OWNER'S MANUAL - Systematics, Inc. 100% Constant … mig combination unit owner's manual the fm140a represents the latest technology in mig combination units. the fm140a operates on

FM140A MIG COMBINATION UNIT

OWNER'S MANUAL

THE FM140AREPRESENTS THE LATEST TECHNOLOGYIN MIG COMBINATION UNITS. THE FM140A OPERATESON 115VOLT AC SINGLE PHASE CURRENT, AND FEATURES"SMOOTH ARC" TRANSFORMER DESIGN CONCEPT.

FOR TECHNICAL SERVICE, CALL TOLL-FREE 1-800-232-9353PROVIDE MODEL & SERIAL NUMBER

FORM WC5357 Rev. 3/98, 8/00,8/02

INSTALLATIONOPERATION

MAINTENANCE

MANUFACTURER’S LIMITED WARRANTY

This equipment is warranted against defects in materialsand workmanship for a period of two years from the date ofpurchase.

EXCEPTION: THE MIG TORCH IS WARRANTED FOR APERIOD 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 returnedto the Manufacturer’s factory, freight prepaid. This warrantydoes not cover: (1) failure due to normal wear and tear; (2)consumable parts, such as, but not limited to, torch contacttips, gas cups and insulating bushings; (3) damage byaccident, force majeure, improper use, neglect, unauthor-ized repair or alteration; (4) anyone other than the originalpurchaser.

THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHERWARRANTIES, EXPRESS OR IMPLIED. THE MANUFAC-TURER SHALL NOT BE LIABLE FOR ANY INJURY TOPERSONS, INCLUDING DEATH; OR LOSS OR DAMAGETO 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 ANDLIABILITY WHATSOEVER IN CONNECTION WITH THEUSE OF THE PRODUCT, AND BEFORE DOING SO,SHALL DETERMINE ITS SUITABILITY FOR HIS IN-TENDED USE, AND SHALL ASCERTAIN THE PROPERMETHOD OF USING IT.

SOME STATES DO NOT ALLOW LIMITATIONS ONHOW LONG AN IMPLIED WARRANTY LASTS, OR THEEXCLUSIONS OR LIMITATIONS OF INCIDENTAL ORCONSEQUENTIAL DAMAGES. SO THE ABOVE LIMITA-TIONS OR EXCLUSIONS MAY NOT APPLY TO YOU. THISWARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, ANDYOU MAY HAVE OTHER RIGHTS WHICH MAY VARYFROM STATE TO STATE.

ARC WELDING CAN BE INJURIOUS TO OPERA-TOR AND PERSONS IN THE WORK AREA -——CONSULT INSTRUCTION MANUAL BEFOREOPERATING.

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 burnskin.• Wear correct eye, ear, and body protection while welding.

FUMES AND GASES can be dangerous to yourhealth.• Use enough ventilation and/or exhaust at the arc.

• Keep your head out of fumes.

• Do not breathe fumes.

READ AND UNDERSTAND THEMANUFACTURER’S INSTRUCTIONS ANDYOUR EMPLOYER’S SAFETY PRACTICES.

See American National Standard Z49.1, “Safety inWelding and Cutting”, published by the AmericanWelding Society, 2501 N.W. 7th St., Miami, Florida33125; OSHA Safety and Health Standards, 29 CFR1910 available from U.S. Dept. of Labor, Wash.,D.C. 20210.

! WARNING

TABLE OF CONTENTSELECTRICAL SUPPLY REQUIREMENTS.......................... 1INTRODUCTION .................................................................. 2SPECIFICATIONS ............................................................... 3INSTALLATION ................................................................... 4OPERATION ........................................................................ 7MAINTENANCE ................................................................. 12TROUBLE SHOOTING CHART ........................................ 14CONNECTING TIGPAK OR SPOOL GUN ........................ 19PARTS BREAKDOWN - MIG TORCH .............................. 21OPTIONS - TIG PAK, SPOOL GUN .................................. 23

Snap-on Tools Corporation Kenosha, WI 53141-1410

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

ELECTRICAL SUPPLY REQUIREMENTS FOR THE FM140AEnsure that there is a 115 volt single phase, 20 amp electrical supply within easy reach

of the unit. The input cable supplied is 20 feet long. A 50 foot cable is an optional extra. Theplug which is factory installed is suitable for use up to 120 amps of output. The plug mustbe changed if the welder is used above 120 amps of output. Attach a suitable plug makingsure the green wire is attached to ground. Refer to boxes below with the WARNING andNOTE headings for more information. All wiring should be performed by a qualifiedelectrician.

WARNINGTo conform to the National Electrical Code, the power input plug must bechanged if this unit is to be operated on a 20 amp circuit or higher.

Never change fuses or circuit breakers to a higher value than the wires andoutlet are designed for.

Breaker size - Wire size15 Amp 14 Gauge20 Amp 12 Gauge30 Amp 10 Gauge

Do not rely on the circuit breaker built into the FM140A to protect your wiring.This circuit breaker protects the FM140A internal wiring only.

Do not use undersized extension cords. Follow the cord manufacturer'srecommendations as to current carrying capacities.

Make sure all electrical wiring is installed by a qualified electrician.

NOTE

The maximum output of the FM140A will be limited by the size (amp rating) ofthe circuit used.

Operation on a 15 amp circuit (14 gauge wire) will limit maximumoutput to 100 amps.Operation on a 20 amp circuit (12 gauge wire) will limit maximumoutput to 120 amps.Operation on a 30 amp circuit (10 gauge wire) will result in maximumoutput of 140 amps.

FM140A output will be limited also by low input voltage (less than 120 volts),long input cords and use of extension cords.

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

INTRODUCTIONThe Snap-On Tools FM140A is a

combination welding power source,wire feed unit, MIG torch andaccessory package. It operates on115 volts AC input current and is de-signed to meet the requirements ofauto body repair shops. The FM140Aproduces fusion welds by the GasMetal Arc Welding process (GMAW orMIG), on steel up to 1/4"thick(aluminum 3/16") , using .023"through .045" steel wire and .025"through 3/64" aluminum wire with theoptional MHG5-A.(Optional linersand contact tips must be purchasedto cover given wire sizes). Heaviersections can be easily welded usingslightly different techniques. Con-sumable MIG Spot Welding on steelcan be performed with this unit.

The number of controls on the unithave been reduced to assist inexpe-rienced operators learn MIG weld-ing. This facilitates rapid set upfor welding different thicknessesof material requiring various heatinputs. The HEAT (voltage) controladjusts the welding voltage and theWIRE SPEED control adjusts the speedof the wire drive motor.

THE MIG PROCESSAS APPLIED TO THE FM140A

The MIG process uses a bare,consumable electrode in the form ofspooled wire, which is fed by acontrollable speed feed unit throughthe cable and torch to the weld. Theemerging wire and the weld areshielded by a stream of CO2, Argon,or a mixture of the two, whichprevents oxidation of the moltenweld puddle. The gas shield enableshigh quality welds to be madewithout the use of flux, eliminatingthe need for slag or flux removalafter the weld is completed.

The consumable electrode wire ismelted and transferred to the weldpuddle by the "short arc" or "dip"transfer mode.

POWER SOURCE

WIRE SPOOL

FEEDROLLS

WORK

MIGTORCH

+REVERSEPOLARITY

(STD.)_

SHIELDING GAS

This sequence of events is re-peated up to 200 times per second.Short arc transfer is suitable forpositional welding. The heat inputto the workpiece is kept to a minimumwhich limits distortion and makespossible the welding of thin sheetmaterial.

FIGURE 2. SHORT ARC TRANSFER

ELEC-TRODE

WORK

SHORT ARC OR DIP TRANSFER

Short arc transfer occurs at 12 to22 arc volts (voltage while weld-ing), depending on wire size. Weld-ing commences as the arc is struckand a weld pool is formed. The tipof the electrode wire dips into thepool and causes a short circuit. Theshort circuit current flow causes arapid temperature rise in the elec-trode wire and the end of the wireis melted off. An arc is immediatelyformed between the tip of the wireand the weld pool, maintaining theelectrical circuit and producingsufficient heat to keep the weldpool fluid. The electrode continuesto feed and again dips into the pool.

FIG. 1. SCHEMATIC OF MIG PROCESS


DESCRIPTIONThe FM140A consists of a combina-

tion MIG welding power source andwire feed unit, a MIG torch with 10foot cable, a fifteen foot work(ground) cable with ground clamp, atwenty foot power input cable, a gasregulator/flowmeter, a torch acces-sory kit, and a built-in cylinderrack and industrial wheel kit.

Welder controls are simple andclearly marked. The output voltageis controlled by a twelve positiontap switch, providing twelve volt-age selections. Wire feed speed iscontrolled by the wire speed poten-tiometer.

A SPOT WELD control switch andadjustable timer circuit provideConsumable MIG Spot Welding capa-bilities of light gauge steel.

SPECIFICATIONSPART NUMBER: FM140A

INPUT POWER REQUIREMENTS:Voltage 115 volts ACPhase single phaseFrequency 50/60 hertzCurrent (see OUTPUT POWER)

OUTPUT POWER @ 100% Duty Cycle:15 Amps Input Current = 100 Amps20 Amps Input Current = 120 Amps30 Amps Input Current = 140 Amps

DUTY CYCLE TIME PERIOD:10 minutes

OPEN CIRCUIT VOLTAGE:18 - 30 volts DC

ARC VOLTAGE: 14 - 26 volts DC

WELD CURRENT RANGE:30 - 140 amps

DUTY CYCLE - SPOT WELDING:30 X 2 second spots per 10 minuteperiod

SPECIFICATIONS (Cont.)SPOT WELD TIME: 0 to 3 seconds

WIRE TYPES: mild steel,stainless steel, aluminum,

bronze, flux cored, flux cored -gaslessRecommended (for steel) ER70S-6

WIRE SIZES: .023" - .045" steel,3/64" aluminum,

(.023" - 3/64" alum. w/ Spool Gun).030" - .035" bronze,

.030" - .045" flux cored(gas shielded or gasless)

Recommended Size:Aluminum .035Others .030

WIRE FEED SPEED RANGE:10 - 500 inches per minute

SHIELDING GASES:For Steel Argon/CO2 mix or CO2Recommended(for steel) 75% Argon/

25% CO2For Aluminum, Bronze ArgonFor Stainless Steel

98% Argon + 2% OxygenFor Flux cored Argon/CO2 mix or

CO2

DIMENSIONS:Height 34 in. (86.4 cm.)Width 14-1/2 in. (36.8 cm.)Depth 23-1/2 in. (59.7 cm.)Weight 105 lbs. (47.7 kg.)

TORCH SPECIFICATIONS

NECK ANGLE: 60 degrees

LEAD LENGTH: 10 feet

OVERALL LENGTH: 10 feet

COOLING METHOD: gas (air)

RATING - 60% DUTY CYCLE:With Argon/CO2 gas 200 ampsWith CO2 gas 225 amps


CHECK LISTTHE SNAP-ON TOOLS FM140A INCLUDESTHE FOLLOWING:

1- Combination Power Source/WireFeeder

1- Cylinder Rack/Industrial WheelKit

1- 15TG10 MIG Torch with adjustablenozzle

1- 20 foot Power Input Cable withPlug

1- 15 foot Work(Ground)Cable andClamp

1- 200PK-1 Parts Kit1- GR-FM Gas Regulator/Flowmeter1- Nozzle, 1/2 in. orifice (in-

stalled 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 WHICHARE NOT PROVIDED WITH THE FM140A

1. Full cover welding helmet withproper colored lens (shade 9 to11 depending on operator’s pref-erence).

2. Proper shielding gas and cylin-der.

3. Leather welding gloves.

4. 115 volt single phase AC power.

5. Other personal protective equip-ment which may vary to match thewelding being performed.

INSTALLATIONPOSITIONING THE UNIT

Locate the unit near the weldingarea and position it so there isadequate clearance all around forventilation and maintenance.

ELECTRICAL SUPPLY

Follow the Electrical Supply Re-quirements on page 1.

SHIELDING GAS CONNECTIONS

1. Place a cylinder of the appro-priate shielding gas in the rackat the rear of the machine andsecure it with the chain pro-vided.

2. Rapidly open and close the cyl-inder valve. This will purgedust and foreign matter from thevalve.

Take care to point thevalve outlet away from your-self or other people, asescaping high pressure gasmay be dangerous.

3. Attach the gas regulator/flow-meter supplied with this unit,to the cylinder valve using asuitable wrench.

NOTEIf this unit is to be usedwith 100% CO2 shieldinggas, an optional gas regu-lator coupler is required.

FIG. 3. GAS FLOW ADJUSTMENT

CAUTION

GAS FLOWADJUSTING

KNOB

INLETFITTING

TOTANK

FLOW TUBEINDICATESFLOW RATE

IN C.F.H.

OUTLETFITTING

TOWELDINGMACHINE

GAUGE -INDICATES

TANKPRESSURE


FITTING AND THREADING THE ELEC-TRODE WIRE - ALWAYS USE ER70S-6WELDING WIRE

1. Remove the wire spool clip fromthe spool hub.

2. Unpack the spool of welding wirefrom its protective packaging.

3. Place the spool of ER70S-6 weld-ing wire onto the hub. The wireis fed off the bottom of thespool.

Look for and remove anywire protruding from thecenter of the spool. Theprotruding wire is elec-trically HOT during weld-ing and must not touch themachine.

4. Replace the spool clip on thehub.

5. Unlatch the pressure roll armand swing it open.

6. Make sure the double v-groovedrive roll is installed to matchthe wire size. To change thewire size setting, remove thedrive roll, turn it over andreinstall it on the shaft.

(continued on following page)

SHIELDING GAS CONNECTIONS(Cont.)

4. Fit the gas hose from the weldingmachine to the regulator outletfitting and tighten it with asuitable wrench. Open the cyl-inder valve.

5. Check that the gas regulator isproperly adjusted. When weldingsteel, the gas flow rate is 30CFH. When welding aluminum, thegas flow rate is 40 CFH.

NOTEThe FM140A must be turned"ON" and the MIG torchtrigger depressed, beforethe gas flow rate can beadjusted.

TORCH CONNECTION

1. Open the access door of themachine to its fullest extent.

2. Back out the thumb screw locatedon the drive assembly mountingbracket inside the machine. In-sert the MIG torch into the torchpanel mount on the front paneland TIGHTEN THE THUMB SCREW.

CAUTION

FIGURE 4. TORCH CONNECTION

FIG. 5. DOUBLE GROOVE DRIVE ROLL

"A" SIDE FACING IN FOR.023" - .035" STEEL WIRES

"B" SIDE FACING IN FOR.040" - .045" STEEL WIRESAND 3/64" ALUMINUM WIRES

TORCH PRESSUREPANEL ROLLMOUNT

MIGTORCH

THUMBSCREW

DRIVE DRIVEROLL ASSEMBLY


FITTING AND THREADING THE ELEC-TRODE WIRE (Continued)

12.Install the contact tip over theprotruding wire and tighten itfirmly using a proper size wrench.Make sure the tip is the correctsize for the wire being used.

13.Install the nozzle on the torch.For steel, the contact tip shouldbe flush or stick out up to 1/16inch beyond the end of thenozzle. For aluminum, the con-tact tip should be recessed 1/8to 1/4 inch inside the nozzle.Using wire cutters, trim off thewire so the stickout is approxi-mately 1/4 inch for steel or 1inch for aluminum. For aluminum,the end of the wire should bebent over so it does not JAM intothe work. This is called a"scratch start".

FITTING AND THREADING THE ELEC-TRODE WIRE (Continued)

7. Release the wire from the spooland trim off the kinked end withwire cutters. The wire must bestraight when it enters theinlet guide.

8. Thread the electrode wire throughthe inlet guide, over the feedroll and into the torch liner.Ensure that the wire locates inthe feed roll groove. Do notallow the wire on the spool toloosen.

9. Close and relatch the pressureroll arm.

10.Stretch the torch cable straightout in front of the machinemaking sure there are no kinks.Remove the nozzle and contacttip from the torch.

11.Turn "ON" the circuit breaker onthe front of the machine. Thecooling fan will start and the"ON" indicator light will illu-minate. Set the HEAT controlswitch to "4", the functionswitch to "CONTINUOUS WELD" andthe WIRE SPEED control to "7".Pull the trigger on the MIGtorch. The wire feed system willstart and wire will be fedthrough the cable liner andtorch. If the wire does not feed,or appears to slip, tighten thepressure roll arm adjusting nut.Feed the wire until it protrudesfrom the front of the torchapproximately six inches.

Keep hands and face awayfrom the front of the torchand do not allow the wire tocontact ground. The wireis electrically HOT whenthe torch trigger is actu-ated.

CAUTION

1"STICK-OUT

1/4"STICK-

OUT

FOR ALUMINUM:CONTACT TIP

RECESSED 1/8" - 3/8"

FOR STEEL:CONTACT TIP

FLUSH WITH NOZZLE

14.For steel welding only, sprayanti-spatter compound inside thenozzle and on the outside of thecontact tip. For aluminum orstainless steel welding, NO anti-spatter compound can be used asit will contaminate the weld.

FIGURE 6.WIRE STICKOUT - STEEL, ALUMINUM


WIRE FEED PRESSURE ROLL ADJUSTMENT

The wire feed pressure roll isadjusted to the proper setting at thefactory, prior to delivery. It may benecessary to readjust the setting ascomponents "seat in" or when changingto a different diameter wire. Tocheck for proper roll pressure, holdthe torch in one hand and the wirebetween two fingers of the other hand.Pull the torch trigger. If the wirecontinues to feed when firm pressureis applied to the wire, the pressureroll adjusting nut should be backedoff until the feed rolls start toslip. If the wire will not feed withvery little pressure applied, thepressure roll adjusting nut should betightened.

OPERATIONThe following operating instruc-

tions and detailed setup proceduresenable an operator without previousexperience to produce quality fu-sion welds. It is recommended thatan operator without prior experi-ence with this equipment, firstpractice on scrap metal of the sametype and thickness as the materialto be welded.

OPERATING SEQUENCE

1. Make sure that the pieces of metalto be welded are free of grease,dirt, paint and scale. Use a wirebrush to remove paint and scale.Paint must be completely removedto bare metal. Grease and oilcould burn and cause a fire orsafety hazard. Failure to cleanthe metal properly will result inerratic and porous welds.

2. Install the unit as directed inthe installation instructionsand make sure the work clamp isfirmly attached to a cleanedarea on the workpiece to bewelded.

3. Open the shielding gas cylindervalve. Press the torch triggerand listen for gas flow. Adjustthe gas flow rate to 30 CFH forsteel and 40 CFH for aluminum.

The welding wire will feedwhen the trigger is actu-ated. Take care that thewire is not directed to hityourself or anything that isgrounded to the ground wireon the welder.

CAUTION

PRESSURE ROLLADJUSTING NUT

PRESSUREROLL

PRESSUREROLL ARM

DRIVEROLL

TORCH SELECTOR CABLE

Plug the torch selector cable intothe Positive (+) terminal on themachine(see PROCESS SELECTION onpage 8 for further details).

WORK (GROUND) CABLE

Uncoil the work cable and plug itinto the negative (-) terminal onthe machine.

FIGURE 7.PRESSURE ROLL ADJUSTMENT


PROCESS SELECTIONThe following controls are lo-

cated on the front of the machine.

A.WIRESPEED

B."ON"INDICATORLIGHT

C.CIRCUITBREAKER

D.(+)POSITIVETERMINAL

E.(-)NEGATIVETERMINAL

F.FUNCTIONSWITCH

G.HEAT(VOLTAGE)CONTROL

H.SPOTTIMER

I.TORCHPANELMOUNT

J.TORCHSELECTORCABLE

FIGURE 8. FRONT PANEL

E. -(NEGATIVE) TERMINALNegative output terminal. Theground cable is plugged intothis terminal during standardwelding operation. The torchselector cable can be pluggedinto this terminal for straightpolarity welding on very lightsheet metal or for using fluxcored gasless wire.

F. FUNCTION SWITCHControls mode of operation ofwelding machine. "CONT. WELD"position is for normal, continu-ous welding operation. "SPOT"position puts the spot timer inthe circuit for automatic MIGConsumable Spot Welding. "STITCH"position is used for stitchwelding on very light material.When in "STITCH" position, thelength of time the welder is "ON"and feeding wire is controlledby the Spot Timer. The lower theSpot Timer setting, the fasterthe welder cycles on and off.

G. HEAT (VOLTAGE) CONTROLTwelve position switch adjustswelder output voltage.

H. SPOT TIMER (STITCH TIMER)After the torch trigger is actu-ated, the timer allows the wireto feed and the gas and power toflow for the time selected. TheFunction Switch must be set inthe "SPOT" position (or the"STITCH" position for stitchwelding).

I. TORCH PANEL MOUNTCombination power output, con-tactor switch connection, gassupply connection, and wire feedoutput in a single unit.

J. TORCH SELECTOR CABLEPlugs into (+) positive terminalfor standard welding operationor (-) negative terminal forstraight polarity welding onvery light sheet metal or forusing flux cored gasless wire.

A. WIRE SPEEDPotentiometer controls speed ofwire drive motor to give wirespeed of 10 to 500 inches perminute.

B. "ON" INDICATOR LIGHTIlluminates when the circuitbreaker on the machine is "ON".

C. CIRCUIT BREAKERPrimary power switch and over-load protection device.

D. +(POSITIVE) TERMINALPositive output terminal fromthe welder DC power source. Thetorch selector cable is pluggedinto this terminal for standardwelding operation. The groundcable can be plugged into thisterminal for straight polaritywelding on very light sheetmetal or for using flux coredgasless wire.


WELDINGOptimum control settings will

vary according to the thickness ofthe metal, the type of joint,operator preference, etc. Best re-sults can be obtained through expe-rience with the welding machine orby making trial welds. Select somesample material of the same type andthickness as the material to bewelded. Set the welding controls foroptimum results using the samplematerial and weld until experienceis gained using the unit.

CONTINUOUS WELDING ONSTEEL

1. Trim the electrode wire to leaveapproximately 1/4 inch stickoutbeyond the end of the contact tipand install the welding nozzle.The contact tip should be flushor stick out up to 1/16 inchbeyond the end of the nozzle.

NOTEWhen welding steel, the idealposition for holding the torchis inclined approximately 30degrees towards the directionof travel. This allows the arcto be seen easily, resulting ingreater control of the weldpool. Most right-handed wel-dors move from left to right.This method, known as forehandwelding, provides a gas shieldfor the cooling weld puddle andhelps in obtaining an oxida-tion free weld deposit.

30 DEGREES

DIRECTIONOF TRAVEL

SHIELDINGGAS

WORK

FIGURE 10. TORCH POSITIONFOR WELDING STEEL

- RIGHTHANDED WELDOR

4. Use a welding helmet with a shade9 to 11 filter lens, depending onoperator preference.

5. Squeeze the torch trigger. Thewire will feed and an arc will beestablished. As the weld isdeposited, move the torch slowlyalong the weld seam at a con-stant speed, maintaining a con-stant arc length and a constanttip-to-work distance.

2. Spray the inside of the nozzleand the outside of the contacttip with anti-spatter spray.

3. Locate the torch over the jointto be welded with the contact tipapproximately 3/8 inch from thework surface.

FIGURE 9. NOZZLE ADJUSTMENTFOR WELDING STEEL

CONTACT TIP(FLUSH TO

1/16" STICKOUT)

ELECTRODE WIRE(1/4" STICKOUT)

NOZZLE


CONTINUOUS WELDINGON ALUMINUM

(Optional Nylon liner and 100% Argonshielding gas are required)

1. Trim the electrode wire, leavingapproximately 1 inch stickoutbeyond the end of the nozzle.Bend the wire over as shown, toallow for a scratch start. Thecontact tip should be recessedinside the nozzle approximately3/8 inch. This helps prevent thewelding wire from burning backto the contact tip.

4. Follow steps 4 and 5 as in"Continuous Welding on Steel".

MIG SPOT WELDING ON STEEL

NOTEMIG Spot Welding is NOTrecommended for aluminum.

1. Trim the electrode wire so thestickout from the contact tipwill be flush with the nozzleface, and fit the spot nozzle inplace.

2. Set the HEAT control to "6", theWIRE SPEED control to "8", theFunction Switch to "SPOT", andthe TIME control to "2", thenadjust the TIME control to ob-tain a perfect weld.

3. Locate the torch on the area tobe welded and press the nozzlefirmly against the work to holdthe metals in place.

DIRECTIONOF TRAVEL

WORK

10 DEGREES

SHIELDING GAS

FIGURE 12. TORCH POSITIONFOR WELDING ALUMINUM

NOZZLE

CONTACT TIP(RECESSED 3/8")

ELECTRODEWIRE

(1" STICKOUT)

2. DO NOT spray any anti-spattermaterial on the torch or basemetal and DO NOT attempt tolubricate the aluminum wire inany way. Weld contamination willoccur unless the wire, basemetal, torch and work area arekept clean.

3. Bring the torch nozzle to 1/2 to5/8 inch from the workpiece. Therecommended position of the torchand direction of travel forwelding aluminum are shown inFigure 12.

FIGURE 11.NOZZLE ADJUSTMENT

FOR WELDING ALUMINUM


MIG SPOT WELDING ON STEEL(Continued)

4. Guard the eyes against stray arcflash. A weldor’s helmet is notnecessary when spot welding.However, care must be taken toavoid looking at the arc.

5. Actuate the torch trigger tostart the weld sequence. Whenthe timer switches off the weldcurrent, release the trigger butmaintain firm contact betweenthe torch and work. Wait onesecond for the weld puddle tosolidify, then move to the nextspot position. If the wire freezesin the puddle, a quick squeeze ofthe torch trigger will melt itoff.

STITCH WELDING ON STEEL

NOTEStitch Welding is used forvery light material.

1. Set Function Switch to "STITCH".

2. Adjust the TIME control to setthe time the welder is "on" andfeeding wire. The lower thesetting, the shorter the "on"time and the faster the unitcycles on and off.

3. Weld using "Continuous Welding"torch position and direction oftravel.

WORKSPOTWELD

SPOTWELDNOZZLE

CONTACTTIP

PRESS NOZZLEFIRMLY

AGAINST WORK

FIGURE 13. MIG SPOT WELDING

6. To ascertain a good spot weld,look at the back side of thewelded material. A small melt-through of approximately 1/16inch diameter is ideal.

DIRECTIONOF TRAVEL

WORK

SHIELDING GAS

30 DEGREES

FIGURE 14. STITCH WELDING


OPERATING HINTSBURN BACK

In the event the welding wireburns back into the contact tip:

1. Remove the nozzle from the torch.

2. Unscrew the contact tip from thegas diffuser using a pair ofpliers as the tip will be veryhot.

3. Free the wire from the contacttip and clean the end of the tipso the new wire will slidesmoothly through the hole. DONOT use a drill or reamer toclean the hole as that willenlarge it and cause an erraticarc. Replace the contact tip ifit is badly damaged.

4. Install the contact tip in thetorch and tighten it firmly withan appropriate wrench.

5. Reinstall the torch nozzle.

6. If the wire continues to burnback, check for erratic wirefeed, or speed up the wire byincreasing the WIRE SPEED con-trol setting or reducing theHEAT control setting.

SPATTER

Before beginning to weld andperiodically during welding, thetorch nozzle must be removed and thespatter (small globules of meltedmetal) cleared from the inside ofthe nozzle and the outside of thecontact tip and the gas diffuser.Spatter buildup between the contacttip and the nozzle can cause a shortcircuit and consequently, failureof the torch or welding machine. Thefrequent use of anti-spatter spraywill help prevent the adherence ofspatter to the torch components.

NOTEDO NOT use any anti-spatterspray when welding alumi-num or stainless steel.

Restricted gas flow, holding thetorch too far from the work piece,and the use of CO2 gas rather than75% Argon - 25% CO2 will increase thespatter levels.

MAINTENANCETo ensure that this equipment

maintains its operating efficiency,the following maintenance scheduleand procedures are recommended.These routines should be performedregularly by the operator.

REGULARLY - Usage and shop condi-tions determine frequency.

1. Remove and clean the torch nozzleand contact tip. The use of anti-spatter spray will reduce theadherence of spatter and makesits removal easier.

2. Blow out the torch liner prior tothe installation of each newspool of wire. The contact tipand gas diffuser must be re-moved, but it is not necessary toremove the liner.

3. If the torch cable assembly isbent severely, a kink may devel-ope in the steel liner. This cancause wire feeding problems so anew liner should be installed.

WEEKLY

1. Remove dirt and dust from thewire feed compartment. Use lowpressure dry compressed air.



In the event of the failure of anypart of this equipment, contact yourSnap-On Tools representative forreplacement parts and service. Whenordering parts from Snap-On ToolsCorporation, order numbers shouldbe preceded by "CKS".

DO NOT lift the unit when a gascylinder is installed or at-tached.

DO NOT weld on any item that hasa common electrical ground.

DO NOT operate the unit withthe side panels removed. Over-heating will occur.

DO NOT weld upon the case of thewelding machine.

ONLY a qualified electricianshould perform work inside thewelding machine.

ALWAYS wear protective cloth-ing, leather gloves and a fullcover welding hood while weld-ing.

DO NOT weld in a closed in area.Proper ventilation is a neces-sity, or a fresh air suppliedhood should be worn.

WHEN welding near combustibles,a helper or "watcher" shouldstand by with a fire extin-guisher or other fire protec-tive device.

NEVER weld on a closed vesselor one that has containedcombustibles.

IF IN DOUBT - DON’T DO IT!

BE SAFE - DON’T BE SORRY!

MAINTENANCE (Cont.)2. Remove dirt and metal deposits

from the grooves in the feedroll. If the grooves are badlyworn, the feed roll should bereplaced. If the pressure rolldoes not turn freely, it shouldbe replaced.

3. Check all gas fittings for leaks.Tighten or repair as required.

EVERY SIX MONTHS

1. Disconnect the welder from itsmain power supply.

2. Remove the machine’s side pan-els.

3. Using low pressure dry com-pressed air, remove dust anddirt from all components.

4. Check for loose or frayed wir-ing. Particularly check weldingcurrent wire connections.

5. Replace the torch liner if nec-essary.

RECOMMENDEDCUSTOMER SPARE PARTS

The Snap-On Tools FM140A is amachine of proven design and relia-bility. Following is a list ofconsumable items recommended asspare parts for this unit.

contact tips ........ M3-T30, etc.gas nozzles .............. M3T-N50nozzle insulators .......... M3T-Bgas diffusers .............. M3T-Dsteel liner(.020-.030) ... M103L-Bsteel liner(.035-.045) ... M104L-N

WARNING


TROUBLE SHOOTING (SYMBOL*)FOR TECH. SERVICE, CALL TOLL-FREE 1-800-232-9353

The Trouble Shooting Chart is a guide in identifying and correctingpossible troubles which may occur when operating this equipment.

FAULT POSSIBLE CAUSE REMEDY

(SYMBOL*) - USE THIS IDENTIFIER, ALONG WITH THE SCHEMATIC DIAGRAM FOUND IN THE SERVICEMANUAL, FOR TROUBLE-SHOOTING PURPOSES.

EQUIPMENT MALFUNCTION

No main power, FM140A 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 FM140A. (CB1) breaker.light is off. Loose or broken connection Tighten or repair

in power input circuit. connection.

Main power on, MIG torch unplugged. Plug in MIG torch.torch Faulty trigger switch. (S1) Replace micro switch.trigger Fault in torch cable. Check torch cableactivated, for continuity.no response. Loose or broken connection Check or repair

on wiring harness. connections.Wire feed motor unplugged. Plug in motor.

(RC1)Faulty control transformer. Check for 28VAC output.

(T2)Loose spot timer circuit Install properly.

board. (PC2)Defective spot timer Replace board.

circuit board. (CR2)(PC2)

Main power on, Pressure roll arm unlatched. Latch arm & add tension.torch "Slippage" at drive rolls. Increase drive rolltrigger tension. See page 7.activated, Wire path restricted. Clean path or replaceno wire feed torch liner.but contactor 5 amp mini breaker is Reset or replaceoperates & tripped. (CB2) breaker.gas flows. Wire feed circuit board Calibrate wire feed

needs calibrated. circuit board. Seepage 18.

Defective wire feed Replace circuit board.circuit board. (PC1)

Faulty wire feed motor Repair or replaceor connection. (M) faulty item.

Check motor on a12VDC battery.

Faulty motor relay. (CR1) Sand points or replacerelay.

Loose or broken connection. Tighten or repairconnection.



TROUBLE SHOOTING (Cont.) (SYMBOL*)FOR TECH. SERVICE, CALL 1-800-232-9353


EQUIPMENT MALFUNCTION (Cont.)

Main power on, Loose torch thumb screw. Tighten thumb screw.torch Broken or loose connection. Check cables fortrigger continuity.activated, Repair or tightenno welding connections.current, but Unplugged or faulty power Plug in or replacegas flows & contactor switch. (W) switch.wire feeds. #1 Transformer wire off.(W) Reattach wire.

"Opened" thermal switch. Allow unit to cool, then(TP1) retry.

Faulty diodes. Check diodes. See page(D1-D2) 17.

Torch No shielding gas Replace tank.trigger - tank empty.activated, Loose or broken Tighten or repairno gas flow, connections. connections.but contactor Faulty Gas solenoid Repair or replaceoperates & valve. (GS) valve.wire feeds. Clogged gas flow path. Locate & clean clog.

Loose spot timer circuit Install properly.board. (PC2)

Defective spot timer Replace board.circuit board. (CR2)(PC2)

FAULTY WELDS

"Jerky" or Worn , kinked or dirty torch Clean or replace"slipping" liner. liner.wire feed. Wire spool turns too Lubricate spool hub

hard. with a dry lubricantWorn 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). Clean or replace guides.Sticking pressure roll. Replace pressure roll.Feed roll tension incorrect. Adjust feed roll ten-

sion. See page 7.


TROUBLE SHOOTING (Cont.) (SYMBOL*)FOR TECH. SERVICE, CALL TOLL-FREE 1-800-232-9353


FAULTY WELDS (Cont.)

"Birdnesting" Excessive feed roll tension. Reduce tension. See page(Wire wrapping 7.around drive Poor alignment. Make sure wire isrolls) properly aligned

across roller.Oversize contact tip. Replace contact tip with

correct size.

"Cold" weld Incorrect machine settings. Increase heat & wirepuddle. speed.

Incorrect shielding gas. Replace with proper gas.Excessive wire stick-out. Hold torch closer to

work.Poor connections. Check and tighten all

connections.Faulty diode. Test diodes, replace

(D1-D2) faulty diode(s). Seepage 17.

Heavy spatter. Incorrect machine settings. Increase heat, decreasewire feed speed.

Incorrect shielding gas. Replace with proper gas.Excessive wire stick-out. Hold torch closer to

work.

Porous welds. No shielding gas. Turn on gas.Not enough gas flow. Check hoses for leaks,

make sure cylinder isnot empty. Increaseflow rate.

Contaminated wire. Change wire.Faulty gas solenoid. 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 SERVICEMANUAL, FOR TROUBLE-SHOOTING PURPOSES.


TESTING AND REPLACING DIODESSilicon diodes have proven to be

highly reliable. However, weld spat-ter build-up in the torch can shortout and cause diode overload andconsequent failure. The followinginformation is provided as a guideshould a failure be suspected.

Silicon diodes exhibit two mainfault conditions:

1. "Open Circuit" - causes a reduc-tion in welder output.

2. "Short Circuit" - causes thecircuit breaker to trip.

If a fault is suspected, the diodemay be tested as follows:

1. Remove the top connection ofeach diode to be tested.

2. Using a Volt-Ohm Meter set onRX1K, check for continuity throughthe diode in both directions. Ifthere is no continuity in eitherdirection, the diode is in "opencircuit" condition and must bereplaced. If there is continuityin both directions, the diode isin "short circuit" condition andmust be replaced. If there iscontinuity in one direction only,the diode is functioning prop-erly.

3. If all the diodes check outsatisfactorily with the Volt-Ohm Meter, a load check must bemade. This is easily accom-plished using a twelve voltbattery and a twelve volt lightbulb connected as shown. Againtest for electrical current flowin both directions. The bulbshould light in one (1) direc-tion only - not both.

NEVER use a "megger" or ahigh voltage device to testa diode.

CAUTION

+ -

+ -

12 VOLTLIGHT BULB

DIODE 12 VOLTBATTERY

12 VOLTLIGHT BULB

DIODE 12 VOLTBATTERY

FIGURE 15. DIODE LOAD CHECKCONNECTION DIAGRAM

- TEST FOR FLOW IN BOTH DIRECTIONS

4. When replacing diodes, it isvery important that a heat con-ductive compound (Radio Shack#276-1372) be used where thediode makes contact with thealuminum heat sink. Do not greasethe threads on the diode.


WIRE FEED CALIBRATION

Due to INPUT LINE VOLTAGE varia-tions supplied to the welding ma-chine. The WIRE FEED SPEED should bechecked for proper operation.

TO CHECK

1. Remove any tension on the driveroll.

2. Turn the wire speed dial (on thefront of the machine) to "0".

3. Activate the torch trigger.

4. The bottom drive roll shouldrotate very slowly(non-jerky).

5. If this proves to be true, noadjustment is required.

IF ADJUSTMENT IS REQUIRED

1. Remove the top cover assemblyfrom the unit.

2. Locate the printed circuit boards.

3. Referring to Figure 16, locatethe trim resistor, this is lo-cated in the upper right handcorner of the wire feed PC board.

4. Turn the wire speed dial (on thefront of the machine) to "0".

5. Remove any tension on the driveroll.

6. Activate the torch trigger.

7. Rotate the trim resistor, backand forth, until the bottomdrive roll moves.

8. Calibrate so the bottom driveroll rotates very slowly (non-jerky).

9. If calibrated correctly the wirespeed dial (on the front of themachine) should affect the speedof the drive roll from "0" thru"10".

10.Adjustment is now complete!

FIGURE 16. WIRE FEED PC BOARD

TRIMRESISTOR


3. Move the selector hose to the"SPOOL GUN" fitting and tighten.

4. Install the thread cap (removedin step 1) on the "MIG TORCH"fitting to prevent dirt andcontaminants from entering theunused gas line.

5. Unplug the wire feed motor plugfrom the function receptacle.

6. Plug the MHG5-A spool gun con-trol cable plug into the welderfunction receptacle.

7. Remove the torch selector cablefrom the welder positive (+)weld connector.

8. Plug the MHG5-A gun cable fit-ting into the welder positive(+) weld connector.

NOTEMake sure the gas regulatorand welder gas hose areconnected to a cylinder ofthe proper shielding gas -100% argon for aluminumwelding; 75% argon + 25%CO2 for steel welding. 98%argon + 2% O2 is recom-mended for stainless steelwelding.

9. Follow the operating instruc-tions in the MHG5-A manual (Form6455).

10.To change back to standard MIGoperation, reverse the proce-dure.

CONNECTING TIGPAK OR SPOOLGUN

FIG. 17. BULKHEAD CONNECTIONS

CHANGING FROM STANDARD MIG OPERATIONTO TIGPAK OPERATION

1. Unplug the wire feed motor plugfrom the function receptacle.

2. Unplug the torch selector cableand the ground cable from thewelder front panel.

3. Plug the TIGPAK torch powercable into the negative (-) weldconnector and plug the groundcable into the positive (+) weldconnector. This provides straightpolarity current as required forTIG welding.

4. Plug the TIGPAK torch switchcord into the welder functionreceptacle.

5. Attach the TIGPAK torch gas hosedirectly to the gas regulator.

NOTEPure argon is the shieldinggas to be used for TIGwelding.

6. Follow the operating instruc-tions in the TIGPAK manual (FormWC5228).

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

CHANGING FROM STANDARD MIG OPERATIONTO SPOOL GUN OPERATION

All current model MIG machines areequipped with bulkhead gas fittingsfor quick and easy changeover fromstandard MIG operation to spool gunoperation.

1. Remove the thread cap from the"SPOOL GUN" fitting.

2. Unscrew the selector hose fromthe "MIG TORCH" fitting.

LABEL THREAD CAP

BULKHEADFITTINGS WIRE FEED

MOTORSELECTOR PLUG

HOSE (PLUGGEDINTO

WIRE FEED FUNCTIONMOTOR RECEPTACLE)

The MIG torch liner providedwith the FM140A is designed for wirediameters from .020 thru .030. Iflarger wire diameters are to be fedand or there is a problem (i.e. clog,kink, etc.), a liner change isrequired.

Following is a step by step guideto aid in liner removal and instal-lation.

NOTEWhen removing the welding wirefrom the MIG torch, care shouldbe taken to avoid the wire fromuncoiling from the wire spool.

REMOVING OLD LINER

1. Remove torch assembly from thewelding machine.

2. Place torch assembly on a flatsurface, making sure torch islaying straight as possible.

3. Remove nozzle, bushing insula-tor, contact tip and gas dif-fuser from the front end of thetorch assembly.

4. Loosen set screw located on theconnector end of the torch as-sembly (see FIG. 19).

5. Grip the liner and gas sealfirmly, then pull. The linershould easily slide from torchassembly.

INSTALLING NEW LINER

1. Remove the new liner from thepackage.

2. Uncoil liner and lay the linerparallel next to the MIG torchassembly.

3. Adjust the liner stickout lengthto 3/4" as shown in FIG. 18.

3/4"

LINERSTICKOUT

GAS SEAL

SET SCREW3/4"

CONNECTORPLUG

1 1/4+"

PROTRUDINGLINER

NECKASSEMBLY

4. Install the new liner into theMIG torch assembly, until gasseal seats flush with the con-nector plug.

5. Tighten set screw. (Do not over-tighten), refer to FIG. 19.

6. Following the diagram in FIG.20, measure out 1 1/4"+ from theneck assembly and cut off theprotruding liner.

7. Debur the cutoff end of the linerto insure unobstructed wire feed.

8. Install the gas diffuser andcontact tip of proper wire size,tighten with a wrench.

9. Install the bushing insulatoronto the gas diffuser. Spray the"O" rings with anti-spatter com-pound for lubrication.

10.Install the TWIST-ON adjustablenozzle and twist the nozzleduring the installation. Turn toPage 7 for correct nozzle ad-justment.

FIGURE 20. TORCH FRONT END

FIGURE 19. TORCH CONNECTOR END

FIGURE 18. LINER STICKOUT

M.I.G. TORCH LINERINSTALLATION (steel only)

PARTS BREAKDOWN - 15 SERIES MIG TORCHTG STYLE FRONT END - STANDARD

WIRE SIZE CONTACT TIP GAS DIFFUSER NOZZLE INSULATOR INSULATOR O-RING

.020 - .025 inch M3-T25 M3T-D M3T-N50 M3T-B M3T-BR.030 inch M3-T30 (1/2" I.D.) (includes o-rings) (3 reqd.).035 inch M3-T35 (1-7/16"

.040 - .047 inch M3-T45 length)

SPECIAL APPLICATION PARTS FOR TG STYLE FRONT ENDSHORT CONTACT TIP (1-1/4" length) LARGER ORIFICE SPOT WELDING NOZZLES

- For Spray Arc Welding NOZZLE Standard Nozzle Low Amp NozzleWIRE SIZE PART NUMBER STYLE PART NUMBER PART NUMBER

.020 - .025 inch M3-ST25 Straight Nozzle Flat Spot M3T-NS1 M3T-NLAS1.030 inch M3-ST30 (3/4 “ I.D.) Inside Corner M3T-NS2 M3T-NLAS2.035 inch M3-ST35 M3T-N75 Outside Corner M3T-NS3 M3T-NLAS3

.040 - .047 inch M3-ST45 Irregular (grind to shape) M3T-NS4 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 M3-D M3-NA50 M3-C50 M3-NB M3-B.030 inch M3-T30 (1/2" I.D.).035 inch M3-T35 (1-7/16"

.040 - .047 inch M3-T45 length)

SPECIAL APPLICATION PARTS FOR SG STYLE FRONT ENDSHORT CONTACT TIP (1-1/4" length) LARGER EXTRA LENGTH FRONT END SPOT WELDING FRONT END

- For Spray Arc Welding ORIFICE 1/2" Longer 1" LongerWIRE SIZE PART NUMBER CUP PART NUMBER PART NUMBER PART NUMBER

CUP (1/2" I.D.) M3-C50L M3-C50XL INS. BUSHING M3H-B.020 - .025 inch M3-ST25 Flared CONTACT TIP NOZZLE NUT M3H-NN

.030 inch M3-ST30 Cup .020 - .025 inch M5-T25 M5-LT25 SPOT NOZZLE

.035 inch M3-ST35 (5/8" I.D.) .030 inch M5-T30 M5-LT30 Flat Spot M3H-NS1.040 - .047 inch M3-ST45 M3-C62 .035 inch M5-T35 M5-LT35 Inside Corner M3H-NS2

.040 - .047 inch M5-T45 M5-LT45 Outside Corner M3H-NS3Irregular 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 M35-D M35-NA62 M5-C62 M5-NB M5-B.040 - .047 inch M5-T45 (5/8" I.D.)

(1-15/16"length)

SPECIAL APPLICATION PARTS FOR 3-5G STYLE FRONT ENDLARGER ORIFICE CUP: Straight Cup (3/4" I.D.) ....... M5-C75

SPECIAL FRONT END FOR GASLESS WIRES - OPTIONALINSULATED 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 & SEALS - FOR STEEL WELDING

ORDER NUMBERWIRE TORCHSIZE LENGTH LINER W/SEAL SEAL ONLY

.020-.030 inch 10 feet M103L-B M3LS-B (Blue)

10 feet M104L-N.035-.045 inch M4LS-N (Natural)

12 feet M124L-N

LINERS & SEALS - FOR ALUMINUM WELDINGORDER NUMBER

WIRE TORCH LINER SEAL HEATSHIELDSIZE LENGTH W/SEAL ONLY ONLY

.035 inch 10 feet M103AL M3-6ALS M3-THS

3/64 inch 10 feet M104AL M3-6ALS M3-THS

FIGURE 21. REPAIR (REPLACEMENT) PARTS


PARTS BREAKDOWN - 15 SERIES MIG TORCH (Cont.)

M3-402 M3-402

M1-401

TORCH NECK GROUP

M3-112M3-119 M3-120*

M3-101B*

M3-405M3-200B ASSEMBLY (2 REQD.)

M3-201BM3-203

(2 REQD.)M3-214

M3-202 M3-211

M3-212 M3-213

M3-407

QUICK CONNECTOR GROUP

M3-406M3-309 (2 REQD.)(2 REQD.)

M3-307

M3-301A M3-305A*

M3-308 M3-306 M3-120*(2 REQD.)

PART NO. DESCRIPTION (SYMBOL)TORCH NECK GROUP

M3-101B...... TORCH NECK *M3-112 ........ NECK INSULATORM3-119 ........ LOCK SCREW - SWITCH HOUSINGM3-120 ........ FERRULE *

M3-200B...... SWITCH ASSEMBLYCONSISTING OF:

M3-201B...... SWITCH HOUSINGM3-202 ........ SWITCH (S1)M3-203 ........ SWITCH SCREW (2 REQUIRED)M3-211 ........ TRIGGER - WITH ADJUSTING SCREWM3-212 ........ TRIGGER ADJUSTING SCREW (ONLY)M3-213 ........ TRIGGER PINM3-214 ........ TRIGGER SPRING

QUICK CONNECTOR GROUPM3-120 ........ FERRULE *M3-301A ..... CONNECTOR HOUSINGM3-305A ..... CONNECTOR STEM *M3-306 ........ CONNECTOR PLUG

- WITH SETSCREW & O-RINGSM3-307 ........ SETSCREW (ONLY)M3-308 ........ O-RING (ONLY) (2 REQUIRED)M3-309 ........ TERMINAL - CONNECTOR CONTACT

(2 REQUIRED)M3-310A ..... BOOT / CABLE SUPPORTSN-807G ..... CABLE COVER

M1-401 ........ HANDLEM3-402 ........ 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 *

FIGURE 22. REPAIR (REPLACEMENT) PARTS

M1510CBL*M1512CBL*

NOTES:

* BECAUSE SPECIAL TOOLSAND PROCEDURES AREREQUIRED TO PROPERLYINSTALL THE CABLE ONTHE TORCH NECK ANDTHE CONNECTOR STEM,ITEMS WITH THE ASTERICKARE AVAILABLE FACTORYINSTALLED ONLY.

TORCH REBUILD PROGRAM15 SERIES TORCHES CANBE REBUILT BY THEFACTORY FOR A NOMINALLABOR + PARTS CHARGE.

M3-310A

SN-807G


NOW! TIG WELD WITH YOURSNAP-ON TOOLS MIG WELDING MACHINE

(M140i, FM140A, 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 yourSnap-On Tools MIG Welder.

The TIG PAK is designed for Tungsten-Inert Gas (TIG) welding withDirect Current, Straight Polarity (DCSP) on steel, stainless steel,chrome-moly, copper or cast iron (12 Gauge minimum plate thickness).

THE TIG PAK WILL NOT WELD ALUMINUM.The TIG PAK consists of a 200 amp, gas cooled TIG torch with built-ingas control valve and remote on-off switch, 12-1/2 or 25 foot cableassembly and accessories required for putting the unit into service.

SPECIFICATIONSPart Number ............... TIG PAK 2112A (12-1/2' cable)

TIG PAK 2125A (25' cable)

Torch Rating .............. 200 Amps, DCSP

Duty Cycle ................. 100% (reduce duty cycle whenoperating over 200 amps.)

Cooling Method ......... Gas

Shielding GasControl Method...... Gas Valve on Torch

Welding CurrentOn-Off Control ...... Locking Switch on Torch

MHG5-A

ONE POUND SPOOL GUNFOR ALUMINUM MIG WELDING

WITH SNAP-ON TOOLSMIG COMBINATION UNITS

(M140i, FM140A, YA204C, YA212A, YA212A INDUSTRIAL)

The MHG5-A (Motorized Hand Gun System) is a compact, light-in-weight, easy to operate MIG welding system designed for aluminumwelding. It will feed .030", .035" or 3/64" diameter wire from 4 inch spools.The standard cable is 25 feet in length. 35 foot and 50 foot cables areoptional. The wire speed control knob is in the gun handle.

With the following options, the MHG5-A can be used to weld steel orstainless steel (.030" - .035" diameter wire sizes).

SN-2160K Knurled Drive Roll - for .030" - .035" steel wireM5-T30 Contact Tip - for .030" steel wire

or M5-T35 Contact Tip - for .035" steel wire

SPECIFICATIONSPart Number ....................... MHG5-A

Gun Rating ......................... 200 Amps @ 100% duty cycle250 Amps @ 60% duty cycle

Wire Feed Speed Range ..... 50 to 650 inches per minute

Cooling Method ................. Air (gas)

MHG5-A SYSTEM COMPONENTS1 each MHG-5 Spool Gun1 each HGC5-25 Hand Gun Cable Assembly

with fittings - 25 foot length7 (total) MG-T series Contact Tip (1 installed in gun)

2 - .030 (MG-T30)3 - .035 (MG-T35)2 - 3/64 (MG-T364)

1 each M35-NA62 Nozzle Assembly(installed on gun)

1 each M35-D Gas Diffuser(installed on gun)

CONTENTS OF TIG PAK1 each TIG Torch with built-in valve1 each Locking Electric Switch with 14 foot cord

(installed on torch)1 each 12-1/2 foot Power Cable with Connector

(installed on torch)1 each 15 foot Gas Hose with fitting (installed on torch)3 each 3C332 Collet - for 3/32" tungsten3 each 3C418 Collet - for 1/8" tungsten2 each 3CB332 Collet Body - for 3/32" tungsten2 each 3CB418 Collet Body - for 1/8" tungsten2 each 3C6 Gas Cup - 3/8" orifice6 each 3C7 Gas Cup - 7/16" orifice2 each 3C8 Gas Cup - 1/2" orifice1 each 300L Long Backcap3 each 3/32" X 3" Tungsten Electrode3 each 1/8" X 3" Tungsten Electrode

OPTIONSTIG PAK


NOTES


NOTES

Snap-on Tools Corporation Kenosha, WI 53141-1410

Documents

OWNER'S MANUAL - Systematics, Inc. 100% Constant … mig combination unit owner's manual the fm140a represents the latest technology in mig combination units. the fm140a operates on