Miller ENPAK Owner'S Manual Download

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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. Engine Hazards

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1-3. Hydraulic Hazards

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1-4. Compressed Air Hazards

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1-5. Additional Symbols For Installation, Operation, And Maintenance

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1-6. California Proposition 65 Warnings

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1-7. Principal Safety Standards

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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 existant en relation avec le moteur

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2-3. Dangers liés à l’hydraulique

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2-4. Dangers liés à l’air comprimé

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2-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

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2-6. Proposition californienne 65 Avertissements

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2-7. Principales normes de sécurité

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SECTION 3

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DEFINITIONS

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3-1. Additional Safety Symbol Definitions

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SECTION 4

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SPECIFICATIONS

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4-1. Serial Number And Rating Label Location

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4-2. Auxiliary Power And Engine Specifications

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4-3. Air Compressor Specifications

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

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4-5. Cold Weather Specifications

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4-6. Fluid Specifications

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4-7. Dimensions, Weights, and Operating Angles

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4-8. Fuel Consumption

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4-9. Auxiliary Power Curves

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4-10. Alternator Power Curve

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4-11. Hydraulic Pressure Flow Curves (Models With Hydraulic Power Source)

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4-12. Hydraulic Pressure Flow Curves

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Combination Loads (Models With Hydraulic Power Source)

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4-13. Air Compressor Curves

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SECTION 5

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INSTALLATION

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5-1. Installing Unit

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5-2. Mounting Unit

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SECTION 6

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ENGINE PREPARATION

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6-1. Connecting the Battery

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6-2. Installing Exhaust Pipe

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6-3. Fuel Connections

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6-4. Engine Prestart Checks

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6-5. Cold Weather Starting And Operation

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SECTION 7

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HYDRAULIC SYSTEM (MODELS WITH HYDRAULIC POWER SOURCE)

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7-1. Hydraulic System Integration

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7-2. Hydraulic Hose Connections

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7-3. Priming Hydraulic Pump

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7-4. Hydraulic System Prestart Checks

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7-5. Hydraulic Pump Operation

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7-6. Load Sense Line Bleeding (Closed Center Systems Only)

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Summary of Contents for ENPAK

Page 1: ...EnPak Description OM 261050F 2016 06 Visit our website at www MillerWelds com EnPak File Mobile Utility Mobile Utility Unit With Air Compressor Hydraulic Pump And Auxiliary Power Capability...

Page 2: ...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 es...

Page 3: ...Specifications 13 4 3 Air Compressor Specifications 13 4 4 Hydraulic Specifications Models With Hydraulic Power Source 13 4 5 Cold Weather Specifications 13 4 6 Fluid Specifications 14 4 7 Dimensions...

Page 4: ...Section 10 2 44 10 4 Safety Interlock 44 10 5 Operation And Error Messages 45 10 6 Auto Start Stop Operation 46 10 7 Service Panel 47 10 8 Kubota D902 Engine Fault Code Guide 48 SECTION 11 MAINTENANCE...

Page 5: ...r s instructions when working on or near a battery BATTERY CHARGING OUTPUT can injure Battery charging feature not present on all models Have only qualified persons do battery charging work Charge lea...

Page 6: ...points created by equipmentconnected 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 MOVI...

Page 7: ...unit Do not direct air stream toward self or others Wear protective equipment such as safety glasses hearing pro tection leather gloves heavy shirt and trousers high shoes and a cap when working on co...

Page 8: ...nt 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 ma...

Page 9: ...rter 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 Su...

Page 10: ...ues l cart des batteries Ces derni res produisent des gaz explosifs en fonctionnementnormal et en cours de charge Respecter les consignes du fabricant de la batterie pour travailler sur une batterie o...

Page 11: ...raulique 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 de provoquer un accident mat riel ou co...

Page 12: ...d air ne peut tre mis sous pression par inadvertance Ne pas intervenir sur le circuit d air comprim lorsque l appareil fonctionne Seul un personnel qualifi est autoris et appliquant les consignes du f...

Page 13: ...r gime de ralenti en basse tension cela endommagerait le disjoncteur diff rentiel qui ne remplirait plus son r le de protection contre une lectrocution caus e par un d faut de masse Couper l alimenta...

Page 14: ...et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipulation Ce produit contient des produits chimiques notamment du plomb dont l tat de Californie recon...

Page 15: ...nty See engine Owner s Manual Safe89 2015 02 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 th...

Page 16: ...anual Engine Coolant Temperature Air Filter Engine Oil Fuel Battery Engine Glow Plug Engine Engine RPM Direct Current DC Alternating Current AC Protective Earth Ground Air Pressure Air Pressure Air Co...

Page 17: ...ulic 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...

Page 18: ...sity Index VI 160 VI 140 VI 140 VI 140 VI 120 VI 120 VI 120 VI 120 Compressor Oil Full Synthetic Mobil1 ATF Mobil1 ATF Mobil1 ATF Mobil1 ATF Mobil1 ATF Mobil1 ATF Mobil1 ATF Mobil1 ATF NOTICE For extr...

Page 19: ...5 15 15 15 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 4...

Page 20: ...261 042 0 10 20 30 40 50 60 70 Cubic Feet Per Minute CFM 0 00 0 20 0 40 0 60 0 80 1 00 1 20 1 40 1 60 U S GAL HR Compressor IDLE 0 00 0 20 0 40 0 60 0 80 1 00 1 20 1 40 U S GAL HR Synthetic Power Sta...

Page 21: ...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 normally This is for the standard generator power...

Page 22: ...tomatic Mode Manual Mode 0 2 4 6 8 10 12 14 16 18 20 0 500 1000 1500 2000 2500 3000 3500 Flow gpm Pressure psi Closed Center Hydraulic PressureFlow Curve Automatic Mode Manual Mode Curves are typical...

Page 23: ...13 8 bar 0 10 20 30 40 50 60 0 2 4 6 8 10 12 14 16 0 500 1000 1500 2000 2500 3000 3500 Air Flow 100psi scfm Hydraulic Flow gpm Hydraulic Pressure psi Pump Flow with Compressor Pump Flow with 6kW Air C...

Page 24: ...Standard Conditions Pressure 100 psi 689 kPa Temperature Operating Tem perature 0 0 10 0 20 0 30 0 40 0 50 0 60 0 70 0 50 75 100 125 150 175 200 Air Flow scfm Air Pressure psi Maximum Air Flow 120psi...

Page 25: ...Section 5 2 for mounting in formation See Section 4 7 for di mensions See Section6 through 9 for spe cific EnPak systems information 1 Hydraulic Reservoir 2 EnPak Typical hydraulic reservoir place me...

Page 26: ...mounting brack ets 3 1 2 in Bolt And Washer Minimum Not Supplied 4 5 16 18 x 3 4 in Screws Supplied To Bolt Unit In Place Using brackets attached to the base mount unit to vehicle with 1 2 in 12 mm or...

Page 27: ...Cable Strain Relief 2 Starter 3 Starter Cable Lug Supplied 4 Engine Block Route cables from vehicle bat tery through strain relief Crimp supplied starter cable lug onto positive cable Connect positiv...

Page 28: ...ep 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 E...

Page 29: ...eaks 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 30: ...ns are made and tight Be sure fuel tank utilized for unit operation is full Coolant Check coolant level in radiator and overflow bottle If coolant is below Low level in overflow bottle add coolant unt...

Page 31: ...to 13 sec Auto 13 sec Auto 10sec Auto 10sec 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...

Page 32: ...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...

Page 33: ...o 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 1...

Page 34: ...mable 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...

Page 35: ...crew 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 pa...

Page 36: ...ds 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 c...

Page 37: ...of air near 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...

Page 38: ...of the system by condens ing 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 reser...

Page 39: ...nnections 265 802 A 287 097 Stop engine and release air pressure before servicing compressor 1 Air Compressor Connection Connect and secure hose After hand tightening connections tight en 2 to 3 full...

Page 40: ...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 com pressor reservoir Oil level sight gauge shows...

Page 41: ...ee Section 10 3 At pressures that are 10 psi above maxi mum set point the compressor clutch will temporarily disengage to prevent further pressure build up and OVerPRES shows temporarily on the remote...

Page 42: ...not required In ambient temperatures below freezing compressor unload and blow down time is extended to build up heat in the compressor This helps increase oil temperature and remove moisture from the...

Page 43: ...propriate 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...

Page 44: ...h strain relief in right side of unit to auxiliary power box for connec tion NOTICE There are two options for installing 120 VAC power see truck wiring diagrams Figure 13 4 and Figure 13 5 2 Supplemen...

Page 45: ...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 EnP...

Page 46: ...harness see instructions provided with harness adapter kit Connect interconnecting cable Part No 244283 between crane remote and RC13 Contact Factory for list of harness adapters available Optional En...

Page 47: ...OM 261050 Page 43 10 2 Remote Panel Use With Section 10 3 248 998 1 2 6 3 4 5 7 8 9 10 11...

Page 48: ...lay reads EN AbLEd 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...

Page 49: ...ion in the engine NoCHARGE Indicates an alternator problem HiTEMP 1 Indicates high engine temperature if CHECK ENGINE LED is on The temperat ure switch has indicated high temperature HiTEMP 2 Indicate...

Page 50: ...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...

Page 51: ...ht loads are present 3 Fuel Pump Switch Use switch to power the engine ECU mod ule and turn fuel pump on 4 Engine Crank Glow Plug Switch See Section 6 5 for appropriate glow plug timing Push down to a...

Page 52: ...rized Service Agent if further assistance is required to clear fault Table 10 1 Engine Error LED Blinking Pattern Blinking Pattern Symptom Error Message Remedy one long blink one short blink Engine ov...

Page 53: ...OM 261050 Page 49 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...

Page 54: ...so equipped Reference Every 8 Hours Sections 10 3 6 4 8 3 11 1 Remote Panel display for maintenanceinformation Coolant Level Engine Oil Level Compressor Oil Level Truck Fuel Tank Level Fluid Spills Af...

Page 55: ...00 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 reg...

Page 56: ...element three times 1 Intake Manifold 2 Service Indicator Optional 3 Window 4 Reset Button Service air cleaner element if red band appears in window A green band means air cleaner is okay Press butto...

Page 57: ...ut disturbingthe fuel line connections Unscrew the bottom portion of fuel pump from the top to expose the fil ter Clean filter and replace 4 Primary Fuel Filter Inspect fuel lines and replace line if...

Page 58: ...ilter 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...

Page 59: ...elays located under the hood of the truck and activated by switches on the parking brake or neutral trans mission position and a truck mounted console switch if so equipped Try to start the EnPak engi...

Page 60: ...te panel 12 2 Engine Troubleshooting Trouble Remedy Engine will not crank Check battery connections and tighten if necessary Check battery voltage Check Manual Remote switch on Service Panel Check to...

Page 61: ...temperatures below 0 F glow plug time is 13 seconds maximum Check glow plug timing to en sure proper heating before cranking engine 12 3 Compressor Troubleshooting Trouble Remedy Air compressor does...

Page 62: ...ry 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 mod...

Page 63: ...rvice Agent check setting and correct as necessary Flow being dumped through crane relief valve instead of being directed to system possibly caused by system contamination See crane manufacturer s own...

Page 64: ...OM 261050 Page 60 SECTION 13 DIAGRAMS Figure 13 1 Training Circuit Diagram For EnPak...

Page 65: ...OM 261050 Page 61 261 040 D...

Page 66: ...OM 261050 Page 62 257 926 C Figure 13 2 EnPak Circuit Diagram...

Page 67: ...OM 261050 Page 63 261 045 A Figure 13 3 Air Compressor Diagram...

Page 68: ...mmended 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 receptacle...

Page 69: ...OM 261050 Page 65 238 945 B1 Figure 13 6 Hydraulic Circuit Diagram Page 1 Models With Hydraulic Power Source...

Page 70: ...OM 261050 Page 66 238 945 B2 Figure 13 7 Hydraulic Circuit Diagram Page 2 Typical Open Center Configuration Models With Hydraulic Power Source...

Page 71: ...OM 261050 Page 67 Figure 13 8 Hydraulic Circuit Diagram Page 3 Typical Closed Center With Load Sense Configuration Models With Hydraulic Power Source 238 945 B3...

Page 72: ...icity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Gen erators 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 M...

Page 73: ...e 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 74: ...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 75: ...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 3...

Page 76: ...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 Volt...

Page 77: ...d back 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...

Page 78: ...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 Use GFCI protection when operating auxiliary...

Page 79: ...OM 261050 Page 75 Notes...

Page 80: ...7 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 Hardware is common and not available unless listed Unit shown is fully equipped Some parts...

Page 81: ...ng this panel 1 26 251879 Assembly Baffle Panel 1 27 239328 Foam Acoustical Top Exit Baffle 1 28 239333 Foam Acoustical Exit Baffle Middle Upper 1 29 239334 Foam Acoustical Exit Baffle Middle Lower 1...

Page 82: ...Sae Jic 24 1 60 604313 Ftg Hose Brs Barbed M 1 4 Tbg X 1 8 Npt 1 61 260990 Bracket Fitting Capture 1 61 272749 Bracket Fitting Capture Models Without Hydraulic Power Source 1 62 216366 Bushing Snap i...

Page 83: ...t 1 239442 Conn Deutsch Wedge Lock 4 Position 1 ALTPLG 192170 Conn Rect 250 2skt 2row Plug Cable Lkg 1 PLG8 237895 Conn Pack 3p 1row Plg Yazaki 1 237896 Conn Skt Female Yazaki 3 240511 Conn Rear Clip...

Page 84: ...OM 261050 Page 80 Hardware is common and not available unless listed 265 799 1 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 Figure 15 2 Controls Remote Assemblies...

Page 85: ...X 1 125 Mtg Hole 4 17 173734 Link Jumper 2 18 1T 172661 Block Stud Connection 6 Position 1 19 CB2 093996 Supplementary Pro Man Reset 1p 20a 250vac Frict 1 20 CB1 241885 Supplementary Protector Man Res...

Page 86: ...available unless listed 265 804 A 1 20 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 RecommendedSpare Parts BOLD callouts are part of air compressor assem...

Page 87: ...d 1 259299 Cap Radiator 14 lb 1 20 239556 Ftg Stl 90 Deg Long Sae 8 M S X Jic 8 M 1 21 237835 Switch Temp Shutdown Nc 120c Open 1 22 239094 Adapter 1 2 Sae X 1 2 Jic 1 23 261003 Hose Assy Oil Compress...

Page 88: ...e Assy Hyd Case Drain 10 1 10 262086 Ftg Stl Elbow 45 Deg Jic 10 M X Sae 10 M S 1 11 262096 Ftg Stl Barbed 1 1 2 Hose X Sae 20 M 1 12 260998 Ftg Stl Jic 16 M X Sae 12 M 1 13 261000 Ftg Stl Jic 16 F S...

Page 89: ...tg Stl Sae 4 M X Jic 4 M 1 12 239108 Hose Assy Hyd Load Sense 4 1 13 260993 Hose Assy Hyd Case Drain 10 1 14 262086 Ftg Stl Elbow 45 Deg Jic 10 M X Sae 10 M S 1 15 262096 Ftg Stl Barbed 1 1 2 Hose X S...

Page 90: ...ring Models Without Hydraulic Power Source Quantity 1 189826 Ring Rtng Int 3 006 Groove Dia X 093 Thk 1 2 268992 Bearing Ball Rdl Sgl Row Long Life w 5K Grease 1 3 272596 Shaft Idler 1 4 268991 Bearin...

Page 91: ...bel Warning Steam And Hot Coolant Can Burn 1 6 261022 Bracket Mtg Radiator 2 7 261018 Assy Radiator And Shroud 1 259299 Cap Radiator Pressure 14lb 1 8 243021 Label Warning Moving Parts Can Cause Injur...

Page 92: ...9 Pump Fuel Electric 12vdc W Filter 1 26 265939 Filter Fuel Element 80 Micron 1 27 261053 Bracket Mtg Engine Kubota D902 Enpak 2 28 010858 Clamp Hose 437 1 000 Clp Dia 1 29 258490 Hose Assy Oil Drain...

Page 93: ...s Can Cause Injury 3in X 1 11 143220 O Ring 2 859 Id X 139 Cs 70 Duro Viton 1 12 260840 Rotor Assembly 1 13 259254 Adapter Engine Kubota D902 1 127854 Clamp Stl Cush 1 312 Dia X 343 Mtg Hole 1 14 2397...

Page 94: ...OM 261050 Page 90 Notes...

Page 95: ...pment 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...

Page 96: ...sonal records Always provide Model Name and Serial Style Number Visit www MillerWelds com EnPak to locate an EnPak supplier Options and Accessories Service and Repair Replacement Parts Training School...

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Miller ENPAK, Owner'S Manual

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