Campbell Hausfeld Welding System GW4500 User Manual

See Warranty on page 20 for important information about commercial use of this product.  
Operating Instructions and Parts Manual  
GW4500  
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.  
Need  
Welder /  
Assistance?  
Call Us First!  
1-800-543-6400  
Generator  
Unpacking  
Table of Contents  
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  
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  
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.  
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  
Troubleshooting Chart . . . . . . . . 13 - 14  
General. . . . . . . . . . . . . . . . . . . . . .13  
Generator. . . . . . . . . . . . . . . . . . . .13  
Welder . . . . . . . . . . . . . . . . . . . . . .14  
Welds . . . . . . . . . . . . . . . . . . . . . . .14  
Danger indicates an  
imminently  
hazardous situation which, if not  
avoided, WILL result in death or serious  
injury.  
Wiring Diagram. . . . . . . . . . . . . . . . . .15  
Welder / Generator Assembly. . . 16 - 17  
Alternator Assembly. . . . . . . . . . 18 - 19  
Warranty . . . . . . . . . . . . . . . . . . . . . . .20  
Warning indicates a  
potentially  
hazardous situation which, if not  
avoided, COULD result in death or  
serious injury.  
GENERATOR  
Type . . . . . . 2 pole, brushless rotating  
Phase . . . . . . . . . . . . . . . . . . . . . Single  
Continuous Power  
Rating (KVA) . . . . . . . . . . . . . . . . . . 4.5  
Rated Voltage (V) . . . . . . . . . 120 / 240  
Caution indicates a  
potentially  
hazardous situation which, if not  
avoided, MAY result in minor or  
moderate injury.  
Description  
WELDER  
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.  
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  
Notice indicates  
important  
information, that if not followed, may  
cause damage to equipment.  
NOTE: Information that requires special  
attention.  
REMINDER: Keep your dated proof of purchase for warranty purposes!  
Attach it to this manual or file it for safekeeping.  
For parts, product & service information  
© 2008 Campbell Hausfeld/Scott Fetzer  
IN954000AV 8/08  
visit www.chpower.com or call 1-800-543-6400  
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GW4500  
General Safety Information  
(Continued)  
All persons operating this  
Always attach the work lead first.  
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.  
Verify that the work piece is  
securely grounded.  
Always  
keep a  
fire extinguisher accessible  
while performing arc welding  
operations.  
Always shut off electric arc welding  
equipment when not in use and  
remove the electrode from the  
holder.  
All installation, maintenance, repair  
and operation of this equipment  
should be performed by qualified  
persons only in accordance with  
national, state, and local codes.  
Never allow any part of the body to  
touch the electrode and ground or  
grounded work piece at the same  
time.  
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.  
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.  
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.  
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.  
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.  
Never attempt to use this  
equipment at current settings  
or duty cycles higher than those  
specified on the equipment labels.  
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 use an electric arc welder to  
thaw frozen pipes.  
Flying  
sparks  
Never touch work pieces until  
completely cooled.  
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.  
Always wear dry protective clothing  
and welding gloves, and insulated  
footwear.  
Heat and  
sparks  
produced during electric arc  
welding and other metal  
Always operate the welder in a  
clean, dry, well ventilated area. Do  
not operate the welder in humid,  
wet, rainy, or poorly ventilated  
areas.  
working operations can ignite  
flammable and explosive materials! Take  
all precautions described in this manual  
to reduce the possibility of flames and  
explosions.  
Wear ANSI approved face shield  
or safety glasses with side shield  
protection when chipping or  
grinding metal parts.  
Be sure that the work piece is  
properly supported and grounded  
prior to beginning any electric arc  
welding operation.  
Wear ear plugs when welding  
overhead to prevent spatter or slag  
from falling into ears.  
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.  
Electric  
arc  
Coiled welding cable should be  
spread out before use to avoid  
overheating and damage to  
insulation.  
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.  
Take precautions to be sure that  
flying sparks and heat do not cause  
flames in hidden areas, cracks,  
behind bulkheads, etc.  
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!  
Do not use any part of the unit as a  
work surface.  
Always shut the equipment off  
prior to moving the unit.  
3
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Operating Instructions and Parts Manual  
ADDITIONAL SAFETY STANDARDS  
General Safety Information  
(Continued)  
The  
ANSI Standard Z49.1 from American  
Welding Society, 550 N.W. LeJune Rd.  
Miami, FL 33126  
electromagnetic field that  
is generated during arc  
Fire  
hazard!  
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.  
Do not weld on containers  
or pipes that contain or  
have contained flammable  
materials or gaseous or liquid  
combustibles.  
Safety and Health Standards  
OSHA 29 CFR 1910, from Superintendent  
of Documents, U.S. Government Printing  
Office, Washington, D.C. 20402  
Arc  
National Electrical Code  
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.  
Route the electrode and work  
cables together and secure with  
tape when possible.  
NFPA Standard 70, from National Fire  
Protection Association, Batterymarch  
Park, Quincy, MA 02269  
Never wrap arc welder cables  
around the body.  
Safe Handling of Compressed Gases in  
Cylinders  
Always position the electrode and  
work leads so that they are on  
the same side of the body.  
CGA Pamphlet P-1, from Compressed  
Gas Association, 1235 Jefferson Davis  
Highway, Suite 501, Arlington, VA 22202  
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.  
Exposure to electromagnetic fields  
during welding may have other  
health effects which are not known.  
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  
Always be sure that  
the welding area  
Keep the head and face out of the  
welding fumes.  
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.  
Cutting And Welding Processes  
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:  
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.  
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.  
4
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GW4500  
Flux Cored Arc Welding (FCAW) -  
also called Gasless, is a welding process  
used with a wire-feed welding machine. other contaminants while the weld is  
The weld wire is tubular with flux  
Slag - a layer of flux soot that  
protects the weld from oxides and  
Getting To Know Your  
Welder / Generator  
Glossary of Terms  
AC or Alternating Current - electric  
current that reverses direction  
periodically. Sixty cycle current travels in  
both directions sixty times per second.  
solidifying (cooling). Slag should be  
removed after weld has cooled.  
material contained inside for shielding.  
Gas Metal Arc Welding (GMAW) -  
also called MIG, is a welding process  
used with a wire feed welding machine.  
The wire is solid and an inert gas is used  
for shielding.  
Spatter - metal particles thrown from  
the weld which cool and harden on the  
work surface. Spatter can be minimized  
by using a spatter resistant spray on the  
work piece before welding.  
Arc Length - the distance from the  
end of the electrode to the point where  
the arc makes contact with the work  
surface.  
Gas Tungsten Arc Welding (GTAW) -  
also called TIG, is a welding process used proper alignment until final welds are  
Tack Weld - weld made to hold parts in  
Base Metal - the material to be  
welded.  
with welding equipment with a high  
frequency generator. The arc is created  
between a non-consumable tungsten  
electrode and the work piece. Filler  
metal may or may not be used.  
made.  
Travel Angle - the angle of the  
electrode in the line of welding. It varies  
from 5º to 45º depending on welding  
conditions.  
Butt Joint - a joint between two  
members aligned approximately in the  
same plane.  
Lap Joint - a joint between two  
overlapping members in parallel planes.  
Crater - a pool, or pocket, that is  
formed as the arc comes in contact with  
the base metal.  
T Joint - made by placing the edge of  
one piece of metal on the surface of  
the other piece at approximately a 90º  
angle.  
Open Circuit Voltage (OCV) - the  
voltage between the electrode and the  
work clamp of the welding machine  
when no current is flowing (not  
welding). The OCV determines how  
quickly the arc is struck.  
DC or Direct Current - electric current  
which flows only in one direction.  
The polarity (+ or -) determines which  
direction the current is flowing.  
Undercut - a condition that results  
when welding amperage is too high.  
The excessive amperage leaves a groove  
in the base metal along both sides of  
the bead which reduces the strength of  
the weld.  
DC Reverse Polarity - occurs when the  
electrode holder is connected to the  
positive pole of the welding machine.  
Reverse Polarity directs more heat  
into melting the electrode rather than  
the work piece. It is used on thinner  
material.  
Overlap - occurs when the amperage is  
set too low. In this instance, the molten  
metal falls from the electrode without  
actually fusing into the base metal.  
Weld Pool or Puddle - a volume of  
molten metal in a weld prior to its  
solidification as weld metal.  
Porosity - gas pockets, or cavities,  
formed during weld solidification. They  
weaken the weld.  
Weld Bead - a narrow layer or layers of  
metal deposited on the base metal as  
the electrode melts. Weld bead width  
is typically twice the diameter of the  
electrode.  
DC Straight Polarity - occurs when  
the electrode holder is connected to the  
negative pole of the welding machine.  
With straight polarity more heat is  
directed to the work piece for better  
penetration on thicker material.  
Penetration - the depth into the work  
piece that has been heat effected by  
the arc during the welding process. A  
good weld achieves 100% penetration  
meaning that the entire thickness of  
the work piece has been heated and  
resolidified. The heat effected area  
should be easily seen on the opposite  
side of the weld.  
Work Angle - the angle of the  
electrode from horizontal, measured at  
right angles to the line of welding.  
Electrode - a coated metal wire having  
approximately the same composition as  
the material being welded.  
Fillet Weld - approximately a triangle  
in cross-section, joining two surfaces at  
right angles to each other in a lap, T or  
corner joint.  
Shielded Metal Arc Welding  
(SMAW) - also called Stick, is a welding  
process that uses a consumable  
electrode to support the arc. Shielding  
is achieved by the melting of the flux  
coating on the electrode.  
Flux - a coating, when heated, that  
produces a shielding gas around the  
welding area. This gas protects the  
parent and filler metals from impurities  
in the air.  
5
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Operating Instructions and Parts Manual  
GROUNDING  
3. Rotate the engine switch to the ON  
position.  
Pre-Operation  
1. Use the ground terminal and wing  
nut on the welder / generator frame  
to connect the unit to a suitable  
ground source. Securely fasten the  
end terminal of the ground wire to  
the ground terminal on the  
LOCATION  
4. Adjust the choke lever as follows:  
Selecting the proper location can  
significantly increase performance,  
reliability and life of the arc welder.  
a. For cold engine, move the choke  
lever as far as possible to the left,  
choke fully ON, position.  
For best results locate the welder /  
generator in an environment that is  
clean and dry. Dust and dirt in the  
unit retain moisture and increase  
wear of moving parts.  
b. For warm / hot engine, move the  
choke lever midway between the  
choke and run positions.  
welder / generators frame. Tighten  
the washer and wing nut on top of  
the ground wire end terminal.  
2. The ground wire should be made  
of #8 gauge wire. Do not use wire  
with a higher gauge number.  
5. Pull the starter rope with a brisk,  
smooth motion.  
Store electrodes in a clean, dry  
location with low humidity to  
preserve the flux coating.  
NOTE: Some models may be  
equipped with an electric starter.  
For models equipped with an  
electric starter, turn the key.  
Higher gauge numbers indicate  
thinner wire, which may not  
provide an adequate ground path.  
INSTRUCTIONS  
1. Check engine oil level. Oil is NOT  
mixed with the gasoline, however  
adequate oil supply is necessary for  
proper engine lubrication. Refer to  
the Engine Manual for SAE, API and  
fill quantity specifications. Unit is  
shipped without oil in engine.  
3. The other end of the ground wire  
must be securely fastened to an  
approved ground source.  
6. After each start up, allow the  
engine to run for 2-3 minutes with  
no load.  
The following are ground sources  
approved by the National Electric  
Code. Other ground sources may be  
acceptable. Refer to the National  
Electric Code and local regulations for  
further ground source information. If  
not sure of regulations or procedures,  
obtain assistance from a qualified  
(licensed or certified) electrical  
technician.  
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.  
2. Use of a Ground Fault Interrupter  
(GFI) is strongly recommended.  
Ground Fault Interrupters can  
significantly reduce the possibility  
of injury if an electrical short occurs.  
In order to install a GFI, the  
Engine speed is  
preset to provide  
proper output voltage. Never attempt  
to modify or adjust engine speed or  
output voltage.  
welder / generators neutral wire  
must be internally grounded to the  
welder / generators frame, and the  
frame must be properly grounded  
to the earth.  
ENGINE BREAK-IN  
a. An underground water pipe at  
least ten feet in length  
b. A non-corrosive underground  
pipe at least eight feet in length  
and 3/4 inch diameter  
c. A steel or iron underground rod  
at least eight feet in length and  
5/8 inch diameter  
d. A non-ferrous rod at least  
eight feet in length, 1/2 inch  
in diameter, and approved for  
grounding purposes  
After initial start-up, the engine  
should be broken in according to the  
manufacturer's instructions. Refer to the  
engine manual for the proper break-in  
procedure.  
A Ground Fault  
Interrupter may  
not be effective if used on a welder /  
generators that is not grounded! Refer  
to the section entitled Grounding for  
proper steps to ground the welder /  
generator.  
SHUT-OFF  
1. Shut off and remove all electrical  
load devices from the welder /  
generator.  
3. When installing a GFI, be sure  
to follow all national and  
2. Allow the engine to run for 2-3  
minutes with no electrical loads.  
local regulations. If not sure of  
regulations or procedures, obtain  
assistance from a qualified (licensed  
or certified) electrical technician.  
Any rod or pipe used for grounding  
must be driven to eight feet deep or  
buried in the deepest possible trench.  
3. Rotate the engine switch to the OFF  
position.  
4. Verify that the welder / generator  
has completely stopped.  
STARTING  
1. Remove all electrical loads from the  
welder / generators.  
5. Close the fuel supply valve.  
6. Allow the unit to cool before  
installing any covers.  
2. Move fuel shut-off lever as far as  
possible to the right to enable fuel  
flow.  
6
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GW4500  
combination of 240 volt loads and  
also with 120 volt loads through  
the 120 volt receptacles.  
If actual watt ratings are not available,  
the Power Usage Chart, see Table 1, may  
be used as a general guideline.  
Pre-Operation (Continued)  
LOW OIL SHUTDOWN  
A low oil shutdown switch is provided  
to protect the engine and welder /  
generators on most extended run  
models. When engine oil level drops  
too low for proper engine operation,  
the low oil shutdown switch causes the  
engine to shut off. If oil level is low  
when attempting to start the welder /  
generators engine, the low oil level  
shutdown switch prevents the engine  
from starting. If engine does not start,  
check oil level.  
The 120/240 volt twist lock  
receptacle, found on some welder /  
generators, is rated for 20 amps and incandescent light bulbs, motors and  
may be used in any combination of  
120 volt and 240 volt loads.  
Remember that devices which generate  
heat during operation such as heaters,  
hair dryers have a higher power draw  
than devices which generate little heat  
during operation such as florescent  
bulbs, radios, and clocks.  
4. Individual receptacles should not  
be loaded beyond the amperage  
rating.  
Long power cords and extension cords  
also draw additional power. Keep cords  
at minimum possible length.  
5. Total combined load through any  
combination of receptacle must  
not exceed the rated load limits of  
the welder / generator. Refer to the  
identification plate on the welder /  
generators for amp and wattage  
specifications.  
Refer to Table 2 for maximum limits for  
lengths of extension cords.  
NOTE: It is important to keep the  
welder / generator unit on a level  
surface. The oil level shutdown switch  
can prevent the engine from starting  
even if oil level is sufficient, when the  
welder / generators unit is placed on an  
uneven surface.  
8. Circuit protection is provided by a  
circuit breaker. The circuit breaker  
opens when the welder / generator  
load exceeds its maximum capacity  
or a short circuit occurs. If the  
circuit breaker opens, perform the  
following procedures to correct the  
problem:  
6. Always shut off and remove loads  
before starting or shutting off the  
welder / generator engine.  
7. When plugging multiple electrical  
load devices into the welder /  
Generator Operation  
(FRONT PANEL SWITCH MUST BE SET TO  
GENERATOR POSITION)  
generators receptacles, be sure to  
connect and activate the highest  
power draw item first. Allow  
the welder / generator engine to  
stabilize, then connect and activate  
the next highest power draw  
device. The smallest power draw  
device should be connected to the  
receptacle and activated last.  
a. Shut off and disconnect all  
electrical loads.  
LOAD DEVICES  
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 breaker  
pushbutton to reset the circuit  
breaker.  
1. All load devices and extension cords  
should use three prong terminals.  
Refer to Table 2 for extension cord  
and cable size requirements.  
2. Allow the engine to run for 2-  
3 minutes before applying any  
electrical loads.  
NOTE: Power draw can be calculated  
by multiplying volts and amps. The  
resulting number is wattage.  
3. The 120 volt receptacles are rated  
for 20 amps and may be used in any  
combination of 120 volt loads and  
also with 240 volt loads through  
the 240 volt receptacles.  
Repeated cycling of  
the circuit breaker  
Never exceed the posted maximum  
wattage for the welder / generator  
or any individual receptacle. Refer to  
owner's manuals and product tags to  
determine the wattage of all electrical  
load devices.  
indicates a problem and may cause  
damage to the welder / generators or  
load devices. Do not operate the  
welder / generators if repeated cycling  
of the circuit breaker occurs.  
The 240 volt receptacles, found on  
some welder / generators, are rated  
for 20 amps and may be used in any  
TABLE 1 - ESTIMATED POWER USAGE (WATTS)  
LOAD DEVICE  
WATTS  
LOAD DEVICE  
WATTS  
LOAD DEVICE  
WATTS  
LOAD DEVICE  
WATTS  
Air conditioner  
2000-3000  
Electric drill  
(large)  
500-1000  
Radio  
50-200  
Toaster  
900-1700  
Automatic  
washer  
150-1500  
100+  
Fan  
40-200  
Refrigerator  
190-2000  
Vacuum cleaner  
200-300  
Brooder  
Freezer  
300-500  
330-1100  
500-1500  
AS RATED  
Skillet  
1200  
Water pump  
1000-3000  
1000-5000  
1000-2000  
1500-2500  
Clothes dryer  
Coffee maker  
5000-10,000 Hot plate  
Space heater  
Sump pump  
Television  
600-4800  
400-3000  
200-500  
Water heater  
Small hand saw  
Large hand saw  
400-700  
Iron  
Electric drill  
(small)  
225-1000  
Light bulb  
7
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Operating Instructions and Parts Manual  
Generator Operation  
(Continued)  
Welder Operation  
(FRONT PANEL SWITCH MUST BE SET TO  
WELDER POSITION)  
INSTALLATION FOR STAND-BY USE  
Precautions must be taken to prevent  
electrical back feeding into utility  
systems. This requires isolation of  
the electrical system. To isolate the  
electrical system, perform the following  
procedures:  
WELDING LEAD ASSEMBLIES  
Welding leads assemblies are not  
included with all units. Use copper  
welding cables in the size specified in  
Table 3.  
GROUND CLAMP (SEE FIGURE 1)  
1. Strip 1/2 inch of insulation from the  
end of one of the welding cables.  
1. Turn off the main electrical system  
switch prior to connecting the  
welder / generators.  
2. Loosen hex nuts on work clamp.  
2. In accordance with national and  
local standards, a double throw  
transfer switch must be installed in  
the system.  
3. Insert the end of the welding cable  
through clamp handle and slide the  
bare wire under the clamp block.  
Figure 1  
Wire Handle  
Sleeve  
4. Tighten the hex nuts, securing the  
cable in place.  
Welding  
Cable  
Always shut off  
main power prior to  
temporary connection of the welder /  
generators to a building electrical  
system.  
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  
sleeve.  
Cable Setscrew  
Handle Phillips Head Screw  
Installation of the  
welder / generator  
as a backup electrical source must be  
performed by a qualified (licensed or  
certified) electrical technician.  
Electrode Holder  
Figure 2  
2. Loosen the phillips head screw  
a few turns. Do not remove it  
completely. Pull the insulated  
handle off of the electrode holder,  
and slide it over the welding cable.  
3. Loosen the set screw on the bottom  
of the electrode holder.  
4. Insert the welding cable / wire  
sleeve into the back of the brass  
body of the electrode holder.  
TABLE 2 - EXTENSION CORDS  
Maximum Recommended Lengths (in feet)  
Amps  
2.5  
5
Watts 120 V  
300  
Watts 240 V  
600  
#8 Wire  
#10 Wire  
1000  
500  
#12 Wire  
600  
#14 Wire  
375  
#16 Wire  
250  
600  
1200  
300  
200  
125  
7.5  
10  
900  
1800  
350  
200  
125  
100  
1200  
1800  
2400  
3000  
3600  
4800  
2400  
250  
150  
100  
50  
15  
3600  
150  
100  
65  
20  
4800  
175  
150  
125  
90  
125  
75  
50  
25  
6000  
100  
60  
30  
7200  
65  
40  
9600  
TABLE 3 - WELDING CABLES  
Total Cable Length *  
0 - 20 feet (0 - 6 m)  
20 - 40 feet (6 - 12 m)  
40 - 60 feet (12 - 18 m)  
Maximum Welding Current  
Recommended Sizes of Copper Welding Cables  
6 AWG (15 mm2)  
100 A  
150 A  
200 A  
250 A  
6 AWG (15 mm2)  
6 AWG (15 mm2)  
4 AWG (20 mm2)  
3 AWG (25 mm2)  
4 AWG (20 mm2)  
2 AWG (35 mm2)  
1 AWG (40 mm2)  
1/0 AWG (55 mm2)  
3 AWG (25 mm2)  
2 AWG (35 mm2)  
2 AWG (35 mm2)  
* Total cable length is the sum of the ground and electrode cable lengths.  
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GW4500  
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.  
STORAGE  
Welder Operation  
(Continued)  
5. Tighten the set screw, securing the  
cable in place.  
If the welder / generators is not to be  
used for extended periods of time,  
the following pre-storage procedures  
should be performed:  
6. Slide the insulated handle onto  
the electrode holder and tighten  
the phillips head screw. Do not  
overtighten the phillips head  
screw. Overtightening will  
1. Make sure engine oil is filled to the  
proper level.  
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.  
2. Drain all fuel from the tank, lines,  
carburetor and fuel valve.  
damage the insulated handle.  
3. Remove the spark plug, and pour  
approximately one teaspoon of oil  
into the spark plug hole.  
DINSE PLUGS (SEE FIGURE 3)  
1. Strip 1/2 inch of insulation from the  
opposite end of the welding cable.  
3. Insert the exposed part of the  
electrode (the end with no flux)  
into the jaws of the electrode  
holder.  
4. Pull the starter cord several times  
to spread the oil throughout the  
cylinder.  
2. Insert this end of the welding cable  
through the dinse plug boot and  
slide the bare wire into the wire  
sleeve.  
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.  
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.)  
3. Insert the welding cable/wire sleeve  
assembly into the back of the dinse  
plug.  
The electrode holder  
and rod are  
electrically “live” (current potential)  
when the engine is running.  
4. Tighten the set screw, securing the  
cable in place.  
5. Slide the boot over the hex portion  
of the dinse plug.  
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. Use of fuel stabilizers or anti-  
gumming agents in the fuel system  
can help prevent the build up of  
gum and varnish.  
6. Repeat for the other lead.  
Boot  
Set Screw  
Whenever the welder / generator is  
stored, be sure that the fuel shut-off  
valve is in the closed position.  
Welding  
Cable  
6. When finished welding, turn  
engine off and store unit properly.  
Refer to the engine manual that  
accompanies this unit for instructions  
regarding maintenance of engine  
components.  
DUTY CYCLE / THERMOSTATIC  
PROTECTION  
Wire Sleeve  
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.  
Dinse Plug  
Figure 3  
Never tamper with  
engine speed  
settings or welder / generators  
frequency settings. Any governor  
adjustments should be made by  
qualified personnel only.  
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.  
Internal components of this welder are  
protected from overheating with an  
automatic thermal switch.  
WELD CABLES  
1. Check condition of weld cables and  
immediately repair or replace any  
cables with damaged insulation.  
Maintenance  
INFREQUENT USAGE  
All persons  
operating this  
2. Check condition of electrode holder  
insulating pieces and immediately  
replace cracked or missing parts.  
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.  
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.  
EVERY 3 MONTHS  
Replace any unreadable labels on the  
welder. Use compressed air to blow  
all dust and lint from the ventilation  
openings.  
9
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Operating Instructions and Parts Manual  
STRIKING AN ARC  
3. E-7014 Fast fill  
Welding Guidelines  
GENERAL  
Place the bare end of the electrode in  
the holder. Grip the holder lightly to  
reduce tiring of the hand and arm.  
Smooth bead and fast deposition  
This line of welding machines utilizes  
a process known as Shielded Metal-Arc  
Welding (SMAW). This process is used  
to bond metals by heating them with  
an electric arc created between the  
electrode and the work piece.  
Ideal for joints with poor fitup and  
general repair work.  
NOTE: Always keep the jaws of the  
holder clean to insure good electrical  
contact with the electrode.  
4. E-7018-AC High Strength  
Ideal for pipes and structural  
applications.  
Be careful not to  
touch the work piece  
Low hydrogen reduces porosity for  
a strong weld.  
Electrodes used for shielded metal arc  
welding have two parts. The inner  
core is a metal rod or wire that should  
be similar in composition to the base  
metal. The outer coating is called  
flux. Various types of flux exist. Each  
coating is used for a particular welding  
situation.  
or welding bench with the electrode as  
this causes arc flashes.  
NOTE: Only the E-7018-AC electrode  
is recommended for use with these  
welders. Other E-7018 electrodes are  
designed for use with higher open  
circuit voltages than these welders are  
capable of producing. Recommended  
electrode diameter is 3/32 inch or 1/8  
inch.  
The best method of striking an arc is the  
scratching method. Drag the electrode  
at an angle along the surface much like  
striking a match. Upon contact with the  
plate, lift the electrode approximately  
1/16” off the surface or it will stick (See  
Figure 5).  
While the metal is molten, it can be  
contaminated by elements in the air.  
This contamination could weaken  
the weld. The flux coating creates  
a protective barrier called slag that  
protects the molten metal from  
contaminants.  
NOTE: Should the electrode stick to the  
work piece, break it loose by quickly  
twisting or bending at the holder  
while pulling upward. If the electrode  
does not break loose, disengage the  
electrode by releasing it from the  
holder.  
ARC WELDING BASICS  
Four basic techniques affect weld  
quality. These are: amperage setting,  
weld angle, arc length, and travel  
speed. Proper use of these techniques is  
necessary for good weld quality.  
When current (amperage) flows  
through the circuit to the electrode, an  
arc is formed between the end of the  
electrode and the work piece. The arc  
melts the electrode and the work piece.  
The melted metal of the electrode flows  
into the molten crater and forms a bond  
with the work piece as shown in  
Figure 4.  
AMPERAGE SETTING  
The correct amperage involves the  
adjustment of the welding machine  
to the required amp setting. This is  
regulated by a knob on the welder. The  
amperage required depends on the size  
(diameter) of electrode used and the  
thickness of the work piece.  
1/16 inch  
NOTE: Discontinue using and discard  
electrodes that burn down to 1 to 2  
inches from the electrode holder.  
Same as Electrode Diameter  
Consult specifications listed on the  
welder. Excessive amps burn through  
light metals and the weld bead is flat  
and porous (See Figure 7). The bead  
appears high and irregular if the  
amperage is too low.  
Figure 5 - Scratching Method  
Wire  
ELECTRODE TYPE AND SIZE  
Four types of electrodes are  
Flux  
recommended for this welder. The  
electrodes are commonly known by  
the AWS (American Welding Society)  
designation as follows:  
WELD ANGLE  
Slag  
Weld  
Weld angle is the angle at which the  
electrode is held during the welding  
process. Using the correct angle  
ensures proper penetration and bead  
formation. Electrode angle involves  
two positions - travel angle and work  
angle (See Figure 6).  
Crater  
1. E-6011 Deep penetrating  
Flat bead with deep penetrating  
arc.  
Work Piece  
For rusted or dirty mild steel  
general repair work.  
Figure 4 - Weld Components  
Travel angle is the angle in the line  
of welding and may vary from 5º to  
45º from the vertical, depending on  
welding conditions.  
2. E-6013 General Purpose  
All position, smooth deposit rod  
with low spatter.  
For all mild steel and general  
purpose work.  
10  
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GW4500  
an arc does not create enough heat to  
melt the work piece, the electrode has  
a tendency 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.  
Welding Guidelines  
(Continued)  
Work angle is the angle from  
horizontal, measured at right angles to  
the line of welding.  
5º - 45º  
For most applications, a 45º travel  
angle and 45º work angle is sufficient.  
For specific applications, consult an arc  
welding handbook.  
The sound of a proper arc is a steady,  
crisp sizzle, similar to bacon frying.  
Travel Angle  
TRAVEL SPEED  
NOTE: Right handed welders should  
weld from left to right. Left handed  
welders should weld from right to left.  
The electrode should always point into  
the weld puddle as shown.  
The travel speed is the rate at which  
the electrode is moved across the weld  
area (See Figure 7). When the speed is  
too fast, the bead is narrow and bead  
ripples are pointed as shown. When the  
speed is to slow, the weld metal piles  
up and the bead is high and wide. To  
control travel speed, watch the width  
of the weld bead (not the arc) when  
welding. The weld bead is the orange,  
molten metal behind the arc. The width  
should be approximately twice the  
diameter of the welding rod. Control  
travel speed to obtain a consistent bead  
width.  
ARC LENGTH  
Arc length is the distance from the  
work piece to the tip of the electrode,  
the distance which the arc must travel.  
A proper arc length is essential to  
generate the heat needed for welding  
(See Figure 7). An arc that is too long  
produces an unstable arc, reduces  
penetration, increases spatter, and  
causes flat and wide beads. Too short  
Work Angle  
Figure 6 - Weld Angle  
W
NOTE: Weld bead  
Work Piece  
width (W) should be  
approximately twice  
the diameter for the  
electrode rod used.  
Normal Amps,  
Arc Length,  
Speed  
Speed Too Fast  
Amperage Too Low  
Amperage Too High  
Speed Too Slow  
Arc Length Too Long  
Arc Length Too Short  
Figure 7 - Weld Appearance  
11  
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Operating Instructions and Parts Manual  
All work should be performed in the  
flat position if possible. For specific  
applications, consult an arc welding  
handbook.  
4. If there is no change in lamp  
brightness when polarity is  
reversed, the diodes must be  
replaced.  
Welding Guidelines  
(Continued)  
SLAG REMOVAL  
Wear ANSI approved  
safety glasses (ANSI  
Standard Z87.1) and protective clothing  
when removing slag. Hot, flying debris  
can cause personal injury to anyone in  
the area.  
For testing of rotor,  
WELD PASS  
stator, or field  
windings, consult an authorized service  
center.  
Sometimes more then one pass is  
necessary to fill the joint. The root pass  
is first, followed by filler passes and the  
cover pass (See Figures 8 and 9). If the  
pieces are thick, it may be necessary to  
bevel the edges that are joined at a 60º  
angle. Remember to remove the slag  
before each pass.  
After completing the weld, wait for the  
welded sections to cool. A protective  
coating called slag now covers the weld  
bead which prevents contaminants in  
the air from reacting with the molten  
metal. Once the weld cools to the point  
that it is no longer glowing red, the slag  
can be removed. Removal is done with  
a chipping hammer. Lightly tap the slag  
with the hammer and break it loose  
from the weld bead. The final clean-up  
is done with a wire brush. When making  
multiple weld passes, remove the slag  
before each pass.  
TESTING WELDER / GENERATOR  
DIODES  
The following method eliminates the  
need to disconnect the diodes from the  
welder / generators wiring.  
1. Use a 12 Volt battery and  
automotive lamp (Type 5001) to  
test the diodes in the welder /  
generators.  
WELDING POSITIONS  
2. Connect the battery and lamp as  
shown in Figure 10.  
Four basic welding positions can be  
used; flat, horizontal, vertical, and  
overhead. Welding in the flat position  
is easier than any of the others because  
welding speed can be increased, the  
molten metal has less tendency to run,  
better penetration can be achieved, and  
the work is less fatiguing.  
3. If the diodes are operating  
properly, the lamp illuminates  
brightly when the battery polarity is  
correct, and goes dim when battery  
polarity is reversed.  
Other positions require different  
techniques such as a weaving pass,  
circular pass, and jogging. A higher  
skill level is required to complete these  
welds.  
Lamp On  
Cover  
Filler  
Root  
Lamp Off  
Figure 8 - Weld Passes  
Figure 9 - Multiple Weld Passes  
Figure 10 - Diode Test Procedure  
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GW4500  
Troubleshooting Chart - General  
Symptom  
Possible Cause(s)  
Corrective Action  
Engine will not start 1. Engine switch is set to "OFF".  
2. Fuel valve is turned to "CLOSE".  
3. Choke is open.  
1. Set engine switch to "ON".  
2. Turn fuel valve to "OPEN" position.  
3. Close the choke.  
4. Engine is out of gas.  
4. Add gas.  
5. Engine is filled with contaminated or  
old gas  
5. Change the gas in the engine.  
6. Spark plug is dirty.  
6. Clean spark plug.  
7. Spark plug is broken.  
7. Replace spark plug.  
8. Unit is not on level surface.  
8. Move unit to a level surface to prevent low oil shutdown from  
triggering.  
9. Oil is low.  
9. Add or replace oil.  
Engine runs but  
there is no electrical  
output  
1. Circuit reset button is off.  
1. Wait for 2 minutes and push the circuit reset button to the "ON"  
position.  
2. If you are using an extension cord, try a different one.  
3. Try connecting a different device.  
2. Bad connecting of wires / cables.  
3. Bad electrical device connected to  
generator / welder.  
Generator / welder  
runs but does not  
support all electrical  
devices connected.  
1. Generator / welder is overloaded  
1. Turn off all electrical devices. Unplug all electrical devices. Turn off  
generator / welder. Wait several minutes. Restart generator / welder.  
Try connecting fewer electrical loads to the generator / welder.  
2. Short in one of the connected devices. 2. Try disconnecting any faulty or short-circuited electrical loads.  
3. Air cleaner is dirty.  
3. Clean or replace air cleaner.  
Troubleshooting Chart - Generator  
Symptom  
Possible Cause(s)  
Corrective Action  
No output voltage  
1. Engine speed is too slow  
2. Open, shorted, or incorrect wiring  
3. Faulty capacitor  
1. Adjust engine speed ★  
2. Referring to the wiring diagram, clean and reconnect all wiring ★  
3. Replace capacitor ★  
4. Open or shorted field windings  
5. Open diodes  
6. Front panel switch set incorrectly  
7. Circuit breaker tripped  
4. Test winding resistance, replace field winding if necessary ★  
5. Test diodes, replace if necessary ★  
6. Set front panel switch to generator  
7. Reset circuit breaker  
Low output voltage 1. Engine speed is too slow  
1. Adjust engine speed ★  
with no load  
2. Open diodes  
3. Faulty capacitor  
2. Test diodes, replace if necessary ★  
3. Replace capacitor ★  
4. Open or shorted field windings  
5. Voltage setting on front panel  
incorrect  
4. Test winding resistance, replace field winding if necessary ★  
5. Adjust setting on front panel  
High output voltage 1. Faulty capacitor  
with no load 2. Engine speed is too fast  
1. Replace capacitor ★  
2. Adjust engine speed ★  
3. Adjust setting on front panel  
3. Voltage setting on front panel  
incorrect  
Low output voltage 1. Open diode  
1. Test diodes, replace if necessary ★  
2. Adjust engine speed ★  
under load  
2. Engine speed too slow at full load  
3. Excessive load applied  
4. Voltage setting on front panel  
incorrect  
3. Reduce the applied load  
4. Adjust setting on front panel  
Erratic output  
voltage  
1. Unbalanced engine  
2. Dirty, corroded, or loose wiring  
connection  
1. Refer to engine manual  
2. Referring to the wiring diagram, clean and reconnect all wiring ★  
3. Unstable load applied  
3. Remove all loads, then apply each one individually to determine which  
one is causing erratic function  
Noisy operation  
1. Loose welder / generators or engine  
bolt  
1. Tighten all mountings  
2. Short circuit in welder / generators  
field or load  
3. Faulty bearing  
2. Test winding resistance, replace field winding if necessary ★  
Test load devices for shorts. Replace defective load device.  
3. Replace bearing  
These diagnostic and repair procedures should be performed by an authorized service center.  
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Operating Instructions and Parts Manual  
Troubleshooting Chart - Welder  
Symptom  
Possible Cause(s)  
Corrective Action  
Welder runs but  
does not weld  
1. Inadequate current at electrode  
1. Check work clamp, cable and connection to work piece. Check  
electrode cable and clamp  
2. Poor connections at welder  
3. Front panel switch set incorrectly  
4. Open, shorted, or incorrect wiring  
5. Faulty capacitor  
2. Check all welder external connections  
3. Set front panel switch to weld  
4. Referring to the wiring diagram, clean and reconnect all wiring ★  
5. Replace capacitor ★  
6. Open or shorted field windings  
7. Open diodes  
6. Test winding resistance, replace field winding if necessary ★  
7. Test diodes, replace if necessary ★  
Welder gives trickle 1. Accidental contact with work piece  
1. Avoid contact with work piece  
shocks  
2. Current leakage caused by moist  
clothing or work area  
2. Make sure clothing and work area are dry  
Arc difficult to strike 1. Wrong type of electrode.  
2. Electrode diameter too large  
1. Verify that electrode is for alternating current (AC)  
2. Use smaller diameter electrode  
3. Work piece not properly grounded  
4. Engine speed is too slow  
3. Verify 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  
Possible Cause(s)  
Corrective Action  
Bead is  
intermittently too  
thin or too thick  
1. Inconsistent travel speed  
2. Output amp setting incorrect  
1. Carefully watch and control the width of the molten weld bead  
2. Adjust output amp setting or change to smaller diameter electrode  
Ragged depressions 1. Travel speed too fast  
1. Watch orange molten weld puddle and control bead width  
2. Practice running electrode across workpiece with welder OFF  
3. Reduce output amp setting  
at edge of weld  
2. Arc length too short  
3. Output amp setting too high  
Weld bead does  
not penetrate base  
metal  
1. Inconsistent travel speed  
2. Output amp setting too low  
3. Electrode diameter too large  
1. Decrease and maintain constant travel speed  
2. Increase output amp setting  
3. Change to smaller diameter electrode  
Electrode sticks to  
workpiece  
1. Arc length short  
2. Amp setting low  
3. Incorrect electrode  
1. Lift electrode to correct arc length as soon as arc is struck  
2. Increase amp setting or change to smaller diameter electrode  
3. Verify electrode is suitable for 62.5 V open circuit voltage  
Electrodes sputter  
and stick  
Damp electrodes  
Use dry electrodes and store in dry location  
14  
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GW4500  
O r a n g e  
l l e o Y w  
B r o w n  
R e d  
G r e y  
B l u e  
W h i t e  
B l a c k  
i o V l e t  
P o w e r S w i t c h  
G e n e r a t o r / W  
e l d e r  
G r e e n  
W h i t e  
G r e e n  
W h i t e  
e l Y l o w  
B l a c k  
R e d  
B r o w n  
G r e y  
B l u e  
R e d  
B r o w n  
B a t t e r y C h a r g e r  
1 2 V A C  
B r o w n  
B l u e  
W h i t e  
O r a n g e  
R e d  
Figure 11 - Wiring Diagram - AC Welder / Generator  
15  
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Operating Instructions and Parts Manual  
Welder / Generator Assembly  
1
17  
18  
19  
20  
16  
22  
21  
11  
10  
3
6
5
7
4
2
15  
14  
11  
11  
12  
11  
13  
9
8
Figure 12  
16  
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GW4500  
For replacement parts or technical assistance,  
call 1-800-543-6400  
Please provide following information:  
- Model number  
- Serial number (if any)  
Address parts correspondence to:  
Campbell Hausfeld  
Attn: Parts Dept.  
- Part description and number as shown in parts list  
100 Production Drive  
Harrison, OH 45030 USA  
Replacement Parts List  
Ref. No.  
Description  
Part Number  
Qty.  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
Engine - Honda GX270  
Welded Frame Assembly  
Tie Bracket  
Isomount - Angle (short)  
Isomount - Angle (extended)  
Isomount  
PM004264AV  
GW004000AD  
GN004399AD  
GN004405AV  
GN004406AV  
GN004401AV  
GW004050AD  
1
1
1
1
1
1
1
1
1
4
9
1
1
2
1
1
1
2
1
1
1
1
Hat Bracket  
Hex head Screw - M8 - 1.25 x 60 mm  
Flat Washer - 2 inch OD  
Hex head Screw - 5/16 - 18 x 3/4 inch  
Serrated Flange Nut - 5/16 - 18  
Ground Wire  
Hex head Screw - 5/16 - 18 x 1-1/4 inch  
Flat Washer - 5/16 inch ID  
Wing Nut - 5/16 - 18  
Ground Clamp  
Electrode Holder  
Dinse Plug  
Welding Cable - 6 AWG (14 foot)  
Welding Cable - 6 AWG (6 foot)  
Warning Decal  
GN003811AJ  
WC100100AV  
WC200200AV  
WC000200AV  
DK689201AV  
DK689202AV  
CPSC Warning Decal  
Standard hardware item, available at local hardware stores  
17  
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Operating Instructions and Parts Manual  
Alternator Assembly  
17  
22  
18  
13  
2
14  
6
11  
21  
20  
12  
4
19  
23  
7
28  
10  
24  
15  
16  
9
25  
27  
4
28  
3
1
5
26  
8
10  
Figure 13  
18  
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GW4500  
For replacement parts or technical assistance,  
call 1-800-543-6400  
Please provide following information:  
- Model number  
- Serial number (if any)  
Address parts correspondence to:  
Campbell Hausfeld  
Attn: Parts Dept.  
- Part description and number as shown in parts list  
100 Production Drive  
Harrison, OH 45030 USA  
Replacement Parts List  
Ref. No.  
Description  
Part Number  
Qty.  
1
2
3
4
5
6
7
8
9
10  
11  
12  
13  
14  
15  
16  
17  
18  
19  
20  
21  
22  
23  
24  
25  
26  
27  
28  
Alternator - 4kW, 140A AC (includes items 2 through 22)  
Engine Adapter  
Rotor Tie Rod  
Nyloc Nut - M8-1.25  
Diode, Suppressor, Capacitor Kit (2 each)  
Air Outlet Guard  
GW001000AV  
GN002301SV  
GN002304SV  
1
1
1
5
1
2
1
1
4
8
4
4
1
1
4
1
1
2
1
1
1
1
2
1
1
1
4
4
GN002337SJ  
GN002310SV  
GN002311SV  
GN002312SV  
GN002313SV  
Retaining Ring  
Bearing  
Stud - M8-1.25 x 30mm  
Phillips Head Screw - M5-0.8 x 10mm  
Phillips Head Screw - M6-1.0 x 10mm  
Serrated Flange Nut - M6-1.0  
Inductor  
Capacitor - 35mF, 450V  
Hex Head Screw - 3/8-16 x 1 inch  
Alternator Fan  
Top Cover  
Dinse Socket - 200A  
Commutator Knob - Small  
Commutator - Output  
Commutator Knob - Large  
Commutator - Gen/Weld  
Circuit Breaker - 25A, 250V  
Endbell with Nutcover - GFCI, T-lock  
Twistlock Receptacle - 125/250V, 20A  
Duplex Receptacle - 120V, 20A  
Nylock Nut - #8-32  
GW001050SV  
GW001016SV  
GW001020SV  
GW001002SV  
WC000300AV  
WC400401AV  
GW001045SV  
GW001046SV  
GW001047SV  
GN003601AV  
GN002480SJ  
GN003501AV  
GN003403AV  
Hex Head Screw - #8-32 x .75 inch  
Standard hardware item, available at local hardware stores  
19  
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Operating Instructions and Parts Manual  
Limited Warranty  
1. DURATION: The manufacturer warrants that it will repair, at no charge for parts or labor, the welder, welding gun, or  
cables, proven defective in material or workmanship, during the following time period(s) after date of original retail  
purchase:  
For 5 Years: The Welder Transformer and Rectifier  
For 3 Years: The Entire Welder and Engine Driven Welder Generators (excluding clamps, welding gun, electrode holder,  
cables, or accessories packed with the welder)  
For 90 Days: The Welding Clamps, MIG Gun, Electrode Holder, Accessories, and Welding Cables (as applicable)  
2. WHO GIVES THIS WARRANTY (WARRANTOR): Campbell Hausfeld / Scott Fetzer Company, 100 Production Drive, Harrison,  
Ohio, 45030, Telephone: (800) 543-6400  
3. WHO RECEIVES THIS WARRANTY (PURCHASER): The original purchaser (other than for purposes of resale) of the Campbell  
Hausfeld Industrial product.  
4. WHAT IS COVERED UNDER THIS WARRANTY: Substantial defects in material and workmanship which occur within the  
duration of the warranty period. This warranty extends to the Welder, the Welders Transformer and Rectifier, Welding Gun  
or Electrode holder, and cables only.  
5. WHAT IS NOT COVERED UNDER THIS WARRANTY:  
A. Implied warranties, including those of merchantability and FITNESS FOR A PARTICULAR PURPOSE ARE LIMITED IN  
DURATION TO THIS EXPRESS WARRANTY. After this period, all risks of loss, from whatever reason, shall be on the  
purchaser. Some States do not allow limitation on how long an implied warranty lasts, so the above limitations may  
not apply to you.  
B. ANY INCIDENTAL, INDIRECT, OR CONSEQUENTIAL LOSS, DAMAGE, OR EXPENSE THAT MAY RESULT FROM ANY  
DEFECT, FAILURE, OR MALFUNCTION OF THE CAMPBELL HAUSFELD INDUSTRIAL PRODUCT. Some States do not allow  
limitations on how long 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 replacement of these items shall be at the expense of the owner. These MIG items include but  
are not limited to; Contact Tips, Nozzles, Gun Liners, Drive Rollers, Felt Wire Cleaner. In addition, this warranty  
does not extend to any damage caused by the untimely replacement or maintenance of any of the previously listed  
CONSUMABLE parts.  
D. Any failure that results from accident, purchaser’s abuse, neglect or failure to operate products in accordance with  
instructions provided in the owner’s manual(s) supplied with product.  
E. Pre-delivery service, i.e. assembly, oil or lubricants, and adjustment.  
F. Gasoline engine components are expressly excluded from coverage under this limited warranty. Such components  
should be returned by the purchaser to the original manufacturer or to its authorized repair stations for service.  
6. RESPONSIBILITIES OF WARRANTOR UNDER THIS WARRANTY: Repair or replace, at Warrantor’s option, products or  
components which have failed within duration of the warranty period.  
7. RESPONSIBILITIES OF PURCHASER UNDER THIS WARRANTY:  
A. Please call 800-543-6400 for warranty assistance.  
B. Provide dated proof of purchase and maintenance records.  
C. All welders must be delivered or shipped to the nearest Campbell Hausfeld Authorized Service Center. Freight costs,  
if any, must be borne by the purchaser.  
D. Use reasonable care in the operation and maintenance of the products as described in the owner’s manual(s).  
8. WHEN WARRANTOR WILL PERFORM REPAIR OR REPLACEMENT UNDER THIS WARRANTY:  
Repair or replacement will be scheduled and serviced according to the normal work flow at the servicing location, and  
depending on the availability of replacement parts.  
This Limited Warranty gives you specific legal rights and you may also have other rights which vary from state to state.  
20  
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