Op e ra t in g In st ru ct io n s & Pa rt s Ma n u a l
Mo d e l WG3013
Ple a se re a d a n d sa ve t h e se in st ru ct io n s. Re a d ca re fu lly b e fo re a t t e m p t in g t o a sse m b le , in st a ll, o p e ra t e o r m a in t a in t h e p ro d u ct d e scrib e d .
Pro t e ct yo u rse lf a n d o t h e rs b y o b se rvin g a ll sa fe t y in fo rm a t io n . Fa ilu re t o co m p ly w it h in st ru ct io n s co u ld re su lt in p e rso n a l in ju ry a n d /o r
p ro p e rt y d a m a g e ! Re t a in in st ru ct io n s fo r fu t u re re fe re n ce .
Wire Feed
Arc Welder
Ne e d
TM
Assist a n ce ?
B UILT T O LA S T
Ca ll Us First !
1-800-746-5641
De scrip t io n
This line of Campbell Hausfeld wire feed
4
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
Metal Arc Welding (Mig) process. As
6
delivered from the factory, this welder
can weld with .024” (.6 mm) to .035”
5
(.9 mm) diameter wire. A starter spool
of .035” (.9 mm) flux-cored wire and a
3
.040 tip are included.
FARMHAND 125
Un p a ckin g
7
Som e w elder com ponents m ay be
2
found in the w ire feed com partm ent.
When unpacking, inspect carefully for
any damage that may have occurred
during transit. Report any damaged or
missing items by calling (800) 746-5641.
Fig u re 1
Co m p o n e n t s a n d Co n t ro ls
1. Gro u n d Cla m p - connect to work
Da n g e r m e a n s a
h a za rd t h a t w ill
ca u se d e a t h o r se rio u s in ju ry if t h e
w a rn in g is ig n o re d .
Circu it Re q u ire m e n t s
!
piece.
DANGER
Th is e q u ip m e n t
re q u ire s a d e d i-
2. Wire Fe e d Gu n w it h .040 t ip
!
CAUTION
ca t e d 115 vo lt circu it . Re fe r t o t h e
fo llo w in g ch a rt fo r t h e co rre ct circu it
b re a ke r o r fu se ra t in g . Do n o t ru n
o t h e r a p p lia n ce s, lig h t s, o r t o o ls o n
t h is circu it w h ile o p e ra t in g t h is
3. Po w e r Co rd - plug into 115 volt
Wa rn in g m e a n s a
h a za rd t h a t co u ld
ca u se d e a t h o r se rio u s in ju ry if t h e
w a rn in g is ig n o re d .
outlet.
!
WARNING
4. On /Off Sw it ch
5. In fin it e Wire Sp e e d Co n t ro l -
turn clockwise to increase wire
speed and counterclockwise to
decrease wire speed.
e q u ip m e n t . Ext e n sio n co rd s a re n o t
re co m m e n d e d . Blo w n fu se s a n d t rip p e d
circu it b re a ke rs ca n re su lt fro m fa ilu re
t o co m p ly w it h t h is re co m m e n d a t io n .
Ca u t io n m e a n s a
h a za rd t h a t m a y
ca u se m in o r o r m o d e ra t e in ju ry if t h e
w a rn in g is ig n o re d . It a lso m a y m e a n a
h a za rd t h a t w ill o n ly ca u se d a m a g e t o
p ro p e rt y.
!
CAUTION
Heat
Selector
Circuit Breaker or
Slow Blow Fuse
6. He a t Se le ct o r - Selects welding
power. Four selections are possible
7. Po la rit y Ho o k-u p - Attach torch
cable to (+) for MIG and (-) for flux
core wire.
NOTE: Note means any additional
information pertaining to the product
or its proper usage.
Low
15 amp
20 amp
High
IN970400AV 11/00
WG3013
cylin d e rs co n t a in g a s u n d e r h ig h
p re ssu re . If d a m a g e d , a cylin d e r ca n
e xp lo d e . Sin ce g a s cylin d e rs a re
n o rm a lly p a rt o f t h e w e ld in g p ro ce ss,
b e su re t o t re a t t h e m ca re fu lly.
Co d e fo r Sa fe t y in We ld in g a n d
Cu t t in g
Ge n e ra l Sa fe t y
(Co n t in u e d )
CSA Standard W117.2, from Canadian
Standards Association, Standards Sales,
178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3
● Protect compressed gas cylinders
from excessive heat, mechanical
shocks, and arcs.
!
WARNING
Cu t t in g An d We ld in g Pro ce sse s
Do n o t b re a t h e fu m e s t h a t
a re p ro d u ce d b y t h e a rc
NFPA Standard 51B, from National Fire
Protection Association, Batterymarch
Park, Quicy, MA 02269
● Install and secure cylinders in an
upright position by chaining them
to stationary support or equipment
cylinder rack to prevent falling or
tipping.
w e ld in g o p e ra t io n . Th e se
fu m e s a re d a n g e ro u s. If t h e w e ld in g
a re a ca n n o t b e a d e q u a t e ly ve n t ila t e d ,
b e su re t o u se a n a ir su p p lie d
re sp ira t o r.
Sa fe Pra ct ice s Fo r Occu p a t io n a l An d
Ed u ca t io n a l Eye An d Fa ce
Pro t e ct io n
ANSI Standard Z87.1, from American
National Standards Institute, 1430
Broadway, New York, NY 10018
● Keep cylinders away from any
● Keep the head and face out of the
welding or other electrical circuits.
welding fumes.
● Never allow a welding electrode to
● Do not perform electric arc welding
operations on metals that are
galvanized or cadmium plated, or
contain zinc, mercury, or beryllium
without completing the following
precautions:
touch any cylinder.
Refer to the Material Safety Data
Sheets and the manufacturers
instructions for metals, wire, coatings
and cleaners.
● Use only correct shielding gas
cylinders, regulators, hoses, and
fittings designed for the specific
application; maintain them and
associated parts in good condition.
a. Remove the coating from the
base metal.
b. Make sure that the welding area
is well ventilated.
c. Use an air-supplied respirator.
Extremely toxic fumes are created
when these metals are heated.
In st a lla t io n
Selecting the proper location can
significantly increase performance,
reliability and life of the arc welder.
● 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.
● For best results locate the welder in
an environment that is clean and
dry. Dust and dirt in the welder
retain moisture and increase wear
of moving parts.
● Read and follow instructions on
compressed gas cylinders, associated
equipment, and CGA publication P-1
listed in Safety Standards.
!
WARNING
Th e e le ct ro m a g n e t ic fie ld
t h a t is g e n e ra t e d d u rin g a rc
w e ld in g m a y in t e rfe re w it h
t h e o p e ra t io n o f va rio u s
e le ct rica l a n d e le ct ro n ic d e vice s su ch a s
ca rd ia c p a ce m a ke rs. Pe rso n s u sin g su ch
d e vice s sh o u ld co n su lt w it h t h e ir
p h ysicia n p rio r t o p e rfo rm in g a n y
e le ct ric a rc w e ld in g o p e ra t io n s.
Ne ve r u se
fla m m a b le g a sse s
● Place the welder in an area that
provides at least 12” (30,48 cm) of
ventilation space at both the front
and rear of the unit. Keep all
obstructions away from this
ventilation space.
● Store wire in a clean, dry location
with low humidity to preserve the
wire coating.
● The receptacle used for the welder
must be properly grounded and the
welder must be the only load on the
power supply circuit. Refer to the
Circuit Amps chart on page 1 for
correct circuit capacity.
● The use of an extension cord is not
recommended for electric arc
welding machines. The voltage drop
in the extension cord may signifi-
cantly degrade the performance of
the welder.
!
DANGER
w it h MIG w e ld e rs. On ly in e rt o r n o n -
fla m m a b le g a sse s su ch a s ca rb o n
d io xid e , a rg o n , h e liu m , o r m ixt u re s o f
o n e o r m o re o f t h e se g a sse s a re
su it a b le fo r MIG w e ld in g .
Never lift cylinders
off the ground by
their valves, caps, or w ith chains or slings.
●● Route the wire gun and work cables
together and secure with tape
when possible.
!
WARNING
●● Never wrap arc welder cables
ADDITIONAL SAFETY STANDARDS
around the body.
ANSI St a n d a rd Z49.1 from American
Welding Society, 550 N.W. LeJune Rd.
Miami, FL 33126
● Always position the wire gun and
work leads so that they are on the
same side of the body.
● Exposure to electromagnetic fields
during welding may have other
Sa fe t y a n d He a lt h St a n d a rd s
OSHA 29 CFR 1910, from
Superintendent of Documents, U.S.
Government Printing Office,
Washington, D.C. 20402
health effects which are not known.
Alw a ys b e su re
t h a t t h e w e ld in g
a re a is se cu re a n d fre e o f h a za rd s
(sp a rks, fla m e s, g lo w in g m e t a l o r sla g )
p rio r t o le a vin g . Be su re t h a t
!
WARNING
Na t io n a l Ele ct rica l Co d e
NFPA Standard 70, from National Fire
Protection Association, Batterymarch
Park, Quincy, MA 02269
Asse m b ly
We ld e r co m p o n e n t s list e d b e lo w
a re in t h e w ire fe e d co m p a rt m e n t .
Op e n a n d re m o ve .
e q u ip m e n t is t u rn e d o ff a n d e xce ss
w ire is cu t o ff. Be su re t h a t ca b le s a re
lo o se ly co ile d a n d o u t o f t h e w a y. Be
su re t h a t a ll m e t a l a n d sla g h a s co o le d .
Sa fe Ha n d lin g o f Co m p re sse d Ga se s
in Cylin d e rs
CGA Pamphlet P-1, from Compressed Gas
Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
HANDLE ASSEMBLY
1. Remove screws from handle. Slide
handle between welder front panel
!
DANGER
Cylin d e rs ca n e xp lo d e if
d a m a g e d . Sh ie ld in g g a s
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Wire Fe e d Arc We ld e r
Asse m b ly (Co n t in u e d )
w e ld in g w ire e ve n w h e n t h e t h e g u n
sw it ch is n o t a ct iva t e d . Do n o t t o u ch
t h e se p a rt s w h e n t h e w e ld in g m a ch in e
is o n .
6. Feed the wire through the wire feed
guide tube, over the groove in the
drive roll and into the gun liner.
Tighten the wire feed tensioning screw
so that it is snug. Do not over tighten.
and top cover aligning the holes in
handle with holes in top cover.
NOTE: Before installing welding wire,
be sure that the diameter of the
welding wire matches the groove in the
drive roller on the wire feed
mechanism and the wire matches the
contact tip in the end of the gun. A
mismatch on any item could cause the
wire to slip or bind.
2. Fasten screws through top cover and
into handle.
7. Remove the nozzle by turning
co u n t e rclo ckw ise . Then unscrew
the contact tip from the end of the
welding torch (See Figure 5). Plug the
welder into the proper power supply
receptacle.
WHEEL AND AXLE ASSEMBLY
1. Insert axle supports into slots in the
welder housing.
2. Insert axle through the axle supports
and firmly push wheels onto axle.
Torch Neck
Contact Tip
1. Verify the unit is off and open the
panel on the welder to expose the
wire feed mechanism.
3. Secure wheel with e-clips and wheel
caps.
GAS CYLINDER BRACKET ASSEMBLY
1. Place bracket on welder aligning the
holes in welder housing.
2. Remove the spool quick lock, by
pushing in and rotating 1/4 turn
counterclockwise. The knob, spring,
and spool spacer can now be removed.
2. Fasten screws through bracket and
into cabinet.
Nozzle
NOTE: Spool spacer and spindle spacer
act as an 8” spool spindle adapter.
Purchase of an adapter is not necessary.
Fig u re 5 - To rch No zzle
FOOT ASSEMBLY
1. Place foot on welder and align holes
in the welder housing.
HINT: Keep torch cable straight when
feeding wire.
* Se e Fig u re 4 fo r a sse m b ly.
3. Loosen the wire feed tensioning
screw on the drive mechanism. This
allows initial feeding of the wire into
the gun liner by hand.
2. Fasten screws through foot into
cabinet.
8. Turn on the welder and set the wire
speed rate to 5. Activate the gun
switch until the wire feeds out past
the torch end. Turn welder off.
9. Carefully slip the contact tip over the
wire and screw it into the torch neck.
Install the nozzle by turning clo ck-
w ise (See Figure 6). Cut the wire off
approximately 1/4” from the end of
the nozzle.
Tension
Screw
Panel
Guide
Drive Roller
Tube
Contact Tip Markings
Wire Size
mm
Spindle
Spacer
.024”
.030”
.035”
.040”
or
or
or
or
.6
.8
Spool
Spacer
Fig u re 2 - WG3013 Asse m b ly
Gro u n d Cla m p
1. Loosen hex nut on work clamp.
.9
Spool
Lock
1.0
2. Insert cord through clamp handle and
slide bare wire under the clamp block.
Tighten hex nut making sure bare
wire is clamped securely (Figure 3).
Spindle
POLARITY
*Reverse
position and
For gas shielded welding, connect the
cable coming out of the torch to the (+)
socket and the ground clamp cable to
the (-) socket on the front panel. For
flux-core (no-gas) welding, connect
torch to (-) and work clamp to (+).
4” or 8”
insert into 8”
Spool
Spring
spool
Fig u re 4 - We ld Wire Ro u t in g
Clamping
Block
4. Install the wire spool onto the
spindle so that the wire can come off
the spool on the end closest to the
wire feed guide tube. Do n o t cu t
t h e w ire lo o se ye t . Install the spool
spacer, spring, and quick lock knob
by pushing in and turning the knob
1/4 rotation clockwise.
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.
Fig u re 3 - Wo rk Cla m p Asse m b ly
Wire In st a lla t io n
We ld in g p o w e r
m a y b e a p p lie d t o
t h e o u t p u t t e rm in a ls, fe e d ro ll, w o rk
cla m p , g u n ca b le co n n e ct io n a n d
!
WARNING
5. Hold the wire and cut the wire end
from the spool. Do not allow the wire
to unravel. Be sure that the end of the
wire is straight and free of burrs.
Internal components of this welder are
protected from overheating with an
automatic thermal switch. A yellow
lamp is illuminated on the front panel
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WG3013
o r d e a t h ! Alw a ys se cu re g a s cylin d e rs
t o t h e t a n k b ra cke t kit , a w a ll o r o t h e r
fixe d su p p o rt t o p re ve n t t h e cylin d e r
fro m fa llin g o ve r. Re a d , u n d e rst a n d ,
a n d fo llo w a ll t h e co m p re sse d g a se s
a n d e q u ip m e n t h a za rd s in t h e sa fe t y
in st ru ct io n s.
connection. Make sure the gas hose
is not kinked or twisted.
Assem bly (Continued)
if the duty cycle is exceeded. Welding
operations may continue when the
yellow lamp is no longer illuminated.
5. Once again, stand opposite the
cylinder outlet and slowly open the
cylinder valve. Inspect for leaks in
the connections.
6. Pull the trigger on the gun to allow
the gas to flow. While the trigger is
pulled and gas is flowing, adjust the
gas regulator to 30-35 cfh (cubic
feet per hour). Release the trigger.
Ha n d sh ie ld
Asse m b ly
1. Cut retainer stiffeners and
detachable handle away from shield.
Trim the excess plastic to remove
sharp edges.
2. Insert filter lens.
3. Attach the stiffeners over the pins on
the lens retainers (See Figure 6).
NOTE: Shielding gas is not required if
flux-cored welding wire is used.
GAS TYPES
There are 3 types of gas generally used
for gas metal arc welding; 100% argon,
a mixture of 75% argon and 25%
carbon dioxide (C25) or 100% carbon
dioxide. However, 100% carbon
dioxide is not recommended due to
unsatisfactory weld beads. This welder
does not perform well with 100%
carbon dioxide. The 75/25 mixture is
recommended for general steel
welding. For aluminum welding, use
100% argon. Cylinders of either type
gas may be obtained at your local
welding supply outlet. Secure cylinder
in place on your welding machine or
other support to prevent the cylinder
from falling over.
7. Remember to close the gas valve
when finished welding.
Op e ra t io n
1. Be sure to read,
understand, and comply
with all precautions in
the General Safety
MANUAL
Lens
Information section. Be
sure to read the entire section
entitled Welding Guidelines prior to
using this equipment.
Lens
Retainer
2. Verify welder is off.
3. Verify that the surfaces of metals to
be joined are free from dirt, rust,
paint, oil, scale or other contam-
inants. These contaminants make
welding difficult and cause poor
welds.
NOTE: Use of incorrect gas may lead to
little or no penetration of welding
bead.
Retainer
Stiffener
REGULATOR (NOT INCLUDED)
The regulator provides a constant
shielding gas pressure and flow rate
during the welding process.
Figure 6
!
DANGER
All p e rso n s o p e ra t in g t h is
e q u ip m e n t o r in t h e a re a
w h ile e q u ip m e n t is in u se
m u st w e a r p ro t e ct ive w e ld in g g e a r
in clu d in g : e ye p ro t e ct io n w it h p ro p e r
sh a d e , fla m e re sist a n t clo t h in g , le a t h e r
w e ld in g g lo ve s, a n d fu ll fo o t
p ro t e ct io n .
4. To attach the handle, place shield on
a flat surface and press handle into
place (See Figure 7).
HOOKUP PROCEDURE
Cylin d e r g a s is
u n d e r h ig h
p re ssu re . Po in t cylin d e r o u t le t a w a y
fro m yo u rse lf a n d a n y b yst a n d e rs
b e fo re o p e n in g .
!
WARNING
1. These units fit a 20 cubic ft bottle.
WHETHER OR
NOT THE TRIGGER
IS PULLED, t h e w e ld in g w ire is LIVE
w h e n e ve r t h e w e ld e r is t u rn e d ON.
2. With the cylinder securely installed,
remove the cylinder cap, stand to the
side of the cylinder opposite the
!
CAUTION
outlet, and open the valve slightly,
turning counterclockwise. When gas
is emitted from the cylinder, close the
valve by turning clockwise. This will
blow out dust or dirt that may have
accumulated around the valve seat.
Fig u re 7
!
WARNING
NOTE: If you have never w elded
before or have little experience, a
full face helm et is recom m ended.
Both hands are needed to stabilize
and control the angle and arc
length of the torch.
If h e a t in g , w e ld in g , o r
cu t t in g m a t e ria ls t h a t a re
g a lva n ize d , zin c p la t e d , le a d ,
o r ca d m iu m p la t e d re fe r t o t h e Ge n e ra l
Sa fe t y In fo rm a t io n Se ct io n fo r
in st ru ct io n s. Ext re m e ly t o xic fu m e s a re
cre a t e d w h e n t h e se m e t a ls a re h e a t e d .
3. Install the regulator onto the
cylinder valve, keeping the face of
the gauges in the vertical position
and tighten the stem nut securely
to the gas valve.
Shielding Gas
Installation
4. Connect the work clamp to the
work piece or workbench (if metal).
Make sure the contact is secure.
Avoid surfaces with paint, varnish,
corrosion, or non-metallic materials.
4. Install one end of the gas hose (not
included) to the fitting on the rear
of the welder and the other end to
the fitting on the regulator using
hose clamps (not included) on each
Im p ro p e r h a n d lin g
a n d m a in t e n a n ce
o f co m p re sse d g a s cylin d e rs a n d
!
DANGER
re g u la t o rs ca n re su lt in se rio u s in ju ry
5. Position the Heat Selector on the
front panel to the desired setting.
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Wire Fe e d Arc We ld e r
MIG WIRE
3. Clean the wire groove on the drive
roll. Remove wire from the feed
mechanism, remove screws from the
drive roll housing. Use a small wire
brush to clean the drive roll. Replace
if worn or damaged.
Op e ra t io n (Continued)
Since MIG wire maintains fair wire
diameter consistency, the contact tip
used should match the wire size used.
When using .024 (.6 mm) wire, use the
small groove on the drive roller. When
using .030 - .035 (.8 - .9 mm) MIG or
Aluminum wire, use the factory set
large groove.
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.
Co n su m e r a n d We a r Pa rt s
The following parts require routine
maintenance:
ALUMINUM WIRE
• Wire feed drive roller
• Gun liner - replace if worn
• Nozzle/contact tips
When using Aluminum wire, it is best
to use a larger size tip than the wire
size being used. For example:
• If wire diameter is .030, use .035 tip.
6. Rotate the Wire Speed Control to
setting number 5 to start with, then
adjust as needed after test weld.
7. Plug the input cord into a proper
voltage receptacle with proper
circuit capacity (See Chart under
circuit requirements on page 1).
• 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
When using .030 - .035 (.8 - .9 mm) MIG
or Aluminum wire, use the factory set
large groove. Aluminum wire is very
weak and should not have the same
tension on the drive roller as Flux Core
or MIG wire should. When tensioning
Aluminum wire down to the Drive
Roller, turn the tension screw three full
turns or until the Drive Roller begins to
grip the wire and feed it through the
torch cable.
8. Switch the welder ON.
9. Verify that the wire is extended
1/4” from the contact tip. If not,
squeeze the trigger to feed
recommended.
additional wire, release the trigger,
and cut wire to proper length.
• Contact tips - use Campbell Hausfeld,
Tweco®, and other compatible tips.
10. Position the wire feed gun near the
work piece, lower the welding
• 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.
helmet by nodding the head, or
position the hand shield, and
squeeze the gun trigger. Adjust heat
setting and wire speed as needed.
Ca ll (800) 746-5641
fo r re p la ce m e n t p a rt s.
11. When finished welding, turn welder
off and store properly.
Ma in t e n a n ce
Disco n n e ct p o w e r
su p p ly a n d t u rn
!
WARNING
m a ch in e o ff b e fo re in sp e ct in g o r
se rvicin g a n y co m p o n e n t s. Ke e p t h e
w ire co m p a rt m e n t co ve r clo se d a t a ll
t im e s u n le ss t h e w ire n e e d s
re p la ce m e n t .
MIG
WT5021
Fig u re 8 - No zzle
Before every use:
Ch a n g in g Wire Size s
DRIVE ROLLER
1. Check condition of weld cables and
immediately repair or replace any
cables with damaged insulation.
There are two grooves in the Drive
Roller. The small groove is for .024” (.6
mm) wire and the other is for .030” -
.035” (.8 - .9 mm) wire. Remove the
roller cover and flip the drive roll to
choose the correct groove (see Parts
Breakdown).
2. Check condition of power cord and
immediately repair or replace any
cord if damaged.
3. Inspect the condition of the gun tip
and nozzle. Remove any weld slag.
Replace gun tip or nozzle if
damaged.
FLUX CORE WIRE
Due to small inconsistencies in wire
diameter, using one size larger tip is
recommended. For example:
• If wire diameter is .030, use .035 tip.
Do n o t o p e ra t e t h is
w e ld in g m a ch in e
!
WARNING
w it h cra cke d o r m issin g in su la t io n o n
w e ld in g ca b le s, w ire fe e d g u n , o r
p o w e r co rd .
• If wire diameter is .035, use .040 tip.
This welder is setup for .035 (.9 mm)
wire and has a .040 tip. Since this
welder uses .030 and .035 Flux Core
Wire, the drive roller should be in its
factory pre-set condition.
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.
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WG3013
We ld in g Gu id e lin e s
ications listed on the welder. It is
suggested that the welder practice with
scrap metal to adjust settings and
compare welds with Figure 11.
zontal, 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.
Ge n e ra l
Nozzle
Contact
Tip
Shielding
Gas
WIRE TYPE AND SIZE
Flux
(Gasless
only)
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.
5º - 45º
Slag
Weld
Wire
WORK ANGLE
Crater
Fig u re 9 - We ld Co m p o n e n t s
Work Piece
FLUX-CORE WIRE
E - 7 0 T - GS
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 9).
5º - 45º
Weld strength, times
10,000 psi
Welding positions (0
for flat or horizontal,
1 for any position)
Tubular flux core wire
Flux type
TRAVEL ANGLE
Fig u re 10 - We ld An g le
WIRE SPEED
The wire speed is controlled by the
knob on the front panel. The speed
needs to be “ t u n e d ” 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
a lu m in u m , wire speed is typically set
higher (7 - 9 speed range).
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
Arc We ld in g Ba sics
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.
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.
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.
HEAT SETTING
The correct heat involves the adjust-
ment of the welding machine to the
required setting. Heat or voltage is
regulated by a switch on the welder.
The heat setting used depends on the
size (diameter) and type of wire,
position of the weld, and the thickness
of the work piece. Consult specif-
TRAVEL SPEED
Travel angle is the angle in the line of
welding and may vary from 5º to 45º
from the vertical, depending on
welding conditions.
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 angle is the angle from hori-
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Wire Fe e d Arc We ld e r
We ld in g Gu id e lin e s (Co n t in u e d )
work piece material thickness all affect
the speed of travel necessary for
overhead. Welding in the flat position
Cover
Filler
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.
completing a good weld (See Fig. 11).
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 a lu m in u m , travel
speed is typically faster.
Root
Other positions require different
techniques such as a weaving pass,
circular pass, and jogging. A higher skill
level is required to complete these
welds.
Fig u re 12 - We ld Pa sse s
SLAG REMOVAL (FLUX-CORE WIRE
ONLY)
We a r ANSI
a p p ro ve d sa fe t y
g la sse s (ANSI St a n d a rd Z87.1) a n d
p ro t e ct ive clo t h in g w h e n re m o vin g
sla g . Ho t , flyin g d e b ris ca n ca u se
p e rso n a l in ju ry t o a n yo n e in t h e a re a .
!
WARNING
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.
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.
All work should be performed in the
flat position if possible. For specific
applications, consult an arc welding
technical manual.
WELD PASSES
Sometimes more then one pass is
necessary to fill the joint. The root pass
is first, followed by filler passes and the
cover pass. If the pieces are thick, it may
be necessary to bevel the edges that
are joined at a 60º angle.
Fig u re 13 - Mu lt ip le We ld Pa sse s
NOTE: When making multiple weld
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
Travel Speed Too Slow
Wire Speed Too Slow
Heat Too Low
Heat Too High
Wire Speed Too Fast
Fig u re 11 - We ld Ap p e a ra n ce
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WG3013
We ld in g Gu id e lin e s (Co n t in u e d )
PUSH VS PULL TECHNIQUE
ALUMINUM WELDING
Su p p ly Ca b le
Re p la ce m e n t
1. Verify that welder is OFF and power
cord disconnected.
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
Any aluminum surface to be welded,
must be cleaned thoroughly with a
stainless steel brush to eliminate any
oxides on the w eld and grounding
surface. 100% Argon m ust be used
when welding aluminum. If Argon is not
used, metal penetration is unlikely.
2. Remove welder cover to expose the
ON/OFF switch.
3. Disconnect the black and white
power cord wires connected to the
ON/OFF switch.
backhand or pull technique
(See Figure 14).
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
Fig u re 14
PUSH
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Wire Fe e d Arc We ld e r
Fo r In fo rm a t io n Ab o u t Th is Pro d u ct , Ca ll 1-800-746-5641
Tro u b le sh o o t in g Ch a rt - We ld e r
Symptom
Possible Cause(s)
Corrective Action
1. Allow welder to cool until ON/OFF Switch lamp goes out
2. Be sure all connections are secure, and attaching surface is
clean
No output
1. Duty cycle exceeded
2. Poor ground clamp connection
3. Replace switch
3. Defective power switch
4. Blown breaker or fuse
4. Reduce circuit load, reset breaker or replace fuse
1. Use proper size gun tip
Wire tangles at drive roller 1. Wrong size gun tip
2. Gun liner clogged or
2. Clean or replace gun liner
damaged
3. Clean or replace gun tip
4. Replace
5. Tighten tensioning screw
3. Gun tip clogged or damaged
4. Feed roller worn
5. Not enough tension
Clean slag from gun nozzle
Gun nozzle arcs to work
surface
Slag inside gun nozzle
1. Be sure all connections are secure, and attaching surface is
clean
2. Never use an extension cord longer than 20 ft
Ground clamp and/or
cable gets hot
1. Poor contact
2. Using an extension cord with
excessive length
1. Reload wire
Wire does not feed
1. Wire jammed
2. Replace wire spool
2. Out of wire
3. Tighten tensioning screws if wire is slipping
4. Replace liner
5. Call 1-800-746-5641 for assistance
6. Replace contact tip
3. Not enough tension
4. Wire liner worn
5. Wire disconnected internally
6. Contact tip clogged
1. Run speed in 7 - 10 range
2. Increase the travel speed or reduce heat settings
(Aluminum) Wire burns back 1. Wire speed too slow
into tip or (Aluminum) Metal 2. Travel speed too slow or heat
bubbles or burns through
is too high
Tro u b le sh o o t in g Ch a rt - We ld s
Symptom
Possible Cause(s)
Corrective Action
Bead is intermittently too
thin
1. Fast and/or inconsistent travel speed
2. Output heat setting too low
1. Decrease and maintain constant travel speed
2. Increase output heat setting
Bead is intermittently too
thick
1. Slow and/or inconsistent travel speed
2. Output heat setting too high
1. Increase and maintain travel speed
2. Reduce output heat setting
Ragged depressions at
edge of weld
1. Travel speed too fast
2. Wire speed too fast
1. Decrease travel speed
2. Decrease wire speed
3. Output heat setting too high
3. Reduce output heat setting
Weld bead does not
penetrate base metal
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 buid-up on
surface
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
Wire sputters and sticks
1. Damp wire
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
2. Wire speed too fast
3. Wrong type of wire
4. No or low shielding gas
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WG3013
Lim it e d 5-3-1 Wa rra n t y
1.
2.
Du ra t io n : 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)
Wh o Give s Th is Wa rra n t y (Wa rra n t o r):
The Campbell Group / A Scott Fetzer Company
100 Production Drive
Harrison, OH 45030
Telephone: (513)-367-4811
3.
4.
Wh o Re ce ive s Th is Wa rra n t y (Pu rch a se r): The original purchaser of the Campbell Hausfeld product.
Wh a t is co ve re d u n d e r t h is w a rra n t y: 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.
Wh a t is n o t co ve re d u n d e r t h is w a rra n t y:
5.
A.
B.
C.
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.
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.
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.
E.
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.
Pre-delivery service, i.e. assembly and adjustment.
7.
8.
Re sp o n sib ilit ie s o f Wa rra n t o r u n d e r t h is w a rra n t y: Repair or replace, at Warrantor’s option, products or components which have failed within duration
of the warranty period.
Re sp o n sib ilit ie s o f p u rch a se r u n d e r t h is w a rra n t y:
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.
Wh e n Wa rra n t o r w ill p e rfo rm re p a ir o r re p la ce m e n t u n d e r t h is w a rra n t y: 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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Wire Fe e d Arc We ld e r
WG3013 Wirin g Dia g ra m
+
-
ON/OFF
S1
T1
S3
S2
T2
S5
1
2
1
~
2
M
~
FAN
MIN
4
-
+
5
6
MAX
S5 NC
OPENS @ 127˚C
Y
GROUND
DRIVE
DECK
~
+
-
S4
GUN
M
L2
L1
4
3
2
1
WIRE SPEED
CONTROL BOARD
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WG3013
Fo r Re p la ce m e n t Pa rt s, ca ll 1-800-746-5641
Please provide following information:
24
28
44
-
-
-
Model number
Serial number
Part description and number as
shown in parts list
27
45
23
33
3
25
29
26
43
Address parts correspondence to:
The Campbell Group
Attn: Parts Department
100 Production Drive
Harrison, Ohio 45030 U.S.A.
2
6
5
27
4
** Contact Tip (See chart on Page 15)
16
17
22
1
18
19
20
21
39
40
34
12
40
46
14
37
13
41
8
7
11
31
35
9 & 10
30
36
38
3
42
15
32
40
1
MODEL WG3013
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Wire Fe e d Arc We ld e r
Re p la ce m e n t Pa rt s List - Mo d e ls WG3013
Re f
No .
Pa rt Nu m b e r fo r Mo d e l:
WG3013
De scrip t io n
Qt y
1
2
3
4
5
Torch assembly and hose (Includes Nos. 2-6, 34, and 50-52)
Torch body, front and back
WC600700AV
WC600201AV
WC600003AV
WT502100AJ
WC600202AV
1
1
1
1
1
Hanger clip
Nozzle, Tweco Style
®
Trigger knob
6
7
8
9
10
Torch contact spring
WC600203AV
WC100100AV
●
WC400201AV
WC402100AV
1
1
1
1
1
Work clamp (Cord not included)
Welding cable 8 AWG (6 ft)
Wire speed knob
Wire speed control board
11
12
13
14
15
Heat selector switch
On/off switch
Safety decal
WC400300AV
WC400000AV
DK670100AV
WC300600AV
●
2
1
1
1
1
Handle
Power cord 14-3 AWG (6 ft) Type SJT
16
17
18
19
20
Spool spindle
#10-32 x .5” Pan head sheet metal screw
Wire
Spool adapter
Spool spring
WC500300AV
●
See Chart Below
WC500200AV
WC500101AV
1
2
1
1
1
21
22
23
24
25
Spool locking hub
Drive deck assembly (Includes Nos. 23-29)
Tension spring
Tension screw
Roller .6-.9mm (.024-.035 in.)
WC500100AV
WC500000AV
WC500003AV
WC500002AV
WC500001AV
1
1
1
1
1
26
27
28
29
30
Roller cover
#8-36 x 1.5” Pan head screw
Swing arm
Swing arm roller
Strain relief
WC500004AV
●
WC500005AV
WC500007AV
WC102000AV
1
3
1
1
1
31
32
33
34
35
Wheel
Front foot
Liner, coated metal
Gas cylinder bracket
Axle
WC701200AV
WC702100AV
WC600208AV
WC702200AV
WC703100AV
2
1
1
1
1
36
37
38
39
40
Wheel hub
Dinse connector
Dinse socket
Torch ring
#10-24 x 1/2” Screw
WC703500AV
WC000200AV
WC000300AV
WC600009AV
●
1
2
2
1
9
41
42
43
44
45
46
Axle support
WC703600AV
●
WC600701AV
WC600305AV
WC600204AV
WC802000AV
2
2
1
1
1
1
5mm I.D. e-ring
Swan neck with Diffuser
Trumpet liner
Valve body
Gas bottle strap
● Standard hardware item, available at local hardware or welder supply store
OPTIONAL WIRE
**OPTIONAL CONTACT TIPS (4/package)
Part Number
(1 pound)
Part Number
(10 pound)
Size
Type
Description
mm
in.
Part Number
Flux
Flux
MIG
MIG
MIG
E71T-GS .030”
E71T-GS .035”
ER70S6 .024”
ER70S6 .030”
ER70S6 .035”
WE200001AV
WE200501AV
WE300001AV
WE300501AV
WE301001AV
WE303001AV
WE201000AV
WE201500AV
WE301500AV
WE302000AV
WE302500AV
N/A
0.6
0.8
0.9
0.024
0.030
0.035
WT501200AJ
WT501300AJ
WT501400AJ
Aluminum MIG ER5356 .030”
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WG3013
Glo ssa ry o f We ld in g Te rm s
AC o r Alt e rn a t in g Cu rre n t - electric
current that reverses direction
periodically. Sixty cycle current travels
in both directions sixty times per
second.
Flu x Co re d Arc We ld in g (FCAW) -
Sla g - 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.
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.
Arc Le n g t h - the distance from the
end of the electrode to the point
where the arc makes contact with the
work surface.
Sp a t t e r - 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.
Ga s Me t a l Arc We ld in g (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.
Ba se Me t a l - the material to be
welded.
Ta ck We ld - weld made to hold parts
in proper alignment until final welds
are made.
Ga s Tu n g st e n Arc We ld in g (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
Bu t t Jo in t - a joint between two
members aligned approximately in the
same plane.
Tra ve l An g le - the angle of the
electrode in the line of welding. It
varies from 5º to 45º depending on
welding conditions.
Cra t e r - a pool, or pocket, that is
formed as the arc comes in contact with tungsten electrode and the work piece.
the base metal. Filler metal may or may not be used.
T Jo in t - made by placing the edge of
one piece of metal on the surface of
the other piece at approximately a 90º
angle.
DC o r Dire ct Cu rre n t - electric current La p Jo in t - a joint between two
which flows only in one direction. The
polarity (+ or -) determines which
direction the current is flowing.
overlapping members in parallel
planes.
Op e n Circu it Vo lt a g e (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.
Un d e rcu t - 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.
DC Re ve rse Po la rit y - 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.
Ove rla p - 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.
We ld Po o l o r Pu d d le - a volume of
molten metal in a weld prior to its
solidification as weld metal.
DC St ra ig h t Po la rit y - 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.
We ld Be a d - 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.
Po ro sit y - gas pockets, or cavities,
formed during weld solidification. They
weaken the weld.
Pe n e t ra t io n - 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.
Ele ct ro d e - a coated metal wire having
approximately the same composition as
the material being welded.
Wo rk An g le - the angle of the
electrode from horizontal, measured at
right angles to the line of welding.
Fille t We ld - approximately a triangle
in cross-section, joining two surfaces at
right angles to each other in a lap, T or
corner joint.
Flu x - a coating, when heated, that
produces a shielding gas around the
welding area. This gas protects the
Sh ie ld e d Me t a l Arc We ld in g
(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.
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Wire Fe e d Arc We ld e r
Notes
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