Question about Hobart Welders Champion 500433A Factory Reconditioned 10,000 Watt Generator

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Welding breaker keeps popping on my Hobart Champion 10,000.

The breaker for the welder side of the machine keeps popping even when not welding. This machine has about 12 hours of run time and I have never went above 120 amps output or used bigger than a 1/8th" rod.

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Look for short inside unit,start at breaker and work your way back.

Posted on Jul 05, 2009

  • hubiam
    hubiam Mar 27, 2017

    Looking for a short and finding one may be 2 separate things. May I suggest you invest in a $10 or $15 analog meter, and two test clips. Connect the pairs of test clips to the opposite ends of the de-energized wire. Set the meter to the lowest ohm setting. Work your way along the wire if the meter's needle moves, then you may have found your short.

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Did you put a battery booster on it to start the machine due to a dead battery? If so, that always blows the circuit boards. If you did, look at the board, near a quarter sized red, round think in a corner, and you will probably see a burnt spot on the board in that area.

Posted on Apr 07, 2017

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Where is the breaker located? The machine runs but it does not give off power.

Posted on Nov 16, 2009

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Could be something as simple as worn brushes, dirty slip rings, or a bad bridge rectifier. If you know how to check them, these are all something you could fix. If it's anything beyond those, you're best bet would be take it to a repair facility. I repaired welders for 18+ years. (just an FYI)

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Rated Output at 20% Duty Cycle 150 A at 16 VAC
150 A at 16 VDC Welding Amperage Ranges AC/DC 10 - 165A Max. Open-Circuit Voltage 80 V Amps Input at Rated Output AC-230V: 21A
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Your local welding shop supply will be able to give you advice, the guys at Lowes and farm supply shops just sell the welders

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I have welded countless hours with Linde & Lincoln & even a few Hobarts & the only time that I ever had the same problem was when the ground connection either to the object I was welding, or the welding cable ground wasn't good & clean & tight. Same on stick welders also. I did develop the habit of grinding not only where I was preparing to weld, but where I was placing my ground clamp & that always provided a better "frying bacon" sound as I went along the business of pushing a bead. In a welder, the only other thing than that is involved is the step-up transformer and your wire. Hope this helps.

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measure ouput on ALL available sockets - anything?
Take cover off electric motor-generator, visually inspect windings.
Measure continuity of all stator windings (2 or 3 points usually)
Measure continuity of stator thru brushset.
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There is no mistery in generator - just stator to induce and rotor to obtain voltage.

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The engine is not running the welding transformer. It may be a fuse, drive belt or gear wheel. Or the transformer is shorting out. Check these points in this order if the last one maybe you will have to replace the transformer. The transformer is 2 coils to stop them shorting out where normal electric wire is cover in plastic or rubber the coils are coated with enamel as are sum cooking pans. If this is damaged in any way it will short.

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sounds like either something is shorted out or the governor is stuck. Check the governor linkage to start with and make sure it is free. Then check the push in breakers for the outlets to see if they are popped. If not the brushes or the armature could be stuck or corroded.

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