Miller EnPak Mechanic OM-240 113H Owner'S Manual Download Page 3

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TABLE OF CONTENTS

SECTION 1

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SAFETY PRECAUTIONS

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READ BEFORE USING

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1-1. Symbol Usage

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1-2. Arc Welding Hazards

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1-3. Engine Hazards

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1-4. Hydraulic Hazards

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1-5. Compressed Air Hazards

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1-6. Additional Symbols For Installation, Operation, And Maintenance

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1-7. California Proposition 65 Warnings

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1-8. Principal Safety Standards

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1-9. EMF Information

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SECTION 2

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CONSIGNES DE SÉCURITÉ

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LIRE AVANT UTILISATION

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2-1. Signification des symboles

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2-2. Dangers relatifs au soudage à l’arc

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2-3. Dangers existant en relation avec le moteur

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2-4. Dangers liés à l’hydraulique

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2-5. Dangers liés à l’air comprimé

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2-6. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

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2-7. Proposition californienne 65 Avertissements

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2-8. Principales normes de sécurité

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2-9. Informations relatives aux CEM

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SECTION 3

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DEFINITIONS

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3-1. Symbol Definitions

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SECTION 4

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SPECIFICATIONS

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4-1. Auxiliary Power And Engine Specifications

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4-2. Air Compressor Specifications

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4-3. Hydraulic Specifications (Models With Hydraulic Power Source)

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4-4. Sound Level Table

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4-5. Dimensions, Weights, and Operating Angles

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4-6. Fuel Consumption Curves

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4-7. Auxiliary Power Curves

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4-8. Alternator Power Curve

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4-9. Air Compressor Curves

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4-10. Hydraulic Pressure Curves (Models With Hydraulic Power Source)

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SECTION 5

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PRESTART CHECKS

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5-1. Hydraulic System Prestart Checks (Models With Hydraulic Power Source)

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5-2. Engine Prestart Checks

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5-3. Compressor Prestart Checks

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SECTION 6

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OPERATION

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6-1. Remote Panel

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6-2. Safety Interlock (Models With Hydraulic Power Source)

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6-3. Operation And Error Messages

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6-4. Cold Weather Operation

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6-5. Service Panel

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SECTION 7

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COMPRESSOR OPERATION

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7-1. Air Compressor Controls

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7-2. Compressor Blow Down

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SECTION 8

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MAINTENANCE

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8-1. Maintenance Label

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8-2. Routine Maintenance

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8-3. Servicing Engine Air Cleaner

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8-4. Safety Interlock Monthly Check (Models With Hydraulic Power Source)

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8-5. Changing Engine Oil, Oil Filter, And Fuel Filters

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Summary of Contents for EnPak Mechanic OM-240 113H

Page 1: ...EnPakt Mechanic Series Description OM 240 113H 2010 04 Visit our website at www EnPak com File Mobile Utility Mobile Utility Unit With Air Compressor Hydraulic Pump And Auxiliary Power Capability...

Page 2: ...oducts 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 hel...

Page 3: ...1 Auxiliary Power And Engine Specifications 16 4 2 Air Compressor Specifications 16 4 3 Hydraulic Specifications Models With Hydraulic Power Source 16 4 4 Sound Level Table 16 4 5 Dimensions Weights...

Page 4: ...stem Integration 41 11 2 Hydraulic Hose Connections 43 11 3 Priming Hydraulic Pump 44 11 4 Load Sense Line Bleeding Closed Center Systems Only 45 SECTION 12 ENGINE PREPARATION 46 12 1 Connecting the B...

Page 5: ...is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2...

Page 6: ...o through small cracks and openings to adjacent areas D Watch for fire and keep a fire extinguisher nearby D Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden...

Page 7: ...can injure D Keep away from moving parts such as fans belts and rotors D Keep all doors panels covers and guards closed and securely in place D Stop engine before installing or connecting unit D Have...

Page 8: ...TS can injure D Keep away from moving parts such as fans belts and rotors D Keep all doors panels covers and guards closed and securely in place D Keep hands hair loose clothing and tools away from mo...

Page 9: ...TS can burn D Do not touch hot compressor or air system parts D Allow cooling period before working on equip ment D To handle hot parts use proper tools and or wear heavy insu lated welding gloves and...

Page 10: ...D Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interfer...

Page 11: ...General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendentof Documents P O Box 371954 Pittsburgh PA 152...

Page 12: ...e t l commande si l appareil en est quip D Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill...

Page 13: ...rmes de s curit D Porter des lunettes de s curit avec crans lat raux m me sous votre casque D Avoir recours des crans protecteurs ou des rideaux pour prot ger les autres contre les rayonnements les bl...

Page 14: ...cher le c ble n gatif en premier lieu Le rebrancher en dernier lieu D Les sources d tincelles flammes nues cigarettes et autres sources d inflammation doivent tre maintenues l cart des batteries Ces d...

Page 15: ...nominal ou la capacit de la pompe hydraulique ou de tout quipement du circuit hydraulique Concevoir le circuit hydraulique de telle sorte que la d faillance d un composant hydraulique ne risque pas d...

Page 16: ...er un accident mat riel ou corporel D Avant d intervenir sur le circuit d air comprim couper l alimentation lectrique verrouiller et tiqueter l appareil d tendre la pression et s assurer que le circui...

Page 17: ...er l appareil proximit de pro duits inflammables D Ne pas surcharger l installation lectrique s assurer que l ali mentationest correctement dimensionn e et prot g e avant de mettre l appareil en servi...

Page 18: ...ec tronique sensible tel que les ordinateurs et l quipementcommand par ordinateur tel que les robots D Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement D Pour...

Page 19: ...926 Subpart J from U S Government Printing Office Super intendentof 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...

Page 20: ...ntinuous Kubota D1105 E3B 3 Cylinder 27 7 HP Liquid Cooled Diesel Engine w Electronic Governor 4 2 Air Compressor Specifications Compressor Type Air Output At Effective Working Pressure Pressure Safet...

Page 21: ...5 Do not exceed tilt angles or engine could be damaged or unit could tip Do not move or operate unit where it could tip Do not operate suspended from lifting eye Weight 955 lb 433 kg Fully Equipped 76...

Page 22: ...ILIARY POWER IN KILOWATTS 0 0 1 0 2 0 3 0 4 0 5 0 6 0 U S GAL HR 1 80 1 60 1 40 1 20 1 00 0 80 0 60 0 40 0 20 0 00 Optional EnVertert Auxiliary Power Auxiliary Power Compressor U S GAL HR 1 80 1 60 1...

Page 23: ...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 generat or should work normall...

Page 24: ...ssor Curves CFM VS ENGINE RPM CFM VS PSI ENGINE SPEED RPM PRESSURE PSI CUBIC FEET PER MINUTE CFM CUBIC FEET PER MINUTE CFM 24 32 39 43 43 42 41 40 1800 2600 3200 3600 0 5 10 15 20 25 30 35 40 45 50 10...

Page 25: ...r 400 PSID 27 6 bar Open Center 200 PSID 13 8 bar 0 500 1000 1500 2000 2500 3000 3500 0 0 2 0 4 0 6 0 8 0 10 0 12 0 14 0 16 0 18 0 20 0 PRESSURE PSI FLOW GPM 0 500 1000 1500 2000 2500 3000 3500 PRESSU...

Page 26: ...system to monitor oil level Open top cover and service side door 1 Oil Dipstick 2 Oil Fill 3 Coolant Overflow Bottle 4 Radiator Cap Fuel Be sure fuel connections are made and tight Be sure fuel tank u...

Page 27: ...rfill 1 Air Compressor Oil Fill Cap Hand tighten oil fill cap Using excess force can damage o ring 2 Air Compressor Oil Sight Hole The unit is shipped with oil in the com pressor reservoir Minimum oil...

Page 28: ...en gine is locked in high speed 8 Engine Off Push Button Press when engine is running to stop en gine 9 Compressor On Off Push Button When engine is running press twice to turn compressor on or off Wh...

Page 29: ...cates the compressor has an over pres sure error OVErSPEEd Indicates an engine over speed error LOW OIL Indicates a low oil pressure condition in the engine NoCHARGE Indicates an alternator problem Hi...

Page 30: ...on the service pan el 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...

Page 31: ...ry voltage NoCHARGE Check alternator terminal L 1 Long 4 Short High coolant temperature HiTEMP 1 Check coolant temperature switch 1 Long 6 Short High coolant temperature HiTEMP2 Check coolant temperat...

Page 32: ...pressure is reduced below 175 psi the compressor controls reset and resume nor mal operation If pressure reaches 200 psi the com pressor clutch will disengage and shut down Once the compressor pressur...

Page 33: ...OM 240 113 Page 29 SECTION 8 MAINTENANCE 8 1 Maintenance Label When working on unit always move Manual Remote switch on Service Panel to Manual position to prevent remote starting...

Page 34: ...important start up service and storage information Service equipment more often if used in severe conditions Recycle fluids n Check Z Change Clean If unit is so equipped Reference Every 8 Hours Sectio...

Page 35: ...f cover and housing Remove cover and dump out dust Remove element s Wipe dust from inside cover and housing with damp cloth Reinstall safety element if present Reinstall cover Do not clean housing wit...

Page 36: ...line if cracked or worn Install new filters Wipe up any spilled fuel Start engine and check for fuel leaks Stop engine tighten connec tions as necessary and wipe up fuel To reset engine maintenance h...

Page 37: ...8 6 Engine Sensors And Governor Locations 805 452 A 805 444 A 1 Coolant Temperature Sensor 2 Actuator Governor 3 Engine Speed Sensor 4 Coolant Temperature Shutdown Switch 5 Oil Pressure Sensor 6 Alte...

Page 38: ...filter Drain compressor oil while compressor is still warm Remove fill cap and plug from oil drain fit ting and drain oil into a suitable container Reinstall oil drain plug Remove filter by turning f...

Page 39: ...y Check battery voltage Check Manual Remote switch on Service Panel Check to ensure crane power switch and safety interlock are working see Section 8 4 Have Factory Authorized Service Agent check Remo...

Page 40: ...zed Service Agent check air compressor control circuit and clutch Air compressor stops after short period of operation Automatic shutdown stops compressor if compressor temperature is too high or over...

Page 41: ...ic oil viscosity too high See Section 11 1 for correct fluid viscosity recommendations at spe cific ambient temperatures Slow crane operation unit remains at low speed Open Center systems No trigger s...

Page 42: ...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 Hy...

Page 43: ...nd comply with all DOT and other applicablecodes NOTICE Do not install unit where air flow is restricted or engine may overheat See Section 10 3 for mounting information See Section 4 5 for dimensions...

Page 44: ...t on flat surface or use cross supports to support base Secure unit with mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 3 8 16 x 1 in Screws Supplied To Bolt Unit In Place Remove h...

Page 45: ...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 fro...

Page 46: ...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...

Page 47: ...ammable 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...

Page 48: ...kwise 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...

Page 49: ...ar the pump This is accomplished us ing 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 suit able container...

Page 50: ...m hot sharp or moving parts Connect negative cable last 1 Battery Cable Strain Relief 2 EnPak Engine Block 3 Starter Route cables from vehicle bat tery through strain relief Connect positive cable to...

Page 51: ...eep away from exhaust out let Do not point exhaust pipe to ward any compressed gas tank Point exhaust pipe in desired di rection but always away from di rection of travel 1 Exhaust Pipe 2 Clamp 3 Nut...

Page 52: ...leaks and wear 1 Fuel Pickup Connection 2 Fuel Return Connection Select hose rated to SAE 30R7 and certified to section 2754 a 1 C of the California Air Re sources Board 2006 Emission Regulations Fuel...

Page 53: ...inants 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...

Page 54: ...onnections 805 443 A 287 097 Stop engine and release air pressure before servicing compressor 1 Air Compressor Connection Connect and secure hose After hand tighteningconnections tight en 2 to 3 full...

Page 55: ...iver in front of the air oil separator filter The safety valve should be tested frequently at regu lar intervals to ensure it is in good working order The valve is type tested and leaded It is spring...

Page 56: ...238027 between re mote panel and RC12 2 Crane Remote Connection Receptacle RC13 NOTICE Connect to this recept acle only when EnPak is equipped with hydraulic power source used to power a hydraulic cra...

Page 57: ...n If a GFCI receptacle is in stalled it must be a Miller recommended GFCI recept acle see Parts List The generator does not provide usable power at engine idle speed 1800 rpm Other GFCI receptacles ca...

Page 58: ...onnected Supplementary protector CB2 pro tects the optional EnVerter power supply from overload when a 120 VAC load is connected Supplementary protector CB3 pro tects the generator winding from overlo...

Page 59: ...Notes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 in 14 Gauge 078 in 1 8 in 125 in 3 16 in 188 in 1 4 in 25 in 5 16 in 313 in 3 8 in 375 in 1 2 in 5 in MATERIAL THICKN...

Page 60: ...OM 240 113 Page 56 SECTION 16 DIAGRAMS Figure 16 1 EnPak Circuit Diagram...

Page 61: ...OM 240 113 Page 57 241 852 F...

Page 62: ...PSI P IC P O T O IL TH ERM O STAT COMPONENT IDENTIFIER LEGEND P PC PRO PORTIO N AL CO N TROL P HC HEATER CONTROL P HTC HEATERTHERM OSTAT CONTROL P PRV PROPORTIONAL RELIEF VALVE P USV UNLOAD SOLENOID...

Page 63: ...OM 240 113 Page 59 238 945 B1 Figure 16 3 Hydraulic Circuit Diagram Page 1 Models With Hydraulic Power Source...

Page 64: ...OM 240 113 Page 60 238 945 B2 Figure 16 4 Hydraulic Circuit Diagram Page 2 Typical Open Center Configuration Models With Hydraulic Power Source...

Page 65: ...OM 240 113 Page 61 Figure 16 5 Hydraulic Circuit Diagram Page 3 Typical Closed Center With Load Sense Configuration Models With Hydraulic Power Source 238 945 B3...

Page 66: ...OM 240 113 Page 62 242 500 C Figure 16 6 EnPak Truck Wiring Diagram...

Page 67: ...ock and static electricity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 EquipmentGrounding Terminal On Front Panel 2 Grounding Cab...

Page 68: ...ve load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when...

Page 69: ...Home 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...

Page 70: ...HP 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...

Page 71: ...must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Vol...

Page 72: ...k to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Insta...

Page 73: ...0 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 GF...

Page 74: ...n and not available unless listed Unit shown is fully equipped Some parts may not be applicable on units without hyrdraulic power source 55 56 58 59 60 61 53 54 1 2 3 4 5 6 7 8 9 10 11 12 13 57 62 63...

Page 75: ...OM 240 113 Page 71 242 707 A 37 38 39 40 41 42 35 36 15 16 17 18 19 20 21 22 23 24 25 26 27 28 30 33 34 29 43 44 45 46 47 32 31 48 50 51 52 49...

Page 76: ...ce Lid Pivot 1 27 239330 Foam Acoustical Top Cover Left 1 28 Label Circuit Diagram Order by Model and Serial No 1 29 239033 Cover Top 1 30 194320 Latch Lever Flush Trigger 4 31 189975 Hinge Door Acces...

Page 77: ...5 239325 Foam Acoustical Service Side Door 1 66 239324 Foam Acoustical Service Side Panel 1 67 239046 Baffle Service Door 1 68 239322 Foam Acoustical Service Door Baffle 2 69 239036 Door Side Service...

Page 78: ...113 Page 74 1 Hardware is common and not available unless listed 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 242 678 A 33 34 Figure 18 2 Controls Remote Assem...

Page 79: ...d X 1 125 Mtg Hole 4 21 173734 Link Jumper 2 22 1T 172661 Block Stud Connection 6 Position 1 23 CB2 083432 Supplementary Pro Man Reset 1p 10a 250vac Frict 1 24 CB3 093996 Supplementary Pro Man Reset 1...

Page 80: ...atic Proportional Control Ap 40 Includes 1 3 P USV 242848 Valve Solenoid Unload Pneumatic 12vdc 10w 2wno 1 4 P HC HTC242846 Heater Control Pneumatic 45w 120v W Thermostat N 1 5 P PRV 242847 Valve Reli...

Page 81: ...4 Hose Assy Oil Compressor 8 Thermostat To Filter 1 34 239555 Ftg Stl 90 Deg 1 2 bspp M S X Jic 8 M 1 35 239558 Ftg Stl Adapter 1 2 bspp M X Jic 8 M 1 36 P OT 239564 Thermostat Oil Air Compressor 71 D...

Page 82: ...Hyd Proportional 12vdc 2way Nc 1 7 239027 Ftg Stl Elbow 90 Sae 12 M S X Jic 12 M 1 8 239011 Hose Assy Hyd Pressure 12 1 9 239015 Ftg Stl Elbow 90 Sae 4 M S X Jic 4 M 2 10 239022 Ftg Stl Sae 16 M S X S...

Page 83: ...Assy Hyd Pressure 12 1 9 239106 Ftg Stl Plug Sae 4 M 1 10 239022 Ftg Stl Sae 16 M S X Sae 16 M 1 11 239306 Pulley Micro v 8 Rib 5 938 Pd 1 12 239308 Tensioner Belt W Pulley 8 Rib 1 13 239316 Belt Micr...

Page 84: ...hroud 1 2 187120 Cap Radiator Pressure 14lb 1 3 243021 Label Warning Moving Parts Can Cause Injury 2 4 243022 Label Warning Steam And Hot Coolant Can Burn 1 5 239819 Guard Fan 1 6 239313 Hose Radiator...

Page 85: ...4 Npt F 1 29 240445 Ftg Brs Barbed M 1 2 Tbg X 1 4 Npt M 1 30 239317 Ftg Brs Union 1 8 Npt 2 31 073432 Ftg Hose Brs Barbed M 3 16 Tbg X 1 8 Npt 1 32 053525 Ftg Hose Brs Barbed M 5 16 Tbg X 1 8 Npt 1 3...

Page 86: ...Rotor Generator 1 7 239009 Fan Rotor Gen 1 8 239019 Bearing Ball Rdl Sgl Row 1 000 X 2 047 X 591 1 241851 Key Stl 250 X 250 X 750 Form A 1 9 244932 Key Stl 187 X 250 X 687 1 10 238950 Stator Generato...

Page 87: ...Engine Kubota D1105 1 27 196484 Screw M 8 1 2 x 55 Hex Hd pln 8 8 Pln Full Thd 3 28 240463 Hose Sae 375 Id X 620 Od X 4 000 4 29 247255 Bracket Support Pump Mtg Flange 1 Use Loctite 271 MILLER Part No...

Page 88: ...1 5mm W P 3 11mm Od Tin Brass 2 237894 Seal Conn Metri pack Dark Red 2 PLG 8 237895 Conn Pack 3p 1row Plg Yazaki 1 PLG 7 237897 Conn Amp Econoseal 2p 1row Plug 1 PLG 6 237901 Conn Body 2 Pin Sealed Su...

Page 89: ...re intended for purchase and use by commercial industrial users and persons trained and experienced in the use and maintenance of industrial equipment In the event of a warranty claim covered by this...

Page 90: ...ur personal records Always provide Model Name and Serial Style Number Visit www EnPak com to locate an EnPak supplier Options and Accessories Service and Repair Replacement Parts Training Schools Vide...

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Miller EnPak Mechanic OM-240 113H, Owner'S Manual

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