Hobart Welding Products OM-240 438B manual Engine Hazards, Hydraulic Hazards

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1-3. Engine Hazards

BATTERY EXPLOSION can injure.

DAlways wear a face shield, rubber gloves, and

protective clothing when working on a battery.

D Stop engine before disconnecting or connect- ing battery cables or servicing battery.

DDo not allow tools to cause sparks when working on a battery.

DDo not use welder to charge batteries or jump start vehicles.

DObserve correct polarity (+ and −) on batteries.

DDisconnect negative (−) cable first and connect it last.

FUEL can cause fire or explosion.

D Stop engine and let it cool off before checking or adding fuel.

DDo not add fuel while smoking or if unit is near any sparks or open flames.

DDo not overfill tank — allow room for fuel to expand.

DDo not spill fuel. If fuel is spilled, clean up before starting engine.

DDispose of rags in a fireproof container.

DAlways keep nozzle in contact with tank when fueling.

MOVING PARTS can injure.

D Keep away from moving parts such as fans, belts, and rotors.

DKeep all doors, panels, covers, and guards closed and securely in place.

DStop engine before installing or connecting unit.

DHave only qualified persons remove doors, panels, covers, or guards for maintenance and troubleshooting as necessary.

DTo prevent accidental starting during servicing, disconnect negative (−) battery cable from battery.

DKeep hands, hair, loose clothing, and tools away from moving parts.

DReinstall doors, panels, covers, or guards when servicing is finished and before starting engine.

DBefore working on generator, remove spark plugs or injectors to keep engine from kicking back or starting.

DBlock flywheel so that it will not turn while working on generator components.

EXHAUST SPARKS can cause fire.

D Do not let engine exhaust sparks cause fire.

DUse approved engine exhaust spark arrestor in required areas — see applicable codes.

HOT PARTS can burn.

DDo not touch hot parts bare handed.

D Allow cooling period before working on equip- ment.

DTo handle hot parts, use proper tools and/or wear heavy, insulated welding gloves and clothing to prevent burns.

STEAM AND HOT COOLANT can burn.

DIf possible, check coolant level when engine is cold to avoid scalding.

D Always check coolant level at overflow tank, if present on unit, instead of radiator (unless told otherwise in maintenance section or engine manual).

DIf the engine is warm, checking is needed, and there is no over- flow tank, follow the next two statements.

DWear safety glasses and gloves and put a rag over radiator cap.

DTurn cap slightly and let pressure escape slowly before completely removing cap.

Using a generator indoors CAN KILL YOU IN MINUTES.

D Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

DNEVER use inside a home or garage, EVEN IF doors and windows are open.

DOnly use OUTSIDE and far away from windows, doors, and vents.

BATTERY ACID can BURN SKIN and EYES.

DDo not tip battery.

DReplace damaged battery.

DFlush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

D Do not locate unit on, over, or near combustible surfaces or flammables.

DKeep exhaust and exhaust pipes way from flammables.

1-4. Hydraulic Hazards

HYDRAULIC EQUIPMENT can injure or kill.

DIncorrect installation or operation of this unit could result in equipment failure and personal injury. Only qualified persons should install, op- erate, and service this unit according to its Owner’s Manual, industry standards, and na- tional, state, and local codes.

DDo not exceed the rated output or capacity of the hydraulic pump or any equipment in the hydraulic system. Design hydraulic sys- tem so failure of any hydraulic component will not put people or property at risk.

DBefore working on hydraulic system, turn off and lockout/tagout unit, release pressure, and be sure hydraulic pressure cannot be accidentally applied.

DDo not work on hydraulic system with unit running unless you are a qualified person and following the manufacturer’s instructions.

DDo not modify or alter hydraulic pump or manufacturer-supplied equipment. Do not disconnect, disable, or override any safety equipment in the hydraulic system.

DUse only components/accessories approved by the manufacturer.

DKeep away from potential pinch points or crush points created by equipment connected to the hydraulic system.

DDo not work under or around any equipment that is supported only by hydraulic pressure. Properly support equipment by mechanical means.

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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