Parts / Accessories E 03 / High Quality Products for maximum requirements Made in Germany

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1 / Accessories E 03 / 20 High Quality Products for maximum requirements Made in Germany

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3 CONTENTS AC / CC Pliers Arm sets, electrodes, caps MTX 4900 / MX 4900 / MX 3900 arm sets, electrodes, caps C-Pliers C-arms, electrodes Dentpulling, studwelding, spotwelding Dentlever, wiggle wire,dent remover Air powerd tools with accessories Accessories for NON - ELEKTRON products Accessories for MIG Welding / Plasma cutting Chapter Chapter Chapter Chapter Chapter Chapter Chapter Chapter I II III IV V VI VII VIII 4.03.

4 Pliers 800 AC / 800 CC Chapter I Pos. Part No Pliers M AC for M 80 / M83 / MI 00 (Air cooled) Pliers M CC for M 80 / M83 / MI 00 (Cable Cooled with liquid) Cooling unit for / MI 00 (Required for liquid cooled Pliers or Guns) Cooling unit for M80 / M 83 (Required for liquid cooled Pliers or Guns) 2 4 Technical Data Pliers: Clamping force: with arms 20 mm / N / 400 lb / at 8 bar (5 psi) Welding leads: cross section area 20 mm² length 2,50 m (98.5 inch) M-800 AC M-800 CC Weight: at handle 3.5 Kg / 7.7 lb 3.5 Kg / 7.7 lb complete.5 Kg / 25.3 lb 2.0 Kg / 26.4 lb Cooling system: compressed air liquid cooled cables Welding current max.: at MI Amp 7000 Amp 3 Technical Data Cooling Units: Working pressure for air driven pump Circulation Capacity Recommended Coolant 8 bar / 5 psi via pressure reducer approx. 5 L/min /.5 gpm approx. 5 L / 4 gal Water and chlorine-free Disinfectant (accord. dosing instructions) 4-Mar- I

5 Pliers 800 AC / 800 CC Chapter I 2 Pos. Part No Electrode tip F Ø 2 R 6 (6 pcs.) Electrode tip A Ø 2 R 25 (6 pcs.) 00/ Electrode tip D Ø 2 (6 pcs.) All electrode arms suitable for pneumatic tongs of the system 2 00/3.9 00/3.9 Pos. Part No. Weigth 200/7.8 25/ Electrode set 0 / 20 0,8 kg,76 lb Electrode set 02/06/25, kg 2,42 lb Electrode set 03 / 08,5 kg 3,3 lb Electrode set 04 / 45 2,6 kg 5,73 lb 00/3.9 00/ Electrode set 04 / 550 3,2 kg 7,05 lb Single arm 0 / 45,45 kg 3,09 lb Single arm 0 / 550,75 kg 3,86 lb 58/6.2 58/ /7 80/ / /2.6 4-Mar- I I/ 2

6 Pliers 800 AC / 800 CC Chapter I 3 Pos. Part No. Weigth Electrode set 05,2 kg 2,64 lb Electrode set, kg 2,42 lb Electrode set 07 / 300 2,3 kg 5,06 lb Electrode set 07 / 45 2,8 kg 6,7 lb Electrode set 07 / 550 3,5 kg 7,7 lb R 25 R 8 00/ Electrode set 02 / 0 / 250,9 kg 4,8 lb 58/6.2" 3mm Ø 2 Pos. Part No Electrode miller Ø3 mm R 25 00/ Electrode miller Ø3 mm R Handle for pliers M /.5" /0.2" 00/ /0.2" 00/ /0.2" 00/ /.8" 45/ / /3.9 00/ /0" 290/.4" 4-Mar- I 3

7 Pliers 800 AC / 800 CC Chapter I 4 Pos. Part No. Length Electrode 200 mm Electrode 200 mm Electrode insulatet 90 mm Electrode 0 mm Electrode L style 70 mm Electrode U style 00 mm Electrode S style 30 mm Electrode S style 90 mm Electrode L style With Tip Clamping piece 70 mm Electrode tip Ø2 R 6 6 pcs Electrode tip R 25 6 pcs Electrode tip form D Ø2 6 pcs Tip for Electrode L Ø2 R 6 6 pcs Electrode rod material D Ø0 Cu-Cr-Zr 500 mm Electrode rod material D Ø2 Cu-Cr-Zr 500 mm Mar- I 4

8 Pliers 800 AC / 800 CC Chapter I Standard arm sets working range Pos. Part No. for Spring Balancer MI-00 / MI-00control Mar- I 5

9 Transformer Pliers MTX-4900 / Cable Pliers MX-4900 / MX-3900 Chapter II Pos. Part No Pliers MTX-4900 with a integrated power full High Frequency Transformer NOTE: Only adaptive with the welders MI-00control T and MI-00 T Features of the MTX- pliers Power full pliers with integrated High Frequency Transformer. (current up to 4 ka) 90 angle design for an unbeatable access to the most welding areas of the car body. Working horse for each car body repair expert! Very efficient cooling of electrode arms and transformer. Large field tested assortment of arm sets for the most common spot welds at the car body. Technical Data Pliers MTX- 4900: (for MI-00control T and MI-00 T) 6 bar (90 psi) 8 bar (5 psi) Clamping force: with arms 90 mm / 7.5 ~ 3300 N / 728 lb 4400 N / 970 lb with arms 60 mm / 6.3 ~ 3950 N / 87 lb 5000 N / 02 lb Welding leads: length 5,00 m / 6 6 (Option 0 m / 34 ) Welding current: max. 4 ka Handling weight: (with Balancer),0.5 kg / lb complete 9,7 kg / 2.4 lb Cooling system: Features: liquid cooling for transformer and rectifier also for the electrodes up to the cabs! Impedance measurement and automatic Electrode arm length identification* *only for MI-00control T 8-Mar- II

10 Transformer Pliers MTX-4900 / Cable Pliers MX-4900 / MX-3900 Chapter II 2 Pos. Part No Pliers MX-4900 for MI-00control with Impedance measurement and Electrode arm length identification ( liquid cooled up to the electrode tips) Pliers MX-3900 for MI-00 M 83 ( liquid cooled up to the electrode tips) Features of the MX- Pliers 90 angle design for an unbeatable access to the most welding areas of the car body. Working horse for each car body repair expert! Very efficient cooling of electrode arms and welding leads. Large field tested assortment of arm sets for the most common spot welds at the car body. Technical Data Pliers MX-4900: (for MI-00control) 6 bar (90 psi) 8 bar (5 psi) Clamping force: with arms 90 mm / 7.5 ~ 3300 N / 728 lb 4400 N / 970 lb with arms 60 mm / 6.3 ~ 3950 N / 87 lb 5000 N / 02 lb Welding leads: cross section area 50 mm² / 300 MCM length 2,50 m (8`3 ) Handling weight : (with Balancer),0.5 kg / lb complete 0,5 kg / 23. lb Cooling system: liquid cooled cables and electrodes up to the tips Features: Impedance measurement and automatic Electrode arm length identification Technical Data Pliers MX-3900: (looks like MX-4900) 8 bar (5 psi) 0 bar (50 psi) Clamping force: with arms 90 mm / 7.5 ~ 3300 N / 728 lb with arms 60 mm / 6.3 ~ 3950 N / 87 lb 5000 N / 02 lb Welding leads: cross section area 20 mm² / 250 MCM length 2,50 m (8`3 ) Handling weight : (with Balancer),0.5 kg / lb complete 9,5 kg / 20.9 lb Cooling system: liquid cooled cables and electrodes up to the tips 8-Mar- II 2

11 Transformer Pliers MTX-4900 / Cable Pliers MX-4900 / MX-3900 Chapter II 3 Pos. Art. No Electrode set 0 / 90 MX coded Electrode set 05 MX coded Electrode set / 280 MX coded Electrode set / 60 MX coded 30/ Electrode set 03 MX coded Electrode set 02 / 06 /45 MX coded Electrode L style Electrode L style with tip Tip for Electrode L style Ø 2 R Electrode U style 2 mm 48 0 Electrode cap 2 mm / R 25 (6 pcs.) Clamping Piece for Pos Electrode for Pos Set of screw in electrode tips instead of Standard cone 0 mm 0 9 Ø 2 for example in combination with Pos. 90/ / /6.3 2 mm /5 280/ 30/5 30/ / mm 30/5 45/ /0 30/5 95/3.7 8-Mar- II 3

12 Transformer Pliers MTX-4900 / Cable Pliers MX-4900 / MX-3900 Chapter II 4 Pos. Part No Electrode set 0 / 550 MX coded Electrode set 0 / 45 MX coded Single arm 04 / 550 MX coded In combination with Pos. 5 30/5.0" Single arm 04 / 45 MX coded In combination with Pos Electrode set 0/ 60 MX coded 60/ /5.0" 30/5.0" 550/2.6 45/6.3" /0.5 98/ /0.5 98/ /2.6 45/6.3" 8-Mar- II 4

13 Transformer Pliers MTX-4900 / Cable Pliers MX-4900 / MX-3900 Chapter II 5 Pos. Part No. Ø mm pcs. NEW Electrode cap type F / R Electrode cap type A / R Ø3 Ø3 Ø3 Ø Electrode cap type A / R Electrode cap type D Spare cone for Ø3 mm caps Electrode miller Ø3 mm R 25 2/3 R 8 R 25 R Electrode miller Ø3 mm R 5 2/ Electrode miller Ø3 mm R 8 2/3 20 NEW Spare O-Rings 7X Abrasive sponge middle fine 80x Abrasive sponge fine 80x50 3mm Cu-Washer 0x6x Star knop for MX Pliers M Balancer System (MI-00, MI-00control) Abrasive sponge fine grid (8) middle fine grid (7) Flexible sponge full made of abrasive material for perfect tip dressing. 8-Mar- II 5

14 Transformer Pliers MTX-4900 / Cable Pliers MX-4900 / MX-3900 Chapter II 6 Overview of the most common applications The applications of the electrode arm sets are different from body type to body type. The most successful way to get the best electrode set combination will be to make the order together with the technicians in the body shop X Mar- II 6

15 C-Pliers MC-5000 / MC-4000 Chapter III Pos. Part No C-Pliers MC 4000 with C-arm 85 LC (420 40) for MI C-Pliers MC 5000 with C-arm 85 LC (420 40) for MI-00control with Impedance measuring system 2 Features of all MC- Pliers Pneumatically electrode movement. High equal electrode force for all C-arm sets. Large inflexibility of all C-arms, minimised distortion. Safety stroke of the middle electrode, no injury. Several electrode kits for virtually options Technical Datas: 8 bar (5 psi) max. air pressure 0 bar (50 psi) Clamping force: all arm sizes 3,6 kn / 794 lb 4,5 kn / 992 lb Weight: C-arm 85 mm + leads at handle 8,0 kg / 7.6 lb complete 4 kg / 30.8 lb at Balancer system,7 kg / 3.4 lb Welding stroke: at 3,6 kn < 5 mm / Working stroke max: 05 mm / Welding leads: cross section area 50 mm² length 2,50 m / 8.2 Cooling system: liquid welding leads and electrodes C-Arm type 85 LC,5 kg / 3.3 lb 60 LC 2,0 kg / 4.4 lb 40 LC 3,5 kg / 7.7 lb Features: Pneumatically electrode movement. Equal electrode force with all C-arm types. Equal flexibilities of all C-arm types, minimised distortion. Safety stoke of the middle electrode with a reduced force to prevents against injury, maximal electrode force only for welding! C-arm set-ups with a lot of different variations are provided water stop system at all arm sets III

16 C-Pliers MC-5000 / MC-4000 Chapter III 2 Pos. Part No. Dim. X mm Dim. Y mm C-arm 85 LC C-arm 60 LC C-arm 330 / 250 LC X Y Y X C-arm 40 / 250 LC C-arm 550 / 250 LC C-arm 700 / 250 LC Y Y X X 3 Y X 6 Y X Water stop system at all arm sets! Disconnecting without coolant leakage III 2

17 C-Pliers MC-5000 / MC-4000 Chapter III 3 Pos. Part No. Piece Electrode cap type F / R Electrode cap type A / R Electrode cap type A / R 25 6 Ø3 Ø3 Ø Electrode kit for C-arm 330 / 250 LC to 700 / 250 LC Extension for C-arm 330 / 250 LC to 700 / 250 LC Electrode miller Ø3 mm R Electrode miller Ø3 mm R Electrode miller Ø3 mm R Electrode straight LC (only for C-arm 60) R 8 R 5 R Electrode kit LC (only for C-arm 60) Electrode LC bended flat end (only for C-arm 60) Electrode LC bended (only for C-arm 60) Electrode LC 29 (only for C-arm 60) Extension 60 mm with EL. cap 3 Ø Extension 86 mm wih EL. cap 3 Ø 3mm Spare O-rings Electrode for C-arm 85 LC Wheelhouse electrode type 2 for C-arm 85 LC Wheelhouse electrode type for C-arm 85 LC Electrode for C-arms 330/250 LC to 700 /250 LC Spare cone for 3 mm caps Cu washer 0x6x Clamping piece Hanger for C-arms 330/250 LC to 700 /250 LC Holding sleeve for welding leads with snap hook suitable only with: C-Arm 330/250 LC C-Arm 40/250 LC C-Arm 550/250 LC C-Arm 700/250 LC III 3

18 C-Pliers MC-5000 / MC-4000 Chapter III 4 Possible combination of C-arms Part numbers see chapter III 3 Combination with: C-arm 85 LC Combination with: C-arm 60 LC Combination with: C-arm 330/250 LC C-arm 40/250 LC C-arm 550/250 LC C-arm 700/250 LC III 4

19 C-Pliers MC-5000 / MC-4000 Chapter III 5 C-arms working range Pos. Part No Spring balancer Balancer System Holder for C-Pliers Abrasive sponge middle fine Abrasive sponge fine Bracket for C-arms Abrasive sponge fine grid (5) middle fine grid (4) Flexible sponge full made of abrasive material for perfect tip dressing III 5

20 Spot welding and Dent pulling Guns Chapter VI Pos. Part No AC Gun (Air cooled) for M 80 / M83 / MI 00 MI 00control AC Gun 4 m (only for dent pulling) (Air cooled) for M20 / M 80 / M83 / MI LC Gun (liquid cooled) for M83 / MI 00 (only for spot welding) Cooling unit for MI 00 (Required for liquid cooled Pliers or Guns) Cooling unit for M80 / M 83 (Required for liquid cooled Pliers or Guns) Technical Data Guns: AC Gun LC Gun AC Gun 4 m Welding leads: cross section area 20 mm² 20 mm² 70 mm² length 2,20 m (7.3 ft) 2,20 m (7.3 ft) 4 m (3.3 ft) Weight: complete 6.5 Kg / 3.5 lb 7 Kg / 5.4 lb 7 Kg / 5.4 lb Cooling system: compressed air liquid cooled compressed air Appliance: universal only spot welding only dent pulling Technical Data Cooling Units: Working pressure for air driven pump Circulation Capacity Recommended Coolant 8 bar / 5 psi via pressure reducer approx. 5 L/min /.5 gpm approx. 5 L / 4 gal Water and chlorine-free disinfectant (accord. dosing instructions) IV

21 Spot welding and Dent pulling Guns Chapter VI 2 2 Pos. Part No. Pieces High speed plan. hammer Extracting tip 25 3* 4* 5* 6* 7* Carbon electrode 0 mm Spot weld electrode + tip Contact U/B Contact piece SB Contact piece SB Contact piece TST 6 9* 0* Contact piece SB Contact piece TST Contact piece TST Electrode for wiggle wire Electrode tips 2 R 6 6 3* 4* 3 5* 6* 7* 8 9* 4* 5* 6* 7* 8* 9* 20* 2* 4* 5* Washers Welding studs M 4X2 50 0* 22* 6* Firtree studs 5,5X9 50 7* Firtree studs 5,5X * Firtree studs 5,5X8 50 9* 20* Firtree studs 5,5X Welding studs M 5X * Welding studs M 6X * T studs 3 X 4, T studs 5 X 0 50 Equipped with Pos.* Service box equipped with * for MI-00 / MI-00control Slide hammer Wiggle wire IV 2

22 Spot welding and Dent pulling Guns Chapter VI 3 Pos. Part No Wiggle wire (30 pieces) 32 3* Mating part GOLF 2 roof Mating part GOLF 3 roof Mating part PORSCHE roof Mating part PASSAT roof R 25 R 8 See repair manuals how to use at the car body Electrode miller Ø3 mm R Electrode miller Ø3 mm R 25 34* Allen wrench SW * Grounding clamp lever 3mm Ø 34* 35* IV 3

23 Liquid cooled Spot welding Gun Chapter VI 4 Pos. Part No Electrode LC Cu Washer Brass pipe Electrode holder Electrode tip 2 mm Ø R Connector Ground liquid cooled Gun instead of ground Welding lead to gun Welding lead to ground Code board IV 4

24 Dent pulling lever DL 0 / Slide hammer / Bear claw MH 9 Chapter V Part No Dent lever DL0 Application Easy removing of substantial and stretched dents in combination with the Bear claw included in the scope of delivery Part No Wiggle wire (30 psc) Wiggle wire (50 psc) Part No Slide hammer 2 kg Application Dent pulling in combination with Bear claw MH 9 (see below) Part No Bear claw MH 9 V

25 Dent remover DP 0, hand operated Chapter V 2 Part No Dent remover DP 0 Application Manual dent puller for application with single sided welding gun. Easy and precise pulling of small damages Part No Pointed tip Part No Round tip Part No Flat tip V 2

26 Dent remover set DRS 0, hand operated Chapter V 3 Part No Dent removal set DRS 0 Pos. Part No Electrode for wiggle wire Wiggle wire (30 pcs) Wiggle wire (50 pcs) Fixing magnet Dent pull electrode rod Spare electrode tip Pull rod Cross bolt V 3

27 Spot weld drill kit, compressed air powered Chapter VI Part No Spot weld drill kit In box Technical dates Revolutions (idle).800 U/min Weight 2,2 kg / 4.4 lb Pressure 6 bar / 90 psi Connection /4 Features Patented pneumatic spindle drive for constant drill-pressure. Drills out the entire spot weld. Detachable hook. Adjustable depth stop. Pos. Part No Drill bits HS Co 8 Ø x Drill bits HS Co 0 Ø x Drill bits HS Co-TIN 8 Ø x Drill bits HS Co-TIN 0 Ø x Drill bits VHM 8 Ø x 45 3 The drill bits Pos. 5 4 Part no are able to drill out spot welds at extremely hard sheet steel e. g. Boron Steel easily. 5 NEW Specially designed spot weld drills made of cobalt steel: These bits ( /623) are perfect for the high temperatures produced when removing spot welds. The TIN titanium drill bits provide a four times longer lifetime and a higher cutting speed. Subject to technical alterations VI

28 Body saw ABS 0, air powered Chapter VI 2 Part No Air body saw ABS 0 Technical dates Strokes per minute H/min (8 mm) Weight 2,2 kg / 4.4 lb Air pressure 6 bar / 90 psi Air input diameter /4 Features Professional air body saw, cuts intricate shapes and tight radius curves on flat and domed surfaces. Front exhaust cools the saw blade and working surface. Extra low vibration Part No Saw blade ZD teeth (5 pcs.) Saw blade ZD teeth (5 pcs.) Saw blade ZD teeth (5 pcs.) VI 2

29 Angle disc grinder C-3865, air powered Chapter VI 3 Part No Angle disc grinder C-3865 Technical data Free speed Weight U/min rpm 0,6 kg /,32 lb Pressure 6 bar / 90 psi Connection /4 Size of pad 50 mm / 2 Ø mit Gewindeaufnahme. With thread Features Low vibration angle sander with direct drive, including case and comprehensive accessories. Pos. Part No Disc sanding pad C Disc sanding pad white C Disc sanding pad yellow C Disc sanding brown ZC Disc sanding blue ZC M Disc grit 80 ZC VI 3

30 Air Drill / Belt sander Chapter VI 4 Part No Air drill Technical data Free speed Chuck diameter 400 U/min 400 rpm 0 mm Weight kg / 2,2 lb Pressure 6 bar / 90 psi Connection /4 Dimension Features 220 mm X 45 mm 8.6 X 5.7 With auto chuck and reversible left / right drive. Part No Belt sander 0 mm Technical data Free speed U/min rpm Weight 0,8 kg /,76 lb 3 Pressure 6 bar / 90 psi 2 Connection /4 Pos. Part No. Length 290 mm / Sanding belt ZC 060 grit 60 Belt size 0 X 330 mm Sanding belt ZC 080 grit 80 Features Easy belt change due to the automatic tension, revolving handle Sanding belt ZC 00 grit 00 VI 4

31 Accessories for NON - ELEKTRON products Chapter VII Pos. Art. No. Part No. For device Drill bits HS Co 8 Ø x 44 Vario Drill Drill bits HS Co8 0 Ø x 44 Vario Drill Drill bits HS Co-TIN 8 Ø x 44 Vario Drill Drill bits HS Co-TIN8 0 Ø x 44 Vario Drill Drill bits VHM 8 Ø x 44 Vario Drill Weld on electrode Airpuller AP 95 Specially designed spot weld drills. Made from cobalt steel, these bits are perfect for the high temperature generated when removing spot welds. The TIN titanium drill bits provide 4 times longer life span Saw blade ZD teeth bi metal SIG (5 pcs.) Saw blade ZD teeth bi metal SIG (5 pcs.) Saw blade ZD teeth bi metal SIG (5 pcs.) Adapter for Airpuller AP 95 M20, M80, MI-00 MI-00control 5 NEW Weld on ground (dent pulling only) M20, M80, MI-00 MI-00control Magnetic ground (dent pulling only) M20, M80, MI-00 MI-00control Extracting tip (triangle) SAH (20 pcs.) The drill bits Pos. 5 Part no are able to drill out spot welds at extremely hard sheet steel e. g. Boron Steel easily VII

32 Multicutter MC 30 / MC 40 Wearing parts kits Chapter VIII Pos. Part No Cutting nozzle long type ( pc.) Cutting nozzle Standard (0 pc.) Electrode long type ( pc.) Electrode Standard (0 pc.) Swirl ring ( pc.) Wearing parts kit ( pc.) Shield cap ( pc.) Flow meter ( pc.) (Spare part, price on request) VIII

33 MULTIMIG 300 MULTIMIG 400puls Wearing parts kits Consumables Chapter VIII 2 Pos. Part. no. MM Cart for MULTIMIG 400puls X MM Gas nozzle, cone MB 24 (ML 2400) 3 pcs. X Gas nozzle, cone MB 5 (ML 500) 3 pcs. X Fixing spring for MB 5 (ML 500) 3 pcs. X Wearing parts MB 24 (ML 2400) Nozzle base / Gas spreader Wire guide liner 5 m for CuSi / Alu wire 0,8-,0 mm Ø (identification black) Wire guide liner 4 m for CuSi / Alu wire,0-,2 mm Ø (identification red) X X X X X Contact tip 0,8 mm Ø for CuSi / Alu / Steel wire 0,8 mm Ø 0 pcs Contact tip,0 mm Ø for CuSi / Alu / Steel wire,0 mm Ø 0 pcs Contact tip,2 mm Ø for CuSi / Alu wire,2 mm Ø 0 pcs. X X X Contact tip 0,8 mm Ø for CuSi / Alu / Steelwire 0,8 mm Ø 0 pcs Contact tip,0 mm Ø for CuSi / Alu /Steelwire,0 mm Ø 0 pcs Contact tip,2 mm Ø for CuSi / Alu wire,2 mm Ø 0 pcs Contact tip,4 mm Ø for Alu wire,2 mm Ø (to weld thick metal) 0 pcs. X X X X 6 8 for MB 5 / ML for MB 24 / ML VIII 2

34 MULTIMIG 300 MULTIMIG 400puls Wearing parts kits Consumables Chapter VIII 3 Pos. Part. no. MM 300 MM Torch ML 500 Power Master 3 m X Torch ML 500 Power Master 4 m X Torch ML 2400 Power Master 3 m X Torch ML 2400 Power Master 4 m X Reel hub X X Wire feed roller 0,8 /,0 for CuSi / Alu wire 0,8 /,0 mm Ø 2 pcs. X X Wire feed roller,0 /,2 for CuSi / Alu wire,0 /,2 mm Ø 2 pcs. X X Wire feed roller 0,8 /,0 for Steel wire 0,8 /,0 mm Ø 2 pcs. X X Wire guide liner 4 m for Steel wire 0,8 /,0 mm Ø (identification red) X X For Steel wire 8 CuSi 3 and Alu-wire U U 9 For Steel wire V V VIII 3

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36 Technical specifications are subject to change without notice

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