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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 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 
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.

MANUAL

Summary of Contents for Welder / Generator GW4500

Page 1: ...ich 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 in...

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: ...ator Welder Power Switch 2 4 6 8 10 12 14 16 18 20 22 24 1 3 5 7 9 11 13 15 17 19 21 23 Capacitor Thermal Trip Fitted Inside the Windings Violet Black Blue Grey Red Brown Yellow Orange Auxiliary Windi...

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: ...3811AJ 1 13 Hex head Screw 5 16 18 x 1 1 4 inch 1 14 Flat Washer 5 16 inch ID 2 15 Wing Nut 5 16 18 1 16 Ground Clamp WC100100AV 1 17 Electrode Holder WC200200AV 1 18 Dinse Plug WC000200AV 2 19 Weldin...

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: ...Alternator 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 2...

Page 20: ...g 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...

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