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GW4500

General Safety Information 
(Continued)

 Always 

 keep a 

fire extinguisher accessible 
while performing arc welding 
operations.

 •  All installation, maintenance, repair 

and operation of this equipment 
should be performed by qualified 
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.

 •  Verify that all components of the 

arc welder are clean and in good 
condition prior to operating the 
welder. Be sure that the insulation  
on all cables, electrode holders, 
and power cords is not damaged. 
Always repair or replace damaged 
components before operating 
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, 
wet, rainy, or poorly ventilated 
areas.

 •  Be sure that the work piece is 

properly supported and grounded 
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!

 •  Always shut the equipment off 

prior to moving the unit.

 •  Always attach the work lead first.

 •  Verify that the work piece is 

securely grounded.

 •  Always shut off electric arc welding 

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

 •  Never allow any part of the body to 

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

 •  Awkward welding conditions 

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.

 •  Never attempt to use this 

equipment at current settings 
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 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 

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

 •  Wear ear plugs when welding 

overhead to prevent spatter or slag 
from falling into ears.

 Electric 

 arc 

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.

 •  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.

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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