owner's manual - systematics inc. · pdf fileowner's manual the ya212a...

OWNER'S MANUAL

THE YA212A "INDUSTRIAL"REPRESENTS THE LATEST TECHNOLOGYIN MIG COMBINATION UNITS. THE YA212A "INDUSTRIAL"OPERATES ON SINGLE PHASE CURRENT, AND FEATURES"SMOOTH ARC" TRANSFORMER DESIGN CONCEPT.

YA212A "INDUSTRIAL"MIG COMBINATION UNIT

FOR TECH. SERVICE, CALL TOLL-FREE 1-800-232-9353

FORM WC5388 Rev. 3/98, 8/00

INSTALLATIONOPERATION

MAINTENANCE

MANUFACTURER’S LIMITED WARRANTY

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

EXCEPTION: THE MIG TORCH IS WARRANTED FOR APERIOD OF 30 DAYS FROM THE DATE OF PURCHASE.

Should the equipment become defective for such reason,the Manufacturer will repair it without charge, if it is returnedto the Manufacturer’s factory, freight prepaid. This warrantydoes not cover: (1) failure due to normal wear and tear; (2)consumable parts, such as, but not limited to, torch contacttips, gas cups and insulating bushings; (3) damage byaccident, force majeure, improper use, neglect, unauthor-ized repair or alteration; (4) anyone other than the originalpurchaser.

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

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

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

ELECTRIC SHOCK can kill.• Do not touch electrodes or other electrically live parts.

• Insulate yourself from work and ground.

• Install and ground machine in accordance with the National

Electical Code and local code(s). Read Operating Manual

before installing or operating.

• Do not operate with protective covers, panels, or guard

removed.

• Disconnect input power before servicing.

• Only qualified personnel should install, use, or service this

equipment.

ARC RAYS can injure your eyes and burnskin.• Wear correct eye, ear, and body protection while welding.

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

• Keep your head out of fumes.

• Do not breathe fumes.

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

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

! WARNING

TABLE OF CONTENTSINTRODUCTION..................................................................1SPECIFICATIONS ...............................................................2CHECK LIST ........................................................................3INSTALLATION ...................................................................4OPERATION ........................................................................8MAINTENANCE .................................................................11TROUBLE SHOOTING CHART ........................................13CONNECTING TIGPAK OR SPOOL GUN ........................18PARTS BREAKDOWN - MIG TORCH ..............................20OPTIONS - TIG PAK, SPOOL GUN ..................................22

Snap-on Tools Corporation Kenosha, WI 53141-1410

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

INTRODUCTIONThe Snap-On Tools YA212A INDUS-

TRIAL is a combination weldingpower source, wire feed unit, MIGtorch and accessory package de-signed to meet the requirements ofthe light to medium metal fabrica-tion industries. The unit producesfusion welds by the Gas Metal ArcWelding process (GMAW or MIG), onsteel and aluminum up to 5/16"thick, using .023" through .045"steel wire and .025" through 3/64"aluminum wire with the optionalMHG5-A. (optional liners must bepurchased to cover given wire sizes).Heavier sections can be easilywelded using slightly differenttechniques.

The number of controls on the unithas been reduced to assist inexpe-rienced operators to learn MIGwelding. This facilitates rapid setup for welding various thicknessesof material requiring various heatinputs. The HEAT (voltage) controladjusts the welding voltage and theWIRE SPEED control adjusts thespeed of the wire feed motor.

THE MIG PROCESSAS APPLIED TO THEYA212A INDUSTRIAL

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

POWER SOURCE

WIRE SPOOL

FEEDROLLS

WORK

MIGTORCH

+REVERSEPOLARITY

(STD.)_

SHIELDING GAS

ELEC-TRODE

WORK

The consumable electrode wire ismelted and transferred to the weldpuddle by any of three arc modes;short arc transfer, globular trans-fer, or spray arc transfer. TheYA212A IND. is capable of perform-ing all modes on steel and aluminum.

SHORT ARC OR DIP TRANSFER

Short arc transfer occurs at 12 to22 arc volts (voltage while weld-ing), depending on wire size. Weld-ing commences as the arc is struckand a weld pool is formed. The tipof the electrode wire dips into thepool and causes a short circuit.The short circuit current flowcauses a rapid temperature rise inthe electrode wire and the end ofthe wire is melted off. An arc isimmediately formed between the tipof the wire and the weld pool,maintaining the electrical circuitand producing sufficient heat tokeep the weld pool fluid. Theelectrode continues to feed andagain dips into the pool.

FIGURE 1. SCHEMATIC OF MIG PROCESS

FIGURE 2. SHORT ARC TRANSFER

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

SHORT ARC OR DIP TRANSFER (Cont.)

This sequence of events is re-peated up to 200 times per second.Short arc transfer is suitable forpositional welding. The heat inputto the workpiece is kept to aminimum which limits distortion andmakes possible the welding of thinsheet material.

GLOBULAR TRANSFER

Globular transfer occurs at theintermediate range of 22 to 24 arcvolts, depending on wire size. Asthe name implies, the transfertakes place in the form of irregu-larly shaped globules. Globulartransfer is useful in cases where alower heat input than that of truespray is required.

DESCRIPTIONThe YA212A INDUSTRIAL consists of

a combination MIG welding powersource and wire feed unit, a 15TG10MIG torch, a fifteen foot groundcable with ground clamp, a twentyfoot power input cable, a gasregulator - flowmeter, a torchaccessory kit, and a built-in cyl-inder rack and industrial wheelkit. Welder components are cooledby forced fan cooling.

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

SPECIFICATIONSPART NUMBER: YA212A INDUSTRIAL

INPUT POWER REQUIREMENTS:Voltage 208/230 volts ACPhase single phaseFrequency 50/60 hertzCurrent 34/30 amps

NOTEThis welder draws 20 amps at100% Duty cycle (185 ampsoutput). A 40 amp 208 or 230volt electrical service isrequired for proper arc start-ing and full utilization ofits maximum output of 230amps.

DUTY CYCLE - OUTPUT POWER:Welding Current

(NEMA) @ 60% 200 Amps@ 60% 230 Amps

DUTY CYCLE TIME PERIOD:10 minutes

OPEN CIRCUIT VOLTAGE:18 - 42 volts DC

ELECTRODE GAS NOZZLE

SHIELDING GASWORK

SPRAY TRANSFER

Spray transfer occurs at 22 to 28arc volts, depending on wire size.The length of the arc is heldconstant by the voltage available.The higher voltage and currentcauses the electrode wire to meltoff before touching the workpiece.The molten metal crosses the gap tothe workpiece in a spray form.Spray transfer is used in the down-hand position and provides higherdeposition rates than short arctransfer or globular transfer.

ELECTRODE GAS NOZZLE

SHIELDING GASWORK

FIGURE 3. GLOBULAR TRANSFER

FIGURE 4. SPRAY TRANSFER


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 .035Others .030

WIRE FEED SPEED RANGE:10 - 500 inches per minute

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

25% CO2For Aluminum, Bronze ArgonFor Stainless Steel 98% Argon/2%OxygenFor Flux cored CO2 or

Argon/CO2 mix

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 SPECIFICATIONSNECK 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%

CHECK LISTTHE SNAP-ON TOOLS YA212A INDUSTRIALINCLUDES THE FOLLOWING:

1- Combination Power Source/WireFeeder

1- Cylinder Rack/Industrial WheelKit

1- 15TG10 MIG Torch with adjust-able nozzle

1- 20 foot Power Input Cable

1- 15 foot Ground Cable and Clamp

1- 230PK-1 Accessory Kit

1- Gas Regulator/Flowmeter - forsteel 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- ER70S-6-30-3, Sample Spool of.030 Steel Wire

OPTIONAL EXTRASRE5-A Range Extender, a wire feed

unit which extends thereach of the YA212A INDUS-TRIAL an extra 25 feet.

50CP-0 50 foot Power Input Cable(replaces standard 20 footpower input cable).

MHG5-A Spool Gun - for weldingaluminum(see page 22)

TIGPAK Tig Torch Kit - for TIGwelding steel, stainlesssteel(see page 22)


ITEMS REQUIRED FOR MIG WELDINGWHICH ARE NOT PROVIDED WITH THEYA212A INDUSTRIAL

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

2. Proper shielding gas and cylin-der.

3. Leather welding gloves.

4. Electrical power.

THE YA212A INDUSTRIAL RE-QUIRES A 208 OR 230 VOLT,SINGLE PHASE, AC, 40 AMP CIR-CUIT.

5. Other personal protectiveequipment which may vary tomatch the welding being per-formed.

208V INPUT SELECTION

1. Remove the top cover.

2. Locate the contactor switch,which is mounted on top of themain power transformer (See Fig-ure 5).

INSTALLATIONPOSITIONING THE UNIT

Locate the unit adjacent to thewelding area and position it sothere is adequate clearance allaround for ventilation and mainte-nance.

ELECTRICAL SUPPLY

Ensure that there is a 208 or 230volt, single phase, 40 amp elec-trical supply within easy reach ofthe unit. The input cable suppliedis 20 feet long. A 50 foot cable isan optional extra. Attach a suit-able plug making sure the greenwire is attached to ground. Allwiring should be performed by aqualified electrician.

230V INPUT SELECTION

1. Factory selected no change isneeded.

MAKE SURE POWER SOURCE ISUNPLUGGED BEFORE MAKING IN-PUT SELECTION CHANGE-OVER.

3. Attached to the power source’scontactor is one (2) two posi-tion plug which allows easyselection of input voltages ofeither 208 or 230 volts.

4. Remove the one (1) plug labeled230V and connect the one (1) pluglabeled 208V.

5. Reattach the top cover of themachine. Voltage input selec-tion is now complete.

CAUTION

FIGURE 5. INPUT VOLTAGE SELECTIONS

CONNECT "208"TERMINAL FOR

WELD POWER OPERATION ONCONTACTOR 208 VOLT INPUT

CONNECT "230"TERMINAL FOROPERATION ON230 VOLT INPUT

FRONT OFMACHINE.


SHIELDING GAS CONNECTIONS

1. Place a cylinder of the appro-priate shielding gas in the rackat the rear of the machine andsecure it with the chain pro-vided. See recommended gases onpage 3.

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

Take care to point the valveoutlet away from yourself orother people, as escapinghigh pressure gas may bedangerous.

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

NOTEIf this unit is to be usedwith 100% CO2 shielding gas,an optional gas regulatorcoupler is required.

4. Fit the gas hose from the weldingmachine to the regulator outletfitting and tighten it with awrench. Open the cylinder valve.When welding steel, the gas flowrate is 30 CFH. When weldingaluminum, the gas flow rate is 40CFH.

NOTEThe YA212A INDUSTRIAL mustbe turned "ON" and the MIGtorch trigger depressed,before the gas flow ratecan be adjusted.

TORCH CONNECTION

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

2. Back out the thumb screw lo-cated on the drive assemblymounting bracket inside the ma-chine. Insert the MIG torch intothe torch panel mount on thefront panel and TIGHTEN THETHUMB SCREW.

(continued on following page)FIGURE 6. GAS FLOW ADJUSTMENT

CAUTION

FITTING AND THREADING THE ELECTRODEWIRE - ALWAYS USE ER70S-6 WELDINGWIRE.

1. Remove the wire spool clip fromthe spool hub.

FIGURE 7. TORCH CONNECTION

TORCH PRESSUREPANEL ROLL

MIG MOUNTTORCH

THUMBSCREW

DRIVE ROLL DRIVE ASSEMBLY

GAUGE -INDICATES

TANKPRESSURE

OUTLETFITTING

TOWELDINGMACHINE

GAS FLOWADJUSTING

KNOB

INLETFITTING

TOTANK

FLOW TUBEINDICATES

FLOW RATEIN C.F.H.


FITTING AND THREADING THE ELECTRODEWIRE (Cont.)

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

3. Place the spool of ER70S-6 weld-ing wire on the hub ensuring thatthe hole in the spool flangelines up with the locating pin onthe hub. The wire is fed off thebottom of the spool.

Look for and remove any wireprotruding from the centerof the spool. The protrudingwire is electrically HOTduring welding and must nottouch the machine.

4. Replace the spool clip on thehub.

5. Unlatch the pressure roll armand swing it open.

6. Make sure the double v-groovedrive roll is installed to matchthe wire size. To change the wiresize setting, remove the driveroll, turn it over and reinstallit on the drive motor shaft.

CAUTION

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

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

9. Close and relatch the pressureroll arm.

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

11.Turn on the circuit breaker onthe front of the machine. Thecooling fan will start and the"ON" indicator light will illu-minate. Set the HEAT controlswitch to "4" and the WIRE SPEEDcontrol to "7". Pull the triggeron the MIG torch. The wire feedsystem will start and wire willbe fed through the cable linerand torch. If the wire does notfeed, or appears to slip, tightenthe pressure roll arm adjustingnut. Feed the wire until itprotrudes from the front of thetorch approximately six inches.

Keep hands and face awayfrom the front of the torchand do not allow the wire tocontact ground. The wire iselectrically HOT when thetorch trigger is actuated.

CAUTION

FIGURE 8. DOUBLE GROOVE DRIVE ROLL

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

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


WIRE FEED PRESSURE ROLL ADJUSTMENT

The wire feed pressure roll isadjusted to the proper setting atthe factory, prior to delivery. Itmay be necessary to readjust thesetting as components "seat in" orwhen changing to a different diam-eter wire. To check for proper rollpressure, hold the torch in one handand the wire between two fingers ofthe other hand. Pull the torchtrigger. If the wire continues tofeed when firm pressure is appliedto the wire, the pressure rolladjusting nut should be backed offuntil the feed rolls start to slip.If the wire will not feed with verylittle pressure applied, the pres-sure roll adjusting nut should betightened.

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

13.Install the nozzle on the torch.For steel, the contact tip shouldbe flush or stick out up to 1/16inch beyond the end of thenozzle. For aluminum, the con-tact tip should be recessed 1/8to 3/8 inch inside the nozzle.Using wire cutters, trim off thewire so the stickout is approxi-mately 1/4 inch for steel or 1inch for aluminum. For aluminum,the end of the wire should bebent over so it does not JAM intothe work. This is called a"scratch start". See Figure 9.

TORCH SELECTOR CABLE

Plug the torch selector cableinto the Positive (+) terminal onthe machine(see PROCESS SELECTIONon page 8 for further details).

WORK (GROUND) CABLE

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

FIGURE 10. PRESSURE ROLL ADJUSTMENT

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

FIG. 9. WIRE STICKOUT - STEEL, ALUMINUM

1/4"STICK-

OUT

1"STICK-OUT

FOR STEEL:CONTACT TIP FOR ALUMINUM:

FLUSH WITH NOZZLE TIP RECESSED 1/8" - 3/8"

PRESSURE ROLL PRESSUREADJUSTING NUT ROLL

PRESSUREROLL ARM

DRIVEROLL


OPERATIONDUTY CYCLE

CONTINUAL EXCEEDING OF THE DUTYCYCLE OF THIS (OR ANY) WELDINGMACHINE CAN CAUSE DAMAGE.

The Duty Cycle of a welding powersource is a percentage of a ten (10)minute time period. It is themaximum amount of time the powersource can be operated at a givenoutput without sustaining possibledamage due to overheating. A 60%Duty Cycle means the welding ma-chine can be operated at its ratedamperage for six (6) minutes out often. The machine must be allowed tocool (machine ON, fan running, butnot welding) for the remaining four(4) minutes. Operating the machineat a higher output requires that theduty cycle percentage be lowered.

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

OPERATING SEQUENCE

1. Make sure that the pieces ofmetal to be welded are free ofgrease, dirt, paint and scale.Use a wire brush to remove paintand scale. Paint must be com-pletely removed to bare metal.Grease and oil could burn andcause a fire or safety hazard.Failure to clean the metal prop-erly will result in erratic andporous welds.

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

3. Open the shielding gas cylindervalve. Press the torch triggerand listen for gas flow.

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

PROCESS SELECTIONThe following controls are lo-

cated on the front of the machine.

CAUTION

FIGURE 11. FRONT PANEL

F.TORCHPANELMOUNT

G.TORCHSELECTORCABLE

H.(+)POSITIVETERMINAL

I.(-)NEGATIVETERMINAL

A.WIRESPEED

B.HEAT(VOLTAGE)CONTROL

C.VOLTMETER

D.CIRCUITBREAKER

E."ON"INDICATORLIGHT

CAUTION


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

WELDINGOptimum control settings will

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

CONTINUOUS WELDING ON STEEL

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

A. WIRE SPEEDPotentiometer controls speed ofwire drive motor to give wirespeed range of 10 to 500 inchesper minute.

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

C. VOLTMETERIndicates open circuit voltagewhen torch switch is actuatedand arc voltage while welding.

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

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

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

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

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

NOZZLE

ELECTRODE WIRE(1/4" STICKOUT)

CONTACT TIP(FLUSH TO

1/16" STICKOUT)

FIGURE 12.NOZZLE ADJUSTMENT FOR WELDING STEEL

(continued on following page)


CONTINUOUS WELDING ON STEEL(Cont.)

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

3. Locate the torch over the jointto be welded with the contact tipapproximately 3/4 inch from thework surface.

NOTEWhen welding steel, the idealposition for holding thetorch is inclined approxi-mately 30 degrees towardsthe direction of travel. Thearc can to be seen easily,which results in greatercontrol of the weld pool.Most right-handed weldorsmove from left to right.This method, known as fore-hand welding, provides a gasshield for the cooling weldpuddle and helps in obtain-ing an oxidation free welddeposit.

CONTINUOUS WELDING ON ALUMINUM(Nylon liner and 100% Argon shielding

gas are required)

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

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

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

FIGURE 13.TORCH POSITION FOR WELDING STEEL

- RIGHTHANDED WELDOR

30 DEGREES

DIRECTIONOF TRAVEL

SHIELDINGGAS

WORK

NOZZLE

ELECTRODE WIRE(1" STICKOUT)

CONTACT TIP(RECESSED 3/8")

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

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

3. Bring the torch nozzle to 1/2 to5/8 inch from the workpiece. Therecommended position of the torchand direction of travel areshown in Figure 15.

FIGURE 14. NOZZLE ADJUSTMENTFOR WELDING ALUMINUM

FIGURE 15.TORCH POSITION FOR WELDING ALUMINUM

WORK

10 DEGREES

DIRECTIONOF TRAVEL

SHIELDINGGAS


OPERATING HINTS

BURN BACK

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

1. Remove the nozzle from the torch.

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

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

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

5. Reinstall the torch nozzle.

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

SPATTER

Before beginning to weld andperiodically during welding, thetorch nozzle must be removed and thespatter (small globules of meltedmetal) cleared from the inside ofthe nozzle and the outside of thecontact tip and the gas diffuser.Spatter buildup between the contacttip and the nozzle can cause a shortcircuit and consequently, failureof the torch or welding machine.The frequent use of anti-spatterspray will help prevent the adher-ence of spatter to the torch compo-nents.

NOTEDO NOT use any anti-spatterspray when welding aluminum orstainless steel.

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

MAINTENANCETo ensure that this equipment

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

REGULARLY - Usage and shop condi-tions determine frequency.

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

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

3. If the torch cable assembly isbent severely, a kink may de-velop in the steel liner. Thiscan cause wire feeding problemsso a new liner should be in-stalled.

WEEKLY

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



In the event of the failure of anypart of this equipment, contactyour Snap-On Tools representativefor replacement parts and service.When ordering parts from Snap-OnTools Corporation, order numbersshould be preceded by "CKS".

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

DO NOT weld on any item thathas a common electrical ground.

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

DO NOT weld upon the case ofthe welding machine.

ONLY a qualified electricianshould perform work inside thewelding machine.

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

DO NOT weld in a closed inarea. Proper ventilation is anecessity, or a fresh airsupplied hood should be worn.

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

NEVER weld on a closed vesselor one that has containedcombustibles.

IF IN DOUBT - DON’T DO IT!

BE SAFE - DON’T BE SORRY!

WARNING

2. Remove dirt and metal depositsfrom the grooves in the feedroll. If the grooves are badlyworn, the feed roll should bereplaced. If the pressure rolldoes not turn freely, it shouldbe replaced.

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

EVERY SIX MONTHS

1. Disconnect the welder from itsmain power supply.

2. Remove the machine’s side pan-els.

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

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

5. Replace torch liner if neces-sary.

RECOMMENDEDCUSTOMER SPARE PARTS

The Snap-On Tools YA212A INDUS-TRIAL is a machine of proven designand reliability. Following is alist of consumable items recom-mended as spare parts for this unit.

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

MAINTENANCE (Cont.)


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

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

FAULT POSSIBLE CAUSE REMEDY

EQUIPMENT MALFUNCTION

No main power, YA212AI switch is "OFF".(CB1) Turn switch "on".fan does not Wall breaker is "tripped". Reset wall breaker.operate, "Open" circuit breaker Reset or replace"on" indicator on YA212AI. (CB1) breaker.light is off. Loose or broken connection Tighten or repair

in power input circuit. connection.

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

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

(RC3)Faulty control transformer. Check for 28VAC output.

(T2)

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

needs calibrated. circuit board. Seepage 17.

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

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

Check motor on a12VDC battery.

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

Loose or broken connection. Tighten or repairconnection.

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




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

EQUIPMENT MALFUNCTION (Cont.)

Main power on, Loose torch thumb screw. Tighten thumb screw.torch Broken or loose connection. Check cables fortrigger continuity.activated, Repair or tightenno welding connections.current, but Unplugged or faulty power Plug in or replacegas flows & contactor switch. (W) switch.wire feeds. 208/230V selector wire off. Reattach wire.

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

(TP1) retry.Faulty diodes. Check diodes. See page

(D1-D4) 16.

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

FAULTY WELDS

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

hard.Worn double v-groove drive Replace drive roll.

roll.Weak pressure roll spring. Replace spring.Worn or dirty contact tip. Replace contact tip.Worn inlet guide(s). Clean or replace guides.Sticking pressure roll. Replace pressure roll.Feed roll tension incorrect. Adjust feed roll ten-

sion.See page 7.


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


FAULTY WELDS (Cont.)

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

across roller.Oversize contact tip. Replace contact tip with

correct size.

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

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

work.Poor connections. Check and tighten all

connections.Faulty diode. Test diodes, replace

(D1-D4) faulty diode(s). Seepage 16.

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

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

work.

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

make sure cylinder isnot empty. Increaseflow rate.

Contaminated wire. Change wire.Faulty gas solenoid. Replace solenoid.

(GS)Incorrect electrode wire. Use correct wire.Contaminated base material. Clean or etch base

material.

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


TESTING AND REPLACING DIODES

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

Silicon diodes exhibit two mainfault conditions:

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

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

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

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

2. Using a Volt-Ohm Meter set onRX1K, check for continuitythrough the diode in both direc-tions. If there is no continuityin either direction, the diodeis in "open circuit" conditionand must be replaced. If there iscontinuity in both directions,the diode is in "short circuit"condition and must be replaced.If there is continuity in onedirection only, the diode isfunctioning properly.

3. If all the diodes check outsatisfactorily with the Volt-Ohm Meter, a load check must bemade using a twelve volt batteryand a twelve volt light bulb.

CAUTIONNEVER use a "megger" or ahigh voltage device to testa diode.

4. Connect the light bulb to one endof the diode. Test for electri-cal flow in both directions asfollows. First, test by connect-ing a lead from the batterypositive (+) terminal to thelight bulb and a lead from thebattery negative (-) terminal tothe other end of the diode. Testagain by reversing the connec-tions. (See Figure 16.) The bulbshould light with the currentflow in one (1) direction only -not both.

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

FIGURE 16.DIODE LOAD CHECK CONNECTION DIAGRAM

- TEST FOR FLOW IN BOTH DIRECTIONS

+ -

12 VOLTLIGHT BULB

DIODE 12 VOLTBATTERY

12 VOLTLIGHT BULB

DIODE 12 VOLTBATTERY

+ -


WIRE FEED CALIBRATION

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

TRIMRESISTOR

TO CHECK

1. Remove any tension on the driveroll.

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

3. Activate the torch trigger.

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

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

IF ADJUSTMENT IS REQUIRED

1. Remove the top cover assemblyfrom the unit.

2. Locate the printed circuit board.

3. Referring to Figure 17, locatethe trim resistor, this is lo-cated in the upper right handcorner of the wire feed PC board.

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

5. Remove any tension on the driveroll.

6. Activate the torch trigger.

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

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

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

10.Adjustment is now complete!

FIGURE 17. WIRE FEED PC BOARD


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

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

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

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

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

CHANGING FROM STANDARD MIG OPERATIONTO TIGPAK OPERATION

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

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

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

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

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

CONNECTING TIGPAK OR SPOOL GUN

NOTEMake sure the regulator isconnected to a cylinder ofthe proper shielding gas -pure argon for TIG welding.

NOTEMake sure the gas regulatorand welder gas hose areconnected to a cylinder ofthe proper shielding gas -100% argon for aluminumwelding; 75% argon + 25% CO2for steel welding. 98% argon+ 2% O2 is recommended forstainless steel welding.

9. Follow the operating instruc-tions in the MHG5-A manual (FormWC5385).

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

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

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

CHANGING FROM STANDARD MIG OPERATIONTO SPOOL GUN OPERATION

All current model MIG machinesare equipped with bulkhead gasfittings for quick and easychangeover from standard MIG opera-tion to spool gun operation.

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

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

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

WIRE FEEDMOTOR PLUG(PLUGGED INTO

WIRE FEED FUNCTIONMOTOR RECEPTACLE)

BULKHEADFITTINGS LABEL

THREADCAP

SELECTORHOSE

FIGURE 18. BULKHEAD CONNECTIONS


M.I.G. TORCH LINER INSTALLATION(steel only)

The MIG torch liner provided withthe YA212A INDUSTRIAL is designedfor wire diameters from .035 thru.045. If smaller wire diameters areto be fed and or there is a problem(i.e. clog, kink, etc.), a linerchange is required.

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

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

3/4"

LINERSTICKOUT

GAS SEAL

SET SCREW3/4"

CONNECTORPLUG

1 1/4+"

PROTRUDINGLINER

NECKASSEMBLY

1. Remove the new liner from thepackage.

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

3. Adjust the liner stickout lengthto 3/4" as shown in FIG. 19.

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

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

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

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

5. Tighten set screw. (Do not over-tighten), refer to FIG. 20.

6. Following the diagram in FIG.21, measure out 1 1/4"+ from theneck assembly and cut off theprotruding liner.

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

1. Remove torch assembly from thewelding machine.

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

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

4. Loosen set screw located on theconnector end of the torch as-sembly (see FIG. 20).

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

REMOVING OLD LINER

INSTALLING NEW LINER

FIGURE 19. LINER STICKOUT

FIGURE 20. TORCH CONNECTOR END

FIGURE 21. TORCH FRONT END


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

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

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

.040 - .047 inch M3-T45 length)

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

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

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

.040 - .047 inch M3-ST45 Irregular (grind to shape) M3T-NS4 M3T-NLAS4

SG STYLE FRONT END - OPTIONAL

WIRE SIZE CONTACT TIP GAS DIFFUSER NOZZLE ASSEMBLY CUP NOZZLE BODY INS. BUSHING

.020 - .025 inch M3-T25 M3-D M3-NA50 M3-C50 M3-NB M3-B.030 inch M3-T30 (1/2" I.D.).035 inch M3-T35 (1-7/16"

.040 - .047 inch M3-T45 length)

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

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

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

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

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

.040 - .047 inch M5-T45 M5-LT45 Outside Corner M3H-NS3Irregular M3H-NS4

XG STYLE FRONT END - OPTIONAL - RECOMMENDED FOR ALUMINUM WELDING

WIRE SIZE CONTACT TIP GAS DIFFUSER NOZZLE ASSEMBLY CUP NOZZLE BODY INS. BUSHING

.035 inch M5-T35 M35-D M35-NA62 M5-C62 M5-NB M5-B.040 - .047 inch M5-T45 (5/8" I.D.)

(1-15/16"length)

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

SPECIAL FRONT END FOR GASLESS WIRES - OPTIONALINSULATED CONTACT TIP (Tip screw directly into torch neck - no gas diffuser is required) (1-15/16" length)

WIRE SIZE PART NUMBER.040 - .047 inch M5HGL-045

LINERS & SEALS - FOR STEEL WELDING

ORDER NUMBERWIRE TORCHSIZE LENGTH LINER W/SEAL SEAL ONLY

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

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

12 feet M124L-N

LINERS & SEALS - FOR ALUMINUM WELDINGORDER NUMBER

WIRE TORCH LINER SEAL HEATSHIELDSIZE LENGTH W/SEAL ONLY ONLY

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

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

FIGURE 22. CONSUMABLE PARTS


PARTS BREAKDOWN - 15 SERIES MIG TORCH (Cont.)

M3-402 M3-402

M1-401

TORCH NECK GROUP

M3-112M3-119 M3-120*

M3-101B*

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

M3-201BM3-203

(2 REQD.)M3-214

M3-202 M3-211

M3-212 M3-213

M3-407

QUICK CONNECTOR GROUP

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

M3-307

M3-301A M3-305A*

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

M3-310A

M1510CBL*M1512CBL*

NOTES:

*

PART NO. DESCRIPTION (SYMBOL)TORCH NECK GROUP

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

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

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

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

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

(2 REQUIRED)M3-310A ..... BOOT / CABLE SUPPORT

M1-401 ....... HANDLEM3-402 ....... HANDLE SCREW (2 REQUIRED)M3-405 ....... TERMINAL - TORCH END

(2 REQUIRED)M3-406 ....... TERMINAL - CONNECTOR END

(2 REQUIRED)M3-407 ....... HANGING BRACKET

M1510CBL... 10 FOOT CABLE *M1512CBL... 12 FOOT CABLE *

FIGURE 23. REPAIR (REPLACEMENT) PARTS

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

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


OPTIONSTIG PAK

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

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

The TIG Welding Process is used to produce the highest quality,porosity-free welds. The TIG PAK adds TIG Welding capabilities to yourSnap-On Tools MIG Welder.

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

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

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

TIG PAK 2125A (25' cable)

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

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

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

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

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

MHG5-A

ONE POUND SPOOL GUNFOR ALUMINUM MIG WELDING

WITH SNAP-ON TOOLSMIG COMBINATION UNITS

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

The MHG5-A (Motorized Hand Gun System) is a compact, light-in-weight, easy to operate MIG welding system designed for aluminumwelding. It will feed .023" Thru 3/64" diameter wire from 4 inch spools.The standard equipment cable is 25 feet in length. 35 foot and 50 footcables 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 orstainless steel (.030" - .035" diameter wire sizes).

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

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

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

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

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

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

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

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

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

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

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

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

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

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

owner's manual - systematics inc. · pdf fileowner's manual the ya212a...

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