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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.