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SAFETY INFORMATION

STORE AND RETAIN THIS MANUAL

 

Retain this manual for the safety warnings and 
precautions, assembly, operating, inspection, 
maintenance and cleaning procedures. Write the 
product’s serial number into the NOTES section at 
the rear, and keep this manual and the receipt in a 
safe and dry place for future reference.

IMPORTANT SAFETY INFORMATION 

Failure to follow the warnings and instructions may 
result in electric shock, fire, serious injury and/or 
death. Save all warnings and instructions for future 
reference. 

 This is the safety alert symbol to alert you to 

potential personal injury hazards. Obey all safety 
messages that follow this symbol to avoid possible 
injury or death.

 

DANGER

 indicates a hazardous situation 

which, if not avoided, will result in death or serious 
injury.

 

WARNING

 indicates a hazardous situation 

which, if not avoided, could result in death or 
serious injury.

 

CAUTION

, used with the safety alert symbol, 

indicates a hazardous situation which, if not 
avoided, could result in minor or moderate injury.

NOTE

, used to address practices not related to 

personal injury.

CAUTION

, without the safety alert symbol, is used to 

address practices not related to personal injury.

GENERAL SAFETY WARNINGS

1. 

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2.  Avoid unintentional starting.

 Make sure the welder 

is setup correctly and you are prepared to begin work
before turning on the welder.

3.  Unplug before performing maintenance. 

Always 

unplug the Welder from its electrical outlet before
performing any inspection, maintenance, or clean-
ing procedures.

4.  Never leave the welder unattended while ener-

gised.

 Turn power off before leaving the welder 

unattended.

5.  Do not touch live electrical parts. 

Wear dry, 

insulating gloves. Do not touch the electrode or the 
conductor tong with bare hands. Do not wear wet or
damaged gloves.

6.  Protect yourself from electric shock. 

Do not use 

the welder outdoors. Insulate yourself from the 
work piece and the ground. Use non-flammable,
dry insulating material if possible, or use dry rubber
mats, dry wood or plywood, or other dry insulating 
material large enough to cover the area of contact 
with the work or the ground. 

7.  Avoid inhaling dust. 

Some dust created by power 

sanding, sawing, grinding, drilling, cutting, welding
and other construction activities, contain chemicals 
known to cause cancer, birth defects or other harm.
Your risk from these exposures varies, depending 
on how often you do this type of work. To reduce
your exposure to these chemicals, work in a 
well-ventilated area, and work with approved safety
equipment, such as dust masks that are specially
designed to filter out microscopic particles. 

8.  People with pacemakers should consult their

physician(s) before using this machine. 

 

WARNING

Electromagnetic fields in close proximity to a heart 
pacemaker could cause interference, or failure of 
the pacemaker. The use of a Welder is NOT  
RECOMMENDED for pacemaker wearers. Consult 
your doctor.

9.  Ensure that the unit is placed on a stable location

before use.

 

 

WARNING

If this unit falls while plugged in, severe injury, 
electric shock, or fire may result.

10. Transportation Methods

CAUTION

 

Disconnect input power conductors from 
de-energized supply line before moving the welding
power source.

Lift unit with the handles provided, or use a 
handcart or similar device of adequate capacity. 
If using a fork lift vehicle, secure the unit to a skid 
before transporting.

11. Exericse good work practices. 

The warnings, 

precautions, and instructions discussed in this 
instruction manual cannot cover all possible
conditions and situations that may occur. It must be 
understood by the operator that common sense and
caution are factors which cannot be built into this 
product, but must be considered by the operator.

WELDING SAFETY INSTRUCTIONS & WARNINGS

 

WARNING

 

PROTECT YOURSELF AND OTHERS FROM 
POSSIBLE SERIOUS INJURY OR DEATH.  
KEEP CHILDREN AWAY. READ THE OPERATING/
INSTRUCTION MANUAL BEFORE INSTALLING, 
OPERATING OR SERVICING THIS EQUIPMENT.

HAVE ALL INSTALLATION, OPERATION, 
MAINTENANCE, AND REPAIR WORK PERFORMED 
BY QUALIFIED PEOPLE. 

If an operator does not strictly observe all safety 
rules and take precautionary actions, welding 
products and welding processes can cause serious 
injury or death, or damage to other equipment or 
property.

Safe practices have developed from past 
experience in the use of welding and cutting. 
These practices must be learned through study 
and training before using this equipment. Some of 
these practices apply to equipment connected to 
power lines; other practices apply to engine driven 
equipment. Anyone not having extensive training in 
welding and cutting practices should not attempt 
to weld.

Safe practices are outlined in the European 
Standard EN60974-1 entitled: Safety in welding  
and allied processes.  

 

WARNING

  

Only use safety equipment that has been approved 
by an appropriate standards agency. Unapproved 
safety equipment may not provide adequate 
protection. Eye and breathing protection must be 
AS/NZS compliant for the specific hazards in the 
work area. 

 

DANGER

  

Always wear AS/NZS compliant safety glasses  and 
a full face shield fitted with the appropriate filter 
shade number. (Refer Filter Table on page 6.)

 

CAUTION

  

Heavy-duty work gloves, non-skid safety shoes and 
hearing protection used for appropriate conditions 
will reduce personal injuries. 

 

CAUTION 

 

Have the equipment serviced by a qualified repair 
person using identical replacement parts. This will 
ensure that the safety of the power tool is 
maintained. 

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Summary of Contents for XM255PRO

Page 1: ...OR WNVK 2TQEGUU 21 5 78 7 216 21 7 385 6 2 285 1 675 7 0 352 19 57 5 0 00 08 7 352 66 1 0 1 3 6 1685 28 9 0 5 6 2856 7 7 16758 7 21 9 1 5 7 217 176 2 7 6 0 18 25 86 1 285 0 1 PLEASE READ THIS MANUAL...

Page 2: ...L ADJUSTING WIRE FEED TENSION 1 CONNECTING THE WELDER 1 GASLESS MIG OPERATION FCAW 1 GAS SHIELDED MIG OPERATION GMAW 1 SPOOL GUN OPERATION 1 MMA WELDING OPERATION 1 TIG WELDING OPERATION 1 MIG WELDING...

Page 3: ...e specially designed to lter out microscopic particles 8 People with pacemakers should consult their physician s before using this machine WARNING Electromagnetic elds in close proximity to a heart pa...

Page 4: ...ng process and well after the welding is completed 5 Do not weld or cut on materials having a combustible coating or combustible internal structure as in walls or ceilings without an approved method f...

Page 5: ...nimum Shade Number of Filter s Manual Metal Arc Welding Covered Electrodes MMA Less than or equal to 100 8 100 to 200 10 200 to 300 11 300 to 400 12 Greater than 400 13 Gas Metal Arc Welding GWAW MIG...

Page 6: ...in 10m of the welding site 4 Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas 5 Watch for re and keep a re extinguisher nea...

Page 7: ...5m 1 Argon Gas Regulator with CO2 Adaptor 1 Gas Hose with clamps 8mm x 2m 1 V Groove Wire Drive Roller Set 0 8 1 0mm 1 Knurled Groove Wire Drive Roller Set 0 8 0 9mm 1 Instruction Manual 1 Instruction...

Page 8: ...hich in turn affects the heat input and the penetration The wire speed feed simply controls the rate at which the welding wire is fed into the weld pool For any voltage position setting there will be...

Page 9: ...Professional Welding Gloves Argon Regulator 5 5 MIG Welding Tip Dip Gel 120g 7 Welding Magnet 5 0 MIG Wire 0 6mm Mild Steel 5kg MW5KG06 MIG Wire 0 8mm Mild Steel 5kg 0 MIG Wire 0 8mm Flux Cored 5kg 0...

Page 10: ...mp to the work piece Contact with the work piece must be rm with clean bare metal with no corrosion paint or scale Connect the MIG Power Connection Lead to the MIG Torch Power Connection Socket 11 and...

Page 11: ...e mains power using the Mains Input Power Lead 21 Switch the Mains Power Switch 16 to ON to power up the machine Connect the Work Lead Clamp Quick Connector to the Positive Welding Power Output Socket...

Page 12: ...supplied gas or gas mixture The process is normally applied semi automatically however the process may be applied automatically or by machine It is commonly used to weld large diameter electrodes in t...

Page 13: ...e Longitudinal Angle Axis of Weld Nozzle Angle Right Handed Operator Fig 1 10 Leading or Pushing Angle Forward Pointing Trailing or Pulling Angle Backward Pointing 90o Direction of Travel Establishing...

Page 14: ...h nozzle Do not restrict gas ow by allowing spatter to build up inside the torch nozzle Check that the MIG torch O rings are not damaged WARNING Disengage the feed roll when testing for gas ow by ear...

Page 15: ...ge too high Adjust voltage and current by adjusting the voltage control and the Current Wire Speed control Wire is wandering Replace contact tip Incorrect shielding gas Check shielding gas Insuf cient...

Page 16: ...e to the porosity caused by gas held in this type of iron Copper and Alloys The most important factor is the high rate of heat conductivity of copper making pre heating of heavy sections necessary to...

Page 17: ...st scale dirt grease etc Slag should be removed from oxy cut surfaces Typical joint designs are shown in Figure 1 19 Open Square Butt Joint Fig 1 19a Gap varies from 1 6mm 1 16 to 4 8mm 3 16 depending...

Page 18: ...o short there is the danger of it being blanketed by slag and the electrode tip being solidi ed in If this should happen give the electrode a quick twist back over the weld to detach it Contact or tou...

Page 19: ...completion of each side motion pause for a moment to allow weld metal to build up at the edges otherwise undercut will form and too much metal will accumulate in the centre of the weld Figure 1 26 ill...

Page 20: ...lectrode Electrode too large for joint Use smaller gauge electrode Insuf cient deposit time at edge of weave Pause for a moment at edge of weave to allow weld metal build up Power source is set for MI...

Page 21: ...3 32 100 165 3 2mm 1 8 135 200 4 0mm 5 32 190 280 4 8mm 3 16 250 340 Tungsten Electrode Types Electrode Type Ground Finish Application Features Colour Code Thoriated 2 DC welding of mild steel stainl...

Page 22: ...ement of ller rod Re position ller rod Electrode melts or oxidises when an arc is struck Torch lead connected to positive welding terminal Connect torch lead to negative welding terminal No gas owing...

Page 23: ...mponents causing electrical short circuits Check for damaged parts Do not use the welder with damaged parts before further use a damaged welder must be carefully checked by a quali ed person to determ...

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