Hobart OM-240 438B - Manuals

Page 2 - From Hobart to You; Register your product at:; Protect Your Investment!

Hobart Welders manufactures a full lineof welders and welding related equipment.For information on other quality Hobart products, contact your local Hobartdistributor to receive the latest full line catalog or individual specification sheets. To locate your nearest distributor or service agency call...

Page 3 - TABLE OF CONTENTS

TABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage 1 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2...

Page 5 - ELECTRIC SHOCK can kill.; SIGNIFICANT DC VOLTAGE exists in inverter power; FLYING METAL or DIRT can injure eyes.

OM-240 438 Page 1 SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING rom_2009 − 08 Protect yourself and others from injury — read and follow these precautions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will result in death or serious injury. The possible haza...

Page 7 - EXHAUST SPARKS can cause fire.; STEAM AND HOT COOLANT can burn.; Using a generator indoors CAN KILL; ENGINE HEAT can cause fire.

OM-240 438 Page 3 1-3. Engine Hazards BATTERY EXPLOSION can injure. Always wear a face shield, rubber gloves, and protective clothing when working on a battery. Stop engine before disconnecting or connect- ing battery cables or servicing battery. Do not allow tools to cause sparks when working on a ...

Page 8 - HOT PARTS AND FLUID can burn.; COMPRESSED AIR EQUIPMENT can; HOT METAL from air arc cutting and; BREATHING COMPRESSED AIR can in-

OM-240 438 Page 4 HYDRAULIC FLUID can injure or kill. Before working on hydraulic system, turn off and lockout/tagout unit, release pressure, and be sure hydraulic pressure cannot be accidentally applied. Relieve pressure before disconnecting or con- necting hydraulic lines. Check hydraulic system c...

Page 10 - ARC WELDING can cause interference.

OM-240 438 Page 6 H.F. RADIATION can cause interference. High-frequency (H.F.) can interfere with radio navigation, safety services, computers, and communications equipment. Have only qualified persons familiar with electronic equipment perform this installation. The user is responsible for having a...

Page 11 - UN CHOC ÉLECTRIQUE peut tuer.; Il reste une TENSION DC NON NÉGLIGEABLE dans

OM-240 438 Page 7 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_rom_2009 − 08 Se protéger, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. 2-1. Signification des symboles DANGER! − Indique une situation dangereuse qui si on l’évite ...

Page 13 - -3. Dangers existant en relation avec le moteur

OM-240 438 Page 9 Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)peuvent affecter les implants médicaux. Les porteurs de stimulateurs cardiaques et autres implants médicaux doivent rester à distance. Les porteurs d’implants médicaux doivent consulter leur médecin et le fabricant du dispositif avant de s’approch...

Page 17 - -7. Proposition californienne 65 Avertissements

OM-240 438 Page 13 LE RAYONNEMENT HAUTE FRÉ- QUENCE (H.F.) risque de provoquer des interférences. Le rayonnement haute fréquence (H.F.) peut provoquer des interférences avec les équipe- ments de radio − navigation et de communica- tion, les services de sécurité et les ordinateurs. Demander seulement...

Page 19 - SECTION 3

A complete Parts List is available at www.HobartWelders.com OM-240 438 Page 15 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, Weld/Power) Fast/Slow (Run/Idle) Slow (Idle) Start Engine Read Operator’s Manual A Amperes V Volts Engine Oil Fuel Battery (Engine) Engine Engine Chok...

Page 21 - -3. Dimensions For Units With Optional Running Gear; elding Amperes

A complete Parts List is available at www.HobartWelders.com OM-240 438 Page 17 4-3. Dimensions For Units With Optional Running Gear Dimensions B D A B C Height All Running Gear Options: 42-1/2 in. (1079 mm) (To Top Of Handle Assembly) A Protective Cage Width: 26 in. (660 mm) B Running Gear Width: 32...

Page 23 - AC VOL

A complete Parts List is available at www.HobartWelders.com OM-240 438 Page 19 4-7. Volt-Ampere Curves 240 426-A / 240 427-A The volt-ampere curve shows the minimum and maximum voltage and amperage output capabilities of the welding generator. Curves of all other settings fall between the curves sho...

Page 24 - SECTION 5; -1. Serial Number And Rating Label Location

A complete Parts List is available at wwwHobartWelders.com OM-240 438 Page 20 SECTION 5 − INSTALLATION 5-1. Serial Number And Rating Label Location The serial number and rating information for this product is located on the back. Use rating label to determine input power requirements and/orrated out...

Page 25 - -3. Grounding Generator To Truck Or Trailer Frame

A complete Parts List is available at www.HobartWelders.com OM-240 438 Page 21 ! Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. ! Also see AWS Safety & Health Fact Sheet No. 29, Grounding of Portable And Vehicle Mounted Welding Generato...

Page 28 - -7. Connecting Or Replacing the Battery

A complete Parts List is available at wwwHobartWelders.com OM-240 438 Page 24 5-6. Installing Exhaust Pipe 803 751 / Ref. 281 080-A ! Engine backfire can cause se- vere burns or other injuries. Do not point exhaust pipe toward control panel. Keep away from exhaust outlet. ! Point exhaust pipe in des...

Page 29 - -8. Connecting To Weld Output Terminals

A complete Parts List is available at www.HobartWelders.com OM-240 438 Page 25 ! Stop engine. ! Failure to properly connect weld cables may cause exces- sive heat and start a fire, or damage your machine. Do not place anything betweenweld cable terminal and cop- per bar. Make sure that the sur- face...

Page 30 - Notes; Pros weld and cut

A complete Parts List is available at wwwHobartWelders.com OM-240 438 Page 26 5-9. Selecting Weld Cable Sizes* NOTICE − The Total Cable Length in Weld Circuit (see table below) is the combined length of both weld cables. For example, if the power source is 100 ft (30 m) from the workpiece, the total...

Page 32 - Frequently; Start Your Professional

A complete Parts List is available at wwwHobartWelders.com OM-240 438 Page 28 6-2. Cold Weather Engine Operation Ref. 240 947 1 Engine Control Switch Carburetor Icing Carburetor icing causes the unit to drop below the normal idle speed and then stall. This condition occurs when the temperature is ne...

Page 33 - -3. Typical Stick Welding Connections And Control Settings

A complete Parts List is available at www.HobartWelders.com OM-240 438 Page 29 ELECTRODE DC* AC POSITION PENETRA TION USAGE MIN. PREP, ROUGH HIGH SPATTER GENERAL SMOOTH, EASY, FAST LOW HYDROGEN, STRONG SMOOTH, EASY, FASTER CAST IRONSTAINLESS DEEPDEEP LOW MED LOW LOW LOWLOW ALLALLALL ALL ALL FLAT HOR...

Page 34 - SECTION 7

A complete Parts List is available at wwwHobartWelders.com OM-240 438 Page 30 SECTION 7 − OPERATING AUXILIARY EQUIPMENT 7-1. Standard Receptacles 244 029-A / 281 080-A ! If unit does not have GFCI recep- tacles, use GFCI-protected exten- sion cord. Generator power decreases as weldcurrent increases....

Page 36 - SECTION 8

A complete Parts List is available at wwwHobartWelders.com OM-240 438 Page 32 SECTION 8 − MAINTENANCE (SUBARU-POWERED UNITS) 8-1. Maintenance Label (Subaru-Powered Units)

Page 42 - SECTION 9

A complete Parts List is available at wwwHobartWelders.com OM-240 438 Page 38 SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) 9-1. Maintenance Label (Kohler-Powered Units)

Page 48 - TROUBLESHOOTING

A complete Parts List is available at wwwHobartWelders.com OM-240 438 Page 44 SECTION 10 − TROUBLESHOOTING 10-1. Welding Troubleshooting Trouble Remedy Low or no weld output; generator pow- er output okay at ac receptacles. Check control settings. Check weld connections. Check fuse F1, and replace i...

Page 50 - PARTS LIST

A complete Parts List is available at wwwHobartWelders.com OM-240 438 Page 46 Trouble Remedy Battery Discharges between uses. Clean battery, terminals, and posts with baking soda and water solution; rinse with clear water. Periodically recharge battery (approximately every 3 months). Replace battery...

Page 51 - SOCKET/WRENCH SELECTION TABLE

A complete Parts List is available at www.HobartWelders.com OM-240 438 Page 47 Notes SOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) SOCKET/WRENCH SELECTION TABLE (METRIC) Specifications Socket or Wrench Size Specifications Socket or Wrench Size Bolt Diameter Decimal Equivalent Bolt Nut Bolt Diameter ...

Page 52 - ELECTRICAL DIAGRAMS; Figure 12-1. Circuit Diagram For Welding Generator

OM-240 438 Page 48 SECTION 12 − ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram For Welding Generator

Page 54 - GENERATOR POWER GUIDELINES; 3-2. Grounding Generator To Truck Or Trailer Frame

OM-240 438 Page 50 SECTION 13 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators. Your unit may differ from those shown. 13-1. Selecting Equipment gen_pwr 2008 − 01 − ST-800 577 1 Generator Power Receptacles − Neutral Bond...

Page 55 - 3-3. Grounding When Supplying Building Systems

OM-240 438 Page 51 13-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding Terminal 2 Grounding Cable Use #10 AWG or larger insulated copper wire.3 Ground Device Use ground device as stated inelectrical codes. ! Ground generator to system earth ground if supplying power to...

Page 56 - 3-5. Approximate Power Requirements For Industrial Motors

OM-240 438 Page 52 13-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Starting Watts Running Watts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP 2100 700 1/2 HP 3175 875 Capacitor Start-Induction Run 1/3 HP 2020 720 1/2 HP 3075 975 3/4 HP 4500 140...

Page 57 - 3-7. Approximate Power Requirements For Contractor Equipment

OM-240 438 Page 53 13-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts Running Watts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6-1/2 in 500 500 7-1/4 in 900 900 8-1/4 in 1400 1400 Table Saw 9 in 4500 1500 10 in 6300 1800 Band Saw ...

Page 59 - 3-10. Typical Connections To Supply Standby Power

OM-240 438 Page 55 13-10. Typical Connections To Supply Standby Power Transfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 1 2 3 4 5 Welding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safe...

Page 62 - 4-2. Electrode and Amperage Selection Chart

OM-240 438 Page 58 14-2. Electrode and Amperage Selection Chart Ref. S-087 985-A 3/32 1/8 5/32 3/16 7/32 1/4 1/16 5/64 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 7/32 1/4 3/32 1/8 5/32 3/16 3/32 1/8 5/32 6010 & 6011 6013 7014 7018 7024 ...

Page 64 - 4-7. Conditions That Affect Weld Bead Shape

OM-240 438 Page 60 14-7. Conditions That Affect Weld Bead Shape S-0061 Slow Normal Fast 10 ° - 30 ° Drag Too Short Normal Too Long Spatter Angle Too Small Angle Too Large Correct Angle Electrode Angle Arc Length Travel Speed Weld bead shape is affectedby electrode angle, arc length, travel speed, an...

Page 71 - Call

Warranty Questions? Call 1-800-332-3281 hobart_warr 2009 − 01 Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor or call 1-800-332-3281. The expertise...

Page 72 - Hobart Welding Products; Please complete and retain with your personal records.; To locate a Distributor,; Contact your Distributor for:; Resources Available; For technical assistance:

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2009 Hobart Welding Products. 2009 − 01 Hobart Welding Products An Illinois Tool Works Company 600 West Main Street Troy, OH 45373 USA For Technical Assistance: Call1-800-332-3281 For Literature Or Nearest Dealer: Call 1-877-Hobart1 Model Name Serial/Style Nu...