Hobart Champion 4500 manual Service, Support

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Effective January 1, 2002 (Equipment with a serial number preface of “LC” or newer)

This limited warranty supersedes all previous Hobart warranties and is exclusive with no other

guarantees or warranties expressed or implied.

Warranty Questions?

Call

1-877-HOBART1 for your local Hobart distributor.

Service

You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours.

Support

Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distributor and Hobart is there to help you, every step of the way.

LIMITED WARRANTY – Subject to the terms and conditions below, Hobart/Miller Electric Mfg. Co., Appleton, Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Hobart. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS.

Within the warranty periods listed below, Hobart will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Hobart must be notified in writing within thirty (30) days of such defect or failure, at which time Hobart will provide instructions on the warranty claim procedures to be followed.

Hobart shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor.

1.5 Years Parts — 3 Years Labor

*Original main power rectifiers

*Inverters (input and output rectifiers only)

2.3 Years — Parts and Labor

*Transformer/Rectifier Power Sources

*Plasma Arc Cutting Power Sources

*Semi-Automatic and Automatic Wire Feeders

*Inverter Power Supplies

*Intellitig

*Engine Driven Welding Generators

(NOTE: Engines are warranted separately by the engine manufacturer.)

3.1 Year — Parts and Labor Unless Specified

*DS-2 Wire Feeder

*Motor Driven Guns (w/exception of Spoolmate Spoolguns)

*Process Controllers

*Positioners and Controllers

*Automatic Motion Devices

*RFCS Foot Controls

*Induction Heating Power Sources

*Water Coolant Systems

*Flowgauge and Flowmeter Regulators (No Labor)

*HF Units

*Grids

*Maxstar 85, 140

*Spot Welders

*Load Banks

*Racks

*Running Gear/Trailers

*Plasma Cutting Torches (except APT & SAF Models)

*Field Options

(NOTE: Field options are covered for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.)

4.6 Months — Batteries

5.90 Days — Parts

*MIG Guns/TIG Torches

*Induction Heating Coils and Blankets

*APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches

*Remote Controls

*Accessory Kits

*Replacement Parts (No labor)

*Spoolmate Spoolguns

*Canvas Covers

HOBART’s Limited Warranty shall not apply to:

1.Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear.

2.Items furnished by Hobart, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any.

3.Equipment that has been modified by any party other than Hobart, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment.

HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT.

In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Hobart’s option: (1) repair; or

(2)replacement; or, where authorized in writing by Hobart in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Hobart service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Hobart’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Hobart authorized service facility as determined by Hobart. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed.

TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL HOBART BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY.

ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY HOBART IS EXCLUDED AND DISCLAIMED BY HOBART.

Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state.

In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province.

hobart standard 6/02

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Contents Description OM-4418210 597AProcesses 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 CurveGrounding Generator To Truck Or Trailer Frame InstallationInstalling Welding Generator 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 GeneratorAmperage Selection Table For Stick Smaw Electrodes To Stop turn engine switch to OffDescription Of Controls See Section 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 PowerStarting difficult With proper viscosity oil for operating temperatureEngine 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 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 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 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