Hobart Welding Products
OM-240 438E
manual
Processes, Description
Troubleshooting
Specs
Poor Weld Bead Characteristics
Install
Parts list
Electrical Diagrams
Symbol Usage
Wiring Optional 240 Volt Plug
Dimension
Maintenance
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OM-240
438E
2011−03
Processes
Stick (SMAW) Welding
Description
Engine Driven Welding Generator
Champion
→
Elite
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Contents
Processes
OM-240 438E
Description
Protect Your Investment
From Hobart to You
Table of Contents
10-1
Arc Welding Hazards
Symbol Usage
Electric Shock can kill
HOT Parts can burn
Buildup of GAS can injure or kill
Fumes and Gases can be hazardous
ARC Rays can burn eyes and skin
Welding can cause fire or explosion
Engine Hazards
Compressed Air Hazards
Hydraulic Hazards
Hydraulic Equipment can injure or kill
Hydraulic Fluid can injure or kill
Fire or Explosion hazard
Compressed AIR can injure or kill
Overheating can damage motors
Falling Equipment can injure
California Proposition 65 Warnings
EMF Information
Principal Safety Standards
About Implanted Medical Devices
− Consignes DE Sécurité − Lire Avant Utilisation
Signification des symboles
UN Choc Électrique peut tuer
Indique des instructions spécifiques
LES Fumées ET LES GAZ peu- vent être dangereux
LES Pièces Chaudes peuvent provoquer des brûlures
LE Soudage peut provoquer un incendie ou une explosion
LE Bruit peut affecter l’ouïe
Les Pièces Mobiles peuvent causer des blessures
’EXPLOSION DE LA Batterie peut provoquer des blessures
LA Chaleur DU Moteur peut pro- voquer un incendie
LES Étincelles À L’ÉCHAPPEMENT peuvent provoquer un incendie
Lire LES Instructions
LA Chute DE L’ÉQUIPEMENT peut provoquer des blessures
Risque D’INCENDIE OU
LE Surchauffement peut endommager le moteur électrique
LES Étincelles Projetées peuvent provoquer des blessures
UNE Remorque QUI Bascule peut provoquer des blessures
Proposition californienne 65 Avertissements
LE Soudage À L’ARC risque de provoquer des interférences
Informations relatives aux CEM
Principales normes de sécurité
En ce qui concerne les implants médicaux
Symbol Definitions
− Specifications
Weld, Power, and Engine Specifications
− Definitions
Weight 562 lb 254 kg
Dimensions, Weights, And Operating Angles
Dimensions
Dimensions For Units With Optional Running Gear
Duty Cycle
Duty Cycle
For CC/DC Mode
For CC/AC Mode
Volt-Ampere Curves
Fuel Consumption
Generator Power Curve
Installing Welding Generator
− Installation
Serial Number And Rating Label Location
Movement Location / Airflow Clearance
GND/PE
Grounding Generator To Truck Or Trailer Frame
Oil
Engine Prestart Checks
Connecting Or Replacing the Battery
Installing Exhaust Pipe
Connect negative − battery cable last
+ −
Stop engine Failure to properly connect
Connecting To Weld Output Terminals
Tools Needed 3/4
150 ft 200 ft 250 ft
Selecting Weld Cable Sizes
350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m
100 150 200 250
Start Your Professional Welding Career Now
− Operating the Welding Generator
Engine Control Switch
Front Panel Controls
Fine Control
Infrequently
Cold Weather Engine Operation
Loaded
Frequently Loaded
Stop engine
Typical Stick Welding Connections And Control Settings
Electrode
Standard Receptacles
− Operating Auxiliary Equipment
Gfci Receptacle Option
At least once a month, run engine at
Wiring Optional 240 Volt Plug
Simultaneous Weld And Power
Current Available in Amperes 240
Receptacle
Maintenance Label
− Maintenance
100
Routine Maintenance
200
500
Servicing Air Cleaner
Stop engine and let cool
Changing Engine Oil, Oil Filter, and Fuel Filter
Close valve and valve cap
Before Adding Oil Running engine
Idle Speed Adjustment
Adjusting Engine Speed
Weld/Power Speed Adjustment
Turn idle speed screw for fine ad- justments
Overload Protection
Stop engine. Disconnect negative − battery cable
Servicing Optional Spark Arrestor
Fuse F1 See Section
Welding Troubleshooting
− Troubleshooting
Generator Power Troubleshooting
Trouble Remedy
Check receptacle wiring and connections
Engine Troubleshooting
Ers SR2 and SR3
Check fuel level
Control switch S2, and throttle solenoid TS1
− Parts List
Recommended Spare Parts
Recommended Spare Parts
Circuit Diagram For Welding Generator
− Electrical Diagrams
240 424-B
Selecting Equipment
− Generator Power Guidelines
How Much Power Does Equipment Require?
Grounding When Supplying Building Systems
Use ground device as stated
Electrical codes
Approximate Power Requirements For Farm/Home Equipment
Approximate Power Requirements For Industrial Motors
Industrial Motors Rating Starting Watts Running Watts
Farm/Home Equipment Rating Starting Watts Running Watts
Contractor Rating Starting Watts Running Watts
Approximate Power Requirements For Contractor Equipment
How Much Power Can Generator Supply?
Power Required To Start Motor
Single-Phase Induction Motor Starting Requirements
KVA/HP x HP x 1000 / Volts = Starting Amperage
Typical Connections To Supply Standby Power
Selecting Extension Cord Use Shortest Cord Possible
− Stick Welding Smaw Guidelines
Stick Welding Procedure
Weld current starts when
Electrode touches work
Striking an Arc
Electrode and Amperage Selection Chart
Scratch Technique
Tapping Technique
Good Weld Bead Characteristics
Poor Weld Bead Characteristics
Positioning Electrode Holder
End View Of Work Angle Side View Of Electrode Angle 10-30
Electrode Movement During Welding
Conditions That Affect Weld Bead Shape
Electrode Angle
Normal
Lap Joint
Groove Butt Joints
Tee Joint
Or Less
Weld Test
Troubleshooting
Possible Causes Corrective Actions
Weld bead
Good Penetration Excessive Penetration
Lack of Penetration Good Penetration
Metal remains
Direction
SOCKET/WRENCH Selection Table Standard Metric
Support
Service
Assistance
Hobart Welding Products
Contact your Distributor for
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