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OM-498 197 849D
December 2001
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
CHAMP 1435
Visit our website at
www.HobartWelders.com
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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 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
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TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_11/98 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Weldi
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WELDING can cause fire or explo- HOT PARTS can cause severe burns. sion. Allow cooling period before maintaining. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks Wear protective gloves and clothing when working on a hot engine. can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and Do not touch hot engine parts or just-welded burns. Accidental contact of electrode to metal objects can cause p
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BATTERY ACID can BURN SKIN and MOVING PARTS can cause injury. EYES. Keep away from fans, belts, and rotors. Do not tip battery. Keep all doors, panels, covers, and guards closed and securely in place. Replace damaged battery. Flush eyes and skin immediately with water. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary. To prevent accidental starting during servicing, disconnect n
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H.F. RADIATION can cause interference. ARC WELDING can cause interference. High-frequency (H.F.) can interfere with radio Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. Have only qualified persons familiar with electronic equipment perform this installation. Be sure all equipment in the welding area is electromagnetically compatib
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SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 11/98 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous
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LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. Prévoir une période de refroidissement avant d’effec- Le soudage effectué sur des conteneurs fermés tels que tuer des travaux d’entretien. des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de Porter des gants et des vêtements de protection pour l’arc de soudure. La projection d’étincelles, des pièces chaudes et des t
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DES ORGANES MOBILES peuvent L’ACIDE DE LA BATTERIE peut pro- provoquer des blessures. voquer des brûlures dans les YEUX et sur la PEAU. Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. Ne pas renverser la batterie. Maintenir fermés et fixement en place les portes, Remplacer une batterie endommagée. panneaux, recouvrements et dispositifs de Rincer immédiatement les yeux et la peau à l’eau. protection. Arrêter le moteur avant d’installer ou branch
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LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique Le rayonnement haute fréquence (H.F.) peut sensible tel que les ordinateurs et l’équipement com- provoquer des interférences avec les équipements mandé par ordinateur tel que les robots. de radio–navigation et de communication, les Veiller à ce que tout l’équi
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SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Read Operator’s Engine Choke Amperes Volts Manual A V Engine Oil Fuel Battery (Engine) Engine Alternating Current Positive Negative Output (AC) Protective Earth Hours Seconds Time (Ground) s h Circuit Breaker Temperature SECTION 3 – SPECIFICATIONS This unit uses either a Kohler or a Honda engine. Differences between models are NOTE noted throughout this manual. 3-1. Weld, Power, And Engine Specifications Weld Maximum Welding Rated Auxiliary Fuel Ou
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3-2. Dimensions, Weights, And Operating Angles Dimensions Height 20-3/4 in (527 mm) D Width 22-3/4 in (577 mm) Depth 31-1/4 in (793 mm) Do not exceed tilt angles or engine could B A 31-1/4 in (793 mm) be damaged or unit could tip. Do not move or operate unit where it B 10-1/2 in (268 mm) could tip. C 13-45/64 in (348 mm) D 22-3/4 in (577 mm) A A E 1-3/4 in (44 mm) C C F 19-1/2 in (495 mm) G 13/32 in (10 mm) Dia. 15° 15° Weight (Kohler-Powered Units) G 15° 222 lb (101 kg) 4 4 15 15° Holes W
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3-4. Fuel Consumption (Honda-Powered Units) 802 121 3-5. Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. Continuous Welding 100% Duty Cycle at 80 Amperes CC/DC 3 Minutes Welding 7 Minutes Resting 30% Duty Cycle at 140 Amperes CC/DC 802 092 OM-498 Page 11
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3-6. Auxiliary Power Curve The ac auxiliary power curves show the auxiliary power available in amperes at the receptacles. 802 129 3-7. Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. 80 70 60 50 40 MAX 30 MID MIN 20 10 0 0 25 50 75 100 125 150 175 200 LOAD AMPS 198 453 OM-498 Page 12 LOAD VOLTS
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SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Movement Airflow Clearance 18 in (460 mm) 18 in 18 in (460 mm) (460 mm) 18 in 18 in (460 mm) (460 mm) Location OR install1 1/97 – 802 512-A / Ref. 151 556 / 158 936-A / S-0854 4-2. Grounding Generator To Truck Or Trailer Frame Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. 1 Generator Base 2 Metal Vehicle Frame 3 Equipment Grounding Terminal 3 1 4 Grounding Cable 4 GND/PE Use
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4-3. Grounding Generator When Supplying Building Systems 1 Equipment Grounding 1 2 GND/PE Terminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Ground generator to sys- tem earth ground if supply- Use ground device as ing power to a premises stated in electrical codes. (home, shop, farm) wiring system. 2 3 800 576-B 4-4. Engine Prestart Checks (Kohler-Powered Units) Follow run-in procedure in en- gine manual. Check all fluids daily. Engine must be 1/2 in col
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4-5. Engine Prestart Checks (Honda-Powered Units) Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil level gets too low. 1/2 in 1 Fuel Valve (13 mm) Full Open valve. Close fuel valve before moving unit or carburetor may flood and make starting difficult. Gasoline Fuel Add fresh fuel before starting engine the first time (see mainte- nance label for specifications). Fill fuel tank up to 1/2 in. (13 mm) from top to allow
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4-7. Connecting To Weld Output Terminals 1 Positive (+) Weld Output Terminal 2 Negative (–) Weld Output Terminal For Direct Current Electrode Posi- tive (DCEP), connect work cable to Negative (–) terminal and electrode holder to Positive (+) terminal. For Direct Current Electrode nega- tive (DCEN), reverse cable con- nections. 12 Tools Needed: 3/4 in 196 921 / 495 179 4-8. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 150 ft 200 ft
