Benutzeranleitung / Produktwartung OM-240 438B des Produzenten Hobart Welding Products
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Champion Elite Processes Description ™ Stick (SMAW) W elding Engine Driven Welding Generator OM-240 438B 2009 − 09.
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
T ABLE OF CONTENTS 8-4. Servicing Optional Spark Arrestor (Subaru-Powered Units) 34 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5. Changing Engine Oil, Oil Filter , and Fuel Filter (Subaru-Powered Units) 35 . . . . . . . . . . .
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 .
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 or servicing battery .
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.
OM-240 438 Page 5 MOVING P ARTS can injure. Keep away from moving parts such as fans, belts and rotors. Keep all doors, panels, covers, and guards closed and securely in place. Keep hands, hair , loose clothing, and tools away from moving parts.
OM-240 438 Page 6 H. F . RADIA TION 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.
OM-240 438 Page 7 SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE A V ANT UTILISA TION fre_rom_2009 − 08 Se protéger , ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud.
OM-240 438 Page 8 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 9 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 10 L ’utilisation d’un groupe autonome à l’intérieur PEUT VOUS TUER EN QUELQUES MINUTES. Le s fumées d’un groupe autonome contient du monoxyde de carbone. C’est un poison invisi- ble et inodore. JAMAIS utiliser dans une maison ou garage, même avec les portes et fenêtres ouvertes.
OM-240 438 Page 1 1 LIRE LES INSTRUCTIONS. Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section.
OM-240 438 Page 12 LIRE LES INSTRUCTIONS. Lire et appliquer les instructions sur les étiquettes et le Mode d’emploi avant l’installation, l’utilisation ou l’entretien de l’appareil. Lire les informations de sécurité au début du manuel et dans chaque section.
OM-240 438 Page 13 LE RA YONNEMENT 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.
OM-240 438 Page 14 2-9. Informations relatives aux CEM Le courant électrique qui traverse tout conducteur génère des champs électromagnétiques (CEM) à certains endroits. Le courant de soudage crée un CEM autour du circuit et du matériel de soudage.
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 15 SECTION 3 − DEFINITIONS 3-1. Symbol Definitions Stop Engine Fast (Run, W eld/Power) Fast/Slow (Run/Idle) Slow (Id.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 16 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 www .HobartW elders.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) (T o T op Of Handle Assembly) A Protective Cage Width: 26 in.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 18 4-5. Fuel Consumption (Subaru-Powered Units) 244 036-A On a typical job using 1/8 in 7018 electrodes (125 amps, 20% duty cycle), expect about 20 hours of op- eration.
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 19 4-7. 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 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 www .HobartW elders.com OM-240 438 Page 21 ! 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 wwwHobartW elders.com OM-240 438 Page 22 5-4. Engine Prestart Checks (Subaru-Powered Units) 244 032-A / 217 015-A Full Full Gasoline Check all fluids daily . Engine must be cold and on a level surface. Unit is shipped with 10W30 engine oil.
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 23 5-5. Engine Prestart Checks (Kohler-Powered Units) 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.
A complete Parts List is available at wwwHobartW elders.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.
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 5-9. 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 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 wwwHobartW elders.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.
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 29 ELECTRODE DC* AC POSITION PENETRA TION USAGE MIN. PREP , ROUGH HIGH SP A TTER GENERAL SMOOTH, EASY , F AST LOW HYDR.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 30 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 www .HobartW elders.com OM-240 438 Page 31 7-2. Simultaneous W eld And Power W eld Current in Amperes T otal Power in W atts 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 wwwHobartW elders.com OM-240 438 Page 32 SECTION 8 − MAINTENANCE (SUBARU-POWERED UNITS) 8-1. Maintenance Label (Subaru-Powered Units).
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 33 8-2. Routine Maintenance (Subaru-Powered Units) ! Stop engine before maintaining. S ee Engine Manual and Maintenance Label for important start-up, service, and storage information.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 34 ! 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 www .HobartW elders.com OM-240 438 Page 35 8-5. Changing Engine Oil, Oil Filter , and Fuel Filter (Subaru-Powered Units) 244 032-A / Ref. 281 080-A / S-0842 ! Stop engine and let cool. 1 Oil Drain V alve 2 Oil Filter Change engine oil and filter accord- ing to engine owner’s manual.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 36 8-6. Adjusting Engine Speed (Subaru-Powered Units) 244 032-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 www .HobartW elders.com OM-240 438 Page 37 8-7. Overload Protection (Subaru-Powered Units) 244 029-A ! Stop engine. Disconnect negative ( − ) battery cable. 1 Fuse F1 (See Section 1 1-1) F1 protects the weld excitation winding from overload.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 38 SECTION 9 − MAINTENANCE − (KOHLER-POWERED UNITS) 9-1. Maintenance Label (Kohler-Powered Units).
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 39 9-2. Routine Maintenance (Kohler-Powered Units) ! Stop engine before maintaining. S ee Engine Manual and Maintenance Label for important start-up, service, and storage information.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 40 ! 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 www .HobartW elders.com OM-240 438 Page 41 9-4. Changing Engine Oil, Oil Filter , and Fuel Filter (Kohler-Powered Units) 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 wwwHobartW elders.com OM-240 438 Page 42 9-5. Adjusting Engine Speed (Kohler-Powered Units) 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 www .HobartW elders.com OM-240 438 Page 43 9-6. Overload Protection (Kohler-Powered Units) 244 029-A ! Stop engine. Disconnect negative ( − ) battery cable. 1 Fuse F1 (See Section 1 1-1) F1 protects the weld excitation winding from overload.
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 44 SECTION 10 − TROUBLESHOOTING 10-1. Welding 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 www .HobartW elders.com OM-240 438 Page 45 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 8-7 or 9-6).
A complete Parts List is available at wwwHobartW elders.com OM-240 438 Page 46 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).
A complete Parts List is available at www .HobartW elders.com OM-240 438 Page 47 Notes SOCKET/WRENCH SELECTION T ABLE (U.S. ST ANDARD) SOCKET/WRENCH SELECTION T ABLE (METRIC) Specifications Socket or Wrench Size Specifications Socket or W rench Size Bolt Diameter Decimal Equivalent Bolt Nut Bolt Diameter U.
OM-240 438 Page 48 SECTION 12 − ELECTRICAL DIAGRAMS Figure 12-1. Circuit Diagram For W elding Generator.
OM-240 438 Page 49 240 424-A.
OM-240 438 Page 50 SECTION 13 − GENERA TOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding generators.
OM-240 438 Page 51 13-3. Grounding When Supplying Building Systems ST-800 576-B 1 Equipment Grounding T erminal 2 Grounding Cable Use #10 A WG or larger insulated copper wire.
OM-240 438 Page 52 13-5. Approximate Power Requirements For Industrial Motors Industrial Motors Rating Startin g 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 53 13-7. Approximate Power Requirements For Contractor Equipment Contractor Rating Starting Watts 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 54 13-8. 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 55 13-10. 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 56 13-1 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 57 SECTION 14 − STICK WELDING (SMA W) GUIDELINES 14-1. Stick W elding Procedure stick 2008 − 05 − ST -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 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.
OM-240 438 Page 59 14-4. Positioning Electrode Holder S-0060 90 ° 90 ° 10 ° -30 ° 45 ° 45 ° 10 ° -30 ° 1 End V iew Of Work Angle 2 Side View Of Electrode Angle 1 1 2 2 Groove Welds Fillet Welds 14-5.
OM-240 438 Page 60 14-7. Conditions That Affect Weld 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 61 14-9. 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 to 3/16 in. (5 mm) thick.
OM-240 438 Page 62 14-12. 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) 14-13. T roubleshooting Porosity − small cavities or holes resulting from gas pockets in weld metal.
OM-240 438 Page 63 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 64 Notes.
OM-240 438 Page 65 Notes.
OM-240 438 Page 66 Notes.
Warranty Questions? Call 1-800-332-3281 hobart_warr 2009 − 01 Service Y o u 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 © 2009 Hobart Welding Products. 2009 − 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 echn.
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Wenn Sie aber schon Hobart Welding Products OM-240 438B besitzen, und noch keine Gelegenheit dazu hatten, die Bedienungsanleitung zu lesen, sollten Sie es aufgrund der oben beschriebenen Gründe machen. Sie erfahren dann, ob Sie die zugänglichen Funktionen richtig genutzt haben, aber auch, ob Sie keine Fehler begangen haben, die den Nutzungszeitraum von Hobart Welding Products OM-240 438B verkürzen könnten.
Jedoch ist die eine der wichtigsten Rollen, die eine Bedienungsanleitung für den Nutzer spielt, die Hilfe bei der Lösung von Problemen mit Hobart Welding Products OM-240 438B. Sie finden dort fast immer Troubleshooting, also die am häufigsten auftauchenden Störungen und Mängel bei Hobart Welding Products OM-240 438B gemeinsam mit Hinweisen bezüglich der Arten ihrer Lösung. Sogar wenn es Ihnen nicht gelingen sollte das Problem alleine zu bewältigen, die Anleitung zeigt Ihnen die weitere Vorgehensweise – den Kontakt zur Kundenberatung oder dem naheliegenden Service.
