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Miller Electric CBI 801D - User Manual

Miller Electric CBI 801D
56 pages
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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

Table of Contents

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Summary

Section 1: Safety Rules for Operation of Arc Welding Power Source

1-1. Introduction

Provides foundational safety knowledge and emphasizes learning from others' experiences.

1-2. General Precautions

Details essential safety practices for welding and cutting, including PPE and ventilation.

1-3. Arc Welding

Discusses specific safety measures for arc welding, including burn protection and eye protection.

1-4. Standards Booklet Index

Lists relevant safety standards and their sources for further information on welding and cutting practices.

Section 2: Safety Precautions and Signal Words

2-1. General Information and Safety

Outlines the importance of understanding the manual and unit labels for safe equipment use.

2-2. Safety Alert Symbol and Signal Words

Explains the use of safety alert symbols and signal words for hazard communication.

Section 3: Specifications

3-1. Duty Cycle

Explains duty cycle as the percentage of operation time without causing overheating or damage.

3-2. Volt-Ampere Curves

Describes volt-ampere curves showing voltage and amperage output capabilities at different ranges.

3-3. Description

Details the unit's design as a CC DC arc welding generator with a diesel engine and auxiliary power.

Section 4: Installation or Relocation

4-1. Location

Emphasizes selecting a proper site for dependable service and mentions engine exhaust gas hazards.

4-2. Exhaust Extension Installation

Provides instructions for installing an exhaust extension, warning about hot engine parts.

4-3. Connecting the Battery

Details the procedure for connecting the battery, warning about acid and abnormal voltage.

4-4. Fuel

Covers fuel handling precautions, refueling, and expansion space, warning about fuel spray and fire.

4-5. Lubrication

Explains oil level checks, oil capacity, and the function of oil pressure/temperature shutdown switches.

4-6. Equipment Grounding Terminal

Describes the grounding terminal and the need to connect to a proper earth ground per codes.

4-7. Weld Output Connections

Guides on selecting, preparing, and connecting weld cables for optimal output and safety.

4-8. Remote Control Connections

Explains the REMOTE 9 receptacle and terminal strip for connecting remote controls and wire feeders.

4-9. Air Compressor Connections

Details connecting an air compressor, noting the unit provides 12 cfm at 100 psi.

4-10. Ether Starting Aid (Optional)

Covers the installation of an optional ether starting aid, including safety warnings and procedure.

Section 5: Auxiliary Power

5-1. General

Discusses calculating load requirements for auxiliary power and limitations for motor starting.

5-2. 120 Volt Terminals

Explains connecting 120-volt auxiliary equipment, with warnings about shock and hot surfaces.

Section 6: Operator Controls

Primary Welding Controls

Covers Ampere Ranges, Amperage/Voltage Adjustment, Remote Controls, and Output switch.

Engine Operation and Status

Details Engine Control Switch, Hour Meter, Fuel Gauge, Air Cleaner & Alternator lights.

Safety Shutdowns and Gauges

Explains oil temp/pressure, broken belt shutdown switches, battery gauge, and meters.

Optional Starting Aid

Details the function and operation of the optional ether starting aid.

Section 7: Sequence of Operation

7-1. Shielded Metal Arc Welding (SMAW)

Step-by-step guide for performing SMAW welding, including safety and control settings.

7-2. Gas Metal Arc (GMAW) and Flux Cored Arc Welding (FCAW)

Step-by-step guide for GMAW/FCAW, including wire feeder setup and safety.

7-3. Air Carbon Arc Cutting and Gouging (CAC-A)

Procedure for CAC-A, detailing setup, controls, and safety for cutting and gouging.

7-4. Auxiliary Power Operation

Instructions for operating auxiliary power, including connecting equipment and starting the engine.

7-5. Air Compressor Operation

Steps for operating the air compressor, involving unit setup and engine start.

7-6. Starting the Engine

Detailed pre-start checks and procedures for starting the diesel engine, including oil level.

7-7. Stopping the Engine

Procedures for safely stopping all operations, auxiliary equipment, and the engine.

Section 8: Maintenance

8-1. Routine Maintenance

Outlines essential daily, hourly, and periodic maintenance tasks for the unit and engine.

8-2. Air Cleaner Service

Provides step-by-step instructions for cleaning or replacing the air cleaner element for engine longevity.

8-3. Fuel;Water Separator and Sludge Drain Plug

Details draining water from the fuel/water separator and sediment from the fuel tank.

8-4. Fuel Filter

Explains the fuel filter replacement interval and procedure, warning about fuel hazards.

8-5. Battery Replacement Procedure

Step-by-step guide for safely replacing the battery, with warnings about sparks and acid.

8-6. Maintenance-Free Battery Charging

Covers charging procedures for maintenance-free batteries, including safety precautions.

8-7. Governor

States the governor is factory set and should not require further adjustment.

8-8. Engine Speed Adjustments

Provides instructions for adjusting engine speed if necessary, with safety warnings.

8-9. Brushes and Slip Rings

Details inspection and maintenance of brushes and slip rings for excitation voltage.

8-10. Ether Starting Aid (Optional)

Explains the optional ether starting aid, cylinder replacement, and handling precautions.

8-11. Spark Arrestor

Discusses the spark arrestor, its purpose, installation requirements, and servicing.

8-12. Run-In Procedure

Guides on the proper run-in procedure for diesel engines, emphasizing load and preventing wetstacking.

Section 10: Electrical Diagrams

Diagram 10-1. Circuit Diagram For Welding Generator

Presents the detailed electrical circuit diagram for the welding generator.

Section 11: Parts List

Figure 11-1 A. Main Assembly

Provides an exploded view and list of parts for the main assembly of the generator.

Figure 11-1 B. Main Assembly

Shows an exploded view and parts list for the generator's main assembly, covering different components.

Figure 11-2. Panel, Front w;Components

Illustrates the front panel with its various components and provides a parts list.

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

Shows the lower front panel with components and lists associated parts.

Figure 11-4. Control Box

Details the control box components and provides a list of parts.

Figure 11-5. Generator

Illustrates the generator assembly with an exploded view and parts list.

Miller Electric CBI 801D Specifications

General IconGeneral
BrandMiller Electric
ModelCBI 801D
CategoryInverter
LanguageEnglish

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