Miller Electric 145 DX manual

Blue Star 145

Processes

Description

Stick (SMAW) Welding

Engine Driven Welding Generator

OM-4417 210 403C

2005−10

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Blue Star 145 DX

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File: Engine Drive

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www.MillerWelds.com

Contents

Main From Miller to You TABLE OF CONTENTS Page OM-4417 Page 1 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING Warning: Protect yourself and others from injury read and follow these precautions. 1-1. Symbol Usage Marks a special safety message. 1-2. Arc Welding Hazards 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. FUEL can cause fire or explosion. MOVING PARTS can cause injury. HOT PARTS can cause severe burns. 1-4. Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death. COMPRESSED AIR can cause injury. TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury. HOT METAL from air arc cutting and gouging can cause fire or explosion. 1-6. California Proposition 65 Warnings 1-7. Principal Safety Standards 1-8. EMF Information OM-4417 Page 5 SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 2-1. Signification des symboles 2-2. Dangers relatifs au soudage larc UN CHOC LECTRIQUE peut tuer. Une tension DC importante subsiste lintrieur des onduleurs aprs avoir coup lalimentation. 2-3. Dangers existant en relation avec le moteur LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. LE CARBURANT MOTEUR peut provo- quer un incendie ou une explosion. DES ORGANES MOBILES peuvent pro- voquer des blessures. DES PIECES CHAUDES peuvent provo- quer des brlures et blessures. 2-4. Dangers lis lair comprim RESPIRER LAIR COMPRIM peut pro- voquer des blessures graves ou causer la mort. LAIR COMPRIM peut provoquer des blessures. LAIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo- quer des blessures. Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in- cendie ou une explosion. 2-6. Proposition californienne 65 Avertissements 2-7. Principales normes de scurit 2-8. Information EMF SECTION 3 DEFINITIONS h Hours s 3-1. Symbol Definitions SECTION 4 SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications 4-2. Dimensions, Weights, And Operating Angles 4-3. Volt-Ampere Curves 4-4. Fuel Consumption 4-5. Duty Cycle 4-6. Generator Power Curve SECTION 5 INSTALLATION 5-1. Installing Welding Generator 5-2. Grounding Generator To Truck Or Trailer Frame 5-3. Grounding Generator When Supplying Building Systems 5-4. Engine Prestart Checks Standard Model 5-5. Engine Prestart Checks DX Model + 5-6. Connecting The Battery (DX Models Only) 5-7. Connecting To Weld Output Terminals 5-8. Selecting Weld Cable Sizes* Page SECTION 6 OPERATING THE WELDING GENERATOR 6-1. Controls (Standard Models) (See Section 6-2) 6-2. Description Of Controls (Standard Models) (See Section 6-1) 6-3. Controls (DX Models) (See Section 6-4) 6-4. Description Of Controls (DX Models) (See Section 6-3) SECTION 7 OPERATING AUXILIARY EQUIPMENT Set Current control to maximum for full generator power output at AC receptacles. 7-1. Generator Power Panel Receptacles SECTION 8 MAINTENANCE 8-1. Routine Maintenance 8-2. Servicing Air Cleaner 8-3. Adjusting Engine Speed (Standard Models Only) 8-4. Adjusting Engine Speed (DX Models Only) SECTION 9 TROUBLESHOOTING 9-1. Troubleshooting A. Welding B. Generator Power C. Engine Page Page SECTION 11 GENERATOR POWER GUIDELINES 11-1. Selecting Equipment 11-2. Grounding Generator To Truck Or Trailer Frame 11-3. Grounding When Supplying Building Systems 11-4. How Much Power Does Equipment Require? 11-5. Approximate Power Requirements For Industrial Motors 11-6. Approximate Power Requirements For Farm/Home Equipment 11-7. Approximate Power Requirements For Contractor Equipment 11-8. Power Required To Start Motor 11-9. How Much Power Can Generator Supply? 11-10.Typical Connections To Supply Standby Power 11-11.Selecting Extension Cord (Use Shortest Cord Possible) SECTION 12 STICK WELDING (SMAW) GUIDELINES 12-1. Stick Welding Procedure OM-4417 Page 39 12-2. Electrode and Amperage Selection Chart 2 3 12-3. Striking an Arc Scratch Start Technique 1 2 3 12-5. Positioning Electrode Holder 12-6. Poor Weld Bead Characteristics 12-7. Good Weld Bead Characteristics 12-8. Conditions That Affect Weld Bead Shape 12-9. Electrode Movement During Welding 12-10.Butt Joints 12-11.Lap Joint 12-12.Tee Joint 12-13.Weld Test 12-14.Troubleshooting Porosity 12-15.Troubleshooting Excessive Spatter 12-16.Troubleshooting Incomplete Fusion 12-17.Troubleshooting Lack Of Penetration 12-18.Troubleshooting Excessive Penetration 12-19.Troubleshooting Burn-Through 12-20.Troubleshooting Waviness Of Bead 12-21.Troubleshooting Distortion SECTION 13 PARTS LIST Figure 13-1. Main Assembly Standard Model Page Page Page Page Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Effective January 1, 2005 (Equipment with a serial number preface of LF or newer) Please complete and retain with your personal records. For Service Always provide Model Name and Serial/Style Number. Contact a DISTRIBUTOR or SERVICE AGENCY near you. Owners Record