Operator’s Manual
CRUISER
™
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
IM10098-B | Issue D ate Sept-14
© Lincoln Global, Inc. All Rights Reserved.
For use with machines having Code Numbers:
11767, 11910, 11947
Save for future reference
Date Purchased
Code: (ex: 10859)
Serial: (ex: U1060512345)
THANK YOU FOR SELECTING
A QUALITY PRODUCT BY
LINCOLN ELEC TRIC.
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.
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.
This statement appears where the information must be followed
exactly to avoid serious personal injury or loss of life.
This statement appears where the information must be followed
to avoid minor personal injury or damage to this equipment.
KEEP YOUR HEAD OUT OF THE FUMES.
DON’T get too close to the arc.
Use corrective lenses if necessary
to stay a reasonable distance
away from the arc.
READ and obey the Safety Data
Sheet (SDS) and the warning label
that appears on all containers of
welding materials.
USE ENOUGH VENTILATION or
exhaust at the arc, or both, to
keep the fumes and gases from
your breathing zone and the general area.
IN A LARGE ROOM OR OUTDOORS, natural ventilation may be
adequate if you keep your head out of the fumes (See below).
USE NATURAL DRAFTS or fans to keep the fumes away
from your face.
If you de velop unusual symptoms, see your supervisor.
Perhaps the welding atmosphere and ventilation system
should be checked.
WEAR CORRECT EYE, EAR &
BODY PROTECTION
PROTECT your eyes and face with welding helmet
properly fitted and with proper grade of filter plate
(See ANSI Z49.1).
PROTECT your body from welding spatter and arc
flash with protective clothing including woolen
clothing, flame-proof apron and gloves, leather
leggings, and high boots.
PROTECT others from splatter, flash, and glare
with protective screens or barriers.
IN SOME AREAS, protection from noise may be appropriate.
BE SURE protective equipment is in good condition.
Also, wear safety glasses in work area
AT ALL TIMES.
SPECIAL SITUATIONS
DO NOT WELD OR CUT containers or materials which previously
had been in contact with hazardous substances unless they are
properly cleaned. This is extremely dangerous.
DO NOT WELD OR CUT painted or plated parts unless special
precautions with ventilation have been taken. They can release
highly toxic fumes or gases.
Additional precautionary measures
PROTECT compressed gas cylinders from excessive heat,
mechanical shocks, and arcs; fasten cylinders so they cannot fall.
BE SURE cylinders are never grounded or part of an
electrical circuit.
REMOVE all potential fire hazards from welding area.
ALWAYS HAVE FIRE FIGHTING EQUIPMENT READY FOR
IMMEDIATE USE AND KNOW HOW TO USE IT.
WARNING
CAUTION
Safety 01 of 04 - 5/16/2018
SECTION A:
WARNINGS
CALIFORNIA PROPOSITION 65 WARNINGS
WARNING: Breathing diesel engine exhaust
exposes you to chemicals known to the State
of California to cause cancer and birth defects,
or other reproductive harm.
• Always start and operate the engine in a
well-ventilated area.
• If in an exposed area, vent the exhaust to the outside.
• Do not modify or tamper with the exhaust system.
• Do not idle the engine except as necessary.
For more information go to
www.P65 warnings.ca.gov/diesel
WARNING: This product, when used for welding or
cutting, produces fumes or gases which contain
chemicals known to the State of California to cause
birth defects and, in some cases, cancer. (California
Health & Safety Code § 25249.5 et seq.)
WARNING: Cancer and Reproductive Harm
www.P65warnings.ca.gov
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.
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.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.
1.d. Keep all equipment safety guards, covers
and devices in position 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. Always use the greatest care when
working near moving parts.
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.
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.
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 pos-
sible to the area being welded.
2.d.5. Do not work next to welding power source.
SAFETY
Safety 02 of 04 - 5/16/2018
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 It ems 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
hardfacing (see instructions on container or SDS)
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
unless exposure assessments indicate otherwise.
In confined spaces or in some circumstances,
outdoors, a respirator may also 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 vapors
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.
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
Safety Data Sheet (SDS) and follow your employer’s safety
practices. SDS forms are available from your welding
distributor or from the manufacturer.
5.f. Also see item 1.b.
SAFETY
Safety 03 of 04 - 5/16/2018
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 the welding sparks
from starting a fire. 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 though they have been
“cleaned”. For information, purchase “Recommended Safe
Practices for the Preparation for Welding and Cutting of
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.
6.f. Sparks and spatter are thrown from the welding arc. Wear oil 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.
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.
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, 14501 George Carter Way
Chantilly, VA 20151.
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.
Refer to
http://www.lincolnelectric.com/safety
for additional safety information.
SAFETY
Safety 04 of 04 - 5/16/2018
Page
Installation.......................................................................................................................Section A
Technical Specifications.......................................................................................................A-1
General Physical Description ...............................................................................................A-2
General Functional Description ............................................................................................A-2
Recommended Processes ...................................................................................................A-2
Process Limitations ..............................................................................................................A-2
Equipment Limitations ..........................................................................................................A-2
Recommended Power Sources............................................................................................A-2
Design Features ...................................................................................................................A-2
Location................................................................................................................................A-3
General Assembly ................................................................................................................A-4
Outriggers, Manual Steering Mechanism, Assembly ...........................................................A-5
Manual Steering Mechanism, Adjustment............................................................................A-6
Cross Slide ...........................................................................................................................A-6
Wire Reel Spindle.................................................................................................................A-6
Wire Wheel Enclosure ..................................................................................................A-7, A-8
Take-Off Arm........................................................................................................................A-9
Wire Straightener Adjustment ............................................................................................A-10
Feedplate Rotation .............................................................................................................A-10
Flux Hopper, Cables...........................................................................................................A-11
Cable Connections, Weld Cable Sizes...............................................................................A-12
System Set-Up ...................................................................................................................A-13
Butt Joints ..................................................................................................................A-14/A-17
Fillet Joints.................................................................................................................A-17/A-18
Horizontal Fillet ..........................................................................................................A-19/A-20
Flat Fillet ....................................................................................................................A-21/A-22
Pipe Welding..............................................................................................................A-23/A-24
Base Dimensions Only .......................................................................................................A-25
________________________________________________________________________________
Operation.........................................................................................................................Section B
Safety Precautions, Graphic Symbols..................................................................................B-1
Pendant Controls..................................................................................................................B-2
Moving The Tractor ..............................................................................................................B-2
Laser Pointer, Touch Sense.................................................................................................B-3
Power-Up Sequence ............................................................................................................B-3
Wire Feeder Setup ...............................................................................................................B-4
Changing And Setting Weld Modes .....................................................................................B-4
Frequency ............................................................................................................................B-4
Balance Adjust .....................................................................................................................B-5
Offset Adjust.........................................................................................................................B-5
Weld Sequence ....................................................................................................................B-5
Start Options ........................................................................................................................B-5
Start Options Operation........................................................................................................B-6
End Options, End Options Operation ...................................................................................B-6
Memories..............................................................................................................................B-7
Limits .............................................................................................................................B-7/B-9
Dip Switches.........................................................................................................................B-9
Set-Up Features Menu ..............................................................................................B-10/B-12
________________________________________________________________________________
Accessories ..............................................................................................Section C
Optional Kits and Accessories ..............................................................................C-1
Drive Roll and Guide Tube Kits .............................................................................C-1
Accessories Included with the CRUISER™ ..........................................................C-2
________________________________________________________________________________
Maintenance ....................................................................................................Section D
Routine Maintenance ............................................................................................D-1
Periodic Maintenance............................................................................................D-1
________________________________________________________________________________
Troubleshooting ..............................................................................................Section E
How to Use Troubleshooting Guide.......................................................................E-1
Troubleshooting Guide...................................................................................E-2, E-3
________________________________________________________________________________
Wiring Diagrams ..............................................................................................Section F
________________________________________________________________________________
Parts Pages............................................................................................................................P-683
7
T
ABLE OF CONTENTS
A-1
INSTALLATIONCRUISER
TM
TECHNICAL SPECIFICATIONS - CRUISER
™
K-3048-1
Wire Feeders - Input Voltage and Current
VOLTAGE INPUT AMPERES
40 VDC 8 AMPS
Rated Output
DUTY CYCLE AMPERES
100% 1000 AMPS
Physical Dimensions (as shipped from the factory)*
(Overall Size and Weight Dependent Upon Configuration)
MODEL HEIGHT WIDTH DEPTH WEIGHT
K3048-1 29 In (736 mm) 23 in (548 mm) 36 in (914 mm) 207 lb (94 kg)
Temperature Ranges
Operating Temperature -40ºF to 122ºF (-40ºC to +50ºC)
Storage Temperature -40ºF to 185ºF (-40ºC to +85ºC)
SAW
GEARING WFS Range Wire Sizes
50 to 500 ipm
(1.3 to 12.5 m/min)
15 to 300 ipm
(0.4 to 7.5 m/min)
15 to 200 ipm
(0.4 to 5.0 m/min)
142:1*
95:1
57:1
1/16 to 7/32 inch
(1.6 to 5.6 mm)
1/16 to 3/32 inch
(1.6 to 2.4 mm)
1/16 to 3/32 inch
(1.6 to 2.4 mm)
* = gearing installed in the wire drive as equipped from the factory.
IP23S
GENERAL PHYSICAL DESCRIPTION
The CRUISER™ is a self propelled, modular platform
for performing submerged arc welds. A unique tube
a
nd clamp design provides flexibility to mount the feed-
ing components in any position.
Wire is fed to the arc with the proven wire drive. All of
the drive rolls, nozzles, contact tips and wire straight-
e
ners are common between the MaxSA wire drives
and the CRUISER™ wire drive. The wire drive rotates
about two axes for setting torch drag/pull angle and
torch tilt angle.
The wire drive is mounted to two heavy duty X-Y
slides. The cross slides allow easy adjustment of the
electrode stick-out and position of the wire in the joint.
The entire mast and arm structure separates from the
base for portability and mobility purposes.
Driving the tractor is a permanent magnet DC motor
with a 5 stage gear box built with all metal gears. A
high resolution encoder keeps the tractor speed con-
sistent even at slow speeds. The wheels are made of
a high temperature rubber specially bonded to an alu-
minum core. Also mounted on the axle are guide
wheels and a gear for operating on K396 track sec-
tions.
The tractor may be configured for 3 or 4 wheel opera-
tion. The flexible wheel configuration allows the tractor
to be assembled in a manner for optimum balance
while aligning the wheels for the tracking of the joint.
All of the controls are housed in a light weight pendant
that connects to the tractor via an ArcLink cable. The
pendant housing is fabricated from aluminum to resist
impacts and high temperatures.
GENERAL FUNCTIONAL DESCRIPTION
The CRUISER™ is a modular platform for submerged
arc welding.
RECOMMENDED PROCESSES
• SAW (AC, DC+, DC-) up to 1000 amps.
• Tiny Twin
PROCESS LIMITATIONS
• The CRUISER™ does not support open arc proce-
dures.
EQUIPMENT LIMITATIONS
• Curved extension nozzle limited to 3/16” wire.
•
Inductance of the electrode and work cables may
affect arc performance. Do not coil excess cable.
• For robust digital communications, do not use more
than 200 feet of control cable.
• The CRUISER™ operates on 40 VDC only.
• There is no 115 VAC in the tractor.
• The minimum turning radius of the CRUISER™ is 10
feet when assembled with 3 wheels.
• The minimum turning radius of the CRUISER™ is 20
feet when assembled with 4 wheels.
• The rubber wheels are rated to 500°F (260°C)
• The laser pointer mounting bracket is not compatible
with the tiny twin nozzle or K148 nozzle.
RECOMMENDED POWER SOURCES
• Power Wave AC/DC 1000
DESIGN FEATURES
Loaded with Standard Features
Arc Performance
• The CRUISER™ and Power Wave AC/DC 1000
combination provide for new levels of submerged arc
productivity.
User Controls
• Light weight, hand-held pendant.
• Four memories for quick selection of common proce-
dures.
• 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 noz-
zles.
Tractor and Frame
• Configures to 3 or 4 wheels with patent pending
design, for the best tracking and balancing.
• Permanent magnet DC motor with encoder for
steady, accurate travel speeds.
• All steel gears for long life.
• Easily engaged travel clutch.
• Fully assembled for track use.
• High temperature rubber wheels for superior traction
and heat resistance up to 500°F (260°C).
• Heavy duty slides for adjusting the electrode position
in the joint.
A-2
INSTALLATIONCRUISER
TM
L
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a
in
tain cle
a
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etwee
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-
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ctor
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tial a
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:
•
W
ire
•
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ire
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•
W
ir
e
str
a
ig
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te
n
er ro
lls
• Brass Conduit bushing adapter
•
4 screw heads on back of the wire straighter
•
Feed plate and drive rolls
•
Contact nozzle assembly
• Nozzle extensions
• Contact Tip
Operate the CRUISER™ only on stable and dry sur-
f
aces.
Operating the tractor on inclined surfaces requires
adjusting and/or assembling the tractor differently than
shipped from the factory.
Do not submerge the tractor.
It is the responsibility of the user/builder/operator to
assemble the tractor to maintain safe electrical clear-
ances and to be stable.
The tractor is rated for outdoor use (IP23S) with the
wire reel enclosure installed.
Protect the CRUISER™ from preheat torches.
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.
------------------------------------------------------------------------
WARNING
MOVING PARTS can injure.
• Keep away from moving parts.
• Tractor parts may move sud-
denly when the bolts are loos-
ened.
• 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.
------------------------------------------------------------------------
WARNING
A-3
INSTALLATIONCRUISER
TM
GENERAL ASSEMBLY
Clamps
• Tighten clamp bolts to 25 ft-lbs (34 Nm).
• Use clamps with a key on horizontal tubes.
Collars
• Tighten collar screw to 42 in-lbs (0.3 Nm)
Lift Bail
• Tighten lift bail hardware to 24 in-lbs (0.17 Nm). Do
not overtighten or the mast may become distorted.
Chain and Mast Anchor
• The chain must be connected from the base to the
mast before lifting.
• Tighten all hardware as shown.
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.
------------------------------------------------------------------------
WARNING
FIGURE A.1 - CLAMPS
FIGURE A.2 - COLLARS
FIGURE A.3 - LIFT BALE
FIGURE A.4 - CHAIN AND MAST ANCHOR
A-4
INSTALLATIONCRUISER
TM
FRONT WHEELS
I
n almost all configurations the front wheels must
remain parallel with the Cruiser base and rear wheels
(See Figure A.5). 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.
Only adjust the front wheels when welding a round
inside or outside seam 25 feet (7.6m) in diameter or
smaller (See Figure A.6). At all other times the front
wheels must be set to 90°.
See Figure A.7. 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.
A-5
INSTALLATIONCRUISER
TM
FIGURE A.5 - FRONT WHEEL CONFIGURATION
FIGURE A.6 - ROUND 25 FOOT DIA. SEAM
FIGURE A.7 - SETTING THE ANGLE
OUTRIGGERS
T
he outriggers “steer” the CRUISER™ along a vertical
surface by driving it at a slight angle. Suggested offset
between the front and rear outriggers is ½” (12.7mm).
L
arger offsets increase the friction driving the CRUIS-
ER™ forward and may cause travel motor overcurrent
errors and rapid wheel wear.
When assembling the CRUISER™, adjust the cross
slide to the middle position and position the wire in the
joint. Then assemble the front and rear outriggers, and
make fine adjustments to the wire position using the
cross slide.
The outriggers may be stacked to gain extra length.
Slide a T Nut (S28835) into the extrusion and then
insert a ¼-20 bolt through the outrigger slots.
MANUAL STEERING MECHANISM,
ASSEMBLY
A
s shipped from the factory, the manual steering
mechanism is assembled with a guide wheel for track-
i
ng in a butt joint. The guide wheel may be replaced
with a rubber wheel for manual steering.
A-6
INSTALLATIONCRUISER
TM
FIGURE A.8 - OUTRIGGERS
FIGURE A.9 - OUTRIGGERS EXTENSION
FIGURE A.10 - MANUAL STEERING MECHANISM
MANUAL STEERING MECHANISM,
ADJUSTMENT
To steer the CRUISER™ to the Right:
Loosen bolt B
Tighten bolt A to set the wheel angle.
Snug bolt B
T
o steer the CRUISER™ to the Left:
Loosen bolt A
Tighten bolt B to set the wheel angle
Snug bolt A
CROSS SLIDE
Each slide has 4” (102mm) of travel.
When assembling the CRUISER™, verify that no com-
ponents at electrode potential contact the frame
throughout the entire travel distance of the slides.
The slides may be disassembled and then positioned
relative to each other.
WIRE REEL SPINDLE
• Position the wire reel spindle to prevent the reel
and electrode from contacting the tractor frame and
base.
• The wire reel spindle must be horizontal or oriented
upwards.
FIGURE A.11 - ADJUSTMENT
FIGURE A.13 - LOAD LIMITS
FIGURE A.12 - SEVERAL POSSIBLE SLIDE CONFIGURATIONS
FIGURE A.14 - WIRE REEL SPINDLE
A-7
INSTALLATIONCRUISER
TM
WIRE REEL ENCLOSURE ASSEMBLY-
FOR CODE 11947 AND ABOVE
1. Remove the #10 screws and lockwashers from the
spindle assembly using a 5/32" hex key.
2. Use the same hardware to fasten the enclosure
b
acking plate to the assembly.
3. For correct wire feeding, the flat portion of the
enclosure should be tilted toward the upright mast
of the Cruiser.
A-8
INSTALLATIONCRUISER
TM
WIRE REEL ENCLOSURE ASSEMBLY-
FOR CODES BELOW 11947
1. Determine the angular orientation of the wire reel
enclosure relative to the spindle clamp. To change
the angle of the enclosure, remove the 6 bolts
s
ecuring the enclosure back to the mounting brack-
et 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.
2. Unscrew the spindle brake and remove the spindle
brake parts and the spindle.
3. Remove two of the bolts from the spindle assem-
bly using a 1/4” hex key. Assemble the enclosure
back to the spindle assembly and tighten the bolts.
BRACKET
GASKET
ENCLOSURE
BACK
HARDWARE
ENCLOSURE
BACK
SPINDLE
ASSEMBLY
HARDWARE
FIGURE A.14c - ENCLOSURE ASSEMBLY
FIGURE A.14a - ENCLOSURE ASSEMBLY
FIGURE A.14b - ENCLOSURE MOUNTING
4. Reassemble the spindle parts as shown (all codes)
5. If required, swap the position of the ball bushing
assembly. Use a 7/16” wrench to loosen and tight-
en 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.
7. When assembling the enclosure cover to the enclo-
sure back, verify the cover is evenly seated all the
way around.
FIGURE A.14d - SPINDLE PARTS
FIGURE A.14e - CONDUIT, BRASS FITTING, BOOT
A-9
INSTALLATIONCRUISER
TM
TAKE-OFF ARM
• Position the take off arm to prevent contact to the
reel and electrode.
• Route the electrode through the conduit from the
take off arm to the wire drive.
FIGURE A.15 - TAKE-OFF ARM
A-10
INSTALLATIONCRUISER
TM
WIRE STRAIGHTENER ADJUSTMENT
The wire straightener controls the amount of cast (or
“curve”) in the wire. Excessive cast may effect align-
ment of the wire in the joint. Too little cast may result
i
n insufficient wire contact in the contact tip.
T
o adjust the wire straightener:
1. Turn off power at the welding power source.
2. Loosen the two screws holding the wire straighten-
er to the feed plate with a ¼” hex key.
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 straighten-
er until the desired cast is achieved when the wire
exits the tip.
NOTE: A slight curvature to the wire helps to maintain
good electrical contact inside the contact tip.
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
a
ngle 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.
A-11
INSTALLATIONCRUISER
TM
FIGURE A.16 - WIRE STRAIGHTENER SCREWS
FIGURE A.17 - WIRE STRAIGHTENER
FIGURE A.18 - FEEDPLATE ROTATION
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
v
ertical as possible.
CABLES
ArcLink Control Cables
ArcLink Control Cables are available in two forms:
•
K1543-xx series for most indoor or factory installa-
tions.
• K2683-xx series for outdoor use or when the equip-
ment is frequently moved.
ArcLink/LincNet control cables are special high quality
cables for digital communication. The cables are cop-
per 5 conductor cable in a SO-type rubber jacket.
There is one 20 gauge twisted pair for network commu-
nications. This pair has an impedance of approximate-
ly 120 ohms and a propagation delay per foot of less
than 2.1 nanoseconds. There are two 12 gauge con-
ductors 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 shut-
downs, 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 con-
trol cable between components.
A-12
INSTALLATIONCRUISER
TM
FIGURE A.19 - VERTICAL TUBE MOUNTING
FIGURE A.20 - HORIZONTAL TUBE MOUNTING
FIGURE A.21 - WIRE DRIVE MOUNTING
FIGURE A.22 - ARCLINK CONTROL CABLES
A
B
C
D
E
A
B
C
D
E
Power Source Wire Feeder
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
CABLE CONNECTIONS
WELD CABLE SIZES
Tabulated below are copper cable sizes recommended
for different currents and duty cycles. Lengths stipulat-
ed 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.
** Tabled values are for operation at ambient temperatures of 40°C and below. Applications above 40°C may
require cables larger than recommended, or cables rated higher than 75°C.
FIGURE A.23 - WIRE DRIVE MOUNTING
RECOMMENDED CABLE SIZES (RUBBER COVERED COPPER - RATED 75°C)**
CABLE SIZES FOR COMBINED LENGTHS OF ELECTRODE AND WORK
CABLES
Amperes
Percent
Duty
Cycle
0 to 50 Ft. 50 to 100 Ft. 100 to 150 Ft. 150 to 200 Ft. 200 to 250 Ft.
600
600
600
650
650
700
60
80
100
60
80
100
3/0
2-1/0
2-1/0
3/0
2-1/0
2-2/0
3/0
2-1/0
2-1/0
3/0
2-1/0
2-2/0
3/0
2-1/0
2-1/0
4/0
2-1/0
2-3/0
4/0
2-2/0
2-2/0
2-2/0
2-2/0
2-3/0
2-3/0
2-3/0
2-3/0
2-3/0
2-3/0
2-4/0
800
800
1000
80
100
80
3-1/0
2-3/0
2-4/0
3-1/0
2-3/0
2-4/0
3-1/0
2-3/0
2-4/0
2-3/0
2-3/0
2-4/0
2-4/0
2-4/0
4-2/0
1000
1200
1200
1500
1500
100
80
100
80
100
3-3/0
3-4/0
4-4/0
4-4/0
5-4/0
3-3/0
3-4/0
4-4/0
4-4/0
5-4/0
3-3/0
3-4/0
4-4/0
4-4/0
5-4/0
3-3/0
3-4/0
4-4/0
4-4/0
5-4/0
3-3/0
3-4/0
4-4/0
4-4/0
5-4/0
A-13
INSTALLATIONCRUISER
TM
SYSTEM SET-UP
FIGURE A.24 - SYSTEM SET-UP
A-14
INSTALLATIONCRUISER
TM
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