Hobart Welding Products 4500 manual Troubleshooting, Welding, Generator Power, Trouble Remedy

Page 31

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 27

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Contents Processes OM-4418210 597KDescription From Hobart to You Table of Contents Page HOT Parts can cause severe burns Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinCompressed Air Hazards Engine HazardsFalling Unit can cause injury Welding Wire can cause injuryHOT Parts can cause burns and injury Fire or Explosion hazardRadiation can cause interference Principal Safety StandardsCalifornia Proposition 65 Warnings EMF Information− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer LE Bruit peut affecter l’ouïe DES Pièces Chaudes peuvent provoquer des brûlures gravesLES Fumées ET LES GAZ peu- vent être dangereux LE Soudage peut provoquer un incendie ou une explosionDES Organes Mobiles peuvent provoquer des blessures ’EXPLOSION DE LA Batterie peut Rendre Aveugle’AIR Comprimé peut provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieRisque D’INCENDIE OU D’EXPLO- Sion UNE Remorque QUI Bascule peut entraîner des blessures LE Surchauffement peut endom- mager le moteur électriqueLES Fils DE Soudage peuvent provoquer des blessures ’EMPLOI Excessif peutEn ce qui concerne les implants médicaux Proposition californienne 65 AvertissementsPrincipales normes de sécurité Information EMF− Definitions − SpecificationsSymbol Definitions Weld, Power, And Engine SpecificationsWeld Amps At Rated Duty Cycle Dimensions, Weights, And Operating AnglesAux Power Gal./Hr Weld Power In KW Fuel ConsumptionDuty Cycle Generator Power CurveAC Power Volts AC Power AmperesVolts Max Amp Min Amp Volt-Ampere CurvesAC Amps Movement − InstallationInstalling Welding Generator Rating Label LocationGrounding Generator To Truck Or Trailer Frame Grounding Generator When Supplying Building Systems13 mm Full Gasoline Open/On Closed/Off Engine Prestart ChecksOil Connecting To Weld Output Terminals 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Connecting to weldSelecting Weld Cable Sizes 150 ft 200 ft 250 ftMaterial Thickness Reference Chart Controls See Section − Operating the Welding GeneratorDescription Of Controls See Section To Stop turn engine switch to OffAmperage Selection Table For Stick Smaw Electrodes X 15 a + 240 V x 9 a = 4 kVA/KW OM-4418 Generator Power Panel Receptacles− Operating Auxiliary Equipment Use GFCI-protected extension cordRoutine Maintenance − MaintenanceStop engine Servicing Air CleanerWelding − TroubleshootingTroubleshooting Generator PowerEngine With proper viscosity oil for operating temperatureStarting difficult Circuit Diagram For Welding Generator − Electrical DiagramsSelecting Equipment − Generator Power GuidelinesResistive Load Volts 115 Amps Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use #10 AWG or larger insulatedFarm/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 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Stick Welding Smaw Guidelines Stick Welding ProcedureStriking an Arc − Scratch Start Technique Electrode and Amperage Selection ChartStriking 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 − Lack Of Penetration Troubleshooting − Incomplete FusionTroubleshooting − Excessive Penetration Troubleshooting − Waviness Of Bead Troubleshooting − Burn-ThroughTroubleshooting − Distortion Work like a Pro Main Assembly − Parts ListSR1 Start Your Professional Welding Career Now Support ServiceAssistance Hobart Welding Products Contact your Distributor for
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