background image

 
Bolt Pro Inductor

 

10

 

 

 
 
 
 
 
 
 
 
 
 
                                                       

 

The Bolt Pro inductor is used for intense heating of rusted or stuck parts such as nuts and bolts.  When 
using the Bolt Pro tip to loosen stuck nuts and bolts, it is OK to use full power to start with. Other uses 
include caulking removal from truck beds and trunks of sedans, as well as soldering large electrical 
connectors and metal forming. 

 

 

Removing stuck or rusted bolts: 

 

The Bolt Pro is particularly useful in removing stuck or rusted nuts and bolts.  It is better than an oxy-
acetylene torch in several ways: 
 
1.  It heats only the metal parts positioned within the gap and without flames that can set fire to the 

many plastic parts in today’s cars. Thus, reduced fire hazards. 

2.  Unlike the torch which tends to heat both the nut and the bolt, the Bolt Pro can be applied to the nut 

only, heating it and making it expand more than the bolt and thus easier to break loose. 

3.  The Bolt Pro plugs into the CarDuction 33, it is light weight and portable, and ready for instant use. 
4.  It is not necessary to heat fasteners to a red color.  In most cases, only mild heat is required to free 

the seized fastener.  Prolonged exposure of the Bolt  Pro Inductor to extreme  heat will shorten the 
life of the inductor, and could cause un-warranted damage.   

5.  It is recommended to maintain an air gap between the bolt pro inductor and the part being heated.  

A small piece of welding blanket or fiberglass cloth can be placed over the jaws of the Bolt Pro 
Inductor to help shield it from the radiated heat from the fastener, as well as protect it from 
accidental contact with a hot part. If the Bolt Pro inductor is in contact with the hot part, it could 
cause un-warranted damage. The maximum temperature allowed for he inductor is 150°. 

 

 

Bending metal parts:  

 

The Bolt Pro can also be used to rapidly bend small round or flat steel stock for most any purpose. 

 

Soldering large electrical connectors.   

 

First crimp the connector to the wire  

 

Place the barrel of the connector in the corner of the jaws of the Bolt Pro Inductor.   

 

Apply heat by depressing the foot switch.  

 

Apply solder once sufficiently heated 

 

Shrinking sheet metal: 
Place the end of the Bolt Pro tip onto the area of the sheet metal to be shrunk.  Leave a small gap between 
the tip and the sheet metal if possible.  This will help extend the life of the tip.  Activate the switch and heat 
the metal to your liking.  Tap the high spot down and cool.  Grind area clean prior to shrinking to help 
eliminate toxic fumes and smoke. 

 

NOTE! Never apply power to an unloaded heating inductor.  The body panel or metal object to be 

heated acts as a load to absorb the energy generated by the inductor.  Without the load, the 

inductor will overheat.  Overheating the inductor can cause damage and/or personal injury. The 

Bolt Pro inductor shall not be in contact with hot parts for tool long time (temperature max 150 °C). 

Summary of Contents for Car Duction 33

Page 1: ...Car Duction 33 Induction Heating System Owner Operator s Manual GYS S A S Tel 33 0 2 43 01 23 60 www gys fr email contact gys fr ...

Page 2: ... Introduction and Warranty 3 Specifications 4 Connections and Utilization 5 Usage of the Body Pro Inductor 9 Usage of the Bolt Pro Inductor 10 Usage of the Glass Pro Inductgor 11 Usage of the Magnepopper Inductor 15 Routine Maintenance 17 Spare Parts 18 Product Registration 21 ...

Page 3: ...g above floor level Keep all panels and covers securely in place SIGNIFICANT DC VOLTAGE exists after removal of input power on inverters Turn Off inverter disconnect input power Wait 5 minutes before removing top cover to allow time for AC and DC capacitors to discharge INDUCTIONHEATINGcan causeburns Hot parts and equipment can injure Do not touch hot parts barehanded Allow cooling period before h...

Page 4: ...tion regularly checked and maintained Keep high frequency source doors and panels tightly shut Do not use the CarDuction Induction System near driver or passenger air bags The heat produced by the CarDuction can ignite the airbag propellant causing the bag to inflate without warning Refer to vehicle manufacturer s service manual for exact location of all airbags before working on a vehicle Be awar...

Page 5: ...attachments do not get hot or produce any heat Only an invisible magnetic field is emitted from the inductor heads WARRANTY Ajax Tocco offers a 1 year guarantee from the date of the delivery for the power supply This guarantee covers material defects and assumes normal care and maintenance Heating inductors are not covered by warranty and are considered consumable items Inductors are guaranteed to...

Page 6: ...ply only attachments and peripherals increase weight Input rated output Input Voltage 120 240 Vac 50 60 Hz 1 phase Input Current 15 amps Output maximum values to induction coil Power 1500 3000 Watts Voltage 400 Vrms 45 60kHz 1 phase Current 60 amps 14 P F minimum Cooling Forced air cooling via internal cooling fans Operating Temperature 125F 52C Max ...

Page 7: ... the system has to be shipped back to our factory for future service Ajax Tocco Magnethermic will not guarantee safety of the system if shipped in non Ajax Tocco Magnethermic approved packaging CONNECTION OF ELECTRIC SUPPLY The heater is designed for 120 or 240 Vac Single Phase 50 60 Hz input It is fitted with an IEC C 20 input receptacle on the rear that allows different cord configurations to be...

Page 8: ...olding the jumper in place Do not completely remove the bolts Loosen the adjacent bolt to the right or left of the jumper depending on which voltage configuration it is currently in Slide the jumper from beneath the bolts and re install the jumper in the alternate position The center bolt standoff is always connected to the jumper Tighten all bolts after re locating the jumper A schematic illustra...

Page 9: ...heating inductor that is suspect of an unsafe condition 2 Connect one of the supplied heating inductors 7 to the induction power source by inserting the plug into the HF receptacle 8 located on the front of the induction power source The inductors are keyed and will only connect in one direction One side of the inductor plug has a hole in it see illustration on next page which marks the top of the...

Page 10: ...he inverter power supply A schematic detailing the proper location of the jumper is located just in front of the jumper inside the cabinet 5 Close circuit breaker CB1 5 The circuit breaker should remain closed in the on position If it doesn t stop use immediately and contact customer service for additional instructions The internal cooling fans should be operating at this point 6 Select the desire...

Page 11: ...ll the glue should be removed with the stripe Body side molding removal Body side moldings are removed in much the same way as decals and graphics However with thick moldings a higher power or time is needed since the metal underneath the molding is farther away from the pad Keep the pad parallel to the work surface for even heat distribution Also instead of a circular motion use a back and forth ...

Page 12: ...ctor and the part being heated A small piece of welding blanket or fiberglass cloth can be placed over the jaws of the Bolt Pro Inductor to help shield it from the radiated heat from the fastener as well as protect it from accidental contact with a hot part If the Bolt Pro inductor is in contact with the hot part it could cause un warranted damage The maximum temperature allowed for he inductor is...

Page 13: ...ting point of the glass removal due to the difficulty of getting the first wedge in place It s best to start in a corner if possible and progress around the window towards the undamaged area of the vehicle 8 Ideally the Glass Pro Inductor should be placed directly on top of the urethane for efficient window removal However some vehicles have narrow pinch welds that cause the Glass Pro Inductor to ...

Page 14: ... with rear or side glass first then progress to windshields as you gain experience It s best to practice on salvage or totaled vehicles first to get familiar with the techniques 13 Add wedges or reposition other wedges as you move around the glass Tempered glass can withstand some prying without breaking If a prying action is used it is best to pry away from the car to prevent unnecessary paint da...

Page 15: ...GlassProInductor 13 Glass Removal Illustration NOTES ...

Page 16: ...GlassProInductor 14 ...

Page 17: ...e dent to expand upward thus removing the dent In some cases the dent will increase in size when heated If this occurs move out to the outer edge of the dent and heat again Continue to move outward until the dent starts to decrease in size Large dents and swells required a circular motion starting at the perimeter of the dent progressing to the middle It is possible and recommended to over raise t...

Page 18: ...ng bearings for thermal expansion prior to installation NOTE Never apply power to an unloaded heating inductor The body panel or metal object to be heated acts as a load to absorb the energy generated by the inductor Without the load the inductor will overheat Overheating the inductor can cause damage and or personal injury ...

Page 19: ...ooling fans and very adequate air flow from the louvers located on the side of the power source Frequently inspect all input power cables as well as all inductor and foot switch cables for signs of wear Do this daily Replace or repair cables as needed Disconnect input power and tighten all internal electrical connections every 6 months Heating and cooling of the electrical components from normal u...

Reviews: