Hobart Welding Products Handler 135 Technical Manual
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Hobart Welding Products Handler 135 Technical Manual

Arc welding power source and wire feeder
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Handler 135 / 175
And H-10 Gun
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

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Summary of Contents for Hobart Welding Products Handler 135

  • Page 1 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...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING ......... . 1-1.

  • Page 3: Section 1 − Safety Precautions For Servicing

    D Keep away from moving parts such as fans. surfaces. D Keep all doors, panels, covers, and guards D Do not service unit near flammables. closed and securely in place. Handler 135 / 175 TM-944 Page 1 Return To Table Of Contents...

  • Page 4: California Proposition 65 Warnings

    To reduce magnetic fields in the workplace, use the following Pacemaker wearers consult your doctor first. If cleared by your doctor, procedures: then following the above procedures is recommended. TM-944 Page 2 Handler 135 / 175 Return To Table Of Contents...

  • Page 5: Section 2 − Specifications

    350 − 900 IPM (9.0 − 23.0 m/min) At No Load .030 − .035 in 50 − 850 IPM (1.3 − 20.3 m/min) Feeding Wire (0.8 − 0.9 mm) Handler 135 / 175 TM-944 Page 3 Return To Table Of Contents...

  • Page 6: Duty Cycle And Overheating

    20% duty cycle at 130 amps, 50 Hz 3 Minutes Welding 7 Minutes Resting Overheating A or V Reduce Duty Cycle Minutes duty1 4/95 − 196 617 / 196 618 TM-944 Page 4 Handler 135 / 175 Return To Table Of Contents...

  • Page 7: Volt-Ampere Curves

    Range 3 15.0 Range 2 Range 1 10.0 100 110 120 130 140 150 160 170 180 190 200 LOAD AMPS ssb1.1 10/91 − 196 608 / 196 609 Handler 135 / 175 TM-944 Page 5 Return To Table Of Contents...

  • Page 8: Section 3 − Installation

    Ref. 802 440-A 3-2. Installing Work Clamp Work Cable From Unit Work Clamp Screw Work Clamp Tabs Bend tabs around work cable. Tools Needed: 3/8, 7/16 in 802 456 TM-944 Page 6 Handler 135 / 175 Return To Table Of Contents...

  • Page 9: Process/Polarity Table

    Always read and follow wire manufacturer’s recommended po- larity, and see Section 3-3. Close door. DCEP Electrode Positive For Solid Wire Ref. 209 228 / Ref. 209 229 Handler 135 / 175 TM-944 Page 7 Return To Table Of Contents...

  • Page 10: Installing Gas Supply

    Typical flow rate is 20 cfh (cubic feet hour). Check wire manufacturer’s recommended flow Argon Gas Or rate. Mixed Gas Tools Needed: 5/8, 1-1/8 in Ref. 802 028-A / 802 441 TM-944 Page 8 Handler 135 / 175 Return To Table Of Contents...

  • Page 11: Selecting A Location And Connecting Input Power For 115 Vac Model

    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 TM-944 Page 9 Return To Table Of Contents...

  • Page 12: Selecting A Location And Connecting Input Power For 230 Vac Model

    = GND/PE 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 Handler 135 / 175 Return To Table Of Contents...

  • Page 13: Electrical Service Guide For 230 Vac Model

    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 TM-944 Page 11 Return To Table Of Contents...

  • Page 14: Threading Welding Wire

    Press gun trigger until wire comes Tighten knob enough to prevent slipping. Reinstall contact tip and nozzle. out of gun. Cut off wire. Close door. Ref. 802 444-C TM-944 Page 12 Handler 135 / 175 Return To Table Of Contents...

  • Page 15: Section 4 − Operation

    As Voltage switch setting in- creases, wire speed range also in- creases (see weld setting label in welding power source or Sections 4-2 or 4-3, as applicable). Power Switch Ref. 196 082 Handler 135 / 175 TM-944 Page 13 Return To Table Of Contents...

  • Page 16: Weld Parameter Chart For 115 Vac Model

    Adjust tension per instructions in the manual. **Aluminum wire is relatively soft so feedability is not as good. Make sure that hub tension is not too tight and TM-944 Page 14 Return To Table Of Contents Handler 135 / 175...
  • Page 17 A ”push angle” for the torch is normally recommended. 209 228 Handler 135 / 175 Return To Table Of Contents TM-944 Page 15...

  • Page 18: Weld Parameter Chart For 230 Vac Model

    Adjust tension per instructions in the manual. **Aluminum wire is relatively soft so feedability is not as good. Make sure that hub tension is not too tight and TM-944 Page 16 Return To Table Of Contents Handler 135 / 175...
  • Page 19 A ”push angle” for the torch is normally recommended. 209 229 Handler 135 / 175 Return To Table Of Contents TM-944 Page 17...

  • Page 20: Section 5 − Theory Of Operation

    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 Return To Table Of Contents Handler 135 / 175...
  • Page 21 Range Switch Main Rectifier Stablizer L1 Main Transformer Capacitor C1 Polarity Changeover Block 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...

  • Page 22: See Section

    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 Handler 135 / 175 Return To Table Of Contents...
  • Page 23 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 TM-944 Page 21 Return To Table Of Contents...

  • Page 24: Troubleshooting Circuit Diagram For Welding Power Source (115 Vac Model)

    6-2. Troubleshooting Circuit Diagram For Welding Power Source (115 VAC Model) V8/R5 V9/R6 V11/R9 See also Section 6-4 for PC1 data Test Equipment Needed: TM-944 Page 22 Return To Table Of Contents Handler 135 / 175...
  • Page 25 Drive Motor RPM At No Load* Voltage Min. Max. Switch S2 Position *All tests done with the pressure assembly open, not feeding wire. Values are nominal. 194 324-C Handler 135 / 175 Return To Table Of Contents TM-944 Page 23...

  • Page 26: Return To Table Of Contents Handler

    6-3. Troubleshooting Circuit Diagram For Welding Power Source (230 VAC Model) V8/R5 V9/R6 V11/R9 See also Section 6-6 for PC1 data Test Equipment Needed: TM-944 Page 24 Return To Table Of Contents Handler 135 / 175...
  • Page 27 Drive Motor RPM At No Load* Voltage Min. Max. Switch S2 Position *All tests done with the pressure assembly open, not feeding wire. Values are nominal. 194 325-A Handler 135 / 175 Return To Table Of Contents TM-944 Page 25...

  • Page 28: Control Board Pc1 Testing Information (115 Vac Model)

    Control Board PC1 Receptacle RC1 Receptacle RC2 Receptacle RC4 Receptacle RC5 TP-A TP-B TP-C TP-D 10 TP-E 11 TP-F Test Equipment Needed: 802 779 / 195 888-B TM-944 Page 26 Handler 135 / 175 Return To Table Of Contents...

  • Page 29: Control Board Pc1 Test Point Values (115 Vac Model)

    30 volts dc, reference to TP-C 15 volts dc with Wire Speed control R1 at minimum, reference to TP-C 11 volts dc with Wire Speed control R1 at maximum, reference to TP-C Handler 135 / 175 TM-944 Page 27 Return To Table Of Contents...

  • Page 30: Control Board Pc1 Testing Information (230 Vac Model)

    Control Board PC1 Receptacle RC1 Receptacle RC2 Receptacle RC4 Receptacle RC5 TP-A TP-B TP-C TP-D 10 TP-E 11 TP-F Test Equipment Needed: 802 779 / 195 889-B TM-944 Page 28 Handler 135 / 175 Return To Table Of Contents...

  • Page 31: Control Board Pc1 Test Point Values (230 Vac Model)

    30 volts dc, reference to TP-C 15 volts dc with Wire Speed control R1 at minimum, reference to TP-C 11 volts dc with Wire Speed control R1 at maximum, reference to TP-C Handler 135 / 175 TM-944 Page 29 Return To Table Of Contents...

  • Page 32: Section 7 − Maintenance &Troubleshooting

    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 Handler 135 / 175 Return To Table Of Contents...

  • Page 33: Changing Drive Roll Or Wire Inlet Guide

    Nozzle Contact Tip Cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. Tools Needed: Ref. 802 399-A Handler 135 / 175 TM-944 Page 31 Return To Table Of Contents...

  • Page 34: Cleaning Or Replacing Gun Liner

    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 Handler 135 / 175 Return To Table Of Contents...

  • Page 35: Replacing Switch And/Or Head Tube

    Hand-tighten head tube into cable connector. nuts are tight. Remove from vice. Reposition handle and install switch housing. Secure with handle locking nut. Tools Needed: 19 mm Ref. ST-800 795-C Handler 135 / 175 TM-944 Page 33 Return To Table Of Contents...

  • Page 36: Section 8 − Electrical Diagrams

    KK213350 and following 194 325-A 196 655-A Circuit Board PC1 KK213350 and following 195 890 ( 115 VAC Model) Circuit Board PC1 KK213350 and following 195 891 (230 VAC Model) TM-944 Page 34 Handler 135 / 175 Return To Table Of Contents...
  • Page 37 194 324-C Figure 8-1. Circuit Diagram For 115 VAC Model Effective With Serial No. KK213350 And Following Handler 135 / 175 TM-944 Page 35 Return To Table Of Contents...
  • Page 38 194 325-A Figure 8-2. Circuit Diagram For 230 VAC Model Effective With Serial No. KK213350 And Following TM-944 Page 36 Handler 135 / 175 Return To Table Of Contents...
  • Page 39 196 637-A Figure 8-3. Wiring Diagram For 115 VAC Model Effective With Serial No. KK213350 And Following Handler 135 / 175 TM-944 Page 37 Return To Table Of Contents...
  • Page 40 196 655-A Figure 8-4. Wiring Diagram For 230 Model Effective With Serial No. KK213350 And Following TM-944 Page 38 Handler 135 / 175 Return To Table Of Contents...
  • Page 41 195 890-A Figure 8-5. Circuit Diagram For 115 VAC Model Control Board PC1 Effective With Serial No. KK213350 And Following Handler 135 / 175 TM-944 Page 39 Return To Table Of Contents...
  • Page 42 195 891-A Figure 8-6. Circuit Diagram For 230 VAC Model Control Board PC1 Effective With Serial No. KK213350 And Following TM-944 Page 40 Handler 135 / 175 Return To Table Of Contents...
  • Page 43 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...

  • Page 44: Section 9 − Parts List

    SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 802 449-E Figure 9-1. Main Assembly TM-944 Page 42 Handler 135 / 175 Return To Table Of Contents...
  • Page 45 SWITCH, rocker SPST (115 VAC model) ......Handler 135 / 175 TM-944 Page 43 Return To Table Of Contents...
  • Page 46 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. 802 447 TM-944 Page 44 Handler 135 / 175 Return To Table Of Contents...

  • Page 47: Tm-944

    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 TM-944 Page 45 Return To Table Of Contents...
  • Page 48 Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy, OH 45373 USA For Technical Assistance: Call1-800-332-3281 For Literature Or Nearest Dealer: Call 1-877-Hobart1 PRINTED IN USA 2003 Hobart Welding Products...

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Handler 175H-10

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