Snap-On MIG220 Owner's Manual

PLEASE VISIT OUR WEB SITE TO DOWNLOAD

SERVICE MANUAL IF NEEDED

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

INTRODUCTION .................................................................. 1

SPECIFICATIONS ............................................................... 2

CHECK LIST ........................................................................3

INSTALLATION ................................................................... 4

OPERATION ........................................................................ 8

MAINTENANCE ................................................................. 11

TROUBLE SHOOTING CHART ........................................13

CONNECTING TIGPAK OR SPOOL GUN ........................ 18

PARTS BREAKDOWN - MIG TORCH .............................. 20

OPTIONS - TIG PAK, SPOOL GUN ..................................22

Snap-on Tools Corporation Kenosha, WI 53141-1410

INTRODUCTION

The Snap-On Tools MIG220 is a combination welding power source, wire feed unit, MIG torch and accessory package de signed to meet the requirements of the light to

medium metal fabrica tion industries. The unit produces fusion welds by the Gas Metal Arc Welding process (GMAW or MIG), on steel and aluminum up to 5/16" thick, using.023" through.045" steel wire

and .025" through 3/64" aluminum wire with the optional MHG5-A.

(optional liners must be purchased to cover given wire

sizes). Heavier sections can be easily welded using slightly different techniques.

The number of controls on the unit has been reduced to assist inexperienced operators to learn MIG welding. This facilitates rapid set up for welding various 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 feed motor.

THE MIG PROCESS

AS APPLIED TO THE

MIG220

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.

WIRE SPOOL

FEED

ROLLS

MIG

TORCH

POWER SOURCE

+

REVERSE

POLARITY

(STD.)

_

SHIELDING GAS

WORK

FIGURE 1. SCHEMATIC OF MIG PROCESS

The consumable electrode wire is melted and transferred to the weld puddle by any of three arc modes; short arc transfer, globular trans- fer, or spray arc transfer.

The

MIG220

is capable of perform- ing all modes on steel and aluminum.

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.

ELEC-

TRODE

WORK

FIGURE 2. SHORT ARC TRANSFER

Snap-on Tools Corporation Kenosha, WI 53141-1410 1

SHORT ARC OR DIP TRANSFER (Cont.)

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.

GLOBULAR TRANSFER

Globular transfer occurs at the intermediate range of 22 to 24 arc volts, depending on wire size. As the name implies, the transfer takes place in the form of irregularly shaped globules. Globular transfer is useful in cases where a lower heat input than that of true spray is required.

DESCRIPTION

The MIG220 consists of a combination MIG welding power source and wire feed unit, a

15TG10 MIG torch, a fifteen foot

ground cable with ground clamp, a twenty foot power input cable, a gas regulator - flowmeter, a torch accessory kit, and a built-in cyl- inder rack and industrial wheel kit.

Welder components are cooled by forced fan cooling.

Welder controls are simple and clearly marked. The output voltage is controlled by a twelve position tap switch, providing twelve voltage selections. Voltages can be monitored by the voltmeter on the control panel. Wire feed speed is controlled by the wire speed potentiometer.

ELECTRODE

WORK

ELECTRODE

WORK

GAS NOZZLE

SHIELDING GAS

FIGURE 3. GLOBULAR TRANSFER

SPRAY TRANSFER

Spray transfer occurs at 22 to 28 arc volts, depending on wire size.

The length of the arc is held constant by the voltage available.

The higher voltage and current causes the electrode wire to melt off before touching the workpiece.

The molten metal crosses the gap to the workpiece in a spray form.

Spray transfer is used in the downhand position and provides higher deposition rates than short arc transfer or globular transfer.

GAS NOZZLE

SHIELDING GAS

FIGURE 4. SPRAY TRANSFER

SPECIFICATIONS

PART NUMBER: MIG220

INPUT POWER REQUIREMENTS:

Voltage 208/230 volts AC

Phase

Frequency

Current single phase

50/60 hertz

34/30 amps

NOTE

This welder draws 20 amps at

100% Duty cycle (185 amps output). A 40 amp 208 or 230 volt electrical service is required for proper arc start- ing and full utilization of its maximum output of 220 amps.

DUTY CYCLE - OUTPUT POWER:

Welding Current

(NEMA)@ 60% 180 Amps

@ 20% 220 Amps

DUTY CYCLE TIME PERIOD:

10 minutes

OPEN CIRCUIT VOLTAGE:

15 - 37.5 volts DC

2 Snap-on Tools Corporation Kenosha, WI 53141-1410

SPECIFICATIONS (Cont.)

WIRE TYPES:

mild steel, stainless steel, aluminum, bronze, flux cored, flux cored - gasless

Recommended (for steel) ER70S-6

WIRE SIZES: .023" - .045" steel,

.035" - 3/64" aluminum,

(.023" - 3/64" alum. w/spool gun)

.030" - .035" bronze,

.035' - .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 CO2 or Argon/CO2 mix

Recommended (for steel)75% Argon/

For Aluminum, Bronze

For Stainless Steel

25% CO2

Argon

98% Argon/2%Oxygen

For Flux cored CO2 or

Argon/CO2 mix

DIMENSIONS:

Height

Width

Depth

Weight

34 in. (86.4 cm.)

14-1/2 in. (36.8 cm.)

35 in. (88.9 cm.)

195 lbs. (88.5 kg.)

TORCH SPECIFICATIONS

NECK ANGLE:

60 degrees

LEAD LENGTH:

OVERALL LENGTH:

10 feet

10 feet

COOLING METHOD:

gas (air)

RATING - DUTY CYCLE:

With Argon/CO2 gas150 amps @ 100%

With CO2 gas 200 amps @ 100%

CHECK LIST

THE SNAP-ON TOOLS MIG220 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

1- 10 foot Ground Cable and Clamp

1- 230PK-1 Accessory Kit

1- Gas Regulator/Flowmeter - for steel or aluminum

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

OPTIONAL EXTRAS

RE5-A Range Extender, a wire feed unit which extends the reach of the MIG220 an

extra 25 feet.

50CP-0

50 foot Power Input Cable

(replaces standard 20 foot power input cable).

MHG5-A

Spool Gun - for welding aluminum(see page 22)

TIGPAK

Tig Torch Kit - for TIG welding steel, stainless steel(see page 22)

Snap-on Tools Corporation Kenosha, WI 53141-1410 3

208V INPUT SELECTION

1. Remove the top cover.

ITEMS REQUIRED FOR MIG WELDING

WHICH ARE NOT PROVIDED WITH THE

MIG220.

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.

Electrial Power.

5. Other personal protective equipment which may vary to match the welding being performed.

THE MIG220 REQUIRES

A 208 OR 230 SINGLE

PHASE, AC, 40 AMP CIRCUIT.

208V INPUT SELECTION

1.

Remove the top cover.

2.

Locate the contactor switch which is mounted on top of the main power transformer (See Figure 5).

WELD POWER

CONTACTOR

CONNECT "208"

TERMINAL FOR

OPERATION ON

208 VOLT INPUT

CONNECT "230"

TERMINAL FOR

OPERATION ON

230 VOLT INPUT

INSTALLATION

POSITIONING THE UNIT

Locate the unit adjacent to the welding area and position it so there is adequate clearance all around for ventilation and maintenance.

FRONT OF

MACHINE.

FIGURE 5. INPUT VOLTAGE SELECTIONS

ELECTRICAL SUPPLY

Ensure that there is a

208 or 230 volt, single phase, 40 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. Attach a suitable plug

making sure the green

wire is attached to ground.

All wiring should be performed by a qualified electrician.

230V INPUT SELECTION

1. Factory selected no change is needed.

4

CAUTION

MAKE SURE POWER SOURCE IS

UNPLUGGED BEFORE MAKING IN-

PUT SELECTION CHANGE-OVER.

3. Attached to the power source’s contactor is one (2) two position plug which allows easy selection of input voltages of either 208 or 230 volts.

4. Remove the one (1) plug labeled

230V and connect the one (1) plug labeled 208V.

5. Reattach the top cover of the machine. Voltage input selection is now complete.

Snap-on Tools Corporation Kenosha, WI 53141-1410

be turned "ON" and the MIG torch trigger depressed, before the gas flow rate can be adjusted.

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

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. See recommended gases on page 3.

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.

4. Fit the gas hose from the welding machine to the regulator outlet fitting and tighten it with a wrench. Open the cylinder valve.

When welding steel, the gas flow rate is 30 CFH. When welding aluminum, the gas flow rate is 40

CFH.

NOTE

The MIG220 must be turned

"ON" and the MIG torch trigger depressed, before the gas flow rate can be adjusted.

TORCH CONNECTION

1.

Open the access door of the machine to its fullest extent.

2.

Back out the thump screw located on the drive assembly mounting bracket inside the machine.

Insert the MIG into the torch panel month on the front panel and

TIGHTEN THE

THUMB SCREW SECURELY

.

AND

CHECK OFTEN

MIG

TORCH

TORCH

PANEL

MOUNT

PRESSURE

ROLL

FLOW TUBE

INDICATES

FLOW RATE

IN C.F.H.

GAUGE -

INDICATES

TANK

PRESSURE

GAS FLOW

ADJUSTING

KNOB

THUMB

SCREW

DRIVE ROLL DRIVE ASSEMBLY

OUTLET

FITTING

TO

WELDING

MACHINE

INLET

FITTING

TO

TANK

FIGURE 6. GAS FLOW ADJUSTMENT

FIGURE 7. TORCH CONNECTION

FITTING AND THREADING THE ELECTRODE

WIRE - ALWAYS USE ER70S-6 WELDING

WIRE.

1. Remove the wire spool clip from the spool hub.

(continued on following page)

Snap-on Tools Corporation Kenosha, WI 53141-1410 5

FITTING AND THREADING THE ELECTRODE

WIRE (Cont.)

2. Unpack the spool of welding wire from its protective packaging.

3. Place the spool of ER70S-6 welding wire on the hub ensuring that the hole in the spool flange lines up with the locating pin on 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.

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 drive motor shaft.

B

"B" SIDE FACING IN FOR

.023" - .035" STEEL WIRES

C

"C" SIDE FACING IN FOR

.040" - .045" STEEL WIRES

AND 3/64" ALUMINUM WIRES

3045DR Large Drive Roller

FIGURE 8. DOUBLE GROOVE DRIVE ROLL

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" 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.

6 Snap-on Tools Corporation Kenosha, WI 53141-1410

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 3/8 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". See Figure 9.

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

1/4"

STICK-

OUT

FOR STEEL:

CONTACT TIP

FLUSH WITH NOZZLE

1"

STICK-OUT

FOR ALUMINUM:

TIP RECESSED 1/8" - 3/8"

FIG. 9. 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.

FIGURE 10. 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.

Snap-on Tools Corporation Kenosha, WI 53141-1410 7

8

OPERATION

DUTY CYCLE

CAUTION

CONTINUAL EXCEEDING OF THE DUTY

CYCLE OF THIS (OR ANY) WELDING

MACHINE CAN CAUSE DAMAGE.

The Duty Cycle of a welding power source is a percentage of a ten (10) minute time period. It is the maximum amount of time the power source can be operated at a given output without sustaining possible damage due to overheating. A 60%

Duty Cycle means the welding machine can be operated at its rated amperage for six (6) minutes out of ten. The machine must be allowed to cool (machine ON, fan running, but not welding) for the remaining four

(4) minutes. Operating the machine at a higher output requires that the duty cycle percentage be lowered.

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 ground 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.

A.

WIRE

SPEED

B.

HEAT

(VOLTAGE)

CONTROL

C.

VOLTMETER

D.

CIRCUIT

BREAKER

E.

"ON"

INDICATOR

LIGHT

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.

PROCESS SELECTION

The following controls are located on the front of the machine.

FIGURE 11. FRONT PANEL

F.

TORCH

PANEL

MOUNT

G.

TORCH

SELECTOR

CABLE

H.

(+)POSITIVE

TERMINAL

I.

(-)NEGATIVE

TERMINAL

Snap-on Tools Corporation Kenosha, WI 53141-1410

A. WIRE SPEED

Potentiometer controls speed of wire drive motor to give wire speed range of 10 to 500 inches per minute.

B. HEAT (VOLTAGE) CONTROL

Twelve position switch adjusts welder output voltage.

C. VOLTMETER

Indicates open circuit voltage when torch switch is actuated and arc voltage while welding.

D. CIRCUIT BREAKER

Primary power switch and overload protection device.

E. "ON" INDICATOR LIGHT

Illuminates when the circuit breaker on the machine is "ON".

F. TORCH PANEL MOUNT

Combination power output, contactor switch connection, gas supply connection, and wire feed output in a single unit.

G. 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.

H. +(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.

I. -(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.

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.

NOZZLE

CONTACT TIP

(FLUSH TO

1/16" STICKOUT)

ELECTRODE WIRE

(1/4" STICKOUT)

FIGURE 12.

NOZZLE ADJUSTMENT FOR WELDING STEEL

(continued on following page)

Snap-on Tools Corporation Kenosha, WI 53141-1410 9

CONTINUOUS WELDING ON STEEL

(Cont.)

2. Spray the inside of the nozzle and the outside of the contact tip with anti-spatter compound.

3. Locate the torch over the joint to be welded with the contact tip approximately 3/4 inch from the work surface.

NOTE

When welding steel, the ideal position for holding the torch is inclined approximately 30 degrees towards the direction of travel. The arc can to be seen easily, which results 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.

CONTINUOUS WELDING ON ALUMINUM

(Nylon liner and 100% Argon shielding gas are required )

USE

1. Trim the electrode wire, leaving approximately 1 inch stickout.

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.

NOZZLE

CONTACT TIP

(RECESSED 3/8")

ELECTRODE WIRE

(1" STICKOUT)

FIGURE 14. 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 are shown in Figure 15.

30 DEGREES

DIRECTION

OF TRAVEL

SHIELDING

GAS

WORK

FIGURE 13.

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, while maintaining a constant arc length and a constant tip-to-work distance.

10

SHIELDING

GAS

Snap-on Tools Corporation Kenosha, WI 53141-1410

10 DEGREES

DIRECTION

OF TRAVEL

WORK

FIGURE 15.

TORCH POSITION FOR WELDING ALUMINUM

4. Follow steps 4 and 5 as in

"Continuous Welding on Steel".

BURN BACK

OPERATING HINTS

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 they 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 develop 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)

Snap-on Tools Corporation Kenosha, WI 53141-1410 11

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 torch liner if necessary.

RECOMMENDED

CUSTOMER SPARE PARTS

The Snap-On Tools MIG220 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!

12 Snap-on Tools Corporation Kenosha, WI 53141-1410

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

EQUIPMENT MALFUNCTION

REMEDY

No main power, MIG220 switch is "OFF".

(CB1)

Turn switch "on".

fan does not Wall breaker is "tripped".

Reset wall breaker.

operate, "Open" circuit breaker Reset or replace

"on" indicator on MIG220.

(CB1) breaker.

light is off.

Loose or broken connection Tighten or repair in power input circuit.

connection.

Main power on, MIG torch unplugged.

torch Faulty trigger switch.

(S1)

Plug in MIG torch.

Replace micro switch.

trigger activated,

Fault in torch cable.

Check torch cable for continuity.

no response.

Loose or broken connection Check or repair on wiring harness.

connections.

Wire feed motor unplugged.

Plug in motor.

(RC3)

Faulty control transformer.

Check for 28VAC output.

(T2)

Main power on, Pressure roll arm unlatched. Latch arm & add tension.

torch "Slippage" at drive rolls.

Increase drive roll trigger activated, 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 17.

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.

(continued on following page)

(SYMBOL*)

- USE THIS IDENTIFIER, ALONG WITH THE SCHEMATIC DIAGRAM FOUND IN THE SERVICE

MANUAL, FOR TROUBLE-SHOOTING PURPOSES.

Snap-on Tools Corporation Kenosha, WI 53141-1410 13

TROUBLE SHOOTING (Cont.)

(SYMBOL*)

FOR TECH. SERVICE, CALL 1-800-232-9353

FAULT POSSIBLE CAUSE

EQUIPMENT MALFUNCTION (Cont.)

REMEDY

Main power on, Loose torch thumb screw.

torch Broken or loose connection.

Tighten thumb screw.

Check cables for trigger activated, continuity.

Repair or tighten no welding current, but Unplugged or faulty power gas flows & wire feeds.

contactor switch.

(W) connections.

Plug in or replace switch.

208/230V selector wire off.

Reattach wire.

(W)

"Opened" thermal switch.

(TP1)

Faulty diodes.

(D1-D4)

Allow unit to cool, then retry.

Check diodes. See page

16.

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.

Replace tank.

Tighten or repair connections.

Repair or replace valve.

Locate & clean clog.

"Jerky" or

"slipping" wire feed.

sion.

FAULTY WELDS

Worn , kinked or dirty torch Clean or replace liner.

liner.

Wire spool turns too hard.

Lubricate spool shaft.

Worn double v-groove drive Replace drive roll.

roll.

Weak pressure roll spring.

Replace spring.

Worn or dirty contact tip.

Replace contact tip.

Worn inlet guide(s).

Sticking pressure roll.

Clean or replace guides.

Replace pressure roll.

Feed roll tension incorrect. Adjust feed roll ten-

See page 7.

14 Snap-on Tools Corporation Kenosha, WI 53141-1410

TROUBLE SHOOTING (Cont.)

(SYMBOL*)

FOR TECH. SERVICE, CALL TOLL-FREE 1-800-232-9353

FAULT

"Birdnesting"

(Wire wrapping around drive rolls)

"Cold" weld puddle.

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-D4) work.

Check and tighten all connections.

Test diodes, replace faulty diode(s). See page 16.

Heavy spatter.

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.

Porous welds.

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.

Snap-on Tools Corporation Kenosha, WI 53141-1410 15

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 diode or 2K, 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 using a twelve volt battery and a twelve volt headlight bulb.

CAUTION

NEVER use a "megger" or a high voltage device to test a diode.

4. Connect the headlight bulb to one end of the diode. Test for electrical flow in both directions as follows. First, test by connecting a lead from the battery positive

(+) terminal to the light bulb and a lead from the battery negative (-) terminal to the other end of the diode. Test again by reversing the connections. (See Figure 16.) The headlight bulb should light with the current flow in one

(1) direction only - not both.

12 VOLT

HEADLIGHT

BULB

DIODE

+ -

12 VOLT

BATTERY

12 VOLT

HEADLIGHT

BULB

DIODE

+ -

12 VOLT

BATTERY

FIGURE 16.

DIODE LOAD CHECK CONNECTION DIAGRAM

- TEST FOR FLOW IN BOTH DIRECTIONS

5. 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.

16 Snap-on Tools Corporation Kenosha, WI 53141-1410

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.

RESISTOR

IF ADJUSTMENT IS REQUIRED

1. Remove the top cover assembly from the unit.

2. Locate the printed circuit board.

3. Referring to Figure 17, 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.

FIGURE 17. 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!

Snap-on Tools Corporation Kenosha, WI 53141-1410 17

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

Make sure the regulator is connected to a cylinder of the proper shielding gas pure argon for TIG welding.

6. Follow the operating instructions in the TIGPAK manual (Form

WC5228).

7. To change back to MIG operation, reverse the procedure.

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.

3. Move the selector hose to the

"SPOOL GUN" fitting and tighten.

18

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

WC5385).

10.To change back to standard MIG operation, reverse the procedure.

WIRE FEED

MOTOR

BULKHEAD

FITTINGS

THREAD

CAP

WIRE FEED

MOTOR PLUG

(PLUGGED INTO

FUNCTION

RECEPTACLE)

LABEL

SELECTOR

HOSE

FIGURE 18. BULKHEAD CONNECTIONS

Snap-on Tools Corporation Kenosha, WI 53141-1410

M.I.G. TORCH LINER INSTALLATION

(steel only)

The MIG torch liner provided with the MIG220 is designed for wire diameters from .030 thru

.045. If smaller 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. 20).

5. Grip the liner and gas seal firmly, then pull. The liner should easily slide from torch assembly.

GAS SEAL

SET SCREW

3/4"

FIGURE 19. 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. 20.

3/4"

CONNECTOR

PLUG

FIGURE 20. TORCH CONNECTOR END

6. Following the diagram in FIG.

21, 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

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. 19.

PROTRUDING

LINER

FIGURE 21. 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.

Snap-on Tools Corporation Kenosha, WI 53141-1410 19

WIRE SIZE

.020 - .025 inch

.030 inch

.035 inch

.040 - .047 inch

M3-T25

M3-T30

M3-T35

M3-T45

PARTS BREAKDOWN - 15 SERIES MIG TORCH

TG STYLE FRONT END - STANDARD

CONTACT TIP GAS DIFFUSER NOZZLE INSULATOR

(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

20

FIGURE 22. CONSUMABLE PARTS

Snap-on Tools Corporation Kenosha, WI 53141-1410

PARTS BREAKDOWN - 15 SERIES MIG TORCH (Cont.)

M3-402

M1-401

TORCH NECK GROUP

M3-101B*

M3-112

M3-200B ASSEMBLY

_

M3-212

M3-402

M3-119

M3-201B

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

M3-203 ....... SWITCH SCREW (2

M3-211K....... SWITCH

TRIGGER PIN

REQUIRED)

(S1)

TRIGGER - WITH ADJUSTING SCREW

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

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 *

M1510CBL*

M1512CBL*

QUICK CONNECTOR GROUP

M3-309

(2 REQD.)

M3-307

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.

M3-310A

FIGURE 23. 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 21

OPTIONS

TIG PAK

NOW!

TIG WELD WITH YOUR SNAP-ON

TOOLS MIG WELDING MACHINE

(MIG140, FM140A, MIG220, YA204C, YA212A or YA212A INDUSTRIAL)

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).

TIG PAK WILL NOT WELD ALUMINUM.

The TIG PAK consists of a 200 amp, gas cooled TIG torch with built-in assembly and accessories required for putting the unit into service.

SPECIFICATIONS

Part Number............... T P2125A (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

1 each

CONTENTS OF TIG PAK

Torch with built-in valve

TIG

1 each Locking Electric Switch with 25 foot cord

(installed on torch)

1 each 25 foot Power Cable with Connector (installed on torch)

1 each 27 1/2 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 3CB418

2 each Collet Body - for 1/8" tungsten

2 each 3C6 Gas Cup - 3/8" orifice

6 each Cup - 7/16" orifice

3C7 Gas

2 each 3C8 Gas Cup - 1/2" orifice

1 each Long Backcap

300L

3 each 3/32" X 3" Tungsten Electrode

3 each 3" Tungsten Electrode

1/8" X

ONE POUND SPOOL GUN FOR

ALUMINUM MIG WELDING

WITH SNAP-ON TOOLS MIG

COMBINATION UNITS

(MIG140, FM140A, MIG220, 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 .023" Thru 3/64" diameter wire from 4 inch spools.

The standard equipment 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)

22 Snap-on Tools Corporation Kenosha, WI 53141-1410