Miller Electric Blue Star 145 Users Manual A ED2 5 Series

145 DX to the manual 8171d7a3-1bfd-4cbd-b32e-b047d3782943

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Four Blue Star models to choose from.

See Page 3 for comparison information.

Blue Star Series

Blue Star 145

Blue Star 145 DX

Blue Star 185

Blue Star 185 DX (shown)

Processes

Stick (SMAW)

DC TIG (GTAW)

Air Plasma Cutting and Gouging

with optional Spectrum models

Industrial Applications

Maintenance

Repair

Farm/Ranch Applications

Construction

Stand-alone Generator

Blue Star®Series Gas Engine-Driven Welder/

AC Generator

Issued January 2008 • Index No. ED/2.5

Compact and portable, its small

footprint uses little truck space.

Optional running gear also makes

the Blue Star one-man portable.

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.

Standard Auto Idle (DX models) idles

engine while not in use. Reduces fuel

consumption and noise.

Reliable air-cooled OHV engines ensure

consistent engine performance.

Quick-reference parameter chart provides

convenient amperage setting guidance.

Hour meter provides easy tracking of

run hours for maintenance intervals

(DX models).

The Power of Blue®

.

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

Web Site

www.MillerWelds.com

International Headquarters

Phone: 920-735-4505

USA FAX: 920-735-4134

Canadian FAX: 920-735-4169

International FAX: 920-735-4125

Weld Output Range

For DC Stick/TIG 145: 40 – 145 A 185: 55 – 185 A

Generator Output Rated at 104˚ F (40˚ C)

145: 4500 Watts Peak, 4000 Watts Continuous

185: 6000 Watts Peak, 5500 Watts Continuous

Weight 145: 263 lb (119 kg) 145 DX: 309 lb (140 kg)

185: 267 lb (121 kg) 185 DX: 315 lb (143 kg)

Class-leading 6000-watt peak power

(185 models) of regulated power to

extend power tool life.

Bulletproof technology eliminates use of

complicated circuit boards.

Receptacle covers improve reliability by

protecting receptacles from debris.

240 V and 120 V receptacles provide

power for jobsite tools. Receptacles are

circuit-breaker protected (optional

120 VAC GFCI receptacles are available).

Single-range amperage control makes

setting amperage levels easy.

Reliable Blue Star engine drives

are the standard for portable

welder/generators.

Quick

Specs

FUEL CONSUMPTION

0.000

0.200

0.400

0.600

0.800

1.000

1.200

01 2 34 5 6

POWER KVA AT 100% DUTY CYCLE

U.S. GAL PER HOUR

Kohler 10 (at idle)

Kohler 10

Kohler 12.75

Honda 13

Kohler 12.75 (at idle)

5

4

1

2

3

Performance Data

2

Control Panel

Welding

Mode

CC/DC

(Stick/TIG)

CC/DC

(Stick/TIG)

Model

Blue Star®145

Blue Star®145 DX

Blue Star®185

Blue Star®185 DX

Weld Output

Range

40 – 145 A

55 – 185 A

Weld Output Rated

at 104˚ F (40˚C)*

145 A at 25 V, 20% Duty Cycle

100 A at 25 V, 60% Duty Cycle

185 A at 25 V, 20% Duty Cycle

130 A at 25 V, 60% Duty Cycle

Single Phase

Generator Power

4500 Watts Peak

4000 Watts Continuous

34 A at 120 V, 17 A at 240 V

6000 Watts Peak

5500 Watts Continuous

40 A at 120 V, 23 A at 240 V

Dimensions

H: 22.75 in (578 mm)

W: 22.75 in (578 mm)

D: 31.6 in (803 mm)

H: 22.75 in (578 mm)

W: 22.75 in (578 mm)

D: 31.6 in (803 mm)

Net Weight

(without fuel)

263 lb (119 kg)

309 lb (140 kg)

267 lb (121 kg)

315 lb (143 kg)

Specifications (Subject to change without notice.)

1. Engine Hour Meter*

2. Auto Idle Switch*

3. Quick-Reference Parameter Chart

4. 240 V and 120 V Receptacles

5. Single-Range Amperage Control

*DX Models only.

*Rated at sea level.

Engine Specifications (Subject to change without notice.)

Engine

Kohler CS10

2 year warranty

Honda GX390

2 year warranty

Kohler CS12.75

2 year warranty

HP

10 HP at 3600 RPM

13 HP at 3600 RPM

12.75 HP at 3600 RPM

Type

1-cylinder, 4-cycle,

air-cooled, OHV

1-cylinder, 4-cycle,

air-cooled, OHV

Engine Speeds

3750 RPM

3750 RPM

(2500 RPM at idle)

3750 RPM

3750 RPM

(2500 RPM at idle)

Fuel

Capacity

1.8 gal

(6.8 L)

5 gal

(18.9 L)

1.7 gal

(6.4 L)

5 gal

(18.9 L)

Oil Capacity

1.1 qt (1.04 L)

1.16 qt (1.10 L)

1.1 qt (1.04 L)

Automatic Engine

Shutdown

Standard

Standard

Model

Blue Star

®

145

Blue Star

®

145 DX

Blue Star

®

185

Blue Star

®

185 DX

Gasoline

Fuel Consumption Data

•5-gallon fuel capacity on DX models. 1.7 and 1.8 gallon on

standard models.

•Under a continuous load of 3000 watts of generator power, the

Blue Star 185 DX would run for about 6.5 hours.

•Welding at 130 amps (at 30% duty cycle), the Blue Star 185 DX

would run for about 15 hours of operation.

3

Why Upgrade?

Blue Star®Value

Power Usage Guide

• 96% of current owners rated

their Blue Star as “good to

very good value.”

*Based on an independent survey

of thousands of Blue Star owners.

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.

Blue Star 96%

Others

UPGRADE

UPGRADE

UPGRADE

UPGRADE

UPGRADE

UPGRADE

UPGRADE

UPGRADE

UPGRADE

UPGRADE

UPGRADE

Blue Star 145 DX

4500 W Peak

145 A at 25 VDC

Kohler CS10

Standard

5 Gallons

Yes

Yes

Electric Start

Blue Star 145

4500 W Peak

145 A at 25 VDC

Kohler CS10

Standard

1.8 Gallons

No

No

Recoil Only

Feature

Generator Power

DC Stick/TIG Output

Engine

Receptacle Covers

Fuel Capacity

Auto Idle

Hour Meter

Engine Starting

Blue Star 185

6000 W Peak

185 A at 25 VDC

Honda GX390

Standard

1.7 Gallons

No

No

Recoil Only

Blue Star 185 DX

6000 W Peak

185 A at 25 VDC

Kohler CS12.75

Standard

5 Gallons

Yes

Yes

Electric Start

Typical Household

Starting

Watts

1,400

1,400

0

0

800

2,200

2,300

1,800

1,800

1,100

1,400

500

750

1,000

1,400

2,350

0

0

1,400

2,100

1,300

2,150

2,200

3,300

4,950

6,500

7,800

Running

Watts

700

1,450

1,500

2,100

625

700

1,150

700

5,750

550

725

300

500

600

700

875

as indicated

50 –200

750

1,000

800

1,050

1,500

2,500

3,800

5,000

6,000

Appliance

Dishwasher,

Cool Dry

Hot Dry

Electric Range,

6-in element

8-in element

Microwave Oven, 625 watts

Refrigerator or Freezer

Automatic Washer

Clothes Dryer, Gas

Electric

Garage Door Opener,

1/4 HP

1/2 HP

Furnace Fan, gas/fuel oil

1/8 Horsepower

1/6 Horsepower

1/4 Horsepower

1/3 Horsepower

1/2 Horsepower

Lights

Radio

Well Pump, 1/3 Horsepower

1/2 Horsepower

Sump Pump, 1/3 Horsepower

1/2 Horsepower

Central Air Conditioner

10,000 BTU

20,000 BTU

24,000 BTU

32,000 BTU

40,000 BTU

Typical Farm Equipment

Starting

Watts

3,400

1,720

8,200

4,500

6,100

Running

Watts

1,000

720

2,200

1,400

1,600

Machine

Portable Conveyor, 1/2 HP

Farm Duty Motors

(e.g. Conveyors, Feed

Augers, Air Compressors)

1/3 Horsepower

1-1/2 Horsepower

Washer, 2 gal/min

550 PSI

700 PSI

Typical Industrial Motors

Starting

Watts

800

3,175

2,020

8,200

8,100

1,000

3,500

Running

Watts

300

875

720

2,200

2,000

400

1,100

Motor

Split Phase

1/8 Horsepower

1/2 Horsepower

Capacitor Start —

Induction Run

1/3 Horsepower

1-1/2 Horsepower

Capacitor Start —

Capacitor Run

1-1/2 Horsepower

Fan,

1/8 Horsepower

1/2 Horsepower

Typical Contractor Tools

Starting

Watts

350

600

500

1,400

6,300

2,500

3,000

8,200

1,100

1,100

125

313

1000

1,250

600

900

3,150

6,100

900

Running

Watts

350

600

500

1,400

1,800

1,100

1,000

2,200

1,100

1,100

100

250

—

1,000

200

500

950

1,600

900

Tool

Hand Drill,

1/4 inch

1/2 inch

Circular Saw

6-1/2 inch

8-1/4 inch

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

HID

Metal Halide

Mercury

Vapor

Submersible Pump, 400 gph

Centrifugal Pump, 900 gph

High Pressure Washer

1/2 Horsepower

1 Horsepower

Wet & Dry Vac,

1.7 Horsepower

Lifting Eye

#195 353

Secure lift point

when picking up

machine.

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.

Remote Oil Drain Kit #224 831

Quick connect for easy engine maintenance.

No. 38 Hand Running Gear #195 352

Compact, balanced, lightweight, wheel-

barrow-style running gear designed for

easy on-site mobility.

Spark Arrestor #195 351

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.

Weld Leads #195 195

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.

Receptacle Kit

#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.

240 V Electrical Plug #213 380

For use with 240 V receptacle.

Litho in USA

Distributed by:

Power Source and Options Stock No. Description Qty. Price

Blue Star®145 #907 266 Kohler engine, recoil start

Blue Star®145 with GFCI #907 266-01-1 Kohler engine, recoil start, GFCI 120 V receptacles.

Blue Star®145 DX #907 267 Kohler engine, electric start, 5-gallon fuel tank, auto idle

Blue Star®145 DX with GFCI #907 267-01-2 Kohler engine, electric start, 5-gallon fuel tank, auto idle, GFCI 120 V receptacles

Blue Star®145 DX (no battery) #907 267-01-3 Kohler engine, electric start, 5-gallon fuel tank, auto idle. (With no battery)

Blue Star®185 #907 268 Honda engine, recoil start

Blue Star®185 with GFCI #907 268-01-1 Honda engine, recoil start, GFCI 120 V receptacles

Blue Star®185 DX #907 269 Kohler engine, electric start, 5-gallon fuel tank, auto idle

Blue Star®185 DX with GFCI #907 269-01-2 Kohler engine, electric start, 5-gallon fuel tank, auto idle, GFCI 120 V receptacles

Blue Star®185 DX (no battery) #907 269-01-3 Kohler engine, electric start, 5-gallon fuel tank, auto idle. (With no battery)

Accessories

Lifting Eye #195 353 Provides safe and secure lifting of machine

Remote Oil Drain Kit #224 831 Quick connect for easy engine maintenance (Purchase from Miller Service Parts)

No. 38 Hand Running Gear #195 352 Balanced running gear for easy transport

Spark Arrestor #195 351 For DX models only. (Standard models include engine manufacturer’s spark arrestor)

Protective Cover #195 193 Blue with logo

Receptacle Kit #088 297 6 ft cord with 240 V plug (Purchase from Miller Service Parts)

Receptacle Kit #300 404 4-wire, 30 A Twistlock receptacle (NEMA L14-30)

240 V Electrical Plug #213 380 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:

Ordering Information

Genuine Miller Options and Accessories