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See Warranty on page 20 for important information about commercial use of this product.
Operating Instructions and Parts Manual GW4500
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.
Need
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Operating Instructions and Parts Manual become entangled in moving GENERAL SAFETY General Safety Information components, causing equipment � Before starting or CALIFORNIA PROPOSITION 65 damage and or personal injury. servicing any welder / The cables on this MANUAL generator, read � Keep all persons away from parts product may contain chemicals, including lead, known to and understand all that move or become hot during the State of California to cause cancer instructions. Failure to
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GW4500 General Safety Information � All persons operating this � Always attach the work lead first. (Continued) equipment or in the area while � Verify that the work piece is Always equipment is in use must wear keep a securely grounded. protective welding gear including: fire extinguisher accessible � Always shut off electric arc welding while performing arc welding welding helmet or shield with equipment when not in use and operations. at least shade 10, flame resistant remov
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Operating Instructions and Parts Manual ADDITIONAL SAFETY STANDARDS General Safety Information The (Continued) ANSI Standard Z49.1 from American electromagnetic field that Fire Welding Society, 550 N.W. LeJune Rd. is generated during arc hazard! welding may interfere with Miami, FL 33126 Do not weld on containers the operation of various electrical Safety and Health Standards or pipes that contain or and electronic devices such as cardiac have contained flammable OSHA 29 CFR
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GW4500 Flux Cored Arc Welding (FCAW) - Slag - a layer of flux soot that Getting To Know Your also called Gasless, is a welding process protects the weld from oxides and Welder / Generator used with a wire-feed welding machine. other contaminants while the weld is Glossary of Terms The weld wire is tubular with flux solidifying (cooling). Slag should be AC or Alternating Current - electric material contained inside for shielding. removed after weld has cooled. current that reverses direc
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Operating Instructions and Parts Manual 3. Rotate the engine switch to the ON GROUNDING Pre-Operation position. 1. Use the ground terminal and wing LOCATION nut on the welder / generator frame 4. Adjust the choke lever as follows: Selecting the proper location can to connect the unit to a suitable significantly increase performance, a. For cold engine, move the choke ground source. Securely fasten the reliability and life of the arc welder. lever as far as possible to the left, end term
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GW4500 If actual watt ratings are not available, combination of 240 volt loads and Pre-Operation (Continued) the Power Usage Chart, see Table 1, may also with 120 volt loads through LOW OIL SHUTDOWN be used as a general guideline. the 120 volt receptacles. A low oil shutdown switch is provided The 120/240 volt twist lock Remember that devices which generate to protect the engine and welder / receptacle, found on some welder / heat during operation such as heaters, generators on most ext
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Operating Instructions and Parts Manual Generator Operation Welder Operation (Continued) (FRONT PANEL SWITCH MUST BE SET TO WELDER POSITION) INSTALLATION FOR STAND-BY USE Precautions must be taken to prevent WELDING LEAD ASSEMBLIES electrical back feeding into utility Welding leads assemblies are not systems. This requires isolation of included with all units. Use copper the electrical system. To isolate the welding cables in the size specified in electrical system, perform the following Tab
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GW4500 If heating, welding, STORAGE Welder Operation or cutting materials If the welder / generators is not to be (Continued) that are galvanized, zinc plated, used for extended periods of time, 5. Tighten the set screw, securing the lead, or cadmium plated refer to the the following pre-storage procedures cable in place. General Safety Information Section for should be performed: instructions. Extremely toxic fumes are 6. Slide the insulated handle onto created when these metals a
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Operating Instructions and Parts Manual STRIKING AN ARC 3. E-7014 Fast fill Welding Guidelines Place the bare end of the electrode in � Smooth bead and fast deposition GENERAL the holder. Grip the holder lightly to This line of welding machines utilizes � Ideal for joints with poor fitup and reduce tiring of the hand and arm. a process known as Shielded Metal-Arc general repair work. NOTE: Always keep the jaws of the Welding (SMAW). This process is used 4. E-7018-AC High Strength holde
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GW4500 an arc does not create enough heat to Welding Guidelines melt the work piece, the electrode has (Continued) 5º - 45º a tendency to stick, penetration will be Work angle is the angle from poor, and uneven beads with irregular horizontal, measured at right angles to ripples result. A proper arc should be no the line of welding. longer than the diameter of the rod. For most applications, a 45º travel The sound of a proper arc is a steady, angle and 45º work angle is sufficient. cr
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Operating Instructions and Parts Manual All work should be performed in the 4. If there is no change in lamp Welding Guidelines flat position if possible. For specific brightness when polarity is (Continued) applications, consult an arc welding reversed, the diodes must be SLAG REMOVAL handbook. replaced. Wear ANSI approved For testing of rotor, safety glasses (ANSI WELD PASS stator, or field Standard Z87.1) and protective clothing Sometimes more then one pass is windings, consu
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GW4500 Troubleshooting Chart - General Symptom Possible Cause(s) Corrective Action Engine will not start 1. Engine switch is set to "OFF". 1. Set engine switch to "ON". 2. Fuel valve is turned to "CLOSE". 2. Turn fuel valve to "OPEN" position. 3. Choke is open. 3. Close the choke. 4. Engine is out of gas. 4. Add gas. 5. Engine is filled with contaminated or 5. Change the gas in the engine. old gas 6. Spark plug is dirty. 6. Clean spark plug. 7. Spark plug is broken. 7. Replace spark plug. 8. Uni
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Operating Instructions and Parts Manual Troubleshooting Chart - Welder Symptom Possible Cause(s) Corrective Action Welder runs but 1. Inadequate current at electrode 1. Check work clamp, cable and connection to work piece. Check does not weld electrode cable and clamp 2. Poor connections at welder 2. Check all welder external connections 3. Front panel switch set incorrectly 3. Set front panel switch to weld 4. Open, shorted, or incorrect wiring 4. Referring to the wiring diagram, clean and rec
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GW4500 Figure 11 - Wiring Diagram - AC Welder / Generator www.chpower.com 15 Capacitor Ground Thermal Trip Clamp Welding (Fitted Inside Impedance the Windings) Electrode Holder Gen. Weld. R/L1 2 4 6 8 10 12 14 16 18 20 22 24 Welding Current 1 7 and Generator 2 13 5 7 9 11 13 15 17 19 21 23 6 3 4 5 Voltage Selector Adjustable 230V 115V Main Winding Auxiliary Winding Rotor Red Orange White Blue Brown Battery Charger 12V AC Brown Blue Red Grey Brown Red White Black Yellow Green White Green Gene
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Operating Instructions and Parts Manual Welder / Generator Assembly 1 17 18 19 16 20 22 21 11 10 3 6 5 7 4 2 15 14 11 11 12 11 13 9 8 Figure 12 www.chpower.com 16
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GW4500 For replacement parts or technical assistance, call 1-800-543-6400 Please provide following information: Address parts correspondence to: - Model number Campbell Hausfeld - Serial number (if any) Attn: Parts Dept. - Part description and number as shown in parts list 100 Production Drive Harrison, OH 45030 USA Replacement Parts List Ref. No. Description Part Number Qty. 1 Engine - Honda GX270 PM004264AV 1 2 Welded Frame Assembly GW004000AD 1 3 Tie Bracket GN004399AD 1 4 Isomount -
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Operating Instructions and Parts Manual Alternator Assembly 17 22 18 13 2 14 6 11 21 20 12 4 19 23 7 28 10 24 15 16 9 25 27 4 28 3 1 5 26 8 10 Figure 13 www.chpower.com 18
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GW4500 For replacement parts or technical assistance, call 1-800-543-6400 Please provide following information: Address parts correspondence to: - Model number Campbell Hausfeld - Serial number (if any) Attn: Parts Dept. - Part description and number as shown in parts list 100 Production Drive Harrison, OH 45030 USA Replacement Parts List Ref. No. Description Part Number Qty. 1 Alternator - 4kW, 140A AC (includes items 2 through 22) GW001000AV 1 2 Engine Adapter GN002301SV 1 3 Rotor Tie
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Operating Instructions and Parts Manual Limited Warranty 1. DURATION: The manufacturer warrants that it will repair, at no charge for parts or labor, the welder, welding gun, or cables, 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 and Engine Driven Welder Generators (excluding clamps, welding gun, electrode holder, cables, or accessories
