097
OM-261050 Page 35
Complete Parts List available at www.MillerWelds.com
8-3. Compressor Prestart Checks
!
Stop engine, wait 10 minutes, and
verify the air pressure gauge reads
0 psi before opening oil cap. Do not
open oil fill cap while running.
The compressor is equipped with high
oil temperature shutdown. High oil
temperature can be caused by low oil
or hot air recirculation.
NOTICE − Do not mix oil types. Do not
overfill.
sor reservoir. Oil level sight gauge shows
oil level.
1
Minimum oil level is half way up the oil fill
pipe. Maximum oil level is in threaded area
of oil fill pipe.
Air Compressor Oil Fill Cap
Hand tighten oil fill cap. Using excess
force can damage o-ring.
2
Oil Level Sight Gauge
The unit is shipped with oil in the compres-
Check level frequently. If oil needs to be
added, be sure unit is off and compressor
case pressure is released according to
Section 8-5 before removing fill cap.
High
1
Low
2
Minimum com-
pressor oil level
is half way up
the fill pipe.
Maximum oil
level
is
in
threaded area
of oil fill pipe.
Ref. 265 802-A
OM-261050 Page 36
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8-4. Air Compressor Controls
1
Adjust system
maximum pressure and
minimum pressure using Remote Panel.
265 802-A / 248 998
!
The air pressure gauge reads the air
compressor case pressure. Case
pressure can be high even when external reservoir pressure is zero. Always release pressure manually according to Section 8-5 before checking/adding oil or performing maintenance.
1 Air Compressor Gauge (P−PG)
Adjust system maximum pressure and
minimum pressure using Remote Panel.
Set at lowest possible pressure for the job
to reduce engine loading.
Pressure
is factory set for 120 psi.
Maximum pressure setting is 175 psi.
Minimum pressure setting is 120 psi.
See Section 10-3.
At pressures that are 10 psi above maximum set point, 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 the maximum set point, the
compressor controls reset and resume normal operation.
The compressor is also equipped with a
mechanical safety valve (P−SV) that will
open if pressure approaches 200 psi.
If the compressor continues to overpressure and disengage, see Section 12.
If compressor shuts down due to overtemperature, it automatically resets when it
cools.
OM-261050 Page 37
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8-5. Compressor Blow Down
!
Stop engine, wait 10
minutes, and verify the air
pressure gauge reads 0 psi
before servicing compressor.
To control the release of air in the
compressor, the compressor goes
through a blow down cycle when it
is turned off. Blow down depressurizes the compressor case; this
provides safe release of case pressure and allows reduced load at restart.
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.
1
2
Pressure Release Valve
Air Compressor Gauge
2
1
265 804-A
Notes
OM-261050 Page 38
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SECTION 9 − AUXILIARY POWER SYSTEM CONNECTIONS
9-1. 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
2
3
4
Auxiliary Power System Ground
Grounding Cable (Not Supplied)
Metal Vehicle Frame
Auxiliary Power Box
Connect grounding cable to auxiliary
power system ground (ground screw
on frame where existing green or
green/yellow lead is attached).
Route grounding cable through auxiliary power box and through ground wire
route hole, away from hot, sharp or
moving parts.
Route grounding cable to appropriate
termination point on metal vehicle
frame. Use #8 AWG or larger insulated
copper wire with green or green striped
insulation.
Electrically bond generator frame
to vehicle frame by metal-to-metal
contact.
Existing Green or
Green/Striped Lead
1
GND/PE
!
Always connect a ground wire
from the auxiliary power system
ground to bare metal on the vehicle frame as shown.
!
Use only Miller-recommended
GFCI receptacles (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.
!
Test GFCI receptacles at least
once a month by running engine
at high speed and pressing Test
button to verify GFCI receptacles are working properly.
4
2
3
265 802-A / 805 447-A / Ref 287 066
OM-261050 Page 39
Complete Parts List available at www.MillerWelds.com
9-2. EnVerter Power System Connections And Overload Protection
!
Stop engine and let cool.
!
Keep wiring away from hot, sharp, or
moving parts.
1
Terminal Block 1T
120 VAC EnVerter power is available
between 1TF and 1TD.
Combined output of all EnVerter power loads
cannot exceed 2.4 kVA/kW. Full EnVerter
power is available regardless of engine
speed.
240V
120V
120V/60HZ
120V
B
A
GROUND
120V/240V
NEUTRAL
120V/240V
120V/60HZ
EnVerter
SUPPLY
C
NEUTRAL
F E D
NEUTRAL
BONDED
TOFRAME
Route conductors through strain relief in right
side of unit to auxiliary power box for connection.
NOTICE − There are two options for installing
120 VAC power, see truck wiring diagrams
Figure 13-4 and Figure 13-5.
2
Supplementary Protector CB2
Supplementary protector CB2 protects the
EnVerter power supply from overload when a
120 VAC load is connected.
If supplementary protector continues to
open, contact Factory Authorized Service Agent.
Tools Needed:
2
1
Route leads from EnVerter
load through strain relief.
265 802-A / 287 066 / 287 097-D
OM-261050 Page 40
Complete Parts List available at www.MillerWelds.com
9-3. Generator Power System Connections And Overload Protection
!
Stop engine and let cool.
!
Keep wiring away from hot, sharp, or
moving parts.
1
Terminal Block 1T
240 VAC power is available between 1TA and
1TE, with terminal 1TC as neutral.
120 VAC standard generator power is available between 1TA and 1TD or 1TE and 1TD.
240V
Combined output of all generator loads cannot exceed 6 kVA/kW.
120V
120V/60HZ
120V
B
A
GROUND
120V/240V
NEUTRAL
120V/240V
120V/60HZ
EnVerter
SUPPLY
C
NEUTRAL
F E D
NEUTRAL
BONDED
TOFRAME
2
Supplementary Protector CB1
Supplementary protector CB1 protects the
generator winding from overload when a
120/240 VAC load is connected.
NOTICE − If the standard generator high
speed (3600 RPM) 120V/20A circuit is used,
supplementary protector CB3 must be installed to match the amperage rating of the receptacle. There are two options for installing
120 VAC power, see truck wiring diagrams
Figure 13-4 and Figure 13-5.
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.
1
Circuit
Breaker
CB3 Location
2
!
Use only Miller-recommended GFCI
receptacles (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.
!
Test GFCI receptacles at least once a
month by running engine at high
speed and pressing Test button to
verify GFCI receptacles are working
properly.
Tools Needed:
Route leads from generator
load through strain relief.
265 802-A / 287 066 / 287 097-D
OM-261050 Page 41
Complete Parts List available at www.MillerWelds.com
SECTION 10 − OPERATION
O
10-1. Remote Devices Connections
3
2
Front of remote
3
4
5
6
3
2
1
1
265 802-A / 287 097
1
EnPak Remote Panel Connection
Receptacle RC12
Pin 6
Not used
Insert wires into included plug to match the
pins as listed.
The EnPak remote panel can transmit engine
data and EnPak system data on a Canbus
network, including engine errors, other component related errors, and general EnPak
system function information. The full data
packet can be found at MillerWelds.com.
3 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.
Pin 1
GND
Pin 2
Canbus HIGH
Pin 3
Canbus LOW
Pin 4
GND
Pin 5
+12 volts DC output only (1 amp
output maximum)
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.
Mount remote panel inside of truck body cabinets where easily accessible. Connect interconnecting cable Part No. 244283 between
remote panel and RC12.
2
EnPak Remote Panel Canbus
Connection
The Canbus connection is for use with a customer-supplied telematics device.
OM-261050 Page 42
Contact Factory for list of harness adapters
available.
Optional Engine Remote Start/Stop Using
Ground Signal
4
Service Panel
Locate wire 120 in the harness close to the
Service Panel control board. It will have a fast
on connector on the end of it.
Connect signal wire from start/stop switch to
this wire 120 and route the wire out through
the base of the unit. The signal from the
switch must be a “ground” signal when the
switch is activated and no signal when the
switch is not activated.
The EnPak control will detect a ground signal
and will start the engine if it is not running, or
it will stop the engine if it is running.
Complete Parts List available at www.MillerWelds.com
10-2. Remote Panel (Use With Section 10-3)
1
4
11
2
5
3
7
6
10
8
9
282711-A
OM-261050 Page 43
Complete Parts List available at www.MillerWelds.com
10-3. Remote Panel Operation (Use With Section 10-2)
1
Alpha-Numeric Display
During the start sequence, the following
appears:
SYSTEMon
GLOWPLUG
STARTING
CRANKING
GLOWPLUG only shows on display
when ambient temperature is less than
415F (55C).
See Section 10-5 for error messages that
appear.
2 Check Engine LED
Lights when display is showing an engine
error.
If an engine error occurs and the engine
shuts down, the error will be stored in
memory. If the display is off, press the
Power button once to activate the Remote
Panel. The display will read ERROR and
after a few seconds will flash the error
code. See Section 10-5 for error messages
that appear.
To erase the error, press and hold the Display Select push button until the display
reads SYSTEMon, and the indicator is off.
The display will now cycle normally when
the Display Select push button is pushed.
3 Check Compressor LED
Lights when display is showing a compressor error.
4 Auto On LED
Lights when Auto Start/Stop mode is selected.
5 Engine LED
Lights when display is showing engine related information.
6 Compressor LED
Lights when display is showing compressor related information.
7 Power Engine Start Push Button
Press and release to turn on power to the
display only. This allows access to the display menu.
To Start: press and release the Power Engine Start push button two times. The first
press and release will power up the control
system and the second press and release
will initiate the automatic starting sequence. The Engine Off push button can
be pressed at any time to stop the start sequence.
The starter will disengage at a predetermined RPM based on the ambient temperature.
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, or to stop the automatic start sequence.
9 Auto Start/Stop Push Button
Press and release the Auto Start/Stop
push button to toggle between automatic
and manual control.
When the automatic mode is selected, the
Auto On LED lights and display reads ENAbLEd.
While the display shows ENAbLEd, press
and hold the push button to change the
auto stop timer (range of two to 30
minutes). This time is placed in memory
and is remembered the next time the EnPak is started.
When the system is placed in manual
mode, the display shows dISAbLEd and
the Auto On LED is off.
10 Display Select Push Button
When engine is running: press and release
to cycle through the following displays:
RPM
Battery voltage
Current fuel usage (Gallons Per Hour)
Engine hours
Engine maintenance hours (Counts down
from 200 hours)
Engine temperature
Compressor hours
Compressor maintenance hours (Counts
down from 500 hours)
When engine is not running: press and release to cycle through the following displays:
Battery voltage
Engine hours
Engine maintenance hours (Counts down
from 400 hours)
Compressor hours
Compressor maintenance hours (Counts
down from 500 hours)
To change the hydraulic control system to
“Lube Truck” or “Crane Truck” operation:
Turn on the interlock power. With the Remote Power display Off, press and hold the
Display Select button for more than five
seconds. The display will turn On and display MAXhYd10. (The number 10 may be
different if the maximum hydraulic output is
set to a different level.)
Press and release the Display Select button again. The display will read
CRANETRK.
Press and release the Compressor On/Off
button to toggle between LuBE TRK and
CRANETRK.
Press and release the Engine Off button to
save the selection and turn Off the display.
When LuBE TRK is selected, the maximum pressure of the compressor is automatically limited to 120 psi and cannot be
changed.
Maintenance
hours initially count
down from 50 hours. Complete maintenance required after first 50 hours of
operation according to Section 11.
Current fuel
usage is for reference
only. Variables such as ambient temperature, altitude and fuel blend affect
actual usage.
11 Compressor On/Off Push Button
When engine is running, press twice to turn
compressor on or off. When turned on, engine will speed up to 2600 RPM. This indicates the compressor is on.
Compressor maximum and minimum
pressure are set using the Remote
Display panel.
When engine is not running, press and release to display SET MAX. When SET
MAX is displayed, press and hold to increment maximum pressure setting. From
120 to 175.
To set minimum pressure, when display
reads SET MAX, press and release to display SET MIN. When SET MIN is displayed, press and hold to increment minimum pressure setting from 90 to 150.
Compressor minimum pressure automatically remains 20 PSI or more lower than
the maximum pressure setting.
10-4. 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.
Models Without Hydraulic Power Source: The safety interlock system requires 12 volts DC be supplied from the accessory position of the truck
ignition switch to pin 5 of RC13. Splice into supplied plug and wire.
Test safety interlock monthly, see Section 11-6.
OM-261050 Page 44
Complete Parts List available at www.MillerWelds.com
10-5. Operation And Error Messages
1
282711-A
Hi TEMP
SENSHORT
The following operational messages
may appear:
Indicates high compressor temperature if
CHECK COMPRESSOR LED is on.
Indicates coolant sensor is shorted.
CHNG OIL
OVErPRES
Indicates an oil change is needed. This light
flashes after the first 50 hours of operation
and then at normal oil change intervals
thereafter.
Indicates the compressor has an over pressure error.
Indicates an open condition in the alternator.
HiVOLTiN
If CHECK ENGINE LED is on, engine oil
change time interval has counted down to
zero, indicating it is time to change engine
oil.
Indicates an engine over speed error.
1
Alpha-Numeric Display
To reset display after oil change, see Section 11-4.
If CHECK 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 11-5.
HIGH SPd
Indicates engine is locked in high speed.
With engine running, press Power/Start
button to toggle speed.
AUTOSTOP
This will flash briefly when unit is in Auto On
mode and the engine stops automatically.
The following error messages may appear:
If
error message appears, consult
troubleshooting section for remedial
actions.
OVErSPEEd
LOW OIL
Indicates a low oil pressure condition in the
engine.
NoCHARGE
Indicates an alternator problem.
HiTEMP 1
Indicates high engine temperature if
CHECK ENGINE LED is on. The temperature switch has indicated high temperature.
HiTEMP 2
Indicates high engine temperature if
CHECK 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.
ALTRNATR
Indicates high input voltage from the battery.
LoVOLTiN
Indicates low input voltage from the battery.
ERROR
Indicates an engine error, and the error is
stored in memory. If the display is off, press
the Power push button once to activate the
Remote Panel. The display will read ERROR and after a few seconds will flash an
error code. See Table 10-1.
To erase the error, press and hold the Display Select push button until the display
reads SYSTEMon, and the indicator is off.
The display will now cycle normally when
the Display Select push button is pushed.
ERROR1
Indicates problem with crane remote interconnecting cable, plug, receptacle, or adapter harness.
ENVRT hot
Indicates the EnVerter power system is
overheated.
ENVRT ok
Indicates the EnVerter power system is
functioning. Press Power/Start button to
enable.
OM-261050 Page 45
Complete Parts List available at www.MillerWelds.com
10-6. Auto Start/Stop Operation
2
1
282711-A
1 Power Engine Start Push Button
Press the Power Engine Start push button
to turn on the EnPak Remote Panel. The
EnPak warning beeper will beep if the EnPak is in auto start/stop mode.
First Start Of The Day
To start the EnPak using the Remote panel,
the first start of the day requires 2 successive push and release operations of the
Power Engine Start push button. To start
the EnPak using the Crane pendant, the
first start of the day requires a press and
hold of the Power Engine Start push button,
or 2 successive push and release operations of the switch. Once the warning beeper is on, the engine will continue to automatically start unless the process is stopped by
pushing the Engine Off button on the Remote Panel or the Engine Stop switch on
the crane pendant.
Any time that the engine is started when the
ambient temperature is below 50°F (10°C)
and the coolant temperature is below 100°F
(38°C), the engine will go to 2600 RPM and
continue to run at that speed until it reaches
an operating temperature of 100°F (38°C).
Once it has reached that temperature, the
auto start/stop feature is activated if it is enabled. The EnPak will then automatically
shut down after the specified time the end
user sets for an unloaded condition.
Auto Stop Timeout
To set the time for the automatic shut down,
press and release the Auto Start/Stop button until the display shows ENAbLEd.
When the display reads ENAbLEd, press
and hold the Auto Start/Stop button, and the
OM-261050 Page 46
time to shut down will display. Continue to
hold the button and it will increase in steps
of 1 minute up to a maximum of 30, and then
start over at 2 again. Release the button
when the desired time is reached.
Automatic Re-Start Of EnPak
The system cannot detect a generator
load that is applied when the engine is
off.
a) When the engine is turned off automatically, the EnPak control boards are still
functioning. This allows the EnPak to sense
any loads that are applied, so it will restart
the engine when needed. The EnPak will
not shut down if there is a load applied to the
EnPak.
b) The EnPak can be started with one
press and release of the Power Engine
Start push button on the EnPak Remote
Panel, or with one press and release of the
Engine Start switch on the Crane pendant.
c) If the compressor is turned on from the
Crane pendant, the EnPak will automatically start and pump up the air tank.
d) If an air tool is used, and the air compressor is in the on condition, the EnPak will
sense the load and start the engine to pump
up the tank.
e) If a crane switch is toggled, and the proportional trigger pulled, the EnPak will
sense that the crane is required, and automatically start the engine. This will work
only for open center systems that have the
proportional signal available from the
crane. Alternately, the start switch could be
pushed and released one time to start the
engine.
Battery Overload
When there is a load applied to battery and
the EnPak shuts down automatically, the
EnPak will restart when the battery voltage
reaches a level that indicates charging is
required. If there is a heavy battery load applied that drags the battery voltage low, the
beeper will beep a warning and the display
will flash bATTERY OVERLOAD.
2 Auto Start/Stop Push Button
Auto Start/Stop Enable/Disable
To toggle between Auto Start/Stop ENAbLEd and Auto Start/Stop dISAbLEd,
press and release the Auto Start/Stop push
button. The Auto On LED lights only when
the Auto Start/Stop feature is enabled.
Auto Stop
If the ambient temperature inside the EnPak is below 0°F (–18°C) the engine will not
automatically shut down.
Engine Stop
If the EnPak engine is turned off using the
Remote Panel Engine Off push button or
the Crane pendant Engine Stop switch, the
EnPak will not turn back on automatically.
EnVerter Load Less Than 300 W
If there is a load applied to the EnVerter
power source, that is less than 300 Watts,
the EnPak will not sense it at this time, and
will automatically shut down.
Error Reporting / Error Clearing
See Section 10-3 and 10-5.
Complete Parts List available at www.MillerWelds.com
10-7. Service Panel
10
11
12
9
8
7
6
5
4
3
1
2
260 718
1
Manual/Remote Switch
!
When working on unit, always
move Manual/Remote switch to
Manual position to prevent remote
or automatic starting.
This unit can be started from a remote location or start automatically 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
Engine Crank / Glow Plug Switch
See Section 6-5 for appropriate glow plug
timing. Push down to activate glow plugs.
To crank engine, push up. 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
Indicates the compressor pressure is too
high.
8
Engine Error LED
Indicates an engine error. See Table 10-1
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 ECU has power and
the fuel pump is active.
OM-261050 Page 47
Complete Parts List available at www.MillerWelds.com
10-8. Kubota D902 Engine Fault Code Guide
If a blink code is present, the engine
does not start or starts and then shuts
down in 10 seconds.
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.
To erase the error message, press
and hold the Display Select push button on the Remote Panel until the display reads SYSTEMon and the Engine Error LED is off.
Multiple error codes will display one after
the other.
The blink pattern repeats as long as the
Engine Control switch is in Run.
Contact
engine Factory Authorized
Service Agent if further assistance is
required to clear fault.
Table 10-1. Engine Error LED Blinking Pattern
Blinking Pattern
Symptom
Error Message
Remedy
Engine over speed
OVErSPEEd
Check actuator.
Low oil pressure
LOW OIL
— = one long blink - = one short blink
——--
Check engine oil level.
Check engine oil pressure
using pressure gauge.
Check low
switch.
—--—---—-----————-——---——----——-----——------——--------
OM-261050 Page 48
oil
pressure
Low battery voltage
NoCHARGE
Check alternator terminal L.
High coolant temperature
HiTEMP 1
Check water temperature
sender.
High coolant temperature
HiTEMP2
Check water temperature
sender.
Abnormal engine speed
SPd SENS
Check engine speed sensor.
Engine does not run
properly
GovCNTRL
Check actuator for current
problem.
No coolant temperature
signal
SEN OPEN
Check water temperature
sender for open-circuit.
Coolant temperature signal
always on
SENSHORT
Check water temperature
sender for short-circuit.
Connection at alternator
terminal L open
ALTRNATR
Alternator disconnected at
terminal L.
Battery voltage too high
HiVOLTiN
Check alternator.
Battery voltage too low
LOWbATT
Check alternator.
Complete Parts List available at www.MillerWelds.com
SECTION 11 − MAINTENANCE
11-1. Maintenance Label
!
When working on unit, always move Manual Remote switch on Service Panel to Manual position to prevent remote starting.
OM-261050 Page 49
Complete Parts List available at www.MillerWelds.com
11-2. Routine Maintenance
Replace engine and air compressor oil and filters after the first 50 hours of operation.
Use information displayed on the Alpha-Numeric display to assist in scheduling maintenance (see Section 10-2).
Engine speed is regulated by an electronic governor. Engine speed adjustments may only be performed by the engine manufacturer’s Factory
Authorized Service Agent.
Test safety interlock monthly, see Section 11-6.
Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period.
!
Recycle fluids.
= Check = Change
* If unit is so equipped
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.
= Clean
Reference
Every
8
Hours
Sections
10-3, 6-4,
8-3, 11-1
Remote Panel display for
maintenance information
Truck Fuel Tank Level
Coolant Level
Engine Oil Level
Compressor Oil Level
Fluid Spills
After
First
50
Hours
Section
11-4, 11-5,
Engine
Manual
Engine Oil
Compressor Oil
Engine Oil Filter
Every
50
Hours
Compressor Oil Filter
Engine
Manual
Engine Fuel Pipes And
Clamps
Every
100
Hours
Section
11-3,
Engine
Manual
Air Cleaner Element
Air Cleaner Hose At
Engine Air Intake
Every
200
Hours
Engine Belt Tightness
Engine
Manual,
Section
11-4
Engine Oil
Every
400
Hours
Engine Oil Filter
Engine
Manual,
Section
11-4
or
Fuel Filters
NOTICE −
The items highlighted above are registered as emission related critical parts by KUBOTA and the U.S. EPA nonroad
emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according
to the above instructions.
OM-261050 Page 50
Complete Parts List available at www.MillerWelds.com
= Check = Change
* If unit is so equipped
= Clean
Reference
Every
500
Hours
or
Yearly
Section
11-5,
Engine
Manual
Compressor Oil
Compressor Oil Filter
Compressor Air Filter
Every
800
Hours
Engine Belt
Engine
Manual
Valve Clearance
Every
1000
Hours
or
Yearly
Section
11-5
Air/Oil Separator
Hydraulic Fluid*
Air Cleaner Element
Every
2000
Hours
or
2
Years
Section
11-5
Hydraulic Pump* And
Compressor Belts
NOTICE −
The items highlighted above are registered as emission related critical parts by KUBOTA and the U. S. EPA nonroad
emission regulation. As the engine owner, you are responsible for the performance of the required maintenance on the engine according
to the above instructions.
NOTICE − For extended service interval information, see engine manual.
Notes
OM-261050 Page 51
Complete Parts List available at www.MillerWelds.com
11-3. Servicing Air Cleaner
!
Stop engine.
NOTICE − 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.
4
1
2
NOTICE − If you decide to clean the primary element, 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.
3
Optional
1
2
5
6
7
3
4
8
Intake Manifold
Service Indicator (Optional,
Customer Supplied)
Service Indicator Window
Service Indicator Reset Button
Service air cleaner element if red band
appears in window. A green band means
air cleaner is okay. Press button to reset
indicator.
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.
Optional
9
5
Housing
6
Safety Element (Optional)
7
Primary Element
8
Cover
9
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.
Keep nozzle
2 in (51 mm)
from element.
!
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.
Blow
Inspect
Reinstall primary element and cover
(dust ejector down).
aircleaner1 5/16− ST-153 929-B / ST-153 585 / Ref. S-0698-B
OM-261050 Page 52
Complete Parts List available at www.MillerWelds.com
11-4. Changing Engine Oil, Oil Filter, And Fuel Filters
!
Stop engine and let cool.
1
Oil Drain Valve
Oil drain valve can exit either side of
base.
Tools Needed:
2
Oil Filter
Change engine oil and filter according to engine manual.
!
Close valve and valve cap
before adding oil and running engine.
Fill crankcase with new oil to full
mark on dipstick (see Section 6-4).
3
Fuel Pump With Filter
To clean fuel pump filter, the assembly must be removed from the unit
base. Remove the screws on either
side of the fuel pump and maneuver
assembly out of the base without
disturbing the fuel line connections.
Unscrew the bottom portion of fuel
pump from the top to expose the filter. Clean filter and replace.
4
4
Primary Fuel Filter
Inspect fuel lines and replace line if
cracked or worn. Wipe up any
spilled fuel.
1
Start engine, and check for fuel
leaks.
!
2
3
Stop engine, tighten connections as necessary, and wipe
up fuel.
To reset engine maintenance
hours: Use the Display Select push
button on Remote Panel and scroll
to the Engine Maintenance Hours.
When the display shows engine
maintenance hours, press and hold
the Display 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.
1
265 802-A / S-0842
OM-261050 Page 53
Complete Parts List available at www.MillerWelds.com
11-5. Changing Compressor Oil, Air Cleaner, And Air/Oil Separator
!
Stop engine.
!
Do not open oil fill cap until unit has been
off for 10 minutes and pressure in the
case has been released according to
Section 8-5. Do not open while running.
!
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
Compressor Air Cleaner Cover
2
Air Cleaner Element
Tools Needed:
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.
4
Air Compressor Oil Filter
5
Air Compressor Oil Drain Knob
6
Customer Supplied Oil Drain Hose
7
Oil Fill Pipe Cap
To change compressor oil and filter:
Drain compressor oil while compressor is still
warm.
Attach oil drain hose to fitting by oil drain knob.
Open oil drain knob and drain oil into a suitable
container. Tighten knob to close oil drain. Remove oil drain hose.
2
3
1
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.
Add recommended oil until oil level is half way up
oil fill pipe (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.
7
5
6
4
To reset compressor maintenance hours: Use
the Display Select push button on Remote
Panel and scroll to the Compressor Maintenance Hours. When the display shows compressor maintenance hours, press and hold the
Display 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.
265 802-A / 265 804-A
OM-261050 Page 54
Complete Parts List available at www.MillerWelds.com
11-6. 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.
Notes
OM-261050 Page 55
Complete Parts List available at www.MillerWelds.com
SECTION 12 − TROUBLESHOOTING
12-1. Generator Power Troubleshooting
Trouble
No power output.
Remedy
Reset supplementary protectors CB1, CB2 and/or CB3 (if installed) (see Section 9-2).
Have Factory Authorized Service Agent check generator.
No power output from EnVerter.
Have Factory Authorized Service Agent check EnVerter module and replace if necessary.
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 is not proper type for application. Replace with Miller approved GFCI device (Contact Factory).
Device using 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 10-2 item 7 for EnPak remote panel).
12-2. 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 11-6).
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 6-4). Low oil pressure shutdown stops engine if oil pressure is too low.
Use correct grade oil for operating temperature. (see Section 11-1).
Check for ERROR codes at the Remote Panel display.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S2.
Engine stopped during normal
operation.
Check fuel level (see Section 6-4).
Check oil level (see Section 6-4). Low oil pressure shutdown stops engine if oil pressure is too low.
Check for ERROR codes at the Remote Panel display.
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.
OM-261050 Page 56
Complete Parts List available at www.MillerWelds.com
Trouble
Engine does not return to idle speed.
Remedy
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.
Ambient temperature may be below 50°F, and engine temperature may be less than 100°F. Warm up
engine to 100°F.
Have Factory Authorized Service Agent check circuit board PC1 and current transformer CT1.
Engine speed does not remain constant.
GFCI receptacle is not proper type for application. Replace with Miller approved GFCI device
(Contact Factory).
Engine overheats.
Check error messages. Check oil and coolant levels.
Engine coolant temperature low.
Have Factory Authorized Service Agent check engine thermostat for proper operation. Replace if
necessary.
During operation in severe cold weather it may be necessary to restrict inlet cooling air by partially
blocking unit air inlet louvers. Do not restrict engine combustion air inlet or engine exhaust or exit
cooling air. Remove restriction when severe cold weather ends to prevent engine overheating.
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 severe cold weather, engine starts and goes to idle but
stalls after a few minutes.
Normal maximum glow plug time is 3 to 10 seconds for temperatures from 50°F down to 0°F. In ambient temperatures below 0°F, glow plug time is 13 seconds maximum. Check glow plug timing to ensure proper heating before cranking engine.
12-3. 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-IC1.
Have Factory Authorized Service Agent check air compressor control circuit and clutch.
Air compressor stops during normal use. Automatic shutdown stops compressor if compressor temperature is too high or over−pressure condition
occurs.
Check compressor oil level (see Section 8-3). 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 the EnPak Remote Panel.
Check air compressor air cleaner (see Section 11-5).
Have Factory Authorized Service Agent check compressor for rated output.
High air pressure.
Adjust compressor air pressure using the EnPak Remote Panel.
Be sure control line is connected at valve manifold and Intake Control Valve (P−IC1).
Check for frozen manifold, Intake Control Valve (P−IC1), and/or Proportional Flow Control Valve
(P−FC1).
Oil in air from compressor.
Check compressor oil level (see Section 8-3). If oil level is too high, system becomes saturated with oil.
Change compressor air/oil separator if close to replacement hours (see Section 11-5).
OM-261050 Page 57
Complete Parts List available at www.MillerWelds.com
Trouble
Oil in compressor air cleaner.
Remedy
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.
Change oil and filter. Use only recommended oil.
Have Factory Authorized Service Agent check thermostat operation.
12-4. Hydraulic Troubleshooting (Models With Hydraulic Power Source)
Trouble
No crane operation.
Remedy
No oil in system. Add oil.
Suction line valve closed. Open valve.
Hydraulic system not primed. Prime system (see Section 7-3). Check reservoir height meets
requirements (see Section 7-1).
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 contaminants causing higher pressure drop across
the valve. Replace valve and flush system.
Have Factory Authorized Service Agent check hydraulic flow rate setting and correct as necessary.
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 owner’s manual.
Hydraulic oil viscosity too high. See Section 7-1 for correct fluid viscosity recommendations at
specific ambient temperatures.
Slow crane operation; unit remains at
low speed with crane switch in high
speed position.
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 7-6.
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 flow may need to be reset (consult Factory
Authorized Service Agent).
Have Factory Authorized Service Agent check hydraulic flow rate setting and correct as necessary.
Hydraulic oil viscosity too low. Consult Section 7-1 for correct fluid viscosity recommendations at
specific ambient temperatures.
OM-261050 Page 58
Complete Parts List available at www.MillerWelds.com
Trouble
No outrigger operation.
Remedy
No oil in system. Add oil.
Suction line valve closed. Open valve.
Hydraulic system not primed. Prime system (see Section 7-3). Check reservoir height meets
requirements of Section 7-1.
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.
Slow outrigger operation.
Flow control valve H−FC1 is partially plugged with contaminants 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 owner’s manual.
Hydraulic oil viscosity too high. Consult Section 7-1 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 7-1 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.
OM-261050 Page 59
SECTION 13 − DIAGRAMS
Figure 13-1. Training Circuit Diagram For EnPak
OM-261050 Page 60
261040-G
OM-261050 Page 61
257 926-F
Figure 13-2. EnPak Circuit Diagram
OM-261050 Page 62
261 045-B
Figure 13-3. Air Compressor Diagram
OM-261050 Page 63
Ref. 242 500-G
Figure 13-4. EnPak Truck Wiring Diagram Option 1
OM-261050 Page 64
NOTICE − If the high speed (3600 RPM) 120 V / 20 A circuit is placed in service on the truck, the following items apply:
CB3 supplementary breaker to be installed in auxiliary power enclosure, it
must match the amperage rating of the receptacle. CAUTION: If a GFCI receptacle is installed, it must be a MILLER-recommended GFCI receptacle.
The generator does not provide useable 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.
NOTICE − 240 V circuit and EnVerter power are protected at the listed current by supplementary protectors located next to 1T inside EnPak. Any type
GFCI may be used for the EnVerter 120 V circuit. If a plug-in adapter is used
to split 120 VAC from the 240 VAC receptacle, it must follow the same guidelines as Notice above.
265 533-B
Figure 13-5. EnPak Truck Wiring Diagram Option 2
OM-261050 Page 65
238 945-B1
Figure 13-6. Hydraulic Circuit Diagram Page 1
(Models With Hydraulic Power Source)
OM-261050 Page 66
238 945-B2
Figure 13-7. Hydraulic Circuit Diagram Page 2: Typical Open−Center Configuration
(Models With Hydraulic Power Source)
OM-261050 Page 67
238 945-B3
Figure 13-8. Hydraulic Circuit Diagram Page 3: Typical Closed−Center With
Load Sense Configuration (Models With Hydraulic Power Source)
OM-261050 Page 68
SECTION 14 − GENERATOR POWER GUIDELINES
The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown.
14-1. Selecting Equipment
1
2
1
3
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_enpak 2018−06 − ST-800 577
14-2. Grounding Generator To Truck Or Trailer Frame
1
2
GND/PE
3
800 652-D
!
!
1
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.
Equipment Grounding Terminal (On
Front Panel)
2
3
Grounding Cable (Not Supplied)
Metal Vehicle Frame
welder/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.
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.
!
Bed liners, shipping skids, and
some running gear insulate the
!
Use GFCI protection when operating auxiliary equipment. Do not use
GFCI receptacles to power life support equipment.
OM-261050 Page 69
14-3. Grounding When Supplying Building Systems
1
2
1
Equipment Grounding
Terminal
Grounding Cable
Use #8 AWG or larger insulated
copper wire.
2
GND/PE
3
Ground Device
Use ground device as stated in
electrical codes.
2
3
!
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.
ST-800 576-B
14-4. 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
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 14-8).
VOLTS 115
AMPS 4.5
Hz
50/60
3
Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
Amperes x Volts = Watts
Example 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts.
3
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-261050 Page 70
14-5. 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
10,550
15,900
23,300
8100
23,300
35,000
46,700
1000
1400
1850
2400
3500
300
500
600
700
875
720
975
1400
1600
2200
2850
3900
6800
2000
6000
8000
10,700
400
550
650
800
1100
14-6. 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)
Farm Duty Motors 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
Refrigerator or Freezer
Shallow Well Pump
Sump Pump
Rating
Starting Watts
Running Watts
2 HP
1/3 HP
1000
1650
3400
4400
2900
10,500
1720
1000
650
1000
1400
1100
2800
720
1/2 HP
2575
975
3/4 HP
4500
1400
1/4 HP
1/2 HP
3/4 HP
1 HP
6100
1600
1-1/2 HP
2 HP
3 HP
5 HP
1-1/2 HP
8200
10,550
15,900
23,300
8100
2200
2850
3900
6800
2000
6000
5 HP
23,300
7-1/2 HP
35,000
8000
10 HP
46,700
10,700
1/2 HP
500 PSI
550 PSI
700 PSI
3300
3150
4500
6100
3100
2150
3100
2100
3200
1000
950
1400
1600
800
750
1000
800
1050
1/3 HP
1/2 HP
1/3 HP
1/2 HP
OM-261050 Page 71
14-7. Approximate Power Requirements For Contractor Equipment
Contractor Equipment
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-261050 Page 72
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
10,500
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
14-8. 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
1
2
3
4
Motor Start Code
Running Amperage
Motor HP
Motor Voltage
To find starting amperage:
4
1
3
AC MOTOR
VOLTS 230
AMPS 2.5
CODE M
Hz
60
HP
1/4
PHASE 1
2
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).
Welder/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
14-9. How Much Power Can Generator Supply?
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
1
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-261050 Page 73
14-10. Typical Connections To Supply Standby Power
1
2
Utility
Electrical
Service
4
3
Transfer Switch
Fused
Disconnect
Switch
(If Required)
Welding
Generator
Output
!
Have only qualified persons
perform these connections
according to all applicable
codes and safety practices.
!
Properly install, ground, and
operate this equipment according to its Owner’s Manual and national, state, and local codes.
!
Do not connect to any electrical distribution system
normally supplied by utility
power unless a proper transfer switch and grounding
procedure are employed.
Customer-supplied equipment
is required if generator will supply standby power during
emergencies or power outages.
5
1 Utility Electrical Service
Essential
Loads
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 Welder/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 14-4).
OM-261050 Page 74
14-11. Selecting Extension Cord (Use Shortest Cord Possible)
Cord Lengths for 120 Volt Loads
Use GFCI protection when operating auxiliary equipment. Do not use GFCI receptacles to power life support equipment.
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
Use GFCI protection when operating auxiliary equipment. Do not use GFCI receptacles to power life support equipment.
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-261050 Page 75
Notes
Notes
Notes
ENPAK ) EQUIPMENT
LIMITED WARRANTY
Effective January 1, 2019
(Equipment with a serial number preface of MK 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. LLC,
Appleton, Wisconsin, 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.MillerWelds.com/EnPak
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. Notifications
submitted as online warranty claims must provide detailed
descriptions of the fault and troubleshooting steps taken to
diagnose failed parts. Warranty claims that lack the required
information as defined in the Miller Service Operation Guide
(SOG) may be denied by Miller.
Miller shall honor warranty claims on warranted equipment
in the event of a defect within the warranty coverage
periods listed below. Warranty time periods start on the
delivery date of the equipment to the end−user purchaser,
or 12 months after the equipment is shipped to a North
American or international distributor, whichever occurs
first.
1.
3 Years — 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
* Accessories (Kits)
* Replacement Parts (No labor)
* Canvas Covers
This Limited Warranty shall not apply to:
1.
Consumable components, such as contactors, relays
or parts that fail due to normal wear and use.
2.
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).
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.
Defects caused by accident, unauthorized repair, or
improper testing.
3.
4.
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 2019-01
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.MillerWelds.com/EnPak
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. LLC
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
© 2019 Miller Electric Mfg. LLC
2019−01
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