Hobart Welding Products 210 597J, OM-4418

OM-4418 Page 28

SECTION 10 − ELECTRICAL DIAGRAMS

226 004-A

Figure 10-1. Circuit Diagram For Welding Generator

Contents

Main Champion 4500 From Hobart to You TABLE OF CONTENTS Page SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1-1. Symbol Usage 1-2. Arc Welding Hazards ELECTRIC SHOCK can kill. SIGNIFICANT DC VOLTAGE exists in inverters after stop- ping engine. FUMES AND GASES can be hazardous. BUILDUP OF GAS can injure or kill. ARC RAYS can burn eyes and skin. WELDING can cause fire or explosion. NOISE can damage hearing. 1-3. Engine Hazards BATTERY EXPLOSION can BLIND. TRAPPED AIR PRESSURE AND WHIPPING BREATHING COMPRESSED AIR can FUEL can cause fire or explosion. 1-5. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. FALLING UNIT can cause injury. OVERHEATING can damage motors. FLYING SPARKS can cause injury. 1-6. California Proposition 65 Warnings 1-7. Principal Safety Standards 1-8. EMF Information SECTION 2 CONSIGNES DE SCURIT LIRE AVANT UTILISATION 2-1. Signification des symboles 2-2. Dangers relatifs au soudage larc UN CHOC LECTRIQUE peut tuer. Une tension DC importante subsiste lintrieur des onduleurs aprs avoir coup lalimentation. DES PICES CHAUDES peuvent provoquer des brlures graves. in- et tre 2-3. Dangers existant en relation avec le moteur LEXPLOSION DE LA BATTERIE pe RENDRE AVEUGLE. LE CARBURANT MOTEUR peut prov quer un incendie ou une explosion. 2-4. Dangers lis lair comprim RESPIRER LAIR COMPRIM peut pro voquer des blessures graves ou cause la mort. LAIR COMPRIM peut provoque Page 2-6. Proposition californienne 65 Avertissements 2-7. Principales normes de scurit 2-8. Information EMF Des implants mdicaux : SECTION 3 DEFINITIONS h Hours s 3-1. Symbol Definitions SECTION 4 SPECIFICATIONS 4-1. Weld, Power, And Engine Specifications 4-2. Dimensions, Weights, And Operating Angles ! 4-3. Fuel Consumption 4-4. Duty Cycle 4-5. Generator Power Curve AC Power Volts AC Power Amperes Work like a Pro! SECTION 5 INSTALLATION 5-1. Installing Welding Generator ! ! 5-2. Grounding Generator When Supplying Building Systems ! 5 -3. Engine Prestart Checks 5-4. Connecting To Weld Output Terminals ! 5-5. Selecting Weld Cable Sizes* ! Work like a Pro! Pros weld and cut safely. Read the safety rules at the beginning of this manual. Page Page 6-2. Description Of Controls (See Section 6-1) 6-3. Amperage Selection Table For Stick (SMAW) Electrodes SECTION 7 OPERATING AUXILIARY EQUIPMENT 7-1. Generator Power Panel Receptacles ! SECTION 8 MAINTENANCE 8-1. Routine Maintenance ! 8-2. Servicing Air Cleaner ! SECTION 9 TROUBLESHOOTING 9-1. Troubleshooting A. Welding B. Generator Power C. Engine Page SECTION 11 GENERATOR POWER GUIDELINES 11-1. Selecting Equipment 1 1-2. Grounding Generator To Truck Or Trailer Frame 11-3. Grounding When Supplying Building Systems 11-4. How Much Power Does Equipment Require? 11-5. Approximate Power Requirements For Industrial Motors 11-6. Approximate Power Requirements For Farm/Home Equipment 11-7. Approximate Power Requirements For Contractor Equipment 11-8. Power Required To Start Motor 11-9. How Much Power Can Generator Supply? 11-10.Typical Connections To Supply Standby Power 11-11.Selecting Extension Cord (Use Shortest Cord Possible) SECTION 12 STICK WELDING (SMAW) GUIDELINES 12-1. Stick Welding Procedure OM-4418 Page 37 12-2. Electrode and Amperage Selection Chart 2 3 12-3. Striking an Arc Scratch Start Technique 1 2 3 12-5. Positioning Electrode Holder 12-6. Poor Weld Bead Characteristics 12-7. Good Weld Bead Characteristics 12-8. Conditions That Affect Weld Bead Shape 12-9. Electrode Movement During Welding 12-10.Butt Joints 12-11.Lap Joint 12-12.Tee Joint 12-13.Weld Test 12-14.Troubleshooting Porosity 12-15.Troubleshooting Excessive Spatter 12-16.Troubleshooting Incomplete Fusion 12-17.Troubleshooting Lack Of Penetration 12-18.Troubleshooting Excessive Penetration 12-19.Troubleshooting Burn-Through 12-20.Troubleshooting Waviness Of Bead 12-21.Troubleshooting Distortion Page SECTION 13 PARTS LIST Figure 13-1. Main Assembly Page Warranty Questions? Call 1-800-332-3281 7 AM 6 PM EST Effective January 1, 2007 * Original Main Power Rectifiers * Transformers * Stabilizers * Reactors Please complete and retain with your personal records. Resources Available Always provide Model Name and Serial/Style Number. Owners Record Protect Your Investment! Register your product at: HobartWelders.com