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OM-261050F 2016−06 Description Mobile Utility Unit With Air Compressor, Hydraulic Pump, And Auxiliary Power Capability EnPak File: Mobile Utility Visit our website at www.MillerWelds.com/EnPak...
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We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING Enpak_2015−09 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury.
Using a generator indoors CAN KILL STEAM AND HOT COOLANT can burn. YOU IN MINUTES. D If possible, check coolant level when engine is cold to avoid scalding. D Generator exhaust contains carbon monoxide. This is a poison you cannot see or smell. D Always check coolant level at overflow tank, if present on unit, instead of radiator (unless told D NEVER use inside a home or garage, EVEN IF...
1-4. Compressed Air Hazards BREATHING COMPRESSED AIR can in- COMPRESSED AIR EQUIPMENT can jure or kill. injure or kill. D Do not use compressed air for breathing. D Incorrect installation or operation of this unit could result in equipment failure and personal D Use only for cutting, gouging, and tools.
1-5. Additional Symbols For Installation, Operation, And Maintenance ELECTRIC SHOCK can kill. OVERHEATING can damage motors. Touching live electrical parts can cause fatal shocks D Turn off or unplug equipment before starting or or severe burns. Machine internal circuits are live stopping engine.
1-6. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...
SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION Enpak_2015−09_fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
D Mettre des lunettes de sécurité et des gants, placer un torchon sur LES ÉTINCELLES À L’ÉCHAPPEMENT le bouchon du radiateur. peuvent provoquer un incendie. D Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. D Empêcher les étincelles d’échappement du moteur de provoquer un incendie.
D Pour intervenir sur un circuit hydraulique, porter un équipement D Prévoir une période de refroidissement avant d’intervenir de protection tel que des lunettes de sécurité, des gants de cuir, sur l’équipement. une chemise et un pantalon en tissu résistant, des chaussures D Ne pas toucher aux pièces chaudes, utiliser les outils recom- montantes et une coiffe.
Les PIÈCES MOBILES peuvent causer PIÈCES CHAUDES peuvent provoquer des brûlures graves. des blessures. D Ne pas toucher de pièces chaudes D S’abstenir de toucher des parties mobiles telles du compresseur ou du circuit d’air. que des ventilateurs, courroies et rotors. D Prévoir une période de refroidissement avant d’intervenir sur l’équipement.
LES ÉTINCELLES PROJETÉES LES CHARGES ÉLECTROSTATI- peuvent provoquer des blessures. QUES peuvent endommager les circuits imprimés. D Porter un écran facial pour protéger le visage et les yeux. D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. D Affûter l’électrode au tungstène uniquement à...
SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbol Definitions Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 Do not use ether or other starting fluids. Using starting fluids voids warranty. See engine Owner’s Manual. Safe89 2015−02 Moving parts can injure.
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3-2. Miscellaneous Symbol Definitions Read Operator’s Glow Plug Air Pressure Manual Engine Coolant Engine Air Pressure Temperature Air Filter Engine RPM Air Compressor Direct Current Engine Oil Hydraulic Pump (DC) Alternating Check Valve Fuel Current (AC) Clearance iso 7000 Protective Earth Battery (Engine) Belt Drive (Ground)
Engines should not be started if ambient temperature is below −40°F, unless measures have been taken to ensure all components inside the EnPak and the Remote Panel are at temperatures above −40°F, and correct low temperature fluids are being used per chart below.
NOTICE − For extreme cold (<−305F), consult with the Miller Service department regarding preheating and suitable lubricants. * For temperatures below −205F an oil heater for the compressor is required. Consult with the Miller Service department. Failure to preheat the oil as specified may void the warranty.
4-7. Dimensions, Weights, and Operating Angles Do not exceed tilt angles or engine could be damaged or unit could tip. Do not move or operate unit where it could tip. Do not operate suspended from lifting eye. Weight: 832 lb (377 kg) 896 lb (406 kg) Fully Equipped (w/Packaging) Lifting Eye Weight Rating:...
4-8. Fuel Consumption The curve shows typical fuel use under compressor or power loads. Compressor 1.60 1.40 1.20 1.00 0.80 0.60 0.40 0.20 0.00 Cubic Feet Per Minute (CFM) Auxiliary Power 1.40 1.20 Standard Generator Power 1.00 0.80 0.60 Synthetic Power 0.40 IDLE 0.20...
4-11. Hydraulic Pressure Flow Curves (Models With Hydraulic Power Source) Curves are typical. Output will vary depending on system pressure losses to load sense pressure location. Open Center Hydraulic Pressure Flow Curve Fluid: ISO 32 Hydraulic Oil Fluid Temperature: 120° F (49° C) Load Sense Pressure: Closed Center −...
4-12. Hydraulic Pressure Flow Curves − Combination Loads (Models With Hydraulic Power Source) Curves are typical. Output will vary depending on system pressure losses to load sense pressure location. Fluid: ISO 32 Hydraulic Oil Fluid Temperature: 49° C (120° F) Load Sense Pressure: Closed Center −...
4-13. Air Compressor Curves Standard Conditions: Pressure = 100 psi (689 kPa) Temperature = Operating Tem- Maximum Air Flow perature 70.0 60.0 50.0 40.0 30.0 20.0 10.0 Air Pressure (psi) 120psi Max Setting 150psi Max Setting 175psi Max Setting 261 043-A Notes OM-261050 Page 20...
See Section6 through 9 for spe- Location/Airflow Clearance cific EnPak systems information. Hydraulic Reservoir EnPak Typical hydraulic reservoir place- ment in relation to EnPak. See Sec- tion 7-1 for complete reservoir re- quirements. 18 in. 7 in. (178 mm) Maintenance (460 mm) 4 in.
5-2. Mounting Unit NOTICE − Do not mount unit by supporting the base only at the four mounting brackets. Use cross-sup- ports to adequately support unit and prevent damage to base. Supporting The Unit See Section 4-7 for dimen- sions. Mounting Surface: Cross-Supports Mounting Brackets (Supplied)
6-2. Installing Exhaust Pipe Engine backfire can cause se- vere burns or other injuries. Keep 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.
6-3. Fuel Connections Route all hoses away from hot, sharp or moving parts. Check all connections and hoses for damage, leaks, and wear. Fuel Pickup Connection 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.
6-4. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Follow run-in procedure in engine manual. This unit has a low oil pressure shutdown switch. However, some conditions may cause engine dam- age before the engine shuts down.
Start engine. If engine fails to start after 10 seconds, turn unit off and repeat start sequence. Allow engine to warm up prior to loading engine, See Note 1A. When ambient temperatures are below 50°F (10°C), the EnPak goes to 2600 RPM and remains there until the engine has warmed to 100°F (38°C).
SECTION 7 − HYDRAULIC SYSTEM (MODELS WITH HYDRAULIC POWER SOURCE) 7-1. Hydraulic System Integration A. General Information − Minimum Requirements The system recommendations are intended for operating a crane of a low duty cycle, such as used on a mechanics truck. The system recommenda- tions are based on intermittent use.
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Obtain hoses of the proper length and type with appropriate fittings for the installation according to Table 7-1. Table 7-1. Hydraulic Hoses Specifications Hydraulic Hoses System Flow Rate Hose ID Minimum Minimum Vacuum Service Operating Working Burst Temperature Pressure Pressure in.
7-2. Hydraulic Hose Connections Hydraulic fluid is flammable. Do not work on hydraulics near sparks or flames; do not smoke near hydraulic fluid. Route all hoses away from hot, sharp or moving parts. Check all connections and hoses for damage, leaks, and wear.
7-3. Priming Hydraulic Pump 265 795-A / 265 802−A / 260 718B Check to be sure hydraulic pump case oil Turn the manual override screw fully coun- When working on unit, always is at its highest point. terclockwise. move Manual/Remote switch to Manual position to prevent remote Fully open suction line valve at the reser- Place the Service Panel Manual/Remote...
For both open and closed centered systems: Placing the crane pendant speed switch in the low speed position will lock the EnPak at 2600 RPM for crane loads. If other loads are applied at the same time, the EnPak will go to the required RPM. When the EnPak is locked at 2600 RPM for crane loads, the hydraulic output is limited to a maximum of 6.5 GPM (open center) or 10 GPM (closed center).
7-6. Load Sense Line Bleeding (Closed Center Systems Only) Load Sense Line Bleeding Valve For systems utilizing closed−center valving and load sensing, the load sense line must be bled of air near the pump. This is accomplished us- ing the push−activated valve on the load sense line.
SECTION 8 − COMPRESSOR SYSTEM 8-1. Air Compressor System Integration A. General Information − Minimum Requirements For use with a mechanics truck crane, the system should at a minimum include the following items: Reservoir of 20 gal (76 L) or more capacity Safety relief valve Properly sized hoses and fittings, restrained and protected Depending on the desired compressed air quality, air conditioning components such as separators, filters or dryers may be required.
8-2. Compressor Connections Stop engine and release air pressure before servicing compressor. Air Compressor Connection Connect and secure hose. After hand-tightening connections, tight- en 2 to 3 full turns. Tools Needed: 1-1/6 in. (27 mm) 265 802-A / 287 097 OM-261050 Page 35...
8-3. Compressor Prestart Checks or hot air recirculation. The unit is shipped with oil in the com- Do not open oil fill cap until unit is pressor reservoir. Oil level sight gauge off and pressure in the compressor NOTICE − Do not mix oil types. Do not shows oil level.
8-4. Air Compressor Controls Adjust system maximum pressure and minimum pressure using Remote Panel. 265 802-A / 248 998 The compressor is also equipped with a The air pressure gauge reads the air Pressure is factory set for 120 psi. mechanical safety valve (P−SV) that will compressor case pressure.
8-5. Compressor Blow Down For compressor blow down to automatically function, the En- Pak engine must be running. Before maintaining com- pressor, manually release compressor case pressure. To control the release of air in the compressor, the compressor goes through a blow down cycle. Blow down depressurizes the com- pressor case when not compress- ing air;...
Always connect a ground wire from the auxiliary power system ground to bare metal on the ve- hicle frame as shown. Existing Green or Use only Miller-recommended Green/Striped Lead GFCI receptacles (see Parts List). The generator does not provide usable power at engine GND/PE idle speed (1800 rpm).
9-2. EnVerter Power System Connections And Overload Protection Stop engine and let cool. Keep wiring away from hot, sharp, or moving parts. Terminal Block 1T 120 VAC EnVertert power is available between 1TF and 1TD. Combined output of all EnVerter power loads cannot exceed 2.4 kVA/kW.
If the electric machine that you are using is not recognized as a load by the EnPak, and does not turn on, place the EnPak in high speed. This will bring the output of the generator up to the nor-...
NOTICE − Connect to this receptacle only Optional Engine Remote Start/Stop Us- when EnPak is equipped with hydraulic The EnPak control will detect a ground sig- ing Ground Signal power source used to power a hydraulic nal and will start the engine if it is not run- crane apparatus.
10-4. Safety Interlock Models With Hydraulic Power Source: The safety interlock system must be engaged before the EnPak engine can be started Contact dealer for detailed description of supplied system. Models Without Hydraulic Power Source: The safety interlock system requires 12 volts DC be supplied from the accessory position of the truck ignition switch to pin 5 of RC13.
10-5. Operation And Error Messages 248 998 Alpha−Numeric Display Hi TEMP Indicates coolant sensor is shorted. The following operational messages Indicates high compressor temperature if ALTRNATR may appear: CHECK COMPRESSOR LED is on. Indicates an open condition in the alternat- OVErPRES CHNG OIL Indicates the compressor has an over pres-...
100°F. Once it has If the EnPak engine is turned off using the reached that temperature, the auto start/ d) If an air tool is used, and the air com- Remote Panel Engine Off push button or stop feature is activated if it is enabled.
10-7. Service Panel 260 718 Manual/Remote Switch Low position is 2600 RPM and is used Compressor Pressure LED when light loads are present. When working on unit, always Indicates the compressor pressure is too Fuel Pump Switch move Manual/Remote switch to high.
10-8. Kubota D902 Engine Fault Code Guide Multiple error codes will display one after If a blink code is present, the engine If error message appears, consult the other. does not start or starts and then shuts troubleshooting section for remedial down in 10 seconds.
SECTION 11 − MAINTENANCE 11-1. Maintenance Label When working on unit, always move Manual Remote switch on Service Panel to Manual position to prevent remote starting. OM-261050 Page 49...
11-2. Routine Maintenance Replace engine and air compressor oil and filters after the first 50 hours of operation. Use information displayed on the Alpha−Numeric display to assist in scheduling maintenance (see Section 10-2). Engine speed is regulated by an electronic governor. Engine speed adjustments may only be performed by the engine manufacturer’s Factory Authorized Service Agent.
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n = Check Z = Change ~ = Clean Reference * If unit is so equipped Every Engine Manual Hours n Valve Clearance Every Section 1000 11-5 Hours Yearly Z Air/Oil Separator Z Hydraulic Fluid* Z Air Cleaner Element Every Section 2000 11-5...
11-3. Servicing Air Cleaner Stop engine. NOTICE − Do not run engine without air cleaner or with dirty element. Engine damage caused by using a damaged ele- ment is not covered by the warranty. The air cleaner primary element can be cleaned but the dirt holding capac- ity of the filter is reduced with each cleaning.
11-4. Changing Engine Oil, Oil Filter, And Fuel Filters Stop engine and let cool. Oil Drain Valve Oil drain valve can exit either side of base. Tools Needed: Oil Filter Change engine oil and filter accord- ing to engine manual. Close valve and valve cap before adding oil and run- ning engine.
11-5. Changing Compressor Oil, Air Cleaner, And Air/Oil Separator Stop engine. Do not open oil fill cap until unit has been off for 10 minutes and pressure in the case has been released according to Section 8-5. Do not open while running. Do not run air compressor without air cleaner or with dirty element.
Check with dealer for detailed descrip- 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.
Factory) Device using regular generator auxili- Engine speed too low and load is not recognized. Using crane remote or EnPak remote panel, manu- ary power does not work. ally place engine in high speed (see Section 10-2 item 7 for EnPak remote panel).
100°F. Have Factory Authorized Service Agent check circuit board PC1 and current transformer CT1. Engine speed does not remain con- GFCI receptacle is not proper type for application. Replace with Miller approved GFCI device (Con- stant. tact Factory).
Trouble Remedy 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. Change oil and filter. Use only recommended oil. Have Factory Authorized Service Agent check thermostat operation.
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Trouble Remedy No outrigger operation. No oil in system. Add oil. Suction line valve closed. Open valve. Hydraulic system not primed. Prime system (see Section 7-3). Check reservoir height meets require- ments of Section 7-1. Flow control valve H−FC1 not functioning. Check to make sure solenoid is plugged in. Check wiring harness to solenoid coil.
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NOTICE − 240 V circuit and EnVerter power are protected at the listed cur- rent by supplementary protectors located next to 1T inside EnPak. Any type GFCI may be used for the EnVerter 120 V circuit. If a plug-in adapter is used to split 120 VAC from the 240 VAC receptacle, it must follow the same guide- lines as Notice above.
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238 945-B1 Figure 13-6. Hydraulic Circuit Diagram Page 1 (Models With Hydraulic Power Source) OM-261050 Page 65...
SECTION 14 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown. 14-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...
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14-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #8 AWG or larger insulated copper wire. GND/PE Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
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14-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
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14-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in. 3/8 in. 1/2 in. Circular Saw 6-1/2 in. 7-1/4 in. 8-1/4 in. 1400 1400 Table Saw 9 in. 4500 1500 10 in. 6300 1800 Band Saw 14 in.
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14-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
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14-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install, ground, and operate this equipment ac- cording to its Owner’s Manu- al and national, state, and lo- cal codes.
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14-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Use GFCI protection when operating auxiliary equipment. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes)
SECTION 15 − PARTS LIST Hardware is common and not available unless listed. Unit shown is fully equipped. Some parts may not be applicable on units without hydraulic power source. Figure 15-2 Figure 15-1. Main Assembly OM-261050 Page 76...
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257926 Label, Ckt Enpak Mechanic Series ........
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Some wiring harness components (switches, relays, supplementary protectors) are also referenced elsewhere in this parts list. Purchase components separately or as part of the associated wiring harness. Item Dia. Part Mkgs. Description Quantity Wiring Harnesses ....260912 Harness, Wrg Unit (Includes) .
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Hardware is common and not available unless listed. 265 799 Figure 15-2. Controls/Remote Assemblies OM-261050 Page 80...
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..White ... . . GF20WLA MILLER Recommended Circuit Breaker For 120 VAC Generator Power ..093996 . . .
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Hardware is common and not available unless listed. *Recommended Spare Parts BOLD callouts are part of air compressor assembly 260 845 265 804-A Figure 15-3. Air Compressor OM-261050 Page 82...
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Item Dia. Part Mkgs. Description Quantity Figure 15-3. Air Compressor ....260845 Assy, Compressor Ev02−Nk ........
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Hardware is common and not available unless listed. 265 795-A Figure 15-4. Hydraulic System Open Center (If Equipped) Item Dia. Part Mkgs. Description Quantity Figure 15-4. Hydraulic System Open Center (If Equipped) ... . . *239316 Belt, Micro−V 8 Rib .
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Hardware is common and not available unless listed. 265 795-A Figure 15-5. Hydraulic System Closed Center (If Equipped) Item Dia. Part Mkgs. Description Quantity Figure 15-5. Hydraulic System Closed Center (If Equipped) ... . . *262560 Belt, Micro−V 8 Rib .
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Hardware is common and not available unless listed. 272 777-A Figure 15-6. Housing Assembly With Shaft And Bearing (Models Without Hydraulic Power Source) Item Dia. Part Mkgs. Description Quantity Figure 15-6. Housing Assembly With Shaft And Bearing (Models Without Hydraulic Power Source) .
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Hardware is common and not available unless listed. 265 800-A Figure 15-7. Engine Item Dia. Part Mkgs. Description Quantity Figure 15-7. Engine ... . . 239077 Muffler, Exhaust Engine ..........
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........*Recommended Spare Parts. ◊ Use Loctite® 242 (MILLER Part No. 009 425) to secure when replacing these parts. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts.
Effective January 1, 2016 (Equipment with a serial number preface of MG or newer) This limited warranty supersedes all previous EnPak warranties and is exclusive with no other guarantees or warranties expressed or implied. LIMITED WARRANTY − Subject to the express terms In the event of a warranty claim covered by this Limited and conditions set forth below, Miller Electric Mfg.
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(Date which equipment was delivered to original customer.) Distributor Address City State Visit www.MillerWelds.com/EnPak to locate an EnPak supplier. Contact your Truck Equipment Distributor for: Options and Accessories Service and Repair Replacement Parts Training (Schools, Videos, Books) Technical Manuals (Servicing Information and Parts) Circuit Diagrams Always provide Model Name and Serial/Style Number.
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