Hobart Handler 125 Owner's Manual

Hobart Handler 125 Owner's Manual

Flux cored (fcaw) welding, mig (gmaw) welding ,(optional), arc welding power source and wire feeder
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Handler 125
And H-9B Gun
OM-947
2010−05
Processes
Flux Cored (FCAW) Welding
MIG (GMAW) Welding (Optional)
Description
Arc Welding Power Source And
Wire Feeder
R
File: Flux Cored (FCAW)
212 149G

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Summary of Contents for Hobart Handler 125

  • Page 1 OM-947 212 149G 2010−05 Processes Flux Cored (FCAW) Welding MIG (GMAW) Welding (Optional) Description Arc Welding Power Source And Wire Feeder Handler 125 And H-9B Gun File: Flux Cored (FCAW)
  • Page 2 From Hobart to You Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. This Owner’s Manual is designed to help you get the most out of your Hobart products.
  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1.
  • Page 4 TABLE OF CONTENTS SECTION 9 − WIRE WELDING GUIDELINES ........... 9-1.
  • Page 5: Section 1 − Safety Precautions - Read Before Using

    SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2010−03 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.
  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can injure. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables.
  • Page 8: California Proposition 65 Warnings

    1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &...
  • Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2010−03 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.
  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Des bouteilles de gaz protecteur contiennent du gaz sous haute pression. Si une bouteille est endom- D Fermer l’alimentation du gaz protecteur en cas magée, elle peut exploser.
  • Page 12: Proposition Californienne 65 Avertissements

    Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- munication, les services de sécurité...
  • Page 13: Principales Normes De Sécurité

    2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (téléphone : 212-642-4900, de Global Engineering Documents (téléphone : 1-877-413-5184, site site Internet : www.ansi.org). Internet : www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, de National Fire Protection Association,...
  • Page 14 OM-947 Page 10...
  • Page 15: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions Amperage Voltage Hertz Negative Direct Current Positive Single Phase Input (DC) Output Voltage Input Do Not Switch Gas Metal Arc Flux Cored Arc Wire Feed While Welding Welding (GMAW) Welding (FCAW) SECTION 4 − SPECIFICATIONS 4-1.
  • Page 16: Duty Cycle And Overheating

    4-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 min- utes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before welding.
  • Page 17: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Work Clamp Connection hardware must be tightened with proper tools. Do not just hand tighten hardware. A loose electrical connection will cause poor Work Cable From Unit weld performance and excessive heating of the work clamp. Work Clamp Screw Work Clamp Tabs...
  • Page 18: Process/Polarity Table

    5-2. Process/Polarity Table Cable Connections Process Polarity Cable To Gun Cable To Work Clamp FCAW − Self-shielding wire − DCEN − Straight Polarity Connect to negative (−) Connect to positive (+) output no shielding gas output terminal terminal GMAW* − Solid wire with DCEP −...
  • Page 19: Installing Gas Supply

    5-4. Installing Gas Supply This Section only applies to MIG units or units equipped with MIG kit. Tools Needed: 11/16, 1-1/8 in. Shielding 802 028 / Ref. 803 379-A Obtain gas cylinder and chain to running Install regulator/flowmeter to cylinder Flow Adjust gear, wall, or other stationary support so valve.
  • Page 20: Installing Wire Spool And Adjusting Hub Tension

    5-5. Installing Wire Spool And Adjusting Hub Tension Installing 4 in. (102 mm) Wire Spool When a slight force is needed to turn spool, tension is set. Installing 8 in. (203 mm) Wire Spool Adapter used with Only applies to units equipped with 8 in.
  • Page 21: Serial Number And Rating Label Location

    5-6. Serial Number And Rating Label Location The serial number and rating information for this product is located on 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. 5-7.
  • Page 22: Installing Contact Tip And Nozzle

    5-8. Installing Contact Tip And Nozzle Turn off welding power source. Nozzle Remove nozzle. Contact Tip Tip Adapter Thread welding wire through gun (see Section 5-9). Slide contact tip over wire and tighten tip into tip adapter. Install nozzle. Flux Nozzle MIG Nozzle Use with flux cored wire only.
  • Page 23: 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 24: Section 6 − Operation

    SECTION 6 − OPERATION 6-1. Controls Voltage Switch 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 Section applicable). Do not switch under load.
  • Page 25 Notes OM-947 Page 21...
  • Page 26: Weld Parameter Chart

    6-3. Weld Parameter Chart OM-947 Page 22...
  • Page 27 210 428 OM-947 Page 23...
  • Page 28: Section 7 − Maintenance &Troubleshooting

    SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe condi- tions. 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 29: 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 30: Replacing Gun Contact Tip

    7-5. Replacing Gun Contact Tip Turn Off power before replacing contact tip. Nozzle Remove nozzle. Contact Tip Tip Adapter Cut off welding wire at contact tip. Remove contact tip from tip adapter, and install new contact tip. Reinstall nozzle. Tools Needed: Ref.
  • Page 31: Cleaning Gun Liner

    7-6. 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 32: Replacing Gun Liner

    7-7. Replacing Gun Liner Turn Off welding power source. Tools Needed: Head 8 mm / 10 mm 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.
  • Page 33 7-7. 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 34: Troubleshooting Table

    7-8. 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). Reset welding power source supplementary protector if open.
  • Page 35: Section 8 − Electrical Diagram

    SECTION 8 − ELECTRICAL DIAGRAM 230 950-A Figure 7-1. Circuit Diagram OM-947 Page 31...
  • Page 36: Section 9 − Wire Welding Guidelines

    SECTION 9 − WIRE WELDING GUIDELINES 9-1. Typical FCAW Process Connections 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. Wire Feeder/ Power Source Work Clamp Workpiece...
  • Page 37: 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 determines weld parameters. 1/8 or 0.125 in Convert Material Thickness to Amperage (A)
  • Page 38: Holding And Positioning Welding Gun

    9-4. Holding And Positioning Welding Gun Welding wire is energized when gun trigger is pressed. Before lowering 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. Hold Gun and Control Gun Trigger Workpiece...
  • Page 39: 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 (stickout), 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 40: 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 41: Troubleshooting − Excessive Spatter

    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 42: Troubleshooting − Lack Of Penetration

    9-12. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics.
  • Page 43: Troubleshooting − Waviness Of Bead

    9-15. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand.
  • Page 44: Section 10 − Parts List

    SECTION 10 − PARTS LIST Hardware is common and not available unless listed. 803 446-B Figure 9-1. Main Assembly OM-947 Page 40...
  • Page 45 Item Dia. Part Mkgs. Description Quantity Figure 9-1. Main Assembly ..... 210 432 . . . CASE SECTION, front/bottom/rear ......
  • Page 46 5 − See Table 9-1 804 243-A Figure 9-2. H-9B Gun Item Part Description Quantity 195 157R Figure 9-2. H-9B Gun ....169 715 ..NOZZLE, slip type .500 orf flush .
  • Page 47 803 442-B Figure 9-3. Wire Drive Assembly Item Part Description Quantity 209 532 Figure 9-3. Wire Drive Assembly ..... 212 377 .
  • Page 48 Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.
  • Page 49 Notes...
  • Page 50 Notes...
  • Page 51 Effective January 1, 2010 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? serial number preface of MA or newer. Call This limited warranty supersedes all previous Hobart warranties and is exclusive with 1-800-332-3281 no other guarantees or warranties expressed or implied.
  • Page 52 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. ORIGINAL INSTRUCTIONS − PRINTED IN USA 2010 Hobart Welding Products. 2010−01...

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