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 Mar. ‘93 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 So...
Page 6 - Thank You; Please Examine Carton and Equipment For Damage Immediately
v v 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...
Page 7 - MASTER TABLE OF CONTENTS FOR ALL SECTIONS
vi vi MASTER TABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1Ident...
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 mm 2 ) or Larger Up to 50 ...
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 SWITCHWHEN WELDING + - FIGURE A.2 Work Clamp Installation Attach the work clamp per the following: 1. Unplug the machine or turn the power switch to the “OFF” position. 2. Insert the work cable terminal lug with the larger hole through the ...
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 N...
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 wiredoes not stick in the weld puddle. FIGURE B.1a FIGURE B.1b ● No external shielding ...
Page 16 - WELDING OPERATIONS; SEQUENCE OF OPERATION; Wire Loading
B-3 OPERATION B-3 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 feedenclosure. The welder is shipped from the factory ready to feed8" (200 mm) diameter spools w...
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 SP...
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 * NR (Not Recommended) CHANGING MACHINE OVER TOFEED OTHER WIRE SIZES The SP-135T is shipped from the...
Page 20 - APPLICATION CHART
Page 21 - ACCESSORIES; OPTIONAL ACCESSORIES; K 6 6 4 - 2 A l u m i n u m F e e d i n g K i t
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 conversions shouldbe made u...
Page 22 - REPLACEMENT PARTS; Complete Gun and Cable Assembly
C-2 ACCESSORIES C-2 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...
Page 23 - ROUTINE MAINTENANCE; POWER SOURCE COMPARTMENT; not; 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 work....
Page 24 - 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 t...
Page 25 - CHANGING THE CONTACT TIP
D-3 MAINTENANCE D-3 SP-135T COMPONENT REPLACEMENT 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 contac...
Page 26 - 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 27 - 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 28 - 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 29 - FEEDING PROBLEMS; GAS FLOW 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 30 - 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 31 - DIAGRAMS
F-1 DIAGRAMS F-1 SP-135T W A RNI NG HI GH VOLT AGE can k ill Only qualified per sons should install, use or ser vice this ma chine. Do not oper ate with c over s r emove d. Disconnect input powe r by unplugging power co rd bef or e ser vicing. Do not touc h elect rically live par ts 7-02 M 20138 S1 ...
Page 32 - NOTES
