Lincoln Electric Tandem Cruiser Operating instructions

Brand: Lincoln Electric

Model: Tandem Cruiser

Category: Welding System

Type: Operating instructions

Operator’s Manual

TANDEM CRUISER

™

www.lincolnelectric.com/register

Authorized Service and Distributor Locator:

www.lincolnelectric.com/locator

IM10114-A | Issue D ate Sept- 14

For use with machines having Code Numbers:

11824, 12332

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.

se 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 - 06/15/2016

SECTION A:

WARNINGS

CALIFORNIA PROPOSITION 65 WARNINGS

Diesel Engines

Diesel engine exhaust and some of its constituents are known

to the State of California to cause cancer, birth defects, and other

reproductive harm.

Gasoline Engines

The engine exhaust from this product contains chemicals known

to the State of California to cause cancer, birth defects, or other

reproductive harm.

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

heir 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 - 06/15/2016

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

f 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 - 06/15/2016

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

rom 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,

tc. 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 - 06/15/2016

Page

Installation.......................................................................................................................Section A

Technical Specifications.......................................................................................................A-1

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

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

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

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

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

Recommended Power Sources, Design Features ...............................................................A-2

Parts Included with Tandem Cruiser ....................................................................................A-3

Location................................................................................................................................A-4

General Assembly, Removing the Butt Joint Guide .............................................................A-5

Outriggers.............................................................................................................................A-6

Butt Joint Guide, 2 Wheels ...........................................................................................A-7, A-8

Front Wheels ........................................................................................................................A-9

Leveling the Wheels ...........................................................................................................A-10

Cross Slide and Wire Drive ................................................................................................A-11

Wire Reel Spindle, Take Off Arm .......................................................................................A-12

Wire Wheel Enclosure and Spindle Parts.................................................................A-13, A-14

50-60LB. Coil Mounting......................................................................................................A-15

Wire Straightener Adjustment, Feedplate Rotation ............................................................A-16

Flux Hopper........................................................................................................................A-17

Cables ................................................................................................................................A-17

Cable Connections .............................................................................................................A-18

Weld Cable Sizes ...............................................................................................................A-19

System Set-Up ...................................................................................................................A-20

Butt Joints, Fillet Joints.......................................................................................................A-21

Flat Fillet ((Trough), 45º (Trough) .............................................................................A-22, A-27

Base Dimensions Only .......................................................................................................A-28

________________________________________________________________________________

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

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

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

Moving The Tractor ..............................................................................................................B-3

Laser Pointer, Touch Sense, Power-Up Sequence..............................................................B-4

Wire Feeder Setup, Changing And Setting Weld Modes, Frequency ..................................B-5

Balance Adjust .....................................................................................................................B-6

Offset Adjust.........................................................................................................................B-6

Weld Sequence ....................................................................................................................B-6

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

Start Options Operation........................................................................................................B-7

End Options, End Options Operation ...................................................................................B-7

Memories..............................................................................................................................B-8

Limits ...........................................................................................................................B-8/B-10

Dip Switches.......................................................................................................................B-10

Set-Up Features Menu ..............................................................................................B-11/B-15

________________________________________________________________________________

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

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

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

________________________________________________________________________________

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

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

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

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

________________________________________________________________________________

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

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

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

________________________________________________________________________________

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

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

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

________________________________________________________________________________

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

________________________________________________________________________________

TABLE OF CONTENTS

A-1

INSTALLATIONTANDEM CRUISER

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)

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 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 con-

sistent 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 con-

nects to the tractor with two ArcLink cables. The pen-

dant 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.

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.

• 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

o 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

AC/DC

1000 combine for new levels of submerged arc pro-

ductivity.

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, includ-

ing 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

• 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 trac-

tion and heat resistance up to 500°F (260°C)

• Heavy duty slides for adjusting the electrode posi-

tion in the joint.

A-2

INSTALLATIONTANDEM CRUISER

PARTS INCLUDED WITH THE TANDEM CRUISER

™

A-3

INSTALLATIONTANDEM CRUISER

Description

Flux Tube

onduit Tubing

Wire Reel Enclosure

Strain Relief Boot

Insulating Tube

Nozzle Adapter

Nozzle Extension

Nozzle Extension, 45° curved

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

5/16-18 x 2.50 Bolt

Purpose

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.

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.

Used when assembling the Tandem Cruiser™ in the

flat fillet position.

Part No.

T10642-10

S20023-5

M25007

M25386

M17225

T7028-245

M13739-1

KP2721-1

KP2721-2

S10125-5/32

T12929

T11807

M8249

T9078-1

S10147

T10575-1

T10574

S24739-20

E106A-3

S9262-121

CF000173

Qty.

*(one shipped loose, one assembled to the trail arc)

CAT

tain cle

twe

ts a

t electrode poten

tia

ll oth

™

mponents.

arts tha

t a

t electr

e po

ten

tia

l a

•

ire

•

ire

•

ss Co

nduit bushing ad

•

Wire Straightener Rolls

•

4 screw heads on back of the wire straighter.

•

Feed plate and drive rolls

•

Contact Nozzle Assemblies

• Nozzle extensions

• Contact Tips

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.

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-4

INSTALLATIONTANDEM CRUISER

FIGURE A.A

GENERAL ASSEMBLY

A-5

INSTALLATIONTANDEM CRUISER

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

IGURE A.1 - BUTT JOINT GUIDE

FIGURE A.1a - BUTT JOINT GUIDE

Loosen bolts

Slide and remove the butt joint kit

REMOVING THE BUTT JOINT GUIDE

1. Loosen the bolts on the clamp as shown. Slide and

remove the butt joint guide 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.

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.

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 out-

riggers, 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 1/4-20 bolt through the outrigger slots.

FIGURE A.5 - OUTRIGGERS

Clutch

FIGURE A.6 - OUTRIGGERS EXTENSION

A-6

INSTALLATIONTANDEM CRUISER

FIGURE A.1b - CLAMPS

FIGURE A.2 - COLLARS

FIGURE A.3 - LIFT BALE

FIGURE A.4 - CHAIN AND MAST ANCHOR

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

uide out and set aside

Then slide the pendant tube until it is flush with the

end of the clamp. Retighten the clamp bolts.

(See Figure A.8)

A-7

INSTALLATIONTANDEM CRUISER

IGURE A.7

FIGURE A.8

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

emoving 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.

FIGURE A.9 - BUTT JOINT, 2 WHEEL

A-8

INSTALLATIONTANDEM CRUISER

FRONT WHEELS

n 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.

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°.

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.10 FRONT WHEEL ADJUSTMENT

FIGURE A.11 ADJUSTMENT 25 FEET DIA. OR SMALLER

FIGURE A.12 DIRECTION OF TRAVEL

A-9

INSTALLATIONTANDEM CRUISER

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)

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.

4. While keeping both rear wheels in contact with

the surface, loosen the 4 front bolts securing

wheel “A” and reposition the wheel lower to

contact the surface, and then tighten the bolts to

10 ft-lbs (13.6 N-m) (See Figure A.12b)

5. If more adjustment is required, loosen the 4

front bolts securing wheel “B” and reposition

to allow both front wheels and both rear wheels

to contact the surface at the same time. Tighten

the bolts to 10 ft-lbs (13.6 N-m)

A-10

INSTALLATIONTANDEM CRUISER

WARNING

FIGURE A.12a

FIGURE A.12b

CROSS SLIDE AND WIRE DRIVE

Each slide has 4” (102mm) of travel.

When assembling the Cruiser, verify that no compo-

ents at electrode potential contact the frame through-

out 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.

FIGURE A.13 FACTORY POSITION

A-11

INSTALLATIONTANDEM CRUISER

A-12

INSTALLATIONTANDEM CRUISER

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.

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

FIGURE A.14 - WIRE REEL SPINDLE

A-13

INSTALLATIONTANDEM CRUISER

WIRE REEL ENCLOSURE ASSEMBLY-

FOR CODE 12332 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

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.

WIRE REEL ENCLOSURE ASSEMBLY-

FOR CODES BELOW 12332

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

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.17a - ENCLOSURE ASSEMBLY

FIGURE A.16 - ENCLOSURE ASSEMBLY

FIGURE A.17 - 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 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.

7. When assembling the enclosure cover to the enclo-

sure back, verify the cover is evenly seated all the

way around.

FIGURE A.18 - SPINDLE PARTS

FIGURE A.19 - CONDUIT, BRASS FITTING, BOOT

A-14

INSTALLATIONTANDEM CRUISER

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Lincoln Electric Tandem Cruiser Operating instructions

Brand: Lincoln Electric

Model: Tandem Cruiser

Category: Welding System

Type: Operating instructions

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Lincoln Electric Tandem Cruiser Operating instructions

Lincoln Electric Tandem Cruiser Operating instructions

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