Campbell Hausfeld WF1800, WF2000, WF1900, WIRE FEED WF1900 User Manual

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Operating Instructions & Parts Manual

Models WF1800, WF1900 and WF2000

 

 

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.

TM

BUILT TO LAST

Wire Feed

Arc Welder

 

 

 

 

 

 

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Assistance?

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Call Us First!

1-800-746-5641

Description

The Campbell Hausfeld WF1800, WF1900 and WF2000 are 70 amp, single phase 115 volt input, wire feed arc welding machines. The WF2000 is 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) process. As delivered from the factory, this welder can weld with .030” (.8 mm) or .035” (.9 mm) diameter flux-cored wire. A starter spool of wire is included.

POLARITY

Welders are configured for DCEN, direct current electrode negative.

DUTY CYCLE / THERMOSTATIC PROTECTION

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.

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.

MIG CONVERSION

The WF1800 and WF1900 are NOT convertible to MIG gas usage. Call 1-800- 746-5641 to purchase conversion kit (WT600400AJ) for WF2000.

Unpacking

All welding accessories for the welder are inside the wire feed compartment. Lift and/or remove

 

 

 

 

 

 

 

 

3

 

 

 

 

WF1800

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

4

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WF2000

UTILITY

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WELDER

 

 

 

 

 

 

 

 

 

 

 

Wire Feed

DELIVERS SMOOTH

 

Feed

Welder

en Fil

 

 

 

 

Wire

 

 

 

 

 

 

Welder

DC POWER

 

Alimente

e Continuo

 

 

 

 

 

 

LOW

 

 

 

 

 

 

 

 

OFF

Soudeur

 

Alambr

 

 

 

 

FLUX

 

 

con

 

 

 

 

 

 

CORE

HIGH

Soladar

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

WORK

 

 

 

 

 

 

 

ON

LOW

 

 

6

CLAMP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

115 VOLT

 

 

 

 

 

 

 

 

 

 

 

60HZ

 

 

 

 

 

OFF

 

 

 

 

 

 

 

 

 

 

 

 

HIGH

 

 

 

 

 

 

 

 

 

 

 

 

 

CAMPBELL

 

 

 

 

 

 

 

 

 

 

 

LAST

Y

 

 

 

 

 

 

 

 

 

 

 

HAUSFELDTO DUT

5

 

 

 

 

 

 

 

 

 

 

BUILT

 

 

 

 

 

 

 

 

 

 

10

SERIOU

 

 

 

1

 

 

 

 

 

 

 

 

 

 

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

1

 

 

 

 

 

 

 

 

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3

Figure 1 - Welder Components and Controls

 

 

 

 

wire feed cover to find handle, workclamp, etc. 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.

Circuit Requirements

This equipment

! CAUTION requires a dedicated 115 volt circuit. Refer to the following chart for the 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.

Heat

Circuit Breaker or

Selector

Slow Blow Fuse

Low

15 amp

High

20 amp

See page 6 for supply cable replacement instructions.

Components and Controls

WF1800/WF1900

1.Work Clamp - connect to work piece.

2.Wire Feed Gun with .035” tip.

3.Power Cord - plug into 115 volt outlet.

4.Low/Off/High Switch - set according to metal thickness. Automatically controls wire speed. Lights if thermostat has automatically shut unit off.

WF2000

1.Work Clamp - connect to work piece.

2.Wire Feed Gun with .035” tip.

3.Power Cord - plug into 115 volt outlet.

4.On/Off Switch - lights 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. Two selections are possible; low and high.

© 2002 Campbell Hausfeld/Scott Fetzer

For parts, product & service information

IN199006AV 3/02

 

visit www.chpower.com

Operating Instructions and Parts Manual

General Safety

Danger means a ! DANGER hazard that will

cause death or serious injury if the warning is ignored.

Warning means a ! WARNING hazard that could

cause death or serious injury if the warning is ignored.

Caution means a ! CAUTION 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.

! WARNING

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.

!WARNING

Improper use of electric arc welders can cause electric shock, injury, and death! Take all precautions described in

this manual to reduce the possibility of electric shock.

Verify that all components of the arc welder are clean and in good condition prior to operating the welder. Be sure that the insulation on all cables, wire feed gun, and power cords is not damaged. Always repair or replace damaged components before operating the welder. Always keep welder panels, shields, etc. in place when operating the welder.

Always wear dry, protective clothing and welding gloves, and insulated footwear.

Always operate the welder in a clean, dry, well ventilated area. Do not operate the welder in humid, wet, rainy, or poorly ventilated areas.

Be sure that the work piece is

properly supported and grounded prior to beginning any electric arc welding operation.

Coiled welding cable should be spread out before use to avoid overheating and damage to insulation.

Never immerse the ! DANGER wire or wire feed

gun in water. If the welder becomes wet for any reason, be absolutely certain that it is completely clean and dry prior to attempting use!

Always shut the equipment off and unplug the power prior to moving the unit.

Always attach the work lead first.

Verify that the work piece is securely grounded.

Always shut off electric arc welding equipment when not in use and cut off any excess wire from the wire feed gun.

Never allow any part of the body to touch the 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 those specified on the equipment labels.

Never use an electric arc welder to thaw frozen pipes.

! WARNING

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.

!WARNING

Electric arc welding operations produce intense light and heat and ultraviolet (UV) rays. This

intense light and UV rays

can cause injury to eyes and skin. Take

all precautions described in this manual to reduce the possibility of injury to eyes and skin.

All persons operating this equipment or in the area while equipment is in use must wear protective welding gear including: welding helmet or shield with at least shade 10 lens, flame resistant clothing, leather welding gloves, and full foot protection.

The welding wire is ! CAUTION live whenever the

welder is turned on - whether the trigger is pulled or not.

Never look at arc

! WARNING 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.

! WARNING

Electric arc welding operations cause sparks and heat metal to temperatures that can cause severe burns! Use

protective gloves and clothing when performing any metal working operation. Take all precautions described in this manual to reduce the possibility of skin and clothing burns.

Make sure that all persons in the welding area are protected from heat, sparks, and ultraviolet rays. Use additional face shields and flame resistant barriers as needed.

Never touch work pieces until completely cooled.

!WARNING

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 be sure that flying sparks and heat do not cause flames in hidden areas, cracks, etc.

Fire hazard! Do not ! WARNING weld on containers

or pipes that contain or have contained flammable materials or gaseous or liquid combustibles.

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! WARNING

Models WF1800, WF1900 and WF2000

General Safety (Continued)

! WARNING 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.

! WARNING Do

not breathe fumes that are produced by the arc welding operation. These fumes are dangerous. If the welding area cannot

be adequately ventilated, be sure to use an air-supplied respirator.

Keep the head and face out of the welding fumes.

Do not perform electric arc welding operations on metals that are galvanized or cadmium plated, or contain zinc, mercury, or beryllium without completing the following precautions:

a.Remove the coating from the base metal.

b.Make sure that the welding area is well ventilated.

c.Use an air-supplied respirator.

Extremely toxic fumes are created when these metals are heated.

! WARNING The

electromagnetic field that is generated during arc welding may interfere with the operation of various electrical and

electronic devices such as cardiac pacemakers. Persons using such devices should consult with their physician prior to performing any electric arc welding operations.

Route the wire gun and work cables together and secure with tape when possible.

Never wrap arc welder cables around the body.

Always position the wire gun and work leads so that they are on the same side of the body.

Exposure to electromagnetic fields during welding may have other health effects which are not known.

Always be sure ! WARNING that the welding

area is secure and free of hazards (sparks, flames, glowing metal or slag) prior to leaving. Be sure that equipment is turned off and excess wire is cut off. Be sure that cables are loosely coiled and out of the way. Be sure that all metal and slag has cooled.

ADDITIONAL SAFETY STANDARDS

ANSI Standard Z49.1 from American Welding Society, 550 N.W. 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 the Material Safety Data Sheets and the manufacturers instructions for metals, wire, coatings and cleaners.

Installation (All Models)

LOCATION

Selecting the proper location can significantly increase performance, reliability and life of the arc welder.

For best results locate the welder in an environment that is clean and dry. Dust and dirt in the welder retain moisture and increase wear of moving parts.

Place the welder in an area that provides at least twelve inches (305 mm) of ventilation space at both the front and rear of the unit. Keep all obstructions away from this ventilation space.

Store flux core wire in a clean, dry location with low humidity to reduce oxidation.

The receptacle used for the welder must be properly grounded and the welder must be the only load on the power supply circuit. Refer to the Circuit Amps chart on page 1 for correct circuit capacity.

The use of an extension cord is not recommended for electric arc welding machines. The voltage drop in the extension cord may

significantly degrade the performance of the welder.

Assembly -

WF1800/WF1900

All welding accessories for the welder are inside the wire feed compartment. Lift wire feed cover to find handle, workclamp, etc.

Handle Assembly

1.Place handle assembly on welder, aligning two holes in the ends with threaded holes in welder housing.

2.Fasten screws through handle ends and into cabinet.

3.Insert cord storage clips into handle ends.

Cord Storage

Clip

Cord

Storage

Clip

UTILITY

WELDER

Figure 2 - Handle Assembly

Shaft Attachment

1.Open up the panel to expose the wire feed platform.

2.Align the shaft hole and notch to the welder screw hole and notch hole.

3.Fasten with screw down through the shaft and into the welder.

4.Press spring into top of spindle.

Spindle

Spring

Attachment

Screw

Spindle

Figure 3 - Shaft Attachment Assembly

Flux Core Wire Installation

Welding power may be applied to

the output terminals, feed roll, work clamp, gun cable connection and welding wire even when the the gun switch is not activated. Do not touch these parts when the welding machine is on.

Note: Before installing welding wire, be sure that the diameter of the welding wire matches the groove in the drive roller on the wire feed mechanism and that the wire size matches the contact tip in the end of the gun (see Figure 5).

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! WARNING

Operating Instructions and Parts Manual

Assembly - WF1800/

WF1900 (Continued)

Any mismatch could cause the wire to slip, bind or weld poorly.

Contact Tip Markings

 

Mark

Wire Size

 

 

 

 

 

 

 

 

 

0.8

0.030”

 

 

 

 

 

0.9

0.035”

 

 

 

 

 

 

 

Wire Size Chart

 

 

Inches

mm

 

 

 

 

 

0.030

0.8

 

 

 

 

 

0.035

0.9

 

 

 

 

 

1.Verify the unit is off and lift the panel on the welder to expose the wire feed mechanism.

2.Loosen the wire feed tensioning screw on the drive mechanism. This allows initial feeding of the wire into the gun liner by hand.

3.Install the wire spool onto the spindle so that the wire can come off the spool on the end closest to the wire feed guide tube. Do not cut the wire loose yet.

4.Hold the wire and cut the wire end from the spool. Do not allow the wire to unravel. Be sure that the end of the wire is straight and free of burrs.

5.Feed the wire through the wire feed guide tube, over the groove in the drive roll and into the gun liner. Tighten the wire feed tensioning screw so that it is snug. Do not over tighten. Close the wire feed panel.

 

Pan Head Screws

 

Roller

Wire Flux

 

Core

Swing

 

 

Arm

 

 

Tension

Tension

 

Screw

 

Spring

 

 

Spindle

 

 

Figure 4 - Weld Wire Routing

6.Remove the nozzle by turning counter-clockwise. Then unscrew the contact tip from the end of the welding torch (See Figure 5). Plug the welder into the proper power supply receptacle.

Torch

Contact Tip

Nozzle

 

Diffuser

 

 

Figure 5 - Torch Nozzle

 

7.Turn on the welder and activate the gun switch until the wire feeds out past the torch end. Turn welder off.

8.Carefully slip the contact tip over the wire and screw it into the torch end. Install the nozzle by turning clockwise. (See Figure 5). Cut the wire off approximately 1/4 inch from the end of the nozzle.

Assembly - WF2000

All welding accessories for the welder are inside the wire feed compartment. Lift and remove wire feed cover to find handle, workclamp, etc.

Handle Assembly

1.Slide handle into plastic ends as shown (Fig. 6).

Figure 6 - Handle Assembly

2.Place handle assembly on welder aligning two holes in plastic ends with threaded holes in welder housing.

3.Fasten screws through handle ends and into cabinet.

WORK CLAMP

1.Loosen hex bolt on work clamp.

2.Insert cord (labeled work on the front panel of the welder) through clamp handle and slide bare wire under the clamp block. Tighten hex bolt making sure bare wire is clamped securely (Fig. 7).

Figure 7 - Work Clamp Assembly

Flux Core Wire Installation

Welding power may be applied to

the output terminals, feed roll, work clamp, gun cable connection and welding wire even when the the gun switch is not activated. Do not touch these parts when the welding machine is on.

Note: Before installing welding wire, be sure that the diameter of the welding wire matches the groove in the drive roller on the wire feed mechanism and that the wire size matches the contact tip in the end of the gun (see Figure 5). Any mismatch could cause the wire to slip, bind or weld poorly.

 

 

Wire Size Chart

 

 

Inches

mm

 

 

 

 

 

 

 

 

0.030

0.8

 

 

 

 

 

 

 

 

0.035

0.9

 

 

 

 

 

 

 

 

 

 

 

 

Contact Tip Markings

 

Mark

Wire Size

 

 

 

 

 

 

 

 

 

 

 

0.8

0.030”

 

 

 

 

 

 

0.9

0.035”

 

 

 

 

 

 

1.Verify the unit is off and lift the panel on the welder to expose the wire feed mechanism.

2.Remove the spool quick lock by pushing in and rotating 1/4 turn counterclockwise. The knob, spring, and spool spacer can now be removed.

3.Loosen the wire feed tensioning screw on the drive mechanism. This allows initial feeding of the wire into the gun liner by hand.

Tension

Panel

Screw

 

 

Drive

Guide

Roller

 

Tube

 

 

Spool

 

Spacer

 

Spool

Spindle

Lock

 

 

Spring

Figure 8 - Weld Wire Routing

4.Install the wire spool onto the spindle so that the wire can come off

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Models WF1800, WF1900 and WF2000

Assembly - WF2000

(Continued)

the spool on the end closest to the wire feed guide tube. Do not cut the wire loose yet. Install the spool spacer, spring, and quick lock knob by pushing in and turning the knob 1/4 rotation clockwise.

5.Hold the wire and cut the wire end from the spool. Do not allow the wire to unravel. Be sure that the end of the wire is straight and free of burrs.

6.Feed the wire through the wire feed guide tube, over the groove in the drive roll and into the gun liner. Tighten the wire feed tensioning screw so that it is snug. Do not over tighten. Install the outer welder panel.

7.Remove the nozzle by turning counter-clockwise. Then unscrew the contact tip from the end of the welding torch (See Figure 5). Plug the welder into the proper power supply receptacle.

8.Turn on the welder and set the wire speed rate to Maximum. Activate the gun switch until the wire feeds out past the torch end. Turn welder off.

9.Carefully slip the contact tip over the wire and screw it into the torch end. Install the nozzle by turning clockwise. (See Fig. 5). Cut the wire off approximately 1/4 inch from the end of the nozzle.

Handshield Assembly

WF1800

Lens

Lens

Retainer

Retainer

Stiffener

Figure 9 (WF2000 shown - WF1800 similar)

1.Cut retainer stiffeners 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).

WF2000

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).

4.To attach the handle, place shield on a flat surface and press handle into place (See Figure 10).

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.

Welding Helmet

Assembly (Promotional

Models Only)

Headgear

 

 

 

 

Tension

Stud Screw

Nut

 

 

Adjustment

Face

 

Arm

 

 

Shield

 

 

 

Clear Lens

 

Figure 11

Shaded Lens

Lens Retainer

1.Remove the lens retainer from the helmet.

2.Place the clear lens into the helmet first, then place the shaded lens into the helmet. The clear lens should be on the outside. Its purpose is the protect the shaded lens from sparks and spatter. Secure the two lenses by snapping the lens retainer in place.

3.Position the adjustment arm on the right side of the helmet. Place the small pin on the arm into one of the small holes in the helmet. This

adjustment controls the fit of the helmet when it is lowered, and can be easily repositioned if necessary.

4.Position the headgear inside the helmet. Assemble the helmet by inserting the stud screw through the headgear and helmet (and adjustment arm on the right side) into the tension nut as shown. Do not tighten the tension nut completely.

5.Trial fit the welding helmet. Adjust headgear ratchet band to a comfortable position and lower the helmet. If the helmet is too far or too close to the face, use a different hole for the adjustment arm. Adjust the tension nuts so the helmet can be easily lowered over the face by nodding the head.

Operation

The welding wire is ! CAUTION live whenever the

welder is turned on - whether the trigger is pulled or not.

1.Be sure to read, understand, and comply with all precautions in the General Safety Information section. Be sure to read the entire section entitled Welding Guidelines prior to using this equipment.

2.Turn welder off.

3.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.

All persons

! WARNING 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,

! WARNING 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.

4.Connect the work clamp to the work piece or workbench (if metal). Make sure the contact is secure. Avoid surfaces with paint, varnish, corrosion, or non-metallic materials.

5.Position the Heat Selector on the front panel to the desired setting.

NOTE: These settings are general guidelines only. Heat setting may vary according to welding conditions and materials.

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Operating Instructions and Parts Manual

Operation (Continued)

 

Metal

Heat

 

Thickness

Setting

 

 

 

 

 

14 - 18 Gauge

Low

 

 

 

 

 

Thicker Than 14 Gauge

High

6.Rotate the Wire Speed Control to setting number 5 to start with, then adjust as needed after test weld. The WF1800’s wire speed is automatically adjusted to the heat selection chosen.

7.Plug the input cord into a proper voltage receptacle with proper circuit capacity (See circuit requirements on front page).

8.Switch the welder ON/OFF switch to the ON position. For the WF1800/WF1900, switch the welder to the desired heat setting.

9.Verify that the wire is extended 1/4” from the contact tip. If not, squeeze the trigger to feed additional wire, release the trigger, and cut wire to proper length.

10.Position the wire feed gun near the work piece, lower the welding helmet by nodding the head, or position the hand shield, and squeeze the gun trigger. Adjust heat setting and wire speed as needed. Wire speed is not adjustable on the WF1800.

11.When finished welding, turn welder off and store properly.

Maintenance

Disconnect power ! WARNING supply and turn

machine off before inspecting or servicing any components. Keep the wire compartment cover closed at all times unless the wire needs to be changed.

Before every use:

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.

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 ! WARNING welding machine

with cracked or missing insulation on welding cables, wire feed gun, or power cord.

Every 3 months:

1.Replace any unreadable safety labels on the welder.

2.Use compressed air to blow all dust and lint from the ventilation openings.

3.Clean the wire groove on the drive roll. Remove wire from the feed mechanism, remove screws from the drive roll housing. Use a small wire brush to clean the drive roll. Replace if worn or damaged

Consumable and Wear Parts

The following parts require routine maintenance:

Wire feed drive roller

Gun liner - replace if worn

Nozzle/contact tips

Wire - The WF2000 will accept either 4” or 8” diameter spools. The WF1800/WF1900 will accept 4” spools only. 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 approximately 6 months. Use AWS type E71T-GS or E71T-11, .030” (.8mm) or .035” (.9mm) diameter.

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.

Welding Guidelines

General

This line of welding machines utilizes a process called Flux Cored Arc Welding (FCAW). The FCAW process uses a tubular wire with a flux material inside. Shielding is obtained from the decomposition of the flux within the tubular wire.

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 in Figure 12.

Diffuser

 

Contact

Nozzle

 

Tip

Slag

 

Flux

Weld

 

Wire

 

Crater

Work Piece

 

 

Figure 12 - Weld Components

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 or generalized chart in the Operation section. It is suggested that the welder practice with scrap metal to adjust settings, and compare welds with Figure 17.

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6

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 - WF2000
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 (See Figure 17). 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.
TRAVEL SPEED
The travel speed is the rate at which the wire is moved across the weld area. 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. 17). 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.
SLAG REMOVAL
Wear ANSI
! WARNING 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
7

Welding Guidelines (Continued)

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.

The AWS classification for self-shielding wire (FCAW process) is a multi digit number preceded by the letter E.

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 these welders.

WELD ANGLE

Weld angle is the angle at which the diffuser 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.

5º - 45º

Work Angle

5º - 45º

Travel Angle

Figure 13 - Weld Angle

Models WF1800, WF1900 and WF2000

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 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 (See Fig. 14). 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.

Cover

Filler

Root

Figure 14 - Fillet Welds (60˚ Bevel)

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Operating Instructions and Parts Manual

Welding Guidelines (Continued)

PUSH VS PULL TECHNIQUE

The type and thickness of the work piece dictate which way to point the gun nozzle. For thin materials (18 gauge and up), 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 16).

Figure 15 - Multiple Weld Passes

PULL

PUSH

Figure 16

Glossary of Welding Terms

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 that 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.

www.chpower.com

8

Models WF1800, WF1900 and WF2000

Base metal

Normal heat, wire speed,

Travel speed too fast

travel speed

 

Heat too low

Travel speed too low

Heat too high

Wire speed too slow

Figure 17 - Weld Appearance

Wire speed too fast

BLACK

WHITE

GREEN

L1 L2

 

 

+ TO WORK CLAMP

- TO TORCH

S1

MIN

T1

 

 

 

 

 

 

 

OFF

~

 

 

 

 

 

MAX

 

 

S3 NC

 

+

-

OPENS @ 120˚C

S3

 

 

 

 

Y

 

~

 

 

 

DRIVE DECK

 

 

 

GROUND

 

S2

- M +

 

GUN

 

 

 

 

WIRE SPEED

4 3 2 1 CONTROL BOARD

Figure 18 - Wiring Schematic (WF1800)

WHITE

BLACK

GREEN

 

 

 

+ TO WORK CLAMP

- TO TORCH

ON/OFF

 

 

 

 

S1

 

S2

T1

 

 

 

MIN

 

 

 

 

 

1

2

 

~

 

 

 

 

MAX

 

4

 

 

 

 

 

5

 

+

-

Y

S4 NC

 

S4

 

OPENS @ 127C

 

 

 

6

 

 

 

GROUND

 

 

~

DRIVE

 

 

 

DECK

 

 

 

 

 

 

S3

-

M

+

 

 

 

 

L2

L1

GUN

 

 

 

 

 

 

 

4 3 2 1

Figure 19 - Wiring Schematic (WF2000)

WIRE SPEED

CONTROL BOARD

 

 

 

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9

Operating Instructions and Parts Manual

For Information About This Product Call 1-800-746-5641

Troubleshooting Chart - Welder

Symptom

Possible Cause(s)

Corrective Action

No output

1. Duty cycle exceeded

1. Allow welder to cool until ON/OFF Switch lamp goes out

 

2. Poor work clamp

2. Be sure all connections are secure, and attaching surface is

 

connection

clean

 

3. Defective ON/OFF

3. Replace switch

 

switch

 

 

4. Blown breaker or fuse

4. Reduce circuit load, reset breaker or replace fuse

 

 

 

Wire tangles at drive roller

1. Wrong size gun tip

1. Use proper size gun tip

 

2. Gun liner clogged or

2. Clean or replace gun liner

 

damaged

 

 

3. Gun tip clogged or

3. Clean or replace gun tip

 

damaged

 

 

4. Feed roller worn

4. Replace

 

5. Not enough tension

5. Tighten tensioning screw

 

 

 

Gun nozzle arcs to work surface

Slag inside gun nozzle

Clean slag from gun nozzle

 

 

 

Work clamp and/or cable gets

Poor contact

Be sure all connections are secure, and attaching surface is

hot

 

clean

 

 

 

Wire does not feed

1. Wire jammed

1. Reload wire

 

2. Out of wire

2. Replace wire spool

 

3. Not enough tension

3. Tighten tensioning screws if wire is slipping

 

4. Wire liner worn

4. Replace liner

Troubleshooting Chart - Welds

 

Symptom

Possible Cause(s)

Corrective Action

 

 

Bead is intermittently too thin

1. Inconsistent travel speed

1. Decrease and maintain constant travel speed

 

 

 

2. Output heat setting too low

2. Increase output heat setting

 

 

 

 

 

 

 

Bead is intermittently too thick

1. Slow and/or inconsistent

1. Increase and maintain travel speed

 

 

 

travel speed

 

 

 

 

2. Output heat setting too high

2. Reduce output heat setting

 

 

 

 

 

 

 

Ragged depressions at edge of

1. Travel speed too fast

1. Decrease travel speed

 

 

weld

2. Wire speed too fast

2. Decrease wire speed (WF2000)

 

 

 

3. Output heat setting too high

3. Reduce output heat setting

 

 

 

 

 

 

 

Weld bead does not penetrate

1. Inconsistent travel speed

1. Decrease and maintain constant travel speed

 

 

base metal

2. Output heat setting too low

2. Increase output heat setting

 

 

 

3. Excessive extension cord length

3. Use an extension cord no longer than 20 ft.

 

 

 

 

 

 

 

Wire sputters and sticks

1. Damp wire

1. Use dry wire and store in dry location

 

 

 

2. Wire speed too fast

2. Reduce wire speed

 

 

 

3. Wrong type of wire

3. Use flux core wire only (Do not use MIG or copper

 

 

 

 

color wire)

 

 

 

 

 

 

 

www.chpower.com

 

 

 

10

Models WF1800 & WF1900

 

 

 

 

 

17

 

 

19

23

 

 

 

 

18

 

 

 

 

 

 

20

 

22

 

 

 

 

21

24

 

 

 

 

 

 

 

 

 

22

 

13

16

 

 

 

 

14

 

 

 

 

 

15

 

 

 

 

For Information

34

 

 

 

Inside

 

 

 

About

 

 

 

 

 

 

 

 

 

This Product

 

 

 

 

 

Call 1-800-746-5641

 

 

 

 

27

25

27

 

 

30

 

 

30

12

11

Inside

28

UTILITY

 

 

 

 

 

 

 

 

 

 

1

 

WELDER

 

 

 

 

 

 

 

 

 

 

 

Wire

Feed

DELIVERS

SMOOTH

 

e Feed

Welder

en

Fil

 

 

 

 

 

DC

 

 

 

 

 

 

 

Welder

POWER

 

Wir

Alimente

e Continuo

 

 

 

 

 

 

LOW

 

 

 

 

 

 

 

 

 

OFF

 

 

Soudeur

 

 

Alambr

 

 

 

 

FLUX

 

 

Soladar

con

 

 

 

 

 

 

CORE

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

HIGH

 

 

 

 

 

 

 

 

 

 

 

WORK

CLAMP

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

115

VOLT

 

 

 

 

 

 

 

 

32

 

 

 

 

60HZ

 

 

 

 

 

 

29

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

33

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

10

 

 

 

 

 

 

 

 

 

 

 

 

 

 

26

 

 

 

 

 

31

 

7

2

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

8

9

4

 

 

 

 

 

6

 

 

 

 

 

 

5

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

 

Figure 20 - Models WF1800 & WF1900

 

 

 

Replacement Parts

 

 

 

 

 

 

 

 

Ref.

 

 

 

 

No.

Description

Part Number

Qty

1

 

Torch assembly and hose

WC600900AJ

1

2

 

Torch body, front and back

WC600201AV

1

3

▲ Hanger clip

WC600003AV

1

4

 

Nozzle

WT502100AV

1

5

 

Contact tip - 0.035” (0.9 mm)

WT501400AV

1

 

 

 

Optional contact tip - 0.030” (0.8 mm)

 

 

 

 

(4-pack)

WT501300AJ

 

 

 

Optional contact tip - 0.035” (0.9 mm)

 

 

 

 

(4-pack)

WT501400AJ

6

 

Trigger

WC600202AV

1

7

 

Torch contact spring

WC600203AV

1

8

 

Work clamp (Cord not included)

WC100300AV

1

9

 

Welding cable 8 AWG (6 ft)

 

1

10

 

High/Off/Low switch

WC401000AV

1

11

 

Safety decal (left)

DK670000AV

1

12

 

Power cord 14-3 AWG (6 ft) type SJT

1

13

 

Spindle

WC500700AV

1

14

 

M4.8-1.6 x 16 mm Sheet metal screw

1

 

 

 

 

 

 

15

 

Optional flux-core wire .030”

 

 

 

 

 

(0.8 mm), 2 lb.

WE200001AV

 

 

 

Optional flux-core wire .035”

 

 

 

 

 

(0.9 mm), 2 lb.

WE200501AV

16

 

Spindle spring

WC500701AV

1

17

 

Drive deck assembly

 

 

 

 

 

(Includes Nos. 18 - 24)

WC500000AV

1

18

 

Tension spring

WC500003AV

1

19

 

Tension screw

WC500002AV

1

Ref.

 

 

 

 

No.

Description

Part Number

Qty

 

20

Roller, .6-.9mm

WC500001AV

1

 

21

Roller cover

WC500004AV

1

 

22

M4.2-1.4 x 35 mm Sheet metal screw

3

 

23

Swing arm

WC500005AV

1

 

24

Swing arm roller

WC500007AV

1

 

25

Handle

WC301300AV

1

 

26

Strain relief

WC102000AV

2

 

27

M4.2-1.4 x 10 mm Sheet metal screw

2

 

28

Safety decal (right)

DK670001AV

1

 

29

Liner, coated metal

WC600208AV

1

 

30

Cord storage clip

WC301301AV

2

 

31

Swan neck w/diffuser

WC600701AV

1

 

32

Valve body

WC600204AV

1

 

33

Trumpet liner

WC600305AV

1

 

34

▲ Wire speed control board (inside)

WC401600AV

1

 

35

▲ Welding helmet (WF1900 only)

WT100000AV

1

 

36

▲ Replacement lens kit - one shaded

 

 

 

and two clear

WT110501AV

37

▲ Handshield (lens not included)

 

 

 

 

(WF1800 only)

WC801200AV

1

 

38

▲ Shaded lens (for handshield)

WC801100AV

1

 

39

▲ Chipping hammer/brush

WC803000AV

1

 

Not Shown

Optional accessory, sold separately

Standard hardware item, available at local hardware or welder supply store

www.chpower.com

11

Operating Instructions and Parts Manual

Model WF2000

 

 

 

 

 

 

23

 

 

 

 

 

25

30

 

 

 

 

 

 

 

24

 

 

 

 

 

 

 

 

 

26

29

28

 

33

 

 

 

 

 

 

15

 

 

 

 

 

 

 

 

 

 

27

 

 

 

 

 

 

 

 

28

 

34

 

 

 

 

 

 

Inside

 

 

 

17

18

 

22

39

 

 

 

 

 

 

 

 

 

 

 

19

 

 

 

 

 

 

 

 

20

21

 

 

 

 

 

 

 

 

 

31

 

ON

 

 

 

 

 

 

 

LOW

 

 

 

 

 

 

 

 

 

13

 

 

OFF

H

IGH

 

 

 

 

 

CH

 

 

 

 

 

 

 

 

 

 

10

 

 

 

 

 

 

 

10, 11

 

33

 

 

For Information About

 

 

 

 

 

 

This Product

 

34

 

Call 1-800-746-5641

 

 

 

 

 

14

1

 

 

 

 

12

35

 

37

 

 

 

 

 

38

 

 

CAMPBELL

32

 

 

2

HAUSFELDTO DUTY

36

7

 

BUILT

 

LAST

 

 

 

SERIOUS

9

 

 

 

 

 

 

 

 

 

4

8

5

6

 

 

Figure 21 - Model WF2000

16

 

 

 

 

 

 

 

 

 

 

 

Replacement Parts

 

 

 

 

 

 

 

 

 

 

 

 

Ref.

 

 

 

 

 

 

No.

 

Description

Part Number

Qty

1

 

Torch assembly and hose

WC600900AJ

1

2

 

Torch body, front and back

WC600201AV

1

3

 

Hanger clip

WC600003AV

1

4

 

Nozzle

WT502100AV

1

5

 

Contact tip - 0.035” (0.9 mm)

WT501400AV

1

 

 

 

Optional contact tip - 0.030” (0.8 mm)

 

 

 

 

 

(4-pack)

WT501300AJ

 

 

 

 

Optional contact tip - 0.035” (0.9 mm)

 

 

 

 

 

(4-pack)

WT501400AJ

 

6

 

Trigger

WC600202AV

1

7

 

Torch contact spring

WC600203AV

1

8

 

Work clamp (Cord not included)

WC100300AV

1

9

 

Welding cable 8 AWG (6 ft)

 

1

10

 

Wire speed knob

WC400201AV

1

11

 

Wire speed control board (inside)

WC402100AV

1

12

 

Low/high switch

WC400300AV

1

13

 

On/off switch

WC400000AV

1

14

 

Safety decal

DK670100AV

1

15

 

Handle

WC300100AV

1

16

 

Power cord 14-3 AWG (6 ft) Type SJT

 

1

17

 

Spool spindle

WC500300AV

1

18

 

M4.8-1.6 x 10 mm Sheet

 

 

 

 

 

 

 

metal screw

 

2

19

 

Optional flux-core wire .030” (0.8 mm)

 

 

 

 

 

2 lbs.

WE200001AV

 

 

 

 

10 lbs.

WE201000AV

 

 

 

 

Optional flux-core wire .035” (0.9 mm)

 

 

 

 

 

2 lbs.

WE200501AV

 

 

 

 

10 lbs.

WE201500AV

 

Ref.

 

 

 

 

No.

Description

Part Number

Qty

 

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

WC500001AV

1

 

27

Roller cover

WC500004AV

1

 

28

M4.2-1.4 x 35 mm Sheet

 

 

 

 

metal screw

 

3

 

29

Swing arm roller

WC500007AV

1

 

30

Swing arm

WC500005AV

1

 

31

Side panel

WC700000AV

1

 

32

Strain relief

WC102000AV

2

 

33

M8 -1.25 x 20 mm Machine screw

 

2

 

34

Handle cap

WC300101AV

2

 

35

Liner, coated metal

WC600208AV

1

 

36

Swan neck w/diffuser

WC600701AV

1

 

37

Valve body

WC600204AV

1

 

38

Trumpet liner

WC600305AV

1

 

39

Torch ring

WC600009AV

1

 

40

Handshield (lens not included)

WC801300AV

1

 

41

Shaded lens (for handshield)

WC801100AV

1

 

42

Chipping hammer/brush

WC803000AV

1

 

Not Shown

Optional accessory, sold separately

Standard hardware item, available at local hardware or welder supply store

www.chpower.com

12

+ 28 hidden pages