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Hobart Welding Products 4500 manual Owner’s Record, Resources Available, Protect Your Investment

Models: 4500

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Owner’s Record

Owner’s Record

Please complete and retain with your personal records.

Model Name	Serial/Style Number

Purchase Date	(Date which equipment was delivered to original customer.)

Distributor

Address

City

State	Zip

Resources Available

Always provide Model Name and Serial/Style Number.

Protect Your Investment!

Register your product at:

HobartWelders.com

To locate a Distributor, retail or service location:

Call 1-877-Hobart1 or visit our website at www.HobartWelders.com

For technical assistance:

Call 1-800-332-3281

Contact your Distributor for:

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

Welding Process Handbooks

Hobart Welding Products

An Illinois Tool Works Company

600 West Main Street

Troy, OH 45373 USA

For Technical Assistance:

Call1-800-332-3281

For Literature Or Nearest Dealer: Call 1-877-Hobart1

Contact the Delivering Carrier to:	File a claim for loss or damage during
	shipment.
	For assistance in filing or settling claims, contact
	your distributor and/or equipment manufacturer’s
	Transportation Department.
PRINTED IN USA	♥ 2008 Hobart Welding Products. 2008−01

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Hobart Welding Products 4500 Owner’s Record, Resources Available, Please complete and retain with your personal records

Contents

OM-4418210 597K ChampionRENGLISH ESPAÑOL ProcessesFrom Hobart to You WARRANTY TABLE OF CONTENTSSECTION 8 − MAINTENANCE SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATIONPage SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1-1. Symbol Usage1-2. Arc Welding Hazards ELECTRIC SHOCK can killARC RAYS can burn eyes and skin FUMES AND GASES can be hazardousBUILDUP OF GAS can injure or kill WELDING can cause fire or explosionBATTERY EXPLOSION can BLIND 1-3. Engine Hazards1-4. Compressed Air Hazards Using a generator indoors CAN KILL YOU IN MINUTESHOT PARTS can cause burns and injury 1-5. Additional Symbols For Installation, Operation, And MaintenanceWELDING WIRE can cause injury READ INSTRUCTIONS1-8. EMF Information 1-7. Principal Safety Standards1-6. California Proposition 65 Warnings H.F. RADIATION can cause interference2-2. Dangers relatifs au soudage à l’arc 2-1. Signification des symbolesSECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION UN CHOC ÉLECTRIQUE peut tuerLE SOUDAGE peut provoquer un incendie ou une explosion DES PIÈCES CHAUDES peuvent provoquer des brûlures gravesLES FUMÉES ET LES GAZ peu- vent être dangereux LE BRUIT peut affecter l’ouïeSi des BOUTEILLES sont endomma- gées, elles pourront exploser 2-3. Dangers existant en relation avec le moteurLES CHAMPS MAGNETIQUES peuvent affecter des implants médicaux L’EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLELES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie 2-4. Dangers liés à l’air compriméLA CHALEUR DU MOTEUR peut pro- voquer un incendie L’AIR COMPRIMÉ peut provoquer des blessuresDES ORGANES MOBILES peuvent provoquer des blessures LE SURCHAUFFEMENT peut endom- mager le moteur électriqueLES ÉTINCELLES VOLANTES ris- quent de provoquer des blessures LES FILS DE SOUDAGE peuvent provoquer des blessures2-8. Information EMF 2-6. Proposition californienne 65 Avertissements2-7. Principales normes de sécurité Pour les moteurs à essence4-1. Weld, Power, And Engine Specifications SECTION 4 − SPECIFICATIONS3-1. Symbol Definitions SECTION 3 − DEFINITIONSDo not move or operate unit where it could tip 4-2. Dimensions, Weights, And Operating Angles4-3. Fuel Consumption Aux PowerAC Power Amperes 4-5. Generator Power CurveAC Power Volts 4-4. Duty CycleVolts Work like a Pro4-6. Volt-Ampere Curves Max Amp5-2. Rating Label Location SECTION 5 − INSTALLATION5-1. Installing Welding Generator Evidence of label tampering voids warrantyAlso see AWS Safety 5-4. Grounding Generator When Supplying Building Systems5-3. Grounding Generator To Truck Or Trailer Frame Always groundClose fuel valve before moving 5-5. Engine Prestart ChecksAlways close fuel valve after unit or carburetor may flood and make starting difficultFailure to properly connect 5-6. Connecting To Weld Output Terminalsnal and copper bar are clean weld cables may cause exSelecting Weld Cable Sizes Work like a Pro14 Gauge .078 in 1/8 in .125 in 3/16 in .188 in 1/4 in .25 in MATERIAL THICKNESS REFERENCE CHART 24 Gauge .025 in 22 Gauge .031 in20 Gauge .037 in 18 Gauge .050 in 16 Gauge .063 in 5/16 in .313 in 3/8 in .375 in 1/2 in .5 inSECTION 6 − OPERATING THE WELDING GENERATOR Controls See Section803 468-D / 803 469-D / 226 This unit has a low oil level shutdown to 6-2. Description Of Controls See Section6-3. Amperage Selection Table For Stick SMAW Electrodes Always close fuel valve after stoppingGenerator power decreases as weld current increases 7-1. Generator Power Panel ReceptaclesSECTION 7 − OPERATING AUXILIARY EQUIPMENT Set Amperage control at max. for full generator powerfor important start-up, service, and storage SECTION 8 − MAINTENANCE8-1. Routine Maintenance information. Service engine more often if8-2. Servicing Air Cleaner Stop engineB. Generator Power SECTION 9 − TROUBLESHOOTING9-1. Troubleshooting A. WeldingRemedy C. EngineTrouble TroubleSECTION 10 − ELECTRICAL DIAGRAMS Figure 10-1. Circuit Diagram For Welding Generator226 004-A 11-2. Grounding Generator To Truck Or Trailer Frame SECTION 11 − GENERATOR POWER GUIDELINES11-1. Selecting Equipment Be sure equipment has double insulated symbol and/or word- ing on itUse ground device as stated in electrical codes 11-3. Grounding When Supplying Building Systems11-4. How Much Power Does Equipment Require? Amperes x Volts = WattsIndustrial Motors 11-5. Approximate Power Requirements For Industrial Motors11-6. Approximate Power Requirements For Farm/Home Equipment RatingRating 11-7. Approximate Power Requirements For Contractor EquipmentContractor Starting WattsSingle-Phase Induction Motor Starting Requirements 11-8. Power Required To Start Motor11-9. How Much Power Can Generator Supply? Motor Start11-10. Typical Connections To Supply Standby Power Customer-supplied equipmentMaximum Allowable Cord Length in ft m for Conductor Size AWG 11-11. Selecting Extension Cord Use Shortest Cord PossibleCord Lengths for 120 Volt Loads Current12-1. Stick Welding Procedure SECTION 12 − STICK WELDING SMAW GUIDELINES12-4. Striking an Arc − Tapping Technique 12-2. Electrode and Amperage Selection Chart12-3. Striking an Arc − Scratch Start Technique workpiece, use a quick twist to free it12-5. Positioning Electrode Holder 12-6. Poor Weld Bead Characteristics12-7. Good Weld Bead Characteristics S-006012-8. Conditions That Affect Weld Bead Shape 12-9. Electrode Movement During WeldingSlow 12-12. Tee Joint 12-10. Butt Joints12-11. Lap Joint S-066212-13. Weld Test 12-14. Troubleshooting − Porosity12-15. Troubleshooting − Excessive Spatter Possible Causes12-18. Troubleshooting − Excessive Penetration 12-16. Troubleshooting − Incomplete Fusion12-17. Troubleshooting − Lack Of Penetration Possible Causes12-21. Troubleshooting − Distortion 12-19. Troubleshooting − Burn-Through12-20. Troubleshooting − Waviness Of Bead Possible CausesWork like a Pro OM-4418 PageSECTION 13 − PARTS LIST Figure 13-1. Main Assembly803 470-E Figure 13-1. Main Assembly MkgsStart Your Professional Welding Career Now Over 80,000 trained since400 Trade Square East, Troy, Ohio Effective January 1 Warranty Questions?Service CallTo locate a Distributor, retail or service location Owner’s RecordResources Available Please complete and retain with your personal records