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_2010 − 03 Protect yourself and others from injury — read, follow, and save these important safety precautions and operating instructions. 1-1. Symbol Usage DANGER! − Indicates a hazardous situation which, if not avoided, will r...
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, battery charging cables (if applicable), or servicing battery. Do not allo...
Page 8 - HOT PARTS AND FLUID can burn.; COMPRESSED AIR EQUIPMENT can
OM-240 438 Page 4 1-4. Hydraulic Hazards HYDRAULIC EQUIPMENT can injure or kill. Incorrect installation or operation of this unit could result in equipment failure and personal injury. Only qualified persons should install, op- erate, and service this unit according to its Owner’s Manual, industry s...
Page 9 - BREATHING COMPRESSED AIR can in-
OM-240 438 Page 5 HOT METAL from air arc cutting and gouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep extinguisher nearby. COMPRESSED AIR can injure or kill. Before working on compressed air system, turn off and lockout/tagout unit, release pres- sure, a...
Page 10 - WELDING WIRE can injure.; OVERUSE can cause OVERHEATING.; ARC WELDING can cause interference.
OM-240 438 Page 6 WELDING WIRE can injure. Do not press gun trigger until instructed to do so. Do not point gun toward any part of the body, other people, or any metal when threading welding wire. OVERUSE can cause OVERHEATING. Allow cooling period; follow rated duty cycle. Reduce current or reduce ...
Page 12 - UN CHOC ÉLECTRIQUE peut tuer.; Il reste une TENSION DC NON NÉGLIGEABLE dans les
OM-240 438 Page 8 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANT UTILISATION fre_rom_2010 − 03 Pour écarter les risques de blessure pour vous − même et pour autrui — lire, appliquer et ranger en lieu sûr ces consignes relatives aux précautions de sécurité et au mode opératoire. 2-1. Signification de...
Page 14 - Si des BOUTEILLES sont endomma-; -3. Dangers existant en relation avec le moteur
OM-240 438 Page 10 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’approc...
Page 15 - Les ÉQUIPEMENTS HYDRAULIQUES
OM-240 438 Page 11 LES ÉTINCELLES À L’ÉCHAPPEMENT peuvent provoquer un incendie. Empêcher les étincelles d’échappement du moteur de provoquer un incendie. Utiliser uniquement un pare-étincelles approuvé − voir codes en vigueur. LES PIÈCES CHAUDES peuvent provoquer des brûlures. Ne pas toucher des pa...
Page 17 - Les PIÈCES MOBILES peuvent causer
OM-240 438 Page 13 Une PRESSION D’AIR RÉSIDUELLE ET DES FLEXIBLES QUI FOUETTENT risquent de provoquer des blessures. Détendre la pression pneumatique des outils et circuits avant d’entretenir, ajouter ou changer des accessoires et avant d’ouvrir le bouchon de vidange ou de remplissage d’huile du com...
Page 18 - LIRE LES INSTRUCTIONS.; -7. Proposition californienne 65 Avertissements
OM-240 438 Page 14 LES CHARGES ÉLECTROSTATI- QUES peuvent endommager les circuits imprimés. Établir la connexion avec la barrette de terre avant de manipuler des cartes ou des pièces. Utiliser des pochettes et des boîtes antistatiques pour stocker, déplacer ou expédier des cartes de circuits imprime...
Page 20 - SECTION 3
A complete Parts List is available at wwwHobartWelders.com OM-240 438 Page 16 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 Choke...
Page 22 - -3. Dimensions For Units With Optional Running Gear; elding Amperes
A complete Parts List is available at wwwHobartWelders.com OM-240 438 Page 18 4-3. Dimensions For Units With Optional Running Gear Dimensions 804 937-B 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 4-5. 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 25 - SECTION 5; -1. Serial Number And Rating Label Location
A complete Parts List is available at www.HobartWelders.com OM-240 438 Page 21 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 ou...
Page 26 - -3. Grounding Generator To Truck Or Trailer Frame
A complete Parts List is available at wwwHobartWelders.com OM-240 438 Page 22 ! 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 Generator...
Page 28 - -6. Connecting Or Replacing the Battery
A complete Parts List is available at wwwHobartWelders.com OM-240 438 Page 24 5-5. 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 - -7. 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 5-8. 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 31 - Start Your Professional
A complete Parts List is available at www.HobartWelders.com OM-240 438 Page 27 Notes 400 Trade Square East, Troy, Ohio 45373 1-800-332-9448 www.welding.org Over 80,000 trained since 1930! Start Your Professional Welding Career Now!
Page 33 - Frequently
A complete Parts List is available at www.HobartWelders.com OM-240 438 Page 29 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 n...
Page 34 - -3. Typical Stick Welding Connections And Control Settings
A complete Parts List is available at wwwHobartWelders.com OM-240 438 Page 30 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 HORI...
Page 35 - SECTION 7
A complete Parts List is available at www.HobartWelders.com OM-240 438 Page 31 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 37 - SECTION 8
A complete Parts List is available at www.HobartWelders.com OM-240 438 Page 33 SECTION 8 − MAINTENANCE 8-1. Maintenance Label
Page 45 - PARTS LIST; Recommended Spare Parts
A complete Parts List is available at www.HobartWelders.com OM-240 438 Page 41 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 batter...
Page 46 - ELECTRICAL DIAGRAMS; Figure 11-1. Circuit Diagram For Welding Generator
OM-240 438 Page 42 SECTION 11 − ELECTRICAL DIAGRAMS Figure 11-1. Circuit Diagram For Welding Generator
Page 48 - GENERATOR POWER GUIDELINES; 2-2. Grounding Generator To Truck Or Trailer Frame
OM-240 438 Page 44 SECTION 12 − 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. 12-1. Selecting Equipment gen_pwr 2010 − 04 − ST-800 577 1 Generator Power Receptacles − Neutral Bond...
Page 49 - 2-3. Grounding When Supplying Building Systems
OM-240 438 Page 45 12-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding Terminal 2 Grounding Cable Use #8 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 50 - 2-5. Approximate Power Requirements For Industrial Motors
OM-240 438 Page 46 12-5. 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 51 - 2-7. Approximate Power Requirements For Contractor Equipment
OM-240 438 Page 47 12-7. 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 53 - 2-10. Typical Connections To Supply Standby Power
OM-240 438 Page 49 12-10. 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 56 - 3-2. Electrode and Amperage Selection Chart
OM-240 438 Page 52 13-2. 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 58 - 3-7. Conditions That Affect Weld Bead Shape
OM-240 438 Page 54 13-7. 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 62 - SOCKET/WRENCH SELECTION TABLE
OM-240 438 Page 58 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 U.S. Decimal Equivalent Bolt Nut 1/4 in .250 in 3/8 in 7/16 ...
Page 64 - 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 © 2011 Hobart Welding Products. 2011 − 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...
