OWNER'S MANUAL · tips, gas cups and insulating bushings; (3) damage by accident, force majeure, improper use, neglect, unauthor-ized repair or alteration; (4) anyone other than the

MP140 MIG COMBINATION UNIT

OWNER'S MANUAL

THE MP140REPRESENTS THE LATEST TECHNOLOGYIN MIG COMBINATION UNITS. THE MP140 OPERATESON 115 VOLT AC SINGLE PHASE CURRENT, AND FEATURES"SMOOTH ARC" TRANSFORMER DESIGN CONCEPT.

FOR TECH. SERVICE, CALL 1-610-696-9040

INSTALLATIONOPERATION

MAINTENANCEFORM WC5342 Rev. 8/00

MANUFACTURER’S LIMITED WARRANTY

This equipment is warranted against defects in materialsand workmanship for a period of two years from the date ofpurchase.

EXCEPTION: THE MIG TORCH IS WARRANTED FOR APERIOD OF 30 DAYS FROM THE DATE OF PURCHASE.

Should the equipment become defective for such reason,the Manufacturer will repair it without charge, if it is returnedto the Manufacturer’s factory, freight prepaid. This warrantydoes not cover: (1) failure due to normal wear and tear; (2)consumable parts, such as, but not limited to, torch contacttips, gas cups and insulating bushings; (3) damage byaccident, force majeure, improper use, neglect, unauthor-ized repair or alteration; (4) anyone other than the originalpurchaser.

THIS LIMITED WARRANTY IS IN LIEU OF ALL OTHERWARRANTIES, EXPRESS OR IMPLIED. THE MANUFAC-TURER SHALL NOT BE LIABLE FOR ANY INJURY TOPERSONS, INCLUDING DEATH; OR LOSS OR DAMAGETO ANY PROPERTY, DIRECT OR CONSEQUENTIAL,INCLUDING, BUT NOT LIMITED TO, LOSS OF USE,ARISING OUT OF THE USE, OR THE INABILITY TO USE,THE PRODUCT. THE USER ASSUMES ALL RISK ANDLIABILITY WHATSOEVER IN CONNECTION WITH THEUSE OF THE PRODUCT, AND BEFORE DOING SO,SHALL DETERMINE ITS SUITABILITY FOR HIS IN-TENDED USE, AND SHALL ASCERTAIN THE PROPERMETHOD OF USING IT.

SOME STATES DO NOT ALLOW LIMITATIONS ONHOW LONG AN IMPLIED WARRANTY LASTS, OR THEEXCLUSIONS OR LIMITATIONS OF INCIDENTAL ORCONSEQUENTIAL DAMAGES. SO THE ABOVE LIMITA-TIONS OR EXCLUSIONS MAY NOT APPLY TO YOU. THISWARRANTY GIVES YOU SPECIFIC LEGAL RIGHTS, ANDYOU MAY HAVE OTHER RIGHTS WHICH MAY VARYFROM STATE TO STATE.

ARC WELDING CAN BE INJURIOUS TO OPERA-TOR AND PERSONS IN THE WORK AREA -——CONSULT INSTRUCTION MANUAL BEFOREOPERATING.

ELECTRIC SHOCK can kill.• Do not touch electrodes or other electrically live parts.

• Insulate yourself from work and ground.

• Install and ground machine in accordance with the National

Electical Code and local code(s). Read Operating Manual

before installing or operating.

• Do not operate with protective covers, panels, or guard

removed.

• Disconnect input power before servicing.

• Only qualified personnel should install, use, or service this

equipment.

ARC RAYS can injure your eyes and burnskin.• Wear correct eye, ear, and body protection while welding.

FUMES AND GASES can be dangerous to yourhealth.• Use enough ventilation and/or exhaust at the arc.

• Keep your head out of fumes.

• Do not breathe fumes.

READ AND UNDERSTAND THEMANUFACTURER’S INSTRUCTIONS ANDYOUR EMPLOYER’S SAFETY PRACTICES.

See American National Standard Z49.1, “Safety inWelding and Cutting”, published by the AmericanWelding Society, 2501 N.W. 7th St., Miami, Florida33125; OSHA Safety and Health Standards, 29 CFR1910 available from U.S. Dept. of Labor, Wash.,D.C. 20210.

! WARNING

Systematics , Inc. 1025 Saunders Lane West Chester, PA. 19380

TABLE OF CONTENTSELECTRICAL SUPPLY REQUIREMENTS................................... 1INTRODUCTION ........................................................................... 2SPECIFICATIONS......................................................................... 3CHECK LIST (CONTENTS) .......................................................... 4INSTALLATION............................................................................. 4OPERATION ................................................................................. 7MAINTENANCE........................................................................... 13TROUBLE SHOOTING CHART.................................................. 15CONNECTING TIGIT2 OR MHG7 SPOOL GUN ........................ 20CONSUMABLE PARTS BREAKDOWN ..................................... 22PARTS BREAKDOWN - MIG TORCH ........................................ 23OPTIONS - TIGIT2, MHG7 SPOOL GUN ................................... 24

Systematics , Inc. 1025 Saunders Lane West Chester, PA. 19380 1

ELECTRICAL SUPPLY REQUIREMENTS FOR THE MP140Ensure that there is a 115 volt single phase, 20 amp electrical supply within easy reach

of the unit. The input cable supplied is 20 feet long. A 50 foot cable is an optional extra. Theplug which is factory installed is suitable for use up to 120 amps of output. The plug mustbe changed if the welder is used above 120 amps of output. Attach a suitable plug makingsure the green wire is attached to ground. Refer to boxes below with the WARNING andNOTE headings for more information. All wiring should be performed by a qualifiedelectrician.

WARNINGTo conform to the National Electrical Code, the power input plug must bechanged if this unit is to be operated on a 20 amp circuit or higher.

Never change fuses or circuit breakers to a higher value than the wires andoutlet are designed for.

Breaker size - Wire size15 Amp 14 Gauge20 Amp 12 Gauge30 Amp 10 Gauge

Do not rely on the circuit breaker built into the MP140 to protect your wiring.This circuit breaker protects the MP140 internal wiring only.

Do not use undersized extension cords. Follow the cord manufacturer'srecommendations as to current carrying capacities.

Make sure all electrical wiring is installed by a qualified electrician.

NOTE

The maximum output of the MP140 will be limited by the size (amp rating) ofthe circuit used.

Operation on a 15 amp circuit (14 gauge wire) will limit maximumoutput to 100 amps.Operation on a 20 amp circuit (12 gauge wire) will limit maximumoutput to 120 amps.Operation on a 30 amp circuit (10 gauge wire) will result in maximumoutput of 140 amps.

MP140 output will be limited also by low input voltage (less than 120 volts),long input cords and use of extension cords.

2 Systematics , Inc. 1025 Saunders Lane West Chester, PA. 19380

INTRODUCTIONThe Systematics MP140 is a com-

bination welding power source,wire feed unit, MIG torch andaccessory package. It operates on115 volts AC input current and isdesigned to meet the requirementsof auto body repair shops and lightfabrication. The MP140 producesfusion welds by the Gas Metal ArcWelding process (GMAW or MIG), onsteel up to 1/4" thick(aluminum 3/16") , using .023" through .045"steel wire and 3/64" aluminumwire(Optional liners and contacttips must be purchased to covergiven wire sizes). Heavier sec-tions can be easily welded usingslightly different techniques. Con-sumable MIG Spot/Stitch Welding onsteel can be performed with theOptional SSTP-2 module installed.

The number of controls on theunit have been reduced to assistinexperienced operators learn MIGwelding. This facilitates rapidset up for welding different thick-nesses of material requiring vari-ous heat inputs. The VOLTAGE con-trol adjusts the welding voltageand the WIRE SPEED control adjuststhe speed of the wire drive motor.

THE MIG PROCESSAS APPLIED TO THE MP140

The MIG process uses a bare,consumable electrode in the form ofspooled wire, which is fed by acontrollable speed feed unit throughthe cable and torch to the weld. Theemerging wire and the weld areshielded by a stream of CO2, Argon,or a mixture of the two, whichprevents oxidation of the moltenweld puddle. The gas shield enableshigh quality welds to be madewithout the use of flux, eliminat-ing the need for slag or fluxremoval after the weld is com-pleted.

The consumable electrode wire ismelted and transferred to the weldpuddle by the "short arc" or "dip"transfer mode.

POWER SOURCE

WIRE SPOOL

FEEDROLLS

WORK

MIGTORCH

+REVERSEPOLARITY

(STD.)_

SHIELDING GAS

SHORT ARC OR DIP TRANSFER

Short arc transfer occurs at 12to 22 arc volts (voltage whilewelding), depending on wire size.Welding commences as the arc isstruck and a weld pool is formed.The tip of the electrode wire dipsinto the pool and causes a shortcircuit. The short circuit currentflow causes a rapid temperaturerise in the electrode wire and theend of the wire is melted off. Anarc is immediately formed betweenthe tip of the wire and the weldpool, maintaining the electricalcircuit and producing sufficientheat to keep the weld pool fluid.The electrode continues to feed andagain dips into the pool.

FIG. 1. SCHEMATIC OF MIG PROCESS

This sequence of events is re-peated up to 200 times per second.Short arc transfer is suitable forpositional welding. The heat inputto the workpiece is kept to aminimum which limits distortionand makes possible the welding ofthin sheet material.

FIGURE 2. SHORT ARC TRANSFER

ELEC-TRODE

WORK


DESCRIPTIONThe MP140 consists of a combina-

tion MIG welding power source andwire feed unit, a MIG torch with 10foot cable, a ten foot work (ground)cable with ground clamp, a fifteenfoot power input cable, a gasregulator/flowmeter, a torch ac-cessory kit, and a built-in cylin-der rack and industrial wheel kit.

Welder controls are simple andclearly marked. The output voltageis controlled by a six position tapswitch, providing six voltage se-lections. Voltages can be moni-tored by the voltmeter on thecontrol panel. Wire feed speed iscontrolled by the wire speed poten-tiometer.

An OPTIONAL SPOT/STITCH WELD(SSTP-2)control module with ad-justable timer circuit providesConsumable MIG Spot Welding orStitch Welding capabilities oflight gauge steel.

SPECIFICATIONSPART NUMBER: MP140

INPUT POWER REQUIREMENTS:Voltage 115 volts ACPhase single phaseFrequency 50/60 hertzCurrent (see OUTPUT POWER)

OUTPUT POWER @ 100% Duty Cycle:15 Amps Input Current = 100 Amps20 Amps Input Current = 120 AmpsOUTPUT POWER @ 60% Duty Cycle:30 Amps Input Current = 140 Amps

DUTY CYCLE TIME PERIOD:10 minutes

OPEN CIRCUIT VOLTAGE:18 - 33 volts DC

SPECIFICATIONS (Cont.)ARC VOLTAGE: 14 - 24 volts DC

WELD CURRENT RANGE:30 - 140 amps

WIRE TYPES: mild steel,stainless steel, aluminum,

bronze, flux cored, flux cored-gasless

WIRE SIZES: .023" - .045" steel,3/64" aluminum,

(.023" - 3/64" alum. w/ Spool Gun).030" - .035" bronze,

.030" - .045" flux cored(gas shielded or gasless)

WIRE FEED SPEED RANGE:50 - 500 inches per minute

SHIELDING GASES:For Steel Argon/CO2 mix or CO2For Aluminum, Bronze ArgonFor Stainless Steel

Argon + 2% OxygenFor Flux cored Argon/CO2 mix or

CO2

DIMENSIONS:Height 31 in.Width 14-1/2 in.Depth 35-1/2 in.Weight 175 lbs.

TORCH SPECIFICATIONS

NECK ANGLE: 60 degrees

LEAD LENGTH: 10 feet

OVERALL LENGTH: 10 feet

COOLING METHOD: gas (air)

RATING - 60% DUTY CYCLE:With Argon/CO2 gas 200 ampsWith CO2 gas 225 amps


CHECK LISTTHE SYSTEMATICS MP140 INCLUDES THEFOLLOWING:

1- Combination Power Source/WireFeeder

1- Cylinder Rack/Industrial WheelKit

1- 15TG10 MIG Torch with adjust-able nozzle

1- 15 foot Power Input Cable withPlug

1- 10 foot Work(Ground)Cable andClamp

1- MP250PK Parts Kit1- GR-FM Gas Regulator/Flowmeter1- Nozzle, 1/2 in. orifice (in-

stalled on MIG torch)1- Contact Tip, for .030 in. wire

(installed on MIG torch)1- ER70S-6-30-3, Sample Spool of

.030" Steel Wire

ITEMS REQUIRED FOR MIG WELDINGWHICH ARE NOT PROVIDED WITH THEMP140

1. Full cover welding helmet withproper colored lens (shade 9 to11 depending on operator’s pref-erence).

2. Proper shielding gas and cylin-der.

3. Leather welding gloves.

4. 115 volt single phase AC power.

INSTALLATION

POSITIONING THE UNIT

Locate the unit near the weldingarea and position it so there isadequate clearance all around forventilation and maintenance.

ELECTRICAL SUPPLY

Follow the Electrical SupplyRequirements on page 1.

SHIELDING GAS CONNECTIONS

1. Place a cylinder of the appro-priate shielding gas in therack at the rear of the machineand secure it with the chainprovided.

2. Rapidly open and close thecylinder valve. This will purgedust and foreign matter fromthe valve.

Take care to point thevalve outlet away fromyourself or other people,as escaping high pressuregas may be dangerous.

3. Attach the gas regulator/flow-meter supplied with this unit,to the cylinder valve using asuitable wrench.

NOTEIf this unit is to be usedwith 100% CO2 shieldinggas, an optional gas regu-lator coupler is re-quired.

CAUTION

FIG. 3. GAS FLOW ADJUSTMENT

GAUGE -INDICATES

TANKPRESSURE

OUTLETFITTING

TOWELDINGMACHINE

GAS FLOWADJUSTING

KNOB

INLETFITTING

TOTANK

FLOW TUBEINDICATES

FLOW RATEIN C.F.H.


FITTING AND THREADING THE ELEC-TRODE WIRE - ALWAYS USE ER70S-6WELDING WIRE

1. Remove the wire spool clip fromthe spool hub.

2. Unpack the spool of weldingwire from its protective pack-aging.

3. Place the spool of ER70S-6welding wire onto the hub. Thewire is fed off the bottom ofthe spool.

Look for and remove anywire protruding from thecenter of the spool. Theprotruding wire is elec-trically HOT during weld-ing and must not touchthe machine.

4. Replace the spool clip on thehub.

5. Unlatch the pressure roll armand swing it open.

6. Make sure the double v-groovedrive roll is installed tomatch the wire size. To changethe wire size setting, removethe drive roll, turn it over andreinstall it on the shaft.

(continued on following page)

SHIELDING GAS CONNECTIONS(Cont.)

4. Fit the gas hose from thewelding machine to the regula-tor outlet fitting and tightenit with a suitable wrench. Openthe cylinder valve.

5. Check that the gas regulator isproperly adjusted. When weld-ing steel, the gas flow rate is30 CFH. When welding aluminum,the gas flow rate is 40 CFH.

NOTEThe MP140 must be turned"ON" and the MIG torchtrigger depressed, beforethe gas flow rate can beadjusted.

TORCH CONNECTION

1. Open the access door of themachine to its fullest extent.

2. Back out the thumb screw lo-cated on the drive assemblymounting bracket inside themachine. Insert the MIG torchinto the torch panel mount onthe front panel and TIGHTEN THETHUMB SCREW.

CAUTION

FIG. 5. DOUBLE GROOVE DRIVE ROLL

"A" SIDE FACING IN FOR.023" - .035" STEEL WIRES

"B" SIDE FACING IN FOR.040" - .045" STEEL WIRESAND 3/64" ALUMINUM WIRES

TORCH PRESSUREPANEL ROLLMOUNT

MIGTORCH

THUMBSCREW

DRIVE DRIVEROLL ASSEMBLY

FIGURE 4. TORCH CONNECTION


FITTING AND THREADING THE ELEC-TRODE WIRE (Continued)

12.Install the contact tip over theprotruding wire and tighten itfirmly using a proper sizewrench. Make sure the tip is thecorrect size for the wire beingused.

13.Install the nozzle on the torch.For steel, the contact tipshould be flush or stick out upto 1/16 inch beyond the end ofthe nozzle. For aluminum, thecontact tip should be recessed1/8 to 1/4 inch inside thenozzle. Using wire cutters,trim off the wire so the stickoutis approximately 1/4 inch forsteel or 1 inch for aluminum.For aluminum, the end of thewire should be bent over so itdoes not JAM into the work. Thisis called a "scratch start".

FITTING AND THREADING THE ELEC-TRODE WIRE (Continued)

7. Release the wire from the spooland trim off the kinked end withwire cutters. The wire must bestraight when it enters theinlet guide.

8. Thread the electrode wire throughthe inlet guide, over the feedroll and into the torch liner.Ensure that the wire locates inthe feed roll groove. Do notallow the wire on the spool toloosen.

9. Close and relatch the pressureroll arm.

10.Stretch the torch cable straightout in front of the machinemaking sure there are no kinks.Remove the nozzle and contacttip from the torch.

11.Turn "ON" the circuit breaker onthe front of the machine. Thecooling fan will start and the"ON" indicator light will illu-minate. Set the VOLTAGE controlswitch to "4", the functionswitch to "CONTINUOUS WELD" (ifthe unit has the optional SSTP-2 installed) and the WIRE SPEEDcontrol to "7". Pull thetrigger on the MIG torch. Thewire feed system will start andwire will be fed through thecable liner and torch. If thewire does not feed, or appearsto slip, tighten the pressureroll arm adjusting nut. Feedthe wire until it protrudesfrom the front of the torchapproximately six inches.

Keep hands and face awayfrom the front of thetorch and do not allow thewire to contact ground.The wire is electricallyHOT when the torch triggeris actuated.

1"STICK-OUT

1/4"STICK-

OUT

FOR ALUMINUM:CONTACT TIP

RECESSED 1/8" - 3/8"

FOR STEEL:CONTACT TIP

FLUSH WITH NOZZLE

14.For steel welding only, sprayanti-spatter compound insidethe nozzle and on the outside ofthe contact tip. For aluminumor stainless steel welding, NOanti-spatter compound can beused as it will contaminate theweld.

FIGURE 6.WIRE STICKOUT - STEEL, ALUMINUMCAUTION


WIRE FEED PRESSURE ROLL ADJUSTMENT

The wire feed pressure roll isadjusted to the proper setting atthe factory, prior to delivery. Itmay be necessary to readjust thesetting as components "seat in" orwhen changing to a different diame-ter wire. To check for proper rollpressure, hold the torch in onehand and the wire between twofingers of the other hand. Pull thetorch trigger. If the wire contin-ues to feed when firm pressure isapplied to the wire, the pressureroll adjusting nut should be backedoff until the feed rolls start toslip. If the wire will not feedwith very little pressure applied,the pressure roll adjusting nutshould be tightened.

OPERATIONThe following operating instruc-

tions and detailed setup proce-dures enable an operator withoutprevious experience to producequality fusion welds. It is recom-mended that an operator withoutprior experience with this equip-ment, first practice on scrap metalof the same type and thickness asthe material to be welded.

OPERATING SEQUENCE

1. Make sure that the pieces ofmetal to be welded are free ofgrease, dirt, paint and scale.Use a wire brush to remove paintand scale. Paint must be com-pletely removed to bare metal.Grease and oil could burn andcause a fire or safety hazard.Failure to clean the metalproperly will result in erraticand porous welds.

2. Install the unit as directed inthe installation instructionsand make sure the work clamp isfirmly attached to a cleanedarea on the workpiece to bewelded.

3. Open the shielding gas cylindervalve. Press the torch triggerand listen for gas flow. Adjustthe gas flow rate to 30 CFH forsteel and 40 CFH for aluminum.

The welding wire will feedwhen the trigger is actu-ated. Take care that thewire is not directed tohit yourself or anythingthat is grounded to theground wire on the welder.

CAUTION

PRESSURE ROLLADJUSTING NUT

PRESSUREROLL

PRESSUREROLL ARM

DRIVEROLL

TORCH SELECTOR CABLE

Plug the torch selector cableinto the Positive (+) terminal onthe machine(see "Process Selec-tion" on page 8 for further de-tails).

WORK (GROUND) CABLE

Uncoil the work cable and plug itinto the negative (-) terminal onthe machine.

FIGURE 7.PRESSURE ROLL ADJUSTMENT


PROCESS SELECTIONThe following controls are lo-

cated on the front of the machine.

D. "ON" INDICATOR LIGHTIlluminates when the circuitbreaker on the machine is "ON".

E. TORCH PANEL MOUNTCombination power output, con-tactor switch connection, gassupply connection, and wirefeed output in a single unit.

F. TORCH SELECTOR CABLEPlugs into (+) positive termi-nal for standard welding opera-tion or (-) negative terminalfor straight polarity weldingon very light sheet metal or forusing flux cored gasless wire.

G. VOLTMETERIndicates open circuit voltagewhen torch switch is actuatedor arc voltage when welding.

H. +(POSITIVE) TERMINALPositive output terminal fromthe welder DC power source. Thetorch selector cable is pluggedinto this terminal for standardwelding operation. The workcable can be plugged into thisterminal for straight polaritywelding on very light sheetmetal or for using flux coredgasless wire.

I. -(NEGATIVE) TERMINALNegative output terminal. Thework cable is plugged into thisterminal during standard weld-ing operation. The torch se-lector cable can be pluggedinto this terminal for straightpolarity welding on very lightsheet metal or for using fluxcored gasless wire.

A. VOLTAGE CONTROLSix position switch adjustswelder output voltage.

B. WIRE SPEEDPotentiometer controls speedof wire drive motor to give wirespeed of 50 to 500 inches perminute.

C. CIRCUIT BREAKERPrimary power switch and over-load protection device.

FIGURE 8. FRONT PANEL

A.VOLTAGECONTROL

B.WIRESPEED

C.CIRCUITBREAKER

D"ON"INDICATORLIGHT

E.TORCHPANELMOUNT

F.TORCHSELECTORCABLE

G.VOLTMETER

H.(+)POSITIVETERMINAL

I.(-)NEGATIVETERMINAL


PROCESS SELECTION (Cont.)The following controls are lo-

cated on the inside of the machine,in the wire feed compartment.

E. *FUNCTION SWITCHControls mode of operation ofwelding machine. "CONT. WELD"position is for normal, con-tinuous welding operation."SPOT" position puts the spottimer in the circuit for auto-matic MIG Consumable Spot Weld-ing. "STITCH" position is usedfor stitch welding on verylight material. When in"STITCH" position, the lengthof time the welder is "ON" andfeeding wire is controlled bythe Spot Timer. The lower theSpot Timer setting, the fasterthe welder cycles on and off.

A.*OPTIONALSSTP-2MODULE

B.*SPOTTIMER

C.SELECTORHOSE

D.PARAMETERCHART

E.*FUNCTIONSWITCH

WELDINGOptimum control settings will

vary according to the thickness ofthe metal, the type of joint,operator preference, etc. Bestresults can be obtained throughexperience with the welding ma-chine or by making trial welds.Select some sample material of thesame type and thickness as thematerial to be welded. Refer to theParameter Chart located on theaccess door to the wire feedcompartment. Set the weldingcontrols for optimum results usingthe sample material thickness andwire size being used as a startingpoint, weld until experience isgained using the unit.

CONTINUOUS WELDING ON STEEL

1. Trim the electrode wire toleave approximately 1/4 inchstickout beyond the end of thecontact tip and install thewelding nozzle. The contact tipshould be flush or stick out upto 1/16 inch beyond the end ofthe nozzle.

A. *OPTIONAL SSTP-2 MODULEWith the optional Spot/StitchModule installed MIG Spot weld-ing and Stitch welding can beperformed.

B. *SPOT/STITCH TIMERAfter the torch trigger isactuated, the timer allows thewire to feed and the gas andpower to flow for the timeselected. The Function Switchmust be set in the "SPOT"position (or the "STITCH" posi-tion for stitch welding).

C. SELECTOR HOSEAttaches to MIG position forStandard welding through theMIG torch assembly or to MHG7position for Aluminum weldingwith the spool gun option.

D. PARAMETER CHARTThis chart is a guide for basicsetup parameters.


FIGURE 9. WIRE FEED COMPARTMENT


CONTINUOUS WELDING ON STEEL(Cont.)

FIGURE 10. NOZZLE ADJUSTMENTFOR WELDING STEEL

CONTACT TIP(FLUSH TO

1/16" STICKOUT)

ELECTRODE WIRE(1/4" STICKOUT)

NOZZLE

2. Spray the inside of the nozzleand the outside of the contacttip with anti-spatter spray.

3. Locate the torch over the jointto be welded with the contacttip approximately 3/8 inch fromthe work surface.

NOTEWhen welding steel, the idealposition for holding the torchis inclined approximately 30degrees towards the directionof travel. This allows the arcto be seen easily, resultingin greater control of the weldpool. Most right-handed wel-dors move from left to right.This method, known as fore-hand welding, provides a gasshield for the cooling weldpuddle and helps in obtainingan oxidation free weld de-posit.

4. Use a welding helmet with ashade 9 to 11 filter lens,depending on operator prefer-ence.

5. Squeeze the torch trigger. Thewire will feed and an arc willbe established. As the weld isdeposited, move the torch slowlyalong the weld seam at a con-stant speed, maintaining a con-stant arc length and a constanttip-to-work distance.

FIGURE 11. TORCH POSITIONFOR WELDING STEEL

- RIGHTHANDED WELDOR

30 DEGREES

DIRECTIONOF TRAVEL

SHIELDINGGAS

WORK


CONTINUOUS WELDINGON ALUMINUM

(Optional Nylon liner and 100%Argon shielding gas are

required)

1. Trim the electrode wire, leav-ing approximately 1 inch stick-out beyond the end of thenozzle. Bend the wire over asshown, to allow for a scratchstart. The contact tip shouldbe recessed inside the nozzleapproximately 3/8 inch. Thishelps prevent the welding wirefrom burning back to the con-tact tip.

DIRECTIONOF TRAVEL

WORK

10 DEGREES

SHIELDING GAS

NOZZLE

CONTACT TIP(RECESSED 3/8")

ELECTRODEWIRE

(1" STICKOUT)

2. DO NOT spray any anti-spattermaterial on the torch or basemetal and DO NOT attempt tolubricate the aluminum wire inany way. Weld contaminationwill occur unless the wire,base metal, torch and work areaare kept clean.

3. Bring the torch nozzle to 1/2 to5/8 inch from the workpiece.The recommended position of thetorch and direction of travelfor welding aluminum are shownin figure 13.

4. Follow steps 4 and 5 as in"Continuous Welding on Steel".

FIGURE 12.NOZZLE ADJUSTMENT

FOR WELDING ALUMINUM

MIG SPOT WELDING ON STEEL(OPTIONAL)

NOTEMIG Spot Welding is NOTrecommended for aluminum.

1. Trim the electrode wire so thestickout from the contact tipwill be flush with the nozzleface, and fit the spot nozzle inplace.

2. Set the VOLTAGE control to "6",the WIRE SPEED control to "9",the Function Switch to "SPOT",and the TIME control to "2",then adjust the various con-trols to obtain a perfect weld.Refer to the Parameter Chart,located on the access door tothe wire feed compartment, forbasic setup recommendations.


FIGURE 13. TORCH POSITIONFOR WELDING ALUMINUM


MIG SPOT WELDING ON STEEL(Continued)

3. Locate the torch on the area tobe welded and press the nozzlefirmly against the work to holdthe metals in place.

4. Guard the eyes against strayarc flash. A weldor’s helmet isnot necessary when spot weld-ing. However, extreme cautionmust be taken to avoid lookingat the arc.

5. Actuate the torch trigger tostart the weld sequence. Whenthe timer switches off the weldcurrent, release the triggerbut maintain firm contact be-tween the torch and work. Waitone second for the weld puddleto solidify, then move to thenext spot position. If the wirefreezes in the puddle, a quicksqueeze of the torch triggerwill melt it off.

6. To ascertain a good spot weld,look at the back side of thewelded material. A small melt-through of approximately 1/16inch diameter is ideal.

STITCH WELDING ON STEEL(OPTIONAL)

NOTEStitch Welding is used forvery light material.

1. Set Function Switch to "STITCH".

2. Adjust the TIME control to setthe time the welder is "on" andfeeding wire. The lower thesetting, the shorter the "on"time and the faster the unitcycles on and off.

3. Weld using "Continuous Weld-ing" torch position and direc-tion of travel.

DIRECTIONOF TRAVEL

WORK

SHIELDING GAS

30 DEGREES

FIGURE 15. STITCH WELDING

WORKSPOTWELD

SPOTWELDNOZZLE

CONTACTTIP

PRESS NOZZLEFIRMLY

AGAINST WORK

FIGURE 14. MIG SPOT WELDING


OPERATING HINTSBURN BACK

In the event the welding wireburns back into the contact tip:

1. Remove the nozzle from thetorch.

2. Unscrew the contact tip fromthe gas diffuser using a pair ofpliers as the tip will be veryhot.

3. Free the wire from the contacttip and clean the end of the tipso the new wire will slidesmoothly through the hole. DONOT use a drill or reamer toclean the hole as that willenlarge it and cause an erraticarc. Replace the contact tip ifit is badly damaged.

4. Install the contact tip in thetorch and tighten it firmlywith an appropriate wrench.

5. Reinstall the torch nozzle.

6. If the wire continues to burnback, check for erratic wirefeed, or speed up the wire byincreasing the WIRE SPEED con-trol setting or reducing theVOLTAGE control setting.

SPATTER

Before beginning to weld andperiodically during welding, thetorch nozzle must be removed andthe spatter (small globules ofmelted metal) cleared from theinside of the nozzle and theoutside of the contact tip and thegas diffuser. Spatter buildup be-tween the contact tip and thenozzle can cause a short circuitand consequently, failure of thetorch or welding machine. Thefrequent use of anti-spatter spraywill help prevent the adherence ofspatter to the torch components.

NOTEDO NOT use any anti-spat-ter spray when weldingaluminum or stainlesssteel.

Restricted gas flow, holding thetorch too far from the work piece,and the use of CO2 gas rather than75% Argon - 25% CO2 will increasethe spatter levels.

MAINTENANCETo ensure that this equipment

maintains its operating efficiency,the following maintenance scheduleand procedures are recommended.These routines should be performedregularly by the operator.

REGULARLY - Usage and shop condi-tions determine frequency.

1. Remove and clean the torchnozzle and contact tip. The useof anti-spatter spray will re-duce the adherence of spatterand makes its removal easier.

2. Blow out the torch liner priorto the installation of each newspool of wire. The contact tipand gas diffuser must be re-moved, but it is not necessaryto remove the liner.

3. If the torch cable assembly isbent severely, a kink may de-velop in the steel liner. Thiscan cause wire feeding problemsso a new liner should be in-stalled.



In the event of the failure of anypart of this equipment, contactyour Systematics representativefor replacement parts and service.

DO NOT lift the unit when a gascylinder is installed or at-tached.

DO NOT weld on any item thathas a common electrical ground.

DO NOT operate the unit withthe side panels removed. Over-heating will occur.

DO NOT weld upon the case ofthe welding machine.

ONLY a qualified electricianshould perform work insidethe welding machine.

ALWAYS wear protective cloth-ing, leather gloves and a fullcover welding hood while weld-ing.

DO NOT weld in a closed inarea. Proper ventilation isa necessity, or a fresh airsupplied hood should be worn.

WHEN welding near com-bustibles, a helper or"watcher" should stand bywith a fire extinguisher orother fire protective device.

NEVER weld on a closed vesselor one that has containedcombustibles.

IF IN DOUBT - DON’T DO IT!

BE SAFE - DON’T BE SORRY!

MAINTENANCE (Cont.)WEEKLY

1. Remove dirt and dust from thewire feed compartment. Use lowpressure dry compressed air.

2. Remove dirt and metal depositsfrom the grooves in the feedroll. If the grooves are badlyworn, the feed roll should bereplaced. If the pressure rolldoes not turn freely, it shouldbe replaced.

3. Check all gas fittings forleaks. Tighten or repair asrequired.

EVERY SIX MONTHS

1. Disconnect the welder from itsmain power supply.

2. Remove the machine’s side pan-els.

3. Using low pressure dry com-pressed air, remove dust anddirt from all components.

4. Check for loose or frayed wir-ing. Particularly check weld-ing current wire connections.

5. Replace the torch liner ifnecessary.

RECOMMENDEDCUSTOMER SPARE PARTS

The Systematics MP140 is a ma-chine of proven design and relia-bility. Following is a list ofconsumable items recommended asspare parts for this unit.

contact tips...... M3-T30, etc.gas nozzles............ M3T-N50nozzle insulators ........M3T-Bgas diffusers ............M3T-Dsteel liner(.020-.030) M103L-Bsteel liner(.035-.045) M104L-N

WARNING


TROUBLE SHOOTING (SYMBOL*)FOR TECH. SERVICE, CALL 1-610-696-9040

The Trouble Shooting Chart is a guide in identifying and correctingpossible troubles which may occur when operating this equipment.

FAULT POSSIBLE CAUSE REMEDY

(SYMBOL*) - USE THIS IDENTIFIER, ALONG WITH THE SCHEMATIC DIAGRAM FOUND IN THE SERVICEMANUAL, FOR TROUBLE-SHOOTING PURPOSES.

EQUIPMENT MALFUNCTION

No main power, MP140 switch is "OFF".(CB1) Turn switch "on".fan does not Wall breaker is "tripped". Reset wall breaker.operate, "Open" circuit breaker Reset or replace"on" indicator on MP140. (CB1) breaker.light is off. Loose or broken connection Tighten or repair

in power input circuit. connection.

Main power on, MIG torch unplugged. Plug in MIG torch.torch Faulty trigger switch. (S1) Replace micro switch.trigger Fault in torch cable. Check torch cableactivated, for continuity.no response. Loose or broken connection Check or repair

on wiring harness. connections.Wire feed motor unplugged. Plug in motor.

(RC1)Faulty control transformer. Check for 28VAC output.

(T2)Loose spot timer (MP140S) Install properly.

circuit board. (PC2)Defective spot timer (MP140S) Replace board.

circuit board. (CR2)(PC2)

Main power on, Pressure roll arm unlatched. Latch arm & add tension.torch "Slippage" at drive rolls. Increase drive rolltrigger tension. See page 7.activated, Wire path restricted. Clean path or replaceno wire feed torch liner.but contactor 5 amp mini breaker is Reset or replaceoperates & tripped. (CB2) breaker.gas flows. Wire feed circuit board Calibrate wire feed

needs calibrated. circuit board. Seepage 19.

Defective wire feed Replace circuit board.circuit board. (PC1)

Faulty wire feed motor Repair or replaceor connection. (M) faulty item.

Check motor on a12VDC battery.

Faulty motor relay. (CR1) Sand points or replacerelay.

Loose or broken connection. Tighten or repairconnection.



TROUBLE SHOOTING (Cont.) (SYMBOL*)FOR TECH. SERVICE, CALL 1-610-696-9040


EQUIPMENT MALFUNCTION (Cont.)

Main power on, Loose torch thumb screw. Tighten thumb screw.torch Broken or loose connection. Check cables fortrigger continuity.activated, Repair or tightenno welding connections.current, but Unplugged or faulty power Plug in or replacegas flows & contactor switch. (W) switch.wire feeds. #1 Transformer wire off.(W) Reattach wire.

"Opened" thermal switch. Allow unit to cool, then(TP1) retry.

Faulty diodes. (D1-D2) Check diodes. See page18.

Torch No shielding gas Replace tank.trigger - tank empty.activated, Loose or broken Tighten or repairno gas flow, connections. connections.but contactor Faulty Gas solenoid Repair or replaceoperates & valve. (GS) valve.wire feeds. Clogged gas flow path. Locate & clean clog.

Loose spot timer (MP140S) Install properly.circuit board. (PC2)

Defective spot timer (MP140S) Replace board.circuit board. (CR2)(PC2)

FAULTY WELDS

"Jerky" or Worn , kinked or dirty torch Clean or replace"slipping" liner. liner.wire feed. Wire spool turns too Lub spool shaft. Read-

justhard. spool drag.

Worn double v-groove drive Replace drive roll.roll.

Weak pressure roll spring. Replace spring.Worn or dirty contact tip. Replace contact tip.Worn inlet guide(s). Clean or replace guides.Sticking pressure roll. Replace pressure roll.Feed roll tension incorrect. Adjust feed roll ten-

sion.See page 7.


TROUBLE SHOOTING (Cont.) (SYMBOL*)FOR TECH. SERVICE, CALL 1-610-696-9040


FAULTY WELDS (Cont.)

"Birdnesting" Excessive feed roll tension. Reduce tension. See page(Wire wrapping 7.around drive Poor alignment. Make sure wire isrolls) properly aligned

across roller.Oversize contact tip. Replace contact tip with

correct size.

"Cold" weld Incorrect machine settings. Increase heat & wirepuddle. speed.

Incorrect shielding gas. Replace with proper gas.Excessive wire stick-out. Hold torch closer to

work.Poor connections. Check and tighten all

connections.Faulty diode. Test diodes, replace

(D1-D2) faulty diode(s). Seepage 18.

Heavy spatter. Incorrect machine settings. Increase heat, decreasewire feed speed.

Incorrect shielding gas. Replace with proper gas.Excessive wire stick-out. Hold torch closer to

work.

Porous welds. No shielding gas. Turn on gas.Not enough gas flow. Check hoses for leaks,

make sure cylinder isnot empty. Increaseflow rate.

Contaminated wire. Change wire.Faulty gas solenoid. Replace solenoid.

(GS)Incorrect electrode wire. Use correct wire.Contaminated base material. Clean or etch base

material.

(SYMBOL*) - USE THIS IDENTIFIER, ALONG WITH THE SCHEMATIC DIAGRAM FOUND IN THE SERVICEMANUAL, FOR TROUBLE-SHOOTING PURPOSES.


TESTING AND REPLACINGDIODES

Silicon diodes have proven to behighly reliable. However, weldspatter build-up in the torch canshort out and cause diode overloadand consequent failure. The fol-lowing information is provided asa guide should a failure be sus-pected.

Silicon diodes exhibit two mainfault conditions:

1. "Open Circuit" - causes a re-duction in welder output.

2. "Short Circuit" - causes thecircuit breaker to trip.

If a fault is suspected, thediode may be tested as follows:

1. Remove the top connection ofeach diode to be tested.

2. Using a Volt-Ohm Meter set onRX1K, check for continuitythrough the diode in both di-rections. If there is nocontinuity in either direc-tion, the diode is in "opencircuit" condition and must bereplaced. If there is continu-ity in both directions, thediode is in "short circuit"condition and must be replaced.If there is continuity in onedirection only, the diode isfunctioning properly.

CAUTION

+ -

+ -

12 VOLTLIGHT BULB

DIODE 12 VOLTBATTERY

12 VOLTLIGHT BULB

DIODE 12 VOLTBATTERY

3. If all the diodes check outsatisfactorily with the Volt-Ohm Meter, a load check must bemade. This is easily accom-plished using a twelve voltbattery and a twelve volt lightbulb connected as shown. Againtest for electrical currentflow in both directions. Thebulb should light in one (1)direction only - not both.

NEVER use a "megger" or ahigh voltage device totest a diode.

4. When replacing diodes, it isvery important that a heatconductive compound (Radio Shack#276-1372) be used where thediode makes contact with thealuminum heat sink. Do notgrease the threads on the di-ode.

FIGURE 16. DIODE LOAD CHECKCONNECTION DIAGRAM

- TEST FOR FLOW IN BOTH DIRECTIONS


WIRE FEED CALIBRATION

Due to INPUT LINE VOLTAGE varia-tions supplied to the weldingmachine. The WIRE FEED SPEED shouldbe checked for proper operation.

TO CHECK

1) Remove any tension on the driveroll.

2) Turn the wire speed dial (on thefront of the machine) to "0".

3) Activate the torch trigger.

4) The bottom drive roll shouldrotate very slowly(non-jerky).

5) If this proves to be true, noadjustment is required.

IF ADJUSTMENT IS REQUIRED

1) Remove the top cover assemblyfrom the unit.

2) Locate the printed circuitboard(s).

3) Referring to Figure 17, locatethe trim resistor, this islocated in the upper right handcorner of the wire feed PCboard.

4) Turn the wire speed dial (on thefront of the machine) to "0".

5) Remove any tension on the driveroll.

6) Activate the torch trigger.

7) Rotate the trim resistor, backand forth, until the bottomdrive roll moves.

8) Calibrate so the bottom driveroll rotates very slowly (non-jerky).

9) If calibrated correctly thewire speed dial (on the front ofthe machine) should affect thespeed of the drive roll from "0"thru "10".

10)Adjustment is now complete!

TRIMRESISTOR

FIGURE 17. WIRE FEED PC BOARD


3. Move the selector hose to the"MHG7 SPOOL GUN" fitting andtighten.

4. Install the thread cap (removedin step 1) on the "MIG STANDARD"fitting to prevent dirt andcontaminants from entering theunused gas line.

5. Unplug the wire feed motor plugfrom the function receptacle.

6. Plug the MHG7 spool gun controlcable plug into the welderfunction receptacle.

7. Remove the torch selector cablefrom the welder positive (+)weld connector.

8. Plug the MHG7 gun cable fittinginto the welder positive (+)weld connector.

NOTEMake sure the gas regula-tor and welder gas hoseare connected to a cylin-der of the proper shield-ing gas - 100% argon foraluminum welding; 75% ar-gon + 25% CO2 for steelwelding. 98% argon + 2% O2is recommended for stain-less steel welding.

9. Follow the operating instruc-tions in the MHG7 manual(FormWC5120).

10.To change back to standard MIGoperation, reverse the proce-dure.

CONNECTING TIGIT2 OR MHG7SPOOL GUN

CHANGING FROM STANDARD MIG OPERATIONTO TIGIT2 OPERATION

1. Unplug the wire feed motor plugfrom the function receptacle.

2. Unplug the torch selector cableand the work (ground) cablefrom the welder front panel.

3. Plug the TIGIT2 torch powercable into the negative (-)weld connector and plug thework (ground) cable into thepositive (+) weld connector.This provides straight polar-ity current as required for TIGwelding.

4. Plug the TIGIT2 torch switchcord into the welder functionreceptacle.

5. Attach the TIGIT2 torch gashose directly to the gas regu-lator.

NOTEPure argon is the shield-ing gas to be used for TIGwelding.

6. Follow the operating instruc-tions in the TIGIT2 manual(Form WC5227).

7. To change back to MIG opera-tion, reverse the procedure.

CHANGING FROM STANDARD MIG OPERATIONTO MHG7 SPOOL GUN OPERATION

All current model MIG machinesare equipped with bulkhead gasfittings for quick and easychangeover from standard MIG op-eration to spool gun operation.

1. Remove the thread cap from the"MHG7 SPOOL GUN" fitting.

2. Unscrew the selector hose fromthe "MIG STANDARD" fitting.

FIG. 18. BULKHEAD CONNECTIONS

LABELWIRE FEED

MOTOR

BULKHEADFITTINGS

SELECTORHOSE

THREADCAP

WIRE FEEDMOTORPLUG(PLUGGEDINTOFUNCTIONRECEPTACLE)


The MIG torch liner providedwith the MP140 is designed for wirediameters from .035 thru .045. Ifsmaller wire diameters are to befed and or there is a problem (i.e.clog, kink, etc.), a liner changeis required.

Following is a step by stepguide to aid in liner removal andinstallation.

NOTEWhen removing the welding wirefrom the MIG torch, care shouldbe taken to avoid the wire fromuncoiling from the wire spool.

REMOVING OLD LINER

1. Remove torch assembly from thewelding machine.

2. Place torch assembly on a flatsurface, making sure torch islaying straight as possible.

3. Remove nozzle, bushing insula-tor, contact tip and gas dif-fuser from the front end of thetorch assembly.

4. Loosen set screw located on theconnector end of the torchassembly (see fig. 20).

5. Grip the liner and gas sealfirmly, then pull. The linershould easily slide from thetorch assembly.

INSTALLING NEW LINER

1. Remove the new liner from thepackage.

2. Uncoil liner and lay the linerparallel next to the MIG torchassembly.

3. Adjust the liner stickout lengthto 3/4" as shown in fig. 19.

3/4"

LINERSTICKOUT

GAS SEAL

SET SCREW3/4"

CONNECTORPLUG

1 1/4+"

PROTRUDINGLINER

NECKASSEMBLY

4. Install the new liner into theMIG torch assembly, until gasseal seats flush with the con-nector plug.

5. Tighten set screw. (Do notovertighten), refer to fig. 20.

6. Following the diagram in fig.21, measure out 1 1/4"+ from theneck assembly and cut off theprotruding liner.

7. Debur the cutoff end of theliner to insure unobstructedwire feed.

8. Install the gas diffuser andcontact tip of proper wiresize, tighten with a wrench.

9. Install the bushing insulatoronto the gas diffuser. Spraythe "O" rings with anti-spattercompound for lubrication.

10.Install the TWIST-ON adjust-able nozzle and twist the nozzleduring the installation. Turnto Page 6 for correct nozzleadjustment.

FIGURE 21. TORCH FRONT END

FIGURE 20. TORCH CONNECTOR END

FIGURE 19. LINER STICKOUT

M.I.G. TORCH LINERINSTALLATION (steel only)


PARTS BREAKDOWN - 15 SERIES MIG TORCHTG STYLE FRONT END - STANDARD

WIRE SIZE CONTACT TIP GAS DIFFUSER NOZZLE INSULATOR INSULATOR O-RING

.020 - .025 inch M3-T25 M3T-D M3T-N50 M3T-B M3T-BR.030 inch M3-T30 (1/2" I.D.) (includes o-rings) (3 reqd.).035 inch M3-T35 (1-7/16"

.040 - .047 inch M3-T45 length)

SPECIAL APPLICATION PARTS FOR TG STYLE FRONT ENDSHORT CONTACT TIP (1-1/4" length) LARGER ORIFICE SPOT WELDING NOZZLES

- For Spray Arc Welding NOZZLE Standard Nozzle Low Amp NozzleWIRE SIZE PART NUMBER STYLE PART NUMBER PART NUMBER

.020 - .025 inch M3-ST25 Straight Nozzle Flat Spot M3T-NS1 M3T-NLAS1.030 inch M3-ST30 (3/4 “ I.D.) Inside Corner M3T-NS2 M3T-NLAS2.035 inch M3-ST35 M3T-N75 Outside Corner M3T-NS3 M3T-NLAS3

.040 - .047 inch M3-ST45 Irregular (grind to shape) M3T-NS4 M3T-NLAS4

SG STYLE FRONT END - OPTIONAL

WIRE SIZE CONTACT TIP GAS DIFFUSER NOZZLE ASSEMBLY CUP NOZZLE BODY INS. BUSHING

.020 - .025 inch M3-T25 M3-D M3-NA50 M3-C50 M3-NB M3-B.030 inch M3-T30 (1/2" I.D.).035 inch M3-T35 (1-7/16"

.040 - .047 inch M3-T45 length)

SPECIAL APPLICATION PARTS FOR SG STYLE FRONT ENDSHORT CONTACT TIP (1-1/4" length) LARGER EXTRA LENGTH FRONT END SPOT WELDING FRONT END

- For Spray Arc Welding ORIFICE 1/2" Longer 1" LongerWIRE SIZE PART NUMBER CUP PART NUMBER PART NUMBER PART NUMBER

CUP (1/2" I.D.) M3-C50L M3-C50XL INS. BUSHING M3H-B.020 - .025 inch M3-ST25 Flared CONTACT TIP NOZZLE NUT M3H-NN

.030 inch M3-ST30 Cup .020 - .025 inch M5-T25 M5-LT25 SPOT NOZZLE

.035 inch M3-ST35 (5/8" I.D.) .030 inch M5-T30 M5-LT30 Flat Spot M3H-NS1.040 - .047 inch M3-ST45 M3-C62 .035 inch M5-T35 M5-LT35 Inside Corner M3H-NS2

.040 - .047 inch M5-T45 M5-LT45 Outside Corner M3H-NS3Irregular M3H-NS4

XG STYLE FRONT END - OPTIONAL - RECOMMENDED FOR ALUMINUM WELDING

WIRE SIZE CONTACT TIP GAS DIFFUSER NOZZLE ASSEMBLY CUP NOZZLE BODY INS. BUSHING

.035 inch M5-T35 M35-D M35-NA62 M5-C62 M5-NB M5-B.040 - .047 inch M5-T45 (5/8" I.D.)

(1-15/16"length)

SPECIAL APPLICATION PARTS FOR XG STYLE FRONT ENDLARGER ORIFICE CUP: Straight Cup (3/4" I.D.) ....... M5-C75

SPECIAL FRONT END FOR GASLESS WIRES - OPTIONALINSULATED CONTACT TIP (Tip screw directly into torch neck - no gas diffuser is required) (1-15/16" length)

WIRE SIZE PART NUMBER.040 - .047 inch M5HGL-045

LINERS & SEALS - FOR STEEL WELDING

ORDER NUMBERWIRE TORCHSIZE LENGTH LINER W/SEAL SEAL ONLY

.020-.030 inch 10 feet M103L-B M3LS-B (Blue)

10 feet M104L-N.035-.045 inch M4LS-N (Natural)

12 feet M124L-N

LINERS & SEALS - FOR ALUMINUM WELDINGORDER NUMBER

WIRE TORCH LINER SEAL HEATSHIELDSIZE LENGTH W/SEAL ONLY ONLY

.035 inch 10 feet M103AL M3-6ALS M3-THS

3/64 inch 10 feet M104AL M3-6ALS M3-THS


PARTS BREAKDOWN - 15 SERIES MIG TORCH (Cont.)

M3-402 M3-402

M1-401

TORCH NECK GROUP

M3-112M3-119 M3-120*

M3-101B*

M3-405M3-200B ASSEMBLY (2 REQD.)

M3-201BM3-203

(2 REQD.)M3-214

M3-202 M3-211

M3-212 M3-213

M3-407(OPTIONAL)

QUICK CONNECTOR GROUP

M3-406M3-309 (2 REQD.)(2 REQD.)

M3-307

M3-301A M3-305A*

M3-308 M3-306 M3-120*(2 REQD.)

M3-310A

PART NO. DESCRIPTION (SYMBOL)TORCH NECK GROUP

M3-101B...... TORCH NECK *M3-112 ........ NECK INSULATORM3-119 ........ LOCK SCREW - SWITCH HOUSINGM3-120 ........ FERRULE *

M3-200B...... SWITCH ASSEMBLYCONSISTING OF:

M3-201B...... SWITCH HOUSINGM3-202 ........ SWITCH (S1)M3-203 ........ SWITCH SCREW (2 REQUIRED)M3-211 ........ TRIGGER - WITH ADJUSTING SCREWM3-212 ........ TRIGGER ADJUSTING SCREW (ONLY)M3-213 ........ TRIGGER PINM3-214 ........ TRIGGER SPRING

QUICK CONNECTOR GROUPM3-120 ........ FERRULE *M3-301A ..... CONNECTOR HOUSINGM3-305A ..... CONNECTOR STEM *M3-306 ........ CONNECTOR PLUG

- WITH SETSCREW & O-RINGSM3-307 ........ SETSCREW (ONLY)M3-308 ........ O-RING (ONLY) (2 REQUIRED)M3-309 ........ TERMINAL - CONNECTOR CONTACT

(2 REQUIRED)M3-310A ..... BOOT / CABLE SUPPORT

M1-401 ........ HANDLEM3-402 ........ HANDLE SCREW (2 REQUIRED)M3-405 ........ TERMINAL - TORCH END

(2 REQUIRED)M3-406 ........ TERMINAL - CONNECTOR END

(2 REQUIRED)M3-407 ........ HANGING BRACKET (OPTIONAL)

M1510CBL... 10 FOOT CABLE *M1512CBL... 12 FOOT CABLE *

M1510CBL*M1512CBL*

NOTES:

* BECAUSE SPECIAL TOOLSAND PROCEDURES AREREQUIRED TO PROPERLYINSTALL THE CABLE ONTHE TORCH NECK ANDTHE CONNECTOR STEM,ITEMS WITH THE ASTERICKARE AVAILABLE FACTORYINSTALLED ONLY.

TORCH REBUILD PROGRAM15 SERIES TORCHES CANBE REBUILT BY THEFACTORY FOR A NOMINALLABOR + PARTS CHARGE.


OPTIONSTIGIT2

MHG7

ONE POUND SPOOL GUNFOR ALUMINUM MIG WELDING

WITH SYSTEMATICSMIG COMBINATION UNITS

(MP140, MP175 & MP250)

The MHG7 (Motorized Hand Gun System) is a compact, light-in-weight,easy to operate MIG welding system designed for aluminum welding. Itwill feed .030", .035" or 3/64" diameter wire from 4 inch spools. Thestandard cable is 25 feet in length. 35 foot and 50 foot cables are optional.The wire speed control knob is in the gun handle.

With the following options, the MHG7 can be used to weld steel orstainless steel (.030" - .035" diameter wire sizes).

HG-160K Knurled Drive Roll - for .030" - .035" steel wireM5-T30 Contact Tip - for .030" steel wire

or M5-T35 Contact Tip - for .035" steel wire

SPECIFICATIONSPart Number ....................... MHG7

Gun Rating ......................... 200 Amps @ 100% duty cycle250 Amps @ 60% duty cycle

Wire Feed Speed Range..... 50 to 650 inches per minute

Cooling Method ................. Air (gas)

MHG7 SYSTEM COMPONENTS1 each MHG-7 Spool Gun1 each HGC5-25 Hand Gun Cable Assembly

with fittings - 25 foot length7 (total) MG-T series Contact Tip (1 installed in gun)

2 - .030 (MG-T30)3 - .035 (MG-T35)2 - 3/64 (MG-T364)

1 each M35-NA62 Nozzle Assembly(installed on gun)

1 each M35-D Gas Diffuser(installed on gun)

CONTENTS OF TIGIT21 each TIG Torch with built-in valve1 each Locking Electric Switch with 14 foot cord

(installed on torch)1 each 12-1/2 foot Power Cable with Connector

(installed on torch)1 each 15 foot Gas Hose with fitting (installed on torch)3 each 3C332 Collet - for 3/32" tungsten3 each 3C418 Collet - for 1/8" tungsten2 each 3CB332 Collet Body - for 3/32" tungsten2 each 3CB418 Collet Body - for 1/8" tungsten2 each 3A6 Gas Cup - 3/8" orifice6 each 3A7 Gas Cup - 7/16" orifice2 each 3A8 Gas Cup - 1/2" orifice1 each 300L Long Backcap3 each 3/32" X 3" Tungsten Electrode3 each 1/8" X 3" Tungsten Electrode

NOW! TIG WELD WITH YOURSYSTEMATICS MIG WELDING MACHINE

(MP140, MP175 & MP250)

The TIG Welding Process is used to produce the highest quality,porosity-free welds. The TIGIT2 adds TIG Welding capabilities to yourSystematics MIG Welder.

The TIGIT2 is designed for Tungsten-Inert Gas (TIG) welding with DirectCurrent, Straight Polarity (DCSP) on steel, stainless steel, chrome-moly,copper or cast iron (12 Gauge (.105") minimum plate thickness).

THE TIGIT2 WILL NOT WELD ALUMINUM.The TIGIT2 consists of a 200 amp, gas cooled TIG torch with built-in gascontrol valve and remote on-off switch, 12-1/2 or 25 foot cable assemblyand accessories required for putting the unit into service.

SPECIFICATIONSPart Number............... TIGIT2-12 (12-1/2' cable)

TIGIT2-25 (25' cable)

Torch Rating .............. 200 Amps, DCSP

Duty Cycle ................. 100% (reduce duty cycle whenoperating over 200 amps.)

Cooling Method ......... Gas

Shielding GasControl Method...... Gas Valve on Torch

Welding CurrentOn-Off Control ...... Locking Switch on Torch


NOTES

Systematics , Inc. 1025 Saunders Lane West Chester, PA. 19380

Documents

OWNER'S MANUAL · tips, gas cups and insulating bushings; (3) damage by accident, force majeure, improper use, neglect, unauthor-ized repair or alteration; (4) anyone other than the