Lincoln Electric IM789 - Manuals

Lincoln Electric IM789 – Manual in PDF format online.

Manuals:

Manual

Manual Lincoln Electric IM789

Summary

Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines

WELDMARK 135 PLUS FOR ENGINEpowered 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 exhau...

Page 3 - ii

ii SAFETY ii ARC RAYS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable...

Page 4 - iii

FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...

Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ

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 suiv- antes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la seco...

Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately

Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and...

Page 7 - TABLE OF CONTENTS

vi vi TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1Identify and Locate Component...

Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS – WELDMARK 135 PLUS; INPUT – SINGLE PHASE ONLY

A-1 A-1 INSTALLATION Fuse or Output Mode Input Voltage Breaker Size Input Amps Extension Cord Three Conductor #14 AWG RATED 115V/60Hz 20 Amp 20 (2.1 mm 2 ) or Larger for up to 25 feet (7.6m) Three Conductor #12 AWG MAXIMUM 115V/60Hz 25 Amp 25 (3.3 mm 2 ) or Larger for up to 50 feet (15.2 m) TECHNICA...

Page 9 - SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.

A-2 A-2 INSTALLATION Read entire installation section before startinginstallation. SAFETY PRECAUTIONS IDENTIFY AND LOCATE COMPONENTS If you have not already done so, unpack the Welderf r o m i t s c a r t o n a n d r e m o v e a l l p a c k i n g m a t e r i a lRemove the following loose items from ...

Page 10 - SELECT SUITABLE LOCATION; OUTPUT CONNECTIONS; Work Clamp Installation

A-3 A-3 INSTALLATION SELECT SUITABLE LOCATION Locate the welder in a dry location where there is freecirculation of clean air into the louvers in the back andout the front of the unit. A location that minimizes theamount of smoke and dirt drawn into the rear louversreduces the chance of dirt accumul...

Page 11 - GAS CONNECTION

A-4 A-4 INSTALLATION 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. Thisis the appropriate configuration for the Gas MetalArc Welding (GMAW) process. To complete instal-latio...

Page 12 - INPUT CONNECTIONS

A-5 A-5 INSTALLATION 3. Attach the flow regulator to the cylinder valve and tighten the union nut securely with a wrench. Theflow regulator for carbon dioxide must have a plas- tic washer seated in the fitting that attaches to thecylinder to prevent leakage. 4. Refer to Figure A.6. Attach one end of...

Page 13 - Requirements For Rated Output; Do not remove the power cord ground prong.; Requirements For Maximum Output

A-6 A-6 INSTALLATION CODE REQUIREMENTS FOR INPUTCONNECTIONS This welding machine must be connected topower source in accordance with applicable elec-trical codes. The United States National Electrical Code (Article630-B, 1990 Edition) provides standards for amperagehandling capability of supply cond...

Page 14 - OPERATION

B-1 B-1 OPERATION Read entire Operation section beforeoperating the WELDMARK 135 PLUS. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin orwet clothing. Insulate yourselffrom work and ground. • Always wear dry insulating gloves. FUMES AND GASES can bedangerous. •...

Page 15 - GENERAL DESCRIPTION; RECOMMENDED PROCESSES; WELDING CAPABILITY

B-2 B-2 OPERATION GENERAL DESCRIPTION The WELDMARK 135 PLUS is a complete semiauto-m a t i c c o n s t a n t v o l t a g e D C a r c w e l d i n g m a c h i n e .Included is a solid state controlled, single phase con-stant voltage transformer/ rectifier power source and awire feeder for feeding soli...

Page 16 - WELDING OPERATIONS; SEQUENCE OF OPERATION; Wire Loading

B-3 B-3 OPERATION FIGURE B.1a 4. Circuit Breaker – Protects machine from damage if maximum output is exceeded. Button will extendout when tripped (Manual reset). 5. Gun Trigger - Activates welding output, wire feed, and gas solenoid operation. Releasing the triggerdeactivates welding and simultaneou...

Page 17 - Friction Brake Adjustment

B-4 B-4 OPERATION FIGURE B.3 Friction Brake Adjustment With wire spool installed on the spindle shaft and thewing nut loose, turn the spool by hand while slowlytightening the wing nut until a light drag is felt. Tightenthe wing nut an additional 1/4 turn. Note: When properly adjusted, the brake shou...

Page 18 - Shielding Gas

B-5 B-5 OPERATION Shielding Gas When using the GMAW process, a cylinder of shield-i n g g a s , m u s t b e o b t a i n e d . R e f e r t o t h e A C C E S -SORIES section for more information about selectinggas cylinders for use with the WELDMARK 135 PLUS. 1. For CO 2 , open the cylinder very slowl...

Page 19 - Cleaning Tip And Nozzle; PROCESS GUIDELINES; OVERLOAD PROTECTION; Output Overload

B-6 B-6 OPERATION 9. To stop welding, release the gun trigger and then pull the gun away from the work after the arc goesout. 10. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate guntrigger to release gas pressure, and turn off thewelder. Cleaning Tip An...

Page 20 - Thermal Protection

B-7 B-7 OPERATION Thermal Protection The WELDMARK 135 PLUS duty cycle is exceeded athermostat will shut off the output until the machinecools to a normal operating temperature. This is anautomatic function and is self resetting. Wire Feed Overload Protection If the WELDMARK 135 PLUS has an automatic...

Page 21 - APPLICATION CHART

Page 22 - ACCESSORIES; OPTIONAL ACCESSORIES; It is important when changing between

C-1 C-1 ACCESSORIES 4. KP666-035C Knurled Drive Roll (optional) — Reversible Drive Roll with double knurled groovesfor .035 (0.9 mm) cored electrode. 5. K549-1 .035 (0.9 mm) Innershield Welding Kit Includes a contact tip, a gasless nozzle and a cableliner to permit the Magnum ™ 100L gun and cable to...

Page 23 - REPLACEMENT PARTS; Complete Gun and Cable Assembly

C-2 C-2 ACCESSORIES INNERSHIELD (FCAW)CONVERSION Several changes are needed to convert the unit foroperation with the Innershield (FCAW) process. TheK549-1 Innershield Kit includes all the necessaryaccessories for this conversion and are provided forthis purpose. The following conversions should bem...

Page 24 - BEFORE EACH USE; MAINTENANCE; PERIODICALLY AS REQUIRED

MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptaclebefore working inside WELD-MARK 135 PLUS. Use onlygrounded receptacle. Do nottouch electrically “hot” partsinside WELDMARK 135 PLUS. • Have qualified personnel do the maintenance and trou...

Page 25 - Gun Cable Cleaning; CAUTION; Contact Tip

D-2 D-2 MAINTENANCE GUN AND CABLE MAINTENANCE FOR MAGNUM™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs(136 kg) of solid wire or 50 lbs (23 kg) of flux-coredwire. Remove the cable from the wire feeder and lay itout straight on the floor. Remove the contact tip fromt...

Page 26 - CHANGING THE CONTACT TIP

D-3 WELDMARK 135 PLUS D-3 MAINTENANCE COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONTACT TIP 1. Unplug or turn power switch to Off “ O ” position. 2. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 3. Remove the existing contact tip from the gun by unscrew...

Page 27 - GUN HANDLE PARTS; Liner trim length for gun with red trigger (MagnumTM 100L); CHANGING LINER

D-4 GUN HANDLE PARTS The gun handle consists of two halves that are heldtogether with a collar on each end. To open up thehandle, turn the collars approximately 60 degreescounter-clockwise until the collar reaches a stop. Thenpull the collar off the gun handle. If the collars are diffi-cult to turn,...

Page 28 - TROUBLESHOOTING; Local Authorized Field Service Facility; HOW TO USE TROUBLESHOOTING GUIDE

If machine case sides and top are removed, the case front must be supported. Failureto do this could result in mechanical or electrical damage to the welder. ___________________________________________________________________ CAUTION E-1 TROUBLESHOOTING E-1 If for any reason you do not understand th...

Page 29 - TROUBLESHOOTING GUIDE; OUTPUT PROBLEMS

E-2 E-2 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS(SYMPTOMS) Major physical or electrical damageis evident. No wire feed, weld output or gasflow when gun trigger is pulled. Fandoes NOT operate. No weld output or wire feed whengu...

Page 30 - FEEDING PROBLEMS

E-3 E-3 TROUBLESHOOTING Observe Safety Guidelinesdetailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS(SYMPTOMS) No wire feed when gun trigger ispulled. Fan runs, gas flows andmachine has correct open circuitvoltage (28 vdc maximum) – weld output. Wire feed speed motor runs veryfa...

Page 31 - WELDING PROBLEMS; GAS FLOW PROBLEMS

E-4 E-4 TROUBLESHOOTING Observe Safety Guidelinesdetailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS(SYMPTOMS) Arc is unstable – Poor starting POSSIBLE AREAS OFMISADJUSTMENT(S) 1. Check for correct input voltage to machine – 115 vac. 2. Check for proper electrode polarity for pr...

Page 32 - WIRING DIAGRAMS; WELDMARK

F-1 F-1 WIRING DIAGRAMS NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside the machine on one of the enclosure panels. WELDMARK 135 PLUS WELDMARK

Page 33 - NOTES

Page 34 - ÇÃ

WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES. SE RECOMIENDA LEER Y ENTENDER LAS I...