Hobart Welding Products TM-944C User Manual

TM-944C October 2003

Handler 135 (500 414) Eff. w/Serial No.
LB096205

Handler 175 (500 416) Eff. w/Serial No.
LB075197

Processes

MIG (GMAW) Welding
Flux Cored (FCAW) W elding

Description

Arc Welding Power Source And
Wire Feeder

Handler 135 / 175

And H-10 Gun

Visit our website at

www.HobartWelders.com

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 − SPECIFICATIONS 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-1. Specifications 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-2. Duty Cycle And Overheating 4 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

2-3. Volt-Ampere Curves 5 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 − INSTALLATION 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Installing Welding Gun 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Installing Work Clamp 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Process/Polarity Table 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Changing Polarity 7 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-5. Installing Gas Supply 8 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-6. Selecting A Location And Connecting Input Power For 115 VAC Model 9 . . . . . . . . . . . . . . . . . . . . . . . . .

3-7. Selecting A Location And Connecting Input Power For 230 VAC Model 10 . . . . . . . . . . . . . . . . . . . . . . . .

3-8. Electrical Service Guide For 230 VAC Model 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-9. Installing Wire Spool And Adjusting Hub Tension 11 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-10. Threading Welding Wire 12 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 − OPERATION 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Controls 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-2. Weld Parameter Chart For 115 VAC Model 14 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-3. Weld Parameter Chart For 230 VAC Model 16 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 − THEORY OF OPERATION 18 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 − TROUBLESHOOTING 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-1. Troubleshooting Table 20 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-2. Troubleshooting Circuit Diagram For Welding Power Source (115 VAC Model) 22 . . . . . . . . . . . . . . . . . .

6-3. Troubleshooting Circuit Diagram For Welding Power Source (230 VAC Model) 24 . . . . . . . . . . . . . . . . . .

6-4. Control Board PC1 Testing Information (115 VAC Model) 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-5. Control Board PC1 Test Point Values (115 VAC Model) 27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-6. Control Board PC1 Testing Information (230 VAC Model) 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

6-7. Control Board PC1 Test Point Values (230 VAC Model) 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 7 − MAINTENANCE &TROUBLESHOOTING 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-1. Routine Maintenance 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-2. Overload Protection 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-3. Drive Motor Protection 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-4. Changing Drive Roll Or Wire Inlet Guide 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-5. Replacing Gun Contact Tip 31 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-6. Cleaning Or Replacing Gun Liner 32 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

7-7. Replacing Switch And/Or Head Tube 33 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 8 − ELECTRICAL DIAGRAMS 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 9 − PARTS LIST 42 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards
with this procedure! The possible hazards are shown in
the adjoining symbols.

safety_stm 5/97

Y Marks a special safety message.

. Means “Note”; not safety related.

1-2. Servicing Hazards

Y 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.

Y Only qualified persons should service, test, maintain, and re-

pair this unit.

Y During servicing, keep everybody, especially children, away.

ELECTRIC SHOCK can kill.

D Do not touch live electrical parts.
D Turn Off welding power source and w ir e fe ed er

and disconnect and lockout input power using
line disconnect switch, circuit breakers, or by removing plug from re­ceptacle, o r stop engine before servicing unless the procedure spe­cifically requires an energized unit.

D Insulate yourself from ground by standing or working on dry insulat-

ing mats big enough to prevent contact with the ground.

D Do not leave live unit unattended.
D If this procedure requires an energized unit, have only personnel

familiar with and following standard safety practices do the job.

D When testing a live unit, use the one-hand method. Do not put both

hands inside unit. Keep one hand free.

D Disconnect input power conductors from deenergized supply line

BEFORE moving a welding power source.

SIGNIFICANT DC VOLTAGE exists after removal of
input power on inverters.

D Turn Off inverter, disconnect input power, and discharge input

capacitors according to instructions in Maintenance Section before
touching any parts.

This group of symbols means Warning! Watch Out! possible
ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions
to avoid the hazards.

FLYING METAL can injure eyes.

D Wear safety glasses with side shields or face

shield during servicing.

D Be careful not to short metal tools, parts, or

wires together during testing and servicing.

HOT PARTS can cause severe burns.

D Do not touch hot parts bare handed.
D Allow cooling period before working on welding

gun or torch.

EXPLODING PARTS can cause injury.

D Failed parts can explode or cause other parts to

explode when power is applied to inverters.

D Always wear a face shield and long sleeves

when servicing inverters.

SHOCK HAZARD from testing.

D Turn Off welding power source and w ir e fe ed er

or stop engine before making or changing me­ter lead connections.

D Use at least one meter lead that has a self-

retaining spring clip such as an alligator clip.

D Read instructions for test equipment.

FALLING UNIT can cause injury.

STATIC (ESD) can damage PC boards.

D Put on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to

store, move, or ship PC boards.

FIRE OR EXPLOSION hazard.

D Do not place unit on, over, or near combustible

surfaces.

D Do not service unit near flammables.

Return To Table Of Contents

D Use lifting eye to lift unit only, NOT running

gear, gas cylinders, or any other accessories.

D Use equipment of adequate capacity to lift and

support unit.

D If using lift forks to move unit, be sure forks are

long enough to extend beyond opposite side of
unit.

MOVING PARTS can cause injury.

D Keep away from moving parts such as fans.
D Keep all doors, panels, covers, and guards

closed and securely in place.

TM-944 Page 1Handler 135 / 175

MOVING PARTS can cause injury.

H.F. RADIATION can cause interference.

D Keep away from moving parts.
D Keep away from pinch points such as drive

rolls.

MAGNETIC FIELDS can affect pacemakers.

D Pacemaker wearers keep away from servicing

areas until consulting your doctor.

OVERUSE can cause OVERHEATING.

D Allow cooling period; follow rated duty cycle.
D Reduce current or reduce duty cycle before

starting to weld again.

D Do not block or filter airflow to unit.

1-3. California Proposition 65 Warnings

D High-frequency (H.F.) can interfere with radio

navigation, safety services, computers, and
communications equipment.

D Have only qualified persons familiar with

electronic equipment install, test, and service
H.F. producing units.

D The user is responsible for having a qualified electrician prompt-

ly correct any interference problem resulting from the installa­tion.

D If notified by the FCC about interference, stop using the

equipment at once.

D Have the installation regularly checked and maintained.
D 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.

D Use MILLER Testing Booklet (Part No. 150

853) when servicing this unit.

D Consult the Owner’s Manual for welding safety

precautions.

D Use only genuine MILLER replacement parts.

Y 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.)

Y Battery posts, terminals and related accessories contain lead

and lead compounds, chemicals known to the State of
California to cause cancer and birth defects or other
reproductive harm. Wash hands after handling.

1-4. EMF Information

Considerations About Welding And The Effects Of Low Frequency
Electric And Ma g netic Fields

Welding current, as it flows through welding cables, will cause electro­magnetic fields. There has been and still is some concern about such
fields. However, after examining more than 500 studies spanning 17
years of research, a special blue ribbon committee of the National
Research Council concluded that: “The body of evidence, in the
committee’s judgment, has not demonstrated that exposure to power­frequency electric and magnetic fields is a human-health hazard.”
However, studies are still going forth and evidence continues to be
examined. Until the final conclusions of the research are reached, you
may wish to minimize your exposure to electromagnetic fields when
welding or cutting.

To reduce magnetic fields in the workplace, use the following
procedures:

For Gasoline Engines:
Y Engine exhaust contains chemicals known to the State of

California t o cause cancer, birth defects, or other reproductive
harm.

For Diesel Engines:
Y Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and
other reproductive harm.

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around your body.

4. Keep welding power source and cables as far away from opera­tor as practical.

5. Connect work clamp to workpiece as close to the weld as possi­ble.

About Pacemakers:

Pacemaker wearers consult your doctor first. If cleared by your doctor,
then following the above procedures is recommended.

TM-944 Page 2 Handler 135 / 175

Return To Table Of Contents

2-1. Specifications

A. 115 VAC Model

Rated W elding

Output

90 A @ 19 Volts DC,

20% Duty Cycle

63 A @ 21 Volts DC,

20% Duty Cycle*

Wire Type

And Dia

* CSA Rating

B. 230 VAC Model

Rated W elding

Output

130 A @ 20 Volts

DC, 30% Duty Cycle

At 60 Hz Input − 20%

Duty Cycle At 50 Hz

Input

Wire Type

And Dia

Amperage

30 − 135

Stainless

.024 − .030 in

(0.6 − 0.8 mm)

Amperage

30 − 175

Stainless

.024 − .035 in

(0.6 − 0.9 mm)

SECTION 2 − SPECIFICATIONS

Amperes Input at

Rated Load Output

115 V, 60 Hz, Single-

Phase

20

15*

370 − 840 IPM (9.2 − 21.8 m/min) At No Load

50 − 800 IPM (1.3 − 20.3 m/min) Feeding Wire

Amperes Input at

Rated Load Output

230 V , 50/60 Hz,

Single-Phase

350 − 900 IPM (9.0 − 23.0 m/min) At No Load

50 − 850 IPM (1.3 − 20.3 m/min) Feeding Wire

KVA KW

2.90

2.20*

Wire Feed Speed Range

KVA KW

Wire Feed Speed Range

Range

Solid/

Range

Solid/

Maximum Open-

Circuit Voltage

DC

28

Flux Cored/

Aluminum

.030 − .035 in

(0.8 − 0.9 mm)/

.030

(0.8 mm)

Maximum Open-

Circuit Voltage

DC

30 19.5 4.60 3.75

Flux Cored/

Aluminum

.030 − .045 in

(0.8 − 1.2 mm)/

.030 − .035 in

(0.8 − 0.9 mm)

2.50

1.77*

Weight

W/ Gun

55 lb

(25 kg)

Weight

W/ Gun

65 lb

(29.5 kg)

Overall

Dimensions

Length: 18-7/8 in

(479 mm)

Width: 10-5/8 in

(270 mm)

Height: 12-3/8 in

(314 mm)

Overall

Dimensions

Length: 18-7/8 in

(479 mm)

Width: 10-5/8 in

(270 mm)

Height: 12-3/8 in

(314 mm)

Return To Table Of Contents

TM-944 Page 3Handler 135 / 175

2-2. Duty Cycle And Overheating

C. 115 VAC Model

200
135

100

80
60

40

20

Output Amperes

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.

Y Exceeding duty cycle can

damage unit or gun and void
warranty.

10

1

D. 230 VAC Model

200

130
100

80

60

40

Output Amperes

20

10

10

410

2

6808

20

40 60 100

Duty Cycle %

20% duty cycle at 90 amps

2 Minutes Welding 8 Minutes Resting

20

30

40 50

60 70 80 100

Duty Cycle %

30% duty cycle at 130 amps, 60 Hz
20% duty cycle at 130 amps, 50 Hz

3 Minutes Welding 7 Minutes Resting

Overheating

0

15

Minutes

TM-944 Page 4 Handler 135 / 175

Return To Table Of Contents

Reduce Duty Cycle

A or V

OR

duty1 4/95 − 196 617 / 196 618

2-3. Volt-Ampere Curves

E. 115 VAC Model

30.0

25.0

20.0

15.0

OUTPUT VOLTS

10.0

5.0

0.0
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160

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.

Range 4
Range 3

Range 2
Range 1

LOAD AMPS

F. 230 VAC Model

30.0

25.0

20.0

15.0

OUTPUT VOLTS

10.0

5.0

0.0

0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160 170 180 190 200

Range 4

Range 3

Range 2

Range 1

LOAD AMPS

Return To Table Of Contents

ssb1.1 10/91 − 196 608 / 196 609

TM-944 Page 5Handler 135 / 175

SECTION 3 − INSTALLATION

3-1. Installing Welding Gun

3-2. Installing Work Clamp

1 Drive Assembly
2 Gun Securing Thumbscrew

4

2

1

3

3 Gun End
Loosen thumbscrew. Insert gun

end through opening until it bottoms
against drive assembly. Tighten
thumbscrew.

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.

Ref. 802 440-A

Tools Needed:

3/8, 7/16 in

3

1

2

5

4

1 Nut
2 Work Cable From Unit
3 Work Clamp
4 Screw
5 Work Clamp Tabs
Bend tabs around work cable.

802 456

TM-944 Page 6 Handler 135 / 175

Return To Table Of Contents

3-3. Process/Polarity Table

Process

Polarity

GMAW − Solid wire with shield­ing gas

FCAW − Self-shielding wire −
no shielding gas

DCEP − Reverse polarity Connect to positive (+) out-

DCEN − Straight Polarity Connect to negative (−)

3-4. Changing Polarity

Cable Connections

Cable To Gun Cable To W ork

Connect to negative (−) output

put terminal

terminal
Connect to positive (+) output

output terminal

terminal

CHANGING

POLARITY

DCEN

Electrode Negative
For Flux Core Wire

1

DCEP

Electrode Positive

For Solid Wire

2

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 3-3.

Close door.

Return To Table Of Contents

Ref. 209 228 / Ref. 209 229

TM-944 Page 7Handler 135 / 175

3-5. Installing Gas Supply

. DO NOT use Argon/Mixed gas regulator/flowmeter

with CO2 shielding gas. See Parts List for optional
CO2 gas regulator/flowmeter.

4

7

5

Argon Gas Or

Mixed Gas

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

1

2

3

Remove c ap, 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 customer supplied gas
hose between regulator/flowmeter
gas hose connection, and fitting on
rear of welding power source.

7 Flow Adjust
Typical flow rate is 20 cfh (cubic

feet per hour). Check wire
manufacturer’s rec o m m e n ded flow
rate.

6

Tools Needed:

5/8, 1-1/8 in

Ref. 802 028-A / 802 441

TM-944 Page 8 Handler 135 / 175

Return To Table Of Contents

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

1 Rating Label
2 Grounded Receptacle
A 115 volt, 20 ampere individual

branch circuit protected by tim e- de­lay fuses or circuit breaker is re­quired.

3 Plug From Unit
Select extension cord of 14 AWG

for up to 50 ft (15 m) or 12 AWG for
50 up to 200 ft (61 m).

Y Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 2 0 .

18 in

(460 mm)

1

18 in

(460 mm)

2

3

802 442-A

Return To Table Of Contents

TM-944 Page 9Handler 135 / 175

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

1 Rating Label
Supply correct input power.
2 Plug (NEMA 6-50P)
3 Receptacle (NEMA 6-50R)
Connect plug to receptacle.

18 in (457 mm) of
space for airflow

4

4 Line Disconnect Device
See Section 3-8.

Y Special installation may be

required where gasoline or
volatile liquids are present −
see NEC Article 511 or CEC
Section 2 0 .

Y Always connect

grounding
conductor first.

= GND/PE

Y Do not move or operate unit

where it could tip.

L1

L2

1

2

3

L2

230 VAC, 1

L1

ssb2.2* 1/94 − 802 443-A / Ref. 802 085

TM-944 Page 10 Handler 135 / 175

Return To Table Of Contents

3-8. Electrical Service Guide For 230 VAC Model

Input Voltage
Input Amperes At Rated Output
Max Recommended Standard Fuse Or Circuit Breaker Rating In Amperes
Min Input Conductor Size In AWG/Kcmil
Max Recommended Input Conductor Length In Feet (Meters)
Min Grounding Conductor Size In AWG/Kcmil

Reference: 1996 National Electrical Code (NEC) S-0092-J

230

20
20
14

66 (20)

12

3-9. Installing Wire Spool And Adjusting Hub Tension

Installing 4 in (102 mm) Wire Spool

When a slight force is needed
to turn spool, tension is set.

Installing 8 in (203 mm) Wire Spool

Retaining ring used

with 8 in (203 mm)

spool only.

Tools Needed:

Adapter used with

8 in (203 mm)

spool only.

When a slight force is needed
to turn spool, tension is set.

1/2 in

803 012 / 803 013-B / Ref. 802 971-C

Return To Table Of Contents

TM-944 Page 11Handler 135 / 175

3-10. Threading Welding Wire

Tools Needed:

1 Wire Spool
2 Welding Wire
3 Inlet Wire Guide
4 Pressure Adjustment Knob
5 Drive Roll
6 Gun Conduit Cable

4

Lay gun cable out straight.

6

Open pressure assembly.

Tighten

1

2

3

5

. Hold wire tightly to keep it

from unraveling.

4 in

(102 mm)

6 in

(150 mm)

Pull and hold wire; cut off end.

Push wire thru guides into gun;

continue to hold wire.

. Use pressure indicator

scale to set a desired
drive roll pressure.

1
2
3
4

Pressure

Indicator

Scale

INPUT

POWER

Be sure that wire is positioned

in proper feed roll groove.

Close and tighten pressure

assembly, and let go of wire.

Press gun trigger until wire comes
out of gun.

Be sure that tip matches wire diameter.
Reinstall contact tip and nozzle.

TM-944 Page 12 Handler 135 / 175

Remove gun nozzle and contact tip.

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Turn power on.

Tighten

1
2
3

WOOD

4

Feed wire to check drive roll pressure.

Tighten knob enough to prevent slipping.

Cut off wire. Close door .

Ref. 802 444-C

4-1. Controls

SECTION 4 − OPERATION

1

2

1 Voltage 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 detent

position 1, 2, 3, 4, or purge for
proper contact.

2 Voltage Switch - Purge “0”

Position

In purge position, fan runs but there
is no weld output.

3 Wire Speed Control
Use control to select a wire feed

speed. A s Voltage switch setting in­creases, wire speed range also in­creases (see weld setting label in
welding power source or Sections
4-2 or 4-3, as applicable).

4 Power Switch

3

4

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Ref. 196 082

TM-944 Page 13Handler 135 / 175