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Hobart Welding Products 4500 manual

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Table of contents for the manual

  • Page 1

    ESP AÑOL Processes Description Stick (SMAW ) W elding Engine Driven Welding Generator OM-4418 210 597K 2008 − 03 Champion 4500  ENGLISH[...]

  • Page 2

    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 specification sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www .H[...]

  • Page 3

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

  • Page 4

    [...]

  • Page 5

    OM-4418 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2007 − 04 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury . The possible hazards are shown in the adjoining symbols or [...]

  • Page 6

    OM-4418 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous.  Keep your head out of the fumes. Do not breathe the fumes.  If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.  If ventilation is [...]

  • Page 7

    OM-4418 Page 3 1-3. Engine Hazards BA TTERY EXPLOSION can BLIND.  Always wear a face shield, rubber gloves, and protective clothing when working on a battery .  Stop engine before disconnecting or connect- ing battery cables or servicing battery .  Do not allow tools to cause sparks when working on a battery .  Do not use welder to char[...]

  • Page 8

    OM-4418 Page 4 HOT MET AL from air arc cutting and gouging can cause fire or explosion.  Do not cut or gouge near flammables.  W atch for fire; keep extinguisher nearby . HOT P ARTS can cause burns and injury .  Do not touch hot compressor or air system parts.  Let system cool down before touching or ser- vicing. READ INSTRUCTIONS.  [...]

  • Page 9

    OM-4418 Page 5 H. F . RADIA TION can cause interference.  High-frequency (H.F .) can interfere with radio navigation, safety services, computers, and communications equipment.  Have only qualified persons familiar with electronic equipment perform this installation.  The user is responsible for having a qualified electrician promptly corre[...]

  • Page 10

    OM-4418 Page 6 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION rom_2007 − 04fre Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite pas peut donner la mort ou des ble[...]

  • Page 11

    OM-4418 Page 7 DES PIÈCES CHAUDES peuvent provoquer des brûlures graves.  Ne pas toucher à mains nues les parties chau - des.  Prévoir une période de refroidissement avant d e travailler à l’équipement.  Ne pas toucher aux pièces chaudes, utiliser les outils recomman - dés et porter des gants de soudage et des vêtements épais [...]

  • Page 12

    OM-4418 Page 8 LES CHAMPS MAGNETIQUES peuvent affecter des implants médicaux.  Porteur de simulateur cardiaque ou autre im- plants médicaux, rester à distance.  Les porteurs d’implants doivent d’abord consulter leur médecin avant d e s’approcher des opérations de soudage à l’arc, de sou- dage par points, de gougeage, du coupage [...]

  • Page 13

    OM-4418 Page 9 L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES.  Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore.  JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.  Uniquement utiliser à l’EXT[...]

  • Page 14

    OM-4418 Page 10 LE SURCHAUFFEMENT peut endom- mager le moteur électrique.  Arrêter ou déconnecter l’équipement avant d e démarrer ou d’a rrêter le moteur .  Ne pas laisser tourner le moteur trop lentement sous risque d’en - dommager l e moteur électrique à cause d’une tension et d’une fré - quence trop faibles.  N e pas [...]

  • Page 15

    OM-4418 Page 1 1 2-6. P r oposition californienne 65 A vertissements Les équipements de soudage et de coupage produisent des fumées et des gaz qui contiennent des produits chimiques dont l’État de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers. (Code de santé et de sécurité de [...]

  • Page 16

    OM-4418 Page 12 SECTION 3 − DEFINITIONS 3-1. 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 Protector T emperature SECTION 4 − SPECIFICA TIONS 4-1. W eld, Power , And En[...]

  • Page 17

    OM-4418 Page 13 4-2. Dimensions, Weights, And Operating Angles Dimensions Height 20-3/4 in (527 mm) D Width 22-3/4 in (577 mm) Depth 31-1/4 in (793 mm) B ! Do not exceed tilt angles or engine could be damaged or unit could tip A 31-1/4 in (793 mm) B be damaged or unit could tip. ! Do not move or operate unit where it B 10-1/2 in (268 mm) ! D o no t[...]

  • Page 18

    OM-4418 Page 14 4-4. Duty Cycle 212 950 Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. 1 100% Duty Cycle This unit is rated for continuous welding at 90 amperes CC/AC. 2 30% Duty Cycle This unit is rated at 30% duty cycle (3 minutes welding, 7 minutes rest- ing) at 140 amperes CC/AC. NOTICE − Exce[...]

  • Page 19

    OM-4418 Page 15 4-6. V olt-Ampere Curves 226 078 The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator . Curves of al l other settings fall between the curves shown. 90 80 70 60 50 40 30 20 10 0 0 50 100 150 200 AC V olts AC Amps Max Amp Min Amp Notes W o r k l i k e a P r o ! Pros w[...]

  • Page 20

    OM-4418 Page 16 SECTION 5 − INST ALLA TION 5-1. Installing Welding Generator Ref install1 8/06 − Ref. 151 556 / 158 936-A / 803 467-C / 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[...]

  • Page 21

    OM-4418 Page 17 ! Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. ! Also see A WS Safety & Health Fact Sheet No. 29, Grounding of Portable And V ehicle Mounted W elding Generators. ! Bed liners, shipping skids, an d some running gear insu- late the welding generator from the vehicle fra[...]

  • Page 22

    OM-4418 Page 18 Open/On 1 Closed/Of f 5-5. Engine Prestart Checks 803 468-D Full Gasoline 1/2 in (13 mm) Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil level gets too low . 1 Fuel V alve Open valve.  Close fuel valve before moving unit or carburetor may flood and ma[...]

  • Page 23

    OM-4418 Page 19 5-6. Connecting T o Weld Output T erminals 803 469-D / 226 005 / 803 778-A 1 AC Weld Output T erminals 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. 2 Weld Output T erminal [...]

  • Page 24

    OM-4418 Page 20 5-7. Selecting Weld Cable Sizes* W eld Cable Size** and T otal Cable (Copper) Length in Weld Circuit Not Exceeding*** 100 ft (30 m) or Less 150 ft (45 m) 200 ft (60 m) 250 ft (70 m) 300 ft (90 m) 350 ft (105 m) 400 ft (120 m) W eld Output T erminals ! T urn off power before connecting to weld output terminals. ! Do not use worn, dam[...]

  • Page 25

    OM-4418 Page 21 Notes 16 Gauge (.063 in) 22 Gauge (.031 in) 24 Gauge (.025 in) 20 Gauge (.037 in) 18 Gauge (.050 in) 14 Gauge (.078 in) 1/8 in (.125 in) 3/16 in (.188 in) 1/4 in (.25 in) 5/16 in (.313 in) 3/8 in (.375 in) 1/2 in (.5 in) MA TERIAL THICKNESS REFERENCE CHART[...]

  • Page 26

    OM-4418 Page 22 SECTION 6 − OPERA TING THE WELDING GENERA TOR 6-1. Controls (See Section 6-2) 803 468-D / 803 469-D / 226 005 2 3 1 4[...]

  • Page 27

    OM-4418 Page 23 6-2. Description Of Controls (See Section 6-1) 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 (Choke) if starting a cold engine. Move control to left (Run) if starting a warm engine. 3 Starter Handle T o Start :  Open fue[...]

  • Page 28

    OM-4418 Page 24 SECTION 7 − OPERA TING AUXILIAR Y EQUIPMENT  Th e welding generator provides power while welding and with the Amperage control in any position. However , under these conditio ns equipment connected t o the welding generator may be subject to larger than normal voltage fluctuations. It is recommended that only lamps be powered u[...]

  • Page 29

    OM-4418 Page 25 SECTION 8 − MAINTENANCE 8-1. Routine Maintenance ! Stop engine before maintaining.  S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions. Recycle engine fluids.  = Check  = Change  = Clean  = Replace * T o be done by[...]

  • Page 30

    OM-4418 Page 26 8-2. Servicing Air Cleaner aircleaner6 10/02 − 803 468-D ! Stop engine. NOTICE − Do not run engine with- ou t air cleaner or with dirty element. 1. Cover 2. Precleaner Remove air cleaner cover . W ash precleaner with soap and water so- lution. Allow precleaner to air dry completely . Spread 1 tablespoon SAE 30 oil evenly into pr[...]

  • Page 31

    OM-4418 Page 27 SECTION 9 − TROUBLESHOOTING 9-1. 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 , and integrated rectifier SR1. No weld[...]

  • Page 32

    OM-4418 Page 28 T rouble Remedy Erratic output at generator power ac receptacles. Check fuel level. Check Amperage control setting. Set Amperage 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 Authoriz[...]

  • Page 33

    OM-4418 Page 29 SECTION 10 − ELECTRICAL DIAGRAMS 226 004-A Figure 10-1. Circuit Diagram For Welding Generator[...]

  • Page 34

    OM-4418 Page 30 SECTION 1 1 − GENERA T OR 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. 1 1-1. Selecting Equipment gen_pwr 2008 − 01 − ST-800 577 1 Generator Power Receptacles − Neutral Bonded T o Frame 2 3-Prong Plug From Cas[...]

  • Page 35

    OM-4418 Page 31 1 1-3. 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  Us e ground device as stated in electrical codes. ! Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring syste[...]

  • Page 36

    OM-4418 Page 32 1 1-5. 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 28[...]

  • Page 37

    OM-4418 Page 33 1 1-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts 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 [...]

  • Page 38

    OM-4418 Page 34 1 1-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 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 l[...]

  • Page 39

    OM-4418 Page 35 1 1-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices. ! Properly install and ground this [...]

  • Page 40

    OM-4418 Page 36 1 1-1 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) 7 840 [...]

  • Page 41

    OM-4418 Page 37 SECTION 12 − STICK WELDING (SMA W) GUIDELINES 12-1. Stick W elding Procedure stick 2007 − 04 − ST-151 593 1 W orkpiece Make sure workpiece is clean be- fore welding. 2 W ork Clamp 3 Electrode A small diameter electrode requires less current than a large one. Fol- low electrode manufacturer’ s instructions when setting weld a[...]

  • Page 42

    OM-4418 Page 38 12-2. 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 ELECTR[...]

  • Page 43

    OM-4418 Page 39 12-5. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° GROOVE WELDS FILLET WELDS End V iew of Work Angle Sid e V iew of Electrode Angle End V iew of Work Angle S ide V iew of Electrode Angle 10 ° -30 ° 12-6. Poor W eld Bead Characteristics S-0053-A 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crat[...]

  • Page 44

    OM-4418 Page 40 12-8. Conditions That Affect Weld Bead Shape  W eld bead shape is affected by electrode angle, arc length, travel speed, and thickness of base metal. 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 12-9. Electro[...]

  • Page 45

    OM-4418 Page 41 12-10. Butt Joints S-0662 1 T ack W elds Prevent edg 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 Weld 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 oxy-[...]

  • Page 46

    OM-4418 Page 42 12-13. 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) 12-14. T roubleshooting − Porosity Porosity − small cavities or holes resulting from gas pockets i n weld metal. Possi[...]

  • Page 47

    OM-4418 Page 43 12-16. 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 prop[...]

  • Page 48

    OM-4418 Page 44 12-19. 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. 12-20. T roubleshooting − W avine[...]

  • Page 49

    OM-4418 Page 45 Notes W o r k l i k e a P r o ! Pros wel d and cut safel y . R ead the safety rules at the beginning of this manual .[...]

  • Page 50

    OM-4418 Page 46 SECTION 13 − P ARTS LIST  Hardware is common and not available unless listed. 803 470-E 4 1 2 3 5 6 9 10 7 8 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Figure 13-1. Main Assembly[...]

  • Page 51

    OM-4418 Page 47 Description Part No. Dia. Mkgs. Item No. Figure 13-1. Main Assembly Quantity 1 RC2 141432 Rcpt, Str Dx Grd 2p3w 20a 125v *5 − 20r 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 RC1 224596 Rcpt, Str Dx Grd 2p3w 20a 250v *6 − 20r 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .[...]

  • Page 52

    OM-4418 Page 48 Notes 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.welding.org Over 80,000 trained since 1930! Start Y our Professional W elding Car eer Now![...]

  • Page 53

    Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST hobart_warr 2008-01 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 distributor and Hobart i[...]

  • Page 54

    PRINTED IN USA © 2008 Hobart Welding Products. 2008 − 01 Hoba rt We lding Product s An Illinois T ool W or ks Compa ny 600 W est Main Street Tr oy , OH 45373 USA For T ech nical Assistan ce: Call1-800-332-3281 Fo r Liter a tur e Or Nea rest Dea ler : Call 1-877-Hobart1 Model Name Serial/Style Number Purchase Date (Date which equipment was delive[...]