Instruction/ maintenance manual of the product OM-240 438E Hobart Welding Products
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Champion Elite Processes Description ® Stick (SMAW) W elding Engine Driven Welding Generator OM-240 438E 201 1 − 03.
Hobart W elders manufactures a full line of welders and welding related equipment. For information on other quality Hobart products, contact your local Hobart distributor to receive the latest full line catalog or individual specification sheets. T o locate your nearest distributor or service agency call 1-877-Hobart1 or visit our website at www .
T ABLE OF CONTENTS SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1 ................................ 1-1. Symbol Usage 1 ....................................................................... 1-2. Arc W elding Hazards 1 ......................
T ABLE OF CONTENTS 8-6. Overload Protection 38 .................................................................. 8-7. Servicing Optional Spark Arrestor 38 ....................................................... SECTION 9 − TROUBLESHOOTING 39 ......
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 result in death or serious injury .
OM-240 438 Page 2 W elding produces fumes and gases. Breathing these fumes and gases can be hazardous to your health. FUMES AND GASES can be hazardous. Keep your head out of the fumes. Do not breathe the fumes. If inside, ventilate the area and/or use local forced ventilation at the arc to remove welding fumes and gases.
OM-240 438 Page 3 1-3. Engine Hazards BA TTER Y 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 .
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 .
OM-240 438 Page 5 HOT MET AL from air arc cutting and gouging can cause fire or explosion. Do not cut or gouge near flammables. W atch for fire; keep extinguisher nearby .
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 OVERHEA TING. Allow cooling period; follow rated duty cycle.
OM-240 438 Page 7 1-8. Principal Safety Standards Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .global.ihs.com). Safe Practices for the Preparation of Containers and Piping for W elding an d Cutting, American W elding Society Standard A WS F4.
OM-240 438 Page 8 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION 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.
OM-240 438 Page 9 LES PIÈCES CHAUDES peuvent provoquer des brûlures. Ne pas toucher à mains nues les parties chau- des. Prévoir une période de refroidissement avant de travailler à l’équipement.
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.
OM-240 438 Page 1 1 LE S 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 .
OM-240 438 Page 12 un médecin familiarisé avec ce type de blessure, faute de quoi la gangrène pourrait apparaître. Les PIÈCES MOBILES peuvent causer des blessures. S’abstenir de toucher des parties mobiles telles que des ventilateurs, courroies et rotors.
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 compresseur .
OM-240 438 Page 14 LES CHARGES ÉLECTROST A TI - 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 imprimes.
OM-240 438 Page 15 2-8. P ri nci pal es n or m es de sé cur i té Safety i n W elding, Cutting, and Allied Processes, ANSI Standard Z49.1, from Global Engineering Documents (phone: 1-877-413-5184, website: www .
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 16 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Idle.
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 17 4-2. Dimensions, W eights, And Operating Angles 244 029-A / 244 030-A / 244 031-A 20 ° 20 ° 20 ° 20 ° ! Do not exceed tilt angles or engine could be damaged or unit could tip.
A complete Parts List is available at wwwHobartW elders.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) (T o T op Of Handle Assembly) A Protective Cage Width: 26 in.
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 19 4-5. V olt-Ampere Curves 240 426-A / 240 427-A The volt-ampere curve shows the minimum and maximum voltage an d amperage output capabilities of th e welding generator .
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 20 4-6. Fuel Consumption 202 094-A On a typical job using 1/8 in 7018 electrodes (125 amps, 20% duty cycle), expect about 20 hours of op- eration. W elding at 150 amps at 40% duty cycle uses approximately 3/4 gal- lon per hour , or about 16 hours of operation.
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 21 SECTION 5 − INST ALLA TION 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/or rated output.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 22 ! Always ground generator frame to vehicle frame to pre- vent electric shock and static electricity hazards. ! Also see A WS Safety & Health Fact Sheet No. 29, Grounding of Portable And V ehicle Mounted W elding Generators.
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 23 5-4. Engine Prestart Checks 244 033-A / 217 015-A Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil. Follow run-in procedure in en- gine manual.
A complete Parts List is available at wwwHobartW elders.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.
A complete Parts List is available at www .HobartW elders.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 between weld cable terminal and cop- pe r bar .
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 26 5-8. Selecting Weld Cable Sizes* NOTICE − The T otal Cable Length in W eld Circuit (see table below) is the combined length of both weld cables.
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 27 Notes 400 T rade Square East, T roy , Ohio 45373 1-800-332-9448 www.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 28 SECTION 6 − OPERA TING THE WELDING GENERA TOR 4 1 3 6 6-1. Front Panel Controls 281 080-A 1 Engine Control Switch Use switch to start engine, select speed, and stop engine.
A complete Parts List is available at www .HobartW elders.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.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 30 ELECTRODE DC* AC POSITION PENETRA TION USAGE MIN. PREP , ROUGH HIGH SP A TTER GENERAL SMOOTH, EASY , F AST LOW HYDROG.
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 31 SECTION 7 − OPERA TING AUXILIAR Y 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.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 32 7-2. Simultaneous W eld And Power W eld Current in Amperes T otal Power in Watts 120 V Full kV A Receptacle Amperes 240 V Full kV A Receptacle Amperes 250 2200 18 9 180 3500 29 14 125 5200 43 21 90 8000 66 33 0 1 1,000 92 46 7-3.
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 33 SECTION 8 − MAINTENANCE 8-1. Maintenance Label.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 34 8-2. Routine Maintenance ! Stop engine before maintaining. S ee Engine Manual and Maintenance Label for important start-up, service, and storage information. Service engine more often if used in severe conditions.
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 35 ! Stop engine. NOTICE − Do not run engine with- ou t air cleaner or with dirty element. 1 Precleaner Was h precleaner with soap and wa- ter solution. Allow precleaner to air dry completely .
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 36 8-4. Changing Engine Oil, Oil Filter , and Fuel Filter 244 033-A / S-0842 ! Stop engine and let cool. 1 Oil Drain V alve 2 1/2 ID x 7 in Hose 3 Oil Filter Change engine oil and filter accord- ing to engine owner’s manual.
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 37 8-5. Adjusting Engine Speed 244 033-A / 244 034-A After tuning engine, check engine speeds with a tachometer (see table). If necessary, adjust speeds as follows: Start engine and run until warm.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 38 8-6. Overload Protection 244 029-A ! Stop engine. Disconnect negative ( − ) battery cable. 1 Fuse F1 (See Section 10-1 ) F1 protects the weld excitation winding from overload.
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 39 SECTION 9 − TROUBLESHOOTING 9-1. W elding T roubleshooting T rouble Remedy Low or no weld output; generator pow- er output okay at ac receptacles. Check control settings.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 40 T rouble Remedy No generator power or weld output. Be sure all equipment is disconnected from receptacles when starting unit. Check fuses F1 and F2, and replace if open (see Section 8-6).
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 41 T rouble 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).
OM-240 438 Page 42 SECTION 1 1 − ELECTRICAL DIAGRAMS Figure 1 1-1. Circuit Diagram For Welding Generator.
OM-240 438 Page 43 240 424-B.
OM-240 438 Page 44 SECTION 12 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators.
OM-240 438 Page 45 12-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #8 A WG or larger insulated copper wire.
OM-240 438 Page 46 12-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Start ing W atts Running W atts Split Phase 1/8 HP 800 300 1/6 HP 1225 500 1/4 HP 1600 600 1/3 HP.
OM-240 438 Page 47 12-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting W atts Running W atts Hand Drill 1/4 in 350 350 3/8 in 400 400 1/2 in 600 600 Circular Saw 6.
OM-240 438 Page 48 12-8. Power Required T o Start Motor Single-Phase Induction Motor Starting Requirements Motor Start Code G H J K L M N P KV A/HP 6.3 7.1 8.0 9.0 10.0 1 1.2 12.5 14.0 S-0624 1 Motor Start Code 2 Running Amperage 3 Motor HP 4 Motor V oltage T o find starting amperage: Step 1: Find code and use table to find kV A/HP .
OM-240 438 Page 49 12-10. T ypical Connections T o Supply Standby Power T ransfer Switch Essential Loads Fused Disconnect Switch (If Required) Utility Electrical Service 12 3 4 5 W elding Generator Output ! Have only qualified persons perform these connections according to all applicable codes and safety practices.
OM-240 438 Page 50 12-1 1. Selecting Extension Cord (Use Shortest Cord Possible) Cord Lengths for 120 V olt Loads If unit does not have GFCI receptacles, use GFCI-protected extension cord.
OM-240 438 Page 51 SECTION 13 − STICK WELDING (SMA W) GUIDELINES 13-1. Stick Welding Procedure stick 2010 − 02 − 151 593 ! Weld current starts when electrode touches work- piece. ! Weld current can damage electronic parts in vehicles. Disconnect both battery cables before welding on a vehicle.
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.
OM-240 438 Page 53 13-4. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° 10 ° -30 ° 1 End View Of W ork Angle 2 Side View Of Electrode Angle 1 1 2 2 Groove Welds Fillet Welds 13-5.
OM-240 438 Page 54 13-7. Conditions That Affect W eld Bead Shape S-0061 Slow Normal Fast 10 ° - 30 ° Drag T oo Short Normal T oo Long Spatter Angle T oo Small Angle T oo Large Correct Angle Electrode Angle Arc Length T ravel Speed Weld bead shape is affected by electrode angle, arc length, travel speed, and thick- ness of base metal.
OM-240 438 Page 55 13-9. Groove (Butt) Joints S-0062 1 T ack Welds Prevent edges of joint from draw- ing together ahead of electrode by tack welding the materials in posi- tion before final weld. 2 Square Groove Weld Good for materials up t o 3/16 in.
OM-240 438 Page 56 13-12. Weld T est S-0057-B 1 Vise 2 Weld Joint 3 Hammer Strike weld joint in direction shown. A good weld bends over but does not break. 2 T o 3 in. 1/4 in. 3 2 1 2 T o 3 in. 3 2 1 (51-76 mm) (6.4 mm) (51-76 mm) 13-13. T roubleshooting Porosity − small cavities or holes resulting from gas pockets in weld metal.
OM-240 438 Page 57 Lack of Penetration Good Penetration Lack Of Penetration − shallow fusion between weld metal and base metal. Possible Causes Corrective Actions Improper joint preparation. Material too thick. Joint preparation and design must provide access to bottom of groove.
OM-240 438 Page 58 Notes SOCKET/WRENCH SELECTION T ABLE (U.S. ST ANDARD) SOCKET/WRENCH SELECTION T ABLE (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 .
Warranty Questions? Call 1-800-332-3281 7 AM − 5 PM EST hobart_warr 201 1 − 01 Service Y ou 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.
ORIGINAL INSTRUCTIONS − PRINTED IN USA © 201 1 Hobart Welding Products. 201 1 − 01 Hoba rt W elding P roduc ts An Illinois T ool W orks Company 600 W est Main Street Tr oy , OH 45373 USA For T ec.
An important point after buying a device Hobart Welding Products OM-240 438E (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Hobart Welding Products OM-240 438E yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Hobart Welding Products OM-240 438E - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Hobart Welding Products OM-240 438E you will learn all the available features of the product, as well as information on its operation. The information that you get Hobart Welding Products OM-240 438E will certainly help you make a decision on the purchase.
If you already are a holder of Hobart Welding Products OM-240 438E, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Hobart Welding Products OM-240 438E.
However, one of the most important roles played by the user manual is to help in solving problems with Hobart Welding Products OM-240 438E. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Hobart Welding Products OM-240 438E along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
