Hobart Welding Products OM-240 438E Engine Troubleshooting, Ers SR2 and SR3, Check fuel level

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	. A complete Parts List is available at wwwHobartWelders.com

Trouble	Remedy

No generator power or weld output.	Be sure all equipment is disconnected from receptacles when starting unit.

	Check fuses F1 and F2, and replace if open (see Section 8-6).

	Check plug PLG6 connection.

	Have Factory Authorized Service Agent check brushes, slip rings, capacitor C1, and integrated rectifi-
	ers SR2 and SR3.

Low power output at ac receptacles.	Check fuse F2, and replace if open (see Section 8-6).

	Increase Fine control R1 setting to max.

High power output at ac receptacles.	Check engine speed, and adjust if necessary (see Section 8-5).

Erratic power output at ac receptacles.	Check fuel level.

	Check engine speed, and adjust if necessary (see Section 8-5).

	Check receptacle wiring and connections.

	Have Factory Authorized Service Agent check brushes and slip rings.

9-3. Engine Troubleshooting

	Trouble	Remedy

	Engine will not crank.	Check fuse F6, and replace if open (see Section 8-6).

		Check battery voltage.

		Check battery connections and tighten if necessary.

		Check plug PLG4 and plug PLG8 connections.

		Have Factory Authorized Service Agent check Engine Control switch S2.

	Engine will not start.	Check fuel level.

		Check battery voltage.

		Check battery connections and tighten if necessary.

		Check oil level (see Section 5-4).

		Check low oil pressure shutdown switch.

		Have Factory Authorized Service Agent check fuel shutoff solenoid FS1 and diode D8.

	Engine starts but stops when Engine	Check oil level.
	Control switch returns to Run position.
	Control switch returns to Run position.	Check and refill crankcase with proper viscosity oil for operating temperature, if necessary.


		Check low oil pressure shutdown switch.

	Engine stopped during normal	Check fuel level.
	operation.

		Check oil level (see Section 5-4).

		Check low oil pressure shutdown switch.

		Periodically recharge battery (approximately every 3 months).

		Replace battery.

		Check voltage regulator and connections according to engine manual.

		Have Factory Authorized Service Agent check fuel shutoff solenoid FS1.

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Contents Description OM-240 438EProcesses From Hobart to You Protect Your InvestmentTable of Contents 10-1 Symbol 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 Hazards Compressed Air HazardsHydraulic Equipment can injure or kill Hydraulic Fluid can injure or killCompressed AIR can injure or kill Fire or Explosion hazardOverheating can damage motors Falling Equipment can injureCalifornia Proposition 65 Warnings About Implanted Medical Devices Principal Safety StandardsEMF Information Signification 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 blessuresLES Étincelles À L’ÉCHAPPEMENT peuvent provoquer un incendie LA Chaleur DU Moteur peut pro- voquer un incendieLire LES Instructions Risque D’INCENDIE OU LA Chute DE L’ÉQUIPEMENT peut provoquer des blessuresLE Surchauffement peut endommager le moteur électrique LES Étincelles Projetées peuvent provoquer des blessuresLE Soudage À L’ARC risque de provoquer des interférences Proposition californienne 65 AvertissementsUNE Remorque QUI Bascule peut provoquer des blessures En ce qui concerne les implants médicaux Principales normes de sécuritéInformations relatives aux CEM − Specifications Symbol DefinitionsWeld, Power, and Engine Specifications − DefinitionsDimensions, Weights, And Operating Angles Weight 562 lb 254 kgDimensions For Units With Optional Running Gear DimensionsDuty Cycle Duty CycleVolt-Ampere Curves For CC/AC ModeFor CC/DC Mode Generator Power Curve Fuel Consumption− Installation Installing Welding GeneratorSerial Number And Rating Label Location Movement Location / Airflow ClearanceGrounding Generator To Truck Or Trailer Frame GND/PEEngine Prestart Checks OilInstalling Exhaust Pipe Connecting Or Replacing the BatteryConnect negative − battery cable last + −Tools Needed 3/4 Connecting To Weld Output TerminalsStop engine Failure to properly connect 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 250Start Your Professional Welding Career Now Engine Control Switch − Operating the Welding GeneratorFront Panel Controls Fine ControlCold Weather Engine Operation InfrequentlyLoaded Frequently LoadedElectrode Typical Stick Welding Connections And Control SettingsStop engine − Operating Auxiliary Equipment Standard ReceptaclesGfci Receptacle Option At least once a month, run engine atSimultaneous Weld And Power Wiring Optional 240 Volt PlugCurrent Available in Amperes 240 Receptacle− Maintenance Maintenance LabelRoutine Maintenance 100200 500Servicing Air Cleaner Changing Engine Oil, Oil Filter, and Fuel Filter Stop engine and let coolClose valve and valve cap Before Adding Oil Running engineAdjusting Engine Speed Idle Speed AdjustmentWeld/Power Speed Adjustment Turn idle speed screw for fine ad- justmentsStop engine. Disconnect negative − battery cable Overload ProtectionServicing Optional Spark Arrestor Fuse F1 See Section− Troubleshooting Welding TroubleshootingGenerator Power Troubleshooting Trouble RemedyEngine Troubleshooting Check receptacle wiring and connectionsErs SR2 and SR3 Check fuel level− Parts List Control switch S2, and throttle solenoid TS1Recommended Spare Parts Recommended Spare Parts− Electrical Diagrams Circuit Diagram For Welding Generator240 424-B − 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 Selecting Extension Cord Use Shortest Cord Possible Stick Welding Procedure − Stick Welding Smaw GuidelinesWeld current starts when Electrode touches workElectrode and Amperage Selection Chart Striking an ArcScratch Technique Tapping TechniquePoor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder End View Of Work Angle Side View Of Electrode Angle 10-30Conditions That Affect Weld Bead Shape Electrode Movement During WeldingElectrode Angle NormalGroove Butt Joints Lap JointTee Joint Or LessTroubleshooting Weld TestPossible Causes Corrective Actions Weld beadLack of Penetration Good Penetration Good Penetration Excessive PenetrationMetal remains DirectionSOCKET/WRENCH Selection Table Standard Metric Assistance ServiceSupport Contact your Distributor for Hobart Welding Products