Hobart Welding Products OM-240 438B manual Specifications, Symbol Definitions

Page 19

. A complete Parts List is available at www.HobartWelders.com

SECTION 3 − DEFINITIONS

3-1. Symbol Definitions

 

Stop Engine

 

Fast

 

Fast/Slow

 

Slow (Idle)

 

 

(Run, Weld/Power)

 

(Run/Idle)

 

 

 

 

 

 

 

 

Start Engine

 

Read Operator’s

A

Amperes

V

Volts

 

 

Manual

 

 

 

 

 

 

Engine Oil

 

Fuel

 

Battery (Engine)

 

Engine

 

Engine Choke

 

Check Valve

 

Do not switch while

 

Work Connection

 

 

Clearance

 

welding

 

 

 

 

 

 

 

 

Positive

 

Negative

 

Alternating Current

 

Output

 

 

 

(AC)

 

h

 

s

 

 

 

 

Hours

Seconds

 

Time

 

Protective Earth

 

 

 

 

(Ground)

 

 

 

 

 

 

 

 

Circuit Protector

 

Temperature

 

Welding Arc

 

Stick (SMAW)

 

 

 

(Electrode)

 

 

 

 

 

 

 

 

SECTION 4 − SPECIFICATIONS

4-1. Weld, Power, and Engine Specifications

.This unit uses either a Subaru EH-65 or a Kohler CH-23 engine. Differences between models are noted throughout this manual.

Welding

Weld Output

Rated

Maximum

 

Fuel

 

Welding

Open Circuit

Generator Power Rating

Engine

Mode

Range

Capacity

Output

Voltage

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

225 A, 25 V,

 

 

 

Subaru EH-65

 

 

 

 

 

Air-Cooled, Two-Cylinder,

CC/AC

50 − 225 A

100% Duty

80

 

 

Peak: 11.0 kVA/kW

 

Four-Cycle, 23 HP

 

 

Cycle

 

 

Gasoline Engine

 

 

 

Continuous: 9.5 kVA/kW

 

 

 

 

 

12 gal

 

 

 

 

 

 

 

 

 

Single-Phase

or

 

 

 

 

(45 L) Tank

 

 

 

 

 

 

210 A, 25 V,

 

92/46 A, 120/240 V AC,

Kohler CH-23

 

 

 

 

 

 

 

60 Hz (while not welding)

 

CC/DC

50 − 210 A

100% Duty

80

 

Air-Cooled, Two-Cylinder,

 

 

 

 

Cycle

 

 

 

Four-Cycle, 23 HP

 

 

 

 

 

 

Gasoline Engine

 

 

 

 

 

 

 

OM-240 438 Page 15

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Contents Processes OM-240 438BDescription Protect Your Investment From Hobart to YouTable of Contents 11-1 10-110-2 10-3HOT Parts can burn Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinHydraulic Hazards Engine HazardsCompressed AIR Equipment can injure or kill Use only genuine replacement parts from the manufacturerCompressed Air Hazards Hydraulic Fluid can injure or killOverheating can damage motors Welding Wire can injureFire or Explosion hazard Falling Equipment can injureARC Welding can cause interference Principal Safety Standards EMF InformationCalifornia Proposition 65 Warnings Radiation can cause interferenceIndique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE Bruit peut affecter l’ouïe LES Pièces Chaudes peuvent provoquer des brûluresLES Fumées ET LES GAZ peu- vent être dangereux LE Soudage peut provoquer un incendie ou une explosionLes 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 LE Surchauffement peut endommager le moteur électrique Risque D’INCENDIE OULES Fils DE Soudage peuvent provoquer des blessures LA Chute DE L’ÉQUIPEMENT peut provoquer des blessuresPrincipales 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 CEM− Definitions − SpecificationsSymbol Definitions Weld, Power, and Engine SpecificationsComplete Parts List is available at wwwHobartWelders.com Dimensions, Weights, And Operating AnglesWeight 562 lb 254 kg Welding Amperes Dimensions For Units With Optional Running GearDimensions Duty CycleFuel Consumption Kohler-Powered Units Fuel Consumption Subaru-Powered UnitsVolt-Ampere Curves Generator Power CurveFor CC/AC Mode For CC/DC ModeInstalling 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 + − + − Installing Exhaust PipeConnecting Or Replacing the Battery Connect negative − battery cable lastStop engine Failure to properly connect Connecting To Weld Output TerminalsTools Needed 3/4 100 150 200 250 Selecting Weld Cable Sizes150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 mFine Control Engine Control Switch− Operating the Welding Generator Front Panel ControlsFrequently Cold Weather Engine OperationInfrequently LoadedStop engine Typical Stick Welding Connections And Control SettingsElectrode Standard Receptacles − Operating Auxiliary EquipmentReceptacle Simultaneous Weld And PowerWiring Optional 240 Volt Plug Current Available in Amperes 240Maintenance Label Subaru-Powered Units − Maintenance SUBARU-POWERED Units200 Routine Maintenance Subaru-Powered UnitsStop engine before maintaining 100Servicing 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 Full Before adding oil Running engine Stop engine and let cool Oil Drain Valve2 ID x 7 in Hose Oil Filter Close valve and valve capTurn idle speed screw for fine ad- justments Adjusting Engine Speed Kohler-Powered UnitsAdjustment Nut Loosen lock nut. Turn adjustmentServicing Optional Spark Arrestor Kohler-Powered Units Overload Protection Kohler-Powered UnitsIf a fuse opens, it usually indi Trouble Remedy − TroubleshootingWelding Troubleshooting Generator Power TroubleshootingCheck receptacle wiring and connections Engine TroubleshootingCheck fuel level Recommended Spare Parts − Parts ListControl switch S2, and throttle solenoid TS1 Recommended Spare PartsSOCKET/WRENCH Selection Table Standard Metric Circuit Diagram For Welding Generator − Electrical Diagrams240 424-A Selecting Equipment − Generator Power GuidelinesElectrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as statedFarm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTional, state, and local codes Typical Connections To Supply Standby PowerSelecting Extension Cord Use Shortest Cord Possible Tools Needed Equipment Needed Piece Weld current can damage Stick Welding Procedure− Stick Welding Smaw Guidelines Electrode touches workTapping Technique Electrode and Amperage Selection ChartStriking an Arc Scratch TechniqueGroove Welds Fillet Welds Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode HolderElectrode Movement During Welding Conditions That Affect Weld Bead ShapeElectrode Angle Lap Joint Butt JointsTee Joint Possible Causes Corrective Actions TroubleshootingWeld Test To 3 51-76 mm .4 mmGood 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