operator’s manual autodrive 4r220...emf fields may interfere with some pacemakers, and welders...

Operator’s Manual

AutoDrive ® 4R220

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IM945-C | Issue D ate Oct-14

© Lincoln Global, Inc. All Rights Reserved.

For use with machines having Code Numbers:

11455, 11882, 11956, 12273

Save for future reference

Date Purchased

Code: (ex: 10859)

Serial: (ex: U1060512345)

2

SAFETY

THANK YOU FOR SELECTING A QUALITY PRODUCT BY LINCOLN ELEC TRIC.

Please examine Carton and equiPment Fordamage immediately

When this equipment is shipped, title passes to the purchaser uponreceipt by the carrier. Consequently, Claims for material damaged inshipment must be made by the purchaser against the transportationcompany at the time the shipment is received.

saFety dePends on you

Lincoln arc welding and cutting equipment is designed and built withsafety in mind. However, your overall safety can be increased byproper installation ... and thoughtful operation on your part. DO NOT INSTALL, OPERATE OR REPAIR THIS EQUIPMENT WITHOUT READING THIS MANUAL AND THE SAFETY PRECAUTIONSCONTAINED THROUGHOUT. And, most importantly, think before youact and be careful.

This statement appears where the information must be followedexactly to avoid serious personal injury or loss of life.

This statement appears where the information must be followed toavoid minor personal injury or damage to this equipment.

KeeP your head out oF the Fumes.

DON’T get too close to the arc. Usecorrective lenses if necessary tostay a reasonable distance awayfrom the arc.

READ and obey the Material SafetyData Sheet (MSDS) and the warninglabel that appears on all containersof welding materials.

USE ENOUGH VENTILATION orexhaust at the arc, or both, to keepthe fumes and gases from your breathing zone and the general area.

IN A LARGE ROOM OR OUTDOORS, natural ventilation may beadequate if you keep your head out of the fumes (See below).

USE NATURAL DRAFTS or fans to keep the fumes away from yourface.

If you de velop unusual symptoms, see your supervisor. Perhaps thewelding atmosphere and ventilation system should be checked.

wear CorreCt eye, ear & body ProteCtion

PROTECT your eyes and face with welding helmetproperly fitted and with proper grade of filter plate(See ANSI Z49.1).

PROTECT your body from welding spatter and arcflash with protective clothing including woolenclothing, flame-proof apron and gloves, leatherleggings, and high boots.

PROTECT others from splatter, flash, and glare withprotective screens or barriers.

IN SOME AREAS, protection from noise may beappropriate.

BE SURE protective equipment is in good condition.

Also, wear safety glasses in work area AT ALLTIMES.

SPECIAL SITUATIONSDO NOT WELD OR CUT containers or materials which previously hadbeen in contact with hazardous substances unless they are properlycleaned. This is extremely dangerous.

DO NOT WELD OR CUT painted or plated parts unless specialprecautions with ventilation have been taken. They can release highlytoxic fumes or gases.

Additional precautionary measuresPROTECT compressed gas cylinders from excessive heat, mechanicalshocks, and arcs; fasten cylinders so they cannot fall.

BE SURE cylinders are never grounded or part of an electrical circuit.

REMOVE all potential fire hazards from welding area.

ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR

IMMEDIATE USE AND KNOW HOW TO USE IT.

WARNING

CAUTION

SECTION A:WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel EnginesDiesel engine exhaust and some of its constituents are known to the State of California to cause cancer, birth defects, and otherreproductive harm.

Gasoline EnginesThe engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects, or otherreproductive harm.

arC welding Can be hazardous. ProteCtyourselF and others From Possible seriousinJury or death. KeeP Children away. PaCe-maKer wearers should Consult with theirdoCtor beFore oPerating.

Read and understand the following safety highlights. For additionalsafety information, it is strongly recommended that you purchase acopy of “Safety in Welding & Cutting - ANSI Standard Z49.1” from theAmerican Welding Society, P.O. Box 351040, Miami, Florida 33135 orCSA Standard W117.2-1974. A Free copy of “Arc Welding Safety”booklet E205 is available from the Lincoln Electric Company, 22801St. Clair Avenue, Cleveland, Ohio 44117-1199.

BE SURE THAT ALL INSTALLATION, OPERATION,MAINTENANCE AND REPAIR PROCEDURES AREPERFORMED ONLY BY QUALIFIED INDIVIDUALS.

FOR ENGINE POWEREDEQUIPMENT.

1.a. Turn the engine off before troubleshootingand maintenance work unless themaintenance work requires it to be running.

1.b. Operate engines in open, well-ventilatedareas or vent the engine exhaust fumes outdoors.

1.c. Do not add the fuel near an open flamewelding arc or when the engine is running.Stop the engine and allow it to cool beforerefueling to prevent spilled fuel fromvaporizing on contact with hot engine partsand igniting. Do not spill fuel when fillingtank. If fuel is spilled, wipe it up and do not start engine untilfumes have been eliminated.

1.d. Keep all equipment safety guards, covers anddevices in position and in good repair.Keephands, hair, clothing and tools away from V-belts, gears, fans and all other moving partswhen starting, operating or repairingequipment.

1.e. In some cases it may be necessary to remove safety guards toperform required maintenance. Remove guards only whennecessary and replace them when the maintenance requiringtheir removal is complete. Always use the greatest care whenworking near moving parts.

1.f. Do not put your hands near the engine fan. Do not attempt tooverride the governor or idler by pushing on the throttle controlrods while the engine is running.

1.g. To prevent accidentally starting gasoline engines while turningthe engine or welding generator during maintenance work,disconnect the spark plug wires, distributor cap or magneto wireas appropriate.

1.h. To avoid scalding, do not remove the radiatorpressure cap when the engine is hot.

ELECTRIC ANDMAGNETIC FIELDS MAYBE DANGEROUS

2.a. Electric current flowing through any conductorcauses localized Electric and Magnetic Fields (EMF). Weldingcurrent creates EMF fields around welding cables and weldingmachines

2.b. EMF fields may interfere with some pacemakers, and weldershaving a pacemaker should consult their physician beforewelding.

2.c. Exposure to EMF fields in welding may have other health effectswhich are now not known.

2.d. All welders should use the following procedures in order tominimize exposure to EMF fields from the welding circuit:

2.d.1. Route the electrode and work cables together - Securethem with tape when possible.

2.d.2. Never coil the electrode lead around your body.

2.d.3. Do not place your body between the electrode and workcables. If the electrode cable is on your right side, thework cable should also be on your right side.

2.d.4. Connect the work cable to the workpiece as close as pos-sible to the area being welded.

2.d.5. Do not work next to welding power source.

3

SAFETY

ELECTRIC SHOCK CAN KILL.

3.a. The electrode and work (or ground) circuits areelectrically “hot” when the welder is on. Donot touch these “hot” parts with your bare skinor wet clothing. Wear dry, hole-free gloves to insulate hands.

3.b. Insulate yourself from work and ground using dry insulation.Make certain the insulation is large enough to cover your full areaof physical contact with work and ground.

in addition to the normal safety precautions, if

welding must be performed under electrically

hazardous conditions (in damp locations or while

wearing wet clothing; on metal structures such as

floors, gratings or scaffolds; when in cramped

positions such as sitting, kneeling or lying, if there

is a high risk of unavoidable or accidental contact

with the workpiece or ground) use the following

equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,electrode reel, welding head, nozzle or semiautomatic weldinggun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electricalconnection with the metal being welded. The connection shouldbe as close as possible to the area being welded.

3.e. Ground the work or metal to be welded to a good electrical (earth)ground.

3.f. Maintain the electrode holder, work clamp, welding cable andwelding machine in good, safe operating condition. Replacedamaged insulation.

3.g. Never dip the electrode in water for cooling.

3.h. Never simultaneously touch electrically “hot” parts of electrodeholders connected to two welders because voltage between thetwo can be the total of the open circuit voltage of bothwelders.

3.i. When working above floor level, use a safety belt to protectyourself from a fall should you get a shock.

3.j. Also see It ems 6.c. and 8.

ARC RAYS CAN BURN.

4.a. Use a shield with the proper filter and cover plates to protect youreyes from sparks and the rays of the arc when welding orobserving open arc welding. Headshield and filter lens shouldconform to ANSI Z87. I standards.

4.b. Use suitable clothing made from durable flame-resistant materialto protect your skin and that of your helpers from the arc rays.

4.c. Protect other nearby personnel with suitable, non-flammablescreening and/or warn them not to watch the arc nor exposethemselves to the arc rays or to hot spatter or metal.

FUMES AND GASESCAN BE DANGEROUS.

5.a. Welding may produce fumes and gaseshazardous to health. Avoid breathing thesefumes and gases. When welding, keep your head out of the fume.Use enough ventilation and/or exhaust at the arc to keep fumes

and gases away from the breathing zone. when welding

with electrodes which require special ventilation

such as stainless or hard facing (see instructions

on container or msds) or on lead or cadmium

plated steel and other metals or coatings which

produce highly toxic fumes, keep exposure as low

as possible and within applicable osha Pel and

aCgih tlV limits using local exhaust or

mechanical ventilation. in confined spaces or in

some circumstances, outdoors, a respirator may

be required. additional precautions are also

required when welding on galvanized steel.

5. b. The operation of welding fume control equipment is affected byvarious factors including proper use and positioning of theequipment, maintenance of the equipment and the specificwelding procedure and application involved. Worker exposurelevel should be checked upon installation and periodicallythereafter to be certain it is within applicable OSHA PEL andACGIH TLV limits.

5.c. Do not weld in locations near chlorinated hydrocarbon vaporscoming from degreasing, cleaning or spraying operations. Theheat and rays of the arc can react with solvent vapors to formphosgene, a highly toxic gas, and other irritating products.

5.d. Shielding gases used for arc welding can displace air and causeinjury or death. Always use enough ventilation, especially inconfined areas, to insure breathing air is safe.

5.e. Read and understand the manufacturer’s instructions for thisequipment and the consumables to be used, including thematerial safety data sheet (MSDS) and follow your employer’ssafety practices. MSDS forms are available from your weldingdistributor or from the manufacturer.

5.f. Also see item 1.b.

4

SAFETY

WELDING AND CUTTINGSPARKS CAN CAUSEFIRE OR EXPLOSION.

6.a. Remove fire hazards from the welding area. Ifthis is not possible, cover them to prevent thewelding sparks from starting a fire. Remember that weldingsparks and hot materials from welding can easily go throughsmall cracks and openings to adjacent areas. Avoid welding nearhydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site, specialprecautions should be used to prevent hazardous situations.Refer to “Safety in Welding and Cutting” (ANSI Standard Z49.1)and the operating information for the equipment being used.

6.c. When not welding, make certain no part of the electrode circuit istouching the work or ground. Accidental contact can causeoverheating and create a fire hazard.

6.d. Do not heat, cut or weld tanks, drums or containers until theproper steps have been taken to insure that such procedures willnot cause flammable or toxic vapors from substances inside.They can cause an explosion even though they have been“cleaned”. For information, purchase “Recommended SafePractices for the Preparation for Welding and Cutting ofContainers and Piping That Have Held Hazardous Substances”,AWS F4.1 from the American Welding Society (see addressabove).

6.e. Vent hollow castings or containers before heating, cutting orwelding. They may explode.

6.f. Sparks and spatter are thrown from the welding arc. Wear oil freeprotective garments such as leather gloves, heavy shirt, cufflesstrousers, high shoes and a cap over your hair. Wear ear plugswhen welding out of position or in confined places. Always wearsafety glasses with side shields when in a welding area.

6.g. Connect the work cable to the work as close to the welding areaas practical. Work cables connected to the building framework orother locations away from the welding area increase thepossibility of the welding current passing through lifting chains,crane cables or other alternate circuits. This can create firehazards or overheat lifting chains or cables until they fail.

6.h. Also see item 1.c.

6.I. Read and follow NFPA 51B “ Standard for Fire Prevention DuringWelding, Cutting and Other Hot Work”, available from NFPA, 1Batterymarch Park, PO box 9101, Quincy, Ma 022690-9101.

6.j. Do not use a welding power source for pipe thawing.

CYLINDER MAY EXPLODE IFDAMAGED.

7.a. Use only compressed gas cylinders containingthe correct shielding gas for the process usedand properly operating regulators designed forthe gas and pressure used. All hoses, fittings,etc. should be suitable for the application andmaintained in good condition.

7.b. Always keep cylinders in an upright position securely chained toan undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjectedto physical damage.

• A safe distance from arc welding or cutting operationsand any other source of heat, sparks, or flame.

7.d. Never allow the electrode, electrode holder or any otherelectrically “hot” parts to touch a cylinder.

7.e. Keep your head and face away from the cylinder valve outletwhen opening the cylinder valve.

7.f. Valve protection caps should always be in place and hand tightexcept when the cylinder is in use or connected for use.

7.g. Read and follow the instructions on compressed gas cylinders,associated equipment, and CGA publication P-l, “Precautions forSafe Handling of Compressed Gases in Cylinders,” availablefrom the Compressed Gas Association 1235 Jefferson DavisHighway, Arlington, VA 22202.

FOR ELECTRICALLYPOWERED EQUIPMENT.

8.a. Turn off input power using the disconnectswitch at the fuse box before working on theequipment.

8.b. Install equipment in accordance with the U.S. National ElectricalCode, all local codes and the manufacturer’s recommendations.

8.c. Ground the equipment in accordance with the U.S. NationalElectrical Code and the manufacturer’s recommendations.

refer to

http://www.lincolnelectric.com/safety

for additional safety information.

5

SAFETY

Welding SafetyInteractive Web Guidefor mobile devices

Page–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––Definition of Welding Terms, Product Description .......................................................................................................7Recommended Processes, Equipment Limitations, Recommended Power Sources.....................................................7Installation ................................................................................................................................................Section A

Technical Specifications................................................................................................................................A-1Safety Precautions ........................................................................................................................................A-2Location........................................................................................................................................................A-2Weld Cable Sizes ..........................................................................................................................................A-2Coaxial Weld Cable .......................................................................................................................................A-3Wire Drive Cable ..........................................................................................................................................A-4Shielding Gas Connection..............................................................................................................................A-5Procedure to Install Drive Rolls and Wire Guides............................................................................................A-6Pressure Arm Adjustment, Conduit Installation ..............................................................................................A-7System Set-Up..............................................................................................................................................A-8

–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––Operation Section B

Safety Precautions ........................................................................................................................................B-1Graphic Symbols that appear on this Machine or in this Manual ....................................................................B-1Definition of Welding Terms ..........................................................................................................................B-2Product Description.......................................................................................................................................B-2Recommended Processes, Equipment Limitations, Recommended Power Sources .......................................B-2

–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––Accessories ...............................................................................................................................................Section C

Optinal Kits and Accessories .........................................................................................................................C-1Drive Roll Kits used .......................................................................................................................................C-1Accessories Used ..................................................................................................................................C-2, C-3

–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––Maintenance..............................................................................................................................................Section D

Safety Precautions........................................................................................................................................D-1Routine Maintenance ....................................................................................................................................D-1

–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––Troubleshooting.........................................................................................................................................Section E

How to Use Troubleshooting Guide ................................................................................................................E-1Troubleshooting Guide ...........................................................................................................................E-2, E-3

–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Wiring Diagram & Dimension Prints .........................................................................................................Section F–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

Parts Pages ..........................................................................................................................................P-825 Series–––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––––

6

TABLE OF CONTENTS

7

PRODUCT DESCRIPTIONAutoDrive® 4R220

DEFINITION OF WELDING TERMS

GMAW• Gas Metal Arc weldingFCAW• Flux Core Arc WeldingSTT®

• Surface Tension Transfer

PRODUCT DESCRIPTION

General Physical DescriptionThe AutoDrive® 4R220 wire feeders are powerful yet compactwire drives for robotic and hard automation applications.

The MAXTRAC 4 roll wire drive gives steady feeding of all wiresizes and types. The drive features split wire guides, tool-lessdrive roll changing, dual spring pressure arms and changeablegun bushings all mounted in a precision die cast aluminum frame.A right angle gear box efficiently transfers motor power for bothhigh torque and high speed.

The AutoDrive® 4R220 features a powerful motor with an efficienttwo stage gearbox. This feeder is best for feeding larger diameterwires, pulling wire through long conduits, and in applicationsrequiring extra ruggedness. A door covers the wire drive, protect-ing it from dust.

General Functional DescriptionA high resolution tachometer precision for wire feeding forwardsand in reverse.

For more information go to the following Web site:http://content.lincolnelectric.com/pdfs/products/literature/RoboticFeederSelectionChart.pdf

RECOMMENDED PROCESSES• GMAW• FCAW• STT®

PROCESS LIMITATIONS

K2685-1 AutoDrive® 4R220:� • �Maximum wire size = 1/16 (1.6mm)

EQUIPMENT LIMITATIONS

K2685-1 AutoDrive® 4R220�• Maximum GMAW gun length =10’ (3.1m)�• Maximum FCAW gun length = 15’ (4.6m)�• Maximum wire drive control cable length = 100ft. (31m)�• Robot and power source software may need to be updated.�• Drive rolls are not included with the feeder.�• Mounts to FANUC ArcMate100iC arms.�• Mounts to FANUC ArcMate100iB arms.• Maximum Conduit Length 50 Ft. (15m).

RECOMMENDED POWER SOURCES

�• Power Wave F355i�• Power Wave 455 (all models)�• Power Wave 455/STT M�• Power Wave 655/ R�• Power Wave 400i

A-1

INSTALLATIONAutoDrive® 4R220

TEMPERATURE RANGE

OPERATION: -40°F to 104°F (-40°C to 40°C)

STORAGE: -40°F to 185°F (-40°C to 85°C)

INPUT VOLTAGE, CURRENT

TECHNICAL SPECIFICATIONS – AutoDrive® 4R220 (K2685-1)

HEIGHT WIDTH LENGTH WEIGHT

10.43 Inches 10.07 Inches 9.92 Inches 20.9 lbs.(265 mm) (256 mm) (252 mm) (9.5 kg.)

PHYSICAL DIMENSIONS

INPUT VOLTAGE ± 10%40 VDC

INPUT AMPERES7A

RATED OUTPUT @ 104°F (40°C)DUTY CYCLE

100% rating

AMPERES

500

MOTOR POWER WATTS

220

GEARING - WIRE FEED SPEED RANGE-WIRE SIZE

WFS RANGE

50 – 1200 ipm(0.8 – 30.5m/min)

WFS RANGE

50 – 1200 ipm(1.3 – 30.5m/min)

WIRE SIZES

.023 – 1/16"(0.6 – 1.6mm)

WIRE SIZES

.035 - 5/64”(0.9 – 2.0mm)

GEARING

K2685-1

GMAW FCAW

A-2


LOCATION

Firmly secure the AutoDrive® 4R220 wire feeder to a robot armor fixture.

See L15169 iB and L15169-1 iC Mechanical InstallationInstructions which are supplied with this Instruction Manual inthe literature package.

Mount only in a dry environment.

** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above 104°F(40°C) may require cables larger than recommended, orcables rated higher than 167°F(75°C).

RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167°F or 75°C)**CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

AMPERES

200200225225250250250250300325350400400500

PERCENTDUTYCYCLE

6010020

40 & 3030406010060100606010060

0 to 50Ft.(0 to15m)

22

4 or 53321112/01/02/03/02/0

50 to 100Ft.(15 to 30m)

2233321112/01/02/03/02/0

100 to 150 Ft.(30 to 46m)

2222211112/02/02/03/03/0

150 to 200 Ft.(46 to 61m)

111111111/02/02/03/03/03/0

200 to 250 Ft.(61 to 76m)

1/01/01/01/01/01/01/01/02/03/03/04/04/04/0

TABLE A.1

SAFETY PRECAUTIONS

ELECTRIC SHOCK CAN KILL.• Turn the input power OFF at the welding

power source before installation orchanging drive rolls and/or guides.

• Do not touch electrically live parts.•When inching with the gun trigger, elec-

trode and drive mechanism are "hot" towork and ground and could remain ener-gized several seconds after the gun trig-ger is released.

• Welding power source must be connected to systemground per the National Electrical Code or any applicablelocal codes.

• Only qualified personnel should perform maintenancework.

--------------------------------------------------------------------

WELD CABLE SIZE

Table A.1 located below are copper cable sizes recommendedfor different currents and duty cycles. Lengths stipulated are thedistance from the welder to work and back to the welder again.Cable sizes are increased for greater lengths primarily for thepurpose of minimizing cable drop.

WARNING

A-3


COAXIAL WELD CABLE

Coaxial welding cables are specially designed welding cables forSTT® and pulse welding. Coaxial weld cables feature low induc-tance, allowing fast changes in the weld current. Regular cableshave a higher inductance which may distort the STT® waveshape.Inductance becomes more severe as the weld cables becomelonger.

Coaxial weld cables are recommended for STT® welding, especiallywhen the total weld cable length (electrode cable + work cable)exceeds 50 feet (7.6m). See Table A.2.

A coaxial weld cable is constructed with multiple small leadswrapped around one large lead. The large inner lead connects to theelectrode stud on the power source and the electrode connection onthe wire feeder. The small leads combine together to form the worklead, one end attached to the power source and the other end to thework piece.

To install:1. Turn the input power off at the welding power source.2. Connect one end of the center lead to the power source elec-

trode connection, and the other end to the wire feeder electrodeconnection.

3. Connect the outer lead bundle to the power source work con-nection, and the other end to the work piece. Minimize thelength of any work lead extension for best results.

4. Insulate all connections.

ElectrodeElectrode

WWorkork

Amperes250300350

DutyCycle100%60%60%

0 to 25 Ft.111/0

25 to 50 Ft.111/0

50 to 75 Ft.11--

75 to 100 Ft.11/0--

COAXIAL CABLE LENGTHRECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 75°C)**

ElectrodeElectrodeWorkWork

ElectrodeElectrode

WorkWork

Power SourcePower Source

Coaxial Weld CableCoaxial Weld Cable

Wire FeederWire Feeder

TABLE A.2

** Tabled values are for operation at ambient temperatures of 104°F(40°C) and below. Applications above104°F(40°C) may require cables larger than recommended, or cables rated higher than 167°F(75°C).

A-4


A

BK

H N L CDMG

F E

JI

POWER SOURCE WIRE FEEDER

AB K

HNLC

D M G

FE

J

I

Function

Motor PowerMotor PowerGas SolenoidGas SolenoidReservedReserved“2A” Differential Tachometer“2B” Differential TachometerReservedReserved“1A” Differential Tachometer“1B” Differential TachometerReserved“67” Electrode Sense Lead

Pin

ABCDEFGHIJKLMN

WIRE DRIVE CABLE, K1785-XXWire drive cables are used to connect power sources and controlboxes to remote wire drives.

The cables have a 14 pin connector at each end. Both ends ofthe cable have a collar and the cables cannot be “daisychained” to make a longer cable.

Function

Motor PowerMotor PowerGas SolenoidGas Solenoid“2A” Differential TachometerReserved+15VDC Tech SupplyTachometer CommonReservedReserved“1A” Differential Tachometer“1B” Differential Tachometer“2B” Differential Tachometer“67” Electrode Sense Lead

Pin

ABCDEFGHIJKLMN

POWER SOURCE WIRE FEEDER

A-5


SHIELDING GAS CONNECTION

CYLINDER may explode if dam-aged.

•Keep cylinder upright andchained to support.

• Keep cylinder away from areas where it may be damaged.• Never lift welder with cylinder attached.• Never allow welding electrode to touch cylinder.• Keep cylinder away from welding or other live electrical

circuits.• BUILD UP OF SHIELDING GAS MAY HARM HEALTH OR KILL.

• Shut off shielding gas supply when not in use.• See American National Standard Z-49.1, "Safety

in Welding and Cutting” Published by theAmerican Welding Society.

--------------------------------------------------------------------Maximum inlet pressure is 100 psi. (6.9 bar.)

Install the shielding gas supply as follows:

1. Secure the cylinder to prevent it from falling.

2. Remove the cylinder cap. Inspect the cylinder valves and regula-tor for damaged threads, dirt, dust, oil or grease. Remove dustand dirt with a clean cloth. DO NOT ATTACH THE REGULATOR IFOIL, GREASE OR DAMAGE IS PRESENT! Inform your gas suppli-er of this condition. Oil or grease in the presence of high pressureoxygen is explosive.

3. Stand to one side away from the outlet and open the cylindervalve for an instant. This blows away any dust or dirt which mayhave accumulated in the valve outlet.

4. Attach the flow regulator to the cylinder valve and tighten theunion nut(s) securely with a wrench. Note: if connecting to 100%CO2 cylinder, insert regulator adapter between regulator andcylinder valve. If adapter is equipped with a plastic washer, besure it is seated for connection to the CO2 cylinder.

5. Attach one end of the inlet hose to the outlet fitting of the flowregulator. Attach the other end to the welding system shieldinggas inlet. Tighten the union nuts with a wrench.

6. Before opening the cylinder valve, turn the regulator adjustingknob counterclockwise until the adjusting spring pressure isreleased.

7. Standing to one side, open the cylinder valve slowly a fraction ofa turn. When the cylinder pressure gage stops moving, open thevalve fully.

8. The flow regulator is adjustable. Adjust it to the flow rate recom-mended for the procedure and process being used before makinga weld.

WARNING

A-6


PROCEDURE TO INSTALL DRIVE ROLLS AND WIREGUIDES

ELECTRIC SHOCK can kill.• Turn the input power OFF at the welding

power source before installation or changingdrive rolls and/or guides.

• Do not touch electrically live parts.• When inching with the gun trigger, electrode and drive

mechanism are "hot" to work and ground and couldremain energized several seconds after the gun trigger isreleased.

• Do not operate with covers, panels or guards removed oropen.


--------------------------------------------------------------------To remove drive rolls and wire guides:

1. Turn power off at the welding power source.

2. Remove the outer wire guide.

3. Rotate all of the triangular rings to the unlocked position.

4. Open the idle arms.

5. Remove the drive rolls and inner wire guide.

To install drive rolls and wire guides:

1. Turn off power at the welding power source.

2. Open the idle arms.

3. Assemble the inner wire guide.

4. Slide the drive rolls onto the drive hubs.

5. Close the idle arms.

6. Rotate all of the triangular rings to the locked position.

7. Assemble the outer wire guide.

8. Adjust the pressure arms to the recommended setting.

INNER WIRE GUIDE

IDLER ARM OPENED

DRIVE ROLLS

OUTER WIRE GUIDE

WARNING

A-7


CONDUIT INSTALLATION

The K1546-xx series of conduits are compatible with K515-xx,K565-xx, Wire Wizard and Electron Beam Technologies conduits.

To install conduit to the wire drive:

1. Slide the conduit bushing into the feed plate and secure withthe set screw.

2. Slide the conduit into the bushing and lock in place with thethumb screw.

CONDUIT

CONDUITBUSHING

THUMBSCREW

SETSCREW

PRESSURE ARM ADJUSTMENT


power source before installation or changingdrive rolls and/or guides.

• Do not touch electrically live parts.• When inching with the gun trigger, electrode and drive

mechanism are "hot" to work and ground and couldremain energized several seconds after the gun trigger isreleased.



--------------------------------------------------------------------The pressure arm controls the amount of force the drive rollsexert on the wire. Proper adjustment of the pressure arm givesthe best welding performance.

Set the pressure arm as follows:(See Figure A.3)

Aluminum wires between 1 and 3Cored wires between 3 and 4Steel, Stainless wires between 4 and 6

LOADING WIRE

• Keep hands, hair, clothing and tools away fromrotating equipment.

• Do not wear gloves when threading wire orchanging wire spool.

• Only qualified personnel should install, use orservice this equipment.

--------------------------------------------------------------------

FIGURE A.3

WARNING

WARNING

A-8


SYSTEM SET-UP

ArcL

ink X

TCo

nnec

tion

ArcL

ink

(5 P

in)

Wor

kSe

nse

Wire

Fee

der

(14 P

in)

Robo

ticTo

rch

Powe

r Wav

e i40

0K2

669-

1

Wor

k Piec

e

FANU

C R-

J30iA

Con

trolle

rwi

thIn

tegr

ated

OpBo

x

Optio

nal W

ork

Sens

e Lea

d (2

1)

K178

5-XX

Wire

Fee

der

K884

-5,-6

Cont

rolC

able

* Wor

k C

able

(-)

Inte

rnal

ArcL

ink X

TCo

mm

unica

tion

* Elec

trode

Cab

le (+

)

SYSTEM SET-UP (SINGLE ARM)

Wire

Fee

der

(14 P

in)

Gas

Air

Auto

Driv

e 4R2

20(W

ithou

t Cov

er S

hown

)Ar

cMat

e 100

iBAr

cMat

e 100

iC

* Ref

er to

"Out

put C

able

Guid

eline

s" fo

r rec

omm

ende

d ca

ble s

ize

Elec

trode

K150

5-XX

K150

7-XX Co

nnec

tion

F-3

NOTES

B-1

OPERATIONAutoDrive® 4R220 OPERATION

• ELECTRIC SHOCK CAN KILL. Unlessusing COLD FEED feature, when feed-ing with gun trigger, the electrode anddrive mechanism are always electri-cally energized and could remainenergized several seconds after thewelding ceases..

• Do not touch electrically live part or electrode with skinor wet clothing.

• Insulate yourself from work and ground.• Always wear dry insulating gloves.• Do not operate with covers, panels or guards removed or

open.------------------------------------------------------------------

• FUMES AND GASSES can be danger-ous.

• Keep your head out of fumes.• Use ventilation or exhaust to remove

fumes from breathing zone.------------------------------------------------------------------

• WELDING SPARKS can cause fire orexplosion.

• Keep flammable material away.

------------------------------------------------------------------ARC RAYS can burn.• Wear eye, ear and body protection.

------------------------------------------------------------------SEE ADDITIONAL WARNING INFORMATION UNDER ARCWELDING SAFETY PRECAUTIONS AND IN THE FRONT OFTHIS OPERATING MANUAL.------------------------------------------------------------------

SAFETY PRECAUTIONSREAD AND UNDERSTAND ENTIRE SECTION BEFORE OPERATINGMACHINE.

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

INPUT POWER

DIRECT CURRENT

OPEN CIRCUIT VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE GROUND

WARNING ORCAUTION

U0

U1

U2

I1

I2

GRAPHIC SYMBOLS THAT APPEAR ON THISMACHINE OR IN THIS MANUAL

WARNING

C-1

ACCESSORIESAutoDrive® 4R220

WIRE TYPE

Steel Wires:

Cored Wires:

Aluminum Wires:

KITS ELECTRODE SIZE

KP1505-030S .023-.030 (0.6-0.8mm)KP1505-035S .035 (0.9mm)KP1505-040S .040 (1.0mm)KP1505-045S .045 (1.2mm)

KP1505-035C .030-.035" (0.8-0.9mm)KP1505-045C .040-.045" (1.0-1.2mm)

KP1507-3/64A 3/64" (1.2mm)

OPTIONAL KITS AND ACCESSORIES

Includes: 4 V groovedrive rolls and inner wireguide.

Includes: 4 Knurled driverolls and inner wire guide.

Includes: 4 polished Ugroove drive rolls, outerwire guide and inner wireguide.

DRIVE ROLL KITS 4 ROLL DRIVE

C-2


K1500-4

K1500-5

K489-7

K515-xxK565-xx

K1546-1

Gun Receiver Bushing (for gun with K466-3 Lincoln gun connectors; compatible

with Miller® guns.)

Gun Receiver Bushing (compatible withOxo® guns.)

Gun Receiver Bushing (for Lincoln Fast-Mate guns.)

Wire ConduitWire Conduit

Incoming Bushing, for Lincoln Conduit.025- 1/16" (0.6 - 1.6mm) wire.

Compatible with Electron Beam Conduit.

Includes: Gun receiver bushing withhose nipple, set screw and hex key

wrench.

Includes: Gun receiver bushing withhose nipple, 4 guide tubes, set screw

and hex key wrench.

Includes: Gun receiver bushing withtrigger connector.

Requires K1546-1Requires K1546-1

Includes: Incoming bushing and hex keywrench.

K1500-1

K1500-2

K1500-3

Gun Receiver Bushing (for guns withK466-1 Lincoln gun connectors;Innershield and Subarc guns)

Gun Receiver Bushing (for guns withK466-2, K466-10 Lincoln gun connectors;Magnum 200/300/400 guns and compati-

ble with Tweco® #2-#4)

Gun Receiver Bushing (for guns withK613-7 Lincoln gun connectors; Magnum550 guns and compatible with Tweco®

#5)

Includes: Gun receiver bushing, setscrew and hex key wrench.


wrench.


wrench.

C-3


K2175-1

K2175-2

K895-2

K836-1

K884-5

K884-6

K1796-xx

K2593-xx

K1785-xx

K2709-xx

K1733-1

500 lb Accu-Pak Box Payoff Kit

1000 lb Accu-Pak Box Payoff Kit

Rotary Wire Dispenser

Dereeler Adapter

Accu-Trak Drum Payoff Kit – 20 inchdiameter

Accu-Trak Drum Payoff Kit – 23 inchdiameter

Coaxial Cables

Coaxial Cables

Wire Drive Cables

Wire Drive Cables

Wire Straightener

Includes: 1 cable of length “xx” feet.14 pin connectors on both ends.

Cable length cannot be extended byconnecting K1785 cables together.

Includes: 1 cable of length “xx” feet.14 pin connectors on both ends. Has

collars at both ends. Used withFANUC arms that have an integrated

cable.

Includes: 1 cable of length “xx” feet.14 pins connectors on both ends.May be daisy chained to make a

longer cable. Used with FANUC armsthat do not have an integrated cable.

Includes: 1 wire straightener

D-1

MAINTENANCEAutoDrive® 4R220


power source before installation orchanging drive rolls and/or guides.

• Do not touch electrically live parts.• When inching with the gun trigger, elec-

trode and drive mechanism are "hot" towork and ground and could remainenergized several seconds after the guntrigger is released.



--------------------------------------------------------------------

SAFETY PRECAUTIONS

ROUTINE MAINTENANCE

To Install or remove the AutoDrive® 4R220 for servicing:

Every 6 months or every 2.5 million arc starts (whichevercomes first), inspect the motor brushes. Replace if shorterthan 0.5” (12.7mm).

See Installation Section of this Instruction Manual.

WARNING

F-3

NOTES

E-1

TROUBLE SHOOTING

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln AuthorizedField Service Facility for technical troubleshooting assistance before you proceed.

AutoDrive® 4R220

CAUTION

This Troubleshooting Guide is provided to help you locate andrepair possible machine malfunctions. Simply follow the three-step procedure listed below.

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMPTOMS)”. Thiscolumn describes possible symptoms that the machine mayexhibit. Find the listing that best describes the symptom that themachine is exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists the obviousexternal possibilities that may contribute to the machine symp-tom.

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause,generally it states to contact your local Lincoln Authorized FieldService Facility.

If you do not understand or are unable to perform theRecommended Course of Action safely, contact your localLincoln Authorized Field Service Facility.

HOW TO USE TROUBLESHOOTING GUIDE

Service and Repair should only be performed by Lincoln Electric Factory Trained Personnel. Unauthorized repairs per-formed on this equipment may result in danger to the technician and machine operator and will invalidate your factorywarranty. For your safety and to avoid Electrical Shock, please observe all safety notes and precautions detailed through-out this manual.

__________________________________________________________________________

ELECTRIC SHOCK can kill.• Turn the input power OFF at the welding power source before installation or changing drive rolls and/or

guides.• Do not touch electrically live parts.• When inching with the gun trigger, electrode and drive mechanism are "hot" to work and ground and

could remain energized several seconds after the gun trigger is released.• Welding power source must be connected to system ground per the National Electrical Code or any

applicable local codes.• Only qualified personnel should perform maintenance work.

WARNING

WARNING

E-2

TROUBLE SHOOTING

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS(SYMPTOMS)

RECOMMENDEDCOURSE OF ACTION

AutoDrive® 4R220

CAUTIONIf for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln AuthorizedField Service Facility for technical troubleshooting assistance before you proceed.

POSSIBLE CAUSE

The wire feeder does not feed wire and thedrive rolls do not spin.

The wire feeds erratically.

No shielding gasVariable or "hunting" arc.

1. Verify the power source is turned on.

2. Verify the circuit breaker for the wirefeeder on the power source has nottripped.

3. Verify power is being supplied to thewire feeder.

1. Verify the correct drive rolls and innerwire guide are installed in the wire drive.

2. Check for sharp bends in the gun liner orconduit.

3. Examine the contact tip for wear andproper size. Replace as necessary.

4. Check the gun liner and conduit. Thewelding electrode should slide easilythrough both.

5. Verify the proper gun liner is installed.

6. Verify the pressure arms are set proper-ly. Too much pressure may crush thewire.

7. Inspect the motor for worn brushes.

1. Verify the gas supply is turned on andnot empty.

2. Check the gas hose for cuts. Make sureit is not crushed.

3. Verify the shielding gas hose is connect-ed to the gun bushing or welding gun.

E-3

TROUBLE SHOOTING

Observe all Safety Guidelines detailed throughout this manual

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln AuthorizedField Service Facility for technical troubleshooting assistance before you proceed.

PROBLEMS(SYMPTOMS)

POSSIBLE CAUSE

RECOMMENDEDCOURSE OF ACTION

AutoDrive® 4R220

CAUTION

Variable or "hunting" arc.

The motor overload errors occur.

1. Check for proper size contact. Makesure the contact tip is not worn, free ofspatter and not melted.

2. Clean and tighten all electrode and workconnections.

3. Verify the proper polarity is being usedfor the weld procedure.

4. Make sure the proper electrode stick-outis being maintained.

5. Check the gas flow rate and mixture.

6. Verify the gun bushing is tightly mountedto the wire drive.

7. Verify the gun is tightly mounted to thegun bushing.

8. Verify the electrode lead is connected tothe proper connection block on the feedhead.

9. Inspect the motor for worn brushes.

1. Check for sharp bends in the gun linerand conduit.

2. Examine the contact tip for wear andproper size. Replace as necessary.

3. Check the gun liner and conduit. Thewelding electrode should slide easilythrough both.

4. Verify the proper gun liner is installed.

5. Reduce the pressure arm setting.

Output Problems

DIAGRAMSAutoDrive® 4R220

NOTE

: Th

is d

iagr

am is

for r

efer

ence

onl

y.

It m

ay n

ot b

e ac

cura

te fo

r all

mac

hine

s co

vere

d by

this

man

ual.

The

spe

cific

dia

gram

for a

par

ticul

ar c

ode

is p

aste

d in

side

the

mac

hine

on

one

of th

e en

clos

ure

pan-

els.

If t

he d

iagr

am is

ille

gibl

e, w

rite

to th

e Se

rvic

e De

partm

ent f

or a

repl

acem

ent.

Giv

e th

e eq

uipm

ent c

ode

num

ber.

F-1

WIR

ING

DIAG

RAM

AU

TODR

IVE

FEE

DER

FOR

COD

ES 1

1455

, 118

82 &

119

56

A

M 2

1562

-1

GND

6767

B

553

552

550

551

846A

845A

P4

1 2 3 4

846A

845A

WHI

TE

BLAC

K

BLAC

KBL

UE

RED

BR WHI

TEBL

ACK

552

553

BLAC

KG

REEN

RED

BLAC

K

BLAC

K

67A

BLAC

KRE

D

GRE

EN

550

535

535

531

534

87654321

87

65

43

21

(J80

0)

58

N.A

.1

453

7

(J80

1)

41

N.A

.8

5

843A

842A

500A

515A

NO

TES:

N

.A.

CAV

ITY

NU

MBE

RIN

G S

EQ

UEN

CE

AS

VIE

WE

D

FRO

M C

OM

PON

EN

T SI

DE

OF

PC B

OAR

D.

N.B

. C

AVIT

Y N

UMB

ER

ING

SE

QUE

NC

E A

S VI

EW

ED

FR

OM

LE

AD S

IDE

OF

CO

NN

EC

TOR

.

E

LEC

TRIC

AL S

YMBO

LS P

ER

E15

37

LEAD

CO

LOR

CO

DING

B

– BL

ACK

W –

WHI

TE

U –

BLUE

R

– RE

D

553A

GAS

SOLE

NOID

551A

843A

842A

515A

500A

553A

552A

550A

551

1 2 3 4 5 6 7 8P3

NMLKJIHGFEDCBJ2 A

L1

L2

1 2 3 4 5 6 755

0A55

1A534

537

U WB

B

531

TAC

H

WMOTO

R /

GEA

RBO

X

8P1FE

EDPL

ATE

TAC

H IN

TERF

ACE

PC B

D

552A

WIR

ING

DIAG

RAM

AU

TODR

IVE

FEE

DER

FOR

COD

E 12

273


NOTE

: Th

is d

iagr

am is

for r

efer

ence

onl

y.

It m

ay n

ot b

e ac

cura

te fo

r all

mac

hine

s co

vere

d by

this

man

ual.

The

spe

cific

dia

gram

for a

par

ticul

ar c

ode

is p

aste

d in

side

the

mac

hine

on

one

of th

e en

clos

ure

pan-

els.

If t

he d

iagr

am is

ille

gibl

e, w

rite

to th

e Se

rvic

e De

partm

ent f

or a

repl

acem

ent.

Giv

e th

e eq

uipm

ent c

ode

num

ber.

F-2

A

M 2

1562

-1

GND

6767

B

553

552

550

551

846A

845A

P4

1 2 3 4

846A

845A

WHI

TE

BLAC

K

BLAC

KBL

UE

RED

BR WHI

TEBL

ACK

552

553

BLAC

KGR

EEN

RED

BLAC

K

BLAC

K

67A

BLAC

KRE

D

GREE

N

550

535

535

531

534

87654321

87

65

43

21

(J80

0)

58

N.A

.1

453

7

(J80

1)

41

N.A

.8

5

843A

842A

500A

515A

NOTE

S:

N.A.

CAV

ITY

NUM

BERI

NG S

EQUE

NCE

AS V

IEW

ED

FROM

COM

PONE

NT S

IDE

OF P

C BO

ARD.

N.

B. C

AVIT

Y NU

MBE

RING

SEQ

UENC

E AS

VIE

WED

FR

OM L

EAD

SIDE

OF

CONN

ECTO

R.

EL

ECTR

ICAL

SYM

BOLS

PER

E15

37

LEAD

COL

OR C

ODIN

G B

– BL

ACK

W –

WHI

TE

U –

BLUE

R

– RE

D

553A

GAS

SOLE

NOID

551A

843A

842A

515A

500A

553A

552A

550A

551

1 2 3 4 5 6 7 8P3

NMLKJIHGFEDCBJ2 A

L1

L2

1 2 3 4 5 6 755

0A55

1A

534

537

U WB

B

531

TACH

WMOT

OR /

GEAR

BOX

8P1FE

EDPL

ATE

TACH

INTE

RFAC

E PC

BD

552A

A

M 2

1562

-1

GND

6767

B

553

552

550

551

846A

845A

P4

1 2 3 4

846A

845A

WHI

TE

BLAC

K

BLAC

KBL

UE

RED

BR WHI

TEBL

ACK

552

553

BLAC

KG

REEN

RED

BLAC

K

BLAC

K

67A

BLAC

KRE

D

GRE

EN

550

535

535

531

534

87654321

87

65

43

21

(J80

0)

58

N.A

.1

453

7

(J80

1)

41

N.A

.8

5

843A

842A

500A

515A

NO

TES:

N

.A.

CAV

ITY

NU

MBE

RIN

G S

EQ

UEN

CE

AS

VIE

WE

D

FRO

M C

OM

PON

EN

T SI

DE

OF

PC B

OAR

D.

N.B

. C

AVIT

Y N

UMB

ER

ING

SE

QUE

NC

E A

S VI

EW

ED

FR

OM

LE

AD S

IDE

OF

CO

NN

EC

TOR

.

ELE

CTR

ICAL

SYM

BOLS

PE

R E

1537

LE

AD C

OLO

R C

ODI

NG

B –

BLAC

K W

– W

HITE

U

– BL

UE

R –

RED

553A

GAS

SOLE

NOID

551A

843A

842A

515A

500A

553A

552A

550A

551

1 2 3 4 5 6 7 8P3

NMLKJIHGFEDCBJ2 A

L1

L2

1 2 3 4 5 6 755

0A55

1A534

537

U WB

B

531

TAC

H

WMOTO

R /

GEA

RBO

X

8P1FE

EDPL

ATE

TAC

H IN

TERF

ACE

PC B

D

552A

WIR

ING

DIAG

RAM

AU

TODR

IVE

FEE

DER

FOR

COD

E 12

273

F-3


L151

57

A.0

1

4.09

1.97

2.76

1.97

1.49

10.2

2

1.24

2.04

4.72

10.4

3

9.40 10

.07

9.92

AutoDrive® 4R220

P-825P-825

PARTS LIST FOR

AutoDrive® 4R220

ILLUSTRATION OF SUB-ASSEMBLIESMISCELLANEOUS ITEMS Base AssemblyWire Drive AssemblyRoof & Door Assembly

AutoDrive® 4R220 Oct-2014

P-825-AP-825-A

ILLUSTRATION OF SUB-ASSEMBLIES

33 22

11

Use the Illustration of Sub-Assemblies page and the table below to determine which sub assembly page andcolumn the desired part is located on for your particular code machine.


Do Not use this Parts List for a machine if its code number is not listed. Contact the Service Department for anycode numbers not listed.

P-825-A.1P-825-A.1

AutoDrive® 4R220

For Codes: 12273

CODE NO.

12273 1 1 1 1

Roof & Door A

ssem

bly

P-825-E

3

Wire Drive As

sembly

P-825-D

2

Base Assem

bly

P-825-C

1Misc

ellaneous Item

s

P-825-B

SUB ASSEMBLY PAGE NAME

PAGE NO.

Sub Assembly ItemNo.

MISCELLANEOUS ITEMS (THESE ITEMS ARE NOT ILLUSTRATED)

Mounting Bracket (100iB) S21164-232 1 XAccessory Bracket (100iC, 120iC) S21164-239 1 XMounting Hardware Kit, Includes: S23858-22 1 XThread Forming Screws S9225-91 6 XT-Handle Hex Key (5mm) S28129 1 X

Harness (Control) M21561-1 1 XHarness (Motor) M21561-2 1 X

Oct-2014

Use only the parts marked “x” in the column under theheading number called for in the model index page.

# Indicates a change this printing.

P-825-B.2

DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

P-825-B.2

AutoDrive® 4R220

AutoDrive® 4R220

NOTES


P-825-CP-825-C

Base Assembly

4A4A

33

8A8A

8B8B

8C8C

9B9B

1111

1515

66

1313

2222

10A10A10B10B

22

1414

4C4C

4B4B

55

9A9A

11

20A20A

20D20D

20B20B 20C20C

Base Assembly (L13855-2), Includes: NSS 1 X1 Mounting Bracket Asbly, Includes: L13278-1 1 X2 Bottom Bracket L13279 1 X3 Base G6021 1 X4A Wire Drive Mounting Bracket L13231 1 X4B #10-24 HN T9187-13 1 X4C Plain Washer S9262-27 1 X5 Thread Forming Screw S9225-90 7 X6 Insulation (Base) (L16709-7) (Part of L16709) NSS 1 X7 Insulation (Gearbox) (L16709-4) (Part of L16709) NSS 1 X7A Bottom Insulator (Not Shown) G7343-3 1 X8A Solenoid Assembly M17294-8 1 X8B Plain Washer S9262-149 1 X8C Conduit Locknut T14370-1 1 X9A Insulator T11267-A 1 X9B Insulator T11267-B 1 X10A Tach Interface PC Bd Assembly L11355-[ ] 1 X10B Expansion Nut S14020-4 3 X10C Self Tapping Screw (Not Shown) S8025-115 3 X13 Maxtrac Decal S26310 1 X14 Cable Assembly (J2, P3, P4), Includes: L13338 1 X

Connector (14 Pin) S12020-39 1 XBox Connector T9639-1 1 X

15 Bypass Assembly S22969-5 1 X20A 1/4-20 x 1.50 HHCS CF000141 1 X20B Lock Washer E106A-2 1 X20C Plain Washer S9262-98 1 X20D Insulating Tube T14767 1 X22 Door Bumper T14882-1 2 X25 Instruction Tag (Not Shown) S27328 1 X

Oct-2014AutoDrive® 4R220



P-825-C.1

ITEM DESCRIPTION PART NO. QTY. 1 2 3 4 5 6 7 8 9

P-825-C.1

Note: When ordering new printed circuit boards indicate the dash number [ ] of the “Old” boardthat is to be replaced. This will aid Lincoln in supplying the correct and latest board alongwith any necessary jumpers or adapters. The dash number brackets [ ] have purposelybeen left blank as to eliminate errors, confusion and updates.

NSS - Not Sold Separately


P-825-DP-825-D

Wire Drive Assembly

11

77

2K2K

2R2R

2J2J 26262N2N 22

2S2S 2T2T1919

2L2L 2M2M

2H2H

2G2G

2F2F

2C2C

2E2E

2D2D

2B2B

12A12A

15A15A

15B15B12B12B 12C12C

3A3A

4A4A991313

202027271818

5A5A

6A6A

8A8A8B8B

8C8C

6B6B

66

5B5B4C4C 4D4D 4E4E

3F3F

3E3E

3K3K3L3L

3M3M

Wire Drive Assembly (L13230-2), Includes: NSS 1 X1 Gearbox Mounting Panel L13229 1 X2 Feedplate Assembly, Includes: G6089 1 X2A Tension Arm Assembly, Includes: M20593-1 2 X2B Shaft S26360-1 1 X2C Base S26359-1 1 X2D Pressure Arm Decal T13086-204 1 X2E Spring T11862-68 1 X2F Spring T11862-69 1 X2G Cap S26358-1 1 X2H #10-24 HN CF000010 1 X2J Connection Bar M19611-6 1 X2K Socket Head Cap Screw T9447-112 1 X2L Retaining Ring S9776-69 1 X2M Plain Washer S9262-167 1 X2N Spring T11862-64 1 X2R 1/4-20 x .50 HHCS CF000012 4 X2S Lock Washer E106A-2 4 X2T Plain Washer S9262-23 4 X2U Feedplate G4642-1 1 X3 Motor Gearbox Assembly, Includes: L12604-2 1 X3A Drive Motor NSS 1 X3B Connector, Molex (Not Shown) S24018-8 1 X3C Locking Post (Not Shown) S24019-8 1 X3E Snap Ring S9776-3 1 X3F Tachometer Sensor S20374-3 1 X3G Ring Magnet (Not Shown) S18011-5 1 X3H Brush (Not Shown) L12604-A 1 X3J Brush Cap (Not Shown) L12604-B 1 X3K Motor Adapter S27547 1 X3L Lock Washer E106A-2 6 X3M M8 x 1.00 PPHS T14731-18 6 X4A Drive Gear M19870-1 1 X4B Woodruff Key (Not Shown) #404 1 X4C Plain Washer S9262-66 1 X4D Lock Washer E106A-1 1 X4E #10-24 x .50 HHCS CF000401 1 X5A Drive Hub Bearing Assembly S25405 1 X5B Retainer S25403 1 X6 Drive Roll Shaft Assembly, Includes: S25638 4 X6A Twist Lock Ring S25308 4 X6B Retainer S25403 4 X7 Wire Guide Assembly (Outer) KP2071-1 1 X8A Cover M20399 1 X8B 1/4-20 x .50 HHCS CF000012 2 X8C Lock Washer E106A-2 2 X9 Set Screw S11604-21 1 X11A Panel Insulator (G7343-1) (Part of G7343) (Front) (Not Shown) NSS 1 X11B Panel Insulator (G7343-2) (Part of G7343) (Rear) (Not Shown) NSS 1 X




P-825-D.1


P-825-D.1


12A 1/2-13 X 1.00 HHCS CF000021 1 X12B Lock Washer E106A-15 1 X12C Plain Washer S9262-80 1 X13 Conduit Bushing S23124-8 1 X15A Flex Tube T10642-243 1 X15B Hose Clamp T13777-8 2 X18 Decal (Gas) (L13295-6) (Part of L13295) NSS 1 X19 Warning Decal S25815 1 X20 Bulkhead Connector T14557-25 1 X25 Flex Tube (Not Shown) T10642-281 1 X26 Sems Screw T10082-27 1 X27 Thread Forming Screw S9225-90 2 X




P-825-D.2


P-825-D.2


AutoDrive® 4R220

NOTES


P-825-EP-825-E

Roof & Door Assembly

1515

1A1A1H1H10A10A

1818

15151919

88

1F1F

66

9B9B9A9A

1717

2020

2222

1C1C

1D1D

10B10B

10C10C

1A Roof Assembly, Includes: G6022-1 1 X1C Support Bracket M25270 1 X1D Support Bracket M25270-1 1 X1E Self Tapping Screw (Not Shown) S9225-102 2 X1F Insulation (Front) (L16227-1) (Part of L16227) NSS 1 X1G Insulation (Side) (L16227-2) (Part of 16227) (Not Shown) NSS 1 X1H Wiring Diagram M21562 1 X6 #10-24 x .50 HHCS CF000401 10 X8 Door G6340 1 X9A Latch S24694 1 X9B Rivet T12584-9 4 X10A Hinge Assembly S27507 2 X10B Lock Washer T9695-3 8 X10C Socket Head Cap Screw T9447-21 8 X15 Logo Decal S11893-13 2 X16 Warning Decal (Not Shown) S25536-1 1 X17 Nameplate Decal (L16227-5) (Part of L16227) NSS 1 X18 Wire Drive Decal (L16227-3) (Part of L16227) NSS 1 X19 Autodrive Logo Decal S28147 1 X20 Decal - Gas Inlet (L16227-6) (Part of L16227) NSS 1 X21A Door Insulator (Not Shown) G7263 1 X21B Plain Washer (Not Shown) S9262-27 4 X21C #10-24 HLN (Not Shown) T9187-13 4 X22 CCC Decal T13086-192 1 X




P-825-E.1


P-825-E.1


AutoDrive® 4R220

NOTES

Customer assistanCe PoliCy

The business of The Lincoln Electric Company is manufacturing andselling high quality welding equipment, consumables, and cuttingequipment. Our challenge is to meet the needs of our customers andto exceed their expectations. On occasion, purchasers may askLincoln Electric for advice or information about their use of ourproducts. We respond to our customers based on the best informationin our possession at that time. Lincoln Electric is not in a position towarrant or guarantee such advice, and assumes no liability, withrespect to such information or advice. We expressly disclaim anywarranty of any kind, including any warranty of fitness for anycustomer’s particular purpose, with respect to such information oradvice. As a matter of practical consideration, we also cannot assumeany responsibility for updating or correcting any such information oradvice once it has been given, nor does the provision of informationor advice create, expand or alter any warranty with respect to the saleof our products.

Lincoln Electric is a responsive manufacturer, but the selection anduse of specific products sold by Lincoln Electric is solely within thecontrol of, and remains the sole responsibility of the customer. Manyvariables beyond the control of Lincoln Electric affect the resultsobtained in applying these types of fabrication methods and servicerequirements.

Subject to Change – This information is accurate to the best of ourknowledge at the time of printing. Please refer to www.lincolnelectric.com for any updated information.

operator’s manual autodrive 4r220...emf fields may interfere with some pacemakers, and welders...

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