Lincoln-electric WELDMARK 135 PLUS IM767 User Manual

WELDMARK 135 PLUSOPERATOR’S MANUALIM767November, 2005Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in

A-3A-3INSTALLATIONSELECT SUITABLE LOCATIONLocate the welder in a dry location where there is freecirculation of clean air into the louvers in the back

A-4A-4INSTALLATION3. Route the cable under and around the back of theWire Feed Gearbox (6).4. For GMAW Only: Refer to Figure A.2. As deliv-ered, the w

A-5A-5INSTALLATION3. Attach the flow regulator to the cylinder valve andtighten the union nut securely with a wrench. Theflow regulator for carbon dio

A-6 A-6INSTALLATIONCODE REQUIREMENTS FOR INPUTCONNECTIONSThis welding machine must be connected topower source in accordance with applicable elec-tric

B-1B-1OPERATIONRead entire Operation section beforeoperating the WELDMARK 135 PLUS.ELECTRIC SHOCK can kill.• Do not touch electrically liveparts or el

B-2B-2OPERATIONGENERAL DESCRIPTIONThe WELDMARK 135 PLUS is a complete semiauto-matic constant voltage DC arc welding machine.Included is a solid state

B-3B-3OPERATIONFIGURE B.1a4. Circuit Breaker – Protects machine from damage ifmaximum output is exceeded. Button will extendout when tripped (Manual r

B-4B-4OPERATIONFIGURE B.3Friction Brake AdjustmentWith wire spool installed on the spindle shaft and thewing nut loose, turn the spool by hand while s

B-5B-5OPERATIONShielding GasWhen using the GMAW process, a cylinder of shield-ing gas, must be obtained. Refer to the ACCES-SORIES section for more in

B-6B-6OPERATION9. To stop welding, release the gun trigger and thenpull the gun away from the work after the arc goesout.10. When no more welding is t

WELDMARK 135 PLUSFOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires

B-7B-7OPERATIONOVERLOAD PROTECTIONOutput OverloadThe WELDMARK 135 PLUS is equipped with a circuitbreaker which protects the machine from potentialdama

B-8B-8LEARNING TO WELDLEARNING TO WELDNo one can learn to weld simply by reading about it.Skill comes only with practice. The following pages willhelp

B-9B-9LEARNING TO WELDThe “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing through th

B-10B-10LEARNING TO WELDFor GMAW (MIG) Process1. Is most of my welding performed on 16 gauge andlighter materials?2. Can I afford the extra expense, s

B-11 B-11 LEARNING TO WELDFIGURE B.12PenetrationUnless a weld penetrates close to 100% of the metalthickness, a butt weld will be weaker than the mate

B-12B-12LEARNING TO WELDFIGURE B.16Vertical-down WeldingRefer to Figure B.17 Vertical-down welds are appliedat a fast pace. These welds are therefore

B-13B-13LEARNING TO WELDARC RAYS can burn eyes and skin.When using an open arc process, itIs necessary to use correct eye,head and body protection.Pro

B-14B-14LEARNING TO WELDMild Steel 16 gauge or 1/16 inch(1.6 mm)Electrode 0.035" (0.9 mm)NR-211-MPInnershield WireVoltage Setting “V” EWire Feed

B-15B-15LEARNING TO WELDMACHINE SET UP FOR THE GMAW (MIG)PROCESS1. See PROCESS GUIDELINES in the OPERATIONsection for selection of welding wire and sh

Helpful Hints1. For general welding, it is not necessary to weavethe arc, neither forward or backward nor sideways.Weld along at a steady pace. You wi

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-17B-17LEARNING TO WELD4. After you strike the arc, practice the correct electri-cal stickout. Learn to distinguish it by its sound.5. When you are s

B-18B-18LEARNING TO WELDProper Gun HandlingMost feeding problems are caused by improper han-dling of the gun cable or electrodes.1. Do not kink or pul

B-19B-19APPLICATION CHARTWELDMARK 135 PLUS

C-1C-1ACCESSORIES4. KP666-035C Knurled Drive Roll (optional) —Reversible Drive Roll with double knurled groovesfor .035 (0.9 mm) cored electrode.5. K6

C-2C-2ACCESSORIESINNERSHIELD (FCAW)CONVERSIONSeveral changes are needed to convert the unit foroperation with the Innershield (FCAW) process. TheK549

MAINTENANCESAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Disconnect input power byremoving plug from receptaclebefore working inside WELD-MARK 135 PLUS.

D-2 D-2MAINTENANCEGUN AND CABLE MAINTENANCEFOR MAGNUM™ 100L GUNGun Cable CleaningClean cable liner after using approximately 300 lbs(136 kg) of solid

D-3WELDMARK 135 PLUSD-3MAINTENANCECOMPONENT REPLACEMENT PROCEDURESCHANGING THE CONTACT TIP1. Unplug or turn power switch to Off “O” position.2. Refer

D-4GUN HANDLE PARTSThe gun handle consists of two halves that are heldtogether with a collar on each end. To open up thehandle, turn the collars appro

If machine case sides and top are removed, the case front must be supported. Failureto do this could result in mechanical or electrical damage to the

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-2E-2TROUBLESHOOTINGObserve Safety Guidelinesdetailed in the beginning of this manual.TROUBLESHOOTING GUIDEPROBLEMS(SYMPTOMS)Major physical or electr

E-3E-3TROUBLESHOOTINGObserve Safety Guidelinesdetailed in the beginning of this manual.TROUBLESHOOTING GUIDEPROBLEMS(SYMPTOMS)No wire feed when gun tr

E-4E-4TROUBLESHOOTINGObserve Safety Guidelinesdetailed in the beginning of this manual.TROUBLESHOOTING GUIDEPROBLEMS(SYMPTOMS)Arc is unstable – Poor s

F-1 F-1WIRING DIAGRAMSM19922L1L23132531TO GROUNDPER NATIONALELECTRICAL CODES1SWITCH202201D1D3D2D4204204204203203203C159,000 f40V203204-+OUTPUT CHOKEG

NOTESWELDMARK 135 PLUS

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicREAD AND UNDERSTAND THE MANUFACTURER’S INSTRUC

WARNINGAVISO DEPRECAUCIONATTENTIONWARNUNGATENÇÃOSpanishFrenchGermanPortugueseJapaneseChineseKoreanArabicLEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE

• Manufactured by Lincoln Electric Company •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric

ivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parra

vvWELDMARK 135 PLUSThank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company p

viviTABLE OF CONTENTSPageInstallation ...Section A

A-1A-1INSTALLATIONFuse orOutput Mode Input Voltage Breaker Size Input Amps Extension CordThree Conductor#14 AWGRATED 115V/60Hz 20 Amp 20 (2.1 mm2) or

A-2 A-2INSTALLATIONRead entire installation section before startinginstallation.SAFETY PRECAUTIONSIDENTIFY AND LOCATE COMPONENTSIf you have not alread