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IM785
SP-
135T April, 2004
For use with machine Code Number:10971
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
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
OPERATOR’S MANUAL
Copyright © 2004 Lincoln Global Inc.
� World's Leader in Welding and Cutting Products �
� 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
i i
SAFETY
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
The engine exhaust from this product contains
Diesel engine exhaust and some of its constituents
chemicals known to the State of California to cause
are known to the State of California to cause can-
cancer, birth defects, or other reproductive harm.
cer, birth defects, and other reproductive harm.
The Above For Gasoline Engines
The Above For Diesel Engines
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 you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1� from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety� booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
FOR ENGINE 1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
powered equipment. hot.
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.
ELECTRIC AND
MAGNETIC FIELDS
____________________________________________________
may be dangerous
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 before 2.a. Electric current flowing through any conductor causes
refueling to prevent spilled fuel from vaporiz- localized Electric and Magnetic Fields (EMF). Welding
ing on contact with hot engine parts and current creates EMF fields around welding cables and
igniting. Do not spill fuel when filling tank. If welding machines
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated. 2.b. EMF fields may interfere with some pacemakers, and
____________________________________________________ welders having a pacemaker should consult their physician
1.d. Keep all equipment safety guards, coversand devices in posi- before welding.
tion and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts 2.c. Exposure to EMF fields in welding may have other health
when starting, operating or repairing equipment. effects which are now not known.
____________________________________________________
2.d. All welders should use the following procedures in order to
1.e. In some cases it may be necessary to remove safety
minimize exposure to EMF fields from the welding circuit:
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
2.d.1. Route the electrode and work cables together - Secure
maintenance requiring their removal is complete.
them with tape when possible.
Always use the greatest care when working near moving
parts.
2.d.2. Never coil the electrode lead around your body.
___________________________________________________
1.f. Do not put your hands near the engine fan.
2.d.3. Do not place your body between the electrode and
Do not attempt to override the governor or
idler by pushing on the throttle control rods work cables. If the electrode cable is on your right
while the engine is running. side, the work cable should also be on your right side.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while 2.d.5. Do not work next to welding power source.
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate. Mar �95
ii ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
4.a. Use a shield with the proper filter and cover
kill. plates to protect your eyes from sparks and
3.a. The electrode and work (or ground) circuits
the rays of the arc when welding or observing
are electrically “hot� when the welder is on. open arc welding. Headshield and filter lens
Do not touch these “hot� parts with your bare should conform to ANSI Z87. I standards.
skin or wet clothing. Wear dry, hole-free
gloves to insulate hands. 4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
3.b. Insulate yourself from work and ground using dry insulation. the arc rays.
Make certain the insulation is large enough to cover your full
area of physical contact with work and ground. 4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
In addition to the normal safety precautions, if welding themselves to the arc rays or to hot spatter or metal.
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
FUMES AND GASES
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
can be dangerous.
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use 5.a. Welding may produce fumes and gases
the following equipment: hazardous to health. Avoid breathing these
� Semiautomatic DC Constant Voltage (Wire) Welder. fumes and gases.When welding, keep
� DC Manual (Stick) Welder. your head out of the fume. Use enough
� AC Welder with Reduced Voltage Control. ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
3.c. In semiautomatic or automatic wire welding, the electrode, welding with electrodes which require special
electrode reel, welding head, nozzle or semiautomatic ventilation such as stainless or hard facing (see
welding gun are also electrically “hot�. instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
3.d. Always be sure the work cable makes a good electrical which produce highly toxic fumes, keep exposure as
connection with the metal being welded. The connection low as possible and below Threshold Limit Values (TLV)
should be as close as possible to the area being welded. using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
3.e. Ground the work or metal to be welded to a good electrical respirator may be required. Additional precautions are
(earth) ground. also required when welding on galvanized steel.
5.b. Do not weld in locations near chlorinated hydrocarbon vapors
3.f. Maintain the electrode holder, work clamp, welding cable and
coming from degreasing, cleaning or spraying
welding machine in good, safe operating condition. Replace
operations.The heat and rays of the arc can react with sol-
damaged insulation.
vent vapors to form phosgene, a highly toxic gas, and other
irritating products.
3.g. Never dip the electrode in water for cooling.
5.c. Shielding gases used for arc welding can displace air and
3.h. Never simultaneously touch electrically “hot� parts of
cause injury or death. Always use enough ventilation,
electrode holders connected to two welders because voltage
especially in confined areas, to insure breathing air is safe.
between the two can be the total of the open circuit voltage
of both welders.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including the
3.i. When working above floor level, use a safety belt to protect
material safety data sheet (MSDS) and follow your
yourself from a fall should you get a shock.
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar �95
iii iii
SAFETY
WELDING SPARKS can CYLINDER may explode
cause fire or explosion. if damaged.
6.a. Remove fire hazards from the welding area.
7.a. Use only compressed gas cylinders
If this is not possible, cover them to prevent
containing the correct shielding gas for the
the welding sparks from starting a fire.
process used and properly operating
Remember that welding sparks and hot
regulators designed for the gas and
materials from welding can easily go through small cracks
pressure used. All hoses, fittings, etc. should be suitable for
and openings to adjacent areas. Avoid welding near
the application and maintained in good condition.
hydraulic lines. Have a fire extinguisher readily available.
7.b. Always keep cylinders in an upright position securely
6.b. Where compressed gases are to be used at the job site,
chained to an undercarriage or fixed support.
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting� (ANSI
7.c. Cylinders should be located:
Standard Z49.1) and the operating information for the
� Away from areas where they may be struck or subjected to
equipment being used.
physical damage.
6.c. When not welding, make certain no part of the electrode
� A safe distance from arc welding or cutting operations and
circuit is touching the work or ground. Accidental contact
any other source of heat, sparks, or flame.
can cause overheating and create a fire hazard.
7.d. Never allow the electrode, electrode holder or any other
6.d. Do not heat, cut or weld tanks, drums or containers until the
electrically “hot� parts to touch a cylinder.
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
7.e. Keep your head and face away from the cylinder valve outlet
inside. They can cause an explosion even though they have
when opening the cylinder valve.
been “cleaned�. For information, purchase “Recommended
Safe Practices for the Preparation for Welding and Cutting of
7.f. Valve protection caps should always be in place and hand
Containers and Piping That Have Held Hazardous
tight except when the cylinder is in use or connected for
Substances�, AWS F4.1 from the American Welding Society
use.
(see address above).
7.g. Read and follow the instructions on compressed gas
6.e. Vent hollow castings or containers before heating, cutting or
cylinders, associated equipment, and CGA publication P-l,
welding. They may explode.
“Precautions for Safe Handling of Compressed Gases in
Cylinders,� available from the Compressed Gas Association
6.f. Sparks and spatter are thrown from the welding arc. Wear oil
1235 Jefferson Davis Highway, Arlington, VA 22202.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
FOR ELECTRICALLY
Always wear safety glasses with side shields when in a
powered equipment.
welding area.
6.g. Connect the work cable to the work as close to the welding
8.a. Turn off input power using the disconnect
area as practical. Work cables connected to the building
switch at the fuse box before working on
framework or other locations away from the welding area
the equipment.
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate cir-
8.b. Install equipment in accordance with the U.S. National
cuits. This can create fire hazards or overheat lifting chains
Electrical Code, all local codes and the manufacturer’s
or cables until they fail.
recommendations.
6.h. Also see item 1.c.
8.c. Ground the equipment in accordance with the U.S. National
Electrical Code and the manufacturer’s recommendations.
Mar �95
iv iv
SAFETY
5. Toujours porter des lunettes de sécurité dans la zone de
PRÉCAUTIONS DE SÛRETÉ soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
Pour votre propre protection lire et observer toutes les instruc-
tions et les précautions de sûreté specifiques qui parraissent
6. Eloigner les matériaux inflammables ou les recouvrir afin de
dans ce manuel aussi bien que les précautions de sûreté
prévenir tout risque d’incendie dû aux étincelles.
générales suivantes:
7. Quand on ne soude pas, poser la pince à une endroit isolé de
Sûreté Pour Soudage A L’Arc
la masse. Un court-circuit accidental peut provoquer un
1. Protegez-vous contre la secousse électrique:
échauffement et un risque d’incendie.
a. Les circuits à l’électrode et à la piéce sont sous tension
8. S’assurer que la masse est connectée le plus prés possible
quand la machine à souder est en marche. Eviter toujours
de la zone de travail qu’il est pratique de le faire. Si on place
tout contact entre les parties sous tension et la peau nue
la masse sur la charpente de la construction ou d’autres
ou les vétements mouillés. Porter des gants secs et sans
endroits éloignés de la zone de travail, on augmente le risque
trous pour isoler les mains.
de voir passer le courant de soudage par les chaines de lev-
b. Faire trés attention de bien s’isoler de la masse quand on
age, câbles de grue, ou autres circuits. Cela peut provoquer
soude dans des endroits humides, ou sur un plancher
des risques d’incendie ou d’echauffement des chaines et des
metallique ou des grilles metalliques, principalement dans
câbles jusqu’� ce qu’ils se rompent.
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
9. Assurer une ventilation suffisante dans la zone de soudage.
masse.
Ceci est particuliérement important pour le soudage de tôles
c. Maintenir le porte-électrode, la pince de masse, le câble
galvanisées plombées, ou cadmiées ou tout autre métal qui
de soudage et la machine à souder en bon et sûr état
produit des fumeés toxiques.
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
10. Ne pas souder en présence de vapeurs de chlore provenant
refroidir.
d’opérations de dégraissage, nettoyage ou pistolage. La
e. Ne jamais toucher simultanément les parties sous tension
chaleur ou les rayons de l’arc peuvent réagir avec les
des porte-électrodes connectés à deux machines à soud-
vapeurs du solvant pour produire du phosgéne (gas forte-
er parce que la tension entre les deux pinces peut être le
ment toxique) ou autres produits irritants.
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
11. Pour obtenir de plus amples renseignements sur la sûreté,
courant pour soudage semi-automatique, ces precautions
voir le code “Code for safety in welding and cutting� CSA
pour le porte-électrode s’applicuent aussi au pistolet de
Standard W 117.2-1974.
soudage.
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. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
PRÉCAUTIONS DE SÛRETÉ POUR
partie du corps.
LES MACHINES À SOUDER À
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
TRANSFORMATEUR ET À
donc:
REDRESSEUR
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude 1. Relier à la terre le chassis du poste conformement au code
ou quand on regarde l’arc. de l’électricité et aux recommendations du fabricant. Le dis-
b. Porter des vêtements convenables afin de protéger la positif de montage ou la piece à souder doit être branché Ã
peau de soudeur et des aides contre le rayonnement de une bonne mise à la terre.
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au 2. Autant que possible, I’installation et l’entretien du poste
soudage à l’aide d’écrans appropriés et non-inflamma- seront effectués par un électricien qualifié.
bles.
3. Avant de faires des travaux à l’interieur de poste, la
4. Des gouttes de laitier en fusion sont émises de l’arc de debrancher à l’interrupteur à la boite de fusibles.
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse, 4. Garder tous les couvercles et dispositifs de sûreté à leur
pantalons sans revers, et chaussures montantes. place.
Mar. �93
v v
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You to take pride in operating this Lincoln Electric Company product
•â?¢â?? as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found 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 you
have 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 packet
accompanying 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.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy 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:
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi vi
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Identify and Locate Components ...........................................................................A-2
Select Suitable Location ........................................................................................A-3
Output Connections ...............................................................................................A-3
Input Connections..................................................................................................A-6
Code Requirements ..............................................................................................A-6
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description ...............................................................................................B-1
Design Features ....................................................................................................B-1
Welding Capability .................................................................................................B-2
Limitations..............................................................................................................B-2
Controls and Settings ............................................................................................B-2
Welding Operations ...............................................................................................B-3
Overload Protection ...............................................................................................B-6
Application Chart ...................................................................................................B-7
Accessories .....................................................................................................Section C
Accessories ...........................................................................................................C-1
Replacement Parts ................................................................................................C-2
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Items Requiring No Maintenance ..........................................................................D-1
Routine Maintenance.............................................................................................D-1
Gun and Cable Maintenance.................................................................................D-2
Component Replacement Procedures ..................................................................D-3
Changing Liner ......................................................................................................D-4
Gun Handle Parts ..................................................................................................D-4
Troubleshooting ..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.........................................................................E-2 THRU E-4
Wiring Diagrams ..............................................................................................Section F
SP-135T Wiring Diagram .......................................................................................F-1
Parts Lists .....................................................................................P451 Series, P202-E
A-1 A-1
INSTALLATION
TECHNICAL SPECIFICATIONS � SP-135T
INPUT � SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current
120V/60Hz 20 Amps - Rated Output
RATED OUTPUT
Duty Cycle Amps Volts at Rated Amperes
20% Duty Cycle 90 19
OUTPUT
Welding Current Range Maximum-Open Circuit Voltage Wire Speed Range
25-135 Amps 29V 50 - 300 in/min
(1.3 - 7.6 m/min)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse or
Output Mode Input Voltage Breaker Size1 Input Amps Power Cord Extension Cord
Three Conductor
#14 AWG
(2.1 mm2) or Larger
Up to 25 Ft. (7.6 mm)
RATED 120V/60Hz 20 Amp 20 15 Amp, 125V,
Three Prong Plug Three Conductor
(NEMA Type 5-15P) #12 AWG
(3.3 mm2) or Larger
Up to 50 Ft. (15.2 mm)
PHYSICAL DIMENSIONS
Height Width Depth Weight
12.0 in 9.75 in 16.5 in 48 Ibs
305 mm 248 mm 419 mm 21.8 kg
1If connected to a circuit protected by fuses use Time Delay Fuse marked “D�.
SP-135T
A-2 A-2
INSTALLATION
Read entire installation section before starting
installation.
SAFETY PRECAUTIONS FIGURE A.1
WARNING
ELECTRIC SHOCK can kill. 2
1
� Only qualified personnel should perform
this installation.
� Only personnel that have read and under-
stood the SP-135T Operating Manual
should install and operate this equipment.
� Machine must be plugged into a receptacle
which is grounded per any national, local
or other applicable electrical codes.
4
� The SP-135T power switch is to be in the
OFF (“O�) position when installing work
cable and gun and when connecting power
cord to input power.
6
3
IDENTIFY AND LOCATE
COMPONENTS
If you have not already done so, unpack the SP-135T
from its carton and remove all packing material
5
around the SP-135T. Remove the following loose
items from the carton (see Figure A.1):
1. SP-135T
2. Gun and cable assembly(1)
8
3. Literature and miscellaneous including: 7
a) This operating manual
b) 6 extra .023"-.025� (0.6 mm) contact tips
c) Hex key wrench for removal of drive roll.
4. 10 ft (3.0 m) work cable.
5. Work clamp.
6. 2 LB. Sample Spool of Super Arc L-56 .025 MIG
Wire.
7. Handshield with filter plate and lens.
8. Adjustable mixed-Gas Regulator & Hose.
For available options and accessories refer to the
Accessories Section of this manual.
As shipped from the factory, the SP-135T gun liner
1)
is ready to feed .023� (0.6 mm) -.035 (0.9 mm) wire.
The contact tip is sized for .023�-.025� (0.6 mm) wire
feeding.
SP-135T
A-3 A-3
INSTALLATION
Work Clamp Installation
SELECT SUITABLE LOCATION
Attach the work clamp per the following:
Locate the welder in a dry location where there is free
circulation of clean air into the louvers in the back and
1. Unplug the machine or turn the power switch to the
out the front of the unit. A location that minimizes the
“OFF� position.
amount of smoke and dirt drawn into the rear louvers
reduces the chance of dirt accumulation that can block
2. Insert the work cable terminal lug with the larger
air passages and cause overheating.
hole through the strain relief hole in the work clamp
as shown in Figure A-3.
STACKING
3. Fasten securely with the bolt and nut provided.
SP-135T’s cannot be stacked.
TILTING
FIGURE A.3
Each machine must be placed on a secure, level sur-
face, or on a recommended cart. The machine may Strain Relief Hole
topple over if this procedure is not followed.
Work Cable
Nut & Bolt
OUTPUT CONNECTIONS
Refer to Figure A.2.
1. Work Cable Access Hole. Work Clamp
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.
4
5
DO NOT SWITCH
WHEN WELDING
+
SP-135T 8
-
6
3 7
1 2
FIGURE A.2
SP-135T
A-4 A-4
INSTALLATION
Connecting Gun Cable to the SP-135T
Work Cable Installation
1. Refer to Figure A.2. Unplug the machine or turn
Refer to Figure A.2.
power switch to the OFF “O� position.
1. Open the wire feed section door on the right side of
2. Pass the insulated terminals of the gun trigger con-
the SP-135T.
trol leads, one at a time, through the Gun Cable
and Control Lead Access Slot (2) in the case front.
2. Pass the end of the work cable that has the termi-
The leads are to be routed under the Wire Feed
nal lug with the smaller hole through the Work
Gearbox (6) and through the Cable Hanger (7) on
Cable Access Hole (1) in the case front.
the inner panel.
3. Route the cable under and around the back of the
3. Insert the connector on the gun conductor cable
Wire Feed Gearbox (6).
through the Gun Cable Access Hole (2) in the SP-
135T case front. Make sure the connector is all the
4. For GMAW Only: Refer to Figure A.2. As deliv-
way in the brass connector block. Unscrew thumb-
ered, the machine is connected for positive elec-
screw on the connector block a few turns if gun
trode polarity. This is the appropriate configuration
connector will not insert fully. Rotate the connector
for the GMAW (MIG) process. To complete installa-
so control leads are on the underside and tighten
tion, use the provided wing nut to connect the work
the Thumbscrew (8) in the connector block.
cable’s terminal lug to the negative (�) output ter-
minal (5) located above the Wire Feed Gearbox
4. Connect the gun trigger control lead terminals to
(6). Make sure that both wing nuts are tight.
the two insulated 1/4" (6.4 mm) tab terminal con-
5. For Innershield Only: Refer to Figure A.4. To wire nector bushings located below the “Gun Trigger
for negative polarity (required for the Innershield Connection� decal in the wire feed section (4).
process), connect the short cable attached to the Either lead can go to either connector. Form the
connector block (1) to the negative (�) output termi- leads so that they are as close as possible to the
nal (2) and the work cable (3) to the positive (+) inside panel.
terminal (4).
CAUTION
4
3
If the gun trigger switch being used is other than
that supplied with the SP-135T, the switch must be
2
a normally open, momentary switch. The terminals
of the switch must be insulated from the welding
circuit. Malfunction of the SP-135T may result if
1 this switch shorts to the SP-135T welding output
circuit or is common to any electrical circuit other
than the SP-135T trigger circuit.
FIGURE A.4
GAS CONNECTION
GUN INSTALLATION
When using the GMAW process, a cylinder of shield-
As shipped from the factory, the SP-135T is ready to
ing gas, must be obtained. For more information about
feed .023" � .025" (0.6 mm) solid wire. If .030-
selecting gas cylinders for use with the SP-135T refer
.035"(0.8-0.9mm) solid wire is to be used, change the
to the ACCESSORIES section.
contact tip to the appropriate size.
NOTE: If .035" (0.9 mm) Innershield flux-cored wire is
to be used, assemble the gasless nozzle and, 035"
contact tip on to gun and reverse drive roll.
SP-135T
A-5 A-5
INSTALLATION
2. With the cylinder securely installed, remove the
WARNING cylinder cap. Stand to one side away from the out-
CYLINDER may explode if dam- let and open the cylinder valve very slightly for an
aged. Keep cylinder upright and instant. This blows away any dust or dirt which may
chained to support have accumulated in the valve outlet.
� Keep cylinder away from areas
where it may be damaged.
WARNING
� Never lift welder with cylinder
attached. BE SURE TO KEEP YOUR FACE AWAY FROM
� Never allow welding electrode to THE VALVE OUTLET WHEN “CRACKING� THE
touch cylinder. VALVE. Never stand directly in front of or behind
the flow regulator when opening the cylinder
� Keep cylinder away from welding
valve. Always stand to one side.
or other live electrical circuits.
3. Attach the flow regulator to the cylinder valve and
tighten the union nut securely with a wrench.
WARNING
NOTE: If connecting to 100% CO2 cylinder, make
BUILDUP OF SHIELDING GAS may
certain the plastic washer is seated in the fitting
harm health or kill.
that attaches to the CO2 cylinder.
� Shut off shielding gas supply
when not in use.
4. Refer to Figure A.6. Attach one end of inlet gas
� SEE AMERICAN NATIONAL hose to the outlet fitting of the flow regulator and
STANDARD Z-49.1, “SAFETY IN tighten the union nut securely with a wrench.
WELDING AND CUTTING� PUB- Connect the other end to the SP-135T Gas
LISHED BY THE AMERICAN Solenoid Inlet Fitting (5/8-18 female threads � for
WELDING SOCIETY. CGA � 032 fitting). Make certain the gas hose is
not kinked or twisted.
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 earth
ground. Refer to Figure A.5.
Cylinder Valve
Flow Regulator
Gas Hose
FIGURE A.5
SP-135T
A-6 A-6
INSTALLATION
INPUT CONNECTIONS Requirements For Rated Output
A power cord with a 15 amp, 125 volt, three prong
Refer to Figure A.6.
plug (NEMA Type 5-15P) is factory installed on the
SP-135T. Connect this plug to a mating grounded
The SP-135T has a power input cable located on the
receptacle which is connected to a 20 amp branch cir-
rear of the machine.
cuit with a nominal voltage rating of 115 to 125 volts,
60 Hertz, AC only.
The rated output with this installation is 90 amps,19
Volts, 20% duty cycle (2 minutes of every 10 minutes
used for welding).
CAUTION
GAS SOLENOID
INLET FITTING
POWER INPUT Do not connect the SP-135T to an input power
CABLE supply with a rated voltage that is greater than 125
volts.
Do not remove the power cord ground prong.
FIGURE A.6
CODE REQUIREMENTS FOR INPUT
CONNECTIONS
WARNING
This welding machine must be connected to a
power source in accordance with applicable elec-
trical codes.
The National Electrical Code provides standards
for amperage handling capability of supply con-
ductors based on duty cycle of the welding
source.
If there is any question about the installation
meeting applicable electrical code requirements,
consult a qualified electrician.
SP-135T
B-1 B-1
OPERATION
Read entire operation section before GENERAL DESCRIPTION
operating the SP-135T.
The SP-135T is a complete semiautomatic constant-
voltage DC wire feeder / power source arc welder. It
has been designed for workshop, hobby, automotive
WARNING and light maintenance. Included is a tap-switch con-
trolled, single phase constant voltage transformer /
ELECTRIC SHOCK can kill. rectifier power source and a wire feeder welding gun
for feeding .023 - .025� (0.6 mm) through .030� (0.8
� Do not touch electrically live
mm) solid steel electrode. An optional kit is available
parts or electrode with skin or
for feeding .035� (0.9 mm) Innershield® NR-211-MP
wet clothing. Insulate yourself
flux-cored wire.
from work and ground.
� Always wear dry insulating
The SP-135T is ideally suited for individuals having
gloves.
access to 120 volt AC input power, and wanting the
ease of use, quality and dependability of both gas
metal arc welding or GMAW (also known as MIG
FUMES AND GASES can be welding) and the Innershield electrode process (self
dangerous. shielded flux cored or FCAW). The SP-135T is a
rugged and reliable machine that has been designed
� Keep your head out of fumes.
for dependable service and long life.
� Use ventilation or exhaust to
remove fumes from breathing
RECOMMENDED PROCESSES
zone.
The SP-135T can be used for welding mild steel using
the Gas Metal Arc Welding (GMAW or MIG, Metal
WELDING SPARKS can Inert Gas) single pass process, which requires a sup-
ply of shielding gas, or the flux-cored arc welding
cause fire or explosion.
(FCAW) process using Innershield® electrode wire.
� Keep flammable material away.
The SP-135T is configured for use with the GMAW
� Do not weld on closed contain- process as delivered from the factory.
ers.
OPERATIONAL CONTROLS
The SP-135T has the following controls as standard:
Control Power ON/OFF Switch, Voltage Control, Wire
Speed Control, Trigger Switch, and a Circuit Breaker.
ARC RAYS can burn eyes
and skin. DESIGN FEATURES
G Operates on 120 volt input
� Wear eye, ear and body protec-
tion.
G “Cold electrode� until gun trigger is pressed for an
added measure of safety.
G Overload protection � incorporates both a thermo-
stat and a circuit breaker.
G Quality wire drive with electronic overload protec-
Observe all safety information throughout tion.
this manual. G “Quick Release� idle roll pressure arm is easily
adjusted.
G Reversible, dual groove drive roll. Drive roll will
feed .023 � .025� (0.6 mm) and .030" - .035" (0.8 -
0.9 mm) diameter wire.
SP-135T
B-2 B-2
OPERATION
G No external shielding gas is required when used 5. Gun Trigger - Activates welding output, wire feed,
with Lincoln Innershield .035� (0.9 mm) NR®-211- and gas solenoid operation. Releasing the trigger
MP electrode. deactivates welding and simultaneously activates
the “burnback� function so that the welding wire
G Accommodates both 4� (100 mm) diameter and 8�
does not stick in the weld puddle.
(200 mm) diameter spools of wire.
WELDING CAPABILITY
The SP-135T is rated at 90 amps, 19 volts, at 20%
2
duty cycle on a ten minute basis. It is capable of high-
1
er output currents at lower duty cycles.
3
LIMITATIONS DO NOT SWITCH
WHEN WELDING
Arc Gouging cannot be performed with the SP-135T.
The SP-135T is not recommended for pipe thawing or
SP-135T
TIG welding.
CONTROLS AND SETTINGS
Refer to Figure B.1a.
1. Control Power ON/OFF Switch
FIGURE B.1a
� When the power is on the
fan motor will run and air will be
exhausted out the louvers in the
OFF
front of the machine. The weld-
ing output and wire feeder
remain off until the gun trigger
+
is pressed. 4
ON -
2. Wire Speed Control �
Controls the wire feed speed
from 50 � 300 in /min (1.3 �
7.6 m/min). The control can
WIRE SPEED
be preset on the dial to the
setting specified on the SP-
135T Application Chart
located on the inside of the
wire feed section door.
3. Voltage Control � A 4-posi-
5
tion tap selector switch gives
full range adjustment of
FIGURE B.1b
power source output voltage.
ARC VOLTS
Do not switch while welding.
Refer to Figure B.1b.
4. Circuit Breaker � Protects machine from damage if
maximum output is exceeded. Button will extend
out when tripped (Manual reset).
SP-135T
B-3 B-3
OPERATION
WELDING OPERATIONS 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 the
SEQUENCE OF OPERATION
shaft and remove the outside plastic wire spool spin-
dle. The spindle can be stored in the wire feed com-
Wire Loading
partment. A 4� (100 mm) diameter spool is mounted
Refer to Figures B.2 and B.3.
directly on the 5/8� (16 mm) diameter shaft and held in
place with the previously removed hardware. Also
The machine power switch should be turned to the
make certain the start end of the wire, which may pro-
OFF (“O�) position before working inside the wire feed
trude through the side of the spool does not contact
enclosure.
any metallic case parts.
The welder is shipped from the factory ready to feed
FIGURE B.3
8" (200 mm) diameter spools with 2.2" (56 mm) maxi-
mum width. These spools fit on a 2" (51 mm) diameter
spindle that has a built in, adjustable friction brake to
prevent overrun of the spool and excess slack in the
wire.
4" Wire Spool
Wire Spindle Shaft
Note:When loading and removing the 8� Spools make
sure that the wing nut (inside the wire spool spindle
hub) is turned 90° from the wire spool spindle locking
tab. If the wing nut is positioned in line with the locking
tab, the tab cannot be depressed to load or unload the
Wing Nut
wire spool. and Spacer
FIGURE B.2 To Wire Drive
Wire Spool Spindle
8� Wire Spool
Be sure that this stud engages
the hole in the wire spool.
To Wire Drive
Wire Spool must be pushed all the way on the spindle so that the
spindle’s tab will hold it in place. The Wire Spool will rotate clock-
wise when wire is dereeled.
Load an 8� (200 mm) diameter spool on the wire spool
spindle shown in Figure B.2.
SP-135T
B-4 B-4
OPERATION
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.
2
Note: When properly adjusted, the brake should pro-
vide only enough drag to prevent overrun of the spool
and excess slack in the wire. Too much drag may
1
result in wire feeding problems, and may cause pre-
4
5
mature wear of wire drive system components.
3 The Wire Drive Feed Roll can
Wire Threading accommodate two wire sizes
by flipping the wire drive feed
Refer to Figure B.4
roll over.
1. Release the Spring Loaded Pressure Arm (1)
rotate the Idle Roll Arm (2) away from. the Wire
FIGURE B.4
Feed Drive Roll (3). Ensure that the groove size in
the feeding position on the drive roll matches the 7. Refer to Figure B.5. Remove gas nozzle and con-
wire size being used. tact tip from end of gun.
2. Carefully detach the end of the wire from the 8. Turn the SP-135T ON (“I�).
spool. To prevent the spool from unwinding,
maintain tension on the wire until after step 5. 9. Straighten the gun cable assembly.
3. Cut the bent portion of wire off and straighten the 10. Depress the gun trigger switch and feed welding
first 4� (100 mm). wire through the gun and cable. (Point gun away
from yourself and others while feeding wire.)
4. Thread the wire through the In-going guide tube Release gun trigger after wire appears at end of
(4), over the drive roll (3), and into the out-going gun.
guide tube (5). NOTE: If the wire will not feed smoothly, or if the wire
feed motor shuts off unexpectedly, see � FEEDING
5. Close the idle roll arm (2) and latch the spring PROBLEMS� section of the “TROUBLESHOOTING
loaded pressure arm (1) in place. Rotate the spool GUIDE� in this manual.
counterclockwise if required in order to take up
extra slack in the wire. 11. Turn the SP-135T OFF (“O�).
6. The idle roll pressure adjustment wing nut is facto- 12. Replace contact tip and gas nozzle.
ry set to approximately five full turns from where
the wing nut first engages the threads of the pres- 13. Refer to Figure B-6. Cut the wire off 3/8� � 1/2� (10
sure arm (1). If feeding problems occur because � 13 mm) from the end of the tip. The SP-135T is
the wire is flattened excessively, turn the pressure now ready to weld.
adjustment counter-clockwise to reduce distortion
of the wire. Slightly less pressure may be required
when using 0.023 � 0.025" (0,6 mm) wire. If the
drive roll slips while feeding wire, the pressure
should be increased until the wire feeds properly. Gun Handle
WARNING
Gas Diffuser/
Contact Tip
When inching the welding wire, the drive rolls, the
gun connector block and the gun contact tip are
Gas Nozzle
electrically energized relative to work and ground
and remain energized for several seconds after
the gun trigger is released.
FIGURE B.5
SP-135T
B-5 B-5
OPERATION
6. Refer to Figure B.7. Connect work clamp to metal
to be welded. Work clamp must make good elec-
trical contact to the workpiece. The workpiece
must also be grounded as stated in “Arc Welding
Contact Tip Safety Precautions� in the beginning of this manu-
al.
7. Position gun over joint. End of wire may be lightly
Wire Electrode
touching the work.
3/8"� 1/2"(10-13mm) Contact
8. Lower welding helmet, close gun trigger, and
Tip to Work Distance(CTWD)
begin welding. Hold the gun so the contact tip to
work distance is about 3/8 inch (10 mm).
FIGURE B.6
9. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
Making A Weld
out.
1. See “Process Guidelines� in this section for selec-
tion of welding wire and shielding gas and for
10. When no more welding is to be done, close valve
range of metal thicknesses that can be welded.
on gas cylinder (if used), momentarily operate gun
trigger to release gas pressure, and turn off the
2. See the Application chart on the inside of the wire
SP-135T.
feed compartment door for information on setting
the SP-135T controls. Refer to Table B.1 for alu-
minum and stainless wire.
Cleaning Tip And Nozzle
Clean the contact tip and nozzle to avoid arc bridging
3. Set the Voltage (“Vâ€?) and Wire Speed (“olo’â??) con-
between the nozzle and contact tip which can result in
trols to the settings suggested for the welding wire
a shorted nozzle, poor welds and an overheated gun.
and base metal thickness being used, refer to
Hint: Anti-stick spray or gel, available from a welding
Applications chart on the inside of the wire drive
supply distributor, may reduce buildup and aid in spat-
compartment door.
ter removal.
4. Check that the polarity is correct for the welding
wire being used and that the gas supply, if
PROCESS GUIDELINES
required, is turned on.
The SP-135T can be used for welding mild steel using
5. When using Innershield electrode, remove the gas
the GMAW, single pass, process which requires a
nozzle and install the gasless nozzle. This will
supply of shielding gas or it can be used for the self-
improve visibility of the arc and protect the gas dif-
shielded, Innershield® process (FCAW).
fuser from weld spatter. Refer to the MAINTE-
NANCE section for details on nozzle replacement.
The recommended gases and electrodes for GMAW
are welding grade CO2 gas or an argon-CO2 blended
gas (75 to 80% argon and 25 to 20% CO2) and .025"
(0.6 mm) diameter Lincoln Super Arc L-56 mild-steel
welding wire, supplied on 12-1/2 lb (5.7 kg) spools.
The recommended electrode for the self-shielded
GUN CABLE
process is .035� (0.9 mm) diameter Lincoln
Innershield® NR-211-MP on 10 lb (4.5 kg) spools.
This electrode can be used for all position welding of
20 gauge (1.0 mm) through 5/16" (8 mm) steel.
Thickness of 1/4" (6 mm) and 5/16" (8 mm) require
WORKPIECE
multiple passes. This wire can also be used for the
ARC
welding of galvanized coated sheet metal.
WORK CLAMP
FIGURE B.7
SP-135T
B-6 B-6
OPERATION
The SP-135T is suitable for .035" aluminum wire and 2. If using a regulator with an adjustable flow meter,
.030" stainless wire. Refer to Table B.1 for recom- press the gun trigger and adjust the flow to give 15
mended procedure settings (requires K499 Argon � 20 cubic ft per hour (CFH) (7 � 10 I/min) [use 20
Regulator Kit). � 25 CFH (10 � 12 I/min) when welding out of
position or in a drafty location for CO2]. For argon
TABLE B.1 mixed gas, press the gun trigger to release gas
pressure, and adjust the flow to give 25 � 30 CFH
(12 � 14 I/min).
Voltage/Wire Speed
Shielding
Process Welding Wire Gas 22 ga 16 ga 12 ga 1/8� 3/16� 1/4�
.035 Dia(0.9mm 100% Argon B-4.5 B-8.5 D-10 NR* NR* NR* 3. Keep the cylinder valve closed, except when using
4043 Aluminum
the SP-135T. When finished welding:
Wire
16 ga 14 ga 12 ga 10 ga
MIG DC+
a) Close the cylinder valve to stop gas flow.
.030 Dia 98% Argon/ A-3 C-6 D-7.5 D-7.5
308L Stainless 2% Oxygen
b) Press the gun trigger briefly to release the pres-
Steel Wire
sure in the gas hose.
*NR (Not Recommended)
c) Turn off the SP-135T.
CHANGING MACHINE OVER TO WELDING WITH FCAW (Innershield)
FEED OTHER WIRE SIZES
When using the FCAW process, the correct drive roll
The SP-135T is shipped from the factory ready to feed and electrode polarity must be used. See Work Cable
.023�-.025� (0.6 mm) diameter wire. To operate the Installation in INSTALLATION section for changing
SP-135T with other sizes of wire, it may be necessary the polarity.
to change the contact tip and change the drive roll
over to other sizes. Refer to Changing the Contact Tip Innershield welding kit K549-1 (for .035" / 0.9mm) is
and Changing the Drive Roll, in the MAINTENANCE also available.
section, for specific information on these procedures.
OVERLOAD PROTECTION
WELDING WITH GMAW (MIG) Output Overload
The SP-135T is equipped with a circuit breaker and a
Shielding Gas thermostat which protects the machine from damage if
maximum output is exceeded. The circuit breaker but-
When using the GMAW process, obtain and install a ton will extend out when tripped. The circuit breaker
gas regulator and hose kit; K463 (for CO2) or K499 must be manually reset.
(Argon mixed) gas regulator and hose kit.
1. For CO2, open the cylinder very slowly. For argon- Thermal Protection
mixed gas, open cylinder valve slowly a fraction of The SP-135T has a rated output duty cycle of 20%. If
a turn. When the cylinder pressure gauge pointer the duty cycle is exceeded, a thermal protector will
stops moving, open the valve fully. shut off the output until the machine cools to a reason-
able operating temperature. This is an automatic func-
tion of the SP-135T and does not require user inter-
vention. The fan continues to run during cooling.
Electronic Wire Drive Motor Protection
The SP-135T has built-in protection for wire drive
motor overload.
SP-135T
B-7 B-7
APPLICATION CHART
SP-135T
C-1 C-1
ACCESSORIES
OPTIONAL ACCESSORIES INNERSHIELD (FCAW)
CONVERSION
1. K549-1 .035" (0.9 mm) Innershield® Welding Kit
� Includes a contact tip, a gasless nozzle and a
Several changes are needed to convert the unit for
.035/.035" (0.8-0.9mm) cable liner to permit the
operation with the Innershield (FCAW) process. The
Magnumâ„? 100L gun and cable to use .035" (0.9
K549-1 or K549-2 Innershield Kits include all the nec-
mm) diameter flux-cored electrode. The fitting on
essary accessories for this conversion and are provid-
the end of the liner is stenciled with the maximum
ed for this purpose. The following conversions should
rated wire size (.045"/1.2 mm). Also included is a
be made using the contents of this kit:
10 lb. (4.5 kg.) spool of .035" (0.9 mm) Innershield
NR-211-MP.
1. Change the output polarity to DC(�). See “Work
See “Innershield (FCAW) Conversion� in this sec- Cable Installation� in Installation section for details.
tion for installation instructions and MAINTE-
NANCE section for proper feeding component con- 2. Install proper drive roll for the wire size selected.
figuration and installation. See “Changing Drive Roll� in Maintenance section
for details.
2. K664-2 Aluminum Feeding Kit � This kit
required for welding with .035 Aluminum wire. 3. Install the proper gun liner* and tip for the wire size
Included with this kit are a drive roll, liner and con- selected. See “Component Replacement� in
tact tip. It is important when changing between Maintenance section for details.
welding with steel wire and aluminum to
exchange these components due to the lubri- 4. Remove gas nozzle (if installed) and install gasless
cant applied to steel wire. Failure to do so may nozzle. To remove, simply unscrew.
result in contaminated welds when welding alu-
minum. 5. Load wire into machine and thread into gun and
cable per “Welding Wire Loading� section.
3. K520 Utility Cart � Designed to transport the
Lincoln family of small welders. Has provisions for * The factory installed Gun Liner will feed .025-.035 (0.6-0.9mm)
mounting a single gas cylinder. Has front casters wire.
and large rear wheels. Handle height is easily
adjustable. Bottom tray provided for tools and
accessories. Easy assembly required; takes less
than 15 minutes.
4. K586-1 Deluxe Adjustable Gas Regulator &
Hose Kit � Accommodates CO2 or mixed Gas
Cylinders.
SP-135T
C-2 C-2
ACCESSORIES
REPLACEMENT PARTS
Complete Gun and Cable Assembly
L8311-6 (K530-4)
Contact Tip .025� (0.6 mm)
KP2039-1B1
Contact Tip .030� (0.8 mm)
KP2039-2B1
Contact Tip .035� (0.9 mm)
KP2039-3B1
Contact Tip-Tapered .025� (0.6 mm)
KP2052-1B1
Contact Tip-Tapered .030� (0.8 mm)
KP2052-2B1
Contact Tip-Tapered .035� (0.9 mm)
KP2052-3B1
Liner .023 - .035� (0.6 - 0.9 mm)
KP1937-3
Gas Diffuser
KP2040-1
Gas Nozzle
KP1938-1
Gas Nozzle-Tip Recessed 3/8� (9.5 mm)
Opening I.D.
KP1942-1
Gas Nozzle-Tip Recessed 1/2� (12.7 mm)
Opening I.D.
KP1942-2
Gas Nozzle-Tip Recessed 5/8� (15.9 mm)
Opening I.D.
KP1942-3
Spot Welding Nozzle
KP1956-1
Gasless Nozzle (Innershield Only)
KP1939-1
SP-135T
D-1 D-1
MAINTENANCE
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
� Disconnect input power by removing
plug from receptacle before working
inside SP-135T. Use only grounded
receptacle. Do not touch electrically
“hot� parts inside SP-135T.
� Have qualified personnel do the mainte-
nance and trouble shooting work.
ROUTINE MAINTENANCE
POWER SOURCE COMPARTMENT
No user serviceable parts inside! Do not attempt to perform
service in the power source (fixed) side of the SP-135T. Take
the unit to an authorized Lincoln Service Center if you experi-
ence problems. NO maintenance is required.
In extremely dusty locations, dirt may clog the air passages
causing 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 dust
build-up on internal parts.
WIRE FEED COMPARTMENT
1. When necessary, vacuum accumulated dirt from gearbox
and wire feed section.
2. Occasionally inspect the incoming guide tube and clean
inside diameter if necessary.
3. Motor and gearbox have lifetime lubrication and require no
maintenance.
FAN MOTOR
Has lifetime lubrication � requires no maintenance.
WIRE REEL SPINDLE
Requires no maintenance. Do not lubricate shaft.
SP-135T
D-2 D-2
MAINTENANCE
2. Replace worn contact tips as required. A variable
GUN AND CABLE
or “hunting� arc is a typical symptom of a worn con-
MAINTENANCE
tact tip. To install a new tip, choose the correct size
contact tip for the electrode being used (wire size is
FOR MAGNUMâ„? 100L GUN
stenciled on the side of the contact tip) and screw it
snugly into the gas diffuser.
Gun Cable Cleaning
Clean cable liner after using approximately 300 lbs
3. Remove spatter from inside of gas nozzle and from
(136 kg) of solid wire or 50 lbs (23 kg) of flux-cored
tip after each 10 minutes of arc time or as required.
wire. Remove the cable from the wire feeder and lay it
out straight on the floor. Remove the contact tip from
4. Be sure the gas nozzle is fully screwed onto the
the gun. Using low pressure air, gently blow out the
diffuser for gas shielded processes. For the
cable liner from the gas diffuser end.
Innershield® process, the gasless nozzle should
be screws onto the diffuser.
CAUTION
5. To remove gun tube from gun, remove gas nozzle
Excessive pressure at the start may cause the dirt
or gasless nozzle and remove diffuser from gun
to form a plug.
tube. Remove both collars from each end of the
gun handle and separate the handle halves.
Loosen the locking nut holding the gun tube in
Flex the cable over its entire length and again blow
place against the gun end cable connector.
out the cable. Repeat this procedure until no further
Unscrew gun tube from cable connector. To install
dirt comes out.
gun tube, screw the locking nut on the gun tube as
far as possible. Then screw the gun tube into the
cable connector until it bottoms. Then unscrew (no
Contact Tips, Nozzles, and Gun Tubes
more than one turn) the gun tube until its axis is
1. Dirt can accumulate in the contact tip hole and
perpendicular to the flat sides of the cable connec-
restrict wire feeding. After each spool of wire is
tor and pointed in the direction of the trigger.
used, remove the contact tip and clean it by push-
Tighten the locking nut so as to maintain the proper
ing a short piece of wire through the tip repeatedly.
relationship between the gun tube and the cable
Use the wire as a reamer to remove dirt that may
connector. Replace the gun handle, trigger and dif-
be adhering to the wall of the hole through the tip.
fuser. Replace the gas nozzle or gasless nozzle.
CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM
Contact Tip Cable Liner Drive Roll
Components shipped with KP2039-1B1 KP1937-3 KP665-035
SP-135T� .025� (0.6mm) .030-.035� 2 Smooth grooves
(0.8-0.9mm) Small .023-.025 (0.6mm)
Large .030� -.035" (0.8mm)-(0.9mm
K549-1 .035� (0.9mm) KP2039-3B1 KP1937-3 Use Large groove of Drive Roll
Innershield Welding Kit .035� (0.9mm) .(0.8-0.9mm) included with machine.
K664-2 .035 (0.9mm) KP2078-1B1 KP1959-1 M19631
Aluminum 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. Failure
to do so may result in contaminated welds when welding aluminum.
SP-135T
D-3 D-3
MAINTENANCE
COMPONENT
8. Push a length of straightened welding wire through
REPLACEMENT
the wire feeder guide tubes and adjust the position
PROCEDURES of the drive roll so that the groove is centered on
the wire. Make certain the set screw is located on
CHANGING THE CONTACT TIP the flat portion of the shaft and tighten.
1. Refer to Figure D.2. Remove the gas nozzle from FIGURE D.1
the gun by unscrewing counter-clockwise.
2. Remove the existing contact tip from the gun by
unscrewing counter-clockwise.
3. Insert and hand tighten desired contact tip.
4. Replace gas nozzle.
3
CHANGING DRIVE ROLL
The drive roll has two grooves; one for .023" � .025"
2
(0.6 mm) solid steel electrode and a larger knurled
groove for .030" (0.8 mm) solid and .035" (0.9 mm)
flux-cored steel electrode. As shipped, the drive roll is
1
installed in the .030"/.035" (0.8/0.9 mm) position.
If .023" � .025" (0.6 mm) wire is to be used, the drive
roll must be reversed as follows:
1. Connect the machine to its rated input power per
instructions in Installation section.
2. Release the spring-loaded idle arm tensioner,Item 2, and
lift the idle roll arm, Item 3, away from the drive roll, Item
1. (See Figure D.1)
3. Turn the power switch to ON (marked “I�).
4. Set the wire speed to minimum and jog the drive
unit with the trigger switch until the drive roll set
screw is facing up.
CAUTION
When inching the welding wire, the drive rolls,
gun connector block, and gun contact tip are
energized relative to work and ground and remain
energized 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" (2.0
mm) hex wrench supplied.
7. Remove the drive roll, flip over and reinstall with the
.023 � .025" (0.6 mm) groove (the smaller groove)
closest to the gearbox.
SP-135T
D-4 D-4
MAINTENANCE
1-1/4 (31.8 mm)
Liner Trim Length
Gas Diffuser
Gas Nozzle or
Gasless Nozzle
Set Screw Brass Cable
Connector
Liner Assembly
(Liner bushing to be sealed tight
against brass cable connector)
FIGURE D.2 8. Screw the gas diffuser onto the end of the gun tube
Liner trim length and securely tighten.
CHANGING LINER
9. Replace the contact tip and nozzle.
NOTICE: The variation in cable lengths prevents the
interchangeability of liners. Once a liner has been cut
GUN HANDLE PARTS
for a particular gun, it should not be installed in anoth-
er gun unless it can meet the liner cutoff length
The gun handle consists of two halves that are held
requirement. Refer to Figure D.2.
together with a collar on each end. To open up the
handle, turn the collars approximately 60 degrees
1. Remove the gas nozzle from the gun by unscrew-
counter-clockwise until the collar reaches a stop. Then
ing counter-clockwise.
pull the collar off the gun handle. If the collars are diffi-
cult to turn, position the gun handle against a corner,
2. Remove the existing contact tip from the gun by
place a screwdriver against the tab on the collar and
unscrewing counter-clockwise.
give the screwdriver a sharp blow to turn the collar
past an internal locking rib. See Figure D-3.
3. Remove the gas diffuser from the gun tube by
unscrewing 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 liner
out of the cable.
5. Insert a new untrimmed liner into the connector end
of the cable. Be sure the liner bushing is stenciled
âž?
Counter-clockwise
appropriately 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 installed
onto the end of the gun tube.
7. With the gas nozzle and diffuser removed from the
gun tube, be sure the cable is straight, and then
trim the liner to the length shown in the Figure D.2.
FIGURE D.3
Remove any burrs from the end of the liner.
SP-135T
E-1 E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
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 and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you Step 3. RECOMMENDED COURSE OF ACTION
locate and repair possible machine malfunctions. This column provides a course of action for the
Simply follow the three-step procedure listed below. Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMP- If you do not understand or are unable to perform the
TOMS)�. This column describes possible symptoms Recommended Course of Action safely, contact your
that the machine may exhibit. Find the listing that local Lincoln Authorized Field Service Facility.
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE� lists
the obvious external possibilities that may contribute
to the machine symptom.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SP-135T
E-2 E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage None
is evident. Contact your local Authorized Field
Service Facility.
No wire feed, weld output or gas 1. Make sure correct voltage is
flow when gun trigger is pulled. Fan applied to the machine (115vac).
does NOT operate.
2. Make certain that power switch
is in the ON position.
3. Make sure circuit breaker is
reset. If all recommended possible areas
of misadjustment have been
No wire feed, weld output or gas 1. The thermostat may be tripped checked and the problem persists,
flow when gun trigger is pulled Fan due to overheating. Let machine Contact your local Lincoln
operates normally. cool. Weld at lower duty cycle. Authorized Field Service
Facility.
2. Check for obstructions in air
flow. Check Gun Trigger connec-
tions. See Installation section.
3. Gun trigger may be faulty.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SP-135T
E-3 E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
FEEDING PROBLEMS
No wire feed when gun trigger is 1. If the wire drive motor is running
pulled. Fan runs, gas flows and make sure that the correct drive
machine has correct open circuit rolls are installed in the machine.
voltage (32VDC maximum) � weld If all recommended possible areas
output. 2. Check for clogged cable liner or of misadjustment have been
contact tip. checked and the problem persists,
Contact your local Lincoln
3. Check for proper size cable liner Authorized Field Service
and contact tip. Facility.
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
GAS FLOW PROBLEMS
Low or no gas flow when gun 1. Check gas supply, flow regulator
trigger is pulled. Wire feed, weld and gas hoses.
output and fan operate normally.
2. Check gun connection to If all recommended possible areas
machine for obstruction or leaky of misadjustment have been
seals. checked and the problem persists,
Contact your local Lincoln
Authorized Field Service
Facility.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SP-135T
E-4 E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
PROBLEMS POSSIBLE AREAS OF RECOMMENDED
(SYMPTOMS) MISADJUSTMENT(S) COURSE OF ACTION
WELDING PROBLEMS
Arc is unstable � Poor starting 1. Check for correct input voltage
to machine � 115vac.
2. Check for proper electrode
polarity for process.
3. Check gun tip for wear or dam-
age and proper size � Replace.
If all recommended possible areas
4. Check for proper gas and flow of misadjustment have been
rate for process. (For MIG only.) checked and the problem persists,
Contact your local Lincoln
5. Check work cable for loose or Authorized Field Service
faulty connections. Facility.
6. Check gun for damage or
breaks.
7. Check for proper drive roll orien-
tation and alignment.
8. Check liner for proper size.
CAUTION
If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your
Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.
SP-135T
F-1
WARNING
Do not operate with covers removed.
Disconnect input power by unplugging power cord before servicing.
Do not touch electrically live parts
J1
CONTROL P.C. BOARD
H2 LS1 Only qualified persons should install, use or service this machine.
HIGH VOLTAGE
can kill
H2
S1
1 2 3 4 6
5 8 9 10
7
ON-OFF H2 THERMOSTAT
N.O.
SWITCH
(MOUNTED TO
209 213 208 203 SEC. COIL)
N.C. WIRE SPEED
F1 CR1
214 539
204
541 N.C.
5K
H1
115V/60HZ GUN TRIGGER
R2
115V/60HZ GAS
FAN MOTOR SOLENOID
H1
24V
208 209
AUXILIARY
WINDING
213
214 (W)
-
539 WIRE
FEED
541 + MOTOR
(B)
SP-135T
OUTPUT
CIRCUIT 204
203 CHOKE
BREAKER
204
DIAGRAMS
S2
204
SELECTOR D1
H1
SWITCH D2 GUN CABLE
204
202
X2
CONDUCTOR
59,000 f
+
X3 N.D. C1
X4 N.B. BLOCK
40V
X5 N.D.
203
H2 X1
T1 N.A.
D4
CASE
N.A. DIODES D2 & D4 ARE MOUNTED 203
D3
GROUNDING
ON THE OUTSIDE HEATSINK.
STUD
203
N.B. DIODES D1 & D3 ARE MOUNTED
TO
ON THE INSIDE HEATSINK, WHICH
WORK
IS CLOSEST TO THE CENTER PANEL.
J1
TO EARTH GROUND PER
N.C. COMPONENT VIEWED FROM REAR.
12345
NATIONAL, LOCAL OR
ELECTRICAL SYMBOLS PER E1537
OTHER APPLICABLE N.D. BOLTED ALUMINUM CONNECTIONS
ELECTRICAL CODES. REQUIRE T12837 JOINT COMPOUND
6 7 8 9 10
LEAD COLOR CODE:
(DOW CORNING 340) WHEN REATTACHING.
LATCH
B-BLACK
CAVITY NUMBERING SEQUENCE
W-WHITE
( COMPONENT SIDE OF BOARD )
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
7-02
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
M20138
F-1
NOTES
SP-135T
NOTES
SP-135T
G Do not touch electrically live parts or G Keep flammable materials away. G Wear eye, ear and body protection.
WARNING electrode with skin or wet clothing.
G Insulate yourself from work and
ground.
Spanish
G No toque las partes o los electrodos G Mantenga el material combustible G Protéjase los ojos, los oÃdos y el
AVISO DE bajo carga con la piel o ropa moja- fuera del área de trabajo. cuerpo.
da.
PRECAUCION G Aislese del trabajo y de la tierra.
French G Ne laissez ni la peau ni des vête- G Gardez à l’écart de tout matériel G Protégez vos yeux, vos oreilles et
ments mouillés entrer en contact inflammable. votre corps.
ATTENTION avec des pièces sous tension.
G Isolez-vous du travail et de la terre.
G Berühren Sie keine stromführenden
German G Entfernen Sie brennbarres Material! G Tragen Sie Augen-, Ohren- und Kör-
Teile oder Elektroden mit Ihrem perschutz!
WARNUNG Körper oder feuchter Kleidung!
G Isolieren Sie sich von den
Elektroden und dem Erdboden!
Portuguese
G Não toque partes elétricas e elec- G Mantenha inflamáveis bem guarda- G Use proteção para a vista, ouvido e
trodos com a pele ou roupa molha- dos. corpo.
ATENÇÃO da.
G Isole-se da peça e terra.
Japanese
Chinese
Korean
Arabic
READ AND UNDERSTAND THE MANUFACTURER’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 FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES 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 A
ETRE 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 UNFALLVERHÃœTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
G Keep your head out of fumes. G Turn power off before servicing. G Do not operate with panel open or
G Use ventilation or exhaust to
WARNING
guards off.
remove fumes from breathing zone.
Spanish
G Los humos fuera de la zona de res- G Desconectar el cable de ali- G No operar con panel abierto o
AVISO DE
piración. mentación de poder de la máquina guardas quitadas.
G Mantenga la cabeza fuera de los antes de iniciar cualquier servicio.
PRECAUCION
humos. Utilice ventilación o
aspiración para gases.
French
G Débranchez le courant avant l’entre- G N’opérez pas avec les panneaux
G Gardez la tête à l’écart des fumées.
G Utilisez un ventilateur ou un aspira- tien. ouverts ou avec les dispositifs de
ATTENTION
protection enlevés.
teur pour ôter les fumées des zones
de travail.
German
G Strom vor Wartungsarbeiten G Anlage nie ohne Schutzgehäuse
G Vermeiden Sie das Einatmen von
abschalten! (Netzstrom völlig öff- oder Innenschutzverkleidung in
Schweibrauch!
WARNUNG
G Sorgen Sie für gute Be- und nen; Maschine anhalten!) Betrieb setzen!
Entlüftung des Arbeitsplatzes!
Portuguese
G Não opere com as tampas removidas. G Mantenha-se afastado das partes
G Mantenha seu rosto da fumaça.
G Desligue a corrente antes de fazer
G Use ventilação e exhaustão para moventes.
ATENÇÃO
serviço. G Não opere com os paineis abertos
remover fumo da zona respiratória.
G Não toque as partes elétricas nuas. ou guardas removidas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÃTICAS DE SEGURANÇA DO EMPREGADOR.
� World's Leader in Welding and Cutting Products �
� 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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