Hobart Handler 135 problems - trigger not working

[yieldmap]

I'm having some problems with my 10-month old Handler 135. When I squeeze the trigger, sometimes it works fine, but most of the time it does not advance the wire. The power is on fine, breaker in the normal position, and the fan is running on the unit as normal. When I squeeze the trigger, it does not click the relay to start the wire advance. It's not like the wire is stuck or anything like that, it simply doesn't click the relay over.

Any ideas on what to check? The troubleshooting in the book was quickly ruled out.

Thanks,
Sam

[Al T.]

Sounds like the wires came off the switch inside your gun or the switch went bad.
You can also test the switch leads inside the welder where the two small wire connections go to your gun. The switch shorts these two together to activate the click you hear. That's a relay by the way.
You probably can fix this easily.

[yieldmap]

I'll try the switch in the gun

I'll try shorting out the two leads in the welder first and listen for the click. If I hear it, then I'll take the gun head apart and check the switch wires. I read in the book how to take it apart.

Thanks for the help.

I suppose if I have a bad switch, I can get a new one? Warranty, maybe?

Thanks.

[Hobart Expert Mike]

yieldmap,

Open up the mig gun. Just ahead of the trigger is a collar, twist clockwise and pop it forward towards the nozzle of the gun. The trigger will now slide out. There are two wires connected to the trigger by friction lug terminals. Disconnect these two leads from the trigger, turn the machine on with these two wires apart from each other. When you touch these two lugs together the machine should trigger in, if it does the trigger is bad. If the machine does not trigger in then go to the other side of the gun. There is a rubber sleeve over the cable of the gun that the trigger wires go into. Under this sleeve is a connection point, make sure the friction lugs are still securely fastened here. If this fails to identify the problem remove the mig gun from machine and using a jumper wire jump the two pins that the gun trigger wires plug into. Aside from this or if this does not identify the problem, a service center or your local distributor will be able to help you. If you need to look up a distributor or service center in your area, there is a locator on the main Hobart web page.
Mike

[yieldmap]

SUCCESS!! WooHoo!!

Guys,

Thanks up front for all your help.

I tried looking at the trigger assembly in the gun...no problems there...continuity through the switch when closed. I then went to the other end of the gun cable, pulled back the rubber sleeve, and found our culprit. The spade connector was loose. I crimped the connector a little tighter, inserted the spade, and applied a generous coating of electrical tape to insure a long-lasting fix.

I'm welding again!! Thanks for all your help. I wasn't looking forward to visiting a dealer.

yieldmap

[Hobart Expert Rock]

YIELDMAP........WELCOME ABOARD..........I WOULD LIKE TO NOTIFY MY GUN MANUFACTURE OF YOUR PROBLEM..........CAN YOU PROVIDE THE SERIAL NUMBER OF MACHINE........... ALSO BY THE GUN TRIGGER IN YOUR HANDLE IS A WHITE PAPER LABEL WITH THE GUN MANUFACTURER'S DATE..............THAT WOULD ALSO BE QUITE HELPFUL.................AND I'M SORRY YOU HAD A PROBLEM WITH THE LOOSE DISCONNECTED WIRE................ROCK.........
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