Hobart Welding Products OM-945 manual

Champion 10,000 Pro cesses Descrip ti on Stick (SMAW) W elding Engine Driven Welding Generator OM -945 194 047AA 2006 − 07 ™[...]

Hobart W elders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www .H[...]

T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . [...]

T ABLE OF CONTENTS SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Routine Maintenance (Kohler-Powered Units) 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Maintenance Label (Kohler-Powered Units) 30 . . . . .[...]

OM-945 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_3/05  W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown i n the adjoining symbols.  Marks a special saf[...]

OM-945 Page 2 W elding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly of f from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns. Accidental contact of electrode to metal objects can cause sparks, explosion, overheating, or fire. Check and be sure the are[...]

OM-945 Page 3 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 pres- 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 [...]

OM-945 Page 4 READ INSTRUCTIONS.  Use only genuine MILLER/Hobart replacement parts.  Perform engine and air compressor (if applicable) maintenance and service according to this manual and the engine/air compressor (if applicable) manu- als. H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio naviga- t[...]

OM-945 Page 5 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_fre 3/05  Avertissement: Protégez vous et les autres des blessures − lisez et suivez ces précautions. 2-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par d[...]

OM-945 Page 6 Le soudage effectué sur des conteneurs fermés tels que des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de l’arc de soudure. La projection d’étincelles, des pièces chaudes et des équipements chauds peut provoquer des incendies et des brûlures. Le contact acc[...]

OM-945 Page 7  Si le moteur est chaud et que le liquide doit être vérifié, opérer comme suivant.  Mettre des lunettes de sécurité et des gants, placer un torchon sur le bouchon du radiateur .  Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enle- ver le bouchon. LES ACCUMULA TIONS DE GAZ ris- quent de p[...]

OM-945 Page 8 LIRE LES INSTRUCTIONS.  Utiliser seulement les pièces de rechange d’origine.  Ef fectuer la maintenance du moteur et du compresseur (s i applicable) suivant ce manuel et le manuel du moteur/ compresseur (si applicable). LE RA YONNEMENT HAUTE FRÉ- QUENCE (H.F .) risque de provoquer des interférences.  Le rayonnement haute[...]

OM-945 Page 9 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Read Operator’s Manual A Amperes V V olts Engine Oil Fuel Battery (Engine) Engine Engine Choke Check V alve Clearance Circuit Protector T emperature Positive Negative Alternating Current (AC) Output h H[...]

OM-945 Page 10 4-2. Dimensions, Weights, and Operating Angles Dimensions Height 33-1/2 in (851 mm) A Width 18-1/2 in (470 mm) A B C Depth 38 in (965 mm)  Do not exceed tilt angles or engine could be damaged or unit could tip B C D G A 18 in (457 mm)  gg be damaged or unit could tip.  Do not move or operate unit where it could D G 4 HOLES B[...]

OM-945 Page 1 1 4-4. Fuel Consumption (All Models) 197 254 Continuous Welding 4-5. Duty Cycle 197 148 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 . 60% Duty Cycle at 210 Amperes CC/DC 100% Duty Cycle at 170 Amperes CC/DC 6 Minutes W eldin[...]

OM-945 Page 12 4-6. V olt-Ampere Curves 197 253 The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of a ll 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)[...]

OM-945 Page 13 SECTION 5 − INST ALLA TION install2 1 1/04 − Ref. 800 652 / Ref. 800 477-A / 803 274  Do not weld on base. W elding on base can cause fuel tank fire or explosion. Bolt unit down using holes provided in base.  Always securely fasten weld- ing generator onto transport vehicle or trailer and comply with all DOT and other appli[...]

OM-945 Page 14 5-2. Engine Prestart Checks (Robin-Powered Units) 802 353-G Full Gasoline 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 switch. However ,[...]

OM-945 Page 15 5-4. Activating The Dry Charge Battery (If Applicable)  Always wear a face shield, rubber gloves and protective clothing when working on a battery . Remove battery from unit. 1 V ent Caps 2 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 3 W ell Fill each cell with electrolyte to bottom of well (maximum).  Do not overfill ba[...]

OM-945 Page 16 5-6. Installing Exhaust Pipe 801 681 / Ref. 226 427-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. T ools Needed: 1/2 in 802 353-G [...]

OM-945 Page 17 5-8. Connecting T o Weld Output T erminals 803 778-A / Ref. 226 427-A  Stop engine.  Failure to properly connect weld cables may cause ex- cessive heat and start a fire, or damage your machine. 1 W eld Output T erminal 2 Supplied W eld Output T erminal Nut 3 W eld Cable T erminal 4 Copper Bar Remove supplied nut from weld outpu[...]

OM-945 Page 18 SECTION 6 − OPERA TING THE WELDING GENERA TOR If the unit is extremely overloaded, weld and generator power will stop. T urn unit off and restart to reset the generator protection circuit and restore weld generator power output. If the rated output of the unit is exceeded, engine speed may vary rapidly until the weld or generator l[...]

OM-945 Page 19 6-2. Cold Weather Engine Operation Ref. 226 427-A 1 Engine Control Switch Carburetor Icing Carburetor icing causes the unit to drop below the normal idle speed and then stall. This condition occurs when the temperature is near freezing and the rela- tive humidity is high. Ice forms on the throttle plate and inner bore of the carbu- r[...]

OM-945 Page 20 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT If the unit is extremely overloaded, weld and generator power will stop. T urn unit off and restart to reset the generator protection circuit and restore weld and generator power output. If the rated output of the unit is exceeded, engine speed may vary rapidly until the weld or generator[...]

OM-945 Page 21 7-2. Optional Generator Power Receptacles  If unit does not have GFCI re- ceptacles, use GFCI- protected extension cord. Combined output of all receptacles limited to 10 kV A/kW rating of the generator . GFCI Receptacle Option 1 120 V 20 A AC GFCI Recep- tacles GFCI2 and GFCI3 GFCI2 and GFCI3 supply 60 Hz single-phase power at wel[...]

OM-945 Page 22 7-3. Wiring Instructions For Optional 240 V olt, Single-Phase Plug (NEMA 14-50P) plug1 1 1/03 − 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 receptacle shares a load with one half of 240 V [...]

OM-945 Page 23 SECTION 8 − MAINTENANCE (ROBIN-POWERED UNITS) 8-1. Routine Maintenance (Robin-Powered Units)  Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. Recycle engine fluids.  = Check  = Chan[...]

OM-945 Page 24 8-2. Maintenance Label (Robin-Powered Units)[...]

OM-945 Page 25 8-3. Servicing Air Cleaner (Robin − Powered Units) aircleaner3 1 1/04 − 803 070 / S-0759  Stop engine.  Do not run engine without ai r cleaner or with dirty element. 1 W rapper Wash wrapper with soap and water solution. Allow wrapper to air dry completely . Spread 1 tablespoon SAE 30 oil evenly into wrapper. Squeeze out exc[...]

OM-945 Page 26 8-4. Overload Protection (Robin-Powered Units) 802 342 / Ref. 802 353-G  Stop engine. Disconnect nega- tive ( − ) battery cable.  If the unit is extremely over- loaded, weld and generator pow- er will stop. T urn unit off and re- start to reset the generator protection circuit and restore weld and generator power output. If t[...]

OM-945 Page 27 8-6. Changing Engine Oil, Oil Filter , and Fuel Filter (Robin-Powered Units) 802 353-G / S-0842  Stop engine and let cool. 1 Oil Drain V alve 2 1/2 ID x 7 in Hose 3 Oil Filter 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[...]

OM-945 Page 28 8-7. Adjusting Engine Speed (Robin-Powered Units) 802 353-G / 802 457 After tuning engine, check engine speeds with a tachometer (see table). If necessary , adjust speeds as follows: Start engine and run until warm. Remove wrapper to access speed adjustments. Idle Speed Adjustment Move Engine Control switch to Run/Idle position. 1 Th[...]

OM-945 Page 29 SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) 9-1. Routine Maintenance (Kohler-Powered Units)  Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. Recycle engine fluids.  = Check  [...]

OM-945 Page 30 9-2. Maintenance Label (Kohler-Powered Units)[...]

OM-945 Page 31 9-3. Servicing Air Cleaner (Kohler − Powered Units) aircleaner3 1 1/04 − 802 772 / S-0759  Stop engine.  Do not run engine without ai r cleaner or with dirty element. 1 W rapper Wash wrapper with soap and water solution. Allow wrapper to air dry completely . Spread 1 tablespoon SAE 30 oil evenly into wrapper. Squeeze out ex[...]

OM-945 Page 32 9-4. Overload Protection (Kohler-Powered Units) Ref. 801 221-B / Ref. 802 353-G  Stop engine.  If the unit is extremely over- loaded, weld and generator pow- er will stop. T urn unit off and re- start to reset the generator protection circuit and restore weld and generator power out- put. I f the rated output of the unit is ex-[...]

OM-945 Page 33 9-6. Changing Engine Oil, Oil Filter , and Fuel Filter (Kohler-Powered Units) 802 339-G / S-0842  Stop engine and let cool. 1 Oil Drain V alve 2 1/2 ID x 7 in Hose 3 Oil Filter Change engine oil and filter accord- ing to engine owner’s manual.  Close valve and valve cap before adding oil and running engine. Fill crankcase wit[...]

OM-945 Page 34 9-7. Adjusting Engine Speed (Kohler-Powered Units) 802 339-G / 801 209-A After tuning engine, check engine speeds with a tachometer (see table). If necessary , adjust speeds as follows: Start engine and run until warm. Remove wrapper to access speed adjustments. Idle Speed Adjustment Move Engine Control switch to Run/Idle position. 1[...]

OM-945 Page 35 SECTION 10 − TROUBLESHOOTING 10-1. T roubleshooting A. Welding T rouble Remedy No weld output. Check control settings. Check weld connections. Reset circuit breaker CB4 (see Section 8-4 or 9-4). Unit overloaded. Stop unit and reduce load. Restart unit to reset generator protection circuit and resume operation. Be sure all equipment[...]

OM-945 Page 36 T rouble Remedy Erratic power output at generator pow- er ac receptacles. Check fuel level. Check engine speed and adjust if necessary (see Section 8-7 or 9-7). Check receptacle wiring and connections. Have Factory Authorized Service Agent check brushes and slip rings. C. Engine T rouble Remedy Engine will not crank. Check fuse F6, a[...]

OM-945 Page 37 T rouble Remedy During operation in near freezing tem- peratures, engine starts and goes to idle but stalls after a few minutes. T reat fuel with isopropyl alcohol de-icer product. 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-[...]

OM-945 Page 38 SECTION 1 1 − ELECTRICAL DIAGRAM 230 514-A Figure 1 1-1. Circuit Diagram For Welding Generator (Robin And Kohler-Powered Units)[...]

OM-945 Page 39 SECTION 12 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. NOTE 12-1. Selecting Equipment gen_pwr 1 1/02 − Ref. ST-159 730 / ST -800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Prong Plu[...]

OM-945 Page 40 12-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e ground device as stated in electrica[...]

OM-945 Page 41 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Startin g W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 2850[...]

OM-945 Page 42 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in 39[...]

OM-945 Page 43 12-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine starting am[...]

OM-945 Page 44 12-10. T ypical Connections T o Supply Standby Power  Have only qualified persons perform these connections according to all applicable codes and safety practic- es.  Properly install and ground this equipment according to its Owner ’s Manual and national, state, and local codes.  Customer -supplied equipment is re- quired[...]

OM-945 Page 45 12-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 84[...]

OM-945 Page 46 SECTION 13 − STICK WELDING (SMA W) GUIDELINES 13-1. Stick Welding Procedure stick 12/96 − ST-151 593  W eld current starts when electrode touches work- piece.  W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla ce w ork cla mp a s close to the weld as possi[...]

OM-945 Page 47 13-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 6010 & 601 1 6013 7014 7018 7024 Ni-Cl 308L 50 100 150 200 250 300 350 400 450 ELECTRO[...]

OM-945 Page 48 13-5. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° GROOVE WELDS FILLET WELDS End V iew of Work Angle Sid e V iew of Electrode Angle End V iew of Work Angle S ide V iew of Electrode Angle 10 ° -30 ° 13-6. Poor W eld Bead Characteristics S-0053-A 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crate[...]

OM-945 Page 49 13-8. Conditions That Affect W eld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. NOTE S-0061 ELECTRODE ANGLE ARC LENGTH TRA VEL SPEED Slow Normal Fast 10 ° - 30 ° Drag T oo Short Normal T oo Long Spatter Angle T oo Small Angle T oo Large Correct Angle 13-9. Electro[...]

OM-945 Page 50 13-10. Butt Joints S-0662 1 T ack Welds Prevent ed ge s o f j oint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. 2 Square Groove W eld Good for materials up to 3/16 in (5 mm) thick. 3 Single V -Groove Weld Good for materials 3/16 − 3/4 in (5-19 mm) thick. Cut bevel with oxy-[...]

OM-945 Page 51 13-13. Weld T est S-0057-B 1 V ise 2 W e ld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 T o 3 in 1/4 in 3 2 1 2 T o 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 13-14. T roubleshooting − Porosity Porosity − small cavities or holes resulting from gas pockets i n weld metal. Possib[...]

OM-945 Page 52 13-16. T roubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insuf ficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in prope[...]

OM-945 Page 53 13-19. T roubleshooting − Burn-Through Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains. Possible Causes Corrective Actions Excessive heat input. Select lower amperage. Use smaller electrode. Increase and/or maintain steady travel speed. 13-20. T roubleshooting − W avines[...]

OM-945 Page 54 SECTION 14 − P ARTS LIST 802 343 − P  Hardware is common and not available unless listed. Figure 14-1. Main Assembly (Robin Engine Shown) Kohler only 41 40 39 38 37 31 30 45 34 33 32 36 35 17 18 44 − FIG 14-2 43 42 1 4 3 2 7 5 8 20 − FIG 14-3 19 18 22 29 28 25 26 27 21 24 23 11 19 14 12 9 10 17 15 16 13 6[...]

OM-945 Page 55 Description Part No. Dia. Mkgs. Item No. Figure 14-1. Main Assembly Quantity 1 +193 777 Wrapper 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 227 725 Label, Use Gasoline Fuel Only 1 . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-945 Page 56 Description Part No. Dia. Mkgs. Item No. Figure 14-1 . Main Assembly (Continued) Quantity 31 181 057 Cover , Base 2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 DC-Z 205 978 Stabilizer Assy , 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

OM-945 Page 57 Description Part No. Dia. Mkgs. Item No. Figure 14-2. Panel, Front w/Components (Figure 14-1 Item 47) Quantity 1 198 122 Stand − of f Support, Pc Card .250w/Post&lock .500 6 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 Nameplate (order by model & serial no.) 1 . . . . . . . . . . . . . . . . .[...]

OM-945 Page 58 Description Part No. Item No. Figure 14-3. Generator (Figure 14-1 Item 20) Quantity 1 +220 832 Generator Assy , Front (consisting of) 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 183 419 O − ring, 1.984 Id X .139 Cs 70 Duro V iton 1 . . . . . . . . . . . . . . . . . . . . . . .[...]

Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST hobart_warr 2006 − 01 Service Y o u always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distributor and Hoba[...]

PRINTED IN USA © 2006 Hobart Welding Products. 2006 − 01 Hoba rt We lding Pr oducts An Illinois T ool W orks Comp any 600 W est Main Street Tr oy , OH 45373 US A For Technical A ssistan ce: Call1-800-332-3281 Fo r Liter atur e Or Nea rest Dea ler: Call 1-877-Hobart 1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivere[...]