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Manual Hobart 125 EZ

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  • Hobart 125 EZ - page 1

    OM-923 223 1 12C 2006 − 08 Processes Arc Welding Power Source And Wire Feeder Description Flux Cored (FCA W ) Welding Handler 125 EZ And H-9B Gun R File: Flux Cored (FCA W) ...

  • Hobart 125 EZ - 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 ...

  • Hobart 125 EZ - 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 . . . . . . . . . . ...

  • Hobart 125 EZ - page 4

    T ABLE OF CONTENTS SECTION 8 − WIRE WELDING GUIDELINES 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1. T ypical FCA W Process Connections 26 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2. T ypical Control Settings 27 . . . . ...

  • Hobart 125 EZ - page 5

    OM-923 Page 1 SECTION 1 − SAFETY PRECAUTIONS - READ BEFORE USING som _3/05 Y W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety messag ...

  • Hobart 125 EZ - page 6

    OM-923 Page 2 Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA YS can burn eyes and skin. D Wear an approved welding helmet fitted with a proper shade of fil- ter lenses to protect your face and eyes when welding or watching (se ...

  • Hobart 125 EZ - page 7

    OM-923 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 ...

  • Hobart 125 EZ - page 8

    OM-923 Page 4 1-5. Principal Safety Standards Safety i n W elding, 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 W elding and Cut- ting of Containers and Piping , American W elding Society Standard A WS F ...

  • Hobart 125 EZ - page 9

    OM-923 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_som _3/05 Y A vertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symbo les uti lisés Sy mbole graphique d’aver tis sement ! At tention ! Cet te pr o- cédur e comporte d es risques poss ibl ...

  • Hobart 125 EZ - page 10

    OM-923 Page 6 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. LES RA YONS D’ARC peuvent entraî- ne r des brûlures aux yeux et à la peau. ...

  • Hobart 125 EZ - page 11

    OM-923 Page 7 2-3 . Da ngers suppléme ntaire s en r e lation avec l’installa tion, le f onc tionnement et l a maintenance Risque D’INCENDIE OU D’EXPLO- SION. D Ne pas placer l’appareil sur , au-dessus ou à proximité de surfaces inflammables. D Ne pas installer l’appareil à proximité de produits inflammables. D Ne pas surcharger l’i ...

  • Hobart 125 EZ - page 12

    OM-923 Page 8 2-5. Princi pales no rmes de sécurit é Safety in W elding, 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 fo r the Preparati on for W elding and Cut- ting of Containers and Piping , American W elding ...

  • Hobart 125 EZ - page 13

    OM-923 Page 9 SECTION 3 − SPECIFICA TIONS 3-1. Specifications Rated Welding Output Maximum Amperage Maximum Open- Circuit V oltage DC Amperes Input at Rated Load Output 1 15 V , 60 Hz, Single- Phase KV A KW W eight W/ Gun Overall Dimensions 90 A @ 1 9 V olts DC, 20% Duty Cycle 63 A @ 2 1 V olts DC, 20% Duty Cycle * 125 29 20 15 * 2.90 2.20 * 2.50 ...

  • Hobart 125 EZ - page 14

    OM-923 Page 10 3-3. V olt-Ampere Curves The volt-ampere curves show the minimum and maximum voltage an d amperage output capabilities of the welding power source. Curves of other settings fall between the curves shown. ssb1.1 10/91 − 210 519-A 8. 0 13. 0 18. 0 23. 0 28. 0 33. 0 0. 0 10. 0 20. 0 30. 0 40. 0 50. 0 60 . 0 70. 0 80. 0 90 . 0 100. 0 1 ...

  • Hobart 125 EZ - page 15

    OM-923 Page 1 1 SECTION 4 − INST ALLA TION 4-1. Installing W ork Clamp 1 Nut 2 W o rk 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 over handles. Ref. 802 456 1 2 3 4 5 T ools Needed: 7/16 in 6 . ...

  • Hobart 125 EZ - page 16

    OM-923 Page 12 4-4. 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 is needed to turn spool, tension is set. Retaining ring used with 8 ...

  • Hobart 125 EZ - page 17

    OM-923 Page 13 4-5. Selecting A Location And Connecting Input Power For 1 15 V AC Model 1 Rating Label 2 Grounded Receptacle A 1 15 volt, 20 ampere individual branch circuit protected by time-de- lay fuses or circuit breaker is re- quired. 3 Plug From Unit Select extension cord of 14 A WG fo r up to 50 ft (15 m) or 12 AWG for 50 up to 200 ft (61 m) ...

  • Hobart 125 EZ - page 18

    OM-923 Page 14 4-6. Installing Contact T ip And Nozzle T ools Needed: Ref. 804 241-A Y T urn off welding power source. 1 Nozzle Remove nozzle. 2 Contact T i p 3 Tip Adapter Thread welding wire through gun (see Section 4-7). Slide contact tip over wire and tighten tip into tip adapter . Install nozzle. 1 2 3 Flux Nozzle MIG Nozzle Use with flux core ...

  • Hobart 125 EZ - page 19

    OM-923 Page 15 4-7. 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: Pull and hold wire; cut off end. 4 in (102 mm) Remove gun nozzle and contact tip. Open pressure assembly . Push wire thru guides into gun liner; continue to hold wir ...

  • Hobart 125 EZ - page 20

    OM-923 Page 16 SECTION 5 − OPERATION 5-1. Controls 1 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. 2 Power Switch Ref. 230 001-A 1 2 ...

  • Hobart 125 EZ - page 21

    OM-923 Page 17 5-2. Operating The Gun Ref. 804 240-A 1 T rigger Switch When pressed, energized wire feeds. 1 ...

  • Hobart 125 EZ - page 22

    OM-923 Page 18 SECTION 6 − MAINTENANCE &TROUBLESHOOTING 6-1. Routine Maintenance Y Disconnect power before maintaining. 3 Months Replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 Months Blow out or vacuum inside. During heavy service, clean monthly . Or 6-2. Overload Protection 804 127-A 1 Su ...

  • Hobart 125 EZ - page 23

    OM-923 Page 19 6-4. 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 u be 6 Inlet Wire Guide Remove screws and pivot tube plate. Lift out pressure arm pivot tube, and slide inlet wire ...

  • Hobart 125 EZ - page 24

    OM-923 Page 20 6-5. Replacing Gun Contact Tip T ools Needed: Ref. 804 241-A Y T urn off welding power source. 1 Nozzle Remove nozzle. 2 Contact T i p 3 Tip Adapter Cut off welding wire at contact tip. Remove contact tip from tip adapter , and install new contact tip. Reinstall nozzle. 1 2 3 ...

  • Hobart 125 EZ - page 25

    OM-923 Page 21 6-6. Cleaning Gun Liner 804 241-A / Ref. 804 123-A / 804 128-A / Ref. 803 837-A Y T urn off welding power source. 1 Nozzle 2 Contact T i p 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 adapter . . Thread wire accor ...

  • Hobart 125 EZ - page 26

    OM-923 Page 22 6-7. Replacing Gun Liner Ref. 804 241-A / 804 123-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 to keep it from unraveling. Secure end of wire at spool. T wist t ...

  • Hobart 125 EZ - page 27

    OM-923 Page 23 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. Slide locking rings over top and bottom of handle, and secure by twisting rings clockwise 1/4 turn. Place other half of handle over head tube and cable. Be sure that cable is s ...

  • Hobart 125 EZ - page 28

    OM-923 Page 24 6-8. T roubleshooting T able T rouble Remedy Electrode wire feeding stops during welding 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 ...

  • Hobart 125 EZ - page 29

    OM-923 Page 25 SECTION 7 − ELECTRICAL DIAGRAM 230 951-A Figure 7-1. Circuit Diagram ...

  • Hobart 125 EZ - page 30

    OM-923 Page 26 SECTION 8 − WIRE WELDING GUIDELINES 8-1. T ypical FCA W Process Connections Y W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla ce wor k cl am p as close t o the weld as possible. Wire Feeder/ Power Source W orkpiece Gun W ork Clamp fcaw 1/2003 / Ref. 803 444-A Se ...

  • Hobart 125 EZ - page 31

    OM-923 Page 27 8-2. 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. NOTE 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 ...

  • Hobart 125 EZ - page 32

    OM-923 Page 28 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. NOTE 1 Hold Gun and Control Gun T rigger 2 W orkpiece 3 W ork Clamp 4 Electrode ...

  • Hobart 125 EZ - page 33

    OM-923 Page 29 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. NOTE Slow FILLET WELD ELECT ODE EXTENSIONS (STICKOUT) ELECTRODE EXTENSIONS (STICKOUT) GUN ANGLES AND WELD BEAD PROFI ...

  • Hobart 125 EZ - page 34

    OM-923 Page 30 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 . NOTE 1 Stringer Bead − Steady Movement Along Seam 2 Weave Bead − Side T o Side Movement Along ...

  • Hobart 125 EZ - page 35

    OM-923 Page 31 8-8. 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 Metal Thickness Selector switch set too high. Set Metal Thickness Selector switch to a lower selection. Electrode extension (stickout) too long. Use s ...

  • Hobart 125 EZ - page 36

    OM-923 Page 32 8-1 1. T roubleshooting − 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 ...

  • Hobart 125 EZ - page 37

    OM-923 Page 33 8-14. T roubleshooting − W aviness Of Bead W aviness O f Bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 Possible Causes Corrective Actions W elding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm) beyond nozzle. Unsteady hand. Support hand ...

  • Hobart 125 EZ - page 38

    OM-923 Page 34 SECTION 9 − P ARTS LIST . Hardware is common and not available unless listed. 804 124-B 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 19 36 20 21 22 23 24 25 26 27 30 28 29 31 32 33 34 35 37 Figure 8-1. Main Assembly ...

  • Hobart 125 EZ - page 39

    OM-923 Page 35 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quantity 1 210 432 CASE SECTION, front/bottom/rear 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210 530 BLANK, snap-in 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ...

  • Hobart 125 EZ - page 40

    OM-923 Page 36 1 804 243-A 2 3 5 − See T able 8-1 4 6 7 7 Figure 8-2. H-9B Gun Description Part No. 225 397 Item No. Figure 8-2. H-9B Gun Quantity 1 169 715 NOZZLE, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 226 190 NOZZLE, flux cored slip type 1 . . . . ...

  • Hobart 125 EZ - page 41

    OM-923 Page 37 803 442-B 4 5 1 6 7 8 9 2 3 Figure 8-3. Wire Drive Assembly Quantity Description Part No. 209 532 Item No. Figure 8-3. Wire Drive Assembly 1 212 377 BEARING, idler 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 212 379 ROLL, drive .024-.030/. ...

  • Hobart 125 EZ - page 42

    Notes ...

  • Hobart 125 EZ - page 43

    Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST hobart_warr 2006 − 01 Service Y o u 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 ...

  • Hobart 125 EZ - page 44

    PRINTED IN USA © 2005 Hobart Welding Products. 6/05 Hoba rt W elding Pr oducts An Illinois T oo l W orks Co mpany 600 W est Main St ree t Tr oy, OH 45373 USA For Technical Assi stance: Call1-800-332-3281 Fo r Lite ratu re Or Nea rest Dea ler : Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to o ...

Manufacturer Hobart Category Welder

Documents that we receive from a manufacturer of a Hobart 125 EZ can be divided into several groups. They are, among others:
- Hobart technical drawings
- 125 EZ manuals
- Hobart product data sheets
- information booklets
- or energy labels Hobart 125 EZ
All of them are important, but the most important information from the point of view of use of the device are in the user manual Hobart 125 EZ.

A group of documents referred to as user manuals is also divided into more specific types, such as: Installation manuals Hobart 125 EZ, service manual, brief instructions and user manuals Hobart 125 EZ. Depending on your needs, you should look for the document you need. In our website you can view the most popular manual of the product Hobart 125 EZ.

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A complete manual for the device Hobart 125 EZ, how should it look like?
A manual, also referred to as a user manual, or simply "instructions" is a technical document designed to assist in the use Hobart 125 EZ by users. Manuals are usually written by a technical writer, but in a language understandable to all users of Hobart 125 EZ.

A complete Hobart manual, should contain several basic components. Some of them are less important, such as: cover / title page or copyright page. However, the remaining part should provide us with information that is important from the point of view of the user.

1. Preface and tips on how to use the manual Hobart 125 EZ - At the beginning of each manual we should find clues about how to use the guidelines. It should include information about the location of the Contents of the Hobart 125 EZ, FAQ or common problems, i.e. places that are most often searched by users in each manual
2. Contents - index of all tips concerning the Hobart 125 EZ, that we can find in the current document
3. Tips how to use the basic functions of the device Hobart 125 EZ - which should help us in our first steps of using Hobart 125 EZ
4. Troubleshooting - systematic sequence of activities that will help us diagnose and subsequently solve the most important problems with Hobart 125 EZ
5. FAQ - Frequently Asked Questions
6. Contact detailsInformation about where to look for contact to the manufacturer/service of Hobart 125 EZ in a specific country, if it was not possible to solve the problem on our own.

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