Hobart Champion 4500

OM-4418 Page 40

Notes

Work like a Pro!

Pros weld and cut

safely. Read the

safety rules at

the beginning

of this manual.

Contents

Main Champion 4500 From Hobart to You TABLE OF CONTENTS Page SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1-2. Arc Welding Hazards ELECTRIC SHOCK can kill. SIGNIFICANT DC VOLTAGE exists in inverters after stopping engine. FUMES AND GASES can be hazardous. 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. FUEL can cause fire or explosion. MOVING PARTS can cause injury. STEAM AND HOT COOLANT can burn. 1-4. Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death. COMPRESSED AIR can cause injury. TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury. HOT METAL from air arc cutting and gouging can cause fire or explosion. 1-6. Principal Safety Standards 1-7. EMF Information OM-4418 Page 5 SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION Avertissement: Protgez vous et les autres des blessures lisez et suivez ces prcautions. 1-1. Signification des symboles Identifie un message de scurit particulier. 1-2. Dangers relatifs au soudage larc 1-3. Engine Hazards LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou mme la mort. LACIDE DE LA BATTERIE peut pro- voquer des brlures dans les YEUX et sur la PEAU. OM-4418 Page 7 LEXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE. 1-4. Dangers lis lair comprim RESPIRER LAIR COMPRIM peut pro- voquer des blessures graves ou causer la mort. LAIR COMPRIM peut provoquer des blessures. LAIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo- quer des blessures. Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in- cendie ou une explosion. 1-6. Principales normes de scurit 1-7. Information sur les champs lectromagntiques SECTION 2 DEFINITIONS h Hours s 2-1. Symbol Definitions SECTION 3 SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications 3-2. Dimensions, Weights, And Operating Angles 3-3. Fuel Consumption 3-4. Duty Cycle Page SECTION 4 INSTALLATION 4-1. Installing Welding Generator 4-2. Grounding Generator To Truck Or Trailer Frame 4-3. Grounding Generator When Supplying Building Systems 4-4. Engine Prestart Checks 4-5. Connecting To Weld Output Terminals 4-6. Selecting Weld Cable Sizes* Page 5-2. Description Of Controls (See Section 5-1) 5-3. Amperage Selection Table For Stick (SMAW) Electrodes SECTION 6 OPERATING AUXILIARY EQUIPMENT 6-1. Generator Power Panel Receptacles SECTION 7 MAINTENANCE 7-1. Routine Maintenance Every 8 h Every 25 h Every 50 h 7-2. Servicing Air Cleaner SECTION 8 TROUBLESHOOTING 8-1. Troubleshooting A. Welding B. Generator Power C. Engine Page SECTION 10 GENERATOR POWER GUIDELINES 10-1. Selecting Equipment 10-2. Grounding Generator To Truck Or Trailer Frame 10-3. Grounding When Supplying Building Systems 10-4. How Much Power Does Equipment Require? 10-5. Approximate Power Requirements For Industrial Motors 10-6. Approximate Power Requirements For Farm/Home Equipment 10-7. Approximate Power Requirements For Contractor Equipment 10-8. Power Required To Start Motor 10-9. How Much Power Can Generator Supply? 10-10.Typical Connections To Supply Standby Power Notes Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. 10-11.Selecting Extension Cord (Use Shortest Cord Possible) SECTION 11 STICK WELDING (SMAW) GUIDELINES 11-1. Stick Welding Procedure OM-4418 Page 31 11-2. Electrode and Amperage Selection Chart 2 3 11-3. Striking an Arc Scratch Start Technique 1 2 3 11-5. Positioning Electrode Holder 11-6. Poor Weld Bead Characteristics 11-7. Good Weld Bead Characteristics 11-8. Conditions That Affect Weld Bead Shape 11-9. Electrode Movement During Welding 11-10.Butt Joints 11-11.Lap Joint 11-12.Tee Joint 11-13.Weld Test 11-14.Troubleshooting Porosity 11-15.Troubleshooting Excessive Spatter 11-16.Troubleshooting Incomplete Fusion 11-17.Troubleshooting Lack Of Penetration 11-18.Troubleshooting Excessive Penetration 11-19.Troubleshooting Burn-Through 11-20.Troubleshooting Waviness Of Bead 11-21.Troubleshooting Distortion SECTION 12 PARTS LIST Figure 12-1. Main Assembly Page Page Page Page Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. Effective January 1, 2002 (Equipment with a serial number preface of LC or newer) Please complete and retain with your personal records. Resources Available Always provide Model Name and Serial/Style Number. Owners Record