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to. working. conditions. as. regards. thickness,. earth.
connection. area,. piece. size,. material. quality;. take. the.
gun.by.the.handgrip.and.press.it.onto.the.sheet,.making.
sure.its.axis.is.perpendicular.to.the.surface.
-.. the.earth.clamp.should.be.placed.as.close.as.possible.to.
the.welding.spot.
-.. make.a.number.of.test.welds,.adjusting.the.voltage.and.
pressure.until.you.obtain.a.perfect.weld.
Note. (only. for. model. 66mF):. larger. sized. stud. bolts. (M5,.
M6),. require. higher. pressure. to. produce. a. correct. weld,.
therefore. the. sheet. to. be. welded. should. have. adequate.
mechanical.properties..For.this.reason,.in.the.body.shop,.
avoid.using.M5.and.M6.stud.bolts.
Before.carrying.out.the.next.spot-weld,.the.gun.should.be.
extracted.and.the.new.stud.bolt.inserted.into.the.stud.bolt.
holder.
The. gun. should. be. extracted,. keeping. it. perfectly. aligned.
with.the.stud.to.prevent.deformation.of.the.clamp.
WELDABILITY OF TYPICAL COMBINATIONS OF STUD
BOLT AND BASE METAL IN CAPACITOR DISCHARGE
WELDING.
It. is. important. to. make. a. careful. study. of. strength. and.
deformation. at. the. point. where. the. stud. bolt. is. welded. to.
the.base.metal..For.steel,.you.should.be.beware.of.fragility.
due.to.hardening..The.material.and.strength.of.the.stud.bolt.
are.subject.to.limited.tolerance..The.carbon.content.of.steel.
stud.bolts.should.be.≤0.2%.(cast.analysis)..The.weldability.
of.various.materials.and.the.possible.combinations.of.stud.
bolt.and.base.metal.are.shown.in.Tab..2.
N.B.. The. base. metal. surface. must. be. clean.. Layers. of.
paint,. rust,. slag,. grease. and. coatings. in. non-weldable.
metals.should.be.removed.from.the.welding.area..Do.this.
adopting. the. method. suited. to. the. job.. Base. metals. with.
layers.of.slag.and.rust.must.be.perfectly.clean.
Fig. I (adjusting.energy.and.spot-welding.pressure).shows.
the. values. of. capacitance. charge. voltage. (which. can. be.
adjusted.with.the.potentiometer).and.of.the.pressure.of.the.
pre-charge.spring,.for.the.different.types.of.stud.bolts.being.
welded.(M3,.M4,.M5,.M6,.faston.pins)..
Note:.for.ferrous.materials,.reduce.the.energy.values.in.the.
table.by.20-30%.
IMPERFECTIONS A ND REMEDIES DURING CAPACITOR
DISCHARGE STUD BOLT WELDING (FIG. H).
To.help.assessment.of.weld.quality,.the.illustration.shows.
possible. imperfections. that. may. occur. during. the. welding.
process,.with.the.corresponding.remedies.
USING THE GUN
WARNING!
-.. To.fasten.accessories.to.the.gun.chuck,.or.remove.them,.
use.a.fixed.hex.key.
-.. When. working. on. doors,. bonnets. or. boots,. you. must.
make. the. earth. connection. on. these. parts. so. as. to.
prevent.current.from.passing.through.the.hinges,.and.in.
any. case. the. connection. must. be. near. the. area. being.
spot-welded. (if. the. current. has. to. travel. long. distances.
this.will.reduce.the.efficiency.of.the.weld).
CONNECTING THE EARTH CABLE
-.. Bare.the.sheet.as.close.as.possible.to.the.point.where.
you.intend.to.work,.then.connect.the.earth.clamp.
Spot welding threaded stud bolts ( Pos.6, Fig.G ),
smooth pins (POS.5, Fig.G ), rivets (POS.4, Fig.G ),
faston holders (POS.7, Fig.G ).
Fit.the.gun.with.the.appropriate.stud.bolt.holder,.insert.the.
piece. to. be. spot-welded. and. place. it. on. the. sheet. at. the.
desired.spot;.adjust.energy.and.gun.pressure.appropriately.
and.press.the.button.on.the.gun.
Using the (optional) extractor (POS.1, Fig. G)
Coupling washers and traction
This. is. carried. out. by. fitting. and. locking. the. chuck. (POS.
3,.Fig..G).to.the.extractor.and.then.working.on.the.washer.
(POS.8. Fig.. G). that. has. already. been. screwed. onto. the.
threaded. bolt. and. starting. traction. on. the. body. of. the.
electrode.(POS.1,.Fig..G)..
Coupling rivets and traction
This.is.carried.out.by.fitting.and.locking.the.chuck.(POS.2,.
Fig..G).to.the.body.of.the.extractor.(POS.1,.Fig..G)..Make.
the. rivet. enter. the. extractor. (POS.. 4,. Fig.. G). by. pulling.
the.chuck.towards.the.hammer..After.completing.insertion.
release.the.chuck.and.start.traction..Finally,.pull.the.chuck.
towards.the.hammer.to.slide.out.the.rivet.
7. MAINTENANCE
WARNING!
MAINTENANCE WORK, MAKE SURE THAT THE
WELDING MACHINE IS SWITCHED OFF AND
DISCONNECTED FROM THE POWER SUPPLY.
ROUTINE MAINTENANCE
ROUTINE MAINTENANCE WORK CAN BE DONE BY
THE OPERATOR.
Check.the.main.power.cable.and.the.welding.cables..They.
should.be.properly.insulated.and.in.perfect.condition;.check.
twists. and. bends. carefully:. near. the. connection. terminals.
and.the.earth.clamp,.and.where.they.enter.the.gun.
Always. make. sure. the. welding. current. connection. to. the.
dinse.socket.is.clean.and.tight.(if.present.-.see.Fig..C)..
The. clamp. connected. to. the. base. metal. should. make. a.
good.contact,.and.this.will.prevent:
-.. heating
-.. sparks;
-.. unbalanced.current.circulation;
-.. damage. to. the. component. to. which. the. studs. are.
welded;
-.. variable.quality.welds;
Do. not. allow. dirt,. dust. or. filings. to. get. inside. the. welding.
machine.
Always.ensure.good.cooling.air.circulation.
Check.that.the.cooling.fan.(if.present).operates.correctly.
Check.the.stud.bolt.holders.to.make.sure.that.all.the.contact.
springs.are.properly.locked.to.the.rivets,.stud.bolts,.pins.or.
fastons.
The. clamp-holder. chuck. should. run. smoothly. along. its.
entire. stroke,. with. no. variations. due. to. friction. or. foreign.
bodies.
EXTRAORDINARY MAINTENANCE
EXTRAORDINARY
CARRIED OUT ONLY AND EXCLUSIVELY BY
EXPERT OR SKILLED ELECTRICAL-MECHANICAL
TECHNICIANS.
WARNING! BEFORE REMOVING THE WELDING
MACHINE PANELS AND WORKING INSIDE THE
MACHINE MAKE SURE THE FOLLOWING CONDITIONS
ARE SATISFIED:
- the main switch on the machine is in the "O"
position;
- the automatic circuit-breaker on the mains circuit
is in the "O" position and locked with a key or, if
there is no lock, the power supply cables have been
physically disconnected from the main supply;
- given the presence of capacitors, the power source
has been switched off for at least 5 minutes before
starting maintenance work.
If checks are carried out while the inside of the welding
machine is live this could cause serious electric shock
8
BEFORE
CARRYING
MAINTENANCE
SHOULD
OUT
BE
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