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

SECTION 8 – TROUBLESHOOTING

8-1. 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, integrated rectifier
	SR1, and integrated rectifier SR2.
No weld output; generator power out-	Check Amperage control setting.
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.
	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, integrated rectifier
	SR1, and integrated rectifier SR2.
High weld output.	Check Amperage control setting.
Erratic weld output.	Check Amperage control setting.
	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, integrated rectifier
	SR1, and integrated rectifier SR2.
No output at generator power ac re-	Reset circuit breaker (see Section 6-1).
ceptacles; weld output okay.
	Check Current control setting. Set Current 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 Current control setting. Set Current control at max for generator power.
receptacles.
	Have Factory Authorized Service Agent check engine speed, and adjust if necessary.

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