Campbell Hausfeld GW4500 User Manual

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.

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Welder /

Assistance?

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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

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

Attach it to this manual or file it for safekeeping.

For parts, product & service information

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

IN954000AV 8/08

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 reproductive harm. Wash hands after handling.

The engine exhaust

from this product contains chemicals known to the State of California to cause cancer, birth defects, or other reproductive harm.

This product, when

used for welding, produces fumes or gases which contain chemicals known to the State of California to cause birth defects (or other reproductive harm) and, in some cases, cancer (California Health & Safety Code Section 25249.5 et seq.)

You can create dust when you cut, sand, drill or grind materials such as wood, paint, metal, concrete, cement, or other masonry. This dust often contains chemicals known to cause cancer, birth defects, or other reproductive harm. Wear protective gear.

EMISSIONS

Engines that are

certiﬁ ed to comply with U.S. EPA emission regulations for SORE (Small Off Road Equipment), are certiﬁ ed to operate on regular unleaded gasoline, and may include the following emission control systems: (EM) Engine Modiﬁ cations 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.

GENERAL SAFETY

• Before starting or servicing any welder / generator, read

MANUAL

and understand all instructions. Failure to follow safety precautions or instructions can 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.

Never

operate this welder / generator in an explosive or flammable atmosphere or poorly ventilated area.

• Never use this welder / generator

for any application other than that specified by the manufacturer. Never operate this welder / generator under conditions not approved by the manufacturer. Never attempt to modify this welder / generator to perform in any manner not intended by the manufacturer.

• For maintenance and repairs,

use only products and parts recommended by the manufacturer.

• Be sure that the welder / generator

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 welder / generator

is operated only by persons who have read and understand these instructions.

• Be sure that the welder / generator

is placed on a flat level surface prior to and during operation. The welder / generator must not slide or shift during operation.

• Keep all persons away from

the welder / generator during operation.

• Do not allow persons wearing

loose clothing or jewelry to start or operate the welder / generator. 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.

• Be sure all powered devices are shut off prior to connecting them to the welder / generator.

• Keep the welder / generator clean and well maintained at all times.

• 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.

Do not operate this

welder / generator

on wet surfaces or in the rain.

Shut off the engine

and disconnect the spark plug wire before performing any service or maintenance to the unit.

• 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.

• This welder / generator 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.

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.

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GW4500

General Safety Information (Continued)

Always

keep a fire extinguisher accessible while performing arc welding operations.

• Always attach the work lead first.

• Verify that the work piece is

• Always shut off electric arc welding

• All installation, maintenance, repair

and operation of this equipment should be performed by qualified

• Never allow any part of the body to

persons only in accordance with national, state, and local codes.

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.

• Awkward welding conditions

• Verify that all components of the

arc welder are clean and in good condition prior to operating the welder. Be sure that the insulation

• Never attempt to use this on all cables, electrode holders, and power cords is not damaged. Always repair or replace damaged components before operating

• Never use an electric arc welder to the welder. Always keep welder

panels, shields, etc. in place when operating the welder.

• Always wear dry protective clothing and welding gloves, and insulated footwear.

• Always operate the welder in a clean, dry, well ventilated area. Do not operate the welder in humid,

Flying

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 approved face shield wet, rainy, or poorly ventilated areas.

• Be sure that the work piece is properly supported and grounded

• Wear ear plugs when welding 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 welder becomes wet for any reason, be absolutely certain that it is completely clean and dry prior to attempting use!

Electric

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.

• Always shut the equipment off

prior to moving the unit.

securely grounded.

equipment when not in use and remove the electrode from the holder.

touch the electrode and ground or grounded work piece at the same time.

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.

equipment at current settings or duty cycles higher than those specified on the equipment labels.

thaw frozen pipes.

sparks

or safety glasses with side shield protection when chipping or grinding metal parts.

overhead to prevent spatter or slag from falling into ears.

arc

• 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 all flammable materials

within 35 feet (10.7 meters) of welding arc. If removal is not possible, tightly cover flammable materials with fire proof covers.

• Take precautions to be sure that

flying sparks and heat do not cause flames in hidden areas, cracks, behind bulkheads, etc.

• Do not use any part of the unit as a

work surface.

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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! 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 air-supplied respirator.

• Keep the head and face 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

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

• Never wrap arc welder cables

• Always position the electrode and

• Exposure to electromagnetic fields

Always be sure that

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.

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

cables together and secure with tape when possible.

around the body.

work leads so that they are on the same side of the body.

during welding may have other health effects which are not known.

the welding area

ADDITIONAL SAFETY STANDARDS

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, Batterymarch Park, Quicy, MA 02269

Safe Practices For Occupational And Educational Eye And Face Protection

ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018 Refer to the Material Safety Data Sheets and the manufacturers instructions for metals, electrodes, coatings and cleaners.

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GW4500

Getting To Know Your Welder / Generator

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 non-consumable 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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Operating Instructions and Parts Manual

Pre-Operation

LOCATION

Selecting the proper location can significantly increase performance, reliability and life of the arc welder.

• For best results locate the welder /

generator in an environment that is

clean and dry. Dust and dirt in the

unit retain moisture and increase

wear of moving parts.

• Store electrodes in a clean, dry

location with low humidity to

preserve the flux coating.

INSTRUCTIONS

1. Check engine oil level. Oil is NOT

mixed with the gasoline, however

adequate oil supply is necessary for

proper engine lubrication. Refer to

the Engine Manual for SAE, API and

fill quantity specifications. Unit is

shipped without oil in engine.

2. Use of a Ground Fault Interrupter

(GFI) is strongly recommended.

Ground Fault Interrupters can

significantly reduce the possibility

of injury if an electrical short occurs.

In order to install a GFI, the

welder / generators neutral wire

must be internally grounded to the

welder / generators frame, and the

frame must be properly grounded

to the earth.

A Ground Fault

Interrupter may not be effective if used on a welder / generators that is not grounded! Refer to the section entitled Grounding for proper steps to ground the welder / generator.

3. When installing a GFI, be sure

to follow all national and local regulations. If not sure of regulations or procedures, obtain assistance from a qualified (licensed or certified) electrical technician.

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 ground wire end terminal.

2. The ground wire should be made of #8 gauge wire. Do not use wire with a higher gauge number. Higher gauge numbers indicate thinner wire, which may not provide an adequate ground path.

3. The other end of the ground wire must be securely fastened to an approved ground source.

The following are ground sources approved by the National Electric Code. Other ground sources may be acceptable. Refer to the National Electric Code and local regulations for further ground source information. If not sure of regulations or procedures, obtain assistance from a qualified (licensed or certified) electrical technician.

a. An underground water pipe at

least ten feet in length

b. A non-corrosive underground

pipe at least eight feet in length and 3/4 inch diameter

c. A steel or iron underground rod

at least eight feet in length and 5/8 inch diameter

d. A non-ferrous rod at least

eight feet in length, 1/2 inch in diameter, and approved for grounding purposes

Any rod or pipe used for grounding must be driven to eight feet deep or buried in the deepest possible trench.

STARTING

1. Remove all electrical loads from the welder / generators.

2. Move fuel shut-off lever as far as possible to the right to enable fuel flow.

3. Rotate the engine switch to the ON position.

4. Adjust the choke lever as follows:

a. For cold engine, move the choke

lever as far as possible to the left, choke fully ON, position.

b. For warm / hot engine, move the

choke lever midway between the choke and run positions.

5. Pull the starter rope with a brisk, smooth motion. NOTE: Some models may be equipped with an electric starter. For models equipped with an electric starter, turn the key.

6. After each start up, allow the engine to run for 2-3 minutes with no load.

7. As the engine warms up and stabilizes, adjust the choke lever to the right, until the lever is positioned as far as possible to the right.

Engine speed is

preset to provide proper output voltage. Never attempt to modify or adjust engine speed or output voltage.

ENGINE BREAK-IN

After initial start-up, the engine should be broken in according to the manufacturer's instructions. Refer to the engine manual for the proper break-in procedure.

SHUT-OFF

1. Shut off and remove all electrical

load devices from the welder / generator.

2. Allow the engine to run for 2-3

minutes with no electrical loads.

3. Rotate the engine switch to the OFF

position.

4. Verify that the welder / generator

has completely stopped.

5. Close the fuel supply valve.

6. Allow the unit to cool before

installing any covers.

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