Hobart Champion 145 User Manual (English)

Questions and Answers:

L
Lindsay RangelAug 19, 2025
What to do if my Hobart Champion 145 Welding System has erratic weld output?
- G
  gnelsonAug 19, 2025
  If your Hobart Welding System shows erratic weld output, try the following: * Check the amperage control setting. * Ensure connections to the electrode and workpiece are tightened and clean. * Use dry, properly stored electrodes for stick welding. * Remove excessive coils from weld cables. * Clean and tighten connections inside and outside the welding generator. * Check the governor linkage for smooth operation. * If the issue persists, have a Factory Authorized Service Agent check and adjust the engine speed.
R
Riley WalkerAug 20, 2025
Why does my Hobart Welding System have no AC receptacle or weld output?
- D
  Dave GonzalesAug 21, 2025
  If your Hobart Welding System isn't providing any output at the generator power AC receptacles and there's no weld output either, make sure all equipment is disconnected from the receptacles when starting the unit. If the problem continues, have a Factory Authorized Service Agent inspect the brushes, slip rings, rotor, stator, integrated rectifier SR1, and capacitor C1.
A
Ashley ReynoldsAug 23, 2025
What to do if the engine stopped during normal operation of my Hobart Champion 145 Welding System?
- S
  Sean RamirezAug 23, 2025
  If your Hobart Welding System's engine stops during normal operation, first check the fuel level and refill if necessary. Also, ensure the fuel valve is open. Remember to close it before moving the unit to prevent potential carburetor flooding. Finally, verify the oil level and add the correct viscosity oil if it's low, as a low oil level can trigger a shutdown.
M
Michelle DouglasAug 26, 2025
How to troubleshoot engine not starting on my Hobart Welding System?
- S
  Stacey BrownAug 26, 2025
  If your Hobart Welding System engine won't start, verify the fuel level and add fuel if needed. Ensure the choke control is in the correct position. Open the fuel valve, but remember to close it before moving the unit. Check the oil level and refill with the proper viscosity oil if low. If the issue continues, have a Factory Authorized Service Agent inspect the low oil level shutdown switch.
F
Francisco OrtegaAug 28, 2025
Why does my Hobart Welding System have low weld output?
- E
  Emily ValenciaAug 28, 2025
  If your Hobart Welding System has low weld output, check the amperage control setting. Service the engine air cleaner. Check the weld cable size and length. Have a Factory Authorized Service Agent check the engine speed, and adjust if necessary. Also, have them check the brushes, slip rings, integrated rectifier SR1, capacitor C1, and main rectifier SR2.
P
peterruizAug 30, 2025
What to do if Hobart Champion 145 Welding System has no weld output but generator power is okay?
- J
  John BrooksAug 30, 2025
  If your Hobart Welding System has no weld output but the generator power output is okay at the AC receptacles, first check the amperage control setting. Then, inspect the weld connections to ensure they are secure. If the problem persists, have a Factory Authorized Service Agent check the stator, stabilizer DC-Z, and main rectifier SR2.
A
Ashlee JensenSep 1, 2025
Why are the engine speeds unstable on my Hobart Welding System?
- T
  tinavelezSep 1, 2025
  If your Hobart Welding System shows unstable or sluggish engine speeds, check the governor linkage for smooth, non-binding operation. You may also need to tune-up the engine. If problems persist, have a Factory Authorized Service Agent check and adjust the engine speed.
Y
ypayneSep 3, 2025
How to fix erratic output at generator power ac receptacles on my Hobart Champion 145?
- B
  bryantteresaSep 4, 2025
  If your Hobart Welding System has erratic output at the generator power AC receptacles, start by checking the fuel level. Then, check the amperage control setting and set it to Max for generator power. Inspect the receptacle wiring and connections. Ensure the governor linkage operates smoothly. Service the air cleaner. If the issue remains, have a Factory Authorized Service Agent check and, if necessary, adjust the engine speed.
E
Erica GilbertSep 6, 2025
Hobart Champion 145 has no output at AC receptacles but weld output is okay, what to do?
- X
  xreidSep 6, 2025
  If your Hobart Welding System has no output at the generator power AC receptacles but the weld output is okay, reset the supplementary protector. Check the amperage control setting and set it to Max for generator power. Check the receptacle wiring and connections. If the problem persists, have a Factory Authorized Service Agent check the engine speed and stator windings, and adjust the engine speed if necessary.
M
Mary LindseySep 8, 2025
What causes high output at generator power ac receptacles on my Hobart Welding System?
- J
  jameskarenSep 9, 2025
  If your Hobart Welding System is producing high output at the generator power AC receptacles, have a Factory Authorized Service Agent check the engine speed, and adjust if necessary.

Hobart Champion 145 Specifications

General

Welding Amperage Range	40-145 Amps
Fuel Type	Gasoline
Welding Processes	Stick (SMAW)
Frequency	60 Hz
Generator Power Output	4, 500 Watts
Rated Output	30% Duty Cycle
Open Circuit Voltage	80 Volts
Electrode Sizes	1/16" - 5/32"

Summary

SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

Explains warning symbols used in the manual to indicate hazards.

1-2. Arc Welding Hazards

Details hazards associated with arc welding processes and required protective measures.

1-3. Engine Hazards

Covers potential dangers related to the engine, including battery, fuel, and moving parts.

1-4. Compressed Air Hazards

Outlines risks associated with compressed air equipment and systems.

1-5. Additional Symbols For Installation, Operation, And Maintenance

Introduces symbols for installation, operation, maintenance, and associated hazards.

1-6. California Proposition 65 Warnings

Lists chemicals known to cause cancer or birth defects per California law.

1-7. Principal Safety Standards

References key safety standards and guidelines for welding and allied processes.

1-8. EMF Information

Explains electromagnetic fields and precautions for personnel with medical implants.

SECTION 2 – SAFETY GUIDELINES - READ BEFORE USE

2-1. Symbol Meaning

Defines danger and warning symbols and their meanings.

2-2. Arc Welding Hazards

Details arc welding hazards like electric shock, and precautions.

2-3. Engine Hazards

Covers engine-specific hazards such as battery explosion, fuel issues, and moving parts.

2-4. Compressed Air Hazards

Explains hazards related to compressed air, including inhalation and pressure risks.

2-5. Additional Hazards Related to Installation, Operation, and Maintenance

Discusses hazards like fire, explosion, falling equipment, and overheating.

2-6. California Proposition 65 Warnings

Lists chemicals in products known to cause cancer or birth defects.

2-7. Principal Safety Standards

Provides references for key safety standards related to welding and allied processes.

2-8. Information Regarding EMC

Explains electromagnetic compatibility and potential interference with medical devices.

SECTION 3 – DEFINITIONS

3-1. Additional Safety Symbols And Definitions

Presents additional safety symbols and their meanings.

3-2. Miscellaneous Symbol Definitions

Defines various symbols used for controls and indicators on the equipment.

SECTION 4 – SPECIFICATIONS

4-1. Weld, Power, And Engine Specifications

Details the technical specifications for welding, power output, and engine.

4-2. Dimensions, Weights, And Operating Angles

Lists the physical dimensions, weight, and safe operating angles for the unit.

4-3. Fuel Consumption

Shows a graph illustrating fuel consumption based on DC weld amperes.

4-4. Duty Cycle

Explains duty cycle and provides a chart relating weld amperes to duty cycle percentage.

4-5. Generator Power Curve

Displays AC power curves showing generator output in amperes at different voltages.

4-6. Volt-Ampere Curves

Illustrates the minimum and maximum voltage and amperage output capabilities.

SECTION 5 - INSTALLATION

5-1. Serial Number And Rating Label Location

Indicates where to find the serial number and rating label on the stator.

5-2. Installing Welding Generator

Provides guidelines for installing the welding generator, including airflow and location.

5-3. Grounding Generator To Truck Or Trailer Frame

Explains the procedure for grounding the generator frame to a vehicle frame.

5-4. Engine Prestart Checks

Details essential checks to perform on the engine before starting, including fuel and oil levels.

5-5. Weld Output Terminals

Identifies the weld output terminals and their purpose for connecting cables.

5-6. Connecting Weld Output Cables

Guides on how to correctly connect weld output cables to the terminals for safety and performance.

5-7. Selecting Weld Cable Sizes

Provides a chart to help select appropriate weld cable sizes based on amperage and cable length.

SECTION 6 – OPERATING THE WELDING GENERATOR

6-1. Controls (See Section 6-2)

Identifies the main controls on the welding generator unit.

6-2. Description Of Controls (See Section 6-1)

Provides detailed descriptions of each control and their functions.

6-3. Amperage Selection Table For Stick (SMAW) Electrodes

Offers a table to select the correct amperage for different stick welding electrodes.

6-4. Cold Weather Operation

Advises on operating the generator in cold weather conditions and potential issues.

SECTION 7 – OPERATING AUXILIARY EQUIPMENT

7-1. Generator Power Panel Receptacles

Describes the different power receptacles available on the generator panel and their ratings.

7-2. GFCI Receptacle Information, Resetting And Testing

Explains GFCI receptacles, how to test, reset, and troubleshoot them.

SECTION 8 – MAINTENANCE

8-1. Routine Maintenance

Outlines routine maintenance tasks and their recommended intervals.

8-2. Servicing Air Cleaner

Provides instructions for cleaning and servicing the air cleaner element and precleaner.

SECTION 9 – TROUBLESHOOTING

9-1. Troubleshooting

Offers solutions for common welding and generator power problems.

SECTION 10 - PARTS LIST

10-1. Recommended Spare Parts

Lists recommended spare parts for the welding generator unit.

SECTION 11 – ELECTRICAL DIAGRAMS

Circuit Diagram For Welding Generator

Presents the electrical circuit diagram for the welding generator unit.

SECTION 12 – GENERATOR POWER GUIDELINES

12-1. Selecting Equipment

Guides on selecting appropriate electrical equipment for use with the generator.

12-2. Grounding Generator To Truck Or Trailer Frame

Details the procedure for grounding the generator to a vehicle frame.

12-3. Grounding When Supplying Building Systems

Explains how to ground the generator for supplying power to building systems.

12-4. How Much Power Does Equipment Require?

Provides guidance on calculating power requirements for various equipment.

12-5. Approximate Power Requirements For Industrial Motors

Lists power requirements for different types of industrial motors.

12-6. Approximate Power Requirements For Farm/Home Equipment

Lists power requirements for common farm and home equipment.

12-7. Approximate Power Requirements For Contractor Equipment

Lists power requirements for various contractor equipment.

12-8. Power Required To Start Motor

Explains how to determine the starting power requirements for single-phase motors.

12-9. How Much Power Can Generator Supply?

Advises on generator output limits and starting non-resistive loads.

12-10. Typical Connections To Supply Standby Power

Illustrates typical connections for supplying standby power using the generator.

12-11. Selecting Extension Cord (Use Shortest Cord Possible)

Provides charts for selecting appropriate extension cords based on load and length.

SECTION 13 – STICK WELDING (SMAW) GUIDELINES

13-1. Stick Welding Procedure

Details the step-by-step procedure for performing stick welding (SMAW).

13-2. Electrode and Amperage Selection Chart

Presents a chart for selecting electrodes and corresponding amperage settings.

13-3. Striking an Arc

Explains two techniques for striking an arc: scratch and tapping.

13-4. Positioning Electrode Holder

Shows correct positioning of the electrode holder for groove and fillet welds.

13-5. Poor Weld Bead Characteristics

Illustrates common weld bead defects and their causes.

13-6. Good Weld Bead Characteristics

Shows examples of good weld beads and their characteristics.

13-7. Conditions That Affect Weld Bead Shape

Explains how electrode angle, arc length, and travel speed affect weld bead shape.

13-8. Electrode Movement During Welding

Demonstrates stringer bead and weave bead techniques for electrode movement.

13-9. Groove (Butt) Joints

Describes different types of groove (butt) joints for welding.

13-10. Lap Joint

Explains the procedure for performing a lap joint weld.

13-11. Tee Joint

Details the procedure for performing a tee joint weld.

13-12. Weld Test

Describes how to perform a weld test to check for strength and integrity.

13-13. Troubleshooting

Provides solutions for weld defects like porosity, spatter, and incomplete fusion.

Warranty

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Hobart Champion 145 User Manual

Table of Contents

Questions and Answers:

Hobart Champion 145 Specifications

Summary

SECTION 1 - SAFETY PRECAUTIONS - READ BEFORE USING

1-1. Symbol Usage

1-2. Arc Welding Hazards

1-3. Engine Hazards

1-4. Compressed Air Hazards

1-5. Additional Symbols For Installation, Operation, And Maintenance

1-6. California Proposition 65 Warnings

1-7. Principal Safety Standards

1-8. EMF Information

SECTION 2 – SAFETY GUIDELINES - READ BEFORE USE

2-1. Symbol Meaning

2-2. Arc Welding Hazards

2-3. Engine Hazards

2-4. Compressed Air Hazards

2-5. Additional Hazards Related to Installation, Operation, and Maintenance

2-6. California Proposition 65 Warnings

2-7. Principal Safety Standards

2-8. Information Regarding EMC

SECTION 3 – DEFINITIONS

3-1. Additional Safety Symbols And Definitions

3-2. Miscellaneous Symbol Definitions

SECTION 4 – SPECIFICATIONS

4-1. Weld, Power, And Engine Specifications

4-2. Dimensions, Weights, And Operating Angles

4-3. Fuel Consumption

4-4. Duty Cycle

4-5. Generator Power Curve

4-6. Volt-Ampere Curves

SECTION 5 - INSTALLATION

5-1. Serial Number And Rating Label Location

5-2. Installing Welding Generator

5-3. Grounding Generator To Truck Or Trailer Frame

5-4. Engine Prestart Checks

5-5. Weld Output Terminals

5-6. Connecting Weld Output Cables

5-7. Selecting Weld Cable Sizes

SECTION 6 – OPERATING THE WELDING GENERATOR

6-1. Controls (See Section 6-2)

6-2. Description Of Controls (See Section 6-1)

6-3. Amperage Selection Table For Stick (SMAW) Electrodes

6-4. Cold Weather Operation

SECTION 7 – OPERATING AUXILIARY EQUIPMENT

7-1. Generator Power Panel Receptacles

7-2. GFCI Receptacle Information, Resetting And Testing

SECTION 8 – MAINTENANCE

8-1. Routine Maintenance

8-2. Servicing Air Cleaner

SECTION 9 – TROUBLESHOOTING

9-1. Troubleshooting

SECTION 10 - PARTS LIST

10-1. Recommended Spare Parts

SECTION 11 – ELECTRICAL DIAGRAMS

Circuit Diagram For Welding Generator

SECTION 12 – GENERATOR POWER GUIDELINES

12-1. Selecting Equipment

12-2. Grounding Generator To Truck Or Trailer Frame

12-3. Grounding When Supplying Building Systems

12-4. How Much Power Does Equipment Require?

12-5. Approximate Power Requirements For Industrial Motors

12-6. Approximate Power Requirements For Farm/Home Equipment

12-7. Approximate Power Requirements For Contractor Equipment

12-8. Power Required To Start Motor

12-9. How Much Power Can Generator Supply?

12-10. Typical Connections To Supply Standby Power

12-11. Selecting Extension Cord (Use Shortest Cord Possible)

SECTION 13 – STICK WELDING (SMAW) GUIDELINES

13-1. Stick Welding Procedure

13-2. Electrode and Amperage Selection Chart

13-3. Striking an Arc

13-4. Positioning Electrode Holder

13-5. Poor Weld Bead Characteristics

13-6. Good Weld Bead Characteristics

13-7. Conditions That Affect Weld Bead Shape

13-8. Electrode Movement During Welding

13-9. Groove (Butt) Joints