Professional Documents
Culture Documents
2009 11
Description
EnPak_Thank 2009 10
TABLE OF CONTENTS
Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions.
BUILDUP OF GAS can injure or kill. Noise from some processes or equipment can dam-
age hearing.
# Shut off shielding gas supply when not in use.
# Wear approved ear protection if noise level is
# Always ventilate confined spaces or use ap- high.
proved air-supplied respirator.
ELECTRIC AND MAGNETIC FIELDS (EMF)
can affect Implanted Medical Devices.
ARC RAYS can burn eyes and skin.
# Wearers of Pacemakers and other Implanted
Arc rays from the welding process produce intense Medical Devices should keep away.
visible and invisible (ultraviolet and infrared) rays that
# Implanted Medical Device wearers should consult their doctor
can burn eyes and skin. Sparks fly off from the weld.
and the device manufacturer before going near arc welding, spot
# Wear an approved welding helmet fitted with a proper shade of filter welding, gouging, plasma arc cutting, or induction heating
lenses to protect your face and eyes from arc rays and sparks operations.
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards). CYLINDERS can explode if damaged.
# Wear approved safety glasses with side shields under your
helmet. Shielding gas cylinders contain gas under high pres-
# Use protective screens or barriers to protect others from flash, sure. If damaged, a cylinder can explode. Since gas
glare, and sparks; warn others not to watch the arc. cylinders are normally part of the welding process, be
# Wear protective clothing made from durable, flame-resistant mate- sure to treat them carefully.
rial (leather, heavy cotton, or wool) and foot protection. # Protect compressed gas cylinders from excessive heat, mechani-
cal shocks, physical damage, slag, open flames, sparks, and arcs.
WELDING can cause fire or explosion. # Install cylinders in an upright position by securing to a stationary
support or cylinder rack to prevent falling or tipping.
Welding on closed containers, such as tanks, drums, # Keep cylinders away from any welding or other electrical circuits.
or pipes, can cause them to blow up. Sparks can fly off # Never drape a welding torch over a gas cylinder.
from the welding arc. The flying sparks, hot workpiece, # Never allow a welding electrode to touch any cylinder.
and hot equipment can cause fires and burns. Accidental contact of
electrode to metal objects can cause sparks, explosion, overheating, # Never weld on a pressurized cylinder — explosion will result.
or fire. Check and be sure the area is safe before doing any welding. # Use only correct shielding gas cylinders, regulators, hoses, and fit-
tings designed for the specific application; maintain them and
# Remove all flammables within 35 ft (10.7 m) of the welding arc. If associated parts in good condition.
this is not possible, tightly cover them with approved covers.
# Turn face away from valve outlet when opening cylinder valve.
# Do not weld where flying sparks can strike flammable material.
# Keep protective cap in place over valve except when cylinder is in
# Protect yourself and others from flying sparks and hot metal. use or connected for use.
# Be alert that welding sparks and hot materials from welding can # Use the right equipment, correct procedures, and sufficient num-
easily go through small cracks and openings to adjacent areas. ber of persons to lift and move cylinders.
# Watch for fire, and keep a fire extinguisher nearby. # Read and follow instructions on compressed gas cylinders,
# Be aware that welding on a ceiling, floor, bulkhead, or partition can associated equipment, and Compressed Gas Association (CGA)
cause fire on the hidden side. publication P-1 listed in Safety Standards.
# Do not charge a battery that has loose terminals or one showing Using a generator indoors CAN KILL
damage such as a cracked case or cover. YOU IN MINUTES.
# Before charging battery, select correct charger voltage to match
battery voltage. # Generator exhaust contains carbon monoxide.
# Set battery charging controls to the Off position before connect- This is a poison you cannot see or smell.
ing to battery. Do not allow battery charging clips to touch each # NEVER use inside a home or garage, EVEN IF
other. doors and windows are open.
# Keep charging cables away from vehicle hood, door, or moving # Only use OUTSIDE and far away from windows, doors, and
parts. vents.
FUEL can cause fire or explosion. BATTERY ACID can BURN SKIN and EYES.
# Stop engine and let it cool off before checking or # Do not tip battery.
adding fuel. # Replace damaged battery.
# Do not add fuel while smoking or if unit is near # Flush eyes and skin immediately with water.
any sparks or open flames.
ENGINE HEAT can cause fire.
# Do not overfill tank — allow room for fuel to expand.
# Do not spill fuel. If fuel is spilled, clean up before starting engine. # Do not locate unit on, over, or near combustible
# Dispose of rags in a fireproof container. surfaces or flammables.
# Always keep nozzle in contact with tank when fueling. # Keep exhaust and exhaust pipes way from
flammables.
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.
COMPRESSED AIR EQUIPMENT can # Do not work on compressed air system with unit running unless
you are a qualified person and following the manufacturer’s in-
injure or kill.
structions.
# Incorrect installation or operation of this unit
could result in equipment failure and personal # Do not modify or alter compressor or manufacturer-supplied
injury. Only qualified persons should install, op- equipment. Do not disconnect, disable, or override any safety
erate, and service this unit according to its equipment in the compressed air system.
Owner’s Manual, industry standards, and na-
tional, state, and local codes. # Use only components and accessories approved by the manufac-
turer.
# Do not exceed the rated output or capacity of the compressor or
any equipment in the compressed air system. Design compressed # Keep away from potential pinch points or crush points created by
air system so failure of any component will not put people or prop- equipment connected to the compressed air system.
erty at risk.
# Before working on compressed air system, turn off and lockout/ # Do not work under or around any equipment that is supported only
tagout unit, release pressure, and be sure air pressure cannot be by air pressure. Properly support equipment by mechanical
accidentally applied. means.
OM-240 113 Page 4
HOT METAL from air arc cutting and MOVING PARTS can injure.
gouging can cause fire or explosion.
# Keep away from moving parts such as fans,
# Do not cut or gouge near flammables. belts and rotors.
# Watch for fire; keep extinguisher nearby. # Keep all doors, panels, covers, and guards
closed and securely in place.
# Keep hands, hair, loose clothing, and tools away from moving
COMPRESSED AIR can injure or kill. parts.
# Before working on compressed air system, turn off and lockout/
# Before working on compressed air system, tagout unit, release pressure, and be sure air pressure cannot be
turn off and lockout/tagout unit, release pres- accidentally applied.
sure, and be sure air pressure cannot be acci-
dentally applied. # Have only qualified people remove guards or covers for maint-
enance and troubleshooting as necessary.
# Relieve pressure before disconnecting or con-
necting air lines. # Reinstall doors, panels, covers, or guards when servicing is
finished and before starting engine.
# 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 pro- HOT PARTS can burn.
tection, leather gloves, heavy shirt and trousers, high shoes, and
a cap when working on compressed air system. # Do not touch hot compressor or air system
# Use soapy water or an ultrasonic detector to search for leaks parts.
never use bare hands. Do not use equipment if leaks are found. # Allow cooling period before working on equip-
# Reinstall doors, panels, covers, or guards when servicing is ment.
finished and before starting unit. # To handle hot parts, use proper tools and/or wear heavy, insu-
# If ANY air is injected into the skin or body seek medical help im- lated welding gloves and clothing to prevent burns.
mediately.
Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
Protective Earth
Engine Cooling Engine Air Filter Glow Plugs
(Ground)
Check Valve
Engine Oil Fuel Battery (Engine)
Clearance
Crank Engine
SECTION 4 SPECIFICATIONS
Single-Phase, 2.4 kVa/kW, 20 A at 2600 to 3600 RPM, Kubota D1105 E3B, 3 Cylinder, 27.7 HP,
6 kVA/kW at 3600 RPM 300 Watts at 1800 RPM Liquid Cooled, Diesel Engine w/Electronic
120/240 V AC, 50/25 A, 120 V AC Pure Sine Wave, Continuous Governor
60 Hz, Continuous
Air Compressor On 63 dB 68 dB 73 dB 75 dB
15°
15°
15°
15°
240 859-A
Compressor
1.80
1.60
1.40
1.20
U. S.. GAL./HR.
1.00
0.80
0.60
0.40
0.20
0.00
0 5 10 15 20 25 30 35 40 45 50
CUBIC FEET PER MINUTE (CFM)
Auxiliary Power
1.80
1.60
1.40
1.20
U. S.. GAL./HR.
1.00
0.80
0.60
0.40
0.20
0.00
0.0 1.0 2.0 3.0 4.0 5.0 6.0
AUXILIARY POWER IN KILOWATTS
242 594-A
15
14.5
14
1800 RPM
VOLTS
13 2600 RPM
3600 RPM
12.5
12
0 20 40 60 80 100
AMPS
242 595-A
45
43
40
39
35
30 32
25
24
20
15
10
5
0
1800 2600 3200 3600
ENGINE SPEED (RPM)
CFM VS PSI
50
CUBIC FEET PER MINUTE (CFM)
48
46
44
42 43
42
40 41
40
38
36
34
32
30
100 125 150 175
PRESSURE (PSI)
Closed Center
20.0
Hydraulic Load Only
18.0
16.0
14.0
FLOW (GPM)
12.0
10.0
Hydraulic +40 CFM @ 100 PSI Compressor Load
8.0
6.0
2.0
0.0
0 500 1000 1500 2000 2500 3000 3500
PRESSURE (PSI)
Open Center
12.0
6.0
Hydraulic Load Only Manual Mode
4.0
Hydraulic Load Only 1800 RPM (Outriggers)
2.0
0.0
0 500 1000 1500 2000 2500 3000 3500
PRESSURE (PSI)
805 444-A
" The compressor is equipped with high NOTICE Do not mix oil types. Do not The unit is shipped with oil in the com-
overfill. pressor reservoir. Minimum oil level is half
oil temperature shutdown. High oil
way up the sight hole. Maximum oil level is
temperature can be caused by low oil 1 Air Compressor Oil Fill Cap
or hot air recirculation. in threaded area of oil fill pipe. Check level
Hand tighten oil fill cap. Using excess frequently. If oil needs to be added, be
" Do not open oil fill cap until unit has force can damage o ring. sure unit is off for 10 minutes before re-
been off for 10 minutes. Do not open moving fill cap.
while running. 2 Air Compressor Oil Sight Hole
805 444-A
1 4 5
2
6
10
7
9
8
239 661-1-A
1 Alpha Numeric Display Lights when display is showing a com- hold to increment minimum pressure set-
During the start sequence, the following pressor error. ting.
appears: 7 Power/Start Push Button " Compressor minimum pressure is set
SYSTEMon Press and release to cycle display until through the control program. Com-
GLOWPLUG display reads GLOWPLUG. When display pressor maximum working pressure is
GLOWdone reads GLOWdone, press and hold to start set at the Air Pressure Regulator
CRANKING engine. (P PRV). See Section 7-1.
NO CRANK 10 Status Select Push Button
Press and release to turn on power to the
See Section 6-3 for error messages that display only. This allows access to the dis- Press and release to cycle through the fol-
appear. play menu. lowing displays:
2 Engine Status LED With engine running, press and release to RPM
Lights when display is showing engine re- toggle between low speed and high speed. Current fuel usage (Gallons Per Hour)
lated information. The display will flash HIGH SPd when en- Engine hours
3 Compressor Status LED gine is locked in high speed. Engine maintenance hours (Counts down
8 Engine Off Push Button from 400 hours)
Lights when display is showing com-
Engine temperature
pressor related information. Press when engine is running to stop en- Compressor hours
4 Engine Off LED gine. Compressor maintenance hours (Counts
Lights when engine is off. 9 Compressor On/Off Push Button down from 500 hours)
5 Engine Shutdown LED When engine is running, press twice to " Current fuel usage is for reference
Lights when display is showing an engine turn compressor on or off. only. Variables such as ambient tem-
error. When engine is not running, Press and re- perature, altitude and fuel blend affect
6 Compressor Shutdown LED lease to display MinPRESS. Press and actual usage.
239 661-1-A
1 Alpha Numeric Display Indicates high compressor temperature if SEN OPEN
The following operational messages may SHUTDOWNS COMPRESSOR LED is
Indicates coolant sensor is open.
appear: on.
OVErPRES SENSHORT
CHNG OIL
Indicates the compressor has an over pres- Indicates coolant sensor is shorted.
Indicates an oil change is needed. This light
flashes after the first 50 hours of operation sure error. ALTRNATR
and then at normal oil change intervals OVErSPEEd
Indicates an open condition in the alternat-
thereafter. Indicates an engine over speed error. or.
If SHUTDOWNS ENGINE LED is on, en- LOW OIL
gine oil change time interval has counted HiVOLTiN
Indicates a low oil pressure condition in the
down to zero, indicating it is time to change engine. Indicates high input voltage from the bat-
engine oil. tery.
NoCHARGE
To reset display after oil change, see Sec- LoVOLTiN
tion 8-5. Indicates an alternator problem.
HiTEMP 1 Indicates low input voltage from the battery.
If SHUTDOWNS COMPRESSOR LED is
on, compressor oil change time interval has Indicates high engine temperature if Optional EnVerter! Power System
counted down to zero, indicating it is time to SHUTDOWNS ENGINE LED is on. The
temperature switch has indicated high tem- The following messages may appear if the
change compressor oil.
perature. unit is equipped with the optional EnVert-
To reset display after oil change, see Sec- er! power system.
tion 8-7. HiTEMP 2
Indicates high engine temperature if ENVRT hot
HIGH SPd
SHUTDOWNS ENGINE LED is on. The Indicates the EnVerter power system is
Indicates engine is locked in high speed. temperature sensor has indicated high overheated.
With engine running, press Power/Start temperature.
button to toggle speed. ENVRT com
SPd SENS
The following error messages may appear: Indicates a communication error.
Indicates a problem with the engine speed
" If error message appears, consult sensor. ENVRT ok
troubleshooting section for remedial GovCNTRL Indicates the EnVerter power system is
actions. Indicates a problem with the engine gov- functioning. Press Power/Start button to
Hi TEMP ernor control. enable.
Ambient Temperature Above 50° F (10° C) 0° F to 50° F ( 18° C to 10° C) Below 0° F ( 18° C)
Starting engine remotely glow plug timing automatic. Not needed 10 seconds 20 seconds
Starting engine from Service Panel manually holding Glow Not needed Up to 10 seconds Up to 20 seconds
Plugs switch.
An optional engine block heater and compressor oil and control heater are required if the unit is normally operated in temperatures below 4° F ( 20° C).
2 1 3 4 5
6
7
10
12 11 239 667-1-A
1 Manual/Remote Switch when light loads are present. Indicates the compressor pressure is too
! When working on unit, always 3 Fuel Pump Switch high.
move Manual/Remote switch to Use switch to power the engine ECU mod- " If both the Compressor Temperature
Manual position to prevent remote ule and turn fuel pump on. and Pressure LEDs are lit, the com-
starting. pressor Pressure Safety Switch
4 Glow Plug Switch
This unit can be started from a remote loca- (P PSW) may be at fault.
tion when this switch is in the Remote posi- Push up to turn glow plugs on. See Section
8 Engine Error LED
tion. Place switch in Manual position when 6-4 for appropriate glow plug timing. Push
service side panel is open or when Remote down to engage engine starter. Once en- Indicates an engine error. See Table 6-1 for
Panel is disconnected. gine has started, allow switch to return to blink pattern.
When this switch is in the Remote position, center position. 9 Glow Plug LED
the remaining switches on the service pan- 5 Compressor Switch Indicates the glow plug is on.
el do not function. 10 Compressor On LED
Use switch to turn compressor (clutch and
2 Engine Speed Switch valve) on during manual operation. Indicates the compressor is on.
High position is 3600 RPM and is used 11 Engine Crank LED
6 Compressor Temperature LED
when generator power is required or the
compressor or hydraulic system will be Indicates the compressor oil temperature Indicates the engine is cranking.
loaded. is too high 12 Engine On LED
Low position is 2600 RPM and is used 7 Compressor Pressure LED Indicates the engine is running.
" If error message appears, consult troubleshooting section for remedial actions.
Blinking Pattern Symptom Error Message Remedy
1 Long 1 Short Engine over speed OVErSPEEd Check actuator
1 Long 2 Short Low oil pressure LOW OIL Check oil pressure sensor
1 Long 3 Short Low battery voltage NoCHARGE Check alternator terminal L
1 Long 4 Short High coolant temperature HiTEMP 1 Check coolant temperature
switch
1 Long 6 Short High coolant temperature HiTEMP2 Check coolant temperature
sensor
2 Long 1 Short Abnormal engine speed SPd SENS Check engine speed sensor
2 Long 2 Short Engine does not run properly GovCNTRL Check actuator for current prob-
lem
2 Long 4 Short No coolant temperature signal SEN OPEN Check coolant temperature
sensor for open circuit
2 Long 5 Short Coolant temperature signal al- SENSHORT Check coolant temperature
ways on sensor for short circuit
2 Long 6 Short Connection at alternator terminal ALTRNATR Alternator disconnected at
L open terminal L
2 Long 7 Short Battery voltage too high HiVOLTiN Check alternator
2 Long 8 Short Battery voltage too low LoVOLTiN Check alternator
Notes
! The air pressure gauge reads the air ing. If pressure reaches 200 psi, the com-
compressor case pressure. Case pressor clutch will disengage and shut
pressure can be high even when ex-
" Pressure is factory set for 120 psi. Do down. Once the compressor pressure is re-
not set pressure above 175 psi. duced below 175 psi, the compressor can
ternal reservoir pressure is zero.
Do not set pressure below 90 psi. Com- be manually re-started.
Wait 10 minutes for compressor
pressor will supply 90 psi regardless of
blow down cycle to complete before The compressor is also equipped with a
setting below 90 psi.
checking/adding oil or performing mechanical safety valve (P SV) that will
maintenance. At pressures above 180 psi, the compres-
sor clutch will temporarily disengage to pre- open if pressure approaches 210 psi.
1 Air Pressure Regulator (P-PRV)
vent further pressure build-up, and OVer- If the compressor continues to overpres-
2 Air Compressor Gauge (P PG) PRES shows temporarily on the remote sure and disengage, see Section 9.
Adjust system maximum pressure with the panel display. Once the compressor outlet
pressure regulator. Set pressure in the no- pressure is reduced below 175 psi, the If compressor shuts down due to over-
flow condition only. Set at lowest possible compressor controls reset and resume nor- temperature, it automatically resets when it
pressure for the job to reduce engine load- mal operation. cools.
! When working on unit, always move Manual Remote switch on Service Panel to Manual position to prevent remote starting.
" Replace engine and air compressor oil and filters after the first 50 hours of operation.
" Test safety interlock monthly, see Section 8-4.
! Stop engine before maintaining.
Recycle fluids.
" See equipment manuals and Maintenance
Label for important start-up, service, and
storage information. Service equipment
more often if used in severe conditions.
$ Remote Panel display for $ Coolant Level $ Engine Oil Level $ Compressor Oil Level
maintenance information View oil level in sight hole.
% Engine Oil % Compressor Oil % Engine Oil Filter % Compressor Oil Filter
Every Section 8-3,
100 13-3
Hours
& Air Cleaner Element $ Air Cleaner Hoses Test Safety Valve
Every Engine
400 Manual,
Hours Section 8-5
Blow
Keep nozzle
2 in. (51 mm)
1 2 3 4 from element.
Optional
5
Inspect
With the EnPak engine running, turn off plied by relays located under the hood mote control panel. The safety interlock is
+12 volts DC power to the crane system. of the truck and activated by switches working properly if the Enpak engine does
The EnPak engine should stop. on the parking brake or neutral trans- not crank or start, and the remote control
mission position; and a truck-mounted panel does not have power to it.
" Check with dealer for detailed descrip- console switch if so equipped. Restore +12 volts DC power to the crane
tion of system supplied. Try to start the EnPak engine from the system. The EnPak should start and func-
Power to the crane system will be sup- crane remote pendant or the EnPak re- tion properly.
3 1
Trouble Remedy
No power output. Reset supplementary protectors CB1, CB2 and/or CB3 (see Section 15-2).
Low power output. Check and clean engine air cleaner as necessary.
High power output. Have Factory Authorized Service Agent check engine speed.
Erratic power output. Have Factory Authorized Service Agent check engine speed.
GFCI device trips at low speed. GFCI receptacle or extension cord not proper type for application. Replace with Miller approved GFCI
device (see Parts List).
Machine plugged into regular generator Engine speed too low and load is not recognized. Using crane remote or EnPak remote panel, manu-
auxiliary power does not work. ally place engine in high speed (see Section 6-1 item 7 for EnPak remote panel).
Trouble Remedy
Engine will not crank. Check battery connections and tighten if necessary.
Check to ensure crane power switch and safety interlock are working (see Section 8-4).
Engine starts but stops. Check oil level (see Section 5-2). Low oil pressure shutdown stops engine if oil pressure is too low.
Use correct grade oil for operating temperature. (see Section 8-1).
Have Factory Authorized Service Agent check low oil pressure shutdown switch S2.
Engine stopped during normal Check fuel level (see Section 5-2).
operation.
Check oil level (see Section 5-2). Low oil pressure shutdown stops engine if oil pressure is too low.
Oil level too high reduces capacity of the fuel pump.
Have Factory Authorized Service Agent check throttle solenoid TS1 according to engine manual.
Have Factory Authorized Service Agent check low oil pressure shutdown switch S2.
Engine does not return to idle speed. Remove all generator power loads, compressor loads, and hydraulic loads.
Check remote panel and crane pendant to see if system is locked in high speed.
Engine does not return to idle speed Have Factory Authorized Service Agent check circuit board PC2 and current transformer CT1.
(Continued).
Engine speed does not remain con- GFCI receptacle or extension cord not proper type for application. Replace with Miller approved GFCI
stant. device (see Parts List).
Engine does not remain at power For small loads, place crane pendant speed control switch in the High or Fast position, or push Power
speed when a load is applied with Start button on remote control panel to lock in high speed.
crane pendant speed switch in the Low
or Idle position.
During operation in near freezing tem- Place crane pendant speed control switch in the High or Fast position until unit has been in operation
peratures, engine starts and goes to and loaded for a period of time.
idle but stalls after a few minutes.
During operation in severe cold weath- Install engine manufacturer’s kit for cold-weather operation. Normal maximum glow plug time is 10
er, engine starts and goes to idle but seconds. In ambient temperatures below 0° F, glow plug time is 20 seconds maximum. Check glow
stalls after a few minutes. plug timing to ensure proper heating before cranking engine.
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 air compressor control circuit and clutch.
Air compressor stops after short period Automatic shutdown stops compressor if compressor temperature is too high or over pressure condition
of operation. occurs.
Check compressor oil level (see Section 5-3). Check for clogged oil cooler. Clean debris from oil cooler.
Recirculation or open covers may cause overheating. Be sure all covers, panels, and doors are in place.
Operate in area with proper airflow.
Check for over-pressure condition by turning on compressor and monitoring air pressure and remote dis-
play for error messages.
Low air pressure. Check for leaks in air lines and hoses, including control line.
Adjust compressor air pressure using pressure regulator (P-PRV) (see Section 7-1).
Have Factory Authorized Service Agent check compressor for rated output.
High air pressure. Adjust compressor air pressure using pressure regulator (P-PRV) (see Section 7-1).
Be sure control line is connected at proportional control (P-PC), and unload solenoid valve (P-USV).
Check for frozen pressure regulator (P-PRV) at proportional control (P-PC), frozen intake control (P-IC),
or frozen control lines.
Oil in air from compressor. Check compressor oil level (see Section 5-3). If oil level is too high, system becomes saturated with oil.
Change compressor air/oil separator if close to replacement hours (see Section 8-7).
Oil in compressor air cleaner. Have Factory Authorized Service Agent check for blocked separator scavenge check valve/filter orifice.
Have Factory Authorized Service Agent verify compressor intake valve P-IC is operating properly.
Water in compressor oil. Have Factory Authorized Service Agent check thermostat operation.
Trouble Remedy
No crane operation. No oil in system. Add oil.
Hydraulic system not primed. Prime system (see Section ). Check reservoir height meets require-
ments (see Section 11-1).
Flow control valve H FC1 not functioning. Check to make sure solenoid is plugged in. Check wiring
harness to solenoid coil. Have Factory Authorized Service agent check solenoid coil.
Flow control valve H FC1 plugged with contaminants. Replace valve and flush system.
Slow crane operation; unit comes up to Other functions in use and unit is power managing. Unit functioning correctly.
higher speed.
Flow control valve H FC1 is partially plugged with contaminates causing higher pressure drop across
the valve. Replace valve and flush system.
Differential pressure setting of pump (load sense) set too low. Have Factory Authorized Service Agent
check setting and correct as necessary.
Displacement setting of pump set too low. Have Factory Authorized Service Agent check setting and
correct as necessary.
Check crane model hydraulic requirements. Pump may need to be reset (consult Factory Authorized
Service Agent).
Flow being dumped through crane relief valve instead of being directed to system, possibly caused by
system contamination. See crane manufacturer’s owners manual.
Hydraulic oil viscosity too high. See Section 11-1 for correct fluid viscosity recommendations at spe-
cific ambient temperatures.
Slow crane operation; unit remains at Open Center systems: No trigger signal from crane pendant present. Have Factory Authorized Ser-
low speed. vice 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 Air trapped in load sense line. Bleed load sense line according to Section 11-4.
higher speed (Closed Center sys-
tems).
Fast crane operation. Differential pressure setting of pump (load sense) set too high. Have Factory Authorized Service
Agent check setting and correct as necessary.
Displacement setting of pump set too high. Have Factory Authorized Service Agent check setting and
correct as necessary.
Check crane model hydraulic requirements. Pump may need to be reset (consult Factory Authorized
Service Agent).
Hydraulic oil viscosity too low. Consult Section 11-1 for correct fluid viscosity recommendations at
specific ambient temperatures.
No outrigger operation. No oil in system. Add oil.
Suction line valve closed. Open valve.
Hydraulic system not primed. Prime system (see Section11-3). Check reservoir height meets require-
ments of Section 11-1.
Flow control valve H FC1 not functioning. Check to make sure solenoid is plugged in. Check wiring
harness to solenoid coil. Have Factory Authorized Service Agent check solenoid coil integrity.
Flow control valve H FC1 plugged with contaminants. Replace valve and flush system.
Relief valve in crane system stuck open from contamination. See crane owner’s manual to correct.
Notes
18 in.
7 in. (178 mm) Mainten- (460 mm)
ance
4 in. (102 mm) Operation
1 in.
(25 mm)
1 in.
(25 mm)
12 in.
(305 mm)
2 3
4
Tools Needed:
9/16 in
Ref: install3 2008--01 803 274 / 200 864-A / 803 231
For use with a mechanics truck crane, the system should at a minimum include the following items:
B. Reservoir
Minimum reservoir size is 20 gal (76 L) with a minimum fluid height of 24 in. ( 610 mm) above base of unit. To accommodate changes in volume due to
cylinder displacement, a filtered breather must be used and vented to atmosphere. This filter should be 10 micron.
The design of the reservoir must allow for adequate oil circulation to disperse entrapped air and to maintain sufficient cooling through the use of baffles.
Changes in oil volume due to cylinder displacement also needs to be accounted for by allowing adequate air space inside the reservoir. The unit must
operate properly at up to a 15° angle.
Place reservoir as near as possible to the unit, see Section 10-2. Suction line length greater than 72 in. (1829 mm) is NOT recommended.
The suction port should be at least 3 in. (76 mm) above the bottom of the reservoir to prevent any debris on the bottom of the reservoir from being drawn
into the suction line. Also, the suction port should be at least 6 in. (152 mm) below the top level of the fluid to prevent vortexing. Oil volume changes
during operation and the 15° maximum operating angle must be considered.
A suction strainer is not recommended by the hydraulic pump manufacturer. If a suction strainer is used, diligent preventive maintenance is required to
prevent the strainer from clogging.
System return lines and drain lines should terminate below the minimum fluid level to prevent aeration of the oil. Return lines should be located away
from the suction line to prevent interaction.
Allowance for a properly sized immersion heater may be necessary in some climates.
The system relief valve should be set according to the crane manufacturer’s recommendations. The maximum pressure of the pump should be set 200
psi (1.38 MPa) above the system relief valve to prevent interaction. For settings above 3800 psi (26.2 MPa), consult the factory.
In this configuration, the system relief valve is the primary relief and the pump maximum pressure setting is secondary.
For most closed centered systems, the pump maximum pressure setting is the primary relief and the system relief valve is secondary. Therefore, the
pump maximum pressure setting should be set at a level recommended by the crane manufacturer. The system relief valve should also be set accord-
ing to the crane manufacturer’s recommendations. In general, this will be approximately 200 psi (1.38 MPa) greater than the pump maximum pressure
setting.
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 11-1.
E. Filtration
System filtration requirements are to maintain a cleanliness code of 18/16/13 per ISO 4406:1999.
Filtration should be met with the use of a return line filter. Per the pump manufacturer, the use of suction line strainer is not recommended due to clogging
issues.
The filter must be compatible with all petroleum and synthetic hydraulic fluids. The filter should operate in a temperature range of 30°C to 121°C.
Consideration should be given to the filter bypass rating. Excessive bypass at low temperatures should be avoided.
F. Hydraulic Fluid
Premium grade petroleum based fluid that contains anti wear agents, rust inhibitors, anti foaming agents, and oxidation inhibitors and has an ISO VG
rating as recommended.
Hose Torque
Suction 160 ft lb (217 N⋅m)
1 Case Drain 60 ft lb (81 N⋅m)
Pressure Line 80 ft lb (108 N⋅m)
2
Load Sense 12 ft lb (16 N⋅m)
Tools Needed:
4
3
2-1/4. 1-1/4. 1, 9/16 in.
(57, 31, 25, 14 mm)
3 4 5
! When working on unit, always highest point. Screw the manual override screw fully
move Manual/Remote switch to counterclockwise.
Manual position to prevent remote Fully open suction line valve at the reser- Place the Service Panel Manual/Remote
starting. See Section 6-5. voir. Screw manual override screw fully switch in the Remote position. Place the
clockwise (fully opens proportional valve). Fuel Pump switch in the On position.
1 Proportional Valve Assembly
2 Manual Override Screw Adjust On Service Panel, place Manual/Remote Start the engine using the remote panel.
3 Service Panel switch in the Manual position. Place the Let the engine run 5 to 10 minutes with no
Fuel Pump switch in the Off position. load.
4 Manual Override Switch
Pressure and displacement are set at the
5 Fuel Pump Switch
Crank the engine for 10 seconds, pause, factory and should not require initial ad-
Make hydraulic system connections ac- crank again for 10 seconds, pause and justment. Have Factory Authorized Ser-
cording to Section 11-2. crank for an additional 10 seconds. This vice Agent correct pressure or displace-
Fill hydraulic pump case with oil at its should prime the hydraulic pump. ment settings.
Top View
805 444-A
Battery Specification:
12 V, 650 CCA at 0° F
Battery Cable Specification:
1
1/0 AWG
3
2
Tools Needed:
1/2 in
Tools Needed:
1/2 in
805 445-A
Notes
Tools Needed:
2
1
B. Reservoir
Recommended reservoir size is 20 gal (78 L) or larger. The addition of an air reservoir provides air delivery capacity and aids in reducing the amount of
water and contaminates discharged to the rest of the system by condensing out these contaminants. The reservoir should be ASME Code for 200 psi
working pressure. A drain valve should also be installed for draining water and contaminants.
The reservoir must have a safety relief valve installed of appropriate relieving pressure and capacity of the system. Also, relief valve must comply with
vessel and code under which the vessel is constructed and inspected.
D. Compressor Oil
" Mobil 1 Synthetic ATF is recommended. Do not mix oil types.
The cooling oil must have high ageing stability, corrosion protection, and dispersive capacity; low emulsification tendency, and minimum foaming. Vis-
cosity class ISO VG 68 is recommended.
Tools Needed:
Top View
805 444-A
Bottom View
1
" Electrically bond generator
frame to vehicle frame by met-
al-to-metal contact.
240V
120V
! Always connect a ground
wire from the auxiliary power
120V/60HZ 120V
system ground to bare metal
on the vehicle frame as
NEUTRAL shown.
A BONDED
F E D C B
TO!FRAME ! If a GFCI receptacle is in-
EnVerter!
120V/60HZ
120V/240V
NEUTRAL
NEUTRAL
120V/240V
120V/240V
NEUTRAL
NEUTRAL
120V/240V
GROUND
Figure 16-6.
EnVerter!
SUPPLY
INLET
REG. AIROUT
VALVE AC2
PC2 IC1
IC1 1.0 mm 1.0 mm
P PRV 0.8 mm
90 175 PSI OIL
FILTER OC1
P A C = AIR CO M PRESSO R
P IC = INTAKECONTROL
P MPCV = MINIMUM PRESSURE CHECK VALVE
P OD = OIL DRAIN
P OH = OIL HEATER (OPTIONAL)
P PG = PRESSURE GAUGE
P PS = PRESSURE SENDER
P PSW = PRESSURE SWITCH, SAFETY
P SV = SAFETYVALVE
P TSW = TEMP SWITCH SHUTDOWN
Figure 16-4. Hydraulic Circuit Diagram Page 2: Typical Open Center Configuration
OM-240 113 Page 60
238 945-B3
Figure 16-5. Hydraulic Circuit Diagram Page 3: Typical Closed Center With Load Sense Configuration
OM-240 113 Page 61
242 500-C
Figure 16-6. EnPak Truck Wiring Diagram
OR
800 652-D
1 Equipment Grounding
1 2 Terminal
GND/PE 2 Grounding Cable
Use #10 AWG or larger insulated
copper wire.
3 Ground Device
" Use ground device as stated in
electrical codes.
! Ground generator to system
earth ground if supplying
2 3 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
1 Resistive Load
A light bulb is a resistive load and
requires a constant amount of power.
2 Non-Resistive Load
Equipment with a motor is a non-re-
3 sistive load and requires approxi-
VOLTS 115 mately six times more power while
2 AMPS 4.5 starting the motor than when running
1 Hz 60 (see Section 17-8).
3 Rating Data
Rating shows volts and amperes, or
watts required to run equipment.
Amperes x Volts = Watts
3 Example 1: If a drill uses 4.5 am-
peres at 115 volts, calculate its run-
ning power requirement in watts.
4.5 A x 115 V = 520 W
The load applied by the drill is 520
watts.
Example 2: If three 200 watt flood
lamps are used with the drill from Ex-
ample 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
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Current
Load (Watts) 4 6 8 10 12 14
(Amperes)
7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19)
10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15)
15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9)
If unit does not have GFCI receptacles, use GFCI-protected extension cord.
Current
Load (Watts) 4 6 8 10 12 14
(Amperes)
7 1680 800 (244) 500 (152) 300 (91) 200 (61) 125 (38)
10 2400 800 (244) 550 (168) 350 (107) 225 (69) 125 (38) 100 (31)
15 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)
2
3
5
6
7
8
11
12
13
9 10
73
14
72
53
54
55
65 64 56
63
71 70 66 62
67 61 57
58
60
68 59
69
30
28
27
26
19 20 25
21 24
22
23
18
17
16
15 34
33
32
31
35
36
41
52 40
39
38
37
51
50
49
48
47
46
45
44
43
42
242 707-A
2
3
4
5
6
7
8
11
10
12
13
14
15
16
18 17
19
20
21
22
34 23
24
33
25
26
32
31
27
30
29
28
242 678-A
14
A 13
B 12
4 8
11
5 7 10
3 6
C
53
52 2 1
50 51
40 41 47
49
46
45 15
48 16
42 44
43
17
18
19
20
28
33 31
35 34 29
36
30
37
27 26 25 24 21
32 22
23
38
39
805 456-D
. . . 1 . . P AC . 238869 . . Compressor, Ap 40 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . . . . . . . . . . . . . . 244487 . . Maintenance Kit, Shaft Sealing (AP40) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 0
. . . 2 . . P PC . 240394 . . Assy, Pneumatic Proportional Control Ap 40 (Includes) . . . . . . . . . . . . . . . . . . . 1
. . . 3 . . P USV 242848 . . . . Valve, Solenoid Unload Pneumatic, 12vdc, 10w, 2wno . . . . . . . . . . . . . . . . . 1
. . . 4 P HC, HTC 242846 . . . . Heater Control, Pneumatic 45w, 120v W/Thermostat, N . . . . . . . . . . . . . . . . 1
. . . 5 . . P PRV 242847 . . . . Valve, Relief Proportional Pneumatic . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 6 . . . . . . . . . . 242542 . . Washer, Flat Bonded Seal 1/4 Bspp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 7 . . P SV . 239563 . . Valve, Safety Air Compressor 1/4 Bspp 210 Psi . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 8 . . . P IC . 242849 . . Valve, Control Intake Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 9 . . . . . . . . . . *232208 . . Filter, Inlet Air Air Compressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 10 . . . . . . . . . . 239309 . . Tensioner, Belt W/Pulley 6 Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 167788 . . Nut, 375 16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 239307 . . Bushing, 25mm Taper Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 13 . . . . . . . . . . 239304 . . Pulley, Micro v 6 Rib 2.938 Pd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . *239315 . . Belt, Micro v 6 Rib . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
OM-240 113 Page 76
Item Dia. Part
No. Mkgs. No. Description Quantity
6
2
1
7
9 5
17
4
8
10 9
16
15
14 11
12
13
805 457-A
17
18
19
20
6
21
3
22 7
5
2
4
1 8
10
16 9
15
14 11
12
13
243 166-A
15 16
19
13 14
12 24
25
11
10 26
9
8
27
2 3 28
4 7 29
30
5 6
1
31
3 34
32
35
33
36
42 37
38
39
40
41
43
805 458-A
12
13
14
15
27 16
17
26 18
25 19
24
23
22
21
20
242 679-B
. . . 1 . . . . . . . . . . 208497 . . Nut, M08 1.2 13mmhex 8.3mm T Stl Pld Sem Con Washer . . . . . . . . . . . . . . 2
. . . 2 . . . . . . . . . . 239746 . . Pin, Spring Dowel Cs 8mm Odx12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . 3 . . . . . . . . . . 239740 . . Lift Eye, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 4 . . . . . . . . . . 192686 . . Screw, M 8 1.25x 25 Hex Hd pln 8.8 Pld Din933 . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 5 . . . . . . . . . . 083883 . . Washer, Lock .402idx0.709odx.087t Stl Pln Split10mm . . . . . . . . . . . . . . . . . . . 2
. . . 6 . . . . . . . . . . 270203 . . Screw, M10 1.25x45 Hex Hd pln 8.8 Pld . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
. . . . . . . . . . . . . . . . 240468 . . Rotor Assembly (Includes)
. . . . . . . . . . . . . . . . 239007 . . . 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, Generator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 11 . . . . . . . . . . 239017 . . Mount, Rear Component . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 12 . . . . . . . . . . 167788 . . Nut, 375 16 .56hex .34h Stl Pld Sem Cone Wshr.88d . . . . . . . . . . . . . . . . . . . . 4
. . . 13 . . . . . . . . . . 183419 . . O ring, 1.984 Id X .139 Cs 70 Duro Viton . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 14 . . . . . . . . . . 244921 . . Spacer, Nylon 1.120 Od X 1.014 Id X .375 Lg . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 15 . . . . . . . . . . 244682 . . Clutch, Electro Magnetic 12vdc W/6.25 Dia Pulley . . . . . . . . . . . . . . . . . . . . . . 1
. . . 16 . . . . . . . . . . 138253 . . Screw, 250 20x .37 Hexwhd.52d Stl Pld Lkg Serr . . . . . . . . . . . . . . . . . . . . . . . 3
. . . 17 . . . . . . . . . ◊244931 . . Nut, Taper Clutch Bushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 18 . . . . . . . . . . 244933 . . Washer, Nylon 1.031 Id X 1.218 Od X .040 Thk . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 19 . . . . . . . . . . 244970 . . Pulley, Micro v 8 Rib 4.750 Pd . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 20 . . . . . . . . . . 241782 . . Bushing, 1.000 Taper Lock . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 21 . . . . . . . . . . 244930 . . Bushing, Stl Taper Clutch 1.000 Id . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
. . . 22 . . . . . . . . . . 225120 . . Label, Warning Moving Parts Can Cause Injury . . . . . . . . . . . . . . . . . . . . . . . . . 1
Wiring Harnesses
Distributor
Address
City
State Zip
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 2009 Miller Electric Mfg. Co. 2009 01