Hobart Handler 140 User manual

115 Volt
Handler®140
115V Wire Feed Welder
Includes:
Comfortable 10-ft. (3 m) H100S2-10 gun
10-ft. (3 m) work cable with clamp
Built-in gas solenoid valve and dual-gauge regulator with gas hose
Spool hub assembly accommodates 4 or 8 in. spools
Sample spool of .030 in. (0.8 mm) self-shielding flux-cored wire
.030 in. (0.8 mm) contact tips
Power cord with plug
Weld set-up chart
Owner’s manual with parts lists, installation, operation and
maintenance guidelines
Stable arc with improved performance on thin gauge material.
Provides positive feed with adjustable tension. Easy access for threading wire.
Provides a broader operating window for each wire, with quick and easy adjustment for different thicknesses and joints.
Eases use and excellent safety feature which makes wire electrically “cold” until trigger is pulled.
Access makes it quick and easy to change polarity for solid or tubular wire. Includes convenient storage holes for
spare tips.
Makes it easy to change from one wire size to another. One knurled groove and one smooth groove for
.030–.035 in. (0.8–0.9 mm) wire.
Makes controls quickly visible and accessible.
Protects unit against current overload.
Protects power transformer to ensure reliability.
Protects wire feed system from overload, no fuses to change or circuit breaker buttons to reset.
Five-year warranty on transformers, three years on electronics (drive motors, rectifiers) and one year on guns.
Excellent arc performance
Proven built-in wire feeder with
quick-release tension lever
Four output voltage settings with
wire feed speed tracking
Built-in contactor
Convenient polarity changeover with
tip holder
Dual-groove quick-change drive roll
Sloped control panel
Short circuit protection
Self-resetting thermal overload
Self-resetting motor protection
Hobart's 5/3/1 Industrial Warranty
217919
March 2011
Features Benefits
Built with Hobart quality and durability, the
Handler 140 is a wire welding package with
industrial performance capable of operating on
standard 115/120 volt, 20 amp home circuits.
The broad output range of 25 –140 amps allows
you to weld 24 gauge up to 1/4 inch steel.
The Handler 140 is capable of running the following
wires: .023 –.035 in. (0.6 – 0.9 mm) mild steel
or stainless steel, .030 –.035 in. (0.8 – 0.9 mm)
flux-cored, and .030 in. (0.8 mm) aluminum. Four
output voltage settings with wire feed tracking
make the unit easy to set and adjust for different
materials and thicknesses.
#500500
Applications:
Home, farm and ranch and light fabrication projects.
Mower Decks/Brackets Grills/Smokers
Fences/Gates Firewood Racks
Kennels Metal Furniture
Signs Machinery and
Window Security Guards Auto Repair, etc.

2
Flux Cored
E71T-11
(DCEN)
Solid Wire
ER70S-6
(DCEP)
Solid Wire
ER70S-6
(DCEP)
Stainless
Steel
(DCEP)
Aluminum**
(DCEP)
Good for windy or
outdoor applications
Produces less spatter.
Better bead appearance.
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—
—
—
— 1/30 2/30
2/20
3/50
3/35
3/30
3/40
4/30
3/40
3/20
4/70
4/40
4/40
4/40
4/35
4/45
4/35
—
—
—
—
—
—
4/50*
—
—
—
—
4/30 —
—
—
—
—
2/30
2/20
—
—
1/25
—
3/40
2/30
3/25
3/30
3/20
4/25
—
4/503/402/30
——4/303/102/15
—4/90**3/90**
—
2/30
—
—
——
—
—
—
—
—
—
—
—
CFH
Settings are approximate. Adjust as required. Thicker materials can be
welded using proper technique, joint preperation and multiple passes.
Recommended Voltage and Wire Speed Settings for thickness of metal being welded.
Number on left of slash is Voltage Setting/Number on right of slash is Wire Feed Setting.
*Multiple passes required. **Aluminum wire is soft so feedability is not as good. Make sure that hub tension is not too tight and keep the torch as straight as possible. A “push angle” for the torch is recommended.
Match feed roll groove to diameter of wire being used.
Set tension knob setting to 3 at start.
Adjust tension per instructions in the manual.
CAUTION! Do not change voltage switch
position while welding. See owners manual
for more information.
Wire speed listed is a starting value only. Wire speed setting can be
fine-tuned while welding. Wire speed also depends on other variables
such as stick out, travel speed, weld angle, cleanliness of metal, etc.
Handler 140 Welding Guide
Control Panel
1. Power Switch
2. Wire Speed Control
3. Voltage Control Switch
1
2
3
Certified by Canadian Standards Association to both the Canadian and U.S. Standards.
* CSA rating.
Specifications (SUBJECT TO CHANGE WITHOUT NOTICE.)
Rated Output
90 A, 19 VDC,
at 20% Duty Cycle
63 A, 21 VDC
at 20% Duty Cycle*
Max. Open-
Circuit Voltage
28 V
Wire Feed
Speed Range
40– 700 IPM
50– 740 IPM
at no load
Current
Range
25 –140 A
Amps Input at Rated Output, 60 Hz, 1-Phase
115 V KVA KW
20 2.9 2.5
15* 2.2* 1.77*
Dimensions
H: 12-3/8 in. (315 mm)
W: 10-5/8 in. (270 mm)
D: 19-1/2 in. (495 mm)
Net
Weight
57 lb.
(26 kg)

Spool Gun 3035-20 #300143
20 ft. (6.1 m) cable and gas hose
Weld 14 gauge –1/8 in. (1.9 – 3.2 mm)
aluminum with the Handler 140
Threaded nozzle and contact tips
Spool gun conversion kit consisting of
control switch and gas diverter valve
Enclosed wire spool compartment with
internal spool hub tension adjustment
for 4 in. (102 mm) rolls of wire
For .030 –.035 in. (0.8 – 0.9 mm) aluminum,
steel and stainless steel
Rated 150 amps, 60% duty cycle
SGA 100 Spool Gun Control #043856
Required to connect spool gun to the Handler®
140. Includes 10 ft. (3 m) 115 VAC power cable
and plug, 6 ft. (1.8 m) interconnecting cable,
and 5 ft. (1.5 m) gas hose.
H100S2-10 Replacement MIG Torch
#245924
Comes in 10-ft. (3 m) length with liner for
.030 –.035 in. (0.8 – 0.9 mm) diameter wire.
Portable CO2Cylinder
Kit #770626
Includes one 20 oz.
CO2cylinder (paintball
style), pre-set regulator
and gas hose, spare
“O” rings, and
mounting hardware.
Small Cart/Cylinder Rack #194776
Designed for portable MIG welders.
Accommodates large and small gas cylinders.
Running Gear/Cylinder Rack #770187
Heavy-duty construction. Accommodates large
and small gas cylinders.
Protective Cover #195186
Weather-resistant nylon resists stains and
mildew while protecting the finish of your welder.
Accessories
3
DUTY CYCLE
1 4 10 20 40 60 10026 808
10
20
40
60
80
100
200
140
DUTY CYCLE %
OUTPUT AMPERES
VOLT/AMP CURVE
0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
0
5
10
15
20
25
30
AMPERAGE
VOLTAGE
RANGE 1
RANGE 2
RANGE 3
RANGE 4
Performance Data

Hobart Welders An Illinois Tool Works Company hobartwelders.com
Hobart Welding Products Service 800-332-3281 Sales 800-626-9420
Litho in USA
Spool Gun Trigger
Control Cord
Spool Gun Gas Hose
Interconnecting Cord Spool Gun Weld Cable
Gas Hose to Gas Regulator
115 VAC Power Cord
Spool Gun
Typical MIG welder
SGA 100
Control Box
Typical Installation for Optional Spool Gun 3035-20 to Handler®140
Item Hobart Package Part # Miller Package Part #
Contact Tips
.023/.025 in. (0.6 mm) #770174 (5 per package) #087 299 (10 per package)
.030 in. (0.8 mm) #770177 (5 per package) #000 067 (10 per package)
.035 in. (0.9 mm) #770180 (5 per package) #000 068 (10 per package)
MIG Nozzle (Standard) #770404 #169 715
Gasless Flux-cored Nozzle #770487 #226 190
Tip Adapter #770402 #169 716
Liners
.023/.025 in. (0.6 mm) #196139 #194 010
.030/.035 in. (0.8/0.9 mm) #196139 #194 011
.035/.045 in. (0.9/1.2 mm) #196140 #194 012
Power Source Drive Rolls
Dual-groove, V-smooth — #237338 —
For .023/.025 in. (0.6 mm) and
.030 –.035 in. (0.8 – 0.9 mm) wire
Dual-groove, V-knurled — #202926 —
For .030 –.035 in. (0.8 – 0.9 mm)
and .045 (1.2 mm) flux-cored wire
Dual-groove, V-knurled and V-smooth — #246565 —
For .030 –.035 in. (0.8 – 0.9 mm)
flux-cored and solid wire
Consumables
For Handler®140, combine Spool Gun 3035-20 with SGA 100 to weld 14 gauge to 1/8 in. aluminum. To weld aluminum with comparable, competitive
power sources, the spool gun may also be used with the SGA unit.
Note: Refer to SGA Owner’s Manual for complete installation instructions.