Miller Electric CBI 801D Sequence of Operation, Maintenance, Troubleshooting, Electrical Diagrams

Page 5

SECTION 7 − SEQUENCE OF OPERATION

 

7-1.

Shielded Metal Arc Welding (SMAW)

19

7-2.

Gas Metal Arc (GMAW) And Flux Cored Arc Welding (FCAW) . . . .

19

7-3.

Air Carbon Arc Cutting And Gouging (CAC-A)

20

7-4.

Auxiliary Power Operation

20

7-5.

Air Compressor Operation

20

7-6.

Starting The Engine

20

7-7.

Stopping The Engine

21

SECTION 8 − MAINTENANCE

 

8-1.

Routine Maintenance

23

8-2.

Air Cleaner Service

25

8-3.

Fuel/Water Separator And Sludge Drain Plug

26

8-4.

Fuel Filter

26

8-5.

Battery Replacement Procedure

26

8-6.

Maintenance-Free Battery Charging

27

8-7.

Governor

27

8-8.

Engine Speed Adjustments

27

8-9.

Brushes And Slip Rings

28

8-10.

Ether Starting Aid (Optional)

28

8-11.

Spark Arrestor

28

8-12.

Run-In Procedure

29

Diagram 8-1. Load Bank Connections

30

Diagram 8-2. Resistance Grid Connections

31

SECTION 9 − TROUBLESHOOTING

 

9-1.

General

31

9-2.

Booster Battery Jump Starting

31

9-3.

Overload Protection

32

9-4.

Circuit Board Handling Precautions

32

9-5.

Troubleshooting

33

SECTION 10 − ELECTRICAL DIAGRAMS

 

Diagram 10-1. Circuit Diagram For Welding Generator

36

SECTION 11 − PARTS LIST

 

Figure 11-1A. Main Assembly

38

Figure 11-1B. Main Assembly

42

Figure 11-2. Panel, Front w/Components

44

Figure 11-3. Panel, Lower Front w/Components

46

Figure 11-4. Control Box

48

Figure 11-5. Generator

49

 

LIST OF TABLES AND CHARTS

 

Table 3-1. Welding Generator Specifications

7

Chart 3-1. Volt-Ampere Curves

8

Chart 3-2. Air Output Curve

8

Chart 4-1. Fuel Consumption Curve

10

Table 4-1. Weld Cable Size

11

Chart 5-1. AC Power Curve For 120 Volt Terminals

15

Table 7-1. Suggested Electrode Diameter For Amperage Range (CAC-A Only) 20

Table 7-2. Flow Of Free Air (CFM) Through Orifices Of Various Diameters

21

Table 7-3. Approximate Air Consumption (Cubic Feet) Required To Operate

 

Various Pneumatic Equipment At Pressure Range 70-90 P.S.I.G

22

Table 8-1. Maintenance Schedule

23

Table 8-2. Air Cleaner Service

25

Table 9-1. Weld/Power Troubleshooting

33

Table 9-2. Auxiliary Power Troubleshooting

34

Table 9-3. Engine Troubleshooting

34

Table 9-4. Air Compressor Troubleshooting

34

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Contents
Processes OM-166 941C Description Per NsprWarranty Page Table of Contents − Troubleshooting − Maintenance− Electrical Diagrams − Parts ListGeneral Precautions − Safety Rules for Operation of ARC Welding Power SourceIntroduction Burn PreventionCompressed Gas Equipment Fire and Explosion PreventionRope Staging-Support User ResponsibilitiesLeaving Equipment Unattended Shock Prevention ARC WeldingBurn Protection Standards Booklet Index General Information and Safety − Safety Precautions and Signal WordsSafety Safety Alert Symbol and Signal WordsOCV − SpecificationsDescription − Installation or RelocationDuty Cycle Connecting the Battery Exhaust Extension InstallationLifting Of Equipment Trailer MountingEquipment Grounding Terminal GroundPositive Negative Rated Weld OutputRemote 9 Receptacle Information And Connections Figures 4-2 Remote Control ConnectionsRemote Feeder AMPERAGE/VOLTAGE Output Contactor Tion C Wire remote control cord directly to terminal stripWithin unit according to Section B Remote Terminal Strip 3T InformationEther Starting AID Optional AIR Compressor ConnectionsPosure to Ether can seriously harm Your healthElectric Sparks can cause fire − Auxiliary Power Power OutputLOW Voltage and Frequency can dam- age electrical equipment General− Operator Controls Amperage and Voltage AdjustmentAmperage & Voltage Adjustment Remote Output Contactor RUNPanel Remote Magnetic Shutdown Switch BatteryBroken Cooling Belt Shutdown Switch FuelARC Rays can burn eyes and skin Noise can damage hearing − Sequence of OperationFumes and Gases can seriously harm your health Shielded Metal ARC Welding SmawAIR Carbon ARC Cutting and Gouging CAC-A Table Auxiliary Power OperationAIR Compressor Operation Tables 7-2 Starting the EngineFlow Of Free Air CFM Through Orifices Of Various Diameters Stopping the EngineMiscellaneous − Maintenance Deutz F4L912 Diesel Engine Air Cleaner Service AIR Cleaner Service TableFUEL/WATER Separator and Sludge Drain Plug Battery Replacement ProcedureFuel/Water Separator Sludge Drain PlugGovernor 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 Moving Parts can cause serious personal injury Overload Protection FigureIncorrect Fuse can damage unit Circuit Breaker CB1 FigureTrouble Probable Cause Remedy Troubleshooting Tables 9-1 ThruWeld/Power Troubleshooting Auxiliary Power Probable Cause Remedy Trouble Auxiliary Power TroubleshootingEngine Troubleshooting Air Compressor 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
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