Hobart Handler 125 User Manual (English)

Other manuals for Hobart Handler 125

Questions and Answers:

J
Joshua PorterJul 26, 2025
What to do if Hobart Handler 125 has no weld output, wire does not feed, but fan motor continues to run?
- N
  Nicole MorrisonJul 27, 2025
  If your Hobart Welding System exhibits these symptoms, it could be due to overheating. Let the fan run with the gun trigger switch off to allow the unit to cool down until the thermostat closes. Also, ensure the Voltage switch is not set between ranges. Finally, disassemble the torch handle and inspect the trigger switch lead connections, tightening or reconnecting any loose connections.
K
Kevin DaltonAug 1, 2025
How to troubleshoot Hobart Handler 125 Welding System when electrode wire feeding stops during welding?
- J
  Jordan SantosAug 1, 2025
  If the electrode wire feeding stops during welding with your Hobart Welding System, the following steps may help: * Straighten the gun cable or replace damaged parts. * Adjust the drive roll pressure. * Change to the correct drive roll groove. * Readjust the hub tension. * Replace the contact tip if it's blocked. * Clean or replace the wire inlet guide or liner if they are dirty or plugged. * Replace the drive roll or pressure bearing if they are worn or slipping. * Check and clear any restrictions at the drive assembly and liner. * Release the gun trigger and allow the gun and motor protection circuitry to reset.
M
marksanthonyAug 6, 2025
How to fix Hobart Handler 125 Welding System with no weld output, wire not feeding, and fan not running?
- H
  Heather MuellerAug 7, 2025
  To resolve a Hobart Welding System experiencing no weld output, wire feed, and fan operation: * Ensure the power cord is securely plugged into the receptacle. * Replace the building line fuse or reset the circuit breaker if it's open. * Confirm the Power switch is in the On position. * Reset the welding power source supplementary protector if it's open.
C
chadgonzalezAug 13, 2025
Why does Hobart Handler 125 have no weld output and wire feeds?
- B
  Bryan PorterAug 14, 2025
  If your Hobart Welding System has no weld output but the wire feeds, ensure the work clamp is connected to establish good metal-to-metal contact. Check the cable connection at the work clamp and tighten the hardware if necessary. You may also need to replace the contact tip or verify that the polarity connections are correct.
S
Samantha VaughanAug 19, 2025
How to fix low weld output on Hobart Welding System?
- J
  John HarveyAug 19, 2025
  To address low weld output on your Hobart Welding System: * Connect the unit to the correct input voltage or check for low line voltage. * Ensure the voltage switch is in the desired position. * If using an extension cord, verify that its wire size and length are appropriate for the welding power source's power rating.

Hobart Handler 125 Specifications

General

Input Voltage	115V
Amperage Output	25-125A
Duty Cycle	20% @ 90A
Weldable Materials	Steel, Stainless Steel, Aluminum
Weight	57 lbs
Processes	MIG (GMAW)
Maximum Material Thickness	3/16 inch
Wire Size	0.023-0.035 inch

Summary

Safety Precautions

Symbol Usage

Explains the meaning of safety symbols used throughout the manual.

Arc Welding Hazards

Details potential hazards encountered during arc welding operations.

General Welding Hazards

Fumes, Gases, and Arc Rays

Covers risks associated with welding fumes, gases, and arc rays.

Fire, Explosion, and Noise Hazards

Addresses hazards related to fire, explosion, and noise exposure.

EMF and Cylinder Safety

Discusses EMF interference with medical devices and cylinder safety.

Additional Safety Considerations

Fire, Explosion, and Equipment Hazards

Details specific hazards related to fire, explosion, and equipment handling.

Electrical and Interference Hazards

Covers hazards from static discharge, H.F., and arc welding interference.

California Proposition 65 Warnings

Engine Emission Warnings

Warnings regarding chemicals in engine exhaust known to cause cancer or birth defects.

Principal Safety Standards and EMF Information

Principal Safety Standards

Lists key safety standards relevant to welding operations.

EMF Information and Medical Devices

Provides guidance on EMF fields and precautions for medical implants.

French Safety Instructions

Symboles et Dangers Généraux

Explains safety symbols and general hazards in French.

Dangers Électriques

Details the severe risks of electric shock in French.

More French Safety Warnings

DC Voltage and Hot Parts Hazards

Warns about residual DC voltage and hot parts in French.

Fumes, Gases, Arc Rays, and Fire/Explosion

Covers hazards from fumes, gases, arc rays, fire, and explosion in French.

Flying Metal and Dirt Hazards

Highlights risks from flying metal and dirt in French.

Further French Safety Guidelines

Gas Accumulation and EMF Risks

Addresses gas accumulation and EMF risks for medical implants in French.

Noise and Cylinder Safety

Covers noise hazards and risks associated with gas cylinders in French.

Operational Hazards

Details fire, explosion, overheating, sparks, and ESD hazards in French.

Additional French Safety Topics

Moving Parts and Welding Wire Hazards

Warns about hazards from moving parts and welding wire in French.

HF and Arc Welding Interference

Discusses interference risks from HF and arc welding in French.

California Proposition 65 (French)

French translation of California Proposition 65 warnings for engines.

Safety Standards and CEM Information

Principal Safety Standards (French)

Lists key safety standards in French.

CEM Information (French)

Details Electromagnetic Compatibility (CEM) information in French.

Definitions and Specifications

Symbols and Definitions

Explains welding symbols and defines key terms.

Product Specifications

Provides technical specifications for the welding unit.

Duty Cycle and Volt-Ampere Curves

Duty Cycle and Overheating

Explains duty cycle limitations and overheating precautions.

Volt-Ampere Curves

Illustrates the voltage and amperage output capabilities.

Installation Procedures

Installing the Work Clamp

Step-by-step guide for installing the work clamp.

Process and Polarity Setup

Process and Polarity Table

Table detailing connections for different welding processes and polarities.

Changing Welding Polarity

Instructions on how to change the welding polarity.

Gas Supply Installation

Installing Gas Supply

Procedure for connecting the shielding gas supply.

Wire Spool Installation

Installing Wire Spool and Hub Tension

Guide for installing wire spools and adjusting hub tension.

Location and Power Connection

Serial Number and Rating Label Location

Identifies the location of serial and rating labels.

Selecting Location and Connecting 115V Power

Guidance on choosing a location and connecting 115V input power.

Gun Assembly Installation

Installing Contact Tip and Nozzle

Steps for fitting the contact tip and nozzle onto the gun.

Wire Threading Procedure

Threading Welding Wire

Detailed instructions on how to thread the welding wire.

Operation Controls and Gun Usage

Controls Overview

Explanation of the welder's main controls.

Operating the Welding Gun

Instructions on how to use the welding gun.

Welding Parameter Guide

Weld Parameter Chart

Provides recommended settings for various welding materials and wires.

115 Volt Welding Settings

115 Volt Wire Welding Package Settings

Recommended voltage and wire feed settings for 115V models.

Maintenance and Troubleshooting

Routine Maintenance Schedule

Outlines a schedule for regular equipment maintenance.

Overload and Motor Protection

Explains overload protection and drive motor protection features.

Drive System Maintenance

Changing Drive Roll or Wire Inlet Guide

Steps for replacing drive rolls and wire inlet guides.

Gun Tip and Liner Maintenance

Replacing Gun Contact Tip

Procedure for replacing the contact tip on the welding gun.

Cleaning Gun Liner

Instructions for cleaning the welding gun liner.

Replacing Gun Liner

Detailed steps for replacing the gun liner.

Troubleshooting Common Issues

Troubleshooting Table

A table listing common problems and their remedies.

Electrical Diagram

Circuit Diagram

Provides the electrical schematic for the welding unit.

Wire Welding Guidelines

FCAW and MIG Process Connections

Illustrates typical connection setups for FCAW and MIG welding.

Typical Control Settings

Guidance on setting welder parameters based on material and wire.

Gun Handling and Weld Bead Shape

Techniques for gun handling and factors affecting weld bead shape.

Weld Bead Quality and Troubleshooting

Describes good/poor weld characteristics and troubleshooting tips.

Advanced Troubleshooting

Excessive Spatter and Porosity

Troubleshooting tips for excessive spatter and porosity issues.

Penetration, Fusion, and Burn-Through

Solutions for problems with penetration, fusion, and burn-through.

Bead Waviness and Distortion

Tips for correcting bead waviness and weld distortion.

Parts Lists and Diagrams

Main Assembly Parts

Exploded view and parts list for the main welding unit.

H-9B Gun and Wire Drive Assembly

Parts breakdown for the H-9B gun and wire drive assembly.

Warranty Information

5/3/1 Limited Warranty

Details the terms and conditions of the limited warranty.

Warranty Exclusions

Lists items and conditions not covered by the warranty.

Owner's Record and Resources

Owner's Record

Section to record personal ownership details.

Available Resources and Assistance

Information on finding distributors, technical help, and supplies.

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Hobart Handler 125 User Manual

Table of Contents

Other manuals for Hobart Handler 125

Questions and Answers:

Hobart Handler 125 Specifications

Summary

Safety Precautions

Symbol Usage

Arc Welding Hazards

General Welding Hazards

Fumes, Gases, and Arc Rays

Fire, Explosion, and Noise Hazards

EMF and Cylinder Safety

Additional Safety Considerations

Fire, Explosion, and Equipment Hazards

Electrical and Interference Hazards

California Proposition 65 Warnings

Engine Emission Warnings

Principal Safety Standards and EMF Information

Principal Safety Standards

EMF Information and Medical Devices

French Safety Instructions

Symboles et Dangers Généraux

Dangers Électriques

More French Safety Warnings

DC Voltage and Hot Parts Hazards

Fumes, Gases, Arc Rays, and Fire/Explosion

Flying Metal and Dirt Hazards

Further French Safety Guidelines

Gas Accumulation and EMF Risks

Noise and Cylinder Safety

Operational Hazards

Additional French Safety Topics

Moving Parts and Welding Wire Hazards

HF and Arc Welding Interference

California Proposition 65 (French)

Safety Standards and CEM Information

Principal Safety Standards (French)

CEM Information (French)

Definitions and Specifications

Symbols and Definitions

Product Specifications

Duty Cycle and Volt-Ampere Curves

Duty Cycle and Overheating

Volt-Ampere Curves

Installation Procedures

Installing the Work Clamp

Process and Polarity Setup

Process and Polarity Table

Changing Welding Polarity

Gas Supply Installation

Installing Gas Supply

Wire Spool Installation

Installing Wire Spool and Hub Tension

Location and Power Connection

Serial Number and Rating Label Location

Selecting Location and Connecting 115V Power

Gun Assembly Installation

Installing Contact Tip and Nozzle

Wire Threading Procedure

Threading Welding Wire

Operation Controls and Gun Usage

Controls Overview

Operating the Welding Gun

Welding Parameter Guide

Weld Parameter Chart

115 Volt Welding Settings

115 Volt Wire Welding Package Settings

Maintenance and Troubleshooting

Routine Maintenance Schedule

Overload and Motor Protection

Drive System Maintenance

Changing Drive Roll or Wire Inlet Guide

Gun Tip and Liner Maintenance

Replacing Gun Contact Tip

Cleaning Gun Liner

Replacing Gun Liner

Troubleshooting Common Issues

Troubleshooting Table

Electrical Diagram