Spot welder accessories and consumables: caps, electrodes, coolant and when to change them

A resistance spot welder has very few wearing parts, but the ones it has decide weld quality. The electrode caps carry 13,000 A into the panel and mushroom with every spot; the arm electrodes and their holders wear more slowly; the coolant that keeps the arms cold ages; and the hoses and covers take the abuse of the shop floor. This guide lists the spot welder accessories and consumables for GYSPOT PTI and BP machines, what each one does, and when to change it.

Electrode caps: the part you change most

Caps are the copper tips at the end of each arm. As they mushroom, the contact area grows, current density drops and the weld nugget shrinks, which is why OEM procedures ask for dressing or replacement at set intervals. GYS caps come in five shapes, and the arm decides which one you need.

Change caps as a pair. Each product page lists the arms and machines the cap fits, and the reference finder takes the six-digit number printed on the old bag.

Dressing instead of replacing

A cap can be dressed back to shape several times before it is spent. The sharpener restores the tip geometry in seconds; the cap remover pulls a seized cap off the electrode without marking the taper, which is the usual way a holder gets damaged.

Arm electrodes and holders

Behind the cap sits the electrode, a longer copper part pressed into the arm. It wears when caps are changed with a hammer, when coolant stops flowing, or simply after years of spots. GYS sells them per arm, with the cap holders and the protections that stop an arm from being scarred against the panel.

	Part	Fits	Price
	Electrode for C6 and G2 arms	C6, G2	$76
	2 electrodes for the X11 arm	X11	$160
	2 electrodes 155 mm	Difficult-access arms	$220
	Under-flange and under-arm electrode set	PTI and BP machines	$127
	Cap holder for C5 arm	C5	$28
	Cap holder for C8 arm	C8	$46
	Cap support for C12 and G6 arms	C12, G6	$44
	Set of 5 G-arm electrode protections	G arms	$50

Coolant, hoses and covers

PTI arms are liquid-cooled. The coolant carries heat away from the electrodes and has to be the welding coolant GYS specifies, not automotive antifreeze, which conducts and corrodes. Change it on the interval in the machine manual, and change a hose at the first sign of a leak: a dry arm overheats in a few spots.

Protective covers and the test kits used to validate welds for OEM programs are in the spot welding accessories collection.

What to keep on the shelf

1. A box of 40 Type A caps and the cap types your arms take.
2. Sharpener blades and the cap remover.
3. One spare electrode for each arm you use daily.
4. Coolant for one full change, and a hose for the arm that works hardest.

Not sure which cap your arm takes? The arms guide lists every C, G and X arm with its fit, or call (415) 419-5824 with the arm number. Everything here is genuine GYS, stocked in California, and ships the same business day.