Campbell Hausfeld Welder WG3013 User Manual

Op e ra t in g In st ru ct io n s & Pa rt s Ma n u a l  
Mo d e l WG3013  
Ple a se re a d a n d sa ve t h e se in st ru ct io n s. Re a d ca re fu lly b e fo re a t t e m p t in g t o a sse m b le , in st a ll, o p e ra t e o r m a in t a in t h e p ro d u ct d e scrib e d .  
Pro t e ct yo u rse lf a n d o t h e rs b y o b se rvin g a ll sa fe t y in fo rm a t io n . Fa ilu re t o co m p ly w it h in st ru ct io n s co u ld re su lt in p e rso n a l in ju ry a n d /o r  
p ro p e rt y d a m a g e ! Re t a in in st ru ct io n s fo r fu t u re re fe re n ce .  
Wire Feed  
Arc Welder  
Ne e d  
TM  
Assist a n ce ?  
B UILT T O LA S T  
Ca ll Us First !  
1-800-746-5641  
De scrip t io n  
This line of Campbell Hausfeld wire feed  
4
1
welders is designed to be used on  
standard 115V household current. The  
welders are equipped with infinite wire  
speed control to accurately select the  
proper wire feed rate needed for various  
welding conditions. Internal components  
are thermostatically protected.  
These welders are designed for use with  
Flux Core Arc Welding (Gasless) or Gas  
Metal Arc Welding (Mig) process. As  
6
delivered from the factory, this welder  
can weld with .024” (.6 mm) to .035”  
5
(.9 mm) diameter wire. A starter spool  
of .035” (.9 mm) flux-cored wire and a  
3
.040 tip are included.  
FARMHAND 125  
Un p a ckin g  
7
Som e w elder com ponents m ay be  
2
found in the w ire feed com partm ent.  
When unpacking, inspect carefully for  
any damage that may have occurred  
during transit. Report any damaged or  
missing items by calling (800) 746-5641.  
Fig u re 1  
Co m p o n e n t s a n d Co n t ro ls  
1. Gro u n d Cla m p - connect to work  
Da n g e r m e a n s a  
h a za rd t h a t w ill  
ca u se d e a t h o r se rio u s in ju ry if t h e  
w a rn in g is ig n o re d .  
Circu it Re q u ire m e n t s  
!
piece.  
DANGER  
Th is e q u ip m e n t  
re q u ire s a d e d i-  
2. Wire Fe e d Gu n w it h .040 t ip  
!
CAUTION  
ca t e d 115 vo lt circu it . Re fe r t o t h e  
fo llo w in g ch a rt fo r t h e co rre ct circu it  
b re a ke r o r fu se ra t in g . Do n o t ru n  
o t h e r a p p lia n ce s, lig h t s, o r t o o ls o n  
t h is circu it w h ile o p e ra t in g t h is  
3. Po w e r Co rd - plug into 115 volt  
Wa rn in g m e a n s a  
h a za rd t h a t co u ld  
ca u se d e a t h o r se rio u s in ju ry if t h e  
w a rn in g is ig n o re d .  
outlet.  
!
WARNING  
4. On /Off Sw it ch  
5. In fin it e Wire Sp e e d Co n t ro l -  
turn clockwise to increase wire  
speed and counterclockwise to  
decrease wire speed.  
e q u ip m e n t . Ext e n sio n co rd s a re n o t  
re co m m e n d e d . Blo w n fu se s a n d t rip p e d  
circu it b re a ke rs ca n re su lt fro m fa ilu re  
t o co m p ly w it h t h is re co m m e n d a t io n .  
Ca u t io n m e a n s a  
h a za rd t h a t m a y  
ca u se m in o r o r m o d e ra t e in ju ry if t h e  
w a rn in g is ig n o re d . It a lso m a y m e a n a  
h a za rd t h a t w ill o n ly ca u se d a m a g e t o  
p ro p e rt y.  
!
CAUTION  
Heat  
Selector  
Circuit Breaker or  
Slow Blow Fuse  
6. He a t Se le ct o r - Selects welding  
power. Four selections are possible  
7. Po la rit y Ho o k-u p - Attach torch  
cable to (+) for MIG and (-) for flux  
core wire.  
NOTE: Note means any additional  
information pertaining to the product  
or its proper usage.  
Low  
15 amp  
20 amp  
High  
IN970400AV 11/00  
WG3013  
cylin d e rs co n t a in g a s u n d e r h ig h  
p re ssu re . If d a m a g e d , a cylin d e r ca n  
e xp lo d e . Sin ce g a s cylin d e rs a re  
n o rm a lly p a rt o f t h e w e ld in g p ro ce ss,  
b e su re t o t re a t t h e m ca re fu lly.  
Co d e fo r Sa fe t y in We ld in g a n d  
Cu t t in g  
Ge n e ra l Sa fe t y  
(Co n t in u e d )  
CSA Standard W117.2, from Canadian  
Standards Association, Standards Sales,  
178 Rexdale Boulevard, Rexdale,  
Ontario, Canada M9W 1R3  
Protect compressed gas cylinders  
from excessive heat, mechanical  
shocks, and arcs.  
!
WARNING  
Cu t t in g An d We ld in g Pro ce sse s  
Do n o t b re a t h e fu m e s t h a t  
a re p ro d u ce d b y t h e a rc  
NFPA Standard 51B, from National Fire  
Protection Association, Batterymarch  
Park, Quicy, MA 02269  
Install and secure cylinders in an  
upright position by chaining them  
to stationary support or equipment  
cylinder rack to prevent falling or  
tipping.  
w e ld in g o p e ra t io n . Th e se  
fu m e s a re d a n g e ro u s. If t h e w e ld in g  
a re a ca n n o t b e a d e q u a t e ly ve n t ila t e d ,  
b e su re t o u se a n a ir su p p lie d  
re sp ira t o r.  
Sa fe Pra ct ice s Fo r Occu p a t io n a l An d  
Ed u ca t io n a l Eye An d Fa ce  
Pro t e ct io n  
ANSI Standard Z87.1, from American  
National Standards Institute, 1430  
Broadway, New York, NY 10018  
Keep cylinders away from any  
Keep the head and face out of the  
welding or other electrical circuits.  
welding fumes.  
Never allow a welding electrode to  
Do not perform electric arc welding  
operations on metals that are  
galvanized or cadmium plated, or  
contain zinc, mercury, or beryllium  
without completing the following  
precautions:  
touch any cylinder.  
Refer to the Material Safety Data  
Sheets and the manufacturers  
instructions for metals, wire, coatings  
and cleaners.  
Use only correct shielding gas  
cylinders, regulators, hoses, and  
fittings designed for the specific  
application; maintain them and  
associated parts in good condition.  
a. Remove the coating from the  
base metal.  
b. Make sure that the welding area  
is well ventilated.  
c. Use an air-supplied respirator.  
Extremely toxic fumes are created  
when these metals are heated.  
In st a lla t io n  
Selecting the proper location can  
significantly increase performance,  
reliability and life of the arc welder.  
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.  
For best results locate the welder in  
an environment that is clean and  
dry. Dust and dirt in the welder  
retain moisture and increase wear  
of moving parts.  
Read and follow instructions on  
compressed gas cylinders, associated  
equipment, and CGA publication P-1  
listed in Safety Standards.  
!
WARNING  
Th e e le ct ro m a g n e t ic fie ld  
t h a t is g e n e ra t e d d u rin g a rc  
w e ld in g m a y in t e rfe re w it h  
t h e o p e ra t io n o f va rio u s  
e le ct rica l a n d e le ct ro n ic d e vice s su ch a s  
ca rd ia c p a ce m a ke rs. Pe rso n s u sin g su ch  
d e vice s sh o u ld co n su lt w it h t h e ir  
p h ysicia n p rio r t o p e rfo rm in g a n y  
e le ct ric a rc w e ld in g o p e ra t io n s.  
Ne ve r u se  
fla m m a b le g a sse s  
Place the welder in an area that  
provides at least 12” (30,48 cm) of  
ventilation space at both the front  
and rear of the unit. Keep all  
obstructions away from this  
ventilation space.  
Store wire in a clean, dry location  
with low humidity to preserve the  
wire coating.  
The receptacle used for the welder  
must be properly grounded and the  
welder must be the only load on the  
power supply circuit. Refer to the  
Circuit Amps chart on page 1 for  
correct circuit capacity.  
The use of an extension cord is not  
recommended for electric arc  
welding machines. The voltage drop  
in the extension cord may signifi-  
cantly degrade the performance of  
the welder.  
!
DANGER  
w it h MIG w e ld e rs. On ly in e rt o r n o n -  
fla m m a b le g a sse s su ch a s ca rb o n  
d io xid e , a rg o n , h e liu m , o r m ixt u re s o f  
o n e o r m o re o f t h e se g a sse s a re  
su it a b le fo r MIG w e ld in g .  
Never lift cylinders  
off the ground by  
their valves, caps, or w ith chains or slings.  
●● Route the wire gun and work cables  
together and secure with tape  
when possible.  
!
WARNING  
●● Never wrap arc welder cables  
ADDITIONAL SAFETY STANDARDS  
around the body.  
ANSI St a n d a rd Z49.1 from American  
Welding Society, 550 N.W. LeJune Rd.  
Miami, FL 33126  
Always position the wire gun and  
work leads so that they are on the  
same side of the body.  
Exposure to electromagnetic fields  
during welding may have other  
Sa fe t y a n d He a lt h St a n d a rd s  
OSHA 29 CFR 1910, from  
Superintendent of Documents, U.S.  
Government Printing Office,  
Washington, D.C. 20402  
health effects which are not known.  
Alw a ys b e su re  
t h a t t h e w e ld in g  
a re a is se cu re a n d fre e o f h a za rd s  
(sp a rks, fla m e s, g lo w in g m e t a l o r sla g )  
p rio r t o le a vin g . Be su re t h a t  
!
WARNING  
Na t io n a l Ele ct rica l Co d e  
NFPA Standard 70, from National Fire  
Protection Association, Batterymarch  
Park, Quincy, MA 02269  
Asse m b ly  
We ld e r co m p o n e n t s list e d b e lo w  
a re in t h e w ire fe e d co m p a rt m e n t .  
Op e n a n d re m o ve .  
e q u ip m e n t is t u rn e d o ff a n d e xce ss  
w ire is cu t o ff. Be su re t h a t ca b le s a re  
lo o se ly co ile d a n d o u t o f t h e w a y. Be  
su re t h a t a ll m e t a l a n d sla g h a s co o le d .  
Sa fe Ha n d lin g o f Co m p re sse d Ga se s  
in Cylin d e rs  
CGA Pamphlet P-1, from Compressed Gas  
Association, 1235 Jefferson Davis  
Highway, Suite 501, Arlington, VA 22202  
HANDLE ASSEMBLY  
1. Remove screws from handle. Slide  
handle between welder front panel  
!
DANGER  
Cylin d e rs ca n e xp lo d e if  
d a m a g e d . Sh ie ld in g g a s  
w w w .ch p o w e r.co m  
3
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Wire Fe e d Arc We ld e r  
Asse m b ly (Co n t in u e d )  
w e ld in g w ire e ve n w h e n t h e t h e g u n  
sw it ch is n o t a ct iva t e d . Do n o t t o u ch  
t h e se p a rt s w h e n t h e w e ld in g m a ch in e  
is o n .  
6. Feed the wire through the wire feed  
guide tube, over the groove in the  
drive roll and into the gun liner.  
Tighten the wire feed tensioning screw  
so that it is snug. Do not over tighten.  
and top cover aligning the holes in  
handle with holes in top cover.  
NOTE: Before installing welding wire,  
be sure that the diameter of the  
welding wire matches the groove in the  
drive roller on the wire feed  
mechanism and the wire matches the  
contact tip in the end of the gun. A  
mismatch on any item could cause the  
wire to slip or bind.  
2. Fasten screws through top cover and  
into handle.  
7. Remove the nozzle by turning  
co u n t e rclo ckw ise . Then unscrew  
the contact tip from the end of the  
welding torch (See Figure 5). Plug the  
welder into the proper power supply  
receptacle.  
WHEEL AND AXLE ASSEMBLY  
1. Insert axle supports into slots in the  
welder housing.  
2. Insert axle through the axle supports  
and firmly push wheels onto axle.  
Torch Neck  
Contact Tip  
1. Verify the unit is off and open the  
panel on the welder to expose the  
wire feed mechanism.  
3. Secure wheel with e-clips and wheel  
caps.  
GAS CYLINDER BRACKET ASSEMBLY  
1. Place bracket on welder aligning the  
holes in welder housing.  
2. Remove the spool quick lock, by  
pushing in and rotating 1/4 turn  
counterclockwise. The knob, spring,  
and spool spacer can now be removed.  
2. Fasten screws through bracket and  
into cabinet.  
Nozzle  
NOTE: Spool spacer and spindle spacer  
act as an 8” spool spindle adapter.  
Purchase of an adapter is not necessary.  
Fig u re 5 - To rch No zzle  
FOOT ASSEMBLY  
1. Place foot on welder and align holes  
in the welder housing.  
HINT: Keep torch cable straight when  
feeding wire.  
* Se e Fig u re 4 fo r a sse m b ly.  
3. Loosen the wire feed tensioning  
screw on the drive mechanism. This  
allows initial feeding of the wire into  
the gun liner by hand.  
2. Fasten screws through foot into  
cabinet.  
8. Turn on the welder and set the wire  
speed rate to 5. Activate the gun  
switch until the wire feeds out past  
the torch end. Turn welder off.  
9. Carefully slip the contact tip over the  
wire and screw it into the torch neck.  
Install the nozzle by turning clo ck-  
w ise (See Figure 6). Cut the wire off  
approximately 1/4” from the end of  
the nozzle.  
Tension  
Screw  
Panel  
Guide  
Drive Roller  
Tube  
Contact Tip Markings  
Wire Size  
mm  
Spindle  
Spacer  
.024”  
.030”  
.035”  
.040”  
or  
or  
or  
or  
.6  
.8  
Spool  
Spacer  
Fig u re 2 - WG3013 Asse m b ly  
Gro u n d Cla m p  
1. Loosen hex nut on work clamp.  
.9  
Spool  
Lock  
1.0  
2. Insert cord through clamp handle and  
slide bare wire under the clamp block.  
Tighten hex nut making sure bare  
wire is clamped securely (Figure 3).  
Spindle  
POLARITY  
*Reverse  
position and  
For gas shielded welding, connect the  
cable coming out of the torch to the (+)  
socket and the ground clamp cable to  
the (-) socket on the front panel. For  
flux-core (no-gas) welding, connect  
torch to (-) and work clamp to (+).  
4” or 8”  
insert into 8”  
Spool  
Spring  
spool  
Fig u re 4 - We ld Wire Ro u t in g  
Clamping  
Block  
4. Install the wire spool onto the  
spindle so that the wire can come off  
the spool on the end closest to the  
wire feed guide tube. Do n o t cu t  
t h e w ire lo o se ye t . Install the spool  
spacer, spring, and quick lock knob  
by pushing in and turning the knob  
1/4 rotation clockwise.  
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.  
Fig u re 3 - Wo rk Cla m p Asse m b ly  
Wire In st a lla t io n  
We ld in g p o w e r  
m a y b e a p p lie d t o  
t h e o u t p u t t e rm in a ls, fe e d ro ll, w o rk  
cla m p , g u n ca b le co n n e ct io n a n d  
!
WARNING  
5. Hold the wire and cut the wire end  
from the spool. Do not allow the wire  
to unravel. Be sure that the end of the  
wire is straight and free of burrs.  
Internal components of this welder are  
protected from overheating with an  
automatic thermal switch. A yellow  
lamp is illuminated on the front panel  
w w w .ch p o w e r.co m  
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WG3013  
o r d e a t h ! Alw a ys se cu re g a s cylin d e rs  
t o t h e t a n k b ra cke t kit , a w a ll o r o t h e r  
fixe d su p p o rt t o p re ve n t t h e cylin d e r  
fro m fa llin g o ve r. Re a d , u n d e rst a n d ,  
a n d fo llo w a ll t h e co m p re sse d g a se s  
a n d e q u ip m e n t h a za rd s in t h e sa fe t y  
in st ru ct io n s.  
connection. Make sure the gas hose  
is not kinked or twisted.  
Assem bly (Continued)  
if the duty cycle is exceeded. Welding  
operations may continue when the  
yellow lamp is no longer illuminated.  
5. Once again, stand opposite the  
cylinder outlet and slowly open the  
cylinder valve. Inspect for leaks in  
the connections.  
6. Pull the trigger on the gun to allow  
the gas to flow. While the trigger is  
pulled and gas is flowing, adjust the  
gas regulator to 30-35 cfh (cubic  
feet per hour). Release the trigger.  
Ha n d sh ie ld  
Asse m b ly  
1. Cut retainer stiffeners and  
detachable handle away from shield.  
Trim the excess plastic to remove  
sharp edges.  
2. Insert filter lens.  
3. Attach the stiffeners over the pins on  
the lens retainers (See Figure 6).  
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. However, 100% carbon  
dioxide is not recommended due to  
unsatisfactory weld beads. This welder  
does not perform well with 100%  
carbon dioxide. The 75/25 mixture is  
recommended for general steel  
welding. For aluminum welding, use  
100% argon. Cylinders of either 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.  
7. Remember to close the gas valve  
when finished welding.  
Op e ra t io n  
1. Be sure to read,  
understand, and comply  
with all precautions in  
the General Safety  
MANUAL  
Lens  
Information section. Be  
sure to read the entire section  
entitled Welding Guidelines prior to  
using this equipment.  
Lens  
Retainer  
2. Verify welder is off.  
3. Verify that the surfaces of metals to  
be joined are free from dirt, rust,  
paint, oil, scale or other contam-  
inants. These contaminants make  
welding difficult and cause poor  
welds.  
NOTE: Use of incorrect gas may lead to  
little or no penetration of welding  
bead.  
Retainer  
Stiffener  
REGULATOR (NOT INCLUDED)  
The regulator provides a constant  
shielding gas pressure and flow rate  
during the welding process.  
Figure 6  
!
DANGER  
All p e rso n s o p e ra t in g t h is  
e q u ip m e n t o r in t h e a re a  
w h ile e q u ip m e n t is in u se  
m u st w e a r p ro t e ct ive w e ld in g g e a r  
in clu d in g : e ye p ro t e ct io n w it h p ro p e r  
sh a d e , fla m e re sist a n t clo t h in g , le a t h e r  
w e ld in g g lo ve s, a n d fu ll fo o t  
p ro t e ct io n .  
4. To attach the handle, place shield on  
a flat surface and press handle into  
place (See Figure 7).  
HOOKUP PROCEDURE  
Cylin d e r g a s is  
u n d e r h ig h  
p re ssu re . Po in t cylin d e r o u t le t a w a y  
fro m yo u rse lf a n d a n y b yst a n d e rs  
b e fo re o p e n in g .  
!
WARNING  
1. These units fit a 20 cubic ft bottle.  
WHETHER OR  
NOT THE TRIGGER  
IS PULLED, t h e w e ld in g w ire is LIVE  
w h e n e ve r t h e w e ld e r is t u rn e d ON.  
2. With the cylinder securely installed,  
remove the cylinder cap, stand to the  
side of the cylinder opposite the  
!
CAUTION  
outlet, and open the valve slightly,  
turning counterclockwise. When gas  
is emitted from the cylinder, close the  
valve by turning clockwise. This will  
blow out dust or dirt that may have  
accumulated around the valve seat.  
Fig u re 7  
!
WARNING  
NOTE: If you have never w elded  
before or have little experience, a  
full face helm et is recom m ended.  
Both hands are needed to stabilize  
and control the angle and arc  
length of the torch.  
If h e a t in g , w e ld in g , o r  
cu t t in g m a t e ria ls t h a t a re  
g a lva n ize d , zin c p la t e d , le a d ,  
o r ca d m iu m p la t e d re fe r t o t h e Ge n e ra l  
Sa fe t y In fo rm a t io n Se ct io n fo r  
in st ru ct io n s. Ext re m e ly t o xic fu m e s a re  
cre a t e d w h e n t h e se m e t a ls a re h e a t e d .  
3. Install the regulator onto the  
cylinder valve, keeping the face of  
the gauges in the vertical position  
and tighten the stem nut securely  
to the gas valve.  
Shielding Gas  
Installation  
4. Connect the work clamp to the  
work piece or workbench (if metal).  
Make sure the contact is secure.  
Avoid surfaces with paint, varnish,  
corrosion, or non-metallic materials.  
4. Install one end of the gas hose (not  
included) to the fitting on the rear  
of the welder and the other end to  
the fitting on the regulator using  
hose clamps (not included) on each  
Im p ro p e r h a n d lin g  
a n d m a in t e n a n ce  
o f co m p re sse d g a s cylin d e rs a n d  
!
DANGER  
re g u la t o rs ca n re su lt in se rio u s in ju ry  
5. Position the Heat Selector on the  
front panel to the desired setting.  
w w w .ch p o w e r.co m  
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Wire Fe e d Arc We ld e r  
MIG WIRE  
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.  
Op e ra t io n (Continued)  
Since MIG wire maintains fair wire  
diameter consistency, the contact tip  
used should match the wire size used.  
When using .024 (.6 mm) wire, use the  
small groove on the drive roller. When  
using .030 - .035 (.8 - .9 mm) MIG or  
Aluminum wire, use the factory set  
large groove.  
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.  
Co n su m e r a n d We a r Pa rt s  
The following parts require routine  
maintenance:  
ALUMINUM WIRE  
• Wire feed drive roller  
• Gun liner - replace if worn  
• Nozzle/contact tips  
When using Aluminum wire, it is best  
to use a larger size tip than the wire  
size being used. For example:  
• If wire diameter is .030, use .035 tip.  
6. Rotate the Wire Speed Control to  
setting number 5 to start with, then  
adjust as needed after test weld.  
7. Plug the input cord into a proper  
voltage receptacle with proper  
circuit capacity (See Chart under  
circuit requirements on page 1).  
• 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  
When using .030 - .035 (.8 - .9 mm) MIG  
or Aluminum wire, use the factory set  
large groove. Aluminum wire is very  
weak and should not have the same  
tension on the drive roller as Flux Core  
or MIG wire should. 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.  
8. Switch the welder ON.  
9. Verify that the wire is extended  
1/4” from the contact tip. If not,  
squeeze the trigger to feed  
recommended.  
additional wire, release the trigger,  
and cut wire to proper length.  
• Contact tips - use Campbell Hausfeld,  
Tweco®, and other compatible tips.  
10. Position the wire feed gun near the  
work piece, lower the welding  
• 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.  
helmet by nodding the head, or  
position the hand shield, and  
squeeze the gun trigger. Adjust heat  
setting and wire speed as needed.  
Ca ll (800) 746-5641  
fo r re p la ce m e n t p a rt s.  
11. When finished welding, turn welder  
off and store properly.  
Ma in t e n a n ce  
Disco n n e ct p o w e r  
su p p ly a n d t u rn  
!
WARNING  
m a ch in e o ff b e fo re in sp e ct in g o r  
se rvicin g a n y co m p o n e n t s. Ke e p t h e  
w ire co m p a rt m e n t co ve r clo se d a t a ll  
t im e s u n le ss t h e w ire n e e d s  
re p la ce m e n t .  
MIG  
WT5021  
Fig u re 8 - No zzle  
Before every use:  
Ch a n g in g Wire Size s  
DRIVE ROLLER  
1. Check condition of weld cables and  
immediately repair or replace any  
cables with damaged insulation.  
There are two grooves in the Drive  
Roller. The small groove is for .024” (.6  
mm) wire and the other is for .030” -  
.035” (.8 - .9 mm) wire. Remove the  
roller cover and flip the drive roll to  
choose the correct groove (see Parts  
Breakdown).  
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.  
FLUX CORE WIRE  
Due to small inconsistencies in wire  
diameter, using one size larger tip is  
recommended. For example:  
• If wire diameter is .030, use .035 tip.  
Do n o t o p e ra t e t h is  
w e ld in g m a ch in e  
!
WARNING  
w it h cra cke d o r m issin g in su la t io n o n  
w e ld in g ca b le s, w ire fe e d g u n , o r  
p o w e r co rd .  
• If wire diameter is .035, use .040 tip.  
This welder is setup for .035 (.9 mm)  
wire and has a .040 tip. Since this  
welder uses .030 and .035 Flux Core  
Wire, the drive roller should be in its  
factory pre-set condition.  
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.  
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WG3013  
We ld in g Gu id e lin e s  
ications listed on the welder. It is  
suggested that the welder practice with  
scrap metal to adjust settings and  
compare welds with Figure 11.  
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.  
Ge n e ra l  
Nozzle  
Contact  
Tip  
Shielding  
Gas  
WIRE TYPE AND SIZE  
Flux  
(Gasless  
only)  
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.  
5º - 45º  
Slag  
Weld  
Wire  
WORK ANGLE  
Crater  
Fig u re 9 - We ld Co m p o n e n t s  
Work Piece  
FLUX-CORE WIRE  
E - 7 0 T - GS  
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 9).  
5º - 45º  
Weld strength, times  
10,000 psi  
Welding positions (0  
for flat or horizontal,  
1 for any position)  
Tubular flux core wire  
Flux type  
TRAVEL ANGLE  
Fig u re 10 - We ld An g le  
WIRE SPEED  
The wire speed is controlled by the  
knob on the front panel. The speed  
needs to be “ t u n e d ” 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  
a lu m in u m , wire speed is typically set  
higher (7 - 9 speed range).  
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  
Arc We ld in g Ba sics  
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.  
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.  
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.  
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.  
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-  
TRAVEL SPEED  
Travel angle is the angle in the line of  
welding and may vary from 5º to 45º  
from the vertical, depending on  
welding conditions.  
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 angle is the angle from hori-  
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Wire Fe e d Arc We ld e r  
We ld in g Gu id e lin e s (Co n t in u e d )  
work piece material thickness all affect  
the speed of travel necessary for  
overhead. Welding in the flat position  
Cover  
Filler  
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.  
completing a good weld (See Fig. 11).  
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 a lu m in u m , travel  
speed is typically faster.  
Root  
Other positions require different  
techniques such as a weaving pass,  
circular pass, and jogging. A higher skill  
level is required to complete these  
welds.  
Fig u re 12 - We ld Pa sse s  
SLAG REMOVAL (FLUX-CORE WIRE  
ONLY)  
We a r ANSI  
a p p ro ve d sa fe t y  
g la sse s (ANSI St a n d a rd Z87.1) a n d  
p ro t e ct ive clo t h in g w h e n re m o vin g  
sla g . Ho t , flyin g d e b ris ca n ca u se  
p e rso n a l in ju ry t o a n yo n e in t h e a re a .  
!
WARNING  
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.  
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.  
All work should be performed in the  
flat position if possible. For specific  
applications, consult an arc welding  
technical manual.  
WELD PASSES  
Sometimes more then 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.  
Fig u re 13 - Mu lt ip le We ld Pa sse s  
NOTE: When making multiple weld  
passes, remove the slag before each  
pass.  
NOTE: Remember to remove the slag  
before each pass for gasless process.  
WELDING POSITIONS  
Four basic welding positions can be  
used; flat, horizontal, vertical, and  
Base Metal  
Normal Heat, Wire Speed, Travel  
Speed  
Travel Speed Too Fast  
Travel Speed Too Slow  
Wire Speed Too Slow  
Heat Too Low  
Heat Too High  
Wire Speed Too Fast  
Fig u re 11 - We ld Ap p e a ra n ce  
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WG3013  
We ld in g Gu id e lin e s (Co n t in u e d )  
PUSH VS PULL TECHNIQUE  
ALUMINUM WELDING  
Su p p ly Ca b le  
Re p la ce m e n t  
1. Verify that welder is OFF and power  
cord disconnected.  
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  
Any aluminum surface to be welded,  
must be cleaned thoroughly with a  
stainless steel brush to eliminate any  
oxides on the w eld and grounding  
surface. 100% Argon m ust be used  
when welding aluminum. If Argon is not  
used, metal penetration is unlikely.  
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.  
backhand or pull technique  
(See Figure 14).  
4. Disconnect the green power cord  
wire connected to welder frame.  
5. Loosen the cord strain screw(s) and  
pull cord out of strain relief.  
6. Install new cord in reverse order.  
PULL  
Fig u re 14  
PUSH  
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Wire Fe e d Arc We ld e r  
Fo r In fo rm a t io n Ab o u t Th is Pro d u ct , Ca ll 1-800-746-5641  
Tro u b le sh o o t in g Ch a rt - We ld e r  
Symptom  
Possible Cause(s)  
Corrective Action  
1. Allow welder to cool until ON/OFF Switch lamp goes out  
2. Be sure all connections are secure, and attaching surface is  
clean  
No output  
1. Duty cycle exceeded  
2. Poor ground clamp connection  
3. Replace switch  
3. Defective power switch  
4. Blown breaker or fuse  
4. Reduce circuit load, reset breaker or replace fuse  
1. Use proper size gun tip  
Wire tangles at drive roller 1. Wrong size gun tip  
2. Gun liner clogged or  
2. Clean or replace gun liner  
damaged  
3. Clean or replace gun tip  
4. Replace  
5. Tighten tensioning screw  
3. Gun tip clogged or damaged  
4. Feed roller worn  
5. Not enough tension  
Clean slag from gun nozzle  
Gun nozzle arcs to work  
surface  
Slag inside gun nozzle  
1. Be sure all connections are secure, and attaching surface is  
clean  
2. Never use an extension cord longer than 20 ft  
Ground clamp and/or  
cable gets hot  
1. Poor contact  
2. Using an extension cord with  
excessive length  
1. Reload wire  
Wire does not feed  
1. Wire jammed  
2. Replace wire spool  
2. Out of wire  
3. Tighten tensioning screws if wire is slipping  
4. Replace liner  
5. Call 1-800-746-5641 for assistance  
6. Replace contact tip  
3. Not enough tension  
4. Wire liner worn  
5. Wire disconnected internally  
6. Contact tip clogged  
1. Run speed in 7 - 10 range  
2. Increase the travel speed or reduce heat settings  
(Aluminum) Wire burns back 1. Wire speed too slow  
into tip or (Aluminum) Metal 2. Travel speed too slow or heat  
bubbles or burns through  
is too high  
Tro u b le sh o o t in g Ch a rt - We ld s  
Symptom  
Possible Cause(s)  
Corrective Action  
Bead is intermittently too  
thin  
1. Fast and/or inconsistent travel speed  
2. Output heat setting too low  
1. Decrease and maintain constant travel speed  
2. Increase output heat setting  
Bead is intermittently too  
thick  
1. Slow and/or inconsistent travel speed  
2. Output heat setting too high  
1. Increase and maintain travel speed  
2. Reduce output heat setting  
Ragged depressions at  
edge of weld  
1. Travel speed too fast  
2. Wire speed too fast  
1. Decrease travel speed  
2. Decrease wire speed  
3. Output heat setting too high  
3. Reduce output heat setting  
Weld bead does not  
penetrate base metal  
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 buid-up on  
surface  
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  
Wire sputters and sticks  
1. Damp wire  
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  
2. Wire speed too fast  
3. Wrong type of wire  
4. No or low shielding gas  
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WG3013  
Lim it e d 5-3-1 Wa rra n t y  
1.  
2.  
Du ra t io n : 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)  
Wh o Give s Th is Wa rra n t y (Wa rra n t o r):  
The Campbell Group / A Scott Fetzer Company  
100 Production Drive  
Harrison, OH 45030  
Telephone: (513)-367-4811  
3.  
4.  
Wh o Re ce ive s Th is Wa rra n t y (Pu rch a se r): The original purchaser of the Campbell Hausfeld product.  
Wh a t is co ve re d u n d e r t h is w a rra n t y: 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.  
Wh a t is n o t co ve re d u n d e r t h is w a rra n t y:  
5.  
A.  
B.  
C.  
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.  
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.  
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.  
E.  
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.  
Pre-delivery service, i.e. assembly and adjustment.  
7.  
8.  
Re sp o n sib ilit ie s o f Wa rra n t o r u n d e r t h is w a rra n t y: Repair or replace, at Warrantors option, products or components which have failed within duration  
of the warranty period.  
Re sp o n sib ilit ie s o f p u rch a se r u n d e r t h is w a rra n t y:  
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.  
Wh e n Wa rra n t o r w ill p e rfo rm re p a ir o r re p la ce m e n t u n d e r t h is w a rra n t y: 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.  
w w w .ch p o w e r.co m  
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Wire Fe e d Arc We ld e r  
WG3013 Wirin g Dia g ra m  
+
-
ON/OFF  
S1  
T1  
S3  
S2  
T2  
S5  
1
2
1
~
2
M
~
FAN  
MIN  
4
-
+
5
6
MAX  
S5 NC  
OPENS @ 127˚C  
Y
GROUND  
DRIVE  
DECK  
~
+
-
S4  
GUN  
M
L2  
L1  
4
3
2
1
WIRE SPEED  
CONTROL BOARD  
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WG3013  
Fo r Re p la ce m e n t Pa rt s, ca ll 1-800-746-5641  
Please provide following information:  
24  
28  
44  
-
-
-
Model number  
Serial number  
Part description and number as  
shown in parts list  
27  
45  
23  
33  
3
25  
29  
26  
43  
Address parts correspondence to:  
The Campbell Group  
Attn: Parts Department  
100 Production Drive  
Harrison, Ohio 45030 U.S.A.  
2
6
5
27  
4
** Contact Tip (See chart on Page 15)  
16  
17  
22  
1
18  
19  
20  
21  
39  
40  
34  
12  
40  
46  
14  
37  
13  
41  
8
7
11  
31  
35  
9 & 10  
30  
36  
38  
3
42  
15  
32  
40  
1
MODEL WG3013  
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Wire Fe e d Arc We ld e r  
Re p la ce m e n t Pa rt s List - Mo d e ls WG3013  
Re f  
No .  
Pa rt Nu m b e r fo r Mo d e l:  
WG3013  
De scrip t io n  
Qt y  
1
2
3
4
5
Torch assembly and hose (Includes Nos. 2-6, 34, and 50-52)  
Torch body, front and back  
WC600700AV  
WC600201AV  
WC600003AV  
WT502100AJ  
WC600202AV  
1
1
1
1
1
Hanger clip  
Nozzle, Tweco Style  
®
Trigger knob  
6
7
8
9
10  
Torch contact spring  
WC600203AV  
WC100100AV  
WC400201AV  
WC402100AV  
1
1
1
1
1
Work clamp (Cord not included)  
Welding cable 8 AWG (6 ft)  
Wire speed knob  
Wire speed control board  
11  
12  
13  
14  
15  
Heat selector switch  
On/off switch  
Safety decal  
WC400300AV  
WC400000AV  
DK670100AV  
WC300600AV  
2
1
1
1
1
Handle  
Power cord 14-3 AWG (6 ft) Type SJT  
16  
17  
18  
19  
20  
Spool spindle  
#10-32 x .5Pan head sheet metal screw  
Wire  
Spool adapter  
Spool spring  
WC500300AV  
See Chart Below  
WC500200AV  
WC500101AV  
1
2
1
1
1
21  
22  
23  
24  
25  
Spool locking hub  
Drive deck assembly (Includes Nos. 23-29)  
Tension spring  
Tension screw  
Roller .6-.9mm (.024-.035 in.)  
WC500100AV  
WC500000AV  
WC500003AV  
WC500002AV  
WC500001AV  
1
1
1
1
1
26  
27  
28  
29  
30  
Roller cover  
#8-36 x 1.5Pan head screw  
Swing arm  
Swing arm roller  
Strain relief  
WC500004AV  
WC500005AV  
WC500007AV  
WC102000AV  
1
3
1
1
1
31  
32  
33  
34  
35  
Wheel  
Front foot  
Liner, coated metal  
Gas cylinder bracket  
Axle  
WC701200AV  
WC702100AV  
WC600208AV  
WC702200AV  
WC703100AV  
2
1
1
1
1
36  
37  
38  
39  
40  
Wheel hub  
Dinse connector  
Dinse socket  
Torch ring  
#10-24 x 1/2Screw  
WC703500AV  
WC000200AV  
WC000300AV  
WC600009AV  
1
2
2
1
9
41  
42  
43  
44  
45  
46  
Axle support  
WC703600AV  
WC600701AV  
WC600305AV  
WC600204AV  
WC802000AV  
2
2
1
1
1
1
5mm I.D. e-ring  
Swan neck with Diffuser  
Trumpet liner  
Valve body  
Gas bottle strap  
Standard hardware item, available at local hardware or welder supply store  
OPTIONAL WIRE  
**OPTIONAL CONTACT TIPS (4/package)  
Part Number  
(1 pound)  
Part Number  
(10 pound)  
Size  
Type  
Description  
mm  
in.  
Part Number  
Flux  
Flux  
MIG  
MIG  
MIG  
E71T-GS .030”  
E71T-GS .035”  
ER70S6 .024”  
ER70S6 .030”  
ER70S6 .035”  
WE200001AV  
WE200501AV  
WE300001AV  
WE300501AV  
WE301001AV  
WE303001AV  
WE201000AV  
WE201500AV  
WE301500AV  
WE302000AV  
WE302500AV  
N/A  
0.6  
0.8  
0.9  
0.024  
0.030  
0.035  
WT501200AJ  
WT501300AJ  
WT501400AJ  
Aluminum MIG ER5356 .030”  
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WG3013  
Glo ssa ry o f We ld in g Te rm s  
AC o r Alt e rn a t in g Cu rre n t - electric  
current that reverses direction  
periodically. Sixty cycle current travels  
in both directions sixty times per  
second.  
Flu x Co re d Arc We ld in g (FCAW) -  
Sla g - 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.  
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.  
Arc Le n g t h - the distance from the  
end of the electrode to the point  
where the arc makes contact with the  
work surface.  
Sp a t t e r - 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.  
Ga s Me t a l Arc We ld in g (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.  
Ba se Me t a l - the material to be  
welded.  
Ta ck We ld - weld made to hold parts  
in proper alignment until final welds  
are made.  
Ga s Tu n g st e n Arc We ld in g (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  
Bu t t Jo in t - a joint between two  
members aligned approximately in the  
same plane.  
Tra ve l An g le - the angle of the  
electrode in the line of welding. It  
varies from 5º to 45º depending on  
welding conditions.  
Cra t e r - a pool, or pocket, that is  
formed as the arc comes in contact with tungsten electrode and the work piece.  
the base metal. Filler metal may or may not be used.  
T Jo in t - made by placing the edge of  
one piece of metal on the surface of  
the other piece at approximately a 90º  
angle.  
DC o r Dire ct Cu rre n t - electric current La p Jo in t - a joint between two  
which flows only in one direction. The  
polarity (+ or -) determines which  
direction the current is flowing.  
overlapping members in parallel  
planes.  
Op e n Circu it Vo lt a g e (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.  
Un d e rcu t - 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.  
DC Re ve rse Po la rit y - 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.  
Ove rla p - 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.  
We ld Po o l o r Pu d d le - a volume of  
molten metal in a weld prior to its  
solidification as weld metal.  
DC St ra ig h t Po la rit y - 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.  
We ld Be a d - 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.  
Po ro sit y - gas pockets, or cavities,  
formed during weld solidification. They  
weaken the weld.  
Pe n e t ra t io n - 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.  
Ele ct ro d e - a coated metal wire having  
approximately the same composition as  
the material being welded.  
Wo rk An g le - the angle of the  
electrode from horizontal, measured at  
right angles to the line of welding.  
Fille t We ld - approximately a triangle  
in cross-section, joining two surfaces at  
right angles to each other in a lap, T or  
corner joint.  
Flu x - a coating, when heated, that  
produces a shielding gas around the  
welding area. This gas protects the  
Sh ie ld e d Me t a l Arc We ld in g  
(SMAW) - also called Stick, is a welding  
parent and filler metals from impurities process with uses a consumable  
in the air.  
electrode to support the arc. Shielding  
is achieved by the melting of the flux  
coating on the electrode.  
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Wire Fe e d Arc We ld e r  
Notes  
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