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1. Lu ie Ja SPECIAL APPLICATION PARTS FOR 3 5G STYLE FRONT END LARGER ORIFICE CUP Straight Cup 3 4 I D M5 C75 SPECIAL FRONT END FOR GASLESS WIRES OPTIONAL INSULATED CONTACT TIP Tip screw directly into torch neck no gas diffuser is required 1 15 16 length WIRE SIZE PARTNUMBER 040 047 inch M5HGL 045 LINERS amp SEALS FOR STEEL WELDING LINERS amp F FOR ALUMINUM WELDING TORCH ORDERNUMBER ORDERNUMBER LENGTH LINERW SEAL SEAL ONLY Ripe LINER SEAL HEATSHIELD WISEAL ONLY ONLY 020 030inch 10feet M103L B M3LS B Blue 035 inch 10feet M103AL M3 6ALS M3 THS 10feet M104L N 035 045inch M4LS N Natural 12 feet M124L N 3 64 inch 10 feet M104AL M3 6ALS M3 THS FIGURE 22 CONSUMABLE PARTS 20 Snap on Tools Corporation Kenosha WI 53141 1410 PARTS BREAKDOWN 15 SERIES MIG TORCH Cont PART NO DESCRIPTION SYMBOL TORCH NECK GROUP M3 101B TORCH NECK M3 402 foe M3 402 M3 112 NECK INSULATOR M3 119 LOCK SCREW SWITCH HOUSING ere c M3 120 FERRULE M3 200B SWITCHASSEMBLY CONSISTING OF M3 201B SWITCH HOUSING TORCH NECK GROUP N M3 203 SWITCH SCREW 2 REQUIRED M3 211K SWITCH S1 TRIGGER WITH ADJUSTING SCREW M3 120 TRIGGER PIN TRIGGER SPRING M3 112 QUICK CONNECTOR GROUP M3 120 FERRULE M3 301A CONNECTOR HOUSING M3 305A2. This method known as fore hand welding provides a gas shield for the cooling weld puddle and helps in obtain ing an oxidation free weld deposit Nylon liner and 100 Argon shielding gas are required USE 3 64 ALUMINUM WIRE Trim the electrode wire leavin approximately 1 Bend the wire over as shown t allow for a scratch start Th contact tip should be recesse inside the nozzle approximatel 3 8 inch This helps prevent th welding wire from burning bac to the contact tip NOZZLE CONTACT TIP RECESSED 3 8 C ELECTRODE WIRE Sec 1 STICKOUT FIGURE 14 NOZZLE ADJUSTMENT FOR WELDING ALUMINUM DO NOT spray any anti spatte material on the torch or bas metal and DO NOT attempt t lubricate the aluminum wire i any way Weld contamination wil inch stickout CONTINUOUS WELDING ON ALUMINUM g k r e occur unless the wire base 5 metal torch and work area kept clean DIRECTION Bring the torch nozzle to 1 2 to OF TRAVEL FIGURE 13 TORCH POSITION FOR WELDING STEEL RIGHTHANDED WELDOR Use a welding helmet with a shade 9 to 11 filter lens depending operator preference 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 con 5 8 inch fr
3. connected Follow the operating instruc tions in the TIGPAK manual Form WC5228 To change back to MIG operation reverse the procedure CHANGING FROM STANDARD MIG OPERATION TO SPOOL GUN OPERATION All current model MIG machines are fittings equipped with bulkhead gas for quick and easy changeover from standard MIG opera tio Iis 18 n to spool gun operation Remove the thread cap from the SPOOL GUN fitting Unscrew the selector hose from the MIG TORCH fitting Move the selector hose to the SPOOL GUN fitting and tighten Snap on Tools Corporation LOs WIRE FEED BULKHEAD Install the thread cap removed in step 1 on the MIG TORCH fitting to prevent dirt and contaminants from entering the unused gas line Unplug the wire feed motor plug from the function receptacle Plug the MHG5 A spool gun con trol cable plug into the welder function receptacle Remove the torch selector cable from the welder positive weld connector Plug the MHG5 A gun cable fit ting into the welder positive weld connector NOTE Make sure the gas regulator and welder gas hose are connected to a cylinder of the proper shielding gas 100 argon for aluminum welding 75 argon 25 CO2 for steel welding 98 argon 2 O2 is recommended for stainless steel welding Follow the oper
4. 13 Install the nozzle on the torch For steel the contact tip shoul be flush or stick out up to 1 1 inch beyond the end of th nozzle For aluminum the con tact tip should be recessed 1 to 3 8 inch inside the nozzle Using wire cutters trim off the wire so the stickout is approxi mately 1 4 inch for steel or 1 inch for aluminum For aluminum the end of the wire should be bent over so it does not JAM into the work This is called a scratch start See Figure 9 co D Oy O 4 7 FORALUMINUM TIP RECESSED 1 8 3 8 STICK UT FOR STEEL CONTACT TIP FLUSH WITH NOZZLE FIG 9 WIRE STICKOUT STEEL ALUMINUM 14 For steel welding only spray anti spatter compound inside the nozzle and on the outside of the contact tip For aluminum or stainless steel welding NO anti Spatter compound can be used as it will contaminate the weld Snap on Tools Corporation WIRE FEED PRESSURE ROLL ADJUSTMENT The wire feed pressure roll is adjusted to the proper setting at the factory prior to delivery It may be necessary to readjust the setting as components seat in or when changing to a different diam eter 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 th pressur roll adjusting nut should be backed off
5. CONNECTOR STEM M3 306 CONNECTOR PLUG WITH SETSCREW amp O RINGS M3 101B M3 307 SETSCREW ONLY M3 308 O RING ONLY 2 REQUIRED M3 309 TERMINAL CONNECTOR CONTACT 2 REQUIRED M3 310A BOOT CABLE SUPPORT Dp M3 405 M1 401 HANDLE M3 402 HANDLE SCREW 2 REQUIRED M3 200B ASSEMBLY 2 REQD M3 405 TERMINAL TORCH END 2 REQUIRED M3 406 TERMINAL CONNECTOR END OO 2 REQUIRED M3 203 l M3 407 HANGING BRACKET 2 pia M1510CBL 10 FOOT CABLE M1512CBL 12 FOOT CABLE M1510CBL M1512CBL QUICK CONNECTOR GROUP 3406 NOTES M3 309 2REQD 2 REQD BECAUSE SPECIAL TOOLS M3 307 lt AND PROCEDURES ARE REQUIRED TO PROPERLY Yero INSTALL THE CABLE ON UD THE TORCH NECK AND M3 301A M3 305A THE CONNECTOR STEM 00 ITEMS WITH THE ASTERICK M3 308 3 306 M3 120 ARE AVAILABLE FACTORY 2 REQD INSTALLED ONLY TORCHREBUILD PROGRAM 15 SERIES TORCHES CAN BE REBUILT BY THE M3 310A FACTORY FOR A NOMINAL I m ee __ 7 LABOR PARTS CHARGE FIGURE 23 REPAIR REPLACEMENT PARTS Snap on Tools Corporation Kenosha WI 53141 1410 21 MIG140 FM140A MIG220 YA204C YA212A YA212A INDUSTRIAL OPTIONS TIG PAK NOW TIG WELD WITH YOUR SNAP ON TOOLS MIG WELDING MACH
6. Clean or replace guides Replace pressure roll Adjust feed roll ten Kenosha WI 53141 1410 FAULT Birdnesting Wire wrapping around drive rolls Cold weld puddle TROUBLE SHOOTING Cont SYMBOL FOR TECH SERVICE CALL TOLL FREE 1 800 232 9353 POSSIBLE CAUSE FAULTY WELDS Cont Excessive feed roll tension Poor alignment Oversize contact tip Incorrect shielding gas Excessive wire stick out Poor connections Faulty diode D1 D4 Heavy spatter Porous welds Incorrect shielding gas Excessive wire stick out No shielding gas Not enough gas flow Contaminated wire Faulty gas solenoid GS Incorrect electrode wire Contaminated base material Incorrect machine settings Incorrect machine settings REMEDY Reduce tension See page Wx Make sure wire is properly aligned across roller Replace contact tip with correct size Increase heat amp wire speed Replace with proper gas Hold torch closer to work Check and tighten all connections Test diodes replac faulty diode s See page 16 Increase heat decrease wire feed speed Replace with proper gas Hold torch closer to work Turn on gas Check hoses for leaks make sure cylinder is not empty Increase flow rate Change wire Replace solenoid Use correct wire Clean or etch base material SYMBOL
7. the kinked end with wire cutters The wire must be straight when it enters the inlet guide Thread the electrode wire through the inlet guide over the feed roll and into the torch liner Ensure that the wire locates in the feed roll groove Do not allow the wire on the spool to loosen Close and relatch the pressure roll arm 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 Turn on the circuit breaker on the front of the machine The cooling fan will start and the ON indicator light will illu minate Set the HEAT control switch to 4 and the WIRE SPEED control to 7 Pullthe 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 Kenosha WI 53141 1410 12 Install the contact tip over the protruding wire and tighten it firmly using a proper size wrench Make sure the tip is the correct size for the wire being used
8. the rear of the machine and secure it with the chain pro vided S recommended gases on page 3 Rapidly open and close the cyl inder 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 Attach the gas regulator flow meter supplied with this unit to the cylinder valve using a suitable wrench NOTE If this unit is to be used with 100 CO2 shielding gas an optional gas regulator coupler is required FLOW TUBE INDICATES FLOW RATE IN C F H GAUGE INDICATES P d TANK PRESSURE GAS FLOW ADJUSTING KNOB N FITTING TO WELDING MACHINE FIGURE 6 GAS FLOW ADJUSTMENT Snap on Tools Corporation 4 Fit the gas hose from the welding machine to the regulator outlet fitting and tighten it with a wrench Open the cylinder valve When welding steel the gas flow rate is 30 CFH When welding aluminum the gas flow rate is 40 CFH NOTE The MIG220 must be turned ON and the MIG torch trigger depressed before th gas flow rate can be adjusted TORCH CONNECTION Open the access door of the machine to its fullest extent 2 Back out the thump screw located on the drive assembly mounting bracket inside the ma chine Insert the MIG into the torch panel month on the front panel and TIGHTEN THE TH
9. until the feed rolls start to slip If the wire will not feed with very little pressure applied the pres sure roll adjusting nut should be tightened PRESSURE ROLL PRESSURE ADJUSTING NUT ROLL PRESSURE ROLL ARM FIGURE 10 PRESSURE ROLL ADJUSTMENT TORCH SELECTOR CABLE Plug the torch selector cable into the Positive terminal on the machine see PROCESS SELECTION on page 8 for further details WORK GROUND CABLE Uncoil the Work cable and plug it into the negative terminal on the machine Kenosha WI 53141 1410 7 OPERATION DUTY CYCLE CAUTION CONTINUAL EXCEEDING OF THE CYCLE OF THIS OR ANY WELDI MACHINE CAN CAUSE DAMAGE The Duty Cycle of a welding power source is a percentage of aten 10 minute time period It is the maximum amount of time the power source can be operated at a given output without sustaining possible damage due to overheating A 60 Duty Cycle means the welding ma chine can be operated at its rated amperage for six 6 minutes out of ten The machine must be allowed to cool machine ON fan running but not welding for the remaining four 4 minutes Operating the machine ata higher output requires that the duty cycle percentage be lowered The following operating instruc tions and detailed setup procedures enable an operator without previous experience to prod
10. 025 through 3 64 aluminum wire with the optional MHG5 A optional liners must be FIGURE 1 SCHEMATIC OF MIG PROCESS purchased to cover given wire sizes Heavier sections can be easilywelded using slightly different techniques WIRE SPOOL POWER SOURCE STD The consumable electrode wire is melted and transferred to the weld puddle by any of three arc modes short arc transfer The number of controls on the unit globular trans fer or spray has been reduced to assist inexpe arc transfer The MIG220 is rienced operators to learn MIG capable of perform ing all modes welding This facilitates rapid set up for welding various thicknesses of material requiring various heat SHORT ARC OR DIP TRANSFER inputs The HEAT voltage control adjusts the welding voltage and the Short arc transfer occurs at 12 to WIRE SPEED control adjusts the 22 arc volts voltage while weld on steel and aluminum speed of the wire feed motor ing depending on wire size Weld ing commences as the arc is struck THE MIG PROCESS and a weld pool is formed The tip AS APPLIED TO THE of the electrode wire dips into the pool and causes a short circuit MIG220 The short circuit current flow causes a rapid temperature rise in The MIG process uses a bare the electrode wire and the end of consumable electrode in the form of the wire is melted off An arc is spooled w
11. CTURER 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 Ju U SUM eisi aaan 1 SPECIFICATIONS Leda Ced Du cu ud rd uu e 2 CHECK LIST E s u u uuu lu ass Een nasi 3 INSTALLATION 4 OPERATION Ju uuu asas 8 MAINTENANCE U uu 11 TROUBLE SHOOTING CHART 13 CONNECTING TIGPAK OR SPOOL GUN 18 PARTS BREAKDOWN MIG TORCH 20 OPTIONS TIG PAK SPOOL GUN 22 Snap on Tools Corporation Kenosha WI 53141 1410 INTRODUCTION The Snap On Tools MIG220 is a combination welding power source wire feed unit MIGtorch and accessory package designed to meet the requirements ofthe light to medium metal fabrication industries The unit produces fusion welds by the Gas Metal ArcWelding REVERSE process GMAW or MIG onsteel T POLARITY and aluminum up to 5 16 thick using 023 through 045 steel wire and
12. ELECTRICAL SUPPLY Ensure that there is a 208 or 230 volt single phase 40 amp elec trical supply within easy reach of the unit The input cable supplied is 20 feet long A 50 foot cable is an optional extra Attach a suit able plug making sure the green wire is attached to ground A11 wiring should be performed by a qualified electrician 230V INPUT SELECTION 1 Factory selected no change is needed 4 Snap on Tools Corporation 4 Remove the on 1 208V INPUT SELECTION 1 Remove the top cover 2 Locate the contactor switch which is mounted on top of the main power transformer 5 Fig ure 5 CONNECT 208 TERMINAL FOR OPERATION ON 208 VOLT INPUT L230 WELD POWER CONTACTOR CONNECT 230 TERMINAL FOR OPERATION ON 230 VOLT INPUT FIGURE 5 INPUT VOLTAGE SELECTIONS 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 posi tion plug which allows easy selection of input voltages of either 208 or 230 volts plug labeled 230V and connect the one 1 plug labeled 208V 5 Reattach the top cover of the machine Voltage input selec tion is now complete Kenosha WI 53141 1410 SHIELDING GAS CONNECTIONS L Place a cylinder of the appro priate shielding gas in the rack at
13. FOUND IN THE SERVICE 13 FAULT Main power on torch trigger activated no welding current but gas flows amp wire feeds Torch trigger activated no gas flow but contactor operates amp wire feeds Jerky or slipping wire feed sion 14 Snap on Tools Corporation TROUBLE SHOOTING Cont SYMBOL FOR TECH SERVICE CALL 1 800 232 9353 POSSIBLE CAUSE REMEDY EQUIPMENT MALFUNCTION Cont Loose torch thumb screw Broken or loose connection Unplugged or faulty power contactor switch w 208 230V selector wire off W Opened thermal switch TP1 Faulty diodes D1 D4 No shielding gas tank empty Loose or broken connections Faulty Gas solenoid valve GS Clogged gas flow path FAULTY WELDS Worn liner Wire spool turns too hard kinked or dirty torch Tighten thumb screw Check cables for continuity Repair or tighten connections Plug in or replace switch Reattach wire Allow unit to cool then retry Check diodes S pag 16 Replace tank Tighten or repair connections Repair or replace valve Locate amp clean clog Clean or replace liner Lubricate spool shaft drive roll Worn double v groove driv roll Spring Weak pressure roll Worn or dirty contact tip Worn inlet guide s Sticking pressure roll Feed roll tension incorrect Replac Replace spring Replace contact tip
14. Figure 17 locate the trim resistor this is lo cated in the upper right hand corner of the wire feed PC board Turn the wire speed dial on the front of the machine to 0 Remove any tension on the drive roll Activate the torch trigger Snap on Tools Corporation REMOVE GLUH AND ADJUST THE TRIM RESISTOR FIGURE 17 WIRE FEED PC BOARD Rotate the trim resistor back and forth until the bottom drive roll moves Calibrate so the bottom drive roll rotates very slowly non jerky If calibrated correctly the wire Speed dial on the front of the machine should affect the speed of the drive roll from 0 thru LIO 10 Adjustment is now complete Kenosha WI 53141 1410 17 CONNECTING TIGPAK OR SPOOL GUN CHANGING FROM STANDARD MIG OPERATION TO TIGPAK OPERATION L Unplug the wire feed motor plug from the function receptacle Unplug the torch selector cable and the ground cable from the welder front panel Plug the TIGPAK torch power cable into the negative weld connector and plug the ground cable into the positive weld connector This provides straight polarity current as required for TIG welding Plug the TIGPAK torch switch cord into the welder function receptacle Attach the TIGPAK torch gas hose directly to the gas regulator NOTE the regulator is to a cylinder of the proper shielding gas pure argon for TIG welding Mak sur
15. INE MIG140 FM140A MIG220 YA204C YA212A or YA212A INDUSTRIAL The TIG Welding Process is used to produce the highest quality porosity free welds The TIG PAK adds TIG Welding capabilities to your Snap On Tools MIG Welder The TIG PAK is designed for Tungsten Inert Gas TIG welding with Direct Current Straight Polarity DCSP on steel stainless steel chrome moly copper or castiron 12 Gauge minimum plate thickness TIG PAK WILL NOT WELD ALUMINUM The TIG PAK consists of a 200 amp gas cooled TIG torch with built in gas control valve and remote on off switch 25 foot cable assembly and accessories required for putting the unit into service SPECIFICATIONS Part Number TP2125A 25 cable Torch Rating 200 Amps DCSP 100 reduce duty cycle when operating over 200 amps Duty Cycle Cooling Method Shielding Gas Control Method Gas Valve on Torch Welding Current On Off Control Locking Switch on Torch MHG5 A ONE POUND SPOOL GUN FOR ALUMINUM MIG WELDING WITH SNAP ON TOOLS MIG COMBINATION UNITS The MHG5 A 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 in the gun handle With the following options the MHG5 A can be used to weld steel or stain
16. LAR TRANSFER SPRAY TRANSFER Spray transfer occurs at 22 to 28 arc volts depending on wire size The length of the arc is held constant by the voltage available The higher voltage and current causes the electrode wire to melt off before touching the workpiece The molten metal crosses the gap to the workpiece in a spray form Spray transfer is used in the down hand position and provides higher deposition rates than short arc transfer or globular transfer ELECTRODE DESCRIPTION The MIG220 combination MIG source and wire feed unit a 15TG10MIG torch a fifteen foot groundcable with ground clamp a twenty foot power input consists of a welding power cable a gas regulator flowmeter a torch accessory kit and a built in cyl inder rack and industrial wheelkit Welder components are cooledby forced fan cooling Welder controls are simple and clearly marked The output voltage is controlled by a twelve position tap switch providing twelve volt age selections Voltages can be monitored by the voltmeter on the control panel Wire feed speed is controlled by the wire speed poten tiometer SPECIFICATIONS PART NUMBER MIG220 INPUT POWER REQUIREMENTS Voltage 208 230 volts AC Phase single phase Frequency 50 60 hertz Current 34 30 amps NOTE This welder draws 20 amps at 100 Duty cycle 185 amps output 40 amp 208 or 230 volt electrical service i
17. OWNER S MANUAL MIG220 MIG COMBINATION UNIT THE MIG220 REPRESENTS THE LATEST TECHNOLOGY IN MIG COMBINATION UNITS THE MIG220 OPERATES ON SINGLE PHASE CURRENT AND FEATURES SMOOTH ARC TRANSFORMER DESIGN CONCEPT FOR TECH SERVICE CALL Toll Free 1 800 222 9353 Or Visit Us On The Web At WWW 800ABCWELD COM INSTALLATION OPERATION MAINTENANCE FORM wes799 7 10 2009 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 unauthor ized 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
18. 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 A 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 MANUFA
19. UMB SCREW SECURELY AND CHECK OFTEN TORCH PRESSURE PANEL MOUNT THUMB SCREW DRIVE ROLL DRIVE ASSEMBLY FIGURE 7 TORCH CONNECTION FITTING AND THREADING THE ELECTRODE WIRE ALWAYS USE ER70S 6 WELDING WIRE 1 Remove the wire spool clip from the spool hub continued on following page Kenosha WI 53141 1410 5 FITTING AND THREADING THE ELECTRODE WIRE Cont 2 Unpack the spool of welding wire from its protective packaging 3 Place the spool of ER70S 6 weld ing wire on the hub ensuring that the hole in the spool flange lines up with the locating pin on the hub The wire is fed off the bottom of the spool CAUTION Look for and remove any wire protruding from the center of the spool The protruding wire is electrically HOT during welding and must not touch the machine 4 Replace the spool clip on the hub 5 Unlatch the pressure roll arm and swing it open 6 Make sure the double v groove drive roll is installed to match the wire size To change the wire size setting remove the drive roll turn it over and reinstall it on the drive motor shaft B SIDE FACING IN FOR 023 035 STEEL WIRES C SIDE FACING IN FOR 040 045 STEEL WIRES AND 3 64 ALUMINUM WIRES 3045DR Large Drive Roller FIGURE 8 DOUBLE GROOVE DRIVE ROLL 6 Snap on Tools Corporation T TO 11 Release the wire from the spool and trim off
20. 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 4 Connect the headlight bulb to TESTING AND REPLACING DIODES one end of the diode Test for electrical flow in both Silicon diodes have proven to be directions as follows First highly reliable However weld spat test by connecting a lead ter build up in the torch can short from the battery positive out and cause diode overload and terminal to the light consequent failure The following bulb and a lead from the information is provided as a guide battery negative terminal to should a failure be suspected the other end of the diode Test again by reversing the connec Silicon diodes exhibit two main tions See Figure 16 The fault conditions headlight bulb should light with the current flow in one 1 Open Circuit causes a reduc 1 direction only not both tion in welder output 2 Short Circuit causes the circuit breaker to trip If a fault is suspected the diode 12 VOLT may be tested as follows ae 1 Remove the top connection of each diode to be tested 2 Using a Volt Ohm Meter set on 12 VOLT diode or 2K check for BATTERY continuity through the diode in both directions If there is no continuity in either direction the diode is in BULB o
21. ating instruc tions in the MHG5 A manual Form WC5385 To change back to standard MIG operation revers the proce dure WIRE FEED MOTOR PLUG PLUGGED INTO FUNCTION MOTOR RECEPTACLE FITTINGS me gt lt HOSE THREAD CAP FIGURE 18 BULKHEAD CONNECTIONS Kenosha WI 53141 1410 M I G TORCH LINER INSTALLATION steel only The MIG torch liner provided with the MIG220 is designed for wire diameters from 030 thru 045 If smaller wire diameters are to be fed and or there is a problem i e clog kink etc a liner change is required Following is a step by step guide to aid in liner removal and instal lation 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 insula tor contact tip and gas dif fuser from the front end of the torch assembly 4 Loosen set screw located on the connector end of the torch as sembly see FIG 20 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 th
22. control settings will vary according to the thickness of the metal the type of joint operator preference etc Best re sults can be obtained through expe rience with the welding machine or by making trial welds Select some sample material of the same type and thickness as the material to be welded Set the welding controls for optimum results using the sample material and weld until experience is gained using the unit CONTINUOUS WELDING ON STEEL 1 Trim the electrode wire to leav approximately 1 4 inch stickout beyond the end of the contact tip and install the welding nozzle The contact tip should be flush or stick out up to 1 16 inch beyond the end of the nozzle NOZZLE CONTACT TIP FLUSH TO 1 16 STICKOUT ELECTRODE WIRE 1 4 STICKOUT MA FIGURE 12 NOZZLE ADJUSTMENT FOR WELDING STEEL continued on following page Kenosha WI 53141 1410 9 CONTINUOUS WELDING STEEL Cont Spray the inside of the nozzle and the outside of the contact tip with anti spatter compound Locate the torch over the Joint to be welded with the contact tip approximately 3 4 inch from the work surface NOTE When welding steel the ideal position for holding the torch is inclined approxi mately 30 degrees towards the direction of travel The arc can to be seen easily which results in greater control of the weld pool Most right handed weldors move from left to right
23. d on following page Kenosha WI 53141 1410 11 MAINTENANCE Cont 2 Remove dirt and metal deposits from the grooves in the feed roll If the grooves are badly worn the feed roll should be replaced If the pressure roll does not turn freely it should be replaced 3 Check all gas fittings for leaks Tighten or repair as required EVERY SIX MONTHS 1 Disconnect the welder from its main power supply 2 Remove the machine s side pan els 3 Using low pressure dry com pressed air remove dust and dirt from all components 4 Check for loose or frayed wir ing Particularly check welding current wire connections 5 Replace torch liner if neces sary RECOMMENDED CUSTOMER SPARE PARTS The Snap On Tools MIG220 isa machine of proven design and reliability Following is a list of consumable items recom mended as spare parts for this unit Contact M3 T30 etc gas gs Sa kki M3T N50 nozzle insulatorS sii9499 a M3T B gas diffU UsGf S s soese e Res M3T D steel liner 020 030 M103L B steel liner 035 045 M104L N 12 Snap on Tools Corporation 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 u
24. e liner parallel next to the MIG torch assembly 3 Adjust the liner stickout length to 3 4 as shown in FIG 19 Snap on Tools Corporation 10 GAS SEAL gt S LINER STICKOUT FIGURE 19 LINER STICKOUT Install the new liner into the MIG torch assembly until gas seal seats flush with the con nector plug Tighten set screw Do not over tighten refer to FIG 20 SET SCREW CONNECTOR PLUG FIGURE 20 TORCH CONNECTOR END Following the diagram in FIG 21 measure out 1 1 4 from the neck assembly and cut off the protruding liner Debur the cutoff end of the liner to insure unobstructed wire feed NECK ASSEMBLY PROTRUDING LINER A FIGURE 21 TORCH FRONT END Install the gas diffuser and contact tip of proper wire size tighten with a wrench Install the bushing insulator onto the gas diffuser Spray the O rings with anti spatter com pound for lubrication Install the TWIST ON adjustable nozzle and twist the nozzle during the installation Turnto Page 7 for correct nozzle ad justment Kenosha WI 53141 1410 19 PARTS BREAKDOWN 15 SERIES MIG TORCH TG STYLE FRONT END STANDARD WIRESIZE GASDIFFUSER NOZZLE INSULATOR INSULATOR O RING 020 025 inch M3 T25 M3T N50 M3T B M3T BR 030 inch M3 T30 1 2 D tings 3 reqd 035 inch M3 T35 1 7 16 040 047i
25. ed of wire drive motor to give wire speed range of 10 to 500 inches per minute HEAT VOLTAGE CONTROL Twelve position switch adjusts welder output voltage VOLTMETER Indicates open circuit voltage when torch switch is actuated and arc voltage while welding CIRCUIT BREAKER Primary power switch and over load protection device ON INDICATOR LIGHT Illuminates when the circuit breaker on the machine is ON TORCH PANEL MOUNT Combination power output con tactor switch connection gas supply connection and wire feed output in a single unit TORCH SELECTOR CABLE Plugs into positive terminal for standard welding operation or negative terminal for straight polarity welding on very light sheet metal or for using flux cored gasless wire POSITIVE TERMINAL Positive output terminal from the welder DC power source The torch selector cable is plugged into this terminal for standard welding operation The ground cable can be plugged into this terminal for straight polarity welding on very light sheet metal or for using flux cored gasless wire Snap on Tools Corporation I NEGATIVE TERMINAL Negative output terminal The ground cable is plugged into this terminal during standard welding operation The torch selector cable can be plugged into this terminal for straight polarity welding on very light sheet metal or for using flux cored gasless wire WELDING Optimum
26. inder Rack Industrial Wheel Kit 1 15TG10 MIG Torch with adjust able nozzle 1 20 foot Power Input Cable 1 10 foot Ground Cable and Clamp 1 230PK 1 Accessory Kit 1 Gas Regulator Flowmeter for steel or aluminum 1 Nozzle 1 2 in orifice in stalled on MIG torch 1 Contact Tip for 030 in wire installed on MIG torch 1 705 6 30 3 Sample Spool of 030 Steel Wire OPTIONAL EXTRAS RE5 A Range Extender a wire feed unit which extends thereach of the MIG220 an extra 25 feet 5O0CP 0 50 foot Power Input Cable replaces standard 20 foot power input cable MHG5 A Spool Gun for welding aluminum see page 22 TIGPAK Tig Torch Kit for TIG welding steel stainless steel s page 22 Kenosha WI 53141 1410 3 ITEMS REQUIRED FOR MIG WELDING WHICH ARE NOT PROVIDED WITH THE MIG220 1 Full cover welding helmet with proper colored lens shade 9 to 11 depending on operator s preference 2 Proper shielding gas and cylinder 3 Leather welding gloves 4 Electrial Power 5 Other personal protective equipment which may vary to match the welding being per formed THE MIG220 REQUIRES A 208 OR 230 VOLT SINGLE PHASE AC 40 AMP CIRCUIT INSTALLATION POSITIONING THE UNIT Locate the unit adjacent to the welding area and position it so there is adequat clearance all around for ventilation and mainte nance
27. ire which is fed by a immediately formed between the tip controllable speed feed unit through of the wire and the weld pool the cable and torch to the weld The maintaining the electrical circuit emerging wire and the weld are and producing sufficient heat to shielded by a stream of CO2 Argon keep the weld pool fluid The or a mixture of the two which electrode continues to feed and prevents oxidation of the molten again dips into the pool weld puddle The gas shield enables high quality welds to be made without the use of flux eliminat ing the need for slag or flux removal after the weld is com pleted ELEC TRODE FIGURE 2 SHORT TRANSFER Snap on Tools Corporation Kenosha WI 53141 1410 1 SHORT ARC OR DIP TRANSFER Cont This sequence of events is re peated 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 irregu larly shaped globules Globular transfer is useful in cases where a lower heat input than that of true spray is required GAS NOZZLE ELECTRODE x SHIELDING GAS 4 FIGURE 3 GLOBU
28. less steel 030 035 diameter wire sizes SN 2160K Knurled Drive Roll for 030 035 steel wire M5 T30 Contact Tip for 030 steel wire or M5 T35 Contact Tip for 035 steel wire SPECIFICATIONS Part Number 200 Amps 100 duty cycle 250 Amps 60 duty cycle Gun Rating Wire Feed Speed Range 50 to 650 inches per minute Cooling Method Air gas 22 Snap on Tools Corporation CONTENTS OF TIG PAK ric 1 each Torch with built in valve 1 each Locking Electric Switch with 25 foot cord installed on torch 1 each 25 foot Power Cable with Connector installed on torch 1 each 27 1 2 foot Gas Hose with fitting installed on torch 3 each 3C332 Collet for 3 32 tungsten 3 each 3C418 Collet for 1 8 tungsten 2 each 3CB332 Collet Body for 3 32 tungsten 3CB418 2 each Collet Body for 1 8 tungsten 2 each 3C6 Gas Cup 3 8 orifice 3C7 Gas 6 each Cup 7 16 orifice 2 each 3C8 Gas Cup 1 2 orifice 300L 1 each Long Backcap 3 each 3 32 X 3 Tungsten Electrode 1 8 X 3 each 3 Tungsten Electrode MHG5 A SYSTEM COMPONENTS 1 each MHG 5 Spool Gun HGC5 25 Hand Gun Cable Assembly with fittings 25 foot length MG T series 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 1 each 7 total Kenosha WI 53141 1410
29. nch M3 T45 length T SPECIAL APPLICATION PARTS FOR TG STYLE FRONT END SHORT CONTACT TIP 1 1 4 length LARGER ORIFICE SPOT WELDING NOZZLES For Spray Arc Welding NOZZLE Standard Nozzle Low Amp Nozzle WIRE SIZE PART NUMBER STYLE PART NUMBER PARTNUMBER 020 025 inch M3 ST25 Straight Nozzle Flat Spot M3T NS1 M3T NLAS1 030 inch M3 ST30 3 4 1 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 020 025inch M3 T25 M3 D M3 NA50 M3 C50 030inch M3 T30 1 2 D 035 inch M3 T35 1 7 16 cIm Q D 040 047 M3 T45 length SPECIAL APPLICATION PARTS FOR SG STYLE FRONT END SHORT CONTACT TIP 1 1 4 length LARGER EXTRA LENGTH FRONT END SPOT WELDING FRONT END For Spray Arc Welding ORIFICE 1 2 Longer 1 Longer WIRE SIZE PARTNUMBER CUP PARTNUMBER PARTNUMBER PARTNUMBER 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 025inch 5 25 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 5 45 M5 LT45 Outside Corner M3H NS3 Irregular M3H NS4 XG STYLE FRONT END OPTIONAL RECOMMENDED FOR ALUMINUM WELDING 035 inch M5 T35 M35 NA62 M5 C62 M5 NB
30. nit when a gas cylinder is installed or at tached DO NOT weld on any item that has a common electrical ground DO NOT operate the unit with the side panels removed Over heating 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 cloth ing leather gloves and a full cover welding hood while weld ing DO NOT weld in a closed in area Proper ventilation is a necessity or a fresh air supplied hood should be worn WHEN welding near combustibles a helper or watcher should stand by with a fire extin guisher or other fire protec tive 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 Kenosha WI 53141 1410 The Trouble Shooting Chart is a guide TROUBLE SHOOTING SYMBOL FOR TECH SERVICE CALL TOLL FREE 1 800 232 9353 in identifying and correcting possible troubles which may occur when operating this equipment POSSIBLE CAUSE EQUIPMENT MALFUNCTION FAULT No main power fan does not operate on indicator light is off Main power on torch trigger activated no response Main power on torch trigger activated no wire feed but contactor operates amp gas flows SYMBOL MIG220 switch is OFF Wall breaker is t
31. om the workpiece Th e recommended position of the torch and direction of travel shown in Figure 15 n I 10 DEGREES DIRECTION OF TRAVEL are Follow Continuous Welding on Steel stant arc length and a constant 4 5 as in tip to work distance steps 4 10 Snap on Tools Corporation Kenosha WI 53141 1410 OPERATING HINTS BURN BACK In the event the welding wire burns back into the contact tip 1 Remove the nozzle from the torch 2 Unscrew the contact tip from the gas diffuser using a pair of pliers as the tip will be very not 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 con trol setting or reducing the HEAT control setting SPATTER Before beginning to weld and periodically during welding the torch nozzle must be removed and the Spatter small globules of melted metal cleared from the inside of the nozzle and the outside of the contact tip and the gas diffuser Spatter b
32. pen circuit condition and must be replaced If there is continuity in both directions the diode is in Short circuit 42 VOLT condition and must be replaced BATTERY If there is continuity in one direction only the diode is 3 If all the diodes check out satisfactorily with the Volt TEST FOR FLOW IN BOTH DIRECTIONS Ohm Meter a load check must be 5 When replacing diodes it is mage ping voli partey very important that heat con bulb ductive compound Radio Shack 276 1372 be used where the CAUTION diode makes contact with the NEVER use a megger or a aluminum heat sink Do not grease high voltage device to test the threads on the diode a diode 16 Snap on Tools Corporation Kenosha WI 53141 1410 ti ch WIRE FEED CALIBRATION Due to INPUT LINE VOLTAGE varia ons supplied to the welding ma ine The WIRE FEED SPEED should be checked for proper operation TO CHECK Ls IF Remove any tension on the drive rol Is Turn the wire speed dial on the front of the machine to Activate the torch trigger The bottom drive roll should rotate very slowly non jerky If this proves to be true no adjustment is required ADJUSTMENT IS REQUIRED Remove the top cover assembly from the unit Locate the printed circuit board Referring to
33. ripped Open circuit breaker on MIG220 1 Loose or broken connection in power input circuit MIG torch unplugged Faulty trigger switch Fault in torch cable S1 Loose or broken connection on wiring harness Wire feed motor unplugged RC3 Faulty control transformer T2 Pressure roll Slippage at drive rolls Wire path restricted is 5 amp mini breaker tripped cB2 Wire feed circuit board needs calibrated Defective wire feed circuit board Pci Faulty wire feed motor or connection M Faulty motor relay CRI Loose or broken connection urn switch arm unlatched REMEDY on Reset wall breaker Reset or replace breaker Tighten or repair connection Plug in MIG torch Replace micro switch Check torch cable for continuity Check or repair connections Plug in motor Check for 28VAC output Latch arm amp add tension Increase drive roll tension See page 7 Clean path or replace torch liner Reset or replace breaker Calibrate wire feed Circuit board See page 17 Replace circuit board Repair or replace faulty item Check motor ona 12VDC battery Sand points or replace relay Tighten or repair connection continued on following page MANUAL FOR TROUBLE SHOOTING PURPOSES Snap on Tools Corporation Kenosha WI 53141 1410 USE THIS IDENTIFIER ALONG WITH THE SCHEMATIC DIAGRAM
34. s required for proper arc start ing full utilization of its maximum output of 220amps DUTY CYCLE OUTPUT POWER Welding Current NEMA 60 180 Amps 20 220 Amps DUTY CYCLE TIME PERIOD 10 minutes OPEN CIRCUIT VOLTAGE 15 37 5 volts DC FIGURE 4 SPRAY TRANSFER 2 Snap on Tools Corporation Kenosha WI 53141 1410 SPECIFICATIONS Cont WIRE TYPES mild steel stainless steel aluminum bronze flux cored flux cored gasless Recommended for steel ER70S 6 WIRE SIZES 023 045 steel 035 3 64 aluminum 023 3 64 alum w spool gun 030 035 bronze 035 045 flux cored gas shielded or gasless Recommended Size Aluminum 035 Others 030 WIRE FEED SPEED RANGE 10 500 inches per minute SHIELDING GASES For Steel CO2 or Argon CO2 mix Recommended for steel 75 Argon 25 CO2 For Aluminum Bronze Argon For Stainless Steel 98 Argon 2 Oxygen CO2 or Argon CO2 mix For Flux cored DIMENSIONS Height 34 in 86 4 cm Width 14 1 2 in 36 8 cm Depth 35 in 88 9 cm Weight 195 lbs 88 5 kg TORCH SPECIFICATIONS NECK ANGLE 60 degrees LEAD LENGTH 10 feet OVERALL LENGTH 10 feet COOLING METHOD gas air RATING DUTY CYCLE With Argon CO2 gas150 amps 100 With CO2 gas 200 amps 100 Snap on Tools Corporation CHECK LIST THE SNAP ON TOOLS MIG220 INCLUDES THE FOLLOWING 1 Combination Power Source Wire Feeder 1 Cyl
35. uce quality fu sion welds It is recommended that an operator without prior experi ence 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 fr of grease dirt paint and scale Use a wire brush to remove paint and scale Paint must be com pletely removed to bare metal Grease and oil could burn and cause a fire or safety hazard Failure to clean the metal prop erly will result in erratic and porous welds 8 Snap on Tools Corporation 2 Install the unit as directed in the installation instructions and make sure the ground clamp is firmly attached to a cleaned area on the workpiece to be welded 3 Open the shielding gas cylinder valve Press the torch trigger and listen for gas flow CAUTION The welding wire will feed when the trigger is actu ated Take care that Lhe wire is not directed to hit yourself or anything that is grounded to the ground wire on the welder PROCESS SELECTION The following controls are lo cated on the front of the machine A WIRE SPEED F B TORCH HEAT PANEL VOLTAGE MOUNT CONTROL G C TORCH VOLTMETE SELECTOR CABLE H POSITIVE TERMINAL ON INDICATOR NEGATIVE LIGHT TERMINAL FIGURE 11 FRONT PANEL Kenosha WI 53141 1410 WIRE SPEED Potentiometer controls spe
36. uildup 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 adher ence of spatter to the torch compo nents Snap on Tools Corporation 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 schedul and procedures ar recommended These routines should be performed regularly by the operator REGULARLY Usage and shop condi tions determine frequency 1 Remove and clean the torch nozzle and contact tip The use of anti Spatter spray will reduce the adherence of spatter and makes its removal easier 2 Blow out the torch liner prior to the installation of each new Spool of wire The contact tip and gas diffuser must be re moved but it is not necessary to remove the liner 3 If the torch cable assembly is bent severely a kink may de velop in the steel liner This can cause wire feeding problems so a new liner should be in stalled WEEKLY 1 Remove dirt and dust from the wire feed compartment Use low pressure dry compressed air continue
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