1. Manuals
  2. Brands
  3. Hobart Manuals
  4. Welding System
  5. 1435
  6. Owner's manual

Hobart 1435 Owner's Manual

Engine driven welding generator
Hide thumbs
Table of Contents

Advertisement

Quick Links

OM-498
197 849D
December 2001
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
CHAMP 1435
Visit our website at
www.HobartWelders.com

Advertisement

Table of Contents
loading

Related Manuals for Hobart 1435

Summary of Contents for Hobart 1435

  • Page 1 OM-498 197 849D December 2001 Processes Stick (SMAW) Welding Description Engine Driven Welding Generator CHAMP 1435 Visit our website at www.HobartWelders.com...
  • Page 2 From Hobart to You Thank you and congratulations on choosing Hobart. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. This Owner’s Manual is designed to help you get the most out of your Hobart products.

  • Page 3: Table Of Contents

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage 1-2. Arc Welding Hazards 1-3. Engine Hazards 1-4. Additional Symbols For Installation, Operation, And Maintenance WARNING 1-5. Principal Safety Standards 1-6. EMF Information This product, when used SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION for welding or cutting, 1-1.

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. Means “Note”; not safety related. 1-2.

  • Page 6: Engine Hazards

    WELDING can cause fire or explo- sion. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and burns.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    MOVING PARTS can cause injury. D Keep away from fans, belts, and rotors. D Keep all doors, panels, covers, and guards closed and securely in place. D Stop engine before installing or connecting unit. D Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary.

  • Page 8: Principal Safety Standards

    H.F. RADIATION can cause interference. D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Have only qualified persons familiar with electronic equipment perform this installation. D The user is responsible for having a qualified electrician prompt- ly correct any interference problem resulting from the installa- tion.

  • Page 9: Section 1 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. Signifie NOTA ;...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    LE SOUDAGE peut provoquer un in- cendie ou une explosion. 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.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    DES ORGANES MOBILES peuvent provoquer des blessures. D Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. D Maintenir fermés et fixement en place les portes, panneaux, recouvrements protection. D Arrêter le moteur avant d’installer ou brancher l’appareil. D Demander seulement à...

  • Page 12: Principales Normes De Sécurité

    LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences. D Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipements de radio–navigation et de communication, les services de sécurité et les ordinateurs. D Demander seulement à des personnes qualifiées familiarisées avec des équipements électroniques de faire fonctionner l’installation.

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Engine Choke Engine Oil Positive Hours Circuit Breaker SECTION 3 – SPECIFICATIONS NOTE This unit uses either a Kohler or a Honda engine. Differences between models are noted throughout this manual. 3-1. Weld, Power, And Engine Specifications Weld Welding Rated...

  • Page 14: Dimensions, Weights, And Operating Angles

    3-2. Dimensions, Weights, And Operating Angles Dimensions Height 20-3/4 in (527 mm) Width 22-3/4 in (577 mm) Depth 31-1/4 in (793 mm) 31-1/4 in (793 mm) 10-1/2 in (268 mm) 13-45/64 in (348 mm) 22-3/4 in (577 mm) 1-3/4 in (44 mm) 19-1/2 in (495 mm) 13/32 in (10 mm) Dia.

  • Page 15: Fuel Consumption (Honda-Powered Units)

    3-4. Fuel Consumption (Honda-Powered Units) 3-5. Duty Cycle 100% Duty Cycle at 80 Amperes CC/DC 3 Minutes Welding 30% Duty Cycle at 140 Amperes CC/DC Continuous Welding 7 Minutes Resting 802 121 Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating.

  • Page 16: Auxiliary Power Curve

    3-6. Auxiliary Power Curve 3-7. Volt-Ampere Curves OM-498 Page 12 LOAD AMPS The ac auxiliary power curves show the auxiliary power available in amperes at the receptacles. 802 129 The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator.

  • Page 17: Section 4 - Installation

    SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Movement Location 4-2. Grounding Generator To Truck Or Trailer Frame Electrically bond generator frame to vehicle frame by metal-to-metal contact. Airflow Clearance 18 in (460 mm) 18 in (460 mm) install1 1/97 – 802 512-A / Ref. 151 556 / 158 936-A / S-0854 GND/PE 18 in (460 mm)

  • Page 18: Grounding Generator When Supplying Building Systems

    4-3. Grounding Generator When Supplying Building Systems Use ground device as stated in electrical codes. 4-4. Engine Prestart Checks (Kohler-Powered Units) Closed Closed Open OM-498 Page 14 GND/PE 1/2 in (13 mm) Full Gasoline Full Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire.

  • Page 19: Engine Prestart Checks (Honda-Powered Units)

    4-5. Engine Prestart Checks (Honda-Powered Units) (13 mm) Open 4-6. Connecting The Battery (Honda Electric-Start Models Only) Tools Needed: 3/8, 1/2 in 1/2 in Full Gasoline Full Y Connect negative (–) cable last. Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil.

  • Page 20: Connecting To Weld Output Terminals

    4-7. Connecting To Weld Output Terminals Tools Needed: 3/4 in 4-8. Selecting Weld Cable Sizes* Weld Output Terminals Y Stop engine before Welding connecting to weld out- Amperes put terminals. Y Do not use worn, dam- aged, undersized, or poorly spliced cables. This chart is a general guideline and may not suit all applications.

  • Page 21: Section 5 - Operating The Welding Generator

    SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Controls (Kohler-Powered Units) 60 Hz Weld and auxiliary power output stops if generator overheats or engine speed is too low. Engine Switch Use switch to open ignition circuit, and to stop engine. Throttle Control Lever Use lever to select engine speed.

  • Page 22: Controls (Honda-Powered Units) (See Section 5-3)

    5-2. Controls (Honda-Powered Units) (See Section 5-3) Recoil-Start Electric-Start 60 Hz 802 099-A / 802 100-A / 953T-5-4 OM-498 Page 18...

  • Page 23: Description Of Controls (Honda-Powered Units) (See Section 5-2)

    5-3. Description Of Controls (Honda-Powered Units) (See Section 5-2) Weld and auxiliary power output stops if generator overheats or engine speed is too low. Engine Switch On models with recoil-start, use switch to open ignition circuit, and to stop engine. On models with electric-start, use switch to open ignition circuit, and to start and stop en- gine.

  • Page 24: Section 6 - Operating Auxiliary Equipment

    SECTION 6 – OPERATING AUXILIARY EQUIPMENT NOTE The welding generator provides power while welding and with the Current control in any position. However, under these conditions equipment connected to the welding generator may be subject to larger than normal voltage fluctuations. It is recommended that only lamps be powered under these conditions.

  • Page 25: Optional Auxiliary Power Panels

    6-2. Optional Auxiliary Power Panels Auxiliary Power Panel 495 315 (USA) Auxiliary Power Panel 495 279 (Canada) Auxiliary Power Panel 495 289 (Australia) Y If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord. Y Power may still be present at a re- ceptacle when a circuit breaker trips.

  • Page 26: Auxiliary Power Panel Ratings

    6-3. Auxiliary Power Panel Ratings NOTE Unless otherwise stated, the rating of duplex outlets is the combined load of all receptacles. Total power from generator NOT to exceed 3500 Watts (60 Hz) Panel Protected Receptacle 495 218 495 315 (USA) 60 Hz 240 V CB1,2...

  • Page 27: Wiring Instructions For Optional 120/240 Volt Twistlock Plug (Nema L14-30P)

    6-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P) 120 V Notes 120V 240 V Plug Wired For 120/240 V, 3-Wire Load When wired for 120 V loads, each du- plex receptacle shares a load with one half of the 240 V receptacle. Neutral (Silver) Terminal Load 1 (Brass) Terminal Load 2 (Brass) Terminal...

  • Page 28: Section 7 - Maintenance

    SECTION 7 – MAINTENANCE 7-1. Routine Maintenance Check fluid levels. See Section 4-4 or 4-5. Service air cleaner element. See engine manual. Change oil. See engine manual and maintenance label. Clean Fuel sediment cup. Clean fuel tank and strainer. Repair or replace cracked cables.

  • Page 29: Maintenance Label

    NOTE Follow the storage procedure in the engine owner’s manual if the unit will not be used for an extended period. 7-2. Maintenance Label ENGINE MAINTENANCE 1.1 l (1.2 US qt, 1.94 lmp qt) Unleaded 86 + Octane 6.5 l (1.7 US Gal, 11.4 lmp pt) 50 h 7-3.

  • Page 30: Adjusting Engine Speed (Kohler-Powered Units)

    7-4. Adjusting Engine Speed (Kohler-Powered Units) Top View Tools Needed: OM-498 Page 26 After tuning engine, check engine speeds. See table for proper no load speeds. If necessary, adjust speeds as follows: 2000 150 rpm Start engine and run until warm. Weld/Power Speed Adjustment 3720...

  • Page 31: Adjusting Engine Speed (Honda-Powered Units)

    7-5. Adjusting Engine Speed (Honda-Powered Units) Tools Needed: 1/4, 3/8 in 1400 150 rpm 3720 50 rpm (60 Hz) After tuning engine, check engine speeds. See table for proper no load speeds. If necessary, adjust speeds as follows: Start engine and run until warm. Weld/Power Speed Adjustment Throttle Control Lever...

  • Page 32: Section 8 - Troubleshooting

    SECTION 8 – TROUBLESHOOTING 8-1. Troubleshooting A. Welding Trouble No weld output. Check Amperage control setting. Check weld connections. Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, reactor L2, output rectifier CR3, stabilizer L3, integrated rectifiers CR1 and CR2, and amperage control R1.
  • Page 33 C. Engine Trouble Engine will not crank (Honda electric- Reset ignition circuit breaker (see Section 7-3). start models only). Check battery voltage. Check battery connections and tighten if necessary. Have Factory Authorized Service Agent check engine ignition circuit. Engine will not start. Check fuel level (see Section 4-4 or 4-5).

  • Page 34: Section 9 - Electrical Diagrams

    SECTION 9 – ELECTRICAL DIAGRAMS 198 016-D Figure 9-1. Circuit Diagram For Welding Generator SC-495 297 OM-498 Page 30...
  • Page 35 198 014-C Figure 9-2. Wiring Diagram For Welding Generator OM-498 Page 31...
  • Page 36 201 026-A Figure 9-3. Wiring Diagram For Auxiliary Power Panels (1 Of 2) OM-498 Page 32...
  • Page 37 201 026-A Figure 9-4. Wiring Diagram For Auxiliary Power Panels (2 Of 2) OM-498 Page 33...

  • Page 38: Section 10 - Auxiliary Power Guidelines

    SECTION 10 – AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment 10-2. Grounding Generator To Truck Or Trailer Frame OM-498 Page 34 Be sure equipment has this symbol and/or wording. GND/PE Electrically bond generator frame to vehicle frame by metal-to-metal contact. Auxiliary Power Receptacles –...

  • Page 39: Grounding When Supplying Building Systems

    10-3. Grounding When Supplying Building Systems 10-4. How Much Power Does Equipment Require? AMPERES x VOLTS = WATTS EXAMPLE 1: If a drill uses 4.5 amperes at 115 volts, calculate its running power requirement in watts. The load applied by the drill is 520 watts. EXAMPLE 2: If three 200 watt flood lamps are used with the drill from Example 1, add the individual loads to calculate total load.
  • Page 40 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Split Phase Capacitor Start-Induction Run Capacitor Start-Capacitor Run Fan Duty 10-6. Approximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Stock Tank De-Icer Grain Cleaner Portable Conveyor Grain Elevator Milk Cooler Milker (Vacuum Pump) FARM DUTY MOTORS Std.
  • Page 41 10-7. Approximate Power Requirements For Contractor Equipment Contractor Hand Drill Circular Saw Table Saw Band Saw Bench Grinder Air Compressor Electric Chain Saw Electric Trimmer Electric Cultivator Elec. Hedge Trimmer Flood Lights Submersible Pump Centrifugal Pump Floor Polisher High Pressure Washer 55 gal Drum Mixer Wet &...
  • Page 42 10-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP kVA/HP x HP x 1000 VOLTS EXAMPLE: Calculate the starting amperage required for a 230 V, 1/4 HP motor with a motor start code of M. Volts = 230 HP = 1/4 11.2 x 1/4 x 1000...
  • Page 43 10-10. Typical Connections To Supply Standby Power Customer-supplied equipment is required if generator is to supply standby power during emergencies or power outages. 120/240 Volt 60 Hz Three-Wire Service Load 120/240 Volt Single-Phase Three-Wire Generator Output Connection 240 V 120 V 120 V 240 V 120 V...
  • Page 44 10-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord. Current Load (Watts) (Amperes) 1200 1800 2400 3000 3600 4200 4800 5400 6000 *Conductor size is based on maximum 2% voltage drop Cord Lengths for 240 Volt Loads Y If unit does not have GFCI receptacles, use GFCI-protected extension cord.

  • Page 45: Section 11 - Stick Welding (Smaw) Guidelines

    SECTION 11 – STICK WELDING (SMAW) GUIDELINES 11-1. Stick Welding Procedure Tools Needed: Y Weld current starts when electrode touches work- piece. Y Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible.

  • Page 46: Electrode And Amperage Selection Chart

    11-2. Electrode and Amperage Selection Chart 3/32 6010 5/32 & 3/16 6011 7/32 1/16 5/64 3/32 6013 5/32 3/16 7/32 3/32 5/32 7014 3/16 7/32 3/32 5/32 7018 3/16 7/32 3/32 5/32 7024 3/16 7/32 3/32 Ni-Cl 5/32 3/16 3/32 308L 5/32 11-3.

  • Page 47: Positioning Electrode Holder

    11-5. Positioning Electrode Holder End View of Work Angle End View of Work Angle 11-6. Poor Weld Bead Characteristics 11-7. Good Weld Bead Characteristics 10 -30 Side View of Electrode Angle GROOVE WELDS 10 -30 Side View of Electrode Angle FILLET WELDS S-0060 Large Spatter Deposits...

  • Page 48: Conditions That Affect Weld Bead Shape

    11-8. Conditions That Affect Weld Bead Shape NOTE Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Angle Too Small Too Short Slow 11-9. Electrode Movement During Welding NOTE 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.

  • Page 49: Butt Joints

    11-10. Butt Joints 11-11. Lap Joint Or Less Single-Layer Fillet Weld 11-12. Tee Joint 1/16 in (1.6 mm) Or Less Multi-Layer Fillet Weld Or Less Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld.

  • Page 50: Weld Test

    11-13. Weld Test 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) 11-14. Troubleshooting – Porosity Possible Causes Arc length too long. Damp electrode. Workpiece dirty. 11-15. Troubleshooting – Excessive Spatter Possible Causes Amperage too high for electrode. Arc length too long or voltage too high. OM-498 Page 46 2 To 3 in (51-76 mm)

  • Page 51: Troubleshooting – Incomplete Fusion

    11-16. Troubleshooting – Incomplete Fusion Possible Causes Insufficient heat input. Improper welding technique. Workpiece dirty. 11-17. Troubleshooting – Lack Of Penetration Lack of Penetration Good Penetration Possible Causes Improper joint preparation. Improper weld technique. Insufficient heat input. 11-18. Troubleshooting – Excessive Penetration Excessive Penetration Good Penetration Possible Causes...

  • Page 52: Troubleshooting – Burn-Through

    11-19. Troubleshooting – Burn-Through Possible Causes Excessive heat input. 11-20. Troubleshooting – Waviness Of Bead Possible Causes Unsteady hand. Use two hands. Practice technique. 11-21. Troubleshooting – Distortion Base metal moves in the direction of the weld bead. Possible Causes Excessive heat input.
  • Page 53 Notes OM-498 Page 49...

  • Page 54: Section 12 - Parts List

    SECTION 12 – PARTS LIST Hardware is common and not available unless listed. 802 513-A / 802 153-B Figure 12-1. Main Assembly OM-498 Page 50...
  • Page 55 Item Dia. Part Mkgs....+495 247 ....495 096 .
  • Page 56 Auxiliary Power Panel 495 298 (USA) Auxiliary Power Panel 495 218 (USA) Auxiliary Power Panel 495 253 (South Africa) Auxiliary Power Panel 495 290 (Europe) Auxiliary Power Panel 495 283 (S.E. Asia) OM-498 Page 52 Hardware is common and not available unless listed. Auxiliary Power Panel 495 315 (USA) Figure 12-2.
  • Page 57 Item Dia. Part Mkgs. Figure 12-2. Auxiliary Power Panels (Figure 12-1, Item 31) Auxiliary Power Panel 495 298 (USA) ....495 220 . . . CB1, CB2 .
  • Page 58 Notes OM-498 Page 54...
  • Page 59 5/3/1 WARRANTY applies to all Handler 135 and 175 models, Airforce 250, 250A, and 375 Warranty Questions? models, and Champion 10,000 models.This warranty also applies to the Beta-Mig 1800, Champ Call 1435, 2060, 8500 models, Ironman 250, Stickmate models, Tigmate models, and HSW-15 and 1-877-HOBART1 for your local Hobart distributor.

  • Page 60: Options And Accessories

    Parts) Circuit Diagrams Welding Process Handbooks File a claim for loss or damage during shipment. 2001 Hobart Welding Products. 1/01 Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy, OH 45373 USA For Technical Assistance:...

This manual is also suitable for:

Champ 1435

Table of Contents