ESAB MobileMaster IV cvcc Instruction manual

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MobileMaster IV cvcc

PORTABLE “OFF THE ARC” WIRE FEEDERS

Instruction Literature

This manual provides instructions for units starting with Serial No. WxJ501xxx

F15-610-J 03/2008

BE SURE THIS INFORMATION REACHES THE OPERATOR.

YOU CAN GET EXTRA COPIES THROUGH YOUR SUPPLIER.

CAUTION

These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the
principles of operation and safe practices for arc 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. Be sure to read the Safety Precautions be­fore installing or operating this equipment.

USER RESPONSIBILITY

This equipment will perform in conformity with the description thereof contained in this manual and accompa­nying labels and/or inserts when installed, operated, maintained and repaired in accordance with the instruc­tions provided. This equipment must be checked periodically. Malfunctioning or poorly maintained equipment
should not be used. Parts that are broken, missing, worn, distorted or contaminated should be replaced imme­diately. Should such repair or replacement become necessary, the manufacturer recommends that a telephone
or written request for service advice be made to the Authorized Distributor from whom it was purchased.

This equipment or any of its parts should not be altered without the prior written approval of the manufacturer.
The user of this equipment shall have the sole responsibility for any malfunction which results from improper
use, faulty maintenance, damage, improper repair or alteration by anyone other than the manufacturer or a ser­vice facility designated by the manufacturer.

READ AND UNDERSTAND THE INSTRUCTION MANUAL BEFORE INSTALLING OR OPERATING.

PROTECT YOURSELF AND OTHERS!

2

DECLARATION OF CONFORMITY

according to the Low Voltage Directive 73/23/EEC, to the EMC Directive 89/336/EEC

FÖRSÄKRAN OM ÖVERENSSTÄMMELSE

enligt Lågspänningsdirektivet 73/23/EEG, EMC-Direktivet 89/336/EEG

Type of equipment Materialslag
Wire feeder

Brand name or trade mark Fabrikatnamn eller varumärke
ESAB

Type designation etc. Typbeteckning etc.
MobileMaster IV cvcc

Manufacturer or his authorised representative established within the EEA
Name, address, telephone No, telefax No: Tillverkarens namn, adress, telefon, telefax:

ESAB AB
Herkulesgatan 72, Box 8004, SE-402 77 Göteborg, Sweden
Phone: [phone], Fax: [phone]

The following harmonised standards in force within the EEA have been used in the design:

Följande harmoniserande standarder har använts i konstruktionen:
EN 60974-1, Arc welding equipment – Part 1: Welding power sources
EN 50 199, Electromagnetic compatibility (EMC) Product standard for arc welding equipment

By signing this document, the undersigned declares as manufacturer, or the manufacturer’s authorised
representative established within the EEA, that the equipment in question complies with the safety requirements
stated above.

Genom att underteckna detta dokument försäkrar undertecknad såsom tillverkare, eller tillverkarens representant inom
EES, att angiven materiel uppfyller säkerhetskraven angivna ovan.

Date Datum
Laxå 2004-12-23

3

4

TABLE OF CONTENTS

Section / Title Page

1.0 Safety Precautions ....................................................................................7

1.1 Safety - English ..................................................................................7

1.2 Safety - Spanish ................................................................................11

1.3 Safety - French .................................................................................15

2.0 Description ..........................................................................................19

2.1 General ....................................................................................... 21

2.2 Receiving & Handling.......................................................................... 21

2.3 Description.................................................................................... 21

3.0 Installation.......................................................................................... 23

3.1 Drive Rolls..................................................................................... 23

3.2 Welding Wire Speed ........................................................................... 23

3.3 Torch Connections............................................................................. 24

3.4 Supply Connections ........................................................................... 24

3.5 Threading the Welding Wire....................................................................25

3.6 Brake Drag Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

4.0 Operation ...........................................................................................27

4.1 Controls........................................................................................27

4.2 Operating Procedures .........................................................................29

4.3 Changing Meter Display - IPM TO MPM .........................................................30

4.4 Setting a Welding Procedure ...................................................................31

4.5 Shutdown..................................................................................... 33

5.0 Maintenance.........................................................................................35

5.1 Maintenance ...................................................................................35

5.2 Inspection and Service......................................................................... 35

5.3 Troubleshooting............................................................................... 36

6.0 Replacement Parts .................................................................................. 39

6.1 General ....................................................................................... 39

6.2 Ordering ...................................................................................... 39

5

TABLE OF CONTENTS

6

SECTION 1 SAFETY PRECAUTIONS

1.0 Safety Precautions

WARNING: These Safety Precautions are

for your protection. They summarize pre­cautionary information from the references

listed in Additional Safety Information sec­tion. Before performing any installation or operating
procedures, be sure to read and follow the safety precau­tions listed below as well as all other manuals, material
safety data sheets, labels, etc. Failure to observe Safety
Precautions can result in injury or death.

PROTECT YOURSELF AND OTHERS -­Some welding, cutting, and gouging
processes are noisy and require ear
protection. The arc, like the sun, emits

ultraviolet (UV) and other radiation
and can injure skin and eyes. Hot metal can cause
burns. Training in the proper use of the processes
and equipment is essential to prevent accidents.
Therefore:

1. Always wear safety glasses with side shields in any

work area, even if welding helmets, face shields, and
goggles are also required.

2. Use a face shield tted with the correct lter and

cover plates to protect your eyes, face, neck, and
ears from sparks and rays of the arc when operating
or observing operations. Warn bystanders not to
watch the arc and not to expose themselves to the
rays of the electric-arc or hot metal.

3. Wear ameproof gauntlet type gloves, heavy long-

sleeve shirt, cuess trousers, high-topped shoes,
and a welding helmet or cap for hair protection, to
protect against arc rays and hot sparks or hot metal.
A ameproof apron may also be desirable as protec­tion against radiated heat and sparks.

4. Hot sparks or metal can lodge in rolled up sleeves,

trouser cus, or pockets. Sleeves and collars should
be kept buttoned, and open pockets eliminated from
the front of clothing.

5. Protect other personnel from arc rays and hot

sparks with a suitable non-ammable partition or
curtains.

6. Use goggles over safety glasses when chipping slag

or grinding. Chipped slag may be hot and can y far.
Bystanders should also wear goggles over safety
glasses.

1.1 Safety - English

FIRES AND EXPLOSIONS -- Heat from
ames and arcs can start res. Hot
slag or sparks can also cause res and
explosions. Therefore:

1. Remove all combustible materials well away from
the work area or cover the materials with a protec­tive non-ammable covering. Combustible materials
include wood, cloth, sawdust, liquid and gas fuels,
solvents, paints and coatings, paper, etc.

2. Hot sparks or hot metal can fall through cracks or
crevices in oors or wall openings and cause a hid­den smoldering re or res on the oor below. Make
certain that such openings are protected from hot
sparks and metal.“

3. Do not weld, cut or perform other hot work until the
workpiece has been completely cleaned so that there
are no substances on the workpiece which might
produce ammable or toxic vapors. Do not do hot
work on closed containers. They may explode.

4. Have re extinguishing equipment handy for instant
use, such as a garden hose, water pail, sand bucket,
or portable re extinguisher. Be sure you are trained
in its use.

5. Do not use equipment beyond its ratings. For ex­ample, overloaded welding cable can overheat and
create a re hazard.

6. After completing operations, inspect the work area
to make certain there are no hot sparks or hot metal
which could cause a later re. Use re watchers when
necessary.

7. For additional information, refer to NFPA Standard
51B, "Fire Prevention in Use of Cutting and Welding
Processes", available from the National Fire Protec­tion Association, Batterymarch Park, Quincy, MA

02269.

ELECTRICAL SHOCK -- Contact with
live electrical parts and ground can
cause severe injury or death. DO NOT
use AC welding current in damp areas,
if movement is conned, or if there is
danger of falling.

7

SECTION 1 SAFETY PRECAUTIONS

1. Be sure the power source frame (chassis) is con­nected to the ground system of the input power.

2. Connect the workpiece to a good electrical
ground.

3. Connect the work cable to the workpiece. A poor
or missing connection can expose you or others
to a fatal shock.

4. Use well-maintained equipment. Replace worn or
damaged cables.

5. Keep everything dry, including clothing, work
area, cables, torch/electrode holder, and power
source.

6. Make sure that all parts of your body are insulated
from work and from ground.

7. Do not stand directly on metal or the earth while
working in tight quarters or a damp area; stand
on dry boards or an insulating platform and wear
rubber-soled shoes.

8. Put on dry, hole-free gloves before turning on the
power.

3. Welders should use the following procedures to
minimize exposure to EMF:

A. Route the electrode and work cables together.

Secure them with tape when possible.

B. Never coil the torch or work cable around your

body.

C. Do not place your body between the torch and

work cables. Route cables on the same side of
your body.

D. Connect the work cable to the workpiece as close

as possible to the area being welded.

E. Keep welding power source and cables as far

away from your body as possible.

FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in conned spaces. Do
not breathe fumes and gases. Shield­ing gases can cause asphyxiation.

Therefore:

9. Turn o the power before removing your gloves.

10. Refer to ANSI/ASC Standard Z49.1 (listed on
next page) for specic grounding recommenda­tions. Do not mistake the work lead for a ground
cable.

ELECTRIC AND MAGNETIC FIELDS
— May be dangerous. Electric cur­rent owing through any conduc­tor causes localized Electric and

Magnetic Fields (EMF). Welding and
cutting current creates EMF around welding cables
and welding machines. Therefore:

1. Welders having pacemakers should consult their

physician before welding. EMF may interfere with
some pacemakers.

2. Exposure to EMF may have other health eects which

are unknown.

1. Always provide adequate ventilation in the work area
by natural or mechanical means. Do not weld, cut, or
gouge on materials such as galvanized steel, stain­less steel, copper, zinc, lead, beryllium, or cadmium
unless positive mechanical ventilation is provided.
Do not breathe fumes from these materials.

2. Do not operate near degreasing and spraying opera­tions. The heat or arc rays can react with chlorinated
hydrocarbon vapors to form phosgene, a highly
toxic gas, and other irritant gases.

3. If you develop momentary eye, nose, or throat ir­ritation while operating, this is an indication that
ventilation is not adequate. Stop work and take
necessary steps to improve ventilation in the work
area. Do not continue to operate if physical discom­fort persists.

4. Refer to ANSI/ASC Standard Z49.1 (see listing below)
for specic ventilation recommendations.

8

SECTION 1 SAFETY PRECAUTIONS

5. WARNING: This product, when used for welding
or cutting, produces fumes or gases
which contain chemicals known to
the State of California to cause birth
defects and, in some cases, cancer.
(California Health & Safety Code

§25249.5 et seq.)

CYLINDER HANDLING -- Cylinders,
if mishandled, can rupture and vio­lently release gas. Sudden rupture
of cylinder, valve, or relief device can
injure or kill. Therefore:

1. Use the proper gas for the process and use the

proper pressure reducing regulator designed to
operate from the compressed gas cylinder. Do not
use adaptors. Maintain hoses and ttings in good
condition. Follow manufacturer's operating instruc­tions for mounting regulator to a compressed gas
cylinder.

1. Always have qualied personnel perform the instal­lation, troubleshooting, and maintenance work.
Do not perform any electrical work unless you are
qualied to perform such work.

2. Before performing any maintenance work inside a
power source, disconnect the power source from
the incoming electrical power.

3. Maintain cables, grounding wire, connections, power
cord, and power supply in safe working order. Do
not operate any equipment in faulty condition.

4. Do not abuse any equipment or accessories. Keep
equipment away from heat sources such as furnaces,
wet conditions such as water puddles, oil or grease,
corrosive atmospheres and inclement weather.

5. Keep all safety devices and cabinet covers in position
and in good repair.

6. Use equipment only for its intended purpose. Do
not modify it in any manner.

2. Always secure cylinders in an upright position by
chain or strap to suitable hand trucks, undercar­riages, benches, walls, post, or racks. Never secure
cylinders to work tables or xtures where they may
become part of an electrical circuit.

3. When not in use, keep cylinder valves closed. Have
valve protection cap in place if regulator is not con­nected. Secure and move cylinders by using suitable
hand trucks. Avoid rough handling of cylinders.

4. Locate cylinders away from heat, sparks, and ames.
Never strike an arc on a cylinder.

5. For additional information, refer to CGA Standard P-1,
"Precautions for Safe Handling of Compressed Gases
in Cylinders", which is available from Compressed
Gas Association, 1235 Jeerson Davis Highway,
Arlington, VA 22202.

EQUIPMENT MAINTENANCE -- Faulty or
improperly maintained equipment can
cause injury or death. Therefore:

ADDITIONAL SAFETY INFORMATION -- For
more information on safe practices for

electric arc welding and cutting equip­ment, ask your supplier for a copy of
"Precautions and Safe Practices for Arc
Welding, Cutting and Gouging", Form
52-529.

The following publications, which are available from
the American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, are recommended to you:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

9

SECTION 1 SAFETY PRECAUTIONS

5. AWS C5.5 - "Recommended Practices for Gas Tung­sten Arc Welding“

6. AWS C5.6 - "Recommended Practices for Gas Metal
Arc Welding"“

7. AWS SP - "Safe Practices" - Reprint, Welding Hand­book.

8. ANSI/AWS F4.1, "Recommended Safe Practices for
Welding and Cutting of Containers That Have Held
Hazardous Substances."

MEANING OF SYMBOLS - As used
throughout this manual: Means Atten­tion! Be Alert! Your safety is involved.

Means immediate hazards which,
if not avoided, will result in im­mediate, serious personal injury
or loss of life.

Means potential hazards which
could result in personal injury or
loss of life.

Means hazards which could result
in minor personal injury.

10

SECTION 1 SEGURIDAD

1.2 Safety - Spanish

ADVERTENCIA: Estas Precauciones de Se-

guridad son para su protección. Ellas hacen

resumen de información proveniente de las
referencias listadas en la sección "Información Adi­cional Sobre La Seguridad". Antes de hacer cualquier
instalación o procedimiento de operación , asegúrese
de leer y seguir las precauciones de seguridad listadas
a continuación así como también todo manual, hoja
de datos de seguridad del material, calcomanias, etc.
El no observar las Precauciones de Seguridad puede
resultar en daño a la persona o muerte.

PROTEJASE USTED Y A LOS DEMAS-­Algunos procesos de soldadura, corte
y ranurado son ruidosos y requiren
protección para los oídos. El arco,

como el sol , emite rayos ultravioleta
(UV) y otras radiaciones que pueden dañar la piel
y los ojos. El metal caliente causa quemaduras. EL
entrenamiento en el uso propio de los equipos y
sus procesos es esencial para prevenir accidentes.
Por lo tanto:

1. Utilice gafas de seguridad con protección a los lados

siempre que esté en el área de trabajo, aún cuando
esté usando careta de soldar, protector para su cara
u otro tipo de protección.

2. Use una careta que tenga el ltro correcto y lente

para proteger sus ojos, cara, cuello, y oídos de las
chispas y rayos del arco cuando se esté operando y
observando las operaciones. Alerte a todas las per­sonas cercanas de no mirar el arco y no exponerse
a los rayos del arco eléctrico o el metal fundido.

3. Use guantes de cuero a prueba de fuego, camisa

pesada de mangas largas, pantalón de ruedo liso,
zapato alto al tobillo, y careta de soldar con capucha
para el pelo, para proteger el cuerpo de los rayos y
chispas calientes provenientes del metal fundido.
En ocaciones un delantal a prueba de fuego es
necesario para protegerse del calor radiado y las
chispas.

4. Chispas y partículas de metal caliente puede alojarse

en las mangas enrolladas de la camisa , el ruedo del
pantalón o los bolsillos. Mangas y cuellos deberán
mantenerse abotonados, bolsillos al frente de la
camisa deberán ser cerrados o eliminados.

5. Proteja a otras personas de los rayos del arco y chis-

pas calientes con una cortina adecuada no-amable
como división.

6. Use careta protectora además de sus gafas de segu-

ridad cuando esté removiendo escoria o puliendo.

La escoria puede estar caliente y desprenderse con
velocidad. Personas cercanas deberán usar gafas
de seguridad y careta protectora.

FUEGO Y EXPLOSIONES -- El calor de
las amas y el arco pueden ocacionar
fuegos. Escoria caliente y las chispas
pueden causar fuegos y explosiones.
Por lo tanto:

1. Remueva todo material combustible lejos del área
de trabajo o cubra los materiales con una cobija a
prueba de fuego. Materiales combustibles incluyen
madera, ropa, líquidos y gases amables, solventes,
pinturas, papel, etc.

2. Chispas y partículas de metal pueden introducirse en
las grietas y agujeros de pisos y paredes causando
fuegos escondidos en otros niveles o espacios.
Asegúrese de que toda grieta y agujero esté cubierto
para proteger lugares adyacentes contra fuegos.

3. No corte, suelde o haga cualquier otro trabajo
relacionado hasta que la pieza de trabajo esté to­talmente limpia y libre de substancias que puedan
producir gases inamables o vapores tóxicos. No
trabaje dentro o fuera de contenedores o tanques
cerrados. Estos pueden explotar si contienen vapores
inamables.

4. Tenga siempre a la mano equipo extintor de fu­ego para uso instantáneo, como por ejemplo una
manguera con agua, cubeta con agua, cubeta con
arena, o extintor portátil. Asegúrese que usted esta
entrenado para su uso.

5. No use el equipo fuera de su rango de operación. Por
ejemplo, el calor causado por cable sobrecarga en
los cables de soldar pueden ocasionar un fuego.

6. Después de termirar la operación del equipo, inspec­cione el área de trabajo para cerciorarse de que las
chispas o metal caliente ocasionen un fuego más
tarde. Tenga personal asignado para vigilar si es
necesario.

7. Para información adicional , haga referencia a la
publicación NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible
a través de la National Fire Protection Association,
Batterymarch Park, Quincy, MA 02269.

CHOQUE ELECTRICO -- El contacto
con las partes eléctricas energizadas
y tierra puede causar daño severo o
muerte. NO use soldadura de corri-

ente alterna (AC) en áreas húmedas,
de movimiento connado en lugares estrechos o
si hay posibilidad de caer al suelo.

11

SECTION 1 SEGURIDAD

1. Asegúrese de que el chasis de la fuente de poder
esté conectado a tierra através del sistema de
electricidad primario.

2. Conecte la pieza de trabajo a un buen sistema de
tierra física.

3. Conecte el cable de retorno a la pieza de trabajo.
Cables y conductores expuestos o con malas
conexiones pueden exponer al operador u otras
personas a un choque eléctrico fatal.

4. Use el equipo solamente si está en buenas condi­ciones. Reemplaze cables rotos, dañados o con
conductores expuestos.

5. Mantenga todo seco, incluyendo su ropa, el área de
trabajo, los cables, antorchas, pinza del electrodo,
y la fuente de poder.

6. Asegúrese que todas las partes de su cuerpo están
insuladas de ambos, la pieza de trabajo y tierra.

7. No se pare directamente sobre metal o tierra mien­tras trabaja en lugares estrechos o áreas húmedas;
trabaje sobre un pedazo de madera seco o una
plataforma insulada y use zapatos con suela de
goma.

8. Use guantes secos y sin agujeros antes de energizar
el equipo.

9. Apage el equipo antes de quitarse sus guantes.

10. Use como referencia la publicación ANSI/ASC
Standard Z49.1 (listado en la próxima página) para
recomendaciones especícas de como conectar el
equipo a tierra. No confunda el cable de soldar a
la pieza de trabajo con el cable a tierra.

CAMPOS ELECTRICOS Y MAGNETI­COS - Son peligrosos. La corriente
eléctrica uye através de cualquier
conductor causando a nivel local

Campos Eléctricos y Magnéticos
(EMF). Las corrientes en el área de corte y soldadura,
crean EMF alrrededor de los cables de soldar y las
maquinas. Por lo tanto:

1. Soldadores u Operadores que use marca-pasos para

el corazón deberán consultar a su médico antes de
soldar. El Campo Electromagnético (EMF) puede
interferir con algunos marca-pasos.

2. Exponerse a campos electromagnéticos (EMF) puede

causar otros efectos de salud aún desconocidos.

3. Los soldadores deberán usar los siguientes proced­imientos para minimizar exponerse al EMF:

A. Mantenga el electrodo y el cable a la pieza de

trabajo juntos, hasta llegar a la pieza que usted
quiere soldar. Asegúrelos uno junto al otro con
cinta adhesiva cuando sea posible.

B. Nunca envuelva los cables de soldar alrededor

de su cuerpo.

C. Nunca ubique su cuerpo entre la antorcha y el

cable, a la pieza de trabajo. Mantega los cables a
un sólo lado de su cuerpo.

D. Conecte el cable de trabajo a la pieza de trabajo

lo más cercano posible al área de la soldadura.

E. Mantenga la fuente de poder y los cables de soldar

lo más lejos posible de su cuerpo.

HUMO Y GASES -- El humo y los
gases, pueden causar malestar o
daño, particularmente en espacios

sin ventilación. No inhale el humo

o gases. El gas de protección puede
causar falta de oxígeno.
Por lo tanto:

1. Siempre provea ventilación adecuada en el área

de trabajo por medio natural o mecánico. No solde,
corte, o ranure materiales con hierro galvanizado,
acero inoxidable, cobre, zinc, plomo, berílio, o cad­mio a menos que provea ventilación mecánica
positiva . No respire los gases producidos por
estos materiales.

2. No opere cerca de lugares donde se aplique sub-

stancias químicas en aerosol. El calor de los rayos
del arco pueden reaccionar con los vapores de
hidrocarburo clorinado para formar un fosfógeno,
o gas tóxico, y otros irritant es.

3. Si momentáneamente desarrolla inrritación de

ojos, nariz o garganta mientras est á operando, es
indicación de que la ventilación no es apropiada.
Pare de trabajar y tome las medidas necesarias
para mejorar la ventilación en el área de trabajo.
No continúe operando si el malestar físico per­siste.

4. Haga referencia a la publicación ANSI/ASC Standard

Z49.1 (Vea la lista a continuación) para recomen­daciones especícas en la ventilación.

12

SECTION 1 SEGURIDAD

5. ADVERTENCIA-- Este producto cuando se uti­liza para soldaduras o cortes,
produce humos o gases, los
cuales contienen químicos
conocidos por el Estado de Cali­fornia de causar defectos en el
nacimiento, o en algunos casos,
Cancer. (California Health &
Safety Code §25249.5 et seq.)

MANEJO DE CILINDROS-- Los

cilindros, si no son manejados
correctamente, pueden romp­erse y liberar violentamente
gases. Rotura repentina del
cilindro, válvula, o válvula de
escape puede causar daño o
muerte. Por lo tanto:

1. Utilize el gas apropiado para el proceso y utilize

un regulador diseñado para operar y reducir la
presión del cilindro de gas . No utilice adapta­dores. Mantenga las mangueras y las conexiones
en buenas condiciones. Observe las instrucciones
de operación del manufacturero para montar el
regulador en el cilindro de gas comprimido.

2. Asegure siempre los cilindros en posición vertical

y amárrelos con una correa o cadena adecuada
para asegurar el cilindro al carro, transportes, tablil­leros, paredes, postes, o armazón. Nunca asegure
los cilindros a la mesa de trabajo o las piezas que
son parte del circuito de soldadura . Este puede ser
parte del circuito elélectrico.

3. Cuando el cilindro no está en uso, mantenga la

válvula del cilindro cerrada. Ponga el capote de
protección sobre la válvula si el regulador no
está conectado. Asegure y mueva los cilindros
utilizando un carro o transporte adecuado. Evite
el manejo brusco de los

1. Siempre tenga personal cualicado para efec­tuar l a instalación, diagnóstico, y mantenimiento
del equipo. No ejecute ningún trabajo eléctrico a
menos que usted esté cualicado para hacer el
trabajo.

2. Antes de dar mantenimiento en el interior de la
fuente de poder, desconecte la fuente de poder
del suministro de electricidad primaria.

3. Mantenga los cables, cable a tierra, conexciones,
cable primario, y cualquier otra fuente de poder
en buen estado operacional. No opere ningún
equipo en malas condiciones.

4. No abuse del equipo y sus accesorios. Mantenga
el equipo lejos de cosas que generen calor como
hornos, también lugares húmedos como charcos
de agua , aceite o grasa, atmósferas corrosivas y
las inclemencias del tiempo.

5. Mantenga todos los artículos de seguridad y
coverturas del equipo en su posición y en buenas
condiciones.

6. Use el equipo sólo para el propósito que fue
diseñado. No modique el equipo en ninguna
manera.

INFORMACION ADICIONAL DE SEGURI­DAD -- Para más información sobre las
prácticas de seguridad de los equipos de
arco eléctrico para soldar y cortar, pregunte
a su suplidor por una copia de "Precautions
and Safe Practices for Arc Welding, Cutting
and Gouging-Form 52-529.

Las siguientes publicaciones, disponibles através de
la American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 33126, son recomendadas para usted:

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"

MANTENIMIENTO DEL EQUIPO -- Equipo
defectuoso o mal mantenido puede
causar daño o muerte. Por lo tanto:

3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

13

SECTION 1 SEGURIDAD

SIGNIFICADO DE LOS SIMBOLOS

-- Según usted avanza en la lectura
de este folleto: Los Símbolos Sig­nican ¡Atención! ¡Esté Alerta! Se
trata de su seguridad.

Signica riesgo inmediato que,
de no ser evadido, puede resultar
inmediatamente en serio daño
personal o la muerte.

Signica el riesgo de un peligro
potencial que puede resultar en
serio daño personal o la muerte.

Signica el posible riesgo que
puede resultar en menores daños
a la persona.

14

SECTION 1 SÉCURITÉ

1.3 Safety - French

AVERTISSEMENT : Ces règles de sécurité

ont pour but d'assurer votre protection. Ils
récapitulent les informations de précaution

provenant des références dans la section
des Informations de sécurité supplémentaires. Avant
de procéder à l'installation ou d'utiliser l'unité, assurez­vous de lire et de suivre les précautions de sécurité ci­dessous, dans les manuels, les ches d'information sur la
sécurité du matériel et sur les étiquettes, etc. Tout défaut
d'observer ces précautions de sécurité peut entraîner
des blessures graves ou mortelles.

PROTÉGEZ-VOUS -- Les processus de
soudage, de coupage et de gougeage

produisent un niveau de bruit élevé et
exige l'emploi d'une protection auditive. L'arc, tout
comme le soleil, émet des rayons ultraviolets en plus
d'autre rayons qui peuvent causer des blessures à la
peau et les yeux. Le métal incandescent peut causer
des brûlures. Une formation reliée à l'usage des
processus et de l'équipement est essentielle pour
prévenir les accidents. Par conséquent:

1. Portez des lunettes protectrices munies d'écrans la-

téraux lorsque vous êtes dans l'aire de travail, même
si vous devez porter un casque de soudeur, un écran
facial ou des lunettes étanches.

2. Portez un écran facial muni de verres ltrants et de

plaques protectrices appropriées an de protéger
vos yeux, votre visage, votre cou et vos oreilles des
étincelles et des rayons de l'arc lors d'une opération
ou lorsque vous observez une opération. Avertissez
les personnes se trouvant à proximité de ne pas re­garder l'arc et de ne pas s'exposer aux rayons de l'arc
électrique ou le métal incandescent.

3. Portez des gants ignifugiés à crispin, une chemise

épaisse à manches longues, des pantalons sans rebord
et des chaussures montantes an de vous protéger des
rayons de l'arc, des étincelles et du métal incandescent,
en plus d'un casque de soudeur ou casquette pour
protéger vos cheveux. Il est également recommandé
de porter un tablier ininammable an de vous proté­ger des étincelles et de la chaleur par rayonnement.

4. Les étincelles et les projections de métal incandescent

risquent de se loger dans les manches retroussées,
les rebords de pantalons ou les poches. Il est recom­mandé de garder boutonnés le col et les manches et
de porter des vêtements sans poches en avant.

5. Protégez toute personne se trouvant à proximité des

étincelles et des rayons de l'arc à l'aide d'un rideau ou
d'une cloison ininammable.

6. Portez des lunettes étanches par dessus vos lunettes

de sécurité lors des opérations d'écaillage ou de
meulage du laitier. Les écailles de laitier incandescent
peuvent être projetées à des distances considérables.
L es p er so n ne s se tr o uv an t à p r ox im it é do iv en t é g al e ­ment porter des lunettes étanches par dessus leur
lunettes de sécurité.

INCENDIES ET EXPLOSIONS -- La
chaleur provenant des ammes ou de
l'arc peut provoquer un incendie. Le
laitier incandescent ou les étincelles

peuvent également provoquer un

incendie ou une explosion. Par conséquent :

1. Éloignez susamment tous les matériaux combus­tibles de l'aire de travail et recouvrez les matériaux
avec un revêtement protecteur ininammable. Les
matériaux combustibles incluent le bois, les vête­ments, la sciure, le gaz et les liquides combustibles,
les solvants, les peintures et les revêtements, le
papier, etc.

2. Les étincelles et les projections de métal incan­descent peuvent tomber dans les ssures dans
les planchers ou dans les ouvertures des murs et
déclencher un incendie couvant à l'étage inférieur
Assurez-vous que ces ouvertures sont bien protégées
des étincelles et du métal incandescent.

3. N'exécutez pas de soudure, de coupe ou autre tra­vail à chaud avant d'avoir complètement nettoyé la
surface de la pièce à traiter de façon à ce qu'il n'ait
aucune substance présente qui pourrait produire
des vapeurs inammables ou toxiques. N'exécutez
pas de travail à chaud sur des contenants fermés
car ces derniers pourraient exploser.

4. Assurez-vous qu'un équipement d'extinction
d'incendie est disponible et prêt à servir, tel qu'un
tuyau d'arrosage, un seau d'eau, un seau de sable
ou un extincteur portatif. Assurez-vous d'être bien
instruit par rapport à l'usage de cet équipement.

5. Assurez-vous de ne pas excéder la capacité de
l'équipement. Par exemple, un câble de soudage
surchargé peut surchauer et provoquer un in­cendie.

6. Une fois les opérations terminées, inspectez l'aire de
travail pour assurer qu'aucune étincelle ou projec­tion de métal incandescent ne risque de provoquer
un incendie ultérieurement. Employez des guetteurs
d'incendie au besoin.

7. Pour obtenir des informations supplémentaires,
consultez le NFPA Standard 51B, "Fire Prevention in
Use of Cutting and Welding Processes", disponible au
National Fire Protection Association, Batterymarch
Park, Quincy, MA 02269.

CHOC ÉLECTRIQUE -- Le contact avec
des pièces électriques ou les pièces
de mise à la terre sous tension peut
causer des blessures graves ou mor-

telles. NE PAS utiliser un courant de
soudage c.a. dans un endroit humide, en espace
restreint ou si un danger de chute se pose.

15

SECTION 1 SÉCURITÉ

1. Assurez-vous que le châssis de la source
d'alimentation est branché au système de mise à
la terre de l'alimentation d'entrée.

2. Branchez la pièce à traiter à une bonne mise de
terre électrique.

3. Branchez le câble de masse à la pièce à traiter et
assurez une bonne connexion an d'éviter le risque
de choc électrique mortel.

4. Utilisez toujours un équipement correctement
entretenu. Remplacez les câbles usés ou endom­magés.

5. Veillez à garder votre environnement sec, incluant
les vêtements, l'aire de travail, les câbles, le porte­électrode/torche et la source d'alimentation.

6. Assurez-vous que tout votre corps est bien isolé
de la pièce à traiter et des pièces de la mise à la
terre.

7. Si vous devez eectuer votre travail dans un espace
restreint ou humide, ne tenez vous pas directe­ment sur le métal ou sur la terre; tenez-vous sur
des planches sèches ou une plate-forme isolée et
portez des chaussures à semelles de caoutchouc.

8. Avant de mettre l'équipement sous tension, isolez
vos mains avec des gants secs et sans trous.

9. Mettez l'équipement hors tension avant d'enlever
vos gants.

10. Consultez ANSI/ASC Standard Z49.1 (listé à
la page suivante) pour des recommandations
spéciques concernant les procédures de mise à
la terre. Ne pas confondre le câble de masse avec
le câble de mise à la terre.

CHAMPS ÉLECTRIQUES ET MAGNÉ­TIQUES — comportent un risque de
danger. Le courant électrique qui
passe dans n'importe quel conduc-

teur produit des champs électriques
et magnétiques localisés. Le soudage et le cou­rant de coupage créent des champs électriques
et magnétiques autour des câbles de soudage et
l'équipement. Par conséquent :

1. Un soudeur ayant un stimulateur cardiaque doit

consulter son médecin avant d'entreprendre une
opération de soudage. Les champs électriques et
magnétiques peuvent causer des ennuis pour cer­tains stimulateurs cardiaques.

2. L'exposition à des champs électriques et magné-

tiques peut avoir des eets néfastes inconnus pour
la santé.

3. Les soudeurs doivent suivre les procédures suivantes
pour minimiser l'exposition aux champs électriques
et magnétiques :

A. Acheminez l'électrode et les câbles de masse

ensemble. Fixez-les à l'aide d'une bande adhésive
lorsque possible.

B. Ne jamais enrouler la torche ou le câble de masse

autour de votre corps.

C. Ne jamais vous placer entre la torche et les câbles

de masse. Acheminez tous les câbles sur le même
côté de votre corps.

D. Branchez le câble de masse à la pièce à traiter le

plus près possible de la section à souder.

E. Veillez à garder la source d'alimentation pour le

soudage et les câbles à une distance appropriée
de votre corps.

LES VAPEURS ET LES GAZ -- peuvent
causer un malaise ou des dommages

corporels, plus particulièrement
dans les espaces restreints. Ne re­spirez pas les vapeurs et les gaz. Le
gaz de protection risque de causer
l'asphyxie. Par conséquent :

1. Assurez en permanence une ventilation adéquate
dans l'aire de travail en maintenant une ventila­tion naturelle ou à l'aide de moyens mécanique.
N'effectuez jamais de travaux de soudage, de
coupage ou de gougeage sur des matériaux tels que
l'acier galvanisé, l'acier inoxydable, le cuivre, le zinc,
le plomb, le berylliym ou le cadmium en l'absence
de moyens mécaniques de ventilation ecaces. Ne
respirez pas les vapeurs de ces matériaux.

2. N'eectuez jamais de travaux à proximité d'une
opération de dégraissage ou de pulvérisation. Lor­sque la chaleur

ou le rayonnement de l'arc entre en contact avec les

vapeurs d'hydrocarbure chloré, ceci peut déclencher
la formation de phosgène ou d'autres gaz irritants,
tous extrêmement toxiques.

3. Une irritation momentanée des yeux, du nez ou de la
gorge au cours d'une opération indique que la ven­tilation n'est pas adéquate. Cessez votre travail an
de prendre les mesures nécessaires pour améliorer
la ventilation dans l'aire de travail. Ne poursuivez
pas l'opération si le malaise persiste.

4. Consultez ANSI/ASC Standard Z49.1 (à la page
suivante) pour des recommandations spéciques
concernant la ventilation.

16

SECTION 1 SÉCURITÉ

5. AVERTISSEMENT : Ce produit, lorsqu'il est utilisé
dans une opération de soudage ou de
coupage, dégage des vapeurs ou des
gaz contenant des chimiques consid­éres par l'état de la Californie comme
étant une cause des malformations
congénitales et dans certains cas, du
cancer. (California Health & Safety
Code §25249.5 et seq.)

MANIPULATION DES CYLINDRES -­La manipulation d'un cylindre, sans
observer les précautions nécessaires,
peut produire des fissures et un

échappement dangereux des gaz.
Une brisure soudaine du cylindre, de la soupape ou
du dispositif de surpression peut causer des bles­sures graves ou mortelles. Par conséquent :

1. Utilisez toujours le gaz prévu pour une opération

et le détendeur approprié conçu pour utilisation
sur les cylindres de gaz comprimé. N'utilisez jamais
d'adaptateur. Maintenez en bon état les tuyaux et
les raccords. Observez les instructions d'opération
du fabricant pour assembler le détendeur sur un
cylindre de gaz comprimé.

2. Fixez les cylindres dans une position verticale, à

l'aide d'une chaîne ou une sangle, sur un chariot
manuel, un châssis de roulement, un banc, un mur,
une colonne ou un support convenable. Ne xez
jamais un cylindre à un poste de travail ou toute autre
dispositif faisant partie d'un circuit électrique.

3. Lorsque les cylindres ne servent pas, gardez les

soupapes fermées. Si le détendeur n'est pas bran­ché, assurez-vous que le bouchon de protection de
la soupape est bien en place. Fixez et déplacez les
cylindres à l'aide d'un chariot manuel approprié.
Toujours manipuler les cylindres avec soin.

4. Placez les cylindres à une distance appropriée

de toute source de chaleur, des étincelles et des
ammes. Ne jamais amorcer l'arc sur un cylindre.

5. Pour de l'information supplémentaire, consultez

CGA Standard P-1, "Precautions for Safe Handling
of Compressed Gases in Cylinders", mis à votre dis­position par le Compressed Gas Association, 1235
Jeerson Davis Highway, Arlington, VA 22202.

ENTRETIEN DE L'ÉQUIPEMENT -- Un équipe­ment entretenu de façon défectueuse ou
inadéquate peut causer des blessures
graves ou mortelles. Par conséquent :

1. Efforcez-vous de toujours confier les tâches
d'installation, de dépannage et d'entretien à un
personnel qualié. N'eectuez aucune réparation
électrique à moins d'être qualié à cet eet.

2. Avant de procéder à une tâche d'entretien à
l'intérieur de la source d'alimentation, débranchez
l'alimentation électrique.

3. Maintenez les câbles, les ls de mise à la terre,
les branchements, le cordon d'alimentation et la
source d'alimentation en bon état. N'utilisez ja­mais un équipement s'il présente une défectuosité
quelconque.

4. N'utilisez pas l'équipement de façon abusive. Gardez
l'équipement à l'écart de toute source de chaleur,
notamment des fours, de l'humidité, des aques
d'eau, de l'huile ou de la graisse, des atmosphères
corrosives et des intempéries.

5. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de la console et maintenez-les
en bon état.

6. Utilisez l'équipement conformément à son usage
prévu et n'eectuez aucune modication.

INFORMATIONS SUPPLÉMENTAIRES RELA­TIVES À LA SÉCURITÉ -- Pour obtenir de
l'information supplémentaire sur les règles
de sécurité à observer pour l'équipement
de soudage à l'arc électrique et le coupage,
demandez un exemplaire du livret "Precau­tions and Safe Practices for Arc Welding,
Cutting and Gouging", Form 52-529.

Les publications suivantes sont également recomman­dées et mises à votre disposition par l'American Welding
Society, 550 N.W. LeJuene Road, Miami, FL 33126 :

1. ANSI/ASC Z49.1 - "Safety in Welding and Cutting"

2. AWS C5.1 - "Recommended Practices for Plasma Arc
Welding"

3. AWS C5.2 - "Recommended Practices for Plasma Arc
Cutting"

4. AWS C5.3 - "Recommended Practices for Air Carbon
Arc Gouging and Cutting"

17

SECTION 1 SÉCURITÉ

SIGNIFICATION DES SYMBOLES
Ce symbole, utilisé partout dans ce manuel,
signie "Attention" ! Soyez vigilant ! Votre
sécurité est en jeu.

DANGER

Signie un danger immédiat. La situation peut
entraîner des blessures graves ou mortelles.

AVERTISSEMENT

Signie un danger potentiel qui peut entraîner des
blessures graves ou mortelles.

ATTENTION

Signie un danger qui peut entraîner des blessures
corporelles mineures.

18

SECTION 2 DESCRIPTION

Features

Arc voltage feeder capable of use with CC or CV units.•
Available with “NAS” or “CC” torch connection.•
4 roll drive unit•
All units include secondary contactor.•
Built for harsh environments such as construction sites, •
pipe lines, shipyards, oshore, general fabrication, mo­bile welding rigs and more.
Totally enclosed, impact-resistant case protects weld-•
ing wire from dirt, metal grit, moisture and other con­taminants - a unique “rain gutter” door design keeps
water from dripping into the wire compartment.
Metal reinforced, ame retardant, molded compos-•
ite plastic case will stand extreme abuse like hot slag,
grinding sparks, corrosive chemicals, knocks, bumps,
drops and more.
Operates with reverse polarity (wire DC +) or straight •
polarity (wire DC-).
Permanent magnet drive motor with PWM drive, solid •
state control - provides powerful, dependable wire
feeding and controlled wire acceleration for smooth
arc starts and chatterfree operation.
Electronic Dynamic Braking•
Safety features include insulated case, low voltage •
torch trigger circuit and overload protection.
Designed to meet the most rigid standards. CSA cer-•
tied for USA and Canadian requirements. Meets
lEC-974-1 specications.
Three-year-warranty•

MobileMaster IV cvcc

Ordering Information

Each MobileMaster IV cvcc wire feeder includes gas solenoid
and .045-1/16 in. (1.2-1.6 mm) dual groove serrated feed rolls.

MobileMaster IV cvcc, NAS ............................ 0558001334

MobileMaster IV cvcc, NAS w/Meters

......................................................................................0558001801

Specications

MobileMaster IV cvcc

Wire Speed Range* ......................................50 - 700 ipm (1.3 - 17.8 m/min)

* actual speed range will depend on the arc voltage

Wire Diameter Capacity .................................. .030 - 5/64 in. (0.8 - 2.0 mm)

Primary Input** (open circuit voltage or arc voltage)

Minimum....................................................................................................16 vdc

Maximum ........................................................................100 vdc (113v peak)

** not for use with AC power

Weight ................................................................................................ 30 lbs (13 kg)

Common to MobileMaster IV cvcc

Standard - 2 in. (5.1 cm) I.D. spindle hub
8 in. (20.3 cm) O.D. spools - require adaptor P/N 17511
10 in. (25.4 cm) O.D. spools - require adaptor P/N 34330
12 in. (30.5 cm) O.D. spools - no adaptor required
14 lb. (6.5 kg) coils - require adaptor P/N 37337

Physical Dimensions

W x H x L ....................9.5 in. (24.1 cm) x 14.0 in. (35.6 cm) x 26.9 in. (68.3 cm)

MobileMaster IV cvcc feeders will t through 16 in. (41 cm) diameter
hole.

Required Accessories

Drive Rolls & Guide Tubes ............................ see Table on next page

19

SECTION 2 DESCRIPTION

Unique rear handle makes it easy
to maneuver feeders into tight spots

Current Wire Spool
Hub Conguration

Optional control kits
are available for the
MobileMaster IV cvcc

Wire drive system
uses dual groove feed rolls and
gear-driven pressure roll for
maximum feeding force

Optional Accessories

Door latch, hinge and

recessed fold-down

top handle

Shock mounts and

a exible base provide

“give” to the case enabling

the wire feeder to survive a

drop, even fully loaded

Optional Digital Meter
(see Accessories for
details)

5 amp
Circuit Breaker

Built-in,
insulated
gun holder

Built-in, insulated quick connector - no
extra gas hoses or switch cables hanging
from the feeder

Drive Roll and Guide Tube Selection

“Rain Gutter” around

door keeps water from

getting inside feeder

Controls are located on
a recessed front panel to
protect dials
and switches

Voltage pickup cable is
included with
MobileMaster IV cvcc

Gas Flowmeter Kit -

Includes an adjustable owmeter with mounting hardware and pro­tective guard that attaches to rear of MobileMaster IV cvcc feeders.
Flow tube is calibrated in cubic feet per hour and liters per min.

shielding gas, order .................................................................37365

For CO

2

For Argon shielding gas mixtures, order .........................................36658

Digital Meter Kit ­ This kit provides a digital display of voltage and wire feed speed (ipm

or m/min) ..............................................................................................2354 0446

Gas Pre/Postow w/Burnback Kit -
This kit provides adjustment for shielding gas preow time (sec) and

postow time (sec). Adjustable burnback stops the wire feed before
the arc is stopped and keeps the wire from sticking to the weld
puddle.

.......................................................................................................................... 36661

Burnback Control Kit ­ Adjustable burnback stops the wire feed before the arc is stopped ...

.......................................................................................................................... 36657

Contactor Replacement ...................................................................1373 5590

Coil Adaptor - adapting to 14 lb. (6.5 kg) coils .................................... 37337

Spool Adaptor -

Use for adapting to 8 in. (20.3 cm) diameter spools...................... 17511

Spool Adaptor -

Use for adapting to 10 in. (25.4 cm) diameter spools ................... 34330

Wire Type

& Diameter Roll Drive*

Hard Wires (“V” groove)

.035 in. (0.9 mm) 21156** 0558001498
.045 in. (1.2 mm) 21156** 0558001498
.052 in. (1.4 mm) 21157** 0558001497
1/16 in. (1.6 mm) 21157** 0558001497

Cored Wires (Knurled “V” groove)

.035 in. (0.9 mm) 21160*** 0558001499
.040 in. (1.0 mm) 21161*** 0558001498
.045 in. (1.2 mm) 21161*** 0558001498
.052 in. (1.4 mm) 21161*** 0558001497
1/16 in. (1.6 mm) 21161*** 0558001497
5/64 in. (2.0 mm) 21162*** 0558001497

Soft (aluminum) Wire (“U” groove)

.035 in. (0.9 mm) 21158** 0558001903
3/64 in. (1.2 mm) 21159** 0558001904
1/16 in. (1.6 mm) 21159** 0558001904

* Two drive rolls are required for four roll drive systems.
** Use at, plain pressure roll(s) (P/N 2361 2397) supplied with

wire feeder.

*** Flat, knurled pressure roll(s) (P/N 2361 2369).

Guide Tube

NAS

20

SECTION 2 DESCRIPTION

2.1 GENERAL

This manual has been prepared especially for use in famil­iarizing personnel with the design, installation, operation,
maintenance, and troubleshooting of this equipment. All
information presented here-in should be given careful
consideration to assure optimum performance of this
equipment.

2.2 RECEIVING-HANDLING

Prior to installing this equipment, clean all packing mate­rial from around the unit and carefully inspect for any
damage that may have occurred during shipment. Any
claims for loss or damage that may have occurred in transit
must be led by the purchaser with the carrier. A copy of
the bill of lading and freight bill will be furnished by the
carrier on request if occasion to le claim arises.

TABLE 2-1. SPECIFICATIONS

2.3 DESCRIPTION

The MobileMaster IV cvcc is a push type portable wire
feeder designed for maximum versatility. The unit oper­ates entirely on the arc voltage from a constant current
or constant voltage welding power source. All models in­clude a secondary contactor for added operator safety.

The unit is designed for use with hard, soft, and cored
electrodes (gas shielded or self-shielded) from 0.023”
through 5/64” diameter with wire feed speed from 50 to
700 IPM. The feeder components are totally enclosed in
a rugged case for optimum mobility.

NOTE

The MobileMaster IV cvcc is not recommended for
short-circuiting transfer using constant current
power sources due to the limited short current

available.

Wire Feed Speed 50 - 800 in./min. (1.3 - 20.3 m/min.)
Maximum open circuit voltage 100 vdc
Wire diameters Hard: .030” (0.8 mm), .035” (0.9 mm), .045” (1.2 mm), .052” (1.4 mm), 1/16” (1.6 mm)
Soft: .035” (0.9 mm), 3/64” (1.2 mm), 1/16” (1.6 mm)
Cored: .030” (0.8 mm), .035” (0.9 mm), .045” (1.2 mm), .052” (1.4 mm), 1/16” (1.6 mm), 5/64” (2.0mm)

Wire supply 8” (203 mm), 10” (254 mm) and 12” (305 mm) diameter spools or 14 lb. (6.4 kg) coils*
Motor type DC permanent magnet pre-lubricated, totally enclosed
Brake type (wire) Drag
Control Solid State
Feed System Push
On-O Switch Standard
Run in start Automatic if required.

Height 14.0” (356 mm)
Width 9.5” (241 mm)
Length 26.9 (683 mm)
Weight (without spool and no contactor) 26 lbs. (11.8 kg)
Weight (with contactor, without spool) 30 lbs. (13.6 mg)

* 8 in. spool requires spool adaptor P/N 17511; 10 in spool requires spool adaptor P/N 34330; and 14 lb coil requires coil adaptor P/N 37337.

The MobileMaster IV cvcc will t through a 16” (406 mm) dia. hole.

21

SECTION 2 DESCRIPTION

22

SECTION 3 INSTALLATION

3.1 DRIVE ROLLS

3.2 WELDING WIRE SPOOL

The unit is supplied ready to feed 0.045”, .052” or 1/16” (1.2
to 1.6mm) diameter cored wires. (Other drive rolls are avail­able to feed other sizes of hard wire, soft wire, and cored
wire. See Drive Roll and Guide Tube Selection in Section

2) The drive roll has two grooves; the small groove feeds

0.045” diameter wire, the large groove feeds .052 and 1/16”
diameter wire. The groove nearest the gear motor feeds
the wire. If the required groove is not in that position or a
dierent drive roll is required:

A. Release the pressure roll assembly lever and lift the

assembly upward.

B. Remove the thumb screw holding the drive roll to the

gear motor shaft.

C. Remove the drive roll and reverse or replace with the

required size for the wire chosen.
D. Secure the screw removed in “B” and tighten.
E. Secure the pressure roll assembly.

Install a spool of welding wire on the hub as follows:

A. Unscrew the spool nut from the hub.
B. Place the wire spool on the hub to rotate clockwise

as the wire is unwound; hub pin must engage the
hole in the wire spool.

C. Screw the spool nut into the hub.

NOTE: If using wire from an 8 or 10-in. spool or from a

14-lb. coil, install proper adaptor (see Optional
Accessories).

TORCH

CONNECTION

PRESSURE

ROLL

CURRENT WIRE SPOOL

HUB CONFIGURATION

WELDING CABLE

CONNECTION

DRIVE

ROLL

Figure 3.1 - Typical Set-up of MobileMaster IV cvcc

23

SECTION 3 INSTALLATION

3.3 TORCH CONNECTIONS

The torch adaptor on the MobileMaster IV cvcc connects
directly to the wire feeder wire drive assembly, power
and shielding gas supply. Line up the torch connector
with the wire feeder adaptor, push on rmly and hand
tighten the holding screw on the NAS Adaptor. The NAS
Adaptor requires the torch trigger leads to be connected
separately.

Make sure the torch chosen is of the proper rating
for the welding current to be used, has the proper
size and type of liner, the proper contact tip and the
proper guide tube.

3.4 SUPPLY CONNECTIONS

Before making any connections between the wire
feeder and the welding power source, turn o power
to the welding power source and the wire feeder.

Be sure to properly insulate this connection before ap­plying power to the power source. Uninsulated cable
and parts can arc when contacting a grounded sur­face. The arc may damage eyes or start a re. Body
contact with an uninsulated weld cable connector, or
uncovered conductor can shock, possibly fatally.

B. Connect a second welding cable to the opposite polar-

ity output connection on the power source and to the
work piece.

C. Connect the wire feeder work lead alligator clip to the

work piece.

D. If using with gas shielded wire, connect the inlet gas

hose to the gas inlet connections on the rear of the
feeder.

1. Make sure all hose and cable connections are
tight.

2. Turn power source ON and close the contactor if
power source is equipped with an output contactor.
Open circuit voltage must be present to operate the
wire feeder.

3. Turn the wire feeder ON and close the torch trig­ger.

The MobileMaster IV cvcc can be used with either po­larity without modications.

A. Connect the proper polarity output welding

cable from the power source; positive terminal
for gas shielded wires, or negative for most gas­less self-shielded cored wires, to the weld cable
lug connection extending from the rear of the
MobileMaster IV cvcc feeder.

- (or +) + (or -)

Unless starting to weld, do not allow the welding wire
to touch a grounded metal surface. The welding wire
becomes electrically hot when the secondary contactor
is closed. Keep ngers clear of the drive rolls; they will
start turning when the torch trigger is pressed.

4. Inspect all gas connections for leaks.

5. If using gas shielded wires, adjust the gas owmeter
to the desired ow rate.

6. Turn power source and wire feeder OFF.

Figure 3.2 - Typical Set-up of MobileMaster IV cvcc

24

SECTION 3 INSTALLATION

3.5 THREADING THE WELDING WIRE

When the wire feeder is connected to the power source,
the work lead from the power source connected to the
work piece, the wire feeder work lead connected to
the work, and the power source is turned on with the
contactor closed, the wire feeder is energized when the
wire feeder is turned on. Closing the torch trigger will
cause the welding wire to become electrically hot, and
will cause the drive rolls to turn. Keep ngers clear!

A. Turn OFF the power source and the wire feeder.
B. Release the pressure roll assembly levers and check for

the proper drive roll and groove position.

Before threading welding wire through the casing, make
sure the chisel point and burrs have been removed from
the end of the wire to prevent the wire from jamming in
the torch casing or liner.

C. Feed the wire from the spool through the inlet guide

along the drive roll groove and into the torch inlet
guide.

D. Lower the pressure roll assemblies and adjust the drive

roll pressure to assure no wire slippage, but not too tight
to create excess pressure.

E. Turn ON the power source and the wire feeder. Close

the torch trigger to feed wire through the torch.

3.6 BRAKE DRAG ADJUSTMENT

Brake disc friction should provide enough drag to keep
the wire spool from spinning freely after the wire feed
stops. If adjustment is required, turn the adjusting
screw clockwise to increase drag, counterclockwise to
decrease drag. Drag should be just enough to limit wire
overrun.

25

SECTION 3 INSTALLATION

26

SECTION 4 OPERATION

4.1 CONTROLS

4.1.1 POWER SWITCH

The ON-OFF switch on the front of the wire feeder case
energizes the wire feeder when the feeder is connected
to the power source and the work piece, and the power
source is turned ON with the contactor closed.

4.1.2 WIRE FEED SPEED (ARC VOLTAGE CONTROL)

The wire feed speed is controlled by the wire feed speed
dial on the front of the wire feeder case. When connected
to a constant voltage (cv) type power source, the wire
feed speed dial controls the welding current. Turning
the dial clockwise increases welding current; turning it
counterclockwise decreases welding current.

When connected to a constant current (cc) type power
source, the wire feed speed dial controls the arc voltage.
Turning the wire feed speed dial clockwise decreases arc
voltage; turning it counterclockwise increases arc voltage.
The actual wire feed speed for any given setting varies
with the arc voltage. Increasing arc voltage causes an
increase in wire feed speed.

4.1.3 WIRE FEED SPEED (CONSTANT SPEED)

The MobileMaster IV can be switched to a “Non” Voltage
Control Mode where the wire feed speed remains relatively
constant and will not change speed with changes in arc
voltage. Locate switch SW1 on the PC board and position
S1 and S2. See Figure 4-2. Factory settings are as follows:
S1 - closed, S2 - open.

SW1

Position S1 - open

Position S2 - closed

Figure 4.2

DIP Switch Functions

The MobileMaster IV wire feeder is equipped with auto­matic “Slow wire run-in”. If the wire feeder senses that the
power source output voltage is in excess of 33 volts, the
“run-in” wire speed automatically decreases for a xed
period of time (250ms) to improve arc starts. When the
arc is established, the wire feed speed is controlled by
the wire feed speed control knob on the MobileMaster
IV front panel.

OPT. METER KIT

10A FUSE

5A CIRCUIT
BREAKER

POWER ON-OFF

SWITCH

WIRE SPEED

CONTROL

TORCH

CONNECTION

WORK LEAD

The DIP switches are located on the control PCB mounted
inside the upper compartment of the wire feeder. See fol­lowing table for switch positions and description.

4.1.4 5 amp CIRCUIT BREAKER (CB1)

This resettable 5 amp circuit breaker, in series with mo­tor armature, protects the control board from damage if
the motor is stalled.

SHIELD GAS

CONNECTION

WELDING CABLE

CONNECTION

(Figure 2.1)

Figure 4.1 - Controls and Connections, MobileMaster IV cvcc

27

SECTION 4 OPERATION

MobileMaster IV Dip Switch Table

Switch Position

OPEN (OFF)

CLOSED (ON)

OPEN

Rocker

Down

Factory Setting - Constant Current Operation ( “Voltage Control Mode” )

1
2

In this operation mode the MobileMaster IV feeder is ready for connection to a “
Constant Current “ power source which typically provides a high open circuit voltage
and low short circuit current which makes arc starting dicult. Therefore, “slow run­in” of the wire is automatically enabled if OCV exceeds 33 volts to provide good and
reliable arc starting. The arc length during welding is determined by a combination
of the wire feed speed knob position (MobileMaster IV feeder front panel) and the
weld “Current” setting on the CC power source. When a good welding condition is
achieved, the arc length will be maintained by changes in wire feed speed provided
by arc voltage control. Variables causing changes in arc voltage, for example, wire
“stick-out”, wire density or shielding variations, will cause the wire feed speed to
compensate to maintain the arc length preset.

Description

OPEN

1
2

Rocker

Down

Alternate Setting - Constant Voltage Operation ( “Constant Wire Feed Speed” )

In this operation mode the feeder is ready for connection to “ Constant Voltage “
power source which is typically used for most GMAW (MIG/MAG) welding. CV power
sources provide high short circuit currents for good arc starting and wire burn-o.
“Slow run-in” of the wire is automatically disabled. The arc length while welding is
determined by a combination of the wire feed speed knob position (MobileMaster IV
feeder front panel) and the weld “Voltage” setting on the CV power source. When a
good welding condition is achieved, the arc length will be maintained by the power
source and the wire feed speed will remain constant. Any variations in wire “stick­out”, wire density or shielding variations, could cause the arc length (arc voltage)
variations.

NOTE:

If both switches are placed in the OPEN (O) position the wire feed motor is disabled and the motor will NOT run.

28

SECTION 4 OPERATION

4.2 OPERATING PROCEDURES

4.2.1 OPERATING SAFETY PRECAUTIONS

Comply with all ventilation, re and other safety require­ments for arc welding as established in the SAFETY Section
at the front of this manual.

A. Because of the radiant energy of the welding arc and

the possibility of drawing an arc before the helmet is
lowered over the face, the operator should wear ash
goggles with lter lenses under his helmet. The hel­met lter plate should be shade number 11 (nonfer­rous) or 12 (ferrous). All those viewing the arc should
use helmets with lter plates, as well as ash goggles.
Nearby personnel should wear ash goggles.

B. The radiant energy of the arc can decompose chlo-

rinated solvent vapors, such as trichloroethane and
perchlorethylene, to form phosgene, even when
these vapors are present in low concentrations. DO
NOT weld where chlorinated solvents are present in
atmospheres in or around the arc.

C. DO NOT touch the electrode, contact tip or metal parts

when power is ON: all are electrically energized (HOT)
and can cause a possibly fatal shock. DO NOT allow
electrode to touch grounded metal. It will create an
arc ash that can injure eyes. It may also start a re or
cause other damage.

D. When working in a conned space, be sure it is safe

to enter. The conned space should be tested for
adequate oxygen (at least 19%) with an approved
oxygen measuring instrument. The conned space
should not contain toxic concentrations of fumes
or gases. If this cannot be determined, the operator
should wear an approved air supplied breathing ap­paratus. Avoid gas leaks in a conned space, as the
leaked gas can dangerously reduce oxygen concen­tration in the breathing air. DO NOT bring gas cylin­ders into conned spaces. When leaving a conned
space, shut OFF gas supply at the source to prevent
gas from leaking into the space. Check the breathing
atmosphere in the conned space to be sure it is safe
to reenter.

E. Never operate the equipment at currents greater than

the rated ampere capacity. Overheating will occur.

F. Never operate equipment in a damp or wet area with-

out suitable insulation for protection against shock.
Keep hands, feet and clothing dry at all times.

G. Whenever the equipment is left unattended, turn

OFF all control power, power supply switches and gas
supplies. Open the main line switch.

H. Wear dark substantial clothing to protect exposed

skin from arc burn, sparks and ying hot metal.

I. Turn o welding power before adjusting or replacing

electrodes.

WARNING

When the power switch is ON, and torch trigger is
depressed, the electrode wire becomes electrically
hot and the wire feed rolls are activated. Do not touch
the wire as it may cause a possibly fatal shock. Unless
welding, do not allow wire to touch a grounded metal
surface as it will cause an arc ash. Keep clear of feed
rolls and drive gears.

WARNING

Prior to welding, it is imperative that proper protective
clothing (welding coat and gloves) and eye protection
(glasses and/or welding helmet) be put on. Failure to
comply may result in serious injury

CAUTION

Do not terminate the arc by removing the torch from
the weld area. Release the torch trigger to stop welding
before removing the torch.

WARNING

Failure to shut OFF shield gas in a conned space may
result in a build-up of fumes, displacing oxygen.

29

SECTION 4 OPERATION

4.3 CHANGING METER DISPLAY - IPM TO MPM

WARNING

TO PREVENT ACCIDENTAL ELECTRIC SHOCK, BE
SURE CONTROL CABLE IS DISCONNECTED FROM
POWER SOURCE BEFORE WORKING INSIDE THE
WIRE FEEDER.

Wire Speed IPM Wire Speed MPM

1. Make sure control cable is removed from the power
source.

2. Remove meter panel from front panel of the wire
feeder. Retain mounting screws.

3. Check the setting of the “dip switches” on the digital
meter board. These switches can be set up for meter
to read in inches per minute (IPM) or in meters per
minute (MPM) as shown below. The meter is factory
set in IPM positions.

Set the switch on the digital meter to the desired mode
of operation. If the IPM mode is selected, the meter will
read the PRE-SET wire speed when not feeding wire and
the ACTUAL wire speed when feeding wire. If the VOLTS
mode is selected, the meter will only read the ACTUAL
voltage.

DIP SWITCHES

OPEN

Rocker

Down

1

OPEN

2

SW1 SW1

1
2

Rocker

Down

30

DIGITAL METER

PC BOARD

DIGITAL METER

WIRE

FEED

SPEED

(IPM)

FLUX CORE

E70T-1 & 2

.045

WIRE /DIAMETER

.045

.052

1/16

.052

1/16

.035

.045

1/16

3/64

1/16

3/64

1/16

METAL CORE

STEEL

SOLID WIRE

Al/Si

ALUMINUM

Al/Mg

ALUMINUM

ARC VOLTS / AMPS (WELD CURRENT)

100

150

200

250

300

350

400

450

500

550

600

650

29

25

30

33

36

29

150

30

250

33

290

34

330

155

300

460

500

37

500

210

33

365

30

300

27

190

33

410

33

450

29

260

28

250

30

270

29

300

29

275

30

325

32

400

30

350

30

300

34

450

25

180

25

20026215

27

230

28

245

25

260

26

28027300

26

290

27

34030400

28

320

30

340

25

110

25

14026150

26

190

26

200

23

26030300

32

350

27

20527220

22

100

23

15023175

24

190

25

20525220

23

20025250

27

280

27

29028340

32

300

32

350

39

500

SECTION 4 OPERATION

4.4 SETTING A WELDING PROCEDURE

QUICK SET-UP PROCEDURE

For Constant Voltage (CV) Power Source - Set the arc voltage desired on the 1.
P/S.
For Constant Current (CC) power source - Set the weld CURRENT desired.2.
On the MobileMaster IV Unit - Set the wire feed speed knob at #5.3.

WELD DATA TABLE

WIRE / DIAMETER

FLUX CORE

E70T-1 & 2

METAL

CORE

STEEL

SOLID WIRE

AL / Si

ALUMINUM

AL / Mg

ALUMINUM

WIRE FEED SPEED (IPM)

ARC VOLTS / AMPS (WELD CURRENT)

31

SECTION 4 OPERATION

MobileMaster IV with

Constant Current Power Sources

Using the table, select the weld CURRENT / VOLT-1.
AGE needed for the wire type and diameter to be
welded.
Set the power supply CURRENT using the cur-2.
rent control knob on the front panel of the power
source.
Read the WIRE FEED SPEED (WFS) at the top of the 3.
column for the wire type, diameter and weld VOLT­AGE / CURRENT chosen.

NOTE

If dIgital meter is installed skip to step

4A.

Use the VOLTAGE and WFS in the WFS Table to 4.
determine the MobileMaster IV wire feed knob posi­tion.
Strike an arc then trim the arc length as needed us-5.
ing the VOLTS / WFS knob.

MobileMaster IV with

Constant Voltage Power Sources

Using the table, select the weld VOLTAGE / CUR-1.
RENT needed for the wire type and diameter to be
welded.
Set the power supply VOLTAGE using the volt-2.
age control knob on the front panel of the power
source.
Read the WIRE FEED SPEED (WFS) at the top of the 3.
column for the wire type, diameter and weld VOLT­AGE / CURRENT chosen.

NOTE

If dIgital meter is installed skip to step

4A.

Use the VOLTAGE and WFS in the WFS Table to 4.
determine the MobileMaster IV wire feed knob
position.
Strike an arc then trim the arc length as needed 5.
using the VOLTS / WFS knob.

4a. Flip the MobileMaster IV digital display switch to the

WFS position.

5a. Release the pressure roll assembly and pull the gun

trigger then set the WFS on the digital display using
the VOLTS / WFS knob.

6a. Reset the pressure roll assembly and strike an arc

then trim the arc length as needed using the VOLTS /
WFS knob.

NOTE

Using the “Constant Feed” dip switch settings when using a CC power source is NOT RECOMMENDED. Extreme wire feed
speed sensitivity exists making it dicult to set stable welding condition. The arc stability is very dependant on maintain­ing constant TTW distance which is almost impossible to control when welding manually. “Constant Speed” settings is only
recommended for use with CV power sources.

Typical welding voltages for 5000 Aluminum are between 21 and 25 volts which limits the wire feed speed of the
MobileMaster IV especially if trying to weld with 035” diameter 5356 alloy. Welding with wire diameters ≤3/64” and/or be­low 22 arc volts could cause problems with limited wire feed speed and the inability to achieve a good welding condition.

4a. Flip the MobileMaster IV digital display switch to

the WFS position.

5a. Release the pressure roll assembly and pull the gun

trigger then set the WFS on the digital display using
the VOLTS / WFS knob.

6a. Reset the pressure roll assembly and strike an arc

then trim the arc length as needed using the VOLTS
/ WFS knob.

32

WFS

Set

19 V 20 V 21 V 22 V 23 V 24 V 25 V 26 V 27 V 28 V 29 V 30 V 31 V 32 V 33 V 34 V

Min 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0

1 4 5 5 6 6 7 7 7 9 11 12 15 14 13 13 11
2 44 51 56 65 70 74 77 85 90 93 95 103 102 102 101 100
3 99 109 116 129 136 140 144 155 165 173 179 196 198 200 201 205
4 152 163 170 184 196 204 211 230 241 250 256 275 282 287 291 302
5 210 225 235 255 270 281 290 315 329 339 347 370 379 385 390 405
6 267 282 292 312 331 345 356 388 412 430 443 483 490 495 499 510
7 334 354 368 395 415 430 441 475 503 524 540 587 594 599 603 615
8 380 411 431 472 494 511 523 560 589 610 626 675 685 693 698 715
9 385 427 454 510 536 556 571 615 649 674 693 750 770 785 796 830

Max 395 435 462 515 544 565 581 630 667 695 716 779 803 820 833 873

SECTION 4 OPERATION

WIRE FEED SPEED TABLE

* Wire

Speed Set

Min

Max

* MobileMaster IV Wire Feed Speed Knob Position

On many CV power sources the actual welding arc voltage is usually less the “Open Circuit Voltage” (OCV) set on the power
source front panel. Therefore, an extra 3 to 6 volts should be added to the power source front panel setting to achieve the
“actual” arc voltage needed or shown in the tables.

4.5 SHUTDOWN

NOTE

A. Release torch trigger to break the arc.

B. When leaving the equipment unattended, always shut OFF and disconnect all power to the equipment and shut o the

shielding gas supply at source.

33

SECTION 5 MAINTENANCE

34

SECTION 5 MAINTENANCE

5.1 MAINTENANCE

WARNING

Be sure the branch circuit or main disconnect switch is
OFF or electrical input circuit fuses are removed from
the power source main supply before attempting any
inspection or work on the inside of the wire feeder.
Placing the power switch on the welding machine in
the OFF position does not remove all power from inside
of the equipment.

WARNING

Inspection, troubleshooting, and repair of this equip­ment should be undertaken by a competent individual
having at least general experience in the maintenance
and repair of semi-conductor electronic equipment.
Maintenance or repair should not be undertaken by
anyone not having such qualications.

As an aid in checking and servicing, refer to the following
pages; Schematic Diagram and/or Wiring Diagram.

5.2 INSPECTION AND SERVICE

Keep equipment in clean and safe operating condition,
free of oil, grease, and (in electrical parts) liquid and metal­lic particles which can cause short-circuits.

Regularly check cylinder valves, regulators, hoses, and gas
connections for leaks with soap solution.

Check for and tighten loose hardware including electrical
connections. Loose power connections overheat during
welding.

Immediately replace all worn or damaged power cables
and connectors. Check for frayed and cracked insulation,
particularly in areas where conductors enter Equipment.

WARNING

If uninsulated cable and parts are not replaced, an arc
caused by a bared cable or part touching a grounded
surface may damage unprotected eyes or start a re.
Body contact with a bared cable, connector, or uncov­ered conductor can shock, possibly fatally.

Keep power cables dry, free of oil and grease, and protect­ed at all times from damage by hot metal and sparks.

Clean dirt and metal particles from drive roll groove
weekly; replace roll if badly worn.

5.2.1 WIRE FEEDER

When soft wire is fed, the drive rolls may pick up metal
from the wire surface. Accumulation on the rolls may score
the wire with resulting unwanted friction and improper
feeding.

Inspect the rolls regularly and clean them with a ne-wire
power brush. Avoid roughening, or removing the hardness
of groove surfaces in grooved rolls. Any roughening may
score the wire, just as the accumulation being removed
may do.

5.2.2 SOLENOID VALVE REPLACEMENT

If there is no gas ow through the wire feeder, the gas
solenoid valve may be clogged or electrically malfunc­tioning and it should be replaced. When replacing the
gas solenoid valve, the inlet (with the word IN) must face
the rear of the unit.

5.2.3 GENERAL REPLACEMENT

The views in the Parts Section indicate wire drive and
feeder parts.

The electrode wire and all metal parts in contact with it are
electrically energized while welding. Inspect these parts
periodically for defective insulation and other electrical
hazards.

35

SECTION 5 MAINTENANCE

5.3 TROUBLESHOOTING

If welding equipment does not work properly, inspect as
follows:

A. With all power controls ON and other operating

controls at required settings, visually check all power
cables and connections for evidence of overheating
or sparking.

WARNING

To avoid shock, do not touch electrode wire or parts in
contact with it, or uninsulated cable or connections.

B. Check all gas hoses and connections, owmeters, and

regulators for possible sources of leakage, breakdown,
or intermittent failure.

C. Isolate trouble to one part of the welding installation:

primary power supply, power source, wire feeder, or
wire guide train (casing, drive rolls, liners, and con­tact tip). If this inspection indicates trouble in the
wire feeder, refer to the following pages; Schematic
Diagram and/or Wiring Diagram.

WARNING

Many troubleshooting situations require that the
power remain on and that power terminals in the
equipment carry voltage. Exercise extreme caution
when working on “live” equipment. Avoid contact with
electrical components, except when testing with an
appropriate instrument.

CAUTION

Do not make any repairs to equipment unless you
are fully qualied, as described in the maintenance
section.

36

SECTION 5 MAINTENANCE

NOTE:

Schematics and Wiring Diagrams on 279.4mm x 431.8mm

(11” x 17”) paper are included inside the back cover of this manual.

37

SECTION 5 MAINTENANCE

38

SECTION 6 REPLACEMENT PARTS

6.0 Replacement Parts

6.1 General

Always provide the serial number of the unit on which the parts will be used. The serial number is stamped on
the unit nameplate.

6.2 Ordering

To ensure proper operation, it is recommended that only genuine ESAB parts and products be used with this
equipment. The use of non-ESAB parts may void your warranty.

Replacement parts may be ordered from your ESAB Distributor.

Be sure to indicate any special shipping instructions when ordering replacement parts.

Refer to the Communications Guide located on the back page of this manual for a list of customer service phone
numbers.

Note

Bill of material items that have blank part numbers are provided for customer information only.

Hardware items should be available through local sources.

39

SECTION 6 REPLACEMENT PARTS

*

CASE, MOLDED - 952680

LATCH, LIFT/TURN - 952684

(R1) POT. LIN 10K 2W - 13730632

HANDLE, FOLDING 2 POS - 952626

(2) NUT, HANDLE - 37334

KNOB - 13730611

PANEL, CONTROL, SILKSCREENED - 32321BK

(J5) TORCH ADAPTOR ASSY. (NAS) - 0558001492

Includes:

Housing - 23610528

Block Assy. - 0558001493

Screw Assy. - 0558001495

Power Lug - 23612350

Conn. Tube Assy. - 0558001494

Boot - 0558001506 (NAS)

METER OPTION - 23540446

FUSE HOLDER 15A 250V - 634709

COVER, OPTION, UPPER FRONT - 34141BK

(F1) FUSE, SLO BLO 10A 250V - 13735464

2062161

5 AMP CIRCUIT BREAKER 

(S1) SWITCH, TOGGLE SPDT

2 POS 20A 125V - 13732469

SWITCH SEAL BLACK - 951474

WORK LEAD CLAMP NO. 2 - 23892433

HOLDER GUN -37333

TORCH LEAD ASSY. - 0558001496

STRAIN RELIEF - 23606172

TORCH ADAPTOR ASSEMBLY

(Internal View)

NAS TORCH SECURING SCREW ASSY. - 0558001495

*

Figure 6.1 - MobileMaster IV cvcc, Front/Right Side View

NUT, CONNECTION TUBE - 0558001836

O-RING - 0558001837

With NAS Torch Connection - 0558001334 and 0558001801

40

SECTION 6 REPLACEMENT PARTS

1/4 Brass

°

LABEL, WARNING

(Roll Pinch Hazard) - 954760

952686

(2) RIVET, Plastic Expansion -952686

(Washer, 2.50)

DOOR STIFFENER - 37806

HUB CONFIGURATION

CURRENT WIRE SPOOL

(2) STUD, RUBBER PLATE MOUNT

952687 (Hidden under 37254BK)

(K1) CONTACTOR, 12VDC 300A - 13735590

SPOOL, HUB ASSY. (See Below)

0558006262

NIPPLE, 1/4 NPTM X 3/16 ID Hose

950263

ADAPTOR, B/IGF X 1/4 NPTM

58V58

ELBOW, PIPE 90

CLAMP, 1 EAR 12.3

(4) NOMEX HINGE - 952694

950731

(16) RIVET, Plastic Expansion

SUPPORT, WIRE REEL - 37254BK

CLAMP 1 EAR 12.3 - 950731

CLAMP 1 EAR 10.0 - 951126

(SOL1) VALVE, SOLENOID - 0558006156

NIPPLE 1/8 NPTM 3/16 ID (2 ea) - 993108

TAB, LATCH - 37378BK

LABEL, WARNING (Gear Pinch Hazard) - 954698

Euro - 0558001079

GUIDE TUBE .060 - .080

4-ROLL DRIVE STAND ASSY. -0558001339

(See Fig. 5.4 & 5.5)

Figure 6.2 - MobileMaster IV cvcc, Right Inside View

(Pre/Postow/Burnback)

PLATE, BLANK, UPPER - 37258

(M1) MOTOR, KSV 5035/556 - 951529

PLATE, BLANK, LOWER - 37257

(2) DRIVE ROLL .052 - 1/16 - 21557

(See Drive Roll & Guide Tube Selection

Guide on Page 11)

41

SECTION 6 REPLACEMENT PARTS

(C1) CAPACITOR, 1.0UF 630WVDC - 951028

(PCB1) CONTROL BOARD ASSY. - 0558038286

(R2) RESISTOR, 5W - 17615250

(MOV1) VARISTOR, METAL OXIDE 950428

(BR1,BR2) (2) RECT. 35A 400V - 13730469

(P4) SHORTING PLUG ASSY. - 37580

Figure 6.3 - MobileMaster IV cvcc, Right Inside View With Upper and Lower Blanking Plates Removed

42

SECTION 6 REPLACEMENT PARTS

For units with serial numbers xxxJ228001 (Mid July 2002 forward)

DRIVE ROLLS

(See Drive Roll & Guide Tube Selection
Guide in SECTION 1)

Figure 6.4 - Auto-Lift Mini Four Roll Geared Wire Drive System - 0558001339

For units with serial numbers starting xxxJ228001 (Mid July 2002 forward)

ITEM PART NO. Q T Y. DESCRIPTION ITEM PART NO. QT Y. DESCRIPTION

1 0558001743 1 Feed Plate 15 0558001752 1 Spacer Tube Pressure Arm Auto Lift

1A 0558001744 1 Safety Guard 16 0558001753 1 Spacer Tube Bogie

2 952927 1 Screw, Thumb (M6X12) 17 0558001754 1 Axle Pressure Arm
3 0558001745 1 Pressure Arm 18 0558001755 1 Allen Screw
4 0558001746 1 Bogie 19 0459441880 2 Gear Adaptor Feed Roll
5 23612368 2 Pressure Roll 20 0558003540 2 Axle Gear Adaptor Feed Roll
6 23612477 2 Axle Pressure Roll 21 34608 3 Washer, Retaining Screw

7 0558001747 1 Locating Pin 22 952925 3 Knurled Screw
8 23612474 2 Nut, Pressure Roll Axle 23 23612460 1 Pressure Device W/Scale

9 23612472 1 Circlip 24 23612470 Pkt. 5 Locating Pin, 2.5 x 12 Pressure Device
10 34609 1 Retaining Screw Pressure Arm 25 23612462 1 Screw (Center) Guide
11 0558001748 1 Spring Bogie Auto Lift 26 0558001757 1 Center Guide (Hard Wire)
12 0558001749 1 Spring to Pressure Arm Auto Lift 0558001895 1 Center Guide for (Aluminum)
13 0558003538 2 Spacer Tube, Small 27 0558001758 1 Inlet Guide (Aluminum & Steel)
14 0558003539 2 Spacer Tube, Big 28 0558003542 1 Main Gear Drive

43

SECTION 6 REPLACEMENT PARTS

For units with serial Numbers between xxxJ102026-xxxJ228001 (Prior to Mid July 2002)

DRIVE ROLLS

(See Drive Roll & Guide Tube Selection
Guide in SECTION 1)

NOTE: Measure hole placement
to distinguish between early & cur­rent version drive stands

Figure 6.5 - Auto-Lift Mini Four Roll Geared Wire Drive System - 0558001339

For units with serial Numbers between xxxJ102026 - xxxJ228001 (Prior to Mid July 2002)

ITEM PART NO. Q T Y. DESCRIPTION ITEM PART NO. QT Y. DESCRIPTION

1 0558001743 1 Feed Plate 15 See Fig. 6.4 Same as new style

1A See Fig. 6.4 Same as new style 16 See Fig. 6.4 Same as new style

2 See Fig. 6.4 Same as new style 17 See Fig. 6.4 Same as new style
3 See Fig. 6.4 Same as new style 18 See Fig. 6.4 Same as new style
4 See Fig. 6.4 Same as new style 19 See Fig. 6.4 Same as new style
5 See Fig. 6.4 Same as new style 20 0558001756 2 Axle Gear Adaptor Feed Roll
6 See Fig. 6.4 Same as new style 21 See Fig. 6.4 Same as new style
7 See Fig. 6.4 Same as new style 22 See Fig. 6.4 Same as new style
8 See Fig. 6.4 Same as new style 23 See Fig. 6.4 Same as new style

9 See Fig. 6.4 Same as new style 24 See Fig. 6.4 Same as new style
10 See Fig. 6.4 Same as new style 25 23612462 1 Screw Intermediate Guide
11 See Fig. 6.4 Same as new style 26 See Fig. 6.4 Same as new style
12 See Fig. 6.4 Same as new style
13 0558001750 2 Spacer Tube, Small 27 0558001758 1 Inlet Guide (Aluminum & Steel)
14 0558001751 2 Spacer Tube, Big 28 0558002149 1 Main Gear Drive

44

SECTION 6 REPLACEMENT PARTS

4

2, 3

11

10

5

1

9

6

7

8

Figure 6.6 - Wire Spool Hub Assembly

Item No. Qty. Req’d. Part No. Description

2 1 64302037 Lockwasher, 3/8”
3 1 61 3 4114 4 Screw, 3/8-16 x .75
4 2 948255 Pad, Braking
5 1 0558003320 Washer, D-Type
6 1 634347 Clip, Hitch
7 1 92044046 Screw, 12043 STLZPC, 3/8-16 x 1.00
8 1 92056007 Washer, Plain 3/8”

9 1 23600982 Spring
10 1 948258 Spindle, Molded
11 1 36756 “D” Shaft

45

NOTES

46

REVISION HISTORY

The “D” edition (11/03) changed the replacement parts for the clamp, P/N 952860 to P/N 950626 1 ear 1.

13.3 GER. Various editorial changes were also made.
The “E” edition (04/04) added section 3.5 MobileMaster IV cvcc Dip Switch Table per Service Bulletin # 2.
M_04_006.
The “F” edition (04/05) added the Declaration of Conformity and “CE” logo. Removed all “EURO” con-3.
nector information and added new wire spool hub conguration per ECN# 053019. Figure 5.4 & 5.5,
Replacement Parts section - chgd item 1, feed plate p/n from: 0558003543 to: 0558001743, item 20, axle
gear adaptor p/n chgd from: 0558003540 to: 0558001756 & item 25, screw p/n chgd from: 0558003541
to: 23612462. Updated format.
The “G” edition (10/06) updated wiring diagram and changed control board part number from 31842 4.
to 0558038286 per CN #063163.
Revision 01/2007 - Numerous updates, complete replacement of section 3 & 4, numerous updates in 5.
replacement parts, updated schematics and wiring diagrams.
03 / 2008 - Updated pictures and updated Replacement Parts section per CN#083002.6.

47

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F15-610-J 03/2008