t944c_hob Handler 135 / 175

TM-944C
October 2003
Handler 135 (500 414) Eff. w/Serial No.
LB096205
Handler 175 (500 416) Eff. w/Serial No.
LB075197
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
Handler 135 / 175
And H-10 Gun
Visit our website at
www.HobartWelders.com
TABLE OF CONTENTS
SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-2. Servicing Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-3. California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1-4. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 2 − SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-2. Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2-3. Volt-Ampere Curves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 3 − INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-1. Installing Welding Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-2. Installing Work Clamp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-3. Process/Polarity Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-4. Changing Polarity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-5. Installing Gas Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-6. Selecting A Location And Connecting Input Power For 115 VAC Model . . . . . . . . . . . . . . . . . . . . . . . . .
3-7. Selecting A Location And Connecting Input Power For 230 VAC Model . . . . . . . . . . . . . . . . . . . . . . . .
3-8. Electrical Service Guide For 230 VAC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-9. Installing Wire Spool And Adjusting Hub Tension . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3-10. Threading Welding Wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 4 − OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-1. Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2. Weld Parameter Chart For 115 VAC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-3. Weld Parameter Chart For 230 VAC Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 5 − THEORY OF OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 6 − TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-1. Troubleshooting Table . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-2. Troubleshooting Circuit Diagram For Welding Power Source (115 VAC Model) . . . . . . . . . . . . . . . . . .
6-3. Troubleshooting Circuit Diagram For Welding Power Source (230 VAC Model) . . . . . . . . . . . . . . . . . .
6-4. Control Board PC1 Testing Information (115 VAC Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-5. Control Board PC1 Test Point Values (115 VAC Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-6. Control Board PC1 Testing Information (230 VAC Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6-7. Control Board PC1 Test Point Values (230 VAC Model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 7 − MAINTENANCE &TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-2. Overload Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-3. Drive Motor Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-4. Changing Drive Roll Or Wire Inlet Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-5. Replacing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-6. Cleaning Or Replacing Gun Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7-7. Replacing Switch And/Or Head Tube . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 8 − ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
SECTION 9 − PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING
1-1. Symbol Usage
safety_stm 5/97
Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.
This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.
Y Marks a special safety message.
. Means “Note”; not safety related.
1-2. Servicing Hazards
Y The symbols shown below are used throughout this manual to
call attention to and identify possible hazards. When you see
the symbol, watch out, and follow the related instructions to
avoid the hazard.
Y Only qualified persons should service, test, maintain, and repair this unit.
FLYING METAL can injure eyes.
D Wear safety glasses with side shields or face
shield during servicing.
D Be careful not to short metal tools, parts, or
wires together during testing and servicing.
Y During servicing, keep everybody, especially children, away.
HOT PARTS can cause severe burns.
ELECTRIC SHOCK can kill.
D Do not touch live electrical parts.
D Turn Off welding power source and wire feeder
and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from receptacle, or stop engine before servicing unless the procedure specifically requires an energized unit.
D
Insulate yourself from ground by standing or working on dry insulating mats big enough to prevent contact with the ground.
D
Do not leave live unit unattended.
D
If this procedure requires an energized unit, have only personnel
familiar with and following standard safety practices do the job.
D
When testing a live unit, use the one-hand method. Do not put both
hands inside unit. Keep one hand free.
D
Disconnect input power conductors from deenergized supply line
BEFORE moving a welding power source.
SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.
D
D Do not touch hot parts bare handed.
D Allow cooling period before working on welding
gun or torch.
EXPLODING PARTS can cause injury.
D Failed parts can explode or cause other parts to
explode when power is applied to inverters.
D Always wear a face shield and long sleeves
when servicing inverters.
SHOCK HAZARD from testing.
D Turn Off welding power source and wire feeder
or stop engine before making or changing meter lead connections.
D Use at least one meter lead that has a selfretaining spring clip such as an alligator clip.
D Read instructions for test equipment.
Turn Off inverter, disconnect input power, and discharge input
capacitors according to instructions in Maintenance Section before
touching any parts.
FALLING UNIT can cause injury.
STATIC (ESD) can damage PC boards.
D Put on grounded wrist strap BEFORE handling
boards or parts.
D Use proper static-proof bags and boxes to
store, move, or ship PC boards.
FIRE OR EXPLOSION hazard.
MOVING PARTS can cause injury.
D Do not place unit on, over, or near combustible
surfaces.
D Do not service unit near flammables.
Handler 135 / 175
D Use lifting eye to lift unit only, NOT running
gear, gas cylinders, or any other accessories.
D Use equipment of adequate capacity to lift and
support unit.
D If using lift forks to move unit, be sure forks are
long enough to extend beyond opposite side of
unit.
Return To Table Of Contents
D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards
closed and securely in place.
TM-944 Page 1
MOVING PARTS can cause injury.
D Keep away from moving parts.
D Keep away from pinch points such as drive
rolls.
MAGNETIC FIELDS can affect pacemakers.
D Pacemaker wearers keep away from servicing
areas until consulting your doctor.
H.F. RADIATION can cause interference.
D High-frequency (H.F.) can interfere with radio
navigation, safety services, computers, and
communications equipment.
D Have only qualified persons familiar with
electronic equipment install, test, and service
H.F. producing units.
D The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation.
D If notified by the FCC about interference, stop using the
equipment at once.
D Have the installation regularly checked and maintained.
D Keep high-frequency source doors and panels tightly shut, keep
spark gaps at correct setting, and use grounding and shielding to
minimize the possibility of interference.
READ INSTRUCTIONS.
OVERUSE can cause OVERHEATING.
D Use MILLER Testing Booklet (Part No. 150
853) when servicing this unit.
D Consult the Owner’s Manual for welding safety
precautions.
D Use only genuine MILLER replacement parts.
D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before
starting to weld again.
D Do not block or filter airflow to unit.
1-3. California Proposition 65 Warnings
Y Welding or cutting equipment produces fumes or gases which
contain chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California Health &
Safety Code Section 25249.5 et seq.)
For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of
California to cause cancer, birth defects, or other reproductive
harm.
Y Battery posts, terminals and related accessories contain lead
and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.
For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known
to the State of California to cause cancer, birth defects, and
other reproductive harm.
1-4. EMF Information
Considerations About Welding And The Effects Of Low Frequency
Electric And Magnetic Fields
Welding current, as it flows through welding cables, will cause electromagnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to powerfrequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.
To reduce magnetic fields in the workplace, use the following
procedures:
TM-944 Page 2
1. Keep cables close together by twisting or taping them.
2. Arrange cables to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep welding power source and cables as far away from operator as practical.
5. Connect work clamp to workpiece as close to the weld as possible.
About Pacemakers:
Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.
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Handler 135 / 175
SECTION 2 − SPECIFICATIONS
2-1. Specifications
A. 115 VAC Model
Rated Welding
Output
Amperage
Range
Maximum OpenCircuit Voltage
DC
KVA
KW
Weight
W/ Gun
Overall
Dimensions
Length: 18-7/8 in
(479 mm)
90 A @ 19 Volts DC,
20% Duty Cycle
30 − 135
20
2.90
2.50
15*
2.20*
1.77*
28
63 A @ 21 Volts DC,
20% Duty Cycle*
Wire Type
And Dia
Amperes Input at
Rated Load Output
115 V, 60 Hz, SinglePhase
55 lb
(25 kg)
Width: 10-5/8 in
(270 mm)
Height: 12-3/8 in
(314 mm)
Solid/
Stainless
Flux Cored/
Aluminum
Wire Feed Speed Range
.024 − .030 in
(0.6 − 0.8 mm)
.030 − .035 in
(0.8 − 0.9 mm)/
.030
(0.8 mm)
370 − 840 IPM (9.2 − 21.8 m/min) At No Load
50 − 800 IPM (1.3 − 20.3 m/min) Feeding Wire
* CSA Rating
B. 230 VAC Model
Rated Welding
Output
130 A @ 20 Volts
DC, 30% Duty Cycle
At 60 Hz Input − 20%
Duty Cycle At 50 Hz
Input
Wire Type
And Dia
Handler 135 / 175
Amperage
Range
Maximum OpenCircuit Voltage
DC
Amperes Input at
Rated Load Output
230 V, 50/60 Hz,
Single-Phase
KVA
KW
Weight
W/ Gun
Overall
Dimensions
Length: 18-7/8 in
(479 mm)
30 − 175
30
19.5
4.60
3.75
65 lb
(29.5 kg)
Width: 10-5/8 in
(270 mm)
Height: 12-3/8 in
(314 mm)
Solid/
Stainless
Flux Cored/
Aluminum
Wire Feed Speed Range
.024 − .035 in
(0.6 − 0.9 mm)
.030 − .045 in
(0.8 − 1.2 mm)/
.030 − .035 in
(0.8 − 0.9 mm)
350 − 900 IPM (9.0 − 23.0 m/min) At No Load
50 − 850 IPM (1.3 − 20.3 m/min) Feeding Wire
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TM-944 Page 3
2-2. Duty Cycle And Overheating
Duty Cycle is percentage of 10 minutes that unit can weld at rated load
without overheating.
If unit overheats, thermostat(s)
opens, output stops, and cooling
fan runs. Wait fifteen minutes for
unit to cool. Reduce amperage or
duty cycle before welding.
C. 115 VAC Model
200
Output Amperes
135
Y Exceeding duty cycle can
damage unit or gun and void
warranty.
100
80
60
40
20
10
1
2
4
6
8 10
40
20
60
80 100
Duty Cycle %
20% duty cycle at 90 amps
2 Minutes Welding
8 Minutes Resting
D. 230 VAC Model
Output Amperes
200
130
100
80
60
40
20
10
10
20
30
40
50
60
70 80
100
Duty Cycle %
30% duty cycle at 130 amps, 60 Hz
20% duty cycle at 130 amps, 50 Hz
3 Minutes Welding
7 Minutes Resting
Overheating
A or V
0
15
OR
Reduce Duty Cycle
Minutes
duty1 4/95 − 196 617 / 196 618
TM-944 Page 4
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Handler 135 / 175
2-3. Volt-Ampere Curves
The volt-ampere curves show the
minimum and maximum voltage
and amperage output capabilities of
the welding power source. Curves
of other settings fall between the
curves shown.
E. 115 VAC Model
30.0
OUTPUT VOLTS
25.0
20.0
Range 4
15.0
Range 3
Range 2
Range 1
10.0
5.0
0.0
0
10
20
30
40
50
60
70
80
90
100 110 120 130 140 150 160
LOAD AMPS
F. 230 VAC Model
30.0
25.0
Range 4
OUTPUT VOLTS
20.0
Range 3
15.0
Range 2
Range 1
10.0
5.0
0.0
0
10
20
30
40
50
60
70
80
90
100 110
120 130 140 150 160 170 180 190 200
LOAD AMPS
ssb1.1 10/91 − 196 608 / 196 609
Handler 135 / 175
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TM-944 Page 5
SECTION 3 − INSTALLATION
3-1. Installing Welding Gun
1
2
3
4
Loosen thumbscrew. Insert gun
end through opening until it bottoms
against drive assembly. Tighten
thumbscrew.
4
2
Drive Assembly
Gun Securing Thumbscrew
Gun End
3
Gun Trigger Leads
Insert leads, one at a time, through
gun opening on front panel.
Connect female friction terminals to
matching male terminals in unit.
Polarity is not important.
Close door.
1
Ref. 802 440-A
3-2. Installing Work Clamp
3
1
2
1
2
3
4
5
Nut
Work Cable From Unit
Work Clamp
Screw
Work Clamp Tabs
Bend tabs around work cable.
Tools Needed:
5
4
3/8, 7/16 in
TM-944 Page 6
802 456
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Handler 135 / 175
3-3. Process/Polarity Table
Cable Connections
Process
Polarity
Cable To Gun
Cable To Work
GMAW − Solid wire with shielding gas
DCEP − Reverse polarity
Connect to positive (+) output terminal
Connect to negative (−) output
terminal
FCAW − Self-shielding wire −
no shielding gas
DCEN − Straight Polarity
Connect to negative (−)
output terminal
Connect to positive (+) output
terminal
3-4. Changing Polarity
1
CHANGING
POLARITY
2
DCEN
Electrode Negative
For Flux Core Wire
Lead Connections For Direct
Current Electrode Negative
(DCEN)
Lead Connections For Direct
Current Electrode Positive
(DCEP)
Always read and follow wire
manufacturer’s recommended polarity, and see Section 3-3.
Close door.
1
DCEP
Electrode Positive
For Solid Wire
2
Ref. 209 228 / Ref. 209 229
Handler 135 / 175
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TM-944 Page 7
3-5. Installing Gas Supply
Obtain gas cylinder and chain to
running gear, wall, or other
stationary support so cylinder
cannot fall and break off valve.
. DO NOT use Argon/Mixed gas regulator/flowmeter
with CO2 shielding gas. See Parts List for optional
CO2 gas regulator/flowmeter.
1
4
2
1
Cap
2
Cylinder Valve
Remove cap, stand to side of valve,
and open valve slightly. Gas flow
blows dust and dirt from valve.
Close valve.
3
Cylinder
4
Regulator/Flowmeter
Install so face is vertical.
7
3
5
5
Regulator/Flowmeter Gas
Hose Connection
6
Welding Power Source Gas
Hose Connection
Connect customer supplied gas
hose between regulator/flowmeter
gas hose connection, and fitting on
rear of welding power source.
7
Argon Gas Or
Mixed Gas
Flow Adjust
Typical flow rate is 20 cfh (cubic
feet per hour). Check wire
manufacturer’s recommended flow
rate.
6
Tools Needed:
5/8, 1-1/8 in
Ref. 802 028-A / 802 441
TM-944 Page 8
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Handler 135 / 175
3-6. Selecting A Location And Connecting Input Power For 115 VAC Model
1
2
1
18 in
(460 mm)
Rating Label
Grounded Receptacle
A 115 volt, 20 ampere individual
branch circuit protected by time-delay fuses or circuit breaker is required.
2
3
3
Plug From Unit
Select extension cord of 14 AWG
for up to 50 ft (15 m) or 12 AWG for
50 up to 200 ft (61 m).
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
18 in
(460 mm)
802 442-A
Handler 135 / 175
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TM-944 Page 9
3-7. Selecting A Location And Connecting Input Power For 230 VAC Model
1
Rating Label
Supply correct input power.
2
3
Plug (NEMA 6-50P)
Receptacle (NEMA 6-50R)
Connect plug to receptacle.
4
18 in (457 mm) of
space for airflow
Line Disconnect Device
See Section 3-8.
4
Y Special installation may be
required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 20.
L1
Y Always connect
grounding
conductor first.
L2
= GND/PE
1
2
3
L1
L2
230 VAC, 1
Y Do not move or operate unit
where it could tip.
ssb2.2* 1/94 − 802 443-A / Ref. 802 085
TM-944 Page 10
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Handler 135 / 175
3-8. Electrical Service Guide For 230 VAC Model
Input Voltage
230
Input Amperes At Rated Output
20
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
20
Min Input Conductor Size In AWG/Kcmil
14
Max Recommended Input Conductor Length In Feet (Meters)
66 (20)
Min Grounding Conductor Size In AWG/Kcmil
12
Reference: 1996 National Electrical Code (NEC)
S-0092-J
3-9. Installing Wire Spool And Adjusting Hub Tension
Installing 4 in (102 mm) Wire Spool
When a slight force is needed
to turn spool, tension is set.
Installing 8 in (203 mm) Wire Spool
Adapter used with
8 in (203 mm)
spool only.
When a slight force is needed
to turn spool, tension is set.
Retaining ring used
with 8 in (203 mm)
spool only.
Tools Needed:
1/2 in
803 012 / 803 013-B / Ref. 802 971-C
Handler 135 / 175
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TM-944 Page 11
3-10. Threading Welding Wire
1
2
3
4
5
6
Wire Spool
Welding Wire
Inlet Wire Guide
Pressure Adjustment Knob
Drive Roll
Gun Conduit Cable
Lay gun cable out straight.
4
6
Tools Needed:
1
2
3
5
. Hold wire tightly to keep it
from unraveling.
4 in
(102 mm)
6 in
(150 mm)
Open pressure assembly.
Pull and hold wire; cut off end.
Push wire thru guides into gun;
continue to hold wire.
. Use pressure indicator
Tighten
scale to set a desired
drive roll pressure.
1
2
3
4
Pressure
Indicator
Scale
INPUT
POWER
Be sure that wire is positioned
in proper feed roll groove.
Close and tighten pressure
assembly, and let go of wire.
Remove gun nozzle and contact tip.
Turn power on.
Tighten
WOOD
Press gun trigger until wire comes
out of gun.
Be sure that tip matches wire diameter.
Reinstall contact tip and nozzle.
1
2
3
4
Feed wire to check drive roll pressure.
Tighten knob enough to prevent slipping.
Cut off wire. Close door.
Ref. 802 444-C
TM-944 Page 12
Return To Table Of Contents
Handler 135 / 175
SECTION 4 − OPERATION
4-1. Controls
1
Voltage Switch
The higher the selected number,
the thicker the material that can be
welded (see weld setting label in
welding power source or Sections
4-2 and 4-3, as applicable). Do not
switch under load.
. Switch must “click” into detent
position 1, 2, 3, 4, or purge for
proper contact.
2
Voltage Switch - Purge “0”
Position
In purge position, fan runs but there
is no weld output.
3
Wire Speed Control
Use control to select a wire feed
speed. As Voltage switch setting increases, wire speed range also increases (see weld setting label in
welding power source or Sections
4-2 or 4-3, as applicable).
1
2
4
Power Switch
3
4
Ref. 196 082
Handler 135 / 175
Return To Table Of Contents
TM-944 Page 13
4-2. Weld Parameter Chart For 115 VAC Model
Welding
Guide
Settings are approximate.
Adjust as required. Thicker materials
using proper technique, joint preparation, and multiple passes.
Material
Wire T ype,
Being
Welded
and
Polarity Setting
Steel
Flux Core
E71T
can be welded
Suggested
Shielding Gas
20−30 cfh Flow Rate
No Shielding
−1 1
Gas Required
Good for Windy
.035” (0.9 mm)
Solid Wire
C25 Gas Mixture
.024” (0.6 mm)
ER70S−6
75% Argon / 25% CO2
Outdoor
Produces
(DCEP)
Better
less Spatter
.024” (0.6 mm)
100%
ER70S−6
CO2
.030” (0.8 mm)
(DCEP)
Stainless
Stainless
Steel
Steel
.024” (0.6 mm)
T ri−Mix
90% He/7.5%
(DCEP)
Aluminum**
Ar/2.5%
100% Argon**
(DCEP)
Match feedroll groove to diameter of wire being used.
Set Tension Knob Setting to 3 at Start.
**Aluminum
TM-944 Page 14
tension
wire is relatively
per instructions
soft so feedability
.030” (0.8 mm)
Appearance
Solid Wire
Adjust
.030” (0.8 mm)
or
Applications
(DCEN)
Aluminum
Diameter
of Wire
Being Used
in the manual.
is not as good.
Make
CO2
.030” (0.8 mm)
.030” (0.8 mm)
CAUTION!
Do not change
Knob position
sure that hub tension
Return To Table Of Contents
V oltage Switch
while welding.
is not too tight and
Handler 135 / 175
for 115 Volt Wire Welding
Package
Recommended
V oltage and Wire Speed Settings for Thickness
of Metal Being Welded.
Number on Left of Slash is Voltage Setting / Number on Right of Slash is Wire Feed Setting.
22 gauge
(.8 mm)
−−−
18 gauge
(1.2 mm)
16 gauge
(1.6 mm)
1/8 inch
(3.2 mm)
3/16 inch
(4.8 mm)
1/10
1/20
3/30
4/40
−−−
−−−
1/10
3/10
4/30
1/10
1/20
2/30
4/65
−−−
−−−
2/10
3/30
4/50
−−−
−−−
2/10
2/15
4/40
−−−
−−−
3/10
4/10
4/20
−−−
−−−
2/30
3/40
4/50
−−−
−−−
2/15
3/10
4/30
−−−
−−−
−−−
−−−
4/90**
−−−
CHANGING
POLARITY
DCEN
Electrode Negative
For Flux Core Wire
DCEP
Electrode Positive
For Solid Wire
Wire Speed listed is a starting value only − Wire Speed setting can be
fine−tuned while welding.
Wire Speed also depends on other variables
such as stick out, travel speed,
keep torch as straight
as possible.
A ”push
angle”
weld angle, cleanliness
for the torch is normally
of metal, etc.
recommended.
209 228
Handler 135 / 175
Return To Table Of Contents
TM-944 Page 15
4-3. Weld Parameter Chart For 230 VAC Model
Welding
Guide
Settings are approximate.
Adjust as required. Thicker materials
using proper technique, joint preparation, and multiple passes.
Material
Wire T ype,
Being
Welded
and
Polarity Setting
Steel
Flux Core
E71T
can be welded
Suggested
Shielding Gas
20−30 cfh Flow Rate
No Shielding
−1 1
Gas Required
Good for Windy
Diameter
of Wire
Being Used
.030” (0.8 mm)
.035” (0.9 mm)
or
Applications
.045” (1.2 mm)
Solid Wire
C25 Gas Mixture
.024” (0.6 mm)
ER70S−6
75% Argon / 25% CO2
.030” (0.8 mm)
(DCEN)
Outdoor
Produces
(DCEP)
less Spatter
.035” (0.9 mm)
Better Appearance
.024” (0.6 mm)
Solid Wire
100%
ER70S−6
CO2
.030” (0.8 mm)
.035” (0.9 mm)
(DCEP)
Stainless
Stainless
Steel
Steel
.024” (0.6 mm)
90% He/7.5%
(DCEP)
Aluminum**
Aluminum
Match feedroll
Ar/2.5%
100% Argon**
(DCEP)
groove
.030” (0.8 mm)
Tri−Mix
to diameter
TM-944 Page 16
wire is relatively
soft so feedability
.035” (0.9 mm)
.030” (0.8 mm)
.035” (0.9 mm)
of wire being used.
is not as good.
Make
CAUTION!
Do not change
Knob position
Set Tension Knob Setting to 3 at Start.
Adjust tension per instructions
in the manual.
**Aluminum
CO2
sure that hub tension
Return To Table Of Contents
Voltage Switch
while welding.
is not too tight and
Handler 135 / 175
for 230 Volt Wire Welding
Package
Recommended
V oltage and Wire Speed Settings for Thickness
of Metal Being Welded.
Number on Left of Slash is Voltage Setting / Number on Right of Slash is Wire Feed Setting.
22 gauge
(.8 mm)
18 gauge
(1.2 mm)
16 gauge
(1.6 mm)
1/8 inch
(3.2 mm)
3/16 inch
(4.8 mm)
1/4 inch
(6.4 mm)
1/10
1/30
3/50
3/60
4/80
−−−
−−−
−−−
1/20
3/40
3/50
4/60
−−−
−−−
−−−
2/20
3/40
4/50
1/20
1/45
2/85
3/90
4/100
−−−
1/10
1/30
2/40
3/80
4/85
4/100
−−−
1/20
2/30
3/75
3/80
4/70
1/10
2/30
2/35
3/70
4/85
−−−
−−−
2/20
2/30
3/65
4/40
4/50
−−−
2/10
2/20
3/40
4/30
4/40
−−−
2/20
2/40
3/50
4/90
−−−
−−−
2/10
2/20
2/40
4/80
−−−
−−−
−−−
2/10
2/30
4/70
−−−
−−−
−−−
1/100**
4/100**
−−−
−−−
−−−
−−−
1/95**
4/90**
−−−
−−−
CHANGING
POLARITY
DCEN
Electrode Negative
For Flux Core Wire
DCEP
Electrode Positive
For Solid Wire
Wire Speed listed is a starting value only − Wire Speed setting can be
fine−tuned while welding.
Wire Speed also depends on other variables
such as stick out, travel speed,
keep torch as straight
as possible.
A ”push
angle”
weld angle, cleanliness
for the torch is normally
of metal, etc.
recommended.
209 229
Handler 135 / 175
Return To Table Of Contents
TM-944 Page 17
SECTION 5 − THEORY OF OPERATION
1
Circuit Breaker CB1
Protects unit from an over-current
condition by opening primary power
line.
2
Power Switch S1
Turns unit and fan motor FM on and
off.
3
3
Fan Motor FM
And Transformer
Fan Motor FM And
Transformer
Controlled by power switch S1. Fan
cools internal components, and
transformer
supplies
control
voltage to PC1.
4
5
4
Thermostat
TP1
Gun Trigger
Receptacle RC3
2
Power Switch
S1
Thermostat TP1
If unit overheats, TP1 opens
stopping all weld output.
5
Gun Trigger Receptacle RC3
Connects gun trigger circuit to
welding power source.
6
Control Board PC1
Controls weld output by connecting
primary power to main transformer
T1 through a board-mounted
contactor that is activated by
pressing the gun trigger. PC1 also
regulates wire feed motor speed
with a motor control circuit. Speed
is set by feedback from Wire Feed
Speed Control R1.
7
6
Control Board
PC1
1
Line
L1
Circuit
Breaker CB1
Single-Phase
Line Input
Power
Gas Valve GS1
Controls shielding gas flow.
Pressing gun trigger opens valve.
Neutral Line
(115 VAC Model)
8
Line L2
(230 VAC Models)
Wire Speed Control R1
Controls wire feed motor speed by
providing a reference voltage to
motor control circuit on PC1.
9
Range Switch S2
Allows selection of weld output
voltage.
7
Gas Valve
GS1
10 Main Transformer T1
8
Supplies power to weld output
circuit.
Wire Speed
Control R1
11 Main Rectifier SR1
Changes the ac output from T1 to
full-wave rectified dc output.
12 Output Capacitor C1
Smooths dc weld voltage from main
rectifier SR1.
13 Stabilizer L1
Smooths dc weld current from main
rectifier SR1.
14 Polarity Changeover Block
Terminals allow changing between
DCEP and DCEN processes.
15 Wire Drive Motor
Feeds wire at a speed set by R1.
Pressing gun trigger activates wire
drive motor.
TM-944 Page 18
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Handler 135 / 175
10
9
11
Range Switch
S2
13
Main Rectifier
SR1
Main
Transformer
T1
Stablizer L1
12
Capacitor C1
14
Polarity
Changeover
Block
15
Wire Drive
Motor
Welding Wire
(Electrode)
Work
AC Or DC Control Circuits
Weld Current Circuit
Handler 135 / 175
Return To Table Of Contents
TM-944 Page 19
SECTION 6 − TROUBLESHOOTING
6-1. Troubleshooting Table
. See Section 6-2 or 6-3 for test points and values
and Section 9 for parts location.
Trouble
No weld output; wire does not feed; fan
does not run.
Remedy
Secure power cord plug PLG1 in receptacle (see Section 3-6 or 3-7).
Replace building line fuse or reset circuit breaker if open.
Place Power switch S1 in On position (see Section 4-1).
Reset power source circuit breaker if open (see Section 7-2).
No weld output; wire does not feed; fan
runs.
Rotate Voltage switch S2 out of the Purge (gas only) position.
Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has
cooled (see Section 7-3).
Secure gun trigger leads to receptacle RC3 (see Section 3-1).
Check continuity of gun trigger leads. Repair or replace gun if necessary.
Check Wire Speed control R1 for proper connections and resistance; R1 is 55k ohms ±20%.
Replace R1 if necessary.
Check continuity of Voltage switch S2, and replace if necessary.
Check diodes in main rectifier SR1, and replace if necessary.
Check main transformer T1 for signs of winding failure. Check continuity across windings and check for
proper connections. Check secondary voltages. Replace T1 if necessary.
Check control board PC1 connections and voltages, and replace if necessary.
Check the setting of Voltage switch S2. Machine will not weld if voltage control is set between range
positions. Rotate switch until it “clicks” into a detent position.
Electrode wire feeding stops during
welding.
Straighten gun cable and/or replace damaged parts (see Section 7-6).
Readjust drive roll pressure (see Section 3-10).
Change to proper groove (see Section 7-4).
Readjust wire reel hub tension (see Section 3-9).
Replace contact tip if blocked (see Section 7-5).
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 7-4 and/or 7-6).
Replace drive roll or pressure bearing if worn or slipping (see Section 7-4).
Secure gun trigger leads in receptacle RC3 (see Section 3-1).
Check continuity of gun trigger leads. Repair or replace gun if necessary.
Check and clear any restrictions at drive assembly and liner (see Section 3-10 and/or 7-6).
Release gun trigger and allow gun and motor protection circuitry to reset.
Check T1 for signs of winding failure. Check continuity across each winding and check for proper
connections. Check secondary voltages. Replace T1 if necessary.
Check Control board PC1 and connections, and replace PC1 if necessary (see Section 6-4).
TM-944 Page 20
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Handler 135 / 175
Trouble
No weld output; wire feeds.
Remedy
Connect work clamp to get good metal-to-metal contact.
Replace gun contact tip (see Section 7-5).
Check thumbscrew securing gun end to feedhead adapter and tighten if necessary.
Low weld output.
Connect unit to proper input voltage or check for low line voltage.
Place Voltage switch S2 in desired position (see Section 4-1).
Low or erratic wire speed.
Readjust weld parameter settings.
Change to correct size drive roll.
Readjust drive roll pressure.
Clean or replace wire inlet guide or liner if dirty or plugged (see Section 7-4 and/or 7-6).
Readjust wire reel hub tension.
Check voltage and connections of wire drive motor. Replace motor if necessary.
Improper or no shielding gas flow.
Clean or replace gas hose.
Check shielding gas valve GS1 for proper coil voltage and connections. Check continuity of coil. Replace
GS1 if necessary.
Clear blockage in gun.
Handler 135 / 175
Return To Table Of Contents
TM-944 Page 21
6-2. Troubleshooting Circuit Diagram For Welding Power Source (115 VAC Model)
V1
R3
V8/R5
R1
R2
V9/R6
V6
R4
V2
V7
V10
R7
R8
V3
V4
V11/R9
V5
See also Section 6-4
for PC1 data
Test Equipment Needed:
TM-944 Page 22
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Handler 135 / 175
Voltage Readings
Resistance Values
b)
Tolerance − ±10 % unless
specified
Wiring Diagram − see Section 8
V1
115 volts ac with power cord plugged in
R1-R6 All values for T1 are less than 1 ohm
V2
115 volts ac with Power switch S1 On
R7
V3
24 volts ac with Power switch S1 On
Less than 1 ohm at minimum position of
Wire Speed control R1; 55k ohms at
maximum position of Wire Speed control R1
V4
30 volts dc with Power switch S1 On
R8
Less than 1 ohm
V5
27 volts dc with gun trigger pressed
R9
V6
115 volts ac with gun trigger pressed
Less than 2 ohms with wire feed motor
disconnected from circuit
V7
115 volts ac with gun trigger pressed
V8,
V9
15.5 volts ac with Voltage switch S2
in position 1
17.0 volts ac with Voltage switch S2
in position 2
18.5 volts ac with Voltage switch S2
in position 3
20.5 volts ac with Voltage switch S2
in position 4
a)
V10
V11
20.5 volts dc with Voltage switch S2
in position 1
22.5 volts dc with Voltage switch S2
in position 2
25.0 volts dc with Voltage switch S2
in position 3
27.5 volts dc with Voltage switch S2
in position 4
12 to 19 volts dc from min. to max. of
Wire Speed control R1 with
Voltage switch S2 in position 1
13 to 21 volts dc from min. to max. of
Wire Speed control R1 with
Voltage switch S2 in position 2
15 to 23 volts dc from min. to max. of
Wire Speed control R1 with
Voltage switch S2 in position 3
17 to 26 volts dc from min. to max. of
Wire Speed control R1 with
Voltage switch S2 in position 4
a)
Tolerance − ±10% unless specified
b)
Turn Off unit and disconnect input
power before checking resistance
Wire Speed And Drive Motor RPM Feeding Wire*
Voltage
Wire Diameter Switch S2
And Type
Position
.030/.035 Solid
or Flux Core
Min.
RPM
Max.
RPM
Min.
IPM
Max.
IPM
1
50
155
190
585
2
60
170
230
640
3
70
190
265
715
4
80
215
300
800
*All tests done with .030-.035 liner in H-10 model 10 foot welding gun, smooth
groove drive roll.
Values are nominal depending on drive roll pressure and spool hub tension.
Drive Motor RPM At No Load*
Voltage
Switch S2
Position
Min.
RPM
Max.
RPM
1
95
170
2
110
180
3
125
200
4
140
225
*All tests done with the pressure assembly
open, not feeding wire. Values are nominal.
194 324-C
Handler 135 / 175
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TM-944 Page 23
6-3. Troubleshooting Circuit Diagram For Welding Power Source (230 VAC Model)
V1
R3
V8/R5
R1
R2
V10
V9/R6
V6
R4
V2
V7
R7
R8
V3
V4
V11/R9
V5
See also Section 6-6
for PC1 data
Test Equipment Needed:
TM-944 Page 24
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Handler 135 / 175
Voltage Readings
Resistance Values
b)
Tolerance − ±10 % unless
specified
Wiring Diagram − see Section 8
V1
230 volts ac with power cord plugged in
R1-R6 All values for T1 are less than 1 ohm
V2
230 volts ac with Power switch S1 On
R7
V3
24 volts ac with Power switch S1 On
Less than 1 ohm at minimum position of
Wire Speed control R1; 55k ohms at
maximum position of Wire Speed control R1
V4
30 volts dc with Power switch S1 On
R8
Less than 1 ohm
V5
27 volts dc with gun trigger pressed
R9
V6
230 volts ac with gun trigger pressed
Less than 2 ohms with wire feed motor
disconnected from circuit
V7
230 volts ac with gun trigger pressed
V8,
V9
13.9 volts ac with Voltage switch S2
in position 1
16.5 volts ac with Voltage switch S2
in position 2
19.1 volts ac with Voltage switch S2
in position 3
21.7 volts ac with Voltage switch S2
in position 4
a)
V10
V11
18.9 volts dc with Voltage switch S2
in position 1
22.6 volts dc with Voltage switch S2
in position 2
25.1 volts dc with Voltage switch S2
in position 3
29.8 volts dc with Voltage switch S2
in position 4
7.0 to 17.5 volts dc from min. to max. of
Wire Speed control R1 with
Voltage switch S2 in position 1
10.0 to 20.5 volts dc from min. to max. of
Wire Speed control R1 with
Voltage switch S2 in position 2
12.7 to 24.0 volts dc from min. to max. of
Wire Speed control R1 with
Voltage switch S2 in position 3
15.5 to 27.0 volts dc from min. to max. of
Wire Speed control R1 with
Voltage switch S2 in position 4
a)
Tolerance − ±10% unless specified
b)
Turn Off unit and disconnect input
power before checking resistance
Wire Speed And Drive Motor RPM Feeding Wire*
Voltage
Wire Diameter Switch S2
And Type
Position
.030/.035 Solid
or Flux Core
Min.
RPM
Max.
RPM
Min.
IPM
Max.
IPM
1
40
135
150
510
2
50
160
190
600
3
70
190
260
700
4
90
205
340
800
*All tests done with .030-.035 liner in H-10 model 10 foot welding gun, smooth
groove drive roll.
Values are nominal depending on drive roll pressure and spool hub tension.
Drive Motor RPM At No Load*
Voltage
Switch S2
Position
Min.
RPM
Max.
RPM
1
80
150
2
110
175
3
135
200
4
160
235
*All tests done with the pressure assembly
open, not feeding wire. Values are nominal.
194 325-A
Handler 135 / 175
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TM-944 Page 25
6-4. Control Board PC1 Testing Information (115 VAC Model)
Be sure plugs are secure before
testing. See Section 6-5 for specific
values during testing.
1
2
3
4
5
6
7
8
9
10
11
1
5
4
Control Board PC1
Receptacle RC1
Receptacle RC2
Receptacle RC4
Receptacle RC5
TP-A
TP-B
TP-C
TP-D
TP-E
TP-F
3
2
6
9
10
8
7
11
Test Equipment Needed:
802 779 / 195 888-B
TM-944 Page 26
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Handler 135 / 175
6-5. Control Board PC1 Test Point Values (115 VAC Model)
a) Tolerance
specified
PC1 Voltage Readings
−
±10% unless
b) Reference − to circuit common
unless noted
Voltage Readings:
a) Tolerance − ±10% unless specified
b) Reference − as noted
Receptacle
Pin
RC1
1
24 volts ac input, reference to pin RC1-2
2
24 volts ac input, reference to pin RC1-1
3,4
Value
35 volts dc with transformer thermostat closed, reference to pin TP-C
5
35 volts dc with gun trigger closed, reference to TP-C
6
35 volts dc, reference to TP-C
7
15.0 volts dc, reference to TP-C
8
15.0 to 6.5 volts dc from min to max of Wire Feed speed control R1, Reference for TP-C
1
Negative (−) welder output voltage
2
Not used
3
Positive (+) output to wire drive motor
4
Negative (−) output to wire drive motor
RC4
−−
Circuit common
RC5
−−
Positive (+) welder output voltage with gun trigger closed
TP
A
35 volts dc, reference to TP-C
TP
B
15 volts dc, reference to TP-C
TP
C
Circuit common
TP
D
30 volts dc, reference to TP-C
TP
E
15 volts dc with Wire Speed control R1 at minimum, reference to TP-C
TP
F
11 volts dc with Wire Speed control R1 at maximum, reference to TP-C
RC2
Handler 135 / 175
Return To Table Of Contents
TM-944 Page 27
6-6. Control Board PC1 Testing Information (230 VAC Model)
Be sure plugs are secure before
testing. See Section 6-7 for specific
values during testing.
1
2
3
4
5
6
7
8
9
10
11
1
4
5
Control Board PC1
Receptacle RC1
Receptacle RC2
Receptacle RC4
Receptacle RC5
TP-A
TP-B
TP-C
TP-D
TP-E
TP-F
3
2
6
9
10
8
7
11
Test Equipment Needed:
802 779 / 195 889-B
TM-944 Page 28
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Handler 135 / 175
6-7. Control Board PC1 Test Point Values (230 VAC Model)
a) Tolerance
specified
PC1 Voltage Readings
−
±10% unless
b) Reference − to circuit common
unless noted
Voltage Readings:
a) Tolerance − ±10% unless specified
b) Reference − as noted
Receptacle
Pin
RC1
1
24 volts ac input, reference to pin RC1-2
2
24 volts ac input, reference to pin RC1-1
3,4
Value
35 volts dc with transformer thermostat closed, reference to pin TP-C
5
35 volts dc with gun trigger closed, reference to TP-C
6
35 volts dc, reference to TP-C
7
15.0 volts dc, reference to TP-C
8
15.0 to 6.5 volts dc from min to max of Wire Feed speed control R1, Reference for TP-C
1
Negative (−) welder output voltage
2
Not used
3
Positive (+) output to wire drive motor
4
Negative (−) output to wire drive motor
RC4
−−
Circuit common
RC5
−−
Positive (+) welder output voltage with gun trigger closed
TP
A
35 volts dc, reference to TP-C
TP
B
15 volts dc, reference to TP-C
TP
C
Circuit common
TP
D
30 volts dc, reference to TP-C
TP
E
15 volts dc with Wire Speed control R1 at minimum, reference to TP-C
TP
F
11 volts dc with Wire Speed control R1 at maximum, reference to TP-C
RC2
Handler 135 / 175
Return To Table Of Contents
TM-944 Page 29
SECTION 7 − MAINTENANCE
7-1. Routine Maintenance
Y Disconnect power before maintaining.
3 Months
Replace
unreadable
labels.
Repair or
replace
cracked
weld cable.
Clean and
tighten weld
terminals.
6 Months
Blow out or
vacuum inside.
During heavy
service, clean
monthly.
Or
7-2. Overload Protection
1
Circuit Breaker CB1
CB1 protects unit from overload. If
CB1 opens, unit shuts down.
1
Reset breaker.
802 441
7-3. Drive Motor Protection
Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, release gun
trigger and wait until protection circuit resets allowing drive motor to feed wire again.
TM-944 Page 30
Return To Table Of Contents
Handler 135 / 175
7-4. Changing Drive Roll Or Wire Inlet Guide
1
2
Inlet Wire Guide Securing
Screw
Inlet Wire Guide
Loosen screw. Slide tip as close to
drive rolls as possible without
touching. Tighten screw.
1
3
3
2
4
Tools Needed:
Stamped .024
Retaining Pin
To secure drive roll, locate open slot
and push drive roll completely over
retaining pin, then rotate drive roll
(1/4 turn) to closed slot.
4
.030/.035 Groove
Drive Roll
The drive roll consists of two different sized grooves. The stamped
markings on the end surface of the
drive roll refers to the groove on the
opposite side of the drive roll. The
groove closest to the motor shaft is
the proper groove to thread (see
Section 3-10).
.024 Groove
Stamped .030/.035
Ref. 802 444-B
7-5. Replacing Gun Contact Tip
Y Turn Off power before
replacing contact tip.
1
2
Nozzle
Contact Tip
Cut off welding wire at contact tip.
Remove nozzle.
Remove contact tip and install new
contact tip. Reinstall nozzle.
2
1
Tools Needed:
Ref. 802 399-A
Handler 135 / 175
Return To Table Of Contents
TM-944 Page 31
7-6. Cleaning Or Replacing Gun Liner
Tools Needed:
Y Disconnect gun from unit.
8 mm / 10mm
Remove nozzle, contact tip,
adapter, gas diffuser, and wire
outlet guide.
Head Tube
8 mm
10 mm
Remove liner.
Lay gun cable out straight
before installing new liner.
To Reassemble Gun:
Insert new liner.
Install wire outlet guide so that 1/8
in (3 mm) of liner sticks out. Hand
tighten outlet guide, and then tighten two full turns more.
Blow out gun casing.
Cut liner off so that 3/4 in (19 mm)
sticks out of head tube.
Install gas diffuser, adapter, contact
tip, and nozzle.
Ref. 802 446
TM-944 Page 32
Return To Table Of Contents
Handler 135 / 175
7-7. Replacing Switch And/Or Head Tube
Y Turn Off welding power source
/wire feeder and disconnect gun.
1
Remove handle
locking nut.
3
2
Slide handle.
Remove switch housing. Install new switch and
connect leads (polarity is not important). Reassemble in reverse order. If replacing head tube,
continue to end of figure.
4 Secure head
tube in vice.
5
6
Loosen jam nut.
Remove from vice
and turn head tube
out by hand.
Hand-tighten head tube into cable connector.
8
7
Place head tube in vice and tighten until
nuts are tight.
Remove from vice. Reposition handle and install
switch housing. Secure with handle locking nut.
Tools Needed:
19 mm
Handler 135 / 175
Ref. ST-800 795-C
Return To Table Of Contents
TM-944 Page 33
SECTION 8 − ELECTRICAL DIAGRAMS
. The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside
machine case or contact your distributor for further information.
Model
Serial Or Style Number
Circuit Diagram
Wiring Diagram
115 VAC Model
KK213350 and following
194 324-C
196 637-A
230 VAC Model
KK213350 and following
194 325-A
196 655-A
Circuit Board PC1
( 115 VAC Model)
KK213350 and following
195 890
Circuit Board PC1
(230 VAC Model)
KK213350 and following
195 891
TM-944 Page 34
Return To Table Of Contents
Handler 135 / 175
194 324-C
Figure 8-1. Circuit Diagram For 115 VAC Model Effective With Serial No. KK213350 And Following
Handler 135 / 175
Return To Table Of Contents
TM-944 Page 35
194 325-A
Figure 8-2. Circuit Diagram For 230 VAC Model Effective With Serial No. KK213350 And Following
TM-944 Page 36
Return To Table Of Contents
Handler 135 / 175
196 637-A
Figure 8-3. Wiring Diagram For 115 VAC Model Effective With Serial No. KK213350 And Following
Handler 135 / 175
Return To Table Of Contents
TM-944 Page 37
196 655-A
Figure 8-4. Wiring Diagram For 230 Model Effective With Serial No. KK213350 And Following
TM-944 Page 38
Return To Table Of Contents
Handler 135 / 175
195 890-A
Figure 8-5. Circuit Diagram For 115 VAC Model Control Board PC1
Effective With Serial No. KK213350 And Following
Handler 135 / 175
Return To Table Of Contents
TM-944 Page 39
195 891-A
Figure 8-6. Circuit Diagram For 230 VAC Model Control Board PC1
Effective With Serial No. KK213350 And Following
TM-944 Page 40
Return To Table Of Contents
Handler 135 / 175
TM-944C
October 2003
Handler 135 (500 414) Eff. w/Serial No.
LB096205
Handler 175 (500 416) Eff. w/Serial No.
LB075197
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
Handler 135 / 175
And H-10 Gun
Visit our website at
www.HobartWelders.com
SECTION 9 − PARTS LIST
22
. Hardware is common and
19
15
24
41
42
43
45
47
46
52
51
48
1
44
49
39
34
40
31
2
50
33
32
36
38
37
35
3
4
30
5
6
7
8
28
29
9
10
11
27
12
13
26
25
17
23
16
14
18
20
21
not available unless listed.
802 449-E
Figure 9-1. Main Assembly
TM-944 Page 42
Return To Table Of Contents
Handler 135 / 175
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Main Assembly
. . . 1 . . . . . . . . . . . . . . . 199 566
. . . 2 . . . . . . . . . . . . . . . 196 006
. . . 3 . . . . . . . . . . . . . . . 211 887
. . . 4 . . . . . . . . . . . . . . . 204 608
. . . 5 . . . . . . . . . . . . . . . 202 998
. . . 6 . . . . . . . . . . . . . . . 203 072
. . . 7 . . . . . . . . . . . . . . . 211 339
. . . 8 . . . . . . . . . . . . . . . 202 726
. . . 9 . . . . . . . . . . . . . . . 195 886
. . . 9 . . . . . . . . . . . . . . . 195 887
. . . 10 . . . . . . . . . . . . . . . 195 999
. . . 11 . . . . . . . . . . . . . . . 210 109
. . . 12 . . . . . . . . . . . . . . . 196 467
. . . 13 . . . . . . . . . . . . . . . 116 996
. . . 13 . . . . . . . . . . . . . . . 128 751
. . . 14 . . . . . . . . . . . . . . . 197 198
. . . 15 . . . . . . . . . . . . . . . 147 545
. . . 15 . . . . . . . . . . . . . . . 152 118
. . . 16 . . . . . . . . . . . . . . . 111 443
. . . 17 . . . . . . . . . . . . . . . 605 227
. . . 18 . . . . . . . . . . . . . . . 196 063
. . . 18 . . . . . . . . . . . . . . . 196 064
. . . 19 . . . . . . . . . . . 409 953-001
. . . 20 . . . . . . . . . . . . . . . 194 268
. . . 20 . . . . . . . . . . . . . . . 194 277
. . . 21 . . . . . . . . . . . . . . . 208 015
. . . 22 . . . . . . . . . . . . . . . 196 005
. . . 23 . . . . . . . . . . . . . . . 204 036
. . . 24 . . . . . . . . . . . . . . . 203 491
. . . 25 . . . . . . . . . . . . . . . 193 039
. . . 25 . . . . . . . . . . . . . . . 193 040
. . . 26 . . . . . . . . . . . . . . . 203 868
. . . 26 . . . . . . . . . . . . . . . 203 874
. . . 27 . . . . . . . . . . . . . . . 193 191
. . . 27 . . . . . . . . . . . . . . . 193 316
. . . 28 . . . . . . . . . . . . . . . 198 585
. . . . . . . . . . . . . . . . . . . . . 203 390
...
...
...
...
...
...
...
...
...
...
...
...
...
...
29
30
31
32
33
34
35
36
37
38
38
39
40
41
. . . . . . . . . . . . . . . 193 193
. . . . . . . . . . . . . . . 196 000
. . . . . . . . . . . 405 576-001
. . . . . . . . . . . . . . . 193 144
. . . . . . . . . . . . . . . 193 194
. . . . . . . . . . . . . . . 199 824
. . . . . . . . . . . . . . . 134 201
. . . . . . . . . . . . . . . 409 477
. . . . . . . . . . . . . . . 194 513
. . . . . . . . . . . . . . . 196 129
. . . . . . . . . . . . . . . 196 007
. . . . . . . . . . . . . . . 010368
. . . . . . . . . . . . . . . 196 619
. . . . . . . . . . . . . . . 196 575
Handler 135 / 175
. . DOOR, access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HINGE, door . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HUB, nut . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SPRING, cprsn . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WASHER, flat . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HUB, spool . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ADAPTER, spool hub . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY, control (115 VAC model) . . . . . . . . . . . . . . . . . . .
. . CIRCUIT CARD ASSY, control (230 VAC model) . . . . . . . . . . . . . . . . . . .
. . BASE, lower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CIRCUIT BREAKER, 25 amp . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TUBING, PVC .187 ID x .312 OD x 24.000 . . . . . . . . . . . . . . . . . . . . . . . .
. . VALVE, gas (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . VALVE, gas (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE TIE, .700-.799 bundle dia . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CORD SET, 125V 5−15P 14GA 3/C 7ft SPT−3 jkt (115 VAC model) . . .
. . CORD SET, 250V 6−50P 12GA 3/C 7ft SPT−3 jkt (230 VAC model) . . .
. . BUSHING, strain relief . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . NUT, gas valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOTOR, fan (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOTOR, fan (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BLADE, fan cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, power assy (115 VAC model) . . . . . . . . . . . . . . . . . . . .
. . TRANSFORMER, power assy (230 VAC model) . . . . . . . . . . . . . . . . . . . .
. . HANDLE, carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . WRAPPER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, electlt 53000uf (115 VAC model) . . . . . . . . . . . . . . . . . . . . .
. . CAPACITOR, electrlt 100000uf (230 VAC model) . . . . . . . . . . . . . . . . . . .
. . REACTOR ASSY (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REACTOR ASSY (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER ASSY (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . RECTIFIER ASSY (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PLATE, support (230 VAC model only) . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KEY, woodruff l (115 VAC model Prior to LC175022 or
230 VAC model Prior to LC155844) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR (positive) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BAFFLE, center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUSHING, terminal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . INSULATOR, output stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . BUS BAR (negative) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . STAND-OFF . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, rotary 25A 5 position . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . POTENTIOMETER, . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, front (purple) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . PANEL, front (black) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CLAMP, work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CABLE, work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, rocker SPST (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . .
Return To Table Of Contents
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
TM-944 Page 43
Item
No.
Dia.
Mkgs.
Part
No.
Description
Quantity
Figure 9-1. Main Assembly (Continued)
...
...
...
...
41
42
43
44
...............
...............
...............
...............
196 574
207 078
207 079
193 187
. . . 44 . . . . . . . . . . . . . . . 202 708
. . . 45 . . . . . . . . . . . . . . . 193 189
. . . 46 . . . . . . . . . . . . . . . 196 654
. . . . . . . . . . . . . . . . . . . . . 203 081
. . . 47 . . . . . . . . . . . . . . . 196 009
. . . 48 . . . . . . . . . . . . . . . 202 925
. . . 49 . . . . . . . . . . . . . . . 194 508
. . . 50 . . . . . . . . . . . . . . . 203 025
. . . 51 . . . . . . . . . . . . . . . 209 228
. . . 51 . . . . . . . . . . . . . . . 209 229
. . . 52 . . . . . . . . . . . . . . . 204 711
. . . . . . . . . . . . . . . . . . . ♦212 492
. . SWITCH, rocker DPST (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, pointer (WFS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . KNOB, pointer (voltage) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOTOR, gear (115 VAC model Prior to LC175022 or
230 VAC model Prior to LC155844) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . MOTOR, gear (115 VAC model Eff w/LC175022 or
230 VAC model w/ LC155844) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . CONNECTOR, gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, thumb . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . SCREW, feed roll (115 VAC model Prior to LC175022 or
230 VAC model Prior to LC155844) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . FITTING, gas barbed . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . ROLL, feed .024 in, .030/.035 in . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . HEAD, feed assy . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . GUIDE, wire inlet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, weld chart (115 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LABEL, weld chart (230 VAC model) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . LATCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . REGULATOR/FLOWMETER, 10-50 CFH CO2 . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
1
♦OPTIONAL
+When ordering a component originally displaying a precautionary label, the label should also be ordered.
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
1
3
2
4
5
6
7
9
8
11
10
802 447
TM-944 Page 44
Return To Table Of Contents
Handler 135 / 175
Figure 9-2. H-10 Gun
Item
No.
Part
No.
Description
195 957
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
...
1
2
2
2
2
3
4
5
6
7
8
9
9
9
9
10
11
. . . . . . . . . . . . . . . 169 715
. . . . . . . . . . . . . ♦087 299
. . . . . . . . . . . . . ♦000 067
. . . . . . . . . . . . . ♦000 068
. . . . . . . . . . . . . ♦000 069
. . . . . . . . . . . . . . . 169 716
. . . . . . . . . . . . . . . 170 470
. . . . . . . . . . . . . . . 169 718
. . . . . . . . . . . . . . . 169 738
. . . . . . . . . . . . . . . 169 719
. . . . . . . . . . . . . . . 079 975
. . . . . . . . . . . . . ♦194 010
. . . . . . . . . . . . . ♦194 011
. . . . . . . . . . . . . ♦194 012
. . . . . . . . . . . . . ♦194 014
. . . . . . . . . . . . . . . 197 123
. . . . . . . . . . . . . . . 196 255
Quantity
Figure 9-2. H-10 Gun
. . . . NOZZLE, slip type .500 orf flush . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TIP, contact scr .023 wire x 1.125
. . . . TIP, contact scr .030 wire x 1.125
. . . . TIP, contact scr .035 wire x 1.125
. . . . TIP, contact scr .045 wire x 1.125
. . . . ADAPTER, contact tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . RING, retaining . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . TUBE, head . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, locking handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . NUT, jam . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . O-RING, .187 ID x .103CS rbr . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . LINER, monocoil .023/.025 wire x 15ft (consisting of) . . . . . . . . . . . . .
. . . . LINER, monocoil .030/.035 wire x 15ft (consisting of) . . . . . . . . . . . . .
. . . . LINER, monocoil .035/.045 wire x 15ft (consisting of) . . . . . . . . . . . . .
. . . . LINER, monocoil 4/64 AL wire x 10ft nyl(consisting of) . . . . . . . . . . . .
. . . . O-RING, .312 ID x .062 70 Dura BUNA-N . . . . . . . . . . . . . . . . . . . . . . .
. . SWITCH, trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1
1
1
1
1
1
1
1
1
1
1
2
1
♦OPTIONAL
To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested
Replacement Parts. Model and serial number required when ordering parts from your local distributor.
9-3. Optional Drive Rolls
For All Feed Head Assemblies
PART NO.
WIRE DIAMETER
INCHES (mm)
202 925
.024 (.6) and .030/.035 (.8 and .9)
202 926
.030/.035 (.8 and .9) and .045 (1.2 VK Groove)
9-4. Options
PART NO.
DESCRIPTION
REMARKS
770 187
Running Gear/Cylinder Rack
For One Small Gas Cylinder, 100 lb (45 kg)
194 776
Small Running Gear/Cylinder Rack
For One Small Gas Cylinder, 75 lb (34 kg)
195 957
H-10 Replacement Gun
10 ft length/.030-.035 wire size
NOTE: If individual parts are required, see Parts List chapter of this manual for part number to order.
Handler 135 / 175
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TM-944 Page 45
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