Instruction/ maintenance manual of the product OM-1594 Hobart Welding Products
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Visit our website at www.HobartWelders.com Olympic XR Control Olympic XR Air- And W ater-Cooled Guns Processes Description OM-1594 181 715H December 2000 MIG (GMA W) W elding Wire Feeder And F.
Hobart W elders 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 catalog sheets. T o locate your near est distributor or service agency call 1-877-Hobart1.
T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS 6-12. Replacing Hub Assembly 38 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13. Overload Protection 39 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 1 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING som _nd_4/98 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message.
OM-1594 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 RA YS can burn eyes and skin. D Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching (see ANSI Z49.
OM-1594 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 sized, rated, and protected to handle this unit.
OM-1594 Page 4 1-5. EMF Information Considerations About W elding And The Effects Of Low Frequency Electric A n d M a g netic Fields W elding current, as it flows through welding cables, will cause electro- magnetic fields. There has been and still is some concern about such fields.
OM-1594 Page 5 SECTION 1 – CONSIGNES DE SECURITE – LIRE A V ANT UTILISA TION som _nd_fre 4/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette proc é dure pr é sente des risques de danger ! Ceux-ci sont identifi é s par des symboles adjacents aux directives.
OM-1594 Page 6 Le rayonnement de l ’ arc du proc é d é de soudage g é n è re des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des br û lures dans les yeux et sur la peau. Des é tincelles sont projet é es pendant le soudage.
OM-1594 Page 7 1-3. Dangers suppl é mentaires en relation avec l ’ installation, le fonctionnement et la maintenance Risque D ’ INCENDIE OU D ’ EXPLOSION. D Ne pas placer l ’ appareil sur , au-dessus ou à proxi- mit é de surfaces infllammables.
OM-1594 Page 8 1-4. Principales normes de s é curit é Safety in W elding and Cutting, norme ANSI Z49.1, de l ’ American Wel- ding Society , 550 N.W . Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.
OM-1594 Page 9 SECTION 2 – DEFINITIONS 1 1.1 1.2 1.3 3 3.1 3.2 3.3 4 4.1 + 2 2.1 2.2 + + 56 + 2.3 S-178 936 A. W arning! Watch Out! There are possible hazards as shown by the symbols. B. Drive rolls can injure fingers. C. W elding wire and drive parts are at welding voltage during operation – keep hands and metal objects clear .
OM-1594 Page 10 1 Read the Owner ’ s Manual. 2 Do not overtighten wire spool brake pressure. Tighten only until wire does not overspool from wire supply spool. 3 Do not overtighten drive roll pressure. Tighten only until drive roll will not slip (motor will not stall) on a stationary wire.
OM-1594 Page 1 1 2-3. Symbols And Definitions Some symbols are found only on CE products. Note A Amperes V V olts Alternating Current X Duty Cycle IP Degree Of Protection Hz Hertz Circuit Breaker Wire.
OM-1594 Page 12 3-2. Duty Cycle And Overheating Duty Cycle is percentage of 10 mi n - utes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit and void warranty .
OM-1594 Page 13 SECTION 4 – INST ALLA TION Be sure that contact tip, liner , and drive rolls are correct for wire size and type. See Parts List to change parts as needed. NOTE Many procedures apply to both guns covered in this manual. Where procedures differ , separate instructions are given.
OM-1594 Page 14 4-2. Air-Cooled Feeder Connections Ref. 801 578-A 1 Gas Fitting Route one end of 10 ft (3 m) gas hose to rear of unit, and connect hose to gas solenoid fitting. Connect remaining end of hose to regulator/flowmeter . 2 Weld Cable T o Welding Power Source Select and prepare weld cable according to welding power source manual.
OM-1594 Page 15 4-3. Air-Cooled Gun Connections Ref. 801 577-A / 801 564 / Ref. 151 666-A 1 Gun Control Cable Insert plug into Gun Control receptacle, and tighten threaded collar .
OM-1594 Page 16 4-4. W ater-Cooled Feeder Connections Ref. 152 431-A / Ref. 801 578-A Obtain coolant supply . 1 Gas Fitting Route one end of 10 ft (3 m) gas hose to rear of unit, and connect hose to gas solenoid fitting. Connect remaining end of hose to regulator/flowmeter .
OM-1594 Page 17 4-5. W ater-Cooled Gun Connections Ref. 801 577-A / 801 563 / Ref. 151 666-A 1 Gun Control Cable Insert plug into Gun Control receptacle, and tighten threaded collar .
OM-1594 Page 18 4-6. 14-Pin Plug Information Pin* Pin Information A 24 volts ac with respect to socket G. B Contact closure to A completes 24 volts ac contactor control circuit. A J K I G Circuit common for 24 volts AC circuit. B I C L N H C +10 volts dc output to remote control with respect to socket D.
OM-1594 Page 19 4-8. Optional Meter Circuit Board Settings Ref. 802 359 / Ref. 186 266 T ools Ne e d e d : 1/4 in 1 Meter Board PC2 2 DIP Switch S2 Set DIP switch S2 for type of welding power source, and desired wire feed speed display . Reinstall hinged door and side panel.
OM-1594 Page 20 4-9. Adjusting Contact Tip Position Ref. 801 556 / 150 434 / Ref. 150 431 / Ref. 151 666-A 1 Contact T ip 2 Nozzle Adjusting barrel changes contact tip location from 1/16 in (1.6 mm) out beyond end of nozzle to 1/4 in (6.3 mm) inside nozzle.
OM-1594 Page 21 4-1 1. Removing T op Cover Of Pistol Grip Gun 1 T op Cover Push back and lift off as shown. T o reinstall cover , set rear of cover in gun, and push cover back, down, and forward until it clicks into position. 802 528 1 4-12. Installing Wire Spool Ref.
OM-1594 Page 22 4-13. Threading Welding Wire Through Feeder Ref. 802 193-A T ools Needed: Pull and hold wire; cut off end. Hold wire tightly to keep it from unraveling. 6 in (150 mm) Open tension arm. Thread wire thru inlet guide, along drive roll groove, and into wire conduit.
OM-1594 Page 23 4-14. Threading Welding Wire Through Gun Ref. 802 193-A / 801 556 T ools Ne e d e d : Refer to Section 4-13 for instructions on feeding wire through feeder. Lay gun cable out straight. Open top cover , and open pressure roll assembly .
OM-1594 Page 24 4-15. Adjusting Wire Feed Starting Speed T o adjust wire feed starting speed, proceed as follows: 1 Motor Speed Control Board PC1 2 Motor Start Control Potentiometer R3 Remove protective white rubber cap before making adjustment. Adjust potentiometer using a small nonconductive screwdriver .
OM-1594 Page 25 4-16. Setting Switches For Preflow And Postflow . Unit arrives from the factory with preflow Off and postflow turned On. T o set switches for preflow and postflow , proceed as follows: 1 Motor Speed Control Board PC1 2 DIP Switch S1 . Preflow and postflow have pr e - set time values and cannot be changed.
OM-1594 Page 26 4-17. Adjusting T rigger Hold Actuation Time T o adjust trigger hold actuation time, proceed as follows: 1 Motor Speed Control Board PC1 2 Potentiometer R50 .
OM-1594 Page 27 SECTION 5 – OPERA TION 5-1. Controls 801 554 1 V oltage/Wire Speed Meter (Optional) 2 V oltage/Wire Speed Switch (Optional) When switch is in V oltage position, and operator is welding, meter displays arc voltage. Cable resistance and poor connections may cause displayed voltage to vary slightly from actual voltage at welding arc.
OM-1594 Page 28 5-2. Internal Controls Ref. 801 578 Open left side door . 1 Run-In Speed Control Use this control to set run-in wire feed sp eed before arc initiation. After arc initiation, weld wire feed speed is controlled by the wire speed setting on the welding gun (see Section 5-3).
OM-1594 Page 29 5-3. Gun Controls 1 T rigger Press trigger to energize welding power source contactor (if applicable), start shielding gas flow , and begin wire feed. Switches inside the wire feeder can be set to provide timed shielding gas preflow and postflow when trigger is pressed and released (see Section 4-16).
OM-1594 Page 30 5-6. Sequence Of Gas Metal Arc Welding (GMA W) – Continuous Or Spot Begin W elding ssb6.1* 9/92 Install & Connect Equipment Put On Personal Safety Equipment Set Controls T urn On.
OM-1594 Page 31 6-1. Feeder Drive Assembly Maintenance 802 193-A Retract wire onto spool. 1 Pressure Roll Assembly 2 Drive Motor Shaft 3 Drive Roll 4 Screw Use wire brush to clean drive roll. 5 Drive Roll Idler 6 Shoulder W ashers Use wire brush to clean idler .
OM-1594 Page 32 6-2. Gun Drive Assembly Maintenance For An XR-Edge Gun Ref. 801 556 Retract wire onto spool. 1 Screw 2 Drive Roll Use wire brush to clean drive roll. Install drive roll with hex opening down toward shaft hex, and secure with screw . . Apply conductive grease to drive roll post every 4 to 6 weeks.
OM-1594 Page 33 6-3. Removing Contact Tip Adapter In XR-Edge Guns Ref. 802 253 1 Nozzle 2 Adapter Nozzle 3 Nozzle Adapter Locking Nut Loosen locking nut to remove nozzle and adapter nozzle. 4 Contact Tip 5 Collet Nut 6 Quick Change Contact Tip Adapter Remove contact tip from contact tip adapter .
OM-1594 Page 34 Ref. 151 599-C / Ref. 802 652 / Ref. 801 556 / 801 564 / Ref. 151 666-A / Ref. 200 371 6-5. Replacing Gun Cable Liner Y T urn Off welding power source and wire feeder . 1 Drive Roll 2 Collet Nut La y gun cable out straight. Remove drive roll on gun and loosen collet nut on liner tube assembly .
OM-1594 Page 35 6-6. Changing Gun Contact Tip 1 Contact T ip W rench 2 Nozzle Insert wrench into nozzle over contact tip. 3 Compression Nut 4 Contact Tip Loosen nut. Pull out contact tip. Install new contact tip. T ighten nut just until contact tip is secure.
OM-1594 Page 36 T urn Off wire feeder and welding power source. 1 T op Cover 2 Pressure Roll Assembly 3 Screw 4 Pressure Roll Remove as shown. Use a wire brush to clean bearing. Reinstall with washers, and tighten screw . Close pressure roll assembly .
OM-1594 Page 37 6-10. Removing Contact Tip Adapter In Air-Cooled Pistol-Grip Guns T urn Off wire feeder and welding power source. 1 Nozzle Extension Remove as shown. 2 Contact Tip 3 Compression Nut T o remove, see Section 6-6. 4 Liner 5 Contact Tip Adapter 6 W asher 7 Extension Adapter 8 Setscrew Loosen setscrew and remove adapter .
OM-1594 Page 38 6-12. Replacing Hub Assembly 801 577 / Ref. 143 223-A Remove gun top cover and release pressure arm (see Sections 4-10 and 4-1 1). Retract w i r e onto spool and remove spool.
OM-1594 Page 39 6-13. Overload Protection Ref. 801 577 / Ref. 800 185-A Y T urn Off wire feeder and welding power source. Stop engine on welding generator .
OM-1594 Page 40 6-15. T roubleshooting Y Disconnect power before troubleshooting. T rouble Remedy Pressing gun trigger does not energize feeder . Welding wire is not energized. Secure plug from gun control cable into Gun Control receptacle on feeder (see Section 4-3 or 4-5 as appli- cable).
OM-1594 Page 41 Notes.
OM-1594 Page 42 SECTION 7 – ELECTRICAL DIAGRAMS Figure 7-1. Circuit Diagram For Wire Feeder.
OM-1594 Page 43 186 931-D.
OM-1594 Page 44 195 712-A Figure 7-2. Circuit Diagram For Gun.
OM-1594 Page 45 Notes.
OM-1594 Page 46 SECTION 8 – P ARTS LIST . Hardware is common and not available unless listed. ST-802 230 49 – Figure 8-2 45 – Figure 8-3 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 30 31 32 33 34 35 36 37 38 39 40 42 41 43 44 50 51 52 53 57 46 47 48 54 55 56 58 Figure 8-1.
OM-1594 Page 47 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly Quantity 1 089 572 CA TCH, link-lock 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 48 Description Part No. Dia. Mkgs. Item No. Figure 8-1. Main Assembly (Continued) Quantity 54 ♦ 028 770 POTENTIOMETER, CP std slot 1T 2W 1M 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 073 562 POTENTIOMETER, CP std slot 1T 2W 10k 1 .
OM-1594 Page 49 Description Part No. Dia. Mkgs. Item No. Figure 8-2. Motor & Wire Drive (Figure 8-1 Item 49) Quantity 1 193 186 DRIVE ASSEMBL Y , wire (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 50 . Hardware is common and not available unless listed. 802 236-A See Figure 8-1 Item 45 1 2 3 6 7 8 9 10 11 12 13 12 14 15 16 18 17 5 4 4 Figure 8-3.
OM-1594 Page 51 Description Part No. Dia. Mkgs. Item No. Figure 8-3. Panel, Front w/Components (Figure 8-1 Item 45) Quantity 1 ♦ 1 1 1 569 METER, flow 6-60 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 52 . Hardware is common and not available unless listed. 802 328-C 1 3 4 5 6 7 8 9 10 11 12 14 15 16 20 21 22 23 24 26 27 28 29 30 31 32 33 34 36 37 38 35 39 40 41 41 42 43 44 45 46 47 48 50 51 47 52 25 53 18 49 23 24 15 13 17 19 25 17 20 21 22 24 23 See Figure 8-5 2 54 55 Figure 8-4.
OM-1594 Page 53 Description Part No. Dia. Mkgs. Item No. Figure 8-4. Exploded View Of XR-Edge Gun Quantity 1 187 000 COVER,handle 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 54 Description Part No. Dia. Mkgs. Item No. Figure 8-4. Exploded View Of XR-Edge Gun (Continued) Quantity 44 187 953 FITTING, liner 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 55 . Hardware is common and not available unless listed. 802 253-A 1 2 3 4 5 6 7 8 9 11 12 13* *Insert chamfered end of liner into head tube. 1 3 4 5 6 7 8 9 10 11 12 14 Air Gun Barrel W ater Gun Barrel Figure 8-5. Barrel Assembly Of XR-Edge Gun Description Part No.
OM-1594 Page 56 . Hardware is common and not available unless listed. 143 1 17-H 1 2 19 20 22 21 24 23 23 25 26 27 28 42 43 44 45 46 47 52 53 54 55 56 57 58 59 60 61 62 64 15(Fig.
OM-1594 Page 57 Description Part No. Dia. Mkgs. Item No. Figure 8-6. Exploded View Of Pistol-Grip Gun Quantity 1 133 479 COVER 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 58 Description Part No. Dia. Mkgs. Item No. Figure 8-6. Exploded View Of Pistol-Grip Gun (Continued ) Quantity 44 058 968 RING, retainer E 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
OM-1594 Page 59 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 7 20 21 22 23 24 25 26 27 4 28 29 30 31 32 33 34 35 36 800 434-A 3 5 19 . Hardware is common and not available unless listed. Figure 8-7. Barrel Assembly Of Pistol-Grip Gun Description Part No.
OM-1594 Page 60 Description Part No. Item No. Figure 8-7. Barrel Assembly Of Pistol-Grip Gun (Continued) Quantity 17 137 042 BARREL ASSEMBL Y , water cooled (15W & 30W models) . . . . . . . . . . . . . . . . (consisting of) 1 . . . . . . . . . . .
OM-1594 Page 61 Notes.
OM-1594 Page 62 Notes.
Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 7/00 Service Y o u 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.
PRINTED IN USA 2000 Hobart Welding Products. 1/00 Hoba rt W elding Produc ts An I l li noi s T ool Works Com pany 600 West Main St reet Troy , O H 45373 US A For Technical A ssistan ce: Call1-800-.
An important point after buying a device Hobart Welding Products OM-1594 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Hobart Welding Products OM-1594 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Hobart Welding Products OM-1594 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Hobart Welding Products OM-1594 you will learn all the available features of the product, as well as information on its operation. The information that you get Hobart Welding Products OM-1594 will certainly help you make a decision on the purchase.
If you already are a holder of Hobart Welding Products OM-1594, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Hobart Welding Products OM-1594.
However, one of the most important roles played by the user manual is to help in solving problems with Hobart Welding Products OM-1594. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Hobart Welding Products OM-1594 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
