Sealey Electrospot7001 Instruction Manual page 6

7.1.4. SPOT WELDING PINS, RIVETS, WASHERS, SPECIAL WASHERS AND SCREWS.
Fit the appropriate electrode into the studder:
fig.3 - item 4 - for special washer (see7.1.5).
fig.3 - item 8 - for rivets.
fig.3 - item 9 - for washers (see 7.1.3).
fig.3 - item 10 - for pins.
fig.3 - items 10 & 11 - for screws.
Lock in place, then insert the item to be welded into the electrode and position on the sheet. Press the button on the studder and only
release after the green LED
7.1.5. SIMULTANEOUS TRACTION AND SPOT WELDING SPECIAL WASHERS.
Mount and fasten the spindle (fig.3.item 4) on the threaded end of the extractor (fig.3.item 1), and then fasten the other end of the
extractor into the studder and lock in place with the nut ring. Place the special washer (fig.3.item 14) into the spindle and lock in place
with the large bolt. Spot weld washer in desired position as for normal washer spot welding and then apply traction. Once finished, rotate
extractor by 90° to remove the washer which can then be re-used.
7.1.6. SPOT WELDING SHEETS ON ONE SIDE ONLY.
Fit the electrode (fig.3.item 6) into the studder and press on the surface to be welded. Press the button on the studder and release only
after the green LED
NOTE: The maximum sheet thickness that can be welded in this way is 1mm + 1mm.
This method must not be used on load bearing structures of vehicle bodies.
In order to achieve good results when spot welding sheets the following conditions must be met:
1. A perfect ground connection.
2. Sheets to be welded must be clean and free from varnish, grease, oil, paint etc.
3. Sheets to be welded must be in contact with no air gap. If pressure is required to achieve this, apply pressure with a separate tool.
4. The thickness of the upper sheet must not exceed 1mm.
5. The electrode tip must have a diameter of 2.5mm.
6. Make sure that the electrode fastening nut is tight and also that the welding cable connectors are locked in place.
7. When spot welding, press lightly (3-4kg) on electrode. DO NOT move electrode until the weld is completed - when green LED goes out.
8. DO NOT attempt to weld at a position more than 300mm from the ground connection.
7.1.7. TEMPERING AND SHEET HEATING / UPSETTING.
In this operating mode, the timer is inoperative. The operating time is determined manually by the amount of time the studder button is
pressed for. Current is controlled automatically according to the sheet thickness. Mount the carbon electrode (fig.3.item 12) on the
studder spindle and lock in place by tightening the nut ring. Touch the cleaned work area with the carbon tip of the electrode and press
studder button. Work from the outside towards the inside of the work area, using circular movements to heat the sheet, which will return
to its original position. In order to prevent the sheet from overheating too much, work on a small area and, when finished, immediately
wipe carefully with a damp cloth to cool the treated area. Alternatively fit smoothing electrode (fig.3.item 7) to use in a similar way to flat
ten sheets that have undergone local deformation
7.1.8. INTERMITTENT SPOT WELDING (PATCHING).
To weld small rectangular pieces of sheet over holes caused by corrosion or minor damage. Mount the electrode (fig.3.item 5) on the
studder spindle and tighten ring nut. Clean area to be worked on and also make sure that patch sheet is free of grease, paint or similar.
Position the patch piece and press the electrode on it, press the studder button and keep it pressed. Move the electrode during each
'pause' in the weld/rest cycle determined by the welder.
Note: The work/rest cycles are controlled automatically by the spot welder according to sheet thickness selected. Keep a light pressure
on the electrode (3-4kg) and weld along a line ideally 2-3mm in from the edge of the new piece.
To achieve good results: DO NOT weld more than 300mm from ground point.
7.1.9. USING THE EXTRACTOR / SLIDE HAMMER FOR TRACTION.
Mount and lock the hook (fig.3.item 3) onto the extractor (fig.3.item 1). Hook washer (fig.3.item 13), previously welded (see 7.1.3) and
begin traction. When finished, rotate the extractor through 90° to break off washer from weld.
To lock onto welded pins, fit chuck (fig.3.item 2) onto the extractor (fig.3.item 1). Insert previously welded pin (fig.3.items 15 &16) into
chuck whilst puiling chuck head towards extractor. Release chuck head when pin is fully inserted. Begin traction. On completion pull chuck
head back to release the pin.
goes out.
goes out.
Use patch sheet of 0.8mm maximum thickness, preferably stainless steel.
Move forwards in rhythm with the welder. Only advance electrode during the 'pauses' and stop during welding.
Original Language Version
ELECTROSPOT7001 Issue: 2 - 09/03/10