Manuels Connexes pour Hobart Welders Champion Elite
Sommaire des Matières pour Hobart Welders Champion Elite
- Page 1 OM-240 438E 2011−03 Processes Stick (SMAW) Welding Description Engine Driven Welding Generator Champion Elite ®...
- Page 2 Protect Your Investment! Hobart Welders 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.
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Page 3: Table Des Matières
TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING ....... . 1-1. - Page 4 TABLE OF CONTENTS 8-6. Overload Protection ..............8-7.
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Page 5: Section 1 − Safety Precautions − Read Before Using
SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2010−03 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 Indicates special instructions. not avoided, will result in death or serious injury. - 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.
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Page 7: Engine Hazards
1-3. Engine Hazards EXHAUST SPARKS can cause fire. BATTERY EXPLOSION can injure. D Do not let engine exhaust sparks cause fire. D Always wear a face shield, rubber gloves, and protective clothing when working on a battery. D Use approved engine exhaust spark arrestor in required areas —... -
Page 8: Hydraulic Hazards
1-4. Hydraulic Hazards D HYDRAULIC FLUID is FLAMMABLE−−do not work on hydraulics HYDRAULIC EQUIPMENT can injure near sparks or flames; do not smoke near hydraulic fluid. or kill. D Reinstall doors, panels, covers, or guards when servicing is D Incorrect installation or operation of this unit finished and before starting unit. -
Page 9: Additional Symbols For Installation, Operation, And Maintenance
HOT METAL from air arc cutting and MOVING PARTS can injure. gouging can cause fire or explosion. D Keep away from moving parts such as fans, D Do not cut or gouge near flammables. belts and rotors. D Watch for fire; keep extinguisher nearby. D Keep all doors, panels, covers, and guards closed and securely in place. -
Page 10: California Proposition 65 Warnings
WELDING WIRE can injure. H.F. RADIATION can cause interference. D Do not press gun trigger until instructed to do D High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. D Do not point gun toward any part of the body, other people, or any metal when threading D Have only qualified persons familiar with welding wire. -
Page 11: Principal Safety Standards
1-8. Principal Safety Standards Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web- from Global Engineering Documents (phone: 1-877-413-5184, website: site: www.ansi.org). www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, from National Fire Protection Association, and Cutting, American Welding Society Standard AWS F4.1, from Glob-... -
Page 12: Section 2 Consignes De Sécurité − Lire Avant Utilisation
SECTION 2 CONSIGNES DE SÉCURITÉ − LIRE AVANT − UTILISATION fre_rom_2010−03 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 13 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...
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Page 14: 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 et circuits électriques. -
Page 15: Dangers Liés À L'hydraulique
D Mettre des lunettes de sécurité et des gants, placer un torchon sur LES ÉTINCELLES À L’ÉCHAPPEMENT le bouchon du radiateur. peuvent provoquer un incendie. D Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. D Empêcher les étincelles d’échappement du moteur de provoquer un incendie. -
Page 16: Dangers Liés À L'air Comprimé
un médecin familiarisé avec ce type de blessure, faute de quoi LES PIÈCES ET LIQUIDES CHAUDS la gangrène pourrait apparaître. peuvent provoquer des brûlures. Les PIÈCES MOBILES peuvent causer D Ne pas toucher les pièces chaudes à main nue des blessures. ni laisser des liquides chauds entrer en contact avec la peau. -
Page 17: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance
D Remettre en place les portes, panneaux, recouvrements ou PRESSION D’AIR RÉSIDUELLE dispositifs de protection à la fin des travaux d’entretien et avant ET DES FLEXIBLES QUI FOUETTENT de mettre le moteur en marche. risquent de provoquer des blessures. D Détendre la pression pneumatique des outils et PIÈCES CHAUDES peuvent... -
Page 18: Proposition Californienne 65 Avertissements
D Demander seulement à des personnes qualifiées familiarisées LES CHARGES ÉLECTROSTATI- avec des équipements électroniques de faire fonctionner l’installa- QUES peuvent endommager les tion. circuits imprimés. D L’utilisateur est tenu de faire corriger rapidement par un électricien qualifié les interférences résultant de l’installation. D Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. -
Page 19: Principales Normes De Sécurité
2-8. Principales normes de sécurité Safety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1, 25 West 43rd Street, New York, NY 10036 (phone: 212-642-4900, web- from Global Engineering Documents (phone: 1-877-413-5184, website: site: www.ansi.org). www.global.ihs.com). Standard for Fire Prevention During Welding, Cutting, and Other Hot Safe Practices for the Preparation of Containers and Piping for Welding Work, NFPA Standard 51B, from National Fire Protection Association, and Cutting, American Welding Society Standard AWS F4.1, from Glob-... -
Page 20: Section 3 − Definitions
A complete Parts List is available at wwwHobartWelders.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 21: Dimensions, Weights, And Operating Angles
A complete Parts List is available at www.HobartWelders.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 22: Dimensions For Units With Optional Running Gear
A complete Parts List is available at wwwHobartWelders.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 23: Volt-Ampere Curves
A complete Parts List is available at www.HobartWelders.com 4-5. 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: Fuel Consumption
A complete Parts List is available at wwwHobartWelders.com 4-6. Fuel Consumption 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 25: Section 5 − Installation
A complete Parts List is available at www.HobartWelders.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 26: Grounding Generator To Truck Or Trailer Frame
A complete Parts List is available at wwwHobartWelders.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 27: Engine Prestart Checks
A 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 10W30 engine oil. Follow run-in procedure in en- gine manual. NOTICE − This unit has a low oil pressure shutdown switch. -
Page 28: Installing Exhaust Pipe
A complete Parts List is available at wwwHobartWelders.com 5-5. 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 5-7. 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 5-8. 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 A complete Parts List is available at www.HobartWelders.com Notes Start Your Professional Over 80,000 400 Trade Square East, Troy, Ohio 45373 Welding Career Now! trained since 1930! 1-800-332-9448 www.welding.org OM-240 438 Page 27...
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Page 32: Section 6 − Operating The Welding Generator
A complete Parts List is available at wwwHobartWelders.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 33: Cold Weather Engine Operation
A complete Parts List is available at www.HobartWelders.com 6-2. Cold Weather Engine Operation Engine Control Switch Carburetor Icing Infrequently Loaded 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. -
Page 34: Typical Stick Welding Connections And Control Settings
A complete Parts List is available at wwwHobartWelders.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 35: Section 7 − Operating Auxiliary Equipment
A complete Parts List is available at www.HobartWelders.com SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Standard Receptacles 244 029-A / 281 080-A Supplementary Protector CB1 If a ground fault is detected, the GFCI Re- If unit does not have GFCI recep- set button pops out and the circuit opens tacles, use GFCI-protected exten- CB1 protects receptacles RC1, RC2,... -
Page 36: Simultaneous Weld And Power
A complete Parts List is available at wwwHobartWelders.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 37: Section 8 − Maintenance
A complete Parts List is available at www.HobartWelders.com SECTION 8 − MAINTENANCE 8-1. Maintenance Label OM-240 438 Page 33... -
Page 38: Routine Maintenance
A complete Parts List is available at wwwHobartWelders.com 8-2. Routine Maintenance 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 39: Servicing Air Cleaner
A complete Parts List is available at www.HobartWelders.com 8-3. Servicing Air Cleaner 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 40: Changing Engine Oil, Oil Filter, And Fuel Filter
A complete Parts List is available at wwwHobartWelders.com 8-4. Changing Engine Oil, Oil Filter, and Fuel Filter 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. Close valve and valve cap before adding... -
Page 41: Adjusting Engine Speed
A complete Parts List is available at www.HobartWelders.com 8-5. Adjusting Engine Speed 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 − 38.3 Hz) Turn Fine Control to 10. -
Page 42: Overload Protection
A complete Parts List is available at wwwHobartWelders.com 8-6. Overload Protection Stop engine. Disconnect negative (−) battery cable. Fuse F1 (See Section 10-1) F1 protects the weld excitation winding from overload. If F1 opens, weld output stops or is low. Fuse F2 (See Section 10-1) F2 protects the generator power excitation winding from overload. -
Page 43: Section 9 − Troubleshooting
A complete Parts List is available at www.HobartWelders.com SECTION 9 − TROUBLESHOOTING 9-1. 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 8-6). Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi- ers SR2 and SR3. -
Page 44: Engine Troubleshooting
A complete Parts List is available at wwwHobartWelders.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 8-6). Check plug PLG6 connection. Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi- ers SR2 and SR3. -
Page 45: Section 10 − Parts List
A complete Parts List is available at www.HobartWelders.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 46: Section 11 − Electrical Diagrams
SECTION 11 − ELECTRICAL DIAGRAMS Figure 11-1. Circuit Diagram For Welding Generator OM-240 438 Page 42... - Page 47 240 424-B OM-240 438 Page 43...
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Page 48: 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 49 12-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #8 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 50 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 51 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 52 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 Motor Voltage AC MOTOR To find starting amperage: VOLTS AMPS Step 1: Find code and use table to CODE find kVA/HP.
- Page 53 12-10. Typical Connections To Supply Standby Power Have only qualified persons perform these connections according to all applicable codes and safety practices. Fused Properly install and ground Welding Utility Disconnect this equipment according to Electrical Generator Transfer Switch Switch its Owner’s Manual and na- Output Service (If Required)
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Page 54: Selecting Extension Cord (Use Shortest Cord Possible)
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 55: 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. 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 56: Electrode And Amperage Selection Chart
13-2. 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 57 13-4. Positioning Electrode Holder End View Of Work Angle Side View Of Electrode Angle ° ° ° ° Groove Welds ° ° ° ° Fillet Welds S-0060 13-5. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration S-0053-A...
- Page 58 13-7. 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 59 13-9. Groove (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 60 13-12. 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 13-13. Troubleshooting Porosity −...
- Page 61 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 62 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 6 mm .2362 in 10 mm 10 mm...
- Page 63 Effective January 1, 2011 5/3/1 WARRANTY applies to all Hobart welding equipment, plasma cutters and spot welders with a Warranty Questions? serial number preface of MB 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 64 Owner’s Record Please complete and retain with your personal records. Protect Your Investment! Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City Register your product at: HobartWelders.com State Resources Available Always provide Model Name and Serial/Style Number. To locate a Distributor, Contact your Distributor for: retail or service location:...