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IM789
WELDMARK 135 PLUS April, 2006
For use with machine Code Numbers : 10975
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 THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S MANUAL
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
Copyright © 2006 Lincoln Global Inc.
•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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.
Read and understand the following safety highlights. For additional safety information, it is strongly recommended that you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box
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.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
1.a. Turn the engine off before troubleshooting and maintenance
work unless the maintenance work requires it to be running.
____________________________________________________
1.b. Operate engines in open, well-ventilated
areas or vent the engine exhaust fumes
outdoors.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
1.c. Do not add the fuel near an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, covers and devices in before welding.
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving 2.c. Exposure to EMF fields in welding may have other health
parts when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
WELDMARK 135 PLUS
ii ii
SAFETY
ELECTRIC SHOCK can ARC RAYS can burn.
kill. 4.a. Use a shield with the proper filter and cover
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� when the welder is on.
open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare
should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
FUMES AND GASES
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
can be dangerous.
accidental contact with the workpiece or ground) use
5.a. Welding may produce fumes and gases
the following equipment:
hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder.
fumes and gases.When welding, keep
� DC Manual (Stick) Welder.
your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control.
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode,
welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic
ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�.
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical
which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection
low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded.
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical
respirator may be required. Additional precautions are
(earth) ground.
also required when welding on galvanized steel.
3.f. Maintain the electrode holder, work clamp, welding cable and
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
welding machine in good, safe operating condition. Replace
coming from degreasing, cleaning or spraying operations.
damaged insulation.
The heat and rays of the arc can react with solvent vapors to
form phosgene, a highly toxic gas, and other irritating prod-
3.g. Never dip the electrode in water for cooling.
ucts.
3.h. Never simultaneously touch electrically “hot� parts of
5.c. Shielding gases used for arc welding can displace air and
electrode holders connected to two welders because voltage
cause injury or death. Always use enough ventilation,
between the two can be the total of the open circuit voltage
especially in confined areas, to insure breathing air is safe.
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
3.i. When working above floor level, use a safety belt to protect
equipment and the consumables to be used, including the
yourself from a fall should you get a shock.
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
3.j. Also see Items 6.c. and 8.
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
Mar �95
WELDMARK 135 PLUS
iii
iii
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.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
WELDMARK 135 PLUS
iv iv
SAFETY
PRÉCAUTIONS DE SÛRETÉ 6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
7. Quand on ne soude pas, poser la pince à une endroit isolé de
manuel aussi bien que les précautions de sûreté générales suiv-
la masse. Un court-circuit accidental peut provoquer un
antes:
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
8. S’assurer que la masse est connectée le plus prés possible
1. Protegez-vous contre la secousse électrique:
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
a. Les circuits à l’électrode et à la piéce sont sous tension
endroits éloignés de la zone de travail, on augmente le risque
quand la machine à souder est en marche. Eviter toujours
de voir passer le courant de soudage par les chaines de lev-
tout contact entre les parties sous tension et la peau nue
age, câbles de grue, ou autres circuits. Cela peut provoquer
ou les vétements mouillés. Porter des gants secs et sans
des risques d’incendie ou d’echauffement des chaines et des
trous pour isoler les mains.
câbles jusqu’� ce qu’ils se rompent.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
9. Assurer une ventilation suffisante dans la zone de soudage.
metallique ou des grilles metalliques, principalement dans
Ceci est particuliérement important pour le soudage de tôles
les positions assis ou couché pour lesquelles une grande
galvanisées plombées, ou cadmiées ou tout autre métal qui
partie du corps peut être en contact avec la masse.
produit des fumeés toxiques.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
10. Ne pas souder en présence de vapeurs de chlore provenant
defonctionnement.
d’opérations de dégraissage, nettoyage ou pistolage. La
d.Ne jamais plonger le porte-électrode dans l’eau pour le
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
refroidir.
du solvant pour produire du phosgéne (gas fortement toxique)
e. Ne jamais toucher simultanément les parties sous tension
ou autres produits irritants.
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
11. Pour obtenir de plus amples renseignements sur la sûreté,
total de la tension à vide des deux machines.
voir le code “Code for safety in welding and cutting� CSA
f. Si on utilise la machine à souder comme une source de
Standard W 117.2-1974.
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
PRÉCAUTIONS DE SÛRETÉ POUR
2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
LES MACHINES À SOUDER À
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
1. Relier à la terre le chassis du poste conformement au code de
a. Utiliser un bon masque avec un verre filtrant approprié
l’électricité et aux recommendations du fabricant. Le dispositif
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
de montage ou la piece à souder doit être branché à une
onnement de l’arc et des projections quand on soude ou
bonne mise à la terre.
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
2. Autant que possible, I’installation et l’entretien du poste seront
peau de soudeur et des aides contre le rayonnement de
effectués par un électricien qualifié.
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
3. Avant de faires des travaux à l’interieur de poste, la debranch-
soudage à l’aide d’écrans appropriés et non-inflammables.
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
4. Garder tous les couvercles et dispositifs de sûreté à leur
soudage. Se protéger avec des vêtements de protection libres
place.
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. �93
zones où l’on pique le laitier.
WELDMARK 135 PLUS
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? 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. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.
On-Line Product Registration
- 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.
� For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links� and then
“Product Registration�. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi
vi
TABLE OF CONTENTS
Page
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
Application Chart ...................................................................................................B-8
Accessories .....................................................................................................Section C
Accessories ...........................................................................................................C-1
Replacement Parts ................................................................................................C-2
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Items Requiring No Maintenance ..........................................................................D-1
Routine and Periodic Maintenance........................................................................D-1
Gun and Cable Maintenance.................................................................................D-2
Configuration of Components in Wire Feeding System.........................................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
WELDMARK 135 PLUS Wiring Diagram ..............................................................F-1
Parts Lists ..............................................................................................P 465 & P202-E
WELDMARK 135 PLUS
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS � WELDMARK 135 PLUS
INPUT � SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current
115V/60Hz 20 Amps - Rated Output
115V/60Hz 25 Amps - Maximum Output
115V/60Hz 15 Amps - CSA Rated output
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
20% Duty Cycle � Rated DC Output 90 18
OUTPUT
Welding Current Range (Continuous) Maximum Open Circuit Voltage Auxiliary Power
Rated DC Output: 25 � 135 Amps 28 N/A
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse or
Output Mode Input Voltage Breaker Size Input Amps Extension Cord
Three Conductor
#14 AWG
RATED 115V/60Hz 20 Amp 20 (2.1 mm2) or Larger
for up to
25 feet (7.6m)
Three Conductor
#12 AWG
MAXIMUM 115V/60Hz 25 Amp 25 (3.3 mm2) or Larger
for up to
50 feet (15.2 m)
PHYSICAL DIMENSIONS
Height Width Depth Weight
12.0 in 9.75 in 16.5 in 54 Ibs
305 mm 248 mm 419 mm 24.3 kg
WELDMARK 135 PLUS
A-2 A-2
INSTALLATION
FIGURE A.1
Read entire installation section before starting
installation.
1
SAFETY PRECAUTIONS 2
WELD
WARNING
ING
25-125AMP RA
NGE
ELECTRIC SHOCK can kill.
� Only qualified personnel should perform
this installation.
� Only personnel that have read and under-
stood the WELDMARK 135 PLUS
Operating Manual should install and oper-
ate this equipment.
4
� Machine must be plugged into a receptacle
which is grounded per any national, local
or other applicable electrical codes. 3
� The WELDMARK135 PLUS power switch is
to be in the OFF (“O�) position when
installing work cable and gun and when
connecting power cord to input power.
6
5
IDENTIFY AND LOCATE
COMPONENTS
7
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. WELDMARK 135 PLUS
2. Gun and cable assembly(1)
3. Literature and miscellaneous including:
a) This operating manual
b) A contact tip for .030� (0.8 mm) diameter wire.
4. 10 ft (3.0 m) work cable.
5. Work clamp.
6. Sample Spool of Super Arc L-56 .025 MIG Wire.
7. Adjustable mixed-Gas Regulator & Hose.
For available options and accessories refer to the
accessories section later in this manual.
As shipped from the factory, the welding gun is
1)
ready to feed .023 or .025 (0.6 mm) wire.
WELDMARK 135 PLUS
A-3 A-3
INSTALLATION
Work Clamp Installation
SELECT SUITABLE LOCATION
Attach the work clamp per the following:
Locate the welder in a dry location where there is free
circulation of clean air into the louvers in the back and
1. Unplug the machine or turn the power switch to the
out the front of the unit. A location that minimizes the
“OFF� position.
amount of smoke and dirt drawn into the rear louvers
reduces the chance of dirt accumulation that can block
2. Insert the work cable terminal lug with the larger
air passages and cause overheating.
hole through the strain relief hole in the work clamp
as shown in Figure A-3.
STACKING
3. Fasten securely with the bolt and nut provided.
WELDMARK 135 PLUS cannot be stacked.
FIGURE A.3
TILTING
Each machine must be placed on a secure, level sur- STRAIN RELIEF HOLE
face, either directly or on a recommended undercar- NUT AND BOLT
riage. The machine may topple over if this procedure WORK CABLE
is not followed.
OUTPUT CONNECTIONS
Refer to Figure A.2. WORK CLAMP
1. Work Cable Access Hole.
Work Cable Installation
2. Gun Cable and Control Lead Access Hole.
Refer to Figure A.2.
3. Connector Block.
4. Gun Trigger Lead Connectors. 1. Open the wire feed section door on the right side of
the welder.
5. Positive (+) and negative (�) output terminals.
6. Wire Feed Gearbox and Gun Connector Block 2. Pass the end of the work cable that has the termi-
nal lug with the smaller hole through the Work
7. Cable Clamp
Cable Access Hole (1) in the case front.
8. Thumbscrew - Secures gun and cable assembly
FIGURE A.2
5 4
WELDING AMP RANGE
25-125
SP-135 Plus
+
8
-
1 6
3 7
2
WELDMARK 135 PLUS
A-4
A-4 INSTALLATION
3. Route the cable under and around the back of the
Wire Feed Gearbox (6). 3. Insert the connector on the gun conductor cable
through the Gun Cable Access Hole (2) in the
4. For GMAW Only: Refer to Figure A.2. As deliv- WELDMARK 135 PLUS case front. Make sure the
ered, the welder is wired for positive polarity. This connector is all the way in the metal connector
is the appropriate configuration for the Gas Metal block to obtain proper gas flow. Rotate the connec-
Arc Welding (GMAW) process. To complete instal- tor so control leads are on the underside and tight-
lation, use the provided wing nut to connect the en the Thumbscrew (8) in the connector block.
work cable’s terminal lug to the negative (�) output
terminal (5) located above the Wire Feed Gearbox 4. Connect the gun trigger control lead terminals to
(6). Make sure that both wing nuts are tight. the two insulated 1/4" (6,4 mm) tab connector
bushings located above the “Gun Trigger
5. For Innershield Only: Refer to Figure A.4. To wire Connection� decal in the wire feed section (4).
for negative polarity, connect the short cable Either lead can go to either connector. Form the
attached to the connector block (1) to the negative leads so that they are as close as possible to the
(�) output terminal (2) and the work cable (3) to the inside panel.
positive (+) terminal (4).
CAUTION
FIGURE A.4
3
4 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
2 of the switch must be insulated from the welding
circuit. Malfunction of the welder will result if this
switch shorts to the welding output circuit or is
common to any electrical circuit other than the
1 welder trigger circuit.
GAS CONNECTION
Refer to Figure A.5
When using the GMAW process, a cylinder of shield-
ing gas, must be obtained. For more information about
GUN INSTALLATION selecting gas cylinders for use with the welder, refer to
the ACCESSORIES section.
As shipped from the factory, the welding gun is ready
to feed .023 - .025� (0,6 mm) wire. If .030-.035 (0.8-
0.9 mm) wire is to be used, change the contact tip to
WARNING
the appropriate size. Refer to the MAINTENANCE
section for contact tip installation details.
Note: If .035 Innershield Flux cored wire is to be used,
see the accessories section for the Innershield weld-
CYLINDER may explode if dam-
ing kit.
aged. Keep cylinder upright and
chained to support
Connecting Gun Cable to the WELDMARK
135 PLUS � Keep cylinder away from areas
where it may be damaged.
1. Refer to Figure A.2. Unplug the machine or turn � Never lift welder with cylinder
power switch to the off “O� position. attached.
� Never allow welding electrode to
2. Pass the insulated terminals of the gun trigger con-
touch cylinder.
trol leads, one at a time, through the Gun Cable
and Control Lead Access Slot (2) in the case front. � Keep cylinder away from welding
The leads are to be routed under the Wire Feed or other live electrical circuits.
Gearbox (6) and through the Cable Hanger (7) on
the inner panel.
WELDMARK 135 PLUS
A-5
INSTALLATION
A-5
3. Attach the flow regulator to the cylinder valve and
WARNING tighten the union nut securely with a wrench. The
flow regulator for carbon dioxide must have a plas-
BUILDUP OF SHIELDING GAS may
tic washer seated in the fitting that attaches to the
harm health or kill.
cylinder to prevent leakage.
� Shut off shielding gas supply
when not in use. 4. Refer to Figure A.6. Attach one end of inlet gas
hose to the outlet fitting of the flow regulator and
� SEE AMERICAN NATIONAL
tighten the union nut securely with a wrench.
STANDARD Z-49.1, “SAFETY IN
Connect the other end to the Gas Solenoid Inlet
WELDING AND CUTTING� PUB-
Fitting (5/8-18 female threads � for CGA � 032
LISHED BY THE AMERICAN
fitting). Make certain the gas hose is not kinked or
WELDING SOCIETY.
twisted.
1. Chain the cylinder to a wall or other stationary sup-
port to prevent the cylinder from falling over.
INPUT CONNECTIONS
Insulate the cylinder from the work circuit and earth
ground.
Refer to Figure A.6.
FIGURE A.5
The WELDMARK 135 PLUS has two input connec-
tions, the power input cable, and the Gas Solenoid
Inlet Fitting. Both are located on the rear of the
Cylinder Valve
Flow Regulator
machine.
FIGURE A.6
Gas Hose
Gas Solenoid
Inlet Fitting
2. With the cylinder securely installed, remove the
cylinder cap. Stand to one side away from the out- Power
let and open the cylinder valve very slightly for an Input
Cable
instant. This blows away any dust or dirt which may
have accumulated in the valve outlet.
WARNING
BE SURE TO KEEP YOUR FACE AWAY FROM THE
VALVE OUTLET WHEN “CRACKING� THE VALVE.
Never stand directly in front of or behind the flow
regulator when opening the cylinder valve. Always
stand to one side.
WELDMARK 135 PLUS
A-6 A-6
INSTALLATION
CODE REQUIREMENTS FOR INPUT
CAUTION
CONNECTIONS
Do not connect the welder to an input power sup-
ply with a rated voltage that is greater than 125
WARNING volts.
This welding machine must be connected to Do not remove the power cord ground prong.
power source in accordance with applicable elec-
trical codes.
Requirements For Maximum Output
The United States National Electrical Code (Article In order to utilize the maximum output capability of the
630-B, 1990 Edition) provides standards for amperage machine, a branch circuit capable of 25 amps at 115
handling capability of supply conductors based on to 125 volts, 60 Hertz is required. This generally
duty cycle of the welding source. applies when welding steel that is equal to or greater
than 12 gauge, 0.105� (2.5 mm) in thickness.
If there is any question about the installation meeting
applicable electrical code requirements, consult a
qualified electrician.
Requirements For Rated Output
A power cord with a 15 amp, 125 volt, three prong
plug (NEMA Type 5-15P) is factory installed on the
welder. Connect this plug to a mating grounded recep-
tacle which is connected to a 20 amp branch circuit
with a nominal voltage rating of 115 to 125 volts, 60
Hertz, AC only.
The rated output with this installation is 90 amps, 18
Volts, 20% duty cycle (2 minutes of every 10 minutes
used for welding).
WELDMARK 135 PLUS
B-1
OPERATION
B-1
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.
� Do not weld on closed contain-
ers.
ARC RAYS can burn eyes
and skin.
� Wear eye, ear and body protec-
tion.
Observe all safety information throughout
this manual.
WELDMARK 135 PLUS
B-2 B-2
OPERATION
G Reversible, dual groove drive roll. Drive roll will
GENERAL DESCRIPTION
feed .023-.035� (0.6- 0.9 mm) diameter wire.
The WELDMARK 135 PLUS is a complete semiauto- G Accommodates both 8� (200 mm) diameter and 4�
matic constant voltage DC arc welding machine. (100 mm) diameter spools of wire.
Included is a solid state controlled, single phase con-
G No external shielding gas is required when used
stant voltage transformer/ rectifier power source and a
with Lincoln Innershield .035� (0,9 mm) NR®-211-
wire feeder for feeding solid steel electrode and cored
MP electrode.
electrode.
G Easy to change polarity.
The WELDMARK 135 PLUS is ideally suited for indi-
viduals having access to 115 volt AC input power, and
wanting the ease of use, quality and dependability of
WELDING CAPABILITY
both gas metal arc welding or GMAW (also known as
MIG welding) and the Innershield electrode process
(self shielded flux cored or FCAW). The WELD- The WELDMARK135 PLUS, as shipped, is rated at 90
MARK135 PLUS is a rugged and reliable machine that amps, 18 volts, at 20% duty cycle on a ten minute
has been designed for dependable service and long basis. It is capable of higher duty cycles at lower out-
life. put currents.
RECOMMENDED PROCESSES
LIMITATIONS
The WELDMARK 135 PLUS can be used for welding
mild steel using the GMAW, single pass, process Arc Gouging cannot be performed with the WELD-
which requires a supply of shielding gas or it can be MARK 135 PLUS and it is not recommended for pipe
used for the self shielded, Innershield electrode thawing.
process (FCAW). The WELDMARK 135 PLUS is con-
figured for use with the GMAW (MIG) process as
CONTROLS AND SETTINGS
delivered from the factory.
Refer to Figures B.1a & B.1b.
OPERATIONAL FEATURES AND
CONTROLS 1. Power ON/OFF Switch �
When the power is on the
The WELDMARK 135 PLUS has the following controls ON
fan motor will run and air will
as standard: Power ON/OFF Switch, Voltage Control, be exhausted out the louvers
Wire Speed Control, and a Circuit Breaker. in the front of the machine.
The welding output and wire
feeder remain off until the
DESIGN FEATURES AND OFF
gun trigger is pressed.
ADVANTAGES
2. Voltage Control � A contin-
uous control that gives full
G Operates on 115 volt input . ON
range adjustment of power
G Solid state output control. ARC VOLTS
source output voltage.
Voltage can be adjusted
G “Cold electrode� until gun trigger is pressed for an
while welding.
added measure of safety.
ARC VOLTS
G Overload protection � incorporates both a thermo-
3. Wire Speed Control �
stat and a circuit breaker. Controls the wire feed speed
G Quality wire drive with electronic overload protec- from 50 � 400 in /min (1.3 � WIRE SPEED
10 m/min). The control can
tion.
be preset on the dial to the
G Easy-to-set continuous range controls for precise
setting specified on the
setting of arc voltage and wire speed.
welder Application Chart
G Continuous voltage control. located on the inside of the
wire feed section door. Wire
G “Quick Release� idle roll pressure arm is easily
speed is not affected when
adjusted.
changes are made in the
voltage control.
WELDMARK 135 PLUS
B-3
OPERATION
B-3
WELDING OPERATIONS
SEQUENCE OF OPERATION
2
1
Wire Loading
WELDING AMP RANGE
Refer to Figure B.2 AND B3.
25-125
3
The machine power switch should be turned to the
OFF (“O�) position before working inside the wire feed
SP-135 Plus
enclosure.
The machine is shipped from the factory ready to feed
4� (100 mm) diameter spools. A 4" (100 mm) diameter
spool is mounted directly on the 5/8" (16 mm) diame-
ter spindle that has a built-in adjustable friction brake
FIGURE B.1a
to prevent overrun of the spool and excess slack in
the wire. The wing nut at the end of the shaft is used
to adjust the tension on the wire spool (See B.3 on the
4. Circuit Breaker � Protects machine from damage if
following page).
maximum output is exceeded. Button will extend
out when tripped (Manual reset).
To use 8" (200 mm) diameter spools, the 2" (51 mm)
diameter M15445 spindle must be used. Remove the
5. Gun Trigger - Activates welding output, wire feed,
spacer and wing nut at the end of the shaft. Insert
and gas solenoid operation. Releasing the trigger
spindle as shown in figure B.2. Reattach spacer and
deactivates welding and simultaneously activates
wing nut.
the “burnback� function so that the welding wire
does not stick in the weld puddle.
Note: When loading and removing the 8� Spools
make sure that the wing nut (inside the wire spool
spindle hub) is turned 90° from the wire spool spindle
locking tab. If the wing nut is positioned in line with the
FIGURE B.1b locking tab, the tab cannot be depressed to load or
unload the wire spool.
Make certain the start end of the wire, which may pro-
trude through the side of the spool, does not contact
any metallic case parts.
+
4
-
FIGURE B.2
Wire Spool Spindle
Locking Tab
8� Wire Spool
Be sure that this stud engages
the hole in the wire spool.
5
To wire drive
Wire Spool must be pushed all the way on the spindle
so that the spindle’s tab will hold it in place. The Wire
Spool must rotate clockwise when wire is dereeled.
WELDMARK 135 PLUS
B-4 B-4
OPERATION
FIGURE B.4
FIGURE B.3
Wire Spindle Shaft
4" Wire Spool
2
1
4
5
Wing Nut
and Spacer
To wire drive
The Wire Drive Feed
3 Roll can accommodate
two wire sizes by flipping
the wire drive feed roll
Friction Brake Adjustment
over. The sizes are sten-
ciled on the drive roll.
With wire spool installed on the spindle shaft and the
wing nut loose, turn the spool by hand while slowly
6. The idle roll pressure adjustment wing nut is factory
tightening the wing nut until a light drag is felt. Tighten
set to approximately five full turns from where the
the wing nut an additional 1/4 turn.
wing nut first engages the threads of the pressure
arm (1). If feeding problems occur because the wire
Note: When properly adjusted, the brake should pro-
is flattened excessively, turn the pressure adjust-
vide only enough drag to prevent overrun of the spool
ment counter-clockwise to reduce distortion of the
and excess slack in the wire. Too much drag may
wire. Slightly less pressure may be required when
result in wire feeding problems, and may cause pre-
using 0.023 � 0.025" (0,6 mm) wire. If the drive roll
mature wear of wire drive system components.
slips while feeding wire, the pressure should be
increased until the wire feeds properly.
WARNING
Wire Threading
Refer to Figure B.4
When inching the welding wire, the drive rolls, the
gun connector block and the gun contact tip are
1. Release the Spring Loaded Pressure Arm (1)
always energized relative to work and ground and
rotate the Idle Roll Arm (2) away from the Wire
remain energized several seconds after the gun
Feed Drive Roll (3). Ensure that the visible, sten-
trigger is released.
ciled size on the drive roll matches the wire size
being used.
7. Refer to Figure B.5. Remove gas nozzle and con-
tact tip from end of gun.
2. Carefully detach the end of the wire from the
spool. To prevent the spool from unwinding, do
8. Turn the WELDMARK 135 PLUS ON (“I�).
not release the wire until after step 5.
9. Straighten the gun cable assembly.
3. Cut the bent portion of wire off and straighten the
first 4� (100 mm).
10. Depress the gun trigger switch and feed welding
wire through the gun and cable. (Point gun away
4. Thread the wire through the In-going guide tube
from yourself and others while feeding wire.)
(4), over the drive roll (3), and into the out-going
Release gun trigger after wire appears at end of
guide tube (5).
gun.
Note: If the wire will not feed smoothly, or if the wire
5. Close the idle roll arm (2) and latch the spring
feed motor shuts off unexpectedly, see the
loaded pressure arm (1) in place (now you may
"FEEDING PROBLEMS" section of the "TROU-
release the welding wire).
BLESHOOTING GUIDE" in this manual.
11. Replace contact tip and gas nozzle.
12. Refer to Figure B-6. Cut the wire off 3/8� � 1/2� (10
� 13 mm) from the end of the tip. The WELD-
MARK 135 PLUS is now ready to weld.
WELDMARK 135 PLUS
B-5
OPERATION
B-5
FIGURE B.5 FIGURE B.6
Gun Handle
Contact Tip
Gas Diffuser
Contact Tip Wire Electrode
3/8"� 1/2"(10-13mm) Contact
Gas Nozzle Tip to Work Distance(CTWD)
4. Check that the polarity is correct for the welding
Shielding Gas wire being used and that the gas supply, if
When using the GMAW process, a cylinder of shield- required, is turned on.
ing gas, must be obtained. Refer to the ACCES-
SORIES section for more information about selecting 5. When using Innershield electrode, remove the gas
gas cylinders for use with the WELDMARK 135 PLUS. nozzle and install the gasless nozzle. This will
improve visibility of the arc and protect the gas dif-
fuser from weld spatter. Refer to the MAINTE-
1. For CO2, open the cylinder very slowly. For argon- NANCE section for details on nozzle replacement.
mixed gas, open cylinder valve slowly a fraction of
a turn. When the cylinder pressure gauge pointer 6. Refer to Figure B.7. Connect work clamp to metal
stops moving, open the valve fully. to be welded. Work clamp must make good elec-
trical contact to the workpiece. The workpiece
2. If using a regulator with an adjustable flow meter, must also be grounded as stated in “Arc Welding
close the gun trigger and adjust the flow to give 15 Safety Precautions� in the beginning of this manu-
� 20 cubic ft per hour (CFH) (7 � 10 I/min) [use 20 al.
-� 25 CFH (10 � 12 I/min) when welding out of
position or in a drafty location for CO2]. For argon 7. Position gun over joint. End of wire may be lightly
mixed gas, trigger to release gas pressure, and touching the work.
turn off the adjust the flow to give 25 � 30 CFH
(12 � 14 I/min). 8. Lower welding helmet, close gun trigger, and
begin welding. Hold the gun so the contact tip to
3. Keep the cylinder valve closed, except when using work distance is about 3/8 inch (10 mm).
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. FIGURE B.7
c) Turn off the welder.
Making A Weld
1. See Recommended Processes And Equipment
section for selection of welding wire and shielding
gas and for range of metal thicknesses that can be
GUN CABLE
welded.
2. See the Application Chart on the inside of wire
feed section door for information on setting the
SP-135 PLUS controls.
WORKPIECE
3. Set the Voltage (“Vâ€?) and Wire Speed (“olo’â??) con- ARC
trols to the settings suggested for the welding wire
and base metal thickness being used. WORK CLAMP
WELDMARK 135 PLUS
B-6 B-6
OPERATION
CAUTION
9. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes It is important when changing between welding
out. with steel wire and aluminum to exchange feeding
components due to the lubricant applied to steel
10. When no more welding is to be done, close valve wire. Failure to do so may result in contaminated
on gas cylinder (if used), momentarily operate gun welds when welding aluminum.
trigger to release gas pressure, and turn off the ------------------------------------------------------------------------
welder. TABLE B.1-- WELDMARK135 PLUS Welding
Procedures
Cleaning Tip And Nozzle
Voltage/Wire Speed
Shielding
Clean the contact tip and nozzle to avoid arc bridging Process Welding Wire Gas 22 ga 16 ga 12 ga 1/8� 3/16� 1/4�
between the nozzle and contact tip which can result in
.035 Dia(0.9mm 100% Argon C-5 E-8.5 H-10 J-10* NR NR
a shorted nozzle, poor welds and an overheated gun. 4043 Aluminum
Wire
Hint: Anti-stick spray or gel, available from a welding 18 ga 16 ga 14 ga 12 ga 10 ga
MIG DC+
supply distributor, may reduce buildup and aid in spat-
.030 Dia 98% Argon/ D-3 E-4.5 F-6 H-8 NR
ter removal. 308L Stainless 2% Oxygen
Steel Wire
NR (Not Recommended)
PROCESS GUIDELINES *Test assembly preheated to 250° F.
The WELDMARK 135 PLUS can be used for welding
mild steel using the GMAW, single pass, process
CHANGING MACHINE OVER TO
which requires a supply of shielding gas or it can be
FEED OTHER WIRE SIZES
used for the self shielded, Innershield ® process
(FCAW).
The WELDMARK135 PLUS is shipped from the facto-
ry ready to feed 0.023-0.025� (0,6 mm) diameter wire.
The recommended gases and electrodes for GMAW
To operate the welder with other sizes of wire, it is
are welding grade CO2 gas or an argon-CO2 blended
necessary to change the contact tip and change the
gas (75 to 80% argon and 25 to 20% CO2) and .025"
drive roll over to other sizes. Refer to Changing the
(0.6 mm) diameter Lincoln L-56 mild-steel welding
Contact Tip and Changing the Drive Roll, in the MAIN-
wire, supplied on 12-1/2 lb (5.7 kg) spools.
TENANCE section, for specific information on these
procedures.
The recommended electrode for the self-shielded
process is 0.035� (0,9 mm) diameter Lincoln
Innershield NR-211-MP on 10 Ib (4,5 kg) spools. This
electrode can be used for all position welding of 20
WELDING WITH FCAW (Innershield)
gauge through 5/16� (1,0 � 8,0 mm) thick steel [multi-
ple passes are required for 1/4� and 5/16� (6,0 and 8,0
Welding with Innershield requires an Innershield
mm)].
Welding Kit. A gasless nozzle is provided in the
Innershield Welding Kit. When using Innershield elec-
WARNING trode, installing the gasless nozzle will improve visibili-
ty of the arc and protect the gas diffuser from weld
spatter. Additionally included is a gun cable liner to
Use of the GMAW process with the WELDMARK
permit proper feeding of .035� (0,9 mm) Innershield
135 PLUS on thicker materials than recommended
wire. Refer to the ACCESSORIES section for details
may result in poor welds. The welds may “look�
on obtaining this kit.
good, but may just be “sitting� on top of the plate.
This is called “cold casting� and will result in weld
failure.
OVERLOAD PROTECTION
Output Overload
The WELDMARK 135 PLUS is suitable for .035"
The WELDMARK 135 PLUS is equipped with a circuit
Aluminum wire and .030" stainless wire. Refer to
breaker which protects the machine from potential
Table B.1 for Recommended Procedure Settings.
damage from excessive output current. The circuit
Aluminum wire requires K663-2 Aluminum Welding kit.
breaker button will extend out when tripped. The cir-
See ACCESSORIES section.
cuit breaker must be manually reset.
WELDMARK 135 PLUS
B-7 B-7
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.
If excessive motor overload occurs (due to excessive
feeding force, jammed drive rolls, or shorted motor
leads) the circuit will shut down the wire feed motor
and the welding power output.
The wire feed shut-down circuit will reset automatically
when the gun trigger is released. However shut-down
will reoccur if the overload situation is not corrected.
WELDMARK 135 PLUS
B-8
APPLICATION CHART
B-8
WELDMARK 135 PLUS
C-1 C-1
ACCESSORIES
OPTIONAL ACCESSORIES 4. KP666-035C Knurled Drive Roll (optional) �
Reversible Drive Roll with double knurled grooves
1. K520 Utility Cart � Designed to transport the for .035 (0.9 mm) cored electrode.
Lincoln family of small welders. Has provisions for
mounting a single gas cylinder. Has front casters
and large rear wheels. Handle height is easily 5. K549-1 .035 (0.9 mm) Innershield Welding Kit
adjustable. Bottom tray provided for tools and Includes a contact tip, a gasless nozzle and a cable
accessories. Easy assembly required; takes less liner to permit the Magnumâ„? 100L gun and cable
than 15 minutes. to use .030/.035� (0.8-0.9 mm) diameter flux-cored
electrode. Also included is a spool of .035 (0.9 mm)
2. K586-1 Deluxe Adjustable Gas Regulator & Innershield NR-211-MP.
Hose Kit
Accommodates CO2 or mixed Gas Cylinders.
3. K663-2 Aluminum Welding Kit � This kit is rec-
ommended for welding with .035 Aluminum wire.
Included with this kit are a drive roll, liner and con-
tact tip. It is important when changing between
welding with steel wire and aluminum to
exchange these components due to the lubri-
cant applied to steel wire. Failure to do so may
result in contaminated welds when welding alu-
minum.
See Maintenance section for instructions on
installing drive roll, cable liner, contact tip and their
proper configuration.
WELDMARK 135 PLUS
C-2
ACCESSORIES
C-2
INNERSHIELD (FCAW) REPLACEMENT PARTS
CONVERSION
Complete Gun and Cable Assembly
L8311-6 (K530-4)
Several changes are needed to convert the unit for
operation with the Innershield (FCAW) process. The
Contact Tip .025� (0.6 mm)
K549-1 Innershield Kit includes all the necessary
KP2039-1B1
accessories for this conversion and are provided for
this purpose. The following conversions should be Contact Tip .030� (0.8 mm)
made using the contents of this kit: KP2039-2B1
1. Change the output polarity to DC(-). See “Work Contact Tip .035� (0.9 mm)
Cable Installation� section for details. KP2039-3B1
Contact Tip-Tapered .025� (0.6 mm)
2. Install proper drive roll for the wire size selected.
KP2052-1B1
See “Changing Drive Roll� in Maintenance section
for details.
Contact Tip-Tapered .030� (0.8 mm)
KP2052-2B1
3. Install the proper gun liner* and tip for the wire size
selected. See “Component Replacement� in Contact Tip-Tapered .035� (0.9 mm)
Maintenance section for details. KP2052-3B1
4. Remove gas nozzle (if installed) and install gasless Contact Tip-Tapered .045� (1.2mm)
nozzle. To remove, simply unscrew. KP2052-4B1
Liner .025 - .035� (0.6 - 0.9 mm)
*The factory installed gun liner will feed .025-.035 KP1937-3
(.06mm-.09mm) wire.
Gas Diffuser
KP2040-1
Gas Nozzle
KP1938-1
Gas Nozzle-Tip Recessed 3/8� (9.5 mm)
Opening I.D.
KP1942-1
Gas Nozzle-Tip Recessed 1/2� (12.7 mm)
Opening I.D.
KP1942-1
Gas Nozzle-Tip Recessed 5/8� (15.9 mm)
Opening I.D.
KP1942-2
Spot Welding Nozzle
M17846-1
Gasless Nozzle (Innershield Only)
KP1939-1
WELDMARK 135 PLUS
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 � Lay cable out straight - blow out gently into gun end
removing plug from receptacle with compressed air. Bend cable back and forth �
before working inside WELD- blow out again � Repeat until clean.
MARK 135 PLUS. Use only
grounded receptacle. Do not
WARNING
touch electrically “hot� parts
inside WELDMARK 135 PLUS.
Excessive pressure at start may cause the dirt to
form a plug.
� Have qualified personnel do the
maintenance and trouble shoot-
ing work.
PERIODICALLY AS REQUIRED
� Blow dirt out of the welder with low pressure air to
ITEMS REQUIRING NO eliminate excessive dirt and dust buildup that could
MAINTENANCE cause welder to run hot.
� Drive Motor and Gearbox � Lifetime lubrication � Blow dirt out of: Rectifier & Fan Motor Assembly;
� Fan Motor- Lifetime lubrication. PC Board located on Case Side Assembly; and
� Wire Reel Spindle � Do NOT lubricate shaft. Center Assembly components.
ROUTINE AND PERIODIC MAINTE- � Vacuum accumulated dirt from gearbox and wire
NANCE feed section.
BEFORE EACH USE � Inspect the incoming guide tube and clean inside
diameter if necessary. Replace when excessively
� Check over machine and accessories for any obvi-
worn.
ous condition that may prevent safe performance or
operation, repair or replace items as necessary to
� Replace Contact Tip � when hole is enlarged or
correct any abnormal condition.
elongated (refer to “CHANGING THE CONTACT
AFTER 5 MINUTES OF WELDING TIP�, in this section).
or when spatter accumulates in nozzle
� Replace gas nozzle.
� Clean nozzle to avoid bridging between nozzle and
� Replace Liner � when wire feeding problems occur
contact tip which results in shorted nozzle, poor
and other items have been checked (refer to
welds and overheated gun. Hint: Anti-stick spray or
“CHANGING LINER� procedure in this section).
gel available from a welding supply distributor may
reduce buildup and aid in spatter removal.
� Replace internal gun handle parts as necessary
(see Procedure at the end of this section).
AFTER EACH SPOOL OF WIRE FEED
� Remove contact tip and clean inside diameter with
short piece of wire
� Clean cable liner � when rough and erratic wire feed-
ing occur.
WELDMARK 135 PLUS
D-2 D-2
MAINTENANCE
2. Replace worn contact tips as required. A variable
GUN AND CABLE
or “hunting� arc is a typical symptom of a worn con-
MAINTENANCE
tact tip. To install a new tip, choose the correct size
contact tip for the electrode being used (wire size is
FOR MAGNUMâ„? 100L GUN
stenciled on the side of the contact tip) and screw it
snugly into the gas diffuser.
Gun Cable Cleaning
Clean cable liner after using approximately 300 lbs
3. Remove spatter from inside of gas nozzle and from
(136 kg) of solid wire or 50 lbs (23 kg) of flux-cored
tip after each 10 minutes of arc time or as required.
wire. Remove the cable from the wire feeder and lay it
out straight on the floor. Remove the contact tip from
4. Be sure the gas nozzle is fully screwed onto the
the gun. Using low pressure air, gently blow out the
diffuser for gas shielded processes. For the
cable liner from the gas diffuser end.
Innershield® process, the gasless nozzle should
be screwed onto the diffuser.
CAUTION
5. To remove gun tube from gun, remove gas nozzle
Excessive pressure at the start may cause the dirt
or gasless nozzle and remove diffuser from gun
to form a plug.
tube. Remove both collars from each end of the
gun handle and separate the handle halves.
Loosen the locking nut holding the gun tube in
Flex the cable over its entire length and again blow
place against the gun end cable connector.
out the cable. Repeat this procedure until no further
Unscrew gun tube from cable connector. To install
dirt comes out.
gun tube, screw the locking nut on the gun tube as
far as possible. Then screw the gun tube into the
cable connector until it bottoms. Then unscrew (no
Contact Tips, Nozzles, and Gun Tubes
more than one turn) the gun tube until its axis is
1. Dirt can accumulate in the contact tip hole and
perpendicular to the flat sides of the cable connec-
restrict wire feeding. After each spool of wire is
tor and pointed in the direction of the trigger.
used, remove the contact tip and clean it by push-
Tighten the locking nut so as to maintain the proper
ing a short piece of wire through the tip repeatedly.
relationship between the gun tube and the cable
Use the wire as a reamer to remove dirt that may
connector. Replace the gun handle, trigger and dif-
be adhering to the wall of the hole through the tip.
fuser. Replace the gas nozzle or gasless nozzle.
CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM
Contact Tip Cable Liner Drive Roll
Components shipped with KP2039-1B1(In Gun) KP1937-3 M15448 Stenciled (.030 / .035)
WELDMARK 135 PLUS .025� (0.6mm) .025�-.035� 2 Smooth grooves
KP2039-2B1(Loose) (0.8mm-0.9mm) Small .030 (0.8mm)
.030� (0.8mm) Large .035� (0.9mm)
K549-1 .035� (0.9mm) KP2039-3B1 KP1937-3 KP666-035 Use Large groove
Innershield Welding Kit .035� (0.9mm) .035 (0.9mm)
K663-2 .035 (0.9mm) KP2078-1B1 M18971-1 S24220 .035-3/64 (Drive roll)
Aluminum*� .035A (0.9mm) .045� (1.2mm) S24219 (Idle roll)
KP666-035C M15448-1 Stenciled
2 Knurled grooves for .035� (0.9mm)
� If .030 Solid wire feeding is desired obtain an KP2039-2B1 Contact Tip, an KP1937-2 Cable Liner and an M15448 Drive Roll (Smaller Groove).
* It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire. Failure
to do so may result in contaminated welds when welding aluminum.
� Recommended for best feeding performance.
WELDMARK 135 PLUS
D-3 MAINTENANCE D-3
COMPONENT REPLACEMENT CAUTION
PROCEDURES
CHANGING THE CONTACT TIP
When inching the welding wire, the drive rolls,
gun connector block, and gun contact tip are
1. Unplug or turn power switch to Off “O� position.
energized relative to work and ground and remain
energized for several seconds after the gun trig-
2. Refer to Figure D.2. Remove the gas nozzle from
ger is released.
the gun by unscrewing counter-clockwise.
3. Remove the existing contact tip from the gun by
4. Remove the drive roll, flip over and reinstall with the
unscrewing counter-clockwise.
opposite groove closest to the gearbox.
4. Insert and hand tighten desired contact tip.
NOTE: The stencil of the groove that you want to use
is marked on the outside of the drive unit
5. Replace gas nozzle.
(when installed)
CHANGING THE WELDMARK 135 PLUS
5. Push a length of straightened welding wire through
FOR USE WITH INNERSHIELD FLUX
the wire feeder guide tubes and reset the Phillips
CORED WIRE
Head screw to secure the drive roll onto the shaft.
� Change The Contact Tip
6. Reapply the spring loaded idle arm tensioner.
1. Refer to Figure D.2. Remove the gas nozzle from
7. Turn the power “ON� (I) and check the drive roll for
the gun by unscrewing counter-clockwise.
slipping when feeding wire. DO NOT OVERTIGHTEN - If
necessary, tighten or loosen the spring loaded idle
2. Remove the existing contact tip from the gun by
arm tensioner (2).
unscrewing counter-clockwise.
3. Insert and hand tighten the contact tip for use with
0.035� Innershield Flux Cored Wire.
4. Replace gas nozzle � The gasless nozzle may be
used instead of the gas nozzle to give improved visi-
3
bility of the arc.
CHANGING DRIVE ROLL
2
The drive roll, Figure D.1 Item 1, has two grooves; one
for .023" � .025" (0.6 mm) solid steel electrode and a
larger groove for .030" (0.8 mm) solid and .035" (0.9 mm)
flux-cored steel electrode. As shipped, the drive roll is 1
installed in the .023"-.025" (0.6 mm) position.
If .030"/.035" (0.8/0.9 mm) wire is to be used, the
drive roll must be reversed as follows:
1. Turn the power switch to OFF (marked “O�).
FIGURE D.1
2. Release the spring-loaded idle arm tensioner,
Figure D.1 Item 2, and lift the idle roll arm, Figure
D.1 Item 3, away from the drive roll.
3. Loosen the Phillips Head screw holding the drive
roll onto the drive shaft.
WELDMARK 135 PLUS
D-4 D-4
MAINTENANCE
1-1/4 (31.8 mm)
Liner Trim Length
Gas Diffuser
Slotted Brass Cable Contact Tip
(Threaded)
Set Screw Connector
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 (Magnumâ„? 100L)
CHANGING LINER 9. Screw the gas diffuser onto the end of the gun
tube and securely tighten.
NOTICE: The variation in cable lengths prevents the
interchangeability of liners. Once a liner has been cut 10. Replace the contact tip and nozzle.
for a particular gun, it should not be installed in anoth-
er gun unless it can meet the liner cutoff length GUN HANDLE PARTS
requirement. Refer to Figure D.2.
The gun handle consists of two halves that are held
1. Remove gun and cable assembly from machine. together with a collar on each end. To open up the
handle, turn the collars approximately 60 degrees
2. Remove the gas nozzle from the gun by unscrew- counter-clockwise until the collar reaches a stop. Then
ing counter-clockwise. pull the collar off the gun handle. If the collars are diffi-
cult to turn, position the gun handle against a corner,
3. Remove the existing contact tip from the gun by place a screwdriver against the tab on the collar and
unscrewing counter-clockwise. give the screwdriver a sharp blow to turn the collar
past an internal locking rib. See Figure D-3.
4. Remove the gas diffuser from the gun tube by
unscrewing counter-clockwise.
5. Lay the gun and cable out straight on a flat sur-
face. Loosen the set screw located in the brass
connector at the wire feeder end of the cable. Pull
the liner out of the cable.
6. Insert a new untrimmed liner into the connector
end of the cable. Be sure the liner bushing is sten-
âž?
Counter-clockwise
ciled appropriately for the wire size being used.
7. Fully seat the liner bushing into the connector.
Tighten the set screw on the brass cable connec-
tor. At this time, the gas diffuser should not be
installed onto the end of the gun tube.
8. 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.
Remove any burrs from the end of the liner. FIGURE D.3
WELDMARK 135 PLUS
E-1 E-1
TROUBLESHOOTING
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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)�. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE� lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
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.
___________________________________________________________________
CAUTION
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.
WELDMARK 135 PLUS
E-2 E-2
TROUBLESHOOTING
Observe Safety Guidelines
TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage Contact your LOCAL AUTHORIZED
is evident. FIELD SERVICE FACILITY.
No wire feed, weld output or gas 1. Make sure correct voltage is
flow when gun trigger is pulled. Fan applied to the machine (115 vac).
does NOT operate.
2. Make certain that power switch is
in the ON position.
3. Make sure circuit breaker is reset.
No weld output or wire feed when Contact your LOCAL AUTHORIZED
gun trigger is pulled. Fan runs and FIELD SERVICE FACILITY.
gas flows normally.
No weld output when gun trigger is 1. Arc voltage may be set too low.
pulled. Fan runs, gas flows and
wire feeds normally. 2. Gun tip may be worn � Replace. Contact your local Authorized Field
Service Facility.
3. Check for correct input voltage to
machine.
4. Gun or work cable may be faulty.
No Wire feed, weld output or gas 1. Check the circuit breaker located
flow when the gun trigger is pulled - in the machine’s wire drive com-
Fan operates normally. partment. Reset if tripped.
2. The thermostat may be tripped
due to overheating. Let machine
cool. Weld within the duty cycle or
remove any air obstruction to
machine.
3. Wire feed motor may be over-
loaded. Correct feeding problem.
4. 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 AUTHORIZED FIELD SERVICE FACILITY for assistance before you proceed.
WELDMARK 135 PLUS
E-3
TROUBLESHOOTING
E-3
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
FEEDING PROBLEMS
No wire feed when gun trigger is 1. If the wire drive motor is running
pulled. Fan runs, gas flows and check to see if the correct wire
machine has correct open circuit is in the machine.
voltage (28 vdc maximum) � weld
output. 2. If the wire drive motor is running
make sure that the correct drive
rolls are installed in the Contact your local Authorized Field
machine. Service Facility.
3. Check for clogged cable liner or
feeding problems.
Wire feed speed motor runs very 1. Make sure that the wire speed
fast. Weld output, gas flow and fan control is not set at maximum.
operate normally.
The wire begins to feed but shuts 1. Wire spool friction brake adjust-
off after a short time, and will feed ment set too tight. Check adjust-
again for another short interval only ment of the wire spool friction
if the trigger is released and brake. See "Friction Brake
pressed again. (See description Adjustment" in the "OPERA-
under wire feed overload protec- TION" section of this manual.
tion).
2. Idle roll pressure adjustment set
too high. Check adjustment of
the idle roll pressure. See "Wire
Threading" in The "OPERA-
TION" section of this manual.
3. Damaged or poorly maintained
wire feed system.
1. Check for clogged or damaged
cable liner, contact tip, and guide
tubes. Replace any damaged or
excessively worn parts.
2. Perform "ROUTINE AND
PERIODIC MAINTENANCE" as
described in this manual.
CAUTION
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.
WELDMARK 135 PLUS
E-4
E-4 TROUBLESHOOTING
Observe Safety Guidelines TROUBLESHOOTING GUIDE
detailed in the beginning of this manual.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
GAS FLOW PROBLEMS
Low or no gas flow when gun 1. Check gas supply, flow regulator
trigger is pulled. Wire feed, weld and gas hoses.
output and fan operate normally. Contact your local Authorized Field
2. Check gun connection to Service Facility.
machine for obstruction or leaky
seals.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
WELDING PROBLEMS
Arc is unstable � Poor starting 1. Check for correct input voltage
to machine � 115 vac.
2. Check for proper electrode
polarity for process.
3. Check gun tip for wear or dam- Contact your local Authorized Field
age � Replace. Service Facility.
4. Check for proper gas and flow
rate for process.
5. Check work cable for loose or
faulty connections.
6. Check gun for damage or
breaks.
CAUTION
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.
WELDMARK 135 PLUS
F-1 F-1
WIRING DIAGRAMS
WELDMARK
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
NOTES
WELDMARK 135 PLUS
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.
LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-
STELLERS. DIE UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� 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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