Diagram 8-2. Resistance Grid Connections; Section 9 − Troubleshooting; General; Booster Battery Jump Starting - Miller Electric CBI 801D Owner's Manual

Voltmeter And
Ammeter
(If so equipped)
Weld Output
Terminals
(Polarity Not
Important)
Voltmeter
Required if welding generator is not equipped with meters.
9-1.

GENERAL

It is assumed that proper installation has been made,
according to Section 4 of this manual, the operator is fa-
miliar with the function of controls, the welding generator
was functioning properly, and the trouble is not related to
the welding process.
9-2.

BOOSTER BATTERY JUMP STARTING

If it is necessary to jump start this unit, use the following
safety precautions and the step-by-step procedures in
order of appearance.
WARNING: BATTERY GASES OR A DAM-
AGED BATTERY can explode thereby shat-
tering the battery; BATTERY ACID can burn
eyes, skin, destroy clothing, and damage
other material; MOVING PARTS AND IM-
PROPER CONNECTIONS can cause serious
personal injury and damage equipment.
Keep sparks, flames, cigarettes, and other ig-
nition sources away from battery.
Ensure that all personnel are a safe distance
from batteries and clear of moving parts while
starting.
Do not jump start a frozen or completely dis-
charged battery.
Do not jump start a battery which has loose
terminals or one having evidence of damage
such as a cracked case or cover.
Be sure that vent caps are tight and level on
both batteries and cover both batteries with a
damp cloth.
Welding
Generator
Weld
Cables
V

Diagram 8-2. Resistance Grid Connections

SECTION 9 − TROUBLESHOOTING
Resistance Grid
Wear correct eye and body protection, and
remove all metal jewelry.
Keep jumper cables clear of moving parts.
Ensure that both batteries are of the same
voltage.
Do not jump start a trailer mounted welding
generator with the towing vehicle battery un-
less the trailer is completely disconnected
from the towing vehicle.
Do not jump start a vehicle mounted welding
generator from the vehicle battery.
If booster battery is installed in vehicle, do not
allow vehicle to make contact with welding
generator case or frame.
Do not jump start by applying power to weld
output receptacles or terminals.
Do not allow jumper cables to contact any
other metal while attaching or removing ca-
bles.
1. Use properly insulated jumper cables of ade-
quate size.
2. Connect ends of one cable to positive (+) termi-
nals of each battery.
3. Connect one end of other cable to negative (−)
terminal of booster battery.
4. Connect remaining end of cable to welding gen-
erator engine block at least 18 inches (457 mm)
from battery (do not connect to welding generator
case, frame, or equipment grounding terminal as
damage to equipment can result).
5. Wait at least one minute after connecting cables
before starting engine.
Input And Output
Receptacles
Clamp-On
DC Ammeter
A
S-0457
OM-166 941 Page 31