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SOLDERING STATION

Instruction Manual
Thank you for purchasing the HAKKO 936 Soldering Station. Please read this manual before operating the HAKKO 936. Store the manual in a safe, easily accessible place for future reference.

Table of Contents Packing List/ Specifications ........................1 Precautions.............................................2 Names of Parts .......................................3 Setting up & Operating the HAKKO 936......3 4 Tip Care and Use Maintenance Calibrating the Iron Temperature............5 Tips ......................................................6 Troubleshooting Guide ..............................7 Checking for breakage of the heating element and cord assembly......8 9 Parts List Station / Iron Holder...........................10 Iron................................................11 Wiring Diagram.......................................11

Packing List
Please check the contents of the HAKKO 936 package and confirm that all the items listed below are included.

HAKKO 936 Station.......................................1 Soldering Iron (HAKKO 900 (S), 907 or 908) ......1 HAKKO Iron Holder (With Cleaning Sponge) ......1 Hex Wrench (1.5 mm,0.059 in.)........................1 Instruction Manual .......................................1
Cleaning Sponge

Iron Holder Station

Iron/907,908 Hex Wrench

Iron/900 (S)

Specifications
Name Power Consumption HAKKO 936 100,110,220-240V / 60W 120V / 65W

Soldering Iron
Power Consumption Tip to Ground Resistance Tip to Ground Potential Heating Element Cord Assembly Total Length (w/o Cord) Weight (w/o Cord) 900S 907 908 900S-ESD 907-ESD 908-ESD 24V AC-50W Under 2 Under 2mV (TYP. 0.6mV) Ceramic heater 1.2m (4 ft.) 176mm 190mm 200mm (7 in.) (7.5 in.) (7.9 in.) 25g 44g 54g (0.06 lbs.) (0.09 lbs.) (0.12 lbs.)

Station
Output Voltage Temperature Range Dimensions Weight (W/O Cord) 936 Station / 936 Station ESD 24V AC 200 C~480 C/392 F~896 F 120(W)x93(H)x70(D)mm 4.7(W)x3.7(H)x6.7(D)in. 1,300g (2.9 lbs.)

The tip temperature was measured using HAKKO 191 thermometer. Specifications and design subject to change without notice.

1

Names of Parts
Iron Receptacle Large Cleaning Sponge LED Heater Lamp Temp. Control Knob Knob Mount Small Cleaning Sponge Iron Holder Base

Cord Assembly CAL Pot Plug/Calibrator

OFF

ON

Power Switch Hex Wrench

Setting up & Operating the HAKKO 936
CAUTION:The sponge is compressed. It will swell when moistened with water. Before using the unit, dampen the sponge with the water and squeeze it dry. Failure to do so may result in damage to the soldering tip.

A. Iron Holder
1. Small Cleaning Sponge Dampen the small cleaning sponge with water and then squeeze it dry. Place it in one of the 4 openings of the iron holder base. 2. Add water to approximately the level as shown. The small sponge will absorb water to keep the larger sponge above it wet at all times.
* The large sponge may be used alone (w/o small sponge & water).

3. Dampen the large cleaning sponge and place it on the iron holder base.
Note:The iron receptacles for the 900(S) and the 907/908 soldering irons are different. Be sure to use the proper one for each type of soldering iron. (Refer to Parts List).

3

CAUTION : Be sure to turn off the power switch before connecting or disconnecting the soldering iron. Failure to do so may damage the P.W.B.

B. Connections
1. Connect the cord assembly to the receptacle. 2. Place the soldering iron in the iron holder. 3. Plug the power cord into the power supply. Be sure to ground the unit.

Receptacle Turn clockwise firmly Align the grooves and pins, and push straight in.

C. Set the Temperature
1. Set the temperature control knob to the desired temperature. 2. Lock the knob. The HAKKO 936 station is equipped with a temperature control knob lock. After setting the desired temperature, tighten the hex nut on the underside of the knob mount using the supplied hex wrench. Turn the nut clockwise to tighten the knob lock. CAUTION : Don't overtighten the knob lock. Don't attempt to turn the knob when the knob lock is on.

D. Turn on the Power Switch.
The heater lamp blinks on and off when the tip temperature reaches the set temperature. The unit is now ready to perform soldering work. For greater convenience, and soldering efficiency, two stations can be securely stacked as shown. CAUTION : The soldering iron must be placed in the iron holder when not in use. 4

Tip Care and Use
Tip Temperature
High soldering temperatures can degrade the tip. Use the lowest possible soldering temperature. The excellent thermal recovery characteristics ensure efficient and effective soldering even at low temperatures. This also protects the soldered items from thermal damage. Clean the tip regularly with a cleaning sponge, as oxides and carbides from the solder and flux can form impurities on the tip. These impurities can result in defective joints or reduce the tip's heat conductivity. When using the soldering iron continuously, be sure to loosen the tip and remove all oxides at least once a week. This helps prevent seizure and reduction of the tip temperature. Never leave the soldering iron sitting at high temperature for long periods of time, as the tip's solder plating will become covered with oxide, which can greatly reduce the tip's heat conductivity. Wipe the tip clean and coat the tip with fresh solder. This helps prevent tip oxidation.

Cleaning

When Not in Use After Use

Maintenance
Inspect and Clean the Tip
1. Set the temperature to 250 C (482 F). 2. When the temperature stabilizes, clean the tip with the cleaning sponge and check the condition of the tip. 3. If there is black oxide on the solder-plated portion of the tip, apply new solder (containing flux) and wipe the tip on the cleaning sponge. Repeat until the oxide is completely removed. Coat with new solder. 4. If the tip is deformed or heavily eroded, replace it with a new one.

CAUTION : Never file the Tip to remove oxide.

Calibrating the Iron Temperature
The soldering iron should be recalibrated after changing the iron, or replacing the heating element or tip. 1) Connect the cord assembly plug to the receptacle on the station. 2) Set the temperature control knob to 400 C (750 F). 3) Turn the power switch to `ON' and wait until the temperature stabilizes. Remove the CAL potentiometer plug. 4) When the temperature stabilizes, use a straight-edge (-) screwdriver or small plus (+) screwdriver to adjust the screw (marked CAL at the station) until the tip thermometer indicates a temperature of 400 C (750 F). Turn the screw clockwise to increase the temperature and counterclockwise to reduce the temperature. Replace the CAL pot plug.
* We recommend the HAKKO191/192 thermometer for measuring the tip temperature.

5

Tips
The tip temperature will vary according to the shape of the tip. The preferred method of adjustment uses a tip thermometer. (See "Calibrating the Iron Temperature" on page 5.) A less accurate method involves adjusting the temperature control knob according to the adjustment value for each tip. Example : When using a 900M-T-H tip at 400 C (750 F), the difference between this tip and a 900M-T-B is -20 C (-36 F). Set the temperature control knob to 420 C (786 F). Refer to the chart for the correct adjustment values.

907
(0.031) 0.8

900M-T-0.8D

900M-T-LB

(0.2) 5

R0.2(0.008)

900M-T-K
45 15(0.6)

(0.047) 1.2

(0.02) 0.5

0C 900M-T-1.2D

0.6(0.024)

17(0.66)

-10 C/-18 F 900M-T-0.5C

25(0.98)

+30 C/+54 F 900M-T-R

2(0.08) (0.2) 5.1 (0.1) 3.2 (0.17) 4.2 (0.08) 2

(0.09) 2.4

(0.12) 3.2

(0.047) 1.2

(0.08) 2

0C 0.5(0.02) 900M-T-1.2LD

(0.25) 6.5

(0.06) 1.5

0C 900M-T-3.2D

(0.2) 5

(0.04) 1

0C 900M-T-2.4D

3 0.5(0.02)

(0.1) 17(0.66)

(0.031) 0.8

0C 900M-T-1.6D

0.7(0.028) (0.06) 1.6

17(0.66)

45

0C 900M-T-0.8C

15(0.6)

0C 900M-T-RT

2

(0.08) 17(0.66)

45

-10 C/-18 F 900M-T-1C 900M-T-1CF* 0C 900M-T-1.5CF*

17(0.66)

0C 900M-T-SI

2

(0.08) 17(0.66)

R0.2(0.008)

60 17(0.66) 15(0.6)

0.5(0.02)

0C 900M-T-I

13(0.51) R0.2(0.008)

60 17(0.66)

0C 900M-T-2C 900M-T-2CF* 0C 900M-T-3C 900M-T-3CF* 0C 900M-T-4C 900M-T-4CF* 0C

15(0.6)

-10 C/-18 F 900M-T-H
3.5 (0.1 3)

17(0.66) 1.2(0.04)

(0.08) 2

(0.1) 3

-10 C/-18 F 900M-T-SB

0.7(0.028)

25(0.98) R0.2(0.008)

45

(0 7.5.29)

25 19(0.74) 1(0.04)

17(0.66)

-20 C/-36 F 900M-T-1.8H
1.8 (0.0 7)

45

(0.16) 4

0C

17(0.66)

45

(0.08) 2

0C 900M-T-B

14(0.55) R0.5(0.02)

17(0.66)

(0 7.5.29)

-10 C/-18 F 900M-T-S4

25 14(0.55)

R0.25(0.01)

17(0.66)

0C

15(0.6)

900M tip Out Diam 6.5

908 For heavy duty soldering HAKKO recommends the 908 iron with heavier tips.
900L-T-B
(0.08) 2 R0.5(0.02)

900L-T-2C 900L-T-2CF*

900L-T-I
45

R0.2(0.008)

(0.08) 2

0C 900L-T-2B

20(0.8)

(0.1) 3

(0.09) 2.4

0C 900L-T-3.2D

0.5(0.02)

5 (0.2) 20(0.8)

(0.15) 4

0C 900L-T-2.4D

20(0.8)

45

0C 900L-T-4C 900L-T-4CF* 0C 900L-T-5C 900L-T-5CF* 0C

20(0.8)

+20 C/ +36 F

(0.2) 5

-20 C/-36 F 900L-T-3C 900L-T-3CF*

20(0.8)

-20 C/-36 F 900L-T-K
45

20(0.8)

2(0.08)

18(0.7)

45

20(0.8)

(0.12) 3.2

(0.2) 5

0C

0.5(0.02)

8(0.3)

45 20(0.8)

15(0.6)

900L tip Out Diam 8.5

900S
(0.047) 1.2

*-These tips are tinned flat only.
For micro soldering HAKKO recommends the 900S iron with fine tips.
900S-T-1C
17(0.66) (0.04) 1 60

900S-T-1.2D

900S-T-B
R0.5(0.02)

(0.06) 1.6

0 C 0.4(0.016) 900S-T-1.6D
17(0.66)

0C 900S-T-2C
(0.08) 2

15(0.6)

0C 900S-T-I

17(0.66)

R0.2(0.008) 45 17(0.66)

0C

0.5(0.02)

0C

0C

17(0.66)

900S Tip Out Diam 5.8

6

Troubleshooting Guide
WARNING : * Disconnect the power plug before servicing. Failure to do so may result in electric shock. * If the power cord is damaged, it must be replaced by the manufacturer, its service agent or similarity qualified person in order to avoid personal injury or damage to the unit. Problem 1.

The heater lamp does not light up.

Check 1. Is the power cord and/or connecting plug disconnected ? Connect it. Check 2. Is the fuse blown? Determine why the fuse blew and eliminate the cause, then replace the fuse. a. Is the inside of the iron short-circuited? b. Is the grounding spring touching the heating element? c. Is the heating element lead twisted and short-circuited?

Problem 2.

The heater lamp lights up but the tip does not heat up.

Check 3. Is the soldering iron cord broken ? Refer to `Checking for breakage in the cord assembly.' Check 4. Is the Heating Element broken? Refer to `Checking for breakage in the heating element.'

Problem 3.

Check 3

The tip heats up intermittently.
Problem 4. Check 5. Is the tip temperature too high? Set an appropriate temperature. Check 6. Is the tip clean? Refer to `Tip Care and Use'

The tip is not wet.

Problem 5.

The tip temperature is too low.

Check 7. Is the tip coated with oxide? Refer to `Inspect and clean the tip' Check 8. Is the iron calibrated correctly? Recalibrate.

Problem 6.

The tip can not be pulled off.

Check 9. Is the tip seized? Is the tip swollen because of deterioration? Replace the tip and the heating element.

Problem 7.

Check 8

The tip doesn't hold the desired temperature.

7

Checking for breakage of the heating element and cord assembly
Disconnect the plug and measure the resistance value between the connecting plug pins as follows. If the values of 'a' and 'b' are outside the above value, replace the heating element (sensor) and/or cord assembly. Refer to Procedures 1 and 2. If the value of 'c' is over the above value, remove the oxidization film by lightly rubbing with sand-paper or steel wool the points shown below.
a Between pins 4&5 (Heating Element) b Between pins 1&2 (Sensor) c Between pin 3&Tip 2.5 - 3.5 (Normal) 43 - 58 (Normal) Under 2

1. Broken Heating Element

Disassembling the 907/908
11

5 4 8 9 6 10 12 7

3 2 1

1. Turn the nut (1) counterclockwise and remove the tip enclosure (2), the tip (3). 2. Turn the nipple (4) counterclockwise and remove it from the iron. 3. Pull both the heating element (6) and the cord assembly (11) out of the handle (12). (Toward the tip of the iron.) 4. Pull the grounding spring (5) out of the D-sleeve.
Heating Element (Red) Senser (Blue)

Measure when the heating element is at room temperature. 1. Resistance value of heating element (RED) 2.5 - 3.5 2. Resistance value of sensor (BLUE) 43 - 58 If the resistance value is not normal, replace the heating element. (Refer to the instructions included with the replacement part.) After replacing the Heating Element, 1. Measure the resistance value between 1) pins 4 & 1 or 2 2) pins 5 & 1 or 2. If it is not , the heating element and sensor are touching. This will damage the P.W.B. 2. Measure the resistance value 'a','b',and 'c' to confirm that the leads are not twisted and that the grounding spring is properly connected. 8

Parts List (Station/Iron Holder)
Note:Spare or repair parts do not include mounting screws, if they are not listed on the description. Screws must be ordered separately.

1

3 6 4

2

5

7

Hexagon Socket Head Cap Screw M 2 ~8 (1) Hexagon Socket Set Screw M 3 ~6 (1) Item No. Part No. B2048 1 B2225 B2001 B2229 2 B2003 3 B2006 4 B2004 5 B2005 6 B2018 7 B2227 8 B2011 9 B2012 B2228 B2013 B2014 B2088 B2000 10 B2226 B2002 B2015 11 B2016 12 B1318 13 B1319 B2042 B2043 B2007 14 B2224 B2008 B2103 15 B1084 16 B2017 17 *w / Rubber Stopper Part Name Description Upper Case 100,110,220~240V (Standard) Upper Case / UL 120V (Standard / UL) Upper Case E.S.D. P.W.B. Panel Receptacle Knob w / a screw Knob Mount w / a screw CAL Pot Plug Grounding Plate Transformer 100-24V Transformer 110-24V Transformer 120-24V (Standard / UL) Transformer 120-24V (ESD) Transformer 220~240-24V Transformer 240-24V (Australia) Lower Case* 100,110,220~240V (Standard) Lower Case / UL* 120V (Standard / UL) Lower Case* E.S.D. Cord Stopper Rubber Stopper set of 2 Power Cord 3 Wired Cord But No Plug Power Cord 3 Wired Cord & American Plug Power Cord 3 Cord & Australian Plug Power Cord 3 Cord & European Plug Fuse / 2A 100,110V Fuse / 2A 120V (UL) Fuse / 0.8A 220~240V Wiring Board for Switch Power Switch Hex Wrench

Binding Head Tapping Screw (Fluted Point) M 3.5 ~50 (4) M 3.5 ~40 (4) for No.B2228 Transformer

8

9

Tapping Screw (Fluted Point) M 3 ~12 (1)

11 10 15

14

16

Tapping Screw (Fluted Point) M 4 ~12 (4)

13 12

17 2
Item No. Part No. 1 C1141 C1142 2 B2020 B2021 3 B2019 4 A1042 Part Name Iron Holder Iron Holder Iron Receptacle Iron Receptacle Iron Holder Base Cleaning Sponge For 900S 907,908 900S 907,908 900S,907,908 900S,907,908

1 3 4

10

Parts List (Iron)
900S
Item No. Part No. 1 900S-006 900S-006S 2 3 A1322 4 900S-101 5 900S-001 900S-001S 6 900S-034 900S-034S 7 900S-010 8 900S-039 900S-039S Part Name Nut Nut Soldering Tip Heating Element Terminal Board Handle Handle Handle Cover Handle Cover Cord Bushing Cord Asse'y Cord Asse'y Description E.S.D. See. P.6 Old part No.900S-H w/Cord Stopper w/Handle Cover w/Handle Cover, E.S.D. E.S.D. (Not shown) (Not shown) E.S.D. (Not shown)

907,908
Item No. Part No. 1 B1784 B1794 2 B1786 B1787 3 4 5 6 7 8 B2022 B2033 B2032 A1321 B2028 B2023 B2024 B2025 B2026 B2027 B2031 B2029 B2030 Part Name Nut Nut Tip Enclosure Tip Enclosure Soldering Tip Soldering Tip Nipple Nipple Grounding Spring Heating Element Terminal Board Handle Handle Handle Handle Handle Cover Cord Bushing Cord Asse'y Cord Asse'y Description For 907 908 907 908 907 908 907 908 907,908 907,908 907,908 907 907 908 908 907,908 907,908 907,908 907,908

See. P. 6 See. P. 6

Old part No.900M-H,900L-H w/Cord Stopper w/Handle Cover w/Handle Cover, E.S.D. w/Handle Cover w/Handle Cover, E.S.D.

9 10 11

E.S.D.

Wiring Diagram
24V Transformer P.W.B. Ground
AC TR

3 Core



HEAD OFFICE
4-5, SHIOKUSA 2-CHOME, NANIWA-KU, OSAKA, 556-0024 JAPAN TEL: (06) 561-3225 FAX: (06) 561-8466

OVERSEAS AFFILIATES
U.S.A.: AMERICAN HAKKO PRODUCTS, INC. 25072 ANZA DR. SANTA CLARITA, CA 91355, U.S.A. TEL: (805) 294-0090 FAX: (805) 294-0096 Toll Free (800)88-HAKKO
4 2 5 5 6

www. hakkousa.com S'PORE: HAKKO PRODUCTS PTE., LTD. 1, GENTING LINK #02-04, PERFECT INDUSTRIAL BUILDING, SINGAPORE 349518 TEL: 7482277 FAX: 7440033

11

HONG KONG: HAKKO DEVELOPMENT CO., LTD. ROOM 1504 EASTERN HARBOUR CENTRE, 28 HOI CHAK STREET, QUARRY BAY, HONG KONG. TEL: 2811-5588 FAX: 2590-0217 PHILIPPINES: HAIKU PHILS TRADING CO., INC. NO. 415 WINDSOR TOWER CONDOMINIUM, 163 LEGASPI ST., LEGASPI VILLAGE MAKATI, METRO MANILA, PHILIPPINES TEL: 2-817-07-12 FAX: 2-810-76-49 MALAYSIA: HAKKO PRODUCTS SDN BHD MALAYSIA HEAD OFFICE: PETALING JAYA LOT 35/1 THE HIGHWAY CENTRE JALAN 51/205 46050 PETALING JAYA WEST MALAYSIA TEL: 03-7941333 FAX: 03-7911232 PENANG BRANCH: TEL: 04-644 6669 FAX: 04-644 8628 JOHORE BAHRU BRANCH: TEL: 07-236 7766 FAX: 07-237 4655

SEP., 1998