Wire Feed Arc Welder

Operating Instructions & Parts Manual Model WG3013

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 SURANCE AS PR Y O IT G L R TM A Need A U M BUILT TO LAST Q Assistance? Arc Welder Call Us First! 1-800-746-5641

Description 4 This line of Campbell Hausfeld wire feed 1 welders is designed to be used on standard 115V household current. The welders are equipped with infinite wire speed control to accurately select the proper wire feed rate needed for various welding conditions. Internal components are thermostatically protected. These welders are designed for use with Flux Core Arc Welding (Gasless) or Gas 6 Metal Arc Welding (Mig) process. As delivered from the factory, this welder 5 can weld with .024” (.6 mm) to .035” (.9 mm) diameter wire. A starter spool 3 of .035” (.9 mm) flux-cored wire and a .040 tip are included. FARMHAND 125 Unpacking 7 Some welder components may be found in the wire feed compartment. 2 When unpacking, inspect carefully for Figure 1 any damage that may have occurred during transit. Report any damaged or missing items by calling (800) 746-5641. Components and Controls General Safety 1. Ground Clamp - connect to work Circuit Requirements Danger means a piece. ! DANGER hazard that will This equipment cause death or serious injury if the ! CAUTION requires a dedi- 2. Wire Feed Gun with .040 tip warning is ignored. cated 115 volt circuit. Refer to the 3. Power Cord - plug into 115 volt following chart for the correct circuit outlet. Warning means a breaker or fuse rating. Do not run ! WARNING hazard that could other appliances, lights, or tools on 4. On/Off Switch cause death or serious injury if the this circuit while operating this 5. Infinite Wire Speed Control - warning is ignored. equipment. Extension cords are not turn clockwise to increase wire Caution means a recommended. Blown fuses and tripped ! circuit breakers can result from failure speed and counterclockwise to CAUTION hazard that may to comply with this recommendation. decrease wire speed. cause minor or moderate injury if the warning is ignored. It also may mean a Heat Circuit Breaker or 6. Heat Selector - Selects welding hazard that will only cause damage to Selector Slow Blow Fuse power. Four selections are possible property.

Low 15 amp 7. Polarity Hook-up - Attach torch NOTE: Note means any additional cable to (+) for MIG and (-) for flux information pertaining to the product High 20 amp core wire. or its proper usage.

wet for any reason, be absolutely Never look at arc General Safety certain that it is completely clean and ! WARNING welding operations dry prior to attempting use! without eye protection as described (Continued) ● Always shut the equipment off and above. Never use a shade filter lens unplug the power prior to moving that is cracked, broken, or rated below Torch is “live” (has ! WARNING the unit. number 10. Warn others in the area not current potential) ● to look at the arc. at all times when machine is turned on. Always attach the work lead first. ● Verify that the work piece is securely grounded. ! WARNING ! WARNING ● Always shut off electric arc welding Electric arc welding Always keep a fire equipment when not in use, and cut operations cause sparks and extinguisher accessible while off any excess wire from the wire heat metal to temperatures performing arc welding feed gun. that can cause severe burns! Use protective gloves and clothing when operations. ● Never allow any part of the body to performing any metal working touch the wire and ground or ● Before starting or servicing any operation. Take all precautions grounded work piece at the same electric arc welder, read and described in this manual to reduce the time. understand all instructions. Failure possibility of skin and clothing burns. to follow safety precautions or ● Awkward welding conditions and ● Make sure that all persons in the instructions can cause equipment positions can be electrically welding area are protected from damage and/or serious personal hazardous. When crouching, heat, sparks, and ultraviolet rays. injury or death. kneeling or at elevations, be sure to Use additional face shields and insulate all conductive parts, wear ● All installation, maintenance, repair flame resistant barriers as needed. and operation of this equipment appropriate protective clothing, and ● Never touch work pieces until should be performed by qualified take precautions to prevent injury completely cooled. persons only in accordance with from falls. national, state, and local codes. ● Never attempt to use this equipment at current settings or ! WARNING ! WARNING duty cycles higher than those Heat and sparks produced specified on the equipment labels. during electric arc welding Improper use of electric arc ● and other metal working welders can cause electric Never use an electric arc welder to operations can ignite flammable and shock, injury, and death! thaw frozen pipes. explosive materials! Take all Take all precautions described in this precautions described in this manual to manual to reduce the possibility of ! WARNING Flying reduce the possibility of flames and electric shock. sparks and hot metal can explosions. ● Verify that all components of the cause injury. As welds cool, ● Remove all flammable materials arc welder are clean and in good slag can be thrown off. Take within 35 feet (10.7 m) of welding condition prior to operating the all precautions described in this manual arc. If removal is not possible, welder. Be sure that the insulation to reduce the possibility of injury from tightly cover flammable materials on all cables, wire feed gun, and flying sparks and hot metal. with fire proof covers. power cords is not damaged. ● Wear ANSI approved face shield or ● Do not operate any electric arc Always repair or replace damaged safety glasses with side shield components before operating the welder in areas where flammable or protection when chipping or explosive vapors may be present. welder. Always keep welder panels, grinding metal parts. ● shields, etc. in place when operating ● Take precautions to be sure that the welder. Wear ear plugs when welding flying sparks and heat do not cause ● overhead to prevent spatter or slag flames in hidden areas, cracks, Always wear dry, protective clothing from falling into ears. and welding gloves, and insulated behind bulkheads, etc. footwear. ! ● Always operate the welder in a WARNING Electric arc ! WARNING clean, dry, well ventilated area. Do welding operations produce Fire hazard! Do not weld on not operate the welder in humid, intense light and heat and containers or pipes that wet, rainy, or poorly ventilated ultraviolet (UV) rays. This contain or have contained areas. intense light and UV rays can cause flammable materials or gaseous or ● Be sure that the work piece is injury to eyes and skin. Take all liquid combustibles. properly supported and grounded precautions described in this manual to reduce the possibility of injury to eyes prior to beginning any electric arc ! WARNING welding operation. and skin. ● ● Coiled welding cable should be All persons operating this Arc welding closed cylinders spread out before use to avoid equipment or in the area while or containers such as tanks overheating and damage to equipment is in use must wear or drums can cause explosion insulation. protective welding gear including: if not properly vented! Verify that any welding helmet or shield with at cylinder or container to be welded has Never immerse the least shade 10, flame resistant an adequate ventilation hole, so that ! DANGER wire or wire feed clothing, leather welding gloves, expanding gases can be released. gun in water. If the welder becomes and full foot protection.

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cylinders contain gas under high Code for Safety in Welding and General Safety pressure. If damaged, a cylinder can Cutting explode. Since gas cylinders are (Continued) normally part of the welding process, CSA Standard W117.2, from Canadian be sure to treat them carefully. Standards Association, Standards Sales, ● 178 Rexdale Boulevard, Rexdale, ! Protect compressed gas cylinders Ontario, Canada M9W 1R3 WARNING from excessive heat, mechanical Do not breathe fumes that shocks, and arcs. Cutting And Welding Processes are produced by the arc ● Install and secure cylinders in an NFPA Standard 51B, from National Fire welding operation. These upright position by chaining them Protection Association, Batterymarch fumes are dangerous. If the welding to stationary support or equipment Park, Quicy, MA 02269 area cannot be adequately ventilated, cylinder rack to prevent falling or Safe Practices For Occupational And be sure to use an air supplied tipping. Educational Eye And Face respirator. ● Protection ● Keep the head and face out of the Keep cylinders away from any welding or other electrical circuits. ANSI Standard Z87.1, from American welding fumes. National Standards Institute, 1430 ● Never allow a welding electrode to ● Do not perform electric arc welding Broadway, New York, NY 10018 operations on metals that are touch any cylinder. galvanized or cadmium plated, or ● Use only correct shielding gas Refer to the Material Safety Data contain zinc, mercury, or beryllium cylinders, regulators, hoses, and Sheets and the manufacturers without completing the following fittings designed for the specific instructions for metals, wire, coatings precautions: application; maintain them and and cleaners. a. Remove the coating from the associated parts in good condition. base metal. ● Turn face away from valve outlet Installation b. Make sure that the welding area when opening cylinder valve. Selecting the proper location can is well ventilated. ● Keep protective cap in place over significantly increase performance, c. Use an air-supplied respirator. valve except when cylinder is in use reliability and life of the arc welder. Extremely toxic fumes are created or connected for use. ● For best results locate the welder in when these metals are heated. ● Read and follow instructions on an environment that is clean and compressed gas cylinders, associated ! WARNING dry. Dust and dirt in the welder equipment, and CGA publication P-1 retain moisture and increase wear The electromagnetic field listed in Safety Standards. of moving parts. that is generated during arc Never use ● welding may interfere with Place the welder in an area that ! DANGER flammable gasses the operation of various provides at least 12” (30,48 cm) of with MIG welders. Only inert or non- electrical and electronic devices such as ventilation space at both the front flammable gasses such as carbon cardiac pacemakers. Persons using such and rear of the unit. Keep all dioxide, argon, helium, or mixtures of devices should consult with their obstructions away from this one or more of these gasses are physician prior to performing any ventilation space. suitable for MIG welding. electric arc welding operations. ● Store wire in a clean, dry location ● Never lift cylinders with low humidity to preserve the Route the wire gun and work cables ! WARNING together and secure with tape off the ground by wire coating. when possible. their valves, caps, or with chains or slings. ● The receptacle used for the welder ● Never wrap arc welder cables ADDITIONAL SAFETY STANDARDS must be properly grounded and the welder must be the only load on the around the body. ANSI Standard Z49.1 from American ● power supply circuit. Refer to the Always position the wire gun and Welding Society, 550 N.W. LeJune Rd. Circuit Amps chart on page 1 for work leads so that they are on the Miami, FL 33126 correct circuit capacity. same side of the body. Safety and Health Standards ● The use of an extension cord is not ● Exposure to electromagnetic fields OSHA 29 CFR 1910, from recommended for electric arc during welding may have other welding machines. The voltage drop health effects which are not known. Superintendent of Documents, U.S. Government Printing Office, in the extension cord may signifi- Always be sure cantly degrade the performance of ! Washington, D.C. 20402 WARNING that the welding the welder. area is secure and free of hazards National Electrical Code (sparks, flames, glowing metal or slag) NFPA Standard 70, from National Fire prior to leaving. Be sure that Protection Association, Batterymarch Assembly equipment is turned off and excess wire is cut off. Be sure that cables are Park, Quincy, MA 02269 Welder components listed below loosely coiled and out of the way. Be Safe Handling of Compressed Gases are in the wire feed compartment. sure that all metal and slag has cooled. in Cylinders Open and remove. CGA Pamphlet P-1, from Compressed Gas HANDLE ASSEMBLY ! DANGER Association, 1235 Jefferson Davis 1. Remove screws from handle. Slide Highway, Suite 501, Arlington, VA 22202 Cylinders can explode if handle between welder front panel damaged. Shielding gas

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3 Wire Feed Arc Welder

welding wire even when the the gun 6. Feed the wire through the wire feed Assembly (Continued) switch is not activated. Do not touch guide tube, over the groove in the these parts when the welding machine drive roll and into the gun liner. and top cover aligning the holes in is on. Tighten the wire feed tensioning screw handle with holes in top cover. NOTE: Before installing welding wire, so that it is snug. Do not over tighten. 2. Fasten screws through top cover and be sure that the diameter of the 7. Remove the nozzle by turning into handle. welding wire matches the groove in the counterclockwise. Then unscrew WHEEL AND AXLE ASSEMBLY drive roller on the wire feed the contact tip from the end of the 1. Insert axle supports into slots in the mechanism and the wire matches the welding torch (See Figure 5). Plug the welder housing. contact tip in the end of the gun. A welder into the proper power supply mismatch on any item could cause the receptacle. 2. Insert axle through the axle supports wire to slip or bind. and firmly push wheels onto axle. Torch Neck 1. Verify the unit is off and open the Contact Tip 3. Secure wheel with e-clips and wheel panel on the welder to expose the caps. wire feed mechanism. GAS CYLINDER BRACKET ASSEMBLY 2. Remove the spool quick lock, by 1. Place bracket on welder aligning the pushing in and rotating 1/4 turn holes in welder housing. counterclockwise. The knob, spring, 2. Fasten screws through bracket and and spool spacer can now be removed. Nozzle into cabinet. NOTE: Spool spacer and spindle spacer Figure 5 - Torch Nozzle FOOT ASSEMBLY act as an 8” spool spindle adapter. Purchase of an adapter is not necessary. 1. Place foot on welder and align holes HINT: Keep torch cable straight when in the welder housing. * See Figure 4 for assembly. feeding wire. 2. Fasten screws through foot into 3. Loosen the wire feed tensioning 8. Turn on the welder and set the wire cabinet. screw on the drive mechanism. This speed rate to 5. Activate the gun allows initial feeding of the wire into switch until the wire feeds out past the gun liner by hand. the torch end. Turn welder off. 9. Carefully slip the contact tip over the Tension wire and screw it into the torch neck. Screw Panel Install the nozzle by turning clockwise (See Figure 6). Cut the wire off approximately 1/4” from the end of Guide the nozzle. Tube Drive Roller Contact Tip Markings Wire Size mm Spindle Spacer .024” or .6 Spool Figure 2 - WG3013 Assembly Spacer .030” or .8

Ground Clamp Spool .035” or .9 1. Loosen hex nut on work clamp. Lock 2. Insert cord through clamp handle and .040” or 1.0 slide bare wire under the clamp block. Spindle Tighten hex nut making sure bare POLARITY wire is clamped securely (Figure 3). *Reverse For gas shielded welding, connect the 4” or 8” position and cable coming out of the torch to the (+) insert into 8” Spool Spring socket and the ground clamp cable to spool the (-) socket on the front panel. For Clamping Figure 4 - Weld Wire Routing flux-core (no-gas) welding, connect Block torch to (-) and work clamp to (+). 4. Install the wire spool onto the DUTY CYCLE / THERMOSTATIC spindle so that the wire can come off PROTECTION the spool on the end closest to the Welder duty cycle is the percentage of wire feed guide tube. Do not cut actual weld time that can occur in a ten Figure 3 - Work Clamp Assembly the wire loose yet. Install the spool minute interval. For example, at a 10% spacer, spring, and quick lock knob duty cycle, actual welding can occur for Wire Installation by pushing in and turning the knob one minute, then the welder must cool Welding power 1/4 rotation clockwise. for nine minutes. ! WARNING may be applied to 5. Hold the wire and cut the wire end the output terminals, feed roll, work from the spool. Do not allow the wire Internal components of this welder are clamp, gun cable connection and to unravel. Be sure that the end of the protected from overheating with an wire is straight and free of burrs. automatic thermal switch. A yellow lamp is illuminated on the front panel

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4 WG3013

or death! Always secure gas cylinders (Continued) connection. Make sure the gas hose Assembly to the tank bracket kit, a wall or other is not kinked or twisted. fixed support to prevent the cylinder if the duty cycle is exceeded. Welding 5. Once again, stand opposite the from falling over. Read, understand, operations may continue when the cylinder outlet and slowly open the and follow all the compressed gases yellow lamp is no longer illuminated. cylinder valve. Inspect for leaks in and equipment hazards in the safety the connections. instructions. Handshield 6. Pull the trigger on the gun to allow NOTE: Shielding gas is not required if the gas to flow. While the trigger is Assembly flux-cored welding wire is used. pulled and gas is flowing, adjust the GAS TYPES gas regulator to 30-35 cfh (cubic 1. Cut retainer stiffeners and feet per hour). Release the trigger. detachable handle away from shield. There are 3 types of gas generally used Trim the excess plastic to remove for gas metal arc welding; 100% argon, 7. Remember to close the gas valve sharp edges. a mixture of 75% argon and 25% when finished welding. 2. Insert filter lens. carbon dioxide (C25) or 100% carbon dioxide. However, 100% carbon 3. Attach the stiffeners over the pins on Operation the lens retainers (See Figure 6). dioxide is not recommended due to unsatisfactory weld beads. This welder 1. Be sure to read, does not perform well with 100% understand, and comply carbon dioxide. The 75/25 mixture is with all precautions in MANUAL Lens recommended for general steel the General Safety welding. For aluminum welding, use Information section. Be 100% argon. Cylinders of either type sure to read the entire section gas may be obtained at your local Lens entitled Welding Guidelines prior to welding supply outlet. Secure cylinder using this equipment. Retainer in place on your welding machine or other support to prevent the cylinder 2. Verify welder is off. from falling over. 3. Verify that the surfaces of metals to NOTE: Use of incorrect gas may lead to be joined are free from dirt, rust, little or no penetration of welding paint, oil, scale or other contam- Retainer bead. inants. These contaminants make Stiffener welding difficult and cause poor REGULATOR (NOT INCLUDED) welds. The regulator provides a constant Figure 6 shielding gas pressure and flow rate ! DANGER during the welding process. 4. To attach the handle, place shield on All persons operating this a flat surface and press handle into HOOKUP PROCEDURE equipment or in the area place (See Figure 7). Cylinder gas is while equipment is in use ! WARNING under high must wear protective welding gear pressure. Point cylinder outlet away including: eye protection with proper from yourself and any bystanders shade, flame resistant clothing, leather before opening. welding gloves, and full foot 1. These units fit a 20 cubic ft bottle. protection. 2. With the cylinder securely installed, WHETHER OR remove the cylinder cap, stand to the ! CAUTION NOT THE TRIGGER side of the cylinder opposite the IS PULLED, the welding wire is LIVE outlet, and open the valve slightly, whenever the welder is turned ON. Figure 7 turning counterclockwise. When gas is emitted from the cylinder, close the NOTE: If you have never welded ! WARNING valve by turning clockwise. This will before or have little experience, a blow out dust or dirt that may have If heating, welding, or full face helmet is recommended. accumulated around the valve seat. cutting materials that are Both hands are needed to stabilize galvanized, zinc plated, lead, and control the angle and arc 3. Install the regulator onto the or cadmium plated refer to the General length of the torch. cylinder valve, keeping the face of Safety Information Section for the gauges in the vertical position instructions. Extremely toxic fumes are Shielding Gas and tighten the stem nut securely created when these metals are heated. to the gas valve. Installation 4. Connect the work clamp to the 4. Install one end of the gas hose (not work piece or workbench (if metal). Improper handling included) to the fitting on the rear Make sure the contact is secure. ! DANGER and maintenance of the welder and the other end to Avoid surfaces with paint, varnish, of compressed gas cylinders and the fitting on the regulator using corrosion, or non-metallic materials. hose clamps (not included) on each regulators can result in serious injury 5. Position the Heat Selector on the front panel to the desired setting.

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5 Wire Feed Arc Welder

3. Clean the wire groove on the drive MIG WIRE Operation (Continued) roll. Remove wire from the feed Since MIG wire maintains fair wire mechanism, remove screws from the diameter consistency, the contact tip See application decal inside door of drive roll housing. Use a small wire used should match the wire size used. wire feed compartment for proper brush to clean the drive roll. Replace When using .024 (.6 mm) wire, use the heat settings. if worn or damaged. small groove on the drive roller. When NOTE: These settings are general Consumer and Wear Parts using .030 - .035 (.8 - .9 mm) MIG or guidelines only. Heat setting may vary Aluminum wire, use the factory set The following parts require routine according to welding conditions and large groove. maintenance: materials. ALUMINUM WIRE • Wire feed drive roller 6. Rotate the Wire Speed Control to When using Aluminum wire, it is best setting number 5 to start with, then • Gun liner - replace if worn to use a larger size tip than the wire adjust as needed after test weld. • Nozzle/contact tips size being used. For example: • If wire diameter is .030, use .035 tip. 7. Plug the input cord into a proper • Wire - this welder will accept either voltage receptacle with proper 4” or 8” diameter spools. Welding wire When using .030 - .035 (.8 - .9 mm) MIG circuit capacity (See Chart under is susceptible to moisture and oxidizes or Aluminum wire, use the factory set circuit requirements on page 1). over time, so it is important to select a large groove. Aluminum wire is very 8. Switch the welder ON. spool size that will be used within weak and should not have the same tension on the drive roller as Flux Core 9. Verify that the wire is extended approximately 6 months. For mild steel welding, AWS ER70S6 solid wire or or MIG wire should. When tensioning 1/4” from the contact tip. If not, Aluminum wire down to the Drive squeeze the trigger to feed AWS E71T-GS flux-core wire is recommended. Roller, turn the tension screw three full additional wire, release the trigger, turns or until the Drive Roller begins to • Contact tips - use Campbell Hausfeld, and cut wire to proper length. grip the wire and feed it through the Tweco®, and other compatible tips. 10. Position the wire feed gun near the torch cable. work piece, lower the welding • Nozzle - use Tweco® style or compatible helmet by nodding the head, or nozzle. Use Campbell Hausfeld nozzle position the hand shield, and model WT5021 found at place of Call (800) 746-5641 squeeze the gun trigger. Adjust heat purchase of welder, or use Tweco® style for replacement parts. setting and wire speed as needed. nozzle (or compatible nozzle) found at 11. When finished welding, turn welder local welding supply store. off and store properly. Maintenance

Disconnect power ! WARNING supply and turn machine off before inspecting or servicing any components. Keep the MIG wire compartment cover closed at all WT5021 times unless the wire needs Figure 8 - Nozzle replacement. Before every use: Changing Wire Sizes 1. Check condition of weld cables and DRIVE ROLLER immediately repair or replace any cables with damaged insulation. There are two grooves in the Drive Roller. The small groove is for .024” (.6 2. Check condition of power cord and mm) wire and the other is for .030” - immediately repair or replace any .035” (.8 - .9 mm) wire. Remove the cord if damaged. roller cover and flip the drive roll to 3. Inspect the condition of the gun tip choose the correct groove (see Parts and nozzle. Remove any weld slag. Breakdown). Replace gun tip or nozzle if FLUX CORE WIRE damaged. Due to small inconsistencies in wire Do not operate this diameter, using one size larger tip is ! WARNING welding machine recommended. For example: with cracked or missing insulation on • If wire diameter is .030, use .035 tip. welding cables, wire feed gun, or • If wire diameter is .035, use .040 tip. power cord. This welder is setup for .035 (.9 mm) Every 3 months: wire and has a .040 tip. Since this 1. Replace any unreadable safety welder uses .030 and .035 Flux Core labels on the welder. Wire, the drive roller should be in its 2. Use compressed air to blow all dust factory pre-set condition. and lint from the ventilation openings.

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6 WG3013

Welding Guidelines

General ications listed on the welder. It is zontal, measured at right angles to the suggested that the welder practice with line of welding. For most applications, a scrap metal to adjust settings and 45º travel angle and 45º work angle is Nozzle Contact compare welds with Figure 11. sufficient. For specific applications, Tip consult an arc welding handbook. Shielding WIRE TYPE AND SIZE Gas Flux Slag (Gasless The correct choice of wire type involves 5º - 45º only) a variety of factors, such as welding Weld Wire position, work piece material type, thickness and condition of surface to be welded. The American Welding Society, AWS, has set up certain requirements Crater Work Piece for each type of wire. WORK ANGLE Figure 9 - Weld Components FLUX-CORE WIRE E - 7 0 T - GS This line of welding machines can 5º - 45º utilize the Flux Cored Arc Welding Weld strength, times 10,000 psi (Gasless) process or the Gas Metal Arc Welding (MIG) process. The weld must Welding positions (0 be protected (shielded) from for flat or horizontal, contaminates in the air while it is TRAVEL ANGLE 1 for any position) molten. The gasless process uses a Tubular flux core wire Figure 10 - Weld Angle tubular wire with a flux material inside. Flux type The flux creates a shielding gas when WIRE SPEED melted. The MIG process uses inert gas The wire speed is controlled by the to shield the weld while molten. AWS E71T-GS or E71T-11 is knob on the front panel. The speed When current is produced by a recommended for this welder. needs to be “tuned” to the rate at which the wire is being melted in the transformer (welding machine) and SOLID WIRE flows through the circuit to the weld arc. Tuning is one of the most critical ER - 70 S - 6 wire, an arc is formed between the end functions in wire feed welding. Tuning should be performed on a scrap piece of the weld wire and the work piece. Weld strength, times of metal the same type and thickness as This arc melts the wire and the work 1,000 psi that to be welded. Begin welding with piece. The melted metal of the weld Solid wire Wire composition one hand “dragging” the gun nozzle wire flows into the molten crater and across the scrap piece while adjusting ER-70S6 is recommended for this forms a bond with the work piece as the wire speed with the other hand. welder. shown (Figure 9). Too slow of speed will cause sputtering WELD ANGLE and the wire will burn up into the Arc Welding Basics contact tip. Too fast a speed will also Five basic techniques affect weld Weld angle is the angle at which the cause a sputtering sound and the wire quality. These are: wire selection, heat nozzle is held during the welding will push into the plate before melting. setting, weld angle, wire speed, and process. Using the correct angle A smooth buzzing sound indicates the ensures proper penetration and bead travel speed. An understanding of wire speed is properly tuned. For formation. As different welding these techniques is necessary for aluminum, wire speed is typically set positions and weld joints become higher (7 - 9 speed range). effective welds. necessary, nozzle angle becomes an NOTE: Repeat the tuning procedure HEAT SETTING increasingly important factor in each time there is a change in heat The correct heat involves the adjust- obtaining a satisfactory weld. Weld setting, wire diameter or type, or work ment of the welding machine to the angle involves two positions - travel piece material type or thickness. required setting. Heat or voltage is angle and work angle. regulated by a switch on the welder. TRAVEL SPEED Travel angle is the angle in the line of The heat setting used depends on the The travel speed is the rate at which welding and may vary from 5º to 45º size (diameter) and type of wire, the torch is moved across the weld from the vertical, depending on position of the weld, and the thickness area. Factors such as diameter and type welding conditions. of the work piece. Consult specif- of weld wire, amperage, position, and Work angle is the angle from hori-

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7 Wire Feed Arc Welder

Welding Guidelines (Continued) work piece material thickness all affect overhead. Welding in the flat position Cover the speed of travel necessary for is easier than any of the others because completing a good weld (See Fig. 11). welding speed can be increased, the Filler When the speed is too fast, the bead is molten metal has less tendency to run, narrow and bead ripples are pointed as better penetration can be achieved, Root shown. When the speed is too slow, the and the work is less fatiguing. Welding weld metal piles up and the bead is is performed with the wire at a 45º high and wide. For aluminum, travel travel angle and 45º work angle. speed is typically faster. Other positions require different Figure 12 - Weld Passes SLAG REMOVAL (FLUX-CORE WIRE techniques such as a weaving pass, ONLY) circular pass, and jogging. A higher skill Wear ANSI level is required to complete these ! WARNING approved safety welds. glasses (ANSI Standard Z87.1) and Overhead welding is the least desirable protective clothing when removing position as it is the most difficult and slag. Hot, flying debris can cause dangerous. Heat setting and wire personal injury to anyone in the area. selection will vary depending upon the After completing the weld, wait for the position. welded sections to cool. A protective All work should be performed in the coating called slag now covers the weld flat position if possible. For specific bead which prevents contaminants in applications, consult an arc welding the air from reacting with the molten technical manual. metal. Once the weld cools to the point that it is no longer glowing red, the WELD PASSES slag can be removed. Removal is done Sometimes more then one pass is with a chipping hammer. Lightly tap the slag with the hammer and break it necessary to fill the joint. The root pass loose from the weld bead. The final is first, followed by filler passes and the clean-up is done with a wire brush. cover pass. If the pieces are thick, it may Figure 13 - Multiple Weld Passes be necessary to bevel the edges that NOTE: When making multiple weld are joined at a 60º angle. passes, remove the slag before each pass. NOTE: Remember to remove the slag before each pass for gasless process. WELDING POSITIONS Four basic welding positions can be used; flat, horizontal, vertical, and

Base Metal

Normal Heat, Wire Speed, Travel Speed Travel Speed Too Fast Heat Too Low Travel Speed Too Slow

Heat Too High Wire Speed Too Slow Wire Speed Too Fast Figure 11 - Weld Appearance

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8 WG3013

Welding Guidelines (Continued)

PUSH VS PULL TECHNIQUE ALUMINUM WELDING The type and thickness of the work Any aluminum surface to be welded, Supply Cable piece dictates which way to point the must be cleaned thoroughly with a Replacement gun nozzle. For thin materials (18 gauge stainless steel brush to eliminate any and up) and all aluminum, the nozzle oxides on the weld and grounding 1. Verify that welder is OFF and power should point out in front of the weld surface. 100% Argon must be used cord disconnected. puddle and push the puddle across the when welding aluminum. If Argon is not 2. Remove welder cover to expose the workpiece. For thicker steel, the nozzle used, metal penetration is unlikely. ON/OFF switch. should point into the puddle to increase weld penetration. This is called 3. Disconnect the black and white backhand or pull technique power cord wires connected to the (See Figure 14). ON/OFF switch. 4. Disconnect the green power cord wire connected to welder frame. 5. Loosen the cord strain screw(s) and pull cord out of strain relief. 6. Install new cord in reverse order.

PULL

Figure 14 PUSH

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9 Wire Feed Arc Welder

For Information About This Product, Call 1-800-746-5641 Troubleshooting Chart - Welder Symptom Possible Cause(s) Corrective Action

No output 1. Duty cycle exceeded 1. Allow welder to cool until ON/OFF Switch lamp goes out 2. Poor ground clamp connection 2. Be sure all connections are secure, and attaching surface is clean 3. Defective power switch 3. Replace switch 4. Blown breaker or fuse 4. Reduce circuit load, reset breaker or replace fuse Wire tangles at drive roller 1. Wrong size gun tip 1. Use proper size gun tip 2. Gun liner clogged or 2. Clean or replace gun liner damaged 3. Gun tip clogged or damaged 3. Clean or replace gun tip 4. Feed roller worn 4. Replace 5. Not enough tension 5. Tighten tensioning screw Gun nozzle arcs to work Slag inside gun nozzle Clean slag from gun nozzle surface

Ground clamp and/or 1. Poor contact 1. Be sure all connections are secure, and attaching surface is cable gets hot clean 2. Using an extension cord with 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 tensioning screws 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 Troubleshooting Chart - Welds Symptom Possible Cause(s) Corrective Action

Bead is intermittently too 1. Fast and/or inconsistent travel speed 1. Decrease and maintain constant travel speed thin 2. Output heat setting too low 2. Increase output heat setting

Bead is intermittently too 1. Slow and/or inconsistent travel speed 1. Increase and maintain travel speed 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 surface brush only

Wire sputters and sticks 1. Damp wire 1. Use dry wire and store in dry location 2. Wire speed too fast 2. Reduce wire speed 3. Wrong type of wire 3. Use flux core wire when not using gas 4. No or low shielding gas 4. Use gas for MIG process or refill bottle

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10 WG3013

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.

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11 Wire Feed Arc Welder

WG3013 Wiring Diagram

ON/OFF S1 T1 S3 1 S5 T2 1 2 ~ 2 M FAN ~ S2 MIN 4 + - 5 MAX S5 NC Y OPENS @ 127˚C 6 GROUND DRIVE ~ DECK WHITE BLACK GREEN - + S4 M GUN L2 L1

432 1

WIRE SPEED CONTROL BOARD

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12 WG3013 For Replacement Parts, call 1-800-746-5641

Please provide following information: 24 28 44 27 - Model number 45 23 - Serial number 33 - Part description and number as 3 shown in parts list 25 26 29 43 Address parts correspondence to: The Campbell Group Attn: Parts Department 2 100 Production Drive Harrison, Ohio 45030 U.S.A. 6 5 27 4 ** Contact Tip (See chart on Page 15) 16 17 22

1 18 19 20 21

40 39 12 40 34

46 13 14

41 37 8 7 31 35 11 9 & 10 36 30 38

42 3 15

32 1 40 MODEL WG3013

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13 Wire Feed Arc Welder Replacement Parts List - Models WG3013 Ref Part Number for Model: No. Description WG3013 Qty 1 Torch assembly and hose (Includes Nos. 2-6, 34, and 50-52) WC600700AV 1 2 Torch body, front and back WC600201AV 1 3 Hanger clip WC600003AV 1 4 Nozzle, Tweco® Style WT502100AJ 1 5 Trigger knob WC600202AV 1 6 Torch contact spring WC600203AV 1 7 Work clamp (Cord not included) WC100100AV 1 8 Welding cable 8 AWG (6 ft) ❋ 1 9 Wire speed knob WC400201AV 1 10 Wire speed control board WC402100AV 1 11 Heat selector switch WC400300AV 2 12 On/off switch WC400000AV 1 13 Safety decal DK670100AV 1 14 Handle WC300600AV 1 15 Power cord 14-3 AWG (6 ft) Type SJT ❋ 1 16 Spool spindle WC500300AV 1 17 #10-32 x .5” Pan head sheet metal screw ❋ 2 18 Wire See Chart Below 1 19 Spool adapter WC500200AV 1 20 Spool spring WC500101AV 1 21 Spool locking hub WC500100AV 1 22 Drive deck assembly (Includes Nos. 23-29) WC500000AV 1 23 Tension spring WC500003AV 1 24 Tension screw WC500002AV 1 25 Roller .6-.9mm (.024-.035 in.) WC500001AV 1 26 Roller cover WC500004AV 1 27 #8-36 x 1.5” Pan head screw ❋ 3 28 Swing arm WC500005AV 1 29 Swing arm roller WC500007AV 1 30 Strain relief WC102000AV 1 31 Wheel WC701200AV 2 32 Front foot WC702100AV 1 33 Liner, coated metal WC600208AV 1 34 Gas cylinder bracket WC702200AV 1 35 Axle WC703100AV 1 36 Wheel hub WC703500AV 1 37 Dinse connector WC000200AV 2 38 Dinse socket WC000300AV 2 39 Torch ring WC600009AV 1 40 #10-24 x 1/2” Screw ❋ 9 41 Axle support WC703600AV 2 42 5mm I.D. e-ring ❋ 2 43 Swan neck with Diffuser WC600701AV 1 44 Trumpet liner WC600305AV 1 45 Valve body WC600204AV 1 46 Gas bottle strap WC802000AV 1 ❋ Standard hardware item, available at local hardware or welder supply store

OPTIONAL WIRE **OPTIONAL CONTACT TIPS (4/package) Part Number Part Number Type Description (1 pound) (10 pound) Size mm in. Part Number Flux E71T-GS .030” WE200001AV WE201000AV Flux E71T-GS .035” WE200501AV WE201500AV 0.6 0.024 WT501200AJ MIG ER70S6 .024” WE300001AV WE301500AV 0.8 0.030 WT501300AJ MIG ER70S6 .030” WE300501AV WE302000AV 0.9 0.035 WT501400AJ MIG ER70S6 .035” WE301001AV WE302500AV Aluminum MIG ER5356 .030” WE303001AV N/A

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14 WG3013 Glossary of Welding Terms

AC or Alternating Current - electric Flux Cored Arc Welding (FCAW) - Slag - a layer of flux soot that protects current that reverses direction also called Gasless, is a welding process the weld from oxides and other periodically. Sixty cycle current travels used with a wire-feed welding contaminants while the weld is in both directions sixty times per machine. The weld wire is tubular with solidifying (cooling). Slag should be second. flux material contained inside for removed after weld has cooled. shielding. Arc Length - the distance from the Spatter - metal particles thrown from end of the electrode to the point Gas Metal Arc Welding (GMAW) - the weld which cool and harden on the where the arc makes contact with the also called MIG, is a welding process work surface. Spatter can be minimized work surface. used with a wire feed welding by using a spatter resistant spray on the machine. The wire is solid and an inert work piece before welding. Base Metal - the material to be gas is used for shielding. welded. Tack Weld - weld made to hold parts Gas Tungsten Arc Welding (GTAW) - in proper alignment until final welds Butt Joint - a joint between two also called TIG, is a welding process are made. members aligned approximately in the used with welding equipment with a same plane. Travel Angle - the angle of the high frequency generator. The arc is electrode in the line of welding. It Crater - a pool, or pocket, that is created between a non-consumable varies from 5º to 45º depending on formed as the arc comes in contact with tungsten electrode and the work piece. welding conditions. the base metal. Filler metal may or may not be used. T Joint - made by placing the edge of DC or Direct Current - electric current Lap Joint - a joint between two one piece of metal on the surface of which flows only in one direction. The overlapping members in parallel the other piece at approximately a 90º polarity (+ or -) determines which planes. angle. direction the current is flowing. Open Circuit Voltage (OCV) - the Undercut - a condition that results DC Reverse Polarity - occurs when voltage between the electrode and the when welding amperage is too high. the electrode holder is connected to work clamp of the welding machine The excessive amperage leaves a the positive pole of the welding when no current is flowing (not groove in the base metal along both machine. Reverse Polarity directs more welding). The OCV determines how sides of the bead which reduces the heat into melting the electrode rather quickly the arc is struck. strength of the weld. then the work piece. It is used on Overlap - occurs when the amperage is thinner material. Weld Pool or Puddle - a volume of set too low. In this instance, the molten molten metal in a weld prior to its DC Straight Polarity - occurs when metal falls from the electrode without solidification as weld metal. the electrode holder is connected to actually fusing into the base metal. the negative pole of the welding Weld Bead - a narrow layer or layers of Porosity - gas pockets, or cavities, machine. With straight polarity more metal deposited on the base metal as formed during weld solidification. They heat is directed to the work piece for the electrode melts. Weld bead width is weaken the weld. better penetration on thicker material. typically twice the diameter of the Penetration - the depth into the work electrode. Electrode - a coated metal wire having piece that has been heat effected by approximately the same composition as Work Angle - the angle of the the arc during the welding process. A the material being welded. electrode from horizontal, measured at good weld achieves 100% penetration right angles to the line of welding. Fillet Weld - approximately a triangle meaning that the entire thickness of in cross-section, joining two surfaces at the work piece has been heated and right angles to each other in a lap, T or resolidified. The heat effected area corner joint. should be easily seen on the opposite side of the weld. Flux - a coating, when heated, that produces a shielding gas around the Shielded Metal Arc Welding welding area. This gas protects the (SMAW) - also called Stick, is a welding parent and filler metals from impurities process with uses a consumable in the air. electrode to support the arc. Shielding is achieved by the melting of the flux coating on the electrode.