Hobart Welding Products Champion Elite User Manual

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

Hobart Welding Products Champion Elite Specifications

General

Voltage	120/240 V
Fuel Type	Gasoline
Welding Processes	Stick, TIG, MIG
Input Phase	Single Phase
Rated Output	225A
Open Circuit Voltage	70 V
Welding Output	225 A DC
Phase	Single Phase
Fuel Tank Capacity	12 Gallons (45.4 L)

Summary

Hobart Champion Elite Owner's Manual

Introduction from Hobart

Safety Precautions

Symbol Usage

Explains the meaning of hazard symbols and warning indicators used in the manual.

Arc Welding Hazards

Details hazards associated with arc welding, including electric shock and hot parts.

Fumes, Gases, and Noise Hazards

Covers dangers from welding fumes, gases, noise exposure, and potential buildup.

Electric and Magnetic Fields (EMF) and Cylinder Safety

Addresses EMF interference with medical implants and hazards of compressed gas cylinders.

Engine Hazards

Details hazards related to the engine, including battery explosion, fuel, and moving parts.

Hydraulic Hazards

Covers potential injuries or fatalities from hydraulic equipment and fluids.

Compressed Air Hazards

Outlines risks associated with compressed air equipment, including injection and pressure hazards.

Installation, Operation, and Maintenance Hazards

Covers general hazards during installation, operation, and maintenance procedures.

California Proposition 65 Warnings

Provides warnings required by California law regarding chemicals in fumes and batteries.

Principal Safety Standards

Lists key safety standards and organizations relevant to welding equipment.

EMF Information

Explains electromagnetic fields and provides procedures to minimize exposure.

Definitions

Symbol Definitions

Defines the various symbols used throughout the manual for controls and indicators.

Specifications

Weld, Power, and Engine Specifications

Details welding output ranges, power ratings, and engine types used in the unit.

Dimensions and Weights

Provides physical dimensions, weights, and operating angle limits for the unit.

Duty Cycle

Explains the concept of duty cycle and its importance in preventing overheating.

Fuel Consumption (Subaru-Powered)

Presents charts showing fuel consumption rates for Subaru-powered units.

Fuel Consumption (Kohler-Powered)

Presents charts showing fuel consumption rates for Kohler-powered units.

Volt-Ampere Curves

Illustrates the output voltage and amperage capabilities for different welding modes.

Generator Power Curve

Shows the generator power output available at the receptacles.

Installation

Serial Number And Rating Label Location

Indicates the location of the serial number and rating information labels.

Installing Welding Generator

Covers placement, movement, mounting, and airflow clearance for installation.

Grounding to Truck or Trailer Frame

Details proper grounding procedures when mounting the generator on a vehicle.

Engine Prestart Checks (Subaru)

Outlines essential pre-start checks for Subaru-powered engines.

Engine Prestart Checks (Kohler)

Outlines essential pre-start checks for Kohler-powered engines.

Installing Exhaust Pipe

Provides instructions for correctly installing the exhaust pipe.

Connecting or Replacing the Battery

Step-by-step guide for connecting or replacing the unit's battery.

Connecting to Weld Output Terminals

Explains how to properly connect weld cables to the output terminals.

Selecting Weld Cable Sizes

Provides a chart to help select the correct weld cable size based on length and current.

Operating the Welding Generator

Front Panel Controls

Describes the function of each control and switch on the generator's front panel.

Cold Weather Engine Operation

Provides guidance and tips for operating the engine in cold weather conditions.

Stick Welding Connections and Control Settings

Details typical connections and control settings for stick welding various electrodes.

Operating Auxiliary Equipment

Standard Receptacles

Describes the various receptacles available for auxiliary power output and their ratings.

Simultaneous Weld and Power

Explains how power is shared between welding and auxiliary loads.

Wiring Optional 240 Volt Plug

Provides instructions for wiring an optional 240-volt plug.

Maintenance (Subaru-Powered Units)

Maintenance Label (Subaru-Powered Units)

Presents the maintenance summary label for Subaru engines.

Routine Maintenance (Subaru)

Outlines routine maintenance tasks based on operating hours for Subaru engines.

Servicing Air Cleaner (Subaru)

Instructions for cleaning and servicing the air cleaner element for Subaru engines.

Servicing Spark Arrestor (Subaru)

Instructions for cleaning and inspecting the spark arrestor screen for Subaru engines.

Changing Oil, Oil Filter, and Fuel Filter (Subaru)

Step-by-step guide for changing engine oil, oil filter, and fuel filter on Subaru engines.

Adjusting Engine Speed (Subaru)

Details on how to adjust idle and weld/power engine speeds for Subaru engines.

Overload Protection (Subaru)

Explains the fuse locations and functions related to overload protection for Subaru units.

Maintenance (Kohler-Powered Units)

Maintenance Label (Kohler-Powered Units)

Presents the maintenance summary label for Kohler engines.

Routine Maintenance (Kohler)

Outlines routine maintenance tasks based on operating hours for Kohler engines.

Servicing Air Cleaner (Kohler)

Instructions for cleaning and servicing the air cleaner element for Kohler engines.

Changing Oil, Oil Filter, and Fuel Filter (Kohler)

Step-by-step guide for changing engine oil, oil filter, and fuel filter on Kohler engines.

Adjusting Engine Speed (Kohler)

Details on how to adjust idle and weld/power engine speeds for Kohler engines.

Overload Protection (Kohler)

Explains the fuse locations and functions related to overload protection for Kohler units.

Servicing Spark Arrestor (Kohler)

Instructions for cleaning and inspecting the spark arrestor screen for Kohler engines.

Troubleshooting

Welding Troubleshooting

Lists common welding output problems and suggested corrective actions.

Generator Power Troubleshooting

Lists common generator power output issues and suggested corrective actions.

Engine Troubleshooting

Lists common engine starting and running problems and their remedies.

Engine Operation Troubleshooting

Addresses issues like battery discharge, idle speed, and unstable engine speeds.

Parts List

Recommended Spare Parts

Lists recommended spare parts with part numbers and quantities.

Electrical Diagrams

Circuit Diagram For Welding Generator

Provides the main electrical circuit diagram for the welding generator.

Generator Power Guidelines

Selecting Equipment

Guidance on selecting appropriate electrical equipment for generator use.

Grounding Generator To Truck Or Trailer Frame

Details proper grounding procedures when mounting the generator on a vehicle.

Grounding Building Systems

Explains how to properly ground the generator when supplying building systems.

Equipment Power Requirements

Explains how to calculate power requirements for various types of equipment.

Power Requirements: Industrial Motors

Provides approximate power requirements for various industrial motors.

Power Requirements: Farm/Home Equipment

Provides approximate power requirements for farm and home equipment.

Power Requirements: Contractor Equipment

Provides approximate power requirements for contractor equipment.

Motor Starting Power Requirements

Explains how to calculate the starting power needed for single-phase induction motors.

Generator Power Supply Limits

Discusses generator load limits and proper starting procedures for motors.

Standby Power Connections

Shows typical electrical connections for supplying standby power from the generator.

Selecting Extension Cords

Provides guidance on selecting appropriate extension cords based on load and length.

Stick Welding Guidelines

Stick Welding Procedure

Outlines the basic procedure for performing stick welding, including safety and setup.

Electrode and Amperage Selection

Chart for selecting appropriate electrodes and amperage settings for various materials.

Striking an Arc

Describes the scratch and tapping techniques for starting a welding arc.

Electrode Holder Positioning

Illustrates proper electrode holder angles for groove and fillet welds.

Weld Bead Characteristics

Explains how to identify good and poor weld bead characteristics.

Factors Affecting Weld Bead Shape

Discusses how electrode angle, arc length, and travel speed affect weld bead appearance.

Electrode Movement Techniques

Describes stringer and weave bead techniques for different welding applications.

Butt Joint Welding

Details types of butt joints and welding techniques, including tack welds.

Lap and Tee Joint Welding

Describes welding procedures and considerations for lap and tee joints.

Weld Test Procedure

Explains how to perform a weld test to evaluate the quality of the weld bead.

Weld Troubleshooting (Bead Defects)

Addresses common weld defects like porosity, spatter, and incomplete fusion.

Weld Troubleshooting (Penetration & Waviness)

Addresses issues such as lack of penetration, excessive penetration, waviness, and distortion.

Warranty Information

Hobart 5/3/1 Warranty Details

Outlines the terms, conditions, and coverage periods of the Hobart 5/3/1 limited warranty.

Owner's Record and Resources

Owner's Record

Section for recording personal ownership details like model, serial number, and purchase date.

Available Resources

Lists contact information for distributors, technical assistance, and available resources.