Lincoln-electric IM725 SP-135 Plus User Manual

SP-135 PLUSOPERATOR’S MANUALIM725December, 2001Safety Depends on YouLincoln arc welding and cuttingequipment is designed and builtwith safety in mind.

A-3A-3INSTALLATIONSP-135 PLUSSELECT SUITABLE LOCATIONLocate the welder in a dry location where there is freecirculation of clean air into the louvers

A-4SP-135 PLUSA-4INSTALLATION3. Route the cable under and around the back of theWire Feed Gearbox (6).4. For GMAW Only: Refer to Figure A.2. As deliv-

A-5A-5INSTALLATIONSP-135 PLUS3. Attach the flow regulator to the cylinder valve andtighten the union nut securely with a wrench. Theflow regulator for

A-6 A-6INSTALLATIONSP-135 PLUSCODE REQUIREMENTS FOR INPUTCONNECTIONSThis welding machine must be connected topower source in accordance with applicabl

SP-135 PLUSB-1B-1OPERATIONRead entire Operation section beforeoperating the SP-135 PLUS.ELECTRIC SHOCK can kill.• Do not touch electrically liveparts

B-2SP-135 PLUSB-2OPERATIONGENERAL DESCRIPTIONThe SP-135 PLUS is a complete semiautomatic con-stant voltage DC arc welding machine. Included is asolid

SP-135 PLUSB-3B-3OPERATIONFIGURE B.1a4. Circuit Breaker – Protects machine from damage ifmaximum output is exceeded. Button will extendout when trippe

B-4B-4OPERATIONFIGURE B.3Friction Brake AdjustmentWith wire spool installed on the spindle shaft and thewing nut loose, turn the spool by hand while s

SP-135 PLUSB-5B-5OPERATIONShielding GasWhen using the GMAW process, a cylinder of shield-ing gas, must be obtained. Refer to the ACCES-SORIES section

B-6SP-135 PLUSB-6OPERATION9. To stop welding, release the gun trigger and thenpull the gun away from the work after the arc goesout.10. When no more w

SP-135 PLUSFOR ENGINEpowered equipment.1.a. Turn the engine off before troubleshooting and maintenancework unless the maintenance work requires it to

SP-135 PLUSB-7B-7OPERATIONOVERLOAD PROTECTIONOutput OverloadThe SP-135 PLUS is equipped with a circuit breakerwhich protects the machine from potentia

B-8SP-135 PLUSB-8LEARNING TO WELDLEARNING TO WELDNo one can learn to weld simply by reading about it.Skill comes only with practice. The following pag

SP-135 PLUSB-9B-9LEARNING TO WELDThe “arc stream” is seen in the middle of the picture.This is the electric arc created by the electric currentflowing

B-10SP-135 PLUSB-10LEARNING TO WELDFor GMAW (MIG) Process1. Is most of my welding performed on 16 gauge andlighter materials?2. Can I afford the extra

SP-135 PLUSB-11B-11LEARNING TO WELDFIGURE B.12PenetrationUnless a weld penetrates close to 100% of the metalthickness, a butt weld will be weaker than

B-12SP-135 PLUSB-12LEARNING TO WELDFIGURE B.16Vertical-down WeldingRefer to Figure B.17 Vertical-down welds are appliedat a fast pace. These welds are

SP-135 PLUSB-13B-13LEARNING TO WELDARC RAYS can burn eyes and skin.When using an open arc process, itIs necessary to use correct eye,head and body pro

B-14SP-135 PLUSB-14LEARNING TO WELDMild Steel 16 gauge or 1/16 inch(1.6 mm)Electrode 0.035" (0.9 mm)NR-211-MPInnershield WireVoltage Setting “V”

SP-135 PLUSB-15B-15LEARNING TO WELDMACHINE SET UP FOR THE GMAW (MIG)PROCESS1. See PROCESS GUIDELINES in the OPERATIONsection for selection of welding

Helpful Hints1. For general welding, it is not necessary to weavethe arc, neither forward or backward nor sideways.Weld along at a steady pace. You wi

SP-135 PLUSiiSAFETYiiARC RAYS can burn.4.a. Use a shield with the proper filter and coverplates to protect your eyes from sparks andthe rays of the ar

SP-135 PLUSB-17B-17LEARNING TO WELD4. After you strike the arc, practice the correct electri-cal stickout. Learn to distinguish it by its sound.5. Whe

SP-135 PLUSB-18B-18LEARNING TO WELDProper Gun HandlingMost feeding problems are caused by improper han-dling of the gun cable or electrodes.1. Do not

B-19B-19APPLICATION CHARTSP-135 PLUS

C-1C-1SP-135 PLUSACCESSORIES4. KP666-035C Knurled Drive Roll (optional) —Reversible Drive Roll with double knurled groovesfor .035 (0.9 mm) cored elec

C-2C-2SP-135 PLUSACCESSORIESINNERSHIELD (FCAW)CONVERSIONSeveral changes are needed to convert the unit foroperation with the Innershield (FCAW) proces

SP-135 PLUSMAINTENANCESAFETY PRECAUTIONSELECTRIC SHOCK can kill.• Disconnect input power byremoving plug from receptaclebefore working inside SP-135PL

D-2SP-135 PLUSD-2MAINTENANCEGUN AND CABLE MAINTENANCEFOR MAGNUM™ 100L GUNGun Cable CleaningClean cable liner after using approximately 300 lbs(136 kg)

D-3SP-135 PLUSD-3MAINTENANCECOMPONENT REPLACEMENT PROCEDURESCHANGING THE CONTACT TIP1. Unplug or turn power switch to Off “O” position.2. Refer to Fig

D-4GUN HANDLE PARTSThe gun handle consists of two halves that are heldtogether with a collar on each end. To open up thehandle, turn the collars appro

SP-135 PLUSIf machine case sides and top are removed, the case front must be supported. Failureto do this could result in mechanical or electrical dam

SP-135 PLUSFOR ELECTRICALLYpowered equipment.8.a. Turn off input power using the disconnectswitch at the fuse box before working onthe equipment.8.b.

E-2SP-135 PLUSE-2TROUBLESHOOTINGObserve Safety Guidelinesdetailed in the beginning of this manual.TROUBLESHOOTING GUIDEPROBLEMS(SYMPTOMS)Major physica

SP-135 PLUSE-3E-3TROUBLESHOOTINGObserve Safety Guidelinesdetailed in the beginning of this manual.TROUBLESHOOTING GUIDEPROBLEMS(SYMPTOMS)No wire feed

E-4SP-135 PLUSE-4TROUBLESHOOTINGObserve Safety Guidelinesdetailed in the beginning of this manual.TROUBLESHOOTING GUIDEPROBLEMS(SYMPTOMS)Arc is unstab

F-1SP-135 PLUSF-1WIRING DIAGRAMSM19922L1L23132531TO GROUNDPER NATIONALELECTRICAL CODES1SWITCH202201D1D3D2D4204204204203203203C159,000 f40V203204-+OUT

SP-135 PLUSNOTES

Now Available...12th EditionThe Procedure Handbook of Arc WeldingWith over 500,000 copies of previous editions publishedsince 1933, the Procedure Hand

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SP-135 PLUSivSAFETYivPRÉCAUTIONS DE SÛRETÉPour votre propre protection lire et observer toutes les instructionset les précautions de sûreté specifique

SP-135 PLUSThank Youfor selecting a QUALITY product by Lincoln Electric. We want youto take pride in operating this Lincoln Electric Company product••

viviSP-135 PLUSTABLE OF CONTENTSPageInstallation ...

A-1A-1INSTALLATIONSP-135 PLUSFuse orOutput Mode Input Voltage Breaker Size Input Amps Extension CordThree Conductor#14 AWGRATED 115V/60Hz 20 Amp 20 (2

A-2 A-2INSTALLATIONSP-135 PLUSRead entire installation section before startinginstallation.SAFETY PRECAUTIONSIDENTIFY AND LOCATE COMPONENTSIf you have