Miller Electric Metro 250D manual Moving Parts can cause injury, Battery Explosion can Blind

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MOVING PARTS can cause injury.

D Keep away from fans, belts, and rotors.

D Keep all doors, panels, covers, and guards closed and securely in place.

DStop engine before installing or connecting unit.

DHave only qualified people remove guards or covers for maint- enance and troubleshooting as necessary.

DTo prevent accidental starting during servicing, disconnect negative (−) battery cable from battery.

DKeep hands, hair, loose clothing, and tools away from moving parts.

DReinstall panels or guards and close doors when servicing is finished and before starting engine.

DBefore working on generator, remove spark plugs or injectors to keep engine from kicking back or starting.

DBlock flywheel so that it will not turn while working on generator components.

BATTERY EXPLOSION can BLIND.

DAlways wear a face shield, rubber gloves, and

protective clothing when working on a battery.

D Stop engine before disconnecting or connect- ing battery cables or servicing battery.

DDo not allow tools to cause sparks when working on a battery.

DDo not use welder to charge batteries or jump start vehicles.

DObserve correct polarity (+ and −) on batteries.

DDisconnect negative (−) cable first and connect it last.

BATTERY ACID can BURN SKIN and EYES.

DDo not tip battery.

DReplace damaged battery.

DFlush eyes and skin immediately with water.

ENGINE EXHAUST GASES can kill.

DUse equipment outside in open, well-ventilated areas.

DIf used in a closed area, vent engine exhaust outside and away from any building air intakes.

ENGINE HEAT can cause fire.

DDo not locate unit on, over, or near combustible surfaces or flammables.

DKeep exhaust and exhaust pipes way from flammables.

EXHAUST SPARKS can cause fire.

DDo not let engine exhaust sparks cause fire.

DUse approved engine exhaust spark arrestor in required areas − see applicable codes.

1.4 Additional Symbols for Installation, Operation, and Maintenance

FALLING UNIT can cause injury.

DUse lifting eye to lift unit only, NOT running gear, gas cylinders, trailer, or any other accessories.

DUse equipment of adequate capacity to lift and support unit.

DIf using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

FLYING SPARKS can cause injury.

D Wear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

DSparks can cause fires — keep flammables away.

OVERUSE can cause OVERHEATING.

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before starting to weld again.

DDo not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling boards or parts.

DUse proper static-proof bags and boxes to store, move, or ship PC boards.

TILTING OF TRAILER can cause injury.

DUse tongue jack or blocks to support weight.

DProperly install welding generator onto trailer according to instructions supplied with trailer.

OVERHEATING can damage motors.

DTurn off or unplug equipment before starting or stopping engine.

DDo not let low voltage and frequency caused by low engine speed damage electric motors.

DDo not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable.

READ INSTRUCTIONS.

DUse only genuine MILLER replacement parts.

DPerform engine maintenance and service according to this manual and the engine manual.

OM-402

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Contents Processes OM-402BDescription From Miller to You Metro 250D Table of ContentsPage Symbol Usage Safety Precautions − Read Before UsingArc Welding Hazards Engine Hazards Engine Heat can cause fire Battery Explosion can BlindMoving Parts can cause injury Engine Exhaust Gases can killARC Welding can cause interference Principal Safety StandardsEMF Information Radiation can cause interferenceLES Fumées ET LES GAZ peuvent être dangereux Signification des symbolesConsignes de sécurité − lire avant utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures gravesLA Chute DE L’APPAREIL peut blesser DES Organes Mobiles peuvent provoquer des blessures’EXPLOSION DE LA Batterie peut LA Chaleur DU Moteur peut pro- voquer un incendieUNE Remorque QUI Bascule peut entraîner des blessures Principales normes de sécuritéInformation sur les champs électromagnétiques Électrostatiques peuvent endommager les circuits imprimésDefinitions Symbols and DefinitionsGeneral Precautionary Label Fan and Moving Parts Label Battery Charging LabelDiesel Fuel Label Hot Muffler LabelActivation Tag Falling Equipment Label− 50 h Std Manufacturer’s Rating Label Do Not Use Ether LabelVolt-Ampere Curve SpecificationsWeld, Power, and Engine Specifications Dimensions, Weights, and Operating AnglesDuty Cycle and Overheating Fuel ConsumptionLocation Grounding InstallationAC Auxiliary Power Curve Installing Welding GeneratorConnect negative − cable last Connecting Battery and Installing Exhaust PipeEngine Prestart Checks Stop engine10 − 60% 60 − 100% Duty 10 − 100% Duty Cycle Connecting to Weld Output TerminalsSelecting Weld Cable Sizes 100 ft 30 m or LessRef. ST-158 Remote 14 Receptacle RC1 InformationSocket Information Plug Using Idle Lock SwitchOperating the Welding Generator Front Panel ControlsRemote Amperage and Contactor Control Operating Auxiliary Equipment Auxiliary Power ReceptaclesMaintenance & Troubleshooting 100 Hrs Maintenance Changing Engine Oil and Oil Filter Changing Fuel Filters Servicing Air CleanerTo Clean air filter Do not clean housing with air hoseIdle Speed Adjustment Adjusting Engine SpeedWeld/Power Speed Adjustment Engine Control Circuit Weld And Auxiliary Power CircuitsRemote Control Circuit Overload ProtectionTrouble Remedy Welding TroubleshootingStop engine and let cool. Reinstall cleanout plug Servicing Optional Spark ArrestorEngine Troubleshooting Auxiliary Power TroubleshootingUle OM-402 Circuit Diagram for Welding Generator Electrical DiagramSC-181 Wetstacking Run-In ProcedureHeavy loading during first Load Bank Run-In Procedure Using Load BankRun-In Procedure Using Resistance Grid Selecting Equipment Auxiliary Power GuidelinesGrounding Generator to Truck or Trailer Frame How Much Power Does Equipment Require? Grounding When Supplying Building SystemsAmperes x Volts = Watts Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements for Industrial MotorsApproximate Power Requirements for Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements for Contractor EquipmentKVA/HP x HP x 1000 = Starting Amperage Volts Power Required to Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections to Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleMain Assembly Parts ListST-801 488-A PC6 11.1CB9 Panel, Front w/Components .1 Item CB5 11.2Generator .1 Item Diode Board Control Box w/Components .1 ItemOM-402 Page OM-402 Page Metro 250D Options and AccessoriesCall Miller for your local Miller distributor Miller Electric Mfg. Co Owner’s Record