Page 2 - TABLE OF CONTENTS
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 3 - SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING; Symbol Usage; Servicing Hazards
TM-944 Page 1 Handler 135 / 175 Return To Table Of Contents SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1-1. Symbol Usage safety_stm 5/97 Means Warning! Watch Out! There are possible hazardswith this procedure! The possible hazards are shown inthe adjoining symbols. Y Marks a special safety message...
Page 4 - MOVING PARTS can cause injury.; OVERUSE can cause OVERHEATING.; California Proposition 65 Warnings; EMF Information
TM-944 Page 2 Handler 135 / 175 Return To Table Of Contents MOVING PARTS can cause injury. D Keep away from moving parts. D Keep away from pinch points such as driverolls. MAGNETIC FIELDS can affect pacemakers. D Pacemaker wearers keep away from servicingareas until consulting your doctor. OVERUSE c...
Page 5 - SECTION 2 − SPECIFICATIONS; Specifications
TM-944 Page 3 Handler 135 / 175 Return To Table Of Contents SECTION 2 − SPECIFICATIONS 2-1. Specifications A. 115 VAC Model Rated Welding Output Amperage Range Maximum Open- Circuit Voltage DC Amperes Input at Rated Load Output 115 V, 60 Hz, Single- Phase KVA KW Weight W/ Gun Overall Dimensions 90 A...
Page 6 - Duty Cycle And Overheating; A or V
TM-944 Page 4 Handler 135 / 175 Return To Table Of Contents 2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating. If unit overheats, thermostat(s)opens, output stops, and coolingfan runs. Wait fifteen minutes forunit to cool. Red...
Page 8 - SECTION 3 − INSTALLATION; Installing Welding Gun
TM-944 Page 6 Handler 135 / 175 Return To Table Of Contents SECTION 3 − INSTALLATION 3-1. Installing Welding Gun Ref. 802 440-A 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew. Insert gunend through opening until it bottomsagainst drive assembly. Tightenthumbscrew. 4 Gun Trigg...
Page 9 - Process/Polarity Table; Changing Polarity
TM-944 Page 7 Handler 135 / 175 Return To Table Of Contents 3-3. Process/Polarity Table Process Polarity Cable Connections Process Polarity Cable To Gun Cable To Work GMAW − Solid wire with shield-ing gas DCEP − Reverse polarity Connect to positive (+) out-put terminal Connect to negative (−) output...
Page 10 - Installing Gas Supply
TM-944 Page 8 Handler 135 / 175 Return To Table Of Contents 3-5. Installing Gas Supply Obtain gas cylinder and chain torunning gear, wall, or otherstationary support so cylindercannot fall and break off valve. 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve,and open valve slightly. Gas flo...
Page 11 - Selecting A Location And Connecting Input Power For 115 VAC Model
TM-944 Page 9 Handler 135 / 175 Return To Table Of Contents 3-6. Selecting A Location And Connecting Input Power For 115 VAC Model 1 Rating Label 2 Grounded Receptacle A 115 volt, 20 ampere individualbranch circuit protected by time-de-lay fuses or circuit breaker is re-quired. 3 Plug From Unit Sele...
Page 12 - Selecting A Location And Connecting Input Power For 230 VAC Model
TM-944 Page 10 Handler 135 / 175 Return To Table Of Contents 3-7. Selecting A Location And Connecting Input Power For 230 VAC Model 1 Rating Label Supply correct input power. 2 Plug (NEMA 6-50P) 3 Receptacle (NEMA 6-50R) Connect plug to receptacle. 4 Line Disconnect Device See Section 3-8. Y Special...
Page 13 - Electrical Service Guide For 230 VAC Model; Installing Wire Spool And Adjusting Hub Tension
TM-944 Page 11 Handler 135 / 175 Return To Table Of Contents 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 Conduct...
Page 15 - SECTION 4 − OPERATION; Controls
TM-944 Page 13 Handler 135 / 175 Return To Table Of Contents SECTION 4 − OPERATION 4-1. Controls 1 Voltage Switch The higher the selected number,the thicker the material that can bewelded (see weld setting label inwelding power source or Sections4-2 and 4-3, as applicable). Do notswitch under load. ...
Page 16 - Weld Parameter Chart For 115 VAC Model; Welding
TM-944 Page 14 Handler 135 / 175 Return To Table Of Contents 4-2. Weld Parameter Chart For 115 VAC Model Welding Guide Settings are approximate. Adjust as required. Thicker materials can be welded using proper technique, joint preparation, and multiple passes. Match feedroll groove to diameter of wi...
Page 17 - olt Wire Welding
TM-944 Page 15 Handler 135 / 175 Return To Table Of Contents 209 228 for 1 15 V olt Wire Welding Package DCEN DCEP 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, weld angle, ...
Page 18 - Weld Parameter Chart For 230 VAC Model
TM-944 Page 16 Handler 135 / 175 Return To Table Of Contents 4-3. Weld Parameter Chart For 230 VAC Model Welding Guide Settings are approximate. Adjust as required. Thicker materials can be welded using proper technique, joint preparation, and multiple passes. Match feedroll groove to diameter of wi...
Page 20 - SECTION 5 − THEORY OF OPERATION
TM-944 Page 18 Handler 135 / 175 Return To Table Of Contents 1 Circuit Breaker CB1 Protects unit from an over-currentcondition by opening primary powerline. 2 Power Switch S1 Turns unit and fan motor FM on andoff. 3 Fan Motor FM AndTransformer Controlled by power switch S1. Fancools internal compone...
Page 22 - SECTION 6 − TROUBLESHOOTING; Troubleshooting Table
TM-944 Page 20 Handler 135 / 175 Return To Table Of Contents SECTION 6 − TROUBLESHOOTING 6-1. Troubleshooting Table . See Section 6-2 or 6-3 for test points and valuesand Section 9 for parts location. Trouble Remedy No weld output; wire does not feed; fandoes not run. Secure power cord plug PLG1 in ...
Page 28 - Control Board PC1 Testing Information (115 VAC Model)
TM-944 Page 26 Handler 135 / 175 Return To Table Of Contents 6-4. Control Board PC1 Testing Information (115 VAC Model) Be sure plugs are secure beforetesting. See Section 6-5 for specificvalues during testing. 1 Control Board PC1 2 Receptacle RC1 3 Receptacle RC2 4 Receptacle RC4 5 Receptacle RC5 6...
Page 29 - Control Board PC1 Test Point Values (115 VAC Model)
TM-944 Page 27 Handler 135 / 175 Return To Table Of Contents 6-5. Control Board PC1 Test Point Values (115 VAC Model) PC1 Voltage Readings a) Tolerance − ± 10% unless specified b) Reference − to circuit common unless noted Voltage Readings: a) Tolerance − ± 10% unless specified b) Reference − as not...
Page 30 - Control Board PC1 Testing Information (230 VAC Model)
TM-944 Page 28 Handler 135 / 175 Return To Table Of Contents 6-6. Control Board PC1 Testing Information (230 VAC Model) Be sure plugs are secure beforetesting. See Section 6-7 for specificvalues during testing. 1 Control Board PC1 2 Receptacle RC1 3 Receptacle RC2 4 Receptacle RC4 5 Receptacle RC5 6...
Page 31 - Control Board PC1 Test Point Values (230 VAC Model)
TM-944 Page 29 Handler 135 / 175 Return To Table Of Contents 6-7. Control Board PC1 Test Point Values (230 VAC Model) PC1 Voltage Readings a) Tolerance − ± 10% unless specified b) Reference − to circuit common unless noted Voltage Readings: a) Tolerance − ± 10% unless specified b) Reference − as not...
Page 32 - SECTION 7 − MAINTENANCE; Routine Maintenance; Months; Overload Protection; Drive Motor Protection
TM-944 Page 30 Handler 135 / 175 Return To Table Of Contents SECTION 7 − MAINTENANCE 7-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replaceunreadablelabels. Repair orreplacecrackedweld cable. Clean andtighten weldterminals. 6 Months Blow out orvacuum inside.During heavyserv...
Page 33 - Changing Drive Roll Or Wire Inlet Guide; Replacing Gun Contact Tip
TM-944 Page 31 Handler 135 / 175 Return To Table Of Contents 7-4. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire Guide SecuringScrew 2 Inlet Wire Guide Loosen screw. Slide tip as close todrive rolls as possible withouttouching. Tighten screw. 3 Drive Roll The drive roll consists of two differ-...
Page 34 - Cleaning Or Replacing Gun Liner
TM-944 Page 32 Handler 135 / 175 Return To Table Of Contents 7-6. Cleaning Or Replacing Gun Liner Ref. 802 446 8 mm / 10mm Y Disconnect gun from unit. Tools Needed: To Reassemble Gun: Insert new liner. Install wire outlet guide so that 1/8in (3 mm) of liner sticks out. Handtighten outlet guide, and ...
Page 36 - SECTION 8 − ELECTRICAL DIAGRAMS
TM-944 Page 34 Handler 135 / 175 Return To Table Of Contents 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 insidemachine case or contact your distributor for further informati...
Page 41 - Figure 8-5. Circuit Diagram For 115 VAC Model Control Board PC1
TM-944 Page 39 Handler 135 / 175 Return To Table Of Contents 195 890-A Figure 8-5. Circuit Diagram For 115 VAC Model Control Board PC1 Effective With Serial No. KK213350 And Following
Page 42 - Figure 8-6. Circuit Diagram For 230 VAC Model Control Board PC1
TM-944 Page 40 Handler 135 / 175 Return To Table Of Contents 195 891-A Figure 8-6. Circuit Diagram For 230 VAC Model Control Board PC1 Effective With Serial No. KK213350 And Following
Page 43 - Processes
Visit our website at www.HobartWelders.com Handler 135 / 175 And H-10 Gun T M - 944C October 2003 Handler 135 (500 414) Eff. w/Serial No.LB096205 Handler 175 (500 416) Eff. w/Serial No.LB075197 Processes Arc Welding Power Source AndWire Feeder Description MIG (GMAW) Welding Flux Cored (FCAW) Welding
Page 44 - SECTION 9 − PARTS LIST
TM-944 Page 42 Handler 135 / 175 Return To Table Of Contents SECTION 9 − PARTS LIST . Hardware is common andnot available unless listed. 802 449-E 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 29 30 35 33 32 50 44 49 48 47 46 45 52 51 36 37 43 42 41 39 40 38 28 31 34 Figure...
Page 47 - Quantity; Optional Drive Rolls; Options
TM-944 Page 45 Handler 135 / 175 Return To Table Of Contents Figure 9-2. H-10 Gun Quantity Description Part No. 195 957 Item No. Figure 9-2. H-10 Gun 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....
Page 48 - Hobart Welding Products
PRINTED IN USA 2003 Hobart Welding Products Hobart Welding Products An Illinois Tool Works Company600 West Main StreetTroy, OH 45373 USA For Technical Assistance:Call1-800-332-3281For Literature Or Nearest Dealer:Call 1-877-Hobart1
