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Miller Air Pak, Owner'S Manual, Page: 1 / 86

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Processes

Description

Air Carbon Arc (CAC-A)

Cutting and Gouging

Stick (SMAW) Welding

MIG (GMAW) Welding
Flux Cored (FCAW) Welding

Engine Driven Welding Generator

OM-478

120 240R

August 1999

TIG (GTAW) Welding

With Optional Equipment:

Battery Charging

Miller Air Pak

Summary of Contents for Air Pak

Page 1: ...es Description Air Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding MIG GMAW Welding Flux Cored FCAW Welding Engine Driven Welding Generator OM 478 120 240R August 1999 TIG GTAW Welding With Op...

Page 2: ...ner 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 works...

Page 3: ...Air Compressor Connections 20 SECTION 5 OPERATING THE WELDING GENERATOR 22 5 1 Front Panel Controls See Section 5 2 22 5 2 Description Of Standard Controls See Section 5 1 23 5 3 Example Of Remote Amp...

Page 4: ......

Page 5: ...replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth...

Page 6: ...aintaining Wear protective gloves and clothing when working on a hot engine Do not touch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipme...

Page 7: ...mmables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see ap...

Page 8: ...une Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet...

Page 9: ...rifier fr quemment le cordon d alimentation pour voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution Mettre l appa...

Page 10: ...lures graves Pr voir une p riode de refroidissement avant d effec tuer des travaux d entretien Porter des gants et des v tements de protection pour travailler sur un moteur chaud Ne pas toucher mains...

Page 11: ...enir distance les produits inflammables de l chappement LES TINCELLES L CHAPPEMENT peuvent provoquer un incendie Emp cher les tincelles d chappement du moteur de provoquer un incendie Utiliser uniquem...

Page 12: ...Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pa...

Page 13: ...k Injectors Pump Check Valve Clearance Fuel Engine Coolant Temperature Hourmeter HM Air Pressure Temperature Circulating Compressor Positive Negative Wire Feed Welding Arc A Amperes V Volts Panel Loca...

Page 14: ...ssor Specifications Effective Working Pressure Air Tank Capacity Tank Pressure Rating Safety Relief Valve Rating Air Control Governor Setting 40 SCFM 1 1 SCMM 90 psig 620 kPa 100 Duty Cycle 21 gal 79L...

Page 15: ...6 06 1 33 1 60 6 81 1 50 1 80 DC WELD AMPERES AT 100 DUTY CYCLE 28 CFM 90 PSI AIR DELIVERY DELIVERY W O AIR 1800 R P M NO LOAD IDLE 1150 R P M Continuous Welding 3 5 Duty Cycle And Overheating ST 188...

Page 16: ...50 60 70 80 90 100 110 120 130 0 10 20 30 40 50 60 70 80 90 100 110 P S I G S C F M 3 7 AC Auxiliary Power ST 109 365 C The ac power curve shows the aux iliary power in amperes available at the 120 a...

Page 17: ...8 220 The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown A For AC Mode B F...

Page 18: ...e phase 120 240 volt or three phase 240 volt terminals A 10 KVA KW Single Phase Auxiliary Power Plant No Weld Load B 15 KVA KW Three Phase Auxiliary Power Plant No Weld Load 0 180 AC AMPERES AC VOLTS...

Page 19: ...ST 188 221 The battery charging curves show the charging amperage and voltage output of the welding generator As battery voltage nears the charg ing voltage charging current de creases 0 0 DC AMPERES...

Page 20: ...tal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does not have GFCI re ceptacles use GFCI protected extension cord 2 OR 18 in 460 m...

Page 21: ...lect in exhaust pipe during run in see Section 10 1 Fuel Add fresh fuel before starting engine the first time see maintenance label for specifications Fill fuel tank up to 1 2 in 13 mm from top to all...

Page 22: ...Cable Sizes Total Cable Copper Length In Weld Circuit Not Exceeding Welding Amperes 100 ft 30 m Or Less 150 ft 45 m 200 ft 60 m 250 ft 70 m 300 ft 90 m 350 ft 105 m 400 ft 120 m Amperes 10 60 Duty Cyc...

Page 23: ...ting when cylinder is removed 1 2 3 4 6 5 4 7 Installing Ether Cylinder Optional Ether Starting Aid 4 8 Remote 14 Receptacle RC3 Information Socket Socket Information A 24 volts ac Protected by circui...

Page 24: ...control method Open lower front door 1 Terminal Strip 3T Connect leads to 3T using terminal information shown in Section 4 8 Reinstall cover Close door Tools Needed 1 4 10 Air Compressor Connections S...

Page 25: ...OM 478 Page 21 Notes...

Page 26: ...OM 478 Page 22 SECTION 5 OPERATING THE WELDING GENERATOR 5 1 Front Panel Controls See Section 5 2 20 19 18 ST 184 780 C Ref ST 121 578 F 23 12 1 2 4 5 6 7 8 9 10 11 14 15 21 22 13 3 16 17 24...

Page 27: ...nal strip 3T see Sections 4 8 and 4 9 12 Service Engine Air Cleaner Light Service engine air cleaner if light goes on see Section 8 3 13 Engine Control Switch Use switch to start engine select engine...

Page 28: ...Remote Amperage Control Ref ST 184 780 C Set Switches Adjust Remote Control Set Polarity Set Percentage Set Range Min 90 A DC CC Max 140 A DC CC 2 In Example Min 90 A DC CC Percentage of Range 50 Max...

Page 29: ...le and resume operation At least once a month run en gine at weld power speed and press Test button to verify GFCI is working properly 5 Total Auxiliary Power Output Maximum output from each duplex re...

Page 30: ...Service Agent 4 Total Auxiliary Power Output Combined output of RC1 and GFCI2 is limited to 3 kVA kW output of the generator EXAMPLE If 10 A is drawn from GFCI2 only 7 5 A is available at RC1 120 V x...

Page 31: ...per 42 may be dis connected from neutral to meet applicable electrical codes 9 User Supplied Leads 10 Load Terminals Connect leads to terminals 11 Fuses F1 F2 And F3 F1 F2 and F3 protect each load lin...

Page 32: ...es Read supplied BCI Battery Service Manual before charging or jump starting 1 Jump Start Battery Charge Plug 2 Red Cable 3 Black Cable Obtain cable with proper connectors 4 Remote Momentary On Switch...

Page 33: ...elector Switch Use switch to select battery jump start or charging output 4 Battery Light If light comes on while charging or jump starting stop the engine and check the following a Polarity of connec...

Page 34: ...onnections Set Output Contactor Switch To On Or Turn On Remote Device If Battery Light Goes On Stop Engine And Check Battery Condition Set Output Selector Switch To Charge In Example Battery Voltage 1...

Page 35: ...itch only while cranking en gine of equipment being started Set Charge Jump Start Switch To Jump Start Do not switch Ampere Ranges while under load SECTION 8 MAINTENANCE TROUBLESHOOTING The air compre...

Page 36: ...d Tighten Weld Terminals 100 h Clean And Tighten Battery Connections Change Oil See Section 8 4 Change Oil Filter See Section 8 4 250 h 200 h 500 h Check And Clean Spark Arrestor See Section 8 9 Repla...

Page 37: ...nged bleeding of air may be required Check engine manual for proper procedure Diesel See Engine Manual for complete engine care Give Engine Specification and Serial Number when ordering parts daily Ba...

Page 38: ...ozzle at least 1 in 25 mm from inside of element Max air pressure 100 psi 690 kPa Do not remove plastic fins Replace ele ment if it has holes or damaged gaskets Reinstall element and cap cap arrows po...

Page 39: ...art engine and place Engine Control switch in Run Idle position 5 Throttle Lever Push lever forward until engine runs at idle speed While holding le ver in the idle position reconnect throttle rod to...

Page 40: ...n and cut out pressure values are 5 psi 34 kPa Check pressure using air pressure gauge on front panel If necessary adjust cut out pressure as follows 1 Governor 2 Rubber Boot 3 Jam Nut 4 Screw Remove...

Page 41: ...st 4 Throttle Solenoid Fuse F11 protects throttle solenoid from overload If F11 opens the en gine does not run at idle rpm Check F11 and replace if open Check movement of solenoid and adjustment of we...

Page 42: ...ht Tighten hex nuts Recheck tightness of belt Readjust if necessary Replace belt if damaged or cracked Replace belt as follows Loosen hex nuts pivot alternator counterclockwise and remove belt Install...

Page 43: ...k CC CV switch position If low weld output check fuse F6 and replace if necessary see Section 8 7 Low open circuit voltage Check engine speed and adjust if necessary see Section 8 5 Check CC CV switch...

Page 44: ...Electrode Negative or AC position Check and replace fuse F1 F2 and or F3 if necessary see Section 6 4 Check engine speed and adjust if necessary see Section 8 5 Have Factory Authorized Service Agent c...

Page 45: ...position Check and tighten battery connections if necessary Battery being charged is bad Properly dispose of battery No battery charge output Battery light is Off Place Output Selector switch in Jump...

Page 46: ...OM 478 Page 42 SECTION 9 ELECTRICAL DIAGRAMS Figure 9 1 Circuit Diagram For Welding Generator...

Page 47: ...OM 478 Page 43 SD 194 053...

Page 48: ...OM 478 Page 44 Figure 9 2 Circuit Diagram For Welding Generator With Optional Battery Charger...

Page 49: ...OM 478 Page 45 SD 194 061...

Page 50: ...OM 478 Page 46 Figure 9 3 Circuit Diagram For Welding Generator With Optional 5 kVA kW Auxiliary Power Plant...

Page 51: ...OM 478 Page 47 SD 194 062...

Page 52: ...ger than necessary Piston rings seat faster if engine runs at weld power rpm and the welding generatoris kept loaded during run in 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exh...

Page 53: ...oad bank to generator weld output terminals using proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adju...

Page 54: ...correct connec tors polarity is not important 4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid swit...

Page 55: ...75 8 6 19 4 34 5 30 0 156 0 632 1 40 2 52 5 6 10 0 22 5 40 0 35 0 173 0 71 1 56 2 80 6 2 11 2 25 0 44 7 40 0 19 0 77 1 71 3 07 6 8 12 3 27 3 49 1 45 0 208 0 843 1 9 3 36 7 6 13 4 30 3 53 8 50 0 225 9...

Page 56: ...AMMERS Horizontal Grinder 2 3 0 5 0 7 0 20 Scaling Hammer 1 3 3 0 4 2 12 Horizontal Grinder 4 9 0 15 0 21 0 60 Chipping Hammer 4 5 7 5 10 5 30 Horizontal Grinder 6 9 0 15 0 21 0 60 Riveting Hammer Lig...

Page 57: ...le Insulated Equipment OR 2 Be sure equipment has this symbol and or wording 3 1 12 2 Grounding Generator To Truck Or Trailer Frame S 0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding...

Page 58: ...istive Load Equipmentwith a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 12 8 3 Rating Data Rating shows volt...

Page 59: ...ome Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Mi...

Page 60: ...P 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3...

Page 61: ...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 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of...

Page 62: ...Connections Connect terminals or plug of ade quate amperage capacity to cord Follow all applicable codes and safety practices Turn off or unplug all equipment connected to generator before starting o...

Page 63: ...15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI...

Page 64: ...0 210 100 180 5 32 360 450 40 55 200 275 160 240 3 16 450 720 55 80 250 350 190 300 1 4 720 950 80 125 325 450 250 400 2 Thorium Alloyed Tungsten Red Band 010 Up to 25 Up to 20 Up to 15 020 15 40 15 3...

Page 65: ...1 1 1 2 Times 2 Electrode Diameter 13 3 Preparing Tungsten For DC Electrode Negative DCEN Welding Ref S 0161 Ref S 0162 1 Tungsten Electrode 2 Tapered End Grind end of tungsten on fine grit hard abra...

Page 66: ...ect and prepare tungsten according to Sections 13 1 and 13 2 or 13 3 Tungsten extension is the distance the tungsten extends out gas cup of torch Arc length is the distance from the tungsten to the wo...

Page 67: ...OM 478 Page 63 14 3 Positioning Torch Tungsten For Various Weld Joints ST 162 003 S 0792 70 70 90 20 20 10 20 70 40 30 20 70 90 20 Butt Weld And Stringer Bead T Joint Lap Joint Corner Joint...

Page 68: ...23 22 20 14 19 29 30 31 32 21 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 31 32 21 50 51 52 53 54 31 32 55 56 57 58 60 59 31 32 55 56 61 31 62 63 64 25 65 66 68 67 69 70 71 Fig15 5 72 73 74 75 76...

Page 69: ...17 088 683 VALVE relief 1 4NPT 1 18 106 394 FITTING brs flrd conn M hd 1 4tbg x 1 4NPT 2 19 134 959 VALVE 1 20 010 678 FITTING pipe brs elbow st 1 4NPT LH 1 21 145 282 FITTING hose brs barbed elbow 5...

Page 70: ...ain consisting of 1 121 430 THYRISTOR SCR 865A 300V 1 117 572 CLAMP thyristor 1 028 516 PIN spring 125 x 250 2 68 118 754 STAND OFF insul 312 16 x 2 000 lg 2 118 755 HEAT SINK 2 69 116 981 BRACKET rec...

Page 71: ...actory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor Description Part No D...

Page 72: ...9 11 12 13 14 15 10 Includes Item 16 16 17 18 19 20 21 22 62 24 25 26 27 28 29 30 31 8 9 32 33 34 9 31 30 29 35 36 37 38 39 40 42 Includes Item 41 43 44 45 46 47 48 47 49 50 51 52 53 54 Fig 15 6 55 41...

Page 73: ...l cush 875dia x 343mtg hole 2 172 071 CLAMP hose 520 605clp dia 1 45 119 956 BALL JOINT 2 46 191 718 ROD throttle 1 47 046 432 HOLDER fuse mintr 1 48 F11 085 874 FUSE mintr gl slo blo 10A 1 49 117 225...

Page 74: ...13 14 15 16 17 18 12 11 10 9 8 7 5 4 1 3 2 1 8 19 20 21 24 25 26 27 28 29 30 31 31 31 26 16 15 14 22 23 6 ST 121 288 D 23 24 Hardware is common and not available unless listed Figure 15 3 Panel Front...

Page 75: ...ine 44 000 in c 1 8NPT x 10mm 1 20 129 837 GAUGE SWITCH temp oil mech 250deg 1 21 118 069 GAUGE air pressure mech 0 150PSI 1 22 HM 118 058 METER hour 8 24VDC 1 23 010 647 PIN spring CS 156 x 1 250 2 2...

Page 76: ...5V 2 073 690 PLUG str grd armd 2P3W 15A 125V P S 5266DF 8 CB1 2 139 266 CIRCUIT BREAKER man reset 1P 15A 250VAC 2 9 CB3 4 083 432 CIRCUIT BREAKER man reset 1P 10A 250V 2 10 RC3 143 976 CONNECTOR w SOC...

Page 77: ...No 36VDC w black cap 1 010 291 WASHER flat 625 ID x 1 250 OD x 125thk nylafil 1 603 588 WASHER fbr 468 ID x 1 000 OD x 031thk 1 008 014 HANDLE grip 1 600 340 CABLE port No 16 2 c order by ft 30ft 141...

Page 78: ...OM 478 Page 74 ST 140 459 A 1 2 3 5 6 4 7 8 9 10 11 12 13 14 15 9 17 18 16 Hardware is common and not available unless listed Figure 15 5 Control Box...

Page 79: ...T CARD voltage regulator 1 PLG2 115 092 CONNECTOR SOCKETS 1 12 PC3 166 685 CIRCUIT CARD battery charger 1 PLG4 148 439 CONNECTOR SOCKETS 1 PLG3 158 720 CONNECTOR SOCKETS 2 13 IM 189 742 MODULE pull to...

Page 80: ...Page 76 Ref ST 143 803 B 10 9 8 7 6 5 4 3 2 1 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 37 36 35 34 33 32 31 30 29 28 Hardware is common and not available unless listed Figure 15 6 Compresso...

Page 81: ...1 18 066 128 SPRING WASHER 2 19 066 127 VALVE PLATE 1 20 066 126 VALVE SEAT 1 066 123 NOTCHED PIN 1 21 066 125 VALVE PLATE 1 22 066 124 SPRING PLATE 1 23 066 122 SPACER RING 1 24 066 121 VALVE SCREW...

Page 82: ...STATOR excitor 1 13 123 687 STATOR excitor 1 14 173 068 ENDBELL generator consisting of 1 15 143 220 O RING 2 859 ID x 139CS 1 16 004 203 STRIP nyl 050 x 4 000 x 9 000 1 ST 134 503 D 1 3 4 5 2 6 8 7 1...

Page 83: ...Notes...

Page 84: ...Notes...

Page 85: ...hes Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Miller s True Blue Limited Warranty shall not apply to 1 Items furnished by Miller but manufactured by others such as engine...

Page 86: ...ss City State Zip Please complete and retain with your personal records Always provide Model Name and Serial Style Number Contact your Distributor for To locate distributor nearest you call 1 800 4 A...

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