Instruction/ maintenance manual of the product OM-4418 Hobart Welding Products
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ESP AÑOL Processes Description Stick (SMAW ) W elding Engine Driven Welding Generator OM-4418 210 597J 2007−05 Champion 4500 ENGLISH.
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 .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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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 .
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.
OM-4418 Page 3 1-3. Engine Hazards BA TTER Y 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 .
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.
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.
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.
OM-4418 Page 7 Une tension DC importante subsiste à l’intérieur des onduleurs après avoir coupé l’alimentation. Couper l’alimentation du poste et décharger les condensateurs d’entrée comme indiqué dans la Section Maintenance avant de toucher des composants.
OM-4418 Page 8 Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et N FP A 51B pour les travaux à chaud et avoir de la surveillance et un extincteur à proximité. LE BRUIT peut affecter l’ouïe. Le bruit des processus et des équipements peut af f ec l’ouïe.
OM-4418 Page 9 Dévisser le bouchon légèrement et laisser la vapeur s’échapper avant d’enlever le bouchon. 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.
OM-4418 Page 10 LE SURCHAUFFEMENT peut endom - mager le moteur électrique. Arrêter ou déconnecter l’équipement avant de démarrer ou d’arrêter le moteur . Ne pas laisser tourner le moteur trop lentement sous risque d’e n- dommager l e moteur électrique à cause d’une tension et d’une fr é- quence trop faibles.
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 ’ É tat de Californie reconnaît qu’ils provoquent des mal- formations congénitales et, dans certains cas, des cancers.
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.
OM-4418 Page 13 4-2. Dimensions, W eights, And Operating Angles Dimensions Height 20-3/4 in (527 mm) D Width 22-3/4 in (577 mm) D 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.
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. NOTICE − Exceeding duty cycle ca n 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 CC/AC 4-5.
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 o f th e welding generator .
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 (4.
OM-4418 Page 17 5-2. Grounding Generator When Supplying Building Systems GND/PE 1 2 2 3 800 576-B ! Ground generator to sys- tem earth ground if supply- ing power to a premises (home, shop, farm) wiring system. 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire.
OM-4418 Page 18 5-4. 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 cable s to weld terminals. (Polarity does no t matter for AC welding.) ! Failure to properly connec t weld cables may cause ex - cessive heat and start a fire , or damage your machine.
OM-4418 Page 19 5-5. 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.
OM-4418 Page 20 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 (.
OM-4418 Page 21 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.
OM-4418 Page 22 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.
OM-4418 Page 23 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.
OM-4418 Page 24 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.
OM-4418 Page 25 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.
OM-4418 Page 26 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.
OM-4418 Page 27 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.
OM-4418 Page 28 SECTION 10 − ELECTRICAL DIAGRAMS 226 004-A Figure 10-1. Circuit Diagram For Welding Generator.
OM-4418 Page 29 SECTION 1 1 − 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. 1 1-1. Selecting Equipment gen_pwr 2007−04 − Ref.
OM-4418 Page 30 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 system.
OM-4418 Page 31 1 1-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting 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 21.
OM-4418 Page 32 1 1-7. 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.
OM-4418 Page 33 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 .
OM-4418 Page 34 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.
OM-4418 Page 35 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.
OM-4418 Page 36 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.
OM-4418 Page 37 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 .
OM-4418 Page 38 12-5. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° GROOVE WELDS FILLET WELDS End View of W ork Angle Side V iew of Electrode Angle End View of W ork Angle Side V iew of Electrode Angle 10 ° -30 ° 12-6.
OM-4418 Page 39 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 S mall Angle T oo Large Correc t Angle 12-9.
OM-4418 Page 40 12-10. Butt Joints S-0662 1 T ack W elds Prevent edges of joint 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.
OM-4418 Page 41 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.
OM-4418 Page 42 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.
OM-4418 Page 43 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.
OM-4418 Page 44 Notes W o r k l i ke a P r o ! Pros wel d and cut safel y . R ead the safety rules at the beginning of this manual ..
OM-4418 Page 45 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.
OM-4418 Page 46 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 .
Warranty Questions? Call 1-800-332-3281 7 AM − 6 PM EST hobart_warr 2007−01 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.
PRINTED IN USA © 2007 Hobart Welding Products. 2007−01 Hoba rt We lding Product s An I l li noi s T ool Works Company 600 W es t Main St reet Troy , OH 45373 U SA For T echn i cal A ssistance: Call.
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If you have not bought Hobart Welding Products OM-4418 yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Hobart Welding Products OM-4418 - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Hobart Welding Products OM-4418 you will learn all the available features of the product, as well as information on its operation. The information that you get Hobart Welding Products OM-4418 will certainly help you make a decision on the purchase.
If you already are a holder of Hobart Welding Products OM-4418, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Hobart Welding Products OM-4418.
However, one of the most important roles played by the user manual is to help in solving problems with Hobart Welding Products OM-4418. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Hobart Welding Products OM-4418 along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
