Hobart Champion 4500 User Manual

ProcessesDescriptionStick (SMAW) WeldingEngine Driven Welding GeneratorOM-4418 210 597AFebruary 2003Visit our website atwww.HobartWelders.comChampion

OM-4418 Page 6LES ACCUMULATIONS DE GAZ ris-quent de provoquer des blessures oumême la mort. Fermer l’alimentation du gaz protecteur en cas denon util

OM-4418 Page 7L’EXPLOSION DE LA BATTERIE peutRENDRE AVEUGLE. Toujours porter une protection faciale, des gants encaoutchouc et vêtements de protectio

OM-4418 Page 8LE SURCHAUFFEMENT peut endom-mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de dé-marrer ou d’arrêter le moteur.

OM-4418 Page 9SECTION 2 – DEFINITIONS2-1. Symbol DefinitionsEngine ChokeRead Operator’sManual AAmperesVVoltsEngine Oil Fuel Battery (Engine) EnginePos

OM-4418 Page 103-3. Fuel Consumption210 5933-4. Duty Cycle212 950Duty cycle is the percentage of 10minutes that unit can weld at ratedload without ove

OM-4418 Page 113-5. Generator Power Curve210 592The ac generator power curvesshow the generator power availablein amperes at the receptacles.3-6. Volt

OM-4418 Page 12SECTION 4 – INSTALLATION4-1. Installing Welding Generatorinstall1 11/02 – / Ref. 151 556 / 158 936-A / 803 467 / S-085418 in(460 mm)18

OM-4418 Page 134-3. Grounding Generator When Supplying Building SystemsGND/PE1 2Use ground device asstated in electrical codes.23800 576-B1 Equipment

OM-4418 Page 144-5. Connecting To Weld Output Terminals803 4691 AC Weld Output TerminalsConnect work and electrode cablesweld terminals. (Polarity doe

OM-4418 Page 15SECTION 5 – OPERATING THE WELDING GENERATOR5-1. Controls (See Section 5-2)803 468 / 803 469 / 210 58642314

Hobart Welders manufactures a full lineof welders and welding related equipment.For information on other quality Hobart products, contact your local H

OM-4418 Page 165-2. Description Of Controls (See Section 5-1)1 Engine SwitchUse switch to control ignition circuit, and tostop engine.2 Choke ControlU

OM-4418 Page 17SECTION 6 – OPERATING AUXILIARY EQUIPMENTThe welding generator provides power while welding and with the Current controlin any position

OM-4418 Page 18SECTION 7 – MAINTENANCEFollow the storage procedure in the engine owner’s manual if the unit will not beused for an extended period.NOT

OM-4418 Page 197-2. Servicing Air Cleaner aircleaner6 9/00 – 803 468 Stop engine. Do not run engine without aircleaner or with dirty element.1 Cove

OM-4418 Page 20SECTION 8 – TROUBLESHOOTING8-1. TroubleshootingA. WeldingTrouble RemedyNo weld output; no generator poweroutput at ac receptacles.Be su

OM-4418 Page 21Trouble RemedyErratic output at generator power acreceptacles.Check fuel level.Check Current control setting. Set Current control at ma

OM-4418 Page 22SECTION 9 – ELECTRICAL DIAGRAMS210 591-AFigure 9-1. Circuit Diagram For Welding Generator

OM-4418 Page 23SECTION 10 – GENERATOR POWER GUIDELINESThe views in this section are intended to be representative of all engine-drivenwelding generato

OM-4418 Page 2410-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #10 AWG or larger insulate

OM-4418 Page 2510-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 800 3

TABLE OF CONTENTSSECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING 1. . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1. . . .

OM-4418 Page 2610-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 3503/8

OM-4418 Page 2710-8. Power Required To Start MotorS-06241 Motor Start Code2 Running Amperage3 Motor HP4 Motor VoltageTo find starting amperage:Step 1:

OM-4418 Page 2810-10. Typical Connections To Supply Standby Power Have only qualified persons performthese connections according to allapplicable cod

OM-4418 Page 2910-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt Loads If unit does not have GFCI receptacles, u

OM-4418 Page 30SECTION 11 – STICK WELDING (SMAW) GUIDELINES11-1. Stick Welding Procedurestick 12/96 – ST-151 593 Weld current starts whenelectrode to

OM-4418 Page 3111-2. Electrode and Amperage Selection ChartRef. S-087 985-A3/321/85/323/167/321/41/165/643/321/85/323/167/321/43/321/85/323/167/321/43

OM-4418 Page 3211-5. Positioning Electrode HolderS-006090° 90°10°-30°45°45°GROOVE WELDSFILLET WELDSEnd View of Work Angle Side View of Electrode Angle

OM-4418 Page 3311-8. Conditions That Affect Weld Bead ShapeWeld bead shape is affected by electrode angle, arc length, travel speed, andthickness o

OM-4418 Page 3411-10. Butt JointsS-06621 Tack WeldsPrevent edges of joint from drawingtogether ahead of electrode by tackwelding the materials in posi

OM-4418 Page 3511-13. Weld TestS-0057-B1 Vise2 Weld Joint3 HammerStrike weld joint in direction shown.A good weld bends over but doesnot break.2 To 3

OM-4418 Page 3611-16. Troubleshooting – Incomplete FusionIncomplete Fusion – failure of weld metal to fuse completely withbase metal or a preceeding w

OM-4418 Page 3711-19. Troubleshooting – Burn-ThroughBurn-Through – weld metal melting completely through base metal resultingin holes where no metal r

OM-4418 Page 38SECTION 12 – PARTS LIST123456789101211131415161720181921222324252627282930313233353436373839 Hardware is common andnot available unles

OM-4418 Page 39DescriptionPartNo.Dia.Mkgs.ItemNo.Figure 12-1. Main AssemblyQuantity1 RC1 193257 Rcpt, Str Dx Grd 2p3w 15/20a 250v *6–20r 1. . . . .

OM-4418 Page 40NotesWork like a Pro!Pros weld and cutsafely. Read thesafety rules atthe beginningof this manual.

Warranty Questions?Call1-877-HOBART1for your localHobart distributor.hobart standard 6/02ServiceYou always get the fast,reliable response youneed. Mos

PRINTED IN USA  2003 Hobart Welding Products. 1/03Hobart Welding ProductsAn Illinois Tool Works Company600 West Main StreetTroy, OH 45373 USAFor Tech

OM-4418 Page 1SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USINGrom _nd_10/02 Warning: Protect yourself and others from injury — read and follow thes

OM-4418 Page 2BUILDUP OF GAS can injure or kill. Shut off shielding gas supply when not in use. Always ventilate confined spaces or useapproved air-

OM-4418 Page 3MOVING PARTS can cause injury. Keep away from fans, belts, and rotors. Keep all doors, panels, covers, and guardsclosed and securely i

OM-4418 Page 4FLYING SPARKS can cause injury. Wear a face shield to protect eyes and face. Shape tungsten electrode only on grinder withproper guard

OM-4418 Page 5SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANTUTILISATIONrom_10_02fre Avertissement: Protégez vous et les autres des blessures – lisez