Processes, Description | Hobart Welding Products OM-240 438B

OM-240 438B

2009−09

Processes

Stick (SMAW) Welding

Description

Engine Driven Welding Generator

Champion™ Elite

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Hobart Welding Products OM-240 438B manual Processes, Description

Contents

Processes OM-240 438BDescription Protect Your Investment From Hobart to You Table of Contents 10-2 10-110-3 11-1 Arc Welding Hazards Symbol UsageElectric Shock can kill HOT Parts can burn Buildup of GAS can injure or kill Fumes and Gases can be hazardousARC Rays can burn eyes and skin Welding can cause fire or explosion Hydraulic Hazards Engine Hazards Compressed Air Hazards Use only genuine replacement parts from the manufacturerHydraulic Fluid can injure or kill Compressed AIR Equipment can injure or kill Fire or Explosion hazard Welding Wire can injureFalling Equipment can injure Overheating can damage motors California Proposition 65 Warnings Principal Safety Standards EMF InformationRadiation can cause interference ARC Welding can cause interference − Consignes DE Sécurité − Lire Avant Utilisation Signification des symbolesUN Choc Électrique peut tuer Indique des instructions spécifiques LES 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’ouïe Les Pièces Mobiles peuvent causer des blessures ’EXPLOSION DE LA Batterie peut provoquer des blessures Les Pièces Mobiles peuvent causer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie Lire LES Instructions LES Fils DE Soudage peuvent provoquer des blessures Risque D’INCENDIE OULA Chute DE L’ÉQUIPEMENT peut provoquer des blessures LE Surchauffement peut endommager le moteur électrique Principales normes de sécurité Proposition californienne 65 AvertissementsLE Soudage À L’ARC risque de provoquer des interférences En ce qui concerne les implants médicaux Informations relatives aux CEM Symbol Definitions − SpecificationsWeld, Power, and Engine Specifications − Definitions Complete Parts List is available at wwwHobartWelders.com Dimensions, Weights, And Operating AnglesWeight 562 lb 254 kg Dimensions Dimensions For Units With Optional Running GearDuty Cycle Welding Amperes Fuel Consumption Kohler-Powered Units Fuel Consumption Subaru-Powered Units For CC/AC Mode Generator Power CurveFor CC/DC Mode Volt-Ampere Curves Installing Welding Generator − InstallationSerial Number And Rating Label Location Grounding Generator To Truck Or Trailer Frame Oil Check Engine Prestart Checks Subaru-Powered UnitsOil Full Engine Prestart Checks Kohler-Powered UnitsTo improve cold weather starting Connecting 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 100 150 200 250 − Operating the Welding Generator Engine Control SwitchFront Panel Controls Fine Control Infrequently Cold Weather Engine OperationLoaded Frequently Stop engine Typical Stick Welding Connections And Control SettingsElectrode Standard Receptacles − Operating Auxiliary Equipment Wiring Optional 240 Volt Plug Simultaneous Weld And PowerCurrent Available in Amperes 240 Receptacle Maintenance Label Subaru-Powered Units − Maintenance SUBARU-POWERED Units Stop engine before maintaining Routine Maintenance Subaru-Powered Units100 200 Servicing Optional Spark Arrestor Subaru-Powered Units Servicing Air Cleaner Subaru-Powered UnitsStop engine and let cool Oil Drain Valve Oil Filter Oil Fill Oil Check Idle Speed Adjustment Adjusting Engine Speed Subaru-Powered Units Stop engine. Disconnect negative − battery cable Overload Protection Subaru-Powered UnitsFuse F1 See Section Maintenance Label Kohler-Powered Units − Maintenance − KOHLER-POWERED Units Hours Nl Weld Cables ~ Slip Rings Nl Brushes OM-240 438 Routine Maintenance Kohler-Powered Units Servicing Air Cleaner Kohler−Powered Units 2 ID x 7 in Hose Oil Filter Stop engine and let cool Oil Drain ValveClose valve and valve cap Full Before adding oil Running engine Adjustment Nut Adjusting Engine Speed Kohler-Powered UnitsLoosen lock nut. Turn adjustment Turn idle speed screw for fine ad- justments Servicing Optional Spark Arrestor Kohler-Powered Units Overload Protection Kohler-Powered UnitsIf a fuse opens, it usually indi Welding Troubleshooting − TroubleshootingGenerator Power Troubleshooting Trouble Remedy Check receptacle wiring and connections Engine TroubleshootingCheck fuel level Control switch S2, and throttle solenoid TS1 − Parts ListRecommended Spare Parts Recommended Spare Parts SOCKET/WRENCH Selection Table Standard Metric Circuit Diagram For Welding Generator − Electrical Diagrams 240 424-A Selecting Equipment − Generator Power Guidelines How Much Power Does Equipment Require? Grounding When Supplying Building SystemsUse ground device as stated Electrical codes Approximate 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 Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment How Much Power Can Generator Supply? Power Required To Start MotorSingle-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting Amperage Tional, state, and local codes Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible − Stick Welding Smaw Guidelines Stick Welding ProcedureElectrode touches work Tools Needed Equipment Needed Piece Weld current can damage Striking an Arc Electrode and Amperage Selection ChartScratch Technique Tapping Technique Good Weld Bead Characteristics Poor Weld Bead CharacteristicsPositioning Electrode Holder Groove Welds Fillet Welds Electrode Movement During Welding Conditions That Affect Weld Bead ShapeElectrode Angle Lap Joint Butt JointsTee Joint Weld Test TroubleshootingTo 3 51-76 mm .4 mm Possible Causes Corrective Actions Good Penetration Excessive Penetration Lack of Penetration Good PenetrationMetal remains OM-240 438 OM-240 438 OM-240 438 Support ServiceAssistance Hobart Welding Products Contact your Distributor for