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  • Champion 10,000 Trouble

    Hobart Champion 10,000 Watt Gen/Welder - Stock# 500434 with the Kohler engine.

    My Dad left this unit (has been setting idle for years) when he passed on to my mother. You may have seen the news of the ice storm that ran thru Kentucky. My mother was without power for 3 days and I pulled this unit up to the house to help her have some heat and try to save her food.

    No go

    History:
    Total engine running time: 15 Hours
    Condition: Looks as if the unit just came from Hobart

    I turn lever to start = No-go

    Change out battery, turn lever = We are good to go

    No power from the 120v receptacle

    Reset circuit breakers but breakers will not close

    Now, more trouble

    Machine will not run/idle or is it to say Auto-Idle ?

    Machine will only run at the run position.

    I am not sure how to move forward at this point, I need your help for a starting point to troubleshoot
    Pull as Hard as You Push

  • #2
    Hobart Champion 10,000 manual

    Page 33: Section 9 – Troubleshooting

    B. Generator power

    Trouble:
    No output at generator ac receptacles (Standard Receptacles)
    Remedy:
    Reset circuit breakers
    Move CB1 toggle switch to ON position (check)
    Reset circuit breakers CB2 and CB3
    Circuit breakers will not reset (always open)
    Pull as Hard as You Push

    Comment


    • #3
      Check fuse F1

      Replace if open (I cannot identify if the fuse is open or closed)

      Digital MultiMeter testing device.

      Fuse F1 resistance measurement
      00.5 ohms
      Pull as Hard as You Push

      Comment


      • #4
        Continuity check of Fuse F1:

        The resistance is approximately less than 30 ohms

        Good / Bad ?
        Pull as Hard as You Push

        Comment


        • #5
          Originally posted by MotorCity View Post
          Continuity check of Fuse F1:

          The resistance is approximately less than 30 ohms

          Good / Bad ?
          That's good. A short in this case indicates continuity.

          Comment


          • #6
            I am totally dead in the water. I just don't know were to start.
            Pull as Hard as You Push

            Comment


            • #7
              Originally posted by MotorCity View Post
              Reset circuit breakers but breakers will not close

              I'm not sure exactly what you mean, but you have to turn a tripped breaker all the way off first to reset it. Then you can turn it on and it will stay. Sorry if you already knew this.

              Comment


              • #8
                You can't turn the breakers off on this machine.

                MotorCity, your best bet now that the workweek has started is give the Hobart folks a call. 1-800-332-3281. They should be able to give you some leads.
                Trailblazer 302 * Millermatic 212 * Syncrowave 180SD * X-Treme 12VS Feeder * Spoolmate 3035
                Thermal Dynamics Cutmaster 52 Plasma * Lincoln 175 MIG

                Victor Superrange II * Victor Journeyman

                Hobart HH 125EZ


                Comment


                • #9
                  Machine will not run/idle or is it to say Auto-Idle ?

                  Machine will only run at the run position
                  MotorCity,
                  Are you saying that the machine won't back down to idle, (which is actually about 2400 rpm), or it won't go from idle to full speed? If you can get your hands a small engine tach, (1 or 2 cylinder measurement) check the engine speed. Run position should be 3750 rpm. Watch the engine speed solenoid when you switch back and forth from run to auto idle. Does it move. It will take a few seconds to drop back when you switch to auto idle. Is the engine speed stuck at 2400 rpm. Try welding with the machine in the run position and see if you get enough current to actually weld something. My GUESS would be either a bad ignition switch, idle solenoid, load sensing tranformer, (which tells it to speed the engine up), or the wiring somewhere in between. Pull the sheet metal off and see if mice took up residence in it at some time, (chewed wires). If I remember right, the machine won't produce power, (generator or welding), unless the engine is running at full speed. Hope this helps. ---Mike---

                  P.S. Any idea how old of a machine it is?
                  BUY AMERICAN... THE JOB YOU SAVE MAY BE YOUR OWN!!!!!

                  Hobart Champion 16
                  Miller external secondary contactor
                  stick foot pedal
                  remote voltage control(homemade)
                  Hobart Portafeed 17(w AG-2000 control box)
                  Bernard Q350 mig gun
                  Hobart AG-2000 pull gun
                  Lincoln Hi-Freq k799(yes, I know it's red)
                  Weldcraft CS300 tig torch
                  Miller RFC-23A foot pedal
                  Thermal Dynamics Cutmaster 50
                  Victor 450/300 series torches
                  oodles of connecting cords

                  I can fix it, just pay me to replace it first

                  Comment


                  • #10
                    Also, make sure the "fine control" knob on the front panel is turned all the way to 10. Check that first.
                    ---Mike---
                    BUY AMERICAN... THE JOB YOU SAVE MAY BE YOUR OWN!!!!!

                    Hobart Champion 16
                    Miller external secondary contactor
                    stick foot pedal
                    remote voltage control(homemade)
                    Hobart Portafeed 17(w AG-2000 control box)
                    Bernard Q350 mig gun
                    Hobart AG-2000 pull gun
                    Lincoln Hi-Freq k799(yes, I know it's red)
                    Weldcraft CS300 tig torch
                    Miller RFC-23A foot pedal
                    Thermal Dynamics Cutmaster 50
                    Victor 450/300 series torches
                    oodles of connecting cords

                    I can fix it, just pay me to replace it first

                    Comment


                    • #11
                      I had the same idle problem you are having but with a Miller Bobcat and it turned out to be a fried idle control module. If I remember, it was about $40 then. Probably $50-60 now.

                      Comment


                      • #12
                        Thank you for your replys.

                        I talked to a Hobart tech (very nice gent) and it was found that the PC1 (Field control board) is bad.
                        Pull as Hard as You Push

                        Comment

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