Pro Spot AL-5 User manual

All Info Copyright © Pro Spot International Inc.
Instruction Manual
MNL-AL-5-2.0
AL-5
Capacitor Discharge
Aluminum Dent
Pulling System

Pro Spot training and services
Pro Spot Distributors and Sub-Distributors are carefully se-
lected and are well trained in the collision repair industry. We offer
technical and service education at our world wide training facilities at
regular intervals so your local distributor will always be up to date and
able to pass on the latest in spot welding technology to our custom-
ers.
Customer service is an important part of any investment and
our distributors and sub-distributors will be there to support your
technical and service needs. We have a great customer service re-
cord, we tend to keep it that way.
About Pro Spot
-
Pro Spot International, Inc. U.S.A.
www.prospot.com
5932 Sea Otter Pl.
Carlsbad, CA 92010
Phone: [phone]
Toll free (US only): 877- PRO SPOT
Fax: [phone]
E-Mail: [email protected]
Contact Information
Pro Spot is certified by CASE and a member of the ICAR Industry Training Alliance
Pro Spot International, Inc., based in Carlsbad, California, manufactures resistance spot welding equipment spe-
cializing in applications for the collision repair industry. The company began in 1986. The company owns and manages
an on site machine shop, research & development department, a fabrication facility and production lines for the various
welders
Pro Spot International exports its products worldwide, export sales are managed through our headquarter office.
The company owns numerous patents for our ingenious application tools, machines, and procedures.
All Info Copyright © Pro Spot International Inc.2

Table of Contents
1.0 INTRODUCTION 4
2.0 SAFETY & ENVIRONMENTAL SPECIFICATIONS 5
3.0 GETTING FAMILIAR WITH YOUR WELDER - READ BEFORE USING 7
4.0 GETTING FAMILIAR WITH YOUR GUN 8
5.0 CREATING A PROPER GROUND 9
6.0 ADJUSTING THE ELECTRODE PRESSURE KNOB 9
7.0 GETTING READY TO WELD 10
8.0 WELDING INSTRUCTIONS 11
9.0 IDENTIFYING COMMON ISSUES 12
10.0 PRO PULL ASSEMBLY INSTRUCTIONS 13
11.0 WELDER PARTS LIST 16
12.0 WELDER GUN PARTS LIST 18
WARRANTY REGISTRATION 19
WARRANTY 20
All Info Copyright © Pro Spot International Inc. 3

All Info Copyright © Pro Spot International Inc.4
Introduction
1.0
Congratulations on aquiring your new PRO SPOT AL-5 Welder!
Team Pro Spot looks forward to supporting you.
The following information will be needed when you call Pro Spot.
* MODEL TYPE: AL-5
* SERIAL NO:
The serial number is located on the back of the unit.
For parts or service contact your local distributor,
Local Number:_____________________________
or in the U.S. call: Toll Free: 1-877 PRO SPOT or 1-760-407-1414
for a customer service representative.
Visit Pro Spot On-Line: www.prospot.com Email: [e-mail]
NOTE: You can now order parts online at prospot.com/store/
Pro Spot’s AL-5 Capacitor Discharge Stud Welder is designed for aluminum dent pulling but can also be used
with steel studs for welding to UHSS panels with no or very little heat applied to the panels. The welder is
very easy to use and is controlled by one knob to adjust weld power. The welder auto detects the line
voltage 110/240 VAC.
NOTE: This instruction manual provides advice as well as instructions for installation, operation, maintenance
and troubleshooting.
IMPORTANT! Read this manual carefully to become familiar with the proper operation of the welder.
Do not neglect to do this as improper handling may result in personal injury and damage to the
equipment.
IMPORTANT! Lisez ce Mode d’Emploi attentivement an de vous familiariser avec le bon
fonctionnement du soudeur. Ne négligez pas de le faire puisque une mauvaise manipulation peut
conduire aux blessures et dommages à l'équipement.
The drawings in this manual are presented for illustrative purposes only and do not necessarily show the
design of the equipment available on the market at any given time. The equipment is intended for use in
accordance with current trade practice and appropriate safety regulations. The equipment illustrated in the
manual may be changed without prior notice.
The contents in this publication can be changed without prior notice.
This publication contains information that is protected by copyright laws. No part of this publication may be
reproduced, stored in a system for information retrieval or be transmitted in any form, in any manner
without Pro Spot International, Inc.’s written consent.
Conformity with directives and standards: AL-5 complies with UL, EN, and CE Standards.

All Info Copyright © Pro Spot International Inc. 5
Safety
2.0
2.0 Safety & Environmental Specications
The AL-5 Stud welder is designed for indoor use - Protection Degree IP21.
The AL-5 Stud welder is designed to operate from -10º C to 40º C.
The unit may be stored and transported in an ambient temperature from -20º C to +55º C. The unit
can be operated at 95% Relative Humidity (RH). For operation above 1000m consult the
manufacturer. Do not operate the unit on a slope of more than 10º. The unit meets the requirements
of IEC|EN60974-1 2005 third edition and UL60974-1 2nd edition. E.M.C. classication CISPR 11,
FCC 15.107(b), Class A.
NOTE: Heating tests were performed at room ambient temperature and the duty cycle at 40º C has
been determined by simulation.
2.1 General
The AL-5 stud welder has been designed and is tested to meet strict safety requirements. Please read
the following instructions carefully before operating the AL-5 and refer to them as needed to ensure
the continued safe operation of the welder.
Information provided in this manual describes the suggested best working practices and should in
no way take precedence over individual responsibilities or local regulations.
The AL-5 Stud Welder is designed to comply with all applicable safety regulations for this type of
equipment. During operation, it is always each individual’s responsibility to consider:
• Their own and other’s personal safety.
• The safety of the welder through correct use of the equipment in accordance
with the descriptions and instructions provided in this manual.
By observing and following the safety precautions, users of the AL-5 will ensure safer
working conditions for themselves and their fellow workers.
2.2 Warnings and Important Notices
The following types of safety signs are used on the equipment and in Pro Spot’s Instruction Manuals:
Prohibited.
Prohibits behaviour that
can cause injury.
Caution.
Read instruction manual.
Command.
Calls for a specific action.
Warning.
Notice of personal injury risk and
or damage to equipment.
Warning.
Some parts of the welder may become
hot after prolonged use.
! ! Attention!
Lire Mode d’Emploi.
Interdit.
Interdit aux comportements
qui peuvent provoquer des blessures.
Commande.
Appelle à une action spécifique.
Avertissement.
Avis de risque de blessure personnelle
et / ou d’endommager l'équipement.
Avertissement.
Certaines parties du soudeur peuvent devenir
chaudes après une utilisation prolongée.

All Info Copyright © Pro Spot International Inc.6
Safety
2.0
The following warnings and important notices are used in the instruction manual:
WARNING! Do not operate or place
WARNING! Do not place the welder on
WARNING! All electrical connections
must be made by a qualified electrician.
Risk for electrical shock.
WARNING! Loose cables and hoses
present tripping risks. Risk for injuries.
WARNING! Make sure to use welding
goggles when stud welding. The sparks
and UV light might otherwise injure the eyes.
WARNING! Sparks from welding
WARNING! Risk for damage to materials
close to the weld, e.g to glass or textiles.
WARNING! All service and maintenance
must be carried out by Pro Spot service
personnel and service support. Risk for
electrical shock.
WARNING! If you are a Pro Spot employee
unplug the welder from the wall outlet before
servicing, cleaning, or maintenance. Risk for
electrical shock.
IMPORTANT! The AL-5 welder may only be
used by qualified personnel. The user of
the welder must have knowledge of stud welding
and of alignment of collision-damaged vehicles.
WARNING! Do not use around combustible
gas.
the welder near water, in wet locations
or outdoors. Risk for injuries or damage
to the welder.
unstable or uneven ground. The welder
might tip causing personal injuries or
serious damage to the welder.
could start a fire. Risk for injuries.
ATTENTION! Ne pas faire fonctionner le soudeur
près de l'eau, en voie humide , ou à l’éxterieur .
Risque de blessures ou de dommages au
soudeur.
ATTENTION! Ne placez pas le soudeur sur un sol
instable ou irrégulière. Le soudeur peut basculer
causant des lésions corporelles ou des dommages
graves au soudeur.
ATTENTION! Toutes les connexions électriques
doivent être faites par un électricien qualifié.
Risque de choc électrique.
ATTENTION! Câbles et tuyaux lâches présentent des
risques de déclenchement. Risque de blessures
ATTENTION! Veuillez utiliser des lunettes de soudeur
sur goujon. Les étincelles et lumiére UV pourraient
autrement blesser les yeux.
ATTENTION! Étincelles de soudure pourrait provoquer
une incendie. Risque de blessures.
ATTENTION! Risque de dommages aux matériaux à
proximité de la soudure, par exemple verre ou textiles.
ATTENTION! Ne pas utiliser à proximité de gaz
combustible.
WARNING! Always use in well ventilated
area.
ATTENTION! Toujours utiliser dans un endroit bien
ventilé
ATTENTION! Tout le service et l'entretien doivent être
effectués par personnel et soutien de service Pro
Spot. Risque de choc électrique.
ATTENTION! Si vous êtes un spot employés Pro
débranchez le soudeur de la prise murale avant de
l'entretien , le nettoyage ou l'entretien . risque pour
choc électrique .
IMPORTANT! Le soudeur AL-5 peut seulement être
utilisé par personnel qualifié. L'utilisateur du soudeur
doit avoir une connaissance de soudage par points et
l'alignement des véhicules endommagés par collisions.

All Info Copyright © Pro Spot International Inc. 7
Getting Familiar With Your Welder
3.0
ON / OFF Switch
Rear View
Input Cable
Front Panel Zoom
Overheat Light
(OH)
Over Voltage Light
(OV)
Ground Light
(GRD)
Ready Light
Power Light
(ON)
Ground
Cable 1
Ground
Cable 2
Ground
Cable 3 Positive
Cable 4
Voltage Adjustment
Knob
ON / OFF Switch
(Not Shown)
Input Cable
Grounding Plate
AL-5 Stud Gun

Getting Familiar With Your Gun
4.0
All Info Copyright © Pro Spot International Inc.8
Trigger
Switch
Stud Electrode
Electrode Shaft
Set Screws
Adjustable Electrode
Pressure Knob
Command
Cable
For Trigger
Positive
Cable
Stud

Creating A Proper Ground
5.0
All Info Copyright © Pro Spot International Inc. 9
Adjusting The Electrode Pressure Knob
6.0
Ground Plate
Clean surface, weld a stud using the AL-5.
Place the ground plate on top of the stud, use
a wing nut or similar to tighten the plate to the panel.
The closer the ground to the weld location, the better.
Ground Clamp
Alternative method to achieve ground.
Clean surface on work piece and use ground
clamp in this location. The closer the ground
to the weld location, the better.
Metal Thickness
0.6 - 0.8mm
0.8 - 1.0mm
1.0 - 2.5mm
Set Knob to:
1 - 2 on Dial
1-3 on Dial
2-4 on Dial

Getting Ready To Weld
7.0
All Info Copyright © Pro Spot International Inc.10
Point Do Not Use
Pressure
The Arc melts the point Base of stud is
fused to the panel
To Weld:
Insert a threaded stud into the matching electrode holder.
Place the gun in a perpendicular 90° position to the weld area.
Figure 3
90
Figure 1
When the stud is placed on the panel, the GRD (ground) Light should turn on and indicate that the
ground circuit is complete. If the voltage setting is changed, the ready light will go out until the
correct capacitor voltage has been verified. Once the correct capacitor voltage has been verified,
the light will turn on again.
In normal operation, the indicator light
on the front panel should be as
follows:
OV
OH
GRD
READY READY and ON
lights are illuminated
when the welder is on.
ON
The point on the stud creates an arc and the pressure on the stud collapses the point and melts
the base of the stud to the panel. All of this occurs in milliseconds to create a proper weld, if the
time were longer it could damage or blow a hole in the panel.
NO GAP
Setting the Weld Voltage:
4mm
5mm 70-110
6mm 80-130
60-90
Stud Diameter
Aluminum
Set weld knob to:

Welding Instructions
8.0
All Info Copyright © Pro Spot International Inc. 11
1.
2.
3.
AluminumAluminum
Place stud in
desired location.
Do not apply pressure
to gun yet.
Squeeze and hold trigger.
Again, do not apply pressure
to gun yet.
With trigger still squeezed, apply
downward pressure until
the gun fires and the weld
has been made.
Aluminum

Identifying Common Issues
9.0
All Info Copyright © Pro Spot International Inc.12
1. Make sure the point ONLY touches the surface.
GOOD! Stud flush to electrode. GOOD.
2. Make sure the point ONLY touches the surface
GOOD! Stud can extend 1/8”(2mm) from electrode. OK.
3. Point and head of stud touches the surface. BAD!
4. Head of stud touches the surface. BAD!
5. Electrode touches surface. BAD!
6. No point on stud. BAD! Will not work.
1.
3.
5.
4.
6.
2.
!DAB.tnioPoN!DOOG.tnioP

Pro Pull Assembly Instructions
10.0
All Info Copyright © Pro Spot International Inc. 13
Step 1
Take the shaft assembly apart as seen below
Step 2
Remove the Black handle from the Pro Pull gun as seen below.

Pro Pull Assembly Instructions10.0
All Info Copyright © Pro Spot International Inc.14
Step 3
Step 4
Insert the large shaft into the back of the gun and slide the 90 degree holder into the
slot on the large shaft and push down until it goes flat over the handle stud. You might
need to back the large nut off to allow that piece to fit into the slot. As seen below.
Tighten the large nut to the back of the Pro Pull handle. Hand tightening should be
sufficient. As seen below.

Pro Pull Assembly Instructions
10.0
All Info Copyright © Pro Spot International Inc. 15
Step 5
Slide the threaded rod through the main shaft, put the washer on the threaded rod and
put the wing nut on as well. As seen below.

Welder Parts List11.0
All Info Copyright © Pro Spot International Inc.16

Welder Parts List
11.0
All Info Copyright © Pro Spot International Inc. 17
2
1
3
5
4
NOT INCLUDED
ITEM NO.
PART NUMBER
DESCRIPTION
QTY.
1
90-0155
COVER
1
2
51-0055
PULL HANDLE
1
3
S-89
M6 X 25 SHCS
2
4
S-97
M4 X 8 PHMS
12
5
80-5155
LABEL, COVER
2
D
C
B
A
A
B
C
D
SCALE:
ASSY. NO.
SHEET
1
OF
1
REV.
1
2
3
4
5
6
7
8
8
7
6
5
4
3
2
1
REVISIONS
REV.
DESCRIPTION
DATE
APPROVED
COVER
SA-0002
A
NONE
JC
12/7/09
RELEASED FOR PRODUCTION
A
AL-5
WHERE USED

Welder Gun Parts List12.0
All Info Copyright © Pro Spot International Inc.18

4/12/2012
Pro Spot International Inc., a California corporation, (hereinafter ‘Pro Spot’)
warrants to the original purchaser (hereinafter ‘Purchaser’) of Pro Spot product(s)
referred to in this Purchase Order (hereinafter ‘Pro Spot Product’) in lieu of all other
warrants that Pro Spot International Inc. of Carlsbad, CA shall be free from defects in
material and workmanship under intended use and service for a period of one (1) year
after delivery of the Pro Spot Product to Purchaser.
Pro Spot’s Obligation under this warranty shall be limited to the repair or
exchange, at Pro Spot’s option of any part or parts, which may prove defective under
intended use and service as determined by Pro Spot after said part or parts have been
returned to and examined by Pro Spot whose address is 5932 Sea Otter Place, Carlsbad
CA 92010. Pro Spot will pay for standard transportation on outgoing warranty related
parts. Charges for expedited shipping will be the responsibility of the customer.
This warranty is in lieu of all other warranties, express or implied, including the
warranties of merchant ability and fitness for a particular purpose. Pro Spot shall not
be liable under expressed or implied warranty for incidental or consequential damages
or other obligations or liabilities on the part of the purchaser.
Pro Spot neither assumes nor authorizes any other person to act on behalf of Pro
Spot’s liability in connection with Pro Spot product.
The above limited warranty does not Apply to damage of Pro Spot product caused
by accidents, alterations, negligence, tampering or improper or unreasonable use or
failure to provide reasonable maintenance.
Pro Spot makes no warranty whatsoever in respect to accessories or parts not
supplied by Pro Spot.
Pro Spot reserves the right to make changes in the design of any product at any
time without obligation for retroactive action to the Pro Spot Product. Failure to
employ, attach, and or use any and all recommended safety devices (including
electrical grounding) and failure to follow and or comply with any recommended safety
procedure shall constitute a waiver of this limited warranty. Pro Spot shall not be
responsible for any incidental or consequential damages as a result of the
aforementioned.
Purchaser is not considered to be a ‘consumer’ under Magnuson-Moss Warranty
Act, but shall be considered a merchant engaged in commerce.
This warranty shall apply within the boundaries of the UNITED STATES and
CANADA.
PRO SPOT INTERNATIONAL INC.
~ AL-5 PRODUCT WARRANTY ~

All Info Copyright © Pro Spot International Inc.20
AL-5 WARRANTY CARD
5932 Sea Otter Place
Carlsbad CA 92010 USA
FAX [phone] PHONE [phone]