Hobart Champion 4500 manual Troubleshooting Burn-Through, Troubleshooting Waviness Of Bead

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11-19. Troubleshooting – Burn-Through

Burn-Through – weld metal melting completely through base metal resulting in holes where no metal remains.

Possible Causes	Corrective Actions

Excessive heat input.	Select lower amperage. Use smaller electrode.

	Increase and/or maintain steady travel speed.

11-20. Troubleshooting – Waviness Of Bead

Waviness Of Bead – weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes	Corrective Actions

Unsteady hand.	Use two hands. Practice technique.

11-21. Troubleshooting – Distortion

			Distortion – contraction of weld met-
			al during welding that forces base
			metal to move.
		Base metal moves
		Base metal moves
		in the direction of
		in the direction of
		the weld bead.

Possible Causes			Corrective Actions

Excessive heat input.			Use restraint (clamp) to hold base metal in position.

			Make tack welds along joint before starting welding operation.

			Select lower amperage for electrode.

			Increase travel speed.

			Weld in small segments and allow cooling between welds.

OM-4418 Page 37

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Contents Description OM-4418210 597AProcesses From Hobart to You Table of Contents Page Arc Welding Hazards Marks a special safety messageElectric Shock can kill Fumes and Gases can be hazardousEngine Hazards Compressed Air Hazards EMF Information Principal Safety StandardsConsignes DE Sécurité Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LES Fumées ET LES GAZ peuvent être dangereuxDES Particules Volantes peuvent blesser les yeux LE Soudage peut provoquer un in- cendie ou une explosionDES Pièces Chaudes peuvent provoquer des brûlures graves LE Bruit peut affecter l’ouïeDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peutLA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresInformation sur les champs électromagnétiques Principales normes de sécuritéSymbol Definitions SpecificationsWeld, Power, And Engine Specifications Dimensions, Weights, And Operating AnglesFuel Consumption Exceeding duty cycle can damage unit and void warrantyDuty Cycle 100% Duty Cycle at 90 Amperes CC/ACVolt-Ampere Curves Generator Power CurveGrounding Generator To Truck Or Trailer Frame InstallationInstalling Welding Generator Engine Prestart Checks Grounding Generator When Supplying Building Systems13 mm Full Gasoline Open Closed OilSelecting Weld Cable Sizes Connecting To Weld Output Terminals45 m 60 m 70 m 90 m 105 m 120 m Put terminalsControls See Section Operating the Welding GeneratorAmperage Selection Table For Stick Smaw Electrodes To Stop turn engine switch to OffDescription Of Controls See Section Operating Auxiliary Equipment Generator Power Panel ReceptaclesUse GFCI-protected extension cord 240 V 20 a AC Duplex Receptacle RC1Maintenance Clean element by gently tapping on a hard surface Servicing Air CleanerWashing Precleaner Stop engineTroubleshooting TroubleshootingGenerator Power WeldingStarting difficult With proper viscosity oil for operating temperatureEngine Circuit Diagram For Welding Generator Electrical DiagramsSelecting Equipment Generator Power GuidelinesHow Much Power Does Equipment Require? Grounding When Supplying Building SystemsEarth ground if supplying Amperes x Volts = WattsApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 = Starting AmperageWork like a Pro Typical Connections To Supply Standby PowerCurrent Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleStick Welding Smaw Guidelines Stick Welding ProcedureWeld current starts when electrode touches work- piece Striking an Arc Tapping Technique Electrode and Amperage Selection ChartStriking an Arc Scratch Start Technique Good Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work AngleElectrode Movement During Welding Conditions That Affect Weld Bead ShapeLap Joint Butt JointsTee Joint 16 in 30 1.6 mm Tack WeldsTroubleshooting Excessive Spatter Troubleshooting PorosityWeld Test Possible Causes Corrective ActionsTroubleshooting Excessive Penetration Troubleshooting Incomplete FusionTroubleshooting Lack Of Penetration Troubleshooting Distortion Troubleshooting Burn-ThroughTroubleshooting Waviness Of Bead 35 36 Parts ListDia Part Description Quantity Mkgs Work like a Pro Page Page Support ServiceHobart Welding Products Contact your Distributor for