Manuals / Miller Electric / Power Tools / Welding System

Miller Electric 145 DXR, 145 manual Installation, Installing Welding Generator, Movement, Hazards

Models: 145 DXR, 145 Blue Star 145

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SECTION 5 − INSTALLATION

5-1. Installing Welding Generator

Movement

Airflow Clearance

18 in

(460 mm)

18 in	18 in
(460 mm)	(460 mm)

	18 in	18 in
	(460 mm)
		(460 mm)

Location

Do not install unit where air flow is restricted or engine may overheat.

OR

Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes

		Always ground generator frame
		to vehicle frame to prevent elec-
		tric shock and static electricity
	2	hazards.
GND/PE	3	1	Metal Vehicle Frame
GND/PE		2	Equipment Grounding
		2	Equipment Grounding
			Terminal
		3	Grounding Cable

Bed liners, shipping skids, and some running gear insulate the welding generator from the ve- hicle frame. Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown.

Use #10 AWG or larger insulated

1copper wire to make metal-to-met- al grounding connection.

If unit does not have GFCI

receptacles, use GFCI- protected extension cord.

Ref 151 556 / Ref. 800 652 / 803 597-B / S-0854

OM-4417 Page 16

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Contents

OM-4417210 403F ProcessesDescription File Engine DriveFrom Miller to You Table of Contents Page Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burnsFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Compressed Air HazardsWelding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injuryPrincipal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation LE Soudage peut provoquer un in cendie ou une explosion DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peuvent être dangereux DES Organes Mobiles peuvent pro voquer des blessures LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peu Risque D’INCENDIE OU D’EXPLO- Sion LA Chaleur DU Moteur peut pro- voquer un incendie’AIR Comprimé peut provoquer des blessures LE Surchauffement peut endom- mager le moteur électrique DES Organes Mobiles peuvent provoquer des blessuresLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutInformation EMF Proposition californienne 65 AvertissementsPrincipales normes de sécurité − Specifications Symbol DefinitionsWeld, Power, And Engine Specifications − DefinitionsVolt-Ampere Curves Dimensions, Weights, And Operating AnglesDimensions Fuel Consumption Generator Power Curve Duty Cycle100% Duty Cycle at 80 Amperes CC/DC Minutes Welding− Installation Installing Welding GeneratorMovement HazardsOil Grounding Generator When Supplying Building SystemsEngine Prestart Checks − Standard Model Connecting The Battery DX Models Only Engine Prestart Checks − DX ModelConnecting To Weld Output Terminals Selecting Weld Cable Sizes45 m 60 m 70 m 90 m 105 m 120 m 10 − Put terminals− Operating the Welding Generator Controls Standard Models See SectionTo Start Description Of Controls Standard Models See SectionStop engine and add oil if light goes on see Section Controls DX Models See Section Description Of Controls DX Models See Section AC Receptacle RC1 Generator Power Panel Receptacles− Operating Auxiliary Equipment − Maintenance Routine MaintenanceServicing Air Cleaner Precleaner Paper ElementStop engine Standard Model ShownAdjusting Engine Speed Standard Models Only Stop Engine CloseValve Tools NeededIdle Speed Adjustment Adjusting Engine Speed DX Models OnlyWeld/Power Speed Adjustment − Troubleshooting TroubleshootingGenerator Power WeldingEngine Recommended Spare Parts − Parts ListRecommended Spare Parts − Electrical Diagrams Circuit Diagram For Standard ModelsCircuit Diagram for DX Models Grounding Generator To Truck Or Trailer Frame − Generator Power GuidelinesSelecting Equipment Grounding When Supplying Building Systems How Much Power Does Equipment Require?Approximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Cord Lengths for 120 Volt LoadsCurrent Load Watts Amperes Cord Lengths for 240 Volt LoadsStick Welding Procedure − Stick Welding Smaw GuidelinesStriking an Arc − Tapping Technique Electrode and Amperage Selection ChartStriking an Arc − Scratch Start Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingButt Joints Lap JointTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective ActionsTroubleshooting − Excessive Penetration Troubleshooting − Incomplete FusionTroubleshooting − Lack Of Penetration Troubleshooting − Distortion Troubleshooting − Burn-ThroughTroubleshooting − Waviness Of Bead Support ServiceYour distributor also gives To locate a Distributor or Service Agency visit Miller Electric Mfg. CoFor assistance in filing or settling claims, contact Your distributor and/or equipment manufacturer’s