Wire Feed Arc Welder
Assembly
Model WG3020
Welder components listed below are in the wire feed compartment. Open and remove.
HANDLE ASSEMBLY
1.Align handle holes to the inside of deck lid holes (as shown in Figure 2).
2.Fasten screws through top cover and into handle using the four small screws.
WHEEL AND AXLE ASSEMBLY
1.Slide axle through holes in bottle deck.
2.Push wheels on until snug.
BOTTLE DECK / GAS CYLINDER BRACKET ASSEMBLY
1.With flat side facing the welder, align holes in bottle deck with fastening holes on the bottom back of the welder.
2.Attach bottle deck with fastening screws.
3.Bend strap tab upward and fasten using screw (See Figure 2).
4.Align bottle bracket with holes directly above vent holes on the back of the welder and fasten with screws.
5.Slide bottle straps through strap holes above bottle bracket and through strap tab (See Figure 2).
Strap tab |
Figure 2 - WG3020 Assembly |
FOOT ASSEMBLY
1.Place foot on welder and align holes in the welder housing.
2.Fasten screws through foot into cabinet.
Wire Installation
NOTE: Before installing welding wire, be sure that the diameter of the welding wire matches the groove in the drive roller on the wire feed mechanism and the wire matches the contact tip in the end of the gun. A mismatch on any item could cause the wire to slip or bind.
1.Verify the unit is off and open the panel on the welder to expose the wire feed mechanism.
2.Remove the spool quick lock, by pushing in and rotating 1/4 turn counterclockwise. The knob, spring, and spool spacer can now be removed.
NOTE: Spool spacer and spindle spacer act as an 8” spool spindle adapter. Purchase of an adapter is not necessary.
* See Figure 3 for assembly.
Spool Lock
Spool Spring
Spacer
Guide Tube
Tension Screw
Drive 
Roller
Figure 3 - Weld Wire Routing
3.Loosen the wire feed tensioning screw on the drive mechanism. This allows initial feeding of the wire into the gun liner by hand.
4.Install the wire spool onto the spindle so that the wire can come off the spool on the end closest to the wire feed guide tube. Do not cut the wire loose yet. Install the spool spacer, spring, and quick lock knob by pushing in and turning the knob 1/4 rotation clockwise.
5.Hold the wire and cut the wire end from the spool. Do not allow the wire to unravel. Be sure that the end of the wire is straight and free of burrs.
6.Feed the wire through the wire feed guide tube, over the groove in the drive roller and into the gun liner. Tighten the wire feed tensioning screw so that it is snug. Do not over tighten.
7.Remove the nozzle by turning counterclockwise. Then unscrew the contact tip from the end of the welding torch (See Figure 4). Plug the welder into the proper power supply receptacle.
Torch Neck | Contact Tip |
| Nozzle |
Figure 4 - Torch Nozzle and Contact Tip | |
HINT: Keep torch cable straight when feeding wire.
8.Turn on the welder and set the wire speed rate to 5. Activate the gun switch until the wire feeds out past the torch end. Turn welder off.
9.Carefully slip the contact tip over the wire and screw it into the torch neck. Install the nozzle by turning clock- wise (See Figure 4). Cut the wire off approximately 1/4” from the end of the nozzle.
Contact Tip Markings
| Wire Size |
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| .024” | or | .6 |
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| .030” | or | .8 |
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| .035” | or | .9 |
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| .040” | or | 1.0 |
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POLARITY
For gas shielded welding, connect the cable coming out of the torch to the (+) socket and the work clamp cable to the
DUTY CYCLE / THERMOSTATIC PROTECTION
Welder duty cycle is the percentage of actual weld time that can occur in a ten minute interval at rated output current. For example, at a 10% duty cycle, actual welding can occur for one minute, then the welder must cool for nine minutes.
Internal components of this welder are protected from overheating with an automatic thermal switch. A yellow lamp is illuminated in the ON/OFF Switch if the duty cycle is exceeded. Welding operations may continue when the yellow lamp is no longer illuminated.
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