Page 2 - SAFETY; WARNING; Mar; CALIFORNIA PROPOSITION 65 WARNINGS; The Above For Diesel Engines
SP-135 PLUS 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 fum...
Page 3 - ii
SP-135 PLUS 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 ...
Page 4 - iii
SP-135 PLUS 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 ’ s recommendations. 8.c. Ground the ...
Page 5 - iv
SP-135 PLUS iv SAFETY iv PR É CAUTIONS DE S Û RET É Pour votre propre protection lire et observer toutes les instructions et les pr é cautions de s û ret é specifiques qui parraissent dans ce manuel aussi bien que les pr é cautions de s û ret é g é n é rales suiv- antes: S û ret é Pour Soudage A L ’...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
SP-135 PLUS 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 th...
Page 7 - TABLE OF CONTENTS; Page
vi vi SP-135 PLUS TABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1Identify and Loca...
Page 8 - INSTALLATION; TECHNICAL SPECIFICATIONS
A-1 A-1 INSTALLATION SP-135 PLUS Fuse or Output Mode Input Voltage Breaker Size Input Amps Extension Cord Three Conductor #14 AWG RATED 115V/60Hz 20 Amp 20 (2.1 mm 2 ) or Larger for up to 25 feet (7.6m) Three Conductor #12 AWG MAXIMUM 115V/60Hz 25 Amp 25 (3.3 mm 2 ) or Larger for up to 50 feet (15.2...
Page 9 - SAFETY PRECAUTIONS; Gun and cable assembly; ELECTRIC SHOCK can kill.
A-2 A-2 INSTALLATION SP-135 PLUS Read entire installation section before startinginstallation. SAFETY PRECAUTIONS IDENTIFY AND LOCATE COMPONENTS If you have not already done so, unpack the SP-135PLUS from its carton and remove all packing materialaround the SP-135 PLUS. Remove the following looseite...
Page 10 - SELECT SUITABLE LOCATION; OUTPUT CONNECTIONS; Accessories; Work Clamp Installation; Work Cable Installation
A-3 A-3 INSTALLATION SP-135 PLUS 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 ...
Page 11 - GAS CONNECTION
A-4 SP-135 PLUS A-4 INSTALLATION 3. Route the cable under and around the back of the Wire Feed Gearbox (6). 4. For GMAW Only: Refer to Figure A.2. As deliv- ered, the SP-135 PLUS is wired for positive polari-ty. This is the appropriate configuration for the GasMetal Arc Welding (GMAW) process. To co...
Page 12 - INPUT CONNECTIONS
A-5 A-5 INSTALLATION SP-135 PLUS 3. Attach the flow regulator to the cylinder valve and tighten the union nut securely with a wrench. Theflow regulator for carbon dioxide must have a plas- tic washer seated in the fitting that attaches to thecylinder to prevent leakage. Refer to K1800-1 inthe access...
Page 13 - Requirements For Rated Output; Do not remove the power cord ground prong.; Requirements For Maximum Output
A-6 A-6 INSTALLATION SP-135 PLUS CODE REQUIREMENTS FOR INPUTCONNECTIONS This welding machine must be connected topower source in accordance with applicable elec-trical codes. The United States National Electrical Code (Article630-B, 1990 Edition) provides standards for amperagehandling capability of...
Page 14 - OPERATION
SP-135 PLUS B-1 B-1 OPERATION Read entire Operation section beforeoperating the SP-135 PLUS. 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 GASES can bedanger...
Page 15 - GENERAL DESCRIPTION; RECOMMENDED PROCESSES; WELDING CAPABILITY
B-2 SP-135 PLUS B-2 OPERATION GENERAL DESCRIPTION The SP-135 PLUS is a complete semiautomatic con-stant voltage DC arc welding machine. Included is asolid state controlled, single phase constant voltagetransformer/ rectifier power source and a wire feederfor feeding solid steel electrode and cored e...
Page 16 - WELDING OPERATIONS; SEQUENCE OF OPERATION; Wire Loading
SP-135 PLUS B-3 B-3 OPERATION FIGURE B.1a 4. Circuit Breaker – Protects machine from damage if maximum output is exceeded. Button will extendout when tripped (Manual reset). Refer to Figure B.1b. 5. Gun Trigger - Activates welding output, wire feed, and gas solenoid operation. Releasing the triggerd...
Page 17 - Friction Brake Adjustment
B-4 B-4 OPERATION FIGURE B.3 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 shou...
Page 18 - Shielding Gas
SP-135 PLUS B-5 B-5 OPERATION Shielding Gas When using the GMAW process, a cylinder of shield-i n g g a s , m u s t b e o b t a i n e d . R e f e r t o t h e A C C E S -SORIES section for more information about selectinggas cylinders for use with the SP-135 PLUS. 1. For CO 2 , open the cylinder very...
Page 19 - To stop welding, release the gun trigger and then; PROCESS GUIDELINES; blended
B-6 SP-135 PLUS B-6 OPERATION 9. To stop welding, release the gun trigger and then pull the gun away from the work after the arc goesout. 10. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate guntrigger to release gas pressure, and turn off theSP-135 PLUS...
Page 20 - OVERLOAD PROTECTION; Output Overload
SP-135 PLUS B-7 B-7 OPERATION OVERLOAD PROTECTION Output Overload The SP-135 PLUS is equipped with a circuit breakerwhich protects the machine from potential damagefrom excessive output current. The circuit breaker but-ton will extend out when tripped. The circuit breakermust be manually reset. Ther...
Page 21 - LEARNING TO WELD; THE ARC-WELDING CIRCUIT; Avoid contact with eyes and skin.
B-8 SP-135 PLUS B-8 LEARNING TO WELD LEARNING TO WELD No one can learn to weld simply by reading about it.Skill comes only with practice. The following pages willhelp the inexperienced operator to understand weld-ing and develop this skill. For more detailed informa-tion, order a copy of “ New Lesso...
Page 22 - PROCESS SELECTION
SP-135 PLUS B-9 B-9 LEARNING TO WELD 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 en...
Page 23 - COMMON METALS; Butt Welds
B-10 SP-135 PLUS B-10 LEARNING TO WELD 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...
Page 24 - angle between the two; Welding In The Vertical Position; drip
SP-135 PLUS B-11 B-11 LEARNING TO WELD 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...
Page 25 - Vertical-down Welding
B-12 SP-135 PLUS B-12 LEARNING TO WELD 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 mater...
Page 27 - Mild Steel; Helpful Hints
B-14 SP-135 PLUS B-14 LEARNING TO WELD Mild Steel 16 gauge or 1/16 inch (1.6 mm) Electrode 0.035" (0.9 mm) NR-211-MP Innershield Wire Voltage Setting “ V ” E Wire Feed Speed “ o|o ” 2 For the SP-135 PLUS, use the following: Helpful Hints 1. For general welding, it is not necessary to weave the a...
Page 30 - TROUBLESHOOTING WELDS; To Eliminate Porosity
SP-135 PLUS B-17 B-17 LEARNING TO WELD 4. After you strike the arc, practice the correct electri- cal stickout. Learn to distinguish it by its sound. 5. When you are sure that you can hold the correct electrical stickout, with a smooth “ crackling ” arc, start moving. Look at the molten puddle const...
Page 31 - Proper Gun Handling
SP-135 PLUS B-18 B-18 LEARNING TO WELD 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...
Page 32 - APPLICATION CHART
Page 33 - ACCESSORIES; Includes spot; OPTIONAL ACCESSORIES; Designed to transport the; K 6 6 3 - 2 A l u m i n u m W e l d i n g K i t; T h i s k i t; It is important when changing between
C-1 C-1 SP-135 PLUS ACCESSORIES 4. KP666-035C Knurled Drive Roll (optional) — Reversible Drive Roll with double knurled groovesfor .035 (0.9 mm) cored electrode. 5. K695-2 Spot / Stitch Timer Kit — Includes spot timer to control the spot welding arc time, and astitch timer to control the on/off cycl...
Page 34 - REPLACEMENT PARTS; Complete Gun and Cable Assembly
C-2 C-2 SP-135 PLUS ACCESSORIES INNERSHIELD (FCAW)CONVERSION Several changes are needed to convert the unit foroperation with the Innershield (FCAW) process. TheK549-1 Innershield Kit includes all the necessaryaccessories for this conversion and are provided forthis purpose. The following conversion...
Page 35 - BEFORE EACH USE; MAINTENANCE; PERIODICALLY AS REQUIRED
SP-135 PLUS MAINTENANCE SAFETY PRECAUTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptaclebefore working inside SP-135PLUS. Use only grounded recep-tacle. Do not touch electrically “ hot ” parts inside SP-135 PLUS. • Have qualified personnel do the maintenance and ...
Page 36 - FOR MAGNUM; Gun Cable Cleaning; CAUTION
D-2 SP-135 PLUS D-2 MAINTENANCE 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 cont...
Page 37 - CHANGING THE CONTACT TIP
D-3 SP-135 PLUS D-3 MAINTENANCE COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONTACT TIP 1. Unplug or turn power switch to Off “ O ” position. 2. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 3. Remove the existing contact tip from the gun by unscrewing co...
Page 38 - GUN HANDLE PARTS; Liner trim length for gun with red trigger (Magnum; CHANGING LINER
D-4 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,...
Page 39 - TROUBLESHOOTING; Local Lincoln Authorized Field Service Facility; Step 3. RECOMMENDED COURSE OF ACTION; HOW TO USE TROUBLESHOOTING GUIDE
SP-135 PLUS If machine case sides and top are removed, the case front must be supported. Failureto do this could result in mechanical or electrical damage to the SP-135 PLUS. ___________________________________________________________________ CAUTION E-1 TROUBLESHOOTING E-1 If for any reason you do ...
Page 40 - TROUBLESHOOTING GUIDE; OUTPUT PROBLEMS; LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY
E-2 SP-135 PLUS E-2 TROUBLESHOOTING Observe Safety Guidelines detailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS(SYMPTOMS) Major physical or electrical damageis evident. No wire feed, weld output or gasflow when gun trigger is pulled. Fandoes NOT operate. No weld output or wire...
Page 41 - FEEDING PROBLEMS
SP-135 PLUS E-3 E-3 TROUBLESHOOTING Observe Safety Guidelinesdetailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS(SYMPTOMS) No wire feed when gun trigger ispulled. Fan runs, gas flows andmachine has correct open circuitvoltage (28 vdc maximum) – weld output. Wire feed speed motor...
Page 42 - WELDING PROBLEMS; GAS FLOW PROBLEMS
E-4 SP-135 PLUS E-4 TROUBLESHOOTING Observe Safety Guidelinesdetailed in the beginning of this manual. TROUBLESHOOTING GUIDE PROBLEMS(SYMPTOMS) Arc is unstable – Poor starting POSSIBLE AREAS OFMISADJUSTMENT(S) 1. Check for correct input voltage to machine – 115 vac. 2. Check for proper electrode pol...
Page 43 - WIRING DIAGRAMS; SP-135PLUS WIRING DIAGRAMS; SP-135PLUS WIRING DIA
F-1 SP-135 PLUS F-1 WIRING DIAGRAMS M19922 L1 L2 31 32 531 TO GROUND PER NATIONAL ELECTRICAL CODE S1 SWITCH 202 201 D1 D3 D2 D4 204 204 204 203 203 203 C1 59,000 f 40V 203 204 - + OUTPUT CHOKE GUN CABLE CONDUCTOR BLOCK TO WORK ELECTRICAL SYMBOLS PER E1537 CIRCUIT BREAKER 31A 12 3 45 6 LATCH FAN MOTO...
Page 44 - NOTES
Page 45 - Lincoln Welding School; BASIC COURSE; weeks of fundamentals
Now Available...12th EditionThe Procedure Handbook of Arc Welding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “ Bible ” of the arc welding industry. T h i s p r i n t i n g w i l l g o f a s t s o d o n ’ t d e l a y . P ...
Page 46 - ÇÃ
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O 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 I...
Page 47 - LEIA E COMPREENDA AS INSTRU
WARNING AVISO DE PRECAUCION ATTENTION WARNUNG ATEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS PR TICAS DE SEGURAN A DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilati...
