© 2016 Nelson Stud Welding, Inc.
Page 17
All Rights Reserved.
February 2016
Part No. 729-110-042 v1.03
5 Maintenance of Stud Welding System
A majority of the maintenance of a stud welding system is in:
1
Stud Welding Gun
2
Welding Cable / Control Cable
3
Power Control Unit
5.1 Stud Welding Gun
The weld tool carries out most of the welding functions and should be periodically (at least every 3 months)
disassembled and cleaned. Special attention should be given to the lifting mechanisms. This shaft must be
absolutely free with no binding inside the gun and there should be no contact between the stud and the spark
shield. Never lubricate the lifting mechanisms. It should be cleaned with a dry cleaner such as electrical contact
cleaner. Caution should also be exercised when reassembling the gun to be certain not to pinch wires or the weld
cable. This could cause erratic welding problems which are usually difficult to isolate.
5.2 Welding Cable / Control Cable
When checking cables for continuity, it is important to slightly pull on all the connectors so that if there is a break,
the wires will be pulled apart. The continuity check can be performed with a standard Ohm meter. All cables:
ground, control and the weld cables should be periodically inspected for damage. Repair or replace any damaged
cables to protect the power control unit.
5.3 Power Control Unit
The power control unit contains electronic control boards. Normally, these items do not require maintenance.
However, in harsh environments, particularly those with grinding or sanding, metallic dust can enter the welder.
This conductive metallic dust can cause unexplained problems with the welding system. Periodically removing the
power control unit cover and blowing out the power control unit is a good idea. Frequency will vary depending on
the environment. Always disconnect power before opening any power control unit. CD units may continue to store
energy after they have been unplugged. To ensure all energy is discharged, wait at least one minute before
removing cover and servicing the power control unit.
