Miller Electric CBI 801D manual MAINTENANCE-FREE Battery CHARG- ING, Governor

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8-6. MAINTENANCE-FREE BATTERY CHARG- ING

WARNING: CHARGING A FROZEN BAT- TERY can cause the battery to explode and result in serious personal injury or damage to equipment.

•Allow battery to warm up to 60° F (16°C) be- fore charging if battery is frozen.

BATTERY ACID can burn eyes and skin and destroy clothing and other materials; BAT- TERY GASES can explode and shatter bat- tery.

•Wear a face shield, proper protective cloth- ing, and remove all metal jewelry.

•Do not spill or splash battery fluid.

•Do not apply pressure to walls of filled bat- tery—use battery carrier or place hands on opposite corners when lifting battery.

•Keep sparks, flames, cigarettes, and other ig- nition sources away from batteries.

•Use enough ventilation to keep battery gases from building up during and for several hours after battery charging.

•Do not touch or move connections on battery while battery charger is on.

•Turn battery charger off before making con- nections to battery.

•Do not lean over battery when charging.

•Be sure battery charger connections to bat- tery are clean and tight.

•Keep vent caps in place and cover top of bat- tery with damp cloth.

•Be sure battery charger output matches bat- tery voltage.

•Turn the battery charger off before discon- necting the charger from the battery.

1.Remove battery from unit, and place on a level worktable or other suitable surface.

2.If battery has removable vent caps, check the condition of the electrolyte as follows:

a.Check electrolyte temperature in one of the

center cells with a battery thermometer. For each 10°F (6°C) increment above 80°F (27°C), a correction factor of 0.004 specific gravity

must be added to the specific gravity reading taken in Step 2b. For each 10°F (6°C) incre- ment below 80°F (27°C), 0.004 must be sub- tracted from the reading taken in Step 2b.

b.Check the specific gravity of each cell with a hy- drometer. (Draw in and expel the electrolyte two or three times from the first cell to be tested to adjust the temperature of the hydrometer to that of the electrolyte.)

c.If a corrected specific 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

12.4volts indicates the battery needs charging. Disconnect both battery cables from the bat- tery, and allow battery voltage to stabilize for several hours.

b.If the stabilized open−circuit voltage is below

12.4volts, charge the battery following the bat- tery charger manufacturer’s instructions.

4.Remove damp cloth from battery.

5.Reinstall battery in unit.

6.Replace battery holddown, and tighten securely. Do not overtighten.

7.Connect positive (+) battery cable to positive (+) battery terminal.

8.Connect negative (−) battery cable to negative

(−)battery terminal.

8-7. GOVERNOR

The governor has been set at the factory and should not require further adjustment.

8-8. ENGINE SPEED ADJUSTMENTS (Figure 8-2)

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

• Stop engine, and disconnect negative (−) battery cable from battery before inspecting, maintaining, or servicing.

MOVING PARTS can cause serious injury.

• Keep away from moving parts such as fans, belts, and rotors.

HOT ENGINE PARTS can cause severe burns.

•Wear protective gloves and clothing when working on a hot engine.

Maintenance to be performed only by qualified persons.

The engine speeds have been factory adjusted and should not require frequent readjustment. After tuning the engine, check the speeds with a tachometer. With no load applied, the weld/power speed should be 1860 rpm. If necessary, adjust the speeds as follows:

1.Open and secure right rear side door.

2.Loosen nut on end of engine speed adjusting screw (see Figure 8-2).

3.Start the engine as instructed in Section 7-6.

4.Adjust the weld/power speed as follows:

IMPORTANT: All directions, such as clockwise and counterclockwise, are with respect to the operator fac- ing the rear panel of the unit.

a.To increase weld/power speed, rotate the en- gine speed adjustment screw clockwise.

b.To decrease weld/power speed, rotate the en- gine adjustment screw counterclockwise.

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Contents OM-166 941C ProcessesDescription Per NsprWarranty Page Table of Contents − Maintenance − Troubleshooting− Electrical Diagrams − Parts List− Safety Rules for Operation of ARC Welding Power Source General PrecautionsIntroduction Burn PreventionFire and Explosion Prevention Compressed Gas EquipmentRope Staging-Support User ResponsibilitiesLeaving Equipment Unattended Shock Prevention ARC WeldingBurn Protection Standards Booklet Index − Safety Precautions and Signal Words General Information and SafetySafety Safety Alert Symbol and Signal Words− Specifications OCVDescription − Installation or RelocationDuty Cycle Exhaust Extension Installation Connecting the BatteryLifting Of Equipment 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 Wire remote control cord directly to terminal strip Tion CWithin unit according to Section B Remote Terminal Strip 3T InformationAIR Compressor Connections Ether Starting AID OptionalPosure to Ether can seriously harm Your health− Auxiliary Power Power Output Electric Sparks can cause fireLOW Voltage and Frequency can dam- age electrical equipment General− Operator Controls Amperage and Voltage AdjustmentAmperage & Voltage Adjustment Remote Output Contactor RUNPanel Remote Battery Magnetic Shutdown SwitchBroken Cooling Belt Shutdown Switch Fuel− Sequence of Operation ARC Rays can burn eyes and skin Noise can damage hearingFumes and Gases can seriously harm your health Shielded Metal ARC Welding SmawAuxiliary Power Operation AIR Carbon ARC Cutting and Gouging CAC-A TableAIR Compressor Operation Tables 7-2 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 ServiceBattery Replacement Procedure FUEL/WATER Separator and Sludge Drain PlugFuel/Water Separator 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 Overload Protection Figure Moving Parts can cause serious personal injuryIncorrect Fuse can damage unit Circuit Breaker CB1 FigureTrouble Probable Cause Remedy Troubleshooting Tables 9-1 ThruWeld/Power Troubleshooting Auxiliary Power Troubleshooting Auxiliary Power Probable Cause Remedy TroubleEngine Troubleshooting 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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