Table of Contents | Hobart Welding Products OM-240 438B specs

TABLE OF CONTENTS

SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING		1
1-1.	Symbol Usage	1
1-2.	Arc Welding Hazards	1
1-3.	Engine Hazards	3
1-4.	Hydraulic Hazards	3
1-5.	Compressed Air Hazards	4
1-6. Additional Symbols For Installation, Operation, And Maintenance		5
1-7. California Proposition 65 Warnings		6
1-8.	Principal Safety Standards	6
1-9.	EMF Information	6

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION		7
2-1.	Signification des symboles	7
2-2. Dangers relatifs au soudage à l’arc		7
2-3. Dangers existant en relation avec le moteur		9
2-4. Dangers liés à l’hydraulique		10
2-5. Dangers liés à l’air comprimé		11
2-6. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance		12
2-7. Proposition californienne 65 Avertissements		13
2-8. Principales normes de sécurité		13
2-9. Informations relatives aux CEM		14
SECTION 3 − DEFINITIONS		15
SECTION 4 − SPECIFICATIONS		15
4-1. Weld, Power, and Engine Specifications		15
4-2. Dimensions, Weights, And Operating Angles		16
4-3. Dimensions For Units With Optional Running Gear		17
4-4.	Duty Cycle	17
4-5. Fuel Consumption (Subaru-Powered Units)		18
4-6. Fuel Consumption (Kohler-Powered Units)		18
4-7.	Volt-Ampere Curves	19
4-8.	Generator Power Curve	19
SECTION 5 − INSTALLATION		20
5-1. Serial Number And Rating Label Location		20
5-2.	Installing Welding Generator	20
5-3. Grounding Generator To Truck Or Trailer Frame		21
5-4. Engine Prestart Checks (Subaru-Powered Units)		22
5-5. Engine Prestart Checks (Kohler-Powered Units)		23
5-6.	Installing Exhaust Pipe	24
5-7. Connecting Or Replacing the Battery		24
5-8. Connecting To Weld Output Terminals		25
5-9. Selecting Weld Cable Sizes*		26
SECTION 6 − OPERATING THE WELDING GENERATOR		27
6-1.	Front Panel Controls	27
6-2. Cold Weather Engine Operation		28
6-3. Typical Stick Welding Connections And Control Settings		29
SECTION 7 − OPERATING AUXILIARY EQUIPMENT		30
7-1.	Standard Receptacles	30
7-2. Simultaneous Weld And Power		31
7-3. Wiring Optional 240 Volt Plug		31
SECTION 8 − MAINTENANCE (SUBARU-POWERED UNITS)		32
8-1. Maintenance Label (Subaru-Powered Units)		32
8-2. Routine Maintenance (Subaru-Powered Units)		33
8-3.	Servicing Air Cleaner (Subaru-Powered Units)	34

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Hobart Welding Products OM-240 438B manual Table of Contents

Contents

OM-240 438B ProcessesDescription Protect Your Investment From Hobart to You Table of Contents 11-1 10-110-2 10-3 HOT Parts can burn Symbol UsageArc Welding Hazards Electric Shock can kill Welding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skin Hydraulic Hazards Engine Hazards Compressed AIR Equipment can injure or kill Use only genuine replacement parts from the manufacturerCompressed Air Hazards Hydraulic Fluid can injure or kill Overheating can damage motors Welding Wire can injureFire or Explosion hazard Falling Equipment can injure ARC Welding can cause interference Principal Safety Standards EMF InformationCalifornia Proposition 65 Warnings Radiation can cause interference Indique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuer LE Bruit peut affecter l’ouïe LES Pièces Chaudes peuvent provoquer des brûluresLES Fumées ET LES GAZ peu- vent être dangereux LE Soudage peut provoquer un incendie ou une explosion 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 LE Surchauffement peut endommager le moteur électrique Risque D’INCENDIE OULES Fils DE Soudage peuvent provoquer des blessures LA Chute DE L’ÉQUIPEMENT peut provoquer des blessures Proposition californienne 65 Avertissements Principales normes de sécuritéLE Soudage À L’ARC risque de provoquer des interférences En ce qui concerne les implants médicaux Informations relatives aux CEM − Definitions − SpecificationsSymbol Definitions Weld, Power, and Engine Specifications Dimensions, Weights, And Operating Angles Complete Parts List is available at wwwHobartWelders.comWeight 562 lb 254 kg Welding Amperes Dimensions For Units With Optional Running GearDimensions Duty Cycle Fuel Consumption Kohler-Powered Units Fuel Consumption Subaru-Powered Units Volt-Ampere Curves Generator Power CurveFor CC/AC Mode For CC/DC Mode − Installation Installing Welding GeneratorSerial Number And Rating Label Location Grounding Generator To Truck Or Trailer Frame Engine Prestart Checks Subaru-Powered Units Oil CheckOil Engine Prestart Checks Kohler-Powered Units FullTo improve cold weather starting + − + − Installing Exhaust PipeConnecting Or Replacing the Battery Connect negative − battery cable last Connecting To Weld Output Terminals Stop engine Failure to properly connectTools Needed 3/4 100 150 200 250 Selecting Weld Cable Sizes150 ft 200 ft 250 ft 350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m Fine Control Engine Control Switch− Operating the Welding Generator Front Panel Controls Frequently Cold Weather Engine OperationInfrequently Loaded Typical Stick Welding Connections And Control Settings Stop engineElectrode Standard Receptacles − Operating Auxiliary Equipment Receptacle Simultaneous Weld And PowerWiring Optional 240 Volt Plug Current Available in Amperes 240 Maintenance Label Subaru-Powered Units − Maintenance SUBARU-POWERED Units 200 Routine Maintenance Subaru-Powered UnitsStop engine before maintaining 100 Servicing Air Cleaner Subaru-Powered Units Servicing Optional Spark Arrestor 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 Overload Protection Subaru-Powered Units Stop engine. Disconnect negative − battery cableFuse 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 Full Before adding oil Running engine Stop engine and let cool Oil Drain Valve2 ID x 7 in Hose Oil Filter Close valve and valve cap Turn idle speed screw for fine ad- justments Adjusting Engine Speed Kohler-Powered UnitsAdjustment Nut Loosen lock nut. Turn adjustment Overload Protection Kohler-Powered Units Servicing Optional Spark Arrestor Kohler-Powered UnitsIf a fuse opens, it usually indi Trouble Remedy − TroubleshootingWelding Troubleshooting Generator Power Troubleshooting Engine Troubleshooting Check receptacle wiring and connectionsCheck fuel level Recommended Spare Parts − Parts ListControl switch S2, and throttle solenoid TS1 Recommended Spare Parts SOCKET/WRENCH Selection Table Standard Metric Circuit Diagram For Welding Generator − Electrical Diagrams 240 424-A Selecting Equipment − Generator Power Guidelines Electrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as stated Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Industrial MotorsApproximate Power Requirements For Farm/Home Equipment Industrial Motors Rating Starting Watts Running Watts Contractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment KVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting Requirements Tional, state, and local codes Typical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Tools Needed Equipment Needed Piece Weld current can damage Stick Welding Procedure− Stick Welding Smaw Guidelines Electrode touches work Tapping Technique Electrode and Amperage Selection ChartStriking an Arc Scratch Technique Groove Welds Fillet Welds Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode Holder Conditions That Affect Weld Bead Shape Electrode Movement During WeldingElectrode Angle Butt Joints Lap JointTee Joint Possible Causes Corrective Actions TroubleshootingWeld Test To 3 51-76 mm .4 mm Lack of Penetration Good Penetration Good Penetration Excessive PenetrationMetal remains OM-240 438 OM-240 438 OM-240 438 Service SupportAssistance Hobart Welding Products Contact your Distributor for