Troubleshooting − Burn-Through | Hobart Welding Products 4500

12-19. Troubleshooting − Burn-Through

Burn-Through − weld metal melting completely through base metal resulting in holes where no metal remains.

Possible Causes	Corrective Actions

Excessive heat input.	Select lower amperage. Use smaller electrode.

	Increase and/or maintain steady travel speed.

12-20. Troubleshooting − Waviness Of Bead

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

Possible Causes	Corrective Actions

Unsteady hand.	Use two hands. Practice technique.

12-21. Troubleshooting − Distortion

			Distortion − contraction of weld met-
			al during welding that forces base
			metal to move.
		Base metal moves
		Base metal moves
		in the direction of
		in the direction of
		the weld bead.

Possible Causes			Corrective Actions

Excessive heat input.			Use restraint (clamp) to hold base metal in position.

			Make tack welds along joint before starting welding operation.

			Select lower amperage for electrode.

			Increase travel speed.

			Weld in small segments and allow cooling between welds.

OM-4418 Page 44

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Hobart Welding Products 4500 manual Troubleshooting − Burn-Through, Troubleshooting − Waviness Of Bead

Contents

OM-4418210 597K ProcessesDescription From Hobart to You Table of Contents Page Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can cause severe burns Fumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosion Engine Hazards Compressed Air Hazards Welding Wire can cause injury HOT Parts can cause burns and injuryFire or Explosion hazard Falling Unit can cause injury Principal Safety Standards California Proposition 65 WarningsEMF Information Radiation can cause interference Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer DES Pièces Chaudes peuvent provoquer des brûlures graves LES Fumées ET LES GAZ peu- vent être dangereuxLE Soudage peut provoquer un incendie ou une explosion LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peut Rendre Aveugle DES Organes Mobiles peuvent provoquer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie ’AIR Comprimé peut provoquer des blessuresRisque D’INCENDIE OU D’EXPLO- Sion LE Surchauffement peut endom- mager le moteur électrique LES Fils DE Soudage peuvent provoquer des blessures’EMPLOI Excessif peut UNE Remorque QUI Bascule peut entraîner des blessures Proposition californienne 65 Avertissements Principales normes de sécuritéInformation EMF En ce qui concerne les implants médicaux − Specifications Symbol DefinitionsWeld, Power, And Engine Specifications − Definitions Dimensions, Weights, And Operating Angles Aux Power Gal./Hr Weld Power In KWFuel Consumption Weld Amps At Rated Duty Cycle Generator Power Curve AC Power VoltsAC Power Amperes Duty Cycle Volt-Ampere Curves Volts Max Amp Min AmpAC Amps − Installation Installing Welding GeneratorRating Label Location Movement Grounding Generator When Supplying Building Systems Grounding Generator To Truck Or Trailer Frame Engine Prestart Checks 13 mm Full Gasoline Open/On Closed/OffOil Connecting To Weld Output Terminals Connecting to weld Selecting Weld Cable Sizes150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Material Thickness Reference Chart − Operating the Welding Generator Controls See Section To Stop turn engine switch to Off Description Of Controls See SectionAmperage Selection Table For Stick Smaw Electrodes Generator Power Panel Receptacles − Operating Auxiliary EquipmentUse GFCI-protected extension cord X 15 a + 240 V x 9 a = 4 kVA/KW OM-4418 − Maintenance Routine Maintenance Servicing Air Cleaner Stop engine − Troubleshooting TroubleshootingGenerator Power Welding With proper viscosity oil for operating temperature EngineStarting difficult − Electrical Diagrams Circuit Diagram For Welding Generator − Generator Power Guidelines Selecting Equipment Grounding When Supplying Building Systems How Much Power Does Equipment Require?Use #10 AWG or larger insulated Resistive Load Volts 115 Amps Approximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Power Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting Amperage Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Stick Welding Procedure − Stick Welding Smaw Guidelines Electrode and Amperage Selection Chart Striking an Arc − Scratch Start TechniqueStriking an Arc − Tapping Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder 10-30 9090 End View of Work Angle Conditions That Affect Weld Bead Shape Electrode Movement During Welding Butt Joints Lap JointTee Joint 16 in 30 1.6 mm Tack Welds Troubleshooting − Porosity Troubleshooting − Excessive SpatterWeld Test Possible Causes Corrective Actions Troubleshooting − Incomplete Fusion Troubleshooting − Lack Of PenetrationTroubleshooting − Excessive Penetration Troubleshooting − Burn-Through Troubleshooting − Waviness Of BeadTroubleshooting − Distortion Work like a Pro − Parts List Main Assembly SR1 Start Your Professional Welding Career Now Service SupportAssistance Contact your Distributor for Hobart Welding Products