FM140A

SERVICE MANUAL
FOR
SERIAL NUMBERS 840-15411 AND LATER

FORM WC5379 Snap-on Tools Corporation Kenosha, WI 53141-1410 2/95 (Rev. 4/97, 1/00)
 CONTENTS

VIEW DESCRIPTION PAGE

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

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

FIGURE 1B ............... SCHEMATIC, SPOT TIME CIRCUIT BOARD ...........................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 B2 ............... PRINTED CIRCUIT BOARD (SN-529U) ..................................12

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

FIGURE C ................ WIRE FEED COMPARTMENT .................................................14

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

FIGURE C1 .............. WIRE DRIVE ASSEMBLY (SN-138C24A)................................ 16

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

WC5379 PAGE 2 Snap-on Tools Corporation Kenosha, WI 53141-1410

 FIGURE 1 - SCHEMATIC DIAGRAM

Snap-on Tools Corporation Kenosha, WI 53141-1410 WC5379 PAGE 3

 1

3
C2
- +
SR1 5
D3
R5
2
R3 6

Q2
R6
PC1 Q1

R11 D4
C3 C4
R4

FIGURE 1A - SCHEMATIC, WIRE FEED CIRCUIT BOARD

WC5379 PAGE 4 Snap-on Tools Corporation Kenosha, WI 53141-1410

 7 9 1 4 2

R7
- + R8 3
SR2
D5
5
8
6
C5
R10

PC2 C6
D6
Q3 CR2

D7

FIGURE 1B - SCHEMATIC, SPOT TIME CIRCUIT BOARD

Snap-on Tools Corporation Kenosha, WI 53141-1410 WC5379 PAGE 5

 *1 10

2 11

3 12
*13

4
14
5
15

16
7

17
8

18

20 19

FIGURE A - FRONT ASSEMBLY

WC5379 PAGE 6 Snap-on Tools Corporation Kenosha, WI 53141-1410

FIGURE A
ITEM DIA. PART
NO. MKGS. NO. DESCRIPTION QTY.

*1 SN-417L COVER, LEFT *(MUST BE PURCHASED AS A COMPLETE ASSY) ................................................ 1

* SN-447 COVER & ACCESS DOOR ASSEMBLY, COMPLETE ....................................................................... 1
2 L SN-184 INDICATOR LAMP .............................................................................................................................. 1

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

SN-955 BREAKER BRACKET ......................................................................................................................... 1
4 + SN-146C WELD CONNECTOR W/GAS HOLE ................................................................................................. 1

5 - SN-146 WELD CONNECTOR .......................................................................................................................... 1

SN-72 NUT, WELD CONNECTOR ................................................................................................................ 2
SN-178 GROUND CABLE ASSEMBLY, 15' (NOT SHOWN) ........................................................................... 1

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

6 S3 SN-245 SWITCH, MODE ................................................................................................................................. 1
7 SN-412D BASE ................................................................................................................................................... 1

8 SN-433B PEDESTAL .......................................................................................................................................... 1

9 SN-124-8 REAR WHEEL, 8" ............................................................................................................................... 2
10 SN-05 HANDLE .............................................................................................................................................. 1

11 SN-1050 LABEL, CONTROL .............................................................................................................................. 1

12 SN-418 FRONT ................................................................................................................................................ 1
*13 SN-417R ACCESS DOOR *(MUST BE PURCHASED AS COMPLETE ASSY) ................................................ 1

14 SN-330A KNOB, HEAT & TRIM .......................................................................................................................... 2

15 SN-71 BUSHING ............................................................................................................................................ 1
16 SN-67 KNOB, SPOT TIME ............................................................................................................................. 1

17 SN-432D BASE, PEDESTAL .............................................................................................................................. 1

18 SN-171 AXLE .................................................................................................................................................... 1
SN-171C AXLE, CAPS ........................................................................................................................................ 2

19 SN-213 CASTER BRACKET ............................................................................................................................ 2

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

Snap-on Tools Corporation Kenosha, WI 53141-1410 WC5379 PAGE 7

 11 14
FIG. FIG.
B2 B1
1 18
9 10 12 13 15 16 17
2 19

20
3

21
4
22

23
5
24
6 25

7 26

27
8

28

29

30

31

FIGURE B - LEFT SIDE VIEW & INTERNAL COMPONENTS

WC5379 PAGE 8 Snap-on Tools Corporation Kenosha, WI 53141-1410

FIGURE B
ITEM DIA. PART
NO. MKGS. NO. DESCRIPTION QTY.

1 F SN-517 FAN, 4" ................................................................................................................................................ 1

2 SN-413 BACK ................................................................................................................................................... 1
3 SN-311 CYLINDER BRACKET ........................................................................................................................ 1
4 SN-211C CYLINDER CHAIN .............................................................................................................................. 1
5 SN-220 STRAIN RELIEF .................................................................................................................................. 1
SN-220N NUT, STRAIN RELIEF ........................................................................................................................ 1
6 SN-313 CYLINDER SUPPORT ........................................................................................................................ 1
7 SN-253A GAS HOSE, PRIMARY ........................................................................................................................ 1
8 PLG1 20CP-140A POWER INPUT CABLE W/PLUG, 20' ................................................................................................ 1
SN-339 SUPPLY PLUG, 115V .......................................................................................................................... 1
9 GS SN-126 SOLENOID ASSEMBLY, 24VAC ........................................................................................................ 1
10 SN-353S GAS HOSE, SELECTOR .................................................................................................................... 1
11 PC2 SN-529U SPOT TIME BOARD (FIGURE B2) ..................................................................................................... 1
12 SN-601 STAND OFF, NYLON BOARD ............................................................................................................ 8
13 SN-6421U BRACKET, CONTROL (U-BOARD) .................................................................................................... 1
14 PC1 SN-774U WIRE FEED CONTROL BOARD (FIGURE B1) ................................................................................. 1
15 SN-685 TERMINAL HOUSING, HARNESS ..................................................................................................... 2
SN-685P PIN, EDGE CONNECTOR ................................................................................................................. 15
16 T2 SN-287M CONTROL TRANSFORMER, 115V-28V ............................................................................................ 1
AD-16 ADAPTER, VOLTAGE ........................................................................................................................ 1
17 RC2 SN-861C RECEPTACLE, FUNCTION ................................................................................................................ 1
18 SN-445E BAFFLE (REVISED) ............................................................................................................................ 1
19 SN-353D HOSE, BULKHEAD REAR .................................................................................................................. 2
20 R1 SN-35U POTENTIOMETER, 75K OHM ............................................................................................................ 1
21 SN-236 SOCKET, RELAY 8 PIN ...................................................................................................................... 1
22 D1,2 SN-260 DIODE ................................................................................................................................................. 2
23 S2 SN-163-12 HEAT SWITCH, 12 POSITION ........................................................................................................... 1
24 Z SN-188C CHOKE (BEHIND) ............................................................................................................................... 1
25 R9 SN-222 POTENTIOMETER, 35K OHM, SPOT TIME ...................................................................................... 1
26 SN-247 STAND-OFF INSULATOR .................................................................................................................. 2
27 SN-437GA HEAT SINK ASSEMBLY, COMPLETE ............................................................................................... 1
SN-437G PLATE ONLY, HEAT SINK ................................................................................................................. 1
SN-239 INSULATOR, HEAT SINK ................................................................................................................... 1
28 R2 SN-162 RESISTOR, 100 OHM 25W ................................................................................................................ 1
29 C1 SN-125S CAPACITOR, 12,000UF 50V (BEHIND) .............................................................................................. 4
30 W SN-153 CONTACTOR, 24VAC ........................................................................................................................ 1
31 T1 SN-86C TRANSFORMER, POWER ................................................................................................................. 1
TP1 SN-654 THERMAL SWITCH (N.C.) ................................................................................................................. 1

Snap-on Tools Corporation Kenosha, WI 53141-1410 WC5379 PAGE 9

 D3

R3 R6
Q2

R11 C4
C3 R5
D4
Q1
R4

HS1 HS2

C2
SR1

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

WC5379 PAGE 10 Snap-on Tools Corporation Kenosha, WI 53141-1410

FIGURE B1
ITEM DIA. PART
NO. MKGS. NO. DESCRIPTION QTY.

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

C3 HG-578 CAPACITOR, .02UF 100V ................................................................................................................... 1
C4 MI-626 CAPACITOR, .68UF 50DC .................................................................................................................. 1

D3 HG-579 DIODE, 2A ........................................................................................................................................... 1

D4 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 53141-1410 WC5379 PAGE 11

 R8 R7
C6 C5

R10
D5

Q3

D6 D7

CR2

SR2

FIGURE B2 - PRINTED CIRCUIT BOARD (SN-529U)

WC5379 PAGE 12 Snap-on Tools Corporation Kenosha, WI 53141-1410

FIGURE B2
ITEM DIA. PART
NO. MKGS. NO. DESCRIPTION QTY.

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

CR2 HG-576 RELAY, 24VDC 4PDT ......................................................................................................................... 1
D5,6,7 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 53141-1410 WC5379 PAGE 13

 1 6

7
2

3 8

4
9

5
FIG. C1
10

FIGURE C - WIRE FEED COMPARTMENT

WC5379 PAGE 14 Snap-on Tools Corporation Kenosha, WI 53141-1410

FIGURE C
ITEM DIA. PART
NO. MKGS. NO. DESCRIPTION QTY.

1 SN-1055 LABEL, MIG-MHG5-A .......................................................................................................................... 1

2 SN-500A BULKHEAD ASSEMBLY, FEMALE ..................................................................................................... 2
SN-501 BULKHEAD, MALE .............................................................................................................................. 2
SN-501K BULKHEAD KIT, COMPLETE ............................................................................................................. 2
SN-880 COVER, THREAD ............................................................................................................................... 1
3 CR1 SN-276S RELAY, 8 PIN 24VAC .......................................................................................................................... 1
4 SN-276CL RELAY CLIP, 8 PIN ............................................................................................................................. 1
5 SN-138C24A WIRE DRIVE ASSEMBLY (FIGURE C1) ............................................................................................ 1
6 CB2 SN-519 BREAKER, MINI 5A ............................................................................................................................. 1
7 SN-314I INSULATOR CARD, SPOOL HUB ...................................................................................................... 1
8 SN-22 SPOOL CLIP ....................................................................................................................................... 1
9 SN-314 SPOOL HUB ........................................................................................................................................ 1
10 SN-450N BOLT, NYLON SPOOL HUB .............................................................................................................. 1
SN-451 NUT, SPOOL HUB .............................................................................................................................. 1
SN-19 WASHER, SPOOL HUB ..................................................................................................................... 2

Snap-on Tools Corporation Kenosha, WI 53141-1410 WC5379 PAGE 15

 1 16

2
17
3
18
4 19
5 20
21
6 22
23
24
25
7
26
8
27
9
28
10 29
10A 30
10B 31
11
32
12

13 33
14
15 34

FIGURE C1 - WIRE DRIVE ASSEMBLY (SN-138C24A)

WC5379 PAGE 16 Snap-on Tools Corporation Kenosha, WI 53141-1410

FIGURE C1
ITEM DIA. PART
NO. MKGS. NO. DESCRIPTION QTY.

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 SN-24 GAS FITTING, BRASS ........................................................................................................................ 1
7 M3-906 THUMB SCREW ................................................................................................................................. 1
8 M3-900C TORCH PANEL MOUNT (HG-525) ..................................................................................................... 1
9 SN-604 WIRE CONNECTOR, 90 DEG. ........................................................................................................... 2
10 RC1 SN-860C FUNCTION PLUG ASSEMBLY ........................................................................................................... 1
10A SN-860 PIN HOUSING ..................................................................................................................................... 1
10B SN-860M MALE PIN CONNECTOR .................................................................................................................... 6
11 J1 AD-10 BLUE JUMPER ................................................................................................................................... 1
12 SN-237 CONTROL WIRE ASSEMBLY ............................................................................................................ 2
13 SN-62 DRIVE ROLL WASHER ...................................................................................................................... 1
14 SN-278C TORCH SELECTOR CABLE ASSEMBLY .......................................................................................... 1
15 SN-169A TERMINAL INSULATOR ..................................................................................................................... 1
16 M SN-138C24 24VDC MOTOR ................................................................................................................................... 1
17 SN-53F ROCKER ARM .................................................................................................................................... 1
18 SN-158 PRESSURE ROLL .............................................................................................................................. 1
19 SN-55F BEARING SPACER ............................................................................................................................. 1
20 1/4-20 KEP NUT .................................................................................................................................. 1
21 SN-89 SPRING WASHER .............................................................................................................................. 1
22 SN-52 SHOULDER BOLT .............................................................................................................................. 1
23 SN-33F INLET GUIDE ...................................................................................................................................... 1
24 SN-34 NUT, INLET GUIDE ............................................................................................................................. 1
HW-58ILW LOCK WASHER, INTERNAL .............................................................................................................. 1
25 SN-136C INLET GUIDE TUBE ........................................................................................................................... 1
26 SN-64 DRIVE ROLL NUT ............................................................................................................................... 1
27 SN-65 DRIVE ROLL LOCK WASHER ........................................................................................................... 1
28 SN-603 ADJUSTING COLLAR (BEHIND) ........................................................................................................ 1
29 SN-63 DRIVE ROLL (1 3/8" DIA.) ................................................................................................................... 1
30 SN-61C 1/2 WOODRUFF DRIVE KEY ............................................................................................................. 1
31 SN-131E MOTOR BRACKET, ADJUSTABLE .................................................................................................... 1
32 SN-40 INSULATING WASHER ...................................................................................................................... 4
33 SN-139 MOTOR BASE INSULATOR ............................................................................................................... 1
34 SN-168A CABLE TERMINAL .............................................................................................................................. 1
SN-170A CABLE TERMINAL ASSEMBLY, COMPLETE .................................................................................... 1

Snap-on Tools Corporation Kenosha, WI 53141-1410 WC5379 PAGE 17

WC5379 PAGE 18 Snap-on Tools Corporation Kenosha, WI 53141-1410
Snap-on Tools Corporation Kenosha, WI 53141-1410 WC5379 PAGE 19
Snap-on Tools Corporation Kenosha, WI 53141-1410
 FM140A

SUPPLEMENT
FOR
SERIAL NUMBERS 840-15411 AND LATER

FORM WC5379S Snap-on Tools Corporation Kenosha, WI 53141-1410 2/95

 T1 D1
1
13
12
+
2 11
3

CB1 4 10 C1 + R2
W 5 9

6 8

7 7

S2 8 6

9 5
10 4

-
12 11 3

120V L F 2 Z

D2
1

S1 J1
+ M -

CABINET RC 1
GROUND 6 5 4 3 1 2 RC 2
PLG1
TP1 C R1
A

R9
GS

STITCH
CONT.
R7
- SR2 + R8 SPOT

D5 STITCH
CONT.
SPOT
C5
R 10
S3
PC2 C6
Q3
D6
CR 2

D7

T2 3
5
2
CB2 C2 6
+ 4
- SR1
D3
R5
R3
PC1
Q2
R6
R1
Q1
R 11 C4
D4 C3

R4
FM140A
840-14461 AND LATER