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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 
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 

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 

cables together and secure with 
tape when 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 have other 
health effects which are not known.

 

Always be sure that 

  the welding area 

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.

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.

Содержание Welder / Generator GW4500

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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...

Страница 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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