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Hobart Welding Products 4500 Connecting To Weld Output Terminals, Failure to properly connect

Models: 4500

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5-6. Connecting To Weld Output Terminals

AC Weld Output Terminals

Connect work and electrode cables

to weld terminals. (Polarity does not

matter for AC welding.)

Failure to properly connect

weld cables may cause ex-

cessive heat and start a fire,

or damage your machine.

Weld Output Terminal

Supplied Weld Output

Terminal Nut

Weld Cable Terminal

Copper Bar

Remove supplied nut from weld

output terminal. Slide weld cable

terminal onto weld output terminal

and secure with nut so that weld

cable terminal is tight against cop-

per bar. Do not place anything be-

tween weld cable terminal and

copper bar. Make sure that the

surfaces of the weld cable termi-

nal and copper bar are clean.

Tools Needed: 3/4 in

Do not place anything between weld cable terminal and copper bar.

Correct Installation

Incorrect Installation

803 469-D / 226 005 / 803 778-A

OM-4418 Page 19

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Hobart Welding Products 4500 Connecting To Weld Output Terminals, Failure to properly connect, weld cables may cause ex

Contents

Processes ChampionRENGLISH ESPAÑOL OM-4418210 597KFrom Hobart to You SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION TABLE OF CONTENTSSECTION 8 − MAINTENANCE WARRANTYPage ELECTRIC SHOCK can kill 1-1. Symbol Usage1-2. Arc Welding Hazards SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGWELDING can cause fire or explosion FUMES AND GASES can be hazardousBUILDUP OF GAS can injure or kill ARC RAYS can burn eyes and skinUsing a generator indoors CAN KILL YOU IN MINUTES 1-3. Engine Hazards1-4. Compressed Air Hazards BATTERY EXPLOSION can BLINDREAD INSTRUCTIONS 1-5. Additional Symbols For Installation, Operation, And MaintenanceWELDING WIRE can cause injury HOT PARTS can cause burns and injuryH.F. RADIATION can cause interference 1-7. Principal Safety Standards1-6. California Proposition 65 Warnings 1-8. EMF InformationUN CHOC ÉLECTRIQUE peut tuer 2-1. Signification des symbolesSECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION 2-2. Dangers relatifs au soudage à l’arcLE 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 explosionL’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE 2-3. Dangers existant en relation avec le moteurLES CHAMPS MAGNETIQUES peuvent affecter des implants médicaux Si des BOUTEILLES sont endomma- gées, elles pourront exploserL’AIR COMPRIMÉ peut provoquer des blessures 2-4. Dangers liés à l’air compriméLA CHALEUR DU MOTEUR peut pro- voquer un incendie LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendieLES FILS DE SOUDAGE peuvent provoquer des blessures LE SURCHAUFFEMENT peut endom- mager le moteur électriqueLES ÉTINCELLES VOLANTES ris- quent de provoquer des blessures DES ORGANES MOBILES peuvent provoquer des blessuresPour les moteurs à essence 2-6. Proposition californienne 65 Avertissements2-7. Principales normes de sécurité 2-8. Information EMFSECTION 3 − DEFINITIONS SECTION 4 − SPECIFICATIONS3-1. Symbol Definitions 4-1. Weld, Power, And Engine SpecificationsAux Power 4-2. Dimensions, Weights, And Operating Angles4-3. Fuel Consumption Do not move or operate unit where it could tip4-4. Duty Cycle 4-5. Generator Power CurveAC Power Volts AC Power AmperesMax Amp Work like a Pro4-6. Volt-Ampere Curves VoltsEvidence of label tampering voids warranty SECTION 5 − INSTALLATION5-1. Installing Welding Generator 5-2. Rating Label LocationAlways ground 5-4. Grounding Generator When Supplying Building Systems5-3. Grounding Generator To Truck Or Trailer Frame Also see AWS Safetyunit or carburetor may flood and make starting difficult 5-5. Engine Prestart ChecksAlways close fuel valve after Close fuel valve before movingweld cables may cause ex 5-6. Connecting To Weld Output Terminalsnal and copper bar are clean Failure to properly connectWork like a Pro Selecting Weld Cable Sizes5/16 in .313 in 3/8 in .375 in 1/2 in .5 in MATERIAL THICKNESS REFERENCE CHART 24 Gauge .025 in 22 Gauge .031 in20 Gauge .037 in 18 Gauge .050 in 16 Gauge .063 in 14 Gauge .078 in 1/8 in .125 in 3/16 in .188 in 1/4 in .25 in803 468-D / 803 469-D / 226 SECTION 6 − OPERATING THE WELDING GENERATORControls See Section Always close fuel valve after stopping 6-2. Description Of Controls See Section6-3. Amperage Selection Table For Stick SMAW Electrodes This unit has a low oil level shutdown toSet Amperage control at max. for full generator power 7-1. Generator Power Panel ReceptaclesSECTION 7 − OPERATING AUXILIARY EQUIPMENT Generator power decreases as weld current increasesinformation. Service engine more often if SECTION 8 − MAINTENANCE8-1. Routine Maintenance for important start-up, service, and storageStop engine 8-2. Servicing Air CleanerA. Welding SECTION 9 − TROUBLESHOOTING9-1. Troubleshooting B. Generator PowerTrouble C. EngineTrouble Remedy226 004-A SECTION 10 − ELECTRICAL DIAGRAMSFigure 10-1. Circuit Diagram For Welding Generator Be sure equipment has double insulated symbol and/or word- ing on it SECTION 11 − GENERATOR POWER GUIDELINES11-1. Selecting Equipment 11-2. Grounding Generator To Truck Or Trailer FrameAmperes x Volts = Watts 11-3. Grounding When Supplying Building Systems11-4. How Much Power Does Equipment Require? Use ground device as stated in electrical codesRating 11-5. Approximate Power Requirements For Industrial Motors11-6. Approximate Power Requirements For Farm/Home Equipment Industrial MotorsStarting Watts 11-7. Approximate Power Requirements For Contractor EquipmentContractor RatingMotor Start 11-8. Power Required To Start Motor11-9. How Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsCustomer-supplied equipment 11-10. Typical Connections To Supply Standby PowerCurrent 11-11. Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Maximum Allowable Cord Length in ft m for Conductor Size AWGSECTION 12 − STICK WELDING SMAW GUIDELINES 12-1. Stick Welding Procedureworkpiece, use a quick twist to free it 12-2. Electrode and Amperage Selection Chart12-3. Striking an Arc − Scratch Start Technique 12-4. Striking an Arc − Tapping TechniqueS-0060 12-6. Poor Weld Bead Characteristics12-7. Good Weld Bead Characteristics 12-5. Positioning Electrode HolderSlow 12-8. Conditions That Affect Weld Bead Shape12-9. Electrode Movement During Welding S-0662 12-10. Butt Joints12-11. Lap Joint 12-12. Tee JointPossible Causes 12-14. Troubleshooting − Porosity12-15. Troubleshooting − Excessive Spatter 12-13. Weld TestPossible Causes 12-16. Troubleshooting − Incomplete Fusion12-17. Troubleshooting − Lack Of Penetration 12-18. Troubleshooting − Excessive PenetrationPossible Causes 12-19. Troubleshooting − Burn-Through12-20. Troubleshooting − Waviness Of Bead 12-21. Troubleshooting − DistortionOM-4418 Page Work like a Pro803 470-E SECTION 13 − PARTS LISTFigure 13-1. Main Assembly Mkgs Figure 13-1. Main Assembly400 Trade Square East, Troy, Ohio Start Your Professional Welding Career NowOver 80,000 trained since Call Warranty Questions?Service Effective January 1Please complete and retain with your personal records Owner’s RecordResources Available To locate a Distributor, retail or service location