Miller Electric CBI 801D manual Maintenance

Page 28

SECTION 8 − MAINTENANCE

8-1. ROUTINE MAINTENANCE (Table 8-1)

C. Oil, Filter, And Drain

IMPORTANT: Every six months inspect the labels on this unit for legibility. All precautionary labels must be maintained in a clearly readable state and replaced when necessary. See the Parts List for part numbers of precautionary labels.

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

•Stop engine, and disconnect negative (−) battery cable from battery before inspecting, maintaining, or servicing.

MOVING PARTS can cause serious injury.

•Keep away from moving parts such as fans, belts, and rotors.

HOT ENGINE PARTS can cause severe burns.

•Wear protective gloves and clothing when working on a hot engine.

BATTERY ACID can burn eyes, skin, destroy clothing, and damage other material.

•Wear correct eye and body protection.

Maintenance to be performed only by qualified persons.

A. Cables And Wiring

WARNING: Read and follow safety informa- tion at beginning of entire Section 8-1 before proceeding.

Check interconnecting wiring and connections for tightness and flaws. Be sure that the weld output cable connections are clean and tight. Check the insulation for breaks or other signs of damage. Repair or replace cables or wiring as necessary.

B. Battery

WARNING: Read and follow safety informa- tion at beginning of entire Section 8-1 before proceeding.

Inspect the battery for loose connections, damaged cables, corrosion, cracked case or cover, loose holddowns, and loose or deformed terminal posts.

Clean and tighten connections, replace cables, or replace battery if necessary.

WARNING: Read and follow safety informa- tion at beginning of entire Section 8-1 before proceeding.

The engine is equipped with a full-flow oil filter. Change the oil and filter according to instructions on unit mainte- nance label and in engine Owner’s Manual (Deutz F4L-912 engine). Use correct type and grade of oil as listed in instructions for expected temperature range be- fore next oil and filter change.

This unit is equipped with an oil drain hose secured in a clamp behind the rear panel. A valve is provided in the hose inside the right side base rail. To drain oil from en- gine, remove drain hose from clamp and open valve. Close valve and reinstall hose into clamp before adding new oil.

IMPORTANT: This engine is equipped with an Oil Pres- sure Shutdown gauge/switch and an Oil Temperature Shutdown gauge/switch. If oil pressure becomes too low or oil temperature rises to a level that may cause en- gine damage, the respective gauge/switch shuts down the unit. The shutdown oil pressure has been factory set at 30 psi (207 kPa), and the shutdown oil temperature has been set at 265° F (130° C).

D. Cleaning And Inspecting

WARNING: Read and follow safety informa- tion at beginning of entire Section 8-1 before proceeding.

When performing routine oil changes at intervals specified on the unit maintenance label, clean and inspect the unit as follows:

1.Keep the inside of the welding generator clean by blowing out the unit with clean, dry compressed air.

2.Wipe oil and fuel spills from engine immediately to avoid accumulation of dust.

3.Check for fluid leaks indicating loose oil or fuel connections. Tighten loose connections, and clean oil or fuel spills off engine.

IMPORTANT: See the engine Owner’s Manual (Deutz F4L-912 engine) for complete engine care.

 

Table 8-1. Maintenance Schedule

Frequency*

Maintenance

 

 

Every day.

Check fuel and oil levels (see Sections 4-4, 4-5, and 8-1C, and engine Owner’s Manual,

 

Deutz F4L-912 engine).

Every 100 to 150 hours.

Change oil and filter (see engine Owner’s Manual, Deutz F4L-912 engine).

 

Check cables, wiring (see Section 8-1A), and battery (see Section 8-1B).

 

 

 

Units in heavy service environments: Check labels; clean and inspect unit (see Section 8-1).

 

 

 

Change fuel/water separator (see Section 8-3).

 

 

Every 250 hours.

Check and clean spark arrestor muffler (see Section 8-11).

 

 

Every 1000 hours.

Replace fuel filter (see Section 8-4).Check brushes and slip rings (see Section 8-9).

 

Check all labels (see IMPORTANT block, Section 8-1). Clean and inspect unit (see Section 8-1D).

 

 

*Frequency of service is based on unit operated 40 hours per week. Increase frequency of maintenance if usage exceeds 40 hours per week. OM-166 941 Page 23

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Contents
OM-166 941C ProcessesDescription Per NsprWarranty Page Table of Contents − Maintenance − Troubleshooting− Electrical Diagrams − Parts List− Safety Rules for Operation of ARC Welding Power Source General PrecautionsIntroduction Burn PreventionFire and Explosion Prevention Compressed Gas EquipmentLeaving Equipment Unattended User ResponsibilitiesRope Staging-Support Burn Protection ARC WeldingShock Prevention Standards Booklet Index − Safety Precautions and Signal Words General Information and SafetySafety Safety Alert Symbol and Signal Words− Specifications OCVDuty Cycle − Installation or RelocationDescription Exhaust Extension Installation Connecting the BatteryLifting Of Equipment Trailer MountingGround Equipment Grounding TerminalRated Weld Output Positive NegativeRemote Feeder AMPERAGE/VOLTAGE Output Contactor Remote Control ConnectionsRemote 9 Receptacle Information And Connections Figures 4-2 Wire remote control cord directly to terminal strip Tion CWithin unit according to Section B Remote Terminal Strip 3T InformationAIR Compressor Connections Ether Starting AID OptionalPosure to Ether can seriously harm Your health− Auxiliary Power Power Output Electric Sparks can cause fireLOW Voltage and Frequency can dam- age electrical equipment GeneralAmperage & Voltage Adjustment Amperage and Voltage Adjustment− Operator Controls Panel Remote RUNRemote Output Contactor Battery Magnetic Shutdown SwitchBroken Cooling Belt Shutdown Switch Fuel − Sequence of Operation ARC Rays can burn eyes and skin Noise can damage hearing Fumes and Gases can seriously harm your health Shielded Metal ARC Welding SmawAuxiliary Power Operation AIR Carbon ARC Cutting and Gouging CAC-A TableAIR Compressor Operation Tables 7-2 Starting the EngineStopping the Engine Flow Of Free Air CFM Through Orifices Of Various DiametersMiscellaneous − Maintenance Deutz F4L912 Diesel Engine AIR Cleaner Service Table Air Cleaner ServiceBattery Replacement Procedure FUEL/WATER Separator and Sludge Drain PlugFuel/Water Separator Sludge Drain PlugEngine Speed Adjustments Figure MAINTENANCE-FREE Battery CHARG- INGGovernor Brush Replacement Ether Starting AID Optional Brushes and Slip Rings FigureRun-In Procedure Using Load Bank Diagram RUN-IN ProcedureMoving Parts can cause severe injury Diagram 8-1. Load Bank Connections Run-In Procedure Using Resistance Grid Dia- gramDiagram 8-2. Resistance Grid Connections − TroubleshootingBooster Battery Jump Starting Overload Protection Figure Moving Parts can cause serious personal injuryIncorrect Fuse can damage unit Circuit Breaker CB1 FigureWeld/Power Troubleshooting Troubleshooting Tables 9-1 ThruTrouble Probable Cause Remedy Auxiliary Power Troubleshooting Auxiliary Power Probable Cause Remedy TroubleEngine Troubleshooting Air Compressor TroubleshootingOM-166 941 − Electrical Diagrams Diagram 10-1. Circuit Diagram For Welding GeneratorSC-168 908-B 11-2 − Parts List66 Fig 1A. Main Assembly 073 FITTING, brs barbed M 3/16tbg x 1/4NPT 0456660009309 1B. Main Assembly 811 6563 62 21 22 15 141532480009309 18 17 16 Includes Item Panel, Front w/ComponentsPanel, Front w/Components -1A Item Panel, Lower Front w/Components Panel, Lower Front w/Components 1A Item Control Box -1A Item Generator -1B Item
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