Miller Big Blue 450X Duo CST Owner'S Manual Download

Page: 20 / 64

Complete Parts List available at www.MillerWelds.com

OM-247969 Page 16

Do not work on unit if engine is running. Stop engine first.

Safe21 2012

−

Do not smoke while fueling or if near fuel.

Safe22 2012

−

Stop engine before fueling.

Safe23 2012

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Do not fuel a hot engine.

Safe24 2012

−

Use lift eye to lift unit and properly installed accessories only, not gas cylinders. Do not exceed maximum lift eye

rating (see Specifications).

Safe25 2012

−

Wear hat and safety glasses. Use ear protection and button shirt

collar. Use welding helmet with correct shade of filter. Wear complete

body protection.

Safe38 2012

−

Kasjf;laksf;lkasdf'l;aksdf;lkasd;flksadflkasd;lk

Become trained and read the instructions before working on the

machine or welding.

Safe40 2012

−

Engine fuel plus flames or sparks can cause fire.

Safe45 2012

−

Remove unit from shipping crate. Remove Owner’s Manual from unit.

Follow instructions to install muffler.

Safe46 2012

−

Read Owner’s Manual. Read labels on unit.

Safe47 2012

−

Read Owner’s Manual. Follow instructions to activate battery.

Safe48 2012

−

Summary of Contents for Big Blue 450X Duo CST

Page 1: ...017 03 Big Blue 450X 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 vis...

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: ...And Definitions 18 SECTION 4 SPECIFICATIONS 19 4 1 Serial Number And Rating Label Locations 19 4 2 Weld Power And Engine Specifications 19 4 3 Dimensions Weights And Operating Angles 19 4 4 Environme...

Page 4: ...cting And Cleaning Spark Arrestor Muffler 40 8 7 Servicing Engine Cooling System 41 8 8 Adjusting Engine Speed 41 8 9 Servicing Fuel And Lubrication Systems 42 8 10 Overload Protection 43 8 11 Trouble...

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 247969 Page 14...

Page 19: ...Protect yourself from electric shock by insulating yourself from work and ground Safe3 2012 05 Keep your head out of the fumes Safe6 2012 05 Use forced ventilation or local exhaust to remove the fumes...

Page 20: ...tection and button shirt collar Use welding helmet with correct shade of filter Wear complete body protection Safe38 2012 05 Kasjf laksf lkasdf l aksdf lkasd flksadflkasd lk Kasjf laksf lkasdf l aksdf...

Page 21: ...se generator inside a home or garage even if doors and win dows are open Safe87 2012 07 Only use generator outside and far away from windows doors and vents Safe88 2012 07 Do not use ether Using ether...

Page 22: ...isk 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 T...

Page 23: ...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 Mitsubishi S4L2 Water Cooled Four Cylinder Diesel Engine 24 7 HP T4F 11 5 gal 43 5 L 4 3 Dimensions Weights...

Page 24: ...ycle 1 100 Duty Cycle Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating Each unit is rated for welding at 175 amperes continuously Combined rating is 350 ampe...

Page 25: ...rves 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 E...

Page 26: ...utput 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 4 9 A...

Page 27: ...hicle 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 down...

Page 28: ...ng 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 Pane...

Page 29: ...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 removed...

Page 30: ...ull 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 of...

Page 31: ...0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2x2 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 2x...

Page 32: ...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 33: ...t 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 abl...

Page 34: ...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 35: ...o maintain a constant engine coolant temperature 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 h...

Page 36: ...Complete Parts List available at www MillerWelds com OM 247969 Page 32 6 4 Fuel Hour Gauge Descriptions...

Page 37: ...ator 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 complete...

Page 38: ...er 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 ar...

Page 39: ...ng procedures 2 Earth Leakage Circuit Breaker ELCB1 ELCB1 protects 240 V AC receptacles from overload and earth leakage fault If circuit breaker opens the receptacles do not work Place switch in On po...

Page 40: ...uit overloads short circuits or shocks not related 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 i...

Page 41: ...CTION 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 locate...

Page 42: ...rs 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 Man...

Page 43: ...ent 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 A...

Page 44: ...near mini mum length Check length from brush holder surface 1 Minimum Length New Length Replace Assembly if Brushes are Damaged 1 4 in 6 5mm 5 8 in 16mm 1 8 6 Inspecting And Cleaning Spark Arrestor Mu...

Page 45: ...intenancelabel Check coolant level in recovery tank daily If necessary add coolant to recov ery tank until coolant level is between Cold Full and Hot Full levels If recovery tank coolant level was low...

Page 46: ...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 fi...

Page 47: ...as facing 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 Protec...

Page 48: ...s 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 con...

Page 49: ...g 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 Ser...

Page 50: ...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 51: ...882 Filter Lube Oil 1 197676 Element Air Cleaner 1 197679 Element Air Cleaner Safety 1 244290 Brushholder Assy Generator W Leads 1 F1 085874 Fuse Mintr Cer Slo blo 10 Amp 250 Volt 1 BATT Battery Stor...

Page 52: ...OM 247969 Page 48 SECTION 10 ELECTRICAL DIAGRAMS Figure 9 1 Circuit Diagram For Welding Generator...

Page 53: ...OM 247969 Page 49 247 963 D...

Page 54: ...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 55: ...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 56: ...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 57: ...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 58: ...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 59: ...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 60: ...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 61: ...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 62: ...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 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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