Handler 140 ®

217919
115-Volt Wire Feed Welder March 2020

115 V Quick Specs

Welding Amp Range
25 –140 A
Rated Output
Now with NEW! 90 A at 18.5 VDC, 20% duty cycle
HR-100 MIG gun. Mild Steel Thickness Range
24 ga.–1/4 in.

500559 Reliable. Durable. Superior arc with

140 A of power.
The Handler 140 operates on 115-volt common household power.
Simply plug it in and weld — no additional power needed.
Weld as thin as 24 gauge and up to 1/4 inch in a single pass,
with a broad output range of 25–140 amps. Easily weld
thicker materials with multiple passes.
Quick and easy setup with Quick Select™ drive rolls which
offer three grooves — two for different sizes of solid wire and
Includes a third for flux-cored wire.
10 ft. (3 m) HR-100 MIG gun with Quick Select ™ drive roll for .024 in. Easy to set and adjust for different materials and thicknesses
ergonomic, rubber-padded handle (0.6 mm) or .030/.035 in. (0.8/0.9 mm) — features five output voltage settings.
10 ft. (3 m) work cable with clamp solid wire, and .030/.035 in.
Power cord with plug (0.8/0.9 mm) flux-cored wire Applications
Built-in gas solenoid valve and Sample spool of .030 in. (0.8 mm) Maintenance/repair Auto body
dual-gauge regulator with gas hose self-shielding flux-cored wire DIY Farm/ranch applications
.030 in. (0.8 mm) contact tips Material thickness gauge Metal art Home repair

Features Benefits
Five-position voltage control and Five voltage ranges allow you to fine-tune the arc.
infinite wire feed speed
Spool hub assembly accommodates Offers you flexibility to use small or large spools of wire to better suit your welding needs.
4- or 8-inch spools
Convenient polarity changeover Access makes it quick and easy to change polarity for solid or tubular wire.
Quick Select drive roll Makes setup quicker by offering three grooves — two for different sizes of solid wire and a third for flux-cored wire.
Hobart 5/3/1 industrial warranty Five-year warranty on transformers, stabilizers and main rectifiers; three years on generators, PC boards and drive systems;
and one year on guns (MIG, plasma and TIG torches).

Specifications (Subject to change without notice.)

Welding Amp Amps Input at Rated Output, 60 Hz Max. Open Wire Feed
Range Rated Output 115 V KVA KW Circuit Voltage Speed Range Dimensions Net Weight
25–140 A 90 A at 18.5 VDC, 20 2.9 2.5 28 VDC 40 –700 ipm H: 12.375 in. (315 mm) 57 lb.
20% duty cycle 50 –740 ipm W: 10.625 in. (270 mm) (26 kg)
at no load D: 19.5 in. (495 mm)

Certified by Canadian Standards Association to both the Canadian and U.S. Standards.

Hobart Welding Products HobartWelders.com

An ITW Welding Company
Sales: 800-626-9420
Service: 800-332-3281
 Control Panel

1. Power Switch
2. Wire Speed Control
3. Voltage Control Switch
2 4. Overtemperature Light

3
4

Performance Data

Duty Cycle Volt/Amp Curve

200 30

140
25
100
80 20
Output Amperes

60
Voltage

15
40 5
4
3
1 2
10

20
5

10 0
1 2 4 6 8 10 20 40 60 80 100 0 10 20 30 40 50 60 70 80 90 100 110 120 130 140 150 160
Duty Cycle % Amperage

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Accessories

Small Cart/Cylinder Rack 194776 Protective Cover 195186

HR-100 Replacement MIG Gun 285033 Designed for portable MIG welders. Weather-resistant nylon resists stains and
Comes in 10 ft. (3 m) length with liner for Accommodates large and small gas cylinders. mildew while protecting the finish of your welder.
.030–.035 in. (0.8–0.9 mm) diameter wire.

Consumables
Item Hobart Package Part # Miller Package Part #
Contact Tips
.023/.025 in. (0.6 mm) 770174 (5 per package) 087299 (10 per package)
.030 in. (0.8 mm) 770177 (5 per package) 000067 (10 per package)
.035 in. (0.9 mm) 770180 (5 per package) 000068 (10 per package)

MIG Nozzle (Standard) 770404 169715

Gasless Flux-cored Nozzle 770487 226190
Tip Adapter 770402 169716

Liners
.023/.025 in. (0.6 mm) 196139 194010
.030/.035 in. (0.8/0.9 mm) 196139 194011
.035/.045 in. (0.9/1.2 mm) 196140 194012

Power Source Drive Rolls

Quick Select™ drive roll for .024 in. (0.6 mm) 261157 261157
or .030/.035 in. (0.8/0.9 mm) solid wire, and
.030/.035 in. (0.8/0.9 mm) flux-cored wire
Dual-groove, V-knurled drive roll 202926 202926
for .030–.035 in. (0.8–0.9 mm)
and .045 (1.2 mm) flux-cored wire

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 Handler® 140 Welding Guide
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
.030 (0.8 mm) aluminum
Settings are approximate. Adjust as required. Thicker materials can be Recommended Voltage and Wire Speed Settings for thickness of metal being welded.
welded using proper technique, joint preperation and multiple passes. Number on left of slash is Voltage Setting/Number on right of slash is Wire Feed Setting.

CHANGING
Material Wire Type Suggested Diameter 24 ga. 20 ga. 18 ga. 16 ga. 12 ga. 10 ga. POLARITY
Being and Shielding Gas of Wire .024 in. .036 in. .048 in. .060 in. .105 in. .135 in. 3/16 in. 1/4 in.
Welded Polarity Setting 20–30 CFH Flow Rate Being Used (0.6 mm) (0.8 mm) (1.2 mm) (1.6 mm) (2.7 mm) (3.4 mm) (4.8 mm) (6.4 mm)
DCEN
No Shielding Gas Electrode Negative
Flux Core .030˝ (0.8 mm) — — 1/30 2/30 3/40 3/45 4/50 5/50*
Steel E71T-11 Required for Flux-Cored
(DCEN) Good for windy or Wire
.035˝ (0.9 mm) — — — 2/25 3/35 4/35 5/35 5/40*
outdoor applications.

C25 Gas Mixture .024˝ (0.6 mm) 1/30 2/40 2/50 3/50 4/55 — — —
Solid Wire
75% Argon / 25% CO2
Steel ER70S-6 .030˝ (0.8 mm) 1/25 2/30 2/35 3/35 4/40 4/50 5/45 5/50*
Produces less spatter.
(DCEP)
Better appearance. .035˝ (0.9 mm) — — 2/30 3/30 4/35 4/40 5/40 5/45*

.024˝ (0.6 mm) 1/25 2/35 3/30 3/40 4/50 5/50 — —

Solid Wire
Steel ER70S-6 100% CO2 .030˝ (0.8 mm) — 2/30 3/30 3/35 4/30 4/35 5/35 5/40*
(DCEP)
.035˝ (0.9 mm) — — — 3/25 4/30 4/35 5/30 5/35*

.024˝ (0.6 mm) — — 3/30 4/50 — 5/50 — —

Tri-Mix DCEP
Stainless 90% He / 7.5% Ar / 2.5% CO2 .030˝ (0.8 mm) — — 3/20 4/40 — 5/40 — — Electrode Positive
Stainless Steel
Steel for Solid Wire
(DCEP) .024˝ (0.6 mm) — — 1/45 2/60 — 4/70 — —
98% Ar / 2% CO2
.030˝ (0.8 mm) — — 1/40 2/50 — 4/60 — —

Aluminum** .030˝ (0.8 mm) — — — 3/90** 5/90** — — —

4043 AL (DCEP)
Aluminum 100% Argon**
Aluminum**
.030˝ (0.8 mm) — — — 2/100** 4/100** — — —
5356 AL (DCEP)
Match feed roll groove to diameter of wire being used. CAUTION! Do not change voltage switch Wire speed listed is a starting value only. Wire speed setting can be
Set tension knob setting to 3 at start. position while welding. See owners manual fine-tuned while welding. Wire speed also depends on other variables
Adjust tension per instructions in the manual. for more information. such as stick out, travel speed, weld angle, cleanliness of metal, etc.

*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.

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