Miller Electric CBI 801D manual Auxiliary Power Troubleshooting, Engine Troubleshooting

Page 39

Table 9-2. Auxiliary Power Troubleshooting

AUXILIARY POWER

PROBABLE CAUSE

REMEDY

TROUBLE

 

 

 

 

 

 

 

 

No 120 volt output at 3T termi-

Circuit breaker CB1 open.

Reset CB1 (see Section 9-3).

nals L and M.

 

 

 

 

 

 

Poor contact between slip

Clean slip rings (see Section 8-9).

 

rings and brushes.

 

 

 

 

 

 

Replace brushes according to Section 8-9.

 

 

 

High auxiliary power output

High engine speed.

Check and adjust engine speed according to

voltage.

 

Section 8-8. (Maximum voltages should not

 

 

exceed 132 volts for single-phase power.)

 

 

 

Table 9-3. Engine Troubleshooting

TROUBLE

PROBABLE CAUSE

REMEDY

 

 

 

 

 

 

Engine does not start.

Out of fuel.

Fill fuel tank, and air vent fuel system (see En-

 

 

gine Manufacturer’s Manual.)

 

 

 

 

Battery problem.

Check engine battery charging system accord-

 

 

ing to engine service manual (not supplied with

 

 

engine).

 

 

 

 

 

Inspect electrical system (see Section 8-1). If

 

 

trouble is isolated to battery, replace it.

 

 

 

 

 

Jump start the engine using approved safety

 

 

practices and booster battery (see Section

 

 

9-2).

 

 

 

 

Engine Control switch S1.

Check S1, and replace if necessary.

 

 

 

 

Oil Pressure gauge/switch or

See Sections 6-10 thru 6-11; see Engine Man-

 

Oil Temperature gauge/switch

ufacturer’s Manual (F4L-912 engine).

 

activated, or other engine

 

 

trouble.

 

 

 

 

 

MS1 fuse F.

Check and replace F, if necessary (see Sec-

 

 

tion 9-3).

 

 

 

Engine suddenly shuts down.

Broken cooling belt.

Check and replace belt (see Section 6-15).

 

 

 

 

High oil temperature.

Check engine oil level and add oil if necessary;

 

 

check for cooling air flow obstructions.

 

 

 

 

Low oil pressure.

Check engine oil level, and add oil if necessary

 

 

(see Section 4-5).

 

 

 

 

MS1 fuse F.

Check and replace F if necessary (see Section

 

 

9-3).

 

 

 

Table 9-4. Air Compressor Troubleshooting

AIR COMPRESSOR

CAUSE

REMEDY

TROUBLE

 

 

 

 

 

 

 

 

Air compressor fails to build

Engine air compressor.

Service air compressor. Contact nearest Au-

pressure or builds pressure

 

thorized Service Station/Service Distributor.

slowly.

 

 

 

 

 

Pneumatic tools freeze up.

Moisture in compressed air.

Induce an antifreeze solution into the air sup-

 

 

ply. Contact nearest Authorized Service Sta-

 

 

tion/Service Distributor.

 

 

 

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Contents 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 IntroductionCompressed Gas Equipment Fire and Explosion PreventionUser Responsibilities Leaving Equipment UnattendedRope Staging-Support ARC Welding Burn ProtectionShock Prevention Standards Booklet Index Safety Alert Symbol and Signal Words − Safety Precautions and Signal WordsGeneral Information and Safety SafetyOCV − Specifications− Installation or Relocation Duty CycleDescription Trailer Mounting Exhaust Extension InstallationConnecting the Battery Lifting Of EquipmentEquipment Grounding Terminal GroundPositive Negative Rated Weld OutputRemote Control Connections Remote Feeder AMPERAGE/VOLTAGE Output ContactorRemote 9 Receptacle Information And Connections Figures 4-2 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 equipmentAmperage and Voltage Adjustment Amperage & Voltage Adjustment− Operator Controls RUN Panel RemoteRemote Output Contactor 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 SeparatorMAINTENANCE-FREE Battery CHARG- ING Engine Speed Adjustments FigureGovernor Brushes and Slip Rings Figure Brush Replacement Ether Starting AID OptionalRUN-IN Procedure Run-In Procedure Using Load Bank DiagramMoving Parts can cause severe injury Run-In Procedure Using Resistance Grid Dia- gram Diagram 8-1. Load Bank Connections− Troubleshooting Diagram 8-2. Resistance Grid ConnectionsBooster Battery Jump Starting Circuit Breaker CB1 Figure Overload Protection FigureMoving Parts can cause serious personal injury Incorrect Fuse can damage unitTroubleshooting Tables 9-1 Thru Weld/Power TroubleshootingTrouble Probable Cause Remedy 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 − Parts List 11-266 Fig 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

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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