Campbell Hausfeld WG3060 User Manual

Name: Campbell Hausfeld WG3060
Brand: Campbell Hausfeld
SKU: 1060862
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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.

IN211104AV 9/99

Operating Instructions & Parts Manual Models WG3000 and WG3060

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 (800) 746-5641.

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. Work 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 -

turns 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.

MODEL WG3000

Low (1-2) 15 amp

High (3-4) 20 amp

Description

MODEL WG3060

4 & 6

Figure 1

General Safety

For parts, product & service information

visit www.campbellhausfeld.com

Need

BUILT TO LAST

Assistance?

Call Us First!

1-800-746-5641

Wire Feed Arc Welder

Torch is “live” (has

current potential) at all times when machine is turned on (WG3000 only).

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, 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.

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.

Model WG3000

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

WG3000 and WG3060

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.

Model WG3060

HANDLE ASSEMBLY

1. Place handle assembly on welder aligning the holes in welder front panel.

2. Fasten screws through handle ends and into cabinet.

WHEEL AND AXLE ASSEMBLY

1. Attach axle on welder housing with attaching hardware.

2. Insert wheels onto axle and lightly

tap in wheel caps.

GAS CYLINDER BRACKET ASSEMBLY

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

2. Fasten screws through bracket into cabinet.

FOOT ASSEMBLY

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

2. Fasten screws through foot into cabinet.

Work Clamp (All Models)

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 4).

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 5 for assembly.

Wire Feed Arc Welder

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.

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 6). 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

Assembly (Continued)

Figure 2 - WG3000 Assembly

Figure 3 - WG3060 Assembly

Clamping Block

Figure 4 - Work Clamp Assembly

Tension Screw

Panel

Drive Roller

Spool Spacer

Guide Tube

Spindle

4” or 8” Spool

Spring

Spool Lock

Figure 5 - Weld Wire Routing

Torch Neck

Contact Tip

Nozzle

Figure 6 - Torch Nozzle

Spindle Spacer

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*Reverse

position and insert into 8” spool

WG3000 and WG3060

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 work clamp cable to the (-) socket on the front panel. For fluxcore (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 if the duty cycle is exceeded. Welding operations may continue when the yellow lamp is no longer illuminated.

MODEL WT1000

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 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.

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 electrode (wire).

REGULATOR

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.

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 to

the fitting on the rear of the welder and the other end to the fitting on the regulator using hose clamps 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.

Contact Tip Markings

Wire Size mm

.024” or .6

.030” or .8

.035” or .9

.040” or 1.0

Assembly (Continued)

Figure 7

Headgear

Face Shield

Shaded Lens

Clear Lens Cover (2)

Post

Lens Retainer

Adjustment Arm (2)

Tension Nut (2)

Stud Screw (2)

Welding Helmet Assembly

Shielding Gas Installation

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Wire Feed Arc Welder

*NOTE: Campbell Hausfeld regulator

WT600100AV is factory preset at 30 cfh. No adjustment is necessary. Also, a popout indicator in the end of the regulator shows the amount of gas left in the cylinder. When not extended, there is approximately 10 minutes of welding left before the cylinder is empty.

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 WG3000 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. See application decal inside door of

wire feed compartment for proper heat settings.

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

6. Rotate the Wire Speed Control to setting number 5 to start with, then adjust as needed after test weld.

7. Plug the input cord into a proper voltage receptacle with proper circuit capacity (See Chart under circuit requirements on page 1).

8. Switch the welder ON.

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.

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

Disconnect power

supply and turn machine off before inspecting or servicing any components. Keep the wire compartment cover closed at all times unless the wire needs replacement.

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 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.

Consumer and Wear Parts

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. 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. For mild steel welding, AWS ER70S6 solid wire or AWS E71T-GS flux-core wire is recommended.

• Contact tips - use Campbell Hausfeld,

Tweco

, and other compatible tips.

Pop-out Indicator

Cap

Adapter

ARGON OR

ARGON MIX

INSTALLATION

Figure 8 - Hookup

Operation

Maintenance

Shielding Gas Installation (Continued)

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MANUAL

WG3000 and WG3060

• Nozzle - use Tweco®style or compatible nozzle. Use Campbell Hausfeld nozzle model WT5021 found at place of purchase of welder, or use Tweco

style nozzle (or compatible nozzle) found at local welding supply store.

Changing Wire Sizes

DRIVE ROLLER

There are two grooves in the Drive Roller. The small groove is for .024 (.6 mm) wire and the other is for .030 .035 (.8 - .9 mm) wire. Remove the roller cover and flip the drive roll to choose the correct groove (see Parts Breakdown).

FLUX CORE WIRE

Due to small inconsistencies in wire diameter, using one size larger tip is recommended. For example:

• If wire diameter is .030, use .035 tip.

• If wire diameter is .035, use .040 tip. This welder is setup for .035 (.9 mm)

wire and has a .040 tip. Since this welder uses .030 and .035 Flux Core Wire, the drive roller should be in its factory pre-set condition.

Welding Guidelines

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 10).

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.

Maintenance

(Continued)

Slag

Weld

Wire

Flux

(Gasless

only)

Work Piece

Shielding

Gas

Contact Tip

Crater

Nozzle

Figure 10 - Weld Components

MIG

WT5021

Figure 9 - Nozzle

MIG WIRE

Since MIG wire maintains fair wire diameter consistency, the contact tip used should match the wire size used. When using .024 (.6 mm) wire, use the small groove on the drive roller. When using .030 - .035 (.8 - .9 mm) MIG or Aluminum wire, use the factory set large groove.

ALUMINUM WIRE

When using Aluminum wire, it is best to use a larger size tip than the wire size being used. For example:

• If wire diameter is .030, use .035 tip. When using .030 - .035 (.8 - .9 mm) MIG

or Aluminum wire, use the factory set large groove. Aluminum wire is very weak and should not have the same tension on the drive roller as Flux Core or MIG wire should. When tensioning Aluminum wire down to the Drive Roller, turn the tension screw three full turns or until the Drive Roller begins to grip the wire and feed it through the torch cable.

Call (800) 746-5641

for replacement parts.

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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 12.

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-CORE WIRE E - 7

0 T - GS

Weld strength, times 10,000 psi

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

Wire Feed Arc Welder

Welding Guidelines (Continued)

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. For aluminum, wire speed is typically set higher (7 - 9 speed range).

NOTE: 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 torch is moved across the weld area. Factors such as diameter and type

of weld wire, amperage, position, and work piece material thickness all affect the speed of travel necessary for completing a good weld (See Fig. 12). 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-CORE 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.

NOTE: 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.

TRAVEL ANGLE

WORK ANGLE

5º - 45º

Figure 11 - Weld Angle

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stainless steel brush to eliminate any oxides on the weld and grounding surface. 100% Argon must be used when welding aluminum. If Argon is not used, metal penetration is unlikely.

1. Verify that welder is OFF and power cord disconnected.

2. Remove welder cover to expose the ON/OFF switch.

WG3000 and WG3060

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 12 - Weld Appearance

Figure 14 - Multiple Weld Passes

Welding Guidelines (Continued)

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.

NOTE: Remember to remove the slag before each pass for gasless process.

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 15).

ALUMINUM WELDING

Any aluminum surface to be welded, must be cleaned thoroughly with a

Figure 13 - Weld Passes

Cover

Filler

Root

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 screw(s) and pull cord out of strain relief.

6. Install new cord in reverse order.

PUSH

PULL

Figure 15

Supply Cable Replacement

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Troubleshooting Chart - Welder

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

Slag inside gun nozzle

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. Fuse blown

6. Wire disconnected internally

7. Contact tip clogged

1. Wire speed too slow

2. Travel speed too slow or heat is too high

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

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 buidup on surface

1. Damp wire

2. Wire speed too fast

3. Wrong type of wire

4. No or low shielding gas

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

Clean slag from gun 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. Replace fuse on wire feed control board inside welder, (1.6 amp time delay)

6. Call 1-800-746-5641 for assistance

7. Replace contact tip

1. Run speed in 7 - 10 range

2. Increase the travel speed or reduce heat settings

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

Troubleshooting Chart - Welds

Symptom Possible Cause(s) Corrective Action

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

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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):

The Campbell Group / A 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.

WG3000 and WG3060

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WG3000 Wiring Diagram

ON / OFF

MAX

MIN

Gun

Wire Feed Arc Welder WG3000

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White

L2 (N)

Black

Green

Ground

5 6 7 84321678

WG3060 Wiring Diagram

Wire Feed Arc Welder WG3060

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L2 (N) White

L1 (R) Black

Green

S20127°

Ground

5 6 7 8 9 104321

K-A2

K-A1

For Replacement Parts, call 1-800-746-5641

Address parts correspondence to:

The Campbell Group Attn: Parts Department 100 Production Drive Harrison, Ohio 45030 U.S.A.

Please provide following information:

- Model number

- Serial number (if any)

- Part description and number as shown in parts list

Wire Feed Arc Welder

MODEL WG3060

MODEL WG3000

9 & 10

11 & 30

9 & 10

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** Contact Tip (See chart on Page 15)

1 Torch assembly and hose (Includes Nos. 2-6, 34 and 50) WC600700AV WC600700AV 1 2 Torch body, front and back WC600201AV WC600201AV 1 3 Hanger clip WC600003AV WC600003AV 1 4 Nozzle, Tweco®Style WT502100AJ WT502100AJ 1 5 Trigger knob WC600202AV WC600202AV 1

6 Torch contact spring WC600203AV WC600203AV 1 7 Work clamp (Cord not included) WC100100AV WC100100AV 1 8 Welding cable 8 AWG (6 ft) ❋ ❋ 1 9 Wire speed knob WC400201AV WC400201AV 1

10 Wire speed control board WC400200AV WC400600AV 1 11 Heat selector switch WC400300AV — 2

Heath selector switch — WC400500AV 1 12 On/off switch WC400000AV — 1 13 Safety decal DK670100AV DK670100AV 1 14 Handle WC300600AV WC300700AV 1 15 Power cord 14-3 AWG (6 ft) Type SJT WC000100AV WC000100AV 1

16 Spool spindle WC500300AV WC500300AV 1 17 #10-32 x .5” Pan head sheet metal screw ❋ ❋ 2 18 Wire-flux core .035” (.9mm) diameter WE200500AJ WE200500AJ 1 19 Spool adapter WC500200AV WC500200AV 1 20 Spool spring WC500101AV WC500101AV 1

21 Spool locking hub WC500100AV WC500100AV 1 22 Drive deck assembly (Includes Nos. 23-29) WC500000AV WC500400AV 1 23 Tension spring WC500003AV WC500003AV 1 24 Tension screw WC500002AV WC500002AV 1 25 Roller .6-.9mm (.024-.035 in.) WC500001AV WC500001AV 1

26 Roller cover WC500004AV WC500004AV 1 27 #8-36 x 1.5” Pan head screw ❋ ❋ 3 28 Swing arm WC500005AV WC500005AV 1 29 Swing arm roller WC500007AV WC500007AV 1 30 Heat selector knob — WC400401AV 1

31 Strain relief WC102000AV WC102000AV 2 32 Wheel WC701200AV WC701300AV 2 33 Front foot WC702100AV WC702300AV 1 34 Liner, metal WC600007AV WC600007AV 1 35 Gas cylinder bracket WC702200AV WC702400AV 1 36 Handle support (Right) — WC300800AV 1 37 Handle support (Left) — WC300900AV 1 38 Axle WC703100AV WC703200AV 1 39 Wheel hub WC703500AV WC703400AV 1 40 Dinse connector WC000200AV WC000200AV 2 41 Dinse socket WC000300AV WC000300AV 2 42 Torch ring WC600009AV WC600009AV 1 43 #10-24 x 1/2” Screw ❋ ❋ 9 44 Axle support WC703600AV — 2 45 5mm I.D. e-ring ❋ — 2 46 #10-24 x 2” Screw — ❋ 2 47 #8-36 x 1” Screw — ❋ 2 48 #8 Flatwasher — ❋ 2 49 #8-36 Nut — ❋ 2 50 Swan neck with Diffuser WC600701AV WC600701AV 1

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

Replacement Parts List - Models WG3000 and WG3060

Ref Part Number for Models: No. Description WG3000 WG3060 Qty

OPTIONAL WIRE

Type Description Part Number

Mig ER70S6 .024” WE300000AJ Mig ER70S6 .030” WE300500AJ Mig ER70S6 .035” WE301000AJ Flux E71T-GS .030” WE200000AJ Flux E71T-GS .035” WE200500AJ

WG3000 and WG3060

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**OPTIONAL CONTACT TIPS

Size

mm in. Part Number

0.6 0.024 WT501200AV

0.8 0.030 WT501300AV

0.9 0.035 WT501400AV

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