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Lincoln Electric POWER MIG 255XT, Operator'S Manual, Page: 55 / 55

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Lincoln Electric POWER MIG 255XT Operator'S Manual Download Page 55

WARNING

●

Turn power off before servicing.

●

Do not operate with panel open or
guards off.

READ

 

AND

 

UNDERSTAND

 

THE

 

MANUFACTURER’S

 

INSTRUCTION

 

FOR

 

THIS

 

EQUIPMENT

 

AND

 

THE

 

CONSUMABLES

 

TO

 

BE

 

USED

 

AND

 

FOLLOW

 

YOUR

 

EMPLOYER’S

 

SAFETY

 

PRACTICES.

Learn more about welding equipment and soldering tools we have.

Summary of Contents for POWER MIG 255XT

Page 1: ...amaged in shipment must be made by the purchaser against the transportation company at the time the shipment is received Please record your equipment identification information below for future refer...

Page 2: ...he arc when welding or observing open arc weld ing Headshield and filter lens should conform to ANSI Z87 I standards 2 b Use suitable clothing made from durable flame resis tant material to protect yo...

Page 3: ...n cleaned For information purchase Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping That Have Held Hazardous Substances AWS F4 1 from the American Weldin...

Page 4: ...nstant Voltage Wire Welder DC Manual Stick Welder AC Welder with Reduced Voltage Control 5 c In semiautomatic or automatic wire welding the elec trode electrode reel welding head nozzle or semi automa...

Page 5: ...s affected by various factors including proper use and positioning of the equipment maintenance of the equipment and the specific welding procedure and application involved Worker exposure level shoul...

Page 6: ...trode electrode holder or any other electrically hot parts to touch a cylinder 7 e Keep your head and face away from the cylinder valve outlet when opening the cylinder valve 7 f Valve protection caps...

Page 7: ...6 Feeding Electrode B 6 Idle Roll Pressure Setting B 7 Wire Drive Configuration B 8 B 9 Setting Run in Speed B 10 Operating Instructions for Timer Setting B 11 B 12 Making a Weld B 13 Avoiding Wire F...

Page 8: ...lation D 1 Gun Tubes and Nozzles D 2 Cable Cleaning D 2 Liner removal and Replacement D 3 D 4 Gun Handle Disassembly D 5 Troubleshooting Section E How to Use Troubleshooting Guide E 1 Troubleshooting...

Page 9: ...6 Volts Welding Current Range Continuous 30 300 Amps Maximum Open Circuit Voltage 40 Volts Welding Voltage Range 10 28 Volts Input Current 200 Amp Rated Output 47 44 Amps 41 20 16 Amps Input Current 2...

Page 10: ...g holding the machine to the skid Remove foam and corrugated packing material Untape accessories from Gas Bottle Platform Unscrew the two wood screws at the Gas Bottle Platform holding the machine to...

Page 11: ...operated on lower voltage it must be reconnected according to the instructions in Figure A 1 for dual voltage machines and Figure A 2 for triple voltage machines Make certain that the input power is...

Page 12: ...the following diagram The center contact in the receptacle is for the grounding connection A green wire in the input cable connects this contact to the frame of the welder This ensures proper groundi...

Page 13: ...ed with a liner for 035 045 0 9 1 2 mm electrode and an 035 0 9 mm contact tip Install the 045 tip also provided if this wire size is being used Turn the welder power switch off before installing gun...

Page 14: ...ylinder on rear platform of POWER MIG 255XT Hook chain in place to secure cylinder to rear of welder 2 Remove the cylinder cap Inspect the cylinder valves and regulator for damaged threads dirt dust o...

Page 15: ...terclockwise until the adjusting spring pressure is released 7 Standing to one side open the cylinder valve slowly a fraction of a turn When the cylinder pressure gauge pointer stops moving open the v...

Page 16: ...k and ground Always wear dry insulating gloves FUMES AND GASES can be dangerous Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone WELDING SPARKS can cause fire...

Page 17: ...zle a 10 ft 3 1 m power cable with plug and a 10ft 3 1 m work cable with clamp The POWER MIG 255XT features a Timer kit that provides variable burnback control a spot function a selectable 4 step trig...

Page 18: ...voltage It can be adjusted while welding over its 10 to 28 volt range Wire Speed Control This controls the wire feed speed from 50 700 inches per minute 1 2 17 8 m min The control can be preset on the...

Page 19: ...roll retaining mechanism to the unlocked position as shown below and remove the drive roll See Figure B 1 FIGURE B 1 5 Remove the inside wire guide plate 6 Replace the drive and idle rolls and inside...

Page 20: ...res on the slot in the retaining spring tab 8 Lower the Readi Reel to depress the retaining spring and align the other inside cage wires with the grooves in the molded adapter 9 Slide cage all the way...

Page 21: ...elease Bar pops up and that the collar retainers fully engage the retaining ring groove on the spindle TO START THE WELDER Turn the Power Switch switch to ON This lights the red LED display lights Wit...

Page 22: ...IC SHOCK can kill Turn the input power OFF at the welding power source before installation or chang ing drive rolls and or guides Do not touch electrically live parts When inching with the gun trigger...

Page 23: ...e 3 Remove the thumb screw from the wire drive 4 Remove the welding gun from the wire drive 5 Loosen the socket head cap screw that holds the con nector bar against the gun bushing Important Do not at...

Page 24: ...GUN RECEIVER BUSHING LOOSEN TIGHTEN SOCKET HEAD CAP SCREW FIGURE B 4 OPERATION THUMB SCREW OUTER WIRE GUIDE CONNRCTOR BLOCK...

Page 25: ...OW RUN IN 1 Turn power OFF on front panel of POWER MIG 255XT 2 Turn the wire feed speed dial to minimum fully counter clockwise 3 With the gun trigger closed turn the power ON at the front panel of th...

Page 26: ...steps 1 Close trigger and establish welding arc 2 Release trigger and continue welding 3 Reclose trigger near end of weld 4 Release trigger again to stop welding If the arc is broken while using this...

Page 27: ...me 0 250 milliseconds for any selected welding mode this control should be set as low as possible without the wire sticking in the puddle after each weld Too long of a burnback time may form a ball on...

Page 28: ...at low speed regardless of the set wire feed speed until the welding arc starts or 1 second has elapsed This feature enhances starting and makes it easier to set the stickout The 1 second limit permit...

Page 29: ...ylinder if used momentarily operate gun trigger to release gas pressure and turn off POWER MIG 255XT AVOIDING WIRE FEEDING PROBLEMS Wire feeding problems can be avoided by observing the following gun...

Page 30: ...eeds 125 of rated input voltage the output will be reduced to the lower level to protect voltage rating of the capacitor bank Low Line Voltage You may not be able to get maximum output from the machin...

Page 31: ...mostats automatically reset when the temperature reaches a safe operating level and welding and feeding are allowed again when gun is retriggered OVERCURRENT PROTECTION The machine will automatically...

Page 32: ...stallation instructions K2378 1 Canvas Cover K468 Spindle Adapter for 8 203 2mm O D spool K363P READI REEL ADAPTER The K363P Readi Reel Adapter mounts to the 2 spindle It is needed to mount the 22 30...

Page 33: ...nector fixed nozzle and insulator and includes a liner diffuser and contact tips for the wire sizes specified 1 Optional liners for different wire diameters are sold seperately see table D 1 MAGNUM GU...

Page 34: ...OWER MIG 255XT s 7 pin spool gun control cable receptacle K1738 1 Spool Gun Hanger Accessory CONNECTING THE SPOOL GUN TO THE POWER MIG 255XT See Figure C 1 1 Connect the Spool Gun control cable to the...

Page 35: ...electrically HOT Be sure unused gun is positioned so electrode or tip will not contact metal case or other metal common to work 1 Pulling the trigger for the built in feeder gun a Disables spool gun...

Page 36: ...ctual WFS at the gun may vary from the displayed value due to tension set ting liner condition or gun variation 4 The following procedure settings for Aluminum 4043 can be used as initial settings for...

Page 37: ...e control will increase or decrease your welding voltage c Adjusting the wire speed control on the spool gun will increase or decrease the spool gun wire feed speed d For the Magnum SG Spool Gun the w...

Page 38: ...push motor Magnum 250LX Push Pull Adapter K2705 1 This adapter box is designed to drive the Magnum 250LX push pull gun when used on a non push ready Lincoln power source feeder such as the POWER MIG...

Page 39: ...Gun Adapter to the 4 pin trigger receptacle located in the front section of the wire drive com partment 3 Connect the 7 pin connector cable of the Push Pull Gun to the 7 pin receptacle cable from the...

Page 40: ...the front panel Refer to the procedure decal mounted at the inside of the wire feeder compartment cover 2 Magnum 250LX Push Pull Gun a Set machine to non spool gun operation b Closing Push Pull gun tr...

Page 41: ...ervice DRIVE ROLLS AND GUIDE PLATES After every coil of wire inspect the wire drive mechanism Clean it as necessary by blowing with low pressure compressed air Do not use solvents for cleaning the idl...

Page 42: ...ation Adjust the gas nozzle as appropriate for the GMAW process to be used Typically the con tact tip end should be flush to 12 3 2 mm extended for the short circuiting transfer process and 12 3 2 mm...

Page 43: ...ve the gas nozzle and nozzle insulator if used to locate the set screw in the gas diffuser which is used to hold the old liner in place Loosen the set screw with a 5 64 2 0 mm Allen wrench 2 Remove th...

Page 44: ...Fully seat the liner bushing into the connector tighten the set screw on the brass cable con nector The gas diffuser at this time should not be installed onto the end of the gun tube 6 With the gas di...

Page 45: ...n as removing a right hand thread until the collar reaches a stop Then pull the collar off the gun handle If the collars are difficult to turn position the gun handle against a corner place a screwdri...

Page 46: ...0 6 mm KP2021 6B1 030 0 8 mm KP2022 1B1 035 0 9 mm KP2022 2B1 045 1 2 mm Notched For Alum KP2010 5B1 3 64 1 2 mm Alum Wire Alum Wire GAS NOZZLES Fixed Flush KP1931 1 3 8 9 5 mm KP1931 2 1 2 12 7 mm KP...

Page 47: ...hroughout this manual _________________________________________ This Troubleshooting Guide is provided to help you locate and repair possible machine malfunctions If you do not understand or are unabl...

Page 48: ...horted to welding circuit Allowing the machine to cool will clear the error condition 3 Make sure input voltage is correct and matches nameplate rating and reconnect panel configuration Machine output...

Page 49: ...un assembly for loose or faulty connections Poor arc striking with electrode sticking or blast ing off 1 Make sure settings for wire feed speed and voltage are correct for process being used 2 The Run...

Page 50: ...d tip are correct for wire size being used 4 Make sure drive rolls and guide plates are clean and are the correct size 5 Make sure the spot timer knob is set to off 6 Check spindle for ease of rotatio...

Page 51: ...or all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service Departmen...

Page 52: ...ccurate for all machines covered by this manual The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels If the diagram is illegible write to the Service...

Page 53: ...A A M19231 M19231 DIMENSION PRINT POWER MIG 255XT F 3...

Page 54: ...parts or electrode with skin or wet clothing Insulate yourself from work and ground Keep flammable materials away Wear eye ear and body protection Keep your head out of fumes Use ventilation or exhau...

Page 55: ...operate with panel open or guards off READ AND UNDERSTAND THE MANUFACTURER S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE USED AND FOLLOW YOUR EMPLOYER S SAFETY PRACTICES Learn more about...

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