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

Models: OM-240 438E

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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	4
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	7
1-9.	EMF Information	7

SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION		8
2-1.	Signification des symboles	8
2-2. Dangers relatifs au soudage à l’arc		8
2-3. Dangers existant en relation avec le moteur		10
2-4. Dangers liés à l’hydraulique		11
2-5. Dangers liés à l’air comprimé		12
2-6. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance		13
2-7. Proposition californienne 65 Avertissements		14
2-8. Principales normes de sécurité		15
2-9. Informations relatives aux CEM		15
SECTION 3 − DEFINITIONS		16
SECTION 4 − SPECIFICATIONS		16
4-1. Weld, Power, and Engine Specifications		16
4-2. Dimensions, Weights, And Operating Angles		17
4-3. Dimensions For Units With Optional Running Gear		18
4-4.	Duty Cycle	18
4-5.	Volt-Ampere Curves	19
4-6.	Fuel Consumption	20
4-7.	Generator Power Curve	20
SECTION 5 − INSTALLATION		21
5-1. Serial Number And Rating Label Location		21
5-2.	Installing Welding Generator	21
5-3. Grounding Generator To Truck Or Trailer Frame		22
5-4.	Engine Prestart Checks	23
5-5.	Installing Exhaust Pipe	24
5-6. Connecting Or Replacing the Battery		24
5-7. Connecting To Weld Output Terminals		25
5-8. Selecting Weld Cable Sizes*		26
SECTION 6 − OPERATING THE WELDING GENERATOR		28
6-1.	Front Panel Controls	28
6-2. Cold Weather Engine Operation		29
6-3. Typical Stick Welding Connections And Control Settings		30
SECTION 7 − OPERATING AUXILIARY EQUIPMENT		31
7-1.	Standard Receptacles	31
7-2. Simultaneous Weld And Power		32
7-3. Wiring Optional 240 Volt Plug		32
SECTION 8 − MAINTENANCE		33
8-1.	Maintenance Label	33
8-2.	Routine Maintenance	34
8-3.	Servicing Air Cleaner	35
8-4. Changing Engine Oil, Oil Filter, and Fuel Filter		36
8-5.	Adjusting Engine Speed	37

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

Contents

OM-240 438E ProcessesDescription Protect Your Investment From Hobart to YouTable of Contents 10-1 HOT Parts can burn Symbol UsageArc Welding Hazards Electric Shock can killWelding can cause fire or explosion Fumes and Gases can be hazardousBuildup of GAS can injure or kill ARC Rays can burn eyes and skinEngine Hazards Hydraulic Fluid can injure or kill Hydraulic HazardsCompressed Air Hazards Hydraulic Equipment can injure or killFalling Equipment can injure Compressed AIR can injure or killFire or Explosion hazard Overheating can damage motorsCalifornia Proposition 65 Warnings Principal Safety Standards EMF InformationAbout Implanted Medical Devices Indique des instructions spécifiques Signification des symboles− Consignes DE Sécurité − Lire Avant Utilisation UN Choc Électrique peut tuerLE 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 explosionLes 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 LES Étincelles Projetées peuvent provoquer des blessures Risque D’INCENDIE OULA Chute DE L’ÉQUIPEMENT peut provoquer des blessures LE Surchauffement peut endommager le moteur électriqueProposition 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 − Definitions − SpecificationsSymbol Definitions Weld, Power, and Engine SpecificationsWeight 562 lb 254 kg Dimensions, Weights, And Operating AnglesDuty Cycle Dimensions For Units With Optional Running GearDimensions Duty CycleFor CC/AC Mode For CC/DC ModeVolt-Ampere Curves Fuel Consumption Generator Power CurveMovement Location / Airflow Clearance − InstallationInstalling Welding Generator Serial Number And Rating Label LocationGND/PE Grounding Generator To Truck Or Trailer FrameOil Engine Prestart Checks+ − Installing Exhaust PipeConnecting Or Replacing the Battery Connect negative − battery cable lastConnecting 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 mStart Your Professional Welding Career Now Fine Control Engine Control Switch− Operating the Welding Generator Front Panel ControlsFrequently Loaded Cold Weather Engine OperationInfrequently LoadedTypical Stick Welding Connections And Control Settings Stop engineElectrode At least once a month, run engine at − Operating Auxiliary EquipmentStandard Receptacles Gfci Receptacle OptionReceptacle Simultaneous Weld And PowerWiring Optional 240 Volt Plug Current Available in Amperes 240Maintenance Label − Maintenance500 Routine Maintenance100 200Servicing Air Cleaner Before Adding Oil Running engine Changing Engine Oil, Oil Filter, and Fuel FilterStop engine and let cool Close valve and valve capTurn idle speed screw for fine ad- justments Adjusting Engine SpeedIdle Speed Adjustment Weld/Power Speed AdjustmentFuse F1 See Section Stop engine. Disconnect negative − battery cableOverload Protection Servicing Optional Spark ArrestorTrouble Remedy − TroubleshootingWelding Troubleshooting Generator Power TroubleshootingCheck fuel level Engine TroubleshootingCheck receptacle wiring and connections Ers SR2 and SR3Recommended Spare Parts − Parts ListControl switch S2, and throttle solenoid TS1 Recommended Spare PartsCircuit Diagram For Welding Generator − Electrical Diagrams240 424-B Selecting Equipment − Generator Power GuidelinesElectrical codes Grounding When Supplying Building SystemsHow Much Power Does Equipment Require? Use ground device as statedFarm/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 WattsContractor Rating Starting Watts Running Watts Approximate Power Requirements For Contractor EquipmentKVA/HP x HP x 1000 / Volts = Starting Amperage Power Required To Start MotorHow Much Power Can Generator Supply? Single-Phase Induction Motor Starting RequirementsTypical Connections To Supply Standby Power Selecting Extension Cord Use Shortest Cord Possible Electrode touches work Stick Welding Procedure− Stick Welding Smaw Guidelines Weld current starts whenTapping Technique Electrode and Amperage Selection ChartStriking an Arc Scratch TechniqueEnd View Of Work Angle Side View Of Electrode Angle 10-30 Poor Weld Bead CharacteristicsGood Weld Bead Characteristics Positioning Electrode HolderNormal Conditions That Affect Weld Bead ShapeElectrode Movement During Welding Electrode AngleOr Less Groove Butt JointsLap Joint Tee JointWeld bead TroubleshootingWeld Test Possible Causes Corrective ActionsDirection Lack of Penetration Good PenetrationGood Penetration Excessive Penetration Metal remainsSOCKET/WRENCH Selection Table Standard Metric Service SupportAssistance Hobart Welding Products Contact your Distributor for