Hobart H-9B Gun, Owner'S Manual

Page 1: ...OM 947 212 149G 2010 05 Processes Arc Welding Power Source And Wire Feeder Description MIG GMAW Welding Optional Flux Cored FCAW Welding Handler 125 And H 9B Gun R File Flux Cored FCAW ...

Page 2: ...oducts 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 pa...

Page 3: ...CIFICATIONS 11 4 1 Specifications 11 4 2 Duty Cycle And Overheating 12 4 3 Volt Ampere Curves 12 SECTION 5 INSTALLATION 13 5 1 Installing Work Clamp 13 5 2 Process Polarity Table 14 5 3 Changing Polarity 14 5 4 Installing Gas Supply 15 5 5 Installing Wire Spool And Adjusting Hub Tension 16 5 6 Serial Number And Rating Label Location 17 5 7 Selecting A Location And Connecting Input Power For 115 VA...

Page 4: ... 7 Poor Weld Bead Characteristics 36 9 8 Good Weld Bead Characteristics 36 9 9 Troubleshooting Excessive Spatter 37 9 10 Troubleshooting Porosity 37 9 11 Troubleshooting Excessive Penetration 37 9 12 Troubleshooting Lack Of Penetration 38 9 13 Troubleshooting Incomplete Fusion 38 9 14 Troubleshooting Burn Through 38 9 15 Troubleshooting Waviness Of Bead 39 9 16 Troubleshooting Distortion 39 9 17 T...

Page 5: ...ds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant volt...

Page 6: ...ess they are properly prepared according to AWS F4 1 see Safety Standards D Do not weld where the atmosphere may contain flammable dust gas or liquid vapors such as gasoline D Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards D Do not use welder to thaw fr...

Page 7: ...anels covers and guards closed and securely in place D Have only qualified persons remove doors panels covers or guards for maintenance and troubleshooting as necessary D Reinstall doors panels covers or guards when maintenance is finished and before reconnecting input power READ INSTRUCTIONS D Read and follow all labels and the Owner s Manual carefully before installing operating or servicing uni...

Page 8: ...eb site www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association Quincy MA 02269 phone 1 800 344 3555 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office S...

Page 9: ...ant électrique s avère nécessaire se servir de la fonction de télécommande si l appareil en est équipé D D autres consignes de sécurité sont nécessaires dans les condi tions suivantes risques électriques dans un environnement humideou si l on porte des vêtements mouillés sur des structures métalliquestelles que sols grilles ou échafaudages en position coincée comme assise à genoux ou couchée ou s ...

Page 10: ...u laine et des bottes de protection LE SOUDAGE peut provoquer un incendie ou une explosion Le soudage effectué sur des conteneurs fermés tels que des réservoirs tambours ou des conduites peut provoquer leur éclatement Des étincelles peuvent être projetées de l arc de soudure La projection d étincelles des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures Le cont...

Page 11: ... D Utiliser les équipements corrects les bonnes procédures et suffi samment de personnes pour soulever et déplacer les bouteilles D Lire et suivre les instructions sur les bouteilles de gaz comprimé l équipement connexe et le dépliant P 1 de la CGA Compressed Gas Association mentionné dans les principales normes de sécu rité 2 3 Dangers supplémentaires en relation avec l installation le fonctionne...

Page 12: ...te et utiliser une terre et un blindage pour réduire les interférences éventuelles LE SOUDAGE À L ARC risque de provoquer des interférences D L énergie électromagnétique risque de provoquer des interférences pour l équipement électroniquesensible tel que les ordinateurs et l équipement commandé par ordinateur tel que les robots D Veiller à ce que tout l équipement de la zone de soudage soit compat...

Page 13: ...5 Chicago est 312 353 2220 site Internet www osha gov U S Consumer Product Safety Commission CPSC 4330 East West Highway Bethesda MD 20814 téléphone 301 504 7923 site inter net www cpsc gov Applications Manual for the Revised NIOSH Lifting Equation The National Institute for Occupational Safety and Health NIOSH 1600 Clifton Rd Atlanta GA 30333 télé hone 1 800 232 4636 site internet www cdc gov NIO...

Page 14: ...OM 947 Page 10 ...

Page 15: ...Circuit Voltage DC Amperes Input at Rated Load Output 115 V 60 Hz Single Phase KVA KW Weight W Gun Overall Dimensions 85 A 17 5 Volts DC 20 Duty Cycle 60 A 20 Volts DC 20 Duty Cycle 30 125 26 20 15 2 90 2 20 2 50 1 77 50 lb 22 7 kg Length 16 7 8 in 429 mm Width 9 7 8 in 251 mm Height 12 1 8 in 308 mm Wire Type And Dia Flux Cored Solid Stainless Wire Feed Speed Range 030 035 in 0 8 0 9 mm 024 030 i...

Page 16: ...un and void warranty Overheating 0 15 A or V OR Reduce Duty Cycle Minutes 20 duty cycle at 85 amps 2 Minutes Welding 8 Minutes Resting Output Amperes Duty Cycle 1 4 10 20 40 60 100 2 6 80 8 10 20 40 60 80 100 200 135 4 3 Volt Ampere Curves The volt ampere curves show the minimum and maximum voltage and amperage output capabilities of the welding power source Curves of other settings fall between t...

Page 17: ...nsulator Grip Slide one insulating grip over work cable before connecting to clamp Slide insulating grips over handles Ref 802 456 Connection hardware must be tightened with proper tools Do not just hand tighten hardware A loose electrical connection will cause poor weld performance and excessive heating of the work clamp 1 2 3 4 5 Tools Needed 7 16 in 6 7 16 in ...

Page 18: ...inal GMAW Solid wire with shielding gas DCEP Reverse polarity Connect to positive out put terminal Connect to negative output terminal Unit must have MIG conversion kit 195 158 installed 5 3 Changing Polarity 1 Lead Connections For Direct Current Electrode Negative DCEN 2 Lead Connections For Direct Current Electrode Positive DCEP Always read and follow wire manufacturer s recommended po larity an...

Page 19: ... gauge face is vertical for viewing and adjusting 5 Regulator Flowmeter Gas Hose Connection 6 Welding Power Source Gas Hose Connection Connect gas hose between regulator flowmetergas hose connection and fitting on rear of welding power source 7 Flow Adjust Turn flow adjust screw to increase or decrease gas flow Flow rate should be set when gas is flowing through welding power source and welding gu...

Page 20: ...set 1 2 in Tools Needed Ref 802 971 C 803 012 803 013 B Installing 8 in 203 mm Wire Spool Installing 4 in 102 mm Wire Spool When a slight force is needed to turn spool tension is set Retaining ring used with 8 in 203 mm spool only Adapter used with 8 in 203 mm spool only Only applies to units equipped with optional hub kit ...

Page 21: ...ecting A Location And Connecting Input Power For 115 VAC Model 1 Grounded Receptacle A 115 volt 20 ampere individual branch circuit protected by time de lay fuses or circuit breaker is re quired 2 Plug From Unit Select extension cord of 12 AWG for up to 50 ft 15 m or 10 AWG for 50 up to 100 ft 30 m Special installation may be required where gasoline or volatile liquids are present see NEC Article ...

Page 22: ... Flux Nozzle MIG Nozzle Use with flux cored wire only Narrow design allows access in tight spaces and provides better visibility of puddle during welding Use with solid or flux cored wire 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 Push nozzle over contact tip and adapter until it is seat...

Page 23: ...ent slipping Cut off wire Close door Press gun trigger until wire comes out of gun 2 Turn power on INPUT POWER 6 in 150 mm Tighten Tighten Be sure that wire is positioned in proper feed roll groove Close and tighten pressure assembly and let go of wire Be sure that contact tip matches wire diameter Reinstall tip adapter if applicable contact tip and nozzle 3 5 4 Tip adapter may also require remova...

Page 24: ...switch under load Switch must click into detent position for weld output 2 Wire Feed Control Use control to select a wire feed speed As Voltage switch setting in creases wire speed range also in creases see weld setting label in welding power source or Section 6 3 as applicable 3 Power Switch Ref 229 999 A 1 2 3 6 2 Operating The Gun Ref 804 240 A 1 Trigger Switch When pressed energized wire feeds...

Page 25: ...OM 947 Page 21 Notes ...

Page 26: ...OM 947 Page 22 6 3 Weld Parameter Chart ...

Page 27: ...OM 947 Page 23 210 428 ...

Page 28: ...bels l Repair Or Replace Cracked Weld Cable Clean And Tighten Weld Terminals 6 Months OR Inside Unit 7 2 Overload Protection 803 379 A 1 SupplementaryProtector CB1 CB1 protects unit from overload If CB1 opens unit shuts down Reset supplementary protector 1 7 3 Drive Motor Protection Drive motor protection circuit protects drive motor from overload If drive motor becomes inoperative release gun tri...

Page 29: ...hing Reinstall plate and tighten screws 7 Retaining Knob Rotate counterclockwise and remove knob 8 Drive Roll The drive roll consists of two different sized grooves Each side is stamped with the proper size Select the groove that matches the wire size on the wire spool Install drive roll onto motor shaft so that correct groove size stamp faces out away from drive housing 9 Retaining Knob Opening I...

Page 30: ... Tools Needed Ref 804 241 A Turn Off power before replacing contact tip 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 1 2 3 ...

Page 31: ...Remove nozzle Cut off wire at contact tip and remove contact tip and tip adapter Thread wire according to Section 5 9 Reassemble drive cover and gun in reverse order from taking it apart Open pressure assembly Retract wire from liner onto spool Hold wire tightly to keep it from unraveling Secure end of wire at spool Remove screws 3 from cover and remove cover from wire drive assembly 8 mm 1 2 3 ...

Page 32: ... cable and top ring forward over head tube Separate gun handle halves Loosen liner setscrew Loosen and remove retaining nut from liner Pull liner out of gun cable If necessary twist cable to ease removal Turn Off welding power source 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 Pus...

Page 33: ... liner after cutting to length 3 8 in 10 mm Reassemble gun by placing head tube and cable into one half of handle Be sure trigger is properly installed into trigger slot Thread welding wire through gun see Section 5 9 Reinstall adapter contact tip and nozzle Reinstall cover onto wire drive assembly and secure with screws 3 Insert retaining nut into adapter and adjust liner stickout as shown Tighte...

Page 34: ...are if necessary see Section 5 1 Replace contact tip see Section 7 5 Check for proper polarity connections see Section 5 3 Low weld output Connect unit to proper input voltage or check for low line voltage Place voltage switch in desired position see Section 6 1 If using an extension cord check that wire size and length is the proper size for power rating of welding power source see Section 4 1 El...

Page 35: ...OM 947 Page 31 SECTION 8 ELECTRICAL DIAGRAM 230 950 A Figure 7 1 Circuit Diagram ...

Page 36: ...ssible Wire Feeder Power Source fcaw 1 2003 Ref 803 444 A Self ShieldingFlux Core Wire Workpiece Gun Work Clamp 9 2 Typical MIG Process Connections Weld current can damage electronic parts in vehicles Disconnect both battery cables before welding on a vehicle Place work clamp as close to the weld as possible Wire Feeder Power Source Regulator Flowmeter Gas Hose Shielding Gas light mig 5 967 Ref 80...

Page 37: ...in Recommendation Wire Speed Approx 1 8 or 0 125 in 0 001 in 1 ampere 0 125 in 125 A Wire Size Amperage Range 0 023 in 0 030 in 0 035 in Select Wire Size Wire Size 0 023 in 0 030 in 0 035 in 3 5 in per ampere 2 in per ampere 1 6 in per ampere Select Wire Speed Amperage 125 A based on 1 8 in material thickness ipm inches per minute Low voltage wire stubs into work High voltage arc is unstable spatt...

Page 38: ...n 13 mm past end of nozzle and tip of wire is positioned correctly on seam 1 Hold Gun and Control Gun Trigger 2 Workpiece 3 Work Clamp 4 Electrode Extension Stickout 1 4 to 1 2 in 6 To 13 mm 5 Cradle Gun and Rest Hand on Workpiece 2 3 5 4 90 90 0 15 45 45 1 0 15 S 0421 A End View of Work Angle Side View of Gun Angle GROOVE WELDS End View of Work Angle Side View of Gun Angle FILLET WELDS ...

Page 39: ...and voltage Slow FILLET WELD ELECTODE EXTENSIONS STICKOUT ELECTRODE EXTENSIONS STICKOUT GUN ANGLES AND WELD BEAD PROFILES 10 10 GUN TRAVEL SPEED S 0634 Push Perpendicular Drag or Pull Short Normal Long Short Normal Long Normal Fast Electrode directed ahead of bead Electrode pointed back into bead Direction Of Welding The Drag or Pull technique is generally recommended when welding with flux cored ...

Page 40: ... Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode S 0054 A 3 1 2 9 7 Poor Weld Bead Characteristics 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 S 0053 A 9 8 Good Weld Bead Characteristics 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer f...

Page 41: ...nsufficient shielding gas at welding arc Increase flow of shielding gas at regulator flowmeter and or prevent drafts near welding arc Remove spatter from gun nozzle Check gas hoses for leaks Place nozzle 1 4 to 1 2 in 6 13 mm from workpiece Hold gun near bead at end of weld until molten metal solidifies Wrong gas Use welding grade shielding gas change to different gas Dirty welding wire Use clean ...

Page 42: ...n Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead S 0637 Possible Causes Corrective Actions Workpiece dirty Remove all grease oil moisture rust paint undercoating and dirt from work surface before welding Insufficient heat input Select higher voltage range and or adjust wire feed speed Improper welding technique Place stringer bead in proper loc...

Page 43: ...amped on wire feed rolls replace to match wire size and type if necessary Wire spool brake pressure too high Decrease brake pressure on wire spool Restriction in the gun and or assembly Check and replace cable gun tip adapter and contact tip if damaged Check size of contact tip and cable liner replace if necessary Wire curling up in front of the wire feed rolls bird nesting Too much pressure on wi...

Page 44: ...N 10 PARTS LIST Hardware is common and not available unless listed 803 446 B 1 2 3 4 5 6 6 7 8 9 10 11 12 13 14 15 16 17 18 19 42 20 21 22 23 24 25 26 27 28 29 32 30 31 33 34 35 36 37 38 39 40 41 43 Figure 9 1 Main Assembly ...

Page 45: ...otary 1 23 211 338 KNOB pointer 1 24 207 079 KNOB pointer 1 25 210 398 BUSHING snap in 1 26 209 412 BUSHING snap in 500 dia 2 27 209 532 DRIVE assy wire 1 28 193 144 INSULATOR output stud 1 29 202 726 ADAPTER spool hub 1 30 202 998 SPRING cprsn 1 31 204 608 NUT 1 32 203 072 WASHER 1 33 195 157R H 9B GUN 8 ft 023 035 1 34 210 428 LABEL door chart 1 35 204 036 LABEL warning 1 36 208 820 CLAMP work 1...

Page 46: ...iner retainer 1 7 226 080 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 Table 9 1 Contact Tip Options HOBART PART NO DESCRIPTION REMARKS 196 134 Tip contact scr 023 wire Pkg of 5 196 131 Tip contact scr 030 wire Pkg of 5 196 13...

Page 47: ...9 SCREW torch cover 1 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 Table 9 2 Options PART NO DESCRIPTION REMARKS 194 776 Small Running Gear Cylinder Rack For One Small Gas Cylinder 75 lb 34 kg 195 158 MIG Conversion Kit For Gas Metal Arc Welding GMA...

Page 48: ...Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 49: ...Notes ...

Page 50: ...Notes ...

Page 51: ... 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...

Page 52: ...utor retail or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com 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 ...