Related Manuals for Hobart Handler 125 EZ
Summary of Contents for Hobart Handler 125 EZ
- Page 1 OM-923 223 112H 2013−05 Processes Flux Cored (FCAW) Welding Description Handler 125 EZ and H−9B Gun 115 V Gasless Flux−Cored Wire Feed Welder File: Flux Cored (FCAW) www.HobartWelders.com...
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Page 2: Table Of Contents
............. Hobart is registered to the ISO 9001 Quality 7-8. - Page 3 TABLE OF CONTENTS SECTION 9 − FCAW WELDING GUIDELINES ..........9-1.
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Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som 2011−10 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. - Page 6 D Remove stick electrode from holder or cut off welding wire at FUMES AND GASES can be hazardous. contact tip when not in use. D Wear oil-free protective garments such as leather gloves, heavy Welding produces fumes and gases. Breathing shirt, cuffless trousers, high shoes, and a cap.
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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. BATTERY EXPLOSION can injure. D Do not install or place unit on, over, or near D Do not use welder to charge batteries or jump combustible surfaces. start vehicles unless it has a battery charging feature designed for this purpose. -
Page 8: California Proposition 65 Warnings
1-4. California Proposition 65 Warnings Welding or cutting equipment produces fumes or gases This product contains chemicals, including lead, known to which contain chemicals known to the State of California to the state of California to cause cancer, birth defects, or other cause birth defects and, in some cases, cancer. -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2011−10 Pour écarter les risques de blessure pour vous−même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. - Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un les sources de soudage onduleur UNE FOIS incendie ou une explosion. l’alimentation coupée. Le soudage effectué sur des conteneurs fermés tels D Arrêter les convertisseurs, débrancher le courant électrique et que des réservoirs, tambours ou des conduites peut décharger les condensateurs d’alimentation selon les instructions provoquer leur éclatement.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
ACCUMULATIONS LES BOUTEILLES peuvent exploser risquent de provoquer des blessures si elles sont endommagées. ou même la mort. Les bouteilles de gaz comprimé contiennent du gaz sous haute pression. Si une bouteille est D Fermer l’alimentation du gaz comprimé en cas endommagée, elle peut exploser. -
Page 12: Proposition Californienne 65 Avertissements
Les PIÈCES MOBILES peuvent RAYONNEMENT HAUTE causer des blessures. FRÉQUENCE (H.F.) risque provoquer des interférences. D Ne pas s’approcher des organes mobiles. D Ne pas s’approcher des points de coincement D Le rayonnement haute fréquence (H.F.) peut tels que des rouleaux de commande. provoquer des interférences avec les équi- pements de radio−navigation et de com- LES FILS DE SOUDAGE peuvent... -
Page 13: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, Spectrum Way, Suite 100, Ontario, Canada L4W 5NS (phone: is available as a free download from the American Welding Society at 800-463-6727, website: www.csa-international.org). http://www.aws.org or purchased from Global Engineering Documents Safe Practice For Occupational And Educational Eye And Face Protec- (phone: 1-877-413-5184, website: www.global.ihs.com). - Page 14 OM-923 Page 10...
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Page 15: Section 3 − Definitions
A complete Parts List is available at www.HobartWelder.com SECTION 3 − DEFINITIONS 3-1. Miscellaneous Symbols And Definitions Some symbols are found only on CE products. Amperage Voltage Hertz Negative Direct Current Positive Single Phase Input (DC) Output Voltage Input Do Not Switch Flux Cored Arc Wire Feed Duty Cycle... -
Page 16: Serial Number And Rating Label Location
A complete Parts List is available at www.HobartWelder.com 4-2. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output. For future reference, write serial number in space provided on back cover of this manual. 4-3. -
Page 17: Volt-Ampere Curves
A complete Parts List is available at www.HobartWelder.com 4-5. Volt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. (18-16 ga) Range 1 Range 2 (16-12 ga) -
Page 18: Section 5 − Installation
A complete Parts List is available at www.HobartWelder.com SECTION 5 − INSTALLATION 5-1. Selecting A Location Special installation may be required where gasoline or volatile liquids are present − see NEC Article 511 or CEC Section 20. Plug From Unit Receptacle −... -
Page 19: Process/Polarity Table
A complete Parts List is available at www.HobartWelder.com 5-3. Process/Polarity Table Cable Connections Process 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... -
Page 20: Installing Wire Spool And Adjusting Hub Tension
A complete Parts List is available at www.HobartWelder.com 5-5. Installing Wire Spool And Adjusting Hub Tension Installing 4 in. (102 mm) Wire Spool Overtightening hub tension may cause wire feed problems. When a slight force is needed to turn spool, tension is set. Installing Optional 8 in. -
Page 21: Connecting 115 Volts Input Power
A complete Parts List is available at www.HobartWelder.com 5-7. Connecting 115 Volts Input Power Installation must meet National and Local Codes − have only qualified persons make this installation. Special installation may be required where gasoline or vola- tile liquids are present − see NEC Article 511 or CEC Section 20. -
Page 22: Threading Welding Wire
A complete Parts List is available at www.HobartWelder.com 5-8. 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. -
Page 23: Section 6 − Operation
A complete Parts List is available at www.HobartWelder.com SECTION 6 − OPERATION 6-1. Controls Material Thickness Selector Switch Use switch to select the material thickness range. Do not switch under load. Switch must “click” into detent position for weld output. Power Switch 16 ga 12 ga... -
Page 24: Section 7 − Maintenance &Troubleshooting
A complete Parts List is available at www.HobartWelder.com SECTION 7 − MAINTENANCE &TROUBLESHOOTING 7-1. Routine Maintenance Disconnect power before maintaining. Maintain more often during severe conditions. Reference n = Check Z = Change ~ = Clean l = Replace * To be done by Factory Authorized Service Agent 3 Months l Damaged Or Unreadable Labels l Repair Or Replace... -
Page 25: Changing Drive Roll Or Wire Inlet Guide
A complete Parts List is available at www.HobartWelder.com 7-4. 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 + −... -
Page 26: Replacing Gun Contact Tip
A complete Parts List is available at www.HobartWelder.com 7-5. Replacing Gun Contact Tip Turn Off power before replacing contact tip. 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. -
Page 27: Cleaning Gun Liner
A complete Parts List is available at www.HobartWelder.com 7-6. Cleaning Gun Liner 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. -
Page 28: Replacing Gun Liner
A complete Parts List is available at www.HobartWelder.com 7-7. Replacing Gun Liner 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 A complete Parts List is available at www.HobartWelder.com 7-7. 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
A complete Parts List is available at www.HobartWelder.com 7-8. Troubleshooting Table Trouble Remedy Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts. welding. Adjust drive roll pressure (see Section 5-8). Change to proper drive roll groove (see Section 7-4). Readjust hub tension (see Section 5-5). -
Page 31: Section 8 − Electrical Diagram
SECTION 8 − ELECTRICAL DIAGRAM 230 951-A Figure 8-1 Circuit Diagram OM-923 Page 27... -
Page 32: Section 9 − Fcaw Welding Guidelines
SECTION 9 − FCAW WELDING GUIDELINES 9-1. Typical FCAW Process Connections 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
9-2. Typical Control Settings Auto-Sett and single-knob control units operate differently than outlined below. See Operation section of Owner’s Manual for specific information on control settings. These settings are guidelines only. Material and wire type, joint design, fit-up, posi- tion, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. -
Page 34: Holding And Positioning Welding Gun
9-3. Holding And Positioning Welding Gun 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
9-4. 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. 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
9-5. 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 across gaps, a weave bead or multiple stringer beads works better. Stringer Bead − Steady Movement Along Seam Weave Bead −... -
Page 37: Troubleshooting − Excessive Spatter
9-8. 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 − Incomplete Fusion
Possible Causes Corrective Actions Improper weld technique. Maintain normal gun angle of 0 to 15 degrees to achieve maximum penetration. Keep arc on leading edge of weld puddle. Be sure welding wire extends not more than 1/2 in. (13 mm) beyond nozzle. Insufficient heat input. -
Page 39: Troubleshooting − Distortion
9-15. Troubleshooting − Distortion Distortion − contraction of weld metal during welding that forces base metal to move. Base metal moves in the direction of the weld bead. S-0642 Possible Causes Corrective Actions Excessive heat input. Use restraint (clamp) to hold base metal in position. Make tack welds along joint before starting welding operation. -
Page 40: Section 10 − Accessories/Consumables
195 157R H−9B Replacement Gun 8 ft (2.4 m) length/.030−.035 in. (0.8−0.9 mm) Wire Size 10-2. Consumables Item Hobart Part No. Miller Part No. Contact Tip .030 in. (0.8 mm) 770 177 (5 per package) 000 067 (10 per package) .035 in. - Page 41 Notes WELD POSITION: FLAT HORIZONTAL VERTICAL OVERHEAD BUTT BUTT WELD JOINT BUTT BUTT TYPES T−JOINT T−JOINT GROOVE T−JOINT FILLET T−JOINT Ref. 804 248-A Ref. AWS/ANSI D1.1...
- Page 42 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in.) 22 Gauge (.031 in.) 20 Gauge (.037 in.) 18 Gauge (.050 in.) 16 Gauge (.063 in.) 14 Gauge (.078 in.) 1/8 in. (.125 in.) 3/16 in. (.188 in.) 1/4 in. (.25 in.) 5/16 in.
- Page 43 Effective January 1, 2013 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? serial number preface of MD 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 44 Thank you for purchasing Hobart. Our trained technical support team is dedicated to your satisfaction. For questions regarding performance, op- eration, or service, contact us! Resources Available Always provide Model Name and Serial/Style Number. To locate a Service Center: Call 1-800-332-3281 or visit our website at www.HobartWelders.com/wheretobuy...