Hobart H-9 User Manual

OM-948 213 220B

May 2003

Processes

Semi-Automatic, Air-Cooled
Flux Cored (FCAW) And MIG
(GMAW) Welding Gun

H-9 Gun

Flux Cored (FCAW) W elding
MIG (GMAW) Welding (Optional)

Description

Visit our website at

www.HobartWelders.com

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. Please take time to read the Safety precautions. They
will help you protect yourself against potential hazards on the worksite.

We’ve made installation and operation quick
and easy. With Hobart you can count on years
of reliable service with proper maintenance.
And if for some reason the unit needs repair,
there’s a Troubleshooting section that will help
you figure out what the problem is. The parts
list will then help you to decide the exact part

Hobart is registered to the
ISO 9001:2000 Quality
System Standard.

you may need to fix the problem. Warranty and
service information for your particular model
are also provided.

Working as hard as you
do – every power source
from Hobart is backed by
the best warranty in the
business.

Hobart Welders 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 catalog sheets.

To locate your nearest distributor or service agency call 1-877-Hobart1.

Hobart offers a Technical
Manual which provides
more detailed service and
parts information for your
unit. T o obtain a Technical
Manual, contact your local
distributor. Your distributor
can also supply you with
Welding Process Manuals
such as SMAW, GTAW,
GMAW, and GMA W-P.

TABLE OF CONTENTS

WARNING

This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section

25249.5 et seq.)

The following terms are
used interchangeably
throughout this manual:
Mig = GMAW

SECTION 1 –SAFETY PRECAUTIONS FOR FCA W AND GMAW WELDING GUNS – READ

1-1. Symbol Usage 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

1-2. FCAW And GMAW Gun Hazards 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

EMF INFORMATION 2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 2 – SAFETY INFORMATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 3 – INSTALLATION 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-1. Specifications 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-2. Duty Cycle And Overheating 3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-3. Installing Gun Into Welding Power Source 4. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

3-4. Threading Welding Wire 5. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 4 – OPERATION 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

4-1. Operating The Gun 6. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 5 – MAINTENANCE & TROUBLESHOOTING 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-1. Replacing Gun Contact Tip 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-2. Cleaning Gun Liner 7. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-3. Replacing Gun Liner 8. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-4. Replacing Liner O-Ring 10. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-5. Replacing Switch And/Or Head Tube 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-6. Removing Gun From Welding Power Source 13. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-7. Routine Maintenance 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

5-8. Troubleshooting 14. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 6 – PARTS LIST 15. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

WARRANTY

BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-948

SECTION 1 –SAFETY PRECAUTIONS FOR FCAW AND

,

l

e

n

GMAW WELDING GUNS – READ BEFORE USING

1-1. Symbol Usage

Means Warning! Watch Out! There are possible hazards with this
procedure! The possible hazards are shown in the adjoining symbols.

This group of symbols means Warning! Watch Out! Possible ELECTRIC SHOCK and HOT PARTS hazards.
Consult symbols and related instructions below for necessary actions to avoid the hazards.

1-2. FCAW And GMAW Gun Hazards

Y Marks a special safety message.

. Means NOTE; not safety related.

SR7_7/01

WARNING

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY.
PACEMAKER WEARERS KEEP AWA Y UNTIL CONSULTING YOUR DOCTOR.

In welding, as in most jobs, exposure to certain hazards occurs. Welding is safe when precautions are taken. The safety
information given below is only a summary of the more complete safety information found in the wire feeder and welding power
source Owner’s Manuals. Read and follow all safety precautions.

HA VE ALL I NST ALLA TI ON, OPERATION, M AINTENANCE, A ND REPAIR W ORK PERFORMED ONL Y B Y Q UALIFIED P EOPLE.

ELECTRIC SHOCK can kill.

1. Always wear dry insulating gloves.

2. Insulate yourself from work and ground.

3. Do not touch live electrode or electrical parts.

4. Repair or replace worn, damaged, or cracked
gun or cable insulation.

5. Turn off welding power source before changing
contact tip or gun parts.

6. Keep all covers and handle securely in place.

GMAW WELDING can be hazardous.

ARC RAYS can burn eyes and skin.

1. Wear welding helmet with correct shade of filter.

2. Wear correct eye and body protection.

3. Cover exposed skin with spatter-resistant
clothing.

HOT SURFACES can burn skin.

1. Allow gun to cool before touching.

2. Do not touch hot metal.

3. Protect hot metal from contact by others.

FUMES AND GASES can be hazardous
to your health.

1. Keep your head out of the fumes.

2. Ventilate area, or use breathing device.

3. Read Material Safety Data Sheets (MSDSs) and
manufacturer’s instructions for material used.

WELDING can cause fire or explosion.

1. Do not weld near flammable material.

2. Do not weld on closed containers.

3. Watch for fire; keep extinguisher nearby.

BUILD UP OF GAS can injure or kill

1. Shut off shielding gas supply when not in use.

2. Always ventilate confined spaces or use
approved air-supplied respirator.

NOISE can damage hearing; SOME
APPLICATIONS, SUCH AS PULSING
are noisy.

1. Check for noise level limits exceeding those
specified by OSHA.

2. Use approved ear plugs or ear muffs if noise leve
is high.

3. Warn others nearby about noise hazard.

WELDING WIRE can cause punctur
wounds.

1. Keep hands and body away from gun tip whe
trigger is pressed.

OM-948 Page 1

EMF INFORMATION

NOTE

The following is a quotation from the General Conclusions Section of
the U.S. Congress, Office of Technology Assessment, Biological

Effects of Power Frequency Electric & Magnetic Fields –
Background Paper, OTA-BP-E-53 (Washington, DC: U.S.

Government Printing Office, May 1989): “. . . there is now a very large
volume of scientific findings based on experiments at the cellular
level and from studies with animals and people which clearly
establish that low frequency magnetic fields can interact with, and
produce changes in, biological systems. While most of this work is
of very high quality, the results are complex. Current scientific
understanding does not yet allow us to interpret the evidence in a
single coherent framework. Even more frustrating, it does not yet
allow us t o draw definite conclusions about questions of possible risk
or to offer clear science-based advice on strategies to minimize or
avoid potential risks.”

Considerations About Welding And The Effects Of Low Frequency Electric And
Magnetic Fields

To reduce magnetic fields in the workplace, use the following
procedures:

1. Keep cables close together by twisting or taping them.

2. Arrange cables to one side and away from the operator.

3. Do not coil or drape cables around the body.

4. Keep welding power source and cables as far away as practical.

5. Connect work clamp to workpiece as close to the weld as
possible.

About Pacemakers:

The above procedures are among those also normally
recommended for pacemaker wearers. Consult your doctor for
complete information.

mod10.1 4/93

OM-948 Page 2

SECTION 2 – SAFETY INFORMATION

Read all safety messages throughout this manual.
Obey all safety messages to avoid injury.
Learn the meaning of WARNING and CAUTION.

1 2

2

WARNING

ELECTRIC SHOCK can kill.

3

• Do not touch live electrical parts.

• Disconnect input power before

installing or servicing.

5

6

7

WARNING

NOTE

Turn Off switch when using high frequency.

4

SECTION 3 – INSTALLATION

3-1. Specifications

Air-Cooled Welding Gun For FCAW And GMA W Welding

Note: Using gasless flux cored wire reduces gun duty cycle.

CAUTION

MOVING PARTS can injure.

• Keep away from moving parts.

• Keep all panels and covers closed

when operating.

READ SAFETY BLOCKS at start of
Section 3-1 before proceeding.

1 Safety Alert Symbol
2 Signal Word
WARNING means possible death

or serious injury can happen.
CAUTION means possible minor

injury or equipment damage can
happen.

3 Statement Of Hazard And

Result

4 Safety Instructions To Avoid

Hazard
5 Hazard Symbol (If Available)
6 Safety Banner
Read safety blocks for each

symbol shown.
7 NOTE
Special instructions for best

operation – not related to safety.

H-9 Feeds .030 To .035 in (0.8 To 0.9 mm) Flux Cored Wire Or .024 To .030 in (0.6 To 0.8 mm) Hard Wire
Duty Cycle Rating:

100%: 40 A With Flux Cored Wire
100%: 100 A With CO
60%: 100 A With Mixed Gases
Weight With 8 ft (2.4 m) Power Cable: 2.2 lb (1.0 kg)

803 495-A

3-2. Duty Cycle And Overheating

See Section 3-1. Specifications for amperage
rating an d d u t y c y c l e .

100%dutycycle

Continuous Welding

Overheating

6 Minutes Welding 4 Minutes Resting

0

Minutes

Shielding Gas

2

60%dutycycle

15

Duty Cycle is percentage of 10
minutes that unit can weld at rated
load without overheating.

Y Exceeding duty cycle can

damage unit and void

warranty.

A or V

OR

Reduce Duty Cycle

sduty1 5/95

OM-948 Page 3

3-3. Installing Gun Into Welding Power Source

Open pressure assembly.

. If existing gun requires removal, see Section 5-6.

Remove screws (3) from
cover, and remove cover
from wire drive assembly.

Y Turn off welding power source.

Insert gun cable through opening in front
panel. Route weld cable, trigger leads, and
gas hose through opening in drive housing.

Remove wrapper from
unit.

Reinstall cover and
secure with screws (3).

. Route wires, cable, and hose to avoid contact

with sharp edges, hot surfaces, or moving parts.

Connect trigger leads to
RC3 and RC4 on PC1.

Route weld cable through
opening in baffle.

Connect gas hose to adapter
(if unit is not equipped with
gas solenoid valve, secure
hose to wiring harness).

Secure leads and hose
with cable tie(s).

Install cable end into drive housing with
retaining ring between the two locating ribs.
Position liner in groove so that black tubing
end is flush with back of groove.

Connect weld cable
to weld terminal.

Reinstall wrapper onto unit.

. Thread wire according to

Section 3-4.

803 497-A / Ref. 803 378-A

OM-948 Page 4