Hobart-welding-products CHAMPION ELITE OM-240 438E User Manual

Champion EliteProcessesDescription®Stick (SMAW) WeldingEngine Driven Welding GeneratorOM-240 438E2011−03

OM-240 438 Page 6WELDING WIRE can injure. Do not press gun trigger until instructed to doso. Do not point gun toward any part of the body,other peop

OM-240 438 Page 71-8. Principal Safety StandardsSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Document

OM-240 438 Page 8SECTION 2 − CONSIGNES DE SÉCURITÉ − LIRE AVANTUTILISATIONfre_rom_2010−03Pour écarter les risques de blessure pour vous−même et pour

OM-240 438 Page 9LES PIÈCES CHAUDES peuventprovoquer des brûlures. Ne pas toucher à mains nues les parties chau-des. Prévoir une période de refroidi

OM-240 438 Page 10Les CHAMPS ÉLECTROMAGNÉTIQUES (CEM)peuvent affecter les implants médicaux. Les porteurs de stimulateurs cardiaques etautres implant

OM-240 438 Page 11LES ÉTINCELLES À L’ÉCHAPPEMENTpeuvent provoquer un incendie. Empêcher les étincelles d’échappement dumoteur de provoquer un incendi

OM-240 438 Page 12un médecin familiarisé avec ce type de blessure, faute de quoila gangrène pourrait apparaître.Les PIÈCES MOBILES peuvent causerdes b

OM-240 438 Page 13Une PRESSION D’AIR RÉSIDUELLEET DES FLEXIBLES QUI FOUETTENTrisquent de provoquer des blessures. Détendre la pression pneumatique de

OM-240 438 Page 14LES CHARGES ÉLECTROSTATI-QUES peuvent endommager lescircuits imprimés. Établir la connexion avec la barrette de terreavant de manip

OM-240 438 Page 152-8. Principales normes de sécuritéSafety in Welding, Cutting, and Allied Processes, ANSI Standard Z49.1,from Global Engineering Doc

Hobart Welders manufactures a full lineof welders and welding related equipment.For information on other quality Hobart products, contact your local H

 A complete Parts List is available at wwwHobartWelders.comOM-240 438 Page 16SECTION 3 − DEFINITIONS3-1. Symbol DefinitionsStop EngineFast(Run, Weld/

 A complete Parts List is available at www.HobartWelders.comOM-240 438 Page 174-2. Dimensions, Weights, And Operating Angles244 029-A / 244 030-A / 2

 A complete Parts List is available at wwwHobartWelders.comOM-240 438 Page 184-3. Dimensions For Units With Optional Running GearDimensions804 937-BH

 A complete Parts List is available at www.HobartWelders.comOM-240 438 Page 194-5. Volt-Ampere Curves240 426-A / 240 427-AThe volt-ampere curve shows

 A complete Parts List is available at wwwHobartWelders.comOM-240 438 Page 204-6. Fuel Consumption202 094-AOn a typical job using 1/8 in 7018electrod

 A complete Parts List is available at www.HobartWelders.comOM-240 438 Page 21SECTION 5 − INSTALLATION5-1. Serial Number And Rating Label LocationThe

 A complete Parts List is available at wwwHobartWelders.comOM-240 438 Page 22! Always ground generatorframe to vehicle frame to pre-vent electric sho

 A complete Parts List is available at www.HobartWelders.comOM-240 438 Page 235-4. Engine Prestart Checks244 033-A / 217 015-ACheck all fluids daily.

 A complete Parts List is available at wwwHobartWelders.comOM-240 438 Page 245-5. Installing Exhaust Pipe803 751 / Ref. 281 080-A! Engine backfire ca

 A complete Parts List is available at www.HobartWelders.comOM-240 438 Page 25! Stop engine.! Failure to properly connectweld cables may cause exces

TABLE OF CONTENTSSECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USING 1...1-1. Symbol Usage 1...

 A complete Parts List is available at wwwHobartWelders.comOM-240 438 Page 265-8. Selecting Weld Cable Sizes*NOTICE − The Total Cable Length in Weld

 A complete Parts List is available at www.HobartWelders.comOM-240 438 Page 27Notes400 Trade Square East, Troy, Ohio 453731-800-332-9448 www.welding.

 A complete Parts List is available at wwwHobartWelders.comOM-240 438 Page 28SECTION 6 − OPERATING THE WELDING GENERATOR41366-1. Front Panel Controls

 A complete Parts List is available at www.HobartWelders.comOM-240 438 Page 296-2. Cold Weather Engine OperationRef. 240 9471 Engine Control SwitchCa

 A complete Parts List is available at wwwHobartWelders.comOM-240 438 Page 30ELECTRODEDC*ACPOSITIONPENETRATIONUSAGEMIN. PREP, ROUGHHIGH SPATTERGENERA

 A complete Parts List is available at www.HobartWelders.comOM-240 438 Page 31SECTION 7 − OPERATING AUXILIARY EQUIPMENT7-1. Standard Receptacles244 0

 A complete Parts List is available at wwwHobartWelders.comOM-240 438 Page 327-2. Simultaneous Weld And PowerWeld Current in Amperes Total Power in W

 A complete Parts List is available at www.HobartWelders.comOM-240 438 Page 33SECTION 8 − MAINTENANCE8-1. Maintenance Label

 A complete Parts List is available at wwwHobartWelders.comOM-240 438 Page 348-2. Routine Maintenance! Stop engine before maintaining. See Engine M

 A complete Parts List is available at www.HobartWelders.comOM-240 438 Page 35! Stop engine.NOTICE − Do not run engine with-out air cleaner or with d

TABLE OF CONTENTS8-6. Overload Protection 38...8-7. Servicing Optional Spark Arrestor 3

 A complete Parts List is available at wwwHobartWelders.comOM-240 438 Page 368-4. Changing Engine Oil, Oil Filter, and Fuel Filter244 033-A / S-0842!

 A complete Parts List is available at www.HobartWelders.comOM-240 438 Page 378-5. Adjusting Engine Speed244 033-A / 244 034-AAfter tuning engine, ch

 A complete Parts List is available at wwwHobartWelders.comOM-240 438 Page 388-6. Overload Protection244 029-A! Stop engine. Disconnectnegative (−) b

 A complete Parts List is available at www.HobartWelders.comOM-240 438 Page 39SECTION 9 − TROUBLESHOOTING9-1. Welding TroubleshootingTrouble RemedyLo

 A complete Parts List is available at wwwHobartWelders.comOM-240 438 Page 40Trouble RemedyNo generator power or weld output. Be sure all equipment i

 A complete Parts List is available at www.HobartWelders.comOM-240 438 Page 41Trouble RemedyBattery Discharges between uses. Clean battery, terminals

OM-240 438 Page 42SECTION 11 − ELECTRICAL DIAGRAMSFigure 11-1. Circuit Diagram For Welding Generator

OM-240 438 Page 43240 424-B

OM-240 438 Page 44SECTION 12 − GENERATOR POWER GUIDELINES The views in this section are intended to be representative of all engine-driven welding ge

OM-240 438 Page 4512-3. Grounding When Supplying Building SystemsST-800 576-B1 Equipment GroundingTerminal2 Grounding CableUse #8 AWG or larger insula

OM-240 438 Page 1SECTION 1 − SAFETY PRECAUTIONS − READ BEFORE USINGrom_2010−03Protect yourself and others from injury — read, follow, and save these i

OM-240 438 Page 4612-5. Approximate Power Requirements For Industrial MotorsIndustrial Motors Rating Starting Watts Running WattsSplit Phase 1/8 HP 80

OM-240 438 Page 4712-7. Approximate Power Requirements For Contractor EquipmentContractor Rating Starting Watts Running WattsHand Drill 1/4 in 350 350

OM-240 438 Page 4812-8. Power Required To Start MotorSingle-Phase Induction Motor Starting RequirementsMotor StartCodeG H J K L M N PKVA/HP 6.3 7.1 8

OM-240 438 Page 4912-10. Typical Connections To Supply Standby PowerTransfer SwitchEssentialLoadsFusedDisconnectSwitch(If Required) UtilityElectricalS

OM-240 438 Page 5012-11. Selecting Extension Cord (Use Shortest Cord Possible)Cord Lengths for 120 Volt LoadsIf unit does not have GFCI receptacles, u

OM-240 438 Page 51SECTION 13 − STICK WELDING (SMAW) GUIDELINES13-1. Stick Welding Procedurestick 2010−02 − 151 593! Weld current starts whenelectrode

OM-240 438 Page 5213-2. Electrode and Amperage Selection ChartRef. S-087 985-A3/321/85/323/167/321/41/165/643/321/85/323/167/321/43/321/85/323/167/321

OM-240 438 Page 5313-4. Positioning Electrode HolderS-006090° 90°10°-30°45°45°10°-30°1 End View Of Work Angle2 Side View Of Electrode Angle1122Groove

OM-240 438 Page 5413-7. Conditions That Affect Weld Bead ShapeS-0061SlowNormal Fast10° - 30°DragToo ShortNormal Too LongSpatterAngle Too SmallAngle To

OM-240 438 Page 5513-9. Groove (Butt) JointsS-00621 Tack WeldsPrevent edges of joint from draw-ing together ahead of electrode bytack welding the mate

OM-240 438 Page 2Welding produces fumes and gases. Breathing thesefumes and gases can be hazardous to your health.FUMES AND GASES can be hazardous. K

OM-240 438 Page 5613-12. Weld TestS-0057-B1 Vise2 Weld Joint3 HammerStrike weld joint in direction shown.A good weld bends over but doesnot break.2 To

OM-240 438 Page 57Lack of PenetrationGood PenetrationLack Of Penetration − shallow fusion between weld metal and base metal.Possible Causes Corrective

OM-240 438 Page 58NotesSOCKET/WRENCH SELECTION TABLE (U.S. STANDARD) SOCKET/WRENCH SELECTION TABLE(METRIC)Specifications Socket or Wrench Size Specif

Warranty Questions?Call1-800-332-32817 AM − 5 PM ESThobart_warr 2011−01ServiceYou always get the fast,reliable response youneed. Most replacementparts

ORIGINAL INSTRUCTIONS − PRINTED IN USA © 2011 Hobart Welding Products. 2011−01Hobart Welding ProductsAn Illinois Tool Works Company600 West Main Stree

OM-240 438 Page 31-3. Engine HazardsBATTERY EXPLOSION can injure. Always wear a face shield, rubber gloves, andprotective clothing when working on a

OM-240 438 Page 41-4. Hydraulic HazardsHYDRAULIC EQUIPMENT can injureor kill. Incorrect installation or operation of this unitcould result in equipm

OM-240 438 Page 5HOT METAL from air arc cutting andgouging can cause fire or explosion. Do not cut or gouge near flammables. Watch for fire; keep ex