im787-a pro-mig 135 - lincoln electric · pro-mig™ 135 • sales and ... are electrically...

Pro-MIG 135

OPERATOR’S MANUAL

IM787-AApril, 2004

Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind. However, youroverall safety can be increased byproper installation ... and thought-ful operation on your part. DONOT INSTALL, OPERATE ORREPAIR THIS EQUIPMENTWITHOUT READING THISMANUAL AND THE SAFETYPRECAUTIONS CONTAINEDTHROUGHOUT. And, mostimportantly, think before you actand be careful.

For use with machine Code Number: 10973, 11125

Pro-MIG™ 135

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

• World's Leader in Welding and Cutting Products •

ISO 9001

CERTIFICATE NUMBER: 30273

Designed and Manufactured Under aQuality Program Certified byABS Quality Evaluations, Inc.to ISO 9001 Requirements.

QMS

ANSI RAB

Copyright © 2004 Lincoln Global Inc.

™

This manual covers equipment which is no longer in production by The Lincoln Electric Co. Speci�cations and availability of optional features may have changed.

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework 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.

____________________________________________________1.c. Do not add the fuel near an open flame

welding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel from vaporiz-ing on contact with hot engine parts andigniting. Do not spill fuel when filling tank. Iffuel is spilled, wipe it up and do not startengine until fumes have been eliminated.

____________________________________________________1.d. Keep all equipment safety guards, covers and devices in

position and in good repair.Keep hands, hair, clothing andtools away from V-belts, gears, fans and all other movingparts when starting, operating or repairing equipment.

____________________________________________________

1.e. In some cases it may be necessary to remove safetyguards to perform required maintenance. Removeguards only when necessary and replace them when themaintenance requiring their removal is complete.Always use the greatest care when working near movingparts.

___________________________________________________1.f. Do not put your hands near the engine fan.

Do not attempt to override the governor oridler by pushing on the throttle control rodswhile the engine is running.

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

turning the engine or welding generator during maintenancework, disconnect the spark plug wires, distributor cap ormagneto wire as appropriate.

iSAFETYi

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

Read and understand the following safety highlights. For additional safety information, it is strongly recommended that youpurchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is availablefrom the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay be dangerous

2.a. Electric current flowing through any conductor causes localized Electric and Magnetic Fields (EMF). Welding current creates EMF fields around welding cables and welding machines

2.b. EMF fields may interfere with some pacemakers, andwelders having a pacemaker should consult their physicianbefore welding.

2.c. Exposure to EMF fields in welding may have other healtheffects which are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode andwork cables. If the electrode cable is on your right side, the work cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close aspossible to the area being welded.

2.d.5. Do not work next to welding power source.

1.h. To avoid scalding, do not remove theradiator pressure cap when the engine ishot.

Diesel engine exhaust and some of its constituentsare known to the State of California to cause can-cer, birth defects, and other reproductive harm.

The engine exhaust from this product containschemicals known to the State of California to causecancer, birth defects, or other reproductive harm.

CALIFORNIA PROPOSITION 65 WARNINGS

The Above For Diesel Engines The Above For Gasoline Engines

iiSAFETYii

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 flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

ELECTRIC SHOCK cankill.3.a. The electrode and work (or ground) circuits

are electrically “hot” when the welder is on.Do not touch these “hot” parts with your bareskin or wet clothing. Wear dry, hole-free

gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your fullarea of physical contact with work and ground.

In addition to the normal safety precautions, if weldingmust be performed under electrically hazardousconditions (in damp locations or while wearing wetclothing; on metal structures such as floors, gratings orscaffolds; when in cramped positions such as sitting,kneeling or lying, if there is a high risk of unavoidable oraccidental contact with the workpiece or ground) usethe following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.• DC Manual (Stick) Welder.• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomaticwelding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connectionshould be as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical(earth) ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts ofelectrode holders connected to two welders because voltagebetween the two can be the total of the open circuit voltageof both welders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see Items 6.c. and 8.

FUMES AND GASEScan be dangerous.5.a. Welding may produce fumes and gases

hazardous to health. Avoid breathing thesefumes and gases.When welding, keepyour head out of the fume. Use enoughventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. Whenwelding with electrodes which require specialventilation such as stainless or hard facing (seeinstructions on container or MSDS) or on lead orcadmium plated steel and other metals or coatingswhich produce highly toxic fumes, keep exposure aslow as possible and below Threshold Limit Values (TLV)using local exhaust or mechanical ventilation. Inconfined spaces or in some circumstances, outdoors, arespirator may be required. Additional precautions arealso required when welding on galvanized steel.

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.

The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating products.

5.c. Shielding gases used for arc welding can displace air andcause injury or death. Always use enough ventilation,especially in confined areas, to insure breathing air is safe.

5.d. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow youremployer’s safety practices. MSDS forms are available fromyour welding distributor or from the manufacturer.

5.e. Also see item 1.b. Mar ‘95

FOR ELECTRICALLYpowered equipment.

8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.

8.b. Install equipment in accordance with the U.S. NationalElectrical Code, all local codes and the manufacturer’srecommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

CYLINDER may explodeif damaged.7.a. Use only compressed gas cylinders

containing the correct shielding gas for theprocess used and properly operatingregulators designed for the gas and

pressure used. All hoses, fittings, etc. should be suitable forthe application and maintained in good condition.

7.b. Always keep cylinders in an upright position securelychained to an undercarriage or fixed support.

7.c. Cylinders should be located:• Away from areas where they may be struck or subjected tophysical damage.

• A safe distance from arc welding or cutting operations andany other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and handtight except when the cylinder is in use or connected foruse.

7.g. Read and follow the instructions on compressed gascylinders, associated equipment, and CGA publication P-l,“Precautions for Safe Handling of Compressed Gases inCylinders,” available from the Compressed Gas Association1235 Jefferson Davis Highway, Arlington, VA 22202.

iiiSAFETYiii

Mar ‘95

WELDING SPARKS cancause fire or explosion.6.a. Remove fire hazards from the welding area.

If this is not possible, cover them to preventthe welding sparks from starting a fire.Remember that welding sparks and hot

materials from welding can easily go through small cracksand openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,special precautions should be used to prevent hazardoussituations. Refer to “Safety in Welding and Cutting” (ANSIStandard Z49.1) and the operating information for theequipment being used.

6.c. When not welding, make certain no part of the electrodecircuit is touching the work or ground. Accidental contactcan cause overheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedureswill not cause flammable or toxic vapors from substancesinside. They can cause an explosion even though they havebeen “cleaned”. For information, purchase “RecommendedSafe Practices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held HazardousSubstances”, AWS F4.1 from the American Welding Society(see address above).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oilfree protective garments such as leather gloves, heavy shirt,cuffless trousers, high shoes and a cap over your hair. Wearear plugs when welding out of position or in confined places.Always wear safety glasses with side shields when in awelding area.

6.g. Connect the work cable to the work as close to the weldingarea as practical. Work cables connected to the buildingframework or other locations away from the welding areaincrease the possibility of the welding current passingthrough lifting chains, crane cables or other alternate cir-cuits. This can create fire hazards or overheat lifting chainsor cables until they fail.

6.h. Also see item 1.c.

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instruc-tions et les précautions de sûreté specifiques qui parraissentdans ce manuel aussi bien que les précautions de sûretégénérales suivantes:

Sûreté Pour Soudage A L’Arc1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tensionquand la machine à souder est en marche. Eviter toujourstout contact entre les parties sous tension et la peau nueou les vétements mouillés. Porter des gants secs et sanstrous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans

les positions assis ou couché pour lesquelles unegrande partie du corps peut être en contact avec lamasse.

c. Maintenir le porte-électrode, la pince de masse, le câblede soudage et la machine à souder en bon et sûr étatdefonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour lerefroidir.

e. Ne jamais toucher simultanément les parties sous tensiondes porte-électrodes connectés à deux machines à soud-er parce que la tension entre les deux pinces peut être letotal de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source decourant pour soudage semi-automatique, ces precautionspour le porte-électrode s’applicuent aussi au pistolet desoudage.

2. Dans le cas de travail au dessus du niveau du sol, se pro-téger contre les chutes dans le cas ou on recoit un choc. Nejamais enrouler le câble-électrode autour de n’importe quellepartie du corps.

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,donc:

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux durayonnement de l’arc et des projections quand on soudeou quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger lapeau de soudeur et des aides contre le rayonnement del‘arc.

c. Protéger l’autre personnel travaillant à proximité ausoudage à l’aide d’écrans appropriés et non-inflamma-bles.

4. Des gouttes de laitier en fusion sont émises de l’arc desoudage. Se protéger avec des vêtements de protectionlibres de l’huile, tels que les gants en cuir, chemise épaisse,pantalons sans revers, et chaussures montantes.

5. Toujours porter des lunettes de sécurité dans la zone desoudage. Utiliser des lunettes avec écrans lateraux dans leszones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin deprévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé dela masse. Un court-circuit accidental peut provoquer unéchauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possiblede la zone de travail qu’il est pratique de le faire. Si on placela masse sur la charpente de la construction ou d’autresendroits éloignés de la zone de travail, on augmente le risquede voir passer le courant de soudage par les chaines de lev-age, câbles de grue, ou autres circuits. Cela peut provoquerdes risques d’incendie ou d’echauffement des chaines et descâbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.Ceci est particuliérement important pour le soudage de tôlesgalvanisées plombées, ou cadmiées ou tout autre métal quiproduit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenantd’opérations de dégraissage, nettoyage ou pistolage. Lachaleur ou les rayons de l’arc peuvent réagir avec lesvapeurs du solvant pour produire du phosgéne (gas forte-ment toxique) ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,voir le code “Code for safety in welding and cutting” CSAStandard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au codede l’électricité et aux recommendations du fabricant. Le dis-positif de montage ou la piece à souder doit être branché àune bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du posteseront effectués par un électricien qualifié.

3. Avant de faires des travaux à l’ interieur de poste, ladebrancher à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leurplace.

Mar. ‘93

vv

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto 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 ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

WARNINGThis statement appears where the information must be followed exactly to avoid serious personal injury orloss of life.

This statement appears where the information must be followed to avoid minor personal injury or damage tothis equipment.

CAUTION

Please Examine Carton and Equipment For Damage ImmediatelyWhen this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claimsfor material damaged in shipment must be made by the purchaser against the transportation company at thetime the shipment is received.

Please record your equipment identification information below for future reference. This information can befound on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information youhave recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packetaccompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then“Product Registration”. Please complete the form and submit your registration.

vivi

MASTER TABLE OF CONTENTS FOR ALL SECTIONS

Page

Installation .......................................................................................................Section ATechnical Specifications ........................................................................................A-1Identify and Locate Components ...........................................................................A-2Select Suitable Location ........................................................................................A-3Output Connections...............................................................................................A-3Input Connections..................................................................................................A-6Code Requirements ..............................................................................................A-6

Operation .........................................................................................................Section BSafety Precautions ................................................................................................B-1General Description ...............................................................................................B-1Design Features ....................................................................................................B-1Welding Capability .................................................................................................B-2Limitations..............................................................................................................B-2Controls and Settings ............................................................................................B-2Welding Operations ...............................................................................................B-3Overload Protection...............................................................................................B-6Application Chart ...................................................................................................B-7

Accessories .....................................................................................................Section CAccessories ...........................................................................................................C-1Replacement Parts ................................................................................................C-2

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1Items Requiring No Maintenance ..........................................................................D-1Routine Maintenance.............................................................................................D-1Gun and Cable Maintenance.................................................................................D-2Component Replacement Procedures ..................................................................D-3Changing Liner ......................................................................................................D-4Gun Handle Parts ..................................................................................................D-4

Troubleshooting ..............................................................................................Section ESafety Precautions.................................................................................................E-1How to Use Troubleshooting Guide.......................................................................E-1Troubleshooting Guide.........................................................................E-2 THRU E-4

Wiring Diagrams ..............................................................................................Section FPro-MIG 135 Wiring Diagram.................................................................................F-1

Parts Lists .....................................................................................P461 Series, P202-E

A-1

Pro-MIG 135

A-1

Fuse orOutput Mode Input Voltage Breaker Size1 Input Amps Power Cord Extension Cord

Three Conductor#14 AWG

(2.1 mm2) or Larger

RATED 120V/60Hz 20 Amp 20 15 Amp, 125V, Up to 25 Ft. (7.6 mm)

Three Prong Plug Three Conductor(NEMA Type 5-15P) #12 AWG

(3.3 mm2) or LargerUp to 50 Ft. (15.2 mm)

INSTALLATION

TECHNICAL SPECIFICATIONS – Pro-MIG 135INPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

RECOMMENDED INPUT CABLE AND FUSE SIZES

Height Width Depth Weight12.0 in 9.75 in 16.5 in 48 Ibs305 mm 248 mm 419 mm 21.8 kg

PHYSICAL DIMENSIONS

Standard Voltage/Frequency Input Current120V/60Hz 20 Amps - Rated Output

Duty Cycle Current Voltage20% Duty Cycle 90 Amps 19 V

Welding Current Range Maximum-Open Circuit Voltage 50 - 300 in/min.25-135 Amps 29V (1.3 - 7.6 m/min.)

1If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.

A-2INSTALLATION

Pro-MIG 135

A-2

Read entire installation section before startinginstallation.

SAFETY PRECAUTIONS

IDENTIFY AND LOCATE COMPONENTSIf you have not already done so, unpack the Pro-MIG135 from its carton and remove all packing materialaround the Pro-MIG 135. Remove the following looseitems from the carton (see Figure A.1):

1. Pro-MIG 135

2. Gun and cable assembly(1)

3. Literature and miscellaneous including:

a) This operating manual

b) 2 extra .023"-.025” (0.6 mm) contact tips

c) 3 extra .035” (0.9 mm) contact tips

d) Hex key wrench for removal of drive roll.

4. 10 ft (3.0 m) work cable.

5. Work clamp.

6. a) 2lb. spool of .025” (0.6 mm) Super Arc L-56MIG wire.

b) Sample spool of Innershield .035” (0.9 mm) NR-211-MP.

7. Welding Helmet.

8. Adjustable mixed-Gas Regulator & Hose.

9. Instructional video.

10. Gasless Nozzle.

For available options and accessories refer to theAccessories Section of this manual.1) As shipped from the factory, the Pro-MIG 135 gun

liner is ready to feed .023” (0.6 mm) -.035 (0.9 mm)wire. The contact tip is sized for .023”-.025” (0.6mm) wire.

ELECTRIC SHOCK can kill.

• Only qualified personnel should performthis installation.

• Only personnel that have read and under-stood the Pro-MIG 135 Operating Manualshould install and operate this equipment.

• Machine must be plugged into a receptaclewhich is grounded per any national, localor other applicable electrical codes.

• The Pro-MIG 135 power switch is to be inthe OFF (“O”) position when installingwork cable and gun and when connectingpower cord to input power.

WARNING

FIGURE A.1

1

2

3

4

6

78

5

Pro-MIG™ 135

910

A-3INSTALLATION

Pro-MIG 135

A-3

Pro-MIG“ 135

45

8

3 6 71 2

DO NOT SWITCHHWHEN WELDING

+

-

FIGURE A.2

Work Clamp Installation

Attach the work clamp per the following:

1. Unplug the machine or turn the power switch to the“OFF” position.

2. Insert the work cable terminal lug with the largerhole through the strain relief hole in the work clampas shown in Figure A-3.

3. Fasten securely with the bolt and nut provided.

FIGURE A.3

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 accumulation that can blockair passages and cause overheating.

STACKING

Pro-MIG 135’s cannot be stacked.

TILTING

Each machine must be placed on a secure, level sur-face, either directly or on either recommended cart.The machine may topple over if this procedure is notfollowed.

OUTPUT CONNECTIONS

Refer to Figure A.2.

1. Work Cable Access Hole. 2. Gun Cable and Control Lead Access Hole. 3. Connector Block. 4. Gun Trigger Lead Connectors. 5. Positive (+) and negative (–) output terminals.6. Wire Feed Gearbox.7. Cable Hanger.8. Thumbscrew.

Strain Relief Hole

Nut & Bolt

Work Clamp

Work Cable

Work Cable Installation


1. Open the wire feed section door on the right side ofthe Pro-MIG 135.

2. Pass the end of the work cable that has the termi-nal lug with the smaller hole through the WorkCable Access Hole (1) in the case front.

3. Route the cable under and around the back of theWire Feed Gearbox (6).

4. For GMAW Only: Refer to Figure A.2. As deliv-ered, the machine is connected for positive elec-trode polarity. This is the appropriate configurationfor the GMAW (MIG) process. To complete installa-tion, use the provided wing nut to connect the workcable’s terminal lug to the negative (–) output ter-minal (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 wirefor negative polarity (required for the Innershieldprocess), connect the short cable attached to theconnector block (1) to the negative (–) output termi-nal (2) and the work cable (3) to the positive (+)terminal (4).

A-4INSTALLATION

Pro-MIG 135

A-4

Connecting Gun Cable to the Pro-MIG 135

1. Refer to Figure A.2. Unplug the machine or turnpower 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 Cableand Control Lead Access Slot (2) in the case front.The leads are to be routed under the Wire FeedGearbox (6) and through the Cable Hanger (7) onthe inner panel.

3. Insert the connector on the gun conductor cablethrough the Gun Cable Access Hole (2) in the Pro-MIG 135 case front. Make sure the connector is allthe way in the brass connector block. Unscrewthumbscrew on the connector block a few turns ifgun connector will not insert fully. Rotate the con-nector so control leads are on the underside andtighten the Thumbscrew (8) in the connector block.

4. Connect the gun trigger control lead terminals tothe two insulated 1/4" (6.4 mm) tab terminal con-nector bushings located below the “Gun TriggerConnection” decal in the wire feed section (4).Either lead can go to either connector. Form theleads so that they are as close as possible to theinside panel.

If the gun trigger switch being used is other thanthat supplied with the Pro-MIG 135, the switchmust be a normally open, momentary switch. Theterminals of the switch must be insulated from thewelding circuit. Malfunction of the Pro-MIG 135may result if this switch shorts to the Pro-MIG 135welding output circuit or is common to any electri-cal circuit other than the Pro-MIG 135 trigger cir-cuit.

GAS CONNECTION

When using the GMAW process, a cylinder of shield-ing gas, must be obtained. For more information aboutselecting gas cylinders for use with the Pro-MIG 135refer to the ACCESSORIES section.

2

43

1

FIGURE A.4

GUN INSTALLATION

As shipped from the factory, the Pro-MIG 135 is readyto feed .023" – .025" (0.6 mm) solid wire. If .030"-.035”(0.8mm-.09mm) solid wire is to be used, change thecontact tip to the appropriate size.

NOTE: If .035" (0.9 mm) Innershield flux-cored wire isto be used, see Innershield (FCAW) Conversion in theAccessories section.

CAUTION

CYLINDER may explode if dam-aged. Keep cylinder upright andchained to support

• Keep cylinder away from areaswhere it may be damaged.

• Never lift welder with cylinderattached.

• Never allow welding electrode totouch cylinder.

• Keep cylinder away from weldingor other live electrical circuits.

BUILDUP OF SHIELDING GAS mayharm health or kill.

• Shut off shielding gas supplywhen not in use.

• SEE AMERICAN NATIONALSTANDARD Z-49.1, “SAFETY INWELDING AND CUTTING” PUB-LISHED BY THE AMERICANWELDING SOCIETY.

1. Chain the cylinder to a wall or other stationary sup-port to prevent the cylinder from falling over.Insulate the cylinder from the work circuit and earthground. Refer to Figure A.5.

FIGURE A.5

A-5INSTALLATION

Pro-MIG 135

A-5

WARNING

Cylinder Valve

Gas Hose

Flow Regulator

WARNING

2. With the cylinder securely installed, remove thecylinder cap. Stand to one side away from the out-let and open the cylinder valve very slightly for aninstant. This blows away any dust or dirt which mayhave accumulated in the valve outlet.

BE SURE TO KEEP YOUR FACE AWAY FROMTHE VALVE OUTLET WHEN “CRACKING” THEVALVE. Never stand directly in front of or behindthe flow regulator when opening the cylindervalve. Always stand to one side.

3. Attach the flow regulator to the cylinder valve andtighten the union nut securely with a wrench.

NOTE: If connecting to 100% CO2 cylinder, makecertain the plastic washer is seated in the fittingthat attaches to the CO2 cylinder.

4. Refer to Figure A.6. Attach one end of inlet gashose to the outlet fitting of the flow regulator andtighten the union nut securely with a wrench.Connect the other end to the Pro-MIG 135 GasSolenoid Inlet Fitting (5/8-18 female threads — forCGA — 032 fitting). Make certain the gas hose isnot kinked or twisted.

WARNING

A-6INSTALLATION

Pro-MIG 135

A-6

INPUT CONNECTIONS


The Pro-MIG 135 has a power input cable located onthe rear of the machine.

FIGURE A.6

CODE REQUIREMENTS FOR INPUT CONNECTIONS

This welding machine must be connected to apower source in accordance with applicable elec-trical codes.

The National Electrical Code provides standardsfor amperage handling capability of supply con-ductors based on duty cycle of the weldingsource.

If there is any question about the installationmeeting applicable electrical code requirements,consult a qualified electrician.

Requirements For Rated Output

A power cord with a 15 amp, 125 volt, three prongplug (NEMA Type 5-15P) is factory installed on thePro-MIG 135. Connect this plug to a mating groundedreceptacle which is connected to a 20 amp branch cir-cuit with a nominal voltage rating of 115 to 125 volts,60 Hertz, AC only.

The rated output with this installation is 90 amps,19Volts, 20% duty cycle (2 minutes of every 10 minutesused for welding).

Do not connect the Pro-MIG 135 to an input powersupply with a rated voltage that is greater than 125volts.

Do not remove the power cord ground prong.

POWER INPUTCABLE

GAS SOLENOIDINLET FITTING

WARNING

CAUTION

B-1OPERATIONB-1

Pro-MIG 135

Read entire operation section beforeoperating the Pro-MIG 135.

ELECTRIC SHOCK can kill.• Do not touch electrically live

parts or electrode with skin orwet clothing. Insulate yourselffrom work and ground.

• Always wear dry insulatinggloves.

FUMES AND GASES can bedangerous.• Keep your head out of fumes.

• Use ventilation or exhaust toremove fumes from breathingzone.

WELDING SPARKS cancause fire or explosion.• Keep flammable material away.

• Do not weld on closed contain-ers.

ARC RAYS can burn eyesand skin.• Wear eye, ear and body protec-

tion.

Observe all safety information throughoutthis manual.

WARNING

GENERAL DESCRIPTIONThe Pro-MIG 135 is a complete semiautomatic con-stant-voltage DC wire feeder / power source arcwelder. It has been designed for workshop, hobby,automotive and light maintenance. Included is a tap-switch controlled, single phase constant voltage trans-former / rectifier power source and a wire feeder weld-ing gun for feeding .023 - .025” (0.6 mm) through.030” (0.8 mm) solid steel electrode. An optional kit isavailable for feeding .035” (0.9 mm) Innershield® NR-211-MP flux-cored wire.

The Pro-MIG 135 is ideally suited for individuals hav-ing access to 120 volt AC input power, and wantingthe ease of use, quality and dependability of both gasmetal arc welding or GMAW (also known as MIGwelding) and the Innershield electrode process (selfshielded flux cored or FCAW). The Pro-MIG 135 is arugged and reliable machine that has been designedfor dependable service and long life.

RECOMMENDED PROCESSES

The Pro-MIG 135 can be used for welding mild steelusing the Gas Metal Arc Welding (GMAW or MIG,Metal Inert Gas) single pass process, which requires asupply of shielding gas, or the flux-cored arc welding(FCAW) process using Innershield® electrode wire.The Pro-MIG 135 is configured for use with theGMAW process as delivered from the factory.

OPERATIONAL CONTROLS

The Pro-MIG 135 has the following controls as stan-dard: Control Power ON/OFF Switch, Voltage Control,Wire Speed Control, Trigger Switch, and a CircuitBreaker.

DESIGN FEATURES ● Operates on 120 volt input

● “Cold electrode” until gun trigger is pressed for anadded measure of safety.

● Overload protection — incorporates both a thermo-stat and a circuit breaker.

● Quality wire drive with electronic overload protec-tion.

● “Quick Release” idle roll pressure arm is easilyadjusted.

● Reversible, dual groove drive roll. Drive roll willfeed .023 – .025” (0.6 mm) and .030" - .035" (0.8 -0.9 mm) diameter wire.

B-2OPERATIONB-2

Refer to Figure B.1b.

4. Circuit Breaker – Protects machine from damage ifmaximum 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 simultaneously activatesthe “burnback” function so that the welding wiredoes not stick in the weld puddle.

FIGURE B.1a

FIGURE B.1b

● No external shielding gas is required when usedwith Lincoln Innershield .035” (0.9 mm) NR®-211-MP electrode.

● Accommodates both 4” (100 mm) diameter and 8”(200 mm) diameter spools of wire.

WELDING CAPABILITYThe Pro-MIG 135 is rated at 90 amps, 19 volts, at20% duty cycle on a ten minute basis. It is capable ofhigher output currents at lower duty cycles.

LIMITATIONSArc Gouging cannot be performed with the Pro-MIG135. The Pro-MIG 135 is not recommended for pipethawing or TIG welding.

CONTROLS AND SETTINGSRefer to Figure B.1a.

1. Control Power ON/OFF Switch— When the power is on thefan motor will run and air will beexhausted out the louvers in thefront of the machine. The weld-ing output and wire feederremain off until the gun triggeris pressed.

2. Wire Speed Control —Controls the wire feed speedfrom 50 – 300 in /min. (1.3 –7.6 m/min.). The control canbe preset on the dial to thesetting specified on the Pro-MIG 135 Application Chartlocated on the inside of thewire feed section door.

3. Voltage Control — A 4-posi-tion tap selector switch givesfull range adjustment ofpower source output voltage.Do not switch while weldingas damage to switch mayoccur.

Pro-MIG 135

OFF

ON

ARC VOLTS

WIRE SPEED

Pro-MIG™ 135

DO NOT SWITCHWHEN WELDING

3

21

B-3OPERATIONB-3

WELDING OPERATIONS

SEQUENCE OF OPERATION

Wire LoadingRefer to Figures B.2 and B.3.

The machine power switch should be turned to theOFF (“O”) position before working inside the wire feedenclosure.

The welder is shipped from the factory ready to feed8" (200 mm) diameter spools with 2.2" (56 mm) maxi-mum width. These spools fit on a 2" (51 mm) diameterspindle that has a built in, adjustable friction brake toprevent overrun of the spool and excess slack in the wire.

Note:When loading and removing the 8” Spools makesure that the wing nut (inside the wire spool spindlehub) is turned 90° from the wire spool spindle lockingtab. If the wing nut is positioned in line with the lockingtab, the tab cannot be depressed to load or unload thewire spool.

FIGURE B.2

Load an 8” (200 mm) diameter spool on the wire spoolspindle shown in Figure B.2.

To use 4” (100 mm) diameter spools, the 2” (50 mm)diameter spindle must be removed (See Figure B.3).Remove the wing nut and spacer at the end of theshaft and remove the outside plastic wire spool spin-dle. The spindle can be stored in the wire feed com-partment. A 4” (100 mm) diameter spool is mounteddirectly on the 5/8” (16 mm) diameter shaft and held inplace with the previously removed hardware. Alsomake certain the start end of the wire, which may pro-trude through the side of the spool does not contactany metallic case parts.

FIGURE B.3

Pro-MIG 135

Wire Spindle Shaft

To Wire Drive

4" Wire Spool

Wing Nut and Spacer

Wire Spool must be pushed all the way on the spindle so that thespindles tab will hold it in place. The Wire Spool will rotate clock-wise when wire is dereeled.

Be sure that this stud engagesthe hole in the wire spool.

To Wire Drive

Wire Spool Spindle

8” Wire Spool

B-4OPERATIONB-4

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 should pro-vide only enough drag to prevent overrun of the spooland excess slack in the wire. Too much drag mayresult in wire feeding problems, and may cause pre-mature wear of wire drive system components.

Wire Threading Refer to Figure B.4

1. Release the Spring Loaded Pressure Arm (1)rotate the Idle Roll Arm (2) away from. the WireFeed Drive Roll (3). Ensure that the groove size inthe feeding position on the drive roll matches thewire size being used.

2. Carefully detach the end of the wire from thespool. To prevent the spool from unwinding, maintain tension on the wire until after step 5.

3. Cut the bent portion of wire off and straighten thefirst 4” (100 mm).

4. Thread the wire through the In-going guide tube(4), over the drive roll (3), and into the out-goingguide tube (5).

5. Close the idle roll arm (2) and latch the springloaded pressure arm (1) in place. Rotate the spoolcounterclockwise if required in order to take upextra slack in the wire.

6. The idle roll pressure adjustment wing nut is facto-ry set to approximately five full turns from wherethe wing nut first engages the threads of the pres-sure arm (1). If feeding problems occur becausethe wire is flattened excessively, turn the pressureadjustment counter-clockwise to reduce distortionof the wire. Slightly less pressure may be requiredwhen using 0.023 – 0.025" (0,6 mm) wire. If thedrive roll slips while feeding wire, the pressureshould be increased until the wire feeds properly.

When inching the welding wire, the drive rolls, thegun connector block and the gun contact tip areelectrically energized relative to work and groundand remain energized for several seconds afterthe gun trigger is released.

FIGURE B.4

7. Refer to Figure B.5. Remove gas nozzle and con-tact tip from end of gun.

8. Turn the Pro-MIG 135 ON (“I”).

9. Straighten the gun cable assembly.

10. Depress the gun trigger switch and feed weldingwire through the gun and cable. (Point gun awayfrom yourself and others while feeding wire.)Release gun trigger after wire appears at end ofgun.

11. Turn the Pro-MIG 135 OFF (“O”).

12. Replace contact tip and gas nozzle.

13. Refer to Figure B-6. Cut the wire off 3/8” – 1/2” (10– 13 mm) from the end of the tip. The Pro-MIG135 is now ready to weld.

FIGURE B.5

Pro-MIG 135

WARNING

The Wire Drive Feed Roll canaccommodate two wire sizesby flipping the wire drive feedroll over.

1

2

345

Gun Handle

Gas Diffuser/Contact Tip

Gas Nozzle

B-5OPERATIONB-5

FIGURE B.6

Making A Weld1. See “Process Guidelines” in this section for selec-

tion of welding wire and shielding gas and forrange of metal thicknesses that can be welded.

2. See the Application chart on the inside of the wirefeed compartment door for information on settingthe Pro-MIG 135 controls. Refer to Table B.1 foraluminum and stainless wire.

3. Set the Voltage (“V”) and Wire Speed (“olo’”) con-trols to the settings suggested for the welding wireand base metal thickness being used, refer toApplications chart on the inside of the wire drivecompartment door.

4. Check that the polarity is correct for the weldingwire being used and that the gas supply, ifrequired, is turned on.

5. When using Innershield electrode, remove the gasnozzle and install the gasless nozzle. This willimprove visibility of the arc and protect the gas dif-fuser from weld spatter. Refer to the MAINTE-NANCE section for details on nozzle replacement.

FIGURE B.7

6. Refer to Figure B.7. Connect work clamp to metalto be welded. Work clamp must make good elec-trical contact to the workpiece. The workpiecemust also be grounded as stated in “Arc WeldingSafety Precautions” in the beginning of this manu-al.

7. Position gun over joint. End of wire may be lightlytouching the work.

8. Lower welding helmet, close gun trigger, andbegin welding. Hold the gun so the contact tip towork distance is about 3/8 inch (10 mm).

9. To stop welding, release the gun trigger and thenpull the gun away from the work after the arc goesout.

10. When no more welding is to be done, close valveon gas cylinder (if used), momentarily operate guntrigger to release gas pressure, and turn off thePro-MIG 135.

Cleaning Tip And NozzleClean the contact tip and nozzle to avoid arc bridgingbetween the nozzle and contact tip which can result ina shorted nozzle, poor welds and an overheated gun.Hint: Anti-stick spray or gel, available from a weldingsupply distributor, may reduce buildup and aid in spat-ter removal.

PROCESS GUIDELINES

The Pro-MIG 135 can be used for welding mild steelusing the GMAW, single pass, process which requiresa supply of shielding gas or it can be used for the self-shielded, Innershield® process (FCAW).

The recommended gases and electrodes for GMAWare welding grade CO2 gas or an argon-CO2 blendedgas (75 to 80% argon and 25 to 20% CO2) and .025"(0.6 mm) diameter Lincoln Super Arc L-56 mild-steelwelding wire, supplied on 12-1/2 lb (5.7 kg) spools.

The recommended electrode for the self-shieldedprocess is .035” (0.9 mm) diameter LincolnInnershield® NR-211-MP. This electrode can be usedfor all position welding of 20 gauge (1.0 mm) through5/16" (8 mm) steel. Thickness of 1/4" (6 mm) and5/16" (8 mm) require multiple passes. This wire canalso be used for the welding of galvanized coatedsheet metal.

Pro-MIG 135

Contact Tip

Wire Electrode

WORKPIECE

GUN CABLE

ARC

WORK CLAMP

Pro-MIG™ 135

3/8"– 1/2"(10-13mm) ContactTip to Work Distance(CTWD)

B-6OPERATIONB-6

The Pro-MIG 135 is suitable for .035" aluminum wireand .030" stainless wire. Refer to Table B.1 for recom-mended procedure settings.

TABLE B.1

NOTE:

NR - Not Recommended

CHANGING MACHINE OVER TOFEED OTHER WIRE SIZES

The Pro-MIG 135 is shipped from the factory ready tofeed .023”-.025” (0.6 mm) diameter wire. To operatethe Pro-MIG 135 with other sizes of wire, it is neces-sary to change the contact tip and change the driveroll over to other sizes. Refer to Changing the ContactTip and Changing the Drive Roll, in the MAINTE-NANCE section, for specific information on these pro-cedures.

WELDING WITH GMAW (MIG)

Shielding Gas

When using the GMAW process, obtain and install agas regulator and hose kit. If using CO2 a CO2adapter is required, sold separately.

1. For CO2, open the cylinder very slowly. For argon-mixed gas, open cylinder valve slowly a fraction ofa turn. When the cylinder pressure gauge pointerstops moving, open the valve fully.

2. If using a regulator with an adjustable flow meter,close the gun trigger and adjust the flow to give 15– 20 cubic ft per hour (CFH) (7 – 10 I/min.) [use 20– 25 CFH (10 – 12 I/min.) when welding out ofposition or in a drafty location for CO2]. For argonmixed gas, trigger to release gas pressure, andadjust the flow to give 25 – 30 CFH (12 – 14I/min.).

3. Keep the cylinder valve closed, except when usingthe Pro-MIG 135. When finished welding:

a) Close the cylinder valve to stop gas flow.

b) Depress the gun trigger briefly to release thepressure in the gas hose.

c) Turn off the Pro-MIG 135.

WELDING WITH FCAW (Innershield)

When using the FCAW process, the correct drive rolland electrode polarity must be used. See Work CableInstallation in INSTALLATION section for changingthe polarity.

Innershield welding kit K549-1 (for .035" / 0.9mm) isalso available.

OVERLOAD PROTECTION

Output OverloadThe Pro-MIG 135 is equipped with a circuit breakerand a thermostat which protects the machine fromdamage if maximum output is exceeded. The circuitbreaker button will extend out when tripped. The cir-cuit breaker must be manually reset.

Thermal ProtectionThe Pro-MIG 135 has a rated output duty cycle of20%. If the duty cycle is exceeded, a thermal protectorwill shut off the output until the machine cools to areasonable operating temperature. This is an auto-matic function of the Pro-MIG 135 and does notrequire user intervention. The fan continues to runduring cooling.

Electronic Wire Drive Motor ProtectionThe Pro-MIG 135 has built-in protection for wire drivemotor overload.

Pro-MIG 135

Shielding Voltage/Wire SpeedProcess Welding Wire Gas 22 ga 16 ga 12 ga 1/8” 3/16” 1/4”

.035 Dia(0.9mm 100% Argon A-4.5 C-8.5 D-10 NR NR NR4043 AluminumWire

MIG DC+ 16 ga 14 ga 12 ga 10 ga

.030 Dia 98% Argon/ A-3 C-6 D-7.5 D-7.5308L Stainless 2% OxygenSteel Wire

B-7APPLICATION CHARTB-7

Pro-MIG 135

C-1ACCESSORIESC-1

OPTIONAL ACCESSORIES

1. K549-1 .035" (0.9 mm) Innershield® Welding Kit— Includes a contact tip, a gasless nozzle and a.030/.035" .08mm-.09 mm) cable liner to permit theMagnum™ 100L gun and cable to use .035" (0.9mm) diameter flux-cored electrode. The fitting onthe end of the liner is stenciled with the maximumrated wire size (.045"/1.2 mm). Also included is a10 lb. (4.5 kg.) spool of .035" (0.9 mm) InnershieldNR-211-MP.

See “Innershield (FCAW) Conversion” in this sec-tion for installation instructions and MAINTE-NANCE section for proper feeding component con-figuration and installation.

2. K664-2 Aluminum Feeding Kit — This kit is rec-ommended for welding with .035 Aluminum wire.This kit may also be used for feeding .035 stainlesswire. Included with this kit are a drive roll, liner andcontact tip. It is important when changingbetween welding with steel wire and aluminumto exchange these components due to thelubricant applied to steel wire. Failure to do somay result in contaminated welds when weld-ing aluminum.

3. K520 Utility Cart — Designed to transport theLincoln family of small welders. Has provisions formounting a single gas cylinder. Has front castersand large rear wheels. Handle height is easilyadjustable. Bottom tray provided for tools andaccessories. Easy assembly required; takes lessthan 15 minutes.

4. K586-1 Deluxe Adjustable Gas Regulator &Hose KitAccommodates CO2 or mixed Gas Cylinders.

Pro-MIG 135

C-2ACCESSORIESC-2

INNERSHIELD (FCAW) CONVERSION

Several changes are needed to convert the unit foroperation with the Innershield (FCAW) process:

1. Change the output polarity to DC(–). See “WorkCable Installation” in Installation section for details.

2. Install proper drive roll for the wire size selected.See “Changing Drive Roll” in Maintenance sectionfor details.

3. Install the proper gun liner1 and tip for the wire sizeselected. See “Component Replacement” inMaintenance section for details.

4. Remove gas nozzle (if installed) and install thegasless nozzle. To remove, simply unscrew.

5. Load wire into machine and thread into gun andcable per “Welding Wire Loading” section.

1The factory installed gun liner will feed up to .035(0.9mm) wire.

REPLACEMENT PARTS

Complete Gun and Cable AssemblyL8311-6 (K530-4)

Contact Tip .025” (0.6 mm)KP2039-1B1



Contact Tip-Tapered .025” (0.6 mm)KP2052-1B1



Liner .025 - .035” (0.6 - 0.9 mm)KP1937-3

Gas DiffuserKP2040-1

Gas NozzleKP1938-1

Gas Nozzle-Tip Recessed 3/8” (9.5 mm) Opening I.D.KP1942-1



Spot Welding NozzleKP1956-1

Gasless Nozzle (Innershield Only)KP1939-1

Pro-MIG 135

MAINTENANCE

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Disconnect input power by removingplug from receptacle before workinginside Pro-MIG 135. Use only groundedreceptacle. Do not touch electrically“hot” parts inside Pro-MIG 135.

• Have qualified personnel do the mainte-nance and trouble shooting work.

ROUTINE MAINTENANCE

POWER SOURCE COMPARTMENTNo user serviceable parts inside! Do not attempt to performservice in the power source (fixed) side of the Pro-MIG 135.Take the unit to an authorized Lincoln Service Center if youexperience problems. NO maintenance is required.

In extremely dusty locations, dirt may clog the air passagescausing the welder to run hot with premature tripping of ther-mal protection. If so, blow dirt out of the welder with low pres-sure air at regular intervals to eliminate excessive dirt and dustbuild-up on internal parts.

WIRE FEED COMPARTMENT

1. When necessary, vacuum accumulated dirt from gearboxand wire feed section.

2. Occasionally inspect the incoming guide tube and cleaninside diameter if necessary.

3. Motor and gearbox have lifetime lubrication and require nomaintenance.

FAN MOTOR

Has lifetime lubrication — requires no maintenance.

WIRE REEL SPINDLE

Requires no maintenance. Do not lubricate shaft.

D-1MAINTENANCED-1

Pro-MIG 135

WARNING

D-2MAINTENANCED-2

Pro-MIG 135

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 fromthe gun. Using low pressure air, gently blow out thecable liner from the gas diffuser end.

Excessive pressure at the start may cause the dirtto form a plug.

Flex the cable over its entire length and again blowout the cable. Repeat this procedure until no furtherdirt comes out.

Contact Tips, Nozzles, and Gun Tubes1. Dirt can accumulate in the contact tip hole and

restrict wire feeding. After each spool of wire isused, remove the contact tip and clean it by push-ing a short piece of wire through the tip repeatedly.Use the wire as a reamer to remove dirt that maybe adhering to the wall of the hole through the tip.

2. Replace worn contact tips as required. A variableor “hunting” arc is a typical symptom of a worn con-tact tip. To install a new tip, choose the correct sizecontact tip for the electrode being used (wire size isstenciled on the side of the contact tip) and screw itsnugly into the gas diffuser.

3. Remove spatter from inside of gas nozzle and fromtip after each 10 minutes of arc time or as required.

4. Be sure the gas nozzle is fully screwed onto thediffuser for gas shielded processes. For theInnershield® process, the gasless nozzle shouldbe screws onto the diffuser.

5. To remove gun tube from gun, remove gas nozzleor gasless nozzle and remove diffuser from guntube. Remove both collars from each end of thegun handle and separate the handle halves.Loosen the locking nut holding the gun tube inplace against the gun end cable connector.Unscrew gun tube from cable connector. To installgun tube, screw the locking nut on the gun tube asfar as possible. Then screw the gun tube into thecable connector until it bottoms. Then unscrew (nomore than one turn) the gun tube until its axis isperpendicular to the flat sides of the cable connec-tor and pointed in the direction of the trigger.Tighten the locking nut so as to maintain the properrelationship between the gun tube and the cableconnector. Replace the gun handle, trigger and dif-fuser. Replace the gas nozzle or gasless nozzle.

CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEMContact Tip Cable Liner Drive Roll

Pro-MIG 135 as configured KP2039-1B1 KP1937-3 KP665-035from the factory • .025” (0.6mm) .035” (0.9mm) 2 Smooth grooves

Small .023-.025 (0.6mm)Large .030” (0.8mm)

K549-1 .035” (0.9mm) KP2039-3B1 KP1937-3 KP665-035 - Use Large grooveInnershield Welding Kit .035” (0.9mm) .035 (0.9mm)

K664-2 .035 (0.9mm) KP2078-1B1 KP1959-1 M19631Aluminum or Stainless Kit* .035A (0.9mm) .035” (0.9mm)

• If .030 Solid wire feeding is desired obtain an KP2039-2B1 Contact Tip.

* It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire. Failureto do so may result in contaminated welds when welding aluminum.

CAUTION

D-3MAINTENANCED-3

Pro-MIG 135

COMPONENTREPLACEMENTPROCEDURES

CHANGING THE CONTACT TIP

1. Refer to Figure D.2. Remove the gas nozzle fromthe gun by unscrewing counter-clockwise.

2. Remove the existing contact tip from the gun byunscrewing counter-clockwise.

3. Insert and hand tighten desired contact tip.

4. Replace gas nozzle.

CHANGING DRIVE ROLL

The drive roll has two grooves; one for .023" – .025"(0.6 mm) solid steel electrode and a larger groove for.030" (0.8 mm) solid and .035" (0.9 mm) flux-coredsteel electrode. As shipped, the drive roll is installed inthe .023"/.025" (0.6 mm) position.

If .035" (0.9 mm) wire is to be used, the drive roll mustbe reversed as follows:

1. Connect the machine to its rated input power perinstructions in Installation section.

2. Release the spring-loaded idle arm tensioner,Item 2, andlift the idle roll arm, Item 3, away from the drive roll, Item1. (See Figure D.1)

3. Turn the power switch to ON (marked “I”).

4. Set the wire speed to minimum and jog the driveunit with the trigger switch until the drive roll setscrew is facing up.

When inching the welding wire, the drive rolls,gun connector block, and gun contact tip areenergized relative to work and ground and remainenergized for several seconds after the gun trig-ger is released.

5. Turn the power switch to OFF (marked “O”).

6. Loosen the drive roll set screw with the 5/64" (2.0mm) hex wrench supplied.

7. Remove the drive roll, flip over and reinstall with the.035" (0.9 mm) groove (the larger groove) closestto the gearbox.

8. Push a length of straightened welding wire throughthe wire feeder guide tubes and adjust the positionof the drive roll so that the groove is centered onthe wire. Make certain the set screw is located onthe flat portion of the shaft and tighten.

3

2

1

FIGURE D.1

CAUTION

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, position the gun handle against a corner,place a screwdriver against the tab on the collar andgive the screwdriver a sharp blow to turn the collarpast an internal locking rib. See Figure D-3.

FIGURE D.3

➣

Counter-clockwise

D-4MAINTENANCED-4

8. Screw the gas diffuser onto the end of the gun tubeand securely tighten.

9. Replace the contact tip and nozzle.

Pro-MIG 135

1-1/4 (31.8 mm)Liner Trim Length

Gas Diffuser

Gas Nozzle orGasless NozzleSet Screw Brass Cable

Connector

Liner Assembly (Liner bushing to be sealed tightagainst brass cable connector)

FIGURE D.2Liner trim length

CHANGING LINER

NOTICE: The variation in cable lengths prevents theinterchangeability of liners. Once a liner has been cutfor a particular gun, it should not be installed in anoth-er gun unless it can meet the liner cutoff lengthrequirement. Refer to Figure D.2.

1. Remove the gas nozzle from the gun by unscrew-ing counter-clockwise.

2. Remove the existing contact tip from the gun byunscrewing counter-clockwise.

3. Remove the gas diffuser from the gun tube byunscrewing counter-clockwise.

4. Lay the gun and cable out straight on a flat surface.Loosen the set screw located in the brass connec-tor at the wire feeder end of the cable. Pull the linerout of the cable.

5. Insert a new untrimmed liner into the connector endof the cable. Be sure the liner bushing is stenciledappropriately for the wire size being used.

6. Fully seat the liner bushing into the connector.Tighten the set screw on the brass cable connector.At this time, the gas diffuser should not be installedonto the end of the gun tube.

7. With the gas nozzle and diffuser removed from thegun tube, be sure the cable is straight, and thentrim the liner to the length shown in the Figure D.2.Remove any burrs from the end of the liner.

E-1TROUBLESHOOTINGE-1

Pro-MIG 135

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact yourLocal Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

CAUTION

This Troubleshooting Guide is provided to help youlocate and repair possible machine malfunctions.Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).Look under the column labeled “PROBLEM (SYMP-TOMS)”. This column describes possible symptomsthat the machine may exhibit. Find the listing thatbest describes the symptom that the machine isexhibiting.

Step 2. POSSIBLE CAUSE.The second column labeled “POSSIBLE CAUSE” liststhe obvious external possibilities that may contributeto the machine symptom.

Step 3. RECOMMENDED COURSE OF ACTIONThis column provides a course of action for thePossible Cause, generally it states to contact yourlocal Lincoln Authorized Field Service Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact yourlocal Lincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel.Unauthorized repairs performed on this equipment may result in danger to the technician andmachine operator and will invalidate your factory warranty. For your safety and to avoid ElectricalShock, please observe all safety notes and precautions detailed throughout this manual.

__________________________________________________________________________

WARNING


Pro-MIG 135


CAUTION

PROBLEMS(SYMPTOMS)

Major physical or electrical damageis evident.

No wire feed, weld output or gasflow when gun trigger is pulled. Fandoes NOT operate.

No wire feed, weld output or gasflow when gun trigger is pulled.Fan operates normally.

POSSIBLE AREAS OFMISADJUSTMENT(S)

NoneContact your local Authorized FieldService Facility.

1. Make sure correct voltage isapplied to the machine (115vac).

2. Make certain that power switchis in the ON position.

3. Make sure circuit breaker isreset.

1. The thermostat may be trippeddue to overheating. Let machinecool. Weld at lower duty cycle.

2. Check for obstructions in airflow. Check Gun Trigger connec-tions. See Installation section.

3. Gun trigger may be faulty.

RECOMMENDEDCOURSE OF ACTION

If all recommended possible areasof misadjustment have beenchecked and the problem persists,Contact your local LincolnAuthorized Field ServiceFacility.

OUTPUT PROBLEMS

Observe all Safety Guidelines detailed throughout this manual


Pro-MIG 135


CAUTION

PROBLEMS(SYMPTOMS)

No wire feed when gun trigger ispulled. Fan runs, gas flows andmachine has correct open circuitvoltage (32VDC maximum) – weldoutput.


1. If the wire drive motor is runningmake sure that the correct driverolls are installed in the machine.

2. Check for clogged cable liner orcontact tip.

3. Check for proper size cable linerand contact tip.



FEEDING PROBLEMS

PROBLEMS(SYMPTOMS)

Low or no gas flow when guntrigger is pulled. Wire feed, weldoutput and fan operate normally.


1. Check gas supply, flow regulatorand gas hoses.

2. Check gun connection tomachine for obstruction or leakyseals.



GAS FLOW PROBLEMS



Pro-MIG 135


CAUTION

PROBLEMS(SYMPTOMS)

Arc is unstable – Poor starting


1. Check for correct input voltageto machine – 115vac.

2. Check for proper electrodepolarity for process.

3. Check gun tip for wear or dam-age and proper size – Replace.

4. Check for proper gas and flowrate for process. (For MIG only.)

5. Check work cable for loose orfaulty connections.

6. Check gun for damage orbreaks.

7. Check for proper drive roll orien-tation and alignment.

8. Check liner for proper size.



WELDING PROBLEMS


F-1DIAGRAMSF-1

Pro-MIG 135

WA

RN

ING

HIG

H V

OLT

AG

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n ki

llOn

ly qu

alifie

d per

sons

shou

ld ins

tall, u

se or

servi

ce th

is ma

chine

.

Do no

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rate

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cove

rs re

move

d.

Disc

onne

ct inp

ut po

wer b

y unp

luggin

g pow

er co

rd be

fore s

ervic

ing.

Do no

t touc

h elec

tricall

y live

parts

7-0

2

M20

138

S1

SW

ITC

H

D1

D3

D2

D4

204

204

204

203

203

203

C1

59,0

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203

204

GU

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CO

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EN

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539

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208

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209

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TC

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X3X4

X5

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120

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320

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8 539

213

214

12

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5

67

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10

12

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56

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N.O

.

214

N.B

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.

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.

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OR

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) WIR

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OU

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TH

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IDE

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ATS

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IOD

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INS

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ATS

INK

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SE

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M C

ON

NE

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ON

S

LEA

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OD

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B-B

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ITE

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IRE

T12

837

JOIN

T C

OM

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(DO

W C

OR

NIN

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HE

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TTA

CH

ING

.

213

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. Thespecific diagram for a particular code is pasted inside the machine on one of the enclosure panels.

NOTES

PRO-MIG 135

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

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 INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOSCONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS AETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER-STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Do not touch electrically live parts orelectrode with skin or wet clothing.

● Insulate yourself from work andground.

● No toque las partes o los electrodosbajo carga con la piel o ropa moja-da.

● Aislese del trabajo y de la tierra.

● Ne laissez ni la peau ni des vête-ments mouillés entrer en contactavec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführendenTeile oder Elektroden mit IhremKörper oder feuchter Kleidung!

● Isolieren Sie sich von denElektroden und dem Erdboden!

● Não toque partes elétricas e elec-trodos com a pele ou roupa molha-da.

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

● Tragen Sie Augen-, Ohren- und Kör-perschutz!

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA ASPRÁTICAS DE SEGURANÇA DO EMPREGADOR.

● Keep your head out of fumes.● Use ventilation or exhaust to

remove fumes from breathing zone.

● Los humos fuera de la zona de res-piración.

● Mantenga la cabeza fuera de loshumos. Utilice ventilación oaspiración para gases.

● Gardez la tête à l’écart des fumées.● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Turn power off before servicing.

● Desconectar el cable de ali-mentación de poder de la máquinaantes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-tien.

● Strom vor Wartungsarbeitenabschalten! (Netzstrom völlig öff-nen; Maschine anhalten!)

● Não opere com as tampas removidas.● Desligue a corrente antes de fazer

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

● N’opérez pas avec les panneauxouverts ou avec les dispositifs deprotection enlevés.

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• Sales and Service through Subsidiaries and Distributors Worldwide •Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

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