Hobart Handler 140 Manuals

www.HobartWelders.com OM-923 223 112H 2013−05 File: Flux Cored (FCAW) Processes Description Flux Cored (FCAW) Welding Handler 125 EZ and H−9B Gun 115 V Gasless Flux−Cored Wire Feed Welder  TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc Welding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols For Installation, Operation, And Maintenance 3 . . . . . . . . . . . . . . . . . . . . . . . 1-4. California Proposition 65 Warnings 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Principal Safety Standards 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-6. EMF Information 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Symboles utilisés 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2. Dangers relatifs au soudage à l’arc 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 7 2-4. Proposition californienne 65 Avertissements 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5. Principales normes de sécurité 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6. Informations relatives aux CEM 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 − DEFINITIONS 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Miscellaneous Symbols And Definitions 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 − SPECIFICATIONS 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Included With Your Unit 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Serial Number And Rating Label Location 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Unit Specifications 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Duty Cycle And Overheating 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Volt-Ampere Curves 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 − INSTALLATION 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Selecting A Location 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Installing Work Clamp 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Process/Polarity Table 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-4. Setting Polarity 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-5. Installing Wire Spool And Adjusting Hub Tension 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-6. Installing Contact Tip And Nozzle 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7. Connecting 115 Volts Input Power 17 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-8. Threading Welding Wire 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 − OPERATION 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1. Controls 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2. Operating The Gun 19 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 − MAINTENANCE &TROUBLESHOOTING 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Routine Maintenance 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Overload Protection 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Drive Motor Protection 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Changing Drive Roll Or Wire Inlet Guide 21 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5. Replacing Gun Contact Tip 22 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6. Cleaning Gun Liner 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-7. Replacing Gun Liner 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8. Troubleshooting Table 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9. Long Term Storage 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 − ELECTRICAL DIAGRAM 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hobart is registered to the ISO 9001 Quality System Standard. TABLE OF CONTENTS SECTION 9 − FCAW WELDING GUIDELINES 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Typical FCAW Process Connections 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Typical Control Settings 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-3. Holding And Positioning Welding Gun 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4. Conditions That Affect Weld Bead Shape 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5. Gun Movement During Welding 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6. Poor Weld Bead Characteristics 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-7. Good Weld Bead Characteristics 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-8. Troubleshooting − Excessive Spatter 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9. Troubleshooting − Porosity 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-10. Troubleshooting − Excessive Penetration 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11. Troubleshooting − Lack Of Penetration 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12. Troubleshooting − Incomplete Fusion 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-13. Troubleshooting − Burn-Through 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14. Troubleshooting − Waviness Of Bead 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-15. Troubleshooting − Distortion 35 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-16. Troubleshooting Guide For Semiautomatic Welding Equipment 35 . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 − ACCESSORIES/CONSUMABLES 36 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COMPLETE PARTS LIST − Available at www.HobartWelders.com WARRANTY

115 Volt Handler ® 140 115V Wire Feed Welder Includes: Comfortable 10-ft. (3 m) H100S2-10 gun 10-ft. (3 m) work cable with clamp Built-in gas solenoid valve and dual-gauge regulator with gas hose Spool hub assembly accommodates 4 or 8 in. spools Sample spool of .030 in. (0.8 mm) self-shielding flux-cored wire .030 in. (0.8 mm) contact tips Power cord with plug Weld set-up chart Owner’s manual with parts lists, installation, operation and maintenance guidelines Stable arc with improved performance on thin gauge material. Provides positive feed with adjustable tension. Easy access for threading wire. Provides a broader operating window for each wire, with quick and easy adjustment for different thicknesses and joints. Eases use and excellent safety feature which makes wire electrically “cold” until trigger is pulled. Access makes it quick and easy to change polarity for solid or tubular wire. Includes convenient storage holes for spare tips. Makes it easy to change from one wire size to another. One knurled groove and one smooth groove for .030–.035 in. (0.8–0.9 mm) wire. Makes controls quickly visible and accessible. Protects unit against current overload. Protects power transformer to ensure reliability. Protects wire feed system from overload, no fuses to change or circuit breaker buttons to reset. Five-year warranty on transformers, three years on electronics (drive motors, rectifiers) and one year on guns. Excellent arc performance Proven built-in wire feeder with quick-release tension lever Four output voltage settings with wire feed speed tracking Built-in contactor Convenient polarity changeover with tip holder Dual-groove quick-change drive roll Sloped control panel Short circuit protection Self-resetting thermal overload Self-resetting motor protection Hobart's 5/3/1 Industrial Warranty 217919 March 2011 Features Benefits B uilt with Hobart quality and durability, the Handler 140 is a wire welding package with industrial performance capable of operating on standard 115/120 volt, 20 amp home circuits. The broad output range of 25–140 amps allows you to weld 24 gauge up to 1/4 inch steel. The Handler 140 is capable of running the following wires: .023–.035 in. (0.6–0.9 mm) mild steel or stainless steel, .030–.035 in. (0.8–0.9 mm) flux-cored, and .030 in. (0.8 mm) aluminum. Four output voltage settings with wire feed tracking make the unit easy to set and adjust for different materials and thicknesses. #500500 Applications: Home, farm and ranch and light fabrication projects. Mower Decks/Brackets Grills/Smokers Fences/Gates Firewood Racks Kennels Metal Furniture Signs Machinery and Window Security Guards Auto Repair, etc. 2 Flux Cored E71T-11 (DCEN) Solid Wire ER70S-6 (DCEP) Solid Wire ER70S-6 (DCEP) Stainless Steel (DCEP) Aluminum** (DCEP) Good for windy or outdoor applications Produces less spatter. Better bead appearance. — — — — — 1/30 2/30 2/20 3/50 3/35 3/30 3/40 4/30 3/40 3/20 4/70 4/40 4/40 4/40 4/35 4/45 4/35 — — — — — — 4/50* — — — — 4/30 — — — — — 2/30 2/20 — — 1/25 — 3/40 2/30 3/25 3/30 3/20 4/25 — 4/50 3/40 2/30 — — 4/30 3/10 2/15 — 4/90** 3/90** — 2/30 — — — — — — — — — — — — CFH Settings are approximate. Adjust as required. Thicker materials can be welded using proper technique, joint preperation and multiple passes. Recommended Voltage 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. *Multiple passes required. **Aluminum wire is soft so feedability is not as good. Make sure that hub tension is not too tight and keep the torch as straight as possible. A “push angle” for the torch is recommended. Match feed roll groove to diameter of wire being used. Set tension knob setting to 3 at start. Adjust tension per instructions in the manual. CAUTION! Do not change voltage switch position while welding. See owners manual for more information. 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, cleanliness of metal, etc. Handler 140 Welding Guide Control Panel 1. Power Switch 2. Wire Speed Control 3. Voltage Control Switch 1 2 3 Certified by Canadian Standards Association to both the Canadian and U.S. Standards. *CSA rating. Specifications (SUBJECT TO CHANGE WITHOUT NOTICE.) Rated Output 90 A, 19 VDC, at 20% Duty Cycle 63 A, 21 VDC at 20% Duty Cycle* Max. Open- Circuit Voltage 28 V Wire Feed Speed Range 40–700 IPM 50–740 IPM at no load Current Range 25–140 A Amps Input at Rated Output, 60 Hz, 1-Phase 115 V KVA KW 20 2.9 2.5 15* 2.2* 1.77* Dimensions H: 12-3/8 in. (315 mm) W: 10-5/8 in. (270 mm) D: 19-1/2 in. (495 mm) Net Weight 57 lb. (26 kg) Spool Gun 3035-20 #300143 20 ft. (6.1 m) cable and gas hose Weld 14 gauge–1/8 in. (1.9–3.2 mm) aluminum with the Handler 140 Threaded nozzle and contact tips Spool gun conversion kit consisting of control switch and gas diverter valve Enclosed wire spool compartment with internal spool hub tension adjustment for 4 in. (102 mm) rolls of wire For .030–.035 in. (0.8–0.9 mm) aluminum, steel and stainless steel Rated 150 amps, 60% duty cycle SGA 100 Spool Gun Control #043856 Required to connect spool gun to the Handler® 140. Includes 10 ft. (3 m) 115 VAC power cable and plug, 6 ft. (1.8 m) interconnecting cable, and 5 ft. (1.5 m) gas hose. H100S2-10 Replacement MIG Torch #245924 Comes in 10-ft. (3 m) length with liner for .030–.035 in. (0.8–0.9 mm) diameter wire. Portable CO2 Cylinder Kit #770626 Includes one 20 oz. CO2 cylinder (paintball style), pre-set regulator and gas hose, spare “O” rings, and mounting hardware. Small Cart/Cylinder Rack #194776 Designed for portable MIG welders. Accommodates large and small gas cylinders. Running Gear/Cylinder Rack #770187 Heavy-duty construction. Accommodates large and small gas cylinders. Protective Cover #195186 Weather-resistant nylon resists stains and mildew while protecting the finish of your welder. Accessories 3 DUTY CYCLE 1 4 10 20 40 60 100 2 6 80 8 10 20 40 60 80 100 200 140 DUTY CYCLE % OUTPUT AMPERES VOLT/AMP CURVE 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 0 5 10 15 20 25 30 AMPERAGE VOLTAGE RANGE 1 RANGE 2 RANGE 3 RANGE 4 Performance Data

www.HobartWelders.com TM-258 267B 2013−03 Eff. w/Serial No. MC370275Y Processes Arc Welding Power Source And Wire Feeder Description MIG (GMAW) Welding Flux Cored (FCAW) Welding Handler 140 And H100S2-10 Gun � File: MIG (GMAW) TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Servicing Hazards 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. California Proposition 65 Warnings 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4. EMF Information 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 − DEFINITIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Miscellaneous Symbols And Definitions 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 − SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Serial Number And Rating Label Location 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Specifications 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Duty Cycle And Overheating 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Volt-Ampere Curves 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 − INSTALLATION 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Selecting A Location 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Installing Welding Gun 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3. Installing Work Clamp 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4. Process/Polarity Table 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5. Changing Polarity 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6. Installing Gas Supply 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-7. Connecting Input Power 9 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9. Installing Wire Spool And Adjusting Hub Tension 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10. Installing Contact Tip And Nozzle 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11. Threading Welding Wire 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 − OPERATION 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Controls 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Weld Parameter Chart 15 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 − THEORY OF OPERATION 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 − TROUBLESHOOTING 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1. Troubleshooting Table 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2. Troubleshooting Circuit Diagram For Welding Power Source 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3. Control Board PC1 Testing Information (Use With Section 7-4) 22 . . . . . . . . . . . . . . . . . . . . . . . . . 7-4. Control Board PC1 Test Point Values 23 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 8 − MAINTENANCE 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. Routine Maintenance 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. Overload Protection 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3. Drive Motor Protection 24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-4. Changing Drive Roll Or Wire Inlet Guide 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5. Replacing Gun Contact Tip 25 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-6. Cleaning Or Replacing Gun Liner 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-7. Replacing Switch And/Or Head Tube 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 9 − ELECTRICAL DIAGRAMS 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 10 − PARTS LIST 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 11 − ACCESSORIES AND CONSUMABLES 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Hobart is registered to the ISO 9001 Quality System Standard. TM-258 267 Page 1 Handler 140 SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage OM-258 267A - 2012 − 09, safety_stm 2011−10 DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. Indicates a hazardous situation which, if not avoided, could result in death or serious injury. The possible hazards are shown in the adjoining symbols or ex- plained in the text. NOTICE − Indicates statements not related to personal injury. � Indicates special instructions. This group of symbols means Warning! Watch Out! ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult sym- bols and related instructions below for necessary actions to avoid the hazards. 1-2. Servicing Hazards 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. Only qualified persons should test, maintain, and repair this unit. During servicing, keep everybody, especially children, away. ELECTRIC SHOCK can kill. � Do not touch live electrical parts. � 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 re- ceptacle, or stop engine before servicing unless the procedure spe- cifically requires an energized unit. � Insulate yourself from ground by standing or working on dry insulat- ing mats big enough to prevent contact with the ground. � Do not leave live unit unattended. � If this procedure requires an energized unit, have only personnel familiar with and following standard safety practices do the job. � When testing a live unit, use the one-hand method. Do not put both hands inside unit. Keep one hand free. � Disconnect input power conductors from deenergized supply line BEFORE moving a welding power source. SIGNIFICANT DC VOLTAGE exists in inverter weld- ing power sources AFTER removal of input power. � Turn Off inverter, disconnect input power, and discharge input capacitors according to instructions in Troubleshooting Section be- fore touching any parts. STATIC (ESD) can damage PC boards. � Put on grounded wrist strap BEFORE handling boards or parts. � Use proper static-proof bags and boxes to store, move, or ship PC boards. FIRE OR EXPLOSION hazard. � Do not place unit on, over, or near combustible surfaces. � Do not service unit near flammables. FLYING METAL or DIRT can injure eyes. � Wear safety glasses with side shields or face shield during servicing. � Be careful not to short metal tools, parts, or wires together during testing and servicing. HOT PARTS can burn. � Do not touch hot parts bare handed. � Allow cooling period before working on equipment. � To handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns. EXPLODING PARTS can injure. � Failed parts can explode or cause other parts to explode when power is applied to inverters. � Always wear a face shield and long sleeves when servicing inverters. SHOCK HAZARD from testing. � Turn Off welding power source and wire feeder or stop engine before making or changing me- ter lead connections. � Use at least one meter lead that has a self- retaining spring clip such as an alligator clip. � Read instructions for test equipment. FALLING EQUIPMENT can injure. � Use lifting eye to lift unit only, NOT running gear, gas cylinders, or any other accessories. � Use equipment of adequate capacity to lift and support unit. � If using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit. � Follow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manu- ally lifting heavy parts or equipment. TM-258 267 Page 2 Handler 140 MOVING PARTS can injure. � Keep away from moving parts such as fans. � Keep away from pinch points such as drive rolls. � Have only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary. � Keep hands, hair, loose clothing, and tools away from moving parts. � Reinstall doors, panels, covers, or guards when maintenance is finished and before re- connecting input power. ELECTRIC AND MAGNETIC FIELDS (EMF) can affect Implanted Medical Devices. � Wearers of Pacemakers and other Implanted Medical Devices should keep away from serv- icing areas until consulting their doctor and the device manufacturer. OVERUSE can cause OVERHEATING. � Allow cooling period; follow rated duty cycle. � Reduce current or reduce duty cycle before starting to weld again. � Do not block or filter airflow to unit. H.F. RADIATION can cause interference. � High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. � Have only qualified persons familiar with electronic equipment install, test, and service H.F. producing units. � The user is responsible for having a qualified electrician prompt- ly correct any interference problem resulting from the installa- tion. � If notified by the FCC about interference, stop using the equipment at once. � Have the installation regularly checked and maintained. � 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. � Use Testing Booklet (Part No. 150 853) when servicing this unit. � Consult the Owner’s Manual for welding safety precautions. � Use only genuine replacement parts from the manufacturer. � Read and follow all labels and the Technical Manual carefully be- fore installing, operating, or servicing unit. Read the safety in- formation at the beginning of the manual and in each section. 1-3. California Proposition 65 Warnings 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.) This product contains chemicals, including lead, known to the state of California to cause cancer, birth defects, or other reproductive harm. Wash hands after use. 1-4. EMF Information Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). Welding current creates an EMF field around the welding circuit and welding equipment. EMF fields may inter- fere with some medical implants, e.g. pacemakers. Protective measures for persons wearing medical implants have to be taken. For example, restrict access for passers−by or conduct individual risk as- sessment for welders. All welders should use the following procedures in order to minimize exposure to EMF fields from the welding circuit: 1. Keep cables close together by twisting or taping them, or using a cable cover. 2. Do not place your body between welding cables. Arrange cables to one side and away from the operator. 3. Do not coil or drape cables around your body. 4. Keep head and trunk as far away from the equipment in the welding circuit as possible. 5. Connect work clamp to workpiece as close to the weld as possible. 6. Do not work next to, sit or lean on the welding power source. 7. Do not weld whilst carrying the welding power source or wire feeder. About Implanted Medical Devices: Implanted Medical Device wearers should consult their doctor and the device manufacturer before performing or going near arc welding, spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures is recom- mended.