Campbell Hausfeld WT2531 User Manual
Notes
Notas
8
Model WT2531
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IN973400AV 8/05
Installation Instructions Model WT2531
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) , smoothgroove 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
drive deck. Remove torch cable
cover by removing three screws (see
figure 1).
3. Disassemble torch handle by
removing five screws (see figure 2).
For parts, manuals, product & service information
visit www.chpower.com
or call 1-800-746-5641
© 2005 Campbell Hausfeld/Scott Fetzer
4. Remove swan neck/valve assembly
from handle (see 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
wire liner in the process (see figure
4b).
Figure 1 – Remove these three screws
Figure 3
Figure 4a - Hold compression nut (1),
loosen jam nut (2)
Figure 4b - Wire liner (1), compression
nut (2), compression seal (3),
swan neck (4)
Figure 5
(1) (2)
(1)
(2)
(3)
(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 2 – Remove these five screws
REMINDER: Keep your dated proof of purchase for warranty purposes! Attach it to this manual or file it for safekeeping.
BUILT TO LAST
Notes
Notas
7
Model WT2531
2
Installation Instructions
Aluminum Welding Kit
www.chpower.com
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.
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).
4. Remove serrated-groove drive roller
and replace with new smoothgroove 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
aluminum to prevent contamination.
If you need to weld mild steel,
Figure 6
Figure 7 – Remove these two screws
remove this kit and install the
original components that came with
your welder.
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