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Campbell Hausfeld Welder / Generator GW4500 manual

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Table of contents for the manual

  • Page 1

    W elder / Generator T able of Contents Description . . . . . . . . . . . . . . . . . . . . . . 1 Unpacking . . . . . . . . . . . . . . . . . . . . . . . 1 Safety Guidelines . . . . . . . . . . . . . . . . . 1 Specifications. . . . . . . . . . . . . . . . . . . . . 1 General Safety Information . . . . . . 2 - 4 Glossary of T erms . . . . . . . . . .[...]

  • Page 2

    2 www .chpower .com Operating Instructions and Parts Manual General Safety Information CALIFORNIA PROPOSITION 65 The cables on this product may contain chemicals, including lead, known to the State of California to cause cancer and birth defects or other repr oductive harm. W ash hands after handling. The engine exhaust from this pr oduct contains [...]

  • Page 3

    3 www .chpower .com GW4500 General Safety Information (Continued) Always keep a fire extinguisher accessible while performing arc welding operations. • All installation, maintenance, repair and operation of this equipment should be performed by qualified persons only in accordance with national, state, and local codes. Improper use of electric ar[...]

  • Page 4

    4 www .chpower .com Operating Instructions and Parts Manual General Safety Information (Continued) Fire hazard! Do not weld on containers or pipes that contain or have contained flammable materials or gaseous or liquid combustibles. Arc welding closed cylinders or containers such as tanks or drums can cause explosion if not properly vented! V erify[...]

  • Page 5

    5 www .chpower .com GW4500 Getting T o Know Y our Welder / Generator Glossary of T erms 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 w[...]

  • Page 6

    6 www .chpower .com Operating Instructions and Parts Manual GROUNDING 1. Use the ground terminal and wing nut on the welder / generator 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 welder / generators frame. Tighten the washer and wing nut on top of the grou[...]

  • Page 7

    7 www .chpower .com GW4500 combination of 240 volt loads and also with 120 volt loads through the 120 volt receptacles. The 120/240 volt twist lock receptacle , found on some welder / generators, is rated for 20 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[...]

  • Page 8

    8 www .chpower .com Operating Instructions and Parts Manual Generator Operation (Continued) INST ALLA TION FOR ST AND-BY USE Precautions must be taken to prevent electrical back feeding into utility systems. This requires isolation of the electrical system. T o isolate the electrical system, perform the following procedures: 1. T urn off the main e[...]

  • Page 9

    9 www .chpower .com GW4500 Welder Operation (Continued) 5. T ighten the set screw , securing the cable in place. 6. Slide the insulated handle onto the electrode holder and tighten the phillips head screw . Do not overtighten the phillips head screw . Overtightening will damage the insulated handle. DINSE PLUGS (SEE FIGURE 3) 1. Strip 1/2 inch of i[...]

  • Page 10

    10 www .chpower .com Operating Instructions and Parts Manual Welding Guidelines GENERAL This line of welding machines utilizes a process known as Shielded Metal-Arc W elding (SMAW). This process is used to bond metals by heating them with an electric arc created between the electrode and the work piece. Electrodes used for shielded metal arc weldin[...]

  • Page 11

    11 www .chpower .com GW4500 Welding Guidelines (Continued) W ork angle is the angle from horizontal, measured at right angles to the line of welding. For most applications, a 45º travel angle and 45º work angle is sufficient. For specific applications, consult an arc welding handbook. NOTE: Right handed welders should weld from left to right. Lef[...]

  • Page 12

    12 www .chpower .com Operating Instructions and Parts Manual Welding Guidelines (Continued) SLAG REMOV AL Wear ANSI approved safety glasses (ANSI Standard Z87.1) and pr otective 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 protecti[...]

  • Page 13

    13 www .chpower .com GW4500 T roubleshooting 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. 4. Engine is out of gas. 5. Engine is filled with contaminated or old gas 6. Spark plug is dirty . 7. Spark plug is[...]

  • Page 14

    14 www .chpower .com Operating Instructions and Parts Manual T roubleshooting Chart - W elder Symptom Possible Cause(s) Corrective Action Welder runs but does not weld 1. Inadequate current at electrode 2. Poor connections at welder 3. Front panel switch set incorrectly 4. Open, shorted, or incorrect wiring 5. Faulty capacitor 6. Open or shorted fi[...]

  • Page 15

    15 www .chpower .com GW4500 Welding Impedance Gen. Weld. Rotor Red White Brown Battery Charger 12V AC Blue Brown Grey Red Black White Y ellow Green Main Winding Brown Red White Green Generator/Welder Power Switch 2 4 6 8 10 12 14 16 18 20 22 24 13 5 7 9 1 1 1 3 1 5 1 7 1 9 2 1 2 3 Capacitor Thermal T rip (Fitted Inside the Windings) Violet Black Bl[...]

  • Page 16

    16 www .chpower .com Operating Instructions and Parts Manual 1 2 7 3 4 5 6 8 9 10 11 12 13 14 15 16 17 18 19 20 11 11 11 21 22 Figure 12 Welder / Generator Assembly[...]

  • Page 17

    17 www .chpower .com GW4500 For r eplacement parts or technical assistance, call 1-800-543-6400 1 Engine - Honda GX270 PM004264A V 1 2 W elded Frame Assembly GW004000AD 1 3 T ie Bracket GN004399AD 1 4 Isomount - Angle (short) GN004405A V 1 5 Isomount - Angle (extended) GN004406A V 1 6 Isomount GN004401A V 1 7 Hat Bracket GW004050AD 1 8 Hex head Scr[...]

  • Page 18

    18 www .chpower .com Operating Instructions and Parts Manual 1 2 3 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 4 10 28 Figure 13 Alternator Assembly[...]

  • Page 19

    19 www .chpower .com GW4500 For r eplacement parts or technical assistance, call 1-800-543-6400 1 Alternator - 4kW , 140A AC (includes items 2 through 22) GW001000A V 1 2 Engine Adapter GN002301SV 1 3 Rotor T ie Rod GN002304SV 1 4 Nyloc Nut - M8-1.25 ▲ 5 5 Diode, Suppressor , Capacitor Kit (2 each) GN002337SJ 1 6 Air Outlet Guard GN002310SV 2 7 R[...]

  • Page 20

    20 www .chpower .com Operating Instructions and Parts Manual Limited W arranty 1. DURA TION: 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 Y ears: The[...]