Hobart Welding Products CHAMP 2060

OM-499 Page 32

197 858-C

Figure 9-3. Wiring Diagram For Welding Generator

Contents

Main CHAMP 2060 From Hobart to You TABLE OF CONTENTS Page SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1-2. Arc Welding Hazards ELECTRIC SHOCK can kill. SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine. FUMES AND GASES can be hazardous. 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. FUEL can cause fire or explosion. MOVING PARTS can cause injury. STEAM AND HOT COOLANT can burn. 1-4. Compressed Air Hazards cause serious injury or death. COMPRESSED AIR can cause injury TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury. 1-6. Principal Safety Standards 1-7. EMF Information OM-499 Page 5 SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION Avertissement: Protgez vous et les autres des blessures lisez et suivez ces prcautions. 1-1. Signification des symboles Identifie un message de scurit particulier. 1-2. Dangers relatifs au soudage larc 1-3. Engine Hazards LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou mme la mort. LACIDE DE LA BATTERIE peut pro- voquer des brlures dans les YEUX et sur la PEAU. OM-499 Page 7 LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. 1-4. Dangers lis lair comprim RESPIRER LAIR COMPRIM peut pro voquer des blessures graves ou cause la mort. LAIR COMPRIM peut provoque 1-6. Principales normes de scurit 1-7. Information sur les champs lectromagntiques SECTION 2 DEFINITIONS 2-1. Symbol Definitions h s SECTION 3 SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications 3-2. Dimensions, Weights, And Operating Angles 3-3. Fuel Consumption (Kohler-Powered Units) Page OM-499 Page 12 3-6. Generator Power Curves The generator power curves show the ac power available in amperes at the receptacles. B. 50 Hz Model A. 60 Hz Model 3-7. Volt-Ampere Curves A. 60 Hz Model MID MAX MIN B. 50 Hz Model SECTION 4 INSTALLATION 4-1. Installing Welding Generator 4-2. Grounding Generator To Truck Or Trailer Frame 4-3. Grounding Generator When Supplying Building Systems 4 -4. Engine Prestart Checks (Kohler-Powered Units) 4 -5. Engine Prestart Checks (Honda-Powered Units) + 4-6. Connecting The Battery (Electric-Start Models Only) 4-7. Connecting To Weld Output Terminals 4-8. Selecting Weld Cable Sizes* SECTION 5 OPERATING THE WELDING GENERATOR 5-1. Controls (Kohler-Powered Units) 5-2. Controls (Honda-Powered Units) (See Section 5-3) 5-3. Description Of Controls (Honda-Powered Units) (See Section 5-2) Notes SECTION 6 OPERATING AUXILIARY EQUIPMENT 6-1. Generator Power Panel 495 218 (USA) 6-2. Optional Generator Power Panels OM-499 Page 23 6-3. Generator Power Panel Ratings Unless otherwise stated, the rating of duplex outlets is the combined load of all receptacles. Total power from generator NOT to exceed 5500 Watts (60 Hz) or 5000 Watts (50 Hz) It exceeds 5500W. 6-4. Wiring Instructions For Optional 120/240 Volt Twistlock Plug (NEMA L14-30P) SECTION 7 MAINTENANCE 200 h 50 h 7-1. Maintenance Label ENGINE MAINTENANCE 7-2. Routine Maintenance 8 h 20 h 50 h 100 h 200 h 7-3. Overload Protection (Honda-Powered Units) 7-4. Adjusting Engine Speed (Kohler-Powered Units) 7-5. Adjusting Engine Speed (Honda-Powered Units) SECTION 8 TROUBLESHOOTING 8-1. Troubleshooting A. Welding B. Generator Power C. Engine Page Page Page Page Page SECTION 10 GENERATOR POWER GUIDELINES 1 10-1. Selecting Equipment 0-2. Grounding Generator To Truck Or Trailer Frame 10-3. Grounding When Supplying Building Systems 10-4. How Much Power Does Equipment Require? 10-5. Approximate Power Requirements For Industrial Motors 10-6. Approximate Power Requirements For Farm/Home Equipment 10-7. Approximate Power Requirements For Contractor Equipment 10-8. Power Required To Start Motor 10-9. How Much Power Can Generator Supply? 10-10.Typical Connections To Supply Standby Power Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. 10-11.Selecting Extension Cord (Use Shortest Cord Possible) SECTION 11 STICK WELDING (SMAW) GUIDELINES 11-1. Stick Welding Procedure OM-499 Page 43 11-2. Electrode and Amperage Selection Chart 2 3 11-3. Striking an Arc Scratch Start Technique 1 2 3 11-5. Positioning Electrode Holder 11-6. Poor Weld Bead Characteristics 11-7. Good Weld Bead Characteristics 11-8. Conditions That Affect Weld Bead Shape 11-9. Electrode Movement During Welding 11-10.Butt Joints 11-11.Lap Joint 11-12.Tee Joint 11-13.Weld Test 11-14.Troubleshooting Porosity 11-15.Troubleshooting Excessive Spatter 11-16.Troubleshooting Incomplete Fusion 11-17.Troubleshooting Lack Of Penetration 11-18.Troubleshooting Excessive Penetration 11-19.Troubleshooting Burn-Through 11-20.Troubleshooting Waviness Of Bead 11-21.Troubleshooting Distortion SECTION 12 PARTS LIST Figure 12-1. Main Assembly Page Page Page Page Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. Effective January 1, 2002 Please complete and retain with your personal records. Resources Available Always provide Model Name and Serial/Style Number. Owners Record