Miller Blue Star 185 Owner's Manual
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Miller Blue Star 185 Owner's Manual

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OM-267212L
2022-08
Processes
Stick (SMAW) Welding
Description
Engine Driven Welder/Generator
Blue Star
185
™
OWNER'S MANUAL
For product information,
Owner's Manual translations,
and more, visit
www.MillerWelds.com

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  • Page 1 OM-267212L 2022-08 Processes Stick (SMAW) Welding Description Engine Driven Welder/Generator Blue Star ™ OWNER’S MANUAL For product information, Owner’s Manual translations, and more, visit www.MillerWelds.com...
  • Page 2 We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING..............1 Symbol Usage .

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! – Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 Accidental contact of electrode to metal objects can cause sparks, ex- FLYING METAL OR DIRT can injure plosion, overheating, or fire. Check and be sure the area is safe be- eyes. fore doing any welding. � Welding, chipping, wire brushing, and grinding �...

  • Page 7: Engine Hazards

    � Install cylinders in an upright position by securing to a stationary � Turn face away from valve outlet when opening cylinder valve. Do support or cylinder rack to prevent falling or tipping. not stand in front of or behind the regulator when opening the valve.

  • Page 8: Compressed Air Hazards

    1-4. Compressed Air Hazards � Reinstall doors, panels, covers, or guards when servicing is fin- COMPRESSED AIR EQUIPMENT can ished and before starting unit. injure or kill. � If ANY air is injected into the skin or body seek medical help immediately.
  • Page 9 � Follow the guidelines in the Applications Manual for the Revised HIGH PRESSURE FLUIDS can injure NIOSH Lifting Equation (Publication No. 94-110) when manually or kill. lifting heavy parts or equipment. � Engine fuel system components can be under high OVERHEATING can damage motors.

  • Page 10: California Proposition 65 Warnings

    � If notified by the FCC about interference, stop using the equipment � Be sure all equipment in the welding area is electromagnetically at once. compatible. � Have the installation regularly checked and maintained. � To reduce possible interference, keep weld cables as short as �...

  • Page 11: Section 2 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 12 � Ne pas toucher aux portes-électrodes qui sont raccordés à deux bien ventilé, et en portant un respirateur à alimentation d’air. Les machines à souder en même temps, car cela entraîne la présence revêtements et tous les métaux renfermant ces éléments peuvent d’une tension de circuit-ouvert double.

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    � Ne pas souder là où l’air ambiant pourrait contenir des poussières, � Les porteurs d’implants médicaux doivent consulter leur médecin gaz ou émanations inflammables (vapeur d’essence, par et le fabricant du dispositif avant de s’approcher de la zone où se exemple).

  • Page 14: Dangers Liés À L'air Comprimé

    � Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces � Ne pas toucher aux pièces chaudes, utiliser les outils recomman- inflammables. dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. � Tenir à distance les produits inflammables de l’échappement. LA VAPEUR ET LE LIQUIDE DE Les PIÈCES MOBILES peuvent REFROIDISSEMENT CHAUD peuvent...

  • Page 15: Symboles De Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    L’AIR COMPRIMÉ risque de Les PIÈCES MOBILES peuvent provoquer des blessures ou même la causer des blessures. mort. � S’abstenir de toucher des parties mobiles telles � Avant d’intervenir sur le circuit d’air comprimé, que des ventilateurs, courroies et rotors. couper l’alimentation électrique, verrouiller etéti- �...
  • Page 16 � Utiliser uniquement des équipements adéquats pour un fonction- � Régler les commandes de charge de batterie sur la position d’arrêt nement avec une alimentation de 50/60 ou de 60 Hz. avant de brancher la batterie. Veiller à ce que les pinces de charge ne se touchent pas.

  • Page 17: Proposition Californienne 65 Avertissements

    � Effectuer l’installation, l’entretien et toute intervention selon les LE SOUDAGE À L’ARC risque de manuels d’utilisateurs, les normes nationales, provinciales et de provoquer des interférences. l’industrie, ainsi que les codes municipaux. � L’énergie électromagnétique risque de provoquer LE RAYONNEMENT HAUTE des interférences pour l’équipement électronique FRÉQUENCE (H.F.) risque de sensible tel que les ordinateurs et l’équipement...
  • Page 18 les porteurs d’implants médicaux doivent être prises: par exemple, 5. Connecter la pince sur la pièce aussi près que possible de la des restrictions d’accès pour les passants ou une évaluation indivi- soudure. duelle des risques pour les soudeurs. Tous les soudeurs doivent ap- 6.

  • Page 19: Section 3 - Definitions

    � Complete Parts List is available at www.MillerWelds.com SECTION 3 – DEFINITIONS Become trained and read the instructions before working on the Become trained and read the instructions before working on the machine or heating. machine or heating. 3-1. Additional Safety Symbol Definitions Safe85 2012 06 Safe85 2012 06 �...

  • Page 20: Section 4 - Specifications

    Information About Default Weld Parameters And Settings NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are for reference purposes only;...

  • Page 21: Duty Cycle And Overheating

    � Complete Parts List is available at www.MillerWelds.com 4-7. Duty Cycle And Overheating 1 100% Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. � This unit is rated for welding at 150 Am- peres continuously.

  • Page 22: Generator Power Curve

    � Complete Parts List is available at www.MillerWelds.com 4-9. Generator Power Curve The AC generator power curves show the generator power available in amperes at the receptacles. 240 Volt 120 Volt AMPS 268591 OM-267212 Page 18...

  • Page 23: 4-10. Fuel Consumption

    � Complete Parts List is available at www.MillerWelds.com 4-10. Fuel Consumption Fuel Consumption While Welding 1.00 1.00 0.80 0.80 0.60 0.60 0.40 0.40 IDLE 0.20 IDLE 0.20 0.00 0.00 DC WELD AMPERES AT RATED DUTY CYCLE 268595 DC WELD AMPERES AT RATED DUTY CYCLE 268595 Fuel Consumption –...

  • Page 24: Section 5 - Installation

    � Complete Parts List is available at www.MillerWelds.com SECTION 5 – INSTALLATION 5-1. Installing Welder/Generator 1-1. Installing Welder/Generator 1-1. Installing Welder/Generator Lifting Handles Use handles to lift unit. Lifting Handles 1 Lifting Handles Movement Hand Cart Use handles to lift unit. Use cart or similar device to move Use handles to lift unit.

  • Page 25: Grounding Generator To Truck Or Trailer Frame

    � Complete Parts List is available at www.MillerWelds.com 5-2. Grounding Generator to Truck or Trailer Frame 1-1. Grounding Generator To Truck Or Trailer Frame Complete Parts List available at www.MillerWelds.com GND/PE Bed liners, shipping skids, and 1 Equipment Grounding Terminal Always ground generator frame to some running gear insulate the Front Panel)

  • Page 26: Fuel Valve Positions

    � Complete Parts List is available at www.MillerWelds.com 5-4. Fuel Valve Positions 1 Fuel Valve � Always close fuel valve after stopping unit. Moving unit may cause carburetor flooding and make starting difficult. 268 699 / 267 206 OM-267212 Page 22...

  • Page 27: Engine Prestart Checks

    � Complete Parts List is available at www.MillerWelds.com 5-5. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W-50 synthetic engine oil. 1 Fuel Valve Open valve. � Close fuel valve before moving unit or carburetor may flood and make starting difficult.

  • Page 28: Connecting The Battery

    cable last. � Complete Parts List is available at www.MillerWelds.com 5-6. Connecting The Battery Turn Engine Switch to Off. Connect negative (-) battery cable last. 268 699 268 699 1/2 in. ps head wrench crescent wrench 5-7. Weld Output Terminals 5-7.

  • Page 29: Connecting Weld Output Cables

    Complete Parts List available at www.MillerWelds.com � Complete Parts List is available at www.MillerWelds.com 5-8. Connecting Weld Output Cables Stop engine. Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. � Do not place anything between weld cable terminal and copper bar.

  • Page 30: Section 6 - Operating The Welder/Generator

    Current Control Setting: 90 120 A starts. Set control at maximum for full generator Miller recommends Hobart filler metals. Open choke as engine warms. power output at AC receptacles. OM-267212 Page 25 OM-267212 Page 26...

  • Page 31: Section 7 - Operating Auxiliary Equipment

    Complete Parts List available at www.MillerWelds.com SECTION 7 OPERATING AUXILIARY EQUIPMENT SECTION 7 – OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Panel Receptacles 7-1. Generator Power Panel Receptacles 265 557 GFCI2 and GFCI3 supply 60 Hz single- Test GFCI monthly. See Section 7-2 Use GFCI protection when operating phase power at weld/power speed.

  • Page 32: Gfci Receptacle Information, Resetting, And Testing

    7-2. GFCI Receptacle Information, Resetting, And Testing Use GFCI protection when operating If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles auxiliary equipment. If unit does not button pops out, and the circuit opens to dis- If a GFCI fault occurs, stop engine and dis- have GFCI receptacles, use GFCI- connect power to the faulty equipment.

  • Page 33: Section 8 - Maintenance

    � Complete Parts List is available at www.MillerWelds.com SECTION 8 – MAINTENANCE � Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. This flowchart is intended as a general guide only. Al- ways read and follow the safety information and specific 8-1.

  • Page 34: Maintenance Label

    � Complete Parts List is available at www.MillerWelds.com 8-2. Maintenance Label OM-267212 Page 30...

  • Page 35: Servicing Air Cleaner

    � Complete Parts List is available at www.MillerWelds.com 8-3. Servicing Air Cleaner Complete Parts List available at www.MillerWelds.com 8-3. Stop engine. Let cool. Stop engine. Let cool Complete Parts List available at www.MillerWelds.com NOTICE – Do not run engine without air NOTICE Do not run engine with- cleaner element or with dirty element.

  • Page 36: Changing Oil

    � 3X longer oil change interval. 300-hour oil change interval for Miller Electric Engine Drives with KOHLER gas engines. � Engineered exclusively for Kohler air cooled engines. (This oil is not available from other manufacturers.) � Full synthetic oil formulated specifically for extended oil change intervals in air-cooled engines �...

  • Page 37: Adjusting Engine Speed

    � Complete Parts List is available at www.MillerWelds.com 8-7. Adjusting Engine Speed After tuning engine, check engine speed. See engine maintenance label for proper no load speed. If necessary, unplug/remove all loads and adjust speed as follows: Start engine and run until warm. tools/ Set Weld Output Control to Max.

  • Page 38: Section 9 - Troubleshooting

    SECTION 9 – TROUBLESHOOTING A. Welding Troubleshooting Trouble Remedy No weld output or generator power Be sure all equipment is disconnected from receptacles when starting unit. output at AC receptacles. Check weld connections. Have Factory Authorized Service Agent flash the rotor. Then check brushes, slip rings, rotor, stator, integrated rectifier SR1, and Weld Output control R1.
  • Page 39 Trouble Remedy Erratic output at generator power AC Check fuel level. receptacles. Have Factory Authorized Service Agent check connections at terminal block 1T. Check receptacle supplementary protector, wiring, and connections. Check throttle linkage for smooth, non-binding operation. Service air cleaner according to engine manual. Service engine fuel filter (see Section 8-3). Check engine speed, and adjust if necessary (see Section 8-7).

  • Page 40: Section 10 - Parts List

    SECTION 10 – PARTS LIST 10-1. Recommended Spare Parts Recommended Spare Parts Part No. Description Quantity 268467 Spark Plug, Kohler (Ch440) 268468 Filter, Air (Kohler Ch440) 246110 Filter, Fuel In−Line .250 Kohler 75um 021718 Fuse, Mintr GL 30. Amp 32 Volt 290693 Kohler Pro 10W-50 (Quart) (300 Hour) 280787...

  • Page 41: Section 11 - Electrical Diagrams

    SECTION 11 – ELECTRICAL DIAGRAMS 274309-B Figure 11-1. Circuit Diagram For Welder/Generator OM-267212 Page 37...

  • Page 42: Section 12 - Generator Power Guidelines

    SECTION 12 – GENERATOR POWER GUIDELINES � The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown. 12-1. Selecting Equipment 1 Generator Power Receptacles – Neutral Bonded To Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated...
  • Page 43 12-3. Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable GND/PE Use #8 AWG or larger insulated copper wire. 3 Ground Device � Use ground device as stated in electri- cal codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wir- ing system.
  • Page 44 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 45 Farm/Home Equipment Rating Starting Watts Running Watts Refrigerator or Freezer 3100 Shallow Well Pump 1/3 HP 2150 1/2 HP 3100 1000 Sump Pump 1/3 HP 2100 1/2 HP 3200 1050 12-7. Approximate Power Requirements For Contractor Equipment Contractor Equipment Rating Starting Watts Running Watts Hand Drill...
  • Page 46 12-8. Power Required To Start Motor 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage AC MOTOR VOLTS AMPS Step 1: Find code and use table to find kVA/ CODE HP. If code is not listed, multiply running am- PHASE perage by six to find starting amperage.
  • Page 47 12-10. Typical Connections To Standby Power 1. Utility Electrical 2. Transfer Switch 3. Fused Disconnect 4. Welder/Generator Service Switch (If Required) Output 5. Essential Loads Have only qualified persons perform 1 Utility Electrical Service 4 Welder/Generator Output these connections according to all 2 Transfer Switch (Double-Throw) Generator output voltage and wiring must applicable...
  • Page 48 12-11. Selecting Extension Cord (Use Shortest Cord Possible) A. Cord Lengths For 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm Current (Amperes)

  • Page 49: Section 13 - Stick Welding (Smaw) Guidelines

    SECTION 13 – STICK WELDING (SMAW) GUIDELINES tools/ 13-1. Stick Welding Procedure wrench crescent wrench allen_set flathead philips head wrench crescent wrench Weld current starts when electrode Tools Needed: touches workpiece. Weld current can damage elec- tronic parts in vehicles. Discon- nect both battery cables before welding on a vehicle.
  • Page 50 13-2. Electrode And Amperage Selection Chart 6010 DEEP 3/32 MIN. PREP, ROUGH HIGH SPATTER 6011 DEEP 6010 5/32 & 6013 EP,EN GENERAL 3/16 6011 7/32 SMOOTH, EASY, 7014 EP,EN FAST 1/16 LOW HYDROGEN, 7018 5/64 STRONG 3/32 FLAT SMOOTH, EASY, 7024 EP,EN 6013...
  • Page 51 13-4. Positioning Electrode Holder 1 End View Of Work Angle Groove Welds 2 Side View Of Electrode Angle After learning to start and hold an arc, prac- tice running beads of weld metal on flat 10 -30 10 -30 plates using a full electrode. Hold the electrode nearly perpendicular to the work, although tilting it ahead (in the di- rection of travel) will be helpful.
  • Page 52 13-7. Conditions That Affect Weld Bead Shape Electrode Angle � Weld bead shape is affected by elec- trode angle, arc length, travel speed, and thickness of base metal. 1 Angle Too Small 2 Correct Angle 3 Drag 4 Angle Too Large 5 Too Short 6 Normal Arc Length...
  • Page 53 13-9. Welding Lap Joints 1-1. Welding Lap Joints 1 Electrode 2 Single-Layer Fillet Weld 1-1. Welding Lap Joints Move electrode in circular motion. 3 Multi-Layer Fillet Weld Weld a second layer when a heavier fillet is needed. Remove slag before making anoth- er weld pass.
  • Page 54 13-11. Welding T-Joints 1-3. Welding T-Joints 1/16 in. (1.6 mm) 1 Electrode 2 Fillet Weld Keep arc short and move at definite rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface. For maximum strength weld both sides of up- 1-3.
  • Page 55 Excessive Spatter - scattering of molten metal particles that cool to solid form near weld bead. Possible Causes Corrective Actions Amperage too high for electrode. Decrease amperage or select larger electrode. Arc length too long or voltage too high. Reduce arc length or voltage. Incomplete Fusion - failure of weld metal to fuse completely with base metal or a preceding weld bead.
  • Page 56 Distortion - contraction of weld metal during welding that forces base metal to move. Illustration: Base metal moves in the direction of the weld bead. Possible Causes Corrective Actions Excessive heat input. Use restraint (clamp) to hold base metal in position. Make tack welds along joint before starting welding operation.
  • Page 57 Notes...
  • Page 58 Notes...
  • Page 59 Effective January 1, 2022 (Equipment with a serial number preface of NC or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or war- ranties expressed or implied. � Field Options (NOTE: Field options are cov-...
  • Page 60 Transportation Department. International Headquarters–USA USA Phone: 920-735-4505 USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 For International Locations Visit www.MillerWelds.com ORIGINAL INSTRUCTIONS – PRINTED IN USA © 2020 Miller Electric Mfg. LLC 2022-08...

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