Page 2 - SAFETY; WARNING; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
FOR ENGINEpowered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors....
Page 3 - ii
ii SAFETY ii 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...
Page 4 - iii
FOR ELECTRICALLYpowered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working onthe equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’srecommendations. 8.c. Ground the equipment in ac...
Page 5 - iv; PRÉCAUTIONS DE SÛRETÉ
iv SAFETY iv PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent d a n s c e m a n u e l a u s s i b i e n q u e l e s p r é c a u t i o n s d e s û r e t é générales suivantes: Sûreté Pour Soudage A L...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and...
Page 7 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS
vi MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1Identify...
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS – SP-135T; INPUT – SINGLE PHASE ONLY
A-1 SP-135T A-1 Fuse or Output Mode Input Voltage Breaker Size 1 Input Amps Power Cord Extension Cord Three Conductor #14 AWG (2.1 mm 2 ) 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 Larger Up to 50 Ft...
Page 9 - SAFETY PRECAUTIONS; ELECTRIC SHOCK can kill.
A-2 INSTALLATION SP-135T A-2 Read entire installation section before startinginstallation. SAFETY PRECAUTIONS IDENTIFY AND LOCATE COMPONENTS If you have not already done so, unpack the SP-135Tf r o m i t s c a r t o n a n d r e m o v e a l l p a c k i n g m a t e r i a laround the SP-135T. Remove th...
Page 10 - Work Clamp Installation; SELECT SUITABLE LOCATION; STACKING; OUTPUT CONNECTIONS
A-3 INSTALLATION SP-135T A-3 SP-135T 4 5 8 3 6 7 1 2 DO NOT SWITCH DO NOT SWITCHWHEN WELDING WHEN 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...
Page 11 - Work Cable Installation; For Innershield Only:; Connecting Gun Cable to the SP-135T; GAS CONNECTION
Work Cable Installation Refer to Figure A.2. 1. Open the wire feed section door on the right side of the SP-135T. 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 ...
Page 13 - INPUT CONNECTIONS; Requirements For Rated Output; Do not remove the power cord ground prong.
A-6 INSTALLATION SP-135T A-6 INPUT CONNECTIONS Refer to Figure A.6. The SP-135T has a power input cable located on therear 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 U...
Page 14 - OPERATION; RECOMMENDED PROCESSES; DESIGN FEATURES
B-1 OPERATION B-1 SP-135T R e a d e n t i r e o p e r a t i o n s e c t i o n b e f o r eoperating the SP-135T. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin orwet clothing. Insulate yourselffrom work and ground. • Always wear dry insulating gloves. FUMES AND...
Page 15 - WELDING CAPABILITY; OFF
B-2 OPERATION B-2 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 wire does not stick in the weld puddle. 6. Optional K695-1 Spot/ Stitch Timer Kit Con...
Page 16 - WELDING OPERATIONS; SEQUENCE OF OPERATION; Wire Loading
B-3 OPERATION B-3 FIGURE B.1a FIGURE B.1b WELDING OPERATIONS SEQUENCE OF OPERATION Wire Loading Refer to Figures B.2 and B.3. The machine power switch should be turned to theOFF ( “ O ” ) position before working inside the wire feed enclosure. The welder is shipped from the factory ready to feed8...
Page 17 - Friction Brake Adjustment
B-4 OPERATION B-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- vid...
Page 18 - Making A Weld; PROCESS GUIDELINES
B-5 OPERATION B-5 FIGURE B.6 Making A Weld 1. 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 wire feed compartment door for information on settingthe ...
Page 19 - Shielding Gas; OVERLOAD PROTECTION; Output Overload
B-6 OPERATION B-6 The SP-135T is suitable for .035" aluminum wire and.030" stainless wire. Refer to Table B.1 for recom-mended procedure settings (requires K499 ArgonRegulator Kit). TABLE B.1 CHANGING MACHINE OVER TOFEED OTHER WIRE SIZES The SP-135T is shipped from the factory ready to feed....
Page 20 - LEARNING TO WELD; THE ARC-WELDING CIRCUIT; • Avoid contact with eyes and skin.
B-7 LEARNING TO WELD B-7 LEARNING TO WELD No one can learn to weld simply by reading about it.Skill comes only with practice. The following pageswill help the inexperienced operator to understandwelding and develop this skill. For more detailed infor-mation, order a copy of “ New Lessons in Arc Weld...
Page 21 - PROCESS SELECTION
B-8 LEARNING TO WELD B-8 The “ arc stream ” is seen in the middle of the picture. This is the electric arc created by the electric currentflowing through the space between the end of the wireelectrode and the base metal. The temperature of thisarc is about 6000 ° F, which is more than enough to melt...
Page 22 - COMMON METALS; Butt Welds
B-9 LEARNING TO WELD B-9 SP-135T For GMAW (MIG) Process 1. Is most of my welding performed on 16 gauge and lighter materials? 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas sup-ply? 3. Do I require clean, finished-looking welds? If you have answe...
Page 23 - Penetration; Welding In The Vertical Position; Vertical-up And Overhead Welding
B-10 LEARNING TO WELD B-10 SP-135T FIGURE B.12 Penetration Unless a weld penetrates close to 100% of the metalthickness, a butt weld will be weaker than the materialwelded together. In the example shown in FigureB.13, the total weld is only half the thickness of thematerial thus the weld is only app...
Page 24 - Vertical-down Welding
B-11 LEARNING TO WELD B-11 SP-135T FIGURE B.16 Vertical-down Welding Refer to Figure B.17 Vertical-down welds are appliedat a fast pace. These welds are therefore shallow andnarrow and, as such, are excellent for sheet metal.Vertical-down welds may be applied to 5/32 ” (3.9 mm) and lighter material....
Page 26 - Helpful Hints; Mild Steel
B-13 LEARNING TO WELD B-13 SP-135T Helpful Hints 1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways.Weld along at a steady pace. You will find it easier. 2. When welding on thin plate, you will find that you will have to increase the welding speed,...
Page 28 - The Correct Welding Speed
B-15 LEARNING TO WELD B-15 SP-135T FIGURE B.24 3. The Correct Electrical Stickout (ESO) The electrical stickout (ESO) is the distance fromthe end of the contact tip to the end of the wire.See Figure B.24. Once the arc has been established, maintainingthe correct ESO becomes extremely important.The E...
Page 29 - TROUBLESHOOTING WELDS; To Eliminate Porosity; To Eliminate a Ropy Convex Bead
B-16 LEARNING TO WELD B-16 TROUBLESHOOTING WELDS Good welds have excellent appearance. To Eliminate Porosity (in order of importance): 1. Turn on gas supply, if used 2. Decrease voltage. 3. Increase stickout. 4. Increase WFS (wire feed speed). 5. Decrease drag angle. 6. Decrease travel speed. NOTE: ...
Page 30 - Proper Gun Handling
B-17 LEARNING TO WELD B-17 Proper Gun Handling Most feeding problems are caused by improper han-dling of the gun cable or electrodes. 1. Do not kink or pull the gun around sharp corners 2. Keep the gun cable as straight as practical when welding. 3. Do not allow dolly wheels or trucks to run over th...
Page 31 - APPLICATION CHART
Page 32 - ACCESSORIES; OPTIONAL ACCESSORIES; Welding Kit
C-1 ACCESSORIES C-1 OPTIONAL ACCESSORIES 1. K549-1 .035" (0.9 mm) Innershield ® Welding Kit — Includes a contact tip, a gasless nozzle and a .035/.045" (.9/1.2 mm) cable liner to permit theMagnum ™ 100L gun and cable to use .035" (0.9 mm) diameter flux-cored electrode. The fitting onthe ...
Page 33 - REPLACEMENT PARTS; Complete Gun and Cable Assembly
C-2 ACCESSORIES C-2 INNERSHIELD (FCAW) CONVERSION Several changes are needed to convert the unit foroperation with the Innershield (FCAW) process. TheK549-1 or K549-2 Innershield Kits include all the nec-essary accessories for this conversion and are provid-ed for this purpose. The following convers...
Page 34 - POWER SOURCE COMPARTMENT; MAINTENANCE
MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before workinginside SP-135T. Use only groundedreceptacle. Do not touch electrically “ hot ” parts inside SP-135T. • Have qualified personnel do the mainte- nance and trouble shooting wo...
Page 35 - FOR MAGNUM; Gun Cable Cleaning; CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM; CAUTION
D-2 MAINTENANCE D-2 SP-135T GUN AND CABLE MAINTENANCE FOR MAGNUM ™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs(136 kg) of solid wire or 50 lbs (23 kg) of flux-coredwire. Remove the cable from the wire feeder and lay itout straight on the floor. Remove the contact ...
Page 36 - CHANGING THE CONTACT TIP
D-3 MAINTENANCE D-3 SP-135T COMPONENTREPLACEMENT PROCEDURES CHANGING THE CONTACT TIP 1. Refer to Figure D.2. Remove the gas nozzle from 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...
Page 37 - GUN HANDLE PARTS; Liner trim length; CHANGING LINER
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, pos...
Page 38 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; HOW TO USE TROUBLESHOOTING GUIDE
E-1 TROUBLESHOOTING E-1 SP-135T 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. CAUTION This Troubleshooting Guide ...
Page 39 - OUTPUT PROBLEMS; Observe all Safety Guidelines detailed throughout this manual
E-2 TROUBLESHOOTING E-2 SP-135T 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. CAUTION PROBLEMS(SYMPTOMS) Major ph...
Page 40 - FEEDING PROBLEMS
E-3 TROUBLESHOOTING E-3 SP-135T 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. CAUTION PROBLEMS(SYMPTOMS) No wire ...
Page 41 - WELDING PROBLEMS
E-4 TROUBLESHOOTING E-4 SP-135T 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. CAUTION PROBLEMS(SYMPTOMS) Arc is u...
Page 42 - DIAGRAMS
F-1 DIAGRAMS F-1 SP-135T S1 SWITCH D1 D3 D2 D4 204 204 204 203 203 203 C1 59,000 f 40V 203 204 - + GUN CABLE CONDUCTOR BLOCK TO WORK ELECTRICAL SYMBOLS PER E1537 CAVITY NUMBERING SEQUENCE ( COMPONENT SIDE OF BOARD ) 539 541 T1 GUN TRIGGER THERMOSTAT 208 5K WIRE SPEED R2 (W) (B) N.C. N.C. COMPONENT V...
Page 43 - NOTES
Page 44 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O 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 ventilati...