Hobart Welding Products 0 Owner'S Manual Download Page 63

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OM-945 Page 59

Description

Part

No.

Dia.

Mkgs.

Item

No.

Figure 14-1. Main Assembly

Quantity

+193 777

Wrapper

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

227 725

Label, Use Gasoline Fuel Only

. .

. . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211 398

Grommet, Plastic Neck Filler Fuel

. .

. . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

220 711

Cap, Tank Screw

−

on w/Vent

. .

. . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

233 639

Label, Warning General Precautionary

. .

. . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . .

220 457

Label, Need Help

. .

. . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

211 527

Pipe, Exhaust Elbow

. .

. . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

196 252

Baffle, engine air (Kohler only)

. .

. . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

226 448

Panel, Rear

. .

. . . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

194 263

Grommet, Plastic Snap

−

in Battery Access

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . .

227 913

Label, Warning Battery Explosion Can Blind

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. . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . .

209 057

Clamp, Muffler 1.625 Dia U Pld

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

224 134

Engine,

Robin

Gas Elec Start (consisting of)

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . .

228 679

Muffler, Exhaust Engine (Robin)

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. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217 441

Gasket, muffler

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*198 754

Filter, oil

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*198 755

Element, air cleaner w/precleaner

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198 756

Pump, fuel

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

198 757

Switch, low oil pressure

. . . . . . . . . . .

. . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*215 985

Filter, fuel w/clamps

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*198 777

Plug, spark

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Solenoid w/ mtg bracket (see engine parts list)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . .

198 778

Regulator, voltage

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

165 271

Valve, Oil Drain 3/8

−

18 Nptf

. .

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*021 718

Fuse, Mintr Gl 30. Amp 32 Volt

. . . . . . . . . . .

. . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114 923

Boot, solenoid

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 062

Kit, tune-up and filter

−

Robin

(includes air filter element and wrapper,

. . . . . . . . . . . . . . . . . . . . . .

. .

oil filter, fuel filter, and spark plugs)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

194 249

Engine,

Kohler

Gas Elec Ch20s

−

64635 (consisting of)

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . .

228 678

Muffler, Exhaust Engine (Kohler)

. .

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . .

189 477

Gasket, muffler

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

066 698

Filter, oil

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

190 248

Pump, fuel

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

067 272

Element, air cleaner

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*215 985

Filter, fuel w/clamps

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*067 273

Wrapper, air filter

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

067 007

Plug, spark

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

199 530

Solenoid, idle

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

165 271

Valve, Oil Drain 3/8

−

18 Nptf

. .

. . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

*021 718

Fuse, Mintr Gl 30. Amp 32 Volt

. . . . . . . . . . .

. . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

114 923

Boot, solenoid

. . . . . . . . . . . . . . . . . . . . . .

. . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

180 096

Kit, tune-up and filter

−

Kohler

(includes air filter element and wrapper,

. . . . . . . . . . . . . . . . . . . . . .

. .

oil filter, fuel filter, and spark plugs)

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

. . . . . . . . . . . . . . . . . . . . . . . . . . . .

196 778

Hose, Vinyl Clear .500 Id X .625 Od X 7.000 (oil drain)

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . .

167 788

Nut, 375

−

16 .56hex .34h Stl Pld Sem Cone Wshr.88d

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . .

151 542

Washer, Flat .438idx1.000odx.125t Stl Pld

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . .

142 156

Screw, 375

−

16x1.75 Hexwhd.81d Gr8 Pld

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . .

Figure 14-3

Generator

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. . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193 782

Cover, Tank Fuel

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

217 848

Cable, Bat Neg 15.000 No 4 Awg W/Clamp & .343 Rng

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . .

168 037

Battery, Stor 12v 430 Crk 75 Rsv Gp 58 Dry

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . .

219 811

Cable, Bat Pos 25.000 No 4 Awg W/Clamp & .312 Rng

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . .

172 669

Cable, Bat Neg 11.000 6ga W/.250 Rng & .375 Rng

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . .

182 935

Hold Down, Battery

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

193 780

Bracket, Mtg Engine

. .

. . . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

+226 446

Base

. .

. . . . . . . . . . . . . . .

. .

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

215 939

Label, Engine Maintenance

. .

. . . . . . . . . . . . . . . .

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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

229 134

Label, warning do not weld on base

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. . . . . . . . . . . . . . . .

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Summary of Contents for 0

Page 1: ...Champion 10 000 Processes Description Stick SMAW Welding Engine Driven Welding Generator OM 945 194 047AD 2007 05 ...

Page 2: ...ducts 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 proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The par...

Page 3: ...Volt Ampere Curves 15 SECTION 5 INSTALLATION 16 5 1 Installing Welding Generator 16 5 2 Engine Prestart Checks Robin Powered Units 17 5 3 Engine Prestart Checks Kohler Powered Units 17 5 4 Activating The Dry Charge Battery If Applicable 18 5 5 Connecting the Battery 18 5 6 Installing Exhaust Pipe 19 5 7 Weld Output Terminals 19 5 8 Connecting To Weld Output Terminals 20 5 9 Selecting Weld Cable Si...

Page 4: ...Overload Protection Kohler Powered Units 35 9 5 Servicing Optional Spark Arrestor Kohler Powered Units 35 9 6 Changing Engine Oil Oil Filter and Fuel Filter Kohler Powered Units 36 9 7 Adjusting Engine Speed Kohler Powered Units 37 SECTION 10 TROUBLESHOOTING 38 SECTION 11 ELECTRICAL DIAGRAM 41 SECTION 12 GENERATOR POWER GUIDELINES 42 SECTION 13 STICK WELDING SMAW GUIDELINES 49 SECTION 14 PARTS LIS...

Page 5: ...h risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop e...

Page 6: ...ing can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may contai...

Page 7: ...ts bare handed Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can burn If possible check coolant level when engine is cold to avoid scalding Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance sect...

Page 8: ...ge and frequency caused by low engine speed damage electric motors Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING SPARKS can cause injury Wear a face shield to protect eyes and face Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face hand and body protection Sparks can cause fires keep flammables away MOVING P...

Page 9: ...c tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from CanadianStandards Association Standards ...

Page 10: ...une source électrique à courant électrique s avère nécessaire se servir de la fonction de télécommande si l appareil en est équipé Des précautions de sécurité supplémentaires sont requises dans des environnements à risque comme les endroits humides ou lorsque l on porte des vêtements mouillés sur des structures mé talliques au sol grillages et échafaudages dans des positions assises à genoux et al...

Page 11: ... provoquer des brûlure dans les yeux et sur la peau Des étincelles sont projetées pendant le soudage Porter un casque de soudage approuvé muni de verres filtrants approprié pour protéger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 énuméré dans les normes de sécurité Porter des lunettes de sécurité avec écrans latéraux même sous votre casque Avoir recours à des écrans protecteurs ou ...

Page 12: ...ovoquer des étincelles avec les outils en travaillant sur la batterie Ne pas utiliser le poste de soudage pour charger les batteries ou des véhicules de démarrage rapide Observer la polarité correcte et sur les batteries Débrancher le câble négatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion Arrêter le moteur avant de vérifier le n...

Page 13: ...système avant d effectuer la maintenance avant de changer ou de rajouter des éléments ou avant d ouvrir la purge ou le bouchon de remplissage d huile Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion Ne pas couper ou gouger à proximité de pro duits inflammables Surveillez et garder un extincteur à proximité DES PIECES CHAUDES peuvent provo quer des brûl...

Page 14: ...ONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil N utiliser que les pièces de rechange recom mandées par le constructeur Effectuer la maintenance et le service du moteur et du compres seur d air suivant les instructions dans ce manuel ou le manuel du moteur compresseur si applicable LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences Le r...

Page 15: ...ational Standards Institute 11 West 43rd Street New York NY 10036 8002 téléphone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 téléphone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus tr...

Page 16: ...IFICATIONS 4 1 Weld Power and Engine Specifications This unit uses either a Robin or a Kohler engine Differences between models are noted throughout this manual Welding Mode Weld Output Range Rated Welding Output Maximum Open Circuit Voltage Single Phase Generator Power Rating Fuel Capacity Engine CC DC 50 230 A 230 A 25 V 30 Duty Cycle 210 A 25 V 60 Duty Cycle 170 A 25 V 100 Duty Cycle 73 Peak 10...

Page 17: ... 16 in 421 mm Do not exceed tilt angles or engine could be damaged or unit could tip C 23 32 in 18 mm unit could tip D 3 in 76 mm E 31 1 2 in 800 mm 25 E F F 37 1 2 in 953 mm 25 G 13 32 in 10 mm Dia 25 25 Weight 25 25 Robin Powered Unit 445 lb 202 kg Kohler Powered Unit 444 lb 201 kg Lifting Eye Weight Rating Engine End 1280 lb 580 kg 802 855 Engine End 4 3 Generator Power Curve 197 252 The genera...

Page 18: ...percentage of 10 minutes that unit can weld at rated load without overheating NOTICE Exceeding duty cycle can damage unit and void warranty 60 Duty Cycle at 210 Amperes CC DC 100 Duty Cycle at 170 Amperes CC DC 6 Minutes Welding 4 Minutes Resting 3 Minutes Welding 7 Minutes Resting 30 Duty Cycle at 230 Amperes CC DC ...

Page 19: ...utput capabilities of the welding generator Curves of all other settings fall between the curves shown Notes 16 Gauge 063 in 22 Gauge 031 in 24 Gauge 025 in 20 Gauge 037 in 18 Gauge 050 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 MATERIAL THICKNESS REFERENCE CHART ...

Page 20: ...low is restricted or engine may overheat Mounting 1 Cross Supports Mount unit on flat surface or use cross supports to support base Grounding 2 Equipment Grounding Terminal On Front Panel 3 Grounding Cable Not Supplied 4 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire Electrically bond generator frame to vehicle fr...

Page 21: ...ting Keep battery in good condition Store bat tery in warm area Use correct grade oil for cold weather Full 5 3 Engine Prestart Checks Kohler Powered Units 802 339 G 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 This unit has a low oil pressure shutdown switc...

Page 22: ...ise to proper level Reinstall vent caps 4 Battery Charger Read and follow all instruc tions supplied with battery charger Charge battery for 12 minutes at 30 amperes or 30 minutes at 5 am peres Disconnect charging cables and install battery When electrolyte is low add only distilled water to cells to maintainproper level 5 4 Activating The Dry Charge Battery If Applicable 1 Tools Needed 2 4 30 A F...

Page 23: ...ed di rection but always away from front panel and direction of travel Tools Needed 1 2 in 802 353 G 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 terminal and electrode holder cable to Positive terminal For Direct Current Electrode Nega tive DCEN reverse cable conne...

Page 24: ... Amperes 10 60 Duty Cycle 60 100 Duty Cycle 10 100 Duty Cycle 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 Stop engine before connecting to weld output terminals 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 2x70 Do not use worn dam aged undersized or l li d bl output ...

Page 25: ...er speed under load In Run position engine runs at weld power speed 2 Engine Choke Control Use control to change engine air fuel mix To Start pull out choke and turn Engine Con trol switch to Start position Release switch and slowly push choke in when engine starts If the engine does not start let the engine come to a complete stop before attempt ing restart During cold weather some gasoline en gi...

Page 26: ... idled This may cause vacuum line freezing oil breather tube freezing or ice in the carburetor All of these cause operating problems Due to ice in the lines the engine may not restart until it is warmed to above freezing Load engine and reduce idle times to prevent engine shutdowns Use an electric fuel pump to avoid pulse line freezing Install engine cold weather kit Both Kohler 1 800 544 2444 and...

Page 27: ...eld power speed Maxi mum output is 10 kVA kW 2 120 V 20 A AC Duplex Recep tacle RC2 3 120 V 20 A AC Duplex Recep tacle RC3 RC2 and RC3 supply 60 Hz single phase power at weld power speed Maximum output from RC2 or RC3 is 2 4 kVA kW 4 Supplementary Protector CB1 CB1 protects the ac receptacles from overload If CB1 opens the ac receptacles do not work Move CB1 toggle switch to On position to reset I...

Page 28: ... is 2 4 kVA kW Cir cuit protection is the same as stan dard receptacles If a ground fault is detected the GFCI Reset button pops out and the circuit opens to disconnect the faulty equipment Check for damaged tools cords plugs etc connected to the receptacle Press button to reset receptacle and resume operation At least once a month run engine at weld power speed and press Test button to verify GFC...

Page 29: ...receptacle shares a load with one half of 240 V receptacle 2 Plug Wired for 240 V 2 Wire Load 3 Neutral Silver Terminal 4 Load 1 Brass Terminal 5 Load 2 Brass Terminal 6 Ground Green Terminal 7 Amperes Available using 120 240 V Plug 1 2 3 4 5 6 3 4 5 6 240V 240V 120V 120V 7 Tools Needed One 240 V load or two 120 V loads Current Available in Amperes 240 V Receptacle Each 120 V Duplex Receptacle V x...

Page 30: ...lace To be done by Factory Authorized Service Agent Reference Every 8 Hours Section 5 2 Fuel Level Oil Level Oil Fuel Spills Every 20 Hours Section 8 5 Spark Arrestor Screen Every 25 Hours Section 8 3 Air Cleaner Wrapper Every 50 Hours Weld Terminals Every 100 Hours Engine Manual Section 8 6 8 3 Battery Terminals Cooling System Oil Air Cleaner Element Every 200 Hours Engine Manual Section 8 6 Unre...

Page 31: ...OM 945 Page 27 8 2 Maintenance Label Robin Powered Units ...

Page 32: ...ith dirty element 1 Wrapper Wash wrapper with soap and water solution Allow wrapper to air dry completely Spread 1 tablespoon SAE 30 oil evenly into wrapper Squeeze out excess oil 2 Element Replace element if damaged dirty or oily Notes Over 80 000 trained since 1930 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now ...

Page 33: ...tion circuit If CB4 opens there is no low weld and generator power output Press button to reset breaker 2 Fuse F6 See Parts List F6 protects the engine wiring system If F6 opens the engine does not crank If F6 opens while the engine is running the engine stops Replace fuse if open Reinstall cover before operating If a fuse or circuit breaker opens it usually indicates a more serious problem exists...

Page 34: ...nd running engine Fill crankcase with new oil to full mark on dipstick see Section 8 2 4 Fuel Filter 5 Fuel Line Replace line if cracked or worn Install new filter Wipe up any spilled fuel Start engine and check for fuel leaks Stop engine tighten connections as necessary and wipe up fuel 8 6 Changing Engine Oil Oil Filter and Fuel Filter Robin Powered Units 802 353 G S 0842 4 5 1 2 Tools Needed Fu...

Page 35: ...g screws Adjust solenoid position so engine runs at idle speed If necessary back out idle speed screw so solenoid can be moved to correct position Tight en mounting screws Be sure sole noid linkage works smoothly Turn idle speed screw for fine adjustments Weld Power Speed Adjustment Move Engine Control switch to Run position 4 Jam Nut 5 Lock Nut 6 Weld Power Speed Adjustment Screw Loosen jam nut a...

Page 36: ...Clean Replace To be done by Factory Authorized Service Agent Reference Every 8 Hours Section 5 3 Fuel Level Oil Level Oil Fuel Spills Every 20 Hours Section 9 5 Spark Arrestor Screen Every 25 Hours Section 9 3 Air Cleaner Wrapper Every 50 Hours Weld Terminals Every 100 Hours Engine Manual Section 9 3 9 6 Battery Terminals Cooling System Oil Air Cleaner Element Every 200 Hours Engine Manual Section...

Page 37: ...OM 945 Page 33 9 2 Maintenance Label Kohler Powered Units ...

Page 38: ...ith dirty element 1 Wrapper Wash wrapper with soap and water solution Allow wrapper to air dry completely Spread 1 tablespoon SAE 30 oil evenly into wrapper Squeeze out excess oil 2 Element Replace element if damaged dirty or oily Notes Over 80 000 trained since 1930 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Start Your Professional Welding Career Now ...

Page 39: ...opens there will be no low weld and generator power output Press button to reset breaker 2 Fuse F6 See Parts List F6 protects the engine wiring harness If F6 opens the engine does not crank If F6 opens while the engine is running the engine stops Replace fuse if open Reinstall panel before operating unit If a fuse or circuit breaker opens it usually indicates a more seri ous problem exists Contact...

Page 40: ...ilter Change engine oil and filter ac cording to engine owner s manual Close valve and valve cap before adding oil and running engine Fill crankcase with new oil to full mark on dipstick see Section 8 2 4 Fuel Filter 5 Fuel Line Replace line if cracked or worn Install new filter Wipe up any spilled fuel Start engine and check for fuel leaks Stop engine tighten connections as necessary and wipe up ...

Page 41: ...eed Screw Loosen mounting screws Adjust solenoid position so engine runs at idle speed If necessary back out idle speed screw so solenoid can be moved to correct position Tight en mounting screws Be sure sole noid linkage works smoothly Turn idle speed screw for fine adjustments Weld Power Speed Adjustment Move Engine Control switch to Run position 4 Weld Power Speed Adjustment Nut 5 Lock Nut Loos...

Page 42: ... settings Tighten and clean connections to electrode and workpiece Use dry properly stored electrodes for Stick and TIG welding Remove excessive coils from weld cables Clean and tighten connections both inside and outside welding generator Check engine speed and adjust if necessary see Section 8 7 or 9 7 Have Factory Authorized Service Agent check brushes and slip rings B Generator Power Trouble R...

Page 43: ...n 5 2 or 5 3 Check fuse F6 and replace if open see Section 8 4 or 9 4 Check low oil pressure shutdown switch see Parts List for location Periodically recharge battery approximately every 3 months Replace battery Check voltage regulator and connections according to engine manual Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 Battery Discharges between uses Clean battery termi...

Page 44: ...roduct Place Engine Control switch in the Run position until unit has been in operation and loaded for a peri od of time During operation in severe cold weath er engine starts and goes to idle but stalls after a few minutes Install engine manufacturer s kit for cold weather operation Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 45: ...OM 945 Page 41 SECTION 11 ELECTRICAL DIAGRAM 222129 B Figure 11 1 Circuit Diagram For Welding Generator Robin And Kohler Powered Units ...

Page 46: ...tric shock and static electricity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insu lated copper wire Electrically bond generator frame to vehic...

Page 47: ...e load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 12 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run nin...

Page 48: ...Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 HP...

Page 49: ...HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 F...

Page 50: ...must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 kVA HP 11 2 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes VOLTS AMPS HP 230 2 5 1 4 Hz PHASE CODE 60 1 M AC MOTOR 1 2 3 4 12 9 How Much Power Can Generator Supply R...

Page 51: ... to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing must be consistent with regular utility system voltage and wiring Conn...

Page 52: ... 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 Volt Loads If unit does not have GFCI receptacles use GFCI protected extension cord Maximum Allowable Cord Length in ft m for Conductor Size AWG Current Amperes Load Watts 4 6 8 10 12 14 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200...

Page 53: ... is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode re quires less current than a large one Follow electrode manufactur er s instructions when setting weld amperage see Section 13 2 4 Insulated Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp crackli...

Page 54: ...LLET ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE AMPERAGE RANGE DIAMETER 13 3 Striking an Arc Scratch Start Technique S 0049 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out elec...

Page 55: ... 13 6 Poor Weld Bead Characteristics S 0053 A 1 Large Spatter Deposits 2 Rough Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 13 7 Good Weld Bead Characteristics S 0052 B 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1 8 in 3 2 mm thickness in metals being welded 4 No Overlap 5 Good Penetration into Base Meta...

Page 56: ...orrect Angle 13 9 Electrode Movement During Welding Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads work better S 0054 A 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide are...

Page 57: ... 4 13 11 Lap Joint S 0063 S 0064 1 Electrode 2 Single Layer Fillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be fore making another weld pass Weld both sides of joint for maxi mum strength 30 Or Less Single Layer Fillet Weld Multi Layer Fillet Weld 30 Or Less 1 1 2 3 13 12 Tee Joint S 0060 S 0058 A S 0061 1 Ele...

Page 58: ... Causes Corrective Actions Arc length too long Reduce arc length Damp electrode Use dry electrode Workpiece dirty Remove all grease oil moisture rust paint coatings slag and dirt from work surface before welding 13 15 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Possible Causes Corrective Actions Amperage too high f...

Page 59: ... dirt from work surface before welding 13 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove Improper weld technique Keep arc on leading edge of weld puddle...

Page 60: ...allel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 13 21 Troubleshooting Distortion Distortion contraction of weld metal during welding that forces base metal to move Base metal moves in the direction of the weld bead Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in p...

Page 61: ...OM 945 Page 57 Notes Welding Symbols Ref AWS ANSI A2 4 ...

Page 62: ...9 12 14 19 11 23 24 21 27 26 25 28 29 22 18 19 20 FIG 14 3 5 7 2 3 4 42 43 1 44 FIG 14 2 18 17 35 36 32 33 34 45 30 31 37 38 39 40 41 Ref 802 343 R Hardware is common and not available unless listed Figure 14 1 Main Assembly Robin Engine Shown Kohler only 46 ...

Page 63: ...filter element and wrapper oil filter fuel filter and spark plugs 1 13 194 249 Engine Kohler Gas Elec Ch20s ps 64635 consisting of 1 14 228 678 Muffler Exhaust Engine Kohler 1 189 477 Gasket muffler 2 066 698 Filter oil 1 190 248 Pump fuel 1 067 272 Element air cleaner 1 215 985 Filter fuel w clamps 1 067 273 Wrapper air filter 1 067 007 Plug spark 2 199 530 Solenoid idle 1 15 165 271 Valve Oil Dr...

Page 64: ...ents 1 45 180 628 Panel Front Lower 1 46 233 088 Label Danger Using A Generator Indoors Can Kill You In Minutes Unit 1 193 067 Kit Accy 20 Ft 2 W Elec Hldr 15 Ft Grd consisting of 1 600 319 Cable Weld Cop Strd No 2 Epdm Jkt order by ft 35ft 040 234 Af 2 Holder Electrode 200a 1 130 750 Clamp Work 300 Amp 1 600 720 Term Ring Tng 500stud Solistrand 2ga 2 034 377 Term Ring Tng 312stud Solistrand 2ga 1...

Page 65: ...11 207 073 Lever Ignition Switch 1 12 173 734 Link Jumper 1 13 1T 172 661 Block Stud Connection 6 Position 1 14 099 255 Terminal Pwr Output Neutral 2 15 Deleted 16 083 030 Stud brs 250 20 x 1 750 1 17 010 915 Washer flat brs 3 18 601 836 Nut 250 20 brs 3 19 RC1 182 954 Rcpt Str 3p4w 50a 125 250v Flush Mtg 14 50 1 20 188 039 Cover Receptacle W Gasket 1 21 159 921 Bezel 1 22 Deleted 1 23 CB4 161 078...

Page 66: ...tor Generator consisting of 1 7 181 134 Fan Rotor Gen 1 8 181 143 Bearing Ball Rdl Sgl Row 984 X 2 047 X 59 1 9 205 725 Brushholder Assy Generator 1 10 142 156 Screw 375 16x1 75 Hexwhd 81d Gr8 Pld 4 802 345 B 2 1 4 5 7 8 6 9 10 3 Figure 14 3 Generator When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance ...

Page 67: ...h as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are covered by the manufacturer s...

Page 68: ... or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to Resource...

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