Miller Electric CBI 801D manual Overload Protection Figure, Incorrect Fuse can damage unit

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INCORRECT INSTALLATION or misaligned plugs can damage circuit board.
• Be sure that plugs are properly installed and aligned before closing access door.
EXCESSIVE PRESSURE can break circuit board.
• Use only minimal pressure and gentle move- ment when disconnecting or connecting board plugs and removing or installing board.
If any circuit board is not working, follow the precautions above, and contact the nearest Factory Authorized Ser- vice Station/Service Distributor.
Perform work only at a static−safe work area.
•
WARNING: ELECTRIC SHOCK can kill
• Do not touch live electrical parts.
• Stop engine, and disconnect negative (−) bat- tery cable from battery before inspecting, maintaining, or servicing.
HOT ENGINE PARTS can cause severe burns.
• Wear protective gloves and clothing when working on a hot engine.
CAUTION: ELECTROSTATIC DISCHARGE (ESD) can damage circuit board compo- nents.
• Put on properly grounded wrist strap BE- FORE handling circuit boards.
• Transport all static−sensitive components in proper static-shielding carriers or packages.
CIRCUIT BOARD HANDLING TIONS
PRECAU-
9-4.
2. Locate shutdown switch MS1 on left, rear side of front access door.
3. Locate fuse F on bottom of shutdown switch MS1.
4. Remove and check fuse, and replace if neces- sary.
5. Close and secure front access door.
Remove securing screws, and open upper front access door.
1.
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 System Fuse F
WARNING: Read and follow safety informa- tion at beginning of Section 9-3 before pro-
ceeding.

6.Start engine following procedures outlined in Section 7 (Sequence of Operation) of this man- ual. If the unit does not start after cranking for twenty seconds, stop the jump starting proce- dure. More than twenty seconds seldom starts the engine unless some mechanical adjustment is made.

7.Remove jumper cable from engine block.

8.Remove other end of same cable from booster battery negative (−) terminal.

9.Remove other jumper cable from booster battery positive (+) terminal.

10.Remove remaining end of cable from welding generator battery positive (+) terminal.

11.Discard damp cloths.

9-3. OVERLOAD PROTECTION (Figure 4-2)

WARNING: ELECTRIC SHOCK can kill.

• Do not touch live electrical parts.

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

MOVING PARTS can cause serious personal 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.

INCORRECT FUSE can damage unit.

•Be sure replacement fuse is same size, type, and rating.

A.Circuit Breaker CB1 (Figure 4-2)

WARNING: Read and follow safety informa- tion at beginning of Section 9-3 before pro- ceeding.

Circuit breaker CB1 protects the 120 volts ac auxiliary power terminals on terminal strip 3T from overload. CB1 is located behind the lower front door. When CB1 opens, the ON/OFF switch goes to the OFF position, and 3T will not operate. If CB1 opens, locate and correct the prob- lem, and place the circuit breaker switch in the ON posi- tion.

B. Circuit Breaker CB3 (Figure 4-2)

WARNING: Read and follow safety informa- 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.

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Contents Processes OM-166 941CDescription Per NsprWarranty Page Table of Contents − Troubleshooting − Maintenance− Electrical Diagrams − Parts ListGeneral Precautions − Safety Rules for Operation of ARC Welding Power SourceIntroduction Burn PreventionCompressed Gas Equipment Fire and Explosion PreventionLeaving Equipment Unattended User ResponsibilitiesRope Staging-Support Burn Protection ARC WeldingShock Prevention Standards Booklet Index General Information and Safety − Safety Precautions and Signal WordsSafety Safety Alert Symbol and Signal WordsOCV − SpecificationsDuty Cycle − Installation or RelocationDescription Connecting the Battery Exhaust Extension InstallationLifting Of Equipment Trailer MountingEquipment Grounding Terminal GroundPositive Negative Rated Weld OutputRemote Feeder AMPERAGE/VOLTAGE Output Contactor Remote Control ConnectionsRemote 9 Receptacle Information And Connections Figures 4-2 Tion C Wire remote control cord directly to terminal stripWithin unit according to Section B Remote Terminal Strip 3T InformationEther Starting AID Optional AIR Compressor ConnectionsPosure to Ether can seriously harm Your healthElectric Sparks can cause fire − Auxiliary Power Power OutputLOW Voltage and Frequency can dam- age electrical equipment GeneralAmperage & Voltage Adjustment Amperage and Voltage Adjustment− Operator Controls Panel Remote RUNRemote Output Contactor Magnetic Shutdown Switch BatteryBroken Cooling Belt Shutdown Switch FuelARC Rays can burn eyes and skin Noise can damage hearing − Sequence of OperationFumes and Gases can seriously harm your health Shielded Metal ARC Welding SmawAIR Carbon ARC Cutting and Gouging CAC-A Table Auxiliary Power OperationAIR Compressor Operation Tables 7-2 Starting the EngineFlow Of Free Air CFM Through Orifices Of Various Diameters Stopping the EngineMiscellaneous − Maintenance Deutz F4L912 Diesel Engine Air Cleaner Service AIR Cleaner Service TableFUEL/WATER Separator and Sludge Drain Plug Battery Replacement ProcedureFuel/Water Separator Sludge Drain PlugEngine Speed Adjustments Figure MAINTENANCE-FREE Battery CHARG- INGGovernor Brushes and Slip Rings Figure Brush Replacement Ether Starting AID OptionalRun-In Procedure Using Load Bank Diagram RUN-IN ProcedureMoving Parts can cause severe injury Run-In Procedure Using Resistance Grid Dia- gram Diagram 8-1. Load Bank ConnectionsDiagram 8-2. Resistance Grid Connections − TroubleshootingBooster Battery Jump Starting Moving Parts can cause serious personal injury Overload Protection FigureIncorrect Fuse can damage unit Circuit Breaker CB1 FigureWeld/Power Troubleshooting Troubleshooting Tables 9-1 ThruTrouble Probable Cause Remedy Auxiliary Power Probable Cause Remedy Trouble Auxiliary Power TroubleshootingEngine Troubleshooting Air Compressor TroubleshootingOM-166 941 Diagram 10-1. Circuit Diagram For Welding Generator − Electrical DiagramsSC-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 6563 62 21 22 15 14 8111532480009309 Panel, Front w/Components 18 17 16 Includes ItemPanel, 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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