Hobart Welding Products OM-240 438E Compressed AIR can injure or kill, Fire or Explosion hazard

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HOT METAL from air arc cutting and gouging can cause fire or explosion.

DDo not cut or gouge near flammables.

DWatch for fire; keep extinguisher nearby.

COMPRESSED AIR can injure or kill.

D Before working on compressed air system, turn off and lockout/tagout unit, release pres- sure, and be sure air pressure cannot be acci- dentally applied.

DRelieve pressure before disconnecting or con- necting air lines.

DCheck compressed air system components and all connections and hoses for damage, leaks, and wear before operating unit.

DDo not direct air stream toward self or others.

DWear protective equipment such as safety glasses, hearing pro- tection, leather gloves, heavy shirt and trousers, high shoes, and a cap when working on compressed air system.

DUse soapy water or an ultrasonic detector to search for leaks−−never use bare hands. Do not use equipment if leaks are found.

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

DIf ANY air is injected into the skin or body seek medical help im- mediately.

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.

BREATHING COMPRESSED AIR can in- jure or kill.

DDo not use compressed air for breathing.

DUse only for cutting, gouging, and tools.

TRAPPED AIR PRESSURE AND WHIPPING HOSES can injure.

DRelease air pressure from tools and system be- fore servicing, adding or changing attach- ments, or opening compressor oil drain or oil fill cap.

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.

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.

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.

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.

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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