Main
Champion 8500
From Hobart to You
TABLE OF CONTENTS
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SECTION 1 SAFETY PRECAUTIONS - READ BEFORE USING
1-1. Symbol Usage
1-2. Arc Welding Hazards
ELECTRIC SHOCK can kill.
SIGNIFICANT DC VOLTAGE exists after stopping engine on inverters.
1-3. Engine Hazards
FUEL can cause fire or explosion.
STEAM AND HOT COOLANT can burn.
MOVING PARTS can cause injury.
BATTERY EXPLOSION can BLIND.
1-4. Additional Symbols For Installation, Operation, And Maintenance
FALLING UNIT can cause injury.
FLYING SPARKS can cause injury.
OVERHEATING can damage motors.
OVERUSE can cause OVERHEATING.
1-5. Principal Safety Standards
1-6. EMF Information
OM-493 Page 5
SECTION 1 CONSIGNES DE SCURIT LIRE AVANT UTILISATION
1-1. Signification des symboles
1-2. Dangers relatifs au soudage larc
UN CHOC LECTRIQUE peut tuer.
Une tension DC importante subsiste lintrieur des onduleurs aprs avoir coup lalimentation.
1-3. Dangers existant en relation avec le moteur
LE CARBURANT MOTEUR peut pro- voquer un incendie ou une explosion.
LA VAPEUR ET LE LIQUIDE DE REFROIDISSEMENT CHAUD peuvent provoquer des brlures.
1-4. Dangers supplmentaires en relation avec linstallation, le fonctionnement et la maintenance
LE RAYONNEMENT HAUTE FR- QUENCE (H.F.) risque de provoquer des interfrences.
LE SOUDAGE LARC risque de provoquer des interfrences.
1-5. Principales normes de scurit
1-6. Information sur les champs lectromagntiques
SECTION 2 DEFINITIONS
h Hours s
2-1. Symbol Definitions
SECTION 3 SPECIFICATIONS
3-1. Weld, Power, and Engine Specifications
3-2. Dimensions, Weights, and Operating Angles
3-3. Auxiliary Power Curve
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3-6. Volt-Ampere Curve
SECTION 4 INSTALLATION
4-1. Installing Welding Generator
4-2. Engine Prestart Checks
4-3. Activating The Dry Charge Battery (If Applicable)
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4-6. Connecting to Weld Output Terminals
4-7. Selecting Weld Cable Sizes
SECTION 5 OPERATING THE WELDING GENERATOR
5-1. Front Panel Controls
SECTION 6 OPERATING AUXILIARY EQUIPMENT
6-1. Standard Receptacles
6-2. Optional Auxiliary Power Receptacles
SECTION 7 MAINTENANCE
7-1. Routine Maintenance
Note
20 h 25 h
50 h
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7-3. Servicing Air Cleaner
7-4. Overload Protection
7-5. Changing Engine Oil, Oil Filter, and Fuel Filter
7-6. Adjusting Engine Speed
7-7. Servicing Optional Spark Arrestor
SECTION 8 TROUBLESHOOTING
A. Welding
B. Auxiliary Power
C. Engine
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SECTION 10 AUXILIARY POWER GUIDELINES
10-1. Selecting Equipment
OR
10-2. Grounding Generator To Truck Or Trailer Frame
10-3. Grounding When Supplying Building Systems
10-4. How Much Power Does Equipment Require?
10-5. Approximate Power Requirements For Industrial Motors
10-6. Approximate Power Requirements For Farm/Home Equipment
10-7. Approximate Power Requirements For Contractor Equipment
10-8. Power Required To Start Motor
10-9. How Much Power Can Generator Supply?
10-10.Typical Connections To Supply Standby Power
10-11.Selecting Extension Cord (Use Shortest Cord Possible)
SECTION 11 STICK WELDING (SMAW) GUIDELINES
11-1. Stick Welding Procedure
OM-493 Page 37
11-2. Electrode and Amperage Selection Chart
2
3
11-3. Striking an Arc Scratch Start Technique
1 2 3
11-5. Positioning Electrode Holder
11-6. Poor Weld Bead Characteristics
11-7. Good Weld Bead Characteristics
11-8. Conditions That Affect Weld Bead Shape
NOTE
11-9. Electrode Movement During Welding
NOTE
11-10.Butt Joints
11-11.Lap Joint
11-12.Tee Joint
11-13.Weld Test
11-14.Troubleshooting Porosity
11-15.Troubleshooting Excessive Spatter
11-16.Troubleshooting Incomplete Fusion
11-17.Troubleshooting Lack Of Penetration
11-18.Troubleshooting Excessive Penetration
11-19.Troubleshooting Burn-Through
11-20.Troubleshooting Waviness Of Bead
11-21.Troubleshooting Distortion
SECTION 12 PARTS LIST
Figure 12-1. Main Assembly
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Warranty Questions?
Call 1-877-HOBART1 for your local Hobart distributor.
Effective January 1, 2000 (Equipment with a serial number preface of LA or newer)
Please complete and retain with your personal records.
Resources Available
Always provide Model Name and Serial/Style Number.
Owners Record
