Hobart Handler 140 Technical Manual

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)

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.

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.

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.

Handler 140 SECTION 2 − DEFINITIONS 2-1. Miscellaneous Symbols And Definitions A Amperage V Voltage Hz Hertz Negative Positive Direct Current (DC) Single Phase Input Output Voltage Input Off On Do Not Switch While Welding Gas Metal Arc Welding (GMAW) Wire Feed Line Connection Single Phase Transformer Rectifier S Suitable For Welding In An Environment With Increased Risk Of Electric Shock Percent U0 Rated No-Load Voltage U1 Rated Supply Voltage U2 Load Voltage I1 Rated Supply Current I2 Rated Welding Current X Duty Cycle SECTION 3 − SPECIFICATIONS 3-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 3-2. Specifications 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 @ 18.5 Volts DC, 20% Duty Cycle 25 − 140 28 20 2.90 2.50 57 lb (26 kg) Length: 19-1/2 in. (495 mm) Width: 10-5/8 in. (270 mm) Height: 12-3/8 in. (314 mm) Wire Type And Diameter Solid/ Stainless Flux Cored Aluminum Wire Feed Speed Range .023 − .035 in. (0.6 − 0.9 mm) .030 − .035 in. (0.8 − 0.9 mm) .030 in. (0.8 mm) 50 − 740 IPM (1.3 − 18.8 m/min) At No Load 40 − 700 IPM (1.0 − 17.8 m/min) Feeding Wire

Handler 140 3-3. Duty Cycle And Overheating Duty Cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, over temperature LED lights, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool, the therostat will automatically reset. Reduce amperage or duty cycle before welding. NOTICE − Exceeding duty cycle can damage unit or gun and void warranty. Overheating 0 15 A or V OR Reduce Duty Cycle Minutes duty1 4/95 − 217 623-A 20% duty cycle at 90 amps 1 4 10 20 40 60 100 2 6 80 8 10 20 40 60 80 100 200 140 Duty Cycle % Output Amperes 2 Minutes Welding 8 Minutes Resting 3-4. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. ssb1.1 10/91 − 257 981-A 0 5 10 15 20 25 30 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 Voltage Amperage RANGE 5 RANGE 4 RANGE 3 RANGE 2 RANGE 1

Handler 140 SECTION 4 − INSTALLATION 4-1. Selecting A Location 1 Plug From Unit 2 Grounded Receptacle Locate unit near correct input power supply. ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. 2 258 641-A ! Do not move or operate unit where it could tip. 1 18 in. (460 mm) 18 in. (460 mm)

Handler 140 4-2. Installing Welding Gun 258 315-A 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew. Insert end of gun through opening in front panel until it bottoms against drive assembly. Tighten thumbscrew. Welding gun must be inserted completely to prevent leakage of shielding gas. 4 Gun Trigger Leads Insert leads, one at a time, through gun opening on front panel. Connect female friction terminals to matching male terminals in unit. Polarity is not important. Close door. Correct Incorrect � Be sure that gun end is tight against drive assembly. Gun Fully Seated 3 Gun Not Seated Exposed O-rings will cause shielding gas leakage. 4 1 2 3 4-3. Installing Work Clamp 1 Work Clamp 2 Work Cable From Unit 3 Screw 4 Flat Washer 5 Lock Washer 6 Nut Route work cable through hole in clamp handle. Secure cable with hardware as shown. 258 550-A � Connection hardware must be tightened with proper tools. Do not just hand tighten hardware. A loose electrical connection will cause poor weld performance and excessive heating of the work clamp. Tools Needed: 10 mm 1 2 3 4 5 6

Handler 140 4-4. Process/Polarity Table Process Polarity Cable Connections Cable To Gun Cable To Work GMAW − Solid wire with shielding gas DCEP − Reverse polarity Connect to positive (+) output terminal Connect to negative (−) output ter- minal FCAW − Self-shielding wire − no shielding gas DCEN − Straight Polarity Connect to negative (−) output terminal Connect to positive (+) output termi- nal 4-5. Changing Polarity 1 Lead Connections For Direct Current Electrode Negative (DCEN) 2 Lead Connections For Direct Current Electrode Positive (DCEP) Always read and follow wire manufacturer’s recommended polarity, and see Section 4-4. Close door. 258 321-A 1 2

Handler 140 4-6. Installing Gas Supply Obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 Cap 2 Cylinder Valve Remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Close valve. 3 Cylinder 4 Regulator/Flowmeter Install so face is vertical. 5 Regulator/Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect supplied gas hose between regulator/flowmeter gas hose connection, and fitting on rear of welding power source. 7 Flow Adjust Flow rate should be set when gas is flowing through welding power source and welding gun. Open feedhead pressure assembly so that wire will not feed. Press gun trigger to start gas flow. Typical flow rate is 20 cfh (cubic feet per hour). Check wire manufacturer’s recommended flow rate. After flow is set, close pressure assembly. Tools Needed: 258 331-B 6 Argon Gas Or Mixed Gas � DO NOT use Argon/Mixed gas regulator/flowmeter with CO2 shielding gas. See Parts List for optional CO2 gas regulator/flowmeter. Feedhead Pressure Assembly Open Feedhead Pressure Assembly Closed 1 2 3 4 5 7 5/8 or 11/16, 1-1/8 in.

Handler 140 4-7. Connecting Input Power ! Installation must meet all National and Local Codes − have only qualified persons make this installation. ! Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. A 115 volts AC, 20 ampere individual circuit protected by time-delay fuses or circuit breaker is required. 1 Plug From Unit 2 Receptacle − NEMA Type 5−15R (Customer Supplied) 2 Input6 2011−03 258 641-A ! Do not move or operate unit where it could tip. 1 4-8. Selecting Extension Cord (Use Shortest Cord Possible) Single Phase AC Input Voltage Conductor Size − AWG (mm2)* 10 (5.3) 12 (3.3) Maximum Allowable Cord Length in ft (m) 115 100 (30.5) 50 (15.0) *Conductor size is based on maximum 3% voltage drop

Handler 140 4-9. Installing Wire Spool And Adjusting Hub Tension When a slight force is needed to turn spool, tension is set. 1/2 in. Tools Needed: Installing 8 in. (203 mm) Wire Spool Installing 4 in. (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set. Retaining ring used with 8 in. (203 mm) spool only. Adapter used with 8 in. (203 mm) spool only. 803 012 / 803 013 -B / Ref. 802 971-C Align locking hole in spool with locking pin on spool hub.

Handler 140 4-10. Installing Contact Tip And Nozzle Tools Needed: Ref. 246 669-A ! Turn off welding power source. 1 Nozzle Remove nozzle. 2 Contact Tip 3 Tip Adapter Thread welding wire through gun (see Section 4-11). Slide contact tip over wire and tighten tip into tip adapter. Install nozzle. Flux Nozzle (Optional) MIG Nozzle (Standard) Use with flux cored wire only. Narrow design allows access in tight spaces and provides better visibility of puddle during welding. Use with solid or flux cored wire. Push nozzle over contact tip and adapter until it is seated onto adapter. Contact tip will be exposed approximately 7/16 in. (11.3 mm) when installed properly. Push nozzle over contact tip and adapter until it is seated onto adapter. End of contact tip will be flush with end of nozzle when installed properly. 1 2 3

Handler 140 4-11. 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. Tools Needed: Pull and hold wire; cut off end. Open pressure assembly. Make sure feed roll is set to correct groove to match wire size (see Section 8-4). � Hold wire tightly to keep it from unraveling. 6 in. (150 mm) 1 2 4 in. (102 mm) Straighten approximately 3 or 4 inches (76 or 102 mm) of wire before inserting wire into guides. Push wire thru guides into gun; continue to hold wire. 3 6 1 3 4 5 2

Handler 140 Remove gun nozzle and contact tip. 258 339-A Feed wire to check drive roll pressure. Tighten knob enough to prevent slipping. Cut off wire. Close door. Press gun trigger until wire comes out of gun. (Keep gun cable as straight as possible.) Turn power on. Be sure that Voltage range switch is set to range 1, 2, 3, or 4 to feed wire. Rotate knob until it “clicks” into detent. Wire will not feed if range switch is set between ranges. � Use pressure indicator scale to set a desired drive roll pressure. (Start with a setting of 2 on the scale.) Pressure Indicator Scale Be sure that wire is positioned in proper feed roll groove. Close and tighten pressure assembly, and let go of wire. Be sure that tip matches wire diameter. Reinstall contact tip and nozzle. 4 5 6 7 8 9 4 2 3 1 Tighten WOOD 4 2 3 1 Tighten 4 To 6 in. (102 To 152 mm)

Handler 140 SECTION 5 − OPERATION 5-1. Controls 1 Wire Speed Control Use control to select a wire feed speed. As Voltage switch setting increases, wire speed range also increases (see weld setting label in welding power source or Section 5-2). 2 Power Switch 3 Voltage Switch The higher the selected number, the thicker the material that can be welded (see weld setting label in welding power source or Section 5-2). Do not switch under load. � Switch must “click” into detent position for weld output. 4 Over Temperature Light Light illuminates if main transformer over- heats. 5 Gun Trigger Switch Pressing gun trigger energizes wire feed motor and gas valve for shielding gas flow. 258 346-A 3 1 2 5 4

Handler 140 1 Supplementary Protector CB1 Protects unit from an over-current condition by opening primary power line. 2 Power Switch S1 Turns unit and fan motor FM on and off. 3 Contactor CR3 Turns weld output on and off. Provides shielding gas flow when CR3 is energized. 4 Fan Motor FM And Control Transformer Controlled by power switch S1. Fan cools internal components, and transformer supplies 24 volts AC to PC1 control circuit. 5 Range Switch S2 Allows selection of a primary winding tap which provides a weld output voltage level. 6 Gas Valve GS1 Provides shielding gas flow when CR3 is energized. 7 Control Board PC1 Switches weld output on and off by controlling CR3. Regulates motor speed at a percentage set with Wire Speed control R2. Provides dynamic motor braking and starting through the motor relay. Provides a bleeder resistor for capacitor C1. 8 Thermostat TP1 If main transformer overheats, TP1 opens gun switch circuit stopping all weld output. 9 Gun Trigger Receptacle RC3 Connects gun trigger circuit to welding power source. 10 Wire Speed Control R2 Sets a wire feed motor speed by providing a reference voltage to motor control circuit on PC1. 11 Wire Drive Motor Feeds wire at a speed set by R2. Wire drive circuit on PC1 receives weld output voltage so that voltage changes result in motor speed changes. 12 Main Transformer T1 Supplies power to weld output circuit. 13 Rectifier SR1 Changes the AC output from T1 to full-wave rectified DC output. SECTION 6 − THEORY OF OPERATION 2 4 6 Single-Phase Line Input Power 1 Supplementary Protector CB1 Power Switch S1 Gas Valve GS1 Line L1 Neutral Line (115 VAC Model) Fan Motor FM And Control Transformer Control Board PC1 7 Line L2 (230 VAC Models) 3 Contactor CR3 5 Range Switch S2 17 Over Temperature Light PL1

Handler 140 AC Or DC Control Circuits Weld Current Circuit Welding Wire Work 14 (Electrode) 12 Main Transformer T1 13 Rectifier SR1 15 Stablizer L1 Capacitor C1 16 Polarity Changeover Block Wire Drive Motor 11 8 9 Thermostat TP1 Gun Trigger Receptacle RC3 10 Wire Speed Control R2 14 Output Capacitor C1 Smooths DC weld voltage from rectifier SR1. 15 Stabilizer L1 Smooths DC weld current. 16 Polarity Changeover Block Terminals allow changing between DCEP and DCEN processes. 17 Over Temperature Light PL1 Indicates that the transformer is overheated.

Handler 140 SECTION 7 − TROUBLESHOOTING 7-1. Troubleshooting Table � See Section 7-2 for test points and values and Section 10 for parts location. � Use Miller Testing Booklet (Part No. 150 853) when servicing this unit. � See the Miller Extranet for service memos that may aid in the repair of this product. Trouble Remedy No weld output; wire does not feed; fan does not run. Secure power cord plug PLG1 in receptacle (see Section 4-7). Replace building line fuse or reset circuit breaker if open. Place Power switch S1 in On position (see Section 5-1). Reset power source supplementary protector if open (see Section 8-2). No weld output; wire does not feed; fan runs. Check Voltage switch S2 position. Rotate knob until it “clicks” into detent at desired range setting. Thermostat TP1 open (overheating). Allow fan to run; the thermostat will close when the unit has cooled (see Section 3-3). Secure gun trigger leads to receptacle RC3 (see Section 4-2). Check continuity of gun trigger leads. Repair or replace gun if necessary. Check continuity of Voltage switch S2, and replace if necessary. Check diodes in main rectifier SR1, and replace if necessary. Check main transformer T1 for signs of winding failure. Check continuity across windings and check for proper connections. Check secondary voltages. Replace T1 if necessary. Check control board PC1 connections and voltages, and replace if necessary. Electrode wire feeding stops during welding. Straighten gun cable and/or replace damaged parts (see Section 8-6). Readjust drive roll pressure (see Section 4-11). Change to proper drive roll groove (see Section 8-4). Readjust wire reel hub tension (see Section 4-9). Replace contact tip if blocked (see Section 8-5). Clean or replace wire inlet guide or liner if dirty or plugged (see Section 8-4 and/or 8-6). Replace drive roll or pressure bearing if worn or slipping (see Section 8-4). Secure gun trigger leads in receptacle RC3 (see Section 4-2). Check continuity of gun trigger leads. Repair or replace gun if necessary. Check and clear any restrictions at drive assembly and liner (see Section 8-4 and/or 8-6). Release gun trigger and allow gun and motor protection circuitry to reset. 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 7-3).

Handler 140 Trouble Remedy No weld output; wire feeds. Connect work clamp to get good metal-to-metal contact. Replace gun contact tip (see Section 8-5). Check thumbscrew securing gun end to feedhead adapter and tighten if necessary. Low weld output. Connect unit to proper input voltage or check for low line voltage. Place Voltage switch S2 in desired position (see Section 5-1). If using an extension cord, be sure that it is the proper size for the input voltage and amperage. Low or erratic wire speed. Readjust weld parameter settings. Change to correct size drive roll. Readjust drive roll pressure. Clean or replace wire inlet guide or liner if dirty or plugged (see Section 8-4 and/or 8-6). Readjust wire reel hub tension. Check voltage and connections of wire drive motor. Replace motor if necessary. Improper or no shielding gas flow. 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. Shielding gas flows continuously. Replace contactor CR3.

Handler 140 7-2. Troubleshooting Circuit Diagram For Welding Power Source Test Equipment Needed: V1 V2 V3 V4 V5 V7,R7 V6,R6 V10 V8 V9 R11 R9 R1 See also Section 7-3 for PC1 data R8 R10 R2 R3 R4 R5

Handler 140 Voltage Readings a) Tolerance − 10 % unless specified b) Wiring Diagram − see Section 9 V1 115 volts AC with power cord plugged in V2 115 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 24 volts AC with gun trigger closed with Power switch S1 On V6 14.0 volts AC with unit turned on, Voltage switch S2 in position 1 and gun trigger closed 15.6 volts AC with unit turned on, Voltage switch S2 in position 2 and gun trigger closed 17.2 volts AC with unit turned on, Voltage switch S2 in position 3 and gun trigger closed 18.7 volts AC with unit turned on, Voltage switch S2 in position 4 and gun trigger closed 20.2 volts AC with unit turned on, Voltage switch S2 in position 5 and gun trigger closed V7 14.0 volts AC with unit turned on, Voltage switch S2 in position 1 and gun trigger closed 15.6 volts AC with unit turned on, Voltage switch S2 in position 2 and gun trigger closed 17.2 volts AC with unit turned on, Voltage switch S2 in position 3 and gun trigger closed 18.7 volts AC with unit turned on, Voltage switch S2 in position 4 and gun trigger closed 20.2 volts AC with unit turned on, Voltage switch S2 in position 5 and gun trigger closed V8 18.7 volts DC with unit turned on, Voltage switch S2 in position 1 and gun trigger closed 20.7 volts DC with unit turned on, Voltage switch S2 in position 2 and gun trigger closed 23.0 volts DC with unit turned on, Voltage switch S2 in position 3 and gun trigger closed 25.1 volts DC with unit turned on, Voltage switch S2 in position 4 and gun trigger closed 27.4 volts DC with unit turned on, Voltage switch S2 in position 5 and gun trigger closed V9 115 volts AC with unit turned on and gun trigger closed V10 2.9 to 15.4 volts DC with unit turned on, Wire Speed control R2 from min. to max. with Voltage switch S2 in position 1 3.7 to 17.5 volts DC with unit turned on, Wire Speed control R2 from min. to max. with Voltage switch S2 in position 2 4.5 to 19.9 volts DC with unit turned on, Wire Speed control R2 from min. to max. with Voltage switch S2 in position 3 5.2 to 22.0 volts DC with unit turned on, Wire Speed control R2 from min. to max. with Voltage switch S2 in position 4 5.9 to 23.6 volts DC with unit turned on, Wire Speed control R2 from min. to max. with Voltage switch S2 in position 5 Voltage Switch S2 Position Min. IPM Max. IPM 1 2 3 4 55 75 97 118 412 500 528 586 Wire Diameter And Type *All tests done with .030 solid wire, .030-.035 liner in H-100 model 10 foot welding gun, smooth groove drive roll. Values are nominal depending on drive roll pressure and spool hub tension. Resistance Values a) Tolerance − 10% unless specified b) Turn Off unit and disconnect input power before checking resistance R1-R8 All values for T1 are less than 1 ohm R9 Less than 1 ohm with gun trigger pressed, high resistance with gun trigger open R10 Less than 1 ohm R11 Less than 1 ohms at minimum position of Wire Speed control R2, 50k ohms at maximum position of R2 .030/.035 Solid or Flux Core 230 952-A Wire Speed While Feeding* Min. RPM Max. RPM 1 2 3 4 22 29 35 40 123 141 160 176 *All tests done with the pressure assembly open, not feeding wire. Values are nominal. Drive Motor RPM At No Load* Voltage Switch S2 Position 5 134 704 5 43 187

Handler 140 7-3. Control Board PC1 Testing Information (Use With Section 7-4) Be sure plugs are secure before testing. See Section 7-4 for specific values during testing. 1 Control Board PC1 Test Equipment Needed: 803 717-A / 256 988-A 1

Handler 140 7-4. Control Board PC1 Test Point Values PC1 Voltage Readings a) Tolerance − 10% unless specified b) Reference − as noted Receptacle Pin Value RC1 1 − 2 0 volts DC with gun trigger open Voltage switch S2 in position 5 5.6 volts DC with Wire Speed control R2 set to min. and gun trigger closed 23.6 volts DC with Wire Speed control R2 set to max. and gun trigger closed RC2 1 30 volts DC, reference to Pin 5 2 30 volts DC, reference to Pin 5, gun trigger closed 3 30 volts DC, reference to Pin 5 4 29 volts DC, reference to Pin 5, gun trigger closed 5 Circuit common 6 27 volts DC, reference to Pin 5, gun trigger closed 7 27 volts DC with Wire Speed control R2 at maximum, reference to Pin 5 6.3 volts DC with Wire Speed control R2 at minimum, reference to Pin 5 8 Not used 9 − 10 24 volts AC with gun trigger open 11 − 12 24 volts AC with gun trigger closed 13 29 volts DC, reference to Pin 5 14 29 volts DC, reference to Pin 5 15 29 volts DC, reference to Pin 5 16 Not used

Handler 140 SECTION 8 − MAINTENANCE 8-1. Routine Maintenance ! Disconnect power before maintaining. � Maintain more often during severe condi- tions. � = Check � = Change � = Clean � = Replace * To be done by Factory Authorized Service Agent Reference 3 Months � Damaged Or Unreadable Labels � Repair Or Replace Cracked Weld Cable � Clean And Tighten Weld Terminals 6 Months OR � Inside Unit 8-2. Overload Protection 802 441 1 Supplementary Protector CB1 CB1 protects unit from overload. If CB1 opens, unit shuts down. Reset supplementary protector. 1 8-3. Drive Motor Protection 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.

Handler 140 8-4. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire Guide Securing Screw 2 Inlet Wire Guide Loosen thumbscrew. Slide tip as close to drive rolls as possible without touching. Tighten thumbscrew. 3 Drive Roll The drive roll consists of two different grooves. The stamped markings on the end surface of the drive roll refers to the groove on the opposite side of the drive roll. The groove closest to the motor shaft is the proper groove to thread (see Section 4-11). � VK (Knurled) groove is used for flux cored wire and V groove is used for solid wire. 4 Retaining Pin To secure drive roll, locate open slot and push drive roll completely over retaining pin, then rotate drive roll (1/4 turn) to closed slot. 5 Drive Roll Tension Knob Using flux core wire with VK groove, tension should be set between 1-1/2 to 2. Higher setting may cause welding wire to deform and not allow proper feeding. Flux Core Wire − Recommended stickout is 1/2 in. (12.7 mm) from gun tip. Solid Wire − Recommended stickout is 3/8 in. (9.5 mm) from gun tip. Actual drive roll may differ from that shown. See Section 11-3 for additional drive roll configurations. 258 380-B .030/.035 VK Groove is used for Flux Core (Gasless) Wire .030/.035 V Groove is used for Solid Wire Stamped .030/.035 VK Grooved Stamped .030/.035 V 2 Example 4 1 3 5 � Be sure gun is fully inserted into drive housing. Liner to drive roll distance should be within 1/8 in. (3.2 mm). of each other. 8-5. Replacing Gun Contact Tip Ref. 246 669-A ! Turn Off power before replacing contact tip. 1 Nozzle 2 Contact Tip Cut off welding wire at contact tip. Remove nozzle. Remove contact tip and install new contact tip. Reinstall nozzle. Tools Needed: 1 2

Handler 140 8-6. Cleaning Or Replacing Gun Liner Ref. 246 669-A 8 mm / 10mm ! Disconnect gun from unit. Tools Needed: To 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 tighten two full turns more. Cut liner off so that 3/4 in. (19 mm) sticks out of head tube. Install gas diffuser, adapter, contact tip, and nozzle. Lay gun cable out straight before installing new liner. Head Tube 8 mm Remove liner. Remove nozzle, contact tip and tip adapter/gas diffuser. Blow out gun casing. 10 mm 1 2 3

Handler 140 8-7. Replacing Switch And/Or Head Tube Ref. 243 840-A Tools Needed: 19 mm Remove screws from handle. Remove handle half. Secure head tube in vice. Loosen jam nut. Remove from vice and turn head tube out by hand. Hand-tighten head tube into cable connector. Place head tube in vice and tighten until nuts are tight. ! Turn Off welding power source/wire feeder and disconnect gun. Remove switch housing. Install new switch and connect leads (polarity is not important). Reassemble in reverse order. If replacing head tube, continue to end of figure. 1 2 3 4 5 6 7 Remove from vice. install switch housing. 8 Install handle half with secure with screws. 9

Handler 140 SECTION 9 − 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 Diagram Wiring Diagram Welding Power Source MC370275YAnd following 257 502-A 257 500-A Circuit Board PC1 (115 VAC Model) MC370275Y and following 256 987-A  �Not included in this manual

Handler 140 AGND AGND AGND AGND + + 3 2 1 A1 16 RC2 15 RC2 14 RC2 13 RC2 +29V 3 RC2 1 RC2 2 RC2 12 RC2 10 RC2 9 RC2 11 RC2 C5 C4 2 3 1 Q3 R16 R13 R14 R15 R7 1% R4 R2 R18 R17 +29V R12 +30V PTC2 C3 4 8 A1 C2 C1 3 2 1 Q2 D6 D7 D14 D9 D10 D12 D8 D5 NC 1 4 3 CR2 5 2 CR2 1 2 CR1 +30V +29V D13 Figure 9-3. Circuit Diagram For 115 VAC Model Control Board PC1 Eff w/MC370275Y And Following

Handler 140 256 987-A AGND AGND HEATSINK VERTICAL AGND CAP − CAP + MOTOR + MOTOR − R3 8 RC2 7 RC2 VOUT 6 RC2 2 RC1 1 RC1 5 RC2 4 RC2 D2 D11 R8 R1 5 6 7 A1 5AMP_50V D3 D1 D15 D4 R5 5AMP_50V VOUT HS1 5AMP_50V 4 5 3 CR1 2 1 3 Q1 PTC1 WFS_REF

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)

Handler 140 SECTION 10 − PARTS LIST � Hardware is common and not available unless listed. 258 385-A 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 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 Figure 10-1. Main Assembly

Handler 140 Description Part No. Dia. Mkgs. Item No. Figure 10-1. Main Assembly Quantity 1 199 566 Door, Access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 196 006 Hinge, Door 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 211 887 Hub, Nut 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 204 608 Nut 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 202 998 Spring, CPRSN 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 203 072 Washer, Flat 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 211 339 Hub, Spool 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 202 726 Adapter, Spool Hub 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 PC1 256 985 Circuit Card Assy, Control 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 195 999 Base, Lower 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CB1 210 109 Supplementary Protector, 25 Amp 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 196 467 Tubing, PVC .187 ID x .312 OD x 23.00 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 GS1 216 397 Valve, Gas 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 197 198 Cable Tie, .700-.799 Bundle Dia 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 147 545 Cord Set, 125v 5−15P 14ga 3/C 7ft SPT−3 JKT 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 111 443 Bushing, Strain Relief 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 137 761 Nut, Gas Valve 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 FM 196 063 Motor, Fan 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 409 953-001 Blade, Fan Cooling 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 T1 257 984 Transformer, Power Assy 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 208 015 Handle, Carrying 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 +196 005 Wrapper 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 204 036 Label, Warning 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 203 491 Clamp, Capacitor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25 C1 193 039 Capacitor, Electlt 53000uf 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Z1 203 868 Reactor Assy 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 SR1 193 191 Rectifier Assy 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 193 193 Bus Bar (Positive) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 217 831 Baffle, Center 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 405 576-001 Bushing, Terminal 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 193 144 Insulator, Output Stud 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 193 194 Bus Bar (Negative) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33 216 830 Label, Warning 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 134 201 Stand-Off 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 S2 257 585 Switch, Rotary 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 R2 209 873 Potentiometer, 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 258 234 Panel, Front W/Nameplate 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 257 796 Clamp, Work 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 196 619 Cable, Work 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 S1 196 575 Switch, Rocker SPST 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 207 079 Knob, Pointer (Voltage) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 211 338 Knob, Pointer (Wfs) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 DM 257 097 Wire Feeder Assy 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 CR3 217 584 Contactor 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 PL1 230 033 LED 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 258 069 Label, Weld Guide 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 258 438 Label, Weld Guide (French) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 204 711 Latch 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 203 572 Label, Warn Gen Precaution (En/Fr Models Only) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Label, Nameplate (Order By Model And Serial Number) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . +When ordering a component originally displaying a precautionary label, the label should also be ordered. 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.

Handler 140 258 389-A 1 2 3 4 5 6 14 8 7 11 9 12 13 10 15 16 17 18 19 20 21 22 Figure 10-2. Wire Feed Drive Assembly Description Part No. Dia. Mkgs. 258 389 Item No. Figure 10-2. Wire Feed Drive Assembly Quantity 1 256 956 Cover, Motor Drive 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 257 420 Housing, Wire Drive 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 257 422 Lever,Mtg Pressure Gear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 189 915 Bearing, Ball 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 176 869 Screw, 010−32 x 0.62 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 203 418 Spring, Torsion 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 257 790 Screw, .250−28 x .953 Shld .1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 082 193 Screw, 010−32 x 0.37 hex hd .4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 197 172 Screw, 006−32 x 0.37 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 196 895 Knob,Tension 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 234 200 Spring, Compression 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 196 896 Cup, Spring Tension 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 225 718 Fastener, Pinned 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 257 792 Screw, Shld Stl 10−32 x .60 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 256 960 Guide, Inlet .023−.052 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 257 865 Knob,T 1.00 Bar W/10−32 x .375 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 246 565 Roll, Drive V/VK Groove .030−.035 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 217 778 Motor, Gear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 230 012 Fitting, Gas 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 196 109 Cable 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 602 154 Screw, .250−20 x .50 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 257 864 KNOB, T 1.265 Bar w/.250-20 Stud .625 Lg Plstc 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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.

Handler 140 246 670-A 1 2 3 4 5 6 7 8 7 11 9 12 13 10 Figure 10-3. H100S2-10 Gun Description Part No. Dia. Mkgs. 245 924 Item No. Figure 10-3. H100S2-10 Gun Quantity 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 226 190 NOZZLE, flux cored slip type 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 087 299 TIP, contact scr .023 wire x 1.125 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 000 067 TIP, contact scr .030 wire x 1.125 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 000 068 TIP, contact scr .035 wire x 1.125 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 000 069 TIP, contact scr .045 wire x 1.125 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 170 470 RING, retaining 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 169 716 ADAPTER, contact tip 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 246 373 TUBE, head 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 243 865 NUT, jam 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 242 832 HANDLE 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 225 410 SWITCH, trigger 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 246 380 HOUSING, power pin 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 245 927 CONNECTOR, feeder 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 197 123 O−RING, .312 ID X .062 70 duro buna−n 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 194 010 LINER, monocoil .023/.025 wire x 15ft (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 194 011 LINER, monocoil .030/.035 wire x 15ft (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 194 012 LINER, monocoil .035/.045 wire x 15ft (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 079 975 O-RING, .187 ID x .103CS rbr 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONAL 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.

Handler 140 SECTION 11 − ACCESSORIES AND CONSUMABLES 11-1. Accessories PART NO. DESCRIPTION REMARKS 770 187 Running Gear/Cylinder Rack For One Small Gas Cylinder, 100 lb (45 kg) max. 194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder, 75 lb (34 kg) max. 195 186 Protective Cover Weatherproof Nylon 11-2. Consumables Item Hobart Package Part No.* Miller Package Part No. ** Contact Tips .023/.025 in (0.6 mm) 770 174 (5 per package) 087 299 (10 per package) .030 in (0.8 mm) 770 177 (5 per package) 000 067 (10 per package) .035 in (0.9 mm) 770 180 (5 per package) 000 068 (10 per package) MIG Nozzle (Standard) 770 404 169 715 Gasless Flux Cored Nozzle 770 487 226 190 Tip Adapter 770 402 169 716 Wire Inlet Guide — 203 025 Replacement Liners .023/.025 in (0.6 mm) 196 139 194 010 .030/.035 in (0.8/0.9 mm) 196 139 194 011 .035/.045 in (0.9/1.2 mm) 196 140 194 012 *Available at farm and tool supply retailers. ** Available at Hobart/Miller welding distributors. 11-3. Replacement Drive Rolls For All Feed Head Assemblies PART NO. WIRE DIAMETER INCHES (mm) 237 338 .023/.025 (.6) and .030/.035 (.8 and .9) 202 926 .030/.035 (.8 and .9) and .045 (1.2 VK Groove) 246 565 .030/.035 (.8 and .9) V and VK Groove 11-4. Regulator/Flowmeter PART NO. REMARKS 221 037** For Argon and Argon mixed shielding gas. Use with replacement hose 222 874. 770 198* 212 492** For CO2 shielding gas. Use with replacement gas hose 144 108. *Available at farm and tool supply retailers. **Available at Hobart/Miller welding distributors. 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.

Pros weld and cut safely. Read the safety rules at the beginning of this manual.

 2013 Hobart Brothers Co. 2013−01 Hobart Brothers Co. An Illinois Tool Works Company 600 West Main Street Troy, OH 45373 USA For Assistance: Call1-800-332-3281