10-1, 10-2, 10-3, 11-1 | Hobart Welding Products OM-240 438B

TABLE OF CONTENTS

8-4.	Servicing Optional Spark Arrestor (Subaru-Powered Units)	34
8-5.	Changing Engine Oil, Oil Filter, and Fuel Filter (Subaru-Powered Units)	35
8-6.	Adjusting Engine Speed (Subaru-Powered Units)	36
8-7.	Overload Protection (Subaru-Powered Units)	37
SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS)		38
9-1.	Maintenance Label (Kohler-Powered Units)	38
9-2.	Routine Maintenance (Kohler-Powered Units)	39
9-3.	Servicing Air Cleaner (Kohler−Powered Units)	40
9-4.	Changing Engine Oil, Oil Filter, and Fuel Filter (Kohler-Powered Units)	41
9-5.	Adjusting Engine Speed (Kohler-Powered Units)	42
9-6.	Overload Protection (Kohler-Powered Units)	43
9-7.	Servicing Optional Spark Arrestor (Kohler-Powered Units)	43
SECTION 10 − TROUBLESHOOTING		44
10-1.	Welding Troubleshooting	44
10-2.	Generator Power Troubleshooting	44
10-3.	Engine Troubleshooting	45
SECTION 11 − PARTS LIST		46
11-1.	Recommended Spare Parts	46
SECTION 12 − ELECTRICAL DIAGRAMS		48
SECTION 13 − GENERATOR POWER GUIDELINES		50
SECTION 14 − STICK WELDING (SMAW) GUIDELINES		57
COMPLETE PARTS LIST − www.HobartWelders.com

OPTIONS AND ACCESSORIES

WARRANTY

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Hobart Welding Products OM-240 438B manual 10-1, 10-2, 10-3, 11-1

Contents

Processes OM-240 438BDescription From Hobart to You Protect Your Investment Table of Contents 10-1 10-210-3 11-1 Symbol Usage Arc Welding HazardsElectric Shock can kill HOT Parts can burn Fumes and Gases can be hazardous Buildup of GAS can injure or killARC Rays can burn eyes and skin Welding can cause fire or explosion Engine Hazards Hydraulic Hazards Use only genuine replacement parts from the manufacturer Compressed Air HazardsHydraulic Fluid can injure or kill Compressed AIR Equipment can injure or kill Welding Wire can injure Fire or Explosion hazardFalling Equipment can injure Overheating can damage motors Principal Safety Standards EMF Information California Proposition 65 WarningsRadiation can cause interference ARC Welding can cause interference Signification des symboles − Consignes DE Sécurité − Lire Avant UtilisationUN Choc Électrique peut tuer Indique des instructions spécifiques LES Pièces Chaudes peuvent provoquer des brûlures LES Fumées ET LES GAZ peu- vent être dangereuxLE Soudage peut provoquer un incendie ou une explosion LE Bruit peut affecter l’ouïe ’EXPLOSION DE LA Batterie peut provoquer des blessures Les Pièces Mobiles peuvent causer des blessures LA Chaleur DU Moteur peut pro- voquer un incendie Les Pièces Mobiles peuvent causer des blessures Lire LES Instructions Risque D’INCENDIE OU LES Fils DE Soudage peuvent provoquer des blessuresLA 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 Informations relatives aux CEM En ce qui concerne les implants médicaux − Specifications Symbol DefinitionsWeld, Power, and Engine Specifications − Definitions Complete Parts List is available at wwwHobartWelders.com Dimensions, Weights, And Operating AnglesWeight 562 lb 254 kg Dimensions For Units With Optional Running Gear DimensionsDuty Cycle Welding Amperes Fuel Consumption Subaru-Powered Units Fuel Consumption Kohler-Powered Units Generator Power Curve For CC/AC ModeFor 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 Installing Exhaust Pipe Connecting Or Replacing the BatteryConnect negative − battery cable last + − + − Stop engine Failure to properly connect Connecting To Weld Output TerminalsTools Needed 3/4 Selecting Weld Cable Sizes 150 ft 200 ft 250 ft350 ft 400 ft 45 m 60 m 70 m 90 m 105 m 120 m 100 150 200 250 Engine Control Switch − Operating the Welding GeneratorFront Panel Controls Fine Control Cold Weather Engine Operation InfrequentlyLoaded Frequently Stop engine Typical Stick Welding Connections And Control SettingsElectrode − Operating Auxiliary Equipment Standard Receptacles Simultaneous Weld And Power Wiring Optional 240 Volt PlugCurrent Available in Amperes 240 Receptacle − Maintenance SUBARU-POWERED Units Maintenance Label Subaru-Powered Units Routine Maintenance Subaru-Powered Units Stop engine before maintaining100 200 Servicing Optional Spark Arrestor Subaru-Powered Units Servicing Air Cleaner Subaru-Powered UnitsStop engine and let cool Oil Fill Oil Check Oil Drain Valve Oil Filter Adjusting Engine Speed Subaru-Powered Units Idle Speed Adjustment Stop engine. Disconnect negative − battery cable Overload Protection Subaru-Powered UnitsFuse F1 See Section − Maintenance − KOHLER-POWERED Units Maintenance Label Kohler-Powered Units Routine Maintenance Kohler-Powered Units Hours Nl Weld Cables ~ Slip Rings Nl Brushes OM-240 438 Servicing Air Cleaner Kohler−Powered Units Stop engine and let cool Oil Drain Valve 2 ID x 7 in Hose Oil FilterClose valve and valve cap Full Before adding oil Running engine Adjusting Engine Speed Kohler-Powered Units Adjustment NutLoosen 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 − Troubleshooting Welding TroubleshootingGenerator Power Troubleshooting Trouble Remedy Check receptacle wiring and connections Engine TroubleshootingCheck fuel level − Parts List Control switch S2, and throttle solenoid TS1Recommended Spare Parts Recommended Spare Parts SOCKET/WRENCH Selection Table Standard Metric − Electrical Diagrams Circuit Diagram For Welding Generator 240 424-A − Generator Power Guidelines Selecting Equipment Grounding When Supplying Building Systems How Much Power Does Equipment Require?Use ground device as stated Electrical codes Approximate Power Requirements For Industrial Motors Approximate Power Requirements For Farm/Home EquipmentIndustrial Motors Rating Starting Watts Running Watts Farm/Home Equipment Rating Starting Watts Running Watts Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Power Required To Start Motor How Much Power Can Generator Supply?Single-Phase Induction Motor Starting Requirements KVA/HP x HP x 1000 / Volts = Starting Amperage Typical Connections To Supply Standby Power Tional, state, and local codes Selecting Extension Cord Use Shortest Cord Possible Stick Welding Procedure − Stick Welding Smaw GuidelinesElectrode touches work Tools Needed Equipment Needed Piece Weld current can damage Electrode and Amperage Selection Chart Striking an ArcScratch Technique Tapping Technique Poor Weld Bead Characteristics Good 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 Troubleshooting Weld TestTo 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 Contact your Distributor for Hobart Welding Products