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Protect yourself and others by observing all safety information. Failure to comply with instructions could result in personal injury and/or Notes property damage! Retain instructions for future reference. Notas BUILT TO LAST Aluminum Welding Kit Description Model WT2531 is an aluminum welding kit designed for use on Campbell Hausfeld wire feed MIG welders (WG206X and WG208X series). This kit includes: Teflon ® wire liner (Part Number: WC403621AV) , smooth-groove drive roller (Part Number: WC500806AV) , four pieces of 0.030" (0.8 mm) aluminum contact tips (Part Number: WT501700AV), and 2 compression seals. These parts, when installed in your welder, allow welding aluminum with greater success. Along with this kit, you will need a spool of 0.030" (0.8 mm) aluminum MIG wire (Part Number: WE303001AV) and a bottle of 100% Argon shielding gas (available from your local welding gas supplier). Teflon ® Wire Liner The Teflon ® wire liner reduces the drag on the soft aluminum welding wire. DO NOT USE TO WELD STEEL. This liner should be used for aluminum welding only to prevent contamination. 1. Verify the welder is OFF and UNPLUGGED. 2. Open wire feed door and locate Figure 1 – Remove these three screws drive deck. Remove torch cable cover by removing three screws (see figure 1). 3. Disassemble torch handle by removing five screws (see figure 2). Figure 2 – Remove these five screws 4. Remove swan neck/valve assembly from handle (see figure 3). Figure 3 5. Using two 14 mm wrenches, hold the compression nut and loosen the jam nut (see figure 4a). Then remove the compression nut. Slide the wire liner, compression nut and compression seal out of the swan neck being careful not to kink the (1) (2) Figure 4a - Hold compression nut (1), loosen jam nut (2) (1) (2) (3) (4) Figure 4b - Wire liner (1), compression nut (2), compression seal (3), swan neck (4) 6. Straighten the torch hose and remove the existing wire liner, compression nut and compression seal. Then remove the compression nut from the wire liner. Note: sometimes the compression seal is stuck to the wire liner; therefore, new seals are included in this kit. 7. Insert new Teflon wire liner into torch hose. Slide compression nut and new compression seal onto wire liner. Slide wire liner into swan neck until it stops against the back of the contact tip. Tighten the compression nut and then tighten the jam nut. 8. Place swan neck/valve assembly into torch handle, making sure small wires are located correctly (see figure 5). Reassemble torch handle with five screws Figure 5 REMINDER: Keep your dated proof © 2005 Campbell Hausfeld/Scott For parts, manuals, product & service information IN973400AV 8/05 visit or call 1-800-746-5641 8 Installation Instructions Model WT2531 Aluminum Welding Kit Notes Notas 9. Reattach torch cable cover onto drive deck, making sure wire liner is aligned with drive roller, but not touching the roller (see figure 6). Note: Trim the liner’s length as needed. Figure 6 Smooth-Groove Drive Roller The existing serrated-groove drive roller will cut notches in the soft aluminum welding wire. These notches increase the drag within the wire liner. The smooth-groove drive roller eliminates this problem. 1. Verify the welder is OFF and UNPLUGGED. 2. Open wire feed door and locate drive deck. Release tension on swing arm by rotating tension screw down. 3. Remove roller cover by removing two screws (see figure 7). Figure 7 – Remove these two screws 4. Remove serrated-groove drive roller and replace with new smooth-groove drive roller. 5. Reinstall roller cover. Aluminum Contact Tip The contact tips in this kit have been designed specifically for welding aluminum. The hole is slightly oversized to reduce drag. There is more mass to handle the extra heat associated with aluminum welding. And, the tip is tapered for use with shielding gases. These tips are to be used with 0.030" (0.8 mm) aluminum MIG wire. 1. Remove nozzle by turning counterclockwise. 2. Remove existing contact tip by turning counterclockwise. 3. Install 0.030" (0.8 mm) aluminum contact tip. 4. Reinstall nozzle. Aluminum Welding Help • Make sure your base metal is very clean. New aluminum will oxidize almost immediately. Thin layers of oxidation are clear and cannot be seen. Use a stainless steel brush to clean the weld area and the work clamp area. Use the stainless steel brush only on aluminum to prevent contamination. • The center of the contact tip must be clean to transfer the current required for welding aluminum. Even new contact tips can benefit from cleaning with a tip cleaner. • Since aluminum conducts heat so well, higher welder output is required. Also, the wire and travel speeds need to be faster. • Work clamp connection must be thoroughly clean and as close to the weld area as possible. • When welding thin material, it is usually easier to use a "push" technique rather than a "pull" technique. • Do not use the components in this kit to weld anything other than al...