Miller Electric Metro 250D Owner'S Manual Download Page 60

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OM-402

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Summary of Contents for Metro 250D

Page 1: ...f 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...

Page 2: ...alue established in 1929 This Owner s Manual is designed to help you get the most out of your Miller products Please take time to read the Safety precautions They will help you protect yourself agains...

Page 3: ...logy Combining advanced design and outstanding DC stick and DC TIG characteristics the Metro is an ideal machine for on site work in construction fabrication repair power generation pipe welding and r...

Page 4: ......

Page 5: ...nput power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do...

Page 6: ...taining Wear protective gloves and clothing when working on a hot engine Do not touch hot engine parts or just welded parts bare handed NOISE can damage hearing Noise from some processes or equipment...

Page 7: ...ables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see appl...

Page 8: ...rch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in We...

Page 9: ...pour voir s il n est pas en dommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas...

Page 10: ...ent avant d effec tuer des travaux d entretien Porter des gants et des v tements de protection pour travailler sur un moteur chaud Ne pas toucher mains nues les parties chaudes du moteur ni les pi ces...

Page 11: ...xt rieur dans des zones ou vertes et bien ventil es En cas d utilisation dans un endroit ferm vacuer les gaz d chappe ment du moteur vers l ext rieur distance des entr es d air dans les b ti ments LA...

Page 12: ...Superintendent of Documents U S Government Printing Office Washington D C 20402 RecommendedSafe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances...

Page 13: ...orce DIG TIG GTAW G Engine Driven Single Phase Alternator With Rectifier Engine Read Operator s Manual Circuit Breaker Positive Negative Alternating Current AC Direct Current DC Certified Trained Mech...

Page 14: ...ead out of the fumes 2 2 Use forced ventilation or local exhaust to remove the fumes 2 3 Use ventilating fan to remove fumes 3 Welding sparks can cause explosion or fire 3 1 Keep flammables away from...

Page 15: ...battery 8 Engine block 9 Fully charged battery 10 Do not connect last negative cable to dead battery connect instead to engine block 11 Jumper cables observe polarity and make connections in numbered...

Page 16: ...burns Do not touch hot muffler or pipes 1 S 176 230 2 2 6 Diesel Fuel Label 3 96 1 Warning Watch Out There are possible hazards as shown by the symbols 2 Engine fuel plus flames or sparks can cause f...

Page 17: ...anual from unit Follow instructions to install muffler 2 Read Owner s Manual Read labels on unit 3 Use Diesel Fuel only and fill fuel tank Leave room for expansion 4 Check oil level Add oil if necessa...

Page 18: ...ead Owner s Manual 4 Use glow plugs for 10 25 seconds to aid starting in cold weather 1 S 176 109 10 25 s 2 3 4 2 10 Manufacturer s Rating Label S 176 095 C 1 METRO 250D X 35 60 100 20A 21V 280A 31V U...

Page 19: ...B A at 23 ft 7 m 3 2 Dimensions Weights and Operating Angles Dimensions Height 41 in 1041 mm A D d i l hil Width 30 in 762 mm Do not exceed operating angles while run ning or engine damage will occur...

Page 20: ...ge of 10 min utes that unit can weld at rated load without overheating Exceeding duty cycle can damage unit and void warranty duty1 5 95 SB 180 262 4 Minutes Welding 6 Minutes Resting 100 Duty Cycle A...

Page 21: ...0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 4 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does not have GFCI re ceptacles use GFCI protected exten...

Page 22: ...ine Prestart Checks Ref ST 159 219 D Check all fluids daily Unit must be cold and on a level surface Oil may be added at either oil fill Engine stops if oil pressure is low Heavy loading during first...

Page 23: ...ctrode terminal Tools Needed 3 4 in 1 2 4 5 Selecting Weld Cable Sizes Total Cable Copper Length in Weld Circuit Not Exceeding Welding Amperes 100 ft 30 m or Less 150 ft 45 m 200 ft 60 m 250 ft 70 m 3...

Page 24: ...sure to A completes 24 volt ac contactor control circuit A J B K I G Circuit common for 24 volt ac circuit B K I C L N H D M G F C 0 to 10 volts dc output to remote control with respect to socket D E...

Page 25: ...ine if engine is still turning Move Idle Lock switch to Run Idle position after engine warms To Stop turn Engine Control switch to Stop position 3 Engine Hour Meter 4 Fuel Gauge 5 Engine Oil Pressure...

Page 26: ...or Control switch is On and engine is running 1 Remote 14 Receptacle RC1 Connect optional remote control to RC1 see Section 4 6 Place Engine Control switch in Run position for HF start TIG welding Ref...

Page 27: ...cuit Breakers CB3 And CB4 CB3 and CB4 protect all the receptacles from overload If CB3 opens RC1 RC3 and RC4 do not work If CB4 opens RC2 RC3 and RC4 do not work 120 volts may still be present at RC3...

Page 28: ...100 h Change oil See Section 7 3 and maintenance label Clean and tighten battery connections See Section 4 2 Clean cooling system See engine manual 200 h Change oil filter See Section 7 3 and maintena...

Page 29: ...30 A 0 F 18 C Deutz 77 656 19 72 F 20 C 0 006 in 0 15 mm Deutz 77 644 39 DIESEL DIN 51 601 BS 2869 A1 A2 ASTM D 975 81 1 D 2 D VV F 800C DF A DF 1 DF 2 S t 5 8 Hrs 50 Hrs 10W F 32 59 86 30 20 10 0 40...

Page 30: ...Ref ST 175 918 C Ref S 0842 Tools Needed Stop engine See engine manual for oil filter change procedure Drain oil while engine is warm 1 Oil Fill Caps Use Either Cap 2 Oil Drain Valve Close oil drain...

Page 31: ...9 219 D Ref S 0698 B Stop engine Do not run engine without air cleaner or with dirty element Use only high pulsation type replacement filter listed on maintenance label or engine damage may occur 1 Du...

Page 32: ...d power speed Tighten linkage lock nut Turn weld power speed screw until engine runs at weld power speed Tighten nut Stop engine Shutdown Adjustment Shutdown mechanism normally does not require adjust...

Page 33: ...anel before operating unit Remote Control Circuit 3 Circuit Breaker CB5 CB5 protects 24 volt ac output to Remote 14 receptacle RC1 If CB5 opens RC1 24 volt output stops Engine Control Circuit 4 Circui...

Page 34: ...trol switch in On position or place switch in Remote 14 position and connect remote contactor to Remote 14 receptacle RC1 See Section 5 1 Have Factory Authorized Service Agent check brushes and slip r...

Page 35: ...r continuity and proper connections Replace receptacle s if necessary Have Factory Authorized Service Agent check brushes slip rings relay CR5 and relay CR6 Low output at receptacles Check fuses F2 an...

Page 36: ...1 relay CR4 and idle control mod ule Engine idles but does not reach weld speed Reset circuit breaker CB7 see Section 7 7 Move Idle Lock switch to Run Idle position Have Factory Authorized Service Age...

Page 37: ...33 OM 402 Notes...

Page 38: ...34 OM 402 8 Electrical Diagram 8 1 Circuit Diagram for Welding Generator...

Page 39: ...35 OM 402 SC 181 758...

Page 40: ...ne runs at weld power rpm and the welding generatoris kept loaded during run in 1 Welding Generator 2 Engine Exhaust Pipe Wetstacking is unburned fuel and oil in the exhaust pipe and occurs during run...

Page 41: ...ing proper size weld cables with correct connectors Observe correct polarity Start engine and run for several minutes Set load bank switches and then adjust Amperage control so load and output are 180...

Page 42: ...4 Voltmeter 5 Clamp On Ammeter Connect voltmeter and ammeter as shown if not provided on generator Start engine and run for several minutes Set grid switches and then adjust Amperage control so load a...

Page 43: ...lated Equipment OR 2 Be sure equipment has this symbol and or wording 3 1 10 2 Grounding Generator to Truck or Trailer Frame S 0854 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Termina...

Page 44: ...tive Load Equipmentwith a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when run ning see Section 10 8 3 Rating Data Rating shows volts...

Page 45: ...e Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milk...

Page 46: ...000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP...

Page 47: ...tarting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M...

Page 48: ...nnections Connect terminals or plug of ade quate amperage capacity to cord Follow all applicable codes and safety practices Turn off or unplug all equipment connected to generator before starting or s...

Page 49: ...40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI p...

Page 50: ...ts List 11 1 Main Assembly 1 2 3 4 5 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 84 85 86 87 88 89 90 91 92 93 96 94 6 7 Fig 11 2 Fig 11 4 95 83 Hardware is common and not availabl...

Page 51: ...47 OM 402 30 ST 801 488 A 31 32 33 34 35 36 37 38 39 40 43 45 47 48 49 50 51 52 53 54 56 Fig 11 3 57 58 59 60 62 63 65 66 67 68 69 70 71 72 73 74 75 76 77 78 80 79 81 61 82 42 64 55 41 44 46...

Page 52: ...0 20 x 9 500 2 21 167 677 BATTERY stor 12V 430crk 75RSV 1 108 081 TERMINAL PROTECTORS battery post 2 22 082 316 CABLE bat pos 1 114 923 BOOT insulator term post red 1 23 179 964 CABLE bat neg 1 24 164...

Page 53: ...NPTF 1 61 176 244 SPRING CLIP oil drain hose 1 62 107 816 HOSE SAE 250 ID x 500 OD order by ft 1ft 63 066 113 FILTER fuel inline 1 64 177 975 GASKET air cleaner 1 65 176 541 AIR CLEANER intake consist...

Page 54: ...8 809 CONNECTOR SOCKETS 1 164 899 CONNECTOR SOCKETS 1 When ordering a component originally displaying a precautionary label the label should also be ordered Optional 043 139 Cold Weather Diesel Starti...

Page 55: ...FG 118 066 GAUGE fuel elec 12V 1 21 148 956 HANDLE switch 1 22 097 924 KNOB pointer 1 23 072 590 LOCK shaft pot 2 24 097 922 KNOB pointer 1 25 119 014 LEVER switch black 1 26 NAMEPLATE order by model...

Page 56: ...R generator 1 7 172 656 GUARD generator wire mesh 1 8 172 674 SPRING ext 2 9 165 850 ADAPTER engine 1 10 176 106 LABEL warning moving parts 2 11 170 861 STUD stl 375 16 x 17 375 4 12 125 548 HOLDER br...

Page 57: ...STAND OFF insul 250 20 x 1 000 lg 4 7 CR5 6 174 596 RELAY encl 110VDC DPST 2 8 CR1 4 173 069 RELAY encl 12VDC SPDT 2 9 171 345 TERMINAL BOARD stator hook up consisting of 1 172 449 BUS BAR 1 10 166 7...

Page 58: ...54 OM 402 Notes...

Page 59: ...Notes...

Page 60: ...56 OM 402 Notes...

Page 61: ...Notes...

Page 62: ...ilers Keeps tools handy Sturdy steel construction with hinged cover 5 in 130 mm divider in center of box Attachment hardware included Height 11 in 280 mm depth 10 in 254 mm length 44 in 1120 mm EDT 24...

Page 63: ...ting Torches Remote Controls Accessory Kits Replacement Parts No labor Spoolmate 185 Spoolmate 250 Canvas Covers Miller s True Blue Limited Warranty shall not apply to 1 Consumable components such as...

Page 64: ...complete and retain with your personal records Always provide Model Name and Serial Style Number Call 1 800 4 A Miller or see our website at www MillerWelds com to locate a DISTRIBUTOR or SERVICE AGEN...

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