Instruction/ maintenance manual of the product TM-944C Hobart Welding Products
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TM -944C Oc tober 2003 Handler 135 (500 414) Eff. w/Serial No. LB096205 Handler 175 (500 416) Eff. w/Serial No. LB075197 Visit our website at www.HobartWelders.
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS FOR SER VICING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM-944 Page 1 Handler 135 / 175 Return T o T able Of Contents SECTION 1 − SAFETY PRECAUTIONS FOR SERVICING 1-1. Symbol Usage safety_stm 5/97 Means Warning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.
TM-944 Page 2 Handler 135 / 175 Return T o T able Of Contents MOVING P ARTS can cause injury . D Keep away from moving parts. D Keep away from pinch points such as drive rolls. MAGNETIC FI ELDS can af fect p acemakers. D Pacemaker wearers keep away from servicing areas until consulting your doctor .
TM-944 Page 3 Handler 135 / 175 Return T o T able Of Contents SECTION 2 − SPECIFICA TIONS 2-1. Specifications A. 1 15 V AC Model Rated Welding Output Amperage Range Maximum Open- Circuit V oltage DC.
TM-944 Page 4 Handler 135 / 175 Return T o T able Of Contents 2-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 mi n- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs.
TM-944 Page 5 Handler 135 / 175 Return T o T able Of Contents 2-3. V olt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown.
TM-944 Page 6 Handler 135 / 175 Return T o T able Of Contents SECTION 3 − INST ALLA TION 3-1. Installing W elding Gun Ref. 802 440-A 1 Drive Assembly 2 Gun Securing Thumbscrew 3 Gun End Loosen thumbscrew . Insert gun en d through opening until it bottoms against drive assembly .
TM-944 Page 7 Handler 135 / 175 Return T o T able Of Contents 3-3. Process/Polarity T able Process Polarity Cable Connections Process Polarity Cable T o Gun Cable T o Work GMAW − Solid wire with shi.
TM-944 Page 8 Handler 135 / 175 Return T o T able Of Contents 3-5. Installing Gas Supply Obtain gas cylinder and chain to running gear , wall, or other stationary support so cylinder cannot fall and break of f valve. 1 Cap 2 Cylinder V alve Remove c ap, stand to side of valve, and open valve slightly .
TM-944 Page 9 Handler 135 / 175 Return T o T able Of Contents 3-6. Selecting A Location And Connecting Input Power For 1 15 V AC Model 1 Rating Label 2 Grounded Receptacle A 1 15 volt, 20 ampere individual branch circuit protected by ti me- de - lay fuses or circuit breaker is re- quired.
TM-944 Page 10 Handler 135 / 175 Return T o T able Of Contents 3-7. Selecting A Location And Connecting Input Power For 230 V AC Model 1 Rating Label Supply correct input power . 2 Plug (NEMA 6-50P) 3 Receptacle (NEMA 6-50R) Connect plug to receptacle.
TM-944 Page 1 1 Handler 135 / 175 Return T o T able Of Contents 3-8. Electrical Service Guide For 230 V AC Model Input V oltage 230 Input Amperes At Rated Output 20 Max Recommended Standard Fuse Or Ci.
TM-944 Page 12 Handler 135 / 175 Return T o T able Of Contents 3-10. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Conduit Cable Lay gun cable out straight. Ref. 802 444-C T ools Ne e d e d : 6 1 3 4 5 Pull and hold wire; cut off end.
TM-944 Page 13 Handler 135 / 175 Return T o T able Of Contents SECTION 4 − O P E R A T I O N 4-1. Controls 1 V oltage Switch The higher the selected number , the thicker the material that can be welded (see weld setting label in welding power source or Sections 4-2 and 4-3, as applicable).
TM-944 Page 14 Handler 135 / 175 Return T o T able Of Contents 4-2. W eld Parameter Chart For 1 15 V AC Model W elding Guide Settings are appr oximate. Adjust as requir ed. Thicker materials can be welded using proper technique, joint preparation, and multiple passes.
TM-944 Page 15 Handler 135 / 175 Return T o T able Of Contents 209 228 for 1 15 V olt W ire W elding Package DCEN DCEP Wi re Speed listed is a starting value only − Wire Speed setting can be fine−tuned while welding. Wire Speed also depends on other variables such as stick out, travel speed, weld angle, cleanliness of metal, etc.
TM-944 Page 16 Handler 135 / 175 Return T o T able Of Contents 4-3. W eld Parameter Chart For 230 V AC Model W elding Guide Settings are approximate. Adjust as requir ed. Thicker materials can be welded using proper technique, joint pr eparation, and multiple passes.
TM-944 Page 17 Handler 135 / 175 Return T o T able Of Contents 209 229 for 230 V olt W ire W elding Package DCEN DCEP Wi re Speed listed is a starting value only − Wire Speed setting can be fine−tuned while welding. Wire Speed also depends on other variables such as stick out, travel speed, weld angle, cleanliness of metal, etc.
TM-944 Page 18 Handler 135 / 175 Return T o T able Of Contents 1 Circuit Breaker CB1 Protects unit from an over-current condition by opening primary power line. 2 Power Switch S1 T urns unit and fan motor FM on and of f. 3 Fa n Motor FM And T ransformer Controlled by power switch S1.
TM-944 Page 19 Handler 135 / 175 Return T o T able Of Contents AC Or DC Control Circuits W eld Current Circuit Welding Wire W ork 12 (Electrode) 9 Range Switch S2 10 Main T ransformer T1 11 Main Recti.
TM-944 Page 20 Handler 135 / 175 Return T o T able Of Contents SECTION 6 − TROUBLESHOOTING 6-1. T roubleshooting T able . See Section 6-2 or 6-3 for test points and values and Section 9 for parts location. T rouble Remedy No weld output; wire does not feed; fan does not run.
TM-944 Page 21 Handler 135 / 175 Return T o T able Of Contents T rouble Remedy No weld output; wire feeds. Connect work clamp to get good metal-to-metal contact. Replace gun contact tip (see Section 7-5). Check thumbscrew securing gun end to feedhead adapter and tighten if necessary .
TM-944 Page 22 Handler 135 / 175 Return T o T able Of Contents 6-2. T roubleshooting Circuit Diagram For Welding Power Source (1 15 V AC Model) T est Equipment Needed: V1 V2 V3 V4 V5 V7 V6 V10 V8/R5 V.
TM-944 Page 23 Handler 135 / 175 Return T o T able Of Contents V oltage Readings a) T olerance − ± 10 % unless specified b) Wiring Diagram − see Section 8 V1 1 15 volts ac with power cord plugged.
TM-944 Page 24 Handler 135 / 175 Return T o T able Of Contents 6-3. T roubleshooting Circuit Diagram For Welding Power Source (230 V AC Model) T est Equipment Needed: V1 V2 V3 V4 V5 V7 V6 V10 V8/R5 V9.
TM-944 Page 25 Handler 135 / 175 Return T o T able Of Contents V oltage Readings a) T olerance − ± 10 % unless specified b) Wiring Diagram − see Section 8 V1 23 0 volts ac with power cord plugged.
TM-944 Page 26 Handler 135 / 175 Return T o T able Of Contents 6-4. Control Board PC1 T esting Information (1 15 V AC Model) Be sure plugs are secure before testing.
TM-944 Page 27 Handler 135 / 175 Return T o T able Of Contents 6-5. Control Board PC1 T est Point V alues (1 15 V AC Model) PC1 V oltage Readings a) T olerance − ± 10% unless specified b) Reference.
TM-944 Page 28 Handler 135 / 175 Return T o T able Of Contents 6-6. Control Board PC1 T esting Information (230 V AC Model) Be sure plugs are secure before testing.
TM-944 Page 29 Handler 135 / 175 Return T o T able Of Contents 6-7. Control Board PC1 T est Point V alues (230 V AC Model) PC1 V oltage Readings a) T olerance − ± 10% unless specified b) Reference .
TM-944 Page 30 Handler 135 / 175 Return T o T able Of Contents SECTION 7 − MAINTENANCE 7-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals.
TM-944 Page 31 Handler 135 / 175 Return T o T able Of Contents 7-4. Changing Drive Roll Or Wire Inlet Guide 1 Inlet Wire G u i d e S e c u r i n g Screw 2 Inlet Wire Guide Loosen screw . Slide tip as close to drive rolls as possible without touching. Tigh ten screw .
TM-944 Page 32 Handler 135 / 175 Return T o T able Of Contents 7-6. Cleaning Or Replacing Gun Liner Ref. 802 446 8 mm / 10mm Y Disconnect gun from unit. T ools Needed: T o Reassemble Gun: Insert new liner . Install wire outlet guide so that 1/8 in (3 mm) of liner sticks out.
TM-944 Page 33 Handler 135 / 175 Return T o T able Of Contents 7-7. Replacing Switch And/Or Head T ube Ref. ST-800 795-C T ools Ne e d e d : 19 mm Remove handle locking nut. Slide handle. Secure head tube in vice. Loosen jam nut. Remove from vice an d turn head tube out by hand.
TM-944 Page 34 Handler 135 / 175 Return T o T able Of Contents SECTION 8 − ELECTRICAL DIAGRAMS . The circuits in this manual can be used for troubleshooting, but there might be minor circuit differences from your machine. Use circuit inside machine case or contact your distributor for further information.
TM-944 Page 35 Handler 135 / 175 Return T o T able Of Contents 194 324-C Figure 8-1. Circuit Diagram For 1 15 V AC Model Effective With Serial No. KK213350 And Following.
TM-944 Page 36 Handler 135 / 175 Return T o T able Of Contents 194 325-A Figure 8-2. Circuit Diagram For 230 V AC Model Effective With Serial No. KK213350 And Following.
TM-944 Page 37 Handler 135 / 175 Return T o T able Of Contents 196 637-A Figure 8-3. Wiring Diagram For 1 15 V AC Model Effective With Serial No. KK213350 And Following.
TM-944 Page 38 Handler 135 / 175 Return T o T able Of Contents 196 655-A Figure 8-4. Wiring Diagram For 230 Model Effective With Serial No. KK213350 And Following.
TM-944 Page 39 Handler 135 / 175 Return T o T able Of Contents 195 890-A Figure 8-5. Circuit Diagram For 1 15 V AC Model Control Board PC1 Effective With Serial No.
TM-944 Page 40 Handler 135 / 175 Return T o T able Of Contents 195 891-A Figure 8-6. Circuit Diagram For 230 V AC Model Control Board PC1 Effective With Serial No.
V isit our website at www.HobartWelders.com H a n d l e r 1 3 5 / 1 7 5 And H-10 Gun TM -944C Oc tober 2003 Handler 135 (500 414) Eff. w/Serial No. LB096205 Handler 175 (500 416) Eff.
TM-944 Page 42 Handler 135 / 175 Return T o T able Of Contents SECTION 9 − P ARTS LIST . Hardware is common and not available unless listed. 802 449-E 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 29 30 35 33 32 50 44 49 48 47 46 45 52 51 36 37 43 42 41 39 40 38 28 31 34 Figure 9-1.
TM-944 Page 43 Handler 135 / 175 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly Quanti ty 1 199 566 DOOR, access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
TM-944 Page 44 Handler 135 / 175 Return T o T able Of Contents Description Part No. Dia. Mkgs. Item No. Figure 9-1. Main Assembly (Continued) Quanti ty 41 196 574 SWITCH, rocker DPST (230 V AC model) 1 . . . . . . . . . . . . . . . . . . . . . . . . .
TM-944 Page 45 Handler 135 / 175 Return T o T able Of Contents Figure 9-2. H-10 Gun Quanti ty Description Part No. 195 957 Item No. Figure 9-2. H-10 Gun 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . .
PRINTED IN USA 2003 Hobart Welding Products Hoba rt We lding Product s An I l li noi s T ool Works Com pany 600 West M ain Street Troy , O H 45373 USA For Technical Assi stance: Call1-800-332-3281.
An important point after buying a device Hobart Welding Products TM-944C (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Hobart Welding Products TM-944C yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Hobart Welding Products TM-944C - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Hobart Welding Products TM-944C you will learn all the available features of the product, as well as information on its operation. The information that you get Hobart Welding Products TM-944C will certainly help you make a decision on the purchase.
If you already are a holder of Hobart Welding Products TM-944C, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Hobart Welding Products TM-944C.
However, one of the most important roles played by the user manual is to help in solving problems with Hobart Welding Products TM-944C. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Hobart Welding Products TM-944C along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
