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OWNER'S MANUAL
FM140A MIG COMBINATION UNIT
THE FM140A
REPRESENTS THE LATEST TECHNOLOGY
IN MIG COMBINATION UNITS. THE FM140A OPERATES
ON 115VOLT AC SINGLE PHASE CURRENT, AND FEATURES
"SMOOTH ARC" TRANSFORMER DESIGN CONCEPT.
FOR TECHNICAL SERVICE, CALL TOLL-FREE 1-800-232-9353
PROVIDE MODEL & SERIAL NUMBER
FORM WC5357
INSTALLATION
OPERATION
MAINTENANCE
Rev. 3/98, 8/00,8/02
MANUFACTURER’S LIMITED WARRANTY
This equipment is warranted against defects in materials and workmanship for a period of two years from the date of purchase.
EXCEPTION: THE MIG TORCH IS WARRANTED FOR A
PERIOD OF 30 DAYS FROM THE DATE OF PURCHASE.
Should the equipment become defective for such reason, the Manufacturer will repair it without charge, if it is returned to the Manufacturer’s factory, freight prepaid. This warranty does not cover: (1) failure due to normal wear and tear; (2) consumable parts, such as, but not limited to, torch contact tips, gas cups and insulating bushings; (3) damage by accident, force majeure, improper use, neglect, unauthorized repair or alteration; (4) anyone other than the original purchaser.
THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHER
WARRANTIES, EXPRESS OR IMPLIED. THE MANUFAC-
TURER SHALL NOT BE LIABLE FOR ANY INJURY TO
PERSONS, INCLUDING DEATH; OR LOSS OR DAMAGE
TO ANY PROPERTY, DIRECT OR CONSEQUENTIAL,
INCLUDING, BUT NOT LIMITED TO, LOSS OF USE,
ARISING OUT OF THE USE, OR THE INABILITY TO USE,
THE PRODUCT. THE USER ASSUMES ALL RISK AND
LIABILITY WHATSOEVER IN CONNECTION WITH THE
USE OF THE PRODUCT, AND BEFORE DOING SO,
SHALL DETERMINE ITS SUITABILITY FOR HIS IN-
TENDED USE, AND SHALL ASCERTAIN THE PROPER
METHOD OF USING IT.
SOME STATES DO NOT ALLOW LIMITATIONS ON
HOW LONG AN IMPLIED WARRANTY LASTS, OR THE
EXCLUSIONS OR LIMITATIONS OF INCIDENTAL OR
CONSEQUENTIAL DAMAGES. SO THE ABOVE LIMITA-
TIONS OR EXCLUSIONS MAY NOT APPLY TO YOU. THIS
WARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, AND
YOU MAY HAVE OTHER RIGHTS WHICH MAY VARY
FROM STATE TO STATE.
!
WARNING
ARC WELDING CAN BE INJURIOUS TO OPERA-
TOR AND PERSONS IN THE WORK AREA -——
CONSULT INSTRUCTION MANUAL BEFORE
OPERATING.
ELECTRIC SHOCK can kill.
• Do not touch electrodes or other electrically live parts.
• Insulate yourself from work and ground.
• Install and ground machine in accordance with the National
Electical Code and local code(s). Read Operating Manual before installing or operating.
• Do not operate with protective covers, panels, or guard removed.
• Disconnect input power before servicing.
• Only qualified personnel should install, use, or service this equipment.
ARC RAYS can injure your eyes and burn skin.
• Wear correct eye, ear, and body protection while welding.
FUMES AND GASES can be dangerous to your health.
• Use enough ventilation and/or exhaust at the arc.
• Keep your head out of fumes.
• Do not breathe fumes.
READ AND UNDERSTAND THE
MANUFACTURER’S INSTRUCTIONS AND
YOUR EMPLOYER’S SAFETY PRACTICES.
See American National Standard Z49.1, “Safety in
Welding and Cutting”, published by the American
Welding Society, 2501 N.W. 7th St., Miami, Florida
33125; OSHA Safety and Health Standards, 29 CFR
1910 available from U.S. Dept. of Labor, Wash.,
D.C. 20210.
TABLE OF CONTENTS
ELECTRICAL SUPPLY REQUIREMENTS.......................... 1
INTRODUCTION .................................................................. 2
SPECIFICATIONS ............................................................... 3
INSTALLATION ................................................................... 4
OPERATION ........................................................................ 7
MAINTENANCE ................................................................. 12
TROUBLE SHOOTING CHART ........................................ 14
CONNECTING TIGPAK OR SPOOL GUN ........................ 19
PARTS BREAKDOWN - MIG TORCH .............................. 21
OPTIONS - TIG PAK, SPOOL GUN .................................. 23
Snap-on Tools Corporation Kenosha, WI 53141-1410
ELECTRICAL SUPPLY REQUIREMENTS FOR THE FM140A
Ensure that there is a
115
volt single phase,
20
amp electrical supply within easy reach of the unit. The input cable supplied is 20 feet long. A 50 foot cable is an optional extra. The plug which is factory installed is suitable for use up to 120 amps of output. The plug must be changed if the welder is used above 120 amps of output. Attach a suitable plug making sure the green wire is attached to ground. Refer to boxes below with the WARNING and
NOTE headings for more information. All wiring should be performed by a qualified electrician.
WARNING
To conform to the National Electrical Code, the power input plug must be changed if this unit is to be operated on a 20 amp circuit or higher.
Never change fuses or circuit breakers to a higher value than the wires and outlet are designed for.
Breaker size -
15 Amp
20 Amp
30 Amp
Wire size
14 Gauge
12 Gauge
10 Gauge
Do not rely on the circuit breaker built into the FM140A to protect your wiring.
This circuit breaker protects the FM140A internal wiring only.
Do not use undersized extension cords. Follow the cord manufacturer's recommendations as to current carrying capacities.
Make sure all electrical wiring is installed by a qualified electrician.
NOTE
The maximum output of the FM140A will be limited by the size (amp rating) of the circuit used.
Operation on a 15 amp circuit (14 gauge wire) will limit maximum output to 100 amps.
Operation on a 20 amp circuit (12 gauge wire) will limit maximum output to 120 amps.
Operation on a 30 amp circuit (10 gauge wire) will result in maximum output of 140 amps.
FM140A output will be limited also by low input voltage (less than 120 volts), long input cords and use of extension cords.
Snap-on Tools Corporation Kenosha, WI 53141-1410 1
INTRODUCTION
The Snap-On Tools FM140A is a combination welding power source, wire feed unit, MIG torch and accessory package. It operates on
115 volts AC input current
and is designed to meet the requirements of auto body repair shops. The FM140A produces fusion welds by the Gas
Metal Arc Welding process (GMAW or
MIG), on steel up to 1/4" thick(aluminum 3/16") , using .023" through .045" steel wire and .025" through 3/64" aluminum wire with the optional MHG5-A.(Optional liners
and contact tips must be purchased
to cover given wire sizes). Heavier sections can be easily welded using slightly different techniques. Consumable MIG Spot Welding on steel can be performed with this unit.
The number of controls on the unit have been reduced to assist inexperienced operators learn MIG welding. This facilitates rapid set up for welding different thicknesses of material requiring various heat inputs. The HEAT (voltage) control adjusts the welding voltage and the
WIRE SPEED control adjusts the speed of the wire drive motor.
WIRE SPOOL
FEED
ROLLS
MIG
TORCH
POWER SOURCE
+
REVERSE
POLARITY
(STD.)
_
SHIELDING GAS
WORK
FIG. 1. SCHEMATIC OF MIG PROCESS
SHORT ARC OR DIP TRANSFER
Short arc transfer occurs at 12 to
22 arc volts (voltage while welding), depending on wire size. Welding commences as the arc is struck and a weld pool is formed. The tip of the electrode wire dips into the pool and causes a short circuit. The short circuit current flow causes a rapid temperature rise in the electrode wire and the end of the wire is melted off. An arc is immediately formed between the tip of the wire and the weld pool, maintaining the electrical circuit and producing sufficient heat to keep the weld pool fluid. The electrode continues to feed and again dips into the pool.
THE MIG PROCESS
AS APPLIED TO THE FM140A
The MIG process uses a bare, consumable electrode in the form of spooled wire, which is fed by a controllable speed feed unit through the cable and torch to the weld. The emerging wire and the weld are shielded by a stream of CO2, Argon, or a mixture of the two, which prevents oxidation of the molten weld puddle. The gas shield enables high quality welds to be made without the use of flux, eliminating the need for slag or flux removal after the weld is completed.
The consumable electrode wire is melted and transferred to the weld puddle by the "short arc" or "dip" transfer mode.
2
ELEC-
TRODE
WORK
FIGURE 2. SHORT ARC TRANSFER
This sequence of events is repeated up to 200 times per second.
Short arc transfer is suitable for positional welding. The heat input to the workpiece is kept to a minimum which limits distortion and makes possible the welding of thin sheet material.
Snap-on Tools Corporation Kenosha, WI 53141-1410
DESCRIPTION
The FM140A consists of a combination MIG welding power source and wire feed unit, a MIG torch with 10 foot cable, a fifteen foot work
(ground) cable with ground clamp, a twenty foot power input cable, a gas regulator/flowmeter, a torch accessory kit, and a built-in cylinder rack and industrial wheel kit.
Welder controls are simple and clearly marked. The output voltage is controlled by a twelve position tap switch, providing twelve voltage selections. Wire feed speed is controlled by the wire speed potentiometer.
A SPOT WELD control switch and adjustable timer circuit provide
Consumable MIG Spot Welding capabilities of light gauge steel.
SPECIFICATIONS
PART NUMBER: FM140A
INPUT POWER REQUIREMENTS:
Voltage
Phase
Frequency
Current
115 volts AC single phase
50/60 hertz
(see OUTPUT POWER)
SPECIFICATIONS (Cont.)
SPOT WELD TIME:
0 to 3 seconds
WIRE TYPES:
mild steel, stainless steel, aluminum, bronze, flux cored, flux cored gasless
Recommended (for steel) ER70S-6
WIRE SIZES:
.023" - .045" steel,
3/64" aluminum,
(.023" - 3/64" alum. w/ Spool Gun)
.030" - .035" bronze,
.030" - .045" flux cored
(gas shielded or gasless)
Recommended Size:Aluminum
Others
.035
.030
WIRE FEED SPEED RANGE:
10 - 500 inches per minute
SHIELDING GASES:
For Steel Argon/CO2 mix or CO2
Recommended(for steel) 75% Argon/
For Aluminum, Bronze
For Stainless Steel
25% CO2
Argon
98% Argon + 2% Oxygen
For Flux cored Argon/CO2 mix or
CO2
DIMENSIONS:
Height
Width
Depth
Weight
34 in. (86.4 cm.)
14-1/2 in. (36.8 cm.)
23-1/2 in. (59.7 cm.)
105 lbs. (47.7 kg.)
OUTPUT POWER @ 100% Duty Cycle:
15 Amps Input Current = 100 Amps
20 Amps Input Current = 120 Amps
30 Amps Input Current = 140 Amps
DUTY CYCLE TIME PERIOD:
10 minutes
OPEN CIRCUIT VOLTAGE:
18 - 30 volts DC
ARC VOLTAGE:
14 - 26 volts DC
WELD CURRENT RANGE:
30 - 140 amps
DUTY CYCLE - SPOT WELDING:
30 X 2 second spots per 10 minute period
TORCH SPECIFICATIONS
NECK ANGLE:
LEAD LENGTH:
Snap-on Tools Corporation Kenosha, WI 53141-1410
60 degrees
10 feet
OVERALL LENGTH:
10 feet
COOLING METHOD:
gas (air)
RATING - 60% DUTY CYCLE:
With Argon/CO2 gas
With CO2 gas
200 amps
225 amps
3
CHECK LIST
THE SNAP-ON TOOLS FM140A INCLUDES
THE FOLLOWING:
1- Combination Power Source/Wire
Feeder
1- Cylinder Rack/Industrial Wheel
Kit
1- 15TG10 MIG Torch with adjustable nozzle
1- 20 foot Power Input Cable with
Plug
1- 15 foot Work(Ground)Cable and
Clamp
1- 200PK-1 Parts Kit
1- GR-FM Gas Regulator/Flowmeter
1- Nozzle, 1/2 in. orifice (installed on MIG torch)
1- Contact Tip, for .030 in. wire
(installed on MIG torch)
1- ER70S-6-30-3, Sample Spool of
.030" Steel Wire
ITEMS REQUIRED FOR MIG WELDING WHICH
ARE NOT PROVIDED WITH THE FM140A
1. Full cover welding helmet with proper colored lens (shade 9 to
11 depending on operator’s preference).
2. Proper shielding gas and cylinder.
3. Leather welding gloves.
4. 115 volt single phase AC power.
5. Other personal protective equipment which may vary to match the welding being performed.
ELECTRICAL SUPPLY
Follow the Electrical Supply Requirements on page 1.
SHIELDING GAS CONNECTIONS
1. Place a cylinder of the appropriate shielding gas in the rack at the rear of the machine and secure it with the chain provided.
2. Rapidly open and close the cylinder valve. This will purge dust and foreign matter from the valve.
CAUTION
Take care to point the valve outlet away from yourself or other people, as escaping high pressure gas may be dangerous.
3. Attach the gas regulator/flowmeter supplied with this unit, to the cylinder valve using a suitable wrench.
NOTE
If this unit is to be used with 100% CO2 shielding gas, an optional gas regulator coupler is required.
INSTALLATION
GAS FLOW
ADJUSTING
KNOB
FLOW TUBE
INDICATES
FLOW RATE
IN C.F.H.
GAUGE -
INDICATES
TANK
PRESSURE
POSITIONING THE UNIT
4
Locate the unit near the welding area and position it so there is adequate clearance all around for ventilation and maintenance.
OUTLET
FITTING
TO
WELDING
MACHINE
FIG. 3. GAS FLOW ADJUSTMENT
INLET
FITTING
TO
TANK
Snap-on Tools Corporation Kenosha, WI 53141-1410
SHIELDING GAS CONNECTIONS(Cont.)
4. Fit the gas hose from the welding machine to the regulator outlet fitting and tighten it with a suitable wrench. Open the cylinder valve.
5. Check that the gas regulator is properly adjusted. When welding steel, the gas flow rate is 30
CFH. When welding aluminum, the gas flow rate is 40 CFH.
NOTE
The FM140A must be turned
"ON" and the MIG torch trigger depressed, before the gas flow rate can be adjusted.
FITTING AND THREADING THE ELEC-
TRODE WIRE - ALWAYS USE ER70S-6
WELDING WIRE
1. Remove the wire spool clip from the spool hub.
2. Unpack the spool of welding wire from its protective packaging.
3. Place the spool of ER70S-6 welding wire onto the hub. The wire is fed off the bottom of the spool.
CAUTION
Look for and remove any wire protruding from the center of the spool. The protruding wire is electrically HOT during welding and must not touch the machine.
TORCH CONNECTION
1. Open the access door of the machine to its fullest extent.
2. Back out the thumb screw located on the drive assembly mounting bracket inside the machine. Insert the MIG torch into the torch panel mount on the front panel and TIGHTEN THE THUMB SCREW.
4. Replace the spool clip on the hub.
5. Unlatch the pressure roll arm and swing it open.
6. Make sure the double v-groove drive roll is installed to match the wire size. To change the wire size setting, remove the drive roll, turn it over and reinstall it on the shaft.
TORCH
PANEL
MOUNT
MIG
TORCH
PRESSURE
ROLL
"A" SIDE FACING IN FOR
.023" - .035" STEEL WIRES
"B" SIDE FACING IN FOR
.040" - .045" STEEL WIRES
AND 3/64" ALUMINUM WIRES
THUMB
SCREW
DRIVE
ROLL
DRIVE
ASSEMBLY
FIG. 5. DOUBLE GROOVE DRIVE ROLL
FIGURE 4. TORCH CONNECTION
(continued on following page)
Snap-on Tools Corporation Kenosha, WI 53141-1410 5
FITTING AND THREADING THE ELEC-
TRODE WIRE (Continued)
7. Release the wire from the spool and trim off the kinked end with wire cutters. The wire must be straight when it enters the inlet guide.
8. Thread the electrode wire through the inlet guide, over the feed roll and into the torch liner.
Ensure that the wire locates in the feed roll groove. Do not allow the wire on the spool to loosen.
9. Close and relatch the pressure roll arm.
10.Stretch the torch cable straight out in front of the machine making sure there are no kinks.
Remove the nozzle and contact tip from the torch.
11.Turn "ON" the circuit breaker on the front of the machine. The cooling fan will start and the
"ON" indicator light will illuminate. Set the HEAT control switch to "4", the function switch to "CONTINUOUS WELD" and the WIRE SPEED control to "7".
Pull the trigger on the MIG torch. The wire feed system will start and wire will be fed through the cable liner and torch. If the wire does not feed, or appears to slip, tighten the pressure roll arm adjusting nut.
Feed the wire until it protrudes from the front of the torch approximately six inches.
CAUTION
Keep hands and face away from the front of the torch and do not allow the wire to contact ground. The wire is electrically HOT when the torch trigger is actuated.
FITTING AND THREADING THE ELEC-
TRODE WIRE (Continued)
12.Install the contact tip over the protruding wire and tighten it firmly using a proper size wrench.
Make sure the tip is the correct size for the wire being used.
13.Install the nozzle on the torch.
For steel, the contact tip should be flush or stick out up to 1/16 inch beyond the end of the nozzle. For aluminum, the contact tip should be recessed 1/8 to 1/4 inch inside the nozzle.
Using wire cutters, trim off the wire so the stickout is approximately 1/4 inch for steel or 1 inch for aluminum. For aluminum, the end of the wire should be bent over so it does not JAM into the work. This is called a
"scratch start".
1/4"
STICK-
OUT
FOR STEEL:
CONTACT TIP
FLUSH WITH NOZZLE
1"
STICK-OUT
FOR ALUMINUM:
CONTACT TIP
RECESSED 1/8" - 3/8"
FIGURE 6.
WIRE STICKOUT - STEEL, ALUMINUM
14.For steel welding only, spray anti-spatter compound inside the nozzle and on the outside of the contact tip. For aluminum or stainless steel welding, NO antispatter compound can be used as it will contaminate the weld.
6 Snap-on Tools Corporation Kenosha, WI 53141-1410
WIRE FEED PRESSURE ROLL ADJUSTMENT
The wire feed pressure roll is adjusted to the proper setting at the factory, prior to delivery. It may be necessary to readjust the setting as components "seat in" or when changing to a different diameter wire. To check for proper roll pressure, hold the torch in one hand and the wire between two fingers of the other hand.
Pull the torch trigger. If the wire continues to feed when firm pressure is applied to the wire, the pressure roll adjusting nut should be backed off until the feed rolls start to slip. If the wire will not feed with very little pressure applied, the pressure roll adjusting nut should be tightened.
PRESSURE ROLL
ADJUSTING NUT
PRESSURE
ROLL
PRESSURE
ROLL ARM
DRIVE
ROLL
FIGURE 7.
PRESSURE ROLL ADJUSTMENT
TORCH SELECTOR CABLE
Plug the torch selector cable into the Positive (+) terminal on the machine(see PROCESS SELECTION on page 8 for further details).
WORK (GROUND) CABLE
Uncoil the work cable and plug it into the negative (-) terminal on the machine.
OPERATION
The following operating instructions and detailed setup procedures enable an operator without previous experience to produce quality fusion welds. It is recommended that an operator without prior experience with this equipment, first practice on scrap metal of the same type and thickness as the material to be welded.
OPERATING SEQUENCE
1. Make sure that the pieces of metal to be welded are free of grease, dirt, paint and scale. Use a wire brush to remove paint and scale.
Paint must be completely removed to bare metal. Grease and oil could burn and cause a fire or safety hazard. Failure to clean the metal properly will result in erratic and porous welds.
2. Install the unit as directed in the installation instructions and make sure the work clamp is firmly attached to a cleaned area on the workpiece to be welded.
3. Open the shielding gas cylinder valve. Press the torch trigger and listen for gas flow. Adjust the gas flow rate to 30 CFH for steel and 40 CFH for aluminum.
CAUTION
The welding wire will feed when the trigger is actuated. Take care that the wire is not directed to hit yourself or anything that is grounded to the ground wire on the welder.
Snap-on Tools Corporation Kenosha, WI 53141-1410 7
PROCESS SELECTION
The following controls are located on the front of the machine.
A.
WIRE
SPEED
B.
"ON"
INDICATOR
LIGHT
C.
CIRCUIT
BREAKER
D.
(+)POSITIVE
TERMINAL
E.
(-)NEGATIVE
TERMINAL
F.
FUNCTION
SWITCH
G.
HEAT
(VOLTAGE)
CONTROL
H.
SPOT
TIMER
I.
TORCH
PANEL
MOUNT
J.
TORCH
SELECTOR
CABLE
FIGURE 8. FRONT PANEL
A. WIRE SPEED
Potentiometer controls speed of wire drive motor to give wire speed of 10 to 500 inches per minute.
B. "ON" INDICATOR LIGHT
Illuminates when the circuit breaker on the machine is "ON".
C. CIRCUIT BREAKER
Primary power switch and overload protection device.
D. +(POSITIVE) TERMINAL
Positive output terminal from the welder DC power source. The torch selector cable is plugged into this terminal for standard welding operation. The ground cable can be plugged into this terminal for straight polarity welding on very light sheet metal or for using flux cored gasless wire.
E. -(NEGATIVE) TERMINAL
Negative output terminal. The ground cable is plugged into this terminal during standard welding operation. The torch selector cable can be plugged into this terminal for straight polarity welding on very light sheet metal or for using flux cored gasless wire.
F. FUNCTION SWITCH
Controls mode of operation of welding machine. "CONT. WELD" position is for normal, continuous welding operation. "SPOT" position puts the spot timer in the circuit for automatic MIG
Consumable Spot Welding. "STITCH" position is used for stitch welding on very light material.
When in "STITCH" position, the length of time the welder is "ON" and feeding wire is controlled by the Spot Timer. The lower the
Spot Timer setting, the faster the welder cycles on and off.
G. HEAT (VOLTAGE) CONTROL
Twelve position switch adjusts welder output voltage.
H. SPOT TIMER (STITCH TIMER)
After the torch trigger is actuated, the timer allows the wire to feed and the gas and power to flow for the time selected. The
Function Switch must be set in the "SPOT" position (or the
"STITCH" position for stitch welding).
I. TORCH PANEL MOUNT
Combination power output, contactor switch connection, gas supply connection, and wire feed output in a single unit.
J. TORCH SELECTOR CABLE
Plugs into (+) positive terminal for standard welding operation or (-) negative terminal for straight polarity welding on very light sheet metal or for using flux cored gasless wire.
8 Snap-on Tools Corporation Kenosha, WI 53141-1410
WELDING
Optimum control settings will vary according to the thickness of the metal, the type of joint, operator preference, etc. Best results can be obtained through experience with the welding machine or by making trial welds. Select some sample material of the same type and thickness as the material to be welded. Set the welding controls for optimum results using the sample material and weld until experience is gained using the unit.
CONTINUOUS WELDING ON
STEEL
1. Trim the electrode wire to leave approximately 1/4 inch stickout beyond the end of the contact tip and install the welding nozzle.
The contact tip should be flush or stick out up to 1/16 inch beyond the end of the nozzle.
NOTE
When welding steel, the ideal position for holding the torch is inclined approximately 30 degrees towards the direction of travel. This allows the arc to be seen easily, resulting in greater control of the weld pool. Most right-handed weldors move from left to right.
This method, known as forehand welding, provides a gas shield for the cooling weld puddle and helps in obtaining an oxidation free weld deposit.
30 DEGREES
DIRECTION
OF TRAVEL
SHIELDING
GAS
NOZZLE
WORK
CONTACT TIP
(FLUSH TO
1/16" STICKOUT)
ELECTRODE WIRE
(1/4" STICKOUT)
FIGURE 9. NOZZLE ADJUSTMENT
FOR WELDING STEEL
2. Spray the inside of the nozzle and the outside of the contact tip with anti-spatter spray.
3. Locate the torch over the joint to be welded with the contact tip approximately 3/8 inch from the work surface.
FIGURE 10. TORCH POSITION
FOR WELDING STEEL
- RIGHTHANDED WELDOR
4. Use a welding helmet with a shade
9 to 11 filter lens, depending on operator preference.
5. Squeeze the torch trigger. The wire will feed and an arc will be established. As the weld is deposited, move the torch slowly along the weld seam at a constant speed, maintaining a constant arc length and a constant tip-to-work distance.
Snap-on Tools Corporation Kenosha, WI 53141-1410 9
CONTINUOUS WELDING
ON ALUMINUM
(Optional Nylon liner and 100% Argon shielding gas are required)
1. Trim the electrode wire, leaving approximately 1 inch stickout beyond the end of the nozzle.
Bend the wire over as shown, to allow for a scratch start. The contact tip should be recessed inside the nozzle approximately
3/8 inch. This helps prevent the welding wire from burning back to the contact tip.
10 DEGREES
SHIELDING GAS
DIRECTION
OF TRAVEL
WORK
NOZZLE
CONTACT TIP
(RECESSED 3/8")
ELECTRODE
WIRE
(1" STICKOUT)
FIGURE 11.
NOZZLE ADJUSTMENT
FOR WELDING ALUMINUM
2. DO NOT spray any anti-spatter material on the torch or base metal and DO NOT attempt to lubricate the aluminum wire in any way. Weld contamination will occur unless the wire, base metal, torch and work area are kept clean.
3. Bring the torch nozzle to 1/2 to
5/8 inch from the workpiece. The recommended position of the torch and direction of travel for welding aluminum are shown in
Figure 12.
FIGURE 12. TORCH POSITION
FOR WELDING ALUMINUM
4. Follow steps 4 and 5 as in
"Continuous Welding on Steel".
MIG SPOT WELDING ON STEEL
NOTE
MIG Spot Welding is NOT recommended for aluminum.
1. Trim the electrode wire so the stickout from the contact tip will be flush with the nozzle face, and fit the spot nozzle in place.
2. Set the HEAT control to "6", the
WIRE SPEED control to "8", the
Function Switch to "SPOT", and the TIME control to "2", then adjust the TIME control to obtain a perfect weld.
3. Locate the torch on the area to be welded and press the nozzle firmly against the work to hold the metals in place.
10 Snap-on Tools Corporation Kenosha, WI 53141-1410
MIG SPOT WELDING ON STEEL
(Continued)
4. Guard the eyes against stray arc flash. A weldor’s helmet is not necessary when spot welding.
However, care must be taken to avoid looking at the arc.
5. Actuate the torch trigger to start the weld sequence. When the timer switches off the weld current, release the trigger but maintain firm contact between the torch and work. Wait one second for the weld puddle to solidify, then move to the next spot position. If the wire freezes in the puddle, a quick squeeze of the torch trigger will melt it off.
SPOTWELD
NOZZLE
CONTACT
TIP
PRESS NOZZLE
FIRMLY
AGAINST WORK
STITCH WELDING ON STEEL
NOTE
Stitch Welding is used for very light material.
1. Set Function Switch to "STITCH".
2. Adjust the TIME control to set the time the welder is "on" and feeding wire. The lower the setting, the shorter the "on" time and the faster the unit cycles on and off.
3. Weld using "Continuous Welding" torch position and direction of travel.
30 DEGREES
DIRECTION
OF TRAVEL
SPOTWELD WORK
FIGURE 13. MIG SPOT WELDING
6. To ascertain a good spot weld, look at the back side of the welded material. A small meltthrough of approximately 1/16 inch diameter is ideal.
SHIELDING GAS
WORK
FIGURE 14. STITCH WELDING
Snap-on Tools Corporation Kenosha, WI 53141-1410 11
OPERATING HINTS
BURN BACK
In the event the welding wire burns back into the contact tip:
1. Remove the nozzle from the torch.
2. Unscrew the contact tip from the gas diffuser using a pair of pliers as the tip will be very hot.
3. Free the wire from the contact tip and clean the end of the tip so the new wire will slide smoothly through the hole. DO
NOT use a drill or reamer to clean the hole as that will enlarge it and cause an erratic arc. Replace the contact tip if it is badly damaged.
4. Install the contact tip in the torch and tighten it firmly with an appropriate wrench.
5. Reinstall the torch nozzle.
6. If the wire continues to burn back, check for erratic wire feed, or speed up the wire by increasing the WIRE SPEED control setting or reducing the
HEAT control setting.
SPATTER
Before beginning to weld and periodically during welding, the torch nozzle must be removed and the spatter (small globules of melted metal) cleared from the inside of the nozzle and the outside of the contact tip and the gas diffuser.
Spatter buildup between the contact tip and the nozzle can cause a short circuit and consequently, failure of the torch or welding machine. The frequent use of anti-spatter spray will help prevent the adherence of spatter to the torch components.
NOTE
DO NOT use any anti-spatter spray when welding aluminum or stainless steel.
Restricted gas flow, holding the torch too far from the work piece, and the use of CO2 gas rather than
75% Argon - 25% CO2 will increase the spatter levels.
MAINTENANCE
To ensure that this equipment maintains its operating efficiency, the following maintenance schedule and procedures are recommended.
These routines should be performed regularly by the operator.
REGULARLY - Usage and shop conditions determine frequency.
1. Remove and clean the torch nozzle and contact tip. The use of antispatter spray will reduce the adherence of spatter and makes its removal easier.
2. Blow out the torch liner prior to the installation of each new spool of wire. The contact tip and gas diffuser must be removed, but it is not necessary to remove the liner.
3. If the torch cable assembly is bent severely, a kink may develope in the steel liner. This can cause wire feeding problems so a new liner should be installed.
WEEKLY
1. Remove dirt and dust from the wire feed compartment. Use low pressure dry compressed air.
(continued on following page)
12 Snap-on Tools Corporation Kenosha, WI 53141-1410
MAINTENANCE (Cont.)
2. Remove dirt and metal deposits from the grooves in the feed roll. If the grooves are badly worn, the feed roll should be replaced. If the pressure roll does not turn freely, it should be replaced.
3. Check all gas fittings for leaks.
Tighten or repair as required.
EVERY SIX MONTHS
1. Disconnect the welder from its main power supply.
2. Remove the machine’s side panels.
3. Using low pressure dry compressed air, remove dust and dirt from all components.
4. Check for loose or frayed wiring. Particularly check welding current wire connections.
5. Replace the torch liner if necessary.
RECOMMENDED
CUSTOMER SPARE PARTS
The Snap-On Tools FM140A is a machine of proven design and reliability. Following is a list of consumable items recommended as spare parts for this unit.
contact tips ........ M3-T30, etc.
gas nozzles .............. M3T-N50 nozzle insulators .......... M3T-B gas diffusers .............. M3T-D steel liner(.020-.030) ... M103L-B steel liner(.035-.045) ... M104L-N
In the event of the failure of any part of this equipment, contact your
Snap-On Tools representative for replacement parts and service. When ordering parts from Snap-On Tools
Corporation, order numbers should be preceded by "CKS".
WARNING
DO NOT lift the unit when a gas cylinder is installed or attached.
DO NOT weld on any item that has a common electrical ground.
DO NOT operate the unit with the side panels removed. Overheating will occur.
DO NOT weld upon the case of the welding machine.
ONLY a qualified electrician should perform work inside the welding machine.
ALWAYS wear protective clothing, leather gloves and a full cover welding hood while welding.
DO NOT weld in a closed in area.
Proper ventilation is a necessity, or a fresh air supplied hood should be worn.
WHEN welding near combustibles, a helper or "watcher" should stand by with a fire extinguisher or other fire protective device.
NEVER weld on a closed vessel or one that has contained combustibles.
IF IN DOUBT - DON’T DO IT!
BE SAFE - DON’T BE SORRY!
Snap-on Tools Corporation Kenosha, WI 53141-1410 13
TROUBLE SHOOTING
(SYMBOL*)
FOR TECH. SERVICE, CALL TOLL-FREE 1-800-232-9353
The Trouble Shooting Chart is a guide in identifying and correcting possible troubles which may occur when operating this equipment.
FAULT POSSIBLE CAUSE REMEDY
Main power on, torch trigger activated, no response.
EQUIPMENT MALFUNCTION
No main power, fan does not operate,
"on" indicator
FM140A switch is "OFF".
Wall breaker is "tripped".
"Open" circuit breaker on FM140A.
(CB1)
(CB1) light is off.
Loose or broken connection in power input circuit.
Turn switch "on".
Reset wall breaker.
Reset or replace breaker.
Tighten or repair connection.
MIG torch unplugged.
Faulty trigger switch.
Fault in torch cable.
(S1)
Loose or broken connection on wiring harness.
Wire feed motor unplugged.
(RC1)
Faulty control transformer.
Check for 28VAC output.
(T2)
Loose spot timer circuit board.
(PC2)
Defective spot timer circuit board.
(CR2)(PC2)
Plug in MIG torch.
Replace micro switch.
Check torch cable for continuity.
Check or repair connections.
Plug in motor.
Install properly.
Replace board.
Main power on, torch trigger activated,
Pressure roll arm unlatched.
Latch arm & add tension.
"Slippage" at drive rolls.
Increase drive roll
Wire path restricted.
tension. See page 7.
Clean path or replace no wire feed but contactor 5 amp mini breaker is operates & gas flows.
tripped.
(CB2)
Wire feed circuit board needs calibrated.
torch liner.
Reset or replace breaker.
Calibrate wire feed circuit board. See page 18.
Replace circuit board.
Defective wire feed circuit board.
(PC1)
Faulty wire feed motor or connection.
(M)
Repair or replace faulty item.
Check motor on a
12VDC battery.
Faulty motor relay.
(CR1)
Sand points or replace relay.
Loose or broken connection.
Tighten or repair connection.
(SYMBOL*)
- USE THIS IDENTIFIER, ALONG WITH THE SCHEMATIC DIAGRAM FOUND IN THE SERVICE
MANUAL, FOR TROUBLE-SHOOTING PURPOSES.
14 Snap-on Tools Corporation Kenosha, WI 53141-1410
TROUBLE SHOOTING (Cont.)
(SYMBOL*)
FOR TECH. SERVICE, CALL 1-800-232-9353
FAULT POSSIBLE CAUSE
EQUIPMENT MALFUNCTION (Cont.)
REMEDY
Main power on, torch trigger activated, no welding current, but gas flows & wire feeds.
Loose torch thumb screw.
Tighten thumb screw.
Broken or loose connection.
Check cables for continuity.
Repair or tighten
Unplugged or faulty power contactor switch.
(W)
#1 Transformer wire off.
"Opened" thermal switch.
(W) connections.
Plug in or replace switch.
Reattach wire.
(TP1)
Faulty diodes.
(D1-D2)
Allow unit to cool, then retry.
Check diodes. See page
17.
Replace tank.
Torch trigger activated, no gas flow,
No shielding gas
- tank empty.
Loose or broken connections.
but contactor Faulty Gas solenoid operates & valve.
(GS) wire feeds.
Clogged gas flow path.
Loose spot timer circuit board.
(PC2)
Defective spot timer circuit board.
(CR2)(PC2)
Tighten or repair connections.
Repair or replace valve.
Locate & clean clog.
Install properly.
Replace board.
"Jerky" or
"slipping" wire feed.
FAULTY WELDS
Worn , kinked or dirty torch Clean or replace liner.
liner.
Wire spool turns too hard.
Lubricate spool hub with a dry lubricant
Worn double v-groove drive roll.
Weak pressure roll spring.
Worn or dirty contact tip.
Worn inlet guide(s).
Sticking pressure roll.
Replace drive roll.
Replace spring.
Replace contact tip.
Clean or replace guides.
Replace pressure roll.
Feed roll tension incorrect.
Adjust feed roll tension. See page 7.
(continued on following page)
Snap-on Tools Corporation Kenosha, WI 53141-1410 15
FAULT
"Birdnesting"
(Wire wrapping around drive rolls)
"Cold" weld puddle.
Heavy spatter.
Porous welds.
TROUBLE SHOOTING (Cont.)
(SYMBOL*)
FOR TECH. SERVICE, CALL TOLL-FREE 1-800-232-9353
POSSIBLE CAUSE
FAULTY WELDS (Cont.)
REMEDY
Excessive feed roll tension.
Reduce tension. See page
7.
Poor alignment.
Make sure wire is properly aligned
Oversize contact tip.
across roller.
Replace contact tip with correct size.
Incorrect machine settings.
Increase heat & wire speed.
Incorrect shielding gas.
Excessive wire stick-out.
Replace with proper gas.
Hold torch closer to
Poor connections.
Faulty diode.
(D1-D2) work.
Check and tighten all connections.
Test diodes, replace faulty diode(s). See page 17.
Incorrect machine settings.
Increase heat, decrease wire feed speed.
Incorrect shielding gas.
Excessive wire stick-out.
Replace with proper gas.
Hold torch closer to work.
No shielding gas.
Not enough gas flow.
Contaminated wire.
Faulty gas solenoid.
Turn on gas.
Check hoses for leaks, make sure cylinder is not empty. Increase flow rate.
Change wire.
Replace solenoid.
(GS)
Incorrect electrode wire.
Use correct wire.
Contaminated base material.
Clean or etch base material.
(SYMBOL*)
- USE THIS IDENTIFIER, ALONG WITH THE SCHEMATIC DIAGRAM FOUND IN THE SERVICE
MANUAL, FOR TROUBLE-SHOOTING PURPOSES.
16 Snap-on Tools Corporation Kenosha, WI 53141-1410
TESTING AND REPLACING DIODES
Silicon diodes have proven to be highly reliable. However, weld spatter build-up in the torch can short out and cause diode overload and consequent failure. The following information is provided as a guide should a failure be suspected.
Silicon diodes exhibit two main fault conditions:
1. "Open Circuit" - causes a reduction in welder output.
2. "Short Circuit" - causes the circuit breaker to trip.
If a fault is suspected, the diode may be tested as follows:
1. Remove the top connection of each diode to be tested.
2. Using a Volt-Ohm Meter set on
RX1K, check for continuity through the diode in both directions. If there is no continuity in either direction, the diode is in "open circuit" condition and must be replaced. If there is continuity in both directions, the diode is in "short circuit" condition and must be replaced. If there is continuity in one direction only, the diode is functioning properly.
3. If all the diodes check out satisfactorily with the Volt-
Ohm Meter, a load check must be made. This is easily accomplished using a twelve volt battery and a twelve volt light bulb connected as shown. Again test for electrical current flow in both directions. The bulb should light in one (1) direction only - not both.
CAUTION
NEVER use a "megger" or a high voltage device to test a diode.
12 VOLT
LIGHT BULB
DIODE
+ -
12 VOLT
BATTERY
12 VOLT
LIGHT BULB
+ -
DIODE 12 VOLT
BATTERY
FIGURE 15. DIODE LOAD CHECK
CONNECTION DIAGRAM
- TEST FOR FLOW IN BOTH DIRECTIONS
4. When replacing diodes, it is very important that a heat conductive compound (Radio Shack
#276-1372) be used where the diode makes contact with the aluminum heat sink. Do not grease the threads on the diode.
Snap-on Tools Corporation Kenosha, WI 53141-1410 17
WIRE FEED CALIBRATION
Due to INPUT LINE VOLTAGE variations supplied to the welding machine. The WIRE FEED SPEED should be checked for proper operation.
TO CHECK
1. Remove any tension on the drive roll.
2. Turn the wire speed dial (on the front of the machine) to "0".
3. Activate the torch trigger.
4. The bottom drive roll should rotate very slowly(non-jerky).
5. If this proves to be true, no adjustment is required.
IF ADJUSTMENT IS REQUIRED
1. Remove the top cover assembly from the unit.
2. Locate the printed circuit boards.
3. Referring to Figure 16, locate the trim resistor, this is located in the upper right hand corner of the wire feed PC board.
4. Turn the wire speed dial (on the front of the machine) to "0".
5. Remove any tension on the drive roll.
6. Activate the torch trigger.
TRIM
RESISTOR
FIGURE 16. WIRE FEED PC BOARD
7. Rotate the trim resistor, back and forth, until the bottom drive roll moves.
8. Calibrate so the bottom drive roll rotates very slowly (nonjerky).
9. If calibrated correctly the wire speed dial (on the front of the machine) should affect the speed of the drive roll from "0" thru
"10".
10. Adjustment is now complete!
18 Snap-on Tools Corporation Kenosha, WI 53141-1410
CONNECTING TIGPAK OR SPOOL
GUN
CHANGING FROM STANDARD MIG OPERATION
TO TIGPAK OPERATION
1. Unplug the wire feed motor plug from the function receptacle.
2. Unplug the torch selector cable and the ground cable from the welder front panel.
3. Plug the TIGPAK torch power cable into the negative (-) weld connector and plug the ground cable into the positive (+) weld connector. This provides straight polarity current as required for
TIG welding.
4. Plug the TIGPAK torch switch cord into the welder function receptacle.
5. Attach the TIGPAK torch gas hose directly to the gas regulator.
NOTE
Pure argon is the shielding gas to be used for TIG welding.
6. Follow the operating instructions in the TIGPAK manual (Form
WC5228).
7. To change back to MIG operation, reverse the procedure.
3. Move the selector hose to the
"SPOOL GUN" fitting and tighten.
4. Install the thread cap (removed in step 1) on the "MIG TORCH" fitting to prevent dirt and contaminants from entering the unused gas line.
5. Unplug the wire feed motor plug from the function receptacle.
6. Plug the MHG5-A spool gun control cable plug into the welder function receptacle.
7. Remove the torch selector cable from the welder positive (+) weld connector.
8. Plug the MHG5-A gun cable fitting into the welder positive
(+) weld connector.
NOTE
Make sure the gas regulator and welder gas hose are connected to a cylinder of the proper shielding gas -
100% argon for aluminum welding; 75% argon + 25%
CO2 for steel welding. 98% argon + 2% O2 is recommended for stainless steel welding.
9. Follow the operating instructions in the MHG5-A manual (Form
6455).
10. To change back to standard MIG operation, reverse the procedure.
LABEL THREAD CAP
CHANGING FROM STANDARD MIG OPERATION
TO SPOOL GUN OPERATION
All current model MIG machines are equipped with bulkhead gas fittings for quick and easy changeover from standard MIG operation to spool gun operation.
1. Remove the thread cap from the
"SPOOL GUN" fitting.
2. Unscrew the selector hose from the "MIG TORCH" fitting.
BULKHEAD
FITTINGS
SELECTOR
HOSE
WIRE FEED
MOTOR
WIRE FEED
MOTOR
PLUG
(PLUGGED
INTO
FUNCTION
RECEPTACLE)
FIG. 17. BULKHEAD CONNECTIONS
Snap-on Tools Corporation Kenosha, WI 53141-1410 19
M.I.G. TORCH LINER
INSTALLATION
(steel only)
The MIG torch liner provided with the FM140A is designed for wire diameters from .020 thru .030. If larger wire diameters are to be fed and or there is a problem (i.e. clog, kink, etc.), a liner change is required.
Following is a step by step guide to aid in liner removal and installation.
NOTE
When removing the welding wire from the MIG torch, care should be taken to avoid the wire from uncoiling from the wire spool.
REMOVING OLD LINER
1. Remove torch assembly from the welding machine.
2. Place torch assembly on a flat surface, making sure torch is laying straight as possible.
3. Remove nozzle, bushing insulator, contact tip and gas diffuser from the front end of the torch assembly.
4. Loosen set screw located on the connector end of the torch assembly (see FIG. 19).
5. Grip the liner and gas seal firmly, then pull. The liner should easily slide from torch assembly.
INSTALLING NEW LINER
1. Remove the new liner from the package.
2. Uncoil liner and lay the liner parallel next to the MIG torch assembly.
3. Adjust the liner stickout length to 3/4" as shown in FIG. 18.
GAS SEAL
3/4"
FIGURE 18. LINER STICKOUT
LINER
STICKOUT
4. Install the new liner into the
MIG torch assembly, until gas seal seats flush with the connector plug.
5. Tighten set screw. (Do not overtighten), refer to FIG. 19.
SET SCREW
3/4"
CONNECTOR
PLUG
FIGURE 19. TORCH CONNECTOR END
6. Following the diagram in FIG.
20, measure out 1 1/4"+ from the neck assembly and cut off the protruding liner.
7. Debur the cutoff end of the liner to insure unobstructed wire feed.
1 1/4+"
NECK
ASSEMBLY
PROTRUDING
LINER
FIGURE 20. TORCH FRONT END
8. Install the gas diffuser and contact tip of proper wire size, tighten with a wrench.
9. Install the bushing insulator onto the gas diffuser. Spray the
"O" rings with anti-spatter compound for lubrication.
10. Install the TWIST-ON adjustable nozzle and twist the nozzle during the installation. Turn to
Page 7 for correct nozzle adjustment.
WIRE SIZE
.020 - .025 inch
.030 inch
.035 inch
.040 - .047 inch
PARTS BREAKDOWN - 15 SERIES MIG TORCH
TG STYLE FRONT END - STANDARD
CONTACT TIP GAS DIFFUSER NOZZLE INSULATOR
M3-T25
M3-T30
M3-T35
M3-T45
(1-7/16" length)
M3T-D M3T-N50
(1/2" I.D.)
M3T-B
(includes o-rings)
INSULATOR O-RING
M3T-BR
(3 reqd.)
SHORT CONTACT TIP (1-1/4" length)
- For Spray Arc Welding
WIRE SIZE
.020 - .025 inch
PART NUMBER
M3-ST25
.030 inch
.035 inch
.040 - .047 inch
M3-ST30
M3-ST35
M3-ST45
SPECIAL APPLICATION PARTS FOR TG STYLE FRONT END
LARGER ORIFICE
NOZZLE
Straight Nozzle
(3/4 “ I.D.)
M3T-N75
SPOT WELDING NOZZLES
STYLE
Flat Spot
Inside Corner
Outside Corner
Irregular (grind to shape)
Standard Nozzle
PART NUMBER
M3T-NS1
M3T-NS2
M3T-NS3
M3T-NS4
Low Amp Nozzle
PART NUMBER
M3T-NLAS1
M3T-NLAS2
M3T-NLAS3
M3T-NLAS4
SG STYLE FRONT END - OPTIONAL
WIRE SIZE CONTACT TIP GAS DIFFUSER NOZZLE ASSEMBLY CUP NOZZLE BODY INS. BUSHING
.020 - .025 inch M3-T25
.030 inch M3-T30
.035 inch M3-T35
.040 - .047 inch M3-T45
(1-7/16" length)
M3-D M3-NA50 M3-C50
(1/2" I.D.)
M3-NB M3-B
SHORT CONTACT TIP (1-1/4" length)
- For Spray Arc Welding
WIRE SIZE PART NUMBER
.020 - .025 inch
.030 inch
.035 inch
.040 - .047 inch
M3-ST25
M3-ST30
M3-ST35
M3-ST45
SPECIAL APPLICATION PARTS FOR SG STYLE FRONT END
LARGER
ORIFICE
CUP
Flared
Cup
(5/8" I.D.)
M3-C62
EXTRA LENGTH FRONT END
CUP (1/2" I.D.)
1/2" Longer 1" Longer
PART NUMBER PART NUMBER
M3-C50L
CONTACT TIP
.020 - .025 inch M5-T25
.030 inch
.035 inch
M5-T30
M5-T35
.040 - .047 inch M5-T45
M3-C50XL
M5-LT25
M5-LT30
M5-LT35
M5-LT45
SPOT WELDING FRONT END
INS. BUSHING
PART NUMBER
M3H-B
NOZZLE NUT
SPOT NOZZLE
M3H-NN
Flat Spot
Inside Corner
M3H-NS1
M3H-NS2
Outside Corner M3H-NS3
Irregular M3H-NS4
XG STYLE FRONT END - OPTIONAL - RECOMMENDED FOR ALUMINUM WELDING
WIRE SIZE CONTACT TIP GAS DIFFUSER NOZZLE ASSEMBLY CUP NOZZLE BODY INS. BUSHING
.035 inch M5-T35
.040 - .047 inch M5-T45
M35-D M35-NA62 M5-C62
(5/8" I.D.)
M5-NB M5-B
(1-15/16" length)
SPECIAL APPLICATION PARTS FOR 3-5G STYLE FRONT END
LARGER ORIFICE CUP: Straight Cup (3/4" I.D.) ....... M5-C75
SPECIAL FRONT END FOR GASLESS WIRES - OPTIONAL
INSULATED CONTACT TIP (Tip screw directly into torch neck - no gas diffuser is required) (1-15/16" length)
WIRE SIZE
.040 - .047 inch
PART NUMBER
M5HGL-045
LINERS & SEALS - FOR STEEL WELDING
WIRE
SIZE
TORCH
ORDER NUMBER
LENGTH LINER W/SEAL
SEAL ONLY
.020-.030 inch 10 feet M103L-B M3LS-B (Blue)
LINERS & SEALS - FOR ALUMINUM WELDING
ORDER NUMBER
WIRE
SIZE
TORCH
LENGTH
LINER
W/SEAL
SEAL HEATSHIELD
ONLY ONLY
.035-.045 inch
10 feet
12 feet
M104L-N
M124L-N
M4LS-N (Natural)
.035 inch
3/64 inch
10 feet
10 feet
M103AL M3-6ALS
M104AL M3-6ALS
M3-THS
M3-THS
FIGURE 21. REPAIR (REPLACEMENT) PARTS
PARTS BREAKDOWN - 15 SERIES MIG TORCH (Cont.)
M3-402
M1-401
TORCH NECK GROUP
M3-101B*
M3-203
(2 REQD.)
M3-112
M3-200B ASSEMBLY
M3-202 M3-211
M3-402
M3-119
M3-201B
M3-214
M3-120*
M3-405
(2 REQD.)
PART NO. DESCRIPTION (SYMBOL)
TORCH NECK GROUP
M3-101B...... TORCH NECK *
M3-112 ........ NECK INSULATOR
M3-119 ........ LOCK SCREW - SWITCH HOUSING
M3-120 ........ FERRULE *
M3-200B...... SWITCH ASSEMBLY
CONSISTING OF:
M3-201B...... SWITCH HOUSING
M3-202 ........ SWITCH (S1)
M3-203 ........ SWITCH SCREW (2 REQUIRED)
M3-211 ........ TRIGGER - WITH ADJUSTING SCREW
M3-212 ........ TRIGGER ADJUSTING SCREW (ONLY)
M3-213 ........ TRIGGER PIN
M3-214 ........ TRIGGER SPRING
QUICK CONNECTOR GROUP
M3-120 ........ FERRULE *
M3-301A ..... CONNECTOR HOUSING
M3-305A ..... CONNECTOR STEM *
M3-306 ........ CONNECTOR PLUG
- WITH SETSCREW & O-RINGS
M3-307 ........ SETSCREW (ONLY)
M3-308 ........ O-RING (ONLY) (2 REQUIRED)
M3-309 ........ TERMINAL - CONNECTOR CONTACT
(2 REQUIRED)
M3-310A ..... BOOT / CABLE SUPPORT
SN-807G ..... CABLE COVER
M1-401 ........ HANDLE
M3-402 ........ HANDLE SCREW (2 REQUIRED)
M3-405 ........ TERMINAL - TORCH END
(2 REQUIRED)
M3-406 ........ TERMINAL - CONNECTOR END
(2 REQUIRED)
M3-407 ........ HANGING BRACKET
M1510CBL... 10 FOOT CABLE *
M1512CBL... 12 FOOT CABLE *
M3-212 M3-213
M3-407
M1510CBL*
M1512CBL*
22
QUICK CONNECTOR GROUP
M3-307
M3-309
(2 REQD.)
M3-308
(2 REQD.)
M3-301A
M3-306
M3-305A*
M3-120*
M3-406
(2 REQD.)
NOTES:
*
BECAUSE SPECIAL TOOLS
AND PROCEDURES ARE
REQUIRED TO PROPERLY
INSTALL THE CABLE ON
THE TORCH NECK AND
THE CONNECTOR STEM,
ITEMS WITH THE ASTERICK
ARE AVAILABLE FACTORY
INSTALLED ONLY.
SN-807G
M3-310A
FIGURE 22. REPAIR (REPLACEMENT) PARTS
TORCH REBUILD PROGRAM
15 SERIES TORCHES CAN
BE REBUILT BY THE
FACTORY FOR A NOMINAL
LABOR + PARTS CHARGE.
Snap-on Tools Corporation Kenosha, WI 53141-1410
OPTIONS
NOW!
TIG WELD WITH YOUR
SNAP-ON TOOLS MIG WELDING MACHINE
(M140i, FM140A, YA204C, YA212A or YA212A INDUSTRIAL)
TIG PAK
The TIG Welding Process is used to produce the highest quality, porosity-free welds. The TIG PAK adds TIG Welding capabilities to your
Snap-On Tools MIG Welder.
The TIG PAK is designed for Tungsten-Inert Gas (TIG) welding with
Direct Current, Straight Polarity (DCSP) on steel, stainless steel, chrome-moly, copper or cast iron (12 Gauge minimum plate thickness).
THE TIG PAK WILL NOT WELD ALUMINUM.
The TIG PAK consists of a 200 amp, gas cooled TIG torch with built-in gas control valve and remote on-off switch, 12-1/2 or 25 foot cable assembly and accessories required for putting the unit into service.
SPECIFICATIONS
Part Number ............... TIG PAK 2112A (12-1/2' cable)
TIG PAK 2125A (25' cable)
Torch Rating .............. 200 Amps, DCSP
Duty Cycle ................. 100% (reduce duty cycle when operating over 200 amps.)
Cooling Method ......... Gas
Shielding Gas
Control Method ...... Gas Valve on Torch
Welding Current
On-Off Control ...... Locking Switch on Torch
CONTENTS OF TIG PAK
1 each TIG Torch with built-in valve
1 each Locking Electric Switch with 14 foot cord
(installed on torch)
1 each 12-1/2 foot Power Cable with Connector
(installed on torch)
1 each 15 foot Gas Hose with fitting (installed on torch)
3 each 3C332 Collet - for 3/32" tungsten
3 each 3C418 Collet - for 1/8" tungsten
2 each 3CB332 Collet Body - for 3/32" tungsten
2 each 3CB418 Collet Body - for 1/8" tungsten
2 each 3C6 Gas Cup - 3/8" orifice
6 each 3C7 Gas Cup - 7/16" orifice
2 each 3C8 Gas Cup - 1/2" orifice
1 each 300L Long Backcap
3 each 3/32" X 3" Tungsten Electrode
3 each 1/8" X 3" Tungsten Electrode
ONE POUND SPOOL GUN
FOR ALUMINUM MIG WELDING
WITH SNAP-ON TOOLS
MIG COMBINATION UNITS
(M140i, FM140A, YA204C, YA212A, YA212A INDUSTRIAL)
MHG5-A
The MHG5-A (Motorized Hand Gun System) is a compact, light-inweight, easy to operate MIG welding system designed for aluminum welding. It will feed .030", .035" or 3/64" diameter wire from 4 inch spools.
The standard cable is 25 feet in length. 35 foot and 50 foot cables are optional. The wire speed control knob is in the gun handle.
With the following options, the MHG5-A can be used to weld steel or stainless steel (.030" - .035" diameter wire sizes).
SN-2160K Knurled Drive Roll - for .030" - .035" steel wire
M5-T30 Contact Tip - for .030" steel wire or M5-T35 Contact Tip - for .035" steel wire
SPECIFICATIONS
Part Number ....................... MHG5-A
Gun Rating ......................... 200 Amps @ 100% duty cycle
250 Amps @ 60% duty cycle
Wire Feed Speed Range ..... 50 to 650 inches per minute
Cooling Method ................. Air (gas)
MHG5-A SYSTEM COMPONENTS
1 each
1 each
MHG-5 Spool Gun
HGC5-25 Hand Gun Cable Assembly with fittings - 25 foot length
7 (total) MG-T series Contact Tip (1 installed in gun)
1 each
2 - .030 (MG-T30)
3 - .035 (MG-T35)
2 - 3/64 (MG-T364)
M35-NA62 Nozzle Assembly
1 each
(installed on gun)
M35-D Gas Diffuser
(installed on gun)
Snap-on Tools Corporation Kenosha, WI 53141-1410 23
NOTES
24 Snap-on Tools Corporation Kenosha, WI 53141-1410
NOTES
Snap-on Tools Corporation Kenosha, WI 53141-1410 25
Snap-on Tools Corporation Kenosha, WI 53141-1410
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