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. 1025 Saunders Ln. West Chester, Pa. 19380
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... 8... PARTS LIST... 9 FIGURE B... LEFT SIDE VIEW & INTERNAL COMPONENTS... 10... PARTS LIST... 11 FIGURE B1... PRINTED CIRCUIT BOARD (FM-774U)... 12... PARTS LIST... 13 FIGURE B2... PRINTED CIRCUIT BOARD (FM-529U) (OPTIONAL)... 14... PARTS LIST... 15 FIGURE C... WIRE FEED COMPARTMENT... 16... PARTS LIST... 17 FIGURE C1... WIRE DRIVE ASSEMBLY (FM-138C24A)... 18... PARTS LIST... 19 WC5310 PAGE 2 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380
FIGURE 1 - MP 140 SCHEMATIC DIAGRAM Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 3
FIGURE 2 - MP 175 SCHEMATIC DIAGRAM WC5310 PAGE 4 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380
FIGURE 3 - MP 250 SCHEMATIC DIAGRAM Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 5
1 4 2 - SR1 + R3 C2 D5 R5 3 5 6 PC1 Q1 Q2 R6 R11 D6 C3 R4 C4 FIGURE 1A - SCHEMATIC, WIRE FEED CIRCUIT BOARD WC5310 PAGE 6 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380
7 9 1 4 2 - SR2 + D7 R7 R8 3 8 5 6 PC2 C5 C6 Q3 R10 D8 CR2 D9 FIGURE 1B - SCHEMATIC, SPOT TIME CIRCUIT BOARD Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 7
*1 2 11 *12 3 13 4 5 14 15 6 7 16 17 18 8 9 10 21 20 19 FIGURE A - FRONT ASSEMBLY WC5310 PAGE 8 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380
FIGURE A ITEM DIA. MKGS. PART MP MODEL DESCRIPTION *1 SY-407L ALL COVER, LEFT *(MUST BE PURCHASED AS A COMPLETE ASSY.)... 1 * SY-427 140 COVER & ACCESS DOOR ASSEMBLY, COMPLETE W/LABELS... 1 " SY-427A 175... 1 " SY-427B 250... 1 2 LB-1053 140 LABEL, UPPER FRONT... 1 LB-1054 175... 1 LB-1055 250... 1 3 MI-330A ALL KNOB, VOLTAGE & WIRE SPEED... 2 4 SY-318 " CABLE HANGER... 2 5 LB-1100 " LABEL, LOWER FRONT... 1 6 CB1 FM-282 " CIRCUIT BREAKER, 35 AMP... 1 FM-955 " BREAKER BRACKET... 1 7 YS-106 " SIDE, LEFT... 1 SY-306 140 SIDE, LEFT (SERIAL# 140P-2741 AND LATER)... 1 " 175 " (SERIAL# 175P-4894 AND LATER)... 1 " 250 " (SERIAL# 250P-3110 AND LATER)... 1 8 L FM-184 ALL INDICATOR LAMP... 1 9 MI-122-6 " REAR WHEEL, 6"... 2 MI-122-8 140 REAR WHEEL, 8" (SERIAL# 140P-2741 AND LATER)... 2 " 175 " (SERIAL# 175P-4894 AND LATER)... 2 " 250 " (SERIAL# 250P-3110 AND LATER)... 2 10 PY-117 ALL AXLE... 1 PY-117C " AXLE, CAPS... 2 11 PH-05 " HANDLE... 1 *12 SY-407R " ACCESS DOOR *(MUST BE PURCHASED AS COMPLETE ASSY.)... 1 13 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)... 1 14 FW-71 ALL BUSHING, 1 3/8"... 1 15 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)... 1 16 - FM-146 " WELD CONNECTOR, GROUND... 1 FM-178/10 " GROUND CABLE ASSEMBLY, 10' (NOT SHOWN)... 1 FM-165 " CLAMP, GROUND (NOT SHOWN)... 1 17 + FM-146C " WELD CONNECTOR, POSITIVE W/GAS HOLE... 1 FW-72 " NUT, WELD CONNECTOR... 2 18 YS-104A " SIDE, RIGHT... 1 SY-304 140 SIDE, RIGHT (SERIAL# 140P-2741 AND LATER)... 1 " 175 " (SERIAL# 175P-4894 AND LATER)... 1 " 250 " (SERIAL# 250P-3110 AND LATER)... 1 19 MI-121-3 ALL CASTER, FRONT 3"... 2 PY-212 140 CASTER BRACKET (SERIAL# 140P-2741 AND LATER)... 1 " 175 " (SERIAL# 175P-4894 AND LATER)... 1 " 250 " (SERIAL# 250P-3110 AND LATER)... 1 20 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)... 1 21 ML-412 ALL BRACKET, AXLE (NOT REQUIRED ON PY-102Z BASE)... 2 QTY. Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 9
1 6 7 *8 FIG. B2 9 *10 11 FIG. B1 *12 *13 *14 15 16 2 17 18 19 3 20 21 22 4 23 24 5 25 26 27 35 34 33 32 31 30 29 28 FIGURE B - LEFT SIDE VIEW & INTERNAL COMPONENTS WC5310 PAGE 10 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380
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)... 1 2 FM-253A ALL GAS HOSE, PRIMARY... 1 3 SY-213 " CYLINDER BRACKET... 1 SY-211 140 CYLINDER BRACKET (SERIAL# 140P-2743 AND LATER)... 1 " 175 " (SERIAL# 175P-4987 AND LATER)... 1 " 250 " (SERIAL# 250P-3156 AND LATER)... 1 4 FM-211C ALL CYLINDER CHAIN... 1 5 PGL1 15CP-140 140 POWER INPUT CABLE W/ PLUG, 15'... 1 " 15CP-0 175, 250 POWER INPUT CABLE, 15'... 1 6 GS FM-126B ALL SOLENOID ASSEMBLY, 24VAC... 1 7 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... 1 9 SC-421U ALL BRACKET, CONTROL (U-BOARD)... 1 10 FM-601 " PIN, EDGE CONNECTOR... 4 * " (W/ SSTP-2 OPTION)... 8 11 PC1 FM-774U " WIRE FEED CONTROL BOARD (FIGURE B1)... 1 12 MI-685 " TERMINAL HOUSING, HARNESS... 1 * " (W/ SSTP-2 OPTION)... 2 MI-685P ' PIN, TERMINAL HOUSING... 6 * " (W/ SSTP-2 OPTION)... 15 *13 S3 FM-245 " SWITCH, MODE (W/ SSTP-2 OPTION)... 1 *14 R9 ST-22 " POTENTIOMETER, 35K OHM, SPOT TIME (W/ SSTP-2 OPTION)... 1 15 CB-236 " SOCKET, RELAY 8 PIN... 1 16 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)... 1 17 FM-353S " GAS HOSE, SELECTOR... 1 18 FM-353D " HOSE, BULKHEAD, (MIG FITTING)... 1 19 S2 FM-163 140, 175 HEAT SWITCH, 6 POSITION... 1 " FM-163-12 250 HEAT SWITCH, 12 POSITION... 1 20 RC2 FW-861C ALL FUNCTION RECEPTACLE ASSEMBLY... 1 21 FM-353E " HOSE, BULKHEAD, (MHG7 FITTING)... 1 22 R1 UC-35 " POTENTIOMETER, 75K OHM... 1 23 T2 FM-287M " TRANSFORMER, CONTROL (220V-28V)... 1 AD-16 140 ADAPTER, VOLTAGE (220V-120V)... 1 24 W FM-153 ALL CONTACTOR, 24VAC... 1 25 D1,2 MI-260 140 DIODE... 2 D1,2,3,4 " 175, 250... 4 26 FM-460 140 HEAT SINK ASSEMBLY, COMPLETE... 1 FM-360 175, 250... 1 27 MI-255M ALL LEG, HEAT SINK... 2 28 C1 FM-125S 140 CAPACITOR, 12000UF 50V... 4 " " 175, 250... 6 29 R2 MI-262 ALL RESISTOR, 100 OHM 25W... 1 30 T1 FM-386 140 TRANSFORMER, POWER... 1 " FM-486 175... 1 " FM-286C 250... 1 TP1 FM-654 ALL THERMAL SWITCH (N.C.)... 1 31 Z FM-188C " CHOKE... 1 32 F MI-717 140 FAN MOTOR, 120V... 1 " FM-117 175, 250 FAN MOTOR, 230V... 1 33 FM-318 ALL FAN BLADE... 1 34 PY-109F 140 FAN BRACKET... 1 PY-109A 175, 250 FAN BRACKET W/ SHROUD... 1 35 FM-120 ALL STRAIN RELIEF... 1 FM-120N " NUT, STRAIN RELIEF... 1 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 11
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. 1025 Saunders Ln. West Chester, Pa. 19380
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. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 13
C5 R8 C6 R7 R10 D9 Q3 D7 D8 CR2 SR2 FIGURE B2 - PRINTED CIRCUIT BOARD (FM-529U)(OPTIONAL) WC5310 PAGE 14 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380
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. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 15
8 1 2 3 4 5 6 9 10 11 12 13 7 FIG. C1 14 15 16 FIGURE C - WIRE FEED COMPARTMENT WC5310 PAGE 16 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380
FIGURE C ITEM DIA. MKGS. PART MP MODEL DESCRIPTION QTY. 1 LB-1351 ALL LABEL, SPOT/STITCH (W/ SSTP-2 OPTION)... 1 2 S3 FM-245 " SWITCH, MODE (W/ SSTP-2 OPTION)... 1 3 AH-67 " KNOB, SPOT TIME (W/ SSTP-2 OPTION)... 1 4 SSTP-2 OPTION SPOT/STITCH CONTROL MODULE... 1 5 FM-276CL ALL RELAY CLIP, 8 PIN... 1 6 CR1 FM-276 " RELAY, 8 PIN 24VAC... 1 7 FM-138C24A " WIRE DRIVE ASSEMBLY (FIGURE C1)... 1 8 LB-1352 140 LABEL, ACCESS DOOR INNER... 1 LB-1353 175 LABEL, ACCESS DOOR INNER... 1 LB-1354 250 LABEL, ACCESS DOOR INNER... 1 9 CB2 FM-519 ALL BREAKER, MINI 5A... 1 10 FM-500A " BULKHEAD ASSEMBLY, FEMALE... 2 FM-501 " BULKHEAD, MALE... 2 FM-501K " BULKHEAD KIT, COMPLETE... 1 FM-880 " COVER, THREAD... 1 11 SY-322 " SPOOL BRACKET... 1 12 FW-22 " SPOOL CLIP... 1 13 FM-222 " SPOOL HUB ASSEMBLY... 1 FW-15 " SHAFT... 1 FW-16 " BUSHING... 2 FW-18 " TENSION SPRING... 1 14 FW-20B " TENSION BOLT... 1 15 PY-119A " SPOOL ADAPTER BASE, 4"... 1 16 LB-1056 " LABEL, MIG-MHG7... 1 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 17
1 2 3 4 5 6 7 8 9 10 10A 10B 11 12 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 13 14 15 33 34 FIGURE C1 - WIRE DRIVE ASSEMBLY (FM-138C24A) WC5310 PAGE 18 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380
FIGURE C1 ITEM DIA. MKGS. PART MP MODEL DESCRIPTION QTY. 1 FW-48 ALL PRESSURE ROLL TENSION BOLT... 1 2 FW-51 " TENSION NUT... 1 3 FW-50F " PRESSURE SPRING... 1 4 FW-49 " TENSION BOLT WASHER... 1 5 FW-47 " TENSION BOLT PIN... 1 6 FM-24 " GAS FITTING (2291, 1192)... 1 7 M3-906 " THUMB SCREW... 1 8 M3-900C " TORCH PANEL MOUNT (HG-525)... 1 9 FW-604 " WIRE CONNECTOR, 90 DEG.... 2 10 RC1 FW-860C " FUNCTION PLUG ASSEMBLY... 1 10A FW-860 " PIN HOUSING... 1 10B FW860M " MALE PIN CONNECTOR... 6 11 J1 AD-10 " BLUE JUMPER... 1 12 FM-237 " CONTROL WIRE ASSEMBLY... 2 13 FW-62 " DRIVE ROLL WASHER... 1 14 FM-278C " TORCH SELECTOR CABLE ASSEMBLY... 1 15 FM-169A " TERMINAL INSULATOR... 1 16 M FM-138C24 " 24VDC MOTOR... 1 17 FW-53F " ROCKER ARM... 1 18 FM-158 " PRESSURE ROLL... 1 19 FW-55F " BEARING SPACER... 1 20 HW-1420KHN " 1/4-20 KEP NUT... 1 21 CF-89 " SPRING WASHER... 1 22 FW-52 " SHOULDER BOLT... 1 23 FM-33F " INLET GUIDE... 1 24 FW-34 " NUT, INLET GUIDE... 1 HW-58ILW " LOCK WASHER, INTERNAL... 1 25 FM-136C " INLET GUIDE TUBE... 1 26 FW-64 " DRIVE ROLL NUT... 1 27 FW-63 " DRIVE ROLL LOCK WASHER... 1 28 FM-603 " ADJUSTING COLLAR... 1 29 FM-63 " DRIVE ROLL (1 3/8" DIA.)... 1 30 FM-61C " 1/2 WOODRUFF DRIVE KEY... 1 31 FM-131E " MOTOR BRACKET, ADJUSTABLE (REPLACES FM-131C)... 1 32 FW-40 " INSULATING WASHER... 4 33 ML-139 " MOTOR BASE INSULATOR... 1 34 FM-168A " CABLE TERMINAL... 1 FM-170A " CABLE TERMINAL ASSEMBLY, COMPLETE... 1 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 19
Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380
MP140 40P-2648 AND LATER