Campbell Hausfeld GW4500 Slag Removal, Weld Pass, Testing Welder / Generator, Diodes

Operating Instructions and Parts Manual

Welding Guidelines		All work should be performed in the		4. If there is no change in lamp
(Continued)		flat position if possible. For specific		brightness when polarity is
SLAG REMOVAL		applications, consult an arc welding		reversed, the diodes must be
		handbook.		replaced.
	Wear ANSI approved
		WELD PASS			For testing of rotor,
	safety glasses (ANSI
Standard Z87.1) and protective clothing		Sometimes more then one pass is			stator, or field
when removing slag. Hot, flying debris				windings, consult an authorized service
		necessary to fill the joint. The root pass
can cause personal injury to anyone in				center.
the area.		is first, followed by filler passes and the
After completing the weld, wait for the		cover pass (See Figures 8 and 9). If the
		pieces are thick, it may be necessary to
welded sections to cool. A protective
		bevel the edges that are joined at a 60º
coating called slag now covers the weld
		angle. Remember to remove the slag
bead which prevents contaminants in
		before each pass.
the air from reacting with the molten
metal. Once the weld cools to the point		TESTING WELDER / GENERATOR
that it is no longer glowing red, the slag		DIODES
can be removed. Removal is done with		The following method eliminates the
a chipping hammer. Lightly tap the slag		need to disconnect the diodes from the
with the hammer and break it loose		welder / generators wiring.
from the weld bead. The final clean-up		1.	Use a 12 Volt battery and
is done with a wire brush. When making
			automotive lamp (Type 5001) to
multiple weld passes, remove the slag
			test the diodes in the welder /
before each pass.
			generators.
WELDING POSITIONS
		2. Connect the battery and lamp as
Four basic welding positions can be
			shown in Figure 10.
used; flat, horizontal, vertical, and		3.	If the diodes are operating
overhead. Welding in the flat position
			properly, the lamp illuminates
is easier than any of the others because
			brightly when the battery polarity is
welding speed can be increased, the
			correct, and goes dim when battery
molten metal has less tendency to run,
			polarity is reversed.
better penetration can be achieved, and
the work is less fatiguing.

Other positions require different techniques such as a weaving pass, circular pass, and jogging. A higher skill level is required to complete these welds.

		Lamp On
Cover
Filler
Root
		Lamp Off
Figure 8 - Weld Passes	Figure 9 - Multiple Weld Passes	Figure 10 - Diode Test Procedure
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