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OM-945 194 047AA
2006 −07
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
™
Champion 10,000
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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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TABLE OF CONTENTS SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 9-1. Routine Maintenance (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 9-2. Maintenance Label (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 9-3. Servicing Air Cleaner (Kohler −Powered Units) . . . . . . . .
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SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05 Warning: Protect yourself and others from injury — read and follow these precautions. 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 nece
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WELDING can cause fire or explosion. HOT PARTS can cause severe burns. Do not touch hot parts bare handed. Welding on closed containers, such as tanks, drums, or Allow cooling period before working on equipment. pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot To handle hot parts, use proper tools and/or wear equipment can cause fires and burns. Accidental contact of electrode to metal heavy, insulated welding gloves and c
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BATTERY ACID can BURN SKIN and EYES. STEAM AND HOT COOLANT can burn. Do not tip battery. If possible, check coolant level when engine is cold to avoid scalding. Replace damaged battery. Always check coolant level at overflow tank, if pres- Flush eyes and skin immediately with water. ent on unit, instead of radiator (unless told otherwise in maintenance section or engine manual). If the engine is warm, checking is needed, and there is no overflow tank, ENGINE HEAT can cause fire. foll
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READ INSTRUCTIONS. ARC WELDING can cause interference. Use only genuine MILLER/Hobart replacement Electromagnetic energy can interfere with sensitive parts. electronic equipment such as microprocessors, computers, and computer-driven equipment such as Perform engine and air compressor (if applicable) robots. maintenance and service according to this manual and the engine/air compressor (if applicable) manu- Be sure all equipment in the welding area is electro- als. magnetically compatibl
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SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION rom_fre 3/05 Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure Ce groupe de symboles signi- présente des risques de danger ! Ceux-ci sont identifiés fie Mise en garde ! Soyez vigi- par des symboles adjacents aux directives. lant ! Il y a des risques de dan- ger reliés aux CHOCS ÉLEC- Identifie un messag
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LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. Ne pas toucher à mains nues les parties chaudes. Le soudage effectué sur des conteneurs fermés tels que des Prévoir une période de refroidissement avant de travailler à réservoirs, tambours ou des conduites peut provoquer leur l’équipement. éclatement. Des étincelles peuvent être projetées de l’arc de Ne pas toucher aux pièces chaudes, utiliser les outils recommandés et por-
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Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant. LA CHALEUR DU MOTEUR peut pro- Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur. voquer un incendie. Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- Ne pas placer l’appareil sur, au-dessus ou à proximité de ver le bouchon. surfaces inflammables. LES ACCUMULATIONS DE GAZ ris- Tenir à distance les produits inflammables de l’échappement.
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LIRE LES INSTRUCTIONS. LE SOUDAGE À L’ARC risque de Utiliser seulement les pièces de rechange d’origine. provoquer des interférences. Effectuer la maintenance du moteur et du compresseur L’énergie électromagnétique risque de provoquer des in- (si applicable) suivant ce manuel et le manuel du moteur/ terférences pour l’équipement électronique sensible tel compresseur (si applicable). que les ordinateurs et l’équipement commandé par ordi- nateur tel que les robots. Veiller à ce que tout l’
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SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Read Operator’s Start Engine Amperes Volts A V Manual Engine Oil Fuel Battery (Engine) Engine Check Valve Engine Choke Circuit Protector Temperature Clearance Alternating Current Positive Negative Output (AC) Protective Earth Hours Seconds Time (Ground) s h Welding Arc Fuse Stick (SMAW) (Electrode) SECTION 4 − SPECIFICATIONS 4-1. Weld, Power, and Engine Specifications This unit use
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4-2. Dimensions, Weights, and Operating Angles Dimensions Height 33-1/2 in (851 mm) A A Width 18-1/2 in (470 mm) B B C C Depth 38 in (965 mm) Do not exceed tilt angles or engine could gg G G D D b be e damaged or unit could tip damaged or unit could tip. 4 HOLES A 18 in (457 mm) D Do o not mo not move or operate unit where it could ve or operate unit where it could B 16-9/16 in (421 mm) tip. C 23/32 in (18 mm) D 3 in (76 mm) E 31-1/2 in (800 mm) E F 25 25° ° F 37-1/2 in (953 mm) 25° G 13
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4-4. Fuel Consumption (All Models) 197 254 4-5. 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 170 Amperes CC/DC 6 Minutes Welding 4 Minutes Resting 3 Minutes Welding 7 Minutes Resting 60% Duty Cycle at 210 Amperes CC/DC 30% Duty Cycle at 230 Amperes CC/DC 197 148 OM-945 Page 11
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4-6. 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. 197 253 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 16 Gauge (.063 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) OM-945 Page 12
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SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Do not weld on base. Welding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base. Movement Always securely fasten weld- Do not lift unit from end. ing generator onto transport vehicle or trailer and comply with all DOT and other applica- ble codes. OR Do not mount unit by support- ing the base only at the four mounting holes. Use cross- supports to adequately sup- port unit and prevent dam
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5-2. Engine Prestart Checks (Robin-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 pressure gets too low. Follow run-in procedure in engine manual. Full This unit has a low oil pressure shutdown switch. However, some conditions may Full cause engine damage before the engine shuts down. Check oil level often and do not use the oil pressure shutdown system to monitor oil level. Fuel Gasoline To help p
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5-4. Activating The Dry Charge Battery (If Applicable) Always wear a face shield, rubber gloves and protective clothing when working on a battery. 3 Remove battery from unit. 1 Vent Caps 2 Sulfuric Acid Electrolyte 2 (1.265 Specific Gravity) 3 Well 1 Fill each cell with electrolyte to bottom of well (maximum). Do not overfill battery cells. Wait ten minutes and check electro- lyte level. If necessary, add electro- lyte to raise to proper level. Reins- tall vent caps. 4 Battery Charger Read
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5-6. Installing Exhaust Pipe Engine backfire can cause se- vere burns or other injuries. Do not point exhaust pipe to- ward control panel. Keep away from exhaust outlet. Point exhaust pipe in desired di- rection but always away from front panel and direction of travel. Tools Needed: 1/2 in 801 681 / Ref. 226 427-A 5-7. Weld Output Terminals 1 Negative ( −) Weld Output Terminal 2 Positive (+) Weld Output Terminal For Direct Current Electrode Posi- tive (DCEP), connect work cable to Negative
