Hobart Champion 4500 manual Weld Test, Troubleshooting Porosity, Troubleshooting Excessive Spatter

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11-13. Weld Test

2 To 3 in

(51-76 mm)

1/4 in (6.4 mm)

3
	3
	2 To 3 in
	(51-76 mm)
2	2
2
1	1

1Vise

2Weld Joint

3Hammer

Strike weld joint in direction shown. A good weld bends over but does not break.

S-0057-B

11-14. Troubleshooting – Porosity

Porosity – small cavities or holes resulting from gas pockets in weld metal.

Possible Causes	Corrective Actions

Arc length too long.	Reduce arc length.

Damp electrode.	Use dry electrode.

Workpiece dirty.	Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before
	welding.

11-15. Troubleshooting – Excessive Spatter

Excessive Spatter – scattering of molten metal particles that cool to solid form near weld bead.

Possible Causes	Corrective Actions

Amperage too high for electrode.	Decrease amperage or select larger electrode.

Arc length too long or voltage too high.	Reduce arc length or voltage.

OM-4418 Page 35

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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