Hobart Welding Products Champion 8500 User Manual (English)

Questions and Answers:

A
Amy PenaAug 20, 2025
What to do if my Hobart Welding Products Champion 8500 Welding System has no weld output?
- P
  Paula WilliamsAug 21, 2025
  If your Hobart Welding Products Welding System isn't producing any weld output, begin by checking the control settings and weld connections. Ensure all equipment is disconnected during unit startup. Inspect fuse F1 and replace it if it's open. Also, check the connection of plug PLG6. If these steps don't resolve the issue, it may be necessary to have a Factory Authorized Service Agent inspect the brushes, slip rings, and integrated rectifier SR2.
L
Lisa EllisonAug 22, 2025
Why does my Hobart Welding Products Champion 8500 have low weld output?
- T
  Thomas RamirezAug 22, 2025
  If your Hobart Welding Products Welding System is showing low weld output, start by checking fuse F1 and replace it if open. Verify the control settings and engine speed, adjusting the latter if needed. Servicing the air cleaner according to the engine manual might also help. If the problem persists, consider having a Factory Authorized Service Agent check the brushes and slip rings.
D
Deanna HarperAug 25, 2025
What causes erratic weld output in a Hobart Welding Products Champion 8500?
- A
  Anthony HutchinsonAug 25, 2025
  Erratic weld output in your Hobart Welding Products Welding System can stem from several factors. First, check the control settings. Ensure connections to the electrode and workpiece are tightened and clean. Use dry, properly stored electrodes for Stick and TIG welding. Remove excessive coils from weld cables. Clean and tighten connections both inside and outside the welding generator. Also, check and adjust the engine speed if necessary. If the issue continues, have a Factory Authorized Service Agent inspect the brushes and slip rings.
C
Christopher ChaneyAug 27, 2025
What to do if my Hobart Welding Products Champion 8500 Welding System engine will not start?
- E
  Evelyn HooverAug 27, 2025
  If your Hobart Welding Products Welding System engine won't start, begin by checking the fuel and battery voltage. Ensure the battery connections are secure. Inspect the oil level. Also, check the low oil pressure shutdown switch. If these steps don't resolve the issue, it may be necessary to have a Factory Authorized Service Agent check the optional fuel shutoff solenoid FS1.
J
jeffrey56Aug 28, 2025
How to troubleshoot high weld output on my Hobart Welding Products Champion 8500 Welding System?
- M
  Michael SchmittAug 28, 2025
  To troubleshoot high weld output on your Hobart Welding Products Welding System, start by checking the control settings. Also, check the engine speed and adjust it if necessary.
C
Connie PowellAug 30, 2025
Why is there no output at the auxiliary power receptacles on my Hobart Welding Products Champion 8500?
- N
  Nancy DoyleAug 30, 2025
  If there's no output at the auxiliary power receptacles of your Hobart Welding Products Welding System, try resetting the circuit breakers. Press the optional GFCI receptacle Reset button. Check fuse F1 and replace it if it's open. Verify the connection of plug PLG6. If these steps don't work, have a Factory Authorized Service Agent check the brushes, slip rings, and integrated rectifier SR2.
D
David WilliamsAug 31, 2025
What to do if Hobart Welding Products Welding System engine starts but stops when Engine Control switch returns to Run position?
- D
  Dean BlackburnAug 31, 2025
  If the engine of your Hobart Welding Products Welding System starts but stops when the Engine Control switch is returned to the Run position, check the oil level. Refill the crankcase with the correct viscosity oil for the operating temperature, if needed. Also, check the low oil pressure shutdown switch.
L
Lindsey CarterSep 2, 2025
What causes a Hobart Welding Products Champion 8500 engine to stop during normal operation?
- T
  Tracy MccartySep 2, 2025
  If your Hobart Welding Products Welding System engine stops during normal operation, first check the fuel and oil levels. Also, check the low oil pressure shutdown switch. Periodically recharge or replace the battery as needed. Inspect the voltage regulator and connections. If problems persist, have a Factory Authorized Service Agent check the optional fuel shutoff solenoid FS1.
S
susan12Sep 4, 2025
How to fix a Hobart Welding Products Welding System engine that will not crank?
- J
  Johnathan BryantSep 4, 2025
  If your Hobart Welding Products Welding System engine won't crank, check fuse F6 and replace it if it's open. Verify the battery voltage and ensure the battery connections are tight. Inspect the connections of plug PLG4 and plug PLG8. If these steps don't resolve the issue, have a Factory Authorized Service Agent check the Engine Control switch S2.
C
Cathy WestSep 6, 2025
Why does the battery in my Hobart Welding Products Champion 8500 discharge between uses?
- K
  Kathryn OlsenSep 6, 2025
  If the battery in your Hobart Welding Products Welding System discharges between uses, clean the battery, terminals, and posts with a baking soda and water solution, then rinse with clear water. Periodically recharge or replace the battery. You should also check the voltage regulator and connections.

Hobart Welding Products Champion 8500 Specifications

General

Model	Champion 8500
Frequency	60 Hz
Fuel Type	Gasoline
Type	Engine Driven Welder/Generator
Max Output	8500 watts
Welding Process	Stick, TIG
Rated Output	6500 watts
Auxiliary Power	120/240 Volts
Voltage	120/240V
Phases	Single Phase

Summary

Section 1 - Safety Precautions - Read Before Using

1-1. Symbol Usage

Explains the meaning of safety symbols used throughout the manual.

1-2. Arc Welding Hazards

Details dangers associated with arc welding processes like electric shock and fumes.

1-3. Engine Hazards

Outlines hazards related to the engine, such as fuel, heat, noise, and exhaust.

1-4. Additional Symbols for Installation, Operation, and Maintenance

Covers supplementary safety symbols for installation, operation, and maintenance procedures.

1-5. Principal Safety Standards

Lists key safety standards and codes relevant to welding and cutting equipment.

1-6. EMF Information

Discusses electromagnetic fields and their potential effects, offering mitigation procedures.

Section 2 – Definitions

2-1. Symbol Definitions

Provides definitions for symbols used in the manual, aiding in understanding technical terms.

Section 3 – Specifications

3-1. Weld, Power, and Engine Specifications

Details technical specifications for welding output, power generation, and the engine.

3-2. Dimensions, Weights, and Operating Angles

Lists the physical dimensions, weight, and recommended operating angles of the unit.

3-3. Auxiliary Power Curve

Illustrates the relationship between AC power output in amperes and voltage.

3-4. Fuel Consumption

Shows fuel consumption rates for different operating modes and welding amperages.

3-5. Duty Cycle

Explains the duty cycle percentage for continuous welding at rated load without overheating.

3-6. Volt-Ampere Curve

Displays the generator's voltage and amperage output capabilities across different ranges.

Section 4 – Installation

4-1. Installing Welding Generator

Provides instructions and considerations for properly installing the welding generator.

4-2. Engine Prestart Checks

Details essential checks to perform on the engine before starting for safe operation.

4-3. Activating The Dry Charge Battery (If Applicable)

Guides on how to activate a dry charge battery before installation and use.

4-4. Connecting the Battery

Step-by-step instructions for correctly connecting the battery to the generator.

4-5. Installing Exhaust Pipe

Instructions for securely installing the exhaust pipe, considering direction and safety.

4-6. Connecting to Weld Output Terminals

Explains how to connect cables to the weld output terminals for proper operation.

4-7. Selecting Weld Cable Sizes

Provides a chart to help select the appropriate weld cable size based on amperage and length.

Section 5 – Operating The Welding Generator

5-1. Front Panel Controls

Identifies and explains the function of each control on the generator's front panel.

Section 6 – Operating Auxiliary Equipment

6-1. Standard Receptacles

Details the standard auxiliary power receptacles and their specifications.

6-2. Optional Auxiliary Power Receptacles

Describes optional auxiliary power receptacles and their features like GFCI protection.

Section 7 – Maintenance

7-1. Routine Maintenance

Outlines a schedule for regular maintenance tasks to keep the unit in optimal condition.

7-2. Maintenance Label

Explains the information provided on the maintenance label for the engine and unit.

7-3. Servicing Air Cleaner

Step-by-step guide on how to service the air cleaner element and wrapper.

7-4. Overload Protection

Details the overload protection mechanisms, including fuses, and how to check them.

7-5. Changing Engine Oil, Oil Filter, and Fuel Filter

Provides instructions for changing the engine oil, oil filter, and fuel filter.

7-6. Adjusting Engine Speed

Guides on how to adjust engine speed for idle and weld/power operations.

7-7. Servicing Optional Spark Arrestor

Instructions for cleaning and inspecting the optional spark arrestor screen.

Section 8 – Troubleshooting

A. Welding

Lists common welding-related problems and their remedies.

B. Auxiliary Power

Provides solutions for issues related to auxiliary power output and receptacles.

C. Engine

Covers troubleshooting steps for various engine starting, running, and stopping issues.

Section 9 – Electrical Diagram

Figure 9-1. Circuit Diagram For Welding Generator

Presents the detailed electrical circuit diagram of the welding generator.

Section 10 – Auxiliary Power Guidelines

10-1. Selecting Equipment

Guidelines for selecting auxiliary equipment compatible with the generator's power output.

10-2. Grounding Generator To Truck Or Trailer Frame

Instructions on how to properly ground the generator when mounted on a vehicle frame.

10-3. Grounding When Supplying Building Systems

Explains how to ground the generator when supplying power to building systems.

10-4. How Much Power Does Equipment Require?

Guides on calculating the power requirements for various types of equipment.

10-5. Approximate Power Requirements For Industrial Motors

Provides approximate power requirements for different types of industrial motors.

10-6. Approximate Power Requirements For Farm/Home Equipment

Lists approximate power needs for common farm and home equipment.

10-7. Approximate Power Requirements For Contractor Equipment

Details approximate power requirements for various contractor tools and equipment.

10-8. Power Required To Start Motor

Explains how to determine the starting amperage required for motors.

10-9. How Much Power Can Generator Supply?

Advises on generator load limits and starting non-resistive loads.

10-10. Typical Connections To Supply Standby Power

Illustrates typical connections for supplying standby power during emergencies.

10-11. Selecting Extension Cord (Use Shortest Cord Possible)

Provides guidance on selecting appropriate extension cords based on load and length.

Section 11 – Stick Welding (SMAW) Guidelines

11-1. Stick Welding Procedure

Describes the step-by-step procedure for performing stick welding.

11-2. Electrode and Amperage Selection Chart

Offers a chart for selecting electrodes and appropriate amperage settings.

11-3. Striking an Arc – Scratch Start Technique

Explains the scratch start technique for striking a welding arc.

11-4. Striking an Arc – Tapping Technique

Details the tapping technique for initiating a welding arc.

11-5. Positioning Electrode Holder

Illustrates proper positioning of the electrode holder for various weld types.

11-6. Poor Weld Bead Characteristics

Shows examples and explanations of common defects in weld beads.

11-7. Good Weld Bead Characteristics

Demonstrates characteristics of a good quality weld bead and its formation.

11-8. Conditions That Affect Weld Bead Shape

Explains factors like electrode angle, arc length, and travel speed affecting weld bead shape.

11-9. Electrode Movement During Welding

Describes different electrode movements (stringer, weave) for welding.

11-10. Butt Joints

Covers techniques and considerations for making butt welds.

11-11. Lap Joint

Explains the procedure and best practices for creating lap joints.

11-12. Tee Joint

Details the method for performing tee joints, including multi-layer deposits.

11-13. Weld Test

Describes a simple test to evaluate the quality of a weld joint.

11-14. Troubleshooting – Porosity

Identifies causes and corrective actions for porosity in weld metal.

11-15. Troubleshooting – Excessive Spatter

Addresses excessive spatter during welding, listing causes and solutions.

11-16. Troubleshooting – Incomplete Fusion

Explains how to resolve issues with incomplete fusion in weld metal.

11-17. Troubleshooting – Lack Of Penetration

Provides guidance on fixing problems related to lack of penetration in welds.

11-18. Troubleshooting – Excessive Penetration

Details how to correct excessive penetration issues in welding.

11-19. Troubleshooting – Burn-Through

Offers solutions for preventing and fixing burn-through during welding.

11-20. Troubleshooting – Waviness Of Bead

Addresses issues causing waviness in the weld bead and how to correct them.

11-21. Troubleshooting – Distortion

Explains how to manage and correct distortion caused by welding.

Section 12 – Parts List

Figure 12-1. Main Assembly

Illustrated breakdown of the main assembly components with part numbers.

Figure 12-2. Panel, Front w/Components

Diagram showing the front panel components, including controls and receptacles.

Figure 12-3. Generator

Exploded view of the generator unit, detailing its internal parts.

Hobart Warranty

LIMITED WARRANTY

Outlines the terms and conditions of the manufacturer's limited warranty.

Warranty Periods

Specifies the duration of warranty coverage for different parts and labor.

Warranty Limitations

Details exclusions and limitations to the provided warranty coverage.

Owner's Record

Resources Available

Related product manuals

Hobart Welding Products Champion 8500 User Manual

Table of Contents

Questions and Answers:

Hobart Welding Products Champion 8500 Specifications

Summary

Section 1 - Safety Precautions - Read Before Using

1-1. Symbol Usage

1-2. Arc Welding Hazards

1-3. Engine Hazards

1-4. Additional Symbols for Installation, Operation, and Maintenance

1-5. Principal Safety Standards

1-6. EMF Information

Section 2 – Definitions

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

3-4. Fuel Consumption

3-5. Duty Cycle

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)

4-4. Connecting the Battery

4-5. Installing Exhaust Pipe

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

7-2. Maintenance Label

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

Section 9 – Electrical Diagram

Figure 9-1. Circuit Diagram For Welding Generator

Section 10 – Auxiliary Power Guidelines

10-1. Selecting Equipment

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

11-2. Electrode and Amperage Selection Chart

11-3. Striking an Arc – Scratch Start Technique

11-4. Striking an Arc – Tapping Technique

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

11-9. Electrode Movement During Welding

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