Miller Electric CBI 801D Safety Precautions and Signal Words, General Information and Safety

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5.ANSI Standard Z41.1, STANDARD FOR MEN’S SAFETY-TOE FOOTWEAR obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018.

6.ANSI Standard Z49.2, FIRE PREVENTION IN THE USE OF CUTTING AND WELDING PROC- ESSES obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018.

7.AWS Standard A6.0, WELDING AND CUTTING CONTAINERS WHICH HAVE HELD COMBUS- TIBLES obtainable from the American Welding Society, 550 N.W. LeJeune Rd, Miami, FL 33126.

8.NFPA Standard 51, OXYGEN-FUEL GAS SYS-

TEMS FOR WELDING, CUTTING, AND ALLIED PROCESSES obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

9.NFPA Standard 70, NATIONAL ELECTRICAL CODE obtainable from the National Fire Protec- tion Association, Batterymarch Park, Quincy, MA 02269.

10.NFPA Standard 51B, CUTTING AND WELDING PROCESSES obtainable from the National Fire Protection Association, Batterymarch Park, Quincy, MA 02269.

11.CGA Pamphlet P-1, SAFE HANDLING OF COMPRESSED GASES IN CYLINDERS obtain- able from the Compressed Gas Association, 1235 Jefferson Davis Highway, Suite 501, Ar- lington, VA 22202.

12.CSA Standard W117.2, CODE FOR SAFETY IN WELDING AND CUTTING obtainable from the Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, On- tario, Canada M9W 1R3.

13.NWSA booklet, WELDING SAFETY BIBLIOG- RAPHY obtainable from the National Welding Supply Association, 1900 Arch Street, Philadel- phia, PA 19103.

14.American Welding Society Standard AWSF4.1,

RECOMMENDED SAFE PRACTICES FOR THE PREPARATION FOR WELDING AND CUTTING OF CONTAINERS AND PIPING THAT HAVE HELD HAZARDOUS SUB- STANCES, obtainable from the American Weld- ing Society, 550 N.W. LeJeune Rd, Miami, FL 33126.

15.ANSI Standard Z88.2, PRACTICE FOR RESPI- RATORY PROTECTION, obtainable from the American National Standards Institute, 1430 Broadway, New York, NY 10018.

SECTION 2 − SAFETY PRECAUTIONS AND SIGNAL WORDS

2-1. GENERAL INFORMATION AND SAFETY

A. General

Information presented in this manual and on various la- bels, tags, and plates on the unit pertains to equipment design, installation, operation, maintenance, and troubleshooting which should be read, understood, and followed for the safe and effective use of this equipment.

The nameplate of this unit uses international symbols for labeling the front panel controls. The symbols also appear at the appropriate section in the text.

B. Safety

The installation, operation, maintenance, and trouble- shooting of arc welding equipment requires practices and procedures which ensure personal safety and the safety of others. Therefore, this equipment is to be in- stalled, operated, and maintained only by qualified per- sons in accordance with this manual and all applicable codes such as, but not limited to, those listed at the end of Section 1 − Safety Rules For Operation Of Arc Weld- ing Power Source.

2-2. SAFETY ALERT SYMBOL AND SIGNAL WORDS

The following safety alert symbol and signal words are used throughout this manual to call attention to and identify different levels of hazard and special instruc- tions.

This safety alert symbol is used with the signal words WARNING and CAUTION to call atten- tion to the safety statements.

WARNING statements identify procedures or practices which must be followed to avoid seri- ous personal injury or loss of life.

CAUTION statements identify procedures or practices which must be followed to avoid minor personal injury or damage to this equipment.

IMPORTANT statements identify special instructions necessary for the most efficient operation of this equip- ment.

OM-166 941 Page 6

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Per Nspr OM-166 941CProcesses DescriptionWarranty Page Table of Contents − Parts List − Maintenance− Troubleshooting − Electrical DiagramsBurn Prevention − Safety Rules for Operation of ARC Welding Power SourceGeneral Precautions Introduction Compressed Gas Equipment Fire and Explosion PreventionRope Staging-Support User ResponsibilitiesLeaving Equipment Unattended Shock Prevention ARC WeldingBurn Protection Standards Booklet Index Safety Alert Symbol and Signal Words − Safety Precautions and Signal WordsGeneral Information and Safety SafetyOCV − SpecificationsDescription − Installation or RelocationDuty Cycle Trailer Mounting Exhaust Extension InstallationConnecting the Battery Lifting Of EquipmentEquipment Grounding Terminal GroundPositive Negative Rated Weld OutputRemote 9 Receptacle Information And Connections Figures 4-2 Remote Control ConnectionsRemote Feeder AMPERAGE/VOLTAGE Output Contactor Remote Terminal Strip 3T Information Wire remote control cord directly to terminal stripTion C Within unit according to Section BYour health AIR Compressor ConnectionsEther Starting AID Optional Posure to Ether can seriously harmGeneral − Auxiliary Power Power OutputElectric Sparks can cause fire LOW Voltage and Frequency can dam- age electrical equipment− Operator Controls Amperage and Voltage AdjustmentAmperage & Voltage Adjustment Remote Output Contactor RUNPanel Remote Fuel BatteryMagnetic Shutdown Switch Broken Cooling Belt Shutdown SwitchShielded Metal ARC Welding Smaw − Sequence of OperationARC Rays can burn eyes and skin Noise can damage hearing Fumes and Gases can seriously harm your healthStarting the Engine Auxiliary Power OperationAIR Carbon ARC Cutting and Gouging CAC-A Table AIR Compressor Operation Tables 7-2Flow Of Free Air CFM Through Orifices Of Various Diameters Stopping the EngineMiscellaneous − Maintenance Deutz F4L912 Diesel Engine Air Cleaner Service AIR Cleaner Service TableSludge Drain Plug Battery Replacement ProcedureFUEL/WATER Separator and Sludge Drain Plug Fuel/Water SeparatorGovernor MAINTENANCE-FREE Battery CHARG- INGEngine Speed Adjustments Figure Brushes and Slip Rings Figure Brush Replacement Ether Starting AID OptionalMoving Parts can cause severe injury RUN-IN ProcedureRun-In Procedure Using Load Bank Diagram Run-In Procedure Using Resistance Grid Dia- gram Diagram 8-1. Load Bank ConnectionsBooster Battery Jump Starting − TroubleshootingDiagram 8-2. Resistance Grid Connections Circuit Breaker CB1 Figure Overload Protection FigureMoving Parts can cause serious personal injury Incorrect Fuse can damage unitTrouble Probable Cause Remedy Troubleshooting Tables 9-1 ThruWeld/Power Troubleshooting Air Compressor Troubleshooting Auxiliary Power TroubleshootingAuxiliary Power Probable Cause Remedy Trouble Engine TroubleshootingOM-166 941 Diagram 10-1. Circuit Diagram For Welding Generator − Electrical DiagramsSC-168 908-B 66 Fig − Parts List11-2 1A. Main Assembly 073 FITTING, brs barbed M 3/16tbg x 1/4NPT 0456660009309 1B. Main Assembly 6563 62 21 22 15 14 8111532480009309 Panel, Front w/Components 18 17 16 Includes ItemPanel, Front w/Components -1A Item Panel, Lower Front w/Components Panel, Lower Front w/Components 1A Item Control Box -1A Item Generator -1B Item