RETURN TO MAIN MENU IM767 WELDMARK 135 PLUS November, 2005 For use with machine Code Numbers : 10947 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONS CONTAINED THROUGHOUT. And, most importantly, think before you act and be careful.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and other reproductive harm. The Above For Diesel Engines The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm. The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS.
ii ii SAFETY ELECTRIC SHOCK can kill. 3.a. The electrode and work (or ground) circuits are electrically “hot” when the welder is on. Do not touch these “hot” parts with your bare skin or wet clothing. Wear dry, hole-free gloves to insulate hands. 3.b. Insulate yourself from work and ground using dry insulation. Make certain the insulation is large enough to cover your full area of physical contact with work and ground.
iii iii SAFETY WELDING SPARKS can cause fire or explosion. 6.a. Remove fire hazards from the welding area. If this is not possible, cover them to prevent the welding sparks from starting a fire. Remember that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas. Avoid welding near hydraulic lines. Have a fire extinguisher readily available. 6.b.
iv iv SAFETY PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instructions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits à l’électrode et à la piéce sont sous tension quand la machine à souder est en marche.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
vi vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components ...........................................................................A-2 Select Suitable Location ........................................................................................
A-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – WELDMARK 135 PLUS INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency 115V/60Hz 115V/60Hz 115V/60Hz Input Current 20 Amps - Rated Output 25 Amps - Maximum Output 15 Amps - CSA Rated output RATED OUTPUT Duty Cycle 20% Duty Cycle – Rated DC Output Amps 90 Volts at Rated Amperes 18 OUTPUT Welding Current Range (Continuous) Rated DC Output: 25 – 135 Amps Maximum Open Circuit Voltage 28 Auxiliary Power N/A RECOMMENDED INPUT CABLE AND FUSE SIZES Output M
A-2 A-2 INSTALLATION FIGURE A.1 Read entire installation section before starting installation. 1 SAFETY PRECAUTIONS 2 WELD ING 25-125AMP RA NGE WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Only personnel that have read and understood the WELDMARK 135 PLUS Operating Manual should install and operate this equipment. 4 • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes.
A-3 A-3 INSTALLATION SELECT SUITABLE LOCATION Work Clamp Installation Locate the welder in a dry location where there is free circulation of clean air into the louvers in the back and out the front of the unit. A location that minimizes the amount of smoke and dirt drawn into the rear louvers reduces the chance of dirt accumulation that can block air passages and cause overheating. Attach the work clamp per the following: 1. Unplug the machine or turn the power switch to the “OFF” position. 2.
A-4 A-4 INSTALLATION 3. Route the cable under and around the back of the Wire Feed Gearbox (6). 4. For GMAW Only: Refer to Figure A.2. As delivered, the welder is wired for positive polarity. This is the appropriate configuration for the Gas Metal Arc Welding (GMAW) process. To complete installation, use the provided wing nut to connect the work cable’s terminal lug to the negative (–) output terminal (5) located above the Wire Feed Gearbox (6). Make sure that both wing nuts are tight. 5.
A-5 INSTALLATION A-5 WARNING BUILDUP OF SHIELDING GAS may harm health or kill. • Shut off shielding gas supply when not in use. • SEE AMERICAN NATIONAL STANDARD Z-49.1, “SAFETY IN WELDING AND CUTTING” PUBLISHED BY THE AMERICAN WELDING SOCIETY. 1. Chain the cylinder to a wall or other stationary support to prevent the cylinder from falling over. Insulate the cylinder from the work circuit and earth ground. FIGURE A.5 Cylinder Valve Flow Regulator 3.
A-6 A-6 INSTALLATION CODE REQUIREMENTS FOR INPUT CONNECTIONS CAUTION Do not connect the welder to an input power supply with a rated voltage that is greater than 125 volts. WARNING This welding machine must be connected to power source in accordance with applicable electrical codes. Do not remove the power cord ground prong.
B-1 OPERATION Read entire Operation section before operating the WELDMARK 135 PLUS. WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work 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 or explosion. • Keep flammable material away.
B-2 B-2 OPERATION GENERAL DESCRIPTION ● Reversible, dual groove drive roll. Drive roll will The WELDMARK 135 PLUS is a complete semiautomatic constant voltage DC arc welding machine. Included is a solid state controlled, single phase constant voltage transformer/ rectifier power source and a wire feeder for feeding solid steel electrode and cored electrode. ● Accommodates both 8” (200 mm) diameter and 4” feed .023-.035” (0.6- 0.9 mm) diameter wire.
B-3 OPERATION B-3 WELDING OPERATIONS 2 1 SEQUENCE OF OPERATION WELDING AMP RANGE 25-125 Wire Loading Refer to Figure B.2 AND B3. 3 SP-135 Plus The machine power switch should be turned to the OFF (“O”) position before working inside the wire feed enclosure. FIGURE B.1a 4. Circuit Breaker – Protects machine from damage if maximum output is exceeded. Button will extend out when tripped (Manual reset). Refer to Figure B.1b. 5.
B-4 B-4 OPERATION FIGURE B.4 FIGURE B.3 Wire Spindle Shaft To wire drive 4" Wire Spool Wing Nut and Spacer 2 4 5 3 Friction Brake Adjustment With wire spool installed on the spindle shaft and the wing nut loose, turn the spool by hand while slowly tightening the wing nut until a light drag is felt. Tighten the wing nut an additional 1/4 turn. Note: When properly adjusted, the brake should provide only enough drag to prevent overrun of the spool and excess slack in the wire.
B-5 OPERATION B-5 FIGURE B.5 FIGURE B.6 Gun Handle Contact Tip Gas Diffuser Contact Tip Wire Electrode Gas Nozzle 3/8" – 1/2" Electrical Stickout Shielding Gas When using the GMAW process, a cylinder of shielding gas, must be obtained. Refer to the ACCESSORIES section for more information about selecting gas cylinders for use with the WELDMARK 135 PLUS. 1. For CO2, open the cylinder very slowly. For argonmixed gas, open cylinder valve slowly a fraction of a turn.
B-6 B-6 OPERATION 9. To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out. 10. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun trigger to release gas pressure, and turn off the welder. Cleaning Tip And Nozzle Clean the contact tip and nozzle to avoid arc bridging between the nozzle and contact tip which can result in a shorted nozzle, poor welds and an overheated gun.
B-7 OPERATION OVERLOAD PROTECTION Output Overload The WELDMARK 135 PLUS is equipped with a circuit breaker which protects the machine from potential damage from excessive output current. The circuit breaker button will extend out when tripped. The circuit breaker must be manually reset. Thermal Protection The WELDMARK 135 PLUS duty cycle is exceeded a thermostat will shut off the output until the machine cools to a normal operating temperature. This is an automatic function and is self resetting.
B-8 B-8 LEARNING TO WELD LEARNING TO WELD WARNING No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced operator to understand welding and develop this skill. For more detailed information, order a copy of “New Lessons in Arc Welding” listed at the end of this manual. Fumes and slag generated from Innershield type electrodes recommended for use with this welding machine can be toxic. • Avoid contact with eyes and skin.
B-9 B-9 LEARNING TO WELD The “arc stream” is seen in the middle of the picture. This is the electric arc created by the electric current flowing through the space between the end of the wire electrode and the base metal. The temperature of this arc is about 6000°F, which is more than enough to melt metal. The arc is very bright, as well as hot, and cannot be looked at with the naked eye without risking painful injury.
B-10 B-10 LEARNING TO WELD For GMAW (MIG) Process 1. Is most of my welding performed on 16 gauge and lighter materials? 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas supply? JOINT TYPES AND POSITIONS Five types of welding joints are: Butt Welds, Fillet Welds, Lap Welds, Edge Welds and Corner Welds. See Figure B.11. Of these, the Butt Weld and Fillet Weld are the two most common welds. 3.
B-11 LEARNING TO WELD B-11 45° FIGURE B.12 Penetration Unless a weld penetrates close to 100% of the metal thickness, a butt weld will be weaker than the material welded together. In the example shown in Figure B.13, the total weld is only half the thickness of the material thus the weld is only approximately half as strong as the metal. FIGURE B.15 Welding In The Vertical Position Welding in the vertical position can be done either vertical-up or vertical-down.
B-12 LEARNING TO WELD B-12 MACHINE SET UP FOR THE SELF-SHIELDED FCAW PROCESS 1. See PROCESS GUIDELINES in the OPERATION section for selection of welding wire and shielding gas, and for range of metal thicknesses that can be welded. 2. See the Application Guide on the inside of wire feed section door for information on setting the controls. PROPER GUN ANGLE FOR GMAW PROCESS WELDING IN THE VERTICAL UP POSITION PROPER GUN ANGLE FOR FCAW PROCESS WELDING IN THE VERTICAL UP POSITION FIGURE B.
B-13 B-13 LEARNING TO WELD Contact Tip Wire Electrode FIGURE B.18 3/8 – 1/2” (10 – 12 mm) Electrical Stickout (ESO) WARNING FIGURE B.19 ARC RAYS can burn eyes and skin. When using an open arc process, it Is necessary to use correct eye, head and body protection. Protect yourself and others, read “ARC RAYS can burn” at the front of this manual. 2. The Correct Way To Strike An Arc 1. Be sure the work clamp makes good electrical contact to the work. 2. Position gun over joint.
B-14 LEARNING TO WELD For the WELD MARK 135 PLUS, use the following: Helpful Hints 1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways. Weld along at a steady pace. You will find it easier. 2. When welding on thin plate, you will find that you will have to increase the welding speed, whereas when welding on heavy plate, it is necessary to go more slowly in order to get good penetration. 3. When welding sheet metal 16 gauge (1.
B-15 B-15 LEARNING TO WELD MACHINE SET UP FOR THE GMAW (MIG) PROCESS 1. See PROCESS GUIDELINES in the OPERATION section for selection of welding wire and shielding gas, and for range of metal thicknesses that can be welded. 2. See the Application Guide on the inside of wire feed section door for information on setting the controls. 3. Set the “Voltage” and “Wire Speed” controls to the settings suggested on the Application Guide for the welding wire and base metal thickness being used.
B-16 B-16 LEARNING TO WELD Helpful Hints 1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways. Weld along at a steady pace. You will find it easier. Contact Tip 2. When welding on thin plate, you will find that you will have to increase the welding speed, whereas when welding on heavy plate, it is necessary to go more slowly in order to get good penetration. Wire Electrode ESO FIGURE B.24 3.
B-17 LEARNING TO WELD 4. After you strike the arc, practice the correct electrical stickout. Learn to distinguish it by its sound. 2. Decrease stickout. 5. When you are sure that you can hold the correct electrical stickout, with a smooth “crackling” arc, start moving. Look at the molten puddle constantly. 4. Decrease travel speed. 6. Run beads on a flat plate. Run them parallel to the top edge (the edge farthest away from you).
B-18 LEARNING TO WELD Proper Gun Handling Most feeding problems are caused by improper handling of the gun cable or electrodes. 1. Do not kink or pull the gun around sharp corners 2. Keep the gun cable as straight as practical when welding. 3. Do not allow dolly wheels or trucks to run over the cables. 4. Keep the cable clean. 5. Innershield electrode has proper surface lubrication. Use only clean, rust-free electrode. 6. Replace contact tip when it becomes worn or the end is fused or deformed.
B-19 APPLICATION CHART WELDMARK 135 PLUS B-19
C-1 ACCESSORIES OPTIONAL ACCESSORIES 1. K520 Utility Cart — Designed to transport the Lincoln family of small welders. Has provisions for mounting a single gas cylinder. Has front casters and large rear wheels. Handle height is easily adjustable. Bottom tray provided for tools and accessories. Easy assembly required; takes less than 15 minutes. 2. K586-1 Deluxe Adjustable Gas Regulator & Hose Kit Accommodates CO2 or mixed Gas Cylinders. 3. K663-2 Aluminum Welding Kit — This kit required for welding with .
C-2 ACCESSORIES REPLACEMENT PARTS INNERSHIELD (FCAW) CONVERSION Several changes are needed to convert the unit for operation with the Innershield (FCAW) process. The K549-1 Innershield Kit includes all the necessary accessories for this conversion and are provided for this purpose. The following conversions should be made using the contents of this kit: Complete Gun and Cable Assembly L8311-6 (K530-4) Contact Tip .025” (0.6 mm) S19726-1 Contact Tip .030” (0.8 mm) S19726-2 1.
D-1 D-1 MAINTENANCE MAINTENANCE AFTER FEEDING 50# OF FLUX CORED WIRE OR 300# OF SOLID WIRE SAFETY PRECAUTIONS WARNING • Unplug machine or turn power switch to OFF – “O” position. Remove gun and cable from machine. ELECTRIC SHOCK can kill. • Remove gas nozzle and contact tip from gun. • Disconnect input power by removing plug from receptacle before working inside WELDMARK 135 PLUS. Use only grounded receptacle. Do not touch electrically “hot” parts inside WELDMARK 135 PLUS.
D-2 D-2 MAINTENANCE GUN AND CABLE MAINTENANCE FOR MAGNUM™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using low pressure air, gently blow out the cable liner from the gas diffuser end. 2. Replace worn contact tips as required. A variable or “hunting” arc is a typical symptom of a worn contact tip.
D-3 MAINTENANCE D-3 COMPONENT REPLACEMENT PROCEDURES CAUTION CHANGING THE CONTACT TIP 1. Unplug or turn power switch to Off “O” position. 2. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 3. Remove the existing contact tip from the gun by unscrewing counter-clockwise. 4. Insert and hand tighten desired contact tip.
D-4 D-4 MAINTENANCE 1-1/4 (31.8 mm) Liner Trim Length Gas Diffuser Slotted Set Screw Brass Cable Connector Contact Tip (Threaded) Gas Nozzle or Gasless Nozzle (Threaded) Liner Assembly (Liner bushing to be seated tight against brass cable connector) FIGURE D.2 Liner trim length for gun with red trigger (Magnum™ 100L) CHANGING LINER NOTICE: The variation in cable lengths prevents the interchangeability of liners.
E-1 TROUBLESHOOTING E-1 HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Factory Trained Personnel. Unauthorized repairs performed on this equipment may result in danger to the technician and machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed throughout this manual.
E-2 Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) E-2 TROUBLESHOOTING POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is evident. Contact your LOCAL AUTHORIZED FIELD SERVICE FACILITY. No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate. 1. Make sure correct voltage is applied to the machine (115 vac). 2.
E-3 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) E-3 TROUBLESHOOTING TROUBLESHOOTING GUIDE POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION FEEDING PROBLEMS No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (28 vdc maximum) – weld output. 1. If the wire drive motor is running check to see if the correct wire is in the machine. 2.
E-4 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) E-4 TROUBLESHOOTING TROUBLESHOOTING GUIDE POSSIBLE CAUSE RECOMMENDED COURSE OF ACTION GAS FLOW PROBLEMS Low or no gas flow when gun trigger is pulled. Wire feed, weld output and fan operate normally. 1. Check gas supply, flow regulator and gas hoses. 2. Check gun connection to machine for obstruction or leaky seals.
WELDMARK 135 PLUS S1 531 32 L1 31 MOTOR FAN 31A BREAKER CIRCUIT AUX WDG. W-WHITE 32 3 5 206 31A 205 4 ( J1 ) * 531 6 NOTES: N.A. DIODES D1 & D3 ARE MOUNTED ON THE OUTSIDE HEATSINK. N.B. DIODES D2 & D4 ARE MOUNTED ON THE INSIDE HEATSINK, WHICH IS CLOSEST TO THE CENTER PANEL. N.C. COMPONENT VIEWED FROM REAR. N.D. BOLTED ALUMINUM CONNECTIONS REQUIRE T12837 JOINT COMPOUND (DOW CORNING 340) WHEN REATTACHING. B-BLACK LEAD COLOR CODE: 2 24 VAC 207 1 ELECTRICAL SYMBOLS PER E1537 N.C.
NOTES WELDMARK 135 PLUS
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el electrode with skin or wet clothing. ● Insulate yourself from work and ground. ● No toque las partes o los electrodos bajo carga con la piel o ropa mojada. ● Aislese del trabajo y de la tierra.
● Keep your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● Los humos fuera de la zona de res- piración. ● Mantenga la cabeza fuera de los humos. Utilice ventilación o aspiración para gases. ● Gardez la tête à l’écart des fumées. ● Utilisez un ventilateur ou un aspira- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
• Manufactured by Lincoln Electric Company • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.
