Campbell Hausfeld WG3013 User Manual

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.

IN970400AV 11/00

Operating Instructions & Parts Manual Model WG3013

Wire Feed
Arc Welder

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.

These welders are designed for use with
Flux Core Arc Welding (Gasless) or Gas
Metal Arc Welding (Mig) process. As
delivered from the factory, this welder
can weld with .024” (.6 mm) to .035”
(.9 mm) diameter wire. A starter spool
of .035” (.9 mm) flux-cored wire and a
.040 tip are included.

Unpacking

Some welder components may be
found in the wire feed compartment.

When unpacking, inspect carefully for
any damage that may have occurred
during transit. Report any damaged or
missing items by calling [phone].

Circuit Requirements

This equipment

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.

Components and Controls

1. Ground Clamp - connect to work
piece.

2. Wire Feed Gun with .040 tip

3. Power Cord - plug into 115 volt
outlet.

4. On/Off Switch

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

7. Polarity Hook-up - Attach torch
cable to (+) for MIG and (-) for flux
core wire.

Heat Circuit Breaker or
Selector Slow Blow Fuse

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.

FARMHAND 125

Low 15 amp

High 20 amp

Description

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Figure 1

General Safety

© 2000 Campbell Hausfeld / Scott Fetzer

For parts, product & service information

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2

Wire Feed Arc Welder

Torch is “live” (has
current potential)

at all times when machine is turned on.

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 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
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 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.

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 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, 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 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.

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 m) 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,
behind bulkheads, 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.

General Safety

(Continued)

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Code for Safety in Welding and
Cutting

CSA Standard W117.2, from Canadian
Standards Association, Standards Sales,
178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3

Cutting And Welding Processes

NFPA Standard 51B, from National Fire
Protection Association, Batterymarch
Park, Quicy, MA 02269

Safe Practices For Occupational And
Educational Eye And Face
Protection

ANSI Standard Z87.1, from American
National Standards Institute, 1430
Broadway, New York, NY 10018

Refer to the Material Safety Data
Sheets and the manufacturers
instructions for metals, wire, coatings
and cleaners.

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 12” (30,48 cm) of
ventilation space at both the front
and rear of the unit. Keep all
obstructions away from this
ventilation space.

● Store wire in a clean, dry location
with low humidity to preserve the
wire coating.

● 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.

Welder components listed below
are in the wire feed compartment.
Open and remove.

HANDLE ASSEMBLY

1. Remove screws from handle. Slide

handle between welder front panel

Do not breathe fumes that
are produced by the arc
welding operation. These
fumes are dangerous. If the welding
area cannot be adequately ventilated,
be sure to use an air supplied
respirator.

● Keep the head and face out of the
welding fumes.

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

a. Remove the coating from the

base metal.

b.Make sure that the welding area

is well ventilated.
c. Use an air-supplied respirator.
Extremely toxic fumes are created

when these metals are heated.

The electromagnetic field
that is generated during arc
welding may interfere with
the operation of various
electrical and electronic devices such as
cardiac pacemakers. Persons using such
devices should consult with their
physician prior to performing any
electric arc welding operations.

● Route the 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

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.

Cylinders can explode if
damaged. Shielding gas

3

WG3013

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 them and
associated parts in good condition.

● 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.

Never use

flammable gasses
with MIG welders. Only inert or non­flammable 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, caps, or with chains or slings.

ADDITIONAL SAFETY STANDARDS
ANSI Standard Z49.1 from American

Welding Society, 550 N.W. LeJune Rd.
Miami, FL 33126

Safety and Health Standards

OSHA 29 CFR 1910, from
Superintendent of Documents, U.S.
Government Printing Office,
Washington, D.C. 20402

National Electrical Code

NFPA Standard 70, from National Fire
Protection Association, Batterymarch
Park, Quincy, MA 02269

Safe Handling of Compressed Gases
in Cylinders

CGA Pamphlet P-1, from Compressed Gas
Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202

General Safety

(Continued)

Installation

Assembly

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and top cover aligning the holes in
handle with holes in top cover.

2. Fasten screws through top cover and
into handle.

WHEEL AND AXLE ASSEMBLY

1. Insert axle supports into slots in the
welder housing.

2. Insert axle through the axle supports
and firmly push wheels onto axle.

3. Secure wheel with e-clips and wheel
caps.

GAS CYLINDER BRACKET ASSEMBLY

1. Place bracket on welder aligning the
holes in welder housing.

2. Fasten screws through bracket and
into cabinet.

FOOT ASSEMBLY

1. Place foot on welder and align holes
in the welder housing.

2. Fasten screws through foot into
cabinet.

Ground Clamp

1. Loosen hex nut on work clamp.

2. Insert cord through clamp handle and
slide bare wire under the clamp block.
Tighten hex nut making sure bare
wire is clamped securely (Figure 3).

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 the wire matches the
contact tip in the end of the gun. A
mismatch on any item could cause the
wire to slip or bind.

1. Verify the unit is off and open 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.

NOTE: Spool spacer and spindle spacer
act as an 8” spool spindle adapter.
Purchase of an adapter is not necessary.

* See Figure 4 for assembly.

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

4. 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. 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.

4

Wire Feed Arc Welder

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.

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

HINT: Keep torch cable straight when
feeding wire.

8. Turn on the welder and set the wire
speed rate to 5. 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 neck.
Install the nozzle by turning clock-
wise (See Figure 6). Cut the wire off
approximately 1/4” from the end of
the nozzle.

POLARITY

For gas shielded welding, connect the
cable coming out of the torch to the (+)
socket and the ground clamp cable to
the (-) socket on the front panel. For
flux-core (no-gas) welding, connect
torch to (-) and work clamp to (+).

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

Assembly (Continued)

Figure 2 - WG3013 Assembly

Clamping
Block

Figure 3 - Work Clamp Assembly

Tension
Screw

Panel

Drive Roller

Spool
Spacer

Guide
Tube

Spindle

4” or 8”
Spool

Spring

Spool
Lock

Figure 4 - Weld Wire Routing

Torch Neck

Contact Tip

Nozzle

Figure 5 - Torch Nozzle

Spindle
Spacer

*Reverse
position and
insert into 8”
spool

Contact Tip Markings

Wire Size mm

.024” or .6
.030” or .8
.035” or .9
.040” or 1.0

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WG3013

if the duty cycle is exceeded. Welding
operations may continue when the
yellow lamp is no longer illuminated.

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 6).

4. To attach the handle, place shield on
a flat surface and press handle into
place (See Figure 7).

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.

Improper handling

and maintenance
of compressed gas cylinders and
regulators can result in serious injury

or death! Always secure gas cylinders
to the tank bracket kit, a wall or other
fixed support to prevent the cylinder
from falling over. Read, understand,
and follow all the compressed gases
and equipment hazards in the safety
instructions.

NOTE: Shielding gas is not required if
flux-cored welding wire is used.

GAS TYPES

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. However, 100% carbon
dioxide is not recommended due to
unsatisfactory weld beads. This welder
does not perform well with 100%
carbon dioxide. 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.

NOTE: Use of incorrect gas may lead to
little or no penetration of welding
bead.

REGULATOR (NOT INCLUDED)

The regulator provides a constant
shielding gas pressure and flow rate
during the welding process.

HOOKUP PROCEDURE

Cylinder gas is

under high
pressure. Point cylinder outlet away
from yourself and any bystanders
before opening.

1. These units fit a 20 cubic ft bottle.

2. With the cylinder securely installed,

remove the cylinder cap, stand to the
side of the cylinder opposite the
outlet, and open the valve slightly,
turning counterclockwise. When gas
is emitted from the cylinder, close the
valve by turning clockwise. This will
blow out dust or dirt that may have
accumulated around the valve seat.

3. Install the regulator onto the

cylinder valve, keeping the face of
the gauges in the vertical position
and tighten the stem nut securely
to the gas valve.

4. Install one end of the gas hose (not

included) to the fitting on the rear
of the welder and the other end to
the fitting on the regulator using
hose clamps (not included) on each

connection. Make sure the gas hose
is not kinked or twisted.

5. Once again, stand opposite the
cylinder outlet and slowly open the
cylinder valve. Inspect for leaks in
the connections.

6. Pull the trigger on the gun to allow
the gas to flow. While the trigger is
pulled and gas is flowing, adjust the
gas regulator to 30-35 cfh (cubic
feet per hour). Release the trigger.

7. Remember to close the gas valve
when finished welding.

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. Verify welder is 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 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.

WHETHER OR

NOT THE TRIGGER
IS PULLED, the welding wire is LIVE
whenever the welder is turned ON.

If heating, welding, or
cutting materials that are
galvanized, zinc plated, lead,
or cadmium plated refer to the General
Safety Information Section for
instructions. Extremely toxic fumes are
created when these metals are heated.

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.

Assembly

(Continued)

Shielding Gas
Installation

Handshield
Assembly

Figure 6

Lens

Lens
Retainer

Retainer
Stiffener

Figure 7

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MANUAL