Campbell Hausfeld GW4502 User Manual Download

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GW4502

Welder Operation
(Continued)

5. Tighten 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 insulation from the

opposite end of the welding cable.

2. Insert this end of the welding cable

through the dinse plug boot and
slide the bare wire into the wire
sleeve.

3. Insert the welding cable/wire sleeve

assembly into the back of the dinse
plug.

4. Tighten the set screw, securing the

cable in place.

5. Slide the boot over the hex portion

of the dinse plug.

6. Repeat for the other lead.

Welding

1. Verify that the surfaces of metals

to be joined are free from dirt,
rust, paint, oil, scale or other
contaminants. These contaminants
make welding difficult and cause
poor welds.

All

persons

operating this

equipment or in the area while
equipment is in use must wear
protective welding gear including: eye
protection with proper shade (minimum
shade 10), flame resistant clothing,
leather welding gloves, and full foot
protection.

If heating, welding,

or cutting materials

that are galvanized, zinc plated,
lead, or cadmium plated refer to the
General Safety Information Section for
instructions. Extremely toxic fumes are
created when these metals are heated.

2. Connect the work clamp to the

work piece. Make sure the contact
is on bare metal and not obstructed
by paint, varnish, corrosion, or non-
metallic materials.

3. Insert the exposed part of the

electrode (the end with no flux)
into the jaws of the electrode
holder.

4. Set the amperage adjustment knob

to the proper amperage for the
electrode diameter. Refer to the
chart on the front panel for proper
electrode current settings.

The electrode holder

and rod are

electrically “live” (current potential)
when the engine is running.

5. Position the electrode to begin

weld, lower the welding helmet or
position the hand shield, and strike
an arc. Adjust weld amperage 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
minute interval. For example, at a 10%
duty cycle, actual welding can occur for
one minute, then the welder must cool
for nine minutes.

Internal components of this welder are
protected from overheating with an
automatic thermal switch.

Maintenance

INFREQUENT USAGE

If the welder / generator is used
infrequently, starting difficulty may
occur. To help prevent this, the
welder / generators should be run for
approximately 30 minutes per week.

STORAGE

If the welder / generators is not to be
used for extended periods of time,
the following pre-storage procedures
should be performed:

1. Make sure engine oil is filled to the

proper level.

2. Drain all fuel from the tank, lines,

carburetor and fuel valve.

3. Remove the spark plug, and pour

approximately one teaspoon of oil
into the spark plug hole.

4. Pull the starter cord several times

to spread the oil throughout the
cylinder.

5. Slowly pull the starter cord, until

resistance is felt. This indicates that
the piston is moving upward on the
compression cycle, and the intake
and exhaust valves are closed. (The
piston pushes a small amount of
air from the spark plug hole on
compression.)

6. Use of fuel stabilizers or anti-

gumming agents in the fuel system
can help prevent the build up of
gum and varnish.

Whenever the welder / generator is
stored, be sure that the fuel shut-off
valve is in the closed position.

Refer to the engine manual that
accompanies this unit for instructions
regarding maintenance of engine
components.

Never tamper with

engine speed

settings or welder / generators
frequency settings. Any governor
adjustments should be made by
qualified personnel only.

WELD CABLES

1. Check condition of weld cables and

immediately repair or replace any
cables with damaged insulation.

2. Check condition of electrode holder

insulating pieces and immediately
replace cracked or missing parts.