Hobart Welding Products OM-240 438E manual Lack of Penetration Good Penetration, Metal remains

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Lack Of Penetration − shallow fusion between weld metal and base metal.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Lack of Penetration

Good Penetration

 

 

 

 

 

 

Possible Causes

 

Corrective Actions

 

 

 

 

Improper joint preparation.

Material too thick. Joint preparation and design must provide access to bottom of groove.

 

 

 

 

Improper weld technique.

Keep arc on leading edge of weld puddle.

 

 

 

 

 

Insufficient heat input.

 

Increase amperage. Select larger electrode and increase amperage.

 

 

 

 

 

 

 

 

 

 

 

Reduce travel speed.

 

 

 

 

 

 

 

 

 

 

 

Excessive Penetration − weld metal melting through base metal and hanging underneath weld.

 

 

 

Good Penetration

 

Excessive Penetration

 

 

 

 

Possible Causes

 

Corrective Actions

 

 

 

Excessive heat input.

 

Select lower amperage. Use smaller electrode.

 

 

 

 

 

 

 

 

 

 

 

Increase and/or maintain steady travel speed.

 

 

 

 

 

 

 

 

 

 

 

Burn-Through− weld metal melting completely through base metal resulting in holes where no

 

 

 

 

 

metal remains.

Possible Causes

Corrective Actions

 

 

 

 

 

 

 

 

Excessive heat input.

Select lower amperage. Use smaller electrode.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Increase and/or maintain steady travel speed.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Waviness Of Bead − weld metal that is not parallel and does not cover joint formed by base metal.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Possible Causes

 

 

 

 

Corrective Actions

 

 

 

 

 

 

 

Unsteady hand.

 

 

 

 

Use two hands. Practice technique.

 

 

 

 

 

 

 

 

 

 

 

 

 

Distortion − contraction of weld metal during welding that forces base metal to move.

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Base metal moves

 

 

in the direction of

 

 

 

the weld bead.

 

 

 

 

 

 

Possible Causes

 

 

 

 

Corrective Actions

 

 

 

 

 

 

Excessive heat input.

 

 

 

 

Use restraint (clamp) to hold base metal in position.

 

 

 

 

 

 

 

 

 

 

 

 

 

Make tack welds along joint before starting welding operation.

 

 

 

 

 

 

 

 

 

 

 

 

 

Select lower amperage for electrode.

 

 

 

 

 

 

 

 

 

 

 

 

 

Increase travel speed.

 

 

 

 

 

 

 

 

 

 

 

 

 

Weld in small segments and allow cooling between welds.

 

 

 

 

 

 

 

 

 

 

 

 

 

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Contents Processes OM-240 438EDescription 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 EMF Information Principal Safety StandardsAbout 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 blessuresUNE Remorque QUI Bascule peut provoquer des blessures Proposition californienne 65 AvertissementsLE Soudage À L’ARC risque de provoquer des interférences Informations relatives aux CEM Principales normes de sécuritéEn 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/DC Mode For CC/AC 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 + −Stop engine Failure to properly connect Connecting To Weld Output TerminalsTools 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 LoadedStop engine Typical Stick Welding Connections And Control SettingsElectrode 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 Support ServiceAssistance Hobart Welding Products Contact your Distributor for
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