Campbell Hausfeld Welder / Generator GW4500 - Manual (Page 14)

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Operating Instructions and Parts Manual
Troubleshooting Chart - Welder
Symptom Possible Cause(s) Corrective Action
Welder runs but
does not weld 1. Inadequate current at electrode
2. Poor connections at welder
3. Front panel switch set incorrectly
4. Open, shorted, or incorrect wiring
5. Faulty
capacitor
6. Open or shorted field windings
7. Open
diodes
1. Check work clamp, cable and connection to work piece. Check
electrode cable and clamp
2. Check all welder external connections
3. Set front panel switch to weld
4. Referring to the wiring diagram, clean and reconnect all wiring ★
5. Replace
capacitor ★
6. Test winding resistance, replace field winding if necessary ★
7. Test diodes, replace if necessary ★
Welder gives trickle
shocks 1. Accidental contact with work piece
2. Current leakage caused by moist
clothing or work area
1. Avoid contact with work piece
2. Make sure clothing and work area are dry
Arc diffi cult to strike 1. Wrong type of electrode.
2. Electrode diameter too large
3. Work piece not properly grounded
4. Engine speed is too slow
1. Verify that electrode is for alternating current (AC)
2. Use smaller diameter electrode
3. Verify proper grounding. (No paint, varnish or corrosion)
4. Adjust
engine speed
★ These diagnostic and repair procedures should be performed by an authorized service center.
Troubleshooting Chart - Welds
Symptom Possible Cause(s) Corrective 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 depressions
at edge of weld 1. Travel speed too fast
2. Arc length too short
3. Output amp setting too high 1. Watch orange molten weld puddle and control bead width
2. Practice running electrode across workpiece with welder OFF
3. Reduce output amp setting
Weld bead does
not penetrate base
metal 1. Inconsistent travel speed
2. Output amp setting too low
3. Electrode diameter too large 1. Decrease and maintain constant travel speed
2. Increase output amp setting
3. Change to smaller diameter electrode
Electrode sticks to
workpiece 1. Arc length short
2. Amp setting low
3. Incorrect
electrode
1. Lift electrode to correct arc length as soon as arc is struck
2. Increase amp setting or change to smaller diameter electrode
3. Verify electrode is suitable for 62.5 V open circuit voltage
Electrodes sputter
and stick Damp electrodes Use dry electrodes and store in dry location