WG2040
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.
IN971503AV 6/03
Operating Instructions & Parts Manual Model WG2040, WG2044, WG2045, WG3000
Wire Feed
Arc Welder
BUILT TO LAST
This line of Campbell Hausfeld wire feed
welders is designed to be used on
standard 115V household current. The
welders are equipped with infinite wire
speed control to accurately select the
proper wire feed rate needed for various
welding conditions. Internal components
are thermostatically protected.
This welding system is designed for use
with the Flux Core Arc Welding (FCAW)
or the Gas Metal Arc Welding (GMAW)
process. As delivered from the factory,
this welder can weld with .024” (.6mm)
to .035” (.9mm) diameter wire in MIG
and .030” (.8mm) to .035” (.9mm)
diameter wire in flux core. A starter
spool of .035” (.9mm) flux core wire is
included.
1. Work Clamp - connect to work piece.
2. Wire Feed Gun
3. Power Cord - plug into 115 volt
outlet.
4. On/Off Switch - illuminates if
thermostat has automatically shut
unit off.
5. Infinite Wire Speed Control - turn
clockwise to increase wire speed and
counterclockwise to decrease wire
speed.
6. Heat Selector - Selects welding
power. Four selections are possible;
low 1, low 2, high 1 and high 2.
Danger means a
hazard that will
cause death or serious injury if the
warning is ignored.
Warning means a
hazard that could
cause death or serious injury if the
warning is ignored.
Caution means a
hazard that may
cause minor or moderate injury if the
warning is ignored. It also may mean a
hazard that will only cause damage to
property.
NOTE: Note means any additional
information pertaining to the product
or its proper usage.
!
CAUTION
!
WARNING
!
DANGER
Figure 1 - Welder Components and Controls
See page 7 for supply cable
replacement instructions.
Q
U
A
L
I
T
Y
A
S
S
U
R
A
N
C
E
P
R
O
G
R
A
M
Need
Assistance?
Call Us First!
1-800-746-5641
Unpacking
Welding accessories for the welder
are packed inside the wire feed
compartment. When unpacking, inspect
carefully for any damage that may have
occurred during transit. Make sure any
loose fittings and screws, etc. are
tightened before putting unit into service.
Report any missing or damaged
items by calling 1-800-746-5641.
This equipment
requires a dedicated
115 volt circuit. Refer to the following
chart for correct circuit breaker or fuse
rating. Do not run other appliances, lights
or tools on this circuit while operating
this equipment. Extension cords are not
recommended. Blown fuses and tripped
circuit breakers can result from failure to
comply with this recommendation.
!
CAUTION
Description
CIRCUIT REQUIREMENTS
COMPONENTS AND CONTROLS
General Safety
1
3
6
5
4
2
For parts, manuals, product & service information
visit www.chpower.com
© 2003 Campbell Hausfeld/Scott Fetzer
REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.
Heat Circuit Breaker or
Selector Slow Blow Fuse
Low 15 amp
High 20 amp
2
Wire Feed Arc Welder
Always keep a fire
extinguisher accessible
while performing arc
welding operations.
● Before starting or
servicing any electric
arc welder, read and
understand all
instructions. Failure
to follow safety
precautions or instructions can cause
equipment damage and/or serious
personal injury or death.
● 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 all components of the arc
welder are clean and in good
condition prior to operating welder.
Be sure insulation on all cables, wire
feed gun and power cord is not
damaged. Always repair or replace
damaged components before
operating the welder. Always keep
welder panels, shields, etc. in place
when operating welder.
● Always wear dry, protective
clothing, welding gloves and
insulated footwear when operating
unit.
● Always operate welder in a clean,
dry, well ventilated area. Do not
operate welder in humid, wet, rainy
or poorly ventilated areas.
● Be sure work piece is properly
supported and grounded prior to
beginning any electric arc welding
operation.
● Spread out coiled welding cable
!
WARNING
!
WARNING
before use to avoid overheating and
damage to insulation.
Never immerse
wire or wire feed
gun in water. If welder becomes wet for
any reason, be absolutely certain it is
completely clean and dry before use!
● Always shut equipment off and
unplug power cord prior to moving
the unit.
● Always attach the work lead first.
● Verify work piece is securely
grounded.
● Always shut off electric arc welding
equipment when not in use and cut off
any excess wire from wire feed gun.
● Never allow any part of the body to
touch flux core wire 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 specified on 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
!
WARNING
!
WARNING
!
DANGER
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 lens,
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 all persons in 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.
● Do not operate any electric arc
welder in areas where flammable or
explosive vapors may be present.
● Take precautions to ensure flying
!
WARNING
!
WARNING
!
WARNING
General Safety
(Continued)
MANUAL
www.chpower.com
sparks and heat do not cause flames
in hidden areas, cracks, etc.
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
produced by arc welding
operation. These fumes
are dangerous. If
welding area cannot be
adequately ventilated, be sure to use
an air-supplied respirator.
● Keep head and face out of welding
fumes.
● Extremely toxic fumes are created
when galvanized or cadmium plated
metals or metals which contain zinc,
mercury or beryllium are heated.
Complete the following precautions
before performing electric arc
welding operations on these metals:
a. Remove coating from base metal.
b. Make sure welding area is well
ventilated.
c. Use an air-supplied respirator.
The electromagnetic field
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 wire gun and work cables
together and secure with tape when
possible.
!
WARNING
!
WARNING
!
WARNING
!
WARNING
Never use
flammable gasses
with MIG welders. Only inert or non-
flammable gasses such as carbon
dioxide, argon, helium or mixtures of
one or more of these gasses are
suitable for MIG welding.
Never lift cylinders
off the ground by
their valves or caps or with chains or
slings.
ANSI Standard Z49.1 from American
Welding Society, 550 N.W. Le June 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, Quincy, 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 Material Safety Data Sheets and
manufacturers instructions for metals,
wire, coatings and cleaners.
!
WARNING
!
DANGER
3
● Never wrap arc welder cables around
the body.
● Always position wire gun and work
leads 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
welding area is
secure and free of hazards (sparks,
flames, glowing metal or slag) prior to
leaving. Be sure equipment is turned off
and excess wire is cut off. Be sure cables
are loosely coiled and out of the way. Be
sure all metal and slag has cooled.
Cylinders can explode if
damaged. Shielding gas
cylinders contain gas
under high pressure. If
damaged, a cylinder can
explode. Since gas cylinders are
normally part of the welding process,
be sure to treat them carefully.
● Protect compressed gas cylinders
from excessive heat, mechanical
shocks and arcs.
● Install and secure cylinders in an
upright position by chaining them
to stationary support or equipment
cylinder rack to prevent falling or
tipping.
● Keep cylinders away from any
welding or other electrical circuits.
● Never allow a welding electrode to
touch any cylinder.
● Use only correct shielding gas
cylinders, regulators, hoses and
fittings designed for the specific
application; maintain all parts
properly.
● Turn face away from valve outlet
when opening cylinder valve.
● Keep protective cap in place over
valve except when cylinder is in use
or connected for use.
● Read and follow
instructions on
compressed gas
cylinders, associated
equipment, and CGA
publication P-1 listed
in Safety Standards.
!
DANGER
!
WARNING
General Safety
(Continued)
Model WG2040, WG2044, WG2045, WG3000
MANUAL
ADDITIONAL SAFETY STANDARDS
www.chpower.com
NOTE: Before installing welding wire,
be sure:
a. Diameter of welding wire matches
groove in drive roller on wire feed
mechanism (See Fig. 5). The drive
roller is marked with metric sizes:
.6mm = .024”, .8 - .9mm = .030 –
.035”
b. Wire matches contact tip in end of
gun. (See Fig. 6).
A mismatch on any item could cause the
wire to slip and bind.
NOTE: Always maintain control of loose
end of welding wire to prevent
unspooling.
1. Verify unit is off and open door
panel to expose wire feed
mechanism.
2. Remove the spool quick lock by
pushing in and rotating 1/4 turn
4
Wire Feed Arc Welder
LOCATION
Selecting the proper location can
significantly increase performance,
reliability and life of the arc welder.
● For best results locate welder in a
clean and dry environment. Dust
and dirt in the welder retain
moisture and increase wear of
moving parts.
● Place welder in an area with at least
twelve inches (305 mm) of ventilation
space at both the front and rear of
unit. Keep all obstructions out of this
ventilation space.
● Store welding wire in a clean, dry
location with low humidity to
prevent oxidation.
● Use a properly grounded receptacle
for the welder and ensure welder is
the only load on power supply
circuit. Refer to chart on page 1 for
correct circuit capacity.
● Use of an extension cord is not
recommended for electric arc welding
machines. Voltage drop in the
extension cord may significantly
degrade performance of the welder.
Welding accessories for the welder
are inside wire feed compartment.
1. Place handle assembly on welder,
aligning two holes in plastic ends
with threaded holes in welder
housing (Fig. 2).
2. Insert screws through cord wraps and
handle ends and fasten into cabinet.
3. Attach cylinder base to unit as shown
(Fig. 3).
1. Loosen hex bolt/nut on work clamp.
2. Insert cord (labeled ‘work clamp’ on
the front panel of the welder)
through clamp handle. Slide bare
wire under clamp block. Tighten hex
bolt/nut, making sure bare wire is
clamped securely (Figure 4).
counterclockwise. Then remove
knob, spring and spool spacer.
3. Loosen wire feed tensioning screw
on drive mechanism. This allows
initial feeding of wire into gun liner
by hand.
4. Install wire spool onto spindle so
wire can come off spool on the end
closest to the wire feed guide tube.
Do not cut the wire loose yet.
Install spool spacer, spring and quick
lock knob by pushing in and turning
knob 1/4 rotation clockwise.
5. Hold wire and cut the wire end from
spool. Do not allow wire to
unravel. Be sure end of wire is
straight and free of burrs.
6. Feed wire through wire feed guide
tube, over the groove in drive roll and
into gun liner. Snugly tighten wire feed
tensioning screw. Do not over tighten.
Three to four full turns is usually
correct.
7. Remove nozzle by turning counter-
clockwise, then unscrew contact tip
from end of welding torch (See
Figure 6). Plug welder into a proper
power supply receptacle.
8. Turn on welder and set wire speed
rate to 10. Activate gun trigger until
wire feeds out past the torch end.
Turn welder off.
9. Carefully slip contact tip over wire
and screw tip into torch end. Install
nozzle by turning clockwise (See
Figure 6). Cut wire off approximately
1/4 inch from nozzle end.
Figure 4a - Work Clamp
Assembly (WG2040,
WG2044, and WG2045)
Figure 3 - Base Assembly
Figure 2 - Handle Assembly
Assembly
Installation
HANDLE AND BASE ASSEMBLY
WORK CLAMP
WIRE INSTALLATION
www.chpower.com
Figure 5 - Weld Wire Routing
Clamping Block
Figure 4b - Work Clamp Assembly
(WG3000)
Clamping Block
Improper handling
and maintenance of
compressed gas cylinders and regulators
can result in serious injury or death!
Always secure gas cylinders to tank
bracket kit, a wall or other fixed support
to prevent cylinder from falling over.
Read, understand and follow all
compressed gas and equipment
warnings in the safety instructions.
NOTE: Shielding gas is not required if
flux-cored welding wire is used.
There are 3 types of gas generally used
for gas metal arc welding; 100% argon,
a mixture of 75% argon and 25%
carbon dioxide (C25) or 100% carbon
dioxide.
Use ONLY the type
of gas
recommended for your welder. Use
ONLY an inert, non-flammable type of
gas. Failure to do so will result in a very
hazardous situation.
NOTE: 100% carbon dioxide is not
recommended due to unsatisfactory
weld beads.
!
DANGER
!
DANGER
The 75/25 mixture is recommended for
general steel welding. For aluminum
welding, use 100% argon. Cylinders of
either type gas may be obtained at your
local welding supply outlet. Secure
cylinder in place on your welding
machine or other support to prevent the
cylinder from falling over.
Obtaining Correct Gas Type. The gas
used in any welding application for your
welder must be an INERT, NON-
FLAMMABLE TYPE. You can get the type
of gas needed from a nearby welding
gas distributor (often found in the
yellow pages under “Welders” or
‘Welding Equipment”).
An adjustable regulator without gauges
is supplied with this welder. The
regulator provides a constant shielding
gas pressure and flow rate during the
welding process. Each regulator is
designed to be used with a specific gas
or mixture of gases. The argon and
argon mixture use the same thread type.
The 100% carbon dioxide uses a
different thread type. An adapter is
available at your local welding gas
supplier to change between the two.
Cylinder gas is under
high pressure. Point
cylinder outlet away
from yourself and any
bystanders before
opening.
1. With cylinder securely installed, stand
on side of cylinder opposite cylinder
outlet then remove cylinder cap and
open valve slightly by turning
!
WARNING
5
Welder duty cycle is the percentage of
actual weld time that can occur in a ten
minute interval. For example, at a 20%
duty cycle, actual welding can occur for
two minutes, then the welder must cool
for eight minutes.
Internal components of this welder are
protected from overheating with an
automatic thermal switch. A yellow
lamp is illuminated on the front
panel (on/off switch) if the duty cycle
is exceeded. Welding operations may
continue when the yellow lamp is no
longer illuminated.
To change between flux wire and MIG
wire the polarity must be changed.
1. Open the wire feed door.
2. Locate red (+) and black (-) polarity
connectors just above wire feed
mechanism (See Figure 7).
3. For MIG welding with gas,
connect torch cable from wire feed
mechanism to red (+) polarity
connector, then connect work cable
to black (-) connector.
4. For flux-core welding, connect
torch cable from wire feed
mechanism to black (-) polarity
connector, then connect work cable
to red (+) connector.
Contact Tip Markings
Mark Wire Size
0.6 mm .024"
0.8 mm .030”
0.9 mm .035”
Assembly (Continued)
Model WG2040, WG2044, WG2045, WG3000
DUTY CYCLE / THERMOSTATIC
PROTECTION
POLARITY
Shielding Gas Preparation
Figure 8 - Hookup
GAS TYPES
REGULATOR
HOOKUP PROCEDURE
Figure 7 - Cable connection
www.chpower.com
Torch Diffuser
Contact Tip
Nozzle
Figure 6 - Torch Nozzle
4. To attach the handle, place shield on
a flat surface and press handle into
place (See Figure 10).
NOTE: If you have never welded
before or have little experience, a
full face helmet is recommended.
Both hands are needed to stabilize
and control the angle and arc
length of the torch.
1. Remove the lens retainer from the
face shield with a regular screwdriver
by prying against the shield and post
of the lens retainer.
2. Remove the protective film covering
from both sides of each lens cover.
Put one clear lens cover on each side
of the shaded lens. Place these three
lenses together into the face shield
and secure with the lens retainer. The
lens retainer should snap into the
second notch in the face shield.
3. Position one of the holes in the
adjustment arm over the pins which
are located in the ear area of the face
shield. These adjustment arms control
the closeness of fit and can be easily
repositioned if necessary.
4. Position the headgear inside the face
shield. Assemble the helmet by
inserting the stud screw through the
headgear and shield into the tension
nut as shown. Do not tighten tension
nut completely.
5. Trial fit the welding helmet. Adjust
headgear ratchet band to a
comfortable position and lower the
face shield. If the shield is too far or
counterclockwise. When gas is
emitted from cylinder, close valve by
turning clockwise. This will blow out
dust or dirt that may have
accumulated around valve seat.
2. Install regulator onto cylinder valve.
Tighten stem nut securely to gas
valve.
3. Install one end of gas hose to fitting
on the rear of welder and other end
of hose to fitting on regulator using
hose clamps on each connection. Make
sure gas hose is not kinked or twisted.
4. While standing opposite cylinder
outlet, slowly open cylinder valve.
Inspect for leaks in the connections.
5. Pull trigger on gun to allow gas to
flow. Adjust gas regulator to
maximum flow by moving clockwise.
Release trigger.
6. Remember to close gas cylinder valve
when finished welding.
1. Cut retainer stiffeners and detachable
handle away from shield. Trim the
excess plastic to remove sharp edges.
2. Insert filter lens.
3. Attach the stiffeners over the pins on
the lens retainers (See Figure 9).
6
Wire Feed Arc Welder
too close to the face, use a different
hole in the adjustment arm. Adjust the
tension nuts so that helmet can be
easily lowered over the face by
nodding the head.
1. Be sure to read,
understand and comply
with all precautions in
the General Safety
Information section. Be
sure to read entire
"Welding Guidelines" section before
using this equipment.
2. Turn welder off.
3. Verify 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.
All persons
operating this
equipment or in the area while
equipment is in use must wear
protective welding gear including: eye
protection with proper shade, flame
resistant clothing, leather welding
gloves and full foot protection.
If heating, welding or
cutting galvanized, zinc
plated, lead, or cadmium
plated materials, refer to
the General Safety
Information Section for instructions.
Extremely toxic fumes are created when
these metals are heated.
4. Connect work clamp to work piece or
workbench (if metal). Make sure
contact is secure. Avoid surfaces with
paint, varnish, corrosion or non-
metallic materials.
5. Position Heat Selector on front panel
to desired setting.
NOTE: These settings are general
guidelines only. Heat setting may vary
according to welding conditions and
materials.
!
WARNING
!
WARNING
Assembly
(Continued)
HOOKUP PROCEDURE (Continued)
Operation
Metal Heat
Thickness Setting
24 - 14 Gauge (MIG only) Low 1 or 2
18 - 14 Gauge (Flux Core)
Thicker Than 14 Gauge High 1 or 2
MANUAL
Figure 11
Headgear
Face Shield
Shaded Lens
Clear Lens Cover (2)
Post
Lens Retainer
Adjustment
Arm (2)
Tension Nut (2)
Stud Screw (2)
www.chpower.com
Figure 9
Lens
Lens
Retainer
Retainer
Stiffener
Figure 10
Handshield
Assembly
Welding Helmet
Assembly (Promotional
Models Only)
3. Inspect the condition of the gun tip
and nozzle. Remove any weld slag.
Replace gun tip or nozzle if damaged.
Do not operate this
welding machine
with cracked or missing insulation on
welding cables, wire feed gun or power
cord.
1. Replace any unreadable safety labels
on the welder.
2. Use compressed air to blow all dust
and lint from ventilation openings.
3. Clean wire groove on drive roll.
Remove wire from feed mechanism,
remove screws from drive roll
housing. Use a small wire brush to
clean drive roll. Replace if worn or
damaged
The following parts require routine
maintenance:
• Wire feed drive roller
• Gun liner - replace if worn
• Nozzle/contact tips
• Wire - This welder will accept either 4”
or 8” diameter spools. Flux-cored welding
wire is susceptible to moisture and
oxidizes over time, so it is important to
select a spool size that will be used within
!
WARNING
7
Welding Guidelines
6. Rotate Wire Speed Control to setting
number 5 to start then adjust as
needed after test weld.
7. Plug power cord into a proper
voltage receptacle with proper circuit
capacity (See circuit requirements on
front page).
8. Switch welder ON/OFF switch to ON
position.
9. Verify wire is extended 1/4” from
contact tip. If not, squeeze trigger to
feed additional wire, release trigger
and cut wire to proper length.
10. Position wire feed gun near work
piece, lower welding helmet by
nodding head or position the hand
shield, and squeeze gun trigger. Adjust
heat setting and wire speed as needed.
11. When finished welding, turn welder
off and store properly.
Disconnect power
supply and turn
machine off before inspecting or
servicing any components. Keep wire
compartment cover closed at all times
unless wire needs to be changed.
1. Check condition of weld cables and
immediately repair or replace any
cables with damaged insulation.
2. Check condition of power cord and
immediately repair or replace any
cord if damaged.
!
WARNING
Model WG2040, WG2044, WG2045, WG3000
Maintenance
Supply Cable Replacement
1. Verify that welder is OFF and
power cord disconnected.
2. Remove welder cover to expose
the ON/OFF switch.
3. Disconnect the black and white
power cord wires connected to
the ON/OFF switch.
4. Disconnect the green power
cord wire connected to welder
frame.
5. Loosen the cord strain relief
screw(s) and pull cord out of
strain relief.
6. Install new cord in reverse order.
MIG
WT5021
Figure 12 - Nozzle
Operation
(Con't.)
BEFORE EVERY USE:
EVERY 3 MONTHS:
Consumable and Wear Parts
General
This line of welding machines can utilize
the Flux Cored Arc Welding (Gasless)
process or the Gas Metal Arc Welding
(MIG) process. The weld must be
protected (shielded) from contaminates
in the air while it is molten. The gasless
process uses a tubular wire with a flux
material inside. The flux creates a
shielding gas when melted. The MIG
process uses inert gas to shield the weld
while molten.
When current is produced by a
transformer (welding machine) and
flows through the circuit to the weld
wire, an arc is formed between the end
of the weld wire and the work piece.
This arc melts the wire and the work
piece. The melted metal of the weld
wire flows into the molten crater and
forms a bond with the work piece as
shown (Figure 13).
Slag
Weld
Wire
Flux
(Gasless
only)
Work Piece
Shielding
Gas
Contact
Tip
Crater
Nozzle
Figure 13 - Weld Components
approximately 6 months. For mild steel
welding, AWS ER70S6 solid wire or AWS
E71T-GS Flux-core wire is recommended.
This welder is setup for .035 (.9mm)
wire. If a different wire size is used, the
wire feed drive roll and contact tip may
need changing. There are two grooves
in the drive roll. The small groove is for
.024 (.6mm) wire and the other is for
.030-.035 (.8-.9mm) wire. Remove the
roller cover and flip the drive roll to
choose the correct groove (See parts
breakdown). The contact tip should
also match the wire diameter used. The
tip diameter is marked on the contact
tip in inches or millimeters.
www.chpower.com
CHANGING WIRE SIZES
Wire Feed Arc Welder
8
Welding Guidelines (Continued)
Arc Welding Basics
Five basic techniques affect weld quality.
These are: wire selection, heat setting,
weld angle, wire speed, and travel speed.
An understanding of these techniques is
necessary for effective welds.
HEAT SETTING
The correct heat involves the adjustment
of the welding machine to the required
setting. Heat or voltage is regulated by a
switch on the welder. The heat setting
used depends on the size (diameter) and
type of wire, position of the weld, and
the thickness of the work piece. Consult
specifications listed on the welder. It is
suggested that the welder practice with
scrap metal to adjust settings, and
compare welds with Figure 15.
WIRE TYPE AND SIZE
The correct choice of wire type involves
a variety of factors, such as welding
position, work piece material type,
thickness, and condition of surface to
be welded. The American Welding
Society, AWS, has set up certain
requirements for each type of wire.
FLUX-CORED WIRE
E - 7
0 T
- GS
Weld strength, times
10,000 pounds per
square inch
Welding positions (0
for flat or horizontal,
1 for any position)
Tubular flux core wire
Flux type
AWS E71T-GS or E71T-11 is
recommended for this welder.
SOLID WIRE
ER - 70 S - 6
Weld strength, times
1,000 PSI
Solid wire
Wire composition
ER-70S6 is recommended for this
welder.
WELD ANGLE
Weld angle is the angle at which the
nozzle is held during the welding
process. Using the correct angle ensures
proper penetration and bead formation.
As different welding positions and weld
joints become necessary, nozzle angle
becomes an increasingly important
factor in obtaining a satisfactory weld.
Weld angle involves two positions -
travel angle and work angle.
Travel angle is the angle in the line of
welding and may vary from 5º to 45º
from the vertical, depending on welding
conditions.
Work angle is the angle from
horizontal, measured at right angles to
the line of welding. For most
applications, a 45º travel angle and 45º
work angle is sufficient. For specific
applications, consult an arc welding
handbook.
WIRE SPEED
The wire speed is controlled by the
knob on the front panel. The speed
needs to be “tuned” to the rate at
which the wire is being melted in the
arc. Tuning is one of the most critical
functions in wire feed welding. Tuning
should be performed on a scrap piece
of metal the same type and thickness as
that to be welded. Begin welding with
one hand “dragging” the gun nozzle
across the scrap piece while adjusting
the wire speed with the other hand.
Too slow of speed will cause sputtering
and the wire will burn up into the
contact tip. Too fast a speed will also
cause a sputtering sound and the wire
will push into the plate before melting.
A smooth buzzing sound indicates the
wire speed is properly tuned. Repeat
the tuning procedure each time there is
a change in heat setting, wire diameter
or type, or work piece material type or
thickness. For Aluminum, wire speed is
typically set higher (7-9 speed range).
TRAVEL SPEED
The travel speed is the rate at which the
torch is moved across the weld area.
TRAVEL ANGLE
WORK ANGLE
5º - 45º
5º - 45º
Figure 14 - Weld Angle
Normal Heat,
Wire Speed,
Travel Speed
Heat Too Low
Heat Too High
Wire Speed
Too Fast
Wire Speed Too Slow
Travel Speed
Too Slow
Travel Speed
Too Fast
Base
Metal
Figure 15 - Weld Appearance
www.chpower.com
9
Model WG2040, WG2044, WG2045, WG3000
Factors such as diameter and type of
weld wire, amperage, position, and work
piece material thickness all effect the
speed of travel necessary for completing
a good weld (See Fig. 15). When the
speed is too fast, the bead is narrow and
bead ripples are pointed as shown. When
the speed is too slow, the weld metal
piles up and the bead is high and wide.
For Aluminum, travel speed is typically
faster.
SLAG REMOVAL
(FLUX-CORED WIRE ONLY)
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.
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.
WELDING POSITIONS
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. Welding is performed with the
wire at a 45º travel angle and 45º work
angle.
Other positions require different
techniques such as a weaving pass,
circular pass, and jogging. A higher skill
level is required to complete these
welds.
Overhead welding is the least desirable
position as it is the most difficult and
dangerous. Heat setting and wire
!
WARNING
Welding Guidelines (Continued)
stainless steel brush to eliminate any
oxidation on the weld and grounding
surface. 100% Argon shielding gas
must be used when welding aluminum.
If 100% Argon is not used, metal
penetration is unlikely. A Teflon
®
wire
liner, smooth-groove drive roller and
aluminum contact tips are
recommended when welding
aluminum. Campbell Hausfeld offers
these parts in Kit WT2530. Call 800-746-
5641 to order.
PUSH VS PULL TECHNIQUE
The type and thickness of the work piece
dictates which way to point the gun
nozzle. For thin materials (18 gauge and
up) and all aluminum, the nozzle should
point out in front of the weld puddle
and push the puddle across the
workpiece. For thicker steel, the nozzle
should point into the puddle to increase
weld penetration. This is called backhand
or pull technique (See Figure 18).
selection will vary depending upon the
position.
All work should be performed in the
flat position if possible. For specific
applications, consult an arc welding
technical manual.
WELD PASSES
Sometimes more then one pass is
necessary to fill the joint. The root pass
is first, followed by filler passes and the
cover pass. 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 for
gasless process.
ALUMINUM WELDING
Any aluminum surface to be welded,
must be cleaned thoroughly with a
www.chpower.com
Figure 16 - Weld Passes
Cover
Filler
Root
Figure 17 - Multiple Weld Passes
PUSH
PULL
Figure 18
10
Wire Feed Arc Welder
www.chpower.com
Figure 19 - Wiring Schematic
11
Troubleshooting Chart - Welder
Symptom Possible Cause(s) Corrective Action
For Information About This Product Call 1-800-746-5641
Troubleshooting Chart - Welds
Symptom Possible Cause(s) Corrective Action
1. Duty cycle exceeded
2. Poor work clamp connection
3. Defective power switch
4. Blown breaker or fuse
1. Wrong size gun tip
2. Gun liner clogged or
damaged
3. Gun tip clogged or damaged
4. Feed roller worn
5. Not enough tension
1. Slag inside gun nozzle
2. Insulation ring melted/expired
1. Poor contact
2. Using an extension cord with
excessive length
1. Wire jammed
2. Out of wire
3. Not enough tension
4. Wire liner worn
5. Wire disconnected internally
6. Contact tip clogged
1. Wire speed too slow
2. Travel speed too slow or heat
is too high
1. Wire speed setting
2. Contact tip size too large
3. Polarity set incorrectly
4. Drive roller slipping
5. Gas bottle empty
1. Allow welder to cool until ON/OFF Switch lamp goes out
2. Be sure all connections are secure, and attaching surface is
clean
3. Replace switch
4. Reduce circuit load, reset breaker or replace fuse
1. Use proper size gun tip
2. Clean or replace gun liner
3. Clean or replace gun tip
4. Replace
5. Tighten tensioning screw
1. Clean slag from gun nozzle
2. Replace nozzle
1. Be sure all connections are secure, and attaching surface is
clean
2. Never use an extension cord longer than 20 ft
1. Reload wire
2. Replace wire spool
3. Tighten tensioning screws if wire is slipping
4. Replace liner
5. Call 1-800-746-5641 for assistance
6. Replace contact tip
1. Run speed in 7 - 10 range
2. Increase the travel speed or reduce heat settings
1. Tune in correct setting
2. Replace contact tip
3. Reverse polarity
4. Increase tension
5. Replace gas bottle
No output
Wire tangles at drive roller
Gun nozzle arcs to work
surface
Work clamp and/or cable
gets hot
Wire does not feed
(Aluminum) Wire burns back
into tip or (Aluminum) Metal
bubbles or burns through
Weld pops and sputters
Bead is intermittently
too thin
Bead is intermittently
too thick
Ragged depressions at
edge of weld
Weld bead does not
penetrate base metal
Wire sputters and
sticks
1. Inconsistent travel speed
2. Output heat setting too low
1. Slow and/or inconsistent travel speed
2. Output heat setting too high
1. Travel speed too fast
2. Wire speed too fast
3. Output heat setting too high
1. Inconsistent travel speed
2. Output heat setting too low
3. No or low shielding gas
4. Wrong shielding gas (aluminum)
5. Extension cord is too long
6. (Aluminum) Possible oxide buid-up on
surface
1. Damp wire
2. Wire speed too fast
3. Wrong type of wire
4. No or low shielding gas
1. Decrease and maintain constant travel speed
2. Increase output heat setting
1. Increase and maintain travel speed
2. Reduce output heat setting
1. Decrease travel speed
2. Decrease wire speed
3. Reduce output heat setting
1. Decrease and maintain constant travel speed
2. Increase output heat setting
3. Use gas for MIG process or refill bottle
4. Use only 100% Argon gas
5. Never use an extension cord longer than 20 ft
6. Clean surface thoroughly with a stainless steel brush only
1. Use dry wire and store in dry location
2. Reduce wire speed
3. Use flux core wire when not using gas
4. Use gas for MIG process or refill bottle
www.chpower.com
Model WG2040, WG2044, WG2045, WG3000
12
Wire Feed Arc Welder
www.chpower.com
5
2
34
36
37
6
4
30
29
28
28
26
25
24
27
18
22
21
17
20
19
23
1
40
39
44
**
1 Service torch – Universal WC600900AJ 1
2 Torch body, front and back WC600201AV 1
3 Hanger clip ▲ WC600003AV 1
4 Nozzle WT502100AJ 1
5 Trigger knob WC600202AV 1
6 Torch contact spring WC600203AV 1
7a Work clamp, all except WG3000
(Cord not included) WC100000AV 1
7b Work clamp, WG3000 (Cord not included) WC100100AV 1
8 Welding cable 6 mm
2
(6 ft) ❋ 1
9 Wire speed knob WC400201AV 1
10 Wire speed control board WC402900AV 1
11 Heat switch WC400300AV 2
12 On/off switch WC400000AV 1
13 Safety decal (1 of 2) DK670000AV 1
14 Safety decal (2 of 2) DK670001AV 1
15 Handle WC301800AV 1
16 Power cord 14-3 AWG (6 ft)
Type SJT ❋ 1
17 Spool spindle WC500300AV 1
18 #10-32 x .5” Pan head sheet
metal screw ❋ 2
19 Wire See Chart Below 1
20 Spool adapter WC500200AV 1
21 Spool spring WC500101AV 1
22 Spool locking hub WC500100AV 1
23 Drive deck assembly
(Includes Nos. 24-30) WC500000AV 1
24 Tension spring WC500003AV 1
25 Tension screw WC500002AV 1
26 Roller, .6-.9mm (.024-.035 in.) WC500001AV 1
Ref. Part
No. Description Number Qty
Figure 20 - Replacement Parts
Model WG2040, WG2044, WG2045, WG3000
27 Roller cover WC500004AV 1
28 #8-36 x 1.5” Pan head screw ❋ 3
29 Swing arm WC500005AV 1
30 Swing arm roller WC500007AV 1
31 Strain relief ▲ WC102000AV 2
32 M6-1.0 x 25mm Machine screw ❋ 2
33 Handle caps WC301802AV 2
34 Liner, coated metal WC600208AV 1
35 Cylinder base ▲ WC704700AV 1
36 Polarity cap (Red) WC704000AV 1
37 Polarity cap (Black) WC704100AV 1
38 Torch ring WC600009AV 1
39 Valve body WC600204AV 1
40 Swan neck w/diffuser WC600701AV 1
41 Hose barb (external) WC802300AV 1
42 Hose barb (internal) WC802400AV 1
43 Regulator ▲ WC802500AV 1
44 Trumpet liner WC600305AV 1
45 Gas bottle strap WC802000AV 1
46 Gas liner ▲ WC802200AV 1
47 Handshield without lens ▲ WC801300AV 1
48 Lens for handshield ▲ WC801100AV 1
49 Welding helmet ▲ WT100500AV ✜
50 Chipping hammer/brush ▲ WC803000AV 1
51 Aluminum welding kit ▲ WT253000AV ✜
(includes Teflon
®
wire liner, smooth-groove drive roller and
4 aluminum contact tips for .030” {0.8mm} wire)
❋ Standard hardware item, available at local hardware or welder
supply store
▲ Not shown
✜ Optional accessory, sold separately
Ref. Part
No. Description Number Qty
Inside
OPTIONAL WIRE
Part Number Part Number
Type Description (2 pound) (10 pound)
Flux E71T-GS .030” WE200001AV WE201000AV
Flux E71T-GS .035” WE200501AV WE201500AV
MIG ER70S6 .024” WE300001AV WE301500AV
MIG ER70S6 .030” WE300501AV WE302000AV
MIG ER70S6 .035” WE301001AV WE302500AV
Aluminum MIG ER5356 .030” WE303001AV (1 lb) N/A
**OPTIONAL CONTACT TIPS (4/package)
Size
mm in. Part Number
0.6 0.024 WT501200AJ
0.8 0.030 WT501300AJ
0.9 0.035 WT501400AJ
7
8
11
12
13, 14
45
16
41, 42
38
15
32
33
9, 10
For Information About This Product
Call 1-800-746-5641
13
Operating Instructions and Parts Manual
AC or Alternating Current - electric
current that reverses direction
periodically. Sixty cycle current travels
in both directions sixty times per
second.
Arc Length - the distance from the
end of the electrode to the point
where the arc makes contact with the
work surface.
Base Metal - the material to be
welded.
Butt Joint - a joint between two
members aligned approximately in the
same plane.
Crater - a pool, or pocket, that is
formed as the arc comes in contact
with the base metal.
DC or Direct Current - electric
current which flows only in one
direction. The polarity (+ or -)
determines which direction the current
is flowing.
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.
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.
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.
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.
Flux Cored Arc Welding (FCAW) -
also called Gasless, is a welding process
used with a wire-feed welding
machine. The weld wire is tubular
with flux 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.
Gas Tungsten Arc Welding (GTAW)
- also called TIG, is a welding process
used 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.
Lap Joint - a joint between two
overlapping members in parallel
planes.
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.
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.
Porosity - gas pockets, or cavities,
formed during weld solidification.
They weaken the weld.
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.
Shielded Metal Arc Welding
(SMAW) - also called Stick, is a
welding process with uses a
consumable electrode to support the
arc. Shielding is achieved by the
melting of the flux coating on the
electrode.
Slag - a layer of flux soot that protects
the weld from oxides and other
contaminants while the weld is
solidifying (cooling). Slag should be
removed after weld has cooled.
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.
Tack Weld - weld made to hold parts
in proper alignment until final welds
are made.
Travel Angle - the angle of the
electrode in the line of welding. It
varies from 5º to 45º depending on
welding conditions.
T Joint - made by placing the edge of
one piece of metal on the surface of
the other piece at approximately a 90º
angle.
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.
Weld Pool or Puddle - a volume of
molten metal in a weld prior to its
solidification as weld metal.
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.
Work Angle - the angle of the
electrode from horizontal, measured
at right angles to the line of welding.
Glossary of Welding Terms
Model WG2040, WG2044, WG2045, WG3000
www.chpower.com
14
Operating Instructions and Parts Manual
Limited Warranty
Limited 5-3-1 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 (excluding clamps, welding gun, electrode holder, cables, or accessories packed with welder)
For 1 Year: The Welding Clamps, MIG Gun, Electrode Holder, Accessories, and Welding Cables (as applicable)
2. Who Gives This Warranty (Warrantor):
Campbell Hausfeld
The Scott Fetzer Company
100 Production Drive
Harrison, OH 45030
Telephone: (513)-367-4811
3. Who Receives This Warranty (Purchaser): The original purchaser of the Campbell Hausfeld product.
4. What is covered under this warranty: 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 limitations on how long an implied warranty lasts, so 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 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 the product.
E. Pre-delivery service, i.e. assembly and adjustment.
7. 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.
8. Responsibilities of purchaser under this warranty:
A. Deliver or ship the Campbell Hausfeld product or component to Campbell Hausfeld. Freight costs, if any, must be borne by
the purchaser.
B. Use reasonable care in the operation and maintenance of the products as described in the owner’s manual(s).
9. 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.
www.chpower.com
Loading...