Lincoln-electric IM740 PRO-MIG 135 User Manual

Pro-MIG 135OPERATOR’S MANUALIM740April, 2002Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind

A-3INSTALLATION Pro-MIG 135A-3Pro-MIG™ 13545836712DO NOT SWITCHWHEN WELDING+-FIGURE A.2Work Clamp InstallationAttach the work clamp per the followin

Work Cable InstallationRefer to Figure A.2.1. Open the wire feed section door on the right side ofthe Pro-MIG 135.2. Pass the end of the work cable th

CYLINDER may explode if dam-aged. Keep cylinder upright andchained to support• Keep cylinder away from areaswhere it may be damaged.• Never lift welde

A-6INSTALLATION Pro-MIG 135A-6INPUT CONNECTIONSRefer to Figure A.6.The Pro-MIG 135 has a power input cable located onthe rear of the machine.FIGURE

B-1OPERATIONB-1Pro-MIG 135Read entire operation section beforeoperating the Pro-MIG 135.ELECTRIC SHOCK can kill.• Do not touch electrically liveparts

B-2OPERATIONB-25. Gun Trigger - Activates welding output, wire feed,and gas solenoid operation. Releasing the triggerdeactivates welding and simultan

B-3OPERATIONB-3FIGURE B.1aFIGURE B.1bWELDING OPERATIONSSEQUENCE OF OPERATION Wire LoadingRefer to Figures B.2 and B.3.The machine power switch should

B-4OPERATIONB-4Friction Brake AdjustmentWith wire spool installed on the spindle shaft and thewing nut loose, turn the spool by hand while slowlytight

B-5OPERATIONB-5FIGURE B.6Making A Weld1. See “Process Guidelines” in this section for selec-tion of welding wire and shielding gas and forrange of met

B-6OPERATIONB-6The Pro-MIG 135 is suitable for .035" aluminum wireand .030" stainless wire. Refer to Table B.1 for recom-mended procedure s

FOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

B-7LEARNING TO WELDB-7LEARNING TO WELDNo one can learn to weld simply by reading aboutit. Skill comes only with practice. The followingpages will help

B-8LEARNING TO WELDB-8The “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing through th

B-9LEARNING TO WELDB-9Pro-MIG 135For GMAW (MIG) Process1. Is most of my welding performed on 16 gauge andlighter materials?2. Can I afford the extra e

B-10LEARNING TO WELDB-10Pro-MIG 135FIGURE B.12PenetrationUnless a weld penetrates close to 100% of the metalthickness, a butt weld will be weaker than

B-11LEARNING TO WELDB-11Pro-MIG 135FIGURE B.16Vertical-down WeldingRefer to Figure B.17 Vertical-down welds are appliedat a fast pace. These welds are

B-12LEARNING TO WELDB-12Pro-MIG 135ARC RAYS can burn eyes and skin.When using an open arc process, itIs necessary to use correct eye,head and body pro

B-13LEARNING TO WELDB-13Pro-MIG 135Helpful Hints1. For general welding, it is not necessary to weavethe arc, neither forward or backward nor sideways.

B-14LEARNING TO WELDB-14Pro-MIG 135MACHINE SET UP FOR THE GMAW (MIG)PROCESS1. See PROCESS GUIDELINES in the OPERATIONsection for selection of welding

B-15LEARNING TO WELDB-15Pro-MIG 135FIGURE B.243. The Correct Electrical Stickout (ESO)The electrical stickout (ESO) is the distance fromthe end of the

B-16LEARNING TO WELDB-16TROUBLESHOOTING WELDSGood welds have excellent appearance.To Eliminate Porosity (in order of importance):1. Turn on gas supply

iiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the arc when weld

B-17LEARNING TO WELDB-17Proper Gun HandlingMost feeding problems are caused by improper han-dling of the gun cable or electrodes.1. Do not kink or pul

B-18APPLICATION CHARTB-18Pro-MIG 135

C-1ACCESSORIESC-1OPTIONAL ACCESSORIES1. K549-1 .035" (0.9 mm) Innershield® Welding Kit— Includes a contact tip, a gasless nozzle and a.035/.045&q

C-2ACCESSORIESC-2INNERSHIELD (FCAW) CONVERSIONSeveral changes are needed to convert the unit foroperation with the Innershield (FCAW) process: 1. Chan

MAINTENANCESAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Disconnect input power by removingplug from receptacle before workinginside Pro-MIG 135. Use on

D-2MAINTENANCED-2Pro-MIG 135GUN AND CABLE MAINTENANCEFOR MAGNUM™ 100L GUNGun Cable CleaningClean cable liner after using approximately 300 lbs(136 kg)

D-3MAINTENANCED-3Pro-MIG 135COMPONENTREPLACEMENTPROCEDURESCHANGING THE CONTACT TIP1. Refer to Figure D.2. Remove the gas nozzle fromthe gun by unscrew

GUN HANDLE PARTSThe gun handle consists of two halves that are heldtogether with a collar on each end. To open up thehandle, turn the collars approxim

E-1TROUBLESHOOTINGE-1Pro-MIG 135If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact

E-2TROUBLESHOOTINGE-2Pro-MIG 135If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact

FOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b. Install equ

E-3TROUBLESHOOTINGE-3Pro-MIG 135If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact

E-4TROUBLESHOOTINGE-4Pro-MIG 135If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact

F-1DIAGRAMSF-1Pro-MIG 135S1SWITCHD1D3D2D4204204204203203203C159,000 f40V203204-+GUN CABLECONDUCTORBLOCKTOWORKELECTRICAL SYMBOLS PER E1537CAVITY NUMBE

NOTESPro-MIG 135

NOTESPro-MIG 135

Now Available...12th EditionThe Procedure Handbook of Arc WeldingWith over 500,000 copies of previous editions publishedsince 1933, the Procedure Hand

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ivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui par

Thank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much p

viMASTER TABLE OF CONTENTS FOR ALL SECTIONSPageInstallation ...

A-1Pro-MIG 135A-1Fuse orOutput Mode Input Voltage Breaker Size1Input Amps Power Cord Extension CordThree Conductor#14 AWG(2.1 mm2) or LargerRATED 120V

A-2INSTALLATION Pro-MIG 135A-2Read entire installation section before startinginstallation.SAFETY PRECAUTIONSIDENTIFY AND LOCATE COMPONENTSIf you ha