Lincoln Electric IM10114 User Manual

TANDEM CRUISER

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™

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

• World's Leader in Welding and Cutting Products •

• Sales and Service through Subsidiaries and Distributors Worldwide •

SAFETY

WARNING

CALIFORNIA PROPOSITION 65 WARNINGS

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

The Above For Diesel Engines

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

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

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

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

The Above For Gasoline Engines

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.

SAFETY

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.

SAFETY

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

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.

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

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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

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

Optional Kits and Accessories, Drive Roll and Guide Tube Kits ..........................C-1

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

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

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

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

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

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

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

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

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

Lead Arc Wiring Diagram.......................................................................................F-1

Trail Arc Wiring Diagram........................................................................................F-2

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Parts Pages............................................................................................................................P-693

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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.

Connects from the bottom of the flux hopper to the concentric cone flux nozzle.

Used for routing the electrode from the inlet bushing to the wire drive. Trim the length as needed.

Keeps the coils of electrode dry when the Cruiser is

stored in wet conditions.

Covers the brass fitting of the wire reel enclosure to keep water out.

Used as connectors for joining the rubber flux tubes together.

Extends the nozzle 3.00”.

Makes the nozzle longer.

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

Contact tips for 5/32 wire.

Supports the rubber flux tube along the nozzle.

Covers the nozzle or nozzle extensions to reduce the potential of contact.

These parts assemble together to direct the flux

around the electrode. 1 1 1

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™

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)

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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