Campbell Hausfeld Welding System GR3000 User Manual

Operating Instructions  
Power Pack  
GR3000  
Table of Contents  
Description . . . . . . . . . . . . . . . . . . . . . . . . . 1  
Description  
Power Pack is a mobile power source that can provide solutions for jobs offsite and in  
remote powerless locations. It can be used as a generator, welder, or air compressor.  
Powered by an air-cooled four cycle engine, this machine is designed to run at  
maximum RPM. The Power Pack offers protection features such as; low-oil level shutoff  
which provides protection for the engine; and a thermostatically protected alternator.  
The welding system is designed to weld in the Stick process (SMAW). The 140 amp AC  
stick welder can weld up to 5/16 inch steel.  
The air compressor provides compressed air to power pneumatic tools and operate  
spray guns. The pump is oil lubricated; therefore a small amount of oil carryover is  
present in the compressed air stream. NOTE: Applications requiring air free of oil or  
water should have the appropriate coalescing filter installed.  
Unpacking. . . . . . . . . . . . . . . . . . . . . . . . . . 1  
Safety Guidelines . . . . . . . . . . . . . . . . . . . . 2  
Safety Symbols . . . . . . . . . . . . . . . . . . . . . . 2  
Important Safety Information . . . . . 2 - 5  
Glossary of Terms. . . . . . . . . . . . . . . . . . . . 6  
Pre-operation . . . . . . . . . . . . . . . . . . . . 7 - 8  
Generator Operation. . . . . . . . . . . . . . 8 - 9  
Welder Operation . . . . . . . . . . . . . . . . . . 10  
Compressor Operation. . . . . . . . . . . . . . 10  
Maintenance. . . . . . . . . . . . . . . . . . . 11 - 12  
Storage . . . . . . . . . . . . . . . . . . . . . . . . . 12  
Unpacking  
Welding Guidelines . . . . . . . . . . . . . 13 - 16  
After unpacking the unit, inspect carefully for any damage that may have occurred  
during transit. Make sure to tighten fittings, bolts, etc., before putting unit into service.  
Report any missing items by calling 1-800-746-5641.  
Troubleshooting Chart . . . . . . . . . . 16 - 18  
General. . . . . . . . . . . . . . . . . . . . . . . . . 16  
Generator. . . . . . . . . . . . . . . . . . . . . . . 17  
Welder. . . . . . . . . . . . . . . . . . . . . . . . . . 17  
Welds . . . . . . . . . . . . . . . . . . . . . . . . . . 18  
Do not operate unit if damaged during shipping, handling or use.  
Damage could result in bursting and cause injury or property damage.  
Wiring Diagram . . . . . . . . . . . . . . . . . . . . 19  
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . 20  
Breathable Air Warning  
This product is neither designed, nor approved by the National Institute for  
Occupational Safety and Health (NIOSH), for use as a supplied air system.  
RegisteR youR pRoduct online now!  
Retain this infoRmation foR futuRe RefeRence  
serial number:  
model number:  
Date of Purchase:  
© 2013 Campbell Hausfeld/Scott Fetzer  
For parts, product & service information  
IN974302AV 6/13  
 
Keep all persons away from the unit during operation.  
NEVER allow children in the work area.  
GeneRatoR safety  
Be sure all powered devices are shut off prior to connecting  
them to the unit.  
Do not allow persons wearing loose clothing or jewelry  
to start or operate the unit. Loose clothing or jewelry  
may become entangled in moving components, causing  
equipment damage and or personal injury.  
Be sure that all tools and appliances are in good repair and  
are properly grounded. Use devices that have three prong  
power cords. If an extension cord is used, be sure that it has  
three prongs for proper grounding.  
Keep all persons away from parts that move or become hot  
This unit may be used for emergency stand-by service.  
In such cases, a manual transfer switch must be installed  
between the electric utilities meter and the electrical  
distribution box. This switch should be installed by a licensed  
electrician.  
during operation.  
Use only unleaded fuel. Do not refill the fuel tank while the  
engine is running. Use precautions to prevent fuel spillage  
during refills. Be sure the fuel tank cap is securely in place  
before starting the engine. Clean up any spilled fuel before  
starting the engine. Allow engine to cool for at least two  
minutes before refueling. Do not add fuel while smoking or if  
unit is near any sparks or open flames. Do not overfill tank -  
allow room for fuel to expand. Always keep nozzle in contact  
with tank during fueling. Never fuel the unit indoors. Failure  
to follow these instructions could result in death or serious  
injury.  
WelDeR safety  
Always keep a fire extinguisher  
accessible while performing arc  
welding operations.  
Improper use of electric arc welders  
can cause electric shock, injury, and  
death! Take all precautions described in this manual to  
reduce the possibility of electric shock.  
To reduce fire hazard, keep engine/motor exterior free of oil,  
solvent, or excessive grease.  
Never mix oil with gasoline for this engine.  
This is a four cycle engine designed to run on  
pure gasoline. Oil is used for engine lubrication purposes only.  
Always wear dry protective clothing and welding gloves, and  
insulated footwear.  
Be sure that the work piece is properly supported and  
grounded prior to beginning any electric arc welding  
operation.  
All installation, maintenance, repair and operation of this  
equipment should be performed by qualified persons only in  
accordance with national, state, and local codes.  
Coiled welding cable should be spread out before use to  
Verify that all components of the unit are clean and in good  
condition prior to operation. Be sure that the insulation on all  
cables, electrode holders, and power cords is not damaged.  
Inspect compressed air system, fuel system and electrical  
components for signs of damage, deterioration, weakness  
or leakage. Always repair or replace damaged components  
before operating the unit. Always keep panels, shields, etc. in  
place when operating.  
avoid overheating and damage to insulation.  
Never immerse the electrode or electrode holder  
in water. If the unit becomes wet for any reason,  
be absolutely certain that it is completely clean and dry prior to  
attempting use!  
Always attach the work lead first.  
Verify that the work piece is securely grounded.  
Always shut off the unit when not in use and remove the  
Check all fasteners at frequent intervals for proper tightness.  
electrode from the holder.  
Always operate the unit in a clean, dry, well ventilated area.  
Do not operate the unit in humid, wet, rainy, or poorly  
ventilated areas.  
Never allow any part of the body to touch the electrode and  
ground or grounded work piece at the same time.  
Always shut the equipment off prior to moving the unit.  
Do not use any part of the unit as a work surface.  
Do not tamper with governor setting on engine.  
Overspeeding the unit severely shortens engine life and may  
also be very hazardous.  
Shut off the engine and disconnect the spark  
plug wire before performing any service or  
maintenance to the unit.  
Operating Instructions  
Important Safety Information (Continued)  
Arc welding closed cylinders or  
containers such as tanks or drums  
can cause explosion if not properly vented! Verify that  
any cylinder or container to be welded has an adequate  
ventilation hole, so that expanding gases can be released.  
Never use an electric arc welder to thaw frozen pipes.  
Flying sparks and hot metal can  
cause injury.As welds cool, slag  
can be thrown off.Take all precautions described in this  
manual to reduce the possibility of injury from flying  
sparks and hot metal.  
Do not breathe fumes that are  
produced by the arc welding  
operation.These fumes are dangerous. If the welding area  
cannot be adequately ventilated, be sure to use an air-  
supplied respirator.  
Wear ANSI compliant face shield or safety glasses with side  
shield protection when chipping or grinding metal parts.  
Wear ear plugs when welding overhead to prevent spatter or  
Keep your head out of the welding fumes.  
slag from falling into ears.  
Electric arc welding operations  
produce intense light and heat  
and ultraviolet (UV) rays.This intense light and UV rays  
can cause injury to eyes and skin.Take all precautions  
described in this manual to reduce the possibility of injury  
to eyes and skin.  
Do not perform electric arc welding operations on metals  
that are galvanized or cadmium plated, or contain zinc,  
mercury, or beryllium without completing the following  
precautions:  
a. Remove the coating from the base metal.  
b. Make sure that the welding area is well ventilated.  
c. Use an air-supplied respirator.  
All persons operating this equipment or in the area while  
equipment is in use must wear protective welding gear  
including: welding helmet or shield with at least shade 10,  
flame resistant clothing, leather welding gloves, and full foot  
protection.  
Extremely toxic fumes are created when these metals are heated.  
The electromagnetic field that is  
generated during arc welding may  
interfere with the operation of various electrical and  
electronic devices such as cardiac pacemakers. Persons  
using such devices should consult with their physician  
prior to performing any electric arc welding operations.  
Never look at arc welding operations without  
eye protection as described above. Never use a  
shade filter lens that is cracked, broken, or rated below number 10.  
Warn others in the area not to look at the arc.  
Electric arc welding operations  
cause sparks and heat metal to  
temperatures that can cause severe burns! Use protective  
gloves and clothing when performing any metal working  
operation.Take all precautions described in this manual to  
reduce the possibility of skin and clothing burns.  
Route the electrode and work cables together and secure with  
tape when possible.  
Never wrap arc welder cables around the body.  
Always position the electrode and work leads so that they are  
on the same side of the body.  
Make sure that all persons in the welding area are protected  
from heat, sparks, and ultraviolet rays. Use additional face  
shields and flame resistant barriers as needed.  
Exposure to electromagnetic fields during welding may have  
other health effects which are not known.  
Always be sure that the welding area is secure  
and free of hazards (sparks, flames, glowing  
Never touch work pieces until completely cooled.  
metal or slag) prior to leaving. Be sure that the equipment is turned off  
and electrode is removed. Be sure that cables are loosely coiled and out  
of the way. Be sure that all metal and slag has cooled.  
Heat and sparks produced during  
electric arc welding and other metal  
working operations can ignite flammable and explosive  
materials! Take all precautions described in this manual to  
reduce the possibility of flames and explosions.  
Remove fire hazards from the welding area. If this is not  
possible, cover them to prevent the welding sparks from  
starting a fire. Welding sparks and hot materials from  
welding can easily go through small cracks and openings to  
adjacent areas. Avoid welding near hydraulic lines. Have a fire  
extinguisher readily available.  
Take precautions to be sure that flying sparks and heat do not  
cause flames in hidden areas, cracks, behind bulkheads, etc.  
Fire and explosion hazard!  
Do not weld on containers or pipes  
that contained flammable/combustible materials or gases.  
4
 
GR3000  
Important Safety Information (Continued)  
comPRessoR safety  
safety stanDaRDs anD suGGesteD ReaDinG  
Never remove or attempt to adjust safety valve.  
Keep safety valve free from paint and other  
ANSI Standard Z49.1 from American Welding Society, 550 N.W.  
LeJune Rd. Miami, FL 33126  
accumulations.  
Safety and Health Standards  
Never attempt to repair or modify  
a tank! Welding, drilling or any  
other modification will weaken the tank resulting in  
damage from rupture or explosion. Always replace worn  
or damaged tanks.  
OSHA 29 CFR 1910, from Superintendent of Documents, U.S.  
Government Printing Office, Washington, D.C. 20402  
National Electrical Code  
NFPA Standard 70, from National Fire Protection Association,  
Batterymarch Park, Quincy, MA 02269  
Tanks rust from moisture build-up, which weakens the tank.  
Make sure to drain tank regularly and inspect periodically for  
unsafe conditions such as rust formation and corrosion.  
Safe Handling of Compressed Gases in Cylinders  
CGA Pamphlet P-1, from Compressed Gas Association, 1235  
Jefferson Davis Highway, Suite 501, Arlington, VA 22202  
Drain liquid from tank daily.  
Fast moving air will stir up dust and debris which may be  
harmful. Release air slowly when draining moisture or  
depressurizing the compressor system.  
Code for Safety in Welding and Cutting  
CSA Standard W117.2, from Canadian Standards Association,  
Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario,  
Canada M9W 1R3  
sPRayinG PRecautions  
Cutting And Welding Processes  
Do not spray flammable materials  
in vicinity of open flame or near  
ignition sources including the compressor unit.  
NFPA Standard 51B, from National Fire Protection Association,  
1 Battery March Park, P.O. Box 9146, Quincy, MA 02269-9959.  
Do not smoke when spraying paint, insecticides,  
Practice For Occupational And Educational Eye And Face  
Protection  
or other flammable substances.  
Use a face mask/respirator when spraying and  
spray in a well ventilated area to prevent health  
and fire hazards.  
ANSI Standard Z87.1, from American National Standards  
Institute, 11 West 42nd Street, New York, NY 10036  
Arc Welding and Your Health: A Handbook of Health  
Information for Welding  
From The American Industrial Hygiene Association, 2700  
Prosperity Avenue, Suite 250, Fairfax, VA 22031-4319.  
Do not direct paint or other sprayed material at the  
compressor. Locate compressor as far away from the spraying  
area as possible to minimize overspray accumulation on the  
compressor.  
Cutting and Welding Processes  
NFPA Standard 51B from National Fire Protection Association,  
1 Battery March Park, P.O. Box 9146, Quincy, MA 02269-9959.  
When spraying or cleaning with solvents or toxic  
chemicals, follow the instructions provided by the chemical  
manufacturer.  
OSHA Hazard Communication Standard 29 CFR 1910.1200  
OSHA General Industry Standard 29 CFR 1910 Subpart Q from  
the Occupational Safety and Health Administration,  
Applications Manual for the Revised NIOSH Lifting Equation  
From The National Institute for Occupational Safety and Health  
(NIOSH), 1600 Clifton Road, Atlanta, GA 30333  
Refer to the Material Safety Data Sheets (MSDS) and the  
manufacturers’ instructions for metals, electrodes, coatings and  
cleaners.  
The DANGER, WARNING, CAUTION, and NOTICE  
notifications and instructions in this manual cannot  
cover all possible conditions and situations that  
may occur. It must be understood by the operator  
that caution is a factor which cannot be built into  
this product, but must be supplied by the operator.  
save these instRuctions  
Do not DiscaRD  
5
 
Operating Instructions  
Glossary of Terms  
AC or Alternating Current - electric current that reverses  
direction periodically. Sixty cycle current travels in both  
directions sixty times per second.  
Open Circuit Voltage (OCV) - the voltage between the  
electrode and the work clamp of the welding machine when  
no current is flowing (not welding). The OCV determines how  
quickly the arc is struck.  
Arc Length - the distance from the end of the electrode to the  
point where the arc makes contact with the work surface.  
Overlap - occurs when the amperage is set too low. In this  
instance, the molten metal falls from the electrode without  
actually fusing into the base metal.  
Base Metal - the material to be welded.  
Butt Joint - a joint between two members aligned  
Porosity - gas pockets, or cavities, formed during weld  
approximately in the same plane.  
solidification. They weaken the weld.  
Crater - a pool, or pocket, that is formed as the arc comes in  
Penetration - the depth into the work piece that has been heat  
effected by the arc during the welding process. A good weld  
achieves 100% penetration meaning that the entire thickness  
of the work piece has been heated and resolidified. The heat  
effected area should be easily seen on the opposite side of the  
weld.  
contact with the base metal.  
DC or Direct Current - electric current which flows only in one  
direction. The polarity (+ or -) determines which direction the  
current is flowing.  
DC Reverse Polarity - occurs when the electrode holder is  
connected to the positive pole of the welding machine. Reverse  
Polarity directs more heat into melting the electrode rather than  
the work piece. It is used on thinner material.  
Shielded Metal Arc Welding (SMAW) - also called Stick, is a  
welding process that uses a consumable electrode to support  
the arc. Shielding is achieved by the melting of the flux coating  
on the electrode.  
DC Straight Polarity - occurs when the electrode holder is  
connected to the negative pole of the welding machine. With  
straight polarity more heat is directed to the work piece for  
better penetration on thicker material.  
Slag - a layer of flux soot that protects the weld from oxides and  
other contaminants while the weld is solidifying (cooling). Slag  
should be removed after weld has cooled.  
Electrode - a coated metal wire having approximately the same  
composition as the material being welded.  
Spatter - metal particles thrown from the weld which cool and  
harden on the work surface. Spatter can be minimized by using  
a spatter resistant spray on the work piece before welding.  
Fillet Weld - approximately a triangle in cross-section, joining  
two surfaces at right angles to each other in a lap, T or corner  
joint.  
Tack Weld - weld made to hold parts in proper alignment until  
final welds are made.  
Flux - a coating, when heated, that produces a shielding gas  
around the welding area. This gas protects the parent and filler  
metals from impurities in the air.  
Travel Angle - the angle of the electrode in the line of welding.  
It varies from 5º to 45º depending on welding conditions.  
T Joint - made by placing the edge of one piece of metal on the  
surface of the other piece at approximately a 90º angle.  
Flux Cored Arc Welding (FCAW) - also called Gasless, is a  
welding process used with a wire-feed welding machine. The  
weld wire is tubular with flux material contained inside for  
shielding.  
Undercut - a condition that results when welding amperage  
is too high. The excessive amperage leaves a groove in the base  
metal along both sides of the bead which reduces the strength  
of the weld.  
Gas Metal Arc Welding (GMAW) - also called MIG, is a welding  
process used with a wire feed welding machine. The wire is solid  
and an inert gas is used for shielding.  
Weld Pool or Puddle - a volume of molten metal in a weld  
prior to its solidification as weld metal.  
Gas Tungsten Arc Welding (GTAW) - also called TIG, is a  
welding process used with welding equipment with a high  
frequency generator. The arc is created between a non-  
consumable tungsten electrode and the work piece. Filler metal  
may or may not be used.  
Weld Bead - a narrow layer or layers of metal deposited on the  
base metal as the electrode melts. Weld bead width is typically  
twice the diameter of the electrode.  
Work Angle - the angle of the electrode from horizontal,  
measured at right angles to the line of welding.  
Lap Joint - a joint between two overlapping members in  
parallel planes.  
6
 
GR3000  
Pre-Operation  
or procedures, obtain assistance from a qualified (licensed or  
location  
certified) electrical technician.  
Selecting the proper location can significantly increase  
performance, reliability and life of the unit.  
a. An underground water pipe at least ten feet in length  
b. A non-corrosive underground pipe at least eight feet in  
For best results locate the unit in an environment that is  
clean and dry. Dust and dirt in the unit retain moisture and  
increase wear of moving parts.  
length and 3/4 inch diameter  
c. A steel or iron underground rod at least eight feet in  
length and 5/8 inch diameter  
There are mounting holes in the bottom of the open frame  
models to permanently mount the unit if desired. The bolt  
pattern is 20 inch x 26 inch and will accept 1/2 inch bolts.  
The wheels (if present) must be removed.  
d. A non-ferrous rod at least eight feet in length, 1/2 inch in  
diameter, and approved for grounding purposes  
Any rod or pipe used for grounding must be driven to eight feet  
deep or buried in the deepest possible trench.  
Store electrodes in a clean, dry location with low humidity to  
preserve the flux coating.  
staRtinG  
lubRication  
1. Remove all electrical loads from the unit.  
2. Set compressor switch to OFF position.  
CHECK ENGINE AND PUMP OIL LEVELS  
BEFORE OPERATING! Follow lubrication  
instructions before operating compressor.  
3. Move fuel shut-off lever as far as possible to the right to  
enable fuel flow.  
1. Oil is NOT mixed with the gasoline, however adequate  
oil supply is necessary for proper engine lubrication.  
Refer to the Engine Manual for SAE, API and fill quantity  
specifications.  
4. Set the engine switch to the RUN position.  
5. For a cool engine, pull the choke knob out.  
6. Push and hold the START switch until the engine starts,  
then release.  
2. Remove pump breather and fill pump with 8.5 oz. of oil. Use  
full synthetic motor oil like Mobil 1® 10W-30. Do not use  
regular automotive oil such as 10W-30. Additives in regular  
oil can cause valve deposits and reduce pump life. For  
pumps with an oil sight glass, oil level can be monitored and  
maintained as shown in Figure 1.  
7. After each start up, allow the engine to run for 2 to 3  
minutes with no load.  
8. As the engine warms up and stabilizes, adjust the choke  
knob in fully.  
Engine speed is preset to provide proper output  
voltage. Never attempt to modify or adjust  
engine speed or output voltage.  
Full  
enGine bReak-in  
After initial start-up, the engine should be broken in according  
to the manufacturers instructions. Refer to the engine manual  
for the proper break-in procedure.  
Add Oil  
figure 1  
comPRessoR bReak-in  
GRounDinG  
Open the drain valves in the end of the two tanks. Turn the  
compressor switch to ON and allow the pump to run without a  
load for 30 minutes. After 30 minutes, close the drain petcocks  
and pressure will begin to build in the tanks.  
1. Use the ground terminal and wing nut on the frame to  
connect the unit to a suitable ground source. Securely fasten  
the end terminal of the ground wire to the ground terminal  
on the frame. Tighten the washer and wing nut on top of the  
ground wire end terminal.  
shut-off  
1. Shut off and remove all electrical load devices from the unit  
2. Set compressor switch to OFF position.  
2. The ground wire should be made of #8 gauge wire. Do  
not use wire with a higher gauge number. Higher gauge  
numbers indicate thinner wire, which may not provide an  
adequate ground path.  
3. Allow the engine to run for  
2-3 minutes with no electrical loads.  
4. Set the engine switch to the OFF position.  
5. Verify that the unit has completely stopped.  
6. Close the fuel supply valve.  
3. The other end of the ground wire must be securely fastened  
to an approved ground source.  
The following are ground sources approved by the National  
Electric Code. Other ground sources may be acceptable.  
Refer to the National Electric Code and local regulations for  
further ground source information. If not sure of regulations  
7. Allow the unit to cool before installing any covers or storing  
unit.  
7
 
Operating Instructions  
Pre-Operation (Continued)  
NOTE: It is important to keep the unit on a level surface. The oil  
level shutdown switch can prevent the engine from starting even  
if oil level is sufficient, when the unit is placed on an uneven  
surface.  
loW oil shutDoWn  
A low oil shutdown switch is provided to protect the engine.  
When engine oil level drops too low for proper engine operation,  
the low oil shutdown switch causes the engine to shut off. If oil  
level is low when attempting to start the engine, the low oil level  
shutdown switch prevents the engine from starting. If engine  
does not start, check oil level.  
Generator Operation  
(FRONT PANEL SWITCHES MUST BE SET TO GENERATOR AND  
120V/240V POSITIONS)  
Never exceed the posted maximum wattage for the unit or any  
individual receptacle. Refer to owners manuals and product tags  
to determine the wattage of all electrical load devices.  
1. All load devices and extension cords should use three prong  
terminals. Refer to Table 2 for extension cord and cable size  
requirements.  
If actual watt ratings are not available, the Power Usage Chart,  
see Table 1, may be used as a general guideline.  
2. Allow the engine to run for 2-3 minutes before applying any  
electrical loads.  
Remember that devices which generate heat during operation  
such as heaters, incandescent light bulbs, motors and hair  
dryers have a higher power draw than devices which generate  
little heat during operation such as florescent bulbs, radios, and  
clocks.  
3. The 120 volt duplex receptacles are rated for 20 amps and  
may be used in any combination of 120 volt loads and also  
with 240 volt loads through the 240 volt receptacles.  
Long power cords and extension cords also draw additional  
power. Keep cords at minimum possible length.  
These duplex receptacles are of the Ground Fault Circuit  
Interupter (GFCI) type. Ground Fault Circuit Interrupters  
can significantly reduce the possibility of injury if an  
electrical short occurs. The engine must be running and the  
front panel switches set to supply power to the receptacles  
before the GFCIs can be reset.  
Refer to Table 2 for maximum limits for lengths of extension  
cords.  
8. Circuit protection is provided by circuit breakers. The main  
circuit breaker is a rocker type rated for 30 amps. This  
is the maximum total current draw for all receptacles in  
combination. A 20 amp circuit breaker supplies each of the  
two duplex receptacles. The circuit breaker opens when  
the load exceeds its maximum capacity or a short circuit  
occurs. If the circuit breaker opens, perform the following  
procedures to correct the problem:  
A Ground Fault Circuit Interrupter may not be  
effective if the unit is not grounded! Refer to the  
section entitled Grounding for proper steps to ground the unit.  
The 120/240 volt twist lock receptacle is rated for 30 amps  
and may be used in any combination of 120 volt and 240  
volt loads.  
4. Individual receptacles should not be loaded beyond the  
amperage rating.  
a. Shut off and disconnect all electrical loads.  
b. Attempt to determine the cause of the electrical  
5. Total combined load through any combination of  
receptacles must not exceed the rated load limits of the unit.  
Refer to the identification plate on the unit for amp and  
wattage specifications.  
problem - overloading or short circuit.  
c. Do not use any devices that have short circuits.  
Avoid overloading the unit.  
d. Press the circuit breaker pushbutton or rocker to reset  
6. Always shut off and remove loads before starting or shutting  
off the engine.  
the circuit breaker.  
Repeated cycling of the circuit breaker indicates  
a problem and may cause damage to the unit or  
load devices. Do not operate the unit if repeated cycling of the circuit  
breaker occurs.  
7. When plugging multiple electrical load devices into the  
receptacles, be sure to connect and activate the highest  
power draw item first. Allow the engine to stabilize, then  
connect and activate the next highest power draw device.  
The smallest power draw device should be connected to the  
receptacle and activated last.  
NOTE: Power draw can be calculated by multiplying volts and  
amps. The resulting number is wattage.  
8
 
GR3000  
Generator Operation (Continued)  
Always shut off main power prior to temporary  
connection of the unit to a building electrical  
installation foR stanD-by use  
Precautions must be taken to prevent electrical back feeding into  
utility systems. This requires isolation of the electrical system. To  
isolate the electrical system, perform the following procedures:  
system.  
Installation of the unit as a backup electrical  
source must be performed by a qualified  
(licensed or certified) electrical technician.  
1. Turn off the main electrical system switch prior to  
connecting the unit.  
2. In accordance with national and local standards, a double  
throw transfer switch must be installed in the system.  
table 1 - estimateD PoWeR usaGe (Watts)  
loaD Device  
Watts  
loaD Device  
Watts  
loaD Device  
Watts  
loaD Device  
Watts  
Bench grinder  
(8 in)  
1400-2500  
Electric fry pan  
1500  
Radio  
50-200  
Window air  
conditioner  
1500-2200  
Coffee maker  
400-700  
440-600  
Fan  
40-200  
Refrigerator or  
freezer  
130-1200  
Microwave  
oven  
1000-1500  
Electric drill  
(3/8 inch,  
4 amps)  
Circular saw  
(Heavy duty  
7-1/4 inch)  
1400-2300  
Sump pump  
Television  
Light bulb  
800-2200  
200-500  
Water pump  
Water heater  
Space heater  
1000-3000  
1000-5000  
600-4800  
Electric drill  
(1/2 inch,  
5.4 amps)  
600-900  
Table saw  
(10 inch)  
1800-4500  
AS RATED  
table 2 - extension coRDs  
Maximum Recommended Lengths (in feet)  
Amps  
2.5  
5
Watts 120 V  
300  
Watts 240 V  
600  
#8 Wire  
#10 Wire  
1000  
500  
#12 Wire  
600  
300  
200  
150  
100  
75  
#14 Wire  
375  
200  
125  
100  
65  
#16 Wire  
250  
600  
1200  
125  
7.5  
10  
900  
1800  
350  
100  
1200  
1800  
2400  
3000  
3600  
4800  
2400  
250  
50  
15  
3600  
150  
20  
4800  
175  
150  
125  
90  
125  
50  
25  
6000  
100  
60  
30  
7200  
65  
40  
9600  
table 3 - WelDinG cables  
Total Cable Length *  
0 - 20 feet (0 - 6 m)  
20 - 40 feet (6 - 12 m)  
40 - 60 feet (12 - 18 m)  
Maximum Welding Current  
Recommended Sizes of Copper Welding Cables  
6 AWG (16 mm2)  
100 A  
150 A  
200 A  
250 A  
6 AWG (16 mm2)  
6 AWG (16 mm2)  
6 AWG (16 mm2)  
6 AWG (16 mm2)  
4 AWG (25 mm2)  
2 AWG (35 mm2)  
2 AWG (35 mm2)  
1 AWG (50 mm2)  
4 AWG (25 mm2)  
4 AWG (25 mm2)  
2 AWG (35 mm2)  
* Total cable length is the sum of the ground and electrode cable lengths.  
9
 
Operating Instructions  
Welder Operation  
(FRONT PANEL SWITCH MUST BE SET TO WELDER POSITION)  
4. Set the amperage adjustment knob to the proper  
amperage for the electrode diameter. Refer to the electrode  
manufacturer for proper current settings.  
The electrode holder and rod are electrically  
“live” (current potential) when the engine is  
running.  
WelDinG leaD assemblies  
Welding leads assemblies are not included with all units. Use  
copper welding cables in the size specified in Table 3.  
1. Verify that the surfaces of metals to be joined are free from  
dirt, rust, paint, oil, scale or other contaminants. These  
contaminants make welding difficult and cause poor welds.  
All persons operating this equipment or in the  
area while equipment is in use must wear  
protective welding gear including: eye protection with proper shade  
(minimum shade 10), flame resistant clothing, leather welding gloves,  
and full foot protection.  
5. Position the electrode to begin weld, lower the welding  
helmet or position the hand shield, and strike an arc. Adjust  
weld amperage as needed.  
6. When finished welding, turn engine off and store unit  
properly.  
Duty cycle /theRmostatic PRotection  
If heating, welding, or cutting materials that are  
galvanized, zinc plated, lead, or cadmium plated  
refer to the General Safety Information Section for instructions.Toxic  
fumes may be created when these materials are heated.  
Welder duty cycle is the percentage of actual weld time that can  
occur in a ten minute interval. For example, at a 10% duty cycle,  
actual welding can occur for one minute, then the welder must  
cool for nine minutes.  
2. Connect the work clamp to the work piece. Make sure  
the contact is on bare metal and not obstructed by paint,  
varnish, corrosion, or non-metallic materials.  
Internal components of the alternator are protected from  
overheating with an automatic thermal switch.  
3. Insert the exposed part of the electrode (the end with no  
flux) into the jaws of the electrode holder.  
Compressor Operation  
Before starting the compressor, thoroughly read  
all component instructions manuals, especially  
the engine manual.  
Drain liquid from tank daily.  
8. All lubricated compressor pumps discharge some  
condensed water and oil with the compressed air. Install  
appropriate water/oil removal equipment and controls as  
necessary for the intended application.  
Failure to install appropriate water/oil removal  
equipment may result in damage to machinery  
or workpiece.  
1. Set compressor switch to ON. The compressor clutch will  
engage and the pressure switch will disengage the clutch  
when the tank pressure reaches the preset maximum  
pressure. As air is discharged from the tanks and the tank  
pressure falls to the preset minimum pressure, the pressure  
switch will engage the clutch again.  
Do not attach air tools to open end of the hose  
until startup is complete and the unit checks  
okay.  
2. Adjust the regulator knob to vary the outlet pressure  
according to the requirements of the tool(s) being used.  
3. Connect air hose(s) to outlet connector(s) and connect  
tool(s) to hose(s).  
MOiSTURE in COMPRESSED AiR  
4. An ASME safety valve in the manifold will automatically  
release air if the tank pressure exceeds the preset maximum.  
Moisture in compressed air will form into droplets as it  
comes from an air compressor pump. When humidity is high  
or when a compressor is in continuous use for an extended  
period of time, this moisture will collect in the tank. When  
using a paint spray or sandblast gun, this water will be carried  
from the tank through the hose, and out of the gun as droplets  
mixed with the spray material.  
5. The discharge tube carries compressed air from the pump  
to the check valve. This tube becomes very hot during use.  
To avoid the risk of severe burns, never touch the discharge  
tube.  
6. The check valve allows air to enter the tanks, but prevent air  
in the tanks from flowing back into the compressor pump.  
IMPORTANT: This condensation will cause water spots in a  
paint job, especially when spraying other than water based  
paints. If sandblasting, it will cause the sand to cake and clog  
the gun, rendering it ineffective.  
7. There is a drain valve in the end of each tank. They have  
weighted tubes to draw air/liquid from the bottom of the  
tanks. Use these valves to drain moisture from the tanks  
daily to reduce the risk of corrosion. Reduce tanks pressure  
below 10 PSI, then drain the moisture from the tanks daily  
to avoid tank corrosion.  
A filter or air dryer in the air line, located as near to the gun as  
possible, will help eliminate moisture.  
10  
 
GR3000  
Maintenance  
Release all pressure from the system  
before attempting to install, service,  
relocate or perform any maintenance.  
5. Adjust engine pulley so that the belt runs parallel to  
the straight edge. The engine pulley is attached to the  
crankshaft with two setscrews.  
In order to maintain efficient operation of the  
6. Tighten four fasteners holding the pump to the baseplate.  
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 on safety valve and allow the  
ring to snap back to normal position. This valve automatically  
releases air if the tank pressure exceeds the preset maximum.  
If air leaks after the ring has been released, or the valve is stuck  
and cannot be actuated by the ring, the ASME safety valve must  
be replaced.  
7. Recheck tension and alignment. If correct, reinstall belt  
guards.  
alteRnatoR DRive belt  
The alternator uses a synchronous drive belt transmitting a  
significant amount of power. Belt tension is critical to belt life.  
New synchronous belts will stretch after installation and use.  
When properly adjusted, the new belt deflects 1/10 inch with  
4.5 to 4.9 pounds of force applied midway between the engine  
pulley and the alternator pulley. For reinstalling a used belt, the  
correct force to apply is 3.3 to 3.7 pounds for the same 1/10 inch  
deflection.  
Do not attempt to tamper with the ASME  
safety valve.  
With engine OFF, clean debris from engine, flywheel, tank, air  
lines and pump cooling fins.  
To adjust alternator belt tension:  
tank  
1. Remove belt guard.  
Never attempt to repair or modify a  
tank! Welding, drilling or any other  
2. Loosen 2 pivot bolts and clamp bolt in alternator base plate.  
modification will weaken the tank resulting in damage  
from rupture or explosion. Always replace worn, cracked or  
damaged tanks.  
3. Adjust tension nut in alternator base plate to obtain the  
proper tension. The belt must be properly aligned when the  
adjustment is made.  
Drain liquid from tank daily.  
4. To align belt, lay a straight edge against the face of the  
alternator pulley, touching the rim at two places. The  
straight edge should be parallel with the belt.  
The tank should be carefully inspected at a minimum of once  
a year. Look for cracks forming near the welds. If a crack is  
detected, remove pressure from tank immediately and replace.  
5. Adjust alternator or engine pulley so that the belt runs  
parallel to the straight edge.  
PumP DRive belt  
6. The synchronous pulleys are attached to the shafts using  
tapered bushings. The two set-screws must be removed and  
one reinserted into the hole with threads on the inner half.  
Tighten this screw to press the pulley and bushing apart.  
Belt stretch is a result of normal use. When properly adjusted,  
the belt deflects about 1/2 inch with five pounds of force applied  
midway between the engine pulley and pump pulley.  
To adjust pump belt tension:  
1. Remove belt guards.  
7. Once the bushing is moved to the correct position, move the  
two set-screws back to their original locations in the holes  
with threads on the outer half and tighten to 175 in-lbs.  
2. Loosen the four fasteners holding the pump to the  
baseplate.  
8. Tighten 2 pivot bolts and clamp bolt in alternator base  
plate.  
3. Shift the pump in the proper direction. The belt must be  
properly aligned when adjustment is made.  
9. Recheck tension and alignment. If correct, reinstall belt  
guard.  
4. To align belt, lay a straight edge against the face of the pump  
pulley, touching the rim at two places.  
maintenance scheDule  
OpeRATiOn  
DAiLy  
WeekLy  
MOnThLy  
3 MOnThS  
Check Oil Level  
Drain Tank  
l
l
Check Air Filter  
Check Safety Valve  
Check Belt Tightness  
Change Oil  
l
l
l
l
11  
 
Operating Instructions  
Maintenance (Continued)  
WelD cables  
infRequent usaGe  
1. Check condition of weld cables and immediately repair or  
replace any cables with damaged insulation.  
If the unit is used infrequently, starting difficulty may occur. To  
help prevent this, the engine should be run for approximately 30  
minutes per week.  
2. Check condition of electrode holder insulating pieces and  
immediately replace cracked or missing parts.  
stoRaGe  
eveRy 3 months  
If the unit is not to be used for extended periods of time, the  
following pre-storage procedures should be performed:  
Replace any unreadable labels on the welder. Use compressed  
air to blow all dust and lint from the ventilation openings.  
1. Make sure engine oil is filled to the proper level.  
2. Drain moisture from air tanks.  
3. Drain all fuel from the tank, lines, carburetor and fuel valve.  
4. Remove the spark plug, and pour approximately one  
teaspoon of oil into the spark plug hole.  
5. Pull the starter cord several times to spread the oil  
throughout the cylinder.  
6. Slowly pull the starter cord, until resistance is felt.  
This indicates that the piston is moving upward on the  
compression cycle, and the intake and exhaust valves are  
closed. (The piston pushes a small amount of air from the  
spark plug hole on compression.)  
7. Use of fuel stabilizers or anti-gumming agents in the fuel  
system can help prevent the build up of gum and varnish.  
Whenever the unit is stored, be sure that the fuel shut-off valve is  
in the closed position.  
Refer to the engine manual that accompanies this unit for  
instructions regarding maintenance of engine components.  
Never tamper with engine speed settings or  
frequency settings.Any governor adjustments  
should be made by qualified personnel only.  
12  
 
GR3000  
Wire  
Welding Guidelines  
GeneRal  
This line of welding machines utilizes a process known as Shielded Metal-Arc Welding  
(SMAW). This process is used to bond metals by heating them with an electric arc  
created between the electrode and the work piece.  
Flux  
Slag  
Weld  
Electrodes used for shielded metal arc welding have two parts. The inner core is a metal  
rod or wire that should be similar in composition to the base metal. The outer coating  
is called flux. Various types of flux exist. Each coating is used for a particular welding  
situation.  
Crater  
While the metal is molten, it can be contaminated by elements in the air. This  
contamination could weaken the weld. The flux coating creates a protective barrier  
called slag that protects the molten metal from contaminants.  
Work Piece  
figure 2 - Weld components  
When current (amperage) flows through the circuit to the electrode, an arc is formed  
between the end of the electrode and the work piece. The arc melts the electrode and  
the work piece. The melted metal of the electrode flows into the molten crater and  
forms a bond with the work piece as shown in Figure 2.  
NOTE: Discontinue using and discard electrodes that burn down to 1 to 2 inches from  
the electrode holder.  
1/16 inch  
stRikinG an aRc  
Place the bare end of the electrode in the holder. Grip the holder lightly to reduce tiring  
of the hand and arm.  
NOTE: Always keep the jaws of the holder clean to insure good electrical contact with  
the electrode.  
Same as Electrode Diameter  
Be careful not to touch the work piece or welding bench with the  
electrode as this causes arc flashes.  
figure 3 - scratching method  
The best method of striking an arc is the scratching method. Drag the electrode at an  
angle along the surface much like striking a match. Upon contact with the plate, lift the  
electrode approximately 1/16 inch off the surface or it will stick (See Figure 3).  
NOTE: Should the electrode stick to the work piece, break it loose by quickly twisting  
or bending at the holder while pulling upward. If the electrode does not break loose,  
disengage the electrode by releasing it from the holder.  
electRoDe tyPe anD size  
Four types of electrodes are recommended for this welder. The electrodes are  
commonly known by the AWS (American Welding Society) designation as follows:  
1. E-6011 Deep penetrating  
• Flat bead with deep penetrating arc.  
• For rusted or dirty mild steel general repair work.  
2. E-6013 General Purpose  
• All position, smooth deposit rod with low spatter.  
• For all mild steel and general purpose work.  
3. E-7014 Fast fill  
• Smooth bead and fast deposition  
• Ideal for joints with poor fitup and general repair work.  
4. E-7018-AC High Strength  
• Ideal for pipes and structural applications.  
• Low hydrogen reduces porosity for a strong weld.  
NOTE: Only the E-7018-AC electrode is recommended for use with these welders.  
Other E-7018 electrodes are designed for use with higher open circuit voltages than  
these welders are capable of producing. Recommended electrode diameter is 3/32 inch  
or 1/8 inch.  
13  
 
Operating Instructions  
Welding Guidelines (Continued)  
Work angle is the angle from horizontal, measured at right  
angles to the line of welding.  
aRc WelDinG basics  
Four basic techniques affect weld quality. These are: amperage  
setting, weld angle, arc length, and travel speed. Proper use of  
these techniques is necessary for good weld quality.  
For most applications, a 45º travel angle and 45º work angle  
is sufficient. For specific applications, consult an arc welding  
handbook.  
amPeRaGe settinG  
NOTE: Right handed welders should weld from left to right. Left  
handed welders should weld from right to left. The electrode  
should always point into the weld puddle as shown.  
The correct amperage involves the adjustment of the welding  
machine to the required amp setting. This is regulated by a  
knob on the welder. The amperage required depends on the size  
(diameter) of electrode used and the thickness of the work piece.  
aRc lenGth  
Arc length is the distance from the work piece to the tip of the  
electrode, the distance which the arc must travel. A proper  
arc length is essential to generate the heat needed for welding  
(See Figure 4). An arc that is too long produces an unstable arc,  
reduces penetration, increases spatter, and causes flat and wide  
beads. Too short an arc does not create enough heat to melt the  
work piece, the electrode has a tendency to stick, penetration  
will be poor, and uneven beads with irregular ripples result. A  
proper arc should be no longer than the diameter of the rod.  
Consult specifications listed on the welder. Excessive amps burn  
through light metals and the weld bead is flat and porous (See  
Figure 4). The bead appears high and irregular if the amperage is  
too low.  
WelD anGle  
Weld angle is the angle at which the electrode is held during  
the welding process. Using the correct angle ensures proper  
penetration and bead formation. Electrode angle involves two  
positions - travel angle and work angle (See Figure 5).  
The sound of a proper arc is a steady, crisp sizzle, similar to  
bacon frying.  
Travel angle is the angle in the line of welding and may vary from  
5º to 45º from the vertical, depending on welding conditions.  
W
NOTE: Weld bead  
Work Piece  
width (W) should be  
approximately twice  
the diameter for the  
electrode rod used.  
Normal Amps,  
Arc Length,  
Speed  
Speed Too Fast  
Amperage Too Low  
Amperage Too High  
Speed Too Slow  
Arc Length Too Long  
Arc Length Too Short  
figure 4 - Weld appearance  
14  
 
GR3000  
Welding Guidelines (Continued)  
tRavel sPeeD  
5º - 45º  
The travel speed is the rate at which the electrode is moved across the weld area (See  
Figure 4). When the speed is too fast, the bead is narrow and bead ripples are pointed  
as shown. When the speed is to slow, the weld metal piles up and the bead is high and  
wide. To control travel speed, watch the width of the weld bead (not the arc) when  
welding. The weld bead is the orange, molten metal behind the arc. The width should  
be approximately twice the diameter of the welding rod. Control travel speed to obtain  
a consistent bead width.  
Travel Angle  
slaG Removal  
Wear ANSI compliant safety glasses (ANSI Standard Z87.1) and protective  
clothing when removing slag. Hot, flying debris can cause personal injury  
to anyone in the area.  
After completing the weld, wait for the welded sections to cool. A protective coating  
called slag now covers the weld bead which prevents contaminants in the air from  
reacting with the molten metal. Once the weld cools to the point that it is no longer  
glowing red, the slag can be removed. Removal is done with a chipping hammer.  
Lightly tap the slag with the hammer and break it loose from the weld bead. The final  
clean-up is done with a wire brush. When making multiple weld passes, remove the  
slag before each pass.  
Work Angle  
figure 5 - Weld angle  
Cover  
WelDinG Positions  
Four basic welding positions can be used; flat, horizontal, vertical, and overhead.  
Welding in the flat position is easier than any of the others because welding speed can  
be increased, the molten metal has less tendency to run, better penetration can be  
achieved, and the work is less fatiguing.  
Filler  
Root  
Other positions require different techniques such as a weaving pass, circular pass, and  
jogging. A higher skill level is required to complete these welds.  
All work should be performed in the flat position if possible. For specific applications,  
consult an arc welding handbook.  
WelD Pass  
figure 6 - Weld Passes  
Sometimes more then one pass is necessary to fill the joint. The root pass is first,  
followed by filler passes and the cover pass (See Figures 6 and 7). If the pieces are thick,  
it may be necessary to bevel the edges that are joined at a 60º angle. Remember to  
remove the slag before each pass.  
figure 7 - multiple Weld Passes  
15  
 
Operating Instructions  
Welding Guidelines (Continued)  
testinG WelDeR/GeneRatoR DioDes  
The following method eliminates the need to disconnect the diodes from the welder/  
generators wiring.  
1. Use a 12 Volt battery and automotive lamp (Type 5001) to test the diodes in the  
welder/generators.  
2. Connect the battery and lamp as shown in Figure 8.  
3. If the diodes are operating properly, the lamp illuminates brightly when the  
battery polarity is correct, and goes dim when battery polarity is reversed.  
4. If there is no change in lamp brightness when polarity is reversed, the diodes must  
be replaced.  
For testing of rotor, stator, or field windings, consult an authorized  
service center.  
Lamp On  
Lamp Off  
figure 8 - Diode test Procedure  
Troubleshooting Chart  
General  
Symptom  
Possible Cause(s)  
Corrective Action  
Engine will not  
start  
1. Engine switch is set to "OFF".  
2. Fuel valve is turned to "CLOSE".  
3. Choke is open.  
1. Set engine switch to "ON".  
2. Turn fuel valve to "OPEN" position.  
3. Close the choke.  
4. Engine is out of gas.  
5. Engine is filled with contaminated or  
old gas  
4. Add gas.  
5. Change the gas in the engine.  
6. Spark plug is dirty.  
6. Clean spark plug.  
7. Spark plug is broken.  
8. Unit is not on level surface.  
9. Oil is low.  
7. Replace spark plug.  
8. Move unit to a level surface to prevent low oil shutdown from triggering.  
9. Add or replace oil.  
Engine runs  
but there is no  
electrical output  
1. Circuit reset button is off.  
1. Wait for 2 minutes and push the circuit reset button to the "ON"  
position.  
2. If you are using an extension cord, use only heavy-duty extension  
cords that are specifically designed for outdoor use. Make sure the  
wattage rating for each cord exceeds the total wattage of all appliances  
connected to the unit.  
2. Bad connecting of wires / cables.  
3. Bad electrical device connected to  
unit.  
3. Try connecting a different device.  
Unit runs but does 1. Unit is overloaded  
not support all  
electrical devices  
1. Turn off all electrical devices. Unplug all electrical devices. Turn off unit.  
Wait several minutes. Restart unit. Try connecting fewer electrical loads  
to the unit.  
connected.  
2. Short in one of the connected devices. 2. Try disconnecting any faulty or short-circuited electrical loads.  
3. Air cleaner is dirty. 3. Clean or replace air cleaner.  
16  
 
GR3000  
Troubleshooting Chart (Continued)  
Generator  
Symptom  
No output voltage 1. Engine speed is too slow  
2. Open, shorted, or incorrect wiring  
Possible Cause(s)  
Corrective Action  
1. Adjust engine speed H  
2. Referring to the wiring diagram, clean and reconnect all wiring H  
3. Replace capacitor H  
3. Faulty capacitor  
4. Open or shorted field windings  
5. Open diodes  
4. Test winding resistance, replace field winding if necessary H  
5. Test diodes, replace if necessary H  
6. Front panel switch set incorrectly  
7. Circuit breaker tripped  
6. Set front panel switch to generator  
7. Reset circuit breaker  
Low output  
voltage with no  
load  
1. Engine speed is too slow  
2. Open diodes  
3. Faulty capacitor  
1. Adjust engine speed H  
2. Test diodes, replace if necessary H  
3. Replace capacitor H  
4. Open or shorted field windings  
5. Voltage setting on front panel  
incorrect  
4. Test winding resistance, replace field winding if necessary H  
5. Adjust setting on front panel  
High output  
voltage with no  
load  
1. Faulty capacitor  
1. Replace capacitor H  
2. Adjust engine speed H  
3. Adjust setting on front panel  
2. Engine speed is too fast  
3. Voltage setting on front panel  
incorrect  
Low output  
voltage under  
load  
1. Open diode  
1. Test diodes, replace if necessary H  
2. Adjust engine speed H  
3. Reduce the applied load  
2. Engine speed too slow at full load  
3. Excessive load applied  
4. Voltage setting on front panel  
incorrect  
4. Adjust setting on front panel  
Erratic output  
voltage  
1. Unbalanced engine  
2. Dirty, corroded, or loose wiring  
connection  
1. Refer to engine manual  
2. Referring to the wiring diagram, clean and reconnect all wiring H  
3. Unstable load applied  
3. Remove all loads, then apply each one individually to determine which  
one is causing erratic function  
Noisy operation  
1. Loose unit or engine bolt(s)  
1. Tighten all mountings  
2. Short circuit in unit field or load  
2. Test winding resistance, replace field winding if necessary H  
Test load devices for shorts. Replace defective load device.  
3. Replace bearing  
3. Faulty bearing  
H These diagnostic and repair procedures should be performed by an authorized service center.  
Welder  
Symptom  
Possible Cause(s)  
Corrective Action  
Welder runs but  
does not weld  
1. Inadequate current at electrode  
1. Check work clamp, cable and connection to work piece. Check electrode  
cable and clamp  
2. Poor connections at welder  
3. Front panel switch set incorrectly  
4. Open, shorted, or incorrect wiring  
5. Faulty capacitor  
2. Check all welder external connections  
3. Set front panel switch to weld  
4. Referring to the wiring diagram, clean and reconnect all wiring H  
5. Replace capacitor H  
6. Open or shorted field windings  
7. Open diodes  
6. Test winding resistance, replace field winding if necessary H  
7. Test diodes, replace if necessary H  
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 difficult to  
strike  
1. Wrong type of electrode.  
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  
2. Electrode diameter too large  
3. Work piece not properly grounded  
4. Engine speed is too slow  
H These diagnostic and repair procedures should be performed by an authorized service center.  
17  
 
Operating Instructions  
Troubleshooting Chart (Continued)  
Welds  
Symptom  
Possible Cause(s)  
Corrective Action  
Bead is  
1. Inconsistent travel speed  
1. Carefully watch and control the width of the molten weld bead  
2. Adjust output amp setting or change to smaller diameter electrode  
intermittently too 2. Output amp setting incorrect  
thin or too thick  
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 1. Arc length short  
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  
workpiece  
2. Amp setting low  
3. Incorrect electrode  
Electrodes sputter Damp electrodes  
and stick  
Use dry electrodes and store in dry location  
Notes  
18  
 
GR3000  
figure 9 - Wiring Diagram  
19  
 
Operating Instructions  
GR3000  
Reminder: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.  
Limited Warranty  
1. DURATION: The manufacturer warrants that it will repair, at no charge for parts or labor, the following Campbell Hausfeld  
products proven defective in material or workmanship, during the following time period(s) after date of original retail purchase:  
For 5 Years: The Welder Transformer and Rectifier  
For 3 Years: The Entire Welder, Engine Driven Welder Generators, and Power Packs (excluding clamps, welding gun, electrode  
holder, cables, or accessories packed with the welder)  
For 1 Year: The compressor pump  
For 90 Days: The Welding Clamps, MIG Gun, Electrode Holder, Accessories, and Welding Cables (as applicable)  
2. WHO GIVES THIS WARRANTY (WARRANTOR): Campbell Hausfeld/Scott Fetzer Company, 100 Mundy Memorial Drive,  
Mount Juliet, Tennessee, 37122, Telephone: (800) 746-5641  
3. WHO RECEIVES THIS WARRANTY (PURCHASER): The original purchaser (other than for purposes of resale) of the Campbell  
Hausfeld product.  
4. WHAT IS COVERED UNDER THIS WARRANTY: Substantial defects in material and workmanship which occur within the  
duration of the warranty period with the exceptions noted below.  
5. WHAT IS NOT COVERED UNDER THIS WARRANTY:  
A. Implied warranties, including those of merchantability and FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED  
IN DURATION TO THIS EXPRESS WARRANTY. After this period, all risks of loss, from whatever reason, shall be on the  
purchaser. Some States do not allow limitation on how long an implied warranty lasts, so the above limitations may not  
apply to you.  
B. ANY INCIDENTAL, INDIRECT, OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY  
DEFECT, FAILURE, OR MALFUNCTION OF THE CAMPBELL HAUSFELD PRODUCT. Some States do not allow limitations  
on how long an implied warranty lasts, so above limitations may not apply to you.  
C. Any failure that results from accident, purchasers abuse, neglect or failure to operate products in accordance with  
instructions provided in the owners manual(s) supplied with product.  
D. Pre-delivery service, e.g. assembly, oil or lubricants, and adjustment.  
E. Items or service that are normally required to maintain the product, e.g. lubricants, filters and gaskets, etc.  
F. Gasoline engine components are expressly excluded from coverage under this limited warranty. Such components should  
be returned by the purchaser to the original manufacturer or to its authorized repair stations for service.  
G. Additional items not covered under this warranty:  
1. Any component damaged in shipment or any failure caused by installing or operating unit under conditions not in  
accordance with installation and operation guidelines or damaged by contact with tools or surroundings.  
2. Pump or valve failure caused by rain, excessive humidity, corrosive environments or other contaminants.  
3. Cosmetic defects that do not interfere with functionality.  
4. Rusted tanks, including but not limited to rust due to improper drainage or corrosive environments.  
5. Check valves and pressure switches after the first year of ownership.  
6. Drain cocks.  
7. Other items not listed but considered general wear parts. In addition, this warranty does not extend to any damage  
caused by the untimely replacement or maintenance of any aforementioned wear parts.  
8. Pressure switches, air governors and safety valves modified from factory settings.  
9. Pump wear or valve damage caused by using oil not specified.  
10. Pump wear or valve damage caused by any oil contamination or by failure to follow proper oil maintenance  
guidelines.  
11. Belts.  
12. Ring wear or valve damage from inadequate filter maintenance.  
13. Manually adjusted load/unload and throttle control devices.  
6. RESPONSIBILITIES OF WARRANTOR UNDER THIS WARRANTY: Repair or replace, at Warrantors option, products or  
components which have failed within the duration of the specific warranty period.  
7. RESPONSIBILITIES OF PURCHASER UNDER THIS WARRANTY:  
A. Please call 800-746-5641 for warranty assistance.  
B. Provide dated proof of purchase and maintenance records.  
C. All products must be delivered or shipped to the nearest Campbell Hausfeld Authorized Service Center. Freight costs, if  
any, must be borne by the purchaser.  
D. Use reasonable care in the operation and maintenance of the products as described in the owners manual(s).  
8. WHEN WARRANTOR WILL PERFORM REPAIR OR REPLACEMENT UNDER THIS WARRANTY:  
Repair or replacement will be scheduled and serviced according to the normal work flow at the servicing location, and  
depending on the availability of replacement parts.  
This Limited Warranty gives you specific legal rights and you may also have other rights which vary from state to state.  
20  
 

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