140P-2674 AND LATER 175P-4023 AND LATER 250P-2783 AND LATER

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1 SERIAL NUMBERS 140P-2674 AND LATER 175P-4023 AND LATER 250P-2783 AND LATER FORM WC5310 3/95 (Rev. 9/97, 6/99, 1/00, 2/00) Systematics, Inc Saunders Ln. West Chester, Pa

2 TABLE OF CONTENTS VIEW DESCRIPTION PAGE FIGURE 1... MP 140 SCHEMATIC DIAGRAM... 3 FIGURE 2... MP 175 SCHEMATIC DIAGRAM... 4 FIGURE 3... MP 250 SCHEMATIC DIAGRAM... 5 FIGURE 4... SCHEMATIC, WIRE FEED CIRCUIT BOARD... 6 FIGURE 5... SCHEMATIC, SPOT TIME CIRCUIT BOARD... 7 FIGURE A... FRONT ASSEMBLY PARTS LIST... 9 FIGURE B... LEFT SIDE VIEW & INTERNAL COMPONENTS PARTS LIST FIGURE B1... PRINTED CIRCUIT BOARD (FM-774U) PARTS LIST FIGURE B2... PRINTED CIRCUIT BOARD (FM-529U) (OPTIONAL) PARTS LIST FIGURE C... WIRE FEED COMPARTMENT PARTS LIST FIGURE C1... WIRE DRIVE ASSEMBLY (FM-138C24A) PARTS LIST WC5310 PAGE 2 Systematics, Inc Saunders Ln. West Chester, Pa

3 FIGURE 1 - MP 140 SCHEMATIC DIAGRAM Systematics, Inc Saunders Ln. West Chester, Pa WC5310 PAGE 3

4 FIGURE 2 - MP 175 SCHEMATIC DIAGRAM WC5310 PAGE 4 Systematics, Inc Saunders Ln. West Chester, Pa

5 FIGURE 3 - MP 250 SCHEMATIC DIAGRAM Systematics, Inc Saunders Ln. West Chester, Pa WC5310 PAGE 5

6 SR1 + R3 C2 D5 R PC1 Q1 Q2 R6 R11 D6 C3 R4 C4 FIGURE 1A - SCHEMATIC, WIRE FEED CIRCUIT BOARD WC5310 PAGE 6 Systematics, Inc Saunders Ln. West Chester, Pa

7 SR2 + D7 R7 R PC2 C5 C6 Q3 R10 D8 CR2 D9 FIGURE 1B - SCHEMATIC, SPOT TIME CIRCUIT BOARD Systematics, Inc Saunders Ln. West Chester, Pa WC5310 PAGE 7

8 * * FIGURE A - FRONT ASSEMBLY WC5310 PAGE 8 Systematics, Inc Saunders Ln. West Chester, Pa

9 FIGURE A ITEM DIA. MKGS. PART MP MODEL DESCRIPTION *1 SY-407L ALL COVER, LEFT *(MUST BE PURCHASED AS A COMPLETE ASSY.)... 1 * SY COVER & ACCESS DOOR ASSEMBLY, COMPLETE W/LABELS... 1 " SY-427A " SY-427B LB LABEL, UPPER FRONT... 1 LB LB MI-330A ALL KNOB, VOLTAGE & WIRE SPEED SY-318 " CABLE HANGER LB-1100 " LABEL, LOWER FRONT CB1 FM-282 " CIRCUIT BREAKER, 35 AMP... 1 FM-955 " BREAKER BRACKET YS-106 " SIDE, LEFT... 1 SY SIDE, LEFT (SERIAL# 140P-2741 AND LATER)... 1 " 175 " (SERIAL# 175P-4894 AND LATER)... 1 " 250 " (SERIAL# 250P-3110 AND LATER) L FM-184 ALL INDICATOR LAMP MI " REAR WHEEL, 6"... 2 MI REAR WHEEL, 8" (SERIAL# 140P-2741 AND LATER)... 2 " 175 " (SERIAL# 175P-4894 AND LATER)... 2 " 250 " (SERIAL# 250P-3110 AND LATER) PY-117 ALL AXLE... 1 PY-117C " AXLE, CAPS PH-05 " HANDLE... 1 *12 SY-407R " ACCESS DOOR *(MUST BE PURCHASED AS COMPLETE ASSY.) YS-108C " FRONT... 1 YS-108E 140 FRONT (SERIAL# 140P-2741 AND LATER)... 1 " 175 " (SERIAL# 175P-4894 AND LATER)... 1 " 250 " (SERIAL# 250P-3110 AND LATER) FW-71 ALL BUSHING, 1 3/8" V FM-115 " VOLTMETER (ROUND CORNERS)... 1 FM-115A 140 VOLTMETER (SQUARE CORNERS) (SERIAL# 140P-2725 AND LATER)... 1 " 175 " (SERIAL# 175P-4637 AND LATER)... 1 " 250 " (SERIAL# 250P-2987 AND LATER)... 1 MI-115L ALL LENS, VOLTMETER (ROUND CORNERS)... 1 FM-115AL " LENS, VOLTMETER (SQUARE CORNERS) FM-146 " WELD CONNECTOR, GROUND... 1 FM-178/10 " GROUND CABLE ASSEMBLY, 10' (NOT SHOWN)... 1 FM-165 " CLAMP, GROUND (NOT SHOWN) FM-146C " WELD CONNECTOR, POSITIVE W/GAS HOLE... 1 FW-72 " NUT, WELD CONNECTOR YS-104A " SIDE, RIGHT... 1 SY SIDE, RIGHT (SERIAL# 140P-2741 AND LATER)... 1 " 175 " (SERIAL# 175P-4894 AND LATER)... 1 " 250 " (SERIAL# 250P-3110 AND LATER) MI ALL CASTER, FRONT 3"... 2 PY CASTER BRACKET (SERIAL# 140P-2741 AND LATER)... 1 " 175 " (SERIAL# 175P-4894 AND LATER)... 1 " 250 " (SERIAL# 250P-3110 AND LATER) YS-102B ALL BASE... 1 PY-102Z 140 BASE (SERIAL# 140P-2741 AND LATER)... 1 " 175 " (SERIAL# 175P-4894 AND LATER)... 1 " 250 " (SERIAL# 250P-3110 AND LATER) ML-412 ALL BRACKET, AXLE (NOT REQUIRED ON PY-102Z BASE)... 2 QTY. Systematics, Inc Saunders Ln. West Chester, Pa WC5310 PAGE 9

10 1 6 7 *8 FIG. B2 9 *10 11 FIG. B1 *12 *13 * FIGURE B - LEFT SIDE VIEW & INTERNAL COMPONENTS WC5310 PAGE 10 Systematics, Inc Saunders Ln. West Chester, Pa

11 FIGURE B1 ITEM DIA. MKGS. PART MP MODEL DESCRIPTION QTY. 1 YS-103 ALL BACK... 1 SY-303F 140 BACK (SERIAL# 140P-2741 AND LATER)... 1 " 175 " (SERIAL# 175P-4894 AND LATER)... 1 " 250 " (SERIAL# 250P-3110 AND LATER) FM-253A ALL GAS HOSE, PRIMARY SY-213 " CYLINDER BRACKET... 1 SY CYLINDER BRACKET (SERIAL# 140P-2743 AND LATER)... 1 " 175 " (SERIAL# 175P-4987 AND LATER)... 1 " 250 " (SERIAL# 250P-3156 AND LATER) FM-211C ALL CYLINDER CHAIN PGL1 15CP POWER INPUT CABLE W/ PLUG, 15'... 1 " 15CP-0 175, 250 POWER INPUT CABLE, 15' GS FM-126B ALL SOLENOID ASSEMBLY, 24VAC YS-105D " BAFFLE... 1 SY-305I 140 BAFFLE (REVISED) (SERIAL# 140P-2741 AND LATER)... 1 " 175 " (SERIAL# 175P-4894 AND LATER)... 1 " 250 " (SERIAL# 250P-3110 AND LATER)... 1 *8 PC2 FM-529U " SPOT TIME BOARD (FIGURE B2) (W/ SSTP-2 OPTION)... 1 * SSTP-2 OPTION SPOT/STITCH CONTROL MODULE SC-421U ALL BRACKET, CONTROL (U-BOARD) FM-601 " PIN, EDGE CONNECTOR... 4 * " (W/ SSTP-2 OPTION) PC1 FM-774U " WIRE FEED CONTROL BOARD (FIGURE B1) MI-685 " TERMINAL HOUSING, HARNESS... 1 * " (W/ SSTP-2 OPTION)... 2 MI-685P ' PIN, TERMINAL HOUSING... 6 * " (W/ SSTP-2 OPTION) *13 S3 FM-245 " SWITCH, MODE (W/ SSTP-2 OPTION)... 1 *14 R9 ST-22 " POTENTIOMETER, 35K OHM, SPOT TIME (W/ SSTP-2 OPTION) CB-236 " SOCKET, RELAY 8 PIN J2 AD-17 " JUMPER, HARNESS (W/O SSTP-2 OPTION)... 1 RC3 FW-187A " MALE HOUSING ASSY., 6 PIN... 1 RC4 FW-186A " FEMALE HOUSING ASSY., 6PIN (W/ SSTP-2 OPTION) FM-353S " GAS HOSE, SELECTOR FM-353D " HOSE, BULKHEAD, (MIG FITTING) S2 FM , 175 HEAT SWITCH, 6 POSITION... 1 " FM HEAT SWITCH, 12 POSITION RC2 FW-861C ALL FUNCTION RECEPTACLE ASSEMBLY FM-353E " HOSE, BULKHEAD, (MHG7 FITTING) R1 UC-35 " POTENTIOMETER, 75K OHM T2 FM-287M " TRANSFORMER, CONTROL (220V-28V)... 1 AD ADAPTER, VOLTAGE (220V-120V) W FM-153 ALL CONTACTOR, 24VAC D1,2 MI DIODE... 2 D1,2,3,4 " 175, FM HEAT SINK ASSEMBLY, COMPLETE... 1 FM , MI-255M ALL LEG, HEAT SINK C1 FM-125S 140 CAPACITOR, 12000UF 50V... 4 " " 175, R2 MI-262 ALL RESISTOR, 100 OHM 25W T1 FM TRANSFORMER, POWER... 1 " FM " FM-286C TP1 FM-654 ALL THERMAL SWITCH (N.C.) Z FM-188C " CHOKE F MI FAN MOTOR, 120V... 1 " FM , 250 FAN MOTOR, 230V FM-318 ALL FAN BLADE PY-109F 140 FAN BRACKET... 1 PY-109A 175, 250 FAN BRACKET W/ SHROUD FM-120 ALL STRAIN RELIEF... 1 FM-120N " NUT, STRAIN RELIEF... 1 Systematics, Inc Saunders Ln. West Chester, Pa WC5310 PAGE 11

12 D5 Q2 R3 R6 R11 C4 C3 D6 Q1 R4 R5 HS1 HS2 C2 SR1 FIGURE B1 - PRINTED CIRCUIT BOARD (FM-774U) WC5310 PAGE 12 Systematics, Inc Saunders Ln. West Chester, Pa

13 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 D6 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 Systematics, Inc Saunders Ln. West Chester, Pa WC5310 PAGE 13

14 C5 R8 C6 R7 R10 D9 Q3 D7 D8 CR2 SR2 FIGURE B2 - PRINTED CIRCUIT BOARD (FM-529U)(OPTIONAL) WC5310 PAGE 14 Systematics, Inc Saunders Ln. West Chester, Pa

15 FIGURE B2 ITEM DIA. MKGS. PART DESCRIPTION QTY. C5,6 MI-143 CAPACITOR, 47UFD 50V... 2 CR2 HG-576 RELAY, 24VDC 4PDT... 1 D7,8,9 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 Systematics, Inc Saunders Ln. West Chester, Pa WC5310 PAGE 15

16 FIG. C FIGURE C - WIRE FEED COMPARTMENT WC5310 PAGE 16 Systematics, Inc Saunders Ln. West Chester, Pa

17 FIGURE C ITEM DIA. MKGS. PART MP MODEL DESCRIPTION QTY. 1 LB-1351 ALL LABEL, SPOT/STITCH (W/ SSTP-2 OPTION) S3 FM-245 " SWITCH, MODE (W/ SSTP-2 OPTION) AH-67 " KNOB, SPOT TIME (W/ SSTP-2 OPTION) SSTP-2 OPTION SPOT/STITCH CONTROL MODULE FM-276CL ALL RELAY CLIP, 8 PIN CR1 FM-276 " RELAY, 8 PIN 24VAC FM-138C24A " WIRE DRIVE ASSEMBLY (FIGURE C1) LB LABEL, ACCESS DOOR INNER... 1 LB LABEL, ACCESS DOOR INNER... 1 LB LABEL, ACCESS DOOR INNER CB2 FM-519 ALL BREAKER, MINI 5A FM-500A " BULKHEAD ASSEMBLY, FEMALE... 2 FM-501 " BULKHEAD, MALE... 2 FM-501K " BULKHEAD KIT, COMPLETE... 1 FM-880 " COVER, THREAD SY-322 " SPOOL BRACKET FW-22 " SPOOL CLIP FM-222 " SPOOL HUB ASSEMBLY... 1 FW-15 " SHAFT... 1 FW-16 " BUSHING... 2 FW-18 " TENSION SPRING FW-20B " TENSION BOLT PY-119A " SPOOL ADAPTER BASE, 4" LB-1056 " LABEL, MIG-MHG Systematics, Inc Saunders Ln. West Chester, Pa WC5310 PAGE 17

18 A 10B FIGURE C1 - WIRE DRIVE ASSEMBLY (FM-138C24A) WC5310 PAGE 18 Systematics, Inc Saunders Ln. West Chester, Pa

19 FIGURE C1 ITEM DIA. MKGS. PART MP MODEL DESCRIPTION QTY. 1 FW-48 ALL PRESSURE ROLL TENSION BOLT FW-51 " TENSION NUT FW-50F " PRESSURE SPRING FW-49 " TENSION BOLT WASHER FW-47 " TENSION BOLT PIN FM-24 " GAS FITTING (2291, 1192) M3-906 " THUMB SCREW M3-900C " TORCH PANEL MOUNT (HG-525) FW-604 " WIRE CONNECTOR, 90 DEG RC1 FW-860C " FUNCTION PLUG ASSEMBLY A FW-860 " PIN HOUSING B FW860M " MALE PIN CONNECTOR J1 AD-10 " BLUE JUMPER FM-237 " CONTROL WIRE ASSEMBLY FW-62 " DRIVE ROLL WASHER FM-278C " TORCH SELECTOR CABLE ASSEMBLY FM-169A " TERMINAL INSULATOR M FM-138C24 " 24VDC MOTOR FW-53F " ROCKER ARM FM-158 " PRESSURE ROLL FW-55F " BEARING SPACER HW-1420KHN " 1/4-20 KEP NUT CF-89 " SPRING WASHER FW-52 " SHOULDER BOLT FM-33F " INLET GUIDE FW-34 " NUT, INLET GUIDE... 1 HW-58ILW " LOCK WASHER, INTERNAL FM-136C " INLET GUIDE TUBE FW-64 " DRIVE ROLL NUT FW-63 " DRIVE ROLL LOCK WASHER FM-603 " ADJUSTING COLLAR FM-63 " DRIVE ROLL (1 3/8" DIA.) FM-61C " 1/2 WOODRUFF DRIVE KEY FM-131E " MOTOR BRACKET, ADJUSTABLE (REPLACES FM-131C) FW-40 " INSULATING WASHER ML-139 " MOTOR BASE INSULATOR FM-168A " CABLE TERMINAL... 1 FM-170A " CABLE TERMINAL ASSEMBLY, COMPLETE... 1 Systematics, Inc Saunders Ln. West Chester, Pa WC5310 PAGE 19

20 Systematics, Inc Saunders Ln. West Chester, Pa

21 MP140 40P-2648 AND LATER

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