Campbell Hausfeld WG3090, WG4130, WG3080, IN974200AV User Manual

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Operating Instructions & Parts Manual

Models WG3080, WG3090 and WG4130



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.

Wire Feed

Arc Welder

































































Call Us First!



These Campbell Hausfeld wire feed welders are designed to be used on standard 120V (WG3080 & WG3090) or 230V (WG4130) outlet. The welder 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 Cored Arc Welding (FCAW) or the Gas Metal Arc Welding (GMAW) process. As delivered from the factory, this welder can weld with .030" (0.8mm) diameter flux core wire. A starter spool of .030" (0.8 mm) flux cored wire is included.

To use the GMAW process with the WG3090 and WG4130, it is necessary to purchase shielding gas and MIG wire only. With the WG3080, a regulator /hose kit must be purchased in addition to the shielding gas and MIG wire.


When unpacking, inspect carefully for any damage that may have occurred during transit. Make sure any loose fittings and screws, etc., are tightened before putting unit into service. Report any missing or damaged items by calling 1-800-746-5641.







Figure 1 - Welder Components and Controls


This equipment requires a dedicated 120 volt or 230 volt circuit (depending on model). Refer to the following chart for correct circuit breaker or fuse rating for 120 volt models. 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.


1.Work Clamp – connects to work piece.

2.Torch with .030" tip.

3.Power Cord – plug into 120 volt or 230 volt outlet (depending on model).

4.Light – illuminates if thermostat has automatically shut welder off.

5.Infinite Wire Speed Control – turn clockwise to increase wire speed and counterclockwise to decrease wire speed.

6.Off/Heat Selector - Selects welding power and turns welder on.

Five selections are possible: 1 – 2 – 3 – 4 – 5.


Circuit Breaker or


Slow Blow Fuse for


120V Models








15 amp








20 amp
















See page 8 for supply cable replacement instructions.

REMINDER: Keep your dated proof of purchase for warranty purposes!

Attach it to this manual or file it for safekeeping.

© 2009 Campbell Hausfeld/Scott Fetzer

For parts, product & service information

IN974200AV 11/09

visit or call 1-800-746-5641

Wire Feed Arc Welder

General Safety






● Always wear dry, protective

● Wear ANSI approved face shield or






















clothing, welding gloves and


safety glasses with side shield















insulated footwear when operating


protection when chipping or



















grinding metal parts.


an imminently hazardous situation




which, if not avoided, will result in

● Always operate welder in a clean,

● Wear ear plugs when welding


death or serious injury.













dry, well ventilated area. Do not


overhead to prevent spatter or slag

















operate welder in humid, wet, rainy


from falling into ears.
























or poorly ventilated areas.















a potentially hazardous situation































which, if not avoided, COULD result in

● Be sure work piece is properly





























death or serious injury.


























supported and grounded prior to

Electric arc welding


















beginning any electric arc welding

operations produce intense
























light and heat and ultraviolet



































a potentially hazardous situation


(UV) rays. This intense light















and UV rays can cause injury to eyes and


which, if not avoided, MAY result in

● Spread out coiled welding cable


skin. Take all precautions described in


minor or moderate injury.













before use to avoid overheating and








this manual to reduce the possibility of













NOTE: Note means any additional


damage to insulation.

injury to eyes and skin.


information pertaining to the product






● All persons operating this equipment







or its proper usage.





















or in the area while equipment is in











wire or torch in water. If welder













use, must wear protective welding











becomes wet for any reason, be













gear including: welding helmet or











absolutely certain it is completely clean



Always keep a fire












and dry before use!


shield with at least shade 10 lens, flame


extinguisher accessible while













● Always shut equipment off and


resistant clothing, leather welding


performing arc welding















unplug power cord prior to moving


gloves and full foot protection.










● Before starting or







the unit.



































servicing any electric arc






● Always attach the work lead first.









look at













welder, read and






● Verify work piece is securely

arc welding operations without eye







protection as described above. Never



understand all








use a shade filter lens that is cracked,











instructions. Failure to






● Always shut off electric arc welding

broken, or rated below number 10.










follow safety precautions or

Warn others in the area not to look at




equipment when not in use and cut off

the arc.



instructions can cause equipment





any excess wire from torch.
















damage and/or serious personal

































● Never allow any part of the body to
















injury or death.


























Electric arc welding















touch welding wire and ground or



● All installation, maintenance, repair


operations cause sparks and




grounded work piece at the same

heat metal to temperatures









and operation of this equipment












that can cause severe burns!














should be performed by qualified


Use protective gloves and clothing when



● Awkward welding conditions and



persons only in accordance with

performing any metal working




positions can be electrically hazardous.

operation. Take all precautions



national, state, and local codes.





described in this manual to reduce the




When crouching, kneeling or at












possibility of skin and clothing burns.












elevations, be sure to insulate all


● Make sure all persons in welding
























conductive parts, wear appropriate



Improper use of electric arc















area are protected from heat, sparks








protective clothing and take



welders can cause electric
















and ultraviolet rays. Use additional


shock, injury, and death! Take







precautions to prevent injury from falls.



all precautions described in








face shields and flame resistant







● Never attempt to use this equipment










this manual to reduce the possibility of


barriers as needed.


electric shock.







at current settings or duty cycles










● Never touch work pieces until


● Verify all components of the arc


higher than specified on equipment





completely cooled.







welder are clean and in good









































condition prior to operating welder.

● Never use an electric arc welder to































Be sure insulation on all cables,


thaw frozen pipes.

















Heat and sparks produced











torch and power cord is not















during electric arc welding





damaged. Always repair or replace






and other metal working












damaged components before






operations can ignite





Flying sparks and hot metal










flammable and explosive materials!



operating the welder. Always keep

can cause injury. As welds





Take all precautions described in this



cool, slag can be thrown off.




welder panels, shields, etc. in place


manual to reduce the possibility of



Take all precautions described




when operating welder.







flames and explosions.








in this manual to reduce the possibility






















of injury from flying sparks and hot metal.


Models WG3080, WG3090 and WG4130

General Safety


Remove all flammable materials within 35 feet (10.7 meters) of welding arc. If removal is not possible, tightly cover flammable materials with fire proof covers.

Do not operate any electric arc welder in areas where flammable or explosive vapors may be present.

Take precautions to ensure flying sparks and heat do not cause flames in hidden areas, cracks, etc.

Fire hazard! Do not weld on containers or pipes that contain or have contained flammable materials or gaseous or liquid combustibles.

Arc welding closed cylinders or containers such as tanks

or drums can cause explosion if not properly vented!

Verify that any cylinder or container to be welded has an adequate ventilation hole, so that expanding gases can be released.

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

Keep head and face out of welding fumes.

Extremely toxic fumes are created when galvanized or cadmium plated metals or metals which contain zinc, mercury or beryllium are heated. Complete the following precautions before performing electric arc welding operations on these metals:

a.Remove coating from base metal.

b.Make sure welding area is well ventilated.

c.Use an air-supplied respirator.

The electromagnetic field generated during arc welding may interfere with the operation of various electrical

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

Route torch and work cables together and secure with tape when possible.

Never wrap arc welder cables around the body.

Always position torch and work leads on the same side of the body.

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


This product, when used for welding, produces fumes or

gases which contain chemicals known to the State of

California to cause birth defects (or other reproductive harm) and, in some cases, cancer (California Health & Safety Code Section 25249.5 et seq.).

The power

cord and other cables on this product contain chemicals, including lead, known to the State of California to cause cancer and birth defects or other reproductive harm. Wash hands after handling.


Always be sure welding area is secure and free of hazards (sparks, flames, glowing metal or slag) prior to leaving. Be

sure equipment is turned off and excess wire is cut off. Be sure cables are loosely coiled and out of the way. Be sure all metal and slag has cooled.

Cylinders can explode if damaged. Shielding gas cylinders contain gas under high pressure. If damaged, a cylinder can explode. Since gas

cylinders are normally part of the welding process, be sure to treat them carefully.

Protect compressed gas cylinders from excessive heat, mechanical shocks and arcs.

Install and secure cylinders in an upright position by chaining them to stationary support or equipment cylinder rack to prevent falling or tipping.

Keep cylinders away from any welding or other electrical circuits.

Never allow a welding electrode to touch any cylinder.

Use only correct shielding gas cylinders, regulators, hoses and fittings designed for the specific application; maintain all parts properly.

Turn face away from valve outlet when opening cylinder valve.

Keep protective cap in place over valve except when cylinder is in use or connected for use.

Read and follow instructions on compressed gas cylinders, associated equipment, and CGA publication P-1 listed in Safety Standards.

Never use

flammable gasses with MIG welders. Only inert or non-flammable gasses such as carbon dioxide, argon, helium or mixtures of one or more of these gasses are suitable for MIG welding.

Never lift

cylinders off the ground by their valves or caps or with chains or slings.


ANSI Standard Z49.1 from American Welding Society, 550 N.W. Le June Rd. Miami, FL 33126

Safety and Health Standards

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

National Electrical Code

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

Safe Handling of Compressed Gases

in Cylinders

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

Code for Safety in Welding and Cutting

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

Cutting And Welding Processes

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


Wire Feed Arc Welder

General Safety


Safe Practices For Occupational And

Educational Eye And Face Protection

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

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



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

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

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

Store welding wire in a clean, dry location with low humidity to prevent oxidation.

Use a properly grounded receptacle for the welder and ensure welder is the only load on power supply circuit. Refer to chart on page 1 for correct circuit capacity.

Use of an extension cord is not recommended for electric arc welding machines. Voltage drop in the extension cord may significantly degrade performance of the welder.



1.Make sure unit is off and unplugged.

2.Feed the connectors for the torch switch through the hole in the control panel. These leads are to be fed up over the polarity studs and through the hanger on the center wall.

3.Insert the brass torch connector through the hole in the control panel and into the drive deck. Make sure the connector is inserted fully into the drive deck. Loosen the torch clamp knob a few turns if the connector will not insert fully. Tighten the torch clamp knob securely after the brass torch connector is fully inserted.

4.Connect the torch switch connectors to the two 1/4" terminals in the center wall. Polarity is not important. Make sure these wires do not interfere with the polarity studs or drive deck.


(See Fig. 3)

1.Remove one hex nut from work clamp.

2.Slide welding cable with ring connector through hole in work clamp.

3.Attach ring connector to work clamp with hex nut removed in step 1.

Torch switch





Torch clamp knob

Torch switch





Torch switch leads

Drive deck




Figure 2 - Torch Installation


Hex Nut

Ring connector

Welding cable

Work clamp

Figure 3 - Clamp Installation


Models WG3080, WG3090 and WG4130

Tension knob

Swing arm


Drive deck




Welding wire









Wire guide








Figure 4 - Weld Wire Installation



Assembly (Continued)


NOTE: Before installing welding wire, be sure:

a.Diameter of welding wire matches groove in drive roller on wire feed mechanism (See Fig. 4).

b.Wire matches contact tip in end of torch (See Fig. 5).

A mismatch on any item could cause the wire to slip and/or bind.

NOTE: Always maintain control of loose end of welding wire to prevent unspooling.

Torch Diffuser

Contact Tip





Figure 5 - Torch Nozzle








Contact Tip Markings



Wire Size





0.6 mm






0.8 mm






0.9 mm





1.Verify unit is off and open door panel to expose wire feed mechanism.

2.Remove the spool lock by pushing in and rotating 1/4 turn counterclockwise. Then remove lock, spring and retainer.

3.Flip tensioning knob down and swing arm up on drive mechanism. This allows initial feeding of wire into torch liner by hand.

4.Install wire spool onto spindle so wire can come off spool bottom of spool. Do not cut the wire loose yet. Install spool retainer, spring and lock by pushing in and turning lock 1/4 rotation clockwise.

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

6.Feed wire through wire guide, over the groove in drive roller and back into wire guide. Flip swing arm down and tension knob up. Adjust tension by rotating tension knob.

7.Unscrew nozzle and contact tip from end of welding torch (See Figure 5). Plug welder into a proper power supply receptacle.

8.Turn on welder and set wire speed to 10. Activate torch trigger until wire feeds out past the torch end.

Turn welder off.

9.Carefully slip contact tip over wire, screw tip into torch end and reinstall nozzle (See Figure 5). Cut wire off approximately 1/4 inch from nozzle end.


Welder duty cycle is the percentage of actual weld time that can occur in a ten minute interval. For example, at a 20% duty cycle, actual welding can occur for two minutes, then the welder must cool for eight minutes.

Internal components of this welder are protected from overheating with an automatic thermal switch. A red lamp is illuminated on the front panel if the duty cycle is exceeded. Do not switch unit off. This will allow the internal fan to cool the unit quickly. Welding operations may continue when the red lamp is no longer illuminated.


The welder is equipped with a circuit breaker which protects the machine if the maximum output is exceeded, such as when the output is short-circuited. The circuit breaker button will extend out when tripped. Manually push the button in to reset.


Wire Feed Arc Welder

Assembly (Continued)


MIG welding wire requires the electrode to be positive.

Flux welding wire requires the electrode to be negative. Always use the polarity recommended by the welding wire manufacturer. The welder is factory set for flux welding wire.

Shielding Gas Preparation

Improper handling

and maintenance of compressed gas cylinders and regulators can result in serious injury or death! Always secure gas cylinders to a wall or other fixed support to prevent cylinder from falling over. Read, understand and follow all compressed gas and equipment warnings in the safety instructions.

To Change Polarity (See Figure 6)

1.Unplug power cord from socket.

2.Open wire feed compartment door.

3.Remove two nuts from polarity studs.

4.Connect cable from drive deck to positive stud and cable from work clamp to negative stud for electrode positive polarity for MIG welding. Connect cable from drive deck to negative stud and cable from work clamp to positive stud for electrode negative polarity for flux core welding.

5.Reinstall two nuts and tighten securely.

If the nuts are

not tightened properly, excessive heat will be generated by the loose connection and the insulators on the studs will be damaged.

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


There are 3 types of gas generally used for gas metal arc welding; 100% argon, a mixture of 75% argon and 25% carbon dioxide (C25) or 100% carbon dioxide.

Use ONLY the type of gas recommended for your welder. Use ONLY an inert, nonflammable type of gas. Failure to do so will result in a very hazardous situation.

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 to prevent it from falling over.

NOTE: Electrode negative polarity (typical for flux core welding) shown in figure.

Reverse cables for electrode positive polarity (typical for MIG welding).

Ground cable

Drive deck cable

Positive stud

Negative stud

Brass nuts

Figure 6 - Polarity control

Obtaining Correct Gas Type. The gas used in any welding application for your welder must be an INERT, NONFLAMMABLE TYPE. You can get the type of gas needed from a nearby welding gas distributor (often found in the yellow pages under “Welders” or “Welding Equipment”).


An adjustable regulator with two gauges is supplied with the WG3090 and WG4130. The WG3080 is not supplied with a regulator (see parts list for optional regulator/hose kit). The regulator provides a constant shielding gas pressure and flow rate during the welding process. Each regulator is designed to be used with a specific gas or mixture of gases. The argon and argon mixture use the same thread type. The 100% carbon dioxide uses a different thread type. An adapter is available at your local welding gas supplier to change between the two.


Cylinder gas is

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

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

2.Install regulator onto cylinder valve. Tighten stem nut securely to gas valve.

3.Install one end of gas hose to fitting on the back of welder and other end of hose to fitting on regulator. Make sure gas hose is not kinked or twisted.

4.While standing opposite cylinder outlet, slowly open cylinder valve. Inspect for leaks in the connections.

5.Turn unit on and pull trigger on torch to allow gas to flow. Adjust gas regulator to between 20 and 40 CFH. Release trigger and turn unit off.

6.Remember to close gas cylinder valve when finished welding.


Models WG3080, WG3090 and WG4130


1. Be sure to read, understand

and comply with all precautions in the General MANUAL Safety Information section.

Be sure to read entire

“Welding Guidelines” section before using this equipment.

2.Turn welder off.

3.Verify surfaces of metals to be joined are free from dirt, rust, paint, oil, scale or other contaminants. These contaminants make welding difficult and cause poor welds.

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

If heating, welding or cutting galvanized, zinc plated, lead,

or cadmium plated materials, refer to the General Safety

Information Section for instructions. Extremely toxic fumes are created when these metals are heated.

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

5.Rotate Wire Speed Control to setting per decal inside wire feed compartment, then adjust as needed after test.

6.Plug power cord into a proper voltage receptacle with proper circuit capacity (see circuit requirements on Page 1).

7.Switch welder on to desired heat setting per decal inside wire feed compartment, then adjust as needed after test.

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

8.Verify wire is extended 1/4" from contact tip. If not, squeeze trigger to feed additional wire, release trigger, turn welder off, and cut wire to proper length. Then, switch back on to desired heat setting.

9.Position torch near work piece, lower welding helmet by nodding head or positioning the hand shield, and squeeze torch trigger. Adjust heat setting and wire speed as needed.

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


Disconnect power supply and turn machine off before inspecting or servicing any components. Keep wire compartment cover closed at all times unless wire needs to be changed.


1.Check condition of weld cables and immediately repair or replace any cables with damaged insulation.

2.Check condition of power cord and immediately repair or replace any cord if damaged.

3.Inspect the condition of the torch contact tip and nozzle. Remove any weld slag. Replace torch contact tip or nozzle if damaged.

Do not operate

this welding machine with cracked or missing insulation on welding cables, torch or power cord.


1.Replace any unreadable safety labels on the welder.

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

3.Clean wire groove on drive roller. Remove drive roller and use a small wire brush to clean. Replace if worn or damaged.

Consumable and Wear Parts

The following parts require replacement:

Wire feed drive roller

Wire guide

Torch liner

Nozzle/contact tips

Wire - This welder will accept either 4" or 8" diameter spools. Flux-Cored welding wire is susceptible to moisture and oxidizes over time, so it is important to select a spool size that will be used within approximately 6 months. For mild steel welding, AWS ER70S6 solid wire or AWS E71T-GS Flux-Cored wire is recommended.


This welder is setup for .030" (0.8 mm) wire. If a different wire size is used, the wire feed drive roller and contact tip may need changing. There are two grooves in the drive roller. The small groove is for .024" (0.6 mm) MIG wire and the large groove is for .030 - .035" (0.8 - 0.9 mm) flux core and MIG wire. Rotate the tension knob down and swing arm up and flip the drive roller to choose the correct groove. Optional drive rollers for other wire sizes are available (See parts breakdown). The contact tip should also match the wire diameter used. The tip diameter is marked on the contact tip in inches and/or millimeters.

Supply Cable Replacement

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

2.Remove welder side panel to expose switches.

3.Disconnect the power cord leads per the diagram inside the unit.

4.Disconnect the ground wire connected to welder base.

5.Loosen the cord strain relief screws and pull cord out of strain relief.

6.Install new cord in reverse order per the diagram inside the unit.


Wire Feed Arc Welder

Welding Guidelines


This welding machine can utilize the Flux Cored Arc Welding (FCAW) process or the Gas Metal Arc Welding (GMAW) process. The weld must be protected (shielded) from contaminants in the air while it is molten. The FCAW process uses a tubular wire with a flux material inside. The flux creates a shielding gas when melted. The GMAW 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 7).















Work Piece

Figure 7 - Weld Components

Arc Welding Basics

Six basic techniques affect weld quality. These are: wire selection, heat setting, weld angle, wire speed, travel speed, and electrode extension. An understanding of these techniques is necessary for effective welds.


The correct heat involves the adjustment of the welding machine to the required setting. Heat or voltage is regulated by a switch on the welder. The heat setting used depends on the size (diameter) and type of wire, position of the weld, and the thickness of the work piece. Consult specifications listed on the welder. It is suggested that the welder practice with scrap metal to adjust settings, and compare welds with Figure 9.


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.


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-cored wire

Flux type

AWS E71T-GS or E71T-11 is recommended for this welder.


ER - 70 S - 6

Weld strength, times 1,000 PSI

Solid wire

Wire composition

ER-70S6 is recommended for this welder.


Weld angle is the angle at which the nozzle is held during the welding process. Using the correct angle ensures proper penetration and bead formation. As different welding positions and weld joints become necessary, nozzle angle becomes an increasingly important factor in obtaining a satisfactory weld. Weld angle involves two positions - travel angle and work angle.

Travel angle is the angle in the line of welding and may vary from 5º to 45º from the vertical, depending on welding conditions.

Work angle is the angle from horizontal, measured at right angles to the line of welding. For most applications, a 45º travel angle and 45º work angle is sufficient. For specific applications, consult an arc welding handbook.

5º - 45º


5º - 45º


Figure 8 - Weld Angle


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 of 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 torch nozzle across the scrap piece while adjusting the wire speed with the other hand. Too slow of speed will cause sputtering and the wire will burn up into the contact tip. Too fast a speed will also cause a sputtering sound and the wire will push into the plate before melting. A smooth buzzing sound indicates the wire speed is properly tuned. Repeat the tuning procedure each time there is a change in heat setting, wire diameter or type, or work piece material type or thickness. For Aluminum, wire speed is typically set higher (7-9 speed range).


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 Figure 9). 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.


Models WG3080, WG3090 and WG4130

Welding Guidelines (Continued)


Electrode extension (or electrode stickout) is the distance between the end of the contact tip and and the end of the welding wire. The recommended electrode extension is from 1/4 to 1/2 in (6 to 13 mm). If the electrode extension is too long, welding current will be reduced and the bead will be high and narrow with less penetration.


Wear ANSI approved safety glasses (ANSI Standard Z87.1) and protective clothing when removing slag. Hot, flying

debris can cause personal injury to anyone in the area.

After completing the weld, wait for the welded sections to cool. A protective coating called slag now covers the weld bead which prevents contaminants in the air from reacting with the molten metal. Once the weld cools to the point that it is no longer glowing red, the slag can be removed. Removal is done with a chipping hammer. Lightly tap the slag with the hammer and break it loose from the weld bead. The final clean-up is done with a wire brush. When making multiple weld passes, remove the slag before each pass.


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.



Normal Heat,


Wire Speed,


Travel Speed

Too Fast

Heat Too Low

Travel Speed

Heat Too High

Too Slow

Wire Speed Too Slow


Wire Speed

Figure 9 - Weld Appearance

Too Fast


All work should be performed in the flat position if possible. For specific applications, consult an arc welding technical manual.


Sometimes more than one pass is necessary to fill the joint. The root pass is first, followed by filler passes and the cover pass. If the pieces are thick, it may be necessary to bevel the edges that are joined at a 60º angle. Remember to remove the slag before each pass for the FCAW process.




Figure 11 - Multiple Weld Passes

Figure 10 - Weld Passes


Wire Feed Arc Welder

Welding Guidelines (Continued)


Any aluminum surface to be welded, must be cleaned thoroughly with a stainless steel brush to eliminate any oxidation on the weld and grounding surface. 100% Argon shielding gas must be used when welding aluminum. If 100% Argon is not used, metal penetration is unlikely. A Teflon® wire liner, smooth-groove drive roller and aluminum contact tips are recommended when welding aluminum. Campbell Hausfeld offers these parts in Kit WT2532. Call 1-800- 746-5641 to order.


The type and thickness of the work piece dictates which way to point the torch nozzle. For thin materials (18 gauge and smaller) 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 12).

Figure 12



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

Troubleshooting Chart - Welder



Possible Cause(s)

Corrective Action


No output

1. Duty cycle exceeded

1. Allow welder to cool until lamp goes out



2. Poor work clamp connection

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



3. Tripped circuit breaker

is clean



3. Reset by pushing button on back of unit



4. Blown breaker or fuse

4. Reduce circuit load, reset breaker or replace fuse






Wire tangles at drive roller

1. Wrong size contact tip

1. Use proper size contact tip



2. Torch liner clogged or

2. Clean or replace wire liner







3. Contact tip clogged or

3. Clean or replace contact tip







4. Drive roller worn

4. Replace



5. Not enough tension

5. Tighten tension knob






Gun nozzle arcs to work

1. Slag inside gun nozzle

1. Clean slag from gun nozzle



2. Insulation ring melted/expired

2. Replace nozzle






Work clamp and/or cable

1. Poor contact

1. Be sure all connections are secure, and attaching surface


gets hot

2. Using an extension cord with

is clean



2. Never use an extension cord longer than 20 ft



excessive length



Wire does not feed

1. Wire jammed

1. Reload wire



2. Out of wire

2. Replace wire spool



3. Not enough tension

3. Tighten tension knob if wire is slipping



4. Wire liner worn

4. Replace liner



5. Wire disconnected internally

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



6. Contact tip clogged

6. Replace contact tip






(Aluminum) Wire burns back

1. Wire speed too slow

1. Run speed in 7 - 10 range


into tip or (Aluminum) Metal

2. Travel speed too slow or heat

2. Increase the travel speed or reduce heat settings


bubbles or burns through

is too high







Weld pops and sputters

1. Wire speed setting

1. Tune in correct setting (1-5 mild steel; 5-10 aluminum)



2. Contact tip size too large

2. Replace contact tip



3. Polarity set incorrectly

3. Reverse polarity



4. Drive roller slipping

4. Increase tension



5. Gas bottle empty

5. Replace gas bottle






Models WG3080, WG3090 and WG4130

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

Troubleshooting Chart - Welds


Possible Cause(s)

Corrective Action

Bead is intermittently

1. Inconsistent travel speed

1. Decrease and maintain constant travel speed

too thin

2. Output heat setting too low

2. Increase output heat setting




Bead is intermittently

1. Slow and/or inconsistent travel speed

1. Increase and maintain travel speed

too thick

2. Output heat setting too high

2. Reduce output heat setting




Ragged depressions at

1. Travel speed too fast

1. Decrease travel speed

edge of weld

2. Wire speed too fast

2. Decrease wire speed


3. Output heat setting too high

3. Reduce output heat setting




Weld bead does not

1. Inconsistent travel speed

1. Decrease and maintain constant travel speed

penetrate base metal

2. Output heat setting too low

2. Increase output heat setting


3. No or low shielding gas

3. Use gas for MIG process or refill bottle


4. Wrong shielding gas (aluminum)

4. Use only 100% Argon gas


5. Extension cord is too long

5. Never use an extension cord longer than 20 ft


6. (Aluminum) Possible oxide buid-up on

6. Clean surface thoroughly with a stainless steel brush







Wire sputters and

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-cored wire when not using gas


4. No or low shielding gas

4. Use gas for MIG process or refill bottle



Wire Feed Arc Welder

For replacement parts or technical assistance, call 1-800-746-5641.

Please provide following information:

-Model number

-Serial number

-Part description and number as shown in parts list

Address any correspondence to:

Campbell Hausfeld Attn: Customer Service 100 Production Drive

Harrison, OH 45030 U.S.A.







































Figure 13Replacement Parts





Replacement Parts List - Models WG3080, WG3090 and WG4130




No. Description








(MIG, 8 ft., WG3080)








(MIG, 10 ft., WG3090 & WG4130)




▲ Wire Liner – 0.024" - 0.035"




(0.6 - 0.9 mm), Cut to Length




▲ Optional Wire Liner – 0.040" - 0.045"




(1.0 - 1.2 mm), Cut to Length







▲ Contact Tip – 0.024" (0.6 mm)




▲ Contact Tip – 0.030" (0.8 mm)




▲ Contact Tip – 0.035" (0.9 mm)




▲ Optional Contact Tip – 0.024"




(0.6 mm) 4 Pack



▲ Optional Contact Tip – 0.030"




(0.8 mm) 4 Pack



▲ Optional Contact Tip – 0.035"




(0.9 mm) 4 Pack







Drive Roller – 0.024" - 0.035"




(0.6 - 0.9 mm)




Optional Drive Roller – 0.040" - 0.045"




(1.0 - 1.2 mm) (WG4130 only)



Drive Deck Wire Guide




Drive Deck Assembly




Spool Spindle




Spool Retainer




Spool Spring




Spool Lock




Flux Weld Wire – 0.030" (0.8 mm)




2 lb. Spool (E71T-GS)



Flux Weld Wire – 0.030" (0.8 mm)




10 lb. Spool (E71T-GS)



Flux Weld Wire – 0.035" (0.9 mm)




2 lb. Spool (E71T-GS)



Flux Weld Wire – 0.035" (0.9 mm)




10 lb. Spool (E71T-GS)



MIG Weld Wire – 0.024" (0.6 mm)




2 lb. Spool (ER70S6)











MIG Weld Wire – 0.024" (0.6 mm)




11 lb. Spool (ER70S6)



MIG Weld Wire – 0.030" (0.8 mm)




2 lb. Spool (ER70S6)



MIG Weld Wire – 0.030" (0.8 mm)




11 lb. Spool (ER70S6)



MIG Weld Wire – 0.035" (0.9 mm)




2 lb. Spool (ER70S6)



MIG Weld Wire – 0.035" (0.9 mm)




11 lb. Spool (ER70S6)



Aluminum MIG Welding Wire –




0.030" (0.8 mm), 1 lb. Spool



Safety Decal




Work Clamp



15 ▲ Gas Hose – 4 ft. (WG3090 & WG4130)



16 ▲ Regulator with 2 gauges




(WG3090 & WG4130)



17 ▲ Optional Regulator Kit




(includes items 15 & 16) (WG3080)


18 ▲ Optional Welding Helmet


19 ▲ Optional Aluminum Welding Kit




[Includes Teflon® Wire liner, U-groove




drive roller for 0.030" (0.8 mm)




aluminum wire and four 0.030"




(0.8 mm) contact tips for aluminum






20 ▲ Handle Assembly


Not Shown

Optional Accessory


Models WG3080, WG3090 and WG4130

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 with uses a consumable electrode to support the arc. Shielding is achieved by the melting of the flux coating on the electrode.

Slag - a layer of flux soot that protects the weld from oxides and other contaminants while the weld is solidifying (cooling). Slag should be removed after weld has cooled.

Spatter - metal particles thrown from the weld which cool and harden on the work surface. Spatter can be minimized by using a spatter resistant spray on the work piece before welding.

Tack Weld - weld made to hold parts in proper alignment until final welds are made.

Travel Angle - the angle of the electrode in the line of welding. It varies from 5º to 45º depending on welding conditions.

T Joint - made by placing the edge of one piece of metal on the surface of the other piece at approximately a 90º angle.

Undercut - a condition that results when welding amperage is too high. The excessive amperage leaves a groove in the base metal along both sides of the bead which reduces the strength of the weld.

Weld Pool or Puddle - a volume of molten metal in a weld prior to its solidification as weld metal.

Weld Bead - a narrow layer or layers of metal deposited on the base metal as the electrode melts. Weld bead width is typically twice the diameter of the electrode.

Work Angle - the angle of the electrode from horizontal, measured at right angles to the line of welding.


Wire Feed Arc Welder

Limited Warranty

Limited Warranty

1.Duration: The manufacturer warrants that it will repair, at no charge for parts or labor, the Welder, Welding Gun, or Cables, proven defective in material or workmanship, during the following time period(s) after date of original retail purchase:

For 5 Years: The Welder Transformer and Rectifier

For 3 Years: The Entire Welder (excluding clamps, welding gun, electrode holder, cables, or accessories packed with welder) For 90 Days: The Welding Clamps, MIG Gun, Electrode Holder, Accessories, and Welding Cables (as applicable)

2.Who Gives This Warranty (Warrantor):

Campbell Hausfeld / Scott Fetzer Company 100 Production Drive

Harrison, OH 45030 U.S.A. Telephone: 1-800-746-5641

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.

6.Responsibilities of Warrantor under this warranty: Repair or replace, at Warrantor’s option, products or components which have failed within duration of the warranty period.

7.Responsibilities of purchaser under this warranty:

A.Please call 1-800-746-5641 for warranty assistance.

B.Provide dated proof of purchase and maintenance records.

C.All welders must be delivered or shipped to the nearest Campbell Hausfeld Authorized Service Center. Freight costs, if any, must be borne by the purchaser.

D.Use reasonable care in the operation and maintenance of the products as described in the owner’s manual(s).

8.When Warrantor will perform repair or replacement under this warranty: Repair or replacement will be scheduled and serviced according to the normal work flow at the servicing location, and depending on the availability of replacement parts.

This Limited Warranty gives you specific legal rights and you may also have other rights which vary from state to state.


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