180 & 250 SERIES

SERVICE MANUALSERIAL NUMBERS .......................... CT180-2013 AND LATER.................................................. CT250-2041 AND LATER.................................................. PBE180-2021 AND LATER.................................................. PBE250-2030 AND LATER

FORM WC5341 4/95 (Rev. 7/97, 9/97, 1/00, 2/00)

WC5341 PAGE 2

CONTENTS

VIEW DESCRIPTION

FIGURE 1.................... SCHEMATIC DIAGRAM, COMPLETE ............................................... 3

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

FIGURE 1B ................. SCHEMATIC, SPOT TIME CIRCUIT BOARD .................................... 5

FIGURE A ................... FRONT VIEW ..................................................................................... 6

.................................... PARTS LIST ....................................................................................... 7

FIGURE B ................... LEFT SIDE VIEW & INTERNAL COMPONENTS .............................. 8

.................................... PARTS LIST ....................................................................................... 9

FIGURE B1 ................. PRINTED CIRCUIT BOARD (FM-774U) ........................................... 10

.................................... PARTS LIST ...................................................................................... 11

FIGURE B2 ................. PRINTED CIRCUIT BOARD (FM-529U) ........................................... 12

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

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

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

FIGURE C1 ................. WIRE DRIVE ASSEMBLY (FM-138C24B) ........................................ 16

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

PAGE

WC5341 PAGE 3

FIGURE 1 - SCHEMATIC DIAGRAM

WC5341 PAGE 4

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

WC5341 PAGE 5

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

WC5341 PAGE 6

FIGURE A - FRONT VIEW

*1

23

4

56

78

9

10

11

12

13

*14

15

16

17

19

18

20

21222324

WC5341 PAGE 7

FIGURE A

QTY.DESCRIPTIONPARTNO.

DIA.MKGS.

ITEMNO.

*1 SY-407L COVER, LEFT *(MUST BE PURCHASED AS A COMPLETE ASSY.) ................................................ 1

* SY-427 COVER & ACCESS DOOR ASSEMBLY, COMPLETE ........................................................................ 1

2 PH-05 HANDLE ............................................................................................................................................... 1

3 HG-520 KNOB, SPOT TIME (180S & 250S ONLY) ........................................................................................... 1

4 S3 FM-245 SWITCH, MODE (180S & 250S ONLY) ............................................................................................... 1

5 AH-67 KNOB, FEED ........................................................................................................................................ 1

6 LB-1082 LABEL, CONTROL W/SPOT TIME (180S & 250S ONLY) ................................................................... 1

LB-1083 LABEL, CONTROL W/O SPOT TIME .................................................................................................. 1

7 MI-330A KNOB, VOLTAGE ................................................................................................................................ 1

8 SY-318 CABLE HANGER ................................................................................................................................. 2

9 SY-306 SIDE, LEFT .......................................................................................................................................... 1

10 V FM-115 VOLTMETER (ROUND CORNERS) .................................................................................................... 1

FM-115A VOLTMETER (SQUARE CORNERS) (SERIAL# CT180-2046 AND LATER; PBE180-2027 AND

LATER) (SERIAL# CT250-2109 AND LATER; PBE250-2057 AND LATER) ....................................... 1

MI-115L LENS, VOLTMETER (ROUND CORNERS) ........................................................................................ 1

FM-115AL LENS, VOLTMETER (SQUARE CORNERS) ...................................................................................... 1

11 CB1 FM-282 CIRCUIT BREAKER, 35 AMP .............................................................................................................. 1

FM-955 BREAKER BRACKET .......................................................................................................................... 1

12 L FM-184 INDICATOR LAMP ............................................................................................................................... 1

13 PY-117 AXLE ..................................................................................................................................................... 1

PY-117C AXLE, CAPS ......................................................................................................................................... 2

*14 SY-407R ACCESS DOOR *(MUST BE PURCHASED AS COMPLETE ASSY.) ................................................ 1

15 PY-208 FRONT ................................................................................................................................................. 1

16 FW-71 BUSHING, 1 3/8" .................................................................................................................................. 1

17 - FM-146 WELD CONNECTOR, GROUND ........................................................................................................ 1

FW-72 NUT, WELD CONNECTOR ................................................................................................................. 1

FM-178/10 GROUND CABLE ASSEMBLY, 10' (NOT SHOWN) ............................................................................ 1

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

18 + FM-146C WELD CONNECTOR, POSITIVE W/GAS HOLE ................................................................................ 1

FW-72 NUT, WELD CONNECTOR ................................................................................................................. 1

19 SY-304 SIDE, RIGHT ........................................................................................................................................ 1

20 LB-1121 LABEL, LOWER FRONT ...................................................................................................................... 1

21 MI-122-8 REAR WHEEL, 8" ................................................................................................................................ 2

22 PY-102Z BASE .................................................................................................................................................... 1

23 PY-212 BRACKET, CASTER ............................................................................................................................ 2

24 MI-121-3 CASTER, FRONT 3" ............................................................................................................................ 2

WC5341 PAGE 8

FIGURE B - LEFT SIDE VIEW & INTERNAL COMPONENTS

19

18

20

3

4

5

6

7

8

9

10

111

FIG. B2

FIG.B113 15

2

12

14

16

17

2122

23

24

25

26272829303132

WC5341 PAGE 9

FIGURE B

QTY.DESCRIPTIONPARTNO.

DIA.MKGS.

ITEMNO.

1 PC2 FM-529U SPOT TIME BOARD (SEE FIGURE B2) (180S & 250S ONLY) ........................................................... 1

J2 AD-17 JUMPER, HARNESS ........................................................................................................................... 1

RC3 FW-187A MALE HOUSING ASSY., 6 PIN ............................................................................................................ 1

RC4 FW-186A FEMALE HOUSING ASSY., 6PIN ........................................................................................................ 1

2 MI-685 TERMINAL HOUSING, HARNESS (1-W/ SPOT TIMER) .................................................................... 2

MI-685P PIN, TERMINAL HOUSING (9-W/ SPOT TIMER) .............................................................................. 15

3 GS FM-126B SOLENOID ASSEMBLY, 24VAC.......................................................................................................... 1

4 FM-253A GAS HOSE, PRIMARY ......................................................................................................................... 1

5 W FM-153 CONTACTOR, 24VAC ......................................................................................................................... 1

6 SY-213 CYLINDER BRACKET (SERIAL# CT180-2013 TO 2049 ; PBE180-2021 TO 2032) ............................ 1

(SERIAL# CT250-2041 TO 2145 ; PBE250-2030 TO 2095)

SY-211 CYLINDER BRACKET (SERIAL# CT180-2050 AND LATER ; PBE180-2033 AND LATER) ............... 1

(SERIAL# CT250-2146 AND LATER ; PBE250-2096 AND LATER)

7 FM-211C CYLINDER CHAIN ............................................................................................................................... 1

8 PY-203 BACK (SERIAL# CT180-2013 TO CT180-2038 ; PBE180-2021 TO PBE180-2029) ............................ 1

(SERIAL# CT250-2041 TO CT250-2102 ; PBE250-2030 TO PBE250-2050)

SY-303F BACK (SERIAL# CT180-2039 AND LATER ; PBE180-2030 AND LATER) ......................................... 1

(SERIAL# CT250-2103 AND LATER ; PBE250-2051 AND LATER)

9 FM-120 STRAIN RELIEF ................................................................................................................................... 1

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

10 PLG1 20CP-0 POWER INPUT CABLE, 20' ................................................................................................................. 1

11 SY-305A BAFFLE (REVISED) ............................................................................................................................. 1

12 FM-601 PIN, EDGE CONNECTOR (4-W/ SPOT TIMER) ................................................................................. 8

13 SC-421U BRACKET, CONTROL (U-BOARD) ..................................................................................................... 1

14 PC1 FM-774U WIRE FEED CONTROL BOARD (SEE FIGURE B1) .......................................................................... 1

15 CB-236 SOCKET, RELAY 8 PIN ....................................................................................................................... 1

16 R9 ST-22 POTENTIOMETER, 35K OHM (180S & 250S ONLY) .......................................................................... 1

17 R1 UC-35 POTENTIOMETER, 75K OHM ............................................................................................................. 1

18 RC2 FW-861C FUNCTION RECEPTACLE ASSEMBLY .............................................................................................. 1

19 S2 FM-163-12 HEAT SWITCH, 12 POSITION ............................................................................................................ 1

20 FM-353D HOSE, BULKHEAD, (TORCH FITTING) .............................................................................................. 1

21 FM-353E HOSE, BULKHEAD, (SPOOL GUN FITTING) ..................................................................................... 1

22 T2 FM-287M TRANSFORMER, CONTROL (220V-28V) ........................................................................................... 1

23 D1,2,3,4 MI-260 DIODE .................................................................................................................................................. 4

24 FM-360 HEAT SINK ASSEMBLY, COMPLETE................................................................................................. 1

25 R2 MI-262 RESISTOR, 100 OHM 25W ................................................................................................................. 1

26 MI-255M LEG, HEAT SINK ................................................................................................................................. 2

27 C1 FM-125S CAPACITOR, 12000UF 50V ................................................................................................................. 6

28 T1 FM-686T 180 SERIES POWER TRANSFORMER .............................................................................................. 1

" FM-286T 250 SERIES POWER TRANSFORMER .............................................................................................. 1

TP1 FM-654 THERMAL SWITCH (N.C.) .................................................................................................................. 1

29 Z FM-188C CHOKE ................................................................................................................................................. 1

30 F FM-117 FAN MOTOR, 230V .............................................................................................................................. 1

31 FM-318 FAN BLADE .......................................................................................................................................... 1

32 PY-109A FAN BRACKET W/SHROUD ............................................................................................................... 1

WC5341 PAGE 10

D6

C4

R3 R6Q2

Q1

HS2

R11

R4

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

HS1

C2SR1

R5C3

D5

WC5341 PAGE 11

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.

WC5341 PAGE 12

D7 D8

C5 C6R8

R10

Q3

D9

R7

CR2

SR2

FIGURE B2 - PRINTED CIRCUIT BOARD (FM-529U)(180S & 250S ONLY)

WC5341 PAGE 13

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

WC5241 PAGE 14

FIGURE C - WIRE FEED COMPARTMENT

123

4

5FIG. C1

6

7

8

9

10

1112

13

WC5241 PAGE 15

ITEMNO.

FIGURE D

QTY.DESCRIPTIONPARTNO.

DIA.MKGS.

1 LB-1358 180 SERIES ACCESS DOOR INNER LABEL ................................................................................ 1

LB-1359 250 SERIES ACCESS DOOR INNER LABEL ................................................................................ 1

2 CB2 FM-519 BREAKER, MINI 5A ........................................................................................................................ 1

3 CR1 FM-276S RELAY, 8 PIN 24VAC ...................................................................................................................... 1

4 FM-276CL RELAY CLIP, 8 PIN ......................................................................................................................... 1

5 FM-138C24B WIRE DRIVE ASSEMBLY (SEE FIGURE C1) ................................................................................ 1

6 FM-500A BULKHEAD ASSEMBLY, FEMALE ................................................................................................. 2

FM-501 BULKHEAD, MALE ......................................................................................................................... 2

FM-501K BULKHEAD KIT, COMPLETE ......................................................................................................... 1

FM-880 COVER, THREAD ........................................................................................................................... 1

7 SY-322 SPOOL BRACKET .......................................................................................................................... 1

8 FW-22 SPOOL CLIP ................................................................................................................................... 1

9 FM-222 SPOOL HUB ASSEMBLY ............................................................................................................... 1

FW-15 SHAFT ............................................................................................................................................. 1

FW-16 BUSHING ........................................................................................................................................ 2

FW-18 TENSION SPRING .......................................................................................................................... 1

10 FW-20B TENSION BOLT .............................................................................................................................. 1

11 PY-119A SPOOL ADAPTER BASE, 4" .......................................................................................................... 1

12 LB-1360 LABEL, MIG TORCH-SPOOL GUN ................................................................................................ 1

13 FM-353S GAS HOSE, SELECTOR ................................................................................................................ 1

WC5241 PAGE 16

FIGURE C1 - WIRE DRIVE ASSEMBLY (FM-138C24B)

1

2

3

4

56

7

8

9

16

17

19

18

20

21

2223

24

252627282930313233

34

10

10A10B

11

12

13

14

15

WC5241 PAGE 17

ITEMNO.

FIGURE C1

QTY.DESCRIPTIONPARTNO.

DIA.MKGS.

1 FW-48 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 M3-906 THUMB SCREW ............................................................................................................................. 1

7 FM-24 GAS FITTING (2291, 1192) ............................................................................................................. 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 FM-278C TORCH SELECTOR CABLE ASSEMBLY ...................................................................................... 1

14 FW-62 DRIVE ROLL WASHER .................................................................................................................. 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 FM-136C INLET GUIDE TUBE ....................................................................................................................... 1

25 FW-34 NUT, INLET GUIDE ........................................................................................................................ 1

HW-58ILW LOCK WASHER, INTERNAL .......................................................................................................... 1

26 FW-64 DRIVE ROLL NUT ........................................................................................................................... 1

27 FW-63 DRIVE ROLL LOCK WASHER ....................................................................................................... 1

28 FM-603 ADJUSTING COLLAR (BEHIND) .................................................................................................... 1

29 FW-60 DRIVE ROLL ................................................................................................................................... 1

30 FM-61C 1/2 WOODRUFF DRIVE KEY (HIDDEN) ........................................................................................ 1

31 FM-131S MOTOR BRACKET, ADJUSTABLE ................................................................................................ 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

WC5241 PAGE 18

PBE180 & 250PBE180-2000 AND LATERPBE250-2000 AND LATER