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Hobart Welding Products 125 manual

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Table of contents for the manual

  • Page 1

    OM-947 212 149J 201 1 − 06 Processes Arc Welding Power Source And Wire Feeder Description MIG (GMAW) W elding (Optional) Flux Cored (FCA W ) W elding Handler 125 A n d H - 9 B G u n R File: Flux Cored (FCA W)[...]

  • Page 2

    Hobart W elders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www .H[...]

  • Page 3

    T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1 ................................. 1-1. Symbol Usage 1 ....................................................................... 1-2. Arc W elding Hazards 1 ................................................................. 1-3. Additional Symbols For Installation, Operation, And[...]

  • Page 4

    T ABLE OF CONTENTS SECTION 9 − F CA W/GMA W WELDI NG GUIDELINES 30 ........................................... 9-1. T ypical FCA W Process Connections 30 .................................................... 9-2. T ypical GMAW (MIG) Process Connections 30 .............................................. 9-3. T ypical Control Settings 31 ............[...]

  • Page 5

    OM-947 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 201 1 − 01 7 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols or [...]

  • Page 6

    OM-947 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. D Keep your head out of the fumes. Do not breathe the fumes. D If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases. D If ventilation is poor , [...]

  • Page 7

    OM-947 Page 3 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over , or near combustible surfaces. D Do not install unit near flammables. D Do not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit. F A[...]

  • Page 8

    OM-947 Page 4 1-4. California Proposition 65 W arnings W elding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer . (California Health & Safety Code Section 25249.5 et seq.) Battery posts, terminals and related accessories contain lead and lead[...]

  • Page 9

    OM-947 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som_2011 − 01 7 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. S ym bol es ut ilisés DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. [...]

  • Page 10

    OM-947 Page 6 Il reste une TENSION DC NON NÉGLIGEABLE dans les sources de soudage onduleur UNE FOIS l’alimentation coupée. D Arrêter les convertisseurs, débrancher le courant électrique et décharger les condensateurs d’alimentation selon les instructions indiquées dans la partie Entretien avant de toucher les pièces. LES PIÈCES CHAUDES[...]

  • Page 11

    OM-947 Page 7 LES ACCUMULA TIONS DE GAZ risquent de provoquer des blessures ou même la mort. D Fermer l’alimentation du gaz comprimé en cas de non utilisation. D V eiller toujours à bien aérer les espaces confi- nés ou se servir d’un respirateur d’adduction d’air homologué. Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) peuvent affecter les im[...]

  • Page 12

    OM-947 Page 8 Les PIÈCES MOBILES peuvent causer des blessures. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement tels que des rouleaux de commande. LES FILS DE SOUDAGE peuvent provoquer des blessures. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Ne pas diriger le pistolet v[...]

  • Page 13

    OM-947 Page 9 2-5. P r inc ipa l es n or me s d e s éc ur i té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www .global.ihs.com). Safe Practices for the Preparation of Containers and Piping for W elding and Cutting, American Welding Society [...]

  • Page 14

    OM-947 Page 10[...]

  • Page 15

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 1 1 SECTION 3 − DEFINITIONS 3-1. Symbols And Definitions A Amperage V V oltage Hz Hertz Negative Positive Direct Current (DC) Single Phase Input Output V oltage Input Of f On Do Not Switch While W elding Gas Metal Arc W elding (GMAW) Wire Feed Flux Cored Arc W elding (FCA[...]

  • Page 16

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 12 4-2. Duty Cycle And Overheating duty1 4/95 − 210 517-B 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. Redu[...]

  • Page 17

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 13 SECTION 5 − INST ALLA TION 5-1. Installing W ork Clamp 1 Nut 2 W ork Cable From Unit 3 W ork Clamp 4 Screw 5 W ork Clamp T a bs Bend tabs around work cable. 6 Insulator Grip Slide one insulating grip over work cable before connecting to clamp. Slide insulating grips ov[...]

  • Page 18

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 14 5-2. Process/Polarity T able Process Polarity Cable Connections Cable T o Gun Cable T o Work Clamp FCAW − Self-shielding wire − no shielding gas DCEN − Straight Polarity Connect to negative ( − ) output terminal Connect to positive (+) output terminal GMA W* − [...]

  • Page 19

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 15 5-4. Installing Gas Supply . This Section only applies to MIG units or units equipped with MIG kit. Obtain gas cylinder and chain to running gear , wall, or other stationary support so cylinder cannot fall and break off valve. 1 Cap 2 Cylinder V alve Remove cap, stand to[...]

  • Page 20

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 16 5-5. Installing Wire Spool And Adjusting Hub T ension When a slight force is needed to turn spool, tension is set. 1/2 in. T ools Needed: Ref. 802 971-C / 803 012 / 803 013 -B Installing 8 in. (203 mm) Wire Spool Installing 4 in. (102 mm) Wire Spool When a slight force i[...]

  • Page 21

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 17 5-6. Serial Number And Rating Label Location Th e 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 cov[...]

  • Page 22

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 18 5-8. Installing Contact T ip And Nozzle T ools Needed: Ref. 804 241-A ! T ur n off welding power source. 1 Nozzle Remove nozzle. 2 Contact T ip 3 Tip Adapter Thread welding wire through gun (see Section 5-9). Slide contact tip over wire and tighten tip into tip adapter .[...]

  • Page 23

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 19 5-9. Threading Welding Wire 1 Wire Spool 2 Welding Wire 3 Inlet Wire Guide 4 Pressure Adjustment Knob 5 Drive Roll 6 Gun Cable Lay gun cable out straight. T ools Needed: 6 1 Pull and hold wire; cut off end. 4 in. (102 mm) Remove gun nozzle and contact tip. Open pressure [...]

  • Page 24

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 20 SECTION 6 − OPERATION 6-1. Controls 1 V oltage 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 or Section 6-3 as applicable). Do not swi[...]

  • Page 25

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 21 6-3. W eld Parameter Chart 210 428-D[...]

  • Page 26

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 22 SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance ! Disconnect power before maintaining. . Maintain more often during severe condi- tions. n = Check Z = Change ~ = Clean l = Replace * T o be done by Factory Authorized Service Agent Reference 3 Month[...]

  • Page 27

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 23 7-4. Changing Drive Roll Or Wire Inlet Guide 1 Pressure Adjustment Knob 2 Pressure Assembly Pivot pressure adjustment knob down, and lift pressure assembly up. 3 Pivot T ube Plate 4 Securing Screws 5 Pressure Arm Pivot T ube 6 Inlet Wire Guide Remove screws and pivot tub[...]

  • Page 28

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 24 7-5. Replacing Gun Contact Tip T ools Needed: Ref. 804 241-A ! T urn Off power before replacing contact tip. 1 Nozzle Remove nozzle. 2 Contact T ip 3 Tip Adapter Cut off welding wire at contact tip. Remove contact tip from tip adapter , and install new contact tip. Reins[...]

  • Page 29

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 25 7-6. Cleaning Gun Liner 804 241-A / 803 838-A ! T urn Off welding power source. 1 Nozzle 2 Contact T ip 3 Adapter Head T ube T ools Needed: 8 mm La y gun cable out straight, and blow out liner . Remove nozzle. Cut of f wire at contact tip, and remove contact tip and tip [...]

  • Page 30

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 26 7-7. Replacing Gun Liner Ref. 804 241-A / 803 497-A / 803 837-A / 803 899-A T ools Needed: 8 mm / 10 mm Remove nozzle. Cut of f wire at contact tip, and remove contact tip and tip adapter . Open pressure assembly. Retract wire from liner onto spool. . Hold wire tightly t[...]

  • Page 31

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 27 7-7. Replacing Gun Liner (Continued) When liner exits cable at gun handle, guide liner into head tube. Continue to push liner until it exits end of head tube. Slide locking rings over top and bottom of handle, and secure by twisting rings clockwise 1/4 turn. Place other [...]

  • Page 32

    . A complete Parts List is available at www .HobartW elders.com OM-947 Page 28 7-8. T roubleshooting T able T rouble Remedy No weld output; wire does not feed; fan does not run. Secure power cord plug in receptacle (see Section 5-7). Replace building line fuse or reset circuit breaker if open. Place Power switch in On position (see Section 6-1). Re[...]

  • Page 33

    OM-947 Page 29 SECTION 8 − ELECTRICAL DIAGRAM 230 950-A Figure 8-1. Circuit Diagram[...]

  • Page 34

    OM-947 Page 30 SECTION 9 − FCA W/GMA W WELDING GUIDELINES 9-1. T ypical FCA W Process Connections Wire Feeder/ Power Source W orkpiece Gun W ork Clamp FCAW/GMA W1 201 1 − 03 − Ref. 803 444-A Self-Shielding Flux Core Wire ! W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pl ac [...]

  • Page 35

    OM-947 Page 31 9-3. T ypical Control Settings . These settings are guidelines only . Material and wire type, joint design, fitup, position, etc. affect settings. T est welds to be sure they comply to specifications. 3.5 x 125 A = 437 ipm 2 x 125 A = 250 ipm 1.6 x 125 A = 200 ipm 30 − 90 A 40 − 145 A 50 − 180 A Convert Material Thickness to Am[...]

  • Page 36

    OM-947 Page 32 9-4. Holding And Positioning Welding Gun . W elding 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 e nd o f noz zle, and tip o f wir e is posi tion ed c orre ctly on s eam. 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 W ork Clamp 4 E[...]

  • Page 37

    OM-947 Page 33 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. Slow FILLET WELD ELECT ODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) GUN ANGLES AND WELD BEAD PROFILES[...]

  • Page 38

    OM-947 Page 34 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 acros s gaps, a weave bead or multiple stringer beads works better . 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement Along Se[...]

  • Page 39

    OM-947 Page 35 9-9. T roubleshooting − 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. V oltage too high. Select lower voltage range. Electrode extension (stickout) too long. Use sh[...]

  • Page 40

    OM-947 Page 36 9-1 1. T roubleshooting − Excessive Penetration Good Penetration Excessive Penetration − weld metal melting through base metal and hanging underneath weld. Excessive Penetration S-0639 Possible Causes Corrective Actions Excessive heat input. Select lower voltage range and reduce wire feed speed. Increase travel speed. 9-12. T rou[...]

  • Page 41

    OM-947 Page 37 9-14. T roubleshooting − 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. T roubleshootin[...]

  • Page 42

    OM-947 Page 38 9-17. Common GMA W (MIG) Shielding Gases This is a general chart for common gases and where they are used. Many different combinations (mixtures) of shielding gases have been developed over the years. The most commonly used shielding gases are listed in the following table. Application Gas Spray Arc Steel Short Circuiting Steel Spray[...]

  • Page 43

    OM-947 Page 39 Problem Remedy Probable Cause Wire feeds, but no gas flows (GMA W). Ga s cylinder empty . Replace empty gas cylinder . Gas nozzle plugged. Clean or replace gas nozzle. Gas cylinder valve not open or flowmeter not adjusted. Open gas valve at cylinder and adjust flow rate. Restriction in gas line. Check gas hose between flowmeter and w[...]

  • Page 44

    OM-947 Page 40 SECTION 10 − ACCESSORIES/CONSUMABLES 10-1. Accessories P A RT NO. DESCRIPTION REMARKS 194 776 Small Running Gear/Cylinder Rack For One Small Gas Cylinder , 75 lb (34 kg) 195 158 MIG Conversion Kit For Gas Metal Arc Welding (GMA W) 195 216 Hub Kit For 8 in Wire Spool 195 186 Protective Cover Weatherproof Nylon 10-2. Consumables HOBA[...]

  • Page 45

    Notes 16 Gauge (.063 in.) 22 Gauge (.031 in.) 24 Gauge (.025 in.) 20 Gauge (.037 in.) 18 Gauge (.050 in.) 14 Gauge (.078 in.) 1/8 in. (.125 in.) 3/16 in. (.188 in.) 1/4 in. (.25 in.) 5/16 in. (.313 in.) 3/8 in. (.375 in.) 1/2 in. (.5 in.) MA TERIAL THICKNESS REFERENCE CHART[...]

  • Page 46

    Notes W or k l i k e a Pr o ! Pros wel d and cut safel y . R ead the safety rules at the beginni ng of this manual .[...]

  • Page 47

    Warranty Questions? Call 1-800-332-3281 7 AM − 5 PM EST hobart_warr 201 1 − 01 Service Y ou always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distributor and Hoba[...]

  • Page 48

    ORIGINAL INSTRUCTIONS − PRINTED IN USA © 201 1 Hobart Welding Products. 201 1 − 01 Hoba rt We lding Pr oducts An Illinois T ool W or ks Comp an y 600 W est Main Stree t Tr oy , OH 45373 USA For Technical Assi stance: Call1-800-332-3281 Fo r Liter atur e Or Nea re st Dea ler : Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Da[...]