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GW4502

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 
rating.

5.  Total combined load through any 

combination of receptacle must 
not exceed the rated load limits of 
the welder / generator. Refer to the 
identification plate on the welder / 
generators for amp and wattage 
specifications.

6.  Always shut off and remove loads 

before starting or shutting off the 
welder / generator engine.

7.  When plugging multiple electrical 

load devices into the welder / 
generators receptacles, be sure to 
connect and activate the highest 
power draw item first. Allow 
the welder / generator engine to 
stabilize, then connect and activate 
the next highest power draw 
device. The smallest power draw 
device should be connected to the 
receptacle and activated last.

NOTE:

 Power draw can be calculated 

by multiplying volts and amps. The 
resulting number is wattage.

Never exceed the posted maximum 
wattage for the welder / generator 
or any individual receptacle. Refer to 
owner's manuals and product tags to 
determine the wattage of all electrical 
load devices. 

If actual watt ratings are not available, 
the Power Usage Chart, see Table 1, may 
be used as a general guideline.

Remember that devices which generate 
heat during operation such as heaters, 
incandescent light bulbs, motors and 
hair dryers have a higher power draw 
than devices which generate little heat 
during operation such as florescent 
bulbs, radios, and clocks.

Long power cords and extension cords 
also draw additional power. Keep cords 
at minimum possible length.

Refer to Table 2 for maximum limits for 
lengths of extension cords.

8.  Circuit protection is provided by a 

circuit breaker. The circuit breaker 
opens when the welder / generator 
load exceeds its maximum capacity 
or a short circuit occurs. If the 
circuit breaker opens, perform the 
following procedures to correct the 
problem:

a.  Shut off and disconnect all 

electrical loads.

b. Attempt to determine the cause 

of the electrical problem - 
 overloading or short circuit.

c.  Do not use any devices that have 

short circuits. Avoid overloading 
the welder / generator.

d. Press the circuit breaker 

pushbutton to reset the circuit 
breaker.

 

Repeated cycling of 

  the circuit breaker 

indicates a problem and may cause 
damage to the welder / generators or 
load devices. Do not operate the 
welder / generators if repeated cycling 
of the circuit breaker occurs.

Pre-Operation (Continued)

LOW OIL SHUTDOWN

A low oil shutdown switch is provided 
to protect the engine and welder / 
generators on most extended run 
models. When engine oil level drops 
too low for proper engine operation, 
the low oil shutdown switch causes the 
engine to shut off. If oil level is low 
when  attempting to start the welder / 
generators engine, the low oil level 
shutdown switch prevents the engine 
from starting. If engine does not start, 
check oil level.

NOTE:

 It is important to keep the 

welder / generator unit on a level 
surface. The oil level shutdown switch 
can prevent the engine from starting 
even if oil level is sufficient, when the 
welder / generators unit is placed on an 
uneven surface.

Generator Operation

(FRONT PANEL SWITCH MUST BE SET TO 
GENERATOR POSITION)

LOAD DEVICES

1.  All load devices and extension cords 

should use three prong terminals. 
Refer to Table 2 for extension cord 
and cable size requirements.

2.  Allow the engine to run for 2-

3 minutes before applying any 
electrical loads.

3. The 

120 volt receptacles

 are rated 

for 20 amps and may be used in any 
combination of 120 volt loads and 
also with 240 volt loads through 
the 240 volt receptacles.

 The 

240 volt receptacles

, found on 

some welder / generators, are rated 
for 20 amps and may be used in any 

TABLE 1 - ESTIMATED POWER USAGE (WATTS)

LOAD DEVICE

WATTS

LOAD DEVICE

WATTS

LOAD DEVICE

WATTS

LOAD DEVICE

WATTS

Air conditioner

2000-3000

Electric drill 
(large)

500-1000

Radio

50-200

Toaster

900-1700

Automatic 
washer

150-1500

Fan

40-200

Refrigerator

190-2000

Vacuum cleaner

200-300

Brooder

100+

Freezer

300-500

Skillet

1200

Water pump

1000-3000

Clothes dryer

5000-10,000

Hot plate

330-1100

Space heater

600-4800

Water heater

1000-5000

Coffee maker

400-700

Iron

500-1500

Sump pump

400-3000

Small hand saw

1000-2000

Electric drill 
(small)

225-1000

Light bulb

AS RATED

Television

200-500

Large hand saw

1500-2500

Summary of Contents for GW4502

Page 1: ...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 fitt...

Page 2: ...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 o...

Page 3: ...or duty cycles higher than those specified on the equipment labels Never use an electric arc welder to thaw frozen pipes Flying sparks and hot metal can cause injury As welds cool slag can be thrown...

Page 4: ...possible Never wrap arc welder cables around the body Always position the electrode and work leads so that they are on the same side of the body Exposure to electromagnetic fields during welding may...

Page 5: ...itions T Joint made by placing the edge of one piece of metal on the surface of the other piece at approximately a 90 angle Undercut a condition that results when welding amperage is too high The exce...

Page 6: ...t 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 Engi...

Page 7: ...ads b Attempt to determine the cause of the electrical problem overloading or short circuit c Do not use any devices that have short circuits Avoid overloading the welder generator d Press the circuit...

Page 8: ...clamp block 4 Tighten the hex nuts securing the cable in place ELECTRODE HOLDER SEE FIGURE 2 1 Strip 1 2 inch of insulation from the end of the other welding cable Slide the bare wire into the wire s...

Page 9: ...mperage as needed 6 When finished welding turn engine off and store unit properly DUTY CYCLE THERMOSTATIC PROTECTION Welder duty cycle is the percentage of actual weld time that can occur in a ten min...

Page 10: ...trode does not break loose disengage the electrode by releasing it from the holder ELECTRODE TYPE AND SIZE Four types of electrodes are recommended for this welder The electrodes are commonly known by...

Page 11: ...to stick penetration will be poor and uneven beads with irregular ripples result A proper arc should be no longer than the diameter of the rod The sound of a proper arc is a steady crisp sizzle simil...

Page 12: ...itions require different techniques such as a weaving pass circular pass and jogging A higher skill level is required to complete these welds All work should be performed in the flat position if possi...

Page 13: ...5 Open diodes 6 Front panel switch set incorrectly 7 Circuit breaker tripped 1 Adjust engine speed 2 Referring to the wiring diagram clean and reconnect all wiring 3 Replace capacitor 4 Test winding r...

Page 14: ...proper grounding No paint varnish or corrosion 4 Adjust engine speed These diagnostic and repair procedures should be performed by an authorized service center Troubleshooting Chart Welds Symptom Poss...

Page 15: ...K BLACK GROUND SCREW AT GENWELDER FRAME GROUND SCREW AT ALTERNATOR HOUSING ALTERNATOR 12V WINDING WELDING IMPEDANCE MAIN WINDINGS THERMOSTAT FITTED IN WINDINGS CAPACITOR AUXILIARY WINDING GROUND SCREW...

Page 16: ...chpower com Operating Instructions and Parts Manual Figure 12 Welder Generator Assembly 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 26 8 14 8 11...

Page 17: ...Valve GN051032AV 1 22 Fuel Hose 250 ID 12 in 23 Iso Mount Assembly PM004290AV 3 24 3 8 inch Fender Washer 3 25 Hex Bolt 3 8 16 UNC X 2 1 2 inch 2 26 3 8 16 UNC Flange Nut 4 27 Hex Bolt M8 X 1 25 X 45m...

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: ...nator Fan GW001020SV 1 17 Top Cover GW001002SV 1 18 Dinse Socket 200A WC000300AV 2 19 Commutator Knob Small WC400401AV 1 20 Commutator Output GW001045SV 1 21 Commutator Knob Large GW001046SV 1 22 Comm...

Page 20: ...an implied warranty lasts so above limitations may not apply to you C This warranty does not apply to any accessory items included with the product which are subject to wear from usage the repair or...

Page 21: ...posicione a chave no painel frontal de acordo com a op o desejada Remo o da Embalagem Al desempacar este producto rev selo con cuidado para cerciorarse de que est en perfecto estado N o deixe de apert...

Page 22: ...er opera o diferente daquela especificada pelo fabricante Nunca opere esta m quina de solda gerador em condi es que n o sejam aprovadas pelo fabricante Nunca tente modificar esta m quina de solda gera...

Page 23: ...idade Utilize roupas de prote o adequadas e tome as precau es para evitar ferimentos devido a quedas Nunca tente usar o equipamento em configura es de voltagem ou ciclos de trabalho superiores queles...

Page 24: ...m quina de solda de arco el trico Sempre posicione as extremidades do eletrodo e da pe a a ser soldada para que as mesmas fiquem do mesmo lado do corpo A exposi o aos campos eletromagn ticos durante...

Page 25: ...el e a pe a que est sendo soldada O metal de enchimento pode ser ou pode n o ser usado Junta Sobreposta uma junta entre dois membros sobrepostos em planos paralelos Open Circuit Voltage Tens o de Aber...

Page 26: ...digo Nacional de Eletricidade Outras fontes de aterramento podem ser aceit veis Consulte o National Electric Code e a regulamenta o local para obter maiores informa es a respeito de fontes de aterrame...

Page 27: ...e maior consumo de energia Permita que o motor da m quina de solda gerador se estabilize e em seguida conecte e ative o pr ximo dispositivo de maior consumo de energia O dispositivo de menor consumo d...

Page 28: ...avadas fixando o cabo no lugar SUPORTE DO ELETRODO CONSULTE A FIGURA 2 1 Remova 1 3 cm de isolamento de uma extremidade do outro cabo de solda Deslize o fio desencapado para dentro da luva de fio 2 Af...

Page 29: ...O TERMOST TICA Ciclo de servi o da m quina de solda a porcentagem do tempo real de solda que pode ocorrer em um intervalo de dez minutos Por exemplo a um ciclo de servi o de 10 a soldagem de fato pode...

Page 30: ...a m quina de solda Os eletrodos geralmente s o conhecidos pela sua designa o AWS American Welding Society Sociedade Americana de Soldagem como se segue 1 E 6011 Penetra o em profundidade Filete plano...

Page 31: ...es Um arco adequado n o deve ser de comprimento superior ao di metro da vareta O som de um arco adequado um crepitar constante e r spido similar ao ru do produzido quando se frita bacon VELOCIDADE DE...

Page 32: ...corrida Um n vel de habilidade mais elevado se faz necess rio para executar essas soldas Todo o trabalho deve ser executado na posi o plana se poss vel Para aplica es espec ficas consulte um manual de...

Page 33: ...Enrolamentos de campo abertos ou em curto 5 Diodos abertos 6 Chave do painel dianteiro na posi o incorreta 7 Disjuntor desarmado 1 Ajuste as RPMs do motor 2 Mediante consulta ao diagrama de fia o limp...

Page 34: ...or Estes procedimentos de diagnose e reparos devem ser executados por um centro de servi os autorizado Tabela de Resolu o de Problemas Soldas Sintoma Motivo s Poss vel is A o Corretiva O filete se apr...

Page 35: ...URA GENWELDER PARAFUSO DE ATERRAMENTO NA CARCA A DO ALTERNADOR ALTERNADOR BOBINA DE 12 V IMPED NCIA DE SOLDA BOBINAS PRINCIPAIS TERMOSTATO INSTALADO EM BOBINAS CAPACITOR BOBINA AUXILIAR PARAFUSO DE AT...

Page 36: ...6 Pg Instru es de Uso e Manual de Pe as Figura 12 Conjunto M quina de Solda Gerador 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 26 8 14 8 11 11 1...

Page 37: ...16 18 UNC 3 15 Porca borboleta 5 16 18 UNC 1 16 Tanque de combust vel 22 litros 5 8 gal es GN051030AV 1 17 Parafuso hexagonal 1 4 20 UNC X 2 5 cm 1 polegada 4 18 Arruela do para choque 1 4 20 4 19 Por...

Page 38: ...38 Pg Instru es de Uso e Manual de Pe as Figura 13 Conjunto do Alternador 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...

Page 39: ...1 17 Tampa Superior GW001002SV 1 18 Soquete Dinse 200A WC000300AV 2 19 Bot o de Comutador Pequeno WC400401AV 1 20 Comutador Sa da GW001045SV 1 21 Bot o de Comutador Grande GW001046SV 1 22 Comutador Ge...

Page 40: ...cima podem n o se aplicar sua situa o C Esta garantia n o abrange os acess rios fornecidos com o produto que est o sujeitos a desgaste devido ao uso O reparo e a substitui o desses itens correr o por...

Page 41: ...ento 50 Almacenaje 50 Instrucciones para soldar 50 Gu a de diagn stico de problemas General 53 Generador 54 Soldador 54 Soldaduras 55 Diagrama de cableado 56 Ensamblaje del soldador generador 58 59 En...

Page 42: ...s manuales para referencia futura Nunca haga funcionar este soldadora generador en una atm sfera explosiva o inflamable o en reas con ventilaci n inadecuada Nunca utilice este soldadora generador para...

Page 43: ...e de soldar enrollado antes de usarlo para evitar un sobrecalentamiento y da o al aislamiento Nunca sumerja el electrodo o el porta electrodo en agua Si la soldadora se moja por alg n motivo aseg rese...

Page 44: ...da adecuadamente aseg rese de usar un respirador con tanque de aire Mantenga la cabeza y el rostro alejado de los gases de la soldadura No realice procedimientos de soldadura de arco el ctrico en meta...

Page 45: ...osici n la uni n de dos miembros superpuestos en planos paralelos Voltaje de circuito abierto el voltaje entre el electrodo y la pinza de conexi n a tierra de la soldadora cuando no hay flujo de corri...

Page 46: ...a tierra aprobada A continuaci n se detallan fuentes de descarga a tierra aprobadas por el C digo el ctrico nacional Otras fuentes de descarga a tierra pueden ser aceptables Rem tase al C digo el ctr...

Page 47: ...ado para 20 amperes y puede usarse en cualquier combinaci n de tensi n de 120 y 240 voltios 4 Los recept culos individuales no deben ser cargados por encima de la clasificaci n de amperaje 5 La tensi...

Page 48: ...e debe instalar un interruptor de transferencia de dos v as en el sistema Siempre apague la fuente principal antes de conectar temporalmente el soldadora generador a un sistema el ctrico de un edifici...

Page 49: ...llamas guantes de cuero para soldar y protecci n total en los pies Si calienta suelda o corta materiales galvanizados enchapados en zinc plomo o enchapados en cadmio rem tase a la Secci n de informaci...

Page 50: ...en la soldadora Utilice aire comprimido para soplar toda la suciedad y pelusas de las aberturas de ventilaci n Instrucciones para Soldar GENERAL Esta l nea de m quinas soldadoras utilizan un proceso...

Page 51: ...sulte las especificaciones listadas en el soldador Un amperaje excesivo quema a trav s de metales ligeros y el reborde es chato y poroso Ver Figura 7 El reborde aparece alto e irregular si el amperaje...

Page 52: ...iza con un martillo cincelador Golpee la escoria suavemente con el martillo y desp guela del reborde La limpieza final se realiza con un cepillo de alambre Cuando hacen varios pasos de soldar quite la...

Page 53: ...a 6 La buj a est sucia 7 La buj a est rota 8 La unidad no est sobre una superficie nivelada 9 Tiene poco aceite 1 Ponga el interruptor en la posici n ON encendido 2 Gire la v lvula de combustible a la...

Page 54: ...2 Rem tase al diagrama de cableado limpie y reconecte todo el cableado 3 Quite todas las cargas luego aplique cada una individualmente para determinar cu l es la que est causando el funcionamiento err...

Page 55: ...la pieza de trabajo con la soldadora en la posici n OFF apagada 3 Reduzca el valor del amperaje de salida El reborde no penetra en el metal b sico 1 Velocidad de desplazamiento inconstante 2 Valor del...

Page 56: ...DEL GENERADOR SOLDADOR TORNILLO A TIERRA EN LA CAJA DEL ALTERNADOR ALTERNADOR BOBINADO DE 12 V BOBINADO PRINCIPAL TERMOSTATO INCLUIDO EN BOBINADO CONDENSADOR BOBINADO AUXILIAR TORNILLO A TIERRA EN LA...

Page 57: ...57 Sp Notas GW4502...

Page 58: ...nstrucciones de Operaci n y Lista de Partes 58 Sp Figura 12 Ensamblaje de Soldador Generador 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 26 8 14...

Page 59: ...UNC 3 15 Tuerca de mariposa 5 16 18 UNC 1 16 Tanque de combustible 22 L 5 8 galones GN051030AV 1 17 Perno hexagonal 1 4 20 UNC X 2 5 cm 1 pulg 4 18 Arandela ancha 1 4 20 4 19 Tuerca con reborde 1 4 2...

Page 60: ...Manual de Instrucciones de Operaci n y Lista de Partes 60 Sp Figura 13 Ensamblaje de Alternador 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...

Page 61: ...ador GW001020SV 1 17 Tapa superior GW001002SV 1 18 Empalme Dinse 200A WC000300AV 2 19 Perilla del conmutador peque a WC400401AV 1 20 Conmutador Salida GW001045SV 1 21 Perilla del conmutator grande GW0...

Page 62: ...aplicables en su caso C Esta garant a no se aplica a ning n art culo accesorio incluido con el producto que est sujeto a desgaste por el uso la reparaci n o el reemplazo de estos art culos se realiza...

Page 63: ...Notes Notas 63 GW4502...

Page 64: ...Notes Notas Operating Instructions and Parts Manual Instru es de Uso e Manual de Pe as Manual de Instrucciones de Operaci n y Lista de Partes 64...

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