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Campbell Hausfeld GR3000 - page 1
Operating Instructions P ower P ack IN974302AV 6/13 © 2013 Campbell Hausfeld/Scott Fetzer For parts, product & service information visit www.campbellhausfeld.com GR3000 RET AIN THIS INFORMA TION FOR FUTURE REFERENCE Serial Number: Model Number: Date of Purchase: T able of Contents Description . . . . . . . . . . . . . . . . . . . . . . . . . 1 ...
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Campbell Hausfeld GR3000 - page 2
Safety Guidelines This manual contains information that is very important to know and understand. This information is pro vided for SAFETY and to PREVENT EQ UIPMENT PROBLEMS. T o help recognize this information, observe the following symbols . Danger indicates an imminently hazardous situation which, if not avoided , WILL result in death or serious ...
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Campbell Hausfeld GR3000 - page 3
◆ Keep all persons away fr om the unit during operation. ◆ NEVER allo w children in the work ar ea. ◆ Do not allo w persons wearing loose clothing or jewelry to start or operate the unit. Loose clothing or jewelry may become entangled in mo ving components, causing equipment damage and or personal injury . ◆ Keep all persons away fr om part ...
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Campbell Hausfeld GR3000 - page 4
Operating Instructions www .campbellhausfeld.com 4 ◆ N ever use an electric arc welder to thaw fro zen pipes. Flying sparks and hot metal can cause injury . As welds cool, slag can be thrown off . T ake all precautions described in this manual to reduce the possibility of injury from flying sparks and hot metal. ◆ W ear ANSI compliant face shie ...
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Campbell Hausfeld GR3000 - page 5
COMPRESSOR SAFETY Never r emo ve or attempt to adjust safety valve. Keep safety v alve free from paint and other accumulations. Nev er attempt to repair or modify a tank! W elding , drilling or any other modification will weaken the tank resulting in damage from ruptur e or explosion. Always r eplace worn or damaged tanks. ◆ T anks rust from moi ...
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Campbell Hausfeld GR3000 - page 6
Operating Instructions www .campbellhausfeld.com 6 AC or Alternating Curr ent - electric current that r everses direction periodically . Sixty cycle curr ent travels in both directions sixty times per second. Arc Length - the distance from the end of the electr ode to the point where the ar c makes contact with the work surface. Base M etal - the m ...
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Campbell Hausfeld GR3000 - page 7
LOCA TION Selecting the proper location can significantly incr ease performance, reliability and life of the unit. ◆ F or best results locate the unit in an environment that is clean and dry . Dust and dirt in the unit retain moistur e and increase wear of mo ving par ts. ◆ There ar e mounting holes in the bottom of the open frame models to per ...
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Campbell Hausfeld GR3000 - page 8
Operating Instructions www .campbellhausfeld.com 8 LOW OIL SHUTDOWN A lo w oil shutdown switch is pro vided to protect the engine. When engine oil level drops too lo w for proper engine operation, the lo w oil shutdown switch causes the engine to shut off. If oil level is lo w when attempting to start the engine, the lo w oil level shutdo wn switch ...
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Campbell Hausfeld GR3000 - page 9
INST ALLA TION FOR ST AND-BY USE Pr ecautions must be taken to prevent electrical back feeding into utility systems. This requires isolation of the electrical system. T o isolate the electrical system, perform the following procedur es: 1. T urn off the main electrical system switch prior to connecting the unit. 2. In accor dance with national and ...
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Campbell Hausfeld GR3000 - page 10
Operating Instructions www .campbellhausfeld.com 10 Welder Operation ( FRONT P ANEL SWITCH MUST BE SET TO WELDER POSITION ) WELDING LEAD ASSEMBLIES W elding leads assemblies are not included with all units. U se copper welding cables in the size specified in T able 3. 1. V erify that the surfaces of metals to be joined are free from dirt, rust, pai ...
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Campbell Hausfeld GR3000 - page 11
GR3000 www .campbellhausfeld.com 11 Release all pr essure from the system before attempting to install, service, relocate or perform any maintenance. In or der to maintain efficient operation of the compressor system, check the air filter , oil level and gasoline level before each use . The ASME safety valve should also be checked daily . Pull ring ...
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Campbell Hausfeld GR3000 - page 12
Operating Instructions www .campbellhausfeld.com 12 Maintenance (Continued) INFREQUENT USAGE If the unit is used infrequently , starting difficulty may occur . T o help prevent this , the engine should be run for approximately 30 minutes per week. STORAGE If the unit is not to be used for extended periods of time, the follo wing pre-storage procedu ...
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Campbell Hausfeld GR3000 - page 13
GR3000 www .campbellhausfeld.com 13 GENERAL This line of welding machines utilizes a process kno wn as Shielded M etal-Ar c W elding (SMA W ). This process is used to bond metals b y heating them with an electric arc created between the electr ode and the work piece. Electrodes used for shielded metal arc welding hav e two parts. The inner core is ...
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Campbell Hausfeld GR3000 - page 14
Operating Instructions Welding Guidelines (Continued) ARC WELDING BASICS F our basic techniques affect weld quality . These ar e: amperage setting, weld angle, ar c length, and travel speed. P roper use of these techniques is necessary for good weld quality . AMPERAGE SETTING The correct amper age involves the adjustment of the welding machine to t ...
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Campbell Hausfeld GR3000 - page 15
TRA VEL SPEED The travel speed is the rate at which the electr ode is moved acr oss the weld area (S ee Figur e 4). When the speed is too fast, the bead is narro w and bead ripples are pointed as sho wn. When the speed is to slo w , the weld metal piles up and the bead is high and wide. T o control travel speed, watch the width of the weld bead (no ...
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Campbell Hausfeld GR3000 - page 16
Operating Instructions www .campbellhausfeld.com 16 Lamp Off Lamp On Figure 8 - Diode T est Procedur e Welding Guidelines (Continued) TESTING WELDER / GENERA TOR DIODES The follo wing method eliminates the need to disconnect the diodes from the welder / generators wiring. 1. U se a 12 V olt battery and automotive lamp ( T ype 5001) to test the diod ...
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Campbell Hausfeld GR3000 - page 17
GR3000 www .campbellhausfeld.com 17 T roubleshooting Chart (Continued) Generator Symptom Possible Cause(s) Corr ective Action No output voltage 1. Engine speed is too slow 2. Open, shorted, or incorrect wiring 3. Faulty capacitor 4. Open or shorted field windings 5. Open diodes 6. Front panel switch set incorrectly 7. Circuit breaker tripped 1. Adj ...
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Campbell Hausfeld GR3000 - page 18
Operating Instructions www .campbellhausfeld.com 18 Welds Symptom Possible Cause(s) Corr ective Action Bead is intermittently too thin or too thick 1. Inconsistent travel speed 2. Output amp setting incorrect 1. Carefully watch and control the width of the molten weld bead 2. Adjust output amp setting or change to smaller diameter electrode Ragged ...
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Campbell Hausfeld GR3000 - page 19
GR3000 www .campbellhausfeld.com 19 Figure 9 - Wiring Diagram ...
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Campbell Hausfeld GR3000 - page 20
Operating Instructions Reminde r: Keep your dated proof of purchase for warr anty purposes! Attach it to this manual or file it for safekeeping. Limited Warranty 1. DURA TION: The manufactur er warrants that it will repair , at no charge for parts or labor , the following C ampbell Hausfeld products pro ven defective in material or workmanship , du ...
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