Miller Electric Welding System 145 DX User Manual

Issued January 2008 • Index No. ED/2.5  
Gas Engine-Driven Welder/  
AC Generator  
®
Blue Star Series  
Industrial Applications  
Processes  
Weld Output Range  
For DC Stick/TIG 145: 40 – 145 A 185: 55 – 185 A  
Maintenance  
Stick (SMAW)  
Repair  
Farm/Ranch Applications  
Construction  
DC TIG (GTAW)  
Air Plasma Cutting and Gouging  
with optional Spectrum models  
Generator Output Rated at 104˚ F (40˚ C)  
145: 4500 Watts Peak, 4000 Watts Continuous  
185: 6000 Watts Peak, 5500 Watts Continuous  
Quick  
Specs  
Stand-alone Generator  
Weight 145: 263 lb (119 kg) 145 DX: 309 lb (140 kg)  
185: 267 lb (121 kg) 185 DX: 315 lb (143 kg)  
®
Four Blue Star models to choose from.  
See Page 3 for comparison information.  
The Power of Blue.  
Reliable Blue Star engine drives  
are the standard for portable  
welder/generators.  
Blue Star Series  
Blue Star 145  
Blue Star 145 DX  
Blue Star 185  
Blue Star 185 DX (shown)  
Large 5-gallon fuel capacity  
(DX models) leads its class.  
Longer run time for welder or  
generator usage. See page 2 for  
fuel consumption data.  
Single-range amperage control makes  
setting amperage levels easy.  
Class-leading 6000-watt peak power  
(185 models) of regulated power to  
extend power tool life.  
Standard Auto Idle (DX models) idles  
engine while not in use. Reduces fuel  
consumption and noise.  
Bulletproof technology eliminates use of  
complicated circuit boards.  
Compact and portable, its small  
footprint uses little truck space.  
Optional running gear also makes  
the Blue Star one-man portable.  
Hour meter provides easy tracking of  
run hours for maintenance intervals  
(DX models).  
Receptacle coversimprove reliability by  
protecting receptacles from debris.  
Reliable air-cooled OHV engines ensure  
consistent engine performance.  
240 V and 120 V receptacles provide  
power for jobsite tools. Receptacles are  
circuit-breaker protected (optional  
Quick-reference parameter chart provides  
convenient amperage setting guidance.  
120 VAC GFCI receptacles are available).  
Welder/generator is warranted by Miller for 3 years, parts and labor.  
Engine is warranted 2 years by engine manufacturer.  
Miller Electric Mfg. Co.  
An Illinois Tool Works Company  
1635 West Spencer Street  
Appleton, WI 54914 USA  
International Headquarters Web Site  
Phone: 920-735-4505  
USA FAX: 920-735-4134  
Canadian FAX: 920-735-4169  
International FAX: 920-735-4125  
 
®
Blue Star Value  
Why Upgrade?  
Feature  
Blue Star 145  
4500 W Peak  
145 A at 25 VDC  
Kohler CS10  
Standard  
Blue Star 145 DX  
4500 W Peak  
145 A at 25 VDC  
Kohler CS10  
Standard  
Blue Star 185  
6000 W Peak  
185 A at 25 VDC  
Honda GX390  
Standard  
Blue Star 185 DX  
6000 W Peak  
185 A at 25 VDC  
Kohler CS12.75  
Standard  
UPGRADE  
UPGRADE  
UPGRADE  
Generator Power  
DC Stick/TIG Output  
Engine  
Blue  
Star  
96%  
Others  
Receptacle Covers  
Fuel Capacity  
Auto Idle  
UPGRADE  
UPGRADE  
5 Gallons  
1.8 Gallons  
5 Gallons  
1.7 Gallons  
• 96% of current owners rated  
their Blue Star as “good to  
very good value.”  
No  
No  
UPGRADE Yes  
UPGRADE Yes  
No  
No  
UPGRADE Yes  
Hour Meter  
UPGRADE Yes  
*Based on an independent survey  
of thousands of Blue Star owners.  
Engine Starting  
Recoil Only UPGRADE Electric Start  
Recoil Only UPGRADE Electric Start  
Power Usage Guide  
Typical Household  
The Power Generator is designed to provide strong power while keeping the voltage within  
10% of 120/240 VAC. 120/240 VAC 10% is the range where tools and motors are designed  
to operate. This increases tool/motor performance and tool/motor life.  
Starting  
Watts  
Running  
Watts  
Appliance  
Dishwasher,  
Cool Dry  
1,400  
1,400  
700  
Hot Dry  
1,450  
Typical Contractor Tools  
Typical Farm Equipment  
Electric Range,  
6-in element  
0
1,500  
2,100  
625  
Starting  
Running  
Watts  
Starting  
Running  
Watts  
Watts  
Machine  
Watts  
Tool  
8-in element  
0
Portable Conveyor, 1/2 HP  
3,400  
1,000  
Hand Drill,  
Microwave Oven, 625 watts  
Refrigerator or Freezer  
Automatic Washer  
Clothes Dryer, Gas  
Electric  
800  
2,200  
2,300  
1,800  
1,800  
350  
600  
350  
600  
Farm Duty Motors  
(e.g. Conveyors, Feed  
Augers, Air Compressors)  
1/4 inch  
700  
1/2 inch  
1,150  
700  
Circular Saw  
1/3 Horsepower  
1-1/2 Horsepower  
Washer, 2 gal/min  
550 PSI  
1,720  
8,200  
720  
500  
500  
6-1/2 inch  
5,750  
2,200  
1,400  
6,300  
2,500  
1,400  
1,800  
1,100  
8-1/4 inch  
Garage Door Opener,  
1/4 HP  
Table Saw, 10 inch  
Band Saw, 14 inch  
Air Compressor  
1/2 Horsepower  
1-1/2 Horsepower  
Electric Chain Saw  
1/2 Horsepower, 12 in  
2 Horsepower, 14 in  
Flood Lights  
1,100  
1,400  
550  
725  
4,500  
6,100  
1,400  
1,600  
1/2 HP  
700 PSI  
Furnace Fan, gas/fuel oil  
1/8 Horsepower  
1/6 Horsepower  
1/4 Horsepower  
1/3 Horsepower  
1/2 Horsepower  
Lights  
3,000  
8,200  
1,000  
2,200  
500  
300  
Typical Industrial Motors  
750  
500  
1,000  
1,400  
2,350  
0
600  
Starting  
Running  
Watts  
1,100  
1,100  
1,100  
1,100  
700  
Motor  
Watts  
875  
Split Phase  
as indicated  
50200  
750  
1/8 Horsepower  
800  
300  
875  
125  
100  
250  
HID  
Radio  
0
1/2 Horsepower  
3,175  
313  
Metal Halide  
Well Pump, 1/3 Horsepower  
1/2 Horsepower  
Sump Pump, 1/3 Horsepower  
1/2 Horsepower  
Central Air Conditioner  
10,000 BTU  
1,400  
2,100  
1,300  
2,150  
Capacitor Start—  
Induction Run  
1000  
1,250  
600  
Mercury  
1,000  
800  
1,000  
200  
500  
Vapor  
1/3 Horsepower  
2,020  
8,200  
720  
Submersible Pump, 400 gph  
Centrifugal Pump, 900 gph  
High Pressure Washer  
1/2 Horsepower  
1 Horsepower  
Wet & Dry Vac,  
1.7 Horsepower  
1-1/2 Horsepower  
1,050  
2,200  
900  
Capacitor Start—  
Capacitor Run  
2,200  
3,300  
4,950  
6,500  
7,800  
1,500  
2,500  
3,800  
5,000  
6,000  
1-1/2 Horsepower  
Fan,  
8,100  
2,000  
3,150  
6,100  
950  
20,000 BTU  
1,600  
24,000 BTU  
1/8 Horsepower  
1/2 Horsepower  
1,000  
3,500  
400  
32,000 BTU  
1,100  
900  
900  
40,000 BTU  
3
 
Genuine Miller Options and Accessories  
Weld Leads #195 195  
Lifting Eye  
#195 353  
Secure lift point  
when picking up  
machine.  
Consists of 50 ft (15.2 m), No. 2 electrode  
cable with insulated electrode holder and  
lug, 50 ft (15.2 m) No. 2 work cable with  
clamp and lug.  
Protective Cover #195 193  
Blue with logo. Attractive, mildew-resistant,  
odor-free, water-resistant cover protects  
your machine’s finish and includes  
easy-off handles.  
No. 38 Hand Running Gear #195 352  
Spectrum® 375  
#903 891  
115/230 V with 20 ft  
torch. Cuts up to  
3/8 in mild steel.  
See Lit. Index  
No. PC/9.1.  
Compact, balanced, lightweight, wheel-  
barrow-style running gear designed for  
easy on-site mobility.  
Receptacle Kit  
Spark Arrestor #195 351  
#088 297 6 ft cord with NEMA 6-50P plug  
to adapt to any 240 V application.  
#300 404 4-wire, 30 A Twistlock provides  
neutral wire required for 120/240 V backup  
power systems.  
For DX Models only. Standard models  
include engine manufacturer’s spark  
arrestor. Mandatory when operating on  
California grasslands, brush, or forest-  
covered land and all National Forests. For  
other areas, check your state and local laws.  
Remote Oil Drain Kit #224 831  
Quick connect for easy engine maintenance.  
240 V Electrical Plug #213 380  
For use with 240 V receptacle.  
Ordering Information  
Power Source and Options  
Stock No.  
Description  
Qty.  
Price  
Blue Star® 145  
#907 266  
Kohler engine, recoil start  
Blue Star® 145 with GFCI  
Blue Star® 145 DX  
Blue Star® 145 DX with GFCI  
Blue Star® 145 DX (no battery)  
Blue Star® 185  
#907 266-01-1  
#907 267  
Kohler engine, recoil start, GFCI 120 V receptacles.  
Kohler engine, electric start, 5-gallon fuel tank, auto idle  
Kohler engine, electric start, 5-gallon fuel tank, auto idle, GFCI 120 V receptacles  
Kohler engine, electric start, 5-gallon fuel tank, auto idle. (With no battery)  
Honda engine, recoil start  
#907 267-01-2  
#907 267-01-3  
#907 268  
Blue Star® 185 with GFCI  
Blue Star® 185 DX  
Blue Star® 185 DX with GFCI  
Blue Star® 185 DX (no battery)  
#907 268-01-1  
#907 269  
Honda engine, recoil start, GFCI 120 V receptacles  
Kohler engine, electric start, 5-gallon fuel tank, auto idle  
Kohler engine, electric start, 5-gallon fuel tank, auto idle, GFCI 120 V receptacles  
Kohler engine, electric start, 5-gallon fuel tank, auto idle. (With no battery)  
#907 269-01-2  
#907 269-01-3  
Accessories  
Lifting Eye  
#195 353  
#224 831  
#195 352  
#195 351  
#195 193  
#088 297  
#300 404  
#213 380  
Provides safe and secure lifting of machine  
Quick connect for easy engine maintenance (Purchase from Miller Service Parts)  
Balanced running gear for easy transport  
For DX models only. (Standard models include engine manufacturer’s spark arrestor)  
Blue with logo  
6 ft cord with 240 V plug (Purchase from Miller Service Parts)  
4-wire, 30 A Twistlock receptacle (NEMA L14-30)  
Remote Oil Drain Kit  
No. 38 Hand Running Gear  
Spark Arrestor  
Protective Cover  
Receptacle Kit  
Receptacle Kit  
240 V Electrical Plug  
For use with 240 V receptacle (Purchase from Miller Service Parts)  
Stick Accessories  
Weld Leads  
#195 195  
Includes 50 ft, No. 2 electrical cable and holder, 50 ft work cable with clamp and lug  
Stick Electrodes  
TIG Accessories  
TIG Torch, Consumables, Tungsten  
Plasma Accessories  
Spectrum® 375  
#903 891  
115/230 V, 20 ft torch. See Lit. Index No. PC9.1  
Date:  
Total Quoted Price:  
Distributed by:  
Litho in USA  
 

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