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Hobart Welding Products CHAMP 2060, Owner'S Manual

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Hobart Welding Products CHAMP 2060 Owner'S Manual Download Page 4

Summary of Contents for CHAMP 2060

Page 1: ...Processes Description Stick SMAW Welding Engine Driven Welding Generator OM 499 197 850G June 2003 Visit our website at www HobartWelders com CHAMP 2060 ...

Page 2: ...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 parts list will then help you to decide the exact part you may need to fix the problem Warranty and service information for your particula...

Page 3: ...4 Engine Prestart Checks Kohler Powered Units 15 4 5 Engine Prestart Checks Honda Powered Units 16 4 6 Connecting The Battery Electric Start Models Only 16 4 7 Connecting To Weld Output Terminals 17 4 8 Selecting Weld Cable Sizes 17 SECTION 5 OPERATING THE WELDING GENERATOR 18 5 1 Controls Kohler Powered Units 18 5 2 Controls Honda Powered Units See Section 5 3 19 5 3 Description Of Controls Honda...

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Page 5: ... stop engine before installing or servicing this equipment Lockout tagout input power according to OSHA 29 CFR 1910 147 see Safety Standards Properly install and ground this equipment according to its Owner s Manual and national state and local codes Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or tha...

Page 6: ... watcher and extinguisher nearby FLYING METAL can injure eyes Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag Wear approved safety glasses with side shields even under your welding helmet HOT PARTS can cause severe burns Allow cooling period before maintaining Wear protective gloves and clothing when working on a hot engine Do not tou...

Page 7: ...ocate unit on over or near combustible surfaces or flammables Keep exhaust and exhaust pipes way from flammables EXHAUST SPARKS can cause fire Do not let engine exhaust sparks cause fire Use approved engine exhaust spark arrestor in required areas see applicable codes 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death Do not use compressed air for breathing Use o...

Page 8: ...ciety Standard AWS F4 1 from American Welding Society 550 N W LeJeune Rd Mi ami FL 33126 phone 305 443 9353 website www aws org National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park 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 Comp...

Page 9: ... à la réparation ou à l entretien de l appareil Déverrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de sécurité Installer et mettre à la terre correctement cet appareil conformément à son manuel d utilisation et aux codes nationaux provinciaux et municipaux Toujours vérifier la terre du cordon d alimentation Vérifier et s assurer que le fil de terre du cordon d alimentatio...

Page 10: ...rd des pantalons sans revers des chaussures hautes et un couvre chef Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes Suivre les recommandations dans OSHA 1910 252 a 2 iv et NFPA 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi mité DES PARTICULES VOLANTES peuvent blesser les yeux Le soudage l écail...

Page 11: ...pansion si présent et non dans le radiateur sauf si précisé autrement dans la section maintenance du manuel du moteur Si le moteur est chaud et que le liquide doit être vérifié opérer comme sui vant Mettre des lunettes de sécurité et des gants placer un torchon sur le bou chon du radiateur Dévisser le bouchon légèrement et laisser la vapeur s échapper avant d enlever le bouchon LA CHALEUR DU MOTEU...

Page 12: ...upplémentaires telles que le déplacement du poste l utilisation de câbles blindés l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail 1 6 Principales normes de sécurité Safety in Welding Cutting and Allied Processes norme ANSI Z49 1 de l American Welding Society 550 N W LeJeune Rd Miami FL 33126 télé phone 305 443 9353 site Web www aws org Recommended Safe Practice...

Page 13: ...al NOTE 3 1 Weld Power And Engine Specifications Welding Mode Weld Output Range Rated Welding Output Maximum Open Circuit Voltage Generator Power Rating Fuel Capacity Engine CC DC 40 180 A 60 Hz 40 160 A 50 Hz 180 A 25 V 30 Duty Cycle 130 A 25 V 60 Duty Cycle 100 A 25 V 100 Duty Cycle 80 60 Hz 70 50 Hz Single Phase 6 kVA kW Peak 5 5 kVA kW Continuous 50 25 A 110 220 V AC 50 Hz 120 240 V AC 60 Hz K...

Page 14: ...10 1 2 in 268 mm Do not move or operate unit where it could tip C 13 45 64 in 348 mm A D 22 3 4 in 577 mm A C E 1 3 4 in 44 mm C F 19 1 2 in 495 mm G 13 32 in 10 mm Dia 15 15 Weight 4 G 15 15 15 15 Kohler 265 lb 120 kg 4 Holes G 15 15 Honda Electric Start Model 278 lb 126 kg Honda Recoil Start Model 253 lb 114 kg 802 096 Holes Engine End F E 802 524 A 3 3 Fuel Consumption Kohler Powered Units 198 ...

Page 15: ...ered Units 802 122 Continuous Welding 3 5 Duty Cycle 802 093 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 100 Duty Cycle at 100 Amperes CC DC ...

Page 16: ...r power curves show the ac power available in amperes at the receptacles A 60 Hz Model B 50 Hz Model 0 25 50 75 100 125 150 175 200 225 250 0 5 10 15 20 25 30 35 LOAD AMPS LOAD VOLTS 0 25 50 75 100 125 150 175 200 225 250 0 5 10 15 20 25 30 35 LOAD AMPS LOAD VOLTS ...

Page 17: ...put capabilities of the welding generator Curves of all other settings fall between the curves shown A 60 Hz Model B 50 Hz Model 0 10 20 30 40 50 60 70 80 0 25 50 75 100 125 150 175 200 225 250 LOAD AMPS LOAD VOLTS MIN MID MAX 0 10 20 30 40 50 60 70 80 0 25 50 75 100 125 150 175 200 225 250 LOAD AMPS LOAD VOLTS MIN MID MAX ...

Page 18: ...l DOT and other applicable codes 4 2 Grounding Generator To Truck Or Trailer Frame install1 10 00 Ref 151 556 S 0854 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 4 Grounding Cable Use 10 AWG or larger insulated copper wire If unit does not have GFCI re ceptacles use GFC...

Page 19: ...w oil level shut down switch However some con ditions may cause engine damage before the engine shuts down Check oil level often and do not use the oil level shutdown system to monitor oil level 1 Fuel Valve Open valve by turning lever to vertical position Close fuel valve before moving unit or carburetor may flood and make starting difficult Fuel Add fresh fuel before starting engine the first ti...

Page 20: ...ting engine the first time see mainte nance label for specifications Fill fuel tank up to 1 2 in 13 mm from top to allow room for expansion Check fuel level on a cold engine before use each day Oil After fueling check oil with unit on level surface If oil is not up to full mark on dipstick add oil see main tenance label To improve cold weather starting Keep battery in good condition Store battery ...

Page 21: ...nnectingto weld out put terminals Do not use worn dam aged undersized or poorly spliced cables Welding 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 0 120 250 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 This char...

Page 22: ...wing to start engine If engine does not start let engine come to a complete stop before at tempting restart 4 Starter Handle To Start Recoil open fuel valve see Sec tion 4 4 move throttle lever to Idle set choke and pull starter handle Open choke as engine warms To Stop turn engine switch to Off Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flood...

Page 23: ...OM 499 Page 19 5 2 Controls Honda Powered Units See Section 5 3 802 094 A 802 095 495 187 Recoil Start Electric Start 60 Hz 50 Hz 1 3 6 2 1 4 5 7 ...

Page 24: ...choke as engine warms To Start Electric open fuel valve move throttle lever to Idle set choke and turn en gine switch to Start position Open choke as engine warms If engine does not start let engine come to a complete stop before at tempting restart To Stop turn engine switch to Off Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flooding and make ...

Page 25: ... 120 V AC Twistlock Receptacle RC1 RC1 supplies 60 Hz single phase power at weld power speed Maximum output is 3 5 kVA kW 2 120 V 20 A AC Duplex Receptacle RC2 3 120 V 20 A AC Duplex Receptacle 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 Each receptacle of the duplex can pro vide 15A 1800W Do not parallel the two 120V duplex rece...

Page 26: ... circuit breaker trips Unplug power cord before attempt ing to service accessories or tools Generator power decreases as weld current increases Set Amperage control at max for full generator power Place throttle lever in Run position far right for generator power Circuit breakers protect the generator from overload Press button to reset circuit breaker If breaker continues to open contact Factory ...

Page 27: ...0W 120 V Duplex CB3 20A 2400W 20A 2400W See Note 3 20A 2400W See Note 3 120 V Duplex CB4 20A 2400W See Note 3 20A 2400W See Note 3 Total Power NOT to exceed 5500W 5500W 5500W 5500W 5000W 5000W 5000W 5000W 5000W For example for the 495 218 Generator Power Panel 120V 3000W heater 3000W 120V 10A chain saw 1200W 120V 500W halogen lamp 500W Total 4700W This loading is OK 120V 3000W heater 3000W 120V 10...

Page 28: ...onductors Strip conductors enough to make good contact with plug terminals Make plug connections and reinstall outer shell and cord grip Tighten assembly screws onto shell Do not overtighten 1 3 2 4 Tools Needed 5 6 120 V 240 V 120V SECTION 7 MAINTENANCE Follow the storage procedure in the engine owner s manual if the unit will not be used for an extended period NOTE 7 1 Maintenance Label Ref S 17...

Page 29: ...e manual 50 h Clean and tighten weld terminals Service air cleaner element See engine manual 100 h Change oil See engine manual and maintenancelabel Check spark plugs Clean and tighten battery connections Electric Start models only Clean Fuel sediment cup 200 h Replace unreadable labels Clean fuel tank and strainer 300 h Check valve clearance 500 h Repair or replace cracked cables Service welding ...

Page 30: ...511 A Kohler Dwg After tuning engine check engine speeds See table for proper no load speeds If necessary adjust speeds as follows Start engine and run until warm Weld Power Speed Adjustment 1 Throttle Control Lever 2 Adjustment Screw Move lever to Run far right posi tion To increase speed turn screw out counterclockwise while lightly pushing lever to the right To de crease speed turn screw in clo...

Page 31: ...l Lever 2 Adjustment Screw Move lever to Run 60 Hz position Turn screw and move lever until en gine runs at weld power speed Idle Speed Adjustment 3 Pilot Screw 4 Throttle Stop Screw Move lever to idle position Turn pi lot screw until engine runs at high est idle speed Turn stop screw until engine runs at rated idle speed normally about 2 1 4 turns out Stop engine Close fuel valve 1 4 3 8 in Tools...

Page 32: ...ler only and circuit board PC1 Erratic weld output Check Amperage control setting Tighten and clean connections to electrode and workpiece Use dry properly stored electrodes for Stick 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 7 4 or 7 5 Check throttle governor linkag...

Page 33: ...valve before moving unit or carburetor may flood and make starting difficult Check battery voltage electric start models only Check battery connections and tighten if necessary electric start models only Check oil level see Section 4 4 or 4 5 Engine stops if oil level is too low Refill crankcase with proper viscosity oil for operating temperature Have Factory Authorized Service Agent check low oil...

Page 34: ...OM 499 Page 30 SECTION 9 ELECTRICAL DIAGRAMS 197 857 E Figure 9 1 Circuit Diagram For Welding Generator 1 Of 2 ...

Page 35: ...OM 499 Page 31 197 857 E Figure 9 2 Circuit Diagram For Welding Generator 2 Of 2 ...

Page 36: ...OM 499 Page 32 197 858 C Figure 9 3 Wiring Diagram For Welding Generator ...

Page 37: ...OM 499 Page 33 201 026 A Figure 9 4 Wiring Diagram For Auxiliary Power Panels 1 Of 2 ...

Page 38: ...OM 499 Page 34 201 026 A Figure 9 5 Wiring Diagram For Auxiliary Power Panels 2 Of 2 ...

Page 39: ...Generator To Truck Or Trailer Frame S 0854 Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 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 insulated copper wire If unit does not have GFCI re ceptacles us...

Page 40: ...sistive 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 10 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment VOLTS 115 4 5 60 AMPS Hz 1 2 3 3 EXAMPLE 1 If a drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5 A x 115 V 520 ...

Page 41: ...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 42: ...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 43: ...r Starting Requirements Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 EXAMPLE Calculate the starting amperage required for a 230 V 1 4 HP motor with a motor start code of M Starting the motor requires 12 2 amperes 11 2 x 1 4 x 1000 230 12 2 A kVA HP x HP x 1000 VOLTS STARTING AMPERAGE Volts 230 HP 1 4 Using Table Code M results in kVA HP 11 2 10 9 How Much Power Can G...

Page 44: ...if required by electrical code 4 Welding Generator Output Generator output voltage and wiring must be consistent with regular utility system volt age and wiring Connect generator with temporary or perma nent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes ...

Page 45: ... 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 46: ...is clean be fore welding 2 Work Clamp 3 Electrode A small diameter electrode requires less current than a large one Fol low electrode manufacturer s instructions when setting weld am perage see Section 11 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 cracklin...

Page 47: ...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 11 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 48: ... 11 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 11 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 49: ...Correct Angle 11 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 NOTE 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 wi...

Page 50: ...3 4 11 11 Lap Joint S 0063 S 0064 1 Electrode 2 Single LayerFillet 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 11 12 Tee Joint S 0060 S 0058 A S 0061 1 Ele...

Page 51: ... 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 11 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 52: ... dirt from work surface before welding 11 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 53: ...allel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 11 21 Troubleshooting Distortion Distortion contraction of weld met al 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 ...

Page 54: ... LIST 802 509 A Hardware is common and not available unless listed 7 32 33 34 31 28 29 30 24 23 46 40 41 44 42 43 36 38 39 37 35 47 48 8 6 5 4 9 10 11 2 1 27 18 25 26 22 20 21 19 15 17 16 14 13 12 45 3 49 50 Figure 12 1 Main Assembly ...

Page 55: ...s 8 5 12 1 203 959 GASKET muffler Kohler cs 8 5 12 1 203 960 SPARK PLUG Kohler cs 8 5 12 1 13 495 055 ENGINE Honda 13HP recoil start 1 13 495 053 ENGINE Honda 13HP electric start 1 14 494 606 ADAPTER engine 1 15 494 629 GUARD generator 1 16 194 509 FAN generator Kohler 1 16 493 868 FAN generator Honda 1 17 204 469 GENERATOR w stator assembly 1 18 495 197 ROTOR assembly 1 495 154 BEARING 1 19 495 3...

Page 56: ...76 007 CAPACITOR 1 47 494 915 CLAMP capacitor 1 48 201 223 LABEL warning electric shock power still present 1 49 495 187 LABEL current selection 1 50 188 039 COVER receptacle w gasket 1 Recommended Spare Parts When ordering a component originally displaying a precautionary label the label should also be ordered To maintain the factory original performance of your equipment use only Manufacturer s ...

Page 57: ...Panel 495 253 South Africa Generator Power Panel 495 289 Australia Generator Power Panel 495 218 USA 7 8 10 16 17 33 12 14 13 13 15 15 22 23 24 25 Generator Power Panel 495 290 Europe Generator Power Panel 495 288 S America 29 30 31 32 Generator Power Panel 495 283 S E Asia Generator Power Panel 495 298 USA 26 27 28 18 19 21 20 35 36 37 34 4 5 3 6 1 2 9 11 Figure 12 2 Generator Power Panels ...

Page 58: ...2P3W 15A 125V Generator Power Panel 495 290 Europe 22 495 282 PANEL generator power assembly 1 23 CB1 CB2 495 245 CIRCUIT BREAKER 15A 2 Generator Power Panel 495 288 S America 24 495 287 PANEL generator power assembly 1 25 CB1 4 495 245 CIRCUIT BREAKER 15A 4 Generator Power Panel 495 283 S E Asia 26 495 282 Panel generator power assembly 1 27 CB1 CB2 495 245 CIRCUIT BREAKER 15A 2 Generator Power P...

Page 59: ...parately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply to 1 Consumable components such 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 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items are cover...

Page 60: ...r To locate a Distributor retail 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 th...

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