Lincoln Electric IM788 User's Manual
Contents
1. OL 1VISOWHAHL SIU 9995 JO esn Pinoys suosjed e sped yono jou oq e pod 1emod BuibBnjdun Aq samod 1ndur jpeuuoosi e DeAOUJGJ S18A09 jou e 9334 I ueo AOVLIOA HOIH ix MS 39VL1OA ONINYVM V 3009 7951419973 Yad OL VLE LES GION3TIOS Svo 20 O d IOHLNOO INVHOVIG ONTAIM 51 45 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 135 PLUS LINCOLN SP Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO Japanese BIR Korean Do not touch electrically live parts or electrode with skin or wet clothing Insulate yourself from work and ground No toque las partes los electrodos bajo carga con la piel o ropa moja a Aislese del trabajo de tierra Ne laissez ni la peau ni des v te ments mouill s entrer en contact avec des pi ces sous tension Isolez vous du travail et de la terre e Ber hren Sie keine stromf hrenden Teile oder Elektroden mit Ihrem K rper oder feuchter Kleidung Isolieren Sie sich2. CAUTION If the gun trigger switch being used is other than that supplied with the SP 135 PLUS 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 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 GAS CONNECTION Refer to Figure A 5 When using the GMAW process a cylinder of shield ing gas must be obtained For more information about selecting gas cylinders for use with the SP 135 PLUS refer to the ACCESSORIES section SP 135 PLUS LINCOLN 5 INSTALLATION a CYLINDER may explode if dam aged 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 BUILDUP OF SHIELDING GAS may 9 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 PUB LISHED BY THE AMERICAN WELDING SOCIETY 1 Chain the cylinder to a wall or other stationary sup port to prevent the cylinder from falling over Insulate the cylinder from the work circuit and earth ground Refer to Figure A 5 FIGURE A 5
3. 9 0 se 110 9NI9V3 3218 03119315 GIYINOIY FHL 7109 TIVLSNI NOIJVIN3IHO 1109 JAIA ui 1321813 SUEd aygewnsuoy pue ung 7001 IUDNOVII GED DED 9 09 14 SS31SV3 03405 aN EE ap CTAIHSANNI SSTISVI gp u 550 207 02 52 08 97 SZJ 40 069 957 013M NT102NI1 3MIM 1331 01105 g o 050 209 02 62 way 908 01 523 19 023 svg TWANVIN 33S SONILI3S WNNINNTIY 14415 SSTINIVIS 401 NIQ13M 401 SONILLAS 03183991 99 1 013M NTIOONTI 1331 017105 g n ui onoiaus 781M SNIGTIM SP 135 PLUS LINCOLN Z C1 ACCESSORIES 1 OPTIONAL ACCESSORIES 4 1 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 5 accessories Easy assembly required takes less than 15 minutes 2 K586 1 Deluxe Adjustable Gas Regulator amp Hose Kit Accommodates CO or mixed Gas Cylinders 3 K663 2 Aluminum Welding Kit This kit required for welding with 035 Aluminum wire Included with this kit are a drive roll liner and con tact tip It is important when changing between welding with steel wire and aluminum to exchange these components
4. 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 A 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 LINCOLN vi TABLE OF CONTENTS Page Section A Technical Specifications sse A 1 Identify and Locate Components 2 Select Suitable Location Output Connections ir t ia doin een A 3 Input Connections sisi A 5 6 OperatiOn Section B Safety Precautions iii B 1 General Description iioii rc ird B 2 Design Features and Advantages B 2 Welding Capability eee 2 IMITATIONS B 2 Controls and Settings 2 Welding Operations iii B 3 Overload Protection cientos sarete B 7 Application C
5. 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 X Connect the work cable to the workpiece as close as possible to the area being welded 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 Do not work next to welding power source Mar 95 LINCOLN SAFETY 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 Ma
6. Flow Regulator Cylinder Valve Gas Hose gt 2 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 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 CO cylinder insert regulator adapter provided with MIG Conversion Kit between regulator and cylinder valve If adapter is equipped with a plastic washer be sure it is seat ed for connection to the CO cylinder 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 machine Gas Solenoid Inlet Fitting 5 8 18 female threads for CGA 032 fitting Make certain the gas hose is not kinked or twisted 5 Reinstall case side before connecting input power INPUT CONNECTIONS Refer to Figure A 6 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 FIGURE A 6 GAS SOLENOID INLET FITTI
7. Welding Current Range Continuous Maximum Open Circuit Voltage Auxiliary Power Rated DC Output 25 135 Amps N A RECOMMENDED INPUT CABLE AND FUSE SIZES Fuse or Output Mode Input Voltage Breaker Size Extension Cord Three Conductor 14 AWG RATED 115V 60Hz 20 Amp 20 2 1 mm or Larger for up to 25 feet 7 6m Three Conductor 12 AWG MAXIMUM 115V 60Hz 25 Amp 25 3 3 mm or Larger for up to 50 feet 15 2 m PHYSICAL DIMENSIONS SP 135 PLUS LINCOLN INSTALLATION ai 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 135 PLUS 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 135 PLUS power switch is to be in the OFF 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 135 PLUS from its carton and remove all packing material around the SP 135 PLUS Remove the following loose items from the carton see Figure A 1 1 SP 135 PLUS 2 Gun and cable assembly 3 Literature and miscellaneous including a This operating m
8. screening and or warn them not to watch the arc nor expose themselves to the arc rays or to hot spatter or metal 23 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 Do not weld in locations near chlorinated hydrocarbon vapors coming from degreasing cleaning or spraying operations The heat and rays of the arc can react with solvent vapors to form phosgene a highly toxic gas and other irritating prod ucts 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 Read and understand the manufacturer s instructions for this equipment and the consumables to be used inclu
9. FIGURE A 4 GUN INSTALLATION As shipped from the factory the SP 135 PLUS gun is ready to feed 023 025 0 6 mm wire If 030 035 0 8 0 9 mm wire is to be used change the contact tip to the appropriate size Refer to the MAINTENANCE section for contact tip installation details NOTE If 035 Innershield Flux cored wire is to be used see the Accessories section for the Innershield Welding Kit Connecting Gun Cable to the SP 135 PLUS 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 con trol 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 SP 135 PLUS case front Make sure the connector is all the way in the metal connector block to obtain proper gas flow 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 connector bushings located above 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
10. Push a length of straightened welding wire through the wire feeder guide tubes and reset the Phillips Head screw to secure the drive roll onto the shaft 6 Reapply the spring loaded idle arm tensioner 7 Turn the power ON I and check the drive roll for slipping when feeding wire DO NOT OVERTIGHTEN If necessary tighten or loosen the spring loaded idle arm tensioner 2 FIGURE D 1 SP 135 PLUS LINCOLN 8 SP 135 PLUS p MAINTENANCE es 1 1 4 31 8 mm Liner Trim Length Gas Diffuser a Slotted Brass Cable 20 Set Screw Connector Gas Nozzle or Gasless ode ee Threaded T Liner Assembly Liner bushing to be seated tight against brass cable connector FIGURE D 2 Liner trim length for gun with red trigger Magnum 100L 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 require ment Refer to Figure D 2 1 Remove gun and cable assembly from machine 2 Remove the gas nozzle from the gun by unscrew ing counter clockwise 3 Remove the existing contact tip from the gun by unscrewing counter clockwise 4 Remove the gas diffuser from the gun tube by unscrewing counter clockwise 5 Lay the gun and cable out straight on a flat sur face Loosen the set screw located in the brass connector at the wire feed
11. and latch the spring loaded pressure arm 1 in place now you may release the welding wire FIGURE B 4 The Wire Drive Feed Roll can accommodate two wire sizes by flippin the wire drive feed ro over The sizes are sten ciled on the drive roll 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 drive roll slips while feeding wire the pressure should be increased until the wire feeds properly WARNING When inching the welding wire the drive rolls the gun connector block and the gun contact tip are always energized relative to work and ground and remain energized several seconds after the gun trigger is released 7 Refer to Figure B 5 Remove gas nozzle and con tact tip from end of gun 8 Turn the SP 135 PLUS ON 1 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 the FE
12. Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed SP 135 PLUS LINCOLN 2 TROUBLESHOOTING GUIDE TROUBLESHOOTING E 2 Observe Safety Guidelines detailed in the beginning of 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 weld output or wire feed when gun trigger is pulled Fan runs and gas flows normally No weld output when gun trigger is pulled Fan runs gas flows and wire feeds normally No Wire feed weld output or gas flow when the gun trigger is pulled Fan operates normally POSSIBLE AREAS OF MISADJUSTMENT S OUTPUT PROBLEMS Contact your LOCAL LINCOLN AUTHORIZED FIELD SERVICE FACILITY RECOMMENDED COURSE OF ACTION 1 Make sure correct voltage is applied to the machine 115 vac 2 Make certain that power switch is in the ON position 3 Make sure Circuit Breaker is Reset Contact your LOCAL LINCOLN AUTHORIZED FIELD SERVICE FACILITY Arc voltage may be set too low Gun tip may be worn Replace Contact your local Lincoln Authorized Field Service Facility Check for correct input voltage to machine Gun or work cable may be faulty Check the circuit breaker locat ed in the machine s wire drive compartment Reset if tripped The thermostat may be tripped due to ove
13. and do not start engine until fumes have been eliminated 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 EMF fields may interfere with some pacemakers and welders having a pacemaker should consult their physician before welding 1 d Keep all equipment safety guards covers and 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 Exposure to EMF fields in welding may have other health effects which are now not known All welders should use the following procedures in order to 1 e In some cases it may be necessary to remove safety Dd MM minimize exposure to EMF fields from the welding circuit 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 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 1 f Do not put your hands near the engine fan Do not attempt to override the governor idler by pushing on the throttle control rods while the engine is running
14. nozzle CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM KP2039 1B1 In Gun 025 0 6mm KP2039 2B1 Loose 030 0 8mm Components shipped with SP 135 PLUS K549 1 035 0 9mm Innershield Welding Kit KP2039 3B1 035 0 9mm K663 2 035 0 9mm Aluminum KP2078 1B1 035A 0 9mm KP666 035C Drive Roll KP1937 3 030 035 0 8 0 9 mm KP1881 1 2 Smooth grooves Small 023 025 Stenciled 025 Large 030 035 Stenciled 030 035 KP1937 3 035 0 9mm KP666 035C Use Large groove KP1959 1 035 0 9mm 524220 Drive roll 524219 Idle roll NOT SOLD SEPARATELY Stenciled 2 Knurled grooves for 035 0 9mm e If 030 Solid wire feeding is desired obtain an KP2039 2B1 Contact an KP1937 2 Cable Liner and an KP1881 1 Drive Roll Smaller Groove Recommended for best feeding performance SP 135 PLUS LINCOLN 4 SP 135 PLUS D 3 MAINTENANCE D 3 COMPONENT REPLACEMENT PROCEDURES CHANGING THE CONTACT TIP 1 Unplug or turn power switch to Off O position 2 Refer to Figure D 2 Remove the gas nozzle from the gun by unscrewing counter clockwise 3 Remove the existing contact tip from the gun by unscrewing counter clockwise 4 Insert and hand tighten desired contact tip 5 Replace gas nozzle CHANGING THE SP 135 PLUS FOR USE WITH INNERSHIELD FLUX CORED WIRE e Change The Contact Tip 1 Refer to Figure D 2 Remove the gas nozzle
15. the hole through the tip MAINTENANCE D 2 2 Replace worn contact tips as required A variable or hunting arc is a typical symptom of a worn con tact 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 screwed 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 connec tor 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 dif fuser Replace the gas nozzle or gasless
16. 0 duty cycle on a ten minute basis It is capable of higher duty cycles at lower output currents LIMITATIONS Arc Gouging cannot be performed with the SP 135 PLUS The SP 135 PLUS is not recommended for pipe thawing CONTROLS AND SETTINGS Refer to Figures B 1a amp B 1b 1 Power ON OFF Switch When the power is the fan motor will run and air will ON 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 OFF 2 Voltage Control A contin uous control that gives full range adjustment of power source output voltage Voltage can be adjusted while welding ARC VOLTS 3 Wire Speed Control Controls the wire feed speed from 50 400 in 1 3 10 m min The control can be preset on the dial to the setting specified on the SP 135 PLUS Application Chart located on the inside of the wire feed section door Wire speed is not affected when changes are made in the voltage control WIRE SPEED SP 135 PLUS LINCOLN 3 OPERATION es FIGURE B 1a SP 135 Plus 4 Circuit Breaker Protects machine from damage if maximum output is exceeded Button will extend out when tripped Manual reset 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 do
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18. D branchez le courant avant l entre tien Strom vor Wartungsarbeiten abschalten Netzstrom v llig ff nen Maschine anhalten opere com as tampas removidas e Desligue a corrente antes de fazer servico toque as partes el tricas nuas e 47TTLA 9 UACNUPD PSB EFFERIA FE o abil 4 gS abil e Do not operate with panel open guards off No operar con panel abierto o guardas quitadas N op rez pas avec les panneaux ouverts ou avec les dispositifs de protection enlev s Anlage nie ohne Schutzgeh use oder Innenschutzverkleidung in Betrieb setzen Mantenha se afastado das partes moventes Nao opere com os paineis abertos ou guardas removidas CRRRTHMRRARS SERB zado Sel e h Yi cus 3 jal lia Jada v e Ale Cut Aii gli Spanish AVISO DE PRECAUCION French ATTENTION German WARNUNG ATENCAO BIA Chinese LEIA E COMPREENDA AS INSTRUCOES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO E SIGA AS PRATICAS DE SEGURANCA DO EMPREGADOR DMR PRU X A OQHRBEE lt RH ETHBRLTF SL ELTHHOREMEI TES TT Uo HAMAD ERRAND RHR B E R E RE o SHS ou AAAS HA eke FAS ETA BEHE cual gl la
19. ECT 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 amp Cutting ANSI Standard 749 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 FOR ENGINE powered equipment 1 Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running 3 X 1 h To avoid scalding do not remove the radiator pressure cap when the engine is hot 1 b Operate engines in open well ventilated areas or vent the engine exhaust fumes outdoors ELECTRIC AND MAGNETIC FIELDS may be dangerous 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 vaporiz ing on contact with hot engine parts and igniting Do not spill fuel when filling tank If fuel is spilled wipe it up
20. EDING PROBLEMS section of the TROU BLESHOOTING GUIDE in this manual 11 Replace contact tip and gas nozzle 12 Refer to Figure B 6 Cut the wire off 3 8 1 2 10 13 mm from the end of the tip The SP 135 SP 135 PLUS PLUS is now ready to weld LINCOLN 5 OPERATION ES FIGURE B 5 Gun Handle Gas Diffuser Contact Tip 9 Gas Nozzle IM Shielding Gas When using the GMAW process a oylinder of shield ing gas must be obtained Refer to the ACCES SORIES section for more information about selecting gas cylinders for use with the SP 135 PLUS 1 For open the cylinder very slowly For argon mixed gas open oylinder valve slowly a fraction of a turn When the cylinder pressure gauge pointer stops moving open the valve fully 2 If using a regulator with an adjustable flow meter close the gun trigger and adjust the flow to give 15 20 cubic ft per hour 7 10 l min use 20 25 10 12 l min when welding out of position or in a drafty location for For argon mixed gas trigger to release gas pressure and turn off the adjust the flow to give 25 30 12 14 l min 3 Keep the cylinder valve closed except when using the SP 135 PLUS When finished welding 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 135 PLUS Making A Weld 1 See Reco
21. NG POWER INPUT CABLE ll o SP 135 PLUS LINCOLN INSTALLATION CODE REQUIREMENTS FOR INPUT CONNECTIONS This welding machine must be connected to power source in accordance with applicable elec trical codes The National Electrical Code provides standards for amperage handling capability of supply con ductors 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 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 135 PLUS Connect this plug to a mating ground ed 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 18 Volts 20 duty cycle 2 minutes of every 10 minutes used for welding CAUTION Do not connect the SP 135 PLUS to an input power supply with a rated voltage that is greater than 125 volts Do not remove the power cord ground prong Requirements For Maximum Output In order to utilize the maximum output capability of the machine a branch circuit capable of 25 amps at 115 to 125 volts 60 Hertz is required This generally applies when welding steel that is equal to or greater than 12 gauge 0 105 2 5 mm in thickness SP 135
22. OPERATION B 6 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 135 PLUS 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 supplier may reduce buildup and aid in spatter removal PROCESS GUIDELINES The SP 135 PLUS 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 self shielded Innershield process FCAW The recommended gases and electrodes for GMAW are welding grade CO gas or an argon CO blended gas 75 to 80 argon and 25 to 20 and 025 0 6 mm diameter Lincoln Super Arc L 56 mild steel welding wire The recommended electrode for the self shielded process is 0 035 0 9 mm diameter Lincoln Innershield NR 211 MP This electrode can be used for all position welding of 20 gauge through 5 16 1 0 8 0 mm thick steel multiple passes are required for 1 4 and 5 16 6 0 and 8 0 WARNING Use of the GMAW process with the SP 135 PLUS on thicker materials than recommended may result in poor welds The wel
23. ORE EACH USE Check over machine and accessories for any obvi ous condition that may prevent safe performance or operation repair or replace items as necessary to correct any abnormal condition AFTER 5 MINUTES OF WELDING or when spatter accumulates in nozzle Clean nozzle to avoid bridging between nozzle and contact tip which results in shorted nozzle poor welds and overheated gun Hint Anti stick spray or gel available from a welding supply distributor may reduce buildup and aid in spatter removal AFTER EACH SPOOL OF WIRE FEED Remove contact tip and clean inside diameter with short piece of wire Clean cable liner when rough and erratic wire feed ing occur AFTER FEEDING 50 OF FLUX CORED WIRE OR 300 OF SOLID WIRE Unplug machine or turn power switch to OFF position Remove gun and cable from machine Remove gas nozzle and contact tip from gun Lay cable out straight blow out gently into gun end with compressed air Bend cable back and forth blow out again Repeat until clean WARNING Excessive pressure at start may cause the dirt to form a plug PERIODICALLY AS REQUIRED Blow dirt out of the welder with low pressure air to eliminate excessive dirt and dust buildup that could cause welder to run hot Blow dirt out of Rectifier amp Fan Motor Assembly PC Board located on Case Side Assembly and Center Assembly components Vacuum accumulated dirt from gearbo
24. PLUS LINCOLN OPERATION B 1 Read entire Operation section before operating the SP 135 PLUS 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 Es WELDING SPARKS can cause fire or explosion Keep flammable material away z yi Do not weld on closed contain ers ARC RAYS can burn eyes and skin Wear eye ear and body protec tion K Da Observe all safety information throughout this manual SP 135 PLUS LINCOLN B 2 OPERATION B 2 GENERAL DESCRIPTION The SP 135 PLUS is a complete semiautomatic con stant voltage DC arc welding machine Included is a solid state controlled single phase constant voltage transformer rectifier power source and a wire feeder for feeding solid steel electrode and cored electrode The SP 135 PLUS is ideally suited for individuals hav ing access to 115 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 135 PLUS is a rugged and reliable machine that has been designed for dependable service and long lif
25. RETURN MAIN MENU IM788 SP 1 95 PLUS ma For use with machine Code Numbers 10974 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 OPERATOR S MANUAL ISO 9001 Ns V9 gy Designed and Manufactured Under a ified by u to ISO 9001 Requirements CERTIFICATE NUMBER 30273 LI NCOLN 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 i SAFETY WARNING CALIFORNIA PROPOSITION 65 WARNINGS A 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 cancer birth defects or other reproductive harm The Above For Diesel Engines The Above For Gasoline Engines ARC WELDING CAN BE HAZARDOUS PROT
26. SUMIBLES 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 HER STELLERS DIE UNFALLVERHUTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN Keep your head out of fumes Use ventilation or exhaust to remove fumes from breathing zone Los humos fuera de zona de res Mantenga cabeza fuera de los humos Utilice ventilaci n o aspiraci n para gases Gardez la t te l cart des fum es Utilisez un ventilateur ou un aspira teur pour les fum es des zones de travail e Vermeiden Sie das Einatmen von Schweibrauch Sorgen Sie f r gute Be und Entl ftung des Arbeitsplatzes e Mantenha seu rosto da fumaca Use ventila o e exhaust o para remover fumo da zona respirat ria 1 FUR Es FL EX SERRE e Y22749 8478 S XAOENE SANTE HAPI AS 7 xpi Ss7lE os Naya dd asd e Jee JAU olia Les galt Qui Ge call 9 Turn power off before servicing Desconectar el cable de ali de poder de maquina antes de iniciar cualquier servicio
27. TMENT S COURSE OF ACTION WELDING PROBLEMS Arc is unstable Poor starting 1 Check for correct input voltage to machine 115 vac Check for proper electrode polarity for process Check gun tip for wear or dam Contact your local Lincoln age Replace Authorized Field Service Facility Check for proper gas and flow rate for process Check work cable for loose or faulty connections 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 LINCOLN P 1 WIRING DIAGRAMS 1 6E LOZIN 3dis LNANOdWOO HONANDAS NIYJANWNN ALIAVO HO1V1 YOLONGNOD 3199 NN9 YOLOW Q334 8 F 655 0c 19 1700066 y 05 AMOHS LNdLNO ONIHOWLLW3Y 08 9NINHOO MOG GNNOdWOo 188611 31033 SNOLLO3NNOO WNANINNTY 931708 O N GAMAIA LNANOdNOO O N TANVd S31N39 JHL OL 1595019 SI HOIHM MNIS LVSH 3GISNI IHL NO GALNNOW 38V 9 530010 EN INISLVSH 3015110 IHL NO GALNNOW 33V 530010 VN LEG SALON SLIHM M 1009 QV31 18913 43 SIOMAS T1VOISHLO3 T3 az HOLIMS 212 0 0 A 35399134 NNO MNISLW3H
28. That Have Held Hazardous Substances AWS F4 1 from the American Welding Society see address above Vent hollow castings or containers before heating cutting or welding They may explode Sparks and spatter are thrown from the welding arc Wear oil 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 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 cir cuits This can create fire hazards or overheat lifting chains or cables until they fail 6 h Also see item 1 c 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 Always keep cylinders in an upright position securely chained to an undercarriage or fixed support Oylinders should be located Away from areas where they may be struck or subjected to physical damage saf
29. a secousse lectrique a Les circuits l lectrode et la pi ce sont sous tension quand la machine souder est en marche Eviter toujours tout contact entre les parties sous tension et la peau nue ou les v tements mouill s Porter des gants secs et sans trous pour isoler les mains Faire tr s 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 couch pour lesquelles une grande partie du corps peut tre en contact avec la masse Maintenir le porte lectrode la pince de masse le c ble de soudage et la machine souder en bon et s r tat defonctionnement d Ne jamais plonger le porte lectrode dans l eau pour le refroidir Ne jamais toucher simultan ment les parties sous tension des porte lectrodes connect s deux machines souder parce que la tension entre les deux pinces peut tre le total de la tension vide des deux machines Si on utilise la machine souder comme une source de courant pour soudage semi automatique ces precautions pour le porte lectrode s applicuent aussi au pistolet de soudage Eloigner les mat riaux inflammables ou les recouvrir afin de pr venir tout risque d incendie d aux tincelles Quand on ne soude pas poser la pince une endroit isol de la masse Un court circuit accidental peut provoquer un chauffement et un risque d ince
30. anual b A contact tip for 030 0 8 mm diameter wire 4 10 ft 3 0 m work cable 5 Work clamp 6 2lb Spool of Super Arc L 56 025 MIG Wire 7 Adjustable mixed Gas Regulator amp Hose For available options and accessories refer to the accessories section later in this manual 1 As shipped from the factory the SP 135 PLUS gun is ready to feed 023 or 025 0 6 mm wire SP 135 PLUS LINCOLN FIGURE A 1 MANUAL na INSTALLATION A 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 135 PLUS cannot be stacked TILTING Each machine must be placed on a secure level sur face either directly or on a recommended undercar riage The machine may topple over if this procedure is not followed OUTPUT CONNECTIONS Refer to Figure A 2 1 Work Cable Access Hole Gun Cable and Control Lead Access Hole Connector Block Gun Trigger Lead Connectors Positive and negative output terminals Wire Feed Gearbox and Gun Connector Block Cable Clamp OO A Thumbscrew Secures gun and cable assembly Work Clamp Installation Attach the work clamp per the fo
31. ding 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 Mar 95 SP 135 PLUS LINCOLN SAFETY WELDING SPARKS lt gt 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 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 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 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 though they have been cleaned For information purchase Hecommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping
32. ds may look good but may just be sitting on top of the plate This is called cold casting and will result in weld fail ure The SP 135 PLUS is suitable for 035 Aluminum wire and 030 stainless wire Refer to Table B 1 for Recommended Procedure Settings Aluminum wire requires K663 2 Aluminum Welding kit See ACCES SORIES section CAUTION 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 Shielding Voltage Wire Speed Welding Wire 16 ga 12 ga 1 8 035 Dia 0 9mm 100 Argon Aluminum Wire 14ga 030 Dia 98 Argon 308L Stainless 2 Oxygen Steel Wire NR Not Recommended CHANGING MACHINE OVER TO FEED OTHER WIRE SIZES The SP 135 PLUS is shipped from the factory ready to feed 0 023 0 025 0 6 mm diameter wire To operate 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 Tip and Changing the Drive Roll in the MAINTE NANCE section for specific information on these pro cedures WELDING WITH FCAW Innershield Welding with Innershield requires an Innershield Welding Kit A gasless nozzle is provided in the Innershield Welding Kit When using Innershield elec trode installi
33. due to the lubri cant applied to steel wire 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 KP666 035C Knurled Drive Roll optional Reversible Drive Roll with double knurled grooves for 035 0 9 mm cored electrode K549 1 035 0 9 mm Innershield Welding Kit Includes a contact tip a gasless nozzle and a cable liner to permit the Magnum 100L gun and cable to use 030 035 0 8 0 9 mm diameter flux cored electrode Also included is a spool of 035 0 9 mm Innershield NR 211 MP SP 135 PLUS LINCOLN P 2 ACCESSORIES c2 INNERSHIELD FCAW CONVERSION Several changes are needed to convert the unit for operation with the Innershield FCAW process The K549 1 Innershield Kit includes 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 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 and tip for the wire size selected See Component Replacement in Maintenance section for details 4 Remove gas nozzle if installed and install gasless nozzle To remove simply
34. e RECOMMENDED PROCESSES The SP 135 PLUS 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 self shielded Innershield electrode process FCAW The SP 135 PLUS is configured for use with the GMAW MIG process as delivered from the factory OPERATIONAL FEATURES AND CONTROLS The SP 135 PLUS has the following controls as stan dard Power ON OFF Switch Voltage Control Wire Speed Control and a Circuit Breaker DESIGN FEATURES AND ADVANTAGES Operates on 115 volt input Solid state output control 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 Easy to set continuous range controls for precise setting of arc voltage and wire speed Continuous voltage control Quick Release idle roll pressure arm is easily adjusted Reversible dual groove drive roll Drive roll will feed 023 035 0 6 0 9 mm diameter wire Accommodates both 8 200 mm diameter and 4 100 mm diameter spools of wire No external shielding gas is required when used with Lincoln 035 0 9 mm Innershield NR 211 MP electrode Easy to change polarity WELDING CAPABILITY The SP 135 PLUS as shipped is rated at 90 amps 18 volts at 2
35. e distance from arc welding or cutting operations and any other source of heat sparks or flame Never allow the electrode electrode holder or any other electrically hot parts to touch a cylinder Keep your head and face away from the cylinder valve outlet when opening the cylinder valve Valve protection caps should always be in place and hand tight except when the cylinder is in use or connected for use Read and follow the instructions on compressed gas cylinders associated equipment and CGA publication 1 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 Install equipment in accordance with the U S National Electrical Code all local codes and the manufacturer s recommendations Ground the equipment in accordance with the U S National Electrical Code and the manufacturer s recommendations Mar 95 SP 135 PLUS LINCOLN id SAFETY PR CAUTIONS DE S RET Pour votre propre protection lire et observer toutes les instructions et les pr cautions de s ret specifiques qui parraissent dans ce manuel aussi bien que les pr cautions de s ret g n rales suiv antes 6 S ret Pour Soudage A L Arc 1 Protegez vous contre l
36. er end of the cable Pull the liner out of the cable 6 Insert a new untrimmed liner into the connector end of the cable Be sure the liner bushing is sten ciled appropriately for the wire size being used 7 Fully seat the liner bushing into the connector Tighten the set screw on the brass cable connec tor At this time the gas diffuser should not be installed onto the end of the gun tube 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 9 Screw the gas diffuser onto the end of the gun tube and securely tighten 10 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 diffi cult 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 Fo FIGURE D 3 SP 135 PLUS LINCOLN P ES TROUBLESHOOTING EI HOW TO USE TROUBLESHOOTING GUIDE WARNING Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel Unauthorized repairs performed
37. es not stick in the weld puddle See FIG B 1b FIGURE B 1b WELDING OPERATIONS SEQUENCE OF OPERATION Wire Loading Refer to Figure B 2 AND The machine power switch should be turned to the OFF position before working inside the wire feed 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 16 mm diame ter spindle that has a built in adjustable friction brake to prevent overrun of the spool and excess slack in the wire The wing nut at the end of the shaft is used to adjust the tension on the wire spool See B 3 on the following page To use 8 200 mm diameter spools the 2 51 mm diameter M15445 spindle must be used Remove the spacer and wing nut at the end of the shaft Insert spindle as shown in figure B 2 Reattach spacer and wing nut Note When loading and removing the 8 Spools make 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 Make certain the start end of the wire which may pro trude through the side of the spool does not contact any metallic case parts FIGURE B 2 Wire Spool Spindle Locking Tab 8 Wire Spool UU Be sure that this stud engages the
38. 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 the contact tip for use with 0 035 Innershield Flux Cored Wire 4 Replace gas nozzle The gasless nozzle may be used instead of the gas nozzle to give improved vis ibility of the arc CHANGING DRIVE ROLL The drive roll Figure D 1 Item 1 has two grooves one for 023 025 0 6 mm solid steel electrode and larger 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 023 025 0 6 mm position If 030 035 0 8 0 9 mm wire is to be used the drive roll must be reversed as follows 1 Turn the power switch to OFF marked O 2 Release the spring loaded idle arm tensioner Figure D 1 Item 2 and lift the idle roll arm Figure D 1 Item 3 away from the drive roll 3 Loosen the Phillips Head screw holding the drive roll onto the drive shaft 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 trig ger is released 4 Remove the drive roll flip over and reinstall with the opposite groove closest to the gearbox NOTE The stencil of the groove that you want to use is marked on the outside of the drive unit when installed 5
39. hart sise B 8 Section C ee ER EE C 1 Replacement 2 c Section D Safety Precautions iii D 1 Items Requiring No Maintenance D 1 Routine and Periodic Maintenance D 1 Gun and Cable Maintenance D 2 Configuration of Components in Wire Feeding D 2 Component Replacement Procedures D 3 Changing Bia ET D 4 Gun Handle H D 4 Troubleshooting EE Section E Safety Precautions iii E 1 How To Use Troubleshooting Guide E 1 Troubleshooting Guide E 2 THRU 4 Wiring Diagrams Section SP 135 PLUS Wiring Diagram F 1 Parts LISTS 454 amp 202 LINCOLN A INSTALLATION in 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 Rated DC Output 90 18 OUTPUT
40. 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 must rotate clockwise when wire is dereeled SP 135 PLUS LINCOLN OPERATION Wire Spindle Shaft 4 Wire Spool Wing Nut and Spacer To wire drive FIGURE B 3 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 Too much drag may result in wire feeding problems and may cause pre mature 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 visible sten ciled size on the drive roll matches the wire size being used 2 Carefully detach the end of the wire from the spool To prevent the spool from unwinding do not release 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
41. lai aut y laiul Gad ol ply Gail gall late ag ls LINCOLN e 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
42. llowing 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 Work Cable Installation Refer to Figure A 2 1 Open the wire feed section door on the right side of the SP 135 PLUS 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 FIGURE A 2 WELDING AMP RANGE 25 125 SP 135 Plus SP 135 PLUS LINCOLN 4 INSTALLATION Route the cable under and around the back of the Wire Feed Gearbox 6 A For GMAW Only Refer to Figure A 2 As deliv ered the SP 135 PLUS is wired for positive polari ty This is the appropriate configuration for the Gas Metal Arc Welding GMAW 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 For Innershield Only Refer to Figure A 4 To wire for negative polarity 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
43. mmended Processes And Equipment 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 wire feed section door for information on setting the SP 135 PLUS controls 3 Set the Voltage V and Wire Speed olo con trols to the settings suggested for the welding wire and base metal thickness being used SP 135 PLUS LINCOLN FIGURE B 6 Contact Tip Wire Electrode 3 8 1 2 10 13mm Contact Tip to Work Distance CTWD Check that the polarity is correct for the welding wire being used and that the gas supply if required is turned on 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 fuser from weld spatter Refer to the MAINTE NANCE section for details on nozzle replacement Refer to Figure B 7 Connect work clamp to metal to be welded Work clamp must make good elec trical contact to the workpiece The workpiece must also be grounded as stated in Arc Welding Safety Precautions in the beginning of this manu al Position gun over joint End of wire may be lightly touching the work 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 FIGURE B 7 GUN CABLE WORK CLAMP B 6
44. ndie S assurer que la masse est connect e le plus pr s 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 loign s de la zone de travail on augmente le risque de voir passer le courant de soudage par les chaines de lev age c bles de grue ou autres circuits Cela peut provoquer des risques d incendie ou d echauffement des chaines et des c bles jusqu ce qu ils se rompent Assurer une ventilation suffisante dans la zone de soudage Ceci est particuli rement important pour le soudage de t les galvanis es plomb es ou cadmi es ou tout autre m tal qui produit des fume s toxiques Ne pas souder en pr sence de vapeurs de chlore provenant d op rations de d graissage nettoyage ou pistolage La chaleur ou les rayons de l arc peuvent r agir avec les vapeurs du solvant pour produire du phosg ne gas fortement toxique ou autres produits irritants Pour obtenir de plus amples renseignements sur la s ret 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 prot ger PR CAUTIONS DE S RET POUR contre les chutes dans le cas ou on recoit un choc Ne jamais enrouler le c ble lectrode autour de n importe quelle partie LES MACHINES SOUDER TRANSFORMATEUR Un coup peut tre plus s v re qu un coup de s
45. ng the gasless nozzle will improve visibili ty of the arc and protect the gas diffuser from weld spatter Additionally included is a gun cable liner to permit proper feeding of 035 0 9 mm Innershield wire Refer to the ACCESSORIES section for details on obtaining this kit SP 135 PLUS LINCOLN 7 OPERATION B 7 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 Thermal Protection The SP 135 PLUS duty cycle is exceeded a thermo stat will shut off the output until the machine cools to a normal operating temperature This is an automatic function and is self resetting Wire Feed Overload Protection If the SP 135 PLUS has an automatic electronic pro tection circuit to protect the wire feed motor If exces sive motor overload occurs due to excessive feeding force jammed drive rolls or shorted motor leads the circuit will shut down the wire feed motor and the welding power output The wire feed shut down circuit will reset automatically when the gun trigger is released However shut down will reoccur if the overload situation is not corrected SP 135 PLUS LINCOLN APPLICATION CHART ee B 8 STU SEL J 821613 UN 195110 529 91790 ON Med alzzon 39
46. nual Stick Welder AC Welder with Reduced Voltage Control In semiautomatic or automatic wire welding the electrode electrode reel welding head nozzle or semiautomatic welding gun are also electrically hot 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 Ground the work or metal to be welded to a good electrical earth ground Maintain the electrode holder work clamp welding cable and welding machine in good safe operating condition Replace damaged insulation Never dip the electrode in water for cooling 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 When working above floor level use a safety belt to protect yourself from a fall should you get a shock Also see Items 6 c and 8 ARC RAYS can burn 4 a Use a shield with the proper filter and cover 2 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 287 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 Protect other nearby personnel with suitable non flammable
47. oliel REDRESSEUR donc a Utiliser un bon masque avec un verre filtrant appropri 1 ainsi qu un verre blanc afin de se prot ger les yeux du ray onnement de et des projections quand on soude ou quand on regarde b Porter des v tements convenables afin de prot ger la peau de soudeur et des aides contre le rayonnement de Prot ger personnel travaillant proximit au soudage l aide d crans appropri s et non inflammables Des gouttes de laitier en fusion sont mises de l arc de soudage Se prot ger avec des v tements de protection libres de l huile tels que les gants en cuir chemise paisse pan talons sans revers et chaussures montantes Toujours porter des lunettes de s curit dans la zone de soudage Utiliser des lunettes avec crans lateraux dans les zones l on pique le laitier SP 135 PLUS LINCOLN Relier la terre le chassis du poste conformement au code de l lectricit et aux recommendations du fabricant Le dispositif de montage ou la piece souder doit tre branch une bonne mise la terre Autant que possible l installation et l entretien du poste seront effectu s par un lectricien qualifi Avant de faires des travaux l interieur de poste la debranch er l interrupteur la boite de fusibles Garder tous les couvercles et dispositifs de s ret leur place for selecting a QUALITY
48. 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 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 SYMP TOMS 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 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 A CAUTION If for any reason you do not understand the test procedures or are unable to perform the tests repairs safely contact your
49. product by Lincoln Electric We want you Thank You to take pride in operating this Lincoln Electric Company product eee 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 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 e 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 WEB SITE at www lincolnelectric com Choose Quick Links and then Product Registration Please complete the form and submit your registration
50. rheating Let machine cool Weld within the duty cycle or remove any air obstruction to machine Wire feed motor may be over loaded Correct feeding prob lem 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 LINCOLN E 3 TROUBLESHOOTING 3 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION FEEDING PROBLEMS No wire feed when gun trigger is If the wire drive motor is running pulled Fan runs gas flows and check to see if the correct wire machine has correct open circuit is in the machine voltage 28 vdc maximum weld output If the wire drive motor is running make sure that the correct drive rolls are installed in the Contact your local Lincoln machine Authorized Field Service Facility Check for clogged cable liner or feeding problems Wire feed speed motor runs very Make sure that the wire speed fast Weld output gas flow and fan control is not set at maximum operate normally The wire begins to feed but shuts 1 Wire spool friction brake adjust off after a short time and will feed ment set too tight Check adjust again for another short inter
51. unscrew The Factory installed Gun Liner will feed 025 035 0 6mm 0 9mm wire 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 Contact Tip Tapered 045 1 2mm KP2052 4B1 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 KP1942 1 Gas Nozzle Tip Recessed 1 2 12 7 mm Opening KP1942 2 Gas Nozzle Tip Recessed 5 8 15 9 mm Opening KP1942 3 Spot Welding Nozzle KP1956 1 Gasless Nozzle Innershield Only KP1939 1 SP 135 PLUS LINCOLN P D 1 MAINTENANCE D 1 MAINTENANCE SAFETY PRECAUTIONS WARNING ELECTRIC SHOCK can kill Disconnect input power by removing plug from receptacle before working inside SP 135 PLUS Use only grounded recep tacle Do not touch electrically hot parts inside SP 135 PLUS Have qualified personnel do the maintenance and trouble shoot ing work ITEMS REQUIRING NO MAINTENANCE Drive Motor and Gearbox Lifetime lubrication Fan Motor Lifetime lubrication Wire Reel Spindle Do NOT lubricate shaft ROUTINE AND PERIODIC MAINTE NANCE BEF
52. val only ment of the wire spool friction if the trigger is released and brake See Friction Brake pressed again See description Adjustment in the OPERA under wire feed overload protec TION section of this manual tion Idle roll pressure adjustment set too high Check adjustment of the idle roll pressure See Wire Threading in The TION section of this manual Damaged or poorly maintained wire feed system Check for clogged or damaged cable liner contact tip and guide tubes Replace any damaged or excessively worn parts Perform ROUTINE AND PERIODIC MAINTENANCE as described in this manual 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 LINCOLN 4 TROUBLESHOOTING E 4 Observe Safety Guidelines TROUBLESHOOTING GUIDE detailed in the beginning of this manual PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUSTMENT S COURSE OF ACTION GAS FLOW PROBLEMS Low or no gas flow when gun 1 Check gas supply flow regulator trigger is pulled Wire feed weld and gas hoses output and fan operate normally Contact your local Lincoln 2 Check gun connection to Authorized Field Service Facility machine for obstruction or leaky seals PROBLEMS POSSIBLE AREAS OF RECOMMENDED SYMPTOMS MISADJUS
53. von den Elektroden und dem Erdboden e Nao toque partes el tricas e elec trodos com a pele ou roupa molha da Isole se da pega e terra e REPOR 7 OMLMPT APSSAPRBS NTUWSHIELT FSU DEBATEER S e EA BORIUBRT ER edu SHEER Xe uc sp nisle ex AXE AMI ous Qi el jad Quali Y O dla 1 gl slt dua ule Y Keep flammable materials away Mantenga el material combustible fuera del rea de trabajo e Gardez l cart de tout mat riel inflammable Entfernen Sie brennbarres Material Mantenha inflamaveis bem guarda dos ORAPTUSOONTO BRIER MMIC L CER EGA e i8 5 SE LIFE Aa AIX mie A ALI pe e Wear eye ear and body protection Prot jase los ojos los o dos y el cuerpo Prot gez vos yeux vos oreilles et votre corps e Tragen Sie Augen Ohren und K r perschutz Use prote o para a vista ouvido e corpo ERO ESI RHER amp UTC SU e ADR HRARSHRERR ez 19 go Soares S ESSAI ddl y die ule Lily uasa y alyd ene T dau 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 CON
54. x and wire feed section nspect the incoming guide tube and clean inside diameter if necessary Replace when excessively worn Replace Contact Tip when hole is enlarged or elongated refer to CHANGING THE CONTACT TIP in this section Replace gas nozzle Replace Liner when wire feeding problems occur and other items have been checked refer to CHANGING LINER procedure in this section Replace internal gun handle parts as necessary see Procedure at the end of this section SP 135 PLUS LINCOLN P D 2 GUN AND CABLE MAINTENANCE FOR MAGNUM 100L GUN Gun Cable Cleaning Clean cable liner after using approximately 300 Ibs 136 kg of solid wire or 50 16 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 push ing 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
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