Miller Electric CBI 801D manual Troubleshooting Tables 9-1 Thru, Weld/Power Troubleshooting

Page 38

9-5. TROUBLESHOOTING (Tables 9-1 Thru 9-4)

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

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

MOVING PARTS can cause serious injury.

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

HOT ENGINE PARTS can cause severe burns.

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

Troubleshooting to be performed only by quali- fied persons.

The following tables are designed to diagnose and pro- vide remedies for some of the troubles that may develop in this welding generator.

Use these tables in conjunction with the circuit diagram while performing troubleshooting procedure. If the trouble is not remedied after performing these proce- dures, contact the nearest Factory Authorized Service Station/Service Distributor. In all cases of equipment malfunction, strictly follow the manufacturer’s proce- dures and instructions.

Table 9-1. Weld/Power Troubleshooting

TROUBLE

PROBABLE CAUSE

REMEDY

 

 

 

 

 

 

No weld output.

Amperage Ranges switch S9

Place S9 in LOW OUTPUT or HIGH OUTPUT

 

between positions.

position (see Section 6-1).

 

 

 

 

 

OUTPUT

(CONTACTOR)

Place S5 in ON position, or install Remote Con-

 

switch S5 in REMOTE position

tactor Control device.

 

and Remote Contactor device

 

 

not connected.

 

 

 

 

 

 

Incorrect or poor connection to REMOTE 9 receptacle or termi- nal strip 3T.

Check and secure connections (see Section 4-8).

 

Circuit breaker CB3 open

Reset CB3 (see Section 9-3).

 

(GMAW only).

 

 

 

 

 

Poor contact between slip rings

Clean slip rings (see Section 8-9).

 

and brushes.

 

 

 

 

 

 

Replace brushes according to Section 8-9.

 

 

 

 

Field Current Regulator board

See Section 9-4, and contact nearest Factory

 

PC1.

Authorized Service Station/Service Distributor.

 

 

 

Erratic weld output.

Loose or dirty connections.

Check connections both inside and outside the

 

 

unit.

 

 

 

 

Connection at work.

Check connection. Be sure connection is clean

 

 

and tight.

 

 

 

Damp electrode.

Use dry, properly stored electrode.

 

Field Current Regulator board

See Section 9-4, and contact nearest Factory

 

PC1.

Authorized Service Station/Service Distributor.

 

 

 

 

Electrode polarity.

See Section 4-7C.

 

 

 

High welding output voltage.

High engine speed.

Check and adjust engine speed according to

 

 

Section 8-8.

 

 

 

 

Field Current Regulator board

See Section 9-4, and contact nearest Factory

 

PC1.

Authorized Service Station/Service Distributor.

 

 

 

Wire feeder inoperative.

Circuit breaker CB3.

Reset CB3 according to Section 9-3.

 

 

 

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Contents Description OM-166 941CProcesses Per NsprWarranty Page Table of Contents − Electrical Diagrams − Maintenance− Troubleshooting − Parts ListIntroduction − Safety Rules for Operation of ARC Welding Power SourceGeneral Precautions Burn PreventionFire and Explosion Prevention Compressed Gas EquipmentRope Staging-Support User ResponsibilitiesLeaving Equipment Unattended Shock Prevention ARC WeldingBurn Protection Standards Booklet Index Safety − Safety Precautions and Signal WordsGeneral Information and Safety Safety Alert Symbol and Signal Words− Specifications OCVDescription − Installation or RelocationDuty Cycle Lifting Of Equipment Exhaust Extension InstallationConnecting the Battery Trailer MountingGround Equipment Grounding TerminalRated Weld Output Positive NegativeRemote 9 Receptacle Information And Connections Figures 4-2 Remote Control ConnectionsRemote Feeder AMPERAGE/VOLTAGE Output Contactor Within unit according to Section B Wire remote control cord directly to terminal stripTion C Remote Terminal Strip 3T InformationPosure to Ether can seriously harm AIR Compressor ConnectionsEther Starting AID Optional Your healthLOW Voltage and Frequency can dam- age electrical equipment − Auxiliary Power Power OutputElectric Sparks can cause fire General− Operator Controls Amperage and Voltage AdjustmentAmperage & Voltage Adjustment Remote Output Contactor RUNPanel Remote Broken Cooling Belt Shutdown Switch BatteryMagnetic Shutdown Switch FuelFumes and Gases can seriously harm your health − Sequence of OperationARC Rays can burn eyes and skin Noise can damage hearing Shielded Metal ARC Welding SmawAIR Compressor Operation Tables 7-2 Auxiliary Power OperationAIR Carbon ARC Cutting and Gouging CAC-A Table 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 ServiceFuel/Water Separator Battery Replacement ProcedureFUEL/WATER Separator and Sludge Drain Plug Sludge Drain PlugGovernor MAINTENANCE-FREE Battery CHARG- INGEngine Speed Adjustments Figure Brush Replacement Ether Starting AID Optional Brushes and Slip Rings FigureMoving Parts can cause severe injury RUN-IN ProcedureRun-In Procedure Using Load Bank Diagram Diagram 8-1. Load Bank Connections Run-In Procedure Using Resistance Grid Dia- gramBooster Battery Jump Starting − TroubleshootingDiagram 8-2. Resistance Grid Connections Incorrect Fuse can damage unit Overload Protection FigureMoving Parts can cause serious personal injury Circuit Breaker CB1 FigureTrouble Probable Cause Remedy Troubleshooting Tables 9-1 ThruWeld/Power Troubleshooting Engine Troubleshooting Auxiliary Power TroubleshootingAuxiliary Power Probable Cause Remedy Trouble Air Compressor TroubleshootingOM-166 941 − Electrical Diagrams Diagram 10-1. Circuit Diagram For Welding GeneratorSC-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 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

CBI 801D specifications

The Miller Electric CBI 801D is a robust and sophisticated multi-process welder, designed for maximum efficiency and versatility in various welding applications. This machine stands out due to its combination of advanced technology and user-friendly design, making it suitable for both seasoned professionals and those new to welding.

One of the key features of the CBI 801D is its ability to perform multiple welding processes, including MIG, TIG, and stick welding. This multi-functionality allows users to tackle a wide range of welding tasks, whether they are working on thin sheet metals or heavy fabrication. The seamless transition between processes is designed to enhance productivity and reduce downtime.

The CBI 801D is powered by Miller's innovative Auto-Set technology, which automatically adjusts the machine settings based on the material type and thickness. This feature simplifies the setup process, allowing welders to focus more on their work rather than on configuring the machine. Additionally, the user interface is designed for simplicity, featuring intuitive controls that are easy to navigate.

In terms of performance, the CBI 801D delivers impressive output, with a maximum welding output of 800 amps. This substantial power provides the capability to weld thicker materials with greater efficiency, making it an ideal choice for industrial applications. The built-in advanced cooling system ensures optimal performance during extended use, preventing overheating and maintaining consistent weld quality.

Durability is another hallmark of the Miller Electric CBI 801D. The machine is constructed with high-quality materials, providing resilience against tough working conditions. Its compact and portable design allows for easy transport to various job sites, while the built-in handles are designed for convenience.

Moreover, the CBI 801D features advanced digital readouts for real-time monitoring of welding parameters. This not only enhances precision but also allows welders to make necessary adjustments on the fly. The machine is also compatible with various accessories, which further expand its functionality and adaptability across different welding scenarios.

In summary, the Miller Electric CBI 801D is a powerful and versatile welding machine, offering multi-process capabilities, user-friendly features, and a robust design. Its combination of advanced technology and reliable performance makes it a top choice for professionals looking for efficiency and precision in their welding tasks. Whether for fabrication, repair, or maintenance, the CBI 801D proves to be an invaluable asset in any welding operation.
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