Hobart Welding Products OM-240 438B manual Contact your Distributor for, Hobart Welding Products

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Owner’s Record

Please complete and retain with your personal records.

Model Name	Serial/Style Number

Purchase Date	(Date which equipment was delivered to original customer.)

Distributor

Address

City

State	Zip

Resources Available

Always provide Model Name and Serial/Style Number.

Protect Your Investment!

Register your product at:

HobartWelders.com

To locate a Distributor, retail or service location:

Call 1-877-Hobart1 or visit our website at www.HobartWelders.com

For technical assistance:

Call 1-800-332-3281

Contact your Distributor for:

Welding Supplies and Consumables

Options and Accessories

Personal Safety Equipment

Service and Repair

Replacement Parts

Training (Schools, Videos, Books)

Technical Manuals (Servicing Information

and Parts)

Circuit Diagrams

Welding Process Handbooks

Hobart Welding Products

An Illinois Tool Works Company

600 West Main Street

Troy, OH 45373 USA

For Technical Assistance:

Call1-800-332-3281

For Literature Or Nearest Dealer: Call 1-877-Hobart1

Contact the Delivering Carrier to:	File a claim for loss or damage during
	shipment.
	For assistance in filing or settling claims, contact
	your distributor and/or equipment manufacturer’s
	Transportation Department.
ORIGINAL INSTRUCTIONS − PRINTED IN USA	♥ 2009 Hobart Welding Products. 2009−01

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Contents OM-240 438B ProcessesDescription From Hobart to You Protect Your InvestmentTable of Contents 10-1 10-210-3 11-1Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can burnFumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosionEngine Hazards Hydraulic HazardsUse only genuine replacement parts from the manufacturer Compressed Air HazardsHydraulic Fluid can injure or kill Compressed AIR Equipment can injure or killWelding Wire can injure Fire or Explosion hazardFalling Equipment can injure Overheating can damage motorsPrincipal Safety Standards EMF Information California Proposition 65 WarningsRadiation can cause interference ARC Welding can cause interferenceSignification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiquesLES Pièces Chaudes peuvent provoquer des brûlures LES Fumées ET LES GAZ peu- vent être dangereuxLE Soudage peut provoquer un incendie ou une explosion 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 Risque D’INCENDIE OU LES Fils DE Soudage peuvent provoquer des blessuresLA Chute DE L’ÉQUIPEMENT peut provoquer des blessures LE Surchauffement peut endommager le moteur électriqueProposition californienne 65 Avertissements Principales normes de sécuritéLE Soudage À L’ARC risque de provoquer des interférences Informations relatives aux CEM En ce qui concerne les implants médicaux− Specifications Symbol DefinitionsWeld, Power, and Engine Specifications − DefinitionsDimensions, Weights, And Operating Angles Complete Parts List is available at wwwHobartWelders.comWeight 562 lb 254 kg Dimensions For Units With Optional Running Gear DimensionsDuty Cycle Welding AmperesFuel Consumption Subaru-Powered Units Fuel Consumption Kohler-Powered UnitsGenerator Power Curve For CC/AC ModeFor CC/DC Mode Volt-Ampere Curves− 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 Pipe Connecting Or Replacing the BatteryConnect negative − battery cable last + − + −Connecting To Weld Output Terminals Stop engine Failure to properly connectTools Needed 3/4 Selecting Weld Cable Sizes 150 ft 200 ft 250 ft350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m 100 150 200 250Engine Control Switch − Operating the Welding GeneratorFront Panel Controls Fine ControlCold Weather Engine Operation InfrequentlyLoaded FrequentlyTypical Stick Welding Connections And Control Settings Stop engineElectrode − Operating Auxiliary Equipment Standard ReceptaclesSimultaneous Weld And Power Wiring Optional 240 Volt PlugCurrent Available in Amperes 240 Receptacle− Maintenance SUBARU-POWERED Units Maintenance Label Subaru-Powered UnitsRoutine Maintenance Subaru-Powered Units Stop engine before maintaining100 200Servicing Air Cleaner Subaru-Powered Units Servicing Optional Spark Arrestor Subaru-Powered UnitsStop engine and let cool Oil Fill Oil Check Oil Drain Valve Oil FilterAdjusting Engine Speed Subaru-Powered Units Idle Speed AdjustmentOverload Protection Subaru-Powered Units Stop engine. Disconnect negative − battery cableFuse F1 See Section − 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 Stop engine and let cool Oil Drain Valve 2 ID x 7 in Hose Oil FilterClose valve and valve cap Full Before adding oil Running engineAdjusting Engine Speed Kohler-Powered Units Adjustment NutLoosen lock nut. Turn adjustment Turn idle speed screw for fine ad- justmentsOverload Protection Kohler-Powered Units Servicing Optional Spark Arrestor Kohler-Powered UnitsIf a fuse opens, it usually indi − Troubleshooting Welding TroubleshootingGenerator Power Troubleshooting Trouble RemedyEngine Troubleshooting Check receptacle wiring and connectionsCheck fuel level − Parts List Control switch S2, and throttle solenoid TS1Recommended Spare Parts Recommended Spare PartsSOCKET/WRENCH Selection Table Standard Metric − Electrical Diagrams Circuit Diagram For Welding Generator240 424-A − Generator Power Guidelines Selecting EquipmentGrounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated Electrical codesApproximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsApproximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running WattsPower Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements 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 Stick Welding Procedure − Stick Welding Smaw GuidelinesElectrode touches work Tools Needed Equipment Needed Piece Weld current can damageElectrode and Amperage Selection Chart Striking an ArcScratch Technique Tapping TechniquePoor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder Groove Welds Fillet WeldsConditions That Affect Weld Bead Shape Electrode Movement During WeldingElectrode Angle Butt Joints Lap JointTee Joint Troubleshooting Weld TestTo 3 51-76 mm .4 mm Possible Causes Corrective ActionsLack of Penetration Good Penetration Good Penetration Excessive PenetrationMetal remains OM-240 438 OM-240 438 OM-240 438 Service SupportAssistance Contact your Distributor for Hobart Welding Products