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Hobart CHAMPION 10,000, Owner'S Manual

The Hobart CHAMPION 10,000 is a powerful and reliable welding generator that will meet all your welding needs. To learn how to operate and maintain this exceptional product, make sure to download the comprehensive Owner's Manual for free from our website. Get the most out of your Hobart CHAMPION 10,000 with our user-friendly manual!

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The following terms are
used interchangeably
throughout this manual:

Stick = SMAW

The engine exhaust from
this product contains
chemicals known to the
State of California to
cause cancer, birth
defects, or other
reproductive harm.

WARNING

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING

1

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1-1.

Symbol Usage

1

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

1-2.

Arc Welding Hazards

1

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1-3.

Engine Hazards

2

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

1-4.

Compressed Air Hazards

3

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

1-5.

Additional Symbols For Installation, Operation, And Maintenance

3

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1-6.

Principal Safety Standards

4

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1-7.

EMF Information

4

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

SECTION 2 – CONSIGNES DE SÉCURITÉ  – LIRE AVANT UTILISATION

5

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2-1.

Signification des symboles

5

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

2-2.

Dangers relatifs au soudage à l’arc

5

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2-3.

Engine Hazards

6

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2-4.

Dangers liés à l’air comprimé

7

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

2-5.

Dangers supplémentaires en relation avec l’installation, le fonctionnement
et la maintenance

7

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2-6.

Principales normes de sécurité

8

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2-7.

Information sur les champs électromagnétiques

8

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SECTION 3 – DEFINITIONS

9

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

SECTION 4 – SPECIFICATIONS

9

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4-1.

Weld, Power, and Engine Specifications

9

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

4-2.

Dimensions, Weights, and Operating Angles

10

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4-3.

Generator Power Curve

10

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4-4.

Fuel Consumption (All Models)

11

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4-5.

Duty Cycle

11

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4-6.

Volt-Ampere Curves

12

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SECTION 5 – INSTALLATION

13

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

5-1.

Installing Welding Generator

13

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

5-2.

Engine Prestart Checks (Onan-Powered Units)

14

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

5-3.

Engine Prestart Checks (Kohler-Powered Units)

14

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

5-4.

Activating The Dry Charge Battery (If Applicable)

15

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

5-5.

Connecting the Battery

16

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5-6.

Installing Exhaust Pipe

16

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

5-7.

Connecting to Weld Output Terminals

17

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

5-8.

Selecting Weld Cable Sizes*

17

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

5-9.

Amperage Selection Table For Stick (SMAW) Electrodes

18

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

SECTION 6 – OPERATING THE WELDING GENERATOR

19

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

6-1.

Front Panel Controls

19

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

SECTION 7 – OPERATING AUXILIARY EQUIPMENT

20

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

7-1.

Standard Receptacles

20

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

7-2.

Optional Generator Power Receptacles

21

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

7-3.

Wiring Optional 240 Volt Plug

21

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

SECTION 8 – MAINTENANCE (ONAN-POWERED UNITS)

22

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

8-1.

Maintenance Label (Onan-Powered Units)

22

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

8-2.

Routine Maintenance (Onan-Powered Units)

23

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

8-3.

Servicing Air Cleaner (Onan-Powered Units)

24

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

8-4.

Overload Protection (Onan-Powered Units)

25

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

8-5.

Servicing Optional Spark Arrestor (Onan-Powered Units)

25

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

8-6.

Changing Engine Oil, Oil Filter, and Fuel Filter (Onan-Powered Units)

26

. . . . . . . . . . . . . . . . . . 

8-7.

Adjusting Engine Speed (Onan-Powered Units)

27

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

SECTION 9 – MAINTENANCE – (KOHLER-POWERED UNITS)

28

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

9-1.

Maintenance Label (Kohler-Powered Units)

28

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

9-2.

Routine Maintenance (Kohler-Powered Units)

29

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

9-3.

Servicing Air Cleaner (Kohler-Powered Units)

30

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

9-4.

Overload Protection (Kohler-Powered Units)

31

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

9-5.

Servicing Optional Spark Arrestor (Kohler-Powered Units)

31

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

9-6.

Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units)

32

. . . . . . . . . . . . . . . . . 

9-7.

Adjusting Engine Speed (Kohler-Powered Units)

33

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

SECTION 10 – TROUBLESHOOTING

34

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

SECTION 11 – ELECTRICAL DIAGRAM

36

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

SECTION 12 – GENERATOR POWER GUIDELINES

37

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

SECTION 13 – STICK WELDING (SMAW) GUIDELINES

44

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

SECTION 14 – PARTS LIST

52

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

OPTIONS AND ACCESSORIES

WARRANTY

WARNING

This product, when used
for welding or cutting,
produces fumes or
gases which contain
chemicals known to the
State of California to
cause birth defects and,
in some cases, cancer.
(California Health &
Safety Code Section
25249.5 et seq.)

WARNING

Battery posts, terminals
and related accessories
contain lead and lead
compounds, chemicals
known to the State of
California to cause
cancer and birth defects
or other reproductive
harm. Wash hands after
handling.

Summary of Contents for CHAMPION 10,000

Page 1: ...Champion 10 000 Processes Description Stick SMAW Welding Engine Driven Welding Generator OM 945 194 047N March 2003 Visit our website at www HobartWelders com ...

Page 2: ...self 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 parts list will then help you to decide the exact part you may need to fix the problem W...

Page 3: ...SMAW Electrodes 18 SECTION 6 OPERATING THE WELDING GENERATOR 19 6 1 Front Panel Controls 19 SECTION 7 OPERATING AUXILIARY EQUIPMENT 20 7 1 Standard Receptacles 20 7 2 Optional Generator Power Receptacles 21 7 3 Wiring Optional 240 Volt Plug 21 SECTION 8 MAINTENANCE ONAN POWERED UNITS 22 8 1 Maintenance Label Onan Powered Units 22 8 2 Routine Maintenance Onan Powered Units 23 8 3 Servicing Air Clea...

Page 4: ......

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 2 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: ...TIONS 4 1 Weld Power and Engine Specifications This unit uses either an Onan or a Kohler engine Differences between models are noted throughout this manual Note 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 14: ... where it could tip 4 HOLES B 16 9 16 in 421 mm tip C 23 32 in 18 mm D 3 in 76 mm 25 E F E 31 1 2 in 800 mm 25 F 37 1 2 in 953 mm 25 25 G 13 32 in 10 mm Dia 25 Weight Onan Powered Unit 445 lb 202 kg Kohler Powered Unit 444 lb 201 kg 802 855 Engine End 4 3 Generator Power Curve The generator power curve shows the generator power in amperes available at the receptacles 0 50 100 150 200 250 300 0 10 ...

Page 15: ...he percentage of 10 minutes that unit can weld at rated load without overheating 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 16: ...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 17: ...d 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 frame by metal to metal contact GND PE 2 ...

Page 18: ...rting Keep battery in good condition Store battery in warm area Use correct grade oil for cold weather Full 5 3 Engine Prestart Checks Kohler Powered Units 802 339 B 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 shut down swit...

Page 19: ... 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 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 ...

Page 20: ...ve cable last 5 6 Installing Exhaust Pipe 801 681 Ref 202 069 A 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 ...

Page 21: ...0 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 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 350 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 2 ea 4 0 2x120 400 1 0 60 2 0 ...

Page 22: ...ction Table For Stick SMAW Electrodes Ref 202 069 A Use table on front panel to se lect correct amperage for the electrode being used Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 23: ... runs at idle speed at no load and weld power 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 rest...

Page 24: ...Hz single phase power at weld 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 Circuit Breaker CB1 CB1 protects the ac receptacles from overload If CB1 opens the ac receptacles do not work Move CB1 toggle switch to On p...

Page 25: ...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 GFCI is working properly 1 7 3 Wiring Optional 240 Volt Plug 120 813 D The plug can be wired for a 240 V 2 wire load or a 120 240V 3 wire load See circuit diagram 1 Plug Wired for 120 240 V 3 Wire Load When wired for 120 V loads each duplex re...

Page 26: ...OM 945 Page 22 SECTION 8 MAINTENANCE ONAN POWERED UNITS 8 1 Maintenance Label Onan Powered Units ...

Page 27: ...rvice Agent Every 8 h Wipe up spills Check fluid levels See Section 5 2 20 h 25 h Check and clean spark arrestor screen See Section 8 5 Service air cleaner wrapper foam element See Section 8 3 Every 50 h Clean and tighten weld terminals Every 100 h Clean cooling system See Engine Manual Change oil See Section 8 6 and maintenancelabel Clean and tighten battery connections Service air cleaner elemen...

Page 28: ...vy service clean monthly OR 8 3 Servicing Air Cleaner Onan Powered Units aircleaner3 1 97 156 852 Ref 183 175 A S 0759 Stop engine Do not run engine without air cleaner or with dirty element 1 Wrapper Foam Element 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 dirty...

Page 29: ...generator excitation circuit If F1 opens there is no low weld and generator power output 2 Fuse F6 See Parts List F6 protects the engine wiring sys tem If F6 opens the engine does not crank If F6 opens while the en gine is running the engine stops Replace any open fuses Reinstall cover before operating If a fuse opens it usually indi cates a more serious problem exists Contact a Factory Au thorize...

Page 30: ...ilter 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 1 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 neces sary and wipe up fuel 4 5 1 2 Tools Needed Fu...

Page 31: ...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 32: ...OM 945 Page 28 SECTION 9 MAINTENANCE KOHLER POWERED UNITS 9 1 Maintenance Label Kohler Powered Units ...

Page 33: ...t Every 8 h Wipe up spills Check fluid levels See Section 5 2 Every 20 h Check and clean optional spark arrestor screen See Section 9 5 Every 25 h Service air cleaner wrapper foam element See Section 9 3 Every 50 h Clean and tighten weld terminals Every 100 h Change oil See Section 9 6 and maintenance label Check air cleaner element See Section 9 3 Clean and tighten battery connections Clean cooli...

Page 34: ...lean monthly OR 9 3 Servicing Air Cleaner Kohler Powered Units aircleaner3 1 97 802 772 Ref 183 175 A S 0759 Stop engine Do not run engine without air cleaner or with dirty element 1 Wrapper Foam Element 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 dirty oily or d...

Page 35: ...citation circuit If F1 opens there will be no low weld and generator power out put 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 any open fuses Reinstall panel before operating unit If a fuse opens it usually indi cates a more serious problem exists Contact a Factory Au thorized ...

Page 36: ...filter accord ing 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 9 1 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 connec tions as necessary and wipe up fuel Tools Needed 3 4 5 1 2...

Page 37: ...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 38: ...ck control 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...

Page 39: ...vel operation Check oil level see Section 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 Dis...

Page 40: ...OM 945 Page 36 SECTION 11 ELECTRICAL DIAGRAM 204 710 Figure 10 1 Circuit Diagram For Welding Generator Onan And Kohler Powered Units ...

Page 41: ...enerator 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 use...

Page 42: ...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 12 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 43: ...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 44: ...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 45: ...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 12 9 How Much Power Can G...

Page 46: ...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 47: ... 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 48: ...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 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 cracklin...

Page 49: ...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 50: ... 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 51: ...Correct 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 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 52: ...3 4 13 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 13 12 Tee Joint S 0060 S 0058 A S 0061 1 Ele...

Page 53: ... 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 54: ... 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 55: ...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 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 56: ...is common and not available unless listed Figure 13 1 Main Assembly Onan Engine Shown 1 3 4 5 6 7 8 9 10 11 12 14 13 15 17 16 18 19 20 Fig 13 3 19 21 22 23 24 25 26 27 28 29 31 32 34 35 36 33 37 38 39 40 41 42 43 44 46 47 Fig 13 2 45 18 17 Kohler only 30 48 ...

Page 57: ...r fuel filter and spark plugs 1 13 194 249 Engine Kohler Gas Elec Ch20s ps 64635 consisting of 1 14 193 856 Muffler Exhaust Engine Kohler 1 189 477 Gasket muffler 2 066 698 Filter oil 1 067 272 Element air cleaner 1 121 652 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 Drain 3 8 18 Nptf 1 F6 021 718 Fuse Mintr Gl 30 Amp 32 Vol...

Page 58: ...810 Upright Base 1 45 160 975 Seal Weather Lift Eye 1 46 180 628 Panel Front Lower 1 47 Figure 13 2 Panel Front w Components 1 48 208 149 Bracket Mtg Rectifier 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...

Page 59: ...203 993 Control Push Pull Snap in 36 000 W 1 750 Extension 1 11 119 014 Lever Switch Black 1 12 173 734 Link Jumper 2 13 1T 172 661 Block Stud Connection 6 Position 1 14 POS 039 047 Terminal Pwr Output Red 1 15 NEG 039 046 Terminal Pwr Output Black 1 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 ...

Page 60: ...nerator Rear 1 5 186 083 Screw 437 14x1 75 Hexwhd 93d Gr8 Pld 4 6 203 933 Rotor 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 5 802 345 B 2 1 4 5 7 8 6 9 10 3 Figure 13 3 Generator When ordering a component originally displaying a precautionary label th...

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Page 63: ...obart 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 covered by the manufacturer s warra...

Page 64: ...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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