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Installation Instructions
Aluminum Welding Kit
Figure 5a
Figure 5b
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. WG3020: Use the smooth-
groove drive roller supplied with your
welder.
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1. Verify the welder is OFF and
UNPLUGGED.
2. Open wire feed door and locate
drive deck. Release tension on swing
arm by removing tension screw and
spring.
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 smooth-groove
drive roller. Install drive roller with
"0,8-0,9" stamping facing out. This
aligns the correct groove for 0.030"-
0.035" (0.8-0.9 mm) wire with the
liner.
5. Reinstall roller cover, tension screw
and spring.
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.
2
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.
