Hobart Welding Products Champion 10,000 Owner's Manual
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Hobart Welding Products Champion 10,000 Owner's Manual

Engine driven welding generator
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OM-945
194 047AD
2007−05
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
Champion 10,000

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  • Page 1 OM-945 194 047AD 2007−05 Processes Stick (SMAW) Welding Description Engine Driven Welding Generator Champion 10,000...
  • 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 ........1-1.
  • Page 4 TABLE OF CONTENTS SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) ........9-1.

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

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007−04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if Indicates special instructions. 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 D Do not weld on closed containers such as tanks, drums, or pipes, FUMES AND GASES can be hazardous. unless they are properly prepared according to AWS F4.1 (see Safety Standards). Welding produces fumes and gases. Breathing these D Do not weld where the atmosphere may contain flammable dust, fumes and gases can be hazardous to your health.

  • Page 7: Engine Hazards

    1-3. Engine Hazards STEAM AND HOT COOLANT can burn. BATTERY EXPLOSION can BLIND. D If possible, check coolant level when engine is D Always wear a face shield, rubber gloves, and cold to avoid scalding. protective clothing when working on a battery. D Always check coolant level at overflow tank, if D Stop engine before disconnecting or connect- present on unit, instead of radiator (unless told...

  • Page 8: Additional Symbols For Installation, Operation, And Maintenance

    HOT METAL from air arc cutting and READ INSTRUCTIONS. gouging can cause fire or explosion. D Read Owner’s Manual before using or servic- D Do not cut or gouge near flammables. ing unit. D Watch for fire; keep extinguisher nearby. D Stop engine and release air pressure before servicing.

  • Page 9: California Proposition 65 Warnings

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as micro- communications equipment. processors, computers, and computer-driven equipment such as robots.

  • Page 10: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION rom_2007−04fre Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on Indique des instructions spécifiques.
  • Page 11 Une tension DC importante subsiste à l’intérieur LES RAYONS DE L’ARC peuvent pro des onduleurs après avoir coupé l’alimentation. voquer des brûlures dans les yeux e sur la peau. D Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de Le rayonnement de l’arc du procédé...

  • Page 12: Dangers Existant En Relation Avec Le Moteur

    D Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et D Protéger les bouteilles de gaz comprimé d’une chaleur excessive, NFPA 51B pour les travaux à chaud et avoir de la surveillance et un des chocs mécaniques, des dommages physiques, du laitier, des extincteur à...

  • Page 13: Dangers Liés À L'air Comprimé

    D Dévisser le bouchon légèrement et laisser la vapeur s’échapper LA CHALEUR DU MOTEUR peut pro- avant d’enlever le bouchon. voquer un incendie. L’utilisation d’un groupe autonome D Ne pas placer l’appareil sur, au-dessus ou à à l’intérieur PEUT VOUS TUER EN proximité...
  • Page 14 UNE REMORQUE QUI BASCULE peut LE SURCHAUFFEMENT peut endom- entraîner des blessures. mager le moteur électrique. D Utiliser les supports de la remorque ou des D Arrêter ou déconnecter l’équipement avant de blocs pour soutenir le poids. démarrer ou d’arrêter le moteur. D Installer convenablement le poste sur la remor- D Ne pas laisser tourner le moteur trop lentement sous risque d’en- que comme indiqué...

  • Page 15: Proposition Californienne 65 Avertissements

    2-6. Proposition californienne 65 Avertissements Pour les moteurs à essence : Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques Les gaz d’échappement des moteurs contiennent des pro- dont l’État de Californie reconnaît qu’ils provoquent des mal- duits chimiques dont l’État de Californie reconnaît qu’ils formations congénitales et, dans certains cas, des cancers.

  • Page 16: Section 3 − Definitions

    SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Read Operator’s Start Engine Amperes Volts Manual Engine Oil Fuel Battery (Engine) Engine Check Valve Engine Choke Circuit Protector Temperature Clearance Alternating Current Positive Negative Output (AC)

  • Page 17: Dimensions, Weights, And Operating Angles

    4-2. Dimensions, Weights, and Operating Angles Dimensions Height 33-1/2 in (851 mm) Width 18-1/2 in (470 mm) Do not move or operate unit Depth 38 in (965 mm) where it could tip. where it could tip. 4 HOLES 18 in (457 mm) Do not exceed tilt angles or Do not exceed tilt angles or 16-9/16 in (421 mm)

  • Page 18: Fuel Consumption (All Models)

    4-4. Fuel Consumption (All Models) 197 254 4-5. Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. NOTICE − Exceeding duty cycle can damage unit and void warranty. Continuous Welding 100% Duty Cycle at 170 Amperes CC/DC 6 Minutes Welding 4 Minutes Resting...

  • Page 19: Volt-Ampere Curves

    4-6. Volt-Ampere Curves The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown. 197 253 Notes MATERIAL THICKNESS REFERENCE CHART 24 Gauge (.025 in) 22 Gauge (.031 in) 20 Gauge (.037 in) 18 Gauge (.050 in)

  • Page 20: Section 5 − Installation

    SECTION 5 − INSTALLATION 5-1. Installing Welding Generator Do not lift unit from end. Movement Do not weld on base. Welding 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-...

  • Page 21: Engine Prestart Checks (Robin-Powered Units)

    5-2. Engine Prestart Checks (Robin-Powered Units) 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. Full This unit has a low oil pressure shutdown switch.

  • Page 22: Activating The Dry Charge Battery (If Applicable)

    5-4. Activating The Dry Charge Battery (If Applicable) Always wear a face shield, rubber gloves and protec- tive clothing when working on a battery. Remove battery from unit. Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to bottom of well (maximum).

  • Page 23: Installing Exhaust Pipe

    5-6. Installing Exhaust Pipe 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. Tools Needed: 1/2 in 801 681 / Ref.

  • Page 24: Connecting To Weld Output Terminals

    5-8. Connecting To Weld Output Terminals Stop engine. Failure to properly connect weld cables may cause ex- cessive heat and start a fire, or damage your machine. Weld Output Terminal Supplied Weld Output Terminal Nut Weld Cable Terminal Copper Bar Remove supplied nut from weld output terminal.

  • Page 25: Section 6 − Operating The Welding Generator

    SECTION 6 − OPERATING THE WELDING GENERATOR If the unit is extremely overloaded, weld and generator power will stop. Turn 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 load is reduced. 6-1.

  • Page 26: Cold Weather Engine Operation

    6-2. Cold Weather Engine Operation 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- Infrequently tive humidity is high. Ice forms on the throttle plate and inner bore of the carbu- retor.

  • Page 27: Section 7 − Operating Auxiliary Equipment

    SECTION 7 − OPERATING AUXILIARY EQUIPMENT If the unit is extremely overloaded, weld and generator power will stop. Turn 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 load is reduced. The welding generator provides power while welding and with the Amperage control in any position.

  • Page 28: Optional Generator Power Receptacles

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

  • Page 29: Wiring Instructions For Optional 240 Volt, Single-Phase Plug (Nema 14-50P)

    7-3. Wiring Instructions For Optional 240 Volt, Single-Phase Plug (NEMA 14-50P) The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load. See circuit diagram. Plug Wired for 120/240 V, 3-Wire Load Current Available in Amperes When wired for 120 V loads, each duplex receptacle shares a load 240 V...

  • Page 30: Section 8 − Maintenance (Robin-Powered Units)

    SECTION 8 − MAINTENANCE (ROBIN-POWERED UNITS) 8-1. Routine Maintenance (Robin-Powered Units) Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids. information. Service engine more often if used in severe conditions. n = Check Z = Change ~ = Clean...

  • Page 31: Maintenance Label (Robin-Powered Units)

    8-2. Maintenance Label (Robin-Powered Units) OM-945 Page 27...

  • Page 32: Servicing Air Cleaner (Robin−Powered Units)

    8-3. Servicing Air Cleaner (Robin−Powered Units) Stop engine and let cool. NOTICE − Do not run engine with- out air cleaner or with dirty element. Wrapper Wash wrapper with soap and water solution. Allow wrapper to air dry completely. Spread 1 tablespoon SAE 30 oil evenly into wrapper.

  • Page 33: Overload Protection (Robin-Powered Units)

    8-4. Overload Protection (Robin-Powered Units) Tools Needed: Stop engine. Disconnect nega- tive (−) battery cable. If the unit is extremely over- loaded, weld and generator pow- 3/8 in er will stop. Turn unit off and re- start to reset the generator protection circuit and restore weld and generator power output.

  • Page 34: Changing Engine Oil, Oil Filter, And Fuel Filter (Robin-Powered Units)

    8-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Robin-Powered Units) Stop engine and let cool. Oil Drain Valve 1/2 ID x 7 in Hose Oil Filter Change engine oil and filter ac- cording to engine owner’s manual. Close valve and valve cap before adding running engine.

  • Page 35: Adjusting Engine Speed (Robin-Powered Units)

    8-7. Adjusting Engine Speed (Robin-Powered Units) After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: 2200 100 rpm Start engine and run until warm. Remove wrapper to access speed 3700 50 rpm adjustments.

  • Page 36: Section 9 − Maintenance − (Kohler-Powered Units)

    SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) 9-1. Routine Maintenance (Kohler-Powered Units) Stop engine before maintaining. See Engine Manual and Maintenance Label Recycle engine for important start-up, service, and storage fluids. information. Service engine more often if used in severe conditions. n = Check Z = Change ~ = Clean...

  • Page 37: Maintenance Label (Kohler-Powered Units)

    9-2. Maintenance Label (Kohler-Powered Units) OM-945 Page 33...

  • Page 38: Servicing Air Cleaner (Kohler−Powered Units)

    9-3. Servicing Air Cleaner (Kohler−Powered Units) Stop engine and let cool. NOTICE − Do not run engine with- out air cleaner or with dirty element. Wrapper Wash wrapper with soap and water solution. Allow wrapper to air dry completely. Spread 1 tablespoon SAE 30 oil evenly into wrapper.

  • Page 39: Overload Protection (Kohler-Powered Units)

    9-4. Overload Protection (Kohler-Powered Units) Stop engine. Tools Needed: If the unit is extremely over- loaded, weld and generator pow- er will stop. Turn unit off and re- start to reset the generator 3/8 in protection circuit and restore weld and generator power out- put.

  • Page 40: Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units)

    9-6. Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units) Stop engine and let cool. Oil Drain Valve 1/2 ID x 7 in Hose Oil Filter Change engine oil and filter ac- cording to engine owner’s manual. Close valve and valve cap before adding running engine.

  • Page 41: Adjusting Engine Speed (Kohler-Powered Units)

    9-7. Adjusting Engine Speed (Kohler-Powered Units) After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: Start engine and run until warm. 2200 50 rpm Remove wrapper to access speed 3700 50 rpm adjustments.

  • Page 42: Section 10 − Troubleshooting

    SECTION 10 − TROUBLESHOOTING 10-1. Troubleshooting A. Welding Trouble 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.
  • Page 43 Trouble Remedy Erratic power output at generator pow- Check fuel level. er ac receptacles. 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.
  • Page 44 Trouble Remedy During operation in near freezing tem- Treat fuel with isopropyl alcohol de-icer product. peratures, engine starts and goes to idle but stalls after a few minutes. Place Engine Control switch in the Run position until unit has been in operation and loaded for a peri- od of time.

  • Page 45: Section 11 − Electrical Diagram

    SECTION 11 − ELECTRICAL DIAGRAM 222129−B Figure 11-1. Circuit Diagram For Welding Generator (Robin And Kohler-Powered Units) OM-945 Page 41...

  • Page 46: Section 12 − Generator Power Guidelines

    SECTION 12 − GENERATOR 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. 12-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...

  • Page 47: Grounding When Supplying Building Systems

    12-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #10 AWG or larger insulated copper wire. Ground Device Use ground device as stated in electrical codes. Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system.
  • Page 48 12-5. 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 49 12-7. Approximate Power Requirements For Contractor Equipment Contractor 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 14 in...
  • Page 50 12-8. Power Required To Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code KVA/HP 10.0 11.2 12.5 14.0 Motor Start Code Running Amperage Motor HP AC MOTOR Motor Voltage VOLTS AMPS To find starting amperage: CODE Step 1: Find code and use table to PHASE find kVA/HP.
  • Page 51 12-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Fused Welding Utility Disconnect Properly install and ground Electrical Generator Transfer Switch Switch this equipment according to Output Service (If Required) its Owner’s Manual and na-...
  • Page 52 12-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current Load (Watts) (Amperes) 350 (106) 225 (68) 137 (42)

  • Page 53: Section 13 − Stick Welding (Smaw) Guidelines

    SECTION 13 − STICK WELDING (SMAW) GUIDELINES 13-1. Stick Welding Procedure Weld current starts when electrode touches work- piece. 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 54: Electrode And Amperage Selection Chart

    13-2. Electrode and Amperage Selection Chart 3/32 6010 5/32 & 3/16 6011 7/32 6010 DEEP MIN. PREP, ROUGH 1/16 HIGH SPATTER 6011 DEEP 5/64 6013 EP,EN GENERAL 3/32 SMOOTH, EASY, 7014 EP,EN 6013 FAST 5/32 3/16 LOW HYDROGEN, 7018 STRONG 7/32 FLAT SMOOTH, EASY,...

  • Page 55: Positioning Electrode Holder

    13-5. Positioning Electrode Holder 10 -30 End View of Work Angle Side View of Electrode Angle GROOVE WELDS 10 -30 End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 13-6. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap...

  • Page 56: Conditions That Affect Weld Bead Shape

    13-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. Correct Angle Angle Too Large Angle Too Small Drag ELECTRODE ANGLE Spatter Normal Too Long Too Short ARC LENGTH Normal Fast...

  • Page 57: Butt Joints

    13-10. Butt Joints Tack Welds Prevent edges of joint from draw- ing together ahead of electrode by tack welding the materials in posi- tion before final weld. Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. Single V-Groove Weld Good for materials 3/16 −...

  • Page 58: Weld Test

    13-13. Weld Test Vise Weld Joint Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 To 3 in (51-76 mm) 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) S-0057-B 13-14. Troubleshooting − Porosity Porosity −...

  • Page 59: Troubleshooting − Incomplete Fusion

    13-16. Troubleshooting − Incomplete Fusion Incomplete Fusion − failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insufficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in proper location(s) at joint during welding.

  • Page 60: Troubleshooting − Burn-Through

    13-19. Troubleshooting − 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. Troubleshooting − Waviness Of Bead Waviness Of Bead −...
  • Page 61 Notes Welding Symbols Ref. AWS/ANSI A2.4 OM-945 Page 57...

  • Page 62: Section 14 − Parts List

    SECTION 14 − PARTS LIST Kohler Hardware is common and only not available unless listed. 44 − FIG 14-2 20 − FIG 14-3 Ref. 802 343−R Figure 14-1. Main Assembly (Robin Engine Shown) OM-945 Page 58...
  • Page 63 Item Dia. Part Mkgs. Description Quantity Figure 14-1. Main Assembly ....+193 777 Wrapper ........... . .
  • Page 64 Item Dia. Part Mkgs. Description Quantity Figure 14-1. Main Assembly (Continued) ....181 057 Cover, Base ..........
  • Page 65 Item Dia. Part Mkgs. Description Quantity Figure 14-2. Panel, Front w/Components (Figure 14-1 Item 47) ....198 122 Stand−off Support, Pc Card .250w/Post&lock .500 .
  • Page 66 Item Part Description Quantity Figure 14-3. Generator (Figure 14-1 Item 20) ....+220 832 Generator Assy, Front (consisting of) ......
  • Page 67 Effective January 1, 2007 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? serial number preface LH or newer. Call This limited warranty supersedes all previous Hobart warranties and is exclusive with 1-800-332-3281 no other guarantees or warranties expressed or implied.
  • Page 68 Welding Process Handbooks Call 1-877-Hobart1 Contact the Delivering Carrier to: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 2007 Hobart Welding Products. 2007−01...

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