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Miller Electric Metro 250D User Manual

Miller Electric Metro 250D
64 pages
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Processes
OM-402B April 1997
Eff. w/Serial Number KH383240
Gas Tungsten Arc
(TIG) Welding
Shielded Metal Arc
(Stick) Welding
Flux Cored Arc Welding
Description
Engine Driven Welding Generator
With Optional Equipment:
Metro 250D
Visit our website at
www.MillerWelds.com
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Miller Electric Metro 250D Specifications

General IconGeneral
BrandMiller Electric
ModelMetro 250D
CategoryWelding System
LanguageEnglish

Summary

From Miller to You

Safety Precautions

Symbol Usage

Explains safety symbols and their meanings, including warning and note indicators.

Arc Welding Hazards

Discusses dangers like electric shock, arc rays, fumes, and gases during arc welding.

Engine Hazards

Covers fuel hazards, hot parts, noise, magnetic fields, and cylinder dangers associated with the engine.

Additional Symbols for Installation, Operation, and Maintenance

Explains symbols related to falling units, flying sparks, overheating, static discharge, and tilting.

H.F. Radiation Interference

Discusses interference from high-frequency radiation with electronic equipment.

Arc Welding Interference

Discusses electromagnetic interference from arc welding with sensitive electronics.

Principal Safety Standards

Lists relevant safety standards and codes for welding and cutting.

EMF Information

Provides information on EMF effects and reduction in the workplace.

Definitions

Symbols and Definitions

Lists and defines various symbols used in the manual for controls and indicators.

General Precautionary Label

Summarizes key safety warnings with visual aids for hazards and precautions.

Battery Charging Label

Details warnings and instructions related to battery charging procedures.

Fan and Moving Parts Label

Highlights hazards associated with moving parts like fans and rotors.

Hot Muffler Label

Warns about hot muffler and exhaust pipes causing burns.

Diesel Fuel Label

Provides warnings and instructions regarding diesel fuel handling and safety.

Falling Equipment Label

Warns about hazards and proper procedures for lifting and moving equipment.

Activation Tag

Guides on unit removal, manual reading, fuel fill, oil check, and initial operation limits.

Do Not Use Ether Label

Warns against using ether as a starting aid due to engine damage.

Manufacturer's Rating Label

Displays the machine's technical specifications, ratings, and classifications.

Specifications

Weld, Power, and Engine Specifications

Details output, range, voltage, auxiliary power, engine, fuel, and sound level.

Dimensions, Weights, and Operating Angles

Provides physical dimensions, weight, and safe operating angle limits.

Volt-Ampere Curve

Illustrates the generator's voltage and amperage output capabilities.

Fuel Consumption

Presents charts showing fuel usage based on load and output.

Duty Cycle and Overheating

Explains duty cycle percentages and overheating prevention.

Installation

Installing Welding Generator

Covers generator placement, movement, airflow clearance, and grounding.

Connecting Battery and Installing Exhaust Pipe

Details battery connection and optional exhaust pipe installation.

Engine Prestart Checks

Outlines daily checks for fluids, oil level, and initial load limits.

Connecting to Weld Output Terminals

Explains how to connect cables to the positive and negative output terminals.

Selecting Weld Cable Sizes

Provides a chart to determine appropriate weld cable sizes based on amperage and circuit length.

Remote 14 Receptacle RC1 Information

Describes the function and pinout of the Remote 14 Receptacle.

Operating the Welding Generator

Front Panel Controls

Explains the function of each control on the front panel.

Remote Amperage and Contactor Control

Details how to use remote controls for amperage and contactor functions.

Operating Auxiliary Equipment

Auxiliary Power Receptacles

Identifies receptacles, circuit breakers, and GFCI protection for auxiliary power.

Maintenance & Troubleshooting

Routine Maintenance

Provides a schedule for regular maintenance tasks based on operating hours.

Changing Engine Oil and Oil Filter

Step-by-step guide for changing engine oil and filter.

Changing Fuel Filters

Instructions for replacing primary and secondary fuel filters.

Servicing Air Cleaner

Details on cleaning or replacing the air filter element and dust valve.

Adjusting Engine Speed

Guide on setting idle and weld/power speeds using a tachometer.

Overload Protection

Explains the function of fuses and circuit breakers for overload protection.

Servicing Optional Spark Arrestor

Instructions for cleaning the spark arrestor.

Welding Troubleshooting

Lists common welding output problems and their remedies.

Auxiliary Power Troubleshooting

Addresses issues with auxiliary power output and receptacle functionality.

Engine Troubleshooting

Lists common engine starting and running problems and their solutions.

Run-In Procedure

Wetstacking

Explains wetstacking and its causes during engine break-in.

Run-In Procedure Using Load Bank

Details the process for running in the unit using a load bank.

Run-In Procedure Using Resistance Grid

Outlines the procedure for running in the unit using a resistance grid.

Auxiliary Power Guidelines

Selecting Equipment

Guidance on choosing auxiliary equipment and proper plug types.

Grounding Generator to Truck or Trailer Frame

Instructions for grounding the generator to a vehicle frame.

Grounding When Supplying Building Systems

Procedures for grounding the generator when supplying power to building systems.

How Much Power Does Equipment Require?

Explains how to calculate power requirements for resistive and non-resistive loads.

Approximate Power Requirements for Industrial Motors

Lists power requirements for various industrial motors.

Approximate Power Requirements for Farm/Home Equipment

Lists power requirements for farm and home equipment.

Approximate Power Requirements for Contractor Equipment

Lists power requirements for various contractor equipment.

Power Required to Start Motor

Explains how to determine starting amperage for motors.

How Much Power Can Generator Supply?

Guidelines on generator load limits and motor starting rules.

Typical Connections to Supply Standby Power

Illustrates typical wiring for standby power supply.

Selecting Extension Cord (Use Shortest Cord Possible)

Provides charts for selecting appropriate extension cords based on load and length.

Parts List

Main Assembly

Exploded view and part numbers for the main assembly.

Panel, Front w/Components (Fig 11.1 Item 91)

Lists components and parts for the front panel assembly.

Generator (Fig 11.1 Item 56)

Exploded view and part numbers for the generator assembly.

Control Box w/Components (Fig 11.1 Item 86)

Lists components and parts for the control box assembly.

Options and Accessories

Metro 250D

Lists optional kits and accessories for the Metro 250D model.

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