Miller Electric 145 User manual

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: [phone]
USA FAX: [phone]
Canadian FAX: [phone]
International FAX: [phone]
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