CO2/ MAG/ MIG/TIG Wire feeding unit

ＡＦ－４０１１、 ＡＦＡ－４０１１
ＡＦＴ－４２１１、ＡＦＵ－４２１１

Instruction Manual
= Safety and Handling Operation =
Instruction Manual No.
Wire feeding unit [AF-4011/AFA-4011/AFT-4211/AFU-4211]…1L10595-E-5

The addresses and telephone numbers for

First, read this instruction
you to contact are listed in the back cover of
manual thoroughly, and
this instruction manual.
operate the unit correctly.
Contents
 To ensure the safety, only the qualified
① Notes on safety..................................S1
personnel or the personnel who has fully
understood the welding robot must perform ② Requirements on safety.....................S2
maintenance, inspection and repair work of
this unit. ③ Transport and Installation ..................S5

 To ensure the safety, only the personnel who

④ Connection ........................................S6
has fully understood this instruction manual
and acquired sufficient knowledge and skill ⑤ Directions .........................................S6
must perform the operation work of this unit.
1. Specifications........................................ 1
 Regarding the safety education, take courses
and classes held by the head/branch offices 2. Installation on Manipulator.................... 5
of Welding Society/Association or related 3. Welding Preparation ........................... 10
societies/associations.
4. Inspection and Maintenance............... 15
Also, utilize the qualifying examination for
welding experts/consultant engineers. 5. Parts List for AF-4011 ......................... 16
 After reading this instruction manual, place it
6. Parts List for AFA-4011 ....................... 20
together with a warranty so that the personnel
concerned can review anytime as needed. 7. Parts List for AFT-4211 ....................... 23
 If you find anything unclear, or about servicing,
8. Parts List for AFU-4211....................... 26
contact our local distributor or sales
representatives in your country. 9. Electrical Wiring Diagram ................... 27
 Note on Safety
1. Note on Safety
● Before operating, thoroughly read this instruction manual, and operate this unit correctly.
● Caution note mentioned in this manual is to use the equipment safely and prevent danger and damage
from occurring.
● This wire feeding unit is designed and manufactured upon due consideration of safety. However, be sure
to follow the instructions and cautions described in this manual when using it. Otherwise, there may occur
an accident resulting in death or a serious injury.
● Mishandling of equipment may cause various levels of accidents and damage. In order to draw attention
to mishandling, three levels of safety alert symbols; “DANGER”, “WARNING” and “CAUTION” are adopted
throughout this manual. See below for the details.

DANGER : Mishandling may cause death or a serious injury to an operator. Also, the
level of urgency to alert is high when a danger occurs. Limited situation of
great urgency.

WARNING : Mishandling may cause death or a serious injury to an operator.

CAUTION : Mishandling may cause a medium or slight injury to an operator or

property damage.

Even if the matters mentioned in CAUTION may occasionally cause a serious injury depending on
a condition. Be sure to comply with the notes and instructions.

”Serious injury”, “Medium or slight injury” and “Property damage” mentioned above give the meanings as
follows.

: Injury that leaves sequelae caused by a loss of eyesight, injury, burn (high/low
Serious injury temperature), electric shock, bone fracture, poisoning etc,.
Or, injury that requires hospitalization or long-term treatment as an outpatient.

Medium or : Damage including injury, burn (high/low temperature), electric shock and others
that does not require either hospitalization or long-term treatment.
slight injury

Property damage : Damage to property and direct/indirect damage to equipment.

―S1－
 Caution Note on Safety
2. Requirements on Safety
2.1 Before starting welding operation, thoroughly read and understand the related safety rules and
caution note below in addition to the instruction manual for welding power supply.
Be sure to follow the instructions.

WARNING ● To avoid a fatal physical accident, follow the notes below.

1) This wire feeding unit is designed and manufactured upon due consideration of safety, however be
sure to follow the notes described in this instruction manual. If operating this unit without following
the instructions, a fatal accident such as death or a serious injury may occur.
2) For selecting the installation area, handling/storing/piping high pressure gas, storing the welded
manufactures and disposal of waste, comply with rules and regulations in your company.
3) Keep away from the welding power supply and the welding operation area.
4) A person with a pacemaker must not approach the welding power supply turned ON and the welding
operation area without getting the permission by his/her doctor. The welding power supply turned
ON generates the magnetic field, which adversely affects on a pacemaker.
5) To ensure safety, only the qualified personnel or those who fully understand this wire feeding unit
must perform the maintenance and repair work of the unit. (※1)
6) To ensure safety, only the personnel who fully understand this instruction manual and have sufficient
knowledge and skill must operate this wire feeding unit. (※1)
7) Do not use this wire feeding unit for other than welding.

2.2 To avoid the electric shock hazard, follow the note below.

WARNING ● Do not touch the live electric parts.

Touching live electric parts may cause a fatal shock or a severe

burn.

1) Only the qualified personnel must perform the grounding work for the welding power supply,
workpiece and jigs electrically connected with workpiece according to the regulations (Technical
Standard of Electrical Facilities).
2) Do not touch live electric parts.
3) Be sure to always wear a dry pair of insulating gloves and fatigue uniform. Never wear torn or wet
gloves and fatigue uniform.
4) Before performing installation, inspection, maintenance and other works, be sure to turn off all the
input-side power. Even if the input-side power is OFF, a capacitor and other components may be
still electrically charged. To start operating, therefore, wait for a few minutes after the power was
turned OFF until no charged voltage is detected.
5) Do not use connection cables with insufficient capacity, with damage or with naked conductors.
6) Be sure to secure the cable connection and insulate them to prevent personnel from easily touching
those parts.
7) Do not use the welding power supply without its case or cover.
8) Before starting operation, secure a firm footing. Also, do not perform operation at unstable footing
or at higher place (2m or higher).
9) Carry out maintenance and inspection periodically, and repair the damaged parts before using the
equipment.
10) Be sure to turn off the input-side power of equipment if not in use.

―S2－
 Caution Notes on Safety (continued)
2.3 To avoid a fire and explosion caused by the heated workpiece right after welding, spatter, slag or
arc spark, and to avoid injury, follow the notes below.
● Do not perform welding near inflammables or combustibles.
● Watch out for a fire and know where a fire extinguisher is placed.
WARNING
● Never perform welding on flammable materials such as wood or cloth.
● Do not perform welding on workpiece that makes it an airproof container.

● Heated workpiece right after welding, spatter, slag and arc spark cause a fire.
● Improper cable connection or improper contact in the workpiece-side current
circuit such as steel frames may cause an exothermic fire.
● An explosion may occur if generating arc on the container for flammables or
combustibles such as gasoline.
● If welding on an airproof tank or pipe, they may burst.
● Heated workpiece right after welding, spatter, slag and arc spark cause a
serious burn.
1) Do not perform welding near inflammables or combustibles.
2) To avoid getting a burn by the heated workpiece right after welding, spatter, slag and arc spark, an
operator must wear a pair of flameproof leather gloves, a long-sleeve fatigue uniform, a leg cover, a
flameproof leather apron and other protective clothes.
3) Always watch out for a fire and other danger.
4) Place a fire extinguisher near the welding work area. Also, each operator must fully know how to use.
5) Do not bring the heated workpiece or the jigs into contact with flammable materials such as wood or
cloth. Otherwise, not only a fire may occur but you may also get a burn.
6) Do not bring the heated workpiece right after welding into contact with combustibles.
7) Keep inflammables and combustibles away from the welding work area to avoid spatters.
8) Never use inflammable gas near the welding work area.
9) Firmly secure the cable connection, and insulate them.
10) Connect the workpiece-side cable as nearer to the welding spot as possible.
11) Do not perform welding on gas-filled pipes, airproof tanks and pipes etc. because they may burst.
12) Do not perform welding on flammable materials such as wood or cloth.
13) To perform welding on ceiling, floor, wall etc., be sure to carefully check behind and clear away the
combustibles and inflammables.

2.4 If you carelessly touch the rotating part, you may get entangled and injured. Be sure to follow the
notes below.
● Do not bring your hands, fingers, hair, clothes etc. close to the rotating
WARNING part.
● Keep your hands, fingers, hair, clothes etc. away from the rotating part of
wire feeding unit such as a feeding roll. You may get entangled and
injured.
● Be sure to turn off the welding power supply and assist feeder or input the
emergency stop signal of the robot (Teach pendant, Operation box,
External controller etc.) before connecting the torch or replacing the wire
and other consumable parts such as the feeding roll.
1) When using a welding power supply, be sure that its case and cover are fixed on.
2) When required to unfix the cover of welding power supply for maintenance, inspection and repair work,
only the personnel who has taken the specified course and fully understands the welding power supply
must perform the operation. During the operation, keep other people away from the work area by
enclosing it.
3) Keep your hands, fingers, hair, clothes etc. away from the feeding roll on rotating.

―S3－
 Caution Notes on Safety (continued)

Reference
< PRINCIPAL SAFETY STANDARDS >

Arc welding equipment ? Installation and use, Technical Specification

IEC 62081, from International Electrotechnical Commission

Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society.

Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S.
Government Printing Office.

Recommended Practices for Plasma Arc Cutting, American Welding Society Standard AWS C5.2,
from American Welding Society.

Recommended Safe Practices for the Preparation for Welding and Cutting of Containers That Have
Held Hazardous Substances, American Welding Society Standard AWS F4.1, from American
Welding Society.

National Electrical Code, NFPA Standard 70, from National Fire Protection Association.

Safe Handling of Compressed Gases in Cylinders, CGA Pamphlet P-1, from Compressed Gas
Association.

Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards
Association, Standards Sales.

Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1,
from American National Standards Institute.

Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association.

―S4－
 Caution Notes on Safety (continued)
3. Transport and Installation
3.1 Transportation
To avoid an accident and damage to the wire feeding unit in transportation, observe the
followings.

WARNING ● Do not touch live electrical parts.

● Before transporting and transferring the wire feeding unit, be sure to turn off
the input power by switching in the switch box.

● For transporting and hanging of this unit, follow the specified procedures.
WARNING ● To fix the unit and other peripheral equipment, use the prescribed
tightening torque.
● Falling objects harm personnel and equipment.
● Use the prescribed tightening torque when fixing the unit. Otherwise, a
fatal physical injury may be caused because of turnover of the unit, flying
or falling of the tool and some other reasons.
● For transporting the wire feeding unit by craning to high, be sure to unset
the wire from the unit.

3.2 Installation
For installing the wire feeding unit, observe the following notes to protect operator’s health from a
fire, an explosion, fumes and gas caused or produced by welding performance.
● Do not place the unit near inflammables.
WARNING ● Watch out for a fire and know where a fire extinguisher is placed.

● Do not install the welding power supply near inflammables or flammable gas.

● Keep inflammables away from the welding area so that they will not be
exposed to spatter. If not possible, cover them with the fireproof cover.

● Do not breathe in fumes.

WARNING ● Ventilate the area enough and wear a protection face guard and other
protective equipment as needed.

● To avoid gas poisoning or asphyxia, use a respirator or adopt a ventilation

system prescribed by the laws in your country.
● When performing welding in a tight space, be sure to ventilate the area
enough or wear a respirator, and operate in control of the trained observer.

< Installation location >

● Install the wire feeding unit in a place meeting the following conditions.
・Indoor place in which no direct sunlight, wind and weather is exposed, and with little moisture and dust
・The ambient temperature is within the range of -10～40℃.
・No wind is blown to the arc part.
(Wind may cause a welding failure. Avoid a wind with a windshield or other items.)

―S5－
 Caution Notes on Safety (continued)
4. Connection

● To avoid electric shock ,be sure to turn off all the input powers by
WARNING
switching in the switch box before performing the connection work.

CAUTION ● Secure the cable connection firmly.

5. Directions

● Do not alter or remodel our products.

● You may get injured or have your equipment damaged because of fire,
DANGER
failure or malfunction caused by altering or remodeling the product.
● The warranty does not cover any altered or remodeled products.

―S6－
 Thank you very much for purchasing our wire feeding unit AF-4011, AFA-4011, AFT-4211, and
AFU-4211 for CO2/ MAG/ MIG/ TIG welding. Read this instruction manual thoroughly before using
this product, and use the product properly.

[Note] 1. The contents in this manual are subject to change without notice.
2. We have carefully compiled this instruction manual so that we will not make any errors in the
content. Even if there errors are found, we are not responsible for any damage caused by the error.
3. No part of this instruction manual may be reproduced, stored in or introduced into a retrieval system,
or transmitted in any form or by any means.

● Do not alter or remodel our products.

● You may get injured or have your equipment damaged because of fire,
DANGER failure or malfunction caused by altering or remodeling the product.
● The warranty does not cover any altered or remodeled products.

1. Specifications
1.1 AF-4011
AF-4011 is the robot dedicated wire feeding unit used for CO2 / MAG welding.
The specifications are shown in Table 1.1 below.
See Fig. 1.1 for the external diagram.
Table 1.1 Specifications of AF-4011
Model AF-4011
Welding method CO2 / MAG welding
Rolling system 4-roll system
Applicable wire diameter Mild steel/ Stainless (φ0.8), φ0.9, φ1.0, φ1.2, (φ1.4), (φ1.6)
Wire feed rate 1.5 to 22m/min
Mass (Weight) Approx. 4.0Kg
Applicable power supply D series welding power supply
(DM, DP, DL, DW series with steel used)
Note) The standard is that this wire feeding unit builds in the components that support steel
wires (φ0.9, φ1.0, and φ1.2). The applicable wire diameter indicated in ( ) is an option.

1.2 AFA-4011
AFA-4011 is the robot dedicated wire feeding unit used for MIG welding.
The specifications are shown in Table 1.2 below.
See Fig. 1.2 for the external diagram.
Table 1.2 Specifications of AFA-4011
Model AFA-4011
Welding method MIG welding
Rolling system 4-roll system
Applicable wire diameter Aluminum : φ1.0, φ1.2, (φ1.6)
Wire feed rate 1.5 to 22m/min
Mass (Weight) Approx. 4.2Kg
Standard assembly Wire straightener
Applicable power supply D series welding power supply
(DP, DW series with ALUMINUM used)
Note) The standard is that this wire feeding unit builds in the components that support aluminum
wires (both φ1.0 and φ1.2). The applicable wire diameter indicated in ( ) is an option.

－1－
1.3 AFT-4211
AFT-4211 is the robot dedicated wire feeding unit used for mild steel/ stainless TIG filler welding.
The specifications are shown in Table 1.3 below.
See Fig. 1.3 for the external diagram.
Table 1.3 Specifications of AFT-4211
Model AFT-4211
Welding method TIG filler (mild steel/ SUS) welding
Rolling system 4-roll system
Applicable wire diameter Mild steel (φ0.8), φ0.9, φ1.0, φ1.2, (φ1.4), (φ1.6)
Stainless (φ0.8), φ1.2, (φ1.6)
Wire feed rate 0.25 to 5m/min
Mass (Weight) Approx. 4.2Kg
Applicable power supply D series welding power supply (DT, DA series)
Note) The standard is that this wire feeding unit builds in the components that support mild steel
wires (φ0.9, φ1.0, and φ1.2). The applicable wire diameter indicated in ( ) is an option.

1.4 AFU-4211
AFU-4211 is the robot dedicated wire feeding unit used for aluminum TIG filler welding.
The specifications are shown in Table 1.4 below.
See Fig. 1.4 for the external diagram.
Table 1.4 Specifications of AFU-4211
Model AFU-4211
Welding method TIG filler (Aluminum) welding
Rolling system 4-roll system
Applicable wire diameter Aluminum : φ1.0, φ1.2, (φ1.6)
Wire feed rate 0.25 to 5m/min
Mass (Weight) Approx. 4.4Kg
Standard assembly Wire straightener
Applicable power supply D series welding power supply (DT, DA series)
Note) The standard is that this wire feeding unit builds in the components that support aluminum
wires (both φ1.0, and φ1.2). The applicable wire diameter indicated in ( ) is an option.

－2－
 Pressure handle Encoder cover
加圧ハンドル Snap lock エンコーダカバ
パチン錠
Center guide
センタガイド
Pressure roll
加圧ロール
Guide adapter (1)
7/16-20UNF
※Conduit side
ガイドアダプタ（１）
7/16-20UNF
※コンジット側

Feeding roll
送給ロール

Fig. 1.1 External diagram of wire feeding unit :AF-4011(for CO2 / MAG) (Unit：mm)

Pressure handle
加圧ハンドル
Center guide
センタガイド
Feeding roll Encoder cover
送給ロール Snap lock エンコーダカバ
Guide adapter (3) パチン錠
7/16-20UNF
※Wire straightener side
ガイドアダプタ（３）
7/16-20UNF
※ワイヤストレートナ側

Guide adapter (4)

※Conduit side
ガイドアダプタ（４）
※コンジット側
Wire straightener
ワイヤストレートナ
Feeding roll
送給ロール

Fig. 1.2 External diagram of wire feeding unit :AFA-4011(for MAG) (Unit：mm)

－3－
 Pressure handle Encoder cover
加圧ハンドル Snap lock エンコーダカバ
パチン錠
Center guide
センタガイド
Pressure roll
加圧ロール
Guide adapter (1)
7/16-20UNF
※Conduit side
ガイドアダプタ（１）
7/16-20UNF
※コンジット側

Feeding roll
送給ロール
Insulating block
絶縁ブロック

Fig. 1.3 External diagram of wire feeding unit :AFT-4211(for TIG filler iron) (Unit：mm)

Pressure handle
加圧ハンドル
Center guide
センタガイド
Feeding roll Encoder cover
送給ロール Snap lock エンコーダカバ
Guide adapter (3) パチン錠
7/16-20UNF
※Wire straightener side
ガイドアダプタ（３）
7/16-20UNF
※ワイヤストレートナ側

Guide adapter (4)

※Conduit side
ガイドアダプタ（４）
※コンジット側
Wire straightener
ワイヤストレートナ
Feeding roll
送給ロール
Insulating block
絶縁ブロック

Fig. 1.4 External diagram of wire feeding unit :AFU-4211(for TIG filler aluminum) (Unit：mm)

－4－
2. Mounting to Manipulator (Almega A II-V6 / A II-B4 series)
2.1 Notes of connecting the cable of wire feeder to each manipulator
Work accordingly to the following precautions when connecting the motor cable, encoder cable and
the cable for the solenoid valve, of the wire feeder, to each manipulator.
・The PE bag covered the connector in the manipulator shoulder is used to protect the connector.
・Detach the PE bag for the connector protection once when you connect.
・Do not throw away the PE bag because it uses it again after wiring ends.

2.2 Mounting to Almega A II-V6 series

Follow the procedures below to mount this wire feeding unit on the shoulder part of manipulator.
The following fixing brackets (for the AII-V6 series) are separately required for mounting. Be sure to
use them.
・Fixing bracket for AF-4011, AFA-4011 ：L10677A
・Fixing bracket for AFT-4211, AFU-4211 ：L10678A
(1) Referring to Fig. 2.1 and 2.2, mount the fixing bracket to the wire feeding unit.
For mounting, use the hexagon head bolts and washers and nuts provided with the feeding unit.
After mounting them, be sure to mount the insulating cover to each fixing bolt.
(2) Referring to Fig. 2.1 and 2.2, mount the fixing bracket onto the shoulder part of manipulator .
Fix it in a position where the coaxial power cable bends as gently as possible. The fixing bracket is
adjustable back and forth.
(3) After mounting it onto the shoulder part, remove the shoulder cover.
(4) Draw out wiring in the shoulder. And, detach the PE bag that protects the connector once.
【Note】Do not throw away the PE bag because it uses it again after wiring ends.
(5) Connect the motor cable, the encoder cable and the voltage detection cable of wire feeding unit with
the in-manipulator cables. For cable connection, see Section 9 “Electrical connection diagram”.
(6) After connecting cables, put the connector in the PE bag as before. And, bind the opening of the
PE bag in the binder.
(7) Return the shoulder cover to its original position.
【Note】A shock sensor connector is included in the manipulator.

－5－
 rgin)
ent ma
(Adjustm ） +37.5
調整代
-37.5 （
Wire feeding unit
ワイヤ送給装置

Fixing bracket
固定ブラケット

Manipulator
(NV type)
マニピュレータ
（NVタイプ）

Fig. 2.1 Mounting to AⅡ-V6 series manipulator (Procedure (1))

Fig. 2.2 Mounting of wire feeding unit and fixing bracket (Procedure (2))
－6－
 2.3 Mounting to Almega A II-B4 series
Follow the procedures below to mount this wire feeding unit on the shoulder part of manipulator.
The fixing bracket (L10680A: for A II-B4) is separately required for mounting.
For the configuration of parts for mounting the wire feeding unit and the fixing bracket, refer to Fig. 2.4.
(1) Referring to Fig. 2.3, dismount the mounting bracket and fixing plate from the fixing bracket once.
(2) Referring to Fig. 2.4, mount the fixing plate and insulating plate (2) to the wire feeding unit.
After mounting them, be sure to mount the insulating cover to each fixing bolt.
For mounting, use the hexagon head bolts provided with the feeding unit. However, mounting to the
AII-B4 series requires no washers and nuts provided (2 pieces each).
(3) Referring to Fig. 2.4, mount the mounting bracket and insulating plate (1) to the manipulator.
Be sure to mount the insulating plate (1) in such a way that it is sandwiched between the
manipulator and the mounting bracket. In addition, mount the insulating bush to each fixing bolt.
After mounting the bushes, be sure to mount the insulating cover to each fixing bolt.
(4) Fix the fixing plate and the mounting bracket with the provided bolts, and then mount the wire
feeding unit to the manipulator. At this time, the mounting position can be adjusted in the forward
and backward directions. For adjustment, unfasten the hexagon head bolts so that the unit can slide.
(5) Connect the coaxial power cable to the wire feeding unit. Subsequently, referring to Fig. 2.5, move
the 5th and 6th axes to the following position (posture), respectively.
5th axis: To the maximum extent to the manipulator’s inward side (software limit)
6th axis: To the maximum extent (software limit) (either to the “” or “” side)
(6) Referring to Fig. 2.5, adjust and fix the position of the slide plate to the extent that the coaxial power
cable does not hit against the cover in the posture described in Step (5) above.
(7) Referring to Fig. 2.6, conduct curing for the connection of gas hoses from the solenoid valve and
spiral tubes.
(8) Dismount the side cover from the robot shoulder.
(9) Draw out wiring in the shoulder. And, detach the PE bag that protects the connector once.
【Note】Do not throw away the PE bag because it uses it again after wiring ends.
(10) Referring to Fig. 2.7, pull in motor cables, encoder cables, and voltage detection cables through a
hole in the blind cover, and then connect them to the robot cables. For detail of cable connections,
refer to the Electrical Wiring Diagram shown in Section 9.
(11) After connecting cables, put the connector in the PE bag as before. And, bind the opening of the PE
bag in the binder.
(12) Return the side cover to its original position.
【Note】The shock sensor connector is incorporated in the manipulator.
The solenoid valve is incorporated in the fixing bracket.
1: Currently, the AII-B4 series are not available for TIG welding.
Fixing plate
Insulating plate (2)
固定プレート
絶縁プレート（２）

Mounting bracket
取付ブラケット

Fig. 2.3 Preparation for mounting of fixing bracket (Procedure (1))

－7－
 Fixing bolt, Insulating cover
Fixing plate 取付用ネジ・絶縁カバ
Insulating plate (2) （送給装置付属品）
固定プレート
絶縁プレート（２）

To
マニ m a n
ピュ ipul
レー ator
Insulating plate (1) タへ
絶縁プレート（１）
Mounting bracket
取付ブラケット
Wire feeding unit
Insulating bush
ワイヤ送給装置
絶縁ブッシュ
Insulating bush
絶縁ブッシュ
Insulating cover
絶縁カバ

Insulating cover Insulating plate (1)

絶縁プレート（１）
絶縁カバ
絶縁詳細図

Fig. 2.4 Mounting of manipulator fixing bracket and wire feeding unit (Procedure (2) and (3))

Operate five axes inward to a maximum extent.

５軸を内側に最大限動作させます。
Wire feeding unit
ワイヤ送給装置 Coaxial power cable
argin) １線式パワーケーブル
(Adjustment m
+10
-10 （調整代）

Operate six axes to a maximum extent.

(either to the "+" or "-" side).
Torch
６軸を最大限動作させます。
トーチ
（＋側－側どちらでも可）

Fig. 2.5 Mounting of manipulator fixing bracket and wire feeding unit (Procedure (5))
－8－
 Bundle gas pipe (IN) and wiring together in a group
using a spiral tube provided with (2).
Coil two gas pipes (IN and OUT) and one wiring twice at midpoint.
Manipulator 固定ブラケット付属のスパイラルチューブにて
(B4 type) ガス配管（IN）・配線をまとめてください。 Blind cover
マニピュレータ ブラインドカバ
※中間でガス配管（IN、OUT）と配線の３本を共に２巻き
（AⅡ-B4タイプ） Side cover
(Adjustment m サイドカバ
argin)
+10 （調整代） Wire feeding unit
-10 ワイヤ送給装置

Wire feeding unit and

fixing bracket mounting part
(Hexagon head bolts : M8X40)
送給装置－固定プレート取付部
（六角ボルトM8x40）

Mounting bracket and fixing

plate mounting part
(Hexagon head bolts : M8X20)
固定プレート－取付ブラケット取付部 Gas pipe (IN)
（六角ボルトM8x20） (From manipulator)
Manipulator and fixing bracket ガス配管 （IN）
mounting part （マニピュレータより）
(Hexagon head bolts : M8x30)
固定プレート－取付ブラケット取付部
（六角ボルトM8x30）

Gas wiring
(To manipulator)
Insulating plate (1) ガス配線
Mounting bracket 絶縁プレート（１） （マニピュレータへ）
取付ブラケット
Hexagon head bolt
Insulating cover
六角ボルト
絶縁カバ
Insulating bush Manipulator
絶縁ブッシュ マニピュレータ

Fig. 2.6 Mounting of manipulator fixing bracket and wire feeding unit (Procedure (7))

Fig. 2.7 Mounting of manipulator fixing bracket and wire feeding unit (Procedure (9))

－9－
3. Welding Preparation

● If you carelessly touch the rotating part, you may get entangled and
WARNING injured. Be sure to follow the note below.
●Keep your hands, fingers, hair, clothes etc. away from a rotating part such as the
feeding roll of wire feeding unit or assist feeder. Otherwise, you may get
entangled and injured.

●Do not use the wire feeding unit and assist feeder with their case or cover
opened.

●When required to unfix the cover of welding power supply for maintenance,
inspection, or repair work, only the personnel who has taken the specified course
and fully understands the welding power supply must perform the operation.
Also, during the operation, keep other people away from the work area by
enclosing it.

●Be sure to turn off the welding power supply and assist feeder or input the
emergency stop signal of the robot (Teach pendant, Operation box, External
controller etc.) before connecting the torch or replacing the wire and other
consumable parts such as the feeding roll.

3.1 Pressure releasing operation

To pass the wire through into this wire feeding unit or to replace the feeding roll, see Fig. 3.1 and
follow the procedures below.

(1) Release the snap lock and pull the clear cover toward.
(2) Pull the pressure handle toward and lift up the pressure holder.
(3) Pass through a wire into the conduit-side adaptor, the center guide and the adaptor on coaxial
power cable side in this order.
(4) To replace the feeding roll, see the following section.
(5) Return the pressure holder and the pressure handle to their original position.

－10－
 Snap lock ① Open the cover

パチン錠 フロントカバを開く

Front cover
フロントカバ

Lift up
Pressure holder
② 持ち上げる
加圧ホルダ Pressure handle
加圧ハンドル

Pull it toward Guide adapter

※Coaxial power cable side
手前に倒す
ガイドアダプタ
Pressure handle ※１線式パワーケーブル側
加圧ハンドル

Guide adapter
※Conduit side
Put through a wire
ガイドアダプタ ワイヤを通す
※コンジット側

Feeding roll ③
送給ロール
Center guide
Replace these feeding roll センタガイド

送給ロールを交換する

④
Fig. 3.1 Pressure releasing operation

－11－
 3.2 Mounting of feeding roll
For shipment, the feeding roll as per the specification under Chapter 1 is incorporated as the
standard equipment. However, to use any wire of different diameter, replace with a feeding roll
corresponding to such diameter.
To replace the feeding roll, see Fig. 3.2 and follow the procedures below.
(1) Release the pressure. (Refer to the section 3.1.)
(2) Remove two pieces of setscrew that fix the feeding roll.
(3) Pull out the feeding roll toward.
(4) Replace the feeding roll so that the same stamp as that of the wire diameter to use can be seen.

Hexagon socket head bolt

穴付きボルト
Gear
中間ギヤ

Feeding roll
送給ロール

Hexagon socket head bolt

穴付きボルト
Fig. 3.2 Mounting of feeding roll

[Note]
If applying an aluminum wire (for AFA-4011, AFU-4211), four feeding rolls and middle gears are required.
Replace with feeding rolls suitable for each type. For the types of feeding rolls, refer to the Parts List.

3.3 Pressure adjustment

Referring to Fig. 3.3 on the following section, turn the pressure handle and set the pressure
according to each wire diameter. The rough standard of set value is as shown in Table 3.1 below.

Table 3.1 Rough standard of pressure

Wire Solid wire Hard aluminum Soft aluminum

diameter Flux-cored wire
φ1.6 3 to 4 2 to 3 2 to 3
φ1.4
φ1.2 2 to 3 1 to 2 1 to 2
φ1.0
φ0.9
φ0.8 1 to 2

[Note] 1. The values in the table above are just rough standards. They may differ depending on the
welding conditions and the wire type.
2. Set the pressure handle to the same scale for the right and left sides.

－12－
 Example : Setting at "2"
(Line up the underpart of handle Pressure handle
with the figure line.) 加圧ハンドル
例：加圧「２」の設定
（数字のラインとハンドルの下部を合わせる）

Fig. 3.3 Pressure adjustment

3.4 Pressure adjustment for straightener

A straightener is the component to correct wire distortion that is standardized in AFA-4011 and
AFU-4211. The model AFA-4001 and AFU-4211 needs not only the pressure adjustment shown in the
previous section but also the pressure adjustment for straightener.
See the following Table 3.2 and Fig. 3.4 to set the appropriate pressure value.

Table 3.2 Rough pressure standard for straightener

Wire Solid wire Hard aluminum Soft aluminum

diameter Flux-cored wire
φ1.6 2 to 3 2 to 3 2 to 3
φ1.4 3 to 4
φ1.2 3 to 4 4 to 5
φ1.0 4 to 5 4 to 5
φ0.9
φ0.8

[Note] The values in the table above are just rough standards. They may differ depending on the welding
conditions and the wire type.

Fig. 3.4 Pressure adjustment for straightener

[Note] As shown in the figure above, there are cases where it is recommended to mount the strainer
the other way around depending on the direction in which wire tends to bend.

－13－
3.5 Wire feeding by inching
To feed a wire, thoroughly read the following caution notes and perform the operation carefully.

WARNING

●While in inching, do not bring the welding torch tip to face, eye, or body.
Doing so may cause wire to get stuck in face, eye, or body when it comes out,
resulting in injury.

CAUTION

●While in inching, do not bring the feeding roll part to hands, fingers, hair,
clothes, etc.. If doing so, you may be entangled and get injured.

* You may get a fatal electric shock or a severe burn

WARNING if touching the live electric parts.

Do not touch the live electric parts such as a wire or a wire feeding part
during welding performance. The shadowed part is
electrified during welding performance. (Inside the clear cover)

－14－
4. Inspection and Maintenance
4.1 Inspection
Carry out inspection on the following points.

Part Inspection point Possible trouble Measures

Pressure scale ●Is the welding Wire distortion or feeding Refer to Chapter 3.3
pressure appropriate failure. “Pressure adjustment”
for the wire diameter? and adjust the welding
pressure.
Guide adaptor ●Is there no dust or Wire feeding failure. Remove dust and wire
Center guide wire chips stuck in the chips.
guide adaptor or the
center guide?
Feeding roll ●Does the stamp on Wire distortion or feeding Use the appropriate
feeding roll match the failure. feeding roll in accordance
actual wire diameter? with the wire diameter.
●Is the groove not Replace the feeding roll
worn out? with new one.
Pressure roll ●Does it smoothly Wire feeding failure or Replace the pressure roll
rotate? strange noise. with new one.
Encoder cable ●Is the cable going to Wire feeding failure or Replace the encoder
be disconnected or its feeding impossibility. cable with new one.
cover broken?
●Is not the connector Remove dust at the
cap off? connector part and put
the connector cap.
Motor cable ●Is the cable going to Wire feeding failure or Replace the motor cable
be disconnected or its feeding impossibility. with new one.
cover broken?
Voltage detection ●Is the cable going to Wire feeding failure or Replace the voltage
cable be disconnected or its feeding impossibility. detection cable with new
cover broken? one.
Motor ●Is the motor replaced Wire feeding impossibility. Replace the motor. Life
periodically due to duration is approx. 4000
the life of the brush? hours (approx. 2yrs).
Wire feeding unit ●Are wire chips not Wire feeding failure or Clean the unit
(lower part) stuck? damage to gears. periodically.

4.2 Replacement of feeding motor

Life duration of the brush part in the feeding motor depends on the load condition, the ambient
temperature, etc., which is normally about 4,000 hours (about 2 years under six operating hours a day).
Replace the feeding motor periodically.

CAUTION Do not disassemble the feeding motor.

● It may cause a trouble.

● Do not inspect abrasion of the brush, and never replace it.
● The encoder and the gearbox cannot be replaced alone.

－15－
5. Parts List for AF-4011(for CO2 / MAG)
●If the components get worn out or damaged while using this wire feeding unit, refer to Fig. 5.1 to 5.4
and Table 5.1 to 5.5 and contact our local distributor or sales agent.
When ordering, be sure to give both the item name and the part number.
The items followed by ( ) in the Q’ty column are optional.

5.1 Parts list for wire feeding unit (AF-4011)

Table 5.1 Parts list for wire feeding unit (AF-4011)

Ref. No. Parts No. Item Q’ty Remarks
1 L10595B00 Feeding frame 1set For details, refer to Chapter 5.2.
2 L10595C00 Assembly parts 1set For details, refer to Chapter 5.3.
3 L10595D00 Wire feeder cover 1set For details, refer to Chapter 5.4.
4 L10595E00 Motor cable 1 For the electrical wiring, see
Chapter 9.1 in the following page.
5 L10595F00 Encoder cable 1 For the electrical wiring, see
Chapter 9.1 on the following page.
6 L7810G Feeding roll 1set For details, refer to Chapter 5.5.
7 L7437D00 Voltage detection cable 1 For the electrical wiring, see
Chapter 9.1 on the following page.

5 4 1

Fig. 5.1 Exploded diagram of wire feeding unit (AF-4011)

－16－
5.2 Parts list for wire feeding unit (L10595B00)

Table 5.2 Parts list for feeding frame (L10595B00)

Ref. No. Parts No. Item Q’ty Remarks
1 L10595B01 Bracket 1
1-1 Setscrew 2 M6x35
2 L10595B04 Coil spring 1
3 L10595B02 Pressure holder pin 2
4 L10595M00 Pressure holder (L) 1 Assembly part
5 L10595N00 Pressure holder (R) 1 Assembly part
6 L10595B03 Driving roll axis 2
7 L10595P00 Middle gear 2 Assembly part
7-1 P socket head setscrew 4 M4x10
8 4802-206 Feeding motor 1
8-1 Setscrew 3 M6x18
9 L10595Q00 Drive gear 1
10 L10595B05 Pressure spring holder 2
11 L10595B08 Compression spring 2
12 L10595B06 Pressure handle 2
13 L10595B07 Pressure bolt 2
13-1 4739-043 Spring pin 2 2.5x14
14 P-flat head screw 2 M5x20
15 L10595B09 Insulating bush 2
15-1 Hexagon head bolt 2 M8x40
16 U5185B15 Insulating cover 2
17 L10595L11 Motor mount 1
18 Bearing 1 No.6000DD
19 U5206J02 Encoder cover 1

Fig. 5.2 Exploded diagram of feeding frame (L10595B00)

－17－
 5.3 List of assembly parts (L10595C00)

Table 5.3 List of assembly parts (L10595C00)

Ref. No. Parts No. Item Q’ty Remarks
1 K5439C00 Pressure roll 2
2 L7810D04 Guide adapter (1) 1 Conduit side
3 L10595C01 Center guide 1
4 L10595C02 Guide block 1
2
4
3

1
Fig. 5.3 Exploded diagram of assembly parts (L10595C00)

5.4 Parts list for wire feeder cover (L10595D00)

Table 5.4 Parts list for wire feeder cover (L10595D00)

Ref. No. Parts No. Item Q’ty Remarks
1-1 Rear plate (1)
1-2 P-flat head screw (4) M4x12
1-3 Base plate (1)
1-4 P-flat head screw (2) M5x20
1-5 Front cover (1)
1-6 Semi snap lock (1) C-23-1
1-7 P-flat head screw, Nut (4) M3x8
1-8 Flat hinge (2) B-1100-1
1-9 P-round screw, Nut (8) M3x8

1-6 1-7
1-7

1-8 1-1

1-9 1-2

1-5
1-4
1-3

Fig. 5.4 Exploded diagram of wire feeder cover (L10595D00)

－18－
5.5 Parts list for feeding roll (L7810G)

Table 5.3 Parts list for feeding roll (L7810G)

Ref. No. Parts No. Item Q’ty Remarks

1 K5439B01 Feeding roll (1.4/1.6) (2) Option
2 K5439B12 Feeding roll (0.9-1.0/1.2) 2 Standard assembly
3 K5439B13 Feeding roll (0.8/0.9-1.0) (2) Option
4 K5439B04 Feeding roll (1.2/1.4) (2) Option
5 K5439B05 Feeding roll (1.2/1.2) (2) Option
6 K5439B06 Feeding roll (1.4/1.4) (2) Option
7 K5439B07 Feeding roll (1.6/1.6) (2) Option
8 K5439B09 Feeding roll (0.6/0.8) (2) Option
9 K5439B11 Feeding roll (1.2/1.6) (2) Option
10 Setscrew 4 M4x16

Table 5.4 Combination by wire diameter

Outlet guide
Wire diameter Feeding roll
(Included in coaxial power cable)
K5439B13
φ0.8 U2770K01
K5439B09
K5439B12
φ0.9-1.0 U69B34
K5439B13
K5439B12
K5439B04 U69B34
φ1.2
K5439B05 U69B35
K5439B11
K5439B01
φ1.4 K5439B04
K5439B06
U69B35
K5439B01
φ1.6 K5439B07
K5439B11

－19－
6. Parts List for AFA-4011
●If the components get worn out or damaged while using this wire feeding unit, refer to Fig. 6.1 to 6.2
and Table 6.1 to 6.4 and contact our local distributor or sales agent.
When ordering, be sure to give both the item name and the part number.
The items followed by ( ) in the Q’ty column are optional.

6.1 Parts list for wire feeding unit (AFA-4011)

Table 6.5 Parts list for wire feeding unit (AFA-4011)

Ref. No. Parts No. Item Q’ty Remarks
1 L10595B00 Feeding frame 1set For details, refer to Chapter 5.2.
2 L10596C00 Assembly parts (AL) 1set For details, refer to Chapter 6.2.
3 L10595D00 Wire feeder cover 1set For details, refer to Chapter 5.4.
For the electrical wiring, see
4 L10595E00 Motor cable 1
Chapter 9.1 in the following page.
For the electrical wiring, see
5 L10595F00 Encoder cable 1
Chapter 9.1 in the following page.
6 L10596G Feeding roll 1set For details, refer to Chapter 6.3.
For the electrical wiring, see
7 L7437D00 Voltage detection cable 1
Chapter 9.1 in the following page.
8 L7812D Wire straightener 1set

8 5 4 1

Fig. 6.1 Exploded diagram of wire feeding unit (AFA-4011)

－20－
6.2 list of assembly parts (L10596C00)

Table 6.2 List of assembly parts (L10596C00)

Ref. No. Parts No. Item Q’ty Remarks
1 L10595P00 Middle gear 2
2 L7812B01 Guide adapter (3) 1 For connecting wire straightener
3 L10596C01 Center guide (1.0 to 1.6) 1
4 L10595C02 Guide block 1
5 U2586F01 Outlet guide 1 Wire diameter (For 1.0 to 1.2)
6 U2586F02 Outlet guide (1) Wire diameter (For 1.6)
7 L7812B02 Guide adapter (4) 1 For connecting conduit
8 L7812B03 Inlet guide 1

8
7

Fig. 6.2 Exploded diagram of assembly parts (L10596C00)

－21－
 6.3 Parts list for feeding roll (L10596G)

Table 6.1 Parts list for feeding roll (L10596G)

Ref. No. Parts No. Item Q’ty Remarks
Standard assembly
1 K5463R02 Feeding roll (1.0/1.2) 4
(U-shape groove)
2 K5463R03 Feeding roll (1.2/1.6) (4) Option (U-shape groove)
3 K5463R06 Feeding roll (0.8/0.9) (4) Option (U-shape groove)
4 Setscrew 8 M4x16

Table 6.4 Combination by wire diameter

Outlet guide
Wire diameter Feeding roll
(Coaxial power cable, wire straightener)
φ1.0 K5463R02 (U-shape groove)
K5463R02 (U-shape groove) U2586F01
φ1.2
K5463R03 (U-shape groove)
φ1.6 K5463R03 (U-shape groove) U2586F02

[Note]
The standard AFA-4011 is designed to use for aluminum.
To use this wire feeding unit for mild steel / stainless steel, use the part listed below to modify
the wire feeding unit for mild steel / stainless steel use. Further, the feeding roll needs to be
replaced referring to Table 5.6 in the preceding Chapter.

Parts No. Item Q’ty Remarks

L10596J Assembly parts (Fe) 1set Parts for the mild steel / stainless specification

－22－
7. Parts List for AFT-4211 (for TIG Filler Iron)
●If the components get worn out or damaged while using this wire feeding unit, refer to Fig. 7.1 to 7.3
and Table 7.1 to 7.4, and contact our local distributor or sales agent.
When ordering, be sure to give both the item name and the part number.
The items followed by ( ) in the Q’ty column are optional.

7.1 Parts list for wire feeding unit (AFT-4211)

Table 7.1 Parts list for wire feeding unit (AFT-4211)

Ref. No. Parts No. Item Q’ty Remarks
1 L10696B00 Feeding frame 1set For details, refer to Chapter 7.2.
2 L10595C00 Assembly part 1set For details, refer to Chapter 5.3.
3 L10595D00 Feeding cover 1set For details, refer to Chapter 5.4.
4 L10696E00 Insulating assembly 1set
For Electrical Wiring Diagram,
5 L10696F00 Motor encoder cable 1set
refer to Chapter 9.2.
6 L7810G Feeding roll 1set For details, refer to Chapter 5.5.
7 L7930C Wire strainer (1set) Option

5 1

6
3

Fig. 7.1 Exploded diagram of wire feeding unit (AFT-4211)

－23－
 7.2 Parts list for wire feeding frame (L10696B00)

Table 7.2 Parts list for wire feeding frame (L10696B00)

Ref. No. Parts No. Item Q’ty Remarks
1 L10595B01 Bracket 1
1-1 Setscrew 2 M6x35
2 L10595B04 Coil spring 1
3 L10595B02 Pressure holder pin 2
4 L10595M00 Pressure holder (L) 1 Assembly part
5 L10595N00 Pressure holder (R) 1 Assembly part
6 L10595B03 Drive roll axis 2
7 L10595P00 Middle gear 2 Assembly part
7-1 P socket head setscrew 4 M4x10
8 4802-207 Feed motor 1
8-1 Setscrew 3 M6x18
9 L10595Q00 Drive gear 1
10 L10595B05 Pressure spring holder 2
11 L10595B08 Compression spring 2
12 L10595B06 Pressure handle 2
13 L10595B07 Pressure bolt 2
13-1 4739-043 Spring pin 2 2.5x14
14 P flat head screw 2 M5x20
15 L10595B09 Insulating bush 2
16 U5185B15 Insulating cover 2
17 L10595L11 Motor mount 1
18 Bearing 1 No.6000DD
19 U5206J02 Encoder cover 1
Different from the feeding frame for the AF-4011 only in No. 8 Feed motor.

Fig. 7.2 Exploded diagram of wire feeding frame (L10696B00)

－24－
7.3 Parts list for insulating assembly (L10696E00)

Table 7.3 Parts list for insulating assembly (L10696E00)

Ref. No. Parts No. Item Q’ty Remarks
1-1 Insulating block (1)
1-2 C cap (4) C10
1-3 Setscrew (2) M8x20
1-4 Setscrew (2) M8x40

1-2

1-3

1-1

1-4

Fig. 7.3 Exploded diagram of insulating assembly (L10696E00)

【Reference】

Table 7.4 List of combinations by wire diameter

Wire diameter Feeding roll Conduit
K5439B12 L7318B (Length: 3.4 m)
φ0.9-1.0
K5439B13 Liner to be cut on site (1.6 m as a guide)
K5439B12
K5439B04 L7318C（(Length: 3.4 m)
φ1.2
K5439B05 Liner to be cut on site (1.6 m as a guide)
K5439B11
K5439B01
φ1.4 K5439B04
K5439B06 L7318D（(Length: 3.4 m)
K5439B01 Liner to be cut on site (1.6 m as a guide)
φ1.6 K5439B07
K5439B11

－25－
8. Parts List for AFU-4211 (for TIG Filler Aluminum)
●If the components get worn out or damaged while using this wire feeding unit, refer to Fig. 8.1 and
Table 8.1, and contact our local distributor or sales agent.
When ordering, be sure to give both the item name and the part number.
The items followed by ( ) in the Q’ty column are optional.

8.1 Parts list for wire feeding unit (AFU-4211)

Table 8.1 Parts list for wire feeding unit (AFU-4211)

Ref. No. Parts No. Item Q’ty Remarks
1 L10696B00 Feeding frame 1set For details, refer to Chapter 7.2.
2 L10596C00 Assembly part 1set For details, refer to Chapter 6.2.
3 L10595D00 Feeding cover 1set For details, refer to Chapter 5.4
4 L10696E00 Insulating assembly 1set
For Electrical Wiring Diagram,
5 L10696F00 Motor encoder cable 1set
refer to Chapter 9.2.
6 L10596G Feeding roll 1set For details, refer to Chapter 6.3.
7 L7812D Wire strainer 1set Option

7 5 1

Fig. 8.1 Exploded diagram of wire feeding unit (AFU-4211)

－26－
9. Electrical Wiring Diagram
9.1 Electrical wiring diagram (L10595E00,L10595F00,L7437D00)

Red

－27－
9.2 Electrical wiring diagram (L10696F00)

Motor encoder cable (L10696F00)

－28－
 INSTRUCTION MANUAL for CO2 /MAG/MIG/TIG wire feeding unit
[AF-4011/AFA-4011/AFT-4211/AFU-4211]

No. 1L10595-E-1 1st Edition, Issue #1 August 7 / 2008

No. 1L10595-E-2 2nd Edition, Issue #1 September 1 / 2008
No. 1L10595-E-3 3rd Edition, Issue #1 January 21 / 2009
No. 1L10595-E-4 4th Edition, Issue #1 March 1 / 2009
No. 1L10595-E-5 5th Edition, Issue #1 July 6 / 2010
 ITEMS OF MAIN PRODUCTS

ARC WELDING MACHINES

AC ARC WELDING MACHINES
DC ARC WELDING MACHINES
CO2 GAS-SHIELDED ARC WELDING MACHINES
MAG ARC WELDING MACHINES
MIG ARC WELDING MACHINES
TIG ARC WELDING MACHINES
SUBMERGED ARC WELDING MACHINES
NO-GAS-SHIELDED ARC WELDING MACHINES
STUD ARC WELDING MACHINES
AIR PLASMA CUTTING MACHINES
ARC WELDING ROBOT

DAIHEN, Inc.
DAIHEN Corporation
DAYTON OFFICE
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OTC DAIHEN EUROPE GmbH OTC DAIHEN Asia Co., Ltd. OTC (Taiwan) Co., Ltd.
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11B/L Hyeongok Industrial Complex, 17F Majesty Building,
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