Hobart-welding-products OM-1594 User Manual

Visit our website atwww.HobartWelders.comOlympic XR ControlOlympic XR Air- And Water-CooledGunsProcessesDescriptionOM-1594 181 715HDecember 2000MI

OM-1594 Page 6Le rayonnement de l’arc du procédé de soudagegénère des rayons visibles et invisibles intenses(ultraviolets et infrarouges) susceptibles

OM-1594 Page 71-3. Dangers supplémentaires en relation avec l’installation, le fonctionnementet la maintenanceRisque D’INCENDIE OUD’EXPLOSION.D Ne pas

OM-1594 Page 81-4. Principales normes de sécuritéSafety in Welding and Cutting, norme ANSI Z49.1, de l’American Wel-ding Society, 550 N.W. Lejeune Rd,

OM-1594 Page 9SECTION 2 – DEFINITIONS1 1.1 1.2 1.33 3.1 3.2 3.34 4.1+22.12.2++56+2.3S-178 936A. Warning! Watch Out! Thereare possible hazards asshown

OM-1594 Page 101 Read the Owner’s Manual.2 Do not overtighten wire spoolbrake pressure. Tighten onlyuntil wire does not overspoolfrom wire supply spoo

OM-1594 Page 112-3. Symbols And DefinitionsSome symbols are found only on CE products.NoteAAmperesVVolts Alternating CurrentXDuty CycleIPDegree OfProt

OM-1594 Page 123-2. Duty Cycle And OverheatingDuty Cycle is percentage of 10 min-utes that unit can weld at rated loadwithout overheating.Y Exceeding

OM-1594 Page 13SECTION 4 – INSTALLATIONBe sure that contact tip, liner, and drive rolls are correct for wire size and type. SeeParts List to change pa

OM-1594 Page 144-2. Air-Cooled Feeder ConnectionsRef. 801 578-A1 Gas FittingRoute one end of 10 ft (3 m) gashose to rear of unit, and connecthose to g

OM-1594 Page 154-3. Air-Cooled Gun ConnectionsRef. 801 577-A / 801 564 / Ref. 151 666-A1 Gun Control CableInsert plug into Gun Controlreceptacle, and

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

OM-1594 Page 164-4. Water-Cooled Feeder ConnectionsRef. 152 431-A / Ref. 801 578-AObtain coolant supply.1 Gas FittingRoute one end of 10 ft (3 m) gash

OM-1594 Page 174-5. Water-Cooled Gun ConnectionsRef. 801 577-A / 801 563 / Ref. 151 666-A1 Gun Control CableInsert plug into Gun Controlreceptacle, an

OM-1594 Page 184-6. 14-Pin Plug InformationPin* Pin InformationA 24 volts ac with respect to socket G.B Contact closure to A completes 24 volts ac con

OM-1594 Page 194-8. Optional Meter Circuit Board SettingsRef. 802 359 / Ref. 186 266Tools Needed:1/4 in1 Meter Board PC22 DIP Switch S2Set DIP switch

OM-1594 Page 204-9. Adjusting Contact Tip PositionRef. 801 556 / 150 434 / Ref. 150 431 / Ref. 151 666-A1 Contact Tip2 NozzleAdjusting barrel changes

OM-1594 Page 214-11. Removing Top Cover Of Pistol Grip Gun1 Top CoverPush back and lift off as shown.To reinstall cover, set rear of coverin gun, and

OM-1594 Page 224-13. Threading Welding Wire Through FeederRef. 802 193-ATools Needed:Pull and hold wire; cut off end.Hold wire tightly to keepit from

OM-1594 Page 234-14. Threading Welding Wire Through GunRef. 802 193-A / 801 556Tools Needed:Refer to Section 4-13 for instructions on feeding wirethro

OM-1594 Page 244-15. Adjusting Wire Feed Starting SpeedTo adjust wire feed starting speed,proceed as follows:1 Motor Speed Control BoardPC12 Motor Sta

OM-1594 Page 254-16. Setting Switches For Preflow And Postflow. Unit arrives from the factorywith preflow Off and postflowturned On.To set switches fo

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

OM-1594 Page 264-17. Adjusting Trigger Hold Actuation TimeTo adjust trigger hold actuationtime, proceed as follows:1 Motor Speed Control BoardPC12 Pot

OM-1594 Page 27SECTION 5 – OPERATION5-1. Controls801 5541 Voltage/Wire Speed Meter (Optional)2 Voltage/Wire Speed Switch (Optional)When switch is in V

OM-1594 Page 285-2. Internal ControlsRef. 801 578Open left side door.1 Run-In Speed ControlUse this control to set run-in wirefeed speed before arc in

OM-1594 Page 295-3. Gun Controls1 TriggerPress trigger to energize weldingpower source contactor (ifapplicable), start shielding gas flow,and begin wi

OM-1594 Page 305-6. Sequence Of Gas Metal Arc Welding (GMAW) – Continuous Or SpotBegin Weldingssb6.1* 9/92Install &ConnectEquipmentPut OnPersonal

OM-1594 Page 316-1. Feeder Drive Assembly Maintenance802 193-ARetract wire onto spool.1 Pressure Roll Assembly2 Drive Motor Shaft3 Drive Roll4 ScrewUs

OM-1594 Page 326-2. Gun Drive Assembly Maintenance For An XR-Edge GunRef. 801 556Retract wire onto spool.1 Screw2 Drive RollUse wire brush to clean dr

OM-1594 Page 336-3. Removing Contact Tip Adapter In XR-Edge GunsRef. 802 2531 Nozzle2 Adapter Nozzle3 Nozzle Adapter Locking NutLoosen locking nut to

OM-1594 Page 34Ref. 151 599-C / Ref. 802 652 / Ref. 801 556 / 801 564 / Ref. 151 666-A / Ref. 200 3716-5. Replacing Gun Cable LinerY Turn Off welding

OM-1594 Page 356-6. Changing Gun Contact Tip1 Contact Tip Wrench2 NozzleInsert wrench into nozzle overcontact tip.3 Compression Nut4 Contact TipLoosen

TABLE OF CONTENTS6-12. Replacing Hub Assembly 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

OM-1594 Page 36Turn Off wire feeder and weldingpower source.1 Top Cover2 Pressure Roll Assembly3 Screw4 Pressure RollRemove as shown.Use a wire brush

OM-1594 Page 376-10. Removing Contact Tip Adapter In Air-Cooled Pistol-Grip GunsTurn Off wire feeder and weldingpower source.1 Nozzle ExtensionRemove

OM-1594 Page 386-12. Replacing Hub Assembly801 577 / Ref. 143 223-ARemove gun top cover and releasepressure arm (see Sections 4-10and 4-11).Retract wi

OM-1594 Page 396-13. Overload ProtectionRef. 801 577 / Ref. 800 185-AY Turn Off wire feeder andwelding power source. Stopengine on weldinggenerator.If

OM-1594 Page 406-15. TroubleshootingY Disconnect power before troubleshooting.Trouble RemedyPressing gun trigger does not energizefeeder. Welding wire

OM-1594 Page 41Notes

OM-1594 Page 42SECTION 7 – ELECTRICAL DIAGRAMSFigure 7-1. Circuit Diagram For Wire Feeder

OM-1594 Page 43186 931-D

OM-1594 Page 44195 712-AFigure 7-2. Circuit Diagram For Gun

OM-1594 Page 45Notes

OM-1594 Page 1SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USINGsom _nd_4/981-1. Symbol UsageMeans Warning! Watch Out! There are possible hazardswith

OM-1594 Page 46SECTION 8 – PARTS LIST. Hardware is common andnot available unless listed.ST-802 23049 – Figure 8-245 – Figure 8-3123456789101112131415

OM-1594 Page 47DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 8-1. Main AssemblyQuantity1 089 572 CATCH, link-lock 2. . . . . . . . . . . . . . . . . . .

OM-1594 Page 48DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 8-1. Main Assembly (Continued)Quantity54 ♦028 770 POTENTIOMETER, CP std slot 1T 2W 1M 1. . .

OM-1594 Page 49DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 8-2. Motor & Wire Drive (Figure 8-1 Item 49)Quantity1 193 186 DRIVE ASSEMBLY, wire (consis

OM-1594 Page 50. Hardware is common andnot available unless listed.802 236-ASee Figure 8-1Item 4512367 8910111213121415161817544Figure 8-3. Panel, Fro

OM-1594 Page 51DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 8-3. Panel, Front w/Components (Figure 8-1 Item 45)Quantity1 ♦111 569 METER, flow 6-60 1. . .

OM-1594 Page 52. Hardware is common andnot available unless listed.802 328-C 13456789101112141516202122232426272829303132333436373835394041

OM-1594 Page 53DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 8-4. Exploded View Of XR-Edge GunQuantity1 187 000 COVER,handle 1. . . . . . . . . . . . . .

OM-1594 Page 54DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 8-4. Exploded View Of XR-Edge Gun (Continued)Quantity44 187 953 FITTING, liner 1. . . . . . .

OM-1594 Page 55. Hardware is common andnot available unless listed.802 253-A123456789111213**Insert chamfered end of liner into head tube.134567891011

OM-1594 Page 2Arc rays from the welding process produce intensevisible and invisible (ultraviolet and infrared) raysthat can burn eyes and skin. Spark

OM-1594 Page 56. Hardware is common andnot available unless listed.143 117-H12192022212423232526272842434445464752535455565758596061626415(Fig. 8–7)16

OM-1594 Page 57DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 8-6. Exploded View Of Pistol-Grip GunQuantity1 133 479 COVER 1. . . . . . . . . . . . . . .

OM-1594 Page 58DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 8-6. Exploded View Of Pistol-Grip Gun (Continued )Quantity44 058 968 RING, retainer E 2. . .

OM-1594 Page 591234567891011121314 15161718720212223242526274282930313233343536800 434-A3519. Hardware is common andnot available unless listed.Figure

OM-1594 Page 60DescriptionPartNo.ItemNo.Figure 8-7. Barrel Assembly Of Pistol-Grip Gun (Continued)Quantity17 137 042 BARREL ASSEMBLY, water cooled (15

OM-1594 Page 61Notes

OM-1594 Page 62Notes

Warranty Questions?Call1-877-HOBART1for your localHobart distributor.hobart standard 7/00ServiceYou always get the fast,reliable response youneed. Mos

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

OM-1594 Page 31-3. Additional Symbols For Installation, Operation, And MaintenanceFIRE OR EXPLOSION hazard.D Do not install or place unit on, over, or

OM-1594 Page 41-5. EMF InformationConsiderations About Welding And The Effects Of Low FrequencyElectric And Magnetic FieldsWelding current, as it flow

OM-1594 Page 5SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANTUTILISATIONsom _nd_fre 4/981-1. Signification des symbolesSignifie Mise en garde ! Soyez v