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  • 135 Handler Problem

    My MIG welder, Hobart 135 Handler is acting up. The wire remains hot when the trigger is NOT depressed and also when the machine is switched OFF! I have been able to continue welding with it, I just have to be careful where I put the gun down. Yesterday, I learned that it also keeps the gas valve open so its getting expensive so I really need to fix it pronto. Anybody have experience with this problem?

  • #2
    One of the relays on the control board has stuck contacts. The CR1 relay controls the power to the main transformer and gas valve. This relay is soldered to the control board. You may be able to source one at www.digikey.com or you can purchase a complete board part# 195886 from your local Hobart/Miller repair center.

    Keith

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    • #3
      Thanks for that and that is what I thought it might be. This problem happened last year and I did buy a replacement relay from Digikey but when I got it, I found it had different pin arrangements. Then I took the welder to a tool repair place and it worked for a about a year. I guess what I need to know is the correct part number for the relay and I can order the correct one. It would be awesome if you could help me with that.

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      • #4
        best way is to pull the number off the top of the relay on the board. NT90RHC-S 24CB was one that may work. Best to check the relay itself.

        Keith

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        • #5
          When I search Digikey's database with that pn I get 0 matches. The relay that I got last year (which I amazingly put my hands on immediately) is an ETE T90S5D12-24 20A NO 10A NC 240VAC and has an extra pin. Also, there are two relays on the board and I am not sure which one (or both) is failing.

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          • #6
            CR1 is the relay causing your issue. Maybe try google search with the number I provided or get the number of the CR1 relay on your board.

            Keith

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            • #7
              Okay, that worked sort of. A company called USbid "has" them but not really. You contact them and then he calls the company that actually has them with an offer of how much you want to pay. The incorrect relay that I boght was $3.41 so I used a similar number as an offer. USBid is going to contact me with the results - if they accepted or whatever. I understand that it is difficult for any company to make any money on small orders of inexpensive parts. I'll let you know what their response is.

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              • #8
                No joy there. They want me to buy 50 pieces for $238.50. Guess I'll keep looking.

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                • #9
                  Look at this spec sheet. You may be able to simply cut off the extra terminal of the T90S5D12-24 to make it into a T90S5D42-24.

                  http://www.te.com/commerce/DocumentD...ocLang=English

                  https://www.digikey.com/products/en?...ds=T90S5D12-24

                  https://www.digikey.com/products/en?...ds=t90s5d42-24

                  Here's a bit of discussion of the TE vs. Zettler relay. http://www.badcaps.net/forum/showthread.php?t=35130
                  Last edited by usmcpop; 08-31-2017, 03:05 PM.
                  --- RJL ----------------------------------------------

                  Ordinarily I'm insane, but I have lucid moments when I'm merely stupid.
                  -------------------------

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                  • #10
                    The big CR1 relay thread: https://www.hobartwelders.com/weldta...umming-Problem
                    --- RJL ----------------------------------------------

                    Ordinarily I'm insane, but I have lucid moments when I'm merely stupid.
                    -------------------------

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                    • #11
                      I took the board and wacked the relay with a hammer. Put it back together and it worked! But only for a bit and then it started in with the problem again. So I rigged up an extension cord and positioned its plug where I could unplug the welder when done with a running a bead. I needed to finish the job I had before I started messing with swapping out components on the board. Since then it has been running just fine for some reason!

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