Troubleshooting Chart - Campbell Hausfeld Welder / Generator GW4500 Operating Instructions And Parts Manual

Operating Instructions and Parts Manual
Troubleshooting Chart - Welder
Symptom Possible Cause(s)
Welder runs but 1. Inadequate current at electrode
does not weld
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
Welder gives trickle 1. Accidental contact with work piece
shocks 2. Current leakage caused by moist
clothing or work area
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
★ These diagnostic and repair procedures should be performed by an authorized service center.
Troubleshooting Chart - Welds
Symptom Possible Cause(s)
Bead is 1. Inconsistent travel speed
intermittently too 2. Output amp setting incorrect
thin or too thick
Ragged depressions 1. Travel speed too fast
at edge of weld 2. Arc length too short
3. Output amp setting too high
Weld bead does 1. Inconsistent travel speed
not penetrate base 2. Output amp setting too low
metal 3. Electrode diameter too large
Electrode sticks to 1. Arc length short
workpiece 2. Amp setting low
3. Incorrect electrode
Electrodes sputter Damp electrodes
and stick
www.chpower.com
Corrective Action
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 ★
1. Avoid contact with work piece
2. Make sure clothing and work area are dry
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
Corrective Action
1. Carefully watch and control the width of the molten weld bead
2. Adjust output amp setting or change to smaller diameter electrode
1. Watch orange molten weld puddle and control bead width
2. Practice running electrode across workpiece with welder OFF
3. Reduce output amp setting
1. Decrease and maintain constant travel speed
2. Increase output amp setting
3. Change to smaller diameter 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
Use dry electrodes and store in dry location
14