Campbell Hausfeld WG3000, WG2045, WG2044, WG2040 manual Installation, Assembly

Wire Feed Arc Welder

Installation

LOCATION

Selecting the proper location can significantly increase performance, reliability and life of the arc welder.

●For best results locate welder in a clean and dry environment. Dust and dirt in the welder retain moisture and increase wear of moving parts.

●Place welder in an area with at least twelve inches (305 mm) of ventilation space at both the front and rear of unit. Keep all obstructions out of this ventilation space.

●Store welding wire in a clean, dry location with low humidity to prevent oxidation.

●Use a properly grounded receptacle for the welder and ensure welder is the only load on power supply circuit. Refer to chart on page 1 for correct circuit capacity.

●Use of an extension cord is not recommended for electric arc welding machines. Voltage drop in the extension cord may significantly degrade performance of the welder.

Assembly

Welding accessories for the welder are inside wire feed compartment.

HANDLE AND BASE ASSEMBLY

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).

WORK CLAMP

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).

Figure 2 - Handle Assembly

Figure 3 - Base Assembly

Clamping Block

Figure 4a - Work Clamp

Assembly (WG2040,

WG2044, and WG2045)

Clamping Block

Figure 4b - Work Clamp Assembly (WG3000)

WIRE INSTALLATION

NOTE: Before installing welding wire, be sure:

a. Diameter of welding wire matches groove in drive roller on wire feed mechanism (See Fig. 5). The drive roller is marked with metric sizes:

.6mm = .024”, .8 - .9mm = .030 –

.035”

b. Wire matches contact tip in end of gun. (See Fig. 6).

A mismatch on any item could cause the wire to slip and bind.

NOTE: Always maintain control of loose end of welding wire to prevent unspooling.

1.Verify unit is off and open door panel to expose wire feed mechanism.

2.Remove the spool quick lock by pushing in and rotating 1/4 turn

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 counter- clockwise, 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 5 - Weld Wire Routing

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