Table of Contents | Miller Electric Blue Star 145, 145 DXR, 145

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING		1
1-1.	Symbol Usage	1
1-2.	Arc Welding Hazards	1
1-3.	Engine Hazards	3
1-4.	Compressed Air Hazards	3
1-5. Additional Symbols For Installation, Operation, And Maintenance		4
1-6. California Proposition 65 Warnings		5
1-7.	Principal Safety Standards	5
1-8.	EMF Information	5

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION		6
2-1.	Signification des symboles	6
2-2.	Dangers relatifs au soudage à l’arc	6
2-3.	Dangers existant en relation avec le moteur	8
2-4.	Dangers liés à l’air comprimé	9
2-5.	Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance	9
2-6.	Proposition californienne 65 Avertissements	11
2-7.	Principales normes de sécurité	11
2-8.	Information EMF	11
SECTION 3 − DEFINITIONS		12
SECTION 4 − SPECIFICATIONS		12
4-1.	Weld, Power, And Engine Specifications	12
4-2.	Dimensions, Weights, And Operating Angles	13
4-3.	Volt-Ampere Curves	13
4-4.	Fuel Consumption	14
4-5.	Duty Cycle	15
4-6.	Generator Power Curve	15
SECTION 5 − INSTALLATION		16
5-1.	Installing Welding Generator	16
5-2.	Grounding Generator When Supplying Building Systems	17
5-3.	Engine Prestart Checks − Standard Model	17
5-4.	Engine Prestart Checks − DX Model	18
5-5.	Connecting The Battery (DX Models Only)	18
5-6.	Connecting To Weld Output Terminals	19
5-7.	Selecting Weld Cable Sizes*	19
SECTION 6 − OPERATING THE WELDING GENERATOR		20
6-1.	Controls (Standard Models) (See Section 6-2)	20
6-2.	Description Of Controls (Standard Models) (See Section 6-1)	21
6-3.	Controls (DX Models) (See Section 6-4)	22
6-4.	Description Of Controls (DX Models) (See Section 6-3)	23
SECTION 7 − OPERATING AUXILIARY EQUIPMENT		24
SECTION 8 − MAINTENANCE		25
8-1.	Routine Maintenance	25
8-2.	Servicing Air Cleaner	26
8-3.	Adjusting Engine Speed (Standard Models Only)	27
8-4.	Adjusting Engine Speed (DX Models Only)	28
SECTION 9 − TROUBLESHOOTING		29
SECTION 10 − PARTS LIST		31
10-1.	Recommended Spare Parts	31
SECTION 11 − ELECTRICAL DIAGRAMS		32
SECTION 12 − GENERATOR POWER GUIDELINES		34
SECTION 13 − STICK WELDING (SMAW) GUIDELINES		41
COMPLETE PARTS LIST - www.MillerWelds.com
WARRANTY

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Contents

File Engine Drive OM-4417210 403FProcesses Description From Miller to You Table of Contents Page HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can kill Welding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skin Compressed Air Hazards Engine Hazards Falling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazard Radiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF Information Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer DES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peuDES Organes Mobiles peuvent pro voquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion ’EMPLOI Excessif peut LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures LES Fils DE Soudage peuvent provoquer des blessures Proposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF − Definitions − SpecificationsSymbol Definitions Weld, Power, And Engine Specifications Dimensions, Weights, And Operating Angles DimensionsVolt-Ampere Curves Fuel Consumption Minutes Welding Generator Power CurveDuty Cycle 100% Duty Cycle at 80 Amperes CC/DC Hazards − InstallationInstalling Welding Generator Movement Grounding Generator When Supplying Building Systems Engine Prestart Checks − Standard ModelOil Engine Prestart Checks − DX Model Connecting The Battery DX Models Only Put terminals Connecting To Weld Output TerminalsSelecting Weld Cable Sizes 45 m 60 m 70 m 90 m 105 m 120 m 10 − Controls Standard Models See Section − Operating the Welding Generator Description Of Controls Standard Models See Section Stop engine and add oil if light goes on see SectionTo Start Controls DX Models See Section Description Of Controls DX Models See Section Generator Power Panel Receptacles − Operating Auxiliary EquipmentAC Receptacle RC1 Routine Maintenance − Maintenance Standard Model Shown Servicing Air CleanerPrecleaner Paper Element Stop engine Tools Needed Adjusting Engine Speed Standard Models OnlyStop Engine Close Valve Adjusting Engine Speed DX Models Only Weld/Power Speed AdjustmentIdle Speed Adjustment Welding − TroubleshootingTroubleshooting Generator Power Engine − Parts List Recommended Spare PartsRecommended Spare Parts Circuit Diagram For Standard Models − Electrical Diagrams Circuit Diagram for DX Models − Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building Systems Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment KVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements Typical Connections To Supply Standby Power Cord Lengths for 240 Volt Loads Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Current Load Watts Amperes − Stick Welding Smaw Guidelines Stick Welding Procedure Electrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique 10-30 9090 End View of Work Angle Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode Holder Electrode Movement During Welding Conditions That Affect Weld Bead Shape 16 in 30 1.6 mm Tack Welds Butt JointsLap Joint Tee Joint Possible Causes Corrective Actions Troubleshooting − PorosityTroubleshooting − Excessive Spatter Weld Test Troubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Service Your distributor also givesSupport Your distributor and/or equipment manufacturer’s To locate a Distributor or Service Agency visitMiller Electric Mfg. Co For assistance in filing or settling claims, contact