Miller Electric CBI 801D Owner'S Manual Download

Page: 46 / 56

OM-166 941 Page 41

Part

No.

Dia.

Mkgs.

Figure 11-1B. Main Assembly

Item

No.

Description

Quantity

1448720009309

BAFFLE, air upper

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006 086

BLANK, snap-in 1.500mtg hole

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See engine manual for replacement parts

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1448200009309

BRACKET, mtg air line to alternator

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138 098

HOSE, sst brd 20.750 lg 3/4NPT M ftg x 3/4NPT M INV

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(same as Item 13 Fig 11-1A)

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192 197

BRACKET, mounting

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1187060009309

AIR LINE, tank to exit

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023 313

CLAMP, hose 3.250-3.000clp dia

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162 625

HOSE, air cleaner

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010 863

CLAMP, hose 2.062-3.000clp dia

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1626660009309

TUBING, air cleaner intake

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073 655

FITTING, pipe brs nipple hex 1/8NPT

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S11

118 067

SWITCH, vacuum air flow

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1371640009309

HOSE, air input

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010 497

CLAMP, hose .750 − 1.750clp dia

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1183490009309

AIR LINE, compressor to tank

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1448300009309

FITTING, pipe brs adapter M 3/4NPSM x 26mm x 1.5

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1448310009309

SEAL, ring copper

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1371790009309

AIR COMPRESSOR, 300cc

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1261620009309

SHIELD, heat compressor

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151 734

ENGINE, Deutz dsl elec

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1065390009309

O-RING

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1065380009146

STARTER, engine 12V

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164 618

SHUTDOWN KIT, rsv type governor

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1528460009309

HOSE, air cleaner elb

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1532490009309

BAFFLE, upper air intake

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1142710009309

COMPOUND, sealant material (order by ft)

5ft

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+1528530010202

COVER, top

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1174860010202

PIPE, exhaust

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122 382

CAP, rain

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108 487

LABEL, warning falling equipment can cause serious injury

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163 226

AIR CLEANER, intake (consisting of)

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021 116

CAP, dust

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004 115

BAFFLE, dust cap

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021 117

NUT, wing

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*020 319

ELEMENT

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021 114

CLAMP ASSEMBLY

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021 115

BAND, mtg

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1528450009309

HOSE, air cleaner elb

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0280890010202

DOOR, access radiator

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147 913

PLATE, ident engine lube oil only

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147 912

PLATE, ident oil specification

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089 178

GROMMET, rbr 3.000 ID x 3.500mtg hole

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049 170

GROMMET, rbr 2.500 ID x 2.750mtg hole

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004 130

BRACKET, support door

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1214130010202

PANEL, end baffle air

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+1453150010202

DOOR, side

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1311870010202

PANEL, engine LH

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146 389

LABEL, diesel engine maintenance

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147 923

LABEL, warning moving parts can cause serious injury

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119 861

LATCH, paddle series 300 w/lock

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1198510010202

PANEL, rocker

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1172190010202

PANEL, side

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149 971

FITTING, pipe brs adapter bhd 1/2NPT x 1.500 lg

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Summary of Contents for CBI 801D

Page 1: ...Processes OM 166 941C July 1999 CBI 801D Per NSPR 10202 Air Carbon Arc CAC A Cutting and Gouging Stick SMAW Welding Flux Cored FCAW Welding Description Engine Driven Welding Generator ...

Page 2: ...il due to normal wear 3 Equipment that has been modified by any party other than manufacturer or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment MANUFACTURER S PRODUCTS ARE INTEND...

Page 3: ......

Page 4: ...n 10 4 6 Equipment Grounding Terminal 10 4 7 Weld Output Connections 11 4 8 Remote Control Connections 12 4 9 Air Compressor Connections 14 4 10 Ether Starting Aid Optional 14 SECTION 5 AUXILIARY POWER 5 1 General 15 5 2 120 Volt Terminals 15 SECTION 6 OPERATOR CONTROLS 6 1 Ampere Ranges Switch 16 6 2 Amperage Voltage Adjustment Control 16 6 3 Engine Control Switch 16 6 4 Remote Amperage Voltage C...

Page 5: ...recautions 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 Spec...

Page 6: ... underneath appropriate filter lenses or plates protected by clear cover glass This is a MUST for welding or cutting and chipping to protect the eyes from radiant energy and flying metal Replace cover glass when broken pitted or spattered See 1 3A 2 Avoid oily or greasy clothing A spark may ignite them Hot metal such as electrode stubs and workpieces should never be handled without gloves Medical ...

Page 7: ...solubility followed by purging and inerting with ni trogen or carbon dioxide and using protective equip ment as recommended in A6 0 Waterfilling just below working level may substitute for inerting A container with unknown contents should be cleaned see preceding paragraph Do NOT depend on sense of smell or sight to determine if it is safe to weld or cut Hollow castings or containers must be vente...

Page 8: ...h regulator to cylinder Before connecting check that the regulator label and cylinder marking area and that the regulator inlet and cylinder outlet match NEVER CONNECT a regulator designed for a particular gas or gases to a cylinder containing any other gas Tighten connections When assembling threaded con nections clean and smooth seats where necessary Tighten If connection leaks disassemble clean...

Page 9: ...ding a sepa rate room or enclosed bay is best In open areas sur round the operation with low reflective non combusti ble screens or panels Allow for free air circulation par ticularly at floor level Viewing the weld Provide face shields for all persons who will be looking directly at the weld Others working in area See that all persons are wearing flash goggles Before starting to weld make sure th...

Page 10: ... electrode wire becomes elec trically HOT when the power source switch is ON and the welding gun switch is closed Never touch the electrode wire or any conducting ob ject in contact with the electrode circuit unless the welding power source is off b Equipment without output on off control no contactor Welding power sources used with shielded metal arc welding SMAW and similar proc esses may not be...

Page 11: ...d 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 d...

Page 12: ...3 kVA kW 60 Hz 26 Amperes At 120 Volts Weight Net Ship 2150 lbs 975 kg 2280 lbs 1034 kg 80 Volts DC Nominal OCV Conforms with NEMA EW1 ANSI C87 1 ELECTRIC ARC WELDING POWER SOURCES Class I 100 A B C D E F G H J Inches 62 3 8 50 1 2 46 1 2 36 28 3 16 13 3 4 9 3 4 6 1 8 29 7 8 Millimeters 1584 1283 1181 914 716 349 248 156 759 K 1 1 16 27 A B C D E F G H J K ST 147 323 B 21 32 in 16 7 mm Dia All Hol...

Page 13: ...an provide up to 3 kVA kW of 120 volts 26 am peres ac electrical power for operating 50 60 Hz or 60 Hz auxiliary equipment while welding This unit is specially prepared for operation in harsh and corrosive environments An optional Ether Starting Aid can be provided on the welding generator and is covered within this Owner s Manual Chart 3 2 Air Output Curve SB 143 883 SECTION 4 INSTALLATION OR REL...

Page 14: ...ling any cover C Spark Arrestor Considerations WARNING ENGINE EXHAUST SPARKS can cause fire Exhaust spark arrestor must be installed in accordance with local state and federal regulations The engine exhaust system on this welding generator is not equipped with a spark arrestor A spark arrestor maintained in effective working order is mandatory if this welding generator is to be operated in a Natio...

Page 15: ...break in oil An oil level indicator is provided on the lower front panel of this unit see Figure 4 2 If oil level is below the lower pointer when engine is running add oil according to the recommendations in the Engine Man ufacturer s Manual F4L 912 engine The oil cap is lo cated under the access door on the top cover IMPORTANT This engine is equipped with an Oil Pres sure Shutdown gauge switch an...

Page 16: ...r connecting to work clamp electrode holder or wire feeder and weld output terminals 3 Install work clamp onto cable C Weld Output Connections POSITIVE NEGATIVE WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Stop engine and disconnect negative bat tery cable before making any weld output connections MOVING PARTS can cause serious injury Keep away from moving parts such as fans ...

Page 17: ... see wire feeder Owner s Manual for location 4 Close and secure front panel access door 4 8 REMOTE CONTROL CONNECTIONS A Remote 9 Receptacle Information And Connections Figures 4 2 And 4 3 REMOTE 9 FEEDER AMPERAGE A V OUTPUT CONTACTOR VOLTAGE REMOTE 9 receptacle RC3 located under the lower front panel access door see Figure 4 2 is provided to connect any of the following equipment to the welding g...

Page 18: ...Connect leads to terminal strip 3T using terminal information provided in Section C 7 Secure the cord in the strain relief 8 Close and secure door C Socket Terminal Information Figure 4 4 The following lists the functions of the sockets of RE MOTE 9 receptacle RC3 see Figure 4 3 and the termi nals of strip 3T see Figure 4 4 The following socket terminal information is provided in case it is necess...

Page 19: ...tions on the cylinder when handling ether compo nents IMPORTANT Before installing the ether cylinder clean nozzle on ether cylinder and fitting into which the ether cylinder is inserted If dirt is present in either of these ar eas the system may not work 1 Open and secure right rear side door 2 If applicable remove protective cap from ether valve or remove old ether cylinder from unit 3 Loosen cyl...

Page 20: ... stopping the engine has low speed which causes low voltage and frequency 5 1 GENERAL Calculate load requirements before connecting equip ment to the auxiliary power terminals on terminal strip 3T For best performance voltage and frequency regu lation limit connected load to approximately 90 of generator capability A brief period less than 5 seconds of large current draw is required for starting m...

Page 21: ...Engine Control Switch Check Alternator Light Output Contactor Switch Ammeter Voltmeter Remote Amperage Voltage Switch Service Engine Air Cleaner Light Amperage Voltage Adjustment Control Ref ST 147 322 E Ampere Ranges Switch Figure 8 1 Operator Controls 6 1 AMPERE RANGES SWITCH Figure 6 1 The Ampere Ranges switch provides two coarse am perage ranges When in LOW OUTPUT amperage range is 100 350 amp...

Page 22: ...TMENT control to the maximum position If remote amperage or voltage is not desired place the AMPERAGE VOLTAGE switch in the PANEL posi tion Only the AMPERAGE VOLTAGE ADJUST MENT control will adjust output 6 5 OUTPUT CONTACTOR SWITCH Figure 6 1 REMOTE OUTPUT CONTACTOR ON WARNING ELECTRIC SHOCK can kill Do not touch live electrical parts Do not touch the output terminals when the contactor is energi...

Page 23: ...Y GAUGE Figure 6 1 BATTERY The BATTERY voltmeter registers the alternator supplied output voltage to the battery The meter should always register 12 15 volts dc while the engine is run ning If the voltage is outside this range stop the engine and determine the cause Do not operate the engine un til the trouble has been corrected 6 14 METERS Figure 6 1 The meters are provided to monitor the welding...

Page 24: ...r Source for basic welding safety information 7 1 SHIELDED METAL ARC WELDING SMAW WARNING Read and follow safety informa tion at beginning of entire Sections 5 and 7 before proceeding 1 Install and connect unit according to Section 4 2 Wear dry insulating gloves and clothing 3 Connect work clamp to clean bare metal at workpiece 4 Select proper electrode 5 Set Ampere Ranges switch and rotate AMPER ...

Page 25: ...ding to Section 5 9 Place Engine Control switch in the RUN position 10 Energize auxiliary equipment if applicable 11 Wear welding helmet with proper filter lens ac cording to ANSI Z49 1 12 Begin welding Table 7 1 Suggested Electrode Diameter For Amperage Range CAC A Only Electrode Diameter Amperage Range Inches Millimeters Minimum Maximum 1 8 3 2 30 60 5 32 4 0 90 150 3 16 4 8 200 250 1 4 6 4 300 ...

Page 26: ...weld or power load applied 7 7 STOPPING THE ENGINE 1 Stop all operations and turn off or disconnect any auxiliary equipment WARNING HIGH CONCENTRATION OF SHIELDING GAS can harm health or kill Shut off gas supply when not in use 2 Rotate Engine Control switch to the OFF posi tion Table 7 2 Flow Of Free Air CFM Through Orifices Of Various Diameters Gauge Pressure In Receiver lbs Orifice Diameter And...

Page 27: ...edium 3 6 6 0 8 4 24 HAMMERS Horizontal Grinder 2 3 0 5 0 7 0 20 Scaling Hammer 1 3 3 0 4 2 12 Horizontal Grinder 4 9 0 15 0 21 0 60 Chipping Hammer 4 5 7 5 10 5 30 Horizontal Grinder 6 9 0 15 0 21 0 60 Riveting Hammer Light 2 25 3 75 5 25 15 Horizontal Grinder 8 12 0 20 0 28 0 80 Riveting Hammer Heavy 4 5 7 5 10 5 30 Vertical Grinders and Sanders 5 Pad 5 25 8 75 12 25 35 SAWS Vertical Grinders an...

Page 28: ... 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...

Page 29: ...e 50 hours or less see Owner s Manual Air Filter Element MILLER 020 319 AC 302C Donaldson P10 1222 Fleetguard AF437K Fram CAK 253 Purolator AF 2030K Injectors MILLER 064 684 Deutz 223 3085 Nozzle MILLER 064 685 Deutz 223 3086 Have only trained technician maintain injection pump and injectors AIR WATER or GASOLINE will harm the injection system If tank is run out of fuel or fuel filter is changed b...

Page 30: ...ing to blowing dust while you clean element don t blow out Donaclone tube Replace cover section without element cover 2 Don t blow out the inside of and inner cover if any the air cleaner with compressed 4 If air cleaner is horizontally mounted correctly installed or you will air be sure that dust cup is positioned so blow dust into the engine arrows point up Clean element by one of the re use How...

Page 31: ... smoke while servicing fuel filter Have a fire extinguisher nearby and know how to use it This welding generator is equipped with a cartridge type fuel filter located above the oil filter on the right side of the unit The fuel filter should be replaced after 1000 hours of operation or more often depending on the qual ity of fuel used and how dusty and dirty the location is in which the engine is b...

Page 32: ...ecific gravity reading of 1 225 at 80 F 27 C is not obtained replace the vent caps and recharge the battery following the bat tery charger manufacturer s instructions 3 If the battery does not have removable vent caps check the condition of the battery as follows a Check the stabilized open circuit voltage of the battery For a 12 volt battery any reading below 12 4 volts indicates the battery need...

Page 33: ...left in the cylinder therefore it is recommended that a spare cylinder be kept on hand Generally the ether cylinder is empty if the engine fails to start in cold weather while uti lizing the cold weather starting system WARNING IMPROPER HANDLING OR EX POSURE TO ETHER can seriously harm your health Follow the manufacturer s safety instructions on the cylinder when handling ether compo nents The cyl...

Page 34: ...cur during the run in period if the engine is left at idle rpm too long or the welding generator is not heavily loaded If wetstacking occurs complete one of the following pro cedures to dry the engine see engine Owner s Manual F4L 912 diesel engine A resistance load is required to fully load the generator during the run in procedure A load bank or resistance grid may provide a constant load for ru...

Page 35: ...to grid input receptacle and remaining weld cable to grid output recep tacle see Diagram 8 2 8 If a voltmeter and ammeter are provided on the welding generator proceed to Step 9 If meters are not provided connect voltmeter and clamp on dc ammeter as shown in Diagram 8 2 9 Connect remaining ends of weld cables to gener ator weld output terminals polarity is not impor tant 10 Start engine as instruc...

Page 36: ...ozen or completely dis charged battery Do not jump start a battery which has loose terminals or one having evidence of damage such as a cracked case or cover Be sure that vent caps are tight and level on both batteries and cover both batteries with a damp cloth Wear correct eye and body protection and remove all metal jewelry Keep jumper cables clear of moving parts Ensure that both batteries are ...

Page 37: ...tion at beginning of Section 9 3 before pro ceeding Circuit breaker CB3 protects the unit wiring from over load and damage CB3 is located behind the lower front door If CB3 opens 115 volts ac output to socket terminal D of REMOTE 9 receptacle RC3 and terminal strip 3T stops and the remote amperage voltage control will not function C Replacement Of Low Oil Pressure High Oil Temperature Shutdown Sys...

Page 38: ... or HIGH OUTPUT position see Section 6 1 OUTPUT CONTACTOR switch S5 in REMOTE position and Remote Contactor device not connected Place S5 in ON position or install Remote Con tactor Control device 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 GMAW only Reset CB3 see Section 9 3 Poor contact between sl...

Page 39: ...oved safety practices and booster battery see Section 9 2 Engine Control switch S1 Check S1 and replace if necessary Oil Pressure gauge switch or Oil Temperature gauge switch activated or other engine trouble See Sections 6 10 thru 6 11 see Engine Man ufacturer s Manual F4L 912 engine MS1 fuse F Check and replace F if necessary see Sec tion 9 3 Engine suddenly shuts down Broken cooling belt Check ...

Page 40: ...OM 166 941 Page 35 NOTES ...

Page 41: ...Diagram 10 1 Circuit Diagram For Welding Generator OM 166 941 Page 36 SECTION 10 ELECTRICAL DIAGRAMS ...

Page 42: ...OM 166 941 Page 37 SC 168 908 B ...

Page 43: ...8 10 11 12 13 14 15 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 62 63 ST 800 491 B 1 of 2 43 16 7 9 Fig 11 4 Fig 4 1 36 37 42 1 17 64 65 66 67 68 69 70 71 72 74 75 77 76 78 79 Fig 11 3 11 2 73 15 61 ...

Page 44: ...ETS consisting of 1 114 066 CONNECTOR rect skt 20 14ga Amp 350536 1 4 20 Z1 1290740009880 REACTOR 1 21 1107430009309 FITTING stl flrd conn M 1 2tbg x 750 16 1 22 1551670009309 UPRIGHT center 1 601 965 SCREW 375 16 x 1 000hexhd 2 23 017 479 SEAL weather lift eye 2 24 1551680009309 UPRIGHT rear 1 25 108 081 TERMINAL PROTECTOR battery post mtg 2 26 134 456 CABLE bat neg 1 27 1186440009309 HOLD DOWN b...

Page 45: ...isting of 1 079 534 CONNECTOR circ skt push in 14 18ga Amp 66358 6 16 65 Fig 11 4 CONTROL BOX 1 66 Fig 11 3 PANEL lower front w components 1 67 122 354 GUARD splash fuel 1 68 107 343 GROMMET rbr neck filter fuel 1 69 0240350009309 CAP tank fuel 1 70 1448230010202 DOOR front lower RH 1 71 147 911 PLATE ident diesel fuel only 1 72 134 792 LABEL warning general precautionary 1 73 1448210009309 WINDOW...

Page 46: ...1065380009146 STARTER engine 12V 1 164 618 SHUTDOWN KIT rsv type governor 1 22 1528460009309 HOSE air cleaner elb 1 23 1532490009309 BAFFLE upper air intake 1 24 1142710009309 COMPOUND sealant material order by ft 5ft 25 1528530010202 COVER top 1 26 1174860010202 PIPE exhaust 1 27 122 382 CAP rain 1 28 108 487 LABEL warning falling equipment can cause serious injury 2 29 163 226 AIR CLEANER intake...

Page 47: ...15 16 17 18 19 20 29 30 31 32 33 34 35 10 28 Figure 11 1B Main Assembly 36 37 38 40 39 68 46 49 50 51 52 55 61 62 63 64 65 66 67 56 57 Fig 11 5 47 48 53 54 58 17 18 21 22 10 23 24 25 27 41 42 43 44 45 59 60 65 69 70 15 71 72 73 74 26 ST 800 491 B 2 of 2 ...

Page 48: ...9309 FITTING pipe stl tee F 1 2NPT 1 67 1107430009309 FITTING brs flrd conn M hd 1 4tbg x 1 8NPT 1 68 1355720009309 HOSE oil 47 000 3 4 swivel both ends same as Item 29 Fig 11 3 1 69 118 452 FITTING adapter oil drain 1 70 131 208 STOP throttle 1 71 1448100009309 HOSE cooling compressor 1 72 Fig 11 5 GENERATOR 1 73 1448640009309 BAFFLE air lower 1 74 132 712 PIPE muffler extension elb 1 875 OD 1 11...

Page 49: ...OM 166 941 Page 44 Figure 11 2 Panel Front w Components 1 2 5 6 7 8 9 10 11 12 13 14 9 15 16 17 18 19 20 21 ST 800 490 A Includes Item 4 4 3 22 23 24 25 ...

Page 50: ...18 066 GAUGE fuel elec 12V neg grd 1 12 V2 164 747 METER volt batt chg 8 18 scale 1 13 OG 129 870 GAUGE pressure oil 25 30PSI 1 128 829 KIT oil line 44 000 in 1 8NPT x 10mm 1 14 1298370009309 GAUGE SWITCH temp oil mech 300deg setting 1 15 HM 118 058 METER hour 12 24VDC 1 16 082 788 HOLDER light ind only 2 17 PL1 3 048 155 BULB incand flg base 12V 2 18 082 789 LENS light ind red 2 19 097 926 KNOB p...

Page 51: ...OM 166 941 Page 46 Figure 11 3 Panel Lower Front w Components ST 147 320 F 1 2 3 4 5 6 7 8 9 10 11 12 14 15 16 19 20 21 22 23 24 25 27 26 13 17 18 2 10 1 28 29 31 30 ...

Page 52: ...02A 20 16S 1 14 CB3 083 432 CIRCUIT BREAKER man reset 1P 10A 250V 1 15 PC4 152 966 CIRCUIT CARD filter HF 1 16 CB1 1532470009309 CIRCUIT BREAKER mag SPDT 30A 250VAC 1 17 1502670009309 PANEL front lower 1 18 083 030 STUD brs grd 250 20 x 1 750 1 19 010 915 WASHER flat brs 250 ID x 625 OD 5 20 601 836 NUT brs hex 250 20 3 21 0918600009309 STRAIN RELIEF 1 22 010 916 CONNECTOR clamp cable 750 3 23 3T ...

Page 53: ...PPORT PC card No 6 screw 8 10 PC2 160 888 CIRCUIT CARD voltage regulator 1 PLG2 168 071 CONNECTOR SOCKETS consisting of 1 114 066 CONNECTOR rect skt 20 14ga Amp 350536 1 9 11 PC1 1337570009309 CIRCUIT CARD field current regulator 1 PLG1 135 275 CONNECTOR SOCKETS consisting of 1 114 066 CONNECTOR rect skt 20 14ga Amp 350536 1 15 12 CR1 044 588 RELAY encl 12VDC 3PDT 1 13 CR3 059 268 RELAY encl 120VA...

Page 54: ...1 ROTOR gen consisting of 1 10 024 617 RING retaining external 1 11 053 390 BEARING ball 1 12 083 748 FAN rotor 1 13 1450210009309 STATOR exciter endbell 1 14 601 965 SCREW 375 16 x 1 000hexhd 6 15 153 299 ENDBELL generator consisting of 1 16 143 220 O RING 2 859 ID x 139CS 1 17 004 203 STRIP nyl 050 x 4 000 x 9 000 2 SD 134 503 C 2 3 4 6 8 9 10 12 15 11 16 1 7 17 14 13 5 Figure 11 5 Generator Rec...

Page 55: ...Notes ...

Page 56: ......

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Miller Electric CBI 801D, Owner'S Manual

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