Miller Big Blue 450 Duo CST Owner'S Manual Download Page 20

Page: 20 / 64

Complete Parts List is available at www.MillerWelds.com

OM-266621 Page 16

Do not spray water on CST units.

Safe92 2017

−

Door must be fully open during operation.

Safe93 2012

−

3-2. Symbols And Definitions

Amperes

Volts

Hertz

Seconds

Duty Cycle

Rated No Load

Voltage (OCV)

Conventional

Load Voltage

Rated Welding

Current

Rated Load

Speed

Rated No Load

Speed

Rated Idle Speed

Maximum Power

Consumption

Current

Suitable For

Welding In An

Environment With

Increased Risk Of

Electric Shock

Engine-Driven,

Three-Phase

Alternator With

Rectifier

Three Phase

Single Phase

Direct Current

(DC)

Alternating

Current

Circuit Protection

Protective Earth

(Ground)

Stick (SMAW)

Welding

TIG (GTAW)

Welding

Welding Arc

Engine Stop

Engine Start

(Engine RPM)

Run (Fast)

Idle (Slow)

Starting Aid

(Preheat)

Output

Off

Remote

Positive

Negative

Engine

Check Air Cleaner

Battery (Engine)

Temperature

Hour Meter

Hours

Read Operator’s

Manual

Engine Coolant

Fuel

Certified/Trained

Mechanic

Check Spark

Arrestor

Check Engine

Belt Tension

Call For

Maintenance

Engine Oil

Air Filter

Check

Injectors/Pump

Summary of Contents for Big Blue 450 Duo CST

Page 1: ...017 10 Big Blue 450 Duo CST Processes Description TIG GTAW Welding Stick SMAW Welding Engine Driven Welder Generator File Engine Drive For product information Owner s Manual translations and more visi...

Page 2: ...ntinue the tradition They re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929 This Owner s Manual is designed to help you get...

Page 3: ...SPECIFICATIONS 17 4 1 Serial Number And Rating Label Locations 17 4 2 Weld Power And Engine Specifications 17 4 3 Dimensions Weights And Operating Angles 17 4 4 Environmental Specifications 18 4 5 Tie...

Page 4: ...gine Cooling System 39 8 9 Adjusting Engine Speed 39 8 10 Servicing Fuel And Lubrication Systems 40 8 11 Overload Protection 41 8 12 Troubleshooting CST 42 8 13 Troubleshooting Generator 43 SECTION 9...

Page 5: ...gh risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC m...

Page 6: ...g sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bu...

Page 7: ...hot parts use proper tools and or wear heavy insu lated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can burn If possible check coolant level when engine is cold to avoid scaldi...

Page 8: ...can burn Do not touch hot compressor or air system parts Allow cooling period before working on equipment To handle hot parts use proper tools and or wear heavy insu lated welding gloves and clothing...

Page 9: ...any metal when threading welding wire OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again Do not block or filte...

Page 10: ...e Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Institute 25 West 43rd Street New York NY 10036 phone 212 642 4900 web site ww...

Page 11: ...appareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des environnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures...

Page 12: ...essures ou m me la mort Fermer l alimentation du gaz comprim en cas de non utilisation Veiller toujours bien a rer les espaces confin s ou se servir d un respirateur d adduction d air homologu LES RAY...

Page 13: ...ication sp cifique les maintenir ainsi que les l ments associ s en bon tat Tourner le dos la sortie de vanne lors de l ouverture de la vanne de la bouteille Ne pas se tenir devant ou derri re le r gul...

Page 14: ...ppement 2 4 Dangers li s l air comprim Un QUIPEMENT PNEUMATIQUE risque de provoquer des blessures ou m me la mort Une installation ou une utilisation incorrecte de cet appareil pourrait conduire des d...

Page 15: ...tretien de l appareil Lire les informations de s curit au d but du manuel et dans chaque section N utiliser que les pi ces de rechange recommand es par le constructeur Effectuer l installation l entre...

Page 16: ...canique en enga geant le fil de soudage L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT Laisser l quipement refroidir respecter le fac teur de marche nominal R duire le courant ou le facteur de marche...

Page 17: ...auga Ontario Canada L4W 5NS phone 800 463 6727 website www csagroup org Safe Practice For Occupational And Educational Eye And Face Protec tion ANSI Standard Z87 1 from American National Standards Ins...

Page 18: ...OM 266621 Page 14...

Page 19: ...rs of operation keep welding load above 200 amperes Do not weld below 200 amperes of output 50 h std Safe55 2012 05 After the first 50 hours of operation change the engine oil and filter Never use gen...

Page 20: ...An Environment With Increased Risk Of Electric Shock Engine Driven Three Phase Alternator With Rectifier Three Phase Single Phase Direct Current DC Alternating Current Circuit Protection Protective Ea...

Page 21: ...ontinuous 120 240 V AC 60 Hz Three Phase 12 kVA kW 240 V AC 60 Hz 71 dB 96 Lwa at 23 ft 7 m Full Load T4F Mitsubishi S4L2 Water Cooled Four Cylinder Diesel Engine 24 7 HP Domestic Models T4F 11 5 gal...

Page 22: ...els Performance Curves 0 100 200 300 400 500 0 10 20 30 40 50 60 70 80 90 100 DUTY CYCLE WELD AMPHERES A Duty Cycle 266 503 A 1 100 Duty Cycle Duty Cycle is percentage of 10 minutes that unit can weld...

Page 23: ...urves of all other settings fall between the curves shown XX10 Stick Mode XX18 Stick Mode 0 20 40 60 80 100 0 100 200 300 400 500 600 DC VOLTS DC AMPERES EXX10 SOFT MIN EXX10 STIFF MIN EXX10 SOFT MAX...

Page 24: ...output capabilities of the welding generator Curves of all other settings fall between the curves shown 0 10 20 30 40 50 60 70 80 0 50 100 150 200 250 300 350 DC Volts DC Amperes Max 150 Amps Min E AC...

Page 25: ...ehicle or trailer and comply with all DOT and other applicable codes Do not weld on base Welding on base can cause fuel tank fire or ex plosion Weld only on the four mounting brackets or bolt unit dow...

Page 26: ...ing auxiliary equipment If unit does not have GFCI receptacles use GFCI protected extension cord Do not use GFCI receptacles to power life support equipment 1 Equipment Grounding Terminal On Front Pan...

Page 27: ...On Always disconnect the negative battery cable before charging battery 5 4 Connecting The Battery 1 2 in Tools Needed Conn_Batt2 2014 11 S 0756 C 161 002 Shown with door open and rocker panel remove...

Page 28: ...Full levels If recovery tank coolant level was low also check coolant level in radiator Add coolant if level is below bottom of radia tor filler neck Unit is shipped with an engine coolant mix ture o...

Page 29: ...x2 0 2x70 2x2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2x2 0 2x70 2x3 0 2x95 2x3 0 2x95 2x4 0 2x120 400 1 0 60 2 0 70 3 0 95 4 0 1...

Page 30: ...ure connecting hardware is adequate for expected amperage and that the junction is properly insulated NOTICE When using these connections as a common work terminal all connections must be of the same...

Page 31: ...the junction is properly insulated NOTICE When using these connections as a common work terminal all connections must be of the same polarity NOTICE For common work connection work cable must be able...

Page 32: ...s Below 325 F 05 C turn engine control switch to Run position Push Preheat switch up for 30 seconds Turn Engine Control switch to Start Release Engine Control switch and Preheat switch when engine sta...

Page 33: ...To turn on heater connect heater plug to 120 volts AC receptacle Do not run engine while en gine block heater is on NOTICE In extremely cold weath er heater should be connected to power source when en...

Page 34: ...Complete Parts List is available at www MillerWelds com OM 266621 Page 30 6 4 Fuel Hour Gauge Descriptions...

Page 35: ...icator light flashes several times and then illuminatescontinuously When unit is shut down the indicator light flashes several times and the cooling fan will run briefly then both will turn off comple...

Page 36: ...gher dig arc force that gives a slightly more fluid weld puddle more arc snap and reduces the potential for electrode sticking at shorter arc lengths Stick E XX10 Soft This setting provides lower dig...

Page 37: ...g procedures RC11 supplies 60 Hz single phase power at weld power speed Maximum continuousoutput from RC11 is 10 kVA kW 3 SupplementaryProtectors CB4 CB5 4 Supplementary Protector CB6 CB4 and CB5 prot...

Page 38: ...lated to ground faults Reset and test GFCI receptacle according to the following procedures A solid green LED indicates power to the GFCI A solid red LED indicates that the GFCI has been tripped Reset...

Page 39: ...ECTION 8 MAINTENANCE TROUBLESHOOTING 8 1 Maintenance Label Mitsubishi Engine North America 1250 Greenbriar Dr Suite E Addison IL 60101 630 268 0750 Http www mitsubishi engine com Use web site to locat...

Page 40: ...ours Section 8 4 Battery Terminals Air Cleaner Hoses Air Cleaner Element Unreadable Labels Every 500 Hours 1 2 in 13 mm NOTICE Change engine oil and filter after initial 50 to 75 hours of use Engine M...

Page 41: ...ement three times 1 Intake Manifold 2 Service Indicator Optional Customer Supplied 3 Service Indicator Window 4 Service Indicator Reset Button Service air cleaner element if red band appears in window...

Page 42: ...Mark and disconnect leads at brush hold er assembly Remove assembly Press on brush to be sure springs compress Replace assembly if brushes are dam aged or if brush material is at or near mini mum leng...

Page 43: ...d coolant to recov ery tank until coolant level is between Cold Full and Hot Full levels If recovery tank coolant level was low also check coolant level in radiator Add coolant if level is below botto...

Page 44: ...on new fil ter Install new filter and reinstall re taining ring Inspect fuel lines and replace if cracked or worn To drain water from fuel system See engine manual To replace secondary in line fuel f...

Page 45: ...acing front panel 4 Fuse F1 F1 protects the stator exciter winding from overload If F1 opens weld and generator power is low or stops entirely 5 Supplementary Protector CB2 6 Supplementary Protector C...

Page 46: ...rts or opens in wir ing Failed boost inductor Have Factory Authorized Service Agent replace boost inductor if necessary Failed LEM Have Factory Authorized Service Agent replace LEM if necessary Open c...

Page 47: ...ring for opens Open secondary thermistor Have Factory Authorized Service Agent check thermistor on output heatsink and associated wiring for opens Shorted secondary thermistor Have Factory Authorized...

Page 48: ...uel information Use correct grade oil for cold weather see Section 8 1 Have Factory Authorized Service Agent check Preheat switch S4 control relay CR3 and the glow plug Engine suddenly stops Check oil...

Page 49: ...2 Filter Kit Mitsubishi S4l2 Includes 1 252781 Filter Fuel Spin on 1 213858 Filter Fuel In line 5 16x5 16 Mic 125 175 1 242882 Filter Lube Oil 1 197676 Element Air Cleaner 1 197679 Element Air Cleaner...

Page 50: ...OM 266621 Page 46 SECTION 10 ELECTRICAL DIAGRAMS Figure 9 1 Circuit Diagram For Welding Generator...

Page 51: ...OM 266621 Page 47 247 963 D...

Page 52: ...ge and current during run in period to properly seat piston rings and prevent wetstacking See name plate rating label or specifications section in this manual to find rated voltage and current NOTICE...

Page 53: ...n if not provided on generator Start engine and run for several minutes For Load Bank Set load bank switches and then adjust generator A V control so load equals rated voltage and current of generator...

Page 54: ...alth Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Gen erators 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable fro...

Page 55: ...e load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approximatelysix times more power while starting the motor than when ru...

Page 56: ...e Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milk...

Page 57: ...00 1 HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10 500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivat...

Page 58: ...must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volt...

Page 59: ...back to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch I...

Page 60: ...0 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads Use GFCI protection when operating auxiliary...

Page 61: ...Notes...

Page 62: ...Notes...

Page 63: ...Guns Subarc SAW Torches and External Cladding Heads Remote Controls and RFCS RJ45 Replacement Parts No labor Spoolmate Spoolguns Miller s True Blue Limited Warranty shall not apply to 1 Consumable co...

Page 64: ...your personal records Always provide Model Name and Serial Style Number Contact a DISTRIBUTOR or SERVICE AGENCY near you Welding Supplies and Consumables Options and Accessories Personal Safety Equip...

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