Campbell-hausfeld Welder / Generator GW4500 User Manual download pdf

Welder /

Generator

Table of Contents

Description . . . . . . . . . . . . . . . . . . . . . .1

Unpacking . . . . . . . . . . . . . . . . . . . . . . .1

Safety Guidelines . . . . . . . . . . . . . . . . .1

Specifications. . . . . . . . . . . . . . . . . . . . .1

General Safety Information . . . . . . 2 - 4

Glossary of Terms . . . . . . . . . . . . . . . . .5

Pre-operation . . . . . . . . . . . . . . . . . 6 - 7

Operation . . . . . . . . . . . . . . . . . . . . 7 - 9

Maintenance . . . . . . . . . . . . . . . . . . . . .9

Storage . . . . . . . . . . . . . . . . . . . . . . . . .9

Welding Guidelines. . . . . . . . . . . 10 - 12

Troubleshooting Chart . . . . . . . . 13 - 14

General . . . . . . . . . . . . . . . . . . . . . .13

Generator . . . . . . . . . . . . . . . . . . . .13

Welder . . . . . . . . . . . . . . . . . . . . . .14

Welds . . . . . . . . . . . . . . . . . . . . . . .14

Wiring Diagram. . . . . . . . . . . . . . . . . .15

Welder / Generator Assembly. . . 16 - 17

Alternator Assembly . . . . . . . . . . 18 - 19

Warranty . . . . . . . . . . . . . . . . . . . . . . .20

Description

This welder / generator is powered by

an air-cooled four cycle engine and

designed to run at maximum RPM and

give a continuous wattage as rated.

A low-oil level shutoff is provided to

protect the engine. The alternator is

thermostatically protected. To operate

this unit as a generator or welder,

set the switch on the front panel

accordingly.

Unpacking

After unpacking the welder / generator,

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

1-800-543-6400.

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.

NOTE: Information that requires special

attention.

Specifications

ENGINE

Engine Type . . . . .270cc, 4 stroke OHV

Net Power . . . . . . . . . . . . . . . . . . . . 6.0

Ignition System . . Transistor Magneto

Start Mode . . . . . . . . . . . . . . . . Manual

Fuel Capacity . . . . . . . . . . . 1.4 gallons

Oil Capacity . . . . . . . 38.4 fluid ounces

GENERATOR

Type . . . . . . 2 pole, brushless rotating

Phase . . . . . . . . . . . . . . . . . . . . . Single

Continuous Power

Rating (KVA) . . . . . . . . . . . . . . . . . . 4.5

Rated Voltage (V) . . . . . . . . . 120 / 240

WELDER

Max Open Circuit Voltage (V). . . . 62.5

Rated Voltage (V) . . . . . . . . . . . . . 25.6

Rated Current (A) . . . . . . . . . . . . . .140

Max No Load Speed (r/min) . . . . .3850

Current Control Range (A) . . . 60 - 140

Rated Duty Cycle (%) . . . . . . . . . . . .35

Electrode Diameter (mm) . . . . 2.4 - 3.2

IN954000AV 8/08

Need

Assistance?

Call Us First!

1-800-543-6400

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.

For parts, product & service information

visit www.chpower.com or call 1-800-543-6400

REMINDER: Keep your dated proof of purchase for warranty purposes!

Attach it to this manual or file it for safekeeping.

Operating Instructions and Parts Manual GW4500

See Warranty on page 20 for important information about commercial use of this product.

1 2 3 4 5 6 ... 19 20

Summary of Contents

Page 1 - Generator

Welder / GeneratorTable of ContentsDescription . . . . . . . . . . . . . . . . . . . . . .1Unpacking . . . . . . . . . . . . . . . . . . . . . . .1Sa

Page 2 - General Safety Information

10www.chpower.comOperating Instructions and Parts ManualWelding GuidelinesGENERALThis line of welding machines utilizes a process known as Shielded Me

Page 3

11www.chpower.comGW4500Welding Guidelines (Continued)Work angle is the angle from horizontal, measured at right angles to the line of welding.For most

Page 4

12www.chpower.comOperating Instructions and Parts ManualWelding Guidelines (Continued)SLAG REMOVAL Wear ANSI approved safety glasses (ANSI Standar

Page 5 - Glossary of Terms

13www.chpower.comGW4500Troubleshooting Chart - GeneralSymptom Possible Cause(s) Corrective ActionEngine will not start 1. Engine switch is set to &qu

Page 6 - Pre-Operation

14www.chpower.comOperating Instructions and Parts ManualTroubleshooting Chart - WelderSymptom Possible Cause(s) Corrective ActionWelder runs but does

Page 7 - Generator Operation

15www.chpower.comGW4500Welding ImpedanceGen. Weld.RotorRedWhiteBrownBattery Charger12V ACBlueBrownGreyRedBlackWhiteYellowGreenMain WindingBrownRedWhit

Page 8

16www.chpower.comOperating Instructions and Parts Manual12734568910111213141516171819201111112122Figure 12Welder / Generator Assembly

Page 9 - Maintenance

17www.chpower.comGW4500For replacement parts or technical assistance, call 1-800-543-6400 1 Engine - Honda GX270 PM004264AV 1 2 Welded Frame Ass

Page 10 - Welding Guidelines

18www.chpower.comOperating Instructions and Parts Manual1232827262524232221201918171615141312111098765441028Figure 13Alternator Assembly

Page 11 - (Continued)

19www.chpower.comGW4500For replacement parts or technical assistance, call 1-800-543-6400 1 Alternator - 4kW, 140A AC (includes items 2 through 22)

Page 12

2www.chpower.comOperating Instructions and Parts ManualGeneral Safety InformationCALIFORNIA PROPOSITION 65 The cables on this product may contain ch

Page 13

20www.chpower.comOperating Instructions and Parts ManualLimited Warranty1. DURATION: The manufacturer warrants that it will repair, at no charge for

Page 14 - Troubleshooting Chart - Welds

3www.chpower.comGW4500General Safety Information (Continued) Always keep a fire extinguisher accessible while performing arc welding operations. • A

Page 15 - Adjustable

4www.chpower.comOperating Instructions and Parts ManualGeneral Safety Information (Continued) Fire hazard! Do not weld on containers or pipes that c

Page 16 - Welder / Generator Assembly

5www.chpower.comGW4500Getting To Know Your Welder / GeneratorGlossary of TermsAC or Alternating Current - electric current that reverses direction per

Page 17 - Replacement Parts List

6www.chpower.comOperating Instructions and Parts ManualGROUNDING1. Use the ground terminal and wing nut on the welder / generator frame to connect th

Page 18 - Alternator Assembly

7www.chpower.comGW4500combination of 240 volt loads and also with 120 volt loads through the 120 volt receptacles. The 120/240 volt twist lock recepta

Page 19

8www.chpower.comOperating Instructions and Parts ManualGenerator Operation (Continued)INSTALLATION FOR STAND-BY USEPrecautions must be taken to preven

Page 20 - Limited Warranty

9www.chpower.comGW4500Welder Operation (Continued)5. Tighten the set screw, securing the cable in place.6. Slide the insulated handle onto the elect

Comments to this Manuals

No comments

Campbell-hausfeld Welder / Generator GW4500 User Manual

Browse online or download User Manual for Tools Campbell-hausfeld Welder / Generator GW4500. Campbell Hausfeld Welder / Generator GW4500 User Manual

Summary of Contents

Comments to this Manuals

Related products and manuals for Tools Campbell-hausfeld Welder / Generator GW4500