SERIAL NUMBERS 140P-2674 AND LATER

175P-4023 AND LATER

250P-2783 AND LATER

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380

FORM WC5310 3/95 (Rev. 9/97, 6/99, 1/00, 2/00)

WC5310 PAGE 2 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380

TABLE OF CONTENTS

VIEW DESCRIPTION

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

PAGE

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 3

FIGURE 1 - MP 140 SCHEMATIC DIAGRAM

WC5310 PAGE 4 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380

FIGURE 2 - MP 175 SCHEMATIC DIAGRAM

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 5

FIGURE 3 - MP 250 SCHEMATIC DIAGRAM

WC5310 PAGE 6 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380

FIGURE 1A - SCHEMATIC, WIRE FEED CIRCUIT BOARD

R3

Q1

+-

4

C2

D6C3

R4

Q2

D5

C4

R6

R5

R11

2

1

3

5

6

PC1

SR1

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 7

FIGURE 1B - SCHEMATIC, SPOT TIME CIRCUIT BOARD

SR2

8

+-D7

PC2

C5

C6

R7

7 9 1 4 2

R8

Q3

D9

D8CR2

6

5

3

R10

WC5310 PAGE 8 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380

FIGURE A - FRONT ASSEMBLY

18

17

13

15

16

*1

2

3

4

5

6

7

8

9

10

11

*12

14

192021

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 9

FIGURE A

QTY.DESCRIPTIONDIA.

MKGS.ITEMNO.

PARTNO.

MPMODEL

*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 ........................................................................................................................................ 12 LB-1053 140 LABEL, UPPER FRONT ................................................................................................. 1

LB-1054 175 ........................................................................................................................................ 1LB-1055 250 ........................................................................................................................................ 1

3 MI-330A ALL KNOB, VOLTAGE & WIRE SPEED................................................................................ 24 SY-318 " CABLE HANGER ............................................................................................................ 25 LB-1100 " LABEL, LOWER FRONT ................................................................................................ 16 CB1 FM-282 " CIRCUIT BREAKER, 35 AMP ......................................................................................... 1

FM-955 " BREAKER BRACKET ..................................................................................................... 17 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 .......................................................................................................... 19 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 ............................................................................................................................... 1PY-117C " AXLE, CAPS ................................................................................................................... 2

11 PH-05 " HANDLE .......................................................................................................................... 1*12 SY-407R " ACCESS DOOR *(MUST BE PURCHASED AS COMPLETE ASSY.) ........................... 113 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" ............................................................................................................. 115 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) ............................................................................. 1MI-115L ALL LENS, VOLTMETER (ROUND CORNERS) ................................................................... 1FM-115AL " LENS, VOLTMETER (SQUARE CORNERS) ................................................................. 1

16 - FM-146 " WELD CONNECTOR, GROUND ................................................................................... 1FM-178/10 " GROUND CABLE ASSEMBLY, 10' (NOT SHOWN) ...................................................... 1FM-165 " CLAMP, GROUND (NOT SHOWN) ............................................................................... 1

17 + FM-146C " WELD CONNECTOR, POSITIVE W/GAS HOLE .......................................................... 1FW-72 " NUT, WELD CONNECTOR ............................................................................................ 2

18 YS-104A " SIDE, RIGHT................................................................................................................... 1SY-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" ....................................................................................................... 2PY-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 ............................................................................................................................... 1PY-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

WC5310 PAGE 10 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380

2

1

3

4

5

6 7

*8FIG.B2 9 *10

11FIG.B1 *12 *13 *14

15

17

181920

21

22

23

2425

26

27

16

2829303132333435

FIGURE B - LEFT SIDE VIEW & INTERNAL COMPONENTS

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 11

FIGURE B1MP

MODEL DESCRIPTION QTY.PARTNO.

DIA.MKGS.

ITEMNO.

1 YS-103 ALL BACK .............................................................................................................................. 1SY-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 ................................................................................................... 13 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 .......................................................................................................... 15 PGL1 15CP-140 140 POWER INPUT CABLE W/ PLUG, 15' ........................................................................... 1

" 15CP-0 175, 250 POWER INPUT CABLE, 15' ........................................................................................... 16 GS FM-126B ALL SOLENOID ASSEMBLY, 24VAC .................................................................................... 17 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 ............................................................................. 19 SC-421U ALL BRACKET, CONTROL (U-BOARD) ............................................................................... 110 FM-601 " PIN, EDGE CONNECTOR .............................................................................................. 4* " (W/ SSTP-2 OPTION) ..................................................................................................... 8

11 PC1 FM-774U " WIRE FEED CONTROL BOARD (FIGURE B1) ............................................................. 112 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) ............................. 115 CB-236 " SOCKET, RELAY 8 PIN .................................................................................................. 116 J2 AD-17 " JUMPER, HARNESS (W/O SSTP-2 OPTION) .............................................................. 1

RC3 FW-187A " MALE HOUSING ASSY., 6 PIN ...................................................................................... 1RC4 FW-186A " FEMALE HOUSING ASSY., 6PIN (W/ SSTP-2 OPTION) .............................................. 1

17 FM-353S " GAS HOSE, SELECTOR ................................................................................................ 118 FM-353D " HOSE, BULKHEAD, (MIG FITTING) .............................................................................. 119 S2 FM-163 140, 175 HEAT SWITCH, 6 POSITION ......................................................................................... 1

" FM-163-12 250 HEAT SWITCH, 12 POSITION ....................................................................................... 120 RC2 FW-861C ALL FUNCTION RECEPTACLE ASSEMBLY ........................................................................ 121 FM-353E " HOSE, BULKHEAD, (MHG7 FITTING) ........................................................................... 122 R1 UC-35 " POTENTIOMETER, 75K OHM ....................................................................................... 123 T2 FM-287M " TRANSFORMER, CONTROL (220V-28V) ..................................................................... 1

AD-16 140 ADAPTER, VOLTAGE (220V-120V) ............................................................................... 124 W FM-153 ALL CONTACTOR, 24VAC .................................................................................................... 125 D1,2 MI-260 140 DIODE ............................................................................................................................. 2

D1,2,3,4 " 175, 250 ........................................................................................................................................ 426 FM-460 140 HEAT SINK ASSEMBLY, COMPLETE ........................................................................... 1

FM-360 175, 250 ........................................................................................................................................ 127 MI-255M ALL LEG, HEAT SINK ............................................................................................................ 228 C1 FM-125S 140 CAPACITOR, 12000UF 50V ........................................................................................... 4

" " 175, 250 ........................................................................................................................................ 629 R2 MI-262 ALL RESISTOR, 100 OHM 25W ............................................................................................ 130 T1 FM-386 140 TRANSFORMER, POWER ............................................................................................ 1

" FM-486 175 ........................................................................................................................................ 1" FM-286C 250 ........................................................................................................................................ 1

TP1 FM-654 ALL THERMAL SWITCH (N.C.) ............................................................................................. 131 Z FM-188C " CHOKE ........................................................................................................................... 132 F MI-717 140 FAN MOTOR, 120V ........................................................................................................ 1

" FM-117 175, 250 FAN MOTOR, 230V ........................................................................................................ 133 FM-318 ALL FAN BLADE .................................................................................................................... 134 PY-109F 140 FAN BRACKET ............................................................................................................... 1

PY-109A 175, 250 FAN BRACKET W/ SHROUD......................................................................................... 135 FM-120 ALL STRAIN RELIEF ............................................................................................................. 1

FM-120N " NUT, STRAIN RELIEF .................................................................................................... 1

WC5310 PAGE 12 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380

D6

C4

R3 R6Q2

Q1

HS2

R11

R4

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

HS1

C2SR1

R5C3

D5

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 13

FIGURE B1

QTY.DESCRIPTION

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

PARTNO.

DIA.MKGS.

ITEMNO.

WC5310 PAGE 14 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380

D7 D8

C5 C6R8

R10

Q3

D9

R7

CR2

SR2

FIGURE B2 - PRINTED CIRCUIT BOARD (FM-529U)(OPTIONAL)

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 15

FIGURE B2

QTY.DESCRIPTIONPARTNO.

DIA.MKGS.

ITEMNO.

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

WC5310 PAGE 16 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380

FIGURE C - WIRE FEED COMPARTMENT

7FIG. C1

3

1

5

6

8

9

10

1112

13

14

15

16

2

4

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 17

FIGURE C

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

DESCRIPTION QTY.MP

MODELPARTNO.

DIA.MKGS.

ITEMNO.

WC5310 PAGE 18 Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380

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

10A10B

1

2

34

5

6

7

89

10

1112

13

14

15

16

17

181920212223

2524

262728293031

32

33

34

Systematics, Inc. 1025 Saunders Ln. West Chester, Pa. 19380 WC5310 PAGE 19

FIGURE C1DIA.

MKGS.MP

MODEL DESCRIPTION QTY.PARTNO.

ITEMNO.

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

MP140140P-2648 AND LATER