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OWNER'S MANUAL
MM250SL M.I.G. COMBINATION UNIT
CONGRATULATIONS!
YOU HAVE PURCHASED THE WORLDS FINEST MIG
WELDING SYSTEM AVAILABLE EXCLUSIVELY FROM
SNAP-ON TOOLS. THE SNAP-ON MUSCLE MIG SYS-
TEM MODEL# MM250SL IS DESIGNED AND ENGI-
NEERED BY THE PROS FOR THE PROS. UNDER
NORMAL CARE THIS SYSTEM WILL PROVIDE YOU
WITH YEARS OF UNSURPASSED SERVICE AND
MOST IMPORTANTLY PERFORMANCE.
FORM WC5377
FOR TECH. SERVICE, CALL TOLL-FREE 1-800-232-9353
INSTALLATION
OPERATION
MAINTENANCE
Rev. 11/98, 1/00, 8/00, 4/01
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
DESCRIPTION, SPECIFICATIONS .............................................. 2
CHECK LIST (CONTENTS) .......................................................... 3
INSTALLATION & ELECTRICAL REQUIREMENTS ................... 4
OPERATION ................................................................................. 8
MAINTENANCE........................................................................... 13
TROUBLE SHOOTING CHART.................................................. 15
CONNECTING FLEXTIG OR SPOOL GUN ............................... 20
LINER INSTALLATION ............................................................... 21
PARTS BREAKDOWN - MIG TORCH ........................................ 22
OPTIONS - FLEXTIG OR SPOOL GUN ..................................... 24
PARAMETER CHARTS .............................................................. 25
Snap-on Tools Corporation Kenosha WI 53141-1410
INTRODUCTION
The Snap-on Tools MM250SL is a combination welding power source, remote feed unit, MIG torch and accessory package, which is designed to meet the requirements of the light to medium metal fabrication industries. The MM250SL produces fusion welds by the Gas Metal
Arc Welding process (GMAW or MIG), on steel and aluminum up to "3/8" thick, using .023" through .045" steel wire and .025" through 3/64" aluminum wire with the optional
MHG5-B spool gun. (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 have 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 VOLTAGE control adjusts the welding voltage and the WIRE FEED control adjusts the speed of the wire feed motor.
A SPOT WELD control switch and adjustable timer circuit provides
Consumable MIG Spot Welding capabilities of light gauge steel.
THE MIG PROCESS
AS APPLIED TO THE MM250SL
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
SHIELDING GAS
WORK
+
REVERSE
POLARITY
(STD.)
_
FIG. 1. SCHEMATIC OF M.I.G. PROCESS
The consumable electrode wire is melted and transferred to the weld puddle by any of three arc modes; short arc transfer, globular transfer, or spray arc transfer. The
MM250SL is capable of performing all modes.
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
FIG. 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.
FIG. 3. GLOBULAR TRANSFER
SPRAY TRANSFER
Spray transfer occurs at 22 to 32 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.
2
ELECTRODE
WORK
ELECTRODE
WORK
GAS NOZZLE
SHIELDING GAS
GAS NOZZLE
SHIELDING GAS
FIG. 4. SPRAY TRANSFER
DESCRIPTION
The MM250SL consists of a combination MIG welding power source and remote feed unit, a MIG torch with
10 foot cable, a fifteen foot feeder control cable, a fifteen foot work cable with 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 4 TIG and 8
MIG voltage selections. Wire feed speed is controlled by the wire speed potentiometer.
SPECIFICATIONS
PART NUMBER: MM250SL
INPUT POWER REQUIREMENTS:
Voltage
Phase
208/230 single phase
Frequency
Current
50/60 hertz
33/30
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 starting and full utilization of its maximum output of 250 amps.
DUTY CYCLE - OUTPUT POWER:
(NEMA) @ 60% - 200 Amps
@ 60% - 230 Amps
@ 35% - 250 Amps
DUTY CYCLE TIME PERIOD:
10 minutes
OPEN CIRCUIT VOLTAGE:
18 - 42 volts DC
ARC VOLTAGE:
WELD CURRENT RANGE:
14 - 28 volts DC
30 - 250 amps
Snap-on Tools Corporation Kenosha, WI 53141-1410
SPECIFICATIONS (Cont.)
REMOTE FEED UNIT
Input Voltage 28 VAC
Wire Feed Speed Range: 50-800 IPM
DUTY CYCLE - SPOT WELDING:
30 X 2 second spots per 10 minute period
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,
.035" - .045" flux cored
(gas shielded or gasless)
Recommended Size:Aluminum
Others
.035
.030
SHIELDING GASES:
For Steel CO2 or Argon/CO2 mix
Recommended (for steel) 75% Argon/
25% CO2
For Aluminum, Bronze
For Stainless Steel
Argon
98% Argon/2% Oxygen
For Flux cored CO2 or
Argon/CO2 mix
DIMENSIONS:
Height
Width
Depth
Weight
35-3/4 in.(90.8 cm.)
14-1/2 in.(36.8 cm.)
34-1/2 in.(87.7 cm.)
175 lbs.(79.5 kg.)
TORCH SPECIFICATIONS
NECK ANGLE:
LEAD LENGTH:
OVERALL LENGTH:
60 degrees
10 feet
10 feet
TORCH SPECIFICATIONS (Cont.)
COOLING METHOD: gas (air)
RATING - DUTY CYCLE:
With Argon/CO2 gas 150 amps @ 100%
With CO2 gas 200 amps @ 100%
CHECK LIST
THE SNAP-ON TOOLS MM250SL INCLUDES
THE FOLLOWING:
1- Combination Power Source/Remote
Feed Unit
1- Cylinder Rack/Industrial Wheel
Kit
1- 15 foot Feeder Control Cable assy (FCA-15).
1- 15TG10 MIG Torch with adjustable nozzle
1- 20 foot Power Input Cable
1- 15 foot 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
MM250SL
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. 208 or 230 volt single phase AC power.
5. Other personal protective equipment which may vary to match the welding being performed.
Snap-on Tools Corporation Kenosha, WI 53141-1410 3
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.
ELECTRICAL SUPPLY
Ensure that there is a
208 or 230 volt, single phase, 40 amp
electrical supply within easy reach of the unit(see note on page 2 under specifications). 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 the ground terminal of the wall plug
. All wiring should be performed by a qualified electrician.
230V INPUT SELECTION
1. Factory selected no change is needed.
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).
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.
INSTALLING THE FEEDER CONTROL CABLE
ASSEMBLY
1. Uncoil the cable assembly.
GAS-
CURRENT
FITTING
CONTROL
PLUG
(FEMALE
PINS)
FEEDER
CONTROL
CABLE
4
CONTACTOR SWITCH
CONNECT "208"
WIRE FOR
OPERATION ON
208 VOLT INPUT
CONTROL
PLUG
(MALE
PINS)
POWER
PLUG
GAS-
CURRENT
CABLE
CONNECT
"230" WIRE FOR
OPERATION ON
230 VOLT INPUT.
FRONT OF
MACHINE
FIG. 5. INPUT VOLTAGE SELECTIONS
FIG. 6. FCA-15 FEEDER CABLE ASSEMBLY
2. With the proper size wrench attach the gas-current fitting to the gas-current terminal (located on the front of the feed unit).
Snap-on Tools Corporation Kenosha, WI 53141-1410
INSTALLING THE FEEDER CONTROL CABLE
ASSEMBLY (Cont.)
3. Connect the control plug (female pins)onto the control receptacle (INPUT) and tighten (located on the front of the feed unit).
TO GAS-
CURRENT
TERMINAL
TO CONTROL
RECEPTACLE
(INPUT)
FEED
UNIT
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.
FIG. 7. CABLE CONNECTION TO FEED UNIT
4. Plug the power plug into the positive (+) terminal(located on the front of the welding machine).
5. Connect the control plug (male pins) onto the control receptacle (OUTPUT)and tighten (located on the front of the welding machine).
GAS FLOW
ADJUSTING
KNOB
FLOW TUBE
INDICATES
FLOW RATE
IN C.F.H.
GAUGE -
INDICATES
TANK
PRESSURE
TO CONTROL
RECEPTACLE
(OUTPUT)
OUTLET
FITTING
TO
WELDING
MACHINE
INLET
FITTING
TO
TANK
WELDING
MACHINE
TO (+)
TERMINAL
(STANDARD)
FIG. 8. CABLE CONNECTION TO
WELDING MACHINE
FIG. 9. GAS FLOW ADJUSTMENT
3. Attach the gas regulator - flowmeter supplied with this unit, to the cylinder valve using a suitable wrench.
(continued on following page)
Snap-on Tools Corporation Kenosha, WI 53141-1410 5
SHIELDING GAS CONNECTIONS (Cont.)
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 MM250SL 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 Feed unit 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.
TORCH
PANEL
MOUNT
PRESSURE
ROLL
INLET
GUIDE
MIG
TORCH
6
FITTING AND THREADING THE ELEC-
TRODE WIRE - ALWAYS USE ER70S-6
WELDING WIRE WHEN WELDING STEEL.
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 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 shaft.
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.
"B" SIDE FACING IN FOR
.023" - .035" STEEL WIRES
THUMB
SCREW
DRIVE
ROLL
DRIVE
ASSEMBLY
MOUNTING
BRACKET
FIG. 10. TORCH CONNECTION
"C" SIDE FACING IN FOR
.040" - .045" STEEL WIRES
AND 3/64" ALUMINUM WIRES
FIG. 11. DOUBLE GROOVE DRIVE ROLL
Snap-on Tools Corporation Kenosha, WI 53141-1410
FITTING AND THREADING THE ELECTRODE
WIRE (Cont.)
8.
Thread the electrode wire through the inlet guide, over the feed roll and into the outlet guide. 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 MIG/TIG VOLTAGE control switch to "MIG 3" and the
WIRE SPEED control to "5". 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 ELECTRODE
WIRE (Cont.)
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
1"
STICK-OUT
FOR STEEL:
CONTACT TIP
FLUSH WITH NOZZLE
FOR ALUMINUM:
CONTACT TIP
RECESSED 1/8" - 1/4"
FIG. 12. 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 anti-spatter compound can be used as it will contaminate the weld.
Snap-on Tools Corporation Kenosha, WI 53141-1410 7
WIRE FEED PRESSURE ROLL ADJUST-
MENT
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
DRIVE
ROLL
PRESSURE
ROLL
PRESSURE
ROLL ARM
FIG. 13. PRESSURE ROLL ADJUSTMENT
WORK (GROUND) CABLE
Uncoil the work (ground) 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.
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 common to the work cable on the welder.
8 Snap-on Tools Corporation Kenosha, WI 53141-1410
PROCESS SELECTION
The following controls are located on the front of the MM250SL.
A.
GAS-
CURRENT
TERMINAL
H.
OCV/GAS
PURGE
B.
CONTROL
RECEP-
TACLE
(INPUT)
I.
SPOT/
STITCH
TIME
C.
MIG/TIG
VOLTAGE
SWITCH
J.
MODE
SWITCH
K.
WIRE
SPEED
D.
VOLT-
METER
L.
TORCH
PANEL
MOUNT E.
"ON"
INDICATOR
LIGHT
F.
CIRCUIT
BREAKER
M.
CONTROL
RECEP-
TACLE
(OUTPUT)
G.
(-)NEGATIVE
TERMINAL
FIGURE 14. FRONT PANEL
N.
(+)POSITIVE
TERMINAL
A.
GAS-CURRENT TERMINAL
Single terminal connection for gas and current from welding machine.
B.
CONTROL RECEPTACLE (INPUT)
Input receptacle for wire feed voltage, trigger circuit and wire speed control from welding machine.
C.
MIG/TIG VOLTAGE SWITCH
Twelve position switch provides
"4" TIG (requires optional FLEX
TIG) and "8" MIG voltage settings.
D.
VOLTMETER
Indicates open circuit voltage when torch trigger switch is activated and arc (welding) voltage during welding.
E.
CIRCUIT BREAKER
Primary power switch and overload protection device.
F.
"ON" INDICATOR LIGHT
Illuminates when the circuit breaker on the machine is "ON".
G.
(-)NEGATIVE TERMINAL
Negative output terminal. The work cable is plugged into this terminal during standard welding operation. The Power plug can be inserted into this terminal for straight polarity welding on very light sheet metal, or for using flux cored gasless wire.
H.
OCV/GAS PURGE
Operates the gas solenoid to purge the lines of impurities prior to welding. Pressing the switch also causes open circuit voltage to be registered on the power source voltmeter.
CAUTION
Torch is electrically HOT when switch is actuated.
I.
SPOT/STITCH TIME
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 Mode Switch must be set in "SPOT or STITCH" position for timing operation.
J.
MODE SWITCH
Controls mode of operation of welding machine. "CONT." 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 materials.
K.
WIRE SPEED
Potentiometer controls speed of wire drive motor to give wire speed of 50 to 800 inches per minute.
(continued on following page)
Snap-on Tools Corporation Kenosha, WI 53141-1410 9
PROCESS SELECTION (Cont.)
L. TORCH PANEL MOUNT
Combination power output, contactor switch connection, gas supply connection, and wire feed output in a single unit.
M. CONTROL RECEPTACLE (OUTPUT)
Output receptacle for wire feed voltage, trigger circuit and wire speed control out to the remote feed unit.
N. (+)POSITIVE TERMINAL
Positive output terminal from the welder DC power source. The
Power plug is inserted into this terminal for standard welding operation. The work cable can be plugged into this terminal for straight polarity welding on very light sheet metal, or for using flux cored gasless wire.
NOZZLE
CONTACT TIP
(FLUSH TO
1/16" STICKOUT)
ELECTRODE WIRE
(1/4" STICKOUT)
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(using the parameter chart located on the door of the feed unit or on page 25) for optimum results using the sample material thickness and wire size being used as a starting point, 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.
10
FIG. 15. NOZZLE ADJUSTMENT
FOR WELDING STEEL
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.
4. Use a welding helmet with a shade
9 to 11 filter lens, depending on operator preference.
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.
Snap-on Tools Corporation Kenosha, WI 53141-1410
NOZZLE
30 DEGREES
CONTACT TIP
(RECESSED 3/8")
DIRECTION
OF TRAVEL
WORK
SHIELDING
GAS
FIG. 16. TORCH POSITION
FOR WELDING STEEL
- RIGHTHANDED WELDOR
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.
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.
ELECTRODE
WIRE
(1" STICKOUT)
FIG. 17. 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 the following illustration.
10 DEGREES
DIRECTION
OF TRAVEL
SHIELDING GAS
WORK
FIG. 18. TORCH POSITION
FOR WELDING ALUMINUM
4. Follow steps 4 and 5 as in
"Continuous Welding on Steel".
Snap-on Tools Corporation Kenosha, WI 53141-1410 11
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 VOLTAGE on the welder around 20 volts, the WIRE FEED control "8", the MODE Switch to
"SPOT", and the TIME control to
"3", then adjust the controls 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.
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. Activate 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.
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.
SPOTWELD
NOZZLE
CONTACT
TIP
PRESS NOZZLE
FIRMLY
AGAINST WORK
SPOTWELD WORK
FIG. 19. MIG SPOT WELDING
STITCH WELDING ON STEEL
NOTE
Stitch Welding is used for very light material.
1. Set MODE 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.
DIRECTION
OF TRAVEL
WORK
30 DEGREES
SHIELDING GAS
FIG. 20. STITCH WELDING
12 Snap-on Tools Corporation Kenosha, WI 53141-1410
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
VOLTAGE 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 anti-spatter compound 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 13
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 MM250SL 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.
W H E N w e l d i n g n e a r c o m b u s t i b l e s , a h e l p e r o r
"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!
14 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 REMEDY
EQUIPMENT MALFUNCTION
No main power, MM250SL switch is "OFF".
(CB1)
Turn switch "on".
fan does not Wall breaker is "tripped".
Reset wall breaker.
operate,
"on" indicator
"Open" circuit breaker on MM250SL.
(CB1)
Reset or replace 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.
(PLG2) connections.
Wire feed motor unplugged.
Plug in motor.
(RC5)
Faulty control transformer.
Check for 28VAC output.
(T2)
Loose spot timer circuit board.
(PC2)
Defective spot timer circuit board.
(CR2)(PC2)
Install properly.
Replace board.
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 8.
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 19.
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 15
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.
Allow unit to cool, then retry.
Check diodes. See page
18.
Main power on, No shielding gas torch - tank empty.
trigger activated,
Loose or broken connections.
no gas flow, Faulty Gas solenoid but contactor valve.
(GS) operates & wire feeds.
Clogged gas flow path.
Loose spot timer circuit board.
(PC2)
Defective spot timer circuit board.
(CR2)(PC2)
Replace tank.
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 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 tension. See page 8.
16 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
8.
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 18.
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 17
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:
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.
1. "Open Circuit" - causes a reduction in welder output.
2. "Short Circuit" - causes the circuit breaker to trip.
DIODE
12 VOLT
LIGHT BULB
12 VOLT
BAT-
TERY
+ -
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.
DIODE
12 VOLT
LIGHT BULB
12 VOLT
BAT-
TERY
+ -
FIG. 21. 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.
18 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.
IF ADJUSTMENT IS REQUIRED
1. Remove the top cover assembly from the base unit.
2. Locate the printed circuit boards.
3. Referring to Figure 22, 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 22. 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 19
CONNECTING THE FLEXTIG
CHANGING FROM STANDARD MIG OPERA-
TION TO FLEXTIG OPERATION
1. Unplug the feeder control cable plug from the control receptacle
(OUTPUT)on the welder.
2. Unplug the feeder gas-current cable/power plug and the work cable from the welders front panel.
3. Plug the FLEXTIG torch power cable into the negative (-) weld terminal and plug the work cable into the positive (+) weld terminal. This provides straight polarity current as required for
TIG welding.
4. Plug the FLEXTIG torch switch cord into the welder control receptacle (OUTPUT).
5. Attach the FLEXTIG torch gas hose directly to the gas regulator/flowmeter and adjust the flow to 20 C.F.H.
NOTE
Pure Argon is the shielding gas to be used for TIG welding.
6. Follow the operating instructions in the F L E X T I G m a n u a l
(Form WC5229).
7. To change back to standard MIG operation, reverse the procedure.
CONNECTING THE MHG5-B
SPOOL GUN
CHANGING FROM STANDARD MIG OPERA-
TION TO SPOOL GUN OPERATION
1. Unplug the feeder control cable plug from the control receptacle
(OUTPUT) of the welder.
2. Plug the MHG5-B spool gun control cable plug into the welder control receptacle (OUTPUT).
3. Remove the feeder gas-current cable/power plug from the welders positive (+) weld terminal.
4. Plug the MHG5-B gun cable fitting into the welder positive
(+) weld terminal.
NOTE
Make sure the welder primary gas hose and regulator/flowmeter are connected to a cylinder of the proper shielding gas - 100%
Argon for aluminum and 98%
Argon + 2% O2 for stainless steel and 75% Argon + 25%
CO2 for steel welding.
5. Follow the operating instructions in the MHG5-B manual (Form
WC5268).
6. To change back to standard MIG operation, reverse the procedure.
20 Snap-on Tools Corporation Kenosha, WI 53141-1410
M.I.G. TORCH LINER INSTALLATION
(steel only)
The MIG torch liner provided with the MM250SL is designed for wire diameters from .035 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. 24).
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. 23.
GAS SEAL 3/4"
LINER
STICKOUT
FIG. 23. - 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. 24.
SET SCREW
3/4"
CONNECTOR
PLUG
FIG. 24. - TORCH CONNECTOR END
6.
Following the diagram in FIG.
25, 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
FIG. 25. - 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 21
CONSUMABLE PARTS BREAKDOWN - 15 SERIES M.I.G. TORCH
TG STYLE FRONT END - STANDARD
WIRE SIZE
.020 - .025 inch
.030 inch
.035 inch
.040 - .047 inch
CONTACT TIP
M3-T25
M3-T30
M3-T35
M3-T45
(1-7/16" length)
GAS DIFFUSER
M3T-D
NOZZLE
M3T-N50
(1/2" I.D.)
INSULATOR
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
1/2" Longer
PART NUMBER
CUP (1/2" I.D.)
CONTACT TIP
M3-C50L
.020 - .025 inch M5-T25
.030 inch M5-T30
.035 inch M5-T35
.040 - .047 inch M5-T45
1" Longer
PART NUMBER
M3-C50XL
M5-LT25
M5-LT30
M5-LT35
M5-LT45
SPOT WELDING FRONT END
PART NUMBER
INS. BUSHING
NOZZLE NUT
M3H-B
M3H-NN
SPOT NOZZLE
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
.035 inch M5-T35
.040 - .047 inch M5-T45
(1-15/16" length)
GAS DIFFUSER
M35-D
NOZZLE ASSEMBLY
M35-NA62
CUP
M5-C62
(5/8" I.D.)
NOZZLE BODY
M5-NB
INS. BUSHING
M5-B
SPECIAL APPLICATION PARTS FOR 3-5G STYLE FRONT END
LARGER ORIFICE CUP: Straight Cup (3/4" I.D.) ....... M5-C75
WIRE
SIZE
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 PART NUMBER
.040 - .047 inch M5HGL-045
LINERS & LINER SEALS
FOR STEEL WELDING FOR ALUMINUM WELDING
TORCH
LENGTH
ORDER NUMBER
LINER W/SEAL SEAL ONLY
WIRE
SIZE
TORCH
LENGTH
LINER
ONLY
ORDER NUMBER
.020-.030 inch 10 feet M103L-B M3LS-B (Blue)
SEAL
ONLY
HEATSHIELD
ONLY
.035 inch 10 feet M103AL M3-6ALS M3-THS
.035-.045 inch
10 feet
12 feet
M104L-N
M124L-N
M4LS-N (Natural)
3/64 inch 10 feet M104AL M3-6ALS M3-THS
22 Snap-on Tools Corporation Kenosha, WI 53141-1410
PARTS BREAKDOWN - 15 SERIES MIG TORCH (Cont.)
M3-402
M1-401
TORCH NECK GROUP
M3-101B*
M3-203
(2 REQD.)
M3-112
M3-200B ASSEMBLY
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
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 *
M3-202 M3-211
M3-212 M3-213
M3-407
M1510CBL*
M1512CBL*
QUICK CONNECTOR GROUP
M3-307
M3-309
(2 REQD.)
M3-308
(2 REQD.)
M3-301A
M3-306
M3-305A*
M3-120*
M3-310A
M3-406
(2 REQD.)
Snap-on Tools Corporation Kenosha, WI 53141-1410
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.
TORCH REBUILD PROGRAM
15 SERIES TORCHES CAN
BE REBUILT BY THE
FACTORY FOR A NOMINAL
LABOR + PARTS CHARGE.
23
OPTIONS
FLEXTIG
TIG WELD WITH YOUR
SNAP-ON TOOLS MUSCLE MIG SYSTEM
(MM140SL, MM250SL)
The TIG Welding Process is used to produce the highest quality, porosity-free welds. The FLEXTIG adds TIG Welding capabilities to your Snap-on Tools MIG
Welder.
The FLEXTIG is designed for Tungsten-Inert Gas (TIG) welding with Direct
Current, Straight Polarity (DCSP) on steel, stainless steel, chrome-moly, copper or cast iron (18 Ga. minimum plate thickness).
THE FLEXTIG WILL NOT WELD ALUMINUM.
The FLEXTIG consists of a 200 amp, gas cooled 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 in service.
1 each
1 each
1 each
SPECIFICATIONS
Part Number ........................ FLEXTIG 12 (12-1/2' cable)
FLEXTIG 25 (25' cable)
Torch Rating ....................... 200 Amps, DCSP
Duty Cycle ........................... 100% (reduce duty cycle when operating over 200 amps.)
Cooling Method ................... Gas(100% ARGON)
Shielding Gas
Control Method ............... Gas Valve on Torch
Welding Current
On-Off Control ................ Locking Switch onTorch
1 each
3 each
3 each
2 each
2 each
2 each
6 each
2 each
1 each
3 each
3 each
CONTENTS OF FLEXTIG
TIG Torch with built-in valve
Locking Electric Switch with cord & plug
(installed on torch)
12-1/2 foot Power Cable with Connector
(installed on torch)
15 foot Gas Hose with fitting
(installed on torch)
3C116 Collet - for 1/16" tungsten
3C332 Collet - for 3/32" tungsten
3CB116 Collet Body - for 1/16" tungsten
3CB332 Collet Body - for 3/32" tungsten
3C6 Gas Cup - 3/8" orifice
3C7 Gas Cup - 7/16" orifice
3C8 Gas Cup - 1/2" orifice
300L Long Backcap
1/16" X 3" Tungsten Electrode
3/32" X 3" Tungsten Electrode
MHG5-B
ONE POUND SPOOL GUN
FOR ALUMINUM MIG WELDING
WITH SNAP-ON TOOLS
MUSCLE MIG SYSTEMS
(MM140SL, MM250SL)
The MHG5-B (Motorized Hand Gun System) is a compact, light-in-weight, 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 built into the gun handle.
With the following options, the MHG5-B can also be used to weld steel or stainless steel (.030"-.035" diameter wire size).
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-B
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)
1 each
1 each
MHG5-B SYSTEM COMPONENTS
MHG-5 Spool Gun (only)
HGC9-25 Hand Gun Cable Assembly with fittings - 25 feet length
7 each
1 each
1 each
MG-TXX Contact Tip(1 installed in gun)
2 - .030 (MG-T30)
3 - .035 (MG-T35)
2 - 3/64 (MG-T364)
M35-NA62 Nozzle Assembly
(installed on gun)
M35-D Gas Diffuser
(installed on gun)
24 Snap-on Tools Corporation Kenosha, WI 53141-1410
MATERIAL
CARBON
STEEL
PARAMETER CHARTS
Guide For Setting Welder - Adjust For Best Results
GAS METAL ARC (MIG) PROCESS - DCEP (REVERSE POLARITY)
Note: Settings are approximate and may vary. Adjust for best results.
SHIELDING GAS
TYPE FLOW
WELDING WIRE
TYPE SIZE
75%
ARGON
25%
CO2
25
CFH
(Min.)
ER70S-6
.023"/
.025"
.030"
.035"
.045"
THICKNESS
24 Ga.(.024")
22 Ga.(.030")
20 Ga.(.036")
18 Ga.(.048")
16 Ga.(.060")
14 Ga.(.075")
12 Ga.(.105")
1/8"
16 Ga.(.060")
14 Ga.(.075")
12 Ga.(.105")
1/8"
3/16"
1/4"
14 Ga.(.075")
12 Ga.(.105")
1/8"
3/16"
1/4"
5/16"**
1/8"
3/16"
1/4"
5/16"**
3/8"**
8
4
6
7
4
5
8
3
7
8
5
6
6
7
4
5
6
3
4
5
MIG
VOLTAGE
1
3
3
2
2
9 1/2
4
4 1/2
5
5 1/2
8
9 1/2
4 1/2
5 1/2
7
8
9 1/2
6
8
4
5
4 1/2
6
7
3 1/2
WIRE
SPEED
2 1/2
2 1/2
3
3
4
**Multiple Passes
TIG WELDING PARAMETERS
VOLTAGE
SETTING
TIG 1
" 2
" 3
" 4
OUTPUT
AMPERAGE
50 AMPS
90 AMPS
105 AMPS
150 AMPS
MATERIAL
THICKNESS
18 GA.(.048")
14 GA.(.075")
1/8" (.125")
3/16" (.188")
SPOT TIME PARAMETERS
WIRE
SIZE
ER70S-6 24 GA.(.024")
.030" 22 GA.(.030")
DIA.
MATERIAL VOLTAGE WIRE SPOT
THICKNESS SETTING FEED TIME
18 GA.(.048")
16 GA.(.060")
MIG 4
" 5
" 6
" 7
3
4
4 1/2
5
1
1
1 1/2
1 1/2
Note: Settings are approximate and may vary. Adjust for best results.
PROPER DRIVE ROLL ORIENTATION
USE LARGE
GROOVE FOR
.045" DIA. WIRE
USE SMALL
GROOVE FOR
.023" - .035"
DIA. WIRE
Position adjusting collar to align drive roll groove with centerline of wire guide tube.
Then secure drive roll with the washer and the nut provided.
Snap-on Tools Corporation Kenosha, WI 53141-1410 25
Snap-on Tools Corporation Kenosha, WI 53141-1410
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