Hobart Welding Products Handler 125 Owner's Manual
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Hobart Welding Products Handler 125 Owner's Manual

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Handler 125
www.HobartWelders.com
OM-283007B
Processes
MIG (GMAW) Welding
Flux Cored (FCAW) Welding
Description
Arc Welding Power Source And
Wire Feeder
)
File: MIG (GMAW)
2019-05

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Summary of Contents for Hobart Welding Products Handler 125

  • Page 1 OM-283007B 2019-05 Processes MIG (GMAW) Welding Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Handler 125 File: MIG (GMAW) www.HobartWelders.com...

  • Page 2: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.

  • Page 3: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2018−01 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions.
  • Page 4 D Do not cut or weld on tire rims or wheels. Tires can explode if heat- FUMES AND GASES can be hazardous. ed. Repaired rims and wheels can fail. See OSHA 29 CFR 1910.177 listed in Safety Standards. D Do not weld on containers that have held combustibles, or on Welding produces fumes and gases.

  • Page 5: Additional Symbols For Installation, Operation, And Maintenance

    D Never weld on a pressurized cylinder − explosion will result. CYLINDERS can explode if damaged. D Use only correct compressed gas cylinders, regulators, hoses, and fittings designed for the specific application; maintain them Compressed gas cylinders contain gas under high and associated parts in good condition.

  • Page 6: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. D Have only qualified persons familiar with electronic equipment D Be sure all equipment in the welding area is electromagnetically perform this installation.

  • Page 7: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION som_2018−01_fre Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 8 D Déplacer toutes les substances inflammables à une distance de LES PIÈCES CHAUDES peuvent 10,7 m de l’arc de soudage. En cas d’impossibilité les recouvrir provoquer des brûlures. soigneusement avec des protections homologués. D Ne pas toucher à mains nues les parties chaudes. D Ne pas souder dans un endroit là...

  • Page 9: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) des chocs mécaniques, des dommages physiques, du laitier, des peuvent affecter les implants médicaux. flammes ouvertes, des étincelles et des arcs. D Placer les bouteilles debout en les fixant dans un support station- D Les porteurs de stimulateurs cardiaques et naire ou dans un porte-bouteilles pour les empêcher de tomber ou autres implants médicaux doivent rester à...

  • Page 10: Proposition Californienne 65 Avertissements

    D Effectuer régulièrement le contrôle et l’entretien de l’installation. LIRE LES INSTRUCTIONS. D Maintenir soigneusement fermés les portes et les panneaux des sources de haute fréquence, maintenir les éclateurs à une distan- D Lire et appliquer les instructions sur les ce correcte et utiliser une terre et un blindage pour réduire les étiquettes et le Mode d’emploi avant l’instal- interférences éventuelles.

  • Page 11: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Additional Safety Symbols And Definitions Some symbols are found only on CE products. Warning! Watch Out! There are possible hazards as shown by the symbols. Safe1 2012−05 3-2. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Amperage Line Connection Suitable For...

  • Page 12: Section 4 − Specifications

    SECTION 4 − SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-2.

  • Page 13: Duty Cycle And Overheating

    4-4. Duty Cycle And Overheating 25% duty cycle at 80 amps 2 Minutes Welding 8 Minutes Resting 60% duty cycle at 50 amps 6 Minutes Welding 4 Minutes Resting 100% duty cycle at 40 amps Continuous Welding Duty Cycle % Duty Cycle is percentage of 10 minutes that If unit overheats, thermostat(s) opens, NOTICE −...

  • Page 14: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Selecting A Location Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. Do not move or operate unit where it could tip. Grounded Receptacle Locate unit near correct input power supply.

  • Page 15: Process/Polarity Table

    5-3. Process/Polarity Table Cable Connections Process Polarity Cable To Gun Cable To Work Clamp FCAW − Self-shielding wire − no DCEN − Straight Polarity Gun cable is connected to the Work cable is connected to the positive shielding gas negative (−) output (+) output GMAW −...

  • Page 16: Installing Gas Supply

    5-6. Installing Gas Supply Tools Needed: 11/16, 1-1/8 in. Shielding Gas 802028 / Ref. 803379-A Obtain gas cylinder and chain to running Install regulator/flowmeter to cylinder valve. Flow Adjust gear, wall, or other stationary support so Be sure that gauge face is vertical for cylinder cannot fall and break off valve.

  • Page 17: Installing Contact Tip And Nozzle

    5-8. Installing Contact Tip And Nozzle Tools Needed: MIG Nozzle Flux Nozzle (Optional) Use with flux cored wire only. Narrow Use with solid or flux cored wire. design allows access in tight spaces and provides better visibility of puddle during welding. Push nozzle over contact tip and adapter until it is seated onto adapter.

  • Page 18: Threading Welding Wire

    5-9. Threading Welding Wire Wire Spool Welding Wire Inlet Wire Guide Pressure Adjustment Knob Drive Roll Gun Cable Lay gun cable out straight. Tools Needed: Hold wire tightly to keep it from unraveling. 6 in. 4 in. (150 mm) (102 mm) Open pressure assembly.

  • Page 19: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Controls Voltage Switch NOTICE − Do not switch under load. Use control to select the weld voltage range. As the thickness of material increases, a higher voltage range must be selected (see weld setting label in welding power source or in Section 6-3).

  • Page 20: Weld Parameter Chart

    6-3. Weld Parameter Chart 283081-B OM-283007 Page 18...

  • Page 21: Section 7 − Maintenance & Troubleshooting

    SECTION 7 − MAINTENANCE & TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. Reference n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent 3 Months l Damaged Or Unreadable Labels l Repair Or Replace...

  • Page 22: Changing Drive Roll Or Wire Inlet Guide

    7-4. Changing Drive Roll Or Wire Inlet Guide Pressure Adjustment Knob Pressure Assembly Pivot pressure adjustment knob down, and lift pressure assembly Pivot Tube Plate Securing Screws Pressure Arm Pivot Tube Inlet Wire Guide Remove screws and pivot tube plate. Lift out pressure arm pivot tube, and slide inlet wire guide out of tube.

  • Page 23: Cleaning Gun Liner

    7-5. Cleaning Gun Liner Turn Off welding power source. Nozzle Contact Tip Adapter Head Tube 8 mm Remove nozzle. Cut off wire Open pressure assembly. Retract Hold wire tightly to keep it at contact tip, and remove wire from liner onto spool. from unraveling.

  • Page 24: Replacing Gun Liner

    7-6. Replacing Gun Liner Turn Off welding power source. Tools Needed: Head 8 mm / 10 mm Tube 8 mm Hold wire tightly to keep it from unraveling. Secure Open pressure assembly. Retract Remove nozzle. Cut off wire at contact tip, end of wire at spool.
  • Page 25 7-6. Replacing Gun Liner (Continued) 13/16 in. (21 mm) 8 mm When liner exits cable at gun handle, guide liner into head tube. Continue to push liner until it exits end of head tube. Insert retaining nut into adapter, and adjust liner stickout as shown.

  • Page 26: Troubleshooting Table

    7-7. Troubleshooting Table Trouble Remedy Secure power cord plug in receptacle (see Section 5-7). No weld output; wire does not feed; fan does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 6-1). Check supplementary protector CB1, and reset if open (see Section 7-2).

  • Page 27: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM 284646-A Figure 8-1. Circuit Diagram OM-283007 Page 25...

  • Page 28: Section 9 − Fcaw/Gmaw Welding Guidelines

    SECTION 9 − FCAW/GMAW WELDING GUIDELINES 9-1. Typical FCAW Process Connections (Electrode Negative) Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. Appearance of actual unit may differ from that shown.

  • Page 29: Typical Control Settings

    9-3. Typical Control Settings These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material Thickness 1/16 or 0.0625 in. Material thickness determines weld parameters.

  • Page 30: Holding And Positioning Welding Gun

    9-4. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before low- ering helmet and pressing trigger, be sure wire is no more than 1/2 in. (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam.

  • Page 31: Conditions That Affect Weld Bead Shape

    9-5. Conditions That Affect Weld Bead Shape Weld bead shape depends on gun angle, direction of travel, electrode extension (stick- out), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. The Drag or Pull technique is generally recommended when welding with flux-cored tubular wire. Push Perpendicular Drag or Pull...

  • Page 32: Gun Movement During Welding

    9-6. Gun Movement During Welding Normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Stringer Bead − Steady Movement Along Seam Weave Bead −...
  • Page 33 9-9. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range. Electrode extension (stickout) too long.
  • Page 34 9-11. Troubleshooting − Excessive Penetration Excessive Penetration − weld metal melting through base metal and hanging underneath weld. Excessive Penetration Good Penetration S-0639 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase travel speed. 9-12.
  • Page 35 9-14. Troubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. S-0640 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase and/or maintain steady travel speed. 9-15.

  • Page 36: Troubleshooting Guide For Semiautomatic Welding Equipment

    9-17. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Remedy Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls. Wire feed motor operates, but wire does not feed. Incorrect wire feed rolls. Check size stamped on wire feed rolls, replace to match wire size and type if necessary.

  • Page 37: Section 10 − Parts List

    Dia. Part Mkgs. Description Quantity Handler 125 ..279992 Rectifier Assembly, 1PH 125 A 500V PIV 25% Duty Cycle ....
  • Page 38 Notes...
  • Page 39 Service LIMITED WARRANTY − Subject to the terms and conditions 6 Months — Parts You always get the fast, below, Miller Electric Mfg. LLC, dba Hobart Welding Products, Batteries reliable response you Appleton, Wisconsin, warrants to its original retail purchaser need.
  • Page 40 Thank you for purchasing Hobart. Our trained technical support team is dedicated to your satisfaction. For questions regarding performance, op- eration, or service, contact us! Resources Available Always provide Model Name and Serial/Style Number. To locate a Service Center: Call 1-800-332-3281 or visit our website at www.HobartWelders.com/wheretobuy For Technical Assistance: Call 1-800-332-3281...

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