Question about Hobart Handler 140 Mig Welder

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Hobart Handler 135 not feeding wire

My Hobart Handler 135 welder drive motor inconsistently works without a load on the rollers. As soon as a load is exerted on the rollers the motor will not work at all. I tested the motor with a 12 volt battery and it will operate properly on a direct feed with and without a load. I had the circuit board tested by an electrical engineer and no problems were found once tested and inspected. Only thing found was a high percentage of metallic flakes that could be discharging the capacitors prematurely. A good cleaning every now and again may help avoid this problem. After cleaning the whole unit I will reinstall the circuit board in the machine tonight and test it. Any suggestions from anyone if all fails. Thanks.

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  • markzuena Aug 03, 2009

    The cleaning did not help at all.... But to respond to the previous comment the relay makes the clicking sound as expected when the triger is pressed and power is sent to the motor. I tested the circuit while everything was reattached. The circuit starts around 20 volts and slowly dies down to zero. Must be a capacitor not holding the rated charge??

  • markzuena Aug 04, 2009

    when you say "contactor", I am assuming it would be the same as a A/C unit contactor. The only contactor component would be the relay assembly, right? There are 2 relays...one for the drive motor and one for the gas solenoid valve. They both are operative but the circuit drains to zero volts at the drive motor terminals. I have the elevctrical engineer looking at it again. Keep the comments coming, I do appreciate the discussions. As soon as I find out I will post the information. Thanks.

  • markzuena Aug 05, 2009

    Thank you. I will check this today.

  • markzuena Aug 12, 2009

    update to progress...I do not have a power supply on this welder. The cord goes into the box and direct to the circuit panel. From there is splits to separate circuits within the panel. Two relays exist on the panel. One to the gas solenoid, and two to the drive motor. In the drive motor circuit is the relay, a diode, a capacitor and a timing chip. The loss is beleived to be at the cip or the relay (which is the only "contactor" part of the circuit. I need to switch out the relay, but cannot find this particular relay without having to buy hundreds of them, which would exceed the cost of the entire circuit panel replacement from Hobart (Miller). Any suggestions where to buy these parts. I am going to call Hobart to see if they spill the beans.

  • markzuena Aug 13, 2009

    yes. sorry

  • markzuena Aug 13, 2009

    yes. sorry

  • markzuena Aug 14, 2009

    That has been my problem. I really appreciate your efforts. I have been dealing with a friend who is an electrical engineer and he told me the same thing, but not in the line of business to stock these particular parts. If you can get your hands on one or indicate how I can, you would be a great deal of help. What goes around comes around....Thank you very much.

  • markzuena Aug 20, 2009

    Has anyone have any idea where to get these parts? Thank you

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Try checking your heat selector switch. the pc board gets power from it. so the pc board relay may function (click) but have little or no power once the curcuit is made to the feed motor. it happened on my 135.

Posted on Sep 14, 2009

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Remember, a relay is operated by value of coil-24vac 24vdc 110vac, think radio shack or electrical supply store.It doesn't have to look exactly the same to work, ratings are what is important. Read what the existing relay is rated for. Explore your options, you might be suprised what you find cheap. Also try taking a look at the relay points to see if burnt. Take a look at motor connections also. Most important don't get shocked (one hand method or insulated gloves)

Posted on Aug 24, 2009

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Sounds like input power problem,or the main contactor is bad.

Posted on Aug 02, 2009

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  • shane covert Aug 04, 2009

    that is a possability,but what I was thinking was the coil on the main contactor breaking down,I assume the board had no affect?Try having someone hold the gun trigger and put a meter across the coil on the contactor for voltage reading holding it there for a few seconds to see if it changes. good luck

  • shane covert Aug 05, 2009

    yes the contactor is where the input power goes once inside the unit,your correct, the one side powers the unit for welding(set of points) the bottem half feeds 110 to rest of unit.so start at the contactor and check the voltage along the travel to the motor,see where you start loosing your power.good luck.

  • shane covert Aug 13, 2009

    when you say circut panel are you talking p.c. board?

  • shane covert Aug 14, 2009

    ok thanks.couple more questions.does the motor lead plug into the pc board ?if it does and from the plug to the motor there is nothing else in line on that wiring then I would say your right on the relay.The company that makes these relays sell by the bulk so that people like you and me cant fix these minor problems without buying an expensive pc board.I will try to get a hold of a friend and see where we c an get this part for you.

  • shane covert Aug 15, 2009

    Im on it for you.

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I have a hobart Handler 135 and it won't feed the wire correctly. At first it will feed about 6 " of wire then it goes down to about an inch at a time then it will just click. If you wait awhile it will...


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To diagnose, locate thermistor @ position PTC1 in upper middle part of circuit board.
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