Hobart Welding Products Champion Elite 225 Owner's Manual
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Hobart Welding Products Champion Elite 225 Owner's Manual

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OM-266040M
2023-05
Processes
Stick (SMAW) Welding
Description
Engine Driven Welder/Generator
Champion
Elite 225
®
OWNER'S MANUAL
www.HobartWelders.com

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Summary of Contents for Hobart Welding Products Champion Elite 225

  • Page 1 OM-266040M 2023-05 Processes Stick (SMAW) Welding Description Engine Driven Welder/Generator Champion Elite 225 ® OWNER’S MANUAL 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

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING..............1 Symbol Usage .
  • Page 4 TABLE OF CONTENTS SECTION 10 – ELECTRICAL DIAGRAMS ..................43 SECTION 11 –...

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

    SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING Protect yourself and others from injury—read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! – Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible hazards are shown in the adjoining symbols or explained in the text.
  • Page 6 Accidental contact of electrode to metal objects can cause sparks, ex- FLYING METAL OR DIRT can injure plosion, overheating, or fire. Check and be sure the area is safe be- eyes. fore doing any welding. � Welding, chipping, wire brushing, and grinding �...

  • Page 7: Engine Hazards

    � Install cylinders in an upright position by securing to a stationary � Turn face away from valve outlet when opening cylinder valve. Do support or cylinder rack to prevent falling or tipping. not stand in front of or behind the regulator when opening the valve.

  • Page 8: Compressed Air Hazards

    1-4. Compressed Air Hazards � Reinstall doors, panels, covers, or guards when servicing is fin- COMPRESSED AIR EQUIPMENT can ished and before starting unit. injure or kill. � If ANY air is injected into the skin or body seek medical help immediately.
  • Page 9 � Follow the guidelines in the Applications Manual for the Revised HIGH PRESSURE FLUIDS can injure NIOSH Lifting Equation (Publication No. 94-110) when manually or kill. lifting heavy parts or equipment. � Engine fuel system components can be under high OVERHEATING can damage motors.

  • Page 10: California Proposition 65 Warnings

    � If notified by the FCC about interference, stop using the equipment � Be sure all equipment in the welding area is electromagnetically at once. compatible. � Have the installation regularly checked and maintained. � To reduce possible interference, keep weld cables as short as �...

  • Page 11: Section 2 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 2 – CONSIGNES DE SÉCURITÉ - LIRE AVANT UTILISATION Pour écarter les risques de blessure pour vous-même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1.
  • Page 12 � Ne pas toucher aux portes-électrodes qui sont raccordés à deux bien ventilé, et en portant un respirateur à alimentation d’air. Les machines à souder en même temps, car cela entraîne la présence revêtements et tous les métaux renfermant ces éléments peuvent d’une tension de circuit-ouvert double.

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    � Ne pas souder là où l’air ambiant pourrait contenir des poussières, � Les porteurs d’implants médicaux doivent consulter leur médecin gaz ou émanations inflammables (vapeur d’essence, par et le fabricant du dispositif avant de s’approcher de la zone où se exemple).

  • Page 14: Dangers Liés À L'air Comprimé

    � Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces � Ne pas toucher aux pièces chaudes, utiliser les outils recomman- inflammables. dés et porter des gants de soudage et des vêtements épais pour éviter les brûlures. � Tenir à distance les produits inflammables de l’échappement. LA VAPEUR ET LE LIQUIDE DE Les PIÈCES MOBILES peuvent REFROIDISSEMENT CHAUD peuvent...

  • Page 15: Symboles De Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    L’AIR COMPRIMÉ risque de Les PIÈCES MOBILES peuvent provoquer des blessures ou même la causer des blessures. mort. � S’abstenir de toucher des parties mobiles telles � Avant d’intervenir sur le circuit d’air comprimé, que des ventilateurs, courroies et rotors. couper l’alimentation électrique, verrouiller etéti- �...
  • Page 16 � Utiliser uniquement des équipements adéquats pour un fonction- � Régler les commandes de charge de batterie sur la position d’arrêt nement avec une alimentation de 50/60 ou de 60 Hz. avant de brancher la batterie. Veiller à ce que les pinces de charge ne se touchent pas.

  • Page 17: Proposition Californienne 65 Avertissements

    � Effectuer l’installation, l’entretien et toute intervention selon les LE SOUDAGE À L’ARC risque de manuels d’utilisateurs, les normes nationales, provinciales et de provoquer des interférences. l’industrie, ainsi que les codes municipaux. � L’énergie électromagnétique risque de provoquer LE RAYONNEMENT HAUTE des interférences pour l’équipement électronique FRÉQUENCE (H.F.) risque de sensible tel que les ordinateurs et l’équipement...
  • Page 18 les porteurs d’implants médicaux doivent être prises: par exemple, 5. Connecter la pince sur la pièce aussi près que possible de la des restrictions d’accès pour les passants ou une évaluation indivi- soudure. duelle des risques pour les soudeurs. Tous les soudeurs doivent ap- 6.

  • Page 19: Section 3 - Definitions

    � Complete Parts List is available at www.HobartWelders.com Become trained and read the instructions before working on the Become trained and read the instructions before working on the machine or heating. machine or heating. SECTION 3 – DEFINITIONS Safe85 2012 06 Safe85 2012 06 3-1.
  • Page 20 � Complete Parts List is available at www.HobartWelders.com Welding Hertz Single Phase Single Phase Alternator OM-266040 Page 16...

  • Page 21: Section 4 - Specifications

    � Complete Parts List is available at www.HobartWelders.com SECTION 4 – SPECIFICATIONS 4-1. Serial Number And Rating Label Location The serial number for this product is located on the front. The rating information for this product is located on the back. Use rating label to deter- mine input power requirements and/or rated output.

  • Page 22: Duty Cycle And Overheating

    � Complete Parts List is available at www.HobartWelders.com 4-6. Duty Cycle And Overheating 1 100% Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. � This unit is rated for welding at 225 am- peres CC/DC continuously.

  • Page 23: Dimensions, Weights, And Operating Angles

    � Complete Parts List is available at www.HobartWelders.com 4-7. Dimensions, Weights, And Operating Angles Do not exceed tilt angles or engine could be damaged or unit could tip. Do not move or operate unit where it could tip. Weight: 490 lb (222 kg) Lifting Eye Weight Rating: 1280 lb (580 kg) 5.07 5.07...

  • Page 24: Fuel Consumption

    1-1. Fuel Consumption 1-1. Fuel Consumption � Complete Parts List is available at www.HobartWelders.com 4-8. Fuel Consumption On a typical job using 1/8 in. 7018 electrodes (125 amps, 20% duty cycle), expect about 20 hours of operation. Welding at 150 amps at 40% duty cycle uses 7.57 2.00 approximately 3/4 gallon per hour, or about...

  • Page 25: Section 5 - Installation

    � Complete Parts List is available at www.HobartWelders.com 1-1. Installing Welder/Generator SECTION 5 – INSTALLATION 1-1. Installing Welder/Generator 5-1. Installing Welder/Generator Complete Parts List available at www.MillerWelds.com Do not move or operate unit where Movement it could tip. Do not lift unit from end. Do not weld on base.

  • Page 26: 1-1. Grounding Generator To Truck Or Trailer Frame

    � Complete Parts List is available at www.HobartWelders.com 5-2. Grounding Generator to Truck or Trailer Frame 1-1. Grounding Generator To Truck Or Trailer Frame GND/PE Bed liners, shipping skids, and 3 Metal Vehicle Frame Always ground generator frame to some running gear insulate the vehicle frame to prevent electric welding generator from the vehicle shock and static electricity hazards.

  • Page 27: Engine Prestart Checks

    � Complete Parts List is available at www.HobartWelders.com 5-4. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W-30 synthetic blend engine oil. � Follow run-in procedure in engine manual.

  • Page 28: Connecting Or Replacing The Battery

    � Complete Parts List is available at www.HobartWelders.com 5-5. Connecting Or Replacing The Battery Connect negative (-) battery cable last. To connect battery, open right side engine access door. � Do not allow the battery cables to touch opposing terminals. When connecting the battery cables attach the positive (+) cable to the positive (+) battery terminal first, followed by negative (-) cable to...

  • Page 29: Connecting Weld Output Cables

    Complete Parts List available at www.MillerWelds.com � Complete Parts List is available at www.HobartWelders.com 5-6. Connecting Weld Output Cables Stop engine. Failure to properly connect weld cables may cause excessive heat and start a fire, or damage your machine. � Do not place anything between weld cable terminal and copper bar.

  • Page 30: Selecting Cable Sizes

    � Complete Parts List is available at www.HobartWelders.com 5-8. Selecting Cable Sizes* NOTICE – The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total cable length in the weld circuit is 200 ft (2 cables x 100 ft). Use the 200 ft (60 m) column to determine cable size.

  • Page 31: Section 6 - Operation

    � Complete Parts List is available at www.HobartWelders.com SECTION 6 – OPERATION 6-1. Front Panel Controls A maintenance interval is reached when the 1 Engine Control Switch � For best arc starts and when using wrench icon appears in the display. weld and generator power together, Use switch to start engine, select speed, use a low Coarse Range setting with...

  • Page 32: Cold Weather Engine Operation

    Complete Parts List available at www.MillerWelds.com � Complete Parts List is available at www.HobartWelders.com 6-2. Cold Weather Engine Operation Ref. 236615-A � Run engine only when expecting to fre- Kohler (1-800-544-2444) offers a kit for cold 1 Engine Control Switch — Infrequently quently load it.

  • Page 33: Typical Stick Welding Connections And Control Settings

    � Complete Parts List is available at www.HobartWelders.com 6-3. Typical Stick Welding Connections And Control Settings Stop engine. � This section provides general guide- lines and may not suit all applications. � The control panel shows the typical set- tings for welding with a 7018 (1/8 in.) electrode.

  • Page 34: Fuel/Hour Gauge Descriptions

    � Complete Parts List is available at www.HobartWelders.com 6-4. Fuel/Hour Gauge Descriptions OM-266040 Page 30...

  • Page 35: Section 7 - Operating Auxiliary Equipment

    � Complete Parts List is available at www.HobartWelders.com SECTION 7 – OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Receptacles 265 985 / 266 064 Use GFCI protection when operating 3 120 V 20 A AC GFCI Receptacle GFCI3 6 Supplementary Protector CB2 auxiliary equipment.

  • Page 36: Gfci Receptacle Information, Resetting, And Testing

    � Complete Parts List is available at www.HobartWelders.com 7-2. GFCI Receptacle Information, Resetting, And Testing Use GFCI protection when operating If a ground fault is detected, the GFCI Reset Resetting GFCI Receptacles auxiliary equipment. If unit does not button pops out, and the circuit opens to dis- If a GFCI fault occurs, stop engine and dis- have GFCI receptacles, use GFCI- connect power to the faulty equipment.

  • Page 37: Simultaneous Weld And Power

    � Complete Parts List is available at www.HobartWelders.com 7-3. Simultaneous Weld And Power Weld Current in Amperes Total Power in Watts 120 V Full kVA Receptacle 240 V Full kVA Receptacle Amperes Amperes 2200 3500 Complete Parts List available at www.MillerWelds.com 5200 8000 11,000...

  • Page 38: Section 8 - Maintenance And Troubleshooting

    SECTION 8 – MAINTENANCE AND TROUBLESHOOTING 8-1. Routine Maintenance Stop engine before maintaining. � See 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. �...

  • Page 39: Maintenance Label

    8-2. Maintenance Label OM-266040 Page 35...

  • Page 40: Servicing Air Cleaner

    8-3. Servicing Air Cleaner Stop engine. NOTICE – Do not run engine without air cleaner or with dirty element. Engine dam- age caused by using a damaged element is not covered by the warranty. 1 Precleaner Wash precleaner with soap and water solu- tion.

  • Page 41: Changing Engine Oil, Oil Filter, And Fuel Filter

    8-4. Changing Engine Oil, Oil Filter, And Fuel Filter tools Stop engine and let cool. 1 Oil Drain Valve Change engine oil and filter according to en- gine owner’s manual. NOTICE – Close valve and valve cap before adding oil and running engine. rubbergloves weldgloves earmuffs...

  • Page 42: Adjusting Engine Speed

    8-5. Adjusting Engine Speed After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: Start engine and run until warm. Turn Fine Control to 10. Open top and side access doors. Idle Speed Adjustment Move Engine Control switch to Run/Idle position.

  • Page 43: Overload Protection

    8-6. Overload Protection Stop engine. Disconnect negative (-) battery cable. � Fuses F1 and F2 located on bracket behind right side panel. 1 Fuse F2 F2 protects the weld excitation winding from overload. If F2 opens, weld output stops or is low.

  • Page 44: Troubleshooting

    8-7. Troubleshooting A. Welding Troubleshooting Trouble Remedy Low or no weld output; generator Check control settings. power output okay at AC receptacles. Check weld connections. Check fuse F1, and replace if open (see Section 8-6). Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated recti- fiers SR2 and SR3.
  • Page 45 Trouble Remedy Erratic power output at AC Check fuel level. receptacles. Check engine speed, and adjust if necessary (see Section 8-5). Check receptacle wiring and connections. Have Factory Authorized Service Agent check brushes and slip rings. C. Engine Troubleshooting Trouble Remedy Engine will not crank.

  • Page 46: Section 9 - Parts List

    � Complete Parts List is available at www.HobartWelders.com SECTION 9 – PARTS LIST 9-1. Recommended Spare Parts Recommended Spare Parts Dia. Mkgs. Part No. Description Quantity F1, F2 169296 Fuse, Mintr Gl 25. Amp 125 Volt 215621 Fuse, 30 Amp Ato Type 276379 Switch, Oil Pressure (Kohler) 190248...
  • Page 47 SECTION 10 – ELECTRICAL DIAGRAMS 265993-C Figure 10-1. Circuit Diagram For Welder/Generator OM-266040 Page 43...
  • Page 48 SECTION 11 – GENERATOR POWER GUIDELINES � The views in this section are intended to be representative of all engine-driven welder/generators. Your unit may differ from those shown. 11-1. Selecting Equipment 1 Generator Power Receptacles – Neutral Bonded To Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated...
  • Page 49 11-3. Grounding When Supplying Building Systems 1 Equipment Grounding Terminal 2 Grounding Cable GND/PE Use #8 AWG or larger insulated copper wire. 3 Ground Device � Use ground device as stated in electri- cal codes. Ground generator to system earth ground if supplying power to a premises (shop,...
  • Page 50 11-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 51 11-7. Approximate Power Requirements For Contractor Equipment Contractor Equipment Rating Starting Watts Running Watts Hand Drill 1/4 in. 3/8 in. 1/2 in. Circular Saw 6-1/2 in. 7-1/4 in. 8-1/4 in. 1400 1400 Table Saw 9 in. 4500 1500 10 in. 6300 1800 Band Saw...
  • Page 52 11-8. Power Required To Start Motor 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor Voltage AC MOTOR VOLTS AMPS Step 1: Find code and use table to find kVA/ CODE HP. If code is not listed, multiply running am- PHASE perage by six to find starting amperage.
  • Page 53 11-10. Typical Connections To Standby Power 1. Utility Electrical 2. Transfer Switch 3. Fused Disconnect 4. Welder/Generator Service Switch (If Required) Output 5. Essential Loads Have only qualified persons perform 1 Utility Electrical Service 4 Welder/Generator Output these connections according to all 2 Transfer Switch (Double-Throw) Generator output voltage and wiring must applicable...
  • Page 54 11-11. Selecting Extension Cord (Use Shortest Cord Possible) A. Cord Lengths For 120 Volt Loads Use GFCI protection when operating auxiliary equipment. If unit does not have GFCI receptacles, use GFCI-protected extension cord. Do not use GFCI receptacles to power life support equipment. Maximum Allowable Cord Length In ft (m) for Conductor Size In AWG (mm Current (Amperes)
  • Page 55 SECTION 12 – STICK WELDING (SMAW) GUIDELINES tools/ 12-1. Stick Welding Procedure wrench crescent wrench allen_set flathead philips head wrench crescent wrench Weld current starts when electrode Tools Needed: touches workpiece. Weld current can damage elec- tronic parts in vehicles. Discon- nect both battery cables before welding on a vehicle.
  • Page 56 12-2. Electrode And Amperage Selection Chart 6010 DEEP 3/32 MIN. PREP, ROUGH HIGH SPATTER 6011 DEEP 6010 5/32 & 6013 EP,EN GENERAL 3/16 6011 7/32 SMOOTH, EASY, 7014 EP,EN FAST 1/16 LOW HYDROGEN, 7018 5/64 STRONG 3/32 FLAT SMOOTH, EASY, 7024 EP,EN 6013...
  • Page 57 12-4. Positioning Electrode Holder 1 End View Of Work Angle Groove Welds 2 Side View Of Electrode Angle After learning to start and hold an arc, prac- tice running beads of weld metal on flat 10 -30 10 -30 plates using a full electrode. Hold the electrode nearly perpendicular to the work, although tilting it ahead (in the di- rection of travel) will be helpful.
  • Page 58 12-7. Conditions That Affect Weld Bead Shape Electrode Angle � Weld bead shape is affected by elec- trode angle, arc length, travel speed, and thickness of base metal. 1 Angle Too Small 2 Correct Angle 3 Drag 4 Angle Too Large 5 Too Short 6 Normal Arc Length...
  • Page 59 12-9. Welding Lap Joints 1-1. Welding Lap Joints 1 Electrode 2 Single-Layer Fillet Weld 1-1. Welding Lap Joints Move electrode in circular motion. 3 Multi-Layer Fillet Weld Weld a second layer when a heavier fillet is needed. Remove slag before making anoth- er weld pass.
  • Page 60 12-11. Welding T-Joints 1-3. Welding T-Joints 1/16 in. (1.6 mm) 1 Electrode 2 Fillet Weld Keep arc short and move at definite rate of speed. Hold electrode as shown to provide fusion into the corner. Square edge of the weld surface. For maximum strength weld both sides of up- 1-3.
  • Page 61 Excessive Spatter - scattering of molten metal particles that cool to solid form near weld bead. Possible Causes Corrective Actions Amperage too high for electrode. Decrease amperage or select larger electrode. Arc length too long or voltage too high. Reduce arc length or voltage. Incomplete Fusion - failure of weld metal to fuse completely with base metal or a preceding weld bead.
  • Page 62 Distortion - contraction of weld metal during welding that forces base metal to move. Illustration: 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 position. Make tack welds along joint before starting welding operation.
  • Page 63 Effective January 1, 2023 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a serial num- ber preface of ND or newer. This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied.
  • Page 64 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Thank you for purchasing Hobart. Our trained technical support team is dedicated to your satisfaction.

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