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OM-291968B
Processes
Flux Cored (FCAW) Welding
MIG (GMAW) Welding
Description
Semi-Automatic, Air-Cooled Flux Cored
(FCAW) And MIG (GMAW) Welding Gun
H-9D Gun
2022-08
www.HobartWelders.com
OWNER’S MANUAL
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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 you may
need to fix the problem. Warranty and service information for your
particular model are also provided.
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
specification sheets. To locate your nearest
distributor or service agency call
1-800-332-3281, or visit us at
www.HobartWelders.com on the web.
For Technical Help call 1-800-332-3281.
Register your product at www.HobartWelders.com
Hobart is registered to the ISO
9001 Quality System
Standard.
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TABLE OF CONTENTS
SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-1 Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-2 Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1-3 California Proposition 65 Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-4 Principal Safety Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
1-5 EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-1 Symboles utilisés. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-2 Dangers relatifs au soudage à l'arc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2-3 Proposition californienne 65 Avertissements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-4 Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2-5 Informations relatives aux CEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
SECTION 3 – SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-1 Information About Default Weld Parameters And Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-2 Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
3-3 Duty Cycle And Overheating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
SECTION 4 – INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4-1 Installing Gun Into Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4-2 Installing Contact Tip And Nozzle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4-3 Threading Welding Wire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
SECTION 5 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5-1 Operating The Gun . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
SECTION 6 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6-1 Replacing Gun Contact Tip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6-2 Cleaning Gun Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6-3 Replacing Gun Liner . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
6-4 Replacing Switch/Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
6-5 Removing Gun From Welding Power Source . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6-6 Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6-7 Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
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SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING
Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions.
1-1. Symbol Usage
DANGER! – Indicates a hazardous situation which, if not
avoided, will result in death or serious injury. The possible
hazards are shown in the adjoining symbols or explained
in the text.
Indicates a hazardous situation which, if not avoided,
could result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in
the text.
NOTICE – Indicates statements not related to personal injury.
Indicates special instructions.
F
1-2. Arc Welding Hazards
The symbols shown below are used throughout this manual
to call attention to and identify possible hazards. When you
see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety
information found in the Principal Safety Standards, and in
welding power source Owner’s Manual. Read and follow all
Safety Standards.
Only qualified persons should install, operate, maintain,
and repair this equipment. A qualified person is defined as
one who, by possession of a recognized degree, certificate,
or professional standing, or who by extensive knowledge,
training and experience, has successfully demonstrated the
ability to solve or resolve problems relating to the subject
matter, the work, or the project and has received safety
training to recognize and avoid the hazards involved.
During operation, keep everybody, especially children,
away.
ELECTRIC SHOCK can kill.
l Always wear dry insulating gloves.
l Insulate yourself from work and ground.
l Do not touch live electrode or electrical parts.
cables.
l Turn off welding power source before changing contact tip or gun
parts.
l Keep all covers and handle securely in place.
is to sample for the composition and quantity of fumes and gases
to which personnel are exposed.
l Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.
l Replace worn, damaged, or cracked guns or
FUMES AND GASES can be
hazardous.
l Keep your head out of the fumes.
l Ventilate area, or use breathing device. The rec-
ommended way to determine adequate ventilation
MOVING PARTS can injure.
l Keep away from moving parts.
l Keep away from pinch points such as drive rolls.
This group of symbols means Warning! Watch Out! ELECTRIC
SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult
symbols and related instructions below for necessary actions to
avoid these hazards.
WELDING can cause fire or
explosion.
l Do not weld near flammable material.
l Do not weld on containers that have held combus-
tibles, or on closed containers such as tanks,
drums, or pipes unless they are properly prepared according to
AWS F4.1 (see Safety Standards).
l Watch for fire; keep extinguisher nearby.
l Read and understand the Safety Data Sheets (SDSs) and the
manufacturer’s instructions for adhesives, coatings, cleaners, consumables, coolants, degreasers, fluxes, and metals.
BUILDUP OF GAS can injure or kill.
l Shut off compressed gas supply when not in use.
l Always ventilate confined spaces or use approved
air-supplied respirator.
ARC RAYS can burn eyes and skin.
Arc rays from the welding process produce intense
visible and invisible (ultraviolet and infrared) rays
that can burn eyes and skin. Sparks fly off from the
weld.
l Wear an approved welding helmet fitted with a proper shade of fil-
ter lenses to protect your face and eyes from arc rays and sparks
when welding or watching (see ANSI Z49.1 and Z87.1 listed in
Safety Standards).
l Wear approved safety glasses with side shields under your
helmet.
l Use protective screens or barriers to protect others from flash,
glare, and sparks; warn others not to watch the arc.
l Wear body protection made from leather or flame-resistant cloth-
ing (FRC). Body protection includes oil-free clothing such as leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap.
HOT PARTS can burn.
l Allow gun to cool before touching.
l Do not touch hot metal.
l Protect hot metal from contact by others.
OM-291968 Page 1
Page 5
NOISE can damage hearing.
Noise from some processes or equipment can
damage hearing.
l Check for noise level limits exceeding those speci-
fied by OSHA.
l Use approved ear plugs or ear muffs if noise level is high.
l Warn others nearby about noise hazard.
WELDING WIRE can injure.
l Keep hands and body away from gun tip when trig-
ger is pressed.
1-3. California Proposition 65 Warnings
WARNING – This product can expose you to chemicals including lead, which are known to the state of California to
cause cancer and birth defects or other reproductive harm.
1-4. Principal Safety Sections
Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org.
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards In-
stitute. Website: www.ansi.org.
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1.
Website: http://www.aws.org.
National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1 from Compressed Gas Association. Website: www.cganet.com.
READ INSTRUCTIONS.
l Read and follow all labels and the Owner’s Manual
carefully before installing, operating, or servicing
unit. Read the safety information at the beginning
of the manual and in each section.
l Use only genuine replacement parts from the manufacturer.
l Perform installation, maintenance, and service according to the
Owner’s Manuals, industry standards, and national, state, and local codes.
For more information, go to www.P65Warnings.ca.gov.
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www.
csagroup.org.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.
Website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:
www.osha.gov.
SR7 2022–01
1-5. EMF Information
Electric current flowing through any conductor causes localized electric and magnetic fields (EMF). The current from arc welding (and allied processes including spot welding, gouging, plasma arc cutting,
and induction heating operations) creates an EMF field around the
welding circuit. EMF fields can interfere with some medical implants,
e.g. pacemakers. Protective measures for persons wearing medical
implants have to be taken. For example, restrict access for passers
−by or conduct individual risk assessment for welders. All welders
should use the following procedures in order to minimize exposure to
EMF fields from the welding circuit:
1. Keep cables close together by twisting or taping them, or using a
cable cover.
2. Do not place your body between welding cables. Arrange cables
to one side and away from the operator.
3. Do not coil or drape cables around your body.
4. Keep head and trunk as far away from the equipment in the welding circuit as possible.
5. Connect work clamp to workpiece as close to the weld as
possible.
6. Do not work next to, sit or lean on the welding power source.
7. Do not weld whilst carrying the welding power source or wire
feeder.
About Implanted Medical Devices:
Implanted Medical Device wearers should consult their doctor and the
device manufacturer before performing or going near arc welding,
spot welding, gouging, plasma arc cutting, or induction heating operations. If cleared by your doctor, then following the above procedures
is recommended.
OM-291968 Page 2
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SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT
UTILISATION
Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives
aux précautions de sécurité et au mode opératoire.
2-1. Symboles utilisés
DANGER! – Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des blessures graves. Les
dangers possibles sont montrés par les symboles joints
ou sont expliqués dans le texte.
Indique une situation dangereuse qui si on l’évite pas peut
donner la mort ou des blessures graves. Les dangers possibles sont montrés par les symboles joints ou sont expliqués dans le texte.
AVIS – Indique des déclarations pas en relation avec des blessures
personnelles.
Indique des instructions spécifiques.
F
2-2. Dangers relatifs au soudage à l'arc
Les symboles donnés ci-après sont utilisés dans tout le manuel pour attirer l’attention sur les dangers possibles et
pour indiquer le type de danger dont il s’agit. Quand on voit
le symbole, prendre garde et suivre les directives correspondantes pour éviter le danger. Les consignes de sécurité
présentées ci-après ne font que résumer l’information
contenue dans les Normes de sécurité principales, et dans
le Guide d’utilisation de la source de courant de soudage.
Lire et suivre toutes les Normes de sécurité.
L’installation, l’utilisation, l’entretien et les réparations ne
doivent être confiés qu’à des personnes qualifiées. Une personne qualifiée est définie comme celle qui, par la possession d’un diplôme reconnu, d’un certificat ou d’un statut
professionnel, ou qui, par une connaissance, une formation
et une expérience approfondies, a démontré avec succès sa
capacité à résoudre les problèmes liés à la tâche, le travail
ou le projet et a reçu une formation en sécurité afin de reconnaître et d’éviter les risques inhérents.
Au cours de l’utilisation, tenir toute personne à l’écart et
plus particulièrement les enfants.
UN CHOC ÉLECTRIQUE peut tuer.
l Porter toujours des gants secs et isolants.
l S’isoler de la pièce et de la terre.
l Ne jamais toucher une électrode ou des pièces
électriques sous tension.
l Remplacer les pistolets ou câbles de soudage qui sont endomma-
gés, usés ou craquelés.
l Mettre la soudeuse hors tension avant de remplacer un bec
contact ou des pièces de pistolet.
l S’assurer que tous les couvercles et poignées sont fermement
assujettis.
LES FUMÉES ET LES GAZ peuvent
être dangereux.
l Garder la tête hors des fumées.
l Aérer la zone de travail ou porter un appareil respi-
recommandé de procéder à un prélèvement pour la composition
et la quantité de fumées et de gaz auxquelles est exposé le
personnel.
l Lire et comprendre les fiches de données de sécurité et les ins-
tructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.
OM-291968 Page 3
ratoire. Pour déterminer la bonne ventilation, il est
Ce groupe de symboles veut dire Avertissement! Attention! DANGER DE CHOC ELECTRIQUE, PIECES EN MOUVEMENT, et PIECES CHAUDES. Reportez-vous aux symboles et aux directives cidessous afin de connaître les mesures à prendre pour éviter tout
danger.
Les PIÈCES MOBILES peuvent
causer des blessures.
l Ne pas s’approcher des organes mobiles.
l Ne pas s’approcher des points de coincement tels
que des rouleaux de commande.
Le SOUDAGE peut provoquer un
incendie ou une explosion.
l Ne pas souder à proximité de matériaux
inflammables
l Ne pas effectuer le soudage sur des conteneurs
fermés tels que des réservoirs, tambours, ou conduites, à moins
qu’ils n’aient été préparés correctement conformément à AWS
F4.1 (voir les Normes de Sécurité).
l Prendre garde aux incendies et toujours avoir un extincteur à
proximité.
l Lire et comprendre les fiches de données de sécurité et les ins-
tructions du fabricant concernant les adhésifs, les revêtements,
les nettoyants, les consommables, les produits de refroidissement, les dégraisseurs, les flux et les métaux.
LES ACCUMULATIONS DE GAZ
risquent de provoquer des blessures
ou même la mort.
l Fermer l’alimentation du gaz comprimé en cas de
non utilisation.
l Veiller toujours à bien aérer les espaces confinés ou se servir d’un
respirateur d’adduction d’air homologué.
LES RAYONS DE L’ARC peuvent
provoquer des brûlures dans les
yeux et sur la peau.
Le rayonnement de l’arc du procédé de soudage
génère des rayons visibles et invisibles intenses
(ultraviolets et infrarouges) susceptibles de provoquer des brûlures
dans les yeux et sur la peau. Des étincelles sont projetées pendant le
soudage.
l Porter un casque de soudage approuvé muni de verres filtrants
approprié pour protéger visage et yeux pendant le soudage (voir
ANSI Z49.1 et Z87.1 énuméré dans les normes de sécurité).
l Porter des lunettes de sécurité avec écrans latéraux même sous
votre casque.
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l Avoir recours à des écrans protecteurs ou à des rideaux pour pro-
téger les autres contre les rayonnements les éblouissements et
les étincelles ; prévenir toute personne sur les lieux de ne pas regarder l’arc.
l Porter une protection corporelle en cuir ou des vêtements ignifu-
ges (FRC). La protection du corps comporte des vêtements sans
huile, comme des gants de cuir, une chemise solide, des pantalons sans revers, des chaussures hautes et une casquette.
l Utiliser des bouche-oreilles ou des serre-tête antibruit approuvés
si le niveau de bruit est élevé.
l Avertir les personnes à proximité au sujet du danger inhérent au
bruit.
LES FILS DE SOUDAGE peuvent
provoquer des blessures.
LES PIÈCES CHAUDES peuvent
provoquer des brûlures.
l Laisser refroidir le pistolet avant de le toucher.
l Ne pas toucher d’objets métalliques chauds.
par les personnes à proximité.
l Abriter les objets métalliques contre tout contact
Le BRUIT peut endommager l’ouie.
Le bruit des processus et des équipements peut
affecter l’ouïe.
l Vérifier si les niveaux de bruit excèdent les limites
spécifiées par l’OSHA.
section.
l N’utiliser que des pièces de remplacement provenant du fabricant.
l Effectuer l’installation, l’entretien et toute intervention selon les
manuels d’utilisateurs, les normes nationales, provinciales et de
l’industrie, ainsi que les codes municipaux.
2-3. Proposition californienne 65 Avertissements
AVERTISSEMENT – Ce produit peut vous exposer à des produits chimiques tels que le plomb, reconnus par l’État de
Californie comme cancérigènes et sources de malformations ou d’autres troubles de la reproduction.
Pour plus d’informations, consulter www.P65Warnings.ca.gov.
2-4. Principales normes de sécurité
Safety in Welding, Cutting, and Allied Processes, American Welding
Society standard ANSI Standard Z49.1. Website: http://www.aws.org.
Safe Practice For Occupational And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards In-
stitute. Website: www.ansi.org.
Safe Practices for the Preparation of Containers and Piping for Welding and Cutting, American Welding Society Standard AWS F4.1.
Website: http://www.aws.org.
National Electrical Code, NFPA Standard 70 from National Fire Protection Association. Website: www.nfpa.org.
Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P1 from Compressed Gas Association. Website: www.cganet.com.
Safety in Welding, Cutting, and Allied Processes, CSA Standard
W117.2 from Canadian Standards Association. Website: www.
csagroup.org.
Standard for Fire Prevention During Welding, Cutting, and Other Hot
Work, NFPA Standard 51B from National Fire Protection Association.
Website: www.nfpa.org.
OSHA, Occupational Safety and Health Standards for General Industry, Title 29, Code of Federal Regulations (CFR), Part 1910.177 Subpart N, Part 1910 Subpart Q, and Part 1926, Subpart J. Website:
www.osha.gov.
SR7_fre 2022–01
l Éloigner les mains et le corps de la buse du pisto-
let après avoir appuyé sur la gâchette.
LIRE LES INSTRUCTIONS.
l Lire et appliquer les instructions sur les étiquettes
et le Mode d’emploi avant l’installation, l’utilisation
ou l’entretien de l’appareil. Lire les informations de
sécurité au début du manuel et dans chaque
2-5. Informations relatives aux CEM
Le courant électrique qui traverse tout conducteur génère des
champs électromagnétiques (CEM) à certains endroits. Le courant issu d’un soudage à l’arc (et de procédés connexes, y compris le soudage par points, le gougeage, le découpage plasma et les opérations
de chauffage par induction) crée un champ électromagnétique (CEM)
autour du circuit de soudage. Les champs électromagnétiques produits peuvent causer interférence à certains implants médicaux,
p. ex. les stimulateurs cardiaques. Des mesures de protection pour
les porteurs d’implants médicaux doivent être prises: par exemple,
des restrictions d’accès pour les passants ou une évaluation individuelle des risques pour les soudeurs. Tous les soudeurs doivent appliquer les procédures suivantes pour minimiser l’exposition aux CEM
provenant du circuit de soudage:
1. Rassembler les câbles en les torsadant ou en les attachant avec
du ruban adhésif ou avec une housse.
2. Ne pas se tenir au milieu des câbles de soudage. Disposer les câbles d’un côté et à distance de l’opérateur.
3. Ne pas courber et ne pas entourer les câbles autour de votre
corps.
4. Maintenir la tête et le torse aussi loin que possible du matériel du
circuit de soudage.
5. Connecter la pince sur la pièce aussi près que possible de la
soudure.
6. Ne pas travailler à proximité d’une source de soudage, ni s’asseoir
ou se pencher dessus.
7. Ne pas souder tout en portant la source de soudage ou le
dévidoir.
En ce qui concerne les implants médicaux :
Les porteurs d’implants doivent d’abord consulter leur médecin avant
de s’approcher des opérations de soudage à l’arc, de soudage par
points, de gougeage, du coupage plasma ou de chauffage par induction. Si le médecin approuve, il est recommandé de suivre les procédures précédentes.
OM-291968 Page 4
Page 8
SECTION 3 – SPECIFICATIONS
6 Minutes Welding 4 Minutes Resting
0
15
A or V
OR
Reduce Duty Cycle
Minutes
3-1. Information About Default Weld Parameters And Settings
NOTICE – Each welding application is unique. Although certain Miller Electric products are designed to determine and default to certain typical
welding parameters and settings based upon specific and relatively limited application variables input by the end user, such default settings are
for reference purposes only; and final weld results can be affected by other variables and application-specific circumstances. The appropriateness of all parameters and settings should be evaluated and modified by the end user as necessary based upon application-specific requirements. The end user is solely responsible for selection and coordination of appropriate equipment, adoption or adjustment of default weld
parameters and settings, and ultimate quality and durability of all resultant welds. Miller Electric expressly disclaims any and all implied warranties including any implied warranty of fitness for a particular purpose.
3-2. Specifications
Wire Diameter Range Cooling Method Duty Cycle Rating Weight
Flux Cored Wire: .030–.035 in.
(0.8–0.9 mm)
Solid Wire: .023–.030 in. (0.6–
0.8 mm)
Air Cooled Welding Gun For
GMAW And FCAW Welding
3-3. Duty Cycle And Overheating
60% Duty Cycle At 100A Using Mixed Gases
Overheating
60%: 70 A With Flux Cored Wire
60%: 90 A With CO
60%: 70 A With Mixed Gases
Duty Cycle is percentage of 10 minutes that unit can weld at rated
load without overheating.
NOTICE – Exceeding duty cycle can damage unit and void warranty.
Gas
Shielding
2
With 8 ft (2.4 m) Power Cable:
2.2 lb (1.0 kg)
OM-291968 Page 5
sduty1 5/95
Page 9
SECTION 4 – INSTALLATION
1 2
3 4
5 6
61063 / 161064 / 803 497‐B / 803 378‐A
4-1. Installing Gun Into Welding Power Source
A. Routing Gun Cables
If existing gun requires removal, see
F
Section 6-5.
Turn off and disconnect input
power.
Step 1. Open pressure assembly.
Step 2. Remove screws (4) from cover, and
remove cover from wire drive assembly.
Step 3. Insert gun cable through opening in
front panel. Route weld cable, trigger leads,
and gas hose through opening in drive
housing.
Step 4. Reinstall cable end into drive housing with retaining grooves inserted into the
two retaining ribs. Be sure to position gas
hose up and trigger leads down. Position liner in groove so that end is flush with back of
groove.
Step 5. Reinstall cover and secure with
screws (4).
Step 6. Remove wrapper from unit.
OM-291968 Page 6
Page 10
B. Making Connections Inside Unit
5
3
2
1
4
161063 / 161064 / 803 497‐B / 803 378‐A
If existing gun requires removal, see
F
Section 6-5.
Turn off and disconnect input
power.
Route wires, cable, and hose to avoid
F
contact with sharp edges, hot surfaces,
or moving parts.
Step 1. Route weld cable through opening in
baffle.
Step 2. Secure leads and hose with cable tie
(s).
Step 3. Connect gas hose to adapter (if unit
is not equipped with gas solenoid valve, secure hose to wiring harness).
Step 4. Connect 2 pin molex connector to
PC1.
Step 5.
Thread wire according to Section 4-3.
F
Connect weld cable to weld terminal.
Reinstall wrapper onto unit.
OM-291968 Page 7
Page 11
4-2. Installing Contact Tip And Nozzle
1
2
3
chippinghammer
crescent wrench
allen_wrench
NGO’s
tools/
flathead philips head wrench
allen_set
crescent wrench
Turn off and disconnect input power.
1 Nozzle
Remove nozzle.
2 Contact Tip
3 Tip Adapter
Thread welding wire through gun (see Section 4-3).
Slide contact tip over wire and tighten tip into
tip adapter.
Install 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. Contact tip will be
exposed approximately 7/16 in. (11.3 mm)
when installed properly.
MIG Nozzle
Use with solid or flux cored wire.
Push nozzle over contact tip and adapter until
it is seated onto adapter. End of contact tip
will be flush with end of nozzle when installed
properly.
804 241-A
OM-291968 Page 8
Page 12
4-3. Threading Welding Wire
6
1
2 3
5
4
61063 / 161064803 / 444-A / 205 837
6 in.
(150 mm)
1
2
3
4
5 6
7
WOOD
9
8
4 in.
(102 mm)
chippinghammer
crescent wrench
allen_wrench
NGO’s
tools/
flathead philips head wrench
allen_set
crescent wrench
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.
Step 1. Open pressure assembly.
Step 2. Pull and hold wire; cut off end.
Hold wire tightly to keep it from
F
unraveling.
Step 3. Push wire through guides into gun liner; continue to hold wire.
Step 4. Be sure that wire is positioned in
proper feed roll groove. Close and tighten
pressure assembly, and let go of wire.
Loosen knob completely, then rotate
F
pressure adjustment knob in a clockwise direction until drive roll is tight
against the welding wire. Adjust drive
roll pressure just tightly enough to
prevent wire from slipping against
drive roll during operation.
Step 5. Remove gun nozzle and contact tip.
Tip adapter may also require removal to
F
allow wire to feed out end of gun.
Step 6. Turn power on.
Step 7. Press gun trigger until wire comes
out of gun.
Step 8. Be sure that contact tip matches wire
diameter. Reinstall tip adapter, if applicable,
contact tip and nozzle.
Step 9. Feed wire to check drive roll pressure. Tighten knob enough to prevent slipping. Cut off wire. Close door.
OM-291968 Page 9
Page 13
5-1. Operating The Gun
804 240-A
1
SECTION 5 – OPERATION
1 Trigger Switch
When pressed, energized wire feeds and
shielding gas flows (if unit is equipped with
optional gas solenoid).
OM-291968 Page 10
Page 14
SECTION 6 – MAINTENANCE AND TROUBLESHOOTING
804 241-A
1
2
3
chippinghammer
crescent wrench
allen_wrench
NGO’s
tools/
flathead philips head wrench
allen_set
crescent wrench
6-1. Replacing Gun Contact Tip
Turn off and disconnect input
power.
1 Nozzle
Remove nozzle.
2 Contact Tip
3 Tip Adapter
Cut off welding wire at contact tip. Remove
contact tip from tip adapter, and install new
contact tip. Reinstall nozzle.
OM-291968 Page 11
Page 15
6-2. Cleaning Gun Liner
4
8 mm
1
2
3
1
3
2
4
161063 / 161064 / 804 241-B / 272 501-A / 803 497-B
chippinghammer
crescent wrench
allen_wrench
NGO’s
tools/
flathead philips head wrench
allen_set
crescent wrench
Turn off and disconnect input
power.
1 Nozzle
2 Contact Tip
3 Adapter
4 Head Tube
Step 1. Remove nozzle. Cut off wire at contact tip, and remove contact tip and tip
adapter.
Step 2. Open pressure assembly. Retract
wire from liner onto spool.
Hold wire tightly to keep it from unravel-
F
ing. Secure end of wire at spool.
Step 3. Remove screws (4) from cover, and
remove cover from wire drive assembly.
Step 4. Lay gun cable out straight, and blow
out liner.
Reassemble drive cover and gun in reverse
order from taking it apart.
Thread wire according to Section 4-3.
F
8 mm
OM-291968 Page 12
Page 16
6-3. Replacing Gun Liner
1
4
8 mm
1
2
3
3
6
2
4 5
7
61063 / 161064803 / 804 241‐A / 803 497‐B / 803 837‐A / 803 899‐A
8 mm
NGO’s
tools/
allen_wrench
NGO’s
tools/
flathead philips head wrench
allen_set
crescent wrench
chippinghammer
crescent wrench
A. Removing Gun Liner
Turn off and disconnect input
power.
1 Nozzle
2 Contact Tip
3 Adapter
4 Head Tube
Step 1. Remove nozzle. Cut off wire at contact tip, and remove contact tip and tip
adapter.
Step 2. Open pressure assembly. Retract
wire from liner onto spool.
Hold wire tightly to keep it from unravel-
F
ing. Secure end of wire at spool.
Step 3. Twist top and bottom handle locking
rings counterclockwise 1/4 turn. Slide bottom
ring down cable and top ring forward over
head tube. Separate gun handle halves.
Step 4. Loosen liner setscrew.
Step 5. Remove screws (4) from cover, and
remove cover from wire drive assembly.
Step 6. Loosen and remove retaining nut
from liner. Pull liner out of gun cable. If necessary, twist cable to ease removal.
Step 7. Remove black sleeving from end of
replacement liner.
OM-291968 Page 13
Install retaining nut on one end of liner. Lay
gun cable straight on a flat surface. Insert
bare end of liner (end without retaining nut)
into wire drive end of cable. Push liner toward gun. If necessary, twist cable to ease
installation.
8 mm / 10 mm
Page 17
B. Installing Gun Liner
1
3 4
5
6
7
13/16 in.
(21 mm)
8 mm
3/8 in (10 mm)
8 mm
2
8
161063 / 161064 / 804 241‐A / 803 497‐B / 803 837‐A / 803 899‐A
804 241-A / 804 242-A
1 2
Turn off and disconnect input
power.
Step 1. When liner exits cable at gun handle,
guide liner into head tube. Continue to push
liner until it exits end of head tube.
Step 2. Insert retaining nut into adapter, and
adjust liner stickout as shown. Tighten retaining nut. Reinstall cable end into drive
housing with retaining grooves inserted into
the two retaining ribs. Be sure to position gas
hose up. Position liner in groove so that end
is flush with back of groove, adjust if
necessary
Step 3. Reinstall cover onto wire drive assembly, and secure with screws (4).
Step 4. Be sure that cable is straight. Tighten
liner setscrew. Cut liner so that 3/8 in. (10
mm) sticks out of head tube. File down any
sharp points on liner after cutting to length.
Step 5. Reassemble gun by placing head
tube and cable into one half of handle. Be
sure trigger is properly installed into trigger
slot.
Step 6. Place other half of handle over head
tube and cable.
Step 7. Slide locking rings over top and bottom of handle, and secure by twisting rings
clockwise 1/4 turn.
Step 8. Thread welding wire through gun
(see Section 4-3). Reinstall adapter, contact
tip, and nozzle.
6-4. Replacing Switch/Handle
Turn off and disconnect input
power.
Step 1. Twist top and bottom handle locking
rings counterclockwise 1/4 turn. Slide bottom
ring down cable and top ring forward over
head tube. Separate gun handle halves.
Step 2. Disconnect switch leads and remove
switch. Connect leads to new switch (polarity
is not important). Be sure trigger is properly
installed into trigger slot. Reassemble in reverse order.
OM-291968 Page 14
Page 18
6-5. Removing Gun From Welding Power Source
1
3 4
5
2
10
4
8 mm
1
2
3
161063 / 161064 / 803 497-B / 803 378-A / 803 838-A
8
7
6
9
Turn off and disconnect input
power.
Step 1. Remove nozzle. Cut off wire at con-
tact tip, and remove contact tip and tip
adapter.
Step 2. Open pressure assembly. Retract
wire from liner onto spool.
Hold wire tightly to keep it from unravel-
F
ing. Secure end of wire at spool.
Step 3. Disconnect weld cable from weld
terminal.
Step 4. Remove screws (4) from cover, and
remove cover from wire drive assembly.
Step 5. Remove wrapper from unit.
Step 6. Pull weld cable through opening in
baffle.
Step 7. Remove leads and hose from cable
tie(s).
Step 8. Disconnect gas hose from adapter (if
unit is not equipped with gas solenoid valve,
loosen hose from wiring harness).
Step 9. Disconnect 2 pin molex connector
from PC1.
Step 10. Pull weld cable, trigger leads, and
gas hose through opening in drive housing.
Pull gun cable out through opening in front
panel. To reinstall gun see Section 4-1.
OM-291968 Page 15
Page 19
6-6. Routine Maintenance
= Check
= Change
= Clean
= Replace
* To be done by Factory Authorized Service Agent
R
eference
NGO’s
tools/
flathead philips head wrench
knife
heavy-duty workclamp light-duty workclamp wirecutter frontcutter
allen_set
steelbrush nutdriver
chippi
nghammer
imp
d
rill
greasegun
handream
f
ilterwrench
crescent wrench
Weld Terminals
Maintain more often
during severe conditions.
Reference
Disconnect power before maintaining.
Maintain more often during severe conditions.
F
ü = Check ◇ = Change m = Clean ¶ = Replace
Each
Spool
Of Wire
ü m Nozzle and contact tip m Blow out gun casing
Every 3
Months
¶Unreadable Labels m Weld Terminals ¶Damaged Gas Hose ü¶Weld Cables
ü¶Cords ü¶Gun Cables
*To be done by factory authorized service agent.
6-7. Troubleshooting
Trouble Remedy
Wire does not feed; wire is not energized; wire feeds unevenly.
Weld porosity. Remove weld spatter buildup in nozzle.
Wire feeding stops or does not feed
properly during welding.
Check contact tip. Check for kinks in gun cable.
Check contact tip. Check for kinks in gun cable. Blow out gun liner (see Section 6-2).
Check for secure gun trigger lead connections at PC1 (see Section 4-1).
Check, and if necessary, replace gun trigger switch (see Section 6-4).
Make sure inner head tube is tight in cable connector.
Check shielding gas flow/supply.
Straighten gun cable and/or replace damaged parts (see Section 6-2 or 6-3).
Adjust drive roll pressure (see Section 4-3).
Change to proper drive roll groove (see welding power source manual).
Readjust hub tension (see weld power source manual).
Clean or replace liner if dirty or plugged (see Section 6-2 or 6-3).
Replace drive roll or pressure bearing if worn or slipping (see welding power source manual).
OM-291968 Page 16
Page 20
SECTION 7 – PARTS LIST
1
5
2
7
4
3
7
6
Figure 7-1. H-9D Gun
Figure 7-1. H-9D Gun
Item No. Dia. Mkgs. Part No. Description Quantity
1 246372 Nozzle, Slip Type .500 Orf Flush 1
2 169716 Adapter, Contact Tip 1
3 225410 Switch, Trigger 1
4 210970 Liner, Monocoil .023/.035 Wire x 8ft 1
5 000067 Tip, Contact Scr .030 Wire x 1.125 1
6 226010 Nut, Liner Retainer 1
7 226080 Handle Assy 1
♦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.
OM-291968 Page 17
Page 21
Table 7–1. Contact Tip Options
HOBART PART NO. DESCRIPTION REMARKS
196134 Tip, contact scr .023 wire Pkg of 5
196131 Tip, contact scr .030 wire Pkg of 5
196132 Tip, contact scr .030 wire Pkg of 5
196137 Nozzle, slip type .500 orf flush Qty 1
196135 Adapter, contact tip Qty 1
WELD-IT PART NO. DESCRIPTION REMARKS
770174 Tip, Contact Scr .023 Wire Pkg of 5
770177 Tip, Contact Scr .030 Wire Pkg of 5
770180 Tip, Contact Scr .030 Wire Pkg of 5
OM-291968 Page 18
Page 22
OM-291968 Page 19
Page 23
Effective January 1, 2022
5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial num-
ber preface of NC or newer.
This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or
warranties expressed or implied.
Hobart products are serviced by Hobart or Miller Authorized Service Agencies.
LIMITED WARRANTY - Subject to the terms and
conditions below, Miller Electric Mfg. LLC, dba Hobart Welding Products, Appleton, Wisconsin, warrants to its original retail purchaser that new
Hobart equipment sold after the effective date of
this limited warranty is free of defects in material
and workmanship at the time it is shipped. THIS
WARRANTY IS EXPRESSLY IN LIEU OF ALL
OTHER WARRANTIES, EXPRESS OR IMPLIED,
INCLUDING THE WARRANTIES OF MERCHANTABILITYAND FITNESS.
Within the warranty periods listed below, Hobart/
Miller will repair or replace any warranted parts or
components that fail due to such defects in material or workmanship. Hobart/Miller must be notified
in writing within thirty (30) days of such defect or
failure, at which time Hobart/Miller will provide instructions on the warranty claim procedures to be
followed. Notifications submitted as online warranty claims must provide detailed descriptions of
the fault and troubleshooting steps taken to diagnose failed parts. Warranty claims that lack the required information as defined in the Miller Service
Operation Guide (SOG) may be denied by Miller.
Hobart/Miller shall honor warranty claims on warranted equipment listed below in the event of a defect within the warranty coverage time periods
listed below. Warranty time periods start on the delivery date of the equipment to the original retail
purchaser, or 12 months after the equipment is
shipped to a US or Canada distributor, or 18
months after the equipment is shipped to an international distributor, whichever occurs first.
1 5 Years — Parts and Labor
l Original Main Power Rectifiers only to include
SCRs, diodes, and discrete rectifier modules
in non-inverter products
l Reactors
l Stabilizers
l Transformers
2 3 Years — Parts and Labor Unless Specified
l Drive Systems
l Idle Module
l PC Boards
l Rotors, Stators and Brushes
l Solenoid Valves
l Switches and Controls
3 1 Year — Parts and Labor Unless Specified(90
days for industrial use)
l Accessories (Kits)
l Field Options (NOTE: Field options are cov-
ered for the remaining warranty period of the
product they are installed in, or for a minimum
of one year — whichever is greater.)
l HF Units
l MIG Flowgauge Regulators (No Labor)
l MIG Guns/TIG Torches
l Plasma Cutting Torches
l Remote Controls
l Replacement Parts (No labor) - 90 days
l Running Gear/Trailers
l Spoolguns
4 6 Months — Parts
l 12 Volt Automotive-Style Batteries
5 Engines and tires are warranted separately by
the manufacturer.
Hobart’s 5/3/1 Limited Warranty shall not apply to:
1. Consumable components; such as contact
tips, cutting nozzles, contactors, brushes,
relays, work station table tops and welding
curtains, or parts that fail due to normal
wear. (Exception: brushes and relays are
covered on all engine-driven products.)
2. Items furnished by Hobart/Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the
manufacturer’s warranty, if any.
3. Equipment that has been modified by any party
other than Hobart/Miller, or equipment that has
been improperly installed, improperly operated
or misused based upon industry standards, or
equipment which has not had reasonable and
necessary maintenance, or equipment which
has been used for operation outside of the
specifications for the equipment.
4. Defects caused by accident, unauthorized repair, or improper testing.
HOBART PRODUCTS ARE INTENDED FOR
COMMERCIAL AND INDUSTRIAL USERS
TRAINED AND EXPERIENCED IN THE USE AND
MAINTENANCE OF WELDING EQUIPMENT.
The exclusive remedies for warranty claims are, at
Hobart’s/Miller’s option, either: (1) repair; or (2) replacement; or, if approved in writing by Hobart/Miller, (3) the pre-approved cost of repair or
replacement at an authorized Hobart/Miller service
station; or (4) payment of or credit for the purchase
price (less reasonable depreciation based upon
use). Products may not be returned without
Hobart’s/Miller’s written approval. Return shipment
shall be at customer’s risk and expense.
The above remedies are F.O. B. Appleton, WI, or
Hobart’s/Miller’s authorized service facility. Transportation and freight are the customer’s responsibility. TO THE EXTENT PERMITTED BY LAW,
THE REMEDIES HEREIN ARE THE SOLE AND
EXCLUSIVE REMEDIES REGARDLESS OF THE
LEGAL THEORY. IN NO EVENT SHALL HOBART/MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR
CONSEQUENTIAL DAMAGES (INCLUDING
LOSS OF PROFIT) REGARDLESS OF THE LEGAL THEORY. ANY WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY,
GUARANTY, OR REPRESENTATION, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR
PURPOSE, ARE EXCLUDED AND DISCLAIMED
BY HOBART/MILLER.
Some US states do not allow limiting the duration
of an implied warranty or the exclusion of certain
damages, so the above limitations may not apply
to you. This warranty provides specific legal rights,
and other rights may be available depending on
your state. In Canada, some provinces provide additional warranties or remedies, and to the extent
the law prohibits their waiver, the limitations set out
above may not apply. This Limited Warranty provides specific legal rights, and other rights may be
available, but may vary by province.
Warranty Questions?
Call 1-800-332-3281
8 AM – 5 PM EST
Service
You 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 1-800332-3281. The expertise of the distributor and
Hobart is there to help you, every step of the
way.
Assistance
Visit the Hobart website:
www.HobartWelders.com
Page 24
Owner’s Record
Please complete and retain with your personal records.
Model Name Serial/Style Number
Purchase Date
Distributor
Address
City
State Zip
(Date which equipment was delivered to original customer.)
For Service
Contact a DISTRIBUTOR or SERVICE AGENCY near you.
Always provide Model Name and Serial/Style Number.
Contact your Distributor for:
Welding Supplies and Consumables
Options and Accessories
Personal Protective Equipment (PPE)
Contact the Delivering Carrier to:
Service and Repair Replacement Parts
Training (Schools, Videos, Books)
Welding Process Handbooks
To locate a Distributor or Service Agency visit
www.millerwelds.com or call 1-800-4-A-Miller
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.
Miller Electric Mfg. LLC
An Illinois Tool Works Company
1635 West Spencer Street
Appleton, WI 54914 USA
For Assistance:
Call 1-800-332-3281
ORIGINAL INSTRUCTIONS – PRINTED IN USA © Miller Electric Mfg. LLC 2022-08
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