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Hobart Welding Products TM-944C manual

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Table of contents for the manual

  • Page 1

    TM -944C Oc tober 2003 Handler 135 (500 414) Eff. w/Serial No. LB096205 Handler 175 (500 416) Eff. w/Serial No. LB075197 Visit our website at www.HobartWelders.com Processes Arc Welding Power Source And Wire Feeder Description MIG (GMAW ) W elding Flux Cored (FCA W ) W elding H a n d l e r 1 3 5 / 1 7 5 And H-10 Gun[...]

  • Page 2

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS FOR SER VICING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Servicing Hazards 1 . . . . [...]

  • Page 3

    TM-944 Page 1 Handler 135 / 175 Return T o T able Of Contents SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1-1. Symbol Usage safety_stm 5/97 Means Warning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. T[...]

  • Page 4

    TM-944 Page 2 Handler 135 / 175 Return T o T able Of Contents MOVING P ARTS can cause injury . D Keep away from moving parts. D Keep away from pinch points such as drive rolls. MAGNETIC FI ELDS can af fect p acemakers. D Pacemaker wearers keep away from servicing areas until consulting your doctor . OVERUSE can cause OVERHEA TING. D Allow cooling p[...]

  • Page 5

    TM-944 Page 3 Handler 135 / 175 Return T o T able Of Contents SECTION 2 − SPECIFICA TIONS 2-1. Specifications A. 1 15 V AC Model Rated Welding Output Amperage Range Maximum Open- Circuit V oltage DC Amperes Input at Rated Load Output 1 15 V , 60 Hz, Single- Phase KV A KW W eight W/ Gun Overall Dimensions 90 A @ 19 V olts DC, 20% Duty Cycle 63 A @[...]

  • Page 6

    TM-944 Page 4 Handler 135 / 175 Return T o T able Of Contents 2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 mi n- utes 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.[...]

  • Page 7

    TM-944 Page 5 Handler 135 / 175 Return T o T able Of Contents 2-3. V olt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. ssb1.1 10/91 − 196 608 / 196 609 E. 1 15 V AC Model F. 230 V AC Model 0.0 5.0 10.0[...]

  • Page 8

    TM-944 Page 6 Handler 135 / 175 Return T o T able Of Contents SECTION 3 − INST ALLA TION 3-1. Installing W elding Gun Ref. 802 440-A 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew . Insert gun en d through opening until it bottoms against drive assembly . Tighten thumbscrew . 4 Gun Trigger Leads Insert leads, one at a time[...]

  • Page 9

    TM-944 Page 7 Handler 135 / 175 Return T o T able Of Contents 3-3. Process/Polarity T able Process Polarity Cable Connections Process Polarity Cable T o Gun Cable T o Work GMAW − Solid wire with shield- ing gas DCEP − Reverse polarity Connect to positive (+) out- put terminal Connect to negative (−) output terminal FCAW − Self-shielding wir[...]

  • Page 10

    TM-944 Page 8 Handler 135 / 175 Return T o T able Of Contents 3-5. Installing Gas Supply Obtain gas cylinder and chain to running gear , wall, or other stationary support so cylinder cannot fall and break of f valve. 1 Cap 2 Cylinder V alve Remove c ap, stand to side of valve, and open valve slightly . Gas flow blows dust and dirt from valve. Close[...]

  • Page 11

    TM-944 Page 9 Handler 135 / 175 Return T o T able Of Contents 3-6. Selecting A Location And Connecting Input Power For 1 15 V AC Model 1 Rating Label 2 Grounded Receptacle A 1 15 volt, 20 ampere individual branch circuit protected by ti me- de - lay fuses or circuit breaker is re- quired. 3 Plug From Unit Select extension cord of 14 A WG fo r up to[...]

  • Page 12

    TM-944 Page 10 Handler 135 / 175 Return T o T able Of Contents 3-7. Selecting A Location And Connecting Input Power For 230 V AC 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 installation may be required where gasoline o[...]

  • Page 13

    TM-944 Page 1 1 Handler 135 / 175 Return T o T able Of Contents 3-8. Electrical Service Guide For 230 V AC Model Input V oltage 230 Input Amperes At Rated Output 20 Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes 20 Min Input Conductor Size In A WG/Kcmil 14 Max Recommended Input Conductor Length In Feet (Meters) 66 (20) Min Groun[...]

  • Page 14

    TM-944 Page 12 Handler 135 / 175 Return T o T able Of Contents 3-10. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Conduit Cable Lay gun cable out straight. Ref. 802 444-C T ools Ne e d e d : 6 1 3 4 5 Pull and hold wire; cut off end. 4 in (102 mm) Remove gun nozzle and contact t[...]

  • Page 15

    TM-944 Page 13 Handler 135 / 175 Return T o T able Of Contents SECTION 4 − O P E R A T I O N 4-1. Controls 1 V oltage 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 [...]

  • Page 16

    TM-944 Page 14 Handler 135 / 175 Return T o T able Of Contents 4-2. W eld Parameter Chart For 1 15 V AC Model W elding Guide Settings are appr oximate. Adjust as requir ed. Thicker materials can be welded using proper technique, joint preparation, and multiple passes. Match feedroll groove to diameter of wire being used. Set Tension Knob Setting to[...]

  • Page 17

    TM-944 Page 15 Handler 135 / 175 Return T o T able Of Contents 209 228 for 1 15 V olt W ire W elding Package DCEN DCEP Wi re 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, cleanliness of metal, etc. keep torch as [...]

  • Page 18

    TM-944 Page 16 Handler 135 / 175 Return T o T able Of Contents 4-3. W eld Parameter Chart For 230 V AC Model W elding Guide Settings are approximate. Adjust as requir ed. Thicker materials can be welded using proper technique, joint pr eparation, and multiple passes. Match feedroll groove to diameter of wire being used. Set T ension Knob Setting to[...]

  • Page 19

    TM-944 Page 17 Handler 135 / 175 Return T o T able Of Contents 209 229 for 230 V olt W ire W elding Package DCEN DCEP Wi re 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, cleanliness of metal, etc. keep torch as s[...]

  • Page 20

    TM-944 Page 18 Handler 135 / 175 Return T o T able Of Contents 1 Circuit Breaker CB1 Protects unit from an over-current condition by opening primary power line. 2 Power Switch S1 T urns unit and fan motor FM on and of f. 3 Fa n Motor FM And T ransformer Controlled by power switch S1. Fan cools internal components, and transformer supplies control v[...]

  • Page 21

    TM-944 Page 19 Handler 135 / 175 Return T o T able Of Contents AC Or DC Control Circuits W eld Current Circuit Welding Wire W ork 12 (Electrode) 9 Range Switch S2 10 Main T ransformer T1 11 Main Rectifier SR1 13 Stablizer L1 Capacitor C1 14 Polarity Changeover Block Wire Drive Motor 15[...]

  • Page 22

    TM-944 Page 20 Handler 135 / 175 Return T o T able Of Contents SECTION 6 − TROUBLESHOOTING 6-1. T roubleshooting T able . See Section 6-2 or 6-3 for test points and values and Section 9 for parts location. T rouble Remedy No weld output; wire does not feed; fan does not run. Secure power cord plug PLG1 in receptacle (see Section 3-6 or 3-7). Repl[...]

  • Page 23

    TM-944 Page 21 Handler 135 / 175 Return T o T able Of Contents T rouble Remedy No weld output; wire feeds. 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 f[...]

  • Page 24

    TM-944 Page 22 Handler 135 / 175 Return T o T able Of Contents 6-2. T roubleshooting Circuit Diagram For Welding Power Source (1 15 V AC Model) T est Equipment Needed: V1 V2 V3 V4 V5 V7 V6 V10 V8/R5 V9/R6 R8 V1 1/R9 R1 R2 R3 R4 See also Section 6-4 for PC1 data R7[...]

  • Page 25

    TM-944 Page 23 Handler 135 / 175 Return T o T able Of Contents V oltage Readings a) T olerance − ± 10 % unless specified b) Wiring Diagram − see Section 8 V1 1 15 volts ac with power cord plugged in V2 1 15 volts ac with Power switch S1 On V3 24 volts ac with Power switch S1 On V4 30 volts dc with Power switch S1 On V5 27 volts dc with gun tri[...]

  • Page 26

    TM-944 Page 24 Handler 135 / 175 Return T o T able Of Contents 6-3. T roubleshooting Circuit Diagram For Welding Power Source (230 V AC Model) T est Equipment Needed: V1 V2 V3 V4 V5 V7 V6 V10 V8/R5 V9/R6 R8 V1 1/R9 R1 R2 R3 R4 See also Section 6-6 for PC1 data R7[...]

  • Page 27

    TM-944 Page 25 Handler 135 / 175 Return T o T able Of Contents V oltage Readings a) T olerance − ± 10 % unless specified b) Wiring Diagram − see Section 8 V1 23 0 volts ac with power cord plugged in V2 230 volts ac with Power switch S1 On V3 24 volts ac with Power switch S1 On V4 30 volts dc with Power switch S1 On V5 27 volts dc with gun trig[...]

  • Page 28

    TM-944 Page 26 Handler 135 / 175 Return T o T able Of Contents 6-4. Control Board PC1 T esting Information (1 15 V AC Model) Be sure plugs are secure before testing. See Section 6 - 5 for specific values during testing. 1 Control Board PC1 2 Receptacle RC1 3 Receptacle RC2 4 Receptacle RC4 5 Receptacle RC5 6 TP-A 7 TP-B 8 TP-C 9 TP-D 10 TP-E 1 1 TP[...]

  • Page 29

    TM-944 Page 27 Handler 135 / 175 Return T o T able Of Contents 6-5. Control Board PC1 T est Point V alues (1 15 V AC Model) PC1 V oltage Readings a) T olerance − ± 10% unless specified b) Reference − to circuit common unless noted V oltage Readings: a) T olerance − ± 10% unless specified b) Reference − as noted Receptacle Pin V alue RC1 1[...]

  • Page 30

    TM-944 Page 28 Handler 135 / 175 Return T o T able Of Contents 6-6. Control Board PC1 T esting Information (230 V AC Model) Be sure plugs are secure before testing. See Section 6 - 7 for specific values during testing. 1 Control Board PC1 2 Receptacle RC1 3 Receptacle RC2 4 Receptacle RC4 5 Receptacle RC5 6 TP-A 7 TP-B 8 TP-C 9 TP-D 10 TP-E 1 1 TP-[...]

  • Page 31

    TM-944 Page 29 Handler 135 / 175 Return T o T able Of Contents 6-7. Control Board PC1 T est Point V alues (230 V AC Model) PC1 V oltage Readings a) T olerance − ± 10% unless specified b) Reference − to circuit common unless noted V oltage Readings: a) T olerance − ± 10% unless specified b) Reference − as noted Receptacle Pin V alue RC1 1 [...]

  • Page 32

    TM-944 Page 30 Handler 135 / 175 Return T o T able Of Contents 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. Overloa[...]

  • Page 33

    TM-944 Page 31 Handler 135 / 175 Return T o T able Of Contents 7-4. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire G u i d e S e c u r i n g Screw 2 Inlet Wire Guide Loosen screw . Slide tip as close to drive rolls as possible without touching. Tigh ten screw . 3 Drive Roll The drive roll consists of two dif fer- ent sized grooves. The stampe[...]

  • Page 34

    TM-944 Page 32 Handler 135 / 175 Return T o T able Of Contents 7-6. Cleaning Or Replacing Gun Liner Ref. 802 446 8 mm / 10mm Y Disconnect gun from unit. T ools Needed: T o 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 tight- en two full turns more. Cut lin[...]

  • Page 35

    TM-944 Page 33 Handler 135 / 175 Return T o T able Of Contents 7-7. Replacing Switch And/Or Head T ube Ref. ST-800 795-C T ools Ne e d e d : 19 mm Remove handle locking nut. Slide handle. Secure head tube in vice. Loosen jam nut. Remove from vice an d turn head tube out by hand. Hand-tighten head tube into cable connector . Place head tube in vice [...]

  • Page 36

    TM-944 Page 34 Handler 135 / 175 Return T o T able 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 inside machine case or contact your distributor for further information. Model Serial Or Style Number Circuit Diag[...]

  • Page 37

    TM-944 Page 35 Handler 135 / 175 Return T o T able Of Contents 194 324-C Figure 8-1. Circuit Diagram For 1 15 V AC Model Effective With Serial No. KK213350 And Following[...]

  • Page 38

    TM-944 Page 36 Handler 135 / 175 Return T o T able Of Contents 194 325-A Figure 8-2. Circuit Diagram For 230 V AC Model Effective With Serial No. KK213350 And Following[...]

  • Page 39

    TM-944 Page 37 Handler 135 / 175 Return T o T able Of Contents 196 637-A Figure 8-3. Wiring Diagram For 1 15 V AC Model Effective With Serial No. KK213350 And Following[...]

  • Page 40

    TM-944 Page 38 Handler 135 / 175 Return T o T able Of Contents 196 655-A Figure 8-4. Wiring Diagram For 230 Model Effective With Serial No. KK213350 And Following[...]

  • Page 41

    TM-944 Page 39 Handler 135 / 175 Return T o T able Of Contents 195 890-A Figure 8-5. Circuit Diagram For 1 15 V AC Model Control Board PC1 Effective With Serial No. KK213350 And Following[...]

  • Page 42

    TM-944 Page 40 Handler 135 / 175 Return T o T able Of Contents 195 891-A Figure 8-6. Circuit Diagram For 230 V AC Model Control Board PC1 Effective With Serial No. KK213350 And Following[...]

  • Page 43

    V isit our website at www.HobartWelders.com H a n d l e r 1 3 5 / 1 7 5 And H-10 Gun TM -944C Oc tober 2003 Handler 135 (500 414) Eff. w/Serial No. LB096205 Handler 175 (500 416) Eff. w/Serial No. LB075197 Processes Arc Welding Power Source And Wire Feeder Description MIG (GMAW ) W elding Flux Cored (FCA W ) W elding[...]

  • Page 44

    TM-944 Page 42 Handler 135 / 175 Return T o T able Of Contents SECTION 9 − P ARTS LIST . Hardware is common and not 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 9-1. Main Assembly[...]

  • Page 45

    TM-944 Page 43 Handler 135 / 175 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly Quanti ty 1 199 566 DOOR, access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 196 006 HINGE, door 2 . . . . . . . . . . . .[...]

  • Page 46

    TM-944 Page 44 Handler 135 / 175 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly (Continued) Quanti ty 41 196 574 SWITCH, rocker DPST (230 V AC model) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 207 078 KNOB, pointer (WFS) 1 . . . . . . . . . . . .[...]

  • Page 47

    TM-944 Page 45 Handler 135 / 175 Return T o T able Of Contents Figure 9-2. H-10 Gun Quanti ty Description Part No. 195 957 Item No. Figure 9-2. H-10 Gun 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 ♦ 087 299 TIP , contact scr .023 wire x 1.[...]

  • Page 48

    PRINTED IN USA  2003 Hobart Welding Products Hoba rt We lding Product s An I l li noi s T ool Works Com pany 600 West M ain Street Troy , O H 45373 USA For Technical Assi stance: Call1-800-332-3281 For Lit erat ure Or Neares t Deal er: Call 1-877-Hobart 1[...]