ESAB Four Roll Drive ""Uniform Pressure"" Accessory Support Assembly Troubleshooting instruction

INSTRUCTIONS for

F-12-821-D

February, 2001

FOUR ROLL DRIVE

UNIFORM PRESSURE

ACCESSORY SUPPORT

ASSEMBLY

Four Roll Drive Accessory Support

Assembly ........................ P/N 600216

FEATURE/BENEFITS

F-12-821-D

■ Not just another Four Roll Drive but, an exclusive

uni-pressure design that provides the uniform
equal feed roll pressure required to assure posi­tive non-slip wire feeding.

■ By uniformly distributing the feed pressure be-

tween all four feed rolls, the uni-pressure design
reduces the amount of feed roll pressure required
to feed any soft, hard or flux-core wire consistently.

■ Because the uni-pressure design assures uniform

equal adjustment of feed roll pressure, wire diam­eter deformation, surface galling, copper flaking
and wire pumping problems can be minimized, and
productively maintained under the most demand­ing conditions.

■ For reducing wire change and pressure resetting

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of
operation and safe practices for electric welding and cutting equipment, we urge you to read our booklet,
Precautions and Safe Practices for Arc Welding, Cutting and Gouging Form 52-529. Do NOT permit
untrained persons to install, operate, or maintain this equipment. Do NOT attempt to install or operate this
equipment until you have read and fully understand these instructions. If you do not fully understand these
instructions, contact your supplier for further information.

time - a quick release clapper with single adjust­ment knob allows releasing and resetting the feed
rolls without disturbing the feed roll pressure set­ting.

■ The uni-pressure accessory support can quickly

and easily be mounted on any EH-10A or EH-10AD
motor-gear units for feeding .030 through 1/8-in.
diameter wire.

■ Available with U groove, Vee hard or serrated V

feed rolls and utilizing standard inlet and outlet
guide accessories, this four roll drive is truly univer­sal in application.

■ Ordering is simplified by the availability of feed roll

kits (see page 2) or mix-and-match a feed roll
combination for your own specific need.

Be sure this information reaches the operator.
You can get extra copies through your supplier.

I. INTRODUCTION

C. CENTER WIRE GUIDE

The Four Roll Drive Accessory Support Assembly (600216)
illustrated in Fig. 1 utilizes four feed rolls to provide force
necessary for positive nonslip wire feed. The four roll drive
assembly is designed to be used with EH-10 Motor-Gear
Units for feeding .030 through 1/8-in. diameter wire.

The four roll drive unit features a quick release clapper
assembly which allows releasing and resetting the feed
rolls without disturbing the pressure spring setting. Two
tension springs are available for the assembly. A silver
spring (182W55) is installed in the assembly at the factory
and a stiffer blue spring (182W54) is available as an
option. The stiffer spring is used with larger diameter hard
and cored wires, while the light spring is used with soft and
smaller diameter hard wires. The four roll drive assembly
also includes quick release turn-locking handles for mount­ing the torch and wire conduits. The four roll drive assem­bly does not include feed rolls or a center wire guide. Refer
to Table 1 for the appropriate feed roll kit.

II. INSTALLATION

A. FOUR ROLL DRIVE ASSEMBLY

To install the four roll drive assembly on an EH-10 Motor­Gear Unit proceed as follows:

To install the proper center wire guide (see Table l)
proceed as follows:

1. Remove the two No. 8-32 x 5/8-in. panhead screws
which attach the Center Guide Clamping Plate (P/N

2075495) to the Center Guide Block (P/N 2075496).
Remove the plate.

2. Insert the center wire guide in the groove of the guide
block.

3. Replace the clamping plate, using the screws removed
in step 1 above.

III. OPERATION

A. THREADING WIRE TO TORCH CONDUIT

1. Round off the free end of the welding wire with a file.

2. Raise the clapper assembly to relieve pressure on the
feed rolls.

3. Thread wire as follows: (a) through the inlet guide; (b)
over the groove in the lower left hand feed roll; (c)
through the center wire guide; (d) over the groove in the
lower right hand feed roll and; (e) into the outlet guide.

4. Lower the clapper assembly.

5. Thread wire through the torch conduit using the torch
switch or inch switch.

1. Remove the thumbscrew and washer from the output
shaft of the motor-gear unit.

2. Fit the Gear and Insulator Assembly (P/N 999179) onto
the motor-gear unit shaft and engage the Key (P/N
28N33).

3. Insert the 1/4-in.-20 x 1/2-in. panhead screw (P/N

61307087), 1/4-in. bell washer (P/N 950783), and 1/4­in. flatwasher (P/N 64309431) in the motor-gear unit
shaft to secure the gear and insulator assembly.

4. Position the four roll drive assembly on the motor-gear
unit insulator ring (P/N 60N90) and secure by tightening
the 5/16-18 capscrew at the bottom of the assembly. Be

sure the gear and insulator assembly meshes cor­rectly with the lower feed roll gears in the four roll
drive assembly.

B. FEED ROLLS

To install the desired feed roll kit (see Table l) proceed as

follows:

1. Position the feed rolls over the four gear assembly hubs
aligning the feed roll holes with the gear assembly
holes.

2. Secure the feed rolls to the gear assemblies using the
No. 8-32 x 5/8-in. screws and lockwashers supplied.

IMPORTANT: When replacing a two-roll drive with a four-

roll drive it will be necessary to reverse the
motor-gear unit rotation to ensure correct
direction of wire feed. Switch the motor
armature leads at the control so that rota­tion (as viewed from shaft end of motor­gear unit) will be in a counterclockwise
direction.

B. ADJUSTING THE PRESSURE SPRING SETTING

When a new wire size or type is to be used, set the
pressure spring adjustment as follows:

1. Release the Clapper Assembly (P/N 2075500) and
unscrew the Pressure Adjusting Knob (P/N 60N68)
until the pressure spring is free.

2. Thread the wire through the four roll drive assembly as
described in Section III-A above.

3. Engage the clapper making sure the wire is held in the
feed roll grooves.

4. Energize the motor-gear unit while slowly tightening the
pressure adjusting knob until the wire begins to feed
without slipping. The spring pressure applied should be
the minimum required to provide positive, nonslip wire
feed. Too little pressure will result in wire slippage while
excessive pressure will scar and deform the wire.

2

T able 1. Feed Roll & Outlet Guide Selection

*

Notes

1

4-roll kit includes center wire guide and 2 upper and 2 lower feed rolls and mounting hardware for them.

* Outlet Guides must be ordered separately from Feed Roll Kit.

3

INLET GUIDE (29N13)

INSERT (05N58)

(Included with Assembly)

CLAPPER ASSY. - 2075500

OUTLET GUIDE

(See Table 1, Page 3)

CAPSCREW - 5/16" - 18 X 1 3/4"
(61340166)
NUT - 5/16" - 18 (63350121)

(2) LOCKING HANDLE
(49V44)

(4) FEED ROLL

( Optional Selections)

Feed Roll Mounting Hardware:

(17) SCREW - No. 8-32 x 5/8"
(61307881)
(17) LOCKWASHER - No. 8
(63402887)

ROLLPIN - 2075523

CLAMPING PLATE - 2075495

GEAR & INSULATOR ASSY. - 999179

SCREW - 1/4 X 20 X 1/2"
(61307087)
BELL WASHER - 1/4"
(950783
FLATWASHER - 1/4"
(64309431)

(4) FLATWASHER - 2075524

PIVOT BLOCK - 2975494

(4) GEAR ASSY.
(2075492)

ROLLPIN - 62350066

(3/16 X 1-3/4")

KNOB - 60N68

SPRING - 182W55

RETAINER - 58N24

FORK - 49V43

Fig.6 - Four Roll Drive Uniform Pressure Accessory Support Assembly - P/N 600216

F-12-821-D 2/2001 Printed in U.S.A.