Related Manuals for Hobart Handler 125 EZ
Summary of Contents for Hobart Handler 125 EZ
- Page 1 OM-923 223 112C 2006−08 Processes Flux Cored (FCAW) Welding Description Arc Welding Power Source And Wire Feeder Handler 125 EZ And H-9B Gun File: Flux Cored (FCAW)
- Page 2 From Hobart to You Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. This Owner’s Manual is designed to help you get the most out of your Hobart products.
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Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage ............... 1-2. - Page 4 TABLE OF CONTENTS SECTION 8 − WIRE WELDING GUIDELINES 8-1. Typical FCAW Process Connections 8-2. Typical Control Settings ............. . . 8-3.
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Page 5: Section 1 − Safety Precautions - Read Before Using
DC constant voltage (wire) welder, 2) a DC manual (stick) welder, or 3) an AC welder with reduced open-circuit volt- age. In most situations, use of a DC, constant voltage wire welder is recommended. And, do not work alone! D Disconnect input power or stop engine before installing or servicing this equipment. - Page 6 D Do not use welder to thaw frozen pipes. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use.
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Page 7: Additional Symbols For Installation, Operation, And Maintenance
READ INSTRUCTIONS. D Read Owner’s Manual before using or servic- ing unit. D Use only genuine Miller/Hobart replacement parts. H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. -
Page 8: Principal Safety Standards
1-5. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard F4.1 from Global... -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION Y Avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés Symbole graphique d’avertissement ! Attention ! Cette pro- cédure comporte des risques possibles ! Les dangers éven- tuels sont représentés par les symboles graphiques joints. - Page 10 LES RAYONS D’ARC peuvent entraî- ner des brûlures aux yeux et à la peau. Le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage.
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Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
Miller/Hobart. RAYONNEMENT HAUTE provoquer des interférences avec les équipe- ments de radio-navigation et de communica- tion, les services de sécurité et les ordinateurs. -
Page 12: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, de Global Engineering Documents (téléphone : 1-877-413-5184, site In- ternet : www.global.ihs.com). Recommended Safe Practices for the Preparation for Welding and Cut- ting of Containers and Piping, American Welding Society Standard AWS F4.1 de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.global.ihs.com). -
Page 13: Section 3 − Specifications
SECTION 3 − SPECIFICATIONS 3-1. Specifications Rated Welding Maximum Output Amperage 90 A @ 19 Volts DC, 20% Duty Cycle 63 A @ 21 Volts DC, 20% Duty Cycle* Flux Cored Wire Type Wire Type .030 − .035 in And Dia (0.8 −... -
Page 14: Volt-Ampere Curves
3-3. Volt-Ampere Curves 33.0 28.0 23.0 18.0 13.0 10.0 20.0 30.0 (18-16 ga) Range 1 (16-12 ga) Range 2 (12-10 ga) Range 3 (10ga-3/16”) Range 4 OM-923 Page 10 40.0 50.0 60.0 70.0 80.0 90.0 100.0 110.0 120.0 130.0 Amperage The volt-ampere curves show the minimum and maximum voltage and amperage output capabilities of... -
Page 15: Section 4 − Installation
SECTION 4 − INSTALLATION 4-1. Installing Work Clamp Connection hardware must be tightened with proper tools. Do not just hand tighten hardware. A loose electrical connection will cause poor weld performance and excessive heating of the work clamp. Tools Needed: 7/16 in 7/16 in 4-2. -
Page 16: Installing Wire Spool And Adjusting Hub Tension
4-4. Installing Wire Spool And Adjusting Hub Tension Installing 8 in (203 mm) Wire Spool Only applies to units equipped with optional hub kit. Retaining ring used with 8 in (203 mm) spool only. Tools Needed: OM-923 Page 12 Installing 4 in (102 mm) Wire Spool Adapter used with 8 in (203 mm) spool only. -
Page 17: Selecting A Location And Connecting Input Power For 115 Vac Model
4-5. Selecting A Location And Connecting Input Power For 115 VAC Model Y Do not move or operate unit where it could tip. 18 in (460 mm) 18 in (460 mm) Rating Label Grounded Receptacle A 115 volt, 20 ampere individual branch circuit protected by time-de- lay fuses or circuit breaker is re- quired. -
Page 18: Installing Contact Tip And Nozzle
4-6. Installing Contact Tip And Nozzle Flux Nozzle Use with flux cored wire only. Narrow design allows access in tight spaces and provides better visibility of puddle during welding. Push nozzle over contact tip and adapter until it is seated onto adapter. -
Page 19: Threading Welding Wire
4-7. Threading Welding Wire Tools Needed: + − Open pressure assembly. Tighten Be sure that wire is positioned in proper feed roll groove. Close and tighten pressure assembly, and let go of wire. Press gun trigger until wire comes out of gun. −... -
Page 20: Section 5 − Operation
SECTION 5 − OPERATION 5-1. Controls OM-923 Page 16 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 Ref. 230 001-A... -
Page 21: Operating The Gun
5-2. Operating The Gun Trigger Switch When pressed, energized wire feeds. Ref. 804 240-A OM-923 Page 17... -
Page 22: Section 6 − Maintenance &Troubleshooting
SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. 6 Months Blow out or vacuum inside. During heavy service, clean monthly. 6-2. Overload Protection 6-3. Drive Motor Protection Drive motor protection circuit protects drive motor from overload. If drive motor becomes inoperative, release gun trigger and wait until protection circuit resets allowing drive motor to feed wire again. -
Page 23: Changing Drive Roll Or Wire Inlet Guide
6-4. Changing Drive Roll Or Wire Inlet Guide + − .030/.035 .024 Groove VK Groove Stamped .030/.035 Stamped .024 Tools Needed: 5/16 in + − − Pressure Adjustment Knob Pressure Assembly Pivot pressure adjustment knob down, and lift pressure assembly Pivot Tube Plate Securing Screws Pressure Arm Pivot Tube... -
Page 24: Replacing Gun Contact Tip
6-5. Replacing Gun Contact Tip Tools Needed: OM-923 Page 20 Y Turn off welding power source. 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. Reinstall nozzle. -
Page 25: Cleaning Gun Liner
6-6. Cleaning Gun Liner Head Tube 8 mm Remove nozzle. Cut off wire at contact tip, and remove contact tip and tip adapter. + − Tools Needed: Lay gun cable out straight, and blow out liner. 8 mm Y Turn off welding power source. + −... -
Page 26: Replacing Gun Liner
6-7. Replacing Gun Liner Head Tube 8 mm Remove nozzle. Cut off wire at contact tip, and remove contact tip and tip adapter. + − Remove screws (3) from cover, and remove cover from wire drive assembly. 8 mm OM-923 Page 22 + −... - Page 27 6-7. 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. 3/8 in (10 mm) Be sure that cable is straight. Tighten liner setscrew. Cut liner so that 3/8 in (10 mm) sticks out of head tube.
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Page 28: Troubleshooting Table
6-8. Troubleshooting Table Trouble Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts. welding welding. Adjust drive roll pressure (see Section 4-7). Change to proper drive roll groove (see Section 6-4). Readjust hub tension (see Section 4-4). Replace contact tip if blocked (see Section 6-5). -
Page 29: Section 7 − Electrical Diagram
SECTION 7 − ELECTRICAL DIAGRAM 230 951-A Figure 7-1. Circuit Diagram OM-923 Page 25... -
Page 30: Section 8 − Wire Welding Guidelines
SECTION 8 − WIRE WELDING GUIDELINES 8-1. Typical FCAW Process Connections Y 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 31: Typical Control Settings
8-2. Typical Control Settings NOTE These settings are guidelines only. Material and wire type, joint design, fitup, position, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. .035 in Wire Recommendation Size 0.023 in 3.5 in per ampere 0.030 in... -
Page 32: Holding And Positioning Welding Gun
8-3. Holding And Positioning Welding Gun NOTE 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. Drag End View of Work Angle End View of Work Angle... -
Page 33: Conditions That Affect Weld Bead Shape
8-4. Conditions That Affect Weld Bead Shape NOTE 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 Electrode directed ahead of bead... -
Page 34: Gun Movement During Welding
8-5. Gun Movement During Welding NOTE 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. 8-6. Poor Weld Bead Characteristics 8-7. -
Page 35: Troubleshooting − Excessive Spatter
8-8. Troubleshooting − Excessive Spatter Possible Causes Metal Thickness Selector switch set too high. Electrode extension (stickout) too long. Workpiece dirty. Dirty welding wire. 8-9. Troubleshooting − Porosity Possible Causes Wrong gas. Dirty welding wire. Workpiece dirty. Welding wire extends too far out of nozzle. 8-10. -
Page 36: Troubleshooting − Lack Of Penetration
8-11. Troubleshooting − Lack Of Penetration Lack of Penetration Good Penetration Possible Causes Improper joint preparation. Improper weld technique. Insufficient heat input. 8-12. Troubleshooting − Incomplete Fusion Possible Causes Workpiece dirty. Insufficient heat input. Improper welding technique. 8-13. Troubleshooting − Burn-Through Possible Causes Excessive heat input. -
Page 37: Troubleshooting − Waviness Of Bead
8-14. Troubleshooting − Waviness Of Bead Possible Causes Welding wire extends too far out of nozzle. Unsteady hand. 8-15. Troubleshooting − Distortion Base metal moves in the direction of the weld bead. Possible Causes Excessive heat input. 8-16. Troubleshooting Guide For Semiautomatic Welding Equipment Problem Probable Cause Wire feed motor operates, but... -
Page 38: Section 9 − Parts List
SECTION 9 − PARTS LIST Hardware is common and not available unless listed. 804 124-B Figure 8-1. Main Assembly OM-923 Page 34... - Page 39 Item Dia. Part Mkgs..... . 210 432 ......210 530 .
- Page 40 226 080 OPTIONAL To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and serial number required when ordering parts from your local distributor. HOBART PART NO. 196 131 196 132 196 137 196 135 WELD-IT PART NO.
- Page 41 Item Part 209 532 ..... 212 377 ..... 212 379 .
- Page 42 Notes...
- Page 43 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST LIMITED WARRANTY − Subject to the terms and conditions below, Hobart/Miller Electric Mfg. Co., Appleton, Wisconsin,...
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Page 44: Owner's Record
File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. 2005 Hobart Welding Products. 6/05 Protect Your Investment! Register your product at: HobartWelders.com Hobart Welding Products...
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