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Manafacture: Campbell Hausfeld File size: 3.32 mb File name: Language of manual:

Voltage drop in the extension cord may significantly degrade performance of the welder. Welding accessories for the welder are inside wire feed compartment. 1. Place handle assembly on welder, aligning two holes in plastic ends with threaded holes in welder housing (Fig. 2). 2. Insert screws through cord wraps and handle ends and fasten into cabinet. 3. Attach cylinder base to unit as shown (Fig. 3). 1. Loosen hex bolt/nut on work clamp. 2. Insert cord (labeled ‘work clamp’ on the front panel of the welder) through clamp handle. Slide bare wire under clamp block. Tighten hex bolt/nut, making sure bare wire is clamped securely (Figure 4). counterclockwise. Then remove knob, spring and spool spacer. 3. Loosen wire feed tensioning screw on drive mechanism. This allows initial feeding of wire into gun liner by hand. 4. Install wire spool onto spindle so wire can come off spool on the end closest to the wire feed guide tube. Do not cut the wire loose yet. Install spool spacer, spring and quick lock knob by pushing in and turning knob 1/4 rotation clockwise. 5. Hold wire and cut the wire end from spool. Do not allow wire to unravel. Be sure end of wire is straight and free of burrs. 6. Feed wire through wire feed guide tube, over the groove in drive roll and into gun liner. Snugly tighten wire feed tensioning screw. Do not over tighten. Three to four full turns is usually correct. 7. Remove nozzle by turning counterclockwise, then unscrew contact tip from end of welding torch (See Figure 6). Plug welder into a proper power supply receptacle. 8. Turn on welder and set wire speed rate to 10. Activate gun trigger until wire feeds out past the torch end. Turn welder off. 9. Carefully slip contact tip over wire and screw tip into torch end. Install nozzle by turning clockwise (See Figure 6). Cut wire off approximately 1/4 inch from nozzle end. Figure 4a - Work Clamp Assembly (WG2040, WG2044, and WG2045) Figure 3 - Base Assembly Figure 2 - Handle Assembly Assembly Installation HANDLE AND BASE ASSEMBLY WORK CLAMP WIRE INSTALLATION Figure 5 - Weld Wire Routing Clamping Block Figure 4b - Work Clamp Assembly (WG3000) Clamping Block Model WG2040, WG2044, WG2045, WG3000 Assembly (Continued) Torch Diffuser Contact Tip Nozzle Figure 6 - Torch Nozzle Contact Tip Markings Mark Wire Size 0.6 mm .024" 0.8 mm .030” 0.9 mm .035” 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 20% duty cycle, actual welding can occur for two minutes, then the welder must cool for eight minutes. Internal components of this welder are protected from overheating with an automatic thermal switch. A yellow lamp is illuminated on the front panel (on/off switch) if the duty cycle is exceeded. Welding operations may continue when the yellow lamp is no longer illuminated. POLARITY To change between flux wire and MIG wire the polarity must be changed. 1. Open the wire feed door. 2. Locate red (+) and black (-) polarity connectors just above wire feed mechanism (See Figure 7). 3. For MIG welding with gas, connect torch cable from wire feed mechanism to red (+) polarity connector, then connect work cable to black (-) connector. 4. For flux-core welding, connect torch cable from wire feed mechanism to black (-) polarity connector, then connect work cable to red (+) connector. Figure 7 - Cable connection Shielding Gas Preparation ! DANGER Improper handling and maintenance of compressed gas cylinders and regulators can result in serious injury or death! Always secure gas cylinders to tank bracket kit, a wall or other fixed support to prevent cylinder from falling over. Read, understand and follow all compressed gas and equipment warnings in the safety instructions. NOTE: Shielding gas is not required if flux-cored welding wire is used. There are 3 types of gas generally used for gas metal arc welding; 100% argon, a mixture of 75% argon and 25% carbon dioxide (C25) or 100% carbon dioxide. Use ONLY the type of gas recommended for your welder. Use ONLY an inert, non-flammable type of gas. Failure to do so will result in a very hazardous situation. NOTE: 100% carbon dioxide is not recommended due to unsatisfactory weld beads. ! DANGER GAS TYPES 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. Obtaining Correct Gas Type. The gas used in any welding application for your welder must be an INERT, NONFLAMMABLE TYPE. You can get the type of gas needed from a nearby welding gas distributor (often found in the yellow pages under “Welders” or ‘Welding Equipment”). REGULATOR An adjustable regulator without gauges is supplied with this welder. The regulator provides a constant shielding gas pressure and flow rate during the we...

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