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IM725
December, 2001
SP-135 PLUS
For use with machine Code Numbers : 10868
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.
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
OPERATOR’S MANUAL
Copyright © 2001 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
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SAFETY
ELECTRIC SHOCK can
ARC RAYS can burn.
4.a. Use a shield with the proper filter and cover
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 Z87. I standards.
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.
4.b. Use suitable clothing made from durable flame-resistant
material to protect your skin and that of your helpers from
the arc rays.
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.
4.c. Protect other nearby personnel with suitable, non-flammable
screening and/or warn them not to watch the arc nor expose
themselves to the arc rays or to hot spatter or metal.
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:
FUMES AND GASES
can be dangerous.
5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
• Semiautomatic DC Constant Voltage (Wire) Welder.
• DC Manual (Stick) Welder.
• AC Welder with Reduced Voltage Control.
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.
3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
welding gun are also electrically “hot”.
3.d. 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.
3.e. Ground the work or metal to be welded to a good electrical
(earth) ground.
3.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
5.b. 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.
3.g. Never dip the electrode in water for cooling.
3.h. Never simultaneously touch electrically “hot” parts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.
5.c. 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.
5.d. Read and understand the manufacturer’s instructions for this
equipment and the consumables to be used, including 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.
3.i. When working above floor level, use a safety belt to protect
yourself from a fall should you get a shock.
3.j. Also see Items 6.c. and 8.
5.e. Also see item 1.b.
Mar ‘95
SP-135 PLUS
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SAFETY
WELDING SPARKS can
cause fire or explosion.
CYLINDER may explode
if damaged.
6.a. Remove fire hazards from the welding area.
If this is not possible, cover them to prevent
7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
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.
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.
7.b. Always keep cylinders in an upright position securely
chained to an undercarriage or fixed support.
6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1) and the operating information for the
equipment being used.
7.c. Cylinders should be located:
•Away from areas where they may be struck or subjected to
physical damage.
6.c. 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.
•A safe distance from arc welding or cutting operations and
any other source of heat, sparks, or flame.
7.d. Never allow the electrode, electrode holder or any other
6.d. 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 “Recommended
Safe Practices for the Preparation for Welding and Cutting of
Containers and Piping That Have Held Hazardous
Substances”, AWS F4.1 from the American Welding Society
(see address above).
electrically “hot” parts to touch a cylinder.
7.e. Keep your head and face away from the cylinder valve outlet
when opening the cylinder valve.
7.f. Valve protection caps should always be in place and hand
tight except when the cylinder is in use or connected for
use.
7.g. Read and follow the instructions on compressed gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.
6.e. Vent hollow castings or containers before heating, cutting or
welding. They may explode.
6.f. 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.
FOR ELECTRICALLY
powered equipment.
8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.
6.g. 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.
8.b. Install equipment in accordance with the U.S. National
Electrical Code, all local codes and the manufacturer’s
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
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SAFETY
zones où l’on pique le laitier.
PRÉCAUTIONS DE SÛRETÉ
Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv-
antes:
6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.
7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-circuit accidental peut provoquer un
échauffement et un risque d’incendie.
Sûreté Pour Soudage A L’Arc
1. Protegez-vous contre la secousse électrique:
8. S’assurer que la masse est connectée le plus prés 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 éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev-
age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.
a. Les circuits à l’électrode et à la piéce sont sous tension
quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.
b. Faire trés 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 couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.
c. Maintenir le porte-électrode, la pince de masse, le câble
de soudage et la machine à souder en bon et sûr état
defonctionnement.
9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.
10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, nettoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.
d.Ne jamais plonger le porte-électrode dans l’eau pour le
refroidir.
e. Ne jamais toucher simultanément les parties sous tension
des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.
f. Si on utilise la machine à souder comme une source de
courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.
11. Pour obtenir de plus amples renseignements sur la sûreté,
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 protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.
PRÉCAUTIONS DE SÛRETÉ POUR
LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR
3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:
a. Utiliser un bon masque avec un verre filtrant approprié
ainsi qu’un verre blanc afin de se protéger les yeux du ray-
onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.
b. Porter des vêtements convenables afin de protéger la
peau de soudeur et des aides contre le rayonnement de
l‘arc.
1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.
2. Autant que possible, I’installation et l’entretien du poste seront
c. Protéger l’autre personnel travaillant à proximité au
soudage à l’aide d’écrans appropriés et non-inflammables.
effectués par un électricien qualifié.
3. Avant de faires des travaux à l’interieur de poste, la debranch-
er à l’interrupteur à la boite de fusibles.
4. Des gouttes de laitier en fusion sont émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan-
talons sans revers, et chaussures montantes.
4. Garder tous les couvercles et dispositifs de sûreté à leur
place.
5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
Mar. ‘93
SP-135 PLUS
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for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product
••• as much pride as we have in bringing this product to you!
Thank 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.
Model Name & Number _____________________________________
Code & Serial Number _____________________________________
Date of Purchase _____________________________________
Whenever you request replacement parts for or information on this equipment always supply the information
you have recorded above.
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:
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.
SP-135 PLUS
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TABLE OF CONTENTS
Page
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-5
Code Requirements ..............................................................................................A-6
Operation .........................................................................................................Section B
Safety Precautions ................................................................................................B-1
General Description...............................................................................................B-2
Design Features and Advantages...................................................................B-2
Welding Capability ..........................................................................................B-2
Limitations.......................................................................................................B-2
Controls and Settings......................................................................................B-2
Welding Operations ...............................................................................................B-3
Overload Protection...............................................................................................B-7
Learning to Weld....................................................................................................B-8
Application Chart .................................................................................................B-19
Accessories.....................................................................................................Section C
Accessories ...........................................................................................................C-1
Replacement Parts................................................................................................C-2
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................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 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 ..............................................................................................P 397 & P202-E
SP-135 PLUS
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – SP-135 PLUS
INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency
115V/60Hz
Input Current
20 Amps - Rated Output
25 Amps - Maximum Output
15 Amps - CSA Rated output
115V/60Hz
115V/60Hz
RATED OUTPUT
Duty Cycle
20% Duty Cycle – Rated DC Output
Amps
90
Volts at Rated Amperes
18
OUTPUT
Welding Current Range (Continuous) Maximum Open Circuit Voltage
Auxiliary Power
Rated DC Output: 25 – 135 Amps
28
N/A
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse or
Output Mode Input Voltage Breaker Size
Input Amps
Extension Cord
Three Conductor
#14 AWG
RATED
115V/60Hz
115V/60Hz
20 Amp
25 Amp
20
(2.1 mm2) or Larger
for up to
25 feet (7.6m)
Three Conductor
#12 AWG
MAXIMUM
25
(3.3 mm2) or Larger
for up to
50 feet (15.2 m)
PHYSICAL DIMENSIONS
Height
Width
Depth
Weight
54 Ibs
24.3 kg
12.0 in
9.75 in
248 mm
16.5 in
419 mm
305 mm
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A-2
A-2
INSTALLATION
FIGURE A.1
Read entire installation section before starting
installation.
1
2
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.
4
3
• 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.
6
5
IDENTIFY AND LOCATE
COMPONENTS
7
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(1)
3. Literature and miscellaneous including:
a) This operating manual
b) A contact tip for .030” (0.8 mm) diameter wire.
4. 10 ft (3.0 m) work cable.
5. Work clamp.
6. Sample Spool of L-56 .025 MIG Wire.
7. Adjustable mixed-Gas Regulator & 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
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A-3
A-3
INSTALLATION
Work Clamp Installation
SELECT SUITABLE LOCATION
Attach the work clamp per the following:
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.
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.
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-
face, either directly or on a recommended undercar-
riage. The machine may topple over if this procedure
is not followed.
Work Cable
Nut & Bolt
OUTPUT CONNECTIONS
Work Clamp
Refer to Figure A.2.
1. Work Cable Access Hole.
Work Cable Installation
2. Gun Cable and Control Lead Access Hole.
3. Connector Block.
Refer to Figure A.2.
4. Gun Trigger Lead Connectors.
5. Positive (+) and negative (–) output terminals.
6. Wire Feed Gearbox and Gun Connector Block
7. Cable Clamp
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.
8. Thumbscrew - Secures gun and cable assembly
9. Optional Spot/Stitch Timer Kit see Accessories.
FIGURE A.2
5
9
4
WELDING AMP RANGE
25-125
SP-135 Plus
+
-
8
1
6
3
7
2
SP-135 PLUS
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A-4
A-4
INSTALLATION
3. Route the cable under and around the back of the
Wire Feed Gearbox (6).
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. 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.
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.
5. 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).
CAUTION
FIGURE A.4
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.
3
4
2
1
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.
GUN INSTALLATION
As shipped from the factory, the SP-135 PLUS gun is
ready to feed 0.023 - 0.025” (0,6 mm) wire. If 0.030”
(0,8 mm) wire is to be used install the 0.030” (0.8 mm)
contact tip. Refer to the MAINTENANCE section for
contact tip installation details.
WARNING
CYLINDER may explode if dam-
aged. Keep cylinder upright and
chained to support
• Keep cylinder away from areas
where it may be damaged.
Connecting Gun Cable to the SP-135
PLUS
1. Refer to Figure A.2. Unplug the machine or turn
• Never lift welder with cylinder
attached.
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.
• Never allow welding electrode to
touch cylinder.
• Keep cylinder away from welding
or other live electrical circuits.
SP-135 PLUS
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A-5
A-5
INSTALLATION
3. Attach the flow regulator to the cylinder valve and
tighten the union nut securely with a wrench. The
flow regulator for carbon dioxide must have a plas-
tic washer seated in the fitting that attaches to the
cylinder to prevent leakage. Refer to K1800-1 in
the accessories section.
WARNING
BUILDUP OF SHIELDING GAS may
harm health or kill.
• Shut off shielding gas supply
when not in use.
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 SP-135 PLUS Gas
Solenoid Inlet Fitting (5/8-18 female threads — for
CGA — 032 fitting). Make certain the gas hose is
not kinked or twisted.
• 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.
INPUT CONNECTIONS
Refer to Figure A.6.
FIGURE A.5
The SP-135 PLUS 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
Gas Hose
FIGURE A.6
Gas Solenoid
Inlet Fitting
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.
Power
Input
Cable
WARNING
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.
SP-135 PLUS
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A-6
A-6
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
than 125 volts.
WARNING
This welding machine must be connected to
power source in accordance with applicable elec-
trical codes.
Do not remove the power cord ground prong.
Requirements For Maximum Output
The United States National Electrical Code (Article
630-B, 1990 Edition) provides standards for amperage
handling capability of supply conductors based on
duty cycle of the welding source.
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.
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).
SP-135 PLUS
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B-1
B-1
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.
FUMES AND GASES can be
dangerous.
• Keep your head out of fumes.
• Use ventilation or exhaust to
remove fumes from breathing
zone.
WELDING SPARKS can
cause fire or explosion.
• Keep flammable material away.
• Do not weld on closed contain-
ers.
ARC RAYS can burn eyes
and skin.
• Wear eye, ear and body protec-
tion.
Observe all safety information throughout
this manual.
SP-135 PLUS
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B-2
B-2
OPERATION
● Reversible, dual groove drive roll. Drive roll will
GENERAL DESCRIPTION
feed .023-.035” (0.6- 0.9 mm) diameter wire.
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.
● Accommodates both 8” (200 mm) diameter and 4”
(100 mm) diameter spools of wire.
● No external shielding gas is required when used
with Lincoln Innershield .035” (0,9 mm) NR®-211-
MP 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 life.
● Easy to change polarity.
● Accepts optional Spot/Stitch Timer Kit.
WELDING CAPABILITY
The SP-135 PLUS, as shipped, is rated at 90 amps,
18 volts, at 20% duty cycle on a ten minute basis. It is
capable of higher duty cycles at lower output currents.
RECOMMENDED PROCESSES
LIMITATIONS
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.
Arc Gouging cannot be performed with the SP-135
PLUS. The SP-135 PLUS is not recommended for
pipe thawing.
CONTROLS AND SETTINGS
OPERATIONAL FEATURES AND
CONTROLS
Refer to Figures B.1a & B.1b.
1. Power ON/OFF Switch —
The SP-135 PLUS has the following controls as stan-
dard: Power ON/OFF Switch, Voltage Control, Wire
Speed Control, and a Circuit Breaker.
When the power is on the
ON
fan motor will run and air will
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.
DESIGN FEATURES AND
ADVANTAGES
OFF
2. Voltage Control — A contin-
uous control that gives full
range adjustment of power
source output voltage.
Voltage can be adjusted
while welding.
● Operates on 115 volt input — no special wiring
required.
ARC VOLTS
● Solid state output control.
● “Cold electrode” until gun trigger is pressed for an
added measure of safety.
● Overload protection — incorporates both a thermo-
3. Wire Speed Control —
Controls the wire feed speed
from 50 – 400 in /min (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.
stat and a circuit breaker.
● Quality wire drive with electronic overload protec-
WIRE SPEED
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.
SP-135 PLUS
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B-3
B-3
OPERATION
WELDING OPERATIONS
2
1
SEQUENCE OF OPERATION
WELDING AAMP RANGE
25-125
Wire Loading
Refer to Figure B.2 AND B3.
3
SP-135 Plus
The machine power switch should be turned to the
OFF (“O”) position before working inside the wire feed
enclosure.
FIGURE B.1a
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).
4. Circuit Breaker – Protects machine from damage if
maximum output is exceeded. Button will extend
out when tripped (Manual reset). Refer to Figure B.1b.
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
does not stick in the weld puddle.
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.
6. Optional K695-2 Spot/Stitch Controls (see ACCES-
SORIES section) - If present, replaces Blank Panel
Assembly located on the center panel inside the
case door:
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.
Mode Switch - Selects between Spot, Stitch, or
Seam (normal welding) mode. Spot mode welds for
an adjustable length of time (set by Time Control;
see below) and then stops, whenever the gun trig-
ger is depressed and held. Stitch mode cycles
between welding and not welding for an adjustable
length of time (also set by Time Control) while the
gun trigger is depressed. In Seam mode the
machine will weld continuously while the gun trig-
ger is depressed. Releasing the gun trigger in any
of the three modes will interrupt welding immedi-
ately.
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
Time Control - In Spot mode, controls spot mode
ON time between approximately .25 and 4.0 sec-
onds. In Stitch mode, controls stitch mode ON time
and OFF time simultaneously between .25 and 4.0
seconds each. This control is deactivated while in
Seam mode.
Wire Spool Spindle
Locking Tab
8” Wire Spool
FIGURE B.1b
4
Be sure that this stud engages
the hole in the wire spool.
5
+
-
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
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B-4
B-4
OPERATION
FIGURE B.4
FIGURE B.3
Wire Spindle Shaft
4" Wire Spool
2
5
1
4
Wing Nut
and Spacer
The Wire Drive Feed
Roll can accommodate
two wire sizes by flipping
the wire drive feed roll
over. The sizes are sten-
ciled on the drive roll.
To wire drive
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.
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.
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.
WARNING
Wire Threading
Refer to Figure B.4
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.
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.
7. Refer to Figure B.5. Remove gas nozzle and con-
tact tip from end of gun.
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.
8. Turn the SP-135 PLUS ON (“I”).
9. Straighten the gun cable assembly.
3. Cut the bent portion of wire off and straighten the
first 4” (100 mm).
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.
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) and latch the spring
loaded pressure arm (1) in place (now you may
release the welding wire).
Note: If the wire will not feed smoothly, or if the wire
feed motor shuts off unexpectedly, see the
"FEEDING 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 1/4” – 3/8”
(6 – 10 mm) from the end of the tip. The SP-135
PLUS is now ready to weld.
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B-5
B-5
OPERATION
FIGURE B.5
FIGURE B.6
Gun Handle
Contact Tip
Gas Diffuser
Contact Tip
Wire Electrode
Gas Nozzle
3/8" – 1/2" Electrical Stickout
4. Check that the polarity is correct for the welding
wire being used and that the gas supply, if
required, is turned on.
Shielding Gas
When using the GMAW process, a cylinder 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.
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-
fuser from weld spatter. Refer to the MAINTE-
NANCE section for details on nozzle replacement.
1. For CO2, open the cylinder very slowly. For argon-
mixed gas, open cylinder valve slowly a fraction of
a turn. When the cylinder pressure gauge pointer
stops moving, open the valve fully.
6. 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.
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 (CFH) (7 – 10 I/min) [use 20
-– 25 CFH (10 – 12 I/min) when welding out of
position or in a drafty location for CO2]. For argon
mixed gas, trigger to release gas pressure, and
turn off the adjust the flow to give 25 – 30 CFH
(12 – 14 I/min).
7. Position gun over joint. End of wire may be lightly
touching the work.
8. 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).
3. Keep the cylinder valve closed, except when using
the SP-135 PLUS. When finished welding:
a) Close the cylinder valve to stop gas flow.
b) Depress the gun trigger briefly to release the
pressure in the gas hose.
FIGURE B.7
c) Turn off the SP-135 PLUS.
Making A Weld
1. See Recommended Processes And Equipment
section for selection of welding wire and shielding
gas and for range of metal thicknesses that can be
welded.
GUN CABLE
2. See the Application Chart on the inside of wire
feed section door for information on setting the
SP-135 PLUS controls.
WORKPIECE
ARC
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.
WORK CLAMP
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B-6
B-6
OPERATION
9. To stop welding, release the gun trigger and then
CAUTION
pull the gun away from the work after the arc goes
out.
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.
------------------------------------------------------------------------
TABLE B.1 — SP-135 PLUS Welding Procedures
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.
Welding
Wire
Shielding
Gas
Process
16 ga 14 ga 12 ga 10 ga
Cleaning Tip And Nozzle
MIG DC+ .035 Dia
100% Argon D-4.5 H-6.5 H-6.5 J-7.5
100% Argon C-5.5 D-6 G-8.5 H-9.5
98% Argon/ D-3 F-4 J-5 J-6.5
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
supply distributor, may reduce buildup and aid in spat-
ter removal.
4043 Aluminum
Wire
MIG DC+ .035 Dia
5356 Aluminum
Wire
MIG DC+ .030 Dia
308L Stainless 2% Oxygen
Steel Wire
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
CHANGING MACHINE OVER TO
FEED OTHER WIRE SIZES
®
shielded,Innershield process (FCAW).
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.
The recommended gases and electrodes for GMAW
are welding grade CO2 gas or an argon-CO2 blended
gas (75 to 80% argon and 25 to 20% CO2) and .025"
(0.6 mm) diameter Lincoln L-56 mild-steel welding
wire, supplied on 12-1/2 lb (5.7 kg) spools.
The recommended electrode for the self-shielded
process is 0.035” (0,9 mm) diameter Lincoln
Innershield NR-211-MP on 10 Ib (4,5 kg) spools. This
electrode can be used for all position welding of 20
gauge through 5/16” (1,0 – 8,0 mm) thick steel [multi-
ple passes are required for 1/4” and 5/16” (6,0 and 8,0
mm)].
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, installing 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.
WARNING
Use of the GMAW process with the SP-135 PLUS
on thicker materials than recommended may
result in poor welds. The welds may “look” good,
but may just be “sitting” on top of the plate. This
is called “cold casting” and will result in weld 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 K663-1 Aluminum Welding kit. See ACCES-
SORIES section.
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B-7
B-7
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.
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.
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B-8
B-8
LEARNING TO WELD
LEARNING TO WELD
WARNING
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 weld-
ing and develop this skill. For more detailed informa-
tion, order a copy of “New Lessons in Arc Welding”
listed at the end of this manual.
Fumes and slag generated from
Innershield type electrodes recom-
mended for use with this welding
machine can be toxic.
• Avoid contact with eyes and skin.
• Do not take internally.
THE ARC-WELDING CIRCUIT
• Keep out of reach of children.
The operator’s knowledge of arc welding must go
beyond the arc itself. The operator must know how to
control the arc, and this requires a knowledge of the
welding circuit and the equipment that provides the
electric current used in the arc. Figure B.7 illustrates
the welding circuit for a typical welding machine. The
circuit begins where the gun cable is attached to the
welding machine. Current flows through the gun cable,
gun, and contact tip, to the wire and across the arc.
On the work side of the arc, current flows through the
base metal to the work cable and back to the welding
machine. This circuit must be complete for the current
to flow.
• Follow all safety precautions
found in this operating manual.
The gun and cable assembly is held by the operator
who guides the automatically fed wire along the joint,
maintaining a contact tip to work distance of about 3/8
to 1/2 inch (10 – 12 mm). This is called electrical stick-
out. This electrical stickout (ESO) must be properly
maintained by the operator. The electric arc is made in
the gap between the work and the tip end of a small
diameter wire. When the power source is properly set,
the arc gap is maintained automatically.
This machine’s welding circuit has a voltage output of
33 volts DC maximum. This voltage is quite low and is
only present when the gun trigger is depressed.
Arc welding is a manual skill requiring a steady hand,
good physical condition, and good eyesight. The oper-
ator controls the welding arc, and therefore, the quality
of the weld made.
To weld, the work clamp must be tightly connected to
clean base metal. Remove paint, rust, dirt or oil as
necessary and connect the work clamp as close as
possible to the area you wish to weld. This helps pre-
vent current from going through an unwanted path.
Avoid allowing the welding circuit to pass through
hinges, bearings, electronic components, or similar
devices that can be damaged. See Figure B.8. Always
disconnect electrical devices before welding upon
them.
THE SELF-SHIELDED FCAW WELDING
ARC
Figure B.9 illustrates the action taking place in the self
shielded FCAW (Innershield) welding arc. It closely
resembles what is actually seen while welding.
FIGURE B.9
FIGURE B.8
Electronic Components
Burning of core
materials inside wire
Cored Wire
Protective Slag
electrode results in
shield of gas.
Arc Stream
Weld Metal
Hinges
Bearings
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B-9
B-9
LEARNING TO WELD
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. The arc is very bright, as well as hot, and
cannot be looked at with the naked eye without risking
painful injury. The very dark lens, specifically
designed for arc welding must be used with the hand
or face shield whenever viewing the arc.
THE GMAW (MIG) WELDING ARC
Figure B.10 illustrates the GMAW (MIG) welding arc.
Solid wire does not contain fluxes or ingredients to
form its own shielding and no slag forms to protect the
molten weld metal. For this reason, a continuous even
flow of shielding gas is needed to protect the molten
weld metal from atmospheric contaminants such as
oxygen and nitrogen. Shielding gas is supplied
through the gun and cable assembly, through the gas
nozzle and into the welding zone.
The arc melts the base metal and actually digs into it
much as water through a nozzle on a garden hose
digs into the earth. The molten metal forms a molten
pool or crater and tends to flow away from the arc. As
it moves away from the arc, it cools and solidifies.
Gas nozzle
The function of the Innershield cored wire electrode is
much more than simply to carry current to the arc. The
wire core is composed of fluxes and/or alloying ingre-
dients around which a steel sheath has been formed.
It is simply a stick electrode turned inside out in a con-
tinuous wire form.
Solid wire
Shielding gas
electrode
Weld metal
Base metal
FIGURE B.10
The cored wire melts in the arc and tiny droplets of
molten metal shoot across the arc into the molten
pool. The wire sheath provides additional filler metal
for the joint to fill the groove or gap between the two
pieces of base metal.
When comparing the GMAW and FCAW processes,
you can see that the principal difference between the
two lies in the type of shielding used. GMAW uses gas
for shielding, thus we have Gas Metal Arc Welding.
FCAW uses the melting or burning of the core ingredi-
ents for shielding, and is thus termed Self-Shielded
Flux Cored Arc Welding.
The core materials also melt or burn in the arc and
perform several functions. They make the arc stead-
ier, provide a shield of smoke-like gas around the arc
to keep oxygen and nitrogen in the air away from the
molten metal, and provide a flux for the molten pool.
The flux picks up impurities and forms the protective
slag on top of the weld during cooling.
The recommended wire for Gas Metal Arc Welding
(MIG) is Lincolnweld 0.025” (0.6 mm) L-56 electrode.
Lincolnweld” L-56 is capable of welding a wide range
of mild steels in all positions, however, more skill is
required for out-of-position welding with the GMAW
process.
After running a weld bead, the slag may be removed
with a chipping hammer and wire brush. This
improves appearance and allows for inspection of the
finished weld.
Since machine size and output characteristics limit the
size and type of wire electrode which can be used,
Lincoln 0.035" and 0.045" (0.9 and 1.2 mm) NR-211-
MP Innershield electrode is recommended for Self-
Shielded Flux Cored Arc Welding with this machine.
PROCESS SELECTION
By gaining knowledge of the differences between the
two processes, you will be able to select the best
process for the job you have at hand. In selecting a
process, you should consider:
SP-135 PLUS
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B-10
B-10
LEARNING TO WELD
For GMAW (MIG) Process
1. Is most of my welding performed on 16 gauge and
lighter materials?
JOINT TYPES AND POSITIONS
Five types of welding joints are: Butt Welds, Fillet
Welds, Lap Welds, Edge Welds and Corner Welds.
See Figure B.11.
2. Can I afford the extra expense, space, and lack of
portability required for gas cylinders and gas sup-
ply?
Of these, the Butt Weld and Fillet Weld are the two
most common welds.
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. If you have
answered no to any of the above questions, then you
should consider using the FCAW process.
Butt weld
Lap weld
For FCAW (Innershield) Process
1. Do I want simplicity and portability?
2. Will welding be performed outdoors or under windy
conditions?
Edge weld
Fillet weld
Corner weld
3. Do I require good all position welding capability?
4. Will most welding be performed on 16 gauge and
heavier, somewhat rusty or dirty materials?
FIGURE B.11
Butt Welds
5. Weld must be cleaned prior to painting.
Place two plates side by side, leaving a space approx-
imately one half the thickness of the metal between
them in order to get deeper penetration.
COMMON METALS
Securely clamp or tack weld the plates at both ends,
otherwise the heat will cause the plates to move apart.
See Figure B.12.
Most metals found around the farm, small shop or
home are low carbon steel, sometimes referred to as
mild steel. Typical items made with this type of steel
include most sheet metal, plate, pipe and rolled
shapes such as channels and angle irons. This type of
steel can usually be easily welded without special pre-
cautions. Some steels, however, contain higher car-
bon levels or other alloys and are more difficult to
weld. Basically, if a magnet sticks to the metal and
you can easily cut the metal with a file, chances are
good that the metal is mild steel and that you will be
able to weld the material. In addition, aluminum and
stainless steel can be welded using the K664-1
Aluminum Welding Kit. For further information on
identifying various types of steels and other metals,
and for proper procedures for welding them, we again
suggest you purchase a copy of “New Lessons in Arc
Welding”.
Now weld the two plates together. Weld from left to
right (if right handed). Point the wire electrode down in
the crack between the two plates, keeping the gun
slightly tilted in the direction of travel. Watch the
molten metal to be sure it distributes itself evenly on
both edges and in between the plates. This is refered
to as the “pull technique”. On thin gauge sheet metal,
use the “push technique”. See “Welding Techniques
for GMAW (MIG) Process”.
Regardless of the type of metal being welded, in order
to get a quality weld, it is important that the metal is
free of oil, paint, rust or other contaminants.
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B-11
B-11
LEARNING TO WELD
45°
FIGURE B.12
FIGURE B.15
Penetration
Welding In The Vertical Position
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.
Welding in the vertical position can be done either ver-
tical-up or vertical-down. Vertical-up is used whenever
a larger, stronger weld is desired. Vertical-down is
used primarily on sheet metal 5/32” (3.9 mm) and
under for fast, low penetrating welds.
WARNING
Use of this unit on thicker materials than recom-
mended may result in poor welds. The welds may
“look” good, but may just be “sitting” on top, of
the plate. This is called “Cold Casting” and will
result in weld failure.
FIGURE B.13
FIGURE B.14
Vertical-up And Overhead Welding
The problem, when welding vertical-up, is to put the
molten metal where it is wanted and make it stay
there. If too much molten metal is deposited, gravity
will pull it downwards and make it “drip”. Therefore, a
certain technique has to be followed.
When welding out-of-position, run stringer beads.
Don’t whip, break the arc, move out of the puddle, or
move too fast in any direction. Use Wire Feed Speed
(WFS) in the low portion of the range. The general
technique and proper gun angle is illustrated in Figure
B.16.
In the example shown in Figure B.14, the joint has
been welded so that 100% penetration could be
achieved. The weld, if properly made, is as strong as
or stronger than the original metal.
Generally, keep the electrode nearly perpendicular to
the joint as illustrated. The maximum angle above per-
pendicular may be required if porosity becomes a
problem.
Fillet Welds
When welding fillet welds, it is very important to hold
the wire electrode at a 45° angle between the two
sides or the metal will not distribute itself evenly. The
gun nozzle is generally formed at an angle to facilitate
this. See Figure B.15.
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B-12
B-12
LEARNING TO WELD
MACHINE SET UP FOR THE
SELF-SHIELDED FCAW 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.
PROPER GUN ANGLE
PROPER GUN ANGLE
FOR GMAW PROCESS
FOR FCAW PROCESS
WELDING IN THE VERTICAL UP POSITION
WELDING IN THE VERTICAL UP POSITION
3. Set the “Voltage” and “Wire Speed” controls to the
settings suggested on the Application Guide for the
welding wire and base metal thickness being used.
The voltage control is marked “V” and the wire feed
speed is marked ‘’olo.’’
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.
Vertical-down welds may be applied to 5/32” (3.9 mm)
and lighter material.
4. Check that the polarity is correct for the welding
wire being used. Set the polarity for DC(–) when
welding with NR-211-MP Innershield electrode.
See Work Cable Installation in the INSTALLATION
section for instructions on changing polarity.
Use stringer beads and tip the gun in the direction of
travel so the arc force helps hold the molten metal in
the joint. Move as fast as possible consistent with
desired bead shape.
5. When using Innershield electrode, the gasless noz-
zle may be used instead of a gas nozzle to improve
visibility of the arc.
The important thing is to continue lowering the entire
arm as the weld is made so the angle of the gun does
not change. Move the electrode wire fast enough that
the slag does not catch up with the arc. Vertical-down
welding gives thin, shallow welds. It should not be
used on heavy material where large welds are
required.
6. Connect work clamp to metal to be welded. Work
clamp must make good electrical contact to the
work piece. The work piece must also be grounded
as stated in the “Arc Welding Safety Precautions”
at the beginning of this manual.
WELDING TECHNIQUES FOR THE SELF-
SHIELDED FCAW PROCESS
Four simple manipulations are of prime importance
when welding. With complete mastery of the four,
welding will be easy. They are as follows:
1. The Correct Welding Position
Figure B.18 illustrates the correct welding position
for right handed people. (For left handed people, it
is the opposite.)
Hold the gun (of the gun and cable assembly) in
your right hand and hold the shield with your left
hand. (Left handers simply do the opposite.)
FIGURE B.17
When using the FCAW Process, weld from left to
right (if you are right handed). This enables you to
clearly see what you are doing. (Left handers do
the opposite.) Tilt the gun toward the direction of
travel holding the electrode at an angle as shown
in Figure B.18.
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B-13
B-13
LEARNING TO WELD
Contact Tip
Wire Electrode
FIGURE B.18
3/8 – 1/2” (10 – 12 mm)
Electrical Stickout (ESO)
WARNING
FIGURE B.19
ARC RAYS can burn eyes and skin.
The easiest way to tell whether the ESO is the cor-
rect length is by listening to its sound. The correct
ESO has a distinctive “crackling” sound, very much
like eggs frying in a pan. A long ESO has a hollow,
blowing or hissing sound. If the ESO is too short,
you may stick the contact tip or nozzle to the weld
puddle and/or fuse the wire to the contact tip.
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.
4. The Correct Welding Speed
2. The Correct Way To Strike An Arc
1. Be sure the work clamp makes good electrical
contact to the work.
The important thing to watch while welding is the
puddle of molten metal right behind the arc. See
Figure B.20. Do not watch the arc itself. It is the
appearance of the puddle and the ridge where the
molten puddle solidifies that indicates correct weld-
ing speed. The ridge should be approximately 3/8”
(10 mm) behind the wire electrode.
2. Position gun over joint. End of wire may be
lightly touching the work.
3. Position face shield to protect face and eyes,
close gun trigger, and begin welding. Hold the
gun so that the contact tip to work distance is
about 3/8 to 1/2 inch (10 – 12 mm).
Most beginners tend to weld too fast, resulting in a
thin uneven, “wormy” looking bead. They are not
watching the molten metal.
4. To stop welding, release the gun trigger and
the pull the gun away from the work after the
arc goes out.
5. A ball may form at the tip end of the wire after
welding. For easier restrikes (with Innershield
wire) the ball may be removed by feeding out a
few inches of wire and simply bending the wire
back and forth until it breaks off.
Solidifying ridge
Molten puddle
6. When no more welding is to be done, turn off
the machine.
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.
FIGURE B.20
See Figure B.19.
Once the arc has been established, maintaining
the correct ESO becomes extremely important.
The ESO should be approximately 3/8 to 1/2 inch
(10 to 12 mm) long.
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B-14
Helpful Hints
B-14
LEARNING TO WELD
For the SP-135 PLUS, use the following:
Mild Steel
16 gauge or 1/16 inch
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.
(1.6 mm)
Electrode
0.035" (0.9 mm)
NR-211-MP
Innershield Wire
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.
Voltage Setting “V”
E
2
Wire Feed Speed “o|o”
3. When welding sheet metal 16 gauge (1.5 mm) and
lighter, heat buildup may cause part warpage and
burn through. One way to eliminate these problems
is to use the back-stepping method illustrated in
Figure B.21.
Refer to Figure B.22.
1. Learn to strike an arc by positioning the gun over
the joint and touching the wire to the work.
2. Position face shield to protect face and eyes.
First weld from A to B; then from C to A; then
from D to C; then from E to D, and so on.
3. Depress gun trigger, hold gun so contact tip to
work distance is about 3/8 to 1/2 inch (10 to 12
mm) and the gun is at proper angle.
B
A
C
D
E
4. After you strike the arc, practice the correct electri-
cal stickout. Learn to distinguish it by its sound.
Back-Stepping
FIGURE B.21
5. When you are sure that you can hold the correct
electrical stickout, with a smooth “crackling” arc
start moving. Look at the molten puddle constantly,
and look at the “ridge” where the metal solidifies.
Practice
The best way of getting practice in the four skills that
enable you to maintain:
6. Run beads on a flat plate. Run them parallel to the
top edge (the edge farthest away from you). This
gives you practice in running straight welds, and
also gives you an easy way to check your
progress. The 10th weld will look considerably bet-
ter than the first weld. By constantly checking on
your mistakes and your progress, welding will soon
be a matter of routine.
1. Correct welding position
2. Correct way to strike an arc
3. Correct electrical stickout
4. Correct welding speed
is to perform the following exercise.
Contact
Tip
ESO
Gun Angle
FIGURE B.22
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B-15
B-15
LEARNING TO WELD
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.
FIGURE B.23
When using the GMAW process on light gauge mater-
ial, weld from right to left (if you are right handed).
This results in a colder weld and has less tendency for
burn through.
3. Set the “Voltage” and “Wire Speed” controls to the
settings suggested on the Application Guide for the
welding wire and base metal thickness being used.
The voltage control is marked “V” and the wire feed
speed is marked ‘’olo.’’
2. The Correct Way To Strike An Arc
WARNING
4. Check that the polarity is correct for the welding
wire being used. Set the polarity for DC(+) when
welding with the GMAW (MIG) process. See Work
Cable Installation in the INSTALLATION section for
instructions for changing polarity.
ARC RAYS can burn eyes and skin.
When using an open arc process, it
Is necessary to use correct eye,
head and body protection.
5. Check that the gas nozzle and proper size liner
and contact tip are being used and that the gas
supply is turned on. If adjustable, set for 15 to 20
cubic feet per hour (7 to 10 l/min.) under normal
conditions, increase to as high as 35 CFH (17
I/min.) under drafty (slightly windy) conditions.
Protect yourself and others, read
“ARC RAYS can burn” at the front
of this manual.
1. Be sure the work clamp makes good electrical con-
tact to the work.
6. Connect work clamp to metal to be welded. Work
clamp must make good electrical contact to the
work piece. The work piece must also be grounded
as stated in the “Arc Welding Safety Precautions”
at the beginning of this manual.
2. Position gun over joint. End of wire may be lightly
touching the work.
3. Position face shield to protect face and eyes, close
gun trigger, and begin welding. Hold the gun so
that the contact tip to work distance is about 3/8 to
1/2 inch (10 – 12 mm).
WELDING TECHNIQUES FOR THE GMAW
(MIG) PROCESS
Four simple manipulations are of prime importance
when welding. With complete mastery of the four,
welding will be easy. They are as follows:
4. To stop welding, release the gun trigger and pull
the gun away from the work after the arc goes out.
5. A ball may form at the tip end of the wire after
welding. For easier restrikes, the ball may be
removed by feeding out a few inches of wire and
cutting off the end of the wire with wire cutters.
1. The Correct Welding Position
Figure B.23 illustrates the correct welding position
for right handed people. (For left handed people, it
is the opposite.)
6. When no more welding is to be done, close the
valve on the gas cylinder, momentarily operate the
gun trigger to release gas pressure, then turn off
the machine.
When GMAW (MIG) welding on sheet metal, it is
important to use the “forehand” push technique.
Hold the gun (of the gun and cable assembly) in
your right hand and hold the shield with your left
hand. (Left handers simply do the opposite.)
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B-16
B-16
LEARNING TO WELD
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.
Contact Tip
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.
Wire Electrode
ESO
3. When welding sheet metal 16 gauge (1.5 mm) and
lighter, heat buildup may cause part warpage and
burn through. One way to eliminate these problems
is to use the back-stepping method illustrated in
Figure B.21.
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.
Practice
Once the arc has been established, maintaining
the correct ESO becomes extremely important.
The ESO should be approximately 3/8 to 1/2 inch
(10 to 12 mm) long.
The best way of getting practice in the four skills that
enable you to maintain:
1. Correct welding position
The easiest way to tell whether the ESO is the cor-
rect length is by listening to its sound. The correct
ESO has a distinctive “crackling” sound, very much
like eggs frying in a pan. A long ESO has a hollow,
blowing or hissing sound. If the ESO is too short,
you may stick the contact tip or nozzle to the weld
puddle and/or fuse the wire to the contact tip.
2. Correct way to strike an arc
3. Correct electrical stickout
4. Correct welding speed
is to perform the following exercise.
For the SP-135 PLUS, use the following:
4. The Correct Welding Speed
The important thing to watch while welding is the
puddle of molten metal right behind the arc. See
Figure B.25. Do not watch the arc itself. It is the
appearance of the puddle and the ridge where the
molten Puddle solidifies that indicates correct weld-
ing speed. The ridge should be approximately 3/8”
(10 mm) behind the wire electrode.
Mild Steel
16 gauge or 1/16 inch
(1.6 mm)
Electrode
Lincolnweld 0.025 L-56
electrode
CO2
Voltage Setting “V”
G
5
Most beginners tend to weld too fast, resulting in a
thin, uneven, “wormy” looking bead. They are not
watching the molten metal.
Wire Feed Speed “o|o”
Refer to Figure B.22.
1. Learn to strike an arc by positioning the gun over
the joint and touching the wire to the work.
Molten puddle
2. Position face shield to protect face and eyes.
Weld metal ridge
Base metal
3. Depress gun trigger, hold gun so contact tip to
work distance Is about 3/8 to 1/2 inch (10 to 12
mm) and the gun is at proper angle.
FIGURE B.25
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B-17
B-17
LEARNING TO WELD
4. After you strike the arc, practice the correct electri-
cal stickout. Learn to distinguish it by its sound.
2. Decrease stickout.
3. Decrease WFS (wire feed speed.
4. Decrease travel speed.
5. Decrease drag angle.
5. When you are sure that you can hold the correct
electrical stickout, with a smooth “crackling” arc,
start moving. Look at the molten puddle constantly.
6. Check for correct gas, if used.
6. Run beads on a flat plate. Run them parallel to the
top edge (the edge farthest away from you). This
gives you practice in running straight welds, and
also gives you an easy way to check your
progress. The 10th weld will look considerably bet-
ter than the first weld. By constantly checking on
your mistakes and your progress, welding will soon
be a matter of routine.
To Reduce Spatter (in order of importance):
TROUBLESHOOTING WELDS
1. Increase voltage.
Good welds have excellent appearance.
2. Increase drag angle.
3. Decrease stickout.
4. Increase WFS (wire feed speed).
5. Decrease travel speed.
6. Check for correct gas, if used.
To Correct Poor Penetration (in order of impor-
tance):
To Eliminate Porosity (in order of importance):
1. Decrease stickout.
2. Increase WFS (wire feed speed).
3. Increase voltage.
4. Decrease speed.
5. Decrease drag angle.
6. Check for correct gas, if used.
1. Turn on gas supply, if used
2. Decrease voltage.
If Arc Blow Occurs (in order of importance):
NOTE: Try different ground connection locations
before adjusting procedures.
3. Increase stickout.
4. Increase WFS (wire feed speed).
5. Decrease drag angle.
6. Decrease travel speed.
1. Decrease drag angle.
2. Increase stickout.
3. Decrease voltage.
NOTE: Always be sure the joint is free from moisture,
oil, rust, paint or other contaminants.
4. Decrease WFS (wire feed speed.
5. Decrease travel speed.
To Eliminate a Ropy Convex Bead
(in order of importance):
To Eliminate Stubbing* (in order of importance):
1. Increase voltage
2. Decrease WFS (wire feed speed)
3. Decrease stickout
4. Increase drag angle
* Stubbing occurs when the electrode drives through
the molten puddle and hits the bottom plate tending
to push the gun up.
1. Increase voltage
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B-18
B-18
LEARNING TO WELD
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.
3. Do not allow dolly wheels or trucks to run over the
cables.
4. Keep the cable clean.
5. Innershield electrode has proper surface lubrica-
tion. Use only clean, rust-free electrode.
6. Replace contact tip when it becomes worn or the
end is fused or deformed.
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B-19
B-19
APPLICATION CHART
SP-135 PLUS
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C-1
C-1
ACCESSORIES
OPTIONAL ACCESSORIES
4. KP666-035C Knurled Drive Roll (optional) —
Reversible Drive Roll with double knurled grooves
for .035 (0.9 mm) cored electrode.
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
accessories. Easy assembly required; takes less
than 15 minutes.
5. K695-2 Spot / Stitch Timer Kit — Includes spot
timer to control the spot welding arc time, and a
stitch timer to control the on/off cycle time of the
arc to prevent burnthrough on thin gauge metals.
Also includes spot welding nozzle.
2. K586-1 Deluxe Adjustable Gas Regulator &
Hose Kit
The Spot/Stitch Timer Kit installs inside the wire
feed compartment, replacing the blank panel locat-
ed below the gun trigger lead connectors, per the
installation instructions included with the kit.
Accommodates CO2 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 due to the lubri-
cant applied to steel wire. Failure to do so may
result in contaminated welds when welding alu-
minum.
6. 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 .035” (0.9 mm) diameter flux-cored elec-
trode. Also included is a spool of .035 (0.9 mm)
Innershield NR-211-MP.
See Maintenance section for instructions on
installing drive roll, cable liner, contact tip and their
proper configuration.
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C-2
C-2
ACCESSORIES
INNERSHIELD (FCAW)
REPLACEMENT PARTS
CONVERSION
Complete Gun and Cable Assembly
L8311-6 (K530-4)
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:
Contact Tip .025” (0.6 mm)
S19726-1
Contact Tip .030” (0.8 mm)
S19726-2
1. Change the output polarity to DC(-). See “Work
Contact Tip .035” (0.9 mm)
Cable Installation” section for details.
S19726-3
Contact Tip .045” (1.2 mm)
2. Install proper drive roll for the wire size selected.
See “Changing Drive Roll” in Maintenance section
for details.
S19726-4
Contact Tip-Tapered .025” (0.6 mm)
S20278-1
3. Install the proper gun liner and tip for the wire size
selected. See “Component Replacement” in
Maintenance section for details.
Contact Tip-Tapered .030” (0.8 mm)
S20278-2
4. Remove gas nozzle (if installed) and install gasless
nozzle. To remove, simply unscrew.
Contact Tip-Tapered .035” (0.9 mm)
S20278-3
Contact Tip-Tapered .045” (1.2mm)
S20278-4
Liner .023 - .030” (0.6 - 0.8 mm)
M16291-2
Liner .030 - .035” (0.8 - 0.9 mm)
M16291-6
Liner .035/.045” (0.9/1.2 mm)
M16291-1
Gas Diffuser
S19728
Gas Nozzle
M16294
Gas Nozzle-Tip Recessed 3/8” (9.5 mm)
Opening I.D.
M16684
Gas Nozzle-Tip Recessed 1/2” (12.7 mm)
Opening I.D.
M16684-1
Gas Nozzle-Tip Recessed 5/8” (15.9 mm)
Opening I.D.
M16684-2
Spot Welding Nozzle
M17846-1
Gasless Nozzle (Innershield Only)
M16418
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D-1
D-1
MAINTENANCE
AFTER FEEDING 50# OF FLUX CORED
WIRE OR 300# OF SOLID WIRE
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
• Unplug machine or turn power switch to OFF – “O”
position. Remove gun and cable from machine.
• Remove gas nozzle and contact tip from gun.
ELECTRIC SHOCK can kill.
• Lay cable out straight - blow out gently into gun end
with compressed air. Bend cable back and forth –
blow out again – Repeat until clean.
• 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.
WARNING
Excessive pressure at start may cause the dirt to
form a plug.
• Have qualified personnel do the
maintenance and trouble shoot-
ing work.
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.
ITEMS REQUIRING NO
MAINTENANCE
• Drive Motor and Gearbox – Lifetime lubrication
• Fan Motor- Lifetime lubrication.
• Wire Reel Spindle – Do NOT lubricate shaft.
• Blow dirt out of: Rectifier & Fan Motor Assembly;
PC Board located on Case Side Assembly; and
Center Assembly components.
ROUTINE AND PERIODIC MAINTE-
NANCE
• Vacuum accumulated dirt from gearbox and wire
feed section.
• Inspect the incoming guide tube and clean inside
diameter if necessary. Replace when excessively
worn.
BEFORE 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.
• Replace Contact Tip – when hole is enlarged or
elongated (refer to “CHANGING THE CONTACT
TIP”, in this section).
AFTER 5 MINUTES OF WELDING
or when spatter accumulates in nozzle
• Replace gas 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.
• 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).
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.
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D-2
D-2
MAINTENANCE
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.
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. Remove the contact tip from
the gun. Using low pressure air, gently blow out the
cable liner from the gas diffuser end.
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.
CAUTION
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 nozzle.
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 the hole through the tip.
CONFIGURATION OF COMPONENTS IN WIRE FEEDING SYSTEM
Contact Tip
Cable Liner
Drive Roll
Components shipped with
SP-135 PLUS
S19726-1(In Gun)
.025” (0.6mm)
S19726-2(Loose)
.030” (0.8mm)
M16291-6
.035” (0.9mm)
M15448 Stenciled (.030 / .035)
2 Smooth grooves
Small .030 (0.8mm)
Large .035” (0.9mm)
K549-1 .035” (0.9mm)
Innershield Welding Kit
S19726-3
.035” (0.9mm)
M16291-6
.035 (0.9mm)
KP666-035 Use Large groove
K663-2 .035 (0.9mm)
Aluminum or Stainless Kit*•
S24221-1
.035A (0.9mm)
M18971-1
.045” (1.2mm)
S24220 .035-3/64 (Drive roll)
S24219 (Idle roll)
KP666-035C
M15448-1 Stenciled
2 Knurled grooves for .035” (0.9mm)
• If .030 Solid wire feeding is desired obtain an S19726-2 Contact Tip, an M16291-2 Cable Liner and an M15448 Drive Roll (Smaller Groove).
* 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.
Δ Recommended for best feeding performance.
SP-135 PLUS
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D-3
D-3
MAINTENANCE
COMPONENT REPLACEMENT
CAUTION
PROCEDURES
When inching the welding wire, the drive rolls,
gun connector block, and gun contact tip are
CHANGING THE CONTACT TIP
energized relative to work and ground and remain
energized for several seconds after the gun trig-
ger is released.
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.
4. Remove the drive roll, flip over and reinstall with the
opposite groove closest to the gearbox.
3. Remove the existing contact tip from the gun by
unscrewing counter-clockwise.
NOTE: The stencil of the groove that you want to use
is marked on the outside of the drive unit
(when installed)
4. Insert and hand tighten desired contact tip.
5. Replace gas nozzle.
5. 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.
CHANGING THE SP-135 PLUS FOR USE
WITH INNERSHIELD FLUX CORED WIRE
• Change The Contact Tip
6. Reapply the spring loaded idle arm tensioner.
1. Refer to Figure D.2. Remove the gas nozzle from
the gun by unscrewing counter-clockwise.
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).
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 visi-
bility of the arc.
3
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 a
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.
2
1
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”).
FIGURE D.1
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.
SP-135 PLUS
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D-4
D-4
MAINTENANCE
1-1/4 (31.8 mm)
Liner Trim Length
Gas Diffuser
Slotted
Set Screw
Brass Cable
Connector
Contact Tip
(Threaded)
Gas Nozzle or
Gasless Nozzle
(Threaded)
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
9. Screw the gas diffuser onto the end of the gun
tube and securely tighten.
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. Refer to Figure D.2.
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.
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 feeder 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.
Counter-clockwise
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.
FIGURE D.3
SP-135 PLUS
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E-1
E-1
TROUBLESHOOTING
HOW TO USE TROUBLESHOOTING GUIDE
WARNING
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.
__________________________________________________________________________
This Troubleshooting Guide is provided to help you
locate and repair possible machine malfunctions.
Simply follow the three-step procedure listed below.
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.
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.
If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.
Step 2. POSSIBLE CAUSE.
The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.
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.
SP-135 PLUS
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E-2
E-2
TROUBLESHOOTING
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage Contact your LOCAL LINCOLN
is evident.
AUTHORIZED FIELD SERVICE
FACILITY.
No wire feed, weld output or gas
flow when gun trigger is pulled. Fan
does NOT operate.
1. Make sure correct voltage is
applied to the machine (115
vac).
2. Make certain that power switch
is in the ON position.
No weld output or wire feed when
gun trigger is pulled. Fan runs and
gas flows normally.
Contact your LOCAL LINCOLN
AUTHORIZED FIELD SERVICE
FACILITY.
No weld output when gun trigger is 1. Arc voltage may be set too low.
pulled. Fan runs, gas flows and
wire feeds normally.
2. Gun tip may be worn – Replace. Contact your local Lincoln
Authorized Field Service Facility.
3. Check for correct input voltage
to machine.
4. Gun or work cable may be
faulty.
No Wire feed, weld output or gas
flow when the gun trigger is pulled -
Fan operates normally.
1. Check the circuit breaker locat-
ed in the machine’s wire drive
compartment. Reset if tripped.
2. The thermostat may be tripped
due to overheating. Let machine
cool. Weld within the duty cycle
or remove any air obstruction to
machine.
3. Wire feed motor may be over-
loaded. Correct feeding prob-
lem.
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
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E-3
E-3
TROUBLESHOOTING
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
FEEDING PROBLEMS
No wire feed when gun trigger is
pulled. Fan runs, gas flows and
machine has correct open circuit
voltage (28 vdc maximum) – weld
output.
1. If the wire drive motor is running
check to see if the correct wire
is in the machine.
2. If the wire drive motor is running
make sure that the correct drive
rolls are installed in the
machine.
Contact your local Lincoln
Authorized Field Service Facility.
3. Check for clogged cable liner or
feeding problems.
Wire feed speed motor runs very
fast. Weld output, gas flow and fan
operate normally.
1. Make sure that the wire speed
control is not set at maximum.
The wire begins to feed butshuts off 1. Wire spool friction brake adjust-
after a short time, and will feed
again for anothershort interval only
if the trigger is released and
pressed again. (See description
under wire feed overload protec-
tion).
ment set too tight. Check adjust-
ment of the wire spool friction
brake. See "Friction Brake
Adjustment" in the "OPERA-
TION" section of this manual.
2. Idle roll pressure adjustment set
too high. Check adjustment of
the idle roll pressure. See "Wire
Threading" in The "OPERA-
TION" section of this manual.
3. Damaged or poorly maintained
wire feed system.
1. Check for clogged or damaged
cable liner, contact tip, and guide
tubes. Replace any damaged or
excessively worn parts.
2. 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
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E-4
E-4
TROUBLESHOOTING
Observe Safety Guidelines
detailed in the beginning of this manual.
TROUBLESHOOTING GUIDE
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
GAS FLOW PROBLEMS
Low or no gas flow when gun
trigger is pulled. Wire feed, weld
output and fan operate normally.
1. Check gas supply, flow regulator
and gas hoses.
Contact your local Lincoln
Authorized Field Service Facility.
2. Check gun connection to
machine for obstruction or leaky
seals.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
WELDING PROBLEMS
Arc is unstable – Poor starting
1. Check for correct input voltage
to machine – 115 vac.
2. Check for proper electrode
polarity for process.
3. Check gun tip for wear or dam-
Contact your local Lincoln
Authorized Field Service Facility.
age – Replace.
4. Check for proper gas and flow
rate for process.
5. Check work cable for loose or
faulty connections.
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
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F-1
F-1
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
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NOTES
SP-135 PLUS
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Now Available...12th Edition
New Lessons in Arc Welding
The Procedure Handbook of Arc Welding
Lessons, simply written, cover manipulatory techniques;
machine and electrode characteristics; related subjects,
such as distortion; and supplemental information on arc
welding applications, speeds and costs. Practice materials,
exercises, questions and answers are suggested for each
lesson.
With over 500,000 copies of previous editions published
since 1933, the Procedure Handbook is considered by many to
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This printing will go fast so don’t delay. Place your
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The hardbound book contains over 750 pages of welding
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$5.00 postage paid U.S.A. Mainland
A must for all welders, supervisors, engineers and
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as a reference for all students by taking advantage of the low
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$15.00 postage paid U.S.A. Mainland
Need Welding Training?
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How To Read Shop Drawings
The book contains the latest information and application
data on the American Welding Society Standard Welding
Symbols. Detailed discussion tells how engineers and
draftsmen use the “short-cut” language of symbols to pass
on assembly and welding information to shop personnel.
For details write:
Lincoln Welding School
22801 St. Clair Ave.
Cleveland, Ohio 44117-1199.
Practical exercises and examples develop the reader’s ability
to visualize mechanically drawn objects as they will appear
in their assembled form.
and ask for bulletin ED-80 or call 216-383-2259 and ask for the
Welding School Registrar.
187 pages with more than 100 illustrations. Size 8-1/2” x 11”
Durable, cloth-covered board binding.
Lincoln Welding School
BASIC COURSE
$700.00
$4.50 postage paid U.S.A. Mainland
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● Do not touch electrically live parts or
electrode with skin or wet clothing.
● Insulate yourself from work and
ground.
● Keep flammable materials away.
● Wear eye, ear and body protection.
WARNING
Spanish
● No toque las partes o los electrodos ● Mantenga el material combustible
● Prot jase los ojos, los o dos y el
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del rea de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
● Ne laissez ni la peau ni des v te-
ments mouill s entrer en contact
avec des pi ces sous tension.
● Gardez l’ cart de tout mat riel
inflammable.
● Prot gez vos yeux, vos oreilles et
votre corps.
ATTENTION
● Isolez-vous du travail et de la terre.
German
● Ber hren Sie keine stromf hrenden
Teile oder Elektroden mit Ihrem
K rper oder feuchter Kleidung!
● Isolieren Sie sich von den
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und K r-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
● N o toque partes el tricas e elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflam veis bem guarda- ● Use prote o para a vista, ouvido e
dos.
corpo.
ATENÇÃO
● Isole-se da pe a e terra.
Japanese
Chinese
Korean
Arabic
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
CONSUMIBLES 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 UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.
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● Keep your head out of fumes.
● Use ventilation or exhaust to
remove fumes from breathing zone.
● Turn power off before servicing.
● Do not operate with panel open or
guards off.
WARNING
Spanish
● Los humos fuera de la zona de res-
piraci n.
● Mantenga la cabeza fuera de los
humos. Utilice ventilaci n o
aspiraci n para gases.
● Desconectar el cable de ali-
mentaci n de poder de la m quina
antes de iniciar cualquier servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● D branchez le courant avant l’entre- ● N’op rez pas avec les panneaux
tien.
● Gardez la t te l’ cart des fum es.
● Utilisez un ventilateur ou un aspira-
teur pour ter les fum es des zones
de travail.
ouverts ou avec les dispositifs de
protection enlev s.
ATTENTION
German
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom v llig ff-
nen; Maschine anhalten!)
● Anlage nie ohne Schutzgeh use
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie f r gute Be- und
Entl ftung des Arbeitsplatzes!
WARNUNG
Portuguese
● N o opere com as tampas removidas.
● Desligue a corrente antes de fazer
servi o.
● Mantenha-se afastado das partes
moventes.
● N o opere com os paineis abertos
ou guardas removidas.
● Mantenha seu rosto da fuma a.
● Use ventila o e exhaust o para
remover fumo da zona respirat ria.
ATENÇÃO
● N o toque as partes el tricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRU ES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PR TICAS DE SEGURAN A DO EMPREGADOR.
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• 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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