Table of Contents

OM-1581

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING		1
1-1.	Symbol Usage	1
1-2.	Arc Welding Hazards	1
1-3. Additional Symbols For Installation, Operation, And Maintenance		3
1-4.	Principal Safety Standards	3
1-5.	EMF Information	4

SECTION 1 – CONSIGNES DE SECURITE – LIRE AVANT UTILISATION		5
1-1.	Signification des symboles	5
1-2.	Dangers relatifs au soudage à l’arc	5
1-3.	Dangers supplémentaires en relation avec l’installation, le fonctionnement
	et la maintenance	7
1-4.	Principales normes de sécurité	8
1-5.	Information sur les champs électromagnétiques	8

SECTION 3 – INSTALLATION		10
3-1.	Connections With A CC, CV Or CC/CV Voltage Welding Power Source Having A
	14-Socket Receptacle	10
3-2.	Connections With A CV Welding Power Source Having Separate 115 VAC And
	Contactor Control Receptacles	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	12
3-5.	Removing Top Cover Of Gun	12
3-6.	Air-Cooled Gun Connections	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
	Twistlock Plug	19
3-14.	Installing Wire Spool	20
3-15.	Threading Welding Wire Through Feeder	21
3-16.	Threading Welding Wire Through Gun	22
3-17.	Coolant Guidelines	22
3-18.	Adjusting Wire Feed Starting Speed	23

SECTION 4 – OPERATION			24
4-1.		Front Panel Controls Of Feeder (Air-Cooled Model Shown)	24
4-2.		Safety Equipment	24
4-3.	Work And Voltage Sensing Cable Clamps		24
4-4.		Run-In Speed Control	25
4-5.		Jog Switch	25
4-6.		Voltage/Wire Speed Switch And Meter (Optional)	25
4-7.		Spot Controls (Optional)	26
4-8.		Remote Voltage Control (Optional)	26
4-9.		Power Switch	26
4-10.		Flowmeter (Optional)	27
4-11.		Internal Controls	27
4-12. Gun Controls			28
4-13.		Shielding Gas	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 & TROUBLESHOOTING			29
5-1.		Routine Maintenance	29
5-2.		Changing Or Cleaning Gun Drive Roll	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 Liner	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 Assembly	34
5-10.		Adjusting Hub Tension	35
5-11.		Overload Protection	35
5-12. Water Flow Switch (Optional For Water-Cooled Models)			35
5-13.		Troubleshooting	36
SECTION 6 – ELECTRICAL DIAGRAMS			38
SECTION 7 – PARTS LIST			40
OPTIONS AND ACCESSORIES
WARRANTY

Hobart OM-1581 manual Table of Contents