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Lincoln Electric WELDMARK 135 PLUS IM789 - page 1
WELDMARK 135 PLUS OPERA TOR’S MANUAL IM789 April, 2006 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 MA ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 2
WELDMARK 135 PLUS 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. ______________________________ ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 3
ii SAFETY ii ARC RA YS 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 ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 4
FOR ELECTRICALL Y 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 C ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 5
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 secousse électrique: a. Les circuits ? ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 6
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 keep it handy for quick reference. Pay par ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 7
vi vi T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components .............................................. ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 8
A-1 A-1 INST ALLA TION 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) TECHNICAL SPECIFICA TIONS – WELDMARK 135 PLUS INPUT ? ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 9
A-2 A-2 INST ALLA TION Read entire installation section before starting installation. SAFETY PRECAUTIONS IDENTIFY AND LOCA TE 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 ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 10
A-3 A-3 INST ALLA TION SELECT SUIT ABLE LOCA TION 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 caus ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 11
A-4 A-4 INST ALLA TION 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 instal- lation, use the provided wing nut to connect the w ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 12
A-5 A-5 INST ALLA TION 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 plas- tic 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 f ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 13
A-6 A-6 INST ALLA TION CODE REQUIREMENTS FOR INPUT CONNECTIONS This welding machine must be connected to power source in accordance with applicable elec- trical codes. 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 s ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 14
B-1 B-1 OPERA TION Read entire Operation section before operating the WELDMARK 135 PLUS. 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 v ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 15
B-2 B-2 OPERA TION GENERAL DESCRIPTION The WELDMARK 135 PLUS is a complete semiauto- matic constant voltage DC arc welding machine. Included is a solid state controlled, single phase con- stant voltage transformer/ rectifier power source and a wire feeder for feeding solid steel electrode and cored electrode. The WELDMARK 135 PLUS is ideally suited ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 16
B-3 B-3 OPERA TION FIGURE B.1a 4. Circuit Breaker – Protects machine from damage if maximum output is exceeded. Button will extend out when tripped (Manual reset). 5. Gun Trigger - Activates welding output, wire feed, and gas solenoid operation. Releasing the trigger deactivates welding and simultaneously activates the “ burnback ” function s ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 17
B-4 B-4 OPERA TION FIGURE B.3 Friction Brake Adjustment With wire spool installed on the spindle shaft and the wing nut loose, turn the spool by hand while slowly tightening the wing nut until a light drag is felt. Tighten the wing nut an additional 1/4 turn. Note: When properly adjusted, the brake should pro- vide only enough drag to prevent overr ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 18
B-5 B-5 OPERA TION Shielding Gas When using the GMAW process, a cylinder of shield- ing gas, must be obtained. Refer to the ACCES- SORIES section for more information about selecting gas cylinders for use with the WELDMARK 135 PLUS. 1. For CO 2 , open the cylinder very slowly. For argon- mixed gas, open cylinder valve slowly a fraction of a turn. W ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 19
B-6 B-6 OPERA TION 9. To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out. 10. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun trigger to release gas pressure, and turn off the welder. Cleaning Tip And Nozzle Clean the contact tip and nozzle to a ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 20
B-7 B-7 OPERA TION 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 th ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 21
B-8 B-8 APPLICA TION CHART WELDMARK 135 PLUS ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 22
C-1 C-1 ACCESSORIES 4 . KP666-035C Knurled Drive Roll (optional) — Reversible Drive Roll with double knurled grooves for .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 cable liner to permit the Magnum ™ 100L gun and cable to use .030/.035 ” (0.8-0.9 mm) diameter fl ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 23
C-2 C-2 ACCESSORIES INNERSHIELD (FCA W) CONVERSION Several changes are needed to convert the unit for operation with the Innershield (FCAW) process. The K549-1 Innershield Kit includes all the necessary accessories for this conversion and are provided for this purpose. The following conversions should be made using the contents of this kit: 1. Chan ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 24
MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside WELD- MARK 135 PLUS. Use only grounded receptacle. Do not touch electrically “hot” parts inside WELDMARK 135 PLUS. • Have qualified personnel do the maintenance and trouble shoot- ing work. ITEMS REQUIRING ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 25
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-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using low pressure air, gently blow ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 26
D-3 WELDMARK 135 PLUS D-3 MAINTENANCE COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONT ACT TIP 1. Unplug or turn power switch to Off “ O ” position. 2. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 3. Remove the existing contact tip from the gun by unscrewing counter-clockwise. 4. Insert and hand tig ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 27
D-4 GUN HANDLE P ARTS The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counter-clockwise until the collar reaches a stop. Then pull the collar off the gun handle. If the collars are diffi- cult to turn, position the gun handle against a corner, p ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 28
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 E-1 TROUBLESHOOTING E-1 If for any reason you do not understand the test procedures or are unable to perform the te ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 29
E-2 E-2 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Major physical or electrical damage is evident. No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate. No weld output or wire feed when gun trigger is pulled. Fan runs and gas flows n ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 30
E-3 E-3 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (28 vdc maximum) – weld output. Wire feed speed motor runs very fast. Weld output, gas flow and fan operate ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 31
E-4 E-4 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS (SYMPTOMS) Arc is unstable – Poor starting POSSIBLE AREAS OF MISADJUSTMENT(S) 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- ag ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 32
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 ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 33
NOTES WELDMARK 135 PLUS ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 34
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA E ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 35
W ARNING A VISO DE PRECAUCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes ...
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Lincoln Electric WELDMARK 135 PLUS IM789 - page 36
• Manufactured by Lincoln Electric Company • Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com ...
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