Lincoln Electric IM767 Maintenance Safety Precautions, Items Requiring no Maintenance

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MAINTENANCE

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MAINTENANCE

SAFETY PRECAUTIONS

WARNING

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 NO

MAINTENANCE

•Drive Motor and Gearbox – Lifetime lubrication

•Fan Motor- Lifetime lubrication.

•Wire Reel Spindle – Do NOT lubricate shaft.

ROUTINE AND PERIODIC MAINTE- NANCE

BEFORE EACH USE

•Check over machine and accessories for any obvi- ous condition that may prevent safe performance or operation, repair or replace items as necessary to correct any abnormal condition.

AFTER 5 MINUTES OF WELDING

or when spatter accumulates in nozzle

•Clean nozzle to avoid bridging between nozzle and contact tip which results in shorted nozzle, poor welds and overheated gun. Hint: Anti-stick spray or gel available from a welding supply distributor may reduce buildup and aid in spatter removal.

AFTER EACH SPOOL OF WIRE FEED

•Remove contact tip and clean inside diameter with short piece of wire

•Clean cable liner – when rough and erratic wire feed- ing occur.

AFTER FEEDING 50# OF FLUX CORED WIRE OR 300# OF SOLID WIRE

•Unplug machine or turn power switch to OFF – “O” position. Remove gun and cable from machine.

•Remove gas nozzle and contact tip from gun.

•Lay cable out straight - blow out gently into gun end with compressed air. Bend cable back and forth – blow out again – Repeat until clean.

WARNING

Excessive pressure at start may cause the dirt to form a plug.

PERIODICALLY AS REQUIRED

•Blow dirt out of the welder with low pressure air to eliminate excessive dirt and dust buildup that could cause welder to run hot.

•Blow dirt out of: Rectifier & Fan Motor Assembly; PC Board located on Case Side Assembly; and Center Assembly components.

•Vacuum accumulated dirt from gearbox and wire feed section.

•Inspect the incoming guide tube and clean inside diameter if necessary. Replace when excessively worn.

•Replace Contact Tip – when hole is enlarged or elongated (refer to “CHANGING THE CONTACT TIP”, in this section).

•Replace gas nozzle.

•Replace Liner – when wire feeding problems occur and other items have been checked (refer to “CHANGING LINER” procedure in this section).

•Replace internal gun handle parts as necessary (see Procedure at the end of this section).

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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