Hobart Welding Products Handler 135 User Manual

TM-944C October 2003
Handler 135 (500 414) Eff. w/Serial No.
LB096205
Handler 175 (500 416) Eff. w/Serial No.
LB075197
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www.HobartWelders.com
Processes
Arc Welding Power Source And
Wire Feeder
Description
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Handler 135 / 175
And H-10 Gun

Hobart Welding Products Handler 135 Specifications

General

Input Frequency	60 Hz
Output Current Range	30 - 135 A
Wire Feed Speed Range	40 - 700 IPM
Wire Size Range	0.023 - 0.035 in
Weight	57 lbs
Welding Processes	MIG (GMAW), Flux-Cored (FCAW)
Input Current	20 A
Duty Cycle	20% @ 90 A
Input Phase	Single Phase

Summary

SECTION 1 - SAFETY PRECAUTIONS FOR SERVICING

1-1. Symbol Usage

Explains the meaning of warning symbols used in the manual.

1-2. Servicing Hazards

Details potential hazards associated with servicing the welding unit.

1-3. California Proposition 65 Warnings

Provides warnings regarding chemicals known to cause birth defects or cancer.

1-4. EMF Information

Discusses electromagnetic fields and recommendations for minimizing exposure.

SECTION 2 - SPECIFICATIONS

2-1. Specifications

Lists technical specifications for both 115 VAC and 230 VAC models.

2-2. Duty Cycle And Overheating

Explains duty cycle limitations and overheating prevention for the unit.

2-3. Volt-Ampere Curves

Presents volt-ampere curves showing output capabilities for different settings.

SECTION 3 - INSTALLATION

3-1. Installing Welding Gun

Step-by-step guide for attaching the welding gun to the unit.

3-2. Installing Work Clamp

Instructions for connecting the work clamp to the welding unit.

3-3. Process/Polarity Table

Details recommended polarity and cable connections for different welding processes.

3-4. Changing Polarity

Provides instructions and diagrams for changing the unit's polarity settings.

3-5. Installing Gas Supply

Guide for connecting the gas cylinder and regulator/flowmeter.

3-6. Selecting A Location And Connecting Input Power For 115 VAC Model

Instructions for selecting a location and connecting power for the 115 VAC model.

3-7. Selecting A Location And Connecting Input Power For 230 VAC Model

Instructions for selecting a location and connecting power for the 230 VAC model.

3-8. Electrical Service Guide For 230 VAC Model

Details electrical service requirements for the 230 VAC model.

3-9. Installing Wire Spool And Adjusting Hub Tension

Guide for mounting wire spools and setting hub tension.

3-10. Threading Welding Wire

Step-by-step instructions for threading welding wire through the unit.

SECTION 4 - OPERATION

4-1. Controls

Explains the function of the main controls on the welding unit.

4-2. Weld Parameter Chart For 115 VAC Model

Provides suggested welding parameters for various materials and wire types on the 115 VAC model.

4-3. Weld Parameter Chart For 230 VAC Model

Provides suggested welding parameters for various materials and wire types on the 230 VAC model.

SECTION 5 - THEORY OF OPERATION

SECTION 6 - TROUBLESHOOTING

6-1. Troubleshooting Table

A table listing common problems and their recommended remedies.

6-2. Troubleshooting Circuit Diagram For Welding Power Source (115 VAC Model)

Provides the circuit diagram for troubleshooting the 115 VAC model.

6-4. Control Board PC1 Testing Information (115 VAC Model)

Details testing procedures and information for the control board on the 115 VAC model.

6-5. Control Board PC1 Test Point Values (115 VAC Model)

Lists specific test point voltage readings for the control board on the 115 VAC model.

6-6. Control Board PC1 Testing Information (230 VAC Model)

Details testing procedures and information for the control board on the 230 VAC model.

6-7. Control Board PC1 Test Point Values (230 VAC Model)

Lists specific test point voltage readings for the control board on the 230 VAC model.

SECTION 7 - MAINTENANCE

7-1. Routine Maintenance

Describes regular maintenance tasks to keep the unit in good condition.

7-2. Overload Protection

Explains the unit's overload protection mechanism and how to reset it.

7-3. Drive Motor Protection

Details the drive motor's protection circuit and its reset function.

7-4. Changing Drive Roll Or Wire Inlet Guide

Instructions for replacing or changing the drive roll and wire inlet guide.

7-5. Replacing Gun Contact Tip

Step-by-step guide for replacing the contact tip on the welding gun.

7-6. Cleaning Or Replacing Gun Liner

Procedures for cleaning or replacing the gun liner.

7-7. Replacing Switch And/Or Head Tube

Instructions for replacing the switch or head tube on the welding gun.

SECTION 8 - ELECTRICAL DIAGRAMS

Figure 8-1. Circuit Diagram For 115 VAC Model

Circuit diagram illustrating the electrical layout for the 115 VAC model.

Figure 8-2. Circuit Diagram For 230 VAC Model

Circuit diagram illustrating the electrical layout for the 230 VAC model.

Figure 8-3. Wiring Diagram For 115 VAC Model

Wiring diagram for the 115 VAC model, showing component connections.

Figure 8-4. Wiring Diagram For 230 VAC Model

Wiring diagram for the 230 VAC model, showing component connections.

Figure 8-5. 115 VAC Model Control Board PC1 Diagram

Detailed circuit diagram for the PC1 control board of the 115 VAC model.

Figure 8-6. 230 VAC Model Control Board PC1 Diagram

Detailed circuit diagram for the PC1 control board of the 230 VAC model.

SECTION 9 - PARTS LIST

Figure 9-1. Main Assembly

Exploded view and parts breakdown of the main welding unit assembly.

9-3. Optional Drive Rolls

Lists optional drive rolls available for different wire diameters.

9-4. Options

Lists optional accessories such as running gear and replacement guns.

Figure 9-2. H-10 Gun Parts

Exploded view and parts list specific to the H-10 gun.