Hobart Champion 4500 Owner's Manual

Text of Hobart Champion 4500 User Guide:

• Hobart Champion 4500, 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 To Start:  Open fuel valve (see Section 4-4).  Turn engine switch to On.  Set choke.  Pull starter handle until engine starts. Open choke as engine warms.  This unit has a low oil level shutdown to prevent starting an engine that is too low on oil. The low oil level shutdown may not stop a running engine. Check oil level if th

• Hobart Champion 4500, 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. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 C1 176007 Capacitor, Elctlt 1200 Uf 300 Vdc Can 1.37 Dia 1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 177136 Clamp, Capacitor 1.

• Hobart Champion 4500, OM-4418 Page 29 10-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads  If unit does not have GFCI receptacles, use GFCI-protected extension cord. Maximum Allowable Cord Length in ft (m) for Conductor Size (AWG)* Current (Amperes) Load (Watts) 4 6 8 10 12 14 5 600 350 (106) 225 (68) 137 (42) 100 (30) 7 840 400 (122) 250 (76) 150 (46) 100 (30) 62 (19) 10 1200 400 (122) 275 (84) 175 (53) 112 (34) 62 (19) 50 (15) 15 1800 300 (91) 175 (53) 112 (34) 75 (23) 37 (11) 30 (9) 20 2400 225 (68) 137 (42) 87 (26) 50 (15) 30 (9) 25 3000 175 (53) 112 (34) 62 (19) 37 (11) 30 3600 150 (46) 87 (26) 50 (15

• OM-4418 Page 30 SECTION 11 – STICK WELDING (SMAW) GUIDELINES 11-1. Stick Welding Procedure stick 12/96 – ST-151 593  Weld current starts when electrode touches work- piece.  Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle. Place work clamp as close to the weld as possible. 1 Workpiece Make sure workpiece is clean be- fore

• Hobart Champion 4500, OM-4418 Page 17 SECTION 6 – OPERATING AUXILIARY 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 these conditions. NOTE 6-1. Generator Power Panel Receptacles  Use GFCI-protected extension cord.  Generator power decreases as weld current increases. Set Amperage control at max. for full generator power. 1 240 V 20 A AC Duplex Receptac

• Hobart Champion 4500, 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 Welding 7 Minutes Resting 30% Duty Cycle at 140 Amperes CC/AC

• Hobart Welders 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. To locate your nearest distributor or service agency call 1-877-Hobart1. Thank you and congratulations on choosing Hobart. Now you can get the job done an

• OM-4418 Page 33 11-8. 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 TRAVEL SPEED Slow Normal Fast 10° - 30° Drag Too Short Normal Too Long Spatter Angle Too Small Angle Too Large Correct Angle 11-9. Electrode Movement During Welding Normally

• Hobart Champion 4500, 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. * To be done by Factory Authorized Service Agent. Every 8 h Clean area around muffler. Check fluid levels. See Section 4-4. Wipe up spills. Every 25 h Service air cleaner precleaner. See Section 7-2. Every 50 h Clean and tig

• Hobart Champion 4500, OM-4418 Page 21 Trouble 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 Service Agent check engine speed, and adjust if necessary. C. Engine Trouble Remedy Engine will not start. Check fuel level (see Section 4-4). Move choke control to correct position (see Section 5-1). Open fuel valve (see Section 4-4).

• Hobart Champion 4500, OM-4418 Page 12 SECTION 4 – INSTALLATION 4-1. Installing Welding Generator install1 11/02 – / 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 all DOT and other applicable codes. 4-2. Grounding Generator To Truck Or Trailer Frame install1 11/02* – Ref. 151 556 / S-0854  Always ground generator

• Hobart Champion 4500, OM-4418 Page 23 SECTION 10 – GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. NOTE 10-1. Selecting Equipment gen_pwr 11/02 – Ref. ST-159 730 / ST-800 577 1 Generator Power Receptacles – Neutral Bonded To Frame 2 3-Prong Plug From Case Grounded Equipment 3 2-Prong Plug From Double Insulated Equipment  Do not use 2-prong plug un- less equipment is double in- sulated. OR 2 Be sure equipment has this symbol and/

• Hobart Champion 4500, OM-4418 Page 28 10-10. Typical Connections To 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- quired if generator will supply standby power during emergencies or power out- ages. 1 Utility Electrical Service 2 Transfer Switch (Double-Throw) Switch transfers the electrical load from electric utility service to t

• Hobart Champion 4500, OM-4418 Page 25 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts 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 2850 3 HP 15900 3900 5 HP 23300 6800 Capacitor Start-Capacitor Run 1-1/2 HP 8100 2000 5 HP 23300 6000 7-1/2 HP 35000 8000 10 HP 46700 10700 Fan Duty 1/8 HP 100

• Hobart Champion 4500, OM-4418 Page 38 SECTION 12 – PARTS 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

• Hobart Champion 4500, OM-4418 Page 6 LES ACCUMULATIONS DE GAZ ris- quent de provoquer des blessures ou même la mort.  Fermer l’alimentation du gaz protecteur en cas de non utilisation.  Veiller 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 génère des rayons visibles et invisibles intenses (ultraviolets et infrarouges) susceptibles de provoquer des brûlures dans les yeux et sur la peau. Des étincelles sont projetées pendant le soudage. LES RAYONS DE

• OM-4418 Page 3 MOVING PARTS 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.  To prevent accidental starting during servicing, discon

• OM-4418 Page 24 10-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding Terminal 2 Grounding Cable Use #10 AWG 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 Use ground device as stated in electrical codes. 2 3 10-4.

• Hobart Champion 4500, OM-4418 Page 32 11-5. Positioning Electrode Holder S-0060 90° 90° 10°-30° 45° 45° GROOVE WELDS FILLET WELDS End View of Work Angle Side View of Electrode Angle End View of Work Angle Side View of Electrode Angle 10°-30° 11-6. Poor Weld Bead Characteristics S-0053-A 1 Large Spatter Deposits 2 Rough, Uneven Bead 3 Slight Crater During Welding 4 Bad Overlap 5 Poor Penetration 5 4 2 3 1 11-7. Good Weld Bead Characteristics S-0052-B 1 Fine Spatter 2 Uniform Bead 3 Moderate Crater During Welding Weld a new bead or layer for each 1/8 in. (3.2 mm) thickness in metals being welded. 4 No Overlap 5 Go

• Hobart Champion 4500, OM-4418 Page 1 SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING rom _nd_10/02  Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols.  Marks a special safety message.  Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards.

• Hobart Champion 4500, OM-4418 Page 35 11-13. Weld Test S-0057-B 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 To 3 in 1/4 in 3 2 1 2 To 3 in 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 11-14. Troubleshooting – Porosity Porosity – small cavities or holes resulting from gas pockets in weld metal. Possible Causes Corrective Actions Arc length too long. Reduce arc length. Damp electrode. Use dry electrode. Workpiece dirty. Remove all grease, oil, moisture, rust, paint, coatings, slag, and dirt from work surface before welding. 11-15. Troubleshooting – Excessive Spatter Excessive Spatter – scatter

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