Lincoln Electric IM767 User Manual
IM767
ISO 9001
CERTIFICATE NUMBER: 30273
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
QMS
ANSI RAB
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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 thoughtful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
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is obsolete and no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
may have changed.
November, 2005
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
Copyright © 2005 Lincoln Global Inc.
•Manufactured by Lincoln Electric Company •
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
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.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
FOR ENGINE
powered equipment.
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.
____________________________________________________
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
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may be dangerous
2.a. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines
2.b. EMF fields may interfere with some pacemakers, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them with tape when possible.
2.d.2. Never coil the electrode lead around your body.
2.d.3. Do not place your body between the electrode and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
WELDMARK 135 PLUS
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii
SAFETY
ii
ELECTRIC SHOCK can
kill.
3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands.
3.b. Insulate yourself from work and ground using dry insulation.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be as close as possible to the area being welded.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating products.
5.c. Shielding gases used for arc welding can displace air and
cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
vapors
to
5.e. Also see item 1.b.
Mar ‘95
WELDMARK 135 PLUS
iii
SAFETY
iii
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.
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic lines. Have a fire extinguisher readily available.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
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.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
recommendations.
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
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suivantes:
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
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
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.
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
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du rayonnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pantalons 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
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
WELDMARK 135 PLUS
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. 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___________________________________________________________________________
vv
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
“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:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
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.
WELDMARK 135 PLUS
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
Learning to Weld....................................................................................................B-8
Application Chart .................................................................................................B-19
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-443 & P-202-E
WELDMARK 135 PLUS
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
Output Mode Input Voltage Breaker Size Input Amps Extension Cord
RATED 115V/60Hz 20 Amp 20 (2.1 mm
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
Three Conductor
#14 AWG
2
) or Larger
for up to
25 feet (7.6m)
A-1A-1
Three Conductor
#12 AWG
MAXIMUM 115V/60Hz 25 Amp 25 (3.3 mm
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
2
) or Larger
WELDMARK 135 PLUS
A-2 A-2
1
2
3
4
5
W
E
L
D
IN
G A
MP
R
A
N
G
E
2
5-12
5
6
7
INSTALLATION
Read entire installation section before starting
installation.
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform
this installation.
• Only personnel that have read and understood the WELDMARK 135 PLUS
Operating Manual should install and operate this equipment.
• Machine must be plugged into a receptacle
which is grounded per any national, local
or other applicable electrical codes.
• 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.
FIGURE A.1
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. WELDMARK 135 PLUS
2. Gun and cable assembly
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 L-56 .025 MIG Wire.
7. Adjustable mixed-Gas Regulator & Hose.
(1)
For available options and accessories refer to the
accessories section later in this manual.
1)
As shipped from the factory, the welding gun is
ready to feed .023 or .025 (0.6 mm) wire.
WELDMARK 135 PLUS
INSTALLATION
44
5
8
3
7
6
1
2
SP-135 Plus
WELDING AMP RANGE
25-125
+
-
9
WORK CLAMP
NUT AND BOLT
STRAIN RELIEF HOLE
WORK CABLE
A-3A-3
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.
STACKING
WELDMARK 135 PLUS cannot be stacked.
TILTING
Each machine must be placed on a secure, level surface, either directly or on a recommended undercarriage. The machine may topple over if this procedure
is not followed.
OUTPUT CONNECTIONS
Refer to Figure A.2.
Work Clamp Installation
Attach the work clamp per the following:
1. Unplug the machine or turn the power switch to the
“OFF” position.
2. Insert the work cable terminal lug with the larger
hole through the strain relief hole in the work clamp
as shown in Figure A-3.
3. Fasten securely with the bolt and nut provided.
FIGURE A.3
1. Work Cable Access Hole.
2. Gun Cable and Control Lead Access Hole.
3. Connector Block.
4. Gun Trigger Lead Connectors.
5. Positive (+) and negative (–) output terminals.
6. Wire Feed Gearbox and Gun Connector Block
7. Cable Clamp
8. Thumbscrew - Secures gun and cable assembly
9. Optional Spot/Stitch Timer Kit see Accessories.
Work Cable Installation
Refer to Figure A.2.
1. Open the wire feed section door on the right side of
the welder.
2. Pass the end of the work cable that has the terminal lug with the smaller hole through the Work
Cable Access Hole (1) in the case front.
FIGURE A.2
WELDMARK 135 PLUS
A-4
INSTALLATION
A-4
3. Route the cable under and around the back of the
Wire Feed Gearbox (6).
4. For GMAW Only: Refer to Figure A.2. As deliv-
ered, the welder is wired for positive polarity. This
is the appropriate configuration for the Gas Metal
Arc Welding (GMAW) process. To complete installation, use the provided wing nut to connect the
work cable’s terminal lug to the negative (–) output
terminal (5) located above the Wire Feed Gearbox
(6). Make sure that both wing nuts are tight.
5. For Innershield Only: Refer to Figure A.4. To wire
for negative polarity, connect the short cable
attached to the connector block (1) to the negative
(–) output terminal (2) and the work cable (3) to the
positive (+) terminal (4).
FIGURE A.4
4
3
2
3. Insert the connector on the gun conductor cable
through the Gun Cable Access Hole (2) in the
WELDMARK 135 PLUS case front. Make sure the
connector is all the way in the metal connector
block to obtain proper gas flow. Rotate the connector so control leads are on the underside and tighten the Thumbscrew (8) in the connector block.
4. Connect the gun trigger control lead terminals to
the two insulated 1/4" (6,4 mm) tab connector
bushings located above the “Gun Trigger
Connection” decal in the wire feed section (4).
Either lead can go to either connector. Form the
leads so that they are as close as possible to the
inside panel.
CAUTION
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. 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
welder trigger circuit.
1
GUN INSTALLATION
As shipped from the factory, the welding gun is ready
to feed 0.023 - 0.025” (0,6 mm) wire. If 0.030” (0,8
mm) wire is to be used install the 0.030” (0.8 mm)
contact tip. Refer to the MAINTENANCE section for
contact tip installation details.
Connecting Gun Cable to the WELDMARK
135 PLUS
1. Refer to Figure A.2. Unplug the machine or turn
power switch to the off “O” position.
2. Pass the insulated terminals of the gun trigger control leads, one at a time, through the Gun Cable
and Control Lead Access Slot (2) in the case front.
The leads are to be routed under the Wire Feed
Gearbox (6) and through the Cable Hanger (7) on
the inner panel.
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
selecting gas cylinders for use with the welder, refer to
the ACCESSORIES section.
WARNING
CYLINDER may explode if damaged. Keep cylinder upright and
chained to support
• Keep cylinder away from areas
where it may be damaged.
• Never lift welder with cylinder
attached.
• Never allow welding electrode to
touch cylinder.
• Keep cylinder away from welding
or other live electrical circuits.
WELDMARK 135 PLUS
A-5
INSTALLATION
A-5
WARNING
BUILDUP OF SHIELDING GAS may
harm health or kill.
• Shut off shielding gas supply
when not in use.
• SEE AMERICAN NATIONAL
STANDARD Z-49.1, “SAFETY IN
WELDING AND CUTTING” PUBLISHED BY THE AMERICAN
WELDING SOCIETY.
1. Chain the cylinder to a wall or other stationary support to prevent the cylinder from falling over.
Insulate the cylinder from the work circuit and earth
ground.
FIGURE A.5
Flow Regulator
Cylinder Valve
3. Attach the flow regulator to the cylinder valve and
tighten the union nut securely with a wrench. The
flow regulator for carbon dioxide must have a plastic washer seated in the fitting that attaches to the
cylinder to prevent leakage.
4. Refer to Figure A.6. Attach one end of inlet gas
hose to the outlet fitting of the flow regulator and
tighten the union nut securely with a wrench.
Connect the other end to the Gas Solenoid Inlet
Fitting (5/8-18 female threads — for CGA — 032
fitting). Make certain the gas hose is not kinked or
twisted.
INPUT CONNECTIONS
Refer to Figure A.6.
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
machine.
Gas Hose
2. With the cylinder securely installed, remove the
cylinder cap. Stand to one side away from the outlet and open the cylinder valve very slightly for an
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.
FIGURE A.6
Gas Solenoid
Inlet Fitting
Power
Input
Cable
WELDMARK 135 PLUS
A-6 A-6
INSTALLATION
CODE REQUIREMENTS FOR INPUT
CONNECTIONS
WARNING
This welding machine must be connected to
power source in accordance with applicable electrical codes.
Do not connect the welder to an input power supply with a rated voltage that is greater than 125
volts.
Do not remove the power cord ground prong.
Requirements For Maximum Output
CAUTION
The United States National Electrical Code (Article
630-B, 1990 Edition) provides standards for amperage
handling capability of supply conductors based on
duty cycle of the welding source.
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 receptacle 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).
In order to utilize the maximum output capability of the
machine, a branch circuit capable of 25 amps at 115
to 125 volts, 60 Hertz is required. This generally
applies when welding steel that is equal to or greater
than 12 gauge, 0.105” (2.5 mm) in thickness.
WELDMARK 135 PLUS
B-1
OPERATION
Read entire Operation section before
operating the WELDMARK 135 PLUS.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrode with skin or
wet clothing. Insulate yourself
from work and ground.
• Always wear dry insulating
gloves.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
B-1
WELDING SPARKS can
cause fire or explosion.
• Keep flammable material away.
• Do not weld on closed containers.
ARC RAYS can burn eyes
and skin.
• Wear eye, ear and body protection.
Observe all safety information throughout
this manual.
WELDMARK 135 PLUS
OPERATION
OFF
ON
ARC VOLTS
WIRE SPEED
ARC VOLTS
B-2B-2
GENERAL DESCRIPTION
The WELDMARK 135 PLUS is a complete semiautomatic constant voltage DC arc welding machine.
Included is a solid state controlled, single phase constant voltage transformer/ rectifier power source and a
wire feeder for feeding solid steel electrode and cored
electrode.
The WELDMARK 135 PLUS is ideally suited for individuals having access to 115 volt AC input power, and
wanting the ease of use, quality and dependability of
both gas metal arc welding or GMAW (also known as
MIG welding) and the Innershield electrode process
(self shielded flux cored or FCAW). The WELDMARK135 PLUS is a rugged and reliable machine that
has been designed for dependable service and long
life.
RECOMMENDED PROCESSES
The WELDMARK 135 PLUS can be used for welding
mild steel using the GMAW, single pass, process
which requires a supply of shielding gas or it can be
used for the self shielded, Innershield electrode
process (FCAW). The WELDMARK 135 PLUS is configured for use with the GMAW (MIG) process as
delivered from the factory.
OPERATIONAL FEATURES AND
CONTROLS
The WELDMARK 135 PLUS has the following controls
as standard: Power ON/OFF Switch, Voltage Control,
Wire Speed Control, and a Circuit Breaker.
DESIGN FEATURES AND
ADVANTAGES
● Operates on 115 volt input — no special wiring
required.
● Solid state output control.
● “Cold electrode” until gun trigger is pressed for an
added measure of safety.
● Overload protection — incorporates both a thermo-
stat and a circuit breaker.
● Quality wire drive with electronic overload protec-
tion.
● Easy-to-set continuous range controls for precise
setting of arc voltage and wire speed.
● Continuous voltage control.
● “Quick Release” idle roll pressure arm is easily
adjusted.
● Reversible, dual groove drive roll. Drive roll will
feed .023-.035” (0.6- 0.9 mm) diameter wire.
● Accommodates both 8” (200 mm) diameter and 4”
(100 mm) diameter spools of wire.
● No external shielding gas is required when used
with Lincoln Innershield .035” (0,9 mm) NR®-211-
MP electrode.
● Easy to change polarity.
● Accepts optional Spot/Stitch Timer Kit.
WELDING CAPABILITY
The WELDMARK135 PLUS, as shipped, is rated at 90
amps, 18 volts, at 20% duty cycle on a ten minute
basis. It is capable of higher duty cycles at lower output currents.
LIMITATIONS
Arc Gouging cannot be performed with the WELDMARK 135 PLUS and it is not recommended for pipe
thawing.
CONTROLS AND SETTINGS
Refer to Figures B.1a & B.1b.
1. Power ON/OFF Switch —
When the power is on the
fan motor will run and air will
be exhausted out the louvers
in the front of the machine.
The welding output and wire
feeder remain off until the
gun trigger is pressed.
2. Voltage Control — A continuous control that gives full
range adjustment of power
source output voltage.
Voltage can be adjusted
while welding.
3. Wire Speed Control —
Controls the wire feed speed
from 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.
ON
WELDMARK 135 PLUS
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