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Operator’s Manual
TANDEM CRUISER
™
Register your machine:
www.lincolnelectric.com/register
Authorized Service and Distributor Locator:
www.lincolnelectric.com/locator
IM10114-A | Issue D ate Sept- 14
© Lincoln Global, Inc. All Rights Reserved.
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.
U
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
t
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
o
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
f
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,
e
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
________________________________________________________________________________
6
TABLE OF CONTENTS
A-1
INSTALLATIONTANDEM CRUISER
TM
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
t
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
TM
PARTS INCLUDED WITH THE TANDEM CRUISER
™
A-3
INSTALLATIONTANDEM CRUISER
TM
Description
Flux Tube
C
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.
3
2
2
2
2
3
2*
2
2
2
2
2
1
1
1
1
1
16
4
*(one shipped loose, one assembled to the trail arc)
L
O
CAT
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N
M
a
in
tain cle
a
r
a
n
ce
b
e
twe
e
n
p
a
r
ts a
t electrode poten
-
tia
l
a
n
d
a
ll oth
e
r
TA
N
DE
M
CR
U
I
S
E
R
™
co
mponents.
P
arts tha
t a
r
e
a
t electr
o
d
e po
ten
tia
l a
r
e
:
•
W
ire
•
W
ire
S
p
o
o
l
•
B
r
a
ss Co
nduit bushing ad
a
p
te
r
•
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
TM
FIGURE A.A
GENERAL ASSEMBLY
A-5
INSTALLATIONTANDEM CRUISER
TM
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
F
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
TM
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
g
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
TM
F
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
r
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
TM
FRONT WHEELS
I
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
TM
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
TM
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-
n
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
TM
A-12
INSTALLATIONTANDEM CRUISER
TM
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
TM
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
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.
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
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.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
TM
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