Hobart Welding Products OM-240 438B manual Fire or Explosion hazard, Welding Wire can injure

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MOVING PARTS can injure.

DKeep away from moving parts such as fans,

belts and rotors.

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

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

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

DHave only qualified people remove guards or covers for maint- enance and troubleshooting as necessary.

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

HOT PARTS can burn.

DDo not touch hot compressor or air system parts.

D Allow cooling period before working on equip- ment.

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

READ INSTRUCTIONS.

DRead and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.

DUse only genuine replacement parts from the manufacturer.

DPerform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes.

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

FIRE OR EXPLOSION hazard.

D Do not install or place unit on, over, or near combustible surfaces.

DDo not install unit near flammables.

DDo not overload building wiring − be sure power supply system is properly sized, rated, and protected to handle this unit.

WELDING WIRE can injure.

DDo not press gun trigger until instructed to do so.

DDo not point gun toward any part of the body, other people, or any metal when threading welding wire.

FALLING EQUIPMENT can injure.

DUse lifting eye to lift unit and properly installed accessories only, NOT gas cylinders. Do not exceed maximum lift eye weight rating (see Specifications).

DUse equipment of adequate capacity to lift and support unit.

DIf using lift forks to move unit, be sure forks are long enough to extend beyond opposite side of unit.

DKeep equipment (cables and cords) away from moving vehicles when working from an aerial location.

DFollow the guidelines in the Applications Manual for the Revised NIOSH Lifting Equation (Publication No. 94−110) when manu- ally lifting heavy parts or equipment.

OVERHEATING can damage motors.

DTurn off or unplug equipment before starting or stopping engine.

DDo not let low voltage and frequency caused by low engine speed damage electric motors.

DDo not connect 50 or 60 Hertz motors to the 100 Hertz receptacle where applicable.

FLYING SPARKS can injure.

D Wear a face shield to protect eyes and face.

D Shape tungsten electrode only on grinder with proper guards in a safe location wearing proper face, hand, and body protection.

DSparks can cause fires — keep flammables away.

MOVING PARTS can injure.

DKeep away from moving parts.

DKeep away from pinch points such as drive rolls.

OVERUSE can cause OVERHEATING.

DAllow cooling period; follow rated duty cycle.

DReduce current or reduce duty cycle before starting to weld again.

DDo not block or filter airflow to unit.

STATIC (ESD) can damage PC boards.

DPut on grounded wrist strap BEFORE handling

boards or parts.

D Use proper static-proof bags and boxes to store, move, or ship PC boards.

TILTING OF TRAILER can injure.

D Use tongue jack or blocks to support weight.

DProperly install welding generator onto trailer according to instructions supplied with trailer.

READ INSTRUCTIONS.

DRead and follow all labels and the Owner’s Manual carefully before installing, operating, or servicing unit. Read the safety information at the beginning of the manual and in each section.

DUse only genuine replacement parts from the manufacturer.

DPerform maintenance and service according to the Owner’s Manuals, industry standards, and national, state, and local codes.

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Contents OM-240 438B ProcessesDescription Protect Your Investment From Hobart to YouTable of Contents 10-2 10-110-3 11-1Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can burnBuildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosionHydraulic Hazards Engine HazardsCompressed Air Hazards Use only genuine replacement parts from the manufacturerHydraulic Fluid can injure or kill Compressed AIR Equipment can injure or killFire or Explosion hazard Welding Wire can injureFalling Equipment can injure Overheating can damage motorsCalifornia Proposition 65 Warnings Principal Safety Standards EMF InformationRadiation can cause interference ARC Welding can cause interference− Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer Indique des instructions spécifiquesLES Fumées ET LES GAZ peu- vent être dangereux LES Pièces Chaudes peuvent provoquer des brûluresLE Soudage peut provoquer un incendie ou une explosion LE Bruit peut affecter l’ouïeLes 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 LES Fils DE Soudage peuvent provoquer des blessures Risque D’INCENDIE OULA 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 En ce qui concerne les implants médicaux Informations relatives aux CEMSymbol Definitions − SpecificationsWeld, Power, and Engine Specifications − DefinitionsDimensions, Weights, And Operating Angles Complete Parts List is available at wwwHobartWelders.comWeight 562 lb 254 kg Dimensions Dimensions For Units With Optional Running GearDuty Cycle Welding AmperesFuel Consumption Kohler-Powered Units Fuel Consumption Subaru-Powered UnitsFor CC/AC Mode Generator Power CurveFor 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 Connecting Or Replacing the Battery Installing Exhaust PipeConnect negative − battery cable last + − + −Connecting To Weld Output Terminals Stop engine Failure to properly connectTools Needed 3/4 150 ft 200 ft 250 ft Selecting Weld Cable Sizes350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m 100 150 200 250− Operating the Welding Generator Engine Control SwitchFront Panel Controls Fine ControlInfrequently Cold Weather Engine OperationLoaded FrequentlyTypical Stick Welding Connections And Control Settings Stop engineElectrode Standard Receptacles − Operating Auxiliary EquipmentWiring Optional 240 Volt Plug Simultaneous Weld And PowerCurrent Available in Amperes 240 ReceptacleMaintenance Label Subaru-Powered Units − Maintenance SUBARU-POWERED UnitsStop engine before maintaining Routine Maintenance Subaru-Powered Units100 200Servicing 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 2 ID x 7 in Hose Oil Filter Stop engine and let cool Oil Drain ValveClose valve and valve cap Full Before adding oil Running engineAdjustment Nut Adjusting Engine Speed Kohler-Powered UnitsLoosen 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 Welding Troubleshooting − TroubleshootingGenerator Power Troubleshooting Trouble RemedyEngine Troubleshooting Check receptacle wiring and connectionsCheck fuel level Control switch S2, and throttle solenoid TS1 − Parts ListRecommended Spare Parts Recommended Spare PartsSOCKET/WRENCH Selection Table Standard Metric Circuit Diagram For Welding Generator − Electrical Diagrams240 424-A Selecting Equipment − Generator Power GuidelinesHow Much Power Does Equipment Require? Grounding When Supplying Building SystemsUse ground device as stated Electrical codesApproximate Power Requirements For Farm/Home Equipment Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentHow Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting AmperageTional, state, and local codes Typical Connections To Supply Standby PowerSelecting Extension Cord Use Shortest Cord Possible − Stick Welding Smaw Guidelines Stick Welding ProcedureElectrode touches work Tools Needed Equipment Needed Piece Weld current can damageStriking an Arc Electrode and Amperage Selection ChartScratch Technique Tapping TechniqueGood Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder Groove Welds Fillet WeldsConditions That Affect Weld Bead Shape Electrode Movement During WeldingElectrode Angle Butt Joints Lap JointTee Joint Weld Test TroubleshootingTo 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 Hobart Welding Products Contact your Distributor for