Lincoln Electric Pro-MIG 135 Operator's Manual
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Lincoln Electric Pro-MIG 135 Operator's Manual

Welding and cutting equipment
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This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
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 thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
ISO 9001
ANSI RAB
QMS
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
• Sales and Service through Subsidiaries and Distributors Worldwide •
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
Pro-MIG 135
For use with machine Code Number:10889
THIS
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
™
Copyright © 2002 Lincoln Global Inc.
IM740
April, 2002

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Summary of Contents for Lincoln Electric Pro-MIG 135

  • Page 1 ™ April, 2002 For use with machine Code Number:10889 This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci cations and availability of optional features may have changed. Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind.

  • Page 2: California Proposition 65 Warnings

    351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199. BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE PERFORMED ONLY BY QUALIFIED INDIVIDUALS.

  • Page 3: Electric Shock Can Kill

    SAFETY ARC RAYS can burn. ELECTRIC SHOCK can 4.a. Use a shield with the proper filter and cover kill. plates to protect your eyes from sparks and 3.a. The electrode and work (or ground) circuits the rays of the arc when welding or observing are electrically “hot”...
  • Page 4 SAFETY WELDING SPARKS can CYLINDER may explode cause fire or explosion. if damaged. 6.a. Remove fire hazards from the welding area. 7.a. Use only compressed gas cylinders If this is not possible, cover them to prevent containing the correct shielding gas for the the welding sparks from starting a fire.
  • Page 5 SAFETY 5. Toujours porter des lunettes de sécurité dans la zone de PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les zones où l’on pique le laitier. Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté...
  • Page 6 QUALITY product by Lincoln Electric. We want you Thank 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.

  • Page 7: Table Of Contents

    Gun and Cable Maintenance.................D-2 Component Replacement Procedures ..............D-3 Changing Liner ......................D-4 Gun Handle Parts ....................D-4 Troubleshooting ....................Section E Safety Precautions....................E-1 How to Use Troubleshooting Guide...............E-1 Troubleshooting Guide.................E-2 THRU E-4 Wiring Diagrams ....................Section F Pro-MIG 135 Wiring Diagram.................F-1 Parts Lists ..................P408 Series, P202-E...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – Pro-MIG 135 INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current 120V/60Hz 20 Amps - Rated Output RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 20% Duty Cycle OUTPUT Welding Current Range Maximum-Open Circuit Voltage 50 - 300 in/min.

  • Page 9: Identify And Locate Components

    • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes. • The Pro-MIG 135 power switch is to be in the OFF (“O”) position when installing work cable and gun and when connecting power cord to input power.

  • Page 10: Select Suitable Location

    Figure A-3. STACKING 3. Fasten securely with the bolt and nut provided. Pro-MIG 135’s cannot be stacked. TILTING FIGURE A.3 Each machine must be placed on a secure, level sur- face, either directly or on either recommended cart.

  • Page 11: Gas Connection

    Malfunction of the Pro-MIG 135 may result if this switch shorts to the Pro-MIG 135 welding output circuit or is common to any electri- cal circuit other than the Pro-MIG 135 trigger cir- cuit.
  • Page 12 STANDARD Z-49.1, “SAFETY IN tighten the union nut securely with a wrench. WELDING AND CUTTING” PUB- Connect the other end to the Pro-MIG 135 Gas LISHED BY THE AMERICAN Solenoid Inlet Fitting (5/8-18 female threads — for WELDING SOCIETY.

  • Page 13: Input Connections

    (NEMA Type 5-15P) is factory installed on the Pro-MIG 135. Connect this plug to a mating grounded The Pro-MIG 135 has a power input cable located on receptacle which is connected to a 20 amp branch cir- the rear of the machine.

  • Page 14: Operation

    FUMES AND GASES can be welding) and the Innershield electrode process (self dangerous. shielded flux cored or FCAW). The Pro-MIG 135 is a rugged and reliable machine that has been designed • Keep your head out of fumes. for dependable service and long life.

  • Page 15: Welding Capability

    Blank Panel Assembly located on the center panel WELDING CAPABILITY inside the case door: The Pro-MIG 135 is rated at 90 amps, 19 volts, at Mode Switch - Selects between Spot, Stitch, or 20% duty cycle on a ten minute basis. It is capable of Seam (normal welding) mode.

  • Page 16: Welding Operations

    These spools fit on a 2" (51 mm) diameter spindle that has a built in, adjustable friction brake to prevent overrun of the spool and excess slack in the wire. Wing Nut and Spacer To Wire Drive Pro-MIG 135...
  • Page 17 2. Carefully detach the end of the wire from the 8. Turn the Pro-MIG 135 ON (“I”). spool. To prevent the spool from unwinding, maintain tension on the wire until after step 5.
  • Page 18 PROCESS GUIDELINES required, is turned on. The Pro-MIG 135 can be used for welding mild steel 5. When using Innershield electrode, remove the gas using the GMAW, single pass, process which requires nozzle and install the gasless nozzle.

  • Page 19: Overload Protection

    .023”-.025” (0.6 mm) diameter wire. To operate the polarity. the Pro-MIG 135 with other sizes of wire, it is neces- sary to change the contact tip and change the drive Innershield welding kit K549-1 (for .035" / 0.9mm) is roll over to other sizes.

  • Page 20: Learning To Weld

    FCAW (Innershield) welding arc. It closely them. resembles what is actually seen while welding. Electronic Components Burning of core materials Cored Wire inside wire electrode results in shield of gas. Protective Slag Arc Stream Weld Metal FIGURE B.9 Bearings Hinges FIGURE B.8 Pro-MIG 135...
  • Page 21 By gaining knowledge of the differences between the trode is recommended for Self-Shielded Flux Cored two processes, you will be able to select the best Arc Welding. process for the job you have at hand. In selecting a process, you should consider: Pro-MIG 135...
  • Page 22 “New Lessons in Arc Welding”. Regardless of the type of metal being welded, in order to get a quality weld, it is important that the metal is free of oil, paint, rust or other contaminant’s. Pro-MIG 135...
  • Page 23 When welding fillet welds, it is very important to hold problem. the wire electrode at a 45° angle between the two sides or the metal will not distribute itself evenly. The gun nozzle is generally formed at an angle to facilitate this. See Figure B.15. Pro-MIG 135...
  • Page 24 (if you are right handed). This enables you to clearly see what you are doing. (Left handers do the opposite.) Tilt the gun toward the direction of travel holding the electrode at an angle as shown in Figure B.18. Pro-MIG 135...
  • Page 25 FIGURE B.20 See Figure B.19. Once the arc has been established, maintaining the correct ESO becomes extremely important. The ESO should be approximately 3/8 to 1/2 inch (10 to 12 mm) long. Pro-MIG 135...
  • Page 26 B-13 B-13 LEARNING TO WELD Helpful Hints For the Pro-MIG 135, use the following: Mild Steel 12 gauge or 1/8 inch 1. For general welding, it is not necessary to weave (3.0 mm) the arc, neither forward or backward nor sideways.
  • Page 27 Hold the gun (of the gun and cable assembly) in your right hand and hold the shield with your left hand. (Left handers simply do the opposite.) Pro-MIG 135...
  • Page 28 4. The Correct Welding Speed For the Pro-MIG 135, use the following: The important thing to watch while welding is the puddle of molten metal right behind the arc. See...

  • Page 29: Troubleshooting Welds

    3. Decrease WFS (wire feed speed. * Stubbing occurs when the electrode drives through 4. Decrease travel speed. the molten puddle and hits the bottom plate tending 5. Decrease drag angle. to push the gun up. 6. Check for correct gas, if used. Pro-MIG 135...
  • Page 30 3. Do not allow dolly wheels or trucks to run over the cables. 4. Keep the cable clean. 5. Innershield electrode has proper surface lubrica- tion. Use only clean, rust-free electrode. 6. Replace contact tip when it becomes worn or the end is fused or deformed. Pro-MIG 135...

  • Page 31: Application Chart

    B-18 B-18 APPLICATION CHART Pro-MIG 135...

  • Page 32: Accessories

    Also includes spot welding nozzle. The Spot/Stitch Timer Kit installs inside the wire feed compartment, replacing the blank panel locat- ed below the gun trigger lead connectors, per the installation instructions (M17920) included with the kit. Pro-MIG 135...

  • Page 33: Replacement Parts

    Gas Nozzle M16294 Gas Nozzle-Tip Recessed 3/8” (9.5 mm) Opening I.D. M16684 Gas Nozzle-Tip Recessed 1/2” (12.7 mm) Opening I.D. M16684-1 Gas Nozzle-Tip Recessed 5/8” (15.9 mm) Opening I.D. M16684-2 Spot Welding Nozzle M17846 Gasless Nozzle (Innershield Only) M16418 Pro-MIG 135...

  • Page 34: Maintenance

    POWER SOURCE COMPARTMENT No user serviceable parts inside! Do not attempt to perform service in the power source (fixed) side of the Pro-MIG 135. Take the unit to an authorized Lincoln Service Center if you experience problems. NO maintenance is required.

  • Page 35: Gun And Cable Maintenance

    Replace the gas nozzle or gasless nozzle. CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM Contact Tip Cable Liner Drive Roll Pro-MIG 135 as configured S19726-1 M16291-6 KP665-035 from the factory • .025” (0.6mm) .035”...

  • Page 36: Component Replacement Procedures

    5. Turn the power switch to OFF (marked “O”). 6. Loosen the drive roll set screw with the 5/64" (2.0 mm) hex wrench supplied. 7. Remove the drive roll, flip over and reinstall with the .035" (0.9 mm) groove (the larger groove) closest to the gearbox. Pro-MIG 135...

  • Page 37: Changing Liner

    7. With the gas nozzle and diffuser removed from the gun tube, be sure the cable is straight, and then trim the liner to the length shown in the Figure D.2. FIGURE D.3 Remove any burrs from the end of the liner. Pro-MIG 135...

  • Page 38: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric 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.
  • Page 39 3. Gun trigger may be faulty. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. Pro-MIG 135...
  • Page 40 Field Service Facility. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. Pro-MIG 135...
  • Page 41 8. Check liner for proper size. CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed. Pro-MIG 135...
  • Page 42 DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate 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. Pro-MIG 135...
  • Page 43 NOTES Pro-MIG 135...
  • Page 44 NOTES Pro-MIG 135...
  • Page 45 Year AMERICAN EXPRESS USE THIS FORM TO ORDER: Order from: BOOK DIVISION, The Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199 for fastest service, FAX this completed form to: 216-361-5901 BOOKS OR FREE INFORMATIVE CATALOGS Telephone: 216-383-2211 or,...
  • Page 46 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
  • Page 47 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
  • Page 48 • World's Leader in Welding and Cutting Products • • Sales and Service through Subsidiaries and Distributors Worldwide • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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