Welder /
Generator
Table of Contents
Description . . . . . . . . . . . . . . . . . . . . . .1
Unpacking . . . . . . . . . . . . . . . . . . . . . . .1
Safety Guidelines . . . . . . . . . . . . . . . . .1
Specifications. . . . . . . . . . . . . . . . . . . . .1
General Safety Information . . . . . . 2 - 4
Glossary of Terms . . . . . . . . . . . . . . . . .5
Pre-operation . . . . . . . . . . . . . . . . . 6 - 7
Operation . . . . . . . . . . . . . . . . . . . . 7 - 9
Maintenance . . . . . . . . . . . . . . . . . . . . .9
Storage . . . . . . . . . . . . . . . . . . . . . . . . .9
Welding Guidelines. . . . . . . . . . . 10 - 12
Troubleshooting Chart . . . . . . . . 13 - 14
General . . . . . . . . . . . . . . . . . . . . . .13
Generator . . . . . . . . . . . . . . . . . . . .13
Welder . . . . . . . . . . . . . . . . . . . . . .14
Welds . . . . . . . . . . . . . . . . . . . . . . .14
Wiring Diagram. . . . . . . . . . . . . . . . . .15
Welder / Generator Assembly. . . 16 - 17
Alternator Assembly . . . . . . . . . . 18 - 19
Warranty . . . . . . . . . . . . . . . . . . . . . . .20
Description
This welder / generator is powered by
an air-cooled four cycle engine and
designed to run at maximum RPM and
give a continuous wattage as rated.
A low-oil level shutoff is provided to
protect the engine. The alternator is
thermostatically protected. To operate
this unit as a generator 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 fittings, bolts, etc.,
before putting unit into service. Report
any missing items by calling
1-800-543-6400.
Safety Guidelines
This manual contains information
that is very important to know and
understand. This information is
provided for SAFETY and to PREVENT
EQUIPMENT PROBLEMS. To help
recognize this information, observe the
following symbols.
Danger indicates an
imminently
hazardous situation which, if not
avoided, WILL result in death or serious
injury.
Warning indicates a
potentially
hazardous situation which, 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
information, that if not followed, may
cause damage to equipment.
NOTE:
Information that requires special
attention.
Specifications
ENGINE
Engine Type . . . . . 270cc, 4 stroke OHV
Net Power . . . . . . . . . . . . . . . . . . . . 6.0
Ignition System . . Transistor Magneto
Start Mode . . . . . . . . . . . . . . . . Manual
Fuel Capacity . . . . . . . . . . . 1.4 gallons
Oil Capacity . . . . . . . 38.4 fluid ounces
GENERATOR
Type . . . . . . 2 pole, brushless rotating
Phase . . . . . . . . . . . . . . . . . . . . . Single
Continuous Power
Rating (KVA) . . . . . . . . . . . . . . . . . . 4.5
Rated Voltage (V) . . . . . . . . . 120 / 240
WELDER
Max Open Circuit Voltage (V). . . . 62.5
Rated Voltage (V) . . . . . . . . . . . . . 25.6
Rated Current (A) . . . . . . . . . . . . . .140
Max No Load Speed (r/min) . . . . .3850
Current Control Range (A) . . . 60 - 140
Rated Duty Cycle (%) . . . . . . . . . . . .35
Electrode Diameter (mm) . . . . 2.4 - 3.2
IN954000AV 8/08
Q
UA
LIT
Y
A
SSURANCE
P
ROGR
AM
Need
Assistance?
Call Us First!
1-800-543-6400
Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described.
Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or
property damage! Retain instructions for future reference.
For parts, product & service information
visit
www.chpower.com
or call
1-800-543-6400
REMINDER: Keep your dated proof of purchase for warranty purposes!
Attach it to this manual or file it for safekeeping.
© 2008 Campbell Hausfeld/Scott Fetzer
Operating Instructions and Parts Manual
GW4500
See Warranty on page 20 for important information about commercial use of this product.
