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Hobart Welders Handler 125 User Manual

Hobart Welders Handler 125
44 pages
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Processes
OM-947 212 149B
June 2004
Handler 125 / 125 MIG
And H-9A Gun
Arc Welding Power Source And
Wire Feeder
Description
MIG (GMAW) Welding (Optional)
Flux Cored (FCAW) Welding
R

Table of Contents

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Hobart Welders Handler 125 Specifications

General IconGeneral
BrandHobart Welders
ModelHandler 125
CategoryWelding System
LanguageEnglish

Summary

Safety Precautions

Symbol Usage

Explains symbols used in the manual for safety warnings and instructions.

Arc Welding Hazards

Details various hazards associated with arc welding, including electric shock and fumes.

Additional Symbols for Installation, Operation, and Maintenance

Covers additional safety symbols for equipment installation, operation, and maintenance.

Principal Safety Standards

Lists key safety standards and organizations relevant to welding processes.

EMF Information

Discusses electromagnetic field (EMF) information and precautions for users.

Specifications

General Specifications

Provides detailed technical specifications for the welding unit, including output and dimensions.

Duty Cycle and Overheating

Explains duty cycle percentages and potential overheating issues and prevention.

Volt-Ampere Curves

Displays volt-ampere curves illustrating welding output capabilities at different settings.

Installation

Installing Work Clamp

Step-by-step instructions for correctly installing the work clamp.

Process and Polarity Table

Shows polarity settings for different welding processes and cable connections.

Changing Polarity

Instructions on how to change the welding polarity between DCEN and DCEP.

Installing Gas Supply

Guides on installing the shielding gas supply system for MIG welding applications.

Installing Wire Spool and Adjusting Hub Tension

Steps to install the wire spool and adjust the hub tension for proper wire feeding.

Location and Input Power Connection (115 VAC)

Guidance on choosing a safe location and correctly connecting the input power.

Threading Welding Wire

Detailed instructions for threading welding wire through the wire feeder system.

Operation

Controls Overview

Explains the function and use of various controls on the welding unit.

Weld Parameter Chart

Provides recommended settings for material thickness, wire type, and gas flow.

Maintenance and Troubleshooting

Routine Maintenance

Outlines regular maintenance tasks for ensuring equipment longevity and performance.

Overload Protection

Explains the overload protection system, its function, and how to reset it.

Drive Motor Protection

Describes the drive motor protection circuit and its reset procedure.

Changing Drive Roll or Wire Inlet Guide

Steps for replacing drive rolls or wire inlet guides for proper wire feeding.

Replacing Gun Contact Tip

Instructions for safely removing and installing a new gun contact tip.

Cleaning or Replacing Gun Liner

Procedure for cleaning or replacing the gun liner to ensure smooth wire feeding.

Replacing Switch or Head Tube

Steps to replace the welding gun's trigger switch or head tube assembly.

Troubleshooting Table

A comprehensive table listing common welding problems and their recommended solutions.

Electrical Diagram

Wire Welding Guidelines

Typical FCAW Process Connections

Shows typical connection setup for Flux Cored Arc Welding (FCAW) process.

Typical MIG Process Connections

Shows typical connection setup for Metal Inert Gas (MIG) welding process.

Typical Control Settings

Provides guideline settings for welding controls based on material and wire type.

Holding and Positioning Welding Gun

Explains correct techniques for holding and positioning the welding gun for optimal welds.

Conditions Affecting Weld Bead Shape

Discusses factors influencing weld bead shape, including gun angle and travel speed.

Gun Movement During Welding

Describes proper gun movement techniques, such as stringer and weave beads.

Poor Weld Bead Characteristics

Illustrates common issues and characteristics of poor quality weld beads.

Good Weld Bead Characteristics

Illustrates characteristics of good quality weld beads and proper welding technique.

Troubleshooting: Excessive Spatter

Addresses problems and solutions for excessive spatter, a common welding issue.

Troubleshooting: Porosity

Addresses problems and solutions for porosity, or gas pockets, in weld metal.

Troubleshooting: Excessive Penetration

Addresses problems and solutions for excessive weld penetration, where metal melts through.

Troubleshooting: Lack of Penetration

Addresses problems and solutions for insufficient fusion or lack of weld penetration.

Troubleshooting: Incomplete Fusion

Addresses problems and solutions for incomplete weld fusion between base metal and weld.

Troubleshooting: Burn-Through

Addresses problems and solutions for burn-through, where weld melts completely through base metal.

Troubleshooting: Waviness of Bead

Addresses problems and solutions for wavy weld beads and improper joint coverage.

Troubleshooting: Distortion

Addresses problems and solutions for distortion caused by weld contraction.

Troubleshooting Guide for Semiautomatic Welding Equipment

A guide for troubleshooting common issues with semiautomatic welding equipment.

Parts List

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