Hobart Champion 4500 manual

Processes Description Stick (SMAW ) W elding Engine Driven Welding Generator OM-4418 210 597A February 2003 Visit our website at www.HobartWelders.com Champion 4500 [...]

Hobart W elders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual catalog sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1. Thank you and congratulations on ch[...]

T ABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Arc W elding Hazards 1 . . . . . . . . . . . . . . . . . . . . . . [...]

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OM-4418 Page 1 SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING rom _nd_10/02  W arning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means W arning! W atch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special sa[...]

OM-4418 Page 2 BUILDUP OF GAS can injure or kill.  Shut off shielding gas supply when not in use.  Always ventilate confined spaces or use approved air-supplied respirator . Arc rays from the w elding process produce intense visible and invisible (ultraviolet and infrared) rays that can burn eyes and skin. Sparks fly off from the weld. ARC RA[...]

OM-4418 Page 3 MOVING P ARTS can cause injury .  Keep away from fans, belts, and rotors.  Keep all doors, panels, covers, and guards closed and securely in place.  Stop engine before installing or connecting unit.  Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary .  T o prevent acc[...]

OM-4418 Page 4 FL YING SP ARKS can cause injury .  W ear a face shield to protect eyes and face.  Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.  Sparks can cause fires — keep flammables away . OVERUSE can cause OVERHEA TING.  Allow cooling period; follow [...]

OM-4418 Page 5 SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE A V ANT UTILISA TION rom_10_02fre  A vertissement: Protégez vous et les autres des blessures – lisez et suivez ces précautions. 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par[...]

OM-4418 Page 6 LES ACCUMULA TIONS DE GAZ ris- quent de provoquer des blessures ou même la mort.  Fermer l’alimentation du gaz protecteur en cas de non utilisation.  V eiller toujours à bien aérer les espaces confinés ou se servir d’un respi- rateur d’adduction d’air homologué. Le rayonnement de l’arc du procédé de soudage gé[...]

OM-4418 Page 7 L ’EXPLOSION DE L A B A TTERIE peut RENDRE A VEUGLE.  T oujours porter une protection faciale, des gants en caoutchouc et vêtements de protection lors d’une in- tervention sur la batterie.  Arrêter le moteur avant de débrancher ou de brancher les câbles de batterie.  Eviter de provoquer des étincelles avec les outil[...]

OM-4418 Page 8 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant de dé- marrer ou d’arrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence trop faibles.  Ne pas brancher [...]

OM-4418 Page 9 SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Engine Choke Read Operator’s Manual A Amperes V V olts Engine Oil Fuel Battery (Engine) Engine Positive Negative Alternating Current (AC) Output h Hours s Seconds T ime Protective Earth (Ground) Circuit Breaker T emperature SECTION 3 – SPECIFICA TIONS 3-1. W eld, Power , And Engin[...]

OM-4418 Page 10 3-3. Fuel Consumption 210 593 3-4. Duty Cycle 212 950 Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating.  Exceeding duty cycle can damage unit and void warranty . Continuous Welding 100% Duty Cycle at 90 Amperes CC/AC 3 Minutes W elding 7 Minutes Resting 30% Duty Cycle at 140 Amperes [...]

OM-4418 Page 1 1 3-5. Generator Power Curve 210 592 The ac generator power curves show the generator power available in amperes at the receptacles. 3-6. V olt-Ampere Curves 212 871 The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of all other settings fall between the c[...]

OM-4418 Page 12 SECTION 4 – INST ALLA TION 4-1. Installing Welding Generator install1 1 1/02 – / Ref. 151 556 / 158 936-A / 803 467 / S-0854 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) 18 in (460 mm) Movement Airflow Clearance Location  Always securely fasten welding generator onto transport vehicle or trailer and comply with[...]

OM-4418 Page 13 4-3. Grounding Generator When Supplying Building Systems GND/PE 1 2 Use ground device as stated in electrical codes. 2 3 800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device  Ground generator to sys- tem earth ground if supply- ing power to a premises (home, sho[...]

OM-4418 Page 14 4-5. Connecting T o Weld Output T erminals 803 469 1 AC Weld Output T erminals Connect work and electrode cables weld terminals. (Polarity does not matter for AC welding.) T ools Needed: 3/4 in 1 4-6. Selecting Weld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Les[...]

OM-4418 Page 15 SECTION 5 – OPERA TING THE WELDING GENERA TOR 5-1. Controls (See Section 5-2) 803 468 / 803 469 / 210 586 4 2 3 1 4[...]

OM-4418 Page 16 5-2. Description Of Controls (See Section 5-1) 1 Engine Switch Use switch to control ignition circuit, and to stop engine. 2 Choke Control Use control to change engine air/fuel mix. Move control to right if starting a cold engine. Move control to left if starting a warm engine. 3 Starter Handle T o Start :  Open fuel valve (see S[...]

OM-4418 Page 17 SECTION 6 – OPERA TING AUXILIAR Y EQUIPMENT The welding generator provides power while welding and with the Current control in any position. However , under these conditions equipment connected to the welding generator may be subject to larger than normal voltage fluctuations. It is recommended that only lamps be powered under the[...]

OM-4418 Page 18 SECTION 7 – MAINTENANCE Follow the storage procedure in the engine owner ’ s manual if the unit will not be used for an extended period. NOTE 7-1. Routine Maintenance Recycle engine fluids.  Stop engine before maintaining.  See Engine Manual and Maintenance Label. Service more often if used in severe conditions. * T o be d[...]

OM-4418 Page 19 7-2. Servicing Air Cleaner aircleaner6 9/00 – 803 468  Stop engine.  Do not run engine without ai r cleaner or with dirty element. 1 Cover 2 Precleaner 3 Element Remove air cleaner cover . W ash precleaner with soap and water so- lution. Allow precleaner to air dry completely .  Do not oil precleaner. Clean element by gen[...]

OM-4418 Page 20 SECTION 8 – TROUBLESHOOTING 8-1. T roubleshooting A. Welding T rouble Remedy No weld output; no generator power output at ac receptacles. Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, rotor , stator , integrated rectifier SR1, and integra[...]

OM-4418 Page 21 T rouble Remedy Erratic output at generator power ac receptacles. Check fuel level. Check Current control setting. Set Current control at max for generator power . Check receptacle wiring and connections. Check governor linkage for smooth, non-binding operation. Service air cleaner according to engine manual. Have Factory Authorized[...]

OM-4418 Page 22 SECTION 9 – ELECTRICAL DIAGRAMS 210 591-A Figure 9-1. Circuit Diagram For Welding Generator[...]

OM-4418 Page 23 SECTION 10 – GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Y our unit may differ from those shown. NOTE 10-1. Selecting Equipment gen_pwr 1 1/02 – Ref. ST-159 730 / ST -800 577 1 Generator Power Receptacles – Neutral Bonded T o Frame 2 3-Prong P[...]

OM-4418 Page 24 10-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire. 3 Ground Device  Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. GND/PE 1 2 Us e ground device as stated in electri[...]

OM-4418 Page 25 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Startin g W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 1400 1 HP 6100 1600 1-1/2 HP 8200 2200 2 HP 10550 285[...]

OM-4418 Page 26 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 T able Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1 100 Bench Grinder 6 in 1720 720 8 in [...]

OM-4418 Page 27 10-8. Power Required T o Start Motor S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP . If code is not listed, multiply running amperage by six to find starting amperage. Step 2 : Find Motor HP and V olts. Step 3: Determine starting a[...]

OM-4418 Page 28 10-10. T ypical Connections T o Supply Standby Power  Have only qualified persons perform these connections according to all applicable codes and safety practic- es.  Properly install and ground this equipment according to its Owner ’ s Manual and national, state, and local codes.  Customer -supplied equipment is re- quir[...]

OM-4418 Page 29 10-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (A WG)* Current (Amperes) Load (W atts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 8[...]

OM-4418 Page 30 SECTION 1 1 – STICK WELDING (SMA W) GUIDELINES 1 1-1. Stick Welding Procedure stick 12/96 – ST-151 593  W eld current starts when electrode touches work- piece.  W eld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Pla c e w o r k c l a m p a s close t o the wel[...]

OM-4418 Page 31 1 1-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 6010 & 601 1 6013 7014 7018 7024 Ni-Cl 308L 50 100 150 200 250 300 350 400 450 ELECT[...]

OM-4418 Page 32 1 1-5. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° GROOVE WELDS FILLET WELDS End V iew of W ork Angle Sid e V iew of Electrode Angle End V iew of W ork Angle S ide View of Electrode Angle 10 ° -30 ° 1 1-6. Poor Weld Bead Characteristics S-0053-A 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Cr[...]

OM-4418 Page 33 1 1-8. Conditions That Affect Weld Bead Shape Weld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. NOTE S-0061 ELECTRODE ANGLE ARC LENGTH TRA VEL SPEED Slow Normal Fast 10 ° - 30 ° Drag T oo Short Normal T oo Long Spatter Angle T oo Small Angle T oo Large Correct Angle 1 1-9. Elect[...]

OM-4418 Page 34 1 1-10. Butt Joints S-0662 1 T ack Welds Prevent e d g es o f j oint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. 2 Square Groove W eld Good for materials up to 3/16 in (5 mm) thick. 3 Single V -Groove Weld Good for materials 3/16 – 3/4 in (5-19 mm) thick. Cut bevel with o[...]

OM-4418 Page 35 1 1-13. W eld T est S-0057-B 1 V ise 2 W eld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 T o 3 in 1/4 in 3 2 1 2 T o 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 1 1-14. T roubleshooting – Porosity Porosity – small cavities or holes resulting from gas pockets i n weld metal. Pos[...]

OM-4418 Page 36 1 1-16. T roubleshooting – Incomplete Fusion Incomplete Fusion – failure of weld metal to fuse completely with base metal or a preceeding weld bead. Possible Causes Corrective Actions Insuf ficient heat input. Increase amperage. Select larger electrode and increase amperage. Improper welding technique. Place stringer bead in pro[...]

OM-4418 Page 37 1 1-19. T roubleshooting – 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. 1 1-20. T roubleshooting – W avi[...]

OM-4418 Page 38 SECTION 12 – P ARTS LIST 1 2 3 4 5 6 7 8 9 10 12 11 13 14 15 16 17 20 18 19 21 22 23 24 25 26 27 28 29 30 31 32 33 35 34 36 37 38 39  Hardware is common and not available unless listed. 803 470 Figure 12-1. Main Assembly[...]

OM-4418 Page 39 Description Part No. Dia. Mkgs. Item No. Figure 12-1. Main Assembly Quantity 1 RC1 193257 Rcpt, Str Dx Grd 2p3w 15/20a 250v *6–20r 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 RC2 141432 Rcpt, Str Dx Grd 2p3w 20a 125v *5–20r 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . [...]

OM-4418 Page 40 Notes W o r k l i ke a P r o! Pros wel d and cut safel y . Read the safety rules at the begi nning of thi s m anual.[...]

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Warranty Questions? Call 1-877-HOBART1 for your local Hobart distributor. hobart standard 6/02 Service Y o u always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise of the distrib[...]

PRINTED IN USA  2003 Hobart Welding Products. 1/03 Hoba rt We lding Produc ts An Illinois T ool W orks Compan y 600 W e s t Main Stree t Tr oy , OH 45373 USA For T echn ical Assistance: Call1-800-332-3281 Fo r Li te ratu re Or Nea rest Dea ler: Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to[...]