Hobart Welding Products OM-4418 manual Troubleshooting, Welding, Generator Power, Trouble Remedy

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SECTION 9 − TROUBLESHOOTING

9-1. Troubleshooting

A. Welding

Trouble

Remedy

 

 

No weld output; no generator power

Be sure all equipment is disconnected from receptacles when starting unit.

output at ac receptacles.

 

 

 

 

Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, and integrated rectifier

 

SR1.

 

 

No weld output; generator power out-

Check Amperage control setting (see Section 6-1).

put okay at ac receptacles.

 

 

 

 

Check weld connections.

 

 

 

Have Factory Authorized Service Agent check Amperage control R1, stator, and integrated rectifier

 

SR1.

 

 

Low weld output.

Check Amperage control setting (see Section 6-1).

 

 

 

Service engine air cleaner.

 

 

 

Check weld cable size and length.

 

 

 

Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

 

 

 

Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, and integrated rectifier

 

SR1.

 

 

High weld output.

Check Amperage control setting (see Section 6-1).

 

 

Erratic weld output.

Check Amperage control setting (see Section 6-1).

 

 

 

Tighten and clean connections to electrode and workpiece.

 

 

 

Use dry, properly-stored electrodes for Stick welding.

 

 

 

Remove excessive coils from weld cables.

 

 

 

Clean and tighten connections both inside and outside welding generator.

 

 

 

Check governor linkage for smooth, non-binding operation.

 

 

 

Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

 

 

B. Generator Power

Trouble

Remedy

 

 

No output at generator power ac re-

Be sure all equipment is disconnected from receptacles when starting unit.

ceptacles; no weld output.

 

 

 

 

Have Factory Authorized Service Agent check brushes, slip rings, rotor, stator, and integrated rectifier

 

SR1.

 

 

No output at generator power ac re-

Reset supplementary protector (see Section 7-1).

ceptacles; weld output okay.

 

 

 

 

Check Amperage control setting (see Section 6-1). Set Amperage control at max for generator power.

 

 

 

Check receptacle wiring and connections.

 

 

 

Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

 

 

 

Have Factory Authorized Service Agent check stator windings.

 

 

High output at generator power ac

Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

receptacles.

 

 

 

Low output at generator power ac

Check Amperage control setting (see Section 6-1). Set Amperage control at max for generator power.

receptacles.

 

 

 

 

Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

 

 

OM-4418 Page 26

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Contents OM-4418 ProcessesDescription From Hobart to You Table of Contents Page Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can cause severe burnsARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosionEngine Hazards Compressed Air HazardsFire or Explosion hazard Welding Wire can cause injuryHOT Parts can cause burns and injury Falling Unit can cause injuryEMF Information Principal Safety StandardsCalifornia Proposition 65 Warnings Radiation can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation Doivent être confiés qu’à des personnes qualifiéesDES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peuvent être dangereuxLE Soudage peut provoquer un in cendie ou une explosion LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peuDES Organes Mobiles peuvent pro voquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion LES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endom- mager le moteur électriqueDES Organes Mobiles peuvent provoquer des blessures ’EMPLOI Excessif peutProposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF Weld, Power, And Engine Specifications − SpecificationsSymbol Definitions − DefinitionsFuel Consumption Dimensions, Weights, And Operating AnglesAux Power Gal./Hr Weld Power In KW Weld Amps At Rated Duty CycleAC Power Amperes Generator Power CurvePower Duty CycleVolt-Ampere Curves Volts Max Amp Min AmpAC Amps Movement − InstallationInstalling Welding Generator LocationGrounding Generator When Supplying Building Systems Engine Prestart ChecksOil Connecting To Weld Output Terminals Weld cable terminal and copper bar Correct InstallationTools Needed 150 ft 200 ft 250 ft Connecting to weldSelecting Weld Cable Sizes 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 mMaterial Thickness Reference Chart − Operating the Welding Generator Controls See SectionAmperage Selection Table For Stick Smaw Electrodes To Stop turn engine switch to OffDescription Of Controls See Section To StartUse GFCI-protected extension cord Generator Power Panel Receptacles− Operating Auxiliary Equipment X 15 a + 240 V x 9 a = 4 kVA/KW OM-4418− Maintenance Routine MaintenanceServicing Air Cleaner Stop engineGenerator Power − TroubleshootingTroubleshooting WeldingWith proper viscosity oil for operating temperature EngineStarting difficult − Electrical Diagrams Circuit Diagram For Welding Generator− Generator Power Guidelines Selecting EquipmentGrounding Generator To Truck Or Trailer Frame Grounding When Supplying Building Systems How Much Power Does Equipment Require?Industrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Current Load Watts Amperes Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Cord Lengths for 240 Volt LoadsStick Welding Procedure − Stick Welding Smaw GuidelinesElectrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique Positioning Electrode Holder Poor Weld Bead CharacteristicsGood Weld Bead Characteristics 10-30 9090 End View of Work AngleConditions That Affect Weld Bead Shape Electrode Movement During WeldingTee Joint Butt JointsLap Joint 16 in 1.6 mm Tack WeldsWeld Test Troubleshooting − PorosityTroubleshooting − Excessive Spatter Possible Causes Corrective ActionsTroubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Work like a Pro − Parts List Main AssemblySR1 Service SupportAssistance Contact your Distributor for Hobart Welding Products

210 597J, OM-4418 specifications

The Hobart Welding Products OM-4418,210 597J is a premium multi-process welder designed to meet the diverse needs of both professional and hobbyist welders. Renowned for its reliability and ease of use, this machine embodies the essence of Hobart's commitment to quality and performance in the welding industry.

One of the standout features of the OM-4418,210 597J is its versatility. This unit supports MIG, TIG, and Stick welding processes, allowing users to seamlessly switch between methods depending on the task at hand. The machine is equipped with a powerful inverter technology that enhances its efficiency and power output while reducing energy consumption. This means you can achieve high-quality welds with less impact on your electricity bill.

Another notable characteristic is its user-friendly interface. The welder features an intuitive control panel that allows for easy adjustments, enabling users to set the voltage and wire feed speed with precision. The digital display provides clear readouts of the current settings, making it easier for welders to monitor their work and make adjustments on the fly.

Safety is a critical concern in welding, and the OM-4418,210 597J incorporates several safety features to protect the operator. It is designed with built-in thermal overload protection, which prevents the machine from overheating during extended use. Additionally, the welder is equipped with a robust and durable housing that can withstand the rigors of a workshop environment.

The portability of the OM-4418,210 597J is another advantage, as it is lightweight and comes with a comfortable carrying handle. This enables users to transport it easily to job sites or move it around the workshop without strain. The unit is also compatible with standard household power outlets, adding to its convenience for both home and professional use.

In terms of build quality, the Hobart OM-4418,210 597J is designed to deliver consistent performance. It supports a wide range of welding materials, including steel, stainless steel, and aluminum, giving users the flexibility to tackle various projects. With a duty cycle that meets the demanding requirements of industrial applications, this welder ensures minimal downtime in production.

Overall, the Hobart Welding Products OM-4418,210 597J stands out as an exceptional choice for welders seeking a reliable, versatile, and user-friendly multi-process welding machine. With its advanced technologies and robust features, it promises to deliver excellent performance and lasting results across a wide range of welding applications.
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