Maintenance & Servicing; General Maintenance; Consumable Maintenance - Yeswelder YWM-200 Operator's Manual

MAINTENANCE & SERVICING

General Maintenance

This welder has been engineered to need minimal service providing that a few very simple steps are taken to properly main-
tain it.
Keep the cabinet cover closed at all times unless the wire needs to be changed or the driving pressure needs adjusting.
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Keep all consumables (contact tips, nozzles, and liner) clean and replace them when necessary. See "Consumable Main-
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tenance" (below) and "Troubleshooting" (page 27) for detailed information.
Replace INPUT POWER CABLE, ground cable,
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Avoid directing grinding particles towards the welder. These conductive particles can build up inside the machine and
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cause severe damage.
Periodically clean dust, dirt, grease, etc. from your welder. Every six months or as necessary, remove the side panels from
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the welder and use compressed air to blow out any dust and dirt that may have accumulated inside the welder.
If available, use compressed air to clean the liner periodically, especially when changing wire spools
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WARNING: DISCONNECT FROM POWER SOURCE WHEN CARRYING OUT THIS OPERATION.
The wire feed drive roller could wear out during service. Therefore, replacing the drive roller is required under specific cir-
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cumstances. For example, if the idler roller and the wire feed drive roller make contact when the correct size of welding
wire in the groove of the drive roller, the wire feed drive roller must be replaced immediately.
Check all cables periodically. They must be in good condition and not cracked.
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WARNING: ELECTRIC SHOCK CAN KILL! Be aware that the ON/OFF SWITCH, when OFF, does not remove power
from all internal circuitry in the welder. To reduce the risk of electric shock, always unplug the welder from its AC power
source and wait several minutes for electrical energy to discharge before removing side panels.

Consumable Maintenance

IT IS VERY IMPORTANT TO MAINTAIN THE CONSUMABLES TO AVOID THE NEED FOR PREMATURE REPLACEMENT
OF THE GUN ASSEMBLY.
MAINTAINING THE CONTACT TIP:
The purpose of the CONTACT TIP is to transfer welding current to the welding wire while allowing the wire to pass through it
smoothly.
Always use a contact tip stamped with the same diameter as the wire.
If the wire burns back into the contact tip, remove it from the gun and clean the hole running through it with an oxygen-
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acetylene torch tip cleaner or tip drill. If the burned-back wire cannot be removed, the contact tip must be replaced.
A failure mode of the contact tip is a worn-out hole with enlarged hole size. A worn-out contact tip usually results in unstable
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arc characteristics and difficult arc starting.
CAUTION: KEEP THE GAS NOZZLE CLEAN!
During the welding, spatter and slag can build up inside the gas nozzle. The user must clean the gas nozzle periodically. Failure
to clean and/or replace the gas nozzle in a timely fashion could cause damage to the front end of the gun assembly, which is
not replaceable. The inaction results may require the replacement of the entire gun assembly.
Failure to keep the nozzle adequately cleaned can result in the following problems:
If the spattering buildup inside the gas nozzle bridges the gas nozzle and the welding torch, it allows the welding current to pass
through the gas nozzle beside the contact tip. This phenomenon causes erratic welds and less weld penetration. In addition, it
leads to an overheating of the end of the welding gun and, in turn, damages the welding gun.
TESTING FOR A SHORTED NOZZLE
Arcing between the nozzle and the workpiece means the nozzle is shorted.
Unplug the AC power source, and use an ohmmeter to measure the resistance between the gas nozzle and the contact tip. If
the resistance is not unlimited, the nozzle is shorted. Please clean or replace the gas nozzle.
work clamp, or gun assembly when damaged or worn.
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