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OM-945 194 047U
September 2004
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
Champion 10,000
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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TABLE OF CONTENTS SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 9-1. Routine Maintenance (Kohler-Powered Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 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_8/03 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. Allow cooling period before maintaining. Welding on closed containers, such as tanks, drums, or Wear protective gloves and clothing when working on pipes, can cause them to blow up. Sparks can fly off from the a hot engine. welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal Do not touch hot engine parts or just-welded parts objects can cau
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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 8/03 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 si- présente des risques de danger ! Ceux-ci sont identifiés par gnifie Mise en garde ! des symboles adjacents aux directives. Soyez vigilant ! Il y a des risques de danger reliés Identifie un message de sécurité partic
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Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B LES ACCUMULATIONS DE GAZ ris- pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi- quent de provoquer des blessures ou mité. même la mort. DES PARTICULES VOLANTES peuvent blesser les yeux. Fermer l’alimentation du gaz protecteur en cas de non utilisation. Le soudage, l’écaillement, le passage de la pièce Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adducti
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Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, L’EXPLOSION DE LA BATTERIE peut débrancher le câble négatif ( −) de batterie de la borne. RENDRE AVEUGLE. Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga- nes mobiles. Toujours porter une protection faciale, des gants en Remettre en place les panneaux ou les dipositifs de protection et fermer les caoutchouc et vêtements de protection lors d’une in- portes à la fin des travaux d’entretien et
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LE SURCHAUFFEMENT peut endom- LIRE LES INSTRUCTIONS. mager le moteur électrique. Utiliser seulement les pièces de rechange d’origine. Effectuer la maintenance du moteur et du compres- Arrêter ou déconnecter l’équipement avant de dé- seur (si applicable) suivant ce manuel et le manuel du marrer ou d’arrêter le moteur. moteur/compresseur (si applicable). Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence tr
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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 Breaker 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 uses
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4-2. Dimensions, Weights, and Operating Angles Dimensions Height 33-1/2 in (851 mm) A A B Width 18-1/2 in (470 mm) C Do Do not exceed tilt angles or engine could not exceed tilt angles or engine could G G Depth 38 in (965 mm) D be damaged or unit could tip. 4 4 HOLES HOLES Do not move or operate unit where it could A 18 in (457 mm) tip. tip. B 16-9/16 in (421 mm) C 23/32 in (18 mm) D 3 in (76 mm) E F 25 25° E 31-1/2 in (800 mm) 25° ° 25° F 37-1/2 in (953 mm) 25 25° ° G 13/32 in (10 mm) Dia
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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 (Onan-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 pr
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5-4. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. 1 Eye Protection − Safety Glasses Or Face Shield 2 Rubber Gloves 5 3 Vent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 Well 4 1 Fill each cell with electrolyte to 3 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. 6 Battery Charger Read and follow all instruc- 2
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5-5. Connecting the Battery Connect negative ( −) cable last. − + Tools Needed: 1/2 in Ref. 202 069-A / Ref. 802 341 / Ref. S-0756-D 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. 202 069-A OM-945 Page 16
