Hobart Welding Products CHAMPION ELITE Owner's Manual
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Hobart Welding Products CHAMPION ELITE Owner's Manual

Hobart Welding Products CHAMPION ELITE Owner's Manual

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Champion Elite
OM-240 438B
2009−09
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
™

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Summary of Contents for Hobart Welding Products CHAMPION ELITE

  • Page 1 OM-240 438B 2009−09 Processes Stick (SMAW) Welding Description Engine Driven Welding Generator Champion Elite ™...
  • 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 8-4. Servicing Optional Spark Arrestor (Subaru-Powered Units) ....... . . 8-5.

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

    SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2009−08 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 HOT PARTS can burn. BATTERY EXPLOSION can injure. D Do not touch hot parts bare handed. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Allow cooling period before working on equip- ment.

  • Page 8: Compressed Air Hazards

    D Keep hands, hair, loose clothing, and tools away from moving HYDRAULIC FLUID can injure or kill. parts. D Before working on hydraulic system, turn off and lockout/tagout D Before working on hydraulic system, turn off and unit, release pressure, and be sure hydraulic pressure cannot be lockout/tagout unit, release pressure, and be sure accidentally applied.

  • Page 9: Additional Symbols For Installation, Operation, And Maintenance

    MOVING PARTS can injure. HOT PARTS can burn. D Do not touch hot compressor or air system D Keep away from moving parts such as fans, parts. belts and rotors. D Allow cooling period before working on equip- D Keep all doors, panels, covers, and guards closed and securely in place.

  • Page 10: 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 11: Section 2 − Consignes De Sécurité − Lire Avant Utilisation

    SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2009−08 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 12 D Porter un casque de soudage approuvé muni de verres filtrants LES PIÈCES CHAUDES peuvent approprié pour protéger visage et yeux pour protéger votre visage provoquer des brûlures. et vos yeux pendant le soudage ou pour regarder (voir ANSI Z49.1 et Z87.1 énuméré...

  • Page 13: Dangers Existant En Relation Avec Le Moteur

    D Placer les bouteilles debout en les fixant dans un support station- Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM) naire ou dans un porte-bouteilles pour les empêcher de tomber ou peuvent affecter les implants médicaux. de se renverser. D Tenir les bouteilles éloignées des circuits de soudage ou autres D Les porteurs de stimulateurs cardiaques circuits électriques.

  • Page 14: Dangers Liés À L'hydraulique

    L’utilisation d’un groupe autonome L’ACIDE DE LA BATTERIE peut pro- à l’intérieur PEUT VOUS TUER EN voquer des brûlures dans les YEUX et QUELQUES MINUTES. sur la PEAU. D Ne pas renverser la batterie. D Les fumées d’un groupe autonome contient du D Remplacer une batterie endommagée.

  • Page 15: Dangers Liés À L'air Comprimé

    D N’utiliser que les pièces de rechange recommandées par le LIRE LES INSTRUCTIONS. constructeur. D Effectuer l’entretien en respectant les manuels d’utilisation, D Lire appliquer instructions les normes industrielles et les codes nationaux, d’état et locaux. les étiquettes et le Mode d’emploi avant l’installation, l’utilisation l’entretien...

  • Page 16: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    D N’utiliser que les pièces de rechange recommandées par le LIRE LES INSTRUCTIONS. constructeur. D Effectuer l’entretien en respectant les manuels d’utilisation, D Lire appliquer instructions les normes industrielles et les codes nationaux, d’état et locaux. les étiquettes et le Mode d’emploi avant l’installation, l’utilisation l’entretien...

  • Page 17: Proposition Californienne 65 Avertissements

    LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. D L’énergie électromagnétique risque de provo- quer des interférences pour l’équipement élec- D Le rayonnement haute fréquence (H.F.) peut tronique sensible tel que les ordinateurs et provoquer des interférences avec les équipe- l’équipement commandé...

  • Page 18: Informations Relatives Aux Cem

    2-9. Informations relatives aux CEM Le courant électrique qui traverse tout conducteur génère des champs Maintenir la tête et le torse aussi loin que possible du matériel du circuit de soudage. électromagnétiques (CEM) à certains endroits. Le courant de soudage crée un CEM autour du circuit et du matériel de soudage.

  • Page 19: Section 3 − Definitions

    A complete Parts List is available at www.HobartWelders.com 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 Do not switch while Engine Choke Work Connection Clearance...

  • Page 20: Dimensions, Weights, And Operating Angles

    A complete Parts List is available at wwwHobartWelders.com 4-2. 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: 562 lb (254 kg) Lifting Eye Weight Rating: 1280 lb (580 kg) °...

  • Page 21: Dimensions For Units With Optional Running Gear

    A complete Parts List is available at www.HobartWelders.com 4-3. Dimensions For Units With Optional Running Gear Dimensions All Running Gear Options: 42-1/2 in. (1079 mm) Height (To Top Of Handle Assembly) Protective Cage Width: 26 in. (660 mm) Running Gear Width: 32 in.

  • Page 22: Fuel Consumption (Subaru-Powered Units)

    A complete Parts List is available at wwwHobartWelders.com 4-5. Fuel Consumption (Subaru-Powered Units) On a typical job using 1/8 in 7018 electrodes (125 amps, 20% duty cycle), expect about 20 hours of op- eration. Welding at 150 amps at 40% duty cycle uses approximately 3/4 gal- lon per hour, or about 16 hours of operation.

  • Page 23: Volt-Ampere Curves

    A complete Parts List is available at www.HobartWelders.com 4-7. Volt-Ampere Curves The volt-ampere curve shows the A. For CC/AC Mode minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves shown.

  • Page 24: Section 5 − Installation

    A complete Parts List is available at wwwHobartWelders.com SECTION 5 − INSTALLATION 5-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/or rated output.

  • Page 25: Grounding Generator To Truck Or Trailer Frame

    A complete Parts List is available at www.HobartWelders.com 5-3. Grounding Generator To Truck Or Trailer Frame Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generators.

  • Page 26: Engine Prestart Checks (Subaru-Powered Units)

    A complete Parts List is available at wwwHobartWelders.com 5-4. Engine Prestart Checks (Subaru-Powered Units) Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Follow run-in procedure in en- gine manual. NOTICE −...

  • Page 27: Engine Prestart Checks (Kohler-Powered Units)

    A complete Parts List is available at www.HobartWelders.com 5-5. Engine Prestart Checks (Kohler-Powered Units) Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Follow run-in procedure in en- gine manual. NOTICE −...

  • Page 28: Installing Exhaust Pipe

    A complete Parts List is available at wwwHobartWelders.com 5-6. Installing Exhaust Pipe Engine backfire can cause se- vere burns or other injuries. Do not point exhaust pipe toward control panel. Keep away from exhaust outlet. Point exhaust pipe in desired di- rection but always away from front panel and direction of trav- Be sure to tighten exhaust clamp...

  • Page 29: Connecting To Weld Output Terminals

    A complete Parts List is available at www.HobartWelders.com 5-8. Connecting To Weld Output Terminals Stop engine. Failure to properly connect weld cables may cause exces- sive heat and start a fire, or damage your machine. Do not place anything between weld cable terminal and cop- per bar.

  • Page 30: Selecting Weld Cable Sizes

    A complete Parts List is available at wwwHobartWelders.com 5-9. Selecting Weld 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).

  • Page 31: Section 6 − Operating The Welding Generator

    A complete Parts List is available at www.HobartWelders.com SECTION 6 − OPERATING THE WELDING GENERATOR 6-1. Front Panel Controls 281 080-A Engine Control Switch position. For best arc starts and when using weld and generator power together, use a low Use switch to start engine, select speed, and Engine Hour Meter/Idle Control stop engine.

  • Page 32: Cold Weather Engine Operation

    A complete Parts List is available at wwwHobartWelders.com 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.

  • Page 33: Typical Stick Welding Connections And Control Settings

    A complete Parts List is available at www.HobartWelders.com 6-3. Typical Stick Welding Connections And Control Settings Stop engine. This section provides general guidelines and may not suit all applications. For best arc starts and best The control panel shows the typi- results using weld and generator cal settings for welding with a power together, use a low...

  • Page 34: Section 7 − Operating Auxiliary Equipment

    A complete Parts List is available at wwwHobartWelders.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Standard Receptacles 244 029-A / 281 080-A RC2 and RC3 supply 60 Hz single-phase CB2 protects RC2 and CB3 protects RC3 If unit does not have GFCI recep- power at weld/power speed.

  • Page 35: Simultaneous Weld And Power

    A complete Parts List is available at www.HobartWelders.com 7-2. 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 5200 8000 11,000 7-3. Wiring Optional 240 Volt Plug The plug can be wired for a 240 V, 2-wire load or a 120/240V, 3-wire load.

  • Page 36: Section 8 − Maintenance (Subaru-Powered Units)

    A complete Parts List is available at wwwHobartWelders.com SECTION 8 − MAINTENANCE (SUBARU-POWERED UNITS) 8-1. Maintenance Label (Subaru-Powered Units) OM-240 438 Page 32...

  • Page 37: Routine Maintenance (Subaru-Powered Units)

    A complete Parts List is available at www.HobartWelders.com 8-2. Routine Maintenance (Subaru-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 38: Servicing Air Cleaner (Subaru-Powered Units)

    A complete Parts List is available at wwwHobartWelders.com 8-3. Servicing Air Cleaner (Subaru-Powered Units) Stop engine. NOTICE − Do not run engine with- out air cleaner or with dirty element. Precleaner Wash precleaner with soap and wa- ter solution. Allow precleaner to air dry completely.

  • Page 39: Changing Engine Oil, Oil Filter, And Fuel Filter (Subaru-Powered Units)

    A complete Parts List is available at www.HobartWelders.com 8-5. Changing Engine Oil, Oil Filter, and Fuel Filter (Subaru-Powered Units) Stop engine and let cool. Oil Drain Valve Oil Filter Change engine oil and filter accord- ing to engine owner’s manual. Oil Fill NOTICE −...

  • Page 40: Adjusting Engine Speed (Subaru-Powered Units)

    A complete Parts List is available at wwwHobartWelders.com 8-6. Adjusting Engine Speed (Subaru-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. Remove rear panel and air cleaner to access idle speed adjustments.

  • Page 41: Overload Protection (Subaru-Powered Units)

    A complete Parts List is available at www.HobartWelders.com 8-7. Overload Protection (Subaru-Powered Units) Stop engine. Disconnect negative (−) battery cable. Fuse F1 (See Section 11-1) F1 protects the weld excitation winding from overload. If F1 opens, weld output stops or is low. Fuse F2 (See Section 11-1) F2 protects the generator power excitation winding from overload.

  • Page 42: Section 9 − Maintenance − (Kohler-Powered Units)

    A complete Parts List is available at wwwHobartWelders.com SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) 9-1. Maintenance Label (Kohler-Powered Units) OM-240 438 Page 38...

  • Page 43: Routine Maintenance (Kohler-Powered Units)

    A complete Parts List is available at www.HobartWelders.com 9-2. 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 44: Servicing Air Cleaner (Kohler−Powered Units)

    A complete Parts List is available at wwwHobartWelders.com 9-3. Servicing Air Cleaner (Kohler−Powered Units) Stop engine. NOTICE − Do not run engine with- out air cleaner or with dirty element. Precleaner Wash precleaner with soap and wa- ter solution. Allow precleaner to air dry completely.

  • Page 45: Changing Engine Oil, Oil Filter, And Fuel Filter (Kohler-Powered Units)

    A complete Parts List is available at www.HobartWelders.com 9-4. 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 accord- ing to engine owner’s manual.

  • Page 46: Adjusting Engine Speed (Kohler-Powered Units)

    A complete Parts List is available at wwwHobartWelders.com 9-5. Adjusting Engine Speed (Kohler-Powered Units) After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: 2200 − 2300 rpm Start engine and run until warm. (36.6 −...

  • Page 47: Overload Protection (Kohler-Powered Units)

    A complete Parts List is available at www.HobartWelders.com 9-6. Overload Protection (Kohler-Powered Units) Stop engine. Disconnect negative (−) battery cable. Fuse F1 (See Section 11-1) F1 protects the weld excitation winding from overload. If F1 opens, weld output stops or is low. Fuse F2 (See Section 11-1) F2 protects the generator power excitation winding from overload.

  • Page 48: Section 10 − Troubleshooting

    A complete Parts List is available at wwwHobartWelders.com SECTION 10 − TROUBLESHOOTING 10-1. Welding Troubleshooting Trouble Remedy Low or no weld output; generator pow- Check control settings. er output okay at ac receptacles. Check weld connections. Check fuse F1, and replace if open (see Section 8-7 or 9-6). Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi- ers SR2 and SR3.

  • Page 49: Engine Troubleshooting

    A complete Parts List is available at www.HobartWelders.com Trouble Remedy No generator power or weld output. Be sure all equipment is disconnected from receptacles when starting unit. Check fuses F1 and F2, and replace if open (see Section 8-7 or 9-6). Check plug PLG6 connection.

  • Page 50: Section 11 − Parts List

    A complete Parts List is available at wwwHobartWelders.com Trouble Remedy Battery Discharges between uses. Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water. Periodically recharge battery (approximately every 3 months). Replace battery. Check voltage regulator and connections according to engine manual. Engine idles but does not come up to Have Factory Authorized Service Agent check hour meter/idle module, and current transformer CT1.
  • Page 51 A complete Parts List is available at www.HobartWelders.com Notes SOCKET/WRENCH SELECTION TABLE SOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size U.S. Bolt Decimal Bolt Bolt Decimal Bolt Diameter Equivalent Diameter Equivalent 1/4 in .250 in 3/8 in 7/16 in...

  • Page 52: Section 12 − Electrical Diagrams

    SECTION 12 − ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram For Welding Generator OM-240 438 Page 48...
  • Page 53 240 424-A OM-240 438 Page 49...

  • Page 54: Section 13 − Generator Power Guidelines

    SECTION 13 − 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. 13-1. Selecting Equipment Generator Power Receptacles − Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment...

  • Page 55: Grounding When Supplying Building Systems

    13-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable Use #10 AWG or larger insulated copper wire. Ground Device GND/PE 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 56 13-5. 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 57 13-7. 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 58 13-8. 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 Motor Voltage To find starting amperage: Step 1: Find code and use table to find kVA/HP.
  • Page 59 13-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Properly install and ground this equipment according to its Owner’s Manual and na- Fused tional, state, and local codes. Welding Utility Disconnect...
  • Page 60 13-11. 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 61: Section 14 − Stick Welding (Smaw) Guidelines

    SECTION 14 − STICK WELDING (SMAW) GUIDELINES 14-1. Stick Welding Procedure Weld current starts when electrode touches work- piece. Equipment Needed: Tools Needed: 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 62: Electrode And Amperage Selection Chart

    14-2. 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 HORIZ...

  • Page 63: Positioning Electrode Holder

    14-4. Positioning Electrode Holder End View Of Work Angle Side View Of Electrode Angle ° ° ° ° Groove Welds ° ° ° ° Fillet Welds S-0060 14-5. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration S-0053-A...

  • Page 64: Conditions That Affect Weld Bead Shape

    14-7. Conditions That Affect Weld Bead Shape Weld bead shape is affected electrode angle, length, travel speed, and thick- ness of base metal. Correct Angle Angle Too Large ° - ° Angle Too Small Electrode Angle Drag Spatter Arc Length Normal Too Long Too Short...

  • Page 65: Butt Joints

    14-9. 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 66: Weld Test

    14-12. 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 14-13. Troubleshooting Porosity −...
  • Page 67 Lack Of Penetration − shallow fusion between weld metal and base metal. Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove. Improper weld technique. Keep arc on leading edge of weld puddle.
  • Page 68 Notes OM-240 438 Page 64...
  • Page 69 Notes OM-240 438 Page 65...
  • Page 70 Notes OM-240 438 Page 66...
  • Page 71 Effective January 1, 2009 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? serial number preface of LK 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 72: Options And Accessories

    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. © ORIGINAL INSTRUCTIONS − PRINTED IN USA 2009 Hobart Welding Products. 2009−01...

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