Miller Electric Metro 250D - Manual (Page 3)

Description Features
H NEW! Warranty extended to 3 years (engine
warranted by engine manufacturer)
H Versatile weld output for DC Stick and DC
TIG welding
H Stepless amperage control for precise heat
selection
H Arc force control ensures a forceful arc for
tight fit-ups − prevents electrode sticking
H Built-in Hot Start circuit for dependable arc
starting
H Remote control receptacle permits remote
current and contactor control
H Panel includes hour meter and fuel gauge
H Earth leakage protection for auxiliary power
receptacles
H Product features and specifications are
subject to change without notice
1. Safety Precautions 1 . . . . . . . . . . . . . . . . . . . . .
1. Consignes de sécurité 5 . . . . . . . . . . . . . . . . .
2. Definitions 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3. Specifications 15 . . . . . . . . . . . . . . . . . . . . . . . . .
4. Installation 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5. Operating the Welding Generator 21 . . . . . . .
6. Operating Auxiliary Equipment 23 . . . . . . . . .
7. Maintenance & Troubleshooting 24 . . . . . . . .
8. Electrical Diagram 34 . . . . . . . . . . . . . . . . . . . . .
9. Run-In Procedure 36 . . . . . . . . . . . . . . . . . . . . . .
10. Auxiliary Power Guidelines 39 . . . . . . . . . . . .
11. Parts List 46 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Options and Accessories
Warranty
Section Page
Table of Contents
Call
1-800-4-A-
MILLER
for your local
Miller distri-
butor.
Your distributor gives
you ...
Service
You always get the fast,
reliable response you
need. Most replacement
parts can be in your
hands in 24 hours.
Support
Need fast answers to the
tough welding questions?
Contact your distributor.
The expertise of the
distributor and Miller is
there to help you, every
step of the way.
Metro 250D
Metro 250D

The following terms are used interchangeably in
this manual: TIG = GTAW, Stick = SMAW
Multiple patented innovations put the new Metro 
250D constant current welder/generator on the
leading edge of engine-driven welding technology.
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 rental markets as well.
Delivering 250 amps at 100% duty cycle (280
amps at 60%), the Metro has the muscle to
handle tough assignments with the spare power
needed for other equipment.
The Metro boasts an industrial, air-cooled,
two-cylinder diesel engine that delivers 10
kVA/kW of auxiliary power and runs for at least 16
hours on one tank of fuel. The low noise case
provides remarkably quiet operation, 99 LW(A) or
74 dB(A) at 23 ft (7 m), making the Metro 250D an
excellent machine for work in noise-restricted
locations.
Processes
TIG (GTAW) Welding
Stick (SMAW) Welding
Flux Cored (FCAW) Welding
Engine
H Deutz/Ruggerini RD 211 twin-cylinder diesel
engine, 23 HP at 3600 RPM
H Air cooling eliminates radiators, belts,
thermostats, coolant hoses, and antifreeze
required in liquid-cooled engines
H Automatic idle for fuel economy and reduced
noise
H Automatic shutdown system protects against
low oil pressure
H Large 12 gallon (45 L) fuel capacity
H Two-year North American warranty from
engine manufacturer
CALIFORNIA
Proposition 65
Warning
Diesel engine exhaust and
some of its constituents
are known to the State of
California to cause
cancer, birth defects, and
other reproductive harm.
Miller offers a Technical Manual
which provides more detailed
service and parts information for
your unit. To obtain a Technical
Manual, contact your local
distributor. Your distributor can also
supply you with Welding Process
Manuals such as SMAW, GTAW,
GMAW, and GMAW-P.
For practical information on welding,
process applications, and Miller
products, visit our website at
www.millerwelds.com
With Optional Equipment: