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Lincoln Electric IM536-D User Manual

Lincoln Electric IM536-D
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SP-125 PLUS
OPERATOR’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
MANUAL AND THE SAFETY
PRECAUTIONS CONTAINED
THROUGHOUT.
And, most
importantly, think before you act
and be careful.
For use with machine Code Numbers
10260, 10481,10685,10689,10690,10740
ISO 9001
CERTIFICATE NUMBER: 30273
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
QMS
ANSI RAB
• 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 •
Date of Purchase:
Serial Number:
Code Number:
Model:
Where Purchased:
Copyright © 2001 Lincoln Global Inc.
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Lincoln Electric IM536-D Specifications

General IconGeneral
BrandLincoln Electric
ModelIM536-D
CategoryWelding System
LanguageEnglish

Summary

Safety Warnings and Precautions

California Proposition 65 Warnings

Specific warnings regarding cancer, birth defects, and reproductive harm.

Engine Powered Equipment Safety

Safety precautions for operating equipment with an engine.

Electric and Magnetic Field Hazards

Information on potential dangers of EMF fields and safety measures.

Electrical and Arc Safety Precautions

Electric Shock Prevention

Guidelines to prevent fatal electric shock while operating the welder.

Arc Ray Protection

How to protect eyes and skin from arc rays and spatter.

Fumes and Gases Dangers

Hazards associated with welding fumes and gases and how to mitigate them.

Fire, Cylinder, and Electrical Safety

Welding Sparks and Fire Hazards

Precautions to prevent fires and explosions caused by welding sparks.

Compressed Gas Cylinder Safety

Safe handling and storage procedures for compressed gas cylinders.

Electrically Powered Equipment Safety

Safety requirements for connecting and operating electrically powered equipment.

French Safety Precautions (PRÉCAUTIONS DE SÛRETÉ)

Arc Welding Safety (Sûreté Pour Soudage A L'Arc)

Safety measures specific to arc welding procedures.

Transformer and Rectifier Machine Safety

Safety guidelines for transformer and rectifier welding machines.

Installation and Technical Specifications

Technical Specifications Overview

Detailed technical data, dimensions, and electrical requirements for the SP-125 Plus.

Installation Preparation

Installation Safety Precautions

Critical safety warnings and guidelines to follow during installation.

Component Identification

Instructions for unpacking and identifying all parts included with the SP-125 Plus.

Installation Setup Procedures

Location, Stacking, and Tilting

Guidelines for choosing a location and proper placement of the welder.

Output Connections and Work Clamp Installation

Connecting output cables, work clamp, and routing the work cable.

Welding Equipment Connection

Gun Installation and Gas Connection

Procedures for installing the welding gun and connecting shielding gas.

Gas Cylinder Setup and Handling

Shielding Gas Cylinder Connection and Safety

Steps for connecting and safely preparing gas cylinders.

Electrical Code Compliance for Installation

Input Power Connection Requirements

Electrical code requirements for input power supply and branch circuits.

Operation Safety Guidelines

General Operation Safety Warnings

Critical safety warnings for operating the welding machine.

Understanding the SP-125 Plus Operation

General Description, Features, and Capabilities

Overview of the welder's capabilities, design, and features.

Controls and Settings Explained

Detailed explanation of the welder's controls and how to adjust them.

Welding Operations Sequence

Wire Loading Procedure

Step-by-step guide for loading welding wire onto the spool.

Wire Feed System Setup

Wire Threading and Friction Brake Adjustment

Instructions for threading wire and adjusting the friction brake.

Welding Process Execution and Gas Management

Shielding Gas Usage and Setup

Proper use and setup of shielding gas for welding processes.

Making a Weld: Core Techniques

Core techniques and steps for performing a weld.

Welding Process Selection and Configuration

Process Selection Criteria (GMAW vs. FCAW)

Guidance on choosing between GMAW and FCAW processes.

Changing Wire Feed System Components

How to adjust the machine for different wire sizes and types.

Welding with Innershield (FCAW)

Specific instructions and considerations for using the FCAW process.

Overload Protection Systems

Understanding Welder Overload Protection

Explanation of output, thermal, and wire feed overload protection features.

Learning Arc Welding Fundamentals

Understanding the Arc Welding Circuit

Explanation of the electrical circuit involved in arc welding.

Welding Arc Principles and Process Selection

The GMAW (MIG) Welding Arc

Detailed explanation of the Gas Metal Arc Welding process.

Process Selection Factors

Factors to consider when selecting the appropriate welding process.

Welding Techniques and Material Considerations

Common Metals and Joint Types

Information on common metals and different welding joint types.

Welding Positions Overview

Overview of different welding joints and their execution.

Advanced Welding Position Techniques

Vertical Welding Procedures

Methods for performing vertical-up and vertical-down welds.

Overhead Welding Techniques

Techniques and considerations for welding in overhead positions.

Process-Specific Setup and Techniques

Setting Up for Self-Shielded FCAW Process

Steps to configure the welder for the Innershield FCAW process.

Self-Shielded FCAW Welding Techniques

Key manipulations and positions for effective FCAW welding.

Mastering Core Welding Skills

Striking the Arc and Electrical Stickout

Proper methods for initiating the arc and maintaining optimal electrical stickout.

Achieving Correct Welding Speed

Techniques for controlling welding speed based on puddle appearance.

Welding Practice and Tips

Helpful Welding Hints

Practical tips for improving general welding performance.

Developing Welding Skills Through Practice

Exercises and advice for mastering core welding skills.

GMAW (MIG) Process Setup and Techniques

Setting Up for GMAW (MIG) Welding

Configuration steps for the Gas Metal Arc Welding process.

GMAW (MIG) Welding Techniques

Key manipulations and positions for effective GMAW welding.

MIG Welding Practice and Tips

Helpful Hints for MIG Welding

Practical tips for improving MIG welding performance.

MIG Welding Practice Exercises

Exercises to develop proficiency in MIG welding techniques.

Troubleshooting Common Weld Defects

Weld Quality Troubleshooting Guide

Solutions for common weld defects like porosity, spatter, and poor penetration.

Welding Gun Handling Best Practices

Proper Gun Handling Techniques

Best practices for handling the welding gun to prevent feeding issues.

Application Chart and Settings Guide

Suggested Welding Settings for Various Processes

Recommended settings for various welding processes and materials.

Drive Roll Orientation and Polarity Settings

How to set polarity and orient the drive roll for different welding wires.

Optional Accessories

Accessory Product Descriptions

Descriptions and part numbers for optional accessories.

Accessory Conversions and Replacement Parts

Innershield (FCAW) Conversion Procedures

Steps to convert the welder for the Innershield FCAW process.

Replacement Parts Catalog

List of available replacement parts and their part numbers.

Maintenance Procedures and Safety

Safety Precautions for Maintenance Operations

Critical safety warnings before performing any maintenance.

Routine and Periodic Maintenance Schedule

Scheduled maintenance activities for optimal welder performance.

Gun and Cable Maintenance

Gun Cable Cleaning and Wire Feeder Configuration

Steps for cleaning the gun cable liner and configuring wire feeder components.

Component Replacement Procedures

Changing Contact Tips and Drive Rolls

Instructions for replacing contact tips and adjusting the drive roll.

Innershield Wire Conversion Setup

Steps to configure for Innershield wire, including contact tip and nozzle.

Liner Replacement Guide

Changing the Welding Gun Liner

Step-by-step instructions for replacing the gun liner.

Gun Handle Maintenance

Servicing Gun Handle Parts

Procedures for disassembling and working on the gun handle.

Troubleshooting Guide Introduction

How to Use the Troubleshooting Guide

Instructions on how to effectively use the troubleshooting section.

Troubleshooting Output Problems

Output Problems Checklist and Solutions

Common output issues and their potential causes and solutions.

Troubleshooting Feeding and Gas Flow

Feeding Problems Diagnosis and Solutions

Troubleshooting steps for wire feeding issues.

Gas Flow Problems Diagnosis and Solutions

Solutions for problems related to shielding gas flow.

Troubleshooting Welding Performance

Welding Problems Diagnosis and Solutions

Troubleshooting steps for unstable arcs and poor starting.

Wiring Diagrams

SP-125 Plus Wiring Diagram

Schematic diagram illustrating the electrical connections of the SP-125 Plus.

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