Lincoln Electric SP-135T IM724 Operator's Manual
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Lincoln Electric SP-135T IM724 Operator's Manual

Lincoln Electric SP-135T IM724 Operator's Manual

Lincoln electric welder user manual
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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 thought-
ful operation on your part. DO
NOT INSTALL, OPERATE OR
REPAIR THIS EQUIPMENT
WITHOUT
READING
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT. And, most
importantly, think before you act
and be careful.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
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
RETURN TO MAIN MENU
SP- 135T
For use with machine Code Number:10867
THIS
OPERATOR'S MANUAL
• World's Leader in Welding and Cutting Products •
Copyright © 2001 Lincoln Global Inc.
IM724
April, 2001

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Summary of Contents for Lincoln Electric SP-135T IM724

  • Page 1 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...

  • Page 2: California Proposition 65 Warnings

    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.

  • Page 3: Electric Shock Can Kill

    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.
  • Page 4 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.
  • Page 5 PRÉCAUTIONS DE SÛRETÉ Pour votre propre protection lire et observer toutes les instruc- tions et les précautions de sûreté specifiques qui parraissent dans ce manuel aussi bien que les précautions de sûreté générales suivantes: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a.
  • Page 6 This statement appears where the information must be followed to avoid minor personal injury or damage to this equipment. for selecting a QUALITY product by Lincoln Electric. We want you to take pride in operating this Lincoln Electric Company product •••...

  • Page 7: Table Of Contents

    MASTER TABLE OF CONTENTS FOR ALL SECTIONS 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...

  • Page 8: Installation

    TECHNICAL SPECIFICATIONS – SP-135T Standard Voltage/Frequency 120V/60Hz Duty Cycle 20% Duty Cycle Welding Current Range 25-135 Amps RECOMMENDED INPUT CABLE AND FUSE SIZES Output Mode Input Voltage RATED 120V/60Hz Height 12.0 in 305 mm If connected to a circuit protected by fuses use Time Delay Fuse marked “D”. INSTALLATION INPUT –...

  • Page 9: Safety Precautions

    Read entire installation section before starting installation. SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill. • Only qualified personnel should perform this installation. • Only personnel that have read and under- stood the SP-135T Operating Manual should install and operate this equipment. •...

  • Page 10: Select Suitable Location

    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.

  • Page 11: Gun Installation

    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 termi- nal lug with the smaller hole through the Work Cable Access Hole (1) in the case front.
  • Page 12 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.

  • Page 13: Input Connections

    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 FIGURE A.6 CODE REQUIREMENTS FOR INPUT CONNECTIONS WARNING This welding machine must be connected to a power source in accordance with applicable elec- trical codes.

  • Page 14: Operation

    OPERATION GENERAL DESCRIPTION The SP-135T is a complete semiautomatic constant- voltage DC wire feeder / power source arc welder. It has been designed for workshop, hobby, automotive and light maintenance. Included is a tap-switch con- trolled, single phase constant voltage transformer / rectifier power source and a wire feeder welding gun for feeding .023 - .025”...

  • Page 15: Welding Capability

    ● 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.

  • Page 16: Welding Operations

    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) maxi- mum width. These spools fit on a 2" (51 mm) diameter...
  • Page 17 Friction Brake Adjustment With wire spool installed on the spindle shaft and the wing nut loose, turn the spool by hand while slowly tightening the wing nut until a light drag is felt. Tighten the wing nut an additional 1/4 turn. Note: When properly adjusted, the brake should pro- vide only enough drag to prevent overrun of the spool and excess slack in the wire.

  • Page 18: Process Guidelines

    Contact Tip Wire Electrode 3/8" – 1/2" Electrical Stickout FIGURE B.6 Making A Weld 1. See “Process Guidelines” in this section for selec- tion of welding wire and shielding gas and for range of metal thicknesses that can be welded. 2.

  • Page 19: Changing Machine Over To Feed Other Wire Sizes

    The SP-135T is suitable for .035" aluminum wire and .030" stainless wire. Refer to Table B.1 for recom- mended procedure settings (requires K499 Argon Regulator Kit). TABLE B.1 Shielding Process Welding Wire 16 ga 14 ga 12 ga 10 ga MIG DC+ .035 Dia 100% Argon 4043 Aluminum...

  • Page 20: Learning To Weld

    LEARNING TO WELD No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced operator to understand welding and develop this skill. For more detailed infor- mation, order a copy of “New Lessons in Arc Welding” listed at the end of this manual.

  • Page 21: The Gmaw (Mig) Welding Arc

    The “arc stream” is seen in the middle of the picture. This is the electric arc created by the electric current flowing through the space between the end of the wire electrode and the base metal. The temperature of this arc is about 6000°F, which is more than enough to melt metal.

  • Page 22: Joint Types And Positions

    For GMAW (MIG) Process 1. Is most of my welding performed on 16 gauge and lighter materials? 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas sup- ply? 3. Do I require clean, finished-looking welds? If you have answered yes to all the above questions GMAW may be the process for you.
  • Page 23 B-10 FIGURE B.12 Penetration Unless a weld penetrates close to 100% of the metal thickness, a butt weld will be weaker than the material welded together. In the example shown in Figure B.13, the total weld is only half the thickness of the material thus the weld is only approximately half as strong as the metal.

  • Page 24: Machine Set Up For The Self-Shielded Fcaw Process

    B-11 PROPER GUN ANGLE PROPER GUN ANGLE FOR GMAW PROCESS FOR FCAW PROCESS WELDING IN THE VERTICAL UP POSITION WELDING IN THE VERTICAL UP POSITION FIGURE B.16 Vertical-down Welding Refer to Figure B.17 Vertical-down welds are applied at a fast pace. These welds are therefore shallow and narrow and, as such, are excellent for sheet metal.
  • Page 25 B-12 FIGURE B.18 WARNING ARC RAYS can burn eyes and skin. When using an open arc process, it Is necessary to use correct eye, head and body protection. Protect yourself and others, read “ARC RAYS can burn” at the front of this manual.
  • Page 26 B-13 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.

  • Page 27: Machine Set Up For The Gmaw (Mig) Process

    B-14 MACHINE SET UP FOR THE GMAW (MIG) PROCESS 1. See PROCESS GUIDELINES in the OPERATION section for selection of welding wire and shielding gas, and for range of metal thicknesses that can be welded. 2. See the Application Guide on the inside of wire feed section door for information on setting the controls.
  • Page 28 B-15 Contact Tip Wire Electrode FIGURE B.24 3. The Correct Electrical Stickout (ESO) The electrical stickout (ESO) is the distance from the end of the contact tip to the end of the wire. See Figure B.24. Once the arc has been established, maintaining the correct ESO becomes extremely important.

  • Page 29: Troubleshooting Welds

    B-16 TROUBLESHOOTING WELDS Good welds have excellent appearance. To Eliminate Porosity (in order of importance): 1. Turn on gas supply, if used 2. Decrease voltage. 3. Increase stickout. 4. Increase WFS (wire feed speed). 5. Decrease drag angle. 6. Decrease travel speed. NOTE: Always be sure the joint is free from moisture, oil, rust, paint or other contaminants.
  • Page 30 B-17 Proper Gun Handling Most feeding problems are caused by improper han- dling of the gun cable or electrodes. 1. Do not kink or pull the gun around sharp corners 2. Keep the gun cable as straight as practical when welding.

  • Page 31: Application Chart

    B-18 B-18 APPLICATION CHART SP-135T...

  • Page 32: Optional Accessories

    OPTIONAL ACCESSORIES 1. K549-1 .035" (0.9 mm) Innershield® Welding Kit — Includes a contact tip, a gasless nozzle and a .035/.045" (.9/1.2 mm) cable liner to permit the Magnum™ 100L gun and cable to use .035" (0.9 mm) diameter flux-cored electrode. The fitting on the end of the liner is stenciled with the maximum rated wire size (.045"/1.2 mm).

  • Page 33: Replacement Parts

    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 nec- essary accessories for this conversion and are provid- ed for this purpose. The following conversions should be made using the contents of this kit: 1.

  • Page 34: Maintenance

    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.

  • Page 35: Gun And Cable 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.

  • Page 36: Changing Drive Roll

    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.

  • Page 37: Changing Liner

    Set Screw Brass Cable Connector Liner Assembly (Liner bushing to be sealed tight against brass cable connector) 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 anoth- er gun unless it can meet the liner cutoff length requirement.

  • Page 38: Troubleshooting

    HOW TO USE TROUBLESHOOTING GUIDE 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.
  • Page 39 Observe all Safety Guidelines detailed throughout this manual 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.
  • Page 40 Observe all Safety Guidelines detailed throughout this manual 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) Low or no gas flow when gun trigger is pulled.
  • Page 41 Observe all Safety Guidelines detailed throughout this manual PROBLEMS (SYMPTOMS) Arc is unstable – Poor starting 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. TROUBLESHOOTING POSSIBLE AREAS OF MISADJUSTMENT(S)
  • Page 42 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-135T...
  • Page 43 NOTES SP-135T...
  • Page 44 ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● ● Spanish ● PRECAUCION French ● ATTENTION German ● WARNUNG Portuguese ● ● Japanese Chinese Korean Arabic WARNING AVISO DE ATENÇÃO...
  • Page 45 • 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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