IM785
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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 thoughtful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT READING THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
SP-135T
April, 2004
For use with machine Code Number:10971
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com
OPERATOR’S MANUAL
Copyright © 2004 Lincoln Global Inc.
• World's Leader in Welding and Cutting Products •
• Sales and Service through Subsidiaries and Distributors Worldwide •
i
SAFETY
i
WARNING
CALIFORNIA PROPOSITION 65 WARNINGS
Diesel engine exhaust and some of its constituents
are known to the State of California to cause cancer, birth defects, and other reproductive harm.
The Above For Diesel Engines
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 you
purchase a copy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from the American Welding Society, P.O. Box
351040, Miami, Florida 33135 or CSA Standard W117.2-1974. A Free copy of “Arc Welding Safety” booklet E205 is available
from the Lincoln Electric Company, 22801 St. Clair Avenue, Cleveland, Ohio 44117-1199.
BE SURE THAT ALL INSTALLATION, OPERATION, MAINTENANCE AND REPAIR PROCEDURES ARE
PERFORMED ONLY BY QUALIFIED INDIVIDUALS.
The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.
The Above For Gasoline Engines
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.
____________________________________________________
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 before
refueling to prevent spilled fuel from vaporizing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.
____________________________________________________
1.d. Keep all equipment safety guards, coversand devices in position and in good repair.Keep hands, hair, clothing and tools
away from V-belts, gears, fans and all other moving parts
when starting, operating or repairing equipment.
____________________________________________________
1.e. In some cases it may be necessary to remove safety
guards to perform required maintenance. Remove
guards only when necessary and replace them when the
maintenance requiring their removal is complete.
Always use the greatest care when working near moving
parts.
___________________________________________________
1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.
1.h. To avoid scalding, do not remove the
radiator pressure cap when the engine is
hot.
ELECTRIC AND
MAGNETIC FIELDS
may 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, and
welders having a pacemaker should consult their physician
before welding.
2.c. Exposure to EMF fields in welding may have other health
effects which are now not known.
2.d. All welders should use the following procedures in order to
minimize exposure to EMF fields from the welding circuit:
2.d.1.
Route the electrode and work cables together - Secure
them 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 and
work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.
___________________________________________________
1.g. To prevent accidentally starting gasoline engines while
turning the engine or welding generator during maintenance
work, disconnect the spark plug wires, distributor cap or
magneto wire as appropriate.
2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.
2.d.5. Do not work next to welding power source.
Mar ‘95
ii
SAFETY
ii
ELECTRIC SHOCK can
kill.
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 bare
skin 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 full
area of physical contact with work and ground.
In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the 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 semiautomatic
welding gun are also electrically “hot”.
3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should 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.
ARC RAYS 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 and that of your helpers from
the arc rays.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fumes and gases.When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep
fumes and gases away from the breathing zone. When
welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and below Threshold Limit Values (TLV)
using local exhaust or mechanical ventilation. In
confined spaces or in some circumstances, outdoors, a
respirator may be required. Additional precautions are
also required when welding on galvanized steel.
3.f.
Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.b.
Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying
operations.The heat and rays of the arc can react with solvent vapors
irritating products.
5.c. Shielding gases used for arc welding can displace air and
cause 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 this
equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.
5.e. Also see item 1.b.
to
form phosgene, a highly toxic gas, and other
vapors
Mar ‘95
iii
SAFETY
iii
WELDING SPARKS can
cause fire or explosion.
6.a.
Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
the welding sparks from starting a fire.
materials from welding can easily go through small cracks
and openings to adjacent areas. Avoid welding near
hydraulic 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 hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
6.c. When not welding, make certain no part of the electrode
circuit is touching the work or ground. Accidental contact
can cause overheating and create a fire hazard.
6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
Sparks and spatter are thrown from the welding arc. Wear oil
6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.
6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibility of the welding current passing
through lifting chains, crane cables or other alternate circuits. This can create fire hazards or overheat lifting chains
or cables until they fail.
6.h. Also see item 1.c.
Remember that welding sparks and hot
though
they have
Preparation
for Welding and Cutting of
CYLINDER may explode
if damaged.
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and
pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
7.c. Cylinders should be located:
• Away from areas where they may be struck or subjected to
physical damage.
• A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
FOR ELECTRICALLY
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 Code and the manufacturer’s recommendations.
Mar ‘95
iv
SAFETY
iv
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions 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 à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés attention de bien s’isoler de la masse quand on
soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une
grande partie du corps peut être en contact avec la
masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de levage, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles 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 tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les
vapeurs du 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” CSA
Standard W 117.2-1974.
2. Dans le cas de travail au dessus du niveau du sol, se protéger contre les chutes dans le cas ou on recoit un choc. Ne
jamais enrouler le câble-électrode autour de n’importe quelle
partie du 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 approprié
ainsi qu’un verre blanc afin de se protéger les yeux du
rayonnement de l’arc et des projections quand on soude
ou quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection
libres de l’huile, tels que les gants en cuir, chemise épaisse,
pantalons sans revers, et chaussures montantes.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
1. Relier à la terre le chassis du poste conformement au code
de l’électricité et aux recommendations du fabricant. Le dispositif de montage ou la piece à souder doit être branché à
une bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste
seront effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la
debrancher à l’interrupteur à la boite de fusibles.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
Mar. ‘93
for selecting a QUALITY product by Lincoln Electric. We want you
Thank You
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Please Examine Carton and Equipment For Damage Immediately
When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.
Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.
Product _________________________________________________________________________________
Model Number ___________________________________________________________________________
Code Number or Date Code_________________________________________________________________
Serial Number____________________________________________________________________________
Date Purchased___________________________________________________________________________
vv
Where Purchased_________________________________________________________________________
Whenever you request replacement parts or information on this equipment, always supply the information you
have 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 packet
accompanying this machine and fax the form per the instructions printed on it.
• For On-Line Registration: Go to our
“Product Registration”. Please complete the form and submit your registration.
Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy 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:
WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then
WARNING
This statement appears where the information must be followed exactly to avoid serious personal injury or
loss of life.
CAUTION
This statement appears where the information must be followed to avoid minor personal injury or damage to
this equipment.
vi
vi
MASTER TABLE OF CONTENTS FOR ALL SECTIONS
Page
Installation .......................................................................................................Section A
Technical Specifications ........................................................................................A-1
Identify and Locate Components...........................................................................A-2
Select Suitable Location ........................................................................................A-3
Output Connections...............................................................................................A-3
Input Connections..................................................................................................A-6
Code Requirements ..............................................................................................A-6
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description...............................................................................................B-1
Design Features ....................................................................................................B-1
Welding Capability.................................................................................................B-2
Limitations..............................................................................................................B-2
Controls and Settings ............................................................................................B-2
Welding Operations ...............................................................................................B-3
Overload Protection...............................................................................................B-6
Application Chart ...................................................................................................B-7
Accessories.....................................................................................................Section C
Accessories ...........................................................................................................C-1
Replacement Parts................................................................................................C-2
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Items Requiring No Maintenance ..........................................................................D-1
Routine Maintenance.............................................................................................D-1
Gun and Cable Maintenance.................................................................................D-2
Component Replacement Procedures ..................................................................D-3
Changing Liner ......................................................................................................D-4
Gun Handle Parts..................................................................................................D-4
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide.........................................................................E-2 THRU E-4
Wiring Diagrams..............................................................................................Section F
SP-135T Wiring Diagram.......................................................................................F-1
Parts Lists .....................................................................................P451 Series, P202-E
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – SP-135T
INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency Input Current
120V/60Hz 20 Amps - Rated Output
RATED OUTPUT
Duty
Cycle Amps Volts at Rated Amperes
20% Duty Cycle 90 19
OUTPUT
Welding Current Range Maximum-Open Circuit Voltage Wire Speed Range
25-135 Amps 29V 50 - 300 in/min
(1.3 - 7.6 m/min)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse or
Output Mode Input Voltage Breaker Size1Input Amps Power Cord Extension Cord
A-1
RATED 120V/60Hz 20 Amp 20 15 Amp, 125V,
Three Prong Plug Three Conductor
(NEMA Type 5-15P) #12 AWG
PHYSICAL DIMENSIONS
Height Width Depth Weight
12.0 in 9.75 in 16.5 in 48 Ibs
305 mm 248 mm 419 mm 21.8 kg
1
If connected to a circuit protected by fuses use Time Delay Fuse marked “D”.
Three Conductor
#14 AWG
(
2.1 mm
Up to 25 Ft. (7.6 mm)
(3.3 mm
Up to 50 Ft. (15.2 mm)
2
) or Larger
2
) or Larger
SP-135T
A-2
1
2
3
4
6
7
8
5
INSTALLATION
Read entire installation section before starting
installation.
A-2
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform
this installation.
• Only personnel that have read and understood the SP-135T Operating Manual
should install and operate this equipment.
• Machine must be plugged into a receptacle
which is grounded per any national, local
or other applicable electrical codes.
• The SP-135T power switch is to be in the
OFF (“O”) position when installing work
cable and gun and when connecting power
cord to input power.
IDENTIFY AND LOCATE
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):
FIGURE A.1
1. SP-135T
2. Gun and cable assembly
(1)
3. Literature and miscellaneous including:
a) This operating manual
b) 6 extra .023"-.025” (0.6 mm) contact tips
c) Hex key wrench for removal of drive roll.
4. 10 ft (3.0 m) work cable.
5. Work clamp.
6. 2 LB. Sample Spool of Super Arc L-56 .025 MIG
Wire.
7. Handshield with filter plate and lens.
8. Adjustable mixed-Gas Regulator & Hose.
For available options and accessories refer to the
Accessories Section of this manual.
1)
As shipped from the factory, the SP-135T gun liner
is ready to feed .023” (0.6 mm) -.035 (0.9 mm) wire.
The contact tip is sized for .023”-.025” (0.6 mm) wire
feeding.
SP-135T
A-3
SP-135T
4
5
8
3
6
7
1
2
DO NOT SWITCH
WHEN WELDING
INSTALLATION
A-3
SELECT SUITABLE LOCATION
Locate the welder in a dry location where there is free
circulation of clean air into the louvers in the back and
out the front of the unit. A location that minimizes the
amount of smoke and dirt drawn into the rear louvers
reduces the chance of dirt accumulation that can block
air passages and cause overheating.
STACKING
SP-135T’s cannot be stacked.
TILTING
Each machine must be placed on a secure, level surface, or on a recommended cart. The machine may
topple over if this procedure is 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.
7. Cable Hanger.
8. Thumbscrew.
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 strain relief hole in the work clamp
as shown in Figure A-3.
3. Fasten securely with the bolt and nut provided.
FIGURE A.3
Strain Relief Hole
Work Cable
Work Clamp
Nut & Bolt
+
-
FIGURE A.2
SP-135T
A-4
2
4
3
1
INSTALLATION
A-4
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 terminal 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: Refer to Figure A.2. As deliv-
ered, the machine is connected for positive electrode polarity. This is the appropriate configuration
for the GMAW (MIG) process. To complete installation, use the provided wing nut to connect the work
cable’s terminal lug to the negative (–) output terminal (5) located above the Wire Feed Gearbox
(6). Make sure that both wing nuts are tight.
5. For Innershield Only: Refer to Figure A.4. To wire
for negative polarity (required for the Innershield
process), connect the short cable attached to the
connector block (1) to the negative (–) output terminal (2) and the work cable (3) to the positive (+)
terminal (4).
Connecting Gun Cable to the SP-135T
1. 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 control leads, one at a time, through the Gun Cable
and Control Lead Access Slot (2) in the case front.
The leads are to be routed under the Wire Feed
Gearbox (6) and through the Cable Hanger (7) on
the inner panel.
3. Insert the connector on the gun conductor cable
through the Gun Cable Access Hole (2) in the SP135T case front. Make sure the connector is all the
way in the brass connector block. Unscrew thumbscrew on the connector block a few turns if gun
connector will not insert fully. Rotate the connector
so control leads are on the underside and tighten
the Thumbscrew (8) in the connector block.
4. Connect the gun trigger control lead terminals to
the two insulated 1/4" (6.4 mm) tab terminal connector bushings located below the “Gun Trigger
Connection” decal in the wire feed section (4).
Either lead can go to either connector. Form the
leads so that they are as close as possible to the
inside panel.
CAUTION
If the gun trigger switch being used is other than
that supplied with the SP-135T, the switch must be
a normally open, momentary switch. The terminals
of the switch must be insulated from the welding
circuit. Malfunction of the SP-135T may result if
this switch shorts to the SP-135T welding output
circuit or is common to any electrical circuit other
than the SP-135T trigger circuit.
FIGURE A.4
GAS CONNECTION
GUN INSTALLATION
As shipped from the factory, the SP-135T is ready to
feed .023" – .025" (0.6 mm) solid wire. If .030.035"(0.8-0.9mm) solid wire is to be used, change the
contact tip to the appropriate size.
NOTE: If .035" (0.9 mm) Innershield flux-cored wire is
to be used, assemble the gasless nozzle and, 035"
contact tip on to gun and reverse drive roll.
When using the GMAW process, a cylinder of shielding gas, must be obtained. For more information about
selecting gas cylinders for use with the SP-135T refer
to the ACCESSORIES section.
SP-135T
A-5
INSTALLATION
A-5
WARNING
CYLINDER may explode if damaged. 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.
WARNING
BUILDUP OF SHIELDING GAS may
harm health or kill.
• Shut off shielding gas supply
when not in use.
• SEE AMERICAN NATIONAL
STANDARD Z-49.1, “SAFETY IN
WELDING AND CUTTING” PUBLISHED BY THE AMERICAN
WELDING SOCIETY.
2. With the cylinder securely installed, remove the
cylinder cap. Stand to one side away from the outlet and open the cylinder valve very slightly for an
instant. This blows away any dust or dirt which may
have accumulated in the valve outlet.
WARNING
BE SURE TO KEEP YOUR FACE AWAY FROM
THE VALVE OUTLET WHEN “CRACKING” THE
VALVE. Never stand directly in front of or behind
the flow regulator when opening the cylinder
valve. Always stand to one side.
3. Attach the flow regulator to the cylinder valve and
tighten the union nut securely with a wrench.
NOTE: If connecting to 100% CO2cylinder, make
certain the plastic washer is seated in the fitting
that attaches to the CO2cylinder.
4. Refer to Figure A.6. Attach one end of inlet gas
hose to the outlet fitting of the flow regulator and
tighten the union nut securely with a wrench.
Connect the other end to the SP-135T Gas
Solenoid Inlet Fitting (5/8-18 female threads — for
CGA — 032 fitting). Make certain the gas hose is
not kinked or twisted.
1. Chain the cylinder to a wall or other stationary support to prevent the cylinder from falling over.
Insulate the cylinder from the work circuit and earth
ground. Refer to Figure A.5.
Flow Regulator
Gas Hose
FIGURE A.5
Cylinder Valve
SP-135T
A-6
INSTALLATION
A-6
INPUT CONNECTIONS
Refer to Figure A.6.
The SP-135T has a power input cable located on the
rear of the machine.
GAS SOLENOID
INLET FITTING
POWER INPUT
CABLE
Requirements For Rated Output
A power cord with a 15 amp, 125 volt, three prong
plug (NEMA Type 5-15P) is factory installed on the
SP-135T. Connect this plug to a mating grounded
receptacle which is connected to a 20 amp branch circuit with a nominal voltage rating of 115 to 125 volts,
60 Hertz, AC only.
The rated output with this installation is 90 amps,19
Volts, 20% duty cycle (2 minutes of every 10 minutes
used for welding).
CAUTION
Do not connect the SP-135T to an input power
supply with a rated voltage that is greater than 125
volts.
Do not remove the power cord ground prong.
FIGURE A.6
CODE REQUIREMENTS FOR INPUT
CONNECTIONS
WARNING
This welding machine must be connected to a
power source in accordance with applicable electrical codes.
The National Electrical Code provides standards
for amperage handling capability of supply conductors based on duty cycle of the welding
source.
If there is any question about the installation
meeting applicable electrical code requirements,
consult a qualified electrician.
SP-135T
B-1
OPERATION
B-1
Read entire operation section before
operating the SP-135T.
WARNING
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 ventilation or exhaust to
remove fumes from breathing
zone.
WELDING SPARKS can
cause fire or explosion.
• Keep flammable material away.
• Do not weld on closed containers.
GENERAL DESCRIPTION
The SP-135T is a complete semiautomatic constantvoltage DC wire feeder / power source arc welder. It
has been designed for workshop, hobby, automotive
and light maintenance. Included is a tap-switch controlled, single phase constant voltage transformer /
rectifier power source and a wire feeder welding gun
for feeding .023 - .025” (0.6 mm) through .030” (0.8
mm) solid steel electrode. An optional kit is available
for feeding .035” (0.9 mm) Innershield®NR-211-MP
flux-cored wire.
The SP-135T is ideally suited for individuals having
access to 120 volt AC input power, and wanting the
ease of use, quality and dependability of both gas
metal arc welding or GMAW (also known as MIG
welding) and the Innershield electrode process (self
shielded flux cored or FCAW). The SP-135T is a
rugged and reliable machine that has been designed
for dependable service and long life.
RECOMMENDED PROCESSES
The SP-135T can be used for welding mild steel using
the Gas Metal Arc Welding (GMAW or MIG, Metal
Inert Gas) single pass process, which requires a supply of shielding gas, or the flux-cored arc welding
(FCAW) process using Innershield®electrode wire.
The SP-135T is configured for use with the GMAW
process as delivered from the factory.
OPERATIONAL CONTROLS
ARC RAYS can burn eyes
and skin.
• Wear eye, ear and body protection.
Observe all safety information throughout
this manual.
The SP-135T has the following controls as standard:
Control Power ON/OFF Switch, Voltage Control, Wire
Speed Control, Trigger Switch, and a Circuit Breaker.
DESIGN FEATURES
● Operates on 120 volt input
● “Cold electrode” until gun trigger is pressed for an
added measure of safety.
● Overload protection — incorporates both a thermo-
stat and a circuit breaker.
● Quality wire drive with electronic overload protec-
tion.
● “Quick Release” idle roll pressure arm is easily
adjusted.
● Reversible, dual groove drive roll. Drive roll will
feed .023 – .025” (0.6 mm) and .030" - .035" (0.8 -
0.9 mm) diameter wire.
SP-135T
B-2
SP-135T
DO NOT SWITCH
WHEN WELDING
3
2
1
+
-
5
4
OPERATION
B-2
● No external shielding gas is required when used
with Lincoln Innershield .035” (0.9 mm) NR®-211MP electrode.
● Accommodates both 4” (100 mm) diameter and 8”
(200 mm) diameter spools of wire.
WELDING CAPABILITY
The SP-135T is rated at 90 amps, 19 volts, at 20%
duty cycle on a ten minute basis. It is capable of higher output currents at lower duty cycles.
LIMITATIONS
Arc Gouging cannot be performed with the SP-135T.
The SP-135T is not recommended for pipe thawing or
TIG welding.
CONTROLS AND SETTINGS
Refer to Figure B.1a.
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.
1. Control Power ON/OFF Switch
— When the power is on the
fan motor will run and air will be
exhausted out the louvers in the
front of the machine. The welding output and wire feeder
remain off until the gun trigger
is pressed.
2. Wire Speed Control —
Controls the wire feed speed
from 50 – 300 in /min (1.3 –
7.6 m/min). The control can
be preset on the dial to the
setting specified on the SP135T Application Chart
located on the inside of the
wire feed section door.
3. Voltage Control — A 4-position tap selector switch gives
full range adjustment of
power source output voltage.
Do not switch while welding.
OFF
ON
WIRE SPEED
ARC VOLTS
FIGURE B.1a
FIGURE B.1b
Refer to Figure B.1b
4. Circuit Breaker – Protects machine from damage if
maximum output is exceeded. Button will extend
out when tripped (Manual reset).
.
SP-135T
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 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" (56 mm) maximum width. These spools fit on a 2" (51 mm) diameter
spindle that has a built in, adjustable friction brake to
prevent overrun of the spool and excess slack in the
wire.
Note:When loading and removing the 8” Spools
sure that the wing nut (inside the wire spool spindle
hub) is turned 90° from the wire spool spindle locking
tab. If the wing nut is positioned in line with the locking
tab, the tab cannot be depressed to load or unload the
wire spool.
FIGURE B.2
make
To use 4” (100 mm) diameter spools, the 2” (50 mm)
diameter spindle must be removed (See Figure B.3).
Remove the wing nut and spacer at the end of the
shaft and remove the outside plastic wire spool spindle. The spindle can be stored in the wire feed compartment. A 4” (100 mm) diameter spool is mounted
directly on the 5/8” (16 mm) diameter shaft and held in
place with the previously removed hardware. Also
make certain the start end of the wire, which may protrude through the side of the spool does not contact
any metallic case parts.
FIGURE B.3
Wire Spindle Shaft
To Wire Drive
4" Wire Spool
Wing Nut
and Spacer
Wire Spool Spindle
8” Wire Spool
Be sure that this stud engages
the hole in the wire spool.
To Wire Drive
Wire Spool must be pushed all the way on the spindle so that the
spindle’s tab will hold it in place. The Wire Spool will rotate clockwise when wire is dereeled.
Load an 8” (200 mm) diameter spool on the wire spool
spindle shown in Figure B.2.
SP-135T
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 provide only enough drag to prevent overrun of the spool
and excess slack in the wire. Too much drag may
result in wire feeding problems, and may cause premature 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 Wire
Feed Drive Roll (3). Ensure that the groove size in
the feeding position on the drive roll matches the
wire size being used.
OPERATION
B-4
2
1
5
3
7. Refer to Figure B.5. Remove gas nozzle and contact tip from end of gun.
4
The Wire Drive Feed Roll can
accommodate two wire sizes
by flipping the wire drive feed
roll over.
FIGURE B.4
2. Carefully detach the end of the wire from the
spool. To prevent the spool from unwinding,
maintain tension on the wire until after step 5.
3. Cut the bent portion of wire off and straighten the
first 4” (100 mm).
4. Thread the wire through the In-going guide tube
(4), over the drive roll (3), and into the out-going
guide tube (5).
5. Close the idle roll arm (2) and latch the spring
loaded pressure arm (1) in place. Rotate the spool
counterclockwise if required in order to take up
extra slack in the wire.
6. The idle roll pressure adjustment wing nut is factory set to approximately five full turns from where
the wing nut first engages the threads of the pressure arm (1). If feeding problems occur because
the wire is flattened excessively, turn the pressure
adjustment counter-clockwise to reduce distortion
of the wire. Slightly less pressure may be required
when using 0.023 – 0.025" (0,6 mm) wire. If the
drive roll slips while feeding wire, the pressure
should be increased until the wire feeds properly.
8. Turn the SP-135T ON (“I”).
9. Straighten the gun cable assembly.
10. Depress the gun trigger switch and feed welding
wire through the gun and cable. (Point gun away
from yourself and others while feeding wire.)
Release gun trigger after wire appears at end of
gun.
NOTE: If the wire will not feed smoothly, or if the wire
feed motor shuts off unexpectedly, see ” FEEDING
PROBLEMS” section of the “TROUBLESHOOTING
GUIDE” in this manual.
11. Turn the SP-135T OFF (“O”).
12. Replace contact tip and gas nozzle.
13. Refer to Figure B-6. Cut the wire off 3/8” – 1/2” (10
– 13 mm) from the end of the tip. The SP-135T is
now ready to weld.
Gun Handle
WARNING
When inching the welding wire, the drive rolls, the
gun connector block and the gun contact tip are
electrically energized relative to work and ground
and remain energized for several seconds after
the gun trigger is released.
Gas Diffuser/
Contact Tip
Gas Nozzle
FIGURE B.5
SP-135T
B-5
Contact Tip
OPERATION
6. Refer to Figure B.7. Connect work clamp to metal
to be welded. Work clamp must make good electrical contact to the workpiece. The workpiece
must also be grounded as stated in “Arc Welding
Safety Precautions” in the beginning of this manual.
B-5
Wire Electrode
3/8"– 1/2"(10-13mm) Contact
Tip to Work Distance(CTWD)
FIGURE B.6
Making A Weld
1. See “Process Guidelines” in this section for selection 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 aluminum and stainless wire.
3. Set the Voltage (“V”) and Wire Speed (“olo’”) controls to the settings suggested for the welding wire
and base metal thickness being used, refer to
Applications chart on the inside of the wire drive
compartment door.
4. Check that the polarity is correct for the welding
wire being used and that the gas supply, if
required, is turned on.
7. Position gun over joint. End of wire may be lightly
touching the work.
8. Lower welding helmet, close gun trigger, and
begin welding. Hold the gun so the contact tip to
work distance is about 3/8 inch (10 mm).
9. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.
10. When no more welding is to be done, close valve
on gas cylinder (if used), momentarily operate gun
trigger to release gas pressure, and turn off the
SP-135T.
Cleaning Tip And Nozzle
Clean the contact tip and nozzle to avoid arc bridging
between the nozzle and contact tip which can result in
a shorted nozzle, poor welds and an overheated gun.
Hint: Anti-stick spray or gel, available from a welding
supply distributor, may reduce buildup and aid in spatter removal.
PROCESS GUIDELINES
5. When using Innershield electrode, remove the gas
nozzle and install the gasless nozzle. This will
improve visibility of the arc and protect the gas diffuser from weld spatter. Refer to the MAINTENANCE section for details on nozzle replacement.
GUN CABLE
WORKPIECE
ARC
WORK CLAMP
FIGURE B.7
SP-135T
The SP-135T can be used for welding mild steel using
the GMAW, single pass, process which requires a
supply of shielding gas or it can be used for the selfshielded, Innershield®process (FCAW).
The recommended gases and electrodes for GMAW
are welding grade CO2gas or an argon-CO2blended
gas (75 to 80% argon and 25 to 20% CO2) and .025"
(0.6 mm) diameter Lincoln Super Arc L-56 mild-steel
welding wire, supplied on 12-1/2 lb (5.7 kg) spools.
The recommended electrode for the self-shielded
process is .035” (0.9 mm) diameter Lincoln
Innershield®NR-211-MP on 10 lb (4.5 kg) spools.
This electrode can be used for all position welding of
20 gauge (1.0 mm) through 5/16" (8 mm) steel.
Thickness of 1/4" (6 mm) and 5/16" (8 mm) require
multiple passes. This wire can also be used for the
welding of galvanized coated sheet metal.
B-6
OPERATION
B-6
The SP-135T is suitable for .035" aluminum wire and
.030" stainless wire. Refer to Table B.1 for recommended procedure settings (requires K499 Argon
Regulator Kit).
TABLE B.1
Process Welding Wire Gas 22 ga 16 ga 12 ga 1/8” 3/16” 1/4”
.035 Dia(0.9mm 100% Argon B-4.5 B-8.5 D-10 NR* NR* NR*
4043 Aluminum
Wire
MIG DC+
.030 Dia 98% Argon/ A-3 C-6 D-7.5 D-7.5
308L Stainless 2% Oxygen
Steel Wire
NR (Not Recommended)
*
Shielding
16 ga 14 ga 12 ga 10 ga
Voltage/Wire Speed
CHANGING MACHINE OVER TO
FEED OTHER WIRE SIZES
The SP-135T is shipped from the factory ready to feed
.023”-.025” (0.6 mm) diameter wire. To operate the
SP-135T with other sizes of wire, it may be necessary
to change the contact tip and change the drive roll
over to other sizes. Refer to Changing the Contact Tip
and Changing the Drive Roll, in the MAINTENANCE
section, for specific information on these procedures.
2. If using a regulator with an adjustable flow meter,
press 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 of
position or in a drafty location for CO2]. For argon
mixed gas, press the gun trigger to release gas
pressure, and adjust the flow to give 25 – 30 CFH
(12 – 14 I/min).
3. Keep the cylinder valve closed, except when using
the SP-135T. When finished welding:
a) Close the cylinder valve to stop gas flow.
b) Press the gun trigger briefly to release the pres-
sure in the gas hose.
c) Turn off the SP-135T.
WELDING WITH FCAW (Innershield)
When using the FCAW process, the correct drive roll
and electrode polarity must be used. See Work Cable
Installation in INSTALLATION section for changing
the polarity.
Innershield welding kit K549-1 (for .035" / 0.9mm) is
also available.
WELDING WITH GMAW (MIG)
Shielding Gas
When using the GMAW process, obtain and install a
gas regulator and hose kit; K463 (for CO2) or K499
(Argon mixed) gas regulator and hose kit.
1. For CO2, open the cylinder very slowly. For argonmixed gas, open cylinder valve slowly a fraction of
a turn. When the cylinder pressure gauge pointer
stops moving, open the valve fully.
OVERLOAD PROTECTION
Output Overload
The SP-135T is equipped with a circuit breaker and a
thermostat which protects the machine from damage if
maximum output is exceeded. The circuit breaker button will extend out when tripped. The circuit breaker
must be manually reset.
Thermal Protection
The SP-135T has a rated output duty cycle of 20%. If
the duty cycle is exceeded, a thermal protector will
shut off the output until the machine cools to a reasonable operating temperature. This is an automatic function of the SP-135T and does not require user intervention. The fan continues to run during cooling.
Electronic Wire Drive Motor Protection
The SP-135T has built-in protection for wire drive
motor overload.
SP-135T
B-7
APPLICATION CHART
B-7
SP-135T
C-1
ACCESSORIES
C-1
OPTIONAL ACCESSORIES
1. K549-1 .035" (0.9 mm) Innershield® Welding Kit
— Includes a contact tip, a gasless nozzle and a
.035/.035" (0.8-0.9mm) 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 maximum
rated wire size (.045"/1.2 mm). Also included is a
10 lb. (4.5 kg.) spool of .035" (0.9 mm) Innershield
NR-211-MP.
See “Innershield (FCAW) Conversion” in this section for installation instructions and MAINTENANCE section for proper feeding component configuration and installation.
2. K664-2 Aluminum Feeding Kit — This kit
required for welding with .035 Aluminum wire.
Included with this kit are a drive roll, liner and contact tip. It is important when changing between
welding with steel wire and aluminum to
exchange these components due to the lubricant applied to steel wire. Failure to do so may
result in contaminated welds when welding aluminum.
3. K520 Utility Cart — Designed to transport the
Lincoln family of small welders. Has provisions for
mounting a single gas cylinder. Has front casters
and large rear wheels. Handle height is easily
adjustable. Bottom tray provided for tools and
accessories. Easy assembly required; takes less
than 15 minutes.
INNERSHIELD (FCAW)
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 necessary accessories for this conversion and are provided for this purpose. The following conversions should
be made using the contents of this kit:
1. Change the output polarity to DC(–). See “Work
Cable Installation” in Installation section for details.
2. Install proper drive roll for the wire size selected.
See “Changing Drive Roll” in Maintenance section
for details.
3. Install the proper gun liner
selected. See “Component Replacement” in
Maintenance section for details.
4. Remove gas nozzle (if installed) and install gasless
nozzle. To remove, simply unscrew.
5. Load wire into machine and thread into gun and
cable per “Welding Wire Loading” section.
*
The factory installed Gun Liner will feed .025-.035 (0.6-0.9mm)
wire.
* and tip for the wire size
4. K586-1 Deluxe Adjustable Gas Regulator &
Hose Kit — Accommodates CO2 or mixed Gas
Cylinders.
SP-135T
C-2
ACCESSORIES
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 Tip-Tapered .035” (0.9 mm)
KP2052-3B1
Liner .023 - .035” (0.6 - 0.9 mm)
KP1937-3
Gas Diffuser
KP2040-1
C-2
Gas Nozzle
KP1938-1
Gas Nozzle-Tip Recessed 3/8” (9.5 mm)
Opening I.D.
KP1942-1
Gas Nozzle-Tip Recessed 1/2” (12.7 mm)
Opening I.D.
KP1942-2
Gas Nozzle-Tip Recessed 5/8” (15.9 mm)
Opening I.D.
KP1942-3
Spot Welding Nozzle
KP1956-1
Gasless Nozzle (Innershield Only)
KP1939-1
SP-135T
D-1
MAINTENANCE
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
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 maintenance and trouble shooting work.
ROUTINE MAINTENANCE
POWER SOURCE COMPARTMENT
No user serviceable parts inside! Do not attempt to perform
service in the power source (fixed) side of the SP-135T. Take
the unit to an authorized Lincoln Service Center if you experience problems. NO maintenance is required.
D-1
In extremely dusty locations, dirt may clog the air passages
causing the welder to run hot with premature tripping of thermal protection. If so, blow dirt out of the welder with low pressure air at regular intervals to eliminate excessive dirt and dust
build-up on internal parts.
WIRE FEED COMPARTMENT
1. When necessary, vacuum accumulated dirt from gearbox
and wire feed section.
2. Occasionally inspect the incoming guide tube and clean
inside diameter if necessary.
3. Motor and gearbox have lifetime lubrication and require no
maintenance.
FAN MOTOR
Has lifetime lubrication — requires no maintenance.
WIRE REEL SPINDLE
Requires no maintenance. Do not lubricate shaft.
SP-135T
D-2
MAINTENANCE
D-2
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-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, gently blow out the
cable liner from the gas diffuser end.
CAUTION
Excessive pressure at the start may cause the dirt
to form a plug.
Flex the cable over its entire length and again blow
out the cable. Repeat this procedure until no further
dirt comes out.
Contact Tips, Nozzles, and Gun Tubes
1. Dirt can accumulate in the contact tip hole and
restrict wire feeding. After each spool of wire is
used, remove the contact tip and clean it by pushing a short piece of wire through the tip repeatedly.
Use the wire as a reamer to remove dirt that may
be adhering to the wall of the hole through the tip.
2. Replace worn contact tips as required. A variable
or “hunting” arc is a typical symptom of a worn contact tip. To install a new tip, choose the correct size
contact tip for the electrode being used (wire size is
stenciled on the side of the contact tip) and screw it
snugly into the gas diffuser.
3. Remove spatter from inside of gas nozzle and from
tip after each 10 minutes of arc time or as required.
4. Be sure the gas nozzle is fully screwed onto the
diffuser for gas shielded processes. For the
Innershield®process, the gasless nozzle should
be screws onto the diffuser.
5. To remove gun tube from gun, remove gas nozzle
or gasless nozzle and remove diffuser from gun
tube. Remove both collars from each end of the
gun handle and separate the handle halves.
Loosen the locking nut holding the gun tube in
place against the gun end cable connector.
Unscrew gun tube from cable connector. To install
gun tube, screw the locking nut on the gun tube as
far as possible. Then screw the gun tube into the
cable connector until it bottoms. Then unscrew (no
more than one turn) the gun tube until its axis is
perpendicular to the flat sides of the cable connector and pointed in the direction of the trigger.
Tighten the locking nut so as to maintain the proper
relationship between the gun tube and the cable
connector. Replace the gun handle, trigger and diffuser. Replace the gas nozzle or gasless nozzle.
CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM
Contact Tip Cable Liner Drive Roll
Components shipped with KP2039-1B1 KP1937-3 KP665-035
SP-135T• .025” (0.6mm) .030-.035”
(0.8-0.9mm) Small .023-.025 (0.6mm)
K549-1 .035” (0.9mm) KP2039-3B1 KP1937-3 Use Large groove of Drive Roll
Innershield Welding Kit .035” (0.9mm) .(0.8-0.9mm) included with machine.
K664-2 .035 (0.9mm) KP2078-1B1 KP1959-1 M19631
Aluminum or Stainless Kit* .035A (0.9mm) .035” (0.9mm)
• If .030 Solid wire feeding is desired obtain an KP2039-2B1 Contact Tip.
* It is important when changing between welding with steel wire and aluminum to exchange feeding components due to the lubricant applied to steel wire. Failure
to do so may result in contaminated welds when welding aluminum.
2 Smooth grooves
Large .030” -.035" (0.8mm)-(0.9mm
SP-135T
D-3
MAINTENANCE
D-3
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 contact tip.
4. Replace gas nozzle.
CHANGING DRIVE ROLL
The drive roll has two grooves; one for .023" – .025"
(0.6 mm) solid steel electrode and a larger knurled
groove for .030" (0.8 mm) solid and .035" (0.9 mm)
flux-cored steel electrode. As shipped, the drive roll is
installed in the .030"/.035" (0.8/0.9 mm) position.
If .023" – .025" (0.6 mm) wire is to be used, the drive
roll must be reversed as follows:
8. Push a length of straightened welding wire through
the wire feeder guide tubes and adjust the position
of the drive roll so that the groove is centered on
the wire. Make certain the set screw is located on
the flat portion of the shaft and tighten.
FIGURE D.1
3
2
1
1. Connect the machine to its rated input power per
instructions in Installation section.
2. Release the spring-loaded idle arm tensioner,Item 2, and
lift the idle roll arm,
1. (See Figure D.1)
3. Turn the power switch to ON (marked “I”).
4. Set the wire speed to minimum and jog the drive
unit with the trigger switch until the drive roll set
screw is facing up.
Item 3,
away from the drive roll, Item
CAUTION
When inching the welding wire, the drive rolls,
gun connector block, and gun contact tip are
energized relative to work and ground and remain
energized for several seconds after the gun trigger is released.
5. Turn the power switch to OFF (marked “O”).
6. Loosen the drive roll set screw with the 5/64" (2.0
mm) hex wrench supplied.
7. Remove the drive roll, flip over and reinstall with the
.023 – .025" (0.6 mm) groove (the smaller groove)
closest to the gearbox.
SP-135T
D-4
Set Screw Brass Cable
Connector
Liner Assembly
(Liner bushing to be sealed tight
against brass cable connector)
MAINTENANCE
1-1/4 (31.8 mm)
Liner Trim Length
Gas Diffuser
Gas Nozzle or
Gasless Nozzle
FIGURE D.2
Liner trim length
CHANGING LINER
NOTICE: The variation in cable lengths prevents the
interchangeability of liners. Once a liner has been cut
for a particular gun, it should not be installed in another gun unless it can meet the liner cutoff length
requirement. Refer to Figure D.2.
1. 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. Remove the gas diffuser from the gun tube by
unscrewing counter-clockwise.
D-4
8. Screw the gas diffuser onto the end of the gun tube
and securely tighten.
9. Replace the contact tip and nozzle.
GUN HANDLE PARTS
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 difficult to turn, position the gun handle against a corner,
place a screwdriver against the tab on the collar and
give the screwdriver a sharp blow to turn the collar
past an internal locking rib. See Figure D-3.
4. Lay the gun and cable out straight on a flat surface.
Loosen the set screw located in the brass connector at the wire feeder end of the cable. Pull the liner
out of the cable.
5. Insert a new untrimmed liner into the connector end
of the cable. Be sure the liner bushing is stenciled
appropriately for the wire size being used.
6. Fully seat the liner bushing into the connector.
Tighten the set screw on the brass cable connector.
At this time, the gas diffuser should not be installed
onto the end of the gun tube.
7. With the gas nozzle and diffuser removed from the
gun tube, be sure the cable is straight, and then
trim the liner to the length shown in the Figure D.2.
Remove any burrs from the end of the liner.
SP-135T
➣
Counter-clockwise
FIGURE D.3
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
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 and
machine operator and will invalidate your factory warranty. For your safety and to avoid Electrical
Shock, please observe all safety notes and precautions detailed throughout this manual.
__________________________________________________________________________
E-1
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
Step 1. LOCATE PROBLEM (SYMPTOM).
Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
Step 3. RECOMMENDED COURSE OF ACTION
This column provides a course of action for the
Possible Cause, generally it states to contact your
local Lincoln Authorized Field Service Facility.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
CAUTION
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.
SP-135T
E-2
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-2
PROBLEMS
(SYMPTOMS)
Major physical or electrical damage
is evident.
No wire feed, weld output or gas
flow when gun trigger is pulled. Fan
does NOT operate.
No wire feed, weld output or gas
flow when gun trigger is pulled Fan
operates normally.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
OUTPUT PROBLEMS
None
Contact your local Authorized Field
Service Facility.
1. Make sure correct voltage is
applied to the machine (115vac).
2. Make certain that power switch
is in the ON position.
3. Make sure circuit breaker is
reset.
1. The thermostat may be tripped
due to overheating. Let machine
cool. Weld at lower duty cycle.
2. Check for obstructions in air
flow. Check Gun Trigger connections. See Installation section.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service
Facility.
3. Gun trigger may be faulty.
CAUTION
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.
SP-135T
E-3
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-3
PROBLEMS
(SYMPTOMS)
No wire feed when gun trigger is
pulled. Fan runs, gas flows and
machine has correct open circuit
voltage (32VDC maximum) – weld
output.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
FEEDING PROBLEMS
1. If the wire drive motor is running
make sure that the correct drive
rolls are installed in the machine.
2. Check for clogged cable liner or
contact tip.
3. Check for proper size cable liner
and contact tip.
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service
Facility.
RECOMMENDED
COURSE OF ACTION
Low or no gas flow when gun
trigger is pulled. Wire feed, weld
output and fan operate normally.
GAS FLOW PROBLEMS
1. Check gas supply, flow regulator
and gas hoses.
2. Check gun connection to
machine for obstruction or leaky
seals.
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service
Facility.
CAUTION
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.
SP-135T
E-4
TROUBLESHOOTING
Observe all Safety Guidelines detailed throughout this manual
E-4
PROBLEMS
(SYMPTOMS)
Arc is unstable – Poor starting
POSSIBLE AREAS OF
MISADJUSTMENT(S)
WELDING PROBLEMS
1. Check for correct input voltage
to machine – 115vac.
2. Check for proper electrode
polarity for process.
3. Check gun tip for wear or damage and proper size – Replace.
4. Check for proper gas and flow
rate for process. (For MIG only.)
5. Check work cable for loose or
faulty connections.
6. Check gun for damage or
breaks.
7. Check for proper drive roll orientation and alignment.
RECOMMENDED
COURSE OF ACTION
If all recommended possible areas
of misadjustment have been
checked and the problem persists,
Contact your local Lincoln
Authorized Field Service
Facility.
8. Check liner for proper size.
CAUTION
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.
SP-135T
F-1
WARNING
W-WHITE
F-1
7-02
M20138
DIAGRAMS
WIRE
FEED
MOTOR
(MOUNTED TO
SEC. COIL)
N.C.
WIRE SPEED
GUN TRIGGER
5K
R2
209
208
213
-
+
539
541
(B)
BLOCK
GUN CABLE
CONDUCTOR
CHOKE
OUTPUT
203
204
203
204
59,000 f
40V
204
+
C1
N.A.
D2
N.D.
D4
(W)
203
203
TO
WORK
LEAD COLOR CODE:
B-BLACK
ELECTRICAL SYMBOLS PER E1537
THERMOSTAT
Disconnect input power by unplugging power cord before servicing.
Only qualified persons should install, use or service this machine.
Do not touch electrically live parts
can kill
HIGH VOLTAGE
Do not operate with covers removed.
204
203
8910
539
7
208
H2
6
1234
LS1
H2
S1
J1
CONTROL P.C. BOARD
5
N.O.
H2
ON-OFF
SWITCH
213
209
N.C.
204
214
S2
541
H1
CR1
H1
GAS
115V/60HZ
SOLENOID
CIRCUIT
BREAKER
F1
24V
115V/60HZ
FAN MOTOR
214
WINDING
AUXILIARY
D1
SELECTOR
H1
N.D.
N.B.
202
SWITCH
X4
X5
X2
X3
X1
H2
D3
T1
(DOW CORNING 340) W HEN REATTACHING.
REQUIRE T12837 JOINT COMPOUND
IS CLOSEST TO THE CENTER PANEL.
ON THE INSIDE HEATSINK, WHICH
CASE
N.A. DIODES D2 & D4 ARE MOUNTED
GROUNDING
ON THE OUTSIDE HEATSINK.
N.B. DIODES D1 & D3 ARE MOUNTED
STUD
J1
TO EARTH GROUND PER
N.C. COMPONENT VIEWED FROM REAR.
5
1234
NATIONAL, LOCAL OR
N.D. BOLTED ALUMINUM CONNECTIONS
LATCH
678910
CAVITY NUMBERING SEQUENCE
ELECTRICAL CODES.
OTHER APPLICABLE
( COMPONENT SIDE OF BOARD )
NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The
specific diagram for a particular code is pasted inside the machine on one of the enclosure panels.
SP-135T
NOTES
SP-135T
NOTES
SP-135T
WARNING
Spanish
AVISO DE
PRECAUCION
● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● No toque las partes o los electrodos
bajo carga con la piel o ropa mojada.
● Aislese del trabajo y de la tierra.
● Keep flammable materials away.
● Mantenga el material combustible
fuera del área de trabajo.
● Wear eye, ear and body protection.
● Protéjase los ojos, los oídos y el
cuerpo.
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Isolez-vous du travail et de la terre.
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
Elektroden und dem Erdboden!
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molhada.
● Isole-se da peça e terra.
● Gardez à l’écart de tout matériel
inflammable.
● Entfernen Sie brennbarres Material!
● Mantenha inflamáveis bem guarda-
dos.
● Protégez vos yeux, vos oreilles et
votre corps.
● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
● Use proteção para a vista, ouvido e
corpo.
READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.
SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES 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 A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.
LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HERSTELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
● Los humos fuera de la zona de res-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● Débranchez le courant avant l’entre-
tien.
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Não toque as partes elétricas nuas.
● No operar con panel abierto o
guardas quitadas.
● N’opérez pas avec les panneaux
ouverts ou avec les dispositifs de
protection enlevés.
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
Spanish
AVISO DE
PRECAUCION
French
ATTENTION
German
WARNUNG
Portuguese
ATENÇÃO
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.
• World's Leader in Welding and Cutting Products •
• 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
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