Lincoln Electric 4R90 User Manual

AutoDrive 4R90

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For use with machines having Code Number : 11492, 11722

Safety Depends on You

Lincoln arc welding an d cu t t i n g
equipment is designed and built with
safety in mind. However, your overall
safety can be increased by proper
installation ... and thoughtful opera­tion o n y o u r part. D O N O T

INSTALL, OPERATE OR REPAIR
THIS EQUIPMENT WITHOU T
READING THIS MANUA L AND
THE SAFE T Y PR E C AUTI O N S
CONTAINED THROUGHOUT. And,

most importantly, think before you
act and be careful.

IM952-A

March, 2010

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com

OPERATOR’S MANUAL

Copyright © Lincoln Global Inc.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

i

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel Engines

ARC WELDING CAN BE HAZARDOUS. PROTECT YOURSELF AND OTHERS FROM POSSIBLE SERIOUS INJURY OR DEATH.
KEEP CHILDREN AWAY. PACEMAKER WEARERS SHOULD CONSULT WITH THEIR DOCTOR BEFORE OPERATING.

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

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

The engine exhaust from this product contains
chemicals known to the State of California to cause
cancer, birth defects, or other reproductive harm.

The Above For Gasoline Engines

i

FOR ENGINE
powered equipment.

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

____________________________________________________

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

____________________________________________________

1.c. Do not add the f uel ne ar an open flame
welding arc or when the engine is running.
Stop the engine and allow it to cool before
refueling to prevent spilled fuel from vaporiz­ing on contact with hot engine parts and
igniting. Do not spill fuel when filling tank. If
fuel is spilled, wipe it up and do not start
engine until fumes have been eliminated.

____________________________________________________

1.d. Keep all equipment safety guards, covers and devices in
position and in good repair.Keep hands, hair, clothing and
tools away from V-belts, gears, fans and all other moving
parts when starting, operating or repairing equipment.

____________________________________________________

1.e. In som e ca ses it ma y be necessary t o remove saf ety

gu a r d s to p e r f o r m requ i r e d mainte n a n c e . Remov e
guards only when necessary and replace them when the
ma i n t e n a n c e r e q u i r i n g t h e i r re m o v a l is complete.
Always use the greatest care when working near moving
parts.

___________________________________________________

1.f. Do not put your hands near the engine fan.
Do not attempt to override the governor or
idler by pushing on the throttle control rods
while the engine is running.

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

ELECTRIC AND
MAGNETIC FIELDS
may be dangerous

2.a. El ectric curren t flowin g throug h any conduc to r caus es
localized Electric and Magnetic Fi el ds (EM F) . Welding
current cre ates E MF fields aro und weldin g cables an d
welding machines

2.b. EMF fiel ds may inte rfe re w ith som e pa cem akers, and
welders having a pacemaker should consult their physician
before welding.

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

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

2.d.1.

Route the electrode and work cables together - Secure
them with tape when possible.

2.d.2. Nev er coil the ele ctrod e le ad arou nd y our bod y.

2.d.3. Do not place your body between the electrode and

work cables. If the electrode cable is on your right
side, the work cable should also be on your right side.

___________________________________________________

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

2.d.4. Connect the work cable to the workpiece as close as
possible to the area being welded.

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

Mar ‘95

ii

SAFETY

ii

ELECTRIC SHOCK can
kill.

3.a. The electrode and work (or ground) circuits
are electrically “hot” when the welder is on.
Do not touch these “hot” parts with your bare
skin or wet cl othing. Wear dry, ho le -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
area of physical contact with work and ground.

In addition to the normal safety precautions, if welding
mu s t b e pe r f o rmed under electrically haz a r d o us
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,
electrod e reel, wel ding h ead, n ozzle or semiautom atic
welding gun are also electrically “hot”.

3.d. Always be sure the work cable makes a good electrical
connection with the metal being welded. The connection
should be 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 and
welding machine in good, safe operating condition. Replace
damaged insulation.

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

3.h. Ne ver simulta neo usl y tou ch el ect ric ally “ho t” pa rts of
electrode holders connected to two welders because voltage
between the two can be the total of the open circuit voltage
of both welders.

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

3.j. Also see Items 6.c. and 8.

ARC RAYS can burn.

4.a. Use a shield with the proper filter and cover
plates to protect your eyes from sparks and
the rays of the arc when welding or observing
open arc welding. Headshield and filter lens
should conform to ANSI Z87. I standards.

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

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

FUMES AND GASES
can be dangerous.

5.a. Welding may produce fumes and gases
hazardous to health. Avoid breathing these
fume s and gases. Whe n weld ing, 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

we l d i n g with electrode s w h ich require speci a l
ve n t ilation suc h a s s tainless or ha r d facing (see
instruc tions on conta iner 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 circum­st a n ces, outdoor s , a r espirator ma y b e r equired.
Additional precautions are also required when welding
on galvanized steel.

5. b. The operation of welding fume control equipment is affected
by various factors including proper use and positioning of
the equipment, maintenance of the equipment and the spe­cific welding procedure and application involved. Worker
exposure level should be checked upon installation and
periodically thereafter to be certain it is within applicable
OSHA PEL and ACGIH TLV limits.

5.c.

Do not weld in locations near chlorinated hydrocarbon
coming from degreasing, cleaning or spraying operations.
The heat and rays of the arc can react with solvent vapors
form phosgene, a highly toxic gas, and other irritating prod­ucts.

5.d. Shielding gases used for arc welding can displace air and

caus e in jur y or dea th. Alway s us e en oug h ve ntila tio n,
especially in confined areas, to insure breathing air is safe.

vapors

to

5.e. Read and understand the manufacturer’s instructions for this

equipment and the consumables to be used, including the
ma t e r i a l saf e t y data s heet ( M S D S) a n d fol l o w your
employer’s safety practices. MSDS forms are available from
yo u r we l d i n g d i s t r i b utor o r f r o m t h e m a n u f a c t u r er.

5.f. Also see item 1.b.

Jan ‘09

iii

SAFETY

iii

WELDING and CUTTING
SPARKS can
cause fire or explosion.

6.a.

Remove fire hazards from the welding area.

If this is not possible, cover them to prevent

Re m e m b e r th a t weldin g sparks and ho t
materials from welding can easily go through small cracks
an d open i ngs to adja c ent ar eas. A void w eldi n g nea r
hydraulic lines. Have a fire extinguisher readily available.

6.b. Where compressed gases are to be used at the job site,
special precautions should be used to prevent hazardous
situations. Refer to “Safety in Welding and Cutting” (ANSI
Standard Z49.1 ) and the o pe rating informat ion fo r the
equipment being used.

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

6.d. Do not heat, cut or weld tanks, drums or containers until the
proper steps have been taken to insure that such procedures
will not cause flammable or toxic vapors from substances
inside. They can cause an explosion even
been “cleaned”. For information, purchase “Recommended
Safe Practices for the
Co n t a i n e r s a n d P i p i n g T h a t H a ve H e ld H azardous
Substances”, AWS F4.1 from the American Welding Society

(see address above).

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

Sparks and spatter are thrown from the welding arc. Wear oil

6.f.
free protective garments such as leather gloves, heavy shirt,
cuffless trousers, high shoes and a cap over your hair. Wear
ear plugs when welding out of position or in confined places.
Always wear safety glasses with side shields when in a
welding area.

6.g. Connect the work cable to the work as close to the welding
area as practical. Work cables connected to the building
framework or other locations away from the welding area
increase the possibil ity of th e welding current pas sing
through lifting chains, crane cables or other alternate cir­cuits. This can create fire hazards or overheat lifting chains
or cables until they fail.

6.h. Also see item 1.c.

the weld ing spark s fr om starti ng a f ire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Us e on l y c o m p r e s s e d g a s cy l i nders
containing the correct shielding gas for the
pr o c e s s used a n d proper l y operating
re g u l a t o r s d e s i g n ed f o r t h e g a s a n d

pressure used. All hoses, fittings, etc. should be suitable for
the application and maintained in good condition.

7.b. Alwa ys keep c yli nde rs in an upr igh t po sit ion sec ure ly
chained to an undercarriage or fixed support.

7.c. Cylinders should be located:

• Away from areas where they may be struck or subjected to

physical damage.

• A safe distance from arc welding or cutting operations and

any other source of heat, sparks, or flame.

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

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

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

7.g. Re ad an d fol low th e ins truc tio n s on compr esse d gas
cylinders, associated equipment, and CGA publication P-l,
“Precautions for Safe Handling of Compressed Gases in
Cylinders,” available from the Compressed Gas Association
1235 Jefferson Davis Highway, Arlington, VA 22202.

FOR ELECTRICALLY
powered equipment.

8.a. Turn off input power using the disconnect
switch at the fuse box before working on
the equipment.

8.b. Insta ll equi pment in accor dance wit h the U.S. N ational
Electrical Code, all lo cal codes and the manufacturer’s
recommendations.

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

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

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

Refer to http://www.lincolnelectric.com/safety for additional safety information.

Jan ‘09

iv

SAFETY

iv

PRÉCAUTIONS DE SÛRETÉ

Pour votre propre protection lire et observer toutes les instructions
et les précautions de sûreté specifiques qui parraissent dans ce
manuel aussi bien que les précautions de sûreté générales suiv­antes:

Sûreté Pour Soudage A L’Arc

1. Protegez-vous contre la secousse électrique:

a. Les circuits à l’électrode et à la piéce sont sous tension

quand la machine à souder est en marche. Eviter toujours
tout contact entre les parties sous tension et la peau nue
ou les vétements mouillés. Porter des gants secs et sans
trous pour isoler les mains.

b. Faire trés attention de bien s’isoler de la masse quand on

soude dans des endroits humides, ou sur un plancher
metallique ou des grilles metalliques, principalement dans
les positions assis ou couché pour lesquelles une grande
partie du corps peut être en contact avec la masse.

c. Maintenir le porte-électrode, la pince de masse, le câble

de soudage et la machine à souder en bon et sûr état
defonctionnement.

d.Ne jamais plonger le porte-électrode dans l’eau pour le

refroidir.

e. Ne jamais toucher simultanément les parties sous tension

des porte-électrodes connectés à deux machines à souder
parce que la tension entre les deux pinces peut être le
total de la tension à vide des deux machines.

f. Si on utilise la machine à souder comme une source de

courant pour soudage semi-automatique, ces precautions
pour le porte-électrode s’applicuent aussi au pistolet de
soudage.

2. Dans le cas de travail au dessus du niveau du sol, se protéger
contre les chutes dans le cas ou on recoit un choc. Ne jamais
enrouler le câble-électrode autour de n’importe quelle partie
du corps.

5. Toujours porter des lunettes de sécurité dans la zone de
soudage. Utiliser des lunettes avec écrans lateraux dans les
zones où l’on pique le laitier.

6. Eloigner les matériaux inflammables ou les recouvrir afin de
prévenir tout risque d’incendie dû aux étincelles.

7. Quand on ne soude pas, poser la pince à une endroit isolé de
la masse. Un court-c ircuit a cc idental peut provoquer un
échauffement et un risque d’incendie.

8. S’assurer que la masse est connectée le plus prés possible
de la zone de travail qu’il est pratique de le faire. Si on place
la masse sur la charpente de la construction ou d’autres
endroits éloignés de la zone de travail, on augmente le risque
de voir passer le courant de soudage par les chaines de lev­age, câbles de grue, ou autres circuits. Cela peut provoquer
des risques d’incendie ou d’echauffement des chaines et des
câbles jusqu’à ce qu’ils se rompent.

9. Assurer une ventilation suffisante dans la zone de soudage.
Ceci est particuliérement important pour le soudage de tôles
galvanisées plombées, ou cadmiées ou tout autre métal qui
produit des fumeés toxiques.

10. Ne pas souder en présence de vapeurs de chlore provenant
d’opérations de dégraissage, ne ttoyage ou pistolage. La
chaleur ou les rayons de l’arc peuvent réagir avec les vapeurs
du solvant pour produire du phosgéne (gas fortement toxique)
ou autres produits irritants.

11. Pour obtenir de plus amples renseignements sur la sûreté,
voir le code “Code for safety in welding and cutting” CSA
Standard W 117.2-1974.

PRÉCAUTIONS DE SÛRETÉ POUR

3. Un coup d’arc peut être plus sévère qu’un coup de soliel,
donc:

a. Utiliser un bon masque avec un verre filtrant approprié

ainsi qu’un verre blanc afin de se protéger les yeux du ray­onnement de l’arc et des projections quand on soude ou
quand on regarde l’arc.

b. Porter des vêtements convenables afin de protéger la

peau de soudeur et des aides contre le rayonnement de
l‘arc.

c. Pr otége r l’au tre perso nnel travai llant à pr oximité au

soudage à l’aide d’écrans appropriés et non-inflammables.

4. De s gouttes de lai ti er en fusion son t émises de l’arc de
soudage. Se protéger avec des vêtements de protection libres
de l’huile, tels que les gants en cuir, chemise épaisse, pan­talons sans revers, et chaussures montantes.

LES MACHINES À SOUDER À
TRANSFORMATEUR ET À
REDRESSEUR

1. Relier à la terre le chassis du poste conformement au code de
l’électricité et aux recommendations du fabricant. Le dispositif
de montage ou la piece à souder doit être branché à une
bonne mise à la terre.

2. Autant que possible, I’installation et l’entretien du poste seront
effectués par un électricien qualifié.

3. Avant de faires des travaux à l’interieur de poste, la debranch­er à l’interrupteur à la boite de fusibles.

4. Garder tous les couvercles et dispositifs de sûreté à leur
place.

Mar. ‘93

TThhaannkk YYoouu

vv

for selecting a QUALITY product by Lincoln Electric. We want you
to take pride in operating this Lincoln Electric Company product

••• as much pride as we have in bringing this product to you!

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

Lincoln Electric is a responsive manufacturer, but the selection and use of specific products sold by Lincoln Electric is solely within the control
of, and remains the sole responsibility of the customer. Many variables beyond the control of Lincoln Electric affect the results obtained in
applying these types of fabrication methods and service requirements.

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

CUSTOMER ASSISTANCE POLICY

Please Examine Carton and Equipment For Damage Immediately

When this equipment is shipped, title passes to the purchaser upon receipt by the carrier. Consequently, Claims
for material damaged in shipment must be made by the purchaser against the transportation company at the
time the shipment is received.

Please record your equipment identification information below for future reference. This information can be
found on your machine nameplate.

Product _________________________________________________________________________________

Model Number ___________________________________________________________________________

Code Number or Date Code_________________________________________________________________

Serial Number____________________________________________________________________________

Date Purchased___________________________________________________________________________

Where Purchased_________________________________________________________________________

Whenever you request replacement parts or information on this equipment, always supply the information you
have recorded above. The code number is especially important when identifying the correct replacement parts.

On-Line Product Registration

- Register your machine with Lincoln Electric either via fax or over the Internet.

• For faxing: Complete the form on the back of the warranty statement included in the literature packet
accompanying this machine and fax the form per the instructions printed on it.

• For On-Line Registration: Go to our

“Product Registration”. Please complete the form and submit your registration.

Read this Operators Manual completely before attempting to use this equipment. Save this manual and keep it
handy for quick reference. Pay particular attention to the safety instructions we have provided for your protection.
The level of seriousness to be applied to each is explained below:

WEB SITE at www.lincolnelectric.com. Choose “Quick Links” and then

WARNING

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

CAUTION

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

vi

TABLE OF CONTENTS

Page

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

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

Safety Precautions ...............................................................................................................A-2

Location................................................................................................................................A-2

Weld Cable Sizes .................................................................................................................A-2

Coaxial Weld Cable..............................................................................................................A-3

Wire Drive Cable .................................................................................................................A-4

Shielding Gas Connection....................................................................................................A-5

Wire Drive Configuration ......................................................................................................A-6

Changing The Gun Receiver Bushing..................................................................................A-6

Procedure to Install Drive Rolls and Wire Guides ................................................................A-7

Conduit Installation...............................................................................................................A-8

System Set-Up .....................................................................................................................A-9

________________________________________________________________________________

Operation.........................................................................................................................Section B

Safety Precautions ...............................................................................................................B-1

Graphic Symbols that appear on this Machine or in this Manual .........................................B-1

Definition of Welding Terms .................................................................................................B-2

Product Description ..............................................................................................................B-2

Recommended Processes, Equipment Limitations, Recommended Power Sources ..........B-2

________________________________________________________________________________

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

Optinal Kits and Accessories ...............................................................................................C-1

Drive Roll Kits used..............................................................................................................C-1

Accessories Used.........................................................................................................C-2, C-3

________________________________________________________________________________

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

Safety Precautions ...............................................................................................................D-1

Routine Maintenance ...........................................................................................................D-1

Periodic Maintenance...........................................................................................................D-1

Calibration Specification.......................................................................................................D-1

________________________________________________________________________________

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

How to Use Troubleshooting Guide .....................................................................................E-1

Troubleshooting Guide .................................................................................................E-2, E-3

________________________________________________________________________________

vi

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

________________________________________________________________________________

Parts Pages ................................................................................................................P-569 Series

_______________________________________________________________________

________

A-1

INSTALLATION

A-1

TECHNICAL SPECIFICATIONS –

INPUT VOLTAGE, CURRENT

INPUT VOLTAGE ± 10%

0-40 VDC

RATED OUTPUT @ 104°F (40°C)

DUTY CYCLE

100% rating

GEARING - WIRE FEED SPEED RANGE-WIRE SIZE

GMAW

GEARING

WFS RANGE

K2685-2

50 – 800 ipm

(1.3 – 20.3m/min)

PHYSICAL DIMENSIONS

HEIGHT WIDTH LENGTH WEIGHT

8.4 Inches 7.5 Inches 9.1 Inches 13.2 lbs
(213 mm) ( 191 mm) (231 mm) (6.0 kg)

AutoDrive 4R90 (K2685-2)

INPUT AMPERES

INPUT AMPERES

500

WIRE SIZES

.023 – .045"

(0.6 – 1.2mm)

WFS RANGE

50 – 800 ipm

(1.3 – 20.3m/min)

4A

FCAW

WIRE SIZES

.035 - .045”

(0.9 – 1.2mm)

TEMPERATURE RANGE

OPERATION: -40°F to 104°F (-40°C to 40°C)
STORAGE: -40°F to 185°F (-40°C to 85°C)

AutoDrive 4R90

A-2

INSTALLATION

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK CAN KILL.

• Turn the input power OFF at the
weldin g 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 wor k and grou nd 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.

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

A-2

WELD CABLE SIZE

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

TABLE A.1

RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 167°F or 75°C)**

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

AMPERES

200
200
225
225
250
250
250
250
300
325
350
400
400
500

** 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, or cables rated higher than 167°F(75°C).

PERCENT

DUTY

CYCLE

60

100

20

40 & 30

30
40
60

100

60

100

60
60

100

60

0 to 50Ft.
(0 to15m)

2
2

4 or 5

3
3
2
1
1

1
2/0
1/0
2/0
3/0
2/0

50 to 100Ft.

(15 to 30m)

2
2
3
3
3
2
1
1

1
2/0
1/0
2/0
3/0
2/0

100 to 150 Ft.

(30 to 46m)

2
2
2
2
2
1
1
1

1
2/0
2/0
2/0
3/0
3/0

150 to 200 Ft.

(46 to 61m)

1
1
1
1
1
1
1

1
1/0
2/0
2/0
3/0
3/0
3/0

200 to 250 Ft.

(61 to 76m)

1/0
1/0
1/0
1/0
1/0
1/0
1/0
1/0
2/0
3/0
3/0
4/0
4/0
4/0

AutoDrive 4R90

A-3

ElectrodeElectrode

WWorkork

ElectrodeElectrode

WorkWork

ElectrodeElectrode

WorkWork

Power SourcePower Source

Coaxial Weld CableCoaxial Weld Cable

Wire FeederWire Feeder

INSTALLATION

COAXIAL WELD CABLE

Coaxial welding cables are specially designed welding
cables for STT™ and pulse welding. Coaxial weld cables
feature low inductance, allowing fast changes in the weld
current. Regular cables have a higher inductance which
may distort the STT™ waveshape. Inductance becomes
more severe as the weld cables become longer.

Coaxial weld cables are recommended for STT™ weld­ing, especially when 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
leads wrapped around one large lead. The large inner
lead connects to the electrode stud on the power source
and the electrode connection on the wire feeder. The
small leads combine together to form the work lead, one
end attached to the power source and the other end to
the work 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 electrode connection, and the other end to the
wire feeder electrode connection.

3. Connect the outer lead bundle to the power source
work connection, and the other end to the work piece.
Minimize the length of any work lead extension for
best results.

4. Insulate all connections.

A-3

TABLE A.2

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

COAXIAL CABLE LENGTH

Duty

Amperes

250
300
350

** 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, or cables rated
higher than 167°F(75°C).

Cycle
100%

60%
60%

0 to 25 Ft.

1
1

1/0

25 to 50 Ft.

1
1

1/0

50 to 75 Ft.

1
1

--

75 to 100 Ft.

1

1/0

--

AutoDrive 4R90

A-4

A

B

K

H

N

L

C

D

M

G

F

E

J

I

POWER SOURCE

WIRE FEEDER

A

B

K

H

N

L

C

D

M

G

F

E

J

I

INSTALLATION

WIRE DRIVE CABLE, K1785-XX

Wire drive cables are used to connect power sources
and control boxes to remote wire drives.

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

A-4

POWER SOURCE

Pin

Motor Power

A

Motor Power

B

Gas Solenoid

C

Gas Solenoid

D

Reserved

E

Reserved

F

“2A” Differential Tachometer

G

“2B” Differential Tachometer

H

Reserved

I

Reserved

J

“1A” Differential Tachometer

K

“1B” Differential Tachometer

L

Reserved

M

“67” Electrode Sense Lead

N

Function

WIRE FEEDER

Pin

Motor Power

A

Motor Power

B

Gas Solenoid

C

Gas Solenoid

D

“2A” Differential Tachometer

E

Reserved

F

+15VDC Tech Supply

G

Tachometer Common

H

Reserved

I

Reserved

J

“1A” Differential Tachometer

K

“1B” Differential Tachometer

L

“2B” Differential Tachometer

M

“67” Electrode Sense Lead

N

Function

AutoDrive 4R90

A-5

INSTALLATION

A-5

SHIELDING GAS CONNECTION

WARNING

CYLINDER may explode if

damaged.

• Keep cylinder upright and
chained 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 SHIELDIN G 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” Publis hed by the
American Welding Society.

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

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

5. Attach one end of the inlet hose to the outlet fitting of
the flow regulator. Attach the other end to the welding
system shielding gas inlet. Tighten the union nuts with
a wrench.

6. Before opening the cylinder valve, turn the regulator
adjusting knob counterclockwise until the adjusting
spring pressure is released.

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

8. The flow regulator is adjustable. Adjust it to the flow
rate recommended for the procedure and process
being used before making a weld.

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 regulator for damaged threads, dirt, dust, oil or
grease. Remove dust and dirt with a clean cloth. DO

NOT ATTACH THE REGULATOR IF OIL, GREASE
OR DAMAGE IS PRESENT! Inform your gas supplier

of this condition. Oil or grease in the presence of high
pressure oxygen is explosive.

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

4. Attach the flow regulator to the cylinder valve and
tighten the union nut(s) securely with a wrench. Note:
if connecting to 100% CO2cylinder, insert regulator
adapter between regulator and cylinder valve. If
adapter is equipped with a plastic washer, be sure it is
seated for connection to the CO2cylinder.

AutoDrive 4R90

A-6

GUN RECEIVER BUSHING

THUMB SCREW

SOCKET HEAD
CAP SCREW

CONNECTOR BLOCK

TIGHTENLOOSEN

INSTALLATION

A-6

WIRE DRIVE CONFIGURATION

(See Figure A.2)

CHANGING THE GUN RECEIVER
BUSHING

WARNING

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.

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

• Only qualified personnel should perform mainte­nance work.

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

Tools required:

• 1/4" hex key wrench.

5. Loosen the socket head cap screw that holds the
connector bar against the gun bushing.

Import ant: Do not attempt to co mpletely
remove the socket head cap screw.

6. Remove the outer wire guide, and push the gun
bushing out of the wire drive. Because of the pre­cision fit, light tapping may be required to remove
the gun bushing.

7. Disconnect the shielding gas hose from the gun
bushing, if required.

8. Connect the shielding gas hose to the new gun
bushing, if required.

9. Rotate the gun bushing until the thumb screw hole
aligns with the thumb screw hole in the feed plate.
Slide the gun receiver bushing into the wire drive
and verify the thumb screw holes are aligned.

10. Tighten the socket head cap screw.

11. Insert the welding gun into the gun bushing and
tighten the thumb screw.

Note: Some gun bushings do not require the use of

the thumb screw.

1. Turn power off at the welding power source.

2. Remove the welding wire from the wire drive.

3. Remove the thumb screw from the wire drive.

4. Remove the welding gun from the wire drive.

FIGURE A.2

AutoDrive 4R90

A-7

INNER WIRE GUIDE

IDLER ARM OPENED

OUTER WIRE GUIDE

INSTALLATION

A-7

PROCEDURE TO INSTALL DRIVE ROLLS
AND WIRE GUIDES

WARNING

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.

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

• Only qualified personnel should perform mainte­nance work.

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

To remove drive rolls and wire guides:

1. Turn power off at the welding power source.

2. Remove the outer wire guide.

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 posi-

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

AutoDrive 4R90

tion.

7. Assemble the outer wire guide.

8. Adjust the pressure arms to the recommended
setting.

A-8

CONDUIT

CONDUIT
BUSHING

THUMB
SCREW

SET
SCREW

INSTALLATION

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 with the set screw.

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

A-8

AutoDrive 4R90

A-9

ArcLink XT

Connection

ArcLink

(5 Pin)

Work

Sense

Wire Feeder

(14 Pin)

Robotic

Torch

Power Wave i400

K2669-1

Work Piece

FANUC R-J30iA Controller

with Integrated Op Box

Optional Work

Sense Lead (21)

K1785-XX Wire Feeder

K884-5,-6

Control Cable

* Work

Cable (-)

Internal ArcLink XT

Communication

* Electrode

Cable (+)

SYSTEM SET-UP (SINGLE NEW ARMS)

Wire Feeder

(14 Pin)

Gas

Air

Auto Drive 4R90

* Refer to "Output Cable Guidelines" for recommended cable size

Electrode

Connection

INSTALLATION

SYSTEM SET-UP

NEW ARMS

A-9

AutoDrive 4R90

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

READ A N D U N DERSTAND ENTIRE SE CTION
BEFORE OPERATING MACHINE.

WARNING

• ELECTRIC SHOCK CAN KILL.
Unless using COLD FEED fea­ture, when feeding with gun trig­ger, the electro de and drive
mechanism are always electri­cally energized and could
remain energized several sec­onds after the welding ceases..

• Do not touch electrically live part or electrode
with skin or 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
dangerous.

• Keep your head out of fumes.

• Use ventilation or exhaust to
remove fumes from breathing
zone.

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

• WELDING SPARKS can cause
fire or explosion.

• Keep flammable material away.

GRAPHIC SYMBOLS THAT APPEAR ON
THIS MACHINE OR IN THIS MANUAL

WIRE FEEDER

POSITIVE OUTPUT

NEGATIVE OUTPUT

INPUT POWER

DIRECT CURRENT

U

U

U

0

1

2

OPEN CIRCUIT
VOLTAGE

INPUT VOLTAGE

OUTPUT VOLTAGE

---------------------------------------------------------------------­ARC RAYS can burn.

• Wear eye, ear and body protec-

tion.

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

SEE ADDITIONAL WARNING INFORMATION
UNDER ARC WELDING SAFETY PRECAUTIONS
AND IN THE FRONT OF THIS OPERATING MAN­UAL.

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

I

1

I

2

INPUT CURRENT

OUTPUT CURRENT

PROTECTIVE
GROUND

WARNING OR
CAUTION

AutoDrive 4R90

B-2

OPERATION

B-2

DEFINITION OF WELDING TERMS

GMAW

• Gas Metal Arc welding

FCAW

• Flux Core Arc Welding

STT™

• Surface Tension Transfer

PRODUCT DESCRIPTION

General Physical Description

The AutoDrive 4R90 wire feeders are powerful yet
compact wire drives for robotic and hard automation
applications.

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

EQUIPMENT LIMITATIONS

K2685-2 AutoDrive 4R90:

ß • Maximum GMAW gun length = 10’ (3.1m)
ß • Maximum FCAW gun length = 10’ (3.1m)
ß • Maximum wire drive control cable length = 100ft

(31m)

ß • Robot and power source software may need to be

updated.

ß • Drive rolls are not included with the feeder.
ß • Mounts only to FANUC ArcMate100iC arms.

RECOMMENDED POWER SOURCES

ß • Power Wave 355M (requires wire drive board)
ß • Power Wave F355i
ß • Power Wave 455 (all models)
ß • Power Wave 455/STT M
ß • Power Wave 655/ R

The AutoDrive 4R90 is optimized for the FANUC
AM100iC arm. The small, light weight package maxi­mizes arm speed and wo r k i n g envelope. Quick
release mounting makes for fast servicing of the feed­er and torch.

General Functional Description

A high resolution tachometer lets the AutoDrive 4R90
accurately feed wire at slow speeds and have good
dynamic response.

RECOMMENDED PROCESSES

• GMAW

• FCAW

• STT™

PROCESS LIMITATIONS

K2685-2 AutoDrive 4R90:

ß • Maximum wire size = .045 (1.2mm)

AutoDrive 4R90

C-1

ACCESSORIES

OPTIONAL KITS AND ACCESSORIES

DRIVE ROLL KITS 4 ROLL DRIVE

C-1

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)

Includes: 4 V groove
drive rolls and inner

wire guide.

Includes: 4 Knurled
drive rolls and inner
wire guide.

Includes: 4 polished
U groove drive rolls,
outer wire guide and
inner wire guide.

AutoDrive 4R90

C-2

ACCESSORIES

C-2

K1500-1

K1500-2

K1500-3

K1500-4

Gun Receiver Bushing (for guns

with K466-1 Lincoln gun connec-

tors; Innershield and Subarc guns)

Gun Receiver Bushing (for guns

with K466-2, K466-10 Lincoln gun
connectors; Magnum 200/300/400
guns and compatible with Tweco®

#2-#4)

Gun Receiver Bushing (for guns

with K613-7 Lincoln gun connec-

tors; Magnum 550 guns and com-

patible with Tweco® #5)

Gun Receiver Bushing (for gun

with K466-3 Lincoln gun connec-

tors; compatible with Miller® guns.)

Includes: Gun receiver bush-

ing, set screw and hex key

wrench.

Includes: Gun receiver bush-

ing with hose nipple, set screw

and hex key wrench.

Includes: Gun receiver bush-

ing with hose nipple, set screw

and hex key wrench.

Includes: Gun receiver bush-

ing with hose nipple, set screw

and hex key wrench.

K1500-5

K489-7

K515-xx
K565-xx

K1546-1

Gun Receiver Bushing (compatible

with Oxo® guns.)

Gun Receiver Bushing (for Lincoln

Fast-Mate guns.)

Wire Conduit
Wire Conduit

Incoming Bushing, for Lincoln

Conduit .025- 1/16" (0.6 - 1.6mm)

wire. Compatible with Electron

Beam Conduit.

Includes: Gun receiver bushing
with hose nipple, 4 guide tubes,

set screw and hex key wrench.

Includes: Gun receiver bushing

with trigger connector.

Requires K1546-1
Requires K1546-1

Includes: Incoming bushing and

hex key wrench.

AutoDrive 4R90

C-3

ACCESSORIES

C-3

K2175-1

K2175-2

K895-2

K836-1

K884-5

K884-6

K1796-xx

K1785-xx

K1733-1

K590-6

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

inch diameter

Accu-Trak Drum Payoff Kit – 23

inch diameter

Coaxial Cables

Wire Drive Cables

Wire Straightener

Water Connection Kit

Includes: 1 cable of length “xx”

feet. 14 pin connectors on

both ends. Cable length can-

not be extended by connecting

K1785 cables together.

AutoDrive 4R90

D-1

MAINTENANCE

D-1

SAFETY PRECAUTIONS

WARNING

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.

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

• Only qualified personnel should perform main­tenance work.

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

ROUTINE MAINTENANCE

To remove the AutoDrive 4R90 for servicing:

(See Figure D.1)

1. Turn off power to the welding power supply and the
entire weld cell.

6. When reassembling the feeder in the mounting
bracket, make sure all of the studs fully are fully
engaged in the slots. (See Figure D.2)

FIGURE D.2

PERIODIC MAINTENANCE

2. Loosen the thumb screw that secures the torch to
the feed plate.

3. Use a 3/4” (19mm) wrench to remove the electrode
cable from the feed plate.

4. Remove the screw from the bottom rear of the
feeder.

5. Slide the feeder back in the bracket and remove.

FIGURE D.1

CALIBRATION SPECIFICATION

AutoDrive 4R90

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

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

__________________________________________________________________________

E-1

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

Step 1. LOCATE PROBLEM (SYMPTOM).

Look under the column labeled “PROBLEM (SYMP­TOMS)”. This column describes possible symptoms
that the machine may exhibit. Find the listing that
best describes the symptom that the machine is
exhibiting.

Step 2. POSSIBLE CAUSE.

The second column labeled “POSSIBLE CAUSE” lists
the obvious external possibilities that may contribute
to the machine symptom.

WARNING

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.

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 Field Service Facility.

If you do not understand or are unable to perform the
Recommended Course of Action safely, contact your
local Lincoln Authorized Field Service Facility.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

AutoDrive 4R90

E-2

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

RECOMMENDED

COURSE OF ACTION

E-2

The wire feeder does not feed wire
and the drive rolls do not spin.

The wire feeds erratically.

1. Verify the power source is turned
on.

2. Verify the circuit breaker for the
wire feeder on the power source
has not tripped.

3. Verify power is being supplied to
the wire feeder.

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

2. Check for sharp bends in the gun
liner or conduit.

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

4. Check the gun liner and conduit.
The weld i n g ele c t r ode sh ould
slide easily through both.

No shielding gas
Variable or "hunting" arc.

5. Verify th e proper gun lin e r is
installed.

6. Verify the pressure arms are set
properly. Too much pressure may
crush the wire.

7. Inspect the motor for worn brush­es.

1. Verify the gas supply is turned on
and not empty.

2. Check th e gas hos e for cut s .
Make sure it is not crushed.

3. Verify the shielding gas hose is
connected to the gun bushing or
welding gun.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

AutoDrive 4R90

E-3

PROBLEMS

(SYMPTOMS)

Variable or "hunting" arc.

TROUBLESHOOTING

Observe all Safety Guidelines detailed throughout this manual

POSSIBLE

CAUSE

Output Problems

1. Check for proper size contact.
Make sure the contact tip is not
worn, free of spatter and not melt­ed.

2. Clean and tighten all electrode
and work connections.

3. Verify the proper polarity is being
used for the weld procedure.

4. Make sure the proper electrode
stick-out is being maintained.

5. Check the gas flow rate and mix­ture.

6. Verify the gun bushing is tightly
mounted to the wire drive.

RECOMMENDED

COURSE OF ACTION

E-3

The motor overload errors occur.

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

8. Verify the electrode lead is con­nected to the proper connection
block on the feed head.

9. Inspect the motor for worn brush­es.

1. Check for sharp bends in the gun
liner and conduit.

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

3. Check the gun liner and conduit.
Th e wel d i ng el ectrode should
slide easily through both.

4. Verify th e proper gu n liner is
installed.

5. Reduce the pressure arm setting.

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your

Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

AutoDrive 4R90

F-1

B

M 21562

552A

TACH INTERFACE PC BD

WIRING DIAGRAM AUTODRIVE 4R90/4R220 FEEDER

FEEDPLATE

P1

8

MOTOR /

GEARBOX

W

TACH

531

B

B

W

BR

537

534

551A

550A

7

6

5

4

3

2

1

L2

L1

A

J2

B

C

D

E

F

G

H

I

J

K

L

M

N

P3

8

7

6

5

4

3

2

1

551

550A

552A

553A

500A

515A

842A

843A

551A

GAS

SOLENOID

553A

ELECTRICAL SYMBOLS PER E1537

LEAD COLOR CODING

B – BLACK

W – WHITE

O – ORANGE

Y – YELLOW

BR – BROWN

R – RED

NOTES:

N.A. CAVITY NUMBERING SEQUENCE AS V IEWED

FROM COMPONENT SIDE OF PC BOAR D.

N.B. CAVITY NUMBERING SEQUENCE AS V IEWED

FROM LEAD SIDE OF CONNECTOR.

515A

500A

842A

843A

5

8

N.A.

1

4

(J801)

537

4

1

N.A.

8

5

(J800)

1 2 3 4 5 6 7 8

1

2

345

6

7

8

534

531

535

535

ORANGE

550

GREEN

RED

BLACK

67A

BLACK

BLACK

RED

GREEN

BLACK

553

552

BLACK

WHITE

Y

O

R

YELLOW

BROWN

RED

BLACK

WHITE

845A

846A

4

3

2

1

P4

845A

846A

551

550

552

553

67B67

GND

Enhanced Diagram

DIAGRAMS

F-1

AutoDrive 4R90

NOTE: This diagram is for reference only. It may not be accurate for all machines covered by this manual. The specific diagram for a particular code is pasted inside

the machine on one of the enclosure panels. If the diagram is illegible, write to the Service Department for a replacement. Give the equipment code number.

F-2

6.02”

4.72”

3.02”

7.50”

3.50”

8.35"

8.35”

9.02”

8.02”

0.27”

0.62”

0.62”

1.97”

1.97”

1.78”

1.46”

1.00”

LINCOLN

ELECTRIC

DIMENSION PRINT

F-2

AutoDrive 4R90

NOTES

AutoDrive 4R90

NOTES

AutoDrive 4R90

NOTES

AutoDrive 4R90

WARNING

Spanish

AVISO DE

PRECAUCION

● Do not touch electrically live parts or

electrode with skin or wet clothing.

● Insulate yourself from work and

ground.

● No toque las partes o los electrodos

bajo carga con la piel o ropa moja­da.

● Aislese del trabajo y de la tierra.

● Keep flammable materials away.

● Mantenga el material combustible

fuera del área de trabajo.

● Wear eye, ear and body protection.

● Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

● Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact
avec des pièces sous tension.

● Isolez-vous du travail et de la terre.

● Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem
Körper oder feuchter Kleidung!

● Isolieren Sie sich von den

Elektroden und dem Erdboden!

● Não toque partes elétricas e elec-

trodos com a pele ou roupa molha­da.

● Isole-se da peça e terra.

● Gardez à l’écart de tout matériel

inflammable.

● Entfernen Sie brennbarres Material!

● Mantenha inflamáveis bem guarda-

dos.

● Protégez vos yeux, vos oreilles et

votre corps.

● Tragen Sie Augen-, Ohren- und Kör-

perschutz!

● Use proteção para a vista, ouvido e

corpo.

READ AND UNDERSTAND THE MANUFACTURER’S INSTRUCTION FOR THIS EQUIPMENT AND THE CONSUMABLES TO BE
USED AND FOLLOW YOUR EMPLOYER’S SAFETY PRACTICES.

SE RECOMIENDA LEER Y ENTENDER LAS INSTRUCCIONES DEL FABRICANTE PARA EL USO DE ESTE EQUIPO Y LOS
CONSUMIBLES QUE VA A UTILIZAR, SIGA LAS MEDIDAS DE SEGURIDAD DE SU SUPERVISOR.

LISEZ ET COMPRENEZ LES INSTRUCTIONS DU FABRICANT EN CE QUI REGARDE CET EQUIPMENT ET LES PRODUITS A
ETRE EMPLOYES ET SUIVEZ LES PROCEDURES DE SECURITE DE VOTRE EMPLOYEUR.

LESEN SIE UND BEFOLGEN SIE DIE BETRIEBSANLEITUNG DER ANLAGE UND DEN ELEKTRODENEINSATZ DES HER­STELLERS. DIE UNFALLVERHÜTUNGSVORSCHRIFTEN DES ARBEITGEBERS SIND EBENFALLS ZU BEACHTEN.

● Keep your head out of fumes.

● Use ventilation or exhaust to

remove fumes from breathing zone.

● Turn power off before servicing.

● Do not operate with panel open or

guards off.

WARNING

● Los humos fuera de la zona de res-

piración.

● Mantenga la cabeza fuera de los

humos. Utilice ventilación o
aspiración para gases.

● Gardez la tête à l’écart des fumées.

● Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones
de travail.

● Vermeiden Sie das Einatmen von

Schweibrauch!

● Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

● Mantenha seu rosto da fumaça.

● Use ventilação e exhaustão para

remover fumo da zona respiratória.

● Desconectar el cable de ali-

mentación de poder de la máquina
antes de iniciar cualquier servicio.

● Débranchez le courant avant l’entre-

tien.

● Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öff­nen; Maschine anhalten!)

● Não opere com as tampas removidas.

● Desligue a corrente antes de fazer

serviço.

● Não toque as partes elétricas nuas.

● No operar con panel abierto o

guardas quitadas.

● N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de
protection enlevés.

● Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in
Betrieb setzen!

● Mantenha-se afastado das partes

moventes.

● Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

LEIA E COMPREENDA AS INSTRUÇÕES DO FABRICANTE PARA ESTE EQUIPAMENTO E AS PARTES DE USO, E SIGA AS
PRÁTICAS DE SEGURANÇA DO EMPREGADOR.

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

Cleveland, Ohio 44117-1199 U.S.A. TEL: [phone] FAX: [phone] WEB SITE: www.lincolnelectric.com