Lincoln Electric IM767 specifications GUN Installation, GAS Connection

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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 instal- lation, 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

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 con- trol 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.

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 connec- tor so control leads are on the underside and tight- en 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.

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 dam- aged. 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

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Contents Weldmark 135 Plus California Proposition 65 Warnings SafetyElectric Shock can kill Iii Welding Sparks can cause fire or explosionSûreté Pour Soudage a L’Arc Précautions DE SûretéOn-Line Product Registration Please Examine Carton and Equipment For Damage ImmediatelyTable of Contents Technical Specifications Weldmark 135 Plus InstallationElectric Shock can kill Safety PrecautionsIdentify and Locate Components Stacking Work Clamp InstallationWork Cable Installation Select Suitable LocationGAS Connection GUN InstallationConnecting Gun Cable to the Weldmark 135 Plus Cable Input ConnectionsGas Solenoid Inlet Fitting InputRequirements For Maximum Output Code Requirements for Input ConnectionsRequirements For Rated Output Welding Sparks can cause fire or explosion Observe all safety information throughout this manualOperation Fumes and Gases can be dangerousWelding Capability Controls and SettingsDesign Features Advantages General DescriptionSequence of Operation Wire LoadingWelding Operations 4OPERATIONB-4 Friction Brake AdjustmentWire Threading Making a Weld Shielding GasProcess Guidelines Changing Machine Over to Feed Other Wire SizesCleaning Tip And Nozzle Thermal Protection Wire Feed Overload ProtectionOverload Protection Output OverloadSELF-SHIELDED Fcaw Welding ARC Learning to WeldLearning to Weld ARC-WELDING CircuitProcess Selection Gmaw MIG Welding ARCFor Fcaw Innershield Process Common MetalsJoint Types and Positions For Gmaw MIG ProcessFillet Welds Welding In The Vertical PositionPenetration Correct Welding Position Machine SET UP for the SELF-SHIELDED Fcaw ProcessWelding Techniques for the SELF- Shielded Fcaw Process Vertical-down WeldingCorrect Welding Speed Correct Electrical Stickout ESOPractice Helpful HintsWelding Techniques for the Gmaw MIG Process Machine SET UP for the Gmaw MIG ProcessFor the Weldmark 135 PLUS, use Following To Eliminate Stubbing* in order of importance Troubleshooting WeldsTo Eliminate a Ropy Convex Bead in order of importance To Correct Poor Penetration in order of impor- tanceProper Gun Handling Application Chart K586-1 Deluxe Adjustable Gas Regulator Hose Kit AccessoriesOptional Accessories Innershield Fcaw Conversion Replacement PartsRoutine and Periodic MAINTE- Nance MaintenanceMaintenance Safety Precautions Items Requiring no MaintenanceContact Tip Cable Liner Drive Roll GUN and Cable MaintenanceConfiguration of Components in Wire Feeding System For Magnum 100L GUNChanging Drive Roll Changing the Contact TIPLiner trim length for gun with red trigger Magnum 100L Changing LinerGUN Handle Parts HOW to USE Troubleshooting Guide TroubleshootingOutput Problems Troubleshooting GuideRecommended Course of Action Problems Possible Symptoms CauseGAS Flow Problems SP-135PLUSWIRINGWIRINGDIAGRAMDIAGRAMS Wiring DiagramsWeldmark 135 Plus Precaucion Warnung Manufactured by Lincoln Electric Company
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