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Lincoln Electric SP-135T IM724 - page 1
SP- 135T OPERA TOR’S MANUAL IM724 April, 2001 Safety Depends on You Lincoln arc welding and cutting equipment is designed and built with safety in mind. However, your overall safety can be increased by proper installation ... and thought- ful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND ...
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Lincoln Electric SP-135T IM724 - page 2
FOR ENGINE powered 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. ________________________________________________ ...
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Lincoln Electric SP-135T IM724 - page 3
ii SAFETY ii ARC RA YS can burn. 4.a. Use a shield with the proper filter and cover plates to protect your eyes from sparks and the rays of the arc when welding or observing open arc welding. Headshield and filter lens should conform to ANSI Z87. I standards. 4.b. Use suitable clothing made from durable flame-resistant material to protect your skin ...
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Lincoln Electric SP-135T IM724 - page 4
FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the 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 equipment in accordance with the U.S. National Electrical C ...
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Lincoln Electric SP-135T IM724 - page 5
iv SAFETY iv PRÉCA UTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. Les circuits ...
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Lincoln Electric SP-135T IM724 - page 6
Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick reference. Pay par ...
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Lincoln Electric SP-135T IM724 - page 7
vi MASTER T ABLE OF CONTENTS FOR ALL SECTIONS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components ......................... ...
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Lincoln Electric SP-135T IM724 - page 8
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 Ft. (15.2 mm) INST ALLA TION TECHNICAL SPECIFICA T ...
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Lincoln Electric SP-135T IM724 - page 9
A-2 INST ALLA TION SP-135T A-2 Read entire installation section before starting installation. SAFETY PRECA UTIONS IDENTIFY AND LOCA TE COMPONENTS If you have not already done so, unpack the SP-135T from its carton and remove all packing material around the SP-135T. Remove the following loose items from the carton (see Figure A.1): 1. SP-135T 2. Gun ...
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Lincoln Electric SP-135T IM724 - page 10
A-3 INST ALLA TION SP-135T A-3 SP-135T 4 5 8 3 6 7 1 2 DO NOT SWITCH DO NOT SWITCH WHEN WELDING WHEN WELDING + - FIGURE A.2 W ork 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 strain relief ...
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Lincoln Electric SP-135T IM724 - page 11
W ork 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 Work Cable Access Hole (1) in the case front. 3. Route the cable under and around the back of the Wire Feed Gearbox (6). 4. For GMAW Only: ...
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Lincoln Electric SP-135T IM724 - page 12
CYLINDER may explode if dam- aged. Keep cylinder upright and chained to support • Keep cylinder away from areas where it may be damaged. • Never lift welder with cylinder attached. • Never allow welding electrode to touch cylinder. • Keep cylinder away from welding or other live electrical circuits. BUILDUP OF SHIELDING GAS may harm health ...
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Lincoln Electric SP-135T IM724 - page 13
A-6 INST ALLA TION SP-135T A-6 INPUT CONNECTIONS Refer to Figure A.6. The SP-135T has a power input cable located on the rear of the machine. FIGURE A.6 CODE REQUIREMENTS FOR INPUT CONNECTIONS This welding machine must be connected to a power source in accordance with applicable elec- trical codes. The United States National Electrical Code (Articl ...
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Lincoln Electric SP-135T IM724 - page 14
B-1 OPERA TION B-1 SP-135T Read entire operation section before operating the SP-135T . ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ve ...
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Lincoln Electric SP-135T IM724 - page 15
B-2 OPERA TION B-2 5. Gun Trigger - Activates welding output, wire feed, and gas solenoid operation. Releasing the trigger deactivates welding and simultaneously activates the “ burnback ” function so that the welding wire does not stick in the weld puddle. 6 . Optional K695-1 Spot/ Stitch Timer Kit Controls (see ACCESSORIES section) - If prese ...
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Lincoln Electric SP-135T IM724 - page 16
B-3 OPERA TION B-3 FIGURE B.1a FIGURE B.1b WELDING OPERA TIONS SEQUENCE OF OPERA TION Wire Loading Refer to Figures B.2 and B.3. The machine power switch should be turned to the OFF ( “ O ” ) position before working inside the wire feed enclosure. The welder is shipped from the factory ready to feed 8" (200 mm) diameter spools with 2.2&quo ...
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Lincoln Electric SP-135T IM724 - page 17
B-4 OPERA TION B-4 Friction Brake Adjustment With wire spool installed on the spindle shaft and the wing nut loose, turn the spool by hand while slowly tightening the wing nut until a light drag is felt. Tighten the wing nut an additional 1/4 turn. Note: When properly adjusted, the brake should pro- vide only enough drag to prevent overrun of the s ...
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Lincoln Electric SP-135T IM724 - page 18
B-5 OPERA TION 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 for range of metal thicknesses that can be welded. 2. See the Application chart on the inside of the wire feed compartment door for information on setting the SP-135T controls. Refer to Table B.1 for al ...
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Lincoln Electric SP-135T IM724 - page 19
B-6 OPERA TION 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 Argon Regulator Kit). TABLE B.1 CHANGING MA CHINE O VER T O FEED O THER WIRE SIZES The SP-135T is shipped from the factory ready to feed .023 ” -.025 ” (0.6 mm) diameter wi ...
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Lincoln Electric SP-135T IM724 - page 20
B-7 LEARNING T O WELD B-7 LEARNING T O WELD No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced operator to understand welding and develop this skill. For more detailed infor- mation, order a copy of “ New Lessons in Arc Welding ” listed at the end of this manual. ...
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Lincoln Electric SP-135T IM724 - page 21
B-8 LEARNING T O WELD B-8 The “ arc stream ” is seen in the middle of the picture. This is the electric arc created by the electric current flowing through the space between the end of the wire electrode and the base metal. The temperature of this arc is about 6000 ° F, which is more than enough to melt metal. The arc is very bright, as well a ...
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Lincoln Electric SP-135T IM724 - page 22
B-9 LEARNING T O WELD B-9 SP-135T For GMAW (MIG) Process 1. Is most of my welding performed on 16 gauge and lighter materials? 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas sup- ply? 3. Do I require clean, finished-looking welds? If you have answered yes to all the above questions GMAW may be t ...
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Lincoln Electric SP-135T IM724 - page 23
B-10 LEARNING T O WELD B-10 SP-135T FIGURE B.12 Penetration Unless a weld penetrates close to 100% of the metal thickness, a butt weld will be weaker than the material welded together. In the example shown in Figure B.13, the total weld is only half the thickness of the material thus the weld is only approximately half as strong as the metal. FIGUR ...
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Lincoln Electric SP-135T IM724 - page 24
B-11 LEARNING T O WELD B-11 SP-135T FIGURE B.16 Vertical-down Welding Refer to Figure B.17 Vertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow and, as such, are excellent for sheet metal. Vertical-down welds may be applied to 5/32 ” (3.9 mm) and lighter material. Use stringer beads and tip the gun in the d ...
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Lincoln Electric SP-135T IM724 - page 25
B-12 LEARNING T O WELD B-12 SP-135T ARC RAYS can burn eyes and skin. When using an open arc process, it Is necessary to use correct eye, head and body protection. Protect yourself and others, read “ ARC RAYS can burn ” at the front of this manual. 2. The Correct Way To Strike An Arc 1. Be sure the work clamp makes good electrical contact to the ...
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Lincoln Electric SP-135T IM724 - page 26
B-13 LEARNING T O WELD B-13 SP-135T Helpful Hints 1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways. Weld along at a steady pace. You will find it easier. 2. When welding on thin plate, you will find that you will have to increase the welding speed, whereas when welding on heavy plate, it is nece ...
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Lincoln Electric SP-135T IM724 - page 27
B-14 LEARNING T O WELD B-14 SP-135T MA CHINE SET UP FOR THE GMA W (MIG) PROCESS 1. See PROCESS GUIDELINES in the OPERATION section for selection of welding wire and shielding gas, and for range of metal thicknesses that can be welded. 2. See the Application Guide on the inside of wire feed section door for information on setting the controls. 3. Se ...
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Lincoln Electric SP-135T IM724 - page 28
B-15 LEARNING T O WELD B-15 SP-135T FIGURE B.24 3. The Correct Electrical Stickout (ESO) The electrical stickout (ESO) is the distance from the end of the contact tip to the end of the wire. See Figure B.24. Once the arc has been established, maintaining the correct ESO becomes extremely important. The ESO should be approximately 3/8 to 1/2 inch (1 ...
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Lincoln Electric SP-135T IM724 - page 29
B-16 LEARNING T O WELD B-16 TR OUBLESHOO TING WELDS Good welds have excellent appearance. To Eliminate Porosity (in order of importance): 1. Turn on gas supply, if used 2. Decrease voltage. 3. Increase stickout. 4. Increase WFS (wire feed speed). 5. Decrease drag angle. 6. Decrease travel speed. NOTE: Always be sure the joint is free from moisture, ...
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Lincoln Electric SP-135T IM724 - page 30
B-17 LEARNING T O WELD B-17 Proper Gun Handling Most feeding problems are caused by improper han- dling of the gun cable or electrodes. 1. Do not kink or pull the gun around sharp corners 2. Keep the gun cable as straight as practical when welding. 3. Do not allow dolly wheels or trucks to run over the cables. 4. Keep the cable clean. 5. Innershiel ...
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Lincoln Electric SP-135T IM724 - page 31
B-18 APPLICA TION CHART B-18 SP-135T ...
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Lincoln Electric SP-135T IM724 - page 32
C-1 A CCESSORIES C-1 OPTIONAL A CCESSORIES 1. K549-1 .035" (0.9 mm) Innershield ® Welding Kit — Includes a contact tip, a gasless nozzle and a .035/.045" (.9/1.2 mm) cable liner to permit the Magnum ™ 100L gun and cable to use .035" (0.9 mm) diameter flux-cored electrode. The fitting on the end of the liner is stenciled with the ...
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Lincoln Electric SP-135T IM724 - page 33
C-2 A CCESSORIES C-2 INNERSHIELD (FCA W) CONVERSION Several changes are needed to convert the unit for operation with the Innershield (FCAW) process. The K549-1 or K549-2 Innershield Kits include all the nec- essary accessories for this conversion and are provid- ed for this purpose. The following conversions should be made using the contents of th ...
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Lincoln Electric SP-135T IM724 - page 34
MAINTENANCE SAFETY PRECA UTIONS ELECTRIC SHOCK can kill. • Disconnect input power by removing plug from receptacle before working inside SP-135T. Use only grounded receptacle. Do not touch electrically “ hot ” parts inside SP-135T. • Have qualified personnel do the mainte- nance and trouble shooting work. R OUTINE MAINTENANCE PO WER SOURCE ...
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Lincoln Electric SP-135T IM724 - page 35
D-2 MAINTENANCE D-2 SP-135T GUN AND CABLE MAINTENANCE FOR MA GNUM ™ 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-cored wire. Remove the cable from the wire feeder and lay it out straight on the floor. Remove the contact tip from the gun. Using low pressure air, ge ...
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Lincoln Electric SP-135T IM724 - page 36
D-3 MAINTENANCE D-3 SP-135T COMPONENT REPLA CEMENT PR OCEDURES CHANGING THE CONT A CT TIP 1. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 2. Remove the existing contact tip from the gun by unscrewing counter-clockwise. 3. Insert and hand tighten desired contact tip. 4. Replace gas nozzle. CHANGING DRIVE R ...
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Lincoln Electric SP-135T IM724 - page 37
GUN HANDLE P ARTS The gun handle consists of two halves that are held together with a collar on each end. To open up the handle, turn the collars approximately 60 degrees counter-clockwise until the collar reaches a stop. Then pull the collar off the gun handle. If the collars are diffi- cult to turn, position the gun handle against a corner, place ...
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Lincoln Electric SP-135T IM724 - page 38
E-1 TR OUBLESHOO TING 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. CA UTION This Troubleshooting Guide is provided to help you locate and repair possi ...
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Lincoln Electric SP-135T IM724 - page 39
E-2 TR OUBLESHOO TING 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. CA UTION PROBLEMS (SYMPT OMS) Major physical or electrical damage is evident. No wi ...
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Lincoln Electric SP-135T IM724 - page 40
E-3 TR OUBLESHOO TING 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. CA UTION PROBLEMS (SYMPT OMS) No wire feed when gun trigger is pulled. Fan runs, ga ...
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Lincoln Electric SP-135T IM724 - page 41
E-4 TR OUBLESHOO TING 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. CA UTION PROBLEMS (SYMPT OMS) Arc is unstable – Poor starting POSSIBLE AREAS OF M ...
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Lincoln Electric SP-135T IM724 - page 42
F-1 DIA GRAMS F-1 SP-135T S1 SWITCH D1 D3 D2 D4 204 204 204 203 203 203 C1 59,000 f 40V 203 204 - + GUN CABLE CONDUCTOR BLOCK TO WORK ELECTRICAL SYMBOLS PER E1537 CAVITY NUMBERING SEQUENCE ( COMPONENT SIDE OF BOARD ) 539 541 T1 GUN TRIGGER THERMOSTAT 208 5K WIRE SPEED R2 (W) (B) N.C. N.C. COMPONENT VIEWED FROM REAR. ON-OFF N.C. 209 WINDING 24V AUXI ...
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Lincoln Electric SP-135T IM724 - page 43
NO TES SP-135T ...
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Lincoln Electric SP-135T IM724 - page 44
W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TEN ÇÃ O Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes ...
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Lincoln Electric SP-135T IM724 - page 45
• 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 • ...
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