Miller Electric CBI 801D manual RUN-IN Procedure, Moving Parts can cause severe injury

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Removal of the device from the exhaust system is not necessary for servicing. Proceed as follows to service spark arrestor:

1.Stop the engine, and allow the exhaust system to cool.

2.Remove the cleanout plug from the bottom of the spark arrestor. If a crust has formed over the hole, break it loose with a screwdriver or similar tool.

3.Start the engine, and run it at idle rpm to blow col- lected particles out the cleanout hole. If particles are slow to discharge, momentarily cover the end of the exhaust stack.

4.Stop the engine, and allow the exhaust system to cool.

5.Replace and secure the cleanout plug.

8-12. RUN-IN PROCEDURE

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

•Stop engine before inspecting, connecting, or servicing.

•Do not leave live unit unattended when engine is running.

•Keep all panels, covers, and guards securely in place while engine is running.

MOVING PARTS can cause severe 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 hot engine parts or components.

CAUTION: LOW OIL LEVEL can damage engine; ENGINE MAY USE OIL AND WETS- TACKING may occur during run-in period.

•Check oil level several times a day during run-in period, and add oil if required.

•See engine Owner’s Manual (Deutz F4L-912 diesel engine) for run-in informa- tion.

•Do not idle engine longer than necessary during run-in period.

•Piston rings seat faster if engine runs at weld/power rpm, and the welding generator is kept loaded during the run-in period.

The run-in procedure for diesel engines is different than those associated with gasoline engines. Diesel engines must be run at near-rated load during the run-in period to ensure proper seating of piston rings and to prevent wetstacking. Wetstacking is an accumulation of un- burned fuel and oil in the exhaust pipe. Wetstacking can

occur 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 run-in, however, a load bank is preferred. If a load bank is available, proceed with the run-in procedure pro- vided in Subsection A. If a resistance grid is being used, proceed to Subsection B.

A.Run-In Procedure Using Load Bank (Diagram 8-1)

WARNING: Read and follow safety infor- mation at beginning of entire Section 8-12 before proceeding.

1.Stop engine.

IMPORTANT: Weld cables supplied with load bank may be inadequate for run-in procedure. Use weld cables of proper size with appropriate connectors to connect load bank to generator (see load bank Owner’s Manual).

2.Connect cables from load bank to generator weld output terminals observing correct polarity (see Diagram 8-1).

3.Place all load switches in the OFF position.

IMPORTANT: If load bank requires 115 volts ac, it may be connected to the welding generator auxiliary power terminal strip, if applicable.

4.Place welding generator AMPERAGE & VOLT- AGE ADJUSTMENT control in the minimum po- sition.

5.Start engine as instructed in Section 7-6, and al- low engine to warm up for approximately three minutes.

6.Adjust load bank switches and generator controls to provide a load equal to rated generator output.

For example, if rated generator output is 350 am- peres, 40 volts at 100% duty cycle, adjust switches until values indicated by load meters equal rated generator output.

7.Allow engine to run under load for at least one hour. Check engine and load bank meters after the first five minutes and every 15 minutes there- after to be sure equipment is operating properly.

8.After running engine under load for at least one hour, remove load by shutting down load bank.

9.Allow engine to idle for approximately three min- utes to permit internal engine temperatures to equalize.

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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 EquipmentLeaving Equipment Unattended User ResponsibilitiesRope Staging-Support Burn Protection ARC WeldingShock Prevention Standards Booklet Index Safety − Safety Precautions and Signal WordsGeneral Information and Safety Safety Alert Symbol and Signal Words− Specifications OCVDuty Cycle − Installation or RelocationDescription Lifting Of Equipment Exhaust Extension InstallationConnecting the Battery Trailer MountingGround Equipment Grounding TerminalRated Weld Output Positive NegativeRemote Feeder AMPERAGE/VOLTAGE Output Contactor Remote Control ConnectionsRemote 9 Receptacle Information And Connections Figures 4-2 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 GeneralAmperage & Voltage Adjustment Amperage and Voltage Adjustment− Operator Controls Panel Remote RUNRemote Output Contactor 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 PlugEngine Speed Adjustments Figure MAINTENANCE-FREE Battery CHARG- INGGovernor Brush Replacement Ether Starting AID Optional Brushes and Slip Rings FigureRun-In Procedure Using Load Bank Diagram RUN-IN ProcedureMoving Parts can cause severe injury Diagram 8-1. Load Bank Connections Run-In Procedure Using Resistance Grid Dia- gramDiagram 8-2. Resistance Grid Connections − TroubleshootingBooster Battery Jump Starting Incorrect Fuse can damage unit Overload Protection FigureMoving Parts can cause serious personal injury Circuit Breaker CB1 FigureWeld/Power Troubleshooting Troubleshooting Tables 9-1 ThruTrouble Probable Cause Remedy 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 11-2 − Parts List66 Fig 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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