Magna-Spot® Studwelder
Contents
1. An adequate power supply is required for proper welding operation The welder is provided with a 9 foot power cord which should be suitable for most work stations If an extension cord is required it must be a three wire grounded cord with a minimum of 12 AWG conductors Cord must not exceed 10 feet in length Reduced welding capacity will result from the use of undersized or long extension cords GENERAL WELDING PROCEDURE Select proper electrode tip for work to be performed Insert electrode tip into welder tapered end first and rotate slightly for a tight fit Fig 1 Use opposite procedure to remove electrode tip A box end wrench can be used to twist electrode slightly to loosen Proper welding requires that the surface to be welded be clean bare metal free of paint primer oil and dust Grind area to be welded to expose bright metal approximately one inch all around area to be welded Insert pin or rivet to be welded in electrode tip and place tip of electrode against exposed metal Press until outer electrode tube is in full contact with bare metal Hold welder in this position and depress trigger for one half to one second A proper weld is achieved when the heat affected area around the weld is approximately a 1 4 in diameter To prevent sparking do not pull electrode tube back until trigger is released Figure 1 Do not hold trigger for more than one second as burn through may result Operating the welder beyond its duty cycle one2. second on 60 times per hour will result in tripping of the circuit breaker Allow welder to cool for one minute before resetting the circuit breaker and resuming welding DENT REMOVAL WITH MAGNA PINS Prepare metal at damaged area per above instructions Insert Magna Pin electrode tip into welder followed by CG a Magna Pin Fig 2 Use 2 0mm pins for dent removal on lightweight body panels and 2 5mm pins for posts and heavier panels Weld pin as instructed above Magna Slide Hammer T Puller or Clamp may be used for dent repair depending on extent of damage and panel thickness Fig 3 Grip pins 1 2 inch from surface and apply steady pressure while working dent with appropriate body hammer Slide hammer action may be used for more extreme pulling difficult areas and to place pins close together for more _ amp 3 3 effective pulling with clamps Rotate wing nut on Magna Figure 3 i Clamp clockwise to tighten Strike end of hook with hammer to release then loosen nut Figure 2 Rotate head of Slide Hammer clockwise 1 4 turn to grip pins opposite direction to release Rotate knurled wheel of T Puller back to lock pin for pulling To release push puller forward while rotating wheel forward Electrode Extension and Adapter Tube may be used for welding in Use side cutting wire cutters to remove studs after repair Rock pin and twist slightly until it breaks off DENT REMOVAL WITH MAGNA WIRE Prepare metal at damaged area
3. 70 19 MACHINE SCREW SLOTTED 1032 X 7 8 2 J P1007 44165 4 HEX NUT 1 4 20 2 44015 20 CIRCUIT BREAKER 1000 1500 SERIES 120V 1 J P10091 52356 5 LOCK WASHER SPLIT 1 4 2 44345 CIRCUIT BREAKER 1000 1500 SERIES 240V 1 J P10093 52351 6 LOCK WASHER SPLIT 5 16 44350 CIRCUIT BREAKER 2000 SERIES 120V 1 J P10092 52360 7 BRAIDED STRAP J P1029 52205 21 INSULATOR ELECTRODE TUBE JP1013 22282 8 MACHINE SCREW SLOTTED 10 32 X 1 3 4 6 J P1005 44170 22 CAP SCREW HEX 1 4 20 X 5 8 GR5 44070 9 CASE RIGHT HAND CALL B RETAINER MPS SYSTEM 1 JP1017 22550 10 FLAT WASHER SAE 1 4 4 44260 24 WASHER MPS SYSTEM JP1018 44285 1 CAP SCREW HEX 1 4 20 X 3 4 GR5 44072 5 SLIDING ELECTRODE INCLUDES RETAINER J P1011 11122 12 TRANSFORMER 1000 1500 SERIES 120V J P0081 52430 26 SPRING SLIDING ELECTRODE JP1015 61280 TRANSFORMER 1000 1500 SERIES 240V J P10083 52433 27 ELECTRODE TUBE ASSEMBLY JP1016 12205 TRANSFORMER 2000 SERIES 120V J P10082 52440 28 WARE ASSEMBLY BARE J P1041 52210 B INSULATOR TRANSFORMER 1 J P1028 52405 2 WRE ASSEMBLY FORK 1 J P1040 52215 4 HEX NUT 10 32 8 J P1006 44010 30 TERMINAL CLOSED END 2 J P1036 52055 5 CASE LEFT HAND CALL 31 MAGNET MPS CASE J P1019 95382 6 POWER CORD J P1000 52010 32 INSULATOR MAGNET J P1031 52407 FIVE YEAR LIMITED WARRANTY Motor Guard Corporation assumes the responsibility of providing products that are free from defects in workmanship and material Should a product fail due to a defect in workmanship or material Motor Guard Co
4. INSTRUCTION MANUAL Magna Spot Studwelder Models JO1000 JO1500 JO2000 AN WARNING Read and understand all instructions before attempting to operate tool Failure to follow instructions may result in electric shock fire and or serious personal injury IMPORTANT SAFETY INSTRUCTIONS To reduce the risk of serious injury and or property This welder must be connected to a properly damage observe all warnings and instructions while grounded outlet installed in accordance with all local operating the welder Keep work area clean and well lit codes and ordinances Never remove the grounding Maintain tool in top condition and obtain service from prong or modify the plug in any way Do not use adapter manufacturer if tool malfunctions Use only accessories plugs Consult an electrician if you are in any doubt as to and replacement parts that are provided by the whether the plug is properly grounded Avoid bodily manufacturer contact with grounded surfaces To reduce the risk of electrical shock Do not expose Do not operate tool in explosive atmospheres such welder to rain or wet conditions Water entering tool will A as in the presence of flammable liquids gases or dust increase the risk of electrical shock Unplug welder when Welders create sparks which may ignite dust or fumes not in use Do not operate welder with any portion of the Use in well ventilated areas only Welders generate heat housing removed Disconnect welder from power
5. ctrode Tip or Electrode Tube not Clean Pins Corroded Not Clean Improperly Sized Extension Cord Weld Time Too Long Base Metal Too Thin MAGNA SLIDE HAMMER Heavy duty construction with quick release chuck to grip pins firmly without slipping Cast iron slide weight and comfortable vinyl grip J20003 MAGNA CLAMP Constructed of heat treated hardened steel with quick wing nut adjustment Clamps on to multiple pins and makes quick work of pulling on posts and other heavy sections J20016 MAGNA T PULLER A compact tool for small damage repair on lightweight metal Convenient thumb wheel locking and a firm grip Hand pulling reduces over pull for detail work J20017 MAGNA CLAW For use with Magna Wire Five finger claw features all welded construction and self leveling design to pull low spots first Excellent for creases J20037 Remedy For malfunctions not covered by this chart contact place of purchase or manufacturer for service Check for power at outlet Replace fuse or reset circuit breaker Ensure that electrode tube is in full contact with clean base metal for proper grounding Increase weld time to achieve proper weld Wait for welder to cool Reset circuit breaker on case Remove all paint rust dust and oil to obtain a dry bright surface Welder is designed for use on sheet steel of the type and thickness used in automobile construction Remove all carbon and oxidation from electr
6. hrink it back to its original shape To remove high spots and repair pin weld points place rounded tip of electrode directly on high spot and Figure 5 depress trigger for one half second Repeat as needed A gentle hammer on heated metal may be used for heavier damage 33115 Rev 10 08 Page 2 MAINTENANCE Disconnect welder from power source and allow all parts to cool before performing service or repair Inspect power cord at each use for signs of wear or damage Do not operate welder if wear or breaks in insulation or wire are present Obtain repair service for damaged power cord Clean electrode tips and electrode tube periodically Steel wool or a fine wire brush can be used to remove oxidation and carbon from electrode surfaces Replace electrodes when they become excessively worn Inspect case switch and circuit breaker periodically and obtain service if damage is present TROUBLESHOOTING Troubleshooting of internal parts must be performed by qualified persons The following chart is intended to provide remedies for simple problems that may be encountered when using the welder Trouble No Output Low Output Poor Weld Quality Pins Won t Hold Burn Through at Point of Weld ACCESSORIES 33115 Rev 10 08 Possible Cause Open Line Fuse or Tripped Line Circuit Breaker Tripped Circuit Breaker On Welder Case Weld Circuit Not Complete Weld Time Too Short Work Surface Not Clean Base Metal Too Thick Ele
7. ode tip and electrode tube to expose clean copper Clean pins to remove contaminants and let dry Sand a small area on tip of pin to expose clean metal Decrease weld time to prevent burn through Do not use an extension cord if at all possible Check instructions for recommended gauge and cord length Check instructions for proper material and thickness lt SS HEN ELECTRODE TIPS Machined from high quality copper for highest conductivity Covers all applications from Magna Pins J20007 and Trim Rivets J20009 to Shrinking J20006 ELECTRODE ADAPTERS Adapter Tube J20022 extends tip of welder for use with Magna Wire Electrode Tip J20020 or Electrode Extension J2001 1 for tight spots or side by side pin welding MAGNA PINS and TRIM RIVETS Copper coated steel is soft for easy flexing and grinding but delivers a 500 Ib pull In two sizes 2 0 mm J20014 2 5 mm J20015 Trim rivets J20012 for repair of all molding MAGNA WIRE Corrugated wire is copper coated steel Use to pull out long creases evenly with the Magna Claw In two sizes 16 Ga J20024 and 12 Ga J20025 Page 3 REPLACEMENT PARTS Ray TEM _DESCRIPTION QIY PARTNO ORDER NO MEM DESCRIPTION QIY PARTNO ORDER NO 1 INSULATOR SLEEVE J P1030 52410 17 TRIGGER SWITCH 1 J P1010 52310 2 HEX NUT 5 16 18 BRASS 2 J P1020 44025 18 BOOT TRIGGER SWITCH 1 J P1039 52305 3 FLAT WASHER SAE 5 16 BRASS 2 JP1021 442
8. per above instructions Slide adapter over outer electrode tube Tap into place as required to seat firmly Insert Magna Wire electrode tip into welder Use 16 Ga wire for dent removal on lightweight body panels and 12 Ga wire on heaver panels Place wire between body panel and tip of electrode as shown Fig 4 Weld as instructed above Weld wire at each contact point or at alternating points as required Take care not to burn through wire by applying too much heat Use Magna Claw or other device to work crease out starting at one end and working to the other Magna Claw fingers provide self leveling action by pulling deeper recesses first until dent is removed Use pliers to remove wire by rocking back and forth at weld points TRIM RIVET INSTALLATION Prepare metal at area of rivet installation per above instructions Insert trim rivet electrode tip into welder Figure 4 followed by trim rivet Fig 5 Rivet will be held by magnet in electrode Weld as instructed above SHRINKING STRESSED METAL Shrinking electrode tip can be used to raise low areas or shrink high spots Prepare area around damage as instructed above Insert shrinking electrode tip into welder To remove low spots place rounded tip of electrode at several points around spot and depress trigger for one half second two or three times Be sure outer electrode tube is in contact with bare metal while doing this Immediately apply cold blocking or wet cloth to area to s
9. rporation will repair or at its option replace the product without charge other than the transportation charges provided that the product is returned to the factory transportation prepaid within Five 5 Years of the date of purchase Please contact Motor Guard Corporation for return authorization and shipping instructions This limited warranty does not cover normal wear and tear or damage to the product due to neglect misuse or accident nor does it cover any loss damage or expense either direct indirect or consequential arising from the non function of this product See enclosed warranty card for coverage details and instructions for obtaining warranty service OBTAINING SERVICE To assure product safety and reliability repairs maintenance and adjustments should be performed by authorized service centers using replacement parts provided by the manufacturer To obtain service return tool to place of purchase or contact the manufacturer directly Motor Guard Corporation 580 Carnegie Street Manteca CA 95337 U S A Toll Free 800 227 2822 info motorguard com Hours Mon Fri 8 00 am to 5 00 pm PST 33115 Rev 10 08 Page 4
10. supply which can ignite surrounding materials causing fires Do before servicing any part of the welder Failure to follow not use welder on body panels containing insulating these instructions will increase the risk of electrical shock material which may be ignited by the heat Do not abuse power cord Never use the power cord for A Always wear proper personal protection when A N carrying pulling or unplugging the welder Keep power operating welder Proper eye protection is required to cord away from heat sharp edges and moving parts reduce the risk of eye injury from sparks and molten Damaged cords increase the risk of electrical shock reduce the risk of burns Allow parts to cool before handling SAVE THESE INSTRUCTIONS IF YOU HAVE ANY QUESTIONS ABOUT THE OPERATION OF PRODUCT CALL TOLL FREE 800 227 2822 8 00 am to 5 00 pm Pacific Time Monday through Friday Replace power cord immediately if it becomes damaged O metal Adequate gloves and clothing are required to PREPARING TOOL FOR USE Read and understand all warnings and instructions prior to use For 120V operation in the US and Canada a three prong plug is provided For units rated at 240V a field supplied approved plug must be installed by the user Consult an electrician for the proper connector Supply circuit receptacle conductors fuses and circuit breakers must be capable of handling a 15 ampere load Welder should be the only device connected to the circuit being used
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