Campbell Hausfeld WF2150 Service manual

Please read and save these instructions. Read carefully before attempting to assemble, install, operate or maintain the
product described. Protect yourself and others by observing all safety information. Failure to comply with instructions could
result in personal injury and/or property damage! Retain instructions for future reference.
IN973801AV 5/08
Operating Instructions & Parts Manual Models WF2150, WF2154,
WG2160 and WG2164
Wire Feed
Arc Welder
Description
These Campbell Hausfeld wire feed
welders are designed to be used on
standard 120V outlets. The welder is
equipped with infinite wire speed
control to accurately select the proper
wire feed rate needed for various
welding conditions. Internal components
are thermostatically protected.
The WF2150 and WF2154 are designed
for use with the Flux Cored Arc Welding
(FCAW) process. The WG2160 and
WG2164 are designed for use with the
Flux Cored Arc Welding (FCAW) or the
Gas Metal Arc Welding (GMAW) process.
As delivered from the factory, this welder
can weld with .030 in. (0.8mm) diameter
flux core wire. A starter spool of .030 in.
CIRCUIT REQUIREMENTS
This equipment requires a dedicated
120 volts. Refer to the following chart
for correct circuit breaker or fuse
rating for 120 volt models. Do not run
other appliances, lights or tools on this
circuit while operating this equipment.
Extension cords are not recommended.
Blown fuses and tripped circuit
breakers can result from failure to
comply with this recommendation.
COMPONENTS AND CONTROLS
(FIGURE 1)
1. Work Clamp – connects to work
piece.
2. Torch with .030 in. tip.
3. Power Cord – plug into 120 volt
outlet.
4. Light – illuminates if thermostat has
automatically shut welder off.
5. Infinite Wire Speed Control – turn
clockwise to increase wire speed and
counterclockwise to decrease wire
speed.
6. Off/Heat Selector - Selects welding
power and turns welder on.
Four selections are possible:
1 – 2 – 3 – 4.
See page 8 for supply cable
replacement instructions.
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Need
Assistance?
Call Us First!
1-800-746-5641
(0.8 mm) flux cored wire is included.
To use the GMAW process with the
WG2160 or WG2164, it is necessary to
purchase shielding gas and MIG wire
only.
Unpacking
When unpacking, inspect carefully for any
damage that may have occurred during
transit. Make sure any loose fittings and
screws, etc., are tightened before putting
unit into service. Report any missing or
damaged items by calling
1-800-746-5641.
For parts, manuals, product & service information
visit www.chpower.com
© 2008 Campbell Hausfeld/ Scott Fetzer
REMINDER: Keep your dated proof of purchase for warranty purposes!
Attach it to this manual or file it for safekeeping.
Circuit Breaker or
Heat Slow Blow Fuse for
Selector 120V Models
1-2-3 15 amp
4 20 amp
Figure 1 - Welder Components and Controls
3
1
6
4
5
2

2
Wire Feed Arc Welder
General Safety
Danger
indicates
an imminently hazardous situation
which, if not avoided, will result in
death or serious injury.
Warning
indicates
a potentially hazardous situation
which, if not avoided, COULD result in
death or serious injury.
Caution
indicates
a potentially hazardous situation
which, if not avoided, MAY result in
minor or moderate injury.
NOTE: Note means any additional
information pertaining to the product
or its proper usage.
CALIFORNIA PROPOSITION 65
This
product
or its power cord may contain
chemicals known to the State of
California to cause cancer and birth
defects or other reproductive harm.
Wash hands after handling.
Always keep a fire
extinguisher accessible while
performing arc welding
operations.
Before starting or
servicing any electric arc
welder, read and
understand all
instructions. Failure to
follow safety precautions or
instructions can cause equipment
damage and/or serious personal
injury or death.
All installation, maintenance, repair
and operation of this equipment
should be performed by qualified
persons only in accordance with
national, state, and local codes.
Improper use of electric arc
welders can cause electric
shock, injury, and death! Take
all precautions described in
this manual to reduce the possibility of
electric shock.
Verify all components of the arc
welder are clean and in good
condition prior to operating welder.
Be sure insulation on all cables,
torch and power cord is not
damaged. Always repair or replace
damaged components before
operating the welder. Always keep
welder panels, shields, etc. in place
when operating welder.
Always wear dry, protective
clothing, welding gloves and
insulated footwear when operating
unit.
Always operate welder in a clean,
dry, well ventilated area. Do not
operate welder in humid, wet, rainy
or poorly ventilated areas.
Be sure work piece is properly
supported and grounded prior to
beginning any electric arc welding
operation.
Spread out coiled welding cable
before use to avoid overheating and
damage to insulation.
Never
immerse
wire or torch in water. If welder
becomes wet for any reason, be
absolutely certain it is completely clean
and dry before use!
Always shut equipment off and
unplug power cord prior to moving
the unit.
Always attach the work lead first.
 Verify work piece is securely
grounded.
Always shut off electric arc welding
equipment when not in use and cut off
any excess wire from torch.
Never allow any part of the body to
touch welding wire and ground or
grounded work piece at the same
time.
Awkward welding conditions and
positions can be electrically hazardous.
When crouching, kneeling or at
elevations, be sure to insulate all
conductive parts, wear appropriate
protective clothing and take
precautions to prevent injury from falls.
Never attempt to use this equipment
at current settings or duty cycles
higher than specified on equipment
labels.
Never use an electric arc welder to
thaw frozen pipes.
Flying sparks and hot metal
can cause injury. As welds
cool, slag can be thrown off.
Take all precautions described
in this manual to reduce the possibility of
injury from flying sparks and hot metal.
Wear ANSI approved face shield or
safety glasses with side shield
protection when chipping or
grinding metal parts.
Wear ear plugs when welding
overhead to prevent spatter or slag
from falling into ears.
Electric arc welding
operations produce intense
light and heat and ultraviolet
(UV) rays. This intense light
and UV rays can cause injury to eyes and
skin. Take all precautions described in
this manual to reduce the possibility of
injury to eyes and skin.
All persons operating this equipment
or in the area while equipment is in
use, must wear protective welding
gear including: welding helmet or
shield with at least shade 10 lens, flame
resistant clothing, leather welding
gloves and full foot protection.
Never
look at
arc welding operations without eye
protection as described above. Never
use a shade filter lens that is cracked,
broken, or rated below number 10.
Warn others in the area not to look at
the arc.
Electric arc welding
operations cause sparks and
heat metal to temperatures
that can cause severe burns!
Use protective gloves and clothing when
performing any metal working
operation. Take all precautions
described in this manual to reduce the
possibility of skin and clothing burns.
Make sure all persons in welding
area are protected from heat, sparks
and ultraviolet rays. Use additional
face shields and flame resistant
barriers as needed.
Never touch work pieces until
completely cooled.
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MANUAL

Heat and sparks produced
during electric arc welding
and other metal working
operations can ignite
flammable and explosive materials!
Take all precautions described in this
manual to reduce the possibility of
flames and explosions.
Remove all flammable materials
within 35 feet (10.7 meters) of
welding arc. If removal is not
possible, tightly cover flammable
materials with fire proof covers.
Do not operate any electric arc
welder in areas where flammable or
explosive vapors may be present.
Take precautions to ensure flying
sparks and heat do not cause flames
in hidden areas, cracks, etc.
Fire hazard! Do not weld on
containers or pipes that
contain or have contained
flammable materials or
gaseous or liquid combustibles.
Arc welding closed cylinders
or containers such as tanks
or drums can cause explosion
if not properly vented!
Verify that any cylinder or container to
be welded has an adequate ventilation
hole, so that expanding gases can be
released.
Do not
breathe fumes produced by arc
welding operation. These fumes are
dangerous. If welding area cannot be
adequately ventilated, be sure to use
an air-supplied respirator.
Keep head and face out of welding
fumes.
Extremely toxic fumes are
created when galvanized or
cadmium plated metals or metals
which contain zinc, mercury or
beryllium are heated. Complete
the following precautions before
performing electric arc welding
operations on these metals:
a. Remove coating from base metal.
b. Make sure welding area is well
ventilated.
c. Use an air-supplied respirator.
Install and secure cylinders in an upright
position by chaining them to stationary
support or equipment cylinder rack to
prevent falling or tipping.
Keep cylinders away from any
welding or other electrical circuits.
Never allow a welding electrode to
touch any cylinder.
Use only correct shielding gas
cylinders, regulators, hoses and
fittings designed for the
specific application; maintain
all parts properly.
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.
Read and follow instructions on
compressed gas cylinders, associated
equipment, and CGA publication P-1
listed in Safety Standards.
Never
use
flammable gasses with MIG welders.
Only inert or non-flammable gasses
such as carbon dioxide, argon, helium
or mixtures of one or more of these
gasses are suitable for MIG welding.
Never
lift
cylinders off the ground by their valves
or caps or with chains or slings.
ADDITIONAL SAFETY STANDARDS
ANSI Standard Z49.1 from American
Welding Society, 550 N.W. Le June Rd.
Miami, FL 33126
Safety and Health Standards
OSHA 29 CFR 1910, from Superintendent
of Documents, U.S. Government Printing
Office, Washington, D.C. 20402
National Electrical Code
NFPA Standard 70, from National Fire
Protection Association, Batterymarch
Park, Quincy, MA 02269
Safe Handling of Compressed Gases
in Cylinders
CGA Pamphlet P-1, from Compressed Gas
Association, 1235 Jefferson Davis
Highway, Suite 501, Arlington, VA 22202
Code for Safety in Welding and
Cutting
CSA Standard W117.2, from Canadian
Standards Association, Standards Sales,
178 Rexdale Boulevard, Rexdale,
Ontario, Canada M9W 1R3
3
The electromagnetic field
generated during arc welding
may interfere with the
operation of various electrical
and electronic devices such as cardiac
pacemakers. Persons using such devices
should consult with their physician prior
to performing any electric arc welding
operations.
 Route torch and work cables
together and secure with tape when
possible.
 Never wrap arc welder cables around
the body.
Always position torch and work leads
on the same side of the body.
Exposure to electromagnetic fields
during welding may have other
health effects which are not known.
CALIFORNIA PROPOSITION 65
This product, when used for
welding, produces fumes or
gases which contain chemicals
known to the State of
California to cause birth defects (or other
reproductive harm) and, in some cases,
cancer (California Health & Safety Code
Section 25249.5 et seq.).
The
power
cord and other cables on this product
contain chemicals, including lead,
known to the State of California to
cause cancer and birth defects or other
reproductive harm. Wash hands after
handling.
GENERAL SAFETY
Always be sure welding area
is secure and free of hazards
(sparks, flames, glowing
metal or slag) prior to leaving.
Be sure equipment is turned off and
excess wire is cut off. Be sure cables are
loosely coiled and out of the way. Be
sure all metal and slag has cooled.
Cylinders can explode if
damaged. Shielding gas
cylinders contain gas under
high pressure. If damaged, a
cylinder can explode. Since gas
cylinders are normally part of the
welding process, be sure to treat them
carefully.
Protect compressed gas cylinders
from excessive heat, mechanical
shocks and arcs.
Models WF2150, WF2154,
WG2160 and WG2164
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General Safety
(Continued)

NOTE: Always maintain control of loose
end of welding wire to prevent
unspooling.
1. Verify unit is off and open door
panel to expose wire feed
mechanism.
2. Remove the spool lock by pushing in
and rotating 1/4 turn
counterclockwise. Then remove lock,
spring and retainer.
3. Flip tensioning knob down and
swing arm up on drive mechanism.
This allows initial feeding of wire
into torch liner by hand.
4. Install wire spool onto spindle so
wire can come off bottom of spool.
Do not cut the wire loose yet.
Install retainer, spring and lock by
pushing in and turning lock 1/4
rotation clockwise.
Wire Feed Arc Welder
Cutting And Welding Processes
NFPA Standard 51B, from National Fire
Protection Association, Batterymarch
Park, Quincy, MA 02269
Safe Practices For Occupational And
Educational Eye And Face Protection
ANSI Standard Z87.1, from American
National Standards Institute, 1430
Broadway, New York, NY 10018
Refer to Material Safety Data Sheets and
manufacturers instructions for metals,
wire, coatings and cleaners.
Installation
LOCATION
Selecting the proper location can
significantly increase performance,
reliability and life of the arc welder.
For best results locate welder in a
clean and dry environment. Dust
and dirt in the welder retain
moisture and increase wear of
moving parts.
Place welder in an area with at least
twelve inches (305 mm) of ventilation
space at both the front and rear of
unit. Keep all obstructions out of this
ventilation space.
Store welding wire in a clean, dry
location with low humidity to
prevent oxidation.
Use a properly grounded receptacle
for the welder and ensure welder is
the only load on power supply
circuit. Refer to chart on page 1 for
correct circuit capacity.
Use of an extension cord is not
recommended for electric arc welding
machines. Voltage drop in the
extension cord may significantly
degrade performance of the welder.
Assembly
WIRE INSTALLATION
NOTE: Before installing welding wire,
be sure:
a. Diameter of welding wire matches
groove in drive roller on wire feed
mechanism (See Figure 2).
b. Wire matches contact tip in end of
torch (See Figure 3).
A mismatch on any item could cause the
wire to slip and/or bind.
5. Hold wire and cut the wire end from
spool. Do not allow wire to
unravel. Be sure end of wire is
straight and free of burrs.
6. Feed wire through wire guide, over the
groove in drive roller and into torch
wire liner. Flip swing arm down and
tension knob up. Adjust tension by
rotating tension knob.
7. Unscrew nozzle and contact tip from
end of welding torch (See Figure 3).
Plug welder into a proper power
supply receptacle.
8. Turn on welder and set wire speed
to 10. Activate torch trigger until
wire feeds out past the torch end.
Turn welder off.
9. Carefully slip contact tip over wire,
screw tip into torch end and
reinstall nozzle (See Figure 3). Cut
wire off approximately 1/4 inch
from nozzle end.
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 20%
duty cycle, actual welding can occur for
two minutes, then the welder must cool
for eight minutes.
Internal components of this welder are
protected from overheating with an
automatic thermal switch. A red lamp is
illuminated on the front panel if the
duty cycle is exceeded. Do not switch
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General Safety
(Continued)
Spindle
Welding wire
Lock
Spring
Retainer
Tension knob
Wire guide
Swing arm
Drive deck
Drive roller
Figure 2 - Weld Wire Installation
Contact Tip Markings
Mark Wire Size
0.6 mm .024 in.
0.8 mm .030 in.
0.9 mm .035 in.
Torch Diffuser Contact Tip
Nozzle
Figure 3 - Torch Nozzle

unit off. This will allow the internal fan
to cool the unit quickly. Welding
operations may continue when the red
lamp is no longer illuminated.
POLARITY (WG2160 AND WG2164
ONLY)
MIG welding wire requires the
electrode to be positive.
Flux welding wire requires the
electrode to be negative. Always use
the polarity recommended by the
welding wire manufacturer. The
welder is factory set for flux welding
wire.
To Change Polarity (See Figure 4)
1. Unplug power cord from socket.
2. Open wire feed compartment door.
3. Remove two nuts from polarity
studs.
4. Connect cable from drive deck to
positive stud and cable from work
clamp to negative stud for electrode
positive polarity for MIG welding.
Connect cable from drive deck to
negative stud and cable from work
clamp to positive stud for electrode
negative polarity for flux core welding.
5. Reinstall two nuts and tighten
securely.
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 to prevent it from falling over.
Obtaining Correct Gas Type. The gas
used in any welding application for your
welder must be an INERT, NON-
FLAMMABLE TYPE. You can get the
type of gas needed from a nearby
welding gas distributor (often found in
the yellow pages under “Welders” or
“Welding Equipment”).
REGULATOR
A regulator is supplied with the WG2160
and WG2164 only. The regulator
provides a constant shielding gas
pressure and flow rate during the
welding process. Each regulator is
designed to be used with a specific gas or
mixture of gases. The argon and argon
mixture use the same thread type. The
100% carbon dioxide uses a different
thread type. An adapter is available at
your local welding gas supplier to
change between the two.
HOSE AND REGULATOR HOOKUP
PROCEDURE
Cylinder
gas is
under high pressure. Point cylinder
outlet away from yourself and any
bystanders before opening.
1. With cylinder securely supported,
stand on side of cylinder opposite
cylinder outlet then remove cylinder
cap and open valve slightly by
turning counterclockwise. When gas is
emitted from cylinder, close valve by
turning clockwise. This will blow out
dust or dirt that may have
accumulated around valve seat.
2. Install regulator onto cylinder valve.
Tighten stem nut securely to gas
valve.
3. Install one end of gas hose to fitting
on the back of welder and other end
of hose to fitting on regulator. Make
sure gas hose is not kinked or twisted.
4. While standing opposite cylinder
outlet, slowly open cylinder valve.
Inspect for leaks in the connections.
5. Remember to close gas cylinder valve
when finished welding.
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If the
nuts are
not tightened properly, excessive heat
will be generated by the loose
connection and the insulators on the
studs will be damaged.
Shielding Gas Preparation
(WG2160 and WG2164 only)
Improper
handling
and maintenance of compressed gas
cylinders and regulators can result in
serious injury or death! Always secure
gas cylinders to a wall or other fixed
support to prevent cylinder from falling
over. Read, understand and follow all
compressed gas and equipment
warnings in the safety instructions.
NOTE: Shielding gas is not required if
flux-core 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.
Use ONLY
the type of gas recommended for your
welder. Use ONLY an inert, non-
flammable type of gas. Failure to do so
will result in a very hazardous situation.
Figure 4 - Polarity control
Ground cable
Brass nuts
Drive deck cable
Positive stud
Negative stud
NOTE: Electrode negative
polarity (typical for flux core
welding) shown in figure.
Reverse cables for electrode
positive polarity (typical for
MIG welding).
Assembly (Continued)
Models WF2150, WF2154,
WG2160 and WG2164

9. Position torch near work piece, lower
welding helmet by nodding head or
positioning the hand shield, and
squeeze torch trigger. Adjust heat
setting and wire speed as needed.
10. When finished welding, turn welder
off and store properly.
Maintenance
Disconnect power supply and turn
machine off before inspecting or
servicing any components. Keep wire
compartment cover closed at all times
unless wire needs to be changed.
BEFORE EVERY USE:
1. Check condition of weld cables and
immediately repair or replace any
cables with damaged insulation.
2. Check condition of power cord and
immediately repair or replace any
cord if damaged.
3. Inspect the condition of the torch
contact tip and nozzle. Remove any
weld slag. Replace torch contact tip
or nozzle if damaged.
Do not
operate
this welding machine with cracked or
missing insulation on welding cables,
torch or power cord.
EVERY 3 MONTHS:
1. Replace any unreadable safety labels
on the welder.
2. Use compressed air to blow all dust
and lint from ventilation openings.
3. Clean wire groove on drive roller.
Remove drive roller and use a small
wire brush to clean. Replace if worn
or damaged.
Consumable and Wear Parts
The following parts require replacement:
• Wire feed drive roller
• Torch liner
• Nozzle/contact tips
• Wire - This welder will accept either 4
in. or 8 in. diameter spools. Flux-
Cored 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-Cored wire is recommended.
Operation
1. Be sure to read, understand
and comply with all
precautions in the General
Safety Information section.
Be sure to read entire
“Welding Guidelines” section before
using this equipment.
2. Turn welder off.
3. Verify 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.
All persons operating this equipment or
in the area while equipment is in use
must wear protective welding gear
including: eye protection with proper
shade, flame resistant clothing, leather
welding gloves and full foot protection.
If heating, welding or cutting
galvanized, zinc plated, lead,
or cadmium plated materials,
refer to the General Safety
Information Section for instructions.
Extremely toxic fumes are created when
these metals are heated.
4. Connect work clamp to work piece or
workbench (if metal). Make sure
contact is secure. Avoid surfaces with
paint, varnish, corrosion or non-
metallic materials.
5. Rotate Wire Speed Control to setting
per decal inside wire feed
compartment, then adjust as needed
after test.
6. Plug power cord into a proper
voltage receptacle with proper circuit
capacity (see circuit requirements on
Page 1).
7. Switch welder on to desired heat
setting per decal inside wire feed
compartment, then adjust as needed
after test.
NOTE: These settings are general
guidelines only. Heat setting may vary
according to welding conditions and
materials.
8. Verify wire is extended 1/4 in. from
contact tip. If not, squeeze trigger to
feed additional wire, release trigger,
turn welder off, and cut wire to
proper length. Then, switch back on
to desired heat setting.
Wire Feed Arc Welder
CHANGING WIRE SIZES
This welder is setup for .030 in. (0.8
mm) wire. If a different wire size is
used, the wire feed drive roller and
contact tip may need changing. There
are two grooves in the drive roller. The
small groove is for .024 in. (0.6 mm)
MIG wire and the large groove is for
.030 - .035 in. (0.8 - 0.9 mm) flux core
and MIG wire. Rotate the tension knob
down and swing arm up. Remove roller
support by removing two screws and
flip the drive roller to choose the
correct groove. The contact tip should
also match the wire diameter used. The
tip diameter is marked on the contact
tip in inches and/or millimeters.
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MANUAL
Supply Cable Replacement
1. Verify that welder is OFF and
power cord disconnected.
2. Remove welder side panel to
expose switches.
3. Disconnect the power cord leads
per the diagram inside the unit.
4. Disconnect the ground wire
connected to welder base.
5. Loosen the cord strain relief screws
and pull cord out of strain relief.
6. Install new cord in reverse order
per the diagram inside the unit.

77
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SOLID WIRE
ER - 70 S- 6
ER-70S6 is recommended for this welder.
WELD ANGLE
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.
Travel angle is the angle in the line of
welding and may vary from 5º to 45º
from the vertical, depending on
welding conditions.
Work angle is the angle from horizontal,
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.
Welding Guidelines
General
The WF2150 and WF2154 can utilize the
Flux Cored Arc Welding (FCAW) process.
The WG2160 and WG2164 can utilize the
Flux Cored Arc Welding (FCAW) process or
the Gas Metal Arc Welding (GMAW)
process. The weld must be protected
(shielded) from contaminants in the air
while it is molten. The FCAW process uses
a tubular wire with a flux material inside.
The flux creates a shielding gas when
melted. The GMAW 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 5).
Arc Welding Basics
Six basic techniques affect weld
quality. These are: wire selection, heat
setting, weld angle, wire speed, travel
speed, and electrode extension. An
understanding of these techniques is
necessary for effective welds.
HEAT SETTING
The correct heat involves the adjustment
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
specifications listed on the welder. It is
suggested that the welder practice with
scrap metal to adjust settings, and
compare welds with Figure 7.
WIRE TYPE AND SIZE
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.
FLUX-CORED WIRE
E- 7 0 T - GS
AWS E71T-GS or E71T-11 is
recommended for this welder.
Weld strength, times
10,000 pounds per
square inch
Welding positions (0 for
flat or horizontal, 1 for
any position)
Tubular flux-cored wire
Flux type
Slag
Weld Wire
Flux
(Gasless only)
Work Piece
Shielding Gas
Contact Tip
Crater
Nozzle
Figure 5 - Weld Components
Weld strength, times
1,000 PSI
Solid wire
Wire composition
TRAVEL ANGLE
WORK ANGLE
5º - 45º
5º - 45º
Figure 6 - Weld Angle
Normal Heat,
Wire Speed,
Travel Speed
Heat Too Low
Heat Too High Wire Speed
Too Fast
Wire Speed Too Slow
Travel Speed
Too Slow
Travel
Speed
Too Fast
Base
Metal
Figure 7 - Weld Appearance
Models WF2150, WF2154,
WG2160 and WG2164

Wire Feed Arc Welder
8
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WIRE SPEED
The wire speed is controlled by the knob
on the front panel. The speed needs to
be “tuned” to the rate at which the wire
is being melted in the arc. Tuning is one
of the most critical functions of 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
torch 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. Repeat the
tuning procedure each time there is a
change in heat setting, wire diameter or
type, or work piece material type or
thickness. For Aluminum, wire speed is
typically set higher (7-9 speed range).
TRAVEL SPEED
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 piece
material thickness all affect the speed of
travel necessary for completing a good
weld (See Figure 7). 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
Aluminum, travel speed is typically faster.
ELECTRODE EXTENSION
Electrode extension (or electrode stick-
out) is the distance between the end of
the contact tip and and the end of the
welding wire. The recommended
electrode extension is from 1/4 to 1/2
in (6 to 13 mm). If the electrode
extension is too long, welding current
will be reduced and the bead will be
high and narrow with less penetration.
SLAG REMOVAL
(FLUX-CORED WIRE ONLY)
Wear ANSI approved safety
glasses (ANSI Standard Z87.1)
and protective clothing when
removing slag. Hot, flying
debris can cause personal injury to
anyone in the area.
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.
WELDING POSITIONS
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.
Welding is performed with the wire at a
45º travel angle and 45º work angle.
Other positions require different
techniques such as a weaving pass,
circular pass, and jogging. A higher skill
level is required to complete these welds.
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.
All work should be performed in the
flat position if possible. For specific
applications, consult an arc welding
technical manual.
WELD PASSES
Sometimes more than 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. Remember to remove the slag
before each pass for the FCAW process.
Welding Guidelines (Continued)
Figure 8 - Weld Passes
Cover
Filler
Root
Figure 9 - Multiple Weld Passes
ALUMINUM WELDING
Any aluminum surface to be welded,
must be cleaned thoroughly with a
stainless steel brush to eliminate any
oxidation on the weld and grounding
surface. 100% Argon shielding gas
must be used when welding aluminum.
If 100% Argon is not used, metal
penetration is unlikely. A Teflon®wire
liner, smooth-groove drive roller and
aluminum contact tips are
recommended when welding
aluminum. Campbell Hausfeld offers
these parts in Kit WT2531. Call 1-800-
746-5641 to order.
PUSH VS PULL TECHNIQUE
The type and thickness of the work piece
dictates which way to point the torch
nozzle. For thin materials (18 gauge and
smaller) 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 backhand
or pull technique (See Figure 10).
PUSH
PULL
Figure 10

9
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Troubleshooting Chart - Welder
Symptom Possible Cause(s) Corrective Action
For Information About This Product Call 1-800-746-5641
1. Duty cycle exceeded
2. Poor work clamp connection
3. Blown breaker or fuse
1. Wrong size contact tip
2. Torch liner clogged or
damaged
3. Contact tip clogged or
damaged
4. Drive roller worn
5. Not enough tension
1. Slag inside gun nozzle
2. Insulation ring melted/expired
1. Poor contact
2. Using an extension cord with
excessive length
1. Wire jammed
2. Out of wire
3. Not enough tension
4. Wire liner worn
5. Wire disconnected internally
6. Contact tip clogged
1. Wire speed too slow
2. Travel speed too slow or heat
is too high
1. Wire speed setting
2. Contact tip size too large
3. Polarity set incorrectly
4. Drive roller slipping
5. Gas bottle empty
1. Inconsistent travel speed
2. Output heat setting too low
1. Slow and/or inconsistent
travel speed
2. Output heat setting too high
1. Travel speed too fast
2. Wire speed too fast
3. Output heat setting too high
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. Damp wire
2. Wire speed too fast
3. Wrong type of wire
4. No or low shielding gas
1. Allow welder to cool until lamp goes out
2. Be sure all connections are secure, and attaching surface
is clean
3. Reduce circuit load, reset breaker or replace fuse
1. Use proper size contact tip
2. Clean or replace wire liner
3. Clean or replace contact tip
4. Replace
5. Tighten tension knob
1. Clean slag from gun nozzle
2. Replace nozzle
1. Be sure all connections are secure, and attaching surface
is clean
2. Never use an extension cord longer than 20 ft
1. Reload wire
2. Replace wire spool
3. Tighten tension knob if wire is slipping
4. Replace liner
5. Call 1-800-746-5641 for assistance
6. Replace contact tip
1. Run speed in 7 - 10 range
2. Increase the travel speed or reduce heat settings
1. Tune in correct setting (1-5 mild steel; 5-10 aluminum)
2. Replace contact tip
3. Reverse polarity
4. Increase tension
5. Replace gas bottle
1. Decrease and maintain constant travel speed
2. Increase output heat setting
1. Increase and maintain travel speed
2. Reduce output heat setting
1. Decrease travel speed
2. Decrease wire speed
3. Reduce output heat setting
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
1. Use dry wire and store in dry location
2. Reduce wire speed
3. Use flux-cored wire when not using gas
4. Use gas for MIG process or refill bottle
No output
Wire tangles at drive roller
Gun nozzle arcs to work
surface
Work clamp and/or cable
gets hot
Wire does not feed
(Aluminum) Wire burns back
into tip or (Aluminum) Metal
bubbles or burns through
Weld pops and sputters
Bead is intermittently too
thin
Bead is intermittently too
thick
Ragged depressions at
edge of weld
Weld bead does not
penetrate base metal
Wire sputters and sticks
Models WF2150, WF2154,
WG2160 and WG2164

Wire Feed Arc Welder
10
www.chpower.com
1 Torch (Flux Core, 8 ft, WF2150
and WF2154) WC601510AJ 1
Torch (MIG, 8 ft, WG2160
and WG2164) WC601520AJ 1
2Wire Liner – 0.024 in. - 0.035 in. WC403620AJ 1
3Contact Tip – 0.024 in. (0.6 mm) WT501200AV 1
Contact Tip – 0.030 in. (0.8 mm) WT501300AV 1
Contact Tip – 0.035 in. (0.9 mm) WT501400AV 1
Optional Contact Tip – 0.024 in.
(0.6 mm) 4 Pack WT501200AJ †
Optional Contact Tip – 0.030 in.
(0.8 mm) 4 Pack WT501300AJ †
Optional Contact Tip – 0.035 in.
(0.9 mm) 4 Pack WT501400AJ †
4 Nozzle WT502100AV 1
5 Drive Roller – 0.024 in. - 0.035 in.
(0.6 - 0.9 mm) WC500805AV 1
6 Drive Deck Assembly WC500800AJ 1
7 Spool Spindle WC707570AV 1
8 Spool Retainer WC707023AV 1
9 Spool Spring WC707026AV 1
10 Spool Lock WC707024AV 1
11 Flux Weld Wire – 0.030 in. (0.8 mm)
2 lb. Spool (E71T-GS) WE200001AV †
Flux Weld Wire – 0.030 in. (0.8 mm)
10 lb. Spool (E71T-GS) WE201000AV †
Flux Weld Wire – 0.035 in. (0.9 mm)
2 lb. Spool (E71T-GS) WE200501AV †
Flux Weld Wire – 0.035 in. (0.9 mm)
10 lb. Spool (E71T-GS) WE201500AV †
MIG Weld Wire – 0.024 in. (0.6 mm)
2 lb. Spool (ER70S6) WE300001AV †
Ref. Part
No. Description Number Qty
MIG Weld Wire – 0.024 in. (0.6 mm)
11 lb. Spool (ER70S6) WE301500AV †
MIG Weld Wire – 0.030 in. (0.8 mm)
2 lb. Spool (ER70S6) WE300501AV †
MIG Weld Wire – 0.030 in. (0.8 mm)
11 lb. Spool (ER70S6) WE302000AV †
MIG Weld Wire – 0.035 in. (0.9 mm)
2 lb. Spool (ER70S6) WE301001AV †
MIG Weld Wire – 0.035 in. (0.9 mm)
11 lb. Spool (ER70S6) WE302500AV †
Aluminum MIG Welding Wire –
0.030 in. (0.8 mm), 1 lb. Spool WE303001AV †
12 Safety Decal DK689105AV 1
13 Work Clamp WC100300AV 1
14 Gas Hose (WG2160 and
WG2164 only) 1
15 Regulator (WG2160
and WG2164 only) WC803500AV 1
16 Optional Welding Helmet WT100500AV †
17 Optional Aluminum Welding Kit
[Includes Teflon®Wire liner,
U-groove drive roller for
0.030 in. (0.8 mm) aluminum wire
and four 0.030 in. (0.8 mm) contact
tips for aluminum wire]
(WG2160 and WG2164 only) WT253100AV †
18 Handle Assembly WC707405AJ †
Not Shown
† Optional Accessory
Standard Hardware Item
Address any correspondence to:
Campbell Hausfeld
Attn: Customer Service
100 Production Drive
Harrison, OH 45030 U.S.A.
Please provide following information:
- Model number
- Serial number
- Part description and number as shown in
parts list
Replacement Parts List - Models WF2150, WF2154, WG2160 and WG2164
For replacement parts
or technical assistance,
call 1-800-746-5641.
Ref. Part
No. Description Number Qty
Figure 11- Replacement Parts
1
11
5
78
9
6
13
12
10
4