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Lincoln Electric IM536-D - page 1
SP- 125 PLUS OPERA TOR’S MANUAL IM536-D March, 2001 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 MANUA ...
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Lincoln Electric IM536-D - page 2
SP-125 PLUS FOR ENGINE powered equipment. 1.a. Turn the engine off before troubleshooting and maintenance work unless the maintenance work requires it to be running. ____________________________________________________ 1.b. Operate engines in open, well-ventilated areas or vent the engine exhaust fumes outdoors. ____________________________________ ...
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Lincoln Electric IM536-D - page 3
SP-125 PLUS ii SAFETY ii ARC RA YS 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. 4.b. Use suitable clothing made from durable flame-resistant material to prote ...
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Lincoln Electric IM536-D - page 4
SP-125 PLUS FOR ELECTRICALL Y powered equipment. 8.a. Turn off input power using the disconnect switch at the fuse box before working on the equipment. 8.b. Install equipment in accordance with the U.S. National Electrical Code, all local codes and the manufacturer’s recommendations. 8.c. Ground the equipment in accordance with the U.S. National ...
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Lincoln Electric IM536-D - page 5
SP-125 PLUS iv SAFETY iv PRÉCA UTIONS 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: Sûreté Pour Soudage A L’Arc 1. Protegez-vous contre la secousse électrique: a. L ...
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Lincoln Electric IM536-D - page 6
SP-125 PLUS v Thank You 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! Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it handy for quick refe ...
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Lincoln Electric IM536-D - page 7
vi SP-125 PLUS T ABLE OF CONTENTS Page Installation .......................................................................................................Section A Technical Specifications ........................................................................................A-1 Identify and Locate Components ..................................... ...
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Lincoln Electric IM536-D - page 8
vii SP-125 PLUS ...
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Lincoln Electric IM536-D - page 9
A-1 INST ALLA TION SP-125 PLUS Fuse or Output Mode Input Voltage Breaker Size Input Amps Extension Cord RATED 115V/60Hz 20 Amp 20 Three Conductor #14 AWG (2.1 mm 2 ) or Larger for up to MAXIMUM 115V/60Hz 25 Amp 25 25 feet (7.6m) Three Conductor #12 AWG CSA 115V/60Hz 15 Amp 15 (3.3 mm 2 ) or Larger for up to 50 feet (15.2 m) TECHNICAL SPECIFICA TION ...
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Lincoln Electric IM536-D - page 10
A-2 INST ALLA TION SP-125 PLUS Read entire installation section before starting installation. SAFETY PRECA UTIONS IDENTIFY AND LOCA TE COMPONENTS If you have not already done so, unpack the SP-125 Plus from its carton and remove all packing material around the SP-125 Plus. Remove the following loose items from the carton (see Figure A.1): 1. SP-125 ...
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Lincoln Electric IM536-D - page 11
A-3 INST ALLA TION SP-125 PLUS SELECT SUIT ABLE LOCA TION 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 ...
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Lincoln Electric IM536-D - page 12
SP-125 PLUS A-4 INST ALLA TION 3. Route the cable under and around the back of the Wire Feed Gearbox (6). 4. For GMAW Only: Refer to Figure A.2. As deliv- ered, the SP-125 Plus is wired for positive polarity. This is the appropriate configuration for the Gas Metal Arc Welding (GMAW) process. To complete installation, use the provided wing nut to co ...
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Lincoln Electric IM536-D - page 13
A-5 INST ALLA TION SP-125 PLUS 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. 4. Refer to Figure A.6. Attach one ...
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Lincoln Electric IM536-D - page 14
A-6 INST ALLA TION SP-125 PLUS CODE REQUIREMENTS FOR INPUT CONNECTIONS This welding machine must be connected to power source in accordance with applicable elec- trical codes. 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 w ...
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Lincoln Electric IM536-D - page 15
SP-125 PLUS B-1 OPERA TION Read entire Operation section before operating the SP-125 Plus. ELECTRIC SHOCK can kill. • Do not touch electrically live parts or electrode with skin or wet clothing. Insulate yourself from work and ground. • Always wear dry insulating gloves. FUMES AND GASES can be dangerous. • Keep your head out of fumes. • Use ...
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Lincoln Electric IM536-D - page 16
SP-125 PLUS SP-125 PLUS B-2 OPERA TION GENERAL DESCRIPTION The SP-125 Plus is a complete semiautomatic con- stant voltage DC arc welding machine. Included is a solid state controlled, single phase constant voltage transformer/ rectifier power source and a wire feeder for feeding solid steel electrode and cored electrode. The SP-125 Plus is ideally ...
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Lincoln Electric IM536-D - page 17
SP-125 PLUS B-3 OPERA TION FIGURE B.1a Refer to Figure B.1b 4. Circuit Breaker – Protects machine from damage if maximum output is exceeded. Button will extend out when tripped (Manual reset). 5. Optional K695-2 Spot/Stitch Controls (see ACCES- SORIES section) - If present, replaces Blank Panel Assembly located on the center panel inside the case ...
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Lincoln Electric IM536-D - page 18
SP-125 PLUS B-4 OPERA TION FIGURE B.3 Note: The brake should be adjusted with a spool of wire installed. When properly adjusted it should move freely but not coast. Friction Brake Adjustments 1 . With wire spool installed, check free movement and coast of the spool. 2. To tighten the brake turn the wing nut clockwise in 1/4 turn increments until co ...
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Lincoln Electric IM536-D - page 19
SP-125 PLUS B-5 OPERA TION 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-125 Plus. 1. For CO 2 , open the cylinder very slowly. For argon- mixed gas, open cylinder valve slowly a fraction of a turn. ...
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Lincoln Electric IM536-D - page 20
SP-125 PLUS B-6 OPERA TION 9. To stop welding, release the gun trigger and then pull the gun away from the work after the arc goes out. 10. When no more welding is to be done, close valve on gas cylinder (if used), momentarily operate gun trigger to release gas pressure, and turn off the SP-125 Plus. Cleaning Tip And Nozzle Clean the contact tip an ...
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Lincoln Electric IM536-D - page 21
SP-125 PLUS B-7 OPERA TION O VERLO AD PR O TECTION Output Overload The SP-125 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-125 Plus duty cycle is ...
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Lincoln Electric IM536-D - page 22
SP-125 PLUS B-8 LEARNING T O WELD LEARNING T O WELD No one can learn to weld simply by reading about it. Skill comes only with practice. The following pages will help the inexperienced operator to understand 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 ...
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Lincoln Electric IM536-D - page 23
SP-125 PLUS B-9 LEARNING T O 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 we ...
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Lincoln Electric IM536-D - page 24
SP-125 PLUS B-10 LEARNING T O WELD 2. Can I afford the extra expense, space, and lack of portability required for gas cylinders and gas sup- ply? 3. Do I require clean, finished-looking welds? If you have answered yes to all the above questions GMAW may be the process for you. If you have answered no to any of the above questions, then you should c ...
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Lincoln Electric IM536-D - page 25
SP-125 PLUS B-11 LEARNING T O WELD FIGURE B.12 Penetration Unless a weld penetrates close to 100% of the metal thickness, a butt weld will be weaker than the material welded together. In the example shown in Figure B.13, the total weld is only half the thickness of the material thus the weld is only approximately half as strong as the metal. FIGURE ...
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Lincoln Electric IM536-D - page 26
SP-125 PLUS B-12 LEARNING T O WELD 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. Use stringer beads and tip the gun in the dir ...
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Lincoln Electric IM536-D - page 27
SP-125 PLUS B-13 LEARNING T O WELD ARC RAYS can burn eyes and skin. When using an open arc process, it Is necessary to use correct eye, head and body protection. Protect yourself and others, read “ARC RAYS can burn” at the front of this manual. 2. The Correct Way To Strike An Arc 1. Be sure the work clamp makes good electrical contact to the wo ...
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Lincoln Electric IM536-D - page 28
SP-125 PLUS B-14 LEARNING T O WELD Mild Steel 16 gauge or 1/16 inch (1.6 mm) Electrode 0.035" (0.9 mm) NR-211-MP Innershield Wire Voltage Setting “V” E Wire Feed Speed “o|o” 2 For the SP-125 Plus, use the follo wing: Helpful Hints 1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways. We ...
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Lincoln Electric IM536-D - page 29
SP-125 PLUS B-15 LEARNING T O WELD MA CHINE SET UP FOR THE GMA W (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. 3. Set ...
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Lincoln Electric IM536-D - page 30
Helpful Hints 1. For general welding, it is not necessary to weave the arc, neither forward or backward nor sideways. Weld along at a steady pace. You will find it easier. 2. When welding on thin plate, you will find that you will have to increase the welding speed, whereas when welding on heavy plate, it is necessary to go more slowly in order to ...
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Lincoln Electric IM536-D - page 31
SP-125 PLUS B-17 LEARNING T O WELD 4. After you strike the arc, practice the correct electri- cal stickout. Learn to distinguish it by its sound. 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. Run beads on a flat plate. Run them parall ...
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Lincoln Electric IM536-D - page 32
SP-125 PLUS B-18 LEARNING T O 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. Inn ...
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Lincoln Electric IM536-D - page 33
B-19 APPLICA TION CHART SP-125 PLUS ...
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Lincoln Electric IM536-D - page 34
C-1 SP-125 PLUS A CCESSORIES 6 . KP666-035C Knurled Drive Roll (optional) — Reversible Drive Roll with double knurled grooves for .035 (0.9 mm) cored electrode. 7. 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 th ...
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Lincoln Electric IM536-D - page 35
C-2 SP-125 PLUS A CCESSORIES INNERSHIELD (FCA W) CONVERSION Several changes are needed to convert the unit for operation with the Innershield (FCAW) process. The K549-1 Innershield Kit includes all the necessary accessories for this conversion and are provided for this purpose. The following conversions should be made using the contents of this kit ...
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Lincoln Electric IM536-D - page 36
SP-125 PLUS MAINTENANCE SAFETY PRECA UTIONS ELECTRIC SHOCK can kill. • Disconnect input power by remov- ing plug from receptacle before working inside SP-125 PLUS. Use only grounded receptacle. Do not touch electrically “hot” parts inside SP-125 PLUS. • Have qualified personnel do the maintenance and trouble shooting work. ITEMS REQUIRING N ...
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Lincoln Electric IM536-D - page 37
SP-125 PLUS D-2 MAINTENANCE GUN AND CABLE MAINTENANCE FOR MA GNUM™ 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, gen ...
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Lincoln Electric IM536-D - page 38
SP-125 PLUS D-3 MAINTENANCE COMPONENT REPLA CEMENT PR OCEDURES CHANGING THE CONT A CT TIP 1. Unplug or turn power switch to Off “O” position. 2. Refer to Figure D.2. Remove the gas nozzle from the gun by unscrewing counter-clockwise. 3. Remove the existing contact tip from the gun by unscrewing counter-clockwise. 4. Insert and hand tighten desi ...
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Lincoln Electric IM536-D - page 39
SP-125 PLUS D-4 MAINTENANCE CHANGING LINER NOTICE: The variation in cable lengths pre- vents the interchangeability of liners. Once a liner has been cut for a particular gun, it should not be installed in another gun unless it can meet the liner cutoff length requirement. Refer to Figure D.2. 1. Remove gun and cable assembly from machine. 2. Remove ...
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Lincoln Electric IM536-D - page 40
SP-125 PLUS D-5 MAINTENANCE GUN HANDLE P ARTS 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 ha ...
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Lincoln Electric IM536-D - page 41
SP-125 PLUS E-1 TR OUBLESHOO TING Step 1. LOCATE PROBLEM (SYMPTOM). Look under the column labeled “PROBLEM (SYMPTOMS)”. This column describes pos- sible symptoms that the machine may exhibit. Find the listing that best describes the symptom that the machine is exhibiting. Symptoms are grouped into the following categories: Output Problems; Feed ...
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Lincoln Electric IM536-D - page 42
SP-125 PLUS E-2 TR OUBLESHOO TING Observe Safety Guidelines detailed in the beginning of this manual. TR OUBLESHOO TING GUIDE PROBLEMS (SYMPT OMS) Major physical or electrical damage is evident. No wire feed, weld output or gas flow when gun trigger is pulled. Fan does NOT operate. No weld output or wire feed when gun trigger is pulled. Fan runs an ...
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Lincoln Electric IM536-D - page 43
SP-125 PLUS E-3 TR OUBLESHOO TING Observe Safety Guidelines detailed in the beginning of this manual. TR OUBLESHOO TING GUIDE PROBLEMS (SYMPT OMS) No wire feed when gun trigger is pulled. Fan runs, gas flows and machine has correct open circuit voltage (28 vdc maximum) – weld output. Wire feed speed motor runs very fast. Weld output, gas flow and ...
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Lincoln Electric IM536-D - page 44
SP-125 PLUS E-4 TR OUBLESHOO TING Observe Safety Guidelines detailed in the beginning of this manual. TR OUBLESHOO TING GUIDE PROBLEMS (SYMPT OMS) Arc is unstable – Poor starting POSSIBLE AREAS OF MISADJUSTMENT(S) 1. Check for correct input voltage to machine – 115 vac. 2. Check for proper electrode polarity for process. 3. Check gun tip for we ...
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Lincoln Electric IM536-D - page 45
SP-125 PLUS F-1 WIRING DIA GRAMS SP-125 PLUS WIRING DIA GRAM: CODE 10260, 10481 M18196 L1 L2 31 32 531 TO GROUND PER NATIONAL ELECTRICAL CODE S1 SWITCH 202 201 D1 D3 D2 D4 204 204 204 203 203 203 C1 59,000 f 40V 203 204 - + OUTPUT CHOKE GUN CABLE CONDUCTOR BLOCK TO WORK ELECTRICAL SYMBOLS PER E1537 CIRCUIT BREAKER 31A 12 3 456 LATCH FAN MOTOR 1 234 ...
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Lincoln Electric IM536-D - page 46
SP-125 PLUS F-2 NO TES ...
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Lincoln Electric IM536-D - page 47
SP-125 PLUS NO TES ...
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Lincoln Electric IM536-D - page 48
Now A vailable...12th Edition The Procedure Handbook of Ar c W elding With over 500,000 copies of previous editions published since 1933, the Procedure Handbook is considered by many to be the “Bible” of the arc welding industry. This printing will go fast so don’t delay. Place your order now using the coupon below. The hardbound book contain ...
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Lincoln Electric IM536-D - page 49
W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic READ AND UNDERST AND THE MANUF ACTURER’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 F ABRICANTE P ARA EL ...
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Lincoln Electric IM536-D - page 50
W ARNING A VISO DE PRECA UCION A TTENTION W ARNUNG A TENÇÃO Spanish French German Portuguese Japanese Chinese Korean Arabic LEIA E COMPREENDA AS INSTRUÇÕES DO F ABRICANTE P ARA ESTE EQUIP AMENTO E AS P ARTES DE USO, E SIGA AS PRÁTICAS DE SEGURANÇA DO EMPREGADOR. ● Keep your head out of fumes. ● Use ventilation or exhaust to remove fumes f ...
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Lincoln Electric IM536-D - page 51
• 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 • World's Leader in Welding and Cutting Products • ...
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