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OM-4418 210 597A
February 2003
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
Champion 4500
Visit our website at
www.HobartWelders.com
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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
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TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-2. Arc Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1-3. Engine Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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SECTION 1 – SAFETY PRECAUTIONS – READ BEFORE USING rom _nd_10/02 Warning: Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. This group of symbols means Warning! Watch Out! possible Marks a special safety message. ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for nec
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BUILDUP OF GAS can injure or kill. FLYING METAL can injure eyes. Shut off shielding gas supply when not in use. Welding, chipping, wire brushing, and grinding cause sparks and flying metal. As welds cool, Always ventilate confined spaces or use they can throw off slag. approved air-supplied respirator. Wear approved safety glasses with side shields even under your welding helmet. ARC RAYS can burn eyes and skin. HOT PARTS can cause severe burns. Arc rays from the welding process produce
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MOVING PARTS can cause injury. ENGINE EXHAUST GASES can kill. Keep away from fans, belts, and rotors. Use equipment outside in open, well-ventilated areas. Keep all doors, panels, covers, and guards closed and securely in place. If used in a closed area, vent engine exhaust outside and away from any building air intakes. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary. To prevent
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FLYING SPARKS can cause injury. H.F. RADIATION can cause interference. Wear a face shield to protect eyes and face. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and Shape tungsten electrode only on grinder with communications equipment. proper guards in a safe location wearing proper face, hand, and body protection. Have only qualified persons familiar with electronic equipment perform this installation. Sparks can cause fires — keep flammables
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SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom_10_02fre Avertissement: Protégez vous et les autres des blessures – lisez et suivez ces précautions. 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure Ce groupe de symboles si- présente des risques de danger ! Ceux-ci sont identifiés par gnifie Mise en garde ! des symboles adjacents aux directives. Soyez vigilant ! Il y a des risques de danger reliés Identifie un message de sécurité partic
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Suivre les recommandations dans OSHA 1910.252(a)(2)(iv) et NFPA 51B LES ACCUMULATIONS DE GAZ ris- pour les travaux à chaud et avoir de la surveillance et un extincteur à proxi- quent de provoquer des blessures ou mité. même la mort. DES PARTICULES VOLANTES peuvent blesser les yeux. Fermer l’alimentation du gaz protecteur en cas de non utilisation. Veiller toujours à bien aérer les espaces confinés ou se servir d’un respi- Le soudage, l’écaillement, le passage de la pièce rateur d’adducti
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Pour empêcher tout démarrage accidentel pendant les travaux d’entretien, L’EXPLOSION DE LA BATTERIE peut débrancher le câble négatif (–) de batterie de la borne. RENDRE AVEUGLE. Ne pas approcher les mains, cheveux, vêtements lâches et outils des orga- nes mobiles. Toujours porter une protection faciale, des gants en Remettre en place les panneaux ou les dipositifs de protection et fermer les caoutchouc et vêtements de protection lors d’une in- portes à la fin des travaux d’entretien et a
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LE SURCHAUFFEMENT peut endom- LIRE LES INSTRUCTIONS. mager le moteur électrique. Utiliser seulement les pièces de rechange d’origine. Effectuer la maintenance du moteur et du compres- Arrêter ou déconnecter l’équipement avant de dé- seur (si applicable) suivant ce manuel et le manuel du marrer ou d’arrêter le moteur. moteur/compresseur (si applicable). Ne pas laisser tourner le moteur trop lentement sous risque d’endommager le moteur électrique à cause d’une tension et d’une fréquence tr
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SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Read Operator’s Engine Choke Amperes Volts Manual A V Engine Oil Fuel Battery (Engine) Engine Alternating Current Positive Negative Output (AC) Protective Earth Hours Seconds Time (Ground) s h Circuit Breaker Temperature SECTION 3 – SPECIFICATIONS 3-1. Weld, Power, And Engine Specifications Weld Maximum Welding Rated Generator Fuel Output Open Circuit Engine Mode Welding Output Power Rating Capacity Range Voltage 140 A, 20 V, 30% Duty Cycle Single-
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3-3. Fuel Consumption 210 593 3-4. Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. Exceeding duty cycle can damage unit and void warranty. Continuous Welding 100% Duty Cycle at 90 Amperes CC/AC 3 Minutes Welding 7 Minutes Resting 30% Duty Cycle at 140 Amperes CC/AC 212 950 OM-4418 Page 10
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3-5. Generator Power Curve The ac generator power curves show the generator power available in amperes at the receptacles. 210 592 3-6. 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. 212 871 OM-4418 Page 11
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SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Movement Airflow Clearance 18 in (460 mm) 18 in 18 in (460 mm) (460 mm) 18 in 18 in (460 mm) (460 mm) Location Always securely fasten welding generator onto transport vehicle or trailer and comply with all DOT and other applicable codes. install1 11/02 – / Ref. 151 556 / 158 936-A / 803 467 / S-0854 4-2. Grounding Generator To Truck Or Trailer Frame Always ground generator frame to vehicle frame to pre- vent electric shock and stati
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4-3. Grounding Generator When Supplying Building Systems 1 Equipment Grounding 1 2 GND/PE Terminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire. 3 Ground Device Ground generator to sys- tem earth ground if supply- Use ground device as ing power to a premises stated in electrical codes. (home, shop, farm) wiring system. 2 3 800 576-B 4-4. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. 1/2 in (13
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4-5. Connecting To Weld Output Terminals 1 AC Weld Output Terminals Connect work and electrode cables weld terminals. (Polarity does not matter for AC welding.) 1 Tools Needed: 3/4 in 803 469 4-6. Selecting Weld Cable Sizes* Weld Cable Size** and Total Cable (Copper) Length in Weld Circuit Not Exceeding*** 150 ft 200 ft 250 ft 300 ft 350 ft 400 ft 100 ft (30 m) or Less (45 m) (60 m) (70 m) (90 m) (105 m) (120 m) Weld Output Terminals Turn off power before 10 – 60% 60 – 100% Welding connecting
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SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Controls (See Section 5-2) 1 2 3 4 4 803 468 / 803 469 / 210 586 OM-4418 Page 15
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5-2. Description Of Controls (See Section 5-1) 1 Engine Switch Open choke as engine warms. Use control to select weld amperage. Control may be adjusted while welding. Set Amper- Use switch to control ignition circuit, and to This unit has a low oil level shutdown to age control at max. for full generator power stop engine. prevent starting an engine that is too low output at ac receptacles. 2 Choke Control on oil. The low oil level shutdown may not To Set Current Control: Use electrode chart
