Instruction/ maintenance manual of the product OM-945 Hobart Welding Products
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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 .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) 29 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1. Routine Maintenance (Kohler-Powered Units) 29 . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
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).
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 .
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.
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.
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.
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.
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.
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.
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 .
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 (.
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.
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.
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).
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.
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.
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.
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.
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.
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 .
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.
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.
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 .
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.
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.
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.
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.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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 210.
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 .
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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.
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 3.
OM-945 Page 55 Description Part No. Dia. Mkgs. Item No. Figure 14-1. Main Assembly Quantity 1 +193 777 Wrapper 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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.
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.
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: Call1-8.
An important point after buying a device Hobart Welding Products OM-945 (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Hobart Welding Products OM-945 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Hobart Welding Products OM-945 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Hobart Welding Products OM-945 you will learn all the available features of the product, as well as information on its operation. The information that you get Hobart Welding Products OM-945 will certainly help you make a decision on the purchase.
If you already are a holder of Hobart Welding Products OM-945, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Hobart Welding Products OM-945.
However, one of the most important roles played by the user manual is to help in solving problems with Hobart Welding Products OM-945. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Hobart Welding Products OM-945 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
