Miller Electric CBI 801D Specifications

ProcessesOM-166 941C July 1999CBI 801D(Per NSPR 10202)Air Carbon Arc (CAC-A)Cutting and GougingStick (SMAW) WeldingFlux Cored (FCAW) WeldingDescriptio

OM-166 941 Page 5quate to carry ground currents safely. Equipment madeelectrically HOT by stray current may shock, possiblyfatally. Do NOT GROUND to e

OM-166 941 Page 65. ANSI Standard Z41.1, STANDARD FOR MEN’SSAFETY-TOE FOOTWEAR obtainable from theAmerican National Standards Institute, 1430Broadway,

OM-166 941 Page 7SECTION 3 − SPECIFICATIONSTable 3-1. Welding Generator SpecificationsRated OutputAt 100%Duty Cycle800 AmperesAt 36 Volts DCWeldingRan

OM-166 941 Page 83-1. DUTY CYCLEThe duty cycle of a welding generator is the percentageof a ten minute period that a welding generator can beoperated

OM-166 941 Page 9A. Lifting Of EquipmentWARNING: INCORRECT LIFTING will dam-age internal parts; FALLING EQUIPMENTcan cause serious personal injury an

OM-166 941 Page 104-4. FUELWARNING: REMOVE FUEL CAP SLOWLY;FUEL SPRAY may cause injury; FUEL maybe under pressure.• Rotate fuel cap slowly and wait un

OM-166 941 Page 114-7. WELD OUTPUT CONNECTIONS (Table 4-1And Figure 4-2)RATED WELD OUTPUTTo obtain full rated output from this unit, it is necessary t

OM-166 941 Page 122. For Shielded Metal Arc Welding (SMAW) and AirCarbon Arc Cutting and Gouging (CAC-A) (Elec-trode Positive/Reverse Polarity), conne

OM-166 941 Page 13If supplied remote control cord is not suitable for con-necting to the REMOTE 9 receptacle RC3, proceed withone of the following alt

OM-166 941 Page 144-9. AIR COMPRESSOR CONNECTIONSThis unit delivers 12 cfm of air at a pressure of 100 psiwhenever the engine is running. A 1/2 in. NP

Effective January 1, 1999(Equipment with a serial number preface of “KK” or newer)This limited warranty supersedes all previous manufacturerswarrantie

OM-166 941 Page 15SECTION 5 − AUXILIARY POWERPOWER OUTPUTWARNING: ELECTRIC SHOCK can kill;MOVING PARTS can cause serious injury;IMPROPER AIR FLOW AND

OM-166 941 Page 16A. Auxiliary Equipment Connections To TerminalStrip 3T (Figure 4-2)WARNING: Read and follow safety infor-mation at beginning of en

OM-166 941 Page 17A. START PositionRotating the switch to the START position starts the en-gine. Release the switch as soon as the engine starts,and t

OM-166 941 Page 186-9. FUEL GAUGE (Figure 6-1)FUELThe FUEL Gauge indicates the level of fuel remaining inthe fuel tank. The unit is equipped with a 30

OM-166 941 Page 19SECTION 7 − SEQUENCE OF OPERATIONWARNING: ELECTRIC SHOCK can kill;MOVING PARTS can cause serious injury;IMPROPER AIR FLOW AND EXPOS

OM-166 941 Page 206. If remote amperage or voltage control is notused, place AMPERAGE & VOLTAGE switch inthe PANEL position. If remote amperage or

OM-166 941 Page 21b. Fuel LevelWARNING: REMOVE FUEL CAP SLOWLY;FUEL SPRAY may cause injury; FUEL maybe under pressure.• Rotate fuel cap slowly and wai

OM-166 941 Page 22Table 7-3. Approximate Air Consumption (Cubic Feet) Required To Operate Various PneumaticEquipment At Pressure Range 70-90 P.S.I.G.D

OM-166 941 Page 23SECTION 8 − MAINTENANCE8-1. ROUTINE MAINTENANCE (Table 8-1)IMPORTANT: Every six months inspect the labels onthis unit for legibilit

OM-166 941 Page 24DEUTZ F4L912 DIESEL ENGINECheckRecommended Oil API Service Classification CD/CE. . . . . Oil And Filter Change dirty conditions 100

OM-166 941 Page 258-2. AIR CLEANER SERVICE (Table 8-2)CAUTION: DIRTY AIR can damage engine.• Do not operate engine with dirty air cleanerelement in pl

OM-166 941 Page 268-3. FUEL/WATER SEPARATOR AND SLUDGEDRAIN PLUGWARNING: ENGINE FUEL can cause fire orexplosion.• Do not drain fuel tank while engine

OM-166 941 Page 278-6. MAINTENANCE-FREE BATTERY CHARG-INGWARNING: CHARGING A FROZEN BAT-TERY can cause the battery to explode andresult in serious per

OM-166 941 Page 285. When the weld/power speed reaches 1860 rpm,prevent the adjustment screw from turning, andtighten the securing nut.6. Stop engine.

OM-166 941 Page 29Removal of the device from the exhaust system is notnecessary for servicing. Proceed as follows to servicespark arrestor:1. Stop the

OM-166 941 Page 30+−+−WeldingGeneratorLoad BankVoltmeterAndAmmeterWeldCablesNegative (−)Weld OutputTerminalPositive (+)Weld OutputTerminalS-0456Diagra

OM-166 941 Page 31AVWeldingGeneratorResistance GridInput And OutputReceptaclesWeldCablesVoltmeter AndAmmeter(If so equipped)Weld OutputTerminals(Polar

OM-166 941 Page 326. Start engine following procedures outlined inSection 7 (Sequence of Operation) of this man-ual. If the unit does not start after

OM-166 941 Page 339-5. TROUBLESHOOTING (Tables 9-1 Thru 9-4)WARNING: ELECTRIC SHOCK can kill.• Do not touch live electrical parts.• Stop engine, and

OM-166 941 Page 34Table 9-2. Auxiliary Power TroubleshootingAUXILIARY POWERTROUBLEPROBABLE CAUSE REMEDYNo 120 volt output at 3T termi-nals L and M.Cir

OM-166 941C − 7/99TABLE OF CONTENTSSection No. Page No.SECTION 1 − SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE1-1. Introduction 1. . . . .

OM-166 941 Page 35NOTES

Diagram 10-1. Circuit Diagram For Welding GeneratorOM-166 941 Page 36SECTION 10 − ELECTRICAL DIAGRAMS

OM-166 941 Page 37SC-168 908-B

OM-166 941 Page 38SECTION 11 − PARTS LISTFigure 11-1A. Main Assembly123456781011121314151718192021222324252627282930313233343536 373839404142444546474

OM-166 941 Page 39PartNo.Dia.Mkgs.Figure 11-1A. Main AssemblyItemNo. Description Quantity1 134 834 HOSE, SAE .187 ID x .410 OD (order by ft) 4ft. . .

OM-166 941 Page 40PartNo.Dia.Mkgs.Figure 11-1A. Main Assembly (Continued)ItemNo. Description Quantity49 073 433 FITTING, brs barbed M 3/16tbg x 1/4NPT

OM-166 941 Page 41PartNo.Dia.Mkgs.Figure 11-1B. Main AssemblyItemNo. Description Quantity1 1448720009309 BAFFLE, air upper 1. . . . . . . . . . . . .

OM-166 941 Page 421234567891011121314151617181920293031323334351028Figure 11-1B. Main Assembly363738403968464950515255616263646566675657Fig 11-5474853

OM-166 941 Page 43PartNo.Dia.Mkgs.Figure 11-1B. Main Assembly (Continued)ItemNo. Description Quantity49 089 351 FITTING, pipe brs plug hexhd 1/2NPT 1.

OM-166 941 Page 44Figure 11-2. Panel, Front w/Components12567891011121314915161718192021ST-800 490-A*Includes Item 443*222324 25

SECTION 7 − SEQUENCE OF OPERATION7-1. Shielded Metal Arc Welding (SMAW) 19. . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Gas Metal Arc (GMAW

OM-166 941 Page 45Description QuantityPartNo.Dia.Mkgs.Figure 11-2. Panel, Front w/Components (Fig 11-1A Item 75)ItemNo.1 S9 1346300009880 SWITCH, rang

OM-166 941 Page 46Figure 11-3. Panel, Lower Front w/ComponentsST-147 320-F12345678910 11121415 16192021222324252726131718210128 293130

OM-166 941 Page 47Description QuantityPartNo.Dia.Mkgs.Figure 11-3. Panel, Lower Front w/ComponentsItemNo.(Fig 11-1A Item 66)1 0386120009309 TERMINAL A

OM-166 941 Page 48Description QuantityPartNo.Dia.Mkgs.Figure 11-4. Control Box (Fig 11-1A Item 65)ItemNo.1 1186380009309 ENCLOSURE, control box 1. . .

OM-166 941 Page 49Description QuantityPartNo.Figure 11-5. Generator (Fig 11-1B Item 72)ItemNo.1 018 614 BRUSH SET, (consisting of) 3. . . . . . . . .

Notes

OM-166 941 Page 1SECTION 1 − SAFETY RULES FOR OPERATION OF ARC WELDING POWER SOURCE1-1. INTRODUCTIONWe learn by experience. Learning safety through pe

OM-166 941 Page 2atmosphere or where the radiant energy can penetrateto atmospheres containing even minute amounts oftrichloroethylene or perchloroeth

OM-166 941 Page 3Locate or secure cylinders so they cannot be knockedover.Passageways and work areas. Keep cylinders clear ofareas where they may be s

OM-166 941 Page 41-3. ARC WELDINGComply with precautions in 1-1, 1-2, and this section.Arc Welding, properly done, is a safe process, but acareless op