Lincoln Electric IM10114 User Manual

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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

________________________________________________________________________________

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

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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™

A-14

INSTALLATION

4. Reassemble the spindle parts as shown.

FIGURE A.18 - SPINDLE PARTS

A-14

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.19 - CONDUIT, BRASS FITTING, BOOT

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

all the way around.

TANDEM CRUISER™

A-15

INSTALLATION

A-15

50-60 LB. (22.7 - 27.2 KG) COIL MOUNTING

WARNING

• Do not wear gloves during threading of wire or changing wire spool.

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

1. Make sure the spindle of the wire reel stand is in the upper position.

With the coil reel assembly mounted to a 2" (51mm) spindle, loosen the spinner nut and remove the cover plate. Alternatively, lay the coil reel assembly flat on the floor and loosen the spinner nut and remove the cover plate.

3. Place the coil of electrode on the reel so it unwinds from the bottom as it rotates.

4. Tighten the spinner nut as much as possible by hand using the cover plate spokes for leverage. DO NOT hammer on the spinner nut.

FIGURE A.20 - COIL MOUNTING

5. Cut and remove only the tie wire holding the free end of the coil. Hook the free end around the rim of the cover plate and secure it by wrapping it around. Cut and remove remaining tie wires.

CAUTION

Always be sure the free end of the coil is securely held while the tie wires are being cut and until the wire is feeding through the drive rolls. Failure to do this will result in "backlashing" of the coil, which may tangle the wire. A tangled coil will not feed and must either be untangled or discarded.

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

6. Be sure the coil is engaged with the spindle brake pin and the release bar on the retaining collar "pops up". The retaining collar must fully engage the retaining groove on the spindle.

TANDEM CRUISER™

A-16

INSTALLATION

A-16

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:

Tools required: 1/4” Hex Key

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.21 - 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 parameter P.19.

FIGURE A.23 - 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.

FIGURE A.22 - WIRE STRAIGHTENER

NOTE: A slight curvature to the wire helps to maintain

good electrical contact inside the contact tip.

TANDEM CRUISER™

A-17

INSTALLATION

A-17

FLUX HOPPER

The flux hopper may be mounted on either a horizontal or vertical tube, or on the wire drive. For the best flow of flux, keep the hose from the hopper to the nozzle as vertical as possible.

FIGURE A.24 - VERTICAL TUBE MOUNTING

FIGURE A.25 - HORIZONTAL TUBE MOUNTING

CABLES

ArcLink Control Cables

ArcLink Control Cables are available in two forms:

• K1543-xx series for most indoor or factory installations.

• K2683-xx series for outdoor use or when the equipment is frequently moved.

ArcLink/LincNet control cables are special high quality cables for digital communication. The cables are copper 5 conductor cable in a SO-type rubber jacket. There is one 20 gauge twisted pair for network communications. This pair has an impedance of approximately 120 ohms and a propagation delay per foot of less than 2.1 nanoseconds. There are two 12 gauge conductors that are used to supply 40VDC to the network. The fifth wire is 18 gauge and is used as an electrode sense lead.

Use of non-standard cables may lead to system shutdowns, poor arc starting and wire feeding problems.

The control cables connect the power source to the wire feeder, and the wire feeder to other wire feeders.

Control cables may be connected end to end to extend their length. Use a maximum of 200 feet (61 m) of control cable between components.

For best operation, do not bundle the control cables with the electrode cables.

FIGURE A.26 - ARCLINK CONTROL CABLES

Pin Function Pin Function

A ArcLink A ArcLink B ArcLink B ArcLink C 67 voltage sense C 67 voltage sense D 40 VDC D 40 VDC E Common E Common

Power Source Wire Feeder

TANDEM CRUISER™

A-18

CABLE CONNECTIONS

FIGURE A.27 REAR AND FRONT VIEW CONNECTIONS

INSTALLATION

A-18

TANDEM CRUISER™

A-19

INSTALLATION

A-19

WELD CABLE SIZES

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

TABLE A.1

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

Amperes

600 600 600 650 650 700 800

800 1000 1000 1200 1200 1500 1500

Percent

Duty Cycle

60 80

100

60 80

100

CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK CABLES

0 to 50 Ft. 50 to 100 Ft. 100 to 150 Ft. 150 to 200 Ft. 200 to 250 Ft.

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

3/0 2-1/0 2-2/0 3-1/0 2-3/0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/0 5-4/0

** Tabled values are for operation at ambient tempera-

tures of 40°C and below. Applications above 40°C may require cables larger than recommended, or cables rated higher than 75°C.

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

3/0 2-1/0 2-2/0 3-1/0 2-3/0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/0 5-4/0

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

4/0 2-1/0 2-3/0 3-1/0 2-3/0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/0 5-4/0

4/0 2-2/0 2-2/0 2-2/0 2-2/0 2-3/0 2-3/0 2-3/0 2-4/0 3-3/0 3-4/0 4-4/0 4-4/0 5-4/0

2-3/0 2-3/0 2-3/0 2-3/0 2-3/0 2-4/0 2-4/0 2-4/0 4-2/0 3-3/0 3-4/0 4-4/0 4-4/0 5-4/0

TANDEM CRUISER™

A-20

INSTALLATION

SYSTEM SET-UP

The Tandem Cruiser is shipped from the factory configured for butt weld joints and horizontal fillet joints. For welding butt welds, assemble the straight nozzle extensions to the nozzles. For welding horizontal fillet welds, assemble the curved nozzle extensions to the nozzles.

FIGURE A.28 - SYSTEM SET-UP

A-20

TANDEM CRUISER™

A-21

INSTALLATION

BUTT JOINTS

Butt Joint, Track Welding

• When operating on K396 track, change the wheel

size in the SET-UP menu to 5.65”.

FIGURE A.29 - BUTT JOINT TRACK WELDING

A-21

FILLET JOINTS

Horizontal Fillet

Uses KP2721-2 curved nozzle extension.

FIGURE A.30 - HORIZONTAL FILLET TRACK WELDING

TANDEM CRUISER™

A-22

INSTALLATION

FIGURE A.31 - FLAT FILLET (TROUGH)

A-22

TANDEM CRUISER™

A-23

To configure the TANDEM CRUISER™ for Flat Fillet welding.

1. Turn off power at the power sources.

2. Remove the lift bail from the mast.

3. Disconnect the lead wire drive and laser cable, lead electrode sense lead and trail wire drive cable.

4. Remove the lead wire drive and trail wire drive from the mounting bracket.

5. Remove the slide assembly from the Cruiser mast. Remove the collar from the mast.

6. Remove the boom and spindle assembly.

FIGURE A.32 - FLAT FILLET 45° (TROUGH)

INSTALLATION

A-23

7. Loosen the 8 bolts as shown, then rotate the upper structure 45°. Reassemble using the bolts that are

1.00” long. (See Figure A.32)

See Step 8

TANDEM FLAT

TANDEM CRUISER™

TILT MAST

A-24

INSTALLATION

8. Reposition the clamp on the slide assembly in a vertical orientation, and reverse the orientation of the wire drive bracket.

FIGURE A.33

A-24

9. Mount the wire drive holders as shown. Use 3 spacers to lower the trail wire drive holder and assemble using the 5/16-18 x 2.50 bolts.

FIGURE A.34

TANDEM CRUISER™

A-25

INSTALLATION

10. Mount the slide assembly to the Tandem Cruiser

base and frame.

FIGURE A.35

A-25

11. Rotate both wire drives 180° by loosening the set

screw, rotating the head, and then tightening the set screw

FIGURE A.36

SET SCREW

TANDEM CRUISER™

A-26

INSTALLATION

12. Swap the position of the wire straightener on both wire drives. Assemble a 3” extension to the trail wire, and the lead wire drive if required.

FIGURE A.37

A-26

LEAD WIRE DRIVE

TRAIL WIRE DRIVE

13. Assemble the wire drives to the brackets. Assemble the nozzles and nozzle extensions.

FIGURE A.38

TANDEM CRUISER™

A-27

INSTALLATION

14. Place the collar and boom assembly on the Tandem Cruiser.

FIGURE A.39

A-27

Important: Position the tube on the boom to prevent both wire drives from contacting the frame when the horizontal slide is adjusted. Position the spindles to prevent the wire coils from touching the frame, slides, or work piece.

FIGURE A.40

TANDEM CRUISER™

A-28

INSTALLATION

13. Assemble the lift bail.

FIGURE A.39

A-28

TANDEM CRUISER™

A-29

INSTALLATION

BASE DIMENSIONS ONLY

A-29

TANDEM CRUISER™

B-1

OPERATION

B-1

SAFETY PRECAUTIONS

WARNING

ELECTRIC SHOCK can kill.

• Turn the input power OFF at the disconnect switch before working on this equipment.

• Do not touch electrically hot parts.

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

• Do not allow parts at electrode potential to touch the tractor frame, cress slides, base flux hopper or other parts.

• Disengaging the clutch does not stop the welding arc.

• Always wear dry insulating gloves.

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

WARNING

MOVING PARTS can injure.

• Do not leave the tractor unattended while it is welding or traveling.

• Electrode reel, drive rolls and wire straightener rolls turn during welding or inching.

• Keep gloved hands away from rotating parts.

• Keep away from pinch points.

• Do not place the tractor on inclined surfaces with the clutch disengaged.

GRAPHIC SYMBOLS

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

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

The serviceability of a product or structure utilizing the welding programs is and must be the sole responsibility of the builder / user. Many variables beyond the control of The Lincoln Electric Company affect the results obtained in applying these programs. These variables include, but are not limited to, welding procedure, plate chemistry and temperature, weldment design, fabrication methods and service requirements. The available range of a welding program may not be suitable for all applications, and the build / user is and must be solely responsible for welding program selection.

PRODUCT DESCRIPTION

The TANDEM CRUISER™ is designed to weld with both the lead and trail arcs. If desired, only the lead arc may be used. It can also be used with just the trail arc when using MANUAL travel.

By default, the lead and trail arc are triggered independently. Change P23 through the set-up menu to have both arcs trigger from the lead start and stop buttons.

Operation of the lead and trail arc is similar. Differences are:

• No travel commands for the trail arc.

• The lead arc has 4 memories, the trail arc has 8 memories.

Wire Feed

TANDEM CRUISER™

B-2

OPERATION

FIGURE B.1 - PENDANT CONTROLS LEAD ARC

B-2

TANDEM C

FIGURE B.2 - PENDANT CONTROLS, TRAIL ARC

CRUISER

TANDEM CRUISER™

B-3

OPERATION

MOVING THE TRACTOR

The tractor will not travel unless the clutch is engaged. To engage the clutch, rotate the handle upwards. To disengage the clutch, rotate the handle to the 3 o’clock position.

The travel speed is adjustable from 7 to 100 in/min (1.78 to 2.54 m/min). From 7 to 20 in/min, the travel speed may be set in 0.5 inch/min increments. Above 20 in/min, the travel speed adjusts at 1.0 inch/min increments.

To drive the tractor without welding:

FIGURE B.3 - ENGAGE THE CLUTCH

B-3

1. Engage the clutch at the rear of the tractor.

FIGURE B.4 - TRAVEL DIRECTION

2. Select either forward or reverse travel on the pendant.

FIGURE B.5 - JOB BUTTON, TOGGLE SWITCH

3. Press and hold the jog button, or place the toggle switch in the MANUAL travel position.

TANDEM CRUISER™

B-4

OPERATION

B-4

LASER POINTER

CAUTION

• Class II laser radiation present. Do not stare into laser beam or view directly with optical instruments.

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

Laser pointer is used to aid in guiding the TANDEM CRUISER™. The laser pointer mounts to the nozzle or

nozzle extensions. Align the wire in the joint, then position the laser pointer approximately 3” (76mm) in front of the wire, also pointing into the joint.

Turn the laser off when not welding.

TOUCH SENSE

WARNING

ELECTRIC SHOCK can kill.

• If the Touch Sense is enabled, the Power Source output is ON as long as the Feed Forward button is held. Avoid touching any portion of the weld circuit while feeding.

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

The touch sense option, when enabled, allows the operator to feed the wire forward until it touches the workpiece. When contact to the work is made, the wire will stop.

POWER-UP SEQUENCE

When power is first applied to the TANDEM CRUISER™ the MODE SELECT Display reads “TANDEM CRUISER™ Initializing...”. Once the Power

Wave AC/DC has initialized (20 to 60 seconds) a “lamp test” is performed.

• All discrete LED’s, seven segment displays and alpha numeric displays will be turned ON for 2 seconds.

• After 2 seconds all displays are turned OFF again and the MSP Display will show:

FIGURE B.6 - MSP DISPLAY

After initialization is complete, the MSP Display will show the weld mode. The upper displays will show the parameters that were selected when the machine was last powered down and the WELD MODE Indicator will be ON.

FIGURE B.7 - WELD MODE INDICATOR

If the touch sense option is disabled, the wire is “cold” during the Feed Forward time. It will not stop when it touches the work.

(See P.15 in the Set-Up Features Menu, this Section)

TANDEM CRUISER™

B-5

OPERATION

B-5

WIRE FEEDER SETUP

WARNING

ELECTRIC SHOCK can kill.

• Prior to inserting the wire, disable “Touch Sense” (P.15 in the Setup Menu).

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

Use the FEED FORWARD pushbutton to insert wire into the feed mechanism.

While pressing either the FEED FORWARD or FEED REVERSE pushbutton the MSP Display will read as shown and the preset wire feed speed will be displayed on the left (AMPS/WFS) display.

FIGURE B.8 - FEED SPEED DISPLAY

CHANGING AND SETTING WELD MODES

To select a weld mode, press the WELD MODE SELECTOR button until the WELD MODE indicator comes ON (it may already be lit by default at power up). Turn the control knob to select the desired mode. After about 1 second, the parameters for the new mode will be displayed. These parameters can be adjusted with the control knobs below each display.

FIGURE B.10 - SETTING WELD MODES

The feed speed can be changed by adjusting the control knob below the display while pressing either button. Use FEED REVERSE to retract the wire from the feed mechanism. FEED FORWARD feeds the wire downward toward the work piece.

The TANDEM CRUISER™ has an option in the Setup

Menu (P.15) to enable the “Touch Sense” circuitry. See the Setup Menu. When P.15 is enabled and the FEED FORWARD button is pressed, the MSP Display will read:

FIGURE B.9 - HOT FEED FEATURE

NOTE: CC Modes will show AMPS in the upper left

display. CV Modes will show wire feed speed and the WFS indicator will be lit.

FREQUENCY

Press the WELD MODE selector until the FREQUENCY/ BALANCE indicator comes ON and the MSP Display reads “Frequency”. If the selected mode allows for frequency adjustment, the Control Knob can be used to select the desired frequency between 10 and 100hz.

FIGURE B.11 - FREQUENCY

WARNING: This “Hot Feed” feature enables the output of the power source and there is voltage on the wire while feeding down. Avoid touching any exposed parts as defined in the SAFETY PRECAU-

TIONS.

TANDEM CRUISER™

Frequency adjustment can be used to fine tune stability of imbalanced waveforms and multiple arc system.

B-6

OPERATION

B-6

BALANCE ADJUST

Press the WELD MODE selector until the MSP Display reads “Balance”. If the selected mode allows for balance adjustment, the Control Knob can be used to select the desired wave balance through a range of 25% to 75%.

FIGURE B.12 - BALANCE ADJUST

DECREASED BALANCE

More Penetration Less Desposition

NEUTRAL BALANCE

Adjusting the Balance (the ratio between Positive and Negative half cycle ‘on time’) changes the deposition for more efficient welding.

INCREASED BALANCE

Less Penetration More Desposition

OFFSET ADJUST

Press the WELD MODE selector until the MSP Display reads “Offset”. If the selected mode allows for offset adjustment, the Control Knob can be used to select the desired offset. The amount of offset allowed is determined by the selected weld mode.

FIGURE B.13 - OFFSET ADJUST

POSITIVE OFFSET

More Penetration Less Desposition

NEUTRAL OFFSET

NEGATIVE OFFSET

Less Penetration More Desposition

WELD SEQUENCE (See Figure B.14)

Independent control of the Positive and Negative cycles

allows for more precise control of penetration and deposition. The weld sequence defines the weld procedure from beginning to end. All adjustments are made through the user interface.

They control run-in (speed at which the wire approaches the workpiece) and provide the power to establish the arc. Typically output

START OPTIONS

levels are increased, and WFS is reduced during the strike portion of the weld sequence.

The delay, strike, start and upslope parameters are used at the beginning of the weld sequence to establish a stable arc and provide a smooth transition to the welding parameters. They are described in the following:

• ARC DELAY inhibits the wire feed for up to 5 seconds to provide

an accurate weld start point. Typically used in multi-arc systems.

• START values allow the arc to become stabilized once it is estab-

lished. Extended start times or improperly set parameters can result in poor starting.

• UPSLOPE TIME determines the amount of time it takes to ramp

from the start parameters to the weld parameters. The transition is linear and may be up or down depending on the relationship

• STRIKE settings are valid from the beginning of the sequence

between the start and weld settings.

(Start) until the arc is established.

FIGURE B.14 - WELD SEQUENCE

TANDEM CRUISER™

B-7

OPERATION

START OPTIONS OPERATION

Pressing the Arc Start/End Options pushbutton will illuminate the START OPTIONS LED and the Arc Delay Time parameter will show on the MSP Display.

FIGURE B.15 - START OPTIONS OPERATION

Use the Mode Select Panel Control to select the desired delay time. Press the Weld Mode Selector to exit the Start parameters. Repeated pressing of the Arc Start/End Options pushbutton will scroll through the parameters. Turning the Mode Select Panel Control, while on a parameter will change its value. When a Start Option is set to a value other than OFF, the START OPTIONS LED will blink synchronous with the WFS or Amps and/or the Volts LED located on the Dual Display Panel prompting the user to enter these parameters. The parameters that can be set by the user in the START OPTIONS will be as follows:

B-7

• RESTRIKE TIME determines how long the system

will try to re-establish the arc in the event of a poor start or if the arc goes out for any reason (short circuit or open circuit). During restrike, the WFS and outputs are driven in an attempt to re-establish the arc.

• A restrike time of 1 to 2 seconds is sufficient in most applications.

• A restrike time of 0 seconds allows the restrike function to continue indefinitely.

END OPTIONS OPERATION

Pressing the Arc Start/End Options pushbutton after scrolling through the Start Options will illuminate the END OPTIONS LED and the Downslope Time parameter will show on the MSP Display.

FIGURE B.16 - END OPTIONS OPERATION

ARC DELAY TIME STRIKE WFS STRIKE TIME START WFS/AMPS START VOLTS START TIME UPSLOPE TIME

END OPTIONS

The downslope, crater, and burnback parameters are used to define the end of the weld sequence. They are defined in the following:

• DOWNSLOPE determines the amount of time it

takes to ramp from the weld parameters to the crater parameters. The transition is linear and may be up or down depending on the relationship between the weld and crater settings.

• CRATER parameters are typically used to fill the

crater at the end of the weld and include both time and output settings.

• BURNBACK defines the amount of time the output

remains on after the wire has stopped. This feature is used to prevent the wire from sticking in the weld puddle and to condition the end of the wire for the next weld. A burnback time of 0.4 second is sufficient in most applications.

Use the Mode Select Panel Control to select the desired delay time. Press the Weld Mode Selector to exit the End parameters. Repeated pressing of the Arc Start/End Options pushbutton will toggle through the parameters. Turning the Mode Select Panel Control while on a parameter will change its value. When the Crater Time is set to a value other than OFF, the END OPTIONS LED will blink synchronous with the WFS or Amps LED (depending on CC or CV Weld Modes) and with the Volts LED located on the Dual Display Panel prompting the user to enter these parameters. The parameters that can be set by the user in the END OPTIONS will be as follows:

DOWNSLOPE TIME CRATER WFS/AMPS CRATER VOLTS CRATER TIME BURNBACK TIME RESTRIKE TIME

TANDEM CRUISER™

B-8

OPERATION

B-8

MEMORIES

The TANDEM CRUISER™ has 4 memories. Each

memory stores :

• Weld Mode

• Amperage (or WFS)

• Voltage

• Travel Speed

• Frequency

• Balance

• DC Offset

• Arc Start Options

• Arc End Options

FIGURE B.17 - MEMORIES

LIMITS

Limits allow the welder to adjust the welding procedure only within a defined range.

Each memory may have a different set of limits. For example, memory 1 may limit the WFS to 100 through 120 in/min, and memory 2 may limit the WFS to 140 through 160 in/min, while memory 3 may have no WFS limits.

Parameters are constrained by machine limits, or by setting memory limits. When memory limits are enabled, the parameter will flash whenever an attempt is made to exceed the memory limit value. The parameter will not flash if an attempt is made to exceed the machine limit.

FIGURE B.18 - LIMITS

Limits may be set for:

Wire Feed Speed Voltage Amperage Travel Speed Frequency Balance DC Offset Arc Start Options Arc End Options

Recall a memory with memory buttons

To recall a memory, press one of the four memory buttons. The memory is recalled when the button is released. Do not hold the button for more than two seconds.

Save a memory with memory buttons

To save a memory, press and hold the desired memory button for two seconds. When the button is initially pressed, the corresponding LED will illuminate. After two seconds, the LED will turn off. Do not hold the button for more than 5 seconds when saving a user memory.

Note that memories may be locked in the set-up menu to prevent accidental overwrite of the memories. If an attempt is made to save a memory when memory saving is locked, the message "Memory save is Disabled!" will appear briefly in the MSP4 display.

Weld modes cannot be selected through the Limits Setup menu, and must be chosen and saved to memory before entering the Limits Setup Menu.

TANDEM CRUISER™

B-9

OPERATION

To set limits, press the desired memory button 1-8 and hold for 5 seconds. Release the memory button when the LED begins to blink rapidly and the MSP4 displays "Memory X Set Limits" as shown below.

FIGURE B.19 - MEMORY SET LIMITS

FIGURE B.20 - MEMORY SET LIMIT DISPLAY

HIGH

LIMIT

MEMO R VALUE

LOW LIMIT

B-9

The Limits Setup menu shows a list of all parameters available for the weld mode stored in the memory chosen

To lock a parameter to a specific value that cannot be changed, set the high and low limits to the same value.

The memory value must always be less than or equal to the high limit, and greater than or equal to the low limit.

After setting limits, press the memory button with the flashing LED. The MSP4 will ask to save or discard the limit changes just made. Press the left MSP4 for button (YES) to save and enable the limits and exit. Press the right MSP4 button (NO) to exit and leave limits unchanged.

ENABLING/DISABLING LIMITS

FIGURE B.22 - ENABLING LIMITS

PARAME TER

NAME

SETUP will illuminate on the MSP4 panel and the display will show the following:

Four items show on the MSP4 panel.

• Memory Value

• High Limit

• Low Limit

• Parameter Name

One of these items will flash to indicate which item will change when the MSP4 encoder is rotated. Press the right button on the MSP4 panel to select the item to change.

FIGURE B.21 - MSP4 PANEL

Limits for each memory may be enabled or disabled by pressing and holding the appropriate memory button for 10 seconds. Release the memory button when the MSP4 display shows the following:

FIGURE B.23 - ENABLE/DISABLE LIMITS

TANDEM CRUISER™

B-10

OPERATION

B-10

SETUP will light and the MSP4 displays the following:

FIGURE B.24 - ENABLE/DISABLE LIMITS

DISPLAY

Press the left MSP4 button (YES) to enable limits or the right MSP4 button (NO) to disable limits. Disabling limits does not change any limits values that may have been previously set.

DIP SWITCHES

The DIP switches on the pc boards are set at the factory and do not require adjustment.

Travel Board DIP Switches Lead Wire Drive Board DIP Switches

All the DIP switches are in the OFF position. All the DIP switches are in the OFF position.

ON OFF

1 2 3 4 5 6 7 8

Trail Wire Drive Board DIP Switches

All the DIP switches are in the OFF position.

1 2 3 4 5 6 7 8

8 7 6 5 4 3 2 1

OFF ON

OFF

TANDEM CRUISER™

B-11

OPERATION

B-11

SET-UP FEATURES MENU

The Setup Menu gives access to the set-up configuration. Stored in the set-up configuration are user parameters that generally need to be set only at installation. The parameters are grouped as follows:

PARAMETER

P.1 through P.99 P.101 through P.199 P.501 through P.599

To access the set-up menu, press the right and left buttons of the MSP4 panel simultaneously. Note that the setup menu cannot be accessed if the system is welding, or if there is a fault (The status LED is not solid green).

Change the value of the blinking parameter by rotating the SET knob.

To exit the set-up menu at any time, press the right and left buttons of the MSP4 panel simultaneously. Alternately, 1 minute of inactivity will also exit the set-up menu.

Secured Parameters (only accessible with Weld Manager)

Unsecured Parameters (always adjustable)

Diagnostic Parameters (always read only)

DEFINITION

PARAMETER DEFINITION

P.0 P.1

P.2

Press the left button to exit the set-up menu.

Wire Feed Speed Units

This option selects which units to use for displaying wire feed speed. English = inches/minute wire feed speed units (default). Metric = meters/minute wire feed speed units.

Arc Display Mode

This option selects what value will be shown on the upper left display while welding. Amps = The left display shows Amperage while welding (default). WFS = The left display shows Wire Feed Speed while welding.

P.3

Display Options

This setup parameter was previously named "Display Energy" If the previous software revision had this parameter set to display energy, that

selection will remain. This option selects the information displayed on the alphanumeric displays

while welding. Not all P.3 selections will be available on all machines. In order for each selection to be included in the list, the power source must support that feature. A software update of the power source may be needed to include the features.

Standard Display = The lower displays will continue to show preset information during and after a weld (default). Show Energy = Energy is displayed, along with time in HH:MM:SS format. Show Weld Score = The accumulative weld score result is shown.

TANDEM CRUISER™

B-12

OPERATION

PARAMETER DEFINITION

Tractor Wheel Size

Press the Right Button to enter the option and rotate the Control Knob to select Wheel Size. Press the Right Button to enter the selected option. Rotate the Control Knob to select the desired value. After selecting the value, press the Left Button to save the value and back out to select another option. Rotate the Control Knob to make another selection, or press the Left Button to exit this option. When the value is set to 5.65 ipm, the display will read "Track" indicating the track wheels are being used.

Tractor Travel Speed

Press the Right Button to enter the option and rotate the Control Knob to select Travel Speed. Press the Right Button to enter the selected option. Rotate the Control Knob to select the desired value. After selecting the value, press the Left Button to save the value and back out to select another option. Rotate the Control Knob to make another selection, or press the Left Button to exit this

P.12

option.

Travel Carriage Start/Stop - Travel Starts

This option allows the adjustment of the start and end travel options for a travel carriage. Press the Right Button to enter the option and rotate the Control Knob to select either starting or ending options. Press the Right Button to enter the selected option. Rotate the Control Knob to select the desired function. After selecting the function, press the Left Button to save the function and back out to select another option. Rotate the Control Knob to make another selection, or press the Left Button to exit this option.

B-12

Travel Carriage Start/Stop - Travel Ends

TANDEM CRUISER™

B-13

OPERATION

PARAMETER DEFINITION

B-13

P.14

P.15

P.18

Reset Consumable Weight

Use this option to reset the initial weight of the consumable package. Press the Right Button to reset the consumable weight. This option will only appear with systems using Production Monitoring.

Cold-Inch Touch Sense Option

This option allows enabling or disabling touch sense when feeding wire forward. Disabled = Touch sensing is disabled when feeding the wire forward (default). Enabled = Touch sensing is active when feeding the wire forward.

When enabled and feeding wire forward, the wire is electrically "hot" and waiting to short to the plate. When a short occurs, the wire feed automatically stops and the flux hopper relay is activated until the feed forward button is released.

Wire Drive Gear Ratio.

This option selects the Wire Drive Gear Ratio that will be used. The possible selectable values are read from the Wire Drive on startup. For semi-automatic systems, if the feedhead board has dip switches, this option does not appear in the menu. Gear ratio can be selected using the dip switches.

Note: Changing this value will cause the system to reset.

P.19

P.21

P.23

Wire Drive Direction

This option selects the direction that the Wire Drive will run in. This option is useful since the Tractor's WD head can be rotated to "point" in different directions.

Shutdown 2 Function Select

This option allows selection of the Shutdown 2 input function on the control box. Normal Shutdown = The Shutdown 2 input functions as a standard shutdown input that locks out all input buttons (default) Output Disable = The Shutdown 2 input functions as a machine output lockout to disable the welding circuit but still allow cold feeding of the wire.

Trigger Fan-Out

For Sub-Arc Lead Arc machines only. Allows the Lead Arc User Interface to control all machine triggers in a multi-arc system. No = Only the machine connected to the User Interface can be triggered on and off (default). Yes = All machines in the system can be triggered on and off simultaneously.

TANDEM CRUISER™

B-14

OPERATION

PARAMETER DEFINITION

B-14

P.80

P.99

P.100

P.101

Sense from Studs.

Use this option for diagnostic purposes only. When power is cycled, this option is automatically reset to False. False = Voltage sensing is automatically determined by the selected weld mode and other machine settings (default). True = Voltage sensing is forced to "studs".

Show Test Modes

Most power sources contain weld modes used for calibration and test purposes. By default, the machine does not include test weld modes in the list of weld modes that are available to the operator. To manually select a test weld mode, set this option to "Yes". When the power source is turned off and back on again, the test modes will no longer appear in the mode list. Test weld modes typically require the machine output to be connected to a grid load and cannot be used for welding.

View Diagnostics

Diagnostics are only used for servicing or troubleshooting the Power Wave system. Select "Yes" to access the diagnostic options in the menu. Additional parameters will now appear in the setup menu (P.101, P.102, etc).

Event Logs

Used for viewing all the system event logs. Press the Right Button to enter the option. Rotate Control Knob to select the desired event log to read. Press the Right Button again to enter the selected log. Rotating the Control Knob will scroll through the event log, displaying the log index number, event code and some other data. Press the Left Button to back out to select another log. Press the Left Button again to exit this option.

P.102

P.103

P.104

Fatal Logs

Used for viewing all the system fatal logs. Press the Right Button to enter the option. Rotate Control Knob to select the desired fatal log to read. Press the Right Button again to enter that log. Rotating the Control Knob will scroll through the log, displaying the log index number and fatal code. Press the Left Button to back out to select another log. Press the Left Button again to exit this option.

Software Version

Used for viewing the software versions for each board in the system. Press the Right Button to enter the option. Rotate Control Knob to select the desired board to read. Press the Right Button again to read the firmware version. Press the Left Button to back out to select another board. Rotate the Control Knob to select another board, or press the Left Button to exit this option.

Hardware Version

Used for viewing the hardware version for each board in the system. Press the Right Button to enter the option. Rotate Control Knob to select the desired board to read. Press the Right Button again to read the hardware version. Press the Left Button to back out to select another board. Press the Left Button again to exit this option.

TANDEM CRUISER™

B-15

OPERATION

PARAMETER DEFINITION

B-15

P.105

P.106

P.107

P.500

Welding Software

Used for viewing the Weld Set in the Power Source. Press the Right Button to read the Weld Set version. Press the Left Button to back out and exit this option.

Ethernet IP Address

Used for viewing the IP address of Ethernet compatible equipment. Press the Right Button to read the IP Address. Press the Left Button to back out and exit this option. The IP address cannot be changed using this option.

Power Source

Used for viewing the type of power source the feeder is connected to. Press the Right Button to identify the power source as either LincNet or ArcLink. Press the Left Button to back out and exit this option.

View Lockout Parameters

Originally used to prevent inadvertent changes of secure setup parameters, P.500 was previously used as a gateway to these parameters. Presently, this option does not exist in any setup menu.

TANDEM CRUISER™

C-1

ACCESSORIES

OPTIONAL KITS AND ACCESSORIES

DRIVE ROLL AND GUIDE TUBE KITS

ITEM K# DESCRIPTION

1 K1733-5 Wire Straightener

KP1899-1 Drive Roll/ Guide Tube Kit, 3/32-7/32

2 KP1899-2 Drive Roll/ Guide Tube Kit, 1/16, 5/64, 3/32

KP1899-3 Drive Roll/ Guide Tube Kit, 035, 045, 052

KP1899-4 Drive Roll/ Guide Tube Kit, 045, 052 cored

K231-5/64 Contact Nozzle Assembly, 5/64 (2.0mm)

K231-3/32 Contact Nozzle Assembly, 3/32 (2.4mm)

3 K231-1/8 Contact Nozzle Assembly, 1/8 (3.2mm)

K231-5/32 Contact Nozzle Assembly, 5/32 (4.0mm)

K231-3/16 Contact Nozzle Assembly, 3/16 (4.8mm)

K231-7/32 Contact Nozzle Assembly, 7/32 (5.6mm)

4 KP2721-1 Nozzle Extension, 5”

KP2721-2 Nozzle Extension, 45º Curved

T12929 Flux Hose Clamp

T11807 Nozzle Extension Insulator

KP1962-3B1 Contact Tip, 3/32

KP1962-1B1 Contact Tip, 1/8

5 KP1962-4B1 Contact Tip, 5/32

KP1962-2B1 Contact Tip, 3/16

KP1962-5B1 Contact Tip, 7/32

K148A or Positive Contact Nozzle Assembly

K148B

K285 Concentric Flux Cone Assembly to use with

K148A or K148B

C-1

K231 nozzles are rated up to 600 Amps

K148 nozzles are rated up to 1000 Amps

TANDEM CRUISER™

C-2

ACCESSORIES

C-2

K3090-1 Tube and clamp kit Includes: one 30”

aluminum splined tube; one 15” aluminum splined tube; one 30” steel tube; 8 clamp assemblies with keys; 2 outrigger assemblies; hardware.

K3089-1 Cross Slide Assembly Includes: two slides with 4

inches of travel. (1 cross slide assembly included with each tractor.)

K1733-5 Wire Straightener Includes: A three roll wire

straightener with adjustable pressure. (1 included with each tractor)

K396 Track Section Includes: a single section

of 70 in (1.8m) of track.

K3070-1 Tiny Twin Kit for the

K1543-xx ArcLink Control Cable Includes: 5 pin to 5 pin

K2683-xx ArcLink Control Cable,

K1504-1 60 lb Coil Adapter Includes: one coil adapter

tractor

Heavy Duty

Includes: 2 rolls, 57:1 gears.

tractor to power source control cable. Cables may be connected end-to-end to make a longer cable. Connectors are black anodized aluminum. Includes: 5 pin to 5 pin tractor to power source control cable. Cables may be connected end-to-end to make a longer cable. Female connector is a brass spin nut. Male connector is made from stainless.

for use with 2” spindles.

spindle, drive

Accessories Included with the TANDEM CRUISER™:

Conduit Tubing, 5 feet (1.5 m) 5/32” 600 Amp contact nozzle assembly 5/32” contact tip Nozzle extension, 5 inches long (127 mm) Nozzle extension insulator Nozzle extension, 45° Curved Flux tubing Flux Hose Clamps Wire Reel Assembly Wheels for track operation Front and Rear outriggers Wire Reel Enclosure

Does not include a control cable.

TANDEM CRUISER™

D-1

MAINTENANCE

D-1

SAFETY PRECAUTION

WARNING

ELECTRIC SHOCK can kill.

• Do not touch electrically live parts such as output terminals or internal wiring.

• When inching with gun trigger, electrode and drive mechanism are “hot” to work and ground and could remain energized several seconds after the gun trigger is released.

• Turn OFF input power at welding power source before installation or changing drive roll and/or guide tubes.

• Welding power source must be connected to system ground per the National Electrical Code or any applicable local codes.

• Only qualified personnel should perform maintenance work.

Observe all additional Safety Guidelines detailed throughout this manual.

ROUTINE MAINTENANCE

• Check the weld cables and control cables for cuts

• Blow out the slides.

PERIODIC MAINTENANCE

• Every 6 months, check wire drive motor brushes. Replace them if they are less than 1/4” (6mm) long.

• Every 6 months, lubricate the front axles.

• Every 12 months, inspect the wire drive gearbox and coat the gear teeth with moly-disulfide grease. DO NOT use graphite grease.

CALIBRATION SPECIFICATION

Wire Feed Speed

There is no wire feed speed calibration adjustment for the Cruiser.

To validate wire feed speed:

• Turn off Touch Sensing with P15 in the Set-Up Menu.

• Adjust the wire feed speed to 100 in/min (2.54 m/min)

• Inch the wire down and measure the actual wire feed speed with a calibrated wire feed speed tachometer. (K283)

• The measured wire feed speed should be within 98 to 102 in/min (2.49 to 2.59 m/min) [±2%]

Travel Speed

When using the K396 track, the P12 Wheel size parameter should be set to 5.65 in.

To validate and calibrate travel speed:

• Set the Travel Speed to 30 in/min (7.6 m/min)

• Engage the clutch and use the manual travel speed switch to travel the tractor for 60 seconds.

• Measure the distance traveled.

• Adjust P12 Wheel Size in the Set-up menu as follows

Example: Set travel speed = 30 in/min

Actual travel speed = 29 in/min Existing P12 wheel size = 6.00 in

New P12 Wheel Size =

6.00in. 30in.

x 29in. = 5.80in.

TANDEM CRUISER™

E-1

TROUBLESHOOTING

HOW TO USE TROUBLESHOOTING GUIDE

WARNING

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

__________________________________________________________________________

E-1

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

Step 1. LOCATE PROBLEM (SYMPTOM).

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

Step 2. POSSIBLE CAUSE.

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

Step 3. RECOMMENDED COURSE OF ACTION

This column provides a course of action for the Possible Cause, generally it states to contact your local Lincoln Authorized Field Service Facility.

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

CAUTION

If for any reason you do not understand the test procedures or are unable to perform the tests/repairs safely, contact your Local Lincoln Authorized Field Service Facility for technical troubleshooting assistance before you proceed.

TANDEM CRUISER™

E-2

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE

CAUSE

E-2

RECOMMENDED

COURSE OF ACTION

A wire drive motor overload occurs. (Error 81)

A travel motor overload occurs. (Error 81)

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

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

3. Do not use more idle roll pressure than necessary. Check for proper setting.

4. Verify that the wire pulls easily through the take-off arm bushing and conduit.

5. Check that the wire straightener is not exerting excessive load on the wire.

6. If using 57:1 gear ratio, switch to 95:1 or 142:1

7. If using 95:1 gear ratio, switch to 142:1.

1. Verify the Cruiser rolls freely when the clutch is disengaged.

2. Check for excessive loads caused by dragging long cables.

3. When using the outriggers to steer the Cruiser, set the offset between the front and rear outriggers at 0.5” (12.7mm).

4. Verify the front wheels are perfectly straight.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

Error 215

Frequency and Balance do not appear on the display.

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

1. Check that all of the DIP switches on the travel drive board and the wire drive board are in the OFF position.

1. Verify a AC square wave weld

mode has been selected.

1. Verify the power source is

turned on.

2. Verify the circuit breaker for the

wire feeder power (on the power source) has not tripped.

3. Verify power is being supplied

to the wire feeder.

4. Check that any equipment con-

nected to the external shut-off inputs has not faulted.

CAUTION

TANDEM CRUISER™

E-3

Observe all Safety Guidelines detailed throughout this manual

PROBLEMS

(SYMPTOMS)

TROUBLESHOOTING

POSSIBLE AREAS OF MISADJUSTMENTS(S)

E-3

RECOMMENDED

COURSE OF ACTION

The wire drive feeds wire in the wrong direction.

The wire drive speed is incorrect.

When the welding arc is activated, the drive rolls spin but no arc is present.

1. Change P19 wire feed direction parameter in the Set-Up menu.

1. Verify the gear ratio of the wire drive and P18 match.

1. Check all electrode and work connections.

If all recommended possible areas of misadjustment have been checked and the problem persists,

Contact your local Lincoln Authorized Field Service Facility.

CAUTION

TANDEM CRUISER™

F-1

WIRING DIAGRAM

F-1

TANDEM CRUISER™

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

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

F-2

WIRING DIAGRAM

F-2

TANDEM CRUISER™

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

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

NOTES

TANDEM CRUISER™

NOTES

TANDEM CRUISER™

WARNING

Spanish

AVISO DE

PRECAUCION

 Do not touch electrically live parts or

electrode with skin or wet clothing.

 Insulate yourself from work and

ground.

 No toque las partes o los electrodos

bajo carga con la piel o ropa mojada.

 Aislese del trabajo y de la tierra.

 Keep flammable materials away.

 Mantenga el material combustible

fuera del área de trabajo.

 Wear eye, ear and body protection.

 Protéjase los ojos, los oídos y el

cuerpo.

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

 Ne laissez ni la peau ni des vête-

ments mouillés entrer en contact avec des pièces sous tension.

 Isolez-vous du travail et de la terre.

 Berühren Sie keine stromführenden

Teile oder Elektroden mit Ihrem Körper oder feuchter Kleidung!

 Isolieren Sie sich von den

Elektroden und dem Erdboden!

 Não toque partes elétricas e elec-

trodos com a pele ou roupa molhada.

 Isole-se da peça e terra.

 Gardez à l’écart de tout matériel

inflammable.

 Entfernen Sie brennbarres Material!

 Mantenha inflamáveis bem guarda-

dos.

 Protégez vos yeux, vos oreilles et

votre corps.

 Tragen Sie Augen-, Ohren- und Kör-

perschutz!

 Use proteção para a vista, ouvido e

corpo.

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

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

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

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

 Keep your head out of fumes.  Use ventilation or exhaust to

remove fumes from breathing zone.

 Turn power off before servicing.

 Do not operate with panel open or

guards off.

WARNING

 Los humos fuera de la zona de res-

piración.

 Mantenga la cabeza fuera de los

humos. Utilice ventilación o aspiración para gases.

 Gardez la tête à l’écart des fumées.  Utilisez un ventilateur ou un aspira-

teur pour ôter les fumées des zones de travail.

 Vermeiden Sie das Einatmen von

Schweibrauch!

 Sorgen Sie für gute Be- und

Entlüftung des Arbeitsplatzes!

 Mantenha seu rosto da fumaça.  Use ventilação e exhaustão para

remover fumo da zona respiratória.

 Desconectar el cable de ali-

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

 Débranchez le courant avant l’entre-

tien.

 Strom vor Wartungsarbeiten

abschalten! (Netzstrom völlig öffnen; Maschine anhalten!)

 Não opere com as tampas removidas.  Desligue a corrente antes de fazer

serviço.

 Não toque as partes elétricas nuas.

 No operar con panel abierto o

guardas quitadas.

 N’opérez pas avec les panneaux

ouverts ou avec les dispositifs de protection enlevés.

 Anlage nie ohne Schutzgehäuse

oder Innenschutzverkleidung in Betrieb setzen!

 Mantenha-se afastado das partes

moventes.

 Não opere com os paineis abertos

ou guardas removidas.

Spanish

AVISO DE

PRECAUCION

French

ATTENTION

German

WARNUNG

Portuguese

ATENÇÃO

Japanese

Chinese

Korean

Arabic

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

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Cleveland, Ohio 44117-1199 U.S.A. TEL: 216.481.8100 FAX: 216.486.1751 WEB SITE: www.lincolnelectric.com

Lincoln Electric IM10114 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual