10-1 | Hobart Welding Products OM-240 438E guide

8-6.	Overload Protection	38
8-7.	Servicing Optional Spark Arrestor	38
SECTION 9 − TROUBLESHOOTING		39
9-1.	Welding Troubleshooting	39
9-2.	Generator Power Troubleshooting	39
9-3.	Engine Troubleshooting	40
SECTION 10 − PARTS LIST		41
10-1.	Recommended Spare Parts	41
SECTION 11 − ELECTRICAL DIAGRAMS		42
SECTION 12 − GENERATOR POWER GUIDELINES		44
SECTION 13 − STICK WELDING (SMAW) GUIDELINES		51

COMPLETE PARTS LIST - www.MillerWelds.com

WARRANTY

Page 4

Image 4

Hobart Welding Products OM-240 438E manual 10-1

Contents

Processes OM-240 438EDescription From Hobart to You Protect Your Investment Table of Contents 10-1 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 Compressed Air HazardsHydraulic Equipment can injure or kill Hydraulic Fluid can injure or kill Compressed AIR can injure or kill Fire or Explosion hazardOverheating can damage motors Falling Equipment can injure California Proposition 65 Warnings EMF Information Principal Safety StandardsAbout Implanted Medical Devices 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 LES Étincelles À L’ÉCHAPPEMENT peuvent provoquer un incendie LA Chaleur DU Moteur peut pro- voquer un incendie Lire LES Instructions Risque D’INCENDIE OU LA Chute DE L’ÉQUIPEMENT peut provoquer des blessuresLE Surchauffement peut endommager le moteur électrique LES Étincelles Projetées peuvent provoquer des blessures UNE Remorque QUI Bascule peut provoquer des blessures Proposition californienne 65 AvertissementsLE Soudage À L’ARC risque de provoquer des interférences Informations relatives aux CEM Principales normes de sécuritéEn ce qui concerne les implants médicaux − Specifications Symbol DefinitionsWeld, Power, and Engine Specifications − Definitions Dimensions, Weights, And Operating Angles Weight 562 lb 254 kg Dimensions For Units With Optional Running Gear DimensionsDuty Cycle Duty Cycle For CC/DC Mode For CC/AC ModeVolt-Ampere Curves Generator Power Curve Fuel Consumption − Installation Installing Welding GeneratorSerial Number And Rating Label Location Movement Location / Airflow Clearance Grounding Generator To Truck Or Trailer Frame GND/PE Engine Prestart Checks Oil 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 Start Your Professional Welding Career Now Engine Control Switch − Operating the Welding GeneratorFront Panel Controls Fine Control Cold Weather Engine Operation InfrequentlyLoaded Frequently Loaded Stop engine Typical Stick Welding Connections And Control SettingsElectrode − Operating Auxiliary Equipment Standard ReceptaclesGfci Receptacle Option At least once a month, run engine at Simultaneous Weld And Power Wiring Optional 240 Volt PlugCurrent Available in Amperes 240 Receptacle − Maintenance Maintenance Label Routine Maintenance 100200 500 Servicing Air Cleaner Changing Engine Oil, Oil Filter, and Fuel Filter Stop engine and let coolClose valve and valve cap Before Adding Oil Running engine Adjusting Engine Speed Idle Speed AdjustmentWeld/Power Speed Adjustment Turn idle speed screw for fine ad- justments Stop engine. Disconnect negative − battery cable Overload ProtectionServicing Optional Spark Arrestor Fuse F1 See Section − Troubleshooting Welding TroubleshootingGenerator Power Troubleshooting Trouble Remedy Engine Troubleshooting Check receptacle wiring and connectionsErs SR2 and SR3 Check fuel level − Parts List Control switch S2, and throttle solenoid TS1Recommended Spare Parts Recommended Spare Parts − Electrical Diagrams Circuit Diagram For Welding Generator 240 424-B − 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 Selecting Extension Cord Use Shortest Cord Possible Stick Welding Procedure − Stick Welding Smaw GuidelinesWeld current starts when Electrode touches work Electrode and Amperage Selection Chart Striking an ArcScratch Technique Tapping Technique Poor Weld Bead Characteristics Good Weld Bead CharacteristicsPositioning Electrode Holder End View Of Work Angle Side View Of Electrode Angle 10-30 Conditions That Affect Weld Bead Shape Electrode Movement During WeldingElectrode Angle Normal Groove Butt Joints Lap JointTee Joint Or Less Troubleshooting Weld TestPossible Causes Corrective Actions Weld bead Lack of Penetration Good Penetration Good Penetration Excessive PenetrationMetal remains Direction SOCKET/WRENCH Selection Table Standard Metric Support ServiceAssistance Contact your Distributor for Hobart Welding Products

Hobart Welding Products OM-240 438E manual 10-1

Models: OM-240 438E

TABLE OF CONTENTS

10-1.