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Champion 4500 - Hobart Welders

1. 13 5 3 Grounding Generator When Supplying Building Systems 14 5 4 Engirie Prestart Checks dns ane m lel A eh Me LAWNS dates 14 5 5 Connecting To Weld Output Terminals 15 5 6 Selecting Weld Cable Sizes v his Lege donner QUERER 16 SECTION 6 OPERATING THE WELDING GENERATOR 18 6 1 Controls See Section 6 2 18 6 2 Description Of Controls See Section 6 1 19 6 3 Amperage Selection Table For Stick SMAW Electrodes 19 SECTION 7 OPERATING AUXILIARY EQUIPMENT 20 7 1 Generator Power Panel Receptacles 20 SECTION 8 MAINTENANCE 21 8 1 Routine Maintenance i eene Ee ke fue racer te Dm 21 8 2 Servicing AI Cleaner RR URNA AA o NU ERG Pu E EUIS 22 SECTION 9 TROUBLESHOOTING 23 SECTION 10 ELECTRICAL DIAGRAMS 25 SECTION 11 GENERATOR POWER GUIDELINES 26
2. G o 4 15 D Holes Engine End 803 403 4 3 Fuel Consumption 0 80 0 70 Aux Power 0 60 0 50 0 40 U S Gal Hr 0 30 0 20 0 10 0 00 25 1 5 2 2 5 3 3 5 4 4 5 Power In KW 50 75 100 140 Weld Amps At Rated Duty Cycle 226 022 A OM 4418 Page 10 4 4 Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating A Exceeding duty cycle can damage unit and void warranty Continuous Welding y 100 Duty Cycle at 90 Amperes CC AC 3 Minutes Welding 7 Minutes Resting 30 Duty Cycle at 140 Amperes CC AC 140 ta x 110 90 a Lr 75 50 0 10 20 50 40 50 60 70 80 90 100 DUTY CYCLE 212 950 4 5 Generator Power Curve The ac generator power curves show the generator power available in amperes at the receptacles 300 250 200 150 100 AC Power Volts 50 0 10 20 30 40 50 60 AC Power Amperes 226 077 OM 4418 Page 11 4 6 Volt Ampere Curves The volt ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator Curves of all other settings fall between the curves shown 90 80 70 60 50 40 AC Volts 30 20 10 0 50 100 150 200 AC Amps 226 078 Notes Work like a Pro Pros weld and cut safely Read the safety rules at
3. 907 90 a 0 T 2 5 End View of Work Angle Side View of Electrode Angle GROOVE WELDS o o 10 30 V ga End View of Work Angle Side View of Electrode Angle FILLET WELDS S 0060 12 6 Poor Weld Bead Characteristics Large Spatter Deposits Rough Uneven Bead Slight Crater During Welding Bad Overlap Poor Penetration ND S 0053 A 12 7 Good Weld Bead Characteristics 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 NoOverlap 5 Good Penetration into Base Metal S 0052 B OM 4418 Page 35 12 8 Conditions That Affect Weld Bead Shape NOTE Weld bead shape is affected by electrode angle arc length travel speed and thickness of base metal Correct Angle Angle Too Small b 4 10 30 Angle Too Large 1 0 5 7 qm prag ELECTRODE ANGLE L R ZA T pe Too Short Normal Too Long ARC LENGTH poe Slow Normal Fast TRAVEL SPEED S 0061 12 9 Electrode Movement During Welding N OT 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 1 Stringer Bead
4. EQUIPMENT FURNISHED BY HOBART MILLER IS EXCLUDED AND DISCLAIMED BY Hobart Miller Some states in the U S A do not allow limitations of how long an implied warranty lasts or the exclusion of incidental indirect special or consequential damages so the above limitation or exclusion may not apply to you This warranty provides specific legal rights and other rights may be available but may vary from state to state In Canada legislation in some provinces provides for certain additional warranties or remedies other than as stated herein and to the extent that they may not be waived the limitations and exclusions set out above may not apply This Limited Warranty provides specific legal rights and other rights may be available but may vary from province to province HOBART 45 hobart warr 2 05 Owner s Record Please complete and retain with your personal records Model Name Serial Style Number Purchase Date Date which equipment was delivered to original customer Distributor Address City State Zip Resources Available Always provide Model Name and Serial Style Number To locate a Distributor Contact your Distributor for retail or service location Welding Supplies and Consumables Call 1 877 Hobart1 or visit our website at www HobartWelders com Options and Accessories Personal Safety Equipment For technical assistance Service and Repair Call 1 800 332 3281 Replacement Parts Training Schools V
5. SECTION 12 STICK WELDING SMAW GUIDELINES 33 13 PARTS LIST an ee one alta X AR c clot Lej ec oie a see te XR di 42 SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING rom _nd_3 05 A 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 A Marks a special safety message Means Note not safety related 1 2 Arc Welding Hazards The symbols shown below are used throughout this manual to call attention to and identify possible hazards When you see the symbol watch out and follow the related instructions to avoid the hazard The safety information given below is only a summary of the more complete safety information found in the Safety Stan dards listed in Section 1 7 Read and follow all Safety Standards Only qualified persons should install operate maintain and re pair this unit During operation keep everybody especially children away FA ELECTRIC SHOCK can kill Touching live electrical parts can cause fatal shocks or severe burns The electrode and work circuit is electrically live whenever the output is on The input power circuit and machine internal circuits are also live when power is on In semiautomatic or automatic wi
6. Valve Clearance Every Engine 500 Manual Hours Weld Cables C Slip Rings Brushes Every 1000 Hours O inside Unit OM 4418 Page 21 8 2 Servicing Air Cleaner Stop engine Do not run engine without 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 30 oil evenly into precleaner Squeeze out excess oil 3 Element Replace element if dirty or oily aircleaner6 10 02 803 468 D OM 4418 Page 22 SECTION 9 TROUBLESHOOTING 9 1 Troubleshooting A Welding Trouble 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 output generator power out put okay at ac receptacles Check Amperage control setting see Section 6 1 Check weld connections Have Factory Authorized Service Agent check Amperage control R1 stator and integrated rectifier SR1 Low weld output Check Amperage control setting see Section 6 1 Service engine air cleaner Check weld cable size and length Have Factory Authorized Service Agent check engine speed and
7. courant lectrique dans les zones hu mides dans les endroits confin s ou l o on risque de tomber Se servir d une source lectrique courant lectrique UNIQUEMENT si le proc d de soudage le demande Si l utilisation d une source lectrique courant lectrique s av re n cessaire se servir de la fonction de t l commande si l appareil en est quip Des pr cautions de s curit suppl mentaires sont requises dans des envi ronnements risque comme les endroits humides ou lorsque l on porte des v tements mouill s sur des structures m talliques au sol grillages et cha faudages dans des positions assises genoux et allong es ou quand il y a un risque important de contact accidentel avec la pi ce ou le sol Dans ces cas utiliser les appareils suivants dans l ordre de pr f rence 1 un poste souder DC semi automatique de type CV MIG MAG 2 un poste souder manuel lectrode enrob e DC 3 un poste souder manuel AC avec tension vide r duite Dans la plupart des cas un poste courant continu de type CV est re command Et ne pas travailler seul Couper l alimentation ou arr ter le moteur avant de proc der l installation la r paration ou l entretien de l appareil D verrouiller l alimentation selon la norme OSHA 29 CFR 1910 147 voir normes de s curit Installer et mettre la terre correctement cet appareil conform ment son manuel d utilisation et aux codes nationaux
8. 8 1 4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in 2500 1100 Bench Grinder 6in 1720 720 8in 3900 1400 10 in 5200 1600 Air Compressor 1 2 HP 3000 1000 1HP 6000 1500 1 1 2 HP 8200 2200 2HP 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 18 400 400 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 Floor Polisher 3 4 HP 16 in 4500 1400 1 20 6100 1600 High Pressure Washer 1 2 HP 3150 950 3 4 4500 1400 1 6100 1600 55 gal Drum Mixer 1 4 HP 1900 700 Wet amp Dry Vac 1 7 HP 900 900 2 1 2 HP 1300 1300 OM 4418 Page 29 11 8 Power Required To Start Motor XS MOTOR 1 Motor Start Code 2 2 Running Amperage AMES 222 3 Motor HP 3 CODE M Hz 60 4 Motor Voltage 1 4 1 To find starting amperage Step 1 Find code and use table to find KVA HP If code is not listed multiply running amperage by six to find starting amperage Step 2 Find Motor HP and Volts Step 3 Determine starting amper age see example Welding generator amperage out put must be at least twice the Single Phase Induction Motor Starting
9. electrodes designated for AC welding 226 005 Values listed are suggested settings Actual settings may vary depending on personal preference and or specific application Suggested electrode for beginners is E7018 AC OM 4418 Page 19 SECTION 7 OPERATING AUXILIARY EQUIPMENT NOTE gt The welding generator provides power while welding and with the Amperage 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 7 1 Generator Power Panel Receptacles Ue Dow 1 3 eg z 69 GENERATOR POWER C hamp i 0 n 4500 4500 WATT GENERATOR 9140 AC WELDER NEUTRAL BONDED TO FRAME NEUTRE RACCORD AUB TI ux A Use GFCl protected extension cord Generator power decreases as weld current increases Set Amperage control at max for full generator power 1 240 V 20 AC Duplex Receptacle RC1 RC1 supplies 60 Hz single phase power at weld power speed Maximum output is 4 kVA kW 2 120V 20A 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 recept
10. the beginning of this manual OM 4418 Page 12 SECTION 5 INSTALLATION 5 1 Installing Welding Generator Movement Airflow Clearance Location A Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes install 11 02 Ref 151 556 158 936 803 467 C S 0854 5 2 Grounding Generator To Truck Or Trailer Frame um A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards 1 Metal Vehicle Frame 2 Equipment Grounding Terminal 3 Grounding Cable Use 10 AWG or larger insulated copper wire lf unit does not have receptacles use GFCI protected extension cord GND PE Electrically bond generator frame to vehicle frame by metal to metal contact A Bed iners shipping skids and some running gear insulate the welding generator from the ve hicle frame Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown install 11 02 Ref 151 556 S 0854 OM 4418 Page 13 5 3 Grounding Generator When Supplying Building Systems sj 1 2 Use ground device as stated in electrical codes Q 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire 3 G
11. Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual OM 4418 Page 41 SECTION 13 PARTS LIST 5 Hardware is common and not available unless listed co e 803 470 E Figure 13 1 Main Assembly OM 4418 Page 42 Item Dia Par No Mkgs No Description Quantity Figure 13 1 Main Assembly 1 RC2 141432 Rept Str Dx 2p3w 20a 125v 5 20r 1 224596 Rept Str Dx Grd 2p3w 20a 250v 6 20r 1 x ese C1 218680 Capacitor Elctlt 2000 Uf 200 Vdc Can 1 42 Dia RTE dL 494915 Clamp Capacitor a mr 154408 Bushing Snap in 562 Id X 875 Mtg Hole Cent 6 SR1 035704 Rectifier Integ Bridge 40 Amp 800v am 4209659 Cover TOP 8 211297 Label Warning General Precautionary zug cde 099255 Terminal Pwr Output Neutral NO Mente elles 201553 Clip Retaining Circuit Breaker 11 Ri vus 218565 Rheostat Ww 150 W 50 Ohm Frict Term 12 ACZ 210588777 1R ACIOR Le M nee ter tes etica diete roS Db ble
12. a safe location wearing proper face hand and body protection N e Sparks can cause fires keep flammables away T OVERUSE can cause OVERHEATING Allow cooling period follow rated duty cycle Reduce current or reduce duty cycle before starting to weld again e Do not block or filter airflow to unit STATIC ESD can damage PC boards e Put on grounded wrist strap BEFORE handling boards or parts Use proper static proof bags and boxes to store move or ship PC boards TILTING OF TRAILER can cause injury e Use tongue jack or blocks to support weight e Properly install welding generator onto trailer accord ing to instructions supplied with trailer OM 4418 Page 3 READ INSTRUCTIONS e Use only genuine MILLER Hobart replacement parts e Perform engine and air compressor if applicable maintenance and service according to this manual and the engine air compressor if applicable manu als H F RADIATION can cause interference e High frequency H F can interfere with radio naviga tion safety services computers and communica tions equipment e Have only qualified persons familiar with electronic equipment perform this installation e The user is responsible for having a qualified electrician promptly correct any interference problem resulting from the installation e If notified by the FCC about interference stop using the equipment at once Have the installation regularly
13. adjust if necessary Have Factory Authorized Service Agent check brushes slip rings rotor stator and integrated rectifier SR1 High weld output Check Amperage control setting see Section 6 1 Erratic weld output Check Amperage control setting see Section 6 1 Tighten and clean connections to electrode and workpiece Use dry properly stored electrodes 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 disconnected from receptacles when starting unit Have Factory Authorized Service Agent check brushes slip rings rotor stator and integrated rectifier SR1 No output at generator power ac re ceptacles weld output okay Reset supplementary protector see Section 7 1 Check Amperage control setting see Section 6 1 Set Amperage control at max for generator power Check receptacle wiring and connections Have Factory Authorized Service Agent check engine speed and adjust if necessary Have Factory Authorized Service Agent check stator windings High output at generator power ac recepta
14. d marrer le moteur e Avant d intervenir d poser les bougies ou injecteurs pour viter la mise en route accidentelle du moteur e Bloquer le volant moteur pour viter sa rotation lors d une intervention sur le g n rateur DES PIECES CHAUDES peuvent provo quer des br lures et blessures Ne pas toucher les parties chaudes du moteur e Laisser l ensemble se refroidir avant d effectuer la maintenance Porter des gants et des v tements de protection pour travailler sur un moteur chaud LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des br lures e Il est pr f rable de v rifier le liquide de refroidissement une fois le moteur refroidi pour viter de se br ler e Toujours v rifier le niveau de liquide de refroidissement dans le vase d expan Sion si pr sent et non dans le radiateur sauf si pr cis autrement dans la section maintenance du manuel du moteur e Sile moteur est chaud et que le liquide doit tre v rifi op rer comme suivant e Mettre des lunettes de s curit et des gants placer un torchon sur le bouchon du radiateur e D visser le bouchon l g rement et laisser la vapeur s chapper avant d enle ver le bouchon LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utilisation e Veiller toujours bien a rer les espaces confin s ou se servir d un respi rateur d adduct
15. ee 211459 Mount Engine Vibration 2 26 Ju t 214727 Mount Generator Flange 1 27 BRUSH 493509 Brushholder Assy Generator 1 tati DON TEE 216012 Base Control Box 1 Re E neve pti RE dim ese Label Nameplate Order By Model And Serial Number 1 iss O AE A 207077 Knob Pointer 1 625 Dia Push On 1 MEAT 197203 Grounding Stud Assy Brass Includes 1 usa pr es 083030 Stud Brs 250 20 X 1 750 W Hex Collar 1 etats hate saam 010915 Washer Flat 257idx0 6400dx 031t Brs 2 RER TRS eT 163167 Washer Lock 254idx0 4890dx 062t Sst Split 250 1 601836 Nut 250 20 50hex 19 Brs 1 32 CB1 201083 Supplementary Protector Man Reset 2 20 250vac 1 end 495281 Cover Receptacle Duplex Includes Gasket And Hardware 2 34 TT hee Secrets 172661 Block Stud Connection 6 Position 1 db etre Sa 1 73734 Link Jumper sso ue nt a net 1 211069 Kit Accessory Includes15 Ft 6 AWG Cable w Electrode Holder amp TE 10 Ft 6 AWG Cable w Clam
16. explosion un surchauffement ou un incendie Avant de commencer le soudage v rifier et s assurer que l endroit ne pr sente pas de danger D placer toutes les substances inflammables une distance de 10 7 m de l arc de soudage En cas d impossibilit les recouvrir soigneusement avec des protections homologu s pas souder dans un endroit l o des tincelles peuvent tomber sur des substances inflammables e Se prot ger et d autres personnes de la projection d etincelles et de m tal chaud e Des tincelles et des mat riaux chauds du soudage peuvent facilement passer dans d autres zones en traversant de petites fissures et des ouvertures e Surveiller tout d clenchement d incendie et tenir un extincteur proximit e Le soudage effectu sur un plafond plancher paroi ou s paration peut d clencher un incendie de l autre c t Ne pas effectuer le soudage sur des conteneurs ferm s tels que des r ser voirs tambours ou conduites moins qu ils n aient t pr par s correctement conform ment AWS F4 1 voir les normes de s curit e Brancher le c ble sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur une longue distance par des chemins incon nus ventuels en provoquant des risques d lectrocution et d incendie e Brancher le c ble de masse sur la pi ce le plus pr s possible de la zone de soudage pour viter le transport du courant sur u
17. or voltage too high Reduce arc length or voltage OM 4418 Page 38 12 16 Troubleshooting Incomplete Fusion Incomplete Fusion failure of weld metal to fuse completely with base metal or a preceeding weld bead AN Possible Causes Corrective Actions Insufficient heat input Increase amperage Select larger electrode and increase amperage Improper welding technique Place stringer bead in proper location s at joint during welding Adjust work angle or widen groove to access bottom during welding Momentarily hold arc on groove side walls when using weaving technique Keep arc on leading edge of weld puddle Workpiece dirty Remove all grease oil moisture rust paint coatings slag and 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 puddle Insufficient heat input Increase amperage Select larger electrode and increase amperage Reduce travel speed 12 18 Troubleshooting Excessive Penetration Excessive Penetration weld metal melting through base metal and hanging underneat
18. provinciaux et municipaux Toujours v rifier la terre du cordon d alimentation V rifier et s assurer que le fil de terre du cordon d alimentation est bien raccord la borne de terre du sectionneur ou que la fiche du cordon est raccord e une prise correctement mise la terre En effectuant les raccordements d entr e fixer d abord le conducteur de mise la terre appropri et contre v rifier les connexions V rifier fr quemment le cordon d alimentation pour voir s il n est pas endom mag ou d nud remplacer le cordon imm diatement s il est endommag un c ble d nud peut provoquer une lectrocution Mettre l appareil hors tension quand on ne l utilise pas Ne pas utiliser des c bles us s endommag s de grosseur insuffisante ou mal piss s Ne pas enrouler les c bles autour du corps Si la pi ce soud e doit tre mise la terre le faire directement avec un c ble distinct ne pas utiliser le connecteur de pi ce ou le c ble de retour Ne pas toucher l lectrode quand on est en contact avec la pi ce la terre ou une lectrode provenant d une autre machine Ne pas toucher des porte lectrodes connect s deux machines en m me temps cause de la pr sence d une tension vide doubl e N utiliser qu un mat riel en bon tat R parer ou remplacer sur le champ les pi ces endommag es Entretenir l appareil conform ment ce manuel Ce groupe de symboles signi fie Mise en g
19. souda ge aussi courts que possible les grouper et les poser aussi bas que pos sible ex par terre e Veiller souder une distance de 100 m tres de tout quipement lec tronique sensible e Veiller ce que ce poste de soudage soit pos et mis la terre conform ment ce mode d emploi e cas d interf rences apr s avoir pris les mesures pr c dentes il in combe l utilisateur de prendre des mesures suppl mentaires telles que le d placement du poste l utilisation de c bles blind s l utilisation de fil tres de ligne ou la pose de protecteurs dans la zone de travail Proposition californienne 65 Avertissements Pour les moteurs essence Les gaz d chappement des moteurs contiennent des produits chimi ques dont l Etat de Californie reconna t qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Pour les moteurs diesel A Les gaz d chappement des moteurs diesel et certains de leurs compo sants sont reconnus par l tat de Californie comme provoquant des cancers et des malformations cong nitales ou autres probl mes de pro cr ation Boulevard Rexdale Ontario Canada M9W 1R3 800 463 6727 ou Toronto 416 747 4044 site www csa international org t l phone Internet Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 de American National Standards Institute 11 West 42nd Street New York
20. welding generators Your unit may differ from those shown 11 1 Selecting Equipment Be sure equipment has this symbol and or wording Generator Power Receptacles Neutral Bonded To Frame 3 Prong Plug From Case Grounded Equipment 2 Prong Plug From Double Insulated Equipment Do not use 2 prong plug un less equipment is double in sulated gen pwr 11 02 Ref ST 159 730 ST 800 577 gt Electrically bond generator vi frame to vehicle frame by metal to metalcontact Bed liners shipping skids and some running gear insulate the welding generator from the ve hicle frame Always connect a ground wire from the generator equipment grounding terminal to bare metal on the vehicle frame as shown A Always ground generator frame to vehicle frame to pre vent electric shock and static electricity hazards Equipment Grounding Terminal On Front Panel Grounding Cable Not Supplied Metal Vehicle Frame Connect cable from equipment ground terminal to metal vehicle frame Use 10 AWG or larger insulated copper wire A If unit does not have GFCI re ceptacles use GFCI pro tected extension cord S 0854 OM 4418 Page 26 11 3 Grounding When Supplying Building Systems Use ground device as stated in electrical codes 1 Equipment Grounding Terminal 2 Grounding Cable Use 10 AWG or larger insulated copper wire
21. 3 1 Symbol Definitions x Engine Choke FE s A Amperes Volts SEES Engine Oil E Fuel Battery Engine 2 4 Positive Negative Ny PR Output h Hours Seconds e Time D d o eot Circuit Protector Temperature 4 1 Weld Power And Engine Specifications Weld Maximum Welding Rated Rm Generator Fuel Mode Berce Welding Output ei ien Power Rating Capacity Engine 140 20 V 30 Duty Cycle Single Phase Briggs amp Stratton 130 25 V 4 5 KVA KW Surge Intek 30 Duty Cvcl 4 KVA KW Air Cooled CC AC 25 140A v 80 Continuous TONG oo One Cylinder 20 17 A Four Cycle 60 Duty Cycle 120 240 V AC 10 HP 305 90 A 25 V 60 Hz Gasoline Engine 10096 Duty Cycle OM 4418 Page 9 4 2 Dimensions Weights And Operating Angles Dimensions Height 20 3 4 in 527 mm Width 22 3 4 in 577 mm Depth 31 1 4 in 793 31 1 4 in 793 10 1 2 in 268 C 13 45 64 in 348 mm D 22 3 4 in 577 mm E 1 3 4 in 44 mm F 19 1 2 in 495 mm G 13 32 in 10 mm Dia Weight 190 Ib 86 kg Optional Lifting Eye Weight Rating 430 Ib 195 kg nx D I 3 Do not exceed tilt angles or engine could B be damaged or unit could tip Do not move or operate unit where it o o O o o could tip AJW L oo oo o
22. 3 Ground Device Ground generator to system earth ground if supplying power to a premises home shop farm wiring system ST 800 576 B 11 4 How Much Power Does Equipment Require VOLTS 115 AMPS 4 5 Hz 60 AMPERES x VOLTS WATTS EXAMPLE 1 drill uses 4 5 amperes at 115 volts calculate its running power requirementin watts 4 5Ax115V 2 520W The load applied by the drill is 520 watts EXAMPLE 2 If three 200 watt flood lamps are used with the drill from Example 1 add the individual loads to calculate total load 200 W 200 W 200 W 520 W 1120 W The total load applied by the three flood lamps and drill is 1120 watts 1 Resistive Load A light bulb is a resistive 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 S 0623 OM 4418 Page 27 11 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 3075 975 3 4 4500 1400 1 6100 1600 1 1 2 8200 2200 2 HP 105
23. 5 53 100 31 60 18 25 6000 350 107 225 69 125 38 75 23 30 7000 300 91 175 53 100 31 75 23 35 8400 250 76 150 46 100 31 40 9600 225 69 125 38 75 23 45 10 800 200 61 125 38 50 12 000 175 53 100 31 Conductor size is based on maximum 2 voltage drop OM 4418 Page 32 SECTION 12 STICK WELDING SMAW GUIDELINES EE 12 1 Stick Welding Procedure Weld current starts when electrode touches work piece A 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 welding 2 Work Clamp 3 Electrode A small diameter electrode requires less current than a large one Fol low electrode manufacturer s instructions when setting weld am perage see Section 12 2 4 Insulated 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 LL mmm stick 12 96 ST 151 593 OM 4418 Page 33 12 2 Electrode and Amperage Selection Chart AMPERAGE RAN
24. 50 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 1000 400 1 6 HP 1400 550 1 4 HP 1850 650 1 3 HP 2400 800 1 2 HP 3500 1100 11 6 Approximate Power Regu irements For Farm Home Eguipment Farm Home Eguipment 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 HP 15900 3900 5 HP 23300 6800 High Torgue e g Barn 1 1 2 HP 8100 2000 Cleaners Silo Unloaders 5 HP 23300 6000 Silo Hoists Bunk Feeders 7 1 2 HP 35000 8000 10 HP 46700 10700 3 1 2 cu ft Mixer 1 2 HP 3300 1000 High Pressure 1 8 Gal Min 500 PSI 3150 950 Washer 2 gal min 550 PSI 4500 1400 2 gal min 700 PSI 6100 1600 Refrigerator or Freezer 3100 800 Shallow Well Pump 1 8 HP 2150 750 1 2 HP 3100 1000 Sump Pump 1 3 HP 2100 800 1 2 HP 3200 1050 OM 4418 Page 28 11 7 Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts 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
25. GE ELECTRODE DIAMETER 250 300 ELECTRODE POSITION PENETRATION DEEP DEEP MIN PREP ROUGH HIGH SPATTER LOW GENERAL MED SMOOTH EASY FAST LOW LOW HYDROGEN STRONG FLAT HORIZ FILLET LOW SMOOTH EASY FASTER NI CL y y ALL LOW CAST IRON 308L ALL LOW STAINLESS EP ELECTRODE POSITIVE REVERSE POLARITY EN ELECTRODE NEGATIVE STRAIGHT POLARITY Ref S 087 985 A 1 Electrode 2 Workpiece 3 Drag electrode across workpiece like striking a match lift electrode slightly after touching work arc goes out electrode was lifted to high electrode sticks to work piece use a quick twist to free it S 0049 12 4 Striking an Arc Tapping Technique n LJ L 2 po UE 1 Electrode 2 Workpiece 3 Bring electrode straight down to workpiece then lift slightly to start arc If arc goes out electrode was lifted too high If electrode sticks to workpiece use a quick twist to free it S 0050 OM 4418 Page 34 12 5 Positioning Electrode Holder 10 30 EAT
26. NY 10036 8002 t l phone 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 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org OSHA Occupational Safety and Health Standards for General Industry Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J de U S Government Printing Office Superintendent of Documents P O Box 371954 Pittsburgh PA 15250 il y a 10 bureaux regionaux le t l phone de la r gion 5 Chicago est 312 353 2220 site Internet www osha gov proc dures suivantes 1 Maintenir les c bles ensemble en les tordant ou en les envelop pant 2 Disposer les c bles d un c t et distance de l op rateur 3 Ne pas courber pas et ne pas entourer pas les c bles autour de votre corps 4 Garder le poste de soudage et les c bles le plus loin possible de vous 5 Connecter la pince sur la pi ce aussi pr s que possible de la sou dure En ce qui concerne les stimulateurs cardiaques Les porteurs de stimulateur cardiaque doivent consulter leur m decin avant de souder ou d approcher des op rations de soudage Si le m decin approuve il est recommand de suivre les proc dures pr c dentes SECTION 3 DEFINITIONS
27. NZ OM 4418 210 597F iem August 2005 lt H2 Stick SMAW Welding Description L1 mE Engine Driven Welding Generator WELDERS Champion 4500 Online Forum www HobartWelders com From Hobart to You Thank you and congratulations on choosing Hobart Now you can get the job done and get it done right We know you don t have time to do it any other way This Owner s Manual is designed to help you get the most out of your Hobart products 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 parts list will then help you to decide the exact part you may need to fix the problem Warranty and service information for your particular model are also provided I0 9001 2000 QUALITY SYSTEM Hobart is registered to the ISO 9001 2000 Quality System Standard Hobart Welders manufactures a full line of welders and welding related eguipment For information on other guality Hobart products contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets To locate your nearest distributo
28. Requirements motors running amperage Motor Start Code G H J K L M N P KVA HP 6 3 7 1 8 0 9 0 10 0 11 2 12 5 14 0 kVA HP x HP x 1000 VOLTS EXAMPLE Calculate the starting amperage reguired for a 230 V 1 4 HP motor with a motor start code of M Volts 230 HP 1 4 Using Table Code M results in KVA HP 11 2 z STARTING AMPERAGE 11 2 x 1 4 x 1000 125 Starting ih t ires 12 2 12 2 amperes 230 arting the motor requires amperes S 0624 11 9 How Much Power Can Generator Supply 1 Limit Load To 90 Of Generator Output Always start non resistive motor loads in order from largest to small est and add resistive loads last 2 5 Second Rule If motor does not start within 5 seconds turn off power to prevent motor damage Motor reguires more power than generator can supply Ref ST 800 396 A S 0625 OM 4418 Page 30 11 10 Typical Connections To Supply Standby Power T A Properly install and ground this equipment according to its Owner s Manual and national state and local codes 1 2 3 4 Utility b Fused Welding isconnect Electrical Ty Transfer Switch Switch c Generator Service If Required Output 5 Essential Loads A Have only qualified persons perform these connections according to all applicable codes and safety practic es A Properly install
29. S L CHAPPEMENT peuvent provoquer un incendie e Emp cher les tincelles d chappement du moteur de provoquer un incendie e Utiliser uniquement un pare tincelles approuv voir codes en vigueur Le METAL CHAUD lors du coupage et gougeage plasma peut provoquer un in cendie ou une explosion e Ne pas couper ou gouger proximit de produits in flammables e Surveillez et garder un extincteur proximit CA 2 6 DES PIECES CHAUDES peuvent provo quer des br lures et blessures e Ne pas toucher le compresseur ou d autres l ments du circuit air comprim chauds e Laisser l ensemble se refroidir avant de toucher ou d effectuer la mainte nance LIRE LES INSTRUCTIONS Lisez le manuel d instructions avant l utilisation ou la maintenance de l appareil Arr ter le moteur et rel cher la pression avant d ef fectuer la maintenance e Utiliser uniquement des pi ces de rechange Miller Hobart Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance m i L EMPLOI EXCESSIF peut SURCHAUFFER L QUIPEMENT R duire le courant ou le facteur de marche avant de poursuivre le soudage e Laisser l quipement refroidir respecter le facteur de marche nominal e e appropri et en suivant les proc dures ad quates Ne pas obstruer les passages d air du poste e En utilisant des fourches de levage pour d placer l unit s assurer que les fourches so
30. Sparks can fly off from the welding arc The flying sparks hot workpiece and hot equipment can cause fires and burns Accidental contact of electrode to metal objects can cause sparks explosion overheating or fire Check and be sure the area is safe before doing any welding e Remove all flammables within 35 ft 10 7 m of the welding arc If this is not possible tightly cover them with approved covers e Do not weld where flying sparks can strike flammable material e Protect yourself and others from flying sparks and hot metal e alert that welding sparks and hot materials from welding can easily go through small cracks and openings to adjacent areas e Watch for fire and keep a fire extinguisher nearby e Be aware that welding on a ceiling floor bulkhead or partition can cause fire on the hidden side Do weld on closed containers such as tanks drums or pipes unless they are properly prepared according to AWS F4 1 see Safety Standards e Connect work cable to the work as close to the welding area as practical to prevent welding current from traveling long possibly unknown paths and causing electric shock sparks and fire hazards e Do not use welder to thaw frozen pipes e Remove stick electrode from holder or cut off welding wire at contact tip when not in use e Wear oil free protective garments such as leather gloves heavy shirt cuf fless trousers high shoes and a cap e Remove any combust
31. Steady Movement Along Seam 2 Weave Bead Side to Side Movement Along Seam 3 Weave Patterns Use weave patterns to cover a wide area in one pass of the electrode Do not let weave width exceed 2 1 2 times diameter of electrode S 0054 A OM 4418 Page 36 12 10 Butt Joints 1 30 1 16 in 1 6 mm 1 Tack Welds Prevent edges of joint 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 acetylene or plasma cutting equip ment Remove scale from material after cutting A grinder can also be used to prepare bevels Create 30 degree angle of bevel on materials in V groove welding 4 Double V Groove Weld Good for materials thicker than 3 16 in 5 mm S 0662 12 11 Lap Joint 30 o 30 Or Less Or Less RA 2 3 Single Layer Fillet Weld Multi Layer Fillet Weld 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 S 0063 S 0064 12 12 Tee Joint 1 Electrode 2 Fill
32. acles do not work 226 005 105 Place switch in the On position to re set If supplementary protector contin ues to open contact Factory Authorized Service Agent Combined output of all receptacles limited to 4 kVA kW rating of the generator See Section 11 Generator Power Guide lines EXAMPLE If 15 A is drawn from the 120 volt duplex receptacle only 9 A is available from the 240 V duplex receptacle 120 V x 15 A 240 V x9 4 KVA KW OM 4418 Page 20 SECTION 8 MAINTENANCE 8 1 gt Routine Maintenance E Ch 4 v s Recycle engine Stop engine before maintaining See Engine Manual and Maintenance Label for important start up service and storage fluids information Service engine more often if used in severe conditions 7 17 Check Change Q Clean x Replace Reference To be done by Factory Authorized Service Agent Every Section 5 4 B s gt Hours Fuel Level Oil Level Q Oil Fuel Spills Muffler Area Every A Section 8 2 25 sa z Hours Q Air Cleaner Precleaner Every 50 p A Hours al 2 Q Weld Terminals Every A Engine 100 45 Manual Hours 2 Section 8 2 X Air Cleaner Element Q Cooling System lt Spark Plug Gap Every re 200 Hours Unreadable Labels Every Engine 300 Manual Hours
33. 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 the generator Trans fer load back to electric utility when service is restored 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 wiring must be consistent with regular utility system volt age and wiring Connect generator with temporary or perma nent wiring suitable for the installation Turn off or unplug all equipment connected to generator before starting or stopping engine When starting or stopping the engine has low speed which causes low voltage and frequency 5 Essential Loads Generator output may not meet the electrical requirements of the premises If generator does not produce enough output to meet all requirements connect only essential loads pumps freezers heaters etc See Sec tion 11 4 Notes Work like a Pro Pros weld and cut safely Read the safety rules at the b
34. arde Soyez vigi lant a des risques de dan ger reli s aux CHOCS LEC cal TRIQUES aux PI CES EN MOUVEMENT et aux PI CES CHAUDES Repor tez vous aux symboles et aux directives ci dessous afin de conna tre les mesu res prendre pour viter tout danger Porter un harnais de s curit quand on travaille en hauteur Maintenir solidement en place tous les panneaux et capots Fixer le c ble de retour de fa on obtenir un bon contact m tal m tal avec la pi ce souder ou la table de travail le plus pr s possible de la soudure Isoler la pince de masse quand pas mis la pi ce pour viter le contact avec tout objet m tallique Une tension DC importante subsiste l int rieur des onduleurs apr s avoir coup l alimentation Couper l alimentation du poste et d charger les condensateurs d entr e com me indiqu dans la Section Maintenance avant de toucher des composants LES FUM ES ET LES GAZ peuvent tre dangereux Le soudage g n re des fum es et des gaz Leur inhalation peut tre dangereux pour votre sant Eloigner votre t te des fum es Ne pas respirer les fum es A l int rieur ventiler la zone et ou utiliser une ventilation forc e au niveau de l arc pour l vacuation des fum es et des gaz de soudage Si la ventilation est m diocre porter un respirateur anti vapeurs approuv Lire et comprendre les sp cifications de s curit des mat riaux MSDS et les inst
35. ble Sizes Weld Cable Size and Total Cable Copper Length in Weld Circuit Not Exceeding For distances longer than those shown in this guide call a factory applications representative at 920 735 4505 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100ft 30m orLess 45m 60m 70m 90m 105 120m Weld Output Terminals A Turn off power before 10 60 60 100 connectingto weld out Welding Duty Duty 10 100 Duty Cycle put terminals Amperes Cycle Cycle Do not use worn dam aged undersized or poorly spliced cables 100 4 20 4 20 4 20 3 30 2 35 1 50 1 0 60 1 0 60 150 3 30 3 30 2 35 1 50 1 0 60 2 0 70 3 0 95 3 0 95 200 3 30 2 35 1 60 1 0 60 2 0 70 3 0 95 4 0 120 4 0 120 2 85 1 60 1 0 60 2 0 70 3 0 95 4 0 120 at o 300 1 50 1 0 60 2 0 70 30 95 40 120 ed c gre 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 drop or a current density of at least 300 circular mils per ampere mm for metric use S 0007 F Notes OM 4418 Page 16 Work like a Pro Pros weld and cut safely Read the safety rules at the beginning of this manual Not
36. checked and maintained Keep high frequency source doors and panels tightly shut keep spark gaps at correct setting and use grounding and shielding to minimize the possibility of interference 1 6 California Proposition 65 Warnings A Welding or cutting equipment produces fumes or gases which contain chemicals known to the State of California to cause birth defects and in some cases cancer California Health amp Safety Code Section 25249 5 et seq Battery posts terminals and related accessories contain lead and lead compounds chemicals known to the State of California to cause cancer and birth defects or other reproductive harm Wash hands after handling 1 7 Principal Safety Standards Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com Recommended Safe Practices for the Preparation for Welding and Cut ting of Containers and Piping American Welding Society Standard AWS F4 1 from Global Engineering Documents phone 1 877 413 5184 website www global ihs com National Electrical Code NFPA Standard 70 from National Fire Protec tion Association P O Box 9101 1 Battery March Park 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 1735 Jefferson Davis Highway Suite 1004 Arlin
37. cles Have Factory Authorized Service Agent check engine speed and adjust if necessary Low output at generator power ac receptacles Check Amperage control setting see Section 6 1 Set Amperage control at max for generator power Have Factory Authorized Service Agent check engine speed and adjust if necessary OM 4418 Page 23 Trouble 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 Authorized Service Agent check engine speed and adjust if necessary C Engine Trouble Remedy Engine will not start Check fuel level see Section 5 4 Move choke control to correct position see Section 6 1 Open fuel valve see Section 5 4 Close fuel valve before moving unit or carburetor may flood and make starting difficult Check oil level see Section 5 4 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 4 Open fuel valve see Section 5 4 C
38. eaning or spraying operations The heat and rays of the arc can react with vapors to form highly toxic and irritating gases Do not weld on coated metals such as galvanized lead or cadmium plated steel unless the coating is removed from the weld area the area is well ventilated and while wearing an air supplied respirator The coatings and any metals containing these elements can give off toxic fumes if welded BUILDUP OF GAS can injure or kill e Shut off shielding gas supply when not in use e Always ventilate confined spaces or use approved air supplied respirator ARC RAYS can burn eyes and skin Arc rays from the welding process produce intense visible and invisible ultraviolet and infrared rays that can burn eyes and skin Sparks fly off from the weld e Wear an approved welding helmet fitted with a proper shade of filter lenses to protect your face and eyes from arc rays and sparks when welding or watching see ANSI Z49 1 and Z87 1 listed in Safety Standards Wear approved safety glasses with side shields under your helmet Use protective screens or barriers to protect others from flash glare and sparks warn others not to watch the arc e Wear protective clothing made from durable flame resistant material leather heavy cotton or wool and foot protection OM 4418 Page 1 RE WELDING can cause fire or explosion Welding on closed containers such as tanks drums or pipes can cause them to blow up
39. ebrancher en dernier lieu LE CARBURANT MOTEUR peut provo quer un incendie ou une explosion e Arr ter le moteur avant de v rifier le niveau de carburant ou de faire le plein e Ne pas faire le plein en fumant ou proche d une source d tincelles ou d une flamme nue e Ne pas faire le plein de carburant ras bord pr voir de l espace pour son expansion e Faire attention de ne pas renverser de carburant Nettoyer tout carburant renvers avant de faire d marrer le moteur e Jeter les chiffons dans un r cipient ignifuge gt DES ORGANES MOBILES peuvent voquer des blessures Ne pas approcher les mains des ventilateurs courroies et autres pi ces en mouvement e Maintenir ferm s et fixement en place les portes panneaux recouvre ments et dispositifs de protection OM 4418 Page 6 e Arr ter le moteur avant d installer ou brancher l appareil e Seules des personnes qualifi es sont autoris es enlever les portes pan neaux recouvrements ou dispositifs de protection pour effectuer s il y a lieu des travaux d entretien et de d pannage e Pour emp cher tout d marrage accidentel pendant les travaux d entretien d brancher le c ble n gatif de batterie de la borne Ne pas approcher les mains cheveux v tements l ches et outils des organes mobiles e Remettre en place les panneaux ou les dispositifs de protection et fermer les portes la fin des travaux d entretien et avant de faire
40. eginning of this manual OM 4418 Page 31 11 11 Selecting Extension Cord Use Shortest Cord Possible gt 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 Load Watts 4 6 8 10 12 14 Amperes 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 37 11 35 4200 125 38 75 23 50 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 Load Watts 4 6 8 10 12 14 Amperes 5 1200 700 213 450 137 225 84 200 61 7 1680 800 244 500 152 300 91 200 61 125 38 10 2400 800 244 550 168 350 107 225 69 125 38 100 31 15 3600 600 183 350 107 225 69 150 46 75 23 60 18 20 4800 450 137 275 84 17
41. ents P O Box 371954 Pittsburgh PA 15250 there are 10 Regional Offices phone for Region 5 Chicago is 312 353 2220 website www osha gov To reduce magnetic fields in the workplace use the following procedures 1 Keepcables close together by twisting or taping them 2 Arrange cables to one side and away from the operator 3 Do not coil or drape cables around your body 4 Keep welding power source and cables as far away from operator as practical 5 Connect work clamp to workpiece as close to the weld as possible About Pacemakers Pacemaker wearers consult your doctor before welding or going near welding operations If cleared by your doctor then following the above procedures is recommended SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION rom fre 3 05 A Avertissement Prot gez vous et les autres des blessures lisez et suivez ces pr cautions 2 1 A Signification des symboles Signifie Mise en garde Soyez vigilant Cette proc dure pr sente des risques de danger Ceux ci sont identifi s par des symboles adjacents aux directives Identifie un message de s curit particulier Signifie NOTA n est pas relatif la s curit 2 2 Dangers relatifs au soudage l arc A Les symboles pr sent s ci apr s sont utilis s tout au long du pr sent manuel pour attirer votre attention et identifier les risques de danger Lorsque vous voyez un symbole soyez vigilant et sui
42. erial and workmanship at the time it is shipped by Hobart THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS Within the warranty periods listed below Hobart Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship Hobart Miller must be notified in writing within thirty 30 days of such defect or failure at which time Hobart Miller will provide instructions on the warranty claim procedures to be followed Hobart Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods All warranty time periods start on the date that the equipment was delivered to the original retail purchaser or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor 1 5 Years Parts and Labor Original Main Power Rectifiers Transformers Stabilizers Reactors 2 Years Parts and Labor Drive Systems PC Boards Rotors Stators and Brushes Idle Module Solenoid Valves Switches and Controls Spot Welder Transformer 3 1 Year Parts and Labor Unless Specified 90 days for industrial use Motor Driven Guns MIG Guns TIG Torches Relays Contactors Regulators Water Coolant Systems Flowgauge and F
43. eriod before working on equipment To handle hot parts use proper tools and or wear heavy insulated welding gloves and clothing to pre vent burns NOISE can damage hearing Noise from some processes or equipment can damage hearing e Wear approved ear protection if noise level is high MAGNETIC FIELDS can affect pacemakers Pacemaker wearers keep away Wearers should consult their doctor before going near arc welding gouging or spot welding opera tions CYLINDERS can explode if damaged Shielding gas cylinders contain gas under high pressure If damaged a cylinder can explode Since gas cylinders are normally part of the welding process be sure to treat them carefully Protect compressed gas cylinders from excessive heat mechanical shocks physical damage slag open flames sparks and arcs Install cylinders in an upright position by securing to a stationary support or cylinder rack to prevent falling or tipping Keep cylinders away from any welding or other electrical circuits Never drape a welding torch over a gas cylinder Never allow a welding electrode to touch any cylinder Never weld on a pressurized cylinder explosion will result Use only correct shielding gas cylinders regulators hoses and fittings de signed for the specific application maintain them and associated parts in good condition Turn face away from valve outlet when opening cylinder valve Keep protective cap in place over va
44. ers existant en relation avec le moteur 6 2 4 Dangers li s comprim 7 2 5 Dangers suppl mentaires en relation avec l installation le fonctionnement et la maintenance 7 2 6 Proposition californienne 65 Avertissements 8 2 7 Principales normes de s curit 8 2 8 Informatio EMF RR EON Ee eR US qi ee ee aed Am s 8 SECTION 3 DEFINITIONS yx X same tease ne REK OE 9 SECTION 4 SPECIFICATIONS 2 can e ra E ER ENA ENE dan M Eee EEG N 9 4 1 Weld Power And Engine Specifications 9 4 2 Dimensions Weights And Operating Angles 10 4 3 Fiel Consumption We RE e COEUR EDU A I 10 4 4 Duty Cycle xo rete re a oU ERR e d Du RR Saas t o Ced SHEER ADR ass 11 4 5 Generator Power 11 4 6 Vol Ampere RE IEEE EUH YU RR X Xue Ca 12 SECTION 5 INSTALLATION umi yx ENE eae te A en Ee MERE E Ra tee Ne 13 5 1 Installing Welding Generator 13 5 2 Grounding Generator To Truck Or Trailer Frame
45. es MATERIAL THICKNESS REFERENCE CHART 24 Gauge 025 in 22 Gauge 031 in 20 Gauge 037 in 18 Gauge 050 in 16 Gauge 063 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 OM 4418 Page 17 SECTION 6 OPERATING THE WELDING GENERATOR 6 1 Controls See Section 6 2 NESTRAL BONDED TO FRAME FOR WEURERAECERD GENERATOR POWER GENERATOR POWER AMPERAGE ADJUST AC WELDING CONNECTIONS WARNING ecd meja vija H Champion 4500 4500 WATT GENERATOR 140 AMP AC WELDER orne poza v GND PE S CONFINED OR FTHERE BA DANGER OF FALLING 803 468 D 803 469 D 226 005 OM 4418 Page 18 6 2 Description Of Controls See Section 6 1 7W 7 2 ae NS y 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 To Start e Open fuel valve see Section 5 4 e Turn Engine switch t
46. et Weld Keep arc short and move at definite rate of speed Hold electrode as shown to provide fusion into the corner Square edge of the weld surface For maximum strength weld both sides of upright section 3 Multi Layer Deposits Weld a second layer when a heavi er fillet is needed Use any of the weaving patterns shown in Section 12 9 Remove slag before making another weld pass S 0060 S 0058 A S 0061 OM 4418 Page 37 12 13 Weld Test 1 Vise 3 2 Weld Joint 3 Hammer A Strike weld joint in direction shown een lle mm do 1 4 in 29 2 6 4 mm 1 DS PUY 2 3 in 1 51 76 mm E good weld bends over but does not break S 0057 B 12 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 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 for electrode Decrease amperage or select larger electrode Arc length too long
47. et por ter des gants de soudage et des v tements pais pour viter les br lures LE BRUIT peut affecter l ouie Le bruit des processus et des quipements peut affecter l ouie e Porter des protections approuv s pour les oreilles si le ni veau sonore est trop lev LES CHAMPS MAGNETIQUES peuvent affecter les stimulateurs cardiaques Porteurs de stimulateur cardiaque restez distance e Les porteurs d un stimulateur cardiaque doivent d abord consulter leur m decin avant de s approcher des op ra tions de soudage l arc de gougeage ou de soudage par points Si des BOUTEILLES sont endomma g es elles pourront exploser Des bouteilles de gaz protecteur contiennent du gaz sous haute pression Si une bouteille est endommag e elle peut exploser Du fait que les bouteilles de gaz font normalement partie du proc d de soudage les manipuler avec pr caution e Prot ger les bouteilles de gaz comprim d une chaleur excessive des chocs m caniques des dommages physiques du laitier des flammes ouvertes des tincelles et des arcs e Placer les bouteilles debout en les fixant dans un support stationnaire ou dans un porte bouteilles pour les emp cher de tomber ou de se renverser Tenir les bouteilles loign es des circuits de soudage ou autres circuits lectri ques Ne jamais placer une torche de soudage sur une bouteille gaz Une lectrode de soudage ne doit jamais entrer en con
48. gton VA 22202 4102 phone 703 412 0900 website www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 from Canadian Standards Association Standards Sales 178 Rexdale Bou 1 8 EMF information Considerations About Welding And The Effects Of Low Freguency Electric And Magnetic Fields Welding current as it flows through welding cables will cause electro magnetic fields There has been and still is some concern about such fields However after examining more than 500 studies spanning 17 years of research a special blue ribbon committee of the National Research Council concluded that The body of evidence in the committees judgment has not demonstrated that exposure to power freguency electric and magnetic fields is a human health hazard However studies are still going forth and evidence continues to be examined Until the final conclusions of the research are reached you may wish to minimize your exposure to electromagnetic fields when welding or cutting OM 4418 Page 4 ARC WELDING can cause interference e Electromagnetic energy can interfere with sensitive electronic equipment such as microprocessors computers and computer driven equipment such as robots e Be sure all equipment in the welding area is electro magnetically compatible e To reduce possible interference keep weld cables as short as possible close together and down low such as on the floor Locate welding operatio
49. h weld Excessive Penetration Good Penetration Possible Causes Corrective Actions Excessive heat input Select lower amperage Use smaller electrode Increase and or maintain steady travel speed OM 4418 Page 39 12 19 Troubleshooting 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 Troubleshooting Waviness Of Bead k Waviness Of Bead weld metal that is not parallel and does not cover joint formed by base metal Possible Causes Corrective Actions Unsteady hand Use two hands Practice technigue 12 21 Troubleshooting Distortion Distortion contraction of weld met al during welding that forces base metal to move a 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 position Make tack welds along joint before starting welding operation Select lower amperage for electrode Increase travel speed Weld in small segments and allow cooling between welds OM 4418 Page 40 Notes
50. he event of a warranty claim covered by this warranty the exclusive remedies shall be at Hobart s Miller s option 1 repair or 2 replacement or where authorized in writing by Hobart Miller in appropriate cases 3 the reasonable cost of repair or replacement at an authorized Hobart Miller service station or 4 payment of or credit for the purchase price less reasonable depreciation based upon actual use upon return of the goods at customer s risk and expense Hobart s Miller s option of repair or replacement will be F O B Factory at Appleton Wisconsin or F O B at a Hobart Miller authorized service facility as determined by Hobart Miller Therefore no compensation or reimbursement for transportation costs of any kind will be allowed TO THE EXTENT PERMITTED BY LAW THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES IN NO EVENT SHALL HOBART MILLER BE LIABLE FOR DIRECT INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES INCLUDING LOSS OF PROFIT WHETHER BASED ON CONTRACT TORT OR ANY OTHER LEGAL THEORY ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANT Y GUARANTY OR REPRESENTATION AS TO PERFORMANCE AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH BUT FOR THIS PROVISION MIGHT ARISE BY IMPLICATION OPERATION OF LAW CUSTOM OF TRADE OR COURSE OF DEALING INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE WITH RESPECT TO ANY
51. ibles such as a butane lighter or matches from your person before doing any welding e Follow requirements in OSHA 1910 252 2 iv and 51B for hot work and have a fire watcher and extinguisher nearby FLYING METAL can injure eyes ESSE e Welding chipping wire brushing and grinding cause sparks and flying metal As welds cool they can throw off slag e Wear approved safety glasses with side shields even under your welding helmet 1 3 Engine Hazards BATTERY EXPLOSION can BLIND e Always wear a face shield rubber gloves and protec tive clothing when working on a battery e Stop engine before disconnecting or connecting bat tery cables or servicing battery Do not allow tools to cause sparks when working on a battery Do not use welder to charge batteries or jump start vehicles Observe correct polarity and on batteries Disconnect negative cable first and connect it last FUEL can cause fire or explosion e Stopengine and let it cool off before checking or add ing fuel e Do not add fuel while smoking or if unit is near any Sparks or open flames Do not overfill tank allow room for fuel to expand Do not spill fuel If fuel is spilled clean up before starting engine Dispose of rags in a fireproof container Always keep nozzle in contact with tank when fueling OM 4418 Page 2 HOT PARTS can cause severe burns Do not touch hot parts bare handed Allow cooling p
52. ideos Books Technical Manuals Servicing Information and Parts Circuit Diagrams Welding Process Handbooks Contact the Delivering Carrier to File a claim for loss or damage during shipment For assistance in filing or settling claims contact your distributor and or equipment manufacturer s Transportation Department PRINTED IN USA 2005 Hobart Welding Products 6 05 Protect Your Investment Register your product at HobartWelders com Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy OH 45373 USA For Technical Assistance Call1 800 332 3281 For Literature Or Nearest Dealer Call 1 877 Hobart1 Se ZN HOBART HS
53. ion d air homologu L ACIDE DE LA BATTERIE peut pro voquer des br lures dans les YEUX et sur la PEAU e pas renverser la batterie e Remplacer une batterie endommag e e Rincer imm diatement les yeux et la peau l eau 2 4 Dangers li s l air comprim RESPIRER L AIR COMPRIM peut pro voquer des blessures graves ou causer la mort Ne pas utiliser l air comprim pour respirer e Utiliser l air comprim seulement pour le coupage gou geage et les outils pneumatiques L AIR COMPRIM peut provoquer des blessures e Porter des lunettes de s curit approuv es Ne pas diriger le jet d air vers d autres ou soi m me Dm L AIR COMPRIME EMMAGASINE ET DES TUYAUX SOUS PRESSION peuvent provo quer des blessures e Relacher la pression d air de l outillage ou du syst me avant d effectuer la maintenance avant de chan ger ou de rajouter des l ments ou avant d ouvrir la purge ou le bouchon de remplissage d huile 4 2 5 LA CHUTE DE L APPAREIL peut blesser e Utiliser un illeton de levage pour lever l appareil et les accessoires correctement install s Ne pas d passer le poids nominal maximal de l illeton voir les sp cifications e lever et ne soutenir l appareil qu avec de l quipement Ne pas placer l appareil sur au dessus ou proximit de surfaces inflammables e Tenir distance les produits inflammables de l chappement LES TINCELLE
54. lose fuel valve before moving unit or carburetor may flood and make starting difficult Check oil level see Section 5 4 Low oil level shutdown may stop if oil level is too low Refill crankcase with proper viscosity oil for operating temperature Unstable or sluggish engine speeds Check governor linkage for smooth non binding operation Tune up engine according to engine manual Have Factory Authorized Service Agent check engine speed and adjust if necessary OM 4418 Page 24 SECTION 10 ELECTRICAL DIAGRAMS 4 WARNING e Do not touch live electrical parts 2 Disconnect input power or stop engine before servicing AC Z Do not operate with covers removed ELECTRODE ELECTRIC Have only qualified persons install a ETE SHOCK HAZARD use or service this unit 9809 O 722 C1 770 PA zx 722 RI 08 WORK LE SR O gt 2 705 706 79 IZ WELD 777 REVOLVING FIELD 722 00000 POWER 87 85 82 94 CB1 2 oU 97 42 RC2 120V B W G 97 RC1 240V 94 B G B A B C D E F 22 81 82 83 84 PANEL SUPE GROUND GROUND 226 004 A Figure 10 1 Circuit Diagram For Welding Generator OM 4418 Page 25 SECTION 11 GENERATOR POWER GUIDELINES NOTE gt The views in this section are intended to be representative of all engine driven
55. lowmeter Regulators No Labor HFUnits Running Gear Trailers Plasma Cutting Torches Remote Controls Replacement Parts No labor Accessories Field Options NOTE Field options are covered for the remaining warranty period of the product they are installed in or for a minimum of one year whichever is greater 4 Engines batteries and tires are warranted separately by the manufacturer Hobart s 5 3 1 Limited Warranty shall not apply 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 are covered by the manufacturer s warranty if any 3 Equipmentthat has been modified by any party other than Hobart Miller or equipment that has been improperly installed improperly operated or misused based upon industry standards or equipment which has not had reasonable and necessary maintenance or equipment which has been used for operation outside of the specifications for the equipment HOBART PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT In t
56. lve except when cylinder is in use or connected for use Use the right equipment correct procedures and sufficient number of per sons to llift and move cylinders Read and follow instructions on compressed gas cylinders associated equipment and Compressed Gas Association CGA publication P 1 listed in Safety Standards MOVING PARTS can cause injury e Keep away from fans belts and rotors A e Keep all doors panels covers and guards closed and securely in place Stop engine before installing or connecting unit Have only gualified people remove doors panels covers or guards for maintenance and troubleshooting as necessary To prevent accidental starting during servicing disconnect negative battery cable from battery Keep hands hair loose clothing and tools away from moving parts Reinstall doors panels covers or guards when servicing is finished and before starting engine Before working on generator remove spark plugs or injectors to keep engine from kicking back or starting Block flywheel so that it will not turn while working on generator compo nents HOT PARTS can cause severe burns Do not touch hot engine parts Allow cooling period before maintaining Wear protective gloves and clothing when working on a hot engine STEAM AND HOT COOLANT can burn e f possible check coolant level when engine is cold to avoid scalding e Always check coolant level at overflow tank if
57. n 100 meters from any sensitive electronic equipment e sure this welding machine is installed and grounded according to this manual e f interference still occurs the user must take extra measures such as moving the welding machine using shielded cables using line filters or shielding the work area For Gasoline Engines Engine exhaust contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm For Diesel Engines Diesel engine exhaust and some of its constituents are known to the State of California to cause cancer birth defects and other reproductive harm levard Rexdale Ontario Canada M9W 1R3 phone 800 463 6727 or in Toronto 416 747 4044 website www csa international org Practice For Occupational And Educational Eye And Face Protection ANSI Standard Z87 1 from American National Standards Institute 11 West 42nd Street New York NY 10036 8002 phone 212 642 4900 website www ansi org Standard for Fire Prevention During Welding Cutting and Other Hot Work NFPA Standard 51B from National Fire Protection Association P O Box 9101 1 Battery March Park Quincy MA 02269 9101 phone 617 770 3000 website www nfpa org OSHA Occupational Safety and Health Standards for General Indus try Title 29 Code of Federal Regulations CFR Part 1910 Subpart Q and Part 1926 Subpart J from U S Government Printing Office Super intendent of Docum
58. nce et des champs magn tiques et lectriques Le courant de soudage pendant son passage dans les c bles de souda ge causera des champs lectromagn tiques a eu et il y a encore un certain souci propos de tels champs Cependant apr s avoir examin plus de 500 tudes qui ont t faites pendant une p riode de recherche de 17 ans un comit sp cial ruban bleu du National Research Council a conclu L accumulation de preuves suivant le jugement du comit n a pas d montr que l exposition aux champs magn tiques et champs lec triques haute fr quence repr sente un risque la sant humaine Toutefois des tudes sont toujours en cours et les preuves continuent tre examin es En attendant que les conclusions finales de la recherche soient tablies il vous serait souhaitable de r duire votre exposition aux champs lectromagn tiques pendant le soudage ou le coupage Pour r duire les champs magn tiques sur le poste de travail appliquer les OM 4418 Page 8 LE SOUDAGE L ARC risque de provoquer des interf rences L nergie lectromagn tique risque de provoquer des in terf rences pour l quipement lectronique sensible tel que les ordinateurs et l quipement command par ordi nateur tel que les robots Veiller ce que tout l quipement de la zone de soudage soit compatible lectromagn tiquement Pour r duire la possibilit d interf rence maintenir les c bles de
59. ne longue distance par des chemins inconnus ventuels en provoquant des risques d lectrocution d tincelles et d incendie Ne pas utiliser le poste de soudage pour d geler des conduites gel es e Encas de non utilisation enlever la baguette d lectrode du porte lectrode ou couper le fil la pointe de contact Porter des v tements de protection d pourvus d huile tels que des gants en cuir une chemise en mat riau lourd des pantalons sans revers des chaus sures hautes et un couvre chef e Avant de souder retirer toute substance combustible de vos poches telles qu un allumeur au butane ou des allumettes e Suivre les recommandations dans 1910 252 2 et 51B pour les travaux chaud et avoir de la surveillance et un extincteur proximit DES PARTICULES VOLANTES peuvent blesser les yeux 1 Le soudage l caillement le passage de la pi ce la bros se en fil de fer et le meulage g n rent des tincelles et des particules m talliques volantes Pendant la p riode de re froidissement des soudures elles risquent de projeter du laitier e Porter des lunettes de s curit avec crans lat raux ou un cran facial DES PI CES CHAUDES peuvent provoquer des br lures graves Ne pas toucher mains nues les parties chaudes e Pr voir une p riode de refroidissement avant de travailler l quipement e Ne pas toucher aux pi ces chaudes utiliser les outils recommand s
60. nt suffisamment longues pour d passer du c t oppos de l appareil LE SURCHAUFFEMENT peut endom mager le moteur lectrique Arr ter ou d connecter l quipement avant de d marrer ou d arr ter le moteur pas laisser tourner le moteur trop lentement sous risque d endommager le moteur lectrique cause d une tension et d une fr quence trop faibles pas brancher de moteur de 50 ou de 60 Hz la prise de 100 Hz s il y a lieu LES TINCELLES VOLANTES risquent 2 de provoquer des blessures e Porter un cran facial pour prot ger le visage et les yeux e Affdter l lectrode au tungst ne uniquement la meuleuse dot e de protec teurs Cette manceuvre est ex cuter dans un endroit s r lorsque l on porte l quipement homologu de protection du visage des mains et du corps e Les tincelles risquent de causer un incendie loigner toute substance in flammable LES CHARGES LECTROSTATI QUES peuvent endommager les circuits imprim s e tablir la connexion avec la barrette de terre avant de manipuler des cartes ou des pi ces e Utiliser des pochettes et des boites antistatiques pour stocker d placer ou exp dier des cartes de circuits imprimes Utiliser les supports de remorque ou des blocs pour e gt soutenir le poids e Installer convenablement le poste sur la remorque com me indiqu dans le manuel s y rapportant UNE REMORQUE QUI BASCULE peut ent
61. o On e Set Choke control Pull starter handle until engine starts e Move Choke control to the left Run as the engine warms EF This unit has a low oil level shutdown to prevent starting an engine that is too low on The low oil level shutdown may not stop a running engine Check oil level if the engine does not start or has stopped and cannot be restarted To Stop turn engine switch to Off Always close fuel valve after 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 and set Amperage control to corresponding amper age range on nameplate Adjust control within selected range to obtain desired weld performance EXAMPLE Electrode Type 6013 Electrode Diameter 1 8 Amperage control Setting 80 125 A 6 3 Amperage Selection Table For Stick SMAW Electrodes ELECTRODE DIAMETER AMPERAGE RANGE 80 100 120 140 1 8 e ce 5 32 6013 5 32 7018 3 32 1 8 Use table to select correct amper age for the electrode being used gt For best results use Stick
62. o Weld Output Terminals Jf Re i ar 1 AC Weld Output Terminals E4 Connect work and electrode cables to weld terminals Polarity does not matter for AC welding A Failure to properly connect weld cables may cause ex cessive heat and start a fire i SSA or damage your machine 2 2 2 Weld Output Terminal m 1 a i 3 Supplied Weld Output e Terminal Nut Ch Lr uL 4 Weld Cable Terminal GENERATOR POWER AMPERAGE ADJUST v 5 Copper Bar ampion 4500 uc aeran 140 ane ac wewer R lied ld emove supplied nut from we 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 UN 1 tween weld cable terminal and copper bar Make sure that the B B D surfaces of the weld cable termi nal and copper bar are clean Tools Needed 2 3 Ain Do not place anything between weld cable terminal and copper bar Correct Installation Incorrect Installation 803 469 D 226 005 803 778 A OM 4418 Page 15 5 6 Selecting Weld Ca
63. p 1 When ordering a part displaying a precautionary label order label also To maintain the factory original performance of your equipment use only Manufacturer s Suggested Replacement Parts Model and serial number required when ordering parts from your local distributor OM 4418 Page 43 Warranty Questions Call 1 800 332 3281 6 PM EST Service You 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 is there to help you every step of the way Assistance Visit the Hobart website www HobartWelders com HOBART 5 3 11 WARRANTY Effective January 1 2005 5 3 1 WARRANTY applies to all Hobart welding equipment plasma cutters and spot welders with a serial number preface LF or newer This limited warranty supersedes all previous Hobart warranties and is exclusive with no other guarantees or warranties expressed or implied Hobart products are serviced by Hobart or Miller Authorized Service Agencies LIMITED WARRANTY Subject to the terms and conditions below Hobart Miller Electric Mfg Co Appleton Wisconsin warrants to its original retail purchaser that new Hobart equipment sold after the effective date of this limited warranty is free of defects in mat
64. peuvent pro voquer des br lures dans les yeux et sur la peau Le rayonnement de l arc du proc d de soudage g n re des rayons visibles et invisibles intenses ultraviolets et infrarou ges susceptibles de provoquer des br lures dans les yeux et sur la peau Des tincelles sont projet es pendant le soudage Porter un casque de soudage approuv muni de verres filtrants appropri pour prot ger visage et yeux pendant le soudage voir ANSI Z49 1 et Z87 1 num r dans les normes de s curit Porter des lunettes de s curit avec crans lat raux m me sous votre cas que Avoir recours des crans protecteurs ou des rideaux pour prot ger les au tres contre les rayonnements les blouissements et les tincelles pr venir toute personne sur les lieux de ne pas regarder l arc Porter des v tements confectionn s avec des mati res r sistantes et ignifu ges cuir coton lourd ou laine et des bottes de protection OM 4418 Page 5 LE SOUDAGE peut provoquer un in ER cendie ou une explosion Le soudage effectu sur des conteneurs ferm s tels que des r servoirs tambours ou des conduites peut provoquer leur clatement Des tincelles peuvent tre projet es de de soudure La projection d tincelles des pi ces chaudes et des quipements chauds peut provoquer des incendies et des br lures Le contact accidentel de l lectrode avec des objets m talliques peut provoquer des tincelles une
65. pres ent on unit instead of radiator unless told otherwise in maintenance section or engine manual e engine is warm checking is needed and there is no overflow tank follow the next two statements Wear safety glasses and gloves and put a rag over radiator cap Turn cap slightly and let pressure escape slowly before completely re moving cap ENGINE EXHAUST GASES can kill Use equipment outside in open well ventilated ar eas e lfusedin a closed area vent engine exhaust outside and away from any building air intakes 1 4 Compressed Air Hazards BREATHING COMPRESSED AIR can cause serious injury or death e Do not use compressed air for breathing e Use only for cutting gouging and tools COMPRESSED AIR can cause injury e Wear approved safety goggles e Do not direct air stream toward self or others TRAPPED AIR PRESSURE AND WHIPPING HOSES can cause injury e Release air pressure from tools and system before servicing adding or changing attachments or open ing compressor oil drain or oil fill cap BATTERY ACID can BURN SKIN and EYES e Donottip battery e Replace damaged battery e Flush eyes and skin immediately with water ENGINE HEAT can cause fire e Do not locate unit on over or near combustible surfaces or flammables e Keep exhaust and exhaust pipes way from flam mables EXHAUST SPARKS can cause fire e Donotlet engine exhaust spark
66. r according to OSHA 29 CFR 1910 147 see Safety Standards e Properly install and ground this equipment according to its Owner s Manual and national state and local codes e Always verify the supply ground check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet e When making input connections attach proper grounding conductor first double check connections e Frequently inspect input power cord for damage or bare wiring replace cord immediately if damaged bare wiring can kill Turn off all equipment when not in use Do not use worn damaged undersized or poorly spliced cables Do not drape cables over your body If earth grounding of the workpiece is required ground it directly with a sep arate cable Do not touch electrode if you are in contact with the work ground or anoth er electrode from a different machine e Use only well maintained equipment Repair or replace damaged parts at once Maintain unit according to manual APA 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 Do not touch electrode holders connected to two welding machines at the same time since double open circuit voltage will be p
67. r or service agency call 1 877 Hobart1 or visit our website at www HobartWelders com For Technical Help call 1 800 332 3281 Hob Thank 4 05 5 31 WARRANTY Working as hard as you do every power source from Hobart is backed by the best warranty in the business Protect Your Investment Register your product at HobartWelders com de PAU THO TABLE OF CONTENTS SECTION 1 SAFETY PRECAUTIONS READ BEFORE USING 1 det Symbol mn rae aha ates EOR ae ee 1 1 2 Arc Welding Hazards nrc PIS WU ete nn 1 1 37 Hazards oet ette vla ee pP eerie ne ne ees ee ar Ee 2 1 4 Compressed Air HazardS uae eter Xa WIE Y NICE PY DEA Y E Y 3 1 5 Additional Symbols For Installation Operation And Maintenance 3 1 6 California Proposition 65 Warnings 4 1 7 Principal Safety Standards 4 1 8 EMPTOR Maton ts se rta cca S Aer ree od taken ael ue doe 4 SECTION 2 CONSIGNES DE S CURIT LIRE AVANT UTILISATION 5 251 Signification des symboles x sise n i bh 5 2 2 Dangers relatifs au soudage l arc 5 2 3 Dang
68. rainer des blessures OM 4418 Page 7 LIRE LES INSTRUCTIONS e Utiliser seulement les pi ces de rechange d origine e Effectuer la maintenance du moteur et du compresseur si applicable suivant ce manuel et le manuel du moteur compresseur si applicable LE RAYONNEMENT HAUTE FR QUENCE H F risque de provoquer des interf rences e Lerayonnement haute fr quence H F peut provoquer des interf rences avec les quipements de radio navigation et de communication les services de s curit et les ordinateurs e Demander seulement des personnes qualifi es familiaris es avec des quipements lectroniques de faire fonctionner l installation e L utilisateur est tenu de faire corriger rapidement par un lectricien quali fi les interf rences r sultant de l installation e Sile FCC signale des interf rences arr ter imm diatement l appareil e Effectuer r guli rement le contr le et l entretien de l installation e Maintenir soigneusement ferm s les portes et les panneaux des sources de haute fr quence maintenir les clateurs une distance correcte et utiliser une terre et un blindage pour r duire les interf rences ventuelles 2 6 Les quipements de soudage et de coupage produisent des fum es et des gaz qui contiennent des produits chimiques dont l tat de Californie reconnait qu ils provoquent des malformations cong nitales et dans certains cas des cancers Code de sant et de
69. re welding the wire wire reel drive roll housing and all metal parts touching the welding wire are electrically live Incorrectly installed or improperly grounded equipment is a hazard Do not touch live electrical parts Wear dry hole free insulating gloves and body protection Insulate yourself from work and ground using dry insulating mats or covers big enough to prevent any physical contact with the work or ground Do notuse AC output in damp areas if movement is confined or if there is a danger of falling Use AC output ONLY if required for the welding process If AC output is required use remote output control if present on unit Additional safety precautions are required when any of the following electri cally hazardous conditions are present in damp locations or while wearing wet clothing on metal structures such as floors gratings or scaffolds when in cramped positions such as sitting kneeling or lying or when there is a high risk of unavoidable or accidental contact with the workpiece or ground For these conditions use the following equipment in order present ed 1 a semiautomatic DC constant voltage wire welder 2 a DC manual stick welder or 3 an AC welder with reduced open circuit voltage In most situations use of a DC constant voltage wire welder is recommended And do not work alone e Disconnect input power or stop engine before installing or servicing this equipment Lockout tagout input powe
70. resent Wear a safety harness if working above floor level Keep all panels and covers securely in place e Clamp work cable with good metal to metal contact to workpiece or work table as near the weld as practical e Insulate work clamp when not connected to workpiece to prevent contact with any metal object e Do not connect more than one electrode or work cable to any single weld output terminal SIGNIFICANT DC VOLTAGE exists in inverters after stop ping engine e Stop engine on inverter and discharge input capacitors according to instructions in Maintenance Section before touching any parts FUMES AND GASES can be hazardous Welding produces fumes and gases Breathing these fumes and gases can be hazardous to your health 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 poor wear an approved air supplied respirator Read and understand the Material Safety Data Sheets MSDSs and the manufacturer s instructions for metals consumables coatings cleaners and degreasers e Work in a confined space only if it is well ventilated or while wearing an air supplied respirator Always have a trained watchperson nearby Welding fumes and gases can displace air and lower the oxygen level causing injury or death Be sure the breathing air is safe e Do not weld in locations near degreasing cl
71. round Device Ground generator to sys tem earth ground if supply ing power to a premises home shop farm wiring system 800 576 B 5 4 Engine Prestart Checks 4 CL F Gasoline Open On Closed Off 5 Always close fuel valve after stopping unit Moving unit with fuel valve open may cause carburetor flooding and make starting difficult 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 FuelValve Open valve Close fuel valve before moving unit or carburetor may flood and make starting difficult Fuel Add fresh fuel before starting engine the first time Fill fuel tank up to 1 2 in 13 mm from top to allow room for expansion Check fuel lev el ona cold engine before use each day Cil After fueling check oil with unit on level surface If oil reservoir is not full add oil until oil nearly overflows at oil fill 5 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 low oil level shutdown system to monitor oil level E To improve cold weather start ing use correct grade oil for cold weather see engine own er s manual 803 468 D OM 4418 Page 14 5 5 Connecting T
72. ructions du fabricant concernant les m taux les consommables les rev tements les nettoyants et les d graisseurs Travailler dans un espace ferm seulement s il est bien ventil ou en portant un respirateur alimentation d air Demander toujours un surveillant d ment form de se tenir proximit Des fum es et des gaz de soudage peuvent d placer l air et abaisser le niveau d oxyg ne provoquant des blessures ou des accidents mortels S assurer que l air de respiration ne pr sente aucun dan ger Ne pas souder dans des endroits situ s proximit d op rations de d grais sage de nettoyage ou de pulv risation La chaleur et les rayons de l arc peuvent r agir en pr sence de vapeurs et former des gaz hautement toxiques et irritants Ne pas souder des m taux munis d un rev tement tels que l acier galvanis plaqu en plomb ou au cadmium moins que le rev tement n ait t enlev dans la zone de soudure que l endroit soit bien ventil et en portant un respi rateur alimentation d air Les rev tements et tous les m taux renfermant ces l ments peuvent d gager des fum es toxiques en cas de soudage LES ACCUMULATIONS DE GAZ ris quent de provoquer des blessures ou m me la mort e Fermer l alimentation du gaz protecteur en cas de non utili sation Veiller toujours bien a rer les espaces confin s ou se servir d un respira teur d adduction d air homologu LES RAYONS DE L ARC
73. s curit de Californie chapitre 25249 5 et suivants Les batteries les bornes et autres accessoires contiennent du plomb et des compos s base de plomb produits chimiques dont l tat de Cali fornie reconnait qu ils provoquent des cancers et des malformations cong nitales ou autres probl mes de procr ation Se laver les mains apr s manipulation 2 T Safety in Welding Cutting and Allied Processes ANSI Standard Z49 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com Principales normes de s curit Recommended Safe Practices for the Preparation for Welding and Cutting of Containers and Piping American Welding Society Standard AWS F4 1 de Global Engineering Documents t l phone 1 877 413 5184 site In ternet www global ihs com National Electrical Code NFPA Standard 70 de National Fire Protection Association Box 9101 1 Battery March Park Quincy MA 02269 9101 t l phone 617 770 3000 site Internet www nfpa org Safe Handling of Compressed Gases in Cylinders CGA Pamphlet P 1 de Compressed Gas Association 1735 Jefferson Davis Highway Suite 1004 Arlington VA 22202 4102 t l phone 703 412 0900 site Internet www cganet com Code for Safety in Welding and Cutting CSA Standard W117 2 de Canadian Standards Association Standards Sales 178 Rexdale 2 8 Information EMF Consid rations sur le soudage et les effets de basse fr que
74. s cause fire Use approved engine exhaust spark arrestor in re quired areas see applicable codes HOT METAL from air arc cutting and gouging can cause fire or explosion e Do not cut or gouge near flammables e Watch for fire keep extinguisher nearby HOT PARTS can cause burns and injury e Do not touch hot compressor or air system parts e Letsystem cool down before touching or servicing READ INSTRUCTIONS Read Owner s Manual before using or servicing unit Stop engine and release air pressure before servicing e Use only genuine Miller Hobart replacement parts 1 5 Additional Symbols For Installation Operation And Maintenance FALLING UNIT can cause injury e Use lifting eye to lift unit and properly installed acces sories only Do not exceed maximum lift eye weight rating see Specifications e Lift and support unit only with proper eguipment and correct procedures e f using lift forks to move unit be sure forks are long enough to extend beyond opposite side of unit OVERHEATING can damage motors e Turn off or unplug equipment before starting or stop ping engine e Do not let low voltage and frequency caused by low engine speed damage electric motors e Do not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable FLYING SPARKS can cause injury e Wear a face shield to protect eyes and face e Shapetungsten electrode only on grinder with proper guards in
75. ss Mes dais cs aerem 209339 se DUCA Rel IN REIR ae aa dite euni 209340 Seal Air DUCK exe su a E vA nie P DEA Ue TR SD EE 225768 Engine Gas Recoil Start ER 067007 Spark Plug ied be he E me vean per eeu is da doy Baste Soa TAM dO NAS 219540 AirFiltet rase eek gant ie ane tam Y pie ac dA AK EAE 226023 Air Filter Pre Cleaner PNG ia hae nues ce 211987 Bracket Mtg Engine FT se LM 222658 Adapter Engine 2 44 14 MR p EAN 18 STATOR 216096 Stator Generator 19 ROTOR 210572 Rotor Generator Includes EM 209004 Fan Rotor Gen eee dN T 495154 Bearing Ball Radial 495349 Screw 250 20 Hwh 26 autrui 222660 Endbell Gen esse cte s x IM taa EF RU Rd os 495348 Screw 312 24 Hwh ed qne EA Cu 222656 Cover Endbell psu sks 214725 2 Fr me Base eei ace 1 eat
76. tact avec une bouteille Ne jamais souder une bouteille pressuris e risque d explosion Utiliser seulement des bouteilles de gaz protecteur r gulateurs tuyaux et rac cords convenables pour cette application sp cifique les maintenir ainsi que les l ments associ s en bon tat Ne pas tenir la t te en face de la sortie en ouvrant la soupape de la bouteille e Maintenir le chapeau de protection sur la soupape sauf en cas d utilisation ou de branchement de la bouteille e Utiliser les quipements corrects les bonnes proc dures et suffisamment de personnes pour soulever et d placer les bouteilles e Lire et suivre les instructions sur les bouteilles de gaz comprim l quipement connexe et le d pliant P 1 de la CGA Compressed Gas Association men tionn dans les principales normes de s curit 2 3 Dangers existant en relation avec le moteur L EXPLOSION DE LA BATTERIE peut RENDRE AVEUGLE e Toujours porter une protection faciale des gants en caout chouc et v tements de protection lors d une intervention sur la batterie e Arr ter le moteur avant de d brancher ou de brancher les cables de batterie e Eviter de provoquer des tincelles avec les outils en travaillant sur la batterie e Ne pas utiliser le poste de soudage pour charger les batteries ou des v hicu les de d marrage rapide Observer la polarit correcte et sur les batteries D brancher le c ble n gatif en premier lieu Le r
77. vez les directives mentionn es afin d viter tout danger Les consignes de s curit pr sent es ci apr s ne font que r sumer l information contenue dans les normes de s curit num r es la section 2 7 Veuillez lire et respecter toutes ces normes de s curit installation l utilisation l entretien et les r parations ne doivent tre confi s qu des personnes qualifi es Au cours de l utilisation tenir toute personne l cart et plus particu li rement les enfants UN CHOC LECTRIQUE peut tuer e Un simple contact avec des pi ces lectriques peut provo quer une lectrocution ou des blessures graves L lectrode et le circuit de soudage sont sous tension d s que l appareil est sur ON Le circuit d entr e et les circuits internes de l appareil sont galement sous tension ce moment l En soudage semi automatique ou automatique le fil le d vidoir le logement des galets d entrainement et les pi ces m talliques en contact avec le fil de soudage Sont sous tension Des mat riels mal install s ou mal mis la terre pr sentent un danger Ne jamais toucher les pi ces lectriques sous tension Porter des gants et des v tements de protection secs ne comportant pas de trous S isoler de la pi ce et de la terre au moyen de tapis ou d autres moyens iso lants suffisamment grands pour emp cher le contact physique ventuel avec la pi ce ou la terre Ne pas se servir de source lectrique

Champion 4500 - Hobart Welders

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