Op e ra t in g In st ru ct io n s & Pa rt s Ma n u a l
Mo d e ls WS0900, WS0950, WS1000 a n d WS1020
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 .
CAMPBELL
Shielded Metal
HAUSFELD
Ne e d
Assist a n ce ?
Arc Welder
Ca ll Us First !
1-800-746-5641
4
De scrip t io n
3
6
This line of Campbell Hausfeld Arc
Welders is designed to be used on
standard 115V household current. These
welders are equipped with infinite
amperage control to accurately select the
proper current needed for various
welding conditions. Internal components
are thermostatically protected.
E
S
A
E
R
C
E
I
D
N
C
R
E
S
1
MODEL
WS1020
ONLY
5
This welder can weld up to 1/8” steel in
a single pass. Recommended electrode
size is 1/16” diameter for 15 amp
circuits, up to 5/64” diameter for 20
amp circuits. For replacement
1
2
3
6
4
electrodes, call (800) 746-5641 for the
nearest dealer.
2
Un p a ckin g
5
When unpacking, inspect carefully for
any damage that may have occurred
during transit. Report any damaged or
missing items by calling 1-800-746-5641.
MODEL WS0900
1
Fig u re 1 - We ld e r Co m p o n e n t s
a n d Co n t ro ls
Ge n e ra l Sa fe t y
Circu it Re q u ire m e n t s
Da n g e r m e a n s a
Com ponents and Controls
1. Work Clamp - connect to work piece
Th is e q u ip m e n t
re q u ire 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 .
d e d ica 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
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 o r 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 .
2. Electrode Holder - holds electrode
welding rod
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 .
3. Power Cord - plug into 115 volt outlet.
4. On/Off Switch - lights if thermostat
has automatically shut unit off.
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.
5. Infinite Amperage Control Knob -
turns clockwise to increase amperage
and counterclockwise to decrease
amperage.
Electrode
Diameter
Circuit Breaker or
Slow Blow Fuse
6. Welding Amp Indicator - as the
amperage control knob (5) is rotated,
the amperage indicator moves
1/16
5/64
15 amp
20 amp
NOTE: Note means any additional
information pertaining to the product
or its proper usage.
displaying approximate weld amps.
IN198903AV 4/97
1
Models WS0900, WS0950, WS1000 and WS1020
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.
Safe Practices For Occupational And
Educational Eye And Face Protection
Ge n e ra l Sa fe t y (Co n ’t )
● Take precautions to be sure that
flying sparks and heat do not cause
flames in hidden areas, cracks,
behind bulkheads, etc.
ANSI Standard Z87.1, from American
National Standards Institute, 1430
Broadway, New York, NY 10018
● Route the electrode and work
cables together and secure with
tape when possible.
Refer to the Material Safety Data
Sheets and the manufacturers
instructions for metals, electrodes,
coatings and cleaners.
● Never wrap arc welder cables
around the body.
Fire h a za rd ! Do n o t
● Always position the electrode and
work leads so that they are on the
same side of the body.
w e ld o n co n t a in e rs o r
p ip e s t h a t co n t a in o r
h a ve co n t a in e d
fla m m a b le m a t e ria ls o r
g a se o u s o r liq u id co m b u st ib le s.
In st a lla t io n
Lo ca t io n
Selecting the proper location can
significantly increase performance,
reliability and life of the arc welder.
● Exposure to electromagnetic fields
during welding may have other
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
e q u ip m e n t is t u rn e d o ff a n d e le ct ro d e
is re m o ve d . 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 .
Arc w e ld in g clo se d
cylin d e rs o r co n t a in e rs
su ch a s t a n ks o r d ru m s
ca n ca u se e xp lo sio n if
n o t p ro p e rly ve n t e d ! Ve rify t h a t a n y
cylin d e r o r co n t a in e r t o b e w e ld e d h a s
a n a d e q u a t e ve n t ila t io n h o le , so t h a t
e xp a n d in g g a se s ca n b e re le a se d .
● 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.
● Store electrodes in a clean, dry
location with low humidity to
preserve the flux coating.
ADDITIONAL SAFETY STANDARDS
ANSI St a n d a rd Z49.1 from American
Welding Society, 550 N.W. LeJune Rd.
Miami, FL 33126
● 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.
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 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 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
● The use of an extension cord is not
recommended for arc welding
machines. Extension cord use will
significantly degrade the
● Keep the head and face out of the
welding fumes.
Na t io n a l Ele ct rica l Co d e
● 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:
NFPA Standard 70, from National Fire
Protection Association, Batterymarch
Park, Quincy, MA 02269
performance of the welder.
Asse m b ly
HANDLE ASSEMBLY-MODELS
Sa fe Ha n d lin g o f Co m p re sse d Ga se s
in Cylin d e rs
WS0950, WS1000 AND WS1020 ONLY
a. Remove the coating from the
base metal.
CGA Pamphlet P-1, from Compressed
Gas Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA
22202
1. Slide handle in slot toward rear of
unit.
b. Make sure that the welding area
is well ventilated.
c. Use an air-supplied respirator.
Co d e fo r Sa fe t y in We ld in g a n d
Cu t t in g
Extremely toxic fumes are created
when these metals are heated.
CSA Standard W117.2, from Canadian
Standards Association, Standards Sales,
178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3
ON
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
OFF
WS1000
A
S
E
E
R
C
E
D
I
N
C
R
E
ELECTR
ODE
A
Cu t t in g An d We ld in g Pro ce sse s
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
1
15
V
OL
T
INFINITE
AMPERA
GE SELECT
OR
60HZ 23A
NFPA Standard 51B, from National Fire
Protection Association, Batterymarch
Park, Quicy, MA 02269
O
U
T
GR
OUND
P
U
T
7
0
A
M
P
S
A
C
@
2
3
V
•
2
0
%
D
U
T
Y
C
Y
C
L
E
•
M
A
X
O
C
V
:
3
8
V
O
L
T
S
•
S
I
N
G
L
E
P
H
A
S
E
Fig u re 2 - Ha n d le Asse m b ly
3
Shielded Metal Arc Welder
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 a s
sp e cifie d in t h e fo llo w in g ch a rt , 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 .
2. Insert filter lens.
Asse m b ly (Co n ’t )
3. Attach the stiffeners over the pins on
the lens retainers (See Figure 5).
2. Push forward and snap front of
handle in cutout in cabinet.
Lens
3. Fasten screw through handle and
into cabinet (See Figure 2).
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
WORK CLAMP (ALL MODELS)
1. Loosen hex bolt or nut on work
clamp.
Lens
Retainer
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 .
2. Insert either cable from the welder
through the clamp handle and slide
bare wire under the clamp block.
Tighten hex bolt or nut making sure
bare wire is clamped securely.
Retainer
Stiffener
4. Connect the work clamp to the
work piece. Make sure the contact is
on bare metal and not obstructed
by paint, varnish, corrosion, or non-
metallic materials.
Clamping
block
Fig u re 5
4. To attach the handle, place shield on
a flat surface and press handle into
place (See Figure 6).
5. Insert the exposed part of the
electrode rod (the end with no flux)
into the jaws of the electrode holder.
6. Set the amperage adjustment knob
to the proper amperage for the
electrode rod diameter. Refer to
the following chart for proper
electrode current settings.
Fig u re 3 - Wo rk Cla m p Asse m b lie s
ELECTRODE HOLDER (ALL MODELS)
1. Remove insulation handle from the
holder body by pulling the two
pieces apart.
Fig u re 6
NOTE: If you have never welded before
or have little experience, a full face
helmet is recommended. Both hands
are needed to stabilize and control the
angle and arc length of the electrode.
Th e e le ct ro d e
h o ld e r a n d ro d a re
e le ct rica lly “ live ” (cu rre n t p o t e n t ia l)
w h e n t h e w e ld e r is o n .
2. Slide the other weld cable through
the handle.
Electrode
Diameter
Current
3. Loosen the wire clamping screw and
slide the bare cord wire under the
clamp block. Tighten the clamping
screw making sure the wire is secure.
Setting (Amps)
Op e ra t io n
1. Be sure to read,
1/16" (1.6 mm)
5/64" (2 mm)
35-80
understand, and
comply with all
precautions in the
General Safety
45-100
4. Slide the handle over the electrode
holder body and press to stop. Make
sure the handle is secure and there
is no exposed metal on the holder.
MANUAL
For specific settings, see weld guide
marked on welder
Information section.
Be sure to read the entire section
entitled Welding Guidelines prior to
using this equipment.
Gro u n d in g a g a in st
a n y m e t a llic
su rfa ce m a y p ro d u ce a n a rc w h ich
co u ld ca u se sp a rks a n d d a m a g e
e ye sig h t .
2. Turn welder off and plug into
appropriate receptacle:
7. Hold the electrode rod away from
the grounded work piece or
115v-15 amp - 1/16 electrodes
115v-20 amp - 5/64 electrodes
workbench. Turn on the welder.
Fig u re 4 - Ele ct ro d e Ho ld e r Asse m b ly
3. Verify that the surfaces of metals to
be joined are free from dirt, rust,
paint, oil, scale or other contaminants.
These contaminants make welding
difficult and cause poor welds.
8. Position the electrode to begin weld,
lower the welding helmet or position
the hand shield, and strike an arc.
Adjust weld amperage as needed.
HANDSHIELD (ALL MODELS EXCEPT
WS1020)
1. Cut retainer stiffeners and
detachable handle away from shield.
Trim the excess plastic to remove
sharp edges.
All p e rso n s
o p e ra t in g t h is
9. When finished welding, turn welder
off and store properly.
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
4
Models WS0900, WS0950, WS1000 and WS1020
Do n o t o p e ra t e t h is
w e ld in g m a ch in e
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, e le ct ro d e h o ld e r, o r
p o w e r co rd .
Op e ra t io n (Co n ’t )
DUTY CYCLE / THERMOSTATIC
PROTECTION
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
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.
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.
Every 3 months;
Replace any unreadable labels on the
welder. Use compressed air to blow all
dust and lint from the ventilation
openings.
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.
Internal components of this welder are
protected from overheating with an
automatic thermal switch. A yellow
lamp is illuminated on the front panel
(on/off switch) if the duty cycle is
exceeded. Welding operations may
continue when the yellow lamp is no
longer illuminated.
3. Check condition of electrode holder
insulating pieces and immediately
replace cracked or missing
insulators. Verify that all fasteners
are tight and insulated.
We ld in g Gu id e lin e s
electrode approximately 1/16” off the
surface or it will stick (See Figure 8).
Wire
Slag
Ge n e ra l
This line of welding machines utilizes a
process known as Shielded Metal-Arc
Welding (SMAW). This process is used
to bond metals by heating them with
an electric arc created between the
electrode and the work piece.
Flux
Work
Piece
Weld
Electrodes used for shielded metal arc
welding have two parts. The inner core
is a metal rod or wire that should be
similar in composition to the base
metal. The outer coating is called flux.
Various types of flux exist. Each coating
is used for a particular welding
situation.
Crater
Fig u re 7 - We ld Co m p o n e n t s
Same as Electrode Diameter
Fig u re 8 - Scra t ch in g Me t h o d
NOTE: Discontinue using and discard
electrodes that burn down to 1 to 2
inches from the electrode holder.
NOTE: Should the electrode stick to the
work piece, break it loose by quickly
twisting or bending at the holder while
pulling upward. If the electrode does
not break loose, disengage the
electrode by releasing it from the
holder.
STRIKING AN ARC
While the metal is molten, it can be
contaminated by elements in the air.
This contamination could weaken the
weld. The flux coating creates a
protective barrier called slag that
protects the molten metal from
contaminants.
Place the bare end of the electrode in
the holder. Grip the holder lightly to
reduce tiring of the hand and arm.
NOTE: Always keep the jaws of the
holder clean to insure good electrical
contact with the electrode.
ELECTRODE TYPE AND SIZE
Two types of electrodes are
Be ca re fu l n o t t o
t o u ch t h e w o rk
p ie ce o r w e ld in g b e n ch w it h t h e
e le ct ro d e a s t h is ca u se s a rc fla sh e s.
recommended for this welder. The
electrodes are commonly known by the
AWS (American Welding Society)
designation as follows:
When current (amperage) flows
through the circuit to the electrode, an
arc is formed between the end of the
electrode and the work piece. The arc
melts the electrode and the work piece.
The melted metal of the electrode
flows into the molten crater and forms
a bond with the work piece as shown in
Figure 7.
The best method of striking an arc is
the scratching method. Drag the
electrode at an angle along the surface
much like striking a match. Upon
contact with the plate, lift the
1. E-6013 GENERAL PURPOSE
•
All position, smooth deposit rod
with low spatter.
•
For all mild steel and general
purpose work.
5
Shielded Metal Arc Welder
We ld in g Gu id e lin e s (Co n t in u e d )
2. E-7014 FAST FILL
WELD ANGLE
For most applications, a 45º travel
angle and 45º work angle is sufficient.
For specific applications, consult an arc
welding handbook.
Weld angle is the angle at which the
electrode is held during the welding
process. Using the correct angle ensures
proper penetration and bead formation.
Electrode angle involves two positions -
travel angle and work angle (See Figure 9).
•
•
Smooth bead and fast deposition
Ideal for joints with poor fitup and
general repair work
NOTE: Right handed welders should
weld from left to right. Left handed
welders should weld from right to left.
The electrode should always point into
the weld puddle as shown.
NOTE: E-6011 and E-6018 are not
recommended for use with these
welders. Recommended electrode
diameter is 1/16” or 5/64”. Call (800)
746-5641 for availability.
5o - 45o
ARC LENGTH
Arc We ld in g Ba sics
Arc length is the distance from the
work piece to the tip of the electrode,
the distance which the arc must travel.
A proper arc length is essential to
generate the heat needed for welding
(See Figure 10). An arc that is too long
produces an unstable arc, reduces
penetration, increases spatter, and
causes flat and wide beads. Too short
an arc does not create enough heat to
melt the work piece, the electrode has
a tendency to stick, penetration will be
poor, and uneven beads with irregular
ripples result. A proper arc should be
no longer then the diameter of the rod.
The sound of a proper arc is a steady,
crisp sizzle, similar to bacon frying.
Four basic techniques affect weld
quality. These are: amperage setting,
weld angle, arc length, and travel
speed. Proper use of these techniques is
necessary for good weld quality.
Travel Angle
AMPERAGE SETTING
The correct amperage involves the
adjustment of the welding machine to
the required amp setting. This is
regulated by a knob on the welder. The
amperage required depends on the size
(diameter) of electrode used and the
thickness of the work piece.
Work Angle
Fig u re 9 - We ld An g le
Travel angle is the angle in the line of
welding and may vary from 5º to 45º
from the vertical, depending on
welding conditions.
Consult specifications listed on the
welder. Excessive amps burn through
light metals and the weld bead is flat
and porous (See Figure 10). The bead
appears high and irregular if the
amperage is too low.
TRAVEL SPEED
Work angle is the angle from
horizontal, measured at right angles to
the line of welding.
The travel speed is the rate at which
the electrode is moved across the weld
NOTE: Weld bead width (W)
should be approximately
twice the diameter fo the
electrode rod used.
W
Workpiece
Speed Too Fast
Normal Amps, Arc Length, Speed
Amperage Too Low
Amperage Too High
Speed Too Slow
Arc Length Too Long
Arc Length Too Short
Fig u re 10 - We ld Ap p e a ra n ce
6
Models WS0900, WS0950, WS1000 and WS1020
We ld in g Gu id e lin e s (Co n t in u e d )
area (See Figure 10). When the speed is
too fast, the bead is narrow and bead
ripples are pointed as shown. When the
speed is to slow, the weld metal piles
up and the bead is high and wide. To
control travel speed, watch the width
of the weld bead (not the arc) when
welding. The weld bead is the orange,
molten metal behind the arc. The width
should be approximately twice the
diameter of the welding rod. Control
travel speed to obtain a consistent
bead width.
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 (See Figure 11). If the pieces
are thick, it may be necessary to bevel
the edges that are joined at a 60º
angle. Remember to remove the slag
before each pass.
Cover
Filler
Root
SLAG REMOVAL
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 .
Fig u re 11 - We ld Pa sse s
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.
When making multiple weld passes,
remove the slag before each pass.
Fig u re 12 - Mu lt ip le We ld Pa sse s
To Work Clamp
Thermal Breaker
S2
To Electrode
Holder
3
WELDING POSITIONS
S2
Thermal Breaker
Four basic welding positions can be used;
flat, horizontal, vertical, and overhead.
Welding in the flat position 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.
5
4
2
1
On/Off
Switch S1
6
Plug
Other positions require different
Ground
techniques such as a weaving pass,
circular pass, and jogging. A higher skill
level is required to complete these welds.
All Models Except WS0900
L1
L2
Green
White
Black
All work should be performed in the
flat position if possible. For specific
applications, consult an arc welding
handbook.
Fig u re 13 - Wirin g Sch e m a t ic
7
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. Check circuit fuse or circuit breaker
2. Power cable requires service
Welder does not hum
when turned on
1. No power at receptacle
2. Broken or damaged power
cable
1. Check work clamp, cable and connection to work piece.
Check electrode cable and clamp
Welder hums but does not
weld
1. Inadequate current at
electrode
2. Check all welder external connections
2. Poor connections at welder
1. Avoid contact with work piece
Welder gives trickle shocks 1. Accidental contact with work
piece
2. Make sure clothing and work area are dry
2. Current leakage caused by
moist clothing or work area
1. If possible, relocated welder to avoid use of extension
cord. If relocation of welder is not possible, use thicker
(lower gauge number) extension cord
Welder overheats - blows
fuses, trips circuit breaker
1. Use of extension cord
2. Use smaller diameter electrode
3. Welder requires a d e d ica t e d 115V circuit
2. Electrode diameter too large
3. Overloaded circuit
1. Verify that electrode is for alternating current (AC) use
2. Use smaller diameter electrode
3. Verify proper grounding. (No paint, varnish or corrosion)
Arc difficult to strike
1. Wrong type of electrode
2. Electrode diameter too large
3. Work piece not properly
grounded
4. Run welder on dedicated 115V circuit
4. Heavy loads making power
line voltage low
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 or too thick
1. Inconsistent travel speed
2. Output amp setting incorrect
1. Carefully watch and control the width of the molten
weld bead
2. Adjust output amp setting or change to smaller diameter
electrode
Ragged depressions at
edge of weld
1. Travel speed too fast
1. Watch orange molten weld puddle and control bead
width
2. Arc length too short
2. Practice running electrode across workpiece with welder
OFF
3. Output amp setting too high
3. Reduce output amp setting
Weld bead does not
penetrate workpiece
1. Inconsistent travel speed
2. Output amp setting too low
1. Decrease and maintain constant travel speed
2. Increase output amp setting or change to smaller
diameter electrode
3. Electrode diameter too large
3. Recommend either 1/16 or 5/64 diameter
Electrode sticks to work
piece
1. Arc length short
2. Amp setting low
1. Lift electrode to correct arc length as soon as arc is struck
2. Increase amp setting or change to smaller diameter
electrode
Electrodes sputter and stick Damp electrodes
Use dry electrodes and store in dry location
8
Shielded Metal Arc Welder
Models WS0900, WS0950, WS1000 and WS1020
Su p p ly Ca b le Re p la ce m e n t (Exce p t WS0900)
1. Disconnect the black, white and green wires from the
relative terminals (A) and (B).
Ground Terminal
(A)
2. Push the cable anchorage (C) on the side and pull the supply
cable towards the outside.
3. Loosen the bushing screw (D) and pull cable through
bushing.
Supply Cable
Green Wire
Terminals
4. Replace the cable, tighten the bushing screw (D) and
reconnect the supply cable wire to the relative terminals.
(B)
Bushing Screw
(D)
Black and White
Wires
Cable Anchorage
Cable Anchorage
(C)
(C)
Supply Cable
Lim it e d 5-3-1 Wa rra n t y
1. 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)
2. 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. 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.
4. 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.
5. 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:
A. 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.
B. 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.
C. 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. Any failure that results from accident, purchaser’s abuse, neglect or failure to operate products in accordance with instructions
provided in the owner’s manual(s) supplied with the product.
E. Pre-delivery service, i.e. assembly and adjustment.
7. 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 Warrantor’s option, products or components which have
failed within duration of the warranty period.
8. 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 owner’s 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.
9
Shielded Metal Arc Welder
Model WS0900
Fo r Re p la ce m e n t Pa rt s, ca ll 1-800-746-5641
Please provide following information:
-
-
-
Model number
Serial number (if any)
Part description and number as
shown in parts list
1
Address parts correspondence to:
The Campbell Group
Attn: Parts Department
100 Production Drive
Harrison, Ohio 45030
2
5
3
4
6
8
11
9
13
12
10
10
7
Re p la ce m e n t Pa rt s List - Mo d e l WS0900
Re f
No .
De scrip t io n
Pa rt Nu m b e r
Qt y
1
2
3
4
5
Electrode holder assembly - Cord not included (Includes reference numbers 2-7)
Electrode holder handle (Cord not included)
Electrode holder body
WC200000AV
WC200001AV
WC200002AV
WC200003AV
❋
1
1
1
1
1
Insulation cap
#10-24 x .5” Machine screw
6
7
8
9
#10-24 x 7/16” Square nut
Work clamp (Cord not included)
Safety decal (Right)
❋
1
1
1
1
2
WC100000AV
DK404300AV
DK404400AV
❋
Safety decal (Left)
10
Welding cable 6 AWG (6 ft)
11
12
13
❋
Power cord 14-2 AWG (6 ft) Type SJT
WC000400AJ
WC400100AJ
WC302100AJ
1
1
1
On/Off switch
Hand wheel
Standard hardware item, available at local hardware or welder supply store
10
Shielded Metal Arc Welder
Models WS0950, WS1000 and WS1020
Fo r Re p la ce m e n t Pa rt s, ca ll 1-800-746-5641
Please provide following information:
-
-
-
Model number
1
Serial number (if any)
Part description and number as
shown in parts list
9
2
8
5
Address parts correspondence to:
The Campbell Group
Attn: Parts Department
100 Production Drive
11
3
4
6
Harrison, Ohio 45030
10
14
13
15
16
7
MODEL
WS1020
12
12
7
12
Re p la ce m e n t Pa rt s List - Mo d e ls WS0950, WS1000 and WS1020
Re f
No .
De scrip t io n
Pa rt Nu m b e r
Qt y
1
2
3
4
5
6
Electrode holder assembly - Cord not included (Includes reference numbers 2-7)
Electrode holder handle (Cord not included)
Electrode holder body
Insulation cap
#10-24 x .5” Machine screw
WC200000AV
WC200001AV
WC200002AV
WC200003AV
❋
1
1
1
1
1
1
#10-24 x 7/16” Square nut
❋
7
Work clamp (Cord not included)
Model WS1020 only
Handle
#8-36 x 1.5” Pan head screw
Amperage window
WC100000AV
WC100100AV
WC300000AV
❋
WC800000AV
WC800100AV
1
1
1
1
1
1
8
9
10
Model WS1020 only
11
12
13
14
15
16
Safety decal
DK404000AV
❋
WC000100AJ
WC400000AJ
WC102000AV
WC302000AJ
1
2
1
1
3
1
Welding cable 6 AWG (6 ft)
Power cord 14-3 AWG (6 ft) Type SJT
On/Off switch
Strain relief
Hand wheel
❋
Standard hardware item, available at local hardware or welder supply store
11
Shielded Metal Arc Welder
Models WS0900, WS0950, WS1000 and WS1020
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.
machine. The weld wire is tubular with
flux material contained inside for
shielding.
contaminants while the weld is
solidifying (cooling). Slag should be
removed after weld has cooled.
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.
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.
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.
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
tungsten electrode and the work piece.
Filler metal may or may not be used.
Ta ck We ld - weld made to hold parts
in proper alignment until final welds
are made.
Ba se Me t a l - the material to be
welded.
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
the base metal.
La p Jo in t - a joint between two
overlapping members in parallel
planes.
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
which flows only in one direction. The
polarity (+ or -) determines which
direction the current is flowing.
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.
Po ro sit y - gas pockets, or cavities,
formed during weld solidification. They
weaken the weld.
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.
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.
Wo rk An g le - the angle of the
electrode from horizontal, measured at
right angles to the line of welding.
Ele ct ro d e - a coated metal wire having
approximately the same composition as
the material being welded.
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.
Sh ie ld e d Me t a l Arc We ld in g
(SMAW) - also called Stick, is a welding
process with uses a consumable
electrode to support the arc. Shielding
is achieved by the melting of the flux
coating on the electrode.
Flu x - the material used to prevent or
dissolve oxides and other weld
contaminants.
Flu x Co re d Arc We ld in g (FCAW) -
also called Gasless, is a welding process
used with a wire-feed welding
Sla g - a layer of flux soot that protects
the weld from oxides and other
12
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