Lincoln Electric IM10098 User Manual

CRUISER

IM10098-A

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For use with machines having Code Numbers:

Safety Depends on You

Lincoln arc welding and cutting
equipment is designed and built
with safety in mind. However,
your overall safety can be
increased by proper installation
... and thoughtful operation on
your part. DO NOT INSTALL,

OPERATE OR REPAIR THIS
EQUIPMENT WITHOUT READ­ING THIS MANUAL AND THE
SAFETY PRECAUTIONS CON­TAINED THROUGHOUT. And,

most importantly, think before
you act and be careful.

1176 7, 1194 7

™

July, 2012

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

IP23S

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

i

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

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.d. Keep all equipment safety guards, covers and devices in posi-

tion 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 some cases it may be necessary to remove safety guards
to perform required maintenance. Remove guards only when
necessary and replace them when the maintenance requiring
their removal is complete.
working near moving

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

1.c. Do not add the fuel near 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.

Always use the greatest care when

parts.

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. Electric current flowing through any conductor causes
localized Electric and Magnetic Fields (EMF). Welding
current creates EMF fields around welding cables and
welding machines

2.b. EMF fields may interfere with some pacemakers, 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.

___________________________________________________

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

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.

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.

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 clothing. Wear dry, hole-free
gloves to insulate hands.

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

In addition to the normal safety precautions, if welding
must be performed under electrically hazardous
conditions (in damp locations or while wearing wet
clothing; on metal structures such as floors, gratings or
scaffolds; when in cramped positions such as sitting,
kneeling or lying, if there is a high risk of unavoidable or
accidental contact with the workpiece or ground) use
the following equipment:

• Semiautomatic DC Constant Voltage (Wire) Welder.

• DC Manual (Stick) Welder.

• AC Welder with Reduced Voltage Control.

3.c. In semiautomatic or automatic wire welding, the electrode,
electrode reel, welding head, nozzle or semiautomatic
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. Never simultaneously touch electrically “hot” parts 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
fumes and gases. When welding, keep
your head out of the fume. Use enough
ventilation and/or exhaust at the arc to keep

fumes and gases away from the breathing zone. When

welding with electrodes which require special
ventilation such as stainless or hard facing (see
instructions on container or MSDS) or on lead or
cadmium plated steel and other metals or coatings
which produce highly toxic fumes, keep exposure as
low as possible and within applicable OSHA PEL and
ACGIH TLV limits using local exhaust or mechanical ven­tilation. In confined spaces or in some circumstances,
outdoors, a respirator may be required. Additional pre­cautions are also required when welding on galvanized
steel.

5. b. The operation of welding fume control equipment is affect­ed 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
to

form phosgene, a highly toxic gas, and other irritating

products.

vapors

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

cause injury or death. Always use enough ventilation,
especially in confined areas, to insure breathing air is safe.

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

equipment and the consumables to be used, including the
material safety data sheet (MSDS) and follow your
employer’s safety practices. MSDS forms are available from
your welding distributor or from the manufacturer.

5.f. Also see item 1.b.

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

Remember that welding sparks and hot materials from weld­ing can easily go through small cracks and openings to adja­cent areas. Avoid welding near 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 operating information for 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
Containers and Piping That Have Held Hazardous
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 possibility of the welding current passing
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 welding sparks from starting a fire.

though

they have

Preparation

for Welding and Cutting of

CYLINDER may explode
if damaged.

7.a. Use only compressed gas cylinders
containing the correct shielding gas for the
process used and properly operating
regulators designed for the gas and

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

7.b. Always keep cylinders in an upright position securely
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. Read and follow the instructions on compressed 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. Install equipment in accordance with the U.S. National
Electrical Code, all local 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.

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.

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-circuit accidental 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, nettoyage 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.

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.

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. Protéger l’autre personnel travaillant à proximité au

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

4. Des gouttes de laitier en fusion sont 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.

PRÉCAUTIONS DE SÛRETÉ POUR
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.

Thank You

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

Your Product”. 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 “Support” and then “Register

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

General Physical Description ...............................................................................................A-2

General Functional Description ............................................................................................A-2

Recommended Processes ...................................................................................................A-2

Process Limitations ..............................................................................................................A-2

Equipment Limitations ..........................................................................................................A-2

Recommended Power Sources............................................................................................A-2

Design Features ...................................................................................................................A-2

Location................................................................................................................................A-3

General Assembly ................................................................................................................A-4

Outriggers, Manual Steering Mechanism, Assembly ...........................................................A-5

Manual Steering Mechanism, Adjustment............................................................................A-6

Cross Slide ...........................................................................................................................A-6

Wire Reel Spindle.................................................................................................................A-6

Wire Wheel Enclosure ..................................................................................................A-7, A-8

Take-Off Arm........................................................................................................................A-9

Wire Straightener Adjustment ............................................................................................A-10

Feedplate Rotation .............................................................................................................A-10

Flux Hopper, Cables...........................................................................................................A-11

Cable Connections, Weld Cable Sizes...............................................................................A-12

System Set-Up ...................................................................................................................A-13

Butt Joints ..................................................................................................................A-14/A-17

Fillet Joints.................................................................................................................A-17/A-18

Horizontal Fillet ..........................................................................................................A-19/A-20

Flat Fillet ....................................................................................................................A-21/A-22

Pipe Welding..............................................................................................................A-23/A-24

Base Dimensions Only .......................................................................................................A-25

________________________________________________________________________________

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

Safety Precautions, Graphic Symbols..................................................................................B-1

Pendant Controls..................................................................................................................B-2

Moving The Tractor ..............................................................................................................B-2

Laser Pointer, Touch Sense.................................................................................................B-3

Power-Up Sequence ............................................................................................................B-3

Wire Feeder Setup ...............................................................................................................B-4

Changing And Setting Weld Modes .....................................................................................B-4

Frequency ............................................................................................................................B-4

Balance Adjust .....................................................................................................................B-5

Offset Adjust.........................................................................................................................B-5

Weld Sequence ....................................................................................................................B-5

Start Options ........................................................................................................................B-5

Start Options Operation........................................................................................................B-6

End Options, End Options Operation ...................................................................................B-6

Memories..............................................................................................................................B-7

Limits .............................................................................................................................B-7/B-9

Dip Switches.........................................................................................................................B-9

Set-Up Features Menu ..............................................................................................B-10/B-12

________________________________________________________________________________

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

Optional Kits and Accessories ..............................................................................C-1

Drive Roll and Guide Tube Kits .............................................................................C-1

Accessories Included with the CRUISER™ ..........................................................C-2

________________________________________________________________________________

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

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

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

________________________________________________________________________________

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

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

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

________________________________________________________________________________

Wiring Diagrams..............................................................................................Section F

________________________________________________________________________________

Parts Pages............................................................................................................................P-683

vi

A-1

TECHNICAL SPECIFICATIONS - CRUISER

INSTALLATION

™

K-3048-1

Wire Feeders - Input Voltage and Current

VOLTAGE INPUT AMPERES

40 VDC 8 AMPS

Rated Output

DUTY CYCLE AMPERES

100% 1000 AMPS

Physical Dimensions (as shipped from the factory)*

(Overall Size and Weight Dependent Upon Configuration)

MODEL HEIGHT WIDTH DEPTH WEIGHT

K3048-1 29 In (736 mm) 23 in (548 mm) 36 in (914 mm) 207 lb (94 kg)

Temperature Ranges

Operating Temperature -40ºF to 122ºF (-40ºC to +50ºC)
Storage Temperature -40ºF to 185ºF (-40ºC to +85ºC)

SAW

A-1

GEARING WFS Range Wire Sizes

57:1

50 to 500 ipm

(1.3 to 12.5 m/min)

95:1

142:1*

15 to 300 ipm

(0.4 to 7.5 m/min)

15 to 200 ipm

(0.4 to 5.0 m/min)

* = gearing installed in the wire drive as equipped from the factory.

1/16 to 3/32 inch

(1.6 to 2.4 mm)

1/16 to 3/32 inch

(1.6 to 2.4 mm)

1/16 to 7/32 inch

(1.6 to 5.6 mm)

CRUISER™

A-2

INSTALLATION

A-2

GENERAL PHYSICAL DESCRIPTION

The CRUISER™ is a self propelled, modular platform
for performing submerged arc welds. A unique tube
and clamp design provides flexibility to mount the feed­ing components in any position.

Wire is fed to the arc with the proven wire drive. All of
the drive rolls, nozzles, contact tips and wire straight­eners are common between the MaxSA wire drives
and the CRUISER™ wire drive. The wire drive rotates
about two axes for setting torch drag/pull angle and
torch tilt angle.

The wire drive is mounted to two heavy duty X-Y
slides. The cross slides allow easy adjustment of the
electrode stick-out and position of the wire in the joint.

The entire mast and arm structure separates from the
base for portability and mobility purposes.

Driving the tractor is a permanent magnet DC motor
with a 5 stage gear box built with all metal gears. A
high resolution encoder keeps the tractor speed con­sistent even at slow speeds. The wheels are made of
a high temperature rubber specially bonded to an alu­minum core. Also mounted on the axle are guide
wheels and a gear for operating on K396 track sec­tions.

The tractor may be configured for 3 or 4 wheel opera­tion. The flexible wheel configuration allows the tractor
to be assembled in a manner for optimum balance
while aligning the wheels for the tracking of the joint.

All of the controls are housed in a light weight pendant
that connects to the tractor via an ArcLink cable. The
pendant housing is fabricated from aluminum to resist
impacts and high temperatures.

GENERAL FUNCTIONAL DESCRIPTION

The CRUISER™ is a modular platform for submerged
arc welding.

RECOMMENDED PROCESSES

• SAW (AC, DC+, DC-) up to 1000 amps.

• Tiny Twin

PROCESS LIMITATIONS

• The CRUISER™ does not support open arc proce­dures.

CRUISER™

EQUIPMENT LIMITATIONS

• Curved extension nozzle limited to 3/16” wire.

• Inductance of the electrode and work cables may
affect arc performance. Do not coil excess cable.

• For robust digital communications, do not use more
than 200 feet of control cable.

• The CRUISER™ operates on 40 VDC only.

• There is no 115 VAC in the tractor.

• The minimum turning radius of the CRUISER™ is 10
feet when assembled with 3 wheels.

• The minimum turning radius of the CRUISER™ is 20
feet when assembled with 4 wheels.

• The rubber wheels are rated to 500°F (260°C)

• The laser pointer mounting bracket is not compatible
with the tiny twin nozzle or K148 nozzle.

RECOMMENDED POWER SOURCES

• Power Wave AC/DC 1000

DESIGN FEATURES

Loaded with Standard Features
Arc Performance

• The CRUISER™ and Power Wave AC/DC 1000

combination provide for new levels of submerged arc
productivity.

User Controls

• Light weight, hand-held pendant.

• Four memories for quick selection of common proce­dures.

• Full sequence control for tailoring the weld from start
to end.

• All welding controls located at the pendant, including
program selection.

• Laser pointer to aid in steering the CRUISER™.

Wire Drive

• Changeable gears for feeding small diameter wires at
high speed and large diameter wires at low speed.

• High torque, permanent magnet DC motor with
tachometer for accurate wire feed speed control.

• Three roll wire straightener included.

• Uses standard Lincoln submerged arc contact noz­zles.

Tractor and Frame

• Configures to 3 or 4 wheels with patent pending
design, for the best tracking and balancing.

• Permanent magnet DC motor with encoder for
steady, accurate travel speeds.

• All steel gears for long life.

• Easily engaged travel clutch.

• Fully assembled for track use.

• High temperature rubber wheels for superior traction
and heat resistance up to 500°F (260°C).

• Heavy duty slides for adjusting the electrode position
in the joint.

A-3

INSTALLATION

LOCATION

WARNING

ELECTRIC SHOCK can kill.

• Do not touch the wire drive,
drive rolls, nozzle, wire coil,
electrode or wire drive motor
when welding output is ON.

• The tractor is an automatic
piece of equipment that may
be remotely controlled.

• Turn the input power OFF at the disconnect
switch or fuse box before attempting to connect
or disconnect input power lines, output cables or
control cables.

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

• Do not let the electrode or wire spool touch the
tractor frame.

• Only qualified personnel should perform this
installation.

• Insulate yourself from the work and ground.

• Always wear dry insulating gloves.

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

A-3

• Contact nozzle assembly

• Nozzle extensions

• Contact Tip

Operate the CRUISER™ only on stable and dry sur-

faces.

Operating the tractor on inclined surfaces requires
adjusting and/or assembling the tractor differently than
shipped from the factory.

Do not submerge the tractor.

It is the responsibility of the user/builder/operator to
assemble the tractor to maintain safe electrical clear­ances and to be stable.

The tractor is rated for outdoor use (IP23S) with the
wire reel enclosure installed.

Protect the CRUISER™ from preheat torches.

WARNING

MOVING PARTS can injure.

• Keep away from moving parts.

• Tractor parts may move sud­denly when the bolts are loos­ened.

• All clamps and collars must be
secured before operating.

• Configure the tractor for stable operation, with a
full and empty flux hopper and a full and empty
spool.

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

Maintain clearance between parts at electrode poten­tial and all other tractor components. Parts that are at
electrode potential are:

• Wire

• Wire spool

• Wire straightener rolls

• Brass Conduit bushing adapter

• 4 screw heads on back of the wire straighter

• Feed plate and drive rolls

CRUISER™

A-4

INSTALLATION

GENERAL ASSEMBLY

WARNING

ELECTRIC SHOCK can kill.

• Improperly secured clamps
and collars may shift, causing
parts at electrode potential to
contact the tractor frame or
other components.

• Only qualified personnel
should install, use or service
this equipment.

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

A-4

Collars

• Tighten collar screw to 42 in-lbs (0.3 Nm)

FIGURE A.2 - COLLARS

WARNING

FALLING EQUIPMENT can cause
injury.

• Lift only with equipment of
adequate capacity

• Be sure the machine is stable
when lifting.

• Do not lift the machine if the lift bail is damaged.

• Do not operate machine while suspended from
lift bail.

• Failure to properly secure the clamps, collars,
chains and lift bail may result in physical injury.

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

Clamps

• Tighten clamp bolts to 25 ft-lbs (34 Nm).

• Use clamps with a key on horizontal tubes.

FIGURE A.1 - CLAMPS

Lift Bail

• Tighten lift bail hardware to 24 in-lbs (0.17 Nm). Do
not overtighten or the mast may become distorted.

FIGURE A.3 - LIFT BALE

Chain and Mast Anchor

• The chain must be connected from the base to the
mast before lifting.

• Tighten all hardware as shown.

FIGURE A.4 - CHAIN AND MAST ANCHOR

CRUISER™

A-5

INSTALLATION

A-5

OUTRIGGERS

The outriggers “steer” the CRUISER™ along a vertical

surface by driving it at a slight angle. Suggested offset
between the front and rear outriggers is ½” (12.7mm).

Larger offsets increase the friction driving the CRUIS-
ER™ forward and may cause travel motor overcurrent

errors and rapid wheel wear.

When assembling the CRUISER™, adjust the cross

slide to the middle position and position the wire in the
joint. Then assemble the front and rear outriggers, and
make fine adjustments to the wire position using the
cross slide.

FIGURE A.5 - OUTRIGGERS

MANUAL STEERING MECHANISM,
ASSEMBLY

As shipped from the factory, the manual steering
mechanism is assembled with a guide wheel for track­ing in a butt joint. The guide wheel may be replaced
with a rubber wheel for manual steering.

FIGURE A.7 - MANUAL STEERING MECHANISM

The outriggers may be stacked to gain extra length.
Slide a T Nut (S28835) into the extrusion and then
insert a ¼-20 bolt through the outrigger slots.

FIGURE A.6 - OUTRIGGERS EXTENSION

CRUISER™

A-6

INSTALLATION

A-6

MANUAL STEERING MECHANISM,
ADJUSTMENT

To steer the CRUISER™ to the Right:

Loosen bolt B
Tighten bolt A to set the wheel angle.
Snug bolt B

To steer the CRUISER™ to the Left:

Loosen bolt A
Tighten bolt B to set the wheel angle
Snug bolt A

FIGURE A.8 - ADJUSTMENT

FIGURE A.9 - LOAD LIMITS

WIRE REEL SPINDLE

• Position the wire reel spindle to prevent the reel
and electrode from contacting the tractor frame and
base.

• The wire reel spindle must be horizontal or oriented
upwards.

FIGURE A.11 - WIRE REEL SPINDLE

CROSS SLIDE

Each slide has 4” (102mm) of travel.

When assembling the CRUISER™, verify that no com-

ponents at electrode potential contact the frame
throughout the entire travel distance of the slides.

The slides may be disassembled and then positioned
relative to each other.

FIGURE A.10 - SEVERAL POSSIBLE SLIDE CONFIGURATIONS

CRUISER™

A-7

WIRE REEL ENCLOSURE ASSEMBLY

1. Determine the angular orientation of the wire reel

BRACKET

GASKET

INSTALLATION

enclosure relative to the spindle clamp. To change
the angle of the enclosure, remove the 6 bolts
securing the enclosure back to the mounting brack­et using a 7/16” wrench. Reassemble at the desire
angle, keep the gasket centered relative to the
enclosure back. Provisions are made to rotate the
enclosure in 30° increments.

FIGURE A.11a - ENCLOSURE ASSEMBLY

A-7

ENCLOSURE
BACK

HARDWARE

2. Unscrew the spindle brake and remove the spindle
brake parts and the spindle.

FIGURE A.11b - ENCLUSURE MOUNTING

3. Remove two of the bolts from the spindle assem­bly using a 1/4” hex key. Assemble the enclosure
back to the spindle assembly and tighten the bolts.

CRUISER™

A-8

INSTALLATION

4. Reassemble the spindle parts as shown.

FIGURE A.11c - SPINDLE PARTS

A-8

5. If required, swap the position of the ball bushing
assembly. Use a 7/16” wrench to loosen and
tighten the hardware.

6. Thread the conduit into the brass fitting on the
ball bushing assembly. Then slide the boot along
the conduit and over the brass fitting.

FIGURE A.11d - CONDUIT, BRASS FITTING, BOOT

7. When assembling the enclosure cover to the
enclosure back, verify the cover is evenly seated

all the way around.

CRUISER™

A-9

INSTALLATION

TAKE-OFF ARM

• Position the take off arm to prevent contact to the
reel and electrode.

• Route the electrode through the conduit from the
take off arm to the wire drive.

FIGURE A.12 - TAKE-OFF ARM

A-9

CRUISER™

A-10

INSTALLATION

A-10

WIRE STRAIGHTENER ADJUSTMENT

The wire straightener controls the amount of cast (or
“curve”) in the wire. Excessive cast may effect align­ment of the wire in the joint. Too little cast may result
in insufficient wire contact in the contact tip.

To adjust the wire straightener:

1. Turn off power at the welding power source.

2. Loosen the two screws holding the wire straighten­er to the feed plate with a ¼” hex key.

FIGURE A.13 - WIRE STRAIGHTENER SCREWS

FEEDPLATE ROTATION

The feedplate of the wire drive may be rotated about
the drive roll axis. Depending upon how the tractor is
assembled, rotating the feed plate will change the tilt
angle or the drag angle.

1. Turn off power at the welding power supply.

2. Loosen the set screw on the feedplate with a 5/16”
hex key.

3. Rotate the feedplate to the new position. Do not
allow surfaces at electrode potential to touch the
frame, flux hopper, base or slides of the tractor.

4. Tighten the set screw to secure the feedplate.

5. As equipped from the factory, the tractor is set-up
with “A” as the inlet and “B” as the outlet. To make
“B” the inlet and “A” the outlet, see the SET-UP
MENU.

FIGURE A.15 - FEEDPLATE ROTATION

3. Position the straightener as desired to remove or
add cast to the wire.

4. Tighten the screws holding the wire straightener to
the feed plate.

5. Turn power on at the welding power source.

6. Feed wire through the straightener. Adjust the
amount of pressure on the wire with the straighten­er until the desired cast is achieved when the wire
exits the tip.

NOTE: A slight curvature to the wire helps to maintain

good electrical contact inside the contact tip.

FIGURE A.14 - WIRE STRAIGHTENER

CRUISER™