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Hi,
I’ve had my Handler 120 for almost 30 years…. Used it occasionally for most of that time, but have really ramped up my usage over the past couple of years. Even added gas recently.

But now it won’t feed the wire.

I opened the cover to watch the feed motor when I pull the trigger… and the wheel doesn’t turn.
It was intermittent for a few short welds, but then stopped completely.

Additionally, I’m seeing sparks off o e of the terminals on the big capacitor (see red circle on pic).

What can I do? New drive motors aren’t cheap and most electronic parts can’t be returned…. So I’ll buy one if I’m sure that’s the issue. How to test? Advice appreciated.
Thanks,
Doug

Sounds like it could be a faulty trigger switch. Does the gas solenoid click on when you pull the trigger?

Now... the sparks from that capacitor..... is the screw on that terminal tight? Make sure the capacitor is discharged before you check the terminal. With the machine unplugged, let it sit overnight or so.

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Yes, the solenoid clicks, so the trigger is working.
It’s been unplugged for a few hours now, I’ll wait and check the connection tomorrow evening.
Thank you for the suggestions. I’ll update with any progress.

 

Hi Doug.

I would try to diagnose it but if parts are expensive I’d consider looking for another used welder. I just bought a like new Hobart 140 with small bottle and mask for $225. I know that is a rare find but you might find something along those lines. I then sold my old Hobart 120 for $200 so upgraded for little money.

After 30 years you have had good service but might be time to upgrade. There may be another hidden reason for the malfunction.

 

There's no need to let it sit before working on the capacitor , there's a bleeder resistor across the capacitor screws that discharges the capacitor , by the time you unplug it and set the plug down it's discharged .....
If you're paranoid just touch a pair of needlenose pliers to the two screws .

 

Judging from the melted insulation on the black lead from the output rectifier I'd guess a failed (shorted) output capacitor or one or both failed (shorted) output rectifier diodes resulting in feeding the capacitor (a DC device) AC voltage.

If one or both output rectifier diodes failed shorted, the wire feed motor likely saw AC voltage and may have been damaged as well.