Home

Hobart OM-1581 User's Manual

1. 1 le She uot 111997 SWITCH rocker SPST 10A 250VAC 1 1 EE E 057 357 BUSHING snap in nyl 937 ID x 1 125mtg hole water cooled model 1 T ne 070 371 BLANK snap in nyl 1 093 1 125mtg hole air cooled model 1 b A 030 170 BUSHING snap in nyl 750 ID x 1 000mtg hole 1 e Part of Gas Flow Meter Option Part of Meter Kit Option Part of Spot Weld Control Option Part of Voltage Control Option 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 OM 1581 Page 45 gt Hardware is common and not available unless listed De LE Y tc SUS SOPN ou 143 117 E Figure 7 4 Exploded View Of Gun OM 1581 Page 46 Item Dia Part No Mkgs No Description Quantity Figure 7 4 Exploded View Of Gun A du BEE e VEA EE ee 1 as 135 196 SPRING Closlire COVER ceso EP e RE RC poe ete de RC geen 1 MEC 112 715 CONDUIT w FITTING 15ft 15A amp W models 1 c PV ERE 112 716 CONDUIT w FITTING 30ft 30A 8 W models 1 A 137 474 HOSE water in 15W model consisting of 1 dos irai dei 137 475 HOSE water in 30W model consisting of
2. 2 MO bar 133083 SPRING tension adj drive roll 1 tata aca 144 860 SCREW mach stl fln 8 32 x 437 1 1 20 Aa Segen 059 969 s RING retainer EE 1 a temesestiss A PIN DINGE EE 1 22 deeg EE 155565 xa SOREW TDUITID hee ere ia to be Aen e gege 1 EET 134 799 O RING 176 ID x 070 CS used w thumbscrew 1 29 dodge i e 135 126 SCREW set stl sch 6 32 x 125 cup point 1 20 clubs ide 1355807 PEEING O85 iu candidata 1 DD c dich dci idc 112896 SPRING cprsn 240 OD x 020 wire x 437 1 20 3 gea O34 135773 KNOB thumb tension adjusting 8 32 1 lidad 143 360 SCREW mach stl rdh 8 32 x 500 1 LO iria 136 679 CLAMP strain relief lille 1 pio NEN 132 269 SCREW mach stl rdhph 8 32 x 375 1 SU cauca 1645911 CASE GUTER xc opel era RS id in id 1 OW nn 173 527 SCREW 8 32 x 1 500 soc hd hex gr8 2 SET TRE ET ns 143 397 BLANK snap in nylon 1 MU o MORTON 173528 SCREW 8 32 x 875 soc hd hex gr 8 1 84 B2 161 813 MOTOR gear PM 24VDC 420RPM 10 2 1 ratio 1 OM 1581 Page 47 Item Dia Par NO Mkgs NO Description Quantit
3. 21 3 16 Threading Welding Wire Through Gun 2 0 cc eee n nee 22 9 17 Goolant GUICCIINGS EE 22 3 18 Adjusting Wire Feed Starting Speed 23 SECTION 4 OPERATION 55 24 6434 94 rA TERR eh LEX DET EREWA S eee E 24 4 1 Front Panel Controls Of Feeder Air Cooled Model Shown 24 4 2 Safety Equipment deo da ct cioe toe diras 24 4 3 Work And Voltage Sensing Cable Clamps 24 4 4 Run In Speed Control 2 25 Ee NEEN 25 4 6 Voltage Wire Speed Switch And Meter Optional 25 2 7 SpobControls OPONA serias Ee ia ad 26 4 8 Remote Voltage Control Optional 2 26 AS tine URN S RIS Doro Ree dae DR EE ERE 26 4 10 e TEE EE e ele EL NEE 27 4 11 Internal Controls oocococccco tenet n teen n ent mms 27 4 12 GUM CODWOIS td A a Ge vy Soe ee ee 28 4 13 Shielding GaS vxccr geo A RES MESS ee RE HUE 28 4 14 Coolant Supply For Water Cooled Models Only 28 4 15 Sequence Of Gas Metal Arc Welding GMAW Continuous Or Spot 28 SECTION 5 MAINTENANCE amp TROUBLESHOOTING 29 Sez ROUIIT Maltenances suae duet a Er bu e bae 29 5 2 Changing Or Cleaning Gun Drive Roll
4. 1 adan 137 473 HOSE gas in 15A amp W models consisting of 1 D ouod TT cte 137 472 HOSE gas in 30A amp W models consisting of 1 AN 056 851 FITTING hose brs barbed nipple 3 16tbg 1 TS 010 607 FITTING hose brs nut 625 18 LH water hose 1 as 010 606 FITTING hose brs nut 625 18RH gas hose 1 RE berg 056 108 FITTING hose brs ferrule 425 ID x 718 lg 1 onm 134 834 HOSE SAE 187 ID x 410 OD 15A W models order by ft 16ft o 134 834 HOSE SAE 187 ID x 410 OD 30A W models order by ft 31ft TEC TIERE 089 120 CLAMP hose 375 450clp dia slfttng 1 Or iu 000 571 HOSE water XR 15 8 30W models consisting of 2 IIR UM ETOT ERE 056 851 FITTING hose brs barbed nipple 3 16tbg 2 ER e E Eet 010607 FITTING hose brs nut 625 18 LH e 2 sph eld atta find ane 056 108 FITTING hose brs ferrule 425 ID x 718 lg 2 A 134 834 HOSE SAE 187 ID x 410 OD order by ft 10ft AA 048 837 HOSE gas consisting Of 1 diia da 010603 FITTING hose brs barbed nipple 1 4tbg 2 RN ie 010606 FITTI
5. 30 5 3 Changing Feeder Drive Roll And Wire Inlet Guide 31 5 4 Replacing Or Cleaning Gun Drive Roll Bearing 32 5 5 Replacing Or Cleaning Feeder Drive Roll Bearing 32 5 6 Changing Gun Contact Tip And mer anaana nanana aaaeeeaa 33 5 7 Removing Contact Tip Adapter In Air Cooled Models 33 5 8 Removing Contact Tip Adapter In Water Cooled Models 34 5 9 Replacing Hub AsSsemlbly z vv retire mo n S d Rc eem e ACRI Rt 34 S10 Adjusting Hub TENSION dun a Pure IPSI DEEP ER DUE DE He PE Eg 35 D ll Overload PIODISCHON 55 3 95 qutd marino e s ed aru ad cmd suit ema Erde emt Cod tae 35 5 12 Water Flow Switch Optional For Water Cooled Models 35 9 19 Troubleshoollrig 35 5 b o oe ele a ROREONMEG S I UR ES E dE MS 36 SECTION 6 ELECTRICAL DIAGRAMS coi a 38 SECTION 7 PARIS BL EE 40 OPTIONS AND ACCESSORIES WARRANTY SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 1 Symbol Usage A Marks a special safety message Means Warning Watch Out There are possible hazards with this procedure The possible hazards are shown in the adjoining symbols CS Means Note not safety related 1 2 Arc Welding Hazards A The symbols shown below are used throughout this manual to call attention to and identify possibl
6. r es dans les normes de s curit 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance Risque D INCENDIE OU f D EXPLOSION e Ne pas placer l appareil sur au dessus ou proxi mit de surfaces infllammables Ne pas installer l appareil proximit de produits inflammables e Ne pas surcharger l installation lectrique s assurer que l alimen tation est correctement dimensionn et prot g avant de mettre l appareil en service LA CHUTE DE L APPAREIL peut blesser e Utiliser l anneau de levage uniquement pour sou lever l appareil NON PAS les chariot les bouteil les de gaz ou tout autre accessoire e Utiliser un engin d une capacit appropri e pour soulever l appareil e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches sont suffisamment longues pour d passer du c t oppos de l appareil L EMPLOI EXCESSIF peut SURCHAUFFER L EQUIPEMENT e Pr voir une p riode de refroidissement respec ter le cycle op ratoire nominal e R duire le courant ou le cycle op ratoire avant de recommancer le soudage e Ne pas obstruer les passages d air du poste LES CHARGES LECTROSTATI QUES peuvent endommager les cir cuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des bo tes antistatiques pour stocker d pl
7. servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conduc tor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill e Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body som nd 4 98 This group of symbols means Warning Watch Out possible ELECTRIC SHOCK MOVING PARTS and HOT PARTS hazards Consult symbols and related instructions below for necessary actions to avoid the hazards e f earth grounding of the workpiece is required ground it directly with a separate cable e Do not touch electrode if you are in contact with the work ground or another electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual Wear a safety harness if working above floor level Keep all panels and covers se
8. 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 HOBART WARRANTY Effective January 1 2000 Equipment with a serial number preface of LA or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied LIMITED WARRANTY Subject to the terms and conditions below Hobart Welding Products Troy Ohio 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 LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart must be notified in writing within thirty 30 days of such defect or failure at which time Hobart will provide instructions on the warranty claim procedures to be followed Hobart shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or on
9. 1 50 PB1 000369 SWITCH lim 10A 125 250VAC DPST plgr 1 E aorta is 183 884 SPRING cprsn 240 OD x 026 wire x 1 000 1 TD WP UPC 184 101 WASHER shldr 140 ID x 250 OD 1 us DO A 1556047 sa NUT SIE 9 32 ebria dad edere druida diodos 3 DAS Eee 162042 CONTACT current pick up 1 4 EEN 602 198 WASHER lock 141 ID stl split 4 T Pm 134 624 BEARING flg nyl 140 ID x 187 OD x 375flg x 031thk 2 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 OM 1581 Page 48 Item Par No No Re 144 862 a rade 156 821 qc Ay ue 136 171 o Re eee 135 427 er eee 135 428 De M P PEIPER 147 314 Dc NER 135 430 A 135 429 EE 135 424 e A 135 426 D A 135 425 AA 136 821 KEPT 166 575 om 136 748 c PT 136 683 EE 136 682 UO ob TER 164 421 mor 164 485 WE CREME 604 612 o T 164 422 TU Li iuit died 058 685 E WEE 602 172 2 ad id ibi 164 423 EcL 134 800 TAE ec do dens 203 675 ELM OR MEM 175 946 AAA 135 128 CS Hardware is common and not available unless listed Description Figure 7 5 Barrel Assembly Fig 7 4 Item 40 EXTENSION nozzle 15A 8 30A models EXTENSION b
10. FITTING ASSEMBLY barrel one e bed Rea rU Rees 1 aseo TUBING TONO oae nta re dn Rea ear paret dca ea ur odia due 1 WASHER flat 594 ID for 1 O RING 926 ID x 070CS 4 Las AI EL OU EEN 1 INSULATOR head tube from adapter 1 WASHER flat 390 ID brs 1 s ADAPT ER GOntaet tube nisi anta dence e pbi dec Oe Moe es 1 WM ISIN A 1 ves IN EEN Bo e TZS o ata stacey area iaa ass HC AR eliana sash ORE D eid 1 vesc DA ER E e era CE QU ROCA Rua EUR TET ACE QU R HAO REOR Eod 1 vag NOZZLE 5 6200 X 155 910 auxi t Dp mh E YA coe e dox dro metes 1 NOZZLE spot outside corner 937 ID x 2 375 1 e NOZZLE TSG On X EM WEE 1 c NOZZLE VZO 1259 6 oia UE b di qm Cp ees 1 t NOZZLE 5 80 5 6 0 EEN 1 ss NOZZE SPO EE 1 en NOZZLE SOO amd oer oido aaa aid ts 1 NOZZLE spot inside corner 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 OM 1581 Page 50 Warranty Questions Call 1 877 HOBART1 for your local Hobart distributor 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
11. and welding power source 1 Nozzle Extension Remove as shown 2 Contact Tip 3 Compression Nut To remove see Section 5 6 Liner Contact Tip Adapter Washer Extension Adapter Setscrew Loosen setscrew and remove adapter Install new adapter and tighten setscrew Reinstall liner contact tip compression nut and nozzle Tools Needed 5 64 3 32 in 150 430 B OM 1581 Page 33 5 8 Removing Contact Tip Adapter In Water Cooled Models amp WARNING AAA WATER IN GUN PARTS can cause ELECTRIC SHOCK and can lower weld quality e Turn Off welding power source and water supply before working on gun Stop engine on welding generators Always point gun downward when removing water cooled barrel to keep water out of gun parts 0 Wipe gun dry before putting it back together Turn Off weld control and welding power source 1 Nozzle 2 Nozzle Adapter Remove as shown 3 Contact Tip Adapter Use supplied 3 32 in allen wrench to remove adapter Coat new adapter with threadlock ing compound such as Loctite No 242 and install 150 431 5 9 Replacing Hub Assembly Turn Off wire feeder and welding power source Remove gun top cover and open pressure roll assembly as shown in Section 5 4 Retract wire onto spool and remove spool Take hub apart as shown Metal Brake Washer Flat Washer Brake Washer Hub Keyed Washer Spring Cap Screw CO NOOO Bb Cc N Retaining Ring Replace broken o
12. e 1 us 058 549 GUIDE wire inlet 1 16 1 1 Sh or ae 602 306 PIN spring G9 125 X3500 5 isa ix Dear Cte OCC eR Ie 2 Tu c ERE 008 667 BEARING ball rdl dbl row 250 x 687 x 31 L lues 2 o c T 113 170 sz GEARS SHAFE MOTOT tica A Y eR Ris de o cd 1 bro CREE 147 624 CASE gear wire drive 1 T CERIS 147 625 BLOCK anchor conduit 1 me eh cer 054 263 SCREW thumb stl 250 20 x 500 1 Promo nu 120 398 ROLL drive V groove 030 1 16 wire consisting of 1 PU cos 602 169 SCREW set stl sch 8 32 x 187 cup point 2 meo PERDE 605 971 WASHER shldr nyl 236 OD x 195 ID x 042tbk 3 mE 113162 INSULATOR motor RR eee 1 TS PR IA 113 898 MOTOR torque 115VAC 1 DE EE 143 169 e ee EEN 1 426 insu 604 612 SCREW set stl sch 8 32 x 125 cup point 2 gt Hardware is common and not available unless listed Includes Items 15 19 114 188 F Figure 7 2 Motor 8 Wire Drive 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 OM 1581 Page 43 L5 H
13. helmet OM 1581 Page 2 BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator HOT PARTS can cause severe burns e Do not touch hot parts bare handed e Allow cooling period before working on gun or torch MAGNETIC FIELDS can affect pacemakers e Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding operations NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechani cal shocks slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fit tings designed for the s
14. la peau Des tincelles sont projet es pendant le soudage Porter un casque de soudage muni d un cran de filtre appropri pour prot ger votre visage et vos yeux pendant le soudage ou pour regar der voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des protections approuv s pour les oreilles si le niveau sondre est trop lev Utiliser des crans ou des barri res pour prot ger des tiers de l clair et de l blouissement demander aux autres personnes de ne pas re garder l arc Porter des v tements de protection constitu dans une mati re dura ble r sistant au feu cuir ou laine et une protection des pieds gt LE SOUDAGE peut provoquer un PER incendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de l arc de soudure La projection d tincel les des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger Sec Se prot ger et d autres personnes de la projection d tincelles et de m tal chaud Ne pas souder dans un endroit l o des tincelles peuvent tombe
15. line catalog or gt distributor Your distributor TP can also supply you with individual catalog sheets To locate your nearest Welding Process Manuals such as SMAW GTAW distributor or service agency call 1 877 Hobartl GMAW and GMAW P WELDING PRODUCTS OM 1581 TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 11 2Symbol Ee EE 1 162 Ate Welding Ne Ee EE 1 1 3 Additional Symbols For Installation Operation And Maintenance 3 1 4 Principal Safety ele e EE dre 3 ES EMPIRE a o ca ete ee 4 SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 5 1 1 Sig ification des symboles s i sei ex x RE RE REX EE RISE EE EE E ES TEXTE RETE Lx 5 1 2 Dangers relatifs au soudage l arc 5 1 3 Dangers suppl mentaires en relation avec l installation le fonctionnement ella OECD EE d 7 1 4 Principales normes de s curit 8 1 5 Information sur les champs lectromagn tiques 8 SECTION 2 SPECIFICATIONS hg vcio eR Orv ak A A CR ee CR 9 2 1 Wire Feeder Specifications ses sonde bete AA RR Si abr ata 9 2 2 GUI SDecilICallolls c sar acordas 9 2 3 Duty Cycle And Overheating 22 9 SECTION S INSTALLATION 5i og way erg das bud Dee tere aR 10 3 1 Connec
16. lt lt 0 o 4 Fi SI 37 GEN T5V 24N 32 lt RC1 1 WHT O PLG52 4 lt 3 PLG51 PLG50 EMT 3 7 lt RC3 1 WEE O lt ALE lt I lt RC1 2 lt RC3 7 15V CLOSURE CONNECT PLGS0 PLGS1 CONTACT CLOSURE CONNECT PLG50 PLG52 lt RC35 3 E e BOARD e GRN lt O8 E A m CW MT REMOTE VOLTAGE CONTROL OPTIONAL lt lt RC3 6 LA Lost RC1 8 PLG2 LONG SHORT S6 2 A B C D 52 33 of 33 109 F METER AND SPOT TMER V V V WD E A ED ET PLG13 PC2 TO RC2 PCD A AR ACA RT CONNECT PLG2 PC1 TO RS BA BG BD BH BC PC3 95 46 7 BB gt 5B F m S 11 mE 57 ASD PN ROT AB gt P 6 7 Q5 RCe 4 25 o Qe BE n D o Q wyle lt AA AD ON RCB H AA 42 BA BH ON RC9 ac gt M M O SPOT TIME CA CF ON RCD AD gt PLG12 PC2 PC3 A gt HE AL K RCI5 6 a5 B DIGITAL METER 32 TOA A B Dc RC15 4 OPTIONAL RC16 5 gt gt o FROM T1 c gt gt 92 lee x 1 2 eee Bo oci p gt ee RcI5 8 CB CA CC CF SE Y V V_V F METER OPTION IS NOT USED EZ g CONNECT PLGN PC3 TO RC2 PC1 38 32 F SPOT TMER OPTION IS NOT USED Ras CONNECT PLG2 ICH TO PLGI2 A PC2 Cw BURNBACK TME GUN GON ASSEMBL Y O Wil FLOW SWITCH OPTIONAL WATER 5 CODLED MODELS ONLY SENSE LEAD e Disconnect input power or stop engine before servicing e Do not operate with covers removed ELECTRIC e Have only qualified persons install SHOCK HAZAR
17. possible de la zone de soudure Consignes relatives aux stimulateurs cardiaques Les personnes qui portent un stimulateur cardiaque doivent avant tout consulter leur docteur Si vous tes d clar apte par votre docteur il est alors recommand de respecter les consignes ci dessus SECTION 2 SPECIFICATIONS 2 1 Wire Feeder Specifications Specification Description Type Of Input Power Control Circuit Voltage Provided At Gun Wire Feed Speed Range Overall Dimensions Maximum Spool Capacity Cooling Method Weight Feeder With Gun 115 Volts AC 3 Amperes At 50 60 Or 100 Hz Power 30 Volts DC 70 875 ipm 1 9 22 2 mpm Length 19 in 483 mm Width 9 1 4 in 235 mm Height 15 1 4 in 387 mm 12 in 805 mm Air Cooled A Models Or Water Cooled W Models Models With 15 ft 4 6 m Cable Assembly Net 56 lb 25 kg Ship 58 lb 26 kg Models With 30 ft 9 1 m Cable Assembly Net 63 Ib 29 kg Ship 65 Ib 30 kg 2 2 Gun Specifications Specification Description Input Voltage Duty Cycle Air Cooled Models Duty Cycle Water Cooled Models Wire Size Range 30 Volts DC At 200 Amperes 100 Using Argon Or Argon Mixture Shielding Gas At 250 Amperes 60 Using Argon Or Argon Mixture Shielding Gas See Section 2 3 At 400 Amperes 100 Using Argon Or Argon Mixture Shielding Gas See Sec tion 2 3 030 Thru 1 16 in 0 8 Thru 1 6 mm Aluminum Wire 030 Thru 0
18. to workpiece as close to the weld as possi ble About Pacemakers Pacemaker wearers consult your doctor first If cleared by your doctor then following the above procedures is recommended SECTION 1 CONSIGNES DE SECURITE LIRE AVANT UTILISATION 1 1 Signification des symboles i ldentifie un message de s curit particulier Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Signifie NOTA n est pas relatif la s curit 1 2 Dangers relatifs au soudage l arc Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les risques de danger Lorsque vous voyez un symbole soyez vigilant et suivez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apres ne font que r sumer l information contenue dans les normes de s curit num r es la section 1 4 Veuillez lire et respecter toutes ces normes de s curit L installation l utilisation l entretien et les r parations ne doi vent tre confi s qu des personnes qualifi es A Au cours de l utilisation tenir toute personne l cart et plus par ticulierement les enfants RN e UN CHOC LECTRIQUE peut tuer ne Un simple contact avec des pi ces lectriques peut provoquer une lectrocution ou de
19. vos poches telles qu un allumeur au butane ou des allumettes DES PARTICULES VOLANTES peuvent blesser les yeux e Le soudage l caillement le passage de la pi ce la brosse en fil de fer et le meulage g n rent des tincelles et des particules m talliques vo lantes Pendant la p riode de refroidissement des soudures elles ris quent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial OM 1581 Page 6 LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduction d air homologu DES PIECES CHAUDES peuvent pro voquer des br lures graves e Ne pas toucher des parties chaudes mains nues e Pr voir une p riode de refroidissement avant d utiliser le pistolet ou la torche LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op rations de soudage l arc de gougeage ou de soudage par points LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le niveau sondre est trop le
20. x 750 OD x 062thk air cooled model 2 TUN ENERO 075 150 WASHER shldr nyl 1 000 OD x 375 ID air cooled model 1 E RR 010 910 WASHER flat stl SAE 375 air cooled model 2 its eee ee 601872 NUT stl hex AUS 75 16 EE ON ols aa ee ee 602 213 WASHER lock stl split 375 00 0 eee 1 J A 602 243 WASHER Tal slEStd 9375 a A Nu enr beeen 1 TN AA 151 663 FITTING plug water block 1 NC AAA 151 664 FITTING diverter water block 1 ME RENS 151 662 FITTING pipe brs plug hex 125NPT 2 ud DO edd cba dog d 940073432 FITTING brs barbed M 3 16tbg x 1 8NPT 2 Os Of pise 011 770 5 SWITGA t0 SPDT 5A LOW scans Do eds 1 A ad ke ce 113 5609 DOOR Biblia cto ua Sos ain oe aa da 1 uro mE Fig 7 2 MOTOR amp WIRE DRIVE 1 iu e ace s E deas 010 546 BUSHING snap in nyl 375 ID x 500mtg hole 1 Tr REED 22 140786 SWITCH reed ii oen die ob eae ile eres 1 etd RR ena re e 010 493 BUSHING snap in nyl 625 ID x 875mtg hole 1 TO ee El zs 0126639 FUSE minitr dlslo blo Acc sumaria LR eate e eure 1 er EE 046 432 HOLDER fuse mintr 250 x 1 250 panel mtg 1 Tien S4 011232 s OWMITCEL PB SPDT Sn dass 1 LO ios GBA cus
21. 1 2 Circuit Breaker CB1 See Section 5 11 3 Motor Torque Switch Use switch to select the force used to push wire The up position is for low force or torque The down position is for high force or torque 1 Last If welding wire appears to be 2 W kinked nicked or damaged place a as ee switch in low torque position 3 4 Brake Release Button Whenever power is On and the welding power source is energized 4 EOW TOROUE button may be pressed to release spool brake so wire spool can turn freely Close and latch door BRAKE RELEASE HIGH TORQUE Ref 151 779 Ref S 120 552 A OM 1581 Page 27 4 12 Gun Controls 1 Trigger Press trigger to energize welding power source contactor if applica ble start shielding gas flow and begin wire feed For shielding gas preflow and post flow partially press trigger before and partially release after welding 2 Wire Speed Control Use control to adjust wire feed speed The numbers around the control are for reference only Ref 802 536 1 Shielding Gas Cylinder 2 Valve 3 Gun Trigger Open valve on cylinder just before welding Gun trigger turns weld output and gas flows on and off see Section 4 12 Close valve on cylinder when finished welding sb5 1 6 92 S 0621 C Ref 802 536 1 Coolant Supply See Section 3 17 for coolant guidelines Turn On coolant supply before welding Turn Off coolant supply when finished
22. 174 092 CIRCUIT BREAKER man reset 1P 7A 250VAC 1 dtl AA S ass 038 861 BLOCK term 204 3P x scusa d ed ec dee dirt ei sete Cede eie 1 LA gid ae ds 601 219 LINK jumper term blk 20A 7 When ordering a component originally displaying a precautionary label the label should also be ordered Part of Spot Weld Control Option Part of Voltage Control Option e Part of Water Flow Shutdown Switch Option Recommended Spare Parts 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 OM 1581 Page 42 Item Dia Part No Mkgs No Description Quantity Figure 7 2 Motor amp Wire Drive Fig 7 1 Item 71 atin vile ek SE 115 191 DRIVE ASSEMBLY wire consisting of 1 E EE 058 968 RING retainer E eee 1 D AA 605 798 WASHER shldr nyl 375 OD x 168 ID x 080thk 4 EE EEN 120 395 SPRING tension pressure roll 1 E Si Sr 112 13 2 ARM pressure e EE 1 TW EH 058409 ccs E GO Le WEE 1 De GE 1120887522 A Be Ve et EE 1 LO qe 057 544 SPRING cprsn 240 OD x 026 wire x 1 000 1 EE WEE 120 397 NUT thumb tension adjustment 1 a 0 diia 147 626 erer COVER gear Wire FINE a vc ee id Ne
23. 45 in 0 8 Thru 1 1 mm Hard Or Cored Wire 2 3 Duty Cycle And Overheating Duty Cycle is percentage of 10 min utes that unit can weld at rated load without overheating A Exceeding duty cycle can damage unit and void warranty Air Cooled Models 100 Duty Cycle At 200 Amperes Using Argon 60 Duty Cycle At 250 Amperes Using Argon gt Continuous Welding 6 Minutes Welding 4 Minutes Resting Water Cooled Models 100 Duty Cycle At 400 Amperes Using Argon D Continuous Welding OM 1581 Page 9 SECTION 3 INSTALLATION Be sure that contact tip liner and drive rolls are correct for wire size and type See Section 5 to change parts as needed See Section 7 for list of other available contact tips Review Section 3 1 through Section 3 4 to determine how equipment will be connected Air cooled models are shown in Section 3 1 through Section 3 4 For water cooled models supplied water hoses must be connected from wire feed er to coolant supply Read entire Section 3 before installing equipment 3 1 Connections With A CC CV Or CC CV Voltage Welding Power Source Having A 14 Socket Receptacle Constant Current CC Constant Voltage CV Or Constant Current Constant Voltage CC CV Welding Power Source 2 115 VAC Contactor Control 14 Pin Plug 3 Workpiece 4 Voltage Sensing Lead Connect lead to workpiece for CC welding only 5 Gun 6 Wire Feeder 7 115 VAC Contactor Control Cord G
24. Cable Insert plug into Gun Control recep tacle and tighten threaded collar 2 Gas Hose Connect to Gas fitting on feeder 3 Weld Cable 4 Weld Cable Terminal In Feeder Connect gun weld cable to weld cable terminal in feeder 5 Wire Conduit 6 Thumbscrew 7 Wire Conduit Block Loosen thumbscrew and insert conduit through Wire opening until it bottoms against block Tighten thumbscrew Close and latch door Tools Needed YT 5 8 3 4 in 145 432 B Ref 802 536 Ref 151 778 B OM 1581 Page 13 3 7 Water Cooled Gun Connections Left Side Tools Needed YX 5 8 1 1 8 in OM 1581 Page 14 1 Gas Hose Connect to Gas fitting on feeder 2 Water Hose Connect to Water To Gun fitting on feeder left hand threads 3 Wire Conduit 4 Thumbscrew 5 Wire Conduit Block Loosen thumbscrew and insert conduit through Wire opening until it bottoms against block Tighten thumbscrew 6 Gun Control Cable Insert plug into Gun Control recep tacle and tighten threaded collar 7 Strain Relief Remove strain relief as shown 8 Power Water Cable Route cable through strain relief and connect to Weld Water From Gun outlet on feeder Reinstall strain relief Close and latch door Ref 151 778 B 152 456 A 3 8 Air Cooled Feeder Connections gt Rear Panel 1 Gas Hose Grommet 2 10ft 3 m Gas Hose 3 Rear Of Gas Fitting Route one end of gas hose through grommet and c
25. Coolant Supply Hose Grommet 5 10 ft 3 m Water Supply Hose With 5 8 in Adapter Fitting 6 Rear Of Water Fitting Left Hand Threads Remove 5 8 in adapter fitting from hose Route one end of a water hose through grommet and con nect to rear of Water To Gun fitting in feeder Connect remaining end to supply fitting on coolant supply 7 Coolant Return Hose Grommet 10 ft 3 m Water Return Hose 9 Connection Block Left Hand Threads Route one end of remaining water hose through grommet and con nect to rear of connection block not shown Connect remaining end of hose to return fitting on coolant supply 10 Weld Cable Grommet 11 Weld Cable To Welding Power Source Select and prepare weld cable according to welding power source manual 12 Current Sensing Reed Relay 13 Weld Cable Screw In Feeder Route one end of weld cable through grommet through reed relay and connect to block in feeder using hardware shown Connect remaining end of cable to positive weld output terminal on welding power source Close and latch door Tools Needed YT 5 8 1 1 8 in Ref 152 431 A 3 10 Adjusting Contact Tip Position Water Cooled Model 3 11 Voltage Sensing Lead Connections Tools Needed 3 E 14in Air Cooled Model Ale de 1 Contact Tip 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 3 J
26. D use or service this unit 42 O 39 O JE O 4 s 4U O 470 J4 O eo 470 35 O 42 O 430 42 O 67 O N ej 156 399 C Figure 6 1 Circuit Diagram For Wire Feeder OM 1581 Page 38 PULL GUN MOTOR ASSEMBLY TRIGGER 195 712 A e Disconnect input power or stop engine before servicing e Do not operate with covers removed ELECTRIC e Have only qualified persons install SHOCK HAZARD use or service this unit Figure 6 2 Circuit Diagram For Gun OM 1581 Page 39 SECTION 7 PARTS LIST CS Hardware is common and not available unless listed This main assembly drawing shows the XR W water cooled model Some parts for the XR A air cooled model vary in appearance When differences occur they are called out in the part description 75 76 77 78 143 223 D Figure 7 1 Main Assembly OM 1581 Page 40 Item Dia Part No Mkgs No Description Quantity Figure 7 1 Main Assembly D WE 089572 CATCH AINK IOCK so cidos dos 2 bis 112167 5 INSULATOR COON EE ds eg 1 e TR ee 134 327 LABEL warning general precautionary 1 No O 113509 WRAPPER EE 1 D ache noue 26415 GOLAMEB Sag3dle 4 55293 2 ur dre etd ct irn t dut vii EN 1 HW ds 126 416 HANDLE molded 1 EE 058 427 RING retaining spool 1 Oe 602 233 WASHER flat stl 250
27. ID x 875 OD x 062thk 1 RS E 057 543 SPRING cprsn 845 OD x 091 wire x 1 500 1 e d od ae eb 119 169 WASHER OCKO s iue na uc tto EUR RR m ala 2 A toa ate eed 058428 MUB SOON NEE 1 EE 0895617 WASHER antiturnisth sul A EE E a 1 ed a a 058424 WASHER fbr brake vastas sew a OE Ca t ia ed 1 nu mE 151 697 STRIP brake surface anti turn 1 no rca a eo qup tiri hts 112198 SHROUD spool wire 12 in 1 Bp EE 030 170 BUSHING snap in nyl 750 ID x 1 000mtg hole 1 Tee 057 357 BUSHING snap in nyl 937 ID x 1 125mtg hole water cooled model 2 Rd Je be 057 357 BUSHING snap in nyl 937 ID x 1 125mtg hole air cooled model 1 A EE EE 070 371 BLANK snap in nyl 1 093 1 125mtg hole air cooled model 1 E EEN 057 358 BUSHING snap in nyl 1 000 ID x 1 375mtg hole 1 zc d EE 134 201 STAND OFF PC Card issue eee ce eee ee ewes eee data 4 20 PC3 0114538 CIRCUIT CARD spot burnback 1 E PLG7 8 11 115 094 HOUSING PLUG 8 SOCKETS 8 BEE PLGO EENG ah RA EEN HOUSING BETEN KEEN ER PLG10 115 093 HOUSING PLUG 8 SOCKETS 1 NEE 073 302 BEARING ball rdl sgl row 669 x 1 378 x 39 2 E ETES 113 161 BLOCK be
28. NG hose brs nut 625 18RH 4 2 ENNER 056 112 FITTING hose brs ferrule 475 ID x 718 lg 2 Eh eg 603 106 HOSE nprn brd No 1 x 250 ID order by ft 10ft Dern 198 891 CABLE control 15 ft 15A amp W models 1 B nice Ud 198 810 CABLE control 30 ft 30A amp W models 1 tae 137 476 CABLE power water out 15ft 15W model 1 S audet UE 137 477 CABLE power water out 30ft SOW model 1 oa 073 476 CLAMP strap rbr 5 holes 375 wide x 4 625 lg 15A 8 W models 6 Ditto 073476 CLAMP strap rbr 5 holes 375 wide x 4 625 lg 30A amp W models 13 Plone ERE 162 041 BEARING BLOCK ASSEMBLY 1 EEN 604 638 SCREW cap stl sch 6 32 x 375 3 SEHR 143 480 SCREW 6 32 x G2beochdheveil d A 136 135 ROLL drive VK groove 023 1 16 wire consisting of 1 E Un 604 612 SCREW set stl sch 8 32 x 125 cup point 2 E M 114045 SCREW 6 32 x 500 hexwhd slt stl slffmg 3 M US 134623 on BEARING idl r toll 5555 de in 1 MO ccc ee 192 952 E OR el socia e paid pw e Pus Gea whole eae 1 LU a 605 798 WASHER shldr nyl 375 OD x 168 ID x 080
29. OM 1581 137 532M March 2001 Processes WELDING PRODUCTS ES MIG GMAW Welding Description Wire Feeder And Feeder Gun Olympic XR A And XR W OWNER S MANUAL 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 W 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 Hobart is registered to the needs repair there s a Troubleshooting section GE bd Quality System that will help you figure out what the problem is The parts list will then help you to decide which exact part you may need to fix the problem Warranty and service information for your particular model are also provided REGISTEHED QUALITY SYSTEM Hobart Welders manufactures a full line of welders and welding related equipment For information on other quality Hobart products contact your local Hobart distributor Hobart offers a Technical Manual which provides more detailed service and parts information for your unit To obtain a Technical Manual contact your local to receive the latest full
30. acer ou exp dier des cartes de circuits imprimes DES ORGANES MOBILES peuvent provoquer des blessures e Ne pas s approcher des organes mobiles e Ne pas s approcher des points de coincement tels que des rouleaux de commande LES FILS DE SOUDAGE peuvent pro voquer des blessures e Ne pas appuyer sur la gachette avant d en avoir recu l instruction e Ne pas diriger le pistolet vers soi d autres person nes ou toute pi ce m canique en engageant le fil de soudage DES ORGANES MOBILES peuvent provoquer des blessures e Rester l cart des organes mobiles comme le ventilateur e Maintenir ferm s et fixement en place les portes panneaux recouvrements et dispositifs de protection LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute frequence peut provoquer des interf rences avec les quipements de ra dio navigation et de communication les services de s curit et les ordinateurs Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installa tion L utilisateur est tenu de faire corriger rapidement par un lectricien qualifi les interf rences r sultant de l installation Si le FCC signale des interf rences arr ter imm diatement l appa reil Effectuer r guli rement le contr le et l entretien de l installation Maintenir soigneusement ferm s les portes et le
31. am Nut 4 Barrel To change contact tip location loosen jam nut and turn barrel Tighten jam nut 150 434 Ref 150 431 Unit is factory set for constant volt age CV welding To set unit for constant current CC welding proceed as follows 1 Terminal Strip 2T 2 Strain Relief Loosen screws of strain relief 3 Voltage Sensing Lead Route ring terminal end of lead through strain relief and connect ring terminal to terminal A of terminal strip 2T Tighten screws on strain relief 4 Motor Speed Control Board PC1 5 Jumper Plug 6 Receptacle RC5 For constant voltage CV welding place jumper plug in INT position Do not connect voltage sensing lead clamp to workpiece For constant current CC welding place plug in EXT position Connect clamp end of voltage sensing lead to workpiece Reinstall right side panel Ref 151 772 A OM 1581 Page 17 3 12 115 VAC Contactor Control Plug Information 1 Interconnecting Cord 2 115 VAC Contactor Control Plug PLG5 If CC or CC CV welding power source is equipped with matching 14 socket receptacle insert plug and tighten threaded collar Proceed to Section 3 14 If plug PLG5 will not connect to CC welding power source receptacle use the following pin information and Section 3 13 to replace PL G5 with a suitable plug Tm Pin Information Contact closure to A completes contactor control circuit Remote 115 volts ac Contactor Contact cl
32. anel Controls Of Feeder Air Cooled Model Shown Voltage Wire Speed Meter Optional Voltage Wire Speed Switch Optional Run In Speed Control Jog Switch Burnback Time Control Optional Spot Continuous Switch Optional Remote Voltage Control Optional Power Switch Time Range Switch Optional Spot Time Control Optional Flowmeter Optional 151 780 A Wear the following while welding 1 Dry Insulating Gloves 2 Safety Glasses With Side Shields Welding Helmet With Correct Shade Of Filter See ANSI Z49 1 sb3 1 1 94 1 Work Clamp Connect work clamp to a clean paint free location on workpiece as close to weld area as possible Use wire brush or sandpaper to clean metal at weld joint area 2 Voltage Sensing Cable Clamp Connect voltage sensing cable clamp to workpiece for constant Tools Needed current CC operations see Section 3 11 OM 1581 Page 24 sb4 1 2 93 Ref 144 451 A 4 4 Run In Speed Control 1 Run In Speed Control Use control to set wire feed speed before arc initiation After arc initiation wire feed speed is controlled by the Wire Speed Control on the welding gun see Section 4 12 The scale around the control is per cent of full range not wire speed As a general rule set run in speed lower than welding wire feed speed Set control at O zero for scratch start Ref 176 700 A 4 5 Jog Switch 1 Jog Switch Use switch to energize d
33. any interference problem resulting from the installa tion e f notified by the FCC about interference stop using the equipmentat once Have the installation regularly checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electromagnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor e locate welding operation 100 meters from any sensitive elec tronic equipment e Be sure this welding machine is installed and grounded according to this manual e lf interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation An
34. ardware is common and not available unless listed See Fig 7 1 Item 59 145 127 B Figure 7 3 Panel Front w Components Water Cooled Model Illustrated OM 1581 Page 44 No Mkgs No Description Quantity Figure 7 3 Panel Front w Components Fig 7 1 Item 59 aude 111 569 METER flow 6 60 1 PR a de 111633 GUARD flow meter 1 NOM GER 134834 HOSE SAE 187 ID x 410 OD order by ft Aft TETTE 056 851 FITTING hose brs barbed nipple 3 16tbg 2 Teo LEES 010 606 FITTING hose brs nut 625 18 2 EE ata doo dilo ds ida do 056 108 FITTING hose brs ferrule 425 ID x 718 lg 2 EE 045 852 CLIP component 687dia mtg adh back d A DEE 089 120 CLAMP hose 375 450clp dia 2 E RN 112 090 FITTING pipe brs elb 1 8NPT x 3 16 hose 2 E WEE 097 922 KNOB e el EE 1 ad A de OA NAMEPLATE order by model and serial number 1 RG A re 139 678 FITTING water water cooled model 1 Veri dir ee eee eu 000 527 BLANK snap in nyl 875mtg hole air cooled model 1 UAE ONG OR 000 434 s FITTING e E EE 1 ni ere 94115 443 STAND OFF No 6 32 x 750 lg 2 aee k ei
35. aring ront sus il as 1 EE 113 165 STAND OFF 250 20 x 1 000 Ig 4 TN 120 396 zs ee Le oi cit amus ater E eb teed hee ee eit foede te wd 1 Os MPA bro da 113 899 BRAKE w terminals 1 E OPENED fee 113 900 BEOGIS Dearing Teal siria dalek ace do ROC mn Sus Ue ems 1 EP 601 229 GLAMP UNV 25A iss ane E EE edule os FIER ce dre PISA 1 EE 601 226 INSULATOR vinyl clamp univ 284 1 HAT EAEE 600 848 WIRE lead mot 12ga strd order by ft 3bft ES E 176 089 TUBING plste PVG black naine rs sise sis 1ft a AA 115 104 CONNECTOR clamp cable 500 1 PS o4 bdo ARA 000 527 BLANK snap in nyl 875mtg hole 1 cad 007 826 CABLE port No 18 3 c order by ft 11ft 34 PLG5 141 162 er HOUSING PLUG amp PINS 5 cad ohne een dh eine Se RE 1 ENEE 079 739 CLAMP cable strain relief 1 Ec P 007 826 CABLE port No 18 3 c order by ft 11ft pO aa ees 007 826 CABLE port No 18 3 c order by ft 11ft NICE 139 042 BUSHING strain relief 270 480 ID x 804mtg hole 2 a EDU 139 042 BUSHING strain relief 270 480 ID x 804mtg hole 1 OO mp POT des 142053 CIRCUIT CARD motor speed cont
36. arrel 2 875 lg 15A amp 30A models TUBE contact 025 31 wire TUBE contact 030 36 wire TUBE contact 030 41 wire TUBE contact 035 41 wire TUBE contact 035 52 wire TUBE contact 047 52 wire TUBE contact 047 61 wire TUBE contact 062 73 wire TUBE contact 062 81 wire WRENCH nut tube contact WRENCH hex 078 across the flat NUT compression 375 24 LINER teflon 045 1 16 wire x 6 875 lg LINER teflon 023 035 wire x 6 875 lg ADAPTER contact tube 15A amp 30A models O RING 176 ID x 070CS 15A amp 30A models SCREW set stl sch 8 32 x 125 15A amp 30A models TUBE head 15A amp 30A models NUT jam nozzle extension 15A amp 30A models SCREW set stl sch 10 32 x 187 cup point 15A amp 30A models ADAPTER tube head 15A amp 30A models O RING 614 ID x 070CS MANIFOLD water 15W amp 30W models consisting of O RING 614 ID x 070CS SCREW cap stl sch 6 32 x 1 000 15W amp 30W models Figure 7 5 Barrel Assembly STAR Legh f d Ke A DAR Quantity Ly Be Se E Eis 800 434 A OM 1581 Page 49 Item No OPTIONAL Description Quantity Figure 7 5 Barrel Assembly Fig 7 4 Item 40 Continued BARREL ASSEMBLY water cooled 15W 8 30W models CONSI UA OL aceso rss is ae a ae esti ee 1 SO RING ak ID x 070 S 1x andara 1 O RING 176 ID x 070CS 15W 8 30W models 1 es
37. as Oylinder 151 774 B OM 1581 Page 10 3 2 Connections With A CV Welding Power Source Having Separate 115 VAC And Contactor Control Receptacles 1 Constant Voltage CV Weld ing Power Source 2 Plug Obtain matching plugs for connect ing to power source receptacles 3 Workpiece 4 Voltage Sensing Lead Do not connect to workpiece 5 Gun 6 Wire Feeder 7 115 VAC Contactor Control Cord Gas Cylinder 151 775 C 3 3 Connections With A CC Welding Power Source Having A Contactor Control Receptacle Constant Current CC Weld ing Power Source 5 Pin Or Two Prong Twistlock Plug Workpiece Voltage Sensing Lead Gun Wire Feeder 3 Conductor Contactor Con trol Cord 3 Conductor 115 VAC Cord Gas Cylinder 10 115 VAC Plug Obtain plug for wire feeder 151 776 B OM 1581 Page 11 3 4 Connections With A CC Welding Power Source And A 115 VAC 12 VDC Secondary Contactor Constant Current CC Weld ing Power Source Workpiece Voltage Sensing Lead Gun Wire Feeder 3 Conductor 115 VAC Cord 3 Conductor Contactor Con trol Cord 5 Pin Plug Secondary Contactor 10 Gas Cylinder 11 115 VAC Plug Obtain plug for wire feeder 151 777 B 1 Top Cover Push back and lift off as shown To reinstall cover set rear of cover in gun and push cover back down and forward until it clicks into position 802 528 OM 1581 Page 12 3 6 Air Cooled Gun Connections 1 Gun Control
38. bart1 WELDING PRODUCTS
39. can cause injury e Keep away from moving parts e Keep away from pinch points such as drive rolls WELDING WIRE can cause injury e Do not press gun trigger until instructed to do SO e Do not point gun toward any part of the body other people or any metal when threading welding wire PAL 1 4 Principal Safety Standards Safety in Welding and Cutting ANSI Standard Z49 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 Safety and Health Standards OSHA 29 CFR 1910 from Superinten dent of Documents U S Government Printing Office Washington D C 20402 Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances American Welding Society Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 from National Fire Protec tion Association Batterymarch Park Quincy MA 02269 MOVING PARTS can cause injury e Keep away from moving parts such as fans e Keep all doors panels covers and guards closed and securely in place H F RADIATION can cause interference e High frequency H F can interfere with radio navigation safety services computers and communications equipment e Have only qualified persons familiar with electronic equipment perform this installation e Theuseris responsible for having a qualified electrician prompt ly correct
40. curely in place Clamp work cable with good metal to metal contact to workpiece or worktable as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters e Turn Off inverter disconnect input power and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health Keep your head out of the fumes Do not breathe the fumes If inside ventilate the area and or use exhaust at the arc to remove welding fumes and gases If ventilation is poor use an approved air supplied respirator Read the Material Safety Data Sheets MSDSs and the manufacturers instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watch person nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breath ing air is safe e Do not weld in locations near degreasing cleaning or spraying op erations The heat and rays of the arc can react with vapors to form
41. d Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 1430 Broadway New York NY 10018 Cutting And Welding Processes NFPA Standard 51B from National Fire Protection Association Batterymarch Park Quincy MA 02269 OM 1581 Page 3 1 5 EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power frequency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting To reduce magnetic fields in the workplace use the following procedures OM 1581 Page 4 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 your body 4 Keep welding power source and cables as far away from opera tor as practical 5 Connect work clamp
42. e hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section 1 4 Read and follow all Safety Standards Only qualified persons should install operate maintain and repair this unit A During operation keep everybody especially children away Lr ELECTRIC SHOCK can kill ven Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wire welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard e Do not touch live electrical parts e Wear dry hole free insulating gloves and body protection e Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground e Do not use AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit e Disconnect input power or stop engine before installing or
43. e 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 3 Years Labor Original main power rectifiers Inverters input and output rectifiers only 2 3 Years Parts and Labor Transformer Rectifier Power Sources Plasma Arc Cutting Power Sources Semi Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators NOTE Engines are warranted separately by the engine manufacturer 3 1 Year Parts and Labor DS 2 Wire Feeder Motor Driven Guns w exception of Spoolmate 185 8 Spoolmate 250 Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Units Grids Maxstar 140 Spot Welders Load Banks Hobart Cyclomatic Equipment Running Gear Trailers Plasma Cutting Torches except APT amp SAF Models Field Options NOTE Field options are covered under True Blue for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 6 Months Batteries 5 90 Days Parts MIG Guns TIG Torches Induction Heating Coils and Blankets APT ZIPCUT amp PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts No labor Spo
44. es prendre pour viter tout danger e Nutiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel e Porter un harnais de s curit quand on travaille en hauteur e Maintenir solidement en place tous les panneaux et capots e Fixer le c ble de retour de facon obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure e isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Il y a DU COURANT CONTINU IMPORTANT dans les convertisseurs apres la suppression de l alimenta tion lectrique e Arr ter les convertisseurs d brancher le courant lectrique et d charger les condensateurs d alimentation selon les instructions indiqu es dans la partie entretien avant de toucher les pi ces LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant e Eloigner votre t te des fum es Ne pas respirer les fum es e l int rieur ventiler la zone et ou utiliser un chappement au niveau de l arc pour l vacuation des fum es et des gaz de soudage e Sila ventilation est insuffisante utiliser un respirateur alimenta tion d air homologu e Lire les sp cifications de s curit des mat riaux MSDSs et les instructions du
45. es op rations de soudage l arc de gou geage ou de soudage par points OM 1581 Page 7 1 4 Principales normes de s curit Safety in Welding and Cutting norme ANSI 249 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 S Government Printing Office Washington D C 20402 Recommended Safe Practice for the Preparation for Welding and Cut ting of Containers That Have Held Hazardous Substances norme AWS F4 1 de l American Welding Society 550 N W Lejeune Rd Miami FL 33126 National Electrical Code NFPA Standard 70 de la National Fire Protec tion Association Batterymarch Park Quincy MA 02269 Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de la Compressed Gas Association 1235 Jefferson Davis Highway Suite 501 Arlington VA 22202 R gles de s curit en soudage coupage et proc d s connexes norme CSA W117 2 de l Association canadienne de normalisation vente de normes 178 Rexdale Boulevard Rexdale Ontario Canada M9W 1R3 Safe Practices For Occupation And Educational Eye And Face Protec tion norme ANSI Z87 1 de l American National Standards Institute 1430 Broadway New York NY 10018 Cutting and Welding Processes norme NFPA 51B de la National Fire Protection Association Batterymarch Park Quincy MA 02269 1 5 Information sur les champs lectromagn tiques Donn es sur le s
46. fabricant concernant les m taux les consomma bles les rev tements les nettoyants et les d graisseurs e Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxy g ne provoquant des blessures ou des accidents mortels S assu rer que l air de respiration ne pr sente aucun danger e Ne pas souder dans des endroits situ s proximit d op rations de d graissage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants e Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev te ment n ait t enlev dans la zone de soudure que l endroit soit bien ventil et si n cessaire en portant un respirateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage OM 1581 Page 5 LES RAYONS DE L ARC peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarouges susceptibles de provoquer des br lures dans les yeux et sur
47. highly toxic and irritating gases e Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and if necessary while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded OM 1581 Page 1 ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays SH burn eyes and skin Sparks fly off from the weld e Wear a welding helmet fitted with a proper shade of filter to protect your face and eyes when welding or watching see ANSI 249 1 and Z87 1 listed in Safety Standards e Wear approved safety glasses with side shields under your helmet e Use protective screens or barriers to protect others from flash and glare warn others not to watch the arc e Wear protective clothing made from durable flame resistant mate rial leather and wool and foot protection f WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Protect yourse
48. ime Range Switch Use switch to select spot weld time range 3 Spot Time Control Use control to set spot weld time Welding wire feeds at speed se lected on the gun Wire Speed Con trol Spot time starts at arc initiation The scale around the control is marked in seconds 4 Burnback Time Control Use control to adjust time up to 0 25 seconds that the welding wire is electrically energized after the wire stops feeding If welding wire sticks in the weld puddle increase burnback time If wire burns back into the gun contact tip decrease burnback time The scale around the control is marked in fractions of a second 1 Voltage Control Use control to adjust arc voltage at the wire feeder The scale around the control is marked in percent 1 Power Switch Use switch to turn unit On and Off 4 10 Flowmeter Optional 4 CAUTION Wire feeding system is designed for maximum of 50 psi 345 kPa gas pressure 9 Be sure that regulator flowmeter has preset conditions of no more than 50 psi 345 kPa gas pressure 1 Flowmeter 2 Valve Use flowmeter to control shielding gas flow at the feeder The scale on the flowmeter is in cubic feet per hour CFH Read gas flow at the widest part of the float in the meter Rotate valve to change gas flow as necessary A regulator is still required on shielding gas supply with this option 4 11 Internal Controls Open left side door 1 Fuse F1 See Section 5 1
49. imitations 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 WELDERS hobart standard 7 00 Owner s Record Please complete and retain with your personal records Model Name Purchase Date Distributor Address City State Serial Style Number Date which equipment was delivered to original customer Resources Avallable Always provide 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 the Delivering Carrier for For assistance in filing or settling claims contact your distributor and or equipment manufacturers Transportation Department PRINTED IN USA 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 File a claim for loss or damage during shipment 2000 Hobart Welding Products 1 00 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 Ho
50. ing Turn Off wire feeder and welding power source 1 Top 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 Reinstall top cover Tools Needed E YH Ref 151 599 C Turn Off wire feeder and welding power source Pressure Roll Assembly Retaining Ring Mounting Arm Hinge Pin Screw Shoulder Washer Drive Roll Bearing Remove as shown Use a wire brush to clean bearing Reinstall and tighten screw Close pressure roll assembly Close and latch door Tools Needed YY 151 778 Ref 151 781 B OM 1581 Page 32 5 6 Changing Gun Contact Tip And Liner Turn Off wire feeder and welding power source Remove top cover and open pres sure roll assembly as shown in Section 5 4 1 Contact Tip Wrench Insert wrench into nozzle over contact tip 2 Compression Nut Loosen nut Pull out contact tip 3 Contact Tip 4 Nozzle Pull wire out nozzle and liner should slide out If necessary tilt nozzle down to remove liner Close pressure roll assembly Reinstall top cover Install new liner and contact tip over wire Cut off wire at end of contact tip Tighten nut just until contact tip is secure Overtightening nut will damage adapter Tools Needed gt 150 437 5 7 Removing Contact Tip Adapter In Air Cooled Models Turn Off wire feeder
51. ive motor operates in the Jog mode with CB1 open Check for blocked gun liner Check for jammed wire binding drive gear or misaligned drive rolls in feeder Correct problem Allow cooling period and manually reset breaker Close and latch door Ref 151 779 A Ref 800 185 A 5 12 Water Flow Switch Optional For Water Cooled Models The water flow switch protects the gun from overheating If coolant flow rate drops below 1 qt min the water flow switch opens and stops the welding wire from feeding See Section 5 13 for remedies to this trouble OM 1581 Page 35 5 13 Troubleshooting A Wire Feeder Trouble Trouble Remedy Pressing gun trigger does not energize feeder Welding wire is not energized Shielding gas flows Secure plug from gun control cable into Gun Control receptacle on feeder see Section 3 6 Secure 115 VAC input plug connection see Section 3 12 Check fuse F1 see Section 5 11 Check water connection to feeder or gun see Sections 3 6 and 3 8 Check for kinks in water hose Be sure coolant supply is turned On see Section 4 14 Have nearest Factory Authorized Service Station Service Distributor check optional water flow switch if applicable see Section 5 12 Wire feeds shielding gas flows but welding wire is not energized Secure 115 VAC contactor control plug connection see Section 3 12 See Troubleshooting section in welding po
52. lf and others from flying sparks and hot metal e Do not weld where flying sparks can strike flammable material e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Be alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side e Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e 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 and fire hazards Do not use welder to thaw frozen pipes Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuffless trousers high shoes and a cap e Remove any combustibles such as a butane lighter or matches from your person before doing any welding Sech FLYING METAL can injure eyes e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding
53. n or F O B at a Hobart authorized service facility as determined by Hobart 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 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 WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART IS EXCLUDED AND DISCLAIMED BY HOBART Some states in the U S A do not allow limitations of 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 l
54. n Thumbnut 8 Jog Switch Turn On wire feeder For proper ad justment loosen thumbnut until drive roll slips when Jog switch is pushed up Grasp spool with one hand and turn thumbnut clockwise until motor stalls when Jog switch is pushed up Feed welding wire through gun see Section 3 16 Turn Off wire feeder Close and latch door Tools Needed EF 151 778 B Ref 176 700 A OM 1581 Page 21 3 16 Threading Welding Wire Through Gun 1 Pressure Roll Assembly Lift arm and open pressure roll assembly 2 Wire Conduit Lay wire conduit out straight 3 Jog Switch Push Jog switch up to feed wire through wire conduit 4 Drive Roll For wire sizes 035 in 0 9 mm and smaller use small groove and 047 in 1 2 mm and 1 16 in 1 6 mm use large groove 5 Contact Tip Manually thread wire along drive roll groove and out contact tip 2 in 51 mm Close pressure roll assembly 6 Tension Thumbnut 7 Pressure Adjustment Knob 8 Final Pressure Adjustment Turn On feeder and check drive roll pressure by feeding wire against a piece of wood or concrete surface wire should feed steadily without slipping If necessary adjust pressure adjustment knob in gun Turn Off feeder and welding power source Reinstall gun cover Close and latch feeder door Ref 157 779 A Ref 176 700 A Ref S 0651 3 17 Coolant Guidelines 4 CAUTION INCORRECT COOLANT OR COOLANT CONTAINING STOP LEAK ADDITIVES can corr
55. ode and or plug gun feeder cooling passages 9 Use only a mix of 50 distilled water and 50 high quality automotive antifreeze as proper coolant for this product Do not use antifreeze containing stop leak additives 9 Use of other coolant voids warranty Follow these guidelines to decrease corrosion in gun feeder and cooling system Am 1 Coolant Distilled Water amp Mix distilled water and high quality Antifreez automotive antifreeze Use anti freeze which does not contain stop leak additives Use of other coolant voids warranty N 2 Coolant System Tank 3 Changing Coolant Change coolant only if dirty Add coolant to keep level full Draining Filling Tighten Connections 4 Tighten Connections 4 Keep gun connections tight s 0760 OM 1581 Page 22 3 18 Adjusting Wire Feed Starting Speed To adjust wire feed starting speed proceed as follows Turn Off wire feeder and welding power source Open right side panel 1 Motor Speed Control Board PC1 2 Motor Start Control Potentiometer R70 Turn potentiometer clockwise to increase time it takes the motor to ramp up to speed Remove protective white rubber cap before making adjustment Adjust potentiometer using a small nonconductive screwdriver Close side door Top Of PC1 Tools Needed Nonconductive O FRIO 1 4 in Ref 151 772 A Ref 142 054 B OM 1581 Page 23 SECTION 4 OPERATION 4 1 Front P
56. ol Ij li Lo M on Nol A Tools Needed gt TT OM 1581 Page 20 Turn Off wire feeder and welding power source 1 Wire Spool 2 Top Cover 3 Pressure Roll Assembly 4 Gun Contact Tip If wire spool is being replaced open pressure roll assembly in gun and cut welding wire off at contact tip For welding power sources without contactor retract wire onto spool For welding power sources with a contactor energize power source turn On feeder press Brake Release button see Section 4 11 and retract wire onto spool Close gun pressure roll assembly and reinstall top cover 5 Hub 6 Hub Pin 7 Compression Spring Optional For 8 in Spool 8 Retaining Ring Slide spool onto hub so wire feeds off bottom Turn spool until hub pin fits hole in back of spool Reinstall retaining ring Thread welding wire see Section 3 15 Close and latch door or go on to Section 3 15 Ref 151 771 A Ref 072 573 B Ref 151 599 C 3 15 Threading Welding Wire Through Feeder 1 Wire Spool Loosen wire from spool cut off bent wire and pull 6 in 150 mm of wire off spool 2 Tension Arm 3 Mounting Arm To open pressure roll assembly open tension arm and lift mounting arm 4 Wire Inlet Guide 5 Drive Roll 6 Wire Conduit Fitting Thread wire through wire inlet guide along drive roll groove and into fitting Close and secure pressure roll assembly 7 Tensio
57. olmate 185 amp Spoolmate 250 Canvas Covers HOBART s Limited Warranty shall not apply to 1 Consumable components such as contact tips cutting nozzles contactors brushes slip rings relays or parts that fail due to normal wear 2 Items furnished by Hobart 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 or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which 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 option 1 repair or 2 replacement or where authorized in writing by Hobart in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Hobart 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 option of repair or replacement will be F O B Factory at Appleton Wisconsi
58. onnect hose to rear of Gas fitting in feeder Connect remaining end of hose to regulator flowmeter 4 Weld Cable To Welding Power Source Select and prepare weld cable ac cording to welding power source manual 5 Weld Cable Grommet 6 Current Sensing Reed Relay 7 Weld Cable Terminal In Feeder no peg Route one end of weld cable gt through grommet through reed A Ye relay and connect to weld cable terminal in feeder Connect remaining end of cable to positive weld output terminal on welding power source 8 Gun Weld Cable Be sure that terminal of welding power source weld cable is in direct contact with terminal from gun weld cable Close and latch door Top View O AT y Connect P4 Positive Weld a To Tools Needed Output Ten nal On Regulator Welding Power Source Flowmeter TL 5 8 1 1 8 in Ref 151 771 A OM 1581 Page 15 3 9 Water Cooled Feeder Connections eee 2 11 12 3 Top View Rear Panel ClE i 8 7 0 j 1 Connect To Connect To Positive Weld Connect To Connect To Return Fitting On Output Terminal On Supply Fitting On Regulator Coolant Supply Welding Power Source Coolant Supply Flowmeter OM 1581 Page 16 Obtain coolant supply 1 Gas Hose Grommet 2 10ft 3 m Gas Hose 3 Rear Of Gas Fitting Route one end of gas hose through grommet and connect hose to rear of Gas fitting in feeder Connect remaining end of hose to regulator flowmeter 4
59. osure to completes 115 volts ac contactor control circuit Circuit common for 115 volts ac circuit 10 volts dc output to remote control Remote Remote control circuit common Voltage Control 0 to 10 volts dc input command signal from remote control Chassis common The remaining pins are not used OM 1581 Page 18 Ref S 0004 A Ref 151 772 3 13 Replacing 115 VAC Contactor Control Plug With Customer Supplied 5 Pin Or Twistlock Plug Tools Needed 1 115 VAC Contactor Control Plug PLG5 2 Contactor Control Cord 3 115 VAC Cord Find and label cords by following leads to back of PLG5 Contactor control cord connects to pins A amp B of PLG5 115 VAC cord connects to pin J of PLG5 Cut off plug PLG5 4 5 Pin Plug 5 Two Prong Twistlock Plug For connections shown in Figure 3 3 or Figure 3 4 install 5 pin or twistlock plug onto contactor con trol cord For Figure 3 2 connection obtain plug to match contactor control receptacle on welding power source and install plug onto contactor control cord Obtain 115 VAC plug and connect to 115 VAC cord as follows green lead to ground white lead to 115 VAC common black lead to 115 VAC hot 6 Plug PLG50 7 Plug PLG51 8 Plug PLG52 Unit shipped with PLG50 con nected to PLG51 to provide 115 VAC for contactor If contact closure needed for con tactor connect PLG50 to PLG52 151 773 C OM 1581 Page 19 3 14 Installing Wire Spo
60. oudage lectrique et sur les effets pour l organisme des champs magn tiques basse fr quence Le courant de soudage pendant son passage dans les c bles de sou dage causera des champs lectromagn tiques Il y a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir ex amin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Re search Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lectriques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les con clusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn ti ques pendant le soudage ou le coupage OM 1581 Page 8 Afin de r duire les champs lectromagn tiques dans l environnement de travail respecter les consignes suivantes 1 Garder les c bles ensembles en les torsadant ou en les attachant avec du ruban adh sif 2 Mettre tous les c bles du c t oppos de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les cables le plus loin possible de vous 5 Relier la pince de masse le plus pr s
61. pecific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over valve except when cylinder is in use or connected for use Read and follow instructions on compressed gas cylinders associated equipment and CGA publication P 1 listed in Safety Standards 1 3 Additional Symbols For Installation Operation And Maintenance FIRE OR EXPLOSION hazard e Do not install or place unit on over or near combustible surfaces e Do not install unit near flammables e Do not overload building wiring be sure power supply system is properly sized rated and protected to handle this unit FALLING UNIT can cause injury e Use lifting eye to lift unit only NOT running gear gas cylinders or any other accessories e Use equipment of adequate capacity to lift and support unit e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERUSE can cause OVERHEATING INN e Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit Le Pe STATIC ESD can damage PC boards J e Puton grounded wrist strap BEFORE handling boards or parts e Use proper static proof bags and boxes to store move or ship PC boards 2 em MOVING PARTS
62. r sur des substances inflammables D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneuse ment avec des protections homologu s Des tincelles et des mat riaux chauds du soudage peuvent facile ment passer dans d autres zones en traversant de petites fissures et des ouvertures Surveiller tout d clenchement d incendie et tenir un extincteur proxi mit Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r servoirs tambours ou conduites moins qu ils n aient t pr pa r s correctement conform ment AWS F4 1 voir les normes de s curit Brancher le c ble sur la pi ce le plus pr s possible de la zone de sou dage pour viter le transport du courant sur une longue distance par des chemins inconnus ventuels en provoquant des risques d lec trocution et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites ge l es En cas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans re vers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de
63. r worn parts and slide parts onto shaft as shown Adjust hub tension see Section 5 10 Thread welding wire see Section 3 15 Close and latch door Close gun pressure roll assembly and reinstall gun cover Tools Needed CORO 7 6 in 151 778 B Ref 143 223 A OM 1581 Page 34 5 10 Adjusting Hub Tension Tools Needed J 7 16 5 11 Overload Protection Y Lol Ok e e Y mi Vooo D y iB ad li I Im EE Q Be 1 Push And Turn y 2 Pull Out And Replace F1 Push And Turn Turn On welding power source and wire feeder to make this adjustment 1 Wire Speed Control Adjust control to wire speed for welding 2 Jog Switch Push up and then release Jog switch Hub tension is okay if wire unwinds freely but wire does not backlash when Jog switch is released 3 Cap Screw Turn cap screw to adjust hub ten sion Do not overtighten Turn Off welding power source and wire feeder Close and latch door 151 778 Ref 802 536 Ref 176 700 A Turn Off wire feeder and welding power source If F1 opens the unit shuts down To check or change F1 proceed as follows 1 Fuse Holder Cover 2 Fuse Fi See Parts List For Rating Insert new fuse into cover and in stall fuse with cover by pressing and turning cover clockwise 3 Circuit Breaker CB1 If CB1 opens the gun drive motor and contactor will not operate but gas flows when trigger is pulled The gun dr
64. rive mo tors in feeder and gun without ener gizing welding power source con tactor When switch is held up in Jog position wire speed is set by Wire Speed Control on gun 4 6 Voltage Wire Speed Switch And Meter Optional 1 Voltage Wire Speed Meter Volt sensing lead must be con nected to workpiece for me 2 Voltage Wire Speed Switch ters to operate When switch is in Voltage position and operator is welding meter dis plays arc voltage Cable resistance and poor connections may cause displayed voltage to vary slightly from actual voltage at welding arc When switch is in Wire Speed posi tion and operator is welding meter displays preset wire speed in in ches per minute This wire speed is set by Wire Speed Control on the gun During run in portion of weld cycle meter displays run in speed as se lected on Run In Speed control on feeder see Section 4 4 When welding Direct Current Elec trode Negative DCEN meter does not display accurate output voltages however meter displays accurate wire speed values OM 1581 Page 25 4 7 Spot Controls Optional 2t02 5S CONTIN JOUS TIME RANGE 4 8 Remote Voltage Control Optional 4 9 Power Switch OM 1581 Page 26 1 Spot Continuous Switch Use switch to select either an un timed continuous weld cycle or a timed spot weld cycle Both weld cycles consist of the following steps run in weld untimed or spot time and burnback 2 T
65. rol 1 TO PLG1 115092 HOUSING PLUG 8 GOChHEIS 1 aida PLG2 sons 115 094 az HOUSING PLUG amp SOCKETS suomi dr dro atar aa d ae une PLG3 115 091 HOUSING PLUG amp SOCKETS l TUER PLG4 131054 HOUSING RECEPTACLE amp SOCKETS 1 SAO T A ARE 088 E EEN BLOCK term 20ACT2D 3 2 ed E erem emend tee eue 1 sMO PLOSO ss 131203 HOUSING PLUG amp PIN Si matters 1 41 PLG51 52 131 204 HOUSING PLUG 8 SOCKETS 2 ra orne GIS aies MSI GAPRAGITOR ES cd taaan 1 43 SNT 110 079 SNUBBER polye MF 5uf 200VDC 1 mU DERE RECO 605 741 CLIP mtg resistor 312 ID core 2 245 Le ROO rx 030 087 RESISTOR WW fxd 25W 200 ohm 1 46 A 114 215 CAPACITOR polye film 2 3uf 250VAC 1 47 C14 044 602 CAPACITOR polye film 47uf 400VDC 1 I o TT 4T 033 765 ve STRIP tetti SP erosiva dira Dk dta ete e E eds 1 To 134 201 STAND OFF SUPPORT PC card 4 OM 1581 Page 41 No Mkgs No Description Quantity Figure 7 1 Main Assembly Continued 22225 incr a od a TA Oe 22 SD ASC AAA A MOM em ended 2 Dean At 1760 7 142 CABINET CONTO aii 1 DEE 153 901 LABEL caution
66. roll in feeder proceed to Section 5 3 Thread welding wire through gun and adjust drive roll pressure if necessary see Section 3 16 Close and secure pressure roll assembly Reinstall top cover Ref 151 599 C 5 3 Changing Feeder Drive Roll And Wire Inlet Guide Turn Off wire feeder and welding power source Lay wire conduit out straight Open gun pressure roll assembly and cut welding wire off at contact tip 1 Pressure Roll Assembly 2 Wire Spool 2 For welding power sources without contactor retract wire onto spool For welding power sources with a contactor energize power source turn On feeder press Brake Re lease button and retract wire onto spool 3 Shaft 4 Setscrew 5 Drive Roll Use wire brush to clean drive roll Install drive roll with desired groove in and turn drive roll so one setscrew faces flat side of shaft 6 Bearing 7 Wire Conduit Fitting Line up drive roll groove with bear ing groove and opening in conduit fitting Tighten setscrews 8 Wire Inlet Guide Pull guide toward rear of feeder to remove Install new guide Thread welding wire and adjust drive roll pressure if necessary see Section 3 15 Close and se cure pressure roll assembly Close and latch door Close gun pressure roll assembly and reinstall gun cover Tools Needed 5 16 in EE Te C OP nm 151 778 Ref 151 781 B OM 1581 Page 31 5 4 Replacing Or Cleaning Gun Drive Roll Bear
67. s blessures graves L lectrode et le circuit de soudage sont sous tension des que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger e Ne jamais toucher les pi ces lectriques sous tension e Porter des gants et des v tements de protection secs ne comportant pas de trous e Sisoler de la pi ce et de la terre au moyen de tapis ou d autres moyens isolants suffisamment grands pour emp cher le contact phy sique ventuel avec la pi ce ou la terre e Ne pas se servir de source lectrique acourant lectrique dans les zones humides dans les endroits confin s ou l o on risque de tomber e Se servir d une source lectrique acourant lectrique UNIQUEMENT si le proc d de soudage le demande e GSil utilisation d une source lectrique acourant lectrique s av re n ces saire se servir de la fonction de t l commande si l appareil en est quip e Couper l alimentation ou arr ter le moteur avant de proc der l instal lation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit e Installer et met
68. s panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et et un blindage pour r duire les interf rences ventuelles LE SOUDAGE L ARC risque de provoquer des interf rences e L nergie lectromagn tique risque de provoquer des interf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordinateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit com patible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les c bles de soudage aussi courts que possible les grouper et les poser aussi bas que possible ex par terre Veiller souder une distance de 100 m tres de tout quipement lectronique sensible Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi En cas d interf rences apr s avoir pris les mesures pr c dentes il incombe l utilisateur de prendre des mesures suppl mentaires tel les que le d placement du poste l utilisation de c bles blind s l uti lisation de filtres de ligne ou la pose de protecteurs dans la zone de travail LES CHAMPS MAGN TIQUES peuvent affecter les stimulateurs cardiaques e Porteurs de stimulateur cardiaque restez dis tance e les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s appro cher d
69. the recommended coolant to be 1 TE 605 970 WASHER shldr nyl 310 OD x 252 ID x 064 water cooled model 4 EE 605 970 WASHER shldr nyl 210 OD x 252 ID x 064 air cooled model 3 OO EE EN ao 090 465 TRANSFORMER signal 115V 24VCT4A 1 Iu DA EE 090 439 LABEL warning electric shock can kill 1 Ec AN 089 573 PLATE keeper link ok 4 21 uere e boe hee mies 2 E A add ac e 131 318 INSULATOR block connection water cooled model 1 EE 113 166 INSULATOR term air cooled model 1 E dit lacio a a 13131142 BLOCK COMMS CON usara a at da 1 DO ER T 150 067 FITTING water block extension 1 DO oui Dedi ed A Fig 7 3 PANEL front w components 1 ia 121276 BUSHING strain relief 709 ID x 1 115mtg hole 1 AN ad 0 134834 HOSE SAE 187 ID X 410 OD order by ft 2ft e EE 089 120 CLAMP hose 375 450clp dia slfttng 4 OO a S8 644164963 SWITCH flow w fittings 1 Po DA teens 601966 SCREW cap stl hexhd 375 16 x 1 250 water cooled model 1 MIL MT 117 498 TERMINAL pwr weld air cooled model 1 sura ads Sod maim Se M ee 117 496 WASHER fbr 312 ID
70. tions With A CC CV Or CC CV Voltage Welding Power Source Having A I4 Sockeb HecepIacle caia cedat Oud EUR Td RU ESPERE ET A Odes nd de 10 3 2 Connections With A CV Welding Power Source Having Separate 115 VAC And Gontactor Control Receptacles ek eg o IRR ER RR IRYTEErRSGE da 11 3 3 Connections With A CC Welding Power Source Having Contactor Control Receptacle 11 3 4 Connections With A CC Welding Power Source And A 115 VAC 12 VDC Secondary Contactor suus isos se Re wb eee eb need Se E de 12 3 5 Removing Top Cover Of Gun linasa aiai aa nent enn ne nee 12 3 6 Al Cooled Guilt Gonneclofis ares sut eux d aud Geol ye Sane DEPO Reese Sane ae ey 13 3 7 Water Cooled Gun Connections 14 3 8 Air Cooled Feeder Connections 15 3 9 Water Cooled Feeder Connections 16 3 10 Adjusting Contact Tip Position 17 3 11 Voltage Sensing Lead Connections 17 3 12 115 VAC Contactor Control Plug Information 18 3 13 Replacing 115 VAC Contactor Control Plug With Customer Supplied 5 Pin Or MSI OUR temm E Emu bad a Rte aed pen at rm ous 19 314 Tostallitig Wire SpOOl sss wind iu macht rito eno E ntm iiie Sue uet 20 3 15 Threading Welding Wire Through Feeder
71. tre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux provinciaux et municipaux e Toujours v rifier la terre du cordon d alimentation V rifier et s assu rer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre e En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions e V rifier fr quemment le cordon d alimentation pour voir s il n est pas endommag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution e Mettre l appareil hors tension quand on ne l utilise pas e Ne pas utiliser des c bles us s endommag s de grosseur insuffi sante ou mal piss s e Ne pas enrouler les c bles autour du corps e Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct e Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine som nd fre 4 98 Ce groupe de symboles signifie Mise en garde Soyez vigilant Il y a des risques de danger reli s aux CHOCS ELECTRIQUES aux PIECES EN MOUVEMENT et aux PIECES CHAUDES Reportez vous aux symboles et aux directives ci dessous afin de connaitre les mesur
72. ue POZ Te 139 897 CIRCUIT CARD meter 1 Eeer PLG12 0115090 HOUSING PLUG 8 PINS e d Las dua PLG13 04115094 HOUSING RECEPTACLE amp SOCKETS 1 p ia PLG15 4115092 HOUSING PLUG amp SOCKETS 1 TUNE PLG16 4131055 HOUSING RECEPTACLE amp SOCKETS 1 EP ET 136339 COVER opening meter 1 rtr 120 304 BLANK snap in nyl 250mtg hole d 12 R44 073562 POTENTIOMETER C sltd sft 1 T 2W 10K ohm 1 Bat AD chal wi SEEE ET 120 400 SWITCH tgl 3PDT MC 15A 125VAC 1 14 R45 46 028 770 POTENTIOMETER C sltd sft 1 T 2W 1 meg ohm 2 ne loss S6 640011 770 SWITCH tgl SPDT 5A 125V 1 Ha TO Sas S5 011 609 SWITCH tgl SPDT 15A 125VAC 1 17 R50 66 035 897 POTENTIOMETER C sltd sft 1 T 2W 1000 ohm 1 18 PC4 RC20 199 508 CIRCUIT CARD AMER er s roce or eO br rt o e 1 EE 146 212 PLUG 10 pin MS 3106A 18 1PX Amphenol EUN PLG14 115092 HOUSING PLUG amp SOCKETS 1 EN PEE 4 9097922 KNOB DOME 4 s borda Cof eR Eier Reb edi deed 2 TEL ok dna rende 90440097922 KNOB pointer
73. v Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endomma g e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques du laitier des flammes ouvertes des tin celles et des arcs Placer les bouteilles debout en les fixant dans un support stationnai re ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser Tenir les bouteilles loign es des circuits de soudage ou autres cir cuits lectriques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en contact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et raccords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille Maintenir le chapeau de protection sur la soupape sauf en cas d uti lisation ou de branchement de la bouteille Lire et suivre les instructions concernant les bouteilles de gaz com prim les quipements associ s et les publications P 1 CGA nu m
74. ve in gun Reduce shielding gas pressure at regulator flowmeter Do not exceed 50 psi 345 kPa OM 1581 Page 36 B Gun Trouble Trouble Remedy No weld output gun feeder does not work Secure 115 VAC input plug in 115 volts ac receptacle see Section 3 12 Place Power switch on welding power source in the On position Erratic weld output Tighten and clean all connections Pressing gun feeder trigger does not en ergize weld control welding wire is not energized shielding gas does nat flow Secure plug from gun control cable into 10 socket receptacle on wire feeder see Section 3 6 Wire does not feed burnback in contact tip Reinstall current pick up tab if applicable see Section 5 2 Wire feeds shielding gas flows but welding wire is not energized Clean or replace drive rolls See Troubleshooting section in welding power source Owner s Manual see Sections 5 2 and 5 3 Wire feeds erratically Check and correct drive roll pressure see Section 3 15 Clean drive roll or replace drive roll see Sections 5 2 and 5 3 Gun overheating water cooled models Be sure coolant flowrate is at least 1 qt min 0 95 L min Corrosion buildup in gun decreasing coolant flowrate Backflush coolant system clean coolant system filter and clean fittings see Section 3 17 OM 1581 Page 37 SECTION 6 ELECTRICAL DIAGRAMS HD zx G
75. welding Ref 150 755 A 4 15 Sequence Of Gas Metal Arc Welding GMAW Continuous Or Spot Install amp Put On Turn On Gas Turn On Feeder l l Connect Personal Safety Set Controls And Water If And Welding Begin Welding Equipment Equipment Applicable Power Source ssb6 1 9 92 OM 1581 Page 28 SECTION 5 MAINTENANCE 8 TROUBLESHOOTING 5 1 Routine Maintenance Replace Unreadable Labels During Heavy Service Clean Monthly Tighten Cracked Weld Parts Terminas 14 Pin Cord Gas Hose Gun Cable OM 1581 Page 29 5 2 Changing Or Cleaning Gun Drive Roll Tools Needed Il ann C OB ssa Mm OM 1581 Page 30 Turn Off wire feeder and welding power source 1 Top Cover 2 Pressure Roll Assembly Cut off wire where it enters pressure roll assembly area 3 Setscrew 4 Current Pick Up Tab This tab helps prevent burnback caused by welding arcs inside the contact tip This tab may be re moved to provide an insulated drive roll If tab is removed a smaller di ameter contact tip is recom mended See options in Parts List Lightly grease top of tab before rein stalling 5 Drive Roll Use wire brush to clean drive roll Install drive roll with desired groove down and turn drive roll so one setscrew faces flat side of shaft 6 Bearing 7 Liner Line up drive roll groove with bear ing groove and liner opening Tighten setscrews If changing drive
76. wer source manual Check plug PLG50 PLG51 and PLG52 connections see Section 3 13 Wire feeds erratically Check position of Motor Torque switch see Section 4 11 Adjust drive roll pressure if necessary see Section 3 15 Replace or clean drive rolls as necessary see Sections 5 2 and 5 3 Align drive roll with opening in gun conduit fitting and groove in bearing see Section 5 3 Arc varies and welding wire is kinked when feeding out gun Place Motor Torque switch in low torque position if welding with 030 0 8 mm aluminum welding wire see Section 4 11 Pressing gun trigger will not feed wire wire is not energized shielding gas flows and Jog switch activates motor Reset circuit breaker CB1 see Section 5 11 Feeder feeds wire but remains in run in mode after arc initiation Route weld cable through current sensing relay see Section 3 8 If constant current CC welding be sure PLG5 is in EXT position on PC1 and voltage sensing lead is connected see Section 3 11 If constant voltage CV welding be sure PLG5 is in INT position on PC1 and that voltage sensing lead is not connected see Section 3 11 Feeder feeds wire but switches from weld mode to run in mode while CV welding with voltage sensing lead installed Be sure PLG5 is in INT position on PC1 Disconnect voltage sensing clamp from workpiece see Section 3 11 Shielding gas leak through gas val
77. y Figure 7 4 Exploded View Of Gun Continued qu uiii 602 066 SCREW mach stl trh 6 32 x 250 2 o qr 164 592 THIGGEEBU rad Mm ERE nai t auae MEA 1 ty OU a a 058202 X CAF VAVE cuore ge De dE tier 1 O aa Fig 75 ix BARREL ASSEMBLY sie dodi Sa nd 1 O ia a 164 582 HOUSING wire drive 15A 8 30A models includes items 24 8 37 1 E pU 164 581 HOUSING wire drive 15W 8 30W models includes items 24 8 37 1 cs 151 661 SCREW set 10 32 x 125 cup sch 30W models only 2 wd uiis means 199 365 2 GEAMP head IUDG saines sh tC Rte esce re osito f e eR 1 PC We 000 417 SCREW cap stl sch 10 24 x 1 000 2 A 203 758 CABLE power 15A model consisting of 1 E aci teu A ticus 203 759 CABLE power 30A model consisting of 1 T 133 362 oc STRAIN RELIEF able is caste to boire a ioo eeu e vlt dem erede 1 44 R4 200 096 POTENTIOMETER C sltd sft 1 T 5W 10K ohm 1 TU ET 144 861 WASHER Antturi 4 eO o cQ Re tm on mem 1 Dt e 135 127 LOCK shaft pot 250 32 x 125dia shaft 1 mI v EM 602 169 SCREW set stl sch 8 32 X 187 1 Tr EE 134 856 KNOB speed control 1 10 140 shaft x 1 125 OD 1 xen AN eee 16430901 CASE dI Ul ee mes doo Mt ae it

Hobart OM-1581 User's Manual

Contents

Download Pdf Manuals

Related Search

Related Contents