Lincoln Electric IM10114 User Manual
TANDEM CRUISER
RETURN TO MAIN MENU
™
IM10114
September, 2012
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.
11824
Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 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, Design Features ...............................................................A-2
Parts Included with Tandem Cruiser ....................................................................................A-3
Location................................................................................................................................A-4
General Assembly, Removing the Butt Joint Guide .............................................................A-5
Outriggers.............................................................................................................................A-6
Butt Joint Guide, 2 Wheels ...........................................................................................A-7, A-8
Front Wheels ........................................................................................................................A-9
Leveling the Wheels ...........................................................................................................A-10
Cross Slide and Wire Drive ................................................................................................A-11
Wire Reel Spindle, Take Off Arm .......................................................................................A-12
Wire Wheel Enclosure and Spindle Parts.................................................................A-13, A-14
50-60LB. Coil Mounting......................................................................................................A-15
Wire Straightener Adjustment, Feedplate Rotation ............................................................A-16
Flux Hopper........................................................................................................................A-17
Cables ................................................................................................................................A-17
Cable Connections .............................................................................................................A-18
Weld Cable Sizes ...............................................................................................................A-19
System Set-Up ...................................................................................................................A-20
Butt Joints, Fillet Joints.......................................................................................................A-21
Flat Fillet ((Trough), 45º (Trough) .............................................................................A-22, A-27
Base Dimensions Only .......................................................................................................A-28
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions, Product Description, Graphic Symbols ................................................B-1
Pendant Controls..................................................................................................................B-2
Moving The Tractor ..............................................................................................................B-3
Laser Pointer, Touch Sense, Power-Up Sequence..............................................................B-4
Wire Feeder Setup, Changing And Setting Weld Modes, Frequency ..................................B-5
Balance Adjust .....................................................................................................................B-6
Offset Adjust.........................................................................................................................B-6
Weld Sequence ....................................................................................................................B-6
Start Options ........................................................................................................................B-6
Start Options Operation........................................................................................................B-7
End Options, End Options Operation ...................................................................................B-7
Memories..............................................................................................................................B-8
Limits ...........................................................................................................................B-8/B-10
Dip Switches.......................................................................................................................B-10
Set-Up Features Menu ..............................................................................................B-11/B-15
________________________________________________________________________________
Accessories...............................................................................................Section C
Optional Kits and Accessories, Drive Roll and Guide Tube Kits ..........................C-1
Accessories Included with the TANDEM CRUISER™..........................................C-2
________________________________________________________________________________
Maintenance ....................................................................................................Section D
Safety Precautions ................................................................................................D-1
Routine Maintenance.............................................................................................D-1
Periodic Maintenance............................................................................................D-1
________________________________________________________________________________
Troubleshooting..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide...................................................................................E-2, E-3
________________________________________________________________________________
Diagrams ..........................................................................................................Section F
Lead Arc Wiring Diagram.......................................................................................F-1
Trail Arc Wiring Diagram........................................................................................F-2
________________________________________________________________________________
Parts Pages............................................................................................................................P-693
________________________________________________________________________________
vi
A-1
INSTALLATION
TECHNICAL SPECIFICATIONS - TANDEM CRUISER™ K-3083-1
Wire Feeders - Input Voltage and Current
VOLTAGE INPUT AMPERES NOTES
40 VDC 8 AMPS Lead Arc
40 VDC 8 AMPS Trail Arc
Rated Output
DUTY CYCLE AMPERES
100% 1000 AMPS per arc
Physical Dimensions (as shipped from the factory)*
(Overall Size and Weight Dependent Upon Configuration)
MODEL HEIGHT WIDTH DEPTH WEIGHT
K3083-1 36.5 in. (901.7mm) 45.50 in (1,155.7mm) 41.5 in (1,054.1mm) 300 lb. (136 kg)
Temperature Ranges
Operating Temperature -40ºF to 122ºF (-40ºC to +50ºC)
Storage Temperature -40ºF to 185ºF (-40ºC to +85ºC)
A-1
SAW
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)
TANDEM CRUISER™
A-2
INSTALLATION
GENERAL PHYSICAL DESCRIPTION
The Tandem 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 proven wire drives. 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.
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
from high temperature rubber specially bonded to an
aluminum core. Also mounted on the axle are guide
wheels and gears for operating on K396 track sections.
The flexible wheel configuration lets the tractor be
assembled in a manner for the best balance while
aligning the wheels for the tracking of the joint.
All of the controls are housed in a pendant that connects to the tractor with two ArcLink cables. The pendant housing is fabricated from aluminum to resist
impacts and high temperatures.
GENERAL FUNCTIONAL DESCRIPTION
The TANDEM CRUISER™ is a modular platform for
submerged arc welding.
A-2
• There is no 115 VAC in the tractor.
• The minimum turning radius of the Tandem
Cruiser™ is 10 feet when assembled with 3 wheels.
• The minimum turning radius of the Tandem
Cruiser™ is 20 feet when assembled with 4 wheels.
• The rubber wheels are rated to 500°F (260°C)
• The curved nozzle extensions may be used with up
to 3/16” wire.
• For use with 50/60 lb coils.
RECOMMENDED POWER SOURCES
• Power Wave®AC/DC 1000
DESIGN FEATURES
Loaded with Standard Features
Arc Performance
• The Tandem Cruiser™ and Power Wave
1000 combine for new levels of submerged arc productivity.
User Controls
• Easy to read pendant displays information for the
lead and trail arc.
• 4 memories on the lead arc and 8 memories on the
trail arc 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.
®
AC/DC
RECOMMENDED PROCESSES
• Tandem SAW (AC, DC+, DC-) up to 1000 amps per
arc.
PROCESS LIMITATIONS
• The TANDEM CRUISER™ does not support open
arc procedures.
EQUIPMENT LIMITATIONS
• 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 Tandem Cruiser™ operates on 40 VDC only.
TANDEM CRUISER™
Tractor and Frame
• 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
A-3
PARTS INCLUDED WITH THE TANDEM CRUISER
Description
Flux Tube
Conduit Tubing
Wire Reel Enclosure
Strain Relief Boot
Insulating Tube
Nozzle Adapter
Nozzle Extension
Nozzle Extension, 45° curved
Part No.
T10642-10
S20023-5
G3674-1
S24669-1
M17225
T7028-245
M13739-1
KP2721-1
KP2721-2
™
Qty.
3
Connects from the bottom of the flux hopper to the
concentric cone flux nozzle.
2
Used for routing the electrode from the inlet bushing
to the wire drive. Trim the length as needed.
2
Keeps the coils of electrode dry when the Cruiser is
2
stored in wet conditions.
2
Covers the brass fitting of the wire reel enclosure to
keep water out.
3
Used as connectors for joining the rubber flux tubes
together.
2*
Extends the nozzle 3.00”.
2
Makes the nozzle longer.
2
Frequently used when making horizontal fillet welds.
Purpose
Nozzle Tip
Flux Hose Clamp
Nozzle Insulator
Flux Cone Nozzle Assembly
5/16-18 x 1.00 Bolt
5/16 Lock Washers
5/16 Flat Washers
S10125-5/32
T12929
T11807
M8249
T9078-1
S10147
T10575-1
T10574
S24739-20
E106A-3
S9262-121
2
Contact tips for 5/32 wire.
2
Supports the rubber flux tube along the nozzle.
2
Covers the nozzle or nozzle extensions to reduce
the potential of contact.
1
These parts assemble together to direct the flux
1
around the electrode.
1
1
1
16
Used when assembling the Tandem Cruiser™ in the
flat fillet position.
5/16-18 x 2.50 Bolt
CF000173
*(one shipped loose, one assembled to the trail arc)
TANDEM CRUISER™
4
A-4
LOCATION
WARNING
INSTALLATION
• Contact Nozzle Assemblies
• Nozzle extensions
• Contact Tips
A-4
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.
------------------------------------------------------------------------
Parts shown in red are at electrode potential.
(See Figure A.A)
It is the responsibility of the user/builder/operator to
assemble the TANDEM CRUISER™ to maintain safe
electrical clearances and to be stable.
Operate the TANDEM CRUISER™ only on stable and
dry surfaces.
Operating the TANDEM CRUISER™ on inclined sur-
faces requires adjusting and/or assembling the tractor
differently than shipped from the factory. Wire reel
enclosures must be installed with the wire exitting the
top of the enclosure. Do not drive the TANDEM
CRUISER™ up or down inclines steeper than 2
degrees.
Do not submerge the TANDEM CRUISER™.
The TANDEM CRUISER™ is rated IP23S when the
wire reel enclosures are installed. It may be stored
outdoors but is not intended for use during precipitation
unless sheltered.
Protect the TANDEM 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 poten-
tial and all other TANDEM CRUISER™ components.
Parts that are at electrode potential are:
•Wire
• Wire Spool
• Brass Conduit bushing adapter
• Wire Straightener Rolls
FIGURE A.A
• 4 screw heads on back of the wire straighter.
• Feed plate and drive rolls
TANDEM CRUISER™
A-5
GENERAL ASSEMBLY
INSTALLATION
A-5
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.
------------------------------------------------------------------------
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.
------------------------------------------------------------------------
REMOVING THE BUTT JOINT GUIDE
1. Loosen the bolts on the clamp as shown. Slide and
remove the butt joint guide kit.
FIGURE A.1 - BUTT JOINT GUIDE
Loosen bolts
Slide and remove the butt joint kit
2. Loosen the pendant clamp bolts. Slide the tube
supporting the pendant and flux hopper until it is
flush with the end of the clamp. Tighten all the
clamp bolts to 25 ft-lb.
FIGURE A.1a - BUTT JOINT GUIDE
TANDEM CRUISER™
A-6
INSTALLATION
A-6
Clamps
• Tighten clamp bolts to 25 ft-lbs (34 Nm).
• Use clamps with a key on horizontal tubes.
FIGURE A.1b - CLAMPS
Collars
• Tighten collar screw to 42 in-lbs (0.3 Nm)
FIGURE A.2 - COLLARS
FIGURE A.4 - CHAIN AND MAST ANCHOR
OUTRIGGERS
The outriggers “steer” the TANDEM CRUISER™ along
a vertical surface by driving it at a slight angle.
Suggested offset between the front and rear outriggers
is 1/2” (12.7mm). Larger offsets increase the friction
driving the TANDEM CRUISER™ forward and may
cause travel motor overcurrent errors and rapid wheel
wear.
When assembling the TANDEM 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
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.
Clutch
The outriggers may be stacked to gain extra length.
Slide a T Nut (S28835) into the extrusion and then
insert a 1/4-20 bolt through the outrigger slots.
FIGURE A.6 - OUTRIGGERS EXTENSION
TANDEM CRUISER™
A-7
INSTALLATION
BUTT JOINT GUIDE, 2 WHEEL
(See Figure A.7)
Remove the butt joint guide assembly as shipped
from the factory. Loosen the clamp bolts on the
clamp holding the pendant tube. Slide the butt joint
guide out and set aside
FIGURE A.7
A-7
Then slide the pendant tube until it is flush with the
end of the clamp. Retighten the clamp bolts.
(See Figure A.8)
FIGURE A.8
TANDEM CRUISER™
A-8
INSTALLATION
Butt Joint Guide, 2 Wheel (See Figure A.9)
To assemble the butt joint guide,
• Support the Cruiser to remove weight from the front
wheels.
• Remove the front outrigger bar.
• Remove one of the front wheel assemblies by
removing the four bolts holding the wheel assembly
to the frame.
• Determine the number of spacer blocks required,
remove as necessary. The guide wheels should be
within 0.5 “ (12.7mm) of the weld wires when the
slides are at the mid position.
• Bolt the butt joint guide assembly to the frame,
using the set of holes that positions the guide
wheels as close as possible to the weld wires.
• Use the clamp to set the coarse vertical height. Set
the height so all three rubber wheels are touching
the ground when the butt joint guide is in the joint.
Tighten the clamp bolts to 25 ft-lbs (34 Nm)
• Use the fine vertical adjustment as necessary to
keep pressure on the guide wheels without lifting
the other rubber wheels off the ground.
A-8
FIGURE A.9 - BUTT JOINT, 2 WHEEL
TANDEM CRUISER™
A-9
INSTALLATION
FRONT WHEELS
In almost all configurations the front wheels must
remain parallel with the Cruiser base and rear wheels.
Improper adjustment of the front wheels will cause
inconsistent tracking of the joint, accelerate wheel
wear, poor operation on K396 track and may lead to
travel motor overload errors.
FIGURE A.10 FRONT WHEEL ADJUSTMENT
A-9
Only adjust the front wheels when welding a round
inside or outside seam 25 feet (7.6m) in diameter or
smaller. At all other times the front wheels must be set
to 90°.
FIGURE A.11 ADJUSTMENT 25 FEET DIA. OR SMALLER
To steer the front wheel to the left, loosen bolt A and
tighten bolt B to set the angle, then snug bolt A.
To steer the front wheel to the right, loosen bolt B and
tighten bolt A to set the angle, then snug bolt B.
FIGURE A.12 DIRECTION OF TRAVEL
TANDEM CRUISER™
A-10
INSTALLATION
LEVELING THE WHEELS
The frame mounting holes for bolting the front wheels
are oversized to allow for leveling of the front wheels.
To level the wheels: (See Figure A.12a)
WARNING
1. Turn off power at the welding power
source.
2. Place the tractor on a stable and level surface.
3. Determine the axis that the tractor pivots.
FIGURE A.12a
A-10
4. While keeping both rear wheels in contact with
the surface, loosen the 4 front bolts securing
wheel “A” and reposition the wheel lower to
contact the surface, and then tighten the bolts to
10 ft-lbs (13.6 N-m) (See Figure A.12b)
5.
If more adjustment is required, loosen the 4
front bolts securing wheel “B” and reposition
to allow both front wheels and both rear wheels
to contact the surface at the same time. Tighten
the bolts to 10 ft-lbs (13.6 N-m)
TANDEM CRUISER™
FIGURE A.12b
A-11
INSTALLATION
CROSS SLIDE AND WIRE DRIVE
Each slide has 4” (102mm) of travel.
When assembling the Cruiser, verify that no components at electrode potential contact the frame throughout the entire travel distance of the slides.
The slides may be disassembled and then the position
adjusted relative to each other. Do not attach other
devices to the wire drive and cross slide assembly.
Instead, mount accessories to the tube and clamp
frame work.
When shipped from the factory, the wire drives are
mounted using the outer set of bracket slots. Each
wire drive has an inner set of bracket slots for spacing
the wire drives closer together.
Assemble the Spacer Blocks and Nozzle Extension as
required to adjust the lead arc stick-out relative to the
trail arc stick-out.
A-11
FIGURE A.13 FACTORY POSITION
TANDEM CRUISER™
A-12
INSTALLATION
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.
• The wire reel must not contact the frame.
FIGURE A.14 - WIRE REEL SPINDLE
A-12
TAKE-OFF ARM
• Position the take off arm to prevent contact to the
reel and electrode.
• Route the electrode through a conduit from the take
off arm to the wire drive.
FIGURE A.15 - TAKE OFF ARM
TANDEM CRUISER™
A-13
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.16 - ENCLOSURE ASSEMBLY
A-13
ENCLOSURE
BACK
HARDWARE
2. Unscrew the spindle brake and remove the spindle
brake parts and the spindle.
FIGURE A.17 - ENCLOSURE 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.
TANDEM CRUISER™
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