Hobart Welding Products CHAMP 2060 manual Table of Contents

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WARNING

This product, when used for welding or cutting, produces fumes or gases which contain chemicals known to the State of California to cause birth defects and, in some cases, cancer. (California Health & Safety Code Section 25249.5 et seq.)

WARNING

Battery posts, terminals and related accessories contain lead and lead compounds, chemicals known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

The following terms are used interchangeably throughout this manual:

TIG = GTAW

Stick = SMAW

MIG = GMAW

TABLE OF CONTENTS

SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING

1

1-1.

Symbol Usage

1

1-2.

Arc Welding Hazards

1

1-3.

Engine Hazards

2

1-4. Additional Symbols For Installation, Operation, And Maintenance

3

1-5.

Principal Safety Standards

4

1-6.

EMF Information

4

SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION

5

1-1.

Signification des symboles

5

1-2. Dangers relatifs au soudage à l’arc

5

1-3. Dangers existant en relation avec le moteur

6

1-4. Dangers supplémentaires en relation avec l’installation, le fonctionnement

 

 

et la maintenance

7

1-5. Principales normes de sécurité

8

1-6. Information sur les champs électromagnétiques

8

SECTION 2 – DEFINITIONS

9

SECTION 3 – SPECIFICATIONS

9

3-1. Weld, Power, And Engine Specifications

9

3-2. Dimensions, Weights, And Operating Angles

10

3-3. Fuel Consumption (Kohler-Powered Units)

10

3-4. Fuel Consumption (Honda-Powered Units)

11

3-5.

Duty Cycle

11

3-6.

Generator Power Curves

12

3-7.

Volt-Ampere Curves

13

SECTION 4 – INSTALLATION

14

4-1.

Installing Welding Generator

14

4-2. Grounding Generator To Truck Or Trailer Frame

14

4-3. Grounding Generator When Supplying Building Systems

15

4-4. Engine Prestart Checks (Kohler-Powered Units)

15

4-5. Engine Prestart Checks (Honda-Powered Units)

16

4-6. Connecting The Battery (Electric-Start Models Only)

16

4-7. Connecting To Weld Output Terminals

17

4-8. Selecting Weld Cable Sizes*

17

SECTION 5 – OPERATING THE WELDING GENERATOR

18

5-1.

Controls (Kohler-Powered Units)

18

5-2. Controls (Honda-Powered Units) (See Section 5-3)

19

5-3. Description Of Controls (Honda-Powered Units) (See Section 5-2)

20

SECTION 6 – OPERATING AUXILIARY EQUIPMENT

21

6-1. Generator Power Panel 495 218 (USA)

21

6-2. Optional Generator Power Panels

22

6-3. Generator Power Panel Ratings

23

6-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P)

24

SECTION 7 – MAINTENANCE

24

7-1.

Maintenance Label

24

7-2.

Routine Maintenance

25

7-3. Overload Protection (Honda-Powered Units)

26

7-4. Adjusting Engine Speed (Kohler-Powered Units)

26

7-5. Adjusting Engine Speed (Honda-Powered Units)

27

SECTION 8 – TROUBLESHOOTING

28

SECTION 9 – ELECTRICAL DIAGRAMS

30

SECTION 10 – GENERATOR POWER GUIDELINES

35

SECTION 11 – STICK WELDING (SMAW) GUIDELINES

42

SECTION 12 – PARTS LIST

50

OPTIONS AND ACCESSORIES

 

WARRANTY

 

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Contents OM-499 ProcessesDescription From Hobart to You Table of Contents Page Fumes and Gases can be hazardous Marks a special safety messageArc Welding Hazards Electric Shock can killEngine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsLES Fumées ET LES GAZ peuvent être dangereux Signification des symbolesConsignes DE Sécurité Lire Avant Utilisation UN Choc Électrique peut tuerProvoquer des brûlures graves LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent’AIR Comprimé peut provoque r des blessures ’EXPLOSION DE LA Batterie peutDES Organes Mobiles peuvent provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieInformation sur les champs électromagnétiques Principales normes de sécuritéWelding Weld Output Rated Maximum Generator Power SpecificationsSymbol Definitions Weld, Power, And Engine SpecificationsBe damaged or unit could tip Dimensions, Weights, And Operating AnglesFuel Consumption Kohler-Powered Units Do not move or operate unit where itContinuous Welding Fuel Consumption Honda-Powered UnitsExceeding duty cycle can damage unit and void warranty Duty CycleHz Model Generator Power CurvesMAX MID MIN Volt-Ampere CurvesInstallation Installing Welding GeneratorGrounding Generator To Truck Or Trailer Frame Oil Grounding Generator When Supplying Building SystemsEngine Prestart Checks Kohler-Powered Units FuelEngine Prestart Checks Honda-Powered Units Connecting The Battery Electric-Start Models OnlyConnect negative cable last Stop engine before Connecting To Weld Output TerminalsSelecting Weld Cable Sizes 45 m 60 m 70 m 90 m 105 m 120 mControls Kohler-Powered Units Operating the Welding Generator50 Hz 60 Hz Controls Honda-Powered Units See Section Recoil-Start 2Electric-Start60 Hz 50 Hz Description Of Controls Honda-Powered Units See Section Generator Power Panel 495 218 USA Operating Auxiliary Equipment120 V x 10 a + 240 V x 9 a = 3.5 kVA/ KW OM-499 Australia Europe Asia Optional Generator Power PanelsGenerator Power Panel 495 Canada-CSA South Africa South AmericaIt exceeds 5500W Generator Power Panel RatingsMaintenance Label Maintenance100 h Routine Maintenance20 h 50 hIdle Speed Adjustment Overload Protection Honda-Powered UnitsAdjusting Engine Speed Kohler-Powered Units Weld/Power Speed AdjustmentStop engine. Close fuel valve Adjusting Engine Speed Honda-Powered UnitsThrottle Control Lever Adjustment Screw Pilot Screw Throttle Stop ScrewWelding TroubleshootingTroubleshooting Generator PowerCircuit board PC1 Check battery voltage electric-start models onlyViscosity oil for operating temperature EngineCircuit Diagram For Welding Generator 1 Electrical DiagramsCircuit Diagram For Welding Generator 2 Wiring Diagram For Welding Generator Wiring Diagram For Auxiliary Power Panels 1 Wiring Diagram For Auxiliary Power Panels 2 Selecting Equipment Generator Power GuidelinesVolts 115 Amps Resistive Load Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Earth ground if supplyingFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsWork like a Pro Typical Connections To Supply Standby PowerCurrent Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleStick Welding Procedure Weld current starts when electrode touches work- pieceStick Welding Smaw Guidelines Electrode and Amperage Selection Chart Striking an Arc Scratch Start TechniqueStriking an Arc Tapping Technique 10-30 9090 End View of Work Angle Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode HolderElectrode Movement During Welding Conditions That Affect Weld Bead Shape16 in 1.6 mm Tack Welds Butt JointsLap Joint Tee JointPossible Causes Corrective Actions Troubleshooting PorosityTroubleshooting Excessive Spatter Weld TestTroubleshooting Incomplete Fusion Troubleshooting Lack Of PenetrationTroubleshooting Excessive Penetration Troubleshooting Burn-Through Troubleshooting Waviness Of BeadTroubleshooting Distortion Main Assembly Parts ListDia Part Dia Part Mkgs Description Quantity Generator Power Panels Item Dia Part Mkgs Description Quantity Support ServiceHobart Welding Products Contact your Distributor for