3. engine hazards, 4. hydraulic hazards – Hobart Welding Products CHAMPION ELITE OM-240 438B User Manual

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OM-240 438 Page 3

1-3. Engine Hazards


D Always wear a face shield, rubber gloves, and

protective clothing when working on a battery.

D Stop engine before disconnecting or connect-

ing battery cables or servicing battery.

D Do not allow tools to cause sparks when working on a battery.
D Do not use welder to charge batteries or jump start vehicles.
D Observe correct polarity (+ and −) on batteries.
D Disconnect negative (−) cable first and connect it last.

FUEL can cause fire or explosion.

D Stop engine and let it cool off before checking or

adding fuel.

D Do not add fuel while smoking or if unit is near

any sparks or open flames.

D Do not overfill tank — allow room for fuel to expand.
D Do not spill fuel. If fuel is spilled, clean up before starting engine.
D Dispose of rags in a fireproof container.
D Always keep nozzle in contact with tank when fueling.

MOVING PARTS can injure.

D Keep away from moving parts such as fans,

belts, and rotors.

D Keep all doors, panels, covers, and guards

closed and securely in place.

D Stop engine before installing or connecting unit.
D Have only qualified persons remove doors, panels, covers, or

guards for maintenance and troubleshooting as necessary.

D To prevent accidental starting during servicing, disconnect

negative (−) battery cable from battery.

D Keep hands, hair, loose clothing, and tools away from moving


D Reinstall doors, panels, covers, or guards when servicing is

finished and before starting engine.

D Before working on generator, remove spark plugs or injectors to

keep engine from kicking back or starting.

D Block flywheel so that it will not turn while working on generator


EXHAUST SPARKS can cause fire.

D Do not let engine exhaust sparks cause fire.
D Use approved engine exhaust spark arrestor in

required areas — see applicable codes.

HOT PARTS can burn.

D Do not touch hot parts bare handed.
D Allow cooling period before working on equip-


D To handle hot parts, use proper tools and/or

wear heavy, insulated welding gloves and

clothing to prevent burns.


D If possible, check coolant level when engine is

cold to avoid scalding.

D Always check coolant level at overflow tank, if

present on unit, instead of radiator (unless told

otherwise in maintenance section or engine


D If the engine is warm, checking is needed, and there is no over-

flow tank, follow the next two statements.

D Wear safety glasses and gloves and put a rag over radiator cap.
D Turn cap slightly and let pressure escape slowly before

completely removing cap.

Using a generator indoors CAN KILL


D Generator exhaust contains carbon monoxide.

This is a poison you cannot see or smell.

D NEVER use inside a home or garage, EVEN IF

doors and windows are open.

D Only use OUTSIDE and far away from windows, doors, and



D Do not tip battery.
D Replace damaged battery.
D Flush eyes and skin immediately with water.

ENGINE HEAT can cause fire.

D Do not locate unit on, over, or near combustible

surfaces or flammables.

D Keep exhaust and exhaust pipes way from


1-4. Hydraulic Hazards


or kill.

D 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 standards, and na-

tional, state, and local codes.

D Do not exceed the rated output or capacity of the hydraulic pump

or any equipment in the hydraulic system. Design hydraulic sys-

tem so failure of any hydraulic component will not put people or

property at risk.

D Before working on hydraulic system, turn off and lockout/tagout

unit, release pressure, and be sure hydraulic pressure cannot be

accidentally applied.

D Do not work on hydraulic system with unit running unless you are a

qualified person and following the manufacturer’s instructions.

D Do not modify or alter hydraulic pump or manufacturer-supplied

equipment. Do not disconnect, disable, or override any safety

equipment in the hydraulic system.

D Use only components/accessories approved by the manufacturer.
D Keep away from potential pinch points or crush points created by

equipment connected to the hydraulic system.

D Do not work under or around any equipment that is supported only

by hydraulic pressure. Properly support equipment by mechanical