Miller Electric BLUE STAR 145 DX manual

Blue Star 145 Processes Description Stick (SMAW) W elding Engine Driven Welding Generator OM-4417 210 403C 2005 − 10  Blue Star 145 DX  File: Engine Drive V isit our website at www.MillerWelds.com[...]

Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-800-4-A-Miller , or visit us at www .Mille[...]

T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

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OM-4417 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05  W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special saf[...]

OM-4417 Page 2 W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly of f from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the ar[...]

OM-4417 Page 3 STEAM AND HOT COOLANT can burn.  If possible, check coolant level when engine is cold to avoid scalding.  Always check coolant level at overflow tank, if pres- ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).  If the engine is warm, checking is needed, and there is no overflow[...]

OM-4417 Page 4 READ INSTRUCTIONS.  Use only genuine MILLER/Hobart replacement parts.  Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio naviga- [...]

OM-4417 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_fre 3/05  Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par [...]

OM-4417 Page 6 Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact ac[...]

OM-4417 Page 7  Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.  Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur .  Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- ver le bouchon. LES ACCUMULA TIONS DE GAZ ris- quent de [...]

OM-4417 Page 8 LIRE LES INSTRUCTIONS.  Utiliser seulement les pièces de rechange d’origine.  Ef fectuer la maintenance du moteur et du compresseur (s i applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). LE RA YONNEMENT HAUTE FRÉ- QUENCE (H.F .) risque de provoquer des interférences.  Le rayonnement haut[...]

OM-4417 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Engine Choke Read Operator ’s Manual A Amperes V V olts Engine Oil Fuel Battery (Engine) Engine Positive Negative Alternating Current (AC) Output h Hours s Seconds T ime Protective Earth (Ground) Circuit Protector T emperature SECTION 4 − SPECIFICA TIONS 4-1. W eld, Power , And En[...]

OM-4417 Page 10 4-2. Dimensions, Weights, And Operating Angles Dimensions Height 22-3/4 in (578 mm) D Width 22-3/4 in (577 mm) D Depth 31-5/8 in (803 mm)  Do not exceed tilt angles or engine could A 31-5/8 in (803 mm) B  Do not e x ceed tilt angles or engine co u ld be damaged or unit could tip. B 10-9/16 in (268 mm)  Do not move or operat[...]

OM-4417 Page 1 1 4-4. Fuel Consumption 220 637 DC WELD AMPERES A T RA TED DUTY CYCLE US Gal./Hr . 0 25 50 75 100 125 150 175 200 0.00 0.20 0.40 0.60 0.80 1.00 IDLE AUXILIARY POWER KW A T 100% DUTY CYCLE US Gal./Hr . 0 12 345 6 0.00 0.20 0.40 0.60 0.80 1.00 IDLE[...]

OM-4417 Page 12 Continuous W elding 4-5. Duty Cycle 220 625 − A Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating.  Exceeding duty cycle can damage unit and void warranty . 100% Duty Cycle at 80 Amperes CC/DC 20% Duty Cycle at 145 Amperes CC/DC % DUTY CYCLE WELD AMPERES 0 0 10 20 20 30 40 40 50 60 [...]

OM-4417 Page 13 SECTION 5 − INST ALLA TION 5-1. Installing W elding Generator Ref 151 556 / Ref. 800 652 / 803 594-B / S-0854 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) OR Movement Airflow Clearance Location Shown with optional running gear.  Always securely fasten welding generator onto transport vehicle or tra[...]

OM-4417 Page 14 5-3. Grounding Generator When Supplying Building Systems GND/PE 1 2 Use ground device as stated in electrical codes. 2 3 800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device  Ground generator to sys- tem earth ground if supply- ing power to a premises (home, shop[...]

OM-4417 Page 15 5-5. Engine Prestart Checks − DX Model 803 595-B Full Gasoline 1/2 in (13 mm) Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. 1 Fuel V alve Open valve.  Close fuel valve before moving unit or carburetor may flood and make starting difficult. Fuel Add fresh fuel before [...]

OM-4417 Page 16 5-7. Connecting T o W eld Output T erminals 803 596 − B / 803 778-A 1 Positive (+) W eld Output T erminal 2 Negative ( − ) W eld Output T erminal For Direct Current Electrode Posi- tive (DCEP), connect work cable to Negative ( − ) terminal and electrode holder to Positive (+) terminal. For Direct Current Electrode nega- tive ([...]

OM-4417 Page 17 Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MA TERIAL THICKNESS REFERENCE CHART[...]

OM-4417 Page 18 SECTION 6 − OPERA TING THE WELDING GENERA T OR 6-1. Controls (Standard Models) (See Section 6-2) 803 956 − B / 803 594 − B / 218 610 4 1 6 3 5 2[...]

OM-4417 Page 19 6-2. Description Of Controls (Standard Models) (See Section 6-1 ) 1 Engine Switch Use switch to control ignition circuit. T urn switch to On position when starting engine. Turn switch to Off position to stop engine. En- gine cannot be started with switch in the Off position. Engine stops if oil level is too low . Engine can- not be [...]

OM-4417 Page 20 6-3. Controls (DX Models) (See Section 6-4) 803 596 − A / 803 595 − A / 218 610 1 8 7 3 5 4 6 2[...]

OM-4417 Page 21 6-4. Description Of Controls (DX Models) (See Section 6-3 ) 1 Engine Switch Use switch to control ignition circuit. T urn switch t o Start position for electric start. Turn switch to On position to start engine using starter ha ndle (recoil). T urn switch to Off posi- tion to stop engine. 2 Low Oil Level Light Light goes on and engi[...]

OM-4417 Page 22 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT Set Current control to maximum for full generator power output at AC receptacles. NOTE 7-1. Generator Power Panel Receptacles  If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord.  Generator power decreases as weld current increases . 1 240 V AC Receptacle[...]

OM-4417 Page 23 SECTION 8 − MAINTENANCE Follow the storage procedure in the engine owner ’s manual if the unit will not be used for an extended period. NOTE 8-1. Routine Maintenance  Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often[...]

OM-4417 Page 24 8-2. Servicing Air Cleaner aircleaner6 9/00 − 803 404  Stop engine.  Do not run engine without a ir cleaner or with dirty element. 1 Precleaner 2 Paper Element  Do not wash paper element or clean with compressed air. Remove cover . Was h precleaner with soap and wa- ter solution. Allow precleaner to air dry completely . D[...]

OM-4417 Page 25 8-3. Adjusting Engine Speed (Standard Models Only) 803 594-B T ools Needed: 3750 ± 30 rpm (62 Hz) After tuning engine, check engine speed. See table for proper no load speed. If necessary , adjust speed as follows: Start engine and run until warm. 1 Adjustment Screw T o increase speed, turn screw in (clockwise). T o decrease speed,[...]

OM-4417 Page 26 8-4. Adjusting Engine Speed (DX Models Only) 803 595 − B 2500 ± 100 rpm (42 Hz) 3750 ± 30 rpm (62 Hz) T ools Needed: After tuning engine, check engine speed. See table for proper no load speed. If necessary , adjust speed as follows: Start engine and run until warm. Set Weld Output Control to Max. W eld/Power Speed Adjustment 1 [...]

OM-4417 Page 27 SECTION 9 − TROUBLESHOOTING 9-1. T roubleshooting A. Welding T rouble Remedy No weld output or generator power out- put at ac receptacles. Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, rotor , stator , integrated rectifier SR2, and Weld O[...]

OM-4417 Page 28 T rouble Remedy Low output at generator power ac receptacles. Check W eld Output control setting. Check engine speed, and adjust if necessary (see Section 8-3 or 8-4). Open circuit voltage is reduced as engine speed drops. Erratic output at generator power ac receptacles Check fuel level. receptacles. Have Factory Authorized Service[...]

OM-4417 Page 29 SECTION 10 − ELECTRICAL DIAGRAMS 226 737-A Figure 10-1. Circuit Diagram For Standard Models[...]

OM-4417 Page 30 226 738-A Figure 10-2. Circuit Diagram for DX Models[...]

OM-4417 Page 31 SECTION 1 1 − GENERA T OR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. NOTE 1 1-1. Selecting Equipment gen_pwr 1 1/02 − Ref. ST-159 730 / ST -800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Prong[...]

OM-4417 Page 32 1 1-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e ground device as stated in electri[...]

OM-4417 Page 33 1 1-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starti ng W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 28[...]

OM-4417 Page 34 1 1-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in [...]

OM-4417 Page 35 1 1-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine starting [...]

OM-4417 Page 36 1 1-10. T ypical Connections T o Supply Standby Power  Have only qualified persons perform these connections according to all applicable codes and safety practic- es.  Properly install and ground this equipment according to its Owner ’s Manual and national, state, and local codes.  Customer -supplied equipment is re- quir[...]

OM-4417 Page 37 1 1-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 [...]

OM-4417 Page 38 SECTION 12 − STICK WELDING (SMA W) GUIDELINES 12-1. Stick Welding Procedure stick 12/96 − ST-151 593  W eld current starts when electrode touches work- piece.  W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pl ac e wo rk c lam p as close to the weld as pos[...]

OM-4417 Page 39 12-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 6010 & 601 1 6013 7014 7018 7024 Ni-Cl 308L 50 100 150 200 250 300 350 400 450 ELECTR[...]

OM-4417 Page 40 12-5. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° GROOVE WELDS FILLET WELDS End V iew of Work Angle Sid e V iew of Electrode Angle End V iew of Work Angle S ide View of Electrode Angle 10 ° -30 ° 12-6. Poor Weld Bead Characteristics S-0053-A 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater[...]

OM-4417 Page 41 12-8. Conditions That Affect W eld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. NOTE S-0061 ELECTRODE ANGLE ARC LENGTH TRA VEL SPEED Slow Normal Fast 10 ° - 30 ° Drag T oo Short Normal T o o Long Spatter Angle T oo Small Angle T oo Large Correct Angle 12-9. Elect[...]

OM-4417 Page 42 12-10. Butt Joints S-0662 1 T ack Welds Prevent ed ge s o f j oint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. 2 Square Groove W eld Good for materials up to 3/16 in (5 mm) thick. 3 Single V -Groove Weld Good for materials 3/16 − 3/4 in (5-19 mm) thick. Cut bevel with oxy[...]

OM-4417 Page 43 12-13. W eld T est S-0057-B 1 V ise 2 W e ld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 T o 3 in 1/4 in 3 2 1 2 T o 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 12-14. T roubleshooting − Porosity Porosity − small cavities or holes resulting from gas pockets i n weld metal. Poss[...]

OM-4417 Page 44 12-16. T roubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insuf ficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in prop[...]

OM-4417 Page 45 12-19. T roubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 12-20. T roubleshooting − W avine[...]

OM-4417 Page 46 SECTION 13 − P ARTS LIST 803 795 − B  Hardware is common and not available unless listed. 1 2 3 4 5 6 7 8 10 11 13 14 15 23 24 29 30 31 32 33 2 34 35 36 37 39 38 9 12 28 27 26 25 22 21 20 19 17 18 16 Figure 13-1. Main Assembly Standard Model[...]

OM-4417 Page 47 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly (Standard Model) Quantity 1A C − Z 218767 Reactor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 099255 T erminal, Pwr Output Neutral 2 . . . . . . . . . . . . . . . . . .[...]

OM-4417 Page 48 803 797-C  Hardware is common and not available unless listed. 59 1 2 3 4 5 6 7 8 10 11 16 17 21 22 23 24 25 13 33 34 35 37 38 39 40 45 46 48 49 50 51 52 53 54 55 56 57 58 14 15 36 9 47 20 19 18 12 52 26 28 27 29 30 31 32 42 43 44 41 Figure 13-2. Main Assembly DX Model Description Part No. Dia. Mkgs. Item No. Figure 13-2. Main As[...]

OM-4417 Page 49 Description Part No. Dia. Mkgs. Item No. Figure 13-2. Main Assembly (Continued) Quantity 15 221007 Bracket,Support Fuel T ank 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 223079 T ank, Fuel 5.0 Gal 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

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Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. miller_warr 1/05 Y o ur distributor also gives you ... Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor . The expertise [...]

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