Related Manuals for Hobart Handler 125
Summary of Contents for Hobart Handler 125
- Page 1 OM-947 212 149D 2006−08 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.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1. - Page 4 TABLE OF CONTENTS SECTION 8 − WIRE WELDING GUIDELINES ........... 8-1.
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Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. - Page 6 ARC RAYS can burn eyes and skin. BUILDUP OF GAS can injure or kill. D Shut off shielding gas supply when not in use. Arc rays from the welding process produce intense visible and invisible (ultraviolet and infrared) rays D Always ventilate confined spaces or use that can burn eyes and skin.
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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 cause injury. 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: Principal Safety Standards
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada (phone: from Global Engineering Documents (phone: 1-877-413-5184, website: 800−463−6727 or in Toronto 416−747−4044, website: www.csa−in- www.global.ihs.com). ternational.org). Practice For Occupational And Educational Eye And Face Protection, Recommended Safe Practices for the Preparation for Welding and Cut- ANSI Standard Z87.1, from American National Standards Institute, 11 ting of Containers and Piping, American Welding Society Standard... -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som _3/05 Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. - Page 10 LES RAYONS D’ARC peuvent entraî- ACCUMULATIONS ner des brûlures aux yeux et à la peau. risquent de provoquer des blessures ou même la mort. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses D Fermer l’alimentation du gaz protecteur en cas (ultraviolets et infrarouges) susceptibles de provo- de non-utilisation.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLO- DES ORGANES MOBILES peuvent SION. provoquer des blessures. D Ne pas placer l’appareil sur, au-dessus ou D S’abstenir de toucher des organes mobiles tels à... -
Page 12: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Boulevard, Rexdale, Ontario, Canada M9W 1R3 (téléphone : de Global Engineering Documents (téléphone : 1-877-413-5184, site In- 800-463-6727 ou à Toronto 416-747-4044, site Internet ternet : www.global.ihs.com). www.csa-international.org). -
Page 13: Section 3 − Specifications
SECTION 3 − SPECIFICATIONS 3-1. Specifications Amperes Input at Maximum Open- Rated Welding Amperage Weight Overall Rated Load Output Circuit Voltage Output Range 115 V, 60 Hz, Single- W/ Gun Dimensions Phase Length: 16-7/8 in (429 mm) 90 A @ 19 Volts DC, 2.90 2.50 20% Duty Cycle... -
Page 14: Volt-Ampere Curves
3-3. Volt-Ampere Curves 33.0 The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves 28.0 of other settings fall between the curves shown. 23.0 18.0 13.0 0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0 90.0 100.0110.0 120.0130.0 Amperage Range 1 Range 2... -
Page 15: Process/Polarity Table
4-2. Process/Polarity Table Cable Connections Process Process Polarity 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* −... -
Page 16: Installing Gas Supply
4-4. Installing Gas Supply NOTE 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 17: Installing Wire Spool And Adjusting Hub Tension
4-5. 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 (203 mm) optional hub kit. -
Page 18: Selecting A Location And Connecting Input Power For 115 Vac Model
4-6. Selecting A Location And Connecting Input Power For 115 VAC Model Rating Label Grounded Receptacle A 115 volt, 20 ampere individual branch circuit protected by time-de- lay fuses or circuit breaker is re- quired. Plug From Unit Select extension cord of 14 AWG for up to 50 ft (15 m) or 12 AWG for 50 up to 200 ft (61 m). -
Page 19: Installing Contact Tip And Nozzle
4-7. Installing Contact Tip And Nozzle Y Turn off welding power source. Nozzle Remove nozzle. Contact Tip Tip Adapter Thread welding wire through gun (see Section 4-8). Slide contact tip over wire and tighten tip into tip adapter. Install nozzle. Flux Nozzle MIG Nozzle Use with flux cored wire only. -
Page 20: Threading Welding Wire
4-8. 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 21: Section 5 − Operation
SECTION 5 − OPERATION 5-1. 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 22: Weld Parameter Chart
5-3. Weld Parameter Chart OM-947 Page 18... - Page 23 210 428 OM-947 Page 19...
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Page 24: Section 6 − Maintenance &Troubleshooting
SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace Repair or Clean unreadable replace tighten weld labels. cracked terminals. weld cable. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. 6-2. -
Page 25: Changing Drive Roll Or Wire Inlet Guide
6-4. 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 26: Replacing Gun Contact Tip
6-5. Replacing Gun Contact Tip Y Turn off welding power source. 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 27: Cleaning Gun Liner
6-6. Cleaning Gun Liner Y 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 28: Replacing Gun Liner
6-7. Replacing Gun Liner Y 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 29 6-7. 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.
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Page 30: Troubleshooting Table
6-8. Troubleshooting Table Trouble Remedy Secure power cord plug in receptacle (see Section 4-6). No weld output; wire does not feed; fan does not run does not run. Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 5-1). Reset welding power source supplementary protector if open. -
Page 31: Section 7 − Electrical Diagram
SECTION 7 − ELECTRICAL DIAGRAM 230 950-A Figure 6-1. Circuit Diagram OM-947 Page 27... -
Page 32: Section 8 − Wire Welding Guidelines
SECTION 8 − WIRE WELDING GUIDELINES 8-1. Typical FCAW Process Connections Y 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 33: Typical Control Settings
8-3. Typical Control Settings NOTE These settings are guidelines only. Material and wire type, joint design, fitup, position, 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) (0.001 in = 1 ampere) -
Page 34: Holding And Positioning Welding Gun
8-4. Holding And Positioning Welding Gun NOTE 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 35: Conditions That Affect Weld Bead Shape
8-5. Conditions That Affect Weld Bead Shape NOTE 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 36: Gun Movement During Welding
8-6. Gun Movement During Welding NOTE 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 37: Troubleshooting − Excessive Spatter
8-9. 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 38: Troubleshooting − Lack Of Penetration
8-12. 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 39: Troubleshooting − Waviness Of Bead
8-15. 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 40: Section 9 − Parts List
SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 803 446-B Figure 8-1. Main Assembly OM-947 Page 36... - Page 41 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ..... 210 432 . . . CASE SECTION, front/bottom/rear ......
- Page 42 5 − See Table 8-1 804 243-A Figure 8-2. H-9B Gun Item Part Description Quantity 225 397 Figure 8-2. H-9B Gun ....169 715 ..NOZZLE, slip type .500 orf flush .
- Page 43 803 442-B Figure 8-3. Wire Drive Assembly Item Part Description Quantity 209 532 Figure 8-3. Wire Drive Assembly ..... 212 377 .
- Page 44 Notes...
- Page 45 Notes...
- Page 46 Notes...
- Page 47 Effective January 1, 2006 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? serial number preface LG 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 48 Welding Process Handbooks Call 1-877-Hobart1 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. PRINTED IN USA 2005 Hobart Welding Products. 6/05...