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
v v WELDMARK 135 PLUS 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...
Page 7 - TABLE OF CONTENTS; Page
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; Gun and cable assembly; 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; Accessories; 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 - Attach the flow regulator to the cylinder valve and; INPUT CONNECTIONS; Chain the cylinder to a wall or other stationary sup-
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). Refer to Figure B.1b. 5. Gun Trigger - Activates welding output, wire feed, and gas solenoid operation. Releasing the triggerdeactivates w...
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 - To stop welding, release the gun trigger and then; Cleaning Tip And Nozzle; PROCESS GUIDELINES; p r o c e s s
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 - OVERLOAD PROTECTION; Output Overload
B-7 B-7 OPERATION OVERLOAD PROTECTION Output Overload The WELDMARK 135 PLUS is equipped with a circuitbreaker which protects the machine from potentialdamage from excessive output current. The circuitbreaker button will extend out when tripped. The cir-cuit breaker must be manually reset. Thermal Pr...
Page 21 - LEARNING TO WELD; THE ARC-WELDING CIRCUIT; • Avoid contact with eyes and skin.
B-8 B-8 LEARNING TO WELD LEARNING TO WELD No one can learn to weld simply by reading about it.Skill comes only with practice. The following pages willhelp the inexperienced operator to understand weld-ing and develop this skill. For more detailed informa-tion, order a copy of “ New Lessons in Arc We...
Page 22 - PROCESS SELECTION
B-9 B-9 LEARNING TO WELD The “ arc stream ” is seen in the middle of the picture. This is the electric arc created by the electric currentflowing through the space between the end of the wireelectrode and the base metal. The temperature of thisarc is about 6000 ° F, which is more than enough to melt...
Page 23 - COMMON METALS; Butt Welds
B-10 B-10 LEARNING TO WELD For GMAW (MIG) Process 1. Is most of my welding performed on 16 gauge and lighter materials? 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas sup-ply? 3. Do I require clean, finished-looking welds? If you have answered ye...
Page 24 - Penetration; angle between the two; Welding In The Vertical Position; Vertical-up And Overhead Welding; drip
B-11 B-11 LEARNING TO WELD FIGURE B.12 Penetration Unless a weld penetrates close to 100% of the metalthickness, a butt weld will be weaker than the materialwelded together. In the example shown in FigureB.13, the total weld is only half the thickness of thematerial thus the weld is only approximate...
Page 25 - Vertical-down Welding
B-12 B-12 LEARNING TO WELD FIGURE B.16 Vertical-down Welding Refer to Figure B.17 Vertical-down welds are appliedat a fast pace. These welds are therefore shallow andnarrow and, as such, are excellent for sheet metal.Vertical-down welds may be applied to 5/32 ” (3.9 mm) and lighter material. Use str...
Page 26 - ARC RAYS can burn eyes and skin.; The Correct Welding Speed
B-13 B-13 LEARNING TO WELD ARC RAYS can burn eyes and skin. When using an open arc process, itIs necessary to use correct eye,head and body protection. Protect yourself and others, read “ ARC RAYS can burn ” at the front of this manual. 2. The Correct Way To Strike An Arc 1. Be sure the work clamp m...
Page 27 - Mild Steel; For the WELD MARK 135 PLUS, use the
B-14 B-14 LEARNING TO WELD Mild Steel 16 gauge or 1/16 inch (1.6 mm) Electrode 0.035" (0.9 mm) NR-211-MP Innershield Wire Voltage Setting “ V ” E Wire Feed Speed “ o|o ” 2 For the WELD MARK 135 PLUS, use the following: Helpful Hints 1. For general welding, it is not necessary to weave the arc, n...
Page 29 - For the WELDMARK 135 PLUS, use the
Helpful Hints 1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways.Weld along at a steady pace. You will find it easier. 2. When welding on thin plate, you will find that you will have to increase the welding speed, whereaswhen welding on heavy plate...
Page 30 - TROUBLESHOOTING WELDS
B-17 B-17 LEARNING TO WELD 4. After you strike the arc, practice the correct electri- cal stickout. Learn to distinguish it by its sound. 5. When you are sure that you can hold the correct electrical stickout, with a smooth “ crackling ” arc, start moving. Look at the molten puddle constantly. 6. Ru...
Page 31 - Proper Gun Handling
B-18 B-18 LEARNING TO WELD Proper Gun Handling Most feeding problems are caused by improper han-dling of the gun cable or electrodes. 1. Do not kink or pull the gun around sharp corners 2. Keep the gun cable as straight as practical when welding. 3. Do not allow dolly wheels or trucks to run over th...
Page 32 - APPLICATION CHART
Page 33 - ACCESSORIES; Includes spot; OPTIONAL ACCESSORIES; Designed to transport the; K 6 6 3 - 2 A l u m i n u m W e l d i n g K i t; T h i s k i t
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. K695-2 Spot / Stitch Timer Kit — Includes spot timer to control the spot welding arc time, and astitch timer to control the on/off cycle time of th...
Page 34 - REPLACEMENT PARTS
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 35 - 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 ” parts inside WELDMARK 135 PLUS. • Have qualified personnel do the maintenance and t...
Page 36 - FOR MAGNUM; CAUTION
D-2 D-2 MAINTENANCE GUN AND CABLE MAINTENANCE FOR MAGNUM ™ 100L GUN Gun Cable CleaningClean 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 37 - CHANGING THE CONTACT TIP; NOTE: The stencil of the groove that you want to use
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 38 - GUN HANDLE PARTS; Liner trim length for gun with red trigger (Magnum; 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 39 - TROUBLESHOOTING; Look under the column labeled; 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 40 - 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 41 - 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 42 - 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 43 - WIRING DIAGRAMS; SP-135PLUS WIRING DIAGRAMS; WIRING DIAGRAM
F-1 F-1 WIRING DIAGRAMS M19922 L1 L2 31 32 531 TO GROUND PER NATIONAL ELECTRICAL CODE S1 SWITCH 202 201 D1 D3 D2 D4 204 204 204 203 203 203 C1 59,000 f 40V 203 204 - + OUTPUT CHOKE GUN CABLE CONDUCTOR BLOCK TO WORK ELECTRICAL SYMBOLS PER E1537 CIRCUIT BREAKER 31A 12 3 45 6 LATCH FAN MOTOR 1 234 LATC...
Page 44 - NOTES
Page 45 - 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...