Hobart Welding Products OM-240 438B manual Table of Contents

Page 3

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING

1

1-1.

Symbol Usage

1

1-2.

Arc Welding Hazards

1

1-3.

Engine Hazards

3

1-4.

Hydraulic Hazards

3

1-5.

Compressed Air Hazards

4

1-6. Additional Symbols For Installation, Operation, And Maintenance

5

1-7. California Proposition 65 Warnings

6

1-8.

Principal Safety Standards

6

1-9.

EMF Information

6

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION

7

2-1.

Signification des symboles

7

2-2. Dangers relatifs au soudage à l’arc

7

2-3. Dangers existant en relation avec le moteur

9

2-4. Dangers liés à l’hydraulique

10

2-5. Dangers liés à l’air comprimé

11

2-6. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance

12

2-7. Proposition californienne 65 Avertissements

13

2-8. Principales normes de sécurité

13

2-9. Informations relatives aux CEM

14

SECTION 3 − DEFINITIONS

15

SECTION 4 − SPECIFICATIONS

15

4-1. Weld, Power, and Engine Specifications

15

4-2. Dimensions, Weights, And Operating Angles

16

4-3. Dimensions For Units With Optional Running Gear

17

4-4.

Duty Cycle

17

4-5. Fuel Consumption (Subaru-Powered Units)

18

4-6. Fuel Consumption (Kohler-Powered Units)

18

4-7.

Volt-Ampere Curves

19

4-8.

Generator Power Curve

19

SECTION 5 − INSTALLATION

20

5-1. Serial Number And Rating Label Location

20

5-2.

Installing Welding Generator

20

5-3. Grounding Generator To Truck Or Trailer Frame

21

5-4. Engine Prestart Checks (Subaru-Powered Units)

22

5-5. Engine Prestart Checks (Kohler-Powered Units)

23

5-6.

Installing Exhaust Pipe

24

5-7. Connecting Or Replacing the Battery

24

5-8. Connecting To Weld Output Terminals

25

5-9. Selecting Weld Cable Sizes*

26

SECTION 6 − OPERATING THE WELDING GENERATOR

27

6-1.

Front Panel Controls

27

6-2. Cold Weather Engine Operation

28

6-3. Typical Stick Welding Connections And Control Settings

29

SECTION 7 − OPERATING AUXILIARY EQUIPMENT

30

7-1.

Standard Receptacles

30

7-2. Simultaneous Weld And Power

31

7-3. Wiring Optional 240 Volt Plug

31

SECTION 8 − MAINTENANCE (SUBARU-POWERED UNITS)

32

8-1. Maintenance Label (Subaru-Powered Units)

32

8-2. Routine Maintenance (Subaru-Powered Units)

33

8-3.

Servicing Air Cleaner (Subaru-Powered Units)

34

Page 2 Page 4
Image 3
Page 2 Page 4
Contents OM-240 438B ProcessesDescription 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 blessuresProposition californienne 65 Avertissements Principales normes de sécuritéLE 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 SpecificationsDimensions, Weights, And Operating Angles Complete Parts List is available at wwwHobartWelders.comWeight 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 Mode− Installation Installing Welding GeneratorSerial Number And Rating Label Location Grounding Generator To Truck Or Trailer Frame Engine Prestart Checks Subaru-Powered Units Oil CheckOil Engine Prestart Checks Kohler-Powered Units FullTo improve cold weather starting + − + − Installing Exhaust PipeConnecting Or Replacing the Battery Connect negative − battery cable lastConnecting To Weld Output Terminals Stop engine Failure to properly connectTools 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 LoadedTypical Stick Welding Connections And Control Settings Stop engineElectrode 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 Air Cleaner Subaru-Powered Units Servicing Optional Spark Arrestor Subaru-Powered UnitsStop engine and let cool Oil Drain Valve Oil Filter Oil Fill Oil CheckIdle Speed Adjustment Adjusting Engine Speed Subaru-Powered UnitsOverload Protection Subaru-Powered Units Stop engine. Disconnect negative − battery cableFuse 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 adjustmentOverload Protection Kohler-Powered Units Servicing Optional Spark Arrestor Kohler-Powered UnitsIf a fuse opens, it usually indi Trouble Remedy − TroubleshootingWelding Troubleshooting Generator Power TroubleshootingEngine Troubleshooting Check receptacle wiring and connectionsCheck 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 HolderConditions That Affect Weld Bead Shape Electrode Movement During WeldingElectrode Angle Butt Joints Lap JointTee Joint Possible Causes Corrective Actions TroubleshootingWeld Test To 3 51-76 mm .4 mmLack of Penetration Good Penetration Good Penetration Excessive PenetrationMetal remains OM-240 438 OM-240 438 OM-240 438 Service SupportAssistance Hobart Welding Products Contact your Distributor for
Top Page Image Contents