Miller Electric STAR 145 DX Owner's Manual

Blue Star 145ProcessesDescriptionStick (SMAW) WeldingEngine Driven Welding GeneratorOM-4417 210 403ASeptember 2004Visit our website atwww.MillerWelds

OM-4417 Page 6LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du gaz protecteur en cas denon util

OM-4417 Page 7L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protectio

OM-4417 Page 8LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-marrer ou d’arrêter le moteur.

OM-4417 Page 9SECTION 3 − DEFINITIONS3-1. Symbol DefinitionsEngine ChokeRead Operator’sManual AAmperesVVoltsEngine Oil Fuel Battery (Engine) EnginePos

OM-4417 Page 104-3. Fuel Consumption220 637DC WELD AMPERES AT RATED DUTY CYCLEUS Gal./Hr.0 25 50 75 100 125 150 175 2000.000.200.400.600.801.00IDLECon

OM-4417 Page 114-5. Generator Power Curve220 581The ac generator power curvesshow the generator power availablein amperes at the receptacles.AMPERES00

OM-4417 Page 12SECTION 5 − INSTALLATION5-1. Installing Welding Generatorinstall1 11/02 − 802 512-A / Ref. 151 556 / 158 936-A / 800 652-A / S-0854 / 8

OM-4417 Page 135-3. Grounding Generator When Supplying Building SystemsGND/PE1 2Use ground device asstated in electrical codes.23800 576-B1 Equipment

OM-4417 Page 145-5. Engine Prestart Checks − DX Model803 595−AFullGasoline1/2 in(13 mm)Check all fluids daily. Engine mustbe cold and on a level surfa

OM-4417 Page 155-7. Connecting To Weld Output Terminals803 596−A1 Positive (+) Weld OutputTerminal2 Negative (−) Weld OutputTerminalFor Direct Current

Miller Electric manufactures a full lineof welders and welding related equipment.For information on other quality Millerproducts, contact your local M

OM-4417 Page 16SECTION 6 − OPERATING THE WELDING GENERATOR6-1. Controls (Standard Models) (See Section 6-2)803 956−A / 803 594−A / 218 610416352

OM-4417 Page 176-2. Description Of Controls (Standard Models) (See Section 6-1)1 Engine SwitchUse switch to control ignition circuit. Turnswitch to On

OM-4417 Page 186-3. Controls (DX Models) (See Section 6-4)803 596−A / 803 595−A / 218 61018732546

OM-4417 Page 196-4. Description Of Controls (DX Models) (See Section 6-3)1 Engine SwitchUse switch to control ignition circuit. Turnswitch to Start po

OM-4417 Page 20SECTION 7 − OPERATING AUXILIARY EQUIPMENT Set Current control to maximum for full generator power output at AC receptacles.NOTE7-1. Gen

OM-4417 Page 21SECTION 8 − MAINTENANCEFollow the storage procedure in the engine owner’s manual if the unit will not beused for an extended period.NOT

OM-4417 Page 228-2. Servicing Air Cleaner aircleaner6 9/00 − 803 404 Stop engine. Do not run engine without aircleaner or with dirty element.1 Prec

OM-4417 Page 238-3. Adjusting Engine Speed (Standard Models Only)803 594−ATools Needed:3750 ± 30 rpm (62 Hz)1After tuning engine, check enginespeed.

OM-4417 Page 248-4. Adjusting Engine Speed (DX Models Only)803 595−A2500 ± 100 rpm (42 Hz)3750 ± 30 rpm (62 Hz)Tools Needed:After tuning engine, check

OM-4417 Page 25SECTION 9 − TROUBLESHOOTING9-1. TroubleshootingA. WeldingTrouble RemedyNo weld output or generator power out-put at ac receptacles.Be s

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol

OM-4417 Page 26Trouble RemedyLow output at generator power acreceptacles.Check Weld Output control setting.Check engine speed, and adjust if necessary

OM-4417 Page 27SECTION 10 − ELECTRICAL DIAGRAMS218 706−BFigure 10-1. Circuit Diagram For Welding Generator

OM-4417 Page 28SECTION 11 − GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding generato

OM-4417 Page 2911-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4417 Page 3011-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

OM-4417 Page 3111-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4417 Page 3211-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-4417 Page 3311-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable cod

OM-4417 Page 3411-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, u

OM-4417 Page 35SECTION 12 − STICK WELDING (SMAW) GUIDELINES12-1. Stick Welding Procedurestick 12/96 − ST-151 593 Weld current starts whenelectrode to

OM-4417 Page 3612-2. Electrode and Amperage Selection ChartRef. S-087 985-A3/321/85/323/167/321/41/165/643/321/85/323/167/321/43/321/85/323/167/321/43

OM-4417 Page 3712-5. Positioning Electrode HolderS-006090° 90°10°-30°45°45°GROOVE WELDSFILLET WELDSEnd View of Work Angle Side View of Electrode Angle

OM-4417 Page 3812-8. Conditions That Affect Weld Bead ShapeWeld bead shape is affected by electrode angle, arc length, travel speed, andthickness o

OM-4417 Page 3912-10. Butt JointsS-06621 Tack WeldsPrevent edges of joint from drawingtogether ahead of electrode by tackwelding the materials in posi

OM-4417 Page 4012-13. Weld TestS-0057-B1 Vise2 Weld Joint3 HammerStrike weld joint in direction shown.A good weld bends over but doesnot break.2 To 3

OM-4417 Page 4112-16. Troubleshooting − Incomplete FusionIncomplete Fusion − failure of weld metal to fuse completely withbase metal or a preceeding w

OM-4417 Page 4212-19. Troubleshooting − Burn-ThroughBurn-Through − weld metal melting completely through base metal resultingin holes where no metal r

OM-4417 Page 43Notes16 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 i

OM-4417 Page 44SECTION 13 − PARTS LIST803 795−A Hardware is common andnot available unless listed.123456781011121314151716181920212223242526272829303

OM-4417 Page 45DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-1. Main Assembly (Standard Model)Quantity1AC−Z 218767 Reactor 1. . . . . . . . . . . .

OM-4417 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom _nd_8/03 Warning: Protect yourself and others from injury — read and follow these

OM-4417 Page 46803 797−A Hardware is common andnot available unless listed.575058591234568915161819 202122232426271028293031323435363738394041424344

OM-4417 Page 47DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 13-2. Main Assembly (Continued)Quantity11 087341 Bumper,Door 1.000 Od X .750 High Rbr 50 Duro

OM-4417 Page 48

Warranty Questions?Call1-800-4-A-MILLERfor your localMiller distributor.miller_warr 6/04Your distributor also givesyou ...ServiceYou always get the fa

PRINTED IN USA  2004 Miller Electric Mfg. Co. 1/04Miller Electric Mfg. Co.An Illinois Tool Works Company1635 West Spencer StreetAppleton, WI 54914 US

OM-4417 Page 2Welding on closed containers, such as tanks, drums, orpipes, can cause them to blow up. Sparks can fly off from thewelding arc. The flyi

OM-4417 Page 3STEAM AND HOT COOLANT can burn. If possible, check coolant level when engine is cold toavoid scalding. Always check coolant level at o

OM-4417 Page 4READ INSTRUCTIONS. Use only genuine MILLER/Hobart replacementparts. Perform engine and air compressor (if applicable)maintenance and s

OM-4417 Page 5SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONrom_fre 8/03 Avertissement: Protégez vous et les autres des blessures − lisez