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IM591-B
March, 2001
SP 170-I and UWW-170
For use with machine Code Numbers
thru
10634, 10693,10694
10488
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
ISO 9001
ANSI RAB
QMS
Designed and Manufactured Under a
Quality Program Certified by
ABS Quality Evaluations, Inc.
to ISO 9001 Requirements.
Copyright © 2001 Lincoln Global Inc.
CERTIFICATE NUMBER: 30273
• 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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ii
ii
SAFETY
ARC RAYS can burn.
ELECTRIC SHOCK can
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.
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.f. Maintain the electrode holder, work clamp, welding cable and
welding machine in good, safe operating condition. Replace
damaged insulation.
3.g. Never dip the electrode in water for cooling.
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.
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.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
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iii
SAFETY
CYLINDER may explode
if damaged.
WELDING SPARKS can
cause fire or explosion.
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.
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.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.
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
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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-
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.
er à l’interrupteur à la boite de fusibles.
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
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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.
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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
Work Clamp Installation ..................................................................................A-3
Work Cable Installation ...................................................................................A-3
Gun Installation......................................................................................................A-4
Gas Connection.....................................................................................................A-4
Input Connections..................................................................................................A-5
Line Cord Connection............................................................................................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
Wire Loading...................................................................................................B-3
Wire Threading................................................................................................B-4
Making a Weld ................................................................................................B-5
Process Guidelines................................................................................................B-5
Chaning Over to Feed Other Wire Sizes ...............................................................B-6
Welding with GMAW..............................................................................................B-6
Welding with FCAW...............................................................................................B-6
Overload Protection...............................................................................................B-6
Learning to Weld....................................................................................................B-7
Application Chart .................................................................................................B-18
Accessories.....................................................................................................Section C
Accessories ...........................................................................................................C-1
Replacement Parts................................................................................................C-2
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Gun and Cable Maintenance.................................................................................D-2
Configuration of Components in Wire Feeding System.........................................D-2
Component Replacement Procedures ..................................................................D-2
Troubleshooting..............................................................................................Section E
Safety Precautions.................................................................................................E-1
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide ..........................................................................................E-2
Wiring Diagrams..............................................................................................Section F
SP 170-I Wiring Diagram .......................................................................................F-1
SP 170-I Parts...............................................................................................P297 Series
UWW-170 Parts............................................................................................P298 Series
Gun and Cable Assembly ...................................................................................P103-Y
Wire Drive Assembly...........................................................................................P189-D
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A-1
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS – SP 170-I /UWW-170 (Above Code 10600)
INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency
Input Current
230V/50/60Hz
20 Amps – Rated Output
RATED OUTPUT
Duty Cycle
25%
Amps
125
85
Volts at Rated Amperes
20.25
18.25
17.50
60%
100%
70
OUTPUT
Welding Current Range
Maximum Open Circuit Voltage
Wire Speed Range
Rated DC Output: 30 – 170 amps
33
50-400IPM (1.3-10.2m/min)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse or
Output Mode
Input Voltage
Breaker Size
Input Amps
Power Cord
RATED
230V/50/60Hz
30 Super Lag
20
16 Amp, 230V,
Two-Prong International
Cord Set (Supplied)
TECHNICAL SPECIFICATIONS – SP 170-I /UWW-170 (Below Code 10600)
INPUT – SINGLE PHASE ONLY
Standard Voltage/Frequency
Input Current
220V/50/60Hz
22 Amps – Rated Output
RATED OUTPUT
Duty Cycle
25%
Amps
120
100
75
Volts at Rated Amperes
20
19
18
60%
100%
OUTPUT
Welding Current Range
Maximum Open Circuit Voltage
Wire Speed Range
Rated DC Output: 30 – 170 amps
32
50-400IPM (1.3-10.2m/min)
RECOMMENDED INPUT CABLE AND FUSE SIZES
Fuse or
Output Mode
Input Voltage
Breaker Size
Input Amps
Power Cord
RATED
220V/50/60Hz
30 Super Lag
22/20
16 Amp, 220V,
Two-Prong International
Cord Set (Supplied)
PHYSICAL DIMENSIONS
Height
12.0 in
305 mm
Width
9.75 in
248 mm
Depth
16.5 in
419 mm
Weight
57 Ibs
25.9 kg
The SP170-I / UWW-170 is designed for industrial and professional use
in accordance with the standard EN 60974-1 / IEC 974-1.
SP-170-I
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A-2
A-2
INSTALLATION
Read entire installation section before starting
installation.
1
2
SAFETY PRECAUTIONS
E
WARNING
ELECTRIC SHOCK can kill.
• Only qualified personnel should perform
this installation.
• Only personnel that have read and under-
stood the SP 170-I 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
• The SP 170-I power switch is to be in the
OFF (“O”) position when installing work
cable and gun and when connecting power
cord to input power.
3
6
IDENTIFY AND LOCATE
COMPONENTS
5
If you have not already done so, unpack the SP 170-I
from its carton and remove all packing material
around the SP 170-I. Remove the following loose
items from the carton (see Figure A.1):
7
FIGURE A.1
1. SP 170-I or UWW-170
2. Gun and cable assembly(1)
3. Literature and miscellaneous including:
a) This operating manual
b) Contact tips:
SP 170-I UWW-170
2
1
2
0
0
2
0
2
.025” (0.6mm) for solid wire
.030” (0.8mm) for solid wire
.035” (0.9mm) for cored wire
.045” (1.2mm) for cored or solid wire
c) 5/64” (2.0 mm) Hex key wrench for removal of
drive roll.
4. 10 ft (3,0 m) work cable.
5. Work clamp.
6. 14.0 ft (4.3 m) .19” (4.8 mm) dia. gas hose
7. 2- Hose clamps
(1) The gun is ready to feed .030" (0.8mm) diameter
wire.
SP 170-I
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A-3
A-3
INSTALLATION
3. Connector Block.
SELECT SUITABLE LOCATION
4. Gun Trigger Lead Connectors.
5. Positive (+) and negative (–) output terminals.
6. Wire Feed Gearbox / Feedplate
7. Cable Hanger.
The SP 170-I has an IP21S rating. 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 pas-
sages and cause overheating.
8. Thumbscrew.
STACKING
9. Circuit Breaker - (Manual Reset)
SP 170-I’s cannot be stacked.
TILTING
10. Optional Spot/Stitch Timer Kit - See “Accessories”
Refer to the Accessories Section for available optional
equipment.
Each machine must be placed on a secure, level sur-
face, either directly or on the recommended cart. The
machine may topple over if this procedure is not fol-
lowed.
Work Clamp Installation
Attach the work clamp per the following: Refer to
Figure A-3
LIMITATIONS
STRAIN RELIEF HOLE
WORK CABLE
NUT AND BOLT
The SP 170-I cannot be used for pipe thawing.
MIG welding and flux cored arc welding are the only
processes supported by the SP 170-I
WORK CLAMP
The handle can not be used for transport by crane.
FIGURE A.3
OUTPUT CONNECTIONS
Refer to Figure A.2.
1. Insert the work cable terminal lug with the larger
hole through the strain relief hole in the work clamp
as shown above.
1. Work Cable Access Hole.
2. Gun Cable and Control Lead Access Hole.
2. Fasten securely with the bolt and nut provided.
9
10
E
4
5
+
-
8
SP 170 - I
6
3
7
1
2
FIGURE A.2
SP 170-I
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A-4
A-4
INSTALLATION
Work Cable Installation
Connecting Gun Cable to the SP 170-I
Refer to Figure A.2.
As shipped the gun is fitted with a liner suitable for all
wire diameters from .025” - .045” (0.6mm - 1.2mm)
and has an .030” (0.8mm) contact tip installed.
1. Open the wire feed section door on the right side of
the SP 170-I.
1. Refer to Figures A.2 and A.4. Unplug the machine
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.
or turn power switch to the OFF “O” position.
2. Pass the insulated terminals of the gun trigger con-
trol leads, one at a time, through the Gun Cable
and Control Lead Access Slot (A.2-2) in the case
front. The leads are to be routed up the inside of
the case front, behind the gas line.
3. Route the cable under the feedplate (6) and in front
of the Wire Feed Motor.
4. For GMAW Only: Refer to Figure A.2. As deliv-
ered, the machine is connected for positive elec-
trode polarity. This is the appropriate configuration
for the GMAW (MIG) process. To complete installa-
tion, use the provided wing nut to connect the work
cable’s terminal lug to the negative (–) output ter-
minal (5) located above the Wire Feed Gearbox
(6). Make sure that both wing nuts are tight.
3. Insert the connector on the gun conductor cable
through the Gun Cable Access Hole (A.2-2) in the
SP 170-I case front. Make sure the connector is all
the way in the brass connector block to obtain
proper gas flow. If the gun connector will not fully
insert, unscrew the thumbscrew on the connector
block a few turns. Rotate the connector so control
leads are on the underside and tighten the
Thumbscrew on the connector block.
5. For Innershield Only: Refer to Figure A.4. To wire
for negative polarity (required for the Innershield
process), connect the short cable attached to the
connector block (1) to the negative (–) output termi-
nal (2) and the work cable (3) to the positive (+) ter-
minal (4).
4. Connect the gun trigger control lead terminals to
the two insulated 1/4" (6,4 mm) tab terminal con-
nector bushings located above the “Gun Trigger
Connection” decal in the wire feed section (A.4).
Either lead can go to either connector.
CAUTION
4
If the gun trigger switch being used is other than
that supplied, 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 170-I may result if this
switch shorts to the SP 170-I welding output cir-
cuit or is common to any electrical circuit other
than the SP 170-I trigger circuit.
3
2
1
5
GAS CONNECTION
6
When using the MIG process, a cylinder of shielding
gas must be obtained. See Table B.1. Additionally a
flow regulator is required. For more information, refer
to the ACCESSORIES section.
FIGURE A.4
GUN INSTALLATION
As shipped from the factory, the SP 170-I gun is ready
to feed .030" solid wire. If other wire is to be used,
change the contact tip to the appropriate size.
SP 170-I
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A-5
A-5
INSTALLATION
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.
WARNING
CYLINDER may explode if dam-
aged. Keep cylinder upright and
chained to support
WARNING
• Keep cylinder away from areas
where it may be damaged.
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.
• Never lift welder with cylinder
attached.
• Never allow welding electrode to
touch cylinder.
• Keep cylinder away from welding
or other live electrical circuits.
3. Attach the flow regulator to the cylinder valve and
tighten the union nut securely with a wrench..
NOTE: If connecting to 100% CO2 cylinder, make
certain the plastic washer is seated in the fitting
that attaches to the CO2 cylinder.
WARNING
BUILDUP OF SHIELDING GAS may
harm health or kill.
4. Refer to Figure A.6. Attach one end of inlet gas
hose to the outlet fitting of the flow regulator and
tighten the gas line hose clamp. Connect the other
end to the SP 170-I Gas Solenoid Inlet nipple.
Make certain the gas hose is not kinked or twisted.
Tighten the gas line hose clamp.
• Shut off shielding gas supply
when not in use.
• SEE AMERICAN NATIONAL
STANDARD Z-49.1, “SAFETY IN
WELDING AND CUTTING” PUB-
LISHED BY THE AMERICAN
WELDING SOCIETY.
INPUT CONNECTIONS
Refer to Figure A.6.
1. Chain the cylinder to a wall or other stationary sup-
port to prevent the cylinder from falling over.
Insulate the cylinder from the work circuit and earth
ground. Refer to Figure A.5.
Cylinder Valve
Flow Regulator
GAS SOLENOID
INLET NIPPLE
Gas Hose
POWER INPUT
CABLE
FIGURE A.6
FIGURE A.5
2. With the cylinder securely installed, remove the
cylinder cap. Stand to one side away from the out-
SP 170-I
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A-6
A-6
INSTALLATION
Line Cord Connection
A 3 conductor international cordset with a 16 amp,
230 volt, two-prong plug is factory installed. Connect
this plug to a mating grounded receptacle which is
connected to an appropriate power supply per any
applicable local codes.
Grounding
Type 75°C
Wire in Conduit,
Copper Cond.
AWG Size
Wire
Copper
Cond.
Fuse
Size
(Super
Lag)
Input
Voltage
Hertz
AWG Size
230
50/60
8
10
40
CONNECT TO A SYSTEM
GROUNDING WIRE. SEE
THE UNITED STATES
NATIONAL ELECTRICAL
CODE AND/OR LOCAL
CODES FOR OTHER
DETAILS AND MEANS FOR
PROPER GROUNDING.
CONNECT TO HOT WIRES
OF A THREE-WIRE SINGLE
PHASE SYSTEM OR TO
ONE PHASE OF A TWO OR
THREE PHASE SYSTEM.
WARNING
This welding machine must be connected to a
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 conduc-
tors based on duty cycle of the welding source.
If there is any question about the installation
meeting applicable electrical code requirements,
consult a qualified electrician.
SP 170-I
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B-1
B-1
OPERATION
GENERAL DESCRIPTION
Read entire operation section before
operating the SP 170-I.
The SP 170-I is a complete semiautomatic constant
voltage DC portable arc welder. Included is a tap-
switch controlled, single phase constant voltage trans-
former/rectifier power source and a wire feeder with
welding gun for feeding .025" (0.6 mm) through .030"
(0.8 mm) solid steel electrode and .035" (0.9 mm)
Innershield® NR-211-MP.
WARNING
ELECTRIC SHOCK can kill.
• Do not touch electrically live
parts or electrode with skin or
wet clothing. Insulate yourself
from work and ground.
It is ideally suited for individuals having access to
230V 50/60 Hz AC input power and want the ease of
use, quality and dependability of both gas metal arc
welding or GMAW (also known as MIG welding) and
the Innershield® process (self-shielded flux-cored or
FCAW). A convenient chart is mounted inside the wire
feed section door for setting welding procedures for 24
gauge (.60 mm) through 5/16" (8.0 mm) mild steel.
The machine is rugged and reliable and is designed
for dependable service and long life.
• 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.
RECOMMENDED PROCESSES
The SP 170-I can be used for welding mild steel,
stainless steels and aluminum using the GMAW, sin-
gle pass, process (MIG) which requires a supply of
shielding gas or it can be used for the self-shielded,
Innershield® process (FCAW).
WELDING SPARKS can
cause fire or explosion.
• Keep flammable material away.
• Do not weld on closed contain-
ers.
OPERATIONAL FEATURES AND
CONTROLS
The SP 170-I has the following controls as standard:
Power ON/OFF Switch, Voltage Control, Wire Speed
Control, Trigger Switch, and a Circuit Breaker.
ARC RAYS can burn eyes
and skin.
DESIGN FEATURES AND
ADVANTAGES
• Wear eye, ear and body protec-
tion.
● “Cold electrode” until gun trigger is pressed for an
added measure of safety.
● Overload protection — incorporates both a thermo-
stat and a circuit breaker.
Observe all safety information throughout
this manual.
● Quality wire drive with electronic overload protec-
tion.
● “Quick Release” idle roll pressure arm is easily
adjusted.
● Reversible, dual groove drive roll, shipped ready
to feed .030" (0.8 mm) diameter solid wire or .035"
diameter flux-cored wire. The drive roll is easily
reversed to feed .025" (0.6 mm) diameter solid
wire.
●
SP-170-I
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B-2
B-2
OPERATION
6. Optional K695-1 Spot/ Stitch Timer Kit Controls (see
ACCESSORIES section) - If present, replaces Blank
Panel Assembly located on the center panel inside the
case door:
● No external shielding gas is required when used
with Lincoln Innershield .035” (0,9 mm) NR®-211-
MP electrode.
● Spindle accommodates both 8 in. (200 mm) diame-
ter and 4 in. (100 mm) diameter spools of wire.
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 trigger is
depressed and held. Stitch mode cycles between weld-
ing 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 trigger is depressed. Releasing the gun trigger in
any of the three modes will interrupt welding immediate-
ly.
● Accepts optional Spot/Stitch Timer Kit.
WELDING CAPABILITY
The SP 170-I is rated at 125 amps, 20.25 volts, at
25% duty cycle on a ten minute basis. It is capable of
higher output currents at lower duty cycles. Actual
welding outputs will range between 30 and 170 amps
for the recommended processes.
LIMITATIONS
Time Control - In Spot mode, controls spot mode ON
time between approximately .25 and 4.0 seconds. 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.
Arc Gouging cannot be performed with the SP 170-I.
The SP 170-I is not recommended for pipe thawing or
TIG welding.
CONTROLS AND SETTINGS
Refer to Figures B.1a,
B.1b and B.1c.
7. 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.
1. Power ON/OFF Switch — When
the power is on the fan motor will
ON
run and air will be exhausted out
2
3
4
1
the louvers in the front of the
machine. The welding output and
wire feeder remain off until the gun
trigger is pressed.
OFF
2. Voltage Control — A 5-position tap
selector switch gives full range
adjustment of power source output
voltage. Do not switch while
E
welding.
ARC VOLTS
SP 170 - I
3. Wire Speed Control — Controls the
wire feed speed from 50 – 400
in/min (1.3 – 10.2 m/min). The con-
FIGURE B.1b
WIRE SPEED
trol can be preset on the dial to the
5
setting specified on the SP 170-I
Application Chart located on the
inside of the wire feed section door.
6
4. Temperature Light — Indicates
thermostat has cut the output. The
fan will be running. Thermostat
resets automatically.
+
-
FIGURE B.1a
5. Circuit Breaker – Protects machine from damage if maxi-
mum output is exceeded. Button will extend out when
tripped (Manual reset).
FIGURE B.1c
SP 170-I
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B-3
B-3
OPERATION
FIGURE B.3
WELDING OPERATIONS
SEQUENCE OF OPERATION
Wire Loading
Refer to Figures B.2 and B.3.
4" Wire Spool
Wire Spindle Shaft
The machine power switch should be turned to the
OFF (“O”) position before working inside the wire feed
enclosure.
The welder is shipped from the factory ready to feed
8" (200 mm) diameter spools with 2.2" (56 mm) maxi-
mum width. These spools fit on a 2" (51 mm) diameter
spindle that has a built in, adjustable friction brake to
prevent overrun of the spool and excess slack in the
wire.
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.
Wing Nut
and Spacer
To Wire Drive
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.
FIGURE B.2
Note: When properly adjusted, the brake should pro-
vide only enough drag to prevent overrun of the spool
and excess slack in the wire. Too much drag may
result in wire feeding problems, and may cause pre-
mature wear of wire drive system components.
Wire Spool Spindle
8” Wire Spool
Be sure that this stud engages
the hole in the wire spool.
To Wire Drive
Wire Spool must be pushed all the way on the spindle so that the
spindle’s tab will hold it in place. The Wire Spool will rotate clock-
wise when wire is dereeled.
Load an 8” (200 mm) diameter spool on the wire spool
spindle shown in Figure B.2.
To use 4” (100 mm) diameter spools, the 2” (50 mm)
diameter spindle must be removed (See Figure B.3).
Remove the wing nut and spacer at the end of the
shaft and remove the outside plastic wire spool spin-
dle. The spindle can be stored in the wire feed com-
partment. A 4” (100 mm) diameter spool is mounted
directly on the 5/8” (16 mm) diameter shaft and held in
place with the previously removed hardware. Also
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.
SP 170-I
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B-4
B-4
OPERATION
Refer to Figure B.4
1. Release the Spring Loaded Pressure Arm (1)
rotate the Idle Roll Arm (2) away from the Wire
Feed Drive Roll (3). Ensure that the groove size
in the feeding position on the drive roll match-
es the wire size being used. This occurs when
the desired groove is located on the inside, toward
the feedplate. See Maintenance section for further
information.
2
1
2. Carefully detach the end of the wire from the
spool. To prevent the spool from unwinding, main-
tain tension on the wire until after step 5.
4
5
3
The Wire Drive Feed Roll can
accommodate two wire sizes by
flipping the wire drive feed roll
over.
3. Cut the bent portion of wire off and straighten the
first 4” (100 mm).
4. Thread the wire through the ingoing guide tube
(4), over the drive roll (3), and into the outgoing
guide tube (5). Check the alignment of the wire
over the drive roll groove and adjust if necessary.
If alignment adjustment is necessary use the allen
wrench provided to loosen the drive roll, move it to
the desired position and then retighten.
FIGURE B.4
7. Refer to Figure B.5. Remove gas nozzle and con-
tact tip from end of gun.
5. Close the idle roll arm (2) and latch the spring
loaded pressure arm (1) in place. Rotate the spool
counterclockwise if required to take up extra slack
in the wire.
Gun Handle
Gas Diffuser
Contact Tip
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.
Gas Nozzle
FIGURE B.5
8. Turn the SP 170-I ON (“I”).
9. Straighten the gun cable assembly.
10. Depress the gun trigger switch and feed welding
wire through the gun and cable. (Point gun away
from yourself and others while feeding wire.)
Release gun trigger after wire appears at end of
gun.
WARNING
When inching the welding wire, the drive rolls, the
gun connector block and the gun contact tip are
electrically energized relative to work and ground
and remain energized for several seconds after
the gun trigger is released.
11. Turn the SP 170-I OFF (“O”).
12. Replace contact tip and gas nozzle.
13. Refer to Figure B-6. Cut the wire off 1/4” – 3/8” (6
– 10 mm) from the end of the tip. The SP 170-I is
now ready to weld.
SP 170-I
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B-5
B-5
OPERATION
Contact Tip
GUN CABLE
Wire Electrode
3/8" – 1/2" Electrical Stickout
WORKPIECE
ARC
FIGURE B.6
Making A Weld
WORK CLAMP
1. See “Process Guidelines” in this section for selec-
tion of welding wire and shielding gas and for
range of metal thicknesses that can be welded.
FIGURE B.7
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 170-I.
2. See the Application chart on the inside of the wire
feed compartment door for information on setting
the SP 170-I controls. Refer to Table B.1 for alu-
minum and stainless wire.
Cleaning Tip And Nozzle
Clean the contact tip and nozzle to avoid arc bridging
between the nozzle and contact tip which can result in
a shorted nozzle, poor welds and an overheated gun.
Hint: Anti-stick spray or gel, available from a welding
supply distributor, may reduce buildup and aid in spat-
ter removal.
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, refer to
3. Applications chart on the inside of the wire drive
compartment door.
4. Check that the polarity is correct for the welding
wire being used and that the gas supply, if
required, is turned on.
PROCESS GUIDELINES
The SP 170-I can be used for welding mild steel,
stainless steel and aluminum using the MIG process
and also for welding mild steel with the gasless self-
shielded, Innershield® process (FCAW).
5. When using Innershield electrode, remove the gas
nozzle and install a gasless nozzle (optional). This
will improve visibility of the arc and protect the gas
diffuser from weld spatter. Refer to the MAINTE-
NANCE section for details on nozzle replacement.
The recommended gases and electrodes for MIG
(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) and .030” (0.8mm) diameter
Lincoln L-56 mild-steel welding wire, supplied on 12-
1/2 lb (5.7 kg) spools. The blended gas is recom-
mended for welding on heavier steel, 14 gauge (2.0
mm), for example.
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.
7. Position gun over joint. End of wire may be lightly
touching the work.
The recommended electrode for the self-shielded
process is Lincoln Innershield® NR-211-MP on 10 lb
(4.5 kg) spools. This electrode is available as .035"
(0.9 mm) and .045" (1.2 mm) NR-211-MP for all posi-
tion welding of 18 gauge (1.2 mm) through 5/16" (8.0
mm) steel. Thickness of 1/4" (6.4 mm) and 5/16" (7.9
mm) require multiple passes. both wire sizes can also
be used for the welding of galvanized coated sheet
metal.
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).
9. To stop welding, release the gun trigger and then
pull the gun away from the work after the arc goes
out.
SP 170-I
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B-6
B-6
OPERATION
The SP 170-I is suitable for .035" (0.9 mm) aluminum
wire and .023"– .035" (0.6 - 0.9 mm) stainless wire.
Refer to Table B.1 for recommended procedure set-
tings. (Requires K499 Argon regulator kit and K664-1
Aluminum - Stainless Feeding Kit.)
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.
3. Keep the cylinder valve closed, except when using
the SP 170-I. When finished welding:
CAUTION
a) Close the cylinder valve to stop gas flow.
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.
b) Depress the gun trigger briefly to release the
pressure in the gas hose.
c) Turn off the SP 170-I.
------------------------------------------------------------------------
TABLE B.1 — SP 170-I
WELDING PROCEDURES
WELDING WITH FCAW (Innershield)
Voltage/Wire Speed
Shielding
Process
Welding Wire
Gas
1.6mm 2.0mm 2.5mm 3.5mm 5.0mm
When using the FCAW process, the correct drive roll
and electrode polarity must be used. See Work Cable
Installation in INSTALLATION section for changing the
polarity.
MIG DC+ .035 Dia (0.9mm) 100% Argon A-5 B6.5 C-8
D-8.5 E-10
4043/5356
Aluminum Wire
MIG DC+ .023 Dia (0.6mm) 98% Argon/ A-4 B-6
C-8
—
—
308L Stainless
Steel Wire
2% Oxygen
MIG DC+ .030 Dia (0.8mm) 98% Argon/ B-3.5 C-6.5 D-7
E-8 E-9
E-8 E-8
Innershield welding kits K549-1 (for .035") and K549-2
(for .045") are also available.
308L Stainless
Steel Wire
2% Oxygen
MIG DC+ .035 Dia (0.9mm) 98% Argon/ B-2.5 C-4
D-6
308L Stainless
Steel Wire
2% Oxygen
OVERLOAD PROTECTION
Output Overload
CHANGING MACHINE OVER TO
FEED OTHER WIRE SIZES
The SP 170-I is equipped with a circuit breaker which
protects the machine from damage if a severe over-
load occurs. The circuit breaker button will extend out
when tripped. The circuit breaker must be manually
reset.
The SP 170-I is shipped from the factory ready to feed
0.030" (0.8 mm) diameter wire. To operate the SP
170-I with other sizes of wire, it is necessary 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 MAINTENANCE sec-
tion, for specific information on these procedures.
Thermal Protection
The SP 170-I has a rated output duty cycle of 20%. If
the duty cycle is exceeded, a thermal protector will
shut off the output until the machine cools to a reason-
able operating temperature. This is an automatic func-
tion of the SP 170-I and does not require user inter-
vention. The fan continues to run during cooling.
WELDING WITH GMAW (MIG)
Shielding Gas
Electronic Wire Drive Motor Protection
The SP 170-I has built-in protection for wire drive
motor overload.
When using the GMAW process, obtain and install a
gas regulator and hose kit K463 (for CO2) or a K499
(Argon-mixed) gas regulator and hose kit.
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.
SP 170-I
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B-7
B-7
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 triggers 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 quali-
ty 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.
Electronic Components
Burning of core materials
inside wire electrode
results in shield of gas.
Cored Wire
Protective Slag
Arc Stream
Weld Metal
FIGURE B.9
Hinges
Bearings
FIGURE B.8
SP 170-I
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B-8
B-8
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
electrode
Shielding gas
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:
For GMAW (MIG) Process
1. Is most of my welding performed on 16 gauge and
lighter materials?
SP 170-I
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B-9
B-9
LEARNING TO WELD
2. Can I afford the extra expense, space, and lack of
portability required for gas cylinders and gas sup-
ply?
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.
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.
Of these, the Butt Weld and Fillet Weld are the two
most common welds.
For FCAW (Innershield) Process
1. Do I want simplicity and portability?
Butt weld
Lap weld
2. Will welding be performed outdoors or under windy
conditions?
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?
Edge weld
Fillet weld
Corner weld
5. Weld must be cleaned prior to painting.
FIGURE B.11
COMMON METALS
Butt Welds
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”.
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.
Securely clamp or tack weld the plates at both ends,
otherwise the heat will cause the plates to move apart.
See Figure B.12.
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-10
B-10
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
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.
FIGURE B.14
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-11
B-11
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.11 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-12
B-12
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-13
B-13
LEARNING TO WELD
Helpful Hints
For the SP 170-I, use the following:
Mild Steel
Electrode
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)
0.035" (0.9 mm)
NR-211-MP
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.
Innershield Wire
Voltage Setting “V”
A
Wire Feed Speed “o|o”
1.5
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-14
B-14
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-15
B-15
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
2. Correct way to strike an arc
3. Correct electrical stickout
4. Correct welding speed
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.
is to perform the following exercise.
4. The Correct Welding Speed
For the SP 170-I, use the following:
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”
C
4
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-16
B-16
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
SP 170-I
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B-17
B-17
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-18
B-18
APPLICATION CHART
I - 0 7 S P 1 2 7 3 L 1 0
SP-170-I
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C-1
C-1
ACCESSORIES
4. K464 .035" (0.9 mm) Innershield® Welding Kit
— Includes a contact tip, a gasless nozzle and a
.035/.045" (0.9/1.2 mm) cable liner to permit the
gun and cable to use .035" (0.9 mm) diameter flux-
cored electrode. The fitting on the end of the liner
is stenciled with the maximum rated wire size
(.045"/1.2 mm). Also included is a 10 lb.(4.5 kg.)
spool of .035" (0.9 mm) Innershield® NR-211-MP.
OPTIONAL ACCESSORIES
See Maintenance section for instructions on
installing drive roll, cable liner, contact tip and their
proper configuration.
1. KP665-045C Drive Roll – Optional — Knurled
drive roll for feeding .035 - .045” (0.9 - 1.2 mm)
diameter flux-cored electrode.
For use with “Lincoln Electric®” gun (with black
trigger). The end of the brass fitting on the end of
the .035/.045” (0.9/1.2mm) liner is color coded
green. (The .023-.030” (0.6-0.8mm) liner is color
coded orange).
2. K695-1 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.
See “Innershield (FCAW) Conversion” in this sec-
tion for installation instructions and MAINTE-
NANCE section for proper feeding component con-
figuration and installation.
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 (M17920) included with the
kit.
5. K491 .045" (1.2 mm) Innershield® Welding Kit
— Includes a contact tip, a gasless nozzle and a
.035/.045" (0.9/1.2 mm) cable liner to permit the
gun and cable to use .045" (1.2 mm) diameter flux-
cored electrode. The fitting on the end of the liner
is stenciled with the maximum rated wire size
(.045"/1.2 mm). Also included is a 10 lb.(4.5 kg.)
spool of .045" (1.2 mm) Innershield® NR-211-MP
and a knurled drive roll for .035” (0.9mm) and .045”
(1.2mm) wire.
3. 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.
For use with “Lincoln Electric®” gun (with black
trigger). The end of the brass fitting on the end of
the .035/.045” (0.9/1.2mm) liner is color coded
green. (The .023-.030” (0.6-0.8mm) liner is color
coded orange).
See “Innershield (FCAW) Conversion” in this sec-
tion for installation instructions and MAINTE-
NANCE section for proper feeding component con-
figuration and installation.
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C-2
C-2
ACCESSORIES
INNERSHIELD (FCAW)
CONVERSION
REPLACEMENT PARTS
Complete Gun and Cable Assembly (Code 10488
Several changes are needed to convert the unit for
operation with the Innershield (FCAW) process. The
following conversions should be reviewed before
welding with (FCAW):
and 10489 only)
L10738
Complete Gun and Cable Assembly (Code 10490
and above only)
1. Change the output polarity to DC(–). See “Work
L10744
Cable Installation” in Installation section for details.
Contact Tip .025” (0.6 mm)
2. Install proper drive roll for the wire size selected.
See “Changing Drive Roll” in Maintenance section
for details.
S18704-1
Contact Tip .030” (0.8 mm)
S18704-2
3. Install the proper gun liner and tip for the wire size
selected. See “Component Replacement” in
Maintenance section for details.
Contact Tip .035” (0.9 mm)
S18704-3
4. Remove gas nozzle (if installed) and install gasless
nozzle.
Contact Tip .045” (1.2 mm)
S18704-13
5. Load wire into machine and thread into gun and
Liner .023 - .030” (0.6 - 0.8 mm)
S18704-4 (Color coded Orange)
cable per “Welding Wire Loading” section.
Liner .035/.045” (0.9/1.2 mm)
S18704-5 (Color coded Green)
Liner for Aluminum .040 (1.0 mm)
S18704-17 (Color coded Black)
Gas Diffuser
S18704-6
Gas Nozzle
S18704-7
Gasless Nozzle (Innershield Only)
S18704-14
SP 170-I
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D-1
D-1
MAINTENANCE
MAINTENANCE
SAFETY PRECAUTIONS
WARNING
ELECTRIC SHOCK can kill.
• Disconnect input power by removing plug
from receptacle before working inside
SP170-I. Use only grounded receptacle. Do
not touch electrically “hot” parts inside
SP 170-I.
• Have qualified personnel do the mainte-
nance and trouble shooting work.
ROUTINE MAINTENANCE
POWER SOURCE COMPARTMENT
In extremely dusty locations, dirt may clog the air passages
causing the welder to run hot. Blow dirt out of the welder with
low pressure air at regular intervals to eliminate excessive dirt
and dust build-up on interval parts.
WIRE FEED COMPARTMENT
1. When necessary, vacuum accumulated dirt from gearbox and
wire feed section.
2. Occasionally inspect the incoming guide tube and clean
inside diameter if necessary.
3. Motor and gearbox have lifetime lubrication and require no
maintenance.
FAN MOTOR
Has lifetime lubrication — requires no maintenance.
WIRE REEL SPINDLE
Requires no maintenance. Do not lubricate shaft.
SP 170-I
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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
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
S18704-2 (Installed)
S18704-5
KP665-035
SP 170-Iº
.030” (0.8mm)
.035”-.045”
(0.9-1.2mm)
2 Smooth grooves
Small .025” (0.6mm)
Large .030” (0.8mm)
Components shipped with
S18704-13
S18704-17
KP665-045C
UWW-170•
.045” (1.2mm)
.040” (1.0mm)
For Aluminum
2 Knurled grooves
Small .035” (0.9mm)
Large .045” (1.2mm)
º If other size wire feeding is desired use the additional Contact Tips shipped loose with your SP 170-I.
• 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.
SP-170-I
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D-3
D-3
MAINTENANCE
6. Loosen the drive roll set screw with the 5/64" (2.0
mm) hex wrench supplied.
COMPONENT
REPLACEMENT
PROCEDURES
7. Remove the drive roll, flip over and reinstall with the
.023/.025" (0.6mm) groove (the smaller groove)
closest to the gearbox.
CHANGING THE CONTACT TIP (These
instructions pertain to the Lincoln Electric® gun having
a black trigger. The instructions for the Magnum™
100L gun, having a red trigger, are similar except that
the gas nozzle and contact tip are both threaded.)
8. Push a length of straightened welding wire through
the wire feeder guide tubes and adjust the position
of the drive roll so that the groove is centered on
the wire. Make certain the set screw is located on
the flat portion of the shaft and tighten.
1. Refer to Figure D.2a or D.2b. Remove the gas noz-
zle from the gun by pulling it off the diffuser.
(Threadless slip fit).
2. Remove the existing contact tip from the gun by
gripping it with pliers and twisting counter-clock-
wise. Tip will now slip out of diffuser.
3. Insert new tip into diffuser. Grip it with pliers, push
tip into diffuser until it bottoms, then twist clockwise
to tighten (cam-lock).
3
4. Replace gas nozzle.
2
CHANGING DRIVE ROLL (SP 170-I only)
1
The drive roll 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 .030"-.035" (0.8/0.9mm) position.
FIGURE D.1
If .023"/.025" (0.6mm) wire is to be used, the drive roll
must be reversed as follows:
CHANGING DRIVE ROLL (UWW-170 only)
1. Connect the machine to its rated input power per
instructions in Installation section.
The UWW-170 has dual knurled grooves of the same
size; either capable of feeding .035/.045 (0.9/1.2mm)
wire. When a groove becomes worn, use the above
procedure to flip the roll to the unused groove.
2. Release the spring-loaded pressure arm and lift the
idle roll arm away from the drive roll.
3. Turn the power switch to ON (marked “I”).
4. Set the wire speed to minimum and jog the drive
unit with the trigger switch until the drive roll set
screw is facing up.
CAUTION
When inching the welding wire, the drive rolls,
gun connector block, and gun contact tip are
energized relative to work and ground and remain
energized for several seconds after the gun trig-
ger is released.
5. Turn the power switch to OFF (marked “O”).
SP 170-I
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D-4
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 require-
ment. Refer to Figure D.2a or D.2b.
5/8” (15.9 mm)
Liner Trim Length
Gas Diffuser
1. Remove the gas nozzle from the gun
(threadless slip-fit or threaded).
Contact Tip
(Cam-Lock)
Slotted
Set Screw
Brass Cable
Connector
2. Remove the existing contact tip from the
gun by twisting counter-clockwise (cam-
lock) or unscrewing (threaded).
Gas Nozzle or
Gasless Nozzle
(Slip-Fit)
3. Remove the gas diffuser from the gun
tube by unscrewing counter-clockwise.
Liner Assembly
(Liner bushing to be seated tight
against brass cable connector)
4. Lay the gun and cable out straight on a
flat surface. Loosen the set screw located
in the brass connector at the wire feeder
end of the cable. Pull the liner out of the
cable.
FIGURE D.2a
Liner trim length for gun with black trigger (Lincoln Electric®)
5. Insert a new untrimmed liner into the con-
nector end of the cable. Be sure the liner
bushing is stenciled appropriately for the
wire size being used.
6. Fully seat the liner bushing into the con-
nector. Tighten the set screw on the brass
cable connector. At this time, the gas dif-
fuser should not be installed onto the end
of the gun tube.
1-1/4 (31.8 mm)
Liner Trim Length
Gas Diffuser
Slotted
Brass Cable
Connector
Contact Tip
(Threaded)
7. 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.2a or D.2b.
Remove any burrs from the end of the
liner.
Set Screw
Gas Nozzle or
Gasless Nozzle
(Threaded)
Liner Assembly
(Liner bushing to be seated tight
against brass cable connector)
8. Screw the gas diffuser onto the end of the
gun tube and securely tighten.
FIGURE D.2b
Liner trim length for gun with red trigger (Magnum™ 100L)
9. Replace the contact tip and nozzle.
SP 170-I
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D-5
D-5
MAINTENANCE
GUN HANDLE PARTS (red trigger)
GUN HANDLE PARTS (black trigger)
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-4.
The gun handle consists of two halves that are held
together with a C-clip (located at the cable end of the
gun). To open up the gun handle assembly, remove
the C-clip and pry down the trigger handle half with a
screwdriver. See Figure D.3.
Screwdriver
C-clip
Counter-clockwise
Cable
FIGURE D.3
FIGURE D.4
SP 170-I
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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 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 170-I
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E-2
E-2
TROUBLESHOOTING
Observe Safety Guidelines detailed in the beginning of this manual.
PROBLEMS
(SYMPTOMS)
POSSIBLE AREAS OF
MISADJUSTMENT(S)
RECOMMENDED
COURSE OF ACTION
OUTPUT PROBLEMS
Major physical or electrical damage None
is evident.
Contact your local 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. See
Installation section, “Electrical
Connections”.
2. Make certain that power switch
is in the ON position.
Contact your local Lincoln
3. Make sure circuit breaker inside
wire drive compartment is reset.
Authorized Field Service Facility.
No wire feed, weld output or gas
flow when gun trigger is pulled Fan
operates normally.
1. The thermostat may be tripped
due to overheating. Let machine
cool. Weld at lower duty cycle.
2. Check for obstructions in air
flow.
3. Check Gun Trigger connections.
See Installation section.
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 170-I
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E-3
E-3
TROUBLESHOOTING
Observe Safety Guidelines detailed in the beginning of this manual.
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 (33 VDC maximum) – weld
output.
1. 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.
2. Check for clogged cable liner or
contact tip.
3. Check for proper size cable liner
and contact tip.
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.
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 170-I
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E-4
E-4
TROUBLESHOOTING
Observe Safety Guidelines detailed in the beginning of this manual.
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. See Installation sec-
tion, “Electrical Input
Connections”.
2. Check for proper electrode
polarity for process.
3. Check gun tip for wear or dam-
age and proper size – Replace.
Contact your local Lincoln
4. Check for proper gas and flow
rate for process. (For MIG only.)
Authorized Field Service Facility.
5. Check work cable for loose or
faulty connections.
6. Check gun for damage or
breaks.
7. Check for proper drive roll orien-
tation and alignment.
8. Check liner for proper size.
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-170-I
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F-1
F-1
WIRING DIAGRAMS
WIRING DIAGRAM:
SP-170-I
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NOTES
SP 170-I
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Now Available...12th Edition
New Lessons in Arc Welding
The Procedure Handbook of Arc Welding
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The book contains the latest information and application
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For details write:
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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
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Lincoln Welding School
BASIC COURSE
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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
● Protéjase los ojos, los oídos y el
bajo carga con la piel o ropa moja-
da.
● Aislese del trabajo y de la tierra.
fuera del área de trabajo.
cuerpo.
AVISO DE
PRECAUCION
French
● Ne laissez ni la peau ni des vête-
ments mouillés entrer en contact
avec des pièces sous tension.
● Gardez à l’écart de tout matériel
inflammable.
● Protégez vos yeux, vos oreilles et
votre corps.
ATTENTION
● Isolez-vous du travail et de la terre.
German
● Berühren Sie keine stromführenden
Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!
● Isolieren Sie sich von den
● Entfernen Sie brennbarres Material! ● Tragen Sie Augen-, Ohren- und Kör-
perschutz!
WARNUNG
Elektroden und dem Erdboden!
Portuguese
● Não toque partes elétricas e elec-
trodos com a pele ou roupa molha-
da.
● Mantenha inflamáveis bem guarda- ● Use proteção para a vista, ouvido e
dos.
corpo.
ATENÇÃO
● Isole-se da peça 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-
piración.
● Mantenga la cabeza fuera de los
humos. Utilice ventilación o
aspiración para gases.
● Desconectar el cable de ali-
mentación de poder de la máquina
antes de iniciar cualquier servicio.
● No operar con panel abierto o
guardas quitadas.
AVISO DE
PRECAUCION
French
● Débranchez le courant avant l’entre- ● N’opérez pas avec les panneaux
tien.
● Gardez la tête à l’écart des fumées.
● Utilisez un ventilateur ou un aspira-
teur pour ôter les fumées des zones
de travail.
ouverts ou avec les dispositifs de
protection enlevés.
ATTENTION
German
● Strom vor Wartungsarbeiten
abschalten! (Netzstrom völlig öff-
nen; Maschine anhalten!)
● Anlage nie ohne Schutzgehäuse
oder Innenschutzverkleidung in
Betrieb setzen!
● Vermeiden Sie das Einatmen von
Schweibrauch!
● Sorgen Sie für gute Be- und
Entlüftung des Arbeitsplatzes!
WARNUNG
Portuguese
● Não opere com as tampas removidas.
● Desligue a corrente antes de fazer
serviço.
● Mantenha-se afastado das partes
moventes.
● Não opere com os paineis abertos
ou guardas removidas.
● Mantenha seu rosto da fumaça.
● Use ventilação e exhaustão para
remover fumo da zona respiratória.
ATENÇÃO
● Não toque as partes elétricas nuas.
Japanese
Chinese
Korean
Arabic
LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA 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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