Lincoln Electric SP-135T, Operator'S Manual

Page 1: ...GHOUT And most importantly think before you act and be careful For use with machine Code Number 10867 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 Date of Purchase Serial Number Code Number Model Where Purchased ISO 9001 CERTIFICATE ...

Page 2: ...R 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 availa...

Page 3: ...rical earth ground 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 ...

Page 4: ...event 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 Where compressed gases are to be used at the job site special precautions should be used to prevent hazardous situations Refer to Safety in Weldin...

Page 5: ...s et non inflamma bles 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 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 Eloign...

Page 6: ...he information must be followed to avoid minor personal injury or damage to this equipment CAUTION 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 receive...

Page 7: ...tings B 2 Welding Operations B 3 Overload Protection B 6 Learning to Weld B 7 Application Chart B 18 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 Sa...

Page 8: ...AL SPECIFICATIONS SP 135T INPUT SINGLE PHASE ONLY RATED OUTPUT OUTPUT RECOMMENDED INPUT CABLE AND FUSE SIZES Height Width Depth Weight 12 0 in 9 75 in 16 5 in 48 Ibs 305 mm 248 mm 419 mm 21 8 kg PHYSICAL DIMENSIONS Standard Voltage Frequency Input Current 120V 60Hz 20 Amps Rated Output Duty Cycle Amps Volts at Rated Amperes 20 Duty Cycle 90 19 Welding Current Range Maximum Open Circuit Voltage 50 ...

Page 9: ...eld 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 ELECTRIC SHOCK can kill Only qualified personnel should perform this installation Only perso...

Page 10: ...an 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 sur face either directly or on either recommended cart The machine may...

Page 11: ... the gun conductor cable through the Gun Cable Access Hole 2 in the SP 135T case front Make sure the connector is all the way in the brass connector block Unscrew thumb screw 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 t...

Page 12: ...With the cylinder securely installed remove the cylinder cap Stand to one side away from the out let 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 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 cylind...

Page 13: ...nstallation meeting applicable electrical code requirements consult a qualified electrician 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 cir cuit with a nominal voltage rating of 115 to 125 volts 60 Hertz AC only The rated...

Page 14: ...wer 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 G...

Page 15: ...eactivated while in Seam mode No external shielding gas is required when used with Lincoln Innershield 035 0 9 mm NR 211 MP electrode Accommodates both 4 100 mm diameter and 8 200 mm diameter spools of wire Accepts optional Spot Stitch Timer Kit 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 high er output currents at lower duty ...

Page 16: ...d an 8 200 mm diameter spool on the wire spool spindle shown in Figure B 2 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 spin dle The spindle can be stored in the wire feed com partment A 4 100 mm diameter spool is mounted directly on the 5 8 16 mm diameter...

Page 17: ...ire 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 adjust ment 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 d...

Page 18: ...out 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 ...

Page 19: ...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 Depress the gun trigger briefly to release the pressure 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 c...

Page 20: ... pre vent current from going through an unwanted path Avoid allowing the welding circuit to pass through hinges bearings electronic components or similar devices that can be damaged See Figure B 8 Always disconnect electrical devices before welding upon them FIGURE B 8 Fumes and slag generated from Innershield type electrodes recom mended for use with this welding machine can be toxic Avoid contac...

Page 21: ...s up impurities and forms the protective slag on top of the weld during cooling After running a weld bead the slag may be removed with a chipping hammer and wire brush This improves appearance and allows for inspection of the finished weld Since machine size and output characteristics limit the size and type of wire electrode which can be used Lincoln 0 035 0 9 mm NR 211 MP Innershield elec trode ...

Page 22: ...ood that the metal is mild steel and that you will be able to weld the material In addition aluminum and stainless steel can be welded using the K664 1 Aluminum Welding Kit For further information on identifying various types of steels and other metals and for proper procedures for welding them we again suggest you purchase a copy of New Lessons in Arc Welding Regardless of the type of metal being...

Page 23: ...cal up or vertical down Vertical up is used whenever a larger stronger weld is desired Vertical down is used primarily on sheet metal 5 32 3 9 mm and under for fast low penetrating welds Use of this unit on thicker materials than recom mended may result in poor welds The welds may look good but may just be sitting on top of the plate This is called Cold Casting and will result in weld failure Vert...

Page 24: ...to the settings suggested on the Application Guide for the welding wire and base metal thickness being used The voltage control is marked V and the wire feed speed is marked olo 4 Check that the polarity is correct for the welding wire being used Set the polarity for DC when welding with NR 211 MP Innershield electrode See Work Cable Installation in the INSTALLATION section for instructions on cha...

Page 25: ...ickout ESO is the distance from the end of the contact tip to the end of the wire See Figure B 19 Once the arc has been established maintaining the correct ESO becomes extremely important The ESO should be approximately 3 8 to 1 2 inch 10 to 12 mm long The easiest way to tell whether the ESO is the cor rect length is by listening to its sound The correct ESO has a distinctive crackling sound very ...

Page 26: ...the work 2 Position face shield to protect face and eyes 3 Depress gun trigger hold gun so contact tip to work distance is about 3 8 to 1 2 inch 10 to 12 mm and the gun is at proper angle 4 After you strike the arc practice the correct electri cal stickout Learn to distinguish it by its sound 5 When you are sure that you can hold the correct electrical stickout with a smooth crackling arc start mo...

Page 27: ...of the four welding will be easy They are as follows 1 The Correct Welding Position Figure B 23 illustrates the correct welding position for right handed people For left handed people it is the opposite When GMAW MIG welding on sheet metal it is important to use the forehand push technique Hold the gun of the gun and cable assembly in your right hand and hold the shield with your left hand Left ha...

Page 28: ...g the molten metal FIGURE B 25 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 necessary to go more slowly in order to get good penetration 3 When w...

Page 29: ...tage 2 Increase drag angle 3 Decrease stickout 4 Increase WFS wire feed speed 5 Decrease travel speed 6 Check for correct gas if used To Correct Poor Penetration in order of impor tance 1 Decrease stickout 2 Increase WFS wire feed speed 3 Increase voltage 4 Decrease speed 5 Decrease drag angle 6 Check for correct gas if used If Arc Blow Occurs in order of importance NOTE Try different ground conne...

Page 30: ... 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 Innershield electrode has proper surface lubrica tion Use only clean rust free electrode 6 Replace contact tip when it becomes worn or the end is fused or deformed SP 135T ...

Page 31: ...B 18 APPLICATION CHART B 18 SP 135T ...

Page 32: ... these components due to the lubricant applied to steel wire Failure to do so may result in contaminated welds when weld ing aluminum 3 KP665 045C Drive Roll Optional Knurled drive roll for feeding 035 0 9 mm diameter flux cored electrode 4 K695 1 Spot Stitch Timer Kit Includes spot timer to control the spot welding arc time and a stitch timer to control the on off cycle time of the arc to prevent...

Page 33: ...enance 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 REPLACEMENT PARTS Complete Gun and Cable Assembly L8311 6 K530 4 Contact Tip 025 0 6 mm S19726 1 Contact Tip 030 0 8 mm S19726 2 Contact Tip 035 0 9 mm S19726 3 Contact Tip Tapered 025 0 6 mm S20278 1...

Page 34: ...blems NO maintenance is required In extremely dusty locations dirt may clog the air passages causing the welder to run hot with premature tripping of ther mal protection If so blow dirt out of the welder with low pres sure 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 fee...

Page 35: ...r 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...

Page 36: ...dle arm tensioner Item 2 and lift the idle roll arm Item 3 away from the drive roll Item 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 When inching the welding wire the drive rolls gun connector block and gun contact tip are energized relative to work and ground and ...

Page 37: ...ts the interchangeability of liners Once a liner has been cut for a particular gun it should not be installed in anoth er gun unless it can meet the liner cutoff length requirement Refer to Figure D 2 1 Remove the gas nozzle from the gun by unscrew ing 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 uns...

Page 38: ... 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 Authorize...

Page 39: ...ADJUSTMENT S 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 inside wire drive compartment 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 Trigge...

Page 40: ... or contact tip 3 Check for proper size cable liner and contact tip 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 FEEDING PROBLEMS PROBLEMS SYMPTOMS Low or no gas flow when gun trigger is pulled Wire feed weld output and fan operate normally POSSIBLE AREAS OF MI...

Page 41: ... 2 Check for proper electrode polarity for process 3 Check gun tip for wear or dam age 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 orien tation and alignment 8 Check liner for proper size RECOMMENDED COURSE OF ACTION If all recommended possible...

Page 42: ...CH 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 AUXILIARY FAN MOTOR X1 202 X2 S2 SELECTOR SWITCH CIRCUIT BREAKER 115V 60HZ 115V 60HZ OUTPUT CHOKE X3 X4...

Page 43: ...NOTES SP 135T ...

Page 44: ...gute Be und Entlüftung des Arbeitsplatzes Mantenha seu rosto da fumaça Use ventilação e exhaustão para remover fumo da zona respiratória Turn power off before servicing Desconectar el cable de ali mentación de poder de la máquina antes de iniciar cualquier servicio Débranchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom völlig öff nen Maschine anhalten Não opere co...

Page 45: ...s 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 ...