Lincoln Electric WELDMARK 135 PLUS IM767 Operator's Manual
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Lincoln Electric WELDMARK 135 PLUS IM767 Operator's Manual

Lincoln Electric WELDMARK 135 PLUS IM767 Operator's Manual

Lincoln electric welder user manual
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WELDMARK 135 PLUS
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.
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
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
RETURN TO MAIN MENU
For use with machine Code Numbers : 10947
This manual covers
equipment which
is obsolete and no
longer in production
by The Lincoln Electric
Co. Specifications
and availability of

optional features

THIS
may have changed.
OPERATOR'S MANUAL
•Manufactured by Lincoln Electric Company •
IM767
November, 2005
Copyright © 2005 Lincoln Global Inc.

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Summary of Contents for Lincoln Electric WELDMARK 135 PLUS IM767

  • Page 1: Optional Features

    Quality Program Certified by ABS Quality Evaluations, Inc. to ISO 9001 Requirements. CERTIFICATE NUMBER: 30273 •Manufactured by Lincoln Electric Company • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com RETURN TO MAIN MENU This manual covers equipment which...

  • Page 2: Electric And Magnetic Fields

    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

    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.
  • Page 4 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.
  • Page 5 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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 The code number is especially important when identifying the correct replacement parts. - Register your machine with Lincoln Electric either via fax or over the Internet. • For faxing: Complete the form on the back of the warranty statement included in the literature packet accompanying this machine and fax the form per the instructions printed on it.

  • Page 7: Table Of Contents

    Installation ...Section A Technical Specifications ...A-1 Identify and Locate Components ...A-2 Select Suitable Location ...A-3 Output Connections ...A-3 Input Connections...A-5 Code Requirements ...A-6 Operation ...Section B Safety Precautions ...B-1 General Description ...B-2 Design Features and Advantages...B-2 Welding Capability ...B-2 Limitations ...B-2 Controls and Settings...B-2 Welding Operations ...B-3 Overload Protection ...B-7...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS – WELDMARK 135 PLUS Standard Voltage/Frequency 115V/60Hz 115V/60Hz 115V/60Hz Duty Cycle 20% Duty Cycle – Rated DC Output Welding Current Range (Continuous) Maximum Open Circuit Voltage Rated DC Output: 25 – 135 Amps RECOMMENDED INPUT CABLE AND FUSE SIZES Output Mode Input Voltage RATED...

  • Page 9: Safety Precautions

    IDENTIFY AND LOCATE COMPONENTS If you have not already done so, unpack the Welder from its carton and remove all packing material Remove the following loose items from the carton (see Figure A.1): 1.

  • Page 10: Tilting

    SELECT SUITABLE LOCATION 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.

  • Page 11: Gun Installation

    If the gun trigger switch being used is other than that supplied with the welder, the switch must be a normally open, momentary switch. The terminals of the switch must be insulated from the welding circuit.

  • Page 12: Input Connections

    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” PUB- LISHED BY THE AMERICAN WELDING SOCIETY. 1. Chain the cylinder to a wall or other stationary sup- port to prevent the cylinder from falling over.

  • Page 13: Code Requirements

    Volts, 20% duty cycle (2 minutes of every 10 minutes used for welding). INSTALLATION Do not connect the welder to an input power sup- ply with a rated voltage that is greater than 125 volts. Do not remove the power cord ground prong.

  • Page 14: Operation

    Read entire Operation section before operating the WELDMARK 135 PLUS. Observe all safety information throughout this manual. OPERATION WARNING ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. •...

  • Page 15: General Description

    50 – 400 in /min (1.3 – 10 m/min). The control can be preset on the dial to the setting specified on the welder Application Chart located on the inside of the wire feed section door. Wire speed is not affected when changes are made in the voltage control.

  • Page 16: Welding Operations

    WELDING AMP RANGE 25-125 SP-135 Plus 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. Gun Trigger - Activates welding output, wire feed, and gas solenoid operation.
  • Page 17 FIGURE B.3 Wire Spindle Shaft To wire drive 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.
  • Page 18 25 – 30 CFH (12 – 14 I/min). 3. Keep the cylinder valve closed, except when using the welder. When finished welding: a) Close the cylinder valve to stop gas flow. b) Depress the gun trigger briefly to release the pressure in the gas hose.

  • Page 19: Process Guidelines

    The WELDMARK135 PLUS is shipped from the facto- ry ready to feed 0.023-0.025” (0,6 mm) diameter wire. blended To operate the welder with other sizes of wire, it is ) and .025" necessary to change the contact tip and change the drive roll over to other sizes.

  • Page 20: Overload Protection

    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 cir- cuit 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...

  • Page 21: Learning To Weld

    LEARNING TO WELD 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 weld- ing and develop this skill. For more detailed informa- tion, order a copy of “New Lessons in Arc Welding” listed at the end of this manual.

  • Page 22: The Gmaw (Mig) Welding Arc

    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.

  • Page 23: Joint Types And Positions

    B-10 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 sup- ply? 3. Do I require clean, finished-looking welds? If you have answered yes to all the above questions GMAW may be the process for you.
  • Page 24 B-11 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.

  • Page 25: Machine Set Up For The Self-Shielded Fcaw Process

    B-12 PROPER GUN ANGLE PROPER GUN ANGLE FOR GMAW PROCESS FOR FCAW PROCESS WELDING IN THE VERTICAL UP POSITION WELDING IN THE VERTICAL UP POSITION FIGURE B.16 Vertical-down Welding Refer to Figure B.17 Vertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow and, as such, are excellent for sheet metal.
  • Page 26 B-13 FIGURE B.18 WARNING 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.
  • Page 27 B-14 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.

  • Page 28: Machine Set Up For The Gmaw (Mig) Process

    B-15 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.
  • Page 29 B-16 Contact Tip Wire Electrode FIGURE B.24 3. The Correct Electrical Stickout (ESO) The electrical stickout (ESO) is the distance from the end of the contact tip to the end of the wire. See Figure B.24. Once the arc has been established, maintaining the correct ESO becomes extremely important.

  • Page 30: Troubleshooting Welds

    B-17 4. After you strike the arc, practice the correct electri- cal stickout. Learn to distinguish it by its sound. 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. 6.
  • Page 31 B-18 Proper Gun Handling Most feeding problems are caused by improper han- dling 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.

  • Page 32: Application Chart

    B-19 APPLICATION CHART B-19 WELDMARK 135 PLUS...

  • Page 33: Optional 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.

  • Page 34: 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: 1.

  • Page 35: Maintenance

    Excessive pressure at start may cause the dirt to form a plug. PERIODICALLY AS REQUIRED • Blow dirt out of the welder with low pressure air to eliminate excessive dirt and dust buildup that could cause welder to run hot.

  • Page 36: Gun And Cable 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.

  • Page 37: Component Replacement Procedures

    COMPONENT REPLACEMENT PROCEDURES 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.

  • Page 38: Changing Liner

    Slotted Brass Cable Set Screw Connector 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.

  • Page 39: Troubleshooting

    If machine case sides and top are removed, the case front must be supported. Failure to do this could result in mechanical or electrical damage to the welder. ___________________________________________________________________ If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

  • Page 40: Troubleshooting Guide

    TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Major physical or electrical damage is evident. No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate. No weld output or wire feed when gun trigger is pulled. Fan runs and gas flows normally.
  • Page 41 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (28 vdc maximum) – weld output. Wire feed speed motor runs very fast.
  • Page 42 Observe Safety Guidelines detailed in the beginning of this manual. PROBLEMS (SYMPTOMS) Low or no gas flow when gun trigger is pulled. Wire feed, weld output and fan operate normally. PROBLEMS (SYMPTOMS) Arc is unstable – Poor starting If for any reason you do not understand the test procedures or are unable to Perform the tests/repairs safely, contact your LOCAL AUTHORIZED FIELD SERVICE FACILITY for assistance before you proceed.

  • Page 43: Wiring Diagrams

    WIRING 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. WELDMARK 135 PLUS...
  • Page 44 NOTES WELDMARK 135 PLUS...
  • Page 45 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
  • Page 46 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE WARNUNG ATENÇÃO...
  • Page 47 • Manufactured by Lincoln Electric Company • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com...

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