Hobart Welding Products Champion 4500 Owner'S Manual Download Page 23 | Manualshive

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OM-4418 Page 19

5-6. Connecting To Weld Output Terminals

803 469-D / 226 005 / 803 778-A

1

AC Weld Output Terminals

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 Terminal

3

Supplied Weld Output

Terminal Nut

4

Weld Cable Terminal

5

Copper Bar

Remove supplied nut from weld

output terminal. Slide weld cable

terminal onto weld output terminal

and secure with nut so that weld

cable terminal is tight against cop-

per bar.

Do not place anything be-

tween weld cable terminal and

copper bar. Make sure that the

surfaces of the weld cable termi-

nal and copper bar are clean.

Tools Needed:

3/4 in

1

5

3

4

Do not place

anything between

Correct Installation

Incorrect Installation

2

weld cable terminal

and copper bar.

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Summary of Contents for Champion 4500

Page 1: ...ESPAÑOL Processes Description Stick SMAW Welding Engine Driven Welding Generator OM 4418 210 597K 2008 03 Champion 4500 ENGLISH ...

Page 2: ...ducts Please take time to read the Safety precautions They will help you protect yourself against potential hazards on the worksite We ve made installation and operation quick and easy With Hobart you can count on years of reliable service with proper maintenance And if for some reason the unit needs repair there s a Troubleshooting section that will help you figure out what the problem is The par...

Page 3: ...SPECIFICATIONS 12 4 1 Weld Power And Engine Specifications 12 4 2 Dimensions Weights And Operating Angles 13 4 3 Fuel Consumption 13 4 4 Duty Cycle 14 4 5 Generator Power Curve 14 4 6 Volt Ampere Curves 15 SECTION 5 INSTALLATION 16 5 1 Installing Welding Generator 16 5 2 Rating Label Location 16 5 4 Grounding Generator When Supplying Building Systems 17 5 5 Engine Prestart Checks 18 5 6 Connecting...

Page 4: ......

Page 5: ...h risk of unavoid able or accidental contact with the workpiece or ground For these conditions use the following equipment in order presented 1 a semiautomaticDC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit volt age In most situations use of a DC constant voltage wire welder is recommended And do not work alone Disconnect input power or stop e...

Page 6: ...ding can easily go through small cracks and openings to adjacent areas Watch for fire and keep a fire extinguisher nearby Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do not weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards Do not weld where the atmosphere may conta...

Page 7: ...ts bare handed Allow cooling period before working on equip ment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to prevent burns STEAM AND HOT COOLANT can burn If possible check coolant level when engine is cold to avoid scalding Always check coolant level at overflow tank if present on unit instead of radiator unless told otherwise in maintenance sect...

Page 8: ...age and frequency caused by low engine speed damage electric motors Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING SPARKS can cause injury Wear 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 MOVING ...

Page 9: ...c tion Association P O Box 9101 Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org and www sparky org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 from Compressed Gas Association 4221 Walney Road 5th Floor Chantilly VA 20151 phone 703 788 2700 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from CanadianStandards Association Standards ...

Page 10: ...est équipé Des précautions de sécurité supplémentaires sont requises dans des environnements à risque comme les endroits humides ou lorsque l on porte des vêtements mouillés sur des structures mé talliques au sol grillages et échafaudages dans des positions assises à genoux et allongées ou quand il y a un risque important de contact accidentel avec la pièce ou le sol Dans ces cas utiliser les appa...

Page 11: ... Porter des lunettes de sécurité avec écrans latéraux même sous votre casque Avoir recours à des écrans protecteurs ou à des rideaux pour protéger les autres contre les rayonnements les éblouissements et les étincelles prévenir toute personne sur les lieux de ne pas regarder l arc Porter des vêtements confectionnés avec des matières résistan tes et ignifuges cuir coton lourd ou laine et des bottes...

Page 12: ...ur les batteries Débrancher le câble négatif en premier lieu Le rebrancher en dernier lieu LE CARBURANT MOTEUR peut pro voquer un incendie ou une explosion Arrêter le moteur avant de vérifier le niveau de carburant ou de faire le plein Ne pas faire le plein en fumant ou proche d une source d étincel les ou d une flamme nue Ne pas faire le plein de carburant à ras bord prévoir de l espace pour son ...

Page 13: ...t de changer ou de rajouter des éléments ou avant d ouvrir la purge ou le bouchon de remplissage d huile Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion Ne pas couper ou gouger à proximité de pro duits inflammables Surveillez et garder un extincteur à proximité DES PIECES CHAUDES peuvent provo quer des brûlures et blessures Ne pas toucher le compresse...

Page 14: ...IONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil N utiliser que les pièces de rechange recom mandées par le constructeur Effectuer la maintenance et le service du moteur et du compres seur d air suivant les instructions dans ce manuel ou le manuel du moteur compresseur si applicable LE RAYONNEMENT HAUTE FRÉ QUENCE H F risque de provoquer des interférences Le ...

Page 15: ...tandards Institute 11 West 43rd Street New York NY 10036 8002 téléphone 212 642 4900 site Internet www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B de National Fire Protection Association P O Box 9101 Quincy MA 02269 9101 téléphone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 2...

Page 16: ...ION 4 SPECIFICATIONS 4 1 Weld Power And Engine Specifications Welding Mode Weld Output Range Rated Welding Output Maximum Open Circuit Voltage Generator Power Rating Fuel Capacity Engine CC AC 60 140 A 140 A 20 V 30 Duty Cycle 130 A 25 V 30 Duty Cycle 110 A 25 V 60 Duty Cycle 90 A 25 V 100 Duty Cycle 80 Single Phase 4 5 kVA kW Surge 4 kVA kW Continuous 20 17 A 120 240 V AC 60 Hz 1 gal 3 75L Tank B...

Page 17: ...B 10 1 2 in 268 mm Do not move or operate unit where it could tip C 13 45 64 in 348 mm A D 22 3 4 in 577 mm A C E 1 3 4 in 44 mm C F 19 1 2 in 495 mm G 13 32 in 10 mm Dia G 15 15 Weight 4 Holes G 15 15 190 lb 86 kg Holes F Optional Lifting Eye Weight Rating 803 403 Engine End F E 430 lb 195 kg 803 403 Engine End 4 3 Fuel Consumption 226 022 A 0 80 0 70 0 60 0 50 0 40 0 30 0 20 0 10 0 00 0 0 5 1 1 ...

Page 18: ...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 Exceeding duty cycle can damage unit and void warranty 1 2 4 5 Generator Power Curve 226 077 The ac generator power curves show the generator power available in amperes at the receptacles 300 250 200 150 100 50 0 0 10 20 30 40 50 60 AC Power Volts AC Power Amperes ...

Page 19: ...ltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown 90 80 70 60 50 40 30 20 10 0 0 50 100 150 200 AC Volts AC Amps Max Amp Min Amp Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 20: ...securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes Do not install unit where air flow is restricted or engine may overheat 3 Rating Label Typical Locate rating label on unit Label pro vides information such as weld output ratings generator ratings and engine information Evidence of label tampering voids warranty Ref rot_label 2008...

Page 21: ... cord 1 Equipment Grounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire Electrically bond generator frame to vehicle frame by met al to metal contact 5 3 Grounding Generator To Truck Or Trailer Frame rot_grnd 2008 01 800 652 D 1 3 2 GND PE 5 4 Grounding Ge...

Page 22: ... Check fuel lev el on a cold engine before use each day Oil After fueling check oil with unit on level surface If oil reservoir is not full add oil until oil nearly overflows at oil fill This unit has a low oil level shutdown switch to prevent starting an engine that is low on oil However some conditions may cause engine damage be fore the engine shuts down Check oil level often and do not use the...

Page 23: ... 3 Supplied Weld Output Terminal Nut 4 Weld Cable Terminal 5 Copper Bar Remove supplied nut from weld output terminal Slide weld cable terminal onto weld output terminal and secure with nut so that weld cable terminal is tight against cop per bar Do not place anything be tween weld cable terminal and copper bar Make sure that the surfaces of the weld cable termi nal and copper bar are clean Tools ...

Page 24: ... 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 250 2 35 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 2 0 2x70 300 1 50 1 0 60 2 0 70 3 0 95 4 0 120 2 ea 2 0 2x70 2 ea 3 0 2x95 2 ea 3 0 2x95 This chart is a general guideline and may not suit all applications If cables overheat use next size larger cable Weld cable size AWG is based on either a 4 volts or less ...

Page 25: ...otes 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 MATERIAL THICKNESS REFERENCE CHART ...

Page 26: ...OM 4418 Page 22 SECTION 6 OPERATING THE WELDING GENERATOR 6 1 Controls See Section 6 2 803 468 D 803 469 D 226 005 2 3 1 4 ...

Page 27: ...ter stopping unit Moving unit with fuel valve open may cause carburetor flooding and make starting difficult 4 Amperage Control Use control to select weld amperage Control may be adjusted while welding Set Amper age control at max for full generator power output at ac receptacles To Set Amperage control Use electrode chart see Section 6 3 to determine correct size electrode Select electrode type a...

Page 28: ...eptacle RC1 RC1 supplies 60 Hz single phase power at weld power speed Maximum output is 4 kVA kW 2 120 V 20 A AC Duplex Receptacle RC2 RC2 supplies 60 Hz single phase power at weld power speed Maximum output from RC2 is 2 4 kVA kW 3 Supplementary Protector CB1 CB1 protects the receptacles from over load If CB1 opens the receptacles do not work Place switch in the On position to re set If supplemen...

Page 29: ... Change Clean Replace To be done by Factory Authorized Service Agent Reference Every 8 Hours Section 5 5 Fuel Level Oil Level Oil Fuel Spills Muffler Area Every 25 Hours Section 8 2 Air Cleaner Precleaner Every 50 Hours Weld Terminals Oil Every 100 Hours Engine Manual Section 8 2 Air Cleaner Element Cooling System Spark Plug Gap Every 200 Hours Unreadable Labels Every 300 Hours Engine Manual Valve...

Page 30: ...ne with out air cleaner or with dirty element 1 Cover 2 Precleaner Remove air cleaner cover Wash precleaner with soap and water so lution Allow precleaner to air dry completely Spread 1 tablespoon SAE 30 oil evenly into precleaner Squeeze out excess oil 3 Element Replace element if dirty or oily oil 1 2 3 ...

Page 31: ...lectrodes for Stick welding Remove excessive coils from weld cables Clean and tighten connections both inside and outside welding generator Check governor linkage for smooth non binding operation Have Factory Authorized Service Agent check engine speed and adjust if necessary B Generator Power Trouble Remedy No output at generator power ac re ceptacles no weld output Be sure all equipment is disco...

Page 32: ...od and make starting difficult Check oil level see Section 5 5 Low oil level shutdown may stop if oil level is too low Refill crankcase with proper viscosity oil for operating temperature Have Factory Authorized Service Agent check low oil level shutdown switch Engine stopped during normal operation Check fuel level see Section 5 5 Open fuel valve see Section 5 5 Close fuel valve before moving uni...

Page 33: ...OM 4418 Page 29 SECTION 10 ELECTRICAL DIAGRAMS 226 004 A Figure 10 1 Circuit Diagram For Welding Generator ...

Page 34: ...ock and static electricity hazards Also see AWS Safety Health Fact Sheet No 29 Grounding of Portable And Vehicle Mounted Welding Generators 1 EquipmentGrounding Terminal On Front Panel 2 Grounding Cable Not Supplied 3 Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire Electrically bond generator frame to vehicle frame ...

Page 35: ...e load and requires a constant amount of power 2 Non Resistive Load Equipment with a motor is a non re sistive load and requires approxi mately six times more power while starting the motor than when running see Section 11 8 3 Rating Data Rating shows volts and amperes or watts required to run equipment Amperes x Volts Watts Example 1 If a drill uses 4 5 am peres at 115 volts calculate its run nin...

Page 36: ... Home Equipment Rating Starting Watts Running Watts Stock Tank De Icer 1000 1000 Grain Cleaner 1 4 HP 1650 650 Portable Conveyor 1 2 HP 3400 1000 Grain Elevator 3 4 HP 4400 1400 Milk Cooler 2900 1100 Milker Vacuum Pump 2 HP 10500 2800 FARM DUTY MOTORS 1 3 HP 1720 720 Std e g Conveyors 1 2 HP 2575 975 Feed Augers Air 3 4 HP 4500 1400 Compressors 1 HP 6100 1600 1 1 2 HP 8200 2200 2 HP 10550 2850 3 H...

Page 37: ...HP 6000 1500 1 1 2 HP 8200 2200 2 HP 10500 2800 Electric Chain Saw 1 1 2 HP 12 in 1100 1100 2 HP 14 in 1100 1100 Electric Trimmer Standard 9 in 350 350 Heavy Duty 12 in 500 500 Electric Cultivator 1 3 HP 2100 700 Elec Hedge Trimmer 18 in 400 400 Flood Lights HID 125 100 Metal Halide 313 250 Mercury 1000 Sodium 1400 Vapor 1250 1000 Submersible Pump 400 gph 600 200 Centrifugal Pump 900 gph 900 500 F...

Page 38: ... must be at least twice the motor s running amperage kVA HP x HP x 1000 Volts Starting Amperage Example Calculate starting amper age required for a 230 V 1 4 HP mo tor with a motor start code of M Volts 230 HP 1 4 kVA HP 11 2 11 2 x 1 4 x 1000 230 12 2A Starting the motor requires 12 2 amperes VOLTS AMPS HP 230 2 5 1 4 Hz PHASE CODE 60 1 M AC MOTOR 1 2 3 4 11 9 How Much Power Can Generator Supply ...

Page 39: ... to electric utility when service is re stored Install correct switch customer supplied Switch rating must be same as or greater than the branch overcurrent protection 3 Fused Disconnect Switch Install correct switch customer supplied if required by electrical code 4 Welding Generator Output Generator output voltage and wir ing must be consistent with regular utility system voltage and wiring Conn...

Page 40: ...0 15 40 4800 112 34 62 19 37 11 45 5400 100 30 62 19 50 6000 87 26 50 15 Conductor size is based on maximum 2 voltage drop Cord Lengths for 240 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 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 20...

Page 41: ...ed Electrode Holder 5 Electrode Holder Position 6 Arc Length Arc length is the distance from the electrode to the workpiece A short arc with correct amperage will give a sharp crackling sound 7 Slag Use a chipping hammer and wire brush to remove slag Remove slag and check weld bead before mak ing another weld pass Tools Needed 1 4 3 5 2 7 6 Weld current starts when elec trode touches workpiece Wel...

Page 42: ...LLET ALL ALL EP EP EP EN EP EN EP EP EN EP EP 6010 6011 6013 7014 7018 7024 NI CL 308L EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY ELECTRODE AMPERAGE RANGE DIAMETER 12 3 Striking an Arc Scratch Start Technique S 0049 1 Electrode 2 Workpiece 3 Arc Drag electrode across workpiece like striking a match lift electrode slightly after touching work If arc goes out elec...

Page 43: ... 12 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 12 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 Good Penetration into Base Meta...

Page 44: ...Correct Angle 12 9 Electrode Movement During Welding Normally a single stringer bead is satisfactory for most narrow groove weld joints however for wide groove weld joints or bridging across gaps a weave bead or multiple stringer beads work better S 0054 A 1 Stringer Bead Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide ar...

Page 45: ... 3 4 12 11 Lap Joint S 0063 S 0064 1 Electrode 2 Single LayerFillet Weld Move electrode in circular motion 3 Multi Layer Fillet Weld Weld a second layer when a heavi er fillet is needed Remove slag be fore making another weld pass Weld both sides of joint for maxi mum strength 30 Or Less Single Layer Fillet Weld Multi Layer Fillet Weld 30 Or Less 1 1 2 3 12 12 Tee Joint S 0060 S 0058 A S 0061 1 El...

Page 46: ...e 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 12 15 Troubleshooting Excessive Spatter Excessive Spatter scattering of molten metal particles that cool to solid form near weld bead Possible Causes Corrective Actions Amperage too high ...

Page 47: ...d dirt from work surface before welding 12 17 Troubleshooting Lack Of Penetration Lack Of Penetration shallow fusion between weld metal and base metal Lack of Penetration Good Penetration Possible Causes Corrective Actions Improper joint preparation Material too thick Joint preparation and design must provide access to bottom of groove Improper weld technique Keep arc on leading edge of weld puddl...

Page 48: ...allel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technique 12 21 Troubleshooting Distortion Distortion contraction of weld met al during welding that forces base metal to move Base metal moves in the direction of the weld bead Possible Causes Corrective Actions Excessive heat input Use restraint clamp to hold base metal in ...

Page 49: ...OM 4418 Page 45 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual ...

Page 50: ...e 46 SECTION 13 PARTS 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: ...60 Endbell Gen 1 22 495348 Screw 312 24 Hwh 1 23 222656 Cover Endbell 1 24 214725 Frame Base 1 25 211459 Mount Engine Vibration 2 26 214727 Mount Generator Flange 1 27 BRUSH 493509 Brushholder Assy Generator 1 28 216012 Base Control Box 1 29 Label Nameplate Order By Model And Serial Number 1 30 207077 Knob Pointer 1 625 Dia Push On 1 31 197203 Grounding Stud Assy Brass Includes 1 083030 Stud Brs 2...

Page 52: ...OM 4418 Page 48 Notes 400 Trade Square East Troy Ohio 45373 1 800 332 9448 www welding org Over 80 000 trained since 1930 Start Your Professional Welding Career Now ...

Page 53: ... to 1 Consumable components such as contact tips cutting nozzles slip rings drive rolls gas diffusers plasma torch tips and electrodes weld cables and tongs and tips or parts that fail due to normal wear Exception brushes slip rings and relays are covered on Hobart Engine Driven models 2 Items furnished by Hobart Miller but manufactured by others such as engines or trade accessories These items ar...

Page 54: ... or service location Call 1 877 Hobart1 or visit our website at www HobartWelders com Contact your Distributor for Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Replacement Parts Training Schools Videos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to Resource...

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