Campbell Hausfeld WG2040 manual Maintenance, Welding Guidelines, Supply Cable Replacement, General

! WARNING

Model WG2040, WG2044, WG2045, WG3000

Operation (Con't.)

6.Rotate Wire Speed Control to setting number 5 to start then adjust as needed after test weld.

7.Plug power cord into a proper voltage receptacle with proper circuit capacity (See circuit requirements on front page).

8.Switch welder ON/OFF switch to ON position.

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

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

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

Maintenance

Disconnect power supply and turn

machine off before inspecting or servicing any components. Keep wire compartment cover closed at all times unless wire needs to be changed.

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 the condition of the gun tip and nozzle. Remove any weld slag. Replace gun tip or nozzle if damaged.

	Do not operate this
! WARNING
	welding machine

with cracked or missing insulation on welding cables, wire feed gun or power cord.

EVERY 3 MONTHS:

1.Replace any unreadable safety labels on the welder.

2.Use compressed air to blow all dust and lint from ventilation openings.

3.Clean wire groove on drive roll. Remove wire from feed mechanism, remove screws from drive roll housing. Use a small wire brush to clean drive roll. Replace if worn or damaged

Consumable and Wear Parts

The following parts require routine maintenance:

•Wire feed drive roller

•Gun liner - replace if worn

•Nozzle/contact tips

MIG

WT5021

Figure 12 - Nozzle

•Wire - This welder will accept either 4” or 8” diameter spools. Flux-cored 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.

CHANGING WIRE SIZES

This welder is setup for .035 (.9mm) wire. If a different wire size is used, the wire feed drive roll and contact tip may need changing. There are two grooves in the drive roll. The small groove is for

.024 (.6mm) wire and the other is for

.030-.035 (.8-.9mm) wire. Remove the roller cover and flip the drive roll to choose the correct groove (See parts breakdown). The contact tip should also match the wire diameter used. The tip diameter is marked on the contact tip in inches or millimeters.

Supply Cable Replacement

1.Verify that welder is OFF and power cord disconnected.

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.

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.

Welding Guidelines
General	When current is produced by a	Nozzle	Contact
This line of welding machines can utilize	transformer (welding machine) and
		Shielding	Tip
the Flux Cored Arc Welding (Gasless)	flows through the circuit to the weld
process or the Gas Metal Arc Welding	wire, an arc is formed between the end	Gas	Flux
		Slag	(Gasless
(MIG) process. The weld must be	of the weld wire and the work piece.
			only)
protected (shielded) from contaminates	This arc melts the wire and the work	Weld	Wire
in the air while it is molten. The gasless	piece. The melted metal of the weld
process uses a tubular wire with a flux	wire flows into the molten crater and
material inside. The flux creates a	forms a bond with the work piece as
shielding gas when melted. The MIG	shown (Figure 13).	Crater	Work Piece
process uses inert gas to shield the weld
while molten.		Figure 13 - Weld Components
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