Snap-On MM250SL Service Manual

MM250SL

SERVICE MANUAL

SERIAL NUMBERS MM250SL-2000 AND LATER

FORM WC5276

FOR

9/94 (Rev. 2/95, 1/96, 7/97, 9/97, 1/00)

CONTENTS

VIEW

FIGURE 1 ................. SCHEMATIC DIAGRAM ............................................................3

FIGURE 1A ............... SCHEMATIC, WIRE FEED CIRCUIT BOARD ..........................4

FIGURE 1B ............... SCHEMATIC, SPOT TIME CIRCUIT BOARD ...........................4

FIGURE 2 ................. WIRING DIAGRAM, CONTROL CABLE ASSEMBLY ...............5

FIGURE A................. FRONT ASSEMBLY ..................................................................6

.................................. PARTS LIST .............................................................................. 7

FIGURE B................. LEFT SIDE VIEW & INTERNAL COMPONENTS ...................... 8

.................................. PARTS LIST .............................................................................. 9

FIGURE B1 ............... PRINTED CIRCUIT BOARD (SN-774U) ..................................10

.................................. PARTS LIST ............................................................................. 11

FIGURE C ................ FRONT VIEW-REMOTE FEED UNIT ...................................... 12

DESCRIPTION

PAGE

.................................. PARTS LIST ............................................................................. 13

FIGURE D ................ RIGHT SIDE VIEW & INTERNAL COMPONENTS ..................14

.................................. REMOTE FEED UNIT

.................................. PARTS LIST ............................................................................. 15

FIGURE D1 .............. PRINTED CIRCUIT BOARD (SN-529U) ..................................16

.................................. PARTS LIST ............................................................................. 17

FIGURE D2 .............. WIRE DRIVE ASSEMBLY (SN-138C24M) ...............................18

.................................. PARTS LIST ............................................................................. 19

FIGURE E ................. FEEDER CABLE ASSEMBLY (FCA-15) ................................... 20

.................................. PARTS LIST ............................................................................. 20

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

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

FIGURE 1 - SCHEMATIC DIAGRAM

1

4

-

2

SR1

+

R3

PC1

R11

D7

C2

D5

R5

Q2

Q1

C3

R4

FIGURE 1A - SCHEMATIC, WIRE FEED CIRCUIT BOARD

3

5

6

R6

C4

79142

D8

C5

R7

C6

Q3

R8

R10

D9

CR2

D10

-

8

SR2

+

PC2

FIGURE 1B - SCHEMATIC, SPOT TIME CIRCUIT BOARD

3

5

6

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

A YELLOW A

B ORANGE B

C BLUE C

D BROWN D

E RED E

F BLACK F

G WHITE G

H PURPLE H

K GREEN K

RC2 RC3

FIGURE 2 - WIRING DIAGRAM, CONTROL CABLE ASSEMBLY

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

1

9

10

2

3

4

5

6

7

8

11

12
13

14

15

16

17

18

19

20

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

2122232425

FIGURE A - FRONT ASSEMBLY

FIGURE A

ITEM

NO.

1 SN-180A HANDLE .............................................................................................................................................. 1

2 SN-330A KNOB, HEAT ....................................................................................................................................... 1

3 SN-319 CABLE HANGER ................................................................................................................................ 2

4 V SN-115 VOLTMETER (ROUND CORNERS) ................................................................................................... 1

5 SN-306M LEFT SIDE .......................................................................................................................................... 1

6 SN-1102 LABEL, ON/OFF .................................................................................................................................. 1

7 CB1 SN-482 CIRCUIT BREAKER, 35 AMP ............................................................................................................. 1

8 L SN-184 INDICATOR LAMP .............................................................................................................................. 1

9 SN-5070 COVER, TOP ...................................................................................................................................... 1

10 SN-1058 LABEL, CONTROL .............................................................................................................................. 1

11 SN-5050 BAFFLE ............................................................................................................................................... 1

12 SN-5080 FRONT ................................................................................................................................................ 1

13 SN-211 BRACKET, CYLINDER ....................................................................................................................... 1

14 SN-699H CLIP, HAIRPIN (SERIAL# MM250SL-2572 AND LATER) ................................................................... 1

15 SN-699A STOP W/ CLIP HOLE, FEEDER (REPLACES ORIGINAL) ................................................................ 1

16 CB2 SN-519 MINI BREAKER, 5A ............................................................................................................................. 1

17 RC1 SN-6191A RECEPTACLE, CONTROL (OUTPUT) .............................................................................................. 1

18 SN-146C WELD CONNECTOR W/GAS HOLE ................................................................................................. 2

19 SN-304M SIDE, RIGHT ....................................................................................................................................... 1

20 SN-1103 LABEL, WELD CONNECTOR ............................................................................................................ 1

21 SN-302W BASE ................................................................................................................................................... 1

22 SN-213 CASTER BRACKET ............................................................................................................................ 2

23 SN-121-3 CASTER, FRONT 3" ........................................................................................................................... 2

24 SN-124-8 REAR WHEEL, 8" ............................................................................................................................... 2

25 SN-171 AXLE .................................................................................................................................................... 1

DIA.

MKGS.

PART

NO.

SN-115A VOLTMETER (SQUARE CORNERS) (SERIAL# MM250SL-6020 AND LATER) ............................... 1

SN-115L LENS, VOLTMETER (ROUND CORNERS) ....................................................................................... 1

SN-115AL LENS, VOLTMETER (SQUARE CORNERS) ..................................................................................... 1

SN-955 BREAKER BRACKET ......................................................................................................................... 1

SN-5070A COVER, TOP (SERIAL# MM250SL-5475 AND LATER) ..................................................................... 1

SN-5080A FRONT (SERIAL# MM250SL-5475 AND LATER) ............................................................................... 1

SN-72 NUT, WELD CONNECTOR ................................................................................................................ 2

SN-178 GROUND CABLE ASSEMBLY, 15' (NOT SHOWN) ........................................................................... 1

SN-165 CLAMP, GROUND (NOT SHOWN) .................................................................................................... 1

SN-1009 LABEL, PRO'S ADVANTAGE ............................................................................................................. 1

SN-171C AXLE CAPS ......................................................................................................................................... 2

SN-217W WASHERS, AXLE ............................................................................................................................... 4

QTY.DESCRIPTION

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

1

2

3

10

11

12 FIG. B1

4

5

6

7

8

9

2627

25 24 23 22

13

14

15

16
17

18
19

20

21

FIGURE B - LEFT SIDE VIEW & INTERNAL COMPONENTS

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

FIGURE B

ITEM

NO.

1 SN-5030 BACK ................................................................................................................................................... 1

2 SN-421U BRACKET, CONTROL (U-BOARD).................................................................................................... 1

3 SN-685 TERMINAL HOUSING, HARNESS ..................................................................................................... 1

4 SN-253A GAS HOSE, PRIMARY ........................................................................................................................ 1

5 GS SN-126B SOLENOID ASSEMBLY, 24VAC ........................................................................................................1

6 SN-353C GAS HOSE .......................................................................................................................................... 1

7 SN-211C CYLINDER CHAIN .............................................................................................................................. 1

8 SN-220 STRAIN RELIEF .................................................................................................................................. 1

9 PLG1 20CP-0 POWER INPUT CABLE, 20' ................................................................................................................ 1

10 SN-601 STAND OFF, NYLON .......................................................................................................................... 4

11 CR1 SN-276S RELAY, 8 PIN ...................................................................................................................................... 1

12 PC1 SN-774U WIRE FEED CONTROL BOARD (FIGURE B1) ................................................................................. 1

13 S2 SN-163-12 HEAT SWITCH, 12 POSITION ........................................................................................................... 1

14 W SN-153 CONTACTOR, 24VAC ........................................................................................................................ 1

15 T2 SN-287M CONTROL TRANSFORMER, 230V-28V ............................................................................................ 1

16 SN-600 FITTING, "Y" HOSE ............................................................................................................................ 1

17 SN-353Y HOSE .................................................................................................................................................. 2

18 D1,2,3,4 SN-260 DIODE ................................................................................................................................................. 4

19 R2 SN-162 RESISTOR, 100 OHM 25W ................................................................................................................ 1

20 SN-360 HEAT SINK ASSEMBLY, COMPLETE ............................................................................................... 1

21 SN-255M LEG, HEAT SINK ................................................................................................................................ 2

22 C1 SN-125S CAPACITOR, 12,000UF 50V ............................................................................................................... 6

23 T1 SN-286T TRANSFORMER, POWER ................................................................................................................. 1

24 Z SN-188C CHOKE ................................................................................................................................................ 1

25 F SN-117 FAN MOTOR ....................................................................................................................................... 1

26 SN-318 BLADE, FAN ........................................................................................................................................ 1

27 SN-310A FAN BRACKET W/SHROUD .............................................................................................................. 1

DIA.

MKGS.

TP1 SN-654 THERMAL SWITCH (N.C.) ................................................................................................................. 1

PART

NO.

SN-685P PIN, TERMINAL HOUSING ................................................................................................................. 6

2200 GAS FITTING, INLET .......................................................................................................................... 1

2200SN GAS FITTING, OUTLET ..................................................................................................................... 1

SN-220N NUT, STRAIN RELIEF ........................................................................................................................ 1

SN-276CL CLIP, RELAY ....................................................................................................................................... 1

SN-236 SOCKET, RELAY 8 PIN ...................................................................................................................... 1

SN-360T HEAT SINK ASSEMBLY, COMPLETE (SERIAL# MM250SL-3949 AND LATER) .............................. 1

QTY.DESCRIPTION

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

D5

Q2

C2

R3 R6

Q1

R4

HS1

R11

D7

C3

HS2

SR1

C4

R5

FIGURE B1 - PRINTED CIRCUIT BOARD (SN-774U)

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

FIGURE B1

ITEM

NO.

DIA.

MKGS.

C2 MI-623 CAPACITOR, 1000uF 50V .................................................................................................................. 1

C3 HG-578 CAPACITOR, .02UF 100V ................................................................................................................... 1

C4 MI-626 CAPACITOR, .68UF 50DC .................................................................................................................. 1

D5 HG-579 DIODE, 2A ........................................................................................................................................... 1

D7 HG-196 DIODE, ZENER 7.5V ........................................................................................................................... 1

HS1 CB-251 HEAT SINK, SCR ................................................................................................................................ 1

HS2 CB-250 HEAT SINK, BRIDGE RECTIFIER ...................................................................................................... 1

Q1 HG-194A SCR, 10A ............................................................................................................................................. 1

Q2 MI-627 TRANSISTOR, PUT ............................................................................................................................ 1

R3,6 CB-043 RESISTOR, 1K OHM 1/2W ................................................................................................................. 2

R4 MI-127 RESISTOR, 100 OHM 1/2W ............................................................................................................... 1

R5 MI-135A RESISTOR, TRIM 1 MEG OHM .......................................................................................................... 1

R11 MI-159 RESISTOR, 330 OHM 1/2W ............................................................................................................... 1

SR1 CB-048 RECTIFIER, BRIDGE .......................................................................................................................... 1

PART

NO.

QTY.DESCRIPTION

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

1

8

*2

9

3

4

5

6

7

10

11

*12

13

*14

FIGURE C - FRONT VIEW - REMOTE FEED UNIT

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

FIGURE C

ITEM

NO.

1 SN-05 HANDLE .............................................................................................................................................. 1

*2 SN-5110 CABINET, FEED UNIT (ONLY) ........................................................................................................... 1

* SN-5110C COMPLETE CABINET ASSEMBLY (MUST BE PURCHASED AS A COMPLETE ASSEMBLY)

3 SN-700 BUMPER PAD, SELF-TAPPING (SERIAL# MM250SL-2572 AND LATER) ....................................... 2

4 SN-246B TERMINAL, GAS-CURRENT .............................................................................................................. 1

5 RC4 SN-6190 RECEPTACLE, CONTROL (INPUT) ................................................................................................... 1

6 SN-5180 FRONT, FEED UNIT ........................................................................................................................... 1

7 SN-889F FEET, RUBBER .................................................................................................................................. 4

8 S4 SN-425B SWITCH, N/O-N/C PURGE ................................................................................................................ 1

9 SN-2520 KNOB, TIMER ..................................................................................................................................... 1

10 SN-67 KNOB, FEED ....................................................................................................................................... 1

11 S3 SN-245M SWITCH, MODE ................................................................................................................................. 1

*12 SN-5270U DOOR, UPPER FEEDER .................................................................................................................... 1

* SN-5270UP DOOR PIN (ONLY), UPPER ............................................................................................................... 1

13 SN-1059 LABEL, FEED UNIT CONTROL .......................................................................................................... 1

*14 SN-5270L DOOR, LOWER FEEDER ................................................................................................................... 1

* SN-5270LP DOOR PIN (ONLY), LOWER .............................................................................................................. 1

* SN-1007 LABEL, MUSCLE MIG ......................................................................................................................... 1

DIA.

MKGS.

PART

NO.

SN-5110A " , (SERIAL# MM250SL-2729 AND LATER) ........................................................................................ 1

QTY.DESCRIPTION

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

1

9

2

3

4

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6

7

8
FIG. D2

10

11 FIG. D1

12

13

14

15

16

17

18

FIGURE D - RIGHT SIDE VIEW & INTERNAL COMPONENTS

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

REMOTE FEED UNIT

FIGURE D

ITEM

NO.

1 LB-1367 LABEL, ACCESS DOOR - LEFT .......................................................................................................1

2 SN-6421U BRACKET, CONTROL (BEHIND COVER) ....................................................................................... 1

3 SN-6230 DUST COVER ................................................................................................................................... 1

4 R9 SN-222 POTENTIOMETER, 35K SPOT TIMER (BEHIND COVER) ............................................................. 1

5 R1 SN-35U POTENTIOMETER, 75K FEED (BEHIND COVER) .......................................................................... 1

6 SN-605A HOSE, SECONDARY ........................................................................................................................ 1

7 SN-609 CABLE, SECONDARY CURRENT ................................................................................................... 1

8 SN-138C24M WIRE DRIVE ASSY., COMPLETE (FIGURE D2) ............................................................................. 1

9 LB-1368 LABEL, ACCESS DOOR - RIGHT .................................................................................................... 1

10 SN-685 TERMINAL HOUSING, HARNESS (BEHIND COVER) .................................................................... 1

11 PC2 SN-529U SPOT TIMER BOARD (BEHIND COVER)(FIGURE D1) .................................................................. 1

12 SN-5220 SPOOL BRACKET ............................................................................................................................ 1

13 SN-22 SPOOL CLIP ..................................................................................................................................... 1

14 SN-122 SPOOL HUB ASSEMBLY ................................................................................................................. 1

15 SN-606 DOOR CATCH, MAGNETIC ............................................................................................................. 1

16 SN-20B BOLT, TENSION ............................................................................................................................... 1

17 SN-5130 BACK, LARGE FEEDER ................................................................................................................... 1

18 SN-314I INSULATOR CARD, SPOOL HUB .................................................................................................... 1

DIA.

MKGS.

PART

NO.

SN-685P PIN, TERMINAL HOUSING (BEHIND COVER) ................................................................................ 9

SN-601 STAND OFF, NYLON (BEHIND COVER) ......................................................................................... 4

SN-5220A " (SERIAL# MM250SL-2729 AND LATER) ........................................................................................ 1

SN-15 SHAFT ............................................................................................................................................... 1

SN-16 BUSHING .......................................................................................................................................... 2

SN-18 TENSION SPRING ............................................................................................................................ 1

SN-19 WASHER, SPOOL HUB ................................................................................................................... 3

SN-5130A " (SERIAL# MM250SL-2729 AND LATER) ........................................................................................ 1

QTY.DESCRIPTION

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

C5 C6

R8

R7

D8

Q3

CR2

R10

D9

D10

SR2

FIGURE D1 - PRINTED CIRCUIT BOARD (SN-529U)

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

FIGURE D1

ITEM

NO.

DIA.

MKGS.

C5,6 MI-143 CAPACITOR, 47uFD 50V .................................................................................................................... 2

CR2 HG-576 RELAY, 24VDC 4PDT ......................................................................................................................... 1

D8,9,10 HG-579 DIODE, 2A ........................................................................................................................................... 3

Q3 MI-627 TRANSISTOR, PUT ............................................................................................................................ 1

R7 MI-125 RESISTOR, 4.7K OHM 1/2W .............................................................................................................. 1

R8 MI-148 RESISTOR, 1.2K OHM 1/2W .............................................................................................................. 1

R10 MI-126 RESISTOR, 3.3K OHM 1/2W .............................................................................................................. 1

SR2 CB-048 RECTIFIER, BRIDGE .......................................................................................................................... 1

PART

NO.

QTY.DESCRIPTION

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

1

2

3

14

15

16

17

10

10A

10B

11

12

4

5

6

7

8

9

18

19

20

21

22

23

24

25
26

27
28
29
30

31
3213

FIGURE D2 - WIRE DRIVE ASSEMBLY (SN-138C24M)

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

FIGURE D2

ITEM

NO.

1 SN-48 PRESSURE ROLL TENSION BOLT ............................................................................................... 1

2 SN-51 TENSION NUT ................................................................................................................................ 1

3 SN-50F PRESSURE SPRING ...................................................................................................................... 1

4 SN-49 TENSION BOLT WASHER .............................................................................................................1

5 SN-47 TENSION BOLT PIN ....................................................................................................................... 1

6 M3-906 THUMB SCREW ............................................................................................................................. 1

7 SN-24 GAS FITTING (2291, 1192) (BEHIND) ............................................................................................ 1

8 M3-900C TORCH PANEL MOUNT (HG-525) ................................................................................................. 1

9 SN-604 WIRE CONNECTOR, 90 DEG. ....................................................................................................... 2

10 RC5 SN-860C FUNCTION PLUG ASSEMBLY ....................................................................................................... 1

10A SN-860 PIN HOUSING ................................................................................................................................. 1

10B SN-860M MALE PIN CONNECTOR ............................................................................................................... 6

11 J1 AD-10 JUMPER .......................................................................................................................................... 1

12 SN-237 CONTROL WIRE ASSEMBLY ........................................................................................................ 2

13 SN-65 DRIVE ROLL LOCK WASHER ....................................................................................................... 1

14 M SN-138C24 24VDC MOTOR............................................................................................................................... 1

15 SN-53F ROCKER ARM ................................................................................................................................ 1

16 SN-158 PRESSURE ROLL .......................................................................................................................... 1

17 SN-55F BEARING SPACER (BEHIND) ....................................................................................................... 1

18 HW-1420KHN 1/4-20 KEP NUT .............................................................................................................................. 1

19 SN-89 SPRING WASHER (BEHIND) ......................................................................................................... 1

20 SN-52 SHOULDER BOLT .......................................................................................................................... 1

21 SN-33F INLET GUIDE .................................................................................................................................. 1

22 SN-136C INLET GUIDE TUBE ....................................................................................................................... 1

23 SN-34 NUT, INLET GUIDE ........................................................................................................................ 1

24 SN-64 DRIVE ROLL NUT ........................................................................................................................... 1

25 SN-62 DRIVE ROLL WASHER .................................................................................................................. 1

26 SN-603 ADJUSTING COLLAR (BEHIND).................................................................................................... 1

27 SN-60 DRIVE ROLL (30-45DR) .................................................................................................................. 1

28 SN-61C 1/2 WOODRUFF DRIVE KEY ......................................................................................................... 1

29 SN-131S MOTOR BRACKET, ADJUSTABLE ................................................................................................ 1

30 SN-139AD INSULATOR, TOP .......................................................................................................................... 1

31 SN-139 MOTOR BASE INSULATOR........................................................................................................... 1

32 SN-40 INSULATING WASHER .................................................................................................................. 4

DIA.

MKGS.

RC6 SN-861C FUNCTION RECEPTACLE ASSEMBLY (NOT SHOWN) .............................................................. 1

PART

NO.

HW-58ILW LOCK WASHER, INTERNAL .......................................................................................................... 1

QTY.DESCRIPTION

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

1

2

3

4

3

5

987

10

11

6

1

98712

FIGURE E - FEEDER CABLE ASSEMBLY (FCA-15)

FIGURE E

ITEM

NO.

1 SN-026 NUT, GAS HOSE ............................................................................................................................ 2

2 RC3 SN-6204 PLUG, 14 PIN (FEMALE PINS) ...................................................................................................... 1

3 SN-6204B CLAMP, 14 PIN PLUG ..................................................................................................................... 2

4 PLG2 CC-300-15 CONTROL CABLE ASSY., 15' 14 PIN ............................................................................................ 1

5 RC2 SN-6191B PLUG, 14 PIN (MALE PINS) ........................................................................................................... 1

6 PS-4A POWER PLUG W/GAS HOLE ........................................................................................................ 1

7 SN-028 FERRULE, HOSE............................................................................................................................ 2

8 SN-025 CABLE FITTING.............................................................................................................................. 2

9 SN-023 WELD CABLE ONLY (14'-10") ........................................................................................................ 1

10 SN-2157E-15 GAS/CURRENT CABLE ASSY., 15' EXTENSION.......................................................................... 1

11 SN-2008 CABLE TIE ..................................................................................................................................... 15

12 SN-807G BOOT/CABLE COVER .................................................................................................................... 1

DIA.

MKGS.

PART

NO.

SN-6209-15 CABLE ONLY, 15' ............................................................................................................................ 1

SN-027-15 GAS HOSE ONLY , 15' ................................................................................................................... 1

QTY.DESCRIPTION

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

M

M

2

5

0

S

L

M

M

2

5

0

S

L

-

2

0

0

0

A

N

D

L

A

T

E

R