Hobart Welding Products OM-945 194 047U manual

Champion 10,000 Pro cesses Descrip ti on Stick (SMAW) W elding Engine Driven Welding Generator OM -945 194 047U September 2004  Visit our website at www.HobartWelders.com[...]

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 catalog sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1. Thank you and congratulations on ch[...]

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) 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Routine Maintenance (Kohler-Powered Units) 28 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2. Maintenance Label (Kohler-Powered Units) 30 . . . . .[...]

OM-945 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom _nd_8/03  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 8/03  A vertissement: 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 [...]

OM-945 Page 6 LES ACCUMULA TIONS DE GAZ ris- quent de provoquer des blessures ou même la mort.  Fermer l’alimentation du gaz protecteur en cas de non utilisation.  V eiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. Le rayonnement de l’arc du procédé de soudage gén[...]

OM-945 Page 7 L ’EXPLOSION DE L A BA TTERIE peut RENDRE A VEUGLE.  T oujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie.  Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.  Eviter de provoquer des étincelles avec les outils [...]

OM-945 Page 8 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.  Ne pas brancher d[...]

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 Breaker T emperature Positive Negative Alternating Current (AC) Output h Hou[...]

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)  Do not exceed tilt angles or engine could A B C G Depth 38 in (965 mm)  Do not exceed tilt angles or engine could be damaged or unit could tip. D G 4 HOLES A 18 in (457 mm)  Do not move or operate unit where it cou[...]

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 6/04 − 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 applica[...]

OM-945 Page 14 5-2. Engine Prestart Checks (Onan-Powered Units) 802 353-D 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) Remove battery from unit. 1 Eye Protection − Safety Glasses Or Face Shield 2 Rubber Gloves 3 V ent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 W ell Fill each cell with electrolyte to bottom of well (maximum).  Do not overfill battery cells. Wai t ten minutes[...]

OM-945 Page 16 5-5. Connecting the Battery Ref. 202 069-A / Ref. 802 341 / Ref. S-0756-D 1/2 in T ools Needed: + −  Connect negative ( − ) 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 o[...]

OM-945 Page 17 5-7. Connecting to Weld Output T erminals Ref. 202 069-A 1 Negative ( − ) Weld Output T erminal 2 Positive (+) W eld Output T erminal For Direct Current Electrode Posi- tive (DCEP), connect work cable to Negative ( − ) terminal and electrode holder cable to Positive (+) terminal. Fo r Direct Current Electrode Nega- tive (DCEN), r[...]

OM-945 Page 18 5-9. Amperage Selection T able For Stick (SMA W) Electrodes Ref. 202 069-A  Use table on front panel to se- lect correct amperage for the electrode being used. Notes W o rk l i k e a P r o ! Pros wel d and cut safel y . Read t he safety rules at the beginni ng of this manual .[...]

OM-945 Page 19 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 and generator power output. If the rated output of the unit is exceeded, engine speed may vary rapidly until the weld or generat[...]

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 SECTION 8 − MAINTENANCE (ONAN-POWERED UNITS) 8-1. Routine Maintenance (Onan-Powered Units) Follow the storage procedure in the engine owner ’s manual if the unit will not be used for an extended period. Note Recycle engine fluids.  Stop engine before maintaining.  See Engine Manual and Maintenance Label for important start-[...]

OM-945 Page 23 Every 500 h Repair or replace cracked cables. Service welding generator brushes and slip rings. Service more often in dirty conditions.* Check valve clearance.* Every 1000 h Blow out or vacuum inside. During heavy service, clean monthly . OR 8-2. Maintenance Label (Onan-Powered Units)[...]

OM-945 Page 24 8-3. Servicing Air Cleaner (Onan-Powered Units) aircleaner3 9/00 − 156 852 / Ref. 183 175-A / S-0759  Stop engine.  Do not run engine without ai r cleaner or with dirty element. 1 W rapper (Foam Element) Wash wrapper with soap and water solution. Allow wrapper to air dry completely . 2 Element Replace element if dirty , oily [...]

OM-945 Page 25 8-4. Overload Protection (Onan-Powered Units) 802 342 / Ref. 802 353-B  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 th[...]

OM-945 Page 26 8-6. Changing Engine Oil, Oil Filter , and Fuel Filter (Onan-Powered Units) 802 353-B / 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 27 8-7. Adjusting Engine Speed (Onan-Powered Units) 802 353-B / 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 Thr[...]

OM-945 Page 28 SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) 9-1. Routine Maintenance (Kohler-Powered Units) Follow the storage procedure in the engine owner ’s manual if the unit will not be used for an extended period. Note Recycle engine fluids.  Stop engine before maintaining.  See Engine Manual and Maintenance Label for importan[...]

OM-945 Page 29 Every 200 h Replace fuel filter . See Section 9-6. Change oil filter . See Section 9-6 and maintenance label. Replace unreadable labels. Check spark plugs. Every 500 h Repair or replace cracked cables. Service welding generator brushes and slip rings. Service more often in dirty conditions.* Every 1000 h Blow out or vacuum inside. Du[...]

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

OM-945 Page 31 9-3. Servicing Air Cleaner (Kohler-Powered Units) aircleaner3 9/00 − 802 772 / Ref. 183 175-A / S-0759  Stop engine.  Do not run engine without ai r cleaner or with dirty element. 1 W rapper (Foam Element) Wash wrapper with soap and water solution. Allow wrapper to air dry completely . Spread 1 tablespoon SAE 30 oil evenly in[...]

OM-945 Page 32 9-4. Overload Protection (Kohler-Powered Units) Ref. 801 221-B / Ref. 802 353-B / Ref. 183 175 − A  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 outp[...]

OM-945 Page 33 9-6. Changing Engine Oil, Oil Filter , and Fuel Filter (Kohler-Powered Units) 802 339-B / 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-B / 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 SECTION 1 1 − ELECTRICAL DIAGRAM 222129 − A Figure 1 1-1. Circuit Diagram For Welding Generator (Onan And Kohler-Powered Units)[...]

OM-945 Page 38 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 39 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 40 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 41 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 42 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 43 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 44 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 45 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 46 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 47 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 48 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 49 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 50 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 51 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 52 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 53 Notes[...]

OM-945 Page 54 SECTION 14 − P ARTS LIST 41 40 39 38 37 31 30 45 34 33 32 36 35 17 18 44 − FIG 14 − 2 43 42 1 5 4 3 7 6 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 2 802 343 − L  Hardware is common and not available unless listed. Figure 14-1. Main Assembly (Onan Engine Shown) Kohler only[...]

OM-945 Page 55 Description Part No. Dia. Mkgs. Item No. Figure 14-1. Main Assembly Quantity 1 +193 777 Wrapper 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 184 791 Label, Hobart 3 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

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 Viton 1 . . . . . . . . . . . . . . . . . . . . . . . [...]

Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart retail 3/04 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 distribut[...]

PRINTED IN USA  2004 Hobart Welding Products. 1/04 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 delivered to o[...]