Snap-On MUSCLE MIG SYSTEM MM350XL Owner'S Manual Download Page 25

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CONSUMABLE PARTS BREAKDOWN - 35XL SERIES M.I.G. TORCH

XL STYLE FRONT END - STANDARD

WIRE SIZE

CONTACT TIP

GAS DIFFUSER

NOZZLE

INSULATOR

.020 - .025 inch

M3-T25

M6-D

M6-C62

M6-B

.030 inch

M3-T30

(5/8" I.D.)

(includes rings)

035 inch

M3-T35

(1-7/16"

.040 - .047 inch

M3-T45

length)

LINERS FOR STEEL WELDING

ORDER NUMBER

WIRE

TORCH

SIZE

LENGTH

LINER W/SEAL

SEAL ONLY

.020-.030 inch

10 feet

M103L-B

M3LS-B (Blue)

12 feet

M123L-B

10 feet

M104L-N

.035-.045 inch

12 feet

M124L-N

M4LS-N (Natural)

15 feet

M154L-N

10 feet

M106L-G

1/16 inch

12 feet

M126L-G

M6LS-G (Green)

15 feet

M156L-G

SHIELDING GAS

WELDING WIRE

MIG

WIRE

AMPS

MATERIAL

TYPE

FLOW

TYPE

SIZE

THICKNESS VOLTAGE

SPEED

OUTPUT

18 Ga.(.048")

1/2

16 Ga.(.060")

3/4

14 Ga.(.075")

110

.030"

12 Ga.(.105")

120

1/8"

135

3/16"

6 1/2

150

1/4"

160

14 Ga.(.075")

110

12 Ga.(.105")

115

1/8"

2 1/2

120

.035"

3/16"

3 1/2

140

75%

1/4"

150

CARBON

ARGON

ER70S-6

5/16"

6 1/2

160

STEEL

25%

CFH

3/8"

7 1/2

190

CO2

(Min.)

1/8"

150

3/16"

200

.045"

1/4"

210

5/16"

220

3/8"

240

1/2"

7 1/2

260

1/16"

Optional Drive Roller and Liner are required.

Guide For Setting Welder - Adjust For Best Results

GAS METAL ARC (MIG) PROCESS - DCEP (REVERSE POLARITY)

Note: Settings are approximate and may vary. Adjust for best results.

Summary of Contents for MUSCLE MIG SYSTEM MM350XL

Page 1: ...STEM MODEL MM350XL IS DESIGNED AND ENGINEERED BY THE PROS FOR THE PROS UNDER NORMAL CARE THIS SYSTEM WILL PROVIDE YOU WITH YEARS OF UNSURPASSED SERVICE AND MOST IMPORTANTLY PERFORMANCE OWNER S MANUAL FOR TECH SERVICE CALL TOLL FREE 1 800 232 9353 PROVIDE MODEL SERIAL NUMBER INSTALLATION OPERATION MAINTENANCE MM350XL M I G COMBINATION UNIT ...

Page 2: ...welding process Use only in well ventilated area Avoid breathing smoke fumes and gases Smoke fumes and gases can cause injury DANGER Electric welding causes ultraviolet rays and weld spatter Bystanders will be exposed to ultra violet rays and weld spatter Wear welding helmet with appropriate shade lens while using electric welders Do not allow bystanders while welding Wear safety shield and protec...

Page 3: ...H OR LOSS OR DAMAGE TO ANY PROPERTY DIRECT OR CONSEQUENTIAL INCLUDING BUT NOT LIMITED TO LOSS OF USE ARISING OUT OF THE USE OR THE INABILITY TO USE THE PRODUCT THE USER ASSUMES ALL RISK AND LIABILITY WHATSOEVER IN CONNECTION WITH THE USE OF THE PRODUCT AND BEFORE DOING SO SHALL DETERMINE ITS SUITABILITY FOR HIS INTENDED USE AND SHALL ASCERTAIN THE PROPER METHOD OF USING IT SOME STATES DO NOT ALLOW...

Page 4: ...rough the cable and torch to the weld The emerging wire and the weld are shielded by a stream of CO2 Argon or a mixture of the two which prevents oxidation of the molten weld puddle The gas shield enables high quality welds to be made without the use of flux eliminating the need for slag or flux removal after the weld is completed POWER SOURCE WIRE SPOOL FEED ROLLS WORK MIG TORCH REVERSE POLARITY ...

Page 5: ...arly marked The output voltage is controlled by a twelve position tap switch providing 4 TIG and 8 MIG voltage selections Wire feed speed is controlled by the wire speed potentiometer on the front of the feed unit SPECIFICATIONS PART NUMBER MM350XL INPUT POWER REQUIREMENTS Voltage 208 230 Phase single phase Frequency 50 60 hertz Current 46 42 DUTY CYCLE OUTPUT POWER 100 300 Amps 60 350 Amps DUTY C...

Page 6: ...electrical plug THE MM350XL REQUIRES A 208 OR 230 VOLT SINGLE PHASE AC 60 AMP CIRCUIT 5 Other personal protective equipment which may vary to match the welding being per formed WIRE TYPES mild steel stainless steel aluminum bronze flux cored flux cored gasless Recommended for steel ER70S 6 WIRE SIZES 023 1 16 steel 3 64 1 16 aluminum 023 3 64 alum w spool gun 030 035 bronze 035 045 flux cored gas ...

Page 7: ...TACTOR SWITCH CONNECT 230 WIRE FOR OPERATION ON 230 VOLT INPUT CONNECT 208 WIRE FOR OPERATION ON 208 VOLT INPUT FRONT OF MACHINE WARNING Electrical shock can result from absence of grounding prong Do not remove or bypass the grounding prong in any electrical plug Electrical shock can cause injury continued on following page WARNING Smoke fumes and gases are created by the welding process Use only ...

Page 8: ...IONS 1 Place a cylinder of the appro priate shielding gas in the rack at the rear of the machine and secure it with the chain pro vided FIG 6 FCA 15X FEEDER CABLE ASSEMBLY GAS FITTING CONTROL PLUG FEMALE PINS CURRENT LUG CONTROL PLUG MALE PINS POWER PLUG CURRENT CABLE FEED CABLE ASSEMBLY GAS HOSE 2 Insert the current lug through the hole on the front of the feed unit and with the proper size wrenc...

Page 9: ...orch into the torch panel mount apply anti spatter spray to the O rings 2 Back out the thumb screw located on the drive bracket inside the machine Insert the MIG torch into the torch panel mount and TIGHTEN THE THUMB SCREW SE CURELY WARNING SEVERE DAMAGE TO THIS PRODUCT MAY RESULT TIGHTEN THUMB SCREW BE FORE EACH USE FIG 9 GAS FLOW ADJUSTMENT GAUGE INDICATES TANK PRESSURE OUTLET FITTING TO WELDING...

Page 10: ...FIG 11 FITTING AND THREADING THE ELECTRODE DRIVE ROLL ELECTRODE MIG WIRE SPOOL CLIP PRESSURE ROLL ARM SPOOL HUB 4 Replace the spool clip on the hub 5 Unlatch the pressure roll arm and swing it open FIG 12 DOUBLE GROOVE DRIVE ROLL B SIDE FACING IN FOR 030 035 STEEL WIRES C SIDE FACING IN FOR 040 045 STEEL WIRES 7 Release the wire from the spool and trim off the kinked end with wire cutters The wire...

Page 11: ...contact tip should be flush or stick out up to 1 16 inch beyond the end of the nozzle Using wire cutters trim off the wire so the stickout is approximately 1 4 inch for steel 14 For steel welding only spray anti spatter compound inside the nozzle and on the outside of the contact tip WIRE FEED PRESSURE ROLL ADJUST MENT The wire feed pressure roll is adjusted at the factory prior to delivery It may...

Page 12: ...the pieces of metal to be welded are free of grease dirt paint and scale Use a wire brush to remove paint and scale Paint must be 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 2 Install the unit as directed in the installation instructions and make sure the work clamp is fir...

Page 13: ... for gas from welding machine H OCV GAS PURGE Operates the gas solenoid to purge the lines of impurities prior to welding Pressing the switch also causes open circuit voltage to be registered on the power source voltmeter CAUTION Torch is electrically HOT when switch is actuated I WIRE SPEED Potentiometer controls speed of wire drive motor to give wire speed of 50 to 800 inches per minute J TORCH ...

Page 14: ...ained using the unit CONTINUOUS WELDING ON STEEL 1 Trim the electrode wire to leave approximately 1 4 inch stickout beyond the end of the contact tip and install the welding nozzle The contact tip should be flush or stick out up to 1 16 inch beyond the end of the nozzle FIG 17 NOZZLE ADJUSTMENT FOR WELDING STEEL NOZZLE CONTACT TIP FLUSH TO 1 16 STICKOUT ELECTRODE WIRE 1 4 STICKOUT WARNING Material...

Page 15: ...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 stant arc length and a constant tip to work distance OPERATING HINTS BURNBACK 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 diffuse...

Page 16: ... 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 effi ciency the following maintenance schedule and procedures are recom mended These routines should be performed regularly by the opera tor REGULARLY Usage and shop condi tions determine frequency 1 Remove and clean the torch nozzle and conta...

Page 17: ...ontained com bustibles IF IN DOUBT DON T DO IT BE SAFE DON T BE SORRY WEEKLY 1 Remove dirt and dust from the wire feed compartment Use low pressure dry compressed air 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 Tigh...

Page 18: ...eplace micro switch trigger Fault in torch cable Check torch cable activated for continuity no response Loose or broken connection Check or repair on wiring harness PLG2 connections Wire feed motor unplugged Plug in motor RC5 Faulty control transformer Check for 28VAC output T3 Main power on Pressure roll arm unlatched Latch arm add tension torch Slippage at drive rolls Increase drive roll trigger...

Page 19: ...ain power on No shielding gas Replace tank torch tank empty trigger Loose or broken Tighten or repair activated connections connections no gas flow Faulty Gas solenoid Repair or replace but contactor valve GS valve operates Clogged gas flow path Locate clean clog wire feeds FAULTY WELDS Jerky or Worn kinked or dirty torch Clean or replace slipping liner liner wire feed Wire spool turns too Lubrica...

Page 20: ...t wire puddle 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 D8 faulty diode s See page 21 Heavy spatter Incorrect machine settings Increase heat decrease wire feed speed Incorrect shielding gas Replace with proper gas Excessive wire stick out Hold torch ...

Page 21: ...ntinuity in either direction the diode is in open circuit condition and must be replaced If there is continuity in both direc tions the diode is in short circuit condition and must be replaced If there is continu ity in one direction only the diode is functioning properly FIG 19 DIODE LOAD CHECK CONNECTION DIAGRAM TEST FOR FLOW IN BOTH DIRECTIONS 3 If all the diodes check out satisfactorily with t...

Page 22: ...ase unit 2 Locate the printed circuit board mounted at the back of the machine 3 Referring to Figure 20 locate the trim resistor this is lo cated in the upper right hand corner of the wire feed PC board 4 Turn the wire speed dial on the front of the machine to 0 5 Remove any tension on the drive roll 6 Activate the torch trigger 7 Rotate the trim resistor back and forth until the bottom drive roll...

Page 23: ...ck to standard MIG operation reverse the proce dure CONNECTING THE FLEXTIG CHANGING FROM STANDARD MIG OPERA TION TO FLEXTIG OPERATION CHANGING FROM STANDARD MIG OPERA TION TO SPOOL GUN OPERATION 1 Unplug the feeder control cable plug from the control receptacle OUTPUT of the welder 2 Plug the MHG5 B spool gun con trol cable plug into the welder control receptacle OUTPUT 3 Remove the feeder gas and...

Page 24: ...ted on the connector end of the torch as sembly see FIG 22 Grip the liner and gas seal firmly then pull The liner should easily slide from torch assembly 1 2 3 4 5 4 5 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 22 6 7 Following the diagram in FIG 23 measure out 1 5 8 from the neck assembly...

Page 25: ...126L G M6LS G Green 15 feet M156L G SHIELDING GAS WELDING WIRE MIG WIRE AMPS MATERIAL TYPE FLOW TYPE SIZE THICKNESS VOLTAGE SPEED OUTPUT 18 Ga 048 1 1 2 80 16 Ga 060 2 3 4 90 14 Ga 075 3 2 110 030 12 Ga 105 3 3 120 1 8 4 4 135 3 16 5 6 1 2 150 1 4 5 8 160 14 Ga 075 2 1 110 12 Ga 105 3 2 115 1 8 3 2 1 2 120 035 3 16 4 3 1 2 140 75 1 4 4 4 150 CARBON ARGON 25 ER70S 6 5 16 5 6 1 2 160 STEEL 25 CFH 3 ...

Page 26: ... M3 213 TRIGGER PIN M3 214 TRIGGER SPRING QUICK CONNECTOR GROUP M3 120 FERRULE M3 301A CONNECTOR HOUSING M3 305A CONNECTOR STEM M3 306 CONNECTOR PLUG WITH SETSCREW O RINGS M3 307 SETSCREW ONLY M3 308 O RING ONLY 2 REQUIRED M3 309 TERMINAL CONNECTOR CONTACT 2 REQUIRED M3 310A BOOT CABLE SUPPORT SN 807G CABLECOVER M3X 401 HANDLE M3 402 HANDLE SCREW 2 REQUIRED M3 405 TERMINAL TORCH END 2 REQUIRED M3 ...

Page 27: ...HG5 B ONE POUND SPOOL GUN FOR ALUMINUM MIG WELDING WITH SNAP ON TOOLS MUSCLE MIG SYSTEMS MM140SL MM250SL MM350XL The MHG5 B Motorized Hand Gun System is a compact light in weight easy to operate MIG welding system designed for aluminum welding It will feed 023 Thru 3 64 diameter wire from 4 inch spools The standard equipment cable is 25 feet in length 35 foot and 50 foot cables are optional The wi...

Page 28: ...Snap on is a trademark of Snap on Technologies Inc 2002 Snap on Technologies Inc Manufactured in USA for Snap on x 2801 80th Street x Kenosha WI 53141 1410 ZMM350XL 6 02 Rev 2 03 ...

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