1. Introduction
This manual provides essential information for the safe and effective operation, setup, and maintenance of your Hobart Handler 125 MIG Welder. The Handler 125 is a portable wire feed welder designed for various projects, capable of welding up to 3/16 inch mild steel using 120V input power. It supports both flux-cored and MIG welding processes with its built-in gas valve.
Image 1.1: The Hobart Handler 125 MIG Welder, shown with its welding gun, ground clamp, and power cord.
Key Features:
- Broad Output Range: 25 – 130 amps, suitable for welding up to 1/8 inch steel with flux-cored wire.
- Four Output Voltage Settings: Provides precise control for different material thicknesses and joint types.
- Factory-Installed Gas Solenoid: Facilitates easy transition between flux-cored and MIG welding.
- Built-in Contactor: Enhances safety by making the wire electrically cold until the gun trigger is pulled.
- Durable Feed Head: Features a quick-release drive roll tension lever for positive wire feed and easy wire threading.
2. Safety Information
Welding can be hazardous. Always follow safety precautions to prevent injury or damage. Read and understand all safety warnings before operating this equipment.
General Safety Precautions:
- Electric Shock: Can kill. Do not touch live electrical parts. Wear dry welding gloves and protective clothing. Ensure the work area is dry.
- Fumes and Gases: Can be hazardous to your health. Keep your head out of the fumes. Use ventilation or exhaust to remove fumes from the breathing zone.
- Arc Rays: Can injure eyes and burn skin. Wear a welding helmet with a proper shade filter. Wear protective clothing to cover exposed skin.
- Fire and Explosion: Welding sparks can cause fire or explosion. Keep flammable materials away from the welding area. Have a fire extinguisher readily available.
- Hot Parts: Can cause severe burns. Allow equipment to cool before touching. Wear insulated gloves.
- Moving Parts: Can cause injury. Keep hands, hair, and loose clothing away from moving parts like fan blades and wire feed rolls.
3. Package Contents
Verify that all items listed below are included in your package:
- Hobart Handler 125 Wire Feed Welder Unit
- 8 Ft. MIG gun with liner for .030-.035 inch diameter wire
- Power cord with plug
- Two .030 inch contact tips
- Weld set-up chart (located inside the wire compartment door)
- Work cable with clamp
Image 3.1: Essential welding accessories and safety gear, including a helmet, gloves, and various tools, arranged near the Handler 125 unit.
4. Setup
Proper setup is crucial for safe and effective welding. Follow these steps carefully.
4.1 Power Connection
- Ensure the welder's power switch is in the OFF position.
- Connect the power cord to a grounded 120V AC power outlet. The Handler 125 requires a dedicated 20-amp circuit for optimal performance.
4.2 Ground Clamp Connection
- Attach the work clamp securely to the workpiece. Ensure good electrical contact by cleaning any paint, rust, or scale from the connection point.
- The work clamp must be connected directly to the metal being welded, not to a painted or insulated surface.
4.3 Wire Spool Installation
- Open the wire compartment door.
- Place the wire spool onto the spool hub, ensuring it rotates freely.
- Thread the welding wire through the drive rolls and into the gun liner.
- Adjust the drive roll tension. It should be tight enough to feed the wire consistently but not so tight that it deforms the wire.
4.4 Gas Connection (for MIG Welding)
If performing MIG welding, a shielding gas cylinder is required.
- Connect the gas hose from your shielding gas cylinder regulator to the gas inlet fitting on the back of the welder.
- Ensure all connections are tight to prevent gas leaks.
- Open the cylinder valve and adjust the gas flow rate at the regulator according to your welding requirements (typically 15-25 CFH).
Image 4.1: A hand connecting the gas line to the inlet on the rear of the Hobart Handler 125, a necessary step for MIG welding operations.
5. Operating Instructions
Before operating, ensure all safety precautions are understood and followed, and the setup is complete.
5.1 Controls Overview
Image 5.1: A close-up view of the control panel on the Hobart Handler 125, showing the voltage selector, wire speed knob, and power switch.
- Voltage Selector (V): This knob allows you to select one of four output voltage settings. Refer to the weld set-up chart inside the wire compartment door for recommended settings based on material thickness and wire type.
- Wire Speed Control (%): This knob adjusts the speed at which the welding wire feeds through the gun. Adjust according to the weld set-up chart and your specific application.
- Power Switch (I/O): Turns the welder ON (I) or OFF (O).
5.2 Welding Process
- Prepare the Workpiece: Clean the metal surface thoroughly to remove any contaminants.
- Set Parameters: Consult the weld set-up chart for initial voltage and wire speed settings.
- Wear Protective Gear: Always wear a welding helmet, gloves, and appropriate protective clothing.
- Start Welding: Position the welding gun nozzle approximately 3/8 to 1/2 inch from the workpiece. Pull the trigger to initiate the arc and wire feed.
- Maintain Arc: Move the gun steadily along the joint, maintaining a consistent arc length and travel speed. Observe the weld puddle and adjust travel speed as needed.
- Stop Welding: Release the trigger to stop the arc and wire feed.
Image 5.2: A welder in full protective gear performing a weld with the Hobart Handler 125, demonstrating the welding process.
6. Maintenance
Regular maintenance ensures the longevity and optimal performance of your Hobart Handler 125.
6.1 Daily/Before Use
- Inspect the welding gun cable for cuts or damage.
- Check the condition of the contact tip and replace if worn or clogged.
- Ensure the ground clamp is clean and makes good contact.
6.2 Monthly/After Extended Use
- Clean the drive rolls and wire guide tube to remove any debris.
- Inspect the gun liner for wear or kinks. Replace if wire feeding issues occur.
- Clean the welder's exterior and ventilation openings to prevent dust buildup.
7. Troubleshooting
This section addresses common issues you might encounter during operation.
| Problem | Possible Cause | Solution |
|---|---|---|
| No arc when trigger is pulled | No power to welder; Poor ground connection; Worn contact tip; Wire not feeding | Check power supply and circuit breaker; Ensure ground clamp is securely attached to clean metal; Replace contact tip; Check wire spool and drive roll tension. |
| Poor weld quality (e.g., porosity, weak welds) | Incorrect voltage/wire speed settings; Contaminated workpiece; Insufficient shielding gas (MIG); Worn contact tip | Adjust voltage and wire speed according to chart; Clean workpiece thoroughly; Check gas flow and connections; Replace contact tip. |
| Wire feeding inconsistently or jamming | Incorrect drive roll tension; Kinked or dirty gun liner; Wrong size drive rolls; Spool tension too tight | Adjust drive roll tension; Clean or replace gun liner; Ensure correct drive rolls are installed for wire size; Loosen spool tension. |
8. Specifications
Technical specifications for the Hobart Handler 125 MIG Welder.
| Feature | Detail |
|---|---|
| Manufacturer | Hobart Welding Products |
| Part Number | 500573 |
| Item Weight | 58 pounds |
| Product Dimensions | 19.4 x 10 x 13.5 inches |
| Power Source | Corded Electric (120V) |
| Material | Metal, Plastic |
| Output Range | 25 – 130 Amps |
| Max Weld Thickness | Up to 3/16 inch mild steel |
| Included Components | 8 Ft. gun with liner, Power cord, Two .030 in. contact tips, Weld set-up chart, Work cable with clamp |
9. Warranty and Support
9.1 Warranty Information
The Hobart Handler 125 MIG Welder comes with a 5-year limited warranty. This warranty covers defects in materials and workmanship under normal use and service. For specific terms and conditions, please refer to the warranty documentation included with your product or contact Hobart customer service.
9.2 Customer Support
For technical assistance, troubleshooting, or warranty claims, please contact Hobart Welding Products customer support. Have your model number (500573) and serial number ready when contacting support.
Hobart Welding Products
Website: www.hobartwelders.com
Phone: Refer to the official website for current contact numbers.
