Miller Electric CBI 801D Lifting Of Equipment, Trailer Mounting, Spark Arrestor Considerations

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A. Lifting Of Equipment

WARNING: INCORRECT LIFTING will dam- age internal parts; FALLING EQUIPMENT can cause serious personal injury and equipment damage.

•Use lifting eye to lift unit only, NOT gas cylin- ders, trailer, or any other heavy options, ac- cessories, or devices.

•Use equipment of adequate capacity to lift the unit.

•Use lift forks at least 42 in. (1067 mm) long.

•Lift only from engine-end (end opposite front panel).

B.Trailer Mounting

CAUTION: UNCONTROLLED TILTING OF TRAILER can result in personal injury or equipment damage.

•Distribute weight so that trailer tongue weight is approximately 10% of gross trailer weight.

•Follow trailer manufacturer’s instructions when mounting welding generator onto trailer.

OPERATION ON UNLEVEL SURFACE can cause improper lubrication and result in severe engine damage.

•Operate unit in an approximately level posi- tion.

•See Figure 4-1 for maximum allowable tilt for proper operation.

•Check crankcase oil level with unit on a level surface.

Exceeding these limits can cause severe engine damage and improper operation.

Front

Panel

17.5

15

Side View Of Unit

Front

Panel

37.5

45

End View Of Unit

Ref. S-0024

Figure 4-1. Allowable Tilt Angles For Welding

Generator Engine

Holes are provided in the base for securing the unit in a permanent location or to a trailer or transport vehicle. Figure 3-1 gives overall dimensions and base mounting hole layout.

The mounting location should allow sufficient room to remove the top cover and side panels for maintenance and repair functions.

Use a properly fitting cover (optional) over the welding generator when not in operation to protect the unit from the environment. Be sure unit is cool before installing 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 National Forest or on California Grasslands, brush, or forest cov- ered land (see Section 4442 of California Public Re- sources Code). For other areas, check your state and local laws. If a spark arrestor (optional) is desired, con- tact your dealer/distributor.

4-2. EXHAUST EXTENSION INSTALLATION

WARNING: HOT ENGINE PARTS can cause severe burns.

•If applicable, shut down engine and allow ex- haust system to cool before installing exhaust extension.

1.Install exhaust extension through top cover opening, over muffler extension elbow. (Be sure to face end of extension away from air cleaner; see Figure 3-1).

2.Secure exhaust extension to top cover of unit us- ing supplied hardware.

4-3. CONNECTING THE BATTERY

WARNING: BATTERY ACID can burn eyes and skin and destroy clothing and other ma- terial.

•Wear a face shield and proper protective clothing when working with batteries.

ABNORMAL VOLTAGE can cause damage to engine electrical components.

•Do not operate engine without the battery connected.

•Do not disconnect the battery while the en- gine is running.

IMPORTANT: Be sure the Engine Control switch is in the OFF position before connecting battery.

This unit is equipped with a maintenance-free battery. To place the unit in service, remove the left, rear side panel, connect the negative (−) battery cable to the neg- ative battery terminal, and reinstall the side panel. No other preparation should be required. If the battery does not supply enough power to crank the engine, charge the battery according to Section 8-6.

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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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