INSTRUCTION MANUAL
MobileMaster 2CV
PORTABLE WIRE FEEDER
F-15-448
July, 1998
This manual provides complete instructions for the following unit starting with Serial No. WORI822001:
36654 - MobileMaster 2cv (42 VAC)
These INSTRUCTIONS are for experienced operators. If you are not fully familiar with the principles of
operation and safe practices for arc welding 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 on pages 3 and 4 before
installing or operating this equipment.
Be sure this information reaches the operator.
You can get extra copies through your supplier.
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 equipment should not be used. Parts that are broken,
missing, plainly worn distorted or contaminated, should be replaced immediately. Should such repair or replacement
become necessary, ESAB recommends that a telephonic or written request for service advice be made to the ESAB
Authorized Distributor from whom purchased or to the nearest ESAB Sales Office.
This equipment or any of its parts should not be altered without the prior written approval of ESAB. 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 ESAB or a a service facility designated by ESAB.
TABLE OF CONTENTS
SECTION TITLE PAGE
SAFETY PRECAUTIONS ................................................................................. 3-4
SECTION 1 DESCRIPTION .................................................................................................... 7
1.1 General ................................................................................................................ 7
1.2 Receiving-Handling .............................................................................................. 7
1.3 Description ........................................................................................................... 7
1.4 Required Equipment ............................................................................................ 7
1.5 Optional Accessories ........................................................................................... 8
1.6 Safety................................................................................................................... 8
SECTION 2 INSTALLATION ................................................................................................... 9
2.1 Drive Rolls ........................................................................................................... 9
2.2 Welding Wire Spool ............................................................................................. 9
2.3 Torch Connections ............................................................................................. 10
2.4 Supply Connections ........................................................................................... 10
2.5 Threading the Welding Wire .............................................................................. 10
2.6 Brake Drag Adjustment ....................................................................................... 11
SECTION 3 OPERATION ...................................................................................................... 12
3.1 Adjustment and Operations................................................................................ 12
3.1.1 Control Setting ................................................................................................... 12
3.1.2 Feeding Wire ..................................................................................................... 12
3.1.3 Shielding Gas Flow Rate .................................................................................... 12
3.1.4 Making the Weld ................................................................................................ 13
3.2 Optional Meter ................................................................................................... 13
3.3 Operating Safety Precautions ............................................................................ 13
3.4 Shutdown ........................................................................................................... 13
SECTION 4 MAINTENANCE ................................................................................................ 14
4.1 Maintenance ...................................................................................................... 14
4.2 Inspection and Service ....................................................................................... 14
4.2.1 42 Volt Wire Feeder and Control Circuits ........................................................... 14
4.2.2 Wire Feeder ....................................................................................................... 14
4.2.3 Drive Roll Pressure Adjustment ......................................................................... 14
4.2.4 Solenoid Valve Replacement ............................................................................. 14
4.2.5 General Replacement ........................................................................................ 14
4.3 Troubleshooting ................................................................................................. 15
SECTION 5 REPLACEMENT PARTS ................................................................................... 18
2
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 fitted with the correct filter 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 flameproof gauntlet type gloves, heavy long-sleeve
shirt, cuffless 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 flameproof apron
may also be desirable as protection against radiated
heat and sparks.
4. Hot sparks or metal can lodge in rolled up sleeves,
trouser cuffs, 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-flammable partition or curtains.
6. Use goggles over safety glasses when chipping slag or
grinding. Chipped slag may be hot and can fly far.
Bystanders should also wear goggles over safety glasses.
FIRES AND EXPLOSIONS -- Heat from
flames and arcs can start fires. Hot slag
or sparks can also cause fires and explosions. Therefore:
1. Remove all combustible materials well away from the
work area or cover the materials with a protective nonflammable 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 floors or wall openings and cause a hidden
smoldering fire or fires on the floor 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 flammable or toxic vapors. Do not do hot work on
closed containers. They may explode.
4. Have fire extinguishing equipment handy for instant use,
such as a garden hose, water pail, sand bucket, or
portable fire 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 fire
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 fire. Use fire 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 confined, or if there is danger of
falling.
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.
9. Turn off the power before removing your gloves.
10. Refer to ANSI/ASC Standard Z49.1 (listed on next page)
for specific grounding recommendations. Do not mistake
the work lead for a ground cable.
ELECTRIC AND MAGNETIC FIELDS —
May be dangerous. Electric current flowing 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 effects which are
unknown.
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.
3
11/95
FUMES AND GASES -- Fumes and
gases, can cause discomfort or harm,
particularly in confined spaces. Do
not breathe fumes and gases. Shielding gases can cause asphyxiation.
Therefore:
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 specific ventilation recommendations.
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 fittings in good condition. Follow
manufacturer's operating instructions for mounting regulator to a compressed gas cylinder.
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 fixtures 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 flames.
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 Jefferson Davis Highway, Arlington,
VA 22202.
EQUIPMENT MAINTENANCE -- Faulty or improperly maintained equipment can cause
injury or death. Therefore:
perform any electrical work unless you are qualified 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.
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"
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."
This symbol appearing throughout this manual
means Attention! Be Alert! Your safety is
involved.
The following definitions apply to DANGER, WARNING,
CAUTION found throughout this manual:
Used to call attention to immediate hazards which, if not avoided, will result in
immediate, serious personal injury or loss
of life.
Used to call attention to potential hazards which could result in personal injury
or loss of life.
1. Always have qualified personnel perform the installation, troubleshooting, and maintenance work. Do not
Used to call attention to hazards which
could result in minor personal injury.
4
PRÉCAUTIONS DE SÉCURITÉ
AVERTISSEMENT: Ces règles de sécurité ont pour objet
d’ assurer votre protection. Veillez à lire et à observer les
précautions énoncées ci-dessous avant de monter l’
équipement ou de commercer à l’utiliser. Tout défaut
d’observation de ces précautions risque d’entraîner des
blessures graves ou mortelles.
1. PROTECTION INDIVIDUELLE-- Les brûlures de la
peau et des yeux dues au rayonnement de l’arc
électrique ou du métal incandescent, lors du soudage
au plasma ou à l’électrode ou lors du gougeage à
l’arc, peuvent s’avérer plus graves que celles
résultant d’une exposition prolongée au soleil. Aussi
convient-il d’observer les précautions suivantes:
a. Portez un écran facial adéquat muni des plaques
protectrices et des verres filtrants appropriés afin de
vous protéger les yeux, le visage, le cou et les oreilles
des étincelles et du rayonnement de l’arc électrique
lorsque vous effectuez des soudures ou des coupes
ou lorsque vous en observez l’exécution.
AVERTISSEZ les personnes se trouvant à proximité
de façon à ce qu’elles ne regardent pas l’arc et à ce
qu’elles ne s’exposent pas à son rayonnement, ni à
celui du métal incandescent.
b. Portez des gants ignifugés à crispins, une tunique
épaisse à manches longues, des pantalons sans
rebord, des chaussures à embout d’acier et un
casque de soudage ou une calotte de protection, afin
d’éviter d’exposer la peau au rayonnement de l’arc
électrique ou du métal incandescent. ll est également
souhaitable d’utiliser un tablier ininflammable de
façon à se protéger des étincelles et du rayonnement
thermique.
c. Les étincelles ou les projections de métal incandes-
cent risquent de se loger dans des manches
retroussées, des bords relevés de pantalons ou dans
des poches. Aussi convient-il de garder boutonnés le
col et les manches et de porter des vêtements sans
poches à l’avant.
d. Protégez des étincelles et du rayonnement de l’arc
électrique les autres personnes travaillant à proximité
à l’aide d’un écran ininflammable adéquat.
e. Ne jamais omettre de porter des lunettes de sécurité
lorsque vous vous trouvez dans un secteur où l’on
effectue des opérations de soudage ou de coupage à
l’arc. Utilisez des lunettes de sécurité à écrans ou
verres latéraux pour piquer ou meûler le laitier. Les
piquetures incandescentes de laitier peuvent être
projetées à des distances considérables. Les
personnes se trouvant à proximité doivent également
porter des lunettes de protection.
f. Le gougeage à l’arc et le soudage à l’arc au plasma
produisent un niveau de bruit extrêmement élevé (de
100 à 114 dB) et exigent par conséquent l’emploi de
dispositifs appropriés de protection auditive.
2. PRÉVENTION DES INCENDES-- Les projections de
laitier incandescent ou d’étincelles peuvent
provoquer de graves incendies au contact de
matériaux combustibles solides, liquides ou gazeux.
Aussi faut-il observer les précautions suivantes:
a. Éloigner suffisamment tous les matériaux combus-
tibles du secteur où l’on exécute des soudures ou
des coupes à l’arc, à moins de les recouvrir
complètement d’une bâche non-inflammable. Ce
type de matériaux comprend notamment le bois, les
vêtements, la sciure, l’essence, le kérosène, les
peintures, les solvants, le gaz naturel, l’acétylène, le
propane et autres substances combustibles
semblables.
b. Les étincelles ou les projections de métal incandes-
cent peuvent tomber dans des fissures du plancher
ou dans des ouvertures des murs et y déclencher
une ignition lente cachée. Veiller à protéger ces
ouvertures des étincelles et des projections de
métal.
c. N’exécutez pas de soudures, de coupes,
d’opérations de gougeage ou autres travaux à chaud
à la surface de barils, bidons, réservoirs ou autres
contenants usagés, avant de les avoir nettoyés de
toute trace de substance susceptible de produire
des vapeurs inflammables ou toxiques.
d. En vue d’assurer la prévention des incendies, il
convient de disposer d’un matériel d’extinction prêt à
servir immédiatement, tel qu’un tuyau d’arrosage, un
seau à eau, un seau de sable ou un extincteur
portatif.
e. Une fois le travail à l’arc terminé, inspectez le
secteur de façon à vous assurer qu’aucune étincelle
ou projection de métal incandescent ne risque de
provoquer ultérieurement un feu.
3. CHOC ÉLECTRIQUE-- Le gougeage à l’arc et à l’arc
au plasma exige l’emploi de tensions à vide
relativement importantes; or, celles-ci risquent de
causer des dommages corporels graves et même
mortels en cas d’utilisation inadéquate. La gravité du
choc électrique reçu dépend du chemin suivi par le
courant à travers le corps humain et de son intensité.
a. Ne laissez jamais de surfaces métalliques sous
tension venir au contact direct de la peau ou de
vêtements humides. Veillez à porter des gants bien
secs.
b. Si vous devez effectuer un travail sur une surface
métallique ou dans un secteur humide, veillez à
assu-rer votre isolation corporelle en portant des
gants secs et des chaussures à semelles de caoutchouc et en vous tenant sur une planche ou une
plate-forme sèche.
c. Mettez toujours à la terre le poste de soudage/
coupage en le reliant par un câble à une bonne prise
de terre.
d. N’utilisez jamais de câbles usés ou endommagés.
Ne surchargez jamais le câble. Utilisez toujours un
équipement correctement entretenu.
e. Mettez l’équipement hors tension lorsqu’il n’est pas
en service. une mise à la masse accidentelle peut en
effet provoquer une surchauffe de l’équipement et un
danger d’incendie. Ne pas enrouler ou passer le
câble autour d’une partie quelconque du corps.
f. Vérifiez si le câble de masse est bien relié à la pièce
en un point aussi proche que possible de la zone de
5
9/97
levage, des câbles de grue ou divers chemins
électriques.
g. Empêchez l’apparition de toute humidité, notamment
sur vos vêtements, à la surface de l’emplacement de
travail, des câbles, du porte-électrode et du poste de
soudage/coupage. Réparez immédiatement toute
fuite d’eau.
4. VENTILATION-- La respiration prolongée des fumées
résultant des opérations de soudage/coupage, à
l’intérieur, d’un local clos, peut provoquer des malaises et des dommages corporels. Aussi convient-il
d’observer les précautions suivantes:
a. Assurez en permanence une aération adéquate de
l’emplacement de travail en maintenant une ventilation naturelle ou à l’aide de moyens mécaniques.
N’effectuez jamais de travaux de soudage ou de
coupage sur des matériaux de zinc, de plomb, de
beryllium ou de cadmium en l’absence de moyens
mécaniques de ventilation capables d’empêcher
l’inhalation des fumées dégagées par ces matériaux.
b. N’effectuez jamais de travaux de soudage ou de
coupage à proximité de vapeurs d’hydrocarbure
chloré résultant d’opérations voisines de dégraissage
ou de pulvérisation. La chaleur dégagée ou le
rayonnement de l’arc peut déclencher la formation de
phosgène -- gaz particulièrement toxique -- et
d’autres gaz irritants, à partir des vapeurs de solvant.
c. Une irritation momentanée des yeux, du nez ou de la
gorge constatée au cours de l’utilisation de
l’équipement dénote un défaut de ventilation. Arrêtezvous de travailler afin de prendre les mesures nécessaires à l’amélioration de la ventilation. Ne
poursuivez pas l’opération entreprise si le malaise
persiste.
d. Certaines commandes comportent des canalisations
où circule de l’hydrogène. L’armoire de commande
est munie d’un ventilateur destiné à empêcher la
formation de poches d’hydrogène, lesquelles
présentent un danger d’explosion; ce ventilateur ne
fonctionne que si l’interrupteur correspondant du
panneau avant se trouve placé en position ON
(Marche). Veillez à manœuvrer cette commande en
vérifiant si le couvercle est bien en place, de façon à
assurer l’efficacité de la ventilation ainsi réalisée. Ne
jamais débrancher le ventilateur.
e. Les fumées produites par l’opération de soudage ou
de coupage peuvent s’avérer toxiques. Aussi est-il
nécessaire de disposer en permanence d’un
dispositif adéquat de ventilation de type aspirant, afin
d’élimi-ner du voisinage de l’opérateur tout
dégagement de fumée visible.
f. Consultez les recommandations particulières en
matière de ventilation indiquées à l’alinéa 6 de la
norme Z49.1 de l’AWS.
5. ENTRETIEN DE L’ÉQUIPEMENT-- Un équipement
entretenu de façon défectueuse ou inadéquate risque
non seulement de réaliser un travail de mauvaise
qualité mais, chose plus grave encore, d’entraîner
des dommages corporels graves, voire mortels en
déclenchant des incendies ou des chocs électriques.
Observez par conséquent les précautions suivantes:
a. Efforcez-vous de toujours confier à un personnel qua-
lifié l’installation, le dépannage et l’entretien du poste
de soudage et de coupage. N’effectuez aucune
réparation électrique sur l’équipement à moins d’être
qua-lifié à cet effet.
b. Ne procédez jamais à une tâche d’entretien
quelconque à l’intérieur du poste de soudage/
coupage, avant d’avoir débranché l’alimentation
électrique.
c. Maintenez en bon état de fonctionnement les câbles,
le câble de masse, les branchements, le cordon
d’alimentation et le poste de soudage/coupage.
N’utilisez jamais le poste ou l’équipement s’il
présente une défectuosité quelconque.
d. Prenez soin du poste de soudage et de coupage et
des équipements accessoires. Gardez-les à l’écart
des sources de charleur, notamment des fours, de
l’humidité, des flaques d’eau maintenez-les à l’abri
des traces d’huile ou de graisse, des atmosphères
corrosives et des intempéries.
e. Laissez en place tous les dispositifs de sécurité et
tous les panneaux de l’armoire de commande en
veillant à les garder en bon état.
f. Utilisez le poste de soudage/coupage conformément
à son usage prévu et n’effectuez aucune modification.
6. INFORMATIONS COMPLÉMENTAIRES RELATIVES
À LA SÉCURITÉ--
Pour obtenir des informations complémentaires sur
les règles de sécurité à observer pour le montage et
l’utilisation d’équipements de soudage et de coupage
électriques et sur les méthodes de travail
recommandées, demandez un exemplaire du livret
N° 52529 “Precautions and Safe Practices for Arc
Welding, Cutting and Gouging” publié par ESAB.
Nous conseillons également de consulter les publications sui-vantes, tenues à votre disposition par
l’American Welding Society, 550 N.W. LeJuene Road,
Miami, FL 32126:
a. “Safety in Welding and Cutting” AWS Z49.1
b. “Recommended Safe Practices for Gas-Shielded Arc
Welding “AWS A6. 1.
c. “Safe Practices for Welding and Cutting Containers
That Have Held Combustibles” AWS-A6.0.
d. “Recommended Safe Practices for Plasma Arc Cut-
ting” AWS-A6. 3.
e. “Recommended Safe Practices for Plasma Arc Weld-
ing” AWS-C5. 1.
f. “Recommended Safe Practices for Air Carbon Arc
Gouging and Cutting” AWS-C5. 3.
g. “Code For Safety in Welding and Cutting”
CSA-Standard W117. 2.
6
SECTION 1 DESCRIPTION
1.1 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.
1.2 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 filed 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 file
claim arises.
1.3 DESCRIPTION
The MobileMaster 2cv Wire Feeder described in this
manual is designed for short arc, spray arc mig or cored
wire welding with a constant potential (CP) welding
power source.
Secondary input from the Power Source can be DC
+ or DC - depending on the requirements of the
wire type being used.
The MobileMaster 2cv uses a PM wire drive motor
designed to feed wires from .023 to 5/64 inches in diameter. Rate of wire feed (50 - 700 inches per minute)
is precisely controlled by a solid-state, Pulse Width
Modulated (PWM) governor printed circuit board
housed in the control assembly. For operator safety,
the torch switch is energized by 12 volts ac supplied by
the control. All interconnecting cables and hoses are
quickly detachable to provide maximum portability of
the wire feeder.
The standard features of the MobileMaster 2cv wire
are as follows:
2-roll geared drive stand
One drive roll and one pressure roll
Internal gas solenoid
Euro style torch connection
Power ON/OFF switch
Wire feed speed potentiometer
Voltage control potentiometer
Remote Power source voltage control
1.4 REQUIRED EQUIPMENT
1.4.1 Constant potential power source. Use the
MobileMaster 2cv with power sources such as: 452cv,
SVI-450i cvcc, 652 cvcc.
1.4.2 Control Cables. Multi-conductor cable with 19pin amphenol plug and receptacle.
25-foot (7.6m) P/N 36663
50-foot (15.3m) P/N 36664
100-foot (30.6m) P/N 36659
1.4.3 115 V ac to 42 V ac Interface (P/N 34351). Adapts
to power sources with only 115 V ac auxiliary and
contactor. Includes interface box and adapter cables
for power sources not equipped with 42 vac control
circuitry.
1.4.4 MT-200cc or MT-400cc Mig Welding Torch.
Torch with contact tip, wire conduit and outlet guide for
wire size/type to be employed. A suitable air cooled
torch with a Euro-style connector (cc) may be used
with the wire feeder.
1.4.5 Shielding gas regulator/flowmeter and fitted
hose to bring gas from flowmeter to wire feeder. Such
as:
Regulator/Flowmeters:
R-5007 Argon/Helium/Nitrogen, P/N 998124.
R-5008 CO2, P/N 998125.
1.4.6 Drive Roll and Guide Tube. (Refer to Table 2.1):
The wire feeder comes equipped with a drive roll and a
guide tube for wire sizes .035 to .045 (0.9 to 1.2mm).
TABLE 1-1. SPECIFICATIONS
Input Power Required................................................................................... 42 V ac, 5A, 50/60 Hz, 1-phase
Wire Feed Speed Range ............................................................................. 50-700 in./min. (1.3--18 m/min.)
Wire Sizes Accommodated:
Hard/Soft ......................................................................................... .023 thru 1/16 in. (0.6 thru 1.6mm)
Flux Cored ....................................................................................... .035 thru 5/64 in. (0.9 thru 2.0mm)
Length ................................................................................................................................ 26.9 in. (683mm)
Width.................................................................................................................................... 9.5 in. (241mm)
Height* ............................................................................................................................... 14.0 in. (356mm)
Weight..................................................................................................................................... 26-lbs. (12kg)
The MobileMaster 2cv will fit through a 16 (406mm) dia. Hole.
7
SECTION 1 DESCRIPTION
Select other size drive rolls from Table 1 for the wire
size and type to be used.
1.5 OPTIONAL ACCESSORIES
1.5.1 Argon Flowmeter Kit, P/N 36658; CO2 Flowmeter Kit, P/N 37365 - These kits include an adjust-
able flowmeter with a protective guard and mounting
hardware for mounting to rear of MobileMaster unit.
1.5.2 Digital Meter Kit, P/N 23540446 - This LCD
meter is simple to mount and displays welding voltage
while welding or preset and actual wire feed speed.
1.5.3 Gas Pre/Postflow with Burnback Kit, P/N
36661 - This kit provides adjustment for shielding gas
preflow and postflow times. Adjustable burnback stops
the wire feed before the arc is stopped to keep the wire
from sticking to the weld.
1.5.4 Burnback Control Kit, P/N 36657 - This kit has
adjustable burnback control for stopping the wire feed
before the arc stops.
1.5.5Crater Control Kit, P/N 36660 - This kit provides
separate settings of wire feed speed and voltage for
crater fill control.
1.5.6 Spool Adaptor, 8-in. Spool, P/N 17511
Spool Adaptor, 10-in. Spool, P/N 34330
Coil Adaptor, 14-lb. Coil, P/N 37337
Required if using wire from a 8 or 10-in. spool or 14-lb.
(6.4 kg) coil.
1.6 SAFETY
Before the equipment is put into operation, the safety
section at the front of this manual should be read completely. This will help avoid possible injury due to misuse or improper welding applications.
8
SECTION 2 INSTALLATION
Table 2-1. Drive Roll & Guide Tube Selection
Upper
Wire Type / Lower Pressure Guide
Diameter Drive Roll Roll Tube
Hard Wires (V groove)
.023 in. (0.6mm) 21155 2361 2397 21163
.030 in. (0.8mm) 21155 2361 2397 21164
.035 in. (0.9mm) 21156 2361 2397 21165
.040 in. (1.0mm) 21156 2361 2397 21165
.045 in. (1.2mm) 21156 2361 2397 21165
.052 in. (1.4mm) 21157 2361 2397 21166
1/16 in. (1.6mm) 21157 2361 2397 21166
Soft (aluminum) Wires (U groove)
.035 in. (0.9mm) 21158 2361 2397 21167**
3/64 in. (1.2mm) 21159 2361 2397 21168**
1/16 in. (1.6mm) 21159 2361 2397 Not Reqd
Cored Wires (Serrated V groove)
.030 in. (0.8mm) 21160 2361 2369 21164
.035 in. (0.9mm) 21160 2361 2369 21165
.040 in. (1.0mm) 21161 2361 2369 21165
.045 in. (1.2mm)* 21161 2361 2369 21165
.045 in. (1.2mm) 37319 37319 21165
.052 in. (1.4mm)* 21161 2361 2369 21166
.052 in. (1.4mm) 37319 37319 21166
1/16 in. (1.6mm)* 21161 2361 2369 21166
1/16 in. (1.6mm) 37320 37320 21166
5/64 in. (2.0mm) 21162 2361 2369 21166
5/64 in. (2.0mm) 37320 37320 21166
* Supplied with MobileMaster wire feeder.
Recommended for use with soft cored wires that are easy to flatten.
Order both lower drive roll and upper pressure roll.
** Requires Support Tube 21169.
2.1 DRIVE ROLLS
The unit is supplied ready to feed 0.035 and 0.045 (0.9
and 1.6mm) diameter hard wires. (Other drive rolls are
available to feed other sizes of hard wire, soft wire, and
cored wire. See Table 2.1.) The drive roll has two grooves;
the small groove feeds 0.035 diameter wire, the large
groove feeds 0.045 diameter wire. The groove nearest
the gear motor feeds the wire. If the required groove is
not in that position or a different drive roll is required:
A. Release the pressure roll assembly lever and lift
the assembly upward.
B. Remove the 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.
2.2 WELDING WIRE SPOOL
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 clock-
wise 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 1.5.6).
LOCATION for OPTIONAL PRE/
POSTFLOW OR BURNBACK KIT
LOCATION for OPTIONAL
CRATER CONTROL KIT
PRESSURE
ROLL
TORCH
CONNECTION
DRIVE
ROLL
WIRE
SPOOL HUB
WELDING CABLE
CONNECTION
GUIDE TUBE
Figure 2.1 - Inside View of MobileMaster 2cv
9
SECTION 2 INSTALLATION
2.3 TORCH CONNECTIONS
The torch adaptor on the MobileMaster connects directly to the wire feeder wire drive assembly, the welding power, torch trigger connections and shielding gas
supply. Line up the respective pins on the torch connector with the wire feeder adaptor, push on firmly and
hand tighten the locking collar.
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.
2.4 SUPPLY CONNECTIONS (See Figure 2.2)
Before making any connections between the wire
feeder and the welding power source, turn off
power to the welding power source and the wire
feeder.
A. Connect the proper polarity output welding cable
from the power source; positive terminal for gas
shielded wires, or negative for most gasless selfshielded cored wires, to the weld cable lug
connection extending from the rear of the
MobileMaster 2cv feeder.
B. Connect a second welding cable to the opposite
polarity output connection on the power source and
to the work piece.
C. Connect control cable (see 1.4.2) to MobileMaster
2cv and to power source.
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.
3. Turn the wire feeder ON and close the torch
trigger.
Unless starting to weld, do not allow the welding
wire to touch a grounded metal surface. The welding wire becomes electrically hot when the welding power source is turned on and the contactor is
closed. Keep fingers 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 flowmeter to the desired flow rate.
6. Turn power source and wire feeder OFF.
2.5 THREADING THE WELDING WIRE
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 fire. Body contact with an
uninsulated weld cable connector, or uncovered
conductor can shock, possibly fatally.
CONTROL CABLE ASSEMBLY
(See 1.4.2)
- (or +) + (or -)
When the wire feeder is connected to the power
source and the power source is turned on, 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 fingers clear!
Figure 2.2 - Typical Set-up of MobileMaster 2cv
10
SECTION 2 INSTALLATION
A. Turn OFF the power source and the wire feeder.
B. Release the pressure roll assembly lever 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 assembly 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.
2.6 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.
11
SECTION 3 OPERATION
3.1 ADJUSTMENTS AND OPERATIONS
3.1.1 CONTROL SETTING
1. Set voltage control on the power source to the
appropriate setting. Set to remote for control
from the wire feeder.
2. Apply power to wire feeder.
3. Set the wire feed rate and voltage by adjusting
the WIRE FEED SPEED and VOLTS control
knobs on the front panel.
4. If optional pre/postflow/burnback Kit (36661)
is installed, set the BURNBACK control to the
desired setting (0-0.6 seconds), depending on
the amount of burnback desired. The higher
the setting, the greater the amount of time that
the contactor is held in to allow the wire to burn
back out of the puddle, after releasing the torch
switch.
3.1.2 FEEDING WIRE
If wire has been threaded through torch and contact tip as directed in Section 2.5, simply cut off
wire, as required, so that the wire extends about
1/2-inch beyond the end of the torch nozzle.
15 seconds to insure adequate purging of gas hose
and torch. Secure the drive roll pressure arm.
If installed, set pre and postflow potentiometers for
the desired preflow interval (range: 0 to 1.5 seconds) and postflow interval (range: 0 to 7.5 seconds).
3.1.4 MAKING THE WELD
Start to weld by pressing the torch switch lever to
actuate the torch switch. This closes the welding
contactor, and starts wire feed and gas flow. Then
touch the end of the welding wire to the workpiece
to establish the arc. The switch lever must be depressed for the duration of the weld. Welding action will be stopped and all services discontinued
when the lever is released and returns to its original position. If the torch is withdrawn from the workpiece during welding, the arc will be interrupted,
but shielding gas flow and welding wire feed will
continue until the switch lever is released.
If the optional Crater Control Kit (36660) is installed,
and crater control switch is in the AUTO position,
the wire feeder will change to crater condition after
releasing torch switch from normal welding and
continue to weld until the torch switch is depressed
again to terminate the weld.
3.1.3 SHIELDING GAS FLOW RATE
Release drive roll pressure arm. Depress gas torch
switch and set desired gas flow rate at the shielding gas regulator-flowmeter. Hold switch in at least
5A CB
OPT. METER KIT
POWER ON-OFF
SWITCH
VOLTAGE
CONTROL
WIRE SPEED
CONTROL
TORCH
CONNECTION
3.2 OPTIONAL METER
The optional meter allows for monitoring the arc voltage or wire feed speed while welding.
19-PIN RECEPTACLE
WELDING CABLE
CONNECTION
(Figure 2.1)
SHIELD GAS
CONNECTION
Figure 3.1 - Controls and Connections, MobileMaster 2cvcc
12
SECTION 3 OPERATION
3.3 OPERATING SAFETY PRECAUTIONS
Comply with all ventilation, fire 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 flash goggles with filter lenses under his helmet. The helmet filter plate should be shade number 11 (nonferrous) or 12 (ferrous). All those viewing the arc should use helmets with filter plates, as
well as flash goggles. Nearby personnel should
wear flash goggles.
B. The radiant energy of the arc can be decomposed
by chlorinated 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 in contact with them 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 flash
that can injure eyes. It may also start a fire or cause
other damage.
D. When working in a confined space, be sure it is
safe to enter. The confined space should be tested
for adequate oxygen (at least 19%) with an approved oxygen measuring instrument. The confined 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 confined
space, as the leaked gas can dangerously reduce
oxygen concentration in the breathing air. DO NOT
bring gas cylinders into confined spaces. When
leaving a confined space, shut OFF gas supply at
the source to prevent gas from leaking into the
space. Check the breathing atmosphere in the
confined 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
without suitable insulation for protection against
shock. Keep hands, feet and clothing dry at all
times.
G. Whenever the equipment is left unattended, turn
all control and power supply switches and gas supplied OFF and open the main line switch.
H. Wear dark substantial clothing to protect exposed
skin from arcburn, sparks and flying hot metal.
I. Turn off welding power before adjusting or replac-
ing electrodes.
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
flash. Keep clear of feed rolls and drive gears.
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.
Do not terminate the arc by removing the torch from
the weld area. Release the torch trigger to stop
welding before removing the torch.
Failure to shut OFF shield gas in a confined space
may result in a build-up of fumes, displacing oxygen.
3.4 SHUTDOWN
A. Release torch trigger and break the arc.
B. When leaving the Equipment unattended, always
shut OFF and disconnect all power to the Equipment and shut off the shielding gas supply at
source.
13
SECTION 4 MAINTENANCE
4.1 MAINTENANCE
Keep power cables dry, free of oil and grease, and protected at all times from damage by hot metal and
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.
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 qualifications.
Shut OFF shielding gas supply at source.
To aid in checking and servicing, use Schematic, Figure 4.1.
4.2 INSPECTION AND SERVICE
sparks.
Clean dirt and metal particles from drive roll groove
weekly; replace roll if badly worn.
4.2.1 42 VOLT WIRE FEEDER AND CONTROL CIRCUITS
The 42-volt circuit is protected by a 5 amp circuit
breaker located on the front panel of the wire feeder.
Failure of this circuit breaker will shut off the contactor,
shielding gas, and wire feeder.
If it should become necessary to replace the 5 amp
wire feeder circuit breaker or any other circuit
breaker/fuse in the welding machine, ensure that
the proper size is used as a replacement.
4.2.2 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.
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.
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.
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 fire. Body contact with a bared cable,
connector, or uncovered conductor can shock,
possibly fatally.
Inspect the rolls regularly and clean them with a finewire 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.
4.2.3 DRIVE ROLL PRESSURE ADJUSTMENT
Adjust the drive roll pressure knob until no wire slippage occurs. DO NOT OVERTIGHTEN - EXCESSIVE
PRESSURE CAN CAUSE WIRE FEEDING PROBLEMS.
4.2.4 SOLENOID VALVE REPLACEMENT
If there is no gas flow through the wire feeder, the gas
solenoid valve 13792051 (42V) 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.
4.2.5 GENERAL REPLACEMENT
The exploded views in the Parts Section indicate generally, in numbered parts sequence, the disassembly
of the wire drive and feeder parts.
Reassemble in reverse order.
14
SECTION 4 MAINTENANCE
4.3 TROUBLESHOOTING
If welding equipment doesnt work right despite compliance with check list, 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.
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, flowmeters,
and regulators for possible sources of leakage,
breakdown, or intermittent failure.
C. Isolate trouble to one part of the welding installa-
tion: 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, use schematic diagram,
Figure 4.1.
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.
Do not make any repairs to equipment unless you
are fully qualified, as described in the maintenance
section.
15
D-37457-B
Figure 4.1 - Schematic Diagram, MobileMaster 2 cv
16
D-37458-B
Figure 4.2 - Wiring Diagram, Mobilemaster 2cv
17
SECTION 5 REPLACEMENT PARTS
5.1 GENERAL
Always provide the series or serial number of the unit
on which the parts will be used. The serial number is
stamped on the unit nameplate.
5.2 ORDERING
To assure 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 distributor or from:
ESAB Welding & Cutting Products
Attn: Customer Service Dept.
P.O. Box 100545
Ebenezer Road
Florence, SC 29501-0545
Be sure to indicate any special shipping instructions
when ordering replacement parts.
To order parts by phone, contact ESAB at 1-843-6645540 or 4460. Orders may also be faxed to 1-800-634-
7548. Be sure to indicate any special shipping instructions when ordering replacements parts.
Refer to the Communication Guide located on the last
page of this manual for a list of customer service phone
numbers.
18
SECTION 5 REPLACEMENT PARTS
6, 7
8
1
10, 11
12
5
4
13
2, 3
Figure 5.1 - MobileMaster 2cv, Front/Right Side View
36654
Item Qty Part Description CKT.
No. Req. No. Desig.
1 1 952680 CASE MOLDED
2 2 13730632 POT. LIN 10K 2W R1, 2
3 2 13730611 KNOB
4 1 32292 PANEL CONTROL SILKSCREENED
5 1 34141BK COVER OPTION UPPER FRONT
6 1 952626 HANDLE FOLDING 2 POS.
7 2 37334 NUT HANDLE W/SHOULDER
8 1 2062161 CIRCUIT BREAKER 5 AMP CB1
10 1 13732469 SWITCH TOGGLE SPST 2 POS 20A 125V S1
11 1 951474 SWITCH SEAL BLACK
12 1 37333 HOLDER GUN
13 1 23610528 HOUSING
14 1 23610696 ADAPTOR BLOCK ASSY J5
15 1 23612590 CONNECTION TUBE
19
SECTION 5 REPLACEMENT PARTS
45
46, 47
44
57
56
40
43
42
41
54
48
51, 52, 53
49
32
31
33
Figure 5.2
34
37, 38, 39, 55
50
36
35
20
SECTION 5 REPLACEMENT PARTS
Figure 5.2 - MobileMaster 2 cvcc, Right Inside View
Item Qty Part Description CKT.
No. Req. No. Desig.
31 1 952684 LATCH LIFT/TURN
32 1 37378BK TAB LATCH
33 1 64309431 WASHER .250
34 1 952627 PLATE BACKING LATCH
35 1 954760 LABEL WARNING ROLL PINCH HAZARD
36 1 37327 HINGE LIVING (18 - RIVET PLASTIC EXPANSION 952686)
37 1 58V58 ADAPTOR B/IGF X 1/4 NPTM
38 1 44251100 ELBOW PIPE 90° 1/4 BRS
39 1 2232017 NIPPLE 1/4 NPTM X 1/4 ID HOSE
40 1 31463 CONTROL BOARD ASSY PCB1
41 1 SPOOL HUB ASSY (See Figure 5.4)
42 1 37254BK SUPPORT WIRE REEL
43 1 951530 MOTOR KSV 5035/388 M1
44 1 37258 PLATE BLANKING UPPER (Removed to show inside)
45 1 37257 PLATE BLANKING LOWER (Removed to show inside)
46 1 23612627 DRIVE STAND ASSY (See Figure 5.3)
47 1 34198 PLATE SHIM (Behind Drive Stand)
48 1 954698 LABEL WARNING GEAR PINCH HAZARD
49 1 21166 GUIDE TUBE .052 - 1/16 (See Table 2.1)
50 2 952687 STUD RUBBER PLATE MOUNT (Under Item 42)
51 1 13792051 VALVE SOLENOID SOL1
52 1 951174 CLAMP 1 EAR 10.0
53 1 952860 CLAMP 1 EAR 12.8 w/insert
54 1 950762 RECEPT. PANEL MT 19 PIN SOLDER TYPE (on rear panel) P1
55 1 950626 CLAMP 1 EAR 13.3 w/insert
56 1 993717 TRANSFORMER 117V T1
57 1 13730469 RECT. 35A 400V BR1
21
SECTION 5 REPLACEMENT PARTS
81
69
66
80
70
63
79
62
75
65
71
64
67
Ite m
No. Qty
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
77
78
79
80
81
68
73, 76
72
74
78
Figure 5.3 - 2 Roll Drive Stand
Part
No. Description
1
1
1
1
1
1
2
1
1
1
1
1
1
1
1
1
1
1
2
5
1
1
23612627
23612626
23612387
23612475
23612385
23612470
23612472
23612386
23612460
23612473
23612461
23612383
23612398
23612478
23612479
23612480
23612384
23612462
23612662
23612663
2 ROLL GEARED WIRE DRIVE SYSTEM, CONSISTS OF:
PRESSURE ARM ASSY., (incls. 2, 3, 4, 7, 8)
AXLE, PRESSURE ROLL
PRESSURE ARM
CIRCLIP, PRESSURE ROLL
PIVOT PIN
CIRCLIP
PRESSURE ROLL, SMOOTH (see Table 2.1)
GEARED ADAPTOR, PRESSURE ROLL
PRESSURE DEVICE ASSY.
LOCATING PIN
INL ET GUID E
DRIVE ROLL, (see Table 2.1)
GEARED ADAPTOR DRIVE ROLL
FEE D ROLL RE TAINING S CRE W
FEED PLATE
FEED ROLL KEY
MOTOR SHAFT SNAP RING (Not Shown)
LOCATING SCREW
SCREW
SPACER TUBE (Pressure Arm)
SPRING PRESSURE ARM
22
SECTION 5 REPLACEMENT PARTS
91
97
98
92
Ite m
No.
91
92
93
94
95
96
97
98
Qty
Req.
2
1
AR
1
1
1
1
1
Part
No. Description
92040101
23600010
64304125
23600952
23606237
23600255
36756
23600982
94
96
95
Figure 5.4 - Wire Spool Hub Assembly
SCREW R.H.M. 3/8-16X.75
NUT, PLASTIC
WASHER, FLAT 3/8"
WASHER
HUB REEL
BRAKE DISC
"D" SHAFT
SPRING
93
Ckt.
Symbol
23
SECTION 5 REPLACEMENT PARTS
MobileMaster 2cv
As of Feb. 4, 1998
QTY
ITEM PER FOR TWO YEARS RUNNING 1 10 25 50-+
NUMBER AY DESCRIPTION UNIT UNITS UNITS UNITS
36756 1 REEL HUB, D SHAFT 1 3 5
31463 1 PCB MOBILEMASTER 2CV 1 3 5
13732469 1 TOGGLE SWITCH SPST 2POS 1 3 5
951474 1 SWITCH SEAL 1 2 6 10
951530 1 MOTOR TYP KSV 503-2DR 1 3 5
13792051 1 SOLENOID VALVE, 42V 1 2 3
13730469 1 RECT *** *** *35A 1 2 4
13730611 2 KNOB 1 2 4 8
13730632 2 POT LIN *10.0K 1 3 5
2062161 1 CIRC. BREAKER 5 AMP 1 2 5 10
23600010 1 PLASTIC NUT 2 5 10
23600255 1 BRAKE DISC 2 5 10
23600952 1 WASHER D-TYPE 2 5 10
23600982 1 SPRING, BRAKE 2 5 10
23606237 1 REEL HUB 2 5 10
23610696 1 EURO ADAPTER BLOCK 1 2 3
23612383 *1 GEARED ADAPTER, DRIVE ROLL 2 5 10
23612384 *2 LOCATING SCREW, DRIVE ROLL 2 4 10 20
23612385 *1 CIRCLIP, AXLE, PRESSURE ROLL 1 3 5
23612386 *1 GEARED ADAPTER, PRESSURE ROLL 2 5 10
23612387 *1 AXLE, PRESSURE ROLL 1 3 5
23612398 *1 RETAINING SCREW, DRIVE ROLL 1 2 5 10
23612460 *1 PRESSURE DEVICE WITH SCALE 1 3 5
23612462 *5 SCREW 1 5 13 25
23612470 *1 LOCATING PIN, PRESSURE DEVICE 1 3 5
23612472 *2 CIRCLIP, LOCATING PIN, PRESSURE ARM 2 5 10
23612473 *1 LOCATING PIN, PRESSURE ARM 1 3 5
23612475 *1 PRESSURE ARM 1 3 5
23612478 *1 FEED PLATE 1 3 5
23612479 1 FEED ROLL KEY 1 3 5
23612590 1 CONNECTION TUBE ASSY. 2 4 8
23612626 *1 PRESSURE ARM GEARED COMPLETE, R. H. 2 5 10
23612627 1 DRIVE STAND ASSY (SEE NOTE-*) 1 2 3
23612662 *1 SPACER TUBE, PRESSURE ARM 1 3 5
23612663 *1 SPRING, PRESSURE ARM, 2DR STAND 1 3 5
92040101 1 SCREW R.H. SLOTTED 3/8-16 X 0.75" 1 2 5 10
AS REQD. 1 DRIVE ROLL (21161 SUPPLIED STANDARD) AS REQUIRED
AS REQD. 1 INLET GUIDE (21166 SUPPLIED STANDARD) AS REQUIRED
AS REQD. 1 PRESSURE ROLL (23612397 SUPPLIED STANDARD) AS REQUIRED
*-DENOTES ITEM IS PART OF 23612627 DRIVE STAND KIT
RECOMMENDED SPARES LISTING NO. OF UNITS TO MAINTAIN
F-15-448 7/98 Printed in U.S.A.
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