IM788 SP-135 PLUS - Lincoln Electric Global Sites · 4.a. Use a shield with the proper filter and...

SP-135 PLUS

OPERATOR’S MANUAL

IM788July, 2005

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

For use with machine Code Numbers : 10974

ISO 9001

CERTIFICATE NUMBER: 30273

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

QMS

ANSI RAB

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

• World's Leader in Welding and Cutting Products •

Copyright © 2005 Lincoln Global Inc.

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

FOR ENGINEpowered equipment.

1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to be running.

____________________________________________________1.b. Operate engines in open, well-ventilated

areas or vent the engine exhaust fumes outdoors.

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

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

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

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

____________________________________________________

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

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

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

___________________________________________________1.g. To prevent accidentally starting gasoline engines while

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

iSAFETYi

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

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

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

WARNING

Mar ‘95

ELECTRIC AND MAGNETIC FIELDSmay be dangerous

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

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

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

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

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

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

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

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

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

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

CALIFORNIA PROPOSITION 65 WARNINGS

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

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

The Above For Diesel Engines The Above For Gasoline Engines

SP-135 PLUS

iiSAFETYii

ARC RAYS can burn.4.a. Use a shield with the proper filter and cover

plates to protect your eyes from sparks andthe rays of the arc when welding or observingopen arc welding. Headshield and filter lensshould conform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistantmaterial to protect your skin and that of your helpers fromthe arc rays.

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

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

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

gloves to insulate hands.

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

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

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

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

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

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

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

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

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

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

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

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

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

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

5.b. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations.The heat and rays of the arc can react with solvent vapors toform phosgene, a highly toxic gas, and other irritating prod-ucts.

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

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

5.e. Also see item 1.b.

Mar ‘95

SP-135 PLUS

FOR ELECTRICALLYpowered equipment.

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

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

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

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

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

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

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

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

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

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

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

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

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

iiiSAFETYiii

Mar ‘95

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

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

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

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

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

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

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

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

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

6.h. Also see item 1.c.

SP-135 PLUS

ivSAFETYiv

PRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifiques qui parraissent dans cemanuel aussi bien que les précautions de sûreté générales suiv-antes:

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

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

b. Faire trés attention de bien s’isoler de la masse quand onsoude dans des endroits humides, ou sur un planchermetallique ou des grilles metalliques, principalement dans les positions assis ou couché pour lesquelles une grandepartie du corps peut être en contact avec la masse.

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

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

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

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

2. Dans le cas de travail au dessus du niveau du sol, se protégercontre les chutes dans le cas ou on recoit un choc. Ne jamaisenrouler le câble-électrode autour de n’importe quelle partiedu corps.

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

a. Utiliser un bon masque avec un verre filtrant appropriéainsi qu’un verre blanc afin de se protéger les yeux du ray-onnement de l’arc et des projections quand on soude ouquand on regarde l’arc.

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

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

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

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

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

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

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

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

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

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

PRÉCAUTIONS DE SÛRETÉ POURLES MACHINES À SOUDER ÀTRANSFORMATEUR ET ÀREDRESSEUR

1. Relier à la terre le chassis du poste conformement au code del’électricité et aux recommendations du fabricant. Le dispositifde montage ou la piece à souder doit être branché à unebonne mise à la terre.

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

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

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

Mar. ‘93

vv

Thank You for selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••• as much pride as we have in bringing this product to you!

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep ithandy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.The level of seriousness to be applied to each is explained below:

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

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

CAUTION

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

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

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

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

On-Line Product Registration

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

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

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

vivi

TABLE OF CONTENTS

Page

Installation .......................................................................................................Section ATechnical Specifications ........................................................................................A-1Identify and Locate Components ...........................................................................A-2Select Suitable Location ........................................................................................A-3Output Connections...............................................................................................A-3Input Connections..................................................................................................A-5Code Requirements ..............................................................................................A-6

Operation .........................................................................................................Section BSafety Precautions ................................................................................................B-1General Description ...............................................................................................B-2

Design Features and Advantages...................................................................B-2Welding Capability ..........................................................................................B-2Limitations .......................................................................................................B-2Controls and Settings......................................................................................B-2

Welding Operations ...............................................................................................B-3Overload Protection...............................................................................................B-7Application Chart ...................................................................................................B-8

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

Maintenance ....................................................................................................Section DSafety Precautions ................................................................................................D-1Items Requiring No Maintenance ..........................................................................D-1Routine and Periodic Maintenance........................................................................D-1Gun and Cable Maintenance.................................................................................D-2Configuration of Components in Wire Feeding System.........................................D-2Component Replacement Procedures ..................................................................D-3Changing Liner ......................................................................................................D-4Gun Handle Parts ..................................................................................................D-4

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

Wiring Diagrams ..............................................................................................Section FSP-135 PLUS Wiring Diagram...............................................................................F-1

Parts Lists ...............................................................................................P454 & P202-E

A-1 A-1 INSTALLATION

SP-135 PLUS

Fuse orOutput Mode Input Voltage Breaker Size Input Amps Extension Cord

Three Conductor#14 AWG

RATED 115V/60Hz 20 Amp 20 (2.1 mm2) or Largerfor up to

25 feet (7.6m)

Three Conductor#12 AWG

MAXIMUM 115V/60Hz 25 Amp 25 (3.3 mm2) or Largerfor up to

50 feet (15.2 m)

TECHNICAL SPECIFICATIONS – SP-135 PLUSINPUT – SINGLE PHASE ONLY

RATED OUTPUT

OUTPUT

RECOMMENDED INPUT CABLE AND FUSE SIZES

Height Width Depth Weight12.0 in 9.75 in 16.5 in 54 Ibs305 mm 248 mm 419 mm 24.3 kg

PHYSICAL DIMENSIONS

Standard Voltage/Frequency Input Current20 Amps @ Rated Output

115V/60Hz 25 Amps @ Maximum Output15 Amps @ CSA Rated output

Duty Cycle Amps Volts at Rated Amperes20% Duty Cycle – Rated DC Output 90 18

Welding Current Range (Continuous) Maximum Open Circuit Voltage Auxiliary PowerRated DC Output: 25 – 135 Amps 28 N/A

A-2 A-2 INSTALLATIONRead 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 looseitems from the carton (see Figure A.1):

1. SP-135 PLUS

2. Gun and cable assembly(1)

3. Literature and miscellaneous including:

a) This operating manual

b) A contact tip for .030” (0.8 mm) diameter wire.

4. 10 ft (3.0 m) work cable.

5. Work clamp.

6. 2lb. Spool of Super Arc L-56 .025 MIG Wire.

7. Adjustable mixed-Gas Regulator & Hose.

For available options and accessories refer to theaccessories section later in this manual.

1) As shipped from the factory, the SP-135 PLUS gunis ready to feed .023 or .025 (0.6 mm) wire.

ELECTRIC SHOCK can kill.

• Only qualified personnel should performthis installation.

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

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

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

WARNING

FIGURE A.1

2

4

6

3

1

7

5

SP-135 PLUS


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 dirt accumulation that can blockair passages and cause overheating.

STACKING

SP-135 PLUS’ cannot be stacked.

TILTING

Each machine must be placed on a secure, level sur-face, either directly or on a recommended undercar-riage. The machine may topple over if this procedureis not followed.

OUTPUT CONNECTIONS

Refer to Figure A.2.

1. Work Cable Access Hole.

2. Gun Cable and Control Lead Access Hole.

3. Connector Block.

4. Gun Trigger Lead Connectors.

5. Positive (+) and negative (–) output terminals.

6. Wire Feed Gearbox and Gun Connector Block

7. Cable Clamp

8. Thumbscrew - Secures gun and cable assembly

Work Clamp Installation

Attach the work clamp per the following:

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

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

3. Fasten securely with the bolt and nut provided.

FIGURE A.3

445

8

3 761 2

SP-135 Plus

WELDING AMP RANGE 25-125

+

-

Work Cable Installation

Refer to Figure A.2.

1. Open the wire feed section door on the right side ofthe SP-135 PLUS.

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.

Strain Relief Hole

Nut & Bolt

Work Clamp

Work Cable

FIGURE A.2

A-4A-4 INSTALLATION3. 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 completeinstallation, use the provided wing nut to connectthe work cable’s terminal lug to the negative (–)output terminal (5) located above the Wire FeedGearbox (6). Make sure that both wing nuts aretight.

5. For Innershield Only: Refer to Figure A.4. To wirefor negative polarity, connect the short cableattached to the connector block (1) to the negative(–) output terminal (2) and the work cable (3) to thepositive (+) terminal (4).

FIGURE A.4

3. Insert the connector on the gun conductor cablethrough the Gun Cable Access Hole (2) in the SP-135 PLUS case front. Make sure the connector isall the way in the metal connector block to obtainproper gas flow. Rotate the connector so controlleads are on the underside and tighten theThumbscrew (8) in the connector block.

4. Connect the gun trigger control lead terminals tothe two insulated 1/4" (6,4 mm) tab connectorbushings located above the “Gun TriggerConnection” decal in the wire feed section (4).Either lead can go to either connector. Form theleads so that they are as close as possible to theinside panel.

If the gun trigger switch being used is other thanthat supplied with the SP-135 PLUS, the switchmust be a normally open, momentary switch. Theterminals of the switch must be insulated from thewelding circuit. Malfunction of the SP-135 PLUSwill result if this switch shorts to the SP-135 PLUSwelding output circuit or is common to any electri-cal circuit other than the SP-135 PLUS triggercircuit.

GAS CONNECTION

Refer to Figure A.5

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

GUN INSTALLATIONAs shipped from the factory, the SP-135 PLUS gun isready to feed .023 - .025” (0,6 mm) wire. If .030-.035”(0.8-0.9 mm) wire is to be used, change the contact tipto the appropriate size. Refer to the MAINTENANCEsection for contact tip installation details.

NOTE: If .035” Innershield Flux-cored wire is to beused, see the Accessories section for the InnershieldWelding Kit.

Connecting Gun Cable to the SP-135PLUS1. Refer to Figure A.2. Unplug the machine or turn

power switch to the off “O” position.

2. Pass the insulated terminals of the gun trigger con-trol leads, one at a time, through the Gun Cableand Control Lead Access Slot (2) in the case front.The leads are to be routed under the Wire FeedGearbox (6) and through the Cable Hanger (7) onthe inner panel.

CAUTION

1

2

34

SP-135 PLUS


SP-135 PLUS

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

BE SURE TO KEEP YOUR FACE AWAY FROM THEVALVE OUTLET WHEN “CRACKING” THE VALVE.Never stand directly in front of or behind the flowregulator when opening the cylinder valve. Alwaysstand to one side.

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

NOTE: If connecting to 100% CO 2 cylinder, insertregulator adapter (provided with MIG ConversionKit) between regulator and cylinder valve. If adapteris equipped with a plastic washer, be sure it is seat-ed for connection to the CO2 cylinder.

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

5. Reinstall case side before connecting input power.

INPUT CONNECTIONSRefer to Figure A.6.

The machine has two input connections, the powerinput cable, and the Gas Solenoid Inlet Fitting. Bothare located on the rear of the machine.

FIGURE A.6

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

• Keep cylinder away from areaswhere it may be damaged.

• Never lift welder with cylinderattached.

• Never allow welding electrode totouch cylinder.

• Keep cylinder away from weldingor other live electrical circuits.

BUILDUP OF SHIELDING GAS mayharm health or kill.

• Shut off shielding gas supplywhen not in use.

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

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

FIGURE A.5

WARNING

Cylinder Valve

Gas Hose

Flow Regulator

WARNING

WARNING

POWER INPUTCABLE

GAS SOLENOIDINLET FITTING


SP-135 PLUS

CODE REQUIREMENTS FOR INPUTCONNECTIONS

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

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

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

Requirements For Rated Output

A power cord with a 15 amp, 125 volt, three prongplug (NEMA Type 5-15P) is factory installed on theSP-135 PLUS. Connect this plug to a mating ground-ed receptacle which is connected to a 20 amp branchcircuit with a nominal voltage rating of 115 to 125volts, 60 Hertz, AC only.

The rated output with this installation is 90 amps, 18Volts, 20% duty cycle (2 minutes of every 10 minutesused for welding).

Do not connect the SP-135 PLUS to an inputpower supply with a rated voltage that is greaterthan 125 volts.

Do not remove the power cord ground prong.

Requirements For Maximum Output

In order to utilize the maximum output capability of themachine, a branch circuit capable of 25 amps at 115to 125 volts, 60 Hertz is required. This generallyapplies when welding steel that is equal to or greaterthan 12 gauge, 0.105” (2.5 mm) in thickness.

WARNING

CAUTION

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 insulatinggloves.

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

• Use ventilation or exhaust toremove fumes from breathingzone.

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

• Do not weld on closed contain-ers.

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

tion.

Observe all safety information throughoutthis manual.

WARNING

B-2B-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 electrode.

The SP-135 PLUS is ideally suited for individuals hav-ing access to 115 volt AC input power, and wantingthe ease of use, quality and dependability of both gasmetal arc welding or GMAW (also known as MIGwelding) and the Innershield electrode process (selfshielded flux cored or FCAW). The SP-135 PLUS is arugged and reliable machine that has been designedfor dependable service and long life.

RECOMMENDED PROCESSES

The SP-135 PLUS can be used for welding mild steelusing the GMAW, single pass, process which requiresa supply of shielding gas or it can be used for the selfshielded, Innershield electrode process (FCAW). TheSP-135 PLUS is configured for use with the GMAW(MIG) process as delivered from the factory.

OPERATIONAL FEATURES AND CONTROLS

The SP-135 PLUS has the following controls as stan-dard: Power ON/OFF Switch, Voltage Control, WireSpeed Control, and a Circuit Breaker.

DESIGN FEATURES AND ADVANTAGES

● Operates on 115 volt input

● Solid state output control.

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

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

● Quality wire drive with electronic overload protec-tion.

● Easy-to-set continuous range controls for precisesetting of arc voltage and wire speed.

● Continuous voltage control.

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

● Reversible, dual groove drive roll. Drive roll willfeed .023-.035” (0.6- 0.9 mm) diameter wire.

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

● No external shielding gas is required when usedwith Lincoln .035” (0,9 mm) Innershield NR®-211-MP electrode.

● Easy to change polarity.

WELDING CAPABILITY

The SP-135 PLUS, as shipped, is rated at 90 amps,18 volts, at 20% duty cycle on a ten minute basis. It iscapable of higher duty cycles at lower output currents.

LIMITATIONS

Arc Gouging cannot be performed with the SP-135PLUS. The SP-135 PLUS is not recommended forpipe thawing.

CONTROLS AND SETTINGS

Refer to Figures B.1a & B.1b.

1. Power ON/OFF Switch —When the power is on thefan motor will run and air willbe exhausted out the louversin the front of the machine.The welding output and wirefeeder remain off until thegun trigger is pressed.

2. Voltage Control — A contin-uous control that gives fullrange adjustment of powersource output voltage.Voltage can be adjustedwhile welding.

3. Wire Speed Control —Controls the wire feed speedfrom 50 – 400 in /min (1.3 –10 m/min). The control canbe preset on the dial to thesetting specified on the SP-135 PLUS Application Chartlocated on the inside of thewire feed section door. Wirespeed is not affected whenchanges are made in thevoltage control.

OFF

ON

ARC VOLTS

WIRE SPEED

ON

ARC VOLTS

SP-135 PLUS

B-3 B-3 OPERATION

FIGURE B.1a

4. Circuit Breaker – Protects machine from damage ifmaximum output is exceeded. Button will extendout when tripped (Manual reset).

5. Gun Trigger - Activates welding output, wire feed,and gas solenoid operation. Releasing the triggerdeactivates welding and simultaneously activatesthe “burnback” function so that the welding wiredoes not stick in the weld puddle. See FIG B.1b

WELDING OPERATIONS

SEQUENCE OF OPERATION

Wire LoadingRefer to Figure B.2 AND B3.

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

The machine is shipped from the factory ready to feed4” (100 mm) diameter spools. A 4" (100 mm) diameterspool is mounted directly on the 5/8" (16 mm) diame-ter spindle that has a built-in adjustable friction brake to prevent overrun of the spool and excess slack inthe wire. The wing nut at the end of the shaft is usedto adjust the tension on the wire spool (See B.3 on thefollowing page).

To use 8" (200 mm) diameter spools, the 2" (51 mm)diameter M15445 spindle must be used. Remove thespacer and wing nut at the end of the shaft. Insertspindle as shown in figure B.2. Reattach spacer andwing nut.

Note: When loading and removing the 8” Spoolsmake sure that the wing nut (inside the wire spoolspindle hub) is turned 90° from the wire spool spindlelocking tab. If the wing nut is positioned in line with thelocking tab, the tab cannot be depressed to load orunload the wire spool.

Make certain the start end of the wire, which may pro-trude through the side of the spool, does not contactany metallic case parts.

FIGURE B.2

11

SP-135 Plus

WELDING AMP RANGE

WELDING AMP RANGE

25-125

25-125

3

2

+

-

5

Wire Spool must be pushed all the way on the spindleso that the spindle’s tab will hold it in place. The WireSpool must rotate clockwise when wire is dereeled.

To wire drive

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

8” Wire Spool

Wire Spool Spindle

Locking Tab

FIGURE B.1b

SP-135 PLUS

B-4 B-4 OPERATION

FIGURE B.3Friction Brake Adjustment

With wire spool installed on the spindle shaft and thewing nut loose, turn the spool by hand while slowlytightening the wing nut until a light drag is felt. Tightenthe wing nut an additional 1/4 turn.

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

Wire Threading Refer to Figure B.4

1. Release the Spring Loaded Pressure Arm (1)rotate the Idle Roll Arm (2) away from the WireFeed Drive Roll (3). Ensure that the visible, sten-ciled size on the drive roll matches the wire sizebeing used.

2. Carefully detach the end of the wire from thespool. To prevent the spool from unwinding, donot release the wire until after step 5.

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

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

5. Close the idle roll arm (2) and latch the springloaded pressure arm (1) in place (now you mayrelease the welding wire).

6. The idle roll pressure adjustment wing nut is factoryset to approximately five full turns from where thewing nut first engages the threads of the pressurearm (1). If feeding problems occur because the wireis flattened excessively, turn the pressure adjust-ment counter-clockwise to reduce distortion of thewire. Slightly less pressure may be required whenusing 0.023 – 0.025" (0,6 mm) wire. If the drive rollslips while feeding wire, the pressure should beincreased until the wire feeds properly.

When inching the welding wire, the drive rolls, thegun connector block and the gun contact tip arealways energized relative to work and ground andremain energized several seconds after the guntrigger is released.

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

8. Turn the SP-135 PLUS ON (“I”).

9. Straighten the gun cable assembly.

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

Note: If the wire will not feed smoothly, or if the wirefeed motor shuts off unexpectedly, see the"FEEDING PROBLEMS" section of the "TROU-BLESHOOTING GUIDE" in this manual.

11. Replace contact tip and gas nozzle.

12. Refer to Figure B-6. Cut the wire off 3/8” – 1/2”(10 – 13 mm) from the end of the tip. The SP-135PLUS is now ready to weld.

FIGURE B.4

The Wire Drive FeedRoll can accommodatetwo wire sizes by flippingthe wire drive feed rollover. The sizes are sten-ciled on the drive roll.

1

2

345

WARNING

Wire Spindle Shaft4" Wire Spool

Wing Nutand SpacerTo wire drive

SP-135 PLUS

SP-135 PLUS

B-5 B-5 OPERATION

Shielding GasWhen using the GMAW process, a cylinder of shield-ing gas, must be obtained. Refer to the ACCES-SORIES section for more information about selectinggas cylinders for use with the SP-135 PLUS.

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

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

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

a) Close the cylinder valve to stop gas flow.

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

c) Turn off the SP-135 PLUS.

Making A Weld1. See Recommended Processes And Equipment

section for selection of welding wire and shieldinggas and for range of metal thicknesses that can bewelded.

2. See the Application Chart on the inside of wirefeed section door for information on setting theSP-135 PLUS controls.

3. Set the Voltage (“V”) and Wire Speed (“olo’”) con-trols to the settings suggested for the welding wireand base metal thickness being used.

FIGURE B.6FIGURE B.5

Gun Handle

Gas DiffuserContact Tip

Gas Nozzle

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

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

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

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

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

Contact Tip

Wire Electrode

FIGURE B.7

WORKPIECE

GUN CABLE

ARC

WORK CLAMP

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

B-6B-6 OPERATION9. 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 valveon gas cylinder (if used), momentarily operate guntrigger to release gas pressure, and turn off theSP-135 PLUS.

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

PROCESS GUIDELINES

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

The recommended gases and electrodes for GMAWare welding grade CO2 gas or an argon-CO2 blendedgas (75 to 80% argon and 25 to 20% CO2) and .025"(0.6 mm) diameter Lincoln Super Arc L-56 mild-steelwelding wire.

The recommended electrode for the self-shieldedprocess is 0.035” (0,9 mm) diameter LincolnInnershield NR-211-MP. This electrode can be usedfor all position welding of 20 gauge through 5/16” (1,0– 8,0 mm) thick steel [multiple passes are required for1/4” and 5/16” (6,0 and 8,0 mm)].

------------------------------------------------------------------------The SP-135 PLUS is suitable for .035" Aluminum wireand .030" stainless wire. Refer to Table B.1 forRecommended Procedure Settings. Aluminum wirerequires K663-2 Aluminum Welding kit. See ACCES-SORIES section.

It is important when changing between weldingwith steel wire and aluminum to exchange feedingcomponents due to the lubricant applied to steelwire. Failure to do so may result in contaminatedwelds when welding aluminum.------------------------------------------------------------------------

TABLE B.1 — SP-135 PLUS Welding Procedures

NR-Not Recommended

CHANGING MACHINE OVER TOFEED OTHER WIRE SIZES

The SP-135 PLUS is shipped from the factory ready tofeed 0.023-0.025” (0,6 mm) diameter wire. To operatethe SP-135 PLUS with other sizes of wire, it is neces-sary to change the contact tip and change the driveroll over to other sizes. Refer to Changing the ContactTip and Changing the Drive Roll, in the MAINTE-NANCE section, for specific information on these pro-cedures.

WELDING WITH FCAW (Innershield)

Welding with Innershield requires an InnershieldWelding Kit. A gasless nozzle is provided in theInnershield Welding Kit. When using Innershield elec-trode, installing the gasless nozzle will improve visibili-ty of the arc and protect the gas diffuser from weldspatter. Additionally included is a gun cable liner topermit proper feeding of .035” (0,9 mm) Innershieldwire. Refer to the ACCESSORIES section for detailson obtaining this kit.

WARNING

Use of the GMAW process with the SP-135 PLUSon thicker materials than recommended mayresult in poor welds. The welds may “look” good,but may just be “sitting” on top of the plate. Thisis called “cold casting” and will result in weld fail-ure.

CAUTION

SP-135 PLUS

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

.035 Dia(0.9mm 100% Argon C-5 E-8.5 H-10 J-109 NR NR4043 Aluminum WireMIG DC+

16 ga 14 ga 12 ga 10 ga

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

B-7 B-7 OPERATION

OVERLOAD PROTECTION

Output OverloadThe 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.

Thermal ProtectionThe SP-135 PLUS duty cycle is exceeded a thermo-stat will shut off the output until the machine cools to anormal operating temperature. This is an automaticfunction and is self resetting.

Wire Feed Overload ProtectionIf the SP-135 PLUS has an automatic electronic pro-tection circuit to protect the wire feed motor. If exces-sive motor overload occurs (due to excessive feedingforce, jammed drive rolls, or shorted motor leads) thecircuit will shut down the wire feed motor and thewelding power output.

The wire feed shut-down circuit will reset automaticallywhen the gun trigger is released. However shut-downwill reoccur if the overload situation is not corrected.

SP-135 PLUS

B-8 B-8 APPLICATION CHART

SP-135 PLUS

C-1 C-1 ACCESSORIES4. KP666-035C Knurled Drive Roll (optional) —

Reversible Drive Roll with double knurled groovesfor .035 (0.9 mm) cored electrode.

5. K549-1 .035 (0.9 mm) Innershield Welding KitIncludes a contact tip, a gasless nozzle and a cableliner to permit the Magnum™ 100L gun and cableto use .030-.035” (0.8-0.9 mm) diameter flux-coredelectrode. Also included is a spool of .035 (0.9 mm)Innershield NR-211-MP.

OPTIONAL ACCESSORIES

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

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

3. K663-2 Aluminum Welding Kit — This kitrequired for welding with .035 Aluminum wire.Included with this kit are a drive roll, liner and con-tact tip. It is important when changing betweenwelding with steel wire and aluminum toexchange these components due to the lubri-cant applied to steel wire. Failure to do so mayresult in contaminated welds when welding alu-minum.

See Maintenance section for instructions oninstalling drive roll, cable liner, contact tip and theirproper configuration.

SP-135 PLUS

C-2 C-2 ACCESSORIESINNERSHIELD (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 conversions should bemade using the contents of this kit:

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

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

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

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

* The Factory installed Gun Liner will feed (.025-.035(0.6mm - 0.9mm) wire.

REPLACEMENT PARTS

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

Contact Tip .025” (0.6 mm)KP2039-1B1



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



Contact Tip-Tapered .045” (1.2mm)KP2052-4B1

Liner .023 - .035” (0.6 - 0.9 mm)KP1937-3

Gas DiffuserKP2040-1

Gas NozzleKP1938-1

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



Spot Welding NozzleKP1956-1

Gasless Nozzle (Innershield Only)KP1939-1

SP-135 PLUS

MAINTENANCE

SAFETY PRECAUTIONS

ELECTRIC SHOCK can kill.

• Disconnect input power byremoving 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 themaintenance and trouble shoot-ing work.

ITEMS REQUIRING NO MAINTENANCE

• Drive Motor and Gearbox – Lifetime lubrication• Fan Motor- Lifetime lubrication.• Wire Reel Spindle – Do NOT lubricate shaft.

ROUTINE AND PERIODIC MAINTE-NANCE

BEFORE EACH USE• Check over machine and accessories for any obvi-

ous condition that may prevent safe performance oroperation, repair or replace items as necessary tocorrect any abnormal condition.

AFTER 5 MINUTES OF WELDING or when spatter accumulates in nozzle

• Clean nozzle to avoid bridging between nozzle andcontact tip which results in shorted nozzle, poorwelds and overheated gun. Hint: Anti-stick spray orgel available from a welding supply distributor mayreduce buildup and aid in spatter removal.

AFTER EACH SPOOL OF WIRE FEED

• Remove contact tip and clean inside diameter withshort piece of wire

• Clean cable liner – when rough and erratic wire feed-ing occur.

MAINTENANCED-1 D-1

WARNING

AFTER FEEDING 50# OF FLUX COREDWIRE OR 300# OF SOLID WIRE

• Unplug machine or turn power switch to OFF – “O”position. Remove gun and cable from machine.

• Remove gas nozzle and contact tip from gun.

• Lay cable out straight - blow out gently into gun endwith compressed air. Bend cable back and forth –blow out again – Repeat until clean.

Excessive pressure at start may cause the dirt toform a plug.

PERIODICALLY AS REQUIRED

• Blow dirt out of the welder with low pressure air toeliminate excessive dirt and dust buildup that couldcause welder to run hot.

• Blow dirt out of: Rectifier & Fan Motor Assembly;PC Board located on Case Side Assembly; andCenter Assembly components.

• Vacuum accumulated dirt from gearbox and wirefeed section.

• Inspect the incoming guide tube and clean insidediameter if necessary. Replace when excessivelyworn.

• Replace Contact Tip – when hole is enlarged orelongated (refer to “CHANGING THE CONTACTTIP”, in this section).

• Replace gas nozzle.

• Replace Liner – when wire feeding problems occurand other items have been checked (refer to“CHANGING LINER” procedure in this section).

• Replace internal gun handle parts as necessary(see Procedure at the end of this section).

WARNING

SP-135 PLUS

SP-135 PLUS

D-2 D-2 MAINTENANCE

GUN AND CABLE MAINTENANCE

FOR MAGNUM™ 100L GUN

Gun Cable CleaningClean cable liner after using approximately 300 lbs(136 kg) of solid wire or 50 lbs (23 kg) of flux-coredwire. Remove the cable from the wire feeder and lay itout straight on the floor. Remove the contact tip fromthe gun. Using low pressure air, gently blow out thecable liner from the gas diffuser end.

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

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

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

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

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

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

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

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

CAUTION

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

Components shipped with KP2039-1B1(In Gun) KP1937-3 KP1881-1SP-135 PLUS .025” (0.6mm) .030-.035” 2 Smooth grooves

KP2039-2B1(Loose) (0.8-0.9 mm) Small .023-.025” (Stenciled .025).030” (0.8mm) Large .030-.035” (Stenciled .030-.035)

K549-1 .035” (0.9mm) KP2039-3B1 KP1937-3 KP666-035C Use Large grooveInnershield Welding Kit .035” (0.9mm) .035 (0.9mm)

K663-2 .035 (0.9mm) KP2078-1B1 KP1959-1 S24220 (Drive roll)Aluminum .035A (0.9mm) .035” (0.9mm) S24219 (Idle roll)

KP666-035C Stenciled2 Knurled grooves for .035” (0.9mm)

• If .030 Solid wire feeding is desired obtain an KP2039-2B1 Contact Tip, an KP1937-2 Cable Liner and an KP1881-1 Drive Roll (Smaller Groove).

Δ Recommended for best feeding performance.

SP-135 PLUS

THESE PARTS

} NOT SOLD

SEPARATELY

SP-135 PLUS

D-3 D-3 MAINTENANCECOMPONENT 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 fromthe gun by unscrewing counter-clockwise.

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

4. Insert and hand tighten desired contact tip.

5. Replace gas nozzle.

CHANGING THE SP-135 PLUS FOR USEWITH INNERSHIELD FLUX CORED WIRE

• Change The Contact Tip

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


3. Insert and hand tighten the contact tip for use with0.035” Innershield Flux Cored Wire.

4. Replace gas nozzle – The gasless nozzle may beused instead of the gas nozzle to give improved vis--ibility of the arc.

CHANGING DRIVE ROLL

The drive roll, Figure D.1 Item 1, has two grooves; onefor .023" – .025" (0.6 mm) solid steel electrode and alarger groove for .030" (0.8 mm) solid and .035" (0.9 mm)flux-cored steel electrode. As shipped, the drive roll isinstalled in the .023"-.025" (0.6 mm) position.

If .030"/.035" (0.8/0.9 mm) wire is to be used, thedrive roll must be reversed as follows:

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

2. Release the spring-loaded idle arm tensioner,Figure D.1 Item 2, and lift the idle roll arm, FigureD.1 Item 3, away from the drive roll.

3. Loosen the Phillips Head screw holding the driveroll onto the drive shaft.

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

4. Remove the drive roll, flip over and reinstall with theopposite groove closest to the gearbox.

NOTE: The stencil of the groove that you want to useis marked on the outside of the drive unit(when installed)

5. Push a length of straightened welding wire throughthe wire feeder guide tubes and reset the PhillipsHead screw to secure the drive roll onto the shaft.

6. Reapply the spring loaded idle arm tensioner.

7. Turn the power “ON” (I) and check the drive roll forslipping when feeding wire. DO NOT OVERTIGHTEN - Ifnecessary, tighten or loosen the spring loaded idlearm tensioner (2).

FIGURE D.1

CAUTION

3

2

1

SP-135 PLUS

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

FIGURE D.3

➣

Counter-clockwise

D-4MAINTENANCE

9. Screw the gas diffuser onto the end of the guntube and securely tighten.

10. Replace the contact tip and nozzle.

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

Gas Diffuser

Contact Tip(Threaded)

Gas Nozzle orGasless Nozzle(Threaded)

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

FIGURE D.2Liner trim length for gun with red trigger (Magnum™ 100L)

Slotted Brass CableSet Screw Connector

CHANGING LINER

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

1. Remove gun and cable assembly from machine.

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


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

5. Lay the gun and cable out straight on a flat sur-face. Loosen the set screw located in the brassconnector at the wire feeder end of the cable. Pullthe liner out of the cable.

6. Insert a new untrimmed liner into the connectorend of the cable. Be sure the liner bushing is sten-ciled appropriately for the wire size being used.

7. Fully seat the liner bushing into the connector.Tighten the set screw on the brass cable connec-tor. At this time, the gas diffuser should not beinstalled onto the end of the gun tube.

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

SP-135 PLUS

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-1TROUBLESHOOTINGE-1

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

CAUTION

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

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

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

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

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

HOW TO USE TROUBLESHOOTING GUIDE

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

__________________________________________________________________________

WARNING

E-2

SP-135 PLUS

E-2 TROUBLESHOOTINGObserve 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 feed whengun trigger is pulled. Fan runs andgas flows normally.

No weld output when gun trigger ispulled. Fan runs, gas flows andwire feeds normally.

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

POSSIBLE AREAS OFMISADJUSTMENT(S)

Contact your LOCAL LINCOLNAUTHORIZED FIELD SERVICEFACILITY.

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

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

3. Make sure Circuit Breaker is Reset.

Contact your LOCAL LINCOLNAUTHORIZED FIELD SERVICEFACILITY.

1. Arc voltage may be set too low.

2. Gun tip may be worn – Replace.

3. Check for correct input voltageto machine.

4. Gun or work cable may befaulty.

1. Check the circuit breaker locat-ed in the machine’s wire drivecompartment. Reset if tripped.

2. The thermostat may be trippeddue to overheating. Let machinecool. Weld within the duty cycleor remove any air obstruction tomachine.

3. Wire feed motor may be over-loaded. Correct feeding prob-lem.

4. Gun trigger may be faulty.

RECOMMENDEDCOURSE OF ACTION

Contact your local LincolnAuthorized Field Service Facility.

OUTPUT PROBLEMS

If for any reason you do not understand the test procedures or are unable to Perform the tests/repairs safely, contact yourLOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed.

CAUTION

SP-135 PLUS

E-3E-3 TROUBLESHOOTINGObserve 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) – weldoutput.

Wire feed speed motor runs veryfast. Weld output, gas flow and fanoperate normally.

The wire begins to feed but shutsoff after a short time, and will feedagain for another short interval onlyif the tr igger is released andpressed again. (See descriptionunder wire feed overload protec-tion).


1. If the wire drive motor is runningcheck to see if the correct wireis in the machine.

2. If the wire drive motor is runningmake sure that the correct driverolls are installed in themachine.

3. Check for clogged cable liner orfeeding problems.

1. Make sure that the wire speedcontrol is not set at maximum.

1. Wire spool friction brake adjust-ment set too tight. Check adjust-ment of the wire spool frictionbrake. See "Friction BrakeAdjustment" in the "OPERA-TION" section of this manual.

2. Idle roll pressure adjustment settoo high. Check adjustment ofthe idle roll pressure. See "WireThreading" in The "OPERA-TION" section of this manual.

3. Damaged or poorly maintainedwire feed system.

1. Check for clogged or damagedcable liner, contact tip, and guidetubes. Replace any damaged orexcessively worn parts.

2. Perform "ROUTINE ANDPERIODIC MAINTENANCE" asdescribed in this manual.



FEEDING PROBLEMS


CAUTION

E-4E-4 TROUBLESHOOTINGObserve Safety Guidelinesdetailed in the beginning of this manual.

TROUBLESHOOTING GUIDE

PROBLEMS(SYMPTOMS)

Arc is unstable – Poor starting


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

2. Check for proper electrodepolarity for process.

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

4. Check for proper gas and flowrate for process.

5. Check work cable for loose orfaulty connections.

6. Check gun for damage orbreaks.



WELDING PROBLEMS


CAUTION

PROBLEMS(SYMPTOMS)

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


1. Check gas supply, flow regulatorand gas hoses.

2. Check gun connection tomachine for obstruction or leakyseals.



GAS FLOW PROBLEMS

SP-135 PLUS

F-1 F-1 WIRING DIAGRAMS

WA

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139

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

SP-135 PLUS

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BEUSED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

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

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

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

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

● Insulate yourself from work andground.

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

● Aislese del trabajo y de la tierra.

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

● Isolez-vous du travail et de la terre.

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

● Isolieren Sie sich von denElektroden und dem Erdboden!

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

● Isole-se da peça e terra.

● Keep flammable materials away.

● Mantenga el material combustiblefuera del área de trabajo.

● Gardez à l’écart de tout matérielinflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-dos.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y elcuerpo.

● Protégez vos yeux, vos oreilles etvotre corps.

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

● Use proteção para a vista, ouvido ecorpo.

WARNING

AVISO DEPRECAUCION

ATTENTION

WARNUNG

ATENÇÃO

Spanish

French

German

Portuguese

Japanese

Chinese

Korean

Arabic

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

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

remove fumes from breathing zone.

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

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

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

teur pour ôter les fumées des zonesde travail.

● Vermeiden Sie das Einatmen vonSchweibrauch!

● Sorgen Sie für gute Be- undEntlüftung des Arbeitsplatzes!

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

remover fumo da zona respiratória.

● Turn power off before servicing.

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

● Débranchez le courant avant l’entre-tien.

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

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

serviço.● Não toque as partes elétricas nuas.

● Do not operate with panel open orguards off.

● No operar con panel abierto oguardas quitadas.

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

● Anlage nie ohne Schutzgehäuseoder Innenschutzverkleidung inBetrieb setzen!

● Mantenha-se afastado das partesmoventes.

● Não opere com os paineis abertosou guardas removidas.

• Sales and Service through Subsidiaries and Distributors Worldwide •

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

• World's Leader in Welding and Cutting Products •

IM788 SP-135 PLUS - Lincoln Electric Global Sites · 4.a. Use a shield with the proper filter and...

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