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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 : 10975
THIS
OPERATOR'S MANUAL
•Manufactured by Lincoln Electric Company •
IM789
April, 2006
Copyright © 2006 Lincoln Global Inc.
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Summary of Contents for Lincoln Electric WELDMARK 135 PLUS IM789
- Page 1 Designed and Manufactured Under a 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 IM789 April, 2006...
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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.
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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). 5. Gun Trigger - Activates welding output, wire feed, and gas solenoid operation. Releasing the trigger deactivates welding and simultaneously activates the “burnback”... - 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.
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Page 19: Process Guidelines
FEED OTHER WIRE SIZES The WELDMARK135 PLUS is shipped from the facto- ry ready to feed 0.023-0.025” (0,6 mm) diameter wire. To operate the welder with other sizes of wire, it is blended necessary to change the contact tip and change the ) and .025"... - Page 20 OPERATION 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. Wire Feed Overload Protection If the WELDMARK 135 PLUS has an automatic elec- tronic protection circuit to protect the wire feed motor.
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Page 21: Application Chart
APPLICATION CHART WELDMARK 135 PLUS... -
Page 22: 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 23: 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 24: 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 25: 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 26: 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 27: 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 28: 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 29: 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 30 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 31 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.
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Page 32: 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 33 NOTES WELDMARK 135 PLUS...
- Page 34 ● WARNING ● Spanish ● AVISO DE PRECAUCION ● French ● ATTENTION ● ● German WARNUNG ● Portuguese ● ATENÇÃO ● Japanese Chinese Korean Arabic ● ● ● ● ● ● ● ● ● ●...
- Page 35 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION ● German Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE WARNUNG ATENÇÃO...
- Page 36 • 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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