Hobart Welding Products OM-240 438E manual Parts List, Recommended Spare Parts

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	. A complete Parts List is available at www.HobartWelders.com

Trouble	Remedy

Battery Discharges between uses.	Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water.

	Periodically recharge battery (approximately every 3 months).

	Replace battery.

	Check voltage regulator and connections according to engine manual.

Engine idles but does not come up to	Have Factory Authorized Service Agent check hour meter/idle module, and current transformer CT1.
weld speed.

Unstable or sluggish engine speeds.	Readjust throttle linkage if necessary. Check throttle solenoid TS1 for smooth operation.

	Check oil level. Oil level should not exceed Full mark on dipstick. Fuel pump will operate erratically if
	crankcase is overfilled.

	Tune-up engine according to engine manual.

Engine does not return to idle speed.	Remove weld and generator power loads.

	Check throttle linkage for smooth, non-binding operation.

	Have Factory Authorized Service Agent check hour meter/idle module, current transformer CT1, Engine
	Control switch S2, and throttle solenoid TS1.

SECTION 10 − PARTS LIST

10-1. Recommended Spare Parts

Dia.	Part	Description	Quantity
Mkgs.	No.	Description	Quantity
		Recommended Spare Parts

. . . . . . . . . F1, F2	. . . 169296 . .	Fuse, Mintr Gl 25. Amp 125 Volt	. . . 2
. . . . . . . . . . . F6 . .	. . . 215621 . .	Fuse, 30 Amp Ato Type	. . . 1
. . . . . . . . . . . . . . . . .	. . . 215984 . .	Filter, Fuel In−line .250	. . . 1
. . . . . . . . . . . . . . . . .	. . . 230015 . .	Tune−up & Filter Kit, (Includes)	. . . 1
. . . . . . . . . . . . . . . . .	. . . 230016 . . .	. Air Filter Element, Kohler	. . . 1
. . . . . . . . . . . . . . . . .	. . . 066698 . . .	. Oil Filter, Kohler	. . . 1
. . . . . . . . . . . . . . . . .	. . . 215985 . . .	. Filter, Fuel w/Clamps & 1/4 in Fuel Line	. . . 1
. . . . . . . . . . . . . . . . .	. . . 067007 . . .	. Spark Plug	. . . 2
. . . . . . . . . . . . . . . . .	. . . 230017 . . .	. Air Filter Wrapper	. . . 1

.A complete Parts List is available on-line at www.HobartWelders.com.

OM-240 438 Page 41

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Contents OM-240 438E ProcessesDescription Protect Your Investment From Hobart to YouTable of Contents 10-1 Arc 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 explosionEngine Hazards Compressed Air Hazards Hydraulic HazardsHydraulic Equipment can injure or kill Hydraulic Fluid can injure or killFire or Explosion hazard Compressed AIR can injure or killOverheating can damage motors Falling Equipment can injureCalifornia Proposition 65 Warnings Principal Safety Standards EMF InformationAbout Implanted Medical Devices − 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 blessuresLA Chaleur DU Moteur peut pro- voquer un incendie LES Étincelles À L’ÉCHAPPEMENT peuvent provoquer un incendieLire LES Instructions LA Chute DE L’ÉQUIPEMENT peut provoquer des blessures Risque D’INCENDIE OULE Surchauffement peut endommager le moteur électrique LES Étincelles Projetées peuvent provoquer des blessuresProposition californienne 65 Avertissements UNE Remorque QUI Bascule peut provoquer des blessuresLE Soudage À L’ARC risque de provoquer des interférences Principales normes de sécurité Informations relatives aux CEMEn ce qui concerne les implants médicaux Symbol Definitions − SpecificationsWeld, Power, and Engine Specifications − DefinitionsWeight 562 lb 254 kg Dimensions, Weights, And Operating AnglesDimensions Dimensions For Units With Optional Running GearDuty Cycle Duty CycleFor CC/AC Mode For CC/DC ModeVolt-Ampere Curves Fuel Consumption Generator Power CurveInstalling Welding Generator − InstallationSerial Number And Rating Label Location Movement Location / Airflow ClearanceGND/PE Grounding Generator To Truck Or Trailer FrameOil Engine Prestart ChecksConnecting 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 250Start Your Professional Welding Career Now − Operating the Welding Generator Engine Control SwitchFront Panel Controls Fine ControlInfrequently Cold Weather Engine OperationLoaded Frequently LoadedTypical Stick Welding Connections And Control Settings Stop engineElectrode Standard Receptacles − Operating Auxiliary EquipmentGfci Receptacle Option At least once a month, run engine atWiring Optional 240 Volt Plug Simultaneous Weld And PowerCurrent Available in Amperes 240 ReceptacleMaintenance Label − Maintenance100 Routine Maintenance200 500Servicing Air Cleaner Stop engine and let cool Changing Engine Oil, Oil Filter, and Fuel FilterClose valve and valve cap Before Adding Oil Running engineIdle Speed Adjustment Adjusting Engine SpeedWeld/Power Speed Adjustment Turn idle speed screw for fine ad- justmentsOverload Protection Stop engine. Disconnect negative − battery cableServicing Optional Spark Arrestor Fuse F1 See SectionWelding Troubleshooting − TroubleshootingGenerator Power Troubleshooting Trouble RemedyCheck receptacle wiring and connections Engine TroubleshootingErs SR2 and SR3 Check fuel levelControl switch S2, and throttle solenoid TS1 − Parts ListRecommended Spare Parts Recommended Spare PartsCircuit Diagram For Welding Generator − Electrical Diagrams240 424-B 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 AmperageTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Stick Welding Smaw Guidelines Stick Welding ProcedureWeld current starts when Electrode touches workStriking an Arc Electrode and Amperage Selection ChartScratch Technique Tapping TechniqueGood Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder End View Of Work Angle Side View Of Electrode Angle 10-30Electrode Movement During Welding Conditions That Affect Weld Bead ShapeElectrode Angle NormalLap Joint Groove Butt JointsTee Joint Or LessWeld Test TroubleshootingPossible Causes Corrective Actions Weld beadGood Penetration Excessive Penetration Lack of Penetration Good PenetrationMetal remains DirectionSOCKET/WRENCH Selection Table Standard Metric Service SupportAssistance Hobart Welding Products Contact your Distributor for