Campbell Hausfeld Welder WS0900 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 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  
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De scrip t io n  
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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.  
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MODEL  
WS1020  
ONLY  
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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  
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electrodes, call (800) 746-5641 for the  
nearest dealer.  
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Un p a ckin g  
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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  
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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  
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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  
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ODE  
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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  
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OUND  
P
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Fig u re 2 - Ha n d le Asse m b ly  
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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  
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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.  
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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
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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
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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
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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, purchasers abuse, neglect or failure to operate products in accordance with instructions  
provided in the owners 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 Warrantors 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 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.  
9
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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  
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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  
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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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