MM250SL SERVICE MANUAL FOR SERIAL NUMBERS MM250SL-2000 AND LATER FORM WC /94 (Rev. 2/95, 1/96, 7/97, 9/97, 1/00)
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1 MM250SL SERVICE MANUAL FOR SERIAL NUMBERS MM250SL-2000 AND LATER FORM WC5276 9/94 (Rev. 2/95, 1/96, 7/97, 9/97, 1/00)
2 CONTENTS VIEW DESCRIPTION PAGE 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 PARTS LIST...7 FIGURE B... LEFT SIDE VIEW & INTERNAL COMPONENTS PARTS LIST...9 FIGURE B1... PRINTED CIRCUIT BOARD (SN-774U) PARTS LIST...11 FIGURE C... FRONT VIEW-REMOTE FEED UNIT PARTS LIST...13 FIGURE D... RIGHT SIDE VIEW & INTERNAL COMPONENTS REMOTE FEED UNIT... PARTS LIST...15 FIGURE D1... PRINTED CIRCUIT BOARD (SN-529U) PARTS LIST...17 FIGURE D2... WIRE DRIVE ASSEMBLY (SN-138C24M) PARTS LIST...19 FIGURE E... FEEDER CABLE ASSEMBLY (FCA-15) PARTS LIST Snap-on Tools Corporation Kenosha, WI
3 Snap-on Tools Corporation Kenosha, WI FIGURE 1 - SCHEMATIC DIAGRAM
4 SR1 + R3 C2 D5 R PC1 Q1 Q2 R6 R11 D7 C3 R4 C4 FIGURE 1A - SCHEMATIC, WIRE FEED CIRCUIT BOARD SR2 + D8 R7 R PC2 C5 C6 Q3 R10 D9 CR2 D10 FIGURE 1B - SCHEMATIC, SPOT TIME CIRCUIT BOARD 4 Snap-on Tools Corporation Kenosha, WI
5 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
6 FIGURE A - FRONT ASSEMBLY 6 Snap-on Tools Corporation Kenosha, WI
7 FIGURE A ITEM DIA. MKGS. PART DESCRIPTION QTY. 1 SN-180A HANDLE SN-330A KNOB, HEAT SN-319 CABLE HANGER V SN-115 VOLTMETER (ROUND CORNERS)... 1 SN-115A VOLTMETER (SQUARE CORNERS) (SERIAL# MM250SL-6020 AND LATER)... 1 SN-115L LENS, VOLTMETER (ROUND CORNERS)... 1 SN-115AL LENS, VOLTMETER (SQUARE CORNERS) SN-306M LEFT SIDE SN-1102 LABEL, ON/OFF CB1 SN-482 CIRCUIT BREAKER, 35 AMP... 1 SN-955 BREAKER BRACKET L SN-184 INDICATOR LAMP SN-5070 COVER, TOP... 1 SN-5070A COVER, TOP (SERIAL# MM250SL-5475 AND LATER) SN-1058 LABEL, CONTROL SN-5050 BAFFLE SN-5080 FRONT... 1 SN-5080A FRONT (SERIAL# MM250SL-5475 AND LATER) SN-211 BRACKET, CYLINDER SN-699H CLIP, HAIRPIN (SERIAL# MM250SL-2572 AND LATER) SN-699A STOP W/ CLIP HOLE, FEEDER (REPLACES ORIGINAL) CB2 SN-519 MINI BREAKER, 5A RC1 SN-6191A RECEPTACLE, CONTROL (OUTPUT) SN-146C WELD CONNECTOR W/GAS HOLE... 2 SN-72 NUT, WELD CONNECTOR... 2 SN-178 GROUND CABLE ASSEMBLY, 15' (NOT SHOWN)... 1 SN-165 CLAMP, GROUND (NOT SHOWN) SN-304M SIDE, RIGHT... 1 SN-1009 LABEL, PRO'S ADVANTAGE SN-1103 LABEL, WELD CONNECTOR SN-302W BASE SN-213 CASTER BRACKET SN CASTER, FRONT 3" SN REAR WHEEL, 8" SN-171 AXLE... 1 SN-171C AXLE CAPS... 2 SN-217W WASHERS, AXLE... 4 Snap-on Tools Corporation Kenosha, WI
8 FIG. B FIGURE B - LEFT SIDE VIEW & INTERNAL COMPONENTS 8 Snap-on Tools Corporation Kenosha, WI
9 FIGURE B ITEM DIA. MKGS. PART DESCRIPTION QTY. 1 SN-5030 BACK SN-421U BRACKET, CONTROL (U-BOARD) SN-685 TERMINAL HOUSING, HARNESS... 1 SN-685P PIN, TERMINAL HOUSING SN-253A GAS HOSE, PRIMARY GS SN-126B SOLENOID ASSEMBLY, 24VAC GAS FITTING, INLET SN GAS FITTING, OUTLET SN-353C GAS HOSE SN-211C CYLINDER CHAIN SN-220 STRAIN RELIEF... 1 SN-220N NUT, STRAIN RELIEF PLG1 20CP-0 POWER INPUT CABLE, 20' SN-601 STAND OFF, NYLON CR1 SN-276S RELAY, 8 PIN... 1 SN-276CL CLIP, RELAY... 1 SN-236 SOCKET, RELAY 8 PIN PC1 SN-774U WIRE FEED CONTROL BOARD (FIGURE B1) S2 SN HEAT SWITCH, 12 POSITION W SN-153 CONTACTOR, 24VAC T2 SN-287M CONTROL TRANSFORMER, 230V-28V SN-600 FITTING, "Y" HOSE SN-353Y HOSE D1,2,3,4 SN-260 DIODE R2 SN-162 RESISTOR, 100 OHM 25W SN-360 HEAT SINK ASSEMBLY, COMPLETE... 1 SN-360T HEAT SINK ASSEMBLY, COMPLETE (SERIAL# MM250SL-3949 AND LATER) SN-255M LEG, HEAT SINK C1 SN-125S CAPACITOR, 12,000UF 50V T1 SN-286T TRANSFORMER, POWER... 1 TP1 SN-654 THERMAL SWITCH (N.C.) Z SN-188C CHOKE F SN-117 FAN MOTOR SN-318 BLADE, FAN SN-310A FAN BRACKET W/SHROUD... 1 Snap-on Tools Corporation Kenosha, WI
10 D5 Q2 R3 R6 R11 C4 C3 D7 Q1 R4 R5 HS1 HS2 C2 SR1 FIGURE B1 - PRINTED CIRCUIT BOARD (SN-774U) 10 Snap-on Tools Corporation Kenosha, WI
11 FIGURE B1 ITEM DIA. MKGS. PART DESCRIPTION QTY. 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 Snap-on Tools Corporation Kenosha, WI
12 1 8 * * *14 7 FIGURE C - FRONT VIEW - REMOTE FEED UNIT 12 Snap-on Tools Corporation Kenosha, WI
13 FIGURE C ITEM DIA. MKGS. PART DESCRIPTION QTY. 1 SN-05 HANDLE... 1 *2 SN-5110 CABINET, FEED UNIT (ONLY)... 1 SN-5110A ", (SERIAL# MM250SL-2729 AND LATER)... 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) SN-246B TERMINAL, GAS-CURRENT RC4 SN-6190 RECEPTACLE, CONTROL (INPUT) SN-5180 FRONT, FEED UNIT SN-889F FEET, RUBBER S4 SN-425B SWITCH, N/O-N/C PURGE SN-2520 KNOB, TIMER SN-67 KNOB, FEED S3 SN-245M SWITCH, MODE... 1 *12 SN-5270U DOOR, UPPER FEEDER... 1 * SN-5270UP DOOR PIN (ONLY), UPPER 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 Snap-on Tools Corporation Kenosha, WI
14 FIG. D FIG. D FIGURE D - RIGHT SIDE VIEW & INTERNAL COMPONENTS REMOTE FEED UNIT 14 Snap-on Tools Corporation Kenosha, WI
15 FIGURE D ITEM DIA. MKGS. PART DESCRIPTION QTY. 1 LB-1367 LABEL, ACCESS DOOR - LEFT SN-6421U BRACKET, CONTROL (BEHIND COVER) SN-6230 DUST COVER R9 SN-222 POTENTIOMETER, 35K SPOT TIMER (BEHIND COVER) R1 SN-35U POTENTIOMETER, 75K FEED (BEHIND COVER) SN-605A HOSE, SECONDARY SN-609 CABLE, SECONDARY CURRENT SN-138C24M WIRE DRIVE ASSY., COMPLETE (FIGURE D2) LB-1368 LABEL, ACCESS DOOR - RIGHT SN-685 TERMINAL HOUSING, HARNESS (BEHIND COVER)... 1 SN-685P PIN, TERMINAL HOUSING (BEHIND COVER) PC2 SN-529U SPOT TIMER BOARD (BEHIND COVER)(FIGURE D1)... 1 SN-601 STAND OFF, NYLON (BEHIND COVER) SN-5220 SPOOL BRACKET... 1 SN-5220A " (SERIAL# MM250SL-2729 AND LATER) SN-22 SPOOL CLIP SN-122 SPOOL HUB ASSEMBLY... 1 SN-15 SHAFT... 1 SN-16 BUSHING... 2 SN-18 TENSION SPRING... 1 SN-19 WASHER, SPOOL HUB SN-606 DOOR CATCH, MAGNETIC SN-20B BOLT, TENSION SN-5130 BACK, LARGE FEEDER... 1 SN-5130A " (SERIAL# MM250SL-2729 AND LATER) SN-314I INSULATOR CARD, SPOOL HUB... 1 Snap-on Tools Corporation Kenosha, WI
16 C5 R8 C6 R7 R10 D10 Q3 D8 D9 CR2 SR2 FIGURE D1 - PRINTED CIRCUIT BOARD (SN-529U) 16 Snap-on Tools Corporation Kenosha, WI
17 FIGURE D1 ITEM DIA. MKGS. PART DESCRIPTION QTY. 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 Snap-on Tools Corporation Kenosha, WI
18 A 10B FIGURE D2 - WIRE DRIVE ASSEMBLY (SN-138C24M) 18 Snap-on Tools Corporation Kenosha, WI
19 FIGURE D2 ITEM DIA. MKGS. PART DESCRIPTION QTY. 1 SN-48 PRESSURE ROLL TENSION BOLT SN-51 TENSION NUT SN-50F PRESSURE SPRING SN-49 TENSION BOLT WASHER SN-47 TENSION BOLT PIN M3-906 THUMB SCREW SN-24 GAS FITTING (2291, 1192) (BEHIND) M3-900C TORCH PANEL MOUNT (HG-525) SN-604 WIRE CONNECTOR, 90 DEG RC5 SN-860C FUNCTION PLUG ASSEMBLY A SN-860 PIN HOUSING B SN-860M MALE PIN CONNECTOR... 6 RC6 SN-861C FUNCTION RECEPTACLE ASSEMBLY (NOT SHOWN) J1 AD-10 JUMPER SN-237 CONTROL WIRE ASSEMBLY SN-65 DRIVE ROLL LOCK WASHER M SN-138C24 24VDC MOTOR SN-53F ROCKER ARM SN-158 PRESSURE ROLL SN-55F BEARING SPACER (BEHIND) HW-1420KHN 1/4-20 KEP NUT SN-89 SPRING WASHER (BEHIND) SN-52 SHOULDER BOLT SN-33F INLET GUIDE SN-136C INLET GUIDE TUBE SN-34 NUT, INLET GUIDE... 1 HW-58ILW LOCK WASHER, INTERNAL SN-64 DRIVE ROLL NUT SN-62 DRIVE ROLL WASHER SN-603 ADJUSTING COLLAR (BEHIND) SN-60 DRIVE ROLL (30-45DR) SN-61C 1/2 WOODRUFF DRIVE KEY SN-131S MOTOR BRACKET, ADJUSTABLE SN-139AD INSULATOR, TOP SN-139 MOTOR BASE INSULATOR SN-40 INSULATING WASHER... 4 Snap-on Tools Corporation Kenosha, WI
20 FIGURE E - FEEDER CABLE ASSEMBLY (FCA-15) FIGURE E ITEM DIA. MKGS. PART DESCRIPTION QTY. 1 SN-026 NUT, GAS HOSE RC3 SN-6204 PLUG, 14 PIN (FEMALE PINS) SN-6204B CLAMP, 14 PIN PLUG PLG2 CC CONTROL CABLE ASSY., 15' 14 PIN... 1 SN CABLE ONLY, 15' RC2 SN-6191B PLUG, 14 PIN (MALE PINS) PS-4A POWER PLUG W/GAS HOLE SN-028 FERRULE, HOSE SN-025 CABLE FITTING SN-023 WELD CABLE ONLY (14'-10") SN-2157E-15 GAS/CURRENT CABLE ASSY., 15' EXTENSION... 1 SN GAS HOSE ONLY, 15' SN-2008 CABLE TIE SN-807G BOOT/CABLE COVER Snap-on Tools Corporation Kenosha, WI
21 MM250SL MM250SL-2000 AND LATER
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