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  4. H-10 Gun
  5. Owner's manual

MAC TOOLS H-10 Gun Owner's manual

Manual is about: Arc Welding Power Source And Wire Feeder

Summary of H-10 Gun

  • Page 1

    Mw 185 plus and h-10 gun ® for warranty claims and technical support, contact: milweld inc., national distributor p.O. Box 338, hortonville, wi 54944-0338 tel 920-779-0916 fax 920-779-0924 processes description mig (gmaw) welding flux cored (fcaw) welding arc welding power source and wire feeder om-...

  • Page 3: Table of Contents

    Table of contents section 1 − safety precautions - read before using 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 4: Table of Contents

    Table of contents section 9 − mig welding (gmaw) guidelines 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Typical mig process connections 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ....

  • Page 5

    Om-230 852 page 1 section 1 − safety precautions - read before using som _3/05 y warning: protect yourself and others from injury — read and follow these precautions. 1-1. Symbol usage means warning! Watch out! There are possible hazards with this procedure! The possible hazards are shown in the adj...

  • Page 6

    Om-230 852 page 2 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. Arc rays can burn eyes and skin. D wear an approved welding helmet fitted with a proper shade of fil- ter lenses to pro...

  • Page 7

    Om-230 852 page 3 1-3. Additional symbols for installation, operation, and maintenance fire or explosion hazard. D do not install or place unit on, over, or near combustible surfaces. D do not install unit near flammables. D do not overload building wiring − be sure power supply system is properly s...

  • Page 8

    Om-230 852 page 4 1-5. Principal safety standards safety in welding, cutting, and allied processes, ansi standard z49.1, from global engineering documents (phone: 1-877-413-5184, website: www.Global.Ihs.Com). Recommended safe practices for the preparation for welding and cut- ting of containers and ...

  • Page 9

    Om-230 852 page 5 section 2 − consignes de sÉcuritÉ − lire avant utilisation fre_som _3/05 y avertissement : se protéger et protéger les autres contre le risque de blessure — lire et respecter ces consignes. 2-1. Symboles utilisés symbole graphique d’avertissement ! Attention ! Cette pro- cédure com...

  • Page 10

    Om-230 852 page 6 le rayonnement de l’arc du procédé de soudage génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provo- quer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. Les rayons d’arc peuvent entraî- ne...

  • Page 11

    Om-230 852 page 7 2-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance risque d’incendie ou d’explo- sion. D ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces inflammables. D ne pas installer l’appareil à proximité de produits inflammable...

  • Page 12

    Om-230 852 page 8 2-5. Principales normes de sécurité safety in welding, cutting, and allied processes, ansi standard z49.1, de global engineering documents (téléphone : 1-877-413-5184, site in- ternet : www.Global.Ihs.Com). Recommended safe practices for the preparation for welding and cut- ting of...

  • Page 13: Section 3 − Definitions

    Om-230 852 page 9 section 3 − definitions 3-1. Symbols and definitions a amperage v voltage hz hertz negative positive direct current (dc) single phase input output voltage input off on do not switch while welding gas metal arc welding (gmaw) wire feed flux cored arc welding (fcaw) section 4 − speci...

  • Page 14

    Om-230 852 page 10 4-2. Duty cycle and overheating duty cycle is percentage of 10 minutes that unit can weld at rated load without overheating. If unit overheats, thermostat(s) opens, output stops, and cooling fan runs. Wait fifteen minutes for unit to cool. Reduce amperage or duty cycle before weld...

  • Page 15: Section 5 − Installation

    Om-230 852 page 11 section 5 − installation 5-1. Installing welding gun 804 621-a 1 drive assembly 2 gun securing thumbscrew 3 gun end loosen thumbscrew. Insert end through opening until it bottoms against drive assembly. Tighten thumbscrew. Welding gun must be inserted completely to prevent leakage...

  • Page 16

    Om-230 852 page 12 5-2. Installing work clamp 1 insulating sleeves 2 nut 3 work cable from unit slide one insulating sleeve over work cable before connecting to clamp. 4 work clamp 5 screw 6 work clamp tabs bend tabs around work cable. Slide insulating sleeves over handles. 802 456-a . Connection ha...

  • Page 17

    Om-230 852 page 13 5-3. Process/polarity table process polarity cable connections process polarity cable to gun cable to work gmaw − solid wire with shield- ing gas dcep − reverse polarity connect to positive (+) out- put terminal connect to negative (−) output terminal fcaw − self-shielding wire − ...

  • Page 18

    Om-230 852 page 14 5-5. Installing gas supply obtain gas cylinder and chain to running gear, wall, or other stationary support so cylinder cannot fall and break off valve. 1 cap 2 cylinder valve remove cap, stand to side of valve, and open valve slightly. Gas flow blows dust and dirt from valve. Clo...

  • Page 19

    Om-230 852 page 15 5-6. Selecting a location and connecting input power y special installation may be required where gasoline or volatile liquids are present − see nec article 511 or cec section 20. Y installation must meet all na- tional and local codes − have only qualified persons make this insta...

  • Page 20

    Om-230 852 page 16 5-7. Electrical service guide input voltage 230 input amperes at rated output 20.5 max recommended standard fuse or circuit breaker rating in amperes circuit breaker 1 , time-delay 2 25 normal operating 3 30 min input conductor size in awg 14 max recommended input conductor length...

  • Page 21

    Om-230 852 page 17 5-9. Installing contact tip and nozzle tools needed: ref. 802 399-a y turn off welding power source. 1 nozzle remove nozzle. 2 contact tip 3 tip adapter thread welding wire through gun (see section 5-10). Slide contact tip over wire and tighten tip into tip adapter. Install nozzle...

  • Page 22

    Om-230 852 page 18 5-10. Threading welding wire 1 wire spool 2 welding wire 3 inlet wire guide 4 pressure adjustment knob 5 drive roll 6 gun conduit cable lay gun cable out straight. Tools needed: pull and hold wire; cut off end. Remove gun nozzle and contact tip. Open pressure assembly. Make sure f...

  • Page 23: Section 6 − Operation

    Om-230 852 page 19 section 6 − operation 6-1. Controls 1 wire speed control use control to select a wire feed speed. As voltage switch setting increases, wire speed range also increases (see weld setting label in welding power source or section 6-2, as applicable). 2 power switch 3 voltage switch th...

  • Page 24

    Om-230 852 page 20 6-2. Weld parameter chart for 230 vac model flux cored e71t−11 “set polarity for (dcen)” solid wire er70s−6 “set polarity for (dcep)” solid wire er70s−6 “set polarity for (dcep)” stainless steel “set polarity for (dcep)” aluminum** “set polarity for (dcep)” good for windy or outdo...

  • Page 25

    Om-230 852 page 21 227 010-a 227010 ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ ~ 2/40 1/25 4/60 3/50 5/40 5/40 5/40 4/60 3/50 3/30 5/80 5/60 5/50 5/60 5/50 5/40 5/50 4/35 6/90 6/60 6/50 6/80 6/50 6 / 40* 6/60 5/35 6 / 70* 7 / 50* 7 / 90* 7 / 50* 5/40 6/40 7/70 7 / 40* 7 / 50* 7 / 60* 6 / 35* 7 / 80* 7 / 60* 7 / 50* 7 / ...

  • Page 26

    Om-230 852 page 22 section 7 − maintenance &troubleshooting 7-1. Routine maintenance y disconnect power before maintaining. 3 months replace unreadable labels. Repair or replace cracked weld cable. Clean and tighten weld terminals. 6 months blow out or vacuum inside. During heavy service, clean mont...

  • Page 27

    Om-230 852 page 23 7-4. Changing drive roll or wire inlet guide 1 inlet wire guide securing screw 2 inlet wire guide loosen screw. Slide tip as close to drive rolls as possible without touching. Tighten screw. 3 retaining pin to remove drive roll, push drive roll in and rotate it (1/4 turn) to the o...

  • Page 28

    Om-230 852 page 24 7-6. Cleaning or replacing gun liner ref. 802 446-a 8 mm / 10mm y disconnect gun from unit. Tools needed: to reassemble gun: insert new liner. Install wire outlet guide so that 1/8 in (3 mm) of liner sticks out. Hand tighten outlet guide, and then tighten two full turns more. Cut ...

  • Page 29

    Om-230 852 page 25 7-7. Replacing switch and/or head tube ref. St-800 795-c tools needed: 19 mm remove handle locking nut. Slide handle. Secure head tube in vice. Loosen jam nut. Remove from vice and turn head tube out by hand. Hand-tighten head tube into cable connector. Place head tube in vice and...

  • Page 30

    Om-230 852 page 26 7-8. Troubleshooting table trouble remedy no weld output; wire does not feed; fan does not run. Secure power cord plug in receptacle (see section 5-6). Does not run. Replace building line fuse or reset circuit breaker if open. Place power switch in on position (see section 6-1). R...

  • Page 31: Notes

    Om-230 852 page 27 notes.

  • Page 32

    Om-230 852 page 28 section 8 − electrical diagram figure 8-1. Circuit diagram.

  • Page 33

    Om-230 852 page 29 228 180-a.

  • Page 34

    Om-230 852 page 30 section 9 − mig welding (gmaw) guidelines 9-1. Typical mig process connections y 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 workpiece...

  • Page 35: Note

    Om-230 852 page 31 9-2. Typical mig process control settings these settings are guidelines only. Material and wire type, joint design, fitup, position, shielding gas, etc. Affect settings. Test welds to be sure they comply to specifications. Note 3.5 x 125 a = 437 ipm 2 x 125 a = 250 ipm 1.6 x 125 a...

  • Page 36: Note

    Om-230 852 page 32 9-3. Holding and positioning welding gun welding wire is energized when gun trigger is pressed. Before lowering helmet and pressing trigger, be sure wire is no more than 1/2 in (13 mm) past end of nozzle, and tip of wire is positioned correctly on seam. Note 1 hold gun and control...

  • Page 37: Note

    Om-230 852 page 33 9-4. Conditions that affect weld bead shape weld bead shape depends on gun angle, direction of travel, electrode extension (stickout), travel speed, thickness of base metal, wire feed speed (weld current), and voltage. Note slow fillet weld electode extensions (stickout) electrode...

  • Page 38: Note

    Om-230 852 page 34 9-5. Gun movement during welding normally, a single stringer bead is satisfactory for most narrow groove weld joints; however, for wide groove weld joints or bridging across gaps, a weave bead or multiple stringer beads works better. Note 1 stringer bead − steady movement along se...

  • Page 39

    Om-230 852 page 35 9-8. Troubleshooting − excessive spatter excessive spatter − scattering of molten metal particles that cool to solid form near weld bead. S-0636 possible causes corrective actions wire feed speed too high. Select lower wire feed speed. Voltage too high. Select lower voltage range....

  • Page 40

    Om-230 852 page 36 9-11. Troubleshooting − lack of penetration lack of penetration − shallow fusion between weld metal and base metal. Lack of penetration good penetration s-0638 possible causes corrective actions improper joint preparation. Material too thick. Joint preparation and design must prov...

  • Page 41

    Om-230 852 page 37 9-14. Troubleshooting − waviness of bead waviness of bead − weld metal that is not parallel and does not cover joint formed by base metal. S-0641 possible causes corrective actions welding wire extends too far out of nozzle. Be sure welding wire extends not more than 1/2 in (13 mm...

  • Page 42

    Om-230 852 page 38 9-17. Troubleshooting guide for semiautomatic welding equipment problem probable cause remedy wire feed motor operates, but wire does not feed. Too little pressure on wire feed rolls. Increase pressure setting on wire feed rolls. Wire does not feed. Incorrect wire feed rolls. Chec...

  • Page 43: Notes

    Om-230 852 page 39 notes.

  • Page 44: Section 10 − Parts List

    Om-230 852 page 40 section 10 − parts list . Hardware is common and not available unless listed. 804 624-a 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 34 32 31 49 43 48 47 46 45 44 51 50 36 35 42 41 40 38 39 37 30 33 52 53 54 figure 10-1. Main assembly.

  • Page 45

    Om-230 852 page 41 description part no. Dia. Mkgs. Item no. Figure 10-1. Main assembly quantity 1 199 566 door, access 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 196 006 hinge, door 2 . . . . . . . . ....

  • Page 46

    Om-230 852 page 42 description part no. Dia. Mkgs. Item no. Figure 10-1. Main assembly (continued) quantity 40 196 574 switch, rocker dpst 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 228 400 knob, pointer (voltage) 1 ...

  • Page 47

    Om-230 852 page 43 1 802 447 2 3 4 5 6 7 9 8 10 11 figure 10-2. H-10 gun quantity description part no. 195 957 item no. Figure 10-2. H-10 gun 1 169 715 nozzle, slip type .500 orf flush 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ♦ 226...

  • Page 48

    Om-230 852 page 44 10-3. Optional drive rolls for all feed head assemblies part no. Wire diameter inches (mm) 202 925 .023/.025 (.6) and .030/.035 (.8 and .9) 202 926 .030/.035 (.8 and .9) and .045 (1.2 vk groove) 10-4. Options part no. Description remarks 770 187 running gear/cylinder rack for one ...

  • Page 49: Notes

    Notes.

  • Page 50: Notes

    Notes work like a pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual..

  • Page 51

    Effective january 1, 2007 (equipment with a serial number preface of “lh” or newer) this limited warranty supersedes all previous manufacturers warranties and is exclusive with no other guarantees or warranties expressed or implied. Limited warranty − subject to the terms and conditions below, warra...

  • Page 52: Resources  Available

    Printed in usa 2007−01 model name serial/style number purchase date (date which equipment was delivered to original customer.) distributor address city state zip please complete and retain with your personal records. Always provide model name and serial/style number. Contact your distributor for: we...