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Hobart Welding Products Champion 8500 Owner's Manual

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Champion 8500
OM-493
191 021
July 1998
Processes
Stick (SMAW) Welding
Non-Critical TIG (GTAW)
Welding
Description
Engine Driven Welding Generator

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Summary of Contents for Hobart Welding Products Champion 8500

  • Page 1 OM-493 191 021 July 1998 Processes Stick (SMAW) Welding Non-Critical TIG (GTAW) Welding Description Engine Driven Welding Generator  Champion 8500...
  • Page 2 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.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING ......1-1. Symbol Usage .

  • Page 5: Section 1 - Safety Precautions - Read Before Using

    SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING rom _nd_5/97 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 Y Marks a special safety message.

  • Page 6: Engine Hazards

    WELDING can cause fire or explo- HOT PARTS can cause severe burns. sion. D Allow cooling period before maintaining. Welding on closed containers, such as tanks, D Wear protective gloves and clothing when drums, or pipes, can cause them to blow up. Sparks working on a hot engine.

  • Page 7: Additional Symbols For Installation, Operation, And Maintenance

    BATTERY ACID can BURN SKIN and MOVING PARTS can cause injury. EYES. D Keep away from fans, belts, and rotors. D Do not tip battery. D Keep all doors, panels, covers, and guards D Replace damaged battery. closed and securely in place. D Flush eyes and skin immediately with water.

  • Page 8: Principal Safety Standards

    H.F. RADIATION can cause interference. ARC WELDING can cause interference. D High-frequency (H.F.) can interfere with radio D Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment D Have only qualified persons familiar with such as robots.

  • Page 9: Section 1 - Consignes De Sécurité - Lire Avant Utilisation

    SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 5/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des Y Identifie un message de sécurité...

  • Page 10: Dangers Existant En Relation Avec Le Moteur

    tous les métaux renfermant ces éléments peuvent dégager des fumées DES PIÈCES CHAUDES peuvent toxiques en cas de soudage. provoquer des brûlures graves. LE SOUDAGE peut provoquer un in- D Prévoir une période de refroidissement avant d’effec- cendie ou une explosion. tuer des travaux d’entretien.

  • Page 11: Dangers Supplémentaires En Relation Avec L'installation, Le Fonctionnement Et La Maintenance

    DES ORGANES MOBILES peuvent L’ACIDE DE LA BATTERIE peut pro- provoquer des blessures. voquer des brûlures dans les YEUX et sur la PEAU. D Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. D Ne pas renverser la batterie. D Maintenir fermés et fixement en place les portes, D Remplacer une batterie endommagée.

  • Page 12: Principales Normes De Sécurité

    LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. D L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique D Le rayonnement haute fréquence (H.F.) peut sensible tel que les ordinateurs et l’équipement com- provoquer des interférences avec les équipements mandé...

  • Page 13: Section 2 - Definitions

    SECTION 2 – DEFINITIONS 2-1. Symbol Definitions Fast Fast/Slow Stop Engine Slow (Idle) (Run, Weld/Power) (Run/Idle) Read Operator’s Start Engine Amperes Volts Manual Engine Oil Fuel Battery (Engine) Engine Check Valve Do not switch while Engine Choke Work Connection Clearance welding Alternating Current Positive...

  • Page 14: Dimensions, Weights, And Operating Angles

    3-2. Dimensions, Weights, and Operating Angles Dimensions Height 33-1/2 in (851 mm) Width 18-3/4 in (476 mm) Y Do not exceed operating angles while run- Y Do not exceed operating angles while run- Depth 46 in (1164 mm) ning or engine damage will occur. Y Do not move or operate unit where it could Do not move or operate unit where it could 18 in (457 mm)

  • Page 15: Fuel Consumption

    3-4. Fuel Consumption SB-191 556 3-5. Duty Cycle Duty cycle is the percentage of 10 minutes that unit can weld at rated load without overheating. Y Exceeding duty cycle can damage unit void warranty. Continuous Welding 100% Duty Cycle at 210 Amperes CC/DC SB-191 554 OM-493 Page 11...

  • Page 16: Volt-Ampere Curve

    3-6. Volt-Ampere Curve 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. ST-191 555 SECTION 4 – INSTALLATION 4-1. Installing Welding Generator Generator Base Metal Vehicle Frame Equipment Grounding...

  • Page 17: Engine Prestart Checks

    4-2. Engine Prestart Checks Check all fluids daily. Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Engine stops if oil pressure gets too low. Full Follow run-in procedure in en- gine manual. Fuel Full Add fresh fuel before starting...

  • Page 18: Activating The Dry Charge Battery (If Applicable)

    4-3. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. Eye Protection – Safety Glasses Or Face Shield Rubber Gloves Vent Caps Sulfuric Acid Electrolyte (1.265 Specific Gravity) Well Fill each cell with electrolyte to bottom of well (maximum). Y Do not overfill battery cells.

  • Page 19: Connecting The Battery

    4-4. Connecting the Battery Y Connect negative (–) cable last. – Tools Needed: 3/8, 1/2 in Ref. ST-190 167-A / Ref. ST-802 212 4-5. Installing Exhaust Pipe Point exhaust pipe in desired direction. If unit is truck or trailer mounted, point pipe away from direction of travel.

  • Page 20: Connecting To Weld Output Terminals

    4-6. Connecting to Weld Output Terminals Work Weld Output Terminal Electrode Weld Output Terminal Direct Current Electrode Positive (DCEP), connect work cable to Negative (–) terminal and electrode holder to Positive (+) terminal. Direct Current Electrode negative (DCEN), reverse cable connections.

  • Page 21: Section 5 - Operating The Welding Generator

    SECTION 5 – OPERATING THE WELDING GENERATOR 5-1. Front Panel Controls Engine Control Switch and slowly push choke in when engine starts. For best arc starts, use lowest amperage Do not crank engine if engine is still turning. Use switch to start engine, select speed, and range possible.

  • Page 22: Section 6 - Operating Auxiliary Equipment

    SECTION 6 – OPERATING AUXILIARY EQUIPMENT 6-1. Standard Receptacles Y If unit does not have GFCI re- ceptacles, GFCI- protected extension cord. Auxiliary power decreases as weld current increases. Set Fine Adjust control R1 at 10 for full auxiliary power. 240 V 30 A AC Receptacle RC1 supplies 60 Hz single-phase power at weld/power speed.

  • Page 23: Optional Auxiliary Power Receptacles

    6-2. Optional Auxiliary Power Receptacles Y If unit does not have GFCI re- ceptacles, GFCI- protected extension cord. Auxiliary power decreases as weld current increases. Set Fine Adjust control R1 at 10 for full auxiliary power. Combined output of all receptacles limited to 8 kVA/kW rating of the generator.

  • Page 24: Section 7 - Maintenance

    SECTION 7 – MAINTENANCE 7-1. Routine Maintenance Y Stop engine before maintaining. See also Engine Manual and maintenance Recycle engine label. Service engine more often if used in fluids. severe conditions. Check fluid levels. Wipe up spills. See Section 4-2. 25 h 20 h Service...

  • Page 25: Maintenance Label

    7-2. Maintenance Label OM-493 Page 21...

  • Page 26: Servicing Air Cleaner

    7-3. Servicing Air Cleaner Y Stop engine. Y Do not run engine without air cleaner or with dirty element. Wrapper (Foam Element) Wash wrapper with soap and water solution. Allow wrapper to air dry completely. Spread 1 tablespoon SAE 30 oil evenly into wrapper.

  • Page 27: Changing Engine Oil, Oil Filter, And Fuel Filter

    7-5. Changing Engine Oil, Oil Filter, and Fuel Filter Y Stop engine and let cool. Oil Drain Valve 1/2 ID x 12 in Hose Oil Filter Change engine oil and filter accord- ing to engine owner’s manual. Y Close valve and valve cap before adding Full...

  • Page 28: Adjusting Engine Speed

    7-6. Adjusting Engine Speed After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: ± 2200 100 rpm Start engine and run until warm. Turn Fine Adjust control to 10. ± 3700 50 rpm Remove top cover to access speed adjustments.

  • Page 29: Servicing Optional Spark Arrestor

    7-7. Servicing Optional Spark Arrestor Y Stop engine and let cool. Spark Arrestor Screen Clean and inspect screen. Replace spark arrestor if screen wires are broken or missing. Tools Needed: 1/4 in ST-802 210 / Ref. ST-801 682-A / Ref. ST-190 167–A OM-493 Page 25...

  • Page 30: Section 8 - Troubleshooting

    SECTION 8 – TROUBLESHOOTING A. Welding Trouble Remedy No weld output. Check control settings. Check weld connections. Check fuse F1 and replace if open (see Section 7-4). Be sure all equipment is disconnected from receptacles when starting unit. Have Factory Authorized Service Agent check brushes, slip rings, and integrated rectifier SR2. Check plug PLG6 connection.
  • Page 31 C. Engine Trouble Remedy Engine will not crank. Check fuse F6, and replace if open (see Section 7-4). Check battery voltage. Check battery connections and tighten if necessary. Check plug PLG4 and plug PLG8 connections. Have Factory Authorized Service Agent check Engine Control switch S2. Engine will not start.

  • Page 32: Section 9 - Electrical Diagram

    SECTION 9 – ELECTRICAL DIAGRAM ST-191 080-A Figure 9-1. Circuit Diagram For Welding Generator OM-493 Page 28...

  • Page 33: Section 10 - Auxiliary Power Guidelines

    SECTION 10 – AUXILIARY POWER GUIDELINES 10-1. Selecting Equipment Auxiliary Power Receptacles – Neutral Bonded To Frame 3-Prong Plug From Case Grounded Equipment 2-Prong Plug From Double Insulated Equipment Be sure equipment has this symbol and/or wording. aux_pwr 12/96 – Ref. ST-159 730 / ST-800 577 10-2.
  • Page 34 10-3. Grounding When Supplying Building Systems Equipment Grounding Terminal Grounding Cable GND/PE Use #10 AWG or larger insulated copper wire. Ground Device Y Ground generator to system earth ground if supplying power to a premises (home, shop, farm) wiring system. Use ground device as stated in electrical codes.
  • Page 35 10-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 1/6 HP 1225 1/4 HP 1600 1/3 HP 2100 1/2 HP 3175 Capacitor Start-Induction Run 1/3 HP 2020 1/2 HP 3075 3/4 HP 4500 1400 1 HP...
  • Page 36 10-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 3/8 in 1/2 in Circular Saw 6-1/2 in 7-1/4 in 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw 14 in...
  • Page 37 10-8. Power Required To Start Motor Motor Start Code AC MOTOR Running Amperage VOLTS AMPS Motor HP CODE Motor Voltage PHASE 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.
  • Page 38 10-10. Typical Connections To Supply Standby Power Power Company Service Meter Main and Branch Overcurrent Protection Double-Pole, Double-Throw Transfer Switch Obtain and install correct switch. Customer-supplied equipment is required if Switch rating must be same as or generator is to supply standby power during greater than the branch overcurrent emergencies or power outages.
  • Page 39 10-11. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 Volt Loads Y 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) (Amperes) 350 (106) 225 (68)

  • Page 40: Section 11 - Stick Welding (Smaw) Guidelines

    SECTION 11 – STICK WELDING (SMAW) GUIDELINES 11-1. Stick Welding Procedure Y Weld current starts when electrode touches work- piece. Y 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.
  • Page 41 11-2. Electrode and Amperage Selection Chart 3/32 6010 5/32 & 3/16 6011 7/32 6010 DEEP MIN. PREP, ROUGH 1/16 HIGH SPATTER 6011 DEEP 5/64 6013 EP,EN GENERAL 3/32 SMOOTH, EASY, 6013 7014 EP,EN FAST 5/32 3/16 LOW HYDROGEN, 7018 STRONG 7/32 FLAT SMOOTH, EASY,...
  • Page 42 11-5. Positioning Electrode Holder ° ° ° ° End View of Work Angle Side View of Electrode Angle GROOVE WELDS ° ° ° ° End View of Work Angle Side View of Electrode Angle FILLET WELDS S-0060 11-6. Poor Weld Bead Characteristics Large Spatter Deposits Rough, Uneven Bead Slight Crater During Welding...
  • Page 43 11-8. 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 Large Angle Too Small Drag ELECTRODE ANGLE Spatter Normal Too Long Too Short...
  • Page 44 11-10. Butt Joints Tack Welds Prevent edges of joint from drawing together ahead of electrode by tack welding the materials in position be- fore final weld. Square Groove Weld Good for materials up to 3/16 in (5 mm) thick. Single V-Groove Weld °...
  • Page 45 11-13. Weld Test Vise Weld Joint Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 To 3 in (51-76 mm) 2 To 3 in (51-76 mm) 1/4 in (6.4 mm) S-0057-B 11-14. Troubleshooting – Porosity Porosity –...
  • Page 46 11-16. Troubleshooting – Incomplete Fusion Incomplete Fusion – failure of weld metal to fuse completely with base metal or a preceeding weld bead. 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.
  • Page 47 11-19. 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. 11-20. Troubleshooting – Waviness Of Bead Waviness Of Bead –...

  • Page 48: Section 12 - Parts List

    SECTION 12 – PARTS LIST Hardware is common and not available unless listed. Figure 12-1. Main Assembly ST-802 214 OM-493 Page 44...
  • Page 49 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly ....181 881 GROMMET, neck filler ..........
  • Page 50 Item Dia. Part Mkgs. Description Quantity Figure 12-1. Main Assembly (Continued) ..035 704 RECTIFIER, integ 40A 800V ........
  • Page 51 Item Dia. Part Mkgs. Description Quantity Figure 12-2. Panel, Front w/Components (Figure 12-1 Item 42) ......NAMEPLATE (order by model and serial number) .
  • Page 52 Item Part Description Quantity Figure 12-3. Generator (Figure 12-1 Item 22) ..013 367 LABEL, warning moving parts ..........
  • Page 53 Notes...
  • Page 54 Notes...
  • Page 55 Hobart Warranty Effective January 1, 1997 This limited warranty supersedes all previous manufacturers Limited Warranty shall not apply to: warranties and is exclusive with no other guarantees or Items furnished by manufacturer, but manufactured by warranties expressed or implied. others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if LIMITED WARRANTY –...
  • Page 56 Call 1-877-Hobart1 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 2003 Hobart Welding Products. 1/03...

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