Related Manuals for Hobart Handler 125 EZ
Summary of Contents for Hobart Handler 125 EZ
- Page 1 OM-923 223 112D 2008−10 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.
-
Page 3: Table Of Contents
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING ....... . . 1-1. - Page 4 TABLE OF CONTENTS SECTION 8 − WIRE WELDING GUIDELINES ........... 8-1.
-
Page 5: Section 1 − Safety Precautions - Read Before Using
SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _2007−04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text. - Page 6 D Do not use welder to thaw frozen pipes. FUMES AND GASES can be hazardous. D Remove stick electrode from holder or cut off welding wire at contact tip when not in use. Welding produces fumes and gases. Breathing D Wear oil-free protective garments such as leather gloves, heavy these fumes and gases can be hazardous to your shirt, cuffless trousers, high shoes, and a cap.
-
Page 7: Additional Symbols For Installation, Operation, And Maintenance
1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. MOVING PARTS can cause injury. D Do not install or place unit on, over, or near D Keep away from moving parts such as fans. combustible surfaces. D Keep all doors, panels, covers, and guards D Do not install unit near flammables. -
Page 8: California Proposition 65 Warnings
1-4. California Proposition 65 Warnings For Gasoline Engines: Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to Engine exhaust contains chemicals known to the State of cause birth defects and, in some cases, cancer. (California California to cause cancer, birth defects, or other reproduc- Health &... -
Page 9: Section 2 − Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_som_2007−04 Se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques. - Page 10 Il reste une TENSION DC NON NÉGLIGEABLE dans LE SOUDAGE peut provoquer un in les sources de soudage onduleur quand on a cendie ou une explosion. coupé l’alimentation. 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.
-
Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, ACCUMULATIONS des chocs mécaniques, des dommages physiques, du laitier, des risquent de provoquer des blessures flammes ouvertes, des étincelles et des arcs. ou même la mort. D Placer les bouteilles debout en les fixant dans un support station- D Fermer l’alimentation du gaz protecteur en cas naire ou dans un porte-bouteilles pour les empêcher de tomber ou de non-utilisation. -
Page 12: Proposition Californienne 65 Avertissements
LES FILS DE SOUDAGE peuvent LE RAYONNEMENT HAUTE FRÉ- provoquer des blessures. QUENCE (H.F.) risque de provoquer des interférences. D Ne pas appuyer sur la gâchette avant d’en avoir reçu l’instruction. D Le rayonnement haute fréquence (H.F.) peut D Ne pas diriger le pistolet vers soi, d’autres per- provoquer des interférences avec les équipe- sonnes ou toute pièce mécanique en enga- ments de radio−navigation et de communica-... -
Page 13: Principales Normes De Sécurité
2-5. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, L4W 5NS (téléphone : 800-463-6727 ou à Toronto 416-747-4044, site de Global Engineering Documents (téléphone : 1-877-413-5184, site Internet : www.csa-international.org). Internet : www.global.ihs.com). Safe Practice For Occupational And Educational Eye And Face Protec- tion, ANSI Standard Z87.1, de American National Standards Institute, Recommended Safe Practices for the Preparation for Welding and Cut- 11 West 43rd Street, New York, NY 10036-8002 (téléphone :... - Page 14 OM-923 Page 10...
-
Page 15: Section 3 − Specifications
SECTION 3 − SPECIFICATIONS 3-1. Specifications Amperes Input at Maximum Open- Rated Welding Maximum Rated Load Output Weight Overall Circuit Voltage Output Amperage W/ Gun Dimensions 115 V, 60 Hz, Single- Phase Length: 16-7/8 in (429 mm) 90 A @ 19 Volts DC, 2.90 2.50 50 lb... -
Page 16: Volt-Ampere Curves
3-3. 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. 33.0 28.0 23.0 18.0 13.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0 80.0... -
Page 17: 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 Work Cable From Unit weld performance and excessive heating of the work clamp. Work Clamp Screw Work Clamp Tabs... -
Page 18: Installing Wire Spool And Adjusting Hub Tension
4-4. 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 8 in (203 mm) Wire Spool Adapter used with Only applies to units equipped with 8 in (203 mm) -
Page 19: Selecting A Location And Connecting Input Power For 115 Vac Model
4-5. Selecting A Location And Connecting Input Power For 115 VAC Model Rating Label Grounded Receptacle A 115 volt, 20 ampere individual branch circuit protected by time-de- lay fuses or circuit breaker is re- quired. Plug From Unit Select extension cord of 12 AWG for up to 50 ft (15 m) or 10 AWG for 50 up to 100 ft (30 m). -
Page 20: Installing Contact Tip And Nozzle
4-6. Installing Contact Tip And Nozzle Turn off welding power source. Nozzle Remove nozzle. Contact Tip Tip Adapter Thread welding wire through gun (see Section 4-7). Slide contact tip over wire and tighten tip into tip adapter. Install nozzle. Flux Nozzle MIG Nozzle Use with flux cored wire only. -
Page 21: Threading Welding Wire
4-7. 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. + − + − 6 in 4 in (150 mm) (102 mm) -
Page 22: Section 5 − Operation
SECTION 5 − OPERATION 5-1. 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 Ref. 230 001-A OM-923 Page 18... -
Page 23: Operating The Gun
5-2. Operating The Gun Trigger Switch When pressed, energized wire feeds. Ref. 804 240-A OM-923 Page 19... -
Page 24: Section 6 − Maintenance &Troubleshooting
SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Disconnect power Maintain more often before maintaining. during severe condi- tions. 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
6-4. 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 Remove screws and pivot tube plate. -
Page 26: Replacing Gun Contact Tip
6-5. 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. Reinstall nozzle. Tools Needed: Ref. -
Page 27: Cleaning Gun Liner
6-6. 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. from unraveling. -
Page 28: Replacing Gun Liner
6-7. 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 6-7. 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.
-
Page 30: Troubleshooting Table
6-8. Troubleshooting Table Trouble Remedy Electrode wire feeding stops during Straighten gun cable and/or replace damaged parts. welding. Adjust drive roll pressure (see Section 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 31: Section 7 − Electrical Diagram
SECTION 7 − ELECTRICAL DIAGRAM 230 951-A Figure 7-1. Circuit Diagram OM-923 Page 27... -
Page 32: Section 8 − Wire Welding Guidelines
SECTION 8 − WIRE WELDING GUIDELINES 8-1. 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
8-2. Typical Control Settings These settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. affect settings. Test welds to be sure they comply to specifications. Material thickness determines weld parameters. 1/8 or 0.125 in Convert Material Thickness to Amperage (A) -
Page 34: Holding And Positioning Welding Gun
8-3. 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
8-4. 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
8-5. 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
8-8. Troubleshooting − Excessive Spatter Excessive Spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 Possible Causes Corrective Actions Metal Thickness Selector switch set too Set Metal Thickness Selector switch to a lower selection. high. -
Page 38: Troubleshooting − Lack Of Penetration
8-11. Troubleshooting − Lack Of Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration S-0638 Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove while maintaining proper welding wire extension and arc characteristics. -
Page 39: Troubleshooting − Waviness Of Bead
8-14. Troubleshooting − Waviness Of Bead Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions Welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand. -
Page 40: 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 36... - Page 41 Item Dia. Part Mkgs. Description Quantity Figure 8-1. Main Assembly ..... 210 432 . . . CASE SECTION, front/bottom/rear ......
- Page 42 ♦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. Table 8-1. Contact Tip Options HOBART PART NO. DESCRIPTION REMARKS 196 131 Tip, contact scr .030 wire...
- Page 43 803 442-B Figure 8-3. Wire Drive Assembly Item Part Description Quantity 209 532 Figure 8-3. Wire Drive Assembly ..... 212 377 .
- Page 44 Notes...
- Page 45 Notes...
- Page 46 Notes...
- Page 47 Effective January 1, 2008 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? serial number preface of LJ 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 48 Call 1-877-Hobart1 Contact the Delivering Carrier to: 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. © PRINTED IN USA 2008 Hobart Welding Products. 2008−01...