Hobart Welding Products OM-240 438B manual Processes, Description

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OM-240 438B

2009−09

Processes

Stick (SMAW) Welding

Description

Engine Driven Welding Generator

Champion™ Elite

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Contents Processes OM-240 438BDescription Protect Your Investment From Hobart to YouTable of Contents 10-2 10-110-3 11-1Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can burnBuildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosionHydraulic Hazards Engine HazardsCompressed Air Hazards Use only genuine replacement parts from the manufacturerHydraulic Fluid can injure or kill Compressed AIR Equipment can injure or killFire or Explosion hazard Welding Wire can injureFalling Equipment can injure Overheating can damage motorsCalifornia Proposition 65 Warnings Principal Safety Standards EMF InformationRadiation can cause interference ARC Welding can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer Indique des instructions spécifiquesLES Fumées ET LES GAZ peu- vent être dangereux LES Pièces Chaudes peuvent provoquer des brûluresLE Soudage peut provoquer un incendie ou une explosion LE Bruit peut affecter l’ouïeLes Pièces Mobiles peuvent causer des blessures ’EXPLOSION DE LA Batterie peut provoquer des blessuresLes Pièces Mobiles peuvent causer des blessures LA Chaleur DU Moteur peut pro- voquer un incendieLire LES Instructions LES Fils DE Soudage peuvent provoquer des blessures Risque D’INCENDIE OULA Chute DE L’ÉQUIPEMENT peut provoquer des blessures LE Surchauffement peut endommager le moteur électriquePrincipales normes de sécurité Proposition californienne 65 AvertissementsLE Soudage À L’ARC risque de provoquer des interférences En ce qui concerne les implants médicaux Informations relatives aux CEMSymbol Definitions − SpecificationsWeld, Power, and Engine Specifications − DefinitionsComplete Parts List is available at wwwHobartWelders.com Dimensions, Weights, And Operating AnglesWeight 562 lb 254 kg Dimensions Dimensions For Units With Optional Running GearDuty Cycle Welding AmperesFuel Consumption Kohler-Powered Units Fuel Consumption Subaru-Powered UnitsFor CC/AC Mode Generator Power CurveFor CC/DC Mode Volt-Ampere CurvesInstalling Welding Generator − InstallationSerial Number And Rating Label Location Grounding Generator To Truck Or Trailer Frame Oil Check Engine Prestart Checks Subaru-Powered UnitsOil Full Engine Prestart Checks Kohler-Powered UnitsTo improve cold weather starting Connecting Or Replacing the Battery Installing Exhaust PipeConnect negative − battery cable last + − + −Stop engine Failure to properly connect Connecting To Weld Output TerminalsTools Needed 3/4 150 ft 200 ft 250 ft Selecting Weld Cable Sizes350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m 100 150 200 250− Operating the Welding Generator Engine Control SwitchFront Panel Controls Fine ControlInfrequently Cold Weather Engine OperationLoaded FrequentlyStop engine Typical Stick Welding Connections And Control SettingsElectrode Standard Receptacles − Operating Auxiliary EquipmentWiring Optional 240 Volt Plug Simultaneous Weld And PowerCurrent Available in Amperes 240 ReceptacleMaintenance Label Subaru-Powered Units − Maintenance SUBARU-POWERED UnitsStop engine before maintaining Routine Maintenance Subaru-Powered Units100 200Servicing Optional Spark Arrestor Subaru-Powered Units Servicing Air Cleaner Subaru-Powered UnitsStop engine and let cool Oil Drain Valve Oil Filter Oil Fill Oil CheckIdle Speed Adjustment Adjusting Engine Speed Subaru-Powered UnitsStop engine. Disconnect negative − battery cable Overload Protection Subaru-Powered UnitsFuse F1 See Section Maintenance Label Kohler-Powered Units − Maintenance − KOHLER-POWERED UnitsHours Nl Weld Cables ~ Slip Rings Nl Brushes OM-240 438 Routine Maintenance Kohler-Powered UnitsServicing Air Cleaner Kohler−Powered Units 2 ID x 7 in Hose Oil Filter Stop engine and let cool Oil Drain ValveClose valve and valve cap Full Before adding oil Running engineAdjustment Nut Adjusting Engine Speed Kohler-Powered UnitsLoosen lock nut. Turn adjustment Turn idle speed screw for fine ad- justmentsServicing Optional Spark Arrestor Kohler-Powered Units Overload Protection Kohler-Powered UnitsIf a fuse opens, it usually indi Welding Troubleshooting − TroubleshootingGenerator Power Troubleshooting Trouble RemedyCheck receptacle wiring and connections Engine TroubleshootingCheck fuel level Control switch S2, and throttle solenoid TS1 − Parts ListRecommended Spare Parts Recommended Spare PartsSOCKET/WRENCH Selection Table Standard Metric Circuit Diagram For Welding Generator − Electrical Diagrams240 424-A Selecting Equipment − Generator Power GuidelinesHow Much Power Does Equipment Require? Grounding When Supplying Building SystemsUse ground device as stated Electrical codesApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTional, state, and local codes Typical Connections To Supply Standby PowerSelecting Extension Cord Use Shortest Cord Possible − Stick Welding Smaw Guidelines Stick Welding ProcedureElectrode touches work Tools Needed Equipment Needed Piece Weld current can damageStriking an Arc Electrode and Amperage Selection ChartScratch Technique Tapping TechniqueGood Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder Groove Welds Fillet WeldsElectrode Movement During Welding Conditions That Affect Weld Bead ShapeElectrode Angle Lap Joint Butt JointsTee Joint Weld Test TroubleshootingTo 3 51-76 mm .4 mm Possible Causes Corrective ActionsGood Penetration Excessive Penetration Lack of Penetration Good PenetrationMetal remains OM-240 438 OM-240 438 OM-240 438 Support ServiceAssistance Hobart Welding Products Contact your Distributor for