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OM-493 191 021C
January 2000
Processes
Stick (SMAW) Welding
Non-Critical TIG (GTAW)
Welding
Description
Engine Driven Welding Generator
Champion 8500
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_11/98 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 necessary actions Means “Note”; not safety related. to avoid the hazards. 1-2. Arc Weldi
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WELDING can cause fire or explosion. HOT PARTS can cause severe burns. Allow cooling period before maintaining. Welding on closed containers, such as tanks, drums, or pipes, can cause them to blow up. Sparks Wear protective gloves and clothing when working on a hot engine. can fly off from the welding arc. The flying sparks, hot workpiece, and hot equipment can cause fires and Do not touch hot engine parts or just-welded burns. Accidental contact of electrode to metal objects can cause par
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BATTERY ACID can BURN SKIN and MOVING PARTS can cause injury. EYES. Keep away from fans, belts, and rotors. Do not tip battery. Keep all doors, panels, covers, and guards closed and securely in place. Replace damaged battery. Flush eyes and skin immediately with water. Stop engine before installing or connecting unit. Have only qualified people remove guards or covers for maint- enance and troubleshooting as necessary. To prevent accidental starting during servicing, disconnect n
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H.F. RADIATION can cause interference. ARC WELDING can cause interference. High-frequency (H.F.) can interfere with radio Electromagnetic energy can interfere with navigation, safety services, computers, and sensitive electronic equipment such as communications equipment. computers and computer-driven equipment such as robots. Have only qualified persons familiar with electronic equipment perform this installation. Be sure all equipment in the welding area is electromagnetically compatib
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SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION rom _nd_fre 11/98 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 Identifie un message de sécurité particulier. risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportez-vous
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LE SOUDAGE peut provoquer un in- DES PIÈCES CHAUDES peuvent cendie ou une explosion. provoquer des brûlures graves. Prévoir une période de refroidissement avant d’effec- Le soudage effectué sur des conteneurs fermés tels que tuer des travaux d’entretien. des réservoirs, tambours ou des conduites peut provoquer leur éclatement. Des étincelles peuvent être projetées de Porter des gants et des vêtements de protection pour l’arc de soudure. La projection d’étincelles, des pièces chaudes et des t
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DES ORGANES MOBILES peuvent L’ACIDE DE LA BATTERIE peut pro- provoquer des blessures. voquer des brûlures dans les YEUX et sur la PEAU. Ne pas approcher les mains des ventilateurs, cour- roies et autres pièces en mouvement. Ne pas renverser la batterie. Maintenir fermés et fixement en place les portes, Remplacer une batterie endommagée. panneaux, recouvrements et dispositifs de Rincer immédiatement les yeux et la peau à l’eau. protection. Arrêter le moteur avant d’installer ou branch
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LE RAYONNEMENT HAUTE FRÉ- LE SOUDAGE À L’ARC risque de QUENCE (H.F.) risque de provoquer provoquer des interférences. des interférences. L’énergie électromagnétique risque de provoquer des interférences pour l’équipement électronique Le rayonnement haute fréquence (H.F.) peut sensible tel que les ordinateurs et l’équipement com- provoquer des interférences avec les équipements mandé par ordinateur tel que les robots. de radio–navigation et de communication, les Veiller à ce que tout l’équi
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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 A V Engine Oil Fuel Battery (Engine) Engine Check Valve Do not switch while Engine Choke Work Connection Clearance welding Alternating Current Positive Negative Output (AC) Welding Arc Off Stick (SMAW) TIG (GTAW) (Electrode) Protective Earth Hours Seconds Time (Ground) s h Circuit Breaker Temperature SECTION 3 – SPECIFICATIONS 3-1.
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3-2. Dimensions, Weights, and Operating Angles Dimensions A B Height 33-1/2 in (851 mm) C C Width 18-3/4 in (476 mm) Do not exceed tilt angles or engine could Depth 46 in (1164 mm) be damaged or unit could tip. D Do not move or operate unit where it could A 18 in (457 mm) G tip. tip. 4 Holes B 16-1/2 in (419 mm) C 3/4 in (19 mm) E F D 3-1/8 in (79 mm) 25 25° E 32-3/4 in (832 mm) 25°° 25° F 45-1/2 in (1156 mm) 25°° G 13/32 in (10 mm) Dia. Weight 529 lb (240 kg) Engine End ST-800 426 3-3. A
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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. Exceeding duty cycle can damage unit and void warranty. Continuous Welding 100% Duty Cycle at 210 Amperes CC/DC SB-191 554 OM-493 Page 11
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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 Do not weld on base. Weld- ing on base can cause fuel tank fire or explosion. Bolt unit down using holes pro- Movement Airflow Clearance vided in base. Always ground generator 18 in Do not lift unit from end. frame to vehi
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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. Follow run-in procedure in engine manual. Full This unit has a low oil pressure shutdown switch. However, some conditions may cause engine damage before the en- Full Gasoline gine shuts down. Check oil lev- el often and do not use the oil pressure shutdown system to monitor oil level. Fuel Add fresh fuel before starting engine the first time (see mainte- nance
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4-3. Activating The Dry Charge Battery (If Applicable) Remove battery from unit. 1 Eye Protection – Safety Glasses Or Face Shield 2 Rubber Gloves 5 3 Vent Caps 4 Sulfuric Acid Electrolyte (1.265 Specific Gravity) 5 Well 4 1 Fill each cell with electrolyte to 3 bottom of well (maximum). Do not overfill battery cells. Wait ten minutes and check electro- lyte level. If necessary, add electro- lyte to raise to proper level. Reins- tall vent caps. 6 Battery Charger Read and follow all instruc- 2
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4-4. Connecting the Battery Connect negative (–) cable last. – + Tools Needed: 3/8, 1/2 in Ref. ST-192 519-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. Tools Needed: 1/2 in Ref. ST-802 212 / Ref. ST-192 519-A OM-493 Page 15
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4-6. Connecting to Weld Output Terminals 1 Negative (–) Weld Output Terminal 2 Positive (+) Weld Output Terminal For Direct Current Electrode Positive (DCEP), connect work cable to Negative (–) terminal and electrode holder to Positive (+) terminal. For Direct Current Electrode negative (DCEN), reverse cable connections. 1 2 Tools Needed: 3/4 in Ref. ST-192 519-A / Ref. ST-802 210-B 4-7. Selecting Weld Cable Sizes Total Cable (Copper) Length In Weld Circuit Not Exceeding 150 ft 200 ft 250 ft 300
