Campbell Hausfeld WF1900, WF1800, WF2000 Welding Guidelines, Maintenance, Operation

Operating Instructions and Parts Manual

Operation (Continued)

Metal	Heat
Thickness	Setting
14 - 18 Gauge	Low
Thicker Than 14 Gauge	High

6. Rotate the Wire Speed Control to

setting number 5 to start with, then

adjust as needed after test weld. The

WF1800’s wire speed is automatically

adjusted to the heat selection chosen.

7. Plug the input cord into a proper

voltage receptacle with proper

circuit capacity (See circuit

requirements on front page).

8. Switch the welder ON/OFF switch to the

ON position. For the WF1800/WF1900,

switch the welder to the desired heat

setting.

9. Verify that the wire is extended 1/4”

from the contact tip. If not, squeeze

the trigger to feed additional wire,

release the trigger, and cut wire to

proper length.

10. Position the wire feed gun near the

work piece, lower the welding

helmet by nodding the head, or

position the hand shield, and

Maintenance

Disconnect power

! WARNING supply and turn machine off before inspecting or servicing any components. Keep the wire compartment cover closed at all times unless the 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 the ventilation openings.

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

Consumable and Wear Parts

The following parts require routine maintenance:

•Wire feed drive roller

•Gun liner - replace if worn

•Nozzle/contact tips

•Wire - The WF2000 will accept either 4” or 8” diameter spools. The WF1800/WF1900 will accept 4” spools only. 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. Use AWS type E71T-GS or E71T-11, .030” (.8mm) or .035” (.9mm) diameter.

squeeze the gun trigger. Adjust heat

setting and wire speed as needed.

Wire speed is not adjustable on the

WF1800.

11. When finished welding, turn welder

off and store properly.

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

This line of welding machines utilizes a process called Flux Cored Arc Welding (FCAW). The FCAW process uses a tubular wire with a flux material inside. Shielding is obtained from the decomposition of the flux within the tubular wire.

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 in Figure 12.

Diffuser		Contact
Nozzle		Tip
Slag		Flux
Weld		Wire
	Crater	Work Piece
Figure 12 - Weld Components

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 adjustment 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 specifications listed on the welder or generalized chart in the Operation section. It is suggested that the welder practice with scrap metal to adjust settings, and compare welds with Figure 17.

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