Hobart Welding Products OM-240 438B manual Parts List, Recommended Spare Parts

Page 50

 

. A complete Parts List is available at wwwHobartWelders.com

 

 

Trouble

Remedy

 

 

Battery Discharges between uses.

Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.

 

 

 

Periodically recharge battery (approximately every 3 months).

 

 

 

Replace battery.

 

 

 

Check voltage regulator and connections according to engine manual.

 

 

Engine idles but does not come up to

Have Factory Authorized Service Agent check hour meter/idle module, and current transformer CT1.

weld speed.

 

 

 

Unstable or sluggish engine speeds.

Readjust throttle linkage if necessary. Check throttle solenoid TS1 for smooth operation.

 

 

 

Check oil level. Oil level should not exceed Full mark on dipstick. Fuel pump will operate erratically if

 

crankcase is overfilled.

 

 

 

Tune-up engine according to engine manual.

 

 

Engine does not return to idle speed.

Remove weld and generator power loads.

 

 

 

Check throttle linkage for smooth, non-binding operation.

 

 

 

Have Factory Authorized Service Agent check hour meter/idle module, current transformer CT1, Engine

 

Control switch S2, and throttle solenoid TS1.

 

 

SECTION 11 − PARTS LIST

11-1. Recommended Spare Parts

Dia.

Part

Description

Quantity

Mkgs.

No.

 

 

Recommended Spare Parts

 

 

 

 

 

. . . . . . . . . F1, F2

. . . 169296 . .

Fuse, Mintr Gl 25. Amp 125 Volt

. . . 2

. . . . . . . . . . . F6 . . . . . 215621 . .

Fuse, 30 Amp Ato Type (Subaru and Kohler)

. . . 1

. . . . . . . . . . . . . . . . .

. . . 215984 . .

Filter, Fuel In−line .250 (Kohler)

. . . 1

. . . . . . . . . . . . . . . . .

. . . 230015 . .

Tune−up & Filter Kit, Kohler (Includes)

. . . 1

. . . . . . . . . . . . . . . . .

. . . 230016 . . .

. Air Filter Element, Kohler

. . . 1

. . . . . . . . . . . . . . . . .

. . . 066698 . . .

. Oil Filter, Kohler

. . . 1

. . . . . . . . . . . . . . . . .

. . . 215985 . . .

. Filter, Fuel w/Clamps & 1/4 in Fuel Line

. . . 1

. . . . . . . . . . . . . . . . .

. . . 067007 . . .

. Spark Plug

. . . 2

. . . . . . . . . . . . . . . . .

. . . 230017 . . .

. Air Filter Wrapper

. . . 1

. . . . . . . . . . . . . . . . .

. . . 237857 . .

Filter, Fuel In−line .250 (Subaru)

. . . 1

. . . . . . . . . . . . . . . . .

. . . 199062 . .

Tune−up & Filter Kit, Subaru (Includes)

. . . 1

. . . . . . . . . . . . . . . . .

. . . 198755 . . .

. Element, Air Filter

. . . 1

. . . . . . . . . . . . . . . . .

. . . 198754 . . .

. Filter, Oil

. . . 1

. . . . . . . . . . . . . . . . .

. . . 241408 . . .

. Filter, Fuel w/Clamps

. . . 1

. . . . . . . . . . . . . . . . .

. . . 198777 . . .

. Spark Plug

. . . 1

.A complete Parts List is available on-line at www.HobartWelders.com.

OM-240 438 Page 46

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Page 49 Page 51
Contents Description OM-240 438BProcesses From Hobart to You Protect Your InvestmentTable of Contents 10-3 10-110-2 11-1Electric Shock can kill Symbol UsageArc Welding Hazards HOT Parts can burnARC Rays can burn eyes and skin Fumes and Gases can be hazardousBuildup of GAS can injure or kill Welding can cause fire or explosionEngine Hazards Hydraulic HazardsHydraulic Fluid can injure or kill Use only genuine replacement parts from the manufacturerCompressed Air Hazards Compressed AIR Equipment can injure or killFalling Equipment can injure Welding Wire can injureFire or Explosion hazard Overheating can damage motorsRadiation can cause interference Principal Safety Standards EMF InformationCalifornia Proposition 65 Warnings ARC Welding can cause interferenceUN Choc Électrique peut tuer Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation Indique des instructions spécifiquesLE Soudage peut provoquer un incendie ou une explosion LES Pièces Chaudes peuvent provoquer des brûluresLES Fumées ET LES GAZ peu- vent être dangereux LE Bruit peut affecter l’ouïe’EXPLOSION DE LA Batterie peut provoquer des blessures Les Pièces Mobiles peuvent causer des blessuresLA Chaleur DU Moteur peut pro- voquer un incendie Les Pièces Mobiles peuvent causer des blessuresLire LES Instructions LA Chute DE L’ÉQUIPEMENT peut provoquer des blessures Risque D’INCENDIE OULES Fils DE Soudage peuvent provoquer des blessures LE Surchauffement peut endommager le moteur électriqueLE Soudage À L’ARC risque de provoquer des interférences Proposition californienne 65 AvertissementsPrincipales normes de sécurité Informations relatives aux CEM En ce qui concerne les implants médicauxWeld, Power, and Engine Specifications − SpecificationsSymbol Definitions − DefinitionsWeight 562 lb 254 kg Dimensions, Weights, And Operating AnglesComplete Parts List is available at wwwHobartWelders.com Duty Cycle Dimensions For Units With Optional Running GearDimensions Welding AmperesFuel Consumption Subaru-Powered Units Fuel Consumption Kohler-Powered UnitsFor CC/DC Mode Generator Power CurveFor CC/AC Mode Volt-Ampere CurvesSerial Number And Rating Label Location − InstallationInstalling Welding Generator Grounding Generator To Truck Or Trailer Frame Oil Engine Prestart Checks Subaru-Powered UnitsOil Check To improve cold weather starting Engine Prestart Checks Kohler-Powered UnitsFull Connect negative − battery cable last Installing Exhaust PipeConnecting Or Replacing the Battery + − + −Tools Needed 3/4 Connecting To Weld Output TerminalsStop engine Failure to properly connect 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Selecting Weld Cable Sizes150 ft 200 ft 250 ft 100 150 200 250Front Panel Controls Engine Control Switch− Operating the Welding Generator Fine ControlLoaded Cold Weather Engine OperationInfrequently FrequentlyElectrode Typical Stick Welding Connections And Control SettingsStop engine − Operating Auxiliary Equipment Standard ReceptaclesCurrent Available in Amperes 240 Simultaneous Weld And PowerWiring Optional 240 Volt Plug Receptacle− Maintenance SUBARU-POWERED Units Maintenance Label Subaru-Powered Units100 Routine Maintenance Subaru-Powered UnitsStop engine before maintaining 200Stop engine and let cool Servicing Air Cleaner Subaru-Powered UnitsServicing Optional Spark Arrestor Subaru-Powered Units Oil Fill Oil Check Oil Drain Valve Oil FilterAdjusting Engine Speed Subaru-Powered Units Idle Speed AdjustmentFuse F1 See Section Overload Protection Subaru-Powered UnitsStop engine. Disconnect negative − battery cable − Maintenance − KOHLER-POWERED Units Maintenance Label Kohler-Powered UnitsRoutine Maintenance Kohler-Powered Units Hours Nl Weld Cables ~ Slip Rings Nl Brushes OM-240 438Servicing Air Cleaner Kohler−Powered Units Close valve and valve cap Stop engine and let cool Oil Drain Valve2 ID x 7 in Hose Oil Filter Full Before adding oil Running engineLoosen lock nut. Turn adjustment Adjusting Engine Speed Kohler-Powered UnitsAdjustment Nut Turn idle speed screw for fine ad- justmentsIf a fuse opens, it usually indi Overload Protection Kohler-Powered UnitsServicing Optional Spark Arrestor Kohler-Powered Units Generator Power Troubleshooting − TroubleshootingWelding Troubleshooting Trouble RemedyCheck fuel level Engine TroubleshootingCheck receptacle wiring and connections Recommended Spare Parts − Parts ListControl switch S2, and throttle solenoid TS1 Recommended Spare PartsSOCKET/WRENCH Selection Table Standard Metric − Electrical Diagrams Circuit Diagram For Welding Generator240 424-A − Generator Power Guidelines Selecting EquipmentUse ground device as stated Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Electrical codesIndustrial Motors Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsSingle-Phase Induction Motor Starting Requirements Power Required To Start MotorHow Much Power Can Generator Supply? KVA/HP x HP x 1000 / Volts = Starting AmperageTypical Connections To Supply Standby Power Tional, state, and local codesSelecting Extension Cord Use Shortest Cord Possible Electrode touches work Stick Welding Procedure− Stick Welding Smaw Guidelines Tools Needed Equipment Needed Piece Weld current can damageScratch Technique Electrode and Amperage Selection ChartStriking an Arc Tapping TechniquePositioning Electrode Holder Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Groove Welds Fillet WeldsElectrode Angle Conditions That Affect Weld Bead ShapeElectrode Movement During Welding Tee Joint Butt JointsLap Joint To 3 51-76 mm .4 mm TroubleshootingWeld Test Possible Causes Corrective ActionsMetal remains Lack of Penetration Good PenetrationGood Penetration Excessive Penetration OM-240 438 OM-240 438 OM-240 438 Assistance ServiceSupport Contact your Distributor for Hobart Welding Products
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