Campbell Hausfeld GR3000 User Manual
Operating Instructions
Power Pack
GR3000
Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . . . . . 1
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
Welding Guidelines .............13 - 16
Troubleshooting Chart ..........16 - 18
General.........................16
Generator.......................17
Welder..........................17
Welds ..........................18
Wiring Diagram ....................19
Warranty ..........................20
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
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.
Do not operate unit if damaged during shipping, handling or use.
Damage could result in bursting and cause injury or property damage.
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:
visit www.campbellhausfeld.com
http://www.campbellhausfeld.com
IN974302AV 6/13© 2013 Campbell Hausfeld/Scott Fetzer For parts, product & service information
Operating Instructions
Safety Guidelines
This manual contains information
that is very important to know
and understand. This information
is provided for SAFETY and to
PREVENT EQUIPMENT PROBLEMS.
To help recognize this information,
observe the following symbols.
Danger indicates
an imminently
hazardous situation which, if not avoided,
WILL result in death or serious injury.
Warning indicates
a potentially
hazardous situation which, if not avoided,
COULD result in death or serious injury.
Caution indicates
a potentially
hazardous situation which, if not avoided,
MAY result in minor or moderate injury.
Notice indicates
important
information, that if not followed, may
cause damage to equipment.
IMPORTANT: Information that
requires special attention.
Please read and save these instructions. Read carefully before attempting to assemble, install,
operate or maintain the product described. Protect yourself and others by observing all safety
information. Failure to comply with instructions could result in personal injury and/or
property damage! Retain instructions for future reference.
Important Safety Information
This manual contains important safety, operational and maintenance information.
If you have any questions, please call 1-800-746-5641 for customer assistance.
CALIFORNIA PROPOSITION 65
This product contains and / or produces chemicals,
including lead, known to the State of California to cause
cancer and birth defects or other reproductive harm.
EMISSIONS
Engines that are certified to comply
with U.S. EPA emission regulations
for SORE (Small Off Road Equipment), are certified to
operate on regular unleaded gasoline, and may include
the following emission control systems: (EM) Engine
Modifications and (TWC) Three-Way Catalyst (if so
equipped).
Using a generator indoors CAN KILL
YOU IN MINUTES. Generator exhaust
contains carbon monoxide. This is a poison you cannot see or
smell.
◆ NEVER use inside a house or garage, EVEN IF doors and windows are open.
◆ Only use OUTSIDE and far away from windows, doors and vents.
Safety Symbols
The following Safety Symbols appear
throughout this manual to alert you
to important safety hazards and
precautions.
MANUAL
Wear Eye
and Mask
Protection
Risk of
Explosion
Risk of Light
Rays
Risk of
Fumes
Read Manual
First
Risk of
Electrocution
Risk of
Hot Parts
Risk of
Magnetism
Wear Eye
and Ear
Protection
Risk of Flying
Fragments
Risk of Fire
Risk of
Pressure
GENERAL SAFETY
◆ Before starting or servicing any unit, read and understand all
instructions. Failure to follow safety precautions or instructions can
MANUAL
cause equipment damage and or serious personal injury or death.
Engine instructions for these units are contained in a separate manual.
Retain all manuals for future reference.
◆ Wear safety glasses and use hearing protection when operating the unit.
Never operate this unit in an explosive, flammable and / or
combustible atmosphere.
◆ Never use this unit for any application other than that specified by the
manufacturer. Never operate this unit under conditions not approved by
the manufacturer. Never attempt to modify this unit to perform in any manner not
intended by the manufacturer.
◆ If the equipment should start to vibrate abnormally, STOP the engine / motor and
check immediately for the cause. Vibration is generally a warning of trouble.
◆ For maintenance and repairs, use only products and parts recommended by the
manufacturer.
◆ Be sure that the unit is properly grounded to an external ground path prior to
operation. Refer to the section entitled “Grounding Instructions” for proper
grounding procedures.
◆ Be sure that the unit is operated only by persons who have read and understand
these instructions.
◆ Be sure that the unit is placed on a flat level surface prior to and during operation.
The unit must not slide or shift during operation.
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2
Important Safety Information (Continued)
GR3000
◆ Keep all persons away from the unit during operation.
◆ NEVER allow children in the work area.
◆ 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.
◆ Keep all persons away from parts that move or become hot
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.
◆ 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.
◆ All installation, maintenance, repair and operation of this
equipment should be performed by qualified persons only in
accordance with national, state, and local codes.
◆ 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.
◆ Check all fasteners at frequent intervals for proper tightness.
◆ Always operate the unit in a clean, dry, well ventilated area.
Do not operate the unit in humid, wet, rainy, or poorly
ventilated areas.
◆ 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.
GENERATOR SAFETY
◆ Be sure all powered devices are shut off prior to connecting
them to the unit.
◆ 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.
◆ 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.
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.
◆ 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.
◆ Coiled welding cable should be spread out before use to
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
electrode from the holder.
◆ Never allow any part of the body to touch the electrode and
ground or grounded work piece at the same time.
◆ Awkward welding conditions and positions can be electrically
hazardous. When crouching, kneeling or at elevations,
be sure to insulate all conductive parts, wear appropriate
protective clothing, and take precautions to prevent injury
from falls.
◆ Never attempt to use this equipment at current settings or
duty cycles higher than those specified on the equipment
labels.
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3
Operating Instructions
Important Safety Information (Continued)
◆ 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.
◆ 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
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.
◆ 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.
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.
◆ 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.
◆ Never touch work pieces until completely 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.
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.
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 airsupplied respirator.
◆ Keep your head out of the welding fumes.
◆ 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.
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.
◆ 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.
◆ 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
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.
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Important Safety Information (Continued)
GR3000
COMPRESSOR SAFETY
Never remove or attempt to adjust safety valve.
Keep safety valve free from paint and other
accumulations.
Never attempt to repair or modify
other modification will weaken the tank resulting in
damage from rupture or explosion. Always replace worn
or damaged tanks.
a tank! Welding, drilling or any
◆ 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.
\
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.
SPRAYING PRECAUTIONS
Do not spray flammable materials
in vicinity of open flame or near
ignition sources including the compressor unit.
◆ Do not smoke when spraying paint, insecticides,
or other flammable substances.
◆ Use a face mask / respirator when spraying and
spray in a well ventilated area to prevent health
and fire hazards.
◆ 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.
◆ When spraying or cleaning with solvents or toxic
chemicals, follow the instructions provided by the chemical
manufacturer.
SAFETY STANDARDS AND SUGGESTED READING
ANSI Standard Z49.1 from American Welding Society, 550 N.W.
LeJune Rd. Miami, FL 33126
Safety and Health Standards
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
Safe Handling of Compressed Gases in Cylinders
CGA Pamphlet P-1, from Compressed Gas Association, 1235
Jefferson Davis Highway, Suite 501, Arlington, VA 22202
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
Cutting And Welding Processes
NFPA Standard 51B, from National Fire Protection Association,
1 Battery March Park, P.O. Box 9146, Quincy, MA 02269-9959.
Practice For Occupational And Educational Eye And Face
Protection
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.
Cutting and Welding Processes
NFPA Standard 51B from National Fire Protection Association,
1 Battery March Park, P.O. Box 9146, Quincy, MA 02269-9959.
OSHA Hazard Communication Standard 29 CFR 1910.1200
OSHA General Industry Standard 29 CFR 1910 Subpart Q from
the Occupational Safety and Health Administration,
www.osha.org or contact your local OSHA office.
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.
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.
SAVE THESE INSTRUCTIONS
DO NOT DISCARD
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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.
Arc Length - the distance from the end of the electrode to the
point where the arc makes contact with the work surface.
Base Metal - the material to be welded.
Butt Joint - a joint between two members aligned
approximately in the same plane.
Crater - a pool, or pocket, that is formed as the arc comes in
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.
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.
Electrode - a coated metal wire having approximately the same
composition as the material being welded.
Fillet Weld - approximately a triangle in cross-section, joining
two surfaces at right angles to each other in a lap, T or corner
joint.
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.
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.
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.
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 nonconsumable tungsten electrode and the work piece. Filler metal
may or may not be used.
Lap Joint - a joint between two overlapping members in
parallel planes.
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.
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.
Porosity - gas pockets, or cavities, formed during weld
solidification. They weaken the weld.
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.
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.
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.
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.
Tack Weld - weld made to hold parts in proper alignment until
final welds are made.
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.
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.
Weld Pool or Puddle - a volume of molten metal in a weld
prior to its solidification as weld metal.
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.
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