HOBART H-9 Gun Flux Cored FCAW Welding Owner’s Manual

HOBART H-9 Gun Flux Cored FCAW Welding

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

WARNING
This product, when used for welding or cutting, produces fumes or gases that 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

SAFETY PRECAUTIONS FOR FCAW AND GMAW WELDING GUNS – READ BEFORE USING

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.
• Marks a special safety message.
• This means NOTE; not safety related.

FCAW And GMAW Gun Hazards

PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH. KEEP CHILDREN AWAY. PACEMAKER WEARERS KEEP AWAY 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.

HAVE ALL INSTALLATION, OPERATION, MAINTENANCE, AND REPAIR WORK PERFORMED ONLY BY QUALIFIED PEOPLE.

EMF INFORMATION

NOTE

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

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 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 to draw definite conclusions about questions of possible risk or to offer clear science-based advice on strategies to minimize or avoid potential risks.”

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 the work clamp to the 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.

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

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.

INSTALLATION

Specifications

• Air-Cooled Welding Gun For FCAW And GMAW Welding
• Note: Using gasless flux cored wire reduces the gun duty cycle.
• 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 CO2 Shielding Gas
• 60%: 100 A With Mixed Gases
• Weight With 8 ft (2.4 m) Power Cable: 2.2 lb (1.0 kg)

Duty Cycle And Overheating

Installing Gun Into Welding Power Source

Threading Welding Wire

1. Wire Spool
2. Welding Wire
3. Inlet Wire Guide
4. Pressure Adjustment Knob
5. Drive Roll
6. Gun Cable

Lay the gun cable out straight.

OPERATION

1. Trigger Switch
   When pressed, energized wire feeds and shielding gas flows.

MAINTENANCE

Replacing Gun Contact Tip

Turn off the welding power source.

1. Nozzle
   Remove nozzle.

2. Contact Tip

3. Tip Adapter

Cut off the welding wire at the contact tip.
Remove the contact tip from the tip adapter, and install a new contact tip. Reinstall nozzle.

Cleaning Gun Liner

Replacing Gun Liner

Replacing Liner O-Ring

Replacing Switch And/Or Head Tube

Removing Gun From Welding Power Source

Routine Maintenance

Troubleshooting

Trouble| Remedy
Wire does not feed; wire is not energized; wire feeds unevenly.| Check contact tip. Check for kinks in the gun cable.
Check contact tip. Check for kinks in the gun cable. Blow out gun liner (see Section 5-2).
Check for secure gun trigger lead connections at PC1 (see Section 3-3).
Check, and if necessary, replace the gun trigger switch (see Section 5-5).
Weld porosity.| Remove the weld spatter buildup in the nozzle.
Make sure the inner head tube is tight in the cable connector.
Check shielding gas flow/supply.
Replace liner O-ring (see Section 5-4).
Wire feeding stops or does not feed properly during welding.| Straighten gun cable and/or replace damaged parts (see Section 5-2 or 5-3).
Adjust drive roll pressure (see Section 3-4).
Change to proper drive roll groove (see welding power source manual).
Readjust hub tension (see weld power source manual).
Clean or replace the liner if dirty or plugged (see Section 5-2 or 5-3).
Replace the drive roll or pressure bearing if worn or slipping (see welding power source manual).

PARTS LIST

OPTIONAL
To maintain the factory’s original performance of your equipment, use only the Manufacturer’s Suggested Replacement Parts. Model and serial number are required when ordering parts from your local distributor.

Table 6-1. Contact Tip Options

Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual.

WARRANTY

Effective January 1, 2002
5/3/1 WARRANTY applies to all Handler 135 and 175 models, Airforce 250, 250A, and 375 models, and Champion 10,000 models. This warranty also applies to the Beta-Mig 1800, Champ 1435, 2060, and 8500 models, Ironman 250, Stickmate models, Tigmate models, and HSW-15 and HSW-25 spot welder models effective with Serial No. KK200262 and 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, Hobart/Miller Electric Mfg. Co., 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 by Hobart. THIS WARRANTY IS EXPRESSLY IN PLACE OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND 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.
Hobart/Miller shall honour warranty claims on warranted equipment listed below in the event of such a failure within the warranty periods. All warranty periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor.

1. 5 Years — Parts and Labor

   • Original Main Power Rectifiers
   • Transformers
   • Stabilizers
   • Reactors
   • Rotors, Stators and Brushes

2. 3 Years — Parts and Labor

   • Drive Systems
   • PC Boards
   • Idle Module
   • Solenoid Valves
   • Switches and Controls
   • Spot Welder Transformer

3. 1 Year — Parts and Labor Unless Specified
   (90 days for industrial use)

   • Motor-Driven Guns
   • MIG Guns/TIG Torches
   • Relays
   • Contactors
   • Regulators
   • Water Coolant Systems
   • Flowgauge and Flowmeter Regulators (No Labor)
   • HF Units
   • Running Gear/Trailers
   • Plasma Cutting Torches
   • Remote Controls
   • Replacement Parts (No labor)
   • Accessories
   • Field Options
     (NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

4. Engines, batteries and tyres 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, slip rings, drive rolls, gas diffusers, plasma torch tips and electrodes, weld cables, tongs and tips, or parts that fail due to normal wear.
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, equipment that has been improperly installed, improperly operated or misused based upon industry standards, equipment that has not had reasonable and necessary maintenance, or equipment that has been used for operation outside of the specifications for the equipment.

HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.
In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Hobart’s/Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Hobart/Miller in appropriate cases, (3) the reasonable 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 actual use) upon return of the goods at customer’s risk and expense. Hobart’s/Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Hobart/Miller authorized service facility as determined by Hobart/Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.
TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL HOBART/MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.
ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, to ANY AND ALL EQUIPMENT FURNISHED BY HOBART/MILLER IS EXCLUDED AND DISCLAIMED BY Hobart/Miller.
Some states in the U.S.A. do not allow limitations on how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available but may vary from state to state.
In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

Warranty Questions?

• Call
• 1-877-HOBART1
• for your local
• Hobart distributor.
• Hobart retail 6/02

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 1-800-332-3281. The expertise of the distributor and Hobart is there to help you, every step of the way.

Please complete and retain your records

• Model Name…………………………………. Serial/Style Number……………………………………………………………….
• Purchase Date………………………………. (Date which equipment was delivered to the original customer.)……….
• Distributor…………………………………………………………………………………….
• Address…………………………………………………………………………………………..
• City…………………………………………………………………………………………….
• State…………………………………… Zip………………………………………………….

Resources Available

Always provide the Model Name and Serial/Style Number.

To locate a Distributor, retail or service location

• Call 1-877-Hobart1 or visit our website at www.HobartWelders.com.
• For technical assistance:
• Call 1-800-332-3281

Contact your Distributor for

• Welding Supplies and Consumables
• Options and Accessories
• Personal Safety Equipment
• Service and Repair
• Replacement Parts
• Training (Schools, Videos, Books)
• Technical Manuals (Servicing Information and Parts)
• Circuit Diagrams
• Welding Process Handbooks

Contact the Delivering Carrier to

• File a claim for loss or damage during shipment.
• For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s
• Transportation Department.

CONTACT

Hobart Welding Products

• An Illinois Tool Works Company
• 600 West Main Street
• Troy, OH 45373 USA

For Technical Assistance:

• Call1-800-332-3281
• For Literature Or Nearest Dealer:
• Call 1-877-Hobart1
• www.HobartWelders.com.

References

• HobartWelders | Welders, Welding Equipment, Accessories & Gear
• Manual-Hub.com – Free PDF manuals!

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