Campbell Hausfeld WG4000 User Manual

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or property damage! Retain instructions for future reference.

IN970800AV 3/03

Operating Instructions & Parts Manual Model WG4000

Wire Feed Arc Welder

This Campbell Hausfeld wire feed welder is designed to be used on standard 230 volt single phase current. The welder is equipped with an infinite wire speed control to accurately select the proper wire feed rate needed for various welding conditions. Internal components are thermostatically protected.

This welder is 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 .030" (.8 mm) to .045” (1.2 mm) diameter wire. A starter spool of .035” (.9 mm) flux core wire and a .035” 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 230 volt, minimum 20 amp circuit. 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 – Connects to work

piece.

2. Wire Feed Gun with .035” tip

3. Power Cord – Plugs into 230 volt

outlet.

4. On/Off/Heat Selector Switch – Turns welder on and off and selects welding power. Six (6) selections are possible.

5. Infinite Wire Speed Control – Controls wire speed (clockwise turn increases speed; counterclockwise turn decreases speed).

6. Polarity Hook-up (Inside Wire Feed Compartment) – Provides connections for MIG, direct current electrode positive (DCEP); and flux core, direct current electrode negative (DCEN).

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.

Always

keep a fire extinguisher accessible while performing arc welding operations.

Description

MODEL WG4000

Figure 1

General Safety

For parts, manuals, product & service information

visit www.chpower.com

or call (800) 746-5641.

FLUX

CORE

MIG

Wire Feed Gun (2)

Work Clamp (1)

Power Cord (3)

Infinite Wire Speed Control (5)

Polarity Hook-up (6)

On/Off/Heat Selector Switch (4)

REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.

BUILT TO LAST

FLU

CORE

Assistance?

Call Us First!

1-800-746-5641

Need

CAUTION

DANGER

WARNING

CAUTION

WARNING

Wire Feed Arc Welder

● 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 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 welder. Always keep welder panels, shields, etc. in place when operating the welder.

● Always wear dry, protective

clothing, welding gloves, and insulated footwear.

● Always operate welder in a clean,

dry, well ventilated area. Do not operate it in humid, wet, rainy, or poorly ventilated areas.

● Be sure work piece is properly

supported and grounded before 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 before using!

● Always shut equipment off and

unplug power prior to moving welder.

● Always attach work lead first.

● Verify that work piece is securely

grounded.

● Always shut off electric arc welding

equipment when not in use, and cut off any excess wire from wire feed gun.

● Never allow any part of body to touch 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 (American

National Standards Instituteapproved) 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. The 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 a rating of 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 metalworking 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 metalworking 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 fireproof 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, in 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.

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 head and face out of welding

fumes.

● Do not perform electric arc welding

operations on metals that are galvanized or cadmium-plated, or that contain zinc, mercury or beryllium without adhering to the following precautions:

General Safety

(Continued)

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WARNING

DANGER

WARNING

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 manufacturer’s instructions for metals, wire, coatings and cleaners.

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

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

● Place welder in an area that provides at least 12” (30,48 cm) of ventilation space at both front and rear of unit. Keep all obstructions away from this ventilation space.

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

● The receptacle used for welder must be properly grounded and welder must be the only load on power supply circuit.

● The use of an extension cord is not recommended for electric arc welding machines. The voltage drop in extension cord may significantly degrade performance of welder.

Model WG4000

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

Tools needed:

1/4”, 9/32”, 5/16” nut driver #2 Phillips head driver Mallet or hammer

After unpacking welder, you will find a box at front surrounding attached torch, ground clamp lead, and power cord.

The box at the rear of the welder contains parts to be assembled:

Wheels (2), axle (1), plastic hubs (2),

axle bolts (2), nuts (2) and washers

(2) Front foot Cylinder bracket and chain Work clamp Regulator, hose, and hose clamps Spool of .035” flux core welding wire

a. Remove coating from base metal. b. Make sure 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 feed gun and work

cables together and secure with tape when possible.

● Never wrap arc welder cables

around body.

● Always position wire feed gun and

work leads so that they are on same side of 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.

Cylin-

ders 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 electric arcs.

● Install and secure cylinders in an

upright position by chaining them to stationary support or equipment cylinder rack to prevent them from falling or tipping.

● Keep cylinders away from any

welding or other electrical circuits.

WG4000

● Never allow a welding electrode to touch any cylinder.

● Use only correct shielding gas cylinders, regulators, hoses, and fittings designed for the specific application; keep 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 (Compressed Gas Association) publication P-1 listed in Safety Standards.

Never use

flammable gases 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

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

General Safety

(Continued)

Installation

Assembly

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WARNING

DANGER

WARNING

WHEEL AND AXLE ASSEMBLY

1. Put one wheel on each end of axle Using a mallet or hammer, drive a plastic hub on axle ends to secure wheels.

2. Align holes in axle assembly with holes in base plate at rear of welder. Secure with two bolts, washers, and nuts.

FOOT ASSEMBLY

1. Remove four screws in bottom panel near the front of the welder.

2. Align holes in metal foot with holes on bottom of welder at front.

3. Secure foot with four screws removed in step 1.

CYLINDER BRACKET ASSEMBLY

1. At back of welder, halfway down each side, are two screws. Remove both pairs of screws. Also remove the screw in center of back panel.

2. Insert cylinder bracket between sides of the welder and its black back, aligning its holes with those in sides of welder. Make sure bracket has chain slots up.

3. Attach the bracket with the five screws removed in Step 1.

WORK CLAMP ASSEMBLY

1. Loosen hex nuts on work clamp.

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

WIRE INSTALLATION

When the welder is

on and the gun switch is activated, electric power may be present in the output terminals, feed roll, work clamp, gun cable connection and welding wire. Do not touch these parts when the welder is on.

Wire Feed Arc Welder

NOTE: Before installing welding wire,

be sure that its diameter matches the diameter of the groove in the drive roller on the wire feed mechanism and that the wire matches the contact tip in the end of the gun. Any mismatch could cause the wire to slip or bind.

1. Verify that welder is off. Open panel on welder to expose wire feed mechanism.

2. Remove spool lock by pushing in and rotating it a 1/4 turn counterclockwise. The knob, spring, and spool spacer can now be removed. (See Figure 4).

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

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

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

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

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

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

HINT: Keep torch cable straight when feeding wire.

8. Turn on welder and set wire speed rate to 5. Activate the gun switch until wire feeds out past torch end. Turn welder off.

Assembly

(Continued)

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Clamping Block

Figure 3 - Work Clamp Assembly

Torch Neck

Contact Tip

Nozzle

Figure 5 - Torch Nozzle

Figure 2 - WG4000 Assembly

Figure 4 - Weld Wire Routing

Bolt

Washer

Nut

Axle

Plastic hub

Wheel

Hex Nuts

Cord

Foot assembly

Bolt

Cylinder chain

Cylinder bracket

WARNING

WG4000

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

POLARITY

Polarity must be set to match the type of welding process you wish to use. MIG wire welding with bottled shielding gas uses DCEP (DC electrode positive). Flux-core wire welding with no gas bottle requires DCEN (DC electrode negative).

The WG4000 features easy-change polarity posts located inside the top section, next to the wire drive deck. The positive (+) post is farthest from the drive deck and has a red knob and base. The negative post is closest to the drive deck and has a black knob and base.

Both leads have spade ends with holes to go over the polarity posts. Turn the polarity knob counterclockwise to remove. Slip the end of the appropriate lead over the post. Then replace the polarity knob on the post and tighten securely, turning clockwise.

These connections must be tight to prevent overheating.

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 lens retainer from face shield with a regular screwdriver by prying against shield and post of lens retainer.

2. Remove 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 in face shield and secure with lens retainer. The lens retainer should snap into second notch in face shield.

3. Position one of the holes in adjustment arm over the pins which are located in the ear area of face shield. These adjustment arms control the closeness of fit and can be easily repositioned if necessary.

4. Position headgear inside face shield. Assemble helmet by inserting stud screw through headgear and shield into 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 face shield. If shield is too far or too close to face, use a different hole in adjustment arm. Adjust tension nuts so that helmet can be easily lowered over the face by nodding the head.

1. Cut two plastic bolts and one nut from handle. Trim excess plastic to remove sharp edges.

2. Insert handle into slot and rotate 90 degrees to align handle stud with hole in shield. Secure stud with plastic nut.

3. Fold the top into position and then one of the sides. Snap the two pins into the holes. Press until you hear an audible click, assuring complete assembly. Repeat for the other side.

4. Install the shaded lens and secure with the two plastic bolts. Tighten securely, but do not overtighten as this may damage the lens.

NOTE: If you have never welded before or have little experience, a full-face helmet is recommended. Both hands are needed to stabilize and control the angle and arc length of the torch.

Improper handling

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

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

(PROMOTIONAL MODELS ONLY)

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Contact Tip Markings

Wire Size mm

.024” or .6

.030” or .8

.035” or .9

.040” or 1.0

Figure 6

Shielding Gas Installation

Work Cable

Torch Cable

Handshield Assembly

Figure 8

Torch Work

Mig + —

Flux —

DANGER

Wire Feed Arc Welder

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. The 75/25 mixture is recommended for general steel welding. For aluminum welding, use 100% argon. Cylinders of each type gas may be obtained at your local welding supply outlet. Secure cylinder in place on your welding machine or other support to prevent the cylinder from falling over.

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

REGULATOR

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 included with this unit 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. A 20 cubic ft bottle fits this unit.

2. With cylinder securely installed,

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

3. Install regulator on cylinder valve,

keeping face of gauges in vertical position. Tighten stem nut securely to gas valve.

4. Install one end of gas hose on

fitting on rear of welder and the other end to the fitting on the regulator. Use hose clamps on each connection. Make sure gas hose is not kinked or twisted.

5. Once again, stand opposite cylinder

outlet and slowly open cylinder valve. Inspect for leaks in connections.

6. Pull trigger on gun to allow gas to flow. While trigger is pulled and gas is flowing, adjust gas regulator to at least 20 cfh (cubic feet per hour). Release trigger.

7. Remember to close gas valve when finished welding.

1. Prior to using this equipment, read, understand, and comply with all precautions in the General Safety section. Also, read the entire section titled Welding Guidelines.

2. Verify welder is off.

3. Verify that 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.

Extremely toxic fumes are created when zinc- or cadmium-plated materials, lead or galvanized items are heated, welded or cut. Before working with any of these materials, refer to the General Safety section for instructions.

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

5. Position Heat Selector on front panel to 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 Wire Speed Control to setting number 5. Then adjust as needed after test weld is completed.

7. Plug input cord into a proper voltage receptacle with proper circuit capacity (20 amps minimum).

8. Switch welder ON.

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

Operation

Shielding Gas Installation (Continued)

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Figure 9 - Hookup

ARGON OR

ARGON MIX

INSTALLATION

Adapter

Cap

WARNING

DANGER

MANUAL

WARNING

WG4000

10. Position wire feed gun near work piece, and then lower the welding helmet by nodding the head or positioning hand shield. Then squeeze gun trigger. Adjust heat setting and wire speed as needed.

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

Disconnect power

supply and turn welder 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 condition of 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.

Maintenance

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.

Operation

(Continued)

Slag

Weld

Wire

Flux

(Gasless

only)

Work Piece

Shielding

Gas

Contact Tip

Crater

Nozzle

Figure 10 - Weld Components

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 wire groove on drive roll. Remove wire from feed mechanism and remove screws from drive roll housing. Use a small wire brush to clean 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.

• 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.

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Call (800) 746-5641

for replacement parts.

Changing Wire Sizes

DRIVE ROLLER

There are two grooves in the Drive Roller. The small groove is for .030".035" (.8 mm-.9 mm) wire and the other is for .045" (1.2 mm) wire. Remove the roller cover and flip the drive roll to choose the correct groove (see Parts Breakdown).When using .030"-.035" (.8 mm-.9 mm) aluminum wire, an optional smooth groove drive roller and Teflon

wire liner are needed. Contact Campbell Hausfeld for more information. Aluminum wire is very soft and should not have the same tension as Flux Core or MIG wire. 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.

CONTACT TIP

Make sure the contact tip size matches the wire size. If the tip is too small, there will be too much drag on the wire. If the tip is too large, arcing will occur inside the tip. This will burn the tip or cause carbon deposits inside the tip that insulate the tip from the wire.

WARNING

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

0T- 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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WARNING

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.

WG4000

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 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.

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 relief 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. Wire disconnected internally

6. 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. Fast and/or 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 build-up 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. Call 1-800-746-5641 for assistance

6. Replace contact tip

1. Run speed in 7 - 10 range

2. Increase the travel speed or reduce heat settings

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.

WG4000

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WG4000 Wiring Diagram

Wire Feed Arc Welder

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WHITE

BLACK

FAN~

GREEN

COM

OPENS

@ 127

S3 NC

DRIVE DECK

OFF

1 2 3 4 5 6

S2 GUN

A1L2

L2L1

XXX XXX

X X

X X X

C2C1

XX X XX X

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

- Part description and number as shown in parts list

WG4000

MODEL WG4000

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** Contact Tip (See chart on Page 14)

41 & 42

(inside)

7 & 9

39 & 40

***

8 & 10

1 Warning decal - 1 pc Italy DK670100AV 1 2 Ground clamp - large (Cord not included) WC100100AV 1 3 Welding cable 6 AWG (6 ft) ❋ 1 4 Strain relief WC102000AV 2 5 Handle WC301700AV 1 6 Power cord 12AWG/3C (10 ft) Type ST with 230V, 50A Plug ❋ 1 7 Wire speed control knob WC400201AV 1 8 Switch knob WC400401AV 1

9 Wire speed control PCB ▲ WC401700AV 1 10 Power switch ▲ WC401800AV 1 11 Capacitor - 15,000 µF ▲ WC401900AV 2 12 Drive deck assembly (Includes nos. 13-18) WC500400AV 1 13 Tension screw WC500002AV 1 14 Tension spring WC500003AV 1 15 Roller cover WC500004AV 1 16 Swing arm WC500005AV 1 17 Drive roller - 0.8-1.2 mm WC500006AV 1

Optional drive roller - 0.6-0.9 mm▲ WC500001AV ✤ 18 Swing arm roller WC500007AV 1 19 Spool lock WC500100AV 1 20 Spindle spring WC500101AV 1 21 Spool adapter WC500200AV 1 22 Spindle WC500300AV 1 23 Torch ring WC600009AV 1 24 Torch assembly - Universal WC600900AJ 1 25 Hanger clip WC600003AV 1 26 Torch handle - 2 pc WC600201AV 1 27 Trigger WC600202AV 1 28 Contact spring WC600203AV 1 29 Gas valve WC600204AV 1 30 Trumpet liner - 5.75” WC600305AV 1 31 Swan neck w/ diffuser (Tweco®) WC600701AV 1 32 Wire liner - coated metal WC600209AV 1 33 Nozzle, Tweco® style WT502100AJ 1 34 Wheel WC701300AV 2 35 Front foot WC702300AV 1 36 Cylinder bracket WC702400AV 1 37 Axle WC703200AV 1 38 Wheel cap WC703400AV 2 39 Polarity cap - red ▲ WC704000AV 1 40 Polarity cap - black ▲ WC704100AV 1 41 Hose barb - external ▲ WC802300AV 1 42 Hose barb - internal ▲ WC802400AV 1 43 Cylinder chain WC802700AV 1 44 Handshield (lens not included) ▲ WC801600AV 1 45 Shaded lens (for handshield) ▲ WC801100AV 1 46 Welding helmet (promotional models only) ▲ WT100000AV 1 or 0 47 Replacement lens kit - one shaded and two clear ▲ WT110501AV ✤ 48 Optional aluminum welding kit (includes Teflon® wire liner, smooth-

groove drive roller and 4 .030" (.8 mm) aluminum contact tips ▲ WT253000AV ✤ 49 Argon regulator with 2 gauges ▲ WC803200AV 1 50 Adapter - Argon regulator/CO2 cylinder ▲ WC803300AV 1

❋ Standard hardware item available at hardware store or welding supply store ▲ Not shown ✤ Optional accessory, sold separately

Replacement Parts List - Model WG4000

Ref No. Description Part Number Qty

***OPTIONAL WIRE

Part Number Part Number

Type Description (2 pounds) (10 pound)

Flux E71T-GS .030” WE200001AV WE201000AV Flux E71T-GS .035” WE200501AV WE201500AV MIG ER70S6 .024” WE300001AV WE301500AV MIG ER70S6 .030” WE300501AV WE302000AV MIG ER70S6 .035” WE301001AV WE302500AV

Aluminum MIG ER5356 .030” WE303001AV (1 lb.) N/A

Wire Feed Arc Welder

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**OPTIONAL CONTACT TIPS (4/package)

Size

mm in. Part Number

0.6 0.024 WT501200AJ

0.8 0.030 WT501300AJ

0.9 0.035 WT501400AJ

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 then 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.

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WG4000

+ 33 hidden pages

Campbell Hausfeld WG4000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual