Hobart Champion 4500 manual Table of Contents

Page 3

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:

Stick = SMAW

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.

Compressed Air Hazards

3

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

3

1-6.

Principal Safety Standards

4

1-7.

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.

Engine Hazards

6

1-4. Dangers liés à l’air comprimé

7

1-5. Dangers supplémentaires en relation avec l’installation, le fonctionnement

 

 

et la maintenance

7

1-6. Principales normes de sécurité

8

1-7. 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

9

3-3.

Fuel Consumption

10

3-4.

Duty Cycle

10

3-5.

Generator Power Curve

11

3-6.

Volt-Ampere Curves

11

SECTION 4 – INSTALLATION

12

4-1.

Installing Welding Generator

12

4-2. Grounding Generator To Truck Or Trailer Frame

12

4-3. Grounding Generator When Supplying Building Systems

13

4-4.

Engine Prestart Checks

13

4-5. Connecting To Weld Output Terminals

14

4-6. Selecting Weld Cable Sizes*

14

SECTION 5 – OPERATING THE WELDING GENERATOR

15

5-1. Controls (See Section 6-2)

15

5-2. Description Of Controls (See Section 6-1)

16

5-3. Amperage Selection Table For Stick (SMAW) Electrodes

16

SECTION 6 – OPERATING AUXILIARY EQUIPMENT

17

6-1. Generator Power Panel Receptacles

17

SECTION 7 – MAINTENANCE

18

7-1.

Routine Maintenance

18

7-2.

Servicing Air Cleaner

19

SECTION 8 – TROUBLESHOOTING

20

SECTION 9 – ELECTRICAL DIAGRAMS

22

SECTION 10 – GENERATOR POWER GUIDELINES

23

SECTION 11 – STICK WELDING (SMAW) GUIDELINES

30

SECTION 12 – PARTS LIST

38

OPTIONS AND ACCESSORIES

 

WARRANTY

 

Page 2 Page 4
Image 3
Page 2 Page 4
Contents OM-4418210 597A 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 tuerLE Bruit peut affecter l’ouïe LE Soudage peut provoquer un in- cendie ou une explosionDES Particules Volantes peuvent blesser les yeux DES Pièces Chaudes peuvent provoquer des brûlures graves’AIR Comprimé peut provoquer 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 sécuritéDimensions, Weights, And Operating Angles SpecificationsSymbol Definitions Weld, Power, And Engine Specifications100% Duty Cycle at 90 Amperes CC/AC Exceeding duty cycle can damage unit and void warrantyFuel Consumption Duty CycleVolt-Ampere Curves Generator Power CurveInstallation Installing Welding GeneratorGrounding Generator To Truck Or Trailer Frame Oil Grounding Generator When Supplying Building SystemsEngine Prestart Checks 13 mm Full Gasoline Open ClosedPut terminals Connecting To Weld Output TerminalsSelecting Weld Cable Sizes 45 m 60 m 70 m 90 m 105 m 120 mControls See Section Operating the Welding GeneratorTo Stop turn engine switch to Off Description Of Controls See SectionAmperage Selection Table For Stick Smaw Electrodes 240 V 20 a AC Duplex Receptacle RC1 Generator Power Panel ReceptaclesOperating Auxiliary Equipment Use GFCI-protected extension cordMaintenance Stop engine Servicing Air CleanerClean element by gently tapping on a hard surface Washing PrecleanerWelding TroubleshootingTroubleshooting Generator PowerWith proper viscosity oil for operating temperature EngineStarting difficult Circuit Diagram For Welding Generator Electrical DiagramsSelecting Equipment Generator Power GuidelinesAmperes x Volts = Watts 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 1000 = Starting Amperage 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 30 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 35 36 Parts ListDia Part Description Quantity Mkgs Work like a Pro Page Page Support ServiceHobart Welding Products Contact your Distributor for
Top Page Image Contents