RETURN TO MAIN MENU IM785 SP-135T April, 2004 For use with machine Code Number:10971 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.
i i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS The engine exhaust from this product contains Diesel engine exhaust and some of its constituents chemicals known to the State of California to cause are known to the State of California to cause cancancer, birth defects, or other reproductive harm. cer, birth defects, and other reproductive harm. The Above For Gasoline Engines The Above For Diesel Engines ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
ii ii SAFETY ARC RAYS can burn. 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.
iii iii SAFETY 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. Remember that welding sparks and hot 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.
iv iv SAFETY 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.
v v Thank You for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product ••• as much pride as we have in bringing this product to you! Please Examine Carton and Equipment For Damage Immediately When this equipment is shipped, title passes to the purchaser upon receipt by the carrier.
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-1 A-1 INSTALLATION TECHNICAL SPECIFICATIONS – SP-135T INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency 120V/60Hz Input Current 20 Amps - Rated Output RATED OUTPUT Duty Cycle 20% Duty Cycle Amps 90 Volts at Rated Amperes 19 OUTPUT Welding Current Range 25-135 Amps Maximum-Open Circuit Voltage 29V Wire Speed Range 50 - 300 in/min (1.3 - 7.
A-2 A-2 INSTALLATION Read entire installation section before starting installation. SAFETY PRECAUTIONS FIGURE A.1 WARNING ELECTRIC SHOCK can kill. 2 • Only qualified personnel should perform this installation. 1 • 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.
A-3 A-3 INSTALLATION SELECT SUITABLE LOCATION Work Clamp Installation 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. Attach the work clamp per the following: 1. Unplug the machine or turn the power switch to the “OFF” position.
A-4 A-4 INSTALLATION Work Cable Installation Connecting Gun Cable to the SP-135T Refer to Figure A.2. 1. Refer to Figure A.2. Unplug the machine or turn power switch to the OFF “O” position. 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.
A-5 A-5 INSTALLATION 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 CYLINDER may explode if damaged. Keep cylinder upright and chained to support • Keep cylinder away from areas where it may be damaged. WARNING • Never lift welder with cylinder attached.
A-6 A-6 INSTALLATION INPUT CONNECTIONS Requirements For Rated Output Refer to Figure A.6. 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 SP-135T has a power input cable located on the rear of the machine.
B-1 OPERATION 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. B-1 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.
B-2 B-2 OPERATION ● 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. 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.
B-3 B-3 OPERATION 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. 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.
B-4 B-4 OPERATION 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.
B-5 OPERATION B-5 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. Contact Tip 7. Position gun over joint. End of wire may be lightly touching the work. Wire Electrode 3/8"– 1/2"(10-13mm) Contact Tip to Work Distance(CTWD) 8. Lower welding helmet, close gun trigger, and begin welding.
B-6 OPERATION 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 Shielding Gas Voltage/Wire Speed 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 16 ga 14 ga 12 ga 10 ga MIG DC+ .030 Dia 98% Argon/ A-3 308L Stainless 2% Oxygen Steel Wire C-6 B-6 2.
B-7 APPLICATION CHART SP-135T B-7
C-1 ACCESSORIES 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.
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 Gas Nozzle KP1938-1 Gas Nozzle-Tip Recessed 3/8” (9.5 mm) Opening I.D.
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.
D-2 D-2 MAINTENANCE GUN AND CABLE MAINTENANCE FOR MAGNUM™ 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 lbs (136 kg) of solid wire or 50 lbs (23 kg) of flux-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.
D-3 D-3 MAINTENANCE COMPONENT REPLACEMENT PROCEDURES 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. CHANGING THE CONTACT TIP 1. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. FIGURE D.1 2.
D-4 D-4 MAINTENANCE 1-1/4 (31.8 mm) Liner Trim Length Gas Diffuser Set Screw Brass Cable Connector Gas Nozzle or Gasless Nozzle Liner Assembly (Liner bushing to be sealed tight against brass cable connector) FIGURE D.2 Liner trim length 8. Screw the gas diffuser onto the end of the gun tube and securely tighten. CHANGING LINER 9. Replace the contact tip and nozzle. NOTICE: The variation in cable lengths prevents the interchangeability of liners.
E-1 TROUBLESHOOTING E-1 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-2 E-2 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION OUTPUT PROBLEMS Major physical or electrical damage is evident. None Contact your local Authorized Field Service Facility. No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate. 1. Make sure correct voltage is applied to the machine (115vac). 2. Make certain that power switch is in the ON position.
E-3 E-3 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION FEEDING PROBLEMS No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (32VDC maximum) – weld output. 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.
E-4 E-4 TROUBLESHOOTING Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) POSSIBLE AREAS OF MISADJUSTMENT(S) RECOMMENDED COURSE OF ACTION WELDING PROBLEMS Arc is unstable – Poor starting 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.
SP-135T 6 7 8 9 10 H2 N.O. LS1 H1 T1 541 3 214 4 X1 X3 X4 X5 S2 SELECTOR SWITCH X2 209 2 J1 6 7 8 N.D. BOLTED ALUMINUM CONNECTIONS REQUIRE T12837 JOINT COMPOUND (DOW CORNING 340) WHEN REATTACHING. N.C. COMPONENT VIEWED FROM REAR. N.B. DIODES D1 & D3 ARE MOUNTED ON THE INSIDE HEATSINK, WHICH IS CLOSEST TO THE CENTER PANEL. N.B. 202 D3 N.D. D1 204 9 10 213 208 203 539 204 5 N.A. DIODES D2 & D4 ARE MOUNTED ON THE OUTSIDE HEATSINK. H1 CR1 1 CONTROL P.C.
NOTES SP-135T
NOTES SP-135T
● Do not touch electrically live parts or WARNING Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG Portuguese ATENÇÃO ● Keep flammable materials away. ● Wear eye, ear and body protection. ● Mantenga el material combustible ● Protéjase los ojos, los oídos y el 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 your head out of fumes. ● Use ventilation or exhaust to ● Turn power off before servicing. ● Do not operate with panel open or guards off. remove fumes from breathing zone. ● 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- ● Desconectar el cable de ali- mentación de poder de la máquina antes de iniciar cualquier servicio.
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