Campbell Hausfeld Welder WG4000 Manuel utilisateur

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Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the product described.
Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or
property damage! Retain instructions for future reference.
IN970800AV 3/03
Operating Instructions & Parts Manual Model WG4000
Wire Feed
Arc Welder
BUILT TO LAST
This Campbell Hausfeld wire feed welder
is designed to be used on standard 230
volt single phase current. The welder is
equipped with an infinite wire speed
control to accurately select the proper
wire feed rate needed for various
welding conditions. Internal components
are thermostatically protected.
This welder is designed for use with flux
core arc welding (gasless) or gas metal
arc welding (MIG) process. As delivered
from the factory, this welder can weld
with .030" (.8 mm) to .045” (1.2 mm)
diameter wire. A starter spool of .035”
(.9 mm) flux core wire and a .035” tip
are included.
Unpacking
Some welder components may be
found in the wire feed compartment.
When unpacking, inspect carefully for
any damage that may have occurred
during transit. Report any damaged or
missing items by calling (800) 746-5641.
Circuit Requirements
This equipment
requires a dedi-
cated 230 volt, minimum 20 amp circuit.
Do not run other appliances, lights, or
tools on this circuit while operating
this equipment. Extension cords are
not recommended. Blown fuses and
tripped circuit breakers can result from
failure to comply with this
recommendation.
Components and Controls
1. Work Clamp – Connects to work
piece.
2. Wire Feed Gun with .035” tip
3. Power Cord – Plugs into 230 volt
outlet.
!
CAUTION
4. On/Off/Heat Selector Switch
Turns welder on and off and selects
welding power. Six (6) selections
are possible.
5. Infinite Wire Speed Control
Controls wire speed (clockwise turn
increases speed; counterclockwise
turn decreases speed).
6. Polarity Hook-up (Inside Wire
Feed Compartment) – Provides
connections for MIG, direct current
electrode positive (DCEP); and flux
core, direct current electrode
negative (DCEN).
Danger means a
hazard that will
cause death or serious injury if the
warning is ignored.
!
DANGER
Warning means a
hazard that could
cause death or serious injury if the
warning is ignored.
Caution means a
hazard that may
cause minor or moderate injury if the
warning is ignored. It also may mean a
hazard that will only cause damage to
property.
NOTE: Note means any additional
information pertaining to the product
or its proper usage.
Always
keep a
fire extinguisher accessible
while performing arc welding
operations.
!
WARNING
!
CAUTION
!
WARNING
Q
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Need
Assistance?
Call Us First!
1-800-746-5641
Description
MODEL WG4000
Figure 1
General Safety
© 2003 Campbell Hausfeld / Scott Fetzer
For parts, manuals, product & service information
visit www.chpower.com
or call (800) 746-5641.
C
H
CH
FLU
X
FLUX
CORE
CORE
M
IG
MIG
Wire Feed Gun (2)
Work
Clamp (1)
Power Cord (3)
Infinite Wire
Speed Control (5)
Polarity Hook-up (6)
On/Off/Heat Selector
Switch (4)
REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.
2
Wire Feed Arc Welder
Before starting or servicing any
electric arc welder, read and
understand all instructions. Failure
to follow safety precautions or
instructions can cause equipment
damage and/or serious personal
injury or death.
All installation, maintenance, repair
and operation of this equipment
should be performed by qualified
persons only, in accordance with
national, state, and local codes.
Improper
use of
electric arc welders can cause
electric shock, injury, and
death! Take all precautions
described in this manual to reduce the
possibility of electric shock.
Verify that all components of arc
welder are clean and in good
condition prior to operating the
welder. Be sure that the insulation
on all cables, wire feed gun, and
power cords is not damaged.
Always repair or replace damaged
components before operating
welder. Always keep welder panels,
shields, etc. in place when operating
the welder.
Always wear dry, protective
clothing, welding gloves, and
insulated footwear.
Always operate welder in a clean,
dry, well ventilated area. Do not
operate it in humid, wet, rainy, or
poorly ventilated areas.
Be sure work piece is properly
supported and grounded before
beginning any electric arc welding
operation.
Coiled welding cable should be
spread out before use to avoid
overheating and damage to
insulation.
Never immerse the
wire or wire feed
gun in water. If the welder becomes
wet for any reason, be absolutely
certain that it is completely clean and
dry before using!
Always shut equipment off and
unplug power prior to moving
welder.
Always attach work lead first.
Verify that work piece is securely
grounded.
Always shut off electric arc welding
equipment when not in use, and cut
off any excess wire from wire feed
gun.
!
DANGER
!
WARNING
Never allow any part of body to
touch wire and ground or grounded
work piece at the same time.
Awkward welding conditions and
positions can be electrically
hazardous. When crouching,
kneeling or at elevations, be sure to
insulate all conductive parts, wear
appropriate protective clothing, and
take precautions to prevent injury
from falls.
Never attempt to use this equip-
ment at current settings or duty
cycles higher than those specified
on the equipment labels.
Never use an electric arc welder to
thaw frozen pipes.
Flying
sparks
and hot metal can cause
injury. As welds cool, slag
can be thrown off. Take all
precautions described in this manual to
reduce the possibility of injury from
flying sparks and hot metal.
Wear ANSI-approved (American
National Standards Institute-
approved) face shield or safety
glasses with side shield protection
when chipping or grinding metal
parts.
Wear ear plugs when welding
overhead to prevent spatter or slag
from falling into ears.
Electric
arc
welding operations produce
intense light and heat and
ultraviolet (UV) rays. The
intense light and UV rays can cause
injury to eyes and skin. Take all
precautions described in this manual to
reduce the possibility of injury to eyes
and skin.
All persons operating this
equipment or in the area while
equipment is in use must wear
protective welding gear including
welding helmet or shield with at
least a rating of shade 10, flame
resistant clothing, leather welding
gloves, and full foot protection.
Never look at arc
welding operations
without eye protection as described
above. Never use a shade filter lens
that is cracked, broken, or rated below
number 10. Warn others in the area not
to look at the arc.
Electric
arc
welding operations cause
sparks and heat metal to
temperatures that can cause
severe burns! Use protective gloves
!
WARNING
!
WARNING
!
WARNING
!
WARNING
and clothing when performing any
metalworking operation. Take all
precautions described in this manual to
reduce the possibility of skin and
clothing burns.
Make sure that all persons in the
welding area are protected from
heat, sparks, and ultraviolet rays.
Use additional face shields and
flame resistant barriers as needed.
Never touch work pieces until
completely cooled.
Heat and
sparks
produced during electric arc
welding and other metal-
working operations can
ignite flammable and explosive
materials! Take all precautions
described in this manual to reduce the
possibility of flames and explosions.
Remove all flammable materials
within 35 feet (10.7 m) of welding
arc. If removal is not possible,
tightly cover flammable materials
with fireproof covers.
Do not operate any electric arc
welder in areas where flammable or
explosive vapors may be present.
Take precautions to be sure that
flying sparks and heat do not cause
flames in hidden areas, in cracks,
behind bulkheads, etc.
Fire
hazard!
Do not weld on containers or
pipes that contain or have
contained flammable
materials or gaseous or liquid
combustibles.
Arc
welding
closed cylinders or containers
such as tanks or drums can
cause explosion if not
properly vented! Verify that any
cylinder or container to be welded has
an adequate ventilation hole, so that
expanding gases can be released.
Do not
breathe
fumes that are produced by
the arc welding operation.
These fumes are dangerous.
If the welding area cannot be
adequately ventilated, be sure to use
an air supplied respirator.
Keep head and face out of welding
fumes.
Do not perform electric arc welding
operations on metals that are
galvanized or cadmium-plated, or
that contain zinc, mercury or
beryllium without adhering to the
following precautions:
!
WARNING
!
WARNING
General Safety
(Continued)
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!
WARNING
!
WARNING
Safe Practices For Occupational And
Educational Eye And Face
Protection
ANSI Standard Z87.1, from American
National Standards Institute, 1430
Broadway, New York, NY 10018
Refer to Material Safety Data Sheets
and manufacturer’s instructions for
metals, wire, coatings and cleaners.
Selecting the proper location can
significantly increase performance,
reliability and life of arc welder.
For best results place welder in an
environment that is clean and dry.
Dust and dirt in the welder retain
moisture and increase wear of
moving parts.
Place welder in an area that
provides at least 12” (30,48 cm) of
ventilation space at both front and
rear of unit. Keep all obstructions
away from this ventilation space.
Store wire in a clean, dry location
with low humidity to preserve wire
coating.
The receptacle used for welder must
be properly grounded and welder
must be the only load on power
supply circuit.
The use of an extension cord is not
recommended for electric arc
welding machines. The voltage drop
in extension cord may significantly
degrade performance of welder.
Model WG4000
Welder components listed below
are in the wire feed compartment.
Open and remove.
Tools needed:
1/4”, 9/32”, 5/16” nut driver
#2 Phillips head driver
Mallet or hammer
After unpacking welder, you will find a
box at front surrounding attached
torch, ground clamp lead, and power
cord.
The box at the rear of the welder contains
parts to be assembled:
Wheels (2), axle (1), plastic hubs (2),
axle bolts (2), nuts (2) and washers
(2)
Front foot
Cylinder bracket and chain
Work clamp
Regulator, hose, and hose clamps
Spool of .035” flux core welding wire
a. Remove coating from base metal.
b. Make sure welding area is well
ventilated.
c. Use an air-supplied respirator.
Extremely toxic fumes are created
when these metals are heated.
The
electro-
magnetic field that is gener-
ated during arc welding may
interfere with the operation
of various electrical and electronic
devices such as cardiac pacemakers.
Persons using such devices should
consult with their physician prior to
performing any electric arc welding
operations.
Route the wire feed gun and work
cables together and secure with
tape when possible.
Never wrap arc welder cables
around body.
Always position wire feed gun and
work leads so that they are on same
side of body.
Exposure to electromagnetic fields
during welding may have other
health effects which are not known.
Always be sure
that the welding
area is secure and free of hazards
(sparks, flames, glowing metal or slag)
prior to leaving. Be sure that equip-
ment is turned off and excess wire is
cut off. Be sure that cables are loosely
coiled and out of the way. Be sure that
all metal and slag has cooled.
Cylin-
ders can
explode if damaged. Shield-
ing gas cylinders contain gas
under high pressure. If
damaged, a cylinder can explode. Since
gas cylinders are normally part of the
welding process, be sure to treat them
carefully.
Protect compressed gas cylinders
from excessive heat, mechanical
shocks, and electric arcs.
Install and secure cylinders in an
upright position by chaining them
to stationary support or equipment
cylinder rack to prevent them from
falling or tipping.
Keep cylinders away from any
welding or other electrical circuits.
!
DANGER
!
WARNING
3
WG4000
Never allow a welding electrode to
touch any cylinder.
Use only correct shielding gas
cylinders, regulators, hoses, and
fittings designed for the specific
application; keep them and
associated parts in good condition.
Turn face away from valve outlet
when opening cylinder valve.
Keep protective cap in place over
valve except when cylinder is in use
or connected for use.
Read and follow instructions on
compressed gas cylinders, associated
equipment, and CGA (Compressed
Gas Association) publication P-1
listed in Safety Standards.
Never use
flammable gases
with MIG welders. Only inert or non-
flammable gasses such as carbon
dioxide, argon, helium, or mixtures of
one or more of these gasses are
suitable for MIG welding.
Never lift cylinders
off the ground by
their valves, caps, or with chains or slings.
ADDITIONAL SAFETY STANDARDS
ANSI Standard Z49.1 from American
Welding Society, 550 N.W. LeJune Rd.
Miami, FL 33126
Safety and Health Standards
OSHA 29 CFR 1910, from
Superintendent of Documents, U.S.
Government Printing Office,
Washington, D.C. 20402
National Electrical Code
NFPA Standard 70, from National Fire
Protection Association, Batterymarch
Park, Quincy, MA 02269
Safe Handling of Compressed Gases
in Cylinders
CGA Pamphlet P-1, from Compressed Gas
Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
Code for Safety in Welding and
Cutting
CSA Standard W117.2, from Canadian
Standards Association, Standards Sales,
178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3
Cutting And Welding Processes
NFPA Standard 51B, from National Fire
Protection Association, Batterymarch
Park, Quicy, MA 02269
!
WARNING
!
DANGER
General Safety
(Continued)
Installation
Assembly
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!
WARNING
WHEEL AND AXLE ASSEMBLY
1. Put one wheel on each end of axle
Using a mallet or hammer, drive a
plastic hub on axle ends to secure
wheels.
2. Align holes in axle assembly with
holes in base plate at rear of welder.
Secure with two bolts, washers, and
nuts.
FOOT ASSEMBLY
1. Remove four screws in bottom panel
near the front of the welder.
2. Align holes in metal foot with holes
on bottom of welder at front.
3. Secure foot with four screws
removed in step 1.
CYLINDER BRACKET ASSEMBLY
1. At back of welder, halfway down
each side, are two screws. Remove
both pairs of screws. Also remove the
screw in center of back panel.
2. Insert cylinder bracket between sides
of the welder and its black back,
aligning its holes with those in sides
of welder. Make sure bracket has
chain slots up.
3. Attach the bracket with the five
screws removed in Step 1.
WORK CLAMP ASSEMBLY
1. Loosen hex nuts on work clamp.
2. Insert cord through clamp handle and
slide bare wire under clamping block.
Tighten hex nuts, making sure bare
wire is clamped securely (Figure 3).
WIRE INSTALLATION
When the welder is
on and the gun
switch is activated, electric power may
be present in the output terminals,
feed roll, work clamp, gun cable
connection and welding wire. Do not
touch these parts when the welder is
on.
4
Wire Feed Arc Welder
NOTE: Before installing welding wire,
be sure that its diameter matches the
diameter of the groove in the drive
roller on the wire feed mechanism and
that the wire matches the contact tip in
the end of the gun. Any mismatch
could cause the wire to slip or bind.
1. Verify that welder is off. Open panel
on welder to expose wire feed
mechanism.
2. Remove spool lock by pushing in and
rotating it a 1/4 turn counterclockwise.
The knob, spring, and spool spacer can
now be removed. (See Figure 4).
NOTE: Spool spacer and spindle spacer
act as an 8” spool adapter. Purchase of
an adapter is not necessary.
3. Loosen wire feed tensioning screw
on drive mechanism. This allows
initial feeding of wire into gun liner
by hand.
4. Place wire spool on spindle so that
wire will come off spool on the end
closest to wire feed guide tube. Do
not cut wire loose yet. Install spool
spacer, spring, and spool lock by
pushing in and turning knob 1/4
rotation clockwise.
5. Hold wire and cut wire end from
spool. Do not allow wire to
unravel. Be sure that end of wire is
straight and free of burrs.
6. Feed wire through wire feed guide
tube, over groove in drive roll and into
gun liner. Tighten wire feed tensioning
screw so that it is snug. Do not
overtighten.
7. Remove torch nozzle by turning
counterclockwise. Unscrew contact
tip from end of welding torch (See
Figure 5). Plug welder into proper
power supply receptacle.
HINT: Keep torch cable straight when
feeding wire.
8. Turn on welder and set wire speed
rate to 5. Activate the gun switch
until wire feeds out past torch end.
Turn welder off.
Assembly
(Continued)
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Clamping
Block
Figure 3 - Work Clamp Assembly
Torch Neck
Contact Tip
Nozzle
Figure 5 - Torch Nozzle
Figure 2 - WG4000 Assembly
Figure 4 - Weld Wire Routing
Bolt
Washer
Nut
Axle
Plastic
hub
Wheel
Hex Nuts
Cord
Foot
assembly
Bolt
Cylinder
chain
Cylinder
bracket
!
WARNING
5
WG4000
9. Carefully slip contact tip over wire
and screw it into torch neck. Install
nozzle by turning clockwise (See
Figure 5). Cut wire off approximately
1/4” from end of nozzle.
POLARITY
Polarity must be set to match the type
of welding process you wish to use.
MIG wire welding with bottled
shielding gas uses DCEP (DC electrode
positive). Flux-core wire welding with
no gas bottle requires DCEN (DC
electrode negative).
The WG4000 features easy-change
polarity posts located inside the top
section, next to the wire drive deck.
The positive (+) post is farthest from
the drive deck and has a red knob and
base. The negative post is closest to the
drive deck and has a black knob and
base.
Both leads have spade ends with holes
to go over the polarity posts. Turn the
polarity knob counterclockwise to
remove. Slip the end of the
appropriate lead over the post. Then
replace the polarity knob on the post
and tighten securely, turning clockwise.
These connections must be tight to
prevent overheating.
DUTY CYCLE / THERMOSTATIC
PROTECTION
Welder duty cycle is the percentage of
actual weld time that can occur in a ten
minute interval. For example, at a 10%
duty cycle, actual welding can occur for
one minute. Then the welder must cool
for nine minutes.
Internal components of this welder are
protected from overheating with an
automatic thermal switch. A yellow
lamp is illuminated on the front
panel if the duty cycle is exceeded.
Welding operations may continue
when the yellow lamp is no longer
illuminated.
MODEL WT1000
1. Remove lens retainer from face shield
with a regular screwdriver by prying
against shield and post of lens
retainer.
2. Remove protective film covering from
both sides of each lens cover. Put one
clear lens cover on each side of the
shaded lens. Place these three lenses
together in face shield and secure
with lens retainer. The lens retainer
should snap into second notch in face
shield.
3. Position one of the holes in
adjustment arm over the pins which
are located in the ear area of face
shield. These adjustment arms control
the closeness of fit and can be easily
repositioned if necessary.
4. Position headgear inside face shield.
Assemble helmet by inserting stud
screw through headgear and shield
into tension nut as shown. Do not
tighten tension nut completely.
5. Trial fit the welding helmet. Adjust
headgear ratchet band to a
comfortable position and lower face
shield. If shield is too far or too close
to face, use a different hole in
adjustment arm. Adjust tension nuts
so that helmet can be easily lowered
over the face by nodding the head.
1. Cut two plastic bolts and one nut
from handle. Trim excess plastic to
remove sharp edges.
2. Insert handle into slot and rotate 90
degrees to align handle stud with
hole in shield. Secure stud with
plastic nut.
3. Fold the top into position and then
one of the sides. Snap the two pins
into the holes. Press until you hear an
audible click, assuring complete
assembly. Repeat for the other side.
4. Install the shaded lens and secure
with the two plastic bolts. Tighten
securely, but do not overtighten as
this may damage the lens.
NOTE: If you have never welded before
or have little experience, a full-face
helmet is recommended. Both hands
are needed to stabilize and control the
angle and arc length of the torch.
Improper handling
and maintenance of
compressed gas cylinders and
regulators can result in serious injury
or death! Always secure gas cylinders
to the tank bracket kit, a wall or other
fixed support to prevent the cylinder
from falling over. Read, understand,
and follow all the warnings relating to
compressed gases and equipment
hazards in the safety instructions.
!
DANGER
Assembly
(Continued)
Figure 7
Headgear
Face Shield
Shaded Lens
Clear Lens Cover (2)
Post
Lens Retainer
Adjustment
Arm (2)
Tension Nut (2)
Stud Screw (2)
Welding Helmet
Assembly
(PROMOTIONAL MODELS ONLY)
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Contact Tip Markings
Wire Size mm
.024” or .6
.030” or .8
.035” or .9
.040” or 1.0
Torch Work
Mig +
Flux
+
Figure 6
Shielding Gas
Installation
Work Cable
Torch
Cable
Handshield
Assembly
Figure 8
6
Wire Feed Arc Welder
NOTE: Shielding gas is not required if
flux-cored welding wire is used.
GAS TYPES
There are 3 types of gas generally used
for gas metal arc welding; 100% argon,
a mixture of 75% argon and 25%
carbon dioxide (C25) or 100% carbon
dioxide. The 75/25 mixture is
recommended for general steel
welding. For aluminum welding, use
100% argon. Cylinders of each type gas
may be obtained at your local welding
supply outlet. Secure cylinder in place
on your welding machine or other
support to prevent the cylinder from
falling over.
NOTE: Use of incorrect gas may lead to
little or no penetration of welding
bead.
REGULATOR
The regulator provides a constant
shielding gas pressure and flow rate
during the welding process. Each
regulator is designed to be used with a
specific gas or mixture of gases. The
argon and argon mixture use the same
thread type. The 100% carbon dioxide
uses a different thread type. An adapter
is included with this unit to change
between the two.
HOOKUP PROCEDURE
Cylinder gas is
under high
pressure. Point cylinder outlet away
from yourself and any bystanders
before opening.
1. A 20 cubic ft bottle fits this unit.
2. With cylinder securely installed,
remove cylinder cap, stand to side of
the cylinder opposite outlet, and
open the valve slightly, turning
counterclockwise. When gas is
emitted from the cylinder, close valve
by turning clockwise. This will blow
out dust or dirt that may have
accumulated around valve seat.
3. Install regulator on cylinder valve,
keeping face of gauges in vertical
position. Tighten stem nut securely
to gas valve.
4. Install one end of gas hose on
fitting on rear of welder and the
other end to the fitting on the
regulator. Use hose clamps on each
connection. Make sure gas hose is
not kinked or twisted.
5. Once again, stand opposite cylinder
!
WARNING
outlet and slowly open cylinder
valve. Inspect for leaks in
connections.
6. Pull trigger on gun to allow gas to
flow. While trigger is pulled and gas
is flowing, adjust gas regulator to at
least 20 cfh (cubic feet per hour).
Release trigger.
7. Remember to close gas valve when
finished welding.
1. Prior to using this
equipment, read,
understand, and comply
with all precautions in the
General Safety section.
Also, read the entire section titled
Welding Guidelines.
2. Verify welder is off.
3. Verify that surfaces of metals to be
joined are free from dirt, rust, paint,
oil, scale or other contaminants.
These contaminants make welding
difficult and cause poor welds.
All persons
operating this
equipment or in the area
while equipment is in use
must wear protective welding gear
including eye protection with proper
shade, flame resistant clothing, leather
welding gloves and full foot
protection.
!
DANGER
Extremely toxic fumes are
created when zinc- or
cadmium-plated materials,
lead or galvanized items are heated,
welded or cut. Before working with any
of these materials, refer to the General
Safety section for instructions.
4. Connect work clamp to work piece
or workbench (if metal). Make sure
the contact is secure. Avoid surfaces
with paint, varnish, corrosion, or
non-metallic materials.
5. Position Heat Selector on front
panel to desired setting.
See application decal inside door of
wire feed compartment for proper
heat settings.
NOTE: These settings are general
guidelines only. Heat setting may vary
according to welding conditions and
materials.
6. Rotate Wire Speed Control to
setting number 5. Then adjust as
needed after test weld is completed.
7. Plug input cord into a proper
voltage receptacle with proper
circuit capacity (20 amps minimum).
8. Switch welder ON.
9. Verify that the wire is extended
1/4 from the contact tip. If not,
squeeze trigger to feed additional
wire, then release trigger, and then
cut wire to proper length.
!
WARNING
Operation
MANUAL
Shielding Gas
Installation (Continued)
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Figure 9 - Hookup
ARGON OR
ARGON MIX
INSTALLATION
CO
2
INSTALLATION
OR
CO
2
Adapter
Cap
7
WG4000
10. Position wire feed gun near work
piece, and then lower the welding
helmet by nodding the head or
positioning hand shield. Then
squeeze gun trigger. Adjust heat
setting and wire speed as needed.
11. When finished welding, turn welder
off and store properly.
Disconnect power
supply and turn
welder off before inspecting or
servicing any components. Keep the
wire compartment cover closed at all
times unless the wire needs
replacement.
Before every use:
1. Check condition of weld cables and
immediately repair or replace any
cables with damaged insulation.
2. Check condition of power cord and
immediately repair or replace any
cord if damaged.
3. Inspect condition of gun tip and
nozzle. Remove any weld slag.
Replace gun tip or nozzle if
damaged.
Do not operate this
welding machine
with cracked or missing insulation on
welding cables, wire feed gun, or
power cord.
!
WARNING
!
WARNING
Maintenance
Welding Guidelines
General
This line of welding machines can
utilize the Flux Cored Arc Welding
(Gasless) process or the Gas Metal Arc
Welding (MIG) process. The weld must
be protected (shielded) from
contaminates in the air while it is
molten. The gasless process uses a
tubular wire with a flux material inside.
The flux creates a shielding gas when
melted. The MIG process uses inert gas
to shield the weld while molten.
When current is produced by a
transformer (welding machine) and
flows through the circuit to the weld
wire, an arc is formed between the end
of the weld wire and the work piece.
This arc melts the wire and the work
piece. The melted metal of the weld
wire flows into the molten crater and
forms a bond with the work piece as
shown (Figure 10).
Arc Welding Basics
Five basic techniques affect weld
quality. These are: wire selection, heat
setting, weld angle, wire speed, and
travel speed. An understanding of
these techniques is necessary for
effective welds.
HEAT SETTING
The correct heat involves the adjust-
ment of the welding machine to the
required setting. Heat or voltage is
regulated by a switch on the welder.
Operation
(Continued)
Slag
Weld
Wire
Flux
(Gasless
only)
Work Piece
Shielding
Gas
Contact
Tip
Crater
Nozzle
Figure 10 - Weld Components
Every 3 months:
1. Replace any unreadable safety
labels on the welder.
2. Use compressed air to blow all dust
and lint from the ventilation
openings.
3. Clean wire groove on drive roll.
Remove wire from feed mechanism
and remove screws from drive roll
housing. Use a small wire brush to
clean drive roll. Replace if worn or
damaged.
CONSUMER AND WEAR PARTS
The following parts require routine
maintenance:
Wire feed drive roller
Gun liner - replace if worn
Nozzle/contact tips
Wire - this welder will accept either
4 or 8 diameter spools. Welding wire
is susceptible to moisture and oxidizes
over time, so it is important to select a
spool size that will be used within
approximately 6 months. For mild steel
welding, AWS ER70S6 solid wire or
AWS E71T-GS flux-core wire is
recommended.
Contact tips - use Campbell Hausfeld,
Tweco
®
, and other compatible tips.
Nozzle - use Tweco
®
style or compatible
nozzle. Use Campbell Hausfeld nozzle
model WT5021 found at place of
purchase of welder, or use Tweco
®
style
nozzle (or compatible nozzle) found at
local welding supply store.
www.chpower.com
Call (800) 746-5641
for replacement parts.
Changing Wire Sizes
DRIVE ROLLER
There are two grooves in the Drive
Roller. The small groove is for .030"-
.035" (.8 mm-.9 mm) wire and the
other is for .045" (1.2 mm) wire.
Remove the roller cover and flip the
drive roll to choose the correct groove
(see Parts Breakdown).When using
.030"-.035" (.8 mm-.9 mm) aluminum
wire, an optional smooth groove drive
roller and Teflon
®
wire liner are needed.
Contact Campbell Hausfeld for more
information. Aluminum wire is very soft
and should not have the same tension
as Flux Core or MIG wire. When
tensioning aluminum wire down to the
Drive Roller, turn the tension screw
three full turns or until the Drive Roller
begins to grip the wire and feed it
through the torch cable.
CONTACT TIP
Make sure the contact tip size matches
the wire size. If the tip is too small,
there will be too much drag on the
wire. If the tip is too large, arcing will
occur inside the tip. This will burn the
tip or cause carbon deposits inside the
tip that insulate the tip from the wire.
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-
ications listed on the welder. It is
suggested that the welder practice with
scrap metal to adjust settings and
compare welds with Figure 12.
WIRE TYPE AND SIZE
The correct choice of wire type involves
a variety of factors, such as welding
position, work piece material type,
thickness and condition of surface to be
welded. The American Welding Society,
AWS, has set up certain requirements
for each type of wire.
FLUX-CORE WIRE
E - 7
0
T
- GS
Weld strength, times
10,000 psi
Welding positions (0
for flat or horizontal,
1 for any position)
Tubular flux core wire
Flux type
AWS E71T-GS or E71T-11 is
recommended for this welder.
SOLID WIRE
ER - 70
S - 6
Weld strength, times
1,000 psi
Solid wire
Wire composition
ER-70S6 is recommended for this
welder.
WELD ANGLE
Weld angle is the angle at which the
nozzle is held during the welding
process. Using the correct angle
ensures proper penetration and bead
formation. As different welding
positions and weld joints become
necessary, nozzle angle becomes an
increasingly important factor in
obtaining a satisfactory weld. Weld
angle involves two positions - travel
angle and work angle.
Travel angle is the angle in the line of
welding and may vary from 5º to 45º
8
Wire Feed Arc Welder
Welding Guidelines
(Continued)
from the vertical, depending on
welding conditions.
Work angle is the angle from hori-
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.
WIRE SPEED
The wire speed is controlled by the
knob on the front panel. The speed
needs to be tuned to the rate at
which the wire is being melted in the
arc. Tuning is one of the most critical
functions in wire feed welding. Tuning
should be performed on a scrap piece
of metal the same type and thickness as
that to be welded. Begin welding with
one hand dragging the gun nozzle
across the scrap piece while adjusting
the wire speed with the other hand.
Too slow of speed will cause sputtering
and the wire will burn up into the
contact tip. Too fast a speed will also
cause a sputtering sound and the wire
will push into the plate before melting.
A smooth buzzing sound indicates the
wire speed is properly tuned. For
aluminum, wire speed is typically set
higher (7 - 9 speed range).
NOTE: Repeat the tuning procedure
each time there is a change in heat
setting, wire diameter or type, or work
piece material type or thickness.
TRAVEL SPEED
The travel speed is the rate at which
the torch is moved across the weld
area. Factors such as diameter and type
of weld wire, amperage, position, and
work piece material thickness all affect
the speed of travel necessary for
completing a good weld (See Fig. 12).
When the speed is too fast, the bead is
narrow and bead ripples are pointed as
shown. When the speed is too slow, the
weld metal piles up and the bead is
high and wide. For aluminum, travel
speed is typically faster.
SLAG REMOVAL (FLUX-CORE WIRE
ONLY)
Wear ANSI
approved safety
glasses (ANSI Standard Z87.1) and
protective clothing when removing
slag. Hot, flying debris can cause
personal injury to anyone in the area.
After completing the weld, wait for the
welded sections to cool. A protective
coating called slag now covers the weld
bead which prevents contaminants in
the air from reacting with the molten
metal. Once the weld cools to the point
that it is no longer glowing red, the
slag can be removed. Removal is done
with a chipping hammer. Lightly tap
the slag with the hammer and break it
loose from the weld bead. The final
clean-up is done with a wire brush.
NOTE: When making multiple weld
passes, remove the slag before each
pass.
WELDING POSITIONS
Four basic welding positions can be
used; flat, horizontal, vertical, and
overhead. Welding in the flat position
is easier than any of the others because
welding speed can be increased, the
molten metal has less tendency to run,
better penetration can be achieved,
and the work is less fatiguing. Welding
is performed with the wire at a 45º
travel angle and 45º work angle.
Other positions require different
techniques such as a weaving pass,
circular pass, and jogging. A higher skill
level is required to complete these
welds.
Overhead welding is the least desirable
position as it is the most difficult and
dangerous. Heat setting and wire
selection will vary depending upon the
position.
All work should be performed in the
flat position if possible. For specific
applications, consult an arc welding
technical manual.
!
WARNING
TRAVEL ANGLE
WORK ANGLE
5º - 45º
5º - 45º
Figure 11 - Weld Angle
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stainless steel brush to eliminate any
oxides on the weld and grounding
surface. 100% Argon must be used
when welding aluminum. If Argon is not
used, metal penetration is unlikely.
1. Verify that welder is OFF and power
cord disconnected.
2. Remove welder cover to expose the
ON/OFF switch.
9
WG4000
Normal Heat, Wire Speed, Travel
Speed
Heat Too Low
Heat Too High
Wire Speed Too Fast
Wire Speed Too Slow
Travel Speed Too Slow
Travel Speed Too Fast
Base Metal
Figure 12 - Weld Appearance
Figure 14 - Multiple Weld Passes
Welding Guidelines
(Continued)
WELD PASSES
Sometimes more than one pass is
necessary to fill the joint. The root pass
is first, followed by filler passes and
the cover pass. If the pieces are thick, it
may be necessary to bevel the edges
that are joined at a 60º angle.
NOTE: Remember to remove the slag
before each pass for gasless process.
PUSH VS PULL TECHNIQUE
The type and thickness of the work
piece dictates which way to point the
gun nozzle. For thin materials (18 gauge
and up) and all aluminum, the nozzle
should point out in front of the weld
puddle and push the puddle across the
workpiece. For thicker steel, the nozzle
should point into the puddle to increase
weld penetration. This is called
backhand or pull technique
(See Figure 15).
ALUMINUM WELDING
Any aluminum surface to be welded,
must be cleaned thoroughly with a
Figure 13 - Weld Passes
Cover
Filler
Root
3. Disconnect the black and white
power cord wires connected to the
ON/OFF switch.
4. Disconnect the green power cord
wire connected to welder frame.
5. Loosen the cord strain relief screw(s)
and pull cord out of strain relief.
6. Install new cord in reverse order.
PUSH
PULL
Figure 15
Supply Cable
Replacement
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10
Troubleshooting Chart - Welder
Symptom Possible Cause(s) Corrective Action
1. Duty cycle exceeded
2. Poor work clamp connection
3. Defective power switch
4. Blown breaker or fuse
1. Wrong size gun tip
2. Gun liner clogged or
damaged
3. Gun tip clogged or damaged
4. Feed roller worn
5. Not enough tension
Slag inside gun nozzle
1. Poor contact
2. Using an extension cord with
excessive length
1. Wire jammed
2. Out of wire
3. Not enough tension
4. Wire liner worn
5. Wire disconnected internally
6. Contact tip clogged
1. Wire speed too slow
2. Travel speed too slow or heat
is too high
For Information About This Product, Call 1-800-746-5641
Bead is intermittently too
thin
Bead is intermittently too
thick
Ragged depressions at
edge of weld
Weld bead does not
penetrate base metal
Wire sputters and sticks
1. Fast and/or inconsistent travel speed
2. Output heat setting too low
1. Slow and/or inconsistent travel speed
2. Output heat setting too high
1. Travel speed too fast
2. Wire speed too fast
3. Output heat setting too high
1. Inconsistent travel speed
2. Output heat setting too low
3. No or low shielding gas
4. Wrong shielding gas (aluminum)
5. Extension cord is too long
6. (Aluminum) Possible oxide build-up on
surface
1. Damp wire
2. Wire speed too fast
3. Wrong type of wire
4. No or low shielding gas
1. Allow welder to cool until ON/OFF Switch lamp goes out
2. Be sure all connections are secure, and attaching surface is
clean
3. Replace switch
4. Reduce circuit load, reset breaker or replace fuse
1. Use proper size gun tip
2. Clean or replace gun liner
3. Clean or replace gun tip
4. Replace
5. Tighten tensioning screw
Clean slag from gun nozzle
1. Be sure all connections are secure, and attaching surface is
clean
2. Never use an extension cord longer than 20 ft
1. Reload wire
2. Replace wire spool
3. Tighten tensioning screws if wire is slipping
4. Replace liner
5. Call 1-800-746-5641 for assistance
6. Replace contact tip
1. Run speed in 7 - 10 range
2. Increase the travel speed or reduce heat settings
No output
Wire tangles at drive roller
Gun nozzle arcs to work
surface
Work clamp and/or cable
gets hot
Wire does not feed
(Aluminum) Wire burns back
into tip or (aluminum) metal
bubbles or burns through
Troubleshooting Chart - Welds
Symptom Possible Cause(s) Corrective Action
1. Decrease and maintain constant travel speed
2. Increase output heat setting
1. Increase and maintain travel speed
2. Reduce output heat setting
1. Decrease travel speed
2. Decrease wire speed
3. Reduce output heat setting
1. Decrease and maintain constant travel speed
2. Increase output heat setting
3. Use gas for MIG process or refill bottle
4. Use only 100% Argon gas
5. Never use an extension cord longer than 20 ft
6. Clean surface thoroughly with a stainless steel
brush only
1. Use dry wire and store in dry location
2. Reduce wire speed
3. Use flux core wire when not using gas
4. Use gas for MIG process or refill bottle
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11
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, purchasers abuse, neglect or failure to operate products in accordance with instructions provided in the owners
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 Warrantors 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 owners manual(s).
9. When Warrantor will perform repair or replacement under this warranty: Repair or replacement will be scheduled and serviced according to the
normal work flow at the servicing location, and depending on the availability of replacement parts.
This Limited Warranty gives you specific legal rights and you may also have other rights which vary from state to state.
WG4000
www.chpower.com
12
WG4000 Wiring Diagram
Wire Feed Arc Welder
www.chpower.com
X
X
X
XX
XX
S1
XXX
6
X
XXX
5
X
A2
X
X
7
@ 127
o
C
OPENS
NC
S3
R
C2C1
-
+
J1
K1
J3
J2
COM
NO
+
-
Y
~
~
M
FAN~
A2
7
S3
DECK
L2
5
X
X
X
6
A1L2
34
L2L1
2
X
X
X
X
1
L1
4
3
2
1
OFF
S1
T1
T2
-
+
GUN
S2
DRIVE
M
BLACK
WHITE
GREEN
6
5
4
3
2
1
A1
L2
L1
13
For Replacement Parts, call 1-800-746-5641
Address parts correspondence to:
The Campbell Group
Attn: Parts Department
100 Production Drive
Harrison, Ohio 45030 U.S.A.
Please provide following information:
- Model number
- Serial number
- Part description and number as
shown in parts list
WG4000
MODEL WG4000
26
33
28
24
25
27
22
21
20
19
12
14
13
17
15
18
16
32
31
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** Contact Tip (See chart on Page 14)
29
30
43
36
41 & 42
37
38
34
11
(inside)
1
24
35
3
2
4
6
7 & 9
23
12
5
39 & 40
***
8 & 10
14
1 Warning decal - 1 pc Italy DK670100AV 1
2 Ground clamp - large (Cord not included) WC100100AV 1
3 Welding cable 6 AWG (6 ft) 1
4 Strain relief WC102000AV 2
5 Handle WC301700AV 1
6 Power cord 12AWG/3C (10 ft) Type ST with 230V, 50A Plug 1
7 Wire speed control knob WC400201AV 1
8 Switch knob WC400401AV 1
9 Wire speed control PCB WC401700AV 1
10 Power switch WC401800AV 1
11 Capacitor - 15,000 µF WC401900AV 2
12 Drive deck assembly (Includes nos. 13-18) WC500400AV 1
13 Tension screw WC500002AV 1
14 Tension spring WC500003AV 1
15 Roller cover WC500004AV 1
16 Swing arm WC500005AV 1
17 Drive roller - 0.8-1.2 mm WC500006AV 1
Optional drive roller - 0.6-0.9 mm WC500001AV
18 Swing arm roller WC500007AV 1
19 Spool lock WC500100AV 1
20 Spindle spring WC500101AV 1
21 Spool adapter WC500200AV 1
22 Spindle WC500300AV 1
23 Torch ring WC600009AV 1
24 Torch assembly - Universal WC600900AJ 1
25 Hanger clip WC600003AV 1
26 Torch handle - 2 pc WC600201AV 1
27 Trigger WC600202AV 1
28 Contact spring WC600203AV 1
29 Gas valve WC600204AV 1
30 Trumpet liner - 5.75 WC600305AV 1
31 Swan neck w/ diffuser (Tweco®) WC600701AV 1
32 Wire liner - coated metal WC600209AV 1
33 Nozzle, Tweco® style WT502100AJ 1
34 Wheel WC701300AV 2
35 Front foot WC702300AV 1
36 Cylinder bracket WC702400AV 1
37 Axle WC703200AV 1
38 Wheel cap WC703400AV 2
39 Polarity cap - red WC704000AV 1
40 Polarity cap - black WC704100AV 1
41 Hose barb - external WC802300AV 1
42 Hose barb - internal WC802400AV 1
43 Cylinder chain WC802700AV 1
44 Handshield (lens not included) WC801600AV 1
45 Shaded lens (for handshield) WC801100AV 1
46 Welding helmet (promotional models only) WT100000AV 1 or 0
47 Replacement lens kit - one shaded and two clear WT110501AV
48 Optional aluminum welding kit (includes Teflon® wire liner, smooth-
groove drive roller and 4 .030" (.8 mm) aluminum contact tips WT253000AV
49 Argon regulator with 2 gauges WC803200AV 1
50 Adapter - Argon regulator/CO
2
cylinder WC803300AV 1
Standard hardware item available at hardware store or welding supply store
Not shown
Optional accessory, sold separately
Replacement Parts List - Model WG4000
Ref
No. Description Part Number Qty
***OPTIONAL WIRE
Part Number Part Number
Type Description (2 pounds) (10 pound)
Flux E71T-GS .030 WE200001AV WE201000AV
Flux E71T-GS .035 WE200501AV WE201500AV
MIG ER70S6 .024 WE300001AV WE301500AV
MIG ER70S6 .030 WE300501AV WE302000AV
MIG ER70S6 .035 WE301001AV WE302500AV
Aluminum MIG ER5356 .030 WE303001AV (1 lb.) N/A
Wire Feed Arc Welder
www.chpower.com
**OPTIONAL CONTACT TIPS (4/package)
Size
mm in. Part Number
0.6 0.024 WT501200AJ
0.8 0.030 WT501300AJ
0.9 0.035 WT501400AJ
15
Glossary of Welding Terms
AC or Alternating Current - electric
current that reverses direction
periodically. Sixty cycle current travels
in both directions sixty times per
second.
Arc Length - the distance from the
end of the electrode to the point
where the arc makes contact with the
work surface.
Base Metal - the material to be
welded.
Butt Joint - a joint between two
members aligned approximately in the
same plane.
Crater - a pool, or pocket, that is
formed as the arc comes in contact with
the base metal.
DC or Direct Current - electric current
which flows only in one direction. The
polarity (+ or -) determines which
direction the current is flowing.
DC Reverse Polarity - occurs when
the electrode holder is connected to
the positive pole of the welding
machine. Reverse Polarity directs more
heat into melting the electrode rather
then the work piece. It is used on
thinner material.
DC Straight Polarity - occurs when
the electrode holder is connected to
the negative pole of the welding
machine. With straight polarity more
heat is directed to the work piece for
better penetration on thicker material.
Electrode - a coated metal wire having
approximately the same composition as
the material being welded.
Fillet Weld - approximately a triangle
in cross-section, joining two surfaces at
right angles to each other in a lap, T or
corner joint.
Flux - a coating, when heated, that
produces a shielding gas around the
welding area. This gas protects the
parent and filler metals from impurities
in the air.
Flux Cored Arc Welding (FCAW) -
also called Gasless, is a welding process
used with a wire-feed welding
machine. The weld wire is tubular with
flux material contained inside for
shielding.
Gas Metal Arc Welding (GMAW) -
also called MIG, is a welding process
used with a wire feed welding
machine. The wire is solid and an inert
gas is used for shielding.
Gas Tungsten Arc Welding (GTAW) -
also called TIG, is a welding process
used with welding equipment with a
high frequency generator. The arc is
created between a non-consumable
tungsten electrode and the work piece.
Filler metal may or may not be used.
Lap Joint - a joint between two
overlapping members in parallel
planes.
Open Circuit Voltage (OCV) - the
voltage between the electrode and the
work clamp of the welding machine
when no current is flowing (not
welding). The OCV determines how
quickly the arc is struck.
Overlap - occurs when the amperage is
set too low. In this instance, the molten
metal falls from the electrode without
actually fusing into the base metal.
Porosity - gas pockets, or cavities,
formed during weld solidification. They
weaken the weld.
Penetration - the depth into the work
piece that has been heat effected by
the arc during the welding process. A
good weld achieves 100% penetration
meaning that the entire thickness of
the work piece has been heated and
resolidified. The heat effected area
should be easily seen on the opposite
side of the weld.
Shielded Metal Arc Welding
(SMAW) - also called Stick, is a welding
process with uses a consumable
electrode to support the arc. Shielding
is achieved by the melting of the flux
coating on the electrode.
Slag - a layer of flux soot that protects
the weld from oxides and other
contaminants while the weld is
solidifying (cooling). Slag should be
removed after weld has cooled.
Spatter - metal particles thrown from
the weld which cool and harden on the
work surface. Spatter can be minimized
by using a spatter resistant spray on the
work piece before welding.
Tack Weld - weld made to hold parts
in proper alignment until final welds
are made.
Travel Angle - the angle of the
electrode in the line of welding. It
varies from 5º to 45º depending on
welding conditions.
T Joint - made by placing the edge of
one piece of metal on the surface of
the other piece at approximately a 90º
angle.
Undercut - a condition that results
when welding amperage is too high.
The excessive amperage leaves a
groove in the base metal along both
sides of the bead which reduces the
strength of the weld.
Weld Pool or Puddle - a volume of
molten metal in a weld prior to its
solidification as weld metal.
Weld Bead - a narrow layer or layers of
metal deposited on the base metal as
the electrode melts. Weld bead width is
typically twice the diameter of the
electrode.
Work Angle - the angle of the
electrode from horizontal, measured at
right angles to the line of welding.
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WG4000
Notes
Wire Feed Arc Welder
16
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l’électrode négative à courant
continu (DCEN).
Danger
indique :
Ne pas suivre cet avertissement causera
la perte de vie ou blessures graves.
Aver-
tissement
indique : Ne pas suivre cet avertis-
sement peut causer la perte de vie ou
blessures graves.
Attention
indique :
Ne pas suivre cet avertissement peut
causer des blessures (légères ou
moyennes) ou dommage matériel.
REMARQUE: Remarque indique :
Information additionnelle concernant
le produit ou son utilisation.
!
ATTENTION
!
AVERTISSEMENT
!
DANGER
2. Pistolet dalimentation en fil
avec buse de 0,035.
3. Cordon dalimentation -
brancher dans une prise de courant
230 V.
4. Interrupteur de sélection
Marche/Arrêt/Chaleur - Pour
choisir la puissance du soudeur. Six
sélections sont possibles.
5. Commande de réglage de
vitesse de fil infini - tourner dans
le sens des aiguilles dune montre
pour augmenter la vitesse de fil et
tourner dans le sens inverse des
aiguilles dune montre pour réduire
la vitesse du fil.
6. Branchement de polarité (à
lintérieur du boîtier
dalimentation du fil) - Fournit
les connexions du MIG, de
l’électrode positive à courant
continu (DCEP); et du fil fourré, de
Ce soudeur à larc alimenté en fil
Campbell Hausfeld est conçu pour un
courant monophasé standard de 230
volts. Ces soudeurs sont équipés dun
réglage de vitesse de fil infini pour la
sélection précise de taux dalimentation
en fil convenable à une variété de
conditions de soudage. Les pièces
internes sont protégées dun
thermostat.
Ces soudeurs sont conçus pour
lutilisation avec les méthodes de
Soudage À LArc Fourré De Flux (sans
gaz) ou le Soudage Au Chalumeau
(Mig). Ce soudeur, livré de lusine peut
souder avec un fil de 0,8 mm à 1,2 mm
de diamètre. Une bobine de fil fourré
de flux et une buse de 0,035 po (0,9
mm) sont comprises.
Déballage
Quelques pièces détachées du
soudeur peuvent être situées dans
le compartiment dalimentation en
fil. Lors du déballage, lexaminer
soigneusement pour toute trace de
dommage susceptible de s’être produit
en cours de transport. Sil y a des pièces
endommagées ou manquantes,
composer le (800) 746-5641.
Exigences De Circuit
Cet
équipe-
ment exige un circuit réservé de 230
volts, minimum 20 ampères. Ne pas
faire fonctionner les appareils
électroménagers, les lampes ou les
outils sur ce circuit pendant
l’utilisation de cet équipement. Les
rallonges ne sont pas recommandées.
Le non-respect de ces directives peut
causer des fusibles sautés et des
disjoncteurs déclenchés.
Commandes et Pièces
Détachées
1. Pince de Soudeur - fixer à lobjet
de travail.
!
ATTENTION
Instructions DUtilisation & Manuel De Pièces De Rechange Modèle WG4000
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Need
Assistance?
Call Us First!
1-800-746-5641
Description
17 Fr
Généralités Sur La Sécurité
© 2003 Campbell Hausfeld / Scott Fetzer
IN970800AV 3/03
Figure 1
C
H
CH
FLUX
FLUX
CORE
CORE
M
IG
MIG
Pistolet d’alimentation
en fil (2)
Pince de
Soudeur (1)
Cordon
d’alimentation (3)
Commande de
réglage de vitesse
de fil infini (5)
Branchement de polarité (6)
Interrupteur de sélection
Marche/Arrêt/Chaleur (4)
Soudeur À LArc
Alimenté En Fil
Sil vous plaît lire et conserver ces instructions. Lire attentivement avant de monter, installer, utiliser ou de procéder à lentretien du produit
décrit. Se protéger ainsi que les autres en observant toutes les instructions de sécurité, sinon, il y a risque de blessure et/ou dégâts matériels!
Conserver ces instructions comme référence.
MODEL WG4000
MÉMENTO: Gardez votre preuve datée d'achat à fin de la garantie!
Joignez-la à ce manuel ou classez-la dans un dossier pour plus de sécurité.
BUILT TO LAST
18 Fr
Toujours avoir un extincteur
dincendie disponible pendant
le soudage à larc.
Lire et comprendre toutes les
instructions avant de démarrer un
soudeur à larc ou de procéder à son
entretien. Ne pas suivre les
précautions et instructions de sécurité
peut mener à des dommages à
l’équipement et/ou à des blessures
graves, perte de vie.
Linstallation, lentretien, la réparation
et ;utilisation de cet équipement
doivent être effectués par des
personnes qualifiées conformément
aux codes nationaux, provinciaux et
locaux.
Lutilisation incorrecte des
soudeurs à larc électriques
peut causer des chocs
électriques, blessures et perte de vie.
Suivre toutes les précautions indiquées
dans ce manuel afin de réduire le
risque de choc électrique.
Sassurer que toutes les pièces
détachées du soudeur à larc soient
propres et en bon état avant dutiliser
le soudeur. Sassurer que lisolation
sur tous les câbles, pistolets
dalimentation en fil et cordons
dalimentation ne soit pas
endommagée. Toujours réparer ou
remplacer les pièces détachées
endommagées avant dutiliser le
soudeur. Toujours garder les
panneaux, écrans de soudage, etc. en
place pendant lutilisation du
soudeur.
Toujours porter des vêtements
protecteurs et gants de soudage
secs ainsi que des chaussures
isolantes.
Toujours faire fonctionner le
soudeur dans un endroit propre, sec
et bien ventilé. Ne jamais utiliser un
soudeur dans un endroit humide,
trempe, pluvieux ou mal-ventilé.
Sassurer que lobjet sur lequel vous
travaillez soit bien fixé et mis à la
terre correctement avant de com-
mencer le soudage électrique à larc.
Le câble de soudage roulé devrait
être étendu avant lutilisation afin
d’éviter le surchauffage et le
dommage à lisolation.
Ne jamais
immerger
!
DANGER
!
AVERTISSEMENT
!
AVERTISSEMENT
le fil ni le pistolet dans leau. Si le
soudeur devient trempe, il est
nécessaire quil soit complètement sec
et propre avant lutilisation!
Toujours mettre l’équipement hors
circuit et le débrancher avant de le
déplacer.
Toujours brancher le conducteur de
travail en premier lieu.
Vérifier que lobjet de travail soit
mis à la terre correctement.
Toujours mettre l’équipement de
soudage électrique à larc hors
circuit sil nest pas en usage et
couper lexcès de fil du pistolet.
Ne jamais permettre que votre corps
touche le fil fourré et la terre ni
lobjet de travail mis à la terre
simultanément.
Les conditions et positions de
soudage difficiles peuvent poser des
dangers électriques. Si vous êtes
accroupi, à genoux ou surélevé,
sassurer que toutes les pièces
conductrices soient isolées. Porter des
vêtements protecteurs convenables et
prendre des précautions contre les
chutes afin d’éviter des blessures.
Ne jamais esayer dutiliser cet
équipement au délà des réglages de
courant ou des facteurs dutilisation
indiqués sur les étiquettes.
Ne jamais utiliser un soudeur
électrique à larc pour dégeler les
tuyaux congelés.
Les étincelles volantes et le
métal chaud peuvent causer
des blessures. La scorie peut
s’échapper pendant le refroidissement
des soudures. Suivre toutes les
directives et précautions indiquées
dans ce manuel pour réduire la
possibilité de blessures causées par les
étincelles volantes et le métal chaud.
Porter un masque de soudeur
approuvé par ANSI ou des lunettes
protectrices avec écrans protecteurs
de bords pendant le burinage ou
l’ébarbage des pièces en métal.
Utiliser des protège-tympans pour le
soudage aérien afin d’éviter que la
scorie ou la bavure tombe dans les
oreilles.
Le soudage électrique à larc
produit une lumière et une
chaleur intenses et des rayons
ultaviolets (UV). Cette lumière intense
et ces rayons UV peuvent causer des
blessures aux yeux et à la peau.
Prendre toutes les précautions
indiquées dans ce manuel afin de
réduire la possibilité de blessures aux
!
AVERTISSEMENT
!
AVERTISSEMENT
yeux et à la peau.
Toutes les personnes qui utilisent cet
équipement ou qui sont présentes là
où l’équipement est utilisé doivent
porter des vêtements de soudage
protecteurs y compris : masque ou
casque de soudeur ou écran avec une
lentille filtrante de classification dau
moins 10, vêtements incombustibles,
gants de soudeur en cuir et protection
complète pour les pieds.
Ne jamais
observer
le soudage sans la protection pour les
yeux indiquée ci-dessus. Ne jamais
utiliser une lentille filtrante qui est
fendue, cassée, ou classifiée moins que
10. Avertir les autres personnes
présentes de ne pas regarder larc.
Le soudage électrique à larc
produit des étincelles et
chauffe le métal aux
températures qui peuvent causer des
brûlures graves ! Utiliser des gants et
vêtements protecteurs pendant
nimporte quel travail de métal.
Prendre toutes les précautions
indiquées dans ce manuel afin de
réduire la possibilité de brûlures de
peau ou de vêtements.
Sassurer que toutes les personnes
dans lendroit de soudage soient
protégées contre la chaleur, les
étincelles et les rayons ultraviolets.
Utiliser des écrans de visage
additionnels et écrans coupe-feu là
où cest nécessaire.
Ne jamais toucher les objets de
travail avant quils se refroidissent
complètement.
La chaleur et les étincelles
qui sont produites pendant le
soudage électrique à larc et
autres travaux de métal peuvent
allumer les matériaux inflammables et
explosifs ! Prendre toutes les
précautions indiquées dans ce manuel
afin de réduire la possibilité de flammes
et dexplosions.
Enlever tous les matériaux
inflammables à moins de
10,7 mètres (35 pieds) de larc de
soudage. Si ceci nest pas possible,
couvrir les matériaux inflammables
avec des couvertures incombustibles.
Ne pas utiliser de soudeur électrique
à larc dans les endroits qui
contiennent des vapeurs
inflammables ou explosives.
Prendre toutes les précautions pour
sassurer que les étincelles volantes
et la chaleur ne produisent pas de
flammes dans des endroits cachés,
fentes, à larrière des cloisons, etc.
!
AVERTISSEMENT
!
AVERTISSEMENT
!
AVERTISSEMENT
Généralités Sur La
Sécurité
(Suite)
Soudeur À LArc Alimenté En Fil
19 Fr
NORMES DE SÉCURITÉ
ADDITIONNELLES
Norme ANSI Z49.1 de l American
Welding Society, 550 N.W. LeJune Rd.
Miami, FL 33126
Safety and Health Standards
(Normes de Sécurité et de Santé)
OSHA 29 CFR 1910, du Superintendent
of Documents, U.S. Government
Printing Office, Washington, D.C. 20402
National Electrical Code (Code
Électrique National)
Norme NFPA 70, du National Fire
Protection Association, Batterymarch
Park, Quincy, MA 02269
Safe Handling of Compressed Gases
in Cylinders (Manipulation Sûr des
Gaz Comprimés en Cylindres)
CGA Pamphlet P-1, du Compressed Gas
Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA
22202
Code for Safety in Welding and
Cutting (Code de Sécurité pour le
Soudage et le Coupage)
Norme CSA W117.2, du Canadian
Standards Association, Standards Sales,
178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3
Cutting And Welding Processes
(Procédés de Coupage et de
Soudage)
Norme NFPA 51B, du National Fire
Protection Association, Batterymarch
Park, Quicy, MA 02269
Safe Practices For Occupational And
Educational Eye And Face
Protection (Règlements
Professionnels et D’Éducation de
Sécurité pour la Protection des
Yeux et du Visage)
Norme ANSI Z87.1, de lAmerican
National Standards Institute, 1430
Broadway, New York, NY 10018
Se référer aux fiches signalitéques de
sécurité du produit et aux instructions
du fabricant de métaux, électrodes,
enduits et produits pour le nettoyage.
Choisir le bon endroit peut augmenter
le rendement, la sécurité de
fonctionnement et la vie du soudeur à
larc.
Pour un meilleur résultat, placer le
soudeur dans un endroit propre et
sec. La poussière et la saleté
absorbent lhumidité dans le
soudeur et augmentent lusure des
pièces mobiles.
Placer le soudeur dans un endroit qui
fournit au moins 12 po (305 mm)
Risque dincendie ! Ne pas
souder les récipients ni les
tuyaux qui contiennent ou
ont contenu des matériaux
inflammables ou combustibles gazeux
ou liquides.
Le soudage à larc des
cylindres ou récipients fer-
més tels que les réservoirs
ou bidons peuvent causer une
explosion sils ne sont pas bien ventilés
! Vérifier quil y ait un trou de
ventilation suffisant dans nimporte
quel cylindre ou récipient pour
permettre la ventilation des gaz en
expansion.
Ne pas respirer les vapeurs
qui sont produites par le
soudage à larc. Ces vapeurs
sont dangereuses. Utiliser un
respirateur si lendroit de soudage nest
pas bien ventilé.
Garder la tête et le visage hors des
vapeurs de soudage.
Ne pas exécuter le soudage
électrique à larc sur les métaux qui
sont galvanisés ou plaqués en
cadmium, ou qui contiennent le
zinc, le mercure, ou le beryllium sans
suivre les précautions suivantes:
a. Enlever lenduit du métal commun.
b. Sassurer que lendroit de soudage
soit bien ventilé.
c. Utiliser un respirateur à air fourni.
Des vapeurs extrêmement toxiques
sont produites pendant le chauffage
de ces métaux.
Le champ électromagnétique
qui est produit pendant le
soudage à larc peut causer de
linterférence avec le fonctionnement
de plusieurs appareils électriques tels
que les pacemakers cardiaques. Toutes
les personnes qui utilisent ces appareils
doivent consulter leur médecin avant
dexécuter le soudage électrique à larc.
Acheminer l’électrode et les câbles
ensemble et les fixer avec du ruban
adhésif là où cest possible.
Ne jamais envelopper les câbles de
soudage à larc autour de votre
corps.
Toujours placer l’électrode et les
conducteurs de terre afin quils
soient sur le même côté du corps.
Lexposition aux champs
électromagnétiques peut avoir
!
AVERTISSEMENT
!
AVERTISSEMENT
!
AVERTISSEMENT
!
AVERTISSEMENT
autres réactions inconnues
concernant la santé.
Toujours
sassurer
que lendroit de soudage soit sans
danger et sans risques (étincelles,
flammes, métal chauffé au rouge ou
scorie) avant de partir. Sassurer que
l’équipement soit hors circuit et que le
surplus de fil soit coupé. Sassurer que
les câbles soient roulés (sans serrer) et
hors du chemin. Sassurer que tout
métal et scorie soient refroidis.
Les bouteilles peuvent
exploser si endommagées.
Elles contiennent du gaz sous
haute pression. Si elles sont
endommagées, elles peuvent exploser.
Puisque les bouteilles de gaz font
partie du processus de soudage,
sassurer de bien les respecter.
Protéger les bouteilles de gaz
comprimé contre la chaleur
excessive, les chocs mécaniques, et
les arcs.
Installer et fixer les bouteilles dans
une position verticale en utilisant
une chaîne sur un support
stationnaire ou un support de
bouteille pour éviter le
renversement ou le basculage.
Garder les bouteilles à l’écart du
soudage ou autres circuits
électriques.
Ne jamais permettre que l’électrode
de soudage touche une bouteille.
Utiliser seulement les bouteilles de
gaz corrects; régulateurs, tuyaux et
raccords conçus pour votre
application et les tenir en bon état
de marche.
Tourner le visage loin de la soupape
d’échappement en ouvrant la
soupape de la bouteille.
Garder le chapeau protecteur en
place sur la soupape sauf si la
bouteille est en service ou branchée
pour le service.
Lire et suivre les instructions pour
les bouteilles de gaz et autre
équipement et la publication P-1 de
CGA indiquée dans les Normes de
Sécurité.
Ne jamais
utiliser
les gaz inflammables avec les soudeurs
MIG. Seuls les gaz inertes ou
ininflammables tels que le gaz
carbonique, largon, lhélium ou un
mélange dun ou plus de ceux-ci
conviennent au soudage MIG.
Ne jamais
soulever
les bouteilles par leurs soupapes,
chapeaux ni avec les chaînes ou élingues.
!
AVERTISSEMENT
!
DANGER
!
DANGER
!
AVERTISSEMENT
Généralités Sur La
Sécurité
(Suite)
WG4000
Installation
3. Installer la fixation avec les cinq vis
retirées à l’étape 1.
MONTAGE DE LA PINCE DE TRAVAIL
1. Desserrer les écrous hex. sur la pince
de travail.
2. Insérer le cordon par la poignée de
pince et glisser le fil nu sous le bloc
de fixation. Resserrer les écrous
hexagonaux en vous assurant que les
fils nus soient bien pincés (Figure 3).
Collier De Mise A La Terre
1. Desserrer le boulon hexagonal ou
l’écrou sur le collier de mise à la
terre.
2. Introduire le cordon à travers le
manche du collier et glisser le fil nu
sous le bloc du collier. Serrer le
boulon hexagonal en sassurant que le
fil nu soit bien fixé (Figure 4).
Installation de Fils
La puis-
sance de
soudage peut être appliquée aux
bornes de sortie, rouleau entraîneur,
collier de mise à la terre, raccord du
câble de pistolet et le fil de soudage
même si linterrupteur du pistolet nest
pas activé. Ne pas toucher à ces pièces
quand le soudeur est en marche.
REMARQUE : Avant dinstaller le fil à
soudage, sassurer que le diamètre du
fil à soudage correspond à lencoche
dans le rouleau dentraînement du
!
AVERTISSEMENT
20 Fr
Figure 4 - LEnfilement du Fil
à Soudage
Collier de
serrage
Figure 3 - Montage du Collier de Mise
à la Terre
Pied avant
Chaîne et fixation de cylindre
Pince de travail
Régulateur, tuyau et brides de serrage
Bobine dévideuse de soudage à fil
fourré de .035 po (0,9 mm)
MONTAGE DE ROUE ET DESSIEU
1. Mettre une roue à chaque extrémité
de lessieu. Utiliser un maillet ou un
marteau, enfoncer un moyeu de
plastique sur les extrémités de
lessieu pour fixer les roues en place.
2. Aligner les trous sur le montage de
lessieu avec les trous dans la plaque
de base à larrière du soudeur. Fixer
avec deux boulons, rondelles et écrous.
MONTAGE DU PIED
1. Retirer quatre vis dans le panneau du
bas près de lavant du soudeur.
2. Aligner les trous du pied de métal
avec les trous au bas du soudeur à
lavant.
3. Fixer le pied avec quatre vis retirées à
l’étape 1.
MONTAGE DE LA FIXATION DU
CYLINDRE
1. A larrière du soudeur, se trouvent
deux vis à moitié chemin de chaque
côté. Retirer les deux paires de vis et
retirer la vis au centre du panneau
arrière.
2. Insérer la fixation du cylindre entre
les côtés du soudeur et son arrière
noir en alignant ses trous avec ceux
des côtés du soudeur. Sassurer que la
fixation ait les fentes de la chaîne
vers le haut.
despace de ventilation devant et
derrière du modèle. Garder lespace
de ventilation libre dobstructions.
Entreposer les fils dans un endroit
propre et sec à basse humidité afin
de conserver le fini du fil.
Le récipient utilisé pour le soudeur
doit être mis à la terre correctement
et le soudeur doit être le seul
appareil de charge sur le circuit
Utiliser une rallonge nest pas
recommandé pour les soudeurs
électriques à larc. La perte de
tension dans la rallonge peut
réduire le rendement du soudeur
.
Modèle WG4000
Les pièces détachées du soudeur
indiquées ci-dessous se trouvent
dans le compartiment dentraîne-
ment de fils. Ouvrir et retirer.
Outils nécessaires
Tourne-écrou 1/4 po (6,4 mm), 9/32 po
(7,1 mm), 5/16 po (7,9 mm)
Tournevis #2 Phillips
Maillet ou marteau
Après avoir déballé le soudeur, vous
trouverez une boîte à lavant entourant
le chalumeau, le fil de la borne agrafe
et le cordon.
La boîte à larrière du soudeur contient
des pièces à assembler.
Roues (2), essieu (1), moyeu de
plastique (2), boulons dessieu (2),
écrous (2) et rondelles (2)
Montage
Figure 2 - WG4000 Assembly
Boulon
Rondelle
Écrou
Arbre de
roue
Moyeu de
plastique
Roue
Montage
de pied
Boulon
Chaîne de
cylindre
Fixation de
cylindre
Écrou hexagonal
Cordon
Soudeur À LArc Alimenté En Fil
Installation (Suite)
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Campbell Hausfeld Welder WG4000 Manuel utilisateur

Catégorie
Système de soudage
Taper
Manuel utilisateur
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