Lincoln Electric SP-135 PLUS Operator's Manual
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Lincoln Electric SP-135 PLUS Operator's Manual

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This manual covers equipment which is no
longer in production by The Lincoln Electric Co.
Speci cations and availability of optional
features may have changed.
Safety Depends on You
Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However, your
overall safety can be increased by
proper installation ... and thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
THIS
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
ISO 9001
ANSI RAB
QMS
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
CERTIFICATE NUMBER: 30273
• 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
SP- 135 PLUS
For use with machine Code Numbers : 10974
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2005 Lincoln Global Inc.
IM788
July, 2005

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Summary of Contents for Lincoln Electric SP-135 PLUS

  • Page 1 ABS Quality Evaluations, Inc. to ISO 9001 Requirements. CERTIFICATE NUMBER: 30273 Copyright © 2005 Lincoln Global Inc. • 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...

  • Page 2: California Proposition 65 Warnings

    SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS Diesel engine exhaust and some of its constituents The engine exhaust from this product contains are known to the State of California to cause can- chemicals known to the State of California to cause cer, birth defects, and other reproductive harm.

  • Page 3: Electric Shock Can Kill

    (MSDS) and follow your employer’s safety practices. MSDS forms are available from 3.j. Also see Items 6.c. and 8. your welding distributor or from the manufacturer. 5.e. Also see item 1.b. Mar ‘95 SP-135 PLUS...
  • Page 4 This can create fire hazards or overheat lifting chains Electrical Code, all local codes and the manufacturer’s or cables until they fail. recommendations. 6.h. Also see item 1.c. 8.c. Ground the equipment in accordance with the U.S. National Electrical Code and the manufacturer’s recommendations. Mar ‘95 SP-135 PLUS...
  • Page 5 épaisse, pan- place. talons 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 Mar. ‘93 zones où l’on pique le laitier. SP-135 PLUS...
  • Page 6 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.

  • Page 7: Table Of Contents

    Configuration of Components in Wire Feeding System.........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-135 PLUS Wiring Diagram................F-1 Parts Lists ....................P454 & P202-E...

  • Page 8: Installation

    INSTALLATION TECHNICAL SPECIFICATIONS – SP-135 PLUS INPUT – SINGLE PHASE ONLY Standard Voltage/Frequency Input Current 20 Amps @ Rated Output 115V/60Hz 25 Amps @ Maximum Output 15 Amps @ CSA Rated output RATED OUTPUT Duty Cycle Amps Volts at Rated Amperes 20% Duty Cycle –...

  • Page 9: Identify And Locate Components

    • Machine must be plugged into a receptacle which is grounded per any national, local or other applicable electrical codes. • The SP-135 PLUS power switch is to be in the OFF (“O”) position when installing work cable and gun and when connecting power cord to input power.

  • Page 10: Select Suitable Location

    Figure A-3. STACKING 3. Fasten securely with the bolt and nut provided. SP-135 PLUS’ cannot be stacked. FIGURE A.3 TILTING Strain Relief Hole Each machine must be placed on a secure, level sur-...

  • Page 11: Gas Connection

    Malfunction of the SP-135 PLUS will result if this switch shorts to the SP-135 PLUS welding output circuit or is common to any electri- cal circuit other than the SP-135 PLUS trigger circuit.

  • Page 12: Input Connections

    The machine has two input connections, the power input cable, and the Gas Solenoid Inlet Fitting. Both are located on the rear of the machine. Cylinder Valve Flow Regulator FIGURE A.6 Gas Hose GAS SOLENOID INLET FITTING POWER INPUT CABLE SP-135 PLUS...

  • Page 13: Code Requirements

    INSTALLATION CODE REQUIREMENTS FOR INPUT CAUTION CONNECTIONS Do not connect the SP-135 PLUS to an input power supply with a rated voltage that is greater WARNING than 125 volts. This welding machine must be connected to Do not remove the power cord ground prong.

  • Page 14: Operation

    OPERATION Read entire Operation section before operating the SP-135 PLUS. 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.

  • Page 15: General Description

    GMAW (also known as MIG WELDING CAPABILITY welding) and the Innershield electrode process (self shielded flux cored or FCAW). The SP-135 PLUS is a rugged and reliable machine that has been designed The SP-135 PLUS, as shipped, is rated at 90 amps, for dependable service and long life.

  • Page 16: Welding Operations

    25-125 The machine power switch should be turned to the OFF (“O”) position before working inside the wire feed SP-135 Plus enclosure. The machine is shipped from the factory ready to feed 4” (100 mm) diameter spools. A 4" (100 mm) diameter spool is mounted directly on the 5/8"...
  • Page 17 2. Carefully detach the end of the wire from the 8. Turn the SP-135 PLUS ON (“I”). spool. To prevent the spool from unwinding, do not release the wire until after step 5.
  • Page 18 Refer to the ACCES- required, is turned on. SORIES section for more information about selecting gas cylinders for use with the SP-135 PLUS. 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 dif- 1.
  • Page 19 Innershield ® process (FCAW). the SP-135 PLUS with other sizes of wire, it is neces- sary to change the contact tip and change the drive roll over to other sizes. Refer to Changing the Contact...

  • Page 20: Overload Protection

    OPERATION OVERLOAD PROTECTION Output Overload The SP-135 PLUS is equipped with a circuit breaker which protects the machine from potential damage from excessive output current. The circuit breaker but- ton will extend out when tripped. The circuit breaker must be manually reset.

  • Page 21: Application Chart

    APPLICATION CHART SP-135 PLUS...

  • Page 22: Accessories

    Failure to do so may result in contaminated welds when welding alu- minum. See Maintenance section for instructions on installing drive roll, cable liner, contact tip and their proper configuration. SP-135 PLUS...

  • Page 23: Replacement Parts

    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-135 PLUS...

  • Page 24: Maintenance

    SP-135 PLUS. Use only grounded recep- WARNING tacle. Do not touch electrically “hot” parts inside SP-135 PLUS. Excessive pressure at start may cause the dirt to form a plug. • Have qualified personnel do the maintenance and trouble shoot- ing work.

  • Page 25: Gun And Cable Maintenance

    CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM Contact Tip Cable Liner Drive Roll Components shipped with KP2039-1B1(In Gun) KP1937-3 KP1881-1 SP-135 PLUS .025” (0.6mm) .030-.035” 2 Smooth grooves KP2039-2B1(Loose) (0.8-0.9 mm) Small .023-.025” (Stenciled .025) .030” (0.8mm) Large .030-.035” (Stenciled .030-.035) K549-1 .035”...

  • Page 26: Component Replacement Procedures

    (when installed) 5. Replace gas nozzle. 5. Push a length of straightened welding wire through CHANGING THE SP-135 PLUS FOR USE the wire feeder guide tubes and reset the Phillips WITH INNERSHIELD FLUX CORED WIRE Head screw to secure the drive roll onto the shaft.

  • Page 27: Changing Liner

    8. 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. FIGURE D.3 SP-135 PLUS...

  • Page 28: Troubleshooting

    CAUTION If machine case sides and top are removed, the case front must be supported. Failure to do this could result in mechanical or electrical damage to the SP-135 PLUS. ___________________________________________________________________ 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.

  • Page 29: Troubleshooting Guide

    4. 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 AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. SP-135 PLUS...
  • Page 30 CAUTION If for any reason you do not understand the test procedures or are unable to Perform the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. SP-135 PLUS...
  • Page 31 6. Check gun for damage or breaks. CAUTION If for any reason you do not understand the test procedures or are unable to Perform the tests/repairs safely, contact your LOCAL AUTHORIZED LINCOLN ELECTRIC FIELD SERVICE FACILITY for assistance before you proceed. SP-135 PLUS...

  • Page 32: Wiring Diagrams

    WIRING DIAGRAMS 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-135 PLUS...
  • Page 33 ● ● ● Do not touch electrically live parts or Keep flammable materials away. Wear eye, ear and body protection. WARNING electrode with skin or wet clothing. ● Insulate yourself from work and ground. Spanish ● ● ● No toque las partes o los electrodos Mantenga el material combustible Protéjase los ojos, los oídos y el AVISO DE...
  • Page 34 ● ● ● Keep your head out of fumes. Turn power off before servicing. Do not operate with panel open or ● Use ventilation or exhaust to guards off. WARNING remove fumes from breathing zone. ● Spanish Los humos fuera de la zona de res- ●...
  • Page 35 • 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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