Hobart OM-1581 User Manual

Olympic XR AAnd XR WProcessesDescriptionMIG (GMAW) WeldingWire Feeder And Feeder GunOM-1581 137 532MMarch 2001

OM-1581 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles

OM-1581 Page 71-3. Dangers supplémentaires en relation avec l’installation, le fonctionnementet la maintenanceRisque D’INCENDIE OUD’EXPLOSION.D Ne pas

OM-1581 Page 81-4. Principales normes de sécuritéSafety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-ding Society, 550 N.W. Lejeune Rd,

OM-1581 Page 9SECTION 2 – SPECIFICATIONS2-1. Wire Feeder SpecificationsSpecification DescriptionType Of Input Power 115 Volts AC, 3 Amperes At 50/60

OM-1581 Page 10SECTION 3 – INSTALLATIONBe sure that contact tip, liner, and drive rolls are correct for wire size and type. SeeSection 5 to change pa

OM-1581 Page 113-2. Connections With A CV Welding Power Source Having Separate 115 VAC AndContactor Control Receptacles1 Constant Voltage (CV) Weld-i

OM-1581 Page 123-4. Connections With A CC Welding Power Source And A 115 VAC/12 VDC SecondaryContactor1 Constant Current (CC) Weld-ing Power Source2

OM-1581 Page 133-6. Air-Cooled Gun Connections31 Gun Control CableInsert plug into Gun Control recep-tacle, and tighten threaded collar.2 Gas HoseCon

OM-1581 Page 143-7. Water-Cooled Gun Connections1 Gas HoseConnect to Gas fitting on feeder.2 Water HoseConnect to Water To Gun fitting onfeeder (left

OM-1581 Page 153-8. Air-Cooled Feeder Connections1 Gas Hose Grommet2 10 ft (3 m) Gas Hose3 Rear Of Gas FittingRoute one end of gas hose throughgromme

Hobart Welders manufactures a full lineof welders and welding related equipment.For information on other quality Hobartproducts, contact your local Ho

OM-1581 Page 163-9. Water-Cooled Feeder ConnectionsObtain coolant supply.1 Gas Hose Grommet2 10 ft (3 m) Gas Hose3 Rear Of Gas FittingRoute one end o

OM-1581 Page 173-10. Adjusting Contact Tip Position13241 Contact Tip2 NozzleAdjusting barrel changes contacttip location from 1/16 in (1.6 mm)out bey

OM-1581 Page 183-12. 115 VAC/Contactor Control Plug Information1 Interconnecting Cord2 115 VAC/Contactor ControlPlug PLG5If CC or CC/CV welding power

OM-1581 Page 193-13. Replacing 115 VAC/Contactor Control Plug With Customer-Supplied 5-Pin OrTwistlock Plug1 115 VAC/Contactor ControlPlug PLG52 Cont

OM-1581 Page 203-14. Installing Wire SpoolTurn Off wire feeder and weldingpower source.1 Wire Spool2 Top Cover3 Pressure Roll Assembly4 Gun Contact T

OM-1581 Page 213-15. Threading Welding Wire Through Feeder1 Wire SpoolLoosen wire from spool, cut off bentwire, and pull 6 in (150 mm) of wireoff spo

OM-1581 Page 223-16. Threading Welding Wire Through Gun1 Pressure Roll AssemblyLift arm and open pressure rollassembly.2 Wire ConduitLay wire conduit

OM-1581 Page 233-18. Adjusting Wire Feed Starting Speed12Top Of PC1Ref. 151 772-A / Ref. 142 054-BTo adjust wire feed starting speed,proceed as follo

OM-1581 Page 24SECTION 4 – OPERATION4-1. Front Panel Controls Of Feeder (Air-Cooled Model Shown)1 Voltage/Wire Speed Meter(Optional)2 Voltage/Wire Sp

OM-1581 Page 254-4. Run-In Speed Control1 Run-In Speed ControlUse control to set wire feed speedbefore arc initiation.After arc initiation, wire feed

TABLE OF CONTENTSSECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1. . .

OM-1581 Page 264-7. Spot Controls (Optional)1 Spot/Continuous SwitchUse switch to select either an un-timed continuous weld cycle or atimed spot weld

OM-1581 Page 274-10. Flowmeter (Optional)CAUTIONWire feeding system is designed for maximum of 50 psi (345 kPa) gas pressure.• Be sure that regulator

OM-1581 Page 284-12. Gun Controls1 TriggerPress trigger to energize weldingpower source contactor (if applica-ble), start shielding gas flow, andbegi

OM-1581 Page 29SECTION 5 – MAINTENANCE & TROUBLESHOOTING5-1. Routine MaintenanceTurn Off all power before maintaining.3 MonthsORBlow OutOrVacuumI

OM-1581 Page 305-2. Changing Or Cleaning Gun Drive RollTurn Off wire feeder and weldingpower source.1 Top Cover2 Pressure Roll AssemblyCut off wire w

OM-1581 Page 315-3. Changing Feeder Drive Roll And Wire Inlet GuideTurn Off wire feeder and weldingpower source. Lay wire conduit outstraight.Open gu

OM-1581 Page 325-4. Replacing Or Cleaning Gun Drive Roll BearingTurn Off wire feeder and weldingpower source.1 Top Cover2 Pressure Roll Assembly3 Scr

OM-1581 Page 335-6. Changing Gun Contact Tip And LinerTurn Off wire feeder and weldingpower source.Remove top cover and open pres-sure roll assembly

OM-1581 Page 345-8. Removing Contact Tip Adapter In Water-Cooled ModelsWATER IN GUN PARTS can cause ELECTRIC SHOCK and can lower weld quality.• Turn

OM-1581 Page 355-10. Adjusting Hub TensionTurn On welding power source andwire feeder to make thisadjustment.1 Wire Speed ControlAdjust control to wi

OM-1581 Page 365-13. TroubleshootingA. Wire Feeder TroubleTrouble RemedyPressing gun trigger does not energizefeeder. Welding wire is not energized.S

OM-1581 Page 37B. Gun TroubleTrouble RemedyNo weld output; gun/feeder does notwork.Secure 115 VAC input plug in 115 volts ac receptacle (see Section

OM-1581 Page 38SECTION 6 – ELECTRICAL DIAGRAMSFigure 6-1. Circuit Diagram For Wire Feeder156 399-C

OM-1581 Page 39195 712-AFigure 6-2. Circuit Diagram For Gun

OM-1581 Page 40SECTION 7 – PARTS LIST123456 7891011121314151617181719 20212223242521262728293031323334353637383942434445464748495051525354555657586059

OM-1581 Page 41DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-1. Main AssemblyQuantity1 089 572 CATCH, link-lock 2. . . . . . . . . . . . . . . . . . .

OM-1581 Page 42DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-1. Main Assembly (Continued)Quantity50 111 152 SKID, base 2. . . . . . . . . . . . . . . .

OM-1581 Page 43DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-2. Motor & Wire Drive (Fig 7-1 Item 71)Quantity1 115 191 DRIVE ASSEMBLY, wire (consistin

OM-1581 Page 4412345678See Fig 7-1Item 5910121314151617181920212223911PC2PC4. Hardware is common andnot available unless listed.145 127-BFigure 7-3. P

OM-1581 Page 45DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-3. Panel, Front w/Components (Fig 7-1 Item 59)Quantity1 ♦111 569 METER, flow 6-60 1. . . .

OM-1581 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_4/981-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith

OM-1581 Page 46Figure 7-4. Exploded View Of Gun*Includes Items 24 & 37. Hardware is common andnot available unless listed.123456768910115713125814

OM-1581 Page 47DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-4. Exploded View Of GunQuantity1 133 479 COVER 1. . . . . . . . . . . . . . . . . . . . .

OM-1581 Page 48DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 7-4. Exploded View Of Gun (Continued)Quantity35 602 066 SCREW, mach stl trh 6-32 x .250 2. .

OM-1581 Page 49DescriptionPartNo.ItemNo.Figure 7-5. Barrel Assembly (Fig 7-4 Item 40)Quantity1 144 862 EXTENSION, nozzle (15A & 30A models) 1. .

OM-1581 Page 50DescriptionPartNo.ItemNo.Figure 7-5. Barrel Assembly (Fig 7-4 Item 40) (Continued)Quantity17 137 042 BARREL ASSEMBLY, water cooled (15W

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PRINTED IN USA  2000 Hobart Welding Products. 1/00Hobart Welding ProductsAn Illinois Tool Works Company600 West Main StreetTroy, OH 45373 USAFor Tech

OM-1581 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Spark

OM-1581 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or

OM-1581 Page 41-5. EMF InformationConsiderations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flow

OM-1581 Page 5SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANTUTILISATIONsom _nd_fre 4/981-1. Signification des symbolesSignifie Mise en garde ! Soyez v